Case 586h Tech Manual Tier 4

Rodney DeLoach
Red E Services Inc.

2042 southwest 760A
arcadia, FL 34266
Email address:
redeservicesinc@gmail.com
Phone:
+18639904545
586H
588H
Tier 4B (final)
Rough Terrain Forklift
SERVICE MANUAL
Printed in U.S.A.
© 2015 CNH Industrial America LLC. All Rights Reserved.
Part number 47821916
Case is a trademark registered in the United States and many
other countries, owned by or licensed to CNH Industrial N.V., 1st edition English
its subsidiaries or affiliates. April 2015
SERVICE MANUAL
586H Four-Wheel Drive (4WD) TIER 4B (FINAL)

586H Two-Wheel Drive (2WD) TIER 4B (FINAL)
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EN
Link Product / Engine
Product Market Product Engine

586H Two-Wheel Drive (2WD) North America F5HFL463D*F005
TIER 4B (FINAL)
586H Four-Wheel Drive (4WD) North America F5HFL463D*F005
TIER 4B (FINAL)
588H Two-Wheel Drive (2WD) North America F5HFL463A*F001
TIER 4B (FINAL)
588H Four-Wheel Drive (4WD) North America F5HFL463A*F001
TIER 4B (FINAL)
47821916 28/04/2015
Contents
INTRODUCTION
Engine....................................................................................... 10
[10.001] Engine and crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.1
[10.202] Air cleaners and lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.2
[10.216] Fuel tanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3
[10.206] Fuel filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.4
[10.218] Fuel injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.5
[10.220] Throttle linkage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.6
[10.254] Intake and exhaust manifolds and muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.7
[10.304] Engine lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.8
[10.400] Engine cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.9
[10.414] Fan and drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.10
[10.501] Exhaust Gas Recirculation (EGR) - Diesel Particulate Filter (DPF) exhaust
treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.11
Transmission.............................................................................. 21
[21.109] Transmission cooler and lines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.1
[21.112] Power shuttle transmission. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.2
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
[27.550] Non-powered rear axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27.4
Brakes and controls .................................................................... 33

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[33.110] Parking brake or parking lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33.1
[33.202] Hydraulic service brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33.2
Hydraulic systems....................................................................... 35
[35.000] Hydraulic systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.1
[35.102] Pump control valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.2
[35.104] Fixed displacement pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.3
[35.300] Reservoir, cooler, and filters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.4
[35.322] Regulated/Low pressure system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.5
[35.359] Main control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.6
[35.728] Telescopic arm control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.7
[35.740] Telescopic arm hydraulic system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.8
Frames and ballasting ................................................................. 39

[39.140] Ballasts and supports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39.1
Steering..................................................................................... 41
[41.101] Steering control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.1
[41.200] Hydraulic control components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.2
[41.216] Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.3
Wheels ...................................................................................... 44
[44.511] Front wheels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.1
[44.520] Rear wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.2
Electrical systems ....................................................................... 55

[55.100] Harnesses and connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.1
[55.201] Engine starting system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.2
[55.301] Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.3
[55.302] Battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.4
[55.408] Warning indicators, alarms, and instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.5
[55.991] Telematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.6
[55.DTC] FAULT CODES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.7
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Telescopic single arm .................................................................. 83
[83.122] Telescopic arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83.1
Platform, cab, bodywork, and decals ............................................. 90

[90.100] Engine hood and panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.1
[90.114] Operator protections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.2
[90.116] Fenders and guards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.3
[90.120] Mechanically-adjusted operator seat. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.4
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INTRODUCTION
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1
Contents
INTRODUCTION
Foreword - Important notice regarding equipment servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Safety rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Personal safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Safety rules - Roll Over Protective Structure (ROPS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Basic instructions - Prepare machine for service/Return machine to use . . . . . . . . . . . . . . . . . . . . . . 7
Basic instructions - Chain Wear Tables - Roller Chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Torque - Minimum tightening torques for normal assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Torque - Standard torque data for hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Basic instructions - Shop and assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Basic instructions - Important notice regarding equipment servicing . . . . . . . . . . . . . . . . . . . . . . . . . 21
Basic instructions - Before welding on the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Hydraulic contamination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
General specification - Recommended operating temperature range . . . . . . . . . . . . . . . . . . . . . . . . 25
General specification Organic Acid Technology (OAT) coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
General specification - Biodiesel fuels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
General specification - Diesel fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Product identification - Fuse and relay locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Product identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Product identification – machine orientation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
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INTRODUCTION
Foreword - 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 manufacturer 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 time of publication but are subject to change without notice.
In case of questions, refer to your CASE CONSTRUCTION Sales and Service Networks.
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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.
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INTRODUCTION
Personal safety
WARNING
Risk of harm during maintenance of the machine!
Before you start servicing the machine, attach a DO NOT OPERATE warning tag to the machine in a
visible area.
Failure to comply could result in death or serious injury.
W1242A
Attach a DO NOT OPERATE (TAG) to the machine in an area that is clearly visible whenever the machine is not
operating properly and/or requires service.
Complete the tag information for the "REASON" the tag is attached by describing the malfunction or service required.
Validate the reason for attaching the tag by signing your name in the designated area on the tag.
The tag should only be removed by the person who signed and attached the tag, after validating the repairs or services
have been completed.
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INTRODUCTION
Safety rules - Roll Over Protective Structure (ROPS)
DANGER
Crushing hazard!
DO NOT operate the machine with the Roll-Over Protective Structure (ROPS) removed. Remove the
ROPS only for service or replacement.
Failure to comply will result in death or serious injury.
D0032A
Your machine is equipped with a ROPS (cab or canopy) protective structure.
A ROPS label is fastened to the protective structure and shows the ROPS PIN, the gross weight, approval, regulation,
and model numbers of the machine.
The protective structure is a special safety component of your machine.
DO NOT attach any device to the protective structure for pulling purposes. DO NOT drill holes into the protective
structure.
After an accident, fire, tip over, or roll over, the following MUST be performed by a qualified technician before
returning the machine to field or job side operation:
• The protective structure MUST be replaced.
• The mounting or suspension for the protective structure, operator's seat and suspension, seat belt and mounting
components, and wiring within the protective structure MUST be carefully inspected for damage.
• All damaged parts MUST be replaced.
DO NOT WELD, DRILL HOLES, ATTEMPT TO STRAIGHTEN, OR REPAIR THE PROTECTIVE STRUCTURE. MOD-
IFICATION IN ANY WAY CAN REDUCE THE STRUCTURAL INTEGRITY OF THE STRUCTURE WHICH COULD
CAUSE DEATH OR SERIOUS INJURY IN THE EVENT OF FIRE, TIP OVER, ROLL OVER, COLLISION, OR ACCI-
DENT.
Seat belts are part of the protective system and must be worn at all times. The operator must be held to the seat
inside the frame in order for the protective system to work.
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INTRODUCTION
Basic instructions - Prepare machine for service/Return machine

to use
Read and understand all service procedures before beginning any repairs on the machine.
Prepare machine for service

1. Park the machine on a firm level surface.
2. Level the forks and lower the mast to the ground.
3. Make sure the park brake switch is in the park position.
4. Turn the engine OFF and chock all the wheels.
WARNING
Escaping fluid!
Hydraulic fluid or diesel fuel leaking under
pressure can penetrate the skin and cause
infection or other injury. To prevent personal
injury: Relieve all pressure before discon-
necting fluid lines or performing work on the
hydraulic system. Before applying pressure,
make sure all connections are tight and all
components are in good condition. Never use
your hand to check for suspected leaks under
pressure. Use a piece of cardboard or wood
for this purpose. If injured by leaking fluid,
see your doctor immediately.
Failure to comply could result in death or se-
rious injury.
W0178A
RAPH12FRK0958BA 1
5. With the key in the ON position, engine NOT running,

operate all hydraulic functions, including the service
brakes, until all hydraulic and hydraulic accumulator
pressure is discharged. Turn the key to the OFF posi-
tion.
6. Open the left engine access door (1) and turn the
battery disconnect switch (2) to the OFF position, if
equipped.
RAPH12FRK0021BA 2
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INTRODUCTION
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.
rious injury.
W0111A
WARNING
Battery gas can explode!
To prevent an explosion: 1. Always discon-
nect the negative (-) battery cable first. 2. Al-
ways connect the negative (-) battery cable
last. 3. Do not short circuit the battery posts
with metal objects. 4. Do not weld, grind, or
smoke near a battery.
rious injury.
W0011A
NOTE: Dual battery configuration shown. Disconnect

both battery negative cables (2) first.
Disconnect the battery or batteries

7. Disconnect the battery negative (2) cable from the bat-
tery or batteries.
8. Disconnect the battery positive (1) cables from the bat-
tery or batteries.
RAPH12FRK0044BA 3
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INTRODUCTION
Return machine to use

WARNING
To prevent an explosion: 1. Always discon-
nect the negative (-) battery cable first. 2. Al-
ways connect the negative (-) battery cable
last. 3. Do not short circuit the battery posts
with metal objects. 4. Do not weld, grind, or
smoke near a battery.
rious injury.
W0011A
NOTE: Dual battery configuration shown. Connect both

battery positive cables (1) first.
1. Connect the battery positive (1) cable to the battery or RAPH12FRK0044BA 4

batteries.
2. Connect the battery negative (2) cable to the battery
or batteries.
3. If equipped, turn the battery disconnect switch (2) to
the ON position and close the left engine access door
(1).
4. Start the machine and allow it to reach normal operat-
ing temperature.
5. Verify that all the functions operate correctly.
RAPH12FRK0021BA 5
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INTRODUCTION
Basic instructions - Chain Wear Tables - Roller Chains

Chain wear
The individual joints in a roller chain articulate as they en-
ter and leave the sprockets. This articulation results in
wear on the pins and bushings. Material that is worn away
from these surfaces will cause the chain to gradually elon-
gate. Chains do not stretch. Material is worn from pin and
bushing.
Critical dimensions of the chain are as follows:

• (1) 2X pitch
• (2) Wear plus 2X pitch
• (3) Elongation due to pin and bushing wear
96091478 1
Elongation is normal and may be minimized by proper

lubrication and drive maintenance. The rate of wear is
dependent upon: the relationship between the load and
the amount of bearing area between pin and bushing, the
material and surface condition of the bearing surfaces, the
adequacy of lubrication, and the frequency and degree
of articulation between pins and bushings. The latter is
determined by the quantity of sprockets in the drive, their
speeds, the number of teeth and the length of the chain
in pitches.
An accurate wear measurement (1) can be made by us-
ing the above illustration. Measure as closely as possible
from the center of one pin to the center of another. The
more pitches (pins) contained within the measurement in-
crease the accuracy. If the measured value exceeds the
nominal by more than the allowable percentage the chain
should be replaced. The maximum allowable wear elon-
gation is approximately 3 % for most industrial applica-
tions, based upon sprocket design. The allowable chain
wear in percent can be calculated using the relationship:
200/ (N), where (N) is the number of teeth in the large
sprocket. This relationship is often useful since the nor-
mal maximum allowable chain wear elongation of 3 % is
valid only up to 67 teeth in the large sprocket. In drives
having fixed center distances, chains running in parallel 96091469 2
or where smoother operation is required, wear should be
limited to approximately 1.5 %.
For example, if 12 pitches (12 pins) of a #80 chain were
measured and the result was 313.944 mm (12.360 in)
or greater (using 3 % as the maximum allowable wear),
the chain should be replaced. Anything less than
313.944 mm (12.360 in) would still be acceptable by
most industrial standards.
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INTRODUCTION
WEAR LIMITS ON ROLLER CHAIN

Strand No. 40 Chain (08A) No. 50 Chain (10A) No. 60 Chain (12A) No. 80 Chain (16A)
Length
in New Replace New Replace New Replace New Replace
Pitches
508 mm 523 mm 635 mm 654 mm 762 mm 787 mm 1016 mm 1047 mm
40P (20.0 in) (20.591 in) (25.0 in) (25.748 in) (30.0 in) (31.0 in) (40.0 in) (41.220 in)
STANDARD ROLLER CHAIN SIZES - NEW CHAINS

Chain No. 150 Chain No. Pitch Width Roller Diameter
40 08A 12.7 mm (0.5 in) 7.9 mm (0.311 in) 7.9 mm (0.311 in)
50 10A 15.8 mm (0.622 in) 9.5 mm (0.374 in) 10.1 mm (0.398 in)
60 12A 19 mm (0.748 in) 12.7 mm (0.500 in) 11.9 mm (0.469 in)
80 16A 25.4 mm (1.000 in) 15.8 mm (0.622 in) 15.8 mm (0.622 in)
100 20A 31.7 mm (1.248 in) 19 mm (0.748 in) 19 mm (0.748 in)
120 24A 38.1 mm (1.500 in) 25.4 mm (1.000 in) 22.2 mm (0.874 in)
140 28A 44.4 mm (1.748 in) 25.4 mm (1.000 in) 25.4 mm (1.000 in)
160 32A 50.8 mm (2.000 in) 31.7 mm (1.248 in) 28.5 mm (1.122 in)
180 * 57.1 mm (2.248 in) 35.7 mm (1.406 in) 35.7 mm (1.406 in)
200 40A 63.4 mm (2.496 in) 38.1 mm (1.500 in) 39.6 mm (1.559 in)
* No. 150 Number does not exist.
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INTRODUCTION
Torque - Minimum tightening torques for normal assembly

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

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

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

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

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

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

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

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

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

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

system clean will extend machine and component life.
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INTRODUCTION
Basic instructions - Shop and assembly

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

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

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

• Operating in optimal technical conditions
• Obtaining the best results
• Saving time and effort
• Working in safe conditions
47821916 28/04/2015
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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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INTRODUCTION
Basic instructions - Before welding on the machine

The following procedures must be completed before welding.
Remove the battery cover and disconnect the batteries.
RAPH12FRK0277AA 1
Disconnect the alternator terminal wires.
RAPH12FRK0163AA 2
Disconnect the Engine Control Unit (ECU)

1. Remove the four bolts and the ECU cover panel from
the right side of the operator seat.
RAPH12FRK0242AA 3
47821916 28/04/2015
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INTRODUCTION
2. Disconnect both connectors.
RAPH12FRK0236AA 4
Disconnect the instrument control panel.

1. Remove the instrument control panel.
2. Disconnect the wire connector on the back of the in-
strument control panel.
RAPH12FRK0718BA 5
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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 are slow. The machine does not have enough 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
General specification - Recommended operating temperature range

For machines using Tier 4b engines
(H) 0W-40 CJ-4 UNITEK to CNH MAT3521

(H) API CJ-4 0W-40*
(H) 5W-30 ACEA E6
(H) 10W-40 CJ-4 UNITEK to CNH MAT3521

(H) API CJ-4 10W-40*
(H) 15W-40 CJ-4 to CNH MAT3522*

(H) API CJ-4 15W-40*
-40 °C -30 °C -20 °C -10 °C 0 °C 10 °C 20 °C 30 °C 40 °C 50 °C

-40 °F -22 °F -4 °F 14 °F 32 °F 50 °F 68 °F 86 °F 104 °F 122 °F
(H) Engine oil pan or coolant block heater recommended in this range
* Requires a 50 % reduction in oil change interval
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INTRODUCTION
General specification Organic Acid Technology (OAT) coolant

Depending on the date of manufacture, your cooling system may be equipped with conventional ethylene glycol
coolant such as CNH XHD HEAVY DUTY COOLANT / ANTI-FREEZE or an Organic Acid Technology (OAT) coolant so-
lution such as CASE AKCELA ACTIFULL™ OT EXTENDED LIFE COOLANT. You should never mix the coolant
types.
NOTE: Organic Acid Technology (OAT) appears yellow in small quantities. OAT coolant can also appear yellow when
against translucent backgrounds. However, under certain lighting conditions and backgrounds, such as looking into
the coolant overflow tank, OAT coolant may appear green. The green appearance is similar to the color of ethylene
glycol coolant. This color appearance is normal, which is not an indication of mixed coolant fill in new units built after
the implementation of OAT coolant.
The coolant solution used must meet the following CNH
Industrial material specifications for either coolant type:
• MAT3624 for OAT coolant
• MAT3620 for conventional coolant
The decal shown is located near the fill point of the cooling
system whenever the factory fill is CASE AKCELA ACT-
IFULL™ OT EXTENDED LIFE COOLANT. This decal is
available in three different sizes. See the table below for
the associated part numbers.
CNH Industrial part Size

number
47757330 50 mm x 50 mm
47757331 75 mm x 75 mm
47757332 100 mm x 100 mm
47757330 1
NOTICE: NEVER mix OAT coolant with conventional coolant. Under no circumstances should you top off a cooling
system with only water. You can use a refractometer to check the concentration level. You should not use Supplemen-
tal Coolant Additives (SCA) when using CASE AKCELA ACTIFULL™ OT EXTENDED LIFE COOLANT. Change the
coolant solution at the recommended change interval.
If you need to change a machine from conventional coolant to OAT coolant or vice versa, you should follow the
“Changing coolant types” procedure below to attain the full benefit of the coolant.
Changing coolant types

To change coolant from OAT coolant to conventional coolant (or vice versa):
1. Empty the engine cooling system by draining the coolant into a suitable container.
2. Fill the system with clean water.
3. Start the engine and run the engine for at least 30 min.
NOTE: Make sure that you activate the heating system (if equipped) to circulate fluid through the heater core.
4. Repeat Steps 1 to 3 for a total of two washes.
5. Fill the system with conventional coolant (or OAT coolant).
6. Operate the engine until it is warm. Inspect the machine for leaks.
7. If you are changing to OAT coolant, then attach the decal (CNH Industrial part number 47757330) to indicate the
use of OAT coolant in the cooling system.
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INTRODUCTION
You may notice the older version of the OAT decal (CNH
Industrial part number 47488993) on some applications.
Definitions
Conventional coolant:
A coolant that relies on inorganic inhibitors such as sil-
icates, nitrites, and phosphates for corrosion and cavi-
tation protection.
Organic Acid Technology (OAT) coolant:

A coolant that relies on inhibitors such as organic acid
salts for corrosion and cavitation protection.
47488993 2
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INTRODUCTION
General specification - Biodiesel fuels

Biodiesel usage in CASE CONSTRUCTION products
Introduction to Fatty Acid Methyl Ester (FAME) biodiesel

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

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

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

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

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

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

1. If the biodiesel blend stock to ASTM D6751-09A is used, special precautions need to be taken to insure that it
fully complies with the following special requirements:
• Group I Metals content (Sodium + Potassium) is ≤ 5 mg/kg per EN14538 as specified in the biodiesel spec.
• Group II Metals content (Calcium + Magnesium) is ≤ 5 mg/kg per EN14538 as specified in the biodiesel spec.
• Phosphorus content lower than specified is a mandatory requirement. Phosphorus must not exceed 4 mg/kg
per ASTM D4951.
2. The resulting greater than B5 through B20 blend must not exceed 1 mg/kg for Group I Metals (Sodium + Potas-
sium) and for Group II Metals (Calcium + Magnesium).
NOTICE: For machines using Tier 4a engines with an exhaust aftertreatment system in regions where
the biodiesel blend stock is supplied to the ASTM D6751-09A standard, it is essential that evidence of
compliance to the special limits for Group I Metals, Group II Metals and the reduced phosphorus content
specified above be obtained on every delivery of fuel from the fuel supplier. Failure to comply with this
requirement can result in damage to the catalyst of the aftertreatment system which will not be covered
under warranty.
NOTICE: CASE CONSTRUCTION may void your warranty if the problem is associated with poor fuel quality due to
improper blending. It is the responsibility of the fuel supplier and/or yourself to ensure the right type of fuel and blend
is delivered and used.
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INTRODUCTION
Maintenance intervals
For machines using the all electronic engines with a high pressure common rail fuel system, the engine oil and filter
change interval is reduced to 250 h when using biodiesel blends greater than B5 up to B20. Please refer to the
maintenance intervals specified in the Operator Manual for all engines.
Check all hoses, connections and gaskets to ensure integrity and cleanliness every 3 months or 150 hours of oper-
ation, whichever comes first.
Regular oil sampling is highly recommended to monitor for oil and engine deterioration.
NOTE: Oil sampling kits are available from your authorized CASE CONSTRUCTION dealer.
When switching back from biodiesel to regular #2 diesel, all fuel filter, oil and oil filter should be changed even if this
falls between routine service intervals.
Storage
The machine should not be stored for more than three months with biodiesel in the fuel system. For longer storage
time, it is strongly suggested that only regular #2 diesel fuel is used.
NOTE: If storage for longer than 3 months is necessary, the engine must be run on regular #2 diesel for a minimum
of 20 h to flush the biodiesel fuel out of the fuel system prior to storage.
Biodiesel is highly hygroscopic and tends to collect water more than diesel fuel. This increases the risk of algae and
bacteria growth which can cause severe damage to the fuel injection system. Keep the machine fuel tanks and on-site
storage tanks as full as possible to limit the amount of air and water vapors inside the tank. Drain water from the tanks
at least once a week.
NOTICE: Do not use biocide additives on Tier 4a engines with an exhaust aftertreatment system.
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INTRODUCTION
General specification - Diesel fuel

Only use diesel fuel that conforms to North American standard ASTM D975 Grade No. 2-D S15 or equivalent in your
engine. Do not use any other low grade diesel fuel.
NOTICE: Use of other low grade diesel fuels will result in loss of engine power, high fuel consumption, and damage
to the exhaust aftertreatment system (if equipped).
NOTE: When operating the machine in very cold climates, the use of winter blended fuel is permitted for a short period
of time. See your fuel supplier for winter fuel requirements in your area.
Fuel conditioner
Diesel fuel conditioner is available from your CASE CONSTRUCTION dealer. Instructions for the use of the fuel
conditioner is on the container.
The use of diesel fuel conditioner will:

• Clean fuel injectors, valves, and manifolds for increased service life
• Disperse insoluble gummy deposits that form in the fuel system
• Separate moisture from the fuel
• Stabilize fuel in storage
NOTICE: Use only CASE CONSTRUCTION approved biocide additives to prevent damage to the exhaust aftertreat-
ment system (if equipped).
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INTRODUCTION
Capacities
Engine crank case
Specification: TUTELA UNITEK CJ-4 ENGINE OIL SAE 10W-40( API CJ-4)
Capacity:
With filter change 8.00 L (8.45 US qt)
NOTE: Refer to the “Engine oil viscosity” General specification - Recommended operating temperature range ()
for recommendations on the oil types designed for your operating environment.
Fuel tank
Specification: ASTM D975 GRADE NO. 2-D S15
Capacity: 117 L (31 US gal)
Cooling system
Specification: CASE AKCELA ACTIFULL™ OT EXTENDED LIFE COOLANT
Capacity: 17.4 L (18.4 US qt)
Hydraulic system
Specification: CASE AKCELA HY-TRAN® ULTRACTION
Capacity:
Total system 70.0 L (74.0 US qt)
Reservoir with filter change 54.5 L (57.6 US qt)
Reservoir without filter change 52.6 L (55.6 US qt)
Transmission
Specification: CASE AKCELA HY-TRAN® ULTRACTION
Capacity:
Manual (Power shuttle)
Two-Wheel Drive (2WD) Four-Wheel Drive (4WD)
Total system 17.0 L (18.0 US qt) 19.4 L (20.5 US qt)
Refill (with or without filter change) 10.5 L (11.1 US qt) 13.0 L (13.7 US qt)
Front drive axle

Specification: TUTELA TRANSAXLE FLUID SAE 80W-140
Capacity:
Differential and planetaries 13.6 L (14.4 US qt)
Rear steer axle — Four-Wheel Drive (4WD)

Specification: TUTELA TRANSAXLE FLUID SAE 80W-140
Capacity:
Differential 5.5 L (5.8 US qt)
Each planetary hub 0.7 L (0.7 US qt)
Brake master cylinder

Brake fluid supplied by the transmission.
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INTRODUCTION
Product identification - Fuse and relay locations

The machine has four fuse and relay locations:
• The main fuse and relay location is under the operator seat on the right hand side
• The Glow-plug Control Unit (GCU) fuse is accessible from either side of the engine side panels.
• The Engine Control Unit (ECU) fuse and relay location is behind the ECU cover panel on the right hand side of the
operator seat
• The Telematics system in-line fuse is located near the starter on the left-hand side of the engine.
Main fuse and relays

1. Locate the main fuse and relay panel on the right hand
side below the operator seat.
RAIL12FRK1097BA 1
2. Remove the four screws and the panel.
(1) Power relay #1

(2) Power relay #2
(3) Flasher relay and Shuttle interlock timing relay
RAPH12FRK0209AA 2
3. Remove the fuse covers.
(1) Fuse, diodes, and relays

(2) Relays
(3) Diagnostic port
RAPH12FRK0211AA 3
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INTRODUCTION
4. Refer to the decal on the interior side of the panel cover

for fuse, relay, and/or diode functions.
RAIL13FRK0001AA 4
Glowplug Control Unit (GCU) fuse

1. Open the right side engine panel.
NOTE: You can access the fuse from the left side as
well.
2. Locate the 60 A fuse (1) for the GCU. Look underneath
the Diesel Particulate Filter (DPF) and in front of the
engine lift hooks (2).
RAPH12FRK0189AA 5
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INTRODUCTION
Engine Control Unit (ECU) fuse and relay

1. Remove the four bolts and the ECU cover panel from
the right side of the operator seat.
RAPH12FRK0242AA 6
2. Locate the ECU B+ relay (1) and the ECU fuse (2)
location.
RAPH12FRK0236AA 7
Remove the cover from the ECU fuse block.

(1) ECU B+ 20 A fuse
(2) ECU B+ 7.5 A fuse
(3) LAMBDA SENSOR B+ 7.5 A fuse
RAPH12FRK0241AA 8
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INTRODUCTION
Telematics system fuse

1. Park the machine and turn off the engine.
2. Open the left-hand side engine panel.
3. Locate the wire harness with the in-line 5 A fuse.
A. Machines equipped with the Battery Power Junc-
tion Stud (1).
B. Machines equipped with a Master Disconnect
Switch (2).
RAIL13TLB0207BA 9
RAIL13TLB0206BA 10
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INTRODUCTION
Product identification
Record the machine and Product Identification Numbers (PIN). If needed, provide these numbers to your dealer when
you require parts or information for your machine. Keep a record of these numbers and your Manufacturer’s Statement
of Origin in a safe place. If the machine is stolen, report the numbers to your local law enforcement agency.
Machine identification
Model name
PIN
Locate the PIN plate on the upper right-hand side of the

Roll-Over Protective Structure (ROPS).
RAPH12FRK0130AA 1
NOTE: The PIN is also stamped on the right-hand side of

the frame.
RAIL14FRK0018BA 2
Roll-Over Protective Structure (ROPS)

PIN
Locate the PIN plate on the upper left-hand side of the

ROPS.
RAPH12FRK0127AA 3
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INTRODUCTION
Engine
PIN
Locate the PIN plate on the left-hand side of the oil pan
near the fuel water separator.
RAPH12FRK0250AA 4
Transmission
PIN
Locate the PIN plate on the left-hand side of the transmis-

sion housing.
RAPH12FRK0257AA 5
Rear steer axle — Two-Wheel Drive (2WD)

PIN
Locate the PIN plate on the left-hand front side of the rear
steer axle.
RAPH12FRK0252AA 6
Rear steer axle — Four-Wheel Drive (4WD)

PIN
Locate the PIN on the left-hand front side of the rear steer
axle.
RCPH10TLB394AAF 7
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INTRODUCTION
Front drive axle

PIN
RAPH12FRK0276AA 8
Forklift mast
PIN
RAPH12FRK0225AA 9
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INTRODUCTION
Product identification – machine orientation

The terms right-hand and left-hand, when used in this manual, indicate the right-hand and left-hand sides of the
machine as seen from the operator's seat.
RAIL12FRK1131GA 1
Top view of the machine

1. Front of the machine
2. Right-hand side of the machine
3. Rear of the machine
4. Left-hand side of the machine
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SERVICE MANUAL
Engine

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Contents
Engine - 10
[10.001] Engine and crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.1
[10.202] Air cleaners and lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.2
[10.216] Fuel tanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3
[10.206] Fuel filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.4
[10.218] Fuel injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.5
[10.220] Throttle linkage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.6
[10.254] Intake and exhaust manifolds and muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.7
[10.304] Engine lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.8
[10.400] Engine cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.9
[10.414] Fan and drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.10
[10.501] Exhaust Gas Recirculation (EGR) - Diesel Particulate Filter (DPF) exhaust
treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.11
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Engine - 10
Engine and crankcase - 001

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Contents
Engine - 10
SERVICE
Engine
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
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Engine - Engine and crankcase
Engine - Remove
1. Prepare the machine for service.
2. Open both side panels.
RAPH12FRK0026BA 1
3. Remove the retaining pin from both ends of the strut.

4. Pull the end of the strut off of the ball stud.
5. Pull the other end of the strut off of the ball stud.
6. Keep the retaining pins with the strut.
RAPH12FRK0027BA 2
7. Remove the nut and washer that secures the strap to

the hood.
RAPH12FRK0028BA 3
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8. WARNING
Heavy objects!
Lift and handle all heavy components using lift-
ing equipment with adequate capacity. Always
support units or parts with suitable slings or
hooks. Make sure the work area is clear of all
bystanders.
Failure to comply could result in death or seri-
ous injury.
W0398A
Remove the cap screws, washers , and the inside sup-

port plate. Carefully remove the side panel.
9. Repeat the procedure on the other side panel.
RAPH12FRK0026BA 4
10. Loosen the clamp (2) and remove the pre-cleaner (1).
NOTE: The procedure is the same if the machine has a
rain cap instead of a air pre-cleaner.
RAPH12FRK0030BA 5
11. Remove the bolts that secure the air filter bracket to
the hood.
RAIL14FRK0086AA 6
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12. Remove the hood mounting bolts.

WARNING
Avoid injury!
The component is heavy. Removal/installation
requires two persons or a lifting device.
ous injury.
W1141A
RAPH12FRK0058BA 7
Specification
Hood weight (approximate) 27.2 kg (60 lb)
13. Using an appropriate lifting device or the aid of an

assistant, remove the hood.
14. Remove the bolts (1) and the radiator grille (2)
RAPH12FRK0031BA 8
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15. WARNING
Hot liquid under pressure!
Never remove the filler cap or the recovery
tank cap while the engine is running or the
coolant is hot. Let the system cool. Turn the
filler cap to the first notch and allow any pres-
sure to escape, and then remove the filler cap.
Loosen the recovery tank cap slowly to allow
any pressure to escape.
ous injury.
W0296A
Remove the de-aeration tank cap
RAPH12FRK0034BA 9
16. Locate the drain valve for the cooling system near the
bottom rear of the radiator.
RAPH12FRK0035BA 10
17. Route an appropriate drain hose (1) to the drain valve

through the opening between the counterweight (2)
and the rear frame (3).
18. Attach the drain hose to the drain valve and place the
opposite end of the hose into an appropriate container
that will hold at a minimum of 20.0 L (21.1 US qt).
RAPH12FRK0036BA 11
19. Open the drain valve slowly and allow the cooling sys-
tem fluid to drain completely.
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20. Remove the hose tie wraps (1).

21. Remove the Closed Crankcase Ventilation (CCV)
hose clamp (2).
22. Remove the aspirator hose clamp (3).
RAIL14FRK0114BA 12
23. Disconnect the air temperature sensor.
RAIL14FRK0115BA 13
24. Remove the air intake hose clamp.
RAIL14FRK0104BA 14
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NOTE: For assembly purposes, identify and label all elec-

trical connectors.
25. Disconnect the wires from the air restriction indication
switch.
26. Remove the air filter assembly and cap all openings.
RAIL14FRK0104BA 15
RAIL14FRK0122BA 16
27. Remove the cable ties from the Particulate Matter

(PM) Catalyst tray.
trical connectors.
RAIL14FRK0128BA 17
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28. Disconnect the lambda connector (1).

29. Disconnect the Diesel Oxidation Catalyst (DOC) up-
stream temperature connector (2).
30. Disconnect the Diesel Oxidation Catalyst (DOC)
downstream temperature connector (3).
31. Move the harness away from the Particulate Matter
(PM) Catalyst tray.
RAIL14FRK0128BA 18
32. Remove the V-clamp bolt.
RAIL14FRK0125BA 19
33. Disconnect the flex pipe (1) at the turbocharger (2).

Close all openings.
RAIL14FRK0131BA 20
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34. Either remove the Glow-plug Control Unit (GCU) from

the Particulate Matter (PM) Catalyst tray or disconnect
the GCU connector.
NOTICE: If you disconnect the GCU connector be careful
not to damage the GCU when you set the PM Catalyst tray
off to the side.
WARNING
Avoid injury!
ous injury.
W1141A
RAIL14FRK0132BA 21
Specification
Particulate Matter (PM) Catalyst tray approximate weight 45.4 kg (100 lb)
35. Support the Particulate Matter (PM) Catalyst tray us-

ing an appropriate lifting device.
36. Remove the bolts and nuts that secures the Particu-
late Matter (PM) Catalyst tray to the operator’s plat-
form.
37. Carefully lift the Particulate Matter (PM) Catalyst tray
away from the machine.
NOTE: Cap and plug all openings to avoid contamination.

38. Disconnect the upper radiator hose (1) ad point (A)
and (B).
RAIL14FRK0125BA 22
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39. At connection point (A) the upper radiator hose is

equipped with a quick disconnect clamp. Pull the
clamp out and remove the hose.
RAIL14TLB0826BA 23
RAIL14TLB0827BA 24
40. Disconnect the lower radiator hose (2) at the engine.
RAPH12FRK0961BA 25
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41. Disconnect the wiring harness connector (1) and the

positive battery cable (2) from the rear of the alterna-
tor.
RAPH12FRK0163AA 26
42. Loosen the lower and upper alternator mounting bolts

and nuts (3). Do not remove at this time.
43. Loosen the jam nut (2) and turn the tension bolt (1)
to reduce tension on the serpentine belt. Remove the
belt from the machine.
44. Remove the lower and upper alternator mounting
bolts and nuts (3). Remove alternator from the ma-
chine.
RAPH12FRK0961BA 27
NOTICE: Avoid machine damage. Be careful during the

removal of the fan blade and the spacer as to not damage
the cooling fins on the radiator.
45. Remove the bolts and washers (1). Carefully remove
the fan spacer (2) and fan blade (3).
RAIL14FRK0146BA 28
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46. Disconnect the radiator overflow hose at the radiator.

Close the opening at the radiator.
RAIL14TLB0817BA 29
47. Loosen the shroud-bracket-to-hydraulic oil cooler line

clamp.
RAPH12FRK0964BA 30
48. Loosen the shroud-bracket-to-transmission oil cooler

line clamp.
RAPH12FRK0965BA 31
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49. Disconnect the radiator fill tube from the de-areation

tank and the radiator. Remove the radiator fill tube
from the machine. Close all openings.
RAIL14FRK0145BA 32
NOTICE: Avoid machine damage. Carefully remove the

fan shroud from the machine as to not damage the radiator
cooling fins.
50. Remove the fan shroud bolts and washers from each
side, and carefully remove the fan shroud from the
machine.
RAIL14FRK0114BA 33
51. If equipped, remove the battery disconnect switch

bracket from the frame and set aside.
RAIL14FRK0033BA 34
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52. Remove the nut (3), disconnect the wire harness (4)
and positive battery cable (2) from the terminal on the
starter (1).
RAIL14FRK0038BA 35
53. Disconnect the ground strap.
RAIL14FRK0129BA 36
54. Disconnect the main electrical harness (1) at the en-

gine.
55. Disconnect the fuel lines (4) at the fuel filter. Close all
openings.
56. Loosen the transmission dipstick at the base of the
transmission (3) and rotate counter-clockwise for ad-
ditional clearance.
57. Disconnect the electrical connector at the base of the
fuel filter (2).
RAPH12FRK0977BA 37
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58. On the right-hand side of the engine remove both caps

to access the flex plate bolts.
RAIL14FRK0141BA 38
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59. Insert the engine turning tool 380000988 into the lower
opening and rotate the flywheel until the flex plate bolt
is visible in the top opening.
RAPH12FRK0979BA 39
RAIL14FRK0139BA 40
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60. Remove all the bolts that fasten the flywheel to the flex
plate.
RAIL14FRK0140BA 41
61. Remove all the bolts and washers that fasten the
transmission to the flywheel housing (two shown).
RAPH12FRK0977BA 42
DANGER
Heavy parts!
Support designated component(s) with ade-
quate lifting equipment.
Failure to comply will result in death or serious
injury.
D0018A
Specification
Engine weight (approximate) 363 kg (800 lb)
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62. Attach an appropriate lifting device (1) to the three

engine lift eyes (2) on the engine as shown.
RAPH12FRK0978BA 43
63. Loosen the motor mount-to-frame bolts on both sides

of the engine.
RAPH12FRK0103BA 44
64. Remove all motor mount-to-engine bolts on both sides

of the engine.
RAPH12FRK0978BA 45
NOTICE: Avoid machine damage. Maintain adequate clearance between the engine and machine frame. Make
sure the engine components DO NOT come in contact or hang up on the frame or frame components during engine
removal.
65. Carefully raise and remove the engine from the ma-
chine.
66. Place the engine on the repair stand and repair or
replace as necessary.
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Engine - Install
DANGER
Heavy objects!
Lift and handle all heavy components using lifting equipment with adequate capacity. Always support
units or parts with suitable slings or hooks. Make sure the work area is clear of all bystanders.
D0076A
1. Attach an appropriate lifting device to the three engine

lift eyelets (1) on the engine as shown.
RAPH12FRK0643HA 1
Specification
Engine Weight (approximate) 362.9 kg (800 lb)
NOTICE: Avoid machine damage. Maintain adequate clearance between the engine and the machine frame. Make
sure engine components DO NOT come in contact or hang up on the frame or frame components when installing the
engine.
2. Carefully lower the engine into the machine.
3. Carefully align the engine with the bell housing. Install
all bolts and washers that fasten the bell housing to the
engine. Do not tighten at this time.
NOTE: View is from underneath the machine.
RAPH11TLB0020BA 2
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4. Install the engine mounts (1) on both sides of the en-

gine and tighten to specification.
5. Install and tighten the engine mount bolts (2) to the
frame. Tighten to specification evenly on each side.
RAPH12FRK0103BA 3
RAIL14TLB1008BA 4
Specification
Mount-to-Engine Bolt (1) Torque 89 - 107 N·m (66 - 79 lb ft)
Mount-to-Frame Bolt (2) Torque 178 - 240 N·m (131 - 177 lb ft)
6. Tighten the bell housing bolts (1) to specification.

RAPH11TLB0020BA 5
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Specification
Engine-to-Bell Housing Bolt Torque 52 - 57 N·m (38.4 - 42.0 lb ft)
7. Remove the lifting device from the engine lift eyes.

8. Remove both plugs from the left-hand side of the en-
gine.
RAIL14FRK0141BA 6
9. Using the engine turning tool 380000988, rotate the

engine until the flex plate bolt hole is aligned with the
opening.
RAIL14FRK0139BA 7
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10. Install the four bolts used to fasten the flywheel to the
flex plate. Torque the flex plate bolts to specification.
RAIL14FRK0140BA 8
Specification
Flywheel-to-Flex Plate Bolt Torque 62 - 68 N·m (46 - 50 lb ft)
11. Install the plugs.
RAIL14FRK0141BA 9
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12. Connect the electrical connector at the fuel filter (3).

13. Rotate the transmission dipstick (2) to the proper lo-
cation and tighten.
14. Connect the fuel supply and return lines (4).
15. Connect the main electrical harness (1) at the engine.
RAPH12FRK0977BA 10
16. Install and secure the fan shroud with bolts. Repeat
on the other side.
RAIL14TLB0792BA 11
17. Install the radiator fill tube (1) to the de-areation tank
and the radiator.
RAIL14FRK0114BA 12
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18. Secure the radiator overflow hose to the radiator.
RAIL14TLB0819BA 13
19. Secure the shroud-bracket-to-hydraulic oil cooler line

clamp.
RAPH12FRK0964BA 14
20. Secure the shroud-bracket-to-transmission oil cooler

line clamp.
RAPH12FRK0965BA 15

install of the fan blade and the spacer as to not damage
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21. Position the fan (3) and spacer (2) on the engine. Se-
cure with bolts and washers (1).
RAIL14FRK0146BA 16
Specification
Fan-to-Engine Bolt Torque 52 - 61 N·m (38 - 45 lb ft)
22. If necessary, adjust the shroud position so that the fan

blades do not touch the fan shroud.
23. Position the alternator and hand tighten with mounting
bolts and nuts.
RAPH12FRK0961BA 17
24. Install the drive belt on the pulleys as shown.
83118087 18
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25. Turn the adjustment bolt (1) clockwise until the pivot
bolt (2) is at the end of the tension bracket slot (3).
26. Tighten the pivot bolt (2), upper alternator bolt (5), and
lower alternator bolt (4). Tighten to specification.
83118121 19
Specification
Pivot bolt and alternator bolt torque 45 - 55 N·m (33 - 41 lb ft)
27. Connect the wiring harness connector (1) and the pos-
itive battery cable (2) to the rear of the alternator.
RAPH12FRK0163AA 20
28. Instal the lower radiator hose (2) at the engine and
tighten the clamp securely.
29. Install the upper radiator hose (1) and tighten the
clamps securely.
RAIL14FRK0125BA 21
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30. Secure the Particulate Matter (PM) Catalyst tray to the

rear of the operator’s platform with bolts, nuts, and
washers.
RAIL14FRK0133BA 22
31. Position and secure the flex pipe (1) to the tur-
bocharger (3) with the V-clamp (2).
RAIL14FRK0125BA 23
32. Secure the Glow-plug Control Unit (GCU) to the Par-

ticulate Matter (PM) Catalyst tray or connect the en-
gine harness connector to the GCU connector if it was
disconnected during the removal.
RAIL14FRK0132BA 24
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33. Route the Diesel Oxidation Catalyst (DOC) connector

harness across the rear of the tray.
34. Connect the lambda connector (1).
35. Connect the Diesel Oxidation Catalyst (DOC) up-
36. Connect the Diesel Oxidation Catalyst (DOC) down-
RAIL14FRK0128BA 25
37. Secure harness route with cable ties.
RAIL14FRK0128BA 26
38. Position the air filter housing (1) on top of the engine.
39. Install and secure the engine air intake hose with a
clamp (2).
RAIL14FRK0109BA 27
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40. Install and secure the aspirator hose clamp (3).

41. Install and secure the Closed Crankcase Ventilation
(CCV) hose clamp (2).
42. Install and secure the CCV hose with tie wraps (1).
RAIL14FRK0087AA 28
43. Connect the air temperature sensor.
RAIL14FRK0123BA 29
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44. Connect the wires (previously identified in the removal

procedure) to the air restriction indication switch.
RAIL14FRK0104BA 30
RAIL14FRK0122BA 31
45. Secure the starter ground strap with the star washer
and bolt.
RAIL14FRK0129BA 32
Specification
Starter-to-engine bolt torque 40 - 47 N·m (30 - 35 lb ft)
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46. Secure the positive battery cable (2) to the starter (1)
with the nut and washer (3).
47. Connect the wire harness (4) to the starter.
RAIL14FRK0038BA 33
48. If equipped, install the battery disconnect switch

bracket to the frame and tighten the bolts.
RAIL14FRK0033BA 34
49. Fill the engine cooling system. Refer to Engine cool-

ing system - Filling (10.400).
50. Install the hood. Refer to Hood - Install (90.100).
NOTICE: Make sure the Particulate Matter (PM) catalyst
exhaust tube is directly in the center of the fixed hood ex-
haust outlet. Otherwise component damage may occur.
51. Install the engine side panels. Refer to Side panels -
Install (90.100).
52. Return the machine to use. Refer to Basic instruc-
tions — Prepare machine for service/Return ma-
chine to use ().
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Index
Engine - 10

Engine - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Engine - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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Engine - 10
Air cleaners and lines - 202

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Contents
Engine - 10
SERVICE
Air intake system

Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
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Engine - Air cleaners and lines
Air intake system - Remove

3. Loosen the clamp (2) on the pre-cleaner.
RAPH12FRK0030BA 1
4. Remove the pre-cleaner (1).

5. Remove the bolts that secure the air filter bracket to the
hood.
RAIL14FRK0086AA 2
6. Disconnect the cable strap from the hood to the side

panel.
RAPH12FRK0028BA 3
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7. Remove the four hood mounting bolts.

WARNING
Avoid injury!
ous injury.
W1141A
RAPH12FRK0058BA 4
Specification
8. Using an appropriate lifting device or the aid of an as-

sistant, remove the hood.
hose clamp (2).
RAIL14FRK0114BA 5
12. Disconnect the air temperature sensor.
RAIL14FRK0115BA 6
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13. Remove the air intake hose clamp.
RAIL14FRK0104BA 7

trical connectors.
14. Disconnect the wires from the air restriction indication
switch.
15. Remove the air filter assembly and cap all openings.
RAIL14FRK0104BA 8
RAIL14FRK0122BA 9
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Air intake system - Install

1. Position the air filter housing on top of the engine.
2. Secure the air intake hose with a clamp.
RAIL14FRK0109BA 1
3. Secure the aspirator hose clamp (3).

4. Secure the Closed Crankcase Ventilation (CCV) hose
clamp (2).
5. Secure the CCV hose with tie wraps (1).
RAIL14FRK0087AA 2
6. Connect the air temperature sensor.
RAIL14FRK0123BA 3
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7. Connect the wires (previously identified in the removal

procedure) to the air restriction indication switch.
RAIL14FRK0104BA 4
RAIL14FRK0122BA 5

sistant, install the hood.
WARNING
Avoid injury!
ous injury.
W1141A
Specification
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9. Install the four hood mounting bolts.

NOTICE: Make adjustments before tightening the mount-
ing hardware. Make sure that the air intake and exhaust
pipes are centered in their designated openings.
RAPH12FRK0058BA 6
10. Install the bolts that secure the air filter bracket to the
hood.
NOTICE: Make adjustments before tightening the mount-
ing hardware. Make sure that the air intake and exhaust
pipes are centered in their designated openings.
RAIL14FRK0086AA 7
11. Install the pre-cleaner (1).

12. Tighten the clamp (2) on the pre-cleaner.
RAPH12FRK0030BA 8
13. Connect the cable strap from the hood to the side
panel.
RAPH12FRK0028BA 9
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Index
Engine - 10

Air intake system - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Air intake system - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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Engine - 10
Fuel tanks - 216

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Contents
Engine - 10
Fuel tanks - 216
SERVICE
Fuel tank
Drain fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
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Engine - Fuel tanks
Fuel tank - Drain fluid

WARNING
Fuel vapors are explosive and flammable.
Do not smoke while handling fuel. Keep fuel away from flames or sparks. Shut off engine and remove
key before servicing. Always work in a well-ventilated area. Clean up spilled fuel immediately.
W0904A

2. Place a suitable container underneath the fuel tank
drain plug (2).
3. Open the fuel cap (1).
4. Remove the drain plug (2).
5. When the tank is empty install the drain plug and the
fuel cap.
RAIL15FRK0029BA 1
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Engine - Fuel tanks
Fuel tank - Remove

WARNING
W0904A

2. Use a suitable lifting device and support the fuel tank.
RAIL15FRK0017BA 1
3. Place a suitable container underneath the fuel tank

drain plug (2).
5. Remove the drain plug (2).
6. When the tank is empty install the drain plug and the
fuel cap.
RAIL15FRK0029BA 2
7. Remove the mounting hardware (1)/ (2) from both sides

of the tank.
NOTE: Do not lose the spacers between the machine
frame and the rear mounting bracket (1) on the fuel tank.
Spacers are not required behind the front mounting bracket
(2).
8. Lower the tank slightly. Just enough to easily access
the tube and wire connections.
RAIL15FRK0029BA 3
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Engine - Fuel tanks
9. Disconnect the fuel tank return line (3). Tube with the
yellow marking.
10. Disconnect the fuel tank suction line (4). Tube with
the white marking.
11. Disconnect the fuel tank vent line (5).
12. Slide the protective rubber boot off of the fuel sender
terminal connection (2).
13. Disconnect the fuel sender terminal wire (2).
14. Disconnect the fuel sender ground wire (1).
RAIL15FRK0028BA 4
15. Carefully remove the fuel tank.
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Engine - Fuel tanks
Fuel tank - Install

WARNING
W0904A

2. Carefully move the fuel tank into position just under-
neath the mounting location.
3. Connect and secure the fuel tank return line (3). Tube
with the yellow marking.
4. Connect and secure the fuel tank suction line (4). Tube
with the white marking.
5. Connect and secure the fuel tank vent line (5).
6. Secure the fuel sender ground wire (1).
7. Secure the fuel sender terminal wire (2).
8. Slide the protective rubber boot over the fuel sender
terminal connection.
9. Raise the tank until the mounting holes align.
RAIL15FRK0028BA 1
10. Behind the rear mounting bracket insert spacers be-

tween the fuel tank mounting bracket and the machine
frame. Install the mounting hardware (1).
11. Install the mounting hardware (2) on the front side of
the tank without spacers.
RAIL15FRK0029BA 2
Specification
Fuel tank-to-chassis torque 407 - 542 N·m (300 - 400 lb ft)
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Engine - Fuel tanks
12. If necessary, install the drain plug (2).

RAIL15FRK0029BA 3
14. Fill the fuel tank with ASTM D975 GRADE NO. 2-D S15.
Tank capacity is 117 L (31 US gal)
15. Bleed the air from the fuel system, see Fuel injection
system - Bleed (10.218).
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Index
Engine - 10
Fuel tanks - 216

Fuel tank - Drain fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Fuel tank - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Fuel tank - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
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Engine - 10
Fuel filters - 206

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Contents
Engine - 10
Fuel filters - 206
SERVICE
Fuel filters
Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Fuel-water separator filter
Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
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Engine - Fuel filters
Fuel filters - Replace

1. Fill the fuel tank before proceeding.
2. Open the fuel tank cap slightly to release pressure.
4. Clean the area around the primary fuel filter of dirt and
debris.
5. Turn the primary filter counter-clockwise to remove.
Use a filter removal tool, if necessary.
6. Apply clean engine oil to the new primary filter seal.
7. Turn the new primary filter clockwise onto the filter head
until the filter gasket makes contact with the filter body.
8. Continue to tighten the primary filter and additional 1/2
to 3/4 turn.
RAPH12FRK0179AA 1
9. Tighten the fuel tank cap.

10. Dispose of the filters and collected fluid in accordance
with local, regional, and federal regulations.
NOTICE: Air in the fuel system causes excessive engine cranking before the engine starts. It is crucial that all air be
removed from the system.
11. WARNING
Pressurized system!
Only use the bleed screw to bleed air from the
fuel system. DO NOT loosen the fuel or injec-
tor lines to bleed air. Injury or damage can oc-
cur. Fuel or injector lines are under very high
pressure.
ous injury.
W0285A
Bleed air from the system. For detailed instructions,

see Fuel injection system - Bleed (10.218).
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Fuel-water separator filter - Replace

1. Fill the fuel tank before proceeding.
2. Open the fuel tank cap slightly to release pressure.
4. Clean the area around the water separator of dirt and
debris.
RAPH12FRK0180AA 1
5. Remove the wire connector at the base of the water

separator.
RAPH12FRK0249AA 2
• Press on the wire clasp that holds the connector to

the drain to remove.
RCPH10TLB031AAF 3
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6. Remove the black collar (1) and the filter (2). Use a
filter removal tool, if necessary.
7. Apply clean engine oil to the new fuel filter seal.
8. Install the new filter.
9. Install the black collar and turn until it snaps into place.
NOTICE: Never use a filter removal tool to install a new
filter.
10. Continue to tighten the filter and additional 1/2 to 3/4
turn.
11. Install the wire connector. You should hear it click into RAIL11TLB0009AA 4
position.
12. Tighten the fuel tank cap.
13. Dispose of the filter and collected fluid in accordance
14. WARNING
Pressurized system!
Only use the bleed screw to bleed air from the
fuel system. DO NOT loosen the fuel or injec-
tor lines to bleed air. Injury or damage can oc-
cur. Fuel or injector lines are under very high
pressure.
ous injury.
W0285A
Bleed air from the system. For detailed instructions,

refer to page Fuel injection system - Bleed (10.218).
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Index
Engine - 10
Fuel filters - 206

Fuel filters - Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Fuel-water separator filter - Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
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Engine - 10
Fuel injection system - 218

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Contents
Engine - 10
SERVICE
Fuel injection system

Bleed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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Engine - Fuel injection system
Fuel injection system - Bleed

WARNING
Pressurized system!
Only use the bleed screw to bleed air from the fuel system. DO NOT loosen the fuel or injector lines
to bleed air. Injury or damage can occur. Fuel or injector lines are under very high pressure.
W0285A
Remove the air from the fuel system if one or more of
these conditions have been met:
• The fuel filters are replaced.
• The components of the fuel system have been re-
placed or serviced.
• The machine has been stored for three months or
more.
• The engine has stopped because the fuel tank ran
dry.
1. Open the bleed screw (2) on the head of the water
separator.
2. Activate the hand primer (1) until fuel flows freely from
the bleed screw. Approximately 35 to 45 pumps.
3. Tighten the bleed screw.
RAPH12FRK0183AA 1
4. Loosen the bleed screw from the primary filter head.

Loosen two or three turns.
5. Activate the hand primer on the water separator head
until fuel flows freely from the bleed screw. Approxi-
mately 100 to 125 pumps.
6. Tighten the bleed screw.
RAPH12FRK0179AA 2
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Engine - Fuel injection system
7. Start up the engine.

• DO NOT crank the engine for more than 30 s.
• If the engine will not start, repeat the bleeding
process.
NOTE: The engine will start hard the next four or five times.
Generally, the engine will crank for ten seconds the second
time it is started and about five seconds the third time it is
started.
8. Run the engine for several minutes and then shut down
the engine.
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Index
Engine - 10

Fuel injection system - Bleed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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Engine - 10
Throttle linkage - 220

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10.6 [10.220] / 1
Contents
Engine - 10
SERVICE
Throttle control linkage

Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
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Engine - Throttle linkage
Throttle control linkage - Remove

1. Prepare machine for service. Refer to Basic instruc-
chine to use ().
2. Remove the lower bolts (3) and the hydraulic control
valve shield (4).
3. Remove the remaining bolts (1) and the outer steering
column access panel (2).
RAPH12FRK0041BA 1
4. Remove pedal pad.
RAIL15FRK0030BA 2
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5. Disconnect the electrical connector (4) at the throttle

assembly.
6. Remove the bolts (5) and the throttle assembly from
the machine.
7. Repair or replace as necessary.
RAPH12FRK0062AA 3
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Throttle control linkage - Install

1. Install the throttle assembly (1) to the machine with
mounting hardware (2). Do not fully tighten the bolt
hardware until the final adjustments are made.
2. Install the electrical connector (3) to the throttle assem-
bly.
RAPH12FRK0062AA 1
3. Install the pedal pad.
RAIL15FRK0030BA 2
4. Press down and hold the pedal (2) in a full throttle po-
sition.
5. Rotate the throttle assembly (1) until the bottom of the
pedal is 2.5 mm (0.1 in) dimension (A) above the floor
mat in the full throttle position.
6. Hold the throttle assembly (1) in place, release the
pedal, and fully tighten the bolt hardware.
RAIL15FRK0031BA 3
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7. Install the steering column access panel (2) with bolts

(1).
8. Install the hydraulic control valve shield (4) with bolts
(3).
9. Return machine to use, see Basic instructions — Pre-
pare machine for service/Return machine to use ().
RAPH12FRK0041BA 4
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Index
Engine - 10

Throttle control linkage - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Throttle control linkage - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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Engine - 10
Intake and exhaust manifolds and muffler - 254

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Contents
Engine - 10
SERVICE
Exhaust pipes
Exhaust stack - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Exhaust stack - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
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Engine - Intake and exhaust manifolds and muffler
Exhaust pipes Exhaust stack - Remove

WARNING
Burn hazard!
Exhaust surfaces are hot! Always wear protective gloves when cleaning or working on the muffler,
catalytic converter, or exhaust stack.
W0329A
1. Loosen the nut (1) on the exhaust clamp (2) and re-
move the exhaust stack (3) from the hood.
RAPH12FRK0040BA 1
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Engine - Intake and exhaust manifolds and muffler
Exhaust pipes Exhaust stack - Install

1. Install the exhaust stack (1) to the hood.
2. Ensure the exhaust clamp (2) is positioned correctly,
and tighten the nut (3) securely.
RAPH12FRK0040BA 1
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Index
Engine - 10

Exhaust pipes Exhaust stack - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Exhaust pipes Exhaust stack - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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Engine - 10
Engine lubrication system - 304

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Contents
Engine - 10
SERVICE
Engine lubrication system

Replace – oil and filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Drain fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
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Engine - Engine lubrication system
Engine lubrication system - Replace – oil and filter

The Engine Control Unit (ECU) monitors the oil life of the machine. The ECU will notify the operator through the
instrument control panel that engine oil service is required.
Change the engine oil and filter when , , and appears on the display. The message will appear
every five minutes for 30 s with a single audible alert.
Change the engine oil and replace the filter after every 500 h of operation or when the Engine Control Unit (ECU)
prompts the operator.
Engine oil specification – 8.00 L (8.45 US qt) of TUTELA UNITEK CJ-4 ENGINE OIL SAE 10W-40 or see the “Engine oil
viscosity” chart General specification - Recommended operating temperature range ().
1. Start the engine and run until the engine is warm. A

warm engine allows a more complete removal of for-
eign material.
2. Turn the engine off and open the right-hand side engine
panel.
3. Clean around the engine fill cap (1), engine oil filter and
head (2), engine oil dipstick (3), and oil pan drain plug
(not shown).
RAIL14FRK0018BA 1
4. Slowly open the drain plug for the engine oil pan and
drain the oil into a suitable container.
RAPH12FRK0250AA 2
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5. Turn the oil filter counter-clockwise to remove. Use a

filter removal tool, if necessary.
6. Dispose of the filter and collected oil in accordance with
local, regional, and federal regulations.
7. Use a clean cloth and wipe the sealing surface of the
oil filter base to remove all dirt.
8. Apply a thin layer of clean grease or oil to the gasket of
the new oil filter.
NOTICE: Do not use a filter wrench to install the oil filter.
The wrench can dent the filter and cause a leak.
9. Turn the new oil filter onto the base until the gasket
makes contact with the base.
RAPH12FRK0182AA 3
10. Continue to tighten the filter for one full rotation or

torque to 35 N·m (26 lb ft).
11. Install the drain plug for the engine oil tank.
12. Fill the engine with new oil.
NOTICE: The Engine Control Unit (ECU) tracks engine oil life and will notify the operator in the display when an oil
change is required. After the oil change service is complete the technician must reset the oil life from the SETUP
menu, otherwise the oil change notification will continue.
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13. If the machine is ready for operation, park the machine

and place the ignition key in the OFF position to clear
the active warning , , and from
the display screen.
14. Simultaneously press and hold the enter button (4)
and the down arrow button (3) until the word SETUP
appears in the display (1).
15. Press the up button (3) until OIL appears in the display
(1).
16. Press the enter button (4). RESET appears in the
display (1).
17. Press the enter button (4) again to reset the oil life.
18. Press the escape button (5) twice. EXIT appears in
the display (1).
19. Press the enter button (4) to exit the menu. The in-
strument control panel is now in Sleep mode.
RAIL12FRK1123CA 4
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Engine lubrication system - Drain fluid

1. Start the engine and run until the engine is warm. A
warm engine allows a more complete removal of for-
eign material.
2. Turn the engine off and open the right-hand side engine
panel.
3. Clean around the engine fill cap (1), engine oil filter and
head (2), engine oil dipstick (3), and oil pan drain plug
(not shown).
RAIL14FRK0018BA 1
4. Slowly open the drain plug for the engine oil pan and
drain the oil into a suitable container.
RAPH12FRK0250AA 2
5. After the oil drains out install the drain plug.

6. Dispose of fluid according to local, state, and national
laws.
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Engine lubrication system - Filling

1. If applicable install the drain plug.
RAPH12FRK0250AA 1
2. Open the right-hand side engine panel.

3. Clean around the engine fill cap (1) and engine oil dip-
stick (2).
4. Remove the oil fill cap (1).
RAIL14FRK0018BA 2
5. Fill with clean oil. Engine oil specification – 8.00 L

(8.45 US qt) of TUTELA UNITEK CJ-4 ENGINE OIL SAE
10W-40 or see the “Engine oil viscosity” chart General
specification - Recommended operating tempera-
ture range ().
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Index
Engine - 10

Engine lubrication system - Drain fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Engine lubrication system - Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Engine lubrication system - Replace – oil and filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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Engine - 10
Engine cooling system - 400

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Contents
Engine - 10
SERVICE
Engine cooling system

Drain fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Flush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Radiator
Remove from Cooling Package . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
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Engine - Engine cooling system
Engine cooling system - Drain fluid

CAUTION
Burn hazard!
Hot coolant can spray out if you remove the filler cap while the system is hot. After the system has
cooled, turn the filler cap to the first notch and wait for all pressure to release before proceeding.
Failure to comply could result in minor or moderate injury.
C0043A
Coolant fluid specification – 16.5 L (17.4 US qt)
1. Open the right-side and left-side engine panels.

2. Remove the four bolts (1) and remove the radiator grille
(2)
RAPH12FRK0031BA 1
3. WARNING
Never remove the filler cap or the recovery tank
cap while the engine is running or the coolant
is hot. Let the system cool. Turn the filler cap
to the first notch and allow any pressure to es-
cape, and then remove the filler cap. Loosen
the recovery tank cap slowly to allow any pres-
sure to escape.
ous injury.
W0296A
RAPH12FRK0034BA 2
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bottom of the radiator.
RAPH12FRK0035BA 3

through the opening between the counterweight (2) and
the rear frame (3).
RAPH12FRK0036BA 4
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Engine cooling system - Remove

WARNING
Burn hazard!
Do not handle any service fluid (engine coolant, engine oil, hydraulic oil, etc.) at temperatures that
exceed 49 °C (120 °F). Allow fluids to cool before proceeding.
W0330B
WARNING
Burn hazard!
Hot coolant can spray and scald if you remove the radiator or deaeration tank cap while the system
is hot. To remove the cap: allow the system to cool, turn the cap to the first notch, and wait for all
pressure to release. Remove the cap only after all pressure has released.
W0367A
NOTE: For assembly purposes, identify and label all lines prior to removing.

RAPH12FRK0026BA 1
3. Remove the retaining pin from both ends of the strut.

4. Pull the end of the strut off of the ball stud.
5. Pull the other end of the strut off of the ball stud.
6. Keep the retaining pins with the strut.
RAPH12FRK0027BA 2
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7. Remove the nut and washer that secures the strap to

the hood.
RAPH12FRK0028BA 3
8. WARNING
Heavy objects!
bystanders.
ous injury.
W0398A
Remove the cap screws (1), washers (2), and inside

support plate. Carefully remove the side panel.
9. Repeat the procedure on the other side panel.
RAPH12FRK0026BA 4
10. Loosen the clamp (2) and remove the pre-cleaner (1).
RAPH12FRK0030BA 5
11. Remove the bolts that secure the air filter bracket to
the hood.
RAIL14FRK0086AA 6
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WARNING
Avoid injury!
ous injury.
W1141A
RAPH12FRK0058BA 7
Specification
13. Using an appropriate lifting device or the aid of an

assistant, remove the hood.
14. Remove the counterweight. Refer to Counterweight
- Remove (39.140)
15. Drain the engine cooling system. Refer to Engine
cooling system - Drain fluid (10.400)
16. Drain the hydraulic oil. Refer to Oil reservoir - Drain
fluid (35.300)
17. Disconnect the upper radiator hose (1) at the radiator.
Close all openings.
18. Disconnect the lower radiator hose (2) at the radiator.
Close all openings
RAIL14FRK0109BA 8
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19. Loosen the lower and upper alternator mounting bolts

and nuts (3). Do not remove at this time.
20. Loosen the jam nut (2) and turn the tension bolt (1)
to reduce tension on the serpentine belt. Remove the
belt from the machine.
RAPH12FRK0961BA 9

RAIL14FRK0146BA 10
22. Remove the cable ties (1) from the Closed Crankcase
Ventilation (CCV) hose (2).
RAIL14FRK0113BA 11
23. Disconnect the aspirator hose (3).
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24. Disconnect two transmission oil cooler hoses at the

transmission oil cooler hard lines. Close all openings.
RAPH12FRK0968BA 12
25. Disconnect the two hydraulic oil hoses at the hydraulic

oil cooler hard lines. Close all openings.
RAPH12FRK0970BA 13
WARNING
Heavy object!
Only use lifting equipment approved for loads
specified in this manual.
ous injury.
W1031A
26. Support the cooling package using an appropriate lift-

ing device.
Specification
Cooling Package Weight (approximate) 22.6 kg (50) lb
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27. Remove the bolts and washers (2) from the cooling
package mounting brackets (1). Repeat on the other
side.
RAIL14FRK0142BA 14
28. Remove the cooling package from the machine.

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Engine cooling system - Install

WARNING
Heavy object!
Only use lifting equipment approved for loads specified in this manual.
W1031A
1. Support the cooling package using an appropriate lift-

ing device.
Specification
Cooling Package Weight (approximate) 22.6 kg (50) lb
2. Align the cooling package on the machine.

3. Secure in place with bolts and washers (2) on the cool-
ing package mounting bracket (1). Repeat on the other
side.
RAIL14FRK0142BA 1
4. Connect two transmission oil cooler hoses at the trans-

mission oil cooler hard lines.
RAPH12FRK0968BA 2
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5. Connect the two hydraulic oil hoses at the hydraulic oil

cooler hard lines.
RAPH12FRK0970BA 3

install of the fan blade and the spacer as to not damage
6. Install the fan blade and spacer. Secure with the bolts
and washers (1).
RAIL14FRK0146BA 4
Specification
Fan-to-engine torque specification 52 - 61 N·m (38 - 45 lb ft)
7. Secure the Closed Crankcase Ventilation (CCV) hose

(2) to the cooling package with cable ties (1).
RAIL14FRK0113BA 5
8. Secure the aspirator hose (3).
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1. Route the drive belt on the pulleys as shown.
83118087 6
2. Setting and securing the fan belt tension:

A. Turn the adjustment bolt (1) clockwise, until the
pivot bolt (2) is at the end of the tension bracket
slot (3).
NOTE: Special belt design will adjust to the proper tension.
83118121 7
B. Tighten the adjustment bolt lock nut (1) securing the

adjustment bolt (2) in position.
RAIL11TLB0004AA 8
3. Torque to 45 - 55 N·m (33 - 41 lb ft):

• Pivot bolt (1)
• Lower alternator bolt (2)
83118121 9
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4. Connect the upper radiator hose (1) at the radiator.

5. Connect the lower radiator hose (2) at the radiator.
RAIL14FRK0109BA 10
6. Fill the hydraulic oil. Refer to Oil reservoir - Filling

(35.300)
7. Fill the engine cooling system. Refer to Engine cool-
ing system - Filling (10.400)
8. Install the counterweight. Refer to Counterweight -
Install (39.140)
10. Install the engine side panels. Refer to Side panels -
Install (90.100).
chine to use ().
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Engine cooling system - Filling

NOTICE: NEVER mix OAT coolant with conventional coolant. Under no circumstances should you top off a cooling
system with only water. You can use a refractometer to check the concentration level. Supplemental Coolant Additives
(SCA) should not be used when using CASE AKCELA ACTIFULL™ OT EXTENDED LIFE COOLANT. Change the
coolant solution at the change interval recommended.
Coolant fluid specification – 16.5 L (17.4 US qt) of CASE AKCELA ACTIFULL™ OT EXTENDED LIFE COOLANT
1. Loosen both bolts from the cover plate on top of the

fixed hood and remove one bolt completely.
RAPH12FRK0215AA 1
2. Slide the cover plate (1) out of the way.
RAPH12FRK0213AA 2
1. Remove the de-aeration tank cap (1).
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2. Add CASE AKCELA ACTIFULL™ OT EXTENDED

LIFE COOLANT into the de-aeration tank until the
fluid reaches between the COLD MIN mark (2) and the
HOT MAX mark (1) on the tank.
RAPH12FRK0034BA 3
NOTE: In some situations air pockets in the coolant system

may prevent you from filling the system to capacity. If this
occurs remove the de-aeration valve cap (1) this allows
the air to escape during the fill procedure. The de-aeration
valve cap (1) is on the top left-hand side of the engine below
the air filter housing.
NOTE: Do not over fill the coolant system.
RAIL14TLB1164AA 4
4. Install the de-aeration tank cap.

5. Start the machine and allow the engine coolant to reach
normal operating temperature.
6. Stop engine and inspect for leaks.
7. WARNING
sure to escape.
ous injury.
W0296A
Check the coolant level. Add if necessary.

RAPH12FRK0034BA 5
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8. Install the radiator grille (2) using four bolts (1).
RAPH12FRK0031BA 6
9. Secure the cover plate to the fixed hood.
RAPH12FRK0215AA 7
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Engine cooling system - Flush

CAUTION
Burn hazard!
Hot coolant can spray out if you remove the filler cap while the system is hot. After the system has
cooled, turn the filler cap to the first notch and wait for all pressure to release before proceeding.
Failure to comply could result in minor or moderate injury.
C0043A
Coolant fluid specification – 16.5 L (17.4 US qt)
1. Open the right-side and left-side engine panels.

2. Remove the four bolts (1) and remove the radiator grille
(2)
RAPH12FRK0031BA 1
3. WARNING
sure to escape.
ous injury.
W0296A
RAPH12FRK0034BA 2
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bottom of the radiator.
RAPH12FRK0035BA 3

through the opening between the counterweight (2) and
the rear frame (3).
RAPH12FRK0036BA 4
8. After all the coolant has been drained, close the drain
valve. Do not detach the drain hose.
9. Pour approximately 18.0 L (19.0 US qt) of clean water
into the de-aeration reservoir until full.
NOTE: In some situations air pockets in the coolant system
may prevent you from filling the system to capacity. If this
occurs remove the de-aeration valve cap (1) this allows
the air to escape during the fill procedure. The de-aeration
valve cap (1) is on the top left-hand side of the engine below
the air filter housing.
NOTE: Do not over fill the coolant system.
RAIL14TLB1164AA 5
11. Secure the filler cap on the de-aeration reservoir.

12. Start the engine and run for at least 30 min.
13. Remove the de-aeration filler cap.
14. Drain the water from the system.
15. Repeat Steps 9– 14 for a clean system flush.
16. After the system flush is complete. Close the radiator
drain valve and detach the drain hose.
Next operation:
Fill the coolant system, see Engine cooling system - Filling (10.400).
47821916 28/04/2015
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Radiator - Remove from Cooling Package

2. Remove the engine side panels (see Side panels -
Remove (90.100)).
3. Remove the engine hood see Hood - Remove
(90.100)).
4. Remove the machine counterweight (see Counter-
weight - Remove (39.140)).
5. Drain engine cooling system (see Engine cooling sys-
tem - Drain fluid (10.400)).
6. Remove the fan shroud (see Fan Shroud - Remove
(10.414)).
7. Remove the cooling package from the machine see
Engine cooling system - Remove (10.400)).
NOTE: The transmission oil cooler and hydraulic oil cooler are combined as one unit.
8. Remove four bolts and washers (5) securing the trans-
mission/hydraulic oil cooler to the radiator. Carefully
separate the transmission/hydraulic oil cooler from the
radiator.
RAPH12FRK0939BA 1
9. Inspect, repair, or replace as necessary.
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Radiator - Install
NOTE: The transmission oil cooler and hydraulic oil cooler are combined as one unit.
1. Carefully install the transmission/hydraulic oil cooler to
the radiator. Install four bolts and washers (1) securing
the transmission/hydraulic oil cooler to the radiator.
RAPH12FRK0939BA 1
2. Install the cooling package to the machine (see Engine

cooling system - Install (10.400)).
3. Install the fan shroud (see Fan Shroud - Install
(10.414)).
4. Fill the engine cooling system (see Engine cooling
system - Filling (10.400)).
5. Install the counterweight (see Counterweight - Install
(39.140)).
6. Install the hood (see Hood - Install (90.100)).
7. Install the engine side panels (see Side panels - Install
(90.100)).
8. Return the machine to use.
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Index
Engine - 10

Engine cooling system - Drain fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Engine cooling system - Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Engine cooling system - Flush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Engine cooling system - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Engine cooling system - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Radiator - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Radiator - Remove from Cooling Package . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
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Engine - 10
Fan and drive - 414

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Contents
Engine - 10
Fan and drive - 414
SERVICE
Fan
Shroud - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Shroud - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Belt
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
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Engine - Fan and drive
Fan Shroud - Remove

2. Remove the engine side panels (see Side panels -
Remove (90.100)).
3. Remove the hood (see Hood - Remove (90.100)).
4. Drain the engine cooling system (see Engine cooling
system - Drain fluid (10.400)).
5. Loosen upper and lower alternator mounting bolts and
nuts (1). Do not remove at this time.
6. Loosen the jam nut (2) and turn the tension bolt (2) to
reduce tension on the serpentine belt. Remove the belt
from the machine.
RAPH12FRK0961BA 1
NOTE: Cap and plug all openings to avoid contamination.

7. Remove the upper radiator hose (1).
8. Disconnect the lower radiator hose (2) at the engine.
RAIL14FRK0125BA 2

hose clamp (2).
RAIL14FRK0114BA 3
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10.10 [10.414] / 3

RAIL14FRK0146BA 4
13. Disconnect the radiator overflow hose at the radiator.

Close the opening at the radiator.
RAPH12FRK0963BA 5
14. Loosen the shroud-bracket-to-hydraulic oil cooler line

clamp (2).
RAIL14FRK0145BA 6
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10.10 [10.414] / 4
15. Loosen the shroud-bracket-to-transmission oil cooler

line clamp.
RAPH12FRK0965BA 7
16. Disconnect and remove the radiator fill tube from the
machine. Close all openings.
RAIL14FRK0145BA 8
NOTICE: Avoid machine damage. Carefully remove the fan shroud from the machine as to not damage the radiator
cooling fins.
17. Remove the fan shroud bolts and washers from both
sides of the machine.
RAIL14FRK0114BA 9
18. Carefully maneuver the fan shroud out of the machine

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Fan Shroud - Install

NOTICE: Avoid machine damage. Carefully install the fan shroud to the cooling package as to not damage the radiator
cooling fins.
1. Carefully maneuver the fan shroud into position on the

machine
2. Secure on both sides of the machine with bolts and
washers.
RAIL14FRK0114BA 1
3. Secure the shroud-bracket-to-hydraulic oil cooler line

clamp (2).
RAIL14FRK0145BA 2
4. Secure the shroud-bracket-to-transmission oil cooler

line clamp.
RAPH12FRK0965BA 3
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10.10 [10.414] / 6
5. Connect the radiator fill tube at the de-areation bottle

and the lower front left-hand side of the radiator.
RAIL14FRK0113BA 4
6. Install and secure the Closed Crankcase Ventilation

(CCV) hose clamp (2).
7. Install and secure the aspirator hose clamp (3).
8. Secure in place with hose tie wraps (1).
RAIL14FRK0114BA 5
9. Attach the radiator overflow hose at the radiator. Close

the opening at the radiator.
RAPH12FRK0963BA 6
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10. Attach the upper radiator hose (1).

11. Attach the lower radiator hose (2) at the engine.
RAIL14FRK0125BA 7
12. Install the drive belt on the pulleys as shown.
83118087 8
13. Turn the adjustment bolt (1) clockwise until the pivot
bolt (2) is at the end of the tension bracket slot (3).
14. Tighten the pivot bolt (2).
15. Tighten the lower alternator bolt (4) and upper alter-
nator bolt (5). Tighten to specification.
83118121 9
Specification
Alternator bolt torque 45 - 55 N·m (33 - 41 lb ft)
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10.10 [10.414] / 8

16. Carefully position the fan spacer (2) and fan blade (3)
and secure with bolts and washers (1).
RAIL14FRK0146BA 10
Specification
Fan-to-engine bolt torque 52 - 61 N·m (38 - 45 lb ft)
17. Fill the engine cooling system (see Engine cooling

system - Filling (10.400)).
18. Install the hood (see Hood - Install (90.100)).
19. Install the engine side panels (see Side panels - In-
stall (90.100)).
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10.10 [10.414] / 9
Belt - Remove
Replace the fan drive belt as needed.
1. Loosen the lower alternator bolt (2).

2. Loosen the pivot bolt (1).
83118121 1
3. Loosen the adjustment bolt lock nut (1) .

4. Turn the adjustment bolt (2) counter-clockwise, to
loosen the belt tension.
RAIL11TLB0004AA 2
5. Slide the belt (1) off of the water pump pulley (2) and
remove the belt.
83118121 3
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Belt - Install
1. Route the drive belt on the pulleys as shown.
83118087 1
2. Setting and securing the fan belt tension:

A. Turn the adjustment bolt (1) clockwise, until the
pivot bolt (2) is at the end of the tension bracket
slot (3).
NOTE: Special belt design will adjust to the proper tension.
83118121 2
B. Tighten the adjustment bolt lock nut (1) securing the

adjustment bolt (2) in position.
RAIL11TLB0004AA 3
3. Torque to 45 - 55 N·m (33 - 41 lb ft):

• Pivot bolt (1)
• Lower alternator bolt (2)
83118121 4
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Index
Engine - 10
Fan and drive - 414

Belt - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Belt - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Fan Shroud - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Fan Shroud - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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Engine - 10
Exhaust Gas Recirculation (EGR) - Diesel Particulate Filter (DPF)

exhaust treatment - 501

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Contents
Engine - 10
Exhaust Gas Recirculation (EGR) - Diesel Particulate Filter (DPF) exhaust

treatment - 501
FUNCTIONAL DATA
Diesel Oxidation Catalyst (DOC)

Dynamic description – Particulate Matter (PM) Catalyst . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Detailed view – Particulate Matter (PM) Catalyst . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
SERVICE
Diesel Oxidation Catalyst (DOC)

Remove – Particulate Matter (PM) Catalyst . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Install – Particulate Matter (PM) Catalyst . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
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Engine - Exhaust Gas Recirculation (EGR) - Diesel Particulate Filter (DPF) exhaust treatment
Diesel Oxidation Catalyst (DOC) - Dynamic description – Particulate

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

The DOC and PM-Catalyst emissions system does not have a DPF. Fiat Power Train (FPT) added an observable re-
generation process to the PM-Catalyst system to improve PM-Catalyst performance. Like other tier four, the operator
is notified by a single audible beep and REGEN ON appears on the instrument cluster when the regeneration process
has started. The audible beep and the REGEN ON notification disappears and reappears during this process. When
the regeneration process is complete, REGEN END will appear on the instrument cluster.
47821916 28/04/2015
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After Treatment System (ATS) Failure

If the DOC and PM-Catalyst and/or Exhaust Gas Recir-
culation (EGR) system detects a malfunction, the ECU
de-rates the engine output and prompts the operator to
seek service for the machine by displaying ATS FAIL on RAPH13SSL0576AA 2
the instrument cluster. The instrument cluster warning is
also accompanied by a red, flashing light and an audible
alarm. An After Treatment System (ATS) failure triggers
one or more fault codes. Please use the Electronic Ser-
vice Tool (EST) to diagnose the fault(s). Once the fault is
corrected and the code is cleared, ATS FAIL, the alarm,
and warning light will disappear from the instrument clus-
ter and the machine will return to normal operations.
47821916 28/04/2015
10.11 [10.501] / 4
Diesel Oxidation Catalyst (DOC) - Detailed view – Particulate Matter

(PM) Catalyst
RAIL14FRK0189GA 1
(1) Upstream temperature sensor (5) PM Catalyst tray and mounting clamps
(2) Downstream temperature sensor (6) Lamda sensor
(3) Particulate Matter (PM) Catalyst (7) V-clamps
(4) PM exhaust outlet (8) Exhaust flex pipe
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10.11 [10.501] / 5
Diesel Oxidation Catalyst (DOC) - Remove – Particulate Matter

(PM) Catalyst
2. Detach the side panel strap from hood.
RAPH12FRK0028BA 1
3. Loosen the clamp (2) on the bottom of the air pre-

cleaner (or rain cap) and remove the assembly (1).
RAPH12FRK0030BA 2
4. Remove the two bolts disconnecting the air filter

bracket from the hood.
RAIL14FRK0086AA 3
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10.11 [10.501] / 6

WARNING
Avoid injury!
ous injury.
W1141A
RAPH12FRK0058BA 4
Specification
6. Use an appropriate lifting device or the aid of an assis-

tant, remove the hood.
NOTE: For assembly purposes, identify and label all electrical connectors.
7. Remove the cable ties from the Particulate Matter (PM)
Catalyst tray.
trical connectors.
RAIL14FRK0128BA 5
8. Disconnect the lambda connector (1).

9. Disconnect the Diesel Oxidation Catalyst (DOC) up-
10. Disconnect the Diesel Oxidation Catalyst (DOC)
downstream temperature connector (3).
11. Move the harness away from the Particulate Matter
(PM) Catalyst tray.
RAIL14FRK0128BA 6
47821916 28/04/2015
10.11 [10.501] / 7
12. Remove the V-clamp bolt.
RAIL14FRK0125BA 7
13. Disconnect the flex pipe (1) at the turbocharger (2).

Close all openings.
WARNING
Avoid injury!
ous injury.
W1141A
RAIL14FRK0131BA 8
Specification
PM Catalyst Assembly Weight (approximate) 45.4 kg (100 lb)
14. Support the PM Catalyst assembly using an appropri-

ate lifting device.
15. Remove bolts and nuts from each end bracket.
RAIL14FRK0117BA 9
16. Carefully remove the PM Catalyst from the machine.

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10.11 [10.501] / 8
Diesel Oxidation Catalyst (DOC) - Install – Particulate Matter (PM)

Catalyst
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. Using an appropriate lifting device, place the PM Cata-

lyst (2) between the two end brackets (3).
RAPH12FRK0721BA 1
Specification
PM Catalyst Assembly Weight (approximate) 45.4 kg (100 lb)
2. Install bolts, washers, and nuts to secure the PM Cat-

alyst assembly to each end bracket.
RAIL14FRK0117BA 2
3. Remove the lifting device.
47821916 28/04/2015
10.11 [10.501] / 9
4. Position and secure the flex pipe (1) to the turbocharger

(3) with the V-clamp (2).
RAIL14FRK0125BA 3
5. Route the Diesel Oxidation Catalyst (DOC) connector

harness across the rear of the tray.
6. Connect the lambda connector (1).
7. Connect the Diesel Oxidation Catalyst (DOC) upstream
temperature connector (2).
8. Connect the Diesel Oxidation Catalyst (DOC) down-
RAIL14FRK0128BA 4
9. Secure harness route with cable ties.

NOTICE: Make sure the Particulate Matter (PM) catalyst
exhaust tube is directly in the center of the fixed hood ex-
haust outlet. Otherwise component damage may occur.
chine to use ().
RAIL14FRK0128BA 5
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10.11 [10.501] / 10
Index
Engine - 10
Exhaust Gas Recirculation (EGR) - Diesel Particulate Filter (DPF) exhaust

treatment - 501
Diesel Oxidation Catalyst (DOC) - Detailed view – Particulate Matter (PM) Catalyst . . . . . . . . . . . . . . . . . . . . . . . . . 5
Diesel Oxidation Catalyst (DOC) - Dynamic description – Particulate Matter (PM) Catalyst . . . . . . . . . . . . . . . . . . . 3
Diesel Oxidation Catalyst (DOC) - Install – Particulate Matter (PM) Catalyst . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Diesel Oxidation Catalyst (DOC) - Remove – Particulate Matter (PM) Catalyst . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
47821916 28/04/2015
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CNH Industrial America - Main 700 State Street Racine, Wisconsin United States 53404
SERVICE - Technical Publications & Tools
PRINTED IN U.S.A.
© 2015 CNH Industrial America LLC.
All rights reserved. No part of the text or illustrations of this publication may be reproduced.
CASE CONSTRUCTION policy is one of continuous improvement and the right to change prices, specification
or equipment at any time without notices is reserved.
All data given in this publication is subject to production variations. Dimensions and weight are approximate only
and the illustrations do not necessarily show products in standard condition. For exact information about any
particular product, please consult your CASE CONSTRUCTION Dealer.
47821916 28/04/2015
EN
SERVICE MANUAL
Transmission

47821916 28/04/2015
21
Contents
Transmission - 21
[21.109] Transmission cooler and lines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.1
[21.112] Power shuttle transmission. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.2
47821916 28/04/2015
21
Transmission - 21
Transmission cooler and lines - 109

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21.1 [21.109] / 1
Contents
Transmission - 21
SERVICE
Transmission cooler
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
47821916 28/04/2015
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Transmission - Transmission cooler and lines
Transmission cooler - Remove

1. Prepare the machine for service. See Basic instruc-
chine to use ().
2. Remove the engine side panels. See Side panels -
Remove (90.100).
3. Remove the hood. See Hood - Remove (90.100).
4. Remove the counterweight. See Counterweight - Re-
move (39.140).
NOTE: The transmission oil cooler and the hydraulic oil cooler are combined as one unit.
5. Use a wrench to hold the oil cooler fittings in place when
you disconnect the upper and lower oil cooler tubes (1).
6. Remove the bolts (2) and washers securing the trans-
mission/hydraulic oil cooler to the radiator.
7. Repeat on the other side.
RAIL14FRK0142BA 1
8. Carefully remove the transmission/hydraulic oil cooler

from the radiator.
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21.1 [21.109] / 3
Transmission cooler - Install

1. Carefully position the the transmission/hydraulic oil
cooler to the radiator.
2. Install bolts and washers (1) that secure the transmis-
sion/hydraulic oil cooler to the radiator.
RAPH12FRK0939BA 1

you connect the upper and lower oil cooler tubes (1).
Torque tube-to-fitting to 77 - 85 N·m (57 - 63 lb ft).
RAIL14FRK0142BA 2

5. Install the counterweight. See Counterweight - Install
(39.140).
6. Install the hood. See Hood - Install (90.100)
7. Install the engine side panels. See Side panels - In-
stall (90.100).
47821916 28/04/2015
21.1 [21.109] / 4
8. Return the machine to use. See Basic instructions

— Prepare machine for service/Return machine to
use ().
47821916 28/04/2015
21.1 [21.109] / 5
Index
Transmission - 21

Transmission cooler - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Transmission cooler - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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Transmission - 21
Power shuttle transmission - 112

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Contents
Transmission - 21
TECHNICAL DATA
Power shuttle transmission

General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Torque (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Special tools (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
FUNCTIONAL DATA

Overview (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Transmission drive and driven shafts - Exploded view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Transmission drive and driven shafts - Exploded view - Four wheel drive transmission (*) . . . . . . . . . . . 12
Transmission drive and driven shafts - Exploded view - Two wheel drive transmission (*) . . . . . . . . . . . 14
Transmission drive and driven shafts - Hydraulic schema - Two Wheel Drive Schematic (*) . . . . . . . . . 16
Hydraulic schema - Four Wheel Drive Schematic (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
SERVICE

Replace – fluid and filter (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Check Checking Supply Pump Pressure (4WD Only) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Test - Checking Converter In Pressure (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Test - Checking Regulated Clutch Pressure (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Test Checking Supply Pump Flow and Relief Pressure (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Test - Checking Converter Out Pressure (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Test Checking Lubrication Pressure (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Test - Checking Differential Lock Valve (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Pressure test – 2 Wheel Drive, Test One - Engine at Idle 900 to 1100 rpm (*) . . . . . . . . . . . . . . . . . . . . . . 48
Pressure test - 2 Wheel Drive, Test Two - Engine at 2200 rpm (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Tool connection Two Wheel Drive Port Identification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Tool connection - Pressure Test Ports, Two Wheel Drive (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Tool connection Pressure Test Ports 4 Wheel Drive (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
(*) See content for specific models
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Tool connection Four Wheel Drive Port Identification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Pressure test – 4 Wheel Drive, Test One - Engine at Idle 900 to 1100 rpm (*) . . . . . . . . . . . . . . . . . . . . . . 54
Pressure test - 4 Wheel Drive, Test Two - Engine at 2200 rpm (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Transmission housing
Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Disassemble - Shifter housing (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Disassemble - Shift rods and shift forks (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Assemble - Shifter housing (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Assemble - Transmission housing (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
DIAGNOSTIC

Testing - Machine Will Not Move (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Testing - Will Not Go Into 4WD (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Testing - Machine Hesitates When Shifting Between Forward and Reverse (*) . . . . . . . . . . . . . . . . . . . . 106
Testing - Loss of Power (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Testing - Transmission Oil is Too Hot (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Testing Problem in the Parking Brake System (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
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Transmission - Power shuttle transmission
Power shuttle transmission - General specification

586H
588H
Type of transmission oil CASE AKCELA HY-TRAN® ULTRA™ HYDRAULIC

TRANSMISSION OIL
Clutch disc clearance 2.3 - 4.3 mm (0.1 - 0.2 in)
Capacity - Two wheel drive

Total system 18.5 l (19.5 US qt)
Refill capacity with or without filter change 11.9 l (12.6 US qt)
Capacity - Four wheel drive

Refill capacity with or without filter change 14.4 l (15.2 US qt)
Specifications
NOTE: All specifications shown were taken from a sampling of new production machines with less than 20 hours.
Your figures may differ slightly depending upon the temperature, instrument variables, engine hours, etc.
Parameter Operating Pressure / Temperature

Output of pump supply 32 - 68 l/min (8.5 - 18.0 US gpm) at 900 - 2200 RPM
Pump supply pressure (4WD) 1248 - 1551 kPa (181 - 225 psi) at 900 - 2200 RPM
Regulated clutch pressure 1103 - 1303 kPa (160 - 189 psi) at 900 - 2200 RPM
Torque pressure IN pressure 48 - 903 kPa (7 - 131 psi) at 900 - 2200 RPM
Torque converter OUT pressure 0 - 427 kPa (0 - 62 psi) at 900 - 2200 RPM
Lubrication pressure 40 - 303 kPa (6 - 44 psi) at 900 - 2200 RPM
Transmission oil operating temperature (normal) 78 - 82 °C (172 - 180 °F)
Forward/Reverse clutch solenoids 4.7 ± 10% Ohm at 20 °C (68 °F)
Four wheel drive solenoid 6.8 ± 10% Ohm at 20 °C (68 °F)
Park brake solenoid 9.8 Ohm at 20 °C (68 °F)
Differential lock solenoid valve pressure
Without differential lock solenoid energized 0 bar (0 psi)
With differential lock solenoid energized (4WD) 12.5 - 15.5 bar (181.3 - 224.8 psi)
With differential lock solenoid energized (2WD) and 11 - 13 bar (159.5 - 188.5 psi)
direction control lever in Forward or Reverse position
Park brake check port 13.5 - 15.5 bar (195.8 - 224.8 psi)
NOTICE: Vehicle may move during park brake pressure check. Check park brake pressure from inside of the cab by
removing the floor plate.
Power shuttle transmission - Torque

586H
588H
Pipe plug in end of four-wheel drive shaft 30 N·m (265.5 lb in)

Solenoid valve in four-wheel drive valve 22.0 N·m (194.7 lb in)
Nut for solenoid coils on transmission control valve 7 - 10 N·m (62.0 - 88.5 lb in)
Fittings for four-wheel drive clutch tube 30 N·m (265.5 lb in)
Allen head screws for valve plate on front housing 23 N·m (203.6 lb in)
Test port plugs 23 N·m (203.6 lb in)
Detent plugs 80 N·m (59.0 lb ft)
Bolts for rear cover 50 N·m (36.9 lb ft)
Bolt for output flange 139 N·m (102.5 lb ft)
Allen head screws for shifter assembly 23 N·m (203.6 lb in)
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Hollow cap screws for tube on front housing 40 N·m (354.0 lb in)
Bolts to fasten front and rear housings 50 N·m (36.9 lb ft)
Bolts to fasten cover below four-wheel drive flange 23 N·m (203.6 lb in)
Bolt for four-wheel drive flange 139 N·m (102.5 lb ft)
Bolts for oil pump 23 N·m (203.6 lb in)
Fitting for oil filter 50 N·m (36.9 lb ft)
Bolts to fasten four-wheel drive valve to front housing 23 N·m (203.6 lb in)
Bolts to fasten cover for oil screen 23 N·m (203.6 lb in)
Bolts for transmission control valve 23 N·m (203.6 lb in)
Drain plug 80 N·m (59.0 lb ft)
Allen head screws to fasten pump support to pump 10 N·m (88.5 lb in)
housing
Nut for four-wheel drive solenoid coil 8 N·m (70.8 lb in)
Allen head screws for modulation cover 11 N·m (97.4 lb in)
Solenoid plunger in transmission control valve 23 N·m (203.6 lb in)
Bolts to fasten pump mount to rear housing 50 N·m (36.9 lb ft)
Power shuttle transmission - Special tools

586H
588H
CAS-1804 Pressure Fitting Kit
RCPH11TLB020BAL 1
CAS-40033 Transmission Tool Kit
RCPH11TLB021BAL 2
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CAS-1808 Flowmeter Fitting Kit
RCPH11TLB022BAL 3
CAS-2011 Filter base adapter used with CAS-2383 filter

adapter tube from CAS-40033, Transmission Tool Kit
RCPH11TLB023BAL 4
CAS-10280 Flowmeter
RCPH11TLB024BAL 5
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380040161 - Teflon seal installation
RCPH10TLB828AAL 6
CAS-2379 Input shaft holder and spring compressor
RCPH10TLB043ABL 7
CAS-2381 Seal driver
RCPH10TLB045BL 8
CAS-2378 transmission leg set
RCPH10TLB044ABL 9
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CAS2771A - Teflon seal installation tool kit - 4 wheel drive

shaft
RCPH10TLB688AAL 10
1. CAS2771-2 Seal Expander/Protector

2. CAS2771-1 Seal Compressor
3. CAS2771-3 Spacer
4. CAS2327 Pusher
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Power shuttle transmission - Overview

586H
588H
RAPH12FRK0650HA 1
TRANSMISSION
1–Dipstick 6–Nut 11–Washer 16–Bolt
2–Bolt 7–Connector 12–Bolt 17–Washer
3–Washer 8–Tube 13–Rubber Mount 18–Washer
4–Left Motor Mount 9– Torque Converter 14–Transmission 19–Bolt
5–Washer 10–Plate Adapter 15–Right Motor Mount
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Transmission drive and driven shafts - Exploded view

586H
588H
1. Nut (2) 90-100 NM (67 - 73 lb-ft) 8. Backing plate

2. Transmission 9. Cap screw (4) 52-57 NM (38-42 lb-ft)
3. Bolt (12) 52-57 NM (67-73 lb-ft) 10. Bolt (4) 52-57 NM (38 - 42 lb-ft)
4. Dipstick tube 11. Nut 90-100 NM (67 - 73 lb-ft)
5. Converter 12. Rubber transmission mount (2)
6. Flex plate with caged nut 13. Constant torque clamp (4) 5.6 - 7.9 NM (50 - 50 in-lb)
7. Flex plate
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RCPH10TLB5GAL 1
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Transmission drive and driven shafts - Exploded view - Four wheel

drive transmission
586H
588H
Four-wheel drive transmission

1. Tube 13. Breather
2. Hollow bolt 14. Breather pipe
3. Copper washer 15. PTO flange
4. Copper washer 16. O-ring
5. Plug 17. Bolt
6. Plug 18. Rear cover
7. Plug 19. Bolt
8. O-ring 20. Dowel pin
9. Fitting 21. Drain plug
10. Copper washer 22. Rear housing
11. Test port plug 23. Four-wheel drive clutch tube
12. Park brake pressure tube 24. Front housing
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RCPH10TLB020GAL 1
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Transmission drive and driven shafts - Exploded view - Two wheel

drive transmission
586H
588H
Two-wheel drive transmission

1. Tube 11. Dowel pin
2. Hollow bolt 12. Park brake pressure tube
3. Copper washer 13. Rear cover
4. Plug 14. PTO flange
5. Copper washer 15. Bolt
6. O-ring 16. O-ring
7. Sealing washer 17. Bolt
8. Test port plug 18. Drain plug
9. Breather 19. Rear housing
10. Breather pipe 20. Front housing
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RCPH10TLB021GAL 1
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Transmission drive and driven shafts - Hydraulic schema - Two

Wheel Drive Schematic
586H
588H
RCPH11TLB001HAL 1
(1) Park Brake Solenoid (16) Differential Lock Solenoid

(2) SAHR Park Brake (17) Flow Divider
(3) Torque Converter Relief Valve (18) Regulated Clutch Pressure
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(4) Torque Converter (19) Modulation Spool and Piston (Regulates

Clutch Pressure)
(5) Oil Cooler (20) Lubrication To Bearings and Clutch Packs
(6) Oil Temperature Sender (Oil Cooler) (21) Reverse Clutch
(7) Lubrication Pressure (22) Reverse Clutch Pressure
(8) Lubrication to Synchronizers and Gears (23) Reverse Clutch Solenoid
(9) Forward Clutch (24) Control Valve Assembly
(10) Forward Clutch Pressure (25) Pressure Regulator
(11) Forward Clutch Solenoid (26) Filter (Full flow with by-pass, 15 micron)
(12) Forward/ Reverse Shuttle Spool (Directs (27) Cold Oil By-Pass
flow to forward/reverse clutches)
(13) Torque Converter Inlet Pressure (28) Supply Pump
(14) Modulator Circuit (Pressure modulation (29) Strainer
for Forward/Reverse)
(15) To Differential Lock (Rear axle)
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Power shuttle transmission - Hydraulic schema - Four Wheel Drive

Schematic
586H
588H
RCPH11TLB002HAL 1
(1) Park Brake Solenoid (18) Regulated Clutch Pressure

(2) SAHR Park Brake (19) Modulation Spool and Picton (Regulates
clutch pressure)
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(3) Torque Converter Relief Valve (20) Lubrication To Bearings And Clutch Packs
(4) Torque Converter (21) Reverse Clutch
(5) Oil Cooler (22) Reverse Clutch Pressure
(6) Oil Temperature Sender (Oil Cooler) (23) Reverse Clutch Solenoid
(7) Lubrication Pressure (24) Control Valve Assembly
(8) Lubrication To Synchronizers and Gears (25) Pressure Regulator
(9) Forward Clutch (26) Filter (Full flow with by-pass, 15 micron)
(10) Forward Clutch Pressure (27) Cold Oil By-Pass
(11) Forward Clutch Solenoid (28) Supply Pump
(12) Forward/ Reverse Shuttle Spool (Directs (29) Strainer
flow to Forward/ Reverse clutches)
(13) Torque Converter Inlet Pressure (30) Check Valve
(14) Modulation Circuit (Pressure modulation (31) Supply Pump Pressure For Four Wheel
for Forward/ Reverse) Drive
(15) To Differential Lock (Rear axle) (32) Four Wheel Drive Selector Valve
(16) Differential Lock Solenoid (33) Four Wheel Drive Clutch (Spring applied,
hydraulic release)
(17) Flow Divider
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Power shuttle transmission - Replace – fluid and filter

586H
588H
Transmission oil specification (Two-Wheel Drive) – 10.5 L (11.1 US qt) of CASE AKCELA HY-TRAN® ULTRACTION
Transmission oil specification (Four-Wheel Drive) – 13.0 L (13.7 US qt) of CASE AKCELA HY-TRAN® ULTRAC-
TION
1. Prepare the machine:

A. Bring transmission fluid to operating temperature.
B. Park the machine on level ground.
C. Place both the directional lever and gear shift lever
in neutral.
D. Turn engine off.
E. Open the left-side and right-side engine panels.
2. Clean the area around the transmission dipstick.
3. Turn dipstick counter-clockwise and remove.
RAIL14FRK0020BA 1
4. Clean the area around the drain plug.

5. Place a suitable container underneath the drain plug.
6. Remove the drain plug and allow the oil to drain out.
RCPH09TLB004AAF 2
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7. After all the fluid has drained from the system, inspect
the transmission oil suction filter.
A. Remove the two cap screws.
B. Remove the plate and pull out the suction filter.
C. Inspect the filter for any type of debris.
NOTICE: If suction filter contains debris, contact your au-
thorized dealer before continuing with this procedure.
RCPH09TLB004AAF 3
8. Insert the suction filter, secure in place with plate and

bolts. Torque bolts to 23 N·m (17 lb ft).
9. Locate the transmission filter (2) on the left hand side
below the brake reservoir tank (1).
10. Clean the area around the transmission filter head and
surrounding areas to help eliminate contamination.
11. Place a suitable container under the transmission filter
to capture fluid during the procedure.
RAPH12FRK0161AA 4
12. Remove the filter. Use a filter removal tool, if neces-

sary.
13. Dispose of the filter and collected fluid in accordance
14. Lubricate the gasket of the new filter with clean oil.
NOTICE: Never use a filter removal tool to install the filter.

15. Install the new filter and turn clockwise until the gasket
contacts the head of the filter assembly.
16. Continue to tighten the filter another 1/3 turn.
17. Replace the transmission dipstick.
19. Check for leaks around the filter
20. Operate the machine in first and second gear for a few
minutes.
21. Park the machine on a level surface.
22. Check the fluid level and add if necessary.
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Power shuttle transmission - Remove

WARNING
Jack stands can slip or fall over. Dropping, tipping, or slipping of machine or its components is pos-
sible.
DO NOT work under a vehicle supported by jack stands only. Park machine on a level surface. Block
wheels. Support machine with safety stands.
W0069A
NOTE: Your machine may look different than the following photos, but the procedures are the same.
1. Prepare the machine for service. Refer to Basic in-
structions — Prepare machine for service/Return
machine to use ()
2. Lift the front end of the machine high enough to remove
the transmission from underneath.
NOTE: You may choose to remove the front wheels to ease
the removal, however this is not necessary.
3. Loosen the transmission dipstick (1) to relieve any
pressure.
4. Disconnect the transmission fill tube (1) at the trans-
mission (2) .
RAPH12FRK0085BA 1
5. Remove the drain plug (2) from the transmission and

allow the oil to drain to an appropriate container for
storage or disposal. Install the drain plug after draining
the fluid.
RAPH12FRK0084BA 2
Specification
2WD Transmission Oil Capacity (approximate) 18.5 l (19.5 US qt)
Specification
4WD Transmission Oil Capacity (approximate) 20.8 l (22.0 US qt)
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6. Remove the cab floor mat (3) and the floor plate (4).
RAPH12FRK0101BA 3
7. Disconnect the wire harness connector (5) at the gear

shift lever (6).
8. Disconnect the transmission gear shift lever from the
transmission shift mechanism (7).
RAPH12FRK0087BA 4
9. Disconnect the wiring harness connector for the trans-

mission shift solenoid (8).
RAPH12FRK0392AA 5
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10. CAUTION
Heavy object!
The component is heavy. Use care not to drop
the component when installing, removing, or
handling.
Failure to comply could result in minor or mod-
erate injury.
C0095A
Support the front drive shaft before disconnecting.

11. Remove the retainer (2) and bolts (3) that attach the
front drive shaft to the output shaft yoke (1).
12. Remove the front drive shaft (4) from the axle pinion
shaft (5) .
RCPH11TLB125AAM 6
13. If equipped with 4WD, disconnect the wiring harness

connector for the four wheel drive solenoid (9), located
at the top of the transmission.
RAPH12FRK0394AA 7
14. CAUTION
Heavy object!
handling.
erate injury.
C0095A
Support the rear drive shaft guard before disconnect-

ing.
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15. If equipped with a 4WD guard shaft, remove the bolts

and washers that fasten the rear drive shaft guard to
the frame.
RCPH11TLB001AAL 8
16. CAUTION
Heavy object!
handling.
erate injury.
C0095A
Support the rear drive shaft before disconnecting.

17. If equipped with 4WD, remove the retainer (11) and
bolts (12) that fasten the rear drive shaft (13) to the
transmission output shaft yoke (14).
RAPH12FRK0089BA 9
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18. Remove the rear drive shaft by sliding it off the axle
pinion shaft splines.
RCPH11TLB005AAL 10
19. CAUTION
Heavy object!
handling.
erate injury.
C0095A
Support the drive shaft before disconnecting.

20. Remove the retainer (15) and the bolts (16) that fasten
the front drive shaft (17) to the transmission output
shaft yoke (18).
RAPH12FRK0089BA 11
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21. Remove the differential lock hydraulic hose (19) from

the fitting (20) located on the top of the transmission.
RAPH12FRK0090BA 12
NOTICE: Limit system contamination, cap or plug all hoses and tubes after disconnecting.
22. CAUTION
Heavy object!
handling.
erate injury.
C0095A
Support the hydraulic pump before disconnecting.

23. Disconnect the lines from hydraulic pump (21) and
unbolt the pump from the transmission (22).
RAPH12FRK0399AA 13
NOTE: The fittings for the inlet hose and outlet hose may look different, but the procedures are the same.
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24. Disconnect the transmission cooler inlet (23) and out-

let (24) hoses at the transmission. Install caps on the
transmission fittings and plugs in the hose ends. Tag
each hose to identify it with its location of removal.
RAPH12FRK0092BA 14
25. On the right-hand side of the engine remove both caps

to access the flex plate bolts.
RAIL14FRK0141BA 15
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26. Insert the engine turning tool 380000988 into the lower
opening and rotate the flywheel until the flex plate bolt
is visible in the top opening.
RAPH12FRK0979BA 16
RAIL14FRK0139BA 17
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27. Remove all the bolts that fasten the flywheel to the flex
plate.
RAIL14FRK0140BA 18
28. Loosen and remove the 12 bolts and flat washers (28)
that fasten the transmission to the engine. Move the
heater hose and the clamps (29) off to the side.
RAPH12FRK0096BA 19
WARNING
Crushing hazard!
Unit could fall if not properly supported. Follow
jacking instructions provided for the unit. Use
suitable jack stands. Be sure to position them
properly.
ous injury.
W0919A
29. Install the transmission jack under the transmission

and apply light upward pressure.
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30. Remove both the left-hand and right-hand transmis-

sion mounting bolts (30).
31. Remove the left-hand and right-hand transmission
mounting brackets (31) and hardware from the trans-
mission.
RAIL14FRK0193BA 20
32. Carefully slide the transmission away from the engine.

Lower to the floor and remove from under the ma-
chine.
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Power shuttle transmission - Install

WARNING
Crushing hazard!
Unit could fall if not properly supported. Follow jacking instructions provided for the unit. Use suitable
jack stands. Be sure to position them properly.
W0919A
1. Use the transmission jack, move the transmission un-

der the machine and carefully raise into position.
• Align the mating surface of the transmission housing
to the engine flywheel housing.
• Center the transmission evenly between the trans-
mission to frame mounting location.
2. Secure the left-hand and right-hand transmission
mounting brackets to the transmission.
3. Install the transmission rubber spacers (1) to the trans-
mission mounting brackets on both sides.
4. Install two mounting bolts (4), special hardened wash-
ers (3), and nuts (2). Do not tighten to specification.
RAIL14FRK0193BA 1
5. Install the 12 bolts and flat washers. Tighten to specifi-

cation.
RAPH12FRK0096BA 2
Specification
Transmission-to-Engine Mounting Bolt Torque 52 - 57 N·m (38.4 - 42.0 lb ft)
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6. Alternate tightening the transmission mounting bolts

and nuts. Tighten to specification.
RAPH12FRK0097BA 3
Specification
Transmission Mounting Bolt Torque 178 - 240 N·m (131 - 177 lb ft)
7. Remove transmission jack from under machine.
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8. Remove both plugs from the left-hand side of the en-

gine.
RAIL14FRK0141BA 4
9. Using the engine turning tool 380000988, rotate the

engine until the flex plate bolt hole is aligned with the
opening.
RAIL14FRK0139BA 5
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10. Install the four bolts used to fasten the flywheel to the
flex plate. Torque the flex plate bolts to specification.
RAIL14FRK0140BA 6
Specification
Flywheel-to-Flex Plate Bolt Torque 62 - 68 N·m (46 - 50 lb ft)
11. Install the plugs.
RAIL14FRK0141BA 7
NOTE: The fittings for the inlet hose and outlet hose may look different, but the procedures are the same.
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12. Connect the transmission cooler inlet (1) and outlet (2)
hoses to the appropriate fittings on the transmission.
RAPH12FRK0092BA 8
13. Bolt the hydraulic pump to the transmission.

14. Connect the lines from the hydraulic pump to the
transmission.
RAPH12FRK0399AA 9
15. Connect the hydraulic differential lock hose (1) to the

fitting (2) on the top of the transmission.
RAPH12FRK0090BA 10
16. Grease the inside of the front drive shaft spline with
TUTELA MULTI -PURPOSE EP GREASE 251H, GR-9.
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17. Slide the front drive shaft (4) onto the axle pinion shaft
spline (5) .
18. Install the retainer (2) and bolts (3) that secures the
front drive shaft to the output shaft yoke (1). Tighten
bolts to specification.
RCPH11TLB125AAM 11
Specification
Front Drive Shaft-to-Output Shaft Yoke Bolt Torque 33 - 39 N·m (24.3 - 28.8 lb ft)
19. Grease the inside of the rear drive shaft spline with
TUTELA MULTI -PURPOSE EP GREASE 251H, GR-9
20. If equipped with 4WD, install the rear drive shaft by
sliding it onto the axle pinion shaft spline.
RCPH11TLB005AAL 12
21. If equipped with 4WD, install the retainer (2) and bolts
(3) that secures the rear drive shaft to the output shaft
yoke (1). Tighten bolts to specification.
RAPH12FRK0089BA 13
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Specification
Rear Drive Shaft-to-Output Shaft Yoke Bolt Torque 33 - 39 N·m (24.3 - 28.8 lb ft)
22. If equipped with a 4WD guard, install the rear drive

shaft guard (three sets of bolts and washers). Tighten
to specification.
RCPH11TLB001AAL 14
Specification
Rear Drive Shaft Guard Bolt Torque 50 - 90 N·m (36.9 - 66.4 lb ft)
23. If equipped with 4WD, connect the wiring harness to

the four wheel drive solenoid at the top of the trans-
mission.
RAPH12FRK0394AA 15
24. Connect the wiring harness for the transmission shift

solenoid located on the top of the transmission.
RAPH12FRK0392AA 16
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25. Install the transmission gear shift lever (2) onto the
transmission shift mechanism (1). Tighten the pinch
bolt (3) securely.
RAPH12FRK0087BA 17
26. Install the cab floor plate (2) and the floor mat (1).
RAPH12FRK0101BA 18
27. Confirm the transmission drain plug is installed and

tightened.
RAPH12FRK0084BA 19
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28. Secure the transmission fill tube (2) to the transmis-

sion.
29. Add CASE AKCELA HY-TRAN® ULTRA™ HY-
DRAULIC TRANSMISSION OIL through the trans-
mission fill tube (1) to specification.
RAPH12FRK0085BA 20
Specification 2WD
Total System 18.5 l 19.5 US qt
Refill Capacity With or Without Filter Change 11.9 l (12.6 US qt)
Specification 4WD
Total System 20.8 l (22.0 US qt)
30. Remove the shop stands from under the machine and
lower the machine to the ground.
chine to use ().
32. With the machine parked on level ground and the en-
gine running at low idle, check the transmission oil
level. The oil level must be between the ADD and the
FULL marks on the dipstick. If the oil level is at the
ADD mark, add oil as required until the oil level is at
the FULL mark.
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Power shuttle transmission - Check Checking Supply Pump

Pressure (4WD Only)
586H
588H
NOTE: See Power shuttle transmission - Tool connection Two Wheel Drive Port Identification (21.112) for port
identification.
NOTE: Two wheel drive machines can only be tested by performing a flow meter test.
1. Engage the parking brake.
2. Start the engine. The oil should be at normal operating
temperatures.
3. Connect a 42 bar (600 psi) gauge to test port 10 (A),
see Power shuttle transmission - Tool connection
Four Wheel Drive Port Identification (21.112).
4. Monitor the gauge and record the values for low idle,
see Power shuttle transmission - Pressure test – 4
Wheel Drive, Test One — Engine at Idle 900 to 1100
rpm (21.112).
5. Monitor the gauge and record the values for full throt-
tle, see Power shuttle transmission - Pressure test
— 4 Wheel Drive, Test Two — Engine at 2200 rpm
(21.112).
RCPH11TLB014BAL 1
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Power shuttle transmission - Test - Checking Converter In Pressure

586H
588H
NOTE: See Power shuttle transmission - Tool connection Two Wheel Drive Port Identification (21.112) or Power
shuttle transmission - Tool connection Four Wheel Drive Port Identification (21.112) for test port locations.
temperatures.
3. Connect a 14 bar (200 psi) to test port 6 (A) for 2WD
or 4WD machines.
4. Place transmission controls in neutral.
see Power shuttle transmission - Pressure test –
2 Wheel Drive, Test One — Engine at Idle 900 to
1100 rpm (21.112) or Power shuttle transmission -
Pressure test – 4 Wheel Drive, Test One — Engine
at Idle 900 to 1100 rpm (21.112).
(21.112) or Power shuttle transmission - Pressure
test — 4 Wheel Drive, Test Two — Engine at 2200
rpm (21.112).
RCPH11TLB015BAL 1
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Power shuttle transmission - Test - Checking Regulated Clutch

Pressure
586H
588H
temperatures.
3. Connect a 42 bar (600 psi) gauge to test port 3 (A).
4. Move the direction control lever to forward.
at Idle 900 to 1100 rpm (21.112).
rpm (21.112).
RCPH11TLB016BAL 1
7. Repeat steps 5 and 6 with the control lever in reverse.
NOTE: Forward and reverse clutch pressure can be recorded separately using test port 5 (C) for Forward and test
port 4 (B) for Reverse.
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Power shuttle transmission - Test Checking Supply Pump Flow

and Relief Pressure
586H
588H

CAS-40033 Transmission Tool Kit
CAS-2011 Adapter with CAS-2383 Adapter Tube
OEM-1239 (CAS-10280) Flowmeter
1. Verify that all test equipment is clean.
temperatures.
4. Connect flowmeter and adapter to the transmission fil-
ter base at test port 1 (A) and test port 2 (B). Open the
load valve on the flowmeter.
5. Move the transmission control into neutral.
at Idle 900 to 1100 rpm (21.112).
rpm (21.112).
8. At full throttle, close the load valve until the flow
drops. Read and record the pressure at which the flow
dropped.
RCPH11TLB017BAL 1
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Power shuttle transmission - Test - Checking Converter Out

Pressure
586H
588H
temperatures.
3. Connect a 20 bar (200 psi) to the service tee on test
port 8 (A).
4. Place the transmission in the neutral position.
at Idle 900 to 1100 rpm (21.112).
rpm (21.112).
RCPH11TLB018BAL 1
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Power shuttle transmission - Test Checking Lubrication Pressure

586H
588H
temperatures.
3. Connect a 42 bar (600 psi) gauge to test port 9 (A).
4. Place the transmission in neutral.
at Idle 900 to 1100 rpm (21.112).
rpm (21.112).
RCPH11TLB019BAL 1
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Power shuttle transmission - Test - Checking Differential Lock Valve

586H
588H
CAS-1804 Pressure Test Kit

2. Place the transmission in neutral.
temperatures.
4. Connect a pressure test fitting and a 42 bar (600 psi)
gauge to test port 7 (A).
5. With the transmission shift lever in Neutral, put the di-
rectional control lever in Forward or Reverse.
6. Run the engine at 2200 RPM.
7. Press and hold the differential lock switch located in the
loader control valve.
at Idle 900 to 1100 rpm (21.112).
rpm (21.112).
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Power shuttle transmission - Pressure test – 2 Wheel Drive, Test

One - Engine at Idle 900 to 1100 rpm
586H
588H
NOTE: All specifications shown were taken from a sampling of new production machines with less than 20 engine
hours, your figures may differ slightly.
Test Port Item Specifications — 2 wheel Actual

Drive
1 and 2 Supply Pump Flow 27 to 28 L/min at 1379 kPa
14 bar at 49° C (7.02 to 7.28
gpm at 200psi at 120° F)
1 and 2 Cold Oil By-Pass 2875 kPa to 3137 kPa
29.3 bar to 32.0 bar at 49° C
(417 to 455 psi I at 120° F)
7 Differential Lock 1262 to 1317 kPa,
Pressure (FNR must 12.7 to 13.4 bar (183 to 191
be in forward or reverse psi)
Forward
10 Pump Supply Pressure 1393 to 1427 kPa
14.2 to 14.6 bar (202 to 207
kPa)
4 Regulated Clutch 1276 to 1317 kPa
Pressure 13.0 to 13.4 bar (185 to 191
psi)
6 Torque Converter IN 545 to 607 kPa
5.6 to 6.2 bar (79 to 88 psi)
8 Torque Converter OUT 393 to 414 kPa
4.0 to 4.2 bar (57 to 60 psi)
9 Lubrication Pressure 269 to 283 kPa
2.7 to 2.9 bar (39 to 42 psi)
Neutral
7.0 to 17.7 bar (194 to 202 psi)
5.3 to 5.9 bar (75 to 84 psi)
4.2 to 4.4 bar (60 to 62 psi)
3.4 to 3.7 bar (51 to 53 psi)
Reverse
14.2 to 14.6 psi (203 to 208 psi)
psi)
6 Torque Converted IN 517 to 565 kPa
5.3 to 5.8 bar (75 to 82 psi)
3.4 to 3.5 bar (48 to 50 psi)
2.2 to 2.3 bar (31 to 33 psi)
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Power shuttle transmission - Pressure test - 2 Wheel Drive, Test

Two - Engine at 2200 rpm
586H
588H

Drive
1 and 2 Supply Pump Flow 62 to 70L/min at 1379 kPa
14 bar at 49° C (16.3 to 18.5
gpm at 200 psi at 120° F)
30.9 bar to 33.7 bar at 49° C
(440 to 480 psi I at 120° F)
Forward
16.2 to 16.9 bar (230 to 240
kPa)
psi)
8.4 to 9.8 bar (120 to 140 psi)
4.4 to 4.6 bar (63 to 65 psi)
3.0 to 3.1bar (42 to 44 psi)
Neutral
8.8 to 9.8 bar (125 to 140psi)
6 Torque Converter IN 724 to 862kPa
7.4 to 8.8 bar (105 to 125 psi)
4.9 to 5.3 bar (70 to 73 psi)
4.2 to 4.4 bar (60 to 63 psi)
Reverse
15.9 to 16.6 psi (226 to 236 psi)
psi)
8.4 to 9.8 bar (120 to 140 psi)
4.0 to 4.2 bar (57 to 60 psi)
2.5 to 2.6 bar (35 to 37 psi)
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Power shuttle transmission - Tool connection Two Wheel Drive

Port Identification
586H
588H
RCPH11TLB002GAL 1
1. Flow meter adapter from charge pump to flow meter (Use CAS-2011). Connect the CAS-1029 Flow
meter or equivalent. Pump supply pressure on 2 Wheel Drive units can only be taken with a flow
meter connected to ports 1 and 2.
2. Return from flow meter to transmission (CAS-2383).
3. Regulated clutch pressure, common to forward and reverse. Use CAS-2745 and CAS-2746
4. Regulated reverse clutch pressure. Use CAS-2745 and CAS-2746
5. Regulated forward clutch pressure. Use CAS-2745 and CAS–2746
6. Torque Converter IN pressure. Use CAS-2745 and CAS-2746
7. Differential lock pressure. Use CAS-2744
8. Converter out to cooler. Use CAS-2747
9. Lubrication pressure, common to converter return. Use CAS-2745 and CAS-2746 or use CAS-2747
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Power shuttle transmission - Tool connection - Pressure Test Ports,

Two Wheel Drive
586H
588H
RCPH11TLB004GAL 1
(1) Reverse Clutch Pressure (3) Regulated Clutch Pressure

(2) Forward Clutch Pressure (4) Torque Converter Pressure
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Power shuttle transmission - Tool connection Pressure Test Ports

4 Wheel Drive
586H
588H
RCPH11TLB005GAL 1
(1) Supply Pump Pressure, Four Wheel Drive (4) Regulated Clutch Pressure
Only
(2) Reverse Clutch Pressure (5) Torque Converter Pressure
(3) Forward Clutch Pressure
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Power shuttle transmission - Tool connection Four Wheel Drive

Port Identification
586H
588H
RCPH11TLB003GAL 1
1. Flow meter adapter from charge pump to flow meter (Use CAS-2011). Connect the CAS-1029 Flow
meter or equivalent.
2. Return from flow meter to transmission (CAS-2383).
3. Regulated clutch pressure, common to forward and reverse. Use CAS-2745 and CAS-2746
4. Regulated reverse clutch pressure. Use CAS-2745 and CAS-2746
5. Regulated forward clutch pressure. Use CAS-2745 and CAS–2746
6. Torque Converter IN pressure. Use CAS-2745 and CAS-2746
7. Differential lock pressure. Use CAS-2744
8. Converter out to cooler. Use CAS-2747
9. Lubrication pressure, common to converter return. Use CAS-2745 and CAS-2746 or use CAS-2747
10. Pump supply pressure, 4 wheel drive only. Use CAS-2745 and CAS-2746
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Power shuttle transmission - Pressure test – 4 Wheel Drive, Test

One - Engine at Idle 900 to 1100 rpm
586H
588H
NOTE: All specifications shown were taken from a sampling of new production machines with less than 20 engine
hours, your figures may differ slightly.

Drive
1 and 2 Supply Pump Flow 27 to 28 L/min at 1379 kPa
14 bar at 49° C (7.02 to 7.28
gpm at 200psi at 120° F)
29.3 bar to 32.0 bar at 49° C
(417 to 455 psi I at 120° F)
Forward
14.2 to 14.6 bar (202 to 207
kPa)
psi)
5.6 to 6.2 bar (79 to 88 psi)
4.0 to 4.2 bar (57 to 60 psi)
2.7 to 2.9 bar (39 to 42 psi)
Neutral
7.0 to 17.7 bar (194 to 202 psi)
5.3 to 5.9 bar (75 to 84 psi)
4.2 to 4.4 bar (60 to 62 psi)
3.4 to 3.7 bar (51 to 53 psi)
Reverse
14.2 to 14.6 psi (203 to 208 psi)
psi)
5.3 to 5.8 bar (75 to 82 psi)
3.4 to 3.5 bar (48 to 50 psi)
2.2 to 2.3 bar (31 to 33 psi)
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Power shuttle transmission - Pressure test - 4 Wheel Drive, Test

Two - Engine at 2200 rpm
586H
588H

Drive
1 and 2 Supply Pump Flow 62 to 70L/min at 1379 kPa
14 bar at 49° C (16.3 to 18.5
gpm at 200 psi at 120° F)
30.9 bar to 33.7 bar at 49° C
(440 to 480 psi I at 120° F)
Forward
16.2 to 16.9 bar (230 to 240
kPa)
psi)
8.4 to 9.8 bar (120 to 140 psi)
4.4 to 4.6 bar (63 to 65 psi)
3.0 to 3.1bar (42 to 44 psi)
Neutral
14.4 to 14.9 bar (205 to 212
psi)
6 Torque Converter IN 724 to 862kPa
7.4 to 8.8 bar (105 to 125 psi)
4.9 to 5.3 bar (70 to 73 psi)
4.2 to 4.4 bar (60 to 63 psi)
Reverse
15.9 to 16.6 psi (226 to 236 psi)
psi)
8.4 to 9.8 bar (120 to 140 psi)
4.0 to 4.2 bar (57 to 60 psi)
2.5 to 2.6 bar (35 to 37 psi)
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Transmission housing - Disassemble

586H
588H
NOTE: Some photos may not represent your transmission, the procedures are the same.
1. Fasten the rear housing to acceptable support equip-
ment . It is recommended that you use equipment that
will let you rotate the transmission.
RCPH10TLB689AAL 1
2. Remove the drain plug and drain the oil from the trans-
mission.
RCPH10TLB690AAL 2
NOTE: The four-wheel drive transmission is shown. On two-wheel drive transmissions, the drain plug is at the rear
of the transmission.
3. Remove the two cap screws that fasten the cover for
the oil screen. Remove the cover.
RCPH10TLB693AAL 3
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4. Remove the oil screen and the O-ring.
RCPH10TLB695AAL 4
NOTE: Steps 8 through 10 are for four-wheel drive transmissions only. If you are working on a two-wheel drive trans-
mission, go to step 11.
5. Remove the oil filter.
RCPH10TLB698AAL 5
6. DO NOT remove the plug unless the plug is leaking.

The plug is sealed with Loctite 542 or Loctite 262 and
is difficult to remove. If removal is necessary, clean all
oil from the threads and apply Loctite 542 or Loctite 262
(red) before installation.
RCPH10TLB703AAL 6
7. Remove the fitting for the oil filter.
RCPH10TLB699AAL 7
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8. Remove the spool.
RCPH10TLB701AAL 8
9. Remove the spring.
RCPH10TLB702AAL 9
10. Use a blind hole puller to remove the four-wheel drive

priority valve.
RCPH10TLB907AAL 10
NOTE: The four-wheel drive priority valve is adjusted at the factory. DO NOT try to disassemble or adjust the four-
wheel drive priority valve. If any of the parts are damaged, use a new four-wheel drive priority valve.
11. Remove the dipstick.
RCPH10TLB908AAL 11
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12. Remove the dipstick tube.
RCPH10TLB909AAL 12
13. Remove the fitting for the dipstick tube.
RCPH10TLB808AAL 13
14. Remove the bolts that fasten the transmission control

valve to the front housing.
RCPH10TLB847AAL 14
15. Remove the transmission control valve and the gas-

ket.
16. Remove the three bolts that fasten the four-wheel
drive valve to the front housing.
RCPH10TLB848AAL 15
17. Remove the four-wheel drive valve and the gasket.
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18. Remove the seven bolts that fasten the pump mount
to the rear housing.
RCPH10TLB849AAL 16
19. Remove the pump mount housing.
RCPH10TLB850AAL 17
20. Use a plastic mallet and tap the through shaft out of
the transmission rear housing.
RCPH10TLB851AAL 18
21. Pull the shaft from the transmission.
RCPH10TLB852AAL 19
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22. Remove the seal from the shaft.
RCPH10TLB814AAL 20
23. Remove the snap ring from the pump shaft.
RCPH10TLB813AAL 21
24. Use a suitable driver and remove the bearing from the
pump drive shaft.
RCPH10TLB812AAL 22
25. Remove the pressure sensor switch from the brake

housing.
RCPH10TLB853AAL 23
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26. Remove the solenoid from the brake housing.
RCPH10TLB854AAL 24
27. Make sure the orifice remains in the brake housing.
RCPH10TLB855AAL 25
28. Remove the three Allen head bolts that fasten the
shifter housing to the rear cover. Remove the shifter
assembly and the O-ring.
RCPH10TLB856AAL 26
29. Remove the bolt and the output flange.
RCPH10TLB857AAL 27
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30. Remove the output flange.
RCPH10TLB858AAL 28
31. Remove three of the parking brake cover bolts.

Loosen the remaining three bolts evenly one turn at a
time to relieve spring pressure in the brake housing.
RCPH10TLB859AAL 29
NOTE: Housing is under spring pressure, failure to follow instructions will result in serious injury and damage to
equipment.
32. Remove the brake discs from the brake housing.
RCPH10TLB859AAL 30
33. Remove the brake disc flange from the output shaft.
RCPH10TLB860AAL 31
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34. Remove the rear cover mounting bolts.
RCPH10TLB861AAL 32
35. At the three prying points, use pry bars and loosen the
rear cover from the transmission.
RCPH10TLB864AAL 33
36. Remove the rear cover from the transmission.
RCPH10TLB865AAL 34
37. Remove the seal from the rear cover.

38. Use a punch to remove the pins that fasten the shift
collars to the shift rods.
RCPH10TLB723AAL 35
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39. Remove the shift collars from the shift rods.
RCPH10TLB725AAL 36
40. Remove the two Allen head bolts that hold the plate
between the two shift rods.
RCPH10TLB726AAL 37
41. Remove the plate.
RCPH10TLB728AAL 38
42. Remove the two shift interlock balls from the groove
between the two shift rods.
RCPH10TLB729AAL 39
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43. Remove one of the detent plugs from the right-hand

side of the rear housing.
RCPH10TLB730AAL 40
44. Remove the detent spring.
RCPH10TLB731AAL 41
45. Remove the detent ball.
RCPH10TLB049ABL 42
46. Repeat steps 43 through 45 to remove the other de-

tent plug, spring, and ball.
NOTE: Rotate the transmission in the stand so the shafts will not fall out when the snap ring is removed.
47. Push the secondary shaft to the rear so that there is
clearance between the snap ring and the rear housing.
Remove the snap ring.
RCPH10TLB732AAL 43
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NOTE: If the bearing is not very tight on the secondary shaft, parts could fall from the secondary shaft when you
remove the secondary shaft from the rear housing. To prevent this, you can install a hose clamp on the output end of
the secondary shaft. This will keep the bearing in position during removal of the secondary shaft.
48. Remove all of the housing bolts that are fastened from
the rear housing to the front housing. There are 13
of these bolts on the four-wheel drive and 14 on the
two-wheel drive. On the two-wheel drive, two of the
bolts are longer than the others. Record the locations
of these two.
RCPH10TLB704AAL 44
49. Rotate the transmission so that the front housing is

up. On four-wheel drive transmissions only, there are
three bolts fastened from the front housing to the rear
housing. Remove these bolts.
RCPH10TLB717AAL 45
NOTE: Steps 50 through 57 are for four-wheel drive transmissions only. If you are working on a two-wheel drive
transmission, go to step 58.
50. Install two bolts in the four-wheel drive flange as
shown. Use a pry bar between the two bolts to hold
the four-wheel drive flange while you remove the bolt
from the four-wheel drive shaft.
RCPH10TLB906AAL 46
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51. Remove the washer.
RCPH10TLB705AAL 47
52. Remove the four-wheel drive flange.
RCPH10TLB706AAL 48
53. Remove the O-ring from the four-wheel drive flange.
RCPH10TLB707AAL 49
54. Remove the three bolts that fasten the cover to the
front housing.
RCPH10TLB708AAL 50
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55. Remove the cover.
RCPH10TLB710AAL 51
56. Remove the O-ring from the cover.
RCPH10TLB711AAL 52
57. Remove the seal from the cover.
RCPH10TLB020ABL 53
58. Make a mark across the joint between the oil pump
and the torque converter housing so that the oil pump
can be aligned the same way during installation.
RCPH10TLB866AAL 54
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59. Remove the six bolts that fasten the oil pump in posi-
tion.
RCPH10TLB867AAL 55
60. Use two pry bars to lift the oil pump evenly until the oil
pump can be removed.
RCPH10TLB713AAL 56
61. Remove the oil pump.
RCPH10TLB714AAL 57
62. Pull up the input shaft to get clearance as you release

the snap ring.
RCPH10TLB715AAL 58
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63. Remove the snap ring.
RCPH10TLB716AAL 59
64. Fasten acceptable lifting equipment to the front hous-

ing as shown. Use pry bars at both ends of the hous-
ings to separate the front housing from the rear hous-
ing.
RCPH10TLB718AAL 60
65. As you lift the front housing, continue to use the pry bar
to make sure that the front housing comes up evenly.
Also, it will probably be necessary to hit the end of
the four-wheel drive shaft, if so equipped, and the end
of the input shaft with a soft hammer so that the two
shafts come down out of the front housing and stay
with the rear housing.
RCPH10TLB910AAL 61
NOTE: The bearings in steps 66 and 67 are a close slip fit. If a bearing is difficult to remove, the bearing is probably
not straight in the bore or on the shaft. Push the bearing back into the installed position and try again.
66. The bearing for the primary shaft and the bearing for
the secondary shaft can stay with either the shafts or
the front housing. Remove the two bearings.
RCPH10TLB720AAL 62
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67. On machines with four-wheel drive, remove the four-

wheel drive shaft bearing from the front housing.
RCPH10TLB911AAL 63
68. Remove the tube from the front housing only if the
tube is damaged or leaking.
RCPH10TLB027ABL 64
69. Remove the three O-rings from the flange of the rear
housing.
RCPH10TLB920AAL 65
70. On machines with four-wheel drive, remove the four-

wheel drive shaft.
RCPH10TLB720AAL 66
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71. Remove the input shaft and the reverse shaft together.
RCPH10TLB921AAL 67
NOTE: Make a mark on the top end of the reverse shaft so that you can install the reverse shaft with the same end
up during assembly.
72. Rotate the rear housing so that the open side is up.
Connect acceptable lifting equipment to the top gear
on the secondary shaft.
RCPH10TLB912AAL 68
73. Use the lifting equipment to begin lifting the secondary

shaft while you use your hands to lift the primary shaft.
At the same time, move the primary shaft back and
forth to keep the primary shaft moving freely. It can be
necessary to tap the ends of the shift rods (from below
the rear housing) so that the shift rod and fork assem-
blies continue to move freely. When the primary shaft
is free of the rear housing and the secondary shaft,
remove the primary shaft.
RCPH10TLB913AAL 69
74. Continue to lift the secondary shaft until you can move
the secondary shaft out of the shift forks. Then re-
move the secondary shaft.
RCPH10TLB914AAL 70
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75. Remove the shift rod and fork assembly for first and
second gear from the rear housing.
RCPH10TLB915AAL 71
76. Remove the shift rod and fork assembly for third and
fourth gear from the rear housing. Remember that this
assembly was installed in the bore nearer the top of
the rear housing.
RCPH10TLB916AAL 72
NOTE: Steps 77 and 78 are for four-wheel drive transmissions only. If you are working on a two-wheel drive trans-
77. Remove the four-wheel drive clutch gear.
RCPH10TLB733AAL 73
78. Remove the bearing.
RCPH10TLB917AAL 74
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79. It is not necessary to remove the test port plugs (1), the
breather (2), or the temperature sender (3) from the
rear housing unless these parts are leaking or dam-
aged.
RCPH10TLB918AAL 75
80. Inspect the input shaft bore in the rear housing. If

there are grooves from the sealing rings, you must use
a new rear housing. Remove any sharp edges at the
ends of the input shaft bore and at the oil distribution
holes.
81. Remove the four-wheel drive clutch tube (four-wheel
drive machines only) from the front housing only if the
front housing must be replaced or if the tube is leaking
or damaged.
RCPH10TLB023ABL 76
82. Remove the three Allen head bolts that fasten the
valve plate to the front housing.
RCPH10TLB025ABL 77
83. Remove the valve plate from the front housing.
RCPH10TLB024ABL 78
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84. Remove the gasket.
RCPH10TLB026ABL 79
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Transmission housing - Disassemble - Shifter housing

586H
588H
1. Use side cutters as shown to release the catch on the

band that fastens the boot to the shifter housing. Re-
move the band.
RCPH10TLB012ABL 1
2. Remove the boot from the shifter housing.
RCPH10TLB013ABL 2
3. Remove the two pins (one on either side of the shifter

housing). Use a screwdriver to lift each pin as shown
until you can reach the pin with your fingers. Then pull
the pin out.
RCPH10TLB013ABL 3
4. Remove the snap ring from the shift lever.
RCPH10TLB016ABL 4
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5. Remove the bushing from the shift lever.
RCPH10TLB019ABL 5
RCPH10TLB018ABL 6
7. Remove the shift lever from the shifter housing.
RCPH10TLB017ABL 7
Next operation:
Transmission housing - Disassemble (21.112)
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Transmission housing - Disassemble - Shift rods and shift forks

586H
588H
1. If disassembly is required, remove the roll pins and sep-

arate the shift forks from the shift rods. Make sure that
you remember how the parts are assembled and which
parts go together. The forks are the only parts that are
not interchangeable. Inspect all parts for burrs and ex-
cessive wear. Assembly is the reverse of disassembly.
RCPH10TLB944AAL 1
Next operation:
Transmission housing - Assemble (21.112)
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Transmission housing - Assemble - Shifter housing

586H
588H
1. Apply lithium grease to the ball of the shift lever. Install

the shift lever in the shifter housing.
RCPH10TLB017ABL 1
2. The correct alignment of the shift lever and the shifter

housing is shown above. The slot (1) in the shift lever
must be toward the flat side (2) of the flange on the
shifter housing. The slots (3) on each side of the shift
lever must be aligned with the holes (4) in each side of
the shifter housing.
RCPH10TLB021ABL 2
3. Install the spring.
RCPH10TLB018ABL 3
4. Install the bushing.
RCPH10TLB019ABL 4
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5. Put the snap ring on the shift lever. Use a deep well
socket to push the snap ring into the snap ring groove.
RCPH10TLB015ABL 5
6. Install the pins through the holes in the shifter housing

so that the pins engage the slots in the shift lever.
RCPH10TLB013ABL 6
7. Install the boot so that the end of the boot fits over the
ends of the pins. Be careful so that the pins do not fall
out during this step.
RCPH10TLB013ABL 7
8. Install the band or clamp on the boot. Use the side

cutters to engage the catch on the band.
RCPH10TLB012ABL 8
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Transmission housing - Assemble - Transmission housing

586H
588H
1. If the four-wheel drive clutch tube (four-wheel drive ma-

chine only) was removed from the front housing, install
the four-wheel drive clutch tube. Tighten the fittings to
a torque of 40 Nm (265 pound-inches).
RCPH10TLB023ABL 1
2. Install plugs (foam ear plugs work well) in the three oil
passages in the edge of the rear housing. Scrape all
sealing material from the sealing surface of the rear
housing. Prepare the sealing surface by rubbing with a
3M Scotch-Brite fiber pad or equivalent. DO NOT use
steel wool or anything that can leave material on the
sealing surface. Flush the rear housing with solvent.
RCPH10TLB028ABL 2
3. Install plugs (foam ear plugs work well) in the three oil
passages in the edge of the front housing. (The plugs
have not been installed in the picture above.) Scrape
all sealing material from the sealing surface of the front
housing. Prepare the sealing surface by rubbing with a
3M Scotch-Brite fiber pad or equivalent. DO NOT use
steel wool or anything that can leave material on the
sealing surface. Flush the front housing with solvent.
RCPH10TLB023ABL 3
4. Install the gasket for the valve plate on the front hous-
ing.
RCPH10TLB026ABL 4
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5. Put the valve plate into position.
RCPH10TLB024ABL 5
6. Install the three Allen head bolts to fasten the valve

plate to the front housing. Tighten the Allen head bolts
to a torque of 23 Nm (204 pound-inches).
RCPH10TLB025ABL 6
7. If the test port plugs (1), the breather (2), and the tem-
perature sender (3) were removed from the rear hous-
ing, install these parts. Tighten the test port plugs (1)
to a torque of 23 Nm (204 pound-inches).
RCPH10TLB918AAL 7
8. Put the bearing for the four-wheel drive shaft into posi-
tion in the rear housing.
RCPH10TLB917AAL 8
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9. Install the four-wheel drive clutch gear so that the side

with the lugs is up.
RCPH10TLB733AAL 9
10. Connect acceptable lifting equipment to the top gear

on the secondary shaft. Lift the secondary shaft over
the rear housing. Engage the shift forks with the syn-
chronizers as shown. Begin to lower the assembly
into the rear housing.
RCPH10TLB029ABL 10
11. As you lower the assembly into the rear housing, also
begin to install the primary shaft so that the gears on
the primary shaft go into mesh with the gears on the
secondary shaft. Continue to lower the parts, making
sure that each part goes into the correct bore in the
rear housing. (Remember that the shift rod and fork
assembly for third and fourth gear goes into the bore
nearer the top of the rear housing). When all of the
parts are in position, disconnect the lifting equipment.
RCPH10TLB913AAL 11
12. Push the secondary shaft toward the rear of the rear
housing so that there is clearance between the snap
ring groove and the rear housing. Install the snap ring.
RCPH10TLB732AAL 12
NOTE: In steps 13 through 15, the photos show the upper detent parts already installed. It is necessary for you to
install both the upper and lower detent parts according to the instructions in the procedure. Make sure that you start
with both shift rods in the NEUTRAL position.
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13. Install the lower detent ball.
RCPH10TLB049ABL 13
14. Install the lower detent spring.
RCPH10TLB731AAL 14
15. Install the copper washer on the detent plug. Install

the lower detent plug. Tighten the lower detent plug
to a torque of 80 Nm (59 pound-feet).
RCPH10TLB730AAL 15
16. Repeat steps 13 through 15 to install the upper detent

ball, spring, copper washer, and plug.
17. Install the two detent balls in the groove between the
two shift rods.
RCPH10TLB729AAL 16
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18. Install the plate over the two detent balls.
RCPH10TLB728AAL 17
19. Apply Loctite 542 or Super bond 321 to the threads

of the two Allen head bolts. Install the two Allen head
bolts to fasten the plate in position. Tighten the two
Allen head bolts to a torque of 50 Nm (37 pound-feet).
RCPH10TLB727AAL 18
20. Install the shift collars on the shift rods.
RCPH10TLB725AAL 19
21. Install the pins to fasten the shift collars to the shift
rods.
RCPH10TLB724AAL 20
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22. Scrape all sealing material from the sealing surface of

the rear cover. Prepare the sealing surface by rubbing
with a 3M Scotch-Brite fiber pad or equivalent. DO
NOT use steel wool or anything that can leave material
on the sealing surface. Wipe the sealing surface with
Loctite Safety Solvent or equivalent. Apply a layer of
Loctite 518 or Super bond 539 to the sealing surface.
23. Put the rear cover in position. Make sure that the
dowel is installed in the rear housing and through the
hole in the rear cover. Install the seven bolts to fas-
ten the rear cover to the rear housing. If necessary,
tap the rear cover with a soft faced hammer to close
the gap between the rear housing and the rear cover
before you tighten the bolts. Tighten the seven bolts
sequentially to a torque of 50 Nm (37 pound-feet).
RCPH10TLB861AAL 21
NOTE: The above photo shows the shifter installed, the shifter should not be installed at this time.
24. Install a new O-ring on the shifter assembly. Use clean
oil to lubricate the O-ring. Put the shifter assembly into
position on the rear cover.
RCPH10TLB722AAL 22
25. Install the three Allen head bolts to fasten the shifter
assembly to the rear cover. Tighten the three Allen
head bolts to a torque of 23 Nm (204 pound-inches).
RCPH10TLB721AAL 23
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26. If the tube was removed from the front housing, install
the tube now. Tighten the hollow bolts to a torque of
40 Nm (354 pound-inches).
RCPH10TLB027ABL 24
27. Install the input shaft and the reverse shaft together
as shown. If you are using the same reverse shaft,
make sure that you install it with the same end up as
when it was removed.
RCPH10TLB921AAL 25
28. On machines with four-wheel drive, install the four-

wheel drive shaft. Use clean transmission oil to lu-
bricate the bearing surfaces on the four-wheel drive
shaft. Make sure that the four-wheel drive shaft goes
through the four-wheel drive clutch gear, the thrust
washer, and the bearing.
RCPH10TLB719AAL 26
29. Wipe the sealing surface of the rear housing and the
front housing with Loctite Safety Solvent or equivalent.
Apply a layer of Loctite 518 or Super bond 529 to the
sealing surface of the rear housing.
RCPH10TLB030ABL 27
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30. Remove the three plugs from the oil passages in the
rear housing (see arrows). Install three new O-rings
for the oil passages. Remove the three plugs from the
oil passages in the front housing.
RCPH10TLB920AAL 28
31. Use clean transmission oil to lubricate the bearing for

the primary shaft and the bearing for the secondary
shaft. Install the bearings.
RCPH10TLB720AAL 29
32. Install the front housing on the rear housing. Make

sure that the bearings on the shafts go straight into
the bores in the front housing. Push the front housing
all the way down on the rear housing.
RCPH10TLB718AAL 30
33. Install all of the housing bolts that fasten the rear hous-
ing to the front housing. There are 13 of these bolts on
four-wheel drive transmissions and 14 on two-wheel
drive transmissions. Tighten the bolts evenly until
the front housing and rear housing are together, then
tighten the bolts to a torque of 50 Nm (37 pound-feet).
RCPH10TLB704AAL 31
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34. Install the three bolts that fasten from the front housing
to the rear housing. Tighten the bolts to a torque of 50
Nm (37 pound-feet).
RCPH10TLB033ABL 32
35. Use clean transmission oil to lubricate the bearing for

the four-wheel drive shaft. Install the bearing on the
four-wheel drive shaft.
RCPH10TLB034ABL 33
36. Use the CAS-2381 special tool to install a new seal

in the cover. Push just until the seal stops moving.
DO NOT use excessive force. Fill the cavity under
the lip of the seal with high temperature wheel bearing
grease.
RCPH10TLB022ABL 34
37. Install a new O-ring on the cover. Use clean transmis-

sion oil to lubricate the O-ring.
RCPH10TLB711AAL 35
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38. Install the cover in the front housing.
RCPH10TLB710AAL 36
39. Install the three bolts that fasten the cover to the front
housing. Tighten the bolts to a torque of 23 Nm (204
pound-inches).
RCPH10TLB709AAL 37
40. Install a new O-ring in the four-wheel drive flange. Use

clean transmission oil to lubricate the O-ring.
RCPH10TLB707AAL 38
41. Install the four-wheel drive flange on the four-wheel

drive shaft.
RCPH10TLB706AAL 39
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42. Install the washer.
RCPH10TLB705AAL 40
43. Install and tighten the cap screw in the four-wheel

drive shaft to a torque of 139 Nm (103 pound-feet).
RCPH10TLB906AAL 41
44. Pull the input shaft toward the front of the transmission
to get clearance for the snap ring.
RCPH10TLB031ABL 42
45. Install the snap ring on the bearing.
RCPH10TLB032ABL 43
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46. It will be easier to install the oil pump if you use a guide
stud as shown above. You can make a guide stud by
cutting the head from an M8 bolt.
RCPH10TLB036ABL 44
47. Use clean transmission oil to lubricate the O-ring on

the oil pump. Install the oil pump. Make sure that the
alignment marks that you made during disassembly
are aligned.
RCPH10TLB035ABL 45
48. If you used a guide stud, remove the guide stud. In-
stall the six bolts that fasten the oil pump in posi-
tion. Tighten the bolts to a torque of 23 Nm (204
pound-inches).
RCPH10TLB712AAL 46
49. Install the hub onto the output shaft as shown.
RCPH10TLB877AAL 47
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50. Install a reaction plate first.
RCPH10TLB876AAL 48
51. Install a friction plate and a wave spring, continue to

install a reaction plate, friction plate and wave spring
until all components are installed.
RCPH10TLB875AAL 49
52. Install the back plate as shown.
RCPH10TLB874AAL 50
53. Install a new O-ring.
RCPH10TLB873AAL 51
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54. Install the brake housing.
RCPH10TLB872AAL 52
55. Install the bolts, use an alternately tightening pattern

until the brake housing is tight against the transmis-
sion. Torque the bolts to 50 Nm (37 pound feet).
RCPH10TLB871AAL 53
56. Install the flange and a new O-ring.
RCPH10TLB869AAL 54
57. Install the bolt and washer.
RCPH10TLB868AAL 55
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58. Torque bolt to 139 Nm (103 pound feet).
RCPH10TLB870AAL 56
59. Make sure the orifice is in the brake housing, install

new O-rings.
RCPH10TLB855AAL 57
60. Install the brake solenoid, torque the solenoid to 20

Nm (15 pound feet).
RCPH10TLB854AAL 58
61. Install the pressure sensor switch into the brake hous-
ing.
RCPH10TLB853AAL 59
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62. Slide the expander/protector onto the pump drive

shaft.
RCPH10TLB842AAL 60
63. Heat the Teflon sealing ring to 80° to 100° C (176°

to 212° F). Install the Teflon sealing ring onto the
380001428 expander/protector.
RCPH10TLB843AAL 61
64. Install the 380001928 pusher over the expander/pro-

tector and slide the sealing ring until it reaches the
groove in the shaft. Remove the pusher and ex-
pander/protector from the shaft.
RCPH10TLB844AAL 62
65. Install the end of the 380001427 seal compressor with

the deep chamfer onto the shaft and over the sealing
ring. Use a back and forth twisting motion to allow the
seal compressor to slip over the top of the sealing ring
and seat the sealing ring into the groove. Be careful
not to damage the sealing ring. After the sealing ring
is seated in the groove, remove the seal compressor
from the shaft.
RCPH10TLB845AAL 63
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66. Turn the seal compressor around and slide the end
with the narrow chamfer over the shaft and over the
sealing ring. Leave the seal compressor in place for
15 minutes until the sealing ring has cooled and is
properly sized and seated in the groove. After the
sealing ring has cooled, remove the seal compressor
from the shaft.
RCPH10TLB846AAL 64
67. Install the bearing and snap ring on the pump drive
shaft, install the shaft in the rear housing.
68. Install the PTO shaft into the transmission.
RCPH10TLB850AAL 65
69. Scrape all sealing material from the sealing surface of

the pump mount and rear cover. Prepare the sea ling
surface by rubbing with a 3M Scotch-Brite fiber pad or
equivalent. DO NOT use steel wool or anything that
can leave material on the sealing surface. Wipe the
sealing surface with Loctite Safety Solvent or equiva-
lent. Apply a layer of Loctite 518 or Super bond 539
to the sealing surface.
70. Install the pump mount on the rear housing, torque
bolts to 50 Nm (37 pound-feet).
RCPH10TLB849AAL 66
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71. Install the fitting for the dipstick tube.
RCPH10TLB808AAL 67
72. Install the dipstick tube.
RCPH10TLB909AAL 68
73. Install the dipstick.
RCPH10TLB908AAL 69
NOTE: The following photo shows the four-wheel drive priority valve installed and is for reference for the plug only.
74. If the plug was removed, make sure that the threads
are clean and apply Loctite 543 or Loctite 262 (red) to
the threads before installation. Tighten the plug to a
torque of 40 Nm (354 pound-inches).
RCPH10TLB703AAL 70
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75. Install the four-wheel drive priority valve in the oil filter
bore.
RCPH10TLB037ABL 71
RCPH10TLB702AAL 72
77. Install the spool.
RCPH10TLB701AAL 73
78. Install the fitting for the oil filter. Tighten the fitting to a
torque of 50 Nm (37 pound-feet).
RCPH10TLB700AAL 74
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79. Use clean transmission oil to lubricate the gasket on

the oil filter. Install the oil filter.
RCPH10TLB698AAL 75
80. Install the gasket for the four-wheel drive valve.
RCPH10TLB905AAL 76
81. Put the four-wheel drive valve in position on the gas-

ket.
RCPH10TLB697AAL 77
82. Install the three bolts that fasten the four-wheel drive
valve to the front housing. Tighten the bolts to a torque
of 23 Nm (204 pound-inches).
RCPH10TLB696AAL 78
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83. Install a new O-ring on the oil screen. Use clean trans-
mission oil to lubricate the O-ring. Install the oil screen
and O-ring.
RCPH10TLB695AAL 79
84. Install the cover for the oil screen. Install the two bolts
that fasten the cover for the oil screen. Tighten the
bolts to a torque of 23 Nm (204 pound-inches).
RCPH10TLB694AAL 80
85. Install the gasket for the transmission control valve.

Put the transmission control valve in position on the
gasket.
RCPH10TLB692AAL 81
86. Install the bolts that fasten the transmission control

valve to the front housing. Tighten the bolts in a pat-
tern alternating from front to back and side to side un-
til all the bolts are at a torque of 23 Nm (204 pound-
inches).
RCPH10TLB691AAL 82
NOTE: The following photo shows the drain plug for four wheel drive machines.
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87. Install a new O-ring on the drain plug. Lubricate the

O-ring with clean transmission oil. Install the drain
plug. Tighten the drain plug to a torque of 80 Nm (59
pound-feet).
RCPH10TLB690AAL 83
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Power shuttle transmission - Testing - Machine Will Not Move

586H
588H
Test N°1
Test Point Check
Verify the transmission oil level. Refer to Power shuttle transmission - General specification (21.112).
Refer to Transmission Fluid Level in the Operator’s Manual.
Expected Result
Result The oil level is correct. Go to next step.
Other Action
Result The transmission oil level is not correct. Check for leaks. Fill the transmission oil to the proper level.
(Possible Refer to Transmission Fluid Level in the Operator’s Manual.
Cause)
Test N°2
Test Point Check
Check for broken universal joint or drive shaft.
Expected Result
Result The drive shaft and universal joint are free from damage. Go to next step.
Other Action
Result The drive shaft and universal joint are damaged. Repair as required.
(Possible
Cause)
Test N°3
Test Point Condition
Raise the rear wheels off the ground.
Check
Verify that the drive shaft turns when the transmission directional control lever (FNR) is moved into For-
ward or Reverse.
Expected Result
Result The drive shaft turns when the transmission directional control lever (FNR) is moved into Forward or
Reverse. Go to next step.
Other Action
Result The drive shaft does not turn. Check the electrical connections to the transmission. Verify that there is
(Possible power to the clutch solenoids. Check fuse F-024.
Cause)
Test N°4
Test Point Check
Check transmission pressure and pump flow. Refer to Power shuttle transmission - Pressure test –
2 Wheel Drive, Test One — Engine at Idle 900 to 1100 rpm (21.112).
Expected Result
Result The transmission pressures and pump flow are within specifications.
Other Action
Result
(Possible The transmission pressures and pump flow are not within specifications. Possible causes include:
Cause) • Cold oil by-pass valve may be stuck or damaged.
• Faulty pressure regulator.

• Faulty transmission oil pump. Refer to Power shuttle transmission - Check Checking Supply
Pump Pressure (4WD Only) (21.112) or Power shuttle transmission - Test Checking Supply
Pump Flow and Relief Pressure (21.112).
Test N°5
Test Point Check
Check the converter IN pressure. Refer to Power shuttle transmission - Test — Checking Converter
In Pressure (21.112)
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Expected Result
Result The converter IN pressure is within specifications. Go to next step.
Other Action
Result The converter IN pressure is not within specifications. Check the transmission control valve. Repair or
(Possible replace as required.
Cause)
Test N°6
Test Point Check
Check the Forward and Reverse solenoid valve. Refer to Power shuttle transmission - Test — Check-
ing Regulated Clutch Pressure (21.112).
Expected Result
Result The regulated clutch pressures are within the specified range. Go to next step.
Other Action
Result The regulated clutch pressures are not within the specified range. Refer to Forward and Reverse solenoid
(Possible troubleshooting in the Service Manual. .
Cause)
Test N°7
Test Point Check
Check regulated clutch pressure at test port 3. Refer to Power shuttle transmission - Test — Checking
Regulated Clutch Pressure (21.112)
Expected Result
Result The regulated clutch pressure is within specifications. Refer to Power shuttle transmission - Pres-
sure test – 2 Wheel Drive, Test One — Engine at Idle 900 to 1100 rpm (21.112) and Power shuttle
transmission - Pressure test — 2 Wheel Drive, Test Two — Engine at 2200 rpm (21.112) OR Power
shuttle transmission - Pressure test – 4 Wheel Drive, Test One — Engine at Idle 900 to 1100 rpm
(21.112) and Power shuttle transmission - Pressure test — 4 Wheel Drive, Test Two — Engine at
2200 rpm (21.112).
Other Action
Result
(Possible The regulated clutch pressure is not within specifications. Possible causes include:
Cause) • Pressure remains zero in Forward, Neutral and Reverse. Check the control valve.
• Pressure is low, check the control valve. Inspect the transmission control valve.
• Pressure in Forward and Reverse are the same. Check the control valve.
• Forward and Reverse pressures are different. Inspect the individual clutch circuits.
Power shuttle transmission - Testing - Will Not Go Into 4WD

586H
588H
Test N°1
Test Point Check
Check for broken universal joint or front drive shaft.
Expected Result
Result The universal joint and front drive shaft are functioning properly. Go to next step.
Other Action
Result The universal joint or front drive shaft are in need of repair. Repair or replace as required.
(Possible
Cause)
Test N°2
Raise the machine off of the ground. All four wheels should be able to rotate freely.
Check
Verify that the front and rear drive shafts turn when the transmission directional control lever (FNR) is
moved into Forward or Reverse.
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Expected Result
Result The front drive shaft turns freely when the transmission control is in gear but the axle does not. There is
a problem in the front axle. Repair as required.
Other Action
Result The front drive shaft does not turn when the transmission control is in gear. Go to next step.
(Possible
Cause)
Test N°3
Test Point Check
Check the electrical connections to the 4WD solenoid on the transmission.
Expected Result
Result The solenoid is receiving the correct voltage and is operating properly. Go to next step.
Other Action
Result The solenoid is not receiving the correct voltage Check the 4WD rocker switch connections. Verify the
(Possible voltage to the switch. Check the fuse F-017.
Cause)
Test N°4
Test Point Check
Check the 4WD solenoid. When power is removed from the solenoid, 4WD is engaged.
Expected Result
Result The solenoid is performing correctly. Inspect the front drive shaft and clutch engagement teeth for dam-
age. Repair or replace as required.
Other Action
Result The solenoid is not performing correctly. Repair or replace as required.
(Possible
Cause)
Power shuttle transmission - Testing - Machine Hesitates When

Shifting Between Forward and Reverse
586H
588H
Test N°1
Test Point Check
Expected Result
Other Action
Cause)
Test N°2
Check the pump supply pressure at test port 10 for 4WD machines. Refer to Power shuttle trans-
mission - Check Checking Supply Pump Pressure (4WD Only) (21.112). 2WD machines, test the
pressure on port 1 and port 2. Refer to Power shuttle transmission - Test Checking Supply Pump
Flow and Relief Pressure (21.112)
Expected Result
Result The pressure are all within specifications. Go to next step.
Other Action
Result The pressures are not within specifications. Inspect the pressure regulator. Repair or replace as required.
(Possible
Cause)
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Test N°3
Test Point Check
Check the regulated clutch pressure at test port 3. Refer to Power shuttle transmission - Test —
Checking Regulated Clutch Pressure (21.112)
Expected Result
Result The pressures are within specifications.
Other Action
Result The pressures were not within specifications. Inspect the modulation spool and piston for sticking or
(Possible damage. Inspect the input shaft sealing rings and forward and reverse clutch piston seals. Repair or
Cause) replace as required.
Power shuttle transmission - Testing - Loss of Power

586H
588H
Test N°1
Test Point Check
Expected Result
Other Action
Cause)
Test N°2
Test Point Check
Verify that there is not a buildup of mud or foreign material on the inside of the wheel wells or along the
drive train.
Expected Result
Result The wheel wells and drive train are free of mud and debris. Go to next step.
Other Action
Result There is mud and debris in the wheel well or along the drive train. Remove all mud and debris. If the
(Possible problem still exists, go to nest step.
Cause)
Test N°3
Test Point Check
Perform a stall test according to the instructions in Power shuttle transmission - Test — Checking
Regulated Clutch Pressure (21.112).
Expected Result
Result The engine performed to specifications during the stall test. Go to next step.
Other Action
Result The engine did not perform to specifications during the stall test. Repair the engine as required.
(Possible
Cause)
Test N°4
Test Point Check
Check the regulated clutch pressure. Refer to Power shuttle transmission - Test — Checking Regu-
lated Clutch Pressure (21.112)
Expected Result
Result The pressures are within specifications. Go to Power shuttle transmission - Testing — Machine Will
Not Move (21.112)
Other Action
Result The pressure is out of range. Inspect the input shaft sealing rings and clutch piston seals. Inspect the
(Possible forward and reverse clutch friction discs. Repair or replace as required.
Cause)
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Power shuttle transmission - Testing - Transmission Oil is Too Hot

586H
588H
Test N°1
Test Point Check
Expected Result
Other Action
Cause)
Test N°2
Test Point Check
Check the transmission oil cooler for air flow restrictions. Clean the exterior of the transmission oil cooler
as required.
Expected Result
Result The transmission oil cooler is clean. Go to next step.
Other Action
Result The transmission oil cooler is dirty and there are air flow restrictions. Clean the exterior of the transmis-
(Possible sion oil cooler as required. Go to the next step if the problem still exists.
Cause)
Test N°3
Test Point Check
Check the converter IN pressure. Refer to Power shuttle transmission - Test — Checking Converter
In Pressure (21.112)
Expected Result
Result The converter IN pressure is within specifications. Go to next step.
Other Action
Result The converter pressure is not within specifications. Refer to Power shuttle transmission - Testing —
(Possible Machine Will Not Move (21.112)
Cause)
Test N°4
Test Point Check
Check the converter OUT pressure. Refer to Power shuttle transmission - Test — Checking Con-
verter Out Pressure (21.112).
Expected Result
Result The converter OUT pressure is within specifications. Go to next step.
Other Action
Result The converter OUT pressure is not within specifications. Refer to Power shuttle transmission - Testing
(Possible — Machine Will Not Move (21.112)
Cause)
Test N°5
Test Point Check
Check the lube pressure. Refer to Power shuttle transmission - Test Checking Lubrication Pressure
(21.112).
Expected Result
Result The lube pressure is within specifications. STOP.
Other Action
Result
(Possible The pressure is not within specifications. If the torque converter pressure is high and the lube pressure
Cause) is low, possible causes include:
• Restriction in the oil cooler. Replace the oil cooler. The transmission oil cooler cannot be flushed or
cleaned out. The complete oil cooler must be replaced is a restriction is found.
• The oil cooler circuit is restricted. Inspect the oil cooler circuit and repair as required.
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Power shuttle transmission - Testing Problem in the Parking Brake

System
586H
588H
Test N°1
Test Point Check
Does the parking brake release?
Expected Result
Result The parking brake will release. Inspect and test the parking brake disks. If the parking brake will not hold
the machine, repair or replace the disc brakes.
Other Action
Result
(Possible Check the electrical and hydraulic circuits.
Cause) • Check the differential lock pressure, refer to Power shuttle transmission - Test — Checking
Differential Lock Valve (21.112). The differential lock and the parking brake are on the same
pressure circuit. If the differential lock pressure is within specifications, refer to Power shuttle
transmission - Pressure test – 2 Wheel Drive, Test One — Engine at Idle 900 to 1100 rpm
(21.112) and Power shuttle transmission - Pressure test — 2 Wheel Drive, Test Two — Engine
at 2200 rpm (21.112) OR Power shuttle transmission - Pressure test – 4 Wheel Drive, Test One
— Engine at Idle 900 to 1100 rpm (21.112) and Power shuttle transmission - Pressure test — 4
Wheel Drive, Test Two — Engine at 2200 rpm (21.112).
• Check fuses, replace fuses as required.
• Check switch operation, repair or replace as required.
• Measure the solenoid resistance. The resistance should be approximately 9.8 Ω at 20 °C (68 °F).
Replace the solenoid as required.
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Index
Transmission - 21

Power shuttle transmission - Check Checking Supply Pump Pressure (4WD Only) (*) . . . . . . . . . . . . . . . . . . . . . . 41
Power shuttle transmission - General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Power shuttle transmission - Hydraulic schema - Four Wheel Drive Schematic (*) . . . . . . . . . . . . . . . . . . . . . . . . . 18
Power shuttle transmission - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Power shuttle transmission - Overview (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Power shuttle transmission - Pressure test - 4 Wheel Drive, Test Two - Engine at 2200 rpm (*) . . . . . . . . . . . . . . 55
Power shuttle transmission - Pressure test – 2 Wheel Drive, Test One - Engine at Idle 900 to 1100 rpm (*) . . . . 48
Power shuttle transmission - Pressure test – 4 Wheel Drive, Test One - Engine at Idle 900 to 1100 rpm (*) . . . . 54
Power shuttle transmission - Pressure test - 2 Wheel Drive, Test Two - Engine at 2200 rpm (*) . . . . . . . . . . . . . . 49
Power shuttle transmission - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Power shuttle transmission - Replace – fluid and filter (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Power shuttle transmission - Special tools (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Power shuttle transmission - Test - Checking Converter In Pressure (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Power shuttle transmission - Test - Checking Converter Out Pressure (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Power shuttle transmission - Test - Checking Differential Lock Valve (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Power shuttle transmission - Test - Checking Regulated Clutch Pressure (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Power shuttle transmission - Test Checking Lubrication Pressure (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Power shuttle transmission - Test Checking Supply Pump Flow and Relief Pressure (*) . . . . . . . . . . . . . . . . . . . . . 44
Power shuttle transmission - Testing - Loss of Power (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Power shuttle transmission - Testing - Machine Hesitates When Shifting Between Forward and Reverse (*) . . 106
Power shuttle transmission - Testing - Machine Will Not Move (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Power shuttle transmission - Testing - Transmission Oil is Too Hot (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Power shuttle transmission - Testing - Will Not Go Into 4WD (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Power shuttle transmission - Testing Problem in the Parking Brake System (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Power shuttle transmission - Tool connection - Pressure Test Ports, Two Wheel Drive (*) . . . . . . . . . . . . . . . . . . . 51
Power shuttle transmission - Tool connection Pressure Test Ports 4 Wheel Drive (*) . . . . . . . . . . . . . . . . . . . . . . . . 52
Power shuttle transmission - Tool connection Four Wheel Drive Port Identification (*) . . . . . . . . . . . . . . . . . . . . . . . 53
Power shuttle transmission - Tool connection Two Wheel Drive Port Identification (*) . . . . . . . . . . . . . . . . . . . . . . . 50
Power shuttle transmission - Torque (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Transmission drive and driven shafts - Exploded view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Transmission drive and driven shafts - Exploded view - Four wheel drive transmission (*) . . . . . . . . . . . . . . . . . . . 12
Transmission drive and driven shafts - Exploded view - Two wheel drive transmission (*) . . . . . . . . . . . . . . . . . . . 14
Transmission drive and driven shafts - Hydraulic schema - Two Wheel Drive Schematic (*) . . . . . . . . . . . . . . . . . 16
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Transmission housing - Assemble - Shifter housing (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Transmission housing - Assemble - Transmission housing (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Transmission housing - Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Transmission housing - Disassemble - Shift rods and shift forks (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Transmission housing - Disassemble - Shifter housing (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
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PRINTED IN U.S.A.
47821916 28/04/2015
EN
SERVICE MANUAL
Front axle system

47821916 28/04/2015
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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Contents
TECHNICAL DATA
Powered front axle

Special tools (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
FUNCTIONAL DATA
Axle housing
Rear axle housing - Drawing - Axle housing (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
SERVICE
Powered front axle

Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
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Front axle system - Powered front axle
Powered front axle - General specification

586H
588H
Gear lubricant Wet brake/Transmission lubricant - TUTELA TRANSAXLE

FLUID SAE 80W-140
Differential Capacity 14.4 l (15.2 US qt)
Special torques
Allen head bolts for hub housing 226 N·m (166.7 lb ft)
Bolts for ring gear 155 N·m (114.3 lb ft)
Bolts for differential support long bolts 80 N·m (59.0 lb ft)
Bolts for differential support short bolts 169 N·m (124.6 lb ft)
Drain hole plugs at wheel hub 60 N·m (44.3 lb ft)
Fill and drain hole plugs at differential 80 N·m (59.0 lb ft)
Ring nut for wheel hub 1000 N·m (737.6 lb ft)
Differential adjusting ring lock screws 10 N·m (88.5 lb in)
Brake self adjuster shouldered bolt 16 N·m (141.6 lb in)
Brake bleeder 8 - 12 N·m (70.8 - 106.2 lb in)
Differential pin plug 25 N·m (18.4 lb ft)
Differential lock plug 180 N·m (132.8 lb ft)
Wheel studs 70 N·m (51.6 lb ft)
Pinion rotating torque (without seal) 2 - 2.4 N·m (17.7 - 21.2 lb in)
Differential bearing preload rotating torque (with seal) 2.6 - 3.3 N·m (23.0 - 29.2 lb in)
Backlash for ring gear 0.2 - 0.29 mm (0.008 - 0.011 in)
Powered front axle - Special tools

586H
588H
Differential ring nut wrench 380002433
RCPH10TLB379AAL 1
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Pinion depth gauge

1. CAS1596A-4
2. CAS1596A-7
3. CAS1596A-6
4. 380002436
RCPH10TLB380AAL 2
CAS2151A offset spanner wrench used to remove and

install the pinion nut
OEM4185 universal bearing cup installer - used to install
the hub bearing cups
RCPH10TLB484AAL 3
CAS1716–3 handle (part of CAS1716 Ag tool kit) - Used

with CAS2374 hub seal installer
Yoke to hold shaft. Order p/n 144279A1
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Self adjusting brake tools 380002435
RCPH10TLB378AAL 5
Socket for ring nut on wheel flange 380002434
RCPH10TLB377AAL 6
Seal protector CAS2369

Pinion depth gauge bar 380000407
RCPH10TLB381AAL 7
Wheel hub seal driver 380002431

Seal driver 380002432
Spanner wrench CAS1840C
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CAS1968 Stud remover/installer - used to remove shoul-

der studs from wheel hubs
RCPH10TLB590AAL 8
Fabricate from locking differential cylinder, used to com-

press differential lock spring to remove "C" clip
RCPH10TLB584AAL 9
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Rear axle housing - Drawing - Axle housing

588H
Axle housing
(1) Vent
(2) Axle housing
(3) Plugs
(4) Pin D15x35
(5) Bolt M6x25
(6) Differential support
(7) Bolt M12x100
(8) Bolt M12x1.75
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RCPH10TLB7GAL 1
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Powered front axle - Remove

586H
588H
WARNING
Jack stands can slip or fall over. Dropping, tipping, or slipping of machine or its components is pos-
sible.
DO NOT work under a vehicle supported by jack stands only. Park machine on a level surface. Block
wheels. Support machine with safety stands.
W0069A
1. Raise and support the machine.

2. Remove the front wheels.
3. Drain oil from the differential. Use a container capable
of holding 20 l (22 US qt).
RCPH11TLB122AAM 1
4. Place suitable container under each drain plug of the

brake hubs.
5. Drain oil from brake hubs.
RCPH11TLB123AAM 2
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6. Install all three drain plugs.
RCPH11TLB124AAM 3
RCPH11TLB123AAM 4
7. CAUTION
Heavy object!
handling.
erate injury.
C0095A

9. Slide the front drive shaft (4) off the axle pinion shaft
(5) .
RCPH11TLB125AAM 5
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10. Disconnect differential lock hose. Cap all open ports.
RCPH11TLB124AAM 6
11. Remove left hand and right hand brake hose guard
hardware.
RCPH11TLB126AAM 7
12. Disconnect brake hoses and cap all open ports.

13. Remove guards.
RCPH11TLB127AAM 8
14. Position jack underneath axle.
RCPH11TLB128AAM 9
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15. Remove hardware securing the axle to the frame.
RCPH11TLB129AAM 10
16. Carefully lower and remove axle.
RCPH11TLB130AAM 11
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Powered front axle - Install

586H
588H
WARNING
Crushing hazard!
Unit could fall if not properly supported. Follow jacking instructions provided for the unit. Use suitable
jack stands. Be sure to position them properly.
W0919A
1. Position the axle under the machine, slowly raise the

axle and align with the mounting holes in the chassis
wheel wells.
RCPH11TLB130AAM 1
2. Install the bolts. Tighten the bolts evenly to pull the axle
against the frame. Tighten to specification.
RCPH11TLB129AAM 2
Specification
Axle-to-Frame Bolt Torque 610 - 680 N·m (449.9 - 501.5 lb ft)
3. Remove the jack from underneath axle.
RCPH11TLB128AAM 3
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4. Slide the guards over the brake hoses. Remove the

caps from the hoses and connectors. Reconnect the
brake hoses.
RCPH11TLB127AAM 4
5. Install the left hand and right hand brake hose guard
hardware.
RCPH11TLB126AAM 5
6. Reconnect the differential lock hose.
RCPH11TLB124AAM 6

spline (5) .
9. Install the retainer (2) and bolts (3) that secures the
front drive shaft to the output shaft yoke (1). Tighten
bolts to specification.
RCPH11TLB125AAM 7
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Specification
10. Remove fill plug and fill the axle with TUTELA
TRANSAXLE FLUID SAE 80W-140 until it reaches the
bottom of the fill orifice.
RCPH11TLB124AAM 8
11. Install the wheels..

12. Raise the machine and remove the supports.
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Index

Powered front axle - General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Powered front axle - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Powered front axle - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Powered front axle - Special tools (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Rear axle housing - Drawing - Axle housing (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
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Front bevel gear set and differential - 102

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Contents
FUNCTIONAL DATA
Differential
Exploded view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Exploded view - Differential lock (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Exploded view - Ring and pinion (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
SERVICE
Differential
Remove - Carrier removal (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Remove - Differential lock fork removal (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Install - Differential lock housing and piston (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Install - Differential lock fork installation (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Adjust - Pinion gear backlash adjustment (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Adjust - Differential bearing preload adjustment (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Install - Pinion shaft seal installation (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Install - Carrier installation (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Check - differential lock (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
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Front axle system - Front bevel gear set and differential
Differential - Exploded view

586H
588H
Differential
1. Ring nut 11. Spider gear
2. Bearing 12. Differential pin
3. Sleeve 13. Pin
4. Cap screw M12 x 25 14. Spacer
5. Pin 15. Housing cover
6. O-ring 16. Locking ring
7. Housing 17. Locking side spider gear
8. Thrust washer 18. Differential pin
9. Plug 19. Side spider gear
10. Thrust washer 20. Pin
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RCPH10TLB10GAL 1
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Differential - Exploded view - Differential lock

586H
588H
Differential lock
1. Cylinder 6. Bushing
2. Cylinder O-ring 7. Spring
3. Piston 8. Shaft
4. Piston O-rings 9. Fork
5. Locking ring
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RCPH10TLB9GAL 1
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Differential - Exploded view - Ring and pinion

586H
588H
Ring and pinion

1. Ring gear 7. Outer bearing
2. Pinion gear 8. Lock washer
3. Shim 9. Ring nut
4. Inner bearing 10. Seal
5. Washer 11. O-ring
6. Crush sleeve 12. Cap
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RCPH10TLB11GAL 1
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Differential - Remove - Carrier removal

586H
588H
1. Remove the wheel hubs and brakes, see Wheel Hubs

And Brakes Disassembly in this section.
2. Remove the differential mounting bolts.
RCPH10TLB373AAL 1
3. Use pry bars in slots.
RCPH10TLB374AAL 2
4. Have an assistant hold the differential housing up away

from the axle housing, attach a lifting eye to the bottom
of the differential housing.
RCPH10TLB370AAL 3
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5. Have an assistant hold the differential housing up away

from the axle housing, attach a lifting eye to the top of
the differential housing.
RCPH10TLB371AAL 4
6. Attach lifting equipment to lifting eyes.
RCPH10TLB369AAL 5
7. Remove the differential and place on a work bench.
Next operation:
Differential - Disassemble (25.102)
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Differential - Disassemble
586H
588H
1. Remove the bolts securing the ring nut.
RCPH10TLB364AAL 1
2. Remove the ring nuts.
RCPH10TLB362AAL 2
3. Remove the differential from the carrier.

4. The bearing cups can be removed with a roll head pry
bar if replacement is needed.
RCPH10TLB432AAL 3
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5. Remove the locking ring.
RCPH10TLB433AAL 4
6. Remove the differential housing cover, remove the anti

rotation pin.
RCPH10TLB434AAL 5
7. The thrust washer may stay on the cover, remove the

thrust washer.
RCPH10TLB435AAL 6
8. Remove the gear from the housing.
RCPH10TLB436AAL 7
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9. Remove three plugs from the differential.
RCPH10TLB437AAL 8
10. Remove the three pins securing the spider pins in the
differential.
RCPH10TLB438AAL 9
11. Remove the ring gear cap screws, remove the ring
gear.
RCPH10TLB440AAL 10
NOTE: Large amounts of Loctite was used during assembly, remove cap screws slowly. If screw binds, turn back in
and then back out.
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12. Note the flat surface on pin (1) and spacer (2).
RCPH10TLB441AAL 11
13. Push the pin towards the flat surface side noted in the
previous step.
RCPH10TLB442AAL 12
NOTE: DO NOT force the pin, it will not come out of the housing at this time.
14. Remove the spider gear and thrust washer.
RCPH10TLB443AAL 13
15. Push the pin out of the housing.
RCPH10TLB444AAL 14
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16. Remove the spider gear and thrust washer.
RCPH10TLB445AAL 15
17. Push one of the short spider pins out of the spacer by
pushing it through the hole in the spacer.
RCPH10TLB446AAL 16
NOTE: Do not remove the pin at this time, leave the pin in far enough to support the spider gear and thrust washer.
18. Push the other short spider pin out of the spacer by
pushing it through the hole in the spacer.
RCPH10TLB447AAL 17
NOTE: Do not remove the pin at this time, leave the pin in far enough to support the spider gear and thrust washer.
47821916 28/04/2015
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19. Remove the spacer from the housing.
RCPH10TLB448AAL 18
20. Remove the spider pin, gear and thrust washer from
the housing.
RCPH10TLB449AAL 19
21. Remove the other pin, gear and thrust washer from
the housing.
RCPH10TLB450AAL 20
22. Remove the gear and thrust washer from the housing.
RCPH10TLB452AAL 21
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23. Remove the differential locking pins from the housing.
RCPH10TLB359AAL 22
24. Remove the cover and seal from the carrier.
RCPH10TLB340AAL 23
25. The pinion gear nut is staked into place on the pinion
shaft.
RCPH10TLB341AAL 24
26. Use a chisel punch to remove the stake from the pin-
ion shaft NUT.
RCPH10TLB342AAL 25
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27. Use the offset spanner, CAS2151A, and yoke P/N

144279A1 to remove the pinion gear ring nut.
RCPH10TLB343AAL 26
28. Use a soft faced hammer and drive the pinion out of
the carrier housing.
29. Remove the crush sleeve and shims from the pinion
shaft.
RCPH10TLB344AAL 27
30. Press the bearing from the pinion shaft.
RCPH10TLB345AAL 28
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31. Remove the shim from the pinion.
RCPH10TLB346AAL 29
32. Remove the outer bearing cup from the carrier.
RCPH10TLB347AAL 30
33. Remove the inner bearing cup from the carrier.
RCPH10TLB348AAL 31
Next operation:
Differential - Remove (25.102)
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Differential - Remove - Differential lock fork removal

586H
588H
NOTE: The differential lock fork may look different for machines equipped with a Power Shift transmission. The
procedure is the same.
1. Loosen the differential lock cylinder from the carrier.
RCPH10TLB349AAL 1
2. Hold the differential lock fork down to catch a block

inside of the housing, remove the cylinder.
RCPH10TLB350AAL 2
NOTE: Use caution removing the cylinder, it is under spring pressure.

3. Place a flat washer over the shaft.
RCPH10TLB351AAL 3
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4. Start the modified cylinder into the differential housing.
RCPH10TLB352AAL 4
5. Block the fork from moving.
RCPH10TLB353AAL 5
6. Tighten the modified cylinder and press down on the

bushing, remove the snap ring.
RCPH10TLB354AAL 6
7. Remove the bushing.
RCPH10TLB355AAL 7
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RCPH10TLB356AAL 8
9. Remove the shaft.
RCPH10TLB357AAL 9
10. Remove the fork, spring and bushing from the shaft.
RCPH10TLB460AAL 10
Next operation:
Differential - Install (25.102)
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Differential - Install - Differential lock housing and piston

586H
588H
1. Install new O-rings on the piston. Lubricate the O-rings

with clean hydraulic oil. Install a new O-ring on the
cover for the differential lock.
RCPH10TLB459AAL 1
2. Lubricate the bore in the cover for the piston with clean
hydraulic oil. Install the piston in the cover for the dif-
ferential lock.
Next operation:
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Differential - Install - Differential lock fork installation

586H
588H
NOTE: The differential lock fork will look different for machines equipped with a Power Shift transmission. The pro-
cedure is the same.
1. When installing the bushings on the shaft make sure
the chamfer is over the snap ring.
RCPH10TLB461AAL 1
2. Lubricate the shaft with clean hydraulic oil. Install the

fork on the shaft with collar towards snap ring (1). Install
bushing (2) and spring (3) onto shaft.
RCPH10TLB460AAL 2
3. Install the shaft into the carrier.
RCPH10TLB357AAL 3
47821916 28/04/2015
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RCPH10TLB356AAL 4
5. Place the bushing on the shaft, make sure the chamfer

in the bushing is facing out.
RCPH10TLB355AAL 5
6. Place a flat washer over the shaft.
RCPH10TLB351AAL 6
7. Start the modified cylinder into the differential housing.
RCPH10TLB352AAL 7
47821916 28/04/2015
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8. Block the fork from moving.
RCPH10TLB353AAL 8
9. Compress the spring by tightening the modified cylin-

der and install the snap ring.
RCPH10TLB354AAL 9
10. Remove the block, push the fork into the carrier and
lock it behind the block inside of the carrier. Hand start
the locking cylinder.
RCPH10TLB350AAL 10
11. Torque the locking cylinder to 180 N·m (133 lb ft).
RCPH10TLB360AAL 11
Next operation:
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Differential - Assemble (25.102)
47821916 28/04/2015
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Differential - Assemble
586H
588H
1. Install new O-rings on the pins. Lubricate the O-rings

with clean hydraulic oil.
RCPH10TLB481AAL 1
2. Install the pins in the differential housing.
RCPH10TLB358AAL 2
3. Lubricate the gear and thrust washer with clean hy-

draulic oil. Install the gear and thrust washer.
RCPH10TLB452AAL 3
47821916 28/04/2015
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4. When installing the pins and thrust washers, align the

flats on the pins with the flats in the thrust washer.
RCPH10TLB451AAL 4
5. Install the pin, thrust washer and spider gear.
RCPH10TLB450AAL 5
NOTE: Push the pin in just far enough to hold the thrust washer and spider.
6. Install the pin, thrust washer, and spider gear.
RCPH10TLB449AAL 6
NOTE: Push the pin in just far enough to hold the thrust washer and spider.
47821916 28/04/2015
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7. Install the spacer as shown, push the pins into the

spacer.
RCPH10TLB448AAL 7
8. Make sure to install the pin so that the dowel pin hole
aligns with the dowel pin hole in the housing.
RCPH10TLB445AAL 8
9. Place the spider gear and thrust washer into the hous-
ing. Align the bushing with the pin and push the pin in
as far as possible.
RCPH10TLB444AAL 9
10. Install the spider gear and thrust washer, push the pin
into the gear and washer.
RCPH10TLB443AAL 10
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11. Install the retaining pins for the spider gear pins into
the housing.
12. The pinion gear and ring gear are a matched set.
Make sure the numbers on the pinion gear and ring
gear are the same.
RCPH10TLB589AAL 11
13. Use LOCTITE® 270 on cap screws, install and torque

ring gear cap screws to 155 N·m (114 lb ft).
RCPH10TLB439AAL 12
NOTE: Torque cap screws in a staggered pattern in order to draw the ring gear up flush.
14. Install plugs and torque to 25.0 N·m (18.4 lb ft).
RCPH10TLB437AAL 13
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15. Use an acceptable driver and install a bearing cup into

the housing.
RCPH10TLB457AAL 14
NOTE: The bearing cup will stay raised above the housing even when properly seated.
16. Place the gear into the housing while aligning the
teeth.
RCPH10TLB436AAL 15
17. Apply a light coat of grease to the thrust washer to

hold it in place on the differential housing cover. The
ears of the thrust washer must align with the slots in
the cover.
RCPH10TLB435AAL 16
18. When installing the differential housing cover, place

the pin in the slot of the cover and align it into the grove
in the housing during assembly.
RCPH10TLB453AAL 17
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19. Install the cover into the housing, install the locking
ring.
RCPH10TLB434AAL 18
20. Use an acceptable driver and install the bearing cup.
RCPH10TLB491AAL 19
21. Install the differential lock ring onto the housing. If it is

difficult to push down, reach through the housing and
rotate the spider gears until the differential lock ring
will go down.
RCPH10TLB458AAL 20
22. Use an acceptable driver and install the inner bearing

cup.
RCPH10TLB454AAL 21
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23. Use an acceptable driver and install the outer bearing

cup.
RCPH10TLB455AAL 22
24. Install the inner bearing.
RCPH10TLB390AAL 23
25. Install depth gauge 380002436, adapter

CAS1596A-6, and bolt CAS1596A-7 into the bearing.
NOTE: You may substitute CAS 1596B-5 for 380002436 if
you wish
RCPH10TLB389AAL 24
26. CAS1596A-4 must be facing up as shown.
RCPH10TLB391AAL 25
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27. Place the outer bearing on CAS1596-A as shown.
RCPH10TLB392AAL 26
28. Tighten CAS1596A-4 and 380002436 until the bear-

ings are tight.
RCPH10TLB388AAL 27
29. Place CAS1716-3 handle in bearing cradles of the car-

rier housing.
RCPH10TLB387AAL 28
NOTE: Make sure the carrier housing is level.

30. Measure the gap between the top of the tool and the
gauge tube with a feeler gauge. If the gap is too great,
you may use something of uniform shape such as a
gauge block to fill the gap.
RAIL14TLB0331AA 29
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31. Measure all of the elements used in Step 30 and add

the values together.
RAIL14TLB0332AA 30
RAIL14TLB0333AA 31
RAIL14TLB0334AA 32
380002436
Gauge block
+ Feeler guages
Total dimension
47821916 28/04/2015
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32. Measure the dimension of the bearing cradle in the

carrier housing as shown. Divide this dimension by 2
and add the quotient to the total from Step 31.
RAIL14TLB0335AA 33
Total from Step 31

+ Quotient (measured dimension divided by 2)
Total dimension
33. Find the number on the end of the pinion shaft. Sub-
tract this value from the Grand Total from Step 32 .
This difference is the shim dimension you need.
RCPH10TLB480AAL 34
Grand total from Step 32

— Pinion shaft number
Shim dimension
34. Compare this shim dimension to the available shims.

Select the closest shim size and use this shim to pro-
ceed with the assembly procedure. Available shim
sizes in millimeters: 2.5, 2.6, 2.6, 2.8, 2.9, 3.0, 3.1,
3.2, 3.3, 3.4
35. Remove the special tools from the center section.
36. Install the shim with the thickness specified in Step 33.
The chamfer on the ID of the shim must be toward the
pinion gear.
RCPH10TLB482AAL 35
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37. Put the inner bearing in position on the shaft.
RCPH10TLB483AAL 36
38. Use a suitable driver and press the inner bearing

against the shim.
RCPH10TLB483AAL 37
39. Lubricate the bearing with hydraulic oil. Install the

washers and a new collapsible spacer on the pinion
gear. The old collapsible spacer MUST NOT be used
again.
RCPH10TLB462AAL 38
40. Lubricate the outer bearing with hydraulic oil. Install

the outer bearing.
RCPH10TLB463AAL 39
47821916 28/04/2015
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41. Install the special washer, make sure to align the

washer with the slot in the pinion shaft.
RCPH10TLB464AAL 40
42. Lubricate the face of the nut, special washer and

threads with hydraulic oil. Install the pinion nut.
RCPH10TLB465AAL 41
43. Use the P/N 144279A1 Yoke and the CAS2151A to

start the pinion nut onto the pinion gear.
RCPH10TLB466AAL 42
44. Install the CAS2375 on the pinion shaft.
NOTICE: If the pinion nut is tightened too much (rotating torque more than specified), pinion shaft must be removed
and a new collapsible spacer must be installed.
47821916 28/04/2015
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45. Use the torque wrench to check the rotating torque of

the pinion gear. The rotating torque of the pinion gear
must be 2.0 - 2.4 N·m (17.7 - 21.2 lb in).
RCPH10TLB467AAL 43
46. Remove the torque wrench and the CAS2375 from the
pinion shaft.
47. Use the yoke and the CAS2151A to tighten the pinion
nut in SMALL amounts as required. Repeat Steps 42
through 46 until the rotating torque is as specified in
Step 45.
RCPH10TLB466AAL 44
48. Stake the lip on the pinion nut into the slot in the pinion
shaft.
RCPH10TLB468AAL 45
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49. Use an acceptable driver and install the bearings onto

the ring nuts.
RCPH10TLB456AAL 46
50. Install the differential housing into the carrier. Tighten

the ring nuts evenly and center the differential housing
in the carrier.
RCPH10TLB362AAL 47
Next operation:
Differential - Adjust (25.102)
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Differential - Adjust - Pinion gear backlash adjustment

586H
588H
1. Mount a dial indicator onto the carrier, set the shaft of

the dial indicator onto the center of a tooth of the ring
gear.
RCPH10TLB361AAL 1
2. Use your hand and move the ring gear back and forth
to check for backlash. Check back lash at three points
on the ring gear approximately 120 ° apart.
3. The pinion gear backlash must be 0.200 - 0.290 mm
(0.008 - 0.011 in). If the backlash is not correct do the
following procedure.
4. If there is not enough backlash, loosen (turn counter-
clockwise) the adjusting ring on the other side of the
center section one notch. tighten (turn clockwise) the
adjusting ring one notch on the side shown. Continue
with this step until the backlash is 0.200 - 0.290 mm
(0.008 - 0.011 in). If there is too much backlash, loosen
(turn counterclockwise) the adjusting ring on the side
shown one notch. tighten (turn clockwise) the adjust-
ing ring one notch on the side opposite of that shown.
Continue with this step until the backlash is 0.200 -
0.290 mm (0.008 - 0.011 in).
RCPH10TLB362AAL 2
Next operation:
Differential - Adjust (25.102)
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Differential - Adjust - Differential bearing preload adjustment

586H
588H
1. Install the CAS2375 on the pinion shaft. Check the

rotating torque of the pinion shaft. The rotating torque
must be 2.6 - 3.3 N·m (23.0 - 29.2 lb in).
RCPH10TLB469AAL 1
2. If the rotating torque is not correct do the following pro-

cedure.
3. If the rotating torque is too high, loosen (turn counter-
clockwise) the adjusting ring one notch on both sides.
Continue with this step until the rotating torque is 2.6
- 3.3 N·m (23.0 - 29.2 lb in). If the rotating torque is
too low, tighten (turn clockwise) the adjusting ring one
notch on both sides. Continue with this step until the
rotating torque is 2.6 - 3.3 N·m (23.0 - 29.2 lb in).
RCPH10TLB362AAL 2
4. Secure the adjusting rings with the Allen screws, torque

the Allen screws to 10.0 N·m (88.5 lb in).
RCPH10TLB363AAL 3
Next operation:
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Differential - Install - Pinion shaft seal installation

586H
588H
1. Use seal driver, 380002432, and drive the seal into the
cover. The lips on the seal must be toward the inside
of the cover.
RCPH10TLB366AAL 1
2. Install a new O-ring on the cover.
RCPH10TLB365AAL 2
3. Put the CAS2369 Pinion Spline Seal Protector on the

pinion gear shaft.
RCPH10TLB367AAL 3
47821916 28/04/2015
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4. Lubricate the O-ring and the seal with clean oil. Install
the cover on the center section.
RCPH10TLB368AAL 4
5. Remove the CAS2369 from the pinion gear shaft.
Next operation:
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Differential - Install - Carrier installation

586H
588H
1. Apply a coat of LOCTITE® 510™ to the mating surface

for the carrier.
RCPH10TLB470AAL 1
2. Attach lifting equipment to the carrier and place onto

the axle housing.
RCPH10TLB369AAL 2
3. Remove the lifting equipment from the carrier, use a

rubber mallet and tap the carrier until the dowel pins
are fully seated.
4. Use LOCTITE® 638™ on carrier bolts and torque the
short carrier bolts to 169 N·m (125 lb ft). Torque the
long carrier bolts to 80 N·m (59 lb ft).
RCPH10TLB372AAL 3
NOTE: DO NOT use any thread locking compound on these bolts.
Next operation:
Differential - Check (25.102)
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Differential - Check - differential lock

586H
588H
1. Connect a hand pump and gauge to the fitting on the

differential lock. Have someone turn the wheel hub
as slight pressure is applied to the hand pump. If the
differential lock is working correctly the wheel hub will
become hard to turn and the wheel hub on the opposite
side of the axle will turn at the same time.
NOTE: Make sure the air is removed from the brake system when the axle is installed on the machine.
47821916 28/04/2015
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Index

Differential - Adjust - Differential bearing preload adjustment (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Differential - Adjust - Pinion gear backlash adjustment (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Differential - Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Differential - Check - differential lock (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Differential - Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Differential - Exploded view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Differential - Exploded view - Differential lock (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Differential - Exploded view - Ring and pinion (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Differential - Install - Carrier installation (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Differential - Install - Differential lock fork installation (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Differential - Install - Differential lock housing and piston (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Differential - Install - Pinion shaft seal installation (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Differential - Remove - Carrier removal (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Differential - Remove - Differential lock fork removal (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
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Final drive hub, steering knuckles, and shafts - 108

47821916 28/04/2015
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Contents
FUNCTIONAL DATA
Planetary drive and hub

Wheel hub - Exploded view - Wheel hub and final reduction unit (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
SERVICE
Planetary drive and hub

Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Inspect (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
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Front axle system - Final drive hub, steering knuckles, and shafts
Wheel hub - Exploded view - Wheel hub and final reduction unit
586H
Wheel hub and final reduction unit
(1) Ring nut

(2) Inner bearing
(3) O-ring
(4) Ring gear (not serviced)
(5) Bleeder valve
(6) Shipping plug
(7) Hub
(8) Spacer
(9) Outer bearing
(10) Cassette seal
(11) Pad
(12) Wheel flange
(13) Snap ring
(14) Gear
(15) Snap ring
(16) Bearing
(17) Planetary carrier
(18) Bolt
(19) Stud
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RCPH10TLB12GAL 1
47821916 28/04/2015
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Planetary drive and hub - Disassemble

586H
588H
1. Remove the axle vent to relieve any pressure inside of

the axle.
RCPH10TLB384AAL 1
2. Place an oil receptacle under the outer housings of the

axle and drain the oil.
RCPH10TLB385AAL 2
3. Place an oil receptacle under the differential carrier and

drain the oil.
RCPH10TLB376AAL 3
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4. Remove all but two of the cap screws.

NOTICE: Large amounts of Loctite were used during as-
sembly, remove cap screws slowly. If screw binds, turn
back in and then back out.
RCPH10TLB382AAL 4
5. Insert three long dowel rods for in vehicle service or two

short dowel rods for bench service.
RCPH10TLB393AAL 5
6. Remove the remaining cap screws.
RCPH10TLB394AAL 6
7. Pry the hub from the axle using slots.
RCPH10TLB395AAL 7
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8. Slowly pull hub away from axle, make sure that the
brake disks and plates stay with the hub.
RCPH10TLB396AAL 8
9. Pull the half shaft out with the hub and brakes.
RCPH10TLB397AAL 9
10. Place the hub, brakes and half shaft on a suitable work
bench.
RCPH10TLB398AAL 10
11. Stand the hub up, mark the reaction plat that was
against the axle housing. Remove the reaction and
brake disks.
NOTE: Keep brake surfaces in same relationship to each
other if being reused.
RCPH10TLB399AAL 11
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12. Remove the half shaft from the planetary gears.
RCPH10TLB311AAL 12
13. Left hand shaft is 807 mm (31.8 in) long and the right
hand shaft is 701 mm (27.6 in) long.
RCPH10TLB375AAL 13
14. Loosen and remove the shouldered bolts, and spring

washers from the brake self adjusters.
RCPH10TLB312AAL 14
15. Check springs and shouldered bolt for damage. If

brakes are being replaced, replace springs and bolts
with kit.
RCPH10TLB401AAL 15
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16. Remove the lock ring.
RCPH10TLB314AAL 16
17. Remove the self adjuster. If brakes are being replaced

replace adjusters.
NOTE: Once removed the self adjusters spring clips must
be replace with genuine parts, DO NOT use after market
parts.
RCPH10TLB315AAL 17
18. Place the tapered end of the self adjuster (1) on tool
380002435.
RCPH10TLB404AAL 18
19. Place the 380002435 driver tool (1) onto the self ad-
juster (2) and drive the spring clips (3) off of the ad-
juster.
RCPH10TLB405AAL 19
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20. Inspect adjuster bushing for wear.
RCPH10TLB406AAL 20
21. Use two acceptable flat bars and evenly pry the brake
piston up from the hub.
RCPH10TLB316AAL 21
22. Remove the piston from the hub.
RCPH10TLB317AAL 22
23. Remove the inner cylinder.
RCPH10TLB421AAL 23
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24. If the cylinder remained in the housing, use a suitable

pry bar to remove the cylinder.
RCPH10TLB318AAL 24
25. If the machine has high work hours, remove and dis-
card the outer brake piston O-ring.
RCPH10TLB415AAL 25
card the inner brake piston O-ring.
RCPH10TLB416AAL 26
card the brake cylinder O-ring.
RCPH10TLB418AAL 27
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28. Remove and discard the hub O-ring.
RCPH10TLB319AAL 28
29. Attach suitable lifting equipment to the planetary

gears.
RCPH10TLB320AAL 29
30. Locate the snap ring slot and place snap ring pliers in
slot.
RCPH10TLB334AAL 30
31. Hold the snap ring open. Carefully raise and remove
the planetary set from the hub. Release the snap ring
after the end of the wheel flange shaft is cleared.
RCPH10TLB321AAL 31
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32. Remove planetary gear retainer snap rings.
RCPH10TLB322AAL 32
33. Remove planetary gear and bearings.
RCPH10TLB323AAL 33
34. Place the wheel end in a suitable press and lock the
wheel hub so it can will not turn.
NOTICE: Do not use excessive force, otherwise damage
to the hub will occur.
RCPH10TLB326AAL 34
35. Loosen the wheel flange nut using a ring nut socket
tool 380002434 and a torque multiplier.
RCPH10TLB320AAL 35
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36. Remove ring nut from wheel hub.
RCPH10TLB423AAL 36
37. Do not press directly against the sun gear pad.
RCPH10TLB329AAL 37
38. Place the wheel hub in a press.
RCPH10TLB330AAL 38
39. Press the wheel flange from the wheel hub.
RCPH10TLB331AAL 39
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40. Attach lifting equipment to hub housing and remove

from the wheel flange.
RCPH10TLB332AAL 40
41. Remove the inner bearing race.
RCPH10TLB425AAL 41
42. Remove the cassette seal.
RCPH10TLB426AAL 42
43. Remove the outer race.
RCPH10TLB429AAL 43
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44. Remove spacer from wheel flange.
RCPH10TLB431AAL 44
45. To remove the inner bearing, use a die grinder to cut

the roller retainer and race. Use a chisel in the slot cut
in the race to crack the race, remove the race.
RCPH10TLB430AAL 45
Next operation:
Planetary drive and hub - Inspect (25.108)
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Planetary drive and hub - Inspect

586H
588H
1. Clean all parts in cleaning solvent.

2. Discard all seals and O-rings.
3. Inspect the bearing cups and the rollers in the wheel
bearings for flat areas, pitting, scoring, and other dam-
age. Also check the inner race for damage. If you find
any of these defects, you must install new wheel bear-
ings and bearing cups.
4. Inspect the planetary shafts for wear and damage. The
planetary shaft bushings are not sold separately. If a
shaft bushing is damaged, you must use a new carrier.
5. Inspect the teeth on the planetary gears, the half shaft,
and the ring gear for wear, pitting, scoring, and other
damage. Use new parts as required.
6. Inspect the needle bearings for the planetary gears for
flat areas, pitting, scoring, and other damage. If you
find any of these defects, use new parts as required.
7. Inspect the brake disks and reaction plates for pitting,
scoring, excessive surface wear, and other damage.
Use new parts as required.
8. Inspect brake pistons and cylinders for scaring on slid-
ing surfaces, brake pistons for pitting, scoring, and ex-
cessive surface wear at brake contact point. Use new
pars as required.
9. Replace O-rings on brake cylinders and pistons.
NOTICE: Use only genuine parts. DO NOT use after market O-rings, they will fail.
Next operation:
Planetary drive and hub - Assemble (25.108).
47821916 28/04/2015
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Planetary drive and hub - Assemble

586H
588H
When installing new brake discs, soak the new brake discs in oil for 24 hours prior to installation.
1. If the outer bearing cups were removed, use an Univer-

sal Bearing Cup Installer or a suitable tool to install the
bearing cups.
NOTE: The illustration shows the cassette seal installed,
the cassette seal will be installed during a later step.
RCPH10TLB427AAL 1
2. If the inner bearing cups were removed, use an Uni-

versal Bearing Cup Installer or other acceptable tool to
install the bearing cups.
RCPH10TLB428AAL 2
NOTICE: Caution possible component damage. The word

"OUTSIDE" on the hub seal must face outward. Do not
push the hub seal further than required during the instal-
lation. Failure to comply may result in damage to the hub
seal.
3. Attach the 380002431 hub seal installer with handle to
install the hub seal. Push only until the hub seal makes
contact with the shoulder inside the hub.
RCPH10TLB333AAL 3
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4. Install the outer wheel flange bearing with a suitable

driver.
RCPH10TLB430AAL 4
5. Install spacer on wheel flange.
RCPH10TLB431AAL 5
6. Clean all sealing surfaces with an alcohol based

cleaner, if any oil residue is on sealing surfaces the
seal will leak.
NOTICE: Caution possible component damage. Install the
hub straight onto the wheel flange, damage to seal can
occur if angled. DO NOT use excess force to seat hub onto
wheel flange. Failure to comply may damage the wheel
flange of hub seal.
7. Attach lifting equipment to hub and carefully install onto
wheel flange.
RCPH10TLB332AAL 6
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8. Install inner bearing with a suitable driver and the ring

nut.
RCPH10TLB423AAL 7
9. Attach the ring nut socket, 380002434, and torque to

1000 N·m (738 lb ft).
NOTE: The use of a torque multiplier as shown is accept-
able.
RCPH10TLB328AAL 8
10. With a suitable driver, press the planetary gears onto

the planet carrier.
RCPH10TLB324AAL 9
11. Install the retaining snap rings on the carrier.
RCPH10TLB325AAL 10
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12. Attach lifting equipment to the planetary set and lower

into the hub.
13. Engage the locking ears on the planetary carrier to
secure the ring nut.
RCPH10TLB424AAL 11
14. Hold the snap ring open and lower the planetary as-
sembly into position.
RCPH10TLB334AAL 12
15. Make sure that the snap ring is fully closed, the two
tips touch before removing the lifting equipment.
RCPH10TLB335AAL 13
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16. Install a new O-ring on the hub.
RCPH10TLB336AAL 14
17. Apply hydraulic oil to the brake cylinder O-ring.
RCPH10TLB419AAL 15
18. Apply hydraulic oil to the inner O-ring of the brake

piston. Press the brake cylinder into the brake piston.
RCPH10TLB420AAL 16
19. Apply hydraulic oil to the outer O-ring of the brake

piston.
RCPH10TLB422AAL 17
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20. Apply hydraulic oil to the brake cavity of the hub hous-
ing.
RCPH10TLB337AAL 18
NOTE: Use brake pins as guides.

21. Place the brake piston and cylinder onto the hub.
RCPH10TLB417AAL 19
22. Tighten the three shoulder bolts to pull the brake pis-
ton and cylinder into the hub.
RCPH10TLB339AAL 20
23. Place the tapered edge of the brake adjuster into the
depth setting tool, part of tool kit 380002435.
RCPH10TLB407AAL 21
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24. Place aligning tool into brake adjuster tool, part of tool
kit 380002435.
RCPH10TLB408AAL 22
NOTE: For ease of installation, look at the inside of the

adjuster ring, place tapered end down.
25. Place the first adjuster ring onto aligning tool.
RCPH10TLB409AAL 23
26. Place the second adjuster ring onto aligning tool with
the slot at 90° from the slot of the first ring.
RCPH10TLB410AAL 24
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27. Place the third adjuster ring onto aligning tool with the
slot at 180° from the slot of the first ring.
RCPH10TLB411AAL 25
28. Place the fourth adjuster ring onto aligning tool with
the slot at 270° from the slot of the first ring.
RCPH10TLB412AAL 26
29. Place driver tool onto aligning tool, driver part of tool
kit 380002435.
RCPH10TLB413AAL 27
30. Drive the rings onto the adjuster until they are seated
against the depth setting tool.
RCPH10TLB414AAL 28
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31. Insert the adjuster into the brake piston, make sure
that the chaffered side is up.
RCPH10TLB403AAL 29
32. Make sure the tabs of the snap ring face the adjuster
during installation.
RCPH10TLB490AAL 30
33. Install the snap ring into the self adjuster bore.
RCPH10TLB314AAL 31
34. Make sure the snap ring fully engages the groove in
the brake piston.
RCPH10TLB338AAL 32
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35. Place spring washers onto the shoulder bolt facing as

shown.
RCPH10TLB400AAL 33
36. Hand tighten the shouldered bolt until seated into

adjuster, spring washers can become bound on the
shoulder of the bolt and be damaged.
RCPH10TLB402AAL 34
37. Torque shoulder bolts to 16 N·m (142 lb in).
RCPH10TLB313AAL 35
38. Put the half shaft (1) and brake separator plate pins
(2) into the axle housing.
RCPH10TLB473AAL 36
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39. Using the reference mark made during disassembly,

place the thinner of the two inner brake separator plate
into the axle housing.
RCPH10TLB474AAL 37
40. Place the inner brake disc onto the half shaft, do not
damage any of the splines or teeth.
RCPH10TLB475AAL 38
NOTE: For the 580N there is only one brake disc, for all Super N models there are two brake discs.
41. Install the second brake separator, SN models only.
RCPH10TLB476AAL 39
NOTE: The thicker of the two separator plates is used here.
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42. Place the outer brake disc onto the half shaft, do not
damage any of the splines or teeth.
RCPH10TLB477AAL 40
43. Make sure the slots of the inner and outer brake discs
are aligned with each other.
RCPH10TLB471AAL 41
44. Install dowel rods into axle housing, two short rods for
bench repair, three long for in vehicle repair.
RCPH10TLB472AAL 42
NOTE: Care needs to be taken that the self adjusters are

not damaged by falling plates or by hitting them on the
housing when bringing hub into position.
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45. Attach lifting equipment to hub assembly and guide

onto dowel rods.
RCPH10TLB478AAL 43
NOTE: The input shaft for the differential may need to be

turned in order to align the splines on the half shaft sun
gear and the planetary gears.
46. Wrap a piece of rope around the axle shaft and lift the
shaft into the planetary gears while pushing the hub
onto the axle. Remove the rope once the axle is in
the planetary gears.
RCPH10TLB479AAL 44
47. Apply LOCTITE® 270 to the threads of the bolts and

systematically tighten the bolts to a torque to 226 N·m
(167 lb ft).
RCPH10TLB383AAL 45
48. Install and tighten drain plugs.

49. Fill the axle with oil.
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Index

Planetary drive and hub - Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Planetary drive and hub - Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Planetary drive and hub - Inspect (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Wheel hub - Exploded view - Wheel hub and final reduction unit (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
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PRINTED IN U.S.A.
47821916 28/04/2015
EN
SERVICE MANUAL
Rear axle system

47821916 28/04/2015
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
[27.550] Non-powered rear axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27.4
47821916 28/04/2015
27
Powered rear axle - 100

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

Torque (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Special tools (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
FUNCTIONAL DATA
Powered rear axle

Drawing (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
SERVICE
Powered rear axle

Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Toe in adjust (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
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27.1 [27.100] / 2
Rear axle system - Powered rear axle
Powered rear axle - General specification

General specifications
Backlash for ring gear 0.20 - 0.25 mm (0.008 - 0.010 in)
Rotating torque for pinion shaft without seal 1.1 - 2.3 N·m (9.74 - 20.36 lb in)
Lubricant
Capacity - center bowl 5.5 l (5.8 US qt)
Capacity - each wheel end 0.71 l (0.75 US qt)
Type of fluid Wet brake/Transmission lubricant - TUTELA TRANSAXLE
FLUID SAE 80W-140 MAT3510
Powered rear axle - Torque

Special torques
Studs for wheels 70 N·m (51.6 lb ft)
Allen head bolts for carrier 25 N·m (18.4 lb ft)
Self locking nut for tie rod ball joint 165 N·m (121.7 lb ft)
Jam nut for tie rod 120 N·m (88.5 lb ft)
Nut for ball joint for steering cylinder 300 N·m (221.3 lb ft)
Bolts for steering cylinder 120 N·m (88.5 lb ft)
Jam nuts for steering stops 150 N·m (110.6 lb ft)
Bolts for king pin 120 N·m (88.5 lb ft)
Bolts for adjusting ring lock 13 N·m (115.1 lb in)
Bolts for bearing caps 266 N·m (196.2 lb ft)
Bolts for hub for planetary ring gear 95 N·m (70.1 lb ft)
Bolts for differential carrier 169 N·m (124.6 lb ft)
Oil drain plugs in axle housing 60 N·m (44.3 lb ft)
Oil drain plugs in planetary ends 80 N·m (59.0 lb ft)
Breather 10 N·m (88.5 lb in)
Grease zerks 8 N·m (70.8 lb in)
Wheel nuts 350 N·m (258.1 lb ft)
Powered rear axle - Special tools

CAS 1839 Pinion setting kit

1. CAS1839-1 Gauge tube
2. CAS1839-2 Gauge block
3. CAS1668 Metric feeler gauge
4. CAS2401 Pilot
5. CAS1596A-4 Handle
6. CAS1596A Stud
RCPH10TLB461ABL 1
47821916 28/04/2015
27.1 [27.100] / 3
CAS1840C Spanner wrench
RCPH10TLB468ABL 2
CAS2151A Wrench for pinion nut
RCPH10TLB465ABL 3
Yoke to hold shaft
RCPH10TLB467ABL 4
CAS1842 Wheel stud removal and installation
RCPH10TLB466ABL 5
47821916 28/04/2015
27.1 [27.100] / 4
CAS1980 V-Block used to support coupling when replac-

ing a universal joint
RCPH10TLB469ABL 6
380100091 - Wrench to loosen and tighten tie rods for

steering cylinder
RCPH10TLB235ABL 7
CAS2369 - Seal protector
CAS2375 - Shaft adapter
CAS10468 - Puller
47821916 28/04/2015
27.1 [27.100] / 5
Powered rear axle - Drawing

RAIL12FRK1181GA 1
1 — Drive shaft guard 4 — Drive shaft 7 — Pivot pin 10 — Cap screw

2 — Flat washer 5 — Axle 8 — Grease fitting 11 — Wheel nuts
3 — Bolt 6 — Snap ring 9 — Thrust washer
The arrow in the illustration points toward the front of the machine.
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27.1 [27.100] / 6
Powered rear axle - Remove

DANGER
Heavy parts!
Support designated component(s) with adequate lifting equipment.
D0018A

2. Place an appropriate floor jack under the drive shaft
guard (1) to hold the drive shaft guard in position.
3. Remove the bolts (3) and flat washers (2) that fasten
the drive shaft guard (1) to the frame.
4. Lower the drive shaft guard, and remove it from under
the machine.
RCPH11TLB001AAL 1
5. Remove the bolts hardware that fasten the drive shaft

to the flange on the transmission, and remove the drive
shaft.
RCPH11TLB003AAL 2
6. Raise the rear wheels above the floor, and use appro-
priate stands to hold the machine in place.
RAPH12FRK0942BA 3
7. Install blocks between the axle stops and the frame

to prevent the axle from tilting or moving during the
removal process.
47821916 28/04/2015
27.1 [27.100] / 7
8. Loosen and remove the wheel nuts and hardened

washers, and remove the wheels.
NOTICE: To avoid contamination, cap and plug all lines and ports when disconnecting.
9. Disconnect both hoses from the power steering cylin-
der.
RCPH11TLB146AAM 4
10. Disconnect the remote grease fitting from the right

hand rear side of the frame.
RAPH12FRK0943BA 5
11. Remove the snap ring (1), washer (3), and any spac-
ers from the front of the pivot pin (2).
RAPH12FRK0075AA 6
12. Remove the bolt on the rear of the pivot pin.
NOTE: It is necessary to use a 1/2 - 13 UNC threaded rod to pull the pivot pin from the axle and frame through the
hole in the counterweight.
47821916 28/04/2015
27.1 [27.100] / 8
13. Turn the threaded rod into the drilled hole in the rear
of the pivot pin.
RAPH12FRK0941BA 7
14. Put an appropriate floor jack under the axle to hold the
axle in position.
RAPH12FRK0944BA 8
15. Pull the pivot pin out of the frame.

16. Thrust washers and any spacers that are used at the
front and rear of the axle, and between the axle and
the frame. Lower the axle slowly and take note the
position and location as you remove the thrust wash-
ers and spacers.
NOTE: Record the number and location of thrust washers
and spacers for use during assembly.
RCPH11TLB144AAM 9
17. Remove the axle from under the machine.
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27.1 [27.100] / 9
Powered rear axle - Install

DANGER
Heavy parts!
Support designated component(s) with adequate lifting equipment.
D0018A
1. Raise the axle into alignment with the frame with an

appropriate lifting device.
RCPH11TLB144AAM 1
2. Install the tapered end of the pivot pin toward the front
of the machine.
3. Start the pivot pin into the frame, spacers, thrust wash-
ers, and axle.
4. Drive the pivot pin into the front pivot of the axle but not
through the front pivot.
5. Install the thrust washer between the front of the axle
and the frame.
NOTE: Remove or install spacers as required between the rear of the axle and the frame to remove any end play.
6. Drive the pivot pin through the front pivot and the frame.
7. Install the thrust washer (3) and any spacer that may
have been present. Install the snap ring (1) on the
tapered end of the pivot pin (2) .
RAPH12FRK0075AA 2
8. Move the pivot pin toward the rear of the machine as

far as possible.
9. Check the end play between the frame and the snap
ring on the pivot pin at the rear of the machine. Use
spacers as required for minimum end play.
10. Remove the threaded rod from the pivot pin.
11. Remove the plugs from the hoses and the caps from
the fittings for the steering cylinder.
12. Connect the hoses to the steering cylinder.
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27.1 [27.100] / 10
13. Install the wheels. Refer to Rear wheel - Install

(44.520).
14. Remove the blocks from between the axle stops and
the frame.
15. Remove the stands and lower the wheels to the floor.
16. Lubricate the pivot pin for the axle.
RAPH12FRK0943BA 3
NOTE: It may be helpful to install an O-ring and spacer on the bolts to hold the hardware in place when securing the
drive shaft to the transmission.
17. Install the drive shaft and the bolts that fasten the drive
shaft to the flange on the transmission.
18. Tighten the bolts to specification.
Specification
Drive shaft bolt torque 33 - 39 N·m (24 - 29 lb ft)
19. Using an appropriate floor jack, raise the drive shaft

guard (1) into alignment with the holes in the frame,
and install the bolts (3) and washers (3) that fasten
the guard to the frame. Tighten bolts to specification.
RCPH11TLB001AAL 4
Specification
Drive shaft guard bolt torque 50 - 90 N·m (37 - 66 lb ft)
20. Prepare machine for service.
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Powered rear axle - Disassemble

1. Do the necessary steps under Disassembly of wheel

hub for access to the swivel housing.
2. Loosen the nut.
RCPH10TLB693ABL 1
3. Use the CAS10468 puller to loosen the ball joint. Re-

move the nut and remove the ball joint from the swivel
housing.
RCPH10TLB692ABL 2
4. Loosen the bolts that hold the top king pin.
RCPH10TLB695ABL 3
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5. Fasten acceptable lifting equipment. Remove the bolts

and use acceptable tools to remove the top king pin.
RCPH10TLB697ABL 4
6. Repeat steps 4 and 5 for the bottom king pin.

7. Remove the swivel housing.
RCPH10TLB698ABL 5
8. Remove the belleville washer from the bottom of the

axle housing.
RCPH10TLB699ABL 6
9. Remove the belleville washer from the top of the axle

housing.
RCPH10TLB640ABL 7
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10. Use an acceptable puller and remove the top and bot-
tom bushings.
RCPH10TLB489ABL 8
11. Use an acceptable puller and remove the seal.
RCPH10TLB491ABL 9
12. Use an acceptable puller and remove the bushing.
RCPH10TLB492ABL 10
13. Use an acceptable puller and remove the seal from

the swivel housing.
RCPH10TLB456ABL 11
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14. Support the swivel housing on a sleeve and press the

bushing out of the swivel housing.
RCPH10TLB457ABL 12
15. Use a hammer and a chisel that has a long taper to

start the bushing off the bottom of the king pin.
RCPH10TLB459ABL 13
16. Press the bottom king pin out of the bushing.
RCPH10TLB460ABL 14
Replacing a universal joint

17. Remove the four snap rings.
RCPH10TLB472ABL 15
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18. Use the CAS1980 V-block to support the coupling.

Adjust the allen bolts in the V-block to hold the cou-
pling level and use additional support as required.
Use an acceptable driver and press the bottom bear-
ing cap against the V-block.
RCPH10TLB599ABL 16
19. Fasten the bearing cap in a vise and drive the coupling
off the bearing cap.
RCPH10TLB473ABL 17
20. Use the V-block to support the coupling and press the
other bearing cap against the V-block.
RCPH10TLB593ABL 18
21. Remove the long axle shaft (or short axle shaft) from
the coupling.
RCPH10TLB594ABL 19
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22. Remove the coupling from the bearing cap.
RCPH10TLB596ABL 20
23. Use an acceptable support and driver to press the

bottom bearing cap out of the yoke as far as possible.
RCPH10TLB474ABL 21
24. Remove the yoke from the bearing cap. DO NOT hit
the axle shaft in the seal area.
RCPH10TLB475ABL 22
25. Press the other bearing cap out of the yoke as far as
possible.
RCPH10TLB476ABL 23
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26. Remove the cross.
RCPH10TLB477ABL 24
27. Use an acceptable driver and press the bearing cap

out of the yoke.
RCPH10TLB478ABL 25
28. Press a bearing cap into the yoke until the top of the
bearing cap is 6 mm (0.24 in) above the top of the
yoke.
RCPH10TLB585ABL 26
29. Carefully install the cross in the bearing cap.
RCPH10TLB586ABL 27
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30. Press the other bearing cap into the yoke until the top
of the bearing cap is 9 mm (0.35 in) above the top of
the yoke.
RCPH10TLB587ABL 28
31. Carefully raise the cross into the bearing cap so that.
the cross is in both bearing caps.
RCPH10TLB588ABL 29
32. Hold the cross and press the bearing caps into the
yoke.
RCPH10TLB589ABL 30
33. Use an acceptable driver and press a bearing cap into

the yoke so that a snap ring can be installed.
RCPH10TLB590ABL 31
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34. Install a snap ring.
RCPH10TLB591ABL 32
35. Repeat steps 31and 32 for the remaining bearing cap.

36. Use the V-block to support the coupling and press a
bearing cap into the coupling even with the outside
diameter of the coupling.
RCPH10TLB592ABL 33
37. Carefully install the cross in the bearing cap.
RCPH10TLB595ABL 34
38. Use an acceptable driver and press the other bearing

cap into the coupling until the top of the bearing cap
is 6 mm (0.24 in) above the top of the coupling.
RCPH10TLB597ABL 35
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39. Carefully raise the cross into the top bearing cap so
that the cross is in both bearing caps.
RCPH10TLB598ABL 36
40. Hold the cross and press the bearing cap into the cou-
pling so that a snap ring can be installed.
RCPH10TLB600ABL 37
41. Install a snap ring.
RCPH10TLB601ABL 38
42. Repeat steps 38 and 39 for the other bearing cap.
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Powered rear axle - Assemble

1. Drive the bushing into the bore until the bushing is

8 mm (0.315 in) beyond the end of the bore. Then in-
stall the seal.
RCPH10TLB493ABL 1
2. Install the bushing for the top king pin on a driver that
has a pilot and drive the bushing all the way into the
bore.
RCPH10TLB490ABL 2
3. Repeat step 2 for the bottom bushing.

4. Install the belleville washer on the top of axle frame.
Then install the belleville washer on the bottom of the
axle frame. Install the swivel housing.
RCPH10TLB698ABL 3
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5. Install the top king pin, belleville washer, spacer, and

bolts. Tighten the bolts to a torque of 120 N·m (88.5 lb
ft).
RCPH10TLB696ABL 4
6. Install the bottom king pin, belleville washer and self-

locking bolts. Tighten the bolts to 120 N·m (88.5 lb ft).
RCPH10TLB497ABL 5
7. Install the ball joint and nut.
RCPH10TLB498ABL 6
8. Tighten the nut to 165 N·m (121.7 lb ft).
RCPH10TLB693ABL 7
9. Repeat steps 1 through 7 for the opposite end of the

axle.
10. Lubricate the king pins.
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11. Assemble the planetary according to instructions.
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Powered rear axle - Toe in adjust

RCPH10TLB001FAL 1
Top view of powered rear axle
1. Mark the center of each tire.
2. Loosen the jam nut (3) and turn the piston rod as re-
quired.
3. Back of rear axle measurement (A) must be equal to or
up to 5 mm (0.20 in) less than front of rear axle mea-
surement (B).
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Index

Powered rear axle - Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Powered rear axle - Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Powered rear axle - Drawing (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Powered rear axle - General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Powered rear axle - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Powered rear axle - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Powered rear axle - Special tools (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Powered rear axle - Toe in adjust (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Powered rear axle - Torque (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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Rear bevel gear set and differential - 106

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Contents
FUNCTIONAL DATA
Differential
Exploded view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
SERVICE
Differential
Disassemble - differential carrier (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Inspect (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Assemble - differential carrier (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
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Rear axle system - Rear bevel gear set and differential
Differential - Exploded view

1. Cover 12. O-ring

2. Seal 13. Lock
3. Pinion nut 14. Shim
4. Washer 15. Pinion gear
5. Bearing 16. Ring gear
6. Flat washer 17. Case half
7. Spacer 18. Thrust washer
8. Bearing cup 19. Side gear
9. Differential carrier 20. Pinion gear
10. Adjusting ring 21. Pinion shaft
11. Bearing cap 22. Dowel pin
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RCPB10TLB002HAL 1
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Differential - Disassemble - differential carrier

1. Drain the lubricant from the center bowl.

2. Loosen the ball joint nut.
RCPH10TLB693ABL 1
3. Use the CAS10468 puller to loosen the ball joint.
RCPH10TLB692ABL 2
4. Remove the nut and ball joint.
RCPH10TLB484ABL 3
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5. Loosen and remove the bolts that hold the top king pin.
RCPH10TLB695ABL 4
6. Fasten suitable lifting equipment as shown and remove

the top king pin.
RCPH10TLB697ABL 5
7. Remove the planetary and axle assembly.
RCPH10TLB698ABL 6
8. Repeat steps 1 through 7 for the opposite end of the

axle.
9. Use tool 380100091 and loosen and remove the right
steering cylinder.
RCPH10TLB502ABL 7
10. Remove the fitting from the closed end of the steering
cylinder.
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11. Remove the bolts.
RCPH10TLB639ABL 8
12. Remove the plug from the cylinder.
RCPH10TLB287ABL 9
13. Remove the steering cylinder.
RCPH10TLB288ABL 10
RCPH10TLB508ABL 11
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15. Use suitable lifting equipment and remove the differ-

ential carrier.
RCPH10TLB509ABL 12
16. Fasten the differential carrier in a repair stand.
RCPH10TLB462ABL 13
17. Prevent the pinion shaft from turning. Measure the

backlash of the ring gear. Record the reading.
RCPH10TLB701ABL 14
18. Make an identification mark on the bearing cap and

leg on one side of the differential carrier.
RCPH10TLB702ABL 15
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19. Remove the bolt and lock that hold each adjusting
ring.
RCPH10TLB703ABL 16
20. Loosen the bolts.
RCPH10TLB704ABL 17
21. Loosen both adjusting rings.
RCPH10TLB715ABL 18
22. Remove the 4 bolts. Use a hammer to loosen the 2

bearing caps.
RCPH10TLB706ABL 19
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23. Remove the adjusting rings, bearing cups and differ-

ential.
RCPH10TLB707ABL 20
24. If the bearing cups are to be used again, fasten an

identification tag to one bearing cup for the current
installation.
25. Remove the seal and cover.
RCPH10TLB511ABL 21
26. Use a narrow chisel to push the nut out of the pinion
shaft.
RCPH10TLB512ABL 22
27. Use the yoke and CAS2151 tool to remove the pinion
nut.
RCPH10TLB471ABL 23
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28. Remove the washer.
RCPH10TLB529ABL 24
29. Use a soft hammer and drive the pinion shaft out of
the outer bearing.
RCPH10TLB530ABL 25
30. Remove the flat washers and spacer. Discard the

spacer. The spacer MUST NOT be used again.
RCPH10TLB533ABL 26
31. Press the pinion shaft out of the inner bearing.
RCPH10TLB534ABL 27
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32. Remove the shim.
RCPH10TLB535ABL 28
33. Remove the bearing cups only if inspection indicates

the need for new parts.
RCPH10TLB531ABL 29
34. Use an acceptable puller and remove the seal form

the cover.
RCPH10TLB713ABL 30
35. Remove the O-ring from the cover.
RCPH10TLB691ABL 31
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Differential - Disassemble
RCPH10TLB513ABL 1
2. Remove the ring gear.
RCPH10TLB514ABL 2
3. Separate the case halves.
RCPH10TLB515ABL 3
4. Remove the thrust washer and side gear.
RCPH10TLB516ABL 4
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5. Remove the pinion shaft assembly and pin.
RCPH10TLB518ABL 5
6. Remove the side gear.
RCPH10TLB520ABL 6
7. Remove the thrust washer.
RCPH10TLB521ABL 7
8. Remove and install new bushings in the case halves as

required.
RCPH10TLB522ABL 8
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9. Remove the bearing from either case half as shown.
RCPH10TLB464ABL 9
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Differential - Inspect

2. Inspect the bearing cup and the rollers in the bearings
for flat areas, pitting, scoring, and other damage. Also
check the inner race for damage. If any of these de-
fects are found, a new bearing and bearing cup must
be installed.
3. Inspect the teeth on the pinion gear and ring gear for
pitting, scoring, and broken teeth. The ring gear and
pinion gear must be replaced as a set.
4. Inspect the side gears, the pinion shaft, and the teeth of
the pinion gears for pitting, scoring, and other damage.
Also inspect the thrust surfaces and the bore of each
pinion gear. Check the splines in the side gears for
wear. Use new parts as required.
5. Inspect the thrust washers for pitting, scoring, and other
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Differential - Assemble
1. Use the CAS 2395 and press a new bearing onto each
case half.
RCPH10TLB463ABL 1
2. Find the case half that has the threaded holes. Make
sure that the threads are free of lubricant.
RCPH10TLB523ABL 2
3. Lubricate the thrust washers, pinion gears and pinion

shaft with gear lubricant.
RCPH10TLB524ABL 3
4. Install a thrust washer in the case half that has threaded

holes.
RCPH10TLB521ABL 4
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5. Install a side gear.
RCPH10TLB520ABL 5
6. Install the thrust washers and pinion gears on the pinion

shaft.
RCPH10TLB525ABL 6
7. Install the pin.
RCPH10TLB519ABL 7
8. Install the pinion shaft assembly.
RCPH10TLB518ABL 8
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9. Apply LOCTITE® 270 to the threads in the case half.
RCPH10TLB526ABL 9
10. Install the other side gear.
RCPH10TLB517ABL 10
11. Install the other thrust washer in the other case half.
RCPH10TLB527ABL 11
NOTE: For limited slip differentials install 5 reaction and 4 friction plates starting with a reaction plate. Make sure the
special friction plate is against the side gear.
12. Using the two reference notches on the case halves,
assemble the two case halves.
RCPH10TLB515ABL 12
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13. Make sure the mounting surfaces for the ring gear are
clean and install the ring gear.
RCPH10TLB514ABL 13
14. Use the press to prevent the differential from turning

and install and tighten the bolts to 95 N·m (70.1 lb ft).
RCPH10TLB528ABL 14
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Differential - Assemble - differential carrier

1. Use a suitable driver and drive the bearing cup(s) into

the differential carrier.
RCPH10TLB532ABL 1
2. Assemble the gauge block, pilot and stud from the

CAS1839 pinion setting kit.
3. Install the gauge block, pilot, bearings and handle. See
special tools. Tighten the handle until the bearings be-
come difficult to turn.
RCPH10TLB537ABL 2
4. Install the gauge tube and bearing caps with marks

aligned.
RCPH10TLB538ABL 3
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5. Tighten the bolts to 156 N·m (115.1 lb ft).
RCPH10TLB539ABL 4
6. Use the metric feeler gauge and measure the space

between the gauge block and the gauge tube. Write
the measurement on line "b" in step 8.
RCPH10TLB540ABL 5
7. Write the number on the end of the pinion shaft on line

"d" in step 8.
RCPH10TLB458ABL 6
8. The number on line "a" does not change. Add line "a"
and line "b" and write the answer on link "c". Subtract
line "d" from line "c" and write the answer on line "e".
Line "e" is the thickness of the shim to be installed on
the pinion shaft. Example: Use 2.75 mm thick shim
A. 109.75 mm A. 109.75 mm
B.+ MM B. + .45 mm
C. MM C. 110.20 mm
D. - MM D. - 107.45 mm
E. MM E. 2.75 mm
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9. Remove the bolts, bearing caps, gauge tube, handle,

gauge block assembly and the bearings.
RCPH10TLB541ABL 7
10. Install the shim with the thickness specified in step 8.

The chamfer on the inside diameter of the shim must
be towards the pinion gear.
RCPH10TLB535ABL 8
11. Use the CAS2370 inner/outer pinion bearing cone in-

staller and press the inner bearing against the shim.
RCPH10TLB536ABL 9
12. Lubricate the bearings with gear lubricant.
RCPH10TLB542ABL 10
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13. Install a new spacer and flat washers. The old spacer
MUST NOT be used again.
RCPH10TLB533ABL 11
14. Install the pinion shaft and the outer bearing.
RCPH10TLB543ABL 12
15. Install the washer.
RCPH10TLB544ABL 13
16. Install a new pinion nut.
RCPH10TLB545ABL 14
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17. Use the yolk and the CAS2151 wrench and tighten the
pinion nut to 68 N·m (50.2 lb ft).
RCPH10TLB470ABL 15
18. The pinion shaft and bearings will still be loose.

Tighten the pinion nut in SMALL amounts until the
bearings become seated.
NOTE: If the pinion nut is tightened too much (rotating torque more than specified), the pinion will have to be removed
and a new spacer installed on the pinion shaft.
19. The art shows a socket being used, use the CAS2375
and a pound-inch torque wrench to check the rotating
torque of the pinion shaft. The rotating torque must be
1.7 - 2.2 N·m (15.0 - 19.5 lb in). If the rotating torque
is less than specified, tighten the pinion nut a SMALL
amount and check the rotating torque again.
RCPH10TLB546ABL 16
20. When the rotating torque is as specified, use a ham-

mer and punch and drive part of the pinion nut into the
slot in the pinion shaft.
RCPH10TLB547ABL 17
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21. Install a new O-ring on the cover.
RCPH10TLB691ABL 18
22. Use a suitable driver and drive a new seal into the
cover.
RCPH10TLB714ABL 19
23. Put the CAS2369 seal protector on the pinion shaft.
RCPH10TLB709ABL 20
24. Lubricate the O-ring and the seal with clean oil. Install
the cove.
RCPH10TLB710ABL 21
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25. Install the differential carrier and lubricate the bearings

with gear lubricant.
RCPH10TLB707ABL 22
26. Install the bearing cups and bearing caps with the
alignment marks.
RCPH10TLB700ABL 23
27. Tighten the bolts to pull the bearing caps against the
differential carrier. Do not overtighten the bolts. The
bearings must be able to rotate.
RCPH10TLB704ABL 24
28. Install the adjusting rings.
RCPH10TLB715ABL 25
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29. Use the CAS1840C and tighten both adjusting rings

while making sure that there is clearance (backlash)
between the ring gear and pinion gear.
RCPH10TLB715ABL 26
30. Use a dial indicator to check for end play.
RCPH10TLB555ABL 27
31. If there is end play, tighten the adjusting ring on the

tooth side of the ring gear until there is no end play.
32. If there is no end play, loosen the adjusting ring on the
back face side of the ring gear to make sure that there
is clearance between the ring gear and pinion gear
and tighten the opposite adjusting ring until there is
no end play.
33. When there is no end play, tighten each adjusting ring
one notch.
34. Use the dial indicator and check the backlash for the
ring gear at 90 ° intervals. If the reading are not equal,
adjust the backlash at the position that had the small-
est reading.
RCPH10TLB701ABL 28
35. If the original ring gear and pinion gear are being used,
the backlash must be equal to the measurement made
during disassembly.
36. If a new ring and pinion gear are being used, the back-
lash must be 0.2 - 0.25 mm (0.008 - 0.010 in).
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37. If there is not enough backlash, use the CAS1840C

and loosen the adjusting ring on the back face side
of the ring gear one notch and tighten the opposite
adjusting ring one notch. Check the backlash again.
Continue with this step until the backlash is correct.
RCPH10TLB715ABL 29
38. If there is too much backlash, use the CAS1840C and

loosen the adjusting ring on the tooth side of the ring
gear one notch and tighten the opposite adjusting ring
one notch. Check the backlash again. Continue with
this step until the backlash is correct.
RCPH10TLB557ABL 30
39. When the backlash is correct, tighten the bolts to

266 N·m (196.2 lb ft).
RCPH10TLB705ABL 31
40. Install the lock, bolt and lock washer that hold each
adjusting ring. Tighten the bolts to 13 N·m (115 lb in).
RCPH10TLB708ABL 32
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41. Apply form-in-place gasket material.
RCPH10TLB559ABL 33
42. Install the differential carrier.
RCPH10TLB560ABL 34
43. Install and tighten the bolts to 169 N·m (124.6 lb ft).
RCPH10TLB508ABL 35
44. Install the steering cylinder.

45. Install and tighten the bolts to 120 N·m (88.5 lb ft).
RCPH10TLB504ABL 36
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46. Install and tighten the tie rod using the 380100091 and
torque to 300 N·m (221.3 lb ft).
RCPH10TLB503ABL 37
47. Install and tighten the fitting at the closed end of the
steering cylinder.
48. Install the planetary and axle assembly. It may be nec-
essary to have another person turn the pinion shaft.
RCPH10TLB698ABL 38
49. Install the top king pin, spacer, and bolts. Tighten the
bolts to a torque of 120 N·m (88.5 lb ft).
RCPH10TLB696ABL 39
50. Install the bottom king pin, belleville washer and bolts.
Tighten the bolts to a torque of 120 N·m (88.5 lb ft).
51. Install the ball join and nut.
RCPH10TLB498ABL 40
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52. Tighten the nuts to 165 N·m (121.7 lb ft).
RCPH10TLB694ABL 41
53. Repeat steps 47 through 51 for the opposite end of

the axle.
54. See specifications for the correct lubricant for the cen-
ter bowl.
55. Lubricate the king pins with molydisulfide grease.
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Index

Differential - Assemble - differential carrier (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Differential - Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Differential - Disassemble - differential carrier (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Differential - Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Differential - Exploded view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Differential - Inspect (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
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Planetary and final drives - 120

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Contents
FUNCTIONAL DATA
Wheel hub
Exploded view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
SERVICE
Wheel hub
Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Inspect (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
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Rear axle system - Planetary and final drives
Wheel hub - Exploded view

1. Seal 11. Thrust washer

2. Wheel bearing 12. Snap ring
3. Bearing cup 13. Retainer
4. Planetary housing 14. Pinion gear
5. Stud 15. Pin
6. Retaining ring 16. O-ring
7. Hub 17. Carrier
8. Bolt 18. Allen head bolt
9. Ring gear 19. Pinion shaft
10. Thrust plate 20. Bushing
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RCPH10TLB001HAL 1
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Wheel hub - Disassemble

1. Raise the wheel(s) off the floor and use acceptable sup-
ports to hold the machine in position.
2. Remove the nuts and hardened washers and remove
the wheel(s). Drain the oil from the carrier.
3. Remove the two Allen head bolts that hold the carrier.
RCPH10TLB561ABL 1
4. Separate the carrier from the planetary housing.
RCPH10TLB562ABL 2
5. Remove the carrier.
RCPH10TLB563ABL 3
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6. Remove the snap ring.
RCPH10TLB564ABL 4
7. Remove the thrust washer with the internal tabs.
RCPH10TLB565ABL 5
8. Remove the thrust plate with the external tabs.
RCPH10TLB566ABL 6
9. Remove the bolts for the hub.
RCPH10TLB567ABL 7
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10. Install two 10 mm bolts in the two threaded holes in

the hub. Tighten the two bolts evenly until the ring
gear is free of the swivel housing.
RCPH10TLB568ABL 8
11. Remove the ring gear.
RCPH10TLB569ABL 9
12. Use an acceptable puller to remove the outer wheel

bearing from the swivel housing.
RCPH10TLB570ABL 10
13. Remove the planetary housing and the wheel bearing.
RCPH10TLB571ABL 11
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14. Use pry-bars to remove the inner wheel bearing from

the swivel housing. Be careful so that you do not
damage the inner wheel bearing.
RCPH10TLB572ABL 12
15. Remove the retaining ring which fastens the hub in the
ring gear.
RCPH10TLB660ABL 13
16. Remove the hub.
RCPH10TLB624ABL 14
17. Press the bushings from the hub only if new bush-
ing(s) are needed or a new hub is installed.
RCPH10TLB625ABL 15
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18. Remove the snap rings.
RCPH10TLB573ABL 16
19. Remove the retainer.
RCPH10TLB574ABL 17
20. Remove the pinion gears and thrust washers. Be

careful so that you do not lose the needles.
RCPH10TLB575ABL 18
21. Press the pinion shafts out of the carrier.
RCPH10TLB576ABL 19
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22. Remove the bearing cups and the seal as necessary.
RCPH10TLB577ABL 20
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Wheel hub - Inspect

1. Clean all parts with cleaning solvent.

2. Inspect the bearing cup and the rollers in the wheel
age. Also check the inner face for damage. If any of
these defects are found, a new wheel bearing and bear-
ing cup must be installed.
3. Inspect the pinion shafts for wear and damage.
4. Inspect the teeth of the pinion gears, the axle shafts,
and the ring gear for wear, pitting, scoring, and other
5. Inspect the needles for the pinion gears for flat areas,
pitting, scoring, and other damage. If any of these
defects are found, also inspect the bore of the pinion
gears and use new parts as required.
6. Inspect the thrust washer for the axle shaft in the bore
in the carrier. Do not remove the thrust washer unless
there is wear or damage. The thrust washer is held
in position with adhesive. If replacement is necessary,
use 324 Loctite and 7075 Loctite activator to install the
new thrust washer. Use the instructions on the con-
tainer. Curing time is approximately five minutes.
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Wheel hub - Assemble

1. If bearing cups were removed, use an acceptable driver

to press new bearing cups into the planetary housing.
RCPH10TLB578ABL 1
2. The words “OUTSIDE” on the seal must be facing up.

Use the CAS2374A to drive the new seal into the plane-
tary housing. Use the flat side of the Hub Seal Installer.
Be careful not to damage the seal.
RCPH10TLB622ABL 2
3. Press the pinion shafts into the carrier until the inner
end of the pinion shafts are 34.3 - 36.8 mm (1.35 -
1.45 in) from the machined surface on the carrier.
4. Apply petroleum jelly to one side and the bore of the
pinion gears.
RCPH10TLB479ABL 3
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5. Install a thrust washer.
RCPH10TLB480ABL 4
6. Install 30 needles in each pinion gear using petroleum

jelly to hold the needles in place.
RCPH10TLB481ABL 5
7. Install the pinion gears so that each thrust washer is

toward the carrier.
RCPH10TLB575ABL 6
8. Install the retainer.
RCPH10TLB574ABL 7
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9. Install the snap rings.
RCPH10TLB573ABL 8
10. Press bushings into the hub as required.
RCPH10TLB626ABL 9
11. Install the hub.
RCPH10TLB624ABL 10
12. Install the retaining ring.
RCPH10TLB623ABL 11
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13. Install a wheel bearing on the swivel housing. In-

stallation will be easier if you heat the wheel bearing
slightly. Do not heat the wheel bearing higher than
149 °C (300 °F). Use clean gear lubricant to lubricate
the wheel bearing.
RCPH10TLB579ABL 12
14. Install the planetary housing.
RCPH10TLB580ABL 13
15. Install the outer wheel bearing. Installation will be In-

stall the thrust plate with the external tabs. easier if
you heat the wheel bearing slightly. Do not heat the
wheel bearing higher than 149 °C (300 °F).
RCPH10TLB581ABL 14
16. Align the holes in the hub with the holes in the swivel
housing and install the ring gear.
RCPH10TLB582ABL 15
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17. Put LOCTITE® 270 in the female threads in the swivel

housing. Install and tighten the bolts evenly to pull the
hub against the swivel housing. Tighten the bolts to a
final torque of 95 N·m (70 lb ft).
RCPH10TLB567ABL 16
18. Install the thrust plate with the external tabs.
RCPH10TLB566ABL 17
19. Install the thrust washer with the internal tabs.
RCPH10TLB565ABL 18
20. Install the snap ring.
RCPH10TLB564ABL 19
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21. Install a new O-ring on the planetary housing.
RCPH10TLB583ABL 20
22. Install the carrier.
RCPH10TLB584ABL 21
23. Install and tighten the Allen head bolts to a torque of

25 N·m (18.4 lb ft).
RCPH10TLB561ABL 22
24. See specifications for the correct lubricant for the plan-
etary.
25. Install the wheel(s), hardened washers, and nuts.
Tighten the nuts to specifications.
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Index

Wheel hub - Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Wheel hub - Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Wheel hub - Exploded view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Wheel hub - Inspect (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
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Non-powered rear axle - 550

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Contents
TECHNICAL DATA
Non-powered rear axle

Torque (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Special tools (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
FUNCTIONAL DATA
Steering knuckle
Exploded view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
SERVICE
Non-powered rear axle

Rear axle - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Rear axle - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Toe in adjust (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Rear axle
Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Inspect (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
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Rear axle system - Non-powered rear axle
Non-powered rear axle - Torque

Specifications
Bolts for steering cylinder 335 N·m (247.1 lb ft)
Tie rod ball joint to steering cylinder 300 N·m (221.3 lb ft)
Tie rod to steering knuckle 165 N·m (121.7 lb ft)
Jam nut for tie rod 120 N·m (88.5 lb ft)
Bolts for king pin 120 N·m (88.5 lb ft)
Bolts for bearing caps 120 N·m (88.5 lb ft)
Bearing cap plug 15 N·m (11.1 lb ft)
Non-powered rear axle - Special tools

CAS1842 Wheel stud removal and installation kit
RCPH10TLB466ABL 1
CAS2159 Wrench to loosen and tighten tie rods for steer-

ing cylinder
RCPH10TLB235ABL 2
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Steering knuckle - Exploded view

RCPH10TLB001GAL 1
1. Bolt 4. Bushing 7. Steering knuckle

2. Top king pin 5. Seal 8. Grease zerk
3. Belleville washer 6. Bushing 9. Bottom king pin
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Rear axle - Remove


machine to use ().
2. Drain the hydraulic fluid. Refer to Oil reservoir - Drain
fluid (35.300).
3. Remove the rear wheels. Refer to Rear wheel - Re-
move (44.520).
DANGER
Heavy parts!
injury.
D0018A
4. Using appropriate lifting equipment (1), lift and support

(2) the rear of the machine.
RAPH12FRK0942BA 1
5. Clean all hydraulic hose connections at the power
steering cylinder.
6. Disconnect the hydraulic hoses at the power steering
cylinder. Close all openings.
7. Loosen and remove the tie rod ends.
RAPH12FRK0332AA 2
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8. Remove the six mounting bolts (3) Remove the power

steering cylinder (2) from the axle (1).
RAPH12FRK0333AA 3
9. Disconnect the remote grease fitting at the rear frame.
RAPH12FRK0943BA 4
NOTE: Make note of the location and quantity of spacers on the pivot pin for installation.
10. Remove the snap ring (1) and spacers (3) from the
front of the pivot pin (2).
RAPH12FRK0075AA 5
NOTE: Use a 1/2 - 13 UNC threaded rod to pull the pivot pin from the axle and frame through the hole in the coun-
terweight.
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27.4 [27.550] / 6
11. Turn the threaded rod into the drilled hole in the rear
of the pivot pin. Do not remove the pivot pin at this
time.
RAPH12FRK0941BA 6
12. Support the rear axle with appropriate lifting device.
RAPH12FRK0944BA 7
NOTE: Make note of the location and quantity of spacers on the pivot pin for installation.
13. Remove the pivot pin and spacers from the axle and
frame using the threaded rod.
14. Lower the axle from the machine.
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Rear axle - Install

DANGER
Heavy parts!
injury.
D0018A
1. Use an appropriate lifting device, raise the steering axle

into alignment with the machine.
RAPH12FRK0944BA 1
2. Install the previously noted spacers between the front

and rear of the axle and frame.
RAPH12FRK0940BA 2
NOTE: It is necessary to use a 1/2 - 13 UNC threaded rod to drive the pivot pin through the axle and frame through
the hole in the counterweight.
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27.4 [27.550] / 8
3. Drive the pivot pin through the axle and frame using
the threaded rod. Verify that all spacers are in the pre-
viously noted locations and that quantities are correct.
RAPH12FRK0941BA 3
4. Install the snap ring on the tapered end of the pivot pin.
RAPH12FRK0075AA 4
5. Check the end play between the frame and the snap
ring on the pivot pin at the rear of the machine. Use
spacers as required to remove any end play.
6. Remove the threaded rod from the pivot pin.
7. Install the power steering cylinder (2) to the axle (1) and
tighten the six bolts (3).
RAPH12FRK0333AA 5
Specification
Power Steering Cylinder Mounting Bolt Torque 335 N·m (247.1 lb ft)
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8. Install the tie rod ends (1) and tighten nuts (2) to spec-
ification.
RAPH12FRK0332AA 6
Specification
Tie Rod Nut Torque 165 N·m (121.7 lb ft)
9. Connect the hydraulic hoses at the power steering

cylinder.
10. Install the rear tires. Refer to Rear wheel - Install
(44.520).
11. Fill the hydraulic fluid. Refer to Oil reservoir - Filling
(35.300).
machine to use ().
13. Start and run the engine at low idle.
14. Turn the steering wheel all the way to the right and
left several times to remove any air from the steering
system.
15. CAUTION
Escaping fluid!
for this purpose. If injured by leaking fluid,
see your doctor immediately.
erate injury.
C0104A
Stop the engine and check for leaks.

16. Check the hydraulic oil level at the reservoir and add
oil as necessary.
17. Grease the pins for the steering links.
18. Check and adjust toe-in if necessary. Refer to Non-
powered rear axle - Toe in adjust (27.550).
19. Return the machine to service.
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Non-powered rear axle - Toe in adjust

RCPH10TLB001FAL 1
Top view of non-powered rear axle
1. Mark the center of each tire.
2. Loosen the jam nut (3) and turn the piston rod as re-
quired.
3. Back of rear axle measurement (A) must be equal to or
up to 5 mm (0.20 in) less than front of rear axle mea-
surement (B).
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Rear axle - Disassemble

1. Loosen and remove the tie rod ends from the swivel
housings.
RCPH10TLB603ABL 1
2. Remove the steering cylinder, ball joints, and tie rod

ends from the axle.
RCPH10TLB716ABL 2
3. Attach suitable lifting equipment to the wheel hub. Re-

move the wheel hub cover, bearing retainer plate bolts,
and bearing retainer plate.
RCPH10TLB604ABL 3
4. Remove the wheel hub from the axle.
RCPH10TLB605ABL 4
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NOTE: Repeat steps 3 and 4 for the other wheel hub.

5. Remove the bearing cups from the wheel hubs.
RCPH10TLB606ABL 5
6. Remove the bearing cone from the swivel housing.
RCPH10TLB607ABL 6
7. Attach suitable lifting equipment to the swivel housing.

Remove the upper and lower king pins.
RCPH10TLB608ABL 7
8. Remove the swivel housing from the axle beam.
RCPH10TLB609ABL 8
NOTE: Repeat steps 7 and 8 for the other swivel housing.
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9. Remove the bevelled washers from the axle beam.
RCPH10TLB610ABL 9
10. If required, remove the upper bushing and lower bear-

ing cup for the king pins.
RCPH10TLB611ABL 10
11. If required, remove the front and rear pivot seals and
bushings.
RCPH10TLB612ABL 11
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Rear axle - Inspect


2. Inspect the bearing cups and the rollers in the wheel
age. Also check the bearing cones for damage. If any
of these defects are found, new wheel bearing cups
and cones must be installed.
3. Inspect king pin bushings and bearings for flat ar-
eas, pitting, scoring, and other damage. Replace as
needed.
4. Inspect axle pivot bushings and pivot pin for flat ar-
eas, pitting, scoring, and other damage. Replace as
needed.
5. Remove and discard all seals and O-rings.
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Rear axle - Assemble

1. Install bushings and seals in the pivot on the axle beam.
RCPH10TLB612ABL 1
NOTE: To ease installation, cool bushings to -100 °C (-148.0 °F).

2. Install the upper bushing and lower bearing cup using
suitable bearing drivers.
RCPH10TLB611ABL 2
NOTE: To ease installation, cool bushings to -100 °C (-148.0 °F).

3. Apply grease to the bevelled washers to assist holding
them in place during assembly.
RCPH10TLB610ABL 3
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4. Use suitable lifting equipment and install the swivel

housing on the axle.
RCPH10TLB609ABL 4
5. Make sure the bevelled washers are in place, install the

upper and lower king pins. Torque the bolts to 120 N·m
(88.5 lb ft)
RCPH10TLB608ABL 5
6. Grease the bearing cone and install it onto the swivel

housing.
RCPH10TLB607ABL 6
7. Use suitable drivers and install new bearing cups and

seal into wheel hub.
RCPH10TLB613ABL 7
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8. Use suitable lifting equipment and install wheel hub

onto the swivel housing.
RCPH10TLB614ABL 8
9. Grease and install the outer bearing on the swivel hous-

ing. Use LOCTITE® 270 on the bolts, position the thrust
washer, install and torque the bolts to 120 N·m (88.5 lb
ft).
RCPH10TLB615ABL 9
10. Install a new O-ring on the wheel hub cover, lubricate

the O-ring with grease. Use a suitable driver and in-
stall the wheel hub cover into the wheel hub.
RCPH10TLB616ABL 10
11. Use LOCTITE® 270 on the bolts, mount the steering

cylinder and torque the bolts to 335 N·m (247.1 lb ft).
RCPH10TLB717ABL 11
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12. Install the ball joints to the steering cylinder, torque the
ball joints to 300 N·m (221.3 lb ft).
RCPH10TLB717ABL 12
13. Loosen the locking nut for the tie rod end, place the
swivel housing parallel with the axle. Adjust the tie rod
end so that it can be slipped into the swivel housing.
RCPH10TLB617ABL 13
14. Tighten the tie rod end to a torque of 165 N·m

(121.7 lb ft).
RCPH10TLB603ABL 14
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Index

Non-powered rear axle - Special tools (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Non-powered rear axle - Toe in adjust (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Non-powered rear axle - Torque (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Rear axle - Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Rear axle - Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Rear axle - Inspect (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Rear axle - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Rear axle - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Steering knuckle - Exploded view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
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PRINTED IN U.S.A.
47821916 28/04/2015
EN
SERVICE MANUAL
Brakes and controls

47821916 28/04/2015
33
Contents
Brakes and controls - 33
[33.110] Parking brake or parking lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33.1
[33.202] Hydraulic service brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33.2
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Parking brake or parking lock - 110

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Contents
SERVICE
Parking brake disks

Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Inspect (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Check (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Test (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
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Brakes and controls - Parking brake or parking lock
Parking brake disks - Disassemble

586H
588H
Some of the following images may not represent your transmission, the procedures are the same.

machine to use ().
2. Block the wheels to keep the machine from moving.
3. Place a suitable container underneath the transmission
drain plug and allow the oil to drain into an appropriate
container for storage or disposal. Install the drain plug
after draining the fluid.
RAPH12FRK0084BA 1
4. CAUTION
Heavy object!
handling.
erate injury.
C0095A

6. Slide the front drive shaft (4) off the axle pinion shaft
(5).
RCPH11TLB125AAM 2
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33.1 [33.110] / 3
7. Loosen the flange bolt.
RCPH10TLB596AAL 3
8. Remove the flange bolt and washer.
RCPH10TLB868AAL 4
9. Remove the O-ring and flange.

NOTE: The transmission was removed from the machine
for clarity only, it is not necessary to remove the transmis-
sion.
RCPH10TLB869AAL 5
10. Loosen brake housing bolts.
RCPH10TLB871AAL 6
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33.1 [33.110] / 4
11. Remove bolts (A), and alternately loosen bolts (B) to

release the load of bellville washer.
NOTE: Housing is under spring pressure, failure to fol-
low instructions will result in serious injury and damage to
equipment.
RCPH10TLB594AAL 7
12. Remove the brake cover from the transmission.
RCPH10TLB872AAL 8
13. Remove and discard the O-ring.
RCPH10TLB873AAL 9
14. Remove back plate.
RCPH10TLB874AAL 10
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15. Remove the springs and remove the friction disc.
RCPH10TLB875AAL 11
16. Remove the reaction plates.
RCPH10TLB876AAL 12
17. Remove the hub.
RCPH10TLB877AAL 13
18. Remove the retaining plate.
RCPH10TLB599AAL 14
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19. Remove and discard the O-rings and backup ring from
the retaining plate.
RCPH10TLB600AAL 15
20. Use CAS2379 to compress the bellville washers, re-

move the retaining ring.
RCPH10TLB601AAL 16
21. Remove the piston from the brake housing.
RCPH10TLB602AAL 17
22. Remove and discard the O-rings and backup rings

from the piston.
RCPH10TLB603AAL 18
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23. Remove the bellville washers from the brake housing.
RCPH10TLB604AAL 19
24. Remove the seal from the brake housing.
RCPH10TLB605AAL 20
25. Remove and discard the O-ring from the brake hous-
ing.
RCPH10TLB606AAL 21
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Parking brake disks - Inspect

586H
588H

2. Inspect the brake disks and reaction plates for pitting,
scoring, excessive surface wear, and other damage.
Use new parts as required.
3. Inspect the bellville washer for cracking and excessive
surface wear at contact points. Use new parts as re-
quired.
4. Inspect brake pistons and housing for scaring on slid-
ing surfaces, brake pistons for pitting, scoring, and ex-
cessive surface wear at brake contact point. Use new
parts as required.
5. Replace O-rings on brake cylinders and pistons.
NOTE: Use only genuine parts. DO NOT use after market
O-rings, they will fail.
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Parking brake disks - Assemble

586H
588H
NOTE: Some of the following images may not represent your transmission, the procedures are the same.
1. Install a new O-ring on the brake housing.
RCPH10TLB607AAL 1
2. Install the bellville washers as shown.
RCPH10TLB595AAL 2
3. Install the backup ring, install the seal ring.
RCPH10TLB608AAL 3
NOTE: Make sure that the seal ring does not twist during installation.
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4. Lubricate the piston seals with transmission fluid, install

the piston into the brake housing.
RCPH10TLB602AAL 4
5. Use CAS2379 and compress the bellville washers, in-

stall the retaining ring.
NOTICE: Make sure the retainer is properly seated before
removing spring compressor.
RCPH10TLB601AAL 5
6. Install new O-rings and backup ring in the retaining

plate.
RCPH10TLB600AAL 6
7. Lubricate the O-rings on the retaining plate, install the

plate into the brake housing.
RCPH10TLB599AAL 7
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8. Install the hub onto the output shaft as shown.
RCPH10TLB877AAL 8
9. Install a reaction plate first.
RCPH10TLB876AAL 9
10. Install a friction plate and a wave spring, continue to

install a reaction plate, friction plate and wave spring
until all components are installed.
RCPH10TLB875AAL 10
11. Install the back plate as shown.
RCPH10TLB874AAL 11
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12. Install a new O-ring.
RCPH10TLB873AAL 12
13. Install the brake housing.
RCPH10TLB872AAL 13
14. Install the bolts, use an alternately tightening pattern

until the brake housing is tight against the transmis-
sion. Torque the bolts to 50 N·m (37 lb ft).
RCPH10TLB871AAL 14
15. Install the flange and a new O-ring.
RCPH10TLB869AAL 15
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33.1 [33.110] / 13
16. Install the bolt and washer.
RCPH10TLB868AAL 16
17. Torque bolt to 139 N·m (103 lb ft).
RCPH10TLB870AAL 17
(5).
20. Install the retainer (2) and bolts (3) that attach the front
drive shaft to the output shaft yoke (1).
RCPH11TLB125AAM 18
Specification
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33.1 [33.110] / 14
21. Confirm the transmission drain plug is installed

and tightened. Fill the transmission system with
CASE AKCELA HY-TRAN® ULTRA™ HYDRAULIC
TRANSMISSION OIL.
RAPH12FRK0084BA 19
22. Remove the transmission dipstick (1).

23. Fill the transmission system through the fill tube with
TRANSMISSION OIL.
RAPH12FRK0085BA 20
Specification 2WD
Specification 4WD

chine to use ().
25. With the machine parked on level ground and the en-
gine running at low idle, check the transmission oil
level. The oil level must be between the ADD and the
FULL marks on the dipstick. If the oil level is at the
ADD mark, add oil as required until the oil level is at
the FULL mark.
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Parking brake disks - Check

586H
588H
1. Block the wheels of the vehicle to prevent any move-

ment.
2. Remove the floor plates to gain access to the brake
solenoid.
RCPH10TLB597AAL 1
3. Remove the solenoid mounting bolts, remove the sole-

noid from the transmission.
RCPH10TLB598AAL 2
4. Turn the solenoid 90° and torque the solenoid to

20 N·m (14.8 lb ft). Pump grease into the grease
fitting until the brake releases.
NOTE: Do not use excess pressure or damage can be done to internal components.
Activate
5. Slowly remove the bolts from the brake solenoid to re-
lease the pressure.
NOTE: Do not unscrew the grease fitting to release the
pressure.
6. Clean excess grease from the solenoid and transmis-
sion housing.
7. Install new O-rings on the transmission.
8. Install the solenoid on the transmission, torque the so-
lenoid to 20 N·m (14.8 lb ft).
9. Activate and release the brake several times to remove
excess grease from the system.
10. Change the transmission filter, check the oil level in
the transmission, add oil as required.
11. Install the floor plates.
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Parking brake disks - Test

586H
588H
WARNING
Equipment failure could cause accident or injury!
Before operating the machine, check for correct operation of steering, brakes, hydraulic controls,
instruments, and safety equipment. Make sure the transmission control lever is in the neutral position.
Make all adjustments before operating the machine.
W0204A
NOTE: Review the procedures in their entirety before proceeding. Ensure that you allow surplus room for machine
travel.
Parking brake
1. Sit in the operator's seat and fasten the seat belt.
3. Disengage four wheel drive, if equipped.
4. Place the direction control lever in neutral and the trans-
mission in 2nd gear.
6. Ensure the forks are raised in preparation of forward
travel.
7. Press and hold the service brakes and release the park-
ing brake.
8. Place the direction control lever in forward.
9. Release the service brakes.
10. Increase the engine speed to full throttle.
11. Travel forward approximately 8 m (26 ft).
12. Engage the parking brake. The machine should come
to a stop within 2 m (6.5 ft) of engaging the parking
brake and the transmission should de-clutch.
NOTE: If the machine does not stop within 2 m (6.5 ft) the
parking brake will have to be repaired, see Parking brake
disks - Disassemble (33.110).
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Index

Parking brake disks - Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Parking brake disks - Check (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Parking brake disks - Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Parking brake disks - Inspect (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Parking brake disks - Test (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
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Hydraulic service brakes - 202

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Contents
TECHNICAL DATA
Brake pedals
Service limits (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
FUNCTIONAL DATA
Brake pedals
Overview (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
SERVICE
Hydraulic service brakes

Test (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Brakes
Bleed (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Brake pedals
Check (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Travel adjust (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Height adjust (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Adjust Switch (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Brake master cylinder
Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Visual inspection (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
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Brakes and controls - Hydraulic service brakes
Brake pedals - Service limits

586H
588H
Specification
Brake pedal height 132 - 136 mm (5.20 - 5.35 in)
Brake pedal free travel 2 - 4 mm (0.08 - 0.16 in)
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Brake pedals - Overview

586H
588H
RAPH12FRK0639HA 1
ILLUSTRATION OF BRAKE PEDALS
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1–Left Brake Pedal 9–Stop Bolt 17–Master Cylinder

2–Right Brake Pedal 10–Cotter Pin 18–Brake Switch Actuator Bolt
3–Bolt 11–Clevis 19–Brake Pedal Shaft
4–Nut 12–Spring 20–Brake Switch Lever
5–Lock Washer 13–Roll Pin 21–Floor
6–Shim Washer 14–Pedal Lock Pin 22–138 mm ± 2 mm (5.43 in. ± 0.08 in.)
7–Spacer 15–Pivot Distance from lower rear edge of brake pedal to the top of the floor mat.
8–Clevis Pin 16–Brake Switch
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Hydraulic service brakes - Test

586H
588H
WARNING
Hazard to bystanders!
Make sure the area surrounding the machine is clear of all persons before starting the engine.
W0090A
NOTE: Check the brake pedal free travel before proceeding. Adjust the brake pedal height. Check the brake system
for leaks or damaged lines. Repair or replace as necessary.
WARNING
Jack stands can slip or fall over. Dropping, tip-
ping, or slipping of machine or its components
is possible.
DO NOT work under a vehicle supported by
jack stands only. Park machine on a level
surface. Block wheels. Support machine with
safety stands.
ous injury.
W0069A
2. Make sure the machine is parked on solid level ground.

Block the rear wheels. Raise the front of machine so
both tires are off the ground and support with appropri-
ate safety stands.
Specification
586H 2WD Machine Weight (approximate) 6350.3 kg (14 000 lb)
Specification
3. Lock the brake pedals with the brake pedal locking pin.
4. Start the machine and place the transmission gear shift
lever in 2nd gear, release the parking brake, and place
the directional control lever in the FORWARD travel or
REVERSE travel position.
NOTE: Make sure the differential lock is not engaged.

5. Slowly apply the brakes. Both tires should stop rotating
at the same time.
6. Remove the safety stands from under the machine and
lower the machine to the ground.
7. Move the machine to a clear level area with sufficient
space to accelerate the machine to 5 km/h (3.1 mph).
8. Once the machine has reached 5 km/h (3.1 mph),
quickly apply the brakes. Both tires should lock and
slide.
9. Accelerate the machine to 5 km/h (3.1 mph).
47821916 28/04/2015
33.2 [33.202] / 6
10. Slowly apply the brakes. There should be no chatter-

ing, growling, or squealing sound from the brake sys-
tem.
11. Unlock the brake pedal locking pin.
12. Accelerate the machine to 1 km/h (0.6 mph), and
quickly apply the right brake. The right tire should
lock and the machine should pull to the right.
13. Repeat the previous step for the left brake.
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Brakes - Bleed
586H
588H
1. Make sure the hydraulic oil level in the reservoir is to

the correct level.
DANGER
Unexpected movement!
Make sure parking brake is applied. Secure ma-
chine with wheel chocks.
injury.
D0013A
2. Chock the wheels on the machine to prevent any ac-

cidental movement of the machine while bleeding the
brakes.
3. Stop the flow of oil through the keep-full brake reser-
voir drain hose (1) by pinching the hose closed using a
suitable clamp.
RAPH12FRK0331AA 1
4. Remove the brake bleeder valve dust cap on one of

the brake bleeders. Install a clear plastic hose with a
1/4 inch I.D. onto the brake bleeder valve. Insert the
opposite end of the hose into a suitable drain pan.
5. Make sure the parking brake is in the ON position. Start
and run the engine.
6. Slowly open the brake bleeder valve. Watch as the oil
flows from the bleeder valve. Allow the oil to flow until
air bubbles are no longer present in the oil. Close the
bleeder valve.
7. Stop the engine and repeat the procedure for the op-
posite side.
8. When the bleeding procedure is complete remove the
clamp from the keep-full brake reservoir drain hose.
9. Remove the wheel chocks. Make sure the brake ped-
als are locked together. Start the machine and dis-
engage the park brake. Apply the service brake and
place transmission into second gear and run engine at
1500 RPM. Verify the service brakes will not allow the
machine to move. If service brakes do not keep the
machine from moving, repeat the above bleeding pro-
cedure until oil free of air bubbles is observed in the
clear plastic hose.
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33.2 [33.202] / 8
10. Install brake bleeder valve dust caps

11. When the brake bleed procedure is complete, make
sure brake pedal height is to specification. Refer to
Brake pedals - Height adjust (33.202)
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Brake pedals - Check

586H
588H
1. Make sure the brake pedal lock pin (14) is disengaged.
NOTE: If the machine is equipped with a floor mat, remove the floor mat before performing step 2.
2. Measure the distance from the floor to the lower rear
edge of each brake pedal (1 and 2) as shown. The
brake pedals (1 and 2) must be 132 - 136 mm (5.2 -
5.4 in) above the floor with the brake pedals (1 and 2)
in the released position.
Refer to Brake pedals - Overview (33.202) for more
information.
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Brake pedals - Travel adjust

586H
588H
NOTE: Free travel is the distance that the brake pedal can move before the push rod makes contact with the outer
piston in the master cylinders.
1. Measure the free travel at the rear edge of each brake
pedal (1 and 2) as shown. The free travel must be 2 -
4 mm (0.1 - 0.2 in).
2. To increase or decrease the free travel, loosen the lock
nut (4) at each clevis (11) and turn the push rod as
necessary to get the correct free travel. Tighten the
lock nut.
information.
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Brake pedals - Height adjust

586H
588H
1. Loosen the nut (4) on the stop bolt (9).

2. Turn the stop bolt (9) clockwise or counterclockwise,
as required, until the rear edge of each brake pedal (1
or2).134 mm ± 2 mm (5.27 in. ± 0.08 in.)
3. Tighten the nut (4) on the stop bolt (9).
4. Repeat steps 1 through 3 for the other brake pedal.
information.
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Brake pedals - Adjust Switch

586H
588H
1. Loosen the lock nut (4) for the actuator bolt (18) that ac-
tuates the brake switch (16). Adjust the actuator bolt so
the brake switch is not damaged with the brake pedal
(1 and 2) in the released position. Tighten the lock nut.
2. The brake switch must actuate when the brake pedal
(1 or 2) is applied.
information.
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Brake master cylinder - Remove

586H
588H

2. Remove the floor mat (1) and floor plate (2) from the
machine.
RAPH12FRK0101BA 1
3. Remove any dirt from the master cylinders (3) and the
area around the master cylinders.
RAPH12FRK0102BA 2
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RAPH12FRK0634HA 3
3–Master Cylinder 6–Clevis 9–Master Cylinder Reservoir

4–Cotter Pin 7–Break Pedal 10–Brake Lines
5–Clevis Pin 8–Jam Nut
4. Remove the cotter pin (4) and the clevis pin (5) from the
clevis (6), securing the brake pedal (7) to the master
cylinder.
NOTE: For assembly purposes, count and record the number of turns when unscrewing the clevis from the push rod.
5. Loosen the jam nut (8) and unscrew the clevis from the
master cylinder push rod.
6. Drain the fluid from the master cylinder reservoir (9).
ATTENTION: To avoid contamination, cap and plug all lines and ports when disconnecting.
7. Disconnect the brake lines (10) from the master cylin-
der reservoir and the master cylinder.
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RAPH12FRK0634HA 4
3–Master Cylinder 12–Brake Line 14–Lock Washer

11–Brake Line 13–Nut
8. Disconnect the brake lines (11) and (12) from the mas-
ter cylinder.
9. Remove nuts (13), and lock washers (14) and remove
bolts (15) securing the master cylinder to the frame.
10. Remove the master cylinder from the frame.
11. Repair or replace parts as necessary.
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Brake master cylinder - Install

586H
588H
1. Install the master cylinder (1) to the frame, and install

bolts (2), lock washers (3), and nuts (4).
RAPH12FRK0634HA 1
1–Master Cylinder 3–Lock Washer

2–Bolt 4–Nut
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2. Connect the brake lines (5) and (7) to the master cylin-
der. Tighten to specification.
Specification
Brake Lines (5) and (7) Torque 31.2 - 35.3 N·m (23.0 - 26.0 lb ft)
3. Connect brake line (6) to the master cylinder, and

tighten to specification.
Specification
Brake Line (6) Torque 22 - 27 N·m (16.2 - 19.9 lb ft)
RAPH12FRK0634HA 2
5–Brake Line 6–Brake Line 7–Brake Line
NOTE: Turning the clevis the same number of turns recorded in the removal procedure will be only a rough adjustment;
push rod to piston clearance will still need to be adjusted. The lock nut can be tightened once final adjustment has
been made.
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4. Install the clevis (8) to the push rod on the master

cylinder, turning the clevis the same numbers of turns
recorded in the removal procedure.
5. Position and align the brake pedal (9) with the clevis,
and install the clevis pin (10).
6. Secure the clevis pin with a cotter pin (11).
7. Adjust the free travel of the brake pedal by depressing
the brake pedal and allowing the piston to return. Turn
the clevis clockwise to decrease or counterclockwise
to increase the length. Adjust the push rod to piston
clearance to specification.
Specification
Free Travel Adjustment 2 - 4 mm (0.08 - 0.16 in)
8. When adjustment has been made, tighten the lock nut

(12).
9. Remove the air from the brake system. See Brakes -
Bleed (33.202)
10. Check the system for leakage at the master cylinder.
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RAPH12FRK0634HA 3
8–Clevis 10–Clevis Pin 12–Lock Nut

9–Brake Pedal 11–Cotter Pin
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11. Install the floor plate (13) and floor mat (14).
RAPH12FRK0101BA 4

chine to use ().
13. Check the hydraulic fluid level, if necessary fill with
TRANSMISSION OIL.
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Brake master cylinder - Disassemble

586H
588H
1. Clean any foreign material from the master cylinder

body (1).
ATTENTION: DO NOT Overtighten when using a vise, and use jaw protectors to protect the master cylinder.
2. Secure the master cylinder body into a vise.
3. Remove the flow valve adapter (2) from the master
cylinder. Remove the gasket (3) from the flow valve
adapter.
4. Remove the flow valve (4) from the master cylinder
body. Remove the flow valve seal (5) from the flow
valve.
5. Remove the ball (6) from the master cylinder body.
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RAPH12FRK0635HA 1
1–Master Cylinder Body 3–Gasket 5–Flow Valve Seal

2–Flow Valve Adapter 4–Flow Valve 6–Ball
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6. If not already removed, loosen the lock nut, and Re-

move the clevis and lock nut from the push rod (15).
NOTE: Clevis and lock nut not shown.
7. Remove the boot (7) from the master cylinder body.
8. Remove the snap ring (8) from the master cylinder
body.
9. Remove the push rod (10) and washer (9) from the
master cylinder body.
10. Using a soft blow or rubber mallet, tap the open end of
the master cylinder, moving the piston (12) assembly
to the end of the master cylinder.
11. Remove the piston assembly from the master cylinder
body.
12. Locate the small tab in the spring seat (13) that holds
the spring seat onto the piston Use a small screwdriver
to left up the tab.
13. Remove the check valve assembly from the piston.
14. Remove the seal (11) from the piston.
15. Disconnect the check valve seat from the spring seat.
16. Remove the spring (14) from the spring seat.
17. Remove the check valve seat from the check valve
piston (17).
18. Remove the wave spring (16) from the check valve
piston.
19. Remove the check valve seal (18) from the check
valve piston.
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RAPH12FRK0635HA 2
7–Boot 11–Seal 15–Check Valve Seat

8–Snap Ring 12–Piston 16–Wave Spring
9–Washer 13–Spring Seat 17–Check Valve Piston
10–Push Rod 14–Spring 18–Check Valve Seal
20. Thoroughly inspect all parts. See Brake master

cylinder - Visual inspection (33.202).
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Brake master cylinder - Assemble

586H
588H
1. Install the check valve seal (1) onto the check valve
piston (2).
2. Install the wave spring (3) onto the check valve piston.
3. Install the check valve seat (4) onto the spring (5).
4. Install the check valve assembly into the spring, and
engage the stem of the check valve piston into the
spring seat (6).
5. Push the check valve assembly onto the piston (7) until
the tab in the spring seat engages the end of the piston.
6. Install the seal (8) onto the piston.
7. Lubricate the bore of the master cylinder body (13) with
clean hydraulic fluid.
8. Install the piston assembly into the bore of the mas-
ter cylinder body enough so that the push rod (9) and
washer (10) can be installed.
9. Install the push rod and washer, and secure the with
snap ring (11) and boot (12).
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RAPH12FRK0635HA 1
1–Check Valve Seal 6–Spring Seat 11–Snap Ring

2–Check Valve Piston 7–Piston 12–Boot
3–Wave Spring 8–Seal 13–Master Cylinder Body
4–Check Valve Seat 9–Push Rod
5–Spring 10–Washer
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10. Install the lock nut and clevis to the push rod. Do not
tighten the lock nut on the push rod at this time.
11. Install the ball (14) in the master cylinder body.
12. Lubricate the flow valve seal (15) and the flow valve
(16) with clean hydraulic fluid. Install the flow valve
into the in the master cylinder body. The flow valve
must be centered in the bore of the master cylinder.
13. Install a new gasket (17) on the flow valve adapter
(18).
14. Carefully start the flow valve adapter into the bore in
the master cylinder by hand, If the flow valve adapter
cannot be turned into the master cylinder completely
by hand remove the flow valve adapter from the mas-
ter cylinder and make sure that the flow valve is in the
center of the bore in the master cylinder.
15. Repeat the previous step until the flow valve adapter
can be turned completely into the master cylinder by
hand.
16. Tighten the flow valve adapter to specifications.
Specification
Flow Valve Adapter Torque 41 - 47 N·m (30.2 - 34.7 lb ft)
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RAPH12FRK0635HA 2
13–Master Cylinder Body 15–Flow Valve Seal 17–Gasket

14–Ball 16–Flow Valve 18–Flow Valve Adapter
17. Install the master cylinder on the machine. See Brake

master cylinder - Install (33.202).
18. Adjust the push rod to piston clearance. See Free
travel adjustment.
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Brake master cylinder - Visual inspection

586H
588H
NOTE: Always replace gaskets and rubber seals if removed.

1. Inspect the bores in the master cylinder body (1) for
scoring, pitting, or other damage. If the bores in the
body are damaged, a new master cylinder must be
used.
2. Check the tab in the spring seat (2), and push the tab
down a small amount so it will engage the end of the
piston (3) to hold the check valve assembly in place. If
the tab is broken, replace with a new master cylinder.
3. Inspect the flow valve (4), ball (5), check valve piston,
piston (6), and push rod (7) for scoring, pitting, or other
damage. If any signs of wear or damage are apparent,
a new master cylinder must be used.
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RAPH12FRK0635HA 1
1–Master Cylinder Body 4–Flow Valve 7–Push Rod

2–Spring Seat 5–Ball
3–Check Valve Piston 6–Piston
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Index

Brake master cylinder - Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Brake master cylinder - Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Brake master cylinder - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Brake master cylinder - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Brake master cylinder - Visual inspection (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Brake pedals - Adjust Switch (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Brake pedals - Check (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Brake pedals - Height adjust (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Brake pedals - Overview (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Brake pedals - Service limits (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Brake pedals - Travel adjust (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Brakes - Bleed (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Hydraulic service brakes - Test (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
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PRINTED IN U.S.A.
47821916 28/04/2015
EN
SERVICE MANUAL
Hydraulic systems

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35
Contents
Hydraulic systems - 35
[35.000] Hydraulic systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.1
[35.102] Pump control valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.2
[35.104] Fixed displacement pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.3
[35.300] Reservoir, cooler, and filters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.4
[35.322] Regulated/Low pressure system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.5
[35.359] Main control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.6
[35.728] Telescopic arm control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.7
[35.740] Telescopic arm hydraulic system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.8
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Contents
TECHNICAL DATA
Hydraulic systems
Special tools (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
FUNCTIONAL DATA
Hydraulic systems
Overview GENERAL INFORMATION (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Overview TYPES OF CONTAMINATION (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Hydrostatic schema Hydraulic Schematic (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
SERVICE
Hydraulic systems
Cleaning (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Flush (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
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Hydraulic systems - Hydraulic systems
Hydraulic systems - Special tools

586H
588H
CAS101162A, Filter Unit (portable)
RAPH12FRK0955BA 1
CAS10192, Vacuum Pump
RAPH12FRK0957BA 2
CAS10508, Fitting Kit
RAPH12FRK0956BA 3
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Hydraulic systems - Overview GENERAL INFORMATION

586H
588H
Contamination in the hydraulic system is a major cause of the malfunction of hydraulic components. Contamination
is any foreign material in the hydraulic oil. Contamination can enter the hydraulic system in several ways.
1. When you drain the oil or disconnect any line.

2. When you disassemble a component.
3. From normal wear of the hydraulic components.
4. From damaged or worn seals.
5. From a damaged component in the hydraulic system.
All hydraulic systems operate with some contamination. The design of the components in this hydraulic system 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.
1. Cylinder rod seals leak.

2. Control valve spools do not return to neutral.
3. Movement of control valve spools is difficult.
4. Hydraulic oil becomes too hot.
5. Pump gears, housing, and other parts wear rapidly.
6. Relief valves or check valves held open by dirt.
7. Quick failure of components that have been repaired.
8. Cycle times are slow; machine does not have enough power.
If your machine has any of these problems, check the hydraulic oil for contamination. If you find contamination, use
the Portable Filter to clean the hydraulic system.
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Hydraulic systems - Overview TYPES OF CONTAMINATION

586H
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There are two types of contamination, microscopic and visible.
1. Microscopic contamination occurs when very fine particles of foreign material are in suspension in the hydraulic
oil.
2. 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 temperature.
3. 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 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.
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Hydraulic systems - Hydrostatic schema Hydraulic Schematic

586H
588H
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RAIL12FRK1173LA 1
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Hydraulic systems - Cleaning

586H
588H
1. Prepare the portable filter on page 3 by doing the fol-

lowing steps:
A) Remove all the hydraulic oil from the inlet and outlet hoses for the portable filter.
B) Remove the filter element from the portable filter.
C) Remove all hydraulic oil from the portable filter.
D) Clean the inside of the housing for the filter element.
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 hydraulic filter.
B) Do steps 6 through 35.
4. If the contamination is visible:
A) Do steps 5 through 35.

B) Change the hydraulic oil and hydraulic filter.
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, hydraulic reservoir, etc.
in the hydraulic system.
6. Remove the breather from the reservoir and connect

the vacuum pump to the opening. Start the vacuum
pump.
7. Loosen and remove the drain plug from the reservoir.
8. Using the fitting kit shown on page 3, install the valve
in the hole for the drain plug. Make sure that the valve
is closed.
9. Stop the vacuum pump.
10. Connect the inlet hose for the portable filter to the
valve that is installed in the hole for the drain plug.
11. Disconnect the vacuum pump from the hydraulic
reservoir air breather hose. Remove the filler cap.
12. Install the outlet hose for the portable filter in the hy-
draulic 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 to the ON posi-
tion. Start and run the engine at 1500 RPM.
15. Run the portable filter for 10 minutes.
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16. Continue to run the portable filter. Increase the engine

speed to full throttle. Heat the oil to operating temper-
ature by doing the following steps:
A) Hold the blade control lever in the TILT position for five seconds. Return the blade control lever in the NEUTRAL
position for five seconds.
B) Return the blade control lever in the NEUTRAL position for five seconds.
C) Repeat steps A and B 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.
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 for 10 minutes.
21. Stop the portable filter.
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 from
the valve. Remove the outlet hose from the reservoir
filler neck and replace filler cap.
26. Connect a vacuum pump to the breather hose of the
hydraulic reservoir.
27. Start the vacuum pump.
28. Remove the valve from the hole for the drain plug.
29. Install the drain plug.
30. Stop the vacuum pump. Disconnect the vacuum
pump 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 - Flush

586H
588H
1. Start and run the engine at 1500 RPM.

2. Completely retract the cylinders of all attachments on
the machine. Angle the blade to the right, the right
cylinder will be fully retracted and the left will be fully
extended. Stop the engine.
ATTENTION: WARNING: If retracting the cylinder rods causes the attachments to be raised, block the attachments
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.
See capacity specifications.

Have available acceptable equipment to drain the hydraulic oil.
Remove the drain plug from the bottom of the reservoir.
6. Remove the hydraulic filter elements from the machine.

8. Install the drain plug in the bottom of the reservoir.
9. Fill the hydraulic reservoir with hydraulic fluid.
10. Disconnect the line from the OPEN end and CLOSED
end of each cylinder.
11. Be sure all control levers are in the NEUTRAL posi-
tion.
ATTENTION: IMPORTANT: Check the oil level in the hydraulic reservoir frequently while doing step 13. Have another
person hold a container under the hydraulic lines while you do step 13.
13. 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.
15. Connect the system line to the CLOSED end of each
cylinder.
16. 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.
17. Start the engine and run the engine at low idle.
18. Slowly and completely extend all cylinders. As the pis-
ton rod comes in/out of the cylinder, oil will be pushed
out of the 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.
19. Support any attachments that will be in the RAISED
position.
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21. Disconnect the drain lines and connect the system
lines to the cylinders.
22. Check the oil level in the hydraulic reservoir. Add oil
as required.
23. Install the filler cap on the reservoir.
24. Remove the hydraulic filter elements from the ma-
chine.
26. Start and run the engine at 1500 RPM, operate each
hydraulic circuit to completely extend and retract the
cylinders.
27. Stop the engine and check for leaks. Check the oil
level in the hydraulic reservoir. Add oil as required.
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Index

Hydraulic systems - Cleaning (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Hydraulic systems - Flush (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Hydraulic systems - Hydrostatic schema Hydraulic Schematic (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Hydraulic systems - Overview GENERAL INFORMATION (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Hydraulic systems - Overview TYPES OF CONTAMINATION (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Hydraulic systems - Special tools (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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Pump control valves - 102

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Contents
TECHNICAL DATA
Pump control valve

Priority/Regulator valve - Service limits (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Priority/Regulator valve - Special tools (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
FUNCTIONAL DATA
Pump control valve

Priority/Regulator valve - Overview (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
SERVICE
Pump control valve

Priority/Regulator valve - Pressure test (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Priority/Regulator valve - Pressure setting (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Priority/Regulator valve - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Priority/Regulator valve - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
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Hydraulic systems - Pump control valves
Pump control valve Priority/Regulator valve - Service limits

586H
588H
Specifications
Location of Steering Relief Valve In priority valve
Pressure Setting 141 - 148 bar (2045 - 2146 psi)
Flow required; at 900 r/min flow is 14.4 L/min (3.8 gal/min)
Capacity at 2200 r/min
586 68 L/min at 207 bar (18 gal/min at 3000 psi)
588 91 L/min at 207 bar (24 gal/min at 3000 psi)
Pump control valve Priority/Regulator valve - Special tools

586H
588H
CAS-1804 PRESSURE FITTING KIT
RAPH12FRK0987BA 1
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Pump control valve Priority/Regulator valve - Overview

586H
588H
RAPH12FRK1053BA 1
1–Inlet 5–To Steering Control Valve

2–To Filter 6–To Forklift Control Valve
3–Steering Relief Valve 7–Spool
4–Pilot Pressure
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RAPH12FRK1051BA 2
1–Inlet 5–To Steering Control Valve

2–To Filter 6–To Forklift Control Valve
3–Steering Relief Valve 7–Spool
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Pump control valve Priority/Regulator valve - Pressure test

586H
588H
Prepare the machine for service.

1. Clean the flow control priority valve and all the connec-
tions.
2. Disconnect the tube from the fitting (3) in the flow con-
trol priority valve.
RAPH12FRK1051BA 1
3. Install a plug in the tube.
4. Loosen and remove the fitting from the port (1) in the
flow control priority valve.
5. The relief valve is inside the port in the flow control pri-
ority valve. Use an allen wrench to turn the adjusting
screw (2) for the relief valve. Turn the adjusting screw
clockwise to increase the pressure setting. Turn the
adjusting screw counterclockwise to decrease the pres-
sure setting.
6. A 1/8 turn on the adjusting screw changes the pressure
setting approximately 13.8 bar (200 psi).
7. Install the fitting in the port and tighten the fitting.
8. Connect the tube to the fitting.
9. Check the pressure again.
10. Repeat steps 2 through 8 until the pressure is within
specification. See Specifications page.
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Pump control valve Priority/Regulator valve - Pressure setting

586H
588H
NOTE: The pressure relief valve for the steering system is located in the flow control priority valve.
2. The oil must be at operating temperature. To heat the
oil, do the following steps:
A. With the engine running at full throttle, hold the tilt
control lever in the BACK position for 15 seconds.
B. Put the tilt control lever in the NEUTRAL position
for 15 seconds.
C. Repeat steps A and B until the temperature of the
oil is 51 °C (125 °F) or the side of the reservoir is
very warm.
3. Stop the engine and apply the parking brake.
4. See illustration. Use a pressure gauge with a capacity
of at least 207 bar (3000 psi). Connect the pressure
gauge to the quick disconnect fitting at the test port (3).
5. Start and run the engine at full throttle. Turn and hold
the steering wheel all the way to the right or to the left
and read the gauge. Make a record of the reading.
6. Decrease the engine speed to low idle for two minutes
and stop the engine.
7. Compare the reading with the specification. If the read-
ing is not correct, adjust the pressure setting of the
steering pressure relief valve.
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RAPH12FRK0104BA 1
1–From Reservoir 3–Test Port

2–Hydraulic Pump 4–Priority Valve
NOTE: Pump is mounted on the transmission.
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Pump control valve Priority/Regulator valve - Remove

586H
588H
WARNING
Pressurized system!
Never disconnect or tighten a hose or tube that
is under pressure. If in doubt, engage the con-
trols several times with the engine switched off
prior to disconnecting or tightening the hose or
tube.
ous injury.
W0998A
2. Operate the control levers in all directions to relieve the

pressure from the hydraulic circuit.
3. Drain the hydraulic system.
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ATTENTION: For assembly purposes, identify and label all lines prior to removing.
Avoid contamination; cap and plug all lines and ports when removing lines.
4. Identify hoses with tags, and disconnect each hose (2)
from the priority valve (3).
RAPH12FRK0056AA 1
RAPH12FRK1056BA 2
NOTE: The horn (5) is fastened in place with one of the valve mounting cap screws. Make a note of the position of
the horn for use during installation.
5. Support the priority valve, and remove the lock nuts,
washers, and bolts (4) that fasten the valve to the chas-
sis. Remove the priority valve from the machine.
RAPH12FRK0981BA 3
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Pump control valve Priority/Regulator valve - Install

586H
588H
1. Position the priority valve (1) onto the machine.

NOTE: Ensure that the horn (2) is properly positioned for
installation.
2. Install the bolts, lock nuts, and washers (3) securing the
priority valve to the chassis.
RAPH12FRK0981BA 1
3. Remove caps and plugs from hoses and ports. Con-

nect the hydraulic hoses (4) to the priority valve accord-
ing to the identification tags installed during the removal
procedure.
RAPH12FRK0056AA 2
RAPH12FRK1056BA 3
4. Fill the hydraulic reservoir.

5. Start the engine and run at low idle. Activate the con-
trol lever for the forks, side shift, and tilt for 15 to 20
seconds.
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CAUTION
Escaping fluid!
for this purpose. If injured by leaking fluid, see
your doctor immediately.
erate injury.
C0104A
6. Stop the engine and check for leaks. Check the hy-
draulic reservoir level and fill as required.
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Index

Pump control valve Priority/Regulator valve - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Pump control valve Priority/Regulator valve - Overview (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Pump control valve Priority/Regulator valve - Pressure setting (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Pump control valve Priority/Regulator valve - Pressure test (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Pump control valve Priority/Regulator valve - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Pump control valve Priority/Regulator valve - Service limits (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Pump control valve Priority/Regulator valve - Special tools (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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Fixed displacement pump - 104

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Contents
FUNCTIONAL DATA
Fixed displacement pump

Overview (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SERVICE
Fixed displacement pump

Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Inspect (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
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Hydraulic systems - Fixed displacement pump
Fixed displacement pump - Overview

586H
588H
RAPH12FRK1052BA 1
Hydraulic Pump: Generates oil flow for the complete hydraulic system.
1–Outlet 2–Inlet 3–Drive Shaft
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Fixed displacement pump - Remove

586H
588H

2. Loosen and remove the bolts (1) and retainers (2) that
fasten the front drive shaft (3) to the transmission output
shaft (4).
3. Remove the front drive shaft by sliding it off the axle
pinion splines.
RAPH12FRK0106BA 1
WARNING
Escaping fluid!
Do not connect or disconnect hydraulic quick
coupler under pressurized conditions. Make
sure all hydraulic pressure is removed from the
system before connecting or disconnecting hy-
draulic quick coupler.
ous injury.
W0095B
5. Remove the three allen head screws (5), and loosen

the hose clamp (6) on the inlet hose to the pump. Close
all openings.
RAPH12FRK0397AA 2
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6. Disconnect the hoses (7) from the fitting on the outlet

of the pump. Close all openings.
RAPH12FRK0398AA 3
DANGER
Heavy objects!
bystanders.
injury.
D0076A
7. Support the hydraulic pump with an appropriate lifting

device.
8. Remove the four bolts (8) that secure the hydraulic
pump to the coupling assembly.
9. Slide the pump toward the front of the machine until the
pump shaft is clear of the coupling assembly. Lower the
pump and remove it from the machine.
10. Remove and discard the O-rings from the pump
mounting flange and the inlet pipe flange.
RAPH12FRK0399AA 4
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Fixed displacement pump - Install

586H
588H
NOTE: Clean and lubricate the pump splines with MOLYKOTE ® G4700 Extreme Pressure Synthetic grease 331–240.
DO NOT SUBSTITUTE.
NOTE: Prevent possible leaks; never re-use O-rings. Always replace with new.
1. Clean and lubricate the pump splines. Install a new
O-ring on the pump mounting flange.
DANGER
Heavy objects!
bystanders.
injury.
D0076A
2. Attach an appropriate lifting device to the hydraulic

pump. Raise the pump into position. Slide the pump
shaft into the coupler, and align the bolt holes with
those in the coupling assembly.
3. Install the four mounting bolts (1), and tighten the bolts
in a split-cross pattern.
RAPH12FRK0399AA 1
4. Remove the lifting device from the pump.

5. Connect the hydraulic hoses (2) to the fittings on the
pump outlet.
RAPH12FRK0398AA 2
NOTE: Prevent possible leaks; never re-use O-rings. Always replace with new.
6. Replace the O-ring on the inlet pipe flange.
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7. Install and securely tighten the three allen head (3)

bolts for the inlet pipe flange.
8. Tighten the inlet flange hose clamp (4) securely.
RAPH12FRK0397AA 3
9. Connect the front drive shaft to the front axle by sliding

it onto the axle pinion shaft splines.
RAPH12FRK0106BA 4
NOTE: Apply LOCTITE® 243™ to the threads of bolts (6).

10. Install retainers (5) and bolts (6) to secure the front
drive shaft (7) to the transmission output yoke (8).
Tighten bolts to specification.
Specification
Drive Shaft Retainer Bolt Torque 33 - 39 N·m (24.3 - 28.8 lb ft)
ATTENTION: The hydraulic pump MUST be filled with oil before starting the machine. Complete the following proce-
dure to fill the hydraulic pump with oil.
ATTENTION: AVOID MACHINE DAMAGE. DO NOT EXCEED 69.0 kPa (10 psi) when pressurizing the hydraulic oil
reservoir. Damage to the reservoir may occur.
11. Pre-Start Pump Bleed Procedure
1. Make sure the oil level in the hydraulic reservoir
is correct.
2. Remove the cap from the hydraulic reservoir.
3. Using a regulated air supply, pressurize the hy-
draulic reservoir to specification.
4. Have an assistant start the machine and run the
engine at low idle while air pressure is being ap-
plied to the hydraulic reservoir.
5. Operate all hydraulic functions.
Specification
Regulated Air Supply for Pump Bleed Procedure 34.5 - 69.0 kPa (5.0 - 10.0 psi) Maximum
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WARNING
Pressurized fluid can penetrate the skin and
cause severe injuries.
Keep hands and body away from any pressur-
ized leak. DO NOT use your hand to check for
leaks. Use a piece of cardboard or paper. If
fluid penetrates the skin, seek medical atten-
tion immediately.
ous injury.
W0158A
12. Stop the engine and inspect for leaks. Fill the hy-
draulic oil reservoir as required.
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Fixed displacement pump - Assemble

586H
588H
1. Install new quad rings in the grooves in the gear hous-

ing. Use petroleum jelly to hold the quad rings in posi-
tion.
RAPH12FRK0122BA 1
2. Apply Loctite Form-A-Gasket #3 sealant to the outer

edge of a new seal and to the seal recess in the shaft
end cover. Press the seal, with the metal side up, into
the shaft end cover until the seal is even with the top of
the seal recess. Wipe off any extra sealant.
RAPH12FRK0121BA 2
RAPH12FRK0120BA 3
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3. Press the bearing into the shaft end cover until the snap
ring can be installed in the groove.
RAPH12FRK0119BA 4
4. Install the snap ring.
RAPH12FRK0124BA 5
5. Install new seals in the thrust plates.
RAPH12FRK0123BA 6
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6. Fasten the shaft end cover in the vise with soft jaws.
RAPH12FRK0433AA 7
7. Install the gear housing.
RAPH12FRK0451BA 8
8. Install the thrust plate so that the seal is down and the
open ends of the rectangular relief groove on the face
of the thrust plate are toward the outlet side of the hy-
draulic pump.
RAPH12FRK0452BA 9
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9. Install the drive gear.
RAPH12FRK0453BA 10
10. Install the driven gear.
RAPH12FRK0454BA 11
11. Install the thrust plate so that the seal is up. The seal
must be toward the outlet side of the hydraulic pump.
RAPH12FRK0111BA 12
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12. Install the port end cover.
RAPH12FRK0456BA 13
13. Install the cap screws and flat washers. Tighten the
cap screws evenly to a torque of 339 N·m (250.0 lb
ft).
RAPH12FRK0457BA 14
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RAPH12FRK1127HA 15
HYDRAULIC PUMP CROSS SECTIONAL VIEW
1–Cap Screw 8–Dowel Pin (not shown)
2– Flat Washer 9–Drive Gear
3–Port End Cover 10– Drive Gear (not shown)
4–Seal 11–Seal
5–Quad Ring 12– Shaft End Cover
6–Thrust Plate 13–Snap Ring
7–Gear Housing 14–Bearing
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Fixed displacement pump - Disassemble

586H
588H
1. Clean the outside of the hydraulic pump. Fasten the

hydraulic pump in a vise with soft jaws. Make alignment
marks on each section of the hydraulic pump.
RAPH12FRK0458BA 1
2. Loosen and remove the cap screws and the flat wash-
ers.
RAPH12FRK0457BA 2
3. Remove the port end cover.
RAPH12FRK0109BA 3
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4. Remove the quad ring.
RAPH12FRK0110BA 4
5. Remove the thrust plate.
RAPH12FRK0111BA 5
6. Remove the driven gear.
RAPH12FRK0112BA 6
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7. Remove the drive gear.
RAPH12FRK0113BA 7
8. Remove the gear housing.
RAPH12FRK0114BA 8
9. If the thrust plate stayed with the shaft end cover, re-
move the thrust plate.
RAPH12FRK0115BA 9
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10. Remove the quad ring from the bottom of the gear
housing.
RAPH12FRK0122BA 10
11. Remove the snap ring from the shaft end cover.
RAPH12FRK0116BA 11
12. Remove the bearing from the shaft end cover.
RAPH12FRK0117BA 12
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13. Remove the seal from the shaft end cover.
RAPH12FRK0118BA 13
14. Remove the seals from the thrust plates.
RAPH12FRK0123BA 14
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Fixed displacement pump - Inspect

586H
588H
NOTICE: Discard all seals and quad rings. Clean all parts in cleaning solvent. Check all machined surfaces for
damage or wear.
1. Hold a straightedge across each gear housing and use
a feeler gauge to measure the amount of wear caused
by the gear teeth in the gear pocket. If the wear in any
gear pocket is more than 0.18 mm (0.007 in), use a
new gear housing.
RAPH12FRK0459BA 1
2. Inspect the gears for wear and damage. There must be

no scoring on the gear hubs or on the outside edges of
the gear teeth. There must be no more than 0.05 mm
(0.002 in) wear in the seal area of the drive shaft. There
must be no damage to the splines of the drive shaft.
If any gear must be discarded, you must use a new
hydraulic pump.
RCPH10TLB449ABL 2
3. Inspect the thrust plates for scoring, pitting, or other

damage. Use a micrometer to measure the thickness
of the thrust plates. If the thickness of a thrust plate is
less than 6.27 mm (0.2 in) use a new thrust plate.
RCPH10TLB450ABL 3
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4. Inspect the bushings in the shaft end cover and the

closed end cover. If the bushings are worn or damaged,
use a new hydraulic pump.
RAPH12FRK0433AA 4
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RAPH12FRK0644HA 5
HYDRAULIC PUMP EXPLODED VIEW
1. Cap Screw 8. Dowel Pin
2. Flat Washer 9. Drive Gear
3. Port End Cover 10. Driven Gear
4. Quad Ring 11. Shaft End Cover
5. Seal 12. Seal
6. Thrust Plate 13. Bearing
7. Gear Housing 14. Snap Ring
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Index

Fixed displacement pump - Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Fixed displacement pump - Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Fixed displacement pump - Inspect (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Fixed displacement pump - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Fixed displacement pump - Overview (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Fixed displacement pump - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
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Reservoir, cooler, and filters - 300

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Contents
SERVICE
Reservoir, cooler, and filters

Replace (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Oil reservoir
Drain fluid (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Filling (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Oil cooler/Heat exchanger
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
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Hydraulic systems - Reservoir, cooler, and filters
Reservoir, cooler, and filters - Replace

586H
588H
WARNING
Personal Protective Equipment (PPE) required.
When assembling, operating, or servicing the machine, wear protective clothing and PPE necessary
for the particular procedure. Some PPE that may be necessary includes protective shoes, eye and/or
face protection, hard hat, heavy gloves, filter mask, and hearing protection.
W0353A
WARNING
Burn hazard!
Before performing any service on the hydraulic system, you must allow it to cool. Hydraulic fluid
temperature should not exceed 40 °C (104 °F).
W0241A
Replace the hydraulic fluid and oil filter every 1000 h of operation.
Hydraulic oil specification – 54.5 L (57.6 US qt) of CASE AKCELA HY-TRAN® ULTRACTION.
1. Warm up the hydraulic fluid by operating the forklift con-

trols.
2. Park the machine on level ground.
3. Lower the carriage to the ground and turn off the en-
gine.
4. Place a suitable container underneath the hydraulic
reservoir drain plug.
5. Remove the hydraulic fill cap.
6. Remove the drain plug.
RAPH12FRK0219AA 1
7. Remove the hydraulic filter:

A. Locate the hydraulic filter under the right front por-
tion of the machine just behind the front drive axle.
B. Clean the area around the filter head area before
removing the old filter.
C. Use a filter wrench and remove the old filter. Have
a suitable container ready to capture any fluid that
might leak or spill.
D. Dispose of the filter in accordance with local, re-
gional, and federal regulations.
RCPH10TLB045AAF 2
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NOTICE: Do not use a filter wrench to install the new filter.

8. Install a new hydraulic filter:
A. Lubricate the gasket of the new filter with clean oil.
B. Install the new filter and turn it clockwise until the
gasket contacts the head of the filter assembly.
C. Continue to tighten the filter 1/3 turn.
9. Install the drain plug.
NOTICE: The hydraulic pump must be filled with oil before
operating the machine. Contact your dealer for assistance.
11. Charge the hydraulic pump:
A. Attach a regulated air supply to pressurize the
hydraulic reservoir. A pressure of 34.5 - 69.0 kPa
(5.0 - 10.0 psi) is all that is required to move the
oil.
NOTICE: Pressure above 69.0 kPa (10.0 psi) can damage
the hydraulic reservoir.
B. Have another person start and run the engine at
low idle while the air pressure is being applied to
the hydraulic reservoir.
C. After three to four minutes turn off the engine.
D. Disconnect the regulated air supply.
12. Tighten the hydraulic reservoir cap.
14. Operate the forklift controls for three to four minutes
15. Inspect for leaks.
16. Confirm that the hydraulic fluid level is at the full mark
on the gauge.
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Oil reservoir - Drain fluid

586H
588H
WARNING
Escaping fluid!
Relieve all pressure before disconnecting fluid lines or performing work on the hydraulic system.
Make sure all components are in good condition and tighten all connections before pressurizing the
system. DO NOT use your hand to check for leaks. Use a piece of cardboard or paper.
W1140A
NOTICE: Avoid machine damage! Do not run machine without the proper amount and type of hydraulic fluid.
1. Prepare machine for service.

2. When all hydraulic pressure has been released slowly
remove the hydraulic reservoir cap (1).
RAPH12FRK0037BA 1
3. Remove the hydraulic oil reservoir drain plug (2) and

drain oil into clean, appropriate size containers for stor-
age or disposal.
Capacity
Hydraulic System If Replacing Filter (approximate) 54.9 l( 58 US qt)
Hydraulic System No Filter Replacement (approximate) 53 l( 56 US qt)
NOTICE: Avoid hydraulic oil leaks; never re-use O-rings. Always replace with new.
4. Inspect the drain plug for damage. Replace as neces-
sary. Install new O-ring to drain plug before installing.
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Oil reservoir - Filling

586H
588H
NOTICE: Make sure the O-ring is installed on the hydraulic oil reservoir drain plug before installing.
1. Install the drain plug (1) with a new O-ring (2) to the
hydraulic oil reservoir and tighten securely.
RAPH12FRK0037BA 1
2. Fill the hydraulic oil reservoir with approved oil to the

correct level. Install the hydraulic oil reservoir cap and
make sure it is closed securely.
Capacity
Hydraulic Oil Reservoir With Filter Replacement 54.9 l( 58 US qt)
(approximate)
Hydraulic Oil Reservoir Without Filter Replacement 53 l( 56 US qt)
(approximate)
NOTICE: If the hydraulic system contains trapped air or if the oil is not to operating temperature, hydraulic functions
may operate slowly. DO NOT attempt normal machine operation until the hydraulic functions operate at close-to-
normal cycle times.
4. Run the machine at low idle for 3 - 4 min.
5. Increase engine speed to high idle for 1 min.
6. Operate the loader controls for 2 - 3 min.
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7. Stop the engine and allow the system to cool. Check

the hydraulic oil reservoir sight glass (3), if necessary
add more hydraulic fluid.
RAPH12FRK0037BA 2
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Oil cooler/Heat exchanger - Remove

chine to use ().
2. Remove the engine side panels. See Side panels -
Remove (90.100).
4. Remove the counterweight. See Counterweight - Re-
move (39.140).
you disconnect the upper and lower oil cooler tubes (1).
6. Remove the bolts (2) and washers securing the trans-
mission/hydraulic oil cooler to the radiator.
RAIL14FRK0142BA 1
8. Carefully remove the transmission/hydraulic oil cooler

from the radiator.
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Oil cooler/Heat exchanger - Install

1. Carefully position the the transmission/hydraulic oil
cooler to the radiator.
2. Install bolts and washers (1) that secure the transmis-
sion/hydraulic oil cooler to the radiator.
RAPH12FRK0939BA 1

you connect the upper and lower oil cooler tubes (1).
Torque tube-to-fitting to 77 - 85 N·m (57 - 63 lb ft).
RAIL14FRK0142BA 2

5. Install the counterweight. See Counterweight - Install
(39.140).
6. Install the hood. See Hood - Install (90.100)
7. Install the engine side panels. See Side panels - In-
stall (90.100).
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8. Return the machine to use. See Basic instructions

use ().
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Index

Oil cooler/Heat exchanger - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Oil cooler/Heat exchanger - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Oil reservoir - Drain fluid (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Oil reservoir - Filling (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Reservoir, cooler, and filters - Replace (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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Regulated/Low pressure system - 322

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Contents
SERVICE
Manifold block
Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
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Hydraulic systems - Regulated/Low pressure system
Manifold block - Remove

586H
588H
WARNING
Pressurized system!
tube.
ous injury.
W0998A
3. Identify hydraulic hoses with tags and disconnect each
hose (1) from the manifold block (2).
RAPH12FRK0406AA 1
4. Support the manifold block with a suitable lifting device.

5. Remove two bolts (3) from the manifold block.
6. Remove the manifold block from machine.
RAPH12FRK0407AA 2
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Manifold block - Install

586H
588H
1. Install the manifold block (1) onto the machine and se-
cure with two bolts (2).
RAPH12FRK0407AA 1

nect the hydraulic hoses (3) to the manifold block ac-
cording to the identification tags installed during the re-
moval procedure.
RAPH12FRK0406AA 2

4. Bleed the air from the lift cylinders using the top bleed
port (4).
A. Start the engine and let it run at low idle.
B. Activate the control lever for the forks, side shift,
and tilt for 15 to 20 seconds.
C. Lower the forks to the ground.
D. Remove the bleeder plug and connect an elbow
fitting to the port on the lift cylinder.
E. Connect a hose to the elbow fitting and place the
other end of the hose into a suitable container with
enough hydraulic oil to cover the end of the hose. RAPH12FRK0421AA 3
F. With the help of an assistant, slowly raise the forks

until all air has escaped from the lift cylinder.
G. Lower the forks to the ground.
H. Remove the fitting and hose, and Install the
bleeder plug.
I. Repeat this procedure for the other lift cylinder.
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CAUTION
Escaping fluid!
erate injury.
C0104A
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Index

Manifold block - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Manifold block - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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Main control valve - 359

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Contents
SERVICE
Stacked control valves

Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
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Hydraulic systems - Main control valve
Stacked control valves - Remove

586H
588H

CAUTION
Escaping fluid!
erate injury.
C0104A
3. Remove two bolts and washers, and remove the control

valve cover (2).
4. Remove the four bolts and washers, and remove the
front access dash panel (3).
RAPH12FRK0041BA 1
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5. Disconnect the control lever linkage (4) from the control
valve (5).
DANGER
Pressurized system!
Always remove all pressure before working
on the hydraulic system. Follow the pressure
BLEED program in the Configuration Mode to
remove the pressure in the entire hydraulic
system.
injury.
D0035A
6. Disconnect the hydraulic lines (6) from the control

valve.
RAPH12FRK0042BA 2
DANGER
Heavy parts!
injury.
D0018A
7. Remove three mounting nuts, and lock washers (7),

and remove control valve.
RAPH12FRK0043BA 3
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Stacked control valves - Install

586H
588H
DANGER
Heavy parts!
injury.
D0018A
1. Install the control valve (1) using three lock washers

and nuts (2).
RAPH12FRK0043BA 1
2. Remove caps and plugs and Install the hydraulic lines

(3) to the control valve.
3. Connect the control lever linkage (4) to the control
valve.
4. Adjust control lever linkage as needed.
RAPH12FRK0042BA 2
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5. To adjust, disconnect the ball joint (6) from the lever,

loosen the jam nut (5), and turn the ball joint and adjust
control lever linkage to the desired length.
6. Reconnect the ball joint to the lever.
RAPH12FRK0020BA 3
7. Install front access panel (7) and secure with four wash-
ers and bolts (8).
8. Install control valve cover (9) and secure with two
washer and bolts (10).
RAPH12FRK0041BA 4
9. Fill the hydraulic system.

trol levers for 15 to 20 seconds.
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CAUTION
Escaping fluid!
erate injury.
C0104A
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Index

Stacked control valves - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Stacked control valves - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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Telescopic arm control - 728

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Contents
FUNCTIONAL DATA
Telescopic arm control

Overview (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SERVICE
Telescopic arm control

Remove Load Control accumulator (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Install Load Control accumulator (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
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Hydraulic systems - Telescopic arm control
Telescopic arm control - Overview

586H
588H
3 SPOOL CONTROL VALVE
RAPH12FRK0959BA 1
1–Lift Control Lever

2–Tilt Control Lever
3–Side Shift Control Lever
No adjustment is required for the three spool forklift control levers.
4 SPOOL CONTROL VALVE
RAPH12FRK0065AA 2
1–Lift Control Lever

2–Tilt Control Lever
3–Side Shift Control Lever
4–Auxiliary Control Lever
No adjustment is required for the four spool forklift control levers.
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RAPH12FRK0640HA 3
Illustration of Forklift Control Levers
1–LIFT CONTROL LEVER 7–SHIM WASHER 13–CLEVIS PIN
2–TILT CONTROL LEVER 8–PIVOT PIN 14–BALL JOINT
3–SIDE SHIFT CONTROL LEVER 9– BOLT 15– LIFT CONTROL ROD
4–AUXILIARY CONTROL LEVER 10–COTTER PIN 16–TILT CONTROL ROD
5– KNOB 11–BELL CRANK 17–SIDE SHIFT CONTROL ROD
6– NUT 12–SPACER 18–AUXILIARY CONTROL ROD
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Telescopic arm control - Remove Load Control accumulator

586H
588H
WARNING
Pressurized system!
Hydraulic accumulator contains gas and oil
pressure under pressure. Service or repair
must be performed only by trained service
technician.
ous injury.
W1176A

pressure from the hydraulic circuits.
NOTE: Accumulator may have some residual pressure. Loosen lines slowly.
ATTENTION: For assembly purposes, identify and label all lines prior to removing. Avoid contamination; cap and
plug all lines and ports when removing lines.
4. Slowly disconnect the hose (1) from the accumulator
(2).
5. Loosen the four nuts (3) on the clamps (4) that fasten
the accumulator to the mounting bracket (5). Slide the
accumulator out of the clamps and remove from the
machine.
RAPH12FRK0946BA 1
WARNING
Pressurized system!
The accumulator contains highly pressurized
nitrogen gas. If the accumulator system does
not function correctly, replace the accumulator.
DO NOT attempt to repair the accumulator.
ous injury.
W0290A
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Telescopic arm control - Install Load Control accumulator

586H
588H
1. Install the accumulator (1) through the clamps (2) on

the mounting bracket (3). Install the four nuts (4) to
secure the accumulator.
RAPH12FRK0946BA 1
2. Remove all caps and plugs from the hose and port.
Connect the hose (5) to the accumulator.
RAPH12FRK0946BA 2
WARNING
Explosion hazard!
Use only nitrogen when charging the accumu-
lator. Do not use air or oxygen that will cause
an explosion.
ous injury.
W0975A
4. Charge the accumulator. For the proper charging of

the accumulator and to check for leaks, see Testing the
Load Control section.
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Index

Telescopic arm control - Install Load Control accumulator (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Telescopic arm control - Overview (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Telescopic arm control - Remove Load Control accumulator (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
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Telescopic arm hydraulic system - 740

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Contents
TECHNICAL DATA
Telescopic arm cylinder

SERVICE
Telescopic arm cylinder

Disassemble Standard Cylinder (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Inspect Standard Cylinder (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Assemble Standard Cylinder (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Disassemble Freelift Cylinder (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Inspect Freelift Cylinder (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Assemble Freelift Cylinder (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Tilt cylinder
Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Inspect (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Compensating cylinder
Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Inspect (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
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Hydraulic systems - Telescopic arm hydraulic system
Telescopic arm cylinder - General specification

586H
588H
Tilt cylinder specifications

Sems/A bolt 340 - 380 Nm (251 - 280 lb ft)
Gland 135 - 542 Nm (100 - 400 lb ft)
Shift cylinder specifications

Jam nut (lubricated) 58 - 63 Nm (43 - 47 lb ft)
Piston retaining nut (lubricated) 474 - 501 Nm (350 - 370 lb ft)
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Telescopic arm cylinder - Disassemble Standard Cylinder

586H
588H
1. Remove the Standard Cylinder.
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.
ous injury.
W0180A
2. To avoid any contamination from entering the cylinder

cavity, clean the outside of the cylinder. If the hoses
were removed with the cylinder, remove the hoses from
the cylinder.
3. Fasten the tube (1) in a soft-jawed vise or other holding
equipment. Be careful to prevent damage to the tube.
4. Use the spanner wrench to turn the gland (2) out of the
tube.
5. Pull the piston rod (5) straight out of the tube to prevent
damage to the tube.
6. Remove the gland from the piston rod.
7. Remove the wear ring (4) from the piston (3).
8. Remove the O-ring (6), backup ring (7), wiper (8),
U-cup (10), and the buffer seal (9) from the gland.
9. Replace parts as necessary.
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RAPH12FRK0641HA 1
1–Tube 5–Piston Rod 9–Buffer Seal

2–Gland 6–O-Ring 10–U-Cup
3–Piston 7–Backup Ring
4–Wear Ring 8–Wiper
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Telescopic arm cylinder - Inspect Standard Cylinder

586H
588H
1. Remove the standard cylinder.

2. Disassemble the standard cylinder.
WARNING
Chemical hazard!
ous injury.
W0180A
3. Clean the piston (3), gland (2), piston rod (5), and tube
(1) in cleaning solvent.
4. Discard the parts that were removed from the piston
and the gland.
5. Illuminate the inside of the tube. Inspect the inside of
the tube for deep grooves and other damage. If there
is damage to the tube, a new tube must be used.
6. Check to be sure that the piston rod is straight. If the
piston rod is not straight, install a new piston rod.
7. Remove small scratches on the inside of the tube with
emery cloth of medium grit. Use the emery cloth with a
rotary motion.
8. Inspect the gland for rust. Clean and remove rust as
required.
9. Inspect the gland end of the tube for sharp edges that
will cut the gland O-ring (6). Replace as required.
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RAPH12FRK0641HA 1

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Telescopic arm cylinder - Assemble Standard Cylinder

586H
588H
NOTE: If a new gland is being installed, record the new part number of the cylinder on the new gland.
WARNING
Chemical hazard!
ous injury.
W0180A
1. Install the buffer seal (9) in the gland (2). The side of
the buffer seal with the lip must be toward the small end
of the gland.
2. Install a new U-cup (10) in the gland. The lips of the
U-cup must be toward the small end of the gland.
3. Install a new wiper (8) in the gland. The lips of the wiper
must be toward the large end of the gland.
4. Install a new backup ring (7) in the groove on the out-
side of the gland. If both sides of the backup ring (7)
are not flat, the side that is not flat must be toward the
small end of the gland.
5. Install the O-ring (6) next to the backup ring in the
groove on the outside of the gland. The O-ring must
be toward the small end of the gland.
6. Remove any marks and sharp edges on the chamfer at
the end of the piston rod (5).
7. Lubricate the bore of the gland with clean oil.
8. Push the gland onto the piston rod. Be careful not to
damage the seals.
9. Fasten the piston rod in a soft-jawed vise. Be careful
to prevent damage to the piston rod.
10. Install a new wear ring (4) in the end groove on the
outside of the piston (3).
11. Lubricate the inside of the tube (1) and the piston with
clean oil.
12. Push the tube straight onto the piston.
13. Start the tube onto the piston rod assembly. Be careful
not to damage the wear ring and seal.
14. Lubricate the O-ring on the gland with clean oil.
15. When the piston is in the smooth part of the tube, start
the gland into the tube.
16. Use a spanner wrench to turn the gland into the tube.
Tighten the gland.
17. 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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RAPH12FRK0641HA 1

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Telescopic arm cylinder - Disassemble Freelift Cylinder

586H
588H
1. Remove the freelift cylinder.
WARNING
Chemical hazard!
ous injury.
W0180A
2. To avoid any contamination from entering the cylinder

the cylinder.
3. Position the hydraulic cylinder on a table with a vise.
Make sure the vise has brass covers for the jaws before
you tighten the cylinder tube in the vise. Tighten the
vise enough to keep the cylinder from turning. Loosen
the gland assembly with a spanner wrench and remove
gland (3).
4. Pull the piston rod (2) from the cylinder tube (1). Be
careful not to nick or scratch the chrome surface. In-
spect the cylinder tube for scratches or nicks inside the
tube.
5. Remove the wiper (4), seal (5), O-ring (6), and backup
ring (7) from gland and replace with new items.
6. Remove the wear ring (8) from the piston from the rod
assembly and replace with new part.
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RAPH12FRK0627HA 1
1–Cylinder Tube 4–Wiper 7–Backup Ring

2–Piston Rod 5–Seal 8–Wear Ring
3–Gland 6–O-Ring
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Telescopic arm cylinder - Inspect Freelift Cylinder

586H
588H
1. Remove the freelift cylinder.

2. Disassemble the freelift cylinder.
WARNING
Chemical hazard!
ous injury.
W0180A
3. Clean the piston (3), gland (3), piston rod (2), and cylin-
der tube (1) in cleaning solvent.
and the gland.
6. Check to be sure that the piston rod is straight. If the
rotary motion.
8. Inspect the gland for rust and clean and remove rust as
required.
will cut the gland O-ring (6), replace as required.
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RAPH12FRK0627HA 1

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Telescopic arm cylinder - Assemble Freelift Cylinder

586H
588H
NOTE: If a new gland is being installed, record the new part number of the cylinder on the new gland.
WARNING
Chemical hazard!
ous injury.
W0180A

2. Remove the wear ring (8) from the piston from the rod
assembly and replace with a new part. Smear oil on
the wear ring and reinsert in the cylinder tube (1).
3. Remove the wiper (4), seal (5), O-ring (6) and the
backup ring (7) from the gland (3) and replace with new
items.
4. Lubricate the bore of the gland (3) with clean oil.
damage the seals.
6. Fasten the piston rod in a soft-jawed vise. Be careful
to prevent damage to the piston rod.
7. Lubricate the inside of the tube and the piston with
clean oil.
not to damage the wear ring and seal.
9. When the piston is in the smooth part of the tube start
10. Use a spanner wrench to turn the gland into the tube.
Tighten the gland to specification.
Gland Assembly Torque

Gland 149 N·m (110 lb ft)
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RAPH12FRK0627HA 1

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Tilt cylinder - Remove

586H
588H

2. Drain the hydraulic oil system.
NOTE: The left tilt cylinder has one hydraulic oil line. The right side cylinder has two hydraulic oil lines.
NOTE: Note the location and quantity of cylinder pin spacers before removing pins.
WARNING
Pressurized hydraulic fluid can penetrate the
skin and cause severe injuries.
Tilt cylinder hoses may have trapped hydraulic
oil under pressure. Use extreme caution when
removing hoses from cylinder.
ous injury.
W0999A
3. Tag and disconnect the hydraulic oil lines (1) from the
cylinder end of the tilt cylinder. Close all openings.
4. Remove the cylinder end pin retaining ring (2) and re-
move the cylinder end pin (3), noting spacer location
and quantity.
RAPH12FRK0954BA 1
5. Tag and disconnect hydraulic oil lines from the rod end
of the tilt cylinder. Close all openings.
6. Remove the rod end pin retaining ring (4) and remove
the cylinder end pin (5), noting spacer location and
quantity. Remove the tilt cylinder.
RAPH12FRK0980BA 2
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7. Repair or replace the cylinder as necessary.
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Tilt cylinder - Install

586H
588H
NOTE: Make sure cylinder end spacers are installed in the same location as noted when removed.
1. Install the tilt cylinder rod end (1) to the mounting
bracket (2). Install spacer(s) into the correct location
as noted during removal.
2. Install the tilt cylinder rod end pin (3) and secure with a
retaining ring.
RAPH12FRK0980BA 1
3. Connect hydraulic oil lines at the rod end of the cylinder.

4. Instal the cylinder end (4) to the mounting bracket (5).
Install spacer(s) into the correct location as noted dur-
ing removal.
5. Instal the cylinder end pin (6) and secure with a retain-
ing ring (7).
6. Connect hydraulic oil lines (8).
7. Fill the hydraulic oil system.
RAPH12FRK0954BA 2
CAUTION
Escaping fluid!
erate injury.
C0104A
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8. Start the machine and allow to warm to normal operat-

ing temperature. Operate the tilt hydraulics and inspect
for leaks.
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Tilt cylinder - Disassemble

586H
588H
WARNING
Chemical hazard!
ous injury.
W0180A
To avoid any contamination from entering the cylinder

the cylinder.
1. Fasten the tube (1) in a soft-jawed vise or other holding
equipment. Be careful to prevent damage to the tube.
2. Use the spanner wrench to turn the gland (2) out of the
tube.
3. Pull the piston rod (3) straight out of the tube to prevent
damage to the tube.
4. Fasten the piston rod eye (10) in a soft-jawed vise and
put a support below the piston rod near the piston (11).
Use a shop cloth between the support and the piston
rod to prevent damage to the piston rod.
5. Loosen and remove the bolt (15) that holds the piston.
6. Remove the piston from the piston rod.
7. Remove the wear ring (14), seal (13), and ring (12) from
the piston.
9. Remove the O-ring (9), backup ring (8), wiper (4), seal
(5), buffer seal (6), and bushing (7) from the gland.
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RAPH12FRK0648HA 1
1–Tube 6–Buffer Seal 11–Piston

2–Gland 7–Bushing 12–Ring
3–Piston Rod 8–Backup Ring 13–Seal
4–Wiper 9–O-Ring 14–Wear Ring
5–Seal 10–Piston Rod Eye 15–Bolt SEMS/A 3/4 X 2.50
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Tilt cylinder - Inspect

586H
588H
WARNING
Chemical hazard!
ous injury.
W0180A
1. Clean the piston (11), gland (2), piston rod (3), and tube
(1) in cleaning solvent.
and the gland.
rotary motion.
5. Check to be sure that the piston rod is straight, If the
required.
7. Inspect the bushing (7) in the rod eye (10) and the
closed end of the tube. Replace as required.
will cut the gland O-ring (9). Remove as required.
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RAPH12FRK0649HA 1
1–Tube 7–Bushing 13–Seal

2–Gland 8–Backup Ring 14–Wear Ring
3–Piston Rod 9–O-Ring 15–Bolt SEMS/A 3/4 X 2.50
4–Wiper 10–Piston Rod Eye 16–Bushing
5–Seal 11–Piston 17–Lube Fitting
6–Buffer Seal 12–Ring 18–Lock Screw
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Tilt cylinder - Assemble

586H
588H
ATTENTION: If a new gland is being installed, record the part number of the cylinder on the new gland.
1. Install the bushing (7) in the gland (2).
2. Install the buffer seal (6) in the gland. The side of the
buffer seal with the lip must be toward the small end of
the gland.
3. Install the seal (5) in the gland. The seal is to be in-
stalled so that the lips of the seal are toward the small
end of the gland.
4. Install a new wiper (4) in the gland. The lips of the wiper
must be toward the large end of the gland.
5. Install a new backup ring (8) in the groove on the out-
side of the gland. 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.
6. Install the O-ring (9) next to the backup ring in the
groove on the outside of the gland. The O-ring must
be toward the small end of the gland.
7. Fasten the piston rod eye (10) in a soft-jawed vise.
10. Push the gland onto the piston rod. If necessary, use
a soft hammer to drive the gland onto the piston rod.
11. Put a support below and near the end of the piston
rod. Use a shop cloth between the support and the
piston rod to prevent damage to the piston (11).
12. Put the piston on the end of the piston rod.
13. Clean the threads on the end of the piston rod and the
threads of the bolt using LOCTITE® 7070™ cleaning
solvent. Allow to dry. Apply LOCTITE® 243™ to the
piston rod threads, approximately, 6.4 mm (1/4 inch)
from the open end of the piston rod so that there is
12.7 mm (1/2 inch) of Loctite on the piston rod threads.
DO NOT apply Loctite to the first 6.4 mm (1/4 inch) of
the piston rod threads.
14. Install the bolt (15). Tighten the bolt to specification.
NOTE: A torque multiplier may be needed to help with de-
sired torque.
Specification
Bolt Torque 340 - 380 N·m (251 - 280 lb ft)
15. Install a new wear ring (14) in the end groove on the
outside of the piston
16. Use a spanner wrench to turn the gland into the tube
(1). Tighten the gland.
17. Install a new seal (13) on top of the backup ring (12)
on the outside of the piston.
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clean oil. Use a piston ring compression tool to hold
the new wear ring in place.
19. Push the tube straight onto the piston.
20. Start the tube onto the piston rod assembly. Push the
tube onto the piston rod assembly until the compres-
sion tool is pushed off the piston rod assembly. Be
careful not to damage the wear ring and seal.
21. When the piston is in the smooth part of the tube start
23. Tighten the gland to specification. If the lock screw
(18) holes become aligned in this torque range, install
the lock screw Tighten the lock screw to specification.
ATTENTION: If the lock screw holes are not aligned, proceed to steps 25 through 27.
Specification
Gland Torque 135 - 542 N·m (100 - 400 lb ft)
Lock Screw Torque 2.3 N·m (20 lb in)
24. Tighten the gland to specification.
Specification
Gland Torque 135 - 542 N·m (100 - 400 lb ft)
25. Use a No. 26 drill and drill a hole half in the gland and
half in the tube. Drill to a depth of 11 mm (7/16 inch).
Do not drill in line with a hole in the gland for the gland
wrench.
26. Install the lock screw. Tighten the lock screw to spec-
ification.
Specification
Lock Screw Torque 2.3 N·m (20 lb in)

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RAPH12FRK0649HA 1
1–Tube 7–Bushing 13–Seal

2–Gland 8–Backup Ring 14–Wear Ring
3–Piston Rod 9–O-Ring 15–Bolt SEMS/A 3/4 X 2.50
4–Wiper 10–Piston Rod Eye 16–Bushing
5–Seal 11–Piston 17–Lube Fitting
6–Buffer Seal 12–Ring 18–Lock Screw
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Compensating cylinder - Remove

586H
588H
WARNING
Pressurized system!
tube.
ous injury.
W0998A

pressure from the hydraulic circuit.
4. Identify hydraulic hoses with tags and disconnect each
hose (1) from the compensating cylinder (2).
5. Support compensating cylinder with suitable lifting de-
vice.
RAPH12FRK0924BA 1
6. Remove the four snap rings (3), washers (4), and drive
out each clevis pin (5).
7. Remove compensating cylinder from machine.
RAPH12FRK0925BA 2
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Compensating cylinder - Install

586H
588H
1. Using a suitable lifting device, install the compensating

cylinder (1) into position on the machine.
RAPH12FRK0924BA 1
2. Install both clevis pins (2), four washers (3), and snap
rings (4) securing the compensating cylinder.
RAPH12FRK0925BA 2

nect the hydraulic hoses (5) to the compensating cylin-
der according to the identification tags installed during
the removal procedure.
RAPH12FRK0924BA 3

trol lever for the forks, side shift, and tilt for 15 to 20
seconds.
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CAUTION
Escaping fluid!
erate injury.
C0104A
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Compensating cylinder - Disassemble

586H
588H
WARNING
Chemical hazard!
ous injury.
W0180A
To avoid any contamination from entering the cylinder

were removed with the cylinder, remove the hoses
from the cylinder.
1. Fasten the clevis (5) in a vise or other holding equip-
ment. Be careful to prevent damage to the clevis.
2. Loosen and remove the four nuts (7).
3. Remove the cap (2) from the tube (1) and remove the
four studs (6).
4. Remove the O-ring (9) and backup ring (8) from the
cap.
5. Fasten the tube in a soft-jawed vise. Be careful not to
damage the tube.
6. Use a wrench to turn the gland (4) out of the tube.
7. Pull the piston (3) straight out of the tube to prevent
damage to the tube.
8. Fasten the clevis in a vise or other holding equipment.
Be careful to prevent damage to the clevis (5).
9. Put a support below the piston rod (18) near the piston.
10. Loosen and remove the lock nut (10) that holds the
piston.
11. Remove the piston from the piston rod.
12. Remove the O-ring from the piston rod.
13. Remove the seal (11) and O-ring (12) from the piston.
15. Remove the O-ring (14), wiper (16), and seal (15) from
the gland.
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RAPH12FRK0552FA 1
1–Tube 7–Nut 13–Backup Ring

2–Cap 8–Backup Ring 14–O-Ring
3–Piston 9–O-Ring 15–Seal
4–Gland 10–Lock Nut 16–Wiper
5–Clevis 11–Seal 17–O-Ring
6–Stud 12–O-Ring 18–Piston Rod
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Compensating cylinder - Inspect

586H
588H
WARNING
Chemical hazard!
ous injury.
W0180A
1. Clean the piston (3), gland (4), piston rod (18), cap (2),
and tube (1) in cleaning solvent.
2. Discard the parts that were removed from the cap, pis-
ton, and gland.
rotary motion.
5. Check to be sure that the piston rod and studs (6) are
straight. If they are not straight, replace with new parts.
required.
7. Inspect both ends of the tube for sharp edges that will
cut the cap O-ring (9) and gland O-ring (14). Remove
as required.
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RAPH12FRK0647HA 1

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Compensating cylinder - Assemble

586H
588H
NOTE: If a new cap or gland is being installed, note the part number of the cylinder on the new part.
1. Install a new backup ring (8) and O-ring (9) on the out-
side of the cap (2).
2. Install a new seal (15) and wiper (16) in the gland (4).
3. Install a new backup ring (13) on the outside of the
gland. 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. Install a new O-ring (14) next to the backup ring in the
groove on the outside of the gland. The O-ring must be
toward the small end of the gland.
5. Fasten the clevis (5) in a soft-jawed vise.
8. Push the gland onto the piston rod. If necessary, use a
soft hammer to drive the gland onto the piston rod.
9. Put a support below the piston rod near the piston (3).
10. Install a new O-ring (17) on the piston rod.
damage the O-ring.
13. Lubricate the threads of the piston rod. Install and
tighten to specifications.
Specification
Torque 474 - 501 N·m (350 - 370 lb ft)
14. Install a new O-ring (12) and seal (11) on the outside
of the piston. Fasten the tube (1) in a soft-jawed vise.
Be careful not to damage the tube.
clean oil.
not to damage the seal.
17. Push the piston straight into the tube.
19. When the piston is in the smooth part of the tube, start
20. Use a soft hammer to tap the gland into the tube.
21. Fasten the clevis in a vise or other holding equipment.
Be careful not to damage the clevis.
22. Install studs (6) into the cap.
47821916 28/04/2015
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23. Lubricate the O-ring on the cap.

24. Install the cap onto the tube.
25. Lubricate threads on the studs with clean oil.
26. Install the nuts (7) and tighten to specifications.
Specification
Torque 58 - 63 N·m (42.8 - 46.5 lb ft)

cate the O-rings with clean oil.
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RAPH12FRK0647HA 1

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Index

Compensating cylinder - Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Compensating cylinder - Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Compensating cylinder - Inspect (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Compensating cylinder - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Compensating cylinder - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Telescopic arm cylinder - Assemble Freelift Cylinder (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Telescopic arm cylinder - Assemble Standard Cylinder (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Telescopic arm cylinder - Disassemble Freelift Cylinder (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Telescopic arm cylinder - Disassemble Standard Cylinder (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Telescopic arm cylinder - General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Telescopic arm cylinder - Inspect Freelift Cylinder (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Telescopic arm cylinder - Inspect Standard Cylinder (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Tilt cylinder - Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Tilt cylinder - Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Tilt cylinder - Inspect (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Tilt cylinder - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Tilt cylinder - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
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PRINTED IN U.S.A.
47821916 28/04/2015
EN
SERVICE MANUAL
Frames and ballasting

47821916 28/04/2015
39
Contents
Frames and ballasting - 39
[39.140] Ballasts and supports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39.1
47821916 28/04/2015
39
Ballasts and supports - 140

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39.1 [39.140] / 1
Contents
SERVICE
Counterweight
Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
47821916 28/04/2015
39.1 [39.140] / 2
Frames and ballasting - Ballasts and supports
Counterweight - Remove
586H
588H

machine to use ().
2. Remove the hood from machine. Refer to Hood - Re-
move (90.100).
3. Remove the side panels from machine. Refer to Side
panels - Remove (90.100)
4. Remove the four bolts and washers (1) securing the
grille (2) to the counterweight.
RAPH12FRK0031BA 1
5. Disconnect the back-up alarm wire harness connector

(3).
RAPH12FRK0716BA 2
47821916 28/04/2015
39.1 [39.140] / 3
WARNING
Heavy object!
Clear the area around and under the counter-
weight removal and installation system before
installing or removing counterweights. Keep
all unauthorized personnel clear of the area.
Make sure all lifting devices are in good condi-
tion and capable of handling the counterweight
mass.
ous injury.
W0037A
6. Install the appropriate straps (4) and lifting device (5),

as shown to support the counterweight.
RAPH12FRK0032BA 3
Specification
Counterweight (approximate weight) 1859.7 kg (4100 lb)
7. Remove the two lower counterweight mounting bolts

and washers (6).
RAPH12FRK0032BA 4
NOTE: For assembly purposes, note the location of the rubber washers between the frame and the counterweight
when lower bolts are removed.
ATTENTION: Caution must be taken when removing the
remaining bolts. The counterweight is free to move without
warning.
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8. Remove the remaining two upper mounting bolts and

washers (7) and lift the counterweight from the ma-
chine. Note the location of the rubber washers (8) be-
tween the frame and the counterweight located on the
bottom two bolts.
RAPH12FRK0032BA 5
RAPH12FRK0033BA 6
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Counterweight - Install
586H
588H
WARNING
Heavy object!
Clear the area around and under the counter-
weight removal and installation system before
installing or removing counterweights. Keep
all unauthorized personnel clear of the area.
Make sure all lifting devices are in good condi-
tion and capable of handling the counterweight
mass.
ous injury.
W0037A
1. Install the appropriate straps (1) and the lifting device

(2), as shown to support the counterweight.
RAPH12FRK0032BA 1
Specification
Counterweight (approximate weight) 1859.7 kg (4100 lb)
2. Install the upper mounting bolts (3) and washers

through the counterweight. Install the lower mounting
bolts (4) and washers through the counterweight and
install two rubber washers (5) to the lower bolts as
shown.
RAPH12FRK0033BA 2
3. Carefully lift and guide counterweight onto the rear side

of frame.
4. Tighten four mounting bolts to specification.
Specification
Counterweight Mounting Bolt Torque 366 - 439 N·m (270 - 324 lb ft)
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5. Connect the back-up alarm wire harness connector (6).
RAPH12FRK0716BA 3
6. Remove the lifting device and lifting straps.

7. Install the grille (7) with 4 bolts (8).
RAPH12FRK0031BA 4
8. Install the hood from machine. Refer to Hood - Install

(90.100) .
9. Install the side panels from machine. Refer to Side
panels - Install (90.100)
machine to use ().
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Index

Counterweight - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Counterweight - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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PRINTED IN U.S.A.
47821916 28/04/2015
EN
SERVICE MANUAL
Steering

47821916 28/04/2015
41
Contents
Steering - 41
[41.101] Steering control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.1
[41.200] Hydraulic control components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.2
[41.216] Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.3
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Steering - 41
Steering control - 101

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Contents
Steering - 41
TECHNICAL DATA
Steering control
Torque (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Special tools (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SERVICE
Steering column
Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
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Steering - Steering control
Steering control - Torque

586H
588H
Special Torques
Specifications
Nut for the steering wheel 41–54 N·m (360–480 lb in.)
Cap screws fastening the steering cylinder to the 2WD 786–944 N·m (580–696 lb ft)
steering axle
Cap screws fastening the steering cylinder to the 4WD 162–178 N·m (119–131 lb ft)
steering axle
Cap screws that hold the rear drive shaft 33–39 N·m (24–29 lb ft)
Cap screws for the 2WD steering axle 156–203 N·m (115–150 lb ft)
Wheel nuts for the 4WD steering axle 112–125 N·m (83–92 lb ft). Then turn the nuts an
additional 90 degrees ± 5 degrees
Nut fastening the ball joint to the arm of the swivel 165 N·m (122 lb ft)
housing on the4WD steering axle
U-clamp for exhaust pipe 19–27 N·m (14–20 lb ft)
Steering control - Special tools

586H
588H
The tool shown is needed to remove the steering wheel. Make the tool in your shop. This tool is first used on page 4.
RAPH12FRK0994BA 1
Make from 6 mm (1/4 in.) cold rolled steel.
Specifications
1–50 mm (2 in.) 5–19 mm (3/4 in.)
2–5.4 mm (1 in.) 6–Two holes, 5.5 mm (7/32 in.)
3–15.9 mm (5/8 in.) 7–Use No. 4 Drill for 1/4 - 24
4–9.5 mm (3/8 in.) 8–Two 10-32 x 1 in. screws required. Metric thread optional.
CAS2150 or 380100091 Wrench

This tool is used to remove and install the tie rod.
This tool may need to be thinned in the highlighted area to work correctly on the H series machines.
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RCPH10TLB235ABL 2
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Steering column - Remove

586H
588H

3. Remove six bolts and washers (1) and remove the
outer dash access panel (2) and the hydraulic hose
shield (3).
RAPH12FRK0041BA 1
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4. Disconnect the five hydraulic steering lines (4) at the

steering valve (5). Close all openings.
RAPH12FRK0012BA 2
5. Remove the steering wheel nut cover (6).
RAPH12FRK0947BA 3
6. Remove the steering wheel nut (7).
RAPH12FRK0948BA 4
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7. Use shop-made tool (8) to remove steering wheel.
RAPH12FRK0995BA 5
8. Remove three screws and remove the steering column

shroud.
9. Disconnect the wiring harness (9) from FNR selector
switch (10).
RAPH12FRK0953BA 6
NOTE: Note the orientation of FNR selector switch alignment hole for installation.
10. Remove the two FNR selector switch screws (11) and
remove FNR selector switch.
11. Remove the two bolts (12) that are not recessed into
the mounting bracket (13). Remove the steering col-
umn and steering valve as a unit through the front of
the machine.
12. Remove the two remaining bolts securing the steer-
ing column to the steering valve and separate the two
components. Repair or replace as necessary.
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Steering column - Install

586H
588H
1. Install the steering column to the steering valve and

install two bolts.
2. Install the steering column and steering valve through
the front of the machine. Secure to the mounting
bracket (1) with two bolts (2).
RAPH12FRK0953BA 1
NOTE: Make sure the alignment pin on the FNR selector switch aligns with the alignment hole on the steering column.
3. Install the FNR selector switch (3) to steering column.
Apply LOCTITE® 290™ to the threads of the FNR switch
retaining screws (4), install both screws and tighten
evenly.
4. Connect the FNR selector switch wiring harness con-
nector (5).
5. Install the steering column shroud with three screws.
6. Install the steering wheel (6) and tighten nut (7) to spec-
ification.
RAPH12FRK0948BA 2
Specification
Steering Wheel Nut Torque 41 - 54 N·m (362.9 - 477.9 lb in)
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7. Install the steering wheel nut cover (8).
RAPH12FRK0947BA 3
8. Connect all hydraulic oil lines (9) at the steering control

valve (10).
RAPH12FRK0012BA 4
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9. Install the hydraulic hose shield (11) and the outer dash
access panel (12) and secure in place with six bolts and
washers (13).
RAPH12FRK0041BA 5

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Index
Steering - 41

Steering column - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Steering column - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Steering control - Special tools (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Steering control - Torque (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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Steering - 41
Hydraulic control components - 200

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Contents
Steering - 41
TECHNICAL DATA
Power steering control valve

Special tools (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
FUNCTIONAL DATA

Overview (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
SERVICE

Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Inspect (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
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Steering - Hydraulic control components
Power steering control valve - Special tools

586H
588H
CAS-1239 Centering Spring Tool
RCPH10TLB233ABL 1
380002000 and 3800002001
RCPH10TLB284ABL 2
Power steering control valve - General specification

586H
588H
SPECIFICATIONS
Rotor and Stator Clearance................................................................................................0.13 mm (0.005 in.)
SPECIAL TORQUES
Special Torques Allen Head Plug ..................................................................................11 Nm (100 pound-in.)
Ferry Head Screws................................................................................... 25 to 31 Nm (225 to 275 pound-in.)
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Power steering control valve - Overview

586H
588H
Steering Control Valve:

• Controls oil flow to the steering cylinder.
RAPH12FRK1054BA 1
1–Inlet 5–Spool Valve 7–Gerotor

2–Outlet 6–Drive Link 8–Anti-Cavitation Valve
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RAPH12FRK1055BA 2
1–Inlet 4–Check Valve 7–Gerotor

2–Outlet 5–Spool Valve 8–Anti-Cavitation Valve
3–Pilot Pressure 6–Drive Link 9–To Steering Cylinder
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Power steering control valve - Remove

586H
588H
NOTE: The power steering control valve and the steering column must be removed and installed as a unit. The
power steering control valve can only be separated from the steering column after removal of both components from
the machine. See Steering Column Remove and see Steering Column Install for the detailed procedure.
2. Remove steering column.
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Power steering control valve - Install

586H
588H
NOTE: The power steering control valve and the steering column must be removed and installed as a unit. The
power steering control valve can only be separated from the steering column after removal of both components from
the machine. See Steering Column Remove and see Steering Column Install for the detailed procedure.
1. Install the steering column.
2. Return machine to use.
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Power steering control valve - Disassemble

586H
588H
1. Mark the pump for proper alignment during assembly.
RCPH10TLB241ABL 1
2. Place the steering control valve in the vise so that the

end plate is up.
RCPH10TLB242ABL 2
3. Remove the cap screws and the end cap.
RCPH10TLB243ABL 3
4. Remove the O-ring from the stator of the metering gear

set.
RCPH10TLB244ABL 4
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5. Lift the spacer plate from the body.
RCPH10TLB245ABL 5
6. Remove the metering gear from the pump.
RCPH10TLB246ABL 6
7. Remove the O-ring from the spacer plate, remove the

spacer plate. Remove and discard the O-ring from the
body.
RCPH10TLB247ABL 7
8. Find the anti cavitation valves (1) in the body. Put iden-
tification marks on the body for use during assembly.
RCPH10TLB248ABL 8
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9. Remove the four spring, pins, and the balls from the
ports in the body.
RCPH10TLB249ABL 9
NOTE: The manual steering check valve is located in the bolt hole with the thread insert.
10. Find the manual steering check valve. Remove the
manual steering check valve ball and roll pin.
RCPH10TLB250ABL 10
NOTE: The photo show the steering control in a horizontal position, disassemble steering control unit in a vertical
position, the pin that links the sleeve, spool, and driver could possibly slip and lock the parts in the housing.
11. Pull the sleeve and spool out of the body.
RCPH10TLB251ABL 11
12. Use a punch to push the pin out of the sleeve and
spool.
RCPH10TLB252ABL 12
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13. Remove the drive shaft from the sleeve and spool.
RCPH10TLB253ABL 13
14. Remove the upper thrust washer, the thrust bearing,

and the lower thrust washer.
RCPH10TLB254ABL 14
NOTE: Hold the spring into the sleeve and spool while removing the ring, they can come out unexpectedly.
15. Remove the spring retainer.
RCPH10TLB255ABL 15
16. Remove the springs and the centering spacers from

the sleeve and spool.
RCPH10TLB256ABL 16
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17. Pull the spool straight out of the sleeve.
RCPH10TLB257ABL 17
18. There are four centering springs and three spacers.
RCPH10TLB258ABL 18
19. Remove the seal from the gland.
RCPH10TLB259ABL 19
20. Remove the spool seal.
RCPH10TLB260ABL 20
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Power steering control valve - Inspect

586H
588H
1. Use cleaning solvent to clean all parts. Put the parts on

paper towels until the parts are dry. Do not use cloths
to wipe the parts dry. Check all machined surfaces for
wear or damage. If there are rough places on the ends
of the stator and rotor or on the machined surfaces on
the body, end plate, or spacer plate, use 600 grit emery
cloth to make the surfaces smooth. Put the emery cloth
on a flat surface. If the emery cloth is new, move a piece
of steel across the emery cloth six times to remove the
sharp pieces of grit. Move the rotor, stator, body, end
plate, or spacer across the emery cloth six times. Then
check to see if the rough places have been removed.
Use this method until all rough places are gone. Make
sure that you keep the part flat on the emery cloth as
you move the part across the emery cloth. Use clean-
ing solvent to remove any grit from the parts.
2. If the spool (1), the sleeve (2), or the bore in the body (3)
of the steering control valve is damaged or worn, use
a complete new steering control valve. The spool (1),
the sleeve (2), and the body (3) of the steering control
valve are not available separately.
RCPH10TLB064GAL 1
3. Inspect the thrust washers (4) and the thrust bearing

(5) for damage or wear. Use new parts as required.
RCPH10TLB065GAL 2
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4. Inspect the springs, the pins, and the balls of the anti
cavitation valve for damage or wear. Use new parts as
required.
5. Inspect the roll pin and ball of the manual steering valve
for damage or wear. Use new parts as required.
6. Use a feeler gauge to measure the clearance between
the rotor and the stator. If the clearance is more than
0.13 mm (0.005 in), a new metering gear set must be
used.
RCPH10TLB283ABL 3
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Power steering control valve - Assemble

586H
588H
1. Install the sleeve into the body.
RCPH10TLB261ABL 1
2. Place the O–ring of the two piece seal onto the re-
cessed tip of the plunger.
RCPH10TLB262ABL 2
3. Place the seal cup onto the recessed tip of the plunger.
RCPH10TLB263ABL 3
NOTE: The flat portion of the seal should be facing you.
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4. Press the seal cup into the O-ring.
RCPH10TLB264ABL 4
5. Lubricate the seal with hydraulic oil.
RCPH10TLB265ABL 5
6. Install the plunger into the bore of the sleeve.
RCPH10TLB266ABL 6
7. Push the plunger into the sleeve until it bottoms out,

remove the special tools.
RCPH10TLB267ABL 7
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8. Inspect the seal to make sure that it is seated properly

in the body.
RCPH10TLB268ABL 8
NOTE: The seal and O-ring must both be within the shaft seal counter bore of the housing.
9. Install the seal in the gland so that the lip is toward the
outside of the body. Drive the seal into the gland until
the seal stops moving.
RCPH10TLB269ABL 9
10. Use clean hydraulic oil to lubricate the inside of the

sleeve.
11. Use clean hydraulic oil to lubricate the outside of the
spool.
12. Install the spool into the sleeve. The spool must be
installed straight into the sleeve. Turn the spool in
both directions as the spool is pushed into the sleeve.
RCPH10TLB071ABL 10
13. There are four centering springs and three spacers.
RCPH10TLB258ABL 11
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14. Insert the spring spacers and springs one at a time

into the spool and sleeve.
RCPH10TLB270ABL 12
15. Place the spring retainer onto the sleeve.
RCPH10TLB271ABL 13
16. Work the retaining ring into place over the springs.
RCPH10TLB272ABL 14
17. Install the inner thrust washer, the thrust bearing, and
the outer thrust washer onto the spool.
RCPH10TLB273ABL 15
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18. Install the drive shaft into the spool.
RCPH10TLB274ABL 16
19. Align the holes for the sleeve, spool, and drive shaft.
Press the pin into the sleeve until it is flush with the
sleeve.
RCPH10TLB275ABL 17
20. Find the port with the screw insert, instal the ball and
roll pin for the manual steering check valve.
RCPH10TLB276ABL 18
21. Install the anti cavitation balls, pins, and springs into
the holes that were marked during disassembly.
RCPH10TLB277ABL 19
NOTE: The photo show the steering control in a horizontal position, assemble steering control unit in a vertical posi-
tion, the pin that links the sleeve, spool, and driver could possibly slip and lock the parts in the housing.
47821916 28/04/2015
41.2 [41.200] / 19
22. The pin can move out of the sleeve and the spool. If
the pin moves out of the sleeve and the spool, the pin
can keep the sleeve and the spool from being pushed
into the body. Assembly the steering control unit in a
vertical position.
RCPH10TLB278ABL 20
23. Install a new O-ring in the groove in the body, place

the spacer on the body. Install a new O-ring in the
spacer.
RCPH10TLB279ABL 21
24. Align the timing mark on the drive shaft with a valley
of the gerotor.
RCPH10TLB280ABL 22
25. Align the marks made during disassembly, install the

gerotor spacer.
RCPH10TLB281ABL 23
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26. Install a new O-ring in the gerotor spacer. Install the

end plate on the metering gear set. Align the holes in
the end plate with the holes in the stator.
RCPH10TLB282ABL 24
27. Torque the cap screws to a torque of 11 - 17 N·m

(97.4 - 150.5 lb in) in the sequence shown. Then final
torque the cap screws to a final torque of 25 - 31 N·m
(221.3 - 274.4 lb in) in the sequence shown. Assem-
bled unit should rotate smoothly.
RCPH10TLB003BAM 25
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Index
Steering - 41

Power steering control valve - Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Power steering control valve - Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Power steering control valve - General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Power steering control valve - Inspect (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Power steering control valve - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Power steering control valve - Overview (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Power steering control valve - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Power steering control valve - Special tools (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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Steering - 41
Cylinders - 216

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Contents
Steering - 41
Cylinders - 216
TECHNICAL DATA
Rear axle steering cylinder

FUNCTIONAL DATA

Exploded view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
SERVICE

Leakage test (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Disassemble Two Wheel Drive (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Inspect Two Wheel Drive (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Assemble Two Wheel Drive (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Assemble Four Wheel Drive (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Disassemble Four Wheel Drive (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Inspect Four Wheel Drive (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
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Steering - Cylinders
Rear axle steering cylinder - General specification

586H
588H
Specifications
4WD steering cylinder mounting screw torque 120 N·m (89 lb ft)
2WD steering cylinder mounting screw torque 335 N·m (247 lb ft)
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Rear axle steering cylinder - Exploded view

586H
588H
RAPH12FRK0550FA 1
1–Left End Cap 4–O-Rings 7–Right End Cap

2–Seals 5–Tube 8–Piston
3–Piston Shaft 6–O-Rings
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Rear axle steering cylinder - Leakage test

586H
588H

2. Turn the steering wheel all the way to the right and stop
the engine.
3. Disconnect the hose at the left side of the steering cylin-
der.
4. Install a plug in the hose. The thread size is 3/4-16.
5. Start the engine and run at full throttle.
WARNING
Pressurized fluid can penetrate the skin and
cause severe injuries.
Keep hands and body away from any pressur-
ized leak. DO NOT use your hand to check for
leaks. Use a piece of cardboard or paper. If
fluid penetrates the skin, seek medical atten-
tion immediately.
ous injury.
W0158A
hold in that position, while another person checks for
leakage at the opening.
7. If there is constant leakage, the piston packing is dam-
aged and must be repaired.
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Rear axle steering cylinder - Remove

586H NA
588H NA

2. Clean all hydraulic hose connections at the power
steering cylinder.
3. Disconnect the hydraulic hoses at the power steering
cylinder. Close all openings.
4. Loosen and remove the tie rod ends (1).
RAPH12FRK0332AA 1
5. Remove the six mounting bolts (2) Remove the power

steering cylinder (3) from the axle (4).
RAPH12FRK0333AA 2
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Rear axle steering cylinder - Install

586H NA
588H NA
1. Install the power steering cylinder (1) to the axle (2) and
tighten the six bolts (3).
RAPH12FRK0333AA 1
Specification
Power Steering Cylinder Mounting Bolt Torque 335 N·m (247.1 lb ft)
2. Install the tie rod ends (4) and tighten nuts (5) to spec-
ification.
RAPH12FRK0332AA 2
Specification
Tie Rod Nut Torque 165 N·m (121.7 lb ft)
3. Connect the hydraulic hoses at the power steering

cylinder.
system.
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41.3 [41.216] / 7
6. CAUTION
Escaping fluid!
Hydraulic fluid or diesel fuel leaking under pres-
sure can penetrate the skin and cause infec-
tion or other injury. To prevent personal in-
jury: Relieve all pressure before disconnecting
fluid lines or performing work on the hydraulic
system. Before applying pressure, make sure
all connections are tight and all components
are in good condition. Never use your hand to
check for suspected leaks under pressure. Use
a piece of cardboard or wood for this purpose.
If injured by leaking fluid, see your doctor im-
mediately.
erate injury.
C0104A
Stop the engine and check for leaks.

7. Check the hydraulic oil level at the reservoir and add
oil as necessary.
8. Grease the pins for the steering links.
9. Check and adjust toe-in if necessary.
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Rear axle steering cylinder - Disassemble Two Wheel Drive

586H
588H
1. Clean the outside of the steering cylinder.

2. Fasten the steering cylinder in a vise or other holding
equipment. Be careful to prevent damage to the tube
(5).
3. Remove the right end cap (7) and the left end cap (1).
4. Pull the piston rod (3) out of the tube.
5. Remove and discard all O-rings (4), and (6), and seals
(2).
RAPH12FRK0348AA 1
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Rear axle steering cylinder - Inspect Two Wheel Drive

586H
588H
WARNING
Chemical hazard!
ous injury.
W0180A

2. Illuminate the inside of the tube (5). Inspect the inside
of the tube for deep grooves and other damage. If there
is damage to the tube, a new steering cylinder must be
used.
3. Verify that the piston rod (3) is straight. If the piston rod
is not straight, a new steering cylinder must be used.
4. Inspect the piston (8) for damage and wear. If the pis-
ton is damaged, or worn, a new steering cylinder must
be used.
5. Remove the small scratches on the piston rod and in-
side the tube with emery cloth of medium grit. Use RAPH12FRK0348AA 1
emery cloth with a rotary motion.
6. Inspect both ends of the tube for sharp edges that will
cut the O-rings in the end caps (1) and (7) and remove
the sharp edges as necessary.
7. Inspect all components for rust. Clean and remove rust
as necessary.
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Rear axle steering cylinder - Assemble Two Wheel Drive

586H
588H
ATTENTION: Always install new seals and O-rings when assembling.

1. Install a new seals (2) and O-rings (4) and (6).
RAPH12FRK0348AA 1
ATTENTION: If a vise is used, installing soft jaw protectors to the vise jaws will help prevent damage to the steering
cylinder tube (5) when securing.
2. Fasten the tube in the vise or other holding equipment.
Be careful to prevent damage to the tube.
3. Lubricated the bore of the tube with clean oil.
4. Lubricate the O-rings on both end caps (1) and (7) and
the bore of both end caps with clean oil.
5. Lubricate the piston (3) with clean oil.
6. Push the piston rod assembly straight into the tube.
7. Carefully start the end caps and onto the piston.
8. Verify the ports in both glands (8) are installed correctly
and drive the end caps into the tube.
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Rear axle steering cylinder - Remove

586H NA
588H NA
NOTE: The following illustrations show the steering cylinder being removed from the axle with the axle removed from
the machine. It is not necessary to remove the axle from the machine to remove the steering cylinder.
2. Clean the hose connections and the steering cylinder.
WARNING
Escaping fluid!
Relieve all pressure before disconnecting fluid
lines or performing work on the hydraulic sys-
tem. Make sure all components are in good
condition and tighten all connections before
pressurizing the system. DO NOT use your
hand to check for leaks. Use a piece of card-
board or paper.
ous injury.
W1140A
3. Disconnect the hoses from the steering cylinder.
4. Remove the cotter pin (1) from the ball joint and loosen
the nut several turns. Do not remove the nut at this
time.
RAPH12FRK0323AA 1
5. Install the CAS10486 puller and tighten the screw.

6. Remove the nut and remove the ball joint (2) from the
arm.
RAPH12FRK0325AA 2
7. Repeat steps 4, 5, and 6 for the other end of the axle.
47821916 28/04/2015
41.3 [41.216] / 12
8. Install the CAS2150 or 380100091 tool (3) on the flats

of the piston rod, and install a wrench on the tie rod.
Prevent the piston rod from turning, and loosen the tie
rod.
RAPH12FRK0324AA 3
NOTE: Check the part number on the serial number plate on the axle. If your axle is P/N 87417387, use wrench
CAS2150; if your axle is P/N 87395365, use wrench 380100091.
9. Remove the tie rod and ball joint assembly (4) from the
piston rod.
10. Loosen and remove the four bolts (5) and lock wash-
ers that fasten the steering cylinder to the axle.
RAPH12FRK0327AA 4
11. Remove the hose fitting (6)from the steering cylinder.
RAPH12FRK0329AA 5
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12. Hit the steering cylinder with a soft-faced hammer to

drive the steering cylinder out of the axle.
RAPH12FRK0328AA 6
13. Remove the steering cylinder from the axle.
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Rear axle steering cylinder - Install

586H NA
588H NA
1. Install the steering cylinder in the axle.

2. Install the four bolts (1) that fasten the steering cylinder
to the axle. Tighten the bolts to specification.
RAPH12FRK0326AA 1
Specification
Steering Cylinder to Axle Bolt Torque 120 N·m (89 lb ft)
3. Install the hose fitting in the steering cylinder.

4. Start the ball joint assembly and tie rod (2) onto the
piston rod.
5. Install the CAS2150 or 380100091 tool (3) on the flats
of the piston rod, and install a wrench on the tie rod.
Prevent the piston rod from turning, and loosen the tie
rod.
RAPH12FRK0330AA 2
NOTE: Check the part number on the serial number plate on the axle. If your axle is P/N 87417387, use wrench
CAS2150; if your axle is P/N 87395365, use wrench 380100091.
6. Install the ball joint (4) in the arm.
RAPH12FRK0325AA 3
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41.3 [41.216] / 15
7. Install the nut (5) on the ball joint. Tighten to specifica-

tion.
RAPH12FRK0323AA 4
Specification
Ball Joint Nut Torque 230 N·m (170 lb ft)
8. Install a new cotter pin in the nut and ball joint.

9. Repeat steps 6, 7, and 8 for the other end of the axle.
10. Connect the hoses to the fittings in the steering cylin-
der.
system.
WARNING
Escaping fluid!
ous injury.
W0178A
13. Stop the engine and check for oil leaks.

14. Check the oil level in the reservoir and add oil as re-
quired.
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Rear axle steering cylinder - Assemble Four Wheel Drive

586H
588H
ATTENTION: Always install new seals, wipers, and seal rings when assembling.
1. Install new seals (1) in the grooves of the piston (2).
2. Lubricate the piston seals with clean oil.
RAPH12FRK0376AA 1
3. Install a new seal (3) into the gland.

NOTE: The lip of the seal must be toward the inside of the
gland.
RAPH12FRK0377AA 2
4. Install a new wiper (4) into the gland.

NOTE: The lip of the wiper must be toward the outside of
the gland.
5. Install a new seal ring into the groove on the gland.
RAPH12FRK0378AA 3
6. Lubricate the wiper, seal, and seal ring on the gland

with clean oil.
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41.3 [41.216] / 17
7. Install the gland (5) onto the piston rod (6).
RAPH12FRK0354AA 4
ATTENTION: Caution must be taken not to damage seals when installing the piston rod assembly .
8. Fasten the steering cylinder tube (7) in a vise with soft
jaws. Carefully install the piston rod assembly into the
steering cylinder tube.
9. Push the piston rod assembly all the way into the tube,
and use a soft-faced hammer to drive the piston and
gland into the tube.
RAPH12FRK0379AA 5
10. Lubricate the wiper, seal, and seal ring on the second
gland with clean oil.
11. Install the second gland onto the piston rod, use a
soft-faced hammer to drive the gland into the tube.
RAPH12FRK0380AA 6
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Rear axle steering cylinder - Disassemble Four Wheel Drive

586H
588H
1. Remove the tie rod ball joint assembly.
ATTENTION: If a vise is used, installing soft jaw protectors (1) to the vise jaws will help prevent damage to the steering
cylinder tube (2) when securing.
2. Fasten the steering cylinder tube in a vise or other hold-
ing equipment.
RAPH12FRK0349AA 1
3. Use a soft-faced hammer and separate the gland (3)

from the steering cylinder tube.
RAPH12FRK0350AA 2
4. Remove the gland from the assembly.
RAPH12FRK0351AA 3
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41.3 [41.216] / 19
5. Use a soft-faced hammer and drive the piston rod (4)

against the second gland. Remove the second gland
and piston rod from the steering cylinder tube.
RAPH12FRK0352AA 4
6. Carefully pull the piston rod and gland straight out of the
tube to prevent damage to the steering cylinder tube.
RAPH12FRK0353AA 5
RAPH12FRK0354AA 6
8. Remove the wiper (5), seal (6), and seal ring (7) from
the gland. Repeat this procedure for the second gland.
RAPH12FRK0355AA 7
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41.3 [41.216] / 20
9. Remove each seal (8) from the piston (9).
RAPH12FRK0376AA 8
10. Inspect all parts for damage. See Rear axle steering
cylinder - Inspect (41.216).
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Rear axle steering cylinder - Inspect Four Wheel Drive

586H
588H
1. Discard all parts removed from the gland and piston rod
assembly.
WARNING
Chemical hazard!
ous injury.
W0180A

3. Inspect the gland (5), piston rod assembly (7), and the
tube on the steering cylinder (1) for damage and wear.
These parts are not serviced separately. If these parts
need to be replaced, a new steering cylinder must be
used.
47821916 28/04/2015
41.3 [41.216] / 22
RAPH12FRK0629HA 1
1–Steering Cylinder 7–Piston Rod Assembly 13–Wiper

2–Wiper 8–Seal 14–Backup Ring
3–Backup Ring 9–Wear Ring 15–Bolt
4–Seal 10–Tube 16–Tie Rod Ball Joint Assembly
5–Gland 11–Nut
6–O-Ring 12–Backup Ring
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Index
Steering - 41
Cylinders - 216
Rear axle steering cylinder - Assemble Four Wheel Drive (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Rear axle steering cylinder - Assemble Two Wheel Drive (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Rear axle steering cylinder - Disassemble Four Wheel Drive (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Rear axle steering cylinder - Disassemble Two Wheel Drive (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Rear axle steering cylinder - Exploded view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Rear axle steering cylinder - General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Rear axle steering cylinder - Inspect Four Wheel Drive (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Rear axle steering cylinder - Inspect Two Wheel Drive (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Rear axle steering cylinder - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Rear axle steering cylinder - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Rear axle steering cylinder - Leakage test (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Rear axle steering cylinder - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Rear axle steering cylinder - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
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PRINTED IN U.S.A.
47821916 28/04/2015
EN
SERVICE MANUAL
Wheels

47821916 28/04/2015
44
Contents
Wheels - 44
[44.511] Front wheels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.1
[44.520] Rear wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.2
47821916 28/04/2015
44
Wheels - 44
Front wheels - 511

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Contents
Wheels - 44
Front wheels - 511
TECHNICAL DATA
Front wheels
General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Tire pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SERVICE
Front wheels
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
47821916 28/04/2015
44.1 [44.511] / 2
Wheels - Front wheels
Front wheels - General specification

General Information
NOTICE: The front wheel mounting nuts on this machine are metric. Use only the mounting nuts shown in the parts
catalog for this machine
When the machine is new or when a wheel is removed for service, check the wheel nut or bolt torques every 10 hours
of operation until the wheel nuts or bolts remain tight.
Check the torque with a dial or click torque wrench. If the nut does not move on the following torques, it is tight and
does not need to be torqued:
Specification
Initial torque in sequence 136 N·m (100.3 lb ft)
Second torque in sequence 271 N·m (199.9 lb ft)
Final torque in sequence Additional 30 ° turn
Front wheels - Torque

Specification
Initial torque in sequence 136 N·m (100.3 lb ft)
Second torque in sequence 271 N·m (199.9 lb ft)
Final torque in sequence Additional 30 ° turn
Front wheels - Tire pressure

DANGER
Explosion hazard!
Welding to a wheel can create an explosive air and gas mixture. Removing air from the tire or loosen-
ing the tire on the wheel (breaking the bead) will NOT eliminate the hazard. ALWAYS remove the tire
completely from the wheel before welding.
D0033A
WARNING
Explosion hazard!
When inflating tires, use a clip-on air chuck with a gauge, remote valve, and hose long enough to
allow you to stand to one side and NOT in front of or over the wheel assembly. Keep others out of the
DANGER AREA. Never inflate a tire beyond the maximum allowable pressure printed on the tire.
W0059A
NOTICE: Check the condition and pressure of the tires as needed. Tires will loose air on a regular basis. Check the
tire pressure and condition more often when working in extreme conditions or weather.
Front drive wheel tire pressure

Model Tire size Recommended tire pressure
586H and 588H 19.5L x 24 — 12 ply 234 kPa (34 psi)
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44.1 [44.511] / 3
Front wheels - Remove

WARNING
is possible.
safety stands.
ous injury.
W0069A
2. Lift and support the machine using the appropriate

shop stands.
3. Remove ten nuts and lock washers (1) securing the
front wheel and tire assembly to the wheel hub (2).
RAPH12FRK0050BA 1
WARNING
Crushing hazard!
The wheels on this vehicle are very heavy. Al-
ways use a wheel remover or chain hoists to re-
move and install the wheels. Use an assistant
as required.
ous injury.
W0149A
4. Using a hydraulic wheel lift jack or equivalent, remove

the front wheel and tire assembly.
Specification
Front Drive Wheel Assembly Weight (approximate) 159 kg ( 350 lb)
47821916 28/04/2015
44.1 [44.511] / 4
Front wheels - Install

1. Clean and inspect the wheel hub (1) before installing
the wheel and tire assembly.
RAPH12FRK0051BA 1
WARNING
Crushing hazard!
as required.
ous injury.
W0149A
2. Using a hydraulic wheel lift jack or equivalent, install

the front wheel and tire assembly to the wheel hub.
Specification
Front Drive Wheel Assembly Weight (approximate) 158.8 kg (350 lb)
3. Install and tighten the ten lock washers and nuts (2)
until the wheel is tight to the wheel hub (3).
RAPH12FRK0050BA 2
47821916 28/04/2015
44.1 [44.511] / 5
4. Tighten the mounting nuts, in the sequence shown to a

torque of 136 N·m (100.3 lb ft).
5. Remove the shop stands and lower the machine to the
ground.
RAIL14FRK0031BA 3
6. Tighten the mounting nuts again, in the sequence

shown, to a torque of 271 N·m (199.9 lb ft).
7. Turn each mounting nut, in the sequence shown, an
additional 30 ° degrees to set the required preload on
the front wheel mounting nuts.
Specification
Front Wheel Assembly Initial Torque 136 N·m (100.3 lb ft)
Second Torque 271 N·m (199.9 lb ft)
Final Torque Additional 30 °
8. Return the machine to use. Check the wheel nut torque

after 10 hours of operation, torque to specifications if
required.
47821916 28/04/2015
44.1 [44.511] / 6
Index
Wheels - 44
Front wheels - 511

Front wheels - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Front wheels - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Front wheels - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Front wheels - Tire pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Front wheels - Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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Wheels - 44
Rear wheels - 520

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Contents
Wheels - 44
Rear wheels - 520
TECHNICAL DATA
Rear wheels
General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Tire pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SERVICE
Rear wheel
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
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Wheels - Rear wheels
Rear wheels - General specification

General Information
NOTICE: Use only the mounting hardware shown in the parts catalog for this machine
When the machine is new or when a wheel is removed for service, check the wheel nut or bolt torques every 10 hours
of operation until the wheel nuts or bolts remain tight.
Check the torque with a dial or click torque wrench. If the nut does not move on the following torques, it is tight and
does not need to be torqued:
Four-Wheel Drive (4WD)

Specification
Steering wheels 4WD initial torque in sequence 119 - 125 N·m (88 - 92 lb ft)
Final torque in sequence Additional 43 °
Two-Wheel Drive (2WD)

Specification – Tire size 12 x 16.5
Steering wheels 2WD Torque in sequence 119 - 125 N·m (88 - 92 lb ft)
Specification – Tire size 11 x 16

Steering wheels 2WD Torque in sequence 156 - 203 N·m (115.1 - 149.7 lb ft)
Rear wheels - Torque

Four-Wheel Drive (4WD)
Specification
Steering wheels 4WD initial torque in sequence 119 - 125 N·m (88 - 92 lb ft)
Two-Wheel Drive (2WD)

Specification – Tire size 12 x 16.5
Steering wheels 2WD Torque in sequence 119 - 125 N·m (88 - 92 lb ft)
Specification – Tire size 11 x 16

Steering wheels 2WD Torque in sequence 156 - 203 N·m (115.1 - 149.7 lb ft)
Rear wheels - Tire pressure

DANGER
Explosion hazard!
Welding to a wheel can create an explosive air and gas mixture. Removing air from the tire or loosen-
ing the tire on the wheel (breaking the bead) will NOT eliminate the hazard. ALWAYS remove the tire
completely from the wheel before welding.
D0033A
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WARNING
Explosion hazard!
When inflating tires, use a clip-on air chuck with a gauge, remote valve, and hose long enough to
allow you to stand to one side and NOT in front of or over the wheel assembly. Keep others out of the
DANGER AREA. Never inflate a tire beyond the maximum allowable pressure printed on the tire.
W0059A
NOTICE: Check the condition and pressure of the tires as needed. Tires will loose air on a regular basis. Check the
tire pressure and condition more often when working in extreme conditions or weather.
Rear steer wheel tire pressure

Model Tire size Recommended tire pressure
586H (2WD) 11L x 16 — 10 ply 359 kPa (52 psi)
588H (2WD) 12 x 16.5 — 12 ply 310 kPa (45 psi)
586H and 588H (4WD) 12 x 16.5 — 8 ply 345 kPa (50 psi)
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Rear wheel - Remove

WARNING
is possible.
safety stands.
ous injury.
W0069A
2. Lift and support the rear of the machine with appropri-

ate jack stands.
3. Remove the eight bolts (1) securing the rear wheel and
tire assembly to the wheel hub (2).
RAPH12FRK0053BA 1
DANGER
Heavy parts!
injury.
D0018A
4. Using a hydraulic wheel lift jack or equivalent, remove

the rear wheel and tire assembly.
Specification
Rear Wheel Assembly Weight (approximate) 45.4 kg (100 lb)
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Rear wheel - Install

WARNING
Crushing hazard!
as required.
ous injury.
W0149A
1. Clean and inspect the wheel hub (1) before installing

the wheel. Using a hydraulic wheel lift jack or equiv-
alent, install the rear wheel and tire assembly to the
wheel hub.
RAPH12FRK0054BA 1
2. Install eight bolts (2) and tighten until the wheel is tight
to the hub.
RAPH12FRK0053BA 2
3. Remove the floor stands, and lower the machine to the

ground.
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4. Tighten hardware to specification in sequential steps as

shown.
RAIL14FRK0032BA 3
Specification 4WD Machines Only

Initial Torque in Sequence 119 - 125 N·m (88 - 92 lb ft)
Final Torque in Sequence Additional 43 °
Specification 2WD Machine Only

Wheel Lug Bolt Torque in Sequence 156 - 203 N·m (115.1 - 149.7 lb ft)
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Index
Wheels - 44
Rear wheels - 520

Rear wheel - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Rear wheel - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Rear wheels - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Rear wheels - Tire pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Rear wheels - Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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PRINTED IN U.S.A.
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EN
SERVICE MANUAL
Electrical systems

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55
Contents
Electrical systems - 55
[55.100] Harnesses and connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.1
[55.201] Engine starting system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.2
[55.301] Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.3
[55.302] Battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.4
[55.408] Warning indicators, alarms, and instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.5
[55.991] Telematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.6
[55.DTC] FAULT CODES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.7
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Contents
FUNCTIONAL DATA
Harnesses and connectors

Overview (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Wiring harnesses
Electrical schematic sheet 01 Power distribution / Charging system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Electrical schematic sheet 02 Starting system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Electrical schematic sheet 03 Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Electrical schematic sheet 04 Engine control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Electrical schematic sheet 05 Engine control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Electrical schematic sheet 06 Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Electrical schematic sheet 07 CAN BUS / Diagnostic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Electrical schematic sheet 08 Telematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Electrical schematic sheet 09 Front exterior lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Electrical schematic sheet 10 Instrument cluster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Electrical schematic sheet 11 Power points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Electrical schematic sheet 12 SAHR Park brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Electrical schematic sheet 13 Rear lights exterior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Electrical schematic sheet 14 Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Electrical schematic sheet 15 Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Electrical schematic sheet 01 – Power distribution and starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Electrical schematic sheet 02 – Pre-start and Selective Catalytic Reduction (SCR) . . . . . . . . . . . . . . . . . 60
Electrical schematic sheet 03 – Exhaust system and Controller Area Network (CAN) bus . . . . . . . . . . . 62
Electrical schematic sheet 04 – Engine Control Unit (ECU) vehicle connector . . . . . . . . . . . . . . . . . . . . . 64
Electrical schematic sheet 05 – Engine Control Unit (ECU) engine connector . . . . . . . . . . . . . . . . . . . . . 66
Electrical schematic sheet 06 – Engine control and fuel injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Wire connectors
Component diagram 00 - Connectors X-001 to X-009 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
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Component diagram 07 - Connectors X-070 to X-079 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Component diagram 00 - Connectors X-9000 to X-9009 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
Component diagram 11 - Connectors X-9110 to X–9119 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
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Electrical systems - Harnesses and connectors
Harnesses and connectors - Overview

586H
588H
Electrical failure modes
Short Circuit
A short circuit is a connection of comparatively low resistance between two points in an electrical circuit. Typically,
when a higher source (positive supply) short circuits to a ground circuit or a frame ground, it causes the circuit protec-
tion device, e.g. a fuse, to open and protect the wiring from damage. However, a short circuit can cause damage to
the wiring and machine. This damage can occur if a circuit is not properly protected with a circuit protection device.
The amount of current allowed to flow through a wire due to a short circuit can cause the wire to overheat. This
heat melts the insulation around the wire, adjacent wires, and may lead to a fire. Proper fusing reduces or eliminates
damage to the machine resulting from a short circuit. A short circuit may result when a cut, pinched or chafed wire
makes contact with a grounded component of the vehicle.
Open Circuit
An open circuit is a loss of connection between two points in a circuit. This condition creates infinite resistance
between two circuits and usually results in the malfunction of an electrical component.
An open circuit may result from:
• Pinched/cut wire(s)
• Terminal(s) improperly seated in a connector
• Poor/improper crimping
• Corroded terminal(s)
• Improperly connected Faston connector/ring terminal
Intermittent Circuit
An Intermittent circuit is a condition in the circuit that caused random or repeated failures, and is usually caused by
repeatedly opens or shorts in the circuit. In other words, the circuit makes and breaks contact intermittently.
An intermittent circuit may be caused by:
• Pinched wire
• Loose ring terminal
• Improper seating of terminal(s) in a connector
• Incomplete mating of connectors
• Corroded terminals
Examples of common electrical problems

Short circuit
• The wires are pinched between two objects, e.g. a
frame and bracket.
RAIL14SSL0590AA 1
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Open circuit
• A cut or broken wire.
RAIL14SSL0589AA 2
Open circuit
• There is no contact between the wire(s) and the termi-
nal due to the insulation not being properly removed
or positioned when the terminal was fastened to the
wire(s) .
RAIL14SSL0595AA 3
Open circuit
• Completely disconnected connectors do not make con-
tact with the terminals.
RAIL14SSL0600AA 4
Open circuit
• The terminal is not positioned properly or did not stay
inside the connector.
RAIL14SSL0601AA 5
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Open circuit
• A wire is missing from a connector.
RAIL14SSL0602AA 6
Open circuit
• A wire length that is shortened.
RAIL14SSL0603AA 7
Intermittent circuit
• The hardware used to secure the terminal is not com-
pletely tightened.
RAIL14SSL0593AA 8
• The ring terminal is not secured with hardware.
RAIL14SSL0594AA 9
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• The terminal is not crimped on the wire(s).
RAIL14SSL0596AA 10
• Bent pins may cause a short circuit if the two terminals
do not contact.
• The male and female connectors may not make contact
because of the bent pin.
RAIL14SSL0597AA 11
• Corrosion on the pin(s) is Indicated by a layer of green-
ish-white powder appearing on the pins.
• Corroded pins may overheat because of increased re-
sistance due to corrosion.
RAIL14SSL0598AA 12
• Partially disconnected connectors make contact with
only some terminals.
RAIL14SSL0599AA 13
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• Cracked, broken or melted connector cause improper
connections.
RAIL14SSL0605AA 14
• A ground terminal not fastened or loose on the machine.
RAIL14SSL0606AA 15
Chaffed wire
• A section of the wire’s insulation is rubbed away, expos-
ing the bare wire.
RAIL14SSL0591AA 16
Burned wire and/or melted insulation

• If the wire(s) are located near a heat source or over-
heated because of continuous, excessive current, the
insulation will be discolored and melt, exposing the
wire(s).
RAIL14SSL0592AA 17
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Cross connection
• Terminals that are connected in the wrong cavity will
result in system malfunction.
RAIL14SSL0604AA 18
Incorrect routing
• A wiring harness not routed properly can lead to prob-
lems.
RAIL14SSL0607AA 19
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Prevention of common electrical problems

In order to prevent common problems and to achieve a higher reliability, please follow the below procedures. Please
use harness diagnostic and repair kit, part number 380040185, to assist you with repairs to wires, harnesses, and
connectors.
Sealed connectors
Sealed connectors are designed with weather-proof seals that protect the connector’s terminals from moisture
and debris. This protection makes them ideal for use on the exterior. Two types of seals are available in these
types of connectors:
• A connector seal which provides an environmental seal between the mating connectors.
• A cable seal which seals the area where each wire enters the connector.
RAIL14SSL0609AA 20
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Unsealed connectors
Unsealed connectors are designed for the interior of the machine where connectors are free from contaminates. Do
not replace sealed connectors with unsealed connectors. Usage of unsealed connectors in place of sealed connectors
could lead to damage by environmental factors such as moisture and debris, and cause corrosion which can lead to a
poor connection. Corroded terminals create high resistance in the connection, which can cause intermittent or open
circuits.
RAIL14SSL0608AA 21
Assembly and disassembly of connectors:
Crimping wires on the terminals

The crimping procedure is the same for sealed and unsealed connectors. The differences are identified below.
Sealed connector
1. Slide the wire seal (1) on the wires.
RAIL14SSL0610AA 22
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2. Remove approximately 10 mm (3/8 in) insulation from

the wire ends.
3. Inspect wire strands for cuts and damage. Remove
the stripped portion of wire and strip again if necessary.
RAIL14SSL0611AA 23
4. Place the wire (1) on the terminal. Verify that the wire
seal (2) rests on the insulation barrel (3).
5. Verify that the wire core (4) is exposed to the wire
barrel (5).
RAIL14SSL0613AA 24
Unsealed connector
1. Remove approximately 10 mm (3/8 in) insulation from
the wire ends.
2. Inspect wire strands for cuts and damage. Remove
the stripped portion of wire and strip again if necessary.
RAIL14SSL0611AA 25
4. Place the wire (1) on the terminal. Verify that the insu-
lation lies on the insulation barrel (2).
5. Verify that the wire core (3) is exposed to the wire
barrel (4).
RAIL14SSL0612AA 26
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Sealed and unsealed connectors

6. Use the appropriate tools to crimp the barrels. Follow
these precautions while crimping:
A. Do not bend or crack the terminal.
B. Do not cut the wire strands with the barrel.
C. Verify that all wire strands are contained inside the
core barrel.
D. Wires must not fall out of the barrels once they
have been crimped.
RAIL14SSL0614AA 27
7. Solder all hand-crimped terminals.

8. Check circuit for electrical continuity.
RAIL14SSL0615AA 28
Installing terminals in the connectors

NOTICE: Installing the terminals do not require any special tools. Do not use excessive force to insert a terminal.
1. Orient the terminal to its proper relationship with the

connector body.
2. Insert the terminal into the correct connector cavity.
3. Push until the terminal “clicks” in place.
4. Gently pull the wire back to ensure the proper seating
of the terminal. Verify that the terminal will not back
out from the connector.
RAIL14SSL0616AA 29
Wires are locked in place with a wire lock or a Terminal

Position Assurance (TPA) lock.
Wire locks or TPA locks are added in the connector to

avoid damage to the wires as the exposed/loose wires
are more prone to damage.
Wire locks and TPA locks vary in size and shape, depend-
ing on the type of connector being used.
Some connectors may not have wire or TPA locks.

NOTE: Image shows connector without wire lock.
RAIL14SSL0617AA 30
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Sealed connector - wire lock
1. Install the wire lock after all terminals have been

seated in the connector.
2. Push the lock over the back of the connector until it
locks onto the connector.
RAIL14SSL0619AA 31
Unsealed connector - TPA lock
1. Install the TPA lock after all terminals have been

seated in the connector.
2. Push the lock into the back of the connector until it
locks into place.
RAIL14SSL0618AA 32
Hinged wire lock
1. On connectors with a hinged wire lock, snap the wire

lock over back of the connector .
RAIL14SSL0620AA 33
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Prior to mating the connectors, visually inspect the con-

nectors for damage. Verify that the connector pins are
straight.
RAIL14SSL0621AA 34
Bent pins will lead to damage to the connector and may

cause a short circuit.
RAIL14SSL0622AA 35
Once the terminals are installed and locked in place, apply

dielectric grease to the connector and on the pins to avoid
corrosion.
RAIL14SSL0623AA 36
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1. Push the connectors together until the connector’s

locks snaps into place.
2. If a manual latch is present, secure the manual latch.
3. Slightly pull the connectors to verify a proper connec-
tion.
NOTICE: Do not test the connectors by pulling the wires.
RAIL14SSL0624AA 37
RAIL14SSL0625AA 38
Precautions to be followed while connecting a connector:

• Verify that the connections are intact. Loose connec-
tions will lead to disconnection and corrosion damage.
RAIL14SSL0626AA 39
• Rubber seals on the connector prevents contamination.

Verify that the seal is present on the connectors before
mating the connectors.
RAIL14SSL0627AA 40
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• On connectors with a missing seal, the connection will

not be intact and may cause intermittent or open circuit.
RAIL14SSL0628AA 41
• Verify that the connectors without internal locks, the “T”

on the pins are flush with the bottom of the mating con-
nector to ensure a proper connection.
RAIL14SSL0629AA 42
• Image 43 shows properly mated connector.
RAIL14SSL0630AA 43
• In regards to Engine Control Unit (ECU) connectors,

verify that the connector is properly locked. Moving the
lever towards the controller locks the connector Moving
the lever away from the controller unlocks the connec-
tor. When the connector is properly locked, you should
be able to feel the lever “click” into place.
RAIL14SSL0631AA 44
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• Install the secondary locks or connector position assur-

ance (CPA) locks as required.
RAIL14SSL0632AA 45
RAIL14SSL0633AA 46
NOTICE: Missing and improperly installed secondary

locks will lead to faulty connections.
RAIL14SSL0634AA 47
Disconnecting connectors
1. Remove the secondary lock or CPA lock as follows:
○ Depress the tabs on either side of the lock
○ Pull the lock out of the connectors.
2. With your thumb and a small screwdriver or a pick, lift
the connector’s lock and pull the connectors apart.
NOTICE: Do not disconnect the connectors by pulling the
wires.
RAIL14SSL0635AA 48
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Unsealed connector – TPA lock removal

1. With a screwdriver or pick, depress the locking tabs of
the TPA lock and pull the lock from the connector.
NOTE: If the locks and connectors are to be used again,
verify that the locking mechanisms are not bent or de-
formed.
RAIL14SSL0636AA 49
Sealed connectors – Wire lock removal

1. With a screwdriver or pick, lift the secondary lock over
the locking tabs on either side of the connector and
remove the lock from the connector.
NOTE: If the locks and connectors are to be used again,
verify that the locking mechanisms are not bent or de-
formed.
RAIL14SSL0637AA 50
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Removal of terminals from the connectors

Special tools are required to remove the terminal without damaging it or the connector in which it is inserted. Please
use harness diagnostic and repair kit, part number 380040185, to assist you with repairs to wires, harnesses, and
connectors.
Because connectors are designed to firmly retain terminals, it is sometimes difficult to remove the terminals.
Different style terminals have different removal procedures, but the most common terminals can be removed by using
the procedure below.
A terminal removal tool (Ex: pick or safety pin) is required
to remove a push-to-seat terminal from a connector.
1. Disconnect the mating connector.
2. Remove any wire or TPA lock.
3. Grasp the wire (3) and push the terminal to the fore-
most position in the cavity of the connector (2). Hold
the terminal in this position.
4. The terminal locking tang should be separated from
the ridge inside the connector cavity. This makes it
easy for the terminal removal tool (1) to unseat the
terminal.
5. Locate the terminal lock tang in the connector cavity RAIL14SSL0638AA 51
channel by looking into the connector from the mating

end.
6. Insert an appropriately sized pick into the connector
cavity from the mating end of the connector.
7. Depress the lock tang with the pick or pin to unseat the
terminal.
8. Gently pull the wire to remove the terminal through the
back of the connector.
NOTICE: If force is required to remove the terminal, the
locking tang has not been properly depressed. Forcing a
terminal out of the connector can damage the cavity walls.
Splicing
To ensure a reliable connection, CNHi does not recommend the use of Quicksplice, Scotchlock, wire nuts, and/or
similar splicing devices.
A crimp and seal splice sleeve is recommended for splicing two wires together.
The advantages of using a crimp-and-seal splice sleeve are as follows:

• Easy to use.
• Only one part is required to complete the splice.
• Does not require soldering.
• Suitable for use in the interior and exterior of the machine.
• The bond between the splice and the wire, in addition to the wire crimp, creates a very strong splice.
When heated, these splices have a glue-lined sleeve that shrinks over the wires to seal them.
For reliable splicing, always select properly sized splice sleeve as per the wire gauge of the wires to be spliced.
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Recommended splicing procedure
Splicing single wires
1. Strip off approximately 10 mm (3/8 in) insulation from

the wire ends.
RAIL14SSL0639AA 52
2. Push the wire cores into the sleeve till they reach the
stop at the center of the sleeve.
RAIL14SSL0640AA 53
3. Individually crimp both the ends of the splice sleeve.
RAIL14SSL0641AA 54
4. With a hot air gun, apply heat to the splice sleeve.

5. Heat will melt the glue and adds a firm seal. When the
sleeve stops shrinking and glue appears at the ends
of the sleeve, remove the heat source.
6. Allow the splice to cool.
RAIL14SSL0642AA 55
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Splicing multiple wires

CNHi recommends the use of splice clip for splicing two or more wires together.
Splice clips are similar to terminal core grip wings, except that the splice clips accept more than one wire.
1. Strip off approximately 10 mm (3/8 in) insulation from

the wire ends.
RAIL14SSL0643AA 56
2. Place the stripped wires in the splice clip.
RAIL14SSL0644AA 57
3. Crimp the splice clip.

NOTICE: Do not crimp the insulation.
RAIL14SSL0645AA 58
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4. Heat the splice clip with a soldering iron and apply

solder to the splice clip.
5. Do not use too much solder. Too much solder might
lead to wicking and makes the wire brittle, resulting in
wire damage.
6. Check the continuity of the spliced wires.
7. Cover the splice with splice tape or heat shrink tubes.
RAIL14SSL0646AA 59
Harness routing guidelines

Proper harness routing must be performed to ensure the electrical system reliability. Improper routing of the harness
may lead to various electrical system malfunctions.
When repairing or replacing wire harnesses, verify that the harnesses are routed in their original position. Observe
the following safety precautions while routing the harness.
Location
Verify that the harness:
• Should not come in contact with any moving parts.
• Should be placed at least 125 mm (5 in) away from
sources of radiant heat
• Should be away from any potentially damaging sur-
faces, such as sharp or abrasive objects, sheet metal
holes, sharp metal flanges, etc.
• Should be placed at least 75 mm (3 in) away from bat-
tery vents
RAIL14SSL0647BA 60
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Verify that the bare wires (without conduit) do not contact

the hydraulic tubes and hoses.
RAIL14SSL0648AA 61
Verify that the bare wires are not secured with cable ties.
RAIL14SSL0649AA 62
Tension
Verify that the harness is not under tension. Tension is
when the strain on the harness between two fixing points
(clamps, brackets, connectors, grommets, etc) is larger
than the weight of the wiring harness.
Verify that the slack between two fixing points is not going
to cause interference with other objects/moving parts.
RAIL14SSL0650BA 63
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When the harness are to be bent, verify that the bend

radius is equal to or more than three time the harness
diameter.
RAIL14SSL0651AA 64
Image 65 is an example of a correct bend radius.
RAIL14SSL0652AA 65
Image 66 is an example of an incorrect bend radius.
RAIL14SSL0653AA 66
Harness fastening guidelines

The wiring harness must be fastened properly to avoid any possible harness damage such as incorrect routing, pinch-
ing, entrapment, and/or other conditions which would damage the wiring harness.
When installing the harness, follow their original routing positions and locations. Follow the guidelines below to verify
that the harness is fastened properly.
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Use the double tie to secure the wiring harness to isolated

points on the machine.
RAIL14SSL0654AA 67
RAIL14SSL0655AA 68
Use the dual clamp to secure the harnesses without any

contact.
RAIL14SSL0657AA 69
RAIL14SSL0658AA 70
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Grounding guidelines
A return path is necessary in an electrical circuit. In CNHi applications, the ground points are equivalent to the battery
negative terminal.
The electrical system should be properly grounded.
Use plated ground fasteners (studs, ring terminals, etc.) for better corrosion resistance.
The ground fasteners must be compatible with the ground terminals to reduce galvanic corrosion. Do not use rivets
or sheet metal screws for grounding.
Grounding surfaces must be free of sealants, paint and/or any non-conductive coatings.
Whenever possible, use ring terminals with an anti-rotation feature. In case of terminals without an anti-rotation fea-
ture, use lock washers.
RAIL14SSL0701AA 71
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Wiring harnesses - Electrical schematic sheet 01 Power distribution

/ Charging system
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RAVE14FRK0172JA 1
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Wiring harnesses - Electrical schematic sheet 02 Starting system
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RAVE14FRK0173JA 1
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Wiring harnesses - Electrical schematic sheet 03 Grounding
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RAVE14FRK0174JA 1
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Wiring harnesses - Electrical schematic sheet 04 Engine control
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RAVE14FRK0175JA 1
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Wiring harnesses - Electrical schematic sheet 05 Engine control
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RAVE14FRK0176JA 1
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Wiring harnesses - Electrical schematic sheet 06 Drives
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RAVE14FRK0177JA 1
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Wiring harnesses - Electrical schematic sheet 07 CAN BUS / Diagnostic
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RAVE14FRK0178JA 1
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Wiring harnesses - Electrical schematic sheet 08 Telematics
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RAVE14FRK0179JA 1
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Wiring harnesses - Electrical schematic sheet 09 Front exterior lights
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RAVE14FRK0180JA 1
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Wiring harnesses - Electrical schematic sheet 10 Instrument cluster
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RAVE14FRK0181JA 1
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Wiring harnesses - Electrical schematic sheet 11 Power points
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RAVE14FRK0182JA 1
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Wiring harnesses - Electrical schematic sheet 12 SAHR Park brake
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RAVE14FRK0183JA 1
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Wiring harnesses - Electrical schematic sheet 13 Rear lights exterior
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RAVE14FRK0184JA 1
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Wiring harnesses - Electrical schematic sheet 14 Horn
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RAVE14FRK0185JA 1
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Wiring harnesses - Electrical schematic sheet 15 Options
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RAVE14FRK0186JA 1
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Wiring harnesses - Electrical schematic sheet 01 – Power distribution

and starting
Component identifier Description
K-9102 Main relay
K-9104 Starter control relay
K-9107 Auxiliary main relay
K-9111 Selective Catalytic Reduction (SCR) relay
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NHIL14ENG1288JA 1
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Wiring harnesses - Electrical schematic sheet 02 – Pre-start and

Selective Catalytic Reduction (SCR)
A-9105 Heater Control Unit (HCU)
B-9123 Lambda sensor (under 56 kW (76 Hp) engines only)
J-9100 Diagnostic connector
K-9100 Fuel filter heater relay
K-9121 Electric fuel pump relay (optional)
K-9122 Cold start bypass valve relay (Tractor Loader Backhoe (TLB)
model applications only)
R-9005 Fuel filter heater
R-9102 Diesel Exhaust Fluid (DEF)/AdBlue® supply module suction
line heater
R-9103 Diesel Exhaust Fluid (DEF)/AdBlue® supply module back
flow line heater
R-9104 Diesel Exhaust Fluid (DEF)/AdBlue® supply module pressure
line heater
S-9102 Water in fuel switch
Y-9102 Coolant control valve (over 56 kW (76 Hp) engines only)
Z-9101 Glow plug control module
NOTE:
Under 56 kW (76 Hp) engine – circuit VE-9071
Over 56 kW (76 Hp) engine – circuit VE-9072
Z-9102 Diesel Exhaust Fluid (DEF)/AdBlue® Supply module
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NHIL14ENG1289JA 1
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Wiring harnesses - Electrical schematic sheet 03 – Exhaust system and

Controller Area Network (CAN) bus
A-9101 NH₃ controller
A-9102 NOx sensor downstream
A-9103 NOx sensor upstream
A-9104 Diesel Exhaust Fluid (DEF)/AdBlue® temperature, level and
quality sensor
B-9104 Selective Catalytic Reduction (SCR) catalyst temperature
(downstream), (over 56 kW (76 Hp) engines only)
B-9106 Exhaust gas temperature upstream Diesel Oxidation Catalyst
(DOC) sensor (over 56 kW (76 Hp) engines only)
B-9107 Selective Catalytic Reduction (SCR) catalyst temperature
(upstream), (over 56 kW (76 Hp) engines only)
B-9110 NH₃ sensor
B-9113 Intake air temperature sensor
B-9126 Particulate Matter (PM) catalytic converter inlet temperature
sensor (under 56 kW (76 Hp) engines only)
B-9127 Diesel Oxidation Catalyst (DOC) inlet temperature sensor
(under 56 kW (76 Hp) engines only)
R-9101 Controller Area Network (CAN) termination resistor
Y-9103 Diesel Exhaust Fluid (DEF)/AdBlue® dosing module
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NHIL14ENG1290JA 1
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Wiring harnesses - Electrical schematic sheet 04 – Engine Control Unit

(ECU) vehicle connector
A-9000 Engine Control Unit (ECU)
NOTE:
Under 56 kW (76 Hp) engine – circuit VE-9071, VE9119A,
VE-9121A, VE-9147, and VE-9168
Over 56 kW (76 Hp) engine – circuit VE-9072, VE-9118A,
VE-9120A, VE-9143, VE-9149, VE-9169, VE9170 and
VE-9173
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NHIL14ENG1291JA 1
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Wiring harnesses - Electrical schematic sheet 05 – Engine Control Unit

(ECU) engine connector
A-9000 Engine Control Unit (ECU)
NOTE:
Under 56 kW (76 Hp) engines – circuit VE-9118 and VE-9120
Over 56 kW (76 Hp) engines – circuit VE-9119, VE-9121
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NHIL14ENG1292JA 1
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Wiring harnesses - Electrical schematic sheet 06 – Engine control and

fuel injection
B-9001 Intake manifold pressure and temperature sensor
NOTE:
Over 56 kW (76 Hp) engines – circuit EN-9104
B-9002 Fuel temperature sensor
B-9003 Coolant temperature sensor
B-9004 Rail pressure sensor
B-9005 Exhaust gas pressure sensor
NOTE:
Under 56 kW (76 Hp) engines – circuit VE-9118, VE-9120,
VE-9143A
Over 56 kW (76 Hp) engines – circuit VE-9118A, VE-9120A,
VE-9143
B-9007 Crankshaft position sensor
B-9017 Camshaft speed sensor
B-9018 Exhaust manifold temperature sensor
NOTE:
Under 56 kW (76 Hp) engines – circuit VE-9119A, VE-9121A
Over 56 kW (76 Hp) engines – circuit VE-9119, VE-9121
R-9000 Intake manifold temperature sensor (under 56 kW (76 Hp)
engines only)
NOTE:
Under 56 kW (76 Hp) engines – circuit EN-9174, EN-9175
R-9001 Glow plug 1
R-9002 Glow plug 2
R-9003 Glow plug 3
R-9004 Glow plug 4
S-9016 Oil pressure switch
Y-9000 Fuel metering unit
Y-9001 Cylinder 1 injector (Bank 1 Injector 1)
Y-9008 Wastegate pressure modulator valve
Z-9000 Exhaust Gas Recirculation (EGR) valve
Z-9001 Throttle valve actuator
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NHIL14ENG1294JA 1
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Wire connectors - Component diagram 00 - Connectors X-001 to

X-009
CONNECTOR X-001 - TO MAIN (X-051)

PIN WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME
NUMBER
A 1023 (RD) SP-219 X-001TO MAIN (X-051)
B 36H1 (BL) X-220HYD FILTER X-001TO MAIN
(X-051)
C 36F1 (YE) X-063 X-001TO MAIN (X-051)
D 32T1 (YE) X-071TRANS TEMP SENDER
X-001TO MAIN (X-051)
E 4031 (WH) X-001TO MAIN (X-051) X-057SAHR
BRAKE SOL
F 4021 (BL) X-099P BRAKE PRESS SW X-001TO
MAIN (X-051)
G 1502 (OR) X-509 X-001TO MAIN (X-051)
H 3401 (YE) X-083ALT X-001TO MAIN (X-051)
J 25E5 (WH) X-001TO MAIN (X-051) X-0784WD
K 25S2 (WH) X-001TO MAIN (X-051) X-077DIFF
LOCK
L 2603 (LB) X-001TO MAIN (X-051)
X-079FORWARD
M 2703 (LB) X-001TO MAIN (X-051) SP-114
N 64B3 (WH) X-001TO MAIN (X-051) X-031
P 3801 (BL) X-067 X-001TO MAIN (X-051)
R - -
S 21B3 (WH) X-001TO MAIN (X-051)
X-820STARTER MTR
87696573 1
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CONNECTOR X-003 - X-003

NUMBER
1 AP53 (OR) X-012 X-003
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NUMBER
1 P028 (RD) X-012 X-005
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CONNECTOR X-009 - VEHICLE DIAGNOSTIC
CONNECTOR X-009 - VEHICLE DIAGNOSTIC

NUMBER
A G076 (BK) X-009VEHICLE DIAGNOSTIC X-487
B 1021 (RD) X-009VEHICLE DIAGNOSTIC X-012
C E246 (YE) X-009VEHICLE DIAGNOSTIC
SP-019
D E256 (GN) X-009VEHICLE DIAGNOSTIC
SP-020
E E682 (YE) X-009VEHICLE DIAGNOSTIC X-497
F - -
G - -
H - -
J - -
87736919 4
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X-019
CONNECTOR X-010 - FLASHER
CONNECTOR X-010 - FLASHER

NUMBER
1 4601 (VT) X-010FLASHER X-150TO FRONT
HARNESS (X-040)
2 AP27 (OR) SP-027 X-010FLASHER
3 47R1 (VT) X-010FLASHER X-150TO FRONT
HARNESS (X-040)
4 G100 (BK) X-010FLASHER X-487
5 45L1 (VT) X-010FLASHER SP-024
6 47L1 (VT) X-010FLASHER X-150TO FRONT
HARNESS (X-040)
7 45R1 (VT) SP-028 X-010FLASHER
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NUMBER
1 E173 (YE) X-012 X-497
2 21A8 (OR) X-012 X-013
3 4041 (OR) SP-014 X-012
4 AP17 (OR) SP-AP02 X-012
5 - -
6 - -
7 4043 (OR) X-012 SP-052
8 AP58 (OR) X-012 X-150TO FRONT HARNESS
(X-040)
9 G346 (BK) X-012 X-488
10 E373 (YE) X-012 X-497
11 25B4 (LB) SP-112 X-012
12 25A3 (LB) SP-113 X-012
13 - -
14 - -
15 5204 (YE) X-012 SP-109
16 5203 (YE) X-012 SP-109
17 P013 (RD) SP-P001 X-012
18 3P01 (OR) SP-012 X-012
19 41F7 (VT) SP-094 X-012
20 AP23 (OR) SP-AP02 X-012
21 1P03 (RD) X-012 X-101TO ROPS HARNESS
(X-020)
22 3P05 (OR) X-101TO ROPS HARNESS (X-020)
X-012
23 41R2 (VT) X-101TO ROPS HARNESS (X-020)
X-012
24 AP26 (OR) X-012 SP-027
25 P027 (RD) X-012 X-123
26 1021 (RD) X-009VEHICLE DIAGNOSTIC X-012
27 AP31 (OR) SP-AP02 X-012
28 AP32 (OR) SP-AP02 X-012
29 P028 (RD) X-012 X-005
30 1019 (RD) SP-P001 X-012
31 AP19 (OR) SP-030 X-012
(X-040)
33 AP52 (OR) SP-AP01 X-012
34 19E1 (OR) SP-012 X-012
35 AP03 (OR) SP-AP01 X-012
36 64A1 (RD) X-012 X-150TO FRONT HARNESS
(X-040)
37 AP53 (OR) X-012 X-003
38 19E9 (OR) X-012 SP-067
(X-040)
40 P029 (RD) SP-P001 X-012
41 3P12 (OR) SP-012 X-012
42 P014 (RD) SP-P001 X-012
43 P012 (RD) SP-P001 X-012
44 P017 (RD) SP-P001 X-012
45 3P13 (OR) X-498TELEMATICS MODULE X-012
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NUMBER
46 P032 (RD) X-013 X-012
47 P018 (RD) X-012 X-150TO FRONT HARNESS
(X-040)
48 8404 (RD) X-012 X-150TO FRONT HARNESS
(X-040)
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NUMBER
1 21A4 (YE) SP-066 X-013
2 P032 (RD) X-013 X-012
3 21C2 (YE) SP-130 X-013
4 21A7 (OR) X-013 X-013
5 - -
6 - -
7 - -
8 - -
9 21B4 (WH) X-051TO CHASSIS HARNESS
(X-001) X-013
10 21A7 (OR) X-013 X-013
11 21A8 (OR) X-012 X-013
12 G077 (BK) X-013 X-488
13 G079 (BK) X-013 X-488
14 19M1 (OR) X-013 X-148TIMER
15 21C3 (YE) SP-130 X-013
16 2401 (YE) X-013 X-148TIMER
17 - -
18 - -
19 5201 (YE) SP-109 X-013
20 - -
21 4037 (WH) X-013 X-013
22 4034 (WH) SP-053 X-013
23 - -
24 G026 (BK) X-013 X-487
25 4053 (YE) SP-051 X-013
26 4042 (OR) SP-052 X-013
27 19E6 (OR) SP-067 X-013
28 4037 (WH) X-013 X-013
29 - -
30 - -
31 2103 (YE) X-013 SP-111
32 - -
33 4052 (YE) X-013 SP-051
34 G081 (BK) X-013 X-487
35 - -
36 2503 (BL) X-013 SP-011DE-CLUTCH SPLICE
37 25A4 (LB) SP-113 X-013
38 19M4 (OR) SP-111 X-013
39 25B3 (LB) SP-112 X-013
40 19M3 (OR) SP-111 X-013
41 - -
42 - -
43 - -
44 - -
45 2602 (LB) X-013 X-051TO CHASSIS HARNESS
(X-001)
46 G065 (BK) X-013 X-488
47 2704 (LB) X-013 X-051TO CHASSIS HARNESS
(X-001)
48 G064 (BK) X-013 X-488
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NUMBER
1 G074 (BK) X-016 X-488
2 4003 (OR) SP-014 X-016
3 P005 (RD) X-123 X-016
5 AP01 (OR) X-016 SP-AP01
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NUMBER
1 G073 (BK) X-017 X-488
2 4004 (OR) SP-014 X-017
3 P008 (RD) X-123 X-017
5 AP15 (OR) X-017 SP-AP02
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X-029
CONNECTOR X-020 - TO MAIN HARNESS

NUMBER
1 G010 (BK) SP-010REAR LIGHTS GROUND
X-020TO MAIN HARNESS
2 - -
3 - -
4 G009 (BK) SP-009FRONT LIGHTS GROUND
5 G023 (BK) SP-007 X-020TO MAIN HARNESS
6 - -
7 - -
8 - -
9 1202 (BL) X-020TO MAIN HARNESS
X-033INTRUMENT CLUSTER
11 2182 (PK) X-020TO MAIN HARNESS
12 2162 (YE) X-020TO MAIN HARNESS
13 45L3 (VT) SP-100 X-020TO MAIN HARNESS
14 - -
15 440B (VT) X-020TO MAIN HARNESS
X-524BREAK LIGHT
16 45R3 (VT) SP-097 X-020TO MAIN HARNESS
17 - -
18 E253 (GR) X-020TO MAIN HARNESS
19 41F9 (VT) SP-099 X-020TO MAIN HARNESS
20 36F2 (YE) X-020TO MAIN HARNESS
21 21A5 (YE) X-020TO MAIN HARNESS
22 - -
23 1P04 (RD) X-020TO MAIN HARNESS
24 0434 (VT) X-020TO MAIN HARNESS SP-118
25 - -
26 41R5 (VT) X-020TO MAIN HARNESS
X-528TAIL LIGHTS
27 32T2 (YE) X-020TO MAIN HARNESS
29 21C8 (YE) X-020TO MAIN HARNESS
31 36H2 (BL) X-020TO MAIN HARNESS
32 - -
33 3P02 (OR) X-020TO MAIN HARNESS SP-318
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NUMBER
34 G066 (BK) X-033INTRUMENT CLUSTER
35 - -
37 E243 (YE) X-020TO MAIN HARNESS
38 - -
39 - -
40 - -
41 - -
42 - -
43 - -
44 - -
45 - -
46 - -
47 - -
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CONNECTOR X-021 - IGNITION SWITCH
CONNECTOR X-021 - IGNITION SWITCH

NUMBER
1 P019 (RD) X-021IGNITION SWITCH X-040TO
MAIN HARNESS
2 21A3 (YE) X-021IGNITION SWITCH X-040TO
MAIN HARNESS
3 3001 (OR) X-021IGNITION SWITCH X-040TO
MAIN HARNESS
MAIN HARNESS
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CONNECTOR X-023 - 4WD SWITCH
CONNECTOR X-023 - 4WD SWITCH

NUMBER
A G072 (BK) X-0234WD SWITCH SP-G13
E AP40 (OR) X-0234WD SWITCH X-040TO MAIN
HARNESS
F 25E3 (LB) X-0234WD SWITCH X-040TO MAIN
HARNESS
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X-039

NUMBER
1 64B3 (WH) X-001TO MAIN (X-051) X-031
84177908 1
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NUMBER
1 G063 (BK) X-032 SP-008CHASSIS GROUND
84177908 2
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CONNECTOR X-033 - INTRUMENT CLUSTER
CONNECTOR X-033 - INTRUMENT CLUSTER

NUMBER
2 36H2 (BL) X-020TO MAIN HARNESS
3 21A5 (YE) X-020TO MAIN HARNESS
4 - -
5 E253 (GR) X-020TO MAIN HARNESS
6 E243 (YE) X-020TO MAIN HARNESS
7 3P04 (OR) SP-318 X-033INTRUMENT
CLUSTER
8 3P03 (OR) X-033INTRUMENT CLUSTER
SP-318
9 1P04 (RD) X-020TO MAIN HARNESS
10 21C8 (YE) X-020TO MAIN HARNESS
13 - -
14 - -
15 - -
16 32T2 (YE) X-020TO MAIN HARNESS
17 2182 (PK) X-020TO MAIN HARNESS
18 - -
20 - -
21 - -
23 - -
24 36F2 (YE) X-020TO MAIN HARNESS
26 - -
27 - -
28 - -
29 - -
30 - -
31 - -
32 - -
33 - -
34 G066 (BK) X-033INTRUMENT CLUSTER
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X-049

NUMBER
1 4602 (VT) X-132HAZARD LIGHT SW X-040TO
MAIN HARNESS
2 AP20 (OR) X-132HAZARD LIGHT SW X-040TO
MAIN HARNESS
3 45LB (VT) X-139TURN LIGHTS SW X-040TO
MAIN HARNESS
4 8403 (RD) SP-040 X-040TO MAIN HARNESS
5 45RB (VT) X-139TURN LIGHTS SW X-040TO
MAIN HARNESS
6 64A2 (RD) X-040TO MAIN HARNESS
X-151HORN SWITCH
7 25B1 (YE) X-146 X-040TO MAIN HARNESS
8 043P (VT) X-112REAR WORKLIGHTS X-040TO
MAIN HARNESS
9 G160 (BK) X-040TO MAIN HARNESS SP-G12
X-139TURN LIGHTS SW
11 47L2 (VT) X-040TO MAIN HARNESS
X-139TURN LIGHTS SW
12 AP25 (OR) X-040TO MAIN HARNESS
X-139TURN LIGHTS SW
13 - -
14 19E4 (OR) X-146 X-040TO MAIN HARNESS
15 2507 (BL) X-175DE-CLUTCH SWITCH
16 25S6 (YE) X-187DIFF LOCK SWITCH X-040TO
MAIN HARNESS
17 21C5 (YE) X-146 X-040TO MAIN HARNESS
18 25A1 (LB) X-146 X-040TO MAIN HARNESS
19 4045 (OR) X-098SAHR BRAKE SWITCH
20 4054 (YE) X-098SAHR BRAKE SWITCH
21 64B1 (WH) X-151HORN SWITCH X-040TO
MAIN HARNESS
22 2508 (BL) X-175DE-CLUTCH SWITCH
23 AP40 (OR) X-0234WD SWITCH X-040TO MAIN
HARNESS
24 4036 (WH) X-098SAHR BRAKE SWITCH
25 25E3 (LB) X-0234WD SWITCH X-040TO MAIN
HARNESS
26 G161 (BK) SP-G13 X-040TO MAIN HARNESS
27 19EF (OR) X-187DIFF LOCK SWITCH X-040TO
MAIN HARNESS
28 21A3 (YE) X-021IGNITION SWITCH X-040TO
MAIN HARNESS
29 P019 (RD) X-021IGNITION SWITCH X-040TO
MAIN HARNESS
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NUMBER
MAIN HARNESS
31 AP59 (OR) X-112REAR WORKLIGHTS X-040TO
MAIN HARNESS
MAIN HARNESS
33 AP36 (OR) X-138DRIVING LIGHTS SWITCH
34 41FE (VT) X-138DRIVING LIGHTS SWITCH
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X-059
CONNECTOR X-051 - TO CHASSIS HARNESS (X-001)
CONNECTOR X-051 - TO CHASSIS HARNESS (X-001)

NUMBER
A 1022 (RD) X-498TELEMATICS MODULE
X-051TO CHASSIS HARNESS
(X-001)
B 36H4 (BL) X-101TO ROPS HARNESS (X-020)
(X-001)
C 36F3 (YE) X-101TO ROPS HARNESS (X-020)
(X-001)
D 32T3 (YE) X-101TO ROPS HARNESS (X-020)
(X-001)
E 4032 (WH) SP-053 X-051TO CHASSIS
HARNESS (X-001)
F 4022 (BL) X-051TO CHASSIS HARNESS
(X-001) X-101TO ROPS HARNESS
(X-020)
G 1507 (OR) SP-012 X-051TO CHASSIS
HARNESS (X-001)
H 3402 (YE) X-051TO CHASSIS HARNESS
(X-001) SP-204
J 25E4 (LB) X-051TO CHASSIS HARNESS
(X-001) X-150TO FRONT HARNESS
(X-040)
K 25S1 (YE) X-051TO CHASSIS HARNESS
(X-040)
L 2602 (LB) X-013 X-051TO CHASSIS HARNESS
(X-001)
M 2704 (LB) X-013 X-051TO CHASSIS HARNESS
(X-001)
N 64B2 (WH) X-150TO FRONT HARNESS (X-040)
(X-001)
P 3803 (BL) X-101TO ROPS HARNESS (X-020)
(X-001)
R - -
S 21B4 (WH) X-051TO CHASSIS HARNESS
(X-001) X-013
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CONNECTOR X-055 - B/U ALARM
CONNECTOR X-055 - B/U ALARM

NUMBER
A 2702 (LB) SP-114 X-055B/U ALARM
B G030 (BK) X-055B/U ALARM SP-G08
87692855 2
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CONNECTOR X-057 - SAHR BRAKE SOL
CONNECTOR X-057 - SAHR BRAKE SOL

NUMBER
1 4031 (WH) X-001TO MAIN (X-051) X-057SAHR
BRAKE SOL
2 G020 (BK) X-057SAHR BRAKE SOL
SP-008CHASSIS GROUND
84277193 3
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X-069

NUMBER
1 36F1 (YE) X-063 X-001TO MAIN (X-051)
84159852 1
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NUMBER
1 G021 (BK) SP-008CHASSIS GROUND X-064
84159852 2
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NUMBER
1 G022 (BK) SP-G08 X-066
84177908 3
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NUMBER
1 3801 (BL) X-067 X-001TO MAIN (X-051)
84177908 4
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X-079
CONNECTOR X-071 - TRANS TEMP SENDER
CONNECTOR X-071 - TRANS TEMP SENDER

NUMBER
1 32T1 (YE) X-071TRANS TEMP SENDER
X-001TO MAIN (X-051)
84159852 1
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CONNECTOR X-077 - DIFF LOCK
CONNECTOR X-077 - DIFF LOCK

NUMBER
1 25S2 (WH) X-001TO MAIN (X-051) X-077DIFF
LOCK
2 G028 (BK) X-077DIFF LOCK SP-G08
84277535 2
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CONNECTOR X-078 - 4WD
CONNECTOR X-078 - 4WD

NUMBER
1 25E5 (WH) X-001TO MAIN (X-051) X-0784WD
2 G029 (BK) SP-G08 X-0784WD
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CONNECTOR X-079 - FORWARD
CONNECTOR X-079 - FORWARD

NUMBER
1 2603 (LB) X-001TO MAIN (X-051)
X-079FORWARD
2 G045 (BK) X-079FORWARD SP-G08
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X-089
CONNECTOR X-080 - REVERSE
CONNECTOR X-080 - REVERSE

NUMBER
1 2701 (LB) SP-114 X-080REVERSE
2 G044 (BK) X-080REVERSE SP-G08
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CONNECTOR X-083 - ALT
CONNECTOR X-083 - ALT

NUMBER
1 3401 (YE) X-083ALT X-001TO MAIN (X-051)
2 1501 (OR) X-083ALT X-509
3 - -
84165069 2
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X-099
CONNECTOR X-098 - SAHR BRAKE SWITCH
CONNECTOR X-098 - SAHR BRAKE SWITCH

NUMBER
1 4036 (WH) X-098SAHR BRAKE SWITCH
2 4054 (YE) X-098SAHR BRAKE SWITCH
3 4045 (OR) X-098SAHR BRAKE SWITCH
4 - -
5 - -
6 - -
7 - -
8 - -
9 - -
10 - -
84159859 1
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CONNECTOR X-099 - P BRAKE PRESS SW
CONNECTOR X-099 - P BRAKE PRESS SW

NUMBER
1 4021 (BL) X-099P BRAKE PRESS SW X-001TO
MAIN (X-051)
87687239 2
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X-109
CONNECTOR X-101 - TO ROPS HARNESS (X-020)

NUMBER
1 G018 (BK) X-487 X-101TO ROPS HARNESS
(X-020)
2 - -
3 - -
4 G019 (BK) X-101TO ROPS HARNESS (X-020)
X-488
X-488
6 - -
7 - -
8 - -
9 1201 (BL) X-155FOOT THROTTLE X-101TO
ROPS HARNESS (X-020)
10 2201 (BL) X-155FOOT THROTTLE X-101TO
11 2181 (PK) X-155FOOT THROTTLE X-101TO
12 2161 (YE) X-155FOOT THROTTLE X-101TO
13 45L2 (VT) SP-024 X-101TO ROPS HARNESS
(X-020)
14 - -
15 4408 (VT) SP-031 X-101TO ROPS HARNESS
(X-020)
16 45R2 (VT) SP-028 X-101TO ROPS HARNESS
(X-020)
17 - -
18 E259 (GN) X-101TO ROPS HARNESS (X-020)
SP-020
19 41F8 (VT) X-101TO ROPS HARNESS (X-020)
SP-094
20 36F3 (YE) X-101TO ROPS HARNESS (X-020)
(X-001)
21 21A1 (YE) X-101TO ROPS HARNESS (X-020)
SP-066
22 - -
23 1P03 (RD) X-012 X-101TO ROPS HARNESS
(X-020)
24 0432 (VT)
25 - -
26 41R2 (VT) X-101TO ROPS HARNESS (X-020)
X-012
27 32T3 (YE) X-101TO ROPS HARNESS (X-020)
(X-001)
28 3803 (BL) X-101TO ROPS HARNESS (X-020)
(X-001)
29 21C7 (YE) SP-130 X-101TO ROPS HARNESS
(X-020)
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NUMBER
30 3403 (YE) SP-204 X-101TO ROPS HARNESS
(X-020)
31 36H4 (BL) X-101TO ROPS HARNESS (X-020)
(X-001)
32 - -
33 3P05 (OR) X-101TO ROPS HARNESS (X-020)
X-012
X-487
35 - -
36 4022 (BL) X-051TO CHASSIS HARNESS
(X-001) X-101TO ROPS HARNESS
(X-020)
37 E249 (YE) X-101TO ROPS HARNESS (X-020)
SP-019
38 - -
39 - -
40 - -
41 - -
42 - -
43 - -
44 - -
45 - -
46 - -
47 - -
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X-119
CONNECTOR X-112 - REAR WORKLIGHTS
CONNECTOR X-112 - REAR WORKLIGHTS

NUMBER
A G099 (BK) X-112REAR WORKLIGHTS SP-G13
D 043P (VT) X-112REAR WORKLIGHTS X-040TO
MAIN HARNESS
E AP59 (OR) X-112REAR WORKLIGHTS X-040TO
MAIN HARNESS
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X-129

NUMBER
1 P002 (RD) X-478STARTER/BATT+ JUNCTION
TERMINAL X-122TO MAIN (X-123)
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NUMBER
1 P005 (RD) X-123 X-016
P008 (RD) X-123 X-017
P010 (RD) X-123 SP-P001
P027 (RD) X-012 X-123
84364890 1
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X-139
CONNECTOR X-132 - HAZARD LIGHT SW
CONNECTOR X-132 - HAZARD LIGHT SW

NUMBER
A G159 (BK) X-132HAZARD LIGHT SW SP-G13
D 4602 (VT) X-132HAZARD LIGHT SW X-040TO
MAIN HARNESS
E AP20 (OR) X-132HAZARD LIGHT SW X-040TO
MAIN HARNESS
87697780 1
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CONNECTOR X-138 - DRIVING LIGHTS SWITCH
CONNECTOR X-138 - DRIVING LIGHTS SWITCH

NUMBER
A G327 (BK) SP-G13 X-138DRIVING LIGHTS
SWITCH
D 41FE (VT) X-138DRIVING LIGHTS SWITCH
E AP36 (OR) X-138DRIVING LIGHTS SWITCH
87697780 2
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CONNECTOR X-139 - TURN LIGHTS SW
CONNECTOR X-139 - TURN LIGHTS SW

NUMBER
A 47L2 (VT) X-040TO MAIN HARNESS
X-139TURN LIGHTS SW
B G089 (BK) X-139TURN LIGHTS SW SP-G13
C 47R2 (VT) X-040TO MAIN HARNESS
X-139TURN LIGHTS SW
D 45RB (VT) X-139TURN LIGHTS SW X-040TO
MAIN HARNESS
E AP25 (OR) X-040TO MAIN HARNESS
X-139TURN LIGHTS SW
F 45LB (VT) X-139TURN LIGHTS SW X-040TO
MAIN HARNESS
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X-149
CONNECTOR X-140 - LEFT BRAKE LIGHT SWITCH
CONNECTOR X-140 - LEFT BRAKE LIGHT SWITCH

NUMBER
2 4405 (VT) X-140LEFT BRAKE LIGHT SWITCH
SP-031
3 AP33 (OR) SP-030 X-140LEFT BRAKE LIGHT
SWITCH
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CONNECTOR X-141 - RIGHT BRAKE LIGHT SWITCH
CONNECTOR X-141 - RIGHT BRAKE LIGHT SWITCH

NUMBER
2 4406 (VT) X-141RIGHT BRAKE LIGHT
SWITCH SP-031
3 AP34 (OR) SP-030 X-141RIGHT BRAKE LIGHT
SWITCH
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NUMBER
A 25B1 (YE) X-146 X-040TO MAIN HARNESS
B 21C5 (YE) X-146 X-040TO MAIN HARNESS
C 25A1 (LB) X-146 X-040TO MAIN HARNESS
D 19E4 (OR) X-146 X-040TO MAIN HARNESS
84165087 1
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CONNECTOR X-148 - TIMER
CONNECTOR X-148 - TIMER

NUMBER
30 19M1 (OR) X-013 X-148TIMER
85 2401 (YE) X-013 X-148TIMER
86 19E2 (OR) SP-067 X-148TIMER
87 G003 (BK) X-148TIMER X-487
84153826 2
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X-159
CONNECTOR X-150 - TO FRONT HARNESS (X-040)

NUMBER
1 4601 (VT) X-010FLASHER X-150TO FRONT
HARNESS (X-040)
2 AP28 (OR) SP-027 X-150TO FRONT HARNESS
(X-040)
3 45L0 (VT) SP-024 X-150TO FRONT HARNESS
(X-040)
4 8404 (RD) X-012 X-150TO FRONT HARNESS
(X-040)
5 45R0 (VT) SP-028 X-150TO FRONT HARNESS
(X-040)
6 64A1 (RD) X-012 X-150TO FRONT HARNESS
(X-040)
7 25B2 (YE) SP-112 X-150TO FRONT HARNESS
(X-040)
8 0432 (VT)
9 G162 (BK) X-150TO FRONT HARNESS (X-040)
X-487
10 47R1 (VT) X-010FLASHER X-150TO FRONT
HARNESS (X-040)
11 47L1 (VT) X-010FLASHER X-150TO FRONT
HARNESS (X-040)
12 AP29 (OR) SP-027 X-150TO FRONT HARNESS
(X-040)
13 - -
14 19E3 (OR) X-150TO FRONT HARNESS (X-040)
SP-067
15 2506 (BL) SP-011DE-CLUTCH SPLICE
X-150TO FRONT HARNESS (X-040)
16 25S1 (YE) X-051TO CHASSIS HARNESS
(X-040)
17 21C4 (YE) X-150TO FRONT HARNESS (X-040)
SP-130
18 25A2 (LB) SP-113 X-150TO FRONT HARNESS
(X-040)
19 4044 (OR) SP-052 X-150TO FRONT HARNESS
(X-040)
20 4051 (YE) SP-051 X-150TO FRONT HARNESS
(X-040)
21 64B2 (WH) X-150TO FRONT HARNESS (X-040)
(X-001)
22 2509 (BL) X-176DE-CLUTCH BREAK PRESS
SW X-150TO FRONT HARNESS
(X-040)
(X-040)
24 4035 (WH) SP-053 X-150TO FRONT HARNESS
(X-040)
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NUMBER
25 25E4 (LB) X-051TO CHASSIS HARNESS
(X-040)
26 G164 (BK) X-150TO FRONT HARNESS (X-040)
X-487
27 19E8 (OR) SP-067 X-150TO FRONT HARNESS
(X-040)
28 21A2 (YE) SP-066 X-150TO FRONT HARNESS
(X-040)
29 P018 (RD) X-012 X-150TO FRONT HARNESS
(X-040)
(X-040)
(X-040)
(X-040)
(X-040)
34 41F6 (VT) SP-094 X-150TO FRONT HARNESS
(X-040)
35 - -
36 - -
84146292 1
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CONNECTOR X-151 - HORN SWITCH
CONNECTOR X-151 - HORN SWITCH

NUMBER
E 64A2 (RD) X-040TO MAIN HARNESS
X-151HORN SWITCH
F 64B1 (WH) X-151HORN SWITCH X-040TO
MAIN HARNESS
87697780 2
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CONNECTOR X-155 - FOOT THROTTLE
CONNECTOR X-155 - FOOT THROTTLE

NUMBER
A 2161 (YE) X-155FOOT THROTTLE X-101TO
B 2201 (BL) X-155FOOT THROTTLE X-101TO
C 2181 (PK) X-155FOOT THROTTLE X-101TO
D - -
E 1201 (BL) X-155FOOT THROTTLE X-101TO
F - -
87699184 3
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X-179
CONNECTOR X-174 - GEAR SHFT LVR DECLUTCH
CONNECTOR X-174 - GEAR SHFT LVR DECLUTCH

NUMBER
A 2504 (BL) X-174GEAR SHFT LVR DECLUTCH
SP-011DE-CLUTCH SPLICE
B G006 (BK) X-174GEAR SHFT LVR DECLUTCH
X-487
87692855 1
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CONNECTOR X-175 - DE-CLUTCH SWITCH
CONNECTOR X-175 - DE-CLUTCH SWITCH

NUMBER
D 2507 (BL) X-175DE-CLUTCH SWITCH
E 2508 (BL) X-175DE-CLUTCH SWITCH
87697780 2
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CONNECTOR X-176 - DE-CLUTCH BREAK PRESS SW

NUMBER
A 2509 (BL) X-176DE-CLUTCH BREAK PRESS
SW X-150TO FRONT HARNESS
(X-040)
B 2505 (BL) X-176DE-CLUTCH BREAK PRESS
SW X-177DE-CLUTCH BREAK
PRESS SW
87692855 3
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NUMBER
A 2505 (BL) X-176DE-CLUTCH BREAK PRESS
SW X-177DE-CLUTCH BREAK
PRESS SW
B G005 (BK) X-487 X-177DE-CLUTCH BREAK
PRESS SW
87692855 4
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X-189
CONNECTOR X-181 - CIGARETTE LIGHTER 2

NUMBER
A 8401 (RD) SP-040 X-181CIGARETTE LIGHTER
2
B G068 (BK) X-181CIGARETTE LIGHTER 2
SP-G12
87697531 1
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NUMBER
A 8402 (RD) X-182CIGARETTE LIGHTER 1
SP-040
B G070 (BK) X-182CIGARETTE LIGHTER 1
SP-G12
87697531 2
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CONNECTOR X-187 - DIFF LOCK SWITCH
CONNECTOR X-187 - DIFF LOCK SWITCH

NUMBER
E 19EF (OR) X-187DIFF LOCK SWITCH X-040TO
MAIN HARNESS
F 25S6 (YE) X-187DIFF LOCK SWITCH X-040TO
MAIN HARNESS
87697780 3
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X-199
CONNECTOR X-193 - FRONT LH WORK LIGHT

NUMBER
1 41FA (VT) X-193FRONT LH WORK LIGHT
SP-099
2 G036 (BK) X-193FRONT LH WORK LIGHT
SP-009FRONT LIGHTS GROUND
87696093 1
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CONNECTOR X-194 - FRONT RH WORK LIGHT
CONNECTOR X-194 - FRONT RH WORK LIGHT

NUMBER
1 41FB (VT) X-194FRONT RH WORK LIGHT
SP-099
2 G037 (BK) X-194FRONT RH WORK LIGHT
SP-009FRONT LIGHTS GROUND
87696093 2
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NUMBER
1 45L4 (VT) X-196FRONT LH WORK LIGHT
SP-100
84120010 3
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CONNECTOR X-197 - FRONT RH SIGNAL LIGHT

NUMBER
1 G039 (BK) X-197FRONT RH SIGNAL LIGHT
SP-007
84120010 4
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NUMBER
1 G041 (BK) X-198FRONT LH WORK LIGHT
SP-007
84120010 5
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X-209

NUMBER
1 45R4 (VT) X-201FRONT RH SIGNAL LIGHT
SP-097
84120010 1
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X-229
CONNECTOR X-220 - HYD FILTER
CONNECTOR X-220 - HYD FILTER

NUMBER
1 36H1 (BL) X-220HYD FILTER X-001TO MAIN
(X-051)
87679525 1
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X-449

NUMBER
A1 E054 (RD) SP-151 X-448
A2 E010 (RD) X-448 X-461ECU
B1 E05A (RD) SP-151 X-448
B2 E052 (RD) SP-158 X-448
C1 E055 (RD) X-448 SP-151
C2 E057 (RD) X-448 SP-152
84423679 1
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X-469
CONNECTOR X-461 - ECU

NUMBER
1 E010 (RD) X-448 X-461ECU
2 G013 (BK) X-461ECU SP-153
3 E051 (RD) X-461ECU SP-158
4 G012 (BK) X-461ECU SP-153
5 E050 (RD) X-461ECU SP-158
6 G014 (BK) X-461ECU SP-153
7 E070 (YE) X-468LAMBDA SENSOR X-461ECU
8 E080 (YE) X-461ECU X-496TO MAIN HARN
(X-497)
9 - -
10 - -
11 - -
12 - -
13 - -
14 - -
15 - -
16 - -
17 - -
18 - -
19 E190 (YE) X-461ECU X-474AIR TEMP
SENSOR
20 E200 (BK/WH) X-461ECU X-474AIR TEMP
SENSOR
21 - -
22 E220 (YE) X-461ECU X-469GCU
23 - -
(X-497)
25 E251 (GN) X-461ECU X-496TO MAIN HARN
(X-497)
26 - -
(X-497)
28 E280 (BL) X-461ECU X-464MAIN RELAY
29 - -
30 E300 (YE) X-461ECU X-463WATER IN FUEL
SWITCH
31 - -
32 - -
33 - -
34 - -
35 - -
36 - -
37 - -
38 - -
39 - -
40 - -
41 E410 (BK) X-461ECU SP-203
42 - -
43 - -
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NUMBER
44 - -
45 - -
46 - -
47 - -
48 - -
49 - -
50 - -
51 - -
52 E520 (YE) X-461ECU X-469GCU
(X-497)
54 1505 (OR) X-461ECU SP-154
55 - -
56 - -
57 - -
58 - -
59 - -
60 - -
61 - -
62 - -
63 E630 (PK) X-468LAMBDA SENSOR X-461ECU
65 - -
66 - -
67 - -
(X-497)
69 - -
70 - -
71 - -
72 - -
73 - -
74 - -
75 - -
76 - -
77 - -
78 - -
79 E790 (BK/WH) X-461ECU X-476GAS TEMP
SENSOR 1 (UPSTREAM)
80 E800 (YE) X-461ECU X-476GAS TEMP
SENSOR 1 (UPSTREAM)
81 E810 (BK/WH) X-461ECU X-470ENGINE
INTERFACE
82 E820 (YE) X-461ECU X-470ENGINE
INTERFACE
SENSOR 2 (DOWNSTREAM)
85 E850 (BK) X-468LAMBDA SENSOR X-461ECU
86 E860 (YE) X-461ECU X-468LAMBDA SENSOR
87 - -
88 - -
89 - -
90 - -
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NUMBER
91 - -
92 - -
93 - -
94 - -
84474047 1
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NUMBER
1 F010 (WH) X-471ELECTRIC VALVE X-462ECU
3 - -
4 F040 (GY) X-462ECU X-470ENGINE
INTERFACE
5 - -
6 F060 (WH) X-470ENGINE INTERFACE
X-462ECU
7 - -
8 F080 (PK) X-462ECU X-470ENGINE
INTERFACE
INTERFACE
INTERFACE
11 F110 (PK) X-470ENGINE INTERFACE
X-462ECU
INTERFACE
X-462ECU
14 F140 (YE) X-470ENGINE INTERFACE
X-462ECU
X-462ECU
18 - -
19 - -
20 - -
21 - -
22 - -
23 F230 (BL) X-470ENGINE INTERFACE
X-462ECU
24 F240 (BK/WH) X-462ECU X-470ENGINE
INTERFACE
INTERFACE
X-462ECU
INTERFACE
X-462ECU
29 - -
30 - -
31 F310 (GY) X-471ELECTRIC VALVE X-462ECU
33 - -
INTERFACE
INTERFACE
36 - -
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NUMBER
INTERFACE
X-462ECU
39 F390 (YE) X-462ECU X-470ENGINE
INTERFACE
INTERFACE
X-462ECU
42 - -
INTERFACE
X-462ECU
45 - -
47 - -
49 F490 (WH) X-462ECU X-470ENGINE
INTERFACE
INTERFACE
51 - -
52 - -
INTERFACE
54 - -
INTERFACE
56 - -
X-462ECU
X-462ECU
X-462ECU
60 F600 (GY) X-470ENGINE INTERFACE
X-462ECU
84474053 2
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CONNECTOR X-463 - WATER IN FUEL SWITCH
CONNECTOR X-463 - WATER IN FUEL SWITCH

NUMBER
1 E300 (YE) X-461ECU X-463WATER IN FUEL
SWITCH
2 G015 (BK) X-463WATER IN FUEL SWITCH
SP-153
3 1504 (OR) X-463WATER IN FUEL SWITCH
SP-154
87709663 3
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CONNECTOR X-464 - MAIN RELAY
CONNECTOR X-464 - MAIN RELAY

NUMBER
1 E280 (BL) X-461ECU X-464MAIN RELAY
2 1015 (RD) X-464MAIN RELAY SP-157
3 E053 (RD) X-464MAIN RELAY SP-151
5 1014 (RD) X-464MAIN RELAY SP-157
84471904 4
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CONNECTOR X-466 - GCU FUSE HOLDER 1
CONNECTOR X-466 - GCU FUSE HOLDER 1

NUMBER
1 F2 (OR) X-466GCU FUSE HOLDER 1 SP-155
2 F1 (OR) SP-156 X-466GCU FUSE HOLDER 1
84177914 5
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CONNECTOR X-468 - LAMBDA SENSOR
CONNECTOR X-468 - LAMBDA SENSOR

NUMBER
2 E850 (BK) X-468LAMBDA SENSOR X-461ECU
4 E056 (RD) X-468LAMBDA SENSOR SP-152
5 E860 (YE) X-461ECU X-468LAMBDA SENSOR
6 E630 (PK) X-468LAMBDA SENSOR X-461ECU
84301132 6
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CONNECTOR X-469 - GCU
CONNECTOR X-469 - GCU

NUMBER
1 1580 (WH) X-470ENGINE INTERFACE
X-469GCU
X-469GCU
3 E220 (YE) X-461ECU X-469GCU
4 1040 (RD) SP-155 X-469GCU
5 E411 (BK) X-469GCU SP-203
X-469GCU
X-469GCU
8 E520 (YE) X-461ECU X-469GCU
84356962 7
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X-479
CONNECTOR X-470 - ENGINE INTERFACE

NUMBER
X-462ECU
2 F600 (GY) X-470ENGINE INTERFACE
X-462ECU
X-462ECU
X-462ECU
X-462ECU
X-462ECU
X-462ECU
X-462ECU
X-462ECU
X-462ECU
11 - -
X-462ECU
X-462ECU
X-462ECU
X-462ECU
X-462ECU
INTERFACE
INTERFACE
INTERFACE
INTERFACE
INTERFACE
INTERFACE
INTERFACE
24 - -
25 E810 (BK/WH) X-461ECU X-470ENGINE
INTERFACE
26 E820 (YE) X-461ECU X-470ENGINE
INTERFACE
INTERFACE
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NUMBER
28 E058 (RD) SP-152 X-470ENGINE INTERFACE
INTERFACE
INTERFACE
31 - -
32 - -
INTERFACE
INTERFACE
INTERFACE
36 - -
INTERFACE
INTERFACE
39 - -
40 - -
INTERFACE
INTERFACE
INTERFACE
44 - -
45 - -
46 - -
47 - -
48 - -
49 - -
50 - -
51 - -
52 - -
53 - -
54 - -
55 - -
56 - -
X-469GCU
X-469GCU
59 - -
X-469GCU
X-469GCU
62 - -
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84154706 1
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CONNECTOR X-471 - ELECTRIC VALVE
CONNECTOR X-471 - ELECTRIC VALVE

NUMBER
A F160 (WH) X-471ELECTRIC VALVE X-462ECU
B F320 (GY) X-471ELECTRIC VALVE X-462ECU
C F310 (GY) X-471ELECTRIC VALVE X-462ECU
D F010 (WH) X-471ELECTRIC VALVE X-462ECU
E F170 (WH) X-471ELECTRIC VALVE X-462ECU
F F480 (GY) X-471ELECTRIC VALVE X-462ECU
G F460 (GY) X-471ELECTRIC VALVE X-462ECU
H F020 (WH) X-471ELECTRIC VALVE X-462ECU
J - -
K - -
87698252 2
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CONNECTOR X-474 - AIR TEMP SENSOR
CONNECTOR X-474 - AIR TEMP SENSOR

NUMBER
1 E190 (YE) X-461ECU X-474AIR TEMP
SENSOR
2 E200 (BK/WH) X-461ECU X-474AIR TEMP
SENSOR
84607243 3
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CONNECTOR X-476 - GAS TEMP SENSOR 1 (UPSTREAM)
CONNECTOR X-476 - GAS TEMP SENSOR 1 (UPSTREAM)

NUMBER
SENSOR 1 (UPSTREAM)
SENSOR 1 (UPSTREAM)
87709793 4
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CONNECTOR X-477 - GAS TEMP SENSOR 2 (DOWNSTREAM)
CONNECTOR X-477 - GAS TEMP SENSOR 2 (DOWNSTREAM)

NUMBER
87709793 5
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CONNECTOR X-478 - STARTER/BATT+ JUNCTION TERMINAL
CONNECTOR X-478 - STARTER/BATT+ JUNCTION TERMINAL

NUMBER
1 ALT1 (RD) X-481 X-478STARTER/BATT+
P002 (RD) JUNCTION TERMINAL
X-478STARTER/BATT+ JUNCTION
TERMINAL X-122TO MAIN (X-123)
84138833 6
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X-489

NUMBER
1 ALT1 (RD) X-481 X-478STARTER/BATT+
JUNCTION TERMINAL
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NUMBER
1 G016 (BK) SP-008CHASSIS GROUND X-485
G158 (BK) SP-G08 X-485
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NUMBER
1 G003 (BK) X-148TIMER X-487
G005 (BK) X-487 X-177DE-CLUTCH BREAK
G006 (BK) PRESS SW
G017 (BK) X-174GEAR SHFT LVR DECLUTCH
G018 (BK) X-487
G026 (BK) X-101TO ROPS HARNESS (X-020)
G076 (BK) X-487
G081 (BK) X-487 X-101TO ROPS HARNESS
G100 (BK) (X-020)
G162 (BK) X-013 X-487
G164 (BK) X-009VEHICLE DIAGNOSTIC X-487
G342 (BK) X-013 X-487
X-010FLASHER X-487
X-487
X-487
SP-G56 X-487
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NUMBER
G019 (BK) X-488
G064 (BK) X-101TO ROPS HARNESS (X-020)
G065 (BK) X-488
G073 (BK) X-013 X-488
G074 (BK) X-013 X-488
G077 (BK) X-017 X-488
G079 (BK) X-016 X-488
G346 (BK) X-013 X-488
X-013 X-488
X-012 X-488
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X-499
CONNECTOR X-496 - TO MAIN HARN (X-497)
CONNECTOR X-496 - TO MAIN HARN (X-497)

NUMBER
A E530 (YE) X-461ECU X-496TO MAIN HARN
(X-497)
B E681 (YE) X-461ECU X-496TO MAIN HARN
(X-497)
C 150A (OR) X-496TO MAIN HARN (X-497)
SP-154
D E080 (YE) X-461ECU X-496TO MAIN HARN
(X-497)
E E251 (GN) X-461ECU X-496TO MAIN HARN
(X-497)
F E270 (YE) X-461ECU X-496TO MAIN HARN
(X-497)
G - -
H - -
J - -
K E241 (YE) X-461ECU X-496TO MAIN HARN
(X-497)
87698252 1
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NUMBER
A E173 (YE) X-012 X-497
B E682 (YE) X-009VEHICLE DIAGNOSTIC X-497
C 150B (OR) SP-012 X-497
D E081 (YE) SP-066 X-497
E E252 (GN) SP-208 X-497
F E373 (YE) X-012 X-497
G - -
H - -
J - -
K E242 (YE) SP-207 X-497
87698254 2
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CONNECTOR X-498 - TELEMATICS MODULE
CONNECTOR X-498 - TELEMATICS MODULE

NUMBER
1 G340 (BK) X-498TELEMATICS MODULE
SP-G56
2 3P13 (OR) X-498TELEMATICS MODULE X-012
3 E245 (YE) X-498TELEMATICS MODULE
SP-207
4 E255 (GN) X-498TELEMATICS MODULE
SP-208
5 - -
6 1710 (LB) X-498TELEMATICS MODULE
X-499TELEMATICS DIAGNOSTIC
7 1720 (TN) X-498TELEMATICS MODULE
8 3404 (YE) SP-204 X-498TELEMATICS
MODULE
9 - -
10 - -
11 - -
12 1022 (RD) X-498TELEMATICS MODULE
(X-001)
87700156 3
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CONNECTOR X-499 - TELEMATICS DIAGNOSTIC
CONNECTOR X-499 - TELEMATICS DIAGNOSTIC

NUMBER
1 G341 (BK) X-499TELEMATICS DIAGNOSTIC
SP-G56
2 1720 (TN) X-498TELEMATICS MODULE
3 1710 (LB) X-498TELEMATICS MODULE
4 - -
87694101 4
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X-509
CONNECTOR X-500 - GRD

NUMBER
1 G008 (BK) X-500GRD SP-007
84120010 1
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NUMBER
1 1041 (RD) SP-156 X-508
P011 (RD) X-508 SP-157
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NUMBER
1 1501 (OR) X-083ALT X-509
2 1502 (OR) X-509 X-001TO MAIN (X-051)
87711966 2
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X-519

NUMBER
1 G011 (BK) SP-153 X-510
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CONNECTOR X-512 - REAR RH SIGNAL LIGHT

NUMBER
1 0436 (VT) SP-118 X-512REAR RH SIGNAL
LIGHT
2 G165 (BK) X-512REAR RH SIGNAL LIGHT
SP-010REAR LIGHTS GROUND
87696093 1
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CONNECTOR X-513 - REAR LH WORK LIGHTS
CONNECTOR X-513 - REAR LH WORK LIGHTS

NUMBER
1 0435 (VT) SP-118 X-513REAR LH WORK
LIGHTS
2 G166 (BK) X-513REAR LH WORK LIGHTS
SP-010REAR LIGHTS GROUND
87696093 2
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X-529

NUMBER
1 45R5 (VT) X-520REAR RH SIGNAL LIGHT
SP-097
84120010 1
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NUMBER
1 G163 (BK) X-521GRD SP-007
84120008 2
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CONNECTOR X-524 - BREAK LIGHT
CONNECTOR X-524 - BREAK LIGHT

NUMBER
1 440B (VT) X-020TO MAIN HARNESS
X-524BREAK LIGHT
84120010 3
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CONNECTOR X-525 - REAR LH SIGNAL LIGHT
CONNECTOR X-525 - REAR LH SIGNAL LIGHT

NUMBER
1 45L5 (VT) X-525REAR LH SIGNAL LIGHT
SP-100
84120010 4
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NUMBER
1 G169 (BK) X-526GRD SP-007
84120010 5
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CONNECTOR X-528 - TAIL LIGHTS
CONNECTOR X-528 - TAIL LIGHTS

NUMBER
X-528TAIL LIGHTS
84120010 6
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X-539
CONNECTOR X-535 - TELEMATICS BATT+ JUNCTION TERMINAL/DISCONNECT SW
CONNECTOR X-535 - TELEMATICS BATT+ JUNCTION TERMINAL/DISCONNECT SW

NUMBER
1 1024 (RD) X-535TELEMATICS BATT+
JUNCTION TERMINAL/
DISCONNECT SW SP-218
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CONNECTOR X-538 - TELEMATICS BATT+ FUSEHOLDER
CONNECTOR X-538 - TELEMATICS BATT+ FUSEHOLDER

NUMBER
1 F4 (OR) SP-219 X-538TELEMATICS BATT+
FUSEHOLDER
2 F3 (OR) SP-218 X-538TELEMATICS BATT+
FUSEHOLDER
87635519 1
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X-829

NUMBER
A 21B3 (WH) X-001TO MAIN (X-051)
X-820STARTER MTR
87697527 1
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87691967 2
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X-9009
Connector X-9003 - Intake manifold pressure and temperature sensor
Over 56kW engines

CONNECTOR X-9003 - Intake manifold pressure and temperature sensor
NUMBER
1 EN-9103 Ground SHEET 06
2 EN-9104 Temperature signal
3 EN-9101 Supply
4 EN-9102 Pressure signal
Under 56kW engines

CONNECTOR X-9003 - Intake manifold pressure and temperature sensor
NUMBER
2 - -
3 EN-9101 Supply SHEET 06
4 EN-9102 Pressure signal
NHIS14ENG0977AA 1
Connector X-9003 is located on top of the engine.
NHIS14ENG0983AA 2
Connector X-9003 is located near the cylinder 2 injector.
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87709809 3
Connector X-9005 - Fuel temperature sensor
CONNECTOR X-9005 - Fuel temperature sensor

NUMBER
1 EN-9117 Signal SHEET 06
2 EN-9116 Ground
NHIS14ENG0977AA 4
Connector X-9005 is located at the rear of the engine.
NHIS14ENG0988AA 5
Connector X-9005 is located above the fuel filter.
Connector X-9006 - Coolant temperature sensor
CONNECTOR X-9006 - Coolant temperature sensor

NUMBER
2 EN-9114 Ground
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NHIS14ENG0977AA 6
Connector X-9006 is located at the front of the engine.
NHIS14ENG0975AA 7
Connector X-9006 is located near the water pump.
Connector X-9007 - Fuel metering unit
CONNECTOR X-9007 - Fuel metering unit

NUMBER
1 EN-9137 Supply SHEET 06
2 EN-9136 Ground
NHIS14ENG0977AA 8
Connector X-9007 is located on the front left-hand side of the engine.
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NHIS14ENG0987AA 9
Connector X-9007 is near the fuel pump.
87709798 10
Connector X-9008 - Camshaft speed sensor
CONNECTOR X-9008 - Camshaft speed sensor

NUMBER
2 EN-9111 Signal
3 EN-9109 Supply
NHIS14ENG0977AA 11
Connector X-9008 is located at the front of the engine.
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NHIS14ENG0974AA 12
Connector X-9007 is located near the crank pulley.
Connector X-9009 - Exhaust manifold temperature sensor
CONNECTOR X-9009 - Exhaust manifold temperature sensor

NUMBER
2 EN-9119 Ground
NHIS14ENG0977AA 13
NHIS14ENG0983AA 14
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X-9019
Connector X-9010 - Exhaust gas recirculation valve
CONNECTOR X-9010 - Exhaust gas recirculation valve

NUMBER
1 EN-9095 Actuator supply SHEET 06
2 EN-9093 Signal
3 - -
5 EN-9096 Actuator supply
6 EN-9094 Sensor supply
NHIS14ENG0978AA 1
Connector X-9010 is located at the top rear of the engine.
NHIS14ENG0982AA 2
Connector X-9011 - Throttle valve actuator
CONNECTOR X-9011 - Throttle valve actuator

NUMBER
1 EN-9098 Sensor supply SHEET 06
3 EN-9100 Ground
4 - -
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NHIS14ENG0977AA 3
Connector X-9011 is located at the top front of the engine.
NHIS14ENG0990AA 4
Connector X-9011 is located above the cylinder 1 injector.
Connector X-9016 - Oil pressure switch
CONNECTOR X-9016 - Oil pressure switch

NUMBER
NHIS14ENG0977AA 5
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NHIS14ENG0988AA 6
Connector X9016 is located above the oil filter.
Connector X-9018 - Exhaust gas pressure sensor
CONNECTOR X-9018 - Exhaust gas pressure sensor

NUMBER
1 EN-9143 Sensor supply SHEET 06
2 EN-9118 Sensor ground
3 EN-9120 Sensor signal
84146681 7
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X-9029
Connector X-9020 - Intake manifold temperature sensor
CONNECTOR X-9020 - Intake manifold temperature sensor

NUMBER
2 EN-9174 Ground
NHIS14ENG0977AA 1
NHIS14ENG0983AA 2
Connector X-9021 - Crankshaft speed sensor
CONNECTOR X-9021 - Crankshaft speed sensor

NUMBER
2 EN-9112 Ground
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NHIS14ENG0977AA 3
Connector X-9021 is located on the left-hand side of the engine.
NHIS14ENG0976AA 4
Connector X-9021 is located on the left-hand side of the engine block.
87709793 5
Connector X-9026 - Rail pressure sensor
CONNECTOR X-9026 - Rail pressure sensor

NUMBER
2 EN-9107 Signal
3 EN-9108 Supply
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NHIS14ENG0978AA 6
Connector X-9026 is located at the left, rear, top of the engine.
NHIS14ENG0989AA 7
Connector X-9026 is at the rear of the fuel rail.
84130322 8
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X-9039
Connector X-9030 - Cylinder 1 injector (Bank 1 Injector 1)
CONNECTOR X-9030 - Cylinder 1 injector (Bank 1 Injector 1)

NUMBER
1 INJ-268 High side driver SHEET 06
2 INJ-269 Low side driver
NHIS14ENG0977AA 1
Connector X-9030 is located at the top, front of the engine.
NHIS14ENG0983AA 2
Connector X-9030 is connected to the cylinder 1 fuel injector.

NUMBER
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NHIS14ENG0977AA 3
NHIS14ENG0983AA 4
Connector X-9031 is connected to the cylinder 3 injector.

NUMBER
NHIS14ENG0977AA 5
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NHIS14ENG0982AA 6

NUMBER
NHIS14ENG0977AA 7
NHIS14ENG0983AA 8
Connector X-9034 - Glow plug 1
CONNECTOR X-9034 - Glow plug 1

NUMBER
1 GP-9001 Control signal, Pulse Width SHEET 06
Modulated (PWM)
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NHIS14ENG0977AA 9
NHIS14ENG0981AA 10
Connector X-9034 is connected to the cylinder 1 glow plug. (Under 56 kW (76 Hp) shown; over 56 kW (76 Hp)
cylinder 1 glow plug is on the side of the cylinder head.)

NUMBER
Modulated (PWM)
NHIS14ENG0977AA 11
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NHIS14ENG0980AA 12

NUMBER
Modulated (PWM)
NHIS14ENG0977AA 13
NHIS14ENG0980AA 14
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NUMBER
Modulated (PWM)
NHIS14ENG0977AA 15
NHIS14ENG0980AA 16
Connector X-9038 - Wastegate pressure modulator valve
CONNECTOR X-9038 - Wastegate pressure modulator valve

NUMBER
1 EN-9024 Actuator supply SHEET 06
2 EN-9133 Low side driver
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NHIS14ENG0977AA 17
Connector X-9038 is located at the top front of the engine.
NHIS14ENG0991AA 18
Connector X-9038 is connected to the waste gate pressure modulator valve.
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X-9049
Connector X-9040 - Engine harness to glow plug harness
CONNECTOR X-9040 - Engine harness to glow plug harness

NUMBER
A EN-9058 Supply voltage, cylinder 1 glow plug SHEET 06
GP-9001
B EN-9059 Supply voltage, cylinder 2 glow plug
GP-9002
C EN-9060 Supply voltage, cylinder 3 glow plug
GP-9003
D EN-9061 Supply voltage, cylinder 4 glow plug
GP-9004
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X-9109
Connector X-9104 - Selective Catalytic Reduction (SCR) downstream exhaust gas temperature sensor
CONNECTOR X-9104 - Selective Catalytic Reduction (SCR) downstream exhaust gas temperature sensor
NUMBER
1 VE-9149 Signal SHEET 03
2 VE-9169 Reference ground
Connector X-9106 - Diesel Oxidation Catalyst (DOC) upstream exhaust gas temperature sensor
CONNECTOR X-9106 - Diesel Oxidation Catalyst (DOC) upstream exhaust gas temperature sensor
NUMBER
Connector X-9107 - Selective Catalytic Reduction (SCR) upstream exhaust gas temperature sensor
CONNECTOR X-9107 - Selective Catalytic Reduction (SCR) upstream exhaust gas temperature sensor
NUMBER
Connector X-9108 - Diesel Exhaust Fluid (DEF)/AdBlue® supply module
CONNECTOR X-9108 - DEF/AdBlue® supply module

NUMBER
1 - -
2 VE-9165 Low Side Driver (LSD), Diesel SHEET 02
Exhaust Fluid (DEF)/AdBlue® pump
motor control signal
3 VE-9031 Supply, Diesel Exhaust Fluid
(DEF)/AdBlue® pump motor
4 VE-9092 Battery negative (for bonding
purposes)
5 VE-9083 Supply, back flow pump
6 VE-9122 Ground, back flow pump
7 - -
8 VE-9124 Reference ground, Diesel Exhaust SHEET 02
Fluid (DEF)/AdBlue® pressure
sensor
9 VE-9123 Signal, Diesel Exhaust Fluid
(DEF)/AdBlue® pressure sensor
10 VE-1923 5V supply, Diesel Exhaust Fluid
(DEF)/AdBlue® pressure sensor
11 VE-9086 Controlled supply, module heater
12 VE-9091 Ground
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X–9119
Connector X-9110 -Diesel Exhaust Fluid (DEF)/AdBlue® dosing module
CONNECTOR X-9110 -Diesel Exhaust Fluid (DEF)/AdBlue® dosing module

NUMBER
1 VE-9138 Low Side Driver (LSD) SHEET 06
2 VE-9139 High Side Driver (HSD)
87709798 1
Connector X-9111 - Heater Control Unit (HCU)
CONNECTOR X-9111 -Heater Control Unit (HCU)

NUMBER
G1 VE-9086 Diesel Exhaust Fluid (DEF)/AdBlue® SHEET 02
supply module, heater supply
G2 VE-9084 Diesel Exhaust Fluid (DEF)/AdBlue®
tank supply and back-flow lines,
heater supply
G3 - -
G4 VE-9085 Diesel Exhaust Fluid (DEF)/AdBlue®
supply module pressure line, heater
supply
G5 - -
87 VE-9025 Switched supply
31 VE-9087 Ground
G6 - -
D1 VE-9079 Controller Area Network (CAN) 2 low
30 VE-9054 Battery supply
ST VE-9080 Controller Area Network (CAN) 2 high
Connector X-9112 - Selective Catalytic Reduction (SCR) tank heating valve
CONNECTOR X-9112 - Selective Catalytic Reduction (SCR) tank heating valve

NUMBER
1 VE-9082 Supply SHEET 02
2 - -
3 VE-9199 Low Side Driver (LSD)
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Connector X-9113 - Glow plug control module
Over 56kW (76hp) engines

CONNECTOR X-9113 - Glow plug control module
NUMBER
1 VE-9060 Controlled supply, glow plug 3 SHEET 02
2 VE-9058 Controlled supply, glow plug 1
3 VE-9073 Feedback signal
8 VE-0972 Control signal
Under 56kW (76hp) engines

CONNECTOR X-9113 - Glow plug control module
NUMBER
1 VE-9060 Controlled supply, glow plug 3 SHEET 02
3 VE-9073 Feedback signal
8 VE-0971 Control signal
84356962 3
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Connector X-9114 - Diagnostic and monitoring connector
CONNECTOR X-9114 - Diagnostic and monitoring connector

NUMBER
A VE-9008 Ground SHEET 03
B VE-9069 Battery voltage
C VE-9067 Controller Area Network (CAN) 1 high
D VE-9068 Controller Area Network (CAN) 1 low
E VE-9070 ISO K-line
47618613 4
Connector X-9115 - Fuel filter heater relay
CONNECTOR X-9115 - Fuel filter heater relay

NUMBER
30 VE-9063 Fused battery
87 VE-9075 switched supply to heater
87A - -
NOTE: Relay connector and conductor naming and numbering conventions are representative – used for engine
diagnostics and schematic referencing. Use machine schematics for exact relay/wiring numbering and pinout.
Connector X-9116 – Cold start bypass valve relay
CONNECTOR X-9116 – Cold start bypass valve relay

NUMBER
30 see product schematics From vehicle power distribution
87 see product schematics Switched supply to cold start bypass
valve
87A - -
Connector X-9117 - Intake air temperature sensor
CONNECTOR X-9117 - Intake air temperature sensor

NUMBER
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X-9129
Connector X-9120 - Starter control relay
CONNECTOR X-9120 - Starter control relay

NUMBER
30 VE-9044 Controlled supply, vehicle controlled SHEET 01
relay
85 VE-9057 High Side Driver (HSD)
87 VE-9055 Controlled signal, starter relay
87A - -
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Connector X-9121 - Engine Control Unit (ECU) connector A

CONNECTOR X-9121 - ECU connector A
NUMBER
A01 VE-9128 High Side Driver (HSD), bank 2 SHEET 05
injector 1 (cylinder 3)
A02 VE-9132 High Side Driver (HSD), bank 2
A03 VE-9138 Low Side Driver (LSD), Diesel
Exhaust Fluid (DEF)/AdBlue® dosing
valve
A04 VE-9133 Low side driver (LSD), waste gate
pressure modulator valve
A05 VE-9124 Reference ground, Diesel Exhaust
Fluid (DEF)/AdBlue® supply module
pressure sensor
A06 VE-9105 Input signal, oil pressure switch
A07 VE-1923 +5 V sensor supply, Diesel Exhaust
pressure sensor
A08 VE-9098 +5 V sensor supply, Throttle Valve
Actuator (TVA) position sensor
A09 VE-9094 +5 V sensor supply, Exhaust Gas
Recirculation (EGR) valve position
sensor
A10 VE-9101 +5 V sensor supply, intake manifold
pressure sensor
A11 VE-9108 +5 V sensor supply, rail pressure
sensor
A12 VE-9138 +5 V sensor supply, exhaust manifold
temperature sensor
A13 VE-9109 +5 V sensor supply, camshaft speed
sensor
A14 VE-9111 Input signal, camshaft speed sensor
A15 VE-9137 Switched voltage supply, fuel
metering unit
A18 VE-9139 High Side Driver (HSD), Diesel
valve
A19 - -
A20 VE-9026 Low side switch, Selective Catalytic SHEET 05
Reduction (SCR) main relay
A21 - -
A22 - -
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NUMBER
A23 VE-9116 Reference ground, fuel temperature SHEET 05
sensor
A24 VE-9097 Reference ground, Exhaust Gas
sensor
A25 VE-9103 Reference ground, intake manifold
pressure sensor
A26 VE-9106 Reference ground, rail pressure
sensor
A27 VE-9119 Reference ground, exhaust manifold
temperature sensor
A28 VE-9110 Reference ground, camshaft speed
sensor
A29 - -
A30 - -
A31 VE-9127 Low Side Driver (LSD), bank 2 SHEET 05
A32 VE-9126 Low Side Driver (LSD), bank 1
A33 - -
A34 VE-9135 H-bridge Pulse-Width Modulated SHEET 05
(PWM) supply, Throttle Valve
Actuator (TVA) motor
A35 VE-9096 H-bridge Pulse-Width Modulated
(PWM) supply, Exhaust Gas
Recirculation (EGR) motor
A36 - -
A37 VE-9100 Reference ground, Throttle Valve SHEET 05
A38 VE-9117 Input signal, fuel temperature sensor
A39 VE-9093 Input signal, Exhaust Gas
Recirculation (EGR) position
sensor
A40 VE-9102 Input signal, intake manifold pressure
sensor
A41 VE-9107 Input signal, rail pressure sensor
A42 - -
A43 VE-9121 Input signal, exhaust manifold SHEET 05
temperature sensor
A44 VE-9112 Input signal, negative, crankshaft
position sensor
Exhaust Fluid (DEF)/AdBlue® supply
module purging solenoid
A46 VE-9131 Low Side Driver (LSD), Bank 2
Injector 2 (Cylinder 2)
A47 - -
A48 VE-9130 Low Side Driver (LSD), Bank 1 SHEET 05
A51 - -
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NUMBER
A52 - -
A53 VE-9099 Input signal, Throttle Valve Actuator SHEET 05
(TVA) position sensor
A54 - -
A55 VE-9104 Input signal, intake manifold
temperature sensor
A56 VE-9123 Input signal, Diesel Exhaust Fluid SHEET 05
(DEF)/AdBlue® supply module
pressure sensor
A57 VE-9115 Input signal, coolant temperature
sensor
A58 VE-9114 Reference ground, coolant
temperature sensor
A59 VE-9113 Input signal, positive, crankshaft
position sensor
A60 VE-9136 Low Side Driver (LSD), fuel metering
unit

NUMBER
A01 VE-9128 High Side Driver (HSD), Bank 2 SHEET 05
A02 VE-9132 High Side Driver (HSD), Bank 2
A03 VE-9138 Low side driver (LSD), Diesel Exhaust
Fluid (DEF)/AdBlue® dosing valve
A04 VE-9133 Low side driver (LSD), Waste gate
pressure modulator valve
A05 VE-9124 Reference ground, Diesel Exhaust
pressure sensor
A06 VE-9105 Input signal, Oil pressure switch
A07 VE-1923 +5 V sensor supply, Diesel Exhaust
pressure sensor
A08 VE-9098 +5 V sensor supply, Throttle Valve
A09 VE-9094 +5 V sensor supply, Exhaust Gas
sensor
A10 VE-9101 +5 V sensor supply, Intake manifold
pressure sensor
A11 VE-9108 +5 V sensor supply, Rail pressure
sensor
A12 - -
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NUMBER
A13 VE-9109 +5 V sensor supply, Camshaft speed SHEET 05
sensor
A14 VE-9111 Input signal, Camshaft speed sensor
A15 VE-9137 Switched voltage supply, Fuel
metering unit
A18 VE-9139 High Side Driver (HSD), Diesel
valve
A19 - -
A20 VE-9026 Low side switch, Selective Catalytic SHEET 05
Reduction (SCR) main relay
A21 - -
A22 - -
A23 VE-9116 Reference ground, Fuel temperature SHEET 05
sensor
A24 VE-9097 Reference ground, Exhaust Gas
sensor
A25 VE-9103 Reference ground, Intake manifold
pressure sensor
A26 VE-9106 Reference ground, Rail pressure
sensor
A27 VE-9118 Reference ground, Exhaust manifold
pressure sensor
A28 VE-9110 Reference ground, Camshaft speed
sensor
A29 - -
A30 - -
A33 - -
A34 VE-9135 H-bridge Pulse-Width Modulated SHEET 05
A36 - -
A37 VE-9100 Reference ground, Throttle Valve SHEET 05
A38 VE-9117 Input signal, Fuel temperature sensor
A39 VE-9093 Input signal, Exhaust Gas
Recirculation (EGR) position
sensor
A40 VE-9102 Input signal, Intake manifold pressure
sensor
A41 VE-9107 Input signal, Rail pressure sensor
A42 - -
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NUMBER
A43 VE-9120 Input signal, Exhaust manifold SHEET 05
pressure sensor
A44 VE-9112 Input signal, negative, Crankshaft
position sensor
module purging solenoid
A47 - -
A51 - -
A52 - -
A53 VE-9099 Input signal, Throttle Valve Actuator SHEET 05
(TVA) position sensor
A54 - -
A55 VE-9104 Input signal, Intake manifold
temperature sensor
A56 VE-9123 Input signal, Diesel Exhaust Fluid SHEET 05
(DEF)/AdBlue® supply module
pressure sensor
A57 VE-9115 Input signal, Coolant temperature
sensor
A58 VE-9114 Reference ground, Coolant
temperature sensor
A59 VE-9113 Input signal, positive, Crankshaft
position sensor
A60 VE-9136 Low Side Driver (LSD), Fuel metering
unit
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Connector X-9122 - Engine Control Unit (ECU) connector K

CONNECTOR X-9122 - ECU connector K
NUMBER
K01 VE-9017 Main relay switched fused supply, SHEET 04
independent source
K02 VE-9158 Ground, Battery minus (negative)
terminal
K03 VE-9141 Main relay switched fused supply,
shared source (K05)
terminal
shared source (K03)
terminal
K07 VE-9161 Low Side Driver (LSD), Diesel
Exhaust Fluid (DEF)/AdBlue® tank
heating valve
K08 VE-9048 Input signal, Key switch start position
K09 - -
K10 - -
K11 - -
K12 - -
K13 - -
K14 - -
K15 - -
K16 - -
K17 - -
K18 VE-9143 +5 V sensor supply, Exhaust manifold SHEET 04
pressure sensor
K19 VE-9144 Input signal, Intake air temperature
sensor
K20 VE-9162 Reference ground, Intake air
temperature sensor
K21 - -
K22 VE-9073 Input signal, Glow-plug Control Unit SHEET 04
(GCU) feedback
K23 VE-9150 CAN 2 High, Selective Catalytic
Reduction (SCR) devices
K24 VE-9068 CAN 1 High, Diagnostic and
maintenance connector
K25 VE-9067 CAN 1 Low, Diagnostic and
K26 VE-9072 Low Side Driver (LSD), GCU relay
K27 VE-9056 Low Side Driver (LSD), Starter control
relay
K28 VE-9018 Low Side Driver (LSD), Main relay
K29 - -
K30 VE-9077 Input signal, Water in fuel switch SHEET 04
K31 - -
k32 - -
K33 - -
K34 - -
K35 - -
K36 - -
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NUMBER
K37 VE-9118A Reference ground, Exhaust manifold SHEET 04
pressure sensor
K38 - -
K39 - -
K40 - -
K41 VE-9074 Reference ground, Glowplug Control SHEET 04
Unit (GCU)
K42 - -
K43 - -
K44 - -
K45 VE-9151 CAN 2 Low, Selective Catalytic SHEET 04
K46 - -
K47 - -
K48 - -
K49 - -
K50 - -
K51 - -
K52 - -
K53 VE-9057 High Side Driver (HSD), Starter SHEET 04
control relay
K54 VE-9053 Input signal, Key switch ON/ACC
position
K55 - -
K56 VE-9145 Input signal, Upstream Diesel SHEET 04
Oxidation Catalyst (DOC) exhaust
gas temperature sensor
K57 VE-9120A Input signal, Exhaust manifold
pressure sensor
K58 - -
K59 - -
K60 - -
K61 - -
K62 - -
K63 - -
K64 - -
K65 VE-9164 Reference ground, upstream Diesel SHEET 04
K66 - -
K67 - -
K68 VE-9070 ISO-K Interface, Diagnostic and SHEET 04
monitoring connector K-line
K69 - -
K70 VE-9064 Low Side Driver (LSD), Fuel filter SHEET 04
heating relay
K71 - -
K72 VE-9166 Low Side Driver (LSD), Diesel SHEET 04
module pump motor
K73 - -
K74 - -
K75 - -
K76 VE-9167 Input signal, Diesel Exhaust Fluid SHEET 04
(DEF)/AdBlue® supply module pump
motor and temperature data
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NUMBER
K77 - -
K78 - -
K79 VE-9169 Reference ground, Downstream SHEET 04
Selective Catalytic Reduction(SCR)
temperature sensor
K80 VE-9149 Input signal, Downstream Selective
Catalytic Reduction(SCR)tempera-
ture sensor
K81 VE-9170 Reference ground, Upstream
Selective Catalytic Reduction(SCR)
temperature sensor
K82 VE-9171 Input signal, Upstream Selective
Catalytic Reduction(SCR)
temperature sensor
K83 - -
K84 - -
K85 - -
K86 - -
K87 - -
K88 - -
K89 - -
K90 - -
K91 - -
K92 - -
K93 - -
K94 - -

NUMBER
K01 VE-9017 Main relay switched fused supply, SHEET 04
independent source
terminal
shared source (K05)
terminal
shared source (K03)
terminal
K07 VE-9161 Low Side Driver (LSD), Diesel
Exhaust Fluid (DEF)/AdBlue® tank
heating valve
K08 VE-9048 Input signal, Key switch start position
K09 - -
K10 - -
K11 - -
K12 - -
K13 - -
K14 - -
K15 - -
K16 - -
K17 - -
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NUMBER
K18 - -
K19 VE-9144 Input signal, Intake air temperature SHEET 04
sensor
K20 VE-9162 Reference ground, Intake air
temperature sensor
K21 - -
K22 VE-9073 Input signal, Glow-plug Control Unit SHEET 04
(GCU) feedback
K23 VE-9150 CAN 2 High, Selective Catalytic
K24 VE-9068 CAN 1 High, Diagnostic and
K25 VE-9067 CAN 1 Low, Diagnostic and
K26 - -
K27 VE-9056 Low Side Driver (LSD), Starter control SHEET 04
relay
K28 VE-9018 Low Side Driver (LSD), Main relay
K29 - -
K30 VE-9077 Input signal, Water in fuel switch SHEET 04
K31 - -
k32 - -
K33 - -
K34 - -
K35 - -
K36 - -
K37 VE-9118A Reference ground, Exhaust manifold SHEET 04
pressure sensor
K38 - -
K39 - -
K40 - -
K41 VE-9074 Reference ground, Glowplug Control SHEET 04
Unit (GCU)
K42 - -
K43 - -
K44 - -
K45 VE-9151 CAN 2 Low, Selective Catalytic SHEET 04
Reduction(SCR) devices
K46 - -
K47 - -
K48 - -
K49 - -
K50 - -
K51 - -
K52 VE-9071 Low Side Driver (LSD), GCU relay SHEET 04
K53 VE-9057 High Side Driver (HSD), Starter
control relay
K54 VE-9053 Input signal, Key switch ON/ACC
position
K55 - -
K56 VE-9145 Input signal, Upstream Diesel SHEET 04
K57 VE-9120A Input signal, Exhaust manifold
pressure sensor
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NUMBER
K58 - -
K59 - -
K60 - -
K61 - -
K62 - -
K63 - -
K64 - -
K65 VE-9164 Reference ground, upstream Diesel SHEET 04
K66 - -
K67 - -
K68 VE-9070 ISO-K Interface, Diagnostic and SHEET 04
monitoring connector K-line
K69 - -
K70 VE-9064 Low Side Driver (LSD), Fuel filter SHEET 04
heating relay
K71 - -
K72 VE-9166 Low Side Driver (LSD), Diesel SHEET 04
module pump motor
K73 - -
K74 - -
K75 - -
K76 VE-9167 Input signal, Diesel Exhaust Fluid SHEET 04
(DEF)/AdBlue® supply module pump
motor and temperature data
K77 - -
K78 - -
K79 VE-9168 Reference ground, Particulate Matter SHEET 04
(PM) Catalyst inlet temperature
sensor
K80 VE-9147 Input signal, Particulate Matter (PM)
Catalyst inlet temperature sensor
K81 VE-9119A Reference ground, exhaust manifold
temperature sensor
K82 VE-9121A Input signal, exhaust manifold
temperature sensor
K83 VE-9153 Reference ground, Diesel Oxidation
Catalyst (DOC) inlet temperature
sensor
K84 -VE-9152 Input signal, Diesel Oxidation Catalyst
(DOC) inlet temperature sensor
K85 - -
K86 - -
K87 - -
K88 - -
K89 - -
K90 - -
K91 VE-9066 Low Side Driver (LSD), fuel pump SHEET 04
relay (on some applications)
K92 - -
K93 - -
K94 - -
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84474047 2
Connector X-9123 - Lambda (Universal Heated Exhaust Gas Oxygen (UHEGO)) sensor
CONNECTOR X-9123 - Lambda (Universal Heated Exhaust Gas Oxygen (UHEGO)) sensor
NUMBER
1 VE-9154 Current pump SHEET 03
2 VE-9155 Ground
3 VE-9200 Low Side Driver (LSD), heater
4 VE-9081 Supply, heater
5 VE-9157 Current adjust
6 VE-9156 Nernst voltage
Connector X-9124 - Auxiliary main relay
CONNECTOR X-9124 - Auxiliary main relay

NUMBER
30 VE-9001 Battery supply, Battery plus / positive SHEET 01
terminal
85 VE-9011 Ground, Battery minus / negative
terminal
86 VE-9020 Switched control signal, Main relay
87 VE-9014 Supply voltage, Selective Catalytic
Reduction (SCR) sensors
87A - -
Connector X-9125 - Water in fuel switch
CONNECTOR X-9125 - Water in fuel switch (black connector on sensor housing)

NUMBER
2 VE-9078 Ground
3 VE-9076 Supply, from key switch
Connector X-9126 -Particulate Matter (PM) catalytic converter inlet temperature sensor
CONNECTOR X-9126 -Particulate Matter (PM) catalytic converter inlet temperature sensor
NUMBER
2 VE-9147 Ground
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Connector X-9127 -Diesel Oxidation Catalyst (DOC) inlet temperature sensor
CONNECTOR X-9127 -Diesel Oxidation Catalyst (DOC) inlet temperature sensor

NUMBER
2 VE-9153 Ground
Connector X-9128 - Selective Catalytic Reduction (SCR) main relay
CONNECTOR X-9128 - Selective Catalytic Reduction (SCR) main relay

NUMBER
terminal
85 VE-9026 Low Side Driver (LSD), Engine
Control Unit (ECU)
86 VE-9021 Switched supply, Main relay
87 VE-9027 Supply voltage, Diesel Exhaust Fluid
(DEF)/AdBlue® supply module and
tank heater valve
87A - -
Connector X-9129 - Main relay
CONNECTOR X-9129 - Main relay

NUMBER
terminal
Control Unit (ECU)
86 VE-9002 Battery supply, Battery plus / positive
terminal
87 VE-9003 Supply voltage, Engine Control Unit
(ECU) and engine devices
87A - -
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X-9139
Connector X-9130 - Electric fuel pump relay (optional)
CONNECTOR X-9130 - Electric fuel pump relay (optional)

NUMBER
30 VE-9065 Controlled supply, battery disconnect SHEET 02
switch
Control Unit (ECU)
86 VE-9022 Controlled supply, main relay
switched
87 See product schematics Controlled source, electric fuel pump
motor
87A
Connector X-9131 - Diesel Exhaust Fluid (DEF)/AdBlue® temperature, level and quality sensor
CONNECTOR X-9131 - Diesel Exhaust Fluid (DEF)/AdBlue® temperature, level and quality sensor
NUMBER
1 VE-9176 Controlled supply, auxiliary main SHEET 03
relay switched
2 VE-9177 Ground
3 - -
4 VE-9174 CAN 2 low SHEET 03
5 VE-9175 CAN 2 high
87688719 1
Connector X-9132 - NH3 sensor controller
CONNECTOR X-9132 - NH3 sensor controller

NUMBER
2 VE-9188 CAN high
3 VE-9187 CAN low
4 VE-9179 Ground
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84146686 2
Connector X-9133 - Diesel Oxidation Catalyst (DOC) upstream NOx sensor
CONNECTOR X-9133 - Diesel Oxidation Catalyst (DOC) upstream NOx sensor

NUMBER
2 VE-9183 Ground
3 VE-9191 CAN low
4 VE-9192 CAN high
5 VE-9182 Ground
47514978 3
Connector X-9134 - Selective Catalytic Reduction (SCR) downstream NOx sensor
CONNECTOR X-9134 - SCR downstream NOx sensor

NUMBER
2 VE-9181 Ground
3 VE-9195 CAN low
4 VE-9196 CAN high
5 - -
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47514978 4
Connector X-9135 - Controller Area Network (CAN) terminator
CONNECTOR X-9135 - Controller Area Network (CAN) terminator

NUMBER
1 VE-9197 CAN 2 low
2 VE-9198 CAN 2 high
84539353 5
Connector X-9136 - DEF/AdBlue® supply module suction line heater
CONNECTOR X-9136 -DEF/AdBlue® supply module suction line heater

NUMBER
1 VE-9084 Heater supply SHEET 02
2 VE-9088 Series supply for heater R-9103.
Connector X-9137 - NH3 sensor controller
CONNECTOR X-9137 - NH3 sensor controller

NUMBER
1 NH3-1 (PU) Heater supply SHEET 03
2 NH3-2 (YE) Trim resistor supply
3 NH3-3 (YE) Trim resistor ground
4 NH3-4 (BK) EMF 2
5 NH3-5 (WH) Heater ground
6 NH3-6 (GN) Temperature signal
7 NH3-7 (BR) Signal ground
8 NH3-8 (GY) EMF 1
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Connector X-9138 - Engine interface 1

CONNECTOR X-9138 - Engine interface 1
NUMBER
1 VE-9137 Switched voltage supply, fuel SHEET 06
EN-9137 metering unit
2 VE-9136 Low Side Driver (LSD), fuel metering
EN-9136 unit
3 VE-9105 Input signal, oil pressure switch
EN-9105
4 VE-9111 Input signal, camshaft speed sensor
EN-9111
5 VE-9106 Reference ground, rail pressure
EN-9106 sensor
6 VE-9107 Input signal, rail pressure sensor
EN-9107
7 VE-9108 +5 V sensor supply, rail pressure
EN-9108 sensor
8 VE-9110 Reference ground, camshaft speed
EN-9110 sensor
9 VE-9113 Input signal, positive, crankshaft
EN-9113 position sensor
10 VE-9112 Input signal, negative, crankshaft
11 - -
12 VE-9109 +5 V sensor supply, camshaft speed SHEET 06
EN-9109 sensor
13 VE-9114 Reference ground, coolant
EN-9114 temperature sensor
14 VE-9115 Input signal, coolant temperature
EN-9115 sensor
15 VE-9116 Reference ground, fuel temperature
EN-9116 sensor
16 VE-9117 Input signal, fuel temperature sensor
EN-9117
17 VE-9101 +5 V sensor supply, intake manifold
EN-9101 pressure sensor
18 VE-9102 Input signal, intake manifold pressure
EN-9102 sensor
19 VE-9103 Reference ground, intake manifold
20 VE-9104 Input signal, intake manifold
21 VE-9143 +5 V sensor supply, exhaust manifold
22 VE-9118A Reference ground, exhaust manifold
23 VE-9120A Input signal, exhaust manifold
24
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NUMBER
25 VE-9119 Reference ground, exhaust manifold SHEET 06
26 VE-9121 Input signal, exhaust manifold
27 VE-9133 Low Side Driver (LSD), wastegate
EN-9133 pressure modulator valve
28 VE-9024 Main relay switched supply,
EN-9024 wastegate pressure modulator valve
29 VE-9095 H-bridge Pulse-Width Modulated
EN-9095 (PWM) supply, Exhaust Gas
31 - -
32 - -
33 VE-9094 +5 V sensor supply, Exhaust Gas SHEET 06
EN-9094 Recirculation (EGR) valve position
sensor
34 VE-9093 Input signal, Exhaust Gas
EN-9093 Recirculation (EGR) position
sensor
35 VE-9097 Reference ground, Exhaust Gas
sensor
36 - -
37 VE-9134 H-bridge Pulse-Width Modulated SHEET 06
EN-9134 (PWM) supply, Throttle Valve
39 - -
40 - -
41 VE-9098 +5 V sensor supply, Throttle Valve SHEET 06
EN-9098 Actuator (TVA) position sensor
42 VE-9099 Input signal, Throttle Valve Actuator
EN-9099 (TVA) position sensor
43 VE-9100 Reference ground, Throttle Valve
44 - -
45 - -
46 - -
47 - -
48 - -
49 - -
50 - -
51 - -
52 - -
53 - -
54 - -
55 - -
56 - -
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NUMBER
57 VE-9061 Glow plug control module controlled SHEET 06
EN-9061 supply, glow plug 4
58 VE-9060 Glow plug control module controlled
59 - -
62 - -

NUMBER
1 VE-9137 Switched voltage supply, fuel SHEET 06
EN-9137 metering unit
2 VE-9136 Low Side Driver (LSD), fuel metering
EN-9136 unit
3 VE-9105 Input signal, oil pressure switch
EN-9105
4 VE-9111 Input signal, camshaft speed sensor
EN-9111
5 VE-9106 Reference ground, rail pressure
EN-9106 sensor
6 VE-9107 Input signal, rail pressure sensor
EN-9107
7 VE-9108 +5 V sensor supply, rail pressure
EN-9108 sensor
8 VE-9110 Reference ground, camshaft speed
EN-9110 sensor
9 VE-9113 Input signal, positive, crankshaft
10 VE-9112 Input signal, negative, crankshaft
11 - -
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NUMBER
12 VE-9109 +5 V sensor supply, camshaft speed SHEET 06
EN-9109 sensor
13 VE-9114 Reference ground, coolant
14 VE-9115 Input signal, coolant temperature
EN-9115 sensor
15 VE-9116 Reference ground, fuel temperature
EN-9116 sensor
16 VE-9117 Input signal, fuel temperature sensor
EN-9117
17 VE-9101 +5 V sensor supply, intake manifold
18 VE-9102 Input signal, intake manifold pressure
EN-9102 sensor
19 VE-9103 Reference ground, intake manifold
20 VE-9104 Input signal, intake manifold
21 VE-9143A +5 V sensor supply, exhaust manifold
22 VE-9118 Reference ground, exhaust manifold
23 VE-9120 Input signal, exhaust manifold
24
25 VE-9119A Reference ground, exhaust manifold SHEET 06
26 VE-9121A Input signal, exhaust manifold
27 VE-9133 Low Side Driver (LSD), wastegate
EN-9133 pressure modulator valve
28 VE-9024 Main relay switched supply,
EN-9024 wastegate pressure modulator valve
31 - -
32 - -
33 VE-9094 +5 V sensor supply, Exhaust Gas SHEET 06
sensor
34 VE-9093 Input signal, Exhaust Gas
EN-9093 Recirculation (EGR) position
sensor
35 VE-9097 Reference ground, Exhaust Gas
sensor
36 - -
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NUMBER
37 VE-9134 H-bridge Pulse-Width Modulated SHEET 06
39 - -
40 - -
41 VE-9098 +5 V sensor supply, Throttle Valve SHEET 06
42 VE-9099 Input signal, Throttle Valve Actuator
EN-9099 (TVA) position sensor
43 VE-9100 Reference ground, Throttle Valve
44 - -
45 - -
46 - -
47 - -
48 - -
49 - -
50 - -
51 - -
52 - -
53 - -
54 - -
55 - -
56 - -
59 - -
62 - -
NHIS14ENG0977AA 6
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NHIS14ENG0985AA 7
Connector X-9138 is located above the fuel filter housing.
84154701 8
Connector X-9139 - Engine interface 2

NUMBER
A VE-9125 High Side Driver (HSD), Bank 1 SHEET 06
INJ-268 Injector 1 (Cylinder 1)
B VE-9126 Low Side Driver (LSD), Bank 1
C VE-9127 Low Side Driver (LSD), Bank 2
D VE-9128 High Side Driver (LSD), Bank 2
E VE-9129 High Side Driver (LSD), Bank 1
F VE-9130 Low Side Driver (LSD), Bank 1
G VE-9131 Low Side Driver (LSD), Bank 2
H VE-9132 High Side Driver (LSD), Bank 2
J
K
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NHIS14ENG0977AA 9
NHIS14ENG0985AA 10
Connector X-9139 is located above the oil fill tube.
87698254 11
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Index

Wiring harnesses - Electrical schematic sheet 02 Starting system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Wiring harnesses - Electrical schematic sheet 03 Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Wiring harnesses - Electrical schematic sheet 04 Engine control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Wiring harnesses - Electrical schematic sheet 05 Engine control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Wiring harnesses - Electrical schematic sheet 06 Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Wiring harnesses - Electrical schematic sheet 07 CAN BUS / Diagnostic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Wiring harnesses - Electrical schematic sheet 08 Telematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Wiring harnesses - Electrical schematic sheet 09 Front exterior lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Wiring harnesses - Electrical schematic sheet 10 Instrument cluster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Wiring harnesses - Electrical schematic sheet 11 Power points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Wiring harnesses - Electrical schematic sheet 12 SAHR Park brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Wiring harnesses - Electrical schematic sheet 13 Rear lights exterior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Wiring harnesses - Electrical schematic sheet 14 Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Wiring harnesses - Electrical schematic sheet 15 Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Wiring harnesses - Electrical schematic sheet 01 – Power distribution and starting . . . . . . . . . . . . . . . . . . . . . . . . . 58
Wiring harnesses - Electrical schematic sheet 02 – Pre-start and Selective Catalytic Reduction (SCR) . . . . . . . 60
Wiring harnesses - Electrical schematic sheet 03 – Exhaust system and Controller Area Network (CAN) bus . . 62
Wiring harnesses - Electrical schematic sheet 04 – Engine Control Unit (ECU) vehicle connector . . . . . . . . . . . . 64
Wiring harnesses - Electrical schematic sheet 05 – Engine Control Unit (ECU) engine connector . . . . . . . . . . . . 66
Wiring harnesses - Electrical schematic sheet 06 – Engine control and fuel injection . . . . . . . . . . . . . . . . . . . . . . . 68
Harnesses and connectors - Overview (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Wire connectors - Component diagram 00 - Connectors X-001 to X-009 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Wire connectors - Component diagram 00 - Connectors X-9000 to X-9009 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
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Wire connectors - Component diagram 07 - Connectors X-070 to X-079 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Wire connectors - Component diagram 11 - Connectors X-9110 to X–9119 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
Wiring harnesses - Electrical schematic sheet 01 Power distribution / Charging system . . . . . . . . . . . . . . . . . . . . . 28
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Engine starting system - 201

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Contents
SERVICE
Engine starter
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
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Electrical systems - Engine starting system
Engine starter - Remove

2. Open the left side engine side panel (1).
RAPH12FRK0021BA 1
NOTE: For assembly purposes, identify and label all wires and cables before removing.
3. Remove the nut (3), disconnect the starter solenoid
wire harness connector (4), and remove the positive
battery cable (2) from the terminal on the starter (1).
RAIL14FRK0038BA 2
4. Remove the starter bolts (1) and washers, and remove

the ground strap (2) securing the starter to the flywheel
housing (3).
RAIL14FRK0137BA 3
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Engine starter - Install

2. Open the left side engine side panel (1).
RAPH12FRK0021BA 1
3. Place the starter into position on the flywheel housing.
RAIL14FRK0138BA 2
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4. Secure the starter in place with bolts and washers (1).

Make sure that you secure ground strap (2) with the
bottom mounting bolt of the starter.
RAIL14FRK0137BA 3
RAIL14FRK0129BA 4
Specification
Starter Bolt Torque 40 - 47 N·m (29.5 - 34.7 lb ft)
5. Connect the wire harness (3) and secure the positive

battery cable (1) to the starter terminal with the terminal
nut (2). Tighten to specification.
RAIL14FRK0038BA 5
Specification
Terminal Nut Torque 17.5 - 24.5 N·m (12.9 - 18.1 lb ft)
47821916 28/04/2015
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Index

Engine starter - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
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
2. Open the left engine side panel (1).
RAPH12FRK0021BA 1
NOTICE: Identify and label all wire connections and cables before removing.
3. Disconnect the wiring harness connector (2) and the
positive battery cable (3) from the rear of the alternator.
4. Loosen the upper mounting nut (4) and the lower
mounting nut (5). Do not remove at this time.
RAPH12FRK0715BA 2
5. Loosen the jam nut (6) on the tension bolt (7) and turn
the tension bolt to relieve the belt tension.
6. Remove the serpentine belt (8) from the alternator pul-
ley (9).
7. Remove the alternator upper mounting bolt (10) and
lower mounting bolt (11). Remove the alternator.
RAPH12FRK0715BA 3
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Electrical systems - Alternator
Alternator - Install
1. Ensure spacer (1) is completely seated in the lower
alternator bracket.
RAPH12FRK0022BA 1
2. Install the alternator into the lower alternator mounting

bracket (2). Install the lower mounting bolt, washer, and
nut (3). DO NOT tighten at this time.
3. Install the serpentine belt (4) onto the alternator pulley
(5).
RAPH12FRK0715BA 2
4. Install the upper mounting bolt, washer, and nut (6). DO

NOT tighten at this time.
5. Turn the tension bolt (7) to adjust the belt to proper
tension. When the belt is at proper tension, tighten the
jam nut (8).
6. Tighten the upper and lower mounting bolts and nuts.
7. Install the positive battery cable (9) and the wiring har-
ness (10).
RAPH12FRK0715BA 3
8. Close the left engine side panel.

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Index
Alternator - 301
Alternator - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Alternator - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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Battery - 302

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Contents
Battery - 302
SERVICE
Battery
Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Remove - Jump post (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Install - Jump post (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Battery connect and disconnect system
Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
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Electrical systems - Battery
Battery - Remove
586H
588H
WARNING
When assembling, operating, or servicing the
machine, wear protective clothing and PPE
necessary for the particular procedure. Some
PPE that may be necessary includes protective
shoes, eye and/or face protection, hard hat,
heavy gloves, filter mask, and hearing protec-
tion.
ous injury.
W0353A

2. Turn the main disconnect switch (1) to the OFF posi-
tion.
RAPH12FRK0004BA 1
3. Remove four bolts (2), and washers (3), and remove

the battery cover (4).
RAPH12FRK0046BA 2
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WARNING
To prevent an explosion: 1. Always disconnect
the negative (-) battery cable first. 2. Always
connect the negative (-) battery cable last. 3.
Do not short circuit the battery posts with metal
objects. 4. Do not weld, grind, or smoke near a
battery.
ous injury.
W0011A
4. Disconnect the negative battery straps (5) from each

battery (6).
5. Disconnect the positive battery cables (9) from each
battery.
6. Remove the bolt (7) and hold-down bracket (8).
RAPH12FRK0044BA 3
CAUTION
Heavy parts!
Machine batteries are extremely heavy. Make
sure the battery is supported safely during the
removal process.
erate injury.
C0050A
7. Using a battery lifting tool, carefully lift each battery

from the battery bay.
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Battery - Install
586H
588H
WARNING
tion.
ous injury.
W0353A
NOTE: Apply Case Battery Saver and Cleaner or Urethane Seal Coat to the cable terminals to prevent corrosion.
See the Parts Counter Catalog. DO NOT apply grease.
1. Using a battery lifting tool, carefully install each battery
into the battery bay.
2. Install the hold-down bracket (1), and secure with a lock
washer and bolt (2).
3. Connect the positive battery cables (3) to each battery
(5).
4. Connect the negative battery straps (4) to each battery.
RAPH12FRK0044BA 1
5. Install the battery cover (6), and secure with four wash-
ers (7) and bolts (8).
RAPH12FRK0046BA 2
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6. Turn the main disconnect switch (9) to the ON position.
RAPH12FRK0004BA 3
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Battery - Remove - Jump post

586H
588H

2. Open the left side engine panel (1).
RAPH12FRK0021BA 1
ATTENTION: For assembly purposes, identify and label all wires and cables before removing.
3. Remove the jump post terminal nut (2) from the rear
side of the jump post (3).
4. Remove the nut from the starter side of the master dis-
connect switch (4), and remove the starter side cable
(7).
5. Remove the jump post bracket connecting plate (6)
from the starter side of the master disconnect switch
and jump post.
6. Remove the nut (5) securing the jump post from the
bracket.
RAPH12FRK0023BA 2
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Battery - Install - Jump post

586H
588H
1. Install the jump post (1) to the bracket (2), and install
the retaining nut.
2. Install the jump post bracket connecting plate (3) to
the starter side of the battery disconnect switch (4) and
jump post.
3. Install the terminal nut to the starter side of the battery
disconnect switch.
4. Install the jump post terminal nut to the rear side of the
jump post.
RAPH12FRK0024BA 1
5. Close the left side engine panel (5).
RAPH12FRK0021BA 2
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Battery connect and disconnect system - Remove

586H
588H
WARNING
tion.
ous injury.
W0353A

2. Open the left side engine panel (1).
RAPH12FRK0021BA 1
ATTENTION: For assembly purposes, identify and label all wires and cables before removing.
3. Remove the battery side cable (2) and starter side ca-
ble (3) from the battery disconnect switch (4).
4. Remove the jump post terminal nut (5) and the jump
post connector plate (6).
5. Remove the center retaining screw (7) and the selector
switch lever (8).
6. Remove the switch nut (9) and the battery disconnect
switch.
RAPH12FRK0023BA 2
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Battery connect and disconnect system - Install

586H
588H
1. Install the battery disconnect switch (1) to the bracket,

and secure with a lock washer and nut (2).
2. Install the selector switch lever (3), and secure with the
center retaining screw (4).
3. Install the jump post connector plate (5) to the jump
post (6) and to the starter side of the battery discon-
nect switch terminal Install the jump post terminal nut
to the jump post, securing that side of the jump post
connector plate.
4. Connect the starter side cable (7) to the battery discon-
nect switch and secure with a nut.
5. Connect the battery side cable (8) to the battery dis- RAPH12FRK0023BA 1
connect switch and secure with a nut.
6. Close the left side engine panel (9).
RAPH12FRK0021BA 2
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Index
Battery - 302
Battery - Install - Jump post (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Battery - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Battery - Remove - Jump post (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Battery - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Battery connect and disconnect system - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Battery connect and disconnect system - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
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Warning indicators, alarms, and instruments - 408

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Contents
SERVICE
Instrument cluster
Digital instrument cluster - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Digital instrument cluster - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
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Electrical systems - Warning indicators, alarms, and instruments
Instrument cluster Digital instrument cluster - Remove

586H
588H
WARNING
Electrical shock hazard!
Before working on any part of the electrical
system, disconnect the battery ground cable.
Complete all electrical work before connecting
the cable.
ous injury.
W0129A
2. Remove two instrument cluster panel screws (1) from

the instrument cluster panel (2).
RAPH12FRK0717BA 1
3. Lift the instrument cluster panel away from the enclo-

sure (3), enough to gain access to the wire harness (4).
4. Disconnect the wire harness, and remove the instru-
ment cluster panel.
RAPH12FRK0718BA 2
NOTE: If the wire harness needs to be removed from the enclosure, proceed to the following steps.
5. Remove two enclosure cover screws, and lift the cover
(5) from the enclosure.
6. Remove the wire harness from the enclosure.
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Electrical systems - Warning indicators, alarms, and instruments
Instrument cluster Digital instrument cluster - Install

586H
588H
1. If removed, install the wire harness (1) into the enclo-

sure (2).
2. Install the cover (3) onto the enclosure, and secure with
two enclosure cover screws.
3. Connect the wire harness to the Instrument cluster
panel (4).
NOTE: The wire harness (1) has extra length and should
form a drip loop behind cluster, when the cluster is installed
into the post.
RAPH12FRK0718BA 1
4. Install the instrument cluster panel into the enclosure,

and secure with two instrument cluster screws (5).
RAPH12FRK0717BA 2
5. Verify that the instrument cluster panel is operating cor-

rectly.
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Index

Instrument cluster Digital instrument cluster - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Instrument cluster Digital instrument cluster - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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Telematics - 991

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55.6 [55.991] / 1
Contents
Telematics - 991
FUNCTIONAL DATA
Telematics
Overview with Case SiteWatch™ (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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Electrical systems - Telematics
Telematics - Overview with Case SiteWatch™

586H
588H
NOTE: The CASE CONSTRUCTION SiteWatch™ website (www.casesitewatch.com) will not be accessible until the
CASE CONSTRUCTION SiteWatch™ subscription for this machine is registered.
This machine may be equipped with a Telematics system. This is an asset-monitoring system that combines Inter-
net, cellular, and GPS technologies. A transponder unit is mounted on the equipment that wirelessly communicates
with the user interface CASE CONSTRUCTION SiteWatch™ at www.casesitwatch.com. Using cellular technology,
the transponder can send equipment data, including location, on/off status, usage and production metrics, diagnostic
data, movement alarms, unauthorized usage and monitor machine maintenance to the user interface CASE CON-
STRUCTION SiteWatch™. The system will help cut costs and keep accurate records.
The Light Emitting Diode (LED) display panel is the con-
troller’s minimum interface used to display and control
data input and output.
LED display showing normal operation with the ignition

key in the ON position:
• (1A) Phone or connectivity — RED (steady)
• (1B) CAN traffic — RED (blinking)
• (1C) GPS — RED (steady)
• (1D) Power — GREEN (steady)
RAIL12GEN0174AA 1
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Additional Information on the LED display

(1A) The GSM/GPRS LED (Red) displays the
GSM/GPRS status:
• Off — No GSM or GPRS coverage or the device is in
“stand-by” mode.
• Slowly Blinking — GSM coverage only. The system can
receive SMS, but the connection with the website is not
available.
• Blinking Fast — GPRS coverage, but the website con-
nection is not available for any reason.
• On — GPRS coverage and server connection. RAIL12GEN0174AA 2
(1B) The CAN LED (Red) displays the CAN status:

• Off — The CAN is not available or the device is in
• Blinking — CAN messages on the BUS.
(1C) The GPS LED (red) displays the GPS status:

• Off — Before the GPS initialization or the device is in
• Blinking — Searching for GPS signal.
• On — GPS fix 2D or 3D.
(1D) The Power LED (Green) displays the power status:

• Off — No power supply
• Blinking — Downloading files or firmware from the
server or waiting for the application firmware.
• On — Power supply and standard work or the device is
in “stand-by” mode.
• Green (fixed) — indicates that power supply is on.
Special LED Configuration

NOTE: Four LEDs ON indicates both the loader and the
firmware are not presently on board. The board is waiting
for the download of the loader.
NOTE: Power LED (Green) ON and the three Red LEDs
blinking indicate problems with the GPRS modem (no SIM
or modem initialization failed).
Troubleshooting
Condition Solution
No Power Check the fuse.
If no power light is on, check power (both constant power
and switched power must be correct and functioning
between 9 - 32 V).
Make sure that grounding is solid (when in doubt, use a
solid chassis ground).
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Condition Solution
GPRS is NOT Solid Red Antenna is installed incorrectly or placed in a poor
reception area (For example, under a metal hood or
headliner). You should be able to see the antenna from
the sky.
Power net work coverage area.
Antenna is defective (replace antenna).
GPRS antenna connector failure (test with ohmmeter).
GPS is NOT Solid Red Current GPS coverage is poor (no Satellite coverage).
Antenna is defective (replace antenna).
Antenna is installed incorrectly or placed in a poor
reception area (For example, under a metal hood or
headliner). You should be able to see the antenna from
the sky.
GPS antenna connector failure (test with ohmmeter).
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Index
Telematics - 991
Telematics - Overview with Case SiteWatch™ (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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FAULT CODES - DTC

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Contents
FAULT CODES - DTC
DIAGNOSTIC
1001-Air Filter Blockage Detected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

1002-Coolant Temperature Above Normal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1004-Hydraulic Filter Blockage Detected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1009-Transmission Oil Temperature Is Too High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1010-Foot Throttle Sensor Signal Not Plausible . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
1011-Foot Throttle Sensor Signal Above Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
1012-Foot Throttle Sensor Signal Below Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
1013-Foot Throttle Sensor Signal Error - No Signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
1014-VCM Battery Voltage Is Too High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
1015-VCM Battery Voltage Is Too Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
1018-Boost Air Temperature Is Above Operating Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
1019-Engine Coolant Is Above Operating Temperature (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
1020-Transmission Oil Is Above Operating Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
1021-Fuel Is Above Operating Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
1022-Water In Fuel Detected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
1024-Foot Throttle Supply Voltage Is Too Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
1026-Foot Throttle Supply Voltage Is Shorted To Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
1030-Foot Throttle Sensor Is Shorted To Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
1040-Engine RPM > 2750 for 5 seconds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
1041-Engine RPM > 3000 for 5 seconds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
1044-Fuel Level Sensor Shorted To Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
1045-Fuel Level Sensor - Open Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
1047-Transmission Temperature Sensor is Shorted Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
1048-Transmission Temperature Sensor - Open Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
1050-Alternator Unable To Charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
1051-Expected CAN Message Not Received (EEC1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
1052-Expected CAN Message Not Received (EEC3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
1053-Expected CAN Message Not Received (EC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
1054-Expected CAN Message Not Received (Engine Temperature) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
1055-Expected CAN Message Not Received (Inlet/Exhaust) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
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1056-Expected CAN Message Not Received (Engine Fluid) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
1057-Expected CAN Message Not Received (Vehicle/Electrical) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
1058-Expected CAN Message Not Received (EDC2BC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
1059-Expected CAN Message Not Received (DM1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
1060-Timeout Of CAN Message EGRIND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
1090-Vehicle Model ID in VCM is UNCONFIGURED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
3007-Engine coolant temperature sensor voltage is higher than expected . . . . . . . . . . . . . . . . . . . . . . . . 88
3008-Coolant Temperature Signal - Signal Below Range Minimum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
3010-Air Intake Temperature Sensor - Signal Above Range Maximum . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
3011-Air Intake Temperature Sensor - Signal Above Range Minimum . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
3015-Fuel Temperature Sensor - Signal Above Range Maximum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
3016-Fuel Temperature Sensor - Signal Below Range Minimum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
3019-Boost Pressure Sensor - Signal Above Range Max . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
3024-Atmospheric Pressure Sensor - Signal Above Range Maximum . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
3025-Atmospheric Pressure Sensor - Signal Below Range Minimum . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
3027-Oil pressure switch failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
3037-Boost Pressure Sensor - Signal Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
3059-ECU Main Relay: Stuck Main Relay Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
3061-Cylinder1 - Short circuit Low/High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
3063-Cylinder 1 - Injector Cable Short Circuit (High Side To Ground) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
3088-Crankshaft Sensor - No Signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
3089-Crankshaft Sensor - Invalid Signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
3090-Camshaft Sensor Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
3091-Camshaft Sensor Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
3093-Camshaft Sensor : Camshaft offset angle exceeded . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
3096-ECM Busoff on vehicle CAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
3102-Rail Pressure Sensor CP3 - Signal Below Range Minimum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
3104-Rail Pressure Relief Valve - Open Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
3105-Rail Pressure Relief Valve - Pressure Shock Requested . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
3106-Pressure Relief valve: pressure relief valve is open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
3108-Fuel Metering Unit - Short Circuit to Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
3112-Rail Pressure Sensor CP3 - Signal Above Maximum Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
3137-Metering Unit - Open Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
3141-Fuel Metering Unit : leakage is detected based on fuel quantity balance . . . . . . . . . . . . . . . . . . . . 159
3146-Water detected in fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
3169-Fuel filter heater ECU driver has an over temperature error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
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3176-High pressure pump fuel delivery quantity in over run exceeds a maximum threshold . . . . . . . . 164
3177-Engine Protection : Over speed detection in component engine protection . . . . . . . . . . . . . . . . . . 165
3179-Timeout of CAN Message BC2EDC2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
3180-CAN communication error between vehicle controller to ECU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
3188-Injector Cylinder 1 Warning - Open Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
3210-Bank 1 - General Short Circuit On Injector Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
3218-Bank 2 - General Short Circuit On Injector Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
3230-Injection Processor (CY33X) Error - SPI Communication Failure . . . . . . . . . . . . . . . . . . . . . . . . . . 182
3235-Injection control: Number of injections is limited by runtime . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
3236-Injection control : Number of injections is limited by quantity balance of high pressure pump . . 184
3237-Injection control : Number of desired injections exceeds threshold . . . . . . . . . . . . . . . . . . . . . . . . . 185
3238-ECM Internal SPI Communication Error - CJ940 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
3239-Error state of Electrically Erasable Programmable Read-Only Memory (EEPROM) . . . . . . . . . . . 188
3241-EEPROM : There was an error during Write/Read EEPROM operation . . . . . . . . . . . . . . . . . . . . . 189
3242-ECU internal : Visibility of Software Resets in DSM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
3243-ECU internal : Visibility of Software Resets in DSM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
3244-ECU internal failure - Software resets in DSM 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
3245-ECM Processor - Watchdog Not Plausible . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
3252-Controller Watchdog - SPI Communication Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
3253-ADC Monitoring - Reference Voltage Too High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
3255-ADC Monitoring Test Impulse Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
3256-ADC Monitoring Queue Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
3258-ECU Power stages : Starter relay HS power stage output short circuit to battery . . . . . . . . . . . . . 198
3259-ECU Power stages : Starter relay HS power stage output short circuit to ground . . . . . . . . . . . . . 200
3260-Low side power - open load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
3261-Low side power - short circuit to battery or excess temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
3262-Low side power - short circuit to ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
3265-Overrun Monitoring - Injection Time Too Long . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
3266-Redundent Engine Speed in Overrun Monitoring - Speed Signal Not Plausible . . . . . . . . . . . . . . 209
3283-Engine regulated 5 Volt sensor supply #2 - Shorted to high source . . . . . . . . . . . . . . . . . . . . . . . . . 210
3285-Sensor Supply Voltage 3 - High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
3293-Fuel Metering Unit: maximum positive deviation of rail pressure exceeded . . . . . . . . . . . . . . . . . . 214
3301-Fuel metering unit: Maximum negative rail pressure deviation with metering unit on lower limit is
exceeded . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
3305-Fuel metering unit: Minimum rail pressure exceeded . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
3309-Fuel metering unit: Maximum rail pressure exceeded . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
3334-Timeout of CAN message TSC1-PE torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
3335-Timeout of CAN message TSC1-PE torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
3338-Timeout of CAN message TSC1-VE Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
3339-Timeout of CAN message TSC1-VE Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
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3350-Terminal 50 - Always On . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226
3358-Engine sensor CAN bus failure (Engine controller can't transmit to sensors, or sensors not on CAN
bus) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228
3361-EEPROM : EEP Erase Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230
3362-Engine internal calculations : DFC to report if the quantity axis points increase strictly linearly above
the torque axis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231
3368-Torque limitation caused by performance limiter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232
3369-Torque Reduction Due to Smoke Limitation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233
3370-Torque limitation due to engine protection (against excessive torque, engine overspeed and over-
heat) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234
3371-Torque Limitation Due To Fuel Quantity Limitation Because Of Injector System Errors . . . . . . . . 235
3374-Injection Quantity Adjustment failure - Invalid EEPROM Adjustment Value Checksum . . . . . . . . 236
3402-Rail pressure sensor: maximum rail pressure exceeded . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237
3403-ECU Power Stages: Starter relay HS power stage over temperature . . . . . . . . . . . . . . . . . . . . . . . 238
3405-Wastegate pressure modulator control circuit open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240
3406-Wastegate pressure modulator control circuit over temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . 242
3409-Engine oil pressure too low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244
3410-Throttle valve actuator will not open to commanded position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247
3411-Throttle valve actuator will not close to commanded position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248
3414-Array of DFCs for short circuit in i+1th Glow Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249
3418-Wastegate pressure modulator control circuit shorted to battery . . . . . . . . . . . . . . . . . . . . . . . . . . . 257
3419-Wastegate pressure modulator control circuit shorted to ground . . . . . . . . . . . . . . . . . . . . . . . . . . . 259
3425-Turbocharger: Over boost deviation at P2 too high in pressure charger regulator . . . . . . . . . . . . 261
3430-EGR Failure - Moderate Inducement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262
3431-EGR Failure - Severe Inducement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263
3432-EGR Failure - Mild Inducement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 264
3517-Ambient air temperature sensor failure (of humidity sensor) - signal too high . . . . . . . . . . . . . . . . 265
3518-Ambient temperature sensor voltage is lower than expected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267
3616-Torque limitation due to turbo charger protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269
3650-Battery voltage: SRC high for battery voltage sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270
3651-Battery voltage: SRC low for battery voltage sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271
3652-CAN Bus: Bus off of CAN node A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273
3655-Torque limitation, Engine protection: General report of the event of torque limitations . . . . . . . . 275
3656-Torque limitation, Engine protection: Torque limitation caused by particulate filter . . . . . . . . . . . . 276
3657-Timeout Error of CAN-Receive-Frame CM1BC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277
3665-EGR valve will not open to commanded position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 279
3666-EGR valve will not close to commanded position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280
3667-EGR valve control circuit open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 281
3668-EGR valve control circuit over current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 283
3669-EGR valve H-bridge control circuit shorted to battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285
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3670-EGR valve H-bridge control circuit shorted to battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 287
3671-EGR valve H-bridge control circuit shorted to ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 289
3672-Short circuit to ground on EGR Out2 pin A35 error for H-bridge . . . . . . . . . . . . . . . . . . . . . . . . . . . 291
3673-EGR valve control circuit over load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 293
3674-EGR valve control circuit supply voltage too low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 296
3676-EGR valve position sensor voltage is higher than expected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 297
3677-EGR valve position sensor voltage is lower than expected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 299
3680-Injection cut off: Injection cut off demand (ICO) for shut off coordinator . . . . . . . . . . . . . . . . . . . . . 301
3684-Exhaust manifold temperature is higher than expected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 302
3688-Water in fuel sensor or sensor circuit failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303
3689-Faulty diagnostic data transmission or protocol error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 305
3692-Over temperature error on ECU power stage for glow plug low voltage system . . . . . . . . . . . . . . 307
3693-Short circuit to battery error for low voltage system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 309
3694-Glow plug control circuits shorted to ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 311
3699-ECU internal failure - EEPROM memory failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 313
3703-Injection control: check of minimum rail pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 314
3704-Injector adjustment programming: Check of missing injector adjustment value programming . . 315
3705-Injector adjustment programming: check of missing injector adjustment value programming . . . 316
3706-Injector adjustment programming: Check of missing injector adjustment value programming . . 317
3707-Lambda sensor circuit - Open circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 318
3708-Lambda sensor: Open circuit at the lambda sensor pump current pin . . . . . . . . . . . . . . . . . . . . . . 320
3709-Lambda sensor circuit - Open circuit at the virtual ground pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 322
3711-Lambda sensor heater circuit - Short circuit to battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 324
3712-Lambda sensor: SCG error of the LSU heater power stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 326
3713-Lambda sensor: Open Load error of the LSU Heater Power stage . . . . . . . . . . . . . . . . . . . . . . . . . 328
3714-Lambda sensor: Fault code to indicate SRC High error for O2 calibration . . . . . . . . . . . . . . . . . . . 330
3715-Lambda sensor : Fault code to indicate SRC Low error for O2 calibration . . . . . . . . . . . . . . . . . . . 331
3716-Lambda sensor: O2 value above the maximum threshold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 332
3720-Lambda sensor: low battery voltage at the SPI chip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 334
3721-Lambda sensor: Fault check to indicate SPI chip error of lambda sensor . . . . . . . . . . . . . . . . . . . 335
3722-LSU (oxygen) sensor temperature exceeds the maximum limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 336
3723-LSU (oxygen) sensor temperature is below the minimum limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 338
3724-Lambda sensor: Short to battery at IA, IP, UN, VG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 340
3725-Lambda sensor: Short to ground at IA, IP, UN, VG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 342
3727-Low oil viscosity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 344
3728-Too low oil viscosity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 345
3735-Fuel Metering Unit: over temperature of device driver of metering unit . . . . . . . . . . . . . . . . . . . . . . 346
3738-Analog Digital Converter (ADC): Diagnostic fault check to report multiple error while checking the
complete ROM memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 348
3739-Power stages, Injector: Loss of synchronization sending bytes to the MM from CPU . . . . . . . . . 349
3740-Injector power stages torque limitation error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 350
3741-Power stages, Injector: Wrong set response time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 351
3742-Power stages, Injector: Too many SPI errors during MoCSOP execution . . . . . . . . . . . . . . . . . . . 352
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3743-Injector power stage diagnostic fault check to report the error in under voltage monitoring . . . . 353
3744-Power stages, injector : Diagnostic fault check to report the error in over voltage monitoring . . 354
3745-Power stages, Injector : Diagnostic fault check to report that WDA is not working correct . . . . . 355
3746-Power stages, Injector : OS timeout in the shut off path test. Failure setting the alarm task period.
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 356
3747-Power stages, Injector: Diagnostic fault check to report that the positive test failed . . . . . . . . . . . 357
3748-Power stages, Injector : Diagnostic fault check to report the timeout in the shutoff path test . . . 358
3750-Injection control: Error in the plausibility of the injection energizing time . . . . . . . . . . . . . . . . . . . . 359
3751-Injection control : Error in the plausibility of the start of energizing angles . . . . . . . . . . . . . . . . . . . 360
3752-Level 2 Monitoring: Error in the plausibility of the energizing times of the zero fuel quantity calibration
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 361
3753-Level 2 Monitoring : Diagnostic fault check to report the error due to Over heating . . . . . . . . . . . 362
3754-Level 2 Monitoring : Diagnostic fault check to report the plausibility error in rail pressure monitoring
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 363
3755-Level 2 Monitoring : Diagnostic fault check to report the error due to torque comparison . . . . . . 364
3756-Level 2 Monitoring : Diagnosis fault check to report the demand for normal mode due to an error in
the PoI2 quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 365
3757-Level 2 Monitoring : Diagnosis fault check to report the error to demand for an ICO due to an error
in the PoI2 shut-off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 366
3758-Level 2 Monitoring : Diagnosis fault check to report the error to demand for an ICO due to an error
in the PoI3 efficiency factor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 367
3759-Level 2 Monitoring : Diagnosis of curr path limitation forced by ECU monitoring level 2 . . . . . . . 368
3760-Level 2 Monitoring : Diagnosis air path limitation due to a functional control unit monitoring forced
by ECU monitoring level 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 369
3761-Level 2 Monitoring : Diagnosis quantity path limitation due to a functional control unit monitoring
(level 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 370
3762-Level 2 Monitoring : Reported Overvoltage of Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 371
3763-Level 2 Monitoring : Reported under voltage of supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 372
3764-Main Relay: Early opening defect of main relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 373
3767-ECU internal : Diagnostic fault check to report 'WDA active' due to errors in query-/response com-
munication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 376
3768-ECU Internal : Diagnostic fault check to report 'ABE active' due to under voltage detection . . . . 377
3769-ECU Internal: Diagnostic fault check to report 'ABE active' due to overvoltage detection . . . . . . 378
3770-ECU internal: Diagnostic fault check to report 'WDA/ABE active' due to unknown reason . . . . . 379
3773-Turbocharger: Underboost detected in pressure charger regulator . . . . . . . . . . . . . . . . . . . . . . . . . 380
3794-Intake air pressure sensor: Plausibility check for air pressure at the upstream of intake valve sensor
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 381
3795-Intake air pressure sensor: Plausibility check for air pressure at the upstream of intake valve sensor
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 382
3799-Pressure Relief valve: pressure relief valve is forced to open, perform pressure shock . . . . . . . 383
3800-Pressure relief valve check if PRV opening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 384
3803-ECU internal : Error on R2S2 module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 385
3808-High pressure pump fuel delivery quantity at low idle is too high . . . . . . . . . . . . . . . . . . . . . . . . . . . 386
3810-Fuel pressure sensor: Rail pressure raw value is intermittent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 387
3811-ECU internal failure - Sensor 5 volt supply 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 389
3812-Physical range check high for ECU temperature sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 395
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3813-Physical range check low for ECU temperature sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 396
3814-ECU temperature sensor: SPI error ECU temperature sensor (LM71) . . . . . . . . . . . . . . . . . . . . . . 397
3818-Throttle valve actuator control circuit open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 398
3819-Throttle valve actuator control circuit over current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 400
3820-Throttle valve actuator control circuit over temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 402
3821-Throttle valve actuator H-bridge control circuit shorted to battery . . . . . . . . . . . . . . . . . . . . . . . . . . 404
3822-Throttle valve actuator H-bridge control circuit shorted to battery . . . . . . . . . . . . . . . . . . . . . . . . . . 406
3823-Throttle valve actuator H-bridge control circuit shorted to ground . . . . . . . . . . . . . . . . . . . . . . . . . . 408
3824-Throttle valve actuator H-bridge control circuit shorted to ground . . . . . . . . . . . . . . . . . . . . . . . . . . 410
3825-Throttle valve actuator control circuit over load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 412
3827-Throttle valve actuator control circuit supply voltage too low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 414
3834-Throttle valve actuator position sensor voltage is higher than expected . . . . . . . . . . . . . . . . . . . . . 415
3835-Throttle valve actuator position sensor voltage is lower than expected . . . . . . . . . . . . . . . . . . . . . . 417
3838-Oxidation catalyst upstream temperature shorted to high source . . . . . . . . . . . . . . . . . . . . . . . . . . 419
3839-Oxidation catalyst upstream temperature shorted to low source . . . . . . . . . . . . . . . . . . . . . . . . . . . 421
3842-Turbine upstream temperature sensor shorted to high source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 423
3843-Turbine upstream temperature sensor : SRC low for turbine upstream temperature sensor . . . 426
3844-Zero fuel calibration by lambda (ZFL) : DFC reporting error state on comparing energizing time to
max value injector 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 428
min value injector 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 432
3899-Engine Protection : Engine temperature reaches prewarning level . . . . . . . . . . . . . . . . . . . . . . . . . 436
3900-Info: Engine temperature exceeded warn level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 437
3906-Injector: Number of injections is limited by quantity balance of high pressure pump . . . . . . . . . . 438
3910-Fuel Metering Unit : Intermittent contact between ECU and MeUn . . . . . . . . . . . . . . . . . . . . . . . . . 439
3915-Pressure Relief Valve: Averaged rail pressure is outside the expected range with open PRV . . 441
3916-Pressure Relief Valve: Open time of PRV for wear out monitoring had exceeded maximum value
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 442
3978-Level 2 of PFlt Overloaded . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 443
3979-Level 3 of PFlt Overloaded . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 444
3993-EGR valve will not close during after run . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 445
9003-J1939 Receive Buffer Overflow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 446
9004-EEPROM Checksum Failure, Hourmeter Location 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 447
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9007-Abnormal Reset Watchdog Timeout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 450
9012-Analog To Digital Fault Fuel Level (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 451
9401-Repair Double Redundant Memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 452
9403-Memory Error - Double Redundant Memory - Unrecoverable Memory Corruption Operable . . . 453
9404-Memory Error - Triple Redundant - Hour Meter Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 454
17105-Turbo protection cold start detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 455
17513-PMCat inlet temperature sensor physical range check high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 456
17514-TSC1 message checksum/counter error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 457
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Electrical systems - FAULT CODES
1001-Air Filter Blockage Detected

Context:
The instrument cluster detects a signal to ground on pin 11, indicating that the air filter restriction switch has been
tripped. The warning lamp will illuminate while the fault is active.
Cause:
The instrument cluster measures a short circuit to ground on the hydraulic oil filter input, X-033 pin 11.
Possible failure modes:
1. Clogged air filter.

2. Signal wire short circuit to minus battery or chassis ground.
3. Faulty air filter restriction switch.
4. Faulty instrument cluster.
Solution:
1. Verify that the fault code is active.
Connect the Electronic Service Tool to the service tool connector.
To check for fault codes: Start and operate the machine.
A. Fault code 1001 is not recorded again. OK to return the machine to service.
B. Fault code 1001 is active and recorded again. Go to step 2.

2. Inspect the engine air filter.
Inspect the engine air filter. The filter should be clean and free of dirt and debris.
RCPH11TLB004BAD 1
A. The filter is clean and does not need to be replaced. Go to step 3.
B. The filter is in poor condition, dirty or is clogged. Replace the filter. Return to step 1 to confirm elimination of
the fault.
3. Verify that the wiring and connectors are free of damage.
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RAIL12FRK1160FA 2
Schematic legend
(1) Instrument cluster (4) S-034 hydraulic filter restriction switch
connector X-033
(2) S-033 air filter restriction switch (5) B-017 fuel level sender
(3) GND008 cab ground firewall (6) B-018 transmission temperature sender
Inspect the instrument cluster and the air filter restriction switch connections. All connections should be secure,
tight, free of corrosion, abrasion and damage.
Inspect the harness from the instrument cluster and the air filter restriction switch. Verify that the harness is free
of damage, corrosion, abrasion and incorrect attachment.
A. The connectors are secure and the harness is free of damage. Go to Step 3.
B. The connectors or the harness has damage. Repair or replace the harness or connectors as required. Return
to Step 1 to confirm elimination of fault.
4. Check the air filter restriction circuit
BD08D002-01 3
(1) Air filter restriction switch (2) Connector air filter restriction switch
Disconnect 3801 BL from air filter restriction switch.
Turn the key switch on. Engine off. Fault code 1001 should no longer be active.
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A. Fault code 1001 is no longer active. Temporarily replace the air filter restriction switch and retest. Return to
step 1 to confirm elimination of the fault.
B. Fault code 1001 is still active. Go to step 5.

5. Measure the resistance of the signal wire to chassis ground.
Turn the ignition switch OFF.
Disconnect the instrument cluster connector X-033.
Measure the resistance between X-033 pin 11 and chassis ground. The resistance should be greater than
20,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition.
A. The resistance is greater than 20,000 Ω. Temporarily replace the instrument cluster and retest. Return to step
1 to confirm elimination of the fault.
B. The resistance is less than 20,000 Ω. There is a short to chassis ground in the signal wire. Repair or replace
the wire as required. Return to step 1 to confirm elimination of fault.
Wiring harnesses - Electrical schematic sheet 10 Instrument cluster (55.100.DP-C.20.E.10)
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1002-Coolant Temperature Above Normal

Context:
The ECU has detected a coolant temperature greater than 111 °C (232 °F) for a period greater than 5 s. The instru-
ment cluster will illuminate the stop lamp and the audible alarm will sound continuously while the fault is active. Fault
code 1002 - Coolant Temperature Above Normal will be active with 3007 - Coolant Temperature Signal - Signal
Above Range Maximum. Follow the troubleshooting procedure for fault code 3007 - Coolant Temperature Signal
- Signal Above Range Maximum.
The fault will reset once the coolant temperature drops below 106 °C (223 °F) for a period greater than 5 s.
Cause:
The coolant temperature signal is above normal. The instrument cluster has received a message from the ECU that
the coolant temperature is above 111 °C (232 °F) for a period greater than 5 s.
Wiring harnesses - Electrical schematic sheet 05 Engine control (55.100.DP-C.20.E.05)
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1004-Hydraulic Filter Blockage Detected

Context:
The instrument cluster measures a short circuit to ground on the hydraulic oil filter restriction input, indicating the
hydraulic filter is clogged or restricted.
Cause:
The instrument cluster measures a short circuit to ground on the hydraulic oil filter input, X-033 pin 2.
1. Clogged hydraulic filter.

2. Signal wire has an short circuit to chassis ground.
3. Faulty reading from the switch.
Solution:
B. Fault code 1004 is recorded again. Go to step 2.

2. Inspect the hydraulic oil filter.
Inspect the hydraulic filter. Replace the filter if needed.
A. The filter is in good condition and does not need to be replaced. Go to step 3.
B. The filter is in poor condition or is clogged. Replace the filter. Return to step 3 to confirm elimination of the fault.
3. Verify the harness and connectors are not damaged.
Inspect the instrument cluster and hydraulic filter restriction switch connections. All connections should be secure,
tight, free of corrosion, abrasion and damage.
Inspect the harness from the instrument cluster to the hydraulic filter restriction switch. Verify that the harness is
free of damage, corrosion, abrasion or incorrect attachment.
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RAIL12FRK1160FA 1
Schematic Legend
(1) Instrument cluster connector (2) S-034 hydraulic filter restriction switch
X-033 pin 2 Switch closed in the fault condition.
A. The wiring is free of corrosion, damage, abrasion, and incorrect attachment. Go to step 3.
B. The wiring is not free of corrosion, damage, abrasion, or incorrect attachment. Repair or replace the harness
as required. Return to step 1 to confirm elimination of the fault.
4. Measure the resistance through the filter restriction switch.
Disconnect the oil filter switch from the harness.
Measure the resistance between the oil filter switch pin and chassis ground. The chassis ground connection must
be clean and free of paint, oil, and dirt. The resistance should be greater than 20,000 Ω.
A. The resistance is greater than 20,000 Ω. Go to step 5.
B. The resistance is less than 10 Ω. Replace hydraulic filter restriction switch and retest. Return to step 1 to
confirm elimination of fault.
Disconnect instrument cluster connector X-033.
Disconnect the hydraulic oil filter restriction switch from the harness.
Measure the resistance between connector X-223 pin 1 and chassis ground. The resistance should be greater
than 20,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition.
A. The resistance is less than 10 Ω. There is a short circuit to chassis ground. Repair or replace the harness as
required. Return to step 1 to confirm elimination of the fault.
B. The resistance is greater than 10 Ω. Temporarily replace the instrument cluster and retest. Return to step 1 to
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1009-Transmission Oil Temperature Is Too High

Context:
The instrument cluster monitored a transmission oil temperature greater than 115 °C (239 °F) for a period greater than
5 s. The instrument cluster will illuminate the stop lamp and the audible alarm will sound continuously while the fault
is active.
The fault will reset once the transmission oil temperature drops below 107 °C (225 °F) for a period greater than 5 s.
Cause:
The transmission oil temperature is greater than 115 °C (239 °F) for a period greater than 5 s.
1. Low transmission oil level.

2. Faulty fan operation.
3. Clogged cooling core.
4. Faulty reading from the sensor.
Solution:

2. Verify transmission oil level.
Check transmission oil level. Refer to Operator's Manual for more details.
A. The oil level is not correct. Add oil as required, refer to the Operator’s Manual for more details. Return to step
B. The oil level is correct but the fault is recorded again, go to step 3.
3. Visually inspect the cooling system.
Run the engine at 1500 RPM.
Check the fan for proper operation.
Check the cooling core for clogs.
A. The cooling system is operating properly. Go to step 4.
B. The cooling system is not operating properly or the cooling core is clogged. Repair fan or clear clogs from
cooling core. Repair as required. Return to step 1 to confirm elimination of fault.
Inspect the instrument cluster and the transmission temperature sender connections. All connections should be
secure, tight, free of corrosion, abrasion, and damage.
Inspect the harness from the instrument cluster to the transmission temperature sender. Verify that the harness is
free of damage, corrosion, abrasion, or incorrect attachment.
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RAIL12FRK1160FA 1
Schematic Legend
(1) Instrument cluster connector (2) B-018 Transmission temperature sender
X-033 pin 16
5. Check temperature sender.
Disconnect terminal connector from the transmission temperature sender.
Measure the resistance between the transmission temperature sender ground connection and chassis ground.
The resistance should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent con-
dition.
Measure the resistance across the temperature sender.
Temperature Measured resistance in ohms

110 °C (230.0 °F) 130 Ω
100 °C (212.0 °F) 175 Ω
92 °C (197.6 °F) 223 Ω
85 °C (185.0 °F) 280 Ω
78 °C (172.4 °F) 358 Ω
68 °C (154.4 °F) 511 Ω
A. The resistance measurement is within range, go to step 5.
B. Resistance reading is not acceptable for a room temperature sender. Replace the transmission temperature
sender. Return to step 1 to confirm elimination of fault.
6. Check wiring to instrument cluster.
Disconnect the instrument cluster connector X 033.
Measure the resistance between the transmission temperature sender connector X-071 pin 1 and chassis ground.
The resistance should be greater than 20,000 Ω. Wiggle the harness during measurement to reveal an intermittent
condition.
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A. The resistance measurement is greater than 20,000 Ω. Temporarily replace the instrument cluster and retest.
Return to step 1 to confirm elimination of the fault.
B. The resistance is less than 20,000 Ω. There is a short circuit to chassis ground in the wire. Repair or replace
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1010-Foot Throttle Sensor Signal Not Plausible

Context:
The IVS (idle validation signal) did not change from a high state ( 12 V) to a low state ( 0 V) when the throttle moved
off of low idle. The instrument cluster will illuminate the warning lamp and will sound the alarm for one second on the
next system power up following the event.
If the throttle failed while the transmission was in neutral, the engine speed is set to 1500 RPM, otherwise the engine
speed is set to 900 RPM.
Cause:
The IVS did not change state in 0.3 s after the throttle was moved off of low idle.
1. Faulty wiring or connections.

2. Faulty signal from the foot throttle sensor.
3. Faulty instrument cluster
Solution:

Inspect the instrument cluster and the foot throttle connections. All connections should be secure, tight, free of
corrosion, abrasion, and damage.
Inspect the harness from the instrument cluster to the foot throttle. Verify that the harness is free of damage,
corrosion, abrasion, or incorrect attachment.
RAIL12FRK1162FA 1
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Schematic Legend
(1) Instrument cluster connector X-033 (2) A-006 foot throttle
Instrument Cluster Signal Name Connector X-101/ X-020 Foot Throttle connector
connector X-033 X-155
pin 17 5 volt supply pin 11 pin C
pin 19 Idle validation signal pin 9 pin E
pin 22 Throttle signal pin 12 pin A
pin 25 Sensor ground pin 10 pin B
3. Measure the voltage at throttle sensor.
Turn the key switch OFF.
Disconnect the foot throttle connector and inspect pins and wiring for damage, corrosion, abrasion or incorrect
attachment.
Turn the ignition switch to the ON position.
Measure the voltage between pin B and pin C. The voltage should be between 4.8 V and 5.2 V. Wiggle the harness
during measurement to reveal an intermittent condition.
A. The voltage is correct. Go to step 4.
B. The voltage is less than 4.8 V or the voltage is greater than 5.2 V, there is a problem in the voltage supply to
the throttle. Repair as required. Return to step 1 to confirm elimination of the fault.
4. Measure the resistance of the signal wire to ground.
Disconnect foot throttle connector X-155.
Measure the resistance between X-155 pin E and chassis ground. The chassis ground connection must be clean
and free of paint, oil, and dirt. The resistance should be greater than 20,000 Ω. Wiggle the harness during mea-
surement to reveal an intermittent condition.
B. The resistance is less than 20,000 Ω, there is a short circuit to chassis ground. Repair or replace the harness
5. Measure the voltage on the signal wire.
Turn the ignition switch ON.
Measure the voltage between X-155 pin E and chassis ground. The chassis ground connection must be clean
and free of paint, oil, and dirt. The voltage should be less than 0.5 V. Wiggle the harness during measurement to
reveal an intermittent condition.
A. The voltage is less than 0.5 V. Go to step 6.
B. The voltage is greater than 0.5 V, there is a short circuit to another voltage source. Repair or replace the
harness as required. Return to step 1 to confirm elimination of the fault.
6. Measure the voltage on the idle validation circuit.
Reconnect the instrument cluster.
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Fabricate a breakout harness and connect it between the foot throttle and the connector X-155.
RAIL12FRK1163FA 2
Schematic legend
(1) Instrument cluster (3) Foot throttle
(2) Dealer supplied breakout T
Turn the key switch ON, engine OFF. Use the breakout T to measure the voltage between pin E and pin B. The
voltage should be approximately 12 V .
Move the throttle approximately 3 degrees. The idle validation signal should change from 12 V to 0 V.
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RCPH10TLB018GAM 3
Throttle Signal Legend

(1) Idle validation signal (3) Throttle movement in degrees of travel. 0
degrees equals low idle. 20 degrees equals
WOT (Wide Open Throttle).
(2) Throttle signal voltage
A. The signal changed from 12 V to 0 V. Temporarily replace the instrument cluster and retest. Return to step 1.
B. The voltage was not correct or the voltage did not change from 12 V to 0 V as the throttle moved off of low idle.
Replace the sensor and retest. Return to step 1 to confirm elimination of fault.
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1011-Foot Throttle Sensor Signal Above Range

Context:
The instrument cluster detects a throttle signal greater than 4.6 V for a period greater than 5 s. The instrument cluster
will illuminate the warning lamp and will sound the alarm for one second on the next system power up following the
event.
The fault will reset once the signal voltage drops below 4.45 V for a period greater than 5 s.
Cause:
The instrument cluster detects the throttle signal voltage is greater than 4.6 V.

Solution:

RAIL12FRK1162FA 1
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Schematic Legend
3. Measure the voltage on the signal wire.
Disconnect the foot throttle connector X-155.
Measure the voltage between X-155 pin A and chassis ground. The chassis ground connection must be clean
and free of paint, oil, and dirt. The voltage should be less than 0.5 V. Wiggle the harness during measurement to
reveal an intermittent condition.
A. The voltage is less than 0.5 V. Go to step 4.
B. The voltage is greater than 0.5 V, there is a short circuit to another voltage source. Repair or replace the
harness as required. Return to step 1 to confirm elimination of the fault.
4. Measure the voltage on the throttle signal.
Fabricate a breakout harness. Connect the breakout between the foot throttle and connector X-155.
RAIL12FRK1163FA 2
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Schematic legend
(2) Dealer supplied breakout harness
Turn the ignition switch ON, engine OFF.
Use the breakout to measure the voltage between pin E and pin B. The voltage should be approximately 12 V .
Use the breakout harness to measure the voltage between pin A and pin B. Place the red probe on pin A and the
black probe on pin B.
Slowly move the throttle while monitoring the voltage. The voltage should range between approximately .25 V and
4.5 V.
A. The signal changed between .25 V and 4.5 V. Temporarily replace the instrument cluster and retest. Return to
step 1 to confirm elimination of fault.
B. The signal voltage is less than .25 V or greater than 4.6 V. Replace the sensor and retest. Return to step 1 to
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1012-Foot Throttle Sensor Signal Below Range

Context:
The instrument cluster detects a throttle signal voltage less than 0.25 V for a period greater than 5 s. The instrument
cluster will illuminate the warning lamp and will sound the alarm for one second on the next system power up following
the event.
The fault will reset once the signal voltage is greater than 0.4 V for a period greater than 5 s.
Cause:
The instrument cluster detects the throttle signal voltage is less than 0.25 V.

Solution:

Inspect the instrument cluster and foot throttle connections. All connections should be secure, tight, free of corro-
sion, abrasion, and damage.
RAIL12FRK1162FA 1
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Schematic Legend
Measure the resistance between X-155 pin A and chassis ground. The chassis ground connection must be clean
and free of paint, oil, and dirt. The resistance should be greater than 20,000 Ω. Wiggle the harness during mea-
surement to reveal an intermittent condition.
B. The resistance is less 20,000 Ω, there is a short circuit to chassis ground. Repair or replace the harness as
4. Measure the voltage of the throttle signal.
RAIL12FRK1163FA 2
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Schematic legend
Use the breakout harness to measure the voltage between pin E and pin B. The voltage should be approximately
12 V .
Move the throttle while monitoring the voltage. The voltage should range between approximately 0.25 V and 4.6 V.
A. The signal changed between 0.25 V and 4.6 V. Temporarily replace the instrument cluster and retest. Return
to step 1.
B. The signal voltage was less than or equal to 0.25 V. Replace the sensor and retest. Return to step 1 to confirm
elimination of fault.
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1013-Foot Throttle Sensor Signal Error - No Signal

Context:
The instrument cluster detects a throttle signal less than 0.1 V for a period greater than 5 s. The instrument cluster
will illuminate the warning lamp and will sound the alarm for one second on the next system power up following the
event.
The fault will reset once the signal voltage drops below 0.1 V for a period greater than 5 s.
Cause:
The instrument cluster detects the throttle voltage is less than 0.1 V.

3. Faulty Instrument Cluster
Solution:

Inspect the instrument cluster and foot throttle connections. All connections should be secure, tight, free of corro-
sion, abrasion, and damage.
RAIL12FRK1162FA 1
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Schematic Legend
3. Measure the resistance through the signal wire.
Measure the resistance between X-155 pin A and chassis ground. The chassis ground connection must be clean
and free of paint, oil, and dirt. The resistance should be less than 10 Ω. Wiggle the harness during measurement
to reveal an intermittent condition.
B. The resistance is less 20,000 Ω, there is a short circuit to chassis ground. Repair or replace the harness as
4. Measure the voltage of the throttle signal.
RAIL12FRK1163FA 2
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Schematic legend
(1) Instrument Cluster (3) Foot throttle
Use the breakout harness to measure the voltage between pin E and pin B. The voltage should be approximately
12 V .
Move the throttle while monitoring the voltage. The voltage should range between approximately 0.25 V and 4.6 V.
A. The signal changed between 0.25 V and 4.6 V. Temporarily replace the instrument cluster and retest. Return
to step 1.
B. The signal was less than 0.1 V. Replace the sensor and retest. Return to step 1 to confirm elimination of fault.
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1014-VCM Battery Voltage Is Too High

Context:
The instrument cluster measured an alternator voltage greater than 16 V for a period greater than 5 s. The instrument
cluster will illuminate the warning lamp indicating that it has detected a problem in the battery charging system.
The fault will reset once the alternator voltage drops below 15.8 V for a period greater than 5 s.
Cause:
The voltage on instrument cluster input, X-033 pin 12 is greater than 16 V.
1. Faulty alternator, alternator output greater than 16 V.

Solution:

2. Measure the alternator output.
Start the engine. Set engine speed to low idle and measure the voltage at the alternator. The voltage should be
approximately 14.5 V.
A. The voltage is approximately 14.5 V. Go to step 3.
B. The voltage is greater than 16 V. Replace the alternator. Return to step 1 to confirm elimination of fault.
3. Measure the voltage at instrument cluster.
RAIL12FRK1164FA 1
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Schematic Legend
(1) Alternator (4) Alternator charge signal to the instrument
cluster.
(2) Alternator connector X-083 (5) Key ON signal from the ignition switch.
(3) Telematics alternator signal
Turn the ignition switch ON. Start the engine.
Measure the voltage between pin X-033 pin 12 and chassis ground. The chassis ground connection should be
clean and free of paint, oil, and dirt. The voltage should be approximately 14.5 V. Wiggle the harness during
measurement to reveal an intermittent condition.
A. The voltage is approximately 14.5 V. Temporarily replace the instrument cluster and retest. Return to step 1
to confirm elimination of the fault code.
B. The voltage is greater than 16 V. Replace the alternator. Return to step 1 to confirm elimination of fault.
Wiring harnesses - Electrical schematic sheet 01 Power distribution / Charging system (55.100.DP-C.20.E.01)
Wiring harnesses - Electrical schematic sheet 02 Starting system (55.100.DP-C.20.E.02)
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1015-VCM Battery Voltage Is Too Low

Context:
The instrument cluster measured an alternator voltage less than 11 V for a period greater than 5 s. The instrument
cluster will illuminate the warning lamp indicating that it has detected a problem in the battery charging system.
The fault will reset once the alternator voltage is greater than 11.2 V for a period greater than 5 s.
Cause:
The voltage on instrument cluster input, X-033 pin 12 is less than 11 V.
1. Faulty wiring
2. Faulty alternator, alternator output less than 11 V.
Solution:

2. Measure the alternator output.
Start the engine.
Set engine speed to low idle.
Measure the voltage at the alternator. The voltage should be approximately 14.5 V.
A. The voltage is approximately 14.5 V. Go to step 3.
B. The voltage is less than 11 V. Replace the alternator. Return to test step 1 to confirm elimination of fault.
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RAIL12FRK1164FA 1
Schematic Legend
cluster.
(2) Alternator connector X-083 (5) Key ON signal from the ignition switch.
Disconnect the Instrument Cluster Connector X-033.
A. The voltage is approximately 14.5 V. Temporarily replace the Instrument Cluster and retest. Return to step 1
B. The voltage is less than 11 V. There is a problem in the wiring between the alternator and the instrument cluster.
Repair as required. Return to step 1 to confirm elimination of the fault.
Wiring harnesses - Electrical schematic sheet 02 Starting system (55.100.DP-C.20.E.02)
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1018-Boost Air Temperature Is Above Operating Temperature

Context:
The ECU has detected that the boost air temperature is greater than 180 °C (356 °F) for a period greater than 5 s.
The instrument cluster will illuminate the warning lamp and will sound the alarm for one second on the next system
power up following the event. Fault code 1018 - Boost Air Temperature Is Above Operating Temperature will be
active with 3010 - Air Intake Temperature Sensor - Signal Above Range Maximum. Follow the troubleshooting
procedure for fault code 3010 - Air Intake Temperature Sensor - Signal Above Range Maximum.
The fault will reset once the boost air temperature drops below 177 °C (351 °F) for a period greater than 5 s.
Cause:
The boost air temperature signal is above normal. The instrument cluster has received a message from the ECU that
the boost air temperature is greater than 180 °C (356 °F) for a period greater than 5 s.
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1019-Engine Coolant Is Above Operating Temperature

586H
588H
Context:
This is an information fault code only. This fault code indicates that the coolant temperature is approaching the fault
code trigger point.
The ECU has detected a coolant temperature greater than 106 °C (223 °F) for a period greater than 5 s.
The fault will reset once the coolant temperature less than or equal to 102 °C (216 °F) for a period greater than 5 s.
Cause:
The coolant temperature signal is above normal. The instrument cluster has received a message from the ECU that
the coolant temperature is above 106 °C (223 °F) for a period greater than 5 s.
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1020-Transmission Oil Is Above Operating Temperature

Context:
The instrument cluster monitored a transmission oil temperature greater than 106 °C (223 °F) for a period greater
than 5 s.
The fault will reset once the transmission oil temperature drops below 101 °C (214 °F) for a period greater than 5 s.
Cause:
The transmission oil temperature is above 106 °C (223 °F) for a period greater than 5 s.
1. Low transmission oil level.

2. Faulty fan operation.
3. Clogged cooling core.
4. Faulty reading from the sensor.
Solution:
B. Fault code 1020 is active and other codes such as 1002, 1009, 1018, or 1019 are active at the same time.
Check for proper fan operation. Check the cooling core and inlet air system for clogs. Reduce engine load.
C. Fault code 1020 is recorded again. Go to step 2.

2. Verify transmission oil level.
Check the transmission oil level. Refer to Operator's Manual for more details.
A. The oil level is not correct. Add oil as required, refer to the Operator’s Manual for more details. Return to step
B. The oil level is correct but the fault is recorded again, go to step 3.
3. Visually inspect the cooling system.
Run the engine at 1500 RPM.
Check the fan for proper operation.
Check the cooling core for clogs.
A. The cooling system is operating properly. Go to step 4.
B. The cooling system is not operating properly or the cooling core is clogged. Repair fan or clear clogs from
cooling core. Repair as required. Return to step 1 to confirm elimination of fault.
Inspect the instrument cluster and transmission temperature sender connections. All connections should be se-
cure, tight, free of corrosion, abrasion, and damage.
free of damage, corrosion, abrasion, or incorrect attachment.
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RAIL12FRK1160FA 1
Schematic Legend
(1) Instrument luster connector X-033 pin 16 (2) B-018 transmission temperature sender
5. Check temperature sender.
Disconnect terminal connector from the transmission temperature sender.
Measure the resistance between the transmission temperature sender ground connection and chassis ground.
The resistance should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent con-
dition.
Measure the resistance between the temperature sender connector X-071, pin 1 and chassis ground.
Temperature Measured resistance in ohms

110 °C (230.0 °F) 130 Ω
100 °C (212.0 °F) 175 Ω
92 °C (197.6 °F) 223 Ω
85 °C (185.0 °F) 280 Ω
78 °C (172.4 °F) 358 Ω
68 °C (154.4 °F) 511 Ω
A. The resistance measurements are within range, go to step 5.
B. Resistance readings are not within range. Replace the transmission temperature sender. Return to step 1 to
6. Check wiring to instrument cluster.
Disconnect the instrument cluster connector X 033.
Measure the resistance between transmission temperature sender connector X-071 pin 1 and chassis ground. The
resistance should be greater than 20,000 Ω. Wiggle the harness during measurement to reveal an intermittent
condition.
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A. The resistance measurement is greater than 20,000 Ω. Temporarily replace the instrument cluster and retest.
B. The resistance is less than 20,000 Ω. There is a short circuit to chassis ground in the wire. Repair or replace
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1021-Fuel Is Above Operating Temperature

Context:
The ECU has detected that the fuel temperature is greater than 86 °C (187 °F) for a period greater than 5 s. The
instrument cluster will illuminate the warning lamp and will sound the alarm for one second on the next system power
up following the event. Fault code 1021 - Fuel Is Above Operating Temperature will be active with 3015 - Fuel
Temperature Sensor - Signal Above Maximum. Follow the troubleshooting procedure for fault code 3015 - Fuel
Temperature Sensor - Signal Above Maximum.
The fault will reset once the fuel temperature is equal to or less than 81 °C (178 °F) for a period greater than 5 s.
Cause:
The fuel temperature signal is above normal. The instrument cluster has received a message from the ECU that the
fuel temperature is above 86 °C (187 °F) for a period greater than 5 s.
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1022-Water In Fuel Detected

Context:
The ECU has detected water in the fuel. The instrument cluster will illuminate the warning lamp and will sound the
alarm for one second on the next system power up following the event. Fault code 1022 - Water In Fuel Detected
will be active with 3146 - Water detected in fuel. Follow the troubleshooting procedure for fault code 3146 - Water
detected in fuel.
The fault will reset once the ECU no longer detects water in the fuel.
Cause:
The ECU has detected water in the fuel.
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1024-Foot Throttle Supply Voltage Is Too Low

Context:
The instrument cluster detects a voltage less than 4.5 V on the throttle sensor 5 V supply line, connector X-033 pin
17, for a period greater than 5 s. The instrument cluster will illuminate the warning lamp and will sound the alarm for
one second on the next system power up following the event.
The fault will reset once the sensor supply voltage is greater than 4.6 V for a period greater than 5 s.
Cause:
The instrument cluster detects a voltage less than 4.5 V on the throttle sensor 5 V supply line, connector X-033, pin
17.
1. Throttle supply wire shorted to minus battery or chassis ground.

2. Failed throttle sensor.
3. Failed instrument cluster.
Solution:

Inspect the instrument cluster and the foot throttle sensor connections. All connections should be secure, tight,
free of corrosion, abrasion, and damage.
Inspect the harness from the instrument cluster to the foot throttle sensor. Verify that the harness is free of damage,
RAIL12FRK1162FA 1
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Schematic Legend
(1) Instrument Cluster connector X-033 (2) A-006 foot throttle
3. Measure the sensor supply voltage.
Disconnect the foot throttle connector X-155.
Measure the voltage between X-155 pin C and X-155 pin B. The voltage should be approximately 5 V. Wiggle the
harness during measurement to reveal an intermittent condition.
Measure the voltage between X-155 pin C and chassis ground. The chassis ground connection must be clean
and free of paint, oil, and dirt. The voltage should be approximately 5 V. Wiggle the harness during measurement
A. The voltage is between 4.8 V and 5.2 V. Fault code 1024 is active when the foot throttle is connected. Fault
code 1024 is not active while the foot throttle is disconnected. Temporarily replace the foot throttle and retest.
B. The voltage is less than 4.8 V, go to step 4.

4. Measure the resistance of the 5 volt supply wire to ground.
Disconnect instrument cluster connector X-033. Leave the foot throttle disconnected from the harness.
Measure the resistance between X-155 pin C and chassis ground. The resistance should be greater than 20,000 Ω.
Wiggle the harness during measurement to reveal an intermittent condition.
Measure the resistance between X-155 pin C and X-155 pin B. The resistance should be greater than 20,000 Ω.
Measure the resistance between X-155 pin C and X-155 pin E. The resistance should be greater than 20,000 Ω.
A. All resistance measurement are greater than 20,000 Ω. Temporarily replace the instrument cluster and retest.
B. One or more resistance measurements are less than 20,000 Ω. There is a short circuit in the harness. Repair
or replace the harness as required. Return to step 1 to confirm elimination of fault.
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1026-Foot Throttle Supply Voltage Is Shorted To Ground

Context:
17 for a period greater than 5 s. The instrument cluster will illuminate the warning lamp and will sound the alarm for
one second on the next system power up following the event.
Cause:
17.
1. Throttle supply wire shorted to minus battery or chassis ground.

2. Failed throttle sensor.
3. Failed instrument cluster.
Solution:

Inspect the harness from the instrument cluster to the foot throttle sensor. Verify that the harness is free of damage,
RAIL12FRK1162FA 1
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Schematic Legend

Disconnect the instrument cluster connector X-033. Leave the foot throttle disconnected from the harness.
B. One or more resistance measurements are less than 20,000 Ω There is a short circuit in the harness. Repair
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1030-Foot Throttle Sensor Is Shorted To Ground

Context:
The instrument cluster detects a throttle signal voltage less than 0.2 V. The Instrument Cluster will illuminate the
warning lamp and will sound the alarm for one second on the next system power up following the event.
Cause:
The instrument cluster detects the throttle signal voltage is less than 0.2 V.

Solution:

RAIL12FRK1162FA 1
Schematic Legend
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Disconnect the instrument cluster connector X-033. Leave the foot throttle disconnected from the harness.
B. One or more resistance measurements are less than 20,000 Ω There is a short circuit in the harness. Repair
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1040-Engine RPM > 2750 for 5 seconds

Context:
The instrument cluster has monitored an engine speed greater than 2750 RPM for a period greater than 5 s. The
warning lamp will illuminate amber and the instrument cluster will sound the alarm for one second upon activation per
key cycle.
Fault Code 1040 - Engine RPM > 2750 for 5 seconds is displayed on the instrument cluster to warn the operator
that the engine speed has exceeded 2750 RPM.
The fault will reset once the engine speed drops below 2650 RPM for a period greater than 5 s.
Cause:
The engine speed is greater than 2750 RPM.
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1041-Engine RPM > 3000 for 5 seconds

NOTICE: Always stop the machine and shut down the engine whenever the stop lamp illuminates.
Context:
The instrument cluster has monitored an engine speed greater than 3000 RPM for a period greater than 5 s. The stop
lamp and engine lamp will illuminate while the fault is active. The instrument cluster will sound the alarm continuously.
Stop the machine and shut down the engine.
Fault Code 1041 - Engine RPM > 3000 for 5 seconds is displayed on the instrument cluster to warn the operator
that the engine speed has exceeded 3000 RPM.
The fault will reset once the engine speed drops below 2800 RPM for a period greater than 5 s.
Cause:
The engine speed is greater than 3000 RPM.
Solution:
1. Stop the machine and shut down the engine.

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1044-Fuel Level Sensor Shorted To Ground

Context:
The instrument cluster has detected the fuel sender resistance is below 10 Ω for a period greater than 5 s. The
instrument cluster will illuminate the warning lamp and sound the alarm for one second on the next system power up
following the event.
Cause:
The instrument cluster has detected the fuel sender resistance is below 10 Ω for a period greater than 5 s.
1. Wiring or circuits shorted to minus battery or chassis ground.

2. Faulty fuel level sensor.
Solution:
A. The fault is not recorded again. OK to return the machine to service.

RCPH10TLB081AAM 1
(1) Fuel level sensor

(2) Fuel level sensor connector X-063
(3) Connector X-001/X-051
Inspect the instrument cluster and the fuel level sender connections. All connections should be secure, tight, free
of corrosion, abrasion and damage.
Inspect the harness from the instrument cluster to the fuel level sender. Verify that the harness is free of damage,
corrosion, abrasion and incorrect attachment.
A. The connectors are secure and the harness is free of damage. Go to step 3.
to step 1 to confirm elimination of fault.
3. Measure the resistance of the fuel level signal wire to chassis ground.
Disconnect connector X-63.
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RCPH11TLB051FAL 2
Schematic legend
(1) Instrument cluster connector X-028 (4) Fuel level sender
(2) Air filter restriction switch (5) Transmission temperature sender
Switch is closed in fault condition.
(3) Hydraulic filter restriction switch ,
Switch is closed in fault condition.
Measure the resistance between X-63, pin A (Sensor side) and X-63, pin B.
Refer to the fuel tank level. The resistance should between 4.5 Ω and 330 Ω.
Level Resistance
Full 10 Ω to 53 Ω
Empty 193 Ω to 240 Ω
Resistance values are measured from the fuel level sensor connector X-063, pins A and B.
If the resistance measurements are taken from connector X-051/X-001 or from the instrument cluster, add
22 Ω to the value.
A. The resistance measurements are within tolerances. Go to step 4.
B. The resistance values did not match the values from the table or the resistance was less than 2.5 Ω. Replace
the sensor. Go to step 1 to confirm elimination of the fault code.
4. Measure the resistance at the fuel level sensor.
Tilt the cab and remove the fuel level sender from the tank.
Disconnect the harness from the sender.
Move the fuel level float from the low position to the high position while measuring the resistance of the sender.
The resistance should change linearly from approximately 4.5 Ω at the full tank position to approximately 340 Ω
at the empty tank position. The resistance should change linearly without any fluctuations to a higher or lower
resistance.
A. The resistance measurements from the sensor are within specifications. Go to step 5.
B. The resistance readings from the sensor are not steady or the values are not accurate. Temporarily replace
sensor and retest. Return to step 1 to confirm elimination of fault.
5. Check fuel level wiring.
Measure the resistance between X-64 pin 1 and chassis ground. The resistance should be less than 10 Ω. Wiggle
the harness during measurement to reveal an intermittent condition.
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Measure the resistance from X-063 pin 1 to instrument cluster connector X-33, pin 24. The resistance should be
approximately 22 Ω. Wiggle the harness during measurement to reveal an intermittent condition.
Measure the resistance between X-63 pin 1 and chassis ground (engine block). The resistance should be greater
A. The resistance measurements are within specifications. Temporarily replace the instrument cluster and retest.
Go to step 1 to confirm elimination of the fault.
B. The resistance readings were not with the limits defined in the step. Repair or replace the harness as required.
Return to step 1 to confirm elimination of fault.
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1045-Fuel Level Sensor - Open Circuit

Context:
The instrument cluster has detected an open circuit in the fuel sender signal. The instrument cluster will illuminate
the warning lamp and will sound the alarm for one second on the next system power up following the event.
Cause:
The instrument cluster has detected an open circuit in the fuel level signal.
1. An open circuit in the fuel level sender signal wire.

2. Faulty fuel level sensor.
Solution:
A. The fault code is not recorded again. OK to return the machine to service.

RCPH10TLB081AAM 1
(1) Fuel level sensor

(2) Fuel level sensor connector - X-063
(3) Connector X-001/X-051
Inspect the instrument cluster and the fuel level sender connections. All connections should be secure, tight, free
of corrosion, abrasion and damage.
Inspect the harness from the instrument cluster to the fuel level sender. Verify that the harness is free of damage,
corrosion, abrasion or incorrect attachment.
3. Measure the resistance of the fuel level signal wire to chassis ground.
Disconnect connector X-63.
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RCPH11TLB051FAL 2
Schematic legend
(1) Instrument cluster connector X-028 (4) Fuel level sender
(2) Air filter restriction switch (5) Transmission temperature sender
Switched closed in fault condition.
(3) Hydraulic filter restriction switch
Switch closed in fault condition.
Measure the resistance from X-63, pin 1 (Sensor side) to chassis ground. Refer to the fuel tank level. The resis-
tance reading should approximately equal the value from the table.
Level Resistance
Full 10 Ω to 53 Ω
Empty 193 Ω to 240 Ω
Resistance values are measured from the fuel level sensor connector X-063, pins A and B.
If the resistance measurements are taken from connector X-051/X-001 or from the instrument cluster, add
22 Ω to the value.
A. The resistance measurements were within tolerances. Go to step 4.
B. The resistance values did not match the values from the table or the resistance was less than 2.5 Ω. Tem-
porarily replace the sensor and retest. Go to step 1 to confirm elimination of the fault code.
4. Measure the resistance at the fuel level sensor.
Tilt the cab and remove the fuel level sender from the tank.
Disconnect the harness from the sender.
Move the fuel level float from the low position to the high position while measuring the resistance across the sender.
The resistance should change linearly from approximately 4.5 Ω at the full tank position to approximately 340 Ω
at the empty tank position. The resistance should change linearly without any fluctuations to a higher or lower
resistance.
A. The resistance measurements from the sensor were within specifications. Go to step 5.
B. The resistance readings from the sensor were not steady or the values were not accurate. Temporarily replace
the sensor and retest. Return to step 1 to confirm elimination of fault.
5. Check fuel level wiring.
Measure the resistance between X-64 pin 1 to chassis ground. The resistance should be less than 10 Ω. Wiggle
the harness during measurement to reveal an intermittent condition.
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Measure the resistance between X-63 pin 1 to instrument cluster connector X-33, pin 24. The resistance should
be approximately 22 Ω. Wiggle the harness during measurement to reveal an intermittent condition.
A. The resistance measurements are within specifications. Temporarily replace the instrument cluster and retest.
Go to step 1 to confirm elimination of the fault.
B. The resistance readings are not within the limits defined in the step. Repair or replace the harness as required.
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1047-Transmission Temperature Sensor is Shorted Low

Context:
The instrument cluster measures a resistance less than 3 Ω on the transmission temperature input, X-033 pin 16.
power up following the event.
The fault will reset once the resistance is greater than 10 Ω for a period greater than 5 s.
Cause:
The instrument cluster measures a resistance less than 3 Ω for a period greater than 5 seconds.
1. Wiring or circuits shorted to minus battery or chassis ground.

2. Faulty reading from sensor.
3. Faulty reading from instrument cluster.
Solution:
A. Fault code 1047 - Transmission Temperature Sensor is Shorted Low is not recorded again. OK to return
the machine to service.
B. Fault code 1047 - Transmission Temperature Sensor is Shorted Low is recorded again. Go to step 2.
secure, tight, free of corrosion, abrasion and damage.
RAIL12FRK1160FA 1
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Schematic Legend
(1) Instrument cluster connector X-033 (2) Transmission temperature sender
connector X-071
3. Measure the resistance across the sensor.
Disconnect the transmission temperature sensor connector X-071.
Measure the resistance across the transmission temperature sensor. The resistance should be between 30 Ω and
68.7k Ω. Refer to the chart for more details.
Temperature Resistance Temperature Resistance

-35 °C 68634 Ω 65 °C 456 Ω
-25 °C 35440 Ω 75 °C 321 Ω
-15 °C 19116 Ω 85 °C 230 Ω
-5 °C 10721 Ω 90 °C 168 Ω
5 °C 10721 Ω 105 °C 124 Ω
15 °C 3756 Ω 115 °C 93 Ω
25 °C 2336 Ω 125 °C 71 Ω
35 °C 1496 Ω 135 °C 55 Ω
45 °C 983 Ω 145 °C 43 Ω
55 °C 662 Ω 155 °C 34 Ω
A. The resistance values are within range. Go to step 1.
B. The resistance measurements are not within range. Temporarily replace the sender and retest. Return to step
Disconnect the transmission temperature sender from the harness.
Measure the resistance between X-033, pin 16 and chassis ground. Wiggle the harness during measurement to
reveal an intermittent condition. The resistance should be greater than 20,000 Ω.
A. The resistance is greater than 20,000 Ω. Temporarily replace the instrument cluster and retest. Return to step
1 to confirm elimination of fault.
B. The resistance is less than 20,000 Ω. There is a short circuit in the signal wire to chassis ground. Repair or
replace the wire as required. Return to step 1 to confirm elimination of fault.
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1048-Transmission Temperature Sensor - Open Circuit

Context:
The instrument cluster measures a resistance greater than 65,000 Ω on the transmission temperature input, X-033
pin 16. The instrument cluster will illuminate the warning lamp and will sound the alarm for one second on the next
system power up following the event.
Cause:
The instrument cluster measures a resistance greater than 65,000 Ω for a period greater than 5 seconds.
1. Wiring or circuits shorted to another voltage source.

2. Open circuit in the sender wiring.
3. Faulty reading from sensor.
4. Faulty reading from instrument cluster.
Solution:
1. Verify that the fault code is still active.
Use the Electronic Service Tool to clear all fault codes. Prior to clearing fault codes write down all fault codes,
number of occurrences, and engine hours at last occurrence.
To check for fault code: Start and operate machine.
A. Fault code 1048 - Transmission Temperature Sensor - Open Circuit is not recorded again. OK to return the
machine to service.
B. Fault code 1048 - Transmission Temperature Sensor - Open Circuit is recorded again. Go to step 2.
secure, tight, free of corrosion, abrasion and damage.
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RAIL12FRK1160FA 1
Schematic Legend
(1) Instrument cluster connector X-033 (2) Transmission temperature sender
connector X-071
3. Measure the resistance across the sensor.
Disconnect the transmission temperature sensor connector X-071.
Measure the resistance across the transmission temperature sensor. The resistance should be between 30 Ω and
68.7k Ω. Refer to the chart for more details.
Temperature Resistance Temperature Resistance

-35 °C 68634 Ω 65 °C 456 Ω
-25 °C 35440 Ω 75 °C 321 Ω
-15 °C 19116 Ω 85 °C 230 Ω
-5 °C 10721 Ω 90 °C 168 Ω
5 °C 10721 Ω 105 °C 124 Ω
15 °C 3756 Ω 115 °C 93 Ω
25 °C 2336 Ω 125 °C 71 Ω
35 °C 1496 Ω 135 °C 55 Ω
45 °C 983 Ω 145 °C 43 Ω
55 °C 662 Ω 155 °C 34 Ω
A. The resistance values are within range. Go to step 1.
B. The resistance measurements are not within range. Temporarily replace the sender and retest. Return to step
4. Measure the resistance through the signal wire.
Disconnect the transmission temperature sender from the harness.
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Fabricate a jumper wire that will connect between instrument cluster connector, X-033 pin 16 and chassis ground.
Connect the jumper wire between instrument cluster connector, X-033 pin 16 and chassis ground. The chassis
ground connection must be clean and free of paint, dirt, and oil.
Measure the resistance between X-071, pin 1 and chassis ground. Wiggle the harness during measurement to
reveal an intermittent condition. The resistance should be less than 10 Ω.
A. The resistance is less than 10 Ω. Temporarily replace the Instrument Cluster and retest. Return to step 1 to
B. The resistance is greater than 10 Ω. There is an open circuit in the signal wire. Repair or replace the harness
as required. Return to step 1 to confirm elimination of fault.
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1050-Alternator Unable To Charge

NOTE: The battery must be at full charge, and all connections must be clean and tight before testing the electrical
system.
Context:
The instrument cluster measured a voltage less than 1.5 V for a period greater than 5 s on connector X-033, pin 12.
power up following the event.
Cause:
The instrument cluster measured a voltage less than 1.5 V for a period greater than 5 s.
1. Wiring or circuits open.

2. Alternator output voltage is less than 11 V.
3. Faulty reading from the instrument cluster.
Solution:
A. Fault code 1050 - Alternator Unable To Charge is not recorded again. OK to return the machine to service.
B. Fault code 1050 - Alternator Unable To Charge is recorded again. Go to step 2.

Inspect the alternator and battery connections. All connections should be secure, tight, free of corrosion, abrasion
and damage.
Inspect the harness from the alternator and battery to the instrument cluster. Verify that the harness is free of
damage, corrosion, abrasion or incorrect attachment.
A. All connections are secure and the harness is free of damage. Go to step 3.
to step1 to confirm elimination of the fault.
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RAIL12FRK1164FA 1
Schematic Legend
cluster.
(2) Alternator connector X-083 (5) Battery key on from the ignition switch.
A. The voltage is approximately 14.5 V. Temporarily replace the instrument cluster and retest. Return to step 1
B. The voltage is less than 11 V. There is a problem in the wiring between the alternator and the instrument cluster.
Repair as required. Return to step 1 to confirm elimination of the fault.
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1051-Expected CAN Message Not Received (EEC1)

Context:
CAN bus communications between the instrument cluster and the ECU may have been interrupted. The instrument
cluster did not receive the EEC1 message from the ECU. This fault code may be displayed with other CAN bus fault
messages. The instrument cluster will illuminate the stop lamp and will continually sound the audible alarm while this
fault is active.
Cause:
The instrument cluster did not receive a CAN message from the ECU. CAN bus communications between the instru-
ment cluster and the ECU may have been interrupted.
1. CAN bus wiring open circuit.

2. CAN bus wiring short circuit.
4. Faulty ECU.
Solution:
A. Fault code 1051 - Expected CAN Message Not Received (EEC1) is not recorded again. Go to step 2.
B. Fault code 1051 - Expected CAN Message Not Received (EEC1) is recorded again. There may be one or
two other CAN bus fault codes associated with 1051 - Expected CAN Message Not Received (EEC1). Go
to step 2.
C. Fault code 1051 - Expected CAN Message Not Received (EEC1) is recorded along with other CAN data link
faults such as 1052-1060, and/or 3096, 3179 and 3180. Go to step 3.
2. Verify that the CAN bus circuit is functioning properly.
Turn the ignition switch ON
Verify the connections to the ECU, instrument cluster, diagnostic connector, and the optional Telematics unit are
tight and secure. Check for CAN bus fault codes while wiggling the harness.
Disconnect the instrument cluster connector X-033. Measure the resistance between X-033 pin 5 and X-033 pin
6 on the instrument cluster. The resistance should be between 108 Ω and 132 Ω.
Disconnect ECU connector X-461. Measure the resistance between X-461 pin 24 and X-461 pin 25 on the ECU.
The resistance should be between 108 Ω and 132 Ω.
A. All connections are secure. Both resistance measurements are within range. OK to return the machine to
service.
B. The harness is damaged or the connectors are loose or damaged. Repair or replace the harness as required.
C. One or both resistance measurements are less than 108 Ω or greater than 132 Ω. Replace the control that
has the bad resistance value. Return to step 1 to confirm elimination of fault.
3. Verify the harness is not damaged.
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tight and secure.
Verify the harness is free of damage, abrasion, corrosion, and incorrect attachment from the ECU to the instrument
cluster. Verify all data link drops are free of damage, abrasion, corrosion and incorrect attachment.
RAIL12FRK1166GA 1
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(1) Switched battery to diagnostic port (4) CAN bus to the instrument cluster
CAN High X-033 pin 6
CAN Low X-033 pin 5
(2) Diagnostic port X-001 (5) CAN bus to the ECU
CAN Low X-461 pin 25
(3) Diagnostic port minus battery connection (6) CAN Bus to the Telematics (optional)
CAN High X-498 pin E
CAN Low X-498 pin D
A. The CAN bus harness is not damaged and all connections are secure. Go to step 4.
4. Measure the resistance through the CAN Data Link harness.
Measure the resistance between the diagnostic port connector, CAN 1 High and CAN 1 Low pins, pins C and D.
The resistance should be approximately 60 Ω. Wiggle the harness during measurement to reveal an intermittent
condition.
A. The resistance is less than 50 Ω. Go to step 6.
B. The resistance is between 54 Ω and 66 Ω. Go to step 5.
C. The resistance is greater than 70 Ω. Go to step 7.

5. Measure harness resistance between chassis ground and positive battery.
Disconnect the instrument cluster connector, X-033.
Disconnect all other devices connected to the CAN bus.
Measure the resistance between X-033 pin 5 and chassis ground. The resistance should be greater than 20,000 Ω.
Measure the resistance between X-033 pin 5 and positive battery ( X-033 pin 9). The resistance should be greater
Measure the resistance between X-033 pin 6 and positive battery ( X-033 pin 9). The resistance should be greater
Measure the resistance between X-033 pin 6 and chassis ground. The resistance should be greater than 20,000 Ω.
Circuit description Instrument cluster connection Alternate diagnostic port connection

Switched battery X-033 pin 9 X–001 pin B
Minus battery X-033 pin 34 X–001 pin A
CAN high X-033 pin 6 X–001 pin C
CAN low X-033 pin 5 X–001 pin D
A. All resistance measurements are greater than 20,000 Ω. Verify the ECU is powered and operational. Verify
that all minus battery and chassis ground connections to the CAN bus modules are clean and secure. Repair
B. The resistance is less than 20,000 Ω. There is a short circuit in the CAN bus. Temporarily replace the CAN
bus wires and retest. Repair or replace the harness as required. Return to step 1 to confirm elimination of the
fault code.
6. Measure the resistance between the CAN high and CAN low wires.
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Turn the ignition switch OFF. Disconnect all modules on the CAN bus.
Measure the resistance between CAN high (diagnostic connector pin C) and CAN low (diagnostic connector pin
D).
A. The resistance is greater than 20,000 Ω. Connect each component to the CAN bus one at a time. The re-
sistance should be greater than 54 Ω. Replace the module that drops the CAN bus resistance below 54 Ω.
B. The resistance is less than 54 Ω there is a short circuit between the CAN high and CAN low wires. Repair or
replace the harness as required. Return to test step 1 to confirm elimination of the fault.
7. Measure the resistance through the CAN bus circuit.
Turn the ignition switch OFF. Disconnect all components connected to the CAN bus.
Fabricate a jumper 20 cm (8 in) that will connect between ECU connetcor X-461 pin 24 and 25.
Connect the jumper between X-461 pin 24 and 25.
Measure the resistance between diagnostic port connector pin C and pin D. The resistance should be less than
10 Ω. Wiggle the harness during measurement to reveal an intermittent condition.
RAIL12FRK1168FA 2
(1) Digital volt meter set to measure (4) CAN Bus to Instrument Cluster
resistance CAN High X-033 pin 6
CAN Low X-033 pin 5
(2) Diagnostic Port X-001 (5) CAN Bus to ECU
CAN Low X-461 pin 25
(3) Jumper wire installed between the CAN (6) CAN Bus to Telematics (optional)
High and CAN Low pins CAN High X-498 pin E
CAN Low X-498 pin D
Measure the resistance between Telematics connector pin E and pin D. The resistance should be less than 10 Ω.
Measure the resistance between instrument cluster connector X-033 pin 6 and pin 5. The resistance should be
less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition.
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RAIL12FRK1167FA 3
(1) Digital volt meter set to measure (4) CAN bus to the instrument cluster
resistance. CAN high X-033 pin 6
CAN low X-033 pin 5
(2) Diagnostic port X-001 (5) CAN bus to the ECU
CAN high X-461 pin 24
CAN low X-461 pin 25
(3) Jumper wire installed between the CAN (6) CAN bus to Telematics (optional)
high and CAN low pins CAN high X-498 pin E
CAN low X-498 pin D
A. All resistance measurements are less than 10 Ω. Temporarily replace the instrument cluster and retest. Return
to step 1 to confirm elimination of the fault.
B. One or more resistance measurements are greater than 20,000 Ω. There is an open circuit in the CAN bus
wires. Repair or replace the harness as required. Go to step 1 to confirm elimination of the fault.
Wiring harnesses - Electrical schematic sheet 07 CAN BUS / Diagnostic (55.100.DP-C.20.E.07)
Wiring harnesses - Electrical schematic sheet 08 Telematics (55.100.DP-C.20.E.08)
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1052-Expected CAN Message Not Received (EEC3)

Context:
cluster did not receive the EEC3 message from the ECU. This fault code may be displayed with other CAN bus fault
fault is active.
Cause:

4. Faulty ECU.
Solution:
A. Fault code 1052 - Expected CAN Message Not Received (EEC3) is not recorded again. Go to step 2.
B. Fault code 1052 - Expected CAN Message Not Received (EEC3) is recorded again. There may be one or
to step 2.
C. Fault code 1052 - Expected CAN Message Not Received (EEC3) is recorded along with other CAN data link
faults such as 1051-1060, and/or 3096, 3179 and 3180. Go to 1051-Expected CAN Message Not Received
(EEC1) (55.640) step 3.
service.
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1053-Expected CAN Message Not Received (EC)

Context:
cluster did not receive the EC message from the ECU. This fault code may be displayed with other CAN bus fault
fault is active.
Cause:

4. Faulty ECU.
Solution:
A. Fault code 1053 - Expected CAN Message Not Received (EC) is not recorded again. Go to step 2.
B. Fault code 1053 - Expected CAN Message Not Received (EC) is recorded again. There may be one or two
other CAN bus fault codes associated with 1051 - Expected CAN Message Not Received (EEC1). Go to step
2.
C. Fault code 1053 - Expected CAN Message Not Received (EC) is recorded along with other CAN data link
(EEC1) (55.640) step 3.
service.
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1054-Expected CAN Message Not Received (Engine Temperature)

Context:
cluster did not receive the engine temperature message from the ECU. This fault code may be displayed with other
CAN bus fault messages. The instrument cluster will illuminate the stop lamp and will continually sound the audible
alarm while this fault is active.
Cause:

4. Faulty ECU.
Solution:
A. Fault code 1054 - Expected CAN Message Not Received (Engine Temperature) is not recorded again. Go
to step 2.
B. Fault code 1054 - Expected CAN Message Not Received (Engine Temperature) is recorded again. There
may be one or two other CAN bus fault codes associated with 1051 - Expected CAN Message Not Received
(EEC1). Go to step 2.
C. Fault code 1054 - Expected CAN Message Not Received (Engine Temperature) is recorded along with other
CAN data link faults such as 1051-1060, and/or 3096, 3179 and 3180. Go to 1051-Expected CAN Message
Not Received (EEC1) (55.640) step 3.
service.
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1055-Expected CAN Message Not Received (Inlet/Exhaust)

Context:
cluster did not receive the inlet/exhaust message from the ECU. This fault code may be displayed with other CAN
bus fault messages. The instrument cluster will illuminate the stop lamp and will continually sound the audible alarm
while this fault is active.
Cause:

4. Faulty ECU.
Solution:
A. Fault code 1055 - Expected CAN Message Not Received (Inlet/Exhaust) is not recorded again. Go to step
2.
B. Fault code 1055 - Expected CAN Message Not Received (Inlet/Exhaust) is recorded again. There may be
one or two other CAN bus fault codes associated with 1051 - Expected CAN Message Not Received (EEC1).
Go to step 2.
C. Fault code 1055 - Expected CAN Message Not Received (Inlet/Exhaust) is recorded along with other CAN
data link faults such as 1051-1060, and/or 3096, 3179 and 3180. Go to 1051-Expected CAN Message Not
Received (EEC1) (55.640) step 3.
service.
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1056-Expected CAN Message Not Received (Engine Fluid)

Context:
cluster did not receive the engine fluid message from the ECU. This fault code may be displayed with other CAN bus
fault messages. The instrument cluster will illuminate the stop lamp and will continually sound the audible alarm while
this fault is active.
Cause:

4. Faulty ECU.
Solution:
A. Fault code 1056 - Expected CAN Message Not Received (Engine Fluid) is not recorded again. Go to step 2.
B. Fault code 1056 - Expected CAN Message Not Received (Engine Fluid) is recorded again. There may be
one or two other CAN bus fault codes associated with 1051 - Expected CAN Message Not Received (EEC1).
Go to step 2.
C. Fault code 1056 - Expected CAN Message Not Received (Engine Fluid) is recorded along with other CAN
data link faults such as 1051-1060, and/or 3096, 3179 and 3180. Go to 1051-Expected CAN Message Not
Received (EEC1) (55.640) step 3.
service.
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1057-Expected CAN Message Not Received (Vehicle/Electrical)

Context:
cluster did not receive the vehicle/electrical message from the ECU. This fault code may be displayed with other CAN
bus fault messages. The instrument cluster will illuminate the stop lamp and will continually sound the audible alarm
while this fault is active.
Cause:

4. Faulty ECU.
Solution:
A. Fault code 1057 - Expected CAN Message Not Received (Vehicle/Electrical) is not recorded again. Go to
step 2.
B. Fault code 1057 - Expected CAN Message Not Received (Vehicle/Electrical) is recorded again. There may
be one or two other CAN bus fault codes associated with 1051 - Expected CAN Message Not Received
(EEC1). Go to step 2.
C. Fault code 1057 - Expected CAN Message Not Received (Vehicle/Electrical) is recorded along with other
CAN data link faults such as 1051-1060, and/or 3096, 3179 and 3180. Go to 1051-Expected CAN Message
Not Received (EEC1) (55.640) step 3.
service.
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1058-Expected CAN Message Not Received (EDC2BC)

Context:
cluster did not receive the EDC2BC message from the ECU. This fault code may be displayed with other CAN bus
Cause:

4. Faulty ECU.
Solution:
A. Fault code 1058 - Expected CAN Message Not Received (EDC2BC) is not recorded again. Go to step 2.
B. Fault code 1058 - Expected CAN Message Not Received (EDC2BC) is recorded again. There may be one
or two other CAN bus fault codes associated with 1051 - Expected CAN Message Not Received (EEC1). Go
to step 2.
C. Fault code 1058 - Expected CAN Message Not Received (EDC2BC) is recorded along with other CAN data
link faults such as 1051-1060, and/or 3096, 3179 and 3180. Go to 1051-Expected CAN Message Not Re-
ceived (EEC1) (55.640) step 3.
service.
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1059-Expected CAN Message Not Received (DM1)

Context:
cluster did not receive the DM1 message from the ECU. This fault code may be displayed with other CAN bus fault
fault is active.
Cause:

4. Faulty ECU.
Solution:
A. Fault code 1059 - Expected CAN Message Not Received (DM1) is not recorded again. Go to step 2.
B. Fault code 1059 - Expected CAN Message Not Received (DM1) is recorded again. There may be one or
to step 2.
C. Fault code 1059 - Expected CAN Message Not Received (DM1) is recorded along with other CAN data link
(EEC1) (55.640) step 3.
service.
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1060-Timeout Of CAN Message EGRIND

Context:
cluster did not receive the EGRIND message from the ECU. This fault code may be displayed with other CAN bus
Cause:

4. Faulty ECU.
Solution:
A. Fault code 1060 - Timeout Of CAN Message EGRIND is not recorded again. Go to step 2.
B. Fault code 1060 - Timeout Of CAN Message EGRIND is recorded again. There may be one or two other CAN
bus fault codes associated with 1051 - Expected CAN Message Not Received (EEC1). Go to step 2.
C. Fault code 1060 - Timeout Of CAN Message EGRIND is recorded along with other CAN data link faults such
as 1051-1059, and/or 3096, 3179 and 3180. Go to 1051-Expected CAN Message Not Received (EEC1)
(55.640) step 3.
service.
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1090-Vehicle Model ID in VCM is UNCONFIGURED

Cause:
The Vehicle Model ID is not programmed in the instrument cluster. One or more parameters in the instrument cluster
are not programmed.
1. The instrument cluster is not configured properly.
Solution:
1. Connect the Electronic Service Tool and configure all programmable parameters in the instrument cluster.
RAIL14FRK0188FA 1
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3007-Engine coolant temperature sensor voltage is higher than

expected
Context:
The Engine Control Unit (ECU) A-9000 monitors the engine coolant temperature sensor B-9003 signal circuit. If the
ECU A-9000 determines that voltage is higher than expected in the engine coolant temperature sensor B-9003 signal
circuit, this fault will occur. If this fault is active, the ECU A-9000 will set the engine coolant temperature value to a
fixed replacement value of 89.96 °C (193.93 °F).
Cause:
The engine coolant temperature sensor B-9003 signal voltage is greater than 4.93 V.
1. Faulty engine coolant temperature sensor B-9003 wiring, short to a voltage source.
2. Faulty engine coolant temperature sensor B-9003, internal failure.
3. Faulty ECU A-9000, software.
Solution:
1. Verify 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.
Continue with Step 6.
2. Check the coolant temperature sensor B-9003 wiring for a short to a voltage source.
Disconnect the engine harness (EN) from the coolant temperature sensor B-9003 at connector X-9006.
With the key in the OFF position, use a multimeter to perform the following voltage check on the engine harness
side :
From To Value
X-9006 pin 1 Chassis ground There should be no voltage.
With the key in the ON position, use a multimeter to perform the following voltage check on the engine harness
side :
From To Value
X-9006 pin 1 Chassis ground There should be less than 5.5 V
A. If the specified values are not measured, there is a short to a voltage source condition in the coolant tempera-
ture sensor B-9003 wiring. Use the appropriate service manual, if necessary, to locate and repair the shorted
conductor.
B. If the specified values are not measured, leave connector X-9006 disconnected and continue to Step 3.
3. Check the coolant temperature sensor B-9003 engine harness (EN) wiring for a short circuit.
Disconnect the vehicle harness (VE) from the engine interface at connector X-9138.
With the key in the OFF position, use a multimeter to perform the following continuity check on the engine harness
(EN) side :
From To Value
X-9006 pin 1 X-9138 pin 14 There should be continuity.
X-9138 pin 14 All pins in connector X-9138 There should be no continuity.
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From To Value
A. If the specified values are measured, leave the connector X-9138 and X-9006 disconnected and continue to
Step 4.
B. If the specified values are not measured, there is an open or short circuit condition in the wiring. Locate and
repair the broken or shorted conductor.
4. Check the coolant temperature sensor B-9003 vehicle harness (VE) wiring for a short circuit.
Disconnect the vehicle harness (VE) from the ECU A-9000 at connector X-9121.
With the key in the OFF position, use a multimeter to perform the following continuity check on the vehicle harness
(VE) side :
From To Value
X-9138 pin 14 X-9121 pin A57 There should be continuity.
A. If the specified values are measured, continue to Step 5.
B. If the specified values are not measured, there is a shorted or broken circuit in the coolant temperature sensor
B-9003 wiring in the vehicle harness (VE). Use the appropriate service manual, if necessary, to locate and
repair the shorted or broken conductor.
5. Replace the engine coolant temperature sensor B-9003.
Use the EST to verify the status of the this fault.
A. If the fault is no longer active, return the machine to service.
B. If the fault is still active, check the ECU A-9000 for the appropriate software and re-flash, if necessary.
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.
A. If you find damage or the display indicates other than normal display readings, then repair the damage discov-
ered during the inspection or locate and repair the other than normal display condition and verify that the error
has been resolved.
B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue
operation.
Wiring harnesses - Electrical schematic sheet 05 – Engine Control Unit (ECU) engine connector
(55.100.DP-C.20.E.05)
Wiring harnesses - Electrical schematic sheet 06 – Engine control and fuel injection (55.100.DP-C.20.E.06)
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3008-Coolant Temperature Signal - Signal Below Range Minimum

Context:
The Engine Control Unit (ECU) A-9000 monitors the engine coolant temperature sensor B-9003 signal circuit. If the
ECU A-9000 determines that voltage is lower than expected in the engine coolant temperature sensor B-9003 signal
circuit, this fault will occur. If this fault is active, the ECU A-9000 will set the engine coolant temperature value to a
fixed replacement value of 89.96 °C (193.93 °F).
Cause:
The engine coolant temperature sensor B-9003 signal voltage is less than 198.00 mV.
1. Faulty engine coolant temperature sensor B-9003 wiring, short to ground condition.
2. Faulty engine coolant temperature sensor B-9003, internal failure.
Solution:
2. Check the coolant temperature sensor B-9003 engine harness (EN) wiring for a short to ground condition.
Disconnect the engine harness (EN) from the coolant temperature sensor B-9003 at connector X-9006.
side :
To From Value
X-9006 pin 1 X-9006 pin 2 There should be no continuity.
X-9006 pin 1 Chassis ground There should be no continuity.
A. If there is no continuity, leave connectors X-9006 and X-9138 disconnected and continue to Step 3.
B. If there is continuity, there is a short to ground condition in the coolant temperature sensor B-9003 engine
harness (EN) wiring. Locate and repair the shorted conductor.
3. Check the coolant temperature sensor B-9003 vehicle harness (VE) wiring for a short to ground condition.
(VE) side :
From To Value
X-9121 pin A57 All pins in connector X-9121 There should be no continuity.
A. If there is no continuity, leave connector X-9006 disconnected and continue to Step 4.
B. If there is continuity, there is a short circuit in the coolant temperature sensor B-9003 vehicle harness (VE)
wiring. Use the appropriate service manual, if necessary, to locate and repair the shorted or broken conductor.
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4. Replace the engine coolant temperature sensor B-9003.
Use the EST to verify the status of the this fault.
has been resolved.
operation.
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3010-Air Intake Temperature Sensor - Signal Above Range

Maximum
Context:
The Engine Control Unit (ECU) A-9000 monitors the intake manifold temperature sensor R-9000 signal circuit. If the
ECU A-9000 determines that the intake manifold temperature sensor R-9000 signal circuit voltage is greater than
4.94 V, this fault will occur.
Cause:
The ECU A-9000 has determined that the intake manifold temperature sensor R-9000 signal circuit voltage is greater
than 4.94 V.
1. Faulty intake manifold temperature sensor R-9000 wiring, short to a voltage source.
2. Faulty intake manifold temperature sensor R-9000 wiring, open circuit.
3. Faulty intake manifold temperature sensor R-9000, internal failure.
Solution:
2. Check the intake manifold temperature sensor R-9000 wiring for a short to battery condition.
Disconnect the engine harness (EN) from the intake manifold temperature sensor R-9000 at connector X-9020.
(EN) side :
From To Value
(EN) side :
From To Value
X-9020 pin 1 Chassis ground There should be less than 5.5 V.
A. If the specified values are not measured, there is a short to a voltage source in the intake manifold temperature
sensor R-9000 signal circuit. Use the appropriate service manual, if necessary, to locate and repair the shorted
conductor.
B. If the specified values are measured, leave connector X-9020 disconnected and continue to Step 3.
3. Check the intake manifold temperature sensor R-9000 wiring for an open circuit condition.
With the key in the OFF position, use a multimeter to perform the following continuity check for an open circuit on
the engine harness (EN) side :
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From To Value
NOTE: Wiggle the harness during the check to promote an intermittent electrical connection.
the vehicle harness (VE) side :
From To Value
A. If there is no continuity, there is an open circuit in the intake manifold temperature sensor R-9000 wiring. Use
the appropriate service manual, if necessary, to locate and repair the broken conductor.
B. If there is continuity, leave connector X-9138 and X-9121 disconnected and continue to Step 4.
4. Check the intake manifold temperature sensor R-9000 engine harness (EN) wiring for a short circuit.
(EN) side :
From To Value
A. If there is continuity, there is a short circuit in the intake manifold temperature sensor R-9000 in the engine
B. If there no continuity, continue to Step 5.

5. Check the intake manifold temperature sensor R-9000 vehicle harness (VE) wiring.
(VE) side :
From To Value
A. If there is continuity, there is a short circuit in the intake manifold temperature sensor R-9000 in the vehicle har-
ness (VE) wiring. Use the appropriate service manual, if necessary, to locate and repair the shorted conductor.
B. If there no continuity, continue to Step 6.

6. Replace the intake manifold temperature sensor R-9000.
has been resolved.
operation.
(55.100.DP-C.20.E.05)
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3011-Air Intake Temperature Sensor - Signal Above Range Minimum

Context:
The Engine Control Unit (ECU) A-9000 monitors the intake manifold temperature sensor R-9000 signal circuit. If
the ECU A-9000 determines that the intake manifold temperature sensor R-9000 signal circuit voltage is less than
266.40 mV, this fault will occur.
Cause:
The ECU A-9000 has determined that the intake manifold temperature sensor R-9000 signal circuit voltage is less
than 266.40 mV.
1. Faulty intake manifold temperature sensor R-9000 wiring, short to ground condition.
2. Faulty intake manifold temperature sensor R-9000, internal failure.
Solution:
2. Check the intake manifold temperature sensor R-9000 engine harness (EN) wiring.
Disconnect the engine harness (EN) from the intake manifold temperature sensor R-9000 at connector X-9020.
(EN) side :
From To Value
A. If there is continuity, there is a short circuit in the intake manifold temperature sensor R-9000 in the engine
B. If there no continuity, leave connector X-9020 and connector X-9138 disconnected and continue to Step 3.
3. Check the intake manifold temperature sensor R-9000 vehicle harness (VE) wiring.
(VE) side :
From To Value
A. If there is continuity, there is a short circuit in the intake manifold temperature sensor R-9000 in the vehicle har-
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B. If there no continuity, leave connector X-9020 disconnected and continue to Step 4.

4. Replace the intake manifold temperature sensor R-9000.
has been resolved.
operation.
(55.100.DP-C.20.E.05)
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3015-Fuel Temperature Sensor - Signal Above Range Maximum

Context:
The Engine Control Unit (ECU) A-9000 monitors the fuel temperature sensor B-9002 signal circuit voltage. If the ECU
A-9000 detects a voltage greater than 4.93 V in the signal circuit, this fault will occur. If this fault is not inhibited by
another fault, the ECU A-9000 will freeze the fuel temperature value to 39.96 °C (103.93 °F).
Cause:
The fuel temperature sensor B-9002 signal circuit voltage is greater than 4.93 V.
1. Faulty fuel temperature sensor B-9002 wiring, short to a voltage source.

2. Faulty fuel temperature sensor B-9002 wiring, open circuit.
3. Faulty fuel temperature sensor B-9002, internal failure.
Solution:
2. Check the fuel temperature sensor B-9002 for an internal failure.
Disconnect the engine harness (EN) from the fuel temperature sensor B-9002 at connector X-9005.
Use a multimeter to measure the resistance of the fuel temperature sensor B-9002 on the sensor pins :
From To Value
X-9005 pin 1 X-9005 pin 2 At approximately 20.0 °C (68.0 °F),
there should be between 2351 -
2648 Ω.
NOTE: The fuel temperature sensor B-9002 is a Negative Temperature Coefficient (NTC) thermistor. The thermis-
tor’s conductivity increases with increasing temperature and resistance decreases with increasing temperature.
A. If there is a nominal resistance value, e.g. greater than 100 Ω, leave connector X-9005 disconnected and
continue to Step 3.
B. If there is not a nominal resistance value, e.g. 0 Ω, the fuel temperature sensor B-9002 has failed. Replace
the fuel temperature sensor B-9002.
3. Check the fuel temperature sensor B-9002 wiring for a short to battery.
With the key in the OFF position, use the a multimeter to perform the following voltage check on the engine harness
(EN) side :
From To Value
With the key in the ON position, use the a multimeter to perform the following voltage check on the engine harness
(EN) side :
From To Value
A. If the specified values are measured, leave connector X-9005 disconnected and continue to Step 4.
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B. If the specified values are not measured, there is a short to battery or switched battery in the fuel temperature
sensor B-9002 wiring. Use the appropriate service manual, if necessary, to locate and repair the failed con-
ductor.
4. Check the fuel temperature sensor B-9002 engine harness (EN) wiring for an open circuit condition.
With the key in the OFF position, use the a multimeter to perform the following continuity check on the engine
harness (EN) side :
From To Value
A. If there is continuity, leave connectors X-9005 and X-9138 disconnected and continue to Step 5.
B. If there is no continuity, there is an open circuit in the fuel temperature sensor B-9002 wiring in the engine
harness (EN). Locate and repair the broken conductor.
5. Check the fuel temperature sensor B-9002 engine harness (EN) wiring for a short circuit condition.
With the key in the OFF position, use the a multimeter to perform the following continuity check on the engine
harness (EN) side :
From To Value
A. If there is continuity, there is a short circuit in the fuel temperature sensor B-9002 wiring in the engine harness
(EN). Locate and repair the shorted conductor.
B. If there is no continuity, leave connectors X-9005 and X-9138 disconnected and continue to Step 6.
6. Check the fuel temperature sensor B-9002 vehicle harness (VE) wiring for an open circuit condition.
With the key in the OFF position, use the a multimeter to perform the following continuity check on the vehicle
harness (VE) side :
From To Value
B. If there is no continuity, there is an open circuit in the fuel temperature sensor B-9002 wiring in the vehicle
harness (EN). Use the appropriate service manual, if necessary, to locate and repair the broken conductor.
7. Check the fuel temperature sensor B-9002 vehicle harness (VE) wiring for a short circuit condition.
With the key in the OFF position, use the a multimeter to perform the following continuity check on the vehicle
harness (EN) side :
From To Value
A. If there is continuity, there is a short circuit in the fuel temperature sensor B-9002 wiring in the engine harness
(EN). Locate and repair the shorted conductor.
B. If there is no continuity, check the ECU A-9000 for the appropriate software and re-flash, if necessary.
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has been resolved.
operation.
(55.100.DP-C.20.E.05)
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3016-Fuel Temperature Sensor - Signal Below Range Minimum

Context:
The Engine Control Unit (ECU) A-9000 monitors the fuel temperature sensor B-9002 signal circuit voltage. If the ECU
A-9000 detects a voltage less than 198.00 mV in the signal circuit, this fault will occur. If this fault is not inhibited by
another fault, the ECU A-9000 will freeze the fuel temperature value to 39.96 °C (103.93 °F).
Cause:
The fuel temperature sensor B-9002 signal circuit voltage is less than 198.00 mV.
1. Faulty fuel temperature sensor B-9002 wiring, short to ground condition.

2. Faulty fuel temperature sensor B-9002, internal failure.
Solution:
2. Check the fuel temperature sensor B-9002 for an internal failure.
Disconnect the engine harness (EN) from the fuel temperature sensor B-9002 at connector X-9005.
Use a multimeter to measure the resistance of the fuel temperature sensor B-9002 on the sensor pins :
From To Value
X-9005 pin 1 X-9005 pin 2 At approximately 20.0 °C (68.0 °F),
there should be between 2351 -
2648 Ω.
NOTE: The fuel temperature sensor B-9002 is a Negative Temperature Coefficient (NTC) thermistor. The thermis-
tor’s conductivity increases with increasing temperature and resistance decreases with increasing temperature.
A. If there is a nominal resistance value, e.g. greater than 100 Ω, leave connector X-9005 disconnected and
continue to Step 3.
B. If there is not a nominal resistance value, e.g. 0 Ω, the fuel temperature sensor B-9002 has failed. Replace
the fuel temperature sensor B-9002.
3. Check the fuel temperature sensor B-9002 engine harness (EN) wiring for a short to ground condition.
With the key in the OFF position, use the a multimeter to perform the following continuity checks for a short to
ground condition on the engine harness (EN) side :
From To Value
B. If there is continuity, there is a short in the fuel temperature sensor B-9002 wiring in the engine harness (EN).Lo-
cate and repair the failed conductor.
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4. Check the fuel temperature sensor B-9002 vehicle harness (VE) wiring for a short to ground condition.
With the key in the OFF position use the a multimeter to perform the following continuity checks for a short to
ground condition on the vehicle harness (VE) side :
From To Value
A. If the specified values are not measured, there is a fault in the fuel temperature sensor B-9002 vehicle harness
(VE) wiring. Locate and repair the failed conductor.
has been resolved.
operation.
(55.100.DP-C.20.E.05)
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3019-Boost Pressure Sensor - Signal Above Range Max

Context:
The Engine Control Unit (ECU) A-9000 monitors the intake manifold pressure sensor B-9001. If the ECU A-9000
determines that the intake manifold pressure sensor B-9001 signal circuit voltage is greater than 4.92 V, this fault will
occur. If this fault is active, the intake manifold pressure value will be frozen at the last valid value for a preliminary
failure or jump to a fixed replacement value of 0.98 bar (14.21 psi) if the failure is validated.
Cause:
The ECU A-9000 has determined that the intake manifold pressure sensor B-9001 signal circuit voltage is greater
than 4.92 V.
1. Faulty intake manifold pressure sensor B-9001 wiring, short to a voltage source.
2. Faulty intake manifold pressure sensor B-9001 wiring, open circuit.
3. Faulty intake manifold pressure sensor B-9001, internal failure.
Solution:
2. Check the intake manifold pressure sensor B-9001 wiring for a short to a voltage source.
Disconnect the engine harness (EN) from the intake manifold pressure sensor B-9001 at connector X-9003.
side :
From To Value
side :
From To Value
A. If there is voltage, there is a short to battery or switched battery in the intake manifold pressure sensor B-9001
wiring. Use the appropriate service manual, if necessary, to locate and repair the shorted conductor.
B. If there is no voltage, leave connector X-9003 disconnected and continue to Step 3.

3. Check the intake manifold pressure sensor B-9001 wiring in the engine harness (EN) for an open circuit.
Disconnect the vehicle harness (VE) from the engine interface connector X-9138.
(EN) side :
From To Value
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(VE) side :
From To Value
A. If there is no continuity, there is an open circuit in the intake manifold pressure sensor B-9001 wiring in the
engine harness (EN). Locate and repair the broken conductor.
B. If there is continuity, leave connectors X-9003, X-9138, and X-9121 disconnected and continue to Step 4.
4. Check the intake manifold pressure sensor B-9001 wiring in the engine harness (EN) for a short to a voltage
source.
(EN) side :
From To Value
A. If there is continuity, there is a short circuit in the intake manifold pressure sensor B-9001 wiring in the engine
harness (EN). Locate and repair the shorted conductor.
B. If there is no continuity, leave connectors X-9003, X-9138, and X-9121 disconnected and continue to Step 5.
5. Check the intake manifold pressure sensor B-9001 wiring in the vehicle harness (VE) for a short circuit.
(VE) side :
From To Value
A. If there is continuity, there is a short circuit in the intake manifold pressure sensor B-9001 wiring in the vehicle
harness (VE). Use the appropriate service manual, if necessary, to locate and repair the shorted conductor.
B. If there is no continuity, leave connector X-9003 disconnected and continue to Step 6.

6. Replace the intake manifold pressure sensor B-9001.
Use the Electronic Service Tool (EST) to check the status of this fault, 3019 - Boost Pressure Sensor - Signal
Above Range Max.
has been resolved.
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operation.
(55.100.DP-C.20.E.05)
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3024-Atmospheric Pressure Sensor - Signal Above Range Maximum

Context:
The Engine Control Unit (ECU) A-9000 monitors atmospheric pressure. The ECU A-9000 performs a signal range
check of the atmospheric pressure sensor value. If the ECU A-9000 determines that the value is too high, this fault
will occur. The atmospheric pressure sensor is internal to the ECU A-9000.
Solution:
1. Check the ECU A-9000 for the appropriate software and re-flash, if necessary.
A. If the fault has been resolved, return the machine to service.
B. If the fault has not been resolved, escalate an ASIST concern.
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3025-Atmospheric Pressure Sensor - Signal Below Range Minimum

Context:
The Engine Control Unit (ECU) A-9000 monitors atmospheric pressure. The ECU A-9000 performs a signal range
check of the atmospheric pressure sensor value. If the ECU A-9000 determines that the value is too low, this fault will
occur. The atmospheric pressure sensor is internal to the ECU A-9000.
Solution:
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3027-Oil pressure switch failure

Context:
The Engine Control Unit (ECU) A-9000 monitors the oil pressure switch S-9016 for proper operation. The oil pressure
switch S-9016 changes from its off to on state between 0.6 - 0.9 bar (8.7 - 13.0 psi). If the oil pressure switch S-9016
does not return to its off state, once the engine is switched OFF, this fault will occur.
Cause:
The ECU A-9000 has sensed that the oil pressure switch S-9016 did not return to its off state.
1. Faulty oil pressure switch S-9016, failed internally.

2. Faulty oil pressure switch S-9016 circuit wiring, open circuit.
Solution:
1. Verify that the fault is present and active.
2. Check the condition of the oil pressure switch S-9016.
Disconnect the engine harness (EN) from the oil pressure switch S-9016 at connector X-9016.
Use a multimeter to check for continuity on the component side :
From To Result
X-9016 pin 1 chassis ground There should be continuity.
A. If there is continuity, leave connector X-9016 disconnected and continue with Step 3.
B. If there is no continuity, the oil pressure switch S-9016 has failed internally, replace the switch.
3. Check the oil pressure switch S-9016 circuit for an open circuit condition.
Carefully disconnect the vehicle harness (VE) from the ECU A-9000 at connector X-9121.
Place a jumper wire between connector X-9121 pin A06 and chassis ground.
Use a multimeter to check for continuity on the engine harness (EN) side :
From To Result
A. If there is no continuity, leave the jumper wire in place and connectors X-9016 and X-9121 disconnected and
continue with Step 4.
B. If there is continuity, check the ECU A-9000 for the appropriate software and re-flash, if necessary.
4. Locate the open circuit condition.
Carefully disconnect the vehicle harness (VE) from the engine interface connector X-9138.
Use a multimeter to check for continuity on the vehicle harness (VE) side :
From To Result
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A. If there is continuity, the open circuit condition is the engine harness (EN) between connector X-9138 pin 3
and connector X-9016 pin 1, wire EN-9105. Locate and repair the broken conductor.
B. If there is no continuity, the open circuit condition is in the vehicle harness (VE) between connector X-9138 pin
3 and connector X-9121 pin A06, wire VE-9105. Use the appropriate service manual, if necessary, to locate
and repair the broken conductor.
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.
operation.
(55.100.DP-C.20.E.05)
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3037-Boost Pressure Sensor - Signal Low

Context:
The Engine Control Unit (ECU) A-9000 monitors the intake manifold pressure sensor B-9001. If the ECU A-9000
determines that the intake manifold pressure sensor B-9001 signal circuit voltage is less than 202.80 mV, this fault
will occur. If this fault is active, the intake manifold pressure value will be frozen at the last valid value for a preliminary
failure or jump to a fixed replacement value of 0.98 bar (14.21 psi) if the failure is validated.
Cause:
The ECU A-9000 has determined that the intake manifold pressure sensor B-9001 signal circuit voltage is less than
202.80 mV.
1. Faulty intake manifold pressure sensor B-9001 wiring, short to ground condition.
Solution:
2. Check the intake manifold pressure sensor B-9001 wiring in the engine harness (EN) for a short to ground condi-
tion.
Disconnect the engine harness (EN) from the intake manifold pressure sensor B-9001 at connector X-9003.
(EN) side :
From To Value
A. If there is continuity, there is a short circuit in the intake manifold pressure sensor B-9001 wiring in the engine
harness (EN). Locate and repair the shorted conductor.
3. Check the intake manifold pressure sensor B-9001 wiring in the vehicle harness (VE) for a short to ground condi-
tion.
Disconnect the vehicle harness from the ECU A-9000 at connector X-9121.
(VE) side :
From To Value
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A. If there is continuity, there is a short circuit in the intake manifold pressure sensor B-9001 wiring in the vehicle
harness (VE).Use the appropriate service manual, if necessary, to locate and repair the shorted conductor.

has been resolved.
operation.
(55.100.DP-C.20.E.05)
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3059-ECU Main Relay: Stuck Main Relay Error

Context:
The Engine Control Unit A-9000 controls the main relay K-9102. The main relay K-9102 is powered on by the ECU
A-9000 to achieve after-run. The main relay K-9102 is powered off once after-run is completed. If the ECU A-9000
determines that the main relay K-9102 is “stuck” or will not shut off as commanded, this fault will occur.
Cause:
The ECU A-9000 has determined that the main relay K-9102 will not shut off as commanded.
1. Faulty main relay K-9102, wiring.

2. Faulty main relay K-9102, internal failure.
Solution:
2. Check the main relay K-9102 coil for an internal failure.
Remove the main relay K-9102.
Use a multimeter to measure the resistance on the main relay K-9102 pins :
From To Value
X-9129 pin 85 X-9129 pin 86 There should be approximately 70 -
130 Ω.
A. If there is approximately 70 - 130 Ω, leave the main relay K-9102 disconnected and continue to Step 3.
B. If there is not approximately 70 - 130 Ω, the main relay K-9102 has failed. Replace the main relay K-9102.
3. Check the main relay K-9102 low side driver wiring for a short to ground.
With the key in the OFF position, use a multimeter to perform the following continuity check for a short to ground
on the vehicle harness (VE) side :
From To Value
A. If there is continuity, there is a short circuit in the main relay K-9102 wiring in the vehicle harness (VE). Use the
appropriate service manual, if necessary, to locate and repair the shorted conductor.
B. If there is no continuity, leave the main relay K-9102 disconnected and continue to Step 4.
4. Check the main relay K-9102 low side driver wiring for a short circuit.
With the key in the OFF position, use a multimeter to perform the following continuity checks for a short circuit on
From To Value
X-9122 pin K28 All pins in connector X-9122 There should be no continuity.
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A. If there is continuity, there is a short circuit in the main relay K-9102 wiring in the vehicle harness (VE). Use the
B. If there is no continuity, leave the main relay K-9102 and connector X-9122 disconnected, then continue to
Step 5.
5. Check the ECU A-9000 voltage supply wiring for a short to a voltage source.
With the key in the OFF position, use a multimeter to perform the following voltage checks for a short to a voltage
source on the vehicle harness (VE) side :
From To Value
X-9122 pin K01 Chassis ground There should be no voltage.
A. If there is voltage, there is a short to a voltage source in the ECU A-9000 voltage supply wiring. Use the
B. If there is no voltage, leave the main relay K-9102 and connector X-9122 disconnected, then continue to Step
6.
6. Check the ECU A-9000 voltage supply wiring for a short to a voltage source.
Re-connect the main relay K-9102.
With the key in the OFF position, use a multimeter to perform the following voltage checks for a short to a voltage
From To Value
A. If there is voltage, the main relay K-9102 has failed. Replace the main relay K-9102.
B. If there is no voltage, check the ECU A-9000 for the appropriate software and re-flash, if necessary.
has been resolved.
operation.
Wiring harnesses - Electrical schematic sheet 01 – Power distribution and starting (55.100.DP-C.20.E.01)
Wiring harnesses - Electrical schematic sheet 04 – Engine Control Unit (ECU) vehicle connector
(55.100.DP-C.20.E.04)
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3061-Cylinder1 - Short circuit Low/High

Context:
The Engine Control Unit (ECU) A-9000 monitors the fuel injector power stages for a short circuit condition. If the ECU
A-9000 detects a short circuit condition in the injector number 1 Y-9001 circuit, this fault will occur.
Cause:
The ECU A-9000 has detected a short circuit between the high side driver and low side driver of the fuel injector
number 1 Y-9001.
1. Faulty fuel injector number 1 Y-9001, wiring.

2. Faulty fuel injector number 1 Y-9001, internal failure.
Solution:
1. Verify this fault code is still present and in an active state.
Use the Easy Engine software provided on the Electronic Service Tool (EST) to check the fault status and to
perform the cylinder cut-out test.
A. If the fault is still present and active, continue with Step 2.
B. If the fault is no longer present or is in an inactive state, the fault may be intermittent and not currently active.
2. Check the fuel injector number 1 Y-9001 internal resistance.
Disconnect the injector harness (INJ) from the fuel injector number 1 Y-9001 at connector X-9030.
Use a multimeter to measure the resistance of fuel injector number 1 Y-9001 on the injector pins :
From To Value
X-9030 pin 1 X-9030 pin 2 There should be between .03 - .05 Ω
A. If there is between .03 - .05 Ω, leave connector X-9030 disconnected and continue to Step 3.
B. If the resistance is not between .03 - .05 Ω, fuel injector number 1 Y-9001 solenoid coil has failed. Replace
fuel injector number 1 Y-9001.
3. Check the fuel injector number 1 Y-9001 injector harness (INJ) wiring.
With the key in the OFF position, use a multimeter to perform the following continuity check on the injector harness
(INJ) side :
From To Value
B. If there is continuity, there is a short circuit in the fuel injector number 1 Y-9001 wiring in the injector harness
(INJ) between wires INJ-268 and INJ-269. Locate and repair the shorted conductor.
4. Check the fuel injector number 1 Y-9001 vehicle harness (VE) wiring for a short circuit condition.
With the key in the OFF position, use a multimeter to perform the following continuity check on vehicle harness
(VE) side :
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From To Value
X-9139 pin A X-9139 pin B There should be no continuity
A. If there is continuity, there is a short circuit in the fuel injector number 1 Y-9000 wiring in the vehicle harness
(VE) between wires VE-9125 and VE-9126. Use the appropriate service manual, if necessary, to locate and
repair the shorted conductor.
B. If there is no continuity, continue with Step 5.

5. Check the ECU A-9000 voltage supply wiring.
Place a jumper wire between X-9122 pin K28 and chassis ground. This will energize the main relay K-9102.
With the key in the ON position, use a multimeter to perform the following voltage checks from the vehicle harness
(VE) side :
From To Value
X-9122 pin K03 chassis ground There should be approximately
12.0 V
12.0 V
12.0 V
A. If there is approximately 12.0 V, leave connector X-9122 disconnected and continue to Step 6.
B. If there is not approximately 12.0 V, there is a faulty ECU A-9000 voltage supply. Use the appropriate service
manual, if necessary, to locate and repair the failed conductor.
6. Check the ECU A-9000 ground supply.
(VE) side : :
From To Value
X-9122 pin K02 chassis ground There should be continuity.
A. If there is no continuity, there is a faulty ECU A-9000 ground supply. Use the appropriate service manual, if
necessary, to locate and repair the failed conductor.
has been resolved.
operation.
(55.100.DP-C.20.E.04)
(55.100.DP-C.20.E.05)
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3063-Cylinder 1 - Injector Cable Short Circuit (High Side To Ground)

Context:
Cause:
The ECU A-9000 has detected a short circuit in the fuel injector number 1 Y-9001 circuit.

Solution:
From To Value
3. Check the fuel injector number 1 Y-9001 injector harness (INJ) wiring for a short to a voltage source.
With the key in the OFF position, use a multimeter to perform the following voltage check on the injector harness
(INJ) side :
From To Value
With the key in the ON position, use a multimeter to perform the following voltage check on the injector harness
(INJ) side :
From To Value
A. If there is no voltage, leave connector X-9030 disconnected and continue to Step 4.
B. If there is voltage, there is a short to battery or switched battery in the fuel injector number 1 Y-9001 wiring in
the injector harness (INJ). Use the appropriate service manual, if necessary, to locate and repair the shorted
conductor.
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4. Check the fuel injector number 1 Y-9001 injector harness (INJ) wiring for a short to ground condition.
With the key in the OFF position, use a multimeter to perform the following continuity checks on the injector harness
(INJ) side :
From To Value
X-9139 pin A All pins in connector X-9139 There should be no continuity.
X-9139 pin B All pins in connector X-9139 There should be no continuity.
(INJ). Locate and repair the shorted conductor.
Disconnect the vehicle harness (VE) from the ECU A-9000 at connector X-9121
With the key in the OFF position, use a multimeter to perform the following continuity checks on vehicle harness
(VE) side :
From To Value
X-9139 pin A X-9139 pin B There should be no continuity
X-9139 pin A Chassis ground There should be no continuity
X-9139 pin B Chassis ground There should be no continuity
X-9139 pin A All pins in connector X-9139 There should be no continuity
X-9139 pin B All pins in connector X-9139 There should be no continuity
(VE). Use the appropriate service manual, if necessary, to locate and repair the shorted conductor.

(VE) side :
From To Value
12.0 V
12.0 V
12.0 V
(VE) side : :
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From To Value
has been resolved.
operation.
(55.100.DP-C.20.E.04)
(55.100.DP-C.20.E.05)
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Context:
Cause:
number 3 Y-9003.

Solution:
From To Value
(INJ) side :
From To Value
(VE) side :
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From To Value
X-9139 pin D X-9139 pin C There should be no continuity

(VE) side :
From To Value
12.0 V
12.0 V
12.0 V
(VE) side : :
From To Value
has been resolved.
operation.
(55.100.DP-C.20.E.04)
(55.100.DP-C.20.E.05)
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Context:
Cause:

Solution:
From To Value
(INJ) side :
From To Value
(INJ) side :
From To Value
conductor.
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(INJ) side :
From To Value
X-9139 pin D All pins in connector X-9139 There should be no continuity.
X-9139 pin C All pins in connector X-9139 There should be no continuity.
(VE) side :
From To Value
X-9139 pin D X-9139 pin C There should be no continuity
X-9139 pin D Chassis ground There should be no continuity
X-9139 pin C Chassis ground There should be no continuity
X-9139 pin D All pins in connector X-9139 There should be no continuity
X-9139 pin C All pins in connector X-9139 There should be no continuity

(VE) side :
From To Value
12.0 V
12.0 V
12.0 V
(VE) side : :
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From To Value
has been resolved.
operation.
(55.100.DP-C.20.E.04)
(55.100.DP-C.20.E.05)
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Context:
Cause:
number 2 Y-9002.

Solution:
From To Value
(INJ) side :
From To Value
(VE) side :
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From To Value
X-9139 pin H X-9139 pin G There should be no continuity

(VE) side :
From To Value
12.0 V
12.0 V
12.0 V
(VE) side : :
From To Value
has been resolved.
operation.
(55.100.DP-C.20.E.04)
(55.100.DP-C.20.E.05)
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Context:
Cause:

Solution:
From To Value
(INJ) side :
From To Value
(INJ) side :
From To Value
conductor.
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(INJ) side :
From To Value
X-9139 pin H All pins in connector X-9139 There should be no continuity.
X-9139 pin G All pins in connector X-9139 There should be no continuity.
(VE) side :
From To Value
X-9139 pin H X-9139 pin G There should be no continuity
X-9139 pin H Chassis ground There should be no continuity
X-9139 pin G Chassis ground There should be no continuity
X-9139 pin H All pins in connector X-9139 There should be no continuity
X-9139 pin G All pins in connector X-9139 There should be no continuity

(VE) side :
From To Value
12.0 V
12.0 V
12.0 V
(VE) side : :
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From To Value
has been resolved.
operation.
(55.100.DP-C.20.E.04)
(55.100.DP-C.20.E.05)
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Context:
Cause:
number 4 Y-9004.

Solution:
From To Value
(INJ) side :
From To Value
(VE) side :
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From To Value
X-9139 pin E X-9139 pin F There should be no continuity

(VE) side :
From To Value
12.0 V
12.0 V
12.0 V
(VE) side : :
From To Value
has been resolved.
operation.
(55.100.DP-C.20.E.04)
(55.100.DP-C.20.E.05)
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Context:
Cause:

Solution:
From To Value
(INJ) side :
From To Value
(INJ) side :
From To Value
conductor.
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(INJ) side :
From To Value
X-9139 pin E All pins in connector X-9139 There should be no continuity.
X-9139 pin F All pins in connector X-9139 There should be no continuity.
(VE) side :
From To Value
X-9139 pin E X-9139 pin F There should be no continuity
X-9139 pin E Chassis ground There should be no continuity
X-9139 pin F Chassis ground There should be no continuity
X-9139 pin E All pins in connector X-9139 There should be no continuity
X-9139 pin F All pins in connector X-9139 There should be no continuity

(VE) side :
From To Value
12.0 V
12.0 V
12.0 V
(VE) side : :
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From To Value
has been resolved.
operation.
(55.100.DP-C.20.E.04)
(55.100.DP-C.20.E.05)
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3088-Crankshaft Sensor - No Signal

Context:
The Engine Control Unit (ECU) A-9000 monitors the crankshaft position sensor B-9007 characteristics for angle,
speed determination, signal plausibility, and quality. If the ECU A-9000 determines that there are no crankshaft posi-
tion signals detected for at least 4 engine revolutions, this fault will occur.
Cause:
The ECU A-9000 has determined that there is no crankshaft position signals detected for at least 4 engine revolutions.
1. Faulty crankshaft position sensor B-9007, not fully seated or loose.

2. Faulty crankshaft tone wheel, damaged or misaligned.
3. Faulty crankshaft position sensor B-9007 wiring, short circuit.
4. Faulty crankshaft position sensor B-9007, internal failure.
Solution:
2. Check the physical integrity of the crankshaft position sensor B-9007. The sensor should be fully seated and
mounted tightly.
Remove the crankshaft position sensor B-9007 and inspect the crankshaft tool wheel. The tone wheel should not
be damaged or loose.
A. If the sensor or tone wheel is damaged or is not mounted/secured properly, repair as necessary.
B. If the sensor or tone wheel is not damaged and is mounted/secured properly, continue to Step 3.
3. Check the crankshaft position sensor B-9007 internal resistance.
Disconnect the engine harness (EN) from the crankshaft position sensor B-9007 at connector X-9021.
Use a multimeter to measure the resistance of the crankshaft position sensor B-9007 on the sensor pins :
From To Value
X-9021 pin 1 X-9021 pin 2 There should be between 774 -
946 Ω.
A. If there is between 774 - 946 Ω, leave connector X-9021 disconnected and continue to Step 4.
B. If there is not between 774 - 946 Ω, the crankshaft position sensor B-9007 has failed. Replace the crankshaft
position sensor B-9007.
4. Check the crankshaft position sensor B-9007 wiring for a short circuit to battery.
(EN) side :
From To Value
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(EN) side :
From To Value
B. If there is voltage, there is a short to battery or key switch battery in the crankshaft position sensor B-9007
5. Check the crankshaft position sensor B-9007 engine harness (EN) wiring.
Disconnect the vehicle harness (VE) connector from the engine interface at connector X-9138.
From To Value
With the key in the OFF position, use a multimeter to perform the following continuity checks for an open circuit
on the engine harness (EN) side :
From To Value
From To Value
A. If the specified values are measured, leave connectors X-9021 and X-9138 disconnected and continue to Step
6.
B. If the specified values are not measured, there is a fault in the crankshaft position sensor B-9007 circuit in the
engine harness (EN). Locate and repair the failed conductor.
6. Check the crankshaft position sensor B-9007 vehicle harness (VE) wiring.
With the key in the OFF position, use a multimeter to perform the following continuity check for a short circuit on
From To Value
From To Value
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From To Value
A. If the specified values are measured, leave connectors X-9021, X-9138, and X-9121 disconnected and con-
tinue to Step 7.
B. If the specified values are not measured, there is a fault in the crankshaft position sensor B-9007 circuit in
the vehicle harness (VE). Use the appropriate service manual, if necessary, to locate and repair the failed
conductor.
7. Replace the crankshaft position sensor B-9007.
Use the Electronic Service Tool (EST) to verify the status of this fault, 3088 - Crankshaft Sensor - No Signal.
B. If the fault has not been resolved, check the ECU A-9000 for the appropriate software and re-flash, if necessary.
has been resolved.
operation.
(55.100.DP-C.20.E.05)
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3089-Crankshaft Sensor - Invalid Signal

Context:
The Engine Control Unit (ECU) A-9000 monitors the crankshaft position sensor B-9007 characteristics for angle,
speed determination, signal plausibility, and quality. If the ECU A-9000 detects greater than 80 crankshaft position
signal plausibility errors, this fault will occur.
Cause:
The ECU A-9000 has detected more than 80 crankshaft position signal plausibility errors.
1. Faulty crankshaft position sensor B-9007, not fully seated or loose.

2. Faulty crankshaft tone wheel, damaged or misaligned.
3. Faulty crankshaft position sensor B-9007 wiring, short circuit.
4. Faulty crankshaft position sensor B-9007, internal failure.
Solution:
2. Check the physical integrity of the crankshaft position sensor B-9007. The sensor should be fully seated and
mounted tightly.
Remove the crankshaft position sensor B-9007 and inspect the crankshaft tool wheel. The tone wheel should not
be damaged or loose.
A. If the sensor or tone wheel is damaged or is not mounted/secured properly, repair as necessary.
B. If the sensor or tone wheel is not damaged and is mounted/secured properly, continue to Step 3.
3. Check the crankshaft position sensor B-9007 internal resistance.
Disconnect the engine harness (EN) from the crankshaft position sensor B-9007 at connector X-9021.
Use a multimeter to measure the resistance of the crankshaft position sensor B-9007 on the sensor pins :
From To Value
X-9021 pin 1 X-9021 pin 2 There should be between 774 -
946 Ω.
A. If there is between 774 - 946 Ω, leave connector X-9021 disconnected and continue to Step 4.
B. If there is not between 774 - 946 Ω, the crankshaft position sensor B-9007 has failed. Replace the crankshaft
position sensor B-9007.
4. Check the crankshaft position sensor B-9007 wiring for a short circuit to battery.
(EN) side :
From To Value
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(EN) side :
From To Value
B. If there is voltage, there is a short to battery or key switch battery in the crankshaft position sensor B-9007
5. Check the crankshaft position sensor B-9007 engine harness (EN) wiring.
Disconnect the vehicle harness (VE) connector from the engine interface at connector X-9138.
From To Value
From To Value
From To Value
6.
B. If the specified values are not measured, there is a fault in the crankshaft position sensor B-9007 circuit in the
engine harness (EN). Locate and repair the failed conductor.
6. Check the crankshaft position sensor B-9007 vehicle harness (VE) wiring.
From To Value
From To Value
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From To Value
A. If the specified values are measured, leave connectors X-9021, X-9138, and X-9121 disconnected and con-
tinue to Step 7.
B. If the specified values are not measured, there is a fault in the crankshaft position sensor B-9007 circuit in
the vehicle harness (VE). Use the appropriate service manual, if necessary, to locate and repair the failed
conductor.
7. Replace the crankshaft position sensor B-9007.
Use the Electronic Service Tool (EST) to verify the status of this fault, 3093 - Camshaft Sensor : Camshaft offset
angle exceeded
has been resolved.
operation.
(55.100.DP-C.20.E.05)
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3090-Camshaft Sensor Failure

Context:
The Engine Control Unit (ECU) A-9000 monitors the camshaft position sensor B-9017 characteristics for angle, speed
determination, signal plausibility, and quality. If the ECU A-9000 determines that no camshaft edge is detected for at
least four crankshaft revolutions, this fault will occur.
Cause:
The ECU A-9000 has detected no camshaft edge for at least four crankshaft revolutions.
1. Faulty camshaft position sensor B-9017, wiring.

2. Faulty camshaft position sensor B-9017, improperly seated or mounted.
3. Faulty camshaft position sensor B-9017, internal failure.
Solution:
2. Check the physical integrity of the camshaft speed sensor B-9017. The sensor should be fully seated and mounted
tightly.
A. If the sensor is not mounted/secured properly, repair as necessary.
B. If the sensor is not damaged and is mounted/secured properly, continue to Step 3.

3. Check the camshaft position sensor B-9017 wiring in the engine harness (EN).
Disconnect the engine harness (EN) from the camshaft position sensor at connector X-9008.
(EN) side :
From To Value
(EN) side :
From To Value
X-9008 pin 2 Chassis ground There should be no voltage
4.
B. If the specified values are not measured, there is failure in the camshaft position sensor B-9017 wiring. Locate
and repair the failed conductor.
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4. Check the camshaft position sensor B-9017 wiring in the vehicle harness (VE).
(VE) side :
From To Value
X-9121 pin A14 Chassis ground There should be no continuity.
With the key in the ON position, use a multimeter to perform the following voltage check on the vehicle harness
(VE) side :
From To Value
X-9121 pin A14 Chassis ground There should be no voltage.
B. If the specified values are not measured, there is failure in the camshaft position sensor B-9017 wiring. Use
the appropriate service manual to locate and repair the failed conductor.
5. Replace the camshaft position sensor B-9017.
Use the Electronic Service Tool (EST) to verify the status of this fault, 3091 - Camshaft Sensor Failure.
has been resolved.
operation.
(55.100.DP-C.20.E.05)
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3091-Camshaft Sensor Failure

Context:
The Engine Control Unit (ECU) A-9000 monitors the camshaft position sensor B-9017 characteristics for angle, speed
determination, signal plausibility, and quality. If the ECU A-9000 determines that the camshaft signal does not match
the expected pattern (edge, distance, level) or not all expected camshaft edges are detected during an engine revo-
lution, this fault will occur.
Cause:
The ECU A-9000 has detected a camshaft pattern signal error.
1. Faulty camshaft position sensor B-9017 wiring.

2. Faulty camshaft position sensor B-9017, improperly seated or mounted.
3. Faulty camshaft position sensor B-9017, internal failure.
Solution:
2. Check the physical integrity of the camshaft speed sensor B-9017. The sensor should be fully seated and mounted
tightly.
A. If the sensor is not mounted/secured properly, repair as necessary.
B. If the sensor is not damaged and is mounted/secured properly, continue to Step 3.

3. Check the camshaft position sensor B-9017 wiring in the engine harness (EN).
Disconnect the engine harness (EN) from the camshaft position sensor at connector X-9008.
(EN) side :
From To Value
(EN) side :
From To Value
X-9008 pin 2 Chassis ground There should be no voltage
4.
B. If the specified values are not measured, there is failure in the camshaft position sensor B-9017 wiring. Locate
and repair the failed conductor.
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4. Check the camshaft position sensor B-9017 wiring in the vehicle harness (VE).
(VE) side :
From To Value
X-9121 pin A14 Chassis ground There should be no continuity.
X-9121 pin A14 All pins in connector X-9138
(VE) side :
From To Value
X-9121 pin A14 Chassis ground There should be no voltage.
B. If the specified values are not measured, there is failure in the camshaft position sensor B-9017 wiring. Use
the appropriate service manual to locate and repair the failed conductor.
5. Replace the camshaft position sensor B-9017.
Use the Electronic Service Tool (EST) to verify the status of this fault, 3091 - Camshaft Sensor Failure.
has been resolved.
operation.
(55.100.DP-C.20.E.05)
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3093-Camshaft Sensor : Camshaft offset angle exceeded

Context:
The Engine Control Unit (ECU) A-9000 monitors the camshaft position sensor B-9017 and the crankshaft position
sensor B-9007 characteristics for angle, speed determination, signal plausibility, and quality. If the ECU A-9000 de-
termines that the offset between the crankshaft signal and the expected camshaft first edge is less or greater than
10.00 ° for longer than four consecutive cycles, this fault will occur.
1. Faulty camshaft position sensor B-9017, improperly mounted or not fully seated.
2. Faulty crankshaft position sensor B-9007, improperly mounted or not fully seated.
3. Faulty camshaft tone wheel, loose or damaged.
4. Faulty crankshaft tone wheel, loose or damaged.
5. Faulty engine timing, incorrectly timed.
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3096-ECM Busoff on vehicle CAN

Context:
The Engine Control Unit (ECU) A-9000 is capable of connecting to and communicating on two separate Controller
Area Networks (CAN). Proper configuration and monitoring of the two twisted pair configured networks is also a func-
tion of the ECU A-9000. CAN Node A Bus is the main vehicle interface bus. The ECU A-9000 provides a CAN
termination resistor for the CAN Node A Bus, internal to the ECU A-9000. If the ECU A-9000 senses that CAN Node
A Bus is not functioning properly, this fault will occur.
Cause:
ECU A-9000 has sensed a Bus Off state to be present at the CAN Node A.
1. Faulty supply voltage or ground, missing.

2. Faulty CAN circuit wiring, open circuit, short to ground, or short circuit.
3. Faulty ECU A-9000, termination resistor or software.
Solution:
1. Verify fault is present and in active state.
2. Check for other vehicle CAN faults.
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 3096 - ECM Busoff
on vehicle CAN is also resolved.
B. If other vehicle CAN faults do not exist, continue with Step 3.

3. Check the ECU A-9000 supply voltage.
Disconnect the vehicle (VE) harness from the ECU A-9000 at connector X-9122.
To energize the Main relay K-9102, place a jumper wire between the vehicle harness (VE) side of connector X-9122
pin K28 and chassis ground.
Use a multimeter to check for voltage on the vehicle (VE) harness side:
From To Value
X-9122 pin K01 chassis ground There should be 12.0 V .
A. If the voltage is present on all of the checks, leave connector X-9122 disconnected and continue with Step 4.
B. If the voltage is not present for one or more of the checks, see the appropriate vehicle service manual and
electrical schematics, if necessary, to locate and restore supply power to the ECU A-9000.
4. Check the ECU A-9000 ground circuits.
Use a multimeter to check for continuity on the vehicle (VE) harness side:
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From To Value
A. If there is continuity on all of the checks, leave connector X-9122 disconnected and continue with Step 5.
B. If there is no continuity for one or more of the checks, see the appropriate vehicle service manual and electrical
schematics, if necessary, to locate and restore the ground circuits to the ECU A-9000.
5. Determine the condition of the ECU A-9000 CAN circuit.
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
X-9122 pin K24 X-9122 pin K25 There should be 120 Ω.
X-9122 pin K24 chassis ground There should not be continuity
Use a multimeter to measure the resistance of the CAN termination resistor, internal to the ECU A-9000:
From To Value
A. If the measured resistances are correct and neither conductor is grounded, check the ECU A-9000 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, see the appropriate
vehicle service manual and electrical schematics, if necessary, to locate and restore the termination resistance
to the CAN circuit.
has been resolved.
operation.
(55.100.DP-C.20.E.04)
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3102-Rail Pressure Sensor CP3 - Signal Below Range Minimum

NOTE: If the rail pressure sensor B-9004 is replaced, it is necessary to perform the Replacement of the Rail Pressure
sensor - Reset ECU Data with the Electronic Service Tool (EST) before you return the machine to service. Refer to
the engine service manual Common rail pressure sensor - Configure - Reset ECU data (Rail pressure sensor)
(55.010), if necessary.
Context:
The Engine Control Unit (ECU) A-9000 monitors the rail pressure sensor B-9004. If the ECU A-9000 detects a voltage
less than 342.20 mV in the rail pressure sensor B-9004 signal circuit, this fault will occur.
Cause:
The ECU A-9000 has detected a voltage less than 342.20 mV in the rail pressure sensor B-9004 signal circuit.
1. Faulty rail pressure sensor B-9004 wiring, short to ground condition.

2. Faulty rail pressure sensor B-9004, internal failure.
Solution:
2. Check the rail pressure sensor B-9004 engine harness (EN) wiring for a short circuit condition.
Disconnect the engine harness (EN) from the rail pressure sensor B-9004 at connector X-9026.
(EN) side :
From To Value
A. If there is continuity, there is a short circuit in the rail pressure sensor B-9004 engine harness (EN) wiring.
Locate and repair the shorted conductor.
3. Check the rail pressure sensor B-9004 vehicle harness (VE) wiring for a short circuit condition.
(VE) side :
From To Value
A. If there is continuity, there is a short circuit in the rail pressure sensor B-9004 vehicle harness (VE) wiring. Use
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B. If there is no continuity, continue to Step 4.

4. Replace the rail pressure sensor B-9004.
has been resolved.
operation.
(55.100.DP-C.20.E.05)
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3104-Rail Pressure Relief Valve - Open Circuit

Context:
The Engine Control Unit (ECU) monitors the fuel metering unit Y-9000 signal circuit. If the ECU A-9000 detects a
short to a voltage source in the fuel metering unit Y-9000 low side driver circuit, this fault will occur.
Cause:
There is a short to a voltage source in the fuel metering unit Y-9000 low side driver circuit.
1. Faulty fuel metering unit Y-9000 wiring, short to a voltage source.

2. Faulty fuel metering unit Y-9000, internal failure.
Solution:
2. Test the fuel metering unit Y-9000 internal resistance.
Disconnect the engine harness (EN) from the fuel metering unit Y-9000 at connector X-9007.
Use a multimeter to measure the resistance on the fuel metering unit Y-9000 pins :
From To Value
X-9007 pin 1 X-9007 pin 2 There should be between 2.6 - 3.2 Ω
at approximately 20.0 °C (68.0 °F).
A. If there is between 2.6 - 3.2 Ω, leave connector X-9007 disconnected and continue to Step 3.
B. If there is not between 2.6 - 3.2 Ω, the fuel metering unit Y-9000 has failed. Replace the fuel metering unit
Y-9000.
3. Check the fuel metering unit Y-9000 low side driver wiring for a short to battery condition.
(EN) side :
From To Value
(EN) side :
From To Value
A. If there is voltage, there is a short circuit to battery or switched battery in the fuel metering unit Y-9000 low
side driver circuit wiring. Use the appropriate service manual, if necessary, to locate and repair the shorted
conductor.

4. Check the fuel metering unit Y-9000 low side driver engine harness (EN) wiring for a short circuit condition.
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(EN) side :
From To Value
X-9138 pin 2 All pins in connector X-9138. There should be no continuity.
B. If there is continuity, there is a short circuit condition in the fuel metering unit Y-9000 low side driver engine
5. Check the fuel metering unit Y-9000 low side driver vehicle harness (VE) wiring for a short circuit condition.
With the key in the OFF position, use a multimeter to perform the following continuity check from the vehicle
harness (VE) side :
From To Value
X-9121 pin A60 All pins in connector X-9121. There should be no continuity.
A. If there is continuity, there is a short circuit condition in the fuel metering unit Y-9000 low side driver vehicle har-
has been resolved.
operation.
(55.100.DP-C.20.E.05)
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3105-Rail Pressure Relief Valve - Pressure Shock Requested

NOTE: If the Pressure Relief Valve (PRV) is replaced, it is necessary to perform the Replacement of the Rail Pressure
Relief Valve (PRV) - Reset ECU Data with the Electronic Service Tool (EST) before you return the machine to service.
Refer to the engine service manual Common rail Relief valve - Configure - Reset ECU data (10.218), if necessary.
Context:
The Engine Control Unit (ECU) A-9000, if necessary, will set the engine into limp home mode. This process is achieved
in two steps by the ECU A-9000, a pressure increase and a pressure shock. The ECU A-9000 will execute step one
by a fuel pressure increase. This is achieved by fully opening the fuel metering unit Y-9000, thus allowing maximum
fuel delivery. If this fault is active, the ECU A-9000 has performed step one for achieving limp home mode, a fuel
pressure increase. Other active faults may have caused this fault to occur. For more information regarding fuel sys-
tem troubleshooting, refer to the engine service manual Fuel injection system - Troubleshooting (10.218).
Cause:
The ECU A-9000 has performed a fuel pressure increase to achieve limp home mode.
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3106-Pressure Relief valve: pressure relief valve is open

Context:
The Engine Control Unit (ECU) A-9000 monitors the fuel Pressure Relief Valve (PRV). If the ECU A-9000 determines
that the PRV has exceeded its maximum open count, 50 times, this fault will occur. If the PRV has opened more than
50 times, the PRV must be replaced. Other active faults may have caused this fault to occur. For more information
regarding fuel system troubleshooting, refer to the engine service manual Fuel injection system - Troubleshooting
(10.218).
Cause:
The ECU A-9000 has determined that the PRV has opened more than 50 times.
1. Faulty fuel metering unit Y-9000, stuck open.

2. Faulty rail pressure sensor B-9004, drifted signal.
3. Faulty PRV, opening pressure too low.
4. Faulty fuel back-flow, clogged or damaged.
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3108-Fuel Metering Unit - Short Circuit to Ground

Context:
The Engine Control Unit (ECU) A-9000 monitors the fuel metering unit Y-9000 low side driver circuit. If the ECU
A-9000 detects a short to ground in the fuel metering unit Y-9000 low side driver circuit, this fault will occur.
Cause:
The ECU A-9000 has detected a short to ground condition in the fuel metering unit Y-9000 low side driver circuit.
1. Faulty fuel metering unit Y-9000 wiring, short to ground condition.

Solution:
2. Test the fuel metering unit Y-9000 internal resistance and for a grounded condition.
Use a multimeter to perform the following continuity and resistance check on the fuel metering unit Y-9000 pins :
From To Value
at approximately 20 °C (68 °F).
A. If there is between 2.6 - 3.2 Ω and there is no continuity to ground, leave connector X-9007 disconnected and
continue to Step 3.
B. If the specified values are not measured, the fuel metering unit Y-9000 has a grounded condition or has failed
internally. Replace the fuel metering unit Y-9000.
3. Check the fuel metering unit Y-9000 engine harness (EN) wiring for a short to ground condition.
With the key switch in the OFF position, use a multimeter to perform the following continuity check on the engine
harness (EN) side :
From To Value
A. If there is continuity, there is a short circuit in the fuel metering unit Y-9000 engine harness (EN) wiring. Locate
and repair the shorted conductor.

4. Check the fuel metering unit Y-9000 vehicle harness (VE) wiring for a short to ground condition.
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With the key switch in the OFF position, use a multimeter to perform the following continuity check on the vehicle
harness (VE) side :
From To Value
A. If there is continuity, there is a short circuit condition in the fuel metering unit Y-9000 vehicle harness (VE)
B. If there is no continuity, check the ECU A-9000 for the appropriate service manual and re-flash, if necessary.
has been resolved.
operation.
(55.100.DP-C.20.E.05)
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3112-Rail Pressure Sensor CP3 - Signal Above Maximum Range

Context:
The Engine Control Unit (ECU) A-9000 monitors the rail pressure sensor B-9004. If the ECU A-9000 detects a voltage
greater than 4.90 V in the rail pressure sensor B-9004 signal circuit, this fault will occur.
Cause:
The ECU A-9000 has detected a voltage greater than 4.90 V in the rail pressure sensor B-9004 signal circuit.
1. Faulty rail pressure sensor B-9004 wiring, short to a voltage source.

2. Faulty rail pressure sensor B-9004 wiring, open circuit.
Solution:
2. Check the rail pressure sensor B-9004 wiring for a short circuit condition.
(EN) side :
From To Value
(EN) side :
From To Value
A. If the specified values are not measured, there is a short to battery or switched battery in the rail pressure
sensor B-9004 wiring. Use the appropriate service manual, if necessary, to locate and repair the shorted con-
ductor.
3. Check the rail pressure sensor B-9004 engine harness (EN) wiring for an open circuit.
(EN) side :
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From To Value
(VE) side :
From To Value
A. If there is no continuity, there is an open circuit in the rail pressure sensor B-9004 vehicle harness (VE) wiring.
Use the appropriate service manual, if necessary, to locate and repair the broken conductor.
B. If there is continuity, leave connectors X-9138, X-9026, and X-9121 disconnected and continue to Step 4.
4. Check the rail pressure sensor B-9004 engine harness (EN) wiring for a short to a voltage source.
(EN) side :
From To Value
A. If there is continuity, there is a short circuit in the rail pressure sensor B-9004 engine harness (EN) wiring.
5. Check the rail pressure sensor B-9004 vehicle harness (VE) wiring for a short to a voltage source.
(VE) side :
From To Value
A. If there is continuity, there is a short circuit in the rail pressure sensor B-9004 vehicle harness (VE) wiring. Use

has been resolved.
operation.
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(55.100.DP-C.20.E.05)
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3137-Metering Unit - Open Load

Context:
The Engine Control Unit (ECU) A-9000 monitors the fuel metering unit Y-9000 signal circuit. If the ECU A-9000 detects
an open load error in the fuel metering unit Y-9000 signal circuit, this fault will occur.
Cause:
There is open load detected in the fuel metering unit Y-9000 signal circuit.
1. Faulty fuel metering unit Y-9000 wiring, open circuit.

Solution:
From To Value
Y-9000.
3. Check the fuel metering unit Y-9000 engine harness (EN) wiring for an open circuit.
(EN) side :
From To Value
NOTE: Wiggle the harness dur-
ing the check to promote an
intermittent electrical connec-
tion.
A. If there is continuity, leave connector X-9138 disconnected and continue to Step 4.
B. If there is no continuity, there is an open circuit condition in the fuel metering unit Y-9000 engine harness (EN)
wiring. Locate and repair the broken conductor.
4. Check the fuel metering unit Y-9000 vehicle harness (VE) wiring for an open circuit.
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(VE) side :
From To Value
tion.
A. If there is no continuity, there is an open circuit condition in the fuel metering unit Y-9000 vehicle harness (VE)
wiring. Use the appropriate service manual, if necessary, to locate and repair the broken conductor.
has been resolved.
operation.
(55.100.DP-C.20.E.05)
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3141-Fuel Metering Unit : leakage is detected based on fuel quantity

balance
Context:
The Engine Control Unit (ECU) Y-9000 monitors fuel rail pressure. If the ECU A-9000 determines that the requested
fuel pressure can not be reached, a leakage in the fuel system is assumed and this fault will occur. For more in-
formation regarding fuel system troubleshooting, refer to the engine service manual Fuel injection system - Trou-
bleshooting (10.218).
Cause:
The ECU A-9000 has determined that a fuel system leakage is present.
1. Faulty fuel filters, clogged.

2. Faulty low pressure fuel lines, clogged or damaged.
3. Faulty high pressure fuel lines, clogged or damaged.
4. Faulty electric fuel pump (if equipped).
5. Faulty charge gear pump, low efficiency.
6. Faulty high pressure pump, low efficiency or excessive leak-off.
7. Faulty fuel injectors, external or internal leakage.
8. Faulty Pressure Relief Valve (PRV), leaking or stuck open.
9. Faulty rail pressure sensor B-9004 or sensor leaking.
10. Faulty fuel metering unit Y-9000
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3146-Water detected in fuel

NOTE: This fault code is for the Water in Fuel switch with black connector housing.
Context:
The Engine Control Unit (ECU) A-9000 monitors the voltage output from the water in fuel switch S-9102 to determine
if water is present in the fuel supply. If water is detected in the fuel, warnings will be displayed to alert the operator
of potential engine damage if operation continues. High voltage signal from the water in fuel switch S-9102 indicates
water present.
Cause:
This fault code is displayed to warn the operator that the Engine Control Unit (ECU) A-9000 has detected excess
water in the fuel system or a fault in the water in fuel switch circuit.
1. Excess water in the fuel supply.

2. Faulty water in fuel switch S-9102, wiring or internal (mechanical and/or electrical) failure.
Solution:
Use the Easy Engine software provided on the Electronic Service Tool (EST) to check the fault status.
B. If the fault is no longer present or is in an inactive state, Continue with Step 7.

2. Check fuel for water contamination.
A. If there is water contamination, continue with Step 3.
B. If there is no water contamination, Continue with Step 4.

3. Verify proper water in fuel switch S-9102 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 minutes.
Check for code to return to active status.
A. If code returns in an active status, replace water in fuel switch S-9102.
B. If code remains inactive, return the machine to service.

4. Check for open, short and grounded circuit conditions in the water in fuel switch S-9102 circuit.
Disconnect the water in fuel switch S-9102 at connector X-9125.
With the key switch in the OFF position, use a multimeter to perform the following tests, on the vehicle (VE) harness
from :
From To Value
X-9125 pin 1 X-9122 pin K30 There should be continuity.
X-9125 pin 2 Chassis ground There should be continuity.
X-9125 pin 3 Refer to the appropriate vehicle There should be continuity.
schematics.
Then use the multimeter to perform the following tests, on the vehicle (VE) harness from :
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From To Value
X-9125 pin 1 X-9125 pin 2 There should be no continuity
From To Value
X-9125 pin 1 Chassis ground There should be no continuity
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 vehicle harness (VE) wiring. Use the appropriate vehicle service manual and schematics
to diagnose and repair the wiring.
B. If the results are as expected in all of the wiring tests listed above, the wiring is ok. Leave connectors X-9122
and X-9125 disconnected and continue with Step 5.
5. Check for key switch voltage supply to water in fuel switch S-9102.
With the key switch in an ON position, use a multimeter to perform the following test, on the vehicle (VE) harness
side from :
From To Value
X-9125 pin 3 Chassis ground There should be key switch voltage.
X-9125 pin 1 Chassis ground There should be no key switch
voltage.
A. If there is key switch voltage present in the first check and not present in the second check, continue with Step
6.
B. If key switch voltage is not present in the first check or present in the second check, use the appropriate vehicle
service manual and schematics to diagnose and repair the wiring.
6. Replace the water in fuel switch S-9102, then check to see if this fault has been resolved.
A. If the fault is resolved, return the machine to service.
B. If the fault is not resolved, check the ECU A-9000 for the appropriate software and re-flash, if necessary.
A. If you find damage or the display indicates other than normal readings, then 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.
operation.
Wiring harnesses - Electrical schematic sheet 02 – Pre-start and Selective Catalytic Reduction (SCR)
(55.100.DP-C.20.E.02)
(55.100.DP-C.20.E.04)
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3169-Fuel filter heater ECU driver has an over temperature error

Context:
The Engine Control Unit (ECU) A-9000 controls the fuel filter heater relay K-9100 using a low side driver. If the ECU
A-9000 detects an over temperature/current condition in the low side driver circuit, this fault will occur.
Cause:
The ECU A-9000 has detected an over temperature/current condition in the fuel filter heater relay K-9100 low side
driver circuit.
1. Faulty fuel filter heater relay K-9100 wiring, short circuit.

2. Faulty fuel filter heater relay K-9100, internal failure.
Solution:
2. Check the fuel filter heater relay K-9100 coil.
Remove the fuel filter heater relay K-9100.
Use a multimeter to measure the resistance on the fuel filter heater relay K-9100 pins :
From To Value
130 Ω.
A. If there is approximately 70 - 130 Ω, leave the fuel filter heater relay K-9100 disconnected and continue to Step
3.
B. If there is not approximately 70 - 130 Ω, the fuel filter heater relay K-9100 has failed. Replace the fuel filter
heater relay K-9100.
3. Check the fuel filter heater relay K-9100 low side driver vehicle harness (VE) wiring for a short circuit.
With the key in the OFF position, use a multimeter to perform the following voltage check on the vehicle harness
(VE) side :
From To Value
(VE) side :
From To Value
A. If there is voltage, there is a short circuit in the fuel filter heater relay K-9100 low side driver circuit in the vehicle
B. If there is no voltage, leave the fuel filter heater relay K-9100 disconnected and continue to Step 4.
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(VE) side :
From To Value
A. If there is continuity, there is a short circuit in the fuel filter heater relay K-9100 low side driver circuit in the vehi-
cle harness (VE). Use the appropriate service manual, if necessary, to locate and repair the shorted conductor.

(VE) side :
From To Value
A. If there is continuity, there is a short circuit in the fuel filter heater relay K-9100 wiring in the vehicle harness
has been resolved.
operation.
(55.100.DP-C.20.E.02)
(55.100.DP-C.20.E.04)
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3176-High pressure pump fuel delivery quantity in over run exceeds

a maximum threshold
Context:
The Engine Control Unit (ECU) A-9000 monitors the high pressure fuel system for leakage during overrun. If the ECU
A-9000 detects that the high pressure pump quantity in overrun exceeds the expected threshold, this fault will occur.
Cause:
The ECU A-9000 has determined that the high pressure fuel pump quantity is higher than the expected fuel quantity
threshold.

2. Faulty high pressure fuel pump, internal failure.
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3177-Engine Protection : Over speed detection in component

engine protection
Context:
This fault is intended for information purposes only and does not require any further action. Other active faults may
have caused this fault to occur. Diagnose any other active faults first and then return to this fault, 3177 - Engine Pro-
tection : Over speed detection in component engine protection. The Engine Control Unit (ECU) A-9000 monitors
for an engine overspeed condition. An engine overspeed condition can occur from such conditions as downhill travel.
If an engine speed of at least 3100 RPM has been detected for at least 0.05 s, this fault will occur.
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3179-Timeout of CAN Message BC2EDC2

Context:
Cause:
ECU A-9000 has sensed a timeout of required vehicle controller data provided on CAN Node A.

Solution:
A. If the fault is present and active, continue with Step2.
A. If other vehicle CAN faults do exist, resolve the vehicle CAN faults, then check to see that 3179 - Timeout of
CAN Message BC2EDC2 is also resolved.

With the key switch in the “ON” position, use a multimeter to check for voltage on the vehicle (VE) harness side:
From To Value
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 ECU A-9000.
4. Check the ECU A-9000 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
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B. If there is no continuity for one or more of the checks, refer to the appropriate vehicle service manual and
electrical schematics to locate and restore the grounding circuit to the ECU A-9000.
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
From To Value
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.
has been resolved.
operation.
(55.100.DP-C.20.E.04)
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3180-CAN communication error between vehicle controller to ECU

Context:
The Engine Control Unit (ECU) A-9000 is capable of connecting to and communicating on two or more separate
Controller Area Networks (CAN). Proper configuration and monitoring of these twisted pair configured networks is also
a function of the ECU A-9000. CAN Node A Bus is the main vehicle interface bus. The ECU A-9000 provides a CAN
termination resistor for the CAN Node A Bus, internal to the ECU A-9000. The ECU A-9000 receives and responds
to proprietary information like low and high idle or intermediate speed set points and parameters or feedback. If the
ECU A-9000 does not receive the message every 0.050 s, this fault will occur.
Cause:
1. Faulty vehicle system, related CAN fault.

Solution:
A. If other vehicle CAN faults do exist, resolve the vehicle CAN faults, then check to see that this fault is also
resolved.

To energize the main relay K-9102, which provides power to the ECU A-9000, place a jumper wire between the
vehicle harness (VE) side of connector X-9122 pin K28 and chassis ground.
From To Value
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From To Value
From To Value
From To Value
circuit or replace the ECU A-9000.
has been resolved.
operation.
(55.100.DP-C.20.E.04)
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3188-Injector Cylinder 1 Warning - Open Load

Context:
The Engine Control Unit (ECU) A-9000 monitors the fuel injector number 1 Y-9001 circuit. If the ECU A-9000 deter-
mines that there is an open circuit condition in the fuel injector number 1 Y-9001 circuit, this fault will occur.
Cause:
The ECU A-9000 has detected an open circuit in the fuel injector number 1 Y-9001 circuit.

2. Faulty fuel injector number 1 Y-9001 wiring, open circuit.
Solution:
2. Check fuel injector number 1 for an internal failure.
Disconnect connector X-9030 from fuel injector number 1 Y-9001.
Use a multimeter to perform the following resistance check on the fuel injector pins :
From To Value
X-9030 pin 1 X-9030 pin 2 There should be approximately 0.3
- 0.5 Ω.
A. If the specified range is not measured, the fuel injector has failed. Replace the fuel injector number 1 Y-9001.
B. If the specified range is measured, leave connector X-9030 disconnected and continue to Step 3.
3. Check the fuel injector number 1 Y-9001 engine harness (EN) wiring for an open circuit.
Disconnect connector X-9139 from the engine interface connector.
With they key in the OFF position, use a multimeter to perform the following continuity check on the engine harness
(EN) side:
From To Value
X-9139 pin A X-9030 pin 1 There should be continuity.
X-9139 pin B X-9030 pin 2 There should be continuity.
A. If there is no continuity, there is an open circuit in the fuel injector number 1 Y-9001 engine harness (EN) wiring.
Locate and repair the broken conductor.
B. If there is continuity, leave connectors X-9030 and X-9139 disconnected and continue to Step 4.
4. Check the fuel injector number 1 Y-9001 vehicle harness (VE) wiring for an open circuit.
With they key in the OFF position, use a multimeter to perform the following continuity check on the vehicle harness
(VE) side:
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From To Value
X-9139 pin A X-9121 pin A16 There should be continuity.
X-9139 pin B X-9121 pin A32 There should be continuity.
A. If there is no continuity, there is an open circuit in the fuel injector number 1 Y-9001 vehicle harness (VE) wiring.
B. If there is continuity, check the ECU A-9000 for the appropriate service manual and re-flash, if necessary.
has been resolved.
operation.
(55.100.DP-C.20.E.05)
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Context:
Cause:

Solution:
From To Value
- 0.5 Ω.
(EN) side:
From To Value
X-9139 pin H X-9033 pin 1 There should be continuity.
X-9139 pin G X-9033 pin 2 There should be continuity.
(VE) side:
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From To Value
X-9139 pin H X-9121 pin A02 There should be continuity.
X-9139 pin G X-9121 pin A46 There should be continuity.
has been resolved.
operation.
(55.100.DP-C.20.E.05)
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Context:
Cause:

Solution:
From To Value
- 0.5 Ω.
(EN) side:
From To Value
X-9139 pin D X-9031 pin 1 There should be continuity.
X-9139 pin C X-9031 pin 2 There should be continuity.
(VE) side:
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From To Value
X-9139 pin D X-9121 pin A01 There should be continuity.
X-9139 pin C X-9121 pin A31 There should be continuity.
has been resolved.
operation.
(55.100.DP-C.20.E.05)
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Context:
Cause:

Solution:
From To Value
- 0.5 Ω.
(EN) side:
From To Value
X-9139 pin E X-9032 pin 1 There should be continuity.
X-9139 pin F X-9032 pin 2 There should be continuity.
(VE) side:
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From To Value
X-9139 pin E X-9121 pin A17 There should be continuity.
X-9139 pin F X-9121 pin A48 There should be continuity.
has been resolved.
operation.
(55.100.DP-C.20.E.05)
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3210-Bank 1 - General Short Circuit On Injector Cable

Context:
The Engine Control Unit (ECU) A-9000 monitors the fuel injector harness for a short circuit condition. If the ECU
A-9000 detects a short circuit pattern in the fuel injector harness of both bank 1 fuel injections, this fault will occur.
The bank 1 fuel injectors are fuel injector number 1 Y-9001 and fuel injector number 4 Y-9004.
Cause:
The ECU A-9000 has detected a a short circuit pattern between both bank 1 fuel injectors.
1. Faulty fuel injector wiring, short circuit.

2. Fault ECU A-9000, software.
Solution:
2. Use the Electronic Service Tool (EST) to check if the following related faults are active:
3063 - Cylinder 1 - Injector Cable Short Circuit (High Side To Ground)
A. If any of the related faults are active, diagnose them first and then return to this fault, 3210 - Bank 1 - General
Short Circuit On Injector Cable.
B. If none of the related faults are active, continue to Step 3.

3. Check the fuel injector harness (INJ) for a short circuit condition.
With the key in the OFF position, use a multimeter to perform the following continuity check on the fuel injector
harness (INJ) side :
From To Value
X-9139 pin A X-9139 pin E There should be no continuity.
X-9139 pin A X-9139 pin F There should be no continuity.
X-9139 pin B X-9139 pin E There should be no continuity.
X-9139 pin B X-9139 pin F There should be no continuity.
A. If there is continuity, there is a short circuit condition in the fuel injector number 4 Y-9004 fuel injector harness
(INJ) wiring. Locate and repair the shorted conductor.
B. If there is no continuity, leave the engine interface connector X-9139 disconnected and continue to Step 4.
4. Check the fuel injector number 4 Y-9004 vehicle harness (VE) for a short circuit condition.
harness (VE) side :
From To Value
X-9139 pin A X-9139 pin E There should be no continuity.
X-9139 pin A X-9139 pin F There should be no continuity.
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From To Value
X-9139 pin B X-9139 pin E There should be no continuity.
X-9139 pin B X-9139 pin F There should be no continuity.
A. If there is continuity, there is a short circuit condition in the fuel injector number 4 Y-9004 vehicle harness (VE)
B. If there is no continuity, Check the ECU A-9000 for the appropriate software and re-flash, if necessary.
has been resolved.
operation.
(55.100.DP-C.20.E.05)
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3218-Bank 2 - General Short Circuit On Injector Cable

Context:
The Engine Control Unit (ECU) A-9000 monitors the fuel injector harness for a short circuit condition. If the ECU
A-9000 detects a short circuit pattern in the fuel injector harness of both bank 2 fuel injections, this fault will occur.
The bank 2 fuel injectors are fuel injector number 2 Y-9002 and fuel injector number 3 Y-9003.
Cause:
The ECU A-9000 has detected a a short circuit pattern between both bank 2 fuel injectors.
1. Faulty bank fuel injector wiring, short circuit.

2. Fault ECU A-9000, software.
Solution:
2. Use the Electronic Service Tool (EST) to check if the following related faults are active:
A. If any of the related faults are active, diagnose them first and then return to this fault, 3218 - Bank 2 - General
Short Circuit On Injector Cable.
B. If none of the related faults are active, continue to Step 3.

3. Check the fuel injector harness (INJ) for a short circuit condition.
(INJ) side :
From To Value
X-9139 pin D X-9139 pin H There should be no continuity.
X-9139 pin D X-9139 pin G There should be no continuity.
X-9139 pin C X-9139 pin H There should be no continuity.
X-9139 pin C X-9139 pin G There should be no continuity.
A. If there is continuity, there is a short circuit condition in the fuel injector harness (INJ) wiring. Locate and repair
the shorted conductor.
B. If there is no continuity, leave the engine interface connector X-9139 disconnected and continue to Step 4.
4. Check the fuel injector vehicle harness (VE) for a short circuit condition.
harness (VE) side :
From To Value
X-9139 pin D X-9139 pin H There should be no continuity.
X-9139 pin D X-9139 pin G There should be no continuity.
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From To Value
X-9139 pin C X-9139 pin H There should be no continuity.
X-9139 pin C X-9139 pin G There should be no continuity.
A. If there is continuity, there is a short circuit condition in the fuel injector vehicle harness (VE) wiring. Use the
B. If there is no continuity, Check the ECU A-9000 for the appropriate software and re-flash, if necessary.
has been resolved.
operation.
(55.100.DP-C.20.E.05)
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3230-Injection Processor (CY33X) Error - SPI Communication

Failure
Context:
The Engine Control Unit (ECU) A-9000 monitors diagnostic checks on the fuel injection power stages. This diagnostic
procedure uses pattern detection to identify specific errors and can trigger the appropriate reaction. If the ECU A-9000
detects a specific combination of errors in the injection power stages, this fault will occur.
Solution:
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3235-Injection control: Number of injections is limited by runtime

Context:
The ECU A-9000 monitors the requested number of fuel injections and the current capability of the injection system
fulfilling that request. If the ECU A-9000 determines that the requested number of injections is greater than the current
capability of the fuel injection system for the current engine speed, this fault will occur.
Cause:
The ECU A-9000 has determined that the requested number of fuel injections is greater than the capability of the fuel
injection system based on engine speed.
Solution:
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3236-Injection control : Number of injections is limited by quantity

balance of high pressure pump
Context:
The ECU A-9000 monitors the requested number of fuel injections and the current capability of the fuel injection sys-
tem to fulfill that request. If the ECU A-9000 determines that the number of requested fuel injections is greater than the
current capability of the fuel injection system, this fault will occur. For more information regarding the troubleshooting
of the fuel system, refer to the engine service manual Fuel injection system - Troubleshooting (10.218).
Cause:
The ECU A-9000 has determined that the number of requested fuel injections is greater than the current capability of
the fuel injection system to fulfill that request.
1. Faulty fuel back-flow, excessive.

2. Faulty high pressure pump, worn or ageing.
3. Faulty fuel metering unit, unable to open.
4. Faulty fuel temperature, too high.
5. Faulty fuel injectors, worn or internal leakage.
8. Faulty Pressure Relief Valve (PRV), leakage.
9. Faulty rail pressure sensor B-9004, drifted signal or leakage.
10. Faulty fuel injection system, leaking or blocked lines.
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3237-Injection control : Number of desired injections exceeds

threshold
Context:
The Engine Control Unit (ECU) A-9000 monitors the requested number of fuel injections. If the ECU A-9000 deter-
mines that the number of requested injections is greater than the current capability of the fuel injection system, this
fault will occur,
Cause:
The ECU A-9000 has determined that the number of requested fuel injections has exceeded the current capability of
the fuel injection system.
1. Faulty battery, low voltage.

2. Faulty ECU A-9000 power supply.
Solution:
1. Check battery voltage.
Load test the battery. There should be approximately 12.0 V.
A. If the battery passes the load test, continue to Step 2.
B. If the battery fails the load test, the battery has failed. Replace the battery.
2. Check the ECU A-9000 power supply wiring.
Disconnect connector X-9122 from the ECU A-9000.
With the key in the ON position, use a multimeter to perform the following voltage check.
From To Value
X-9122 pin K03 Chassis ground There should be approximately
12.0 V.
12.0 V.
12.0 V.
A. If there is approximately 12.0 V, leave the connector disconnected and continue to Step 3.
B. If there is not approximately 12.0 V, there is a fault in the ECU A-9000 power supply wiring. Locate and repair
the failed conductor.
3. Check the ECU A-9000 ground supply wiring.
With the key in the OFF position, use a multimeter to perform the following continuity check.
From To Value
X-9122 pin K02 Chassis ground There should be continuity.
A. If there is no continuity, there is a fault in the ECU A-9000 ground supply wiring. Locate and repair the failed
conductor.
B. If there is continuity, continue to Step 4.

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(55.100.DP-C.20.E.04)
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3238-ECM Internal SPI Communication Error - CJ940

Context:
The Engine Control Unit (ECU) A-9000 performs a diagnostic check of the sensor supplies by monitoring the sensor
supplies communication. If the ECU A-9000 detects a communication error during this diagnostic check, this fault will
occur.
Solution:
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3239-Error state of Electrically Erasable Programmable Read-Only

Memory (EEPROM)
Context:
The Engine Control Unit (ECU) A-9000 has detected an error during the last EEPROM write operation. The hardware
encapsulation of the ECU A-9000 checks each data block of the EEPROM and sets a status flag depending on if an
error is found or not found. These flags are processed every 20 milliseconds by the Diagnostic System Management
(DSM) and if the value is out of range, this fault will occur.
Solution:
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3241-EEPROM : There was an error during Write/Read EEPROM

operation
Context:
The Engine Control Unit (ECU) A-9000 has detected an error during the last EEPROM write operation. The hardware
encapsulation of the ECU A-9000 checks each data block of the EEPROM and sets a status flag depending on if an
error is found or not found. These flags are processed every 20 milliseconds by the Diagnostic System Management
(DSM) and if the value is out of range, this fault will occur.
Solution:
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3242-ECU internal : Visibility of Software Resets in DSM

Context:
If this fault is active, the Engine Control Unit (ECU) A-9000 has detected an error that has led to a software reset.
Solution:
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3243-ECU internal : Visibility of Software Resets in DSM

Context:
The Engine Control Unit (ECU) A-9000 will perform a software reset if a software failure is detected. If this fault is
active, a software failure has been reported and a software reset has occurred.
Solution:
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3244-ECU internal failure - Software resets in DSM 2

Context:
The Engine Control Unit (ECU) A-9000 will perform a software reset if a software failure is detected. If this fault is
active, a software failure has been reported and a software reset has occurred.
Solution:
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3245-ECM Processor - Watchdog Not Plausible

Context:
The Engine Control Unit (ECU) A-9000 monitors the communication between the ECU A-9000 processor and the
power stage controller over the SPI bus. If there is an error in the communication, this fault will occur.
Solution:
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3252-Controller Watchdog - SPI Communication Failure

Context:
The Engine Control Unit (ECU) A-9000 monitors the communication between the ECU A-9000 processor and the
power stage controller over the SPI bus. If there is an error in the communication, this fault will occur.
Solution:
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3253-ADC Monitoring - Reference Voltage Too High

Context:
The Engine Control Unit (ECU) A-9000 monitors the Analog Digital Converter (ADC) for plausibility by providing a test
voltage to be converted. If the converted voltage is out of range, this fault will occur.
Solution:
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3255-ADC Monitoring Test Impulse Error

Context:
The Engine Control Unit (ECU) A-9000 monitors the Analog Digital Converter (ADC) plausibility by performing a fixed
input voltage test. If the voltage during the test is out of range, this fault will occur.
Solution:
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3256-ADC Monitoring Queue Error

Context:
The Engine Control Unit (ECU) A-9000 monitors the Analog Digital Converter (ADC) plausibility by running a No-load
Test Pulse operation (NTP). If the ECU A-9000 detects an error during this operation, this fault will occur.
Solution:
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3258-ECU Power stages : Starter relay HS power stage output short

circuit to battery
Context:
The Engine Control Unit (ECU) A-9000 controls the starter control relay K-9104 using a low side and high side driver.
If the ECU A-9000 detects a short circuit to battery in the high side driver circuit, this fault will occur.
Cause:
The ECU A-9000 has detected a short circuit to battery in the starter control relay K-9104 high side driver circuit.
1. Faulty starter control relay K-9104 wiring, short to a voltage source.

2. Faulty starter control relay K-9104, internal failure.
Solution:
2. Check the starter control relay K-9104 coil for an internal failure.
Remove the starter control relay K-9104.
Use a multimeter to measure the relay coil resistance on the starter control relay K-9104 pins :
From To Value
130 Ω.
A. If there is approximately 70 - 130 Ω, leave the starter control relay K-9104 disconnected and continue to Step
3.
B. If there is not approximately 70 - 130 Ω, the relay has failed. Replace the starter control relay K-9104.
3. Check the starter control relay K-9104 high side driver vehicle harness (VE) wiring for a short to a voltage source.
With the key in the OFF position, use a multimeter to perform the following voltage check for short to a voltage
From To Value
With the key in the ON position, use a multimeter to perform the following voltage check for short to a voltage
From To Value
A. If there is voltage, there is a short to a voltage source in the starter control relay K-9104 wiring in the vehicle
B. If there is no voltage, continue to Step 4.

4. Check the starter control relay K-9104 high side driver vehicle harness (VE) wiring for a short circuit.
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With the key in the OFF position, use a multimeter to perform the following continuity check for short circuit on the
vehicle harness (VE) side :
From To Value
A. If there is continuity, there is a short circuit in the starter control relay K-9104 wiring in the vehicle harness (VE).
Use the appropriate service manual, if necessary, to locate and repair the shorted conductor.
has been resolved.
operation.
(55.100.DP-C.20.E.04)
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3259-ECU Power stages : Starter relay HS power stage output short

circuit to ground
Context:
If the ECU A-9000 detects a short circuit to ground in the high side driver circuit, this fault will occur.
Cause:
The ECU A-9000 has detected a short circuit to ground in the starter control relay K-9104 high side driver circuit.
1. Faulty starter control relay K-9104 wiring, short to ground.

Solution:
From To Value
130 Ω.
3.
3. Check the starter control relay K-9104 high side driver vehicle harness (VE) wiring for a short to ground.
From To Value
A. If there is continuity, there is a short to ground in the starter control relay K-9104 wiring in the vehicle harness

4. Check the starter control relay K-9104 high side driver vehicle harness (VE) wiring for a short circuit.
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From To Value
A. If there is continuity, there is a short to ground in the starter control relay K-9104 wiring in the vehicle harness
has been resolved.
operation.
(55.100.DP-C.20.E.04)
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3260-Low side power - open load

Context:
If the ECU A-9000 detects an open circuit in the high side driver circuit, this fault will occur.
Cause:
The ECU A-9000 has detected an open circuit in the starter control relay K-9104 high side driver circuit.
1. Faulty starter control relay K-9104 wiring, open circuit.

Solution:
From To Value
130 Ω.
3.
3. Check the starter control relay K-9104 vehicle harness (VE) wiring for an open circuit.
From To Value
A. If there is no continuity, there is an open circuit in the starter control relay K-9104 wiring in the vehicle harness
(VE). Use the appropriate service manual, if necessary, to locate and repair the broken conductor.
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has been resolved.
operation.
(55.100.DP-C.20.E.04)
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3261-Low side power - short circuit to battery or excess temperature

Context:
If the ECU A-9000 detects a short circuit to battery in the low side driver circuit, this fault will occur.
Cause:
The ECU A-9000 has detected a short circuit to battery in the starter control relay K-9104 low side driver circuit.
1. Faulty starter control relay K-9104 wiring, short to a voltage source.

Solution:
From To Value
130 Ω.
3.
3. Check the starter control relay K-9104 low side driver vehicle harness (VE) wiring for a short to a voltage source.
With the key in the OFF position, use a multimeter to perform the following voltage check for a short to a voltage
From To Value
With the key in the ON position, use a multimeter to perform the following voltage check for a short to a voltage
From To Value
A. If there is voltage, there is a short to a voltage source in the starter control relay K-9104 low side driver wiring
in the vehicle harness (VE). Use the appropriate service manual, if necessary, to locate and repair the shorted
conductor.
B. If there is no voltage, leave the starter control relay K-9104 disconnected and continue to Step 4.
4. Check the starter control relay K-9104 low side driver vehicle harness (VE) wiring for a short circuit.
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(VE) side :
From To Value
A. If there is continuity, there is a short circuit in the starter control relay K-9104 wiring in the vehicle harness (VE).
has been resolved.
operation.
(55.100.DP-C.20.E.04)
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3262-Low side power - short circuit to ground

Context:
If the ECU A-9000 detects a short circuit to ground in the low side driver circuit, this fault will occur.
Cause:
The ECU A-9000 has detected a short circuit to ground in the starter control relay K-9104 low side driver circuit.
1. Faulty starter control relay K-9104 wiring, short to ground.

Solution:
2. Check the starter control relay K-9104 coil internal resistance.
Using a multimeter, to measure the resistance on the starter control relay K-9104 pins :
From To Value
130 Ω.
A. If there is approximately 70 - 130 Ω, leave the relay disconnected and continue to Step 3.
B. If there is not approximately 70 - 130 Ω, the relay starter control relay K-9104 has failed. Replace the starter
control relay K-9104.
3. Check the starter control relay K-9104 low side driver vehicle harness (VE) wiring for a short circuit.
(VE) side :
From To Value
Disconnect the ECU A-9000 connector X-9122.
(VE) side :
From To Value
A. If there is continuity, there is a short circuit in the starter control relay K-9104 vehicle harness (VE) wiring. Use
the appropriate service manual, if necessary, to locate and repair the shorted conductor.
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has been resolved.
operation.
(55.100.DP-C.20.E.04)
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3265-Overrun Monitoring - Injection Time Too Long

Context:
The Engine Control Unit (ECU) A-9000, during after run, monitors fuel injector actuation time by calculating the de-
manded fuel injection quantity of actual injection and actual fuel pressure. If the ECU A-9000 determines that ener-
gizing time is greater than engine speed, this fault will occur.
Solution:
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3266-Redundent Engine Speed in Overrun Monitoring - Speed

Signal Not Plausible
Context:
The Engine Control Unit (ECU) A-9000 monitors engine speed in multiple software levels. If the ECU A-9000 deter-
mines that there is plausibility error in the engine speed monitoring, this fault will occur.
Solution:
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3283-Engine regulated 5 Volt sensor supply #2 - Shorted to high

source
Context:
The Engine Control Unit (ECU) A-9000 provides three independent five volt sensor supplies. The ECU A-9000 mon-
itors each sensor supply voltage to ensure they operate within a given range. If the ECU A-9000 determines that the
voltage for sensor supply 2 is out of range, this fault will occur.
The ECU A-9000 pin numbers associated with sensor supply 2 are K12, K13, K14, K15, and K16.
Cause:
The ECU A-9000 has determined that the sensor supply 2 voltage is out of range.
1. Faulty battery voltage.

2. Faulty ECU A-9000 supply voltage.
3. Faulty ECU A-9000 sensor supply 2 pins.
4. Faulty ECU A-9000 connector X-9121, corrosion or damage.
Solution:
2. Check the battery voltage.
Charge the battery, then, perform a load test on the battery.
(VE) side :
From To Value
X-9122 pin K03 X-9122 pin K02 There should be approximately 12 V.
A. If there is approximately 12 V, leave connector X-9122 disconnected and continue to Step 4.
B. If there is not approximately 12 V, there is a failure in the ECU A-9000 supply wiring. Use the appropriate
service manual, if necessary, to locate and repair the failed conductor.
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4. Check the following pins listed below on the ECU A-9000 and in connector X-9122.
Pin Physical condition

X-9122 pin K12 The pin and connector should be free of corrosion or
damage.
damage.
damage.
damage.
damage.
A. If a pin or connector shows signs of corrosion or damage, repair as necessary.
B. If a pin or connector shows no signs of corrosion or damage, continue to Step 5.


has been resolved.
operation.
(55.100.DP-C.20.E.04)
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3285-Sensor Supply Voltage 3 - High

Context:
The ECU A-9000 pin numbers associated with sensor supply 3 are K17, K18 and A29.
Cause:

2. Faulty ECU A-9000, supply voltage.
4. Faulty ECU A-9000 connector X-9122 or X-9121, corrosion or damage.
Solution:
(VE) side :
From To Value
A. If there is approximately 12 V, leave connector X-9122 disconnected and continue to Step 4.
4. Disconnect the vehicle harness (VE) from the ECU A-9000 at connector X-9121.
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Check the following pins listed below on the ECU A-9000 and in connectors X-9122 and X-9121.

damage.
damage.
X-9121 pin A29 The pin and connector should be free of corrosion or
damage.
B. If a pin or connector shows no signs of corrosion or damage, continue to Step 5.


A. If you find damage or the display indicates other than normal display readings, Then, repair the damage dis-
covered during the inspection or locate and repair the other than normal display condition and verify that the
error has been resolved.
B. If you do not find damage and the display indicates only normal readings, Then, erase the fault code and
continue operation.
(55.100.DP-C.20.E.04)
(55.100.DP-C.20.E.05)
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3293-Fuel Metering Unit: maximum positive deviation of rail

pressure exceeded
Context:
The Engine Control Unit (ECU) A-9000 monitors fuel rail pressure. If the measured rail pressure is lower than the de-
sired pressure by 100 bar (1450 psi) depending on engine speed, this fault will occur. For more information regarding
fuel system troubleshooting, refer to th eengine service manual Fuel injection system - Troubleshooting (10.218).
Cause:
The ECU A-9000 has determined that the measured rail pressure is 100 bar (1450 psi) lower than desired fuel pres-
sure based on engine speed.

4. Faulty low pressure fuel supply lines, clogged or damaged.
5. Faulty high pressure fuel supply lines, clogged or damaged.
7. Faulty high pressure fuel pump, low efficiency.
8. Faulty fuel injectors, worn, clogged or internal leakage.
9. Faulty rail pressure sensor B-9004, drifted or leaking.
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3301-Fuel metering unit: Maximum negative rail pressure deviation

with metering unit on lower limit is exceeded
Context:
The Engine Control Unit (ECU) A-9000 monitors fuel rail pressure. If the ECU A-9000 determines that fuel pressure is
higher than the desired fuel pressure, depending on engine speed, this fault will occur. For more information regarding
fuel system troubleshooting, refer to the engine service manual Fuel injection system - Troubleshooting (10.218).
Cause:
The ECU A-9000 has determined that the fuel rail pressure is higher than desired based on engine speed.
1. Faulty fuel metering unit Y-9000, stuck open.

3. Faulty Pressure Relief Valve (PRV), stuck or blocked.
4. Faulty rail pressure sensor B-9004, drifted.
5. Faulty high pressure pump.
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3305-Fuel metering unit: Minimum rail pressure exceeded

Context:
The Engine Control Unit (ECU) A-9000 monitors fuel rail pressure using the rail pressure sensor B-9004. If the ECU
A-9000 determines that the measured rail pressure is less than a dependent engine speed value, this fault will occur.
Other active faults may have caused this fault to occur. For more information regarding fuel system troubleshooting,
refer to the engine service manual Fuel injection system - Troubleshooting (10.218).
Cause:
The ECU A-9000 has determined that the measured rail pressure is less than a dependent engine speed value.

2. Faulty low pressure fuel lines, clogged or damaged.
3. Faulty high pressure fuel lines, clogged or damaged.
6. Faulty high pressure pump, low efficiency or excessive leak-off.
7. Faulty fuel injectors, excessive or leaking internally.
8. Faulty Pressure Relief Valve (PRV), leaking or stuck open.
9. Faulty rail pressure sensor B-9004 or sensor leaking.
10. Faulty fuel metering unit Y-9000
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3309-Fuel metering unit: Maximum rail pressure exceeded

Context:
A-9000 determines that the measured rail pressure is greater than desired by more than a dependent engine speed
value, this fault will occur. For more information regarding fuel system troubleshooting, refer to the engine service
manual Fuel injection system - Troubleshooting (10.218).
Cause:
The ECU A-9000 has determined that the measured rail pressure is greater than desired by more than a dependent
engine speed value.
1. Faulty fuel metering unit Y-9000, stuck open or internal failure.

2. Faulty fuel back-flow lines, blocked or damaged.
3. Faulty Pressure Relief Valve (PRV), stuck closed or mechanically unable to open.
4. Faulty high pressure pump, zero delivery throttle valve clogged.
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3334-Timeout of CAN message TSC1-PE torque

Context:
Cause:
ECU A-9000 has sensed a timeout of vehicle data provided on CAN Node A.

Solution:
CAN message TSC1-PE torque (when active) is also resolved.

From To Value
From To Value
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From To Value
From To Value
circuit.
has been resolved.
operation.
(55.100.DP-C.20.E.04)
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3335-Timeout of CAN message TSC1-PE torque

Context:
Cause:
ECU A-9000 has sensed a timeout of vehicle data provided on CAN Node A.

Solution:
CAN message TSC1-PE torque is also resolved.

From To Value
From To Value
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From To Value
From To Value
circuit.
has been resolved.
operation.
(55.100.DP-C.20.E.04)
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3338-Timeout of CAN message TSC1-VE Speed

Context:
Cause:

Solution:
CAN message TSC1-VE Speed is also resolved.

From To Value
From To Value
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From To Value
From To Value
circuit.
has been resolved.
operation.
(55.100.DP-C.20.E.04)
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3339-Timeout of CAN message TSC1-VE Speed

Context:
Cause:

Solution:
CAN message TSC1-VE Speed is also resolved.

From To Value
From To Value
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From To Value
From To Value
circuit.
has been resolved.
operation.
(55.100.DP-C.20.E.04)
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3350-Terminal 50 - Always On
Context:
The Engine Control Unit (ECU) A-9000 is notified of a request for engine cranking at connector X-9122 pin K08. If the
request for cranking signal exists for longer than 80.0 s the ECU A-9000 assumes a mechanical failure in the ignition
key module or start relay or a short to a voltage source condition exists in the input circuit and this fault occurs.
Cause:
The engine cranking signal has exceeded the signal ON time established be the ECU A-9000.
1. Faulty vehicle cranking circuit component, key switch or crank / start relay.
2. Faulty cranking circuit wiring, shorted to a voltage source.
Solution:
1. Verify that the fault present and active.
2. Check the cranking circuit wiring for a short to voltage source condition.
With the key switch in the ON position, use a multimeter to check for voltage on the vehicle harness (VE) side :
From To Result
X-9122 pin K08 chassis ground There should be no voltage.
A. If there is voltage, Use the appropriate vehicle service manual, if necessary, to locate the voltage source.
B. If there is no voltage, leave connector X-9122 disconnected and continue with Step 3.
3. Check the cranking circuit wiring for an ECU A-9000 sourced short to voltage condition.
With the key switch in the OFF position, use a multimeter to check for continuity on the vehicle harness (VE) side :
From To Result
X-9122 pin K08 to all other pins in connector X-9122 There should be no continuity.
A. If there is continuity, there is a short to a voltage source condition in the vehicle harness (VE). Use the appro-
priate vehicle service manual, if necessary, to locate and repair the shorted conductors.
or broken wires.
has been resolved.
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operation.
(55.100.DP-C.20.E.04)
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3358-Engine sensor CAN bus failure (Engine controller can't

transmit to sensors, or sensors not on CAN bus)
Context:
Cause:

Solution:
A. If other vehicle CAN faults do exist, resolve the vehicle CAN faults, then check to see that 3358 - Engine
sensor CAN bus failure (Engine controller can't transmit to sensors, or sensors not on CAN bus) is also
resolved.

From To Value
From To Value
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From To Value
From To Value
From To Value
circuit.
has been resolved.
operation.
(55.100.DP-C.20.E.04)
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3361-EEPROM : EEP Erase Error

Context:
The Engine Control Unit (ECU) A-9000 has a functionality for reading and erasing values to a memory media (Flash
or EEPROM). If the ECU A-9000 determines that this process can not be performed or successfully completed, this
fault will occur.
Solution:
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3362-Engine internal calculations : DFC to report if the quantity

axis points increase strictly linearly above the torque axis
Context:
The Engine Control Unit (ECU) A-9000 checks the map for the conversion from fuel quantity to torque for consistency.
If there is an error during this conversion check, this fault will occur.
Solution:
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3368-Torque limitation caused by performance limiter

Context:
This fault is for informational purposes only and may have been caused by another fault. The Engine Control Unit
(ECU) A-9000 has detected higher level of NOx emissions than expected. If this fault occurs, a toque limitation of
equal to or greater than 25 % will occur. Other active faults may have caused this fault to occur.
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3369-Torque Reduction Due to Smoke Limitation

Context:
This fault is for informational purposes only and is active because there has been a torque limitation set by the Engine
Control Unit (ECU) A-9000. The (ECU) A-9000 monitors air/fuel ratio. If the ECU A-9000 determines that the ratio is
too lean, a torque limitation of 25 % will be active to prevent engine damage. Though no action is necessary due to
this error, if the power reduction occurred due to an actual defect, the error triggering the torque limitation should also
be in fault memory. Use the Electronic Service Tool (EST) to check for related faults. Diagnose the related faults first
and then return to this fault, 3369 - Torque Reduction Due to Smoke Limitation. Also, see the list below of possible
mechanical failures that may have caused this fault. Refer to the engine service manual Fuel injection system -
Poor quality (10.218) for more information on troubleshooting a lean air/fuel ratio condition.
Cause:
The ECU A-9000 has set a torque limitation due to a lean air/fuel ratio.
1. Operating in extreme high altitudes, greater than an altitude of 1800 m (5906 ft).
2. Operating in low ambient pressure conditions, less than an ambient pressure of 0.78 bar (11.31 psi).
3. Faulty lambda sensor B-9123, drifted.
4. Faulty Exhaust Gas Recirculation (EGR) actuator, stuck or inoperative.
5. Faulty turbocharger wastegate Y-9008, sticking or stuck open.
6. Faulty turbocharger, low efficiency.
7. Faulty air induction, leakage or blockage.
8. Faulty intake manifold pressure sensor B-9001. At key ON there should be approximately the value of ambient
pressure.
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3370-Torque limitation due to engine protection (against excessive

torque, engine overspeed and overheat)
Context:
This fault is for information purposes only and may have been caused by another fault. The Engine Control Unit (ECU)
A-9000 has detected an active power reduction due to too high exhaust gas temperature, engine coolant temperature,
engine oil temperature or fuel temperature. If this fault is active, an engine power or engine speed reduction of equal
to or greater than 25 % of the desired torque will be active to protect the engine from damage. Though no action is
necessary due to this error, if the power reduction occurred due to an actual defect, the error triggering the torque
limitation should also be in fault memory. Use the Electronic Service Tool (EST) to check for related fault codes and
diagnose them first, then check the status of this fault, 3370 - Torque limitation due to engine protection (against
excessive torque, engine overspeed and overheat).
Cause:
This fault is an information only fault. It has been triggered by another fault.
Solution:
1. Use the Electronic Service Tool (EST) to check for other faults that may have caused this fault to occur.
A. If any related faults are active, diagnose them first, then return to this fault, 3370 - Torque limitation due to
engine protection (against excessive torque, engine overspeed and overheat).
B. If there are no related faults active, continue to Step 2.

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3371-Torque Limitation Due To Fuel Quantity Limitation Because

Of Injector System Errors
Context:
A-9000 has detected an active power reduction due to higher than expected fuel temperature. If this fault is active,
a power reduction of equal to or greater than 25 % of the desired torque will be active to protect the high pressure
fuel pump from damage. Though no action is necessary due to this error, if the power reduction occurred due to an
actual defect, the error triggering the torque limitation should also be in fault memory. Use the Electronic Service Tool
(EST) to check for related fuel system faults and diagnose them first, then check the status of this fault, 3371 - Torque
Limitation Due To Fuel Quantity Limitation Because Of Injector System Errors. For information regarding fuel
system troubleshooting, refer to the engine service manual Fuel injection system - Troubleshooting (10.218).
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3374-Injection Quantity Adjustment failure - Invalid EEPROM

Adjustment Value Checksum
Context:
The Engine Control Unit (ECU) A-9000 uses an IMA code to correct fuel trim for each fuel injector equipped with the
engine at every key ON. If the ECU A-9000 determines that this trim correction for fuel injector number 1 Y-9001 can
not be performed, this fault will occur. For more information about how to configure injector IMA codes, refer to the
engine service manual Fuel injectors - Configure - IMA codes (10.218).
Cause:
The ECU A-9000 has determined that the fuel injector number 1 Y-9001 fuel trim correction can not be performed.
Solution:
1. Use the Electronic Service Tool (EST) ensure that the correct IMA code is programmed to fuel injector number 1
Y-9001.
A. If the correct code is not programmed. Use the EST to program the correct code.
B. If the correct code is programmed, continue to Step 2.

NOTE: The IMA code may be under the paint on the fuel injector.
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3402-Rail pressure sensor: maximum rail pressure exceeded

Context:
A-9000 determines that rail pressure has exceeded 1790 bar (25955 psi), this fault will occur. A Pressure Relief Valve
(PRV), integral to the fuel rail, is designed to open in the event of an over-pressure in the fuel rail at approximately
1790 bar (25955 psi). If the ECU A-9000 determines that rail pressure has exceeded this threshold, a PRV failure is
assumed. Other related faults may have caused this fault to occur. Diagnose any related fault that is active and may
have caused this fault to occur first, then return to this fault, 3402 - Rail pressure sensor: maximum rail pressure
exceeded. For more information regarding fuel system troubleshooting, refer to the engine service manual Fuel
injection system - Troubleshooting (10.218).
Cause:
The ECU A-9000 has determined that rail pressure has exceeded 1790 bar (25955 psi).
1. Faulty fuel back-flow, clogged.

2. Faulty PRV, unable to open to clogged return.
3. Faulty fuel metering unit Y-9000, stuck open or internal failure.
4. Faulty rail pressure sensor B-9004, drifted.
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3403-ECU Power Stages: Starter relay HS power stage over

temperature
Context:
If the ECU A-9000 detects an over temperature/current condition in the high side driver circuit, this fault will occur.
Cause:
The ECU A-9000 has detected an over temperature/current condition in the starter control relay K-9104 high side
driver circuit.
1. Faulty starter control relay K-9104 wiring, short circuit.

Solution:
From To Value
130 Ω.
3.
3. Check the starter control relay K-9104 high side driver vehicle harness (VE) wiring for a short to ground.
With the key in the OFF position, use a multimeter to perform the following continuity check for short to ground on
From To Value
A. If there is continuity, there is a short to ground in the starter control relay K-9104 high side driver circuit in
the vehicle harness (VE). Use the appropriate service manual, if necessary, to locate and repair the shorted
conductor.
B. If there is no continuity, leave the starter control relay K-9104 disconnected and continue to Step 4.
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From To Value
From To Value
A. If there is voltage, there is a short to a voltage source in the starter control relay K-9104 high side driver circuit
conductor.

With the key in the OFF position, use a multimeter to perform the following continuity check for a short to a voltage
From To Value
A. If there is continuity, there is a short circuit in the starter control relay K-9104 high side driver circuit in the vehicle
has been resolved.
operation.
(55.100.DP-C.20.E.04)
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3405-Wastegate pressure modulator control circuit open

Context:
The Engine Control Unit (ECU) A-9000 monitors the wastegate pressure modulator valve Y-9008 circuit. If the ECU
A-9000 determines that there is an open load in the wastegate pressure modulator valve Y-9008 circuit, this fault will
occur.
Cause:
The ECU A-9000 has detected an open load in the wastegate pressure modulator valve Y-9008 circuit.
1. Faulty wastegate pressure modulator valve Y-9008 wiring, open circuit.

2. Faulty wastegate pressure modulator valve Y-9008, internal failure.
Solution:
2. Check the wastegate pressure modulator valve Y-9008 internal resistance.
Disconnect the wastegate pressure modulator valve Y-9008 connector X-9038.
Use a multimeter to perform the following resistance check on the wastegate pressure modulator valve Y-9008
pins :
From To Value
X-9038 pin 1 X-9038 pin 2 There should be between 21.8 -
24.2 Ω.
NOTE: The provided value should be measured at a temperature of approximately 20 °C (68 °F).
B. If there is not between 21.8 - 24.2 Ω, the wastegate pressure modulator valve Y-9008 has failed internally.
Replace the wastegate pressure modulator valve Y-9008.
3. Check the wastegate pressure modulator valve Y-9008 engine harness (EN) wiring for an open circuit.
(EN) side :
From To Value
A. If there is no continuity, there is an open circuit in the wastegate pressure modulator valve wiring in the engine
harness (EN). Locate and repair the broken conductor.
B. If there is continuity, leave connector X-9138 disconnected and continue to Step 4.

4. Check the wastegate pressure modulator valve Y-9008 vehicle harness (VE) wiring for an open circuit.
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side :
From To Value
X-9138 pin 28 Chassis ground There should be approximately
12.0 V.
A. If there is no voltage, there is an open circuit in the wastegate pressure modulator valve wiring in the vehicle
harness (VE). Use the appropriate service manual, if necessary to locate and repair the broken conductor.
B. If there is approximately 12.0 V, leave connector X-9138 disconnected and continue to Step 5.
5. Check the wastegate pressure modulator valve Y-9008 vehicle harness (VE) wiring for an open circuit.
(VE) side :
From To Value
A. If there is no continuity, there is an open circuit in the wastegate pressure modulator valve wiring in the vehicle
harness (VE). Use the appropriate service manual, if necessary to locate and repair the broken conductor.
has been resolved.
operation.
(55.100.DP-C.20.E.05)
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3406-Wastegate pressure modulator control circuit over

temperature
Context:
A-9000 determines that there is an over temperature/current condition in the wastegate pressure modulator valve
Y-9008 circuit, this fault will occur.
Cause:
The ECU A-9000 has detected an over temperature/current condition in the wastegate pressure modulator valve
Y-9008 circuit.
1. Faulty wastegate pressure modulator valve Y-9008 wiring, short to a voltage source.
Solution:
pins :
From To Value
24.2 Ω.
3. Check the wastegate pressure modulator valve Y-9008 wiring for a short circuit.
(EN) side :
From To Value
A. If there is continuity, there is a short circuit in the wastegate pressure modulator valve wiring. Use the appro-
priate service manual, if necessary to locate and repair the shorted conductor.

4. Check the wastegate pressure modulator valve Y-9008 wiring for a short to battery condition.
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(EN) side :
From To Value
A. If there is voltage, there is a short to battery in the wastegate pressure modulator valve wiring. Use the appro-

5. Check the wastegate pressure modulator valve Y-9008 wiring for a short to a voltage source.
(EN) side :
From To Value
A. If there is voltage, there is a short to a voltage source in the wastegate pressure modulator valve wiring in the
engine harness (EN). Locate and repair the shorted conductor.

(VE) side :
From To Value
vehicle harness (VE). Locate and repair the shorted conductor.
has been resolved.
operation.
(55.100.DP-C.20.E.05)
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3409-Engine oil pressure too low

Context:
The Engine Control Unit (ECU) A-9000 monitors the oil pressure switch S-9016 for proper operation. The oil pressure
switch S-9016 changes from its off to on state between 0.6 - 0.9 bar (8.7 - 13.0 psi). If the oil pressure switch S-9016
does actuate once the engine has been running for 6.0 s at greater than 500.0 RPM, this fault will occur.
Cause:
The ECU A-9000 has determined that the oil pressure switch S-9016 did not actuate.
1. Faulty oil level, too low.

2. Faulty oil pressure switch S-9016, failed internally.
3. Faulty oil pressure switch S-9016 circuit wiring, shorted to chassis ground.
4. Faulty oil pressure, too low or blockage.
5. Faulty ECU A-9000, hardware or software.
Solution:
2. Check oil level.
Use the appropriate operator or service manual, if necessary, to determine if the lubrication system has the ap-
propriate amount of oil.
There should be at least the minimum acceptable level of oil.
A. If there is at least the minimum acceptable level of oil, continue with Step 3.
B. If there less than the minimum acceptable level of oil, use the appropriate operator or service manual, if nec-
essary, to determine the type and quantity of oil required to re-fill the oil system.
3. Check the condition of the oil pressure switch S-9016.
Disconnect the engine harness (EN) from the oil pressure switch S-9016 at connector X-9016.
With the engine not running, use a multimeter to check for continuity on the component side :
From To Result
Start the engine and allow it to run at greater than 500 RPM for at least 6.0 s.
While the engine is running at greater than 500 RPM, use a multimeter to check for continuity on the component
side :
From To Result
X-9016 pin 1 chassis ground There should be no continuity.
A. If the specified values are measured, leave connector X-9016 disconnected and continue with Step 4.
B. If the oil pressure switch S-9016 did not change state, leave connector X-9016 disconnected and continue with
Step 7.
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4. Check the oil pressure switch S-9016 circuit for a short to ground condition.
With the key switch in the OFF position, use a multimeter to check for continuity on the engine harness (EN) side :
From To Result
5. Locate the short to ground condition.
From To Result
B. If there is no continuity, the short to a ground condition is in the engine harness (EN) between connector X-9016
pin 1 and connector X-9138 pin 3, wire EN-9105. Locate and repair the grounded conductor.
From To Result
X-9121 pin A06 chassis ground There should be no continuity.
A. If there is continuity, the short to chassis ground condition is in the vehicle harness (VE) between connector
X-9121 pin A06 and connector X-9138 pin 3, wire VE-9105. Use the appropriate service manual, if necessary,
to locate and repair the grounded conductor.
B. If there is no continuity, the ECU A-9000 has failed internally, replace the ECU A-9000.
7. Check lubrication system for blockage.
Refer to the engine service manual, Engine lubrication system - Test (10.304), if necessary, to determine if the
lubrication system has the appropriate amount of oil pressure.
Between 0.6 - 0.9 bar (8.7 - 13.0 psi) is required to actuate the oil pressure switch S-9016.
There should be at least the minimum acceptable level of oil pressure.
A. If there is adequate oil pressure, the oil pressure switch S-9016 has failed internally replace the switch.
B. If there less than the minimum acceptable level of oil pressure, use the appropriate service manual, if neces-
sary, to locate and restore oil pressure to the lubrication system.
or broken wires.
has been resolved.
operation.
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(55.100.DP-C.20.E.05)
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3410-Throttle valve actuator will not open to commanded position

NOTE: Once repaired, this fault may take up to up to 10 min of operation to reset.
Context:
The Engine Control Unit (ECU) A-9000 monitors the Throttle Valve Actuator (TVA) Z-9001. The TVA Z-9001 provides
the ECU A-9000 with a feedback using a position sensor. If the ECU A-9000 determines that there is a positive
deviation between the required and measured position, this fault will occur. If this fault is active, the ECU A-9000 will
command the TVA Z-9001 to open and close at a fast rate in order to attempt to “unblock “ the actuator. This fault
is not caused by a wiring failure. It is likely caused by an obstruction to the throttle valve flap or excessive carbon
build up on the throttle valve seat. For more information regarding TVA Z-9001 inspection, refer to the engine service
manual Throttle Valve Actuator (TVA) - Inspect (55.014).
Cause:
The ECU A-9000 has detected a positive deviation between the required and measured position of the TVA Z-9001.
The desired throttle valve position can not be reached.
1. Faulty throttle valve actuator Z-9001, sticking or blocked.

2. Faulty throttle valve actuator Z-9001, internal failure.
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3411-Throttle valve actuator will not close to commanded position

NOTE: Once repaired, this fault may take up to up to 10 min of operation to reset.
Context:
The Engine Control Unit (ECU) A-9000 monitors the Throttle Valve Actuator (TVA) Z-9001. The TVA Z-9001 provides
the ECU A-9000 with a feedback using a position sensor. If the ECU A-9000 determines that there is a negative
deviation between the required and measured position, this fault will occur. If this fault is active, the ECU A-9000 will
command the TVA Z-9001 to open and close at a fast rate in order to attempt to “unblock “ the actuator. This fault is
not caused by a wiring failure. It is likely caused by an obstruction to the throttle valve flap or excessive carbon build
up on the throttle valve seat.
Cause:
The ECU A-9000 has detected a negative deviation between the required and measured position of the TVA Z-9001.
The desired throttle valve position can not be reached. For more information regarding TVA Z-9001 inspection, refer
to the engine service manual Throttle Valve Actuator (TVA) - Inspect (55.014).
1. Faulty throttle valve actuator Z-9001, sticking or blocked.

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3414-Array of DFCs for short circuit in i+1th Glow Plug

Context:
For information regarding the functional operation of the glow plug control module Z-9101, refer to the engine service
manual Glow plug system Glow plug control module - Overview (55.202). The Engine Control Unit (ECU) A-9000
requests operation of the glow plug control module Z-9101 via a Pulse Width Modulated (PWM) control circuit and
monitors the status of possible electrical defects via a diagnostic feedback signal from the glow plug control module
Z-9101. If the ECU A-9000 is notified of a short circuit condition in the glow plug 1 R-9001 circuit, this fault will occur.
Cause:
The glow plug control module Z-9101 has communicated to the ECU A-9000, via a diagnostic connection, that a short
circuit condition exists in the glow plug 1 R-9001 circuit.
1. Faulty glow plug 1 R-9001, internal failure.

2. Faulty glow plug 1 R-9001 control circuit wiring, shorted to ground.
Solution:
2. Check the glow plug for a short to ground condition.
Disconnect the engine harness (EN) from glow plug 1 R-9001 at connector X-9034.
Use a multimeter to check on the component for a grounded (shorted) condition :
From To Result
X-9034 pin 1 chassis ground There should be 0.2 - 5.0 Ω.
A. If there is greater than 0.2 Ω, leave connector X-9034 disconnected and continue with Step 3.
B. If there is less than 0.2 Ω, the glow plug 1 R-9001 has failed internally, replace the glow plug.
3. Check the glow plug 1 R-9001 control circuit for a short to ground condition.
From To Result
A. If there is continuity, continue with Step 4.

From To Result
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Carefully disconnect the vehicle harness (VE) from the glow plug control module Z-9101 at connector X-9113.
From To Result
X-9113 pin 2 and connector X-9138 pin 61, wire VE-9058. Use the appropriate service manual, if necessary,

6. Replace the glow plug control module Z-9101, then use EST to check to see that this fault has been resolved.
has been resolved.
operation.
(55.100.DP-C.20.E.02)
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Context:
Cause:

Solution:
From To Result
From To Result

From To Result
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pin 1 and connector X-9138 pin 58 , wire EN-9060. Locate and repair the grounded conductor.
From To Result

has been resolved.
operation.
(55.100.DP-C.20.E.02)
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Context:
Cause:

Solution:
From To Result
From To Result

From To Result
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From To Result

has been resolved.
operation.
(55.100.DP-C.20.E.02)
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Context:
Cause:

Solution:
From To Result
From To Result

From To Result
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From To Result

has been resolved.
operation.
(55.100.DP-C.20.E.02)
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3418-Wastegate pressure modulator control circuit shorted to

battery
Context:
A-9000 determines that there is a short to a voltage source in the wastegate pressure modulator valve Y-9008 circuit,
this fault will occur.
Cause:
The ECU A-9000 has detected a short to a voltage source in the wastegate pressure modulator valve Y-9008 circuit.
1. Faulty wastegate pressure modulator valve Y-9008 wiring, short to a voltage source.
Solution:
pins :
From To Value
24.2 Ω.
3. Check the wastegate pressure modulator valve Y-9008 wiring for a short circuit.
(EN) side :
From To Value
A. If there is continuity, there is a short circuit in the wastegate pressure modulator valve wiring. Use the appro-

4. Check the wastegate pressure modulator valve Y-9008 wiring for a short to battery condition.
(EN) side :
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From To Value
A. If there is voltage, there is a short to battery in the wastegate pressure modulator valve wiring. Use the appro-

(EN) side :
From To Value
engine harness (EN). Locate and repair the shorted conductor.

(VE) side :
From To Value
vehicle harness (VE). Locate and repair the shorted conductor.
has been resolved.
operation.
(55.100.DP-C.20.E.05)
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3419-Wastegate pressure modulator control circuit shorted to

ground
Context:
A-9000 determines that there is a short to ground in the wastegate pressure modulator valve Y-9008 circuit, this fault
will occur.
Cause:
The ECU A-9000 has detected a short to ground in the wastegate pressure modulator valve Y-9008 circuit.
1. Faulty wastegate pressure modulator valve Y-9008 wiring, short to ground.

Solution:
pins :
From To Value
24.2 Ω.
3. Check the wastegate pressure modulator valve Y-9008 engine harness (EN) wiring.
(EN) side :
From To Value
A. If there is continuity, there is a short circuit in the wastegate pressure modulator valve engine harness (EN)
wiring. Locate and repair the shorted conductor.

4. Check the wastegate pressure modulator valve Y-9008 vehicle harness (VE) wiring.
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(VE) side of the connectors from :
From To Value
A. If there is continuity, there is an short circuit in the wastegate pressure modulator valve vehicle harness (VE)
wiring. Use the appropriate service manual, if necessary to locate and repair the shorted conductor.
has been resolved.
operation.
(55.100.DP-C.20.E.05)
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3425-Turbocharger: Over boost deviation at P2 too high in pressure

charger regulator
Context:
The Engine Control Unit (ECU) A-9000 monitors boost pressure using the intake manifold pressure sensor B-9001.
If the ECU A-9000 determines that boost pressure is higher than expected, this fault will occur. For more information
regarding the troubleshooting of an over-boost condition, refer to the engine service manual Turbocharger - Trou-
Cause:
The ECU A-9000 has determined that boost pressure is higher than expected.
1. Faulty wastegate pressure modulator valve Y-9008, if applicable.

2. Faulty wastegate, sticking or broken linkage.
3. Faulty intake manifold pressure sensor B-9001, signal drifted.
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3430-EGR Failure - Moderate Inducement

Context:
The Engine Control Unit (ECU) A-9000 monitors the efficiency of the Exhaust Gas Recirculation (EGR) valve Z-9000.
If the ECU A-9000 detects an efficiency failure, inducement will be triggered and this fault will occur. This fault indi-
cates a least severe inducement level. Other active faults may have caused this fault to occur.
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3431-EGR Failure - Severe Inducement

Context:
If the ECU A-9000 detects an efficiency failure, inducement will be triggered and this fault will occur. This fault indi-
cates a most severe inducement level. Other active faults may have caused this fault to occur.
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3432-EGR Failure - Mild Inducement

Context:
If the ECU A-9000 detects an efficiency failure, an inducement warning will be triggered and this fault will occur. Other
active faults may have caused this fault to occur.
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3517-Ambient air temperature sensor failure (of humidity sensor) -

signal too high
Context:
The Engine Control Unit (ECU) A-9000 monitors the intake air temperature sensor B-9113. If the ECU A-9000 deter-
mines that the intake air temperature sensor B-9113 signal circuit voltage is greater than 4.93 V, this fault will occur.
Once this fault occurs, the intake air temperature value is frozen by the ECU A-9000 at the last valid value for a
preliminary failure or jumps to a fixed replacement value of 29.96 °C (85.93 °F) if the failure is validated.
Cause:
The intake air temperature sensor B-9113 signal circuit voltage is greater than 4.93 V.
1. Faulty intake air temperature sensor B-9113 wiring, short to a voltage source.
2. Faulty intake air temperature sensor B-9113, internal failure.
Solution:
2. Check the intake air temperature sensor B-9113 wiring for a short circuit to battery.
Disconnect the vehicle harness from the intake air temperature sensor B-9113 at connector X-9117.
(VE) side :
From To Value
(VE) side :
From To Value
B. If the specified values are not measured, there is a short circuit to battery in the intake temperature sensor
B-9113 signal circuit in the vehicle harness (VE). Use the appropriate service manual, if necessary, to locate
3. Check the intake air temperature sensor B-9113 wiring for an open circuit condition.
(VE) side :
From To Value
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B. If there is no continuity, there is an open circuit condition in the intake temperature sensor B-9113 signal circuit
vehicle harness (VE) wiring. Use the appropriate service manual, if necessary, to locate and repair the broken
conductor.
4. Check the intake air temperature sensor B-9113 wiring for a short circuit condition.
With the key in the OFF position, use a multimeter to perform the following continuity check at the vehicle harness
(VE) side of the connector from :
From To Value
A. If there is continuity, there is a short to ground condition in the intake temperature sensor B-9113 signal circuit
vehicle harness (VE).Use the appropriate service manual, if necessary, to locate and repair the shorted con-
ductor.

5. Replace the intake temperature sensor B-9113.
has been resolved.
operation.
Wiring harnesses - Electrical schematic sheet 03 – Exhaust system and Controller Area Network (CAN) bus
(55.100.DP-C.20.E.03)
(55.100.DP-C.20.E.04)
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3518-Ambient temperature sensor voltage is lower than expected

Context:
The Engine Control Unit (ECU) A-9000 monitors the intake air temperature sensor B-9113. If the ECU A-9000 de-
termines that the intake air temperature sensor B-9113 signal circuit voltage is less than 198.00 mV, this fault will
occur. Once this fault occurs, the intake air temperature value is frozen by the ECU A-9000 at the last valid value for
a preliminary failure or jumps to a fixed replacement value of 29.96 °C (85.93 °F) if the failure is validated.
Cause:
The intake air temperature sensor B-9113 signal circuit voltage is less than 198.00 mV.
1. Faulty intake air temperature sensor B-9113 wiring, short to ground condition.
2. Faulty intake air temperature sensor B-9113, internal failure.
Solution:
2. Check the intake air temperature sensor B-9113 vehicle harness (VE) wiring for a short to ground condition.
Disconnect the vehicle harness (VE) from the intake air temperature sensor B-9113 at connector X-9117.
(VE) side :
From To Value
A. If there is continuity, there is a short to ground condition in the air temperature sensor B-9113 signal circuit
vehicle harness (VE) wiring. Use the appropriate service manual, if necessary, to locate and repair the shorted
conductor.

3. Check the intake air temperature sensor B-9113 vehicle harness (VE) wiring for a short to ground condition.
(VE) side :
From To Value
X-9122 pin K19 Chassis ground There should be no continuity.
A. If there is continuity, there is a short to ground condition in the air temperature sensor B-9113 signal circuit
conductor.

4. Replace the intake temperature sensor B-9113.
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Use the Electronic Service Tool (EST) to check the status of this fault, 3518 - Ambient temperature sensor
voltage is lower than expected .
has been resolved.
operation.
(55.100.DP-C.20.E.03)
(55.100.DP-C.20.E.04)
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3616-Torque limitation due to turbo charger protection

Context:
A-9000 has detected an active power reduction due to turbocharger protection. This fault may have been caused by a
detection of high altitude or extreme working conditions for a period greater than 120.00 s. If this fault occurs, a power
reduction or engine speed reduction of equal to or greater than 25 % of the desired torque will be active in order to
protect the turbocharger from a potential overspeed condition. If the power reduction occurred due to actual defect,
the failure triggering the torque limitation should also be in the failure memory. Use the Electronic Service Tool (EST)
to check for related fault codes and diagnose them first, then check the status of this fault, 3616 - Torque limitation
due to turbo charger protection.
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3650-Battery voltage: SRC high for battery voltage sensor

Context:
The Engine Control Unit (ECU) A-9000 monitors the battery voltage. If the ECU A-9000 detects a voltage higher than
expected, this fault will occur.
Cause:
The ECU A-9000 has detected a battery voltage of greater than 28.8 V.
1. Faulty alternator, failed regulator.

Solution:
2. Start the engine and raise the Revolutions Per Minute (RPM) to approximately 1500 RPM for 1.00 min. Lower the
RPM to idle speed and check the battery voltage with the engine running.
With the engine running, use a multimeter to perform the following voltage check on the battery posts :
From To Value
Battery + Battery - 14.8 - 16.2 V
A. If the voltage is high, out of range (normal engine running operating range is approximately 14.8 - 16.2 V, the
alternator has failed. Replace the alternator.
B. If the voltage is within range (normal engine running operating range is approximately 14.8 - 16.2 V, check the
ECU A-9000 for the appropriate software and re-flash, if necessary.
has been resolved.
operation.
(55.100.DP-C.20.E.04)
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3651-Battery voltage: SRC low for battery voltage sensor

Context:
The Engine Control Unit (ECU) A-9000 monitors the battery voltage. If the ECU A-9000 detects a voltage lower than
expected, this fault will occur.
Cause:
The ECU A-9000 has detected a battery voltage of less than 8.3 V.
1. Faulty battery.
2. Faulty alternator, failed regulator.
3. Engine started in extreme cold conditions.
Solution:
2. Charge the battery and perform a battery load test.
A. If the pass battery does not pass the load test, replace the battery.
B. If the battery passes the load test, continue to Step 3.

3. Start the engine and raise the Revolutions Per Minute (RPM) to about 1500 RPM for 1.00 min. Lower the RPM to
idle speed and check the battery voltage with the engine running.
With the engine running, use a multimeter to perform the following voltage check on the battery posts :
From To Value
Battery + Battery - 14.8 - 16.2 V
A. If the voltage is low, out of range (normal engine running operating range is approximately 14.8 - 16.2 V, the
alternator has failed. Replace the alternator.
B. If the voltage is within range (normal engine running operating range is approximately 14.8 - 16.2 V, continue
to Step 4.
(VE) side :
From To Value
X-9122 pin K01 Chassis ground There should be approximately 12 V.
A. If there is less than approximately 12 V, continue to Step 5.
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B. If there is approximately 12 V, check the ECU A-9000 for the appropriate software and re-flash, if necessary.
5. Check the ECU A-9000 voltage supply wiring for a short circuit to ground.
(VE) side :
From To Value
A. If there is continuity, there is a short circuit to ground condition in the ECU A-9000 voltage supply wiring. Locate
has been resolved.
operation.
(55.100.DP-C.20.E.04)
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3652-CAN Bus: Bus off of CAN node A

Context:
Cause:
ECU A-9000 has sensed a “Bus Off” state to be present at the CAN Node A.

Solution:
A. If other vehicle CAN faults do exist, resolve the vehicle CAN faults, then check to see that 3652 - CAN Bus:
Bus off of CAN node A is also resolved.

To energize the Main relay K-9102, place a jumper wire between the vehicle harness (VE) side of connector X-9122
pin K28 and chassis ground.
From To Value
B. If the voltage is not present for one or more of the checks, see the appropriate vehicle service manual and
electrical schematics, if necessary, to locate and restore supply power to the ECU A-9000.
4. Check the ECU A-9000 ground circuits.
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From To Value
B. If there is no continuity for one or more of the checks, see the appropriate vehicle service manual and electrical
schematics, if necessary, to locate and restore the ground circuits to the ECU A-9000.
From To Value
From To Value
vehicle service manual and electrical schematics, if necessary, to locate and restore the termination resistance
to the CAN circuit.
has been resolved.
operation.
(55.100.DP-C.20.E.04)
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3655-Torque limitation, Engine protection: General report of the

event of torque limitations
Context:
This fault is for informational purposes only and may have been caused by another fault. The Engine Control Unit
(ECU) A-9000 has detected one or more torque reductions. Though there are no actions necessary for this fault
alone, if the power reduction occurred due to actual defect, the failure triggering the torque limitation should also be
in the failure memory. Use the Electronic Service Tool (EST) to check for related faults and diagnose them first, then
check the status of this fault, 3655 - Torque limitation, Engine protection: General report of the event of torque
limitations.
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3656-Torque limitation, Engine protection: Torque limitation caused

by particulate filter
Context:
This fault has set due to a performance limitation to protect the particulate filter from high pressure. If there was a
power reduction greater than 25 % or an engine speed limitation greater than 25 % due to particulate filter protection
for more than 120.00 s a fault code was stored. This fault code is for information only and does not require any further
action. That there was an active performance limitation due to the particulate filter protection against too high pres-
sure, which was not caused by a failure, but an extreme working condition. If other fault codes are present that could
influence the particulate filter high pressure, those faults could pinpoint an actual failure. Follow the troubleshooting
procedure for the other fault.
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3657-Timeout Error of CAN-Receive-Frame CM1BC

Context:
Cause:

Solution:
A. If other vehicle CAN faults do exist, resolve the vehicle CAN faults, then check to see that 3657 - Timeout
Error of CAN-Receive-Frame CM1BC is also resolved.

From To Value
From To Value
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From To Value
From To Value
circuit.
has been resolved.
operation.
(55.100.DP-C.20.E.04)
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3665-EGR valve will not open to commanded position

NOTE: Because the Engine Control Unit (ECU) A-9000 stores historical data relevant to the operation of the EGR
valve Z-9000, it is necessary to perform the Replacement of the Exhaust GAs Recirculation Valve (EGR) – Reset ECU
Data with the Electronic Service Tool (EST), if the EGR valve Z-9000 is replaced. Refer to the engine service manual
Exhaust Gas Recirculation (EGR) valve - Configure - Reset ECU data (EGR valve) (10.501), if necessary.
Context:
The Engine Control Unit (ECU) A-9000 controls the position of the EGR valve Z-9000 with an H-bridge Pulse Width
Modulated (PWM) circuit. The ECU A-9000 also monitors the position of the EGR valve Z-9000 by monitoring the
potentiometer feedback voltage. If the ECU A-9000 determines that the feedback position signal is 12 % greater than
it should be for the commanded position for a period of time longer than that established by the ECU A-9000, this fault
will occur. For information regarding the functional operation of the Exhaust Gas Recirculation (EGR) valve Z-9000
refer to the engine service manual Exhaust Gas Recirculation (EGR) valve - Overview (10.501).
Cause:
The ECU A-9000 has determined that the positive deviation between the required and measured position of the EGR
valve Z-9000 has been exceeded.
1. Faulty EGR valve Z-9000, valve sticks, clean or replace, as required.

2. Faulty EGR valve Z-9000 position sensor, internal failure.
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3666-EGR valve will not close to commanded position

NOTE: Because the Engine Control Unit (ECU) A-9000 stores historical data relevant to the operation of the Exhaust
Gas Recirculation (EGR) valve Z-9000, it is necessary to perform the “Replacement of the Exhaust Gas Recirculation
Valve (EGR) – Reset ECU Data” with the Electronic Service Tool (EST), if the EGR valve Z-9000 is replaced. Refer to
the engine service manual for Exhaust Gas Recirculation (EGR) valve - Configure - Reset ECU data (EGR valve)
Context:
The ECU A-9000 controls the position of the EGR valve Z-9000 with an H-bridge Pulse Width Modulated (PWM)
circuit. The ECU A-9000 also monitors the position of the EGR valve Z-9000 by monitoring the potentiometer feed-
back voltage. If the ECU A-9000 determines that the feedback position signal is 12 % less than it should be for the
commanded position for a period of time longer than that established by the ECU A-9000, this fault will occur. For in-
formation regarding the functional operation of the Exhaust Gas Recirculation (EGR) valve Z-9000 refer to the engine
service manual Exhaust Gas Recirculation (EGR) valve - Overview (10.501).
Cause:
The ECU A-9000 has determined that the negative deviation between the required and measured position of the EGR
valve Z-9000 has been exceeded.
1. Faulty EGR valve Z-9000, valve sticks, clean or replace, as required.

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3667-EGR valve control circuit open

NOTE: If the Exhaust Gas Recirculation (EGR) valve Z-9000 is replaced, it is necessary to perform the “Replacement
of the Exhaust Gas Recirculation Valve (EGR) – Reset ECU Data” with the Electronic Service Tool (EST) before
you return the machine to service. Refer to the engine service manual Exhaust Gas Recirculation (EGR) valve -
Configure - Reset ECU data (EGR valve) (10.501), if necessary.
Context:
The Engine Control Unit (ECU) A-9000 internally monitors the operation of the H-bridge Pulse Width Modulated
(PWM) control circuit for the Exhaust Gas Recirculation (EGR) valve Z-9000 actuator for electrical defects. If the ECU
A-9000 detects no current flow when EGR valve Z-9000 actuation is requested, this fault will occur. For information
regarding the functional operation of the EGR valve Z-9000, refer to the engine service manual Exhaust Gas Recir-
culation (EGR) valve - Overview (10.501). For more information regarding the technical specifications of the EGR
valve Z-9000, refer to the engine service manual Exhaust Gas Recirculation (EGR) valve actuator - Technical
Data (55.989).
Cause:
The ECU A-9000 is sensing an open circuit condition in the EGR valve Z-9000 control circuit.
1. Faulty EGR valve Z-9000 actuator motor, failed internally.

2. Faulty EGR valve Z-9000 circuit wiring, open conductor.
Solution:
2. Check the condition of the EGR valve Z-9000 actuator motor.
Disconnect the engine harness (EN) from the EGR valve Z-9000 at connector X-9010.
Use a multimeter to measure the resistance, on the EGR valve Z-9000 actuator motor:
From To Value
A. If the specified value is measured, leave connector X-9010 disconnected and continue with Step 3.
B. If the measured resistance is infinite, the EGR valve Z-9000 actuator motor has failed internally, replace the
EGR valve Z-9000. Then use the EST, see Exhaust Gas Recirculation (EGR) valve - Configure - Reset
ECU data (EGR valve) (10.501) if necessary, to perform the Replacement of the Exhaust Gas Recirculation
Valve (EGR) – Reset ECU Data.
3. Check the engine harness (EN) for an open circuit condition.
Carefully disconnect the vehicle harness (VE) from the engine interface at connector X-9138.
Use a multimeter to check for continuity in the engine harness (EN) :
From To Result
A. If there is continuity on both tests, leave connector X-9138 disconnected and continue with Step 4.
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B. If there is no continuity on either or both of the checks, there is an open circuit condition in the engine harness
(EN) between connector X-9010 pin 1 and/or X-9010 pin 5 and connector X-9138 pin 29 and/or X-9138 pin
30, wire EN-9095 and/or EN-9096. Locate and repair the broken conductor.
4. Check the vehicle harness (VE) for an open circuit condition.
Use a multimeter to check for continuity in the vehicle harness (VE) :
From To Result
X-9121 pin A50 X-9138 pin 29 There should be continuity.
X-9121 pin A35 X-9138 pin 30 There should be continuity.
A. If there is no continuity on either or both of the checks, there is an open circuit condition in the vehicle harness
(VE) between connector X-9121 pin A50 and/or X-9121 pin A35 and connector X-9138 pin 29 and/or X-9138
pin 30, wire VE-9095 and/or VE-9096. Use the appropriate service manual, if necessary, to locate and repair
the broken conductor.
has been resolved.
operation.
(55.100.DP-C.20.E.05)
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3668-EGR valve control circuit over current

NOTE: If the Exhaust Gas Recirculation (EGR) valve Z-9000 is replaced, it is necessary to perform the Replacement
of the Exhaust Gas Recirculation Valve (EGR) – Reset ECU Data with the Electronic Service Tool (EST) before you
return the machine to service. Refer to the engine service manual, Exhaust Gas Recirculation (EGR) valve - Con-
figure - Reset ECU data (EGR valve) (10.501), if necessary.
Context:
The Engine Control Unit (ECU) A-9000 internally monitors the operation of the H-bridge Pulse Width Modulated (PWM)
control circuit for the Exhaust Gas Recirculation (EGR) valve Z-9000 actuator for electrical defects. If the ECU A-9000
detects excessive current flow when EGR valve Z-9000 actuation is requested, this fault will occur. For information
regarding the functional operation of the EGR valve Z-9000, refer to the engine service manual Exhaust Gas Recir-
culation (EGR) valve - Overview (10.501). For more information regarding the technical specifications of the EGR
valve Z-9000, refer to the engine service manual Exhaust Gas Recirculation (EGR) valve actuator - Technical
Data (55.989).
Cause:
The ECU A-9000 is sensing a short circuit condition in the EGR valve Z-9000 control circuit.
1. Faulty EGR valve Z-9000 actuator motor, failed internally.

2. Faulty EGR valve Z-9000 circuit wiring, short circuit.
Solution:
2. Check the condition of the EGR valve Z-9000 actuator motor.
Use a multimeter to measure the resistance, on the EGR valve Z-9000 actuator motor:
From To Value
B. If the measured resistance is zero Ω or there is continuity to ground, the EGR valve Z-9000 actuator motor
has failed internally, replace the EGR valve Z-9000. Then use the EST, refer to the engine service manual
Exhaust Gas Recirculation (EGR) valve - Configure - Reset ECU data (EGR valve) (10.501) if necessary,
to perform the Replacement of the Exhaust Gas Recirculation Valve (EGR) – Reset ECU Data.
3. Check the EGR valve Z-9000 actuator motor circuit for a short circuit condition.
Use a multimeter to check for continuity on the engine harness (EN) side :
From To Result
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A. If there is continuity on any of the tests, continue with Step 4.
B. If there is no continuity on any of the checks, check the ECU A-9000 for the appropriate software and re-flash,
if necessary.
4. Determine the location of the short circuit condition.
Disconnect the vehicle harness (VE) from the interface connector X-9138.
Then carefully disconnect the vehicle harness (VE) from the ECU A-9000 at connector X-9121.
Use a multimeter to check for continuity in the vehicle harness (VE) :
From To Result
X-9121 pin A50 X-9121 pin A35 There should be no continuity.
A. If there is continuity on any of the checks, there is a short circuit condition in the vehicle harness (VE) between
connector X-9121 pin A50 and X-9121 pin A35 or a short to ground condition between connector X-9121
pin A50 and X-9138 pin 29 or X-9121 pin A35 and X-9138 pin 30. Use the appropriate service manual, if
necessary, to locate and repair the damaged conductors or grounded conductor.
B. If there is no continuity on any of the checks, there is a short circuit condition in the engine harness (EN)
between connector X-9010 pin 1 and X-9010 pin 5 or a short to ground condition between connector X-9010
pin 1 and X-9138 pin 29 or X-9010 pin 5 and X-9138 pin 30. Locate and repair the damaged conductors or
grounded conductor.
has been resolved.
operation.
(55.100.DP-C.20.E.05)
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3669-EGR valve H-bridge control circuit shorted to battery

Context:
detects a short circuit of the circuit wiring to an external source, this fault will occur. For information regarding the
functional operation of the EGR valve Z-9000, refer to the engine service manual Exhaust Gas Recirculation (EGR)
valve - Overview (10.501). For more information regarding the technical specifications of the EGR valve Z-9000,
refer to the engine service manual Exhaust Gas Recirculation (EGR) valve actuator - Technical Data (55.989).
Cause:
The ECU A-9000 is sensing a short to a voltage source condition in the EGR valve Z-9000 motor actuator control
circuit.
1. Faulty EGR valve Z-9000 circuit wiring, shorted to voltage source.

Solution:
2. Check the EGR valve Z-9000 motor actuator control circuit for a short to voltage source condition.
With the key switch in the ON position, use a multimeter to check for voltage on the engine harness (EN) side :
From To Result
X-9010 pin 1 chassis ground There should be no voltage.
A. If there is voltage on either or both tests, leave connector X-9121 and connector X-9010 disconnected and
B. If there is no voltage on either of the checks, leave connector X-9121 and connector X-9010 disconnected and
3. Locate the short to voltage source condition.
From To Result
A. If there is no voltage on either of the checks, the short to a voltage source condition is in the engine harness
(EN) between connector X-9010 pin 1 or X-9010 pin 5 and connector X-9138 pin 29 or X-9138 pin 30. Locate
and repair the damaged conductors.
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B. If there is voltage on either or both tests, the short to a voltage source condition is in the vehicle harness (VE)
between connector X-9121 pin A50 or X-9121 pin A35 and connector X-9138 pin 29 or X-9138 pin 30. Use
the appropriate service manual, if necessary, to locate and repair the damaged conductors.
4. Check the EGR valve Z-9000 motor actuator control circuit for a short to another circuit condition.
From To Result
X-9121 pin A50 to all other pins in connector X-9121 There should be no continuity.
A. If there is continuity on any of the tests, there is a short to another circuit condition in the vehicle harness (VE)
between connector X-9121 pin A50 and/or X-9121 pin A35, and another circuit. Use the appropriate service
manual, if necessary, to locate and repair the damaged conductors.
if necessary.
has been resolved.
operation.
(55.100.DP-C.20.E.05)
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3670-EGR valve H-bridge control circuit shorted to battery

Context:
detects a short circuit of the circuit wiring to an external source, this fault will occur. For information regarding the
Cause:
The ECU A-9000 is sensing a short to a voltage source condition in the EGR valve Z-9000 motor actuator control
circuit.
1. Faulty EGR valve Z-9000 circuit wiring, shorted to voltage source.

Solution:
2. Check the EGR valve Z-9000 motor actuator control circuit for a short to voltage source condition.
From To Result
A. If there is voltage on either or both tests, leave connector X-9121 and connector X-9010 disconnected and
B. If there is no voltage on either of the checks, leave connector X-9121 and connector X-9010 disconnected and
From To Result
(EN) between connector X-9010 pin 1 or X-9010 pin 5 and connector X-9138 pin 29 or X-9138 pin 30. Locate
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B. If there is voltage on either or both tests, the short to a voltage source condition is in the vehicle harness (VE)
between connector X-9121 pin A50 or X-9121 pin A35 and connector X-9138 pin 29 or X-9138 pin 30. Use
the appropriate service manual, if necessary, to locate and repair the damaged conductors.
From To Result
A. If there is continuity on any of the tests, there is a short to another circuit condition in the vehicle harness (VE)
between connector X-9121 pin A50 and/or X-9121 pin A35, and another circuit. Use the appropriate service
if necessary.
has been resolved.
operation.
(55.100.DP-C.20.E.05)
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3671-EGR valve H-bridge control circuit shorted to ground

return the machine to service. Refer to the engine service manual Exhaust Gas Recirculation (EGR) valve - Con-
Context:
A-9000 detects a short circuit of the circuit wiring to chassis ground, this fault will occur. For information regarding the
service manual Exhaust Gas Recirculation (EGR) valve actuator - Technical Data (55.989).
Cause:
The ECU A-9000 is sensing a short to chassis ground condition in the EGR valve Z-9000 motor actuator control circuit.
1. Faulty EGR valve Z-9000 motor, failed internally.

2. Faulty EGR valve Z-9000 circuit wiring, short to ground.
Solution:
2. Check the EGR valve Z-9000 motor actuator for a short to ground condition.
Use a multimeter to check on the component for a grounded condition :
From To Result
A. If there is no continuity, leave connector X-9010 disconnected and continue with Step 3.
B. If there is continuity, the EGR valve Z-9000 motor has failed internally, replace the EGR valve Z-9000. Then
use the EST, refer to the engine service manual Exhaust Gas Recirculation (EGR) valve - Configure - Reset
3. Check the EGR valve Z-9000 motor actuator control circuit for a short to ground condition.
From To Result

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From To Result
From To Result
X-9121 pin A50 and connector X-9138 pin 29, wire VE-9095. Use the appropriate service manual, if neces-
sary, to locate and repair the grounded conductor.
has been resolved.
operation.
(55.100.DP-C.20.E.05)
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3672-Short circuit to ground on EGR Out2 pin A35 error for H-bridge
Context:
A-9000 detects a short circuit of the circuit wiring to chassis ground, this fault will occur. For information regarding the
Cause:
The ECU A-9000 is sensing a short to chassis ground condition in the EGR valve Z-9000 motor actuator control circuit.

2. Faulty EGR valve Z-9000 circuit wiring, shorted to chassis ground.
Solution:
2. Check the EGR valve Z-9000 motor actuator for a short to ground condition.
Use a multimeter to check on the component for a grounded condition :
From To Result
A. If there is no continuity, leave connector X-9010 disconnected and continue with Step 3.
B. If there is continuity, the EGR valve Z-9000 motor has failed internally, replace the EGR valve Z-9000. Then
use the EST, refer to th eengine service manual Exhaust Gas Recirculation (EGR) valve - Configure - Reset
From To Result

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From To Result
From To Result
X-9121 pin A35 and connector X-9138 pin 30, wire VE-9096. Use the appropriate service manual, if neces-
sary, to locate and repair the grounded conductor.
has been resolved.
operation.
(55.100.DP-C.20.E.05)
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3673-EGR valve control circuit over load

Context:
A-9000 detects a short circuit of the circuit wiring to an external source or to chassis ground, this fault will occur. For
information regarding the functional operation of the EGR valve Z-9000, refer to the engine service manual Exhaust
Gas Recirculation (EGR) valve - Overview (10.501). For more information regarding the technical specifications
of the EGR valve Z-9000, refer to the engine service manual Exhaust Gas Recirculation (EGR) valve actuator -
Technical Data (55.989).
Cause:
The ECU A-9000 is sensing a short to a voltage source or a short to chassis ground condition in the EGR valve Z-9000
motor actuator control circuit.

2. Faulty EGR valve Z-9000 motor actuator circuit wiring, grounded or shorted to voltage source.
Solution:
2. Check the EGR valve Z-9000 motor for a shorted or grounded condition.
Use a multimeter to perform the following resistance and continuity checks on the component side of connector
X-9010 :
From To Result
B. If the specified values are not measured, the EGR valve Z-9000 motor has failed internally, replace the EGR
valve Z-9000. Then use the EST, refer to the engine service manual Exhaust Gas Recirculation (EGR) valve
- Configure - Reset ECU data (EGR valve) (10.501) if necessary, to perform the Replacement of the Exhaust
Gas Recirculation Valve (EGR) – Reset ECU Data.
From To Result
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A. If there is continuity on either check, continue with Step 4.
B. If there is no continuity on both checks, leave connector X-9010 disconnected and continue with Step 6.
From To Result
A. If there is continuity on either check, leave connector X-9138 disconnected and continue with Step 5.
B. If there is no continuity on both checks, the short to a ground condition is in the engine harness (EN) between
connector X-9010 pin 1 or X-9010 pin 5 and connector X-9138 pin 29 or X-9138 pin 30, wire EN-9095 or
EN-9096. Locate and repair the grounded conductor.
From To Result
A. If there is continuity on either check, the short to chassis ground condition is in the vehicle harness (VE) be-
tween connector X-9121 pin A50 or X-9121 pin A35 and connector X-9138 pin 29 or X-9138 pin 30, wire
VE-9095 or VE-9096. Use the appropriate service manual, if necessary, to locate and repair the grounded
conductor.
B. If there is no continuity on both checks, check the ECU A-9000 for the appropriate software and re-flash, if
necessary.
6. Check the EGR valve Z-9000 motor actuator control circuit for a short to a voltage source condition.
From To Result
A. If there is voltage on either or both tests, leave connectors X-9010 and X-9121 disconnected and continue with
Step 7.
B. If there is no voltage on either of the checks, leave connectors X-9010 and X-9121 disconnected and continue
with Step 8.
7. Locate the short to a voltage source condition.
From To Result
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(EN) between connector X-9010 pin 1 or X-9010 pin 5 and connector X-9138 pin 29 or X-9138 pin 30, wire
EN-9095 or EN-9096. Locate and repair the damaged conductors.
B. If there is voltage on either or both of the checks, the short to a voltage source condition is in the vehicle
harness (VE) between connector X-9138 pin 29 and/or X-9138 pin 30 and connector X-9121 pin A50 and/or
connector X-9121 pin A35, wire VE-9095 or VE-9096. Use the appropriate service manual, if necessary, to
locate and repair the damaged conductors.
From To Result
A. If there is continuity on any of the tests, there is a short to another circuit condition in the vehicle harness
(VE) between connector X-9121 pin A50 and/or X-9121 pin A35, wire VE-9095 and/or VE-9096, and another
circuit. Use the appropriate service manual, if necessary, to locate and repair the damaged conductors.
if necessary.
has been resolved.
operation.
(55.100.DP-C.20.E.05)
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3674-EGR valve control circuit supply voltage too low

Context:
control circuit for the Exhaust Gas Recirculation (EGR) valve Z-9000 motor actuator for electrical defects. If the ECU
A-9000 senses too low an output driver supply voltage, this fault will occur. For information regarding the functional
operation of the EGR valve Z-9000, refer to the engine service manual Exhaust Gas Recirculation (EGR) valve -
Overview (10.501). For more information regarding the technical specifications of the EGR valve Z-9000, refer to the
engine service manual Exhaust Gas Recirculation (EGR) valve actuator - Technical Data (55.989).
Cause:
The ECU A-9000 is sensing too high a system voltage fluctuation.
Solution:
A. If the fault is present and active, continues with Step 2.
2. Check for related faults.
Use the EST to check for faults relative to low battery or control system voltage level.
A. If low voltage level faults are present, resolve those faults. Then determine if this fault has also been resolved.
B. If no low voltage level faults are present, continue with Step 3.


or broken wires. Verify that the connectors are fully installed.
has been resolved.
operation.
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3676-EGR valve position sensor voltage is higher than expected

Context:
The Engine Control Unit (ECU) A-9000 monitors the electrical signal provided by the Exhaust Gas Recirculation (EGR)
valve Z-9000 position feedback potentiometer. If the signal level becomes greater than 4.86 V the ECU A-9000 pro-
vides a replacement value and this fault will occur. For information regarding the functional operation of the EGR
valve Z-9000, refer to the engine service manual Exhaust Gas Recirculation (EGR) valve - Overview (10.501). For
more information regarding the technical specifications of the EGR valve Z-9000, refer to the engine service manual
Exhaust Gas Recirculation (EGR) valve actuator - Technical Data (55.989).
Cause:
The ECU A-9000 is sensing the EGR valve Z-9000 position signal is greater than 4.86 V.
1. Faulty EGR valve Z-9000, failed internally.

2. Faulty EGR valve Z-9000 position sensor circuit wiring, shorted to a high source.
Solution:
2. Check the EGR valve Z-9000 potentiometer signal circuit for a short to voltage source condition.
From To Result
X-9010 pin 2 chassis ground There should be less than 4.86 V.
A. If there is greater than 4.86 V, leave connector X-9010 disconnected and continue with Step 3.
B. If there is less than 4.86 V, leave connector X-9010 disconnected and continue with Step 5.
From To Result
X-9138 pin 34 chassis ground There should be less than 4.86 V.
A. If there is less than 4.86 V, the short to a voltage source condition is in the engine harness (EN) between
connector X-9010 pin 2 and connector X-9138 pin 34. Locate and repair the damaged conductors.
B. If there is greater than 4.86 V, leave connector X-9138 disconnected and continue with Step 4.
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From To Result
X-9121 pin A39 chassis ground There should be no voltage.
A. If there is voltage, there is a short to a voltage source condition in the vehicle harness (VE) between connector
X-9121 pin A39 and connector X-9138 pin 34. Use the appropriate service manual, if necessary, to locate
5. Replace the EGR valve Z-9000.
Then use the EST, refer to the engine service manual Exhaust Gas Recirculation (EGR) valve - Configure -
Reset ECU data (EGR valve) (10.501) if necessary, to perform the Replacement of the Exhaust Gas Recirculation
Then check to see that the fault is resolved.
A. If the fault is resolved, return the vehicle to operation.
has been resolved.
operation.
(55.100.DP-C.20.E.05)
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3677-EGR valve position sensor voltage is lower than expected

Context:
The Engine Control Unit (ECU) A-9000 monitors the electrical signal provided by the Exhaust Gas Recirculation (EGR)
valve Z-9000 position feedback potentiometer. If the signal level becomes less than 0.225 V the ECU A-9000 pro-
vides a replacement value and this fault will occur. For information regarding the functional operation of the EGR
valve Z-9000, refer to the engine service manual Exhaust Gas Recirculation (EGR) valve - Overview (10.501). For
more information regarding the technical specifications of the EGR valve Z-9000, refer to the engine service manual
Exhaust Gas Recirculation (EGR) valve actuator - Technical Data (55.989).
Cause:
The ECU A-9000 is sensing the EGR valve Z-9000 position signal is less than 0.225 V.
1. Faulty EGR valve Z-9000, failed internally.

2. Faulty EGR valve Z-9000 position sensor circuit wiring, shorted to ground.
Solution:
2. Check the EGR valve Z-9000 potentiometer for a short to ground condition.
Use a multimeter to check for continuity on the EGR valve Z-9000 potentiometer side :
From To Result
A. If there is continuity, the EGR valve Z-9000 has failed internally, replace the EGR valve Z-9000. Then use the
EST, refer to the engine service manual Exhaust Gas Recirculation (EGR) valve - Configure - Reset ECU
data (EGR valve) (10.501) if necessary, to perform the Replacement of the Exhaust Gas Recirculation Valve
(EGR) – Reset ECU Data.
B. If there is no continuity, leave connector X-9010 disconnected and continue with Step 3.
3. Check the EGR valve Z-9000 potentiometer signal circuit for a short to ground condition.
From To Result
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From To Result
A. If there is no continuity, the short to ground condition is in the engine harness (EN) between connector X-9010
pin 2 and connector X-9138 pin 34. Locate and repair the damage to the conductor.
B. If there is continuity, leave connector X-9138 disconnected and continue with Step 5.
From To Result
A. If there is continuity, there is a short to ground condition in the vehicle harness (VE) between connector X-9121
pin A39 and connector X-9138 pin 34. Use the appropriate service manual, if necessary, to locate and repair
the damage to the conductor.
has been resolved.
operation.
(55.100.DP-C.20.E.05)
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3680-Injection cut off: Injection cut off demand (ICO) for shut off
coordinator
Context:
The Engine Control Unit (ECU) A-9000 will perform an injection cut-off to limit the engine speed to a controllable range,
if needed. Implausible signals from certain parameters such as accelerator pedal signal, fuel injection parameters
or engine speed can cause an injection cut-off. If torque or injection quantity are not plausible and engine speed is
greater than 1200 RPM, this fault will occur. Other active faults may have caused this fault to occur.
Solution:
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3684-Exhaust manifold temperature is higher than expected

Context:
The Engine Control Unit (ECU) A-9000 monitors the exhaust manifold temperature sensor B-9018. If the ECU A-9000
detects an exhaust manifold temperature greater than 950 °C (1742 °F), this fault will occur. For more information
regarding the exhaust manifold temperature sensor B-9018, refer to the engine service manual Exhaust manifold
temperature sensor - Overview (55.014). For more information regarding the technical specifications of the exhaust
manifold temperature sensor B-9018, refer to the engine service manual Exhaust manifold temperature sensor -
Technical Data (55.014).
Cause:
The ECU A-9000 has detected a temperature greater than 950 °C (1742 °F) from the exhaust manifold temperature
sensor B-9018.
1. Faulty exhaust manifold temperature sensor B-9018, drifted signal.

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3688-Water in fuel sensor or sensor circuit failure

NOTE: This fault code is for the Water in Fuel switch with black connector housing.
Context:
The water in fuel switch S-9102 provides a diagnostic self-test signal (less than 3.9 V for 2.5 s +/- 20%) at key-ON.
If the Engine Control Unit (ECU) A-9000 does not sense the diagnostic self-test signal, this fault will occur and there
will be no monitoring of water content in the fuel supply.
Cause:
The ECU A-9000 has not received an acceptable water in fuel switch S-9102 self-test signal.
1. Faulty water in fuel switch S-9102 circuit wiring, damaged.

2. Faulty water in fuel switch S-9102, internal failure.
Solution:
Use the Easy Engine software provided on the Electronic Service Tool (EST) to check the fault status.
B. If the fault is no longer present or is in an inactive state, Continue with Step 7.

2. Use the EST to check the status of the related fault
3146 - Water detected in fuel - Shorted to high source
A. If fault 3146 - Water detected in fuel - Shorted to high source is active, resolve fault 3146 - Water detected
in fuel - Shorted to high source, then return to this fault, 3688 - Water in fuel sensor or sensor circuit
failure.
B. If fault 3146 - Water detected in fuel - Shorted to high source is not active,continue with Step 3.
3. Check the water in fuel switch S-9102 for the initial self-test voltage pulse.
Carefully back probe the water in fuel switch S-9102 at connector X-9125 pin 1.
With the help of an assistant, use a multimeter to perform the following test at Key-ON:
From To Value
X-9125 pin 1 Chassis ground There should be less than 3.9 V for
2.5 s +/- 20%.
NOTE: The signal line should switch to battery voltage after the self-test period.
A. If the self-test is successful, continue with Step 4.
B. If the self-test is not successful, the water in fuel switch S-9102 has failed internally. Replace the switch.
4. Check for open, short and grounded circuit conditions in the water in fuel switch S-9102 circuit.
Disconnect the water in fuel switch S-9102 at connector X-9125.
With the key switch in the OFF position, use a multimeter to perform the following tests, on the vehicle (VE) harness
from :
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From To Value
X-9125 pin 2 Chassis ground There should be continuity.
X-9125 pin 3 Refer to the appropriate vehicle There should be continuity.
schematics.
From To Value
From To Value
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 vehicle harness (VE) wiring. Use the appropriate vehicle service manual and schematics
to diagnose and repair the wiring.
B. If the results are as expected in all of the wiring tests listed above, the wiring is ok. Leave connectors X-9122
and X-9125 disconnected and continue with Step 5.
5. Check for key switch voltage supply to water in fuel switch S-9102.
With the key switch in an ON position, use a multimeter to perform the following test, on the vehicle (VE) harness
side from :
From To Value
X-9125 pin 3 Chassis ground There should be key switch voltage.
X-9125 pin 1 Chassis ground There should be no key switch
voltage.
A. If there is key switch voltage present in the first check and not present in the second check, continue with Step
6.
B. If key switch voltage is not present in the first check or present in the second check, use the appropriate vehicle
service manual and schematics to diagnose and repair the wiring.
6. Replace the water in fuel switch S-9102, then check to see if this fault has been resolved.
A. If the fault is resolved, return the machine to service.
A. If you find damage or the display indicates other than normal readings, then 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.
operation.
(55.100.DP-C.20.E.02)
(55.100.DP-C.20.E.04)
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3689-Faulty diagnostic data transmission or protocol error

Context:
Z-9101. If the ECU A-9000 determines the diagnostic data transmission is faulty, this fault will occur.
Cause:
The glow plug control module Z-9101 diagnostic connection with the ECU A-9000 is damaged or the data protocol is
incorrect.
1. Faulty glow plug control module Z-9101 diagnostic circuit wiring, open, shorted or grounded circuit.
2. Faulty glow plug control module Z-9101, internal failure.
Solution:
2. Check for damaged diagnostic circuit wiring.
From To Result
X-9122 pin K22 chassis ground There should be no continuity.
X-9122 pin K22 all other pins in connector X-9122 There should be no continuity.
Place a jumper wire between connector X-9113 pin 3 and chassis ground.
From To Result
A. If there is continuity from connector X-9122 pin K22 to ground or any other pin in connector X-9122 or there is
no continuity from X-9122 pin K22 to connector X-9113 pin 3, there is a short to ground or another circuit or
an open circuit condition is in the vehicle harness (VE) between connector X-9113 pin 3 and connector X-9122
pin K22, wire VE-9073. Use the appropriate service manual, if necessary, to locate and repair the damage in
the circuit.
B. If there is no continuity from connector X-9122 pin K22 to ground or any other pin in connector X-9122 and
there is continuity from X-9122 pin K22 to connector X-9113 pin 3, continue with Step 3.
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has been resolved.
operation.
(55.100.DP-C.20.E.02)
(55.100.DP-C.20.E.04)
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3692-Over temperature error on ECU power stage for glow plug

low voltage system
Context:
Z-9101. If the ECU A-9000 is notified of a short circuit to ground, over current, condition in one or more of the glow
plugs or glow plug circuits, this fault will occur.
Cause:
to ground circuit condition exists in one or more of the glow plugs or glow plug circuits.
1. Faulty glow plug, internal failure.

2. Faulty glow plug control circuit wiring, open circuit.
Solution:
2. Check each of the glow plugs for a short circuit condition.
Disconnect the engine harness (EN) from each of the glow plugs.
Use a multimeter to check on the component for a short to ground circuit condition :
From To Result
A. If there is a nominal amount of resistance measured on each of the glow plugs, leave all of the glow plugs
disconnected and continue with Step 3.
B. If there is less than 0.2 Ω resistance measured on any of the glow plugs, that glow plug has failed internally,
replace the faulted glow plug.
3. Check the glow plug control circuits in the engine harness (EN) for a short to ground circuit condition.
From To Result
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A. If there is no continuity on all of the checks, leave connector X-9138 disconnected and continue with Step 4.
B. If there is continuity on one or more of the checks, there is a short to ground circuit condition in the engine (EN)
harness between the engine interface connector X-9138 and the respective glow plug. Locate and repair the
damaged conductor.
4. Check the glow plug control circuits in the vehicle harness (VE) for a short to ground circuit condition.
From To Result
A. If there is continuity on one or more of the checks, there is a short circuit to ground condition in the vehicle
harness (VE) between connector X-9113 pin 2 and connector X-9138 pin 61 and/or connector X-9113 pin
7 and connector X-9138 pin 60 and/or connector X-9113 pin 1 and X-9138 pin 58 and/or connector X-9113
pin 6 and connector X-9138 pin 57, wire VE-9058, VE-9059, VE-9060 and/or VE-9061. Use the appropriate
service manual, if necessary, to locate and repair the grounded conductor.
B. If there is no continuity on all of the checks, continue with Step 5.

has been resolved.
operation.
(55.100.DP-C.20.E.02)
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3693-Short circuit to battery error for low voltage system

Context:
Z-9101. If the ECU A-9000 is notified of a short to a voltage source condition in one or more of the glow plug circuits,
Cause:
circuit to a voltage source condition exists in one or more of the glow plug circuits.
1. Faulty glow plug control circuit wiring, shorted to a voltage source.

Solution:
2. Check each of the glow plug circuits for a short to voltage source condition.
From To Result
A. If there is voltage measured on any of the checks, leave all of the connectors disconnected and continue with
Step 3.
B. If there is no voltage measured on any of the checks, continue with Step 4.

From To Result
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A. If there is no voltage on any of the checks, the short to voltage source condition is in the engine harness (EN)
between connector X-9034 pin 1 and connector X-9138 pin 61 and/or connector X-9035 pin 1 and connector
X-9138 pin 60 and/or connector X-9036 pin 1 and X-9138 pin 58 and/or connector X-9037 pin 1 and con-
nector X-9138 pin 57, wire EN-9058, EN-9059, EN-9060 and/or EN-9061. Locate and repair the damaged
conductors.
B. If there is voltage on one or more of the checks, the short to a voltage source condition is in the vehicle har-
ness (VE) between connector X-9113 pin 2 and connector X-9138 pin 61 and/or connector X-9113 pin 7 and
connector X-9138 pin 60 and/or connector X-9113 pin 1 and X-9138 pin 58 and/or connector X-9113 pin 6
and connector X-9138 pin 57, wire VE-9058, VE-9059, VE-9060 and/or VE-9061. Use the appropriate service
has been resolved.
operation.
(55.100.DP-C.20.E.02)
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3694-Glow plug control circuits shorted to ground

Context:
The Engine Control Unit (ECU) A-9000 requests operation of the glow plug control module Z-9101 via a Pulse Width
Modulated (PWM) control circuit and monitors the status of possible electrical defects via a diagnostic feedback signal
from the glow plug control module Z-9101. If the ECU A-9000 is notified of a short to ground condition in one or
more of the glow plug circuits, this fault will occur. For information regarding the functional operation of the glow
plug control module Z-9101 refer to the engine service manual, Glow plug system Glow plug control module -
Overview (55.202).
Cause:
to ground circuit condition exists in one or more of the glow plugs or glow plug circuits.
1. Faulty glow plug, internal failure.

2. Faulty glow plug control circuit wiring, shorted to ground.
Solution:
2. Check each of the glow plugs for a short circuit condition.
Use a multimeter to check on the component for a short to ground circuit condition :
From To Result
A. If there is a nominal amount of resistance measured on each of the glow plugs, leave all of the glow plugs
disconnected and continue with Step 3.
B. If there is less than 0.2 Ω resistance measured on any of the glow plugs, that glow plug has failed internally,
replace the faulted glow plug.
3. Check the glow plug control circuits in the engine harness (EN) for a short to ground circuit condition.
From To Result
A. If there is no continuity on all of the checks, leave connector X-9138 disconnected and continue with Step 4.
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B. If there is continuity on one or more of the checks, there is a short to ground circuit condition in the engine
(EN) harness between the respective glow plug connector X-9034 pin 1 and the engine interface connector
X-9138 pin 61 and/or connector X-9035 pin 1 and connector X-9138 pin 60 and/or connector X-9036 pin 1
and connector X-9138 pin 58 and/or connector X-9037 pin 1 and connector X-9138 pin 57, wire EN-9058
and/or EN-9059 and/or EN-9060 and/or EN-9061. Locate and repair the grounded conductor.
4. Check the glow plug control circuits in the vehicle harness (VE) for a short to ground circuit condition.
From To Result
A. If there is continuity on one or more of the checks, there is a short circuit to ground condition in the vehicle
harness (VE) between connector X-9113 pin 2 and connector X-9138 pin 61 and/or connector X-9113 pin
7 and connector X-9138 pin 60 and/or connector X-9113 pin 1 and X-9138 pin 58 and/or connector X-9113
pin 6 and connector X-9138 pin 57, wire VE-9058, VE-9059, VE-9060 and/or VE-9061. Use the appropriate
service manual, if necessary, to locate and repair the grounded conductor.
B. If there is no continuity on all of the checks, continue with Step 5.

has been resolved.
operation.
(55.100.DP-C.20.E.02)
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3699-ECU internal failure - EEPROM memory failure

Context:
The Engine Control Unit (ECU) A-9000 calculates the correction values from the EEPROM. If the ECU A-9000 detects
an error n the EEPROM block, this fault will occur.
Solution:
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3703-Injection control: check of minimum rail pressure

Context:
The Engine Control Unit (ECU) A-9000 monitors fuel rail pressure. If the ECU A-9000 determines that fuel rail pressure
is less than 130.0 bar (1885.0 psi) or below a limit value from an ECU A-9000 calculated curve, this fault will occur.
Other active faults may have caused this fault to occur. For more information regarding fuel system troubleshooting,
refer to the engine service manual Fuel injection system - Troubleshooting (10.218).
Cause:
The ECU A-9000 has determined that fuel rail pressure is too low to continue engine operation.
1. Faulty fuel metering unit Y-9000, stuck closed or internal failure.

2. Faulty high pressure pump, low efficiency.
5. Faulty fuel lines, leakage or blockage.
7. Faulty fuel injectors, internal leakage or stuck open.
9. Faulty rail pressure sensor B-9004 drifted signal or leaking.
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3704-Injector adjustment programming: Check of missing injector

adjustment value programming
Context:
not be performed, this fault will occur.
Cause:
Solution:
Y-9002.

NOTE: For more information regarding programming IMA codes, refer to the engine service manual Fuel injectors
- Configure - IMA codes (10.218).
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3705-Injector adjustment programming: check of missing injector

Context:
not be performed, this fault will occur.
Cause:
Solution:
Y-9003.

NOTE: For more information regarding programming IMA codes, refer to the service manual Fuel injectors -
Configure - IMA codes (10.218).
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3706-Injector adjustment programming: Check of missing injector

Context:
not be performed, this fault will occur. For more information about how to configure injector IMA codes, refer to the
engine service manual Fuel injectors - Configure - IMA codes (10.218).
Cause:
Solution:
Y-9004.

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3707-Lambda sensor circuit - Open circuit

NOTE: If the Lambda sensor B-9123 is replaced, it is necessary to perform the Replacement of the Lambda Sensor -
Reset ECU Data with the Electronic Service Tool (EST) before you return the machine to service. Refer to the engine
service manual Lambda sensor - Configure - Reset ECU data (Lambda sensor) (55.989), if necessary.
Context:
For information regarding the functional operation of the Lambda sensor B-9123, refer to the engine service manual
Lambda sensor - Overview (55.989). The Engine Control Unit (ECU) A-9000 has determined that the Lambda
sensor B-9123 nernst signal is not present. The Lambda sensor B-9123 is the primary measurement device for ECU
A-9000 fuel control, to determine if the engine is too rich or too lean.
Cause:
The ECU A-9000 is sensing an open circuit condition in the Lambda sensor B-9123 nernst signal circuit.
1. Faulty Lambda sensor B-9123 circuit wiring, open circuit.

2. Faulty Lambda sensor B-9123, failed internally.
Solution:
2. Check the Lambda sensor B-9123 nernst signal circuit wiring for an open circuit condition.
Disconnect the vehicle harness (VE) from the Lambda sensor B-9123 at connector X-9123.
Carefully disconnect the vehicle harness (VE) from the ECU A-9000 at connector X-9122 and place a jumper wire
between X-9122 pin K63 and chassis ground.
From To Result
A. If there is no continuity, there is an open circuit condition in the vehicle harness (VE) between connector X-9123
pin 6 and X-9122 pin K63, wire VE-9156. Use the appropriate vehicle service manual, if necessary, to locate
B. If there is continuity, continue with Step 3.

3. Replace the Lambda sensor B-9123.
Use EST to check to see that this fault has been resolved.
B. If this fault has not been resolved, check the ECU A-9000 for the appropriate software and re-flash, if necessary.
or broken wires.
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has been resolved.
operation.
(55.100.DP-C.20.E.02)
(55.100.DP-C.20.E.04)
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3708-Lambda sensor: Open circuit at the lambda sensor pump

current pin
Context:
The Engine Control Unit (ECU) A-9000 has determined that the Lambda sensor B-9123 pump current is not present.
The Lambda sensor B-9123 is the primary measurement device for ECU A-9000 fuel control, to determine if the
engine is too rich or too lean. For information regarding the functional operation of the Lambda sensor B-9123, refer
to the engine service manual Lambda sensor - Overview (55.989). For more information regarding the technical
specifications of the lambda sensor B-9123, refer to the engine service manual Lambda sensor - Technical Data
(55.989).
Cause:
The ECU A-9000 is sensing an open circuit condition in the Lambda sensor B-9123 pump current control circuit.
1. Faulty Lambda sensor B-9123 pump current control circuit wiring, open circuit.
Solution:
2. Check the Lambda sensor B-9123 pump current control circuit wiring for an open circuit condition.
From To Result
pin 1 and X-9122 pin K64 , wire VE-9154. Use the appropriate vehicle service manual, if necessary, to locate

Use the EST, refer to the engine service manual Lambda sensor - Configure - Reset ECU data (Lambda sen-
sor) (55.989) if necessary, to perform the Replacement of the Lambda Sensor - Reset ECU Data.
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or broken wires.
has been resolved.
operation.
(55.100.DP-C.20.E.02)
(55.100.DP-C.20.E.04)
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3709-Lambda sensor circuit - Open circuit at the virtual ground pin

Context:
For information regarding the functional operation of the Lambda sensor B-9123 refer to the engine service manual
Lambda sensor - Overview (55.989). The Engine Control Unit (ECU) A-9000 has determined that the Lambda
sensor B-9123 virtual ground circuit is open. The Lambda sensor B-9123 is the primary measurement device for ECU
A-9000 fuel control, to determine if the engine is too rich or too lean.
Cause:
The ECU A-9000 is sensing an open circuit condition in the Lambda sensor B-9123 virtual ground circuit.
1. Faulty Lambda sensor B-9123 virtual ground circuit wiring, open circuit.
Solution:
2. Check the Lambda sensor B-9123 virtual ground circuit wiring for an open circuit condition.
From To Result

A. If the fault has been resolved, use the EST, refer to the engine service manual Lambda sensor - Configure -
Reset ECU data (Lambda sensor) (55.989) if necessary, to perform the Replacement of the Lambda Sensor
- Reset ECU Data. Then return the machine to service.
or broken wires.
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has been resolved.
operation.
(55.100.DP-C.20.E.02)
(55.100.DP-C.20.E.04)
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3711-Lambda sensor heater circuit - Short circuit to battery

Context:
The Lambda sensor B-9123 has a heating element encased in ceramic that heats the sensor tip. Whenever the heater
is operating, the heater low side driver power stage contained in the Engine Control Unit (ECU) A-9000 is monitored for
a short circuit to battery condition. If a short circuit to a power source condition exists in the heater control circuit, this
fault will occur. For information regarding the functional operation of the Lambda sensor B-9123, refer to the engine
service manual Lambda sensor - Overview (55.989). For more information regarding the technical specifications of
the lambda sensor B-9123, refer to the engine service manual Lambda sensor - Technical Data (55.989).
Cause:
The Lambda sensor B-9123 low side driver heater control circuit is shorted to a voltage source.
1. Faulty Lambda sensor B-9123 heater control circuit wiring, shorted to a voltage source.
Solution:
2. Check the Lambda sensor B-9123 heater control circuit wiring for a short to voltage source condition.
From To Result
A. If there is voltage, leave connector X-9123 disconnected and continue with Step 3.
B. If there is no voltage, continue with Step 4.

3. Locate the Lambda sensor B-9123 heater control circuit wiring short to voltage source condition.
From To Result
X-9122 pin K07 to all other pins in connector X-9122 There should be no continuity.
A. If there is continuity, there is a short to a voltage source condition in the vehicle harness (VE). Use the appro-
priate vehicle service manual, if necessary, to locate and repair the shorted conductors.
B. If there is no continuity, the ECU A-9000 connector X-9122 is damaged or the ECU A-9000 has failed. Locate
and repair the damage or replace the ECU A-9000.
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or broken wires.
has been resolved.
operation.
(55.100.DP-C.20.E.02)
(55.100.DP-C.20.E.04)
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3712-Lambda sensor: SCG error of the LSU heater power stage

Context:
The Lambda sensor B-9123 has a heating element encased in ceramic that heats the sensor tip. Whenever the heater
is operating, the heater low side driver power stage contained in the Engine Control Unit (ECU) A-9000 is monitored
for a short circuit to ground condition. If a short to ground condition exists in the heater control circuit, this fault will
occur. For information regarding the functional operation of the Lambda sensor B-9123, refer to the engine service
manual Lambda sensor - Overview (55.989). For more information regarding the technical specifications of the
lambda sensor B-9123, refer to the engine service manual Lambda sensor - Technical Data (55.989).
Cause:
The Lambda sensor B-9123 low side driver heater control circuit is shorted to ground.
1. Faulty Lambda sensor B-9123 heater control circuit wiring, shorted to ground.
Solution:
2. Check the Lambda sensor B-9123 heater control circuit wiring for a short to ground condition.
From To Result

3. Locate the Lambda sensor B-9123 heater control circuit wiring short to ground condition.
From To Result
X-9122 pin K07 chassis ground There should be no continuity.
and repair the grounded conductor.
B. If there is no continuity, the ECU A-9000 connector X-9122 is damaged or the ECU A-9000 has failed. Locate
and repair the damage or replace the ECU A-9000.
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or broken wires.
has been resolved.
operation.
(55.100.DP-C.20.E.02)
(55.100.DP-C.20.E.04)
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3713-Lambda sensor: Open Load error of the LSU Heater Power

stage
Context:
The Lambda sensor B-9123 has a heating element encased in ceramic that heats the sensor tip. Whenever the
heater is operating, the heater low side driver power stage contained in the Engine Control Unit (ECU) A-9000 is
monitored for an open circuit condition. If an open circuit condition exists in the heater control circuit, this fault will
occur. For information regarding the functional operation of the Lambda sensor B-9123, refer to the engine service
manual Lambda sensor - Overview (55.989). For more information regarding the technical specifications of the
lambda sensor B-9123, refer to the engine service manual Lambda sensor - Technical Data (55.989).
Cause:
The Lambda sensor B-9123 low side driver heater control circuit is open.
1. Faulty Lambda sensor B-9123 heater control circuit wiring, open circuit.
Solution:
2. Check the Lambda sensor B-9123 heater circuit wiring for an open circuit condition.
From To Result
X-9123 pin 4 chassis ground There should be approximately
12.0 V.
From To Result
A. If there is no voltage or no continuity, there is an open circuit condition in the vehicle harness (VE) between
connector X-9123 pin 4 and the vehicle switched battery source, wire VE-9081 or between connector X-9123
B. If there is voltage and continuity, leave connector X-9123 disconnected and continue with Step 3.
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or broken wires.
has been resolved.
operation.
(55.100.DP-C.20.E.02)
(55.100.DP-C.20.E.04)
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3714-Lambda sensor: Fault code to indicate SRC High error for

O2 calibration
Context:
The Engine Control Unit (ECU) A-9000 performs an electrical zero-offset calibration every 10 min of engine operation
on the Lambda sensor B-9123 as long as the engine has been running for longer than 10 s after start, after-treatment
regeneration is not active, the engine is in operating range one (speed between 300 - 1200 RPM and load between
2.00 - 11.00 mg per stroke), and the calibration is not inhibited due to a failure. The measured oxygen signal during
calibration should be between - 0.200 - 0.200 V. If the oxygen signal, during this calibration, is out of range, higher
than 0.200 V, this fault will occur. For more information regarding rich air/fuel ratio troubleshooting, refer to the engine
service manual Fuel injection system - Poor quality (10.218). For more information regarding fuel system trou-
bleshooting, refer to the engine service manual Fuel injection system - Troubleshooting (10.218). For information
regarding the functional operation of the Lambda sensor B-9123, refer to the engine service manual Lambda sensor
- Overview (55.989). For more information regarding the technical specifications of the lambda sensor B-9123, refer
to the engine service manual Lambda sensor - Technical Data (55.989).
Cause:
The Lambda sensor B-9123 oxygen level signal, during calibration, to the ECU A-9000 is greater than 0.200 V.
1. Faulty injector, leaking.

2. Faulty Exhaust Gas Recirculation (EGR) Z-9000 valve, stuck closed.
3. Faulty Lambda sensor B-9123, contaminated.
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3715-Lambda sensor : Fault code to indicate SRC Low error for

O2 calibration
Context:
The Engine Control Unit (ECU) A-9000 performs an electrical zero-offset calibration every 10 min of engine operation
on the Lambda sensor B-9123 as long as the engine has been running for longer than 10 s after start, after-treatment
regeneration is not active, the engine is in operating range one (speed between 300 - 1200 RPM and load between
2.00 - 11.00 mg per stroke), and the calibration is not inhibited due to a failure. The measured oxygen signal during
calibration should be between - 0.200 - 0.200 V. If the oxygen signal, during this calibration, is out of range, less than
- 0.200 V, this fault will occur. For more information regarding lean air/fuel ratio troubleshooting, Refer to the engine
service manual Fuel injection system - Poor quality (10.218). For more information regarding fuel system trou-
bleshooting, refer to the engine service manual Fuel injection system - Troubleshooting (10.218). For information
regarding the functional operation of the Lambda sensor B-9123 refer to the engine service manual Lambda sensor
- Overview (55.989). For more information regarding the technical specifications of the lambda sensor B-9123, refer
to the engine service manual Lambda sensor - Technical Data (55.989).
Cause:
The Lambda sensor B-9123 oxygen level signal, during calibration, to the ECU A-9000 is less than – 0.200 V.
1. Faulty fuel back-flow, excessive.

2. Faulty Exhaust Gas Recirculation (EGR) Z-9000 valve, stuck open.
3. Faulty Lambda sensor B-9123, contaminated.
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3716-Lambda sensor: O2 value above the maximum threshold

Context:
The Engine Control Unit (ECU) A-9000 has detected a fault associated with the oxygen sensor. This fault is a result of
an open circuit condition in the factory installed trim resistor circuit. For information regarding the functional operation
of the Lambda sensor B-9123, refer to the engine service manual Lambda sensor - Overview (55.989). For more
information regarding the technical specifications of the lambda sensor B-9123, see Lambda sensor - Technical
Data (55.989).
Cause:
The ECU A-9000 is sensing an open circuit condition in the Lambda sensor B-9123 trim resistor circuit.
1. Faulty Lambda sensor B-9123 circuit wiring, open circuit.

Solution:
2. Check the Lambda sensor B-9123 trim resistor circuit wiring for an open circuit condition.
From To Result
pin 5 and X-9122 pin K86. Use the appropriate vehicle service manual, if necessary, to locate and repair the
broken conductor.

or broken wires.
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has been resolved.
operation.
(55.100.DP-C.20.E.02)
(55.100.DP-C.20.E.04)
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3720-Lambda sensor: low battery voltage at the SPI chip

Context:
The SPI chip, which is internal to the ECU A-9000, controls the Lambda sensor B-9123 device for the measuring or
the calibrating of the inner resistance for temperature evaluation, switches on and off the pump current to measure
O2 content and monitors the hardware related to the open load and short circuit monitoring devices. If the SPI chip
senses a very low battery voltage, less than 9.0 V this fault will occur.
Solution:
47821916 28/04/2015
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3721-Lambda sensor: Fault check to indicate SPI chip error of

lambda sensor
Context:
The SPI chip, which is internal to the ECU A-9000, controls the Lambda sensor B-9123 device for the measuring or
the calibrating of the inner resistance for temperature evaluation, switches on and off the pump current to measure
O2 content and monitors the hardware related to the open load and short circuit monitoring devices. The requests for
these listed actions are made by software and result in a configuration of the initialization register, which is hardware
controlled. The same configuration is calculated by software. If both configurations are not identical, the SPI is not
plausible and this fault will occur. For information regarding the functional operation of the Lambda sensor B-9123,
refer to the engine service manual Lambda sensor - Overview (55.989). For more information regarding the tech-
nical specifications of the lambda sensor B-9123, refer to the engine service manual Lambda sensor - Technical
Data (55.989).
Solution:
47821916 28/04/2015
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3722-LSU (oxygen) sensor temperature exceeds the maximum limit

service manual, Lambda sensor - Configure - Reset ECU data (Lambda sensor) (55.989), if necessary.
Context:
The Engine Control Unit (ECU) A-9000 monitors the internal resistance of the nernst cell to estimate the internal tem-
perature of the Lambda sensor B-9123. If the ECU A-9000 calculates the internal temperature to be greater than
929.96 °C (1705.9 °F), this fault will occur. For information regarding the functional operation of the Lambda sensor
B-9123 , refer to the engine service manual, Lambda sensor - Overview (55.989). For more information regarding
the technical specifications of the lambda sensor B-9123, refer to the engine service manual Lambda sensor - Tech-
nical Data (55.989).
Cause:
The ECU A-9000 calculated temperature, based on inner resistance, of the Lambda sensor B-9123 is greater than
929.96 °C (1705.9 °F).
1. Faulty Lambda sensor B-9123 nernst cell circuit wiring, shorted to ground.
2. Faulty Lambda sensor B-9123 connection, loose.
Solution:
2. Visually inspect the Lambda sensor B-9123 for proper connection.
A. If the Lambda sensor B-9123 is not properly connected or is loose, repair as necessary.
B. If the Lambda sensor B-9123 is properly connected, continue to Step 3.

3. Check the Lambda sensor B-9123 nernst cell circuit wiring for a short to ground condition.
With the key in the OFF position, use a multimeter to check for continuity on the vehicle harness (VE) side :
From To Value
pin 6 and connector X-9122 pin K63, wire VE-9156. Use the appropriate vehicle service manual, if necessary,

47821916 28/04/2015
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or broken wires.
has been resolved.
operation.
(55.100.DP-C.20.E.02)
(55.100.DP-C.20.E.04)
47821916 28/04/2015
55.7 [55.DTC] / 337
3723-LSU (oxygen) sensor temperature is below the minimum limit

service manual, Lambda sensor - Configure - Reset ECU data (Lambda sensor) (55.989), if necessary.
Context:
The Engine Control Unit (ECU) A-9000 monitors the internal resistance of the nernst cell to estimate the internal tem-
perature of the Lambda sensor B-9123. If the ECU A-9000 calculates the internal temperature to be equal to or less
than 719.96 °C (1327.9 °F), this fault will occur. For information regarding the functional operation of the Lambda
sensor B-9123 refer to the engine service manual Lambda sensor - Overview (55.989). For more information re-
garding the technical specifications of the lambda sensor B-9123, refer to the engine service manual Lambda sensor
- Technical Data (55.989).
Cause:
The ECU A-9000 calculated temperature, based on inner resistance, of the Lambda sensor B-9123 is below or equal
to 719.96 °C (1327.9 °F).
1. Faulty Lambda sensor B-9123 nernst cell or virtual ground circuit wiring, open circuit.
Solution:
2. Check the Lambda sensor B-9123 nernst cell and virtual ground circuit wiring for an open circuit condition.
From To Result
Move the connector X-9122 end of the jumper wire from connector X-9122 pin K85 to connector X-9122 pin K63.
From To Result
A. If there is no continuity on either of the checks, there is an open circuit condition in the vehicle harness (VE)
between connector X-9123 pin 2 or connector X-9123 pin 6 and X-9122 pin K85 or connector X-9122 pin
K63, wire VE-9155 or VE-9156. Use the appropriate vehicle service manual, if necessary, to locate and repair
the broken conductor.
B. If there is continuity on both checks, continue with Step 3.

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or broken wires.
has been resolved.
operation.
(55.100.DP-C.20.E.02)
(55.100.DP-C.20.E.04)
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3724-Lambda sensor: Short to battery at IA, IP, UN, VG

Context:
The Engine Control Unit (ECU) A-9000 monitors the condition of the nernst cell, pump cell and virtual ground circuits.
If the ECU A-9000 detects a short to a voltage source condition in any of the circuits or an open circuit condition in
the virtual ground circuit, this fault will occur. For information regarding the functional operation of the Lambda sensor
B-9123, refer to the engine service manual Lambda sensor - Overview (55.989). For more information regarding the
technical specifications of the lambda sensor B-9123, refer to the engine service manual Lambda sensor - Technical
Data (55.989).
Cause:
The ECU A-9000 is sensing an open circuit condition in the Lambda sensor B-9123 virtual ground circuit or a short to
a voltage source condition in the nernst cell, pump cell or virtual ground circuit.
1. Faulty Lambda sensor B-9123 nernst cell, pump cell, or virtual ground circuit wiring, shorted to voltage source.
2. Faulty Lambda sensor B-9123 virtual ground circuit wiring, open circuit.
Solution:
2. Check the Lambda sensor B-9123 nernst cell, pump cell, and virtual ground circuit wiring for a short to voltage
condition.
From To Result
X-9122 pin K63 all the other pins in connector X-9122 There should be no continuity.
From To Result
A. If there is no continuity or voltage, leave connector X-9123 and connector X-9122 disconnected and continue
with Step 3.
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B. If there is continuity or voltage, there is a short to another circuit condition is in the vehicle harness (VE). Use
the appropriate vehicle service manual, if necessary, to locate and repair the damaged conductors.
3. Check the Lambda sensor B-9123 virtual ground circuit wiring for an open circuit condition.
Carefully place a jumper wire between X-9122 pin K85 and chassis ground.
From To Result

or broken wires.
has been resolved.
operation.
(55.100.DP-C.20.E.02)
(55.100.DP-C.20.E.04)
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3725-Lambda sensor: Short to ground at IA, IP, UN, VG

Context:
The Engine Control Unit (ECU) A-9000 monitors the condition of the Lambda sensor B-9123 nernst cell, pump cell
and virtual ground circuits. If the ECU A-9000 detects a short to ground in any of the circuits, this fault will occur.
For information regarding the functional operation of the Lambda sensor B-9123, refer to the engine service manual
Lambda sensor - Overview (55.989). For more information regarding the technical specifications of the lambda
sensor B-9123, refer to the engine service manual Lambda sensor - Technical Data (55.989).
Cause:
The ECU A-9000 is sensing a short to ground condition in the Lambda sensor B-9123 nernst cell, pump cell or virtual
ground circuit.
1. Faulty Lambda sensor B-9123 circuit wiring, shorted to ground.

Solution:
2. Check the Lambda sensor B-9123 circuit wiring for a short to ground condition.
From To Result
A. If there is continuity on any of the checks, there is a short to ground condition in the vehicle harness (VE)
between connector X-9123 pin 1 or connector X-9123 pin 2 or connector X-9123 pin 6 and connector X-9122
pin K64 or connector X-9122 pin K85 or connector X-9122 pin K63, wire VE-9154 or VE-9155 or VE-9156.
Use the appropriate vehicle service manual, if necessary, to locate and repair the damaged conductor.
B. If there is no continuity on any of the checks, continue with Step 3.

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or broken wires.
has been resolved.
operation.
(55.100.DP-C.20.E.02)
(55.100.DP-C.20.E.04)
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3727-Low oil viscosity

NOTE: If the engine oil/filter is replaced, it is necessary to perform the Replacement of the Engine Oil/Filter - Reset
Change Reminder with the Electronic Service Tool (EST) before you return the machine to service. Refer to the
engine service manual Engine oil system - Configure - Replacement of the Engine Oil/Filter – Reset Change
Reminder (55.013), if necessary.
Context:
The ECU A-9000 monitors engine oil viscosity. If the ECU A-9000 determines that the engine oil viscosity is low, an
oil change is necessary and this fault will occur. For more information on lubrication system troubleshooting, refer to
the engine service manual Engine lubrication system - Troubleshooting (10.304).
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3728-Too low oil viscosity

NOTE: If the engine oil/filter is replaced, it is necessary to perform the Replacement of the Engine Oil/Filter - Reset
Change Reminder with the Electronic Service Tool (EST) before you return the machine to service. Refer to the
engine service manual Engine oil system - Configure - Replacement of the Engine Oil/Filter – Reset Change
Reminder (55.013), if necessary.
Context:
The ECU A-9000 monitors engine oil viscosity. If the ECU A-9000 determines that the engine oil viscosity is too low,
an oil change is necessary and this fault will occur. For more information on lubrication system troubleshooting, refer
to the engine service manual Engine lubrication system - Troubleshooting (10.304).
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3735-Fuel Metering Unit: over temperature of device driver of

metering unit
Context:
The Engine Control Unit (ECU) monitors the fuel metering unit Y-9000 signal circuit for an over temperature/current
condition. If the ECU A-9000 detects an over temperature/current condition in the fuel metering unit Y-9000 signal
circuit, this fault will occur.
Cause:
The ECU A-9000 has detected an over temperature/current condition in the fuel metering unit Y-9000 signal circuit.
1. Faulty fuel metering unit Y-9000 wiring, short to a voltage source.

Solution:
From To Value
Y-9000.
3. Check the fuel metering unit Y-9000 low side driver wiring for a short to battery condition.
(EN) side :
From To Value
(EN) side :
From To Value
A. If there is voltage, there is a short circuit to battery or switched battery in the fuel metering unit Y-9000 low
side driver circuit wiring. Use the appropriate service manual, if necessary, to locate and repair the shorted
conductor.
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4. Check the fuel metering unit Y-9000 low side driver engine harness (EN) wiring for a short circuit condition.
(EN) side :
From To Value
B. If there is continuity, there is a short circuit condition in the fuel metering unit Y-9000 low side driver engine
5. Check the fuel metering unit Y-9000 low side driver vehicle harness (VE) wiring for a short circuit condition.
harness (VE) side :
From To Value
A. If there is continuity, there is a short circuit condition in the fuel metering unit Y-9000 low side driver vehicle har-
has been resolved.
operation.
(55.100.DP-C.20.E.05)
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3738-Analog Digital Converter (ADC): Diagnostic fault check to

report multiple error while checking the complete ROM memory
Context:
The Engine Control Unit (ECU) A-9000 runs a diagnostic fault check of the ROM memory. If any checksum errors in
ROM-memory blocks are detected, this fault will occur.
Solution:
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3739-Power stages, Injector: Loss of synchronization sending

bytes to the MM from CPU
Context:
The Engine Control Unit (ECU) A-9000 performs a shut-off path test of the fuel injection power stages. Every time
the key is turned ON, this test is performed to verify the correct functioning of the shut-off procedure. If an error is
detected during the shut-off test, the fault will occur.
Solution:
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3740-Injector power stages torque limitation error

Context:
The Engine Control Unit (ECU) A-9000 performs a series of “shut-off path” tests which deactivates all power stages
relevant to fuel injection if certain ECU A-9000 errors are detected. If an incorrect response to the power stage supply
(CY320) is detected during this test, this fault will occur.
Solution:
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3741-Power stages, Injector: Wrong set response time

Context:
relevant to fuel injection if certain ECU A-9000 errors are detected. If there is a time-out error during this test, this
fault will occur.
Solution:
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3742-Power stages, Injector: Too many SPI errors during MoCSOP

execution
Context:
relevant to fuel injection if certain ECU A-9000 errors are detected. If there is a faulty communication detected during
this test, this fault will occur.
Solution:
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3743-Injector power stage diagnostic fault check to report the error

in under voltage monitoring
Context:
The Engine Control Unit (ECU) A-9000 performs “shut-off paths” which deactivate all power stages relevant to fuel
injection if certain ECU A-9000 errors are detected. If an under-voltage condition is detected during this test, this fault
will occur.
Solution:
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3744-Power stages, injector : Diagnostic fault check to report the

error in over voltage monitoring
Context:
injection if certain ECU A-9000 errors are detected. If an over-voltage condition is detected during this test, this fault
will occur.
Solution:
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3745-Power stages, Injector : Diagnostic fault check to report that

WDA is not working correct
Context:
The Engine Control Unit (ECU) A-9000 performs “shut-off paths” which deactivate all power stages relevant to fuel in-
jection if certain ECU A-9000 errors are detected. If an implausible response in the power-stage feedback is detected
during this test, this fault will occur.
Solution:
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3746-Power stages, Injector : OS timeout in the shut off path test.

Failure setting the alarm task period.
Context:
injection if certain ECU A-9000 errors are detected. If an alarm task can not be set or reset after having detected a
time-out error during this test, this fault will occur.
Solution:
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3747-Power stages, Injector: Diagnostic fault check to report that

the positive test failed
Context:
injection if certain ECU A-9000 errors are detected. If the ECU A-9000 determines that the test has failed, this fault
will occur.
Solution:
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3748-Power stages, Injector : Diagnostic fault check to report the

timeout in the shutoff path test
Context:
injection if certain ECU A-9000 errors are detected. If a time-out in the power-stage feedback is detected during this
test, this fault will occur.
Solution:
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3750-Injection control: Error in the plausibility of the injection

energizing time
Context:
The Engine Control Unit (ECU) A-9000 monitors fuel injector energizing time for plausibility. If the ECU A-9000 de-
termines that this value is implausible for either pilot, main or post injection, this fault will occur.
Solution:
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3751-Injection control : Error in the plausibility of the start of

energizing angles
Context:
The Engine Control Unit (ECU) A-9000 monitors fuel injector energizing start time for plausibility. If the ECU A-9000
determines that this value is implausible for either pilot, main or post injection, this fault will occur.
Solution:
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3752-Level 2 Monitoring: Error in the plausibility of the energizing

times of the zero fuel quantity calibration
Context:
The Engine Control Unit (ECU) A-9000 checks the plausibility of the Zero Fuel Quantity Calibration (ZFC) energizing
time. The ZFC is used to correct pilot injection quantity. If the ECU A-9000 determines the energizing time of the ZFC
is implausible, this fault will occur.
Solution:
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3753-Level 2 Monitoring : Diagnostic fault check to report the error

due to Over heating
Context:
The Engine Control Unit (ECU) A-9000 checks the plausibility of the Zero Fuel Quantity Calibration (ZFC) energizing
time. The ZFC is used to correct pilot injection quantity. If the ECU A-9000 determines the energizing time of the ZFC
is implausible, this fault will occur.
Solution:
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3754-Level 2 Monitoring : Diagnostic fault check to report the

plausibility error in rail pressure monitoring
Context:
The Engine Control Unit (ECU) A-9000 monitors fuel pressure in the common rail. This monitoring is performed using
two software levels of monitoring because fuel pressure monitoring is a critical functionality. If the ECU A-9000 sees
an error in the level two monitoring but not in level one monitoring, this fault will occur.
Solution:
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3755-Level 2 Monitoring : Diagnostic fault check to report the error

due to torque comparison
Context:
The Engine Control Unit (ECU) A-9000 performs a diagnostic comparison of requested engine torque to allowed
engine torque. If the ECU A-9000 determines that requested engine torque is greater than maximum allowed torque,
Solution:
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3756-Level 2 Monitoring : Diagnosis fault check to report the

demand for normal mode due to an error in the PoI2 quantity
Context:
The Engine Control Unit (ECU) A-9000 performs a diagnostic fault check for post injection 2 by monitoring start angle
and efficiency. If the ECU A-9000 determines that there is an error during this check, this fault will occur.
Solution:
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3757-Level 2 Monitoring : Diagnosis fault check to report the error

to demand for an ICO due to an error in the PoI2 shut-off
Context:
The Engine Control Unit (ECU) A-9000 performs a diagnostic fault check for post injection 2. If the ECU A-9000
determines that the post injection 2 quantity has exceeded the expected value, this fault will occur.
Solution:
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3758-Level 2 Monitoring : Diagnosis fault check to report the error

to demand for an ICO due to an error in the PoI3 efficiency factor
Context:
The Engine Control Unit (ECU) A-9000 performs a diagnostic fault check for post injection 3. If the ECU A-9000
determines that there is a post injection 3 plausibility error, this fault will occur.
Solution:
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3759-Level 2 Monitoring : Diagnosis of curr path limitation forced

by ECU monitoring level 2
Context:
The Engine Control Unit (ECU) A-9000 monitors “lead torque”, which is the input torque request that is calculated for
determining fuel pressure. If the ECU A-9000 determines that “lead torque” is less than the limited maximal torque,
Solution:
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3760-Level 2 Monitoring : Diagnosis air path limitation due to a

functional control unit monitoring forced by ECU monitoring level 2
Context:
The Engine Control Unit (ECU) A-9000 monitors “lead torque”, which is the input torque request that is calculated for
determining fuel pressure. If the ECU A-9000 determines that “lead torque” is less than the limited maximal torque,
Solution:
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3761-Level 2 Monitoring : Diagnosis quantity path limitation due to

a functional control unit monitoring (level 2)
Context:
The Engine Control Unit (ECU) A-9000 calculates and monitors “inner torque”, torque produced by the engine. The
ECU A-9000 compares “inner torque” to allowed “inner torque”. If the ECU A-9000 determines that “Inner torque” is
greater than allowed “inner torque”, this fault will occur.
Solution:
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3762-Level 2 Monitoring : Reported Overvoltage of Supply

Context:
The Engine Control Unit (ECU) A-9000 monitors the ECU A-9000 internal 5 V supply. If the 5 V supply exceeds the
maximal limit, this fault will occur.
Cause:
The ECU A-9000 has determined that the 5 V internal voltage supply is too high.
1. Faulty voltage supply.

Solution:
(VE) side :
From To Value
A. If there is not approximately 12 V, there is a failure in the ECU A-9000 supply wiring. Use the appropriate
has been resolved.
operation.
(55.100.DP-C.20.E.04)
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3763-Level 2 Monitoring : Reported under voltage of supply

Context:
The Engine Control Unit (ECU) A-9000 monitors the ECU A-9000 internal 5 V supply. If the 5 V supply is below the
minimal limit, this fault will occur.
Cause:
The ECU A-9000 has determined that the 5 V internal voltage supply is too low.
1. Faulty voltage supply.

Solution:
(VE) side :
From To Value
A. If there is not approximately 12 V, there is a failure in the ECU A-9000 supply wiring. Use the appropriate
has been resolved.
operation.
(55.100.DP-C.20.E.04)
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3764-Main Relay: Early opening defect of main relay

Context:
The Engine Control Unit A-9000 controls the main relay K-9102. The main relay K-9102 is powered on by the ECU
A-9000 to achieve after-run. The main relay K-9102 is powered off once after-run is completed. If the ECU A-9000
determines that the main relay K-9102 has shut off before commanded, this fault will occur.
Cause:
The ECU A-9000 has determined that the main relay K-9102 has shut off before commanded to shut off.
1. Faulty main relay K-9102, wiring.

2. Faulty main relay K-9102, internal failure.
Solution:
2. Check the main relay K-9102 coil for an internal failure.
Remove the main relay K-9102.
Use a multimeter to measure the resistance on the main relay K-9102 pins :
From To Value
130 Ω.
A. If there is approximately 70 - 130 Ω, leave the main relay K-9102 disconnected and continue to Step 3.
B. If there is not approximately 70 - 130 Ω, the main relay K-9102 has failed. Replace the main relay K-9102.
3. Check the main relay K-9102 vehicle harness (VE) wiring for a short to a voltage source.
From To Value
From To Value
A. If there is voltage, there is a short to a voltage source in the main relay K-9102 wiring in the vehicle harness
B. If there is no voltage, leave the main relay K-9102 disconnected and continue to Step 4.
4. Check the main relay K-9102 vehicle harness (VE) wiring for a short to ground.
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From To Value
A. If there is continuity, there is a short to ground in the main relay K-9102 wiring in the vehicle harness (VE). Use
the appropriate service manual, if necessary, to locate and repair the broken or damaged conductor.
B. If there is no continuity, leave the main relay K-9102 disconnected and continue to Step 5.
5. Check the main relay K-9102 vehicle harness (VE) wiring for an open circuit.
From To Value
A. If there is no continuity, there is an open circuit in the main relay K-9102 wiring in the vehicle harness (VE).
Use the appropriate service manual, if necessary, to locate and repair the broken or damaged conductor.
B. If there is continuity, leave the main relay K-9102 and connector X-9122 disconnected, then continue to Step 6.
6. Check the main relay K-9102 wiring for a short circuit condition.
From To Value
A. If there is continuity, there is a short circuit in the main relay K-9102 vehicle harness (VE) wiring. Use the
B. If there is no continuity, leave the main relay K-9102 and connector X-9122 disconnected, then continue to
Step 7.
7. Check the main relay K-9102 load-side wiring.
With the key in the ON position, use a multimeter to perform the following voltage checks on the vehicle harness
(VE) side :
From To Value
12.0 V.
12.0 V.
A. If there is not approximately 12.0 V, there is a failure in the main relay K-9102 load-side wiring. Use the appro-
priate service manual, if necessary, to locate and repair the shorted conductor.
B. If there is approximately 12.0 V, leave the main relay K-9102 and connector X-9122 disconnected, then con-
tinue to Step 8.
8. Check the main relay K-9102 load-side wiring.
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With the key in the OFF position, use a multimeter to perform the following continuity checks on the vehicle harness
(VE) side :
From To Value
A. If there is no continuity, there is an open circuit in the main relay K-9102 load-side wiring or fuse. Use the
appropriate service manual, if necessary, to locate and repair the shorted conductor or open fuse.
has been resolved.
operation.
(55.100.DP-C.20.E.04)
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3767-ECU internal : Diagnostic fault check to report 'WDA active'

due to errors in query-/response communication
Context:
The Engine Control Unit (ECU) A-9000 monitors the communication between CJ945 (power stage chips) and CY320
(power stage voltage supplier). If the ABE wire between the CJ-945 and CY320 becomes active due to an unknown
reason, this fault will occur.
Solution:
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3768-ECU Internal : Diagnostic fault check to report 'ABE active'

due to under voltage detection
Context:
(power stage voltage supplier). If the ABE wire between the CJ-945 and CY320 becomes active due to an under-
voltage detection, this fault will occur.
Solution:
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3769-ECU Internal: Diagnostic fault check to report 'ABE active'

due to overvoltage detection
Context:
(power stage voltage supplier). If the ABE wire between the CJ-945 and CY320 becomes active due to an over-
voltage detection, this fault will occur.
Solution:
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3770-ECU internal: Diagnostic fault check to report 'WDA/ABE

active' due to unknown reason
Context:
(power stage voltage supplier). If there is an unexpected communication during this process, this fault will occur.
Solution:
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3773-Turbocharger: Underboost detected in pressure charger

regulator
Context:
The Engine Control Unit (ECU) A-9000 monitors boost pressure using the intake manifold pressure sensor B-9001.
If the ECU A-9000 determines that boost pressure is lower than expected, this fault will occur. For more information
regarding the troubleshooting of an under-boost condition, refer to the engine service manual Turbocharger - Trou-
Cause:
The ECU A-9000 has determined that boost pressure is lower than expected.
1. Faulty intake plumbing, boost leakage.

2. Faulty air filter, clogged.
3. Faulty wastegate pressure modulator valve Y-9008, if applicable.
4. Faulty boost pressure accumulator, if applicable.
5. Faulty wastegate, sticking.
6. Faulty turbocharger, low efficiency.
7. Faulty intake manifold pressure sensor B-9001, drifted signal.
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3794-Intake air pressure sensor: Plausibility check for air pressure

at the upstream of intake valve sensor
Context:
The Engine Control Unit (ECU) A-9000 monitors boost pressure. Boost pressure is compared to environmental pres-
sure by the ECU A-9000. If the ECU A-9000 determines that the difference between measured boost pressure and
environmental pressure is greater than 0.1 bar (1.5 psi), this fault will occur.
Cause:
The ECU A-9000 has determined that boost pressure is greater than environmental pressure by 0.1 bar (1.5 psi).

Solution:
2. Use the Electronic Service Tool (EST) to check the status of following related faults:
3019 - Boost Pressure Sensor - Signal Above Range Maximum
3037 - Boost Pressure Sensor - Signal Low
A. If any of the listed faults are active, diagnose them first and then return to this fault, 3794 - Intake air pressure
sensor: Plausibility check for air pressure at the upstream of intake valve sensor.
B. If none of the listed faults are active, continue to Step 3.

Use the EST to verify the status of this fault, 3794 - Intake air pressure sensor: Plausibility check for air
pressure at the upstream of intake valve sensor.
has been resolved.
operation.
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3795-Intake air pressure sensor: Plausibility check for air pressure

at the upstream of intake valve sensor
Context:
The Engine Control Unit (ECU) A-9000 monitors boost pressure. Boost pressure is compared to environmental pres-
sure by the ECU A-9000. If the ECU A-9000 determines that the boost pressure is less than environmental pressure
by 0.1 bar (1.5 psi), this fault will occur.
Cause:
The ECU A-9000 has determined that boost pressure is less than environmental pressure by 0.1 bar (1.5 psi).

Solution:
2. Use the Electronic Service Tool (EST) to check the status of following related faults:
3019 - Boost Pressure Sensor - Signal Above Range Maximum
3037 - Boost Pressure Sensor - Signal Low
A. If any of the listed faults are active, diagnose them first and then return to this fault, 3795 - Intake air pressure
sensor: Plausibility check for air pressure at the upstream of intake valve sensor.
B. If none of the listed faults are active, continue to Step 3.

Use the EST to verify the status of this fault, 3795 - Intake air pressure sensor: Plausibility check for air
pressure at the upstream of intake valve sensor.
has been resolved.
operation.
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3799-Pressure Relief valve: pressure relief valve is forced to open,

perform pressure shock
Context:
This fault is intended for information purposes only. Other active faults may have caused this fault to occur. The
Engine Control Unit (ECU) A-9000, if necessary, will set the engine into limp home mode. This process is achieved
in two steps by the ECU A-9000, a pressure increase and a pressure shock. The ECU A-9000 will execute step two
by a fuel pressure shock. This is achieved by setting injection quantity to zero. If this fault is active, the ECU A-9000
has performed step two for achieving limp home mode, a fuel pressure shock.
Cause:
The ECU A-9000 has performed a fuel pressure shock to achieve limp home mode.
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3800-Pressure relief valve check if PRV opening

Context:
This fault is intended for information purposes only. Other active faults may have caused this fault to occur. The
Engine Control Unit (ECU) A-9000, monitors the fuel Pressure Relief Valve (PRV). To determine mechanical wear-out
of the PRV, the ECU A-9000 will perform a fuel pressure increase and pressure shock, thus opening the PRV. Both
steps are recorded in the ECU A-9000 failure memory.
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3803-ECU internal : Error on R2S2 module

Context:
The Engine Control Unit (ECU) A-9000 has detected an error on the R2S2 module (low-level chip driver for the power-
stage chips).
Solution:
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3808-High pressure pump fuel delivery quantity at low idle is too

high
Context:
The Engine Control Unit (ECU) A-9000 monitors fuel rail pressure. If the ECU A-9000 determines that the requested
fuel pressure is greater than the actual fuel pressure at idle, leakage is assumed and this fault will occur. Other active
faults may have caused this fault to occur. Use the Electronic Service Tool (EST) to check for other active faults.
Diagnose any active faults related to the fuel system first and then return to this fault. For more information regarding
fuel system troubleshooting, refer to the engine service manual Fuel injection system - Troubleshooting (10.218).
Cause:
The ECU A-9000 has determined that the requested fuel pressure is greater than the actual fuel pressure at idle.
1. Faulty low pressure fuel system, clogged filter or leakage/blockage.

2. Faulty charge gear pump, low efficiency or line clogged/damaged.
4. Faulty fuel metering unit, unable to fully open.
5. Faulty high pressure pump, low efficiency.
6. Faulty fuel injectors, stuck open or internal leakage.
8. Faulty rail pressure sensor B-9004 drifted signal or leaking.
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3810-Fuel pressure sensor: Rail pressure raw value is intermittent

Context:
The Engine Control Unit (ECU) A-9000 monitors the rail pressure sensor B-9004 If the ECU A-9000 detects more than
5 pressure jumps of greater than 500 bar (7250 psi) and the time between the pressure jumps is less than 3.00 s, an
intermittent connection is assumed and this fault will occur.
Cause:
The ECU A-9000 has detected an intermittent connection in the rail pressure sensor B-9004 signal circuit.
1. Faulty rail pressure sensor B-9004 wiring, intermittent electrical connection.

Solution:
2. Check the rail pressure sensor B-9004 engine harness (EN) harness wiring for an open circuit condition.
(EN) side :
From To Value
A. If there is no continuity, there is an open circuit in the rail pressure sensor B-9004 wiring in the engine harness
(EN). Locate and repair the broken conductor.
3. Check the rail pressure sensor B-9004 vehicle harness (VE) wiring for an open circuit condition.
(VE) side :
From To Value
NOTE: Shake the harness during the check to promote an intermittent electrical connection.
A. If there is no continuity, there is an open circuit in the rail pressure sensor B-9004 wiring in the vehicle harness
(VE). Use the appropriate service manual, if necessary, to locate and repair the broken conductor.
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has been resolved.
operation.
(55.100.DP-C.20.E.05)
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3811-ECU internal failure - Sensor 5 volt supply 1

Context:
The ECU A-9000 pin numbers associated with sensor supply 1 are A07, A08, A09, A10, A11, A12, and A13.
Cause:

2. Faulty ECU A-9000 supply voltage.
4. Faulty ECU A-9000 connector X-9121, corrosion or damage.
5. Faulty Throttle Valve Actuator (TVA) Z-9001, position sensor wiring or internal failure.
6. Faulty Exhaust Gas Recirculation (EGR) valve Z-9000, position sensor wiring or internal failure.
7. Faulty intake manifold pressure and temperature sensor B-9001, wiring or internal failure.
8. Faulty rail pressure sensor B-9004, wiring or internal failure.
9. Faulty exhaust manifold pressure sensor B-9005, wiring to internal failure.
10. Faulty camshaft speed sensor B-9017, wiring or internal failure.
Solution:
3. Disconnect the ECU A-9000 connector X-9121.
Check the following pins listed below on the ECU A-9000 and in connector X-9121 .

damage.
damage.
damage.
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damage.
damage.
damage.
damage.
B. If a pin or connector shows no signs of corrosion or damage, re-connect the ECU A-9000 at connector X-9121
and continue to Step 4.
(VE) side :
From To Value
A. If there is approximately 12 V, remove the jumper wire and re-connect the ECU A-9000 at connector X-9122,
then continue to Step 5.
5. Disconnect each of the following connectors one at a time. Monitor the status of this fault, 3811 - ECU internal
failure - Sensor 5 volt supply 1 during the check.
The TVA Z-9001 connector X-9011.
The EGR valve Z-9000 connector X-9010.
The intake manifold pressure and temperature sensor B-9001 connector X-9003.
The rail pressure sensor B-9004 connector X-9026.
The exhaust manifold pressure sensor B-9005 connector X-9018.
The camshaft speed sensor B-9017 connector X-9008.
A. If the fault is no longer active after a component disconnection, the relevant component has failed. Replace
the component.
B. If the fault is still active after the component disconnections, leave all of the connectors disconnected and
continue to Step 6.
6. Check the TVA Z-9001 voltage supply wiring.
Disconnect the vehicle harness (VE) from the ECU A-9000 at connectors X-9122 and X-9121.
(EN) side :
From To Value
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With the key in the OFF position, use a multimeter to perform the following continuity checks on the engine
harness (EN) side :
From To Value
With the key in the OFF position, use a multimeter to perform the following continuity checks on the vehicle
harness (VE) side :
From To Value
A. If the specified values are measured, re-connect the engine interface connector X-9138 and leave the ECU
A-9000 connectors X-9121 and X-9122 disconnected. Then, continue to Step 7.
B. If the specified values are not measured, there is a failure in the TVA Z-9001 voltage supply wiring. Use the
appropriate service manual, if necessary, to locate and repair the failed conductor.
7. Check the EGR valve Z-9000 voltage supply wiring.
(EN) side :
From To Value
harness (EN) side :
From To Value
harness (VE) side :
From To Value
B. If the specified values are not measured, there is a failure in the EGR valve Z-9000 voltage supply wiring.
Use the appropriate service manual, if necessary, to locate and repair the failed conductor.
8. Check the intake manifold pressure and temperature sensor B-9001 voltage supply wiring.
(EN) side :
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From To Value
harness (EN) side :
From To Value
harness (VE) side :
From To Value
B. If the specified values are not measured, there is a failure in the intake manifold pressure and temperature
sensor B-9001 voltage supply wiring. Use the appropriate service manual, if necessary, to locate and repair
the failed conductor.
9. Check the rail pressure sensor B-9004 voltage supply wiring.
(EN) side :
From To Value
harness (EN) side :
From To Value
harness (VE) side :
From To Value
B. If the specified values are not measured, there is a failure in the rail pressure sensor B-9004 voltage supply
wiring. Use the appropriate service manual, if necessary, to locate and repair the failed conductor.
10. Check the exhaust manifold pressure sensor B-9005 voltage supply wiring.
(EN) side :
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From To Value
harness (EN) side :
From To Value
harness (VE) side :
From To Value
B. If the specified values are not measured, there is a failure in the rail pressure sensor B-9004 voltage supply
11. Check the camshaft speed sensor B-9017 voltage supply wiring.
(EN) side :
From To Value
harness (EN) side :
From To Value
harness (VE) side :
From To Value
A. If the specified values are measured, re-connect all of the connectors and continue to Step 12.
B. If the specified values are not measured, there is a failure in the camshaft speed sensor B-9017 voltage supply
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A. If you find damage or the display indicates other than normal display readings, Then, 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, Then, erase the fault code and
continue operation.
(55.100.DP-C.20.E.04)
(55.100.DP-C.20.E.05)
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3812-Physical range check high for ECU temperature sensor

Context:
The Engine Control Unit (ECU) A-9000 has an internal temperature sensor. The ECU A-9000 monitors this sensor.
If the ECU A-9000 determines that the temperature sensor value is too high, this fault will occur.
Cause:
The ECU A-9000 has determined that the internal ECU A-9000 temperature sensor value is too high.
1. Machine is operating in extreme environmental conditions.

Solution:
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3813-Physical range check low for ECU temperature sensor

Context:
The Engine Control Unit (ECU) A-9000 has an internal temperature sensor. The ECU A-9000 monitors this sensor.
If the ECU A-9000 determines that the temperature sensor value is too low, this fault will occur.
Cause:
The ECU A-9000 has determined that the internal ECU A-9000 temperature sensor value is too low.
1. Machine is operating in extreme environmental conditions.

Solution:
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3814-ECU temperature sensor: SPI error ECU temperature sensor

(LM71)
Context:
The Engine Control Unit (ECU) A-9000 has an internal temperature sensor. The ECU A-9000 monitors this sensor
and if the ECU A-9000 determines that there is an internal SPI communication error, this fault will occur.
Cause:
The ECU A-9000 has detected an error in the internal ECU A-9000 temperature sensor communication.
Solution:
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3818-Throttle valve actuator control circuit open

Context:
The Engine Control Unit (ECU) A-9000 monitors the throttle valve actuator Z-9001 output 1 and output 2 h-bridge
circuits. If the ECU A-9000 detects a an open circuit in the throttle valve actuator Z-9001 output h-bridge circuits, this
fault will occur.
Cause:
The ECU A-9000 has detected an open circuit in the throttle valve actuator Z-9001 output h-bridge circuits.
1. Faulty throttle valve actuator Z-9001 wiring, open circuit.

Solution:
2. Check the throttle valve actuator Z-9001 h-bridge engine harness (EN) wiring for an open circuit.
Disconnect the throttle valve actuator Z-9001 connector X-9011.
From To Value
A. If there is no continuity, there is an open circuit in the throttle valve actuator Z-9001 engine harness (EN)
h-bridge circuit. Locate and repair the broken conductor.
3. Check the throttle valve actuator Z-9001 h-bridge vehicle harness (VE) wiring for an open circuit..
From To Value
A. If there is no continuity, there is an open circuit in the throttle valve actuator Z-9001 vehicle harness (VE)
h-bridge circuit. Use the appropriate service manual, if necessary, to locate and repair the broken conductor.

4. Replace the throttle valve actuator Z-9001.
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has been resolved.
operation.
(55.100.DP-C.20.E.05)
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3819-Throttle valve actuator control circuit over current

Context:
circuits. If the ECU A-9000 detects an over temperature/current condition in the throttle valve actuator Z-9001 h-bridge
Cause:
The ECU A-9000 has detected an over temperature/current condition in the throttle valve actuator Z-9001 h-bridge
circuit.
1. Faulty throttle valve actuator Z-9001 wiring, short to ground condition.

2. Faulty throttle valve actuator Z-9001 wiring, short to high source condition.
Solution:
2. Check the throttle valve actuator Z-9001 h-bridge wiring for a short to battery condition.
Disconnect the engine harness (EN) from the throttle valve actuator Z-9001 at connector X-9011.
(EN) side :
From To Value
A. If there is voltage, there is a short to battery in the throttle valve actuator Z-9001 h-bridge circuit. Use the
B. If there is no voltage, leave connectors X-9011 and X-9121 disconnected and continue to Step 3.
3. Check the throttle valve actuator Z-9001 h-bridge wiring for a short to ground condition.
From To Value
A. If there is continuity, there is a short to ground in the throttle valve actuator Z-9001 h-bridge circuit. Use the
4. Check the throttle valve actuator Z-9001 engine harness (EN) wiring for a short circuit condition.
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From To Value
A. If there is continuity, there is a short circuit in the throttle valve actuator Z-9001 engine harness (EN) h-bridge
circuit. Locate and repair the shorted conductor.
5. Check the throttle valve actuator Z-9001 vehicle harness (VE) h-bridge circuit for a short to high source condition.
From To Value
A. If there is continuity, there is a short to high source in the throttle valve actuator Z-9001 vehicle harness (VE)
h-bridge circuit. Use the appropriate service manual, if necessary, to locate and repair the shorted conductor.

has been resolved.
operation.
(55.100.DP-C.20.E.05)
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3820-Throttle valve actuator control circuit over temperature

Context:
circuits. If the ECU A-9000 detects an over temperature/current condition in the throttle valve actuator Z-9001 h-bridge
Cause:
The ECU A-9000 has detected an over temperature/current condition in the throttle valve actuator Z-9001 h-bridge
circuit.

2. Faulty throttle valve actuator Z-9001 wiring, short to high source condition.
Solution:
2. Check the throttle valve actuator Z-9001 h-bridge wiring for a short to battery condition.
(EN) side :
From To Value
A. If there is voltage, there is a short to battery in the throttle valve actuator Z-9001 h-bridge circuit. Use the
3. Check the throttle valve actuator Z-9001 h-bridge wiring for a short to ground condition.
From To Value
A. If there is continuity, there is a short to ground in the throttle valve actuator Z-9001 h-bridge circuit. Use the
4. Check the throttle valve actuator Z-9001 engine harness (EN) wiring for a short circuit condition.
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From To Value
A. If there is continuity, there is a short circuit in the throttle valve actuator Z-9001 engine harness (EN) h-bridge
circuit. Locate and repair the shorted conductor.
5. Check the throttle valve actuator Z-9001 vehicle harness (VE) h-bridge circuit for a short to high source condition.
From To Value
A. If there is continuity, there is a short to high source in the throttle valve actuator Z-9001 vehicle harness (VE)
h-bridge circuit. Use the appropriate service manual, if necessary, to locate and repair the shorted conductor.

has been resolved.
operation.
(55.100.DP-C.20.E.05)
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3821-Throttle valve actuator H-bridge control circuit shorted to

battery
Context:
circuits. If the ECU A-9000 detects a short to high source condition in the throttle valve actuator Z-9001 output 1
h-bridge circuit, this fault will occur.
Cause:
The ECU A-9000 has detected a short to high source condition in the throttle valve actuator Z-9001 output 1 h-bridge
circuit.
1. Faulty throttle valve actuator Z-9001 wiring, short to a voltage source.

Solution:
2. Check the throttle valve actuator Z-9001 output 1 h-bridge wiring for a short to battery condition.
(EN) side :
From To Value
A. If there is voltage, there is a short to battery in the throttle valve actuator Z-9001 output 1 h-bridge circuit. Use
the appropriate service manual if necessary, to locate and repair the shorted conductor.
3. Check the throttle valve actuator Z-9001 engine harness (EN) wiring for a short to high source condition.
(EN) side :
From To Value
A. If there is continuity, there is a short to high source in the throttle valve actuator Z-9001 output 1 h-bridge circuit.
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4. Check the throttle valve actuator Z-9001 vehicle harness (VE) wiring for a short to high source condition.
(VE) side :
From To Value

has been resolved.
operation.
(55.100.DP-C.20.E.05)
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battery
Context:
The Engine Control Unit (ECU) A-9000 monitors the throttle valve actuator Z-9001 output 1and output 2 h-bridge
circuits. If the ECU A-9000 detects a short to high source condition in the throttle valve actuator Z-9001 output 2
h-bridge circuit, this fault will occur.
Cause:
The ECU A-9000 has detected a short to high source condition in the throttle valve actuator Z-9001 output 2 h-bridge
circuit.

Solution:
2. Check the throttle valve actuator Z-9001 output 2 h-bridge wiring for a short to battery condition.
Disconnect the vehicle harmess (VE) from the ECU A-9000 at connector X-9121.
(EN) side :
From To Value
A. If there is voltage, there is a short to battery in the throttle valve actuator Z-9001 output 2 h-bridge circuit. Use
the appropriate service manual if necessary, to locate and repair the shorted conductor.
3. Check the throttle valve actuator Z-9001 engine harness (EN) wiring for a short to high source condition.
(EN) side :
From To Value
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4. Check the throttle valve actuator Z-9001 vehicle harness (VE) wiring for a short to high source condition.
(VE) side :
From To Value

has been resolved.
operation.
(55.100.DP-C.20.E.05)
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ground
Context:
circuits. If the ECU A-9000 detects a short to ground condition in the throttle valve actuator Z-9001 output 1 h-bridge
Cause:
The ECU A-9000 has detected a short to ground condition in the throttle valve actuator Z-9001 output 1 h-bridge
circuit.

Solution:
2. Check the throttle valve actuator Z-9001 output 1 h-bridge engine harness (EN) wiring for a short to ground con-
dition.
Disconnect the throttle valve actuator Z-9001 connector X-9011.
(EN) side :
From To Value
A. If there is continuity, there is a short circuit in the throttle valve actuator Z-9001 output 1 h-bridge circuit. Use
3. Check the throttle valve actuator Z-9001 output 1 h-bridge vehicle harness (VE) wiring for a short to ground con-
dition.
(VE) side of the connector from :
From To Value
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has been resolved.
operation.
(55.100.DP-C.20.E.05)
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ground
Context:
circuits. If the ECU A-9000 detects a short to ground condition in the throttle valve actuator Z-9001 output 2 h-bridge
Cause:
The ECU A-9000 has detected a short to ground condition in the throttle valve actuator Throttle valve actuator H-bridge
control circuit shorted to ground output 2 h-bridge circuit.

Solution:
2. Check the throttle valve actuator Z-9001 output 2 h-bridge engine harness (EN) wiring for a short to ground con-
dition.
(EN) side :
From To Value
B. If there is no continuity, leave connector X-9011 and X-9138 disconnected and continue to Step 3.
3. Check the throttle valve actuator Z-9001 output 2 h-bridge vehicle harness (VE) wiring for a short to ground con-
dition.
(VE) side :
From To Value
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has been resolved.
operation.
(55.100.DP-C.20.E.05)
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3825-Throttle valve actuator control circuit over load

Context:
circuits. The ECU A-9000 monitors both circuits for a short circuit condition. If the ECU A-9000 determines that the
output 1 circuit and output 2 circuits are shorted together, this fault will occur.
Cause:
The ECU A-9000 has detected a short circuit between the throttle valve actuator Z-9001 output 1 and output 2 h-bridge
circuits.
1. Faulty throttle valve actuator Z-9001 h-bridge wiring short circuit.

Solution:
2. Check the throttle valve actuator Z-9001 h-bridge circuits engine harness (EN) wiring for a short circuit.
(EN) side :
From To Value
A. If there is continuity, there is a short circuit in the throttle valve actuator Z-9001 h-bridge wiring. Locate and
B. If there is no continuity, leave the connectors disconnected and continue to Step 3.

3. Check the throttle valve actuator Z-9001 h-bridge circuits vehicle harness (VE) wiring for a short circuit.
(VE) side :
From To Value
A. If there is continuity, there is a short circuit in the throttle valve actuator Z-9001 h-bridge wiring. Use the appro-
priate service manual, if necessary, to locate and repair the shorted conductor.
B. If there is no continuity, leave the connectors disconnected and continue to Step 4.

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has been resolved.
operation.
(55.100.DP-C.20.E.05)
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3827-Throttle valve actuator control circuit supply voltage too low

Context:
control circuit for the Throttle Valve Actuator (TVA) Z-9001 motor actuator for electrical defects. If the ECU A-9000
senses too low an output driver supply voltage, this fault will occur.
Cause:
The ECU A-9000 is sensing too high a system voltage fluctuation.
Solution:
A. If the fault is present and active, continues with Step 2.
2. Check for related faults.
Use the EST to check for faults relative to low battery, control system voltage level or throttle valve actuator Z-9001.
A. If low voltage level faults are present, resolve those faults and then return to this fault.
B. If no low voltage level faults are present, continue with Step 3.


or broken wires. Verify that the connectors are fully installed.
has been resolved.
operation.
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3834-Throttle valve actuator position sensor voltage is higher than

expected
Context:
The Engine Control Unit (ECU) A-9000 monitors the throttle valve actuator Z-9001 position sensor signal circuit. If the
ECU A-9000 detects a voltage greater than 4.75 V in the throttle valve actuator Z-9001 position sensor signal circuit,
Cause:
The ECU A-9000 has detected a voltage greater than 4.75 V in the throttle valve actuator Z-9001 position sensor
signal circuit.

Solution:
2. Check the throttle valve actuator Z-9001 position sensor wiring for a short to battery condition.
(EN) side :
From To Value
A. If there is voltage, there is a short to battery in the throttle valve actuator Z-9001 position sensor signal circuit.
Use the appropriate service manual if necessary, to locate and repair the shorted conductor.
B. If there is no voltage, leave connectors X-9011, X-9138, and X-9121 disconnected. Then, continue to Step 3.
3. Check the throttle valve actuator Z-9001 position sensor wiring for an open circuit.
With the key in the OFF position, use a multimeter to perform the following continuity check on the harness side :
From To Value
A. If there is no continuity, there is an open circuit in the throttle valve actuator Z-9001 position sensor signal
circuit. Use the appropriate service manual if necessary, to locate and repair the broken conductor.
B. If there is continuity, continue to Step 4.
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4. Check the throttle valve actuator Z-9001 position sensor engine harness (EN) wiring for a short to high source
condition.
(EN) side :
From To Value
A. If there is continuity, there is a short to high source in the throttle valve actuator Z-9001 engine harness (EN)
position sensor signal circuit. Locate and repair the shorted conductor.

5. Check the throttle valve actuator Z-9001 position sensor vehicle harness (VE) wiring for a short to high source
condition.
(VE) side :
From To Value
A. If there is continuity, there is a short to high source in the throttle valve actuator Z-9001 position sensor signal
circuit in the vehicle harness (VE).Use the appropriate service manual, if necessary, to locate and repair the
shorted conductor.

has been resolved.
operation.
(55.100.DP-C.20.E.05)
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3835-Throttle valve actuator position sensor voltage is lower than

expected
Context:
The Engine Control Unit (ECU) A-9000 monitors the throttle valve actuator Z-9001 position sensor signal circuit. If
the ECU A-9000 detects a voltage less than 0.25 V in the throttle valve actuator Z-9001 position sensor signal circuit,
Cause:
The ECU A-9000 has detected a voltage less than 0.25 V in the throttle valve actuator Z-9001 position sensor signal
circuit.

Solution:
2. Check the throttle valve actuator Z-9001 position sensor engine harness (EN) wiring for a short to ground condition.
(EN) side :
From To Value
A. If there is continuity, there is a short to ground condition in the throttle valve actuator Z-9001 position sensor
signal circuit in the engine harness (EN).Locate and repair the shorted conductor.
3. Check the throttle valve actuator Z-9001 position sensor vehicle harness (VE) wiring for a short to ground condition.
(VE) side :
From To Value
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A. If there is continuity, there is a short to ground in the throttle valve actuator Z-9001 position sensor signal circuit
conductor.

has been resolved.
operation.
(55.100.DP-C.20.E.05)
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3838-Oxidation catalyst upstream temperature shorted to high

source
Context:
The Engine Control Unit (ECU) A-9000 monitors the Diesel Oxidation Catalyst (DOC) inlet temperature sensor B-9127.
If the ECU A-9000 detects a voltage greater than 3.59 V in the diesel oxidation catalyst inlet temperature sensor
B-9127 signal circuit, this fault will occur.
Cause:
The ECU A-9000 has detected a voltage greater than 3.59 V in the diesel oxidation catalyst inlet temperature sensor
B-9127 signal circuit. For more information regarding the technical specifications of the DOC inlet temperature sensor
B-9127, refer to the engine service manual Exhaust Gas Recirculation (EGR) temperature sensors - Technical
Data (55.989).
1. Faulty diesel oxidation catalyst inlet temperature sensor B-9127 wiring, short to voltage source.
2. Faulty diesel oxidation catalyst inlet temperature sensor B-9127 wiring, open circuit.
3. Faulty diesel oxidation catalyst inlet temperature sensor B-9127, internal failure.
Solution:
2. Check the diesel oxidation catalyst inlet temperature sensor B-9127 for an internal failure.
Disconnect the engine harness (EN) from the diesel oxidation catalyst inlet temperature sensor B-9127 at con-
nector X-9127.
Use a multimeter to measure the resistance on the diesel oxidation catalyst inlet temperature sensor B-9127 :
From To Value
849.7 Ω.
B. If there is not between 170.2 - 849.7 Ω, the diesel oxidation catalyst inlet temperature sensor B-9127 has failed.
Replace the diesel oxidation catalyst inlet temperature sensor B-9127.
3. Check the diesel oxidation catalyst inlet temperature sensor B-9127 vehicle harness (VE) wiring for a short circuit.
side :
From To Value
A. If there is voltage, there is a short to battery in the diesel oxidation catalyst inlet temperature sensor B-9127
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4. Check the diesel oxidation catalyst inlet temperature sensor B-9127 vehicle harness (VE) wiring for an open circuit
condition.
(VE) side :
From To Value
A. If there is no continuity, there is an open circuit in the diesel oxidation catalyst inlet temperature sensor B-9127
vehicle harness (VE) wiring. Use the appropriate service manual, if necessary, to locate and repair the broken
conductor.

5. Check the diesel oxidation catalyst inlet temperature sensor B-9127 vehicle harness (VE) wiring for a short circuit
condition.
(VE) side of the connectors from :
From To Value
A. If there is continuity, there is a short circuit in the diesel oxidation catalyst inlet temperature sensor B-9127
conductor.
has been resolved.
operation.
(55.100.DP-C.20.E.03)
(55.100.DP-C.20.E.04)
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3839-Oxidation catalyst upstream temperature shorted to low

source
Context:
The Engine Control Unit (ECU) A-9000 monitors the Diesel Oxidation Catalyst (DOC) inlet temperature sensor B-9127.
If the ECU A-9000 detects a voltage less than 459.40 mV in the diesel oxidation catalyst inlet temperature sensor
B-9127 signal circuit, this fault will occur.
Cause:
The ECU A-9000 has detected a voltage less than 459.40 mV in the diesel oxidation catalyst inlet temperature sensor
B-9127 signal circuit. For more information regarding the technical specifications of the DOC inlet temperature sensor
B-9127, refer to the engine service manual Exhaust Gas Recirculation (EGR) temperature sensors - Technical
Data (55.989).
1. Faulty diesel oxidation catalyst inlet temperature sensor B-9127 wiring, short circuit to ground.
2. Faulty diesel oxidation catalyst inlet temperature sensor B-9127, internal failure.
Solution:
2. Check the diesel oxidation catalyst inlet temperature sensor B-9127 for an internal failure.
Disconnect the engine harness (EN) from the diesel oxidation catalyst inlet temperature sensor B-9127 at con-
nector X-9127.
Use a multimeter to measure the resistance on the diesel oxidation catalyst inlet temperature sensor B-9127 :
From To Value
849.7 Ω.
B. If there is not between 170.2 - 849.7 Ω, the diesel oxidation catalyst inlet temperature sensor B-9127 has failed.
Replace the diesel oxidation catalyst inlet temperature sensor B-9127.
condition.
Disconnect the engine harness from the diesel oxidation catalyst inlet temperature sensor B-9127 at connector
X-9127.
(VE) side :
From To Value
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conductor.
B. If there is no continuity, leave the connector X-9127 disconnected and continue to Step 4.
condition.
(VE) side :
From To Value
conductor.
has been resolved.
operation.
(55.100.DP-C.20.E.03)
(55.100.DP-C.20.E.04)
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3842-Turbine upstream temperature sensor shorted to high source

Context:
detects a voltage greater than 3.59 V in the exhaust manifold temperature sensor B-9018 signal circuit, this fault will
occur. The sensor value will be frozen at the last valid value for a preliminary failure or jump to a fixed replacement
value of 350 °C (662 °F) if the failure is validated. For more information regarding the technical specifications of the
exhaust manifold temperature sensor B-9018, refer to the engine service manual Exhaust manifold temperature
sensor - Technical Data (55.014).
Cause:
The ECU A-9000 has detected a voltage greater than 3.59 V in the exhaust manifold temperature sensor B-9018
signal circuit.
1. Faulty exhaust manifold temperature sensor B-9018 circuit wiring, shorted to a voltage source.
2. Faulty exhaust manifold temperature sensor B-9018 circuit wiring, open circuit.
3. Faulty exhaust manifold temperature sensor B-9018, internal failure.
Solution:
2. Check the exhaust manifold temperature sensor B-9018 for an internal failure.
Disconnect the engine harness (EN) from the exhaust manifold temperature sensor B-9018 at connector X-9009.
Use a multimeter to measure the resistance on the exhaust manifold temperature sensor B-9018 pins :
From To Value
849.7 Ω.
B. If there is not between 170.2 - 849.7 Ω, the exhaust manifold temperature sensor B-9018 has failed. Replace
the exhaust manifold temperature sensor B-9018.
3. Check the exhaust manifold temperature sensor B-9018 engine harness (EN) wiring.
(EN) side :
From To Value
(EN) side :
From To Value
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A. If the specified values are not measured, there is a short to battery condition in the exhaust manifold tempera-
ture sensor B-9018 signal circuit wiring. Use the appropriate service manual, if necessary, to locate and repair
the damaged conductors.
4. Check the exhaust manifold temperature sensor B-9018 circuit wiring for an open circuit condition.
Disconnect the vehicle harness (VE) from the engine interface connector at connector X-9138.
(EN) side :
From To Value
(VE) side :
From To Value
A. If there is no continuity, there is an open circuit in the exhaust manifold temperature sensor B-9018 signal circuit
B. If there is continuity on both checks, leave connector X-9138 and connector X-9121 disconnected and continue
to Step 5.
With the key in the OFF position, use a multimeter to perform the following continuity check at the engine harness
(EN) side :
From To Value
A. If there is continuity, there is a short to a voltage source condition in the exhaust manifold temperature sensor
B-9018 signal circuit in the engine harness (EN) wiring. Locate and repair the shorted conductor.

6. Check the exhaust manifold temperature sensor B-9018 vehicle harness (VE) wiring.
(VE) side :
From To Value
A. If there is continuity, there is a short to voltage source condition in the exhaust manifold temperature sensor
B-9018 signal circuit in the vehicle harness (VE) wiring. Use the appropriate service manual, if necessary, to
locate and repair the damaged conductors.
B. If there is no continuity, Check the ECU A-9000 software and re-flash, if necessary.
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has been resolved.
operation.
(55.100.DP-C.20.E.05)
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3843-Turbine upstream temperature sensor : SRC low for turbine

upstream temperature sensor
Context:
detects a voltage less than 0.45 V in the exhaust manifold temperature sensor B-9018 signal circuit, this fault will
occur. The sensor value will be frozen at the last valid value for a preliminary failure or jump to a fixed replacement
value of 350 °C (662 °F) if the failure is validated.
Cause:
The ECU A-9000 has detected a voltage less than 0.45 V in the exhaust manifold temperature sensor B-9018 sig-
nal circuit. For more information regarding the technical specifications of the exhaust manifold temperature sensor
B-9018, refer to the engine service manual Exhaust manifold temperature sensor - Technical Data (55.014).
1. Faulty exhaust manifold temperature sensor B-9018 wiring, short circuit to ground.
2. Faulty exhaust manifold temperature sensor B-9018, internal failure.
Solution:
2. Check the exhaust manifold temperature sensor B-9018 for an internal failure.
Disconnect the engine harness (EN) from the exhaust manifold temperature sensor B-9018 at connector X-9009.
Use a multimeter to measure the resistance on the exhaust manifold temperature sensor B-9018 pins :
From To Value
849.7 Ω.
B. If there is not between 170.2 - 849.7 Ω, the exhaust manifold temperature sensor B-9018 has failed. Replace
the exhaust manifold temperature sensor B-9018.
(EN) side :
From To Value
A. If there is continuity , there is a short circuit in the exhaust manifold temperature sensor B-9018 signal circuit
in the engine harness (EN) wiring. Locate and repair the shorted conductor.
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4. Check the exhaust manifold temperature sensor B-9018 vehicle harness (VE) wiring.
(VE) side :
From To Value
A. If there is continuity, there is a short circuit in the exhaust manifold temperature sensor B-9018 signal circuit
in the vehicle harness (VE) wiring. Use the appropriate service manual, if necessary, to locate and repair the
shorted conductor.
has been resolved.
operation.
(55.100.DP-C.20.E.05)
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3844-Zero fuel calibration by lambda (ZFL) : DFC reporting error

state on comparing energizing time to max value injector 1
Context:
The Zero Fuel Calibration (ZFL) evaluates energizing time for injectors at low idle. The ZFL uses learned calibration
values to change the energizing time of the pilot fuel injection. If the Engine Control Unit (ECU) A-9000 determines
that there is an error during this process, this fault will occur.
Cause:
The ECU A-9000 has determined that there is an error in the ZFL process for fuel injector number 1 Y-9001.
Solution:
1. Verify that the correct IMA injector code has been programmed to injector number 1.
A. If the correct IMA code is present, continue to Step 2.
B. If the correct IMA code has not been uploaded, program the correct IMA code.
2. Replace the fuel injector number 1 Y-9001.
Use the Electronic Service Tool (EST) to verify the status of this fault.
B. If the fault has not been resolved, continue to Step 3.

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Context:
Cause:
Solution:

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Context:
Cause:
Solution:
Use the Electronic Service Tool (EST) to verify the status of this fault, 3846 - Zero fuel calibration by lambda
(ZFL) : DFC reporting error state on comparing energizing time to max value injector 3.

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Context:
Cause:
Solution:
(ZFL) : DFC reporting error state on comparing energizing time to max value injector 4.

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state on comparing energizing time to min value injector 1
Context:
Cause:
Solution:

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Context:
Cause:
Solution:

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Context:
Cause:
Solution:
(ZFL) : DFC reporting error state on comparing energizing time to min value injector 3.

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Context:
Cause:
Solution:
(ZFL) : DFC reporting error state on comparing energizing time to min value injector 4.

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3899-Engine Protection : Engine temperature reaches prewarning

level
Context:
The Engine Control Unit (ECU) A-9000 monitors the engine coolant temperature. Two engine temperature thresholds
are monitored by the ECU A-9000, a pre-warning, and a warning. If the ECU A-9000 monitors a temperature greater
than 107.96 °C (226.33 °F), a pre-warning is set and this fault will occur. For more information regarding cooling
system troubleshooting, refer to the engine service manual Engine cooling system - Troubleshooting (10.400).
Cause:
A coolant temperature level pre-warning has been set by the ECU A-9000.
1. Coolant level low.

2. Faulty cooling system, leakage or blockage.
3. Extremely high environmental temperature or heavy machine use.
4. Faulty coolant temperature sensor B-9003, wiring or internal failure of sensor.
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3900-Info: Engine temperature exceeded warn level

Context:
The Engine Control Unit (ECU) A-9000 monitors the engine coolant temperature. Two engine temperature thresholds
are monitored by the ECU A-9000, a pre-warning, and a warning. If the ECU A-9000 monitors a temperature greater
than 111.96 °C (233.53 °F), a warning is set and this fault will occur. For more information regarding cooling system
troubleshooting, see Engine cooling system - Troubleshooting (10.400) in the engine service manual.
Cause:
A coolant temperature level warning has been set by the ECU A-9000.
1. Coolant level low.

2. Faulty cooling system, leakage or blockage.
3. Extremely high environmental temperature or heavy machine use.
4. Faulty coolant temperature sensor B-9003, wiring or internal failure of sensor.
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3906-Injector: Number of injections is limited by quantity balance

of high pressure pump
Context:
The Engine Control Unit (ECU) A-9000 monitors the requested number of fuel injections and the current capability
of the fuel injection system to fulfill that request. If the ECU A-9000 determines that the requested number of fuel
injections can not be reached, this fault will occur.
Cause:
The ECU A-9000 has determined that the requested number of fuel injections is greater than the current capability of
the fuel injection system.
Solution:
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3910-Fuel Metering Unit : Intermittent contact between ECU and

MeUn
Context:
The Engine Control Unit (ECU) A-9000 monitors the fuel metering unit Y-9000 signal circuit. If the ECU A-9000 detects
an intermittent connection in the fuel metering unit Y-9000 signal circuit, this fault will occur.
Cause:
The ECU A-9000 has detected a intermittent connection in the fuel metering unit Y-9000 signal circuit.
1. Faulty fuel metering unit Y-9000 wiring, open circuit.

Solution:
From To Value
Y-9000.
3. Check the fuel metering unit Y-9000 engine harness (EN) wiring for an open circuit.
(EN) side :
From To Value
tion.
A. If there is continuity, leave connector X-9138 disconnected and continue to Step 4.
B. If there is no continuity, there is an open circuit condition in the fuel metering unit Y-9000 engine harness (EN)
wiring. Locate and repair the broken conductor.
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4. Check the fuel metering unit Y-9000 vehicle harness (VE) wiring for an open circuit.
(VE) side :
From To Value
tion.
A. If there is no continuity, there is an open circuit condition in the fuel metering unit Y-9000 vehicle harness (VE)
wiring. Use the appropriate service manual, if necessary, to locate and repair the broken conductor.
has been resolved.
operation.
(55.100.DP-C.20.E.05)
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3915-Pressure Relief Valve: Averaged rail pressure is outside the

expected range with open PRV
Context:
The Engine Control Unit (ECU) A-9000 monitors fuel rail pressure using the rail pressure sensor B-9004. After a fuel
pressure evaluation, if the ECU A-9000 suspects that the Pressure Relief Valve (PRV) should be open but has not
opened, this fault occur. If this fault is active, the ECU A-9000 has performed step one for achieving limp home mode,
a fuel pressure increase. Other active faults may have caused this fault to occur. For more information regarding fuel
system troubleshooting, refer to the engine service manual Fuel injection system - Troubleshooting (10.218).
Cause:
The ECU A-9000 has determined that the PRV should be open but is not open.
1. Faulty PRV, unable to open or partially open.

2. Faulty PRV fuel back-flow, clogged or damaged.
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3916-Pressure Relief Valve: Open time of PRV for wear out

monitoring had exceeded maximum value
Context:
The Engine Control Unit (ECU) A-9000 monitors the fuel Pressure Relief Valve (PRV). If the ECU A-9000 determines
that the PRV has been open for too long, this fault will occur. The PRV opening duration is monitored by the ECU
A-9000 and stored in the EEPROM during after run. This fault is for informational purposes only. If this fault is active,
other fuel system faults may be active that caused this fault to occur. Diagnose any faults that may have caused
this one to occur first, and then return to this fault, 3916 - Pressure Relief Valve: Open time of PRV for wear out
monitoring had exceeded maximum value. For more information regarding fuel system troubleshooting, refer to
the engine service manual Fuel injection system - Troubleshooting (10.218).
Cause:
The ECU A-9000 has determined that the PRV has reached its maximum allowed open time.
1. Faulty PRV, stuck open or worn.

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3978-Level 2 of PFlt Overloaded

Context:
The Engine Control Unit (ECU) A-9000 monitors the Particulate Matter Catalytic Converter (PMcat) soot load level.
If the ECU A-9000 determines that the soot load level is high, this fault will occur. If this fault is active, it may be
necessary to use the Electronic Service Tool (EST) to perform a service regeneration.
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3979-Level 3 of PFlt Overloaded

Context:
The Engine Control Unit (ECU) A-9000 monitors the Particulate Matter Catalytic Converter (PMcat) soot load level. If
the ECU A-9000 determines that the soot load level is very high, this fault will occur. If this fault is active, it may be
necessary to use the Electronic Service Tool (EST) to perform a service regeneration.
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3993-EGR valve will not close during after run

Context:
The Engine Control Unit (ECU) A-9000 monitors the position of the Exhaust Gas Recirculation (EGR) valve Z-9000 by
monitoring the potentiometer feedback voltage. During after run, the EGR valve Z-9000 will open and close in attempt
to remove any build-up from the valve seat. If during after run, the ECU A-9000 determines that the feedback voltage
is not within the desired range 0.5 s after full closure, this fault will occur. For information regarding the functional
operation of the Exhaust Gas Recirculation (EGR) valve Z-9000, refer to the engine service manual Exhaust Gas
Recirculation (EGR) valve - Overview (10.501). For more information regarding the technical specifications of the
EGR valve Z-9000, refer to the engine service manual Exhaust Gas Recirculation (EGR) valve actuator - Technical
Data (55.989).
Cause:
The ECU A-9000 has detected an EGR valve Z-9000 actuator feedback voltage outside of the 0.75 - 1.30 V range
for the closed position.
1. Faulty EGR valve Z-9000, dirt or debris on valve seat, requires cleaning.
2. Faulty EGR valve Z-9000, blocked or mechanically damaged, does not fully close.
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9003-J1939 Receive Buffer Overflow

Cause:
1. Internal failure within the instrument cluster.
Solution:
A. Fault code 9003 - J1939 Receive Buffer Overflow is recorded again. Replace instrument cluster. Return to
step 1 to confirm elimination of the fault.
B. The fault code is not recorded again. OK to return the machine to service.
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9004-EEPROM Checksum Failure, Hourmeter Location 1

Cause:
Solution:
A. Fault code 9004 - EEPROM Checksum Failure, Hourmeter Location 1 is recorded again. Replace the in-
strument cluster. Return to step 1 to confirm elimination of the fault.
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Cause:
Solution:
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Cause:
Solution:
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9007-Abnormal Reset Watchdog Timeout

Cause:
Solution:
A. Fault code 9007 - Abnormal Reset Watchdog Timeout is recorded again. Replace the instrument cluster.
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9012-Analog To Digital Fault Fuel Level

586H
588H
Cause:
Solution:
A. Fault code 9012 - Analog To Digital Fault Fuel Level is recorded again. Replace the instrument cluster.
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9401-Repair Double Redundant Memory

Cause:
Solution:
A. Fault code 9401 - Repair Double Redundant Memory is recorded again. Replace the instrument cluster.
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9403-Memory Error - Double Redundant Memory - Unrecoverable

Memory Corruption Operable
Cause:
Solution:
A. Fault code 9403 - Memory Error - Double Redundant Memory - Unrecoverable Memory Corruption Op-
erable is recorded again. Replace the instrument cluster. Return to step 1 to confirm elimination of the fault.
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9404-Memory Error - Triple Redundant - Hour Meter Failure

Cause:
Solution:
A. Fault code 9404 - Memory Error - Triple Redundant - Hour Meter Failure is recorded again. Replace the
instrument cluster. Return to step 1 to confirm elimination of the fault.
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17105-Turbo protection cold start detection

Context:
This fault is for information purposes only and does not require any action. The recognition of a cold start condition
is provided by the turbocharger protection speed limitation module. The Engine Control Unit (ECU) A-9000 will limit
the number of engine revolutions until the engine oil pressure has reached a calibrated threshold.
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17513-PMCat inlet temperature sensor physical range check high

Context:
The Engine Control Unit (ECU) A-9000 monitors the Particulate Matter (PM) catalytic converter inlet temperature sen-
sor B-9126. If the ECU A-9000 detects a temperature greater than 1000 °C (1832 °F) from the PM catalytic converter
inlet temperature sensor B-9126, this fault will occur. Other active faults may have caused this fault to occur.
Cause:
The ECU A-9000 has detected a temperature too high from the PM catalytic converter inlet temperature sensor
B-9126.
1. PM catalytic converter temperature too high.

2. Faulty PM catalytic converter inlet temperature sensor B-9126.
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17514-TSC1 message checksum/counter error

Context:
The Engine Control Unit (ECU) monitors Controller Area Network (CAN) communication by performing a CAN bus
data check. If the ECU A-9000 detects a failure during this check, this fault will occur.
Solution:
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Index
FAULT CODES - DTC

1001-Air Filter Blockage Detected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1002-Coolant Temperature Above Normal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1004-Hydraulic Filter Blockage Detected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1009-Transmission Oil Temperature Is Too High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1010-Foot Throttle Sensor Signal Not Plausible . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
1011-Foot Throttle Sensor Signal Above Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
1012-Foot Throttle Sensor Signal Below Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
1013-Foot Throttle Sensor Signal Error - No Signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
1014-VCM Battery Voltage Is Too High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
1015-VCM Battery Voltage Is Too Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
1018-Boost Air Temperature Is Above Operating Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
1019-Engine Coolant Is Above Operating Temperature (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
1020-Transmission Oil Is Above Operating Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
1021-Fuel Is Above Operating Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
1022-Water In Fuel Detected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
1024-Foot Throttle Supply Voltage Is Too Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
1026-Foot Throttle Supply Voltage Is Shorted To Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
1030-Foot Throttle Sensor Is Shorted To Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
1040-Engine RPM > 2750 for 5 seconds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
1041-Engine RPM > 3000 for 5 seconds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
1044-Fuel Level Sensor Shorted To Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
1045-Fuel Level Sensor - Open Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
1047-Transmission Temperature Sensor is Shorted Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
1048-Transmission Temperature Sensor - Open Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
1050-Alternator Unable To Charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
1051-Expected CAN Message Not Received (EEC1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
1052-Expected CAN Message Not Received (EEC3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
1053-Expected CAN Message Not Received (EC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
1054-Expected CAN Message Not Received (Engine Temperature) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
1055-Expected CAN Message Not Received (Inlet/Exhaust) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
1056-Expected CAN Message Not Received (Engine Fluid) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
1057-Expected CAN Message Not Received (Vehicle/Electrical) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
1058-Expected CAN Message Not Received (EDC2BC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
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1059-Expected CAN Message Not Received (DM1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
1060-Timeout Of CAN Message EGRIND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
1090-Vehicle Model ID in VCM is UNCONFIGURED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
17105-Turbo protection cold start detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 455
17513-PMCat inlet temperature sensor physical range check high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 456
17514-TSC1 message checksum/counter error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 457
3007-Engine coolant temperature sensor voltage is higher than expected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
3008-Coolant Temperature Signal - Signal Below Range Minimum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
3010-Air Intake Temperature Sensor - Signal Above Range Maximum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
3011-Air Intake Temperature Sensor - Signal Above Range Minimum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
3015-Fuel Temperature Sensor - Signal Above Range Maximum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
3016-Fuel Temperature Sensor - Signal Below Range Minimum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
3019-Boost Pressure Sensor - Signal Above Range Max . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
3024-Atmospheric Pressure Sensor - Signal Above Range Maximum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
3025-Atmospheric Pressure Sensor - Signal Below Range Minimum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
3027-Oil pressure switch failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
3037-Boost Pressure Sensor - Signal Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
3059-ECU Main Relay: Stuck Main Relay Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
3061-Cylinder1 - Short circuit Low/High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
3063-Cylinder 1 - Injector Cable Short Circuit (High Side To Ground) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
3088-Crankshaft Sensor - No Signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
3089-Crankshaft Sensor - Invalid Signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
3090-Camshaft Sensor Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
3091-Camshaft Sensor Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
3093-Camshaft Sensor : Camshaft offset angle exceeded . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
3096-ECM Busoff on vehicle CAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
3102-Rail Pressure Sensor CP3 - Signal Below Range Minimum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
3104-Rail Pressure Relief Valve - Open Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
3105-Rail Pressure Relief Valve - Pressure Shock Requested . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
3106-Pressure Relief valve: pressure relief valve is open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
3108-Fuel Metering Unit - Short Circuit to Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
3112-Rail Pressure Sensor CP3 - Signal Above Maximum Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
3137-Metering Unit - Open Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
3141-Fuel Metering Unit : leakage is detected based on fuel quantity balance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
3146-Water detected in fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
3169-Fuel filter heater ECU driver has an over temperature error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
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3176-High pressure pump fuel delivery quantity in over run exceeds a maximum threshold . . . . . . . . . . . . . . . . 164
3177-Engine Protection : Over speed detection in component engine protection . . . . . . . . . . . . . . . . . . . . . . . . . . 165
3179-Timeout of CAN Message BC2EDC2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
3180-CAN communication error between vehicle controller to ECU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
3188-Injector Cylinder 1 Warning - Open Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
3210-Bank 1 - General Short Circuit On Injector Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
3218-Bank 2 - General Short Circuit On Injector Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
3230-Injection Processor (CY33X) Error - SPI Communication Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
3235-Injection control: Number of injections is limited by runtime . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
3236-Injection control : Number of injections is limited by quantity balance of high pressure pump . . . . . . . . . . 184
3237-Injection control : Number of desired injections exceeds threshold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
3238-ECM Internal SPI Communication Error - CJ940 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
3239-Error state of Electrically Erasable Programmable Read-Only Memory (EEPROM) . . . . . . . . . . . . . . . . . . . 188
3241-EEPROM : There was an error during Write/Read EEPROM operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
3242-ECU internal : Visibility of Software Resets in DSM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
3243-ECU internal : Visibility of Software Resets in DSM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
3244-ECU internal failure - Software resets in DSM 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
3245-ECM Processor - Watchdog Not Plausible . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
3252-Controller Watchdog - SPI Communication Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
3253-ADC Monitoring - Reference Voltage Too High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
3255-ADC Monitoring Test Impulse Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
3256-ADC Monitoring Queue Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
3258-ECU Power stages : Starter relay HS power stage output short circuit to battery . . . . . . . . . . . . . . . . . . . . . 198
3259-ECU Power stages : Starter relay HS power stage output short circuit to ground . . . . . . . . . . . . . . . . . . . . . 200
3260-Low side power - open load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
3261-Low side power - short circuit to battery or excess temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
3262-Low side power - short circuit to ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
3265-Overrun Monitoring - Injection Time Too Long . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
3266-Redundent Engine Speed in Overrun Monitoring - Speed Signal Not Plausible . . . . . . . . . . . . . . . . . . . . . . 209
3283-Engine regulated 5 Volt sensor supply #2 - Shorted to high source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
3285-Sensor Supply Voltage 3 - High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
3293-Fuel Metering Unit: maximum positive deviation of rail pressure exceeded . . . . . . . . . . . . . . . . . . . . . . . . . . 214
3301-Fuel metering unit: Maximum negative rail pressure deviation with metering unit on lower limit is exceeded
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
3305-Fuel metering unit: Minimum rail pressure exceeded . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
3309-Fuel metering unit: Maximum rail pressure exceeded . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
3334-Timeout of CAN message TSC1-PE torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
3335-Timeout of CAN message TSC1-PE torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
3338-Timeout of CAN message TSC1-VE Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
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3339-Timeout of CAN message TSC1-VE Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
3350-Terminal 50 - Always On . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226
3358-Engine sensor CAN bus failure (Engine controller can't transmit to sensors, or sensors not on CAN bus) 228
3361-EEPROM : EEP Erase Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230
3362-Engine internal calculations : DFC to report if the quantity axis points increase strictly linearly above the torque
axis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231
3368-Torque limitation caused by performance limiter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232
3369-Torque Reduction Due to Smoke Limitation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233
3370-Torque limitation due to engine protection (against excessive torque, engine overspeed and overheat) . 234
3371-Torque Limitation Due To Fuel Quantity Limitation Because Of Injector System Errors . . . . . . . . . . . . . . . . 235
3374-Injection Quantity Adjustment failure - Invalid EEPROM Adjustment Value Checksum . . . . . . . . . . . . . . . . 236
3402-Rail pressure sensor: maximum rail pressure exceeded . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237
3403-ECU Power Stages: Starter relay HS power stage over temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238
3405-Wastegate pressure modulator control circuit open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240
3406-Wastegate pressure modulator control circuit over temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242
3409-Engine oil pressure too low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244
3410-Throttle valve actuator will not open to commanded position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247
3411-Throttle valve actuator will not close to commanded position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248
3414-Array of DFCs for short circuit in i+1th Glow Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249
3418-Wastegate pressure modulator control circuit shorted to battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257
3419-Wastegate pressure modulator control circuit shorted to ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259
3425-Turbocharger: Over boost deviation at P2 too high in pressure charger regulator . . . . . . . . . . . . . . . . . . . . 261
3430-EGR Failure - Moderate Inducement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262
3431-EGR Failure - Severe Inducement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263
3432-EGR Failure - Mild Inducement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 264
3517-Ambient air temperature sensor failure (of humidity sensor) - signal too high . . . . . . . . . . . . . . . . . . . . . . . . 265
3518-Ambient temperature sensor voltage is lower than expected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267
3616-Torque limitation due to turbo charger protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269
3650-Battery voltage: SRC high for battery voltage sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270
3651-Battery voltage: SRC low for battery voltage sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271
3652-CAN Bus: Bus off of CAN node A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273
3655-Torque limitation, Engine protection: General report of the event of torque limitations . . . . . . . . . . . . . . . . 275
3656-Torque limitation, Engine protection: Torque limitation caused by particulate filter . . . . . . . . . . . . . . . . . . . . 276
3657-Timeout Error of CAN-Receive-Frame CM1BC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277
3665-EGR valve will not open to commanded position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 279
3666-EGR valve will not close to commanded position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280
3667-EGR valve control circuit open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 281
3668-EGR valve control circuit over current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 283
3669-EGR valve H-bridge control circuit shorted to battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285
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3670-EGR valve H-bridge control circuit shorted to battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 287
3671-EGR valve H-bridge control circuit shorted to ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 289
3672-Short circuit to ground on EGR Out2 pin A35 error for H-bridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 291
3673-EGR valve control circuit over load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 293
3674-EGR valve control circuit supply voltage too low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 296
3676-EGR valve position sensor voltage is higher than expected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 297
3677-EGR valve position sensor voltage is lower than expected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 299
3680-Injection cut off: Injection cut off demand (ICO) for shut off coordinator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301
3684-Exhaust manifold temperature is higher than expected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 302
3688-Water in fuel sensor or sensor circuit failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303
3689-Faulty diagnostic data transmission or protocol error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 305
3692-Over temperature error on ECU power stage for glow plug low voltage system . . . . . . . . . . . . . . . . . . . . . . 307
3693-Short circuit to battery error for low voltage system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 309
3694-Glow plug control circuits shorted to ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 311
3699-ECU internal failure - EEPROM memory failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 313
3703-Injection control: check of minimum rail pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 314
3704-Injector adjustment programming: Check of missing injector adjustment value programming . . . . . . . . . . 315
3705-Injector adjustment programming: check of missing injector adjustment value programming . . . . . . . . . . . 316
3706-Injector adjustment programming: Check of missing injector adjustment value programming . . . . . . . . . . 317
3707-Lambda sensor circuit - Open circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 318
3708-Lambda sensor: Open circuit at the lambda sensor pump current pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 320
3709-Lambda sensor circuit - Open circuit at the virtual ground pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 322
3711-Lambda sensor heater circuit - Short circuit to battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 324
3712-Lambda sensor: SCG error of the LSU heater power stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 326
3713-Lambda sensor: Open Load error of the LSU Heater Power stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 328
3714-Lambda sensor: Fault code to indicate SRC High error for O2 calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . 330
3715-Lambda sensor : Fault code to indicate SRC Low error for O2 calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . 331
3716-Lambda sensor: O2 value above the maximum threshold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 332
3720-Lambda sensor: low battery voltage at the SPI chip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 334
3721-Lambda sensor: Fault check to indicate SPI chip error of lambda sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . 335
3722-LSU (oxygen) sensor temperature exceeds the maximum limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 336
3723-LSU (oxygen) sensor temperature is below the minimum limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 338
3724-Lambda sensor: Short to battery at IA, IP, UN, VG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 340
3725-Lambda sensor: Short to ground at IA, IP, UN, VG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 342
3727-Low oil viscosity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 344
3728-Too low oil viscosity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 345
3735-Fuel Metering Unit: over temperature of device driver of metering unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 346
3738-Analog Digital Converter (ADC): Diagnostic fault check to report multiple error while checking the complete
ROM memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 348
3739-Power stages, Injector: Loss of synchronization sending bytes to the MM from CPU . . . . . . . . . . . . . . . . . 349
3740-Injector power stages torque limitation error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 350
3741-Power stages, Injector: Wrong set response time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 351
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3742-Power stages, Injector: Too many SPI errors during MoCSOP execution . . . . . . . . . . . . . . . . . . . . . . . . . . . 352
3743-Injector power stage diagnostic fault check to report the error in under voltage monitoring . . . . . . . . . . . . 353
3744-Power stages, injector : Diagnostic fault check to report the error in over voltage monitoring . . . . . . . . . . 354
3745-Power stages, Injector : Diagnostic fault check to report that WDA is not working correct . . . . . . . . . . . . . 355
3746-Power stages, Injector : OS timeout in the shut off path test. Failure setting the alarm task period. . . . . . 356
3747-Power stages, Injector: Diagnostic fault check to report that the positive test failed . . . . . . . . . . . . . . . . . . . 357
3748-Power stages, Injector : Diagnostic fault check to report the timeout in the shutoff path test . . . . . . . . . . . 358
3750-Injection control: Error in the plausibility of the injection energizing time . . . . . . . . . . . . . . . . . . . . . . . . . . . . 359
3751-Injection control : Error in the plausibility of the start of energizing angles . . . . . . . . . . . . . . . . . . . . . . . . . . . 360
3752-Level 2 Monitoring: Error in the plausibility of the energizing times of the zero fuel quantity calibration . . 361
3753-Level 2 Monitoring : Diagnostic fault check to report the error due to Over heating . . . . . . . . . . . . . . . . . . . 362
3754-Level 2 Monitoring : Diagnostic fault check to report the plausibility error in rail pressure monitoring . . . . 363
3755-Level 2 Monitoring : Diagnostic fault check to report the error due to torque comparison . . . . . . . . . . . . . . 364
3756-Level 2 Monitoring : Diagnosis fault check to report the demand for normal mode due to an error in the PoI2
quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 365
3757-Level 2 Monitoring : Diagnosis fault check to report the error to demand for an ICO due to an error in the PoI2
shut-off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 366
3758-Level 2 Monitoring : Diagnosis fault check to report the error to demand for an ICO due to an error in the PoI3
efficiency factor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 367
3759-Level 2 Monitoring : Diagnosis of curr path limitation forced by ECU monitoring level 2 . . . . . . . . . . . . . . . 368
3760-Level 2 Monitoring : Diagnosis air path limitation due to a functional control unit monitoring forced by ECU
monitoring level 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 369
3761-Level 2 Monitoring : Diagnosis quantity path limitation due to a functional control unit monitoring (level 2) 370
3762-Level 2 Monitoring : Reported Overvoltage of Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 371
3763-Level 2 Monitoring : Reported under voltage of supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 372
3764-Main Relay: Early opening defect of main relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 373
3767-ECU internal : Diagnostic fault check to report 'WDA active' due to errors in query-/response communication
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 376
3768-ECU Internal : Diagnostic fault check to report 'ABE active' due to under voltage detection . . . . . . . . . . . . 377
3769-ECU Internal: Diagnostic fault check to report 'ABE active' due to overvoltage detection . . . . . . . . . . . . . . 378
3770-ECU internal: Diagnostic fault check to report 'WDA/ABE active' due to unknown reason . . . . . . . . . . . . . 379
3773-Turbocharger: Underboost detected in pressure charger regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 380
3794-Intake air pressure sensor: Plausibility check for air pressure at the upstream of intake valve sensor . . . 381
3795-Intake air pressure sensor: Plausibility check for air pressure at the upstream of intake valve sensor . . . 382
3799-Pressure Relief valve: pressure relief valve is forced to open, perform pressure shock . . . . . . . . . . . . . . . 383
3800-Pressure relief valve check if PRV opening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 384
3803-ECU internal : Error on R2S2 module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 385
3808-High pressure pump fuel delivery quantity at low idle is too high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 386
3810-Fuel pressure sensor: Rail pressure raw value is intermittent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 387
3811-ECU internal failure - Sensor 5 volt supply 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 389
3812-Physical range check high for ECU temperature sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 395
3813-Physical range check low for ECU temperature sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 396
3814-ECU temperature sensor: SPI error ECU temperature sensor (LM71) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 397
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3818-Throttle valve actuator control circuit open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 398
3819-Throttle valve actuator control circuit over current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 400
3820-Throttle valve actuator control circuit over temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 402
3821-Throttle valve actuator H-bridge control circuit shorted to battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
3822-Throttle valve actuator H-bridge control circuit shorted to battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406
3823-Throttle valve actuator H-bridge control circuit shorted to ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 408
3824-Throttle valve actuator H-bridge control circuit shorted to ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 410
3825-Throttle valve actuator control circuit over load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 412
3827-Throttle valve actuator control circuit supply voltage too low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 414
3834-Throttle valve actuator position sensor voltage is higher than expected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 415
3835-Throttle valve actuator position sensor voltage is lower than expected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 417
3838-Oxidation catalyst upstream temperature shorted to high source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 419
3839-Oxidation catalyst upstream temperature shorted to low source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 421
3842-Turbine upstream temperature sensor shorted to high source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 423
3843-Turbine upstream temperature sensor : SRC low for turbine upstream temperature sensor . . . . . . . . . . . 426
3844-Zero fuel calibration by lambda (ZFL) : DFC reporting error state on comparing energizing time to max value
injector 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 428
injector 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 429
injector 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 430
injector 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 431
3848-Zero fuel calibration by lambda (ZFL) : DFC reporting error state on comparing energizing time to min value
injector 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 432
injector 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 433
injector 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 434
injector 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 435
3899-Engine Protection : Engine temperature reaches prewarning level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 436
3900-Info: Engine temperature exceeded warn level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 437
3906-Injector: Number of injections is limited by quantity balance of high pressure pump . . . . . . . . . . . . . . . . . . 438
3910-Fuel Metering Unit : Intermittent contact between ECU and MeUn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 439
3915-Pressure Relief Valve: Averaged rail pressure is outside the expected range with open PRV . . . . . . . . . . 441
3916-Pressure Relief Valve: Open time of PRV for wear out monitoring had exceeded maximum value . . . . . . 442
3978-Level 2 of PFlt Overloaded . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 443
3979-Level 3 of PFlt Overloaded . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 444
3993-EGR valve will not close during after run . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 445
9003-J1939 Receive Buffer Overflow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 446
9004-EEPROM Checksum Failure, Hourmeter Location 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 447
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9007-Abnormal Reset Watchdog Timeout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 450
9012-Analog To Digital Fault Fuel Level (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 451
9401-Repair Double Redundant Memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 452
9403-Memory Error - Double Redundant Memory - Unrecoverable Memory Corruption Operable . . . . . . . . . . . 453
9404-Memory Error - Triple Redundant - Hour Meter Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 454
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PRINTED IN U.S.A.
47821916 28/04/2015
EN
SERVICE MANUAL
Telescopic single arm

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83
Contents
Telescopic single arm - 83
[83.122] Telescopic arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83.1
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Telescopic arm - 122

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Contents
SERVICE
Telescopic arm
Remove - Forklift mast with Freelift cylinder (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Disassemble - Forklift mast with Freelift cylinder (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Assemble - Forklift mast with Freelift cylinder (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Install - Forklift mast with Freelift cylinder (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Remove - Forklift mast (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Disassemble - Forklift mast with standard cylinder (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Assemble - Forklift mast with standard cylinder (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Install - Forklift mast with Standard Cylinder (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
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Telescopic single arm - Telescopic arm
Telescopic arm - Remove - Forklift mast with Freelift cylinder

586H
588H

WARNING
Heavy object!
ALWAYS use adequate lifting equipment
(heavy-duty hoist, loader, or forklift) to lift the
component.
ous injury.
W0101A
3. Using the proper lifting equipment, remove the forks

from the mast assembly.
Specification
Fork Weight (approximate) 137 kg (302.0 lb)
4. To prevent the mast assembly from falling forward dur-

ing this procedure, attach a suitable chain (1) between
the ROPS and mast as shown.
RAPH12FRK0334AA 1
5. Disconnect the rod end (2) of the shift cylinder by re-

moving the snap ring and pin (3). Swing the rod end of
the shift cylinder away from mast assembly.
RAPH12FRK0391AA 2
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WARNING
Heavy object!
component.
ous injury.
W0101A
6. Attach an appropriate lifting device to the mast assem-

bly. Tighten the lifting equipment to eliminate any slack.
Specification
Mast Assembly Weight (approximate) 1606 kg (3540.6 lb)
7. Disconnect the hydraulic lines (4) and (5) from mast

assembly.
8. Remove four bolts (6), two from each side of mast
mounting bar.
9. Disconnect tilt cylinders from mast assembly by remov-
ing the pin and snap ring (7) for each cylinder.
RAPH12FRK0357AA 3
WARNING
Heavy object!
component.
ous injury.
W0101A
10. Using the proper lifting device, remove forklift mast.

Once the mast is free, remove the mast to ROPS
chain.
11. Place the mast in an area big enough to disassemble
the components. Lower the mast to the ground. Use
suitable blocking to hold the mast off the ground. Lay
mast face down with carriage assembly on the bottom.
RAPH12FRK0358AA 4
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Telescopic arm - Disassemble - Forklift mast with Freelift cylinder

586H
588H
1. Remove the forklift mast.

2. Remove four allen head bolts (1) from the top of the
crosshead valve (2), and remove the chain retainer
plates (3).
RAPH12FRK0338AA 1
CAUTION
Crushing hazard!
When removing or installing the chain, wear
heavy gloves and hold the chain carefully on
the outside. Do not position hand or fingers be-
tween the drive sprocket or idler sprocket.
erate injury.
C0017A
3. Remove the chain (4) from the rollers (5). Remove the
snap ring (6). Remove the roller from the stub shaft (7).
Check for excessive wear between the pulley and the
bearing. Replace if necessary.
RAPH12FRK0339AA 2
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4. Remove the crosshead retaining bolt (8), and remove

the cross head valve (9) from the lift cylinder (10).
RAPH12FRK0342AA 3
5. Disconnect the rod end of the side shift cylinder from

the mast, and swing it away from the mast assembly.
Remove the hydraulic hose (11) and the 90 ° elbow
(12) from the bottom of the free lift cylinder. Close all
openings.
RAPH12FRK0343AA 4
DANGER
Heavy objects!
bystanders.
injury.
D0076A
6. Attach an appropriate lifting device to the lift cylinder

(13), and remove the two bolts (14). Remove the cylin-
der from the mast.
RAPH12FRK0345AA 5
47821916 28/04/2015
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Telescopic arm - Assemble - Forklift mast with Freelift cylinder

586H
588H
WARNING
Heavy object!
component.
ous injury.
W0101A
1. Using an appropriate lifting device, install the cylinder

to the mast. Install two mounting bolts (1) and tighten.
RAPH12FRK0345AA 1
2. Install the 90 degree elbow (2) to the hydraulic cylinder.
RAPH12FRK0344AA 2
3. Install the rod end of the side shift cylinder to the mast
assembly. Install the 90 degree elbow (3) to the bottom
of the free lift cylinder and connect the hydraulic hose
(4).
RAPH12FRK0343AA 3
47821916 28/04/2015
83.1 [83.122] / 7
4. Install the cross head valve (5) at the top of the lift
cylinder. Install the retaining bolt (6) and tighten.
RAPH12FRK0342AA 4
CAUTION
Crushing hazard!
erate injury.
C0017A
5. Install the pulley (7) to the stub shaft (8) and Install the
retaining ring (9). Install the chain (10) over pulley as
shown.
RAPH12FRK0339AA 5
6. Install the lift chain retainer plates (11) to the crosshead

bar (12) using four allen head bolts (13).
RAPH12FRK0338AA 6
7. Install the forklift mast.

47821916 28/04/2015
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Telescopic arm - Install - Forklift mast with Freelift cylinder

586H
588H
WARNING
Heavy object!
component.
ous injury.
W0101A
1. Using an appropriate lifting device, lift and align the

mast assembly to the forklift.
RAPH12FRK0358AA 1
Specification
2. Install tilt cylinders to the mast assembly by installing

pin and snap rings (1) for each tilt cylinder.
3. Install four bolts (2), two on each side of mast mounting
bar and tighten.
4. Connect hydraulic lines (3) and (4).
RAPH12FRK0357AA 2
47821916 28/04/2015
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5. Place the rod end of the shift cylinder to the mast as-
sembly. Connect the rod end (5) of the shift cylinder by
installing the pin and snap ring (6).
RAPH12FRK0391AA 3
6. Remove the lifting equipment.
WARNING
Heavy object!
component.
ous injury.
W0101A
7. Using an appropriate lifting device, install the forks to

the mast assembly.
Specification

9. Return machine to service.
47821916 28/04/2015
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Telescopic arm - Remove - Forklift mast

586H
588H
WARNING
Heavy object!
component.
ous injury.
W0101A
2. Using the proper lifting equipment, remove the forks

from the mast assembly.
Specification
3. To prevent the mast assembly from falling forward dur-

ing this procedure, attach a suitable chain (1) between
the ROPS and mast as shown.
RAPH12FRK0334AA 1
4. Disconnect the rod end (2) of the shift cylinder by re-

moving the snap ring and pin (3). Swing the rod end of
the shift cylinder away from mast assembly.
RAPH12FRK0391AA 2
WARNING
Heavy object!
component.
ous injury.
W0101A
47821916 28/04/2015
83.1 [83.122] / 11
5. Attach an appropriate lifting device to the mast assem-

bly. Tighten the lifting equipment to eliminate any slack.
Specification
6. Disconnect the hydraulic lines (4) and (5) from mast

assembly.
7. Remove four bolts (6), two from each side of mast
mounting bar.
8. Disconnect tilt cylinders from mast assembly by remov-
ing the pin and snap ring (7) for each cylinder.
RAPH12FRK0357AA 3
WARNING
Heavy object!
component.
ous injury.
W0101A
9. Using the proper lifting device, remove forklift mast.

Once the mast is free, remove the mast to ROPS chain.
10. Place the mast in an area big enough to disassemble
the components. Lower the mast to the ground. Use
suitable blocking to hold the mast off the ground. Lay
mast face down with carriage assembly on the bottom.
RAPH12FRK0358AA 4
47821916 28/04/2015
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Telescopic arm - Disassemble - Forklift mast with standard cylinder

586H
588H
1. Remove the fork lift mast.

2. Disconnect the hydraulic cylinder hoses (1) and (2) at
the manifold block (3). Close all openings.
3. Remove two allen head bolts (4) and remove the man-
ifold block from the mounting plate (5).
RAPH12FRK0359AA 1
WARNING
Heavy object!
component.
ous injury.
W0101A
4. Support the carriage assembly using an appropriate

lifting device. Remove the chain anchor bolts (6) and
slide the carriage out of rails.
RAPH12FRK0361AA 2
Specification
47821916 28/04/2015
83.1 [83.122] / 13
5. Remove the carriage thrust rollers (7) and inspect for

play between the roller and the bearing. Replace if
necessary.
RAPH12FRK0362AA 3
NOTE: There is a total of six rollers on the carriage assembly. Only the top two rollers are secured in place with allen
screws.
6. Remove the allen screw (8) securing the top roller (9) to
the stub shaft (10) and remove the roller. Take note of
any shims between the roller and the carriage frame.
Inspect all rollers for end play between the roller and
the bearing. Replace as necessary.
RAPH12FRK0363AA 4
WARNING
Heavy object!
component.
ous injury.
W0101A
7. Using an appropriate lifting device, support the outer

rail assembly. Loosen the cylinder head bolts (11) but
do not remove at this time.
RAPH12FRK0364AA 5
8. Remove the retaining rings from the opposite ends of

the cylinders.
47821916 28/04/2015
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9. Remove the nuts (12) from the chain anchor bolts (13)
at the top of the mast assembly.
RAPH12FRK0367AA 6
10. Remove the grease fitting from the stub shaft (14).
Remove the retaining ring (15) from the chain roller
assembly at the top of the mast. Remove the chain
(16) and roller as an assembly (17). Remove the in-
ner thrust washer. Inspect the roller assembly and the
bearing for excessive end play. Replace as neces-
sary.
RAPH12FRK0368AA 7
RAPH12FRK0369AA 8
47821916 28/04/2015
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11. Remove the nuts (18) from the chain anchor bolts (19)
at the top of the mast assembly.
RAPH12FRK0367AA 9
WARNING
Heavy object!
component.
ous injury.
W0101A
12. Using an appropriate lifting device fastened to the

outer rail, pull outer rail away from the inner rail. Make
sure there are blocks under the top and bottom por-
tions of the inner rail. Pull the outer rail approximately
6 feet from the inner rail top.
WARNING
Heavy object!
component.
ous injury.
W0101A
13. Support the hydraulic cylinders (20) using appropriate

lifting equipment (21) as shown.
RAPH12FRK0370AA 10
NOTE: Some cylinders have shims on the bottom side of the cylinder. Take note of quantity and location of shims, if
equipped.
NOTE: Avoid cylinder damage. Be careful not to nick or scrape the chrome rod of the cylinder assembly.
47821916 28/04/2015
83.1 [83.122] / 16
14. Remove the cylinder head bolt (22) and remove the
hydraulic cylinder. Remove the opposite cylinder fol-
lowing the same procedure.
RAPH12FRK0365AA 11
WARNING
Heavy object!
component.
ous injury.
W0101A
15. Using an appropriate lifting device, as shown, slide the

outer rail until it comes to a stop.
RAPH12FRK0371AA 12
47821916 28/04/2015
83.1 [83.122] / 17
16. Remove the outer rail stop bolt (23) and lift the outer
rail from the inner rail.
RAPH12FRK0372AA 13
RAPH12FRK0373AA 14
47821916 28/04/2015
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Telescopic arm - Assemble - Forklift mast with standard cylinder

586H
588H
DANGER
Heavy objects!
bystanders.
injury.
D0076A
1. Install shims and rollers (1) if removed during disas-

sembly. Using an appropriate lifting device (2), slide
the outer rail assembly (3) to the inner rail (4).
RAPH12FRK0371AA 1
2. Install bolt stops (5) to the outer rail assembly.
RAPH12FRK0372AA 2
47821916 28/04/2015
83.1 [83.122] / 19
3. Using an appropriate lifting device, install the cylinder

(6) to the mast.
RAPH12FRK0370AA 3
4. Install and tighten cylinder head retention bolts (7).
RAPH12FRK0365AA 4
5. Using an appropriate lifting device, support the outer

rail assembly. Install cylinder retaining rings (8) on the
opposite ends of cylinders.
RAPH12FRK0366AA 5
CAUTION
Crushing hazard!
erate injury.
C0017A
47821916 28/04/2015
83.1 [83.122] / 20
6. Install the chain (9) over the roller (10) as shown. Install
the roller assembly to the stub shaft (11). Install the
retaining ring (12) and grease fitting (not shown).
RAPH12FRK0368AA 6
7. Install nuts (13) on the chain anchor bolts (14) on top

of the mast assembly.
RAPH12FRK0367AA 7
DANGER
Heavy objects!
bystanders.
injury.
D0076A
8. Install roller shims to the stub shaft (15) if removed.

Install the roller (16) to the stub shaft. Install retaining
screws (17) to the two outermost stub shafts. Install
carriage thrust rollers (18).
NOTE: Only the two outermost rollers are secured to the
stub shaft using screws.
RAPH12FRK0363AA 8
47821916 28/04/2015
83.1 [83.122] / 21
DANGER
Heavy objects!
bystanders.
injury.
D0076A
9. Support the carriage assembly using an appropriate

lifting device. Slide the carriage assembly into the rails.
Install chain anchor bolts (19) and tighten.
10. Install the hydraulic manifold (20) using two allen head
bolts (21) and tighten. Connect hydraulic hoses to lift
cylinders (22).
RAPH12FRK0361AA 9
47821916 28/04/2015
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Telescopic arm - Install - Forklift mast with Standard Cylinder

586H
588H
WARNING
Heavy object!
component.
ous injury.
W0101A
1. Using an appropriate lifting device, lift and align the

mast assembly to the forklift.
RAPH12FRK0358AA 1
Specification
2. Install tilt cylinders to the mast assembly by installing

pin and snap rings (1) for each tilt cylinder.
3. Install four bolts (2), two on each side of mast mounting
bar and tighten.
4. Connect hydraulic lines (3) and (4).
RAPH12FRK0357AA 2
47821916 28/04/2015
83.1 [83.122] / 23
5. Place the rod end of the shift cylinder to the mast as-
sembly. Connect the rod end (5) of the shift cylinder by
installing the pin and snap ring (6).
RAPH12FRK0391AA 3
6. Remove the lifting equipment.
WARNING
Heavy object!
component.
ous injury.
W0101A
7. Using an appropriate lifting device, install the forks to

the mast assembly.
Specification

47821916 28/04/2015
83.1 [83.122] / 24
Index

Telescopic arm - Assemble - Forklift mast with Freelift cylinder (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Telescopic arm - Assemble - Forklift mast with standard cylinder (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Telescopic arm - Disassemble - Forklift mast with Freelift cylinder (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Telescopic arm - Disassemble - Forklift mast with standard cylinder (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Telescopic arm - Install - Forklift mast with Freelift cylinder (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Telescopic arm - Install - Forklift mast with Standard Cylinder (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Telescopic arm - Remove - Forklift mast (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Telescopic arm - Remove - Forklift mast with Freelift cylinder (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
47821916 28/04/2015
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PRINTED IN U.S.A.
47821916 28/04/2015
EN
SERVICE MANUAL
Platform, cab, bodywork, and decals

47821916 28/04/2015
90
Contents
Platform, cab, bodywork, and decals - 90
[90.100] Engine hood and panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.1
[90.114] Operator protections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.2
[90.116] Fenders and guards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.3
[90.120] Mechanically-adjusted operator seat. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.4
47821916 28/04/2015
90
Engine hood and panels - 100

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90.1 [90.100] / 1
Contents
SERVICE
Hood
Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Side panels
Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
47821916 28/04/2015
90.1 [90.100] / 2
Platform, cab, bodywork, and decals - Engine hood and panels
Hood - Remove
586H
588H

2. Disconnect the right and left side panel straps (1) from
the hood (2).
RAPH12FRK0028BA 1
3. Loosen the clamp and remove the pre-cleaner (3) from

the air cleaner assembly (4).
RAPH12FRK0030BA 2
4. Remove the two bolts (5) disconnecting the air filter

bracket from the hood.
RAPH12FRK0057AA 3
47821916 28/04/2015
90.1 [90.100] / 3
5. Remove four hood mounting bolts (6).
RAPH12FRK0058BA 4
WARNING
Avoid injury!
ous injury.
W1141A

sistant, remove the hood.
Specification
Hood Weight (approximate) 27.2 kg (60 lb)
47821916 28/04/2015
90.1 [90.100] / 4
Hood - Install
586H
588H
WARNING
Avoid injury!
ous injury.
W1141A

sistant, install the hood to the machine.
Specification
Hood Weight (approximate) 27.2 kg (60 lb)
2. Install the four hood mounting bolts (1) and tighten se-
curely.
RAPH12FRK0058BA 1
3. Connect the air filter bracket to the hood using two bolts
(2).
RAPH12FRK0057AA 2
47821916 28/04/2015
90.1 [90.100] / 5
4. Install the pre-cleaner (3) to the air cleaner assembly

(4) and tighten clamp securely.
RAPH12FRK0030BA 3
NOTICE: Make sure that the Particulate Matter (PM) catalyst exhaust tube is directly in the center of the fixed hood
exhaust outlet. Otherwise component damage may occur.
5. If necessary, adjust the Particulate Matter (PM) catalyst
tray position until the exhaust tube is centered in the
hood exhaust outlet.
6. Connect the left and right engine side panel straps (5)
to the hood (6).
RAPH12FRK0028BA 4
7. Close the engine side panels.

47821916 28/04/2015
90.1 [90.100] / 6
Side panels - Remove

586H
588H
NOTE: Procedure is the same for both side panels.

2. Open the side panel (1).
RAPH12FRK0026BA 1
3. Remove the nut (2) securing the first strut screw fitting
(3) to the side panel.
4. Unscrew the second strut screw fitting from the welded
block (4), and remove the hydraulic strut (5).
RAPH12FRK0027BA 2
5. Remove nuts (8) and washers (7), and remove the side
panel strap (6).
RAPH12FRK0028BA 3
47821916 28/04/2015
90.1 [90.100] / 7
WARNING
Heavy objects!
bystanders.
ous injury.
W0398A
6. Remove cap screws (9) and washers (10), and care-

fully remove the side panel.
RAPH12FRK0029BA 4
47821916 28/04/2015
90.1 [90.100] / 8
Side panels - Install

586H
588H
DANGER
Heavy parts!
injury.
D0018A
1. Position bracket holes on the side panel with the holes

located on the counterweight.
2. Install washers (1) and bolts (2). Tighten to specifica-
tion.
RAPH12FRK0029BA 1
Specification
Bolt Torque 49 - 65 N·m (36 - 48 lb ft)
3. Install the side panel strap (3), and secure with washers
(4) and nuts (5). Tighten to specification.
RAPH12FRK0028BA 2
Specification
Nut Torque 49 - 65 N·m (36 - 48 lb ft)
47821916 28/04/2015
90.1 [90.100] / 9
4. Install the hydraulic strut (6) and strut screw fitting (7)
to the welded block (8). Tighten to specification.
5. Install the second strut screw fitting to the side panel
(9), and secure with a nut (10). Tighten to specification.
RAPH12FRK0027BA 3
Specification
Nut Torque 49 - 65 N·m (36 - 48 lb ft)
Strut Screw Fitting to Welded Block Torque 49 - 65 N·m (36 - 48 lb ft)
6. Ensure that the side panel closes with no binding.

NOTE: If binding is present loosen cap screws securing the
side panel and readjust to fit.
47821916 28/04/2015
90.1 [90.100] / 10
Index

Hood - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Hood - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Side panels - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Side panels - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
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Operator protections - 114

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90.2 [90.114] / 1
Contents
TECHNICAL DATA
Roll Over Protective Structure (ROPS) frame canopy

Torque (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SERVICE
Roll Over Protective Structure (ROPS) frame canopy

Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
47821916 28/04/2015
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Platform, cab, bodywork, and decals - Operator protections
Roll Over Protective Structure (ROPS) frame canopy - Torque

586H
588H
TORQUE SPECIFICATIONS
Rear canopy to bracket mounting bolts (1 each side) 630 - 730 N·m (464.7 - 538.4 lb ft)
Rear bracket to frame mounting bolts (2 each side) 93 - 112 N·m (68.6 - 82.6 lb ft)
Front canopy mounting bolts (2 each side) 134 - 151 N·m (98.8 - 111.4 lb ft)
47821916 28/04/2015
90.2 [90.114] / 3
Roll Over Protective Structure (ROPS) frame canopy - Remove

chine to use ().
2. Open the engine side panels.
4. Drain the hydraulic system. See Oil reservoir - Drain
fluid (35.300).
5. Disconnect the clamp (1). Remove the breather hose
(2) from the hydraulic oil tank breather assembly (3).
6. Remove the ground wires and the ground strap (4) from
the bulkhead.
RAPH12FRK0005AA 1
7. Disconnect the brake hydraulic fluid supply line (5) and

return line (6) from the brake reservoir (7).
8. Remove the fuse holder (8) from the bulkhead.
RAPH12FRK0005AA 2
NOTE: To aid in assembly, label all wire harness connectors prior to removing.
47821916 28/04/2015
90.2 [90.114] / 4
9. Remove the ring terminal from the ground stud (9).

10. Tag and disconnect three electrical connectors (11),
(12), and (13) from the ROPS bracket (10) from area
(A).
RAIL14FRK0134BA 3
RAIL14FRK0100BA 4
11. Remove the Engine Control Unit (ECU) cover (15).

12. Remove the Particulate Matter (PM) Catalyst assem-
bly. See Diesel Oxidation Catalyst (DOC) - Remove
– Particulate Matter (PM) Catalyst (10.501).
RAIL15FRK0032BA 5
NOTE: To aid in assembly, label all wire harness connectors prior to removing.
47821916 28/04/2015
90.2 [90.114] / 5
13. Disconnect the Engine Control Unit (ECU) connec-

tors. (17).
14. Remove the fuse block (18) from the back panel.
15. Remove the relay block (19) from the back panel.
16. Pull the complete electrical harness back through the
opening in the ROPS bulkhead (20).
RAIL14FRK0147BA 6
17. Remove the left and right side front fender. See
Fender guard - Remove (90.116).
18. Remove six bolts and washers (22) and remove the
front access dash panel (23) and the control valve
cover (24).
RAPH12FRK0011BA 7
NOTE: To aid in assembly, label all hydraulic lines prior to removing.
47821916 28/04/2015
90.2 [90.114] / 6
NOTE: Avoid contamination; cap and plug all lines and ports when removed.
19. Disconnect five steering valve hydraulic hoses (25).
Close all openings.
20. Disconnect seven mast control valve hydraulic hoses
(26). Close all openings.
RAPH12FRK0012BA 8
21. Remove four floor mat screws (27) from the right and
left side of machine. Remove the floor mat (28).
RAPH12FRK0013BA 9
22. Remove six floor access panel screws (29) and re-
move the access panel (30).
RAPH12FRK0014BA 10
47821916 28/04/2015
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NOTE: To aid in assembly, label all harness connectors prior to removing.

23. Disconnect two front brake pressure sensor wire har-
ness connectors (31).
RAPH12FRK0015AA 11
NOTE: To aid in assembly, label all lines prior to removing.
NOTE: Avoid contamination; cap and plug all lines and ports when removed.
24. Disconnect two hydraulic lines (32) at the brake reser-
voir. Close all openings.
25. Disconnect two front hydraulic brake lines (33) and
(34) from the master cylinders. Close all openings.
26. Disconnect the gear selector wire harness (35).
27. Disconnect the gear selector (36) at the top of trans-
mission by removing gear selector pinch bolt (37).
RAPH12FRK0714BA 12
DANGER
Heavy objects!
bystanders.
injury.
D0076A
28. Attach an appropriate lifting device (38) to the ROPS

as shown.
RAPH12FRK0016BA 13
47821916 28/04/2015
90.2 [90.114] / 8
Specification
ROPS Weight (approximate) 363 kg( 800 lb)
ATTENTION: The rear corner brackets MUST be removed with the ROPS or machine damage may result.
29. Loosen the nut and lock washer (39) (do not remove)
relieving tension between the rear corner brackets
(40) and the machine frame (41).
30. Remove the rear ROPS to frame mounting bolts and
two washers (42). The procedure is the same for the
opposite side.
RAPH12FRK0017BA 14
31. Note the location of hydraulic hose brackets (43) to

aid with assembly. Remove two front ROPS to frame
mounting bolts and four washers (44). The procedure
is the same for the opposite side.
RAPH12FRK0018BA 15
NOTE: When lifting the ROPS, carefully guide the steering hydraulic hoses through the opening in the ROPS floor.
47821916 28/04/2015
90.2 [90.114] / 9
32. With the aid of assistants slowly raise the ROPS

from the frame. Carefully guide the hydraulic steering
hoses (45) through the opening in the ROPS floor.
RAPH12FRK0020BA 16
NOTE: Do not place the ROPS directly to the ground: make sure all four corners of the ROPS structure are supported
on wood blocks or equivalent.
DANGER
Crushing hazard!
Do not change the Roll Over Protective Struc-
ture (ROPS) in any way. Unauthorized changes
such as welding, drilling, or cutting will weaken
the ROPS and decrease your protection. Have
an authorized dealer replace the ROPS if dam-
age of any kind occurs. DO NOT TRY TO RE-
PAIR THE ROPS.
injury.
D0037A
33. Guide the ROPS away from the machine and slowly
lower to the ground, making sure the ROPS structure
is supported off the ground.
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Roll Over Protective Structure (ROPS) frame canopy - Install

DANGER
Heavy objects!
bystanders.
injury.
D0076A
1. Attach appropriate slings and lifting device (1) to the

ROPS as shown.
RAPH12FRK0019BA 1
Specification
ROPS Weight (approximate) 363 kg (800 lb)
CAUTION
Pinch hazard!
Always use suitable tools to align mating parts.
DO NOT use your hand or fingers.
erate injury.
C0044A
NOTE: When installing the ROPS, carefully route the steering hoses from the undercarriage into the steering column.
47821916 28/04/2015
90.2 [90.114] / 11
2. Slowly lower the ROPS onto the frame while routing the
steering hoses (2) into steering column dash panel.
RAPH12FRK0020BA 2
3. Ensure the holes in ROPS and frame are aligned.

NOTE: Using a drift pin may help with alignment.
NOTE: Do not tighten nuts and bolts until all nuts and bolts have been installed.
4. Install the rear ROPS to frame mounting bolts (3) and
two washers. Repeat this procedure for the opposite
side.
RAPH12FRK0017BA 3
47821916 28/04/2015
90.2 [90.114] / 12
5. Install two washers, and two bolts (4) through the top
side of the ROPS.
6. Position the hydraulic hose bracket (as noted when re-
moved) (5) onto the bolts and secure with two washers
and two nuts (6). Repeat this procedure for the oppo-
site side.
RAPH12FRK0018BA 4
7. Once all nuts and bolts have been installed securing

the ROPS to the frame, tighten to specifications.
Specification
Front Canopy-to-Frame Mounting Bolts (2 each Side) 134 - 151 N·m (98.8 - 111.4 lb ft)
Rear Canopy Bracket-to-Frame Mounting Bolts (2 each 93 - 112 N·m (68.6 - 82.6 lb ft)
side)
8. Locate the nuts and lock washers (7) on the underside

of each corner bracket and tighten to specification.
NOTE: Nuts were loosened to relieve bracket-to-frame ten-
sion during the removal procedure.
RAPH12FRK0017BA 5
Specification
Corner Bracket-to-Canopy Nut and Bolt Torque (1 each 630 - 730 N·m (464.7 - 538.4 lb ft)
side)
9. Connect two hydraulic brake lines (8) at the master

cylinder.
10. Connect two front hydraulic brake lines (9) to the mas-
ter cylinders.
11. Connect gear selector linkage (10) to the transmission
shift shaft and tighten pinch bolt (11) securely.
12. Connect the gear selector wire harness (12).
RAPH12FRK0714BA 6
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90.2 [90.114] / 13
13. Connect two front brake pressure sensors (13).
RAPH12FRK0015AA 7
14. Connect mast control valve hydraulic hoses (14).

15. Connect steering valve hydraulic hoses (15).
RAPH12FRK0012BA 8
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16. Pull the complete electrical harness back through the

opening in the ROPS bulkhead (20).
17. Connect the Engine Control Unit (ECU) connectors
(17).
18. Attach the fuse block (18) to the back panel.
19. Attach the relay block (19) to the back panel.
RAIL14FRK0147BA 9
20. Install ECU cover (22).
RAIL15FRK0032BA 10
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90.2 [90.114] / 15
21. Install the ring terminal to the ground stud (23)..

22. Connect the three electrical connectors (25), (26), and
(27) on the ROPS bracket (24) in area (A).
RAIL14FRK0134BA 11
RAIL14FRK0100BA 12
23. Install fuse holder (28)

24. Connect supply line (29) and return line (30) to brake
reservoir (31).
RAPH12FRK0005AA 13
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90.2 [90.114] / 16
25. Install ground wires and ground strap to bulkhead

(32).
26. Install breather hose (33) and tighten clamp (34) se-
curely.
RAPH12FRK0005AA 14
27. Install the Particulate Matter (PM) Catalyst assembly.

See Diesel Oxidation Catalyst (DOC) - Remove –
Particulate Matter (PM) Catalyst (10.501).
28. Fill hydraulic system. See Oil reservoir - Filling
(35.300).
29. WARNING
Escaping fluid!
Relieve all pressure before disconnecting fluid
lines or performing work on the hydraulic sys-
tem. Make sure all components are in good
condition and tighten all connections before
pressurizing the system. DO NOT use your
hand to check for leaks. Use a piece of card-
board or paper.
ous injury.
W1140A
Start machine and inspect all hydraulic lines for leaks.

Repair all leaks as necessary.
30. Install floor access panel (35) and floor access panel
screws (36).
RAPH12FRK0014BA 15
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90.2 [90.114] / 17
31. Install floor mat (37).

32. Install two floor mat screws (38) on the right side of
the floor mat and two floor mat screws on the left side
of the floor mat.
RAPH12FRK0013BA 16
33. Install front access dash panel (39) and the protective
control valve cover (40). Secure with six washers and
six bolts (41).
RAPH12FRK0011BA 17
34. Install the left-hand and right-hand front fenders. See

Fender guard - Install (90.116).
35. Install hood. See Hood - Install (90.100).
36. Close engine side panels.
37. Return machine to service. See Basic instructions
use ().
47821916 28/04/2015
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Index

Roll Over Protective Structure (ROPS) frame canopy - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Roll Over Protective Structure (ROPS) frame canopy - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Roll Over Protective Structure (ROPS) frame canopy - Torque (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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Fenders and guards - 116

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Contents
SERVICE
Fender guard
Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
47821916 28/04/2015
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Platform, cab, bodywork, and decals - Fenders and guards
Fender guard - Remove

586H
588H

2. Remove the two nuts (1) and lock washers (2) from the
rear portion of fender (3).
RAPH12FRK0047BA 1
3. Remove the two bolts (4) and washers (5) from rear
portion of fender.
RAPH12FRK0048BA 2
4. With assistance, hold the fender and remove the two

bolts (6) and washers (7) from fender mounting bracket
(8).
5. Remove fender from the machine.
RAPH12FRK0049BA 3
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Platform, cab, bodywork, and decals - Fenders and guards
Fender guard - Install

586H
588H
1. With assistance, hold the fender (1) and install two bolts
(2) and washers (3) securing the front portion of fender.
RAPH12FRK0049BA 1
2. Install two bolts (4) and washers (5) to rear portion of

fender.
RAPH12FRK0048BA 2
3. Install two washers (6) and nuts (7) to the rear portion
of fender.
RAPH12FRK0047BA 3
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Index

Fender guard - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Fender guard - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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Mechanically-adjusted operator seat - 120

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Contents
FUNCTIONAL DATA
Operator seat
Overview Non-suspension seat (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Overview Suspension seat (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
SERVICE
Operator seat
Remove Non-suspension seat (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Install Non-suspension seat (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Seat suspension unit
Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
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Platform, cab, bodywork, and decals - Mechanically-adjusted operator seat
Operator seat - Overview Non-suspension seat

586H
588H
RAIL12FRK1177BA 1
Operator’s Seat
NOTE: Install seat tethers under rear seat mounting stud between seat and seat mounting plate.
47821916 28/04/2015
90.4 [90.120] / 3
1– Seat 5– Plate, Seat Mounting

2– Washer .406 x 1.25 x .134 in. 6– Nut, M10
3– Bolt, M10 x 25 7– Nut, M8
4– Washer 11 x 24 x 2 mm 8– Washer, 9 x 16 x 1.6 mm
47821916 28/04/2015
90.4 [90.120] / 4
Operator seat - Overview Suspension seat

586H
588H
RAIL12FRK1179GA 1
Operator’s Seat
NOTE: Install seat tethers under rear seat mounting stud between seat and seat mounting plate.
1– Seat 4– Assembly, Susp standard
2– Bolt, 5/16–18 x 3/4. 5– Plate, Adapter, housing lower
3– Washer 6– Bracket Assembly
47821916 28/04/2015
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Operator seat - Remove Non-suspension seat

586H
588H
1. Remove four nuts and washers (1) and remove the

seat from the seat base (2). Note the location of the
front seat spacer washers (3) and the seat belt reten-
tion strap brackets (4).
RAPH12FRK0038BA 1
NOTE: Only the front two seat mounting bolts use spacer washers (3) between the seat rail (5) and seat base (2).
The rear two seat mounting bolts retain the seat belt retention strap brackets between the seat rail and seat base.
Make sure they are installed in the correct location when installing the seat.
47821916 28/04/2015
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Operator seat - Install Non-suspension seat

586H
588H
1. Install the seat to the seat base (1). Make sure the front
two spacer washers (2) and two rear seat belt retention
strap brackets (3) are installed in the correct location as
noted during removal.
2. Install four washers and nuts (4) and tighten to specifi-
cation.
RAPH12FRK0038BA 1
Specification
Seat Retaining Bolt Torque 33.9 - 54.2 N·m (25 - 40 lb ft)
47821916 28/04/2015
90.4 [90.120] / 7
Seat suspension unit - Remove

586H
588H
1. Remove four nuts and washers (1) and remove the

seat from the seat base (2). Note the location of the
front seat spacer washers (3) and the seat belt reten-
tion strap brackets (4).
RAIL12FRK1180BA 1
NOTE: Only the front two seat mounting bolts use spacer washers (3) between the seat rail (5) and seat base (2).
The rear two seat mounting bolts retain the seat belt retention strap brackets between the seat rail and seat base.
Make sure they are installed in the correct location when installing the seat.
47821916 28/04/2015
90.4 [90.120] / 8
Seat suspension unit - Install

586H
588H
1. Install the seat to the seat base (1). Make sure the front
two spacer washers (2) and two rear seat belt retention
strap brackets (3) are installed in the correct location as
noted during removal.
2. Install four washers and nuts (4) and tighten to specifi-
cation.
RAIL12FRK1180BA 1
Specification
Seat Retaining Bolt Torque 33.9 - 54.2 N·m (25 - 40 lb ft)
47821916 28/04/2015
90.4 [90.120] / 9
Index

Operator seat - Install Non-suspension seat (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Operator seat - Overview Non-suspension seat (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Operator seat - Overview Suspension seat (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Operator seat - Remove Non-suspension seat (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Seat suspension unit - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Seat suspension unit - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
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PRINTED IN U.S.A.
47821916 28/04/2015
EN
SPECIAL TOOL INDEX
Genuine Reference PAGE

380000988 [Starter opening Engine - Remove 10.1 / 17
plate and Flywheel Rotation
Blocker]
380000988 [Starter opening Engine - Install 10.1 / 22
Blocker]
380000988 [Starter opening Power shuttle transmission - Remove 21.2 / 29
Blocker]
380000988 [Starter opening Power shuttle transmission - Install 21.2 / 34
Blocker]
380002436 [Dummy pinion Differential - Assemble 25.2 / 35
depth guage]
depth guage]
depth guage]
depth guage]
380002432 [Assembly Of Differential - Install - Pinion shaft seal installation 25.2 / 45
Sliding Block In The Swivel
Housing]
380040185 [Harness Harnesses and connectors - Overview 55.1 / 10
Diagnostic /Repair Kit (NEF)]
380040185 [Harness Harnesses and connectors - Overview 55.1 / 20
Diagnostic /Repair Kit (NEF)]
47821916 28/04/2015
PRINTED IN U.S.A.
47821916 28/04/2015
EN
X-496
X-481 X-497 OR 0.5_MM^2 3P12 WB-209 Sheet 8
D D TELEMATICS IGN
1 1
RD 19_MM^2 ALT1 WB-002 Sheet 2 Sheet 4 WB-021 YE 0.5_MM^2 E080 YE 0.5_MM^2 E081
G-002
ECU CRANK X-013 K-015
ALTERNATOR X-507 ALTERNATOR
1 1 SP-066 NEUTRAL RELAY
RD 62_MM^2 BATT1 TO STARTER B+ WB-037 Sheet 2 Sheet 10 WB-063 YE 0.5_MM^2 21A1 87A
B+ X-496 X-497 4 4
ST FROM IGNITION SW C C
30
87
Sheet 4 WB-011
YE 0.5_MM^2 21A2
OR 0.5_MM^2 150A OR 0.5_MM^2 150B
GND ECU WIF SENSOR OR 0.8_MM^2 19E1

3 3
X-480 X-482 X-483 Sheet 10 WB-029 OR 0.5_MM^2 3P01
85 86
1 1 1 1
OR 1_MM^2 3002
BK 32_MM^2 G002
INSTRUMENT CLUSTER
BATTERY CONNECTION WITH
1 1
Sheet 1 WB-005 SP-012

OR 0.5_MM^2 1507 11 11
G-001
GND-002 BATTERY GND-001 STANDARD EQUIPMENT ALT/ECU 32 32
Sheet 1 WB-086 30 28
YE 0.5_MM^2 21A4
OR 0.5_MM^2 4002 OR 0.5_MM^2 4001
X-479 X-506 X-507A ACC FROM IGNITION SW X-150 S-001 X-150
OR 0.5_MM^2 21A7
1 1 1
X-040
1
X-040
1 1
RD 62_MM^2 BATT2 RD 62_MM^2 BATT3 TO STARTER B+ WB-037 Sheet 2 Sheet 1 WB-057 IGNITION SWITCH 30 28 X-012
OR 0.5_MM^2 21A8
RD 1_MM^2 P012
BATT. DISCONNECT X-507B X-021-4 K-016
REMOTE JUMP START IGNITION SW B+ 42 42
SWITCH
1 1
X-012 X-021-3 START RELAY
(OPTIONAL) F-003
OR 1_MM^2 3001
X-480 X-482 X-483 43 43 X-150 X-021-2
46 46
30
87A
1 1 1 1
YE 0.5_MM^2 3404 WB-208 Sheet 8 X-040 20.0 A
1 1
BK 32_MM^2 G002
BATTERY CONNECTION WITH TELAMATICS ALT SIGNAL
F-002
47 47 29 29
X-021-1
YE 0.5_MM^2 21A3
X-013 87
OPTIONAL EQUIPMENT
RD 1_MM^2 P018 RD 1_MM^2 P019
G-001
GND-001 YE 0.5_MM^2 3403 WB-067 Sheet 10 10.0 A 1 1 85 86
BATTERY SP-204
ALT CHARGE SIGNAL TO CLUSTER
X-001 Sheet 1 WB-103 RD 2_MM^2 P014
X-083 STARTER SOLENOID B+ 2 2
X-051 YE 0.5_MM^2 3402 RD 0.5_MM^2 1019 WB-039 Sheet 7 RD 2_MM^2 P032
1 1 H H
FAULT YE 0.5_MM^2 3401 DIAGNOSTIC B+ Sheet 6 WB-032 YE 0.5_MM^2 21C2 10 10
WB-036 Sheet 14 X-001
DIODE RD 0.5_MM^2 P029 NEUTRAL SIGNAL TO NEUTRAL RELAY X-051
X-509-1 X-509-2 HORN X-496 S S 9 9
ALTERNATOR EXCITATION 2 2
OR 0.5_MM^2 1501 OR 0.5_MM^2 1502
G G
RD 1_MM^2 P012 WB-057 Sheet 2 X-497 WH 2_MM^2 21B4
IGN SW SUPPLY Sheet 4 WB-003 A A K-017

YE 0.5_MM^2 E530 YE 0.5_MM^2 E173
RD 0.5_MM^2 P013 WB-114 Sheet 10
CRANK ENABLE/ECU ECU START
SP-P001 INSTRUMENT CLUSTER X-012 RELAY
RD 8_MM^2 P010 RD 2_MM^2 P014 WB-103 Sheet 2 Sheet 4 WB-008 F F
YE 0.5_MM^2 E270 YE 0.5_MM^2 E373 87A
STARTER SOLENOID CRANK ENABLE/ECU M-002

2 2 30
Sheet 2 WB-005 OR 0.5_MM^2 1507

87
WB-117 Sheet 11 Sheet 1 WB-037 STARTER MOTOR

IGN FROM KEY RD 3_MM^2 P017 X-820 A
STARTER B+ A A 1 1
POWER POINTS Sheet 1 WB-002 RD 19_MM^2 ALT1 X-478 WH 2_MM^2 21B3
85 86
B+ FROM ALTERNATOR
1 1
OR 0.5_MM^2 AP31 WB-019 Sheet 13 M 10 10
X-122 BRAKE LIGHTS Sheet 1 WB-056 RD 32_MM^2 P002
X-123 OR 1.0_MM^2 AP32 WB-004 Sheet 9 CAB B+ POWER 9 9
Sheet 2 WB-056 RD 32_MM^2 P002
1 1
DRIVING LIGHTS Sheet 4 WB-112 RD 8_MM^2 P011
GND-003
OR 1_MM^2 AP17 WB-120 Sheet 13 X-508 12 12
B+ FROM STARTER ECU B+
SP-AP02 REAR LIGHTS 1 1 OR 0.5_MM^2 19E3 X-013
K-002 OR 8_MM^2 AP15 OR 0.8_MM^2 AP23 WB-109 Sheet 9 Sheet 4 WB-027 RD 6_MM^2 1041 BK 0.5_MM^2 G077 GB-029 Sheet 3
X-012 POWER RELAY 2 FLASHER GCU POWER X-012 NEUTRAL RELAY COIL GND
25 25 87A 34 34 BK 0.5_MM^2 G346 GB-030 Sheet 3
RD 3_MM^2 P027 X-017-3 30 X-013
F-001 RD 8_MM^2 P008 87 X-017-5 F-004 87A
START RELAY GND
29 29 38 38
BK 0.5_MM^2 G073 GB-025 Sheet 3 OR 0.5_MM^2 19E9 28 28 30
X-150 X-040 14
SP-067
87
K-009
30.0 A POWER RELAY 2 COIL GROUND 7.5 A 27 27 OR 0.5_MM^2 19E4 WB-001 Sheet 6
X-017-2 85 86 X-017-1 Sheet 6 WB-007 OR 0.5_MM^2 19E2 OR 0.5_MM^2 19E6 CLUTCH RELAY
OR 0.5_MM^2 4004 FNR SW KEY ON
SHUTTLE INTERLOCK TIMING B+ BL 0.5_MM^2 2503
36 36 85 86
X-005 OR 3_MM^2 AP52 WB-053 Sheet 2 S-041 WH 0.5_MM^2 4037 WB-031 Sheet 12
Sheet 15 WB-009 31 31
CUSTOMER OPTION TO TAP INTO
1 1
RD 3_MM^2 P028
SP-AP01 INSTALLER TAP OR 0.5_MM^2 19E8 YE 0.5_MM^2 2103
GEAR SHIFT LEVER CLUTCH RELAY LOGIC B+
OR 8_MM^2 AP01 LOADER CONTROL KEY ON SP-011
K-001 DE-CLUTCH SWITCH
RD 8_MM^2 P005 OR 0.5_MM^2 AP03 WB-126 Sheet 6 X-174-A X-174-B
POWER RELAY 1 BL 0.5_MM^2 2504 BK 0.5_MM^2 G006 GB-009 Sheet 3
87A
4WD / RC Sheet 6 WB-077 S-004
X-016-3 30 FNR KEY ON FROM CLUTCH RELAY S-002 S-003
G.S. LEVER DE-CLUTCH GROUND
Sheet 12 WB-010 OR 0.5_MM^2 4041 87 X-016-5 CONSOLE
SAHR PARK BRAKE Sheet 1 WB-053 OR 3_MM^2 AP52 DE-CLUTCH SWITCH DE-CLUTCH PRESS SW DE-CLUTCH PRESS SW
X-175-D X-175-E X-176-A X-176-B X-177-A X-177-B
Sheet 2 WB-086
X-016-2 85 86 X-016-1 INSTALLER TAP KEY ON X-012 BL 0.5_MM^2 2506 BL 0.5_MM^2 2507 BL 0.5_MM^2 2508 BL 0.5_MM^2 2509 BL 0.5_MM^2 2505 BK 0.5_MM^2 G005 GB-032 Sheet 3
OR 0.5_MM^2 4002 OR 0.5_MM^2 4003
ACC FROM IGNITION SW SP-014 33 33 X-003 X-150 X-040 15 X-040 X-150 22 DE-CLUTCH PRESS SW GROUND
GB-026 Sheet 3 F-005
BK 0.5_MM^2 G074 37 37 1 1
OR 3_MM^2 AP53
POWER RELAY 1 COIL GROUND 30.0 A CUSTOMER OPTION TO TAP INTO
POWER DISTRIBUTION / CHARGING SYSTEM 1 STARTING SYSTEM 2

X-020 X-101 34 A-009
Sheet 10 GB-019 BK 0.5_MM^2 G066 BK 0.8_MM^2 G017 ENGINE CONTROLLER UNIT
INSTRUMENT CLUSTER X-448
SP-158 X-461-5
C1 C1 RD 2.5_MM^2 E050 BATTERY +C
Sheet 11 GB-021 BK 3_MM^2 G068 X-461-68
SP-G12 X-040 X-150 9 X-461-3 K LINE YE 0.5_MM^2 E681 WB-058 Sheet 7
POWER POINT 1 BK 3_MM^2 G160
F-006
C2 C2 RD 2.5_MM^2 E051 BATTERY +B ECU K LINE
RD 1.0_MM^2 E057
Sheet 11 GB-022 BK 3_MM^2 G070 7.5 A X-461-1
RD 2.5_MM^2 E010 BATTERY VOLTAGE
POWER POINT 2
BK 3_MM^2 G162
RD 1.0_MM^2 E055
RD 4.0_MM^2 E052
Sheet 2 GB-009 BK 0.5_MM^2 G006
DE-CLUTCH Sheet 5 WB-080 RD 0.8_MM^2 E058
X-448
Sheet 8 GB-213 BK 0.8_MM^2 G342
ELECTRIC VALVE B+
TELEMATICS GROUND SP-152 A2 A2
Sheet 6 GB-043 BK 0.5_MM^2 G026 F-008
Sheet 4 WB-493 RD 0.8_MM^2 E056 RD 2.5_MM^2 E054
SHUTTLE INTERLOCK RELAY A1 A1
7.5 A
Sheet 7 GB-028 BK 0.5_MM^2 G076 X-472 X-495
LAMBDA SENSOR B+
DIAGNOSTIC PORT X-487 1 1 1 1 TO REMOTE K-023 B2 B2
BK 64_MM^2 G177
JUMP START F-009
1
Sheet 12 GB-033 X-461-24
BK 0.5_MM^2 G081
1 ECU RELAY RD 4.0_MM^2 E05A CAN 1 HIGH YE 0.5_MM^2 E241 WB-060 Sheet 7
SAHR BRAKE RELAY COIL X-464-5 SP-151 B1 B1
20.0 A CAN 1 HIGH
Sheet 9 GB-038 BK 0.5_MM^2 G100
SP-157 X-461-25
Sheet 2 WB-112 RD 8_MM^2 P011 RD 8_MM^2 1014 X-464-3 CAN 1 LOW GN 0.5_MM^2 E251 WB-059 Sheet 7
FLASHER RELAY ECU B+ RD 6.0_MM^2 E053
CAN 1 LOW
Sheet 6 GB-042 BK 0.5_MM^2 G003 X-464-2 X-464-1 X-461-28
ECU RELAY
SHUTTLE INTERLOCK TIMING RD 0.5_MM^2 1015 BL 0.5_MM^2 E280
Sheet 13 GB-053 BK 2_MM^2 G018 SP-153 X-461-4 X-517 B-001
Sheet 3 GB-002 BATTERY MINUS 2
REAR WORK LIGHTS BK 8_MM^2 G011 BK 2.5_MM^2 G012 X-474 AIR TEMP SENSOR
Sheet 2 GB-032 BK 0.5_MM^2 G005 ECU GROUND B-006 X-461-2 X-461-20 2 2 X-518-2
BATTERY MINUS 1
DE-CLUTCH PRESS SW WIF SENSOR BK 2.5_MM^2 G013
AIR TEMP GND
BK/WH 0.5_MM^2 E200 BK/WH 0.8_MM^2 E201
T°
Sheet 6 GB-024 BK 0.5_MM^2 G072 X-463-2 X-461-6
BK 0.8_MM^2 G015 BK 2.5_MM^2 G014 BATTERY MINUS 3 X-461-19 X-518-1
4WD SW LAMP X-463-1 X-461-30 AIR TEMP SIGNAL YE 0.5_MM^2 E190
1 1
YE 0.8_MM^2 E191
Sheet 13 GB-061 BK 0.5_MM^2 G099 YE 0.8_MM^2 E300 WIF LEVEL SIGNAL
X-463-3
REAR LIGHTS SWITCH LAMP SP-G13 X-040 X-150 26 BK 0.5_MM^2 G020 GB-006 Sheet 12 OR 0.8_MM^2 1504
Sheet 9 GB-100 BK 0.5_MM^2 G327 BK 2_MM^2 G161 BK 2_MM^2 G164
B-002
SP-008 SAHR BRAKE SOLENOID X-461-54
T3 SENSOR (EPIQ)
DRIVING LIGHT SW LAMP BK 1_MM^2 G016 BK 0.8_MM^2 G021 GB-007 Sheet 10 Sheet 2 WB-011 OR 0.5_MM^2 150A OR 0.8_MM^2 1505 15 SW BATT+
SP-154 X-461-82 X-470-26
Sheet 9 GB-036 BK 0.5_MM^2 G159 ECU KEY ON POWER
FUEL SENDER T3 SIGNAL YE 0.5_MM^2 E820
HAZARD LIGHT SWITCH BK 0.5_MM^2 G063 GB-054 Sheet 14 Sheet 2 WB-021
X-461-8 T°
Sheet 9 GB-037 X-485 YE 0.5_MM^2 E080 START SW SIGNAL
BK 0.5_MM^2 G089
HORN X-461-81 X-470-25
TURN SIGNAL INDICATOR 1 1
BK 1_MM^2 G158 CRANK T3 GND BK/WH 0.5_MM^2 E810
X-461-27
Sheet 2 WB-008 YE 0.5_MM^2 E270 CRANK ENABLE
Sheet 9 GB-051 BK 2_MM^2 G019
CRANK ENABLE/ECU
FRONT WORK LIGHTS BK 0.5_MM^2 G022 GB-008 Sheet 10 X-461-53
Sheet 1 GB-025 BK 0.5_MM^2 G073
GND-004 GND-013 Sheet 2 WB-003 CRANK ENABLE
CAB GROUND CHASSIS GROUND AIR FILTER RESTRICTION YE 0.5_MM^2 E530
X-461-36
POWER RELAY 2 COIL BK 0.5_MM^2 G030 GB-016 Sheet 6 CRANK ENABLE/ECU A-010 DIFF PRESSURE GND
Sheet 1 GB-026 BK 0.5_MM^2 G074 RIGHT SIDE CAB LEFT CHANNEL GCU
BACKUP ALARM X-466-2 F-007 X-466-1 X-469-4 X-461-58
POWER RELAY 1 COIL SP-G08 BK 0.5_MM^2 G044 GB-012 Sheet 6 Sheet 2 WB-027 RD 6_MM^2 1041 RD 6_MM^2 1040 DIFF PRESSURE SIGNAL
Sheet 2 GB-029 BK 0.5_MM^2 G077 GCU POWER SP-156 60.0 A SP-155
REVERSE SOLENOID X-461-14
NEUTRAL RELAY COIL X-488 BK 0.5_MM^2 G045 GB-013 Sheet 6 A-011 X-469-8 X-461-52 DIFF PRESSURE SUPPLY
Sheet 2 GB-030 BK 0.5_MM^2 G346 GLOW PLUGS YE 0.5_MM^2 E520
GLOW PLUG SIGNAL
1
FORWARD SOLENOID
START RELAY COIL 1
BK 0.5_MM^2 G028 GB-014 Sheet 6 X-470-61 X-469-2 X-469-3 X-461-22
B-003
WH 2_MM^2 1610 YE 0.5_MM^2 E220
Sheet 12 GB-031 BK 0.5_MM^2 G079 GLOW PLUG SIGNAL
DIFF LOCK SOLENOID X-470-60 X-469-7
SP-203 EXHAUST GAS TEMP SENSOR #1
SAHR BRAKE CUTOUT RELAY BK 0.5_MM^2 G029 GB-015 Sheet 6 WH 2_MM^2 1600
X-469-1
X-469-5 X-461-41
X-476-2
Sheet 6 GB-018 BK 0.5_MM^2 G065
X-470-58 BK 3.0_MM^2 E411 BK 0.8_MM^2 E410 GLOW PLUG GROUND X-461-79
4WD SOLENOID WH 2_MM^2 1580
X-469-6 GAS TEMP GND 1 BK/WH 0.5_MM^2 E790
T°
FORWARD RELAY X-470-57
WH 2_MM^2 1570
Sheet 6 GB-017 BK 0.5_MM^2 G064 X-461-80 X-476-1
REVERSE RELAY GAS TEMP SIGNAL 1 YE 0.5_MM^2 E800
B-005
Sheet 13 GB-003 BK 1_MM^2 G007 LAMBDA SENSOR
BRAKE AND TAIL GROUND X-468-3 X-461-7 B-004
YE 0.8_MM^2 E070 LAMBDA HEATING
EXHAUST GAS TEMP SENSOR #2
X-510 1 X-468-1 X-461-64 X-461-83 X-477-2
LAMBDA CURRENT PUMP
Sheet 4 GB-002 BK 8_MM^2 G011 YE 0.5_MM^2 E640
GAS TEMP GND 2
BK/WH 0.5_MM^2 E830
X-489 1 X-468-5 X-461-86 T°
ECU GROUND YE 0.5_MM^2 E860 LAMBDA CURRENT ADJUST
X-461-84 X-477-1
X-468-2 X-461-85 GAS TEMP SIGNAL 2 YE 0.5_MM^2 E840
BK 0.5_MM^2 E850 LAMBDA VIRTUAL GROUND
X-468-4 X-468-6 X-461-63
GND-008 Sheet 4 WB-493 RD 0.8_MM^2 E056 PK 0.5_MM^2 E630 LAMBDA VOLTAGE NERNST
CAB GROUND FIREWALL LAMBDA SENSOR POWER
GROUNDING 3 ENGINE CONTROL 4

LEGEND COLOR ABBREVIATIONS
ROUGH TERRAIN FORK LIFT SHEET 1 SIDE 1
INDICATES CONSTANT POWER 12V ABBREVIAT ION-------COLOR
BK----------------------------BLACK GY-------------------------GRAY RD---------------------------RED 586H and 588H Tier 4B
INDICATES POWER WHEN KEY
SWITCH IS ON
BK\WH----------------------BLACK\WHITE
BL---------------------------BLUE
LB--------------------------LIGHT BLUE
LG--------------------------LIGHT GREEN
TN---------------------------TAN
VT--------------------------VIOLET ELECTRICAL SCHEMATIC
INDICATES POWER WHEN KEY BR---------------------------BROWN OR--------------------------ORANGE WH--------------------------WHITE
SWITCH IS IN START POSITION GN---------------------------GREEN PK--------------------------PINK YE--------------------------YELLOW
Additional copies of this schematic can be ordered through Technical Publications Distribution System. Part # RAC 47736518
A-008
X-012
Y-046 ENGINE CONTROLLER UNIT
INJEKTOR ELECTRIC VALVE CYL 1 12 12 K-007
LB 0.5_MM^2 25A3
X-471-A X-462-16 RD 0.8_MM^2 E058 WB-080 Sheet 4 V-008
16 16 X-013 FORWARD RELAY
WH 1.5_MM^2 F160 INJECTOR 1 HIGH BANK 1 ELECTRIC VALVE B+ YE 0.5_MM^2 5203 87A
30
X-462-32 Y-051 11 11 38 38
X-471-B V-007
LB 0.5_MM^2 25B4 OR 0.5_MM^2 19M4 87
GY 1.5_MM^2 F320 INJECTOR 1 LOW BANK 1 ELECTRIC VALVE (WG) 15 15 SP-109 SP-113 37 37
YE 0.5_MM^2 5204 LB 0.5_MM^2 25A4
X-470-28 46 46 85 86
Y-047
INJEKTOR ELECTRIC VALVE CYL 3 SP-111 45 45
X-462-4 X-470-27 Sheet 2 WB-077 YE 0.5_MM^2 2103
X-471-C X-462-31 BOOST PRESSURE ACTUATOR 1 GY 1_MM^2 F040
GY 1.5_MM^2 F310 INJECTOR 1 LOW BANK 2 FNR KEY ON
X-462-1 B-013
FROM CLUTCH RELAY SP-112
X-471-D
WH 1.5_MM^2 F010 INJECTOR 1 HIGH BANK 2 Sheet 3 GB-043 BK 0.5_MM^2 G026 GB-018 Sheet 3
P3 - EXHAUST GAS ABSOLUTE BK 0.5_MM^2 G065
PRESSURE SENSOR SHUTTLE INTERLOCK FORWARD RELAY GROUND

Y-048 X-462-12 RELAY GROUND GB-017 Sheet 3
OR 0.5_MM^2 19M3
X-470-21
YE 0.5_MM^2 25B2
LB 0.5_MM^2 25A2
LB 0.5_MM^2 25B3
LB 0.5_MM^2 2602
BK 0.5_MM^2 G064
INJEKTOR ELECTRIC VALVE CYL 4 GAS PRESSURE SENSOR SUPPLY PK 0.5_MM^2 F120
ΔP
K-013 REVERSE RELAY GROUND
X-471-E X-462-17 X-462-27 X-470-22
WH 1.5_MM^2 F170 INJECTOR 2 HIGH BANK 1 BK/WH 0.5_MM^2 F270 SHUTTLE INTERLOCK RELAY
GAS PRESSURE SENSOR GND 87A X-013 K-014
X-471-F X-462-48 INJECTOR 2 LOW BANK 1 X-462-43 X-470-23 30
X-013 48 48 REVERSE RELAY
GY 1.5_MM^2 F480 GAS PRESSURE SENSOR SIGNAL YE 0.5_MM^2 F430 87
87A
19 19 47 47 30
YE 0.5_MM^2 5201 WB-013 Sheet 10
B-014 LB 0.5_MM^2 2704 87 YE 0.5_MM^2 21C7
Y-049 85 86
24 24
INJEKTOR ELECTRIC VALVE CYL 2 EGR PIERBURG 40 40 NEUTRAL SIGNAL TO CLUSTER
EGR ACTUATOR MOTOR PLUS X-462-50 X-470-29 15 15
X-462-46 YE 0.5_MM^2 21C3 39 39 85 86
Sheet 2
X-471-G INJECTOR 2 LOW BANK 2
WH 0.8_MM^2 F500 YE 0.5_MM^2 21C2 WB-032
GY 1.5_MM^2 F460 16 16
EGR ACTUATOR MOTOR MINUS
X-462-35 X-470-30 SP-130 NEUTRAL SIGNAL TO NEUTRAL RELAY
X-471-H X-462-2 GY 0.8_MM^2 F350
WH 1.5_MM^2 F020 INJECTOR 2 HIGH BANK 2 S-013 X-040 WB-034 Sheet 12
X-462-9 X-470-33
S-062 EGR POSITION SENSOR SUPPLY PK 0.5_MM^2 F090 F&R SWITCH X-150 SAHR PARK BRAKE DECLUTCH
OIL PRESSURE SW X-462-39 F X-146-C 18 18 RELAY KEY ON
EGR POSITION SENSOR SIGNAL X-470-34 LB 0.5_MM^2 25A1
X-470-3 X-462-6 YE 0.5_MM^2 F390
X-146-A WB-131 Sheet 15
WH 0.5_MM^2 F060 OIL PRESSURE SWITCH SIGNAL R 7 7
YE 0.5_MM^2 25B1
X-462-24 X-470-35 X-146-B DIFF LOCK FROM LOADER CONT
EGR POSITION SENSOR GND BK/WH 0.5_MM^2 F240 N YE 0.5_MM^2 21C5
17 17
YE 0.5_MM^2 21C4
B-008
GND-011 B-015 X-055-A
RAIL PRESSURE SENSOR X-146-D
TVA DELLORTO
YE 0.5_MM^2 2401
X-470-5 X-462-26 OR 0.5_MM^2 19M1 H-001
BL 0.5_MM^2 F260 RAIL PRESSURE SENSOR GND X-462-49 X-470-37
ΔP TVA ACTUATOR MOTOR PLUS WH 0.8_MM^2 F490
X-055-B BACKUP ALARM
X-470-6 X-462-41
YE 0.5_MM^2 F410 RAIL PRESSURE SENSOR SIGNAL X-462-34 X-470-38 YE 0.5_MM^2 25S1
TVA ACTUATOR MOTOR MINUS GY 0.8_MM^2 F340
X-470-7 X-462-11 Sheet 2 WB-001 OR 0.5_MM^2 19E4
PK 0.5_MM^2 F110 RAIL PRESSURE SENSOR SUPPLY X-462-8 X-470-41 GB-016 Sheet 3
TVA POSITION SENSOR SUPPLY PK 0.5_MM^2 F080 FNR SW KEY ON LB 0.5_MM^2 2702
BK 0.5_MM^2 G030
B-009 Sheet 2 WB-007 X-051 Y-022 BACKUP ALARM GROUND

X-462-53 X-470-42 OR 0.5_MM^2 19E2
INCREMENT SPEED SENSOR TVA POSITION SENSOR SIGNAL YE 0.5_MM^2 F530 X-001 REVERSE SOLENOID
X-470-9 X-462-59 SHUTTLE INTERLOCK TIMING B+ SP-114
YE 0.5_MM^2 F590 CRANKSHAFT SPEED SIGNAL + X-462-37 M M X-080-1 X-080-2
X-470-43 LB 0.5_MM^2 2703 LB 0.5_MM^2 2701 BK 0.5_MM^2 G044 GB-012 Sheet 3
X-470-10 X-462-44 TVA POSITION SENSOR GROUND BK/WH 0.5_MM^2 F370 K-022
YE 0.5_MM^2 F440
CRANKSHAFT SPEED SIGNAL - SHUTTLE INTERLOCK TIMING RELAY L L
REVERSE SOLENOID GROUND
Y-050 Y-024
B-010
FUEL METERING UNIT X-148-85 FORWARD SOLENOID
SEGMENT SPEED SENSOR FUEL METERING UNIT
I
X-040 K K
X-079-1 X-079-2
X-470-4 X-462-14 X-462-60 X-470-2 GB-013 Sheet 3
YE 0.5_MM^2 F140 SEGMENT SPEED SIGNAL GY 1_MM^2 F600 X-150 LB 0.5_MM^2 2603 BK 0.5_MM^2 G045
X-470-8 X-462-28 25 25 J J FORWARD SOLENOID GROUND
BL 0.5_MM^2 F280 SEGMENT SPEED GROUND X-462-15 B+ X-148-86 LB 0.5_MM^2 25E3 LB 0.5_MM^2 25E4
X-470-1 Y-029
X-470-12 X-462-13 FUEL METERING UNIT SUPPLY WH 1_MM^2 F150
PK 0.5_MM^2 F130 SEGMENT SPEED SUPPLY DIFF LOCK SOLENOID
B-007 L X-148-30 X-077-1 X-077-2
B-011 WH 0.5_MM^2 25S2 BK 0.5_MM^2 G028 GB-014 Sheet 3
COOLANT TEMPERATURE SENSOR BOOST PRESSURE
X-462-58 X-462-10 X-470-17 DIFF LOCK SOLENOID GROUND
X-470-13 BOOST PRESSURE SENSOR SUPPLY PK 0.5_MM^2 F100 Y-012
BL 0.5_MM^2 F580 G X-148-87
COOLANT TEMP GND ΔP S-021
T° X-462-40 X-470-18 4WD SOLENOID
X-462-57 BOOST PRESSURE SENSOR SIGNAL YE 0.5_MM^2 F400
4WD SWITCH X-078-1 X-078-2
X-470-14 X-023-C GB-015 Sheet 3
YE 0.5_MM^2 F570 COOLANT TEMP SIGNAL X-462-25 X-470-19 Sheet 3 GB-042
WH 0.5_MM^2 25E5 BK 0.5_MM^2 G029
BK 0.5_MM^2 G003
BOOST PRESSURE SENSOR GND BK/WH 0.5_MM^2 F250 4WD SOLENOID GROUND
B-012 SHUTTLE INTERLOCK X-023-F 2WD X-023-A
B-019 TIMING GROUND GB-024 Sheet 3
FUEL TEMPERATURE SENSOR BK 0.5_MM^2 G072
X-470-15 X-462-23
FUEL TEMP GROUND STRAIGHT TURBO TEMP SENSOR Sheet 1 WB-126 4WD SW LAMP GROUND
BL 0.5_MM^2 F230 X-462-55 X-470-20 OR 0.5_MM^2 AP03
STRAIGHT TURBO TEMP SENSOR SIGNAL X-012 X-023-E
T°
YE 0.5_MM^2 F550
4WD/RIDE CONTROL KEY ON OR 0.5_MM^2 AP40 4WD
X-462-38 T° X-040
X-470-16 35 35 X-150
YE 0.5_MM^2 F380 FUEL TEMP SIGNAL
F-010 23 23
39 39
OR 0.5_MM^2 AP38
THIS CONNECTION IS PART OF THE FPT ENGINE HARNESS 7.5 A
ENGINE CONTROL 5 DRIVES 6
Sheet 1 WB-039 RD 0.5_MM^2 1019

DIAGNOSTIC B+ GB-213 Sheet 3
X-012 BK 0.8_MM^2 G342
30 30 TELEMATICS GROUND
X-498
F-011 26 26 X-001 CHASSIS SP-G56 1 1
RD 0.5_MM^2 1021
X-051 SIDE BK 0.8_MM^2 G340
5.0 A
X-535 1 SP-218 F-041 SP-219 A A 12 12
YE 0.5_MM^2 E249 WB-066 Sheet 10 Sheet 7 WB-210 RD 1_MM^2 1024 RD 1_MM^2 1023 RD 1_MM^2 1022
X-001 X-538-2 5.0 A X-538-1
CAN HIGH TO INSTR CLUSTER BATTERY B+ M10_RING
DIAGNOSTIC PORT GN 0.5_MM^2 E259 WB-065 Sheet 10 X-012 41 F-042 X-012 45 2 2
X-009-B Sheet 2 WB-209 OR 0.5_MM^2 3P12 OR 0.5_MM^2 3P13
B+ X-496 CAN LOW TO INSTR CLUSTER IGNITION 5.0 A
X-497
8 8
X-009-E B B Sheet 1 WB-208 YE 0.5_MM^2 3404
K LINE YE 0.5_MM^2 E682 YE 0.5_MM^2 E681 WB-058 Sheet 4
ALTERNATOR
ECU K LINE 3 3
X-009-C SP-207 K K
Sheet 7 WB-211 YE 0.5_MM^2 E245
CAN 1 HIGH YE 0.5_MM^2 E246 YE 0.5_MM^2 E244 YE 0.5_MM^2 E242 YE 0.5_MM^2 E241 WB-060 Sheet 4
SP-019 CAN HI
X-009-D SP-208 E E
CAN 1 HIGH 4 4
CAN 1 LOW GN 0.5_MM^2 E256 GN 0.5_MM^2 E254 GN 0.5_MM^2 E252 GN 0.5_MM^2 E251 WB-059 Sheet 4 Sheet 7 WB-212 GN 0.5_MM^2 E255
SP-020 CAN-LO
CAN 1 LOW
6 6
BK 0.8_MM^2 G341
7 7
TN 0.8_MM^2 1720
LB 0.8_MM^2 1710
X-009-A X-499
GROUND BK 0.5_MM^2 G076 GB-028 Sheet 3
TELEMATICS
DIAGNOSTIC PORT GROUND DIAGNOSTIC
YE 0.5_MM^2 E245 WB-211 Sheet 8 2 2

TELEMATICS CAN HIGH
GN 0.5_MM^2 E255 WB-212 Sheet 8
3 3
TELEMATICS CAN LOW
1 1
CAN BUS / DIAGNOSTIC 7 TELEMATICS 8

LEGEND COLOR ABBREVIATIONS ROUGH TERRAIN FORK LIFT SHEET 1 SIDE 2
ABBREVIAT ION-------COLOR
586H and 588H Tier 4B
INDICATES CONSTANT POWER 12V
BK----------------------------BLACK GY-------------------------GRAY RD---------------------------RED
INDICATES POWER WHEN KEY LB--------------------------LIGHT BLUE TN---------------------------TAN
BK\WH----------------------BLACK\WHITE
SWITCH IS ON
BL---------------------------BLUE
BR---------------------------BROWN
LG--------------------------LIGHT GREEN
OR--------------------------ORANGE
VT--------------------------VIOLET
WH--------------------------WHITE
ELECTRICAL SCHEMATIC
E-001
X-020
X-101 RIGHT INDICATOR LIGHT
16 16 SP-097 X-201-1 X-197-1 Sheet 13
VT 0.5_MM^2 45R3 VT 0.5_MM^2 45R4 BK 0.5_MM^2 G039 GB-001
RIGHT INDICATOR LIGHT GND
E-004
FRONT DRIVING LIGHT
19 19 SP-099 X-193-1 X-193-2
VT 1.0_MM^2 41F9 VT 1.0_MM^2 41FA BK 1.0_MM^2 G036
A-002 X-101 MAIN X-001 CHASSIS S-033

X-020 X-101 4 X-051 MAIN
E-005 SP-009 GB-051 Sheet 3 INSTRUMENT CLUSTER X-020 AIR FILTER RESTRICTION SWITCH
BK 2_MM^2 G009 BK 2_MM^2 G019
X-033-11 X-067-1 X-066-1
FRONT DRIVING LIGHT FRONT WORK LIGHTS BL 0.5_MM^2 3802
28 28
BL 0.5_MM^2 3803
P P
BL 0.5_MM^2 3801 BK 0.5_MM^2 G022 GB-008 Sheet 3
X-194-1 X-194-2 Sheet 1 WB-114 RD 0.5_MM^2 P013
Sheet 1 WB-109 OR 0.8_MM^2 AP23 VT 1.0_MM^2 41FB BK 1.0_MM^2 G037 AIR FILTER RESTRICTION GROUND
CLUSTER B+ X-020
VT 0.5_MM^2 45R2
SWITCH CLOSED IN FAULT CONDITION
VT 1.0_MM^2 41F8
SIGNAL LTS KEY ON NA X-012
X-012 X-101
E-007 17 17 S-034
20 20 X-062
LEFT INDICATOR LIGHT X-220
HYDRAULIC FILTER RESTRICTION SWITCH
F-012 F-014 23 23 X-033-9 X-033-2 31 31 B B 1 1 X-223-1
24 24 13 13 SP-100 X-196-1 X-198-1 21 21
VT 0.5_MM^2 45L3 VT 0.5_MM^2 45L4 BK 0.5_MM^2 G041 GB-004 Sheet 13 RD 0.5_MM^2 1P03 RD 0.5_MM^2 1P04 BL 0.5_MM^2 36H2 BL 0.5_MM^2 36H4 BL 0.5_MM^2 36H1 BL 0.5_MM^2 36H3
10.0 A 5.0 A
LEFT INDICATOR LIGHT GND SWITCH CLOSED IN FAULT CONDITION
B-017
GND-012
SP-094
Sheet 13 WB-017 FUEL LEVEL SENDER
VT 0.5_MM^2 45L2
VT 0.5_MM^2 41F7
X-033-24 20 20 C C X-063-1 X-064-1
TAIL LIGHTS VT 0.5_MM^2 45R5 WB-022 Sheet 13 YE 0.5_MM^2 36F2 YE 0.5_MM^2 36F3 YE 0.8_MM^2 36F1 BK 0.8_MM^2 G021 GB-007 Sheet 3
Sheet 1 WB-004 OR 1.0_MM^2 AP32
RIGHT REAR TURN SIGNAL Sheet 2 WB-029 OR 0.5_MM^2 3P01 FUEL SENDER GROUND
DRIVING LIGHTS KEY ON S-012 B-018
X-012 INSTRUMENT CLUSTER KEY
X-040 DRIVING LIGHT VT 0.5_MM^2 45L5 WB-020 Sheet 13 TRANSMISSION TEMPERATURE SENDER
28 28 X-033-16
X-150 SWITCH LEFT REAR TURN SIGNAL X-012 27 27 D D X-071-1
F-013 X-033-7 YE 0.5_MM^2 32T2 YE 0.5_MM^2 32T3 YE 0.8_MM^2 32T1
33 33 X-138-E X-138-A OR 0.5_MM^2 3P04
32 32
OR 1.0_MM^2 AP30 OR 1.0_MM^2 AP36 BK 0.5_MM^2 G327 GB-100 Sheet 3 18 18
15.0 A DRIVING LIGHT F-015 22 22 33 33 X-033-8
OR 0.5_MM^2 3P05 OR 0.5_MM^2 3P02 OR 0.5_MM^2 3P03
34 34 X-138-D SW LAMP GROUND GND-010
5.0 A SP-318
VT 1.0_MM^2 41F6 VT 1.0_MM^2 41FE
29 29 X-033-10
OR 0.8_MM^2 AP26
Sheet 6 WB-013 YE 0.5_MM^2 21C7 YE 0.5_MM^2 21C8

X-101 A-006
NEUTRAL SIGNAL TO CLUSTER X-020
K-018 FOOT THROTTLE
FLASHER RELAY X-033-19 9 9 X-155-E
BL 0.5_MM^2 1202 BL 0.5_MM^2 1201 IDLE VALIDATION
SP-024 X-010-5 LEFT TURN LAMP X-010-4 X-033-25 10 10 X-155-B
VT 0.5_MM^2 45L1 GROUND BK 0.5_MM^2 G100 GB-038 Sheet 3 21 21 X-033-3 BL 0.5_MM^2 2202 BL 0.5_MM^2 2201 GROUND
X-010-7 RIGHT TURN LAMP
Sheet 2 WB-063 YE 0.5_MM^2 21A1 YE 0.5_MM^2 21A5 X-033-17 11 11 X-155-C
SP-028 FLASHER RELAY GROUND PK 0.5_MM^2 2182 PK 0.5_MM^2 2181 +5V
SP-027
VT 0.5_MM^2 45R1
X-010-2 X-010-3 S-009 CRANK SIGNAL X-033-22 12 12 X-155-A
OR 0.8_MM^2 AP27 KEY ON B+ RIGHT INDICATOR 36 36 X-033-1 YE 0.5_MM^2 2162 YE 0.5_MM^2 2161 SIGNAL
X-010-1 X-010-6
HAZARD LIGHT SWITCH Sheet 12 WB-064 BL 0.5_MM^2 4022 BL 0.5_MM^2 4023
HAZARD INPUT LEFT INDICATOR X-132-E X-132-A
BK 0.5_MM^2 G159 GB-036 Sheet 3 SAHR PARK BRAKE SIGNAL
HAZARD LIGHT SWITCH GROUND 18 18 X-033-5
Sheet 7 WB-065 GN 0.5_MM^2 E259 GR 0.5_MM^2 E253
X-132-D
VT 0.8_MM^2 4601 1 1
VT 0.8_MM^2 4602 CAN BUS LOW
X-040 FRONT 37 37 X-033-6
Sheet 7 WB-066 YE 0.5_MM^2 E249 YE 0.5_MM^2 E243
X-150 MAIN 120.00 Ohms
CAN BUS HIGH 30 30 X-033-12
VT 0.5_MM^2 47L1 Sheet 1 WB-067 YE 0.5_MM^2 3403 YE 0.5_MM^2 3405
ALTERNATOR CHARGE SIGNAL
OR 0.8_MM^2 AP29
OR 0.8_MM^2 AP28
VT 0.5_MM^2 45R0
VT 0.5_MM^2 45L0
VT 0.5_MM^2 47R1
X-033-34
BK 0.5_MM^2 G066 GB-019 Sheet 3
X-040
X-150 INSTRUMENT CLUSTER GROUND
OR 0.8_MM^2 AP20
2 2
X-139-B
3 3 X-139-F RIGHT TURN BK 0.5_MM^2 G089 GB-037 Sheet 3
VT 0.5_MM^2 45LB GROUND
5 5 X-139-D LEFT TURN TURN SIGNAL INDICATOR GROUND
VT 0.5_MM^2 45RB S-011
12 12 X-139-E
OR 0.8_MM^2 AP25 TURN SIGNAL SW
10 10 X-139-C
VT 0.5_MM^2 47R2
11 11 X-139-A
VT 0.5_MM^2 47L2
FRONT EXTERIOR LIGHTS 9 INSTRUMENT CLUSTER 10

S-014 Y-001
X-040 X-001
SAHR PARK BRAKE SWITCH X-150 X-051 SAHR BRAKE SOLENOID
X-098-1 24 24 SP-053 E E X-057-1 X-057-2
X-098-2 WH 0.5_MM^2 4036 WH 0.5_MM^2 4035 WH 0.5_MM^2 4032 WH 0.5_MM^2 4031 BK 0.5_MM^2 G020 GB-006 Sheet 3
X-098-3 SAHR BRAKE SOLENOID GROUND
PARK BRAKE IS APPLIED
WHEN SOLENOID NOT
POWERED
YE 0.5_MM^2 4054
OR 0.5_MM^2 4045
X-001
X-051
F F
BL 0.5_MM^2 4021 BL 0.5_MM^2 4022 WB-064 Sheet 10
SAHR PARK BRAKE SIGNAL
S-024
TO CLUSTER
PARKING BRAKE PRESSURE SWITCH
X-099-1
20 19
X-040
X-150 CLOSED WHEN PARK
20 19 BRAKE IS APPLIED
GND-009
J-001
POWER SOCKET 1
WH 0.5_MM^2 4034
OR 0.5_MM^2 4044
YE 0.5_MM^2 4051
Sheet 1 WB-117 RD 3_MM^2 P017
X-181-A X-181-B
POWERPOINT B+ X-012 RD 3_MM^2 8401 BK 3_MM^2 G068 GB-021 Sheet 3
POWER POINT 1 GROUND Sheet 1 WB-010
44 44 X-040 OR 0.5_MM^2 4041
F-016
X-150 SAHR PARK BRAKE KEY ON K-005
48 48 4 4 X-012
RD 3_MM^2 8404 RD 3_MM^2 8403 SP-040 J-002 X-013 SAHR PARK
30.0 A
POWER SOCKET 2 3 3 SP-051 33 33 BRAKE RELAY
YE 0.5_MM^2 4052 87A
30
X-182-A X-182-B F-017 7 7 SP-052 26 26 87
RD 3_MM^2 8402 BK 3_MM^2 G070 GB-022 Sheet 3 OR 0.5_MM^2 4043 OR 0.5_MM^2 4042
5.0 A
POWER POINT 2 GROUND 25 25 85 86
YE 0.5_MM^2 4053
34 34
BK 0.5_MM^2 G081 GB-033 Sheet 3

SAHR BRAKE RELAY COIL GROUND
X-013
22 22 K-006
SAHR PARK BRAKE
Sheet 2 WB-031 WH 0.5_MM^2 4037
21 21 TRANSMISSION CUTOUT RELAY
CLUTCH RELAY LOGIC B+ 14 14 30
87A
87
13 13
85 86
Sheet 6 WB-034 OR 0.5_MM^2 19M1
SAHR PARK BRAKE DECLUTCH CUTS POWER TO FORWARD AND REVERSE
RELAY KEY ON RELAYS WHEN THE PARK BRAKE IS ENGAGED
BK 0.5_MM^2 G079 GB-031 Sheet 3

SAHR BRAKE DECLUTCH
RELAY GROUND
POWER POINTS 11 SAHR PARK BRAKE 12


BK\WH----------------------BLACK\WHITE LB--------------------------LIGHT BLUE TN---------------------------TAN
SWITCH IS ON
BL---------------------------BLUE LG--------------------------LIGHT GREEN VT--------------------------VIOLET
Sheet 1 WB-120 OR 1_MM^2 AP17
REAR LIGHTS KEY ON
X-012
X-040
4 4 X-150
F-018 8 8 31 31
OR 1_MM^2 AP58
15.0 A
S-010
REAR LIGHT SWITCH
X-112-E X-112-A
Sheet 9 WB-017 VT 0.5_MM^2 41F7 OR 1_MM^2 AP59 BK 0.5_MM^2 G099 GB-061 Sheet 3
X-040
REAR TAIL LIGHTS X-012 X-150 REAR LIGHTS
19 19 8 8 X-112-D E-017 SWITCH LAMP GROUND
VT 1_MM^2 043P
F-019 23 23 REAR WORK LIGHT R1
VT 0.5_MM^2 41R2
5.0 A X-512-1 X-512-2
VT 1_MM^2 0432
VT 0.8_MM^2 0436 BK 0.8_MM^2 G165 X-020 ROPS
Sheet 1 WB-036 RD 0.5_MM^2 P029
X-101 MAIN
E-018 SP-010 X-020 X-101 1 HORN B+ X-012
BK 2_MM^2 G010 BK 2_MM^2 G018 GB-053 Sheet 3 S-011
REAR WORK LIGHT L1 X-040
X-020 SP-118 X-513-1 X-513-2 REAR WORK GND 40 40
X-150
HORN SWITCH
X-101 VT 0.8_MM^2 0435 BK 0.8_MM^2 G166 F-021 X-151-E
36 36 6 6
24 RD 0.5_MM^2 64A1 RD 0.5_MM^2 64A2
24
VT 1_MM^2 0434 E-012 5.0 A
TAIL LIGHT 21 21
X-151-F
26 26
X-528-1 WH 0.5_MM^2 64B2 WH 0.5_MM^2 64B1
VT 0.5_MM^2 41R5
15 15 X-500 1
VT 0.5_MM^2 440B E-015
BRAKE LIGHT X-001
X-524-1 X-051
BK 1_MM^2 G008
N N
WH 0.5_MM^2 64B3
E-016 BK 0.5_MM^2 G041 GB-004 Sheet 9
LH TURN SIGNAL/HAZARD LIGHT LEFT INDICATOR LIGHT
X-525-1 X-526-1 SP-007 X-020 X-101 5
Sheet 9 WB-020 VT 0.5_MM^2 45L5 BK 0.5_MM^2 G169 BK 1_MM^2 G023 BK 1_MM^2 G007 GB-003 Sheet 3
LEFT REAR TURN SIGNAL BRAKE AND TAIL GROUND X-031-1
H-005
E-010 BK 0.5_MM^2 G039 GB-001 Sheet 9 X-032-1 HORN
RH TURN SIGNAL/HAZARD LIGHT RIGHT INDICATOR LIGHT
X-520-1 X-521-1
Sheet 9 WB-022 VT 0.5_MM^2 45R5 BK 0.5_MM^2 G163
GB-054 Sheet 3
RIGHT REAR TURN SIGNAL BK 0.5_MM^2 G063
HORN GROUND
VT 0.5_MM^2 4408
S-042
Sheet 1 WB-019 OR 0.5_MM^2 AP31 LEFT BRAKE LIGHT SWITCH
X-012 X-140-3 X-140-2
BRAKE LIGHTS KEY ON OR 0.5_MM^2 AP33 VT 0.5_MM^2 4405
27 27
F-020 SP-030 SWITCHES CLOSED WHEN
31 31 BRAKES ARE APPLIED S-043 SP-031
OR 0.5_MM^2 AP19
5.0 A RIGHT BRAKE LIGHT SWITCH
X-141-3 X-141-2
OR 0.5_MM^2 AP34 VT 0.5_MM^2 4406
REAR LIGHTS EXTERIOR 13 HORN 14
X-040 S-005
X-150 DIFF LOCK SWITCH
16 16 X-187-F
Sheet 6 WB-131 YE 0.5_MM^2 25S1 YE 0.5_MM^2 25S6
DIFF LOCK TO X-187-E
27 27
DIFF LOCK SOL OR 0.5_MM^2 19EF
Sheet 2 WB-009 OR 0.5_MM^2 19E8

KEY ON POWER
OPTIONS 15 16

BK\WH----------------------BLACK\WHITE LB--------------------------LIGHT BLUE TN---------------------------TAN
SWITCH IS ON
BL---------------------------BLUE LG--------------------------LIGHT GREEN VT--------------------------VIOLET
HIGH PRESSURE OIL HYDRAULIC SCHEMATIC 47388794
RETURN/SUMP 586H/588H Tier 4 Rough Terrain Forklift
TRAPPED OIL (from PIN NCC570000)

Case 586h Tech Manual Tier 4

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Case 586h Tech Manual Tier 4

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Rodney DeLoach

Red E Services Inc.

586H Four-Wheel Drive (4WD) TIER 4B (FINAL)

Product Market Product Engine

[10.202] Air cleaners and lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.2

[10.216] Fuel tanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3

[10.206] Fuel filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.4

[10.218] Fuel injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.5

[10.220] Throttle linkage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.6

[10.254] Intake and exhaust manifolds and muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.7

[10.304] Engine lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.8

[10.400] Engine cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.9

[10.414] Fan and drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.10

[21.112] Power shuttle transmission. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.2

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

[27.550] Non-powered rear axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27.4

Brakes and controls .................................................................... 33

[33.202] Hydraulic service brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33.2

[35.102] Pump control valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.2

[35.104] Fixed displacement pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.3

[35.300] Reservoir, cooler, and filters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.4

[35.322] Regulated/Low pressure system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.5

[35.359] Main control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.6

[35.728] Telescopic arm control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.7

[35.740] Telescopic arm hydraulic system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.8

Frames and ballasting ................................................................. 39

[41.200] Hydraulic control components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.2

[41.216] Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.3

[44.520] Rear wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.2

Electrical systems ....................................................................... 55

[55.201] Engine starting system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.2

[55.301] Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.3

[55.302] Battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.4

[55.408] Warning indicators, alarms, and instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.5

[55.991] Telematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.6

[55.DTC] FAULT CODES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.7

Platform, cab, bodywork, and decals ............................................. 90

[90.114] Operator protections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.2

[90.116] Fenders and guards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.3

[90.120] Mechanically-adjusted operator seat. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.4

Foreword - Important notice regarding equipment servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Foreword - Important notice regarding equipment servicing

FAILURE TO FOLLOW DANGER, WARNING, AND CAUTION MESSAGES COULD RESULT

Safety rules - Roll Over Protective Structure (ROPS)

Your machine is equipped with a ROPS (cab or canopy) protective structure.

The protective structure is a special safety component of your machine.

Basic instructions - Prepare machine for service/Return machine

Prepare machine for service

5. With the key in the ON position, engine NOT running,

NOTE: Dual battery configuration shown. Disconnect

Disconnect the battery or batteries

Return machine to use

NOTE: Dual battery configuration shown. Connect both

1. Connect the battery positive (1) cable to the battery or RAPH12FRK0044BA 4

Basic instructions - Chain Wear Tables - Roller Chains

Critical dimensions of the chain are as follows:

Elongation is normal and may be minimized by proper

WEAR LIMITS ON ROLLER CHAIN