Service Manual 1021F

1021F
1121F
Tier 2
Wheel Loader
SERVICE MANUAL
Printed in U.S.A. Part number 47392461

1st edition English
Copyright © 2012 CNH America LLC. All Rights Reserved.
Case is a registered trademark of CNH America LLC. July 2012
Racine Wisconsin 53404 U.S.A.
Contents
INTRODUCTION
Engine....................................................................................... 10
Engine and crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.001
Air cleaners and lines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.202

Engine lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.304
Aftercooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.310
Fan and drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.414
Transmission.............................................................................. 21
Powershift transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.113
Powershift transmission external controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.135
Gearbox internal components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.145
Powershift transmission internal components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.155
Four-Wheel Drive (4WD) system .................................................. 23

Drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23.314
Front axle system ....................................................................... 25

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

Powered rear axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27.100
Brakes and controls .................................................................... 33

Parking brake / Parking lock. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33.110
Hydraulic service brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33.202
Hydraulic systems....................................................................... 35
Hydraulic systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.000
Variable displacement pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.106
Reservoir, cooler, and filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.300
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Pilot system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.357
Main control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.359

Auxiliary hydraulic valves and lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.525
Front loader arm hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.701
Steering..................................................................................... 41
Auxiliary steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.910
Wheels ...................................................................................... 44
Front wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.511
Cab climate control ..................................................................... 50

Air conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50.200
Electrical systems ....................................................................... 55

Electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.000
Fuel tank system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.011
Engine cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.012
Engine control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.015
Transmission control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.024
Service brake electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.030
Parking brake electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.031
Hydraulic system control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.036
Steering control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.047
Heating, Ventilation, and Air-Conditioning (HVAC) control system . . . . . . . . . . . . . . . . . . . . . . . 55.050
Cab Heating, Ventilation, and Air-Conditioning (HVAC) controls . . . . . . . . . . . . . . . . . . . . . . . . . 55.051
Harnesses and connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.100

Engine starting system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.201
Cold start aid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.202

Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.301
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.302
External lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.404
External lighting switches and relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.405
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Warning indicators, alarms, and instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.408
Loader arm and bucket control system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.415
Cab/Platform harnesses and connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.510

Cab controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.512
Cab lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.514
Wiper/Washer system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.518
Cab brake controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.519

Cab controls (Lift arm, Boom, Dipper, Bucket) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.524
FAULT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.DTC
Platform, cab, bodywork, and decals ............................................. 90

Machine shields and guards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.105
Protections and footboards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.118

Pneumatically-adjusted operator seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.124
Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.150
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INTRODUCTION
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Contents
INTRODUCTION
Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1021F INT, 1121F INT
Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Consumables - Biodiesel Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Hydraulic contamination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
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INTRODUCTION
Torque
Alternator
Alternator pulley retaining nut 95 - 109 N·m (70 - 80 lb ft)
Battery terminal nut 6 - 8 N·m (55 - 72 lb in)
Indicator light terminal nut 2 - 3 N·m (16 - 24 lb in)
Axle
Planetary carrier lock screws 200 N·m (148 lb ft)
Brake spring retainer cover 34 N·m (25 lb ft)
Axle wheel end screw plug 50 N·m (37 lb ft)
Nut Securing Brake Tube to Connector 100 N·m (74 lb ft)
Brake Tube Fitting to Wheel End Fitting 36 N·m (27 lb ft)
Axle housing bolts 560 N·m (413 lb ft)
Input flange slotted nut 1200 N·m (885 lb ft)
Differential releasing housing cover bolts 185 N·m (136 lb ft)
Differential housing cover bolts 400 N·m (295 lb ft)
Wheel mounting bolts 644 - 719 N·m (475 - 530 lb ft)
Axle breather valve 4 - 6 N·m (35 - 53 lb in)
Front axle mounting bolts 1519 - 1708 N·m (1120 - 1260 lb ft)
Rear trunnion cover bolts 103 - 115 N·m (76 - 85 lb ft)
Rear trunnion spacer bolts 285 - 319 N·m (210 - 235 lb ft)
Trunnion casting mounting 651 - 732 N·m (480 - 540 lb ft)
Chassis
Cab and canopy mounting bolts 773 - 854 N·m (570 - 630 lb ft)
Counterweight mounting bolts 1125 - 1261 N·m (830 - 930 lb ft)
Lower step support bolts 27 - 31 N·m (20 - 23 lb ft)
Battery hold down bolts 651 - 732 N·m (480 - 540 lb ft)
Cooling
Cooling frame mounting 271 - 298 N·m (200 - 220 lb ft)
Fan mounting nut 109 - 122 N·m (80 - 90 lb ft)
Drivetrain
Flex plate to flywheel bolts 33 - 41 N·m (24 - 30 lb ft)
Carrier bearing bolt 149 - 163 N·m (110 - 120 lb ft)
Drive line mounting bolts 136 - 149 N·m (100 - 110 lb ft)
Transmission sight gauge mounting bolts 3 - 5 N·m (24 - 48 lb in)
Transmission shock mount nuts 929 - 1044 N·m (685 - 770 lb ft)
Transmission-to-bracket bolts 1125 - 1275 N·m (830 - 940 lb ft)
Transmission-to-flywheel housing bolts 54 - 60 N·m (40 - 44 lb ft)
Transmission fill tube bolts 17 - 33 N·m (151 - 292 lb in)
Banjo tube bolt 160 N·m (118 lb ft)
Bypass valve hose clamps 10 - 11 N·m (90 - 100 lb in)
Engine
Air intake hose clamps 4 - 5 N·m (35 - 44 lb in)
Aspirator hose clamps 3 N·m (30 lb in)
Muffler flex tube clamp 18 - 22 N·m (13 - 16 lb ft)
Muffler clamp at turbo 5 - 6 N·m (44 - 53 lb in)
Starter motor mounting bolts 41 - 48 N·m (30 - 35 lb ft)
Engine support bracket-to-rear chassis bolts 386 - 434 N·m (285 - 320 lb ft)
Engine shock mount nuts 397 - 447 N·m (293 - 330 lb ft)
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INTRODUCTION
Fuel tank
Tighten the fuel sender bolts in the sequence as shown in the image (2) to a torque of 6 - 8 N·m (53 - 71 lb in).
RCPH11WHL117AAR 1
Fuel sender mounting bolts 6 - 8 N·m (53 - 71 lb in)

Fuel tank skid plate bolts (bolts and nuts are to be 122 - 164 N·m (90 - 121 lb ft)
torqued only one time. Replace as necessary)
Fuel tank mounting bolts (bolts and nuts are to be 301 - 407 N·m (222 - 300 lb ft)
torqued only one time. Replace as necessary)
Hydraulics
Priority valve mounting bolts 85 - 102 N·m (63 - 75 lb ft)
Main hydraulic pump elbow 85 - 102 N·m (63 - 75 lb ft)
Hydraulic tank sight gauge mounting 3 - 6 N·m (27 - 53 lb in)
Surge tank hose clamp mounting 48 N·m (35 lb ft)
Brake pump mounting bolts 149 - 170 N·m (110 - 125 lb ft)
Hydraulic oil tank suction hose clamps 10 - 11 N·m (90 - 100 lb in)
Split, half clamp flange bolts (hydraulic tank-to-pumps 73 - 90 N·m (54 - 67 lb ft)
and priority valve-to-pump)
Split, half clamp flange bolts (priority valve-to-loader 198 - 242 N·m (146 - 179 lb ft)
valve)
Pump mounting bolts 149 - 170 N·m (110 - 125 lb ft)
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INTRODUCTION
Wheels
Tighten the wheel nuts in two stages. First, tighten the wheel nuts in the sequence as shown in the image (1) to a
torque of 278 N·m (205 lb ft). Second, tighten the wheel nuts in the sequence as shown in the image (1) to a torque
of 640 - 720 N·m (472 - 531 lb ft).
RCPH11WHL202AAH 2
Wheel nuts First stage: 278 N·m (205 lb ft). Second stage: 640 -
720 N·m (472 - 531 lb ft)
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INTRODUCTION
Capacities
1021F Capacities and specifications

Engine
Type of oil CASE AKCELA ENGINE OIL 15W-40
Capacity (with filter change) 28.5 l (30.1 US qt)
Cooling system
System capacity 56.8 l (60.0 US qt)
Fuel system
System capacity 473.0 l (125.0 US gal)
Hydraulic system
Type of fluid CASE AKCELA HY-TRAN® ULTRA™
HYDRAULIC TRANSMISSION OIL
Total system capacity 250.0 l (66.0 US gal)
Reservoir capacity 134.0 l (35.4 US gal)
Transmission
Type of oil CASE AKCELA NEXPLORE™ FLUID
Service capacity - with filter change 45.4 l (48.0 US qt)
Axles
Front axle 42.0 l (44.4 US qt)
Rear axle 42.0 l (44.4 US qt)
Front axle with axle cooler 45.7 l (48.3 US qt)
Rear axle with axle cooler 45.7 l (48.3 US qt)
Heavy duty front axle 62.0 l (65.5 US qt)
Heavy duty front axle with cooler 65.7 l (69.4 US qt)
Grease fittings, as required CASE AKCELA MOLY GREASE
* Machines are shipped from the factory with break-in oil.
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INTRODUCTION
1121F Capacities and specifications

Engine
Type of oil CASE AKCELA ENGINE OIL 15W-40
Capacity (with filter change) 28.5 l (30.1 US qt)
Cooling system
System capacity 56.8 l (60.0 US qt)
Fuel system
System capacity 473.0 l (125.0 US gal)
Hydraulic system
Type of fluid CASE AKCELA HY-TRAN® ULTRA™
HYDRAULIC TRANSMISSION OIL
Total system capacity 250.0 l (66.0 US gal)
Reservoir capacity 134.0 l (35.4 US gal)
Transmission
Service capacity - with filter change 45.4 l (48.0 US qt)
Axles
Front axle 64.0 l (67.6 US qt)
Rear axle 64.0 l (67.6 US qt)
Front axle with axle cooler 67.7 l (71.5 US qt)
Rear axle with axle cooler 67.7 l (71.5 US qt)
Front axle with differential lock 62.0 l (65.5 US qt)
Front axle with differential lock and axle cooler 65.7 l (69.4 US qt)
Grease fittings, as required CASE AKCELA MOLY GREASE
* Machines are shipped from the factory with break-in oil.
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INTRODUCTION
Engine oil viscosity/Temperature ranges
RCPH11WHL023FAH 1
NOTE: Use of an engine oil pan heater or an engine coolant heater may be required when operating temperatures
are in Winter or Arctic conditions.
Transmission oil viscosity/Temperature ranges
RCPH10WHL453BAH 2
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INTRODUCTION
Hydraulic/Brake system - temperature range
RCPH10WHL006EAL 3
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INTRODUCTION
Coolant solution
Put only ethylene-glycol coolant solution in the cooling system. Use good quality ethylene-glycol that has a high
boiling point with no additives to prevent leakage. Do not use non-approved anti-rust additives. Anti-rust additives
and ethylene-glycol can mix and work against each other, reducing anti-corrosion protection, forming deposits in the
cooling system, and causing damage to the cooling system and radiator. Contact your dealer who can supply you
with the suitable coolant solution.
Anti-freeze/Anti-corrosion
Use anti-freeze in all seasons to protect the cooling system from corrosion and risk of freezing. For areas where the
ambient temperature is over -36 °C (-32.8 °F) use a blend of 50% ethylene-glycol based anti-freeze.
For areas where the temperature is below -36 °C (-32.8 °F)- it is advisable to use a blend of 40% water and 60%
anti-freeze.
Fuel
Use diesel fuel suitable for the ambient temperature conditions (ASTM-D-975).
Use fuel which is to ASTM (American Society for Testing and Materials) D975 standard.
Use grade No. 2 fuel. The use of other types of fuel can result in a loss of power of the engine and may cause high
fuel consumption.
In very low ambient temperatures, use a mixture of fuels No. 1 and No. 2 as necessary. Consult your fuel supplier
for appropriate fuel supply.
If the temperature falls below the fuel cloud point (point at which wax begins to form) the wax crystals will cause power
loss or will prevent the engine from starting.
In cold weather, fill the fuel tank at the end of the day's work in order to prevent the formation of condensation.
Fuel storage
Prolonged storage of fuel can lead to the accumulation of impurities and condensation in the fuel. Engine trouble can
often be traced to the presence of water in the fuel.
The storage tank must be placed outside and the temperature of the fuel should be kept as low as possible. Drain off
water and impurities regularly.
Hydraulic fluid
Case Akcela Hy-Tran Ultra hydraulic fluid is specifically designed for high pressure applications and for Case hydraulic
systems. Your Case Dealer can provide hydraulic fluid to fulfill different climate/temperature conditions. Refer to the
charts at the beginning of this section.
Transmission component oil

Extreme pressure oil should be used for enclosed transmission components. Choose an oil that is manufactured
for your climate/temperature conditions such as Case Nexplore or CNH F200A. See charts at the beginning of this
section.
Grease
The type of grease to use depends on ambient temperature such as: Case Akcela Molydisulfide Grease
Environment
Before you service this machine and dispose of oil, fluids, and lubricants, obey environmental regulations. Do not
drain oil or fluids on to the ground or into containers that leak. Check with your local environmental, recycling center
or your dealer for correct disposal information.
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INTRODUCTION
Engine oil
Case Akcela engine oil is recommended for your engine.
This oil insures correct lubrication of your engine in all
working conditions. See charts at the beginning of this
section to choose the correct oil for climate/temperatures.
If Case Akcela engine oil cannot be obtained, use only oil

of the API SERVICE CI-4 category.
NOTE: Do not put any Performance Additive or other ad-
ditive in the sump. Oil change intervals shown in this man-
ual are based on tests carried out utilizing Case lubricants.
RCPH10WHL012AAD 4
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INTRODUCTION
Consumables - Biodiesel Fuel

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

Biodiesel fuels must be purchased from a trusted supplier that understands the product and maintains good fuel
quality. Biodiesel fuels must be pre-blended by the supplier. Mixing biodiesel fuels on site can result in an incorrect
mixture which can damage engine and fuel system.
Engine performance is effected by the use of biodiesel fuels. There may be up to 12 percent reduction in power or
torque depending on the blend used.
NOTICE: DO NOT modify the engine and/or fuel injection pump settings to recover reduced performance.
The reduced power must be accepted if using any biodiesel fuel blends.
NOTICE: The use of high biodiesel fuel blends is not recommended in cold weather conditions.
Using biodiesel fuels may require changing engine oil, engine oil filters, and fuel filter elements more frequently.
Biodiesel fuels can remove rust and other particles that adhere to the inside of the fuel tank. These particles are
trapped by vehicle filters and may cause shortened filter life or filter blockages. Blockages are more common in cold
weather conditions. Consult your dealer for information on cold weather operation and proper maintenance intervals
when using any biodiesel fuel blend.
Biodiesel fuel may degrade natural rubber gaskets and hoses, as it is more solvent than petro-diesel. Frequently
inspect hoses and other engine components when using biodiesel fuel.
DO NOT allow water to collect in the fuel or storage tanks. Biodiesel fuel attracts moisture from the atmosphere.
Keep fuel tanks and storage tanks as full as possible to limit the amount of air and water vapors. It may be necessary
to drain machine fuel filter more frequently. Potential oxidation and stability could create a problem with fuel stored in
the machine.
Biodiesel Storage
NOTICE: DO NOT store machines for more than three months with biodiesel blends in the fuel system. DO NOT
store biodiesel fuel in on-site storage tanks for more than three months.
If long periods of storage are required, run the machine for 20 hours using regular diesel fuel to flush the biodiesel
fuel from the engine fuel system.
NOTICE: Biodiesel fuels must not be stored in on-site storage tanks for more than 3 months. Any spillage of biodiesel
fuels must be cleaned up immediately before it can cause damage to the environment or the paint finish of the ma-
chine. Before using biodiesel fuel blends, you should consult with your dealer to receive full information about the
approved blend for your machine and any detailed conditions of its usage. Failure to follow the requirements and
conditions of biodiesel fuel usage will void your machine’s warranty.
NOTE: B7 is the highest biodiesel (7% blend) that should be used in this machine.
47392461 19/06/2012
12
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.
(A) When you drain the oil or disconnect any line.
(B) When you disassemble a component.
(C) From normal wear of the hydraulic components.
(D) From damaged or worn seals.
(E) From a damaged component in the hydraulic 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.
(A) Cylinder rod seals leak.
(B) Control valve spools do not return to neutral.
(C) Movement of control valve spools is difficult.
(D) Hydraulic oil becomes too hot.
(E) Pump gears, housing, and other parts wear rapidly.
(F) Relief valves or check valves held open by dirt.
(G) Quick failure of components that have been repaired.
(H) Cycle times are slow; machine does not have enough power.
If your machine has any of these problems, check the hydraulic oil for contamination. There are two types of contam-
ination, microscopic and visible.
Microscopic contamination occurs when very fine particles of foreign material are in suspension in the hydraulic oil.
These particles are too small to see or feel. Microscopic contamination can be found by identification of the following
problems or by testing in a laboratory. Examples of the problems:
(A) Cylinder rod seal leak.
(B) Control valve spools do not return to NEUTRAL.
(C) The hydraulic system has a high operating temperature.
Visible contamination is foreign material that can be found by sight, touch, or odor. Visible contamination can cause
a sudden failure of components. Examples of visible contamination:
(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.
If you find contamination, use a Portable Filter to clean the hydraulic system.
47392461 19/06/2012
13
CONSUMABLES INDEX
Consumable IU PAGE
CASE Akcela Engine oil Capacities 6
15W-40
CASE Akcela HY-TRAN® Capacities 6
Ultra™ hydraulic transmission
oil
CASE Akcela NEXPLORE™ Capacities 6
fluid
fluid
CASE Akcela Moly grease Capacities 6
CASE Akcela Engine oil Capacities 7
15W-40
CASE Akcela HY-TRAN® Capacities 7
Ultra™ hydraulic transmission
oil
fluid
fluid
CASE Akcela Moly grease Capacities 7
47392461 19/06/2012
14
SERVICE MANUAL
Engine
1021F
1121F
47392461 19/06/2012
10
Contents
Engine - 10
Engine and crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.001

1021F , 1121F
Air cleaners and lines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.202

1021F , 1121F
Engine lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.304

1021F , 1121F
Aftercooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.310
1021F , 1121F
Fan and drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.414

1021F , 1121F
47392461 19/06/2012
10
CONSUMABLES INDEX
Consumable IU PAGE
DOW 732 RTV Silicone clear Engine - Install 10.001 / 19
47392461 19/06/2012
10
47392461 19/06/2012
10
Engine - 10
Engine and crankcase - 001
1021F
1121F
47392461 19/06/2012
10.001 / 1
Contents
Engine - 10
TECHNICAL DATA
Engine
Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
SERVICE
Engine
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
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CONSUMABLES INDEX
Consumable IU PAGE
DOW 732 RTV Silicone clear Engine - Install 10.001 / 19
47392461 19/06/2012
10.001 / 3
Engine - Engine and crankcase
Engine - Speeds
1021F \ 1121F
Machine idled (alternate low idle) 570 - 630 rpm
Machine idled (cold weather alternate accelerated low idle) 1170 - 1230 rpm
47392461 19/06/2012
10.001 / 4
Engine - Remove
Prior operation:
Engine hood - Remove (90.105)
NOTE: Put caps on the fittings and plugs in the hoses to prevent foreign material from entering the system when
disconnecting fuel lines or hydraulic hoses.
1. Park the machine on a level surface and lower the
bucket to the ground. Put the articulation lock (1) in
the locked position.
RCPH11WHL039AAH 1
2. Key in the run position, engine off, place the pilot

control switch (1) in the normal operation position.
RCPH10WHL982FAH 2
3. Move the loader hydraulic control handle to the raise

and lower position in order to release any hydraulic
pressure in the lift circuit.
4. Move the loader control handle in and out of the tilt
position several times, this will relieve any pressure
in the pilot accumulator.
5. Release the pressure in the ride control accumulator
with the bleeder valve in the valve load travel stabi-
lizer.
6. Depress the brake pedal several times to discharge
brake accumulators.
7. Slowly loosen the filler cap on the hydraulic oil tank
to release air pressure.
47392461 19/06/2012
10.001 / 5
8. Put the master disconnect switch (1) in the off posi-

tion.
RCPH11WHL094AAH 3
9. Drain the engine radiator coolant.

10. Drain the engine oil.
11. Loosen the hose clamp (1) on the air intake hose
under the air inlet hood.
RCPH11WHL053AAR 4
12. Remove the mounting bolts on the exhaust stack

hood. Attach lifting equipment to the exhaust stack.
Remove the exhaust stack hood (1).
RCPH11WHL010AAR 5
13. Remove the muffler assembly.
47392461 19/06/2012
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14. Disconnect the deaeration tank overflow hose (2).

15. Remove the P-clamps (1) that secure the overflow
hose to the wall and brackets. Position the overflow
hose away from the engine and engine wall.
RCPH11WHL012AAR 6
16. Remove the left bracket (1) and right bracket (2).
RCPH11WHL012AAR 7
17. Remove the hydraulic oil lines (1).
RCPH11WHL013AAR 8
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18. Remove the after air cooler tube (1) .

19. Remove the bulkheads (2).
RCPH11WHL014AAR 9
20. Remove the oil dipstick P-clamp (3) . Pull the oil
dipstick tube (1) through the wall.
21. Label and disconnect the hood lift strut electrical con-
nector (2).
RCPH11WHL015AAR 10
22. Remove the before air cooler tube (1).

23. Remove the upper radiator tube (2).
RCPH11WHL016AAR 11
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24. Label and disconnect the humidity sensor electrical

connector (1).
25. Remove the turbo inlet tube (2).
26. Label and disconnect the air filter restriction sensor
electrical connector (3).
RCPH11WHL017AAR 12
27. Remove the wire harness P-clamp (1).

28. Loosen the hose clamp on the air intake hose (2).
Disconnect the air intake hose (3).
RCPH11WHL018AAR 13
29. Remove the lower, right panel (1) on the engine wall.
RCPH11WHL020AAR 14
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10.001 / 9
30. Remove the air box assembly.
RCPH11WHL019AAR 15
31. Remove the lower radiator tube (1) .
RCPH11WHL021AAR 16
32. Attach lifting equipment to the engine wall. Remove

the engine wall’s hold-down bolts. Lift and remove
the engine wall.
RCPH11WHL039AAR 17
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33. Remove the turbo exhaust tube (1).
RCPH11WHL022AAR 18
34. Remove two bolts (2), washers (3), and nuts (4). Re-
move the air intake hose (1) .
RCPH11WHL023AAR 19
35. Disconnect the inlet and outlet heater core heater

hoses (1).
RCPH11WHL038AAR 20
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10.001 / 11
36. Disconnect the starter battery cables (1) and starter

switch wire (2).
RCPH11WHL049AAR 21
37. Disconnect the following from the crank case venti-

lation/fuel filter bracket assembly:
• Fuel pump electrical connector
• Water sensor electrical connector
• Ground wire
• Wire harness P-clamp
• Crank case filter inlet hose
• Crank case filter outlet hose
• Crank case filter oil return hose
• Fuel pump inlet tube
• Fuel pump outlet tube
38. Remove the crank case ventilation/fuel filter bracket RCPH11WHL040AAR 22
assembly.
39. Label and disconnect the engine control module
electrical connector (1).
RCPH11WHL041AAR 23
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10.001 / 12
40. Disconnect the fuel return line (1).

41. Disconnect the battery positive wire (2) on the air grid
heater.
RCPH11WHL042AAR 24
42. Disconnect the engine ground wires (1).

RCPH11WHL043AAR 25
44. Remove the engine serpentine belt (1).
RCPH11WHL051AAR 26
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10.001 / 13
45. Label and disconnect the A/C compressor electrical

connector (1).
46. Label and disconnect the A/C pressure switch elec-
trical connector (4).
47. Remove the alternator power wire. (3).
48. Label and disconnect the bulk electrical connector
(5).
RCPH11WHL045AAR 27
49. Remove the A/C compressor (2). Position the A/C

compressor (2) away from the engine.
50. Remove the wire harness P-clamps (1).
RCPH11WHL046AAR 28
51. Remove the engine oil drain tube (1).
RCPH11WHL047AAR 29
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52. Attach lifting equipment to the engine. Support the

engine.
RCPH11WHL048AAR 30
53. Remove the hydraulic oil return tube P-clamp (1).

Position the hydraulic oil return tube away from the
converter housing cover plate.
RCPH11WHL050AAR 31
54. For 1021F models, do procedure A. For 1121F mod-

els, do procedure B.
A. Remove the converter housing cover plate (1).
See figure 32.
B. Remove access cover located above starter,
then remove plug behind cover. Carefully re-
move torque converter bolts through plug hole.
Use care to ensure bolts do not fall into en-
gine housing. Supporting figure is currently not
available.
RCPH11WHL034AAR 32
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55. Remove the flex plate bolts (1).
RCPH11WHL035AAR 33
56. Remove the harmonic balancer (1).
RCPH11WHL051AAR 34
57. Remove the front engine mounts (1) and engine

mount plate (2).
RCPH11WHL052AAR 35
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58. Remove the bell housing bolts (1).
RCPH11WHL036AAR 36
59. Remove the engine.
RCPH11WHL048AAR 37
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10.001 / 17
Engine - Install
1. Carefully lower the engine into the chassis.
RCPH11WHL048AAR 1
2. Install the bell housing bolts (1). Tighten the bell

housing bolts (1) to a torque of 54 - 60 N·m (40 -
44 lb ft).
RCPH11WHL036AAR 2
3. Install the engine mount plate (5) and the engine

mount brackets (1), but do not tighten the bolts to
a torque value.
4. Tighten the engine bracket upper bolts (2) to a torque
of 171 - 231 N·m (126 - 170 lb ft). Tighten the engine
bracket lower bolts (3) to a torque of 69 - 80 N·m (51
- 59 lb ft). Tighten the engine mount plate bolts (4) to
a torque of 386 - 434 N·m (285 - 320 lb ft). Tighten
the engine bracket-to-engine mount plate bolts (6) to
a torque of 397 - 447 N·m (293 - 330 lb ft).
RCPH11WHL052AAR 3
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10.001 / 18
5. Install the harmonic balancer (1). Tighten the har-

monic balancer bolts (2) to a torque of 115 N·m (85
lb ft).
RCPH11WHL051AAR 4
6. Install the flex plate bolts (1). Tighten the flex plate
bolts (1) to a torque of 33 - 41 N·m (24 - 30 lb ft).
RCPH11WHL035AAR 5
7. For 1021F models, do procedure A. For 1121F mod-

els, do procedure B.
A. Apply DOW 732 RTV SILICONE CLEAR to the
converter housing cover plate (1). See figure
6.
B. Carefully install torque converter bolts through
plug hole. Tighten bolts to standard torque. In-
stall plug and housing cover plate. Supporting
figure is currently not available.
8. Install the converter housing cover plate (1).
RCPH11WHL034AAR 6
47392461 19/06/2012
10.001 / 19
9. Connect the inlet and outlet heater core heater hoses

(1).
RCPH11WHL038AAR 7
10. Reposition the hydraulic oil return tube. Install the

hydraulic oil return tube P-clamp (1).
RCPH11WHL050AAR 8
11. Install the air box snorkel (1). Install two bolts (2),
washers (3), and nuts (4).
RCPH11WHL023AAR 9
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10.001 / 20
12. Install the turbo exhaust tube (1).

13. Tighten the turbo muffler clamp (2) to a torque of 5 -
6 N·m (44 - 53 lb in).
RCPH11WHL022AAR 10
14. Remove lifting equipment (1) from the engine.
RCPH11WHL048AAR 11
15. Install the engine wall.
RCPH11WHL039AAR 12
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10.001 / 21
16. Install the lower radiator tube (1).
RCPH11WHL021AAR 13
17. Install the air box.
RCPH11WHL019AAR 14
18. Install the wire harness P-clamp (1) .

19. Connect the air intake hose (3). Tighten the hose
clamp on the air intake hose (2) to a torque of 4 - 5
N·m (35 - 40 lb in).
RCPH11WHL018AAR 15
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20. Install the lower, right panel (1) on the engine wall.
RCPH11WHL020AAR 16
21. Install the turbo inlet tube (2).

22. Tighten the air intake hose clamp (3) to a torque of 4
- 5 N·m (35 - 40 lb in).
23. Connect the humidity sensor electrical connector (1).
24. Connect the air filter restriction sensor electrical con-
nector (4).
RCPH11WHL017AAR 17
25. Install the upper radiator tube (2).

26. Install the before air cooler tube (1).
RCPH11WHL016AAR 18
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10.001 / 23
27. Install the engine oil drain tube (1).
RCPH11WHL047AAR 19
28. Install the wire harness P-clamps (1).
RCPH11WHL046AAR 20
29. Install the engine serpentine belt (1).
RCPH11WHL051AAR 21
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10.001 / 24
30. Install the A/C compressor (2).

31. Connect the A/C compressor electrical connector (1).
32. Connect the A/C pressure switch electrical connector
(4).
33. Connect the alternator power wire (3). Tighten the
nut to a torque of 6 - 8 N·m (55 - 70 lb in).
34. Connect the bulk electrical connector (5).
RCPH11WHL045AAR 22
35. Connect the engine ground wires (1).

36. Install the wire harness P-clamp (2).
RCPH11WHL043AAR 23
37. Connect the fuel return line (1).

38. Connect the battery positive wire (2) on the air grid
heater.
RCPH11WHL042AAR 24
47392461 19/06/2012
10.001 / 25
39. Connect the engine control module electrical con-

nector (1).
RCPH11WHL041AAR 25
40. Install the crank case ventilation/fuel filter bracket as-

sembly.
41. Connect the following on the crank case ventilation/
fuel filter bracket assembly:
• Fuel pump electrical connector
• Water sensor electrical connector
• Ground wire
• Wire harness P-clamp
• Crankcase filter inlet hose
• Crankcase filter outlet hose
• Crankcase filter oil return hose
• Fuel pump inlet tube RCPH11WHL040AAR 26
• Fuel pump outlet tube

42. Connect the starter battery cables (1) and starter
switch wire (2).
RCPH11WHL049AAR 27
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10.001 / 26
43. Connect the hood lift strut electrical connector (2).

44. Slip the oil dipstick tube (1) through the engine wall.
Install the dipstick tube P-clamp (3).
RCPH11WHL015AAR 28
45. Install the bulkheads (2).

46. Install the after air cooler tube (1).
RCPH11WHL014AAR 29
47. Install the hydraulic lines (1).
RCPH11WHL013AAR 30
47392461 19/06/2012
10.001 / 27
48. Install the left bracket (1) and right bracket (2).
RCPH11WHL012AAR 31
49. Install the P-clamps (2) and overflow tube (1) to the
engine wall, left bracket, and deaeration tank (3).
RCPH11WHL012AAR 32
50. Install the muffler assembly.

51. Lower the exhaust stack hood (1) in front of the en-
gine wall and onto the left bracket, right bracket, and
hydraulic oil tank.
52. Install the exhaust stack hood mounting bolts.
RCPH11WHL010AAR 33
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10.001 / 28
53. Attach the air box snorkel to the air inlet hood. .
54. Tighten the air box snorkel hose clamp (1) to a torque
of 4 - 5 N·m (35 - 40 lb in).
RCPH11WHL053AAR 34
55. Check and adjust all fluid levels.
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Index
Engine - 10

Engine - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Engine - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Engine - Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
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Engine - 10
Air cleaners and lines - 202
1021F
1121F
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10.202 / 1
Contents
Engine - 10
SERVICE
Air cleaner
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
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Engine - Air cleaners and lines
Air cleaner - Remove

1. Lower bucket to the ground and install the transport/
service link into the locked position.
RCPH11WHL039AAH 1
2. Raise the hood and remove the side body panel from
the right hand side of the engine compartment. Lo-
cate the engine air filter housing.
RCPH11WHL007BAQ 2
3. Turn master electric switch OFF.
RCPH11WHL307AAH 3
47392461 19/06/2012
10.202 / 3
4. Release clips securing the air filter element housing

cover.
RCPH11WHL008BAQ 4
5. Remove cover from the air filter element housing.
RCPH11WHL009BAQ 5
6. Remove primary filter element. Use handle to pull

the element down and straight out of housing.
RCPH11WHL012BAQ 6
47392461 19/06/2012
10.202 / 4
7. Remove secondary filter element. Use the handle to

pull element down and out of the housing.
RCPH11WHL011BAQ 7
NOTE: Remove extra debris and wipe the inside of the filter housing with a clean cloth.
NOTE: Do not clean the secondary filter element. It must be replaced if damaged or clogged. Check both filter
elements for damage.
Next operation:
Air cleaner - Install (10.202)
47392461 19/06/2012
10.202 / 5
Air cleaner - Install

Prior operation:
Air cleaner - Remove (10.202)
1. Install secondary filter element using the locating tab

as a guide.
RCPH11WHL014BAQ 1
2. Position locating tab into slot within the housing and

push the filter element up into place.
RCPH11WHL013BAQ 2
3. Install primary filter element by sliding it into housing

and pushing it up into place. Make sure filter element
tabs are positioned inside the grooves located on the
housing.
NOTE: Make sure primary and secondary filter elements
are fully seated and form an effective seal.
RCPH11WHL015BAQ 3
47392461 19/06/2012
10.202 / 6
4. Replace housing cover.

5. Lock clips (2) and secure filter housing cover.
NOTE: Make sure tabs of housing cover are correctly in-
serted into slots of filter housing. If cover does not fit prop-
erly, recheck filter element installation. Cover will be diffi-
cult to install if filter elements are not properly installed.
RCPH11WHL016BAQ 4
6. Reinstall side body panel. Turn master electric

switch ON and close hood.
RCPH11WHL307AAH 5
7. Remove the transport/service link from the locked

position and store it.
RCPH11WHL039AAH 6
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10.202 / 7
Index
Engine - 10

Air cleaner - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Air cleaner - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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Engine - 10
Engine lubrication system - 304
1021F
1121F
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Contents
Engine - 10
SERVICE
Blowby re-circulation system

Filter - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Filter - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
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Engine - Engine lubrication system
Blowby re-circulation system Filter - Remove

service link into the lock position.
RCPH11WHL039AAH 1
2. Raise the engine compartment hood and then turn

the Master electric switch to the OFF position.
RCPH11WHL307AAH 2
3. To access the engine air filter housing in the left side

of the engine compartment, raise the hood and re-
move the side body panel.
RCIL11WHL244BAF 3
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4. Locate the engine crankcase breather air filter ele-

ment housing cover.
RCIL11WHL245BAF 4
5. Release the clips securing engine crankcase

breather air filter element housing cover.
RCIL11WHL246BAF 5
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6. Remove filter element housing cover.
RCIL11WHL247BAF 6
RCIL11WHL248BAF 7
7. Remove the filter element and check it for damage.

Do not attempt to clean or recondition the filter. Re-
place the element per the recommended service in-
terval.
RCIL11WHL249BAF 8
Next operation:
Blowby re-circulation system Filter - Install (10.304)
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Blowby re-circulation system Filter - Install

Prior operation:
Blowby re-circulation system Filter - Remove (10.304)
1. Lubricate filter element seals with clean engine oil.

Reinstall filter element into filter element housing.
RCIL11WHL249BAF 1
2. Replace cover.
RCIL11WHL248BAF 2
RCIL11WHL247BAF 3
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3. Secure housing cover by fastening clips.
RCIL11WHL246BAF 4
4. Turn the master electric power switch ON and clear

any fault codes. Start machine and confirm the prob-
lem has been corrected. Lower the engine compart-
ment hood.
RCPH11WHL307AAH 5
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Index
Engine - 10

Blowby re-circulation system Filter - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Blowby re-circulation system Filter - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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Engine - 10
Aftercooler - 310
1021F
1121F
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Contents
Engine - 10
Aftercooler - 310
DIAGNOSTIC
Aftercooler
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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Engine - Aftercooler
Aftercooler - Testing
N° Test Point Expected Result Other Result (Possible Cause)
1 Condition Result Action
Check the core for leaks by clos- Action
ing off the outlet tube and attaching If leakage is detected replace the af-
regulated air pressure 550 kPa ( 80 ter cooler.
psi) to the inlet tube. Submerge the
cooler in water and watch for air leak-
age.
Check
bs03b028 1
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Index
Engine - 10
Aftercooler - 310
Aftercooler - Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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Engine - 10
Fan and drive - 414
1021F
1121F
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Contents
Engine - 10
Fan and drive - 414
FUNCTIONAL DATA
Reverse fan control system

Dynamic description – Cooling Fan System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Dynamic description – Fan Auto Mode Activation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Dynamic description – Fan Speed Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
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Engine - Fan and drive
Reverse fan control system - Dynamic description – Cooling Fan

System
Overview
The Wheel Loaders have a hydraulically driven cooling system fan. The cooling system module is located between
the cab and the engine on the smaller models and at the rear of the vehicle on the 1021F model. The hydraulic
reservoir is located at the rear of the cab. The cooling system module includes the radiator, the engine charge air
cooler, the hydraulic oil cooler, transmission oil cooler, fuel cooler and the AC condenser. Air flow enters the cooling
system module from both the right and left sides of the machine as well as the top. On the small models the air flow
exits into the engine compartment. On the 1021F the air flow exits out the rear of the machine.
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Fan Hydraulic Function

To drive the fan motor the fan drive system uses oil flow from the brake pump (36) that is not required to maintain
the brake accumulator charge to drive the fan motor (43). The brake pump (36) is mounted to the engine near the
injection pump. Brake actuation is controlled by the foot pedal in the brake valve (13). The oil required to apply the
brakes comes from accumulators which are charged by the brake valve (13). Once the accumulators are charged,
all of the flow from the brake pump (36) flows to the fan drive system. As the accumulator charge cuts in and out, the
operator may notice a slight change in fan sound and speed.
Non-Reversible Fan
In standard form, oil flows directly from the brake valve (13) to the inlet of the fan drive motor (43). The standard
non-reversible fan drive motor is protected by an external relief valve and a check valve that allows oil to recirculate
as the motor freewheels due to fan inertia when the engine stops. This protection valve (51) is teed into the inlet and
outlet of the fan drive motor (43). Oil returning from the fan drive motor (43) returns to the hydraulic oil cooler (42) and
then to the hydraulic filter (40). An optional thermal controlled bypass valve (41) allows the oil to bypass the cooler
until the temperature reaches 44 - 53 °C (111 - 127 °F). This thermal bypass gradually increases the flow through the
cooler until all of the fan drive flow passes through the oil cooler by the time the oil temperature reaches 63 °C (145
°F). The thermal bypass valve is included in the optional cold weather package.
Non-Reversible Fan Circuit Legend

1 – Rear brakes 38 – Reservoir 51 – External relief valve
2 – Front brakes 40 – Filter HC – Return from hydraulic circuit
4 – Parking brake 41 – Thermal cooler bypass HP – to hydraulic pump
13 – Brake valve 42 – Oil cooler
36 – Gear pump 43 – Fan motor
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RCPH11WHL032HAN 1
Non-Reversible Fan Circuit
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Fan Reverser and Speed Control (optional)

The cooling fan drive system can be equipped with an optional fan reverser / speed valve (45). The optional fan
reverse/speed control valve can reverse the airflow through the radiator and coolers to clear debris. This allows for
debris to be cleared without stopping for shop maintenance. With the fan reverser system, oil flows directly from the
brake valve (13) to the inlet of the reverser and variable speed control valve (45). The reversible fan drive motor is
protected by two relief valves (45E). These relief valves are part of the reverser valve assembly.
Oil returning from the fan drive motor (43) returns to the hydraulic oil cooler (42) and then to the hydraulic filter (40).
An optional thermal controlled bypass valve (41) allows the oil to bypass the cooler until the temperature reaches 44
- 53 °C (111 - 127 °F). This thermal bypass gradually increases the flow through the cooler until all of the fan drive
flow passes through the oil cooler by the time the oil temperature reaches 63 °C (145 °F). The thermal bypass valve
is included in the optional cold weather package. This reverser valve also has the ability to control the fan rotating
speed. The Advanced Instrument Cluster (AIC) controls the fan reverser valve. The AUTO function can be selected
within the AIC. The AUTO fan operating mode is activated in the Option settings screen menu of the AIC.
In addition to the Auto Fan mode selection in the AIC, there is a three position (MANUAL / AUTO / OFF) reverser
rocker switch in the right console in the cab. This switch allows the operator to override the auto fan reverse feature.
The MANUAL position of the switch is momentary contact with a spring return. In the MANUAL position the operator
controls how often that the fan reverses to clear debris. In the center AUTO position of the switch the fan speed
is regulated by a proportional solenoid valve (45B) depending on system temperatures. Also with the switch in the
AUTO position, the AIC will initiate a reverse fan cycle, as long as the engine speed is greater than 1600 RPM after
about 30 minutes of operation. In the OFF position of the switch the fan will operate at full speed and will not reverse
unless manually selected. If either MANUAL or AUTO position of the switch is selected, the fan reversal is disabled
if hydraulic oil temperature is below 10 °C (50 °F).
When the AIC AUTO Fan mode is active:

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

• Fan speed is set to 100% for that particular model.
• Fan reversing by activating the MANUAL reverse switch on the right console.
Service Tip
The reversing pilot valves (45C) (45D) are not identical. If the pilot valves happened to be installed in the opposite
ports, the fan would operate in the wrong direction, i.e. no electrical signal would cause the motor operate in reverse.
If one of either of the pilot valves were replaced with the incorrect one, the fan would not rotate at all.
Reversible Fan Circuit

1 – Rear brakes 38 – Reservoir 51 – External relief valve
2 – Front brakes 40 – Filter HC – Return from hydraulic circuit
4 – Parking brake 41 – Thermal cooler bypass HP – to hydraulic pump
13 – Brake valve 42 – Oil cooler
36 – Gear pump 43 – Fan motor
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RCPH11WHL043GAN 2
Reversible Fan Circuit
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Forward Fan Drive

reverse / speed control valve (45) can reverse the airflow through the radiator and coolers to clear debris. The fan
drive system uses oil flow from the brake pump (36) that is not required to maintain the brake accumulator charge to
drive the fan motor (43). The brake pump (36) is mounted to the engine near the injection pump. Brake actuation is
controlled by the foot pedal in the brake valve (13). The oil required to apply the brakes comes from accumulators
which are charged by the brake valve (13). Once the accumulators are charged, all of the flow from the brake pump
(36) flows to the fan drive system. As the accumulator charge cuts in and out, the operator may notice a slight change
in fan sound and speed.
Upon startup with no control input the fan motor (43) would operate in the forward direction. Power beyond oil flow
from the brake control valve (13) enters the fan speed and reverser valve (45) inlet port. Within the reverser valve
this oil is available to the fan reverse solenoid valve (45A), speed control solenoid valve (45B), forward pilot valve
(45C) and the reverse pilot valve (45D). With no electrical signal, all of the flow will then pass through the forward pilot
control valve (45C), out the M2 port to the fan drive motor (43). Return oil from the fan drive motor (43) then enters the
speed and reverser valve (45) through the M1 port, flows through the reverse pilot valve (45D) and out the TANK port
of the reverser valve (45). The Advanced Instrument Cluster (AIC) controls the fan reverser valve. The AUTO mode
must be selected within the AIC for the fan speed and auto reverse feature to function. The AIC AUTO fan operating
mode is activated in the Option settings screen menu of the AIC.
The reversible fan drive motor is protected by two relief valves (45E). These relief valves are in the reverser valve
assembly. They are teed into both the M1 and M2 motor ports. These relief valves limit the maximum pressure in the
motor port connections. Excessive pressure in these ports would be caused by the inertia of the fan blades driving
the motor as the engine shuts down. As the relief valve opens, the return oil from that valve is ported to the opposite
motor port.
Oil returning from the fan speed and reverser valve (45) returns to the hydraulic oil cooler (42) and then to the hydraulic
filter (40). An optional thermal controlled bypass valve (41) allows the oil to bypass the cooler until the temperature
reaches 44 - 53 °C (111 - 127 °F). This thermal bypass gradually increases the flow through the cooler until all of
the fan drive flow passes through the oil cooler by the time the oil temperature reaches 63 °C (145 °F). The thermal
bypass valve is included in the optional cold weather package.
can initiate a fan reverse cycle to clear debris at any time required. In the center AUTO position of the switch the fan
speed is regulated by a proportional solenoid valve (45B) depending on system temperatures. Also with the switch
in the AUTO position, the AIC will initiate a reverse fan cycle, as long as the engine speed is greater than 1600 RPM,
after about 30 minutes of operation. In the switch OFF position the fan will operate at full speed for that model and will
not reverse unless manually selected. If either MANUAL or AUTO position of the switch is selected, the fan reversal
is disabled if hydraulic oil temperature is below 10 °C (50 °F).
This reverser valve also has the ability to control the fan rotating speed. The Advanced Instrument Cluster (AIC) con-
trols the fan reverser valve. Based on a Pulse Width Modulated (PWM) electrical input from the Advanced Instrument
cluster (AIC) to the fan speed control solenoid valve (45B), inlet flow will be allowed to bypass the fan motor circuit
directly to the TANK port. Oil flowing through this speed control valve (45B) will reduce and control the speed of the
fan drive motor. The PWM electrical amperage signal from the AIC to the speed control solenoid (45B) varies based
on temperature inputs to the AIC from the engine coolant, engine intake air, transmission, hydraulic circuit tempera-
tures. The fan speed control valve (45B) is actually a variable pressure regulator. It takes a given torque output to
drive the fan at a specified speed. Changing the pressure available at the fan motor (43) causes it to rotate at different
controlled speeds. The higher the pressure setting of the proportional solenoid, the faster the fan rotates. Increased
pressure is caused by a reduced electrical signal, hence a higher PWM reading slows the fan.
As a fan reversing cycle is initiated, the AIC regulates the PWM signal to the speed control solenoid (45B). This
dampens the shocks as the blades reverse.
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RCPH11WHL033HAN 3
Fan Drive – Forward
13– Oil flow from brake valve 43 – Fan drive motor 45C – Forward pilot control valve
40 – Filter 45 – Fan speed and reverser valve 45D – Reverse pilot control valve
41A – Oil cooler thermal bypass 45A – Fan reverse solenoid valve 45E – Fan drive pressure relief
41B – Oil cooler pressure bypass 45B – Fan speed control solenoid
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Reverse Fan Drive

reverse/speed control valve can reverse the airflow through the radiator and coolers to clear debris. The fan drive
system uses oil flow from the brake pump (36) that is not required to maintain the brake accumulator charge to drive
the fan motor (43). The brake pump (36) is mounted to the engine near the injection pump. Brake actuation is con-
trolled by the foot pedal in the brake valve (13). The oil required to apply the brakes comes from accumulators which
are charged by the brake valve (13). Once the accumulators are charged, all of the flow from the brake pump (36)
flows to the fan drive system. As the accumulator charge cuts in and out, the operator may notice a slight change in
fan sound and speed.
An electrical signal can be sent from the Advanced Instrument Cluster (AIC) to the reverser valve (45A). With the
electrical signal input the fan (43) would operate in the reverse direction. Power beyond oil flow from the brake control
valve (13) enters the fan speed and reverser valve (45) inlet port. Within the reverser this oil is available to the fan
reverse solenoid valve (45A), speed control solenoid valve (45B), forward pilot valve (45C) and the reverse pilot valve
(45D). With an electrical signal to the reverser fan reverse valve (45A), the fan reverse valve sends a pilot signal to
both the forward pilot control valve (45C) and the reverse pilot control valve (45D). As the pilot control valves shift, all
of the flow will then pass through the reverse pilot control valve (45D) , out the M1 port to the fan drive motor (43).
Return oil from the fan drive motor (43) then enters the speed and reverser valve (45) through the M2 port, flows
through the Forward pilot valve (45C) and out the TANK port of the reverser valve. The AIC controls the fan reverser
valve. The AUTO fan mode must be selected for the fan speed and auto reverse feature to function. The AIC AUTO
fan operating mode is activated in the Option settings screen menu of the AIC.
The reversible fan drive motor is protected by two relief valves (45E). These relief valves are in the reverser valve
assembly. They are teed into both the M1 and M2 motor ports. These relief valves limit the maximum pressure in the
motor port connections. Excessive pressure in these ports would be caused by the inertia of the fan blades driving
the motor as the engine shuts down. As the relief valve opens, the return oil from that valve is ported to the opposite
motor port.
Oil returning from the fan speed and reverser valve (45) returns to the hydraulic oil cooler and then to the hydraulic
filter. An optional thermal controlled bypass valve (41) allows the oil to bypass the cooler until the temperature reaches
44 - 53 °C (111 - 127 °F). This thermal bypass gradually increases the flow through the cooler until all of the fan drive
flow passes through the oil cooler by the time the oil temperature reaches 63 °C (145 °F). The thermal bypass valve
is included in the optional cold weather package.
controls how often that the fan reverses to clear debris. While holding the MANUAL REVERSE position of the switch, if
either the engine or hydraulic temperature increases by more than 3 °C (37.4 °F) the fan will revert back to the forward
direction. In the center AUTO position of the switch the fan speed is regulated by a proportional solenoid valve (45B)
depending on system temperatures. Also with the switch in the AUTO position, the AIC will send a reverse signal to
the reverse solenoid valve (45A) to initiate a reverse fan cycle after about 30 minutes of operation. In the AUTO mode
the reverse function will only initiate as long as the engine speed is greater than 1600 RPM. In the switch OFF position
the fan will operate at full speed for that model and will not reverse unless manually selected. If either MANUAL or
AUTO position of the switch is selected, the fan reversal is disabled if hydraulic oil temperature is below 10 °C (50 °F).
This reverser valve also has the ability to control the fan rotating speed. The Advanced Instrument Cluster (AIC) con-
trols the fan reverser valve. Based on a Pulse Width Modulated (PWM) electrical input from the Advanced Instrument
cluster (AIC) to the fan speed control solenoid valve (45B) , inlet flow will be allowed to bypass the fan motor circuit
directly to the TANK port. Oil flowing through this speed control valve (45B) will reduce and control the speed of the
fan drive motor. The PWM electrical amperage signal from the AIC to the speed control solenoid varies based on
temperature inputs to the AIC from the engine coolant, engine intake air, transmission, hydraulic circuit temperatures.
The fan speed control valve (45B) is actually a variable pressure regulator. It takes a given torque output to drive the
fan at a specified speed. Changing the pressure available at the fan motor causes it to rotate at different controlled
speeds. The higher the pressure setting of the proportional solenoid, the faster the fan rotates. Increased pressure
is caused by a reduced electrical signal, hence a higher PWM reading slows the fan.
As a fan reversing cycle is initiated, the AIC regulates the PWM signal to the speed control solenoid (45B). This
dampens the shocks as the blades reverse.
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RCPH11WHL034HAN 4
Fan Drive – Reverse
13– Oil flow from brake valve 43 – Fan drive motor 45C – Forward pilot control valve
40 – Filter 45 – Fan speed and reverser valve 45D – Reverse pilot control valve
41A – Oil cooler thermal bypass 45A – Fan reverse solenoid valve 45E – Fan reversing pressure relief
41B – Oil cooler pressure bypass 45B – Fan speed control solenoid
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Reverse fan control system - Dynamic description – Fan Auto Mode

Activation
The Wheel Loaders can be equipped with reversible cooling fans. This reversible option can be set to automatically
trigger the clearing of debris from the cooling system elements approximately every ½ hour of operation. This feature
also allows the operator to clear debris from the cooling system elements as required at any time by activating a
reversing switch in the cab.
In the auto mode, machine operating conditions control the fan speed. The highest measured temperature in the
coolant, air intake, hydraulic or transmission systems regulates the fan speed. Reduced fan speed lowers the machine
noise level as well as reduces the power required to drive the fan. This can contribute to improved fuel economy. See
Accessing Fan Auto Mode Test for procedures to select Fan Auto ON-OFF mode:
Multifunction Navigation Key Pad

The multifunction navigation key pad is located on operator console, below the steering wheel. This key pad enables
users to navigate from screen to screen, select menu options, monitor machine functions, or retrieve information.
All functions are accessed using the following keys:
A. Escape key
The escape key is used to exit and return to the
driving screen. It can be used at anytime to start
over or to exit a field.
B. Enter / Confirm key
This key is used to enter and confirm selected menu
items. After selections are highlighted, press enter
/ confirm key to choose selections.
C. Up key
This key scrolls upward to desired menu selections.
D. Down key
This key scrolls downward to desired menu selec-
tions.
RCPH11WHL023BAN 1
When screen prompts appear, use the Enter / Confirm key to respond accordingly.
During operation or with key switch in ON position, users can use arrow keys to scroll through four information screens
and two trip screens. These screens are in a circular loop and can be accessed by using the up or down key.
NOTE: Press the escape key to return the display to main driving screen. Press the confirm key to lock selections
into system memory. After locking selections, press the escape key to return to main driving screen. Selections will
also be locked into system memory when machine is turned OFF.
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Accessing Fan Auto Mode Test

1. To access the main menu screen, hold the confirm
key for two seconds.
2. Highlight Settings icon from main menu screen. Use

the Enter / Confirm key to choose selection.
NOTE: Screen arrows will display to indicate if ad-
ditional menu options are available.
RCPH11WHL020BAN 2
3. Highlight Engine icon from Setting screen. Use the

Enter / Confirm key to choose selection.
RCPH11WHL029BAN 3
NOTE: Joystick Steering menu option displays on if ma-

chine is equipped with feature.
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4. Highlight EngOptions icon from Engine screen. Use

RCPH11WHL026BAN 4
Fan Auto Feature (if equipped)

In automatic mode, the fan speed gradually changes be-
tween high and low based on operating temperatures in
the coolant, air intake, hydraulic or transmission systems.
NOTE: The following procedure is only available for ma-
chines equipped with auto fan feature.
5. Highlight Fan Auto icon from EngOptions screen.

Scroll through ON or OFF choices and choose de-
sired setting. Use the Enter / Confirm key to choose
selection and lock into memory.
Use navigation pad Escape key to return to main
driving menu.
RCPH11WHL027BAN 5
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Reverse fan control system - Dynamic description – Fan Speed

Adjustment
Reversible Fan Speed Option
trigger the clearing of debris from the cooling system elements aproximately every ½ hour of operation. This feature
reversing switch in the cab. The auto reverse feature only activates at elevated engine speed.
In the auto mode, machine operating conditions also control the fan speed. Adjusting the pressure delivered to the
hydraulic drive motor changes the fan speed. In auto mode, the fan speed varies from a minimum speed up to the
100% speed value entered into the Advanced Instrument Cluster (AIC) memory for that model. Using the procedure
below allows adjustment of the 100% fan speed value for that specific model. To return to the factory default value,
select the reset option on the display. The highest measured temperature in either of the coolant, air intake, hydraulic
or transmission systems regulates the fan speed.
Lower fan speeds allow the machine to warm up faster in cold conditions. Reduced speed also lowers the machine
noise level as well as reduces the power required to drive the fan. This can contribute to improved fuel economy.
Use the following procedures to select the Fan Test mode.

A. Escape key
C. Up key
D. Down key
tions.
RCPH11WHL023BAN 1
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Accessing Fan Test Feature

2. Select Service icon from main menu screen. Use

RCPH11WHL020BAN 2
3. Highlight Calibration icon from Service menu. Use

RCPH11WHL022BAN 3
4. Highlight Fan Test icon from Calibration menu. Use

RCPH11WHL021BAN 4
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5. Run the engine at full rpm. Use the Enter / Confirm

key to initiate the fan speed option.
RCPH10WHL383BAH 5
6. Use the Enter / Confirm key to start the100% or full

fan speed adjustment for that model.
RCPH11WHL031BAN 6
7. Use up or down arrows to highlight Adjust 100%

speed or Reset (factory default). Use the Enter /
Confirm to choose either option.
RCPH11WHL033BAN 7
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8. To adjust the 100% fan speed, scroll up or down

to the required speed. Use the Enter / Confirm to
choose the adjustment. Use the escape key to re-
turn to the main menu.
Model 100% Default Speed

521F 946
621F 763
721F 835
821F 920
921F 920
1021F 857
1121F 857
RCPH11WHL035BAN 8
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Index
Engine - 10
Fan and drive - 414

Reverse fan control system - Dynamic description – Cooling Fan System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Reverse fan control system - Dynamic description – Fan Auto Mode Activation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Reverse fan control system - Dynamic description – Fan Speed Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
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CNH - Main 700 State Street Racine, Wisconsin United States 53404
SERVICE - Technical Publications & Tools
PRINTED IN U.S.A.
© 2012 CNH 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.
47392461 19/06/2012
EN
SERVICE MANUAL
Transmission
1021F
1121F
47392461 19/06/2012
21
Contents
Transmission - 21
Powershift transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.113

1021F , 1121F
Powershift transmission external controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.135

1021F , 1121F
Gearbox internal components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.145

1021F , 1121F
Powershift transmission internal components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.155

1021F , 1121F
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CONSUMABLES INDEX
Consumable IU PAGE
Loctite® 262 Powershift transmission - Assemble 21.113 / 38
DOW 732 RTV Silicone clear Powershift transmission - Install 21.113 / 86
Loctite® 767 Anti-seize Drive shaft - Install Carrier Bearing 21.145 / 14
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Transmission - 21
Powershift transmission - 113
1021F
1121F
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Contents
Transmission - 21
TECHNICAL DATA
Powershift transmission
Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
General specification Pressures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
General specification Clutch Plate Thicknesses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
FUNCTIONAL DATA
Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
SERVICE
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Pressure test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
DIAGNOSTIC
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
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CONSUMABLES INDEX
Consumable IU PAGE
DOW 732 RTV Silicone clear Powershift transmission - Install 21.113 / 86
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Transmission - Powershift transmission
Powershift transmission - Torque

Solenoid Housing Cover 7.5 N·m (66 lb in)
Solenoid Retainer Plate 5.5 N·m (49 lb in)
Valve Duct Plate 9.5 N·m (84 lb in)
Control Valve Test Plugs 6 N·m (53 lb in)
Transmission Housing Duct Plate (M10X1) 6 N·m (53 lb in)
Transmission Housing Duct Plate (M15x1.5) 40 N·m (30 lb ft)
Transmission Housing Duct Plate (M26X15) 80 N·m (59 lb ft)
Transmission Housing Duct Plate (M8/10.9) 23 N·m (17 lb ft)
Control Valve Mounting 12 N·m (106 lb in)
Transmission Pump Rotor Cover (M6/8.8) 9.5 N·m (84 lb in)
Transmission Pump Rotor Cover ((M8/8.8) 23 N·m (17 lb ft)
Hydraulic Pump Mounting Flange 125 N·m (92 lb ft)
K3/K4 Bearing Cover 46 N·m (34 lb ft)
KR/K2 Bearing Cover 46 N·m (34 lb ft)
Output Flange 46 N·m (34 lb ft)
Parking Brake Disc 125 N·m (92 lb ft)
Transmission Pump Retaining Flange 79 N·m (58 lb ft)
Input Shaft Clamping Plate 32 N·m (24 lb ft)
Front Input Shaft Bearing Cover 46 N·m (34 lb ft)
Converter Outlet Temperature Sensor 25 N·m (18 lb ft)
Converter Back Pressure Spring Plug 130 N·m (96 lb ft)
Converter Bell (M8/10.9) 34 N·m (25 lb ft)
Converter Bell (M12/10.9) 115 N·m (85 lb ft)
Converter Flex Plate 46 N·m (34 lb ft)
Coarse Filter (Suction Screen) Cover 23 N·m (17 lb ft)
Engine Speed Sensor 30 N·m (22 lb ft)
Output Speed Sensor 23 N·m (17 lb ft)
Transmission Breather 12 N·m (106 lb in)
Powershift transmission - General specification Pressures

Main pressure and clutch pressure 16 - 18 bar ( 232 - 261 psi)
Converter in pressure 8.5 bar (123 psi)
Pressure reduction for solenoids 9 bar (131 psi)
Converter out pressure 5 bar (73 psi) minimum
Lubrication pressure 0.2 - 1.2 bar ( 3 - 18 psi)
Minimum pump output (at 2000 rpm)
LW 170.B 115 l/min (30 US gpm)
Transmission oil operating temperature 80 - 120 °C ( 176 - 248 °F)
Clutch KV 16 - 18 bar ( 232 - 261 psi)
Clutch KR 16 - 18 bar ( 232 - 261 psi)
Clutch K1 16 - 18 bar ( 232 - 261 psi)
Clutch K2 16 - 18 bar ( 232 - 261 psi)
Clutch K3 16 - 18 bar ( 232 - 261 psi)
Clutch K4 16 - 18 bar ( 232 - 261 psi)
Powershift transmission - General specification Clutch Plate

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

K1 Clutch 2.2 - 2.4 mm (0.087 - 0.094 in)
KR Clutch 2.8 - 3.0 mm (0.110 - 0.118 in)
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Powershift transmission - Dynamic description

The Wheel Loaders use an electro-hydraulically controlled transmission. A 4-speed version is standard and a 5-speed
version is also available as an option on some of the wheel loader models. The transmissions incorporate a solid
state Electronic Control Module (ECM). The ECM monitors system functions and controls the shifting of the transmis-
sion. Transmission ECM inputs and outputs are noted in a table that follows. Fault codes will display when electrical
components become a problem.
The transmission ECM works together with the Advanced Information Cluster (AIC). The ECM uses the information
center as a communication mechanism to talk to the operator or service technician. The transmission ECM acts as
the computer and the AIC acts as a readout device. By monitoring the transmission oil temperature and varying the
current that is applied to the electrical shift solenoids the transmission ECM controls the rate at which the clutches
engage and release.
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Transmission Legend
1 - Transmission 13 - Powerinch clutch cut-out
2 - Engine speed sensor 14 - Transmission Electronic Control Module (TECM)
3 - Intermediate speed sensor 15 - Power supply
4 - Turbine speed sensor 16 - CAN BUS for information transfer
5 - Output speed sensor 17 - F-N-R switch
6 - Filter restriction switch 18 - F-N-R enable switch
7 - Transmission PWM solenoid and valve temperature 19 - Declutch pressure switch
sensor
8 - AIC 20 - Front differential lock-up (option)
9 - Transmission shifter 21 - Torque converter outlet temperature sensor
10 - Downshift switch 22- Transmission diagnostic connector
11 - Declutch switch 23 - Electronic Service Tool (EST)
12 - Auto/manual mode switch 24 - Differential lock foot switch (option)
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RCPH11WHL039HAN 1
Transmission
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Transmission Control Electrical / Electronics

The transmission ECM is located under the right hand access door of the cab. The Electronic Service Tool (EST)
diagnostic connector is also located under this access door.
The transmission ECM carries out a variety of tasks in the overall system. These tasks include:
1. Determining which clutches should be engaged in the transmission
2. Receiving signals from the shifter, remote F-N-R enable switch, remote F-N-R switch, the automatic/manual
rocker switch, the downshift button, the declutch control and the differential lock switches. It uses these to
determine control under normal operating conditions.
3. Receiving speed information from the engine speed sensor, the turbine speed sensor, the intermediate clutch
speed sensor and the transmission output speed sensor. These sensors are monitored to determine that sensor
operation is normal. The data is also used to control clutch application during shifting and determine appropriate
shift patterns. If one of the sensors fails the transmission will operate in a limp-home mode and a fault code will
also be logged by the ECM.
4. On 4-speed transmission models an adjustable pressure switch controls the full transmission declutch function.
This allows the operator to totally declutch the transmission by depressing and pressurizing the service brake.
The 4-speed declutch feature can be turned on or off by a rocker switch on the steering column. This allows the
operator to throttle up to raise a load more rapidly while approaching a pile or truck. Five speed transmission
models are equipped with the Powerinch intelligent clutch cutout. This system provides a variable declutch
feature based upon the position of the brake pedal. A potentiometer signals the position of the brake. This
feature allows the operator to gradually inch up an incline to a pile or a truck. Depressing the brake pedal fully
totally declutches the transmission. The 5 speed Powerinch intelligent clutch cutout function is active at all times.
5. Receiving signals from the filter condition indicator switch, the valve temperature sensor and the converter outlet
temperature sensor.
6. Provides outputs to the clutch control PWM solenoids, differential lock solenoid, torque converter lock-up sole-
noid, the ride control relay and backup alarm relay.
7. Protect the engine and transmission from over-speed conditions during downshifting.
8. Determines if there are any system failures and determines appropriate alternative actions.
9. Provides diagnostic messages and fault codes to the vehicle AIC.
10. Provides input to the AIC to inform the operator of engine speed, wheel speed, gear shifter selection, actual
gear selection and instrumentation information.
11. Sends an electronic signal by CAN BUS for engine torque curve selection in AUTO mode.
12. Manages the Powerinch intelligent clutch cut-out on 5 speed transmission limiting the vehicle tractive effort to
the minimum required to hold the vehicle and not to the maximum possible via the brake pedal potentiometer,
independent of engine speed.
13. The transmission ECM has the capability to be re-calibrated to improve shift quality. This should also be done
at 250 hours. and every 1000 hours. thereafter.
Transmission ECM Inputs and Outputs Legend

A/M MS - Auto/manual mode switch FNR SS - F-N-R selection switch
BUR - Back-up alarm relay FRS - Filter restriction switch
CAN - CAN BUS ISS - Intermediate speed sensor
DCL PSI 4 SPD - Declutch brake psi switch (4-speed) OSS - Output speed sensor
DCL S 4 SPD - Declutch on/off switch (4-speed) PWM SOL - Pulse width modulation solenoid
DIAG - Diagnostic connector PWRIN POT 5 SPD - Powerinch potentiometer (5-speed)
DLFS - Differential lock foot switch (5-speed) RCR - Ride control relay
DLRS - Differential lock rocker switch (5-speed) TCLS 5 SPD - Torque converter lockup solenoid
(5-speed)
DL SOL 5 SPD - Differential lock solenoid (5-speed) TCT - Torque converter temperature
DSB - Downshift button TECM - Transmission electronic control module
ESS - Engine speed sensor TSS - Turbine speed sensor
FNR ES - F-N-R enable switch VOT - Valve oil temperature
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RCPH11WHL037HAN 2
Transmission ECM Inputs and Outputs
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Transmission Hydraulic Controls

The transmission hydraulic system consists of the following components:
• The transmission hydraulic pump (1) is a gerotor type hydraulic pump. It is driven by the transmission input
shaft.
• The transmission hydraulic filter (2) is located on the rear outside cover of the transmission.
• The filter bypass (F) is located in the head of the filter base.
• The transmission control valve directs the flow of oil into the appropriate clutches at the appropriate time to drive
the machine. The valve is located on the back cover of the transmission on the 521 through the 921 models.
On the 1021 and 1121 models, the valve is located on the top of the transmission.
• The transmission control valve consists of six PWM solenoid valves which control hydraulic spools that control
the application of hydraulic pressure to the required clutches for the requested speeds. The PWM solenoids are
gradually activated by the controller to provide smooth shifts.
• The control valve also has two more spools located inside of the assembly. The largest spool in the control
valve is the main pressure spool (system pressure valve) (3). It sets the regulated pressure at 16 - 18 bar (232
- 261 psi). Main regulated pressure is used to lock up the clutch packs inside the transmission.
• The second smaller spool, is the pressure reducing valve (4). It reduces the main regulated pressure down
to 9 bar (131 psi). The pilot oil is used to shift the spools inside the transmission control valve. There is no
adjustment for either the main or pilot control spools. If it is not within the specification limits the spools and
springs must be replaced.
• Excess pump flow not required for clutch activation flows through the main pressure spool (3) to the torque
converter (6). The torque converter is a fluid drive coupling that allows for slippage between the input from the
engine and the output to the transmission. A torque converter lock-up clutch is fitted on the 5-speed models.
When locked, there is no slippage between the input and output.
• The oil pressure within the torque converter is controlled by the outlet back-pressure valve (7).
• Fluid returning from the torque converter flows through the cooler (8).
• The clutches and bearings within the transmission are lubricated (9) by the return oil from the converter and
cooler.
4-Speed Transmission Drive Paths 5-Speed Transmission Drive Paths

Gear engaged Activated clutches Gear engaged Activated clutches
1st gear FW K1 + KV 1st gear FW K1 + KV
2nd gear FW K2 + KV 2nd gear FW K2 + KV
3rd gear FW K3 + KV 3rd gear FW K2 + K4
4th gear FW K3 + K4 4th gear FW K3 + KV
5th gear FW K3 + K4
1st gear RV K1 + KR 1st gear RV K1 + KR
2nd gear RV K2 + KR 2nd gear RV K2 + KR
3rd gear RV K3 + KR 3rd gear RV K3 + KR
1021F and 1121F Schematic Legend

1 - Transmission pump 51 - Converter inlet pressure F - Filter by-pass valve
2 - Transmission filter 52 - Converter outlet pressure G - PWM solenoid valves
3 - Main pressure regulator 53 - KV clutch pressure – Y1 - KR clutch solenoid
4 - Pilot pressure regulator 55 - KR clutch pressure – Y2 - KR clutch solenoid
5 - Converter pressure relief valve 56 - K1 clutch pressure – Y3 - K1 clutch solenoid
6 - Torque converter 57 - K2 clutch pressure – Y4 - K2 clutch solenoid
7 - Back pressure relief valve 58 - K3 clutch pressure – Y5 - K3 clutch solenoid
8 - Oil cooler 60 - K4 clutch pressure – Y6 - K4 clutch solenoid
9 - Transmission bearing lubrication 63 - Converter outlet temperature
67 - Converter lockup solenoid (option)
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RCPH11WHL040HAN 3
1021F and 1121F Schematic
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Diagnostic Pressure Testing

If the transmission controller indicates a hydraulic problem (clutch slippage, improper activation, etc.), diagnostic pres-
sure testing is required. Diagnostic pressure can be measured at test ports located outside of the transmission control
valve.
Specifications 721F, 821F, and 921F 1021F and 1121F

Recommended oil (Summer) Akcela NEXPLORE™ fluid
Temperature range: -30 °C to 50 °C (-22 °F to 122 °F)
Recommended oil (Winter) F200A HYD FLUID
Temperature range: -40 °C to 25 °C (-40 °F to 77 °F)
Main pressure and clutch 16 - 18 bar (232 - 261 psi) 16 - 18 bar (232 - 261 psi)
Converter inlet pressure 8 - 10 bar (116 - 145 psi) 8.5 bar (123 psi)
Converter outlet pressure 3.5 - 6.5 bar (51 - 94 psi) 5 bar (73 psi) minimum
Pilot pressure 7 - 9 bar (102 - 131 psi) 9 bar (131 psi)
Lubrication pressure 0.2 - 1.2 bar (3 - 17 psi) 0.2 - 1.2 bar (3 - 17 psi)
Minimum pump output 2000 RPM 80 l/min (21 US gpm) 115 l/min (30 US gpm)
Transmission oil temperature 80 - 120 °C (176 - 248 °F) 80 - 120 °C (176 - 248 °F)
Clutch KV 16 - 18 bar (232 - 261 psi) 16 - 18 bar (232 - 261 psi)
Clutch KR 16 - 18 bar (232 - 261 psi) 16 - 18 bar (232 - 261 psi)
Clutch K1 16 - 18 bar (232 - 261 psi) 16 - 18 bar (232 - 261 psi)
Transmission filter bypass 5.2 - 7.2 bar (75 - 104 psi)
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RCPH11WHL021HAN 4
Item Test Point Thread Diameter

65 Main pressure M10
53 KV FW (forward) M10
55 KV RV (reverse) M10
56 K1 1st clutch M10
57 K2 2nd clutch M10
58 K3 3rd clutch M10
60 K4 4th clutch M10
51 Converter inlet M10
52 Converter outlet M14
69 Not installed
15 Cooler inlet 1-5/16”
16 Cooler outlet 1-5/16”
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The transmission ECM also reviews voltage from the shifter and the transmission solenoids to determine if there are
any short circuits or open circuits in the system.
If the transmission ECM detects a problem in the transmission system, it will generate a service code in the information
center and enter one of the following modes:
• Clutch modulation substitute mode

• Limp-home mode
• Transmission / transmission ECM shutdown mode
Clutch Modulation Substitute Mode

In the clutch modulation substitute mode, the transmission clutch modulation is time dependant rather than load de-
pendant. If the output speed sensor is working and the transmission is in gear, the shifts points in automatic mode
will be speed dependant but the modulation will be a predetermined amount of time. If the output speed sensor is not
working and the transmission is in gear, the shift points will still be load dependant but the modulation will be a pre-
determined amount time. If the transmission is shifted from neutral into a direction in the clutch modulation substitute
mode in automatic, the transmission will shift into 4th gear and shift down until it gets the correct output speed from
the turbine. The transmission will go into the clutch modulation substitute mode if any of the four speed sensors fail.
Limp-home Mode
In the limp-home mode, the transmission will go into second gear forward or reverse no matter which speed is se-
lected. If second gear is not obtainable, the transmission ECM selects a series of prioritized gears until an operable
gear is found. The transmission will go into the limp-home mode if there is a fault on one clutch, a fault on one clutch
valve or a fault on more than more than speed sensor.
Transmission / Transmission ECM Shutdown Mode

In the transmission / transmission ECM shutdown mode, the transmission ECM has detected a severe failure that
disables control of the transmission or system. The transmission ECM will shut off all solenoid valves and the power
supply. The transmission shifts to neutral and stays in neutral. The transmission will go into the shutdown mode if
there is a fault on more than one clutch, a fault on solenoid power supply, or invalid voltage. System voltage to the
transmission solenoids is cut off by the transmission ECM in this mode.
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Powershift transmission - Remove

Prior operation:
Ladder - Remove (90.118), Cab suspension - Remove (90.150), Oil reservoir - Remove (35.300), Pump Pressure
and Flow Compensated (PFC) piston pump - Remove (35.106),
1. Drain the transmission.

2. Disconnect the transmission fill tube (1) from the
transmission.
NOTE: Splashback shield located inside transmission fill
tube.
RCPH11WHL024AAR 1
3. Disconnect the park brake caliper line (1).
RCPH11WHL025AAR 2
4. Disconnect the transmission-to-cooler oil return line

(1).
5. Disconnect the output speed sensor electrical con-
nector (2).
RCPH11WHL026AAR 3
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6. Disconnect the redundant brake switch electrical

connectors (1), (2).
RCPH11WHL027AAR 4
7. Disconnect the valve body electrical connector (1).

8. Disconnect the torque converter output temperature
sender electrical connector (2).
9. Disconnect the transmission-to-cooler oil line (3).
RCPH11WHL028AAR 5
10. Disconnect the engine speed sensor electrical con-

nector (1).
RCPH11WHL029AAR 6
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11. Disconnect the intermediate speed sensor electrical

connector (1).
12. Disconnect the turbine speed sensor electrical con-
nector (2).
RCPH11WHL054AAR 7
13. Remove the wire harness P-clamps (2). Position the

wire harness (1) away from the transmission.
RCPH11WHL030AAR 8
14. Remove the transmission-to-transmission oil filter

lines (1).
RCPH11WHL031AAR 9
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15. Attach lifting equipment to the transmission. Support

the transmission.
RCPH11WHL033AAR 10
16. Remove two transmission mounting bolts (1).
RCPH11WHL032AAR 11
17. Remove the converter housing cover plate (1).
RCPH11WHL034AAR 12
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18. Remove the flex plate bolts (1).
RCPH11WHL035AAR 13
19. Lift and support the engine and transmission approx-

imately three inches.
RCPH11WHL033AAR 14
20. Remove the bell housing bolts (1).
RCPH11WHL036AAR 15
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21. Remove the transmission.
RCPH11WHL037AAR 16
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Powershift transmission - Disassemble

1. Attach the transmission to a suitable work stand.
2. Remove the plug (1) and drain the transmission oil.
Remove the oil cylinder (2).
RCPH11WHL221BAU 1
3. Remove all oil lines, the complete gear shift system,

and the duct plate.
RCPH11WHL220BAU 2
4. Using a suitable lifting device, remove the torque

converter and the flexplate.
RAPH12WEL0453AA 3
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5. Remove the bolts and install two threaded forcing

screws into the holes and force the cover off.
RCPH11WHL208BAU 4
6. Install the CAS2268 puller and remove the oil supply

flange out of the converter bell.
RCPH11WHL209BAU 5
7. Remove the converter safety valve (1) if required.

NOTE: The converter safety valve is fixed with a slotted pin
(2).
RAPH12WEL0454AA 6
8. Loosen the bolt connection with a lifting tackle and

pry bar. Separate the converter bell from the trans-
mission.
RCPH11WHL210BAU 7
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9. Remove the rectangle ring.
RAPH12WEL0456AA 8
10. Press the input shaft out of the spur gear bearing.
Remove the release bearing inner ring and the spur
gear.
RCPH11WHL212BAU 9
11. Press off the bearing inner ring from the spur gear.
RAPH12WEL0458AA 10
12. Remove the converter back – up valve.
RAPH12WEL0459AA 11
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13. Remove the inductive transmitter.
RCPH11WHL233BAU 12
Input shaft — Version with 2nd and/or 3rd and 4th Power Take-Off (PTO)
14. Pull the complete input shaft out of the transmission
housing and the pump.
RCPH11WHL223BAU 13
15. Remove the rectangular ring.
RCPH11WHL225BAU 14
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16. Remove the spur gear from the shaft and remove the
snap ring from the shaft.
RCPH11WHL227BAU 15
17. Pull off the bearing inner ring from the spur gear.
RCPH11WHL224BAU 16
18. Secure the input shaft in a suitable clamping vice de-

vice. Loosen the cap screw and remove the clamp-
ing plate.
RCPH11WHL226BAU 17
19. Remove the bearing inner ring and the driver from
the shaft. Watch for shims when removed.
NOTE: Put a cap over the bolt hole before installing the
puller to protect the threads in the shaft. Support the puller
on the face-input shaft. Pay attention to the released shim.
RCPH11WHL228BAU 18
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20. Separate the bearing inner ring from the driver.

Watch for shims.
NOTE: If necessary snap out the V-rings.
RCPH11WHL229BAU 19
Transmission pump
21. Loosen the cam and the hexagon bolt (depending
on version) and separate the pump flange from the
housing.
RAPH12WEL0460AA 20
22. Loosen the cap bolts. Install the CAS2268 puller on

the transmission pump and fasten to the transmis-
sion pump.
NOTE: Extracting is supported by slightly tapping onto the
transmission housing.
RAPH12WEL0461AA 21
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Remove bearing outer ring — K2, K3, and K4 power take-off

23. Pull out the bearing outer ring from the bore.
RAPH12WEL0462AA 22
24. Loosen the cap bolts. Take off the pump cover and
remove the rotor set. Assemble the rotor set with
the chamfer on the tooth tip showing downward and
install the housing cover again. Torque (M8) to 23
N·m (17 lb ft), and torque (M6) to 9.5 N·m (84 lb in).
NOTE: If marks due to running-in are found on the pump
housing or the housing cover, the complete pump is to be
replaced
RAPH12WEL0463AA 23
Layshaft
25. Remove the sealing cover and loosen the hexagon
bolt.
RCPH11WHL239BAU 24
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26. Use a slide hammer and remove the idler shaft from
the housing bore and the layshaft bearings.
RCPH11WHL240BAU 25
Removal of inductive and speed transmitter.

27. Remove the turbine (1) and the internal speed input
(2).
RCPH11WHL242BAU 26
28. Remove the output speed transmitter (3).
RCPH11WHL244BAU 27
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Output — standard version

29. On the converter side, remove the lock plate. Loosen
the hexagon bolts and take off the output flange. Ro-
tate the housing 180 ° and remove the output flange
on the housing rear-side.
RAPH12WEL0468AA 28
With parking brake

30. On the transmission rear-side, unscrew the screw
cap.
NOTE: For work on the brake system, observe the instruc-
tions and specifications of the brake manufacturer.
RAPH12WEL0469AA 29
31. Loosen the counternut and unscrew the adjusting

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

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

33. Loosen the hexagon bolts and expel the bearing
cover KV/K1 with a striker from the housing bore.
Repeat step to remove the bearing cover KR/K2
(arrow).
NOTE: Mark the installation location of the bearing cover.
RAPH12WEL0472AA 32
34. Pull out the bearing cover K4/K3 with the forcing
screws from the housing bore.
RAPH12WEL0473AA 33
47392461 19/06/2012
21.113 / 31
35. Separate the bearing inner ring from the bearing

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

cover from the housing by equally tightening both
forcing screws (1) and (2) as well as the threaded
spindle (3).
RAPH12WEL0475AA 35
37. Remove the output shaft from the output gear.
RAPH12WEL0476AA 36
38. Loosen the hexagon bolts. Remove the oil baffle. Lift
the output gear out of the transmission housing.
RAPH12WEL0477AA 37
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21.113 / 32
39. Remove the bearing inner ring from the output gear.
RAPH12WEL0478AA 38
40. Take the roller bearing out of the housing bore and
remove the oil baffle.
RAPH12WEL0479AA 39
41. When removing multi-disc clutches, the removal or-

der of the single clutches must follow this sequence:
K4/K3 to → KR/K2 to → KV/K1.
NOTE: For removal of clutch K4/K3, lift the clutch KR/K2
slight and move it in direction of the noted arrow.
RAPH12WEL0671AA 40
42. The clutches K3/K4 (1), K2/KR, and K1/KV (3) are
shown after removal.
RAPH12WEL0481AA 41
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21.113 / 33
43. Remove the layshaft gear.
RAPH12WEL0482AA 42
Removal of the 2nd power take – off

44. Snap out the retaining ring and remove the shims.
RAPH12WEL0483AA 43
45. Lift the output shaft with the pry bar set until the bear-
ing outer ring is released.
RCPH11WHL271BAU 44
47392461 19/06/2012
21.113 / 34
46. Take the output shaft out of the housing.
RCPH11WHL268BAU 45
47. Pull the bearing outer ring out of the housing bore.
RAPH12WEL0486AA 46
48. Pull off the bearing inner ring from the shaft. Press
the opposite bearing inner ring from the shaft.
NOTE: The shaft and the gear cannot be separated (shrink
fit).
RAPH12WEL0487AA 47
Next operation:
Powershift transmission - Assemble (21.113)
47392461 19/06/2012
21.113 / 35
Powershift transmission - Assemble

CAUTION
Hot area!
Use care when working near hot components. Wear protective gloves.
Failure to comply could result in minor or moderate injury.
C0034A
CAUTION
Eye injury hazard!
Wear protective goggles when using compressed air.
C0035A
Prior operation:
Powershift transmission - Disassemble (21.113)
Transmission assembly
1. This figure shows the installation view order of the
single power takes-off as follows:
1. 1st power take-off (standard version).
2. 2nd power take-off assembly. (See steps 3 to
8).
RAPH12WEL0722BA 1
NOTE: Image may vary depending on the model.
47392461 19/06/2012
21.113 / 36
2nd power take-off

2. Undercool the shaft to about 80 °C (176 °F), and heat
the gear to approximately 120 °C (248 °F) and install
on the shaft.
RAPH12WEL0335AA 2
3. Press the bearing inner ring in place. Press the op-

posite bearing inner ring in place.
RAPH12WEL0336AA 3
4. Insert the bearing outer ring into the housing bore.
RAPH12WEL0337AA 4
47392461 19/06/2012
21.113 / 37
5. Position the preassembled power take-off shaft in the

housing and insert the bearing outer ring.
RAPH12WEL0487AA 5
6. Adjust the axial play — power take-off bearing to

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

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

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

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

K3/K4 into the housing bores.
RAPH12WEL0340AA 10
11. Position clutch KV/K1 with a lifting tackle.
RAPH12WEL0341AA 11
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12. Position the clutch KR/K2.
RAPH12WEL0342AA 12
13. Check the installation position of the layshaft gear

and correct as needed.
RAPH12WEL0343AA 13
14. Fasten the spur gear K3 with a proper fixture and

eyebolt axially.
NOTE: The fastened spur gear prevents the clutch discs
from dislocating when the clutch is lifted in.
RAPH12WEL0344AA 14
47392461 19/06/2012
21.113 / 40
15. Lift the clutch KR/K2 slightly, and move it in the di-
rection of the shown arrow and position the clutch
K3/K4. Then remove the fixture.
RAPH12WEL0671AA 15
16. Insert the bearing outer ring into the housing bore.
RAPH12WEL0345AA 16
17. Heat the bearing inner ring and install.

NOTE: Use safety gloves as the unit may be hot.
NOTE: Observe that the installation position — collar (ar-
row) faces toward the spur gear. Install the bearing inner
ring after cooling down and then press in place.
RAPH12WEL0346AA 17
18. Position the oil baffle.
RAPH12WEL0347AA 18
47392461 19/06/2012
21.113 / 41
19. Install the output gear with a lifting tackle.
RAPH12WEL0348AA 19
20. Position the upper oil baffle, and install the wash-
ers. Fasten both plates with LOCTITE® 243 treated
hexagon bolts. Torque to 23 N·m (17 lb ft).
RAPH12WEL0349AA 20
Preassembly and mounting of the housing cover

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

LOCTITE® 574. Using a lifting tackle, place the
housing cover on the transmission housing.
RAPH12WEL0352AA 23
24. Install the cylindrical pins (1) and (2) and the slotted
pin (3). Fasten the housing cover with the hexagon
and the cap bolts. Torque to 46 N·m (34 lb ft).
RAPH12WEL0353AA 24
47392461 19/06/2012
21.113 / 43
25. Adjust the bearing preload of the clutch K4/K3 = 0.0

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

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

mounting face until contact/bearing inner ring. (Di-
mension II e.g. ... 42.12 mm (1.7 in)).
RAPH12WEL0675AA 28
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21.113 / 44
Dimension I 43.65 mm (1.7 in)

Dimension II — 42.12 mm (1.7 in)
Difference = 1.53 mm (0.1 in)
Bearing + 0.02 mm (0.0 in)
preload...e.g.
Resulting shim(s) s = 1.55 mm (0.1 in)
29. Put on the shim.
RAPH12WEL0354AA 29
30. Heat the bearing inner ring. Install the bearing inner
ring and press down after cooling.
NOTE: Hot. Wear protective gloves.
RAPH12WEL0355AA 30
31. Grease the rectangular rings and centrally align

them.
RAPH12WEL0356AA 31
47392461 19/06/2012
21.113 / 45
32. Grease and install the O-ring. Heat the inner diame-
ter of the bearing cover (bearing seat) to 120 °C (248
°F) with a blower, an oven or a induction heater.
NOTE: Do not use a torch!
RAPH12WEL0357AA 32
33. Install two adjusting screws. Assemble the bear-

ing cover and evenly tighten it with hexagon bolts.
NOTE: Observe the radial installation position.
RAPH12WEL0358AA 33
34. Check the function of both the clutches with com-

pressed air. Replace the rectangular rings if needed.
NOTE: In case of a decisive pressure loss, a possible
cause might be a breakage of one or several of the rect-
angular rings.
RAPH12WEL0359AA 34
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21.113 / 46
35. Adjust the bearing preload of the clutch KR/K2 = 0.0

- 0.05 mm
36. For installation of a new bearing cover (1) and (3),
both of the finished bores (2) have to be sealed with
a plug (4). Finished bores are located opposite to
each other.
RAPH12WEL0360AA 35
RAPH12WEL0361AA 36
37. Install the two studs. Torque to 13 N·m (115 lb in).
RAPH12WEL0362AA 37
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38. Install the bearing outer ring.

NOTICE: Pay attention to exact contact.
RAPH12WEL0363AA 38
39. Housing dimension: Determine dimension I from the

bearing outer ring to the mounting face. (Dimension
I e.g.... 16.13 mm (0.6 in)).
RAPH12WEL0364AA 39

contact/bearing outer ring to the mounting face. (Di-
mension II e.g. ... 17.75 mm (0.7 in)).
RAPH12WEL0365AA 40
Example:
Dimension II 17.75 mm (0.7 in)
Dimension I — 16.13 mm (0.6 in)
Bearing + 0.03 mm (0 in)
preload...e.g.
47392461 19/06/2012
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41. Place the shim with assembly grease into the cover.
Install the O-ring.
RAPH12WEL0366AA 41
42. Grease and centrally align the rectangular rings.
RAPH12WEL0367AA 42
43. Pull the bearing cover evenly until contact is made.

RAPH12WEL0368AA 43
47392461 19/06/2012
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44. With compressed air, check the function of both

of the clutches. Replace the rectangular rings if
needed.
cause might be a breakage of one or several of the rect-
angular rings.
RAPH12WEL0369AA 44
45. Adjusting the bearing preload of the clutch KV/K1 =

0.0 - 0.05 mm
46. For installation of a new bearing cover (1), both of the
finished bores (2) have to be sealed with a plug (4).
RAPH12WEL0370AA 45
47. Put the bearing outer ring over the bearing inner ring.
48. Housing dimension: Press evenly on the bearing
outer ring and determine Dimension I from the
mounting face to the bearing outer ring. (Dimension
I e.g. ... 52.67 mm (2.1 in)).
NOTE: Take several measuring points and determine the
mean value.
RAPH12WEL0371AA 46
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21.113 / 50
49. Put the ring with the chamfer facing downwards into
the bearing cover.
RAPH12WEL0372AA 47

mounting face to the ring. (Dimension II e.g. ... 50.75
mm (2.0 in)).
RAPH12WEL0373AA 48
Example:
Bearing preload + 0.03 mm (0.0 in)
47392461 19/06/2012
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51. Put in the shim.
RAPH12WEL0374AA 49
52. Install the bearing outer ring (1). Assembly the O-ring
(2).
RAPH12WEL0375AA 50
53. Grease and centrally align the rectangular rings.
RAPH12WEL0376AA 51
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54. Heat the bearing bore to 120 °C (248 °F) with a

blower, an oven or a induction heater.
RAPH12WEL0377AA 52
55. Install the two adjusting bolts (1). Place the bearing
cover (2) over the adjusting bolts and fasten with the
hexagon bolts.
RAPH12WEL0378AA 53
56. With compressed air, check the function of both

of the clutches. Replace the rectangular rings if
needed.
cause might be the breakage of one or several of the
rectangular rings.
RAPH12WEL0379AA 54
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21.113 / 53
Installation of the output shaft

57. Heat the inner diameter of the output gear to 120 °C
(248 °F) with a blower, an oven or a induction heater.
RAPH12WEL0380AA 55
58. Insert the output shaft with the long gearing facing
downward.
RAPH12WEL0381AA 56
59. Rotate the transmission housing into a ( 90 °) vertical

position. Temporarily attach the output shaft axially
to the converter side with a mounting tool.
RAPH12WEL0382AA 57
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60. Rotate the transmission housing 90 ° back.
RAPH12WEL0383AA 58
61. Adjust the axial play of the output bearing = 0.3 - 0.5
mm
62. Determine Dimension I from the plane face-housing
to the end face-output shaft. (Dimension I e.g. ...
66.90 mm (2.6 in).
RAPH12WEL0384AA 59
63. Measure Dimension II from the plane face-housing

to the contact of the face-ball bearing. (Dimension II
e.g. ... 64.20 mm (2.5 in)).
RAPH12WEL0385AA 60
Example:
Required axial play — 0.40 mm (0.0 in)
(0.3...0.5mm) e.g.
Resulting shim s = 2.30 mm (0.1 in).
47392461 19/06/2012
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64. Install the shim.
RAPH12WEL0386AA 61
65. Install the ball bearing.
RAPH12WEL0387AA 62
66. With the output flange, pull the ball bearing until con-
tact is made. Then remove the output flange.
RAPH12WEL0388AA 63
47392461 19/06/2012
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67. Fasten the ball bearing with a retaining ring.
RAPH12WEL0389AA 64
68. Remove the converter-side mounting tool. Install the

shaft seal (1) with the sealing lip facing the oil sump.
Use a mounting tool or equivalent, to set the shaft
seal.
NOTE: Depending on the version, different shaft seals can
be used.
NOTE: If the outer diameter is rubber coated. Wet it with
spirits.
NOTE: If the outer diameter is metallic, wet it with sealing
compound LOCTITE® 574.
RAPH12WEL0390AA 65
Output flange-version with parking brake

69. Press on the screen sheet.
NOTE: The installation position of the screen sheet is iden-
tical with the output flange-standard version.
RAPH12WEL0391AA 66
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70. Install the output flange-brake.

NOTE: Installation of the output flange and the adjustment
of the gap size is identical with the standard version.
RAPH12WEL0392AA 67
71. To mount the brake, remove the bolt cap and loosen
the locking nut. Unbolt the adjusting bolt counter-
clockwise until > 13.0 mm (0.5 in) of the brake disc
shim appears.
NOTE: For working on the brake system, the instructions
and the specifications of the brake manufacturer are
mandatory!
RAPH12WEL0393AA 68
72. Position the brake and fasten with the cap bolts.
Torque to 125 N·m (92.2 lb ft).
RAPH12WEL0394AA 69
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21.113 / 58
73. Adjust the nominal clearance = 2.0 mm (0.1 in).

Make the pressure connection and apply the re-
quired release pressure = 150 bar (2175 psi) to the
brake (the cup spring set is preloaded). Fasten the
adjusting bolt in a clockwise direction until both of
the brake lining carriers contact the brake disc.
NOTE: The turning of the adjusting screw is not possible or
admissible any more without a higher application of force.
74. Then turn back the adjusting bolt counterclockwise
by 4/5 turns. This turn equals the nominal clearance
of 2.0 mm (0.1 in).
RAPH12WEL0395AA 70
75. Keep the adjusting screw positioned and secure it

with a lock nut.
RAPH12WEL0396AA 71
76. Put a new O-ring into the bolt cap and grease it. In-
stall the bolt cap.
RAPH12WEL0397AA 72
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21.113 / 59
Output flange (converter side)

77. With a mounting tool or equivalent, install the shaft
seal with the sealing lip facing the oil sump.
NOTE: Depending on the version, different shaft seals can
be used.
NOTE: If the outer diameter is rubber-coated: wet with spir-
its.
NOTE: If the outer diameter is metallic: wet with sealing
compound LOCTITE® 574.
RAPH12WEL0398AA 73
78. Press the screen sheet over the collar of the output
flange.
NOTE: Observe the installation position.
RAPH12WEL0399AA 74
79. The image exhibits the screen sheet (1), and the out-
put flange (2).
RAPH12WEL0329AA 75
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21.113 / 60
80. Install the output flange until contact is made.

NOTE: Securing of the output flange and the gap size set-
ting is identical with the output flange installation at the
transmission rear side.
RAPH12WEL0400AA 76
Installation of the idler shaft

81. Centrically align the layshaft gear and the single
components. Heat the layshaft gear to 120 °C (248
°F) with a blower, an oven or a induction heater.
RAPH12WEL0401AA 77
82. Install the adjusting screw.
RAPH12WEL0402AA 78
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21.113 / 61
83. Install the idler shaft.
RAPH12WEL0403AA 79
84. Remove the adjusting screw and fasten the axle with
a hexagon bolt. Torque to 46 N·m (40 lb ft).
NOTE: Wet the thread of the hexagon bolt with LOCTITE®
243.
RAPH12WEL0404AA 80
85. Insert the sealing covers with the concave side facing
downward, flush to the housing surface. Wet the
contact face with LOCTITE® 262.
RAPH12WEL0405AA 81
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Transmission pump — version combined with 2nd/3rd or 4th power take-off

86. Press the needle sleeve with the reinforced coating
toward the press-in tool until.
RAPH12WEL0406AA 82
87. Locate the bearing outer ring.
RAPH12WEL0407AA 83
88. Install the O-ring and grease it.
RAPH12WEL0408AA 84
47392461 19/06/2012
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89. Heat the housing bore to 120 °C (248 °F) with a

RAPH12WEL0409AA 85
90. Install two adjusting screws (1) and correctly place

the pump (2).
RAPH12WEL0410AA 86
91. Put the O-ring into the annular groove of the pump
flange.
NOTE: Depending on the transmission version, fastening
of the pump flange may differ.
RAPH12WEL0411AA 87
92. Wet both cap bolts threads with LOCTITE® 574. Fas-
ten the pump flange and the pump with the cap bolts
(1). Torque to 79 N·m (58.3 lb ft). Through the holes,
wet the threads with LOCTITE® 574.
RAPH12WEL0412AA 88
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21.113 / 64
93. Rotate the transmission housing by 180 °. Snap the

V-rings into the recess of the driver (internal gearing).
Install the key (1).
RCPH11WHL420BAU 89
94. Install the shims (s = 2.0 mm (0.1 in)) and locate the
bearing inner ring.
RCPH11WHL421BAU 90
95. Install the shims (s = 2.0 mm (0.1 in)).
RCPH11WHL416BAU 91
96. Install the driver with a clamping plate and fasten with
the cap bolt. Torque to 32 N·m (23.6 lb ft). Wet the
thread of the cap bolt with LOCTITE® 243.
RCPH11WHL417BAU 92
47392461 19/06/2012
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97. Press down the bearing inner ring.
RCPH11WHL418BAU 93
98. Snap in the retaining ring (1) and install the input
gear.
RCPH11WHL452BAU 94
99. Snap-in and lock the rectangular ring.
RCPH11WHL453BAU 95
47392461 19/06/2012
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100. Install the pre-assembled input shaft.

NOTE: Align the key to the keyway.
101. Adjust the axial play of the input shaft bearing = 0.0
- 0.05 mm.
RCPH11WHL419BAU 96
102. Put on the gasket. Insert the bearing outer ring and
press evenly. To determine dimension I, measure
from the mounting face (gasket) to the bearing outer
ring. (Dimension I e.g. ... 128.5 mm (5.1 in)
NOTE: Take several measurements to determine the mean
value.
RAPH12WEL0413AA 97
103. To measure Dimension II, measure from the mount-

ing face-converter bell to the mounting face-bearing
outer ring. (Dimension II e.g. ... 127.46 mm (5.0 in).
NOTE: Take several measurements to determine the mean
value.
RAPH12WEL0414AA 98
Example:
Axial play — 0.04 mm (0.0 in)
47392461 19/06/2012
21.113 / 67
104. Insert the shim and the bearing inner ring.
RAPH12WEL0415AA 99
Input — converter bell

105. To install a new converter bell, the three finished
bores have to be sealed with the plugs.
RAPH12WEL0416AA 100
106. Locate the bearing outer ring in the housing bore and
the bearing inner ring.
RAPH12WEL0417AA 101
47392461 19/06/2012
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107. Install the spur gear positioning the long collar facing
upward.
RAPH12WEL0418AA 102
108. Heat the spur gear bore to 120 °C (248 °F) with a
RAPH12WEL0419AA 103
109. Install the input shaft.
RAPH12WEL0420AA 104

NOTE: Hot, wear protective gloves.
RAPH12WEL0421AA 105
47392461 19/06/2012
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111. Install the bearing outer ring.
RAPH12WEL0422AA 106
112. Snap the rectangular ring into the angular groove of

the input shaft and lock it. Grease the rectangular
ring and centrally align it.
RAPH12WEL0423AA 107
113. Install the converter safety valve (1) and fasten it with
a slotted pin (2). Then flush mount the slotted pin
within the recessed area. Put the O-ring (3) into the
annular groove.
RAPH12WEL0424AA 108
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114. Press the needle bearing with the reinforced coating

facing toward the press-in tool, into the bore of the
bearing cover until seated.
RAPH12WEL0425AA 109
115. Flush mount the shaft seal with the sealing lip facing
downward toward the oil sump. Wet the outer diam-
eter with spirit. Grease the sealing lip.
RAPH12WEL0426AA 110
116. Heat the housing bore to 120 °C (248 °F) with a

NOTE: Keep in direct time sequence to secure the precise
contact to the oil supply flange.
RAPH12WEL0427AA 111
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117. Install the two adjusting screws (1) and insert the
flange (2) for the oil supply. Observe the radial in-
stallation position.
RAPH12WEL0428AA 112
118. Grease the O-ring and put it into the annular groove
of the bearing cover.
RAPH12WEL0429AA 113
119. Put on the bearing cover and fasten with the hexagon
bolts. Torque to 46 N·m (34 lb ft).
RAPH12WEL0430AA 114
47392461 19/06/2012
21.113 / 72
120. Install the bolt plug (1). Torque to 150 N·m (110.6 lb
ft). Install the next bolt plug (2) and torque to 25 N·m
(18.4 lb ft). Lastly, install the temperature sensor (3)
and torque to 25 N·m (18.4 lb ft) followed with the
bolt plug (depending on the version) and torque to
35 N·m (25.8 lb ft).
NOTE: Always install new O-rings.
RAPH12WEL0431AA 115
121. Install the slotted pin in the converter pressure

back-up valve.
RAPH12WEL0432AA 116
122. Insert the piston and the compression spring (1). In-
stall a new O-ring and a bolt plug. Torque to 130 N·m
(96 lb ft)
RAPH12WEL0433AA 117
47392461 19/06/2012
21.113 / 73
123. Install the washers on the hexagon bolts. Fasten the

gasket and the cover plate (1) with bolts and torque
to 9.5 N·m (84 lb in).
RAPH12WEL0434AA 118
124. Install the two adjusting screws and a gasket (1). Put
the O-ring into the annular groove (2).
RAPH12WEL0435AA 119
125. Install the converter bell with a lifting tackle. Observe

the radial installation position.
NOTE: Slightly rotate the input shaft during the installation
to protect the teeth from damage.
RAPH12WEL0436AA 120
47392461 19/06/2012
21.113 / 74
126. Fasten the converter bell with the hexagon bolts.

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

and lock it. Then grease the rectangular ring and
centrally align it.
RAPH12WEL0439AA 123
129. Attach the lifting tackle to the converter.
RAPH12WEL0440AA 124
47392461 19/06/2012
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130. At a control dimension of < 43 mm (1.7 in), the exact

installation position of the converter is ensured.
RAPH12WEL0441AA 125
131. Temporarily attach the converter axially until the

transmission installation.
RAPH12WEL0442AA 126
Coarse filter
132. Install the filter assembly (1) into the housing bore.
Oil the seal (2).
RAPH12WEL0443AA 127
47392461 19/06/2012
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133. Install a new O-ring (1). Fasten the cover with the
hexagon bolts and washers. Torque to 23 N·m (17.0
lb ft).
RAPH12WEL0444AA 128
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Inductive and speed transmitters

134. Inductive (A) and speed (B) transmitters installation
positions.
RCPH11WHL480BAU 129
RCPH11WHL481BAU 130
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Installation positions
14 = Inductive transmitter n-Turbine
9 = Inductive transmitter n-Engine
5 = Inductive transmitter n-int. speed input
13 = Speed transmitter n-Output
NOTE: Depending on the version, the installation position of the speed transmitter (13) may be different as shown in
image B.
135. The following image describes the installation and
setting of the inductive transmitter n-engine, the
n-turbine, and the n-internal speed input. Observe
the different settings for dimension “X”.
RAPH12WEL0331AA 131
Inductive transmitter n - X = 0.5 +0.3 mm

Engine
Inductive transmitter n - X = 0.5 +0.3 mm
Turbine
Inductive transmitter n - X = 0.3 ±0.1 mm
int. Speed input
136. To adjust dimension “X” with shim rings, measure Di-

mension I on the inductive transmitter from the con-
tact face to the bolt-in face. (Dimension I e.g. ... 30.
mm (1.2 in).
RCPH11WHL443BAU 132
137. Turn the counting disc until one tooth tip is central to
the inductive transmitter bore.
138. Turn the plug gauge until touching.
RCPH11WHL444BAU 133
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21.113 / 79
139. Find the anvil at the tooth tip and lock in place with a
threaded pin.
RAPH12WEL0334BA 134
140. Turn out the plug gauge and determine Dimension II.
(Dimension II e.g. ... 30.10 mm (1.2 in).
RCPH11WHL445BAU 135
Example A1
Dimension II 30.10 mm (1.2 in)
Dimension X (0.5 − 0.60 mm (0.02 in)
+0.3 mm)
Results in = 29.50 mm (1.2 in)
installation in
dimension A
47392461 19/06/2012
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Example A2
Dimension I 30. mm (1.2 in)
Installation − 29.50 mm (1.2 in)
dimension A
Results in shim s = 0.50 mm (0.020 in)
ring(s)
141. Install the correct shim ring(s) (1) and wet the thread
(3) with LOCTITE® 574.
142. Install the inductive transmitter n-Engine (2). Torque
to 30 N·m (22.1 lb ft). Install the inductive transmitter
n- Turbine and the n- internal speed input the same
way.
NOTE: Observe the different setting dimensions.
RCPH11WHL446BAU 136
143. Install the speed transmitter n-output/speed (13).
RAPH12WEL0332AA 137
Speed transmitter n- output/speed legend

1. Housing 13. Speed transmitter (Hall sensor)
2. Spur gear K3 X. Setting dimension. X = 1.0 +0.5 mm
3. Disc carrier
47392461 19/06/2012
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144. Speed transmitter (hall sensor)
RAPH12WEL0445AA 138
145. To determine Dimension I, measure from the housing

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

mounting face. (Dimension II e.g. ... 40 mm (1.6
in)).
RCPH11WHL448BAU 140
Example B1
Dimension X (1.0 +0.5mm) − 1.20 mm (0.0 in)
Results in installation dimension = 38.5 mm (1.5 in)
Example B2
Dimension II 40 mm (1.6 in)
Installation dimension − 38.5 mm (1.5 in)
Results in Shim(s) s = 1.5 mm (0.1
in).
47392461 19/06/2012
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147. Install the three 0.50 mm shims (1) and grease the
O-ring (2).
RCPH11WHL449BAU 141
148. Fasten the speed transmitter with a cap bolt. Torque

to 23 N·m (17 lb ft).
RCPH11WHL450BAU 142
149. Insert new O-ring on the bolt plug (1) and install.
Torque to 145 N·m (107 lb ft). Insert the sealing cov-
ers (2) with the concave side facing downwards, flush
to housing recess. Wet contact face with LOCTITE®
262.
NOTE: Depending on the transmission version, differences
of the single components and their installation positions
may be possible.
RAPH12WEL0446AA 143
150. Flush mount the cap to the housing face and install
the breather. Torque to 12 N·m (106 lb in). Wet the
sealing surface of the cup with LOCTITE® 262.
RAPH12WEL0449AA 144
47392461 19/06/2012
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151. Install the bolt plugs with new O-rings in (1) and (2).
Torque to 100 N·m (73.8 lb ft). Place a new O-ring
on the adapter (3) and install it. Torque to 145 N·m
(107 lb ft).
RAPH12WEL0450AA 145
152. Install both of the fixing plates.
RAPH12WEL0451AA 146
153. Put a new O-ring on the bolt plug and install it. Torque
to 80 N·m (59 lb ft).
NOTE: Prior to transmission operation, oil must be properly
filled.
RAPH12WEL0452AA 147
47392461 19/06/2012
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Powershift transmission - Install

1. Carefully lower the transmission into the chassis.
RCPH11WHL037AAR 1
2. Install the bell housing bolts (1). Tighten the bell

housing bolts (1) to a torque of 54 - 60 N·m (40 -
44 lb ft).
RCPH11WHL036AAR 2
3. Install the flex plate bolts (1). Tighten the flex plate
bolts (1) to a torque of 33 - 41 N·m (24 - 30 lb ft).
RCPH11WHL035AAR 3
47392461 19/06/2012
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4. Apply DOW 732 RTV SILICONE CLEAR to the con-

verter housing cover plate (1).
5. Install the converter housing cover plate (1).
RCPH11WHL034AAR 4
6. Install two transmission mounting bolts (1). Tighten

the two transmission mounting bolts (1) to a torque
of 929 - 1044 N·m (685 - 770 lb ft).
RCPH11WHL032AAR 5
7. Remove the lifting equipment (1) on the transmis-

sion.
RCPH11WHL033AAR 6
47392461 19/06/2012
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8. Install the transmission-to-transmission oil filter lines

(1).
RCPH11WHL031AAR 7
9. Position the wire harness (1) as shown. Install the

wire harness P-clamps (2).
RCPH11WHL030AAR 8
10. Connect the engine speed sensor electrical connec-

tor (1).
RCPH11WHL029AAR 9
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11. Connect the intermediate speed sensor electrical

connector (1).
12. Connect the turbine speed sensor electrical connec-
tor (2).
RCPH11WHL054AAR 10
13. Connect the valve body electrical connector (1).

14. Connect the torque converter output temperature
sender electrical connector (2).
15. Connect the transmission-to-cooler oil line (3).
RCPH11WHL028AAR 11
16. Connect the redundant brake switch electrical con-

nectors (1), (2).
RCPH11WHL027AAR 12
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17. Connect the transmission-to-cooler oil return line (1)

18. Connect the output speed sensor electrical connec-
tor (2).
RCPH11WHL026AAR 13
19. Connect the park brake caliper line (1).
RCPH11WHL025AAR 14
20. Connect the transmission fill tube (1) to the trans-

mission. Tighten the transmission fill tube bolts to
a torque of 16 - 33 N·m (12 - 24 lb ft).
NOTE: Splashback shield located inside transmission fill
tube.
RCPH11WHL024AAR 15
21. Check and adjust all fluid levels.
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22. Bleed the parking brake caliper using the bleeder

screw (1).
RCPH11WHL025AAR 16
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Powershift transmission - Pressure test
RCPH11WHL047GAN 1
MEASURING POINTS AND CONNECTIONS
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Item Denomination of Position Connec- Valve

tion Block
Marking
Measuring points for hydraulic oil and temperature
51 In front of converter 16 - 18 bar (232 - 261 psi) M10 x 1 H
52 Behind converter 16 - 18 bar (232 - 261 psi) M10 x 1
53 Clutch forward 16 - 18 bar (232 - 261 psi) KV M10 x 1 B
55 Clutch reverse 16 - 18 bar (232 - 261 psi) KR M10 x 1 E
56 Clutch 16 - 18 bar (232 - 261 psi) K1 M10 x 1 D
57 Clutch 16 - 18 bar (232 - 261 psi) K2 M10 x 1 A
58 Clutch 16 - 18 bar (232 - 261 psi) K3 M10 x 1 C
60 Clutch 16 - 18 bar (232 - 261 psi) K4 M10 x 1 F
63 Behind converter temperature 100 °C (212 °F) M14 x 1.5
120 °C (248 °F) (short time)
65 16 - 18 bar (232 - 261 psi) M10 x 1 K
Connections
10 Breather M10 x 1
15 Connection to heat exchanger
16 Connection from heat exchanger
28 To filter M42 x 2
29 From filter M42 x 2
30 From filter pressure differential valve M42 x 2
(option)
31 To brake valve M16 x 1.5
32 Return pipe from brake valve M26 x 1.5
36 Oil filter plug M42 x 2
49 Plug connection on electro-hydraulic
control unit
68 System pressure (option) M16 x 1.5 G
69 Control (option) M16 x 1.5 J
Inductive transmitters and speed sensor
5 Inductive transmitter Central gear train M18 x 1.5
9 Inductive transmitter Engine M18 x 1.5
13 Speed sensor Output and speedometer
14 Inductive transmitter Turbine M18 x 1.5
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PRESSURE TEST RESULTS

1. All or Most Pressures Low and/or Flow Test Low
Possible causes include:
1. Oil level not correct.
2. Oil type and grade not correct.
3. Oil operating temperature high.
4. Screen for suction tube plugged.
5. Suction tube or gaskets leak.
6. Main pressure valve, springs, or valve bore.
7. Reduction valve, springs, or valve bore.
8. Charge pump seals or gaskets leak.
9. Charge pump worn.
10. Oil supply flange not sealing correctly.
2. Some Pressures Low
1. Circuit isolation does not correct low pressure.
A. Control valve or gasket.
B. Channel plate or gasket.
2. Circuit isolation corrects low pressure.
A. Clutch shaft or seals.
B. Clutch drum or piston.
3. Not Enough Power
1. Check Battery - Electrical test (55.302) to verify
actual gear selected.
2. Engine RPM below Stall Test specified RPM. (Re-
fer to Engine - Speeds (10.001).)
A. Check engine and fuel system for problem.
B. Check that torque converter installation is correct.
3. Engine RPM above Stall Test specified RPM. (Re-
fer to Engine - Speeds (10.001).)
A. Check converter pressures and flow.
B. Check that torque converter installation is correct.
4. Machine Stops or Hesitates While Shifting - Intermit-
tent
1. Check orifice and O-ring. (See Transmission
control valve - Disassemble (21.135) for replac-
ing.)
2. Check for foreign material plugging orifices or
sticking valves.
3. Check for reduced pressure at test pressure
points.
CONVERTER OUT PRESSURE CHECK

5. Test Equipment Required
0 - 28 bar ( 400 psi) gauge with hose long enough
to take readings in the cab and CAS2324 Special
Adapter.
6. Test Procedure
1. Block the machine tires.
2. Apply the parking brakes.
3. Install the pressure gauge to test point 63.
4. Heat the oil to an operating temperature of 80 -
100 ˚ C ( 176 - 212 ˚ F ).
5. While in the cab, put the transmission in NEU-
TRAL. Run the engine at full throttle. Record the
reading. Pressure must be a minimum of 5 bar (73
psi) .
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LUBRICATION PRESSURE CHECK

0 - 7 bar ( 100 psi) gauge.
8. Test Procedure
3. Install the pressure gauge in the cooler return line
at the transmission.
100 ˚ C ( 176 - 212 ˚ F ).
5. While in the cab, run the engine at full throttle. Put
the transmission in each gear and record the reading.
Pressure must be 0.2 - 1.2 bar ( 3 - 18 psi).
FLOWMETER TEST
CAS1808 Flowmeter Kit.
10. Flowmeter Test Procedure
100 ˚ C ( 176 - 212 ˚ F )
4. Install the flowmeter between the transmission
and the filter.
the transmission in NEUTRAL and record the flow
measurement. The correct flow is 115 l/min (30 US
gpm) at 2000 rpm.
CONSUMPTION TEST PROCEDURE

11. CONSUMPTION TEST PROCEDURE
100 ˚ C ( 176 - 212 ˚ F ).
4. Install the flowmeter to converter outlet line (line to
cooler) in series. Flowmeter at minimum pressure.
the transmission in NEUTRAL and record the flow
measurement. The flow must be 9.1 L/min ( 2 U.S.
gpm ).
6. Repeat the procedure with the transmission in
FORWARD in third gear. The flow must be 9.1 L/min
( 2 U.S. gpm).
7. Repeat the procedure with the transmission in
REVERSE in third gear. The flow must be 9.1 L/min
( 2 U.S. gpm).
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Powershift transmission - Testing

Operate machine in normal operat-
ing conditions and observe:
A. Verify actual oil temperature at
test point. Normal operating temper-
ature can be 56 °C ( 100 °F) above
the ambient temperatures.
B. Use a stop watch to establish the
exact length of time required to reach
the overheating condition.
C. Observe engine temperature.
Check
Does the engine overheat? Which
overheats first - engine or transmis-
sion?
When the transmission reaches Oil temperature returns to Normal - Oil temperature remains over-
overheated condition, shift to Neu- establish length of time (2 to 3 min- heated.
tral and maintain engine RPM at a utes). 1. Check for dirty radiator - airflow
fast idle ( 1250 - 1450 RPM ). Action restricted.
Check 1. Check oil level, type and grade is 2. Check for engine overheating
correct. problem.
2. Check operator’s gear selection is 3. Check for faulty oil temperature
correct for conditions. gauge and sender or switch.
3. Make sure brakes are fully re-
leased.
4. Check the engine full throttle and
stall speeds are correct as specified.
Perform all the pressure and flow
tests.
Compare the pressure and flow test
results to the specifications in Pow-
ershift transmission - General
specification (21.113) to determine
if any circuits are not within specifi-
cations.
Refer to Powershift transmission -
Pressure test (21.113) to determine
possible cause of any test results not
within specifications.
47392461 19/06/2012
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Index
Transmission - 21

Powershift transmission - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Powershift transmission - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Powershift transmission - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Powershift transmission - General specification Clutch Plate Thicknesses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Powershift transmission - General specification Pressures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Powershift transmission - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Powershift transmission - Pressure test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Powershift transmission - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Powershift transmission - Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Powershift transmission - Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
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Transmission - 21
Powershift transmission external controls - 135
1021F
1121F
47392461 19/06/2012
21.135 / 1
Contents
Transmission - 21
SERVICE
Transmission control valve

Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Visual inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
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Transmission - Powershift transmission external controls
Transmission control valve - Assemble

Prior operation:
Transmission control valve - Visual inspection (21.135) Transmission control valve - Disassemble (21.135)
NOTE: Apply clean engine oil (15W-40) to pistons and springs, orifices, new O-rings, and filter screens before as-
sembly.
1. Place the valve body on the bench with the orifices
up.
RCPH11WHL180BAU 1
2. Install the vibration damper (1), pistons (2), pressure

reducing valve (3) and other components in the po-
sitions shown.
RCPH11WHL181BAU 2
3. Preload the compression springs of the pistons. In-

stall a 5 mm (0.20 in) diameter roll pin.
RCPH11WHL182BAU 3
47392461 19/06/2012
21.135 / 3
4. Install the adjusting screws, gasket, and housing

cover.
RCPH11WHL183BAU 4
5. Tighten the adjusting screws equally until the cover

is flush on the valve body.
RCPH11WHL184BAU 5
6. Push the pistons down through the pressure con-

troller holes and remove the roll pins.
RCPH11WHL185BAU 6
7. Install the bolts and torque them in a criss cross pat-

ter to 7.5 N·m (66 lb in).
RCPH11WHL186BAU 7
47392461 19/06/2012
21.135 / 4
8. Install the solenoids and secure them with the retain-

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

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

install a 5 mm (0.20 in) diameter roll pin. Install the
adjusting screws, gasket, and housing cover.
RCPH11WHL189BAU 10
11. Install bolts and torque in a criss cross pattern to 7.5

N·m (66 lb in).
RCPH11WHL186BAU 11
47392461 19/06/2012
21.135 / 5
12. Install the solenoids and secure them with retaining

plates and bolts. Torque bolts to 5.5 N·m (49 lb in).
NOTE: Install the retaining plate with the neck towards
valve body, install controllers with connectors as shown.
RCPH11WHL190BAU 12
13. Install the wiring harness with connector on side of

the valve body with marking made during disassem-
bly. Connect wiring harness to the solenoids.
RCPH11WHL191BAU 13
14. Install the gasket, install the wiring harness plug in

the cover. Install the bolts and torque them in a criss
cross pattern to 7.5 N·m (66 lb in).
RCPH11WHL192BAU 14
15. Install the wiring harness retaining clamp.
RCPH11WHL193BAU 15
47392461 19/06/2012
21.135 / 6
16. Install the screens into the bores of the intermediate

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

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

in a criss cross pattern to 9.5 N·m (84 lb in).
RCPH11WHL196BAU 18
19. Install new O-rings on the plugs. Install plugs and

torque to 6 N·m (53 lb in).
RCPH11WHL197BAU 19
47392461 19/06/2012
21.135 / 7
20. Preassemble the duct plate. Install connection pipes

(1), (2), (3), and (4). Torque to 6 N·m (53 lb in).
Install screw plugs (5) and (6) and torque to 40 N·m
(30 lb ft).
NOTE: Always install new O-rings.
RCPH11WHL437BAU 20
21. Using a new O-ring, install screw plug and torque to

80 N·m (59 lb ft).
RCPH11WHL438BAU 21
22. Install two M8 adjusting screws and a new gasket

(arrow).
RCPH11WHL439BAU 22
23. Install the duct plate and secure it equally with bolts
torqued to 23 N·m (17 lb ft).
RCPH11WHL440BAU 23
47392461 19/06/2012
21.135 / 8
24. Insert two M6 adjusting screws and install gasket (ar-

row).
RCPH11WHL441BAU 24
25. Install valve block and secure evenly using bolts (6

pieces M6 x 100 mm and 17 pieces M6 x 76 mm)
torqued to 12 N·m (9 lb ft).
NOTE: Note positioning of M6 x 100 mm bolts (arrow).
NOTE: Install lines depending on transmission version.
Use markings made during disassembly.
RCPH11WHL442BAU 25
Next operation:
Powershift transmission - Install (21.113)
47392461 19/06/2012
21.135 / 9
Transmission control valve - Disassemble

Prior operation:
Powershift transmission - Remove (21.113)
1. Remove mounting bolts and remove transmission

control valve body.
RCPH11WHL220BAU 1
2. Remove the hose lines from duct plate. Remove

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

the valve block.
RCPH11WHL170BAU 3
47392461 19/06/2012
21.135 / 10
4. Remove the bolts securing the duct plate and inter-

mediate plate to the valve block. Remove the duct
and intermediate plates.
RCPH11WHL171BAU 4
5. Remove the wiring harness retaining clamp.
RCPH11WHL172BAU 5
6. Remove the bolts and cover. Repeat the process for

opposite cover.
RCPH11WHL173BAU 6
7. Remove the wiring harness.
RCPH11WHL174BAU 7
47392461 19/06/2012
21.135 / 11
8. Remove the retaining plate bolts, the retaining plates

and pressure solenoids.
RCPH11WHL175BAU 8
9. Remove two bolts and temporarily install two adjust-

ing bolts (housing is preloaded). Remove the re-
maining bolts.
RCPH11WHL176BAU 9
10. Separate the housing from the valve body by equally

loosening the adjusting bolts.
RCPH11WHL177BAU 10
11. Remove the components.
RCPH11WHL178BAU 11
47392461 19/06/2012
21.135 / 12
12. Remove the opposite side solenoids, housing and

components.
RCPH11WHL179BAU 12
Next operation:
Transmission control valve - Visual inspection (21.135)
47392461 19/06/2012
21.135 / 13
Transmission control valve - Visual inspection

WARNING
Flying debris!
Compressed air can propel dirt, rust, etc. into the air. Wear eye and face protection when using com-
pressed air.
Failure to comply could result in death or serious injury.
W0307A
Prior operation:
Transmission control valve - Disassemble (21.135)
1. Clean all metal parts in cleaning solvent.

2. Immerse end housing, valve housing, valve plate,
and distribution plate in cleaning solvent and agitate
cleaning solvent. Use compressed air to remove for-
eign matter from interior of housings and plates and
to ensure that all bores are clear of foreign matter.
3. Use compressed air to ensure that orifices are clear
of foreign matter.
4. Check filter screens for blockage, rips or tears. Re-
place if any of these conditions are seen.
5. Inspect the plates, housings and covers for cor-
rosion, cracks, breaks, chipping or other damage.
Check bores in housings for deep scratches, gouges,
and other damage. Replace a housing or cover if
any of the above conditions are seen.
6. Check pressure regulators for cracks, breaks, or
other damage. Check connector contacts for loose-
ness of signs of corrosion. Replace a pressure
regulator if any of these conditions are seen. Check
resistance of pressure regulators using a multimeter.
Replace a pressure regulator if resistance is not 17
- 21 Ω.
7. Check wiring harness connectors for signs of breaks,
cracks, or other damage. Check contacts for for-
eign matter or corrosion. Check harness wiring for
signs of broken or cracked insulation and broken or
frayed wiring at connection to the connectors. Re-
place wiring harness if any of these conditions are
seen.
8. Check springs for cracks, breaks, distortion, or signs
of permanent set. Replace a spring if any of these
conditions are seen.
9. Inspect pistons for cracks, breaks, chipping grooves,
or other damage. Replace if any of these conditions
are seen.
Next operation:
Transmission control valve - Assemble (21.135)
47392461 19/06/2012
21.135 / 14
Index
Transmission - 21

Transmission control valve - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Transmission control valve - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Transmission control valve - Visual inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
47392461 19/06/2012
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47392461 19/06/2012
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Transmission - 21
Gearbox internal components - 145
1021F
1121F
47392461 19/06/2012
21.145 / 1
Contents
Transmission - 21
TECHNICAL DATA
Drive shaft
General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
SERVICE
Drive shaft
Remove Front Drive Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Install Front Drive Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Remove Carrier Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Install Carrier Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Remove Center Drive Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Install Center Drive Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Remove Rear Drive Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Install Rear Drive Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Disassemble UNIVERSAL JOINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
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CONSUMABLES INDEX
Consumable IU PAGE
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Transmission - Gearbox internal components
Drive shaft - General specification

Center, Rear and Front Drive Shaft Bolts 136 - 149 N·m (100 - 110 lb ft)
Carrier Bearing Bolts 150 - 164 N·m (111 - 121 lb ft)
Lock Nut for Yoke on Front Drive Shaft 339 - 375 N·m (250 - 277 lb ft)
Universal Joints 136 - 149 N·m (100 - 110 lb ft)
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Drive shaft - Remove Front Drive Shaft

RCPH11WHL039AAH 1
RCPH11WHL307AAH 2
3. Remove lock nut from the end of the center bearing

lubrication hose.
RCIL11WHL212BAF 3
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4. Remove the bolts fastening the center drive shaft

front universal joint to the yoke at the rear of the front
drive shaft.
NOTE: Mark the positioning of the yoke to ensure proper
drive shaft positioning during reassembly.
RCIL11WHL228BAF 4
5. Use a pry bar to disengage the universal joint from

the yoke and move the center drive shaft out of the
way.
RCIL11WHL225BAF 5
6. Loosen and remove the bolts fastening the front uni-

versal joint of the front drive shaft to the front axle.
Use a pry bar to disengage the universal joint from
the yoke on the axle.
NOTE: Mark the positioning of the yoke to ensure proper
drive shaft positioning during reassembly.
RCIL11WHL226BAF 6
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7. Mark the alignment of the center bearing housing po-

sition on the mounting bracket (1). Place a suitable
wedge (2) between the bearing/housing mounting
bracket and the hydraulic line guide/mount bracket.
RCIL11WHL223BAF 7
8. Loosen and remove the nuts, lock washers, and bolts

securing the bearing housing to the mounting sup-
port bracket.
RCIL11WHL227BAF 8
9. Slide the drive shaft to the rear of the machine and

lower it down through opening in the bearing housing
mounting bracket.
NOTE: It may be necessary to loosen the lock nut and set
screw in the center bearing to allow drive shaft movement.
RCIL11WHL222BAF 9
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10. Remove the front drive shaft from the machine and
place it on a suitable work surface.
RCIL11WHL221BAF 10
Next operation:
Drive shaft - Remove Carrier Bearing (21.145) Drive shaft - Install Front Drive Shaft (21.145)
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Drive shaft - Install Front Drive Shaft

Prior operation:
Drive shaft - Remove Front Drive Shaft (21.145) Drive shaft - Install Carrier Bearing (21.145) Drive shaft - As-
semble (21.145)
1. Raise drive shaft up through the bearing housing

mounting bracket opening and slide it into position
towards the front of the machine.
RCIL11WHL222BAF 1
2. Install bolts, lock washers and nuts into center bear-

ing housing and through the mounting bracket to hold
the drive shaft in position.
NOTE: Do not tighten bolts at this time.
RCIL11WHL227BAF 2
3. Install bolts that fasten the universal joint at the front

of the drive shaft to the yoke of the front axle. Torque
bolts to 136 - 149 N·m (100 - 110 lb ft)
NOTE: Use alignment marks made during disassembly to
ensure proper drive shaft positioning.
RCIL11WHL226BAF 3
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4. Using marks made during disassembly, position

bearing hosing on the mounting bracket and secure
it. Torque bolts to 150 - 164 N·m (111 - 121 lb ft)
RCIL11WHL223BAF 4
5. Install bolts that fasten the center drive shaft to the

yoke at the rear of the front drive shaft. Torque bolts
to 136 - 149 N·m (100 - 110 lb ft).
NOTE: If a new front drive shaft has been installed, make
sure the yoke being installed is 90 ˚ to the yoke on the other
end of the front drive shaft.
NOTE: Use alignment marks made during disassembly to
ensure proper drive shaft positioning.
RCIL11WHL228BAF 5
6. Tighten set screw located in the bearing housing until

it bottoms out in the slot on the drive shaft. Then,
loosen the set screw one full turn. Hold the set screw
so it will not turn and tighten the jam nut.
RCIL11WHL227BAF 6
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7. Install lubrication hose and secure it to machine

frame with jam nut.
RCIL11WHL212BAF 7
8. Turn master electric switch ON.
RCPH11WHL307AAH 8
9. Move the transport/service link to the stored position.

Start machine and confirm problem has been cor-
rected.
RCPH11WHL039AAH 9
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Drive shaft - Remove Carrier Bearing

Prior operation:
Drive shaft - Remove Front Drive Shaft (21.145)
NOTE: The center bearing and the bearing housing are not serviced separately. If the center bearing is worn or
damaged or if the bearing housing is cracked, a new center bearing and bearing housing must be used.
1. Place front drive shaft and center bearing housing
assembly on a work bench and remove the lubrica-
tion hose.
RCIL11WHL221BAF 1
2. Remove self-locking nut (1) and flat washer (2) se-

curing the yoke to the rear of the front drive shaft.
RCIL11WHL220BAF 2
3. Mark alignment position of yoke on the drive shaft to

ensure proper positioning during reassembly.
RCPH11WHL142AAR 3
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4. Use an acceptable puller, remove the yoke from the

RCIL11WHL217BAF 4
5. Loosen the set screw that secures the center bearing

to the front drive shaft. Remove any paint or rust
from the drive shaft and apply WD40 or similar oil to
loosen any rust between the inner race and the drive
shaft.
RCIL11WHL216BAF 5
6. Use an acceptable puller to remove the bearing

housing from the drive shaft.
NOTE: Install two longer bolts, at least 76.2 mm (3.0 in) to
hold the bearing housing during removal.
RCIL11WHL215BAF 6
Next operation:
Drive shaft - Install Carrier Bearing (21.145)
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Drive shaft - Install Carrier Bearing

Prior operation:
Drive shaft - Remove Carrier Bearing (21.145)
1. Apply LOCTITE® 767 ANTI-SEIZE to the bearing area
of the front drive shaft.
RCIL11WHL215BAF 1
2. Use an acceptable press and install the bearing

housing on to the drive shaft so that the set screw is
aligned with the groove in the drive shaft.
RCIL11WHL216BAF 2
3. Apply LOCTITE® 767 ANTI-SEIZE to the splines on the

front drive shaft.
RCIL11WHL217BAF 3
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4. With a suitable press, install the yoke on the font

drive shaft. For proper position, make sure the align-
ment marks made during removal are aligned.
RCPH11WHL142AAR 4
5. Install the washer (1) and lock nut (2) that fasten the
yoke to the front drive shaft. Torque lock nut to 339 -
375 Nm ( 250 - 275 lb.ft).
RCIL11WHL220BAF 5
6. Install the lubrication hose in to the bearing housing.
RCIL11WHL221BAF 6
Next operation:
Drive shaft - Install Front Drive Shaft (21.145)
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Drive shaft - Remove Center Drive Shaft

RCPH11WHL039AAH 1
RCPH11WHL307AAH 2
3. Remove bolts securing the front universal joint to the

back of the front drive shaft at the center bearing
mounting support.
NOTE: Note drive shaft positioning. Mark the connection
between the drive shaft and the yoke of the front drive shaft
and the drive shaft and the yoke of the transmission for
reference during reassembly.
RCIL11WHL228BAF 3
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4. Remove bolts securing the rear universal joint that

connects the center drive shaft to the transmission.
RCIL11WHL229BAF 4
5. Properly support the center drive shaft. Use a pry bar

to disengage the center drive shaft from the yoke on
the transmission.
NOTE: Note drive shaft positioning. Mark the connection
between the drive shaft and the yoke of the front drive shaft
and the drive shaft and the yoke of the transmission for
reference during reassembly.
RCIL11WHL224BAF 5
6. Properly support the center drive shaft. Use a prybar

to disengage the center drive shaft from the yoke at
the front of the drive shaft. Remove from the ma-
chine.
RCIL11WHL225BAF 6
Next operation:
Drive shaft - Install Center Drive Shaft (21.145) Drive shaft - Disassemble UNIVERSAL JOINTS (21.145)
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Drive shaft - Install Center Drive Shaft

Prior operation:
Drive shaft - Remove Center Drive Shaft (21.145)
1. Grease or apply anti-seize compound to the front

drive shaft yoke. Engage the front universal joint with
the yoke and install the bolts. Torque bolts to 136 -
149 N·m (100 - 110 lb ft).
NOTE: Note drive shaft position. Use alignment marks
made during disassembly to ensure proper alignment.
RCIL11WHL228BAF 1
2. Grease or apply anti-seize compound to the trans-

mission yoke. Engage the rear universal joint with
the yoke and install the bolts. Torque bolts to 136 -
149 N·m (100 - 110 lb ft).
NOTE: Note drive shaft position. Use alignment marks
made during disassembly to ensure proper alignment.
RCIL11WHL229BAF 2
RCPH11WHL307AAH 3
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rected.
RCPH11WHL039AAH 4
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Drive shaft - Remove Rear Drive Shaft

RCPH11WHL039AAH 1
RCPH11WHL307AAH 2
3. Loosen and remove the bolts (1) that attach the uni-
versal joint of the drive shaft to the rear axle.
NOTE: Note drive shaft positioning. Mark connection be-
tween the drive shaft and the yoke of the rear axle for ref-
erence during reassembly.
RCIL11WHL233BAF 3
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4. Use a pry bar to disengage the rear drive shaft from

the rear axle yolk.
RCIL11WHL236BAF 4
5. Properly support the rear drive shaft. Loosen and

remove the bolts (1) that attach the rear drive shaft
to the transmission.
RCIL11WHL234BAF 5
6. Properly support the rear drive shaft and remove

from the machine.
RCIL11WHL230BAF 6
Next operation:
Drive shaft - Install Rear Drive Shaft (21.145)
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Drive shaft - Install Rear Drive Shaft

Prior operation:
Drive shaft - Remove Rear Drive Shaft (21.145)
1. Grease or apply anti-seize compound to the rear

drive shaft.
RCIL11WHL230BAF 1
2. Engage the front universal joint with the yoke and

install the bolts (1) . Torque bolts to 136 - 149 N·m
(100 - 110 lb ft).
NOTE: Refer to markings made during disassembly to en-
sure proper drive shaft positioning.
RCIL11WHL234BAF 2
3. Engage the rear universal joint with the yoke and

install the bolts (1). Torque bolts to 136 - 149 N·m
(100 - 110 lb ft).
RCIL11WHL233BAF 3
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RCPH11WHL307AAH 4

rected.
RCPH11WHL039AAH 5
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Drive shaft - Disassemble UNIVERSAL JOINTS

Prior operation:
Drive shaft - Remove Front Drive Shaft (21.145) Drive shaft - Remove Center Drive Shaft (21.145) Drive shaft
- Remove Rear Drive Shaft (21.145)
1. Remove the drive shaft from the machine.
RCIL11WHL225BAF 1
2. Unbolt and remove the universal joint (1) from the

drive shaft.
RCIL11WHL211BAF 2
Next operation:
Drive shaft - Assemble (21.145)
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Drive shaft - Assemble

Prior operation:
Drive shaft - Disassemble UNIVERSAL JOINTS (21.145)
NOTE: The bearing race and journal that make up the universal joint are not serviced separately. If the bearing race
or journal is worn or damaged, a new universal joint must be used.
1. Clean the slots in the yoke or the drive sliding yoke.
RCIL11WHL225BAF 1
2. Install the universal joint and the securing bolts (1).

Torque the bolts (1) to 136 - 149 N·m (100 - 110 lb
ft).
RCIL11WHL211BAF 2
3. Lubricate the universal joints if serviceable.
Next operation:
Drive shaft - Install Front Drive Shaft (21.145) Drive shaft - Install Center Drive Shaft (21.145) Drive shaft -
Install Rear Drive Shaft (21.145)
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Index
Transmission - 21

Drive shaft - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Drive shaft - Disassemble UNIVERSAL JOINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Drive shaft - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Drive shaft - Install Carrier Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Drive shaft - Install Center Drive Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Drive shaft - Install Front Drive Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Drive shaft - Install Rear Drive Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Drive shaft - Remove Carrier Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Drive shaft - Remove Center Drive Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Drive shaft - Remove Front Drive Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Drive shaft - Remove Rear Drive Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
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Transmission - 21
Powershift transmission internal components - 155
1021F
1121F
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Contents
Transmission - 21
FUNCTIONAL DATA
Clutch
Dynamic description – Transmission Clutch Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SERVICE
Clutch
Disassemble - Multi-disc clutch K3/K4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Disassemble - Multi-disc clutch KR/K2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Assemble - Multi-disc clutch KR/K2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Disassemble - Multi-disc clutch KV/K1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Assemble - Multi-disc clutch KV/K1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
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Transmission - Powershift transmission internal components
Clutch - Dynamic description – Transmission Clutch Calibration

The Wheel Loader transmission control system can be calibrated to improve the shift quality. The clutches gradually
wear in the transmission therefore the calibration procedure should first be performed after the first 250 hours of
operation and then every 1000 hours thereafter. The calibration needs to first be conducted to make up for the rapid
wear that happens as the initial break-in happens.

A. Escape key
C. Up key
D. Down key
tions.
RCPH11WHL023BAN 1
be locked into system memory when machine is turned OFF.
Accessing Clutch Calibration Feature

2. Use Up and Down keys to highlight Service icon

from main menu screen. Use the Enter / Confirm
key to choose selection.
NOTE: Screen arrows will display to indicate if additional
menu options are available.
RCPH11WHL020BAN 2
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3. Use Up and Down keys to highlight Calibration icon

from Service menu. Use the Enter / Confirm key to
choose selection.
RCPH11WHL022BAN 3
NOTE: Ensure oil is warm to temperature of 90 °C (194 °F). Use transmission stall test procedure to achieve required
temperature.
4. Park machine on firm, level surface.
5. Place the transmission control lever in NEUTRAL.
6. Set the parking brake.

7. Use Up and Down keys to highlight ClutchCalib icon
from Calibration menu. Use the Enter / Confirm key
to choose selection.
If machine conditions are not correct, an error message

will appear. The calibration procedure will not complete.
Follow the prompt to aid in correcting any machine condi-
tions.
The screen may display the following prompts to guide the
user to correct machine conditions:
• Not in neutral Action required – Shift into neutral

• Parking brake OFF Action required – Turn the Park-
ing Brake ON
• Machine moving Action required – Stop the machine
Oil temp too low Action required – Stall the trans- RCPH11WHL021BAN 4
•
mission to heat the oil to 90 °C (194 °F)
• Oil temp too high Action required – Run at high idle
with no load to cool the oil
• Engine RPM low Action required – Operate the en-
gine at full RPM
• Engine RPM high Action required – Operate the en-
gine at idle speed
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8. Run engine at idle rpm. Use Enter / Confirm key to

start the transmission clutch calibration procedure.
NOTE: You must use the transmission stall test procedure
to raise the oil temperature above 90 °C (194 °F).
RCPH10WHL378BAH 5
9. If machine conditions are correct, operator is

prompted to confirm. Use the Enter / Confirm key
to confirm.
If conditions are correct, the user will see six calibration

screens displayed. They will appear in the following order:
• Adjust K1
• Adjust K2
• Adjust K3
• Adjust K4
• Adjust KV
• Adjust KR
• Adjust KW (5-speed only on smaller models)
When calibration process is complete, the user will be

prompted to turn the engine Off and restart the machine.
If the process is not completed correctly, the screen will
prompt the user to escape.
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Clutch - Disassemble - Multi-disc clutch K3/K4

CAUTION
Eye injury hazard!
C0035A
1. Using the clamping ring, fasten the clutch to the as-

sembly truck.
RAPH12WEL0488AA 1
2. Pull off the roller bearing from the disc carrier.
RAPH12WEL0489AA 2
3. Separate the spur gear K3 from the disc gear.
RAPH12WEL0490AA 3
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4. Pull off the bearing inner ring from the disc carrier.
RAPH12WEL0491AA 4
5. Squeeze out the snap ring. Remove the end shim

and the disc set K3.
RAPH12WEL0492AA 5
6. Rotate the disc carrier by 90 °. Loosen the slotted

nut.
RAPH12WEL0493AA 6
7. Rotate the disc carrier by 90 °. Pull off the taper roller

bearing.
RAPH12WEL0494AA 7
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8. Pull off the spur gear K4 from the disc carrier.
RAPH12WEL0495AA 8
9. Remove the ring.
RAPH12WEL0496AA 9
10. Pull off the taper roller bearing.
RAPH12WEL0497AA 10
RAPH12WEL0498AA 11
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12. Preload the compression spring with an appropri-

ate fixture. Squeeze out the snap ring and the re-
leased single components. Remove the opposite
single components (K3 side) the same way.
RAPH12WEL0499AA 12
13. Separate both pistons with compressed air from the

disc carrier.
RAPH12WEL0500AA 13
Next operation:
Clutch - Assemble — Multi-disc clutch K4/K3 (21.155)
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Clutch - Disassemble - Multi-disc clutch KR/K2

1. Fasten the clutch with the clamping ring (1) on the
assembly truck.
RAPH12WEL0501AA 1

nut with an appropriated wrench.
RAPH12WEL0502AA 2
3. Pull off the taper roller bearing from the carrier.
RAPH12WEL0503AA 3
4. Press off the spur gear K2 from the disc carrier.

NOTE: Pay attention to the released disc carrier.
RAPH12WEL0504AA 4
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5. Fasten the disc carrier using a clamping ring. Pull off

the taper roller bearing from the disc carrier.
RAPH12WEL0505AA 5

RAPH12WEL0506AA 6

nut with an appropriate wrench.
RAPH12WEL0507AA 7
8. Pull off the taper roller bearing from the disc carrier.
RAPH12WEL0508AA 8
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9. Fasten the spur gear KR with the clamping ring and

pull it from the disc carrier.
NOTE: The collar of the clamping ring must show upwards
(to the spur gear).
RAPH12WEL0509AA 9
10. Remove the ring.
RAPH12WEL0510AA 10
and the disc set KR.
RAPH12WEL0511AA 11
Remove both pistons described in steps 12 and 13 of
Clutch - Disassemble — Multi-disc clutch K3/K4
(21.155).
RAPH12WEL0512AA 12
Next operation:
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Clutch - Assemble — Multi-disc clutch KR/K2 (21.155)
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Clutch - Assemble - Multi-disc clutch KR/K2

CAUTION
Hot area!
C0034A
CAUTION
Eye injury hazard!
C0035A
Prior operation:
Clutch - Disassemble — Multi-disc clutch KR/K2 (21.155)
RAPH12WEL0559EA 1
Clutch sectioning
Clutch sectioning legend

1. Disc carrier 4. Piston
2. Spur gear KR 5. Compression spring
3. Spur gear K2 6. Plug (2x)
KR. Multi-disc clutch KR 7. Plug (1x)
K2. Multi-disc clutch K2
47392461 19/06/2012
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1. Lift the disc carrier with the KR side facing downward

into the clamping ring and fasten it. Then rotate disc
carrier 180 °. Seal the finished bore with a plug (1).
RAPH12WEL0560AA 2
2. To install the new disc carriers, the finished bores

have to be sealed with the plugs (2).
RAPH12WEL0561AA 3
3. Flush mount the drain valve with the chamfer facing

downward.
RAPH12WEL0562AA 4
4. Put both of the O-rings (scroll free) into the annular

grooves of the piston.
RAPH12WEL0533AA 5
47392461 19/06/2012
21.155 / 15
5. Oil the O-rings and the piston contact surfaces. In-

stall the K2 piston evenly.
NOTE: Observe the installation position of the pistons.
RAPH12WEL0564AA 6
6. Install the spacer and the compression ring.
RAPH12WEL0565AA 7
7. Place the guide ring with the chamfer facing upward,

over the compression spring and install the snap ring.
RAPH12WEL0566AA 8
8. Lift the disc carrier out of the clamping ring.
47392461 19/06/2012
21.155 / 16
9. Preload the compression spring using an appropri-

ate fixture and insert the snap ring into the annular
groove of the disc carrier.
10. Install the drain valve, the piston and the compres-
sion spring on the opposite side (clutch KR) following
the steps 3 to 9.
11. Then lift the disc carrier with the KR side facing down-
ward into the clamping ring and fasten it. Rotate the
disc carrier by 180 °.
RAPH12WEL0567AA 9
47392461 19/06/2012
21.155 / 17
Disc components KR
RAPH12WEL0563FA 10
Standard version of installation position of the KR single components

Pos. Description Quantity s(mm) Remarks
1 Disc carrier 1
2 Piston 1
3 Outer clutch disc 2 1.85 Coated on one side
4 Outer clutch disc 11 3.35 Coated on both sides
5 Inner clutch disc 5 2.5
7 Inner clutch disc 2 2.5...4.0 optional
8 Snap ring 1 2.10...3.10 optional
9 End shim 1
Number of friction surfaces: 24
Disc clearance: 2.8...3.0 mm
12. Install the outer clutch Position 3 with the uncoated

sides facing toward the piston and the end shim.
The individual clutch side lengths of the disc are
shown in the diagram and as follows:
KR = Dimension Y (the long disc carrier side) and
K2 = Dimension X (the short disc carrier side).
47392461 19/06/2012
21.155 / 18
13. In order to ensure a perfect measuring result, the disc

set is first installed without oil. Check the disc clear-
ance KR = 2.8...3.0 mm. Install the disc set accord-
ing to Standard Version of Installation Position of the
KR Single Components table and Disc components
diagram.
RAPH12WEL0568AA 11
14. Install the end shim and fasten it with the snap ring.
RAPH12WEL0569AA 12
15. Press the end shim (1) with approximately 100 N

(22.5 lb) or 10.2 kg and set the dial indicator to
“zero”. Press the end shim against the snap ring up-
ward and read the disc clearance on the dial indica-
tor. If the required disc clearance differs, it has to be
corrected with adequate inner clutch discs or snap
rings. Refer to the Standard Version of Installation
Position of the KR Single Components table Position
7 and Position 8.
16. Upon setting of the disc clearance, remove the disc
set, the oil clutch discs and reinstall them.
RAPH12WEL0540AA 13
17. Preassemble and install the spur gear KR.

1. Bearing inner ring (75 x 37 mm)
2. Ring
3. Spur gear
4. Bearing inner ring (75 x 41 mm)
RAPH12WEL0571AA 14
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21.155 / 19
18. Heat the bearing inner ring (1) and install.

NOTE: Hot, wear protective hand gear.
RAPH12WEL0572AA 15
19. Insert the spur gear (3) lining up with all the inner
clutch discs.
RAPH12WEL0573AA 16
20. Install the ring (2).
RAPH12WEL0574AA 17
21. Heat the bearing inner ring (4) and install.

RAPH12WEL0575AA 18
47392461 19/06/2012
21.155 / 20
22. Heat the bearing inner ring (the clutch bearing) and
install.
RAPH12WEL0576AA 19
47392461 19/06/2012
21.155 / 21
Disc components K2
RAPH12WEL0577FA 20
Standard version of installation position of the K2 single components

1 Disc carrier 1
2 Piston 1
9 End shim 1

KR = Dimension Y (the long disc carrier side) and
47392461 19/06/2012
21.155 / 22

ance KR = 2.2...2.4 mm. Install the disc set accord-
ing to the Standard Version of Installation Position of
the K2 Single Components table and Disc compo-
nents diagram.
RAPH12WEL0578AA 21
RAPH12WEL0579AA 22
26. Press the end shim with approximately 100 N (22.5

lb) or 10.2 kg and set the dial indicator to “zero”.
Press the end shim against the snap ring upward and
read the disc clearance on the dial indicator. If the
required disc clearance differs, it has to be corrected
with adequate inner clutch discs or the snap rings.
Refer to the Standard Version of Installation Position
of the K2 Single Components table Position 7 and
Position 8.
set, the oil clutch discs and reinstall the outer clutch.
RAPH12WEL0580AA 23
28. Preassemble and install the spur gear K2. Undercool

the gear (1) to approximately -80 °C (-112.0 °F) and
heat the gear (2) to approximately 120 °C (248 °F).
29. Insert the snap ring (3), preload it and join both of
the components with a hydraulic press, until the snap
rings inserts into the annual groove near gear (2).
RAPH12WEL0581AA 24
47392461 19/06/2012
21.155 / 23
30. The single components of the spur gear bearing.

1. Bearing inner ring
2. Spur gear assembly
RAPH12WEL0582AA 25

NOTE: Hot, wear hand gear.
RAPH12WEL0583AA 26
32. Insert the spur gear and line up all the inner clutch
discs.
RAPH12WEL0584AA 27
33. Heat the bearing inner ring (the spur gear bearing)
and install.
RAPH12WEL0585AA 28
47392461 19/06/2012
21.155 / 24
install.
RAPH12WEL0586AA 29
35. Lift the disc carrier out of the clamping ring. To en-
sure the exact location of the single components,
preload the bearing with 100000 N (22481 lb) or 10
ton. Support the lower and the upper bearing ring
with the pressure pieces.
RAPH12WEL0587AA 30
36. Lift the disc carrier into the clamping ring and fasten
it. Rotate the disc carrier 90 °.
37. On the K2 side, install the slotted nut. Observe the
installation position of the slotted nut. The chamfer
must show to the bearing inner ring. Oil the thread
then torque to 800 N (180 lb).
RAPH12WEL0588AA 31
38. On the KR side, install the slotted nut. Observe the

installation position of the slotted nut. The collar must
show to the bearing inner ring. Oil the thread then
torque to 800 N (180 lb).
RAPH12WEL0589AA 32
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39. Using compressed air, check the functions of K3 and

K4. The closing or the opening of the clutches will be
clearly audible with correct assembly.
40. Snap in and lock the rectangular rings.
RAPH12WEL0590AA 33
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Clutch - Disassemble - Multi-disc clutch KV/K1

1. Fasten the clutch with the clamping ring to the as-
sembly truck. Loosen the slotted nut.
RAPH12WEL0513AA 1
RAPH12WEL0514AA 2
3. Remove the shim.
RAPH12WEL0515AA 3
47392461 19/06/2012
21.155 / 27
4. Pull off the spur gear K1 from the disc carrier.
RAPH12WEL0516AA 4
5. Figure shows the spur gear bearing K1. Bearing (1)

can only be obtained as a complete part or unit.
NOTE: If it is necessary to remove the clutch pack sided
ball bearing (arrow), the complete bearing (1) has to be
removed. Refer to following steps 7 and 8 for procedures.
RAPH12WEL0517AA 5
6. Take off the bush.
RAPH12WEL0518AA 6
47392461 19/06/2012
21.155 / 28
7. Pull off the ball bearing from the disc carrier.
RAPH12WEL0519AA 7
8. Pull off the ball bearing from the disc carrier.

NOTE: Pay attention to the released ball bearings.
RAPH12WEL0520AA 8

RAPH12WEL0521AA 9

nut with appropriate tool.
RAPH12WEL0522AA 10
47392461 19/06/2012
21.155 / 29
RAPH12WEL0523AA 11
12. Pull off the spur gear KV from the disc carrier.
RAPH12WEL0524AA 12
13. Remove the ring.
RAPH12WEL0525AA 13
Squeeze out the snap ring. Remove the end shim
and the disc set KV. Remove both pistons as de-
scribed in steps 12 and 13 of Clutch - Disassemble
— Multi-disc clutch K3/K4 (21.155).
RAPH12WEL0526AA 14
Next operation:
47392461 19/06/2012
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Clutch - Assemble — Multi-disc clutch KV/K1 (21.155)
47392461 19/06/2012
21.155 / 31
Clutch - Assemble - Multi-disc clutch KV/K1

CAUTION
Hot area!
C0034A
CAUTION
Eye injury hazard!
C0035A
Prior operation:
Clutch - Disassemble — Multi-disc clutch KV/K1 (21.155)
RAPH12WEL0591EA 1
Clutch sectioning
Clutch sectioning legend

1. Disc carrier 4. Piston
2. Spur gear KV 5. Compression spring
3. Spur gear K1 6. Plug (2x)
KV. Multi-disc clutch KV 7. Plug (1x)
K1. Multi-disc clutch K1
47392461 19/06/2012
21.155 / 32
1. Lift the disc carrier with the KV side facing downward

into the clamping ring and fasten it. Rotate the disc
carrier 180 °. Install the seal plugs in the finished
bores (1).
RAPH12WEL0594AA 2
2. To install the new disc carriers, the finished bores (1)

have to be sealed with the plugs.
RAPH12WEL0641AA 3
3. Flush mount the drain valve with the chamfer facing

downward.
RAPH12WEL0532AA 4
4. Put both of the O-rings (scroll free) into the annular

grooves of the piston.
RAPH12WEL0533AA 5
47392461 19/06/2012
21.155 / 33
5. Oil the O-rings and the piston contact surfaces. In-

stall the K1 piston evenly.
NOTE: Observe the installation position of the piston.
RAPH12WEL0642AA 6
6. Install the spacer and the compression spring.
RAPH12WEL0643AA 7
7. Place the guide ring with the chamfer facing upward,

over the compression spring and install the snap ring.
RAPH12WEL0644AA 8
8. Lift the disc carrier out of the clamping ring.

9. Preload the compression spring with an appropriate
fixture and place the snap ring (arrow) into the annu-
lar groove of the disc carrier.
10. Install the drain valve, the piston and the compres-
sion spring on the opposite side (KV) following steps
3 to 9.
11. Then lift the disc carrier with the KV side facing down-
ward into the clamping ring and fasten it. Rotate the
disc carrier 180 °.
RAPH12WEL0645AA 9
47392461 19/06/2012
21.155 / 34
Disc components KV
RAPH12WEL0592FA 10
Standard version of installation position of the KV single components

1 Disc carrier 1
2 Piston 1
9 End shim 1

KV = Dimension Y (the long disc carrier side) and
47392461 19/06/2012
21.155 / 35

ance KV = 2.8...3.0 mm. Install the disc set accord-
ing to Standard Version of Installation Position of the
KV Single Components table and Disc components
diagram.
RAPH12WEL0646AA 11
RAPH12WEL0647AA 12
15. Press on the end shim with approximately 100 N

“zero”. Then press the end shim against the snap
ring upward and read the disc clearance on the dial
indicator. If the required disc clearance differs, it has
to be corrected with adequate inner clutch disc or the
snap rings. Refer to the Standard Version of Installa-
tion Position of the KV Single components table Po-
sition 7 and Position 8.
set, oil the clutch discs and reinstall them.
RAPH12WEL0570AA 13
17. Preassemble and install the spur gear KV.

2. Bearing outer ring
3. Ring
4. Spur gear
18. Install both of the bearing outer rings (2).
RAPH12WEL0648AA 14
47392461 19/06/2012
21.155 / 36

RAPH12WEL0649AA 15
20. Install the ring.
RAPH12WEL0650AA 16
21. Insert the spur gear and line up all the inner clutch
discs.
RAPH12WEL0651AA 17
22. Heat the bearing inner ring (the spur gear bearing)
and install.
RAPH12WEL0652AA 18
47392461 19/06/2012
21.155 / 37
install. Rotate the disc carrier 180 °.
RAPH12WEL0653AA 19
47392461 19/06/2012
21.155 / 38
Disc components K1
RAPH12WEL0593FA 20
Standard version of installation position of the K1 single components

1 Disc carrier 1
2 Piston 1
9 End shim 1

KV = Dimension Y (the long disc carrier side) and
47392461 19/06/2012
21.155 / 39

ance K1 = 2.2...2.4 mm. Install the disc set according
to Standard Version of Installation Position of the K1
Single Components table and Disc components dia-
gram
RAPH12WEL0654AA 21
RAPH12WEL0655AA 22
27. Press on the end shim with approximately 100 N

“zero”. Press the end shim against the snap ring up-
ward and read the disc clearance on the dial indica-
tor. If the required disc clearances differs, it has to be
corrected with adequate inner clutch disc or the snap
rings. Refer to the Standard Version of Installation
Position of theK1 Single Components table Position
7 and Position 8.
set, the oil clutch discs and reinstall them.
RAPH12WEL0570AA 23
29. Preassemble and install the spur gear K1.

1. Ball bearing assembly
2. Snap ring
3. Spur gear
RAPH12WEL0656AA 24
47392461 19/06/2012
21.155 / 40
30. Prior to the installation of the single components,

align the disc set using the spur gear (3) to center
it. Once centered, remove the spur gear and begin
the spur gear pre-assembly.
RAPH12WEL0657AA 25
31. Install the snap ring (2).
RAPH12WEL0658AA 26
32. Install the bush with the collar on the side facing the
snap ring.
RAPH12WEL0659AA 27
33. Install the ball bearing with the lubricating groove fac-
ing downward. Put the press-in tool only to the bear-
ing outer ring and press in until seated.
RAPH12WEL0660AA 28
47392461 19/06/2012
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34. Heat the second ball bearing and install it with the
groove facing upward. Then lubricate the groove.
RAPH12WEL0661AA 29
35. Insert the bush.
RAPH12WEL0662AA 30
36. Heat the spur gear to approximately 120 °C (248.0

°F) and insert over the inner clutch discs.
RAPH12WEL0663AA 31
37. Install the shim (1.2 mm).
RAPH12WEL0665AA 32
47392461 19/06/2012
21.155 / 42
38. Heat the bearing inner ring and install it until seated.
RAPH12WEL0666AA 33
39. Lift the disc carrier out of the clamping ring. To en-
sure the exact location of the single components,
preload the bearing with 100000 N (22481 lb) or 10.2
t. Support the lower and the upper bearing ring with
the pressure pieces.
RAPH12WEL0667AA 34
40. Lift the disc carrier into the clamping ring. Rotate the
disc carrier by 90 °.
41. Install the slotted nut. Observe the installation posi-
tion of the slotted nut. The collar must show to the
taper roller bearing. Oil the thread. Torque to 500
N·m (369 lb ft).
42. On the KV side, install the opposite slotted nut. Ob-
serve the installation position of the slotted nut. Oil
the thread and torque accordingly.
RAPH12WEL0664AA 35
43. Using compressed air, check the functions of the

clutches KV and K1. The closing or the opening of
the clutches will be clearly audible with correct as-
sembly.
RAPH12WEL0668AA 36
47392461 19/06/2012
21.155 / 43
44. Snap in and lock the rectangular rings.
RAPH12WEL0669AA 37
47392461 19/06/2012
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Index
Transmission - 21

Clutch - Assemble - Multi-disc clutch KR/K2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Clutch - Assemble - Multi-disc clutch KV/K1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Clutch - Disassemble - Multi-disc clutch K3/K4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Clutch - Disassemble - Multi-disc clutch KR/K2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Clutch - Disassemble - Multi-disc clutch KV/K1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Clutch - Dynamic description – Transmission Clutch Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
47392461 19/06/2012
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PRINTED IN U.S.A.
47392461 19/06/2012
EN
SERVICE MANUAL
Four-Wheel Drive (4WD) system
1021F
1121F
47392461 19/06/2012
23
Contents
Four-Wheel Drive (4WD) system - 23
Drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23.314

1021F , 1121F
47392461 19/06/2012
23
CONSUMABLES INDEX
Consumable IU PAGE
Loctite® 242 Shaft support - Install - Carrier Bearing 23.314 / 15
47392461 19/06/2012
23
47392461 19/06/2012
23
Drive shaft - 314
1021F
1121F
47392461 19/06/2012
23.314 / 1
Contents
Drive shaft - 314
TECHNICAL DATA
Drive shaft
Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
SERVICE
Drive shaft
Remove - Front Drive Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Install - Front Drive Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Front drive shaft - Remove - Center Drive Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Front drive shaft - Install - Center Drive Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Drive shaft
Remove - Engine to Transmission Drive Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Install - Engine to Transmission Drive Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Shaft support
Remove - Carrier Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Install - Carrier Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Drive shaft universal joint
Disassemble - Universal Joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Assemble - Universal Joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
47392461 19/06/2012
23.314 / 2
CONSUMABLES INDEX
Consumable IU PAGE
Loctite® 242 Shaft support - Install - Carrier Bearing 23.314 / 15
47392461 19/06/2012
23.314 / 3
Four-Wheel Drive (4WD) system - Drive shaft
Drive shaft - Torque

Center, Rear and Front Drive Shaft Bolts 75 - 81 Nm ( 55 - 60 lb.ft)
Carrier Bearing Bolts 99 - 128 Nm ( 73 - 94 lb.ft)
Lock Nut for Yoke on Front Drive Shaft 339 - 375 Nm ( 250 - 275 lb.ft)
Drive shaft - Torque

Coupler to Flywheel Bolts 53 - 62 Nm ( 39 - 46 lb.ft)
Engine Drive Shaft to Coupler Bolts 53 - 62 Nm ( 39 - 46 lb.ft)
Engine Drive Shaft to Transmission Bolt 75 - 81 Nm ( 55 - 60 lb.ft)
47392461 19/06/2012
23.314 / 4
Drive shaft - Remove - Front Drive Shaft

1. Loosen and remove the bolts and straps that fasten
the center drive shaft to the yoke of the front drive
shaft.
bd03a166 1
2. Remove the lock nut that fastens the yoke to the front
drive shaft.
bd03a183 2
3. Make an alignment mark on the yoke and the end

of the front drive shaft to make sure that the yoke is
installed correctly.
4. Use an acceptable puller and remove the yoke from
the end of the front drive shaft.
5. Loosen the set screws that secure the center bearing
to the front drive shaft.
6. Remove any paint or rust from the rear of the front
drive shaft and apply WD40 or similar oil to loosen
any rust between the inner race and the front drive
shaft.
the front drive shaft to the front axle.
bd03a167 3
47392461 19/06/2012
23.314 / 5
8. Use a prybar to disengage the front drive shaft from

the front axle and remove the front drive shaft from
the machine.
NOTE: If necessary, use a brass hammer to drive the front
drive shaft out of the center bearing.
Next operation:
Drive shaft - Install — Front Drive Shaft (23.314)
47392461 19/06/2012
23.314 / 6
Drive shaft - Install - Front Drive Shaft

Prior operation:
Drive shaft - Remove — Front Drive Shaft (23.314)
1. Apply antiseize compound to the bearing area of the

front drive shaft.
2. Place the front drive shaft into position in the center
bearing of the machine.
3. Install the bolts and straps that fasten the front drive
shaft to the front axle. Tighten the bolts to a torque
of 75 - 81 Nm ( 55 - 60 lb.ft).
bd03a167_520 1
4. Apply antiseize compound to the splines on the front

drive shaft.
5. Install the yoke to the front drive shaft, making
sure the alignment marks made during removal are
aligned.
NOTE: If a new front drive shaft has been installed, make
sure the yoke being installed is 90 ˚ to the yoke on the other
6. Install the lock nut and washer which fastens the
yoke to the front drive shaft. Tighten the lock nut to
a torque of 339 - 375 Nm ( 250 - 275 lb.ft).
bd03a183_521 2
7. Tighten the set screws that secure the center bearing

to the front drive shaft alternately until they stop turn-
ing and the hex head socket wrench starts to spring.
47392461 19/06/2012
23.314 / 7
8. Install the bolts and straps that fasten the front drive
shaft to the center drive shaft. Tighten the bolts to a
torque of 75 - 81 Nm ( 55 - 60 lb.ft).
bd03a166_522 3
47392461 19/06/2012
23.314 / 8
Front drive shaft - Remove - Center Drive Shaft

the center drive shaft to the yoke of the front drive
shaft.
bd03a166_494 1
2. Use a prybar to disengage the center drive shaft from

the yoke of the front drive shaft.
the center drive shaft to the transmission.
bd03a165 2
4. Hold the center drive shaft and remove from the ma-
chine.
Next operation:
Drive shaft - Remove — Carrier Bearing (23.314) Drive shaft - Install — Center Drive Shaft (23.314)
47392461 19/06/2012
23.314 / 9
Front drive shaft - Install - Center Drive Shaft

Prior operation:
Drive shaft - Install — Carrier Bearing (23.314) Drive shaft - Remove — Center Drive Shaft (23.314)
1. Hold the center drive shaft in position and install the

bolts and straps that fasten the center drive shaft to
the transmission. Tighten the bolts to a torque of 75
- 81 Nm ( 55 - 60 lb.ft).
bd03a165_526 1
2. Install the bolts and straps that fasten the center drive
shaft to the yoke of the front drive shaft. Tighten the
bolts to a torque of 75 - 81 Nm ( 55 - 60 lb.ft).
bd03a166_527 2
47392461 19/06/2012
23.314 / 10
Drive shaft - Remove - Engine to Transmission Drive Shaft

1. Remove and discard the bolts and straps that fasten
the engine drive shaft to the transmission.
NOTICE: The bolts and straps that fasten the engine drive
shaft to the transmission must be replaced when removed.
bd01d342_530 1
2. Loosen and remove the six bolts that fasten the en-
gine drive shaft to the engine.
bd03a172_531 2
3. Remove the engine drive shaft from the machine.
Next operation:
Drive shaft - Install — Engine to Transmission Drive Shaft (23.314)
47392461 19/06/2012
23.314 / 11
Drive shaft - Install - Engine to Transmission Drive Shaft

Prior operation:
Drive shaft - Remove — Engine to Transmission Drive Shaft (23.314)
1. Place the engine drive shaft into position on the

transmission and install new straps and bolts.
Tighten the bolts to a torque of 61 - 81 Nm ( 45 - 60
lb.ft).
bd01d342 1
2. Install new bolts that fasten the engine drive shaft to

the engine. Tighten the bolts to a torque of 53 - 62
Nm ( 39 - 46 lb.ft)
bd03a172_495 2
47392461 19/06/2012
23.314 / 12
Shaft support - Remove - Carrier Bearing

the center drive shaft to the front drive shaft.
bd03a166_490 1
2. Loosen and remove the lubrication hose from the

center bearing
bd03a183_491 2
3. Loosen and remove the lock nut that fastens the yoke
bd03a183_492 3
4. Make an alignment mark on the yoke and the front

drive shaft to be sure that the yoke is installed cor-
rectly.
5. Use an acceptable puller and remove the yoke from
the end of the front drive shaft.
6. Remove any paint or rust from the rear of the front
drive shaft and apply WD40 or similar oil to loosen
any rust between the inner race and the front drive
shaft.
7. Loosen the set screws that secure the center bearing
47392461 19/06/2012
23.314 / 13
8. Loosen and remove the bolts, washers and nuts that

fasten the bearing housing to the front frame.
bd03a183_493 4
9. Install two longer bolts, at least 3 inches, to hold the

bearing housing during removal. Use an acceptable
puller to remove the bearing housing from the front
drive shaft.
Next operation:
Drive shaft - Install — Carrier Bearing (23.314)
47392461 19/06/2012
23.314 / 14
Shaft support - Install - Carrier Bearing

Prior operation:
Drive shaft - Remove — Carrier Bearing (23.314)
1. Apply antiseize compound to the bearing area of the
front drive shaft.
2. Install the bearing housing so that the lubrication fit-
ting is at the top.
3. Apply LOCTITE® 242 to bolt threads. Install the bolts,
washers and nuts that fasten the bearing housing to
the front frame. Tighten the bolts to a torque of 99 -
128 Nm ( 73 - 94 lb.ft).
bd03a183_523 1
4. Turn the set screw down to the shaft and then back
it off 1/4 turn and lock it with the jam nut. Repeat the
procedure with the other set screw.
RAPH11WEL0530AA 2
5. Apply antiseize compound to the splines on the front

drive shaft.
6. Install the yoke to the front drive shaft, making
sure the alignment marks made during removal are
aligned.
47392461 19/06/2012
23.314 / 15
7. Install the washer and lock nut that fasten the yoke to
the front drive shaft. Tighten the lock nut to a torque
of 339 - 375 Nm ( 250 - 275 lb.ft).
bd03a183_524 3
8. Install the straps and bolts that fasten the center drive
shaft to the yoke on the front drive shaft. Tighten the
bolts to a torque of 75 - 81 Nm ( 55 - 60 lb.ft).
bd03a166_525 4
9. Install the lubrication hose into the fitting on the bear-

ing housing.
10. Lubricate the center bearing with the grease.
47392461 19/06/2012
23.314 / 16
Drive shaft universal joint - Disassemble - Universal Joints

1. Remove the drive shaft from the machine.
2. Remove the ring (1) and the bearing (2) from the
drive shaft.
NOTE: The above photo shows the drive shaft on the ma-
chine and is for reference of the ring and bearing only.
bd01f304_532 1
3. Remove the universal joint from the drive shaft.
Next operation:
Drive shaft - Assemble — Universal Joints (23.314)
47392461 19/06/2012
23.314 / 17
Drive shaft universal joint - Assemble - Universal Joints

Prior operation:
Drive shaft - Disassemble — Universal Joints (23.314)
NOTE: The bearing race and journal that make up the universal joint are not serviced separately. If the bearing race
or journal is worn or damaged, a new universal joint must be used.
1. Clean the slots in the yoke of the drive shaft.
2. Install the universal joint and install the bearings (2)
and the rings (1).
bd01f304_532 1
3. Install the drive shaft.
47392461 19/06/2012
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Index
Drive shaft - 314

Drive shaft - Install - Engine to Transmission Drive Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Drive shaft - Install - Front Drive Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Drive shaft - Remove - Engine to Transmission Drive Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Drive shaft - Remove - Front Drive Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Drive shaft - Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Drive shaft - Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Drive shaft universal joint - Assemble - Universal Joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Drive shaft universal joint - Disassemble - Universal Joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Front drive shaft - Install - Center Drive Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Front drive shaft - Remove - Center Drive Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Shaft support - Install - Carrier Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Shaft support - Remove - Carrier Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
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PRINTED IN U.S.A.
47392461 19/06/2012
EN
SERVICE MANUAL
Front axle system
1021F
1121F
47392461 19/06/2012
25
Contents
Front axle system - 25
Powered front axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.100

1021F , 1121F
Front bevel gear set and differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.102

1021F , 1121F
Final drive hub, steering knuckles, and shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.108

1021F , 1121F
47392461 19/06/2012
25
CONSUMABLES INDEX
Consumable IU PAGE
Loctite® 262 Differential - Remove Model 3105 II 25.102 / 27
Loctite® 262 Differential - Install Model 3105 II 25.102 / 37
Terostat® MS-9360 Wheel hub - Assemble Model 3105 II 25.108 / 22
47392461 19/06/2012
25
47392461 19/06/2012
25
Powered front axle - 100
1021F
1121F
47392461 19/06/2012
25.100 / 1
Contents
TECHNICAL DATA
Powered front axle

1021F
Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1021F
General specification Model 3115 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Torque Model 3115 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SERVICE
Powered front axle

Remove Model 3105 II/3115 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Install Model 3105 II/3115 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Filling Model 3105 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1021F
Filling Model 3115 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
47392461 19/06/2012
25.100 / 2
Front axle system - Powered front axle
Powered front axle - General specification

1021F
Model 3105 II
Lubrication capacity for axles 42.0 l (44.4 US qt)
Lubrication capacity for axles with axle cooler 45.7 l (48.3 US qt)
Lubrication capacity for heavy duty axles 62.0 l (65.5 US qt)
Lubrication capacity for heavy duty axles with axle cooler 65.7 l (69.4 US qt)
Sun Gear Shaft End Play 0.5 - 2.0 mm (0.02 - 0.08 in)
Drive Pinion Rolling Torque 1.5 - 3.0 Nm (13.28 - 26.55 lb in)
Powered front axle - Torque

1021F
Model 3105 II
Outboard planetary drive bolts 200 N·m (148 lb ft)
Axle wheel end screw plug 50 N·m (37 lb ft)
Axle brake tube 100 N·m (74 lb ft)
Brake tube fitting to wheel end fitting 36 N·m (27 lb ft)
Axle housing bolts 560 N·m (413 lb ft)
Differential releasing housing cover bolts 185 N·m (136 lb ft)
Powered front axle - General specification Model 3115 II

Lubrication capacity for axles 42.0 l (44.4 US qt)
Lubrication capacity for axles with axle cooler 45.7 l (48.3 US qt)
Lubrication capacity for heavy duty axles 62.0 l (65.5 US qt)
Lubrication capacity for heavy duty axles with axle cooler 65.7 l (69.4 US qt)
Sun gear shaft end play 0.5 - 2.0 mm (0.02 - 0.08 in)
Drive pinion rolling torque 1.5 - 5.0 N·m (13 - 44 lb in)
Powered front axle - Torque Model 3115 II

Outboard planetary drive bolts 560 N·m (413 lb ft)
Locknut securing planetary carrier 700 - 1000 N·m (516 - 738 lb ft)
Axle brake tube 100 N·m (74 lb ft)
Axle brake tube mount 36 N·m (27 lb ft)
Axle drive housing bolts 560 N·m (413 lb ft)
Bearing housing cylindrical screws 50 N·m (37 lb ft)
Differential case oil tube 100 N·m (74 lb ft)
Differential case oil tube mounting nut 100 N·m (74 lb ft)
Spider gear mount disk bolts 50 N·m (37 lb ft)
47392461 19/06/2012
25.100 / 3
Powered front axle - Remove Model 3105 II/3115 II

1. Park machine on level surface. Have assistant put
articulation lock in LOCKED position.
2. Raise bucket and have assistant install safety link.
Lower loader arms slowly until safety link is support-
ing loader arms.
3. Stop engine. Actuate brake pedal several times to
discharge brake accumulators. Put key switch in ON
position and move loader control lever back and forth
at least 30 times to release any pressure from hy-
draulic circuit. Put key switch in OFF position.
4. Remove bolts fastening the front drive shaft universal
joint to the front axle.
5. Use a prybar and disengage the front drive shaft uni-
versal joint from the front axle.
6. Tag and disconnect the brake, differential lock (if
equipped) and cooler lines from the front axle. In-
stall caps and plugs on open lines.
7. Raise the front wheels off the floor and use accept-
able supports to hold the machine.
8. Remove the wheels from the front axle.
9. Use acceptable lifting equipment (transmission jack)
to hold and lower the front axle.
10. Fasten the jack to the front axle to keep the front axle
from moving when the mounting bolts are removed.
11. Remove the self-locking nuts, washers, and bolts on
each side of the front axle.
12. Carefully lower and remove the front axle from the
machine.
Next operation:
Differential - Remove Model 3105 II (25.102) Wheel hub - Remove Model 3105 II (25.108) Differential - Remove
Model 3115 II (25.102) Wheel hub - Remove Model 3115 II (25.108)
47392461 19/06/2012
25.100 / 4
Powered front axle - Install Model 3105 II/3115 II
Prior operation:
Differential - Install Model 3105 II (25.102) Wheel hub - Install Model 3105 II (25.108) Differential - Install Model
3115 II (25.102) Wheel hub - Install Model 3115 II (25.108)
1. Correctly position front axle using a suitable jack.

2. Install one bolt and washer on each side of the front
axle. The bolts should be placed through the top of
the frame and then through the axle mounting holes.
3. From the bottom of the front axle, secure the front
axle to the frame with a washer and a nut.
4. Place the remaining bolts and washers through the
top of the frame and then through the front axle
mounting holes. From the bottom of the front axle,
secure the front axle to the frame with washers and
nuts.
5. Slowly tighten the bolt on each side of the front axle
and raise the front axle against the frame. Tighten
bolts until snug.
6. Using a criss-cross pattern, tighten the eight axle
mounting nuts to a torque of 1520 - 1710 Nm (1121
- 1261 lb ft).
7. Engage the front drive shaft universal joint with the
front axle and install the four bolts. Tighten the bolts
to a torque of 136 - 149 Nm (100 - 110 lb ft).
8. Install the wheels, washers, and wheel bolts.
9. Torque the wheel bolts in the sequence shown, to
a preliminary torque of 298 N·m (220 lb ft). Final
torque the wheel bolts to 640 - 720 Nm (472 - 531 lb
ft) in the same sequence.
RCPH11WHL202AAH 1
10. Lower the machine to the ground.

11. Connect the brake, differential lock (if equipped) and
cooler lines to the front axle.
12. If necessary, fill axle with gear lubricant specified.
13. See front axle filling Powered front axle - Filling
(25.100).
47392461 19/06/2012
25.100 / 5
14. Refer to Hydraulic service brakes - Bleed (33.202)

and bleed brakes.
47392461 19/06/2012
25.100 / 6
Powered front axle - Filling Model 3105 II

1021F
RCPH11WHL143AAR 1
1. Brake bleeder 4. Oil filler hole

2. Bleeder 5. Oil drain hole (Axle casing)
3. Oil drain hole (Outputs)
47392461 19/06/2012
25.100 / 7
Powered front axle - Filling Model 3115 II
RCPH11WHL143AAR 1
1. Brake bleeder 4. Oil filler hole

2. Bleeder 5. Oil drain hole (Axle casing)
3. Oil drain hole (Outputs)
47392461 19/06/2012
25.100 / 8
Index

Powered front axle - Filling Model 3105 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1021F
Powered front axle - Filling Model 3115 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Powered front axle - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1021F
Powered front axle - General specification Model 3115 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Powered front axle - Install Model 3105 II/3115 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Powered front axle - Remove Model 3105 II/3115 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Powered front axle - Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1021F
Powered front axle - Torque Model 3115 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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Front bevel gear set and differential - 102
1021F
1121F
47392461 19/06/2012
25.102 / 1
Contents
TECHNICAL DATA
Bevel gear set and differential carrier

1021F
General specification Model 3115 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
SERVICE
Bevel gear set and differential carrier

Backlash Model 3105 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1021F
Backlash Model 3115 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Differential
Remove Model 3105 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
1021F
Disassemble Model 3105 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

1021F
Assemble Model 3105 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

1021F
Install Model 3105 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

1021F
Remove Model 3115 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

1121F
Assemble Model 3115 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

1121F
Install Model 3115 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Differential lock
47392461 19/06/2012
25.102 / 2
CONSUMABLES INDEX
Consumable IU PAGE
Loctite® 262 Differential - Remove Model 3105 II 25.102 / 27
Loctite® 262 Differential - Install Model 3105 II 25.102 / 37
47392461 19/06/2012
25.102 / 3
Front axle system - Front bevel gear set and differential
Bevel gear set and differential carrier - General specification

1021F
Model 3105 II
Ideal tooth contact pattern
bs01d011 1
Coast side (concave) bs01d012 2
Drive side (convex)
Pinion distance must be increased
bs01d009 3
bs01d013 4 bs01d014 5
Coast side (concave) Drive side (convex)
47392461 19/06/2012
25.102 / 4
Pinion distance must be decreased
bs01d010 6
bs01d015 7 bs01d016 8
Bevel gear set and differential carrier - General specification Model

3115 II
Ideal tooth contact pattern
bs01d011 1
Coast side (concave) bs01d012 2
Drive side (convex)
47392461 19/06/2012
25.102 / 5
Pinion distance must be increased
bs01d009 3
bs01d013 4 bs01d014 5
Pinion distance must be decreased
bs01d010 6
bs01d015 7 bs01d016 8
47392461 19/06/2012
25.102 / 6
Bevel gear set and differential carrier - Backlash Model 3105 II

1021F
CAUTION
Burn hazard!
Always wear heat-resistant protective gloves when handling heated parts.
C0047A
Prior operation:
Differential - Assemble Model 3105 II (25.102)
1. Determine shim thickness to obtain correct gear con-

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

mension II e.g. 202.00 mm (7.95 in).
RCIL11WHL088BAF 2
47392461 19/06/2012
25.102 / 7
3. Determine dimension III (bearing width). Dimension

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

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

in) into housing.
RCIL11WHL091BAF 5
47392461 19/06/2012
25.102 / 8
6. Cool internal bearing outer ring. Bring it into contact

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

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

seal at 1.5 - 3.0 N·m (13.3 - 26.6 lb in). Insert spacer
(e.g. s= 8.18 mm (0.32 in)).
NOTE: Based on experience, necessary rolling torque is
obtained when reusing the spacer removed during disas-
sembly e.g. s = 8.18 mm (0.32 in).
NOTE: A later check of rolling torque is needed.
RCIL11WHL094BAF 8
47392461 19/06/2012
25.102 / 9
9. Insert preassembled input pinion into axle drive

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

contact is made.
NOTE: Do not fit shaft seal until contact pattern has been
checked.
RCIL11WHL096BAF 10
11. Insert input flange and secure it with disk and slot-
ted nut. Torque to 1200 N·m (885 lb ft) using pin-
ion locknut wrench CAS2842 and clamping device
380001564.
NOTE: Temporarily mount slotted nut without Loctite.
While tightening, rotate input pinion several times in both
directions.
RCIL11WHL097BAF 11
47392461 19/06/2012
25.102 / 10
12. Check rolling torque. It should be 1.5 - 3.0 N·m (13.3

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

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

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

Crown wheel marking -20 -10 N/A 10
Deviation –0.2 -0.1 0 0.1
Shim diff. cage side 0.8 0.9 1.0 1.1
Shim thickness
Shim Crown wheel 1.2 1.1 1.0 0.9
side Shim thickness
47392461 19/06/2012
25.102 / 11
15. Insert selected shim e.g. s = 1.0 mm (0.04 in) into

hole of axle housing and adjust bearing outer ring
(arrow) until contact is obtained.
RCIL11WHL102BAF 15
16. Cover some drive and coast flanks of crown wheel

with marking ink. Insert premounted differential into
axle drive housing.
RCIL11WHL103BAF 16
17. Insert selected shim e.g. s = 1.0 mm (0.04 in) into

hole of axle housing and adjust bearing outer ring
(arrow) until contact is made.
RCIL11WHL104BAF 17
47392461 19/06/2012
25.102 / 12
18. Mount two locating pins and bring axle housing into
contact position with axle drive housing using a suit-
able lifting device. Temporarily attach axle housing
with hex bolts. Torque to 560 N·m (413 lb ft).
NOTE: Test mount axle housing without O-ring.
RCIL11WHL105BAF 18
19. Rotate input flange, in both directions several times,

to roll crown wheel over input pinion. Remove axle
housing and lift differential out of axle drive housing.
Compare obtained contact pattern with contact patter
examples at the beginning of this section.
NOTE: If a contact pattern deviation exists, a measuring
error was made during shim size determination. This must
be corrected.
RCIL11WHL107BAF 19
Next operation:
Differential - Install Model 3105 II (25.102) .
47392461 19/06/2012
25.102 / 13
Bevel gear set and differential carrier - Backlash Model 3115 II

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

1. Determine shim thickness to obtain correct gear con-
tact pattern. Read dimension I (arrow) from axle
drive housing. Dimension I e.g. 331.25 mm (13.0
in).
NOTE: If crown wheel or input pinion are damaged, both
parts must be replaced together. In case of an installation
of a complete new bevel gear set, pay attention to an iden-
tical mating number on input pinion and crown wheel.
NOTE: The following measuring procedures must be com-
pleted accurately. Inaccurate measurements lead to incor-
rect contact pattern requiring additional disassembly and
reassembly of input pinion and differential.
RCPH11WHL577BAU 1
2. Read pinion dimension (arrow), Dimension II. Di-

mension II e.g. 265.00 mm (10.4 in).
RCPH11WHL578BAU 2
3. Determine dimension III (bearing width). See follow-

ing table for dimension determination procedure.
RCIL11WHL089BAF 3
47392461 19/06/2012
25.102 / 14
Calculation Example A
Dimension I 331.25 mm
Dimension II — 265.00 mm
Dimension III — 63.60 mm
Dimension = shim s = 2.60 mm
Reassembly of input pinion

4. Undercool the external bearing outer ring and insert
it into the axle drive housing until contact is obtained.
RCIL11WHL090BAF 4
5. Insert determined shim size e.g. s = 2.60 mm (0.1

in) into housing hole.
RCPH11WHL581BAU 5
47392461 19/06/2012
25.102 / 15
6. Undercool the internal bearing outer ring. and bring

it into contact position in the housing hole using the
assembly fixture (S).
RCIL11WHL092BAF 6
7. Heat tapered roller bearing. Insert it onto input pinion

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

seal at 1.0 - 5.0 N·m (8.9 - 44.3 lb in). Insert spacer
(e.g. s= 7.13 mm (0.3 in) ).
NOTE: According to our experience the necessary rolling
torque is obtained when reusing the spacer which has been
removed during disassembly (e.g.: s = 7.13 mm (0.3 in))!
A later check of the rolling torque however is absolutely
necessary!
RCIL11WHL094BAF 8
47392461 19/06/2012
25.102 / 16
9. Insert the preassembled input pinion into axle drive

housing. Insert the heated tapered roller bearing until
contact is obtained.
RCPH11WHL585BAU 9
10. Press protection plate onto input flange (arrow) until

NOTE: Do not fit shaft seal until contact pattern has been
checked.
RCIL11WHL096BAF 10
11. Insert input flange and fix it by means of disk and

slotted nut. Tightening torque to 1200 N·m (10620.9
lb in).
• (S) Wrench — 38002318
NOTE: Preliminarily mount slotted nut without Locite!
NOTE: While tightening, rotate the input pinion several
times in both directions!
RCPH11WHL587BAU 11
47392461 19/06/2012
25.102 / 17
12. Check rolling torque. It should be 1.5 - 5.0 N·m (13.3

- 44.3 lb in) without shaft seal.
• Insufficient rolling torque — Install thinner
spacer ring.
• Excessive rolling torque — Install thicker
spacer ring.
NOTE: When installing new bearings try to achieve the up-
per value of rolling torque.
NOTE: In case of deviations from the necessary rolling
torque, correct with a corresponding spacer as specified
in step 8 following specifications below:
RCPH11WHL588BAU 12
13. Mount threaded connection. Tightening torque to

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

in).
RCPH11WHL590BAU 14
15. Grease O-rings (arrows) and insert them into the an-
nular groves of the piston.
NOTE: This step is for locking differential equipped axles
only!
RCPH11WHL591BAU 15
47392461 19/06/2012
25.102 / 18
16. Insert piston (arrow) into the bearing housing until

only!
RCPH11WHL592BAU 16
Determination of shims for setting bearing rolling torque (differential housing) and back-
lash (bevel gear set)
17. Determine the required shims on the basis of the
read value (deviation/test dimension) and the corre-
sponding specifications of the table below: )KRS —
SET — RIGHT) (KRS = bevel gear set).
The test dimension „108“ is stamped into the crown wheel
rear side. If no + or – deviation is indicated, this value cor-
responds to the actual value “O” in the following table. Any
+ or – deviation of the test dimension caused by produc-
tion will be marked on the crown wheel rear side (e.g. - 20
or - 10 or 10 or 20). In accordance with this deviation, the
required shims are allocated in the following table.
NOTE: Deviation see crown wheel rear side.
RCPH11WHL593BAU 17
18. Legend to sketch:

1. Bearing housing
2. Shim (crown wheel side)
3. Shim (diff. carrier side)
4. Axle drive housing
RCPH11WHL649BAU 18
47392461 19/06/2012
25.102 / 19
Shims for differential D /DL and DHL — 5000 in ZF axles MT — L 3115/3125

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

in) into the hole of axle drive housing and reset until
contact with bearing outer ring is obtained.
RCPH11WHL594BAU 19
20. Cover some drive and coast flanks of the crown

wheel with marking ink. Then insert premounted
differential into axle drive housing.
RCPH11WHL595BAU 20
47392461 19/06/2012
25.102 / 20
21. Insert the determined shim (e.g. s = 1.4 mm (0.1 in))

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

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

screws (3x). Tightening torque (M12/10.9) to 50
N·m (442.5 lb in).
RCPH11WHL598BAU 23
47392461 19/06/2012
25.102 / 21
Leak test of lock

24. Pressurize the lock (p= 1 bar (14.5 psi)), close shut-
off valve and remove air line.
NOTE: No noticeable pressure loss in allowed to occur
within 10 sec.
NOTE: Operation is only necessary for version with DHL!
RCPH11WHL599BAU 24
25. By rotating the input flange, roll crown wheel over

input pinion in both directions.
26. Then remove the bearing housing again and lift the
differential out of axle drive housing.
27. Compare the obtained contact pattern with contact
pattern examples at the beginning of this section.
NOTE: In case of any contact pattern deviation, a measur-
ing error was made during shim size determination. This
must be corrected.
RCPH11WHL600BAU 25
Next operation:
Differential - Install Model 3115 II (25.102)
47392461 19/06/2012
25.102 / 22
Differential - Remove Model 3105 II

1021F
Prior operation:
Powered front axle - Remove Model 3105 II/3115 II (25.100) Powered rear axle - Remove Model 3105 II/3115 II
(27.100)
NOTE: The front axle is shown in the following images and may appear slightly different externally than the rear axle.
The use of the tools and disassembly/assembly of the axles are the same regardless of appearance.
1. Use a suitable lifting device and attach axle to as-
sembly stand.
RCIL11WHL001BAF 1
2. Remove plug and drain oil from differential carrier.

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

and disposal.
RCIL11WHL003BAF 3
47392461 19/06/2012
25.102 / 23
4. Remove bleeder valves to avoid damage during out-

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

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

NOTE: Watch for loose shim(s).
RCIL11WHL006BAF 6
47392461 19/06/2012
25.102 / 24
7. Secure axle housing with suitable lifting device and

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

lease tube.
RCIL11WHL025BAF 8
9. Remove screw neck.
RCIL11WHL026BAF 9
47392461 19/06/2012
25.102 / 25
10. Pull bearing outer ring and remove shim behind.

Then remove O-ring (arrow).
RCIL11WHL027BAF 10
11. Use a suitable lifting device and pull differential from

axle drive housing.
NOTE: Disassembly of differential is covered in a separate
section.
RCIL11WHL028BAF 11
12. Pull bearing outer ring (arrow) from housing and re-
move shim.
RCIL11WHL029BAF 12
47392461 19/06/2012
25.102 / 26
13. Heat slotted nut.

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

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

shaft seal.
RCIL11WHL034BAF 15
47392461 19/06/2012
25.102 / 27
16. Press input pinion from axle drive housing and re-
move releasing tapered roller bearing.
RCIL11WHL035BAF 16
17. Remove spacer ring and pull tapered roller bearing

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

drive housing.
RCIL11WHL037BAF 18
Next operation:
Differential - Disassemble Model 3105 II (25.102)
47392461 19/06/2012
25.102 / 28
Differential - Disassemble Model 3105 II

1021F
Prior operation:
Differential - Remove Model 3105 II (25.102) .
1. Pull both tapered roller bearings from differential.
RCIL11WHL050BAF 1
2. Preload differential using a press. Remove hex bolts

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

bolts and housing cover.
RCIL11WHL052BAF 3
47392461 19/06/2012
25.102 / 29
4. Remove axle bevel gear with thrust washers from

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

leasing spider gears with thrust washers from differ-
ential housing.
RCIL11WHL055BAF 6
47392461 19/06/2012
25.102 / 30
7. Pull long differential axle. Remove releasing spider

gears with thrust washers from differential housing.
RCIL11WHL056BAF 7
8. Remove axle bevel gear and shim.
RCIL11WHL057BAF 8
9. Press crown wheel from differential carrier.
RCIL11WHL058BAF 9
Next operation:
47392461 19/06/2012
25.102 / 31
Differential - Assemble Model 3105 II

1021F
CAUTION
Burn hazard!
C0047A
Prior operation:
1. Mount locating pins and press heated crown wheel

onto differential housing until contact is made.
RCIL11WHL076BAF 1
2. Insert thrust washer into differential housing.
RCIL11WHL077BAF 2
47392461 19/06/2012
25.102 / 32
3. Insert axle bevel gear.
RCIL11WHL078BAF 3
4. Insert spider gears with thrust washers into differen-

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

ential housing. Secure them with two short spider
shafts.
NOTE: Thrust washers must be positioned with tabs (1)
located in recesses of differential housing. Pay attention
to radial installation position of spider shaft securing holes
(2).
RCIL11WHL080BAF 5
47392461 19/06/2012
25.102 / 33
6. Secure short spider shafts with slotted pins.

NOTE: Flush mount slotted pins.
RCIL11WHL081BAF 6
7. Mount second axle bevel gear.
RCIL11WHL082BAF 7
8. Secure thrust washers into housing cover with

grease.
RCIL11WHL083BAF 8
47392461 19/06/2012
25.102 / 34
9. Mount two adjusting bolts and insert housing cover

until contact with differential housing is obtained.
Preload differential using a press. Secure with new
locking bolts. Torque to 400 N·m (295 lb ft).
RCIL11WHL084BAF 9
10. Attach housing cover and preload differential with a

suitable press. Secure housing cover with hex bolts
and torque to 185 N·m (136 lb ft).
RCIL11WHL085BAF 10
11. Heat both tapered roller bearings and insert until con-
tact is made. Adjust tapered roller bearing after cool-
ing down.
RCIL11WHL086BAF 11
Next operation:
Bevel gear set and differential carrier - Backlash Model 3105 II (25.102) .
47392461 19/06/2012
25.102 / 35
Differential - Install Model 3105 II

1021F
Prior operation:
Bevel gear set and differential carrier - Backlash Model 3105 II (25.102)
1. After successful contact pattern check, reinsert dif-

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

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

shaft seal with seal lip facing oil chamber.
NOTE: Exact installation position of seal is obtained when
using specified tool.
NOTE: Wet outer diameter of shaft seal with mineral spirits
just before installation. Fill space between seal and dust lip
with grease.
RCIL11WHL110BAF 3
47392461 19/06/2012
25.102 / 36
4. Insert input flange and secure with disc and slotted

nut using pinion locknut wrench CAS2842 and clamp
device 380001546. Torque to 1200 N·m (885 lb ft).
NOTE: Cover threads of slotted nut with LOCTITE® 262.
RCIL11WHL111BAF 4
5. Grease O-ring (arrow) insert it into axle housing.
RCIL11WHL112BAF 5
6. Mount M20 locating pins. Use a suitable lifting device

and bring axle housing into contact position with axle
drive housing. Secure axle housing with hex bolts.
NOTE: After assembling axle housing secure axle with
clamping brackets.
RCIL11WHL113BAF 6
47392461 19/06/2012
25.102 / 37
7. Mount fitting. Torque to 36 N·m (27 lb ft).
RCIL11WHL114BAF 7
8. Grease O-ring. Insert it into annular groove of brake

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

nut (arrow). Torque to 100 N·m (74 lb ft).
RCIL11WHL116BAF 9
47392461 19/06/2012
25.102 / 38
10. Install plug and new O-ring. Torque to 50 N·m (37 lb

ft).
RCIL11WHL117BAF 10
Next operation:
Wheel hub - Install Model 3105 II (25.108)
47392461 19/06/2012
25.102 / 39
Differential - Remove Model 3115 II

CAUTION
Eye injury hazard!
C0035A
Prior operation:
(27.100)
Disassembly output and brake

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

drain oil from axle.
RCPH11WHL486BAU 2
RCPH11WHL487BAU 3
47392461 19/06/2012
25.102 / 40
3. Remove bleeder valve (arrow).

NOTE: To avoid any damage, the breather valve must be
removed when separating the output.
RCPH11WHL488BAU 4
4. Secure the output with the lifting device (S) and

loosen hexagon screws. Then separate the output
assembly from the axle housing
NOTE: Fix the load carrying device (S) with a wheel nut.
RCPH11WHL489BAU 5
5. Pull stub shaft and sun gear shaft.

NOTE: Pay attention to potentially releasing shim(s)
RCPH11WHL490BAU 6
47392461 19/06/2012
25.102 / 41
Disassembly axle housing

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

leasing brake tube.
RCPH11WHL508BAU 8
8. Loosen both screw necks.
RCPH11WHL509BAU 9
47392461 19/06/2012
25.102 / 42
Disassembly axle drive housing

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

ing housing with the lifting device.
RCPH11WHL512BAU 12
13. Pull bearing outer ring (arrow) out of the bearing hole
and remove the shim behind.
RCPH11WHL513BAU 13
47392461 19/06/2012
25.102 / 43
14. Press the piston out of the bearing housing by means

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

NOTE: Slotted nut is secured with Loctite (type no.: 262).
RCPH11WHL517BAU 17
47392461 19/06/2012
25.102 / 44
18. Loosen the slotted nut and remove the shim behind.
RCPH11WHL518BAU 18
19. Pull input flange from the input pinion. Use a lever
to lift the shaft seal ring behind, out of the axle drive
housing.
RCPH11WHL519BAU 19
20. Use a two-armed puller to press the input pinion out

of the axle drive housing and remove the releasing
tapered roller bearing.
RCPH11WHL520BAU 20
21. Remove the spacer ring and pull the tapered roller
bearing from the input pinion.
RCPH11WHL521BAU 21
47392461 19/06/2012
25.102 / 45
22. Loosen the threaded connection and remove the re-

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

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

axle drive housing.
RCPH11WHL524BAU 24
Next operation:
Differential - Disassemble Model 3115 II (25.102) Differential lock - Disassemble Model 3115 II (25.102)
47392461 19/06/2012
25.102 / 46
Differential - Disassemble Model 3115 II

1121F
Prior operation:
Differential - Remove Model 3115 II (25.102)
Disassembly differential D-5000

1. Pull both tapered roller bearings from differential.
RCPH11WHL526BAU 1
2. Preload the differential by means of the press and

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

by means of the lifting device.
RCPH11WHL528BAU 3
47392461 19/06/2012
25.102 / 47
4. Loosen hexagon screws and remove the releasing

disk.
RCPH11WHL531BAU 4
5. Remove the thrust washer and axle bevel gear from

the differential housing.
RCPH11WHL532BAU 5
6. Force out slotted pins (4x).
RCPH11WHL533BAU 6
7. Pull spider shafts (4x) and remove the releasing spi-

der gears with the thrust washers from the differential
housing.
RCPH11WHL534BAU 7
47392461 19/06/2012
25.102 / 48
8. Remove axle bevel gear and shims behind.
RCPH11WHL535BAU 8
9. Support the crown wheel and force out the differential

housing.
RCPH11WHL536BAU 9
Next operation:
47392461 19/06/2012
25.102 / 49
Differential - Assemble Model 3115 II

1121F
CAUTION
Burn hazard!
C0047A
Prior operation:
Assemble differential D-5000

1. Mount two adjusting screws (S) and press the heated
crown wheel onto the differential housing until con-
tact is obtained.
RCPH11WHL546BAU 1
2. Insert disk and thrust washer into differential housing.
RCIL11WHL077BAF 2
47392461 19/06/2012
25.102 / 50
RCIL11WHL078BAF 3
4. Insert spider gears with thrust washers into differen-

tial housing and fix them with the spider shafts.
NOTE: Thrust washers must be positioned with tabs (1)
located in recesses of differential housing. Pay attention
to radial installation position of spider shaft securing holes
(2).
RCPH11WHL549BAU 4
5. Fix spider shafts with slotted pins (2 pieces/hole).

NOTE: Press the slotted pins with 180º offset openings into
flush position.
RCPH11WHL550BAU 5
6. Mount second axle bevel gear and thrust washer.
RCPH11WHL551BAU 6
47392461 19/06/2012
25.102 / 51
7. Mount disk and fix with hexagon screws.

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

ential cover by means of the lifting device.
• (S) Adjusting screws (M16 x 1.5)
RCPH11WHL574BAU 8

bolt with NEW locking screws.
• Tightening torque (M/16/12.9) to 400 N·m
(3540 lb in).
RCPH11WHL564BAU 9
tact is obtained.
NOTE: Adjust tapered roller bearing after cooling down.
RCPH11WHL565BAU 10
47392461 19/06/2012
25.102 / 52
Next operation:
47392461 19/06/2012
25.102 / 53
Differential - Install Model 3115 II

Prior operation:
Bevel gear set and differential carrier - Backlash Model 3115 II (25.102)
1. After the contact pattern check, insert the differential

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

2. Loosen slotted nut and pull input flange from the input
pinion.
• (S) Wrench — 380002318
RCPH11WHL602BAU 2
3. Mount the shaft seal ring with the seal lip showing to
the oil chamber.
NOTE: The exact installation position of the shaft seal rings
is obtained when using the specified driver tool (S).
NOTE: Wet the outer diameter of the shaft seal ring with
spirit directly before installation and fill the space between
seal and dust lip with grease.
RCPH11WHL603BAU 3
47392461 19/06/2012
25.102 / 54
4. Insert input flange and finally tighten by means of

disk and slotted nut. Tightening torque to 1200 N·m
(10620.9 lb in).
• (S) Wrench — 380002318
NOTE: Cover the thread of the slotted nut with Locite (Type
no.: 262)!
RCPH11WHL604BAU 4
5. Grease O-ring (arrow) and insert it into the annular

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

device and finally tighten it with cylindrical screws.
Tightening torque (M12/10.9) to 50 N·m (442.5 lb in)
RCPH11WHL606BAU 6
7. Grease O-rings (arrows) and insert them on both

sides of the axle drive housing.
RCPH11WHL607BAU 7
47392461 19/06/2012
25.102 / 55
8. Mount two adjusting screws (S) and bring axle drive

housing in contact position with the axle housing by
using the lifting device.
9. Then fix the axle drive housing with hexagon screws.
Tightening torque (M20/10.9) to 560 N·m (4956 lb in)
• (S) Adjusting screws (M20/10.9).
• (S) Eye bolt (M20).
NOTE: After mounting the axle drive housing, unbolt the
support (S) until contact is obtained.
RCPH11WHL608BAU 8
Reassembly axle housing

10. Mount both fittings. Tightening torque to 36 N·m (319
lb in).
RCPH11WHL609BAU 9
11. Mount brake tube. Tightening torque to 100 N·m

(885 lb in).
RCPH11WHL610BAU 10
47392461 19/06/2012
25.102 / 56
12. Mount two adjusting screws (S) and bring the axle
housing into contact position with the axle drive hous-
ing by using the lifting device.
13. Then fix the housing by means of hexagon screws.
Tightening torque (M20/10.9) to 560 N·m (4956 lb
in).
• (S) Adjusting screws (M20)
NOTE: After assembling the axle housing, secure the axle
with clamping brackets (S)!
RCPH11WHL611BAU 11
Next operation:
47392461 19/06/2012
25.102 / 57
Differential lock - Disassemble Model 3115 II

Prior operation:
Differential - Remove Model 3115 II (25.102)
Disassembly multi-disk differential lock DHL-5000

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

loosen the locking screws.
RCPH11WHL527BAU 3
47392461 19/06/2012
25.102 / 58
4. Lift the differential cover from the differential housing

by means of the lifting device.
RCPH11WHL528BAU 4
5. Preload the compression spring by means of the

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

1. Disk
2. Pressure piece
3. Cage
4. Lever (15x)
5. Disk carrier
6. Disk package
RCPH11WHL530BAU 6
8. Loosen hexagon screws and remove the releasing

disk.
RCPH11WHL531BAU 7
47392461 19/06/2012
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9. Remove thrust washer and axle bevel gear from the

differential housing.
RCPH11WHL532BAU 8
10. Force out slotted pins (4x).
RCPH11WHL533BAU 9
11. Pull spider shafts (4x) and remove the releasing spi-
der gears with the thrust washers from the differential
housing.
RCPH11WHL534BAU 10
12. Remove the axle bevel gears and the shims behind.
RCPH11WHL535BAU 11
47392461 19/06/2012
25.102 / 60
13. Support the crown wheel and force out the differential
housing.
RCPH11WHL536BAU 12
Next operation:
Differential lock - Assemble Model 3115 II (25.102)
47392461 19/06/2012
25.102 / 61
Differential lock - Assemble Model 3115 II

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

1. Mount two adjusting screws (S) and press the heated
crown wheel onto the differential housing until con-
tact is obtained.
RCPH11WHL546BAU 1
2. Insert disk and thrush washer into the differential

housing.
RCPH11WHL547BAU 2
RCPH11WHL548BAU 3
47392461 19/06/2012
25.102 / 62
4. Insert spider gears with thrust washers into the dif-

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

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

• Tightening torque (M10/10.9) to 50 N·m (443
lb in).
RCPH11WHL552BAU 7
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Setting of disk package

8. Premount single parts according to the adjacent
sketch.
Setting of disk package
1. = Differential cover.
2. = Pressure piece.
3. = Disk.
4. = Cage.
5. = Lever (15x).
6. = End plate.
7. = Outer disks (optional). RCPH11WHL647BAU 8
8. = Inner disks.
9. Preload disk package with an axial force of F = 7 t.
Then check the setting dimension „A” = 15.5 mm (0.6
in) ± 0.2 mm (0.0 in) from the mounting face of the
differential cover to the plane face of the outer disk.
(Also see sketch below).
NOTE: Any deviation form the specified setting dimension
must be corrected with a corresponding outer disk!
RCPH11WHL553BAU 9
10. Legend to sketch

• A = Setting dimension = 15.5 mm (0.6 in) ± 0.2
mm (0.0 in).
RCPH11WHL648BAU 10
47392461 19/06/2012
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11. Engage the snap ring (see arrow) into the annular
groove of the disk carrier.
RCPH11WHL554BAU 11
12. Insert the premounted disk carrier onto the axle bevel
gear.
RCPH11WHL555BAU 12
13. Mount outer and inner disks.

NOTE: For the number of disks and disk arrangement
please refer to the relating spare parts list.
NOTE: Pay attention to the radial installation position of the
disk package, as shown on the adjacent figure.
RCPH11WHL556BAU 13
14. Insert end plate.
RCPH11WHL557BAU 14
47392461 19/06/2012
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15. Mount cage and lever (15x).
RCPH11WHL558BAU 15
16. Insert pressure piece (see arrow) and install disk.
RCPH11WHL559BAU 16
17. Insert compression springs (6x) into the differential

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

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

bolt with NEW locking screws.
• Tightening torque (M/16/12.9).to 400 mm (15.7
in)
RCPH11WHL564BAU 21
tact is obtained.
NOTE: Adjust tapered roller bearing after cooling down.
RCPH11WHL565BAU 22
47392461 19/06/2012
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23. Insert axial roller cage (see arrow).
RCPH11WHL566BAU 23
Locking differential axles.

24. Grease O-rings (see arrows) and insert them into the
annular grooves of the piston.
only.
RCPH11WHL591BAU 24
25. Insert piston (see arrow) into the bearing housing un-
til contact is obtained.
only.
RCPH11WHL592BAU 25
47392461 19/06/2012
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Check operability of DHL

26. Build up pressure p = 20 bar (290 psi) max. and
close connection to HP pump via shut-off valve.
Lock on:
• When rotating the input flange, both outputs
must have the same direction of rotation.
Lock off:
• When rotating the input flange, one side holds
or has the opposite direction of rotation.
ATTENTION: This procedure MUST be completed after
axle assembly, prior to axle installation!
NOTE: Prior to putting the axle into operation, fill it with RCPH11WHL645BAU 26
oil according to the related lubrication and maintenance
instructions.
Next operation:
47392461 19/06/2012
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Index

Bevel gear set and differential carrier - Backlash Model 3105 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1021F
Bevel gear set and differential carrier - Backlash Model 3115 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Bevel gear set and differential carrier - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1021F
Bevel gear set and differential carrier - General specification Model 3115 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Differential - Assemble Model 3105 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
1021F
Differential - Assemble Model 3115 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
1121F
Differential - Disassemble Model 3105 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
1021F
Differential - Disassemble Model 3115 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
1121F
Differential - Install Model 3105 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
1021F
Differential - Install Model 3115 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Differential - Remove Model 3105 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
1021F
Differential - Remove Model 3115 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Differential lock - Assemble Model 3115 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Differential lock - Disassemble Model 3115 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
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Final drive hub, steering knuckles, and shafts - 108
1021F
1121F
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Contents
SERVICE
Wheel hub
Remove Model 3105 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1021F
Disassemble Model 3105 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

1021F
Visual inspection Model 3105 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

1021F

1021F
Install Model 3105 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

1021F
Remove Model 3115 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Install Model 3115 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
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CONSUMABLES INDEX
Consumable IU PAGE
47392461 19/06/2012
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Front axle system - Final drive hub, steering knuckles, and shafts
Wheel hub - Remove Model 3105 II

1021F
Prior operation:
Powered front axle - Remove Model 3105 II/3115 II (25.100)Powered front axle - Remove Model 3105 II/3115 II
(25.100)
1. Use a suitable lifting device and attach axle to as-
sembly stand.
RCIL11WHL001BAF 1
2. Remove plug and drain oil from differential carrier.

and disposal.
RCIL11WHL002BAF 2
3. Remove plugs and drain oil from outputs.

and disposal.
RCIL11WHL003BAF 3
47392461 19/06/2012
25.108 / 4
4. Remove bleeder valves to avoid damage during out-

put and axle housing separation.
RCIL11WHL004BAF 4
5. Attach appropriate lifting device to output assembly.

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

NOTE: Watch for loose shim(s).
RCIL11WHL006BAF 6
Next operation:
Wheel hub - Disassemble Model 3105 II (25.108)
47392461 19/06/2012
25.108 / 5
Wheel hub - Disassemble Model 3105 II

1021F
Prior operation:
Wheel hub - Remove Model 3105 II (25.108)
1. Attach output assembly to suitable work stand.
RCIL11WHL007BAF 1
2. Use a lever to remove output shaft cover.
RCIL11WHL008BAF 2
3. Remove locking bolts and releasing cover.
RCIL11WHL009BAF 3
47392461 19/06/2012
25.108 / 6
4. Use a puller and press planetary carrier from profile

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

of brake housing.
RCIL11WHL011BAF 5
6. Pull tapered roller bearing from planetary carrier.
RCIL11WHL012BAF 6
47392461 19/06/2012
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7. Remove retaining rings.
RCIL11WHL013BAF 7
8. Pull off planetary gears.
RCIL11WHL014BAF 8
9. Lift end plate out of brake housing.
RCIL11WHL015BAF 9
47392461 19/06/2012
25.108 / 8
10. Lift disk package out of brake housing.
RCIL11WHL016BAF 10
11. Remove hex bolts, releasing cover and cup spring.
RCIL11WHL017BAF 11
12. Mount bleeder valve and use compressed air to re-

move piston from brake housing.
RCIL11WHL018BAF 12
47392461 19/06/2012
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13. If needed, remove guide ring, back-up rings and

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

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

output shaft.
RCIL11WHL020BAF 15
47392461 19/06/2012
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16. Use levers to remove slide ring seal from brake hous-
ing. If needed, remove both bearing outer rings.
RCIL11WHL021BAF 16
17. Use levers to remove slide ring seal from output

shaft.
RCIL11WHL022BAF 17
18. Pull tapered roller bearing from output shaft.
RCIL11WHL023BAF 18
Next operation:
Wheel hub - Visual inspection Model 3105 II (25.108)
47392461 19/06/2012
25.108 / 11
Wheel hub - Visual inspection Model 3105 II

1021F
Prior operation:
NOTICE: Do not use compressed air to dry bearings. Allow bearings to air dry.
1. Clean all parts except friction plates in brake disc
pack using cleaning solvent. WEAR FACE PRO-
TECTION WHEN USING COMPRESSED AIR. Use
compressed air to clear passages in planetary ring
gear and brake housing.
2. Inspect bearing rollers for pitting, scoring, defor-
mation, or other damage. Check inner face and
bearing cage for deformation, dents, and other dam-
age. Check associated bearing cups for scratches,
grooves, or cracks. Check bearings for rough spots
or binding by holding bearing and rotating. If bearing
binds or action is not smooth, replace the bearing.
3. Inspect bearing cups for pitting, scoring, cracks, or
other damage. Replace if any of these conditions
are seen.
NOTE: If a bearing or bearing cup requires replacement,
the associated part must also be replaced.
4. Check planetary ring gear, planetary gears, and plan-
etary carrier gear teeth for cracks, breaks, chipping,
or other damage. Replace the part if any of these
conditions are seen. Check planetary carrier shaft
splines for broken, cracked, or twisted condition. Re-
place if necessary.
5. Check wheel end shaft for cracked, broken, or
twisted splines. Replace if any of these conditions
are seen.
Next operation:
Wheel hub - Assemble Model 3105 II (25.108)
47392461 19/06/2012
25.108 / 12
Wheel hub - Assemble Model 3105 II

1021F
CAUTION
Burn hazard!
C0047A
Prior operation:
1. Pull wheel stud into output shaft until contact is made.

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

shaft.
RCIL11WHL119BAF 2
47392461 19/06/2012
25.108 / 13
3. Wet O-ring of slide ring seal and locating hole with

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

NOTE: For installation position of seal, see Step 9.
NOTE: Surface of slide ring seal may not have any
grooves, scratches or other damage. Make sure that
sealing surface is parallel to housing face. O-rings must
be mounted evenly into locating hole and must not bulge
out.
ATTENTION: Risk of injury - metal rings have extremely
sharp edges. Wear protective gloves.
RCIL11WHL121BAF 4
5. Insert both bearing outer rings (arrows) into brake

housing.
RCIL11WHL122BAF 5
47392461 19/06/2012
25.108 / 14
6. Use suitable lifting device and place premounted

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

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

spirits. Insert guide ring into annular grove (see Step
9). Secure it with Loctite (type no. 415) at its ends
(arrows).
NOTE: Full circumference of guide ring must be in an exact
contact position.
NOTE: Upon installation, orifice of guide ring must show
upwards - 12 o’clock position.
RCIL11WHL125BAF 8
47392461 19/06/2012
25.108 / 15
9. 1. Brake housing
2. Guide ring
3. Back-up ring
4. Piston seal
5. Piston seal
6. Back-up ring
7. Metal Face Seal (Heavy Duty Option) Combi
Seal (Standard)
8. Output shaft
RCIL11WHL153BAF 9
10. Flush-mount slotted pins into holes of piston.
RCIL11WHL126BAF 10
11. Insert piston into brake housing and install with

dealer fabricated fixing device until contact is made.
NOTE: Sufficiently oil seal surface of piston/back-up rings,
grooved rings and guide ring with W-10 oils.
RCIL11WHL127BAF 11
47392461 19/06/2012
25.108 / 16
12. Insert disk and cup spring with convex side showing
upwards into piston.
RCIL11WHL128BAF 12
13. Insert cover and secure it with hex bolts. Torque to

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

NOTE: For number of disks and disk arrangement, refer to
related spare parts list.
RCIL11WHL130BAF 14
47392461 19/06/2012
25.108 / 17
RCIL11WHL131BAF 15
16. Press stop bolt (1) into planetary carrier (2).
RCIL11WHL158BAF 16
47392461 19/06/2012
25.108 / 18
17. Insert cylindrical roller bearing into planetary gear.

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

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

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

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

old locking bolts (removed during disassembly) into
contact position. Torque to 200 N·m (148 lb ft).
RCIL11WHL137BAF 22
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23. Pivot output 180 ° and measure gap width from the
output shaft to the planetary carrier, see Step 24.
Then remove locking bolts and measure disk again.
NOTE: Gap width e.g.: 0.21 mm (0.01 in).
RCIL11WHL159BAF 23
24. Legend to Sketch:

1 = Planetary carrier
2 = Output shaft
X = Gap width
RCIL11WHL166BAF 24
25. Select the cover (optional) based on the following

table.
NOTE: Cover has an offset of 0.07 mm (0.003 in) on one
side and an offset of 0.13 mm (0.005 in) on the other side.
NOTE: Offset of 0.13 mm (0.005 in) is visually marked with
an annular groove).
RCIL11WHL165BAF 25
Determined gap Width (Delta) Offset to be used on the cover

0.30 - 0.24 mm (0.012 - 0.009 in) 0.13 mm (0.005 in)
0.239 - 0.18 mm (0.009 - 0.007 in) 0.07 mm (0.003 in)
0.179 - 0.10 mm (0.007 - 0.004 in) 0.0 mm (0.000 in)
47392461 19/06/2012
25.108 / 21
26. Pivot output 90 °. Insert the cover with the offset e.g.
0.07 mm (0.003 in) showing towards the planetary
carrier and tighten with new locking bolts.
NOTE: When using the cover with offset of 0.07 mm (0.003
in), the groove (arrow step 25) must be visible when the
cover is installed.
NOTE: Torque locking bolts successively to 200 N·m (148
lb ft). Then, retorque to 500 N·m (369 lb ft).
RCIL11WHL138BAF 26
27. Install new O-ring (1) and cover. Wet contact face (2)
with TEROSTAT® MS-9360.
NOTE: Curing period for TEROSTAT® MS-9360 is greater
than 24-hours.
RCIL11WHL139BAF 27
28. Insert cover into output shaft until contact is made.
RCIL11WHL140BAF 28
Next operation:
47392461 19/06/2012
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Wheel hub - Install Model 3105 II

1021F
Prior operation:
1. Set sun gear shaft axial play range to 0.5 - 2.0 mm

(0.02 - 0.08 in). Use a straight edge to determine
dimension I, from mounting face of brake housing to
front face of stop bolt. Dimension I e.g. 40.80 mm
(1.61 in).
RCIL11WHL141BAF 1
2. Insert stub shaft into teeth of axle bevel gear until

contact is made.
NOTE: Mount stub shaft with long teeth towards differen-
tial.
RCIL11WHL142BAF 2
3. Insert sun gear shaft until contact is made.
RCIL11WHL143BAF 3
47392461 19/06/2012
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4. Using a straight edge, measure dimension II, from

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

into sun gear shaft.
RCIL11WHL146BAF 6
47392461 19/06/2012
25.108 / 24
7. Attach O-ring (arrow) with grease into countersink of

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

vice to bring output into contact position with axle
housing. Secure output using hex bolts. Torque to
560 N·m (413 lb ft).
NOTE: Attach load carrying device with wheel stud.
RCIL11WHL149BAF 9
47392461 19/06/2012
25.108 / 25
10. Mount bleeder valve (arrow).
RCIL11WHL150BAF 10
Next operation:
Brakes - Leakage test (33.202)
47392461 19/06/2012
25.108 / 26
Wheel hub - Remove Model 3115 II

Prior operation:
(27.100)
1. Fix axle to assembly truck.
RCPH11WHL485BAU 1
2. Loosen screw plugs (3x, see Figures 2 and 3) and

drain oil from axle.
RCPH11WHL486BAU 2
RCPH11WHL487BAU 3
47392461 19/06/2012
25.108 / 27
3. Remove bleeder valve (arrow).

NOTE: To avoid any damage, the breather valve must be
removed when separating the output.
RCPH11WHL488BAU 4
4. Secure the output with the lifting device (S) and

loosen hexagon screws. Then separate the output
assembly from the axle housing.
NOTE: Fix the load carrying device (S) with a wheel nut.
RCPH11WHL489BAU 5
5. Pull stub shaft and sun gear shaft.

NOTE: Pay attention to potentially releasing shim(s).
RCPH11WHL490BAU 6
Next operation:
47392461 19/06/2012
25.108 / 28
Wheel hub - Disassemble Model 3115 II

CAUTION
Eye injury hazard!
C0035A
Prior operation:
1. Attach output to a suitable stand.
RCPH11WHL491BAU 1
RCIL11WHL008BAF 2
3. Loosen locking screws and remove the releasing

cover.
RCPH11WHL493BAU 3
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4. Lift the planetary carrier out of the brake housing by

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

cup spring.
RCPH11WHL500BAU 10
11. Mount bleeder valve and press piston out of the

brake housing by means of compressed air.
RCPH11WHL501BAU 11
47392461 19/06/2012
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grooved rings out of the annular grooves of brake
housing (see arrows).
NOTE: For the installation position of the single parts refer
to the following sketch.
RCPH11WHL502BAU 12

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

from output shaft.
RCPH11WHL503BAU 14
47392461 19/06/2012
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15. Use levers to remove slide ring seal from brake hous-
ing. If needed, force out both bearing outer rings.
RCPH11WHL504BAU 15
16. Use lever to remove slide ring seal from output shaft.
RCPH11WHL505BAU 16
17. Pull tapered roller bearing from output shaft.
RCPH11WHL506BAU 17
Next operation:
47392461 19/06/2012
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Wheel hub - Visual inspection Model 3115 II

CAUTION
Flying debris!
Compressed air can propel dirt, rust, etc. into the air. Wear eye and face protection when using com-
pressed air.
C0049A
WARNING
Chemical hazard!
Always wear protective clothing and goggles when cleaning with solvents, acids, or alkaline chemical
agents. Always follow the chemical manufacturer's instructions.
W0180A
Prior operation:

pack using cleaning solvent. Use compressed air
to clear passages in planetary ring gear and brake
housing.
ATTENTION: Do not use compressed air to dry bearings.
Allow bearings to air dry.
2. Inspect bearing rollers for pitting, scoring, defor-
mation, or other damage. Check inner face and
bearing cage for deformation, dents, and other dam-
age. Check associated bearing cups for scratches,
grooves, or cracks. Check bearings for rough spots
or binding by holding bearing and rotating. If bearing
binds or action is not smooth, replace the bearing.
3. Inspect bearing cups for pitting, scoring, cracks, or
other damage. Replace if any of these conditions
are seen.
NOTE: If a bearing or bearing cup requires replacement,
the associated part must also be replaced.
4. Check planetary ring gear, planetary gears, and plan-
etary carrier gear teeth for cracks, breaks, chipping,
or other damage. Replace the part if any of these
conditions are seen. Check planetary carrier shaft
splines for broken, cracked, or twisted condition. Re-
place if necessary.
5. Check wheel end shaft for cracked, broken, or
twisted splines. Replace if any of these conditions
are seen.
Next operation:
47392461 19/06/2012
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Wheel hub - Assemble Model 3115 II

CAUTION
Burn hazard!
C0047A
CAUTION
Sharp object!
Wear gloves when handling worn discs.
C0006A
Prior operation:
1. Pull wheel stud into output shaft until contact is ob-

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

put shaft until contact is obtained.
RCPH11WHL613BAU 2
47392461 19/06/2012
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3. Wet O-ring of slide ring seal and locating hole with

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

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

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

the lifting device over the output shaft until contact is
obtained.
NOTE: Before clamping seal rings to installation dimen-
sion, clean sliding surfaces and apply an oil film. A leather
cloth soaked in oil is recommended for this step.
RCPH11WHL617BAU 6
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9. Insert back-up rings and grooved rings into annular

grooves of brake housing (arrows).
NOTE: For installation position, see refer to Legend Sketch
step 12.
RCIL11WHL124BAF 7
10. Clean annular groove of brake housing with mineral

spirits.
11. Then insert the guide ring into annular grove (refer to
Legend Sketch in step 12) and fix it with Loctite (type
no. 415) at its extremities (arrows).
NOTE: The full circumference of guide ring must be in an
exact contact position.
NOTE: Upon installation, the orifice of the guide ring must
show upwards - 12 o’clock position.
RCIL11WHL125BAF 8

1. Brake housing
2. Guide ring
3. Back-up ring
4. Grooved ring
5. Grooved ring
6. Back-up ring
7. Slide ring seal
8. Output shaft
RCPH11WHL646BAU 9
47392461 19/06/2012
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13. Insert the piston into the brake housing and carefully
install with the fixing device (S) until contract is ob-
tained.
grooved rings and guide ring (W-10 oils to be used)!
RCPH11WHL620BAU 10
14. Insert cup spring into the piston with the convex side
showing upwards.
RCPH11WHL621BAU 11
15. Insert disk and fix it by means of hexagon screws.

Tightening torque (M8/10.9) to 34 N·m (301 lb in).
RCPH11WHL622BAU 12

NOTE: For the number of disks and the disk arrangement
please refer to the relating spare parts list.
RCPH11WHL623BAU 13
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RCPH11WHL624BAU 14
Setting of installation dimension

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

— for this purpose press the cylindrical roller bear-
ing through packaging sleeve until the snap ring en-
gages into annular groove of planetary gear.
NOTE: Use packaging sleeve to facilitate assembly.
1. Cylindrical roller bearing.
2. Packaging sleeve.
3. Snap ring.
4. Planetary gear.
RCPH11WHL626BAU 17
47392461 19/06/2012
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22. Heat bearing inner rings and insert the premounted

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

etary carrier until contact is obtained.
RCPH11WHL628BAU 19
25. Wet front face (contact face bearing inner ring, ar-
row 1) and profile (teeth, arrow 2) in the output shaft
with anti-corrosive agent Weicon Anti-seize (ZF-or-
der no.:0671 196 001).
RCPH11WHL629BAU 20
26. Align disk package centrally and radially.

27. Then insert the planetary carrier by means of the lift-
ing device into the teeth of the output shaft until con-
tact is obtained.
RCPH11WHL630BAU 21
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28. Pivot output 90 ° (90 °). Insert disk and fix planetary
carrier with NEW locking screws.
NOTE: Tighten locking screws successively with a tight-
ening torque of 200 N·m (1770 lb in). Then retighten the
locking screws successively with a tightening torque of 500
N·m (4425 lb in).
RCPH11WHL631BAU 22
29. Install O-ring (see arrow) to the cover.
RCPH11WHL632BAU 23
30. Insert the cover into the output shaft until contact is
obtained.
RCPH11WHL633BAU 24
Next operation:
47392461 19/06/2012
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Wheel hub - Install Model 3115 II

Prior operation:
1. Set the axial play of the sun gear shaft 0.5 - 2.0 mm
(0.02 - 0.08 in). Determine dimension I, from mount-
ing face of brake housing to front face of stop bolt.
Dimension I e.g. 58.60 mm (2.3 in).
• (S) Gauge blocks
• (S) Straightedge
RCPH11WHL634BAU 1
2. Insert stub shaft into teeth of axle bevel gear until

NOTE: Pay attention to the installation position; mount the
stub shaft with the long teeth showing to the differential.
RCPH11WHL635BAU 2
3. Insert sun gear shaft until contact is obtained.
RCPH11WHL636BAU 3
47392461 19/06/2012
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4. Measure dimension II, from front face of sun gear

shaft to mounting surface of axle housing.
NOTE: Refer to following calculation example table for cal-
culation procedure.
• Dimension II e.g.: 56.60 mm (2.2 in)
• (S) Straightedge
RCPH11WHL637BAU 4
CALCULATION EXAMPLE:
Dimension I 58.60 mm
Dimension II — 56.60 mm
Difference 2.00 mm
Required axial play e.g.: — 1.00 mm
Difference = shim e.g.: s = 1.00 mm
5. Insert sun gear shaft into planetary carrier.
RCPH11WHL638BAU 5
6. Fix determined shim(s) e.g. s = 1.00 mm (0.04 in)

with grease into sun gear shaft.
RCPH11WHL639BAU 6
47392461 19/06/2012
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7. Fix O-ring (arrow) with grease into countersink of

brake housing.
RCPH11WHL640BAU 7
8. Grease O-ring (arrow) and install it in axle housing.
RCPH11WHL641BAU 8
9. Mount two adjusting screws (S) and use appropriate

lifting device to bring output into contact position with
axle housing. Secure output using hex bolts. Torque
to 560 N·m (4956 lb in).
10. Then fix the output by means of hexagon screws.
Tightening torque (M20/10.9) to 560 N·m (4956 lb
in).
• (S) Adjusting screws (M20)
NOTE: Fix load carrying device (S) with wheel stud.
RCPH11WHL642BAU 9
11. Mount bleeder (arrow).
RCPH11WHL643BAU 10
Next operation:
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Brakes - Leakage test Model 3115 II (33.202)
47392461 19/06/2012
25.108 / 45
Index

Wheel hub - Assemble Model 3105 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1021F
Wheel hub - Assemble Model 3115 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Wheel hub - Disassemble Model 3105 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1021F
Wheel hub - Disassemble Model 3115 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Wheel hub - Install Model 3105 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
1021F
Wheel hub - Install Model 3115 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Wheel hub - Remove Model 3105 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1021F
Wheel hub - Remove Model 3115 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Wheel hub - Visual inspection Model 3105 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1021F
Wheel hub - Visual inspection Model 3115 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
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PRINTED IN U.S.A.
47392461 19/06/2012
EN
SERVICE MANUAL
Rear axle system
1021F
1121F
47392461 19/06/2012
27
Contents
Rear axle system - 27
Powered rear axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27.100

1021F , 1121F
47392461 19/06/2012
27
Powered rear axle - 100
1021F
1121F
47392461 19/06/2012
27.100 / 1
Contents
TECHNICAL DATA
Rear axle control transmission shaft

Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SERVICE
Powered rear axle

Remove Model 3105 II/3115 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Install Model 3105 II/3115 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Rear axle control transmission shaft
Remove - Rear Drive Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Install - Rear Drive Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
47392461 19/06/2012
27.100 / 2
Rear axle system - Powered rear axle
Rear axle control transmission shaft - Torque

Center, Rear and Front Drive Shaft Bolts 75 - 81 Nm ( 55 - 60 lb.ft)
47392461 19/06/2012
27.100 / 3
Powered rear axle - Remove Model 3105 II/3115 II

1. Park machine on a level surface; be sure to allow
adequate space at side of machine for removal of
rear axle. Stop engine. Actuate brake pedal sev-
eral times to discharge brake accumulators. Put key
switch in ON position and move loader control lever
back and forth at least 30 times to release any pres-
sure from hydraulic circuit.
2. Have assistant put articulation lock in LOCKED po-
sition.
3. Install wood blocks between rear axle and chassis to
prevent rear axle from pivoting.
4. Remove the grease hoses from the rear axle trun-
nions.
5. Tag and disconnect the brake and oil cooler lines
from the rear axle. Install caps and plugs.
6. Remove the cap screws that fasten the rear drive
shaft to the rear axle.
7. Use a prybar and disengage the rear drive shaft from
the rear axle. Raise the rear wheels off the floor
and use acceptable supports to hold the machine in
place.
8. Remove the rear wheels.
9. Put acceptable lifting equipment (transmission jack)
under the rear axle and trunnions. The weight of the
axle is approximately 3039 kg (6700 lb).
10. Remove the self-locking nuts from the bolts holding
the trunnions to the machine frame.
11. Remove the rear axle and trunnions from the ma-
chine. Place the rear axle and trunnions onto blocks
or suitable work bench.
12. Remove the front trunnion from the rear axle.
13. Remove the cap screws and washers from the rear
cover on the rear trunnion.
14. Remove the rear cover from the rear trunnion.
15. Remove the thrust washer.
16. Remove the cap screws and washers that fasten the
spacer to the rear axle.
17. Remove the spacer and thrust washer.
18. Remove the rear trunnion from the rear axle.
Next operation:
Differential - Remove Model 3105 II (25.102) Wheel hub - Remove Model 3105 II (25.108) Differential - Remove
Model 3115 II (25.102) Wheel hub - Remove Model 3115 II (25.108)
47392461 19/06/2012
27.100 / 4
Powered rear axle - Install Model 3105 II/3115 II
Prior operation:
Differential - Install Model 3105 II (25.102) Wheel hub - Install Model 3105 II (25.108) Differential - Install Model
3115 II (25.102) Wheel hub - Install Model 3115 II (25.108)
NOTE: Replace the seals and bushings in the trunnions as required.

1. Put the rear axle on blocks.
2. Install the rear trunnion to the rear axle. Ensure
bushing is properly positioned.
3. Install a thrust washer and the spacer. Use cap
screws and hardened washers to fasten the spacer
to the rear axle.
4. Tighten the cap screws to a torque of 285 - 320 Nm
(210 - 236 lb ft).
5. Install the other thrust washer. Fasten the rear cover
to the rear trunnion using washers and cap screws.
6. Tighten the cap screws to a torque of 105 - 115 Nm
(77 - 85 lb ft).
7. Install the front trunnion to the rear axle. Ensure trun-
nion is properly positioned for installation into ma-
chine chassis.
8. Using acceptable lifting equipment, slowly move the
rear axle and trunnions into position under the rear
chassis.
9. Install the bolts, hardened washers and nuts to fasten
the trunnions to the rear chassis.
10. Tighten the nuts to a torque of 651 - 732 Nm (480 -
540 lb ft).
11. Fasten the rear drive shaft to the rear axle. Use four
cap screws and tighten to a torque of 136 - 149 Nm
(100 - 110 lb ft).
12. Install the rear wheels, hardened washers and nuts.
13. Torque the wheel nuts in the sequence shown to
a preliminary torque of 298 N·m (220 lb ft). Final
torque the wheel nuts to 640 - 720 Nm (472 - 531 lb
ft) in the same sequence.
RCPH11WHL202AAH 1
47392461 19/06/2012
27.100 / 5
14. Lower the machine to the ground.

15. Connect the brake and axle cooler lines to the rear
axle.
16. Connect the grease hoses to the trunnions.
17. Fill axle with gear lubricant specified in Capacities.
18. See Powered rear axle - Filling (27.100) for oil fill
plug location.
19. Refer to Hydraulic service brakes - Bleed (33.202)
and bleed brakes.
20. Put articulation lock in OPERATING position.
47392461 19/06/2012
27.100 / 6
Rear axle control transmission shaft - Remove - Rear Drive Shaft

the rear drive shaft to the transmission.
bd01d323_528 1
2. Use a prybar to disengage the rear drive shaft from

the transmission.
the rear drive shaft to the rear axle.
bd01f304_529 2
4. Hold the rear drive shaft and remove from the ma-
chine.
Next operation:
Drive shaft - Install — Rear Drive Shaft (27.100)
47392461 19/06/2012
27.100 / 7
Rear axle control transmission shaft - Install - Rear Drive Shaft

Prior operation:
Drive shaft - Remove — Rear Drive Shaft (27.100)
1. Hold the rear drive shaft into position and install the
bolts and straps that fasten the rear drive shaft to the
rear axle. Tighten the bolts to a torque of 75 - 81 Nm
( 55 - 60 lb.ft).
bd01f304 1
2. Install the bolts and straps that fasten the rear drive
shaft to the transmission. Tighten the bolts to a
torque of 75 - 81 Nm ( 55 - 60 lb.ft).
bd01d323 2
47392461 19/06/2012
27.100 / 8
Index

Powered rear axle - Install Model 3105 II/3115 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Powered rear axle - Remove Model 3105 II/3115 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Rear axle control transmission shaft - Install - Rear Drive Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Rear axle control transmission shaft - Remove - Rear Drive Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Rear axle control transmission shaft - Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
47392461 19/06/2012
27.100 / 9
PRINTED IN U.S.A.
47392461 19/06/2012
EN
SERVICE MANUAL
Brakes and controls
1021F
1121F
47392461 19/06/2012
33
Contents
Brakes and controls - 33
Parking brake / Parking lock. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33.110

1021F , 1121F
Hydraulic service brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33.202

1021F , 1121F
47392461 19/06/2012
33
CONSUMABLES INDEX
Consumable IU PAGE
DEXRON® Brakes - Leakage test Model 3105 II 33.202 / 11
Terostat® MS-9360 Brake disks - Assemble Model 3105 II 33.202 / 27
47392461 19/06/2012
33
47392461 19/06/2012
33
Parking brake / Parking lock - 110
1021F
1121F
47392461 19/06/2012
33.110 / 1
Contents
FUNCTIONAL DATA
Parking brake / Parking lock

Dynamic description – Park Brake Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
47392461 19/06/2012
33.110 / 2
Brakes and controls - Parking brake / Parking lock
Parking brake / Parking lock - Dynamic description – Park Brake

Test
The Wheel Loaders are equipped with a spring applied hydraulically released parking brake located at the transmis-
sion output. The Parking Brake must be applied before shutting the unit down. The Parking Brake is automatically
applied as the unit is first started in case it was not applied before shutdown. The Parking Brake is controlled by a
two position rocker switch on the steering column. When the lamp on the switch is lit there is no hydraulic oil pressure
available at the parking brake actuator and the parking brake is applied. The switch light goes out when pressure is
sent to the park brake actuator.
Engaging the Parking Brake

To engage the parking brake, do the following:
1. Move the gearshift lever to neutral (N).
2. Stop machine. Engage the parking brake by push-
ing down on top of the Park Brake switch.
The parking brake will automatically engage when
machine is shut OFF.
NOTE: A failure in the operating procedure or a failure
in the electrical or hydraulic function can result in abrupt
engagement of the parking brake. Always wear your seat
belt.
RCPH10WHL005BAL 1
Releasing the Parking Brake

The oil pressure to release the parking brake comes from the brake valve. The brake pressure light in the Advanced
Instrument Cluster (AIC) must not be lit prior to releasing the parking brake. The following steps are required to
release the Parking Brake:
1. Ensure the shift lever is in neutral.
RCPH10WHL116BAL 2
47392461 19/06/2012
33.110 / 3
2. Turn Park Brake switch to OFF position.
RCPH10WHL005BAL 3
3. Apply the service brake. Put machine into gear (for-

ward / reverse).
Parking brake light on cluster will turn off at this time.
NOTE: If the shifter is not in neutral or the park
brake switch has not been turned to ON position,
the AIC will instruct the operator to cycle the appro-
priate control to verify that the correct operation has
been requested.
4. Place the transmission back into neutral before pro-
ceeding.
NOTE: Park brake will not release until the machine shift
control is placed in forward or reverse. This means that
the park brake light will remain ON even when the park
brake switch is placed in the OFF position.
RCPH11WHL034BAN 4
Parking Brake Function Check

Before operating machine, periodically check the parking
brake functions.
NOTE: Test the parking brake at a maximum of every 250
hours.
WARNING
Improper operation or service of this machine
can result in an accident.
Make sure you perform the required service
and adjustments correctly to avoid injury and
machine damage.
Failure to comply could result in death or se-
rious injury.
W0352A

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A. Escape key
C. Up key
D. Down key
tions.
RCPH11WHL023BAN 5
Accessing Parking Brake Test


RCPH11WHL020BAN 6
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choose selection.
RCPH11WHL022BAN 7
4. Use Up and Down keys to highlight ParkBrake icon

RCPH11WHL021BAN 8
5. Use the Enter / Confirm key to start Test Park Brake

procedures.
RCPH10WHL381BAH 9
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6. Follow the on-screen prompts to complete Park

Brake Test.
If all conditions are not met to test the brake, the
monitor will display the condition that must be cor-
rected prior to completion of the test. The parking
brake switch must be engaged.
RCPH10WHL382BAH 10
When all conditions are met, the monitor will display “Test Park Brake Ready.”
1. Place the transmission mode switch, located on
right console, to the Manual (OFF) position.
RCIL10WHL177BAL 11
2. Shift to 3rd gear with the transmission selector.

3. Shift the gear selector into 3rd gear forward. Slowly
increase engine speed to full open throttle.
4. Verify machine does not move.
5. Reduce engine speed to low idle. Return transmis-
sion to neutral.
6. Shift the gear selector to 3rd gear reverse. Slowly
increase engine speed to wide open throttle.
sion to neutral.
9. Press the escape key on navigation pad to exit test.
RCIL10WHL193BAL 12
Before operating machine, periodically test parking brake activation. Do the following steps to test the activation of
Parking Brake.
NOTE: Test the parking brake at a maximum of every 250 hours.
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WARNING
machine damage.
rious injury.
W0352A
1. To release parking brake, all of the following are

required
A. Transmission shifter positioned in neutral
B. Push the Parking Brake switch to the release
position
C. Transmission shifter positioned from N to F or
R for a second, and back to N
2. Parking brake will engage under any of the following
conditions. Always wear your seat belt in the event
that the parking brake would unexpectedly engage.
A. Parking Brake switch in engaged position
B. Loss of system electrical power (key OFF)
C. Loss of brake accumulator pressure
D. Engine goes in Accelerated Idle Mode (warm-
ing up)
E. Engine goes out of low idle without an operator
command
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3. To test these functions:

A. Start on a clear level surface.
B. With step 1, A through C complete, start the
engine first, then release the parking brake.
The red park brake indicator warning light
should not be illuminated.
C. Turn the engine OFF. Turn the key switch to
the ON position. With the engine OFF, the
parking brake light should come ON.
D. Release the parking brake using B and C in
step 1. Make sure the AIC parking brake light
is out.
E. With the engine still off pump the service
brakes repeatedly, the low brake pressure
warning light should come ON. Continue to
pump the service brakes until the parking
brake light comes ON, pump the brakes three
more times. This could require as many as
forty brake pumps.
F. Start the engine and allow the brake pressure
to build until the AIC brake pressure warning
light goes OFF.
G. Depress the service brake and release. The
AIC PARK brake indicator light must stay ON.
H. Put the transmission in F or R and back to
N. The AIC (PARK BRAKE ON SWITCH
LIGHT?) brake light must stay ON
I. Put the parking brake switch in the engaged
(OFF) position, attempt B and C in step 1. The
parking brake switch light must stay ON
4. Put the parking brake switch in the release position.
A. Repeat steps B and C in step 1 above. The
parking brake light must turn OFF
B. Allow the machine to roll slowly forward with
the transmission in Forward. Engage the
parking brake. The machine must come to a
stop immediately. Parking brake switch light
must come ON. The AIC park brake indicator
lamp must also come on. Transmission must
disengage.
Repair as necessary to eliminate problems.
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Index

Parking brake / Parking lock - Dynamic description – Park Brake Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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Hydraulic service brakes - 202
1021F
1121F
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Contents
TECHNICAL DATA
Hydraulic service brakes

Brake pump
Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Accumulator
Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Brake disks
Service limits Model 3105 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1021F
Service limits Model 3115 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
SERVICE
Hydraulic service brakes

Bleed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Brakes
Leakage test Model 3105 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1021F
Leakage test Model 3115 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Brake pump
Remove with fan pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Install with fan pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Brake disks
1021F

1021F

1021F

Brake lines
Remove Model 3105 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
1021F
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Install Model 3105 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
1021F
Remove Model 3115 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Install Model 3115 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
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CONSUMABLES INDEX
Consumable IU PAGE
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Brakes and controls - Hydraulic service brakes
Hydraulic service brakes - General specification

Brake pump output 42 - 45 L/min at 172 bar
( 11 - 12 gpm at 2500 psi at 2000 rpm)
Accumulator nitrogen pre-charge pressure 70 bar (1015.0 psi)
Brake Warning Pressure Switch (Normally Closed) Opening 115 bar (1668 psi)
Setpoint
Brake Declutch Pressure Switch (Normally Closed) Opening 521F-621F: 10 bar (145.0 psi)
Setpoint 721F – 1121F: 24 Bar ( 350 psi)
Redundant Brake Pressure Switches (Normally Open) Closing 70 bar (1015.0 psi)
Setpoint
Brake Lamp Pressure Switch (Normally Open) Closing 4.14 bar (60 psi)
Setpoint
NOTE: See hydraulic schematics for additional specifications:
521F Hydraulic systems - Hydraulic schematic frame 01 – 521F Tier 2\4 (35.000)
1021/ Hydraulic systems - Hydraulic schematic frame 01 — 1021F/1121F Wheel Loader (35.000)
1121F
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Brake pump - General specification
Brake pump - Special tools
b785789m 1
CAS-10280 FLOW METER
b877168v 2
CAS-1808 FLOW METER FITTING KIT
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Accumulator - Special tools
BS06M002-01 1
380001676 NITROGEN REGULATOR VALVE
BS06M003-01 2
380001390 ACCUMULATOR CHARGING HOSE
bc04a001 3
380001168 ACCUMULATOR CHARGING ADAPTER
Accumulator - General specification

TEMPERATURE/CHARGE PRESSURE BRAKE ACCUMULATOR
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Brake disks - Service limits Model 3105 II

1021F
RCIL11WHL163BAF 1
RCIL11WHL164BAF 2
NOTE: The images may differ slightly from your machine, the procedure is the same.
NOTICE: A wear measurement on the multi-disc brake must be made at least once a year. Wear measurement should
also be made if brake noise is heard, if braking power is reduced, or anytime it is suspected that braking function is
impaired.
Wear measurement must be made on both wheel end sides.

Remove plug, actuate brake and determine dimension (A) using a thickness gauge. If dimension (A) is less than or
equal to 3.5 mm (0.14 in) the lined discs on both output sides must be replaced. Replace O-ring when installing the
plug. Tighten plug to a torque of .
Brake disks - Service limits Model 3115 II
RCIL11WHL163BAF 1
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RCIL11WHL164BAF 2
NOTE: The images may differ slightly from your machine, the procedure is the same.
NOTICE: A wear measurement on the multi-disc brake must be made at least once a year. Wear measurement should
also be made if brake noise is heard, if braking power is reduced, or anytime it is suspected that braking function is
impaired.
Wear measurement must be made on both wheel end sides.

Remove plug, actuate brake and determine dimension (A) using a thickness gauge. If dimension (A) is less than or
equal to 3.8 mm (0.15 in) the lined discs on both output sides must be replaced. Replace O-ring when installing the
plug. Tighten plug to a torque of .
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Hydraulic service brakes - Bleed

1. Check the level of hydraulic fluid in the reservoir. Add
fluid to the reservoir if necessary.
NOTICE: If machine is equipped with quick-attached com-
ponents, disconnect them from machine prior to proceed-
ing.
2. Disconnect the fuel solenoid located behind the fuel
injection pump near the fuel lines.
3. Loosen the pressure side fittings on the brake pump/
fan pump assembly. The pressure side fittings can
be found on the sides of the pump. The fan section
(closest to transmission) is difficult to reach, so the
line may be loosened at the fan control valve inlet.
This can be reached from beneath the machine in
the rear. The inlet line connects to the port marked
“IN”.
4. Turn the key to the start position. Crank the engine
until a few drops of oil leak past the pressure side
fittings. Tighten the fittings, and reconnect the fuel
solenoid.
5. Start the engine and allow it to idle until both accu-
mulators are fully charged. This should be about 30
seconds after the low brake pressure light goes out.
Stop the engine.
6. Turn the key to the off position. Fully discharge the
two accumulators by pumping the brake pedal until
there is no hydraulic pressure in the brake system
(approximately 20 pumps) or by removing the plastic
and rubber cap from one of the bleed screws on a
front or rear axle and open the bleed screw, then
slowly pushing down on the brake pedal until there is
no forced flow from the opened bleed screw. (Attach
hose to the bleed screw to prevent oil spillage).
7. Remove the plastic and rubber caps from each wheel
end and slowly open all four bleed screws.
8. Attach hoses to the bleed screws at each wheel end
to prevent oil spillage. Submerge hoses in fluid to
prevent air entering the brake system.
9. Start the machine and allow it to idle.
10. Depress the brake pedal. Observe the fluid. Keep
brake pedal depressed until bubble no longer appear
in the stream of fluid.
11. Close all four wheel end bleed screws.
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Brakes - Leakage test Model 3105 II

1021F
Prior operation:
1. Check brake hydraulics for leakage. Before starting

test bleed hydraulic system. Pressurize brake tem-
porarily five times with a maximum pressure of p =
100 bar (1450 psi).
High-pressure test:
Build up test pressure p = 100-10 bar maximum
and close connection to HP pump via shut-off
valve. A maximum pressure drop of 2 % or 2
bar (29 psi) is permissible during a 5 min test
period.
Low-pressure test:
Reduce test pressure p = 5 bar (73 psi) and
close shut-off valve. No pressure drop is al-
lowed during a 5 min.
Test media:
Engine oils SAE 10-W corresponds to MIL-L
2104 C, MIL-L 46152, API-CC, CD, SC, SD,
SE, ATF-oils type A, Suffic A DEXRON® of II
D.
RCIL11WHL151BAF 1
Next operation:
Powered front axle - Install Model 3105 II/3115 II (25.100) Powered rear axle - Install Model 3105 II/3115 II
(27.100)
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Brakes - Leakage test Model 3115 II

Prior operation:
1. Check brake hydraulics for leakage. Before starting

test bleed hydraulic system. Pressurize brake tem-
porarily five times with a maximum pressure of p =
100 bar (1450 psi).
High-pressure test:
Build up test pressure p = 100-10 bar maximum
and close connection to HP pump via shut-off
valve. A maximum pressure drop of 2 % or 2
bar (29 psi) is permissible during a 5 min test
period.
Low-pressure test:
Reduce test pressure p = 5 bar (73 psi) and
close shut-off valve. No pressure drop is al-
lowed during a 5 min.
Test media:
Engine oils SAE 10-W corresponds to MIL-L
2104 C, MIL-L 46152, API-CC, CD, SC, SD,
SE, ATF-oils type A, Suffic A DEXRON® of II
D.
RCIL11WHL151BAF 1
Next operation:
Powered front axle - Install Model 3105 II/3115 II (25.100) Powered rear axle - Install Model 3105 II/3115 II
(27.100)
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Brake pump - Remove with fan pump

Prior operation:
Ladder - Remove (90.118), Cab suspension - Remove (90.150)
NOTE: Hydraulic pump suction hose removed for picture clarity.

1. Drain the hydraulic tank.
2. Remove the hydraulic pump suction hose (not
shown).
3. Remove the brake pump-to-brake valve hose (1).
4. Remove the valve tube (2).
RCPH11WHL066AAR 1
5. Attach lifting equipment to the brake pump/fan pump

assembly. Remove the fan pump mounting bolts (1).
Remove brake pump/fan pump assembly.
RCPH11WHL058AAR 2
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Brake pump - Install with fan pump

1. Lubricate and install the pump O-ring.
RCPH11WHL057AAR 1
2. Attach lifting equipment to the brake pump/fan pump

assembly. Install the brake pump/fan pump assem-
bly. Tighten the fan pump mounting bolts (1) to a
torque of 149 - 170 N·m (110 - 125 lb ft).
RCPH11WHL058AAR 2
3. Install the brake pump-to-brake valve hose (3).

4. Install the valve tube (2).
5. Install the hydraulic pump suction hose (not shown).
Tighten the split, flange clamp bolts (1) to a torque of
73 - 90 N·m (54 - 66 lb ft).
RCPH11WHL066AAR 3
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Brake disks - Disassemble Model 3105 II

1021F
Prior operation:
1. Attach output to suitable work stand.
RCIL11WHL007BAF 1
RCIL11WHL008BAF 2
3. Remove locking bolts and releasing cover.
RCIL11WHL009BAF 3
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4. Use a two-armed puller, press planetary carrier from

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

of brake housing.
RCIL11WHL011BAF 5
RCIL11WHL012BAF 6
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7. Remove retaining rings.
RCIL11WHL013BAF 7
RCIL11WHL014BAF 8
RCIL11WHL015BAF 9
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RCIL11WHL016BAF 10
11. Remove hex bolts, releasing cover and cup spring.
RCIL11WHL017BAF 11
12. Mount bleeder valve. Use compressed air to remove

piston from brake housing.
RCIL11WHL018BAF 12
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grooved rings from annular grooves of brake hous-
ing (see arrows).
RCIL11WHL019BAF 13
14. 1. Brake housing

2. Guide ring
3. Back-up ring
4. Piston seal
5. Piston seal
6. Back-up ring
seal (Standard)
8. Output shaft
RCIL11WHL153BAF 14
Next operation:
Brake disks - Visual inspection Model 3105 II (33.202)
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Brake disks - Visual inspection Model 3105 II

1021F
Prior operation:
Brake disks - Disassemble Model 3105 II (33.202) Wheel hub - Disassemble Model 3105 II (25.108)

housing.
ATTENTION: Eye injury hazard! Wear protective goggles
when using compressed air. Failure to comply could result
in minor or moderate injury.
Next operation:
Brake disks - Assemble Model 3105 II (33.202) Wheel hub - Assemble Model 3105 II (25.108)
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Brake disks - Assemble Model 3105 II

1021F
Prior operation:
1. 1. Brake housing
2. Guide ring
3. Back-up ring
4. Piston seal
5. Piston seal
6. Back-up ring
seal (Standard)
8. Output shaft
RCIL11WHL153BAF 1
2. Flush-mount slotted pins into holes of piston.
RCIL11WHL126BAF 2
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3. Insert piston into brake housing and install with

dealer fabricated fixing device until contact is made.
grooved rings and guide ring with W-10 oils.
RCIL11WHL127BAF 3
4. Insert disk and cup spring with convex side showing

upwards into piston.
RCIL11WHL128BAF 4
5. Insert cover and secure it with hex bolts. Torque to

34 N·m (25 lb ft).
RCIL11WHL129BAF 5
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6. Insert outer and inner disks.

RCIL11WHL130BAF 6
RCIL11WHL131BAF 7
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8. Press stop bolt (1) into planetary carrier (2).
RCIL11WHL158BAF 8
9. Heat bearing inner race. Insert premounted plane-

(downwards) until contact is made. Secure plane-
tary gears with retaining rings.
RCIL11WHL133BAF 9
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10. Heat tapered roller bearing. Install it on planetary

carrier until contact is made.
RCIL11WHL134BAF 10
11. Wet contact face of bearing inner race (1) and profile
teeth (2) in output shaft with anti-corrosive agent.
RCIL11WHL135BAF 11
12. Align disk package centrally and radially. Heat output

shaft. Use a suitable lifting device to insert planetary
carrier into teeth of output shaft.
RCIL11WHL136BAF 12
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13. Bring planetary carrier with measuring disk and three

old locking bolts (removed during disassembly) into
contact position. Torque to 200 N·m (148 lb ft).
RCIL11WHL137BAF 13
14. Pivot output 180 ° and measure gap width from

the output shaft to the planetary carrier — see next
sketch. Then remove locking bolts and measure
disk again.
NOTE: Gap width e.g.: 0.21 mm (0.01 in).
RCIL11WHL159BAF 14
15. Legend to Sketch:

1 = Planetary carrier
2 = Output shaft
X = Gap width
RCIL11WHL166BAF 15
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16. Select the cover (optional) based on the following

table.
NOTE: Cover has an offset of 0.07 mm (0.003 in) on one
side and an offset of 0.13 mm (0.005 in) on the other side.
NOTE: Offset of 0.13 mm (0.005 in) is visually marked with
an annular grove (arrow)!
RCIL11WHL165BAF 16
Determined gap Width (Delta) Offset to be used on the cover

0.30 - 0.24 mm (0.012 - 0.009 in) 0.13 mm (0.005 in)
0.239 - 0.18 mm (0.009 - 0.007 in) 0.07 mm (0.003 in)
0.179 - 0.10 mm (0.007 - 0.004 in) 0.0 mm (0.000 in)
17. Pivot output 90 °. Insert the cover with the offset e.g.
0.07 mm (0.003 in) showing towards the planetary
carrier and tighten with new locking bolts.
NOTE: When using the cover with offset of 0.07 mm (0.003
in), the groove (arrow step 16) must be visible when the
cover is installed.
NOTE: Tighten locking bolts successively to a torque of
200 N·m (148 lb ft). Then, retighten successively to a
torque of 500 N·m (369 lb ft).
RCIL11WHL138BAF 17
18. Install new O-ring (1) and cover. Wet contact face (2)
with TEROSTAT® MS-9360.
NOTE: Curing period for TEROSTAT® MS-9360 is greater
than 24-hours.
RCIL11WHL139BAF 18
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19. Insert cover into output shaft until contact is made.
RCIL11WHL140BAF 19
Next operation:
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Brake disks - Disassemble Model 3115 II

CAUTION
Eye injury hazard!
C0035A
Prior operation:
1. Attach output to a suitable work stand.
RCPH11WHL491BAU 1
RCIL11WHL008BAF 2
3. Loosen locking screws and remove the releasing

cover.
RCPH11WHL493BAU 3
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4. Lift the planetary carrier out of the brake housing by

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

cup spring.
RCPH11WHL500BAU 10
11. Mount bleeder valve and press piston out of the

brake housing by means of compressed air.
RCPH11WHL501BAU 11
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grooved rings out of the annular grooves of brake
housing (see arrows).
NOTE: For the installation position of the single parts refer
to the following sketch.
RCPH11WHL502BAU 12

1. Brake housing
2. Guide ring
3. Back-up ring
4. Grooved ring
5. Grooved ring
6. Back-up ring
7. Slide ring seal
8. Output shaft
RCPH11WHL646BAU 13
Next operation:
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Brake disks - Visual inspection Model 3115 II

CAUTION
Eye injury hazard!
C0035A
WARNING
Chemical hazard!
Always wear protective clothing and goggles when cleaning with solvents, acids, or alkaline chemical
agents. Always follow the chemical manufacturer's instructions.
W0180A
Prior operation:
Brake disks - Disassemble Model 3115 II (33.202) Wheel hub - Disassemble Model 3115 II (25.108)

housing.
Next operation:
Brake disks - Assemble Model 3115 II (33.202) Wheel hub - Assemble Model 3115 II (25.108)
47392461 19/06/2012
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Brake disks - Assemble Model 3115 II

Prior operation:
1. Brake housing
2. Guide ring
3. Back-up ring
4. Grooved ring
5. Grooved ring
6. Back-up ring
7. Slide ring seal
8. Output shaft
RCPH11WHL646BAU 1
2. Insert the piston into the brake housing and carefully

install with the fixing device (S) until contact is ob-
tained.
grooved rings and guide ring (W-10 oils to be used).
RCPH11WHL620BAU 2
3. Insert cup spring into piston with the convex side

showing upwards.
RCPH11WHL621BAU 3
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4. Insert disk and fix it by means of hexagon screws.

Tightening torque (M8/10.9) to 34 N·m (25 lb ft).
RCPH11WHL622BAU 4

RCPH11WHL623BAU 5
RCIL11WHL131BAF 6
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Setting of installation dimension 57.25....57.79 mm

7. Measure installation dimension from the mounting
face of the brake housing to the front face of the end
plate.
• Installation dimension e.g.: 57.5 mm (2.3 in)
mm.
NOTE: Any deviation from the necessary installation di-
mension must be corrected with an appropriate out disk
(see spare parts list).
RCPH11WHL625BAU 7
8. Press stop bolt into the cover until contact is ob-

tained.
9. Insert the premounted cover into the planetary carrier
until contact is obtained.
Legend to sketch
1. Stop bolt
2. Cover
3. Planetary carrier
RCPH11WHL651BAU 8
10. Insert the cylindrical roller bearing into the planetary

gear. For this purpose, press the cylindrical roller
bearing through the packaging sleeve until the snap
ring engages into the annular groove of the planetary
gear.
1. Cylindrical roller bearing
2. Packaging sleeve
3. Snap ring
4. Planetary gear
NOTE: Use packaging sleeve to facilitate assembly!
RCPH11WHL626BAU 9
11. Heat bearing inner ring. Insert premounted plane-

(downwards) until contact is obtained.
12. Then fix planetary gears by means of retaining rings.
NOTE: Adjust bearing inner rings after cooling down.
RCPH11WHL627BAU 10
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13. Heat tapered roller bearing and install it on planetary

carrier until contact is obtained.
RCPH11WHL628BAU 11
14. Wet front face (contact face bearing inner ring, (1))
and profile (teeth (2)) in output shaft with anti-corro-
sive agent Weicon anti-seize (ZF-order no.: 067 196
001).
RCPH11WHL629BAU 12
15. Align disk package centrally and radially.

16. Insert the planetary carrier by means of the lifting
device into the teeth of the output shaft until contact
is obtained.
RCPH11WHL630BAU 13
17. Pivot output 90 °.

18. Insert disk and fix planetary carrier with NEW locking
screws.
NOTE: Tighten locking screws successively with a tighten-
ing torque of 200 N·m (1770 lb in).
RCPH11WHL631BAU 14
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19. Install O-ring (arrow) to the cover.
RCPH11WHL632BAU 15
20. Insert the cover into the output shaft until contact is
obtained.
RCPH11WHL633BAU 16
Next operation:
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Brake lines - Remove Model 3105 II

1021F
Prior operation:
1. Secure axle housing to suitable lifting device.

Loosen hex bolts. Separate axle housing from drive
housing.
NOTE: Be aware of possible release of differential.
RCIL11WHL024BAF 1

lease tube.
RCIL11WHL025BAF 2
3. Remove screw neck.
RCIL11WHL026BAF 3
47392461 19/06/2012
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4. Pull bearing outer ring and remove shim behind.

Then remove O-ring (arrow).
RCIL11WHL027BAF 4
Next operation:
Differential - Remove Model 3105 II (25.102) Brake lines - Install Model 3105 II (33.202)
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Brake lines - Install Model 3105 II

1021F
Prior operation:
Brake lines - Remove Model 3105 II (33.202)
1. Grease O-ring (arrow) insert it into axle housing.
RCIL11WHL112BAF 1
2. Mount M20 locating pins. Use a suitable lifting device

and bring axle housing into contact position with axle
drive housing. Secure axle housing with hex bolts.
NOTE: After assembling axle housing secure axle with
clamping brackets.
RCIL11WHL113BAF 2
3. Mount fitting. Torque to 36 N·m (27 lb ft).
RCIL11WHL114BAF 3
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4. Grease O-ring. Insert it into annular groove of brake

tube (arrow).
RCIL11WHL115BAF 4
5. Mount brake tube with threaded connection and hex

nut (arrow). Torque to 100 N·m (74 lb ft).
RCIL11WHL116BAF 5
6. Install plug and new O-ring. Torque to 50 N·m (37 lb

ft).
RCIL11WHL117BAF 6
Next operation:
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Brake lines - Remove Model 3115 II

Prior operation:
1. Secure axle housing to suitable lifting device.

Loosen hexagon screws, then. separate axle hous-
ing from drive housing.
RCPH11WHL507BAU 1
2. Loosen threaded connections and remove the re-

leasing brake tube.
RCPH11WHL508BAU 2
3. Loosen both screw necks.
RCPH11WHL509BAU 3
Next operation:
Differential - Remove Model 3115 II (25.102) Brake lines - Install Model 3115 II (33.202)
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Brake lines - Install Model 3115 II

Prior operation:
Brake lines - Remove Model 3115 II (33.202)
Reassembly axle housing

1. Mount both fittings. Tightening torque to 36 N·m (319
lb in).
RCPH11WHL609BAU 1
2. Mount brake tube. Tightening torque to 100 N·m

(885 lb in)
RCPH11WHL610BAU 2
3. Mount two adjusting screws (S) and bring the axle

housing into contact position with the axle drive hous-
ing by using the lifting device.
4. Then fix the housing by means of hexagon screws.
Tightening torque (M20/10.9) to 560 N·m (4956 lb in)
• (S) Adjusting screws (M20).
NOTE: After assembling the axle housing, secure the axle
with clamping brackets (S)!
RCPH11WHL611BAU 3
Next operation:
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Index

Accumulator - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Accumulator - Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Brake disks - Assemble Model 3105 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
1021F
Brake disks - Assemble Model 3115 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Brake disks - Disassemble Model 3105 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1021F
Brake disks - Disassemble Model 3115 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Brake disks - Service limits Model 3105 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1021F
Brake disks - Service limits Model 3115 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Brake disks - Visual inspection Model 3105 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
1021F
Brake disks - Visual inspection Model 3115 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Brake lines - Install Model 3105 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
1021F
Brake lines - Install Model 3115 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Brake lines - Remove Model 3105 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
1021F
Brake lines - Remove Model 3115 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Brake pump - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Brake pump - Install with fan pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Brake pump - Remove with fan pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Brake pump - Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Brakes - Leakage test Model 3105 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1021F
Brakes - Leakage test Model 3115 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Hydraulic service brakes - Bleed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Hydraulic service brakes - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
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PRINTED IN U.S.A.
47392461 19/06/2012
EN
SERVICE MANUAL
Hydraulic systems
1021F
1121F
47392461 19/06/2012
35
Contents
Hydraulic systems - 35
Hydraulic systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.000

1021F , 1121F
Variable displacement pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.106

1021F , 1121F
Reservoir, cooler, and filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.300

1021F , 1121F
Pilot system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.357

1021F , 1121F
Main control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.359

1021F , 1121F
Auxiliary hydraulic valves and lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.525

1021F , 1121F
Front loader arm hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.701

1021F , 1121F
47392461 19/06/2012
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1021F
1121F
47392461 19/06/2012
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Contents
TECHNICAL DATA
Hydraulic systems
Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
FUNCTIONAL DATA
Hydraulic systems
Dynamic description – Hydraulic Oil Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Hydraulic schematic frame 01 - 1021F/1121F Wheel Loader . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
SERVICE
Hydraulic systems
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Decontaminating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Test – Brake accumulator tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Test – Brake pump flow test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Test – First pump high pressure cut-off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Test – Auxiliary steering pump flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Test – Steering cylinder leakage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Test – Pilot pressure at end of loader valve spool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Test – Ride control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Test – Ride control valve system function test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
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Hydraulic systems - Hydraulic systems
Hydraulic systems - Special tools
806127 1
CAS101162A, Filter Unit, Portable.
tr98h032 2
CAS10192, Vacuum Pump.
806128 3
CAS10508, Fitting Kit.
47392461 19/06/2012
35.000 / 3
633l95 4
CAS1904 Pressure Fitting Kit
632l95 5
b785789m_678 6
CAS10280 Flowmeter
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b877168v 7
CAS1808 Flowmeter Fitting Kit
b877895m 8
CAS10090 Hand Pump
b877558m 9
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Hydraulic systems - Dynamic description – Hydraulic Oil Supply

The wheel Loaders use a combination of variable displacement Pressure and Flow Compensated (PFC) piston
type pump and a gear type pump open-center hydraulic system. The closed center variable PFC hydraulic system
supplies the oil flow requirements for:
• Steering
• Loader controls
• Loader lift
• Loader bucket
• Loader auxiliary system
• Loader valve pilot controls
The open center gear pump hydraulic system supplies, oil flow to the brakes, cooling fan, and oil cooler.
In a closed center variable displacement PFC system, oil flow is minimal unless there is a hydraulic demand. In an
open-center system, oil is constantly pumped through the system regardless of hydraulic demand. When problems
are present in more than one steering or loader hydraulic function, consider that the problem could be within the
variable PFC hydraulic pump control system.
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Hydraulic Oil Supply Components

A single variable Pressure and Flow Compensated (PFC) hydraulic system controls both the steering (24) and the
loader control (22) systems on the Wheel Loaders. When it appears that there are malfunctions in both the steering
and loader control circuits consider there may be problems with one or both of the two pump PFC pumps (33) (34).
Oil flows from the reservoir (38) to the PFC piston pump. The large wheel loaders have two piston type PFC pumps.
Both pumps directly supply oil to the steering priority valve (35). The steering priority valve (35) first supplies oil to
steering (24) with any excess flow then available to the loader valve (22). On units equipped with two PFC pumps,
each body of the piston pump has a compensator flow control system to deliver only the oil flow required by the
hydraulic system. On units equipped with a single PFC pump, a single compensator flow control system delivers only
the oil flow required by the hydraulic system. This control system requires a feedback signal (LS signal) from the
loader control valve (22) and/or from the steering valve (24) to deliver the oil required by the system.
The steering priority valve assembly (35) is located at the outlet of the 2nd pump. The function of this valve is to first
supply oil to the steering control system (24). The steering control valve (24) is located at the base of the steering
column.
The loader valve is mounted at the rear of the front chassis and can be accessed through the articulation joint or the
access cover at the front of the chassis. As the oil enters the loader valve, it supplies oil to the pilot hand control circuit
and to the loader control spools. A pilot pressure regulator limits the maximum pilot pressure available to the pilot
hand controls. The bucket and loader lift sections are both included in the mono-block assembly. If the machine is
equipped with optional auxiliary hydraulic controls, each additional section consists of a separate section block. Each
active spool throughout the loader control valve generates a load sense (LS) signal pressure.
The LS feedback signal system sends the highest operating pressure signal requirement back to the compensator
flow regulator spool at the piston pump. The loader LS, as well as the steering LS signals, pass through the LS
shuttle check valve (35B) in the steering priority valve (35). From the LS shuttle check valve (35B) the LS signal is
then connected to flow regulator spools (33A) (34A) of the PFC pump assembly (32). This signals the pump to deliver
only the quantity of oil required by the hydraulic system.
The smaller wheel loaders use one variable displacement PFC pump to deliver flow to the steering priority valve (35),
the steering control valve (24), the loader valve (22), and the pilot hand controls (16). Included later in this section is
a detailed functional explanation of a single PFC pump.
The larger wheel loaders use two variable PFC pumps (35) to deliver flow to the steering priority flow divider (35),
the steering control valve (24), the loader valve (22) and the pilot hand controls (16). On units equipped with two
PFC hydraulic pumps, the first pump (34) is the only pump to supply the flow required to operate any of the hydraulic
circuits at lower flow requirements until it reaches maximum delivery. The second pump (33) only begins to deliver
flow when the total hydraulic flow requirements exceed the maximum capability of the first pump (34). The second
pump (33) is idling at no flow delivery until the first pump (34) reaches maximum delivery.
Both of the PFC pumps are mounted as an assembly (32) to the transmission towards the front of the wheel loader.
The first pump (34) is located closest to the transmission. The second pump (33) is mounted to the back of the first
pump (34) and is furthest from the transmission. The priority flow divider (35) is mounted directly to the second pump
(33). The outlet line from the first pump (34) is directly connected to the priority flow divider (35).
Component Flow Chart Legend

16 – Pilot hand controls 34 – First pump
22 – Loader valve 34A – First pump compensator flow regulator spool
22A – Bucket 34B – First pump compensator pressure regulator spool
22B – Arm 35 – Steering priority valve
22C – Auxiliary 35A – Steering priority spool
24 – Steering orbitrol control valve 35B – Load sense (LS) signal shuttle check valve
24A – Steering isolation check valve 35C – Second pump isolation check valve
33 – Second pump 35D – Differential pressure relief valve
33A – Second pump compensator flow regulator spool 35E – Steering relief valve
33B – Second pump compensator pressure regulator
spool
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RCPH11WHL035HAN 1
Component Flow Chart
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Each of the hydraulic pumps are controlled by a compensator. Each of the compensators have two spools. The flow
regulator spools ( (33A) (34A)) control the output flow of each pump. The pressure regulator spools ( (33B) (34B))
control the maximum pressure that the pumps are capable of delivering. In the wheel loader hydraulic system, these
valves are adjusted higher than the maximum pressure in any of the circuits. Because of this higher adjustment, the
pressure regulator spools do not function. If one or both of these pressure regulator spools are adjusted too low, the
specified steering or loader relief valve pressures might not be able to be reached.
The priority flow divider (35) has many functions which require numerous components. The components of the
steering priority flow divider consists of the following components:
• Steering priority spool (35A)
• Load sense shuttle check valve (35B)
• Second pump isolation check valve (35C)
• Differential pressure relief valve (35D)
• Steering relief valve (35E)
Steering is more critical to the operation of the machine so the steering priority spool (35A) is in the circuit to provide
oil to the steering control valve (24) first. The priority spool (34A) is spring loaded to send all of the oil that the steering
system requires. Between the steering priority valve (35) and the steering orbitrol control valve (24), the oil flows
through the steering isolation check valve (24A). Once the steering circuit (24) is satisfied, all of the excess supply oil
then becomes available to the loader hydraulic system.
Both PFC pumps ( (33) (34)) require a load sense (LS) signal from the either the steering or loader systems, whichever
requires a higher pressure. The PFC pumps do not deliver flow until a command LS signal is received, Once a load
sense (LS) signal is received, the PFC pumps deliver as much flow as is required to satisfy the required LS pressure.
The LS signals from both the steering control system and the loader system are connected to the steering priority
valve. The LS signal shuttle check valve (34B) shifts away from the highest LS signal towards the lower LS signal. The
higher LS signal is then sent to the flow regulator spools of both of the PFC pumps. The higher pressure adjustment
of the first pump flow regulator (34A) causes that pump to begin to deliver flow first. The flow regulator pressure of
the first pump (34A) must be adjusted to specification. The adjustment of the flow regulator pressure of second pump
(33A) is lower than the first pump. If one compensator is adjusted, the opposite compensator must also be checked
and adjusted. The first pump flow regulator pressure must 3 - 4 bar (44 - 58 psi) higher than the adjustment of the
second pump flow regulator. It is preferable to use the same gauge to make both of these adjustments.
The second pump isolation check valve (35C) prevents pressurizing the second pump (33) from the outlet of the first
pump (34). Until the first pump (34) reaches full delivery, the second pump (33) is idling. The isolation valve (35C)
protects the second pump (33).

spool
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RCPH11WHL035HAN 2
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If the PFC pump control system malfunctions the pumps might deliver more flow than the hydraulic systems require,
causing excessive pressure at the pump outlet. A differential pressure relief valve (35D) is installed in the steering
priority valve limits this excessive pressure. The differential pressure relief (35D) provides a connection between the
PFC pump outlet flow and tank. The differential pressure relief valve is spring biased to the closed position. Pump
outlet pressure is ported to the non spring end of differential pressure relief valve spool. Load sense (LS) pressure is
ported to the spring end of the spool. The differential pressure relief opens when the pump outlet pressure is about
40 bar (580 psi) higher than load sense (LS) pressure.
The maximum steering pressure is lower than the maximum loader pressure. To limit this pressure in the steering
system, a steering pressure relief valve (35E) is connected between the steering LS signal (35B) in the steering priority
valve (35) and tank. This steering relief valve (35E) limits the maximum LS signal from the steering system and hence
limits the maximum steering pressure. The maximum pressure in the loader circuit is regulated by the loader relief
LS control valve located in the loader valve.
If only one of the complete steering or all of the loader circuits are malfunctioning, a quick check is to operate both
steering and loader at the same time. If both systems then operate, the PFC pumps should be OK. If only one circuit
of the loader valve malfunctions, the problem is in the loader valve only. If either the steering or all of the loader circuits
malfunction and both systems function when operated at the same time. A possible problem is then the shuttle check
valve (35B) in the steering priority valve (35).

spool
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RCPH11WHL035HAN 3
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The piston pumps used in the wheel loaders have variable displacement and are pressure and flow compensated
(PFC). The smallest wheel loader has a power control system to gradually reduce pump flow at pressures greater
than the setting of the power control system.This system is not to be adjusted. The power control system on the
smallest wheel loader prevents overloading and stalling of the engine while operating at lower engine speeds. The
smaller wheel loaders have a single PFC pump to supply the hydraulic systems. The large wheel loaders use a two
PFC pump tandem assembly to deliver the required flow. The two pump system operates the same as the single
pump system. The first pump delivers all of the flow when under low flow requirements. The second pump is idling
at no flow until the first pump reaches maximum flow. Only one pump is shown in this detailed explanation.
The counterbalance spring (1) pushes the piston pump swash plate (3) to deliver maximum flow until the control piston
(2) reduces the pump output to what is required to satisfy system requirements. When the engine is off, the swash
plate rests at the full displacement position as shown.
The flow control spool (FR2) monitors the load sensing (LS) signal from the loader control valve to control the piston
pump so that it only delivers the flow required by the system.
The pressure control spool (FR1) can regulate the maximum pressure that the piston pump will deliver. On the wheel
loaders, the pressure regulator spool (FR1) does not function. If the pump outlet pressure exceeds the pressure
control spool setting, the displacement, and therefore outlet flow, of the piston pump will be reduced to only that
which is required to maintain the maximum pressure. On the wheel loaders the pressure regulator spool is set much
higher than the maximum pressure control, (main relief valve) located within the loader valve. The pressure regulator
spool (FR1) is not functional within these pumps unless it was incorrectly adjusted to a pressure lower than the main
relief valve. If either the steering and loader systems operate well at lower pressures but cannot be adjusted to the
maximum specified relief valve pressure, the pressure regulator spool may have been incorrectly adjusted.
1 – Counterbalance spring FR1 – Pressure regulator spool

2 – Control piston FR2 – Flow regulator spool
3 – Swash plate LS – Load sense signal pressure
4 – Pump outlet pressure L – Drain flow to reservoir
5– Flow regulator spring
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RCPH11WHL038GAN 4
RCPH11WHL009FAN 5
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System Function Overview

This section provides a detailed explanation of how the Pressure and Flow Ccompensated (PFC) pump compensator
controls the pump.
When the engine is off, the pressure regulator spool (FR1) and the flow regulator spool (FR2) are spring loaded to
the closed position. The counterbalance spring pushes the swash plate to the full flow position. At start-up, pump
output flow is available to the steering and loader valve. The steering and loader control systems are closed center
design. The oil supply from the PFC pumps are blocked with the controls in neutral. With all controls in neutral, the LS
pressure will be vented to tank pressure. Pump outlet pressure is internally ported to the non spring end of the flow
regulator spool (FR2). Pump outlet pressure pushes on the left end of the flow regulator spool (FR2) overcoming the
flow regulator spring (5). Pump outlet pressure is then ported through the flow regulator spools to the control piston
(2). The control piston (2) then pushed the swash plate towards minimum displacement. The pump then delivers only
the flow required to maintain the flow regulator spring (5) pressure.
The flow regulator spring (5) is adjustable. Typically this spring does not require adjustment. If adjustment is required,
use the table below for the specifications. The flow regulator pressure of the first pump (34A) must be adjusted
to specification. The adjustment of the flow regulator pressure of second pump (33A) is lower than the first pump.
If one compensator is adjusted, the opposite compensator must also be checked and adjusted. Measure both the
pump outlet pressure and the LS pressure for the pump. Adjust the flow regulator spool to the pressure differential
specification. DO NOT activate any of the controls while making the adjustment, as the gauge may be damaged.
It is preferable to have a shutoff valve at the gauge to protect it from overpressure. The first pump flow regulator
pressure must 3 - 4 bar (44 - 58 psi) higher than the adjustment of the second pump flow regulator. It is preferable
to use the same gauge to make both of these adjustments to assure accuracy. The pump outlet pressure would be
approximately 24 - 35 bar (348 - 508 psi).
Model Pump 1 Delta P Pump 2 Delta P

621F 22 - 25 bar (319 - 363 psi) Not applicable
721F 28 - 30 bar (406 - 435 psi) 24 - 26 bar (348 - 377 psi)
821F 28 - 30 bar (406 - 435 psi) 24 - 26 bar (348 - 377 psi)
921F 24 - 26 bar (348 - 377 psi) 21 - 23 bar (305 - 334 psi)
1021F 25 - 27 bar (363 - 392 psi) 21 - 23 bar (305 - 334 psi)
1121F 25 - 27 bar (363 - 392 psi) 21 - 23 bar (305 - 334 psi)
When the steering or loader control system is activated, pump output pressure is available to the control spools. When
the loader circuit is activated, oil flow across the spool causes a pressure drop (Delta P) between the (PFC) pump
outlet pressure (4) and the LS signal pressure (6) back to the pump compensator. Pump output flow is delivered to
the inlet of the loader control valve through the steering priority valve.
When the pump outlet pressure (4) is higher than the LS signal pressure (6) plus the spring force (5) , the flow regulator
spool (FR2) will gradually shift to send pump outlet oil (4) to the control piston (2) to reduce the output of the pump.
The flow regulator spool (FR2) will remain in balance between the pump outlet pressure (4) on the left end and the LS
pressure (6) plus the spring force (5) on the right end of the spool. The control piston (2) will move the swash plate
(3) so that the flow from the pump will maintain the specified differential pressure (Delta P).
The pressure at which the flow control spool (2) shuts the pump down is adjustable. The flow control spool of the
second pump is to be adjusted approximately 4 bar (58 psi) lower than the flow regulator on the first pump. Any time
that the pump is at less than full displacement, the flow control spool (2) will maintain the Delta P. At less than full
flow delivery of the 1st pump, the difference between pump outlet pressure and the LS pressure (Delta P) will be the
higher pressure setting of the 1st pump compensator. When the 1st pump is at maximum flow, the difference between
pump outlet pressure and the LS pressure (Delta P) will be the lower pressure setting of the 2nd pump. If the load
in the bucket would require 138 bar (2000 psi) pump outlet pressure to raise the load, the signal pressure would be
138 bar (2000 psi) minus Delta P.
The maximum pressure available to loader hydraulic system is controlled by loader main relief valve located in the
loader valve (7). The loader main relief connects between the LS signal pressure and the tank passage in the loader
valve (7). When the LS signal pressure is restricted, the pump will not be able to deliver flow above that pressure. The
steering signal relief valve located in the steering priority valve limits the maximum pressure available to the signal
line from steering control circuit to the spring end of the piston pump flow control spool (FR2).
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RCPH11WHL046GAN 6
1 – Counterbalance spring 6– Load sense signal pressure

2 – Control piston 7 – Loader valve
3 – Swash plate LS – Load sense signal pressure
4 – Pump outlet pressure L – Output port
5 – Flow regulator spring S – Sump
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Hydraulic systems - Hydraulic schematic frame 01 - 1021F/1121F

Wheel Loader
Callout # Description Callout # Description
(1) Rear Axle Brakes, Modulation Pressure 68 - (2) Front Axle Brakes, Modulation Pressure 70
75 bar (986.0 - 1087.5 psi) - 77 bar (1015.0 - 1116.5 psi) )
(3) Brake Damping Accumulators (2), 0.16 l (4) Parking Brake
(0.17 US qt) , 7 bar (101.5 psi) Precharge
(5) Brake Signal, HVT transmission (6) Brake Declutch Switch, 4-speed
transmission, Electrical Connector PBD, 24
bar (348.0 psi)
(7) Brake Light Switch, 4.1 bar (59.5 psi) (8) Parking Brake Accumulator, 0.16 l (0.17 US
Increasing qt) 96 bar (1392.0 psi) Precharge
(9) Front Brake Accumulator, 3.5 l (3.7 US qt) , (10) Rear Brake Accumulator, 3.5 l (3.7 US qt) ,
70 bar (1015.0 psi) Precharge 70 bar (1015.0 psi) Precharge
(11) Redundant Brake Accumulator Pressure (12) Low Brake Pressure Warning Switch, Alarm
Switches, Electrical Connectors PRB1 OFF 138 bar (2001.0 psi) Increasing, Alarm
(Front), PRB2 (Rear), Rising < 91 bar (< ON 115 - 129 bar (1667.5 - 1870.5 psi)
1320 PSI), Falling 70 - 84 bar (1015.0 - Decreasing
1218.0 psi)
(13) Additional Front Brake Accumulator, (14) Additional Rear Brake Accumulator, 1121F
1021F-Heavy Duty and 1121F, 2.8 l (2.96 Only, 2.8 l (2.96 US qt) , 70 bar (1015.0
US qt) , 70 bar (1015.0 psi) Precharge psi) Precharge
(15) Brake Valve (15A) Parking Brake Solenoid, Electrical
Connector YPB
(15B) Front Brake Valve (15C) Rear Brake Valve
(15D) Accumulator Isolation Check Valve (15E) Accumulator Charging Spool
(15F) Priority Valve, Cut-In Pressure 157 - 167 bar (16) Pilot Control Valve
(2276.5 - 2421.5 psi) , Cut-Out Pressure
190 - 196 bar (2755.0 - 2842.0 psi)
(16A) Pilot ON/OFF Solenoid, Electrical Connector (16B) Bucket Pilot Control
YPP
(16C) Lift Pilot Control (16D) Auxiliary Hydraulics Pilot Control 1
(16E) Auxiliary Hydraulics Pilot Control 2 (17) Pilot Control Accumulator, 0.75 l (0.79 US
qt) , 13.8 bar (200.1 psi) Precharge
(18) Bucket Cylinder (19) Lift Cylinders
(20) Ride Control Valve (20A) Ride Control Solenoid, Electrical Connector
YRC
(20B) Ride Control Spool Valve (20C) Manual Bleed Valve
(20D) Pressure Relief Valve, 280 bar (4060.0 psi) (21) Ride Control Accumulators, (2) 3.78 l (4.0
US qt) , 14.5 bar (210.3 psi) Precharge
(22) Loader Valve (22A) Load Sense Shuttle Valve
(22B) Regeneration Relief Valve, 8 - 10.8 bar (22C) Flow Compensator Spools (4)
(116.0 - 156.6 psi)
(22D) Regeneration Check Valves (4) (22E) Circuit Relief Valves with Anti-Cavitation (4)
(22F) Pilot Pressure Generation Valve, 29 - 40 (22G) Loader Main Relief, 219 - 226 bar (3175.5 -
bar (420.5 - 580.0 psi) ) 3277.0 psi)
(22H) Load Sense Signal Bleed Down Orifice, 0.7 (22J) Shuttle Check Valves (6)
l/min (0.2 US gpm)
(22K) Lift Circuit Spool Valves (2) (22L) Bucket Circuit Spool Valve
(22M) Auxiliary Circuit Spool Valve (23) Steering Cylinders
(24) Steering Control Valve (24A) Steering Spool
(24B) Gerotor Pump (24C) Circuit Relief Valve
(25) Steering Cylinder Relief Valve, 345 bar (26) Joystick Steering Valve
(5000 PSI)
(26A) Control Spool (26B) Pressure Reducer
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Callout # Description Callout # Description

(26C) Pilot Dump Valve (27) Joystick Steering Load Sense Accumulator,
0.32 l (0.34 US qt) , 60 bar (870.0 psi)
Precharge
(28) Steering Back Pressure Valve, 8 - 10 bar (29) Steering Back Pressure Sensor, Joystick
(116.0 - 145.0 psi) Steering Only
(30) Joystick Steering Load Sense Resolver (31) Auxiliary Steering Accumulator, 0.32 l (0.34
US qt) , 60 bar (870.0 psi) Precharge
(32) Auxiliary Steering Pressure Switch, (33) Auxiliary Steering Pump
Electrical Connector PSS
(34) Auxiliary Steering Control Valve (34A) Auxiliary Steering Activation Solenoid,
Electrical Connector YSS
(34B) Relief Valve, 240 bar (3480 PSI) (34C) Priority Spool
(35) Second Pump (Farthest from Transmission), (35A) Compensator Differential Pressure Spool
1021F: 162 l/min (42.8 US gpm) , 1121F:
190 l/min (50.2 US gpm) , Cut Off 280 bar
(4060.0 psi) , Delta 21 - 23 bar (304.5 -
333.5 psi)
(35B) Compensator High Pressure Cutoff Spool (35C) Control Piston with Spring
(35D) Rotating Group with Swash Plate (36) First Pump (Closest to Transmission), 190
l/min (50.2 US gpm) , Cut Off 280 bar
(4060.0 psi) , Delta 25 - 27 bar (362.5 -
391.5 psi)
(36A) Compensator Differential Pressure Spool (36B) Compensator High Pressure Cutoff Spool
(36C) Control Piston with Spring (36D) Rotating Group with Swash Plate
(37) Priority Valve (37A) Priority Spool, 10 bar (145.0 psi)
(37B) Differential Pressure Relief, 40 bar (580.0 (37C) Steering Relief, 216 bar (3132.0 psi)
psi).
(38) Brake and Fan Pumps (39) Hydraulic Reservoir, 134 l (35.4 US gal)
(39A) Hydraulic Oil Filter Assembly, 10 micron (39B) 100 Mesh Strainers (4)
media, 3.4 bar (49.3 psi) bypass
(40) Reservoir Vent, 100 mesh, 0.03 bar (0.4 (41) Filter Warning Switch, Electrical Connector
psi) check, 0.35 bar (5.1 psi) relief PHF, 2.7 bar (39.2 psi)
(42) Rear Axle (43) Front Axle
(44) Axle Cooler Anti-Caviation Valves (2), 0.3 (45) Air-to-Oil Axle Coolers (2)
bar (4.4 psi) )
(46) Axle Oil Filters (2), Electrical Connectors (47) Axle Cooler Motor-Pump-Pump
PRA, PFA, 3.4 bar (49.3 psi) bypass Combination, 55 bar (797.5 psi) bypass
(48) Oil Cooler Thermal Valve, 2.4 - 3.6 bar (34.8 (49) Hydraulic Oil Cooler
- 52.2 psi) Bypass
(50) Oil Cooler Fan (51) Standard Fan Valve, 162 bar (2349.0 psi)
(52) Fan Reversing and Variable Valve (52A) Crossover Relief 234 bar (3393.0 psi)
(52B) Reversing Spools (2) (52C) Pulse Width Modulation (PWM) Relief
Valve, 165 bar (2392.5 psi)
(52D) ON/OFF Reversing Solenoid, Electrical TP1 Pump 2 pressure
Connector YFR
TP3 Load sense signal TP5 Pump 1 pressure
TP6 Rear brake accumulator TP7 Front brake accumulator
TP9 Pilot pressure supply TP10 Rear brake to axle
TP11 Front brake to axle Note 1 Check and relief valves not used with fan
reverser
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RCIL11WHL013JAK 1
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RCIL11WHL014EAK 2
NOTE: Conversion information
1 bar = 14.5 pounds per square inch (PSI)

1 liter per minute = .264 gallons per minute
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Hydraulic systems - Cleaning

1. 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.
(A) When you drain the oil or disconnect any line.
(B) When you disassemble a component.
(C) From normal wear of the hydraulic components.
(D) From damaged or worn seals.
(E) From a damaged component in the hydraulic sys-
tem.
2. All hydraulic systems operate with some contami-
nation. The design of the components in this hy-
draulic system permits efficient operation with a small
amount of contamination. An increase in this amount
of contamination can cause problems in the hydraulic
system. The following list includes some of these
problems.
(A) Cylinder rod seals leak.
(B) Control valve spools do not return to neutral.
(C) Movement of control valve spools is difficult.
(D) Hydraulic oil becomes too hot.
(E) Pump gears, housing, and other parts wear
rapidly.
(F) Relief valves or check valves held open by dirt.
(G) Quick failure of components that have been re-
paired.
(H) Cycle times are slow; machine does not have
enough power.
3. If your machine has any of these problems, check
the hydraulic oil for contamination. See types of con-
tamination below. If you find contamination, use the
Portable Filter to clean the hydraulic system.
NOTE: There are two types of contamination, microscopic
and visible.
4. Microscopic contamination occurs when very fine
particles of foreign material are in suspension in the
hydraulic oil.
5. These particles are too small to see or feel. Micro-
scopic contamination can be found by identification
of the following 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 tem-
perature.
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6. Visible contamination is foreign material that can be

found by sight, touch, or odor. Visible contamination
can cause a sudden failure of components. Exam-
ples 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.
NOTE: The hydrostatic system uses a third port bypass fil-
ter system. If the filter becomes plugged it bypasses back
to the reservoir to stop contamination from entering the
hydrostatic system. Upon completion of cleaning the hy-
draulic system replace the hydrostatic system filter.
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Hydraulic systems - Decontaminating

DANGER
Crushing hazard!
Always install the safety lock before working under the raised attachment.
Failure to comply will result in death or serious injury.
D0075A
1. Start and run the engine at 1500 rpm (r/min).

2. Completely retract the cylinders of all attachments on
the machine. Angle the blade to the right, the right
cylinder will be fully retracted and the left will be fully
extended. Stop the engine.
NOTE: If retracting the cylinder rods causes the attachment
to be raised, block the attachment in place before proceed-
ing 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.
bd02n160_732 1
5. Drain the hydraulic oil from the reservoir.

A. The reservoir holds approximately 20 U.S. gal-
lons ( 75.7 litres) of hydraulic oil.
B. Have available acceptable equipment to drain the
hydraulic oil.
C. Remove the drain cap from the remote drain.
6. Apply brakes at least 30 times to drain oil from accu-
mulators.
7. Remove the hydraulic filter elements from the ma-
chine.
8. Install new hydraulic filter elements on the machine.
9. Install the drain cap in the remote drain.
10. Fill the hydraulic reservoir with 20 U.S. gallons ( 75.7
litres) of hydraulic fluid.
11. Disconnect the line from the OPEN end and
CLOSED end of each cylinder.
12. Be sure all control levers are in the NEUTRAL posi-
tion.
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13. Start and run the engine at low idle.

NOTICE: Check the oil level in the hydraulic reservoir fre-
quently while doing 13. Have another person hold a con-
tainer under the hydraulic lines while you do 13.
14. Slowly move each control lever in both directions un-
til oil begins to flow from the open line. Hold the con-
trol lever in place until clean oil flows from the open
line.
15. Stop the engine.
16. Connect the system line to the CLOSED end of each
cylinder.
17. Connect a suitable drain line to the OPEN end of
each cylinder and place the other end in an accept-
able container for contaminated oil.
18. Start the engine and run the engine at low idle.
19. Slowly and completely extend all cylinders. As the
piston rod comes in/out of the cylinder, oil will be
pushed out of the OPEN end of the cylinders.
NOTE: Any attachment or part of an attachment that is
raised must be supported with acceptable equipment to
prevent the attachment from falling.
20. Support any attachments that will be in the RAISED
position.
22. Disconnect the drain lines and connect the system
lines to the cylinders.
23. Check the oil level in the hydraulic reservoir. Add oil
as required.
24. Install the filler cap on the reservoir.
25. Remove the hydraulic filter elements from the ma-
chine.
26. Install new hydraulic filter elements on the machine.
27. Start and run the engine at 1500 rpm(r/min) , oper-
ate each hydraulic circuit to completely extend and
retract the cylinders.
28. Stop the engine and check for leaks. Check the oil
level in the hydraulic reservoir. Add oil as required.
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Hydraulic systems - Test – Brake accumulator tests

NOTE: The hydraulic brake schematic is included in the hydraulic schematic.
1. Make sure the oil level in the hydraulic reservoir is
correct. Remove all pressure from the brake system
by pushing and releasing the brake pedal many times
with the engine stopped, until there is no pressure on
the pedal.
2. Install two 207 bar ( 3000 psi) pressure gauges
to both front and rear hydraulic brake accumulator
lines. The test ports for the accumulators are located
behind the cab skirts.
BD06F145 1
(1) Front axle test port (3) Front brake accumulator test port
(2) Rear axle test port (4) Rear brake accumulator test port
3. Make sure that the hoses on the pressure gauges are

long enough so the gauges can be read while sitting
in the operators seat.
NOTE: The gauges can not be connected if hydraulic pres-
sure remains in the system.
4. Start the engine. Run the engine at low idle while
reading the pressure gauges. The alarms (buzzer,
master warning light and brake pressure warning
light) should shut off when the accumulator with
the lowest pressure reaches 142 - 150 bar (2059 -
2175 psi) , approximately 40 seconds at any engine
speed.
5. After the alarms stop, run the machine at high idle to
finish charging the accumulators. The pressure must
increase on both gauges until 190 - 196 bar ( 2755 -
2842 psi) is reached. This is the accumulator valve
cut-out pressure. It is normal for the pressure to drop
slightly once the cut-out pressure is reached.
6. With the engine running at high idle, push and re-
lease the brake pedal rapidly while reading the drop
in pressure on the gauges. The pressure drops may
not be equal, but as the lowest pressure reaches 157
- 167 bar (2277 - 2422 psi), the system pressure
must start to increase. This is the valve cut in pres-
sure.
NOTE: The brake cut-in and cut-out pressures of the brake
system charge valve are factory preset and are not ad-
justable.
NOTE: If the pressure on one of the pressure gauges is
lower than specified, the problem can be a bad accumula-
tor valve.
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7. Stop the engine. Turn the ignition switch to the ON

position. Push and release the brake several times
while reading the pressure on the gauges. Each
push and release of the pedal will result in a slight
drop in pressure, but not necessarily equal on the
two gauges.
8. As the lowest pressure reaches 115 - 129 bar (1668
- 1871 psi) the brake warning lamp and alarm buzzer
must actuate. If the warning lamp and alarm buzzer
fail to work, test the low brake pressure warning
switches and electrical circuit. If the warning lamp
and alarm buzzer actuate at a higher or lower pres-
sure than specified, test the low brake pressure
warning switches and replace as needed.
9. After the low brake pressure light activates, press the
brake pedal eight more times.
10. Record the readings on the pressure gauges. The
pressure gauges should read at or above 70 bar
(1015 psi) .
11. If the pressures are at or above 70 bar (1015 psi) ,
the test is complete.
12. If the pressures are not within the required specifica-
tions, then the brake system must be bled.
13. After bleeding the brake system, perform the brake
system check again.
14. Continue to slowly push and release the brake pedal
several times until the gauge pressure suddenly
drops to zero. The last pressure reading before the
drop to zero is the nitrogen charge pressure in the
accumulator. Test the pressure in both accumula-
tors. If the pressure is below 70 bar (1015 psi) ,
charge or replace the accumulator(s).
NOTE: Nominal temperature of 20 °C (68 °F), colder tem-
perature will reduce pressure, hotter temperature will in-
crease pressure.
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Hydraulic systems - Test – Brake pump flow test

See Hydraulic systems - Check - Hydraulic Check Sheet, F Series Wheel Loaders (35.000) for form to record
test results.
1. Connect the flowmeter to the brake pump as shown,

refer to the illustration below.
2. Make sure the load control of the flowmeter is open.
Start the engine. Run the engine at full throttle. Make
sure the oil is at operating temperature.
3. Measure the flow at 0 bar (0.0 psi) . Record the flow
reading. Slowly close the load valve on the flowmeter
and read the flow at 170 bar (2465.0 psi). Record
the flow reading.
4. Divide the flow reading at 170 bar (2465.0 psi) by
the reading at 0 bar (0.0 psi). Multiply the result by
100. This is the percent efficiency of the pump. If
the efficiency of the pump is less than 85%, repair or
replace the pump.
RAIL12WEL0135GA 1
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1. Brake pump 3. Flowmeter inlet hose 5. Filter inlet manifold

2. Pump output elbow 4. Flowmeter outlet hose 6. Filters
NOTE: If unit is equipped with auxiliary steering a tee fitting will have to be used in this location.
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Hydraulic systems - Test – First pump high pressure cut-off

See Hydraulic systems - Check - Hydraulic Check Sheet, F Series Wheel Loaders (35.000) for form to record
test results.

RCPH11WHL039AAH 1
2. Connect two 345 bar (5002.5 psi) test gauges to the

test port (1) located on the large hydraulic tube on
the bottom of the pump.
RAIL12WEL0136AA 2
3. Make sure that the temperature of the hydraulic oil is

at least 54 - 57 °C (129.2 - 134.6 °F). The following
is the procedure for heating the hydraulic oil:
A. Measure the oil temperature with the instrument
cluster by using the up or down arrow key to display
the temperatures that need to be monitored.
B. Heat the hydraulic oil by running the engine at full
throttle. Hold the bucket control lever in the ROLL-
BACK position while raising and lowering the lift arms
from ground level to full height.
C. Continue this procedure until the temperature of
the hydraulic oil is 54 - 57 °C (129.2 - 134.6 °F) .
After heating oil to operating temperature, lower
bucket to the ground, turn off the engine, and relieve
all pressure in the hydraulic system.
4. Start the engine and run at full throttle.
5. Roll the loader bucket back against the stops.
6. Record the reading on the test gauge.
7. Reading should be 198 - 202 bar (2871.0 - 2929.0
psi) .
8. If this reading is more or less than specified, it will be
necessary to adjust the pump cutoff pressure.
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9. Adjusting the Loader pump cutoff pressure : The un-

loading adjuster is the longer of the two adjusters on
the loader pump. Turn the screw clockwise to in-
crease the cutoff pressure. Turning the screw coun-
terclockwise will decrease the cutoff pressure.
NOTE: The adjusting screw is located just above the steer-
ing priority valve on the pump closest to the transmission.
This test is only required if the loader main relief valve pres-
sure cannot be reached. The pump would shut off before
getting that pressure.
RAIL12WEL0137AA 3
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Hydraulic systems - Test – Auxiliary steering pump flow

NOTE: The following procedures is for the steering pump section flow test, readings will be much lower than that of
a combined flow test.
NOTE: If unit is equipped with auxiliary steering a tee fitting will have to be used in this location
bc03n237 1
1. Pump inlet hoses 8. Steering pressure hose

2. Filter inlet manifold 9. Steering pump section
3. Flowmeter outlet hose 10. Loader pump
4. Filters 11. Loader pressure hose
5. CAS10280 flowmeter 12. Check valve
6. Flowmeter inlet hose 13. Articulation pressure hose
7. Elbow 14. Priority valve
1. Connect the flow meter to the filter manifold as
shown.
2. Disconnect steering pressure hose (8) from elbow
(7).
3. Cap elbow (7) and connect the flowmeter inlet hose
(6) to the steering pressure hose (8).
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4. Make sure the load control of the flow meter is open.

Start the engine. Run the engine at full throttle. Make
sure the oil is at operating temperature.
5. Measure the flow at 0 bar ( 0 psi ). Record the
flow reading. Slowly close the load valve on the flow
meter and read the flow at 170 bar ( 2500 psi ).
Record the flow reading.
6. Divide the flow reading at 170 bar ( 2500 psi) by
the reading at 0 bar ( 0 psi). Multiply the result by
100. This is the percent efficiency of the pump. If
the efficiency of the pump is less than 85 %, repair
or replace the pump.
7. Stop the engine. Remove cap from elbow (7).
8. Disconnect the flowmeter inlet hose (6) from the
steering pressure hose (8).
9. Connect steering pressure hose (8) to elbow (7).
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Hydraulic systems - Test – Steering cylinder leakage

NOTE: Make sure all persons are clear of the area of the center pivot. Make sure the center pivot is free of any
obstructions.
1. Park the machine on a level surface.
2. Turn the machine all the way to the right.
3. Stop the engine and apply the parking brake.
4. Find the tube that is connected to the rod end of the
left-hand steering cylinder. Disconnect the tube from
the left-hand cylinder.
5. Install a plug in the tube.
6. Start and run the engine at full throttle.
7. Turn the steering wheel to the right. Hold the steering
wheel for a full right turn. Have another person check
for leakage from the opening of the rod end of the
left-hand steering cylinder.
8. If there is constant leakage from the rod end, the
piston packing in the left-hand steering cylinder is
damaged. Repairs must be made.
9. Connect the tube to the rod end of the left-hand steer-
ing cylinder.
10. Turn the machine all the way to the left.
12. Find the tube that is connected to the rod end of
the right-hand steering cylinder. Disconnect the tube
from the right-hand steering cylinder.
13. Install a plug in the tube.
14. Start and run the engine at full throttle.
15. Turn the steering wheel to the left. Hold the steering
wheel for a full left turn. Have another person check
for leakage at the opening of the rod end of the right-
hand steering cylinder.
16. If there is constant leakage from the rod end, the
piston packing in the right-hand steering cylinder is
damaged. Repairs must be made.
17. Connect the tube to the rod end of the right-hand
steering cylinder.
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Hydraulic systems - Test – Pilot pressure at end of loader valve

spool
1. Insert a pressure test tee and gauge between the end
of hose (1) and the loader valve.
2. Verify that the control pilot pressure is being deliv-
ered to the end of each spool.
3. Continue this procedure for the remaining hoses (2)
through (8)
Hydraulic Valve Pilot Line Connections
RAIL12WEL0138FA 1
(1) Green White Green (4)Orange Black Green (7) Green Black Green
(2) Red White Green (5) Green White Green (8) Red Black Green
(3) Yellow Black Green (6) Red White Green
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Hydraulic systems - Test – Ride control

1. Move the machine to a clear level surface with clear-
ance for full lift arm and bucket movement.
2. Install the articulation lock, start the machine, acti-
vate the parking brake.
RCPH11WHL039AAH 1
3. With the pilot controller in neutral, set the ride control

rocker switch on the right side console to the “Always
On” position and observe the switch lamp, the lamp
should illuminate.
4. Set the ride control rocker switch to the “Off” position
and observe the switch lamp, the lamp should go out.
NOTE: This indicates that the switch is operating correctly
and has power, if the switch does not illuminate see Load
travel stabilization switch - Testing (55.524) for electrical
troubleshooting.
5. Raise the lift arms to the top of their travel and dump
the bucket.
6. Dump the bucket until it hits the dump stops. Hold
the bucket in the dump position for 5 - 10 s .
NOTE: This will charge the ride control accumulator.
7. Lower the lift arms and roll the bucket back to a carry
position. Do not leave the lift arms or the bucket on
their stops. Place the pilot control lever in the neutral
position.
8. Set the ride control rocker switch to the “Always On”
position. The lift arms should rise 15 - 30 cm (5.9 -
11.8 in) with an empty bucket.
NOTE: Test results will be for a machine with an empty
factory bucket and no attachments.
9. If there is little or no lift arm raise, the test may have
been done too slowly. The elapsed time between
step 6 and step 8 should not exceed 6 s .
NOTE: If test was done too slowly repeat in the allotted
time.
10. If test was completed in the allotted time and the lift
arms still do not rise, test the nitrogen charge in the
accumulator.
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Hydraulic systems - Test – Ride control valve system function test

1. Move the machine to a clear level area with sufficient
space to accelerate the machine to 5 km/hr ( 3 mph)
for 30 seconds and stop.
2. Start the engine.
3. Activate the ride control. Press down on the symbol
side of the switch to activate. The indicator light WILL
NOT illuminate at this time.
NOTE: The ride control switch is located in the bank of
rocker switches to the right of the operator's seat. It is in
the center row, second switch from the front.
4. Raise the lift arms to near the top of their travel.
5. Rapidly dump the bucket until it hits the dump stops.
This will create a down force on the lift arms and they
should drop visibly. Repeat this process 2 or 3 times
if necessary.
NOTE: The oil displaced from the lift cylinders is used to
charge the ride control accumulator.
6. Lower the lift arms and roll the bucket back to a carry
position. Do not leave the lift arms or the bucket on
their stops.
7. Accelerate the machine to at least 5 km/hr ( 3 mph).
At 5 km/hr ( 3 mph) the lift arms should raise a visible
amount, 102 - 635 mm ( 4 - 12 inches ) depending
on bucket and coupler weight. This is an indication
that the ride control is functioning. As the machine
continues to travel there should be visible cylinder
movement in response to the road conditions.
NOTE: With an empty bucket, cylinder travel will not ex-
ceed 25 mm ( 1 inch ).
8. With the machine traveling over 5 km/hr ( 3 mph)
check the indicator light on the ride control rocker
switch, it should be illuminated.
9. Slow the machine down and observe the indicator
light. The indicator light should go out when the ma-
chine slows below 5 km/hr ( 3 mph).
10. Stop the machine.
11. De-activate the ride control with the rocker switch.
Repeat steps 5, 6 and 7.
12. Accelerate the machine to at least 5 km/hr ( 3 mph).
This time there should be no visible raising of the
lift arms and the light should remain off. The quality
of the ride should be noticeably worse with the ride
control de-activated.
13. Stop the machine.
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Index

Hydraulic systems - Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Hydraulic systems - Decontaminating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Hydraulic systems - Dynamic description – Hydraulic Oil Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Hydraulic systems - Hydraulic schematic frame 01 - 1021F/1121F Wheel Loader . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Hydraulic systems - Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Hydraulic systems - Test – Auxiliary steering pump flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Hydraulic systems - Test – Brake accumulator tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Hydraulic systems - Test – Brake pump flow test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Hydraulic systems - Test – First pump high pressure cut-off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Hydraulic systems - Test – Pilot pressure at end of loader valve spool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Hydraulic systems - Test – Ride control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Hydraulic systems - Test – Ride control valve system function test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Hydraulic systems - Test – Steering cylinder leakage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
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Variable displacement pump - 106
1021F
1121F
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Contents
TECHNICAL DATA
Variable displacement pump

SERVICE
Pump
Pressure and Flow Compensated (PFC) piston pump - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Pressure and Flow Compensated (PFC) piston pump - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Pressure and Flow Compensated (PFC) piston pump - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Pressure and Flow Compensated (PFC) piston pump - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
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Hydraulic systems - Variable displacement pump
Variable displacement pump - General specification

Model \ Pump Specification
521F Closed centered pressure / flow compensated
Pump (1) 135 l/min (35.7 US gpm) @ 2000 RPM
Pump (1) 170 l/min (44.9 US gpm) @ 2000 RPM
First Pump (Closest to transmission) 120 l/min (31.7 US gpm) @ 2000 RPM
Second Pump (Farthest from transmission) 86 l/min (22.7 US gpm) @ 2000 RPM
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Pump Pressure and Flow Compensated (PFC) piston pump -

Remove
Prior operation:
Ladder - Remove (90.118), Cab suspension - Remove (90.150), Pump Pressure and Flow Compensated (PFC)
piston pump - Remove (35.106), Brake pump - Remove with fan pump (33.202)

1. Drain the hydraulic oil tank.
shown).
3. Attach lifting equipment to the PFC pump. Remove
the PFC pump mounting bolts (1). Remove the PFC
pump.
RCPH11WHL056AAR 1
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Pump Pressure and Flow Compensated (PFC) piston pump - Install

1. Lubricate and install the PFC pump O-ring.
RCPH11WHL055AAR 1
2. Attach lifting equipment to the PFC pump. Attach

the PFC pump to the transmission. Tighten the PFC
pump mounting bolts (2) to a torque of 149 - 170 N·m
(110 - 125 lb ft).
RCPH11WHL056AAR 2
3. Install the hydraulic pump suction hose (not shown),

split, flange clamp, and split, flange clamp bolts (1).
73 - 90 N·m (54 - 66 lb ft).
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Pump Pressure and Flow Compensated (PFC) piston pump -

Remove
Prior operation:
Ladder - Remove (90.118), Cab suspension - Remove (90.150)
with Loader Valve

NOTE: Hydraulic pump suction hoses removed for picture clarity.
1. Drain the hydraulic tank.
shown).
4. Remove the case drain tube (1) from the two PFC
pumps.
RCPH11WHL068AAR 1
5. Remove the loader valve drain hose (1).
RCPH11WHL065AAR 2
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6. Remove the loader valve hose (1).
RCPH11WHL064AAR 3
7. Remove the pump-to-manifold tube bolts (1).
RCPH11WHL061AAR 4
8. Remove the articulation load sense hose (1).

9. Remove the priority valve-to-pump hose (2).
10. Remove the loader valve hose (3).
11. Remove the articulation pressure hose (4).
RCPH11WHL062AAR 5
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12. Remove the hydraulic oil line P-clamp (2).

13. Remove the hydraulic oil lines (1).
RCPH11WHL063AAR 6
14. Remove the pump hose (1).
RCPH11WHL067AAR 7
15. Remove the split, half clamp flange (2).

16. Attach lifting equipment to the PFC pump with loader
valve. Remove the PFC pump with loader valve
mounting bolts (1). Remove the PFC pump with
loader valve.
RCPH11WHL060AAR 8
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Pump Pressure and Flow Compensated (PFC) piston pump - Install

with Loader Valve
NOTE: Hydraulic pump suction hoses removed for picture clarity.
1. Lubricate and install the PFC pump O-ring.
RCPH11WHL059AAR 1
2. Attach lifting equipment to the PFC pump with loader

valve. Attach the PFC pump with loader valve to the
PFC pump without the loader valve. Tighten the PFC
pump mounting bolts (1) to a torque of 149 - 170 N·m
(110 - 125 lb ft).
RCPH11WHL060AAR 2
3. Install the pump hose (1).
RCPH11WHL067AAR 3
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4. Install the hydraulic oil lines (1).

5. Install the hydraulic oil line P-clamp (2).
RCPH11WHL063AAR 4
6. Install the articulation load sense hose (1).

7. Install the priority valve-to-pump hose (2).
8. Install the loader valve hose (3).
9. Install the articulation pressure hose (5).
10. Install the split, half clamp flange and bolts (4).
Tighten the split, half clamp flange bolts (4) to a
torque of 198 - 242 N·m (146 - 179 lb ft).
RCPH11WHL062AAR 5
11. Install the pump-to-manifold tube bolts (1). Tighten

the pump-to-manifold tube bolts (1) to a torque of 85
- 102 N·m (63 - 75 lb ft).
RCPH11WHL061AAR 6
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12. Install the loader valve hose (1).
RCPH11WHL064AAR 7
13. Install the loader valve drain hose (2).

14. Install the suction, hydraulic pump hose (not shown),
split, flange clamp, and split, flange clamp bolts (1).
73 - 90 N·m (54 - 66 lb ft).
RCPH11WHL065AAR 8
15. Install the case drain tube (1).
RCPH11WHL068AAR 9
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Index

Pump Pressure and Flow Compensated (PFC) piston pump - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Pump Pressure and Flow Compensated (PFC) piston pump - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Pump Pressure and Flow Compensated (PFC) piston pump - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Pump Pressure and Flow Compensated (PFC) piston pump - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Variable displacement pump - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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Reservoir, cooler, and filters - 300
1021F
1121F
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Contents
SERVICE
Oil reservoir
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
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Hydraulic systems - Reservoir, cooler, and filters
Oil reservoir - Remove

Prior operation:
Engine hood - Remove (90.105), Ladder - Remove (90.118), Cab suspension - Remove (90.150)

RCPH11WHL039AAH 1
2. Key in the run position, engine off, place the pilot

control switch (1) in the normal operation position.
RCPH10WHL982FAH 2
3. Move the loader hydraulic control handle to the raise

and lower position in order to release any hydraulic
pressure in the lift circuit.
4. Move the loader control handle in and out of the tilt
position several times, this will relieve any pressure
in the pilot accumulator.
5. Release the pressure in the ride control accumulator
with the bleeder valve in the ride control valve.
6. Actuate brake pedal several times to discharge brake
accumulators.
7. Slowly loosen the filler cap for hydraulic reservoir to
release air pressure in hydraulic reservoir.
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8. Put the master disconnect switch (1) in the off po-

sition. Remove both battery covers and disconnect
`the batteries from the machine.
RCPH11WHL094AAH 3

10. Loosen the hose clamp (1) under the inlet air hood.
RCPH11WHL053AAR 4
11. Remove the mounting bolts on the exhaust stack

hood. Attach lifting equipment to the exhaust stack.
Remove the exhaust stack hood (1).
RCPH11WHL010AAR 5
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12. Remove the P-clamp (2) that secures the overflow

hose to the left bracket.
13. Remove the left bracket (1) and right bracket (3).
RCPH11WHL012AAR 6
14. Remove the three hydraulic oil lines (1).
RCPH11WHL013AAR 7
15. Remove the return hose (1) and the outlet hose (2)
on the deaeration tank.
RCPH11WHL001AAR 8
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16. Remove the relay mounting plate (1).
RCPH11WHL001AAR 9
RCPH11WHL001AAR 10
18. Remove the turbo exhaust tube mounting bracket

(1).
19. Remove the air box snorkel mounting bracket (1).
RCPH11WHL022AAR 11
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20. Remove hydraulic line cover (1).
RCPH11WHL002AAR 12
21. Remove the hydraulic lines (1).
RCPH11WHL003AAR 13
22. Remove the hydraulic oil return tube (1).
RCPH11WHL004AAR 14
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23. Remove the supply hose (1) and tank drain hose (2).
RCPH11WHL005AAR 15
24. Remove the three hydraulic pump suction hoses (1).
RCPH11WHL006AAR 16
25. Remove the hydraulic pump case drain hose (2) and
the two pilot hoses (1).
RCPH11WHL007AAR 17
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26. Remove the hose P-clamp (1).
RCPH11WHL008AAR 18
27. Remove the four hydraulic oil tank mounting bolts (1),
washers (2), and poly-lock nuts (3).
RCPH11WHL008AAR 19
28. Attach lifting equipment to the hydraulic oil tank. Re-

move the hydraulic oil tank.
RCPH11WHL094AAR 20
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Oil reservoir - Install

1. Attach lifting equipment to the hydraulic oil tank.

Lower the hydraulic oil tank onto the chassis.
RCPH11WHL094AAR 1
2. Install the two hydraulic oil tank front mounting bolts

(1). Tighten the hydraulic oil tank front mounting bolts
(1) to a torque of 302 - 407 N·m (223 - 300 lb ft).
3. Install the two hydraulic oil tank rear mounting bolts
(2), washers (3), (4), and poly-lock nuts (5). Tighten
the hydraulic oil tank rear mounting bolts (2) to the
torque of 407 - 542 N·m (300 - 400 lb ft).
NOTICE: Hydraulic tank rear mounting bolts (2), washers
(3), (4), and nuts (5) are designed to be torqued only one
time. Replace rear mounting bolts (2), washers (3), (4),
and nuts (5) as required.
RCPH11WHL008AAR 2
4. Install the hose P-clamp (1).
RCPH11WHL008AAR 3
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5. Install the hydraulic pump case drain hose (2) and

the two pilot hoses (1) .
RCPH11WHL007AAR 4
6. Install the three hydraulic pump suction hoses (1).

7. Tighten the split, half clamp flange bolts (2) to the
torque of 73 - 90 N·m (54 - 66 lb ft).
RCPH11WHL006AAR 5
8. Install supply hose (1) and tank drain hose (2).
RCPH11WHL005AAR 6
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9. Install the hydraulic oil return tube (1). Tighten the

split, half clamp flange bolts (2) to the torque of 73 -
90 N·m (54 - 66 lb ft).
RCPH11WHL004AAR 7
10. Install the hydraulic lines (1).
RCPH11WHL003AAR 8
11. Install the hydraulic line cover (1).
RCPH11WHL002AAR 9
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12. Install the turbo exhaust tube mounting bracket (1).

13. Install the air box snorkel mounting bracket (2).
RCPH11WHL022AAR 10
14. Install the wire harness P-clamp (2).
RCPH11WHL001AAR 11
15. Install relay mounting plate (1).
RCPH11WHL001AAR 12
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16. Install the return hose (1) and the outlet hose (2) on
the deaeration tank.
RCPH11WHL001AAR 13
17. Install the three hydraulic lines (1).
RCPH11WHL013AAR 14
18. Install the left bracket (1) and right bracket (4).
19. Install the P-clamp (2) that secures the overflow hose
to the left bracket.
20. Attach the overflow hose to the deaeration tank (3).
RCPH11WHL012AAR 15
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21. Attach lifting equipment to the exhaust stack. Lower

the exhaust stack hood (1) in front of the engine wall
and on the left bracket, right bracket, and hydraulic
oil tank.
22. Install the mounting bolts on the exhaust stack hood
(1).
RCPH11WHL010AAR 16
23. Attach the air box snorkel to the inlet air hood.
Tighten the air box snorkel hose clamp (1).
RCPH11WHL053AAR 17
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Index

Oil reservoir - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Oil reservoir - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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Pilot system - 357
1021F
1121F
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Contents
Pilot system - 357
TECHNICAL DATA
Pilot accumulator
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Hydraulic systems - Pilot system
Pilot accumulator - General specification

Pilot Pressure Accumulator Dry Nitrogen Pressure 13.8 bar +/- 1 (200 psi +/- 15) at 20 ˚ C
( 68 ˚ F)
Pilot Pressure Accumulator Fluid Capacity 0.75 liters ( 45 cu. inch)
Pilot Pressure Accumulator Maximum operating Pressure 210 bar ( 3046 psi)
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Index
Pilot system - 357

Pilot accumulator - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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Main control valve - 359
1021F
1121F
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Contents
DIAGNOSTIC
Stacked control valves

Loader arm lifting electromagnetic detent - Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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Hydraulic systems - Main control valve
Stacked control valves Loader arm lifting electromagnetic detent -

Testing
Turn the key switch OFF. Disconnect The resistance should be approxi- The resistance is out of range. Re-
the wiring harness connector from mately 65 - 71 ohms. place the Return To Travel detent
the control valve electromagnetic de- electromagnet.
tents connector.
Check
Measure the resistance between pin
1 and pin 6.
2 Check Result Action
Measure the resistance between pinThe resistance should be approxi- The resistance is out of range. Re-
2 and pin 5. mately 65 - 71 ohms. place the Height Control detent elec-
tromagnet.
Measure the resistance between pin The resistance should be approxi- The resistance is out of range. Re-
3 and pin 4. mately 65 - 71 ohms. place the Return To Dig detent elec-
tromagnet.
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Index

Stacked control valves Loader arm lifting electromagnetic detent - Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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Auxiliary hydraulic valves and lines - 525
1021F
1121F
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Contents
FUNCTIONAL DATA
Optional control valve

Exploded view 3rd Spool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Exploded view 4th Spool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Exploded view 3rd and 4th Spool Pilot Caps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
DIAGNOSTIC
Auxiliary hydraulic valves and lines

Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
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Hydraulic systems - Auxiliary hydraulic valves and lines
Optional control valve - Exploded view 3rd Spool
bs03c036 1
3 Spool Mounting Configuration
2. Plate 10. O-rings

3. Bolt 34. Housing
4. Washer 35. Anticavitation and circuit relief
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Optional control valve - Exploded view 4th Spool
bs03c035 1
4 Spool Mounting Configuration
2. Plate 35. Anticavitation and circuit relief

4. Washer 36. Nut
34. Housing 37. Stud
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Optional control valve - Exploded view 3rd and 4th Spool Pilot Caps
bs03c037 1
3 and 4 Spool Valve Spool Configuration
25. Piston 29. Cover 33. Spool

26. Jam nut 30. Adjusting rod
27. Cap nut 31. Spring retainer
28. Bolt 32. Spring
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Auxiliary hydraulic valves and lines - Testing

Visually check the machine for oil YES NO
leakage and damaged or missing Action Fill the hydraulic reservoir with the
parts. Repair or replace any dam- Heat the oil in the hydraulic system to hydraulic oil.
aged or missing parts. operating temperature. Operate the
Check the oil level in the hydraulic machine to find which circuits have
reservoir. Is the oil level correct? problems.
Problems in All Circuits YES NO
Replace the return line hydraulic fil- Action See Variable displacement pump
ter. See Hydraulic systems - Decon- - Flow test (35.106). Do the flow
See Engine - Speeds (10.001). Do taminating (35.000) and clean or re- meter test of the hydraulic pump.
the stall test to see if the engine is place the oil.
good.
See Hydraulic systems - Decon-
taminating (35.000) and check for
contaminated oil. Is the oil contami-
nated?
Problem in All Loader Circuits YES NO
See Relief valve - Pressure test Adjust the limit pressure. See Relief
(35.359) and check the pressure set- valve - Pressure setting (35.359).
ting of the limit pressure in the loader
control valve.
Is the pressure setting correct?
Problem in the Braking Circuit YES NO
Action
See Hydraulic service brakes
- Troubleshooting (33.202) and
check the braking circuit.
Problem in a Single Loader Circuit YES NO
Start and run the engine at full throt- Action The loader control valve is damaged.
tle. Operate the control for the bad Go to test 6 See Stacked control valves - Dis-
circuit. Does the cylinder move in assemble (35.359) and repair the
both directions? loader control valve
Check the cylinder piston packing. Is YES NO
the packing good? Action See Bucket cylinder - Disassem-
Go to test 7 ble (35.738) and Lift arm cylinder
- Disassemble (35.701) and repair
the cylinder.
See Tilting relief valve - Pressure YES NO
test (35.738). Check and adjust the Action See Stacked control valves - Dis-
circuit relief valves. Then check the The problem is repaired. assemble (35.359). Disassemble
operation of the circuit again. Does the loader control valve and check
the circuit work correctly? for worn or damaged parts.
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Problem in the Steering Circuit YES NO
See Hydraulic control compo- Action Repair the component as necessary.
nents - Troubleshooting (41.200) See Hydraulic control compo-
nents - Pressure test (41.200). Do
and check the steering circuit. Is the
steering circuit good? the Steering Pump Limit Pressure
Test and Adjustment
Problem in the Ride Control YES NO
Lift arms rapidly and continuously Action See the Ride Control Test Proce-
sink towards the ground. Check the manual bleed valve for the dure in Ride control solenoid valve
ride control accumulator to be sure block - Testing (35.701).
that it is closed.
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Index

Auxiliary hydraulic valves and lines - Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Optional control valve - Exploded view 3rd Spool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Optional control valve - Exploded view 3rd and 4th Spool Pilot Caps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Optional control valve - Exploded view 4th Spool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
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Front loader arm hydraulic system - 701
1021F
1121F
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Contents
FUNCTIONAL DATA
Ride control solenoid valve block

Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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Hydraulic systems - Front loader arm hydraulic system
Ride control solenoid valve block - Exploded view
RCPH11WHL040FAH 1
Ride Control Valve Configuration
1. Ride control valve 2. Relief valve

3. Solenoid 4. Bleed screw
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Index

Ride control solenoid valve block - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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PRINTED IN U.S.A.
47392461 19/06/2012
EN
SERVICE MANUAL
Steering
1021F
1121F
47392461 19/06/2012
41
Contents
Steering - 41
Auxiliary steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.910

1021F , 1121F
47392461 19/06/2012
41
Steering - 41
Auxiliary steering - 910
1021F
1121F
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41.910 / 1
Contents
Steering - 41
DIAGNOSTIC
Motor
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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Steering - Auxiliary steering
Motor - Testing
Turn the key switch OFF. The resistance should be less than The resistance is greater than 10
Check 10 Ω. Ω, there is a problem in the chassis
Measure the resistance from the ground circuit to the Steering Motor.
Secondary Steering Motor terminal Verify all connections are secure and
242F to chassis ground. free of corrosion, abrasion and incor-
rect attachment. Repair as required.
Turn the key swicth OFF. Disconnect The voltage should be approximately The voltage is less than 10 V. There
wire 51_B W-1.0 from the Secondary 24 V. is a problem in the Secondary Steer-
Steering Motor Relay. Fabricate a Action ing Motor Relay. Refer to Auxiliary
jumper that will reach from terminal Temporarily replace the Secondary steering relay - Testing (55.047)
SSS to the positive battery terminal. Starting Motor and retest.
Place one end of the wire to terminal
SSS .
Check
Place the other end of the wire to the
positive battery terminal. Measure
the voltage across the Secondary
Steering Motor.
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RCPH11WHL003HAL 1
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41.910 / 4
(1) Switched Battery, 24 V (11) Secondary Starting Solenoid

39.3 Ω 20 °C (68 °F)
(2) Switched Battery, 24 V (12) Secondary Steering Module
(3) Emerg Strg ECA-F4 (13) Secondary Steering Pressure Switch
7.5 A Normally Open contact closes at 241 kPa
(35 psi)
Pin A — Normally Open Contact
Pin B — Switch Common
Pin C — Normally Closed Contact
(4) Emerg Strg ECA-F17 (14) GND_SSCHAS, Chassis Connection Near
7.5 A Motor/Pump Ground
(5) 24 V from Diode Module pin C (15) GND_SSMOD
Chassis Connection Near SS Module
Ground
(6) Diode Module (16) Secondary Steering Module Chassis
Ground
(7) Instrument Cluster connector 2, pin 11 (17) CAB_T/ TRANS connector
AIC_2
(8) Diode Module, (18) Trans/ Sec Steer connector
Flyback Protection
(9) Secondary Steering Motor Power Relay (19) Unswitched 24 V from Master Disconnect
Switch, Starter Motor terminal.
(10) Secondary Steering Motor (20) Secondary Steering Module
24 V from Relay Module PRM_B,
SEC STRG Fuse, F2. 20 A
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Index
Steering - 41

Motor - Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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PRINTED IN U.S.A.
47392461 19/06/2012
EN
SERVICE MANUAL
Wheels
1021F
1121F
47392461 19/06/2012
44
Contents
Wheels - 44
Front wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.511

1021F , 1121F
47392461 19/06/2012
44
Wheels - 44
Front wheels - 511
1021F
1121F
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44.511 / 1
Contents
Wheels - 44
Front wheels - 511
SERVICE
Front wheels
Service instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
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Wheels - Front wheels
Front wheels - Service instruction

1. The wheel bolts must be tightened after every 20
hours of operation until the wheel bolts stay tight:
A. If the machine is new.
B. If a wheel has been removed and installed.
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Wheels - Front wheels
Front wheels - Install

1. Make sure the mounting surfaces of the rim and axle
flange are clean and free of dirt and grease.
2. Install the wheel, hardened washers and wheel bolts.
3. Use a hand wrench (not an impact) to tighten the
wheel bolts to pull the wheel against the planetary
housing. DO NOT use an impact wrench to tighten
the wheel bolts.
Stud mounted wheels

Machines are equipped with stud mounted wheels. Wheel
studs offer greater strength due to an increase in clamping
force and resistance to loosening.
4. Tighten the wheel bolts to 278 N·m (205.0 lb ft), then
tighten to a final torque of 640 - 720 N·m (472.0 -
531.0 lb ft), using the same sequence.
RCPH11WHL073AAH 1
RCPH11WHL202AAH 2
Wheel bolt torque sequence
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Index
Wheels - 44
Front wheels - 511

Front wheels - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Front wheels - Service instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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PRINTED IN U.S.A.
47392461 19/06/2012
EN
SERVICE MANUAL
Cab climate control
1021F
1121F
47392461 19/06/2012
50
Contents
Cab climate control - 50
Air conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50.200

1021F , 1121F
47392461 19/06/2012
50
Air conditioning - 200
1021F
1121F
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Contents
TECHNICAL DATA
Air conditioning
FUNCTIONAL DATA
Air conditioning
Dynamic description - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
SERVICE
Air conditioning
Service instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Pressure test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Air-conditioning evaporator
Visual inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
DIAGNOSTIC
Air conditioning
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
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Cab climate control - Air conditioning
Air conditioning - General specification
BC04D002 1
NOTE: The pressure temperature chart is based on the following conditions:
(1) Engine operating at 1500 rpm. No engine load.

(2) Fan speed control in maximum position (full clockwise) and all louvers open.
(3) Cab temperature control set to maximum cooling (full counterclockwise).
(4) A/C switch ON. Both cab doors open.
(5) All panels and access doors installed and closed.
(6) Cab filters clean and installed. Heater valve at engine closed.
(7) Measurements taken 15 minutes after start-up.
Refrigerant charge 1600 g ( 3.5 lb)
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Air conditioning - Dynamic description - Troubleshooting

PROBLEM: NO COOLING
476l7 1
see pressure - temperature chart on Air conditioning - General specification (50.200)
Indication of No Refrigerant or Low Refrigerant Charge:
1. Leak test the system, see Air condition-

ing - Visual inspection (50.200). It may be
necessary to add refrigerant. See Air con-
ditioning - Charging (50.200).
2. Evacuate and reclaim remaining refrigerant
from system. See Air conditioning - Dis-
charging (50.200).
A. Discharge air from evaporator warm. 3. Repair system leaks as needed. Follow the
B. Compressor does not run, or cycles off Yes given repair procedure.
rapidly after start-up. (A/C warning light in 4. Check level of oil in compressor - possible
cab should illuminate). for compressor to have an oil loss.
5. Remove air and moisture from the system
Air conditioning - Evacuate (50.200).
6. Charge system with new refrigerant. See
Air conditioning - Charging (50.200).
7. Continue performance test for other possi-
ble problems.
476l7_745 2
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Indication of Large Quantity of Air in System:
1. Evacuate and reclaim refrigerant from sys-

tem. See Air conditioning - Discharging
(50.200).
Discharge air from evaporator warm Yes
2. Remove air and moisture from the system.
See Air conditioning - Evacuate (50.200).
Condenser Malfunctioning - Indications:
1. Check for loose or worn compressor or en-

gine fan belt and proper condenser fan op-
eration.
2. Check to see that condenser is clean and
unobstructed and that the fins are straight.
3. Check system for too much refrigerant.
Evacuate, reclaim and recharge refrigerant
until gauge pressure is normal. See Air
conditioning - Discharging (50.200).
4. Remove and check condenser for restric-
tions caused by oil or reduced heat transfer.
A. Liquid line (between evaporator and con- A. Remove refrigerant from the system.
denser) is very hot. See Air conditioning - Discharging
B. Discharge air from evaporator warm. (50.200).
B. Use compressed air to remove oil
from condenser.
C. Replace receiver-drier Air-con-
ditioning condenser - Remove
(50.200).
D. Remove moisture Air conditioning
- Evacuate (50.200)and charge the
system. See Air conditioning -
Charging (50.200).
5. Continue the performance test for other
possible problems.
Expansion Valve Malfunctioning - Indications:
A. Discharge air from heater/evaporator

warm. See Expansion valve - Remove (50.200) and
B. Much condensation on suction hose at replace the expansion valve.
compressor.
C. Much condensation on evaporator outlet.
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Refrigerant Contamination:
1. See table below and check stable satura-

tion pressures at given temperature to de-
termine if contamination exists.
A. Measure pressure from gauge on
reclamation unit.
B. Measure temperature from refriger-
Refrigerant Contamination ant in reclamation tank. If refriger-
ant has been in reclamation unit for
some time, use ambient temperature.
The numbers in the table represent
the boiling point for HFC-134a.
C. Pressure readings below range given
in chart indicate contaminated refrig-
erant.
NOTICE: Do not use contaminated refrigerant or mix with uncontaminated refrigerant. Dispose of in accordance with
all applicable laws and local procedure.
HFC-134a Stable Saturation Pressure/ Temperature Chart

Temperature °F (° C) Pressure PSIG (Bar)
50 (10) 45 (3.1)
55 (13) 51 (3.5)
60 (16) 57 (3.9)
65 (18) 64 (4.4)
70 (21) 71 (4.9)
75 (24) 78 (5.4)
80 (27) 88 (6.1)
85 (29) 95 (6.6)
90 (32) 104 (7.2)
95 (35) 114 (7.9)
100 (38) 124 (8.6)
102 (39) 129 (8.9)
104 (40) 133 (9.2)
106 (41) 138 (9.5)
108 (42) 142 (9.8)
110 (43) 147 (10.1)
112 (44) 152 (10.5)
114 (46) 157 (10.8)
116 (47) 162 (11.2)
118 (48) 167 (11.5)
120 (49) 172 (11.9)
PROBLEM: NOT ENOUGH COOLING
476l7_746 3
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Air in the System - Indications:
1. Test system for leaks. See Air condition-

ing - Visual inspection (50.200). Possi-
ble leak has let air enter; check compressor
seal carefully.
2. Discharge system of refrigerant. See Air
A. Suction line warm to your hand. conditioning - Discharging (50.200).
B. Discharge air from heater/evaporator only a 3. Repair system leak as necessary.
little cool.
4. Check compressor oil level.
476l7_747 4
Not Enough Refrigerant - Indications:
1. Leak test system - system has a loss of refrigerant.

A. If leak is found, go to Step 2.
B. If no leak is found, go to Step 6.
2. Discharge refrigerant from system. See Air conditioning - Discharg-
ing (50.200).
A. Discharge air from evapora-
tor cool or warm - not cold. 3. Repair system leaks as needed.
4. Check oil level in compressor - It is possible for compressor to lose oil.
5. Remove air and moisture from the system Air conditioning - Evacu-
ate (50.200).
6. Charge system with new refrigerant. See Air conditioning - Charging
(50.200).
NOTE: Normally, the system will lose 1/2 - 1 ounce ( 14.7 - 29.5 grams ) of refrigerant between seasons.
High Side Restriction - Indications:
1. Discharge refrigerant from system-restric-

tion in receiver-drier or liquid line must be
A. Discharge air from heater/evaporator only a removed.
little cool.
2. Remove and replace part with restriction.
B. Condensation or frost on receiver-drier.
C. Liquid line to receiver-drier cool, with frost See Air conditioning - Evacuate (50.200).
or condensation.
47392461 19/06/2012
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NOTE: The frost will form downstream from or at the point of the restriction
Expansion Valve Not Operating - Indications:
1. Expansion valve outlet with condensation

or frost is an indication of a restriction in the
expansion valve. Replace expansion valve.
A. Discharge air from evaporator warm or cool See Expansion valve - Remove (50.200).
- not cold.
2. Inlet end of expansion valve is warm (not
B. Condensation or frost on expansion valve hot), indicating expansion valve is not com-
outlet. pletely open. If the valve is stuck closed,
C. Inlet end of expansion valve is warm. there will be little or no flow of refrigerant
through the valve. Replace expansion
valve. See Expansion valve - Remove
(50.200).
476l7_748 5
see the pressure - temperature chart on Air conditioning - General specification (50.200).
Compressor Turning But Not Pumping Properly - Indications:
1. Discharge refrigerant from system. See Air

2. Remove the compressor from the machine.
See Air-conditioning compressor - Re-
move (50.200).
A. System is fully charged.
3. Remove and replace compressor because
B. Cool discharge air from evaporator. there is indication of internal leak in com-
pressor.
4. Replace compressor.
5. Charge the system with refrigerant. See Air
conditioning - Charging (50.200).
Expansion Valve Stuck Open
Expansion Valve Stuck Open 1. Replace expansion valve. See Expansion

valve - Remove (50.200).
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476l7_749 6
Condenser Not Operating - Indications:
1. Check for loose or worn compressor belt

and proper condenser fan operation.
2. Check to see that condenser is clean and
that the fins are straight.
3. Check system for too much refrigerant.
A. Remove refrigerant from system un-
til gauge pressure is below normal.
See Air conditioning - Discharging
(50.200).
B. Add refrigerant until gauge pressures
are normal. See Air conditioning -
Charging (50.200).
A. Liquid line very hot. C. If there is still a problem, do step 4.
B. Discharge air from evaporator warm. 4. Remove and inspect condenser for restric-
tions caused by oil or reduced heat transfer.
A. Discharge refrigerant from system.
See Air conditioning - Discharging
(50.200).
B. Use compressed air to remove oil
from condenser.
C. Replace receiver-drier. See Air-con-
ditioning condenser - Remove
(50.200).
D. Charge system with new refrigerant.
See Air conditioning - Charging
(50.200)
Air in the System - Indications:
1. Discharge refrigerant from system. See Air

2. Replace receiver-drier Air-conditioning
Warm discharge air from evaporator. condenser - Remove (50.200).
PROBLEM: INTERMITTENT COOLING
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476l7_750 7
Moisture in the System - Indications:
1. Discharge system of refrigerant. If too

much moisture enters the orifice of the ex-
pansion valve, the freezing of this moisture
can stop refrigerant flow. See Air condi-
tioning - Discharging (50.200).
Cooling is acceptable during cool part of day but 2. Replace receiver-drier. The moisture re-
not acceptable during hot part of day. moving material could be full to capacity
with moisture. See Air-conditioning evap-
orator - Remove (50.200).
NOTE: The time needed to remove a large amount of moisture will be two to three hours minimum.
PROBLEM: NOISE IN SYSTEM
476l7_751 8
Too Much Refrigerant in System - Indications:
1. Remove refrigerant from system until

gauge readings are below normal. See Air
A. Cool discharge air from heater/evaporator. conditioning - Discharging (50.200).
B. Compressor makes noise. 2. Add new refrigerant until gauge readings
are normal. See Air conditioning - Charg-
ing (50.200).
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Air conditioning - Service instruction

DANGER
Avoid injury!
Observe ALL precautions listed below when servicing the air-conditioning system and handling re-
frigerant.
D0043A
Refrigerant HFC-134a is the most stable, and easiest to work with of the refrigerants now used in air conditioner
systems. Refrigerant HFC-134a does not contain any chlorofluorocarbons (CFC's) which are harmful to the earth's
ozone layer.
Safety procedures must be followed when working with Refrigerant HFC-134a to prevent possible personal injury.
ATTENTION: Only authorized technicians certified by an approved training and certification organization may service
or repair motor vehicle or mobile air conditioning systems. It is mandatory that all refrigerant must be RECOVERED
and RECYCLED when removed from a system during servicing.
1. Always wear safety goggles when doing any service
work near an air conditioner system. Liquid refrig-
erant getting into the eyes can cause serious injury.
Do the following if you get refrigerant near or in your
eyes:
A. Flush your eyes with water for 15 minutes.
B. See a physician immediately.
2. A drop of liquid refrigerant on your skin may cause
frostbite. Open the fittings carefully and slowly when
it is necessary to service the air conditioner system.
Your skin must be treated for frostbite or a physician
must be seen if you get refrigerant on your skin.
3. Keep refrigerant containers in the correct upright po-
sition. Always keep refrigerant containers away from
heat and sunlight. The pressure in a container will in-
crease with heat.
4. Always reclaim refrigerant from the system, if you are
going to weld or steam clean near the air conditioner
system.
5. Always check the temperature and pressure of the
air conditioner system before reclaiming refrigerant
and when you test the system.
6. Dangerous gas can form when refrigerant comes in
contact with an open flame. Never permit fumes to
be inhaled.
7. Never leak test with compressed air or flame testers.
Tests have indicated that compressed mixtures of
HFC-134a and air can form a combustible gas.
8. Always reclaim refrigerant from the system before
removing any air conditioning component.
47392461 19/06/2012
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Air conditioning - Pressure test

NOTICE: Refer to Air conditioning - Service instruction (50.200)
1. Manifold Gauge Set
NOTE: The gauge set is not accurate enough to optimize
an existing charge of HFC-134a. The best use of the gauge
set is to determine whether undercharge or overcharge ex-
ists, and then evacuate, reclaim and recharge system with
the recommended quantity (charge) of HFC-134a.
2. The manifold gauge set is the most important tool
used to service the air conditioning system. The
manifold gauge set is used to measure the high and
low pressures of the system, as a tool to troubleshoot
for correct refrigerant charge quantity, system diag-
nosis, and operating efficiency. The manifold gauge
set can read both the high (discharge) and low (suc-
tion) sides at the same time, since pressure must be
compared in order to make a diagnosis of system op-
eration.
3. LOW PRESSURE GAUGE - The low pressure gauge
is a compound gauge. It is best used to judge evac-
uation effectiveness. A vacuum reading indicates a
system malfunction. For this reason, it is necessary
to use a compound gauge that will indicate both pres-
sure and vacuum.
4. During normal operation the low pressure gauge
must always indicate from 10 - 35 psi ( 0.7 - 2.4 bar)
after the system has run 10 - 15 minutes.
5. HIGH PRESSURE GAUGE - The high pressure
gauge is used to indicate pressures in the high side
of the system. The gauge must indicate from 0 - 400
psi ( 0 - 27.6 bar) minimum.
6. During normal operation, the high pressure gauge
will normally indicate from 120 - 310 psi ( 8.3 - 21.4
bar). See pressure-temperature chart on Air condi-
tioning - General specification (50.200).
7. Pressure Test Connection
Connect the manifold gauge set into the air condition-
ing system as shown. Make sure that both valves in
the manifold gauge set are closed.
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Air-conditioning evaporator - Visual inspection

WARNING
Explosion hazard!
Air-conditioning refrigerant boils at -12 °C (10 °F)!
-NEVER expose any part of the air-conditioning system to a direct flame or excessive heat.
-NEVER disconnect or disassemble any part of the air-conditioning system.
Discharging refrigerant gas into the atmosphere is illegal in many countries.
W0340A
WARNING
Avoid injury!
Avoid breathing air-conditioning refrigerant, lubricant vapor or mist. If accidental system discharge
occurs, ventilate the work area before resuming service.
W1000B
1. Evaporator/Heater Core
1. Refer to Air-conditioning evaporator - Remove
(50.200).
2. Inspect the fins on the evaporator/heater core. All
the fins that have bends or damage must be made
straight.
3. Inspect the evaporator/heater core for restrictions.
If the core is dry, use compressed air or a brush and
vacuum cleaner. If the core is wet or filled with mud,
flush the core with water using a hose without pres-
sure. Make sure the water drains freely from the
evaporator/heater core. DO NOT USE STEAM.
2. Evaporator/Heater Core Sealing
1. Refer to Air-conditioning evaporator - Remove
(50.200)
2. Make sure seals are in place so blower will pull
air only through the evaporator/heater core and not
around the evaporator/heater core.
3. Filters
1. Make sure the filters are clean.
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Air conditioning - Troubleshooting

Problem Possible Cause Correction
System Makes Noise MECHANICAL See Mechanical Compressor Check Heat-
ing, Ventilation, and Air-Condition-
ing (HVAC) control system - Testing
(55.050).
INTERNAL SYSTEM PROBLEMS See Pressure Testing, Air conditioning -
Pressure test (50.200).
Not Enough Cooling HEATER Make sure the heater control is OFF and
that there is no coolant flow through the
heater core.
SEAL Make sure the sealing material is correctly
in place.
MECHANICAL See Mechanical Compressor Check Air
conditioning - Pressure test (50.200).
Also see Air conditioning - Abnormal
noise (50.200), Air conditioning - Visual
inspection (50.200).
ELECTRICAL Test the electrical system Heating, Ventila-
tion, and Air-Conditioning (HVAC) con-
trol system - Testing (55.050).
REFRIGERANT See Cab Temperature Check Temperature
sensor - Testing (55.050).
INTERNAL SYSTEM PROBLEM See Pressure Testing, Air conditioning -
Erratic Cooling MECHANICAL See Mechanical Compressor Check Air
trol system - Testing (55.050)
Air conditioning - Troubleshooting

Not Enough Cooling HEATER Make sure the heater control is OFF and
that there is no coolant flow through the
heater core.
SEAL Make sure the sealing material is correctly
in place.
MECHANICAL See Mechanical Compressor Check Air
trol system - Testing (55.050).
REFRIGERANT See Cab Temperature Check Temperature
sensor - Testing (55.050).
INTERNAL SYSTEM PROBLEM See Pressure Testing, Air conditioning -
47392461 19/06/2012
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Erratic Cooling MECHANICAL See Mechanical Compressor Check Air
trol system - Testing (55.050)
System Makes Noise MECHANICAL See Mechanical Compressor Check Heat-
ing, Ventilation, and Air-Condition-
ing (HVAC) control system - Testing
(55.050).
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Index

Air conditioning - Dynamic description - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Air conditioning - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Air conditioning - Pressure test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Air conditioning - Service instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Air conditioning - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Air conditioning - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Air-conditioning evaporator - Visual inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
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PRINTED IN U.S.A.
47392461 19/06/2012
EN
SERVICE MANUAL
Electrical systems
1021F
1121F
47392461 19/06/2012
55
Contents
Electrical systems - 55
Electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.000

1021F , 1121F
Fuel tank system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.011

1021F , 1121F
Engine cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.012

1021F , 1121F
Engine control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.015

1021F , 1121F
Transmission control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.024

1021F , 1121F
Service brake electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.030

1021F , 1121F
Parking brake electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.031

1021F , 1121F
Hydraulic system control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.036

1021F , 1121F
Steering control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.047

1021F , 1121F
Heating, Ventilation, and Air-Conditioning (HVAC) control system . . . . . . . . . . . . . . . . . . . . . . . . . 55.050

1021F , 1121F
Cab Heating, Ventilation, and Air-Conditioning (HVAC) controls . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.051

1021F , 1121F
Harnesses and connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.100

1021F , 1121F
Engine starting system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.201

1021F , 1121F
Cold start aid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.202

1021F , 1121F
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55
Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.301
1021F , 1121F
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.302
1021F , 1121F
External lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.404

1021F , 1121F
External lighting switches and relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.405

1021F , 1121F
Warning indicators, alarms, and instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.408

1021F , 1121F
Loader arm and bucket control system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.415

1021F , 1121F
Cab/Platform harnesses and connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.510

1021F , 1121F
Cab controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.512

1021F , 1121F
Cab lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.514

1021F , 1121F
Wiper/Washer system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.518

1021F , 1121F
Cab brake controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.519

1021F , 1121F
Cab controls (Lift arm, Boom, Dipper, Bucket) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.524

1021F , 1121F
FAULT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.DTC

1021F , 1121F
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Electrical system - 000
1021F
1121F
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Contents
TECHNICAL DATA
Electrical system
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Electrical systems - Electrical system
Electrical system - General specification

Electrical System Two 12 volt batteries connected in series, negative
ground
System Voltage 24 volts
Batteries
Specifications are the same for production battery and
replacement battery.
Group Size 31
Reserve Capacity 170 minutes
Cold Cranking Capacity At - 17 °C ( 0 °F) for 60 Seconds 700 amperes
At 6.0 Volts
Load of Capacity (Load) Test 400 amperes
Alternator 24 volt, 65 amperes

Voltage Regulator Solid State, Not Adjustable
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Index

Electrical system - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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Fuel tank system - 011
1021F
1121F
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Contents
DIAGNOSTIC
Fuel level sensor

Testing - Fuel level sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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Electrical systems - Fuel tank system
Fuel level sensor - Testing - Fuel level sender

NOTE: Fuel level sender is unique for the 1021F.
Turn the ignition key switch OFF. Re- The resistance should be between If the resistance is outside of the ex-
move connector RFL 23 for model 33 - 240 Ω. pected results replace the fuel level
1021F , or connectors RFL \ RFLG sender.
for models 521F, 621F, 721F, 821F,
921F, and 1121F .
Check
Measure the resistance across the
fuel level sender.
Measure the resistance from con- The resistance should be less than If the resistance is greater than 10 Ω
nector RFL 23 to chassis ground 10 Ω. or an open circuit is indicated, check
for model 1021F . Measure the re- the ground circuits for corrosion or
sistance from connector RFLG to damage. Repair or replace as nec-
ground for models 521F, 621F, 721F, essary.
821F, 921F, and 1121F.
Turn the ignition key switch ON. Re- The resistance should be approxi- If the resistance does not match the
move connector RFL 23 for model mately 20,000 Ω. expected result, check connectors
1021F , or connector RFL for models CAB E \ ENG pin 1 for corrosion or
521F, 621F, 721F, 821F, 921F, and damage. Repair or replace wiring or
1121F. faulty AIC module as necessary.
Check
Measure the resistance from RFL 23
pin A or RFL pin 1 to ground.
RCIL11WHL049FAK 1
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Electrical systems - Fuel tank system
(1) Fuel level sender (33–240 ohms) — 521F, (3) Advanced Instrument Cluster — analog
621F, 721F, 821F, 921F, and 1121F. input
(2) Fuel level sender (33–240 ohms) — (4) Chassis ground — on engine block near
1021F oil filter.
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Index

Fuel level sensor - Testing - Fuel level sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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Engine cooling system - 012
1021F
1121F
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Contents
DIAGNOSTIC
Cooling fan reversing solenoid

Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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Electrical systems - Engine cooling system
Cooling fan reversing solenoid - Testing

Turn the ignition key switch OFF. Re- The resistance should measure 36 - If the resistance does not meet the
move connector YFR from the fan re- 42 ohms at 20 °C (68.0 °F). expected values replace the sole-
versing solenoid. noid.
Check
Measure the resistance on the sole-
noid across pin 1 and 2.
Measure the resistance on connec- The resistance should be less than If the resistance does not match the
tor YFR pin 2 to chassis ground. 10 Ω. expected result or an open circuit is
indicated, check connector and wire
(0 BB Bk-1.0) for corrosion or dam-
age. Repair or replace as necessary.
Turn the ignition switch ON, and re- The voltage should be approximately If the voltage does not meet the ex-
move connector YFR. Hold the fan 24 volts. pected result, check wire 52A back
reversing switch ON. through connectors ENG and CAB E
Check to the fan reversing relay K4. Check
Measure the voltage on connector for 24 V supply from fan reversing re-
YFR pin 1. lay terminal 87.
RCIL11WHL048FAK 1
(1) 24 Volt switched battery to Pin Eng / Fan (6) Pin engage switch (option)
RVSR fuse ECA-F7, 7.5 amp
(2) Advanced Instrument Cluster (7) SPL BCK LT GD2 Back light ground
(3) Fan control switch (option) (8) Fan reversing solenoid ( 39.3 Ω at 20 °C
(68.0 °F) )
(4) Fan RVSR K4 relay (option) (9) Fan PWM solenoid ( 29.3 Ω at 20 °C (68.0
°F) )
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Electrical systems - Engine cooling system
(5) SPL BCK LGT2 Back light power (10) Heat load valve solenoid ( 39.3 Ω at 20
°C (68.0 °F) )
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Index

Cooling fan reversing solenoid - Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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Engine control system - 015
1021F
1121F
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Contents
DIAGNOSTIC
Engine control unit

Testing - Engine controller EDC7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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Electrical systems - Engine control system
Engine control unit - Testing - Engine controller EDC7

Turn the ignition key switch and mas- The voltage should be approximately If the voltage does not match the ex-
ter disconnect OFF. Remove con- 24 V. pected result check fuse F2 30 A on
nector EDC7 from the engine con- power relay module D.
troller and turn master disconnect
ON..
Check
Measure voltage on connector
EDC7 from pins 2, 3, 8, and 9 to
chassis ground.
Measure the resistance on connec- The resistance should be less than If the resistance does not match the
tor EDC7 from pins 5, 6, 10, and 11 10 Ω. expected results check the wiring
to chassis ground. and connectors for corrosion or
damage. Repair or replace as nec-
essary.
Use diagnostic service tool for ad-
ditional tests on EDC7. See fault
codes for troubleshooting specific
items.
RCIL11WHL050EAK 1
(1) Engine controller EDC7 (3) Chassis ground, on engine block near
starter.
(2) 24 Volt power supply from power relay
module D, fuse F2 — 30 amp.
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Index

Engine control unit - Testing - Engine controller EDC7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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Transmission control system - 024
1021F
1121F
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Contents
TECHNICAL DATA
Transmission control system

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Electrical systems - Transmission control system
Transmission control system - General specification

Torque Converter 3521 ohms
Transmission Filter Restriction Switch with 510 ohms
Internal Resistor (Normally Open)
Closing Setpoint 5.2 - 7.2 bar (75 - 104 psi)
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Index

Transmission control system - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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Service brake electrical system - 030
1021F
1121F
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Contents
DIAGNOSTIC
Brake low pressure switch

Testing - Redundant Brake Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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Electrical systems - Service brake electrical system
Brake low pressure switch - Testing - Redundant Brake Pressure

Switch
Turn the key switch OFF. Fabricate The low pressure diagnostic code The diagnostic code did not become
a jumper wire that will reach from should become active. active. There is a problem in with
the Instrument Cluster to chassis the Instrument Cluster. Temporarily
ground. Turn the key switch ON. replace the Instrument Cluster and
Check retest.
Connect one end of the jumper wire
to a clean chassis ground connec-
tion point. Connect the other end to
pin 4 on Instrument Cluster connec-
tor 2.
Turn the key switch OFF. Discon- The resistance should be less than The resistance is greater than 10
nect both Redundant Brake Pres- 10 Ω. Ω, there is problem in the chassis
sure Switches. ground circuit to the Brake Pressure
Check Switch. Verify all connections are se-
Measure the resistance from the cure and free of corrosion, abrasion
first Brake Pressure Switch pin B and incorrect attachment. Repair as
to chassis ground. Measure the required.
resistance from the second Brake
Pressure Switch pin B to chassis
ground. Wiggle the harness during
measurement to reveal an intermit-
tent condition.
Turn the key switch OFF. Discon- The resistance should be greater The resistance is less than 10 Ω,
nect both Redundant Brake Pres- than 20,000 Ω. there is problem with the Brake Pres-
sure Switches. sure Switch. Temporarily replace the
Check Brake Pressure Switch and retest.
first Brake Pressure Switch pin A
to pin B. Measure the resistance
across the second Brake Pressure
Switch pin A to pin B.
Turn the key switch OFF. Discon- The low pressure diagnostic code The diagnostic code did not become
nect both Redundant Brake Pres- should become active. active. There is a problem in with
sure Switches. Fabricate a jumper the wiring from the sensor to the In-
wire that will reach from the Brake strument Cluster. Verify all connec-
Pressure Switch to chassis ground. tions are secure and free of corro-
Turn the key switch ON. sion, abrasion and incorrect attach-
Check ment. Repair as required.
pin A of the first Redundant Pressure
Switch.
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Electrical systems - Service brake electrical system

Connect one end of the jumper wire The low pressure diagnostic code The diagnostic code did not become
to a clean chassis ground connec- should become active. active. There is a problem in with the
tion point. Connect the other end to wiring to the sensor to the Instrument
pin A of the second Redundant Pres- Cluster. Verify all connections are
sure Switch. secure and free of corrosion, abra-
sion and incorrect attachment. Re-
pair as required.
Turn the key switch OFF. Discon- The resistance should be greater The resistance measurement did not
nect both Redundant Brake Pres- than 20000 Ω while the pressure is change. There is a problem with
sure Switches. less than 6205 kPa (900 psi) ± 10%. the pressure switch. Temporarily re-
Check The resistance should be less than place the switch and retest.
Connect the suspect brake pressure 10 Ω while the pressure is greater
switch to a hydraulic hand pump. than 6205 kPa (900 psi) ± 10%.
switch. Pump up the hydraulic pres-
sure to 6205 kPa (900 psi).
RCPH11WHL021FAL 1
(1) Advanced Instrument Cluster connector (4) GND_TRANS

2, AIC2
(2) Redundant Brake Pressure Switch (5) CAB_T/ TRANS connector
Normally Open, closes at 6250 kPa (900
psi)
(3) Redundant Brake Pressure Switch
Normally Open, closes at 6250 kPa (900
psi)
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Index

Brake low pressure switch - Testing - Redundant Brake Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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Parking brake electrical system - 031
1021F
1121F
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Contents
DIAGNOSTIC
Brake control solenoids

Testing - Parking Brake Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Control relay - Testing - Parking Brake Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Pressure sensor
Testing - Parking Brake Warning Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
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Electrical systems - Parking brake electrical system
Brake control solenoids - Testing - Parking Brake Solenoid

Check 10 Ω. Ω. There is a problem in the wiring
Measure the resistance from the from the Parking Brake Relay to the
Parking Brake Relay K5, terminal 87 Parking Brake Solenoid. Verify all
to the Parking Brake Solenoid, pin connections are secure and free of
1. Measure the resistance from the corrosion, abrasion and incorrect at-
Parking Brake Relay K5, terminal 87 tachment. Repair as required.
to TEL connector, pin E.
Measure the resistance from the The resistance should be less than The resistance is greater than 10 Ω.
Parking Brake Solenoid pin 2 to 10 Ω. There is a problem in the wiring from
chassis ground. the Parking Brake Solenoid to chas-
sis ground. Verify all connections are
secure and free of corrosion, abra-
sion and incorrect attachment. Re-
pair as required.
Fabricate a jumper wire that will The Parking Brake Solenoid should The solenoid did not actuate, tem-
reach from the Parking Brake So- actuate while the jumper is installed. porarily replace the solenoid and
lenoid, pin 1 to the positive battery retest.
terminal.
Check
to the positive battery terminal. Con-
nect the other end of the jumper wire
to the Parking Brake Solenoid, pin 1.
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RCPH11WHL011GAL 1
(1) Switched Battery, 24 V (7) Parking brake Solenoid

(2) Park Brake ECA-F6 (8) Brake Warning Pressure Switch
5A Normally Closed, switch open at 11032
kPa (1600 psi)
(3) Advanced Instrument Cluster (9) Backlight power and ground source
AIC connector 2
(4) Advanced Instrument Cluster (10) To TEL connector pin E
AIC connector 1
(5) Parking Brake Switch on pedestal (11) GND_ENG3, chassis ground connection
(6) Parking Brake Relay, K5 (12) CAB_B/ BTM_C connector
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Brake control solenoids Control relay - Testing - Parking Brake

Relay
Turn the key switch to the OFF. The resistance should be less than The resistance is greater than 10
Check 10 Ω. Ω. There is a problem in the signal
Measure the resistance from the Ad- wire from the Instrument Cluster to
vanced Instrument Cluster connec- the Parking Brake Relay. Verify all
tor 1, pin 14 to the Parking Brake Re- connections are secure and free of
lay pin 85. corrosion, abrasion and incorrect at-
tachment. Repair as required.
Turn the key switch to the ON. The voltage should be approximately The voltage is less than 10 volts
Check 24 volts. there is a problem with the battery
Measure the voltage from the Park- supply voltage to the Parking Brake
ing Brake Relay K5, terminal 86 to Solenoid. Check fuse ECA-F6. Ver-
chassis ground. Measure the volt- ify all connections are secure and
age from the Parking Brake Relay free of corrosion, abrasion and incor-
K5, terminal 30 to chassis ground rect attachment. Repair as required.
Fabricate a jumper wire that will The voltage should be approximately The voltage is less than 10 V. there
reach from the Parking Brake Relay, 24 V. is a problem with the Parking Brake
terminal 85 to chassis ground. Turn Relay. Temporarily replace the relay
the key switch OFF. Disconnect the and retest.
wire from terminal 87. Turn the key
switch ON.
Check
tion point. Place the other end of
the jumper wire on the Parking Brake
Relay, terminal 87. Measure the
voltage from terminal 87 to chassis
ground.
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RCPH11WHL011GAL 1

kPa (1600 psi)
AIC connector 2
AIC connector 1
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Pressure sensor - Testing - Parking Brake Warning Pressure Switch

Check 10 Ω. Ω. There is a problem in the Brake
Measure the resistance from the Warning Pressure Switch chassis
Brake Warning Pressure Switch pin ground connection. Verify all con-
2 to chassis ground. nections are secure and free of
corrosion, abrasion and incorrect
attachment. Repair as required.
Check 10 Ω. Ω. There is a problem in the Brake
Measure the resistance from the Warning Pressure signal wire to
Brake Warning Pressure Switch pin the Instrument Cluster. Verify all
1 to the Instrument Cluster connec- connections are secure and free of
tor 2, pin 5. corrosion, abrasion and incorrect
Turn the key switch ON. The High Brake Pressure Warning The diagnostic code does not be-
Check diagnostic code should become ac- come active. Temporarily replace
Disconnect the Brake Warning Pres- tive. the Instrument Cluster and retest.
sure Switch from the wire harness. Action
Temporarily replace the Brake Warn-
ing Pressure Switch and retest.
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RCPH11WHL011GAL 1

kPa (1600 psi)
AIC connector 2
AIC connector 1
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Index

Brake control solenoids - Testing - Parking Brake Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Brake control solenoids Control relay - Testing - Parking Brake Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Pressure sensor - Testing - Parking Brake Warning Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
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Hydraulic system control - 036
1021F
1121F
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Contents
TECHNICAL DATA
Hydraulic fluid temperature control sensor

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Electrical systems - Hydraulic system control
Hydraulic fluid temperature control sensor - General specification

Hydraulic Temperature Sender 20 °C ( 68 °F) 3521 ohms
Hydraulic Temperature Sender (Yellow Line) 105 °C ( 221 °F) 154 ohms
Hydraulic Temperature Sender (Red Line) 110 °C ( 230 °F) 133.9 ohms
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Index

Hydraulic fluid temperature control sensor - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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Steering control system - 047
1021F
1121F
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Contents
DIAGNOSTIC
Auxiliary steering pressure switch

Testing - Secondary Steering Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Auxiliary steering solenoid
Testing - Secondary Steering Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Auxiliary steering relay
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
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Electrical systems - Steering control system
Auxiliary steering pressure switch - Testing - Secondary Steering

Pressure Switch
Turn the key switch OFF. The resistance should be less than The resistance is greater than 10 Ω,
Check 10 Ω. there is a problem in the chassis
Measure the resistance from the ground connection to the pressure
Secondary Steering Pressure switch. Verify all connections are se-
Switch, pin B to chassis ground. cure and free of corrosion, abrasion
Wiggle the harness during mea- and incorrect attachment. Repair as
surement to reveal an intermittent required.
condition.
Check 10 Ω. Ω, there is a problem in the wiring
Measure the resistance from the from the pressure switch. Verify all
Secondary Steering Pressure connections are secure and free of
Switch, pin C to the Instrument Clus- corrosion, abrasion and incorrect at-
ter connector 2, pin 11. Measure tachment. Repair as required.
the resistance from the Secondary
Steering Pressure Switch, pin C
to the Secondary Steering Module
connector SSM pin 8. Wiggle the
harness during measurement to re-
veal an intermittent condition.
Check 10 Ω. Ω, there is a problem in the wiring
Measure the resistance from the from the pressure switch to the Sec-
Secondary Steering Pressure ondary Steering Module. Verify all
Switch, pin A to the Secondary connections are secure and free of
Steering Module connector SSM pin corrosion, abrasion and incorrect at-
9. Wiggle the harness during mea- tachment. Repair as required.
surement to reveal an intermittent
condition.
Fabricate a jumper that will reach The Low Steering Pressure warning The Low Steering Pressure diagnos-
from the Instrument Cluster connec- should be active while the jumper is tic is not active. Temporarily replace
tor 2, to chassis ground. Turn the installed. the Instrument Cluster and retest.
key switch ON.
Check
Connect one end on the jumper wire
the Instrument Cluster connector 2,
pin 11.
Turn the key switch OFF. Discon- The resistance should be greater The resistance measurement did not
nect the Secondary Steering Pres- than 20000 Ω while the pressure change. There is a problem with
sure Switch. is less than 240 kPa (35 psi). The the pressure switch. Temporarily re-
Check resistance should be less than 10 place the switch and retest.
Connect the suspect pressure switch Ω while the pressure is greater than
to a hydraulic hand pump. Measure 240 kPa (35 psi).
the resistance across pin A and pin B Action
on the switch. Pump up the hydraulic Temporarily replace the Secondary
pressure to 240 kPa (35 psi). Steering Module and retest.
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RCPH11WHL003HAL 1
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39.3 Ω 20 °C (68 °F)
(35 psi)
Ground
Ground
AIC_2
Flyback Protection
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Auxiliary steering solenoid - Testing - Secondary Steering Solenoid

Turn the key switch OFF. Disconnect The resistance should be between The resistance is out of range. Tem-
the Secondary Steering Solenoid. 36 - 42 ohms porarily replace the solenoid and
Check retest.
Measure the resistance between
pins A and B on the solenoid.
Measure the resistance from the The resistance should be less than The resistance is greater than 10
Secondary Steering Solenoid pin 2 10 Ω. Ω, there is problem in the chassis
to chassis ground. Wiggle the har- ground circuit to the solenoid. Verify
ness during measurement to reveal all connections are secure and free
an intermittent condition. of corrosion, abrasion and incorrect
Measure the resistance from the The resistance should be less than The resistance is greater than 10 Ω,
Secondary Steering Module, pin 2, 10 Ω. there is problem in the wiring. Verify
to the Secondary Steering Solenoid all connections are secure and free
pin 1. Measure the resistance from of corrosion, abrasion and incorrect
the Secondary Steering Module pin, attachment. Repair as required.
1 to the Secondary Steering Motor,
SSS terminal. Measure the resis-
tance from the Secondary Steering
Motor, SSS terminal to pin C on the
SSD Diode Module. Wiggle the har-
ness during measurement to reveal
an intermittent condition.
Turn the key switch OFF. Fabricate The solenoid should energize while The solenoid did not energize while
a jumper wire that will reach from the jumper is installed. the jumper is installed. Temporarily
the Secondary Steering Solenoid to Action replace the solenoid and retest.
unswitched battery. Temporarily replace the Secondary
Check Steering Module and retest.
to unswitched battery. Connect the
other end of the jumper wire to pin 1
on the Secondary Steering Solenoid.
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RCPH11WHL003HAL 1
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39.3 Ω 20 °C (68 °F)
(35 psi)
Ground
Ground
AIC_2
Flyback Protection
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Auxiliary steering relay - Testing

Measure the resistance from Sec- ground circuit to the relay. Verify all
ondary Steering Relay terminal 245F connections are secure and free of
to chassis ground. corrosion, abrasion and incorrect at-
Turn the key switch OFF. Discon- The resistance should be less than The resistance is greater than 10 Ω,
nect SSD Diode Module from the 10 Ω. there is a problem in the wiring from
harness. the relay to the Diode Module. Verify
Check all connections are secure and free
Measure the resistance from Sec- of corrosion, abrasion and incorrect
ondary Steering Relay terminal 245F attachment. Repair as required.
to Diode Module connector, SSD
connector pin A. Measure the re-
sistance from Secondary Steering
Relay terminal 245F to SSD connec-
tor pin B. Measure the resistance
from Secondary Steering Relay ter-
minal SSS to SSD connector pin C.
Turn the key switch OFF. Discon- The resistance should be greater The resistance is less than . 20000
nect SSD Diode Module from the than 20000 Ω. Ω, there is a short circuit to chassis
harness. ground. Repair as required.
Check
Measure the resistance from Sec-
ondary Steering Relay terminal SSS
to chassis ground.
Turn the key switch OFF. Discon- The voltage reading should be be- The voltage is not between 0.6 - 0.8
nect SSD Diode Module from the tween 0.6 - 0.8 V. V, replace the Diode Module and
harness. Set the digital voltmeter to retest.
the diode check.
Check
Place the red probe on Diode Mod-
ule, pin A and place the black probe
on Diode Module pin C. Place the red
probe on Diode Module, pin B and
place the black probe on Diode Mod-
ule pin C.
Turn the key switch ON. The voltage should be approximately The voltage is less than 10 V there
Check 24 V. is problem with the supply voltage
Measure the voltage from Sec- to the relay. Check PRM_B, SEC
ondary Steering Relay terminal 244F STRG Fuse, F2. Repair as required.
to chassis ground.
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Check 10 Ω. there is problem in the wiring. Verify
Measure the resistance from the all connections are secure and free
Secondary Steering Module, pin 2, of corrosion, abrasion and incorrect
to the Secondary Steering Solenoid attachment. Repair as required.
pin 1. Measure the resistance from
the Secondary Steering Module pin,
1 to the Secondary Steering Motor,
SSS terminal. Wiggle the harness
during measurement to reveal an
intermittent condition.
Turn the key switch OFF. Fabricate The Secondary Starting Solenoid The relay did not energize while the
a jumper wire that will reach from and the Secondary Starting Relay jumper is installed. Temporarily re-
the Secondary Steering Module to should energize while the jumper is place the relay and retest.
unswitched battery. installed.
Check Action
Connect one end of the jumper wire Temporarily replace the Secondary
to unswitched battery. Connect the Steering Module and retest.
other end of the jumper wire to pin 2
on the Secondary Steering Module.
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RCPH11WHL003HAL 1
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39.3 Ω 20 °C (68 °F)
(35 psi)
Ground
Ground
AIC_2
Flyback Protection
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Index

Auxiliary steering pressure switch - Testing - Secondary Steering Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Auxiliary steering relay - Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Auxiliary steering solenoid - Testing - Secondary Steering Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
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Heating, Ventilation, and Air-Conditioning (HVAC) control system -

050
1021F
1121F
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Contents
Heating, Ventilation, and Air-Conditioning (HVAC) control system - 050
DIAGNOSTIC
Heating, Ventilation, and Air-Conditioning (HVAC) control system

Testing A/C System Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Air-conditioning system pressure switch
High pressure - Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Low pressure - Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Temperature sensor
Testing - Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
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Electrical systems - Heating, Ventilation, and Air-Conditioning (HVAC) control system
Heating, Ventilation, and Air-Conditioning (HVAC) control system -

Testing A/C System Test
Turn the key switch OFF. Disconnect The voltage should be approximately The voltage is less than 10 V there is
the HVAC1 connector. Disconnect 24 V. a problem in the battery supply to the
the HVAC2connector. connectors. Check fuse ECA-F11.
Check
Measure the voltage from HVAC1
pin 2 to chassis ground. Measure
the voltage from HVAC2 pin 1 to
chassis ground.
Turn the key switch OFF. Disconnect The A/C system should operate. The The A/C system does not operate.
the HVAC1 Connector. Fabricate a is a problem with the thermostat cir- There may be a problem with in the
jumper 15 cm (6 in). cuit in the HVAC Standard Denso HVAC Standard Denso Box. Verify
Check Box. that the A/C High Pressure Switch
Install the jumper between pins 1 is not tripped. Verify that the Low
and 2 on HVAC1 Connector. Turn Pressure Switch is not tripped.
the key switch ON.
RCPH11WHL017FAL 1
(1) Switched Battery, 24 V (7) CAB_E/ ENG connector

(2) Blower Motor ECA-F11 25 Amp Fuse (8) Advanced Instrument Cluster connector
2, pin 12
(3) A/C High Pressure Switch (9) Ground Connection, GND_CAB_SPL
Closes at 27.6 bar (400.2 psi) ± 0.7 bar
(10.2 psi)
(4) A/C High Pressure Switch (10) A/C Compressor
Closes at 1.4 bar (20.3 psi) ± 0.2 bar (2.9
psi)
(5) HVAC1 Connector, connects to (11) HVAC2 Connector, connects to
DNS_HVAC1_S DNS_HVAC2_S
(6) Air Condition Relay K5
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Air-conditioning system pressure switch High pressure - Testing

Turn the key switch OFF. Disconnect The AC system should turn off. The AC did not turn off. There is
the High Pressure Switch. Fabricate Action a problem with the Air Conditioning
a jumper 15 cm (6 in) long. Turn Replace the A/C High Pressure Relay or the wiring to the relay. Re-
the key switch ON. Set the AC to the Switch pair or replace the relay or wiring as
coldest setting. needed.
Check
Short pin A to pin B on the High Pres-
sure Switch.
RCPH11WHL017FAL 1
(1) Switched Battery, 24 V (6) Air Condition Relay K5

(2) Blower Motor ECA-F11 25 Amp Fuse (7) CAB_E/ ENG connector
(3) A/C High Pressure Switch (8) Advanced Instrument Cluster connector
Closes with pressure above 27.6 bar 2, pin 12
(400.2 psi) ± 0.7 bar (10.2 psi)
Opens with pressure below 20.7 bar
(300.2 psi) ± 0.7 bar (10.2 psi)
(4) A/C Low Pressure Switch (9) Ground Connection, GND_CAB_SPL
Closes with pressure below 0.3 bar (4.4
psi) ± 0.1 bar (1.5 psi)
Opens with pressure above 1.4 bar (20.3
psi) ± 0.2 bar (2.9 psi)
(5) HVAC1 Connector, connects to (10) A/C Compressor
DNS_HVAC1_S
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Air-conditioning system pressure switch Low pressure - Testing

Turn the key switch OFF. Disconnect The AC system should turn off. The AC did not turn off. There is
the Low Pressure Switch. Fabricate Action a problem with the Air Conditioning
a jumper 15 cm (6 in) long. Turn Replace the A/C Low Pressure Relay or the wiring to the relay. Re-
the key switch ON. Set the AC to the Switch pair or replace the relay or wiring as
coldest setting. needed.
Check
Short pin A to pin B on the Low Pres-
sure Switch.
RCPH11WHL017FAL 1
(1) Switched Battery, 24 V (6) Air Condition Relay K5

(2) Blower Motor ECA-F11 25 Amp Fuse (7) CAB_E/ ENG connector
(3) A/C High Pressure Switch (8) Advanced Instrument Cluster connector
Closes at 27.6 bar (400.2 psi) ± 0.7 bar 2, pin 12
(10.2 psi)
(4) A/C High Pressure Switch (9) Ground Connection, GND_CAB_SPL
Closes at 1.4 bar (20.3 psi) ± 0.2 bar (2.9
psi)
(5) HVAC1 Connector, connects to (10) A/C Compressor
DNS_HVAC1_S
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Temperature sensor - Testing - Thermostat

Turn the key switch OFF. Disconnect The voltage should be approximately The voltage is less than 10 V there is
the DNS_HVAC1_S connector. Turn 24 V. a problem with the supply voltage to
the key switch ON. the HVAC Control Panel. Repair as
Check required. Check fuse ECA-F11.
Measure the voltage from
DNS_HVAC1_S connector, pin 2 to
chassis ground.
Turn the key switch OFF. Reconnect The voltage should be approximately The voltage is less than 10 V. There
DNS_HVAC1_S connector. Dis- 24 V. is a problem in the supply voltage to
connect the thermostat connector the thermostat. Repair as required.
DNS_Thermostat_2. Turn the key
switch ON.
Check
Turn the A/C switch ON and the
Blower speed selector to high. Mea-
sure the voltage from DNS_Ther-
mostat_2 connector ( DNS78 Y-0.5
) to chassis ground.
Turn the key switch OFF. Fabri- The A/C system should turn on and Replace the thermostat and retest.
cate a jumper wire 15 cm (6 in) operate properly. If the thermostat is OK there is a
long. Disconnect the thermostat problem in the HVAC Relay Circuit.
connector DNS_Thermostat_1 and Refer to Heating, Ventilation, and
DNS_Thermostat_2. Turn the key Air-Conditioning (HVAC) control
switch ON. system - Testing A/C System Test
Check (55.050)
Turn the fan selector switch to high.
Turn the A/C switch ON. Use the
jumper to short the thermostat wires
DNS78 Y-0.5 and DNS67 G-0.5 to-
gether.
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RAIL12WEL0143GA 1
(1) HVAC1 connector, DNS_HVAC1_S (5) Recirculation switch

(2) HVAC2 connector, DNS_HVAC2_S (6) DNS Resistor
(3) Blower speed selector (7) DNS Electric fan
(4) A/C Switch (8) DNS Thermostat
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Index
Heating, Ventilation, and Air-Conditioning (HVAC) control system - 050

Air-conditioning system pressure switch High pressure - Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Air-conditioning system pressure switch Low pressure - Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Heating, Ventilation, and Air-Conditioning (HVAC) control system - Testing A/C System Test . . . . . . . . . . . . . . . . . 3
Temperature sensor - Testing - Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
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Cab Heating, Ventilation, and Air-Conditioning (HVAC) controls -

051
1021F
1121F
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Contents
Cab Heating, Ventilation, and Air-Conditioning (HVAC) controls - 051
DIAGNOSTIC
Heat command switch

Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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Electrical systems - Cab Heating, Ventilation, and Air-Conditioning (HVAC) controls
Heat command switch - Testing

Turn the key switch ON. The voltage should be approximately The voltage is less than 10 volts
Check 24 volts. there is a problem in the supply volt-
Measure the voltage across HVAC2 age to the fan switch. Check fuse
connector pins 1 and pin 2. ECA-F11. Check chassis connec-
tion GND_CAB4.
Measure the voltage from the The should be approximately 24 The voltage is less than 10 volts
BLOWER_SPEED_SELECTOR volts. there is a problem with the supply
switch pin E to chassis ground. voltage from HVAC2 connector. Re-
pair or replace as required.
Turn the BLOWER_SPEED_SE- The voltage should be approximately There is a problem in the wiring to
LECTOR to the first position. 24 volts. the DNS_RESISTOR. Repair as re-
Check quired.
Measure the voltage from DNS_RE-
SISTOR pin 1 to chassis ground.
LECTOR to the second position. 24 volts. the DNS_RESISTOR. Repair as re-
Check quired.
LECTOR to the third position. 24 volts. the DNS_RESISTOR. Repair as re-
Check quired.
LECTOR to the forth position. 24 volts. the DNS_RESISTOR. Repair as re-
Check quired.
Measure the voltage from
DNS_RESISTOR pin 4 to chassis
ground. Measure the voltage from
DNS_ELECTRIC_FAN wire DNS65
UR-2.5 to chassis ground.
Check 10 Ω. Ω there is a problem in the chassis
Measure the resistance from ground circuit to the fan motor. Re-
DNS_ELECTRIC_FAN wire DNS66 pair as required.
UR-2.5 to chassis ground
Fabricate two jumper wires that will The fan should operate while the The fan does not operate when the
reach from the fan motor to the bat- jumper wires are installed. jumpers are installed. Temporarily
tery. Disconnect the fan motor con- replace the fan motor and retest. .
nections.
Check
Connect one end of a jumper wire
to chassis ground and connect the
other end to the fan motor chassis
ground terminal. Connect one end of
the other jumper wire to the positive
terminal of the fan motor and con-
nect the other end to positive battery.
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Electrical systems - Cab Heating, Ventilation, and Air-Conditioning (HVAC) controls
RAIL12WEL0143GA 1
(1) HVAC1 connector, DNS_HVAC1_S (5) Recirculation switch

(2) HVAC2 connector, DNS_HVAC2_S (6) DNS Resistor
(3) Blower speed selector (7) DNS Electric fan
(4) A/C Switch (8) DNS Thermostat
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Index
Cab Heating, Ventilation, and Air-Conditioning (HVAC) controls - 051

Heat command switch - Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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Harnesses and connectors - 100
1021F
1121F
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Contents
FUNCTIONAL DATA
Wire harnesses
Electrical schematic frame 01 -Index of functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Electrical schematic frame 02 - Wire color abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Electrical schematic frame 03 - Wire information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Electrical schematic frame 04 - Cold start , Power distribution, Ignition switch . . . . . . . . . . . . . . . . . . . . . . 8
Electrical schematic frame 05 - Engine control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Electrical schematic frame 06 - Lighting1, Backup alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Electrical schematic frame 07 - Lighting 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Electrical schematic frame 08 - Transmission controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Electrical schematic frame 09 - Instrument cluster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Electrical schematic frame 10 - Machine controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Electrical schematic frame 11 - Secondary steering, Hood lift, Wiper/Washer system . . . . . . . . . . . . . . . 22
Electrical schematic frame 12 - HVAC, Air seat, Radio power/converter . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Electrical schematic frame 13 -Joystick steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Electrical schematic frame 14 - Standard HVAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Wire connectors
Component diagram 01 - Engine control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Component diagram 02 - Engine control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Component diagram 03 - Engine control / emissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Component diagram 04 - Engine / machine controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Component diagram 05 - Machine controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Component diagram 06 - Transmission controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Component diagram 09 - Instrument cluster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Component diagram 10 - Instrument cluster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Component diagram 11 - Backup alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Component diagram 12 - Lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
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Component diagram 15 - Engine / Lighting / Backup alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Component diagram 16 - Wiper / Washer system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

Component diagram 17 - Secondary steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Component diagram 18 - Diagnostic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Component diagram 19 - Radio power / converter / Heated mirrors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Component diagram 20 - Air seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112

Component diagram 21 - Cigar lighter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Component diagram 22 - HVAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Component diagram 23 - HVAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Component diagram 24 - Hood lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Component diagram 25 - Engine controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Component diagram 26 - Joystick Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
DIAGNOSTIC
Diagnostic connector
Testing - DIA and DIA-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
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Electrical systems - Harnesses and connectors
Wire harnesses - Electrical schematic frame 01 -Index of functions

Function Sheet
Air seat 12
Backup alarm 6
Cold start 4
Engine control 5
Hood lift 11
HVAC 12
Ignition switch 4
Instrument cluster 9
Joystick steering 13
Lighting 1 6
Lighting 2 7
Machine controls 10
Radio / Power converter 12
Power distribution 4
Secondary steering 11
Standard HVAC 14
Transmission controls 8
Wiper / Washer system 11
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Wire harnesses - Electrical schematic frame 02 - Wire color

abbreviations
Wire color abbreviations Electrical schematic circuit colors
Abbreviation Color Circuit Circuit color
Bk Black Indicates constant power Red
DU Dark blue Indicates power when key switch is Green
G Green on
K Pink Indicates power when key switch is Blue
LG Light green in start postion
LU Light blue Power relay A Orange
N Brown Power relay B Purple
Or Orange Power relay C Dark blue
P Purple or Violet Power relay D Brown
R Red Illumination Dark green
S Grey
T Tan
U Blue
W White
Y Yellow
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Wire harnesses - Electrical schematic frame 03 - Wire information

Callout Electrical schematic symbol description
A Splice symbol
B Splice name
C Wire name
D Wire color
E Wire size (mm^2)
F Male connector
G Female connector
H Connector reference designator
I Connector interface
J Indicates wires crossing (not connected)
K Indicates partial connector (not all entry ports shown)
L Indicates that the wire connects to connector TECM on sheet 6
M Indicates internally grounded component
RCIL11WHL012FAK 1
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Wire harnesses - Electrical schematic frame 04 - Cold start , Power

distribution, Ignition switch
# Component
1 Starting relay
2 Resistor — 75 ohm
3 Alternator
4 Crank control relay
5 Batteries
6 Crank request relay
8 Master disconnect switch
9 Starter
10 Ignition switch
11 Neutral start relay
13 Power relay module A
14 Power relay module B
15 Power relay module C
16 Grid heater relay
17 Grid heater
18 Power relay module D
20 Water separator heater
21 Fuel filter heater
24 Engine controller
158 Ignition power latch
159 Ignition power control
160 Start lockout
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RCIL11WHL001JAK 1
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Wire harnesses - Electrical schematic frame 05 - Engine control

# Component
22 Water in fuel sensor
23 Throttle potentiometer
24 Engine controller
131 EVGT relay
132 Turbo controller
133 Dia-2 diagnostic connector
161 NOX sensor – Tier 4 systems only
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RAIL12WEL0141JA 1
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Wire harnesses - Electrical schematic frame 06 - Lighting1, Backup alarm

# Component
78 Backup alarm relay
79 Backup alarm disable switch
90 Brake lamp switch
91 Brake lamp relay
92 Flasher module
93 Hazard switch
94 Turn signal, high-low beam, and horn switch
95 Driving lamps switch
96 Left hand front combination lamps
97 Right hand front combination lamps
100 Right hand rear combination lamps
101 Left hand rear combination lamps
102 License plate lamp
103 Backup alarm
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RCIL11WHL003JAK 1
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Wire harnesses - Electrical schematic frame 07 - Lighting 2

# Component
80 Work lamps switch
81 Door switch
82 Rotating beacon (optional)
83 Dome lamp
84 Rotating beacon switch (optional)
85 Left hand front work lamp
86 Right hand front work lamp
87 Left hand rear work lamp
88 Right hand rear work lamp
89 Diodes
170 Rear view camera / monitor
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RCIL11WHL004JAK 1
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Wire harnesses - Electrical schematic frame 08 - Transmission controls

# Component
45 Output speed sensor
46 Transmission solenoid valve and temp sender
47 Filter maintenance switch
48 Torque converter output temperature sender
49 Engine speed sensor
50 Intermediate speed sensor
51 Turbine speed sensor
52 Transmission shifter
53 Transmission electronic control module
54 Transmission enable switch
55 FNR switch for joystick controls
56 Transmission kick down switch
57 FNR switch for single axis controls
58 Transmission auto switch
59 Brake declutch pressure switch
60 Declutch switch
61 Diagnostic connector
171 Differential lock switch (manual)
172 Differential lock switch
173 Differential lock solenoid
174 Lockup solenoid
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RCIL11WHL005JAK 1
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Wire harnesses - Electrical schematic frame 09 - Instrument cluster

# Component
63 Warning buzzer
64 Parking brake relay
65 Fuel level sender
66 Air filter restriction switch
67 Parking brake solenoid
68 Radiator coolant temperature sender
69 Brake pressure warning switch
72 Hydraulic filter restriction switch
73 Hydraulic oil temperature sender
74 Park brake switch
75 Redundant brake pressure switch 1
76 Redundant brake pressure switch 2
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RCIL11WHL006JAK 1
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Wire harnesses - Electrical schematic frame 10 - Machine controls

# Component
25 Return to travel float switch
26 Height control switch
27 Electromagnetic detents
28 Return to dig proximity switch
29 Pilot control relay ECD-K3
30 Height control and return to travel proximity switch
31 Return to dig switch
32 Pin engage switch (option)
33 Pilot pressure solenoid
35 Ride control switch (option)
36 Ride control relay (option)
37 Fan control switch (option)
38 Fan reverse relay (option)
39 Pilot control switch
40 Ride control solenoid (option)
41 Rollback pressure switch (XT with ride control only)
42 Rollback jumper
43 Fan PWM solenoid
44 Fan reverse solenoid (option)
98 Horn relay
99 Horn
134 Heat load valve solenoid
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RCIL11WHL007JAK 1
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Wire harnesses - Electrical schematic frame 11 - Secondary steering,

Hood lift, Wiper/Washer system
# Component
104 Front wiper high speed relay
105 Wiper cutout relay
106 Front wiper low speed relay
107 Rear wiper and washer switch
108 Front wiper and washer switch
109 Front wiper motor
110 Rear wiper motor
111 Rear washer motor
112 Front washer motor
113 Diodes
114 Secondary steering diodes
115 Secondary steering solenoid
116 Secondary steering module
117 Secondary steering motor
118 Secondary steering pressure switch
154 Hood up relay
155 Hood down relay
156 Hood switch
157 Hood motor
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RCIL11WHL008JAK 1
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Wire harnesses - Electrical schematic frame 12 - HVAC, Air seat, Radio

power/converter
# Component
119 Diagnostic connector
121 Power converter — 24 to 12 volt
122 12 volt power outlets (option)
123 Radio
124 Right speaker
125 Left speaker
126 Air seat
127 Cigar lighter
128 Air conditioning clutch relay
129 Air conditioning high-low pressure switch
130 Air conditioning compressor clutch
135 Mirror heat timer relay
136 Mirror heat switch
137 Mirror heat right
138 Mirror heat left
139 Telematics
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RCIL11WHL009JAK 1
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Wire harnesses - Electrical schematic frame 13 -Joystick steering

# Component
175 Joystick pvres
176 Transmission kick down switch
177 Arm pos
178 FNR switch (option)
179 FNR relay
180 Pilot dump valve
181 JSS valve
182 Load sense pressure sensor
183 Pilot pressure switch
184 JSS relay
185 Joystick STR switch (option)
186 JSS controller
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RCIL11WHL010JAK 1
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Wire harnesses - Electrical schematic frame 14 - Standard HVAC

# Component
143 DNS Actuator
144 DNS Driver
145 DNS Electronic water valves
146 DNS resistor
147 DNS Electric fan
148 DNS Thermostat 2
149 Blower speed selector
150 Air conditioning switch
151 HVAC Control panel lamps
152 DNS Water valve potentiometer
153 Recirculation switch
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RAIL12WEL0139JA 1
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Wire connectors - Component diagram 01 - Engine control

Connector CAB-E - Cab to Engine
291661A1 1
Cavity Wire ID Circuit Cavity Wire ID Circuit

(1) 36F-A Fuel level analog (17) 0-DX AIC Sensor Ground
(2) 61C AC Relay Out (18) 23J-B DNOX2 K-line
(3) 21G EDC7 Crank Control Relay (19) 0-DW AIC Power Ground
(4) 21H Crank Control Relay LSD (20) 0-DB AIC Power Ground Red
(5) 36C-A Radiator cool temp signal (21) 13C-B Fuel Shutoff Fused Power
(6) 0-DF Crank request relay control ground (22) 52A-A Fan Reverse Relay Out
(7) 0–L Telematics ground (23) 56 Fan Control PWM
(8) 61H Heat load valve solenoid (24) 68W Rear Washer Pump
(9) Not used (25) 63W Front Washer Pump
(10) Not used (26) 14-AB Alternator D+
(11) 21F EDC7 Digital Ground (27) 21E-B Key Switch Crank
(12) Not used (28) 31F-A Air Filter Restriction Switch Signal
(13) CAN-LL Can2 LO, EDC (29) 61R-B AC Relay Control
(14) CAN-HM Can2 HI, EDC (30) 61A-B Trinary Pressure Switch Input
(15) 21D-A Starter Relay Signal (31) 20G-B EDC7 ISO-K Interface
(16) Not used
Connector ENG - Engine to Cab
NO_IMAGE 2
Connector mates with Cab-E connector

(1) 36F Fuel level analog (17) 0-BJ AIC Sensor Ground
36J
(2) 61C-A AC Relay Out (18) 38H DNOX2 K-line
(3) 21G-A EDC7 Crank Control Relay (19) 0-BG AIC Power Ground
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(4) 21H-A Crank Control Relay LSD (20) 0-BH AIC Power Ground Red
(5) 36C Radiator cool temp signal (21) 13C-A Fuel Shutoff Fused Power
(6) 0-BAT Crank request ground (22) 52A-B Fan Reverse Relay Out
(7) O-BK Telematics ground (23) 56-A Fan Control PWM
(8) 61H-A Heat load valve solenoid (24) 68W-A Rear Washer Pump
(9) Not used (25) 63W-A Front Washer Pump
(10) Not used (26) 14 Alternator D+
14–5
(11) 21F-A EDC7 Digital Ground (27) 21E-A Key Switch Crank
(12) Not used (28) 31F Air Filter Restriction Switch Signal
(13) CAN1–L Can LO (29) 61R AC Relay Control
CAN-L Can LOW
(14) CAN1–H Can HI (30) 61A AC Pressure Switch Input
CAN-H Can HIGH
(15) 21D Starter Relay Signal (31) 20G-A EDC7 ISO-K Interface
(16) 460 Fan speed sensor signal
Connector ECB - Electrical Center B
87312843 3

(A1) 12V-D Plug 1 12V switched power (B1) O-EW Power relay ground
(A2) 12V-E Plug 2 12v switched power (B2) 0–EV Ignition latch ground
(A3) 41H-B High beam LH power (B3) 21K-B Ignition switch start signal
(A4) 41H-C High beam RH power (B4) 0-DE Neutral start relay control ground
(A5) 41L-C Low beam RH power (B5) 21F EDC7 digital ground
(A6) 41L-B Low beam LH power (B6) 0-DF Crank request relay control ground
(A7) 41T-B Position light LH switch power (B7) 19P-E Fan reverse relay fused power
(A8) 41T-A Position lights RH switch power (B8) 52 Fan reverser LSD
(A9) 12V-F Radio 12V switched power (B9) 19D-C Park brake relay fused power
(A10) 12V-G 2 way radio 12V switched power (B10) 52C Park brake solenoid LSD
(C2) 0–EA Power relay ground
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(AA1) 12V 12V power to outlet 1 (D1) 13K-B Ignition power latch B+
(AA2) 12V-A 12V power to outlet 2 (D2) 0–ET Power relay ground
(AA3) 18B-A LH High beam fused power (D3) 25T Neutral signal
(AA4) 18C-A RH High beam fused power (D4) 21C Neutral start relay output
(AA5) 18E-A RH Low beam fused power (D5) 21C-A Neutral start relay output
(AA6) 18D-A LH Low beam fused power (D6) 21E Key switch crank
(AA7) 18F-C LH Position tail lights fused power (D7) 19P-D Fan reverse relay fused power
(AA8) 18G RH Position tail lights fused power (D8) 52A-A Fan reverse relay out
(AA9) 12V-B 12V fused power to radio (D9) 19D-B Park brake relay fused power
(D10) 52P-B Park brake relay out
Connector FSS - Fan speed sensor
CNH_87747172AAA 4

(1) 460 Fan speed sensor signal (3) Not used
(2) 017A Fan speed sensor ground
Connector GND-CAB-SPL2 - Splice back light ground
87324393 5

(A) 0-J Start lockout relay ground (G) 0-DE Neutral start relay control ground
(B) 0-KA Ignition power control ground (H) 0-EQ Splice pack ground cab SPL2 GND
(C) 0-K Camera ground (J) Not used
(D) Not used (K) 0-EH Flasher module ground
(E) 0-EW Power relay ground (L) 0-EG Flasher module ground
(F) 0-BBC Joystick ground (M) 0-EF Brake lights relay control ground
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Connector RFL-23 - Fuel level sender
256340A1 6

(A) 36J Fuel level analog (B) 0-BZ Fuel level sender ground
Connector S-KEY - Ignition switch to pedestal harness
225253C1 7

(1) 1DM Time delay / Ignition switch fused (4) 12ACC Ignition switch accessory power
power
(2) 21K Ignition switch start signal (5) Not used
(3) 13K Ignition switch power (6) Not used
Connector SPL-PK1 - Splice 3 - 4 way
87324462 8

(A) Not used (G) Not used
(B) Not used (H) Not used
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(C) Not used (J) 18K-D Diagnostic fused B+
(D) Not used (K) 18K-A Diagnostic fused power
(E) Not used (L) 18K-B Diagnostic fused B+
(F) Not used (M) Not used
Connector SRC-1 - Starter relay
225316C1 9

(1) 21D Starter relay signal (2) 0-GB Starter relay control ground
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Wire connectors - Component diagram 02 - Engine control

Connector ECA - Electrical center A
87315248 1

(A1) 19A-N Transmission fused power (L1) J1 Transmission ECM power
(A2) 18S-A B+, JSS fused (L1) J2 Transmission ECM power
(A3) 19E-A AIC wake up ignition (L1) J3 Emergency steering AIC power
(A4) 19RR Secondary steering ignition fused (L1) J4 Emergency steering AIC power
power
(A5) 19C-A Pilot control relay fused power (L1) J5 Emergency steering Plt Em Dtnts
(A6) 19D-A Park brake relay fused power (L1) J6 Pltem Dtnts Park brake solenoid
(A7) 19P Pin engage/fan fused power (L1) J7 Park brake solenoid horn
(A8) 19B Turn signal fused power (L1) J8 Fan reverse/turn signal
(A9) 13C-B Fuel shutoff fused power (L1) J9 Turn signal engine shutdown
(A10) 18T DNOX switch B+ – 1 (L1) J10 DNOX switch B+ – 1
(C1) 18N Blower motor fused power (L2) J11 Blower motor power
(C2) 19J Front wiper fused power (L2) J12 Blower motor front wiper washer
(C3) 19K Rear wiper fused power (L2) J13 Front wiper rear wiper washer
(C4) 19H Backup alarm B+ (L2) J14 Rear wiper washer backup
(C5) 18V Heated mirror power (L2) J15 Backup AC
(C6) 19N Seat compressor fused power (L2) J16 Heated mirrors
(C7) 19M Secondary steering accessory (L2) J17 Seat compressor emergency steering
fused power
(C8) 19W Cigar lighter fused power (L2) J18 Diagnostic power
(C9) 66A RR camera power (L2) J19 Not used
1 -Not used on Tier 2 models.
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Connector FFH - Fuel filter heater
182069A1 2

(A) 1-GB Fuel filter heater power (B) 0-BX Fuel filter heater ground
Connector GHC - Grid heater relay
3227856R1 3

(1) 28G Grid heater source DR (2) 0-BV Grid heater control ground
Connector PRM-A1 - PRM output
409084A1 4

(A) 18U-A DCU B+ non-disconnected (C) 19L Power converter fused power
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Connector PRM-A2 - PRM signal
256340A1 5

(A) 12AC- Power converter PRM control (B) 0-EU Power converter relay control ground
C-C power
Connector PRM-B1 - PRM Signal
256340A1 6

(A) 12AC- ACC PRM control power (B) 0-EC ACC relay control ground
C-B
Connector PRM-C1 - PRM Signal
256340A1 7

(A) 13C-K Ignition switch power (B) 0-EB Ignition relay control ground
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Connector PRM-D1 - PRM Output
409084A1 8

(A) 18J-F EDC7 fused power (C) 1–GA Filter heater power
Connector PRM-D2 - PRM signal
256340A1 9

(A) 28F Fuel filter heater relay control (B) 31B Filter heater control
Connector WSH - Water separator heater
182069A1 10

(A) 0-BW Water Separator Heater Ground (B) 1-GC Water Separator Heater Power
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Wire connectors - Component diagram 03 - Engine control /

emissions
Connector BPP - Pedal postion
RCPH11WHL017AAK 1

(1) 22G Pedal sensor ground (4) 401B Pedal POS signal
(2) 22E Pedal sensor +5V (5) 255E Pedal sensor +5V
(3) 22F Pedal POS signal (6) 016B Pedal sensor ground
Connector BTM-E - Cab bottom
NO_IMAGE 2

(1) 21F-D EDC7 digital ground (5) 24S-A Throttle supply
(2) 0–AK Park brake / warning ground (6) 24L-A Low idle switch
(3) 24B-A Throttle signal (7) 61R-E AC switch output
(4) 24R-A Throttle ground (8) 61A-E AC swtich input
Connector DIA-2 - Diagnostic
87736919 3
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(A) 0D-C Diag2 ground (D) CAN-LX CAN2 LO, Diag2
(B) 18K-B Diagnostic fused B+ (E) 23J-B DNOX2 K-line – 1
(C) CAN-HO CAN2 HI, Diag2
Connector DISC - Disconnect engine
245482C1 4

(A) 13C Fuel Shutoff Fused Power (B) 13M Fuel Shutoff Fused Power
Connector EDC7 - Engine controller
BOSCH-89-POLE 5

(2) 18J-C EDC7 fused power (34) CAN1-L CAN LOW
CAN LOW, EDC
(3) 18J-B EDC7 fused power (35) CAN1-H CAN HI
CAN-HK CAN HI, EDC
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(5) 0-BE EDC7 ground (36) 28F Fuel filter heater relay control
(6) 0-BF EDC7 ground (37) 21G-A EDC7 crank control relay
(8) 18J-D EDC7 fused power (40) 13M-A Fuel shutoff fused power
(9) 18J-E EDC7 fused power (42) 35W Water in fuel indicator
(10) 0-BD EDC7 ground (48) 24L Low idle switch
(11) 0-BC EDC7 ground (51) 13A EVGT relay
(12) 28G Grid heater source DR (52) CAN-L3 CAN2 LO, NOX – 1
CAN-LS CAN2 LO, NOX – 1
(13) 31 EDC relay control (53) CAN-H3 CAN2 HI, NOX – 1
CAN-HS CAN2 HI, NOX – 1
(17) 21H-A Crank control relay LSD (68) 23K-A Temp / Humid B+
(26) 23K-B Temp / Humid TEMP (75) 0-BV Grid heater control ground
(27) 23K-C Temp / Humid HUMIDITY (77) 24S Throttle supply
(28) 23K-E Temp / Humid ground (78) 24R Throttle ground
(29) 21F-B EDC7 digital ground (79) 24B Throttle signal
(32) 21E-A Key switch crank (89) 20G-A EDC7 ISO-K interface
Connector ENG-B -CAB bottom
NO_IMAGE 6

(1) 21F-C EDC7 digital ground (5) 24S Throttle supply
(2) 0-BBR Ground (6) 24L Low idle switch
(3) 24B Throttle signal (7) 61R-C AC switch output
(4) 24R Throttle ground (8) 61A-C AC switch input
Connector ENG-D - Disconnect harness
245483C1 7

(A) 13C-A Fuel Shutoff Fused Power (B) 13M-B WIF ignition power
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Connector EVGT-3 - EVGT fuse
NO_IMAGE 8

(A) 1-T EVGT-3 power (B) 1-B EVGT relay power
Connector EVGT-4 - EVGT
NO_IMAGE 9

(A) 13B EVGT-3 power (C) 13A EVGT relay power
(B) 31A EVGT-3 power (D) 1-B EVGT relay power
Connector HTS - Humidity and ambient temperature
87709809 10

(1) 23K-A Temperature / Humidity B+ (3) 23K-E Temperature / Humidity Humidity
(2) 23K-B Temperature / Humidity (4) 23K-C Temperature / Humidity ground
Temperature
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Connector RTHP - Throttle pedal
225351C1 11

(1) 21F-D EDC7 digital ground (4) 24R-A Throttle ground
(2) Not used (5) 24S-A Throttle supply
(3) 24B-A Throttle signal (6) 24L-A Low idle switch
Connector TERM-CAN-2 - CAN bulk head
225295C1 12

(A) CAN-L2 CAN2 LO, TERM (B) CAN-H2 CAN2 HI, TERM
CAN-LV CAN2 LO, TERM CAN-HV CAN2 HI, TERM
Connector WIF - Water in fuel sensor
8602416-01 13

(1) 35W WIF Indicator (3) 13M-C WIF sensor fused power
(2) 0-BP WIF Sensor Ground
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Wire connectors - Component diagram 04 - Engine / machine

controls
Connector CAB-F - Cab front chassis
RCPH11WHL015EAK 1

(1) Not used (10) 18F-E LH position / tail fused power
(2) 45L-C Left turn signal (11) 54B-A HC RTT control signal
(3) 45R-D Right turn signal (12) 53B-B RTD control signal
(4) Not used (13) 64-A Horn power
(5) 18G-G RH position / tail fused power (14) 18D-A LH Low beam fused power
(6) 18B-A LH high beam fused power (15) 18E-A RH Low beam fused power
(7) Not used (16) 18C-A RH High beam fused power
(8) Not used (17) 57-A Pin engage solenoid power
(9) 53P-F Pilot control relay out (18) 58-C Ride control solenoid power
Connector FRONT - Cab front chassis
RCPH11WHL016EAK 2

(1) Not used (10) 18F LH postion / tail fused power
(2) 45L Left turn signal (11) 54B HC RTT control signal
(3) 45R Right turn signal (12) 53B RTD control signal
(4) Not used (13) 64 Horn power
(5) 18G-A RH position / tail fused power (14) 18D LH Low beam fused power
(6) 18B LH high beam fused power (15) 18E RH Low beam fused power
(7) Not used (16) 18C RH High beam fused power
(8) Not used (17) 57 Pin engage solenoid power
(9) 53P-G Pilot control relay out (18) 58-B Ride control solenoid power
58-G Ride control solenoid power
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Connector ECD - Electrical center D
87312843 3

(A1) 0-EF Brake lights relay control ground (B1) 19J-E Front wiper relay fused power
(A2) 1-DW Brake light relay battery power (B2) 63HC-B Front wiper relay HS
(A3) 0-EZ Power relay control (B3) 63C3 Front wiper park control
(A4) 0-EY Power relay ground (B4) 63LC Front wiper LS relay control
(A5) 21H Crank control relay LSD (B5) 19C-B Pilot control relay fused power
(A6) 21C-B Neutral start relay output (B6) 53C-A Pilot control solenoid LSD
(A7) 23B-C NOX relay ground – 1 (B7) 58T Ride control relay switched power
(A8) 23B-A NOX sensor B+ – 1 (B8) 58L Ride control relay LSD
(A9) 35C Backup alarm control (B9) 61A-G Trinary pressure switch input
(A10) 19H Backup alarm B+ (B10) 0-DJ AC relay control ground
(AA1) 44A-A Brake light relay out (C2) 63C2 Front wiper park control
(AA2) 44-A Brake light control power (C4) 63C Front wiper park control
(AA3) 0-KA Ignition power control ground (C10) 61C AC relay out
(AA4) 13K-A Ignition power control B+ (D1) 19J-D Front wiper relay fused power
(AA5) 21D-A Starter relay signal (D2) 63H-B Front wiper relay HS
(AA6) 21G EDC7 crank control relay (D3) 19J-f Front wiper relay LS control fused
power
(AA7) 23B-B NOX sensor B+ – 1 (D4) 63C2 Front wiper park control
(AA8) 23B-D NOX relay B+ – 1 (D5) 19C-C Pilot control relay fused power
(AA9) 35A-A Backup alarm (D6) 53P-C Pilot control relay out
(AA10) 19A-P Backup alarm relay (D7) 58H-C Power
(D8) 58-E Ride control solenoid power
(D9) 61R-B AC relay control
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Connector EM - Height control RTD - RTT
225351C1 4

(1) 55A-A RTT/float switched power (4) 53B-B RTD control signal
(2) 54A Height control switched power (5) 54B-B HC-RTT control signal
(3) 53A RTD switched power (6) 55B RTT float switch control
Connector PXF - RTD
245485C1 5

(A) 53B RTD signal (C) 53P-H Pilot control relay out
(B) 0-AC Proximity switch ground
Connector PXH - Height control RTT
RC07CCH245484C1 6

(A) 54B HC RTT control signal (C) 53P-J Pilot control relay out
(B) 0-AA Proximity switch ground
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Connector PXM - RTD
RC07CCH245484C1 7

(A) 53B-A RTD control signal (C) 53P-I Pilot control relay out
(B) 0-AM RTD ground
Connector PXT - RTD
RC07CCH245484C1 8

(A) 53B-A RTD control signal (C) 53P-I Pilot control relay out
(B) 0-AM RTD ground
Connector SFL - Return to travel switch
382391A1 9

(1) 55A-B RTT / float switch power (6) 54B-C HC RTT control signal
(2) 52P-B Pilot control relay out (7) 0-B2 Back light ground
(3) 55A-C RTT / float switch power (8) 49-K Back light power
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(4) 0-29 RTT / float ground (9) Not used
(5) 55B RTT float switch control (10) Not used
Connector SHC - Height control switch
382391A1 10

(1) Not used (6) 54A Height Control Switch Power
(2) 53P-D Pilot Control Relay Out (7) 0-B3 Back Light Ground
(3) Not used (8) 49-M Back Light Power
(4) Not used (9) Not used
Connector SPE - Pin engage switch
382391A1 11

(1) 57-B Pin Engage Solenoid Power (6) Not used
(2) 19P-A Pin Engage Switch Fused Power (7) Not used
(4) Not used (9) 0-B5 Back Light Ground
(5) Not used (10) 49-F Back Light Power
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Connector SRTD - Detent switch
382391A1 12

(2) 53P-E Pilot Control Relay Out (7) 0-B4 Back Light Ground
(3) 53A RTD Switched Power (8) 49-J Back Light Power
Connector SPL-BCK-LT-GD2 - Splice back light ground
87324393 13

(A) 0-B31 SDA ground (G) Not used
(B) 0-B2 Back light ground (H) Not used
(C) 0-B3 Back light ground (J) 0-B20 Back light ground
(D) 0-B4 Back light ground (K) 0-29 RTT / float ground
(E) 0-B5 Back light ground (L) 0-B11 Back light ground
(F) 0-B6 CAB2 ground (M) 0-B7 Back light ground
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Connector SPL-BCK-LGT2 - Splice back light power
87324393 14

(A) 49-E Back light power (G) 49-Q Back light power
(B) 49Y-A Back lighting power (H) 49-T Back light power
(C) 49-J Back light power (J) 49-Z Back light power
(D) 49-M Back light power (K) 49-G Back light power
(E) 49-K Back light power (L) Not used
(F) 49-F Back light power (M) 49-S Back light power
Connector YPE - Pin engage (Option)
245482C1 15

(A) 57 Pin Engage Solenoid Power (B) 0-AE Pin Engage Ground
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Connector YPP - Pilot pressure solenoid
245482C1 16

(A) 53P-A Pilot Control Relay Out (B) 0-DU Pilot Pressure Solenoid Ground
Connector YRC-J - Ride control jumper
RCPH11WHL019EAK 17

(1) 58-H Ride control signal (2) 0-RD Ride control ground
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Wire connectors - Component diagram 05 - Machine controls

Connector 202M - Rollback jumper
245482C1 1

(A) 58-A Ride Control Solenoid Power (B) 58-A Ride Control Solenoid Power
Connector PRBF - Rollback pressure switch
245483C1 2

(A) 58 Ride Control Solenoid Power (B) 58-B Ride Control Solenoid Power
Connector SPL-PED-BL - SPL backlight power 6 pack
87324391 3

(A) 49-W JSS back light (D) 49X Back light AIC
(B) 49-N Back light power (E) 49-V Back light power
(C) 49-D Back light power (F) 49-S Back light power
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Connector SPL-PED-BL-GD - SPL back light ground 6 pack
87324391 4

(A) Not used (D) Not used
(B) 0-B1 Back light ground (E) 0-B29 RTT/float ground
(C) 0-B24 Back light ground (F) 0-B11 Back light ground
Connector SPL-PIN - SPL back light power
87324391 5

(A) 19P-A Pin Engage Switch Fused Power (D) Not used
(B) 19P Pin Engage/Fan Fused Power (E) 19P-D Fan Reverse Relay Fused Power
(C) 19P-C Fan Reverse Switch Fused Power (F) 19P-E Fan Reverse Relay Fused Power
Connector SFC - Fan control switch
382391A1 6
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(1) Not used (6) 52M Fan reverse auto
(2) 52J Fan control switch jumper (7) 0-B7 Back light groung
(3) 52-AU Fan reverse auto (8) 49-Q Back light power
(4) 52J Fan control switch jumper (9) Not used
(5) 19P-C Fan reverse switch fused power (10) Not used
Connector SPC - Pilot control switch
382391A1 7

(2) 19C-F Pilot control switch fused power (7) 0-B1 Back light ground
(3) 31L Pilot control switch high (8) 49-N Back light power
Connector SRC - Ride control switch
382391A1 8

(1) Not used (6) 58-F Ride control solenoid power
(2) 19C-D Ride control switch fused power (7) 0-B20 Back light ground
(3) 58C Ride control switch jumper (8) 49-G Back light power
(4) 58T Ride control relay switch power (9) Not used
(5) 58C Ride control switch jumper (10) Not used
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Connector YFN - Fan PWM solenoid
256340A1 9

(A) 56-A Fan Control PWM (B) 0-BQ Fan Speed PWM Solenoid Ground
Connector YFR - Fan reversing solenoid
225316C1 10

(1) 52A-B Fan Reversing Relay Out (2) 0-BB Fan Reversing Solenoid Ground
Connector YRC - Ride control (Option).
291718A1 11

(1) 58 Ride Control Solenoid Power (2) 0-AD Ride Control Ground
58-G Ride Control Solenoid Power
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Wire connectors - Component diagram 06 - Transmission controls

Connector 20M - Transmission kick down
225316C1 1

(1) 19A-U Transmission kick down switch (2) 25Y-C Transmission kick down signal
fused power
Connector CAB-T - Cab to transmission
380839A1 2

(1) 33R Redundant brake accumulator (17) 25L-A Trans solenoid valve Y2
pressure low
(2) 33A-C Diff lock solenoid B+ (18) 25M-A Trans solenoid valve Y3
(3) 19M Secondary steering accessory (19) 25N-A Trans solenoid valve Y4
fused power
(4) 19R-E Secondary steering ignition fused (20) 25P-A Trans solenoid valveY5
power
(5) 36T-A Valve body temperature signal (21) 25J-A Trans solenoid valve Y6
(6) 35X Secondary steering low pressure (22) 25S-A Output switch power VPS1
signal
(7) 25A-A Engine speed signal (23) 31H-A Hydraulic filter restriction switch
signal
(8) 25C-A Turbine speed signal (24) 19A-T Brake declutch switch fused power
(9) 25B-A Intermediate speed signal (25) 25T-A TC lockup solenoid ground
(10) 25D-A Output speed signal (26) 19S2 Secondary steering fused power
(11) 0-DM Speed sensor ground (27) 34C Diff lock solenoid ground
(12) 36R-E Transmission temperature / filter (28) 0-DN Output speed sensor ground
return
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(13) 36G-A Torque converter output (29) 19A-M Output speed sensor fused power
temperature signal
(14) 25G-A Brake declutch switch control (30) 36H-A Hydraulic oil temperature signal
(15) 25R-A TC lockup solenoid power (31) 32F-A Transmission filter maintenance
switch
(16) 25K-A Trans solenoid valve Y1
Connector ESS - Engine speed sensor
291718A1 3

(1) 25A Engine Speed Signal (2) 0-HF Engine Speed Sensor Ground
Connector FM - Filter maintenance switch
371614A1 4

(1) 32F Trans Filter Maintenance Switch (2) 36R-B Trans Filter Maintenance Switch
Return
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Connector ISS - Intermediate speed sensor
291718A1 5

(1) 25B Intermediate Speed Signal (2) 0-HG Intermediate Speed Sensor Ground
Connector OSS - Output speed sensor
291719A1 6

(1) 0-HE Output Speed Sensor Ground (3) 19A Output Speed Sensor Fused Power
(2) 25D Output Speed Signal
Connector TCOT - Torque converter output temperature sender
291718A1 7

(1) 36G TCO Temperature Signal (2) 36R-D TCO Temperature Return
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Connector TRANS - Cab to transmission
380838A1 8

(1) 33R-A Redundant brake accumulator (17) 25L-9 Trans solenoid valve Y1
pressure low 25L Trans solenoid valve Y2
(2) 34C-A Diff lock solenoid ground (18) 25M Trans solenoid valve Y3
(3) 19M-A Secondary steering accessory (19) 25N Trans solenoid valve Y4
fused power
(4) 19R-A Secondary steering ignition fused (20) 25P Trans solenoid valveY5
power
(5) 36T Valve body temperature signal (21) 25J Trans solenoid valve Y6
(6) 35X-B Secondary steering low pressure (22) 25S Output switch power VPS1
signal
(7) 25A Engine speed signal (23) 31H Hydraulic filter restriction switch
31H9 signal
(8) 25C Turbine speed signal (24) 19A-A Brake declutch switch fused power
(9) 25B Intermediate speed signal (25) 24T-B TC lockup solenoid ground
(10) 25D Output speed signal (26) 19S1-E Secondary steering fused power
(11) 0-HD Speed sensor ground (27) 34A-D Diff lock solenoid B+
(12) 36R-A Transmission temperature / filter (28) 0-HE Output speed sensor ground
return
(13) 36G Torque converter output (29) 19A Output speed sensor fused power
temperature signal
(14) 25G Brake declutch switch control (30) 36H Hydraulic oil temperature signal
(15) 25R-B TC lockup solenoid power (31) 32F Transmission filter maintenance
switch
(16) 25K Trans solenoid valve Y1
25K-9 Trans solenoid valve Y2
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Connector TRC - Transmission control
371566A1-01 9

(1) 25K Trans Solenoid Valve Y1 (9) 36R-C Valve Body Temp Return
25L-9 Trans Solenoid Valve Y1
(2) 25K-9 Trans Solenoid Valve Y2 (10) Not used
25L Trans Solenoid Valve Y2
(3) 25M Trans Solenoid Valve Y3 (11) Not used
(4) 25N Trans Solenoid Valve Y4 (12) Not used
(5) 25P Trans Solenoid Valve Y5 (13) Not used
(6) 25J Trans Solenoid Valve Y6 (14) Not used
(7) 25S Output Switch Power VPS1 (15) Not used
(8) 36T Valve Body Temp Signal (16) Not used
Connector TS1 - Transmission shifter
245486C1 10

(A) 19A-H Trans Shifter Fused Power (C) 25R Reverse Signal
(B) 25F Forward Signal (D) 25T-B Neutral Signal
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Connector TS2 - Transmission shifter
245487C1 11

(A) not used (C) 25Z 1st and 4th Gear Signal
(B) 25W 3rd and 4th Gear Signal (D) 25Y Transmission Kick Down Signal
Connector TSS - Turbine speed sensor
291718A1 12

(1) 25C Turbine Speed Signal (2) 0-HH Turbine Speed Sensor Ground
Connector YDL - Diff lock solenoid
225316C1 13

(1) 34A-D Diff lock solenoid B+ (2) 34C-A Diff lock solenoid ground
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Connector YDL-1 - Diff lock solenoid
225315C1 14

(1) 34A-E Diff lock solenoid B+ (2) 34C-D Diff lock solenoid ground
Connector YDL-2 - Diff lock solenoid
225316C1 15

(1) 34A-E Diff lock solenoid B+ (2) 34C-D Diff lock solenoid ground
Connector YLS - TC lockup valve
371614A1 16

(1) 25R-B TC lockup solenoid power (2) 24T-B TC lockup solenoid ground
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Connector BTM-C - Cab bottom bulkhd
87703931 1

(A) 22G Pedal sensor ground (H) Not used
22D Pedal sensor ground
(B) 22E Pedal sensor +5V (J) 44 Brake light control power
22B Pedal sensor +5V 44-A Brake light control power
(C) 22F Pedal POS signal (K) 1-AA Brake light switch power
22C Pedal POS signal 1-DR Brake light switch power
(D) 016B Pedal sensor ground (L) 33P Brake warning pressure low
(E) 255E Pedal sensor +5V (M) 52P Park brake relay output
52P-A Park brake relay output
(F) 401B Pedal POS signal (N) Not used
(G) Not used (P) Not used
Connector CAB-B - CAB bottom bulkhead
NO_IMAGE 2

(A) 22D Pedal sensor ground (H) Not used
(B) 22B Pedal sensor +5V (J) 44-A Brake light control power
(C) 22C Pedal POS signal (K) 1-DR Brake light switch power
(D) Not used (L) 33P-A Brake warning pressure low
(E) Not used (M) 52P-A Park brake relay output
(F) Not used (N) Not used
(G) Not used (P) Not used
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Connector TECM - Tramsmission electronic control module
411398A1 3

(1) 0-DP Diag TECM ground (35) 34B Diff lock switch signal
(2) 0-DQ Diag TECM ground (36) Not used
(3) 0-DM Speed sensors ground (37) 22B Pedal sensor +5V
(4) 0-DN Output speed sensor ground (38) 22C Pedal pos signal
(5) 32J-D Trans enable indiction (39) 36T-A Valve body temperature signal
(7) 35C Backup alarm relay control (41) 25C-A Turbine speed signal
(8) 58H-A Power VPS2 (42) 25B-A Intermediate speed signal
(9) 25P-A Trans solenoid valve Y5 (43) 25F Forward signal
(10) 25L-A Trans solenoid valve Y2 (44) 26N-B FNR neutral signal
(11) 34C Diff lock solenoid ground (45) 19A-K TECM fused power
(12) 25S-B Output switched power VPS1 (46) 36R-E Trans temp / filter return
(13) 25S-C Output switched power VPS1 (47) Not used
(15) 37D-A Diagnostic signal (49) 36G-A Torque converter out temperature
signal
(16) Not used (50) 25R-A TC lockup solenoid power
(17) 32F-A Trans filter maintenance switch (51) 25J-A Trans solenoid valve Y6
(18) 37E Diagnostic signal switched (52) Not used
(19) 25A-A Engine speed signal (53) 58H-B Power VPSL
(20) 26F-B FNR forward signal (54) Not used
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(21) 22A Declutch switch (55) 25N-A Trans solenoid valve Y4
(22) 25Y-A Trans kick down signal (56) 25K-A Trans solenoid valve Y1
(23) 19T-A Fused battery power (57) 58L Ride control relay LSD
(24) 22D Pedal sensor ground (58) Not used
(25) CAN-HD CAN high (59) 34D Diff lock switch signal
(26) CAN-LD CAN low (60) Not used
(28) Not used (62) 25D-A Output speed signal
(29) 25H Trans auto signal (63) 25Z 1st and 4th gear signal
(30) 26R-B FNR reverse signal (64) 25R Reverse signal
(31) 26E-A Trans enable signal (65) 25W 3rd and 4th gear signal
(32) 25M-A Trans solenoid valve Y3 (66) 25G-C Brake declutch switch control
(33) Not used (67) 25T-C Neutral signal
(34) Not used (68) 19T-B Fused battery power
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Connector 108F - Diagnostic connector
291663A1 1

(1) 19A-W Diagnostic connector fused power (4) 37E Diagnostic signal switched
(2) 37D-A Diagnostic signal (5) Not used
(3) 0-DAV Diagnostic TECM ground (6) Not used
Connector 197F - Main cab FNR
225350C1 2

(1) 19A-C FNR switch fused power (4) 26R-B FNR reverse signal
(2) 26F-B FNR forward signal (5) 32J-E Trans enable indication lamp
(3) 26N-B FNR neutral signal (6) 25Y-B Trans kick down signal
Connector 197M - FNR main cab
225351C1 3
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(1) 19A-B FNR switch fused power (4) 26R-A FNR reverse signal
(2) 26F-A FNR forward signal (5) 32J-A Trans enable indication lamp
(3) 26N-A FNR neutral signal (6) 25Y-C Trans kick down signal
Connector 202M - Rollback jumper
225316C1 4

(1) 58-A Ride Control Solenoid Power (2) 58-A Ride Control Solenoid Power
Connector PBD - Brake declutch pressure switch
245482C1 5

(A) 19A-A Brake Declutch switch fused power (B) 25G Brake Declutch Switch Control
Connector SDA - Diff lock switch
382391A1 6
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(2) 34A-A Diff lock switch B+ (7) 0-B31 SDA ground
(3) 34B Diff lock switch signal (8) 49-Z Back light power
Connector SDC - Declutch switch
382391A1 7

(1) 25G-B Brake Declutch Switch Control (6) Not used
(2) 19A-R Declutch Switch Fused Power (7) 0-B18 Back Light Ground
(3) 22A Declutch switch (8) 49-R Back Light Power
Connector SDM - Diff lock switch
371614A1 8

(1) 34D Diff lock switch signal (2) 34A-B Diff lock switch signal B+
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Connector SFNR - FNR switch
382391A1 9

(1) 26R-A FNR reverse signal (6) 26F-A FNR forward signal
(2) 26J FNR switch jumper (7) 32J-A Trans enable indiction
(3) 26N-A FNR neutral signal (8) 19A-G FNR switch fused power
(4) 26J FNR switch jumper (9) Not used
(5) 19A-V FNR switched fused power (10) Not used
Connector SPL-TRNS-PWR - Transmission power
87324393 10

(A) 19A-N Trans fused power (G) 19A-P Backup alarm relay
(B) 19A-F Trans enable switch fused power (H) 19A-R Declutch switch fused power
(C) 19A-Q Trans/auto switch fused power (J) 19A-K TECM fused power
(D) 19A-T Brake declutch switch fused power (K) 19A-M Output speed sensor fused power
(E) 19A-W Diagnostic connector fused power (L) Not used
(F) 19A-C FNR switch fused power (M) 19A-H Trans shifter fused power
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Connector STE - Transmission enable switch
382391A1 11

(2) 19A-D Trans enable switch fused power (7) 0-DAP Back light ground
(3) 26E-A Trans enable signal (8) 49-H Back light power
(4) Not used (9) 32J-C Trans enable indiction
(5) Not used (10) 19A-E AIC fused power
Connector STA - Transmission auto switch
382391A1 12

(2) 19A-Q Trans auto switch fused power (7) 0-B17 Back light ground
(3) 25H Trans auto signal (8) 49S Back light power
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Wire connectors - Component diagram 09 - Instrument cluster

Connector AIC1 - Advanced instrument cluster
87419488 1

(1) 19S-E AIC Battery B+ (14) 52C Park brake solenoid LSD
(2) 36F-A Fuel level ANALOG (15) Not used
(3) CAN-HG CAN high (16) Not used
(4) CAN-LG CAN low (17) Not used
(6) 0-DX AIC sensor ground (19) 61H Heat load valve solenoid
(7) 43-A Dome light auto mode (20) 53C-A Pilot control solenoid LSD
(8) Not used (21) 51D-A Relay control ground
(9) 36H-A Hydraulic oil temperature (22) 0–EZ Power relay control
(10) Not used (23) 52 Fan reverser LSD
(11) 36C-A Radiator coolant temperature (24) Not used
signal
(12) 0-DW AIC power ground (25) 17P-B Switch pad power from AIC power
(13) 35B AIC buzzer HSD (26) 56 Fan control PWM
Connector BUZ - AIC buzzer
222136A1 2

(1) 35B AIC Buzzer HSD (2) 0-B27 Buzzer Ground
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Connector PAF - Air filter restriction switch
291718A1 3

(1) 31F Air Filter Restriction Switch Signal (2) 0-BY Air Filter Restriction Switch Ground
Connector PBW - Brake pressure warning switch
371614A1 4

(1) 33P Low Brake Press Warning (2) 0-AL Brake Pressure Warning Switch
Ground
Connector RECT - Engine coolant temperature
194788A1 5

(A) 36C Radiator Coolant Temp Signal (B) 0-BAE EDC7 Sender Ground
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Connector YPB Parking brake solenoid
225316C1 6

(1) 52P Parking Brake Relay Out (2) 0-AN Park Brake Solenoid Ground
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Wire connectors - Component diagram 10 - Instrument cluster

Connector AIC2 - Advanced instrument cluster 2
87410948 1

(1) Not used (14) 19S-D AIC delay fused power
(2) 43S-C Door open signal (15) 0-DB AIC power ground red
(3) Not used (16) 57-C Pin engage solenoid power
(4) 33R Redundant brake accumulator (17) 21K-A Ignition switch start signal
pressure low
(5) 33P-A Brake low pressure warning (18) 31L Pilot control switch high
(6) 33U Park brake switch (19) Not used
(7) 52M Fan reverse manual (20) 19S-C AIC delay fused power
(8) 52AU Fan reverse auto (21) 19S-F AIC wake up ignition
(9) 45L-E Left turn signal (22) 0-DA AIC chassis ground
(10) 45R-C Right turn signal (23) Not used
(11) 35X Secondary steering low pressure (24) Not used
signal
(12) 61B-A AC signal (25) Not used
Connector HOT - Hydraulic oil temperature sender
194788A1 2

(A) 36H Hydraulic Oil Temp Signal (B) 0-HW Hydraulic Oil Temp Ground
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Connector PHF9 - Hydraulic filter restriction switch
371614A1 3

(1) 0-HR Hydraulic filter switch ground (2) 31H9 Hydraulic filter restriction switch 9
Connector PRB1 - Redundant brake switch
245483C1 4

(A) 33R-C Redundant Brake Accumulator (B) 0-HM Redundant brake switch ground
Pressure Low
Connector PRB2 - Redundant brake switch
245483C1 5

(A) 33R-B Redundant Brake Accumulator (B) 0-HL Redundant brake switch ground
Pressure Low
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Connector SPB - Parking brake switch
382391A1 6

(2) 19A-L Park Brake Switch Fused Power (7) 0-B29 RTT/Float Ground
(3) 33U Park Brake Switch (8) 49-V Back Light Power
Connector SW-PD - Switch pad
87635073 7

(1) 41H-D High beam power (6) Not used
(2) Not used (7) CAN-HF CAN high
(3) 42-X Back light AIC (8) CAN-LF CAN low
(4) 31H-A Hydraulic filter restriction switch (9) 17P-A Switch pad power from AIC power
signal
(5) 31F-A Air filter restriction switch signal (10) 0-B28 Switch pad ground
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Wire connectors - Component diagram 11 - Backup alarm

Connector 209F - Backup alarm disable jumper
245481C1 1
Cavity Wire ID Circuit

(1) 35A-E Backup Alarm Relay Out
Connector 209M - Backup alarm disable jumper
245480C1 2

(A) 35A-D Backup Alarm Relay Out
Connector SBU - Backup alarm disable switch
382391A1 3

(1) 35R-C Backup Alarm Switch (6) Not used
(2) 35A-B Backup Alarm Disable Switch (7) 0-B21 Back Light Ground
(3) Not used (8) 49-L Back Light Power
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87324462 4

(A) Not used (G) Not used
(B) Not used (H) Not used
(C) Not used (J) 18K-D Diagnostic fused B+
(D) Not used (K) 18K-A Diagnostic fused power
(E) Not used (L) 18K-B Diagnostic fused B+
(F) Not used (M) Not used
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Wire connectors - Component diagram 12 - Lighting

Connector CAB-RF - Cab to roof connection
388710A1 1

(A) 0–DZ Work lights ground (J) 19K-C Rear wiper motor fused power
(B) 0–DY Roof splice grounds (K) 68C Rear wiper park control
(C) 42-A Dome light auto mode (L) 68L-B Rear wiper switch power
(D) 19U-D Dome light fused power (M) 0-EM Radio ground
(E) 46-C Beacon switch power (N) 12V-B 12V fused power to radio
(F) 0-DR Roof splice grounds (P) 19U-G Door switch fused power
(G) 0-DS Roof splice grounds (R) 43S-A Door open signal
(H) 42C-A Front work lights fused power (S) 42R-C Rear work lights fused power
Connector D-OR - Diode OR
245485C1 2

(A) 42C-D Front Work Lights Fused Power (C) 49 Back Light Power
(B) 41T-C Position Lights Switched Power
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Connector DS - Door switch
245482C1 3

(A) 19U-F Door Switch Fused Power (B) 43S-B Door Open Signal
Connector LLFW - LH front work light
225316C1 4

(1) 42C-H LH Front Work Lights fusedPower (2) 0-MU LH Front Work Lights Ground
Connector LLRW - LH rear work light
225316C1 5

(1) 42R-H LH Rear Work Lights fused power (2) 0-ME LH Rear Work Light Ground
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Connector LRFO - Front work light option
225316C1 6

(1) 42R-K Right hand front work lights fused (2) 0–MP Right hand front work lights ground
power
Connector LRFR - Front work light option
225316C1 7

(1) 42R-B Right hand front work lights fused (2) 0–ML Right hand front work lights ground
power
Connector LRFS - Front work lights option
225315C1 8

(1) 42R-A Right hand Front Work Lights fused (2) 0-MG Right hand Front Work Light Ground
power
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Connector LRFW - RH front work light
225316C1 9

(1) 42C-G RH Front Work Lights fused power (2) 0-MJ RH Front Work Light Ground
Connector LRRW - RH rear work light
225316C1 10

(1) 42R-G RH Rear Work Lights fused power (2) 0-MF RH Rear Work Light Ground
Connector MON - Camera / Monitor
280451A1 11

(1) 66A RR camera power (3) 35A-M Reverse signal
(2) 0-K Camera ground
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Connector ROOF - Roof to cab connection
388708A1 12

(A) 0-MV RH front work light ground (J) 19K-D Rear wiper motor fused power
(B) 0-MH Rear work light ground (K) 68C-A Rear wiper park control
(C) 43-B Dome light auto mode (L) 68L-A Rear wiper switch power
(D) 19U-C Dome light fused power (M) 0-EN Radio ground
(E) 46-D Beacon switch power (N) 12V-H 12V fused power to radio
(F) 0-MN Roof grounds (P) 19U-F Door switch fused power
(G) 0-MK Roof grounds (R) 43S-B Door open signal
(H) 42C-F Front work lights fused power (S) 42R-F Rear work lights fused power
Connector SBE - Beacon switch
382391A1 13

(2) 19U-H Beacon Switch Fused Power (7) 0-B15 Back Light Ground
(3) 46-C Beacon Switched Power (8) 49-B Back Light Power
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Connector SPL-ROOF - Splice roof ground
87324391 14

(A) 0-MC Beacon light ground (D) 0-MN Roof grounds
(B) 0-MB Dome light ground (E) 0-MK Roof grounds
(C) 0-MA Rear wiper motor ground (F) Not used
Connector SPL-BCK-LGT - Splice back light power
87324393 15

(A) 49 Back light power (G) 49-P Back light power
(B) Not used (H) 49-R Back light power
(C) 49-C Back light power (J) 49S Back light power
(D) 49-H Back light power (K) 49-E Back light power
(E) 49-L Back light power (L) 49-B Back light power
(F) 49A Back light power (M) 49-A Back light power
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Connector SPL-BCK-LGT-GD - Splice back light ground
87324393 16

(A) 0-B13 Back light ground (G) 0-B19 Back light ground
(B) 0-B14 Back light ground (H) Not used
(C) 0-B15 Back light ground (J) 0-B21 Back light ground
(D) 0-B6 CAB2 ground (K) 0-DAP Back light ground
(E) 0-B17 Back light ground (L) 0-B23 Back light ground
(F) 0-B18 Back light ground (M) 0-B32 Back light ground
Connector SWL - Work lights switch
382391A1 17

(1) Not used (6) 42R-C Rear work lights fused power
(2) 42-A Work lights fused power (7) 0-B14 Back Light Ground
(3) 42C-C Front work lights fused power (8) 49-A Back Light Power
(5) 42-B Work lights fused power (10) Not used
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Connector ECC - Electrical center C
87315249 1

(A1) 19U-B Beacon/Dome Lt Fused Pwr (D1) 59U Hood Up Relay Control
(A2) 42 Work Lights Sw Fused Pwr (D2) 19Y-A Hood Up Relay Fused Power
(A3) 19Z Driving Lights Sw Fused Pwr (D3) 59D Hood Down Relay Control
(A4) 1-DV Brake Lts/Flasher Bat Pwr (D4) 19Y-B Hood Down Relay Fused Power
(A5) 1DM Time Delay/Ign Sw Fused Pwr (D5) Brake Light Control Power
(A6) 19U Horn Relay Fused Power (D6) Brake Light Relay Out
(A7) 19Y Hood Control Fused Power (D7) 19U-E Horn relay Fused Power
(A8) 19S-B Cigar Lighter Fused Power (D8) 64-A Horn Power
(A9) 18K-A Diagnostic Fused Power (D9) 21J AC signal
(A10) 19T-C (D10) 61B AC signal
(B1) 60U Hood Up Relay Out (L1-1) ECC-L1 Beacon/Dome Lights LI ECC
(B2) 0-B25 Hood Up Control Ground (L1-1) J2-ECC Beacon/Dome Light Work Lights
(B3) 60D Hood Down Relay Out (L1-2) J2-ECC Beacon/Dome Light Work Lights
(B4) 0-B16 Hood Down Control Ground (L1-2) J3-ECC Work Lights Driving Lights
(B5) Not used (L1-3) J3-ECC Work Lights Driving Lights
(B6) Not used (L1-3) J4-ECC Driving Lights Brake Lights
(B7) 19U-A Horn Relay Fused Power (L1-4) J4-ECC Driving Lights Brake Lights
(B8) 64C Horn Relay Control (L1-4) J5-ECC Brake Lights Delay Power
(B9) 21E Key switch crank (L1-5) J5-ECC Brake Lights Delay Power
(B10) 0-J AC fan control relay ground (L1-5) J6-ECC Delay Power Horn
(C2) 0-B22 Hood Up Relay Ground (L1-6) J6-ECC Delay Power horn
(C4) 0-B12 Hood Down Relay Ground (L1-6) J7-ECC Horn HOD Control
(C10) 21E-B AC fan control relay ground (L1-7) J7-ECC Horn HOD Control
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Connector FLSHR - Flasher module
225389C1 2

(1) 1-DU Flasher Module Power (7) 45R-E Right Turn Signal
(2) 45N-A Flasher Optional Side Control (8) 45L-D Left Turn Signal
(3) 0-EH Flasher Module Ground (9) 45A-A Left Turn Switch Power
(4) 0-EG Flasher Module Ground (10) 45B-A Right Turn Switch Power
(5) Not Used (11) 45H Hazard Switch Power
(6) Not Used (12) 45N-B Flasher Optional Side Control
Connector PBL - Brake light pressure switch
222136A1 3

(1) 1-AA Brake Light Switch Power (2) 44 Brake Light Control Power
Connector SDR - Driving lights switch
382391A1 4
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(1) Not used (6) 41J Driving Lights Power
(2) 19Z-A Driving lights Switch Fused Pwr (7) 0-B19 Back Light Ground
(3) 41T Position Lights Switch Power (8) 49-P Back Light Power
(5) 19Z-B Driving Lights Switch Fused Power (10) Not used
Connector SHZ - Hazard switch
382391A1 5

(2) 1-KA Hazard switch power (7) 0-B24 Back Light Ground
(3) 45H Hazard switch power (8) 49-D Back Light Power
87324462 6

(A) 45L-E Left turn signal (G) 45R-D Right turn signal
(B) 45L-D Left turn signal (H) 45R-B Right turn signal
(C) 45L- C Left turn signal (J) 19J-B Front wiper/washer switch fused
power
(D) 45L-B Left turn signal (K) 19J-C Front wiper relay fused power
(E) 45R-C Right turn signal (L) 19J-D Front wiper relay fused power
(F) 45R-E Right turn signal (M) 19J-F Front wiper relay LS control fused
power
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Connector SRHSTLK - RH stalk switch
87318288 7

(31b) 64C Horn Relay Control (31) 0-EP Horn Switch Ground
(49a) 19B Turn Signal Fused Power (56) 41J Drive Lights Power
(56a) 41H-A High Beam Power (L) 45A-A Left Turn Switch Power
(56b) 41L-A Low Beam Power (R) 45B-A Right Turn Switch Power
(56d) 19Z-C High Beam Flash Fused Power
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Connector LLF - LH front lights
225351C1 1

(1) 0-AJ LH front lights ground (4) 18F LH Position / tail Fused Power
(2) 18D LH Low Beam fused power (5) 45L Left Turn Signal
(3) 18B LH High Beam fused power (6) Not used
Connector LRF - RH front lights
225351C1 2

(1) 0-AH RH front lights ground (4) 18G-A RH Position / Tail Fused Power
(2) 18E RH Low Beam fused power (5) 45R Right Turn Signal
(3) 18C RH High Beam fused power (6) Not used
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Wire connectors - Component diagram 15 - Engine / Lighting /

Backup alarm
Connector ENG-H - Engine to hood
225320C1 1

(1) 0-BAG-N Hood Ground (NA) (5) 18G-HN RH Position/Tail Fused Power
(2) 44A-DN Brake Light Relay Out (6) 18F-AN LH Position/Tail Fused Power
(3) 45L-AN Left Turn Signal (7) 35A-GN Backup alarm Relay Out
(4) 45R-AN Right Turn Signal (8) 35A-R Backup alarm relay out
Connector CABE2 - CAB to ENG2 bulkhead
NO_IMAGE 2

(A) 23B-D NOX relay B+ –1 (M) 18F-A Left hand position / tail fused power
(B) 18U-C DCU B+ non-disconnected – 1 (N) 18G-F Right hand position / tail fused power
(C) 23B-B NOX sensor B+ – 1 (P) 45R-B Right turn signal
(D) 1–NM Power non-disconnect (R) 45L-B Left turn signal
(E) 18U-E DCU B+ non-disconnected – 1 (S) 44A-A Brake light relay output
(F) 23B-A NOX sensor B+ – 1 (T) 19Y-C Hood switch fused power
(G) 1–NL Power non-disconnect (U) 60D Hood down relay output
(H) 18T DNOX switch B+ – 1 (V) 59D Hood down relay control
(K) 35A-F Backup alarm relay output (W) 60U Hood up relay output
(L) 35A-C Backup alarm relay output (X) 59U Hood up relay control
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Connector ENG2 - Engine bulkhead 2
NO_IMAGE 3

(A) 23B-F NOX relay B+ – 1 (M) 18F-AN Left hand position / tail fused power
18F-B Left hand position / tail fused power
(B) 18U-D DCU B+ non-disconnected – 1 (N) 18G-H Right hand position / tail fused power
18G-HN Right hand position / tail fused power
(C) 23A-A DNOX2 module B+ – 1 (P) 45R-A Right turn signal
45R-AN Right turn signal
(D) 1–NK Power non-disconnect (R) 45L-A Left turn signal
45L-AN Left turn signal
(E) 18U-B DCU B+ non-disconnected – 1 (S) 44A-D Brake light relay output
44A-DN Brake light relay output
(F) 23B-E NOX sensor B+ – 1 (T) 19Y-D Hood switch fused power
(G) 1–NJ Power non-disconnect (U) 60D-A Hood down relay output
(H) 18T-A DNOX2 switch B+ – 1 (V) 59D-A Hood down relay control
(K) 35A-G Backup alarm relay output (W) 60U-A Hood up relay output
35A-GN Backup alarm relay output
(L) 35A-J Reverse LT (X) 59U-A Hood up relay control
35A-R Backup alarm relay output
Connector HD-N - Hood to engine
225319C1 4

(1) 0-JA-N Hood Ground (NA) (5) 18G-JN RH Position/Tail Fused Pwr
(2) 44A-EN Brake Light Relay Out (6) 18F-BN LH Position/Tail Fused Pwr
(3) 45L-BN Left Turn Signal (7) 35A-HN Backup Alarm Relay Out
(4) 45R-BN Right Turn Signal (8) Not used
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Connector LLR - LH rear combination light
239451A1 5

(1) 0-BR-N LH Rear Light Ground (NA) (3) 18F-BN LH POSN / Tail Light Fused Power
(2) 44A-FN Brake Light Relay Out (4) 45L-BN Left Turn Signal
Connector LPL - License plate light
245482C1 6

(A) 18G-E License Plate Light Fused Pwr (B) 0-JC License Plate Light Ground
18G-EN License Plate Lamp Fused Pwr
18G-L License Plate Lamp Fused Pwr
Connector LRR - RH rear combination light
239451A1 7

(1) 0-BT-N RH Rear Light Ground (NA) (3) 18G-CN RH POSN / Tail Light Fused Power
(2) 44A-GN Brake Light Relay Out (4) 45R-BN Right Turn Signal
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Wire connectors - Component diagram 16 - Wiper / Washer system

Connector 140M - Diode module
245488C1 1

(A) 63H-C Front wiper high speed relay out (D) 58-D Ride control solenoid power
(B) 63L-C Front wiper low speed relay out (E) Not used
(C) 0-EE Diode suppression grounds (F) 68L-C Rear wiper switch power
Connector FWM - Front wiper motor
245715C1 2

(A) 63H-A Front wiper high speed relay out (C) 19J-A Front wiper motor fused power
(B) 63L-A Front wiper low speed relay out (D) 63C Front wiper park control
Connector FWMG - Front wiper motor ground
245480C1 3
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(A) 0-B8 Front wiper motor ground
Connector FWW - Front washer
3227856R1 4

(1) 63W-A Front washer pump (2) 0-B Front washer ground
Connector K-WCO - Wiper cutout
245731C1 5

(30) 63L-B Front wiper LS relay out (87) Not used
(85) 63HC-A Wiper cut out relay control (87A) 63C3 Front wiper park control
(86) 19J-G Wiper cut out relay fused power
Connector RWM - Rear wiper motor
245715C1 6
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(A) Not used (C) 19K-D Rear wiper motor fused power
(B) 68L-A Rear wiper switch power (D) 68C-A Rear wiper park control
Connector RWMG - Rear wiper motor ground
245480C1 7

(1) 0-MA Rear wiper motor ground
Connector RWW - Rear washer
3227856R1 8

(1) 68W-A Rear washer pump (2) 0-BL Rear washer ground
Connector SFWW - Front wiper and washer switch
87345132 9

(2) O-DT Front wiper/washer SW ground (7) 63W Front washer pump
(3) 63LC Front wiper LS relay control (8) 49-T Back light power
(4) Not used (9) 63HC Front wiper HS relay control
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(5) 19J-B INT wiper/washer SW fused power (10) Not used
Connector SPL-ENG — Ground splice 6 pack
87324391 10

(A) 0-BM Engine splice grounds
(B) 0-BY Chassis ground
(C) Not used
(D) 0-BS Fan control ground
(E) 0-B Front washer motor ground
(F) 0-BL Rear washer motor ground
Connector SPL-PK3 - Splice 3 4 way
87324462 11

(A) 45L-E Left turn signal (G) 45R-D Right turn signal
(B) 45L-D Left turn signal (H) 45R-B Right turn signal
(C) 45L-C Left turn signal (J) 19J-B Front wiper/washer switch fused
power
(D) 45L-B Left turn signal (K) 19J-C Front wiper relay fused power
(E) 45R-C Right turn signal (L) 19J-D Front wiper relay fused power
(F) 45R-E Right turn signal (M) 19J-F Front wiper relay LS control fused
power
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Connector SRWP - Rear wiper switch
382391A1 12

(1) 68C Rear wiper park control (6) 68W Rear washer pump
(2) 68L Rear wiper switch power (7) O-B23 Back light ground
(3) 19K-A Rear wiper switch fused power (8) 49-C Back light power
(5) 19K-b Rear wiper switch fused power (10) Not used
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Wire connectors - Component diagram 17 - Secondary steering

Connector 242F - Chassis ground secondary steering motor
NO_IMAGE 1

(1) 0–ND Secondary steering motor ground
Connector 245F - Secondary steering flyback
NO_IMAGE 2

(1) 0–CG Secondary steering flyback ground
0–CH Secondary steering flyback ground
Connector DM - Diode OR
245485C1 3

(A) 19RR Sec. steering ignition fused power (C) 19R Sec. steering ignition fused power
(B) Not used
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Connector PSS - Secondary steering pressure switch
245485C1 4

(A) 51P-A Secondary steer high pressure (C) 35X-A Secondary steer low pressure signal
(B) 0-CC Sec. steer press switch ground
Connector SPL-SEC- Sec Str 6pk
87324391 5

(A) 0-CB Sec. steering signal ground (D) 0-CF Sec. steering solenoid ground
(B) 0-CA Sec. steering signal ground (E) Not used
(C) 0-CC Sec. steering press switch ground (F) 0-CD Sec. steering splice ground
Connector SSD - Secondary steering diode
245485C1 6

(A) 0–CH Secondary steering flyback ground (C) 51–D Secondary steering flyback
(B) 0–CG Secondary steering flyback ground
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Connector SSM - Secondary steering module
225389C1 7

(1) 19R-C Sec. steering ignition fused power (7) 19M-C Secondary steer accessory fused
power
(2) 51-A Secondary steer motor control (8) 35X-D Secondary steer low press signal
(3) 19S1-X Secondary steer fused power (9) 51P-A Secondary steer high press
(4) 0-CE Secondary steer chassis ground (10) Not used
(5) Not used (11) 0-CA Secondary steer signal ground
(6) Not used (12) 0-CB Secondary steer signal ground
Connector SSS - Secondary steering magnetic switch
NO_IMAGE 8

(1) 51D Secondary steering flyback
51B Secondary steering motor control
Connector SS-TR - SS-mod trans
245489C1 9

(A) 19M-C Sec. steer accessory fused power (D) Not used
(B) 19R-C Sec. steer ignition fused power (E) 19S1-X Sec. steer fused power
(C) 35X-C Sec. steer low press signal (F) Not used
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Connector TR-SS
245488C1 10

(A) 19M-A Sec. steer accessory fused power (D) Not used
(B) 19R-A Sec. steer ignition fused power (E) 19S1-E Sec. steer fused power
(C) 35X-B Sec. steer low press signal (F) Not used
Connector YSS - Secondary steering solenoid
225316C1 11

(1) 51-C Sec. steering solenoid control (2) 0-CF Sec. steering solenoid ground
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Wire connectors - Component diagram 18 - Diagnostic

Connector DIA - Diagnostic
87736919 1

(A) 0-DH Diagnostic connector ground (D) CAN-LB Controller area network low
(B) 18K-D Diagnostics fused B+ (E) 20G-B EDC7 ISO-K interface
(C) CAN-HB Controller area network high
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Wire connectors - Component diagram 19 - Radio power / converter

/ Heated mirrors
Connector CNV - 24V to 12V power convertor
225351C1 1

(1) 19L-A Power convertor fused power (4) Not used
(2) 19L-B Power convertor fused power (5) 12V-C 12V switched power
(3) O-EJ Power convertor ground (6) O-ER Power convertor ground
Connector GND-CAB-SPL - Cab ground splice
87324393 2

(A) O-EE Diode suppression grounds (G) O-DT Front wiper/washer switch ground
(B) O-EM Radio ground (H) O-VA Heated mirrors ground
(C) O-EP Horn switch ground (J) 0-DK Seat compressor motor ground
(D) 0D-C Diag2 ground (K) O-DJ AC relay control ground
(E) 23B-C NOX relay ground –1 (L) O-DU Pilot pressure solenoid ground
(F) O-DG Cab splice grounds (M) O-DH Diagnostic connector ground
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Connector LSPK - Left speaker
195552A1 3

(A) 65L Left speaker signal (B) O-PA Left speaker ground
Connector PO1 - Power outlet
12176446 4

(A) 12V 12V power to outlet 1 (C) O-EK Auxiliary power outlet 1 ground
(B) Not used
Connector PO2 - Power outlet
12176446 5

(A) 12V-A 12V power to outlet 2 (C) O-EL Auxiliary power outlet 2 ground
(B) Not used
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Connector RAD - Radio power
292495A1 6

(3) Not used (7) 12V-HA 12V fused power to radio
(4) 12V-HB 12V fused power to radio (8) O-EN Radio ground
Connector RAD-J1 - Radio power
292497A1 7

(3) Not used (7) RAD2 12V fused power to radio
(4) RAD3 12V fused power to radio (8) RAD1 Radio ground
Connector RAD-J2 - Speaker
292501A1 8
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(1) RAD11 Right speaker (5) Not used
(2) RAD10 Right speaker ground (6) Not used
(3) Not used (7) RAD5 Left speaker
(4) Not used (8) RAD4 Left speaker ground
Connector RAD-J3 - Radio jumper
411311A1 9

(1) RAD10 Right speaker ground (8) RAD11 Right speaker
(2) RAD8 Not used (9) RAD9 Not used
(3) RAD4 Left speaker ground (10) RAD5 Left speaker
(4) RAD6 Not used (11) RAD7 Not used
(5) RAD1 Radio ground (12) RAD2 12V fused power to radio
(7) RAD3 12V fused power to radio (14) Not used
Connector RSPK - Right speaker
195552A1 10

(A) 65R Right speaker signal (B) O-PB Right speaker ground
Connector SPK - Speaker
292494A1 11
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(1) 65R Right speaker (5) Not used
(2) O-PB Right speaker ground (6) Not used
(3) Not used (7) 65L Left speaker
(4) Not used (8) O-PA Left speaker ground
Connector MH -Mirror Heater
225295C1 12

(A) 18V Mirror heater power (C) 49Y A Mirror switch illumination power
(B) O VA Mirror heater ground Not used
Connector MHS - Mirror heat switch
382391A1 13

(2) 18V C Mirror heat switch contact power (7) O VE Mirror heat switch illumination
ground
(3) 69F Mirror heat switch signal (8) 49Y B Mirror heat switch illumination power
(4) Not used (9) O VD Mirror heat switch illumination output
ground
(5) Not used (10) 69 B Mirror heat timer signal output
Connector MH C -Mirror heaters
225294C1 14
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(A) 18V A Mirror heater power (C) 49Y B Mirror switch illumination power
(B) O VB Mirror heater ground Not used
Connector MH L– Mirror heater left
225316C1 15

(1) 69 E Mirror heater left power (2) O VH Mirror heater left ground
Connector MH R- Mirror heater right
225316C1 16

(1) 69 D Mirror heater right power (2) O VJ Mirror heater right ground
Connector TRLY- Mirror heater timer relay
245731C1 17
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(87) 69F Mirror heater switch signal (85) Not used
(87A) O VC Timer relay ground (86) 69 A Timer relay output
(30) 18V B Timer relay power
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Wire connectors - Component diagram 20 - Air seat

Connector SC - Seat compressor motor
245482C1 1

(A) 19N Seat compressor fused power (B) 0-DK Seat compressor motor ground
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Wire connectors - Component diagram 21 - Cigar lighter

Connector CL - Cigar lighter
3227856R1 1

(1) 19W Cigar lighter fused power (2) 0-DV Cigar lighter ground
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Wire connectors - Component diagram 22 - HVAC

Connector HVAC1 - HVAC1
239451A1 1

(1) 61A-F Trinary pressure switch input (3) 49A Back light power
(2) 18N-A Blower motor fused power (4) 61B-A AC signal
Connector HVAC2 - HVAC2
87552622 2

(1) 18N-B Blower motor fused power (2) O-ED HVAC grounds
Connector PRH - AC high pressure switch
245482C1 3

(A) 61A-D AC switch input (B) 61R-D AC switch output
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Wire connectors - Component diagram 23 - HVAC

Connector SAC – AC switch

(2) DNS73 (7) DNS71
(3) DNS68 (8) DNS80
Connector DNS actuator

(5) DNS48 (6) DNS49
Connector DNS driver
411311A1 1

(1) (8) DNS58
(2) DNS50 (9) DNS59
(3) DNS52 (10)
(4) DNS49 (11) DNS51
(5) DNS48 (12) DNS53
(6) DNS55 (13) DNS54
(7) DNS57 (14) DNS56
Connector DNS electric fan

(1) DNS65 (2) DNS66
Connector DNS electric water valve

(1) DNS60 (4) DNS57
(2) (5) DNS58
(3) DNS56 (6) DNS59
Connector DNS HVAC1 S
225326C1 2
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(1) DNS67 (3) DNS69
(2) DNS76 (4) DNS77
Connector DNS HVAC2 S
225315C1 3

(1) DNS74 (2) DNS75
Connector SRC1 – Recirculation switch

(2) DNS51 (7) DNS70
(3) DNS53 (8) DNS79
Connector DNS resistor

(1) DNS61 (3) DNS63
(2) DNS62 (4) DNS64
Connector SB1 – Blower speed selector

(A) DNS61 (D) DNS81
(B) DNS62 (E) DNS74
(C) DNS63 (F) DNS73
Connector DNS thermostat 1

(1) DNS67
Connector DNS thermostat 2

(1) DNS78
Connector DNS Water valve pot

(B) DNS54 (C) DNS55
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Wire connectors - Component diagram 24 - Hood lift

Connector HD - Hood switch
245485C1 1

(A) 59D-A Hood relay control down (C) 59U-A Hood relay control up
(B) 19Y-D Hood switch fused power
Connector HDM - Hood lift motor
225316C1 2

(1) 60U-A Hood up relay out (2) 60D-A Hood down relay out
Connector SPL-HOOD-GND - Hood ground 6 pack
87324391 3

(A) O-B12 Hood down relay ground (D) O-B25 Hood up control ground
(B) O-B16 Hood down control ground (E) O-B10 Hood ground
(C) O-B22 Hood up relay ground (F) Not used
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Wire connectors - Component diagram 25 - Engine controller

Connector A — Engine Controller
BS07J141 1
For Six Cylinder Models

Cavity Circuit Cavity Circuit
(1) Cylinder 5 injector (9) High pressure regulator with fuel
metering
(2) Cylinder 6 injector (10) High pressure regulator with fuel
metering
(3) Cylinder 4 injector (11) Cylinder 2 injector
(7) Not used (15) Cylinder 6 injector
(8) Not used (16) Cylinder 5 injector
Connector C — Sensor connector
BS07J142 2

(1) Not used (19) Crankshaft speed sensor- Ground
(5) Not used (23) Crankshaft speed sensor- Signal
(6) Not used (24) Engine oil pressure and
temperature sensor- Ground
(7) Not used (25) Boost intake pressure sensor-
Ground
(8) Not used (26) Coolant temperature sensor-
Ground
(9) Camshaft speed sensor- Signal (27) Oil pressure sensor- Signal
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(10) Camshaft speed sensor- Ground (28) Oil temperature sensor- Signal
(12) Common rail temperature and (30) Not used
pressure sensor- Ground
(13) Common rail temperature and (31) Not used
pressure sensor- Positive
(14) Common rail temperature and (32) Engine oil pressure and
pressure sensor- Signal temperature sensor- Positive
(15) Coolant temperature sensor- (33) Boost intake pressure sensor-
Signal Positive
(16) Not used (34) Boost intake pressure sensor-
Signal
(17) Not used (35) Fuel temperature sensor- Signal
(18) Fuel temperature sensor- Signal (36) Boost intake temperature sensor-
Signal
Connector injectors
BD08J012-01 3
Shown from front of connector.

(1) Odd numbered injectors (3) Even numbered injectors
(2) Odd numbered injectors (4) Even numbered injectors
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Wire connectors - Component diagram 26 - Joystick Steering

Connector JSS 197F — Main CAB FNR
225350C1 1

(1) 0 SS Joystick ground (4) 26R D FNR reverse signal
(2) 26F D FNR forward signal (5) 32J G Trans enable indiction
(3) 26N D FNR neutral signal (6) 25Y F
Connector JSS 197M — FNR main CAB
225351C1 2

(1) 19B A FNR switched fused power (4) 16R C FNR reverse signal
(2) 26F C FNR forward signal (5) 32J F Trans enable indiction
(3) 26N C FNR neutral signal (6) 25Y D Trans kick down signal
Connector 21M — Trans kick down
225316C1 3
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(1) 19B D FNR switched fused power (2) 25Y G Trans kick down signal
Connector SAJ — FNR switch
382391A1 4

(1) 26R F FNR reverse signal (6) 26F F FNR forward signal
(2) 26K FNR switch jumper (7) 32J J Trans enable indiction
(3) 26N F FNR neutral signal (8) 19B F FNR switch fused power
(4) Not used (9) NOT
USED
(5) 19B E FNR switch fused power (10) NOT
USED
Connector JSS-Valve — JSS hydraulic valve
239451A1 5

(1) 51L Joystick signal (3) O AT JSS valve ground
(2) 51J C JSS alarm (4) 51S J JSS okay power
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Connector JSS-Pil-Dump — JSS pilot dump
225316C1 6

(1) 51PW K JSS power (2) O AU Pilot dump ground
Connector Arm-FNR — FNR main CAB
280453A1 7

(1) 19B C FNR switched power (4) 26R F FNR reverse signal
(2) 26F F FNR forward signal (5) 32J J FNR LT signal
(3) 26N F FNR neutral signal (6) 25Y G Trans kickdown signal
Connector Cab-FNR — Main cab FNR
280451A1 8

(1) 19B B Trans enable switched power (4) 26R E FNR reverse signal
(2) 26F E FNR forward signal (5) 32J H Trans enable LT signal
(3) 26N E FNR neutral signal (6) 25Y E none
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Connector JSS-Pil-Pr — JSS pilot pressure
245483C1 9

(A) 18S E JSS fused B+ (B) 51K C Pilot pressure switch signal
Connector JSS-LS — JSS load sense
245483C1 10

(A) 51PW J JSS power (B) 51F A LS pressure switch signal
Connector Cab-Frm — CAB to JSS frame
256354A1 11

(A) 51F B LS pressure switch (F) 51S F JSS okay power
(B) 51J A Valve alarm (G) 0 SF Ground
(C) 51K B Pilot pressure switch (H) 51PW T JSS power
(D) 51L A Joystick signal (J) 18S D JSS fused B+
(E) Not used (K) Not used
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Connector JSS Frm — JSS frame to CAB
256352A1 12

(A) 51F C LS pressure switch signal (F) 51S J JSS okay power
51F-A LS pressure switch signal
(B) 51J C JSS alarm (G) O AS Joystick ground
(C) 51K C Pilot pressure switch signal (H) 51PW H JSS power
(D) 51L Joystick signal (J) 18S E JSS fused B+
(E) Not used (K) Not used
Connector RVS-Diode — Diode assembly
245485C1 13

(A) 26R D FNR reverse signal (C) 16R C FNR reverse signal
(B) 26R E FNR reverse signal
Connector NTRL-Diode — Diode assembly
245485C1 14
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(A) 26N D FNR neutral signal (C) 26N C FNR neutral signal
(B) 26N E FNR neutral signal
Connector FWD-Diode — Diode assembly
245485C1 15

(A) 26F D FNR forward signal (C) 26F C FNR forward signal
(B) 26F E FNR forward signal
Connector KD-Diode — Diode assembly
245485C1 16

(A) 25Y F Trans kick down signal (C) 25Y D Trans kick down signal
(B) 25Y E Trans kick down signal
Connector FNR Rly — Relay K2
245731C1 17
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(30) 19B A FNR switch fused power (87) 19B B Trans enable switch power
(85) 0 ST Joystick ground (87A) 0 SS Trans enable switch power
(86) 51B K JSS power
Connector Cab-Arm — Cab to armrest
225402C1 18

(1) CANS CAN HI, CAN MOD2 (7) 0 SD Joystick ground
HB
(2) 0 SJ CAN MOD ground (8) 51PW R JSS power
(3) 51E A Armrest lower (9) 51S B JSS okay power
(4) 17P D CAN MOD B+ (10) 51H B Joystick signal
(5) Not used (11) 51NO A NO neutral switch
(6) 51B H JSS ACT switch (12) CANS LB CAN LO, CAN MOD2
Connector JSS-Rly — Relay K2
245731C1 19

(30) 51PW P JSS power (87) 51B G JSS B+
(85) 51D B Relay control ground (87A) 0 SL Ground
(86) 51B E JSS B+
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Connector Cab-Arm-Frm — Cab to arm to frm
225388C1 20

(1) CANS CAN LO, CAN MOD2 (7) CANS HD CAN HI, CAN MOD3
LB
(2) 17P G Joystick B+ (8) 0 SK CAN MOD ground
(3) Not used (9) 51PW M JSS power
(4) 51D B Relay control ground (10) 51C B JSS ACT BTN
(5) 51B D JSS ACT switch (11) 18S D JSS fused B+
(6) CANS CAN LO, CAN MOD3 (12) CANS HB CAN HI, CAN MOD2
LD
Connector JSS-Cab — JSS cab
225389C1 21

(1) CAN LP CAN LOW, CAN MOD3 (7) CAN HR CAN HI, CAN MOD3
(2) 17P C CAN MOD B+ (8) 0 BBD Joystick ground
0.8
(3) Not used (9) 51PW N 8 JSS power
(4) 51D A Relay control ground (10) 51C A JSS ACT BTN
(5) 51B C JSS ACT switch (11) 18S C JSS fused B+
(6) CAN LR CAN LOW, CAN MOD2 (12) CAN HP CAN HI, MOD2
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Connector SJS — Joystick control switch
382391A1 22

(1) Not used (6) 51B B JSS ACT switch
(2) 18S B JSS fused B+ (7) 0 BBB Joystick ground
(3) 51B A JSS ACT switch (8) 49 W JSS backlight
(4) 0 BBA Joystick ground (9) 0 BBE Joystick ground
(5) 51C A JSS ACT BTN (10) 51PW N JSS power
Connector JSS-Cnt — JSS controller
967242 23

(1) CANS CAN HI, CAN MOD3 (9) 51PW Q JSS power
HD
(2) CANS CAN LO, CAN MOD3 (10) 0 SM Joystick ground
LD
(3) 17P F JSS controller B+ (11) 0 SN Joystick ground
(4) 51H B Joystick signal (12) 51J B Valve alarm
(5) 51S A JSS okay power (13) 51C B JSS ACT BTN
(6) 51E A Armrest lower (14) 51NO A NO neutral switch
(7) 51L A Joystick signal (15) 0 SR Joystick ground
(8) 51K B Pilot pressure switch (16) 51F B LS pressure switch
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Connector JSS-Arm — JSS armrest to cab
225400C1 24

(1) CANS CAN HI, CAN MOD2 (7) 0 SC Joystick ground
HA
(2) 0 SH CAN MOD ground (8) 51PW S JSS power
(3) 51E B Armrest lower (9) 51S C JSS okay power
(4) 17P E CAN module B+ (10) 51H C Joystick signal
(5) Not used (11) 51NO NO neutral switch
(6) 51B J JSS ACT switch (12) CANS LA CAN LO, CAN MOD2
Connector Arm-Pos — Arm position
225259C1 25

(1) 0 SG Common (3) 51E B Armrest lower
(2) 51R Armrest raise
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Connector PVRES — JSS joystick
NO_IMAGE 26

(R) 51S E JSS okay power (T) 51H C Joystick signal
(W) 51NC NC neutral switch (U) 51NO NO neutral switch
(S) 51PW V JSS power (V) 0 SC Joystick ground
Connector Can-Mod-2 — JSS Can Mod
87635073 27

(1) 51B J JSS ACT switch (6) Not used
(2) 51PW U JSS power (7) CANS HA CAN HI, CAN MOD2
(3) 51NC NC neutral switch (8) CANS LA CAN LO, CAN MOD2
(4) 51S D JSS okay power (9) 17P E CAN MODULE B+
(5) 51R Armrest raise (10) 0 SE Ground
Connector Gnd-JSS — Ground A
NO_IMAGE 28
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(1) O AV Ground
NOTE: Ring terminal
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Diagnostic connector - Testing - DIA and DIA-2

Turn the ignition key switch OFF. Re- The voltage should be approximately If the voltage is less than 10 V check
move connector DIA or DIA-2 from 24 volts. Diagnostic fuse ECC-F9, 10 A. Diag-
the appropriate diagnostic connec- nostic connectors are identical other
tor. than the ISO K line for connector DIA
Check goes to the engine controller, and
Measure voltage on the connector DIA-2 goes to the DNOX controller.
from pin B to chassis ground.
Measure the resistance from pin A to The resistance should be less than If the resistance is greater than 10 Ω
chassis ground. 10 Ω. . or an open circuit is indicated, check
connectors and wires for corrosion
or damage. Repair or replace as
necessary.
RCIL11WHL051EAK 1
(1) CAN bus to engine controller (3) ISO K interface

(2) 24 Volt unswitched battery power, fuse (4) Diagnostic connector
ECC-F9 10 amp.
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Index

Wire harnesses - Electrical schematic frame 05 - Engine control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Wire harnesses - Electrical schematic frame 06 - Lighting1, Backup alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Wire harnesses - Electrical schematic frame 07 - Lighting 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Wire harnesses - Electrical schematic frame 08 - Transmission controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Wire harnesses - Electrical schematic frame 09 - Instrument cluster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Wire harnesses - Electrical schematic frame 10 - Machine controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Wire harnesses - Electrical schematic frame 11 - Secondary steering, Hood lift, Wiper/Washer system . . . . . . . 22
Wire harnesses - Electrical schematic frame 12 - HVAC, Air seat, Radio power/converter . . . . . . . . . . . . . . . . . . . 24
Wire harnesses - Electrical schematic frame 13 -Joystick steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Wire harnesses - Electrical schematic frame 14 - Standard HVAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Diagnostic connector - Testing - DIA and DIA-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
Wire connectors - Component diagram 01 - Engine control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Wire connectors - Component diagram 02 - Engine control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Wire connectors - Component diagram 03 - Engine control / emissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Wire connectors - Component diagram 04 - Engine / machine controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Wire connectors - Component diagram 05 - Machine controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Wire connectors - Component diagram 06 - Transmission controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Wire connectors - Component diagram 09 - Instrument cluster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Wire connectors - Component diagram 10 - Instrument cluster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Wire connectors - Component diagram 11 - Backup alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Wire connectors - Component diagram 12 - Lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Wire connectors - Component diagram 15 - Engine / Lighting / Backup alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Wire connectors - Component diagram 16 - Wiper / Washer system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Wire connectors - Component diagram 17 - Secondary steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Wire connectors - Component diagram 18 - Diagnostic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Wire connectors - Component diagram 19 - Radio power / converter / Heated mirrors . . . . . . . . . . . . . . . . . . . . . 105
Wire connectors - Component diagram 20 - Air seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Wire connectors - Component diagram 21 - Cigar lighter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Wire connectors - Component diagram 22 - HVAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Wire connectors - Component diagram 23 - HVAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
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Wire connectors - Component diagram 24 - Hood lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Wire connectors - Component diagram 25 - Engine controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Wire connectors - Component diagram 26 - Joystick Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
Wire harnesses - Electrical schematic frame 01 -Index of functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Wire harnesses - Electrical schematic frame 02 - Wire color abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Wire harnesses - Electrical schematic frame 03 - Wire information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Wire harnesses - Electrical schematic frame 04 - Cold start , Power distribution, Ignition switch . . . . . . . . . . . . . . . 8
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Engine starting system - 201
1021F
1121F
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Contents
DIAGNOSTIC
Engine starter
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Ignition switch
Testing Ignition switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Engine start relay
Testing - Starting relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Neutral start relay - Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
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Electrical systems - Engine starting system
Engine starter - Testing

Turn the key switch OFF. The connections are secure. The The connections are not secure or
Check connections are free of corrosion, the connections show signs of corro-
Verify the battery connections are abrasion and damage. sion, abrasion and damage. Repair
tight and secure. Check the wiring as required.
and connections for corrosion, abra-
sion and damage. Verify that the
chassis ground frame connections
are secure and tight and free of oil,
paint, dirt, damage and debris.
Check 10 Ω. Ω, there is a problem in the chas-
Measure the resistance from the sis ground circuit to the Starter Mo-
Starter Ground Stud to chassis tor. Verify all connections are secure
ground. Measure the resistance and free of corrosion, abrasion and
from the Starter Ground Stud to the incorrect attachment. Repair as re-
Minus Battery terminal. quired.
Turn the key switch OFF. The voltage should be approximately There voltage is less than 10 volts,
Check 24 volts. there is a problem in the battery sup-
Measure the voltage from the Start- ply to the Starting Relay. Verify all
ing Relay terminal 87 to chassis connections are secure and free of
ground. corrosion, abrasion and incorrect at-
Check 10 Ω. there is a problem in the signal wire
Measure the resistance from Starter from the relay to the starter. Verify
Relay terminal 30 to the Starter So- all connections are secure and free
lenoid terminal 194/S. of corrosion, abrasion and incorrect
Set the parking brake. Place the ma- Starter motor solenoid should en- The starter did not engage. Replace
chine in NEUTRAL. Turn the Mas- gage. You will hear an audible click the starter and retest.
ter Disconnect Switch to the OFF po- when the solenoid is engaged.
sition. Disconnect wire 1_Z R-8.0 Action
from relay terminal 87. Fabricate two The problem is in the starting circuit
jumper wires that will reach from the to the starting relay. Repair as re-
BT1 terminal on the battery to termi- quired. Refer to Engine start re-
nal 86 on the Starting Relay. Con- lay Neutral start relay - Testing
nect one end of each jumper to BT1 (55.201), Engine start relay - Test-
terminal on the battery. ing — Starting relay (55.201) or
Check Ignition switch - Testing Ignition
Connect the one end of a jumper switch (55.201).
wire to terminal 87. Connect the
other jumper wire to terminal 86.
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RCPH11WHL004HAL 1
(1) Left Battery, 12 V (5) Starting Motor

(2) Right Battery, 12 V (6) Starting Solenoid
(3) Master Disconnect Switch (7) Power Relay Module, PRM_D
(4) Starting Relay (8) Starting Signal from Crank Control Relay
Chassis Ground on Engine Block Near
Starter
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Ignition switch - Testing Ignition switch

Turn the ignition key OFF and re- The voltage should be approximately If the voltage is less than 10 V check
move connector S KEY from the Ig- 24 volts. fuse ECC-F5. Replace as required.
nition switch.
Check
Measure the voltage on the connec-
tor from pin 1 to chassis ground.
Disconnect the connector S KEY The resistance should be less than If the resistance is greater than 10
from the ignition switch. Turn the 10 Ω. Ω or an open circuit is indicated, re-
switch to ON (IGN). place bad ignition switch.
Check
BAT and IGN.
Measure the resistance between The resistance should be less than If the resistance is greater than 10
BAT and ACC. 10 Ω. Ω or an open circuit is indicated, re-
place bad ignition switch.
from the ignition switch. Hold the ig- 10 Ω. Ω or an open circuit is indicated, re-
nition switch in the START position. place bad ignition switch.
Check
BAT and ST.
Measure the resistance between The resistance should be less than If the resistance is greater than 10
BAT and IGN. 10 Ω. Ω or an open circuit is indicated, re-
place bad ignition switch.
from the ignition switch. Turn the 10 Ω. Ω or an open circuit is indicated, re-
ignition switch to the ACC position. place bad ignition switch.
Check
BAT and ACC.
RCIL11WHL044EAK 1
(1) AIC indicator light (5) Ignition power control relay – coil
(2) Ignition power latch relay – coil (6) Power relay module C – coil
(3) Neutral start relay – contact (7) 24 Volt supply, unswitched power to
ECC-F5 10 Amp fuse
(4) Power relay modules A and B – coil (8) Ignition switch
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Engine start relay - Testing - Starting relay

Turn the ignition key switch OFF. The resistance should be less than If the resistance is greater than 10 Ω
Remove connector SRC 1 from the 10 Ω or an open circuit is indicated, repair
starting relay. or replace wire (0 GB Bk-1.0).
Check
Measure resistance from connector
pin 2 to chassis ground.
Turn the ignition key switch OFF The resistance should be less than If the resistance is greater than 10 Ω
and remove connectors 193 from 10 Ω. or an open circuit is indicated, repair
the starting relay and 194 from the or replace wire (1 BB R-8.0).
starter.
Check
Measure the resistance from 193 to
194.
Turn the ignition key switch OFF The voltage should be approximately If the voltage is less than 10 V check
and remove connector 195 from the 24 volts. wire (1 Z R-8.0) termination at power
starting relay. relay module D. Also verify the mas-
Check ter disconnect switch is ON. Check
Measure the voltage from 195 to circuit to batteries.
chassis ground.
Put the transmission in NEUTRAL. The voltage should be approximately If the voltage is less than 10 V check
Remove connector SRC 1 from the 24 volts. for voltage at connectors ENG pin
starting relay. Have another person 15 and CAB E pin 15. If no voltage
hold the ignition switch in the START trace circuit back through the Crank
position. control relay and Neutral start relay.
Check Also verify crank control signals from
Measure the voltage from the con- EDC7 engine controller pins 17 and
nector pin 1 to chassis ground. 37.
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RCIL11WHL043EAK 1
(1) Starting relay (5) EDC7 engine controller

(2) Cranking motor (6) Crank control relay
(3) 24 Volt supply power, unswitched (7) Chassis ground
(4) Ground – on engine block near starter
Engine start relay Neutral start relay - Testing

Turn the ignition key switch OFF. The resistance should be less than If the resistance is greater than 10 Ω
Check 10 Ω. check the circuit through splice GND
Measure the resistance from the CAB SPL2. Repair or replace wire
Neutral start relay terminal 85 to as necessary.
chassis ground.
Turn the ignition key switch ON and The voltage should be approximately Check signals from TECM module
the transmission in neutral. 24 volts. pin 67 and the transmission shifter
Check TS1 pin D.
Measure the voltage from the Neu-
tral start relay terminal 86 to chassis
ground.
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Turn the ignition key switch OFF and The voltage should be approximately If the voltage is less than 10 V check
remove wire (21C W-0.8) from termi- 24 volts. wire (21K B W-0.8) through splice
nal 87 on the neutral start relay. Turn SPL CRK to the ignition switch (21K
the ignition key switch ON. With the W-0.8). Verify voltage on ignition
transmission in neutral, have some- switch connector S KEY on pin 2.
one hold the ignition switch in the
START position.
Check
ground.
Turn the ignition key switch OFF and The voltage should be approximately If the voltage is less than 10 V and
remove wire (21C W-0.8) from termi- 24 volts. there is voltage on the Neutral start
nal 87 on the neutral start relay. Turn relay terminals 86 and 30, then re-
the ignition key switch ON. With the place the relay.
transmission in neutral, have some-
one hold the ignition switch in the
START position.
Check
ground.
RCIL11WHL045FAK 1
(1) TECM neutral signal pin 67 (5) Neutral start relay

(2) TS1 transmission shifter pin D (6) Crank request relay — coil
(3) CAB E pin 15 starting relay (7) Ground GND CAB SPL2 pin G
(4) Crank control relay — contact (8) Ignition switch
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Index

Engine start relay - Testing - Starting relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Engine start relay Neutral start relay - Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Engine starter - Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Ignition switch - Testing Ignition switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
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Cold start aid - 202
1021F
1121F
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Contents
DIAGNOSTIC
Grid heater relay

Testing - Grid heater relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Fuel pre-heater
Testing - Water separator heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Testing - Fuel filter heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
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Electrical systems - Cold start aid
Grid heater relay - Testing - Grid heater relay

Turn the ignition key switch OFF and The voltage should be approximately If the voltage is less than 10 V check
remove connector GHF4 from the 24 volts. GH fuse.
grid heater relay.
Check
Measure the voltage from GHF4 to
chassis ground.
Turn the ignition key switch OFF and The resistance should be less than If the resistance is greater than 10 Ω
remove connector GHF4 from the 10 Ω. or an open circuit is indicated, check
grid heater relay and GHF3 from the wire for corrosion or damage. Re-
GH fuse. place or repair as necessary.
Check
Measure the resistance from GHF4
to GHF3.
Have an assistant put the transmis- The voltage should be approximately If the voltage is less than 10 V ver-
sion in neutral and the ignition switch 24 volts. ify wiring circuit from GHC pin 1 to
in the START position. Remove con- EDC7 pin 12, wire (28G W-1.0).
nector GHC from the grid heater re- Check voltage on EDC7 pin 12 for
lay. Make sure engine temperature 24 volts and that the engine tem-
is below - 10 °C (50.0 °F) perature is below 10 °C (50.0 °F).
Check
Measure the voltage from GHC pin 1
to chassis ground.
Remove connector GHC from the The resistance should be less than If the resistance is greater than 10 Ω
grid heater relay, and connector 10 Ω. or an open circuit is indicated, check
EDC7 from the engine controller. the wiring and connectors for corro-
Check sion or damage. Repair or replace
Measure the resistance from GHC wire (28G W-1.0) if necessary.
pin 1 to EDC7 pin 12.
Measure the resistance from GHC The resistance should be less than If the resistance is greater than 10 Ω
pin 2 to EDC7 pin 75 on wire (0 BV 10 Ω. or an open circuit is indicated, check
Bk-0.8) . the wiring and connectors for corro-
sion or damage. Repair or replace
wire if necessary.
Have an assistant put the transmis- The voltage should be approximately If the voltage is less than 10 V and
sion in neutral and the ignition switch 24 V. there is 24 V on terminal 30 and 86,
in the START position. . Make sure then replace the grid heater relay.
engine temperature is below - 10 °C
(50.0 °F)
Check
Measure the voltage from connector
115 (terminal 87 on grid heater relay)
to chassis ground..
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RCIL11WHL054FAK 1
Schematic legend
(1) Grid Heater Relay (5) EDC7 Engine Controller
(2) Grid Heater Fuse (6) ENG/ CAB_E connector
1021F\1121F – 200 A
521F\621F\721F\821F\921F – 150 A
(3) Grid Heater (7) 24 V supply to Grid Heater Fuse and Grid
1021F\1121F – 150 A ± 8% at 22 V Heater Relay.
521F\621F\721F\821F\921F – 110 A ± 8% Note 521F\621F\721F\821F\921F use 19mm
at 22 V squared wiring instead of 32mm squared.
(4) GND_GH1 , On engine block near grid (8) Key Switch 24 V from Master Disconnect
heater Switch
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Fuel pre-heater - Testing - Water separator heater

Turn ignition key switch OFF. Re- The resistance should be 1.9 Ω +/- If the resistance is not within the
move connector WSH from the wa- 0.3 Ω. stated tolerance replace the heater.
ter separator heater.
Check
Measure the resistance from termi-
nal A to terminal B on the heater.
Measure the resistance on con- The resistance should be less than If the resistance is greater than 10 Ω
nector WSH from pin A to chassis 10 Ω. or an open circuit is indicated, check
ground. wire (0 BW Bk-2.0) for corrosion or
damage. Replace or repair as nec-
essary.
Turn the ignition key switch OFF. Re- The resistance should be less than If the resistance is greater than 10
move connector WSH from the water 10 Ω Ω or an open circuit is indicated,
separator heater and PRM D1 from check wire (1 GC R-2.0) for corro-
power relay module D. sion or damage. Replace or repair
Check as necessary. Also check power re-
Measure the resistance from WSH lay module D for proper operation
pin B to PRM D1 pin C. and F1 40 amp fuse. Power relay
module D is energized by the en-
gine controller, EDC7 pin 36 and pin
13. Engine controller turns heaters
on when ambient temperature is be-
low 10 °C (50.0 °F).
RCIL11WHL046EAK 1
(1) Power relay module D — Fuel filter heater (5) Fuel filter heater – 1.9 ohm +/- 0.3 ohm
F1 fuse 40 Amp @ 20 degrees C
(2) 24 Volt power supply from starter terminal (6) Water separator heater – 1.9 ohm +/- 0.3
B1 ohm @ 20 degrees C
(3) EDC7 – Fuel filter heater relay, pin 36 (7) Chassis ground – GND ENG1
(4) EDC7 – Switched B+ output LSD, pin 13 (8) Power relay module D Fuel filter heater
fuse F1 – 40 Amp.
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Fuel pre-heater - Testing - Fuel filter heater

Turn ignition key switch OFF. Re- The resistance should be 1.9 Ω +/- If the resistance is not within the
move connector FFH from the fuel fil- 0.3 Ω. stated tolerance replace the heater.
ter heater.
Check
Measure the resistance from termi-
nal A to terminal B on the heater.
Measure the resistance on connec- The resistance should be less than If the resistance is greater than 10 Ω
tor FFH from pin B to chassis ground. 10 Ω. or an open circuit is indicated, check
wire (0 BX Bk-2.0) for corrosion or
damage. Replace or repair as nec-
essary.
Turn the ignition key switch OFF. Re- The resistance should be less than If the resistance is greater than 10
move connector FFH from the fuel fil- 10 Ω Ω or an open circuit is indicated,
ter heater and PRM D1 from power check wire (1 GB R-2.0) for corro-
relay module D. sion or damage. Replace or repair
Check as necessary. Also check power re-
Measure the resistance from FFH lay module D for proper operation
pin A to PRM D1 pin C. and F1 40 amp fuse. Power relay
module D is energized by the en-
gine controller, EDC7 pin 36 and pin
13. Engine controller turns heaters
on when ambient temperature is be-
low 10 °C (50.0 °F).
RCIL11WHL046EAK 1
(1) Power relay module D — Fuel filter heater (5) Fuel filter heater – 1.9 ohm +/- 0.3 ohm
F1 fuse 40 Amp @ 20 degrees C
(2) 24 Volt power supply from starter terminal (6) Water separator heater – 1.9 ohm +/- 0.3
B1 ohm @ 20 degrees C
(3) EDC7 – Fuel filter heater relay, pin 36 (7) Chassis ground – GND ENG1
(4) EDC7 – Switched B+ output LSD, pin 13 (8) Power relay module D Fuel filter heater
fuse F1 – 40 Amp.
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Index

Fuel pre-heater - Testing - Fuel filter heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Fuel pre-heater - Testing - Water separator heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Grid heater relay - Testing - Grid heater relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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Alternator - 301
1021F
1121F
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Contents
Alternator - 301
DIAGNOSTIC
Alternator
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Power converter
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
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Electrical systems - Alternator
Alternator - Testing
tight and secure. Check the wiring as required.
and connections for corrosion, abra-
sion and damage. Verify that the
chassis ground frame connections
are secure and tight and free of oil,
paint, dirt, damage and debris.
Check 10 Ω. there is a problem with the chassis
Measure the resistance from the al- ground connection to the alternator.
ternator case connection to the BT4 Repair as required.
minus battery connection.
Check 10 Ω. there is a problem with the connec-
Measure the resistance from the al- tion between the alternator and the
ternator B+ terminal to the Starter B2 starter. Verify that the cable con-
terminal. nections are secure and tight. Verify
that the connections are free of cor-
rosion, abrasion, damage and incor-
Check 10 Ω. there is a problem with the connec-
Measure the resistance from the Al- tion between the alternator and the
ternator D+ terminal to the TEL con- TEL connector pin D. Verify that the
nector pin D. cable connections are secure and
tight. Verify that the connections are
free of corrosion, abrasion, damage
and incorrect attachment. Repair as
required.
Check 28 volts. there is a problem with the alterna-
Measure the voltage from the al- tor or battery(s). Repair as required.
ternator B+ connection to chassis
ground.
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RCPH11WHL023FAL 1
(1) Alternator, 28 V, 65 A (5) Right Battery, 12 V

(2) Starting Motor (6) Connector ENG/ CAB_E
(3) Master Disconnect Switch (7) 75 Ω Resistor
(4) Left Battery, 12 V
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Power converter - Testing

Turn the key switch OFF. The resistance should be less than The resistance is greater than 10 Ω
Check 10 Ω. there is an open circuit in the ground
Measure the resistance from the connection to the converter. Check
power converter connector, pin 3 to for corrosion, abrasion, damage or
chassis ground. Measure the re- incorrect attachment. Repair as re-
sistance from the power converter quired.
connector, pin 6 to chassis ground.
Check 24 V. is a problem with the supply voltage
Measure the voltage from the power to the power converter. Repair as
converter connector, pin 1 to chassis required.
the power converter connector, pin 2
to chassis ground.
Measure the voltage from the power The voltage should be approximately The voltage is less than 10 V there
converter connector, pin 5 to chassis 12 V. is a problem with 12 V output from
ground. the power converter. Temporarily re-
place the converter and retest.
RCPH11WHL008GAL 1
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(1) CNV 24V to 12V Power Converter (10) Power Outlet 2 (option)
(2) Switched Battery, PRM_A pin C (11) CAB_RF/ ROOF connector
(3) GND_CAB4 Right Console (12) RAD/ RAD_J1 connector
(4) GND_CAB5 Right Console (13) SPK/ RAD_J2 connector
(5) Radio, 12 V, ECB-F9 (14) Left Speaker
10 A
(6) Remote, 12 V, ECB-F1 (15) Right Speaker
10 A
(7) Remote, 12 V, ECB-F2 (16) GND_CAB_SPL, pin B
10 A
(8) Two Way Radio, 12 V, ECB-F10 (17) 12V Radio
15 A
(9) Power Outlet 1 (option) (18) Antenna, Top Cab Ground Weld Stud
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Index
Alternator - 301
Alternator - Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Power converter - Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
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Battery - 302
1021F
1121F
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Contents
Battery - 302
TECHNICAL DATA
Battery
SERVICE
Battery
Visual inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
DIAGNOSTIC
Battery connect/disconnect system

Battery switch - Testing - Master Disconnect Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
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Electrical systems - Battery
Battery - General specification

Charging Guide for Maintenance Free Batteries
Recommended Rate1 and Time for Fully Discharged Battery
Battery Capacity2 Slow Charge Fast Charge
80 min or less 10 h at 5 A 2.5 h at 20 A
5 h at 10 A 1.5 h at 30 A
Above 80 - 125 min 15 h at 5 A 3.75 h at 20 A
7.5 h at 10 A 1.5 h at 50 A
Above 125 - 170 min 20 h at 5 A 5 h at 20 A
10 h at 10 A 2 h at 50 A
15 h at 10 A 3 h at 50 A
1 Initial rate for standard taper
2 See Reserve Capacity in Specifications
Charging Guide for Batteries other than Maintenance Free Batteries

Recommended Rate1 and Time for Fully Discharged Battery
Battery Capacity2 Slow Charge Fast Charge
80 min or less 10 h at 5 A 2.5 h at 20 A
5 h at 10 A 1.5 h at 30 A
7.5 h at 10 A 1.5 h at 50 A
10 h at 10 A 2 h at 50 A
10 h at 10 A 2 h at 50 A
Above 250 min 24 h at 10 A 6 h at 40 A
4 h at 60 A
1 Initial rate for standard taper
2 See Reserve Capacity in Specifications
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Battery - Visual inspection

WARNING
Explosion hazard!
If battery electrolyte is frozen, attempting to charge the battery or jump-start the engine can cause the
battery to explode. Always keep batteries at full charge to prevent frozen battery electrolyte. Never
charge a frozen battery.
W0203A
WARNING
Explosion hazard!
Batteries emit explosive gases. Always ventilate when using in an enclosed area or when charging.
Keep the battery away from sparks, open flames, and other ignition sources.
W0369A
WARNING
Improper operation or service of this machine can result in an accident.
Before working on any part of the electrical system, disconnect the battery ground cable. Complete
all electrical work before connecting the cable.
W0137A
WARNING
Chemical hazard!
Battery acid can cause severe burns. Some batteries have a ventilation tube. If there is battery acid
in the tube, this acid can be released when the battery is turned upside down. If you turn the battery
upside down, point the ventilation tube away from you and any other people in the area.
W1084A
WARNING
Hazardous chemicals!
Battery electrolyte contains sulfuric acid. Contact with skin and eyes could result in severe irritation
and burns. Always wear splash-proof goggles and protective clothing (gloves and aprons). Wash
hands after handling.
W0006A
WARNING
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
1. If the battery is a maintenance free battery, check the

level of the electrolyte every 1000 hours of operation
or six months, whichever occurs first. For all other
batteries, check the level of the electrolyte every 250
hours of operation.
NOTE: A maintenance free battery will have the words
Maintenance Free on the decal on the top of the battery. If
the center part of the decal has been removed for access to
the battery caps, it is possible that the words Maintenance
Free have been removed from the decal.
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2. Check the level of the electrolyte more often during

hot weather. The use of a large amount of water by
the battery can be caused by high battery temper-
ature or a voltage regulator setting that is too high.
Keep the electrolyte level above the top of the plates
in the battery at all times to prevent damage to the
battery.
NOTE: On maintenance free batteries it is necessary to
remove the center part of the decal for access to the battery
caps. Do not discard the center part of the decal. Install
the center part of the decal after the battery caps have been
installed.
3. If the level of the electrolyte is low, add distilled water
or other clean water until the electrolyte is 5 mm (1/4
inch) below the level of the ring. Do not add more
water than is needed. Too much water can cause
bad performance, a short service life, and corrosion
around the battery.
NOTE: Add water only. DO NOT add electrolyte.
4. If damage causes an electrolyte leak, replace the
battery.
5. Inspect the battery at regular intervals for dirt, cor-
rosion, and damage. Electrolyte and dirt on the top
of the battery can cause the battery to discharge by
making a passage for the current to flow.
6. If the battery must be cleaned, remove the battery
from the battery carrier and clean the battery, cable
terminals, and the battery carrier. When available,
use Case Battery Saver and Cleaner according to
the instructions on the container. Case Battery Saver
and Cleaner also helps prevent corrosion. If Case
Battery Saver and Cleaner is not available, use bak-
ing soda and water as a cleaner. DO NOT permit any
type of cleaner to enter the cells of the battery.
7. Install the battery in the machine and make sure the
fasteners are tight. 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.
8. Make sure the cable connections are clean and tight.
Clean foreign material from the top of the battery.
9. Inspect the battery case, battery posts, and cables
for damage.
10. Check the electrolyte level.
11. If you added water to the battery, the battery must be
charged for 15 minutes at 15 to 25 amperes to mix
the water with the electrolyte.
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Battery - Charging
WARNING
Explosion hazard!
If battery electrolyte is frozen, attempting to charge the battery or jump-start the engine can cause the
battery to explode. Always keep batteries at full charge to prevent frozen battery electrolyte. Never
charge a frozen battery.
W0203A
WARNING
Explosion hazard!
Batteries emit explosive gases. Always ventilate when using in an enclosed area or when charging.
Keep the battery away from sparks, open flames, and other ignition sources.
W0369A
WARNING
Improper operation or service of this machine can result in an accident.
Before working on any part of the electrical system, disconnect the battery ground cable. Complete
all electrical work before connecting the cable.
W0137A
WARNING
Chemical hazard!
Battery acid can cause severe burns. Some batteries have a ventilation tube. If there is battery acid
in the tube, this acid can be released when the battery is turned upside down. If you turn the battery
upside down, point the ventilation tube away from you and any other people in the area.
W1084A
WARNING
Hazardous chemicals!
Battery electrolyte contains sulfuric acid. Contact with skin and eyes could result in severe irritation
and burns. Always wear splash-proof goggles and protective clothing (gloves and aprons). Wash
hands after handling.
W0006A
WARNING
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
1. Before you charge the battery, check the level of the

electrolyte.
2. It is difficult to give an exact charging rate because of
the following variable conditions: (1) temperature of
the electrolyte, (2) level of charge, and (3) condition
of the battery. Use the charging guide for the correct
charging rate and time.
3. See the following for the reserve capacity of the bat-
tery in this machine. Battery - General specifica-
tion (55.302).
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4. The charging rate must be decreased if too much gas

causes the electrolyte to flow from the cells or if the
electrolyte rises above 52 °C (125.6 °F).
5. The battery is fully charged when, over a three hour
period at a low charging rate, no cell is giving too
much gas, and the specific gravity does not change.
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Battery - Filling
1. Remove the caps from the battery.
2. Fill each cell to the top of the separators with elec-
trolyte. This will permit the volume of electrolyte to
increase when heated by charging the battery.
3. Install the caps on the battery.
4. Connect a battery charger to the battery.
5. Charge the battery at 30 amperes until the specific
gravity is 1.250 or more and the temperature of the
electrolyte is at least 15.5 °C (60 °F).
6. If necessary, fill each cell with electrolyte until the
electrolyte is just below split ring at the bottom of the
cell opening.
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Battery connect/disconnect system Battery switch - Testing -

Master Disconnect Switch
tight and secure. Verify that the con- as required.
nections to the Master Disconnect
Switch are tight and secure. Check
the wiring and connections for corro-
sion, abrasion and damage. Verify
that the chassis ground frame con-
nections are secure and tight and
free of oil, paint, dirt, damage and
debris.
Turn the Master disconnect Switch The voltage should be approximately The voltage is less than 10 V. There
OFF. 24 V. is a problem in the battery circuit to
Check the Master Disconnect Switch. Ver-
Measure the voltage from Master ify that voltage across the batteries,
Disconnect Switch terminal DC1 to terminal BT1 to BT4. Repair as re-
chassis ground. quired.
Turn the Master disconnect Switch The voltage should be less than 1 V. The voltage is greater than 10 V.
OFF. There is a problem in the Master Dis-
Check connect Switch. Temporarily replace
Measure the voltage from Master the Master Disconnect Switch and
Disconnect Switch terminal DC2 to retest.
chassis ground. Measure the volt-
age from Master Disconnect Switch
terminal DC3 to chassis ground.
Measure the voltage from Master
Disconnect Switch terminal DC4 to
chassis ground.
Turn the Master disconnect Switch The voltage should be approximately The voltage is less than 10 V on one
ON. 24 V. or more terminals, there is a prob-
Check lem in the Master Disconnect Switch.
Measure the voltage from Master Temporarily replace the Master Dis-
Disconnect Switch terminal DC2 to connect Switch and retest.
age from Master Disconnect Switch
terminal DC3 to chassis ground.
Measure the voltage from Master
Disconnect Switch terminal DC4 to
chassis ground.
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RCPH11WHL023FAL 1
(1) Alternator, 28 V, 65 A (5) Right Battery, 12 V

(2) Starting Motor (6) Connector ENG/ CAB_E
(3) Master Disconnect Switch (7) 75 Ω Resistor
(4) Left Battery, 12 V
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Index
Battery - 302
Battery - Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Battery - Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Battery - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Battery - Visual inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Battery connect/disconnect system Battery switch - Testing - Master Disconnect Switch . . . . . . . . . . . . . . . . . . . . . 9
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External lighting - 404
1021F
1121F
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Contents
DIAGNOSTIC
Beacon
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Work light
Front - Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Clearance lamp
Combination lamp - Testing - Left hand (LH) front combo light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Combination lamp - Testing - Right hand (RH) front combo light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
License plate light
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Flasher unit
Testing - Hazard switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
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Electrical systems - External lighting
Beacon - Testing
Turn the key switch OFF and the Ro- The voltage should be approximately If the voltage is less than 10 V check
tating Beacon switch ON. 24 V. fuse ECC-F1 or the Rotating Beacon
Check switch and circuit.
Measure the voltage from LBEPWR
Turn the key switch OFF. Disconnect The resistance should be less than If the resistance is greater than 10 Ω
connector LBEGRD from the Rotat- 10 Ω. or an open circuit is indicated, check
ing Beacon. the ground wiring circuit through
Check connectors SPL ROOF, ROOF, and
Measure the resistance from LBE- CAB RF.
GRD pin 1 to chassis ground.
Turn the key switch OFF and the Ro- The bulb filament should be good. Replace bad bulb.
tating Beacon switch ON.
Check
If the unit rotates but the light is not
on, check the bulb for continuity.
If readings are good replace the ro-
tating beacon.
RCIL11WHL040FAK 1
(1) Advanced Instrumentation Cluster (6) Rotating Beacon (option)

(2) Door switch — closes with door open (7) Dome light
(3) 24 Volt supply, unswitched battery (8) L1 located on electrical center C
(4) Beacon \ Dome light power ECC-F1 7.5 (9) Right console ground
Amp fuse
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(5) Rotating Beacon switch (option) (10) Back light power
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Work light Front - Testing

Turn the key switch OFF and the The bulb should have continuity. Replace bad light bulb.
front Work lights switch ON. Remove
connector LLFW from the left hand
front work light.
Check
Measure for continuity on the light
from terminal A to terminal B.
Turn the key switch OFF and the The voltage should be approximately If the voltage is less than 10 V check
front Work lights switch ON. Remove 24 volts. ECC-F2 fuse or work lights switch.
connector LLFW from the left hand Replace as required.
front work light.
Check
Turn the key switch OFF and the The resistance should be less than If the resistance is greater than 10
front Work lights switch ON. Remove 10 Ω. Ω or an open circuit is indicated, re-
connector LLFW from the left hand pair or replace ground wire (0 MU
front work light. Bk-1.0).
Check
Measure the resistance on the con-
nector from pin 2 to chassis ground.
connector LRFR from the right hand
front work light.
Check
connector LRFR from the right hand Replace as required.
front work light.
Check
connector LRFR from the right hand pair or replace ground wire (0 ML
Check
connector LRFO from the optional
front work light.
Check
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connector LRFO from the optional Replace as required.
front work light.
Check
connector LRFO from the optional pair or replace ground wire (0 MP
Check
RCIL11WHL041FAK 1
(1) Diode OR module (7) Left hand rear work light

(2) SPL BCK LT GD (ground connector) (8) Right hand front work light
(3) Work lights switch (9) Front work light (option)
(4) 24 Volt supply, unswitched battery to fuse (10) Option — H/O work light (LH & RH)
ECC-F2 20 amp
(5) Right console ground (11) Left hand front work light
(6) Right hand rear work light
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Clearance lamp Combination lamp - Testing - Left hand (LH) front

combo light
Turn the key switch OFF. Disconnect The resistance should be less than If the resistance is greater than 10
connector LLF . 10 Ω . Ω there is a bad high beam bulb or
Check open circuit. Repair or replace as
High Beam necessary.
Measure the resistance on the high
beam light from pin 3 to pin 1 (chas-
sis ground).
Turn the key switch OFF. Disconnect The resistance should be less than If the resistance is greater than . 10
connector LLF. 10 Ω . Ω there is a bad position bulb or open
Check circuit. Repair or replace as neces-
Position light sary.
Measure the resistance on the posi-
tion light from pin 4 to pin 1 (chassis
ground).
connector LLF. 10 Ω . Ω there is a bad low beam bulb or
Low Beam necessary.
Measure the resistance on the low
sis ground).
connector LLF. 10 Ω . Ω there is a bad turn bulb or open cir-
Check cuit. Repair or replace as necessary.
Turn light
Measure the resistance on the turn
light from pin 5 to pin 1 (chassis
ground).
Turn the key switch OFF. Disconnect The voltage should be approximately If the voltage is less than 10 V check
connector LLF and turn the driving 24 V . fuse ECB-F3 . If voltage \ fuse is
lights ON with the high beam se- good disconnect connectors Front
lected. and Cab F and check for voltage
Check between Cab F pin 6 and chassis
High Beam ground. If voltage is present at pin
Measure the voltage for the high 6 check continuity between connec-
beam light between LLF pin 3 and tor Front pin 6, wire (18B Or-2.0) to
chassis ground. LLF pin 3. Repair or replace as nec-
essary.
connector LLF and turn the driving 24 V . fuse ECB-F7 . If voltage \ fuse is
lights ON. good disconnect connectors Front
Check and Cab F and check for voltage
Position light between Cab F pin 10 and chassis
Measure the voltage for the position ground. If voltage is present at pin 10
light between LLF pin 4 and chassis check continuity between connector
ground. Front pin 10, wire (18F Or-1.0) to
LLF pin 4. Repair or replace as nec-
essary.
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Turn the key switch OFF. Discon- The voltage should be approximately If the voltage is less than 10 V check
nect connector LLF and turn the driv- 24 V . fuse ECB-F6 . If voltage \ fuse is
ing lights ON with the low beam se- good disconnect connectors Front
Low Beam ground. If voltage is present at pin 14
Measure the voltage for the low check continuity between connector
beam light between LLF pin 2 and Front pin 14, wire (18D Or-1.0) to
chassis ground. LLF pin 2. Repair or replace as nec-
essary.
Turn the key switch ON. Disconnect The voltage should be cycling on \ off If approximately 24 V is not present
connector LLF and turn the left turn at approximately 24 V . check fuse ECA-F8 . If voltage \
signal ON. fuse is good disconnect connectors
Check Front and Cab F and check for volt-
Turn signal age between Cab F pin 2 and chas-
Measure the voltage for the left turn sis ground. If voltage is present at
signal between LLF pin 5 and chas- pin 2 check continuity between con-
sis ground. nector Front pin 2, wire (45L N-1.0)
to LLF pin 5. Repair or replace as
necessary. If there is no voltage on
the Cab F connector, verify voltage
at flasher module. Left turn switch
power to FLSHR pin 9 should be a
steady 24 V, and turn signal voltage
from.pin 8 should be cycling on \off.
If all readings are good, and lamps
still do not turn ON replace the LH
front combination lamp.
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RCIL11WHL042GAK 1
(1) 24 Volt switched battery (10) Position light Right (running / tail) and License
plate light power ECB-F8 5 Amp fuse
(2) 24 Volt supply, unswitched battery (11) High beam power left ECB-F3 5 Amp fuse
(3) Driving lights power switch (12) High beam power right ECB-F4 5 Amp fuse
(4) Driving lights power ECC-F3 15 Amp fuse (13) Low beam power left ECB-F6 5 Amp fuse
(5) Turn signal, Hi \ Low beam & Horn power switch (14) Low beam power right ECB-F5 5 Amp fuse
(6) Turn signal power ECA-F8 5 Amp fuse (15) AIC high beam indicator light
(7) Left hand front combo lights (16) Left (FLSHR pin 8)/ Right (FLSHR pin 7) turn
signals from Flasher module
(8) Right hand front combo lights (17) Position (tail) lights power to left (LLR pin 3)/
Right (LRR pin 3)
(9) Position light Left (running / tail) power ECB-F7 (18) Chassis ground
5 Amp fuse
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Clearance lamp Combination lamp - Testing - Right hand (RH) front

combo light
connector LRF . 10 Ω . Ω there is a bad high beam bulb or
High Beam necessary.
Measure the resistance on the high
sis ground).
connector LRF. 10 Ω . Ω there is a bad position bulb or open
Check circuit. Repair or replace as neces-
Position light sary.
Measure the resistance on the posi-
tion light from pin 4 to pin 1 (chassis
ground).
connector LRF. 10 Ω . Ω there is a bad low beam bulb or
Low Beam necessary.
Measure the resistance on the low
sis ground).
connector LRF. 10 Ω . Ω there is a bad turn bulb or open cir-
Check cuit. Repair or replace as necessary.
Turn light
Measure the resistance on the turn
light from pin 5 to pin 1 (chassis
ground).
connector LRF and turn the driving 24 V . fuse ECB-F4 . If voltage \ fuse is
lights ON with the high beam se- good disconnect connectors Front
High Beam ground. If voltage is present at pin 16
Measure the voltage for the high check continuity between connector
beam light between LRF pin 3 and Front pin 16, wire (18C Or-1.0) to
chassis ground. LRF pin 3. Repair or replace as nec-
essary.
connector LRF and turn the driving 24 V . fuse ECB-F8 . If voltage \ fuse is
lights ON. good disconnect connectors Front
Check and Cab F and check for voltage
Position light between Cab F pin 5 and chassis
Measure the voltage for the position ground. If voltage is present at pin
light between LRF pin 4 and chassis 5 check continuity between connec-
ground. tor Front pin 5, wire (18G A Or-1.0)
to LRF pin 4. Repair or replace as
necessary.
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Turn the key switch OFF. Discon- The voltage should be approximately If the voltage is less than 10 V check
nect connector LRF and turn the 24 V . fuse ECB-F5 . If voltage \ fuse is
driving lights ON with the low beam good disconnect connectors Front
selected. and Cab F and check for voltage
Low Beam ground. If voltage is present at pin 15
Measure the voltage for the low check continuity between connector
beam light between LRF pin 2 and Front pin 15, wire (18E Or-1.0) to
chassis ground. LRF pin 2. Repair or replace as nec-
essary.
Turn the key switch ON. Disconnect The voltage should be cycling on \ off If approximately 24 V is not present
connector LRF and turn the right turn at approximately 24 V . check fuse ECA-F8 . If voltage \
signal ON. fuse is good disconnect connectors
Check Front and Cab F and check for volt-
Turn signal age between Cab F pin 3 and chas-
Measure the voltage for the right turn sis ground. If voltage is present at
signal between LRF pin 5 and chas- pin 3 check continuity between con-
sis ground. nector Front pin 3, wire (45R N-1.0)
to LRF pin 5. Repair or replace as
necessary. If there is no voltage on
the Cab F connector, verify voltage
at flasher module. Right turn switch
power to FLSHR pin 10 should be a
steady 24 V, and turn signal voltage
from.pin 7 should be cycling on \off.
If all readings are good, and lamps
still do not turn ON replace the LH
front combination lamp.
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RCIL11WHL042GAK 1
Right (LRR pin 3)
5 Amp fuse
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License plate light - Testing

Turn the key switch OFF, Driving The voltage should be approximately If the voltage is less than 10 V check
lights (position lights) ON, and dis- 24 volts. fuse ECB-F8. Replace as required.
connect connector LPL.
Check
Measure the voltage from LPL pin A
to chassis ground.
Turn the key switch OFF and discon- The resistance should be less than If the resistance is greater than 10
nect connector LPL. 10 Ω . Ω or an open circuit is indicated, re-
Check place or repair faulty ground wire cir-
Measure the resistance on the con- cuit (0 JC Bk-1.0) .
nector between pin B and chassis
ground.
Turn the key switch OFF and discon- There should be continuity across If there is no continuity replace the
nect connector LPL. the bulb.. bulb.
Check
Measure the continuity on the light
bulb between terminal A and termi-
nal B.
RCIL11WHL039FAK 1
(1) 24 Volt supply, unswitched battery power (6) Brake light pressure switch (normally
to fuse ECC-F4, 10 amp open, closes at 414 kPa (60.0 psi) )
(2) 24 Volt supply, switched illumination (7) Brake lights relay
power to position fuses
(3) Flasher module (8) Left hand rear combo light
(4) Position left fuse ECB-F7, 5 amp (9) Right hand rear combo light
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(5) Position right fuse ECB-F8, 5 amp (10) License plate light
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Flasher unit - Testing - Hazard switch

Turn the key switch OFF and the The resistance should be less than If the resistance is greater than 10 Ω
hazard switch ON. Disconnect con- 10 Ω. replace the switch.
nector SHZ from the hazard switch.
Check
Measure the resistance on the haz-
ard switch between terminal 2 and 3.
hazard switch ON. Disconnect con- 24 volts. fuse ECC-F4. If voltage \ fuse is
nector FLSHR from the flasher mod- good check for voltage on hazard
ule. switch connector SHZ pin 2.
Check
Measure the voltage from FLSHR
pin 11, wire (45H N-0.8) to chassis
ground.
Turn the key switch OFF and the The voltage should be a steady 24 If the voltage is less than 10 V check
hazard switch ON. volts at pin 11, and cycling on \ off at fuse ECC-F4 and flasher module
Check pins 7 and 8. power at FLSHR pin 1. If the flasher
Measure for voltage with FLSHR module has power on pin 1 replace
connected at pins 11 and pins 7 \ 8. the module.
RCIL11WHL038EAK 1
(1) 24 Volt supply to ECC-F4 10 amp fuse, unswitched power for brake lights and flasher module
(2) Flasher module
(3) Right \ Left turn signals to lights
(4) Jumper — Connect for North American operation (opp side steady on), disconnect for European
operation (opp side off)
(5) Hazard switch
(6) Illumination power
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Index

Beacon - Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Clearance lamp Combination lamp - Testing - Left hand (LH) front combo light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Clearance lamp Combination lamp - Testing - Right hand (RH) front combo light . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Flasher unit - Testing - Hazard switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
License plate light - Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Work light Front - Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
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External lighting switches and relays - 405
1021F
1121F
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Contents
DIAGNOSTIC
Beacon switch
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Headlight switch
Testing - Hi \ Low beam switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Testing Driving Lights Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Work light switch
Front - Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Rear - Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Hazard light switch
Testing - Hazard switch light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Turn signal switch
Testing - Turn signal switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Brake light switch
Testing - Brake light pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
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Electrical systems - External lighting switches and relays
Beacon switch - Testing

connector SBE. 24 volts. fuse ECC-F1. Replace as required.
Check
Measure the voltage from SBE pin 2
to chassis ground.
Rotating Beacon switch ON. Discon- 10 Ω . Ω or the switch is indicating an open
nect connector SBE from Rotating circuit replace the switch.
Beacon switch.
Check
Measure the resistance from SBE
pin 2 to pin 3.
Rotating Beacon switch ON. Discon- 24 volts. wiring circuit through ROOF pin E
nect connector LBEPWR from Ro- and CAB RF pin E connectors.
tating Beacon.
Check
Measure the voltage from LBEPWR
to chassis ground.
RCIL11WHL040FAK 1

Amp fuse
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Headlight switch - Testing - Hi \ Low beam switch

High Beam The voltage should be approximately If there is less than 10 V then check
Turn the key switch OFF. Turn the 24 volts power to SRHSTLK pin 56D (check
driving lights ON with the high beam ECC-F3 fuse). If 24V on pin 56D but
selected. not at the high beam fuses, either the
Check Hi / Low beam switch or wiring is bad.
Measure the voltage from ECB-F3 Repair or replace as necessary.
terminal A3 (41H_B Or 0.8) to chas-
sis ground.
Measure the voltage from ECB-F4
terminal A4 (41H_C Or 0.8) to chas-
sis ground.
Low beam The voltage should be approximately If there is less than 10 V then check
Turn the key switch OFF. Turn the 24 volts power to SRHSTLK pin 56 (check
driving lights ON with the low beam driving lights switch pin 6). If 24V on
selected. pin 56 but not at the low beam fuses,
Check either the Hi / Low beam switch or
Measure the voltage from ECB-F5 wiring is bad. Repair or replace as
terminal A5 (41L_C Or 0.8) to chas- necessary.
sis ground.
Measure the voltage from ECB-F6
terminal A6 (41L_B Or 0.8) to chas-
sis ground.
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RCIL11WHL042GAK 1
Right (LRR pin 3)
5 Amp fuse
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Headlight switch - Testing Driving Lights Switch

Driving lights power The voltage should be approximately The voltage is less than 10 V. Check
Turn the key switch OFF. Discon- 24 volts . fuse ECC-F3. Replace as neces-
nect connector SDR from the Driving sary.
Lights switch.
Check
SDR pin 5 (19Z_B Or-1.0) to chassis
ground.
SDR pin 2 (19Z_A Or-1.0) to chassis
ground.
Driving lights switch The voltage should be approximately There is an open circuit in the wire
Turn the key switch OFF. Turn the 24 volts (41J Or -1.0) or the driving lights
driving lights ON. Disconnect con- switch is bad.
nector SRHSTLK from the Turn sig-
nal Hi / Low beam & Horn switch.
Check
Measure the voltage from SRHSTLK
pin 56 (41J Or-1.0) to chassis
ground.
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RCIL11WHL042GAK 1
Right (LRR pin 3)
5 Amp fuse
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Work light switch Front - Testing

Turn the key switch OFF and discon- The voltage should be approximately If the voltage is less than 10 V check
nect connector SWL. 24 volts. fuse ECC-F2. Replace as required.
Check
Measure the voltage from SWL pin 2
to chassis ground.
nect connector SWL. Turn on front 10 Ω . Ω or an open circuit is indicated, re-
work light. place the work lights switch.
Check
Measure the resistance on the
switch between terminal 2 and 3.
nect connector SWL. 10 Ω . Ω or an open circuit is indicated, re-
Check pair or replace ground wire (0 B14
Measure the resistance on the con- Bk-0.8) . If switch lights still don’t il-
nector between terminal 7 and chas- luminate replace switch.
sis ground.
RCIL11WHL041FAK 1

(4) 24 Volt supply, unswitched battery to fuse (10) Option — H / O work light (LH & RH)
ECC-F2 20 amp
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Work light switch Rear - Testing

Turn the key switch OFF and discon- The voltage should be approximately If the voltage is less than 10 V check
nect connector SWL. 24 volts. fuse ECC-F2. Replace as required.
Check
Measure the voltage from SWL pin 5
to chassis ground.
nect connector SWL. Turn on rear 10 Ω . Ω or an open circuit is indicated, re-
work light. place the work lights switch.
Check
switch between terminal 5 and 6.
nect connector SWL. 10 Ω . Ω or an open circuit is indicated, re-
Check pair or replace ground wire (0 B14
Measure the resistance on the con- Bk-0.8) . If switch lights still don’t il-
nector between terminal 7 and chas- luminate replace switch.
sis ground.
RCIL11WHL041FAK 1

(4) 24 Volt supply, unswitched battery to fuse (10) Option — H/O work light (LH & RH)
ECC-F2 20 amp
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Hazard light switch - Testing - Hazard switch light

connector SHZ . 24 volts . fuse ECC-F4.
Check
Measure the unswitched voltage
from SHZ pin 2 to chassis ground.
Turn the key switch OFF. Disconnect The resistance should be less than If the resistance is greater than 10 Ω
connector SHZ. 10 Ω. than the switch ground wire (0 B24
Check Bk 0.8) is open or damaged. Repair
Measure the resistance between or replace as necessary.
connector SHZ pin 7 and chassis
ground.
connector SHZ and turn the hazard 10 Ω. Ω than the switch contact or LED is
switch ON. open or damaged. You may also
Check perform a diode check from terminal
Measure the resistance on the 2 to 7. Repair or replace as neces-
switch between terminal 2 and ter- sary.
minal 7.
RCIL11WHL038EAK 1
(1) 24 Volt supply to ECC-F4 10 amp fuse, unswitched power for brake lights and flasher module
(2) Flasher module
(3) Right \ Left turn signals to lights
(4) Jumper — Connect for North American operation (opp side steady on), disconnect for European
operation (opp side off)
(5) Hazard switch
(6) Illumination power
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Turn signal switch - Testing - Turn signal switch

Turn the key switch OFF and move The resistance should be less than If the resistance is greater than 10 Ω
the turn signal lever to RIGHT turn 10 Ω. replace the switch.
position. Disconnect connector
SRHSTLK from the switch.
Check
switch terminal from pin 49A to pin
R.
Turn the key switch OFF and move The resistance should be less than If the resistance is greater than 10 Ω
the turn signal lever to LEFT turn 10 Ω. replace the switch.
position. Disconnect connector
SRHSTLK from the switch.
Check
switch terminal from pin 49A to pin
L.
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RCIL11WHL042GAK 1
Right (LRR pin 3)
5 Amp fuse
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Brake light switch - Testing - Brake light pressure switch

connector PBL from the Brake light 24 volts. fuse ECC-F4. If fuse is good check
pressure switch. for power through connector CAB B
Check pin K, wire (1 DR R-1.0) and connec-
Measure the voltage on PBL pin 1 to tor BTM C pin K, wire (1 AA R-1.0).
chassis ground. Repair or replace as necessary.
Turn the key switch OFF. The voltage should be 0 volt. If the voltage is approximately 24
Check V replace the Brake light pressure
Measure voltage on connector PBL switch.
Turn the key switch OFF. Have an- The voltage should be approximately If the voltage is less then 10 V
other person press and hold down 24 volts replace the Brake light pressure
brake pedal. switch.
Check
Measure the voltage on connector
PBL pin 2, wire (44 T-1.0) to chassis
ground.
RCIL11WHL039FAK 1
(1) 24 Volt supply, unswitched battery power (6) Brake light pressure switch (normally
to fuse ECC-F4, 10 amp open, closes at 414 kPa (60.0 psi) )
(2) 24 Volt supply, switched illumination (7) Brake lights relay
power to position fuses
(3) Flasher module (8) Left hand rear combo light
(4) Position left fuse ECB-F7, 5 amp (9) Right hand rear combo light
(5) Position right fuse ECB-F8, 5 amp (10) License plate light
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Index

Beacon switch - Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Brake light switch - Testing - Brake light pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Hazard light switch - Testing - Hazard switch light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Headlight switch - Testing - Hi \ Low beam switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Headlight switch - Testing Driving Lights Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Turn signal switch - Testing - Turn signal switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Work light switch Front - Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Work light switch Rear - Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
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Warning indicators, alarms, and instruments - 408
1021F
1121F
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Contents
FUNCTIONAL DATA
Instrument cluster
Dynamic description - Brake pedal calibration (5-speed transmission) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Dynamic description – Fault Code Retrieval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Dynamic description – Park Brake Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Dynamic description – Fan Auto Mode Activation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Dynamic description – Transmission Clutch Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Dynamic description – Fan Speed Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Static description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Digital instrument cluster - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
DIAGNOSTIC
Buzzer
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Backup/Reverse alarm relay
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Instrument cluster
Digital instrument cluster - Testing - Advanced Instrument Cluster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
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Electrical systems - Warning indicators, alarms, and instruments
Instrument cluster - Dynamic description - Brake pedal calibration

(5-speed transmission)
NOTE: 5 -speed transmission not available on 621F.
Brake Pedal Calibration Feature

All wheel loaders are equipped with a transmission declutch feature. This feature deactivates the transmission and
enables the operator to increase throttle to rapidly raise payload as required.
The declutch feature on 4-speed transmission machines is controlled by an operator adjustable pressure switch. The
adjustable pressure switch is part of the service brake system. When the pressure switch activates, either the forward
or reverse clutches maintain some pressure to allow a smooth modulation once the brake pedal is released. The
speed clutch maintains full pressure.
Wheel loaders equipped with 5-speed transmission use a variable declutch feature (POWERINCH) based on brake
pedal position. This feature enables operators to gradually maneuver machine as required. The brake pedal position
signal can be calibrated to ensure proper performance. A properly calibrated machine will gradually declutch the
transmission and enable operator to increase throttle without moving the machine. This allows the operator to grad-
ually move the machine while loading on and incline. The variable declutch feature is controlled by a potentiometer
connected to the brake pedal.
When the operator fully depresses the brake pedal, the transmission is completely disengaged.
The variable declutch feature requires that the transmission Electronic Control Module (ECM) receives a brake pedal
position signal. Technicians can calibrate the transmission brake pedal position signal by accessing the Advanced
Instrument Cluster (AIC) brake pedal calibration program screen.

A. Escape key
C. Up key
D. Down key
tions.
RCPH11WHL023BAN 1
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Accessing Brake Pedal Calibration Feature


RCPH11WHL020BAN 2

choose selection.
RCPH11WHL022BAN 3
4. Use Up and Down keys to highlight PedalCalib icon

RCPH11WHL021BAN 4
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5. Fully depress brake pedal to bottom pedal stop.

NOTE: Brake pedal must be fully depressed over-
coming pressure resistance.
RCPH10WHL379BAH 5
6. Release brake pedal when prompted.
RCPH11WHL030BAN 6
7. Turn ignition key switch to OFF position. New cali-

bration is now stored in system memory.
RCPH10WHL380BAH 7
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Instrument cluster - Dynamic description – Fault Code Retrieval

Numerous systems on the Wheel Loaders are monitored by electronic controllers. The Advanced Instrument Cluster
(AIC) has the capability to store and display the fault code number. For the most part the electronic controller for
that specific system sets the error code and then sends that information to the AIC. The AIC then basically is the
“messenger” in the communication loop. An Electronic Service Tool (EST) is the preferred method of retrieving fault
codes and function information directly from the machine system. Fault codes can also be retrieved by using the
keypad and the AIC display screen. The EST provides additional functionality interfacing with the machine controllers.
The AIC has limited functionality communicating with machine controllers.

A. Escape key
C. Up key
D. Down key
tions.
RCPH11WHL023BAN 1
Accessing Fault Code Retrieval Feature

2. Use Up and Down keys to highlight Diagnostics icon

RCPH11WHL020BAN 2
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3. Use Up and Down keys to highlight Show Errors

icon from Diagnostics menu. Use the Enter / Con-
firm key to choose selection.
RCPH11WHL024BAN 3
The Show Errors screen displays all active faults (RED, YELLOW, WHITE). The MEMORY selection displays all
stored inactive fault codes. The number of occurences of each severity and type of fault is also shown.
RED displayed errors are severe and referred to as faults. YELLOW displayed errors are less severe and referred to
as warnings. WHITE displayed errors are the least severe. Due to minimal severity level, these errors may not be
displayed.
In the example shown, one RED severity code is active and two inactive fault codes are noted in MEMORY.
4. Use the Up and Down key to highlight desired error
to view. Use the Enter / Confirm key to choose se-
lection.
NOTE: When more than one fault code is displayed as
active, active codes may share a common root cause.
If there are active faults relating to different sensors,
there could be a problem with a common power supply
or ground to all of them.
RCPH11WHL025BAN 4
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The following example shows typical data fields displayed

when MEMORY is selected:
A. Number of inactive fault codes in memory (1 of 2)

B. Fault code number – Fault code ranges include the
following:
• 1000 to 1999 (Vehicle faults)
• 3000 to 3999 (Engine faults)
• 4000 to 4999 (Transmission faults)
• 9000 to 9999 (AIC or CAN bus)
• 19000 to 19999 (Emission Control System)
C. Severity status (Red displays fault, Yellow displays
warning)
D. Defines machine sub-systems (engine, transmis-
sion, hydraulics, SCR control, etc.)
E. Additional details about fault code
F. Actual problem (timed out, short-circuit, too high) RCPH11WHL032BAN 5
G. Beginning date of the last fault occurrence

H. Hourmeter at beginning of last fault occurrence
J. Total number of fault code occurrences
K. Total time (hours) active fault code since last reset
The following example shows typical data fields
displayed when active YELLOW fault is selected:
6. Use the Up and Down key to highlight desired error
to view. Use the Enter / Confirm key to choose se-
lection.
RCPH11WHL036BAN 6
Similar to the MEMORY data display, the fault code num-

ber, description, hours, etc. is displayed.
RCPH11WHL037BAN 7
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Audible Alarm
When a RED fault occurs, the stop master indicator illuminates and the audible alarm will sound intermittent fast
(longer ON and short OFF).
When a YELLOW fault occurs, the caution master indicator illuminates and the audible alarm will sound intermittent
slow (short ON and long OFF).
If an audible alarm sounds, information displays on the driving screen indicating the cause. The operator is requested
on the third line to take an action. (typically press return key). Complying with the screen command silences the
buzzer.
• For RED errors, the message stays on the screen, but the third line now shows the suggested flashing action
(Stop Engine, Stop Operation, etc.)
• For YELLOW errors, the complete prompt will disappear.
In the event of multiple faults, the following priority display order occurs:
• Priority 1: RED faults not acknowledged

• Priority 2: RED faults acknowledged
• Priority 3 YELLOW faults not acknowledged
Only one of the highest priority faults are shown at any given time. For multiple faults of the same priority, the display
scrolls through successively at a rate of 1 fault every 2 seconds. When faults are displayed and a new fault occurs, it
is shown immediately, 2 seconds for amber and 4 seconds if red.
NOTE: Active list of errors can be viewed any time by pressing navigation pad Escape key.
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Instrument cluster - Dynamic description – Park Brake Test

The Wheel Loaders are equipped with a spring applied hydraulically released parking brake located at the transmis-
sion output. The Parking Brake must be applied before shutting the unit down. The Parking Brake is automatically
applied as the unit is first started in case it was not applied before shutdown. The Parking Brake is controlled by a
two position rocker switch on the steering column. When the lamp on the switch is lit there is no hydraulic oil pressure
available at the parking brake actuator and the parking brake is applied. The switch light goes out when pressure is
sent to the park brake actuator.
Engaging the Parking Brake

To engage the parking brake, do the following:
1. Move the gearshift lever to neutral (N).
2. Stop machine. Engage the parking brake by push-
ing down on top of the Park Brake switch.
The parking brake will automatically engage when
machine is shut OFF.
NOTE: A failure in the operating procedure or a failure
in the electrical or hydraulic function can result in abrupt
engagement of the parking brake. Always wear your seat
belt.
RCPH10WHL005BAL 1
Releasing the Parking Brake

The oil pressure to release the parking brake comes from the brake valve. The brake pressure light in the Advanced
Instrument Cluster (AIC) must not be lit prior to releasing the parking brake. The following steps are required to
release the Parking Brake:
1. Ensure the shift lever is in neutral.
RCPH10WHL116BAL 2
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2. Turn Park Brake switch to OFF position.
RCPH10WHL005BAL 3
3. Apply the service brake. Put machine into gear (for-

ward / reverse).
Parking brake light on cluster will turn off at this time.
NOTE: If the shifter is not in neutral or the park
brake switch has not been turned to ON position,
the AIC will instruct the operator to cycle the appro-
priate control to verify that the correct operation has
been requested.
4. Place the transmission back into neutral before pro-
ceeding.
NOTE: Park brake will not release until the machine shift
control is placed in forward or reverse. This means that
the park brake light will remain ON even when the park
brake switch is placed in the OFF position.
RCPH11WHL034BAN 4
Parking Brake Function Check

Before operating machine, periodically check the parking
brake functions.
NOTE: Test the parking brake at a maximum of every 250
hours.
WARNING
machine damage.
rious injury.
W0352A

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A. Escape key
C. Up key
D. Down key
tions.
RCPH11WHL023BAN 5
Accessing Parking Brake Test


RCPH11WHL020BAN 6
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choose selection.
RCPH11WHL022BAN 7
4. Use Up and Down keys to highlight ParkBrake icon

RCPH11WHL021BAN 8
5. Use the Enter / Confirm key to start Test Park Brake

procedures.
RCPH10WHL381BAH 9
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6. Follow the on-screen prompts to complete Park

Brake Test.
If all conditions are not met to test the brake, the
monitor will display the condition that must be cor-
rected prior to completion of the test. The parking
brake switch must be engaged.
RCPH10WHL382BAH 10
When all conditions are met, the monitor will display “Test Park Brake Ready.”
1. Place the transmission mode switch, located on
right console, to the Manual (OFF) position.
RCIL10WHL177BAL 11
2. Shift to 3rd gear with the transmission selector.

3. Shift the gear selector into 3rd gear forward. Slowly
increase engine speed to full open throttle.
sion to neutral.
6. Shift the gear selector to 3rd gear reverse. Slowly
increase engine speed to wide open throttle.
sion to neutral.
9. Press the escape key on navigation pad to exit test.
RCIL10WHL193BAL 12
Before operating machine, periodically test parking brake activation. Do the following steps to test the activation of
Parking Brake.
NOTE: Test the parking brake at a maximum of every 250 hours.
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WARNING
machine damage.
rious injury.
W0352A
1. To release parking brake, all of the following are

required
A. Transmission shifter positioned in neutral
B. Push the Parking Brake switch to the release
position
C. Transmission shifter positioned from N to F or
R for a second, and back to N
2. Parking brake will engage under any of the following
conditions. Always wear your seat belt in the event
that the parking brake would unexpectedly engage.
A. Parking Brake switch in engaged position
B. Loss of system electrical power (key OFF)
C. Loss of brake accumulator pressure
D. Engine goes in Accelerated Idle Mode (warm-
ing up)
E. Engine goes out of low idle without an operator
command
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3. To test these functions:

A. Start on a clear level surface.
B. With step 1, A through C complete, start the
engine first, then release the parking brake.
The red park brake indicator warning light
should not be illuminated.
C. Turn the engine OFF. Turn the key switch to
the ON position. With the engine OFF, the
parking brake light should come ON.
D. Release the parking brake using B and C in
step 1. Make sure the AIC parking brake light
is out.
E. With the engine still off pump the service
brakes repeatedly, the low brake pressure
warning light should come ON. Continue to
pump the service brakes until the parking
brake light comes ON, pump the brakes three
more times. This could require as many as
forty brake pumps.
F. Start the engine and allow the brake pressure
to build until the AIC brake pressure warning
light goes OFF.
G. Depress the service brake and release. The
AIC PARK brake indicator light must stay ON.
H. Put the transmission in F or R and back to
N. The AIC (PARK BRAKE ON SWITCH
LIGHT?) brake light must stay ON
I. Put the parking brake switch in the engaged
(OFF) position, attempt B and C in step 1. The
parking brake switch light must stay ON
4. Put the parking brake switch in the release position.
A. Repeat steps B and C in step 1 above. The
parking brake light must turn OFF
B. Allow the machine to roll slowly forward with
the transmission in Forward. Engage the
parking brake. The machine must come to a
stop immediately. Parking brake switch light
must come ON. The AIC park brake indicator
lamp must also come on. Transmission must
disengage.
Repair as necessary to eliminate problems.
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Instrument cluster - Dynamic description – Fan Auto Mode

Activation
trigger the clearing of debris from the cooling system elements approximately every ½ hour of operation. This feature
reversing switch in the cab.
In the auto mode, machine operating conditions control the fan speed. The highest measured temperature in the
coolant, air intake, hydraulic or transmission systems regulates the fan speed. Reduced fan speed lowers the machine
noise level as well as reduces the power required to drive the fan. This can contribute to improved fuel economy. See
Accessing Fan Auto Mode Test for procedures to select Fan Auto ON-OFF mode:

A. Escape key
C. Up key
D. Down key
tions.
RCPH11WHL023BAN 1
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Accessing Fan Auto Mode Test

2. Highlight Settings icon from main menu screen. Use

RCPH11WHL020BAN 2
3. Highlight Engine icon from Setting screen. Use the

Enter / Confirm key to choose selection.
RCPH11WHL029BAN 3

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4. Highlight EngOptions icon from Engine screen. Use

RCPH11WHL026BAN 4
Fan Auto Feature (if equipped)

In automatic mode, the fan speed gradually changes be-
tween high and low based on operating temperatures in
the coolant, air intake, hydraulic or transmission systems.
NOTE: The following procedure is only available for ma-
chines equipped with auto fan feature.
5. Highlight Fan Auto icon from EngOptions screen.

Scroll through ON or OFF choices and choose de-
sired setting. Use the Enter / Confirm key to choose
selection and lock into memory.
Use navigation pad Escape key to return to main
driving menu.
RCPH11WHL027BAN 5
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Instrument cluster - Dynamic description – Transmission Clutch

Calibration
The Wheel Loader transmission control system can be calibrated to improve the shift quality. The clutches gradually
wear in the transmission therefore the calibration procedure should first be performed after the first 250 hours of
operation and then every 1000 hours thereafter. The calibration needs to first be conducted to make up for the rapid
wear that happens as the initial break-in happens.

A. Escape key
C. Up key
D. Down key
tions.
RCPH11WHL023BAN 1
Accessing Clutch Calibration Feature


NOTE: Screen arrows will display to indicate if additional
menu options are available.
RCPH11WHL020BAN 2
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choose selection.
RCPH11WHL022BAN 3
NOTE: Ensure oil is warm to temperature of 90 °C (194 °F). Use transmission stall test procedure to achieve required
temperature.
4. Park machine on firm, level surface.
5. Place the transmission control lever in NEUTRAL.
6. Set the parking brake.

7. Use Up and Down keys to highlight ClutchCalib icon
If machine conditions are not correct, an error message

will appear. The calibration procedure will not complete.
Follow the prompt to aid in correcting any machine condi-
tions.
The screen may display the following prompts to guide the
user to correct machine conditions:
• Not in neutral Action required – Shift into neutral

• Parking brake OFF Action required – Turn the Park-
ing Brake ON
• Machine moving Action required – Stop the machine
Oil temp too low Action required – Stall the trans- RCPH11WHL021BAN 4
•
mission to heat the oil to 90 °C (194 °F)
• Oil temp too high Action required – Run at high idle
with no load to cool the oil
• Engine RPM low Action required – Operate the en-
gine at full RPM
• Engine RPM high Action required – Operate the en-
gine at idle speed
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8. Run engine at idle rpm. Use Enter / Confirm key to

start the transmission clutch calibration procedure.
NOTE: You must use the transmission stall test procedure
to raise the oil temperature above 90 °C (194 °F).
RCPH10WHL378BAH 5
9. If machine conditions are correct, operator is

prompted to confirm. Use the Enter / Confirm key
to confirm.
If conditions are correct, the user will see six calibration

screens displayed. They will appear in the following order:
• Adjust K1
• Adjust K2
• Adjust K3
• Adjust K4
• Adjust KV
• Adjust KR
• Adjust KW (5-speed only on smaller models)
When calibration process is complete, the user will be

prompted to turn the engine Off and restart the machine.
If the process is not completed correctly, the screen will
prompt the user to escape.
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Instrument cluster - Dynamic description – Fan Speed Adjustment

Reversible Fan Speed Option
trigger the clearing of debris from the cooling system elements aproximately every ½ hour of operation. This feature
reversing switch in the cab. The auto reverse feature only activates at elevated engine speed.
In the auto mode, machine operating conditions also control the fan speed. Adjusting the pressure delivered to the
hydraulic drive motor changes the fan speed. In auto mode, the fan speed varies from a minimum speed up to the
100% speed value entered into the Advanced Instrument Cluster (AIC) memory for that model. Using the procedure
below allows adjustment of the 100% fan speed value for that specific model. To return to the factory default value,
select the reset option on the display. The highest measured temperature in either of the coolant, air intake, hydraulic
or transmission systems regulates the fan speed.
Lower fan speeds allow the machine to warm up faster in cold conditions. Reduced speed also lowers the machine
noise level as well as reduces the power required to drive the fan. This can contribute to improved fuel economy.
Use the following procedures to select the Fan Test mode.

A. Escape key
C. Up key
D. Down key
tions.
RCPH11WHL023BAN 1
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Accessing Fan Test Feature

2. Select Service icon from main menu screen. Use

RCPH11WHL020BAN 2
3. Highlight Calibration icon from Service menu. Use

RCPH11WHL022BAN 3
4. Highlight Fan Test icon from Calibration menu. Use

RCPH11WHL021BAN 4
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5. Run the engine at full rpm. Use the Enter / Confirm

key to initiate the fan speed option.
RCPH10WHL383BAH 5
6. Use the Enter / Confirm key to start the100% or full

fan speed adjustment for that model.
RCPH11WHL031BAN 6
7. Use up or down arrows to highlight Adjust 100%

speed or Reset (factory default). Use the Enter /
Confirm to choose either option.
RCPH11WHL033BAN 7
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8. To adjust the 100% fan speed, scroll up or down

to the required speed. Use the Enter / Confirm to
choose the adjustment. Use the escape key to re-
turn to the main menu.
Model 100% Default Speed

521F 946
621F 763
721F 835
821F 920
921F 920
1021F 857
1121F 857
RCPH11WHL035BAN 8
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Instrument cluster - Static description

RCPH10WHL015GAH 1
1. Four way flashers 4. Secondary steering lamp

2. Brake pressure indicator 5. Parking brake indicator
3. Lamp indicator
RCPH10WHL015GAH 2
6. Caution master indicator (Yellow non-critical) 7. Stop master indicator (Red — critical)
8. Transmission oil temperature gauge 9. Hydraulic oil temperature gauge
10. Coolant temperature gauge 9. Fuel Level gauge
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Stop master indicator (Red — critical)

The Stop Master Indicator is a critical
warning display. See Critical Warning
Displays. When the Stop Master indicator
illuminates, IMMEDIATELY bring the
machine safely to a stop, and turn the
engine OFF. Failure to do so may result
in personal injury and/or damage to the
machine.
RCIL10WHL178BAL 3
Critical Warnings
Display Description Corrective Action
Engine oil pressure Low engine oil pressure Bring machine to stop. Turn engine OFF.
Brake pressure Low brake pressure Bring machine to stop. Turn engine OFF.
Steering pressure (w/auxiliary
Low steering pressure Bring machine to stop. Turn engine OFF.
steering)
Coolant temperature High engine coolant temperature Bring machine to stop. Turn engine OFF. Allow
engine and coolant to cool. Check coolant
levels.
Hydraulic oil temperature High hydraulic oil temperature Bring machine to stop. Turn engine OFF.
Transmission oil temperature High transmission oil Bring machine to stop. Turn engine OFF.
temperature
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Caution master indicator

(Yellow — non-critical)
The caution master indicator is a non-critical
warning display. See the non critical warning
chart. When the caution master indicator
is ON, change the operating method,
schedule a shutdown for maintenance, or if
the condition persists, contact your dealer.
The non-critical warning table lists warning
displays that may appear on the instrument
cluster and the corrective action required.
RCIL10WHL179BAL 4
NOTICE: When a fault occurs, an audible alarm may sound and the Caution Master Indicator will be yellow. The
caution message will be displayed in the message area. If this occurs, return the machine to a service position, and
turn the engine off, and take corrective action to help avoid expensive repairs.
Non-critical warnings
Display Description Corrective action
Parking brake Parking brake engaged and Release the parking brake. Check parking brake system.
machine shifted forward or
reverse
Coolant High engine coolant
temperature temperature 1. Idle machine and monitor temperature.
2. Clean radiator or operate fan reverser (If equipped).
3. Check coolant level and add coolant if necessary.
Hydraulic High hydraulic temperature
temperature 1. Idle machine and monitor temperature.
2. Clean cooler or operate fan reverser (If equipped).
3. Check hydraulic fluid level.
4. Check hydraulic system.
Transmission High transmission
temperature temperature 1. Idle machine and monitor temperature.
2. Clean cooler or operate fan reverser (If equipped).
3. Check transmission
Air filter High air filter restriction
1. Clean air filter.
2. Replace primary and secondary filters.
Transmission filter Transmission filter restriction
1. Replace transmission filter.
Hydraulic filter Hydraulic filter restriction
1. Replace hydraulic filter
Alternator Alternator malfunction
1. Check electrical system.
2. Voltages are out of range.
3. Check alternator
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Instrument cluster Digital instrument cluster - Dynamic description

The LCD Multi-Function Display (liquid crystal display) is
located at the center of the modular dashboard. On start
up, the console indicator lamps will momentarily flash.
The LCD Multi-Display will flash the machine model. The
initial standard driving screen will then appear. Once op-
erator preferences are set, the screen will reflect those
selections.
NOTE: Upon initial startup, the operator can push the re-
turn/escape key, and the language selection screen will
appear immediately. This allows the operator to make a
language selection without having to use an unknown lan-
guage to scroll through to preferences.
RCPH10WHL348AAH 1
Information will be displayed on the LCD as directed by

the operator or automatically by machine operations. The
screen offers prompts to assist the operator when pro-
gramming machine functions and or performing diagnos-
tics.
The top section of the LCD display will show the machine
hours, speed, or RPM's. The display is controlled by
machine technology and geared toward operator prefer-
ences. The screen shown is the default screen. By turn-
ing the ground speed or engine speed off, the hour meter
time registered will display.
RCPH10WHL348AAH 2
The left side of the screen displays the transmission se-

lection forward, neutral, or reverse as selected by the op-
erator. (F-N-R)
RCPH10WHL348AAH 3
In the example, gearbox function selections (1) are dis-

played on the right side of the screen. This would include
power mode, declutch, joystick steering, etc.
The gear chosen (2) and in this instance automatic trans-
mission mode are displayed.
The lower right (3) displays the clock. Time can be set in
either 12 or 24 hour increments.
A DEF fluid gauge (4) is shown at the bottom of the
screen. Bars indicate amount of DEF fluid in the tank as
the bars are illuminated.
RCPH10WHL348AAH 4
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Instrument cluster - Dynamic description


A. Escape key
C. Up key
D. Down key
tions.
RCPH11WHL023BAN 1
Viewing screens
1. Info 1 screen is displayed when using the down
arrow from the driving screen. Displayed data in-
cludes engine RPM's, speed, and fuel level.
RCPH10WHL533AAH 2
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2. Press the down key to display Info 2 screen. Dis-

played data includes coolant temperature, engine oil
temperature, and oil pressure. Temperature value
can be displayed in Fahrenheit or Celsius.
RCPH10WHL534AAH 3
3. Press the down key to display Info 3 screen. Dis-

played data includes temperature of transmission
oil, hydraulic oil, and sump oil. Temperature value
can be displayed in Fahrenheit or Celsius.
RCPH10WHL531AAH 4
4. Press the down key to display the Info 4 screen.

Displayed data includes turbocharger voltage and
turbocharger temperature. Temperature value can
be displayed in Fahrenheit or Celsius.
RCPH10WHL530AAH 5
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Entering the service screens

After key switch is turned to ON position or machine has
been started, the main menu can be accessed. The fol-
lowing options can be navigated to from the main menu:
• Adjust machine operation to suit working conditions

• View fault codes
• Select system and component testing (parking
brake test, fan test, etc.)
• Select languages
Main Menu
1. To access the Main Menu screen, hold the confirm
2. Use the Enter / Confirm key to choose Main Menu

selections.
RCPH11WHL020BAN 6
Settings Menu
1. Use the Enter / Confirm key to choose Settings
menu selections.
RCPH11WHL029BAN 7

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Service Menu
1. Use the Enter / Confirm key to choose Service menu
selections.
NOTE:
RCPH11WHL022BAN 8
Diagnostics Menu
1. Use the Enter / Confirm key to choose Diagnostics
selection.
RCPH11WHL024BAN 9
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Software legend
RCPH10WHL060HAH 10
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Parking Brake Indicator

The parking brake indicator illuminates when the parking brake is applied.
Air Filter Indicator

The air filter indicator illuminates when the air filter is restricted.
Transmission Oil Temperature Gauge

The transmission oil temperature gauge is shown with a normal or red zone.
• Normal zone indicates a normal operating temperature of 20 - 120 °C (68 - 248 °F).
• Red zone indicates transmission oil temperature has increased to unsafe temperature above 125 °C (257 °F).
An audible warning alarm will sound continuously.
NOTE: Machine must not be operated when temperature is in red zone.
Transmission Oil Temperature Indicator

The transmission oil temperature indicator illuminates when temperature exceeds 125 °C (257 °F).
Fuel Level
Fuel level is displayed in the percentage of fuel remaining in the tank.
Fuel Reserve Indicator

Fuel reserve indicator notes fuel tank is approaching empty (5 percent or below).
Engine Oil Pressure Indicator

The engine oil pressure indicator illuminates when oil pressure is below 70 kPa (10 psi) or when oil filter is clogged.
Engine Coolant Temperature

The engine coolant temperature gauge is shown with a normal or red zone.
• Normal zone indicates a normal operating temperature of 20 - 105 °C (68 - 221 °F)
• Red zone indicates engine coolant temperature continues to increase to 110 °C (230 °F) or above.
NOTE: Machine must not be operated when temperature is in red zone.
Engine Coolant Temperature Indicator

The engine coolant temperature indicator illuminates when coolant temperature exceeds 110 °C (230 °F) or above.
Hourmeter
The hourmeter displays the accumulated engine running time. An hour glass symbol displays units in hours and
tenths of an hour.
Tachometer
The tachometer displays the engine speed in revolutions per minute along with a “r/min” symbol.
Speedometer
The speedometer displays the ground speed in either kilometers per hour (km/h) or miles per hour (mph) along with
either a “km/h” or “mph” symbol.
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Battery Charge Indicator

The battery charge indicator illuminates when battery charge is insufficient.
Requested Gear
The gear position indicator is located on shift lever and displayed in the center of lever as follows:
• 1 = 1st gear
• 2 = 2nd gear
• 3 = 3rd gear
• 4 = 4th gear
Brake Pressure Indicator

Brake pressure indicator Illuminates when brake pressure is below 105 - 115 bar (1523 - 1668 psi).
Emergency Steering Indicator

The emergency steering indicator illuminates when the emergency steering pump is actuated.
High Beam Indicator

The high beam indicator illuminates when road light high beam is turned on.
Turning Indicator Lamps

Turning lamp indicator illuminates when turning light control lever is used to indicate turn.
General Warning Indicator

The general warning indicator Illuminates when a fault is detected. The machine must be shut down. Correct the
problem as required.
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Buzzer - Testing
Turn the key switch OFF. Disconnect The horn should sound while the Replace the horn switch and retest.
the Turn Signal, Hi-/ Low Beam & jumper is installed.
Horn connector. Fabricate a jumper
15 cm (6 in) long. Turn the key
switch ON.
Check
Short pin 31 to 31B on the Turn Sig-
nal, Hi-/ Low Beam & Horn connec-
tor.
Turn the key switch OFF. Reconnect The voltage should be approximately The voltage is less than 10 volts.
the Turn Signal, Hi-/ Low Beam & 24 V. There is a problem in the key switch
Horn connector. Turn the key switch supply voltage to the relay. Check
ON. fuse ECC-F6.
Check
Measure the voltage from the Horn
Relay terminal 86 to chassis ground.
Measure the voltage from the Horn
Relay terminal 30 to chassis ground.
Check 10 Ω. ohms. There is a problem in the
Activate the horn switch while mea- ground circuit from the relay, through
sure the resistance from the Horn the switch to ground. Repair or re-
Relay terminal 85 to chassis ground. place the harness or horn switch as
required.
Fabricate two jumper wires that can The horn should sound while the The horn did not sound. Replace the
reach from the horn to the battery jumpers are in place. horn and retest.
posts.
Check
Connect one jumper wire from the
positive terminal on the horn to the
positive battery post. Connect the
other jumper wire from the negative
terminal on the horn to the negative
battery post.
Check 10 Ω. there is an open circuit in the wire
Measure the resistance from the from the relay to the horn or the horn
Horn Relay terminal 87 to the posi- to chassis ground. Repair or replace
tive terminal on the horn. Measure the wire as required.
the resistance from the negative ter-
minal on the horn to chassis ground.
Turn the key switch ON. The horn should sound while the The horn did not sound. Replace the
Check jumper is in place. horn relay and retest.
Connect one jumper wire from termi-
nal 85 on the Horn Relay to chassis
ground.
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RCPH11WHL004GAL 1
(1) Switched Battery, 24 Volts (6) Ground, GND_CAB_SPL

(2) Horn ECC-F6 , 7.5 Amp Fuse (7) Front Connector
(3) Turn Signal, Hi/Low Beam & Horn Switch (8) Horn
(4) Horn Relay, K4 (9) Rear Chassis, Below Cab Ground
(5) Horn Switch
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Backup/Reverse alarm relay - Testing

Turn the key switch OFF. Fabricate The alarm should sound while the The alarm did not sound. Replace
two jumper wires that will reach jumper wires are installed. the backup alarm.
from the back-up alarm to the bat-
tery posts. Disconnect the back-up
alarm connector.
Check
Connect one jumper wire from the
positive terminal on the back-up
alarm to the positive battery post.
Connect the other jumper wire from
the negative terminal on the back-up
alarm to the negative battery post.
Reconnect the back-up alarm into The voltage should be approximately The voltage is less than 24 volts.
the circuit. Turn the key switch ON. 24 volts Check fuse ECA-F14 and retest.
Check
Measure the voltage from the
Back-up Alarm Relay, terminal 30 to
chassis ground.
Turn the key switch OFF. The resistance should be less than The resistance is greater than 10 Ω.
Check 10 Ω. There is an open circuit in th ewire.
Measure the resistance from the Repair or replace as required.
Back-up Relay terminal 87 to the
Back-up Alarm terminal 2. Measure
the resistance from the Back-up
Alarm terminal 1 to chassis ground.
Turn the key switch OFF. Fabricate The Back-up Alarm should sound Replace the Back-up Alarm Relay
two jumper wires that can reach from while the jumper is installed. There and retest.
the Back-up Alarm Relay to the bat- is a problem in the circuit from the
tery posts. TECM to the Back-up Alarm Relay.
Check Repair as required.
Connect one jumper wire from termi-
nal 86 on the Back-up Alarm Relay
to the positive battery post. Connect
the other jumper wire from the termi-
nal 85 on the Back-up Alarm Relay
to the negative battery post.
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RCPH11WHL006GAL 1
(1) Key Switch, 24 V (8) Back-up Alarm

(2) Back-up ECA-F14, 5 Amp Fuse (9) SPL_J1 Ground Connection
(3) Back-up Alarm Relay (10) Disconnect when back-up alarm disable
switch is installed (on TUV road approved
machines only).
(4) Back-up Alarm Signal From TECM , (11) Back-up Alarm Disable Switch
Pull down (Ground) signal from TECM
(5) Switch Battery Supply from ECA-F1, 7.5 (12) Back light power, 24 V
Amp Fuse.
SPL_TRANS_PWR
(6) CABE2/ ENG2 Connector (13) Back light ground
(7) ENG_H/ HD_N Connector
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Instrument cluster Digital instrument cluster - Testing - Advanced

Instrument Cluster
Turn the key switch OFF. Disconnect The voltage should be approximately The voltage is less than 10 V. Check
both AIC connectors. 24 V. fuse ECC-F8. Replace as required.
Check
Measure the voltage from AIC Con-
nector 2, pin 14 to chassis ground.
Turn the key switch ON. The voltage should be approximately The voltage is less than 10 V. Check
Check 24 V. fuse ECA-F3. Replace as required.
Turn the key switch ON. The voltage should be approximately The voltage is less than 10 V. Ver-
Check 24 V. ify the dedicated ground connections
Measure the voltage from AIC Con- are free of damage, corrosion and
nector 1, pin 1, to AIC Connector 1, incorrect attachment. Repair or re-
pin 12. Measure the voltage from place the harness as required.
AIC Connector 2, pin 21, to AIC Con-
nector 2, pin 22.
Check 10 Ω. there is an open circuit in the chassis
Measure the resistance from AIC ground connection. Verify that the
Connector 2, pin 22 to chassis connection is free of damage, corro-
ground. sion and incorrect attachment. Re-
pair or replace the harness as re-
quired.
RCPH11WHL014FAL 1
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(1) Advanced Instrument Cluster (5) AIC Power ECA-F3 7.5 Amp Fuse
(2) 24 Volt Supply, Unswitched Battery (6) Dedicated Ground
(3) 24 Volt Switched Battery (7) ENG/ CAB_E Connector
(4) AIC Power ECC-F8 10 Amp Fuse (8) Ground Post 1,Near AIC within 4 inches
47392461 19/06/2012
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Index

Backup/Reverse alarm relay - Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Buzzer - Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Instrument cluster - Dynamic description - Brake pedal calibration (5-speed transmission) . . . . . . . . . . . . . . . . . . . 3
Instrument cluster - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Instrument cluster - Dynamic description – Fan Auto Mode Activation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Instrument cluster - Dynamic description – Fan Speed Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Instrument cluster - Dynamic description – Fault Code Retrieval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Instrument cluster - Dynamic description – Park Brake Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Instrument cluster - Dynamic description – Transmission Clutch Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Instrument cluster - Static description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Instrument cluster Digital instrument cluster - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Instrument cluster Digital instrument cluster - Testing - Advanced Instrument Cluster . . . . . . . . . . . . . . . . . . . . . . . 42
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Loader arm and bucket control system - 415
1021F
1121F
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Contents
DIAGNOSTIC
Load travel stabilization system

Control solenoid - Testing - Ride Control Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Testing - Ride Control Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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Electrical systems - Loader arm and bucket control system
Load travel stabilization system Control solenoid - Testing - Ride

Control Solenoid
Turn the key switch OFF. Disconnect The resistance should be less than The resistance is greater than 10
connector YRC from the ride control 10 ohms. ohms. There is a bad ground cir-
solenoid. cuit. Repair or replace the wire as
Check required.
Measure the resistance from con-
nector YRC pin 2 (0_AD Bk-1.0) to
chassis ground.
Measure the resistance from con- The resistance should be less than The resistance is greater than 10
nector YRC pin 1 (58G W-1.0) to 10 ohms. ohms. There is an open circuit in the
Ride Control Switch pin 6 (58_F wiring. Repair or replace the wire as
W-0.8). required.
Measure the resistance between ter- The resistance should be approxi- The resistance is out of range. The
minals 1 and 2 on the control sole- mately 20 - 26 ohms. ride control solenoid is bad. Replace
noid. (23 Ω at 20 °C (68 °F)) the solenoid.
Load travel stabilization system - Testing - Ride Control Solenoid

Turn the key switch OFF. Disconnect The resistance should be less than The resistance is greater than 10
connector YRC from the ride control 10 ohms. ohms. There is a bad ground cir-
solenoid. cuit. Repair or replace the wire as
Check required.
Measure the resistance from con-
nector YRC pin 2 (0_AD Bk-1.0) to
chassis ground.
Measure the resistance from con- The resistance should be less than The resistance is greater than 10
nector YRC pin 1 (58G W-1.0) to 10 ohms. ohms. There is an open circuit in the
Ride Control Switch pin 6 (58_F wiring. Repair or replace the wire as
W-0.8). required.
Measure the resistance between ter- The resistance should be approxi- The resistance is out of range. The
minals 1 and 2 on the control sole- mately 20 - 26 ohms. ride control solenoid is bad. Replace
noid. (23 Ω at 20 °C (68 °F)) the solenoid.
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Electrical systems - Loader arm and bucket control system
RAIL12WEL0144GA 1
(1) Ride control switch. (4) Note: The YRC_J jumper is only used on
model 821F \ W190.
(2) Ride control relay K4. (5) Ride control solenoid (option).
(3) 24 V power from the fuse ECA-F5.
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Index

Load travel stabilization system - Testing - Ride Control Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Load travel stabilization system Control solenoid - Testing - Ride Control Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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Cab/Platform harnesses and connectors - 510
1021F
1121F
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Contents
DIAGNOSTIC
Auxiliary power plugs and sockets

Outlet 1 - Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Outlet 2 - Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
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Electrical systems - Cab/Platform harnesses and connectors
Auxiliary power plugs and sockets Outlet 1 - Testing

Measure the resistance from Power ground connection to the Power Out-
Outlet 1 pin C to chassis ground. let 1. Verify the wiring is secure and
free of corrosion, abrasion and incor-
Turn the key switch ON. The voltage should be approximately The voltage is less than 10 volts,
Check 12 volts. there is a problem in the 12 supply
Measure the voltage from Power Action to the Power Outlet. Check Fuse
Outlet 1 terminal A and terminal C . Temporarily replace the Power Out- ECB-F1. Refer to Power converter
let and retest. - Testing (55.301). Repair as re-
quired.
RCPH11WHL012GAL 1
(1) Switched Battery, PRM_A pin C (6) Power Outlet 2 (option)

(2) CNV 24V to 12V Power Converter (7) Two Way Radio, 12 V, ECB-F10
15 A
(3) Remote, 12 V, ECB-F1 (8) GND_CAB4 Right Console
10 A
(4) Power Outlet 1 (option) (9) GND_CAB5 Right Console
(5) Remote, 12 V, ECB-F2
10 A
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Electrical systems - Cab/Platform harnesses and connectors
Auxiliary power plugs and sockets Outlet 2 - Testing

Measure the resistance from Power ground connection to the Power Out-
Outlet 2 pin C to chassis ground. let 2. Verify the wiring is secure and
free of corrosion, abrasion and incor-
Check 12 volts. there is a problem in the 12 supply
Measure the voltage from Power Action to the Power Outlet. Check Fuse
Outlet 2 terminal A and terminal C . Temporarily replace the Power Out- ECB-F2. Refer to Power converter
let and retest. - Testing (55.301). Repair as re-
quired.
RCPH11WHL012GAL 1
(1) Switched Battery, PRM_A pin C (6) Power Outlet 2 (option)

(2) CNV 24V to 12V Power Converter (7) Two Way Radio, 12 V, ECB-F10
15 A
(3) Remote, 12 V, ECB-F1 (8) GND_CAB4 Right Console
10 A
(4) Power Outlet 1 (option) (9) GND_CAB5 Right Console
(5) Remote, 12 V, ECB-F2
10 A
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Index

Auxiliary power plugs and sockets Outlet 1 - Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Auxiliary power plugs and sockets Outlet 2 - Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
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Cab controls - 512
1021F
1121F
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Contents
Cab controls - 512
DIAGNOSTIC
Cigarette lighter
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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Electrical systems - Cab controls
Cigarette lighter - Testing

Turn the key switch OFF. The resistance should be less than The resistance is greater than 10 Ω.
Check 10 Ω. There is an open circuit in the chas-
Measure the resistance from Cigar sis ground connection to the Cigar
Lighter connector, pin 2 to chassis Lighter. Repair as required.
ground.
Turn the key switch ON. The voltage should approximately be The voltage is less than 10 V. There
Check 24 V. is a problem with the battery sup-
Measure the voltage across the Action ply to the Cigar Lighter. Check fuse
Cigar Lighter connector pins 1 and Temporarily replace the Cigar ECA-F18 .
2. Lighter and retest.
RCPH11WHL019FAL 1
(1) Cigar Lighter (optional) (3) GND_CAB3, Right Console

(2) Cigar Lighter 24 V, ECA-F18
15 A
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Index
Cab controls - 512

Cigarette lighter - Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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Cab lighting - 514
1021F
1121F
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Contents
Cab lighting - 514
DIAGNOSTIC
Cab interior light

Dome light - Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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Electrical systems - Cab lighting
Cab interior light Dome light - Testing

Dome light to manual. Remove con- 24 V. fuse ECC-F1. Replace as required.
nector LDM1.from the Dome light.
Check
Measure the voltage from LDM1 pin
1 to chassis ground.
Turn the key switch OFF. Remove The resistance should be less than If the resistance is greater than 10 Ω
connector LDM3 from the Dome 10 Ω. or an open circuit is indicated, check
light. the ground wiring circuit through
Check connectors SPL ROOF, ROOF, and
Measure the resistance from LDM3 CAB RF.
Turn the key switch OFF and the The bulb filament should be good Replace bad bulb.
Dome light manual switch ON. (continuity).
Check
If the light is not on, check the bulb
for continuity.
If readings are all good replace the
Dome light.
RCIL11WHL040FAK 1

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Electrical systems - Cab lighting
Amp fuse
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Index
Cab lighting - 514

Cab interior light Dome light - Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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Wiper/Washer system - 518
1021F
1121F
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Contents
DIAGNOSTIC
Windshield wiper motor

Testing Front Wiper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Testing Rear Wiper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Wiper switches
Testing Front Washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Delay timer
Testing Wiper Cutout Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
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Electrical systems - Wiper/Washer system
Windshield wiper motor - Testing Front Wiper

Check 10 Ω. Ω, there is a problem in the chas-
Measure the resistance from Front sis ground circuit to the Front Wiper
Wiper Washer Switch SFWW pin 2 to Washer Switch, Wiper Motor or the
chassis ground. Measure the resis- Diode Module. Verify that the wire
tance from the Wiper Motor connec- and connection points are free of
tor pin 1/A to chassis ground. Mea- abrasion, corrosion or incorrect at-
sure the resistance from the Diode tachment. Repair as required.
Module pin C to chassis ground.
Check 24 volts. there is a problem in the battery sup-
Measure the voltage from the Wiper ply to the component. Check fuse
Cutout Relay pin 86 to chassis ECA-F12.
Front Wiper High Speed Relay pin
86 and pin 30 to chassis ground.
Measure the voltage from Front
Wiper Low Speed Relay pin 86 to
age from the Front Wiper Motor pin
3 to chassis ground. Measure the
voltage from SFWW Front Wiper
Washer Switch pin 5 to chassis
ground.
Check 10 Ω. there is a problem in the wiring. Re-
Measure the resistance from Wiper pair or replace the wiring as required.
Motor pin B to the Wiper Cutout Re-
lay pin 30. Measure the resistance
from Wiper Motor pin B to the Diode
Module pin B. Wiggle the harness
during measurement to reveal an in-
termittent condition.
Motor pin A to the Front Wiper High
Speed Relay pin 87. Measure the
resistance from Wiper Motor pin A
to the Diode Module pin A. Wiggle
the harness during measurement to
reveal an intermittent condition.
Motor pin D to the Front Wiper Low
Speed Relay pin 87A. Wiggle the
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Motor pin D to the Front Wiper Low
Speed Relay pin 87A. Wiggle the
Measure the resistance from Low pair or replace the wiring as required.
Speed Relay pin 30 to Wiper Cutout
Relay pin 87A. Measure the resis-
tance from Low Speed Relay pin
85 to SFWW Front Wiper Washer
Switch pin 3. Measure the resis-
tance from Low Speed Relay pin 87
to High Speed Relay pin 87A. Wiggle
Measure the resistance from SFWW pair or replace the wiring as required.
Front Wiper Washer Switch pin 9 to
High Speed Relay pin 85. Measure
the resistance from SFWW Front
Wiper Washer Switch pin 9 to Wiper
Cutout Relay pin 85. Wiggle the har-
ness during measurement to reveal
an intermittent condition.
Turn the key switch OFF. Fabricate The wiper motor should turn ON at The wipers did not turn on. Tem-
a jumper wire long enough to reach the low speed. porarily replace the Low Speed Re-
from the Low Speed Relay terminal Action lay and retest.
85 to chassis ground. There is a problem in the SFWW
Check Front Wiper Washer Switch. Tem-
Place one end of the jumper wire on porarily replace the switch and
the Low Speed Repay terminal 85. retest. Refer to Delay timer - Test-
Place the other end of the jumper ing Wiper Cutout Relay (55.518).
wire on a clean chassis ground con-
nection.
Turn the key switch OFF. Fabricate The wiper motor should turn ON at The wipers did not turn on. Tem-
a jumper wire long enough to reach the high speed. porarily replace the High Speed Re-
from the High Speed Relay terminal Action lay and retest.
85 to chassis ground. There is a problem in the SFWW
Check Front Wiper Washer Switch. Tem-
Place one end of the jumper wire on porarily replace the switch and
the High Speed Repay terminal 85. retest.
Place the other end of the jumper
wire on a clean chassis ground con-
nection.
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RCPH11WHL002HAL 1
(1) Switched Battery 24 V (8) Diode Module

(2) Front Wiper/Washer ECA-F12 (9) Front Washer Motor
10 A
(3) SFWW Front Wiper Switch (10) GND_CAB_SPL
(4) Front Wiper High Speed, K1 (11) Front Wiper Motor Ground
GND_CAB2
(5) Wiper Cutout Relay (12) GND_CAB_SPL
(6) Front Wiper Low Speed, K2 (13) Front Washer Motor Ground
SPL_ENG
(7) Front Wiper Motor (14) CAB_E/ ENG connector
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Windshield wiper motor - Testing Rear Wiper

Check 10 Ω. Wiggle the harness during Ω, there is a problem in the chassis
Measure the resistance from the measurement to reveal an intermit- ground circuit to the Rear Wiper Mo-
Rear Wiper Motor, terminal A/1 to tent condition. tor or the Rear Washer Motor. Verify
chassis ground. Measure the resis- that the wire and connection points
tance from the Rear Washer Motor, are free of abrasion, corrosion or in-
pin 2 to chassis ground. correct attachment. Repair as re-
quired.
Check 10 Ω. Wiggle the harness during there is a problem in the chassis
Measure the resistance from Diode measurement to reveal an intermit- ground circuit to the Diode Module.
Module pin C to chassis ground. tent condition. Verify that the wire and connection
points are free of abrasion, corrosion
or incorrect attachment. Repair as
required.
Turn the key switch ON. The voltage should be approximately The voltage is less than 10 volts.
Check 24 volts. There is a problem with the battery
Measure the voltage from the Rear supply voltage to the switch. Check
Wiper Switch pin 5 to chassis fuse ECA-F13. Repair as required.
the Rear Wiper Switch pin 3 to chas-
sis ground.
Turn the key switch ON. The voltage should be approximately The voltage is less than 10 volts.
Check 24 volts. There is a problem with the battery
Measure the voltage from the Rear supply voltage to the motor. Check
Wiper Motor pin C to chassis ground. fuse ECA-F13. Repair as required.
Turn the key switch OFF. Turn the The resistance is less than 10 Ω. The resistance is greater than 10
Rear Wiper Switch to the OFF posi- Ω. There is a problem in the wiring
tion. circuit from the motor to the Wiper
Check Switch. Repair as required.
Measure the resistance from the
Rear Wiper Motor, pin B to the Rear
Wiper Switch pin 2. Measure the
resistance from the Rear Wiper Mo-
tor, pin B to the Diode Module pin
F. Measure the resistance from the
Rear Wiper Motor, pin D to the Rear
Wiper Switch pin 1.
Turn the key switch ON. Turn the The voltage should be approximately The voltage is less than 10 V. Tem-
Rear Wiper Switch to the LOW po- 24 V. porarily replace the Rear Wiper
sition. Action Switch and retest.
Check Temporarily replace the Rear Wiper
Measure the voltage from the Rear Motor and retest.
Wiper Motor pin B to chassis ground.
Turn the key switch ON. Turn the The voltage should be approximately The voltage is less than 10 V. Tem-
Rear Wiper Switch to the HIGH po- 24 V. porarily replace the Rear Wiper
sition. Action Switch and retest.
Check Temporarily replace the Rear Wiper
Measure the voltage from the Rear Motor and retest.
Wiper Motor pin D to chassis ground.
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RCPH11WHL010GAL 1
(1) Switched Battery, 24 V (8) GND_CAB_SPL

(2) Rear Wiper Washer, ECA-F13 (9) GND_ENG3
10 A
(3) Rear Wiper Switch (10) Chassis Ground
(4) Rear Washer Motor (11) SPL_ROOF
(5) Diode Module (12) ENG/ CAB_E connector
(6) Rear Wiper Motor (13) ROOF/ CAB_RF connector
(7) Switch Backlight Power
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Windshield wiper motor - Testing

Measure the resistance from the ground circuit to the Rear Washer
Rear Washer Motor pin 2 to chassis Motor. Verify that the wire and con-
ground. Wiggle the harness during nection points are free of abrasion,
measurement to reveal an intermit- corrosion or incorrect attachment.
tent condition. Repair as required.
Check 10 Ω. there is a problem in the signal wire
Measure the resistance from the to the Rear Washer Motor. Verify
Rear Wiper Switch pin 6 to the Rear that the wire and connection points
Washer Motor pin 1. Wiggle the har- are free of abrasion, corrosion or in-
ness during measurement to reveal correct attachment. Repair as re-
an intermittent condition. quired.
Turn the key switch ON. The voltage should be approximately The voltage is less than 10 V, there is
Check 24 V. a problem with the battery supply to
Measure the voltage from the Rear the Rear Wiper Switch. Check fuse
Wiper Switch pin 5 to chassis ECA-F13 . Repair as required.
ground. Wiggle the harness during
measurement to reveal an intermit-
tent condition.
Turn the key switch ON. Activate the The voltage should be approximately The voltage is less than 10 V. Tem-
Rear Washer Switch. 24 V. porarily replace the Rear Washer
Check Action Switch and retest.
Measure the voltage from the Rear Temporarily replace the Washer Mo-
Washer Motor, pin 1 to chassis tor and retest.
ground.
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RCPH11WHL010GAL 1
(1) Switched Battery, 24 V (8) GND_CAB_SPL

(2) Rear Wiper Washer, ECA-F13 (9) GND_ENG3
10 A
(3) Rear Wiper Switch (10) Chassis Ground
(4) Rear Washer Motor (11) SPL_ROOF
(5) Diode Module (12) ENG/ CAB_E connector
(6) Rear Wiper Motor (13) ROOF/ CAB_RF connector
(7) Switch Backlight Power
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Wiper switches - Testing Front Washer

Measure the resistance from the ground to the washer motor. Verify
Front Washer Motor pin 2 to chassis that the wire and connection points
ground. Wiggle the harness during are free of abrasion, corrosion or in-
measurement to reveal an intermit- correct attachment. Repair as re-
tent condition. quired.
Measure the resistance from the ground to the washer motor. Verify
Front Washer Switch pin 2 to chassis that the wire and connection points
ground. Wiggle the harness during are free of abrasion, corrosion or in-
measurement to reveal an intermit- correct attachment. Repair as re-
tent condition. quired.
Check 10 Ω. there is a problem with the signal
Measure the resistance from the wire from the switch to the washer
Front Washer Switch pin 7 to the motor. Repair as required.
Front Washer Motor pin 1. Wiggle
Check 24 volts. there is a problem with the battery
Measure the voltage from the Front supply voltage to the switch. Check
Wiper/ Washer Switch pin 5 to chas- fuse ECA-F12. Repair as required.
sis ground.
Turn the key switch ON. Turn the The voltage should be approximately The voltage is less than 10 volts.
Front Washer Switch ON. 24 volts. There is a problem with the Wiper/
Check Action Washer Switch. Temporarily replace
Measure the voltage from the Front Temporarily replace the Front the switch and retest.
Washer Switch pin 7 to chassis Washer Motor and retest.
ground.
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RCPH11WHL002HAL 1

10 A
GND_CAB2
SPL_ENG
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Delay timer - Testing Wiper Cutout Relay

Turn the key switch FF The resistance should be less than The resistance is greater than 10
Check 10 Ω. Ω. Temporarily replace the relay and
Measure the resistance between retest.
Wiper Cutout pin 87 and 30.
Turn the key switch ON. The voltage should be approximately The voltage is less than 10 V. There
Check 24 V. is a problem with the battery sup-
Measure the voltage from the Wiper ply voltage to the relay. Check fuse
Cutout Relay pin 86 to chassis ECA-F12 . Repair as required.
ground.
Turn the key switch OFF. Discon- The resistance should be less than The resistance is greater than 10
nect the Wiper Cutout Relay from the 10 Ω. Ω, temporarily replace the relay and
circuit. Fabricate two jumper wires retest.
long enough to reach from the Wiper
Cutout Relay to the battery.
Check
Connect one end of the first jumper
wire to terminal 86 on the other end
to the positive battery terminal. Con-
nect one end of th eother jumper wire
to terminal 85 and the other end to a
clean chassis ground. Measure the
resistance between terminal 30 and
87 while the relay is energized.
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RCPH11WHL002HAL 1

10 A
GND_CAB2
SPL_ENG
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Index

Delay timer - Testing Wiper Cutout Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Windshield wiper motor - Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Windshield wiper motor - Testing Front Wiper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Windshield wiper motor - Testing Rear Wiper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Wiper switches - Testing Front Washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
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Cab brake controls - 519
1021F
1121F
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Contents
DIAGNOSTIC
Parking brake control

Button switch - Testing - Parking Brake Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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Electrical systems - Cab brake controls
Parking brake control Button switch - Testing - Parking Brake

Switch
Turn the key switch ON. The voltage should be approximately The voltage is less than 10 V, there is
Check 24 V. a problem in the battery supply to the
Measure the voltage from Park- switch. Check fuse ECA-F6. Repair
ing Brake Switch pin 2 to chassis as required.
ground.
Actuate the Parking Brake Switch. The voltage should be approximately The voltage is less than 10 V, there
Check 24 volts. is a problem in the Parking Brake
Measure the voltage from Park- Switch. Temporarily replace the
ing Brake Switch pin 3 to chassis switch and retest.
ground.
Actuate the Parking Brake Switch. The voltage should be approximately The voltage is less than 10 volts
Check 24 volts. there is a problem in the signal wire
Measure the voltage from AIC con- Action from the switch to the AIC display.
nector pin 6 to chassis ground. Temporarily replace the Instrument Repair as required.
Cluster and retest.
RCPH11WHL011GAL 1
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Electrical systems - Cab brake controls

kPa (1600 psi)
AIC connector 2
AIC connector 1
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Index

Parking brake control Button switch - Testing - Parking Brake Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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Cab controls (Lift arm, Boom, Dipper, Bucket) - 524
1021F
1121F
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Contents
SERVICE
Lift arm lifting controls

Proximity switch - Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
DIAGNOSTIC
Load travel stabilization switch

Testing - Ride Control Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Testing - Ride Control Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
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Electrical systems - Cab controls (Lift arm, Boom, Dipper, Bucket)
Lift arm lifting controls Proximity switch - Adjust
RCPH11WHL031FAH 1
1. Proximity switch 4. Height control target

2. Return to travel target 5. Lift arm
3. Target mounting plate 6. Front chassis (top left hand side)
1. Keep all non-authorized personnel clear of the area.

Park the machine on firm, level ground.
2. Start the engine, and apply the parking brake.
3. Lower the lift arms, and place the bucket flat on the
ground. Stop the engine.
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4. Locate the return to travel target (2) opposite the

proximity switch and then tighten it to the target
mounting plate. Next adjust the proximity switch out
toward the target until and air gap of 3.5 - 5 mm
(0.1 - 0.2 in) is obtained. Lock the proximity switch
in position with its jam nut. Torque the jam nut to 5
ft.lbs
5. The location of the height control target (4) within its
slot in the target mounting plate will determine the
automatic stopping height of the lift arms as they are
raised. The higher the target is positioned in its slot
in the target mounting plate, the lower the lift arms
will automatically stop as they are raised. Position
the target per the table. Tighten the target in this
position.
6. The location of the return to travel target (2) within
its slot in the target mounting plate will determine
where the lift arms will automatically stop while they
are lowered. The higher this target is located in its
slot in the target mounting plate the lower the lift arms
will automatically stop as they are lowered. Position
the target per the table. Tighten the target in this RCPH11WHL281 2
position.
7. Make sure the proximity switch and all the mounting
bolts are tight. Start the engine. Set the detent switch
to the on position, and set the return to travel/float de-
tent switch to the return to travel position. Raise the
lift arms to approximately the horizontal position. Put
the loader control lever in the raise position, and ver-
ify that the electromagnet holds it in that position until
the height control target passes in front of the prox-
imity switch. Next, with the lift arms still raised, put
the loader control lever in the lower position, and ver-
ify that the electromagnet holds it in that position until
the return to travel target passes in front of the prox-
imity switch. Position the bucket flat on the ground.
Shut the machine OFF.
Machine A in (mm) Approximate B in (mm) Approximate resulting

resulting return height control hinge
to travel hinge pin pin height in (mm)
height
1021F Z-Bar 67.0 mm (2.6 in) 540.0 mm (21.3 in) 75.0 mm (3.0 in) 4140.0 mm (163.0 in)
1021F XR 50.0 mm (2.0 in) 693.0 mm (27.3 in) 60.0 mm (2.4 in) 4140.0 mm (163.0 in)
1121F Z-Bar 59.0 mm (2.3 in) 653.5 mm (25.7 in) 76.0 mm (3.0 in) 4220.0 mm (166.0 in)
1121F XR 46.0 mm (1.8 in) 694.0 mm (27.3 in) 65.0 mm (2.6 in) 4220.0 mm (166.0 in)
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Load travel stabilization switch - Testing - Ride Control Switch

Turn the key switch OFF. Disconnect The voltage should be approximately The voltage is less than 24 volts. Re-
connector from ride control switch. 24 volts. place fuse ECA-F5.
Turn the key switch ON.
Check
Measure the voltage from Ride Con-
trol Switch connector pin 2 to chassis
ground.
Check 10 ohms. ohms. Repair or replace the ground
Measure the resistance from Ride connection as required. Verify that
Control Switch connector pin 2 to the chassis connection is free of cor-
chassis ground. rosion, abrasion or incorrect attach-
ment. Repair as required.
Measure the resistance between The resistance should be less than The resistance is greater than 10
Ride Control Switch connector pin 3 10 ohms. ohms. There is an open circuit in the
and 5. wire. Repair or replace as required.
Measure the resistance from Ride The resistance measurements The resistance is greater than 10
Control Switch connector pin 4 to ter- should be less than 10 ohms. ohms, there is an open circuit in
minal 30 on the Ride Control Relay. the wiring. Repair or replace as re-
Measure the resistance from Ride quired.
Control Switch connector pin 6 to ter-
minal 87 on the Ride Control Relay.
Measure the resistance from Ride
Control Switch connector pin 6 to pin
Ride Control Solenoid pin 1.
Measure the resistance from Ride The resistance should be less than The resistance is greater than 10
Control Switch connector pin 8 10 ohms. ohms. Repair or replace the wire as
SPL_BCK_LGT2 connector pin K. required.
Load travel stabilization switch - Testing - Ride Control Switch

Turn the key switch OFF. Disconnect The voltage should be approximately The voltage is less than 24 volts. Re-
connector from ride control switch. 24 volts. place fuse ECA-F5.
Turn the key switch ON.
Check
Measure the voltage from Ride Con-
trol Switch connector pin 2 to chassis
ground.
Check 10 ohms. ohms. Repair or replace the ground
Measure the resistance from Ride connection as required. Verify that
Control Switch connector pin 7 to the chassis connection is free of cor-
chassis ground. rosion, abrasion or incorrect attach-
Measure the resistance between The resistance should be less than The resistance is greater than 10
Ride Control Switch connector pin 3 10 ohms. ohms. There is an open circuit in the
and 5. wire. Repair or replace as required.
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Measure the resistance from Ride The resistance measurements The resistance is greater than 10
Control Switch connector pin 4 to ter- should be less than 10 ohms. ohms, there is an open circuit in
minal 30 on the Ride Control Relay. the wiring. Repair or replace as re-
Measure the resistance from Ride quired.
Control Switch connector pin 6 to ter-
minal 87 on the Ride Control Relay.
Measure the resistance from Ride
Control Switch connector pin 6 to pin
Ride Control Solenoid pin 1.
Measure the resistance from Ride The resistance should be less than The resistance is greater than 10
Control Switch connector pin 8 10 ohms. ohms. Repair or replace the wire as
SPL_BCK_LGT2 connector pin K. required.
RAIL12WEL0144GA 1
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(1) Ride control switch. (4) Note: The YRC jumper is only used on
model 821F \ W190.
(2) Ride control relay K4. (5) Ride control solenoid (option).
(3) 24 V power from the fuse ECA-F5.
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Index

Lift arm lifting controls Proximity switch - Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Load travel stabilization switch - Testing - Ride Control Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Load travel stabilization switch - Testing - Ride Control Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
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FAULT CODES - DTC
1021F
1121F
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Contents
FAULT CODES - DTC
DIAGNOSTIC
0000-Retrieving fault codes, Wheel Loaders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

1310-Hydraulic Filter Blocked . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1311-Engine Air Filter Blocked . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1312-Hydraulic Oil Temperature Above Normal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1313-Hydraulic Oil Temperature Too High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
1314-Transmission Oil Temperature Above Normal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
1315-Transmission Oil Temperature Too High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
1316-Brake Pressure Too Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
1317-Steering Pressure Too Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
1318-Engine Coolant Temperature Above Normal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
1319-Engine Coolant Temperature High - Critical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
1320-Engine Oil Pressure Too Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
1321-Engine Oil Pressure Below Normal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
1322-Engine Oil Pressure Above Normal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
1323-Battery Voltage Too Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
1324-Battery Voltage High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
1325-Engine Oil Temperature Too High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
1331-Electrical charging system voltage too low, critical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
1332-Water Detected In Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
1333-Engine Overspeed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
1334-Intake Manifold Temperature High - Critical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
1335-Brake pressure too low, critical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
1336-Transmission Oil Filter Blocked . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
3004-Foot Throttle Sensor - No Signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
3006-Coolant Temperature Sensor - Signal Not Plausible . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
3007-Coolant temperature signal - signal above range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
3008-Coolant Temperature Signal - Signal Below Range Minimum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
3009-Coolant Temperature Sensor Circuit Open Or Sensor Disconnected . . . . . . . . . . . . . . . . . . . . . . . . 77
3015-Fuel Temperature Sensor - Signal Above Maximum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
3016-Fuel Temperature Sensor - Signal Below Range Minimum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
3019-Boost Pressure Sensor - Signal Above Range Maximum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
3021-Boost pressure sensor - (via CAN) no signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
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3022-Boost Pressure Sensor - Signal Not Plausible . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
3023-Atmospheric Pressure Sensor - Signal Not Plausible . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
3024-Atmospheric Pressure Sensor - Signal Above Range Maximum . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
3025-Atmospheric Pressure Sensor - Signal Below Range Minimum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
3028-Oil Pressure Too Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
3029-Oil Pressure Sensor - Short Circuit To Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
3030-Oil Pressure Sensor - Short Circuit To Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
3031-Oil Pressure Sensor - Hardware Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
3032-Oil Pressure Sensor - Value Too High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
3033-Oil Temperature Sensor - Signal Not Plausible (Compared With Coolant Temperature) . . . . . . . 110
3034-Oil Temperature Sensor - Signal Above Range Maximum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
3035-Oil Temperature Sensor - Signal Below Range Minimum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
3036-Oil temperature sensor circuit open or sensor disconnected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
3037-Boost Pressure Sensor - Signal Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
3051-Battery Voltage To Engine Controller - Voltage Too High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
3052-Battery Voltage To Engine Controller - Voltage Too Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
3060-Cylinder 1 - Unclassifiable Error In Injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
3061-Cylinder 1 - Injector Cable Short Circuit (Low Side To Battery) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
3062-Cylinder 1 - Electronic injector , Low signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
3063-Cylinder 1 - Injector Cable Short Circuit (High Side To Ground) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
3070-Cylinder 3 - Electronic injector , Low signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
3078-Cylinder 2 - Electronic injector, Low signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
3082-Cylinder 4 - Electronic injector, Low signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
3088-Crankshaft sensor lost synchronization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
3089-Crankshaft Sensor - Invalid Signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
3090-Camshaft Sensor - Lost Phase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
3091-Camshaft sensor phase synchronization failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
3093-Offset Between Camshaft And Crankshaft - Outside Boundaries . . . . . . . . . . . . . . . . . . . . . . . . . . 179
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3095-Operating With Camshaft Sensor Only - Backup Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
3102-Rail Pressure Sensor CP3 - Signal Below Range Minimum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
3104-Rail Pressure Relief Valve - Open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
3105-Rail Pressure Relief Valve - Pressure Shock Requested . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
3106-Rail Pressure Relief Valve - Did Not Open After Pressure Shock . . . . . . . . . . . . . . . . . . . . . . . . . . 193
3107-Metering unit output short circuit to battery on low side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
3110-Rail Pressure Sensor Monitoring - Signal Above Range Maximum . . . . . . . . . . . . . . . . . . . . . . . . . 195
3111-Rail Pressure Sensor Monitoring - Signal Below Range Minimum . . . . . . . . . . . . . . . . . . . . . . . . . . 196
3112-Rail Pressure Sensor CP3 - Signal Above Maximum Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
3113-Grid heater battery switch relay short circuit to battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
3114-Grid heater battery switch relay short circuit to ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
3118-ECM 12V sensor supply voltage high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
3119-ECM 12V sensor supply voltage low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
3131-Grid Heater Always Switched On . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
3137-Metering Unit - Open Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
3138-Metering Unit - Signal Not Plausible . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
3141-Set point of fuel volume flow through metering unit is lower than calculated limit . . . . . . . . . . . . . 218
3147-Oil Temperature Sensor - Signal Above Normal Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
3154-Grid Heater Relay - Short Circuit To Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
3155-Grid Heater Relay - Short Circuit To Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226
3156-Grid Heater Relay - No Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230
3171-Fuel rail system pressure too low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233
3172-Fuel rail system pressure too high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237
3173-Rail Pressure Governor Deviation Below Min. Limit for Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241
3174-Rail Pressure Governor Deviation Exceeded Max. Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245
3175-Fuel system leak detected - large leak . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249
3176-Fuel delivery exceeded threshold for pressure in overrun mode . . . . . . . . . . . . . . . . . . . . . . . . . . . 253
3178-Timeout of CAN Message BC2EDC1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 254
3179-Timeout of CAN Message BC2EDC2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 256
3180-Timeout of CAN Message VCM2EDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258
3188-Cylinder 1 - Open Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260
3210-Bank 1 - General Short Circuit To Injector Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 275
3211-Bank 1 - Injector cable Short Circuit Low Side to Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 278
3212-Bank 1 - No Signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280
3213-Bank 1 - Unclassifiable Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 286
3218-Bank 2 - General Short Circuit On Injector Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 291
3219-Bank 2 - Injector Cable Short Circuit Low Side To Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 296
3220-Bank 2 No Signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301
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3221-Bank 2 - Unclassifiable Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 307
3227-Injection Processor Error - Internal Reset/Clock Loss/Voltage Too Low . . . . . . . . . . . . . . . . . . . . . 312
3228-Injection Processor Error - Unlocked/Initialization Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 313
3229-Injection Processor Error - Injections Limited By Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 314
3230-Injection Processor Error - SPI Communication Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 315
3231-Injection Processor Error - Internal Reset/Clock Loss/Voltage Too Low . . . . . . . . . . . . . . . . . . . . . 316
3232-Injection Processor Error - Unlocked/Initialization Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 317
3233-Injection Processor Error - Test Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 318
3234-Injection Processor Error - SPI Communication Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 319
3238-Communication error of CJ940 processor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 320
3242-Engine Controller (Locked) Recovery Occurred . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 321
3243-Engine Controller Recovery (Suppressed) - Recovery Occurred . . . . . . . . . . . . . . . . . . . . . . . . . . . 322
3244-Engine Controller Recovery (Visible) - Recovery Occurred . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 323
3245-Engine Controller - Watchdog Not Plausible . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 324
3246-Shutoff Paths During Initialization - Watchdog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 325
3247-Shutoff Paths Failed During Initialization - Supply Voltage Too High . . . . . . . . . . . . . . . . . . . . . . . . 326
3248-Shutoff Paths During Initialization - Supply Voltage Too Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 327
3253-ADC Monitoring - Reference Voltage Too Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 328
3254-ADC Monitoring - Reference Voltage Too High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 329
3255-ADC Monitoring Test Impulse Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 330
3256-ADC Monitoring Queue Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 331
3258-HS power stage hardware reports 'short circuit to battery' longer than 500 ms. . . . . . . . . . . . . . . 332
3259-HS power stage hardware reports 'short circuit to ground' longer than 100 ms. . . . . . . . . . . . . . . 334
3260-LS power stage hardware reports 'open load' longer than 100 ms . . . . . . . . . . . . . . . . . . . . . . . . . 336
3261-LS power stage hardware reports 'short circuit to battery' or 'excess temperature' longer than 100
ms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 338
3262-LS power stage hardware reports 'short circuit to ground' longer than 100 ms. . . . . . . . . . . . . . . 340
3265-Energizing time exceeds limit of over run monitoring, injection time too long . . . . . . . . . . . . . . . . 342
3266-Error in engine speed check, speed signal not plausible . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 343
3278-Engine Controller Internal Supply Voltage Too High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 344
3279-Engine Controller Internal Supply Voltage Too Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 346
3280-Sensor Supply Voltage 1 - High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 348
3281-Sensor Supply Voltage 1 - Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 350
3998-Unknown error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 360
3999-Unknown error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 362
4113-Logical error at FNR switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 364
4114-Logical error at direction select signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 368
4116-Logical error at park brake status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 372
4117-Logic error at direction select signal 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 379
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4119-Short circuit to ground at ride control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 383
4120-Short circuit to battery voltage at ride control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 390
4121-Open circuit at ride control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 397
4133-Short circuit to battery voltage or open circuit at transmission sump temperature sensor input . 404
4134-Short circuit to ground at transmission sump temperature sensor input . . . . . . . . . . . . . . . . . . . . . 406
4135-Short circuit to battery voltage or open circuit at retarder/ torque converter temperature sensor input
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 408
4136-Short circuit to ground at retarder/ torque converter temperature sensor input . . . . . . . . . . . . . . . 410
4137-Short circuit to battery voltage or open circuit at parking brake sensor input . . . . . . . . . . . . . . . . . 412
4145-Short circuit to battery voltage or open circuit at engine speed input . . . . . . . . . . . . . . . . . . . . . . . . 419
4146-Short circuit to ground at engine speed input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 422
4147-Logical error at engine speed input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 425
4148-Short circuit to battery voltage or open circuit at turbine speed input . . . . . . . . . . . . . . . . . . . . . . . 428
4149-Short circuit to ground at turbine speed input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 431
4150-Logical error at turbine speed input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 434
4151-Short circuit to battery voltage or open circuit at internal speed input . . . . . . . . . . . . . . . . . . . . . . . 437
4152-Short circuit to ground at internal speed input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 440
4153-Logical error at internal speed input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 443
4154-Short circuit to battery voltage or open circuit at output speed input . . . . . . . . . . . . . . . . . . . . . . . . 446
4155-Short circuit to ground at output speed input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 450
4156-Logical error at output speed input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 454
4158-Output speed zero, doesn't fit to other speed signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 458
4160-Invalid gear range restriction (CAN) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 462
4186-Invalid park brake status (CAN) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 464
4209-Short circuit to battery voltage at clutch K1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 466
4210-Short circuit to ground at clutch K1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 468
4211-Open circuit at clutch K1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 470
4228-Short circuit to battery voltage at clutch KV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 490
4229-Short circuit to ground at clutch KV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 492
4230-Open circuit at clutch KV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 494
4231-Short circuit to battery voltage at clutch KR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 496
4232-Short circuit to ground at clutch KR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 498
4233-Open circuit at clutch KR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 500
4241-Short circuit to ground at backup alarm relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 502
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4242-Short circuit to battery voltage at backup alarm relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 505
4243-Open circuit at backup alarm relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 508
4273-Slippage at clutch K1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 511
4277-Slippage at clutch KV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 515
4278-Slippage at clutch KR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 516
4279-Overtemp sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 517
4281-Engine overspeed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 520
4282-TCM sensed a voltage at oil filter maintenance switch out of the allowed range (dirty filter) . . . . 523
4284-Overspeed output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 526
4290-Transmission input torque overload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 530
4291-Overtemp converter output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 531
4292-Short circuit to ground at joystick status indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 534
4293-Short circuit to battery voltage at joystick status indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 538
4294-Open circuit at joystick status indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 542
4305-Short circuit to battery voltage at power supply for sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 546
4306-Short circuit to ground at power supply for sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 547
4307-Low voltage at battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 548
4308-High voltage at battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 549
4309-Error at valve power supply VPS1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 550
4310-Error valve power supply VPS2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 551
4325-VehicleID#1 timeout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 552
4326-Illegal ID request via CAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 555
4337-General EEPROM fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 556
4338-Configuration error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 557
4339-Application error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 558
4341-Clutch failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 559
4342-Clutch adjustment data lost . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 560
9128-CAN Timed Out During Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 561
9160-Hour Meter Failure - Both Copies Are Wrong . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 570
9161-Hour Meter Failure - One Of Two Copies Are Wrong . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 571
9162-Hour Meter Failure - Pre-crank And After-crank Checks Are Wrong . . . . . . . . . . . . . . . . . . . . . . . . 572
[EDC] - 3001-Foot Throttle Sensor - Signal Not Plausible . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 573
[EDC] - 3002-Foot Throttle Sensor - Signal Above Range Maximum . . . . . . . . . . . . . . . . . . . . . . . . . . . . 578
[EDC] - 3003-Foot Throttle Sensor - Signal Below Range Minimum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 582
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Electrical systems - FAULT CODES
0000-Retrieving fault codes, Wheel Loaders

Context:
General fault code identification, clearing faults from memory.
Solution:
1. Press and hold the escape key and up arrow key for more than 2 seconds to access the fault codes.
BC07F333-01 1
(A) Escape key (C) Up key

(B) Enter key (D) Down key
2. Yellow Faults, buzzer will beep once every 2 seconds:
(A) Operator can acknowledge it by pressing the enter key.

(B) The message will disappear.
(C) Buzzer will not beep anymore.
(D) Yellow lamp will stay ON.
(E) Fault will remain in Yellow list until it is closed.
3. Red Faults, buzzer will be continuous, alternating sounds:
(A) Operator can acknowledge it by pressing the enter key.

(B) Buzzer will change tone, but will remain ON.
(C) Message will remain on display with indication of URGENT STOP.
4. Fault Code Grouping
(1) 1000 to 1999 vehicle errors

(2) 2000 to 2999 Not Used
(3) 3000 to 3999 engine errors
(4) 4000 to 4999 transmission errors
(5) 5000 to 5999 Not Used
(6) 6000 to 6999 Not Used
(7) 7000 to 7999 Not Used.
(8) 8000 to 8999 Not Used
(9) 9000 to 9999 internal AIC errors
(10) 19000 to 19999 SCR System errors
5. Removing faults from memory.
(1) Press the "ENTER" key and hold for two seconds, this will bring you into the internal AIC screens.
(2) Us the UP or DOWN arrows and scroll to "CONFIG", then press "ENTER".
(3) Us the UP or DOWN arrows and scroll to "SPECIAL", then press "ENTER".
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(4) Highlight "RESET ERRORS" the press "ENTER" twice.
(5) Turn the ignition switch OFF and wait for 20 seconds.
(6) The next time the machine is started the memory field will be empty.
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1310-Hydraulic Filter Blocked

Cause:
1. Clogged hydraulic filter.

2. Connectors not mated fully, pins not pushed into connector fully, bent pin or broken wire at rear of connector.
3. Wiring or circuits shorted.
4. Faulty reading from switch.
5. Faulty Switch Panel.
Solution:
1. Verify that the fault code is still active, refer to 0000 - Retrieving fault codes, Wheel Loaders.
Prior to clearing fault codes write down all fault codes, number of occurrences, and engine hours at last occur-
rence.
(1) Turn ignition switch to RUN position.
(2) Clear all fault codes.
(3) To check for fault code: Start and operate machine.
A. Fault code 1310 is recorded again. Go to Step 2.
B. Fault is not recorded again. OK for return to service.

2. Inspect Hydraulic Filter.
(1) Turn the key switch OFF.
(2) Inspect the hydraulic filter. Replace the filter if needed.
RCPH11WHL004AAL 1
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. Go to Step 1 to confirm elimination of the
fault.
3. Verify the harness and connectors are not damaged.
(1) Inspect the AIC and Switch Panel connections and Hydraulic Filter Restriction Switch connections. All con-
nections should be secure, tight, free of corrosion, abrasion and damage.
(2) Inspect the harness from the Switch Panel to the Hydraulic Filter Restriction Switch. Verify that the harness
is free of damage, corrosion, abrasion or incorrect attachment.
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RCPH11WHL005FAL 2
Schematic legend
(1) AIC connector 1, pin 6 (5) Hydraulic filter restriction switch, 1021F
only
Normally Open, closes at 40 PSIG (276
kPaG)
(2) AIC connector 2, pin 4 (6) Hydraulic filter restriction switch, All ma-
chines
kPaG)
(3) Switch pad connector, pin 4 (7) Transmission Ground
(4) Cab T/ Trans Connector
A. The wiring is free of corrosion, damage, abrasion and incorrect attachment. Go to Step 4.
B. The wiring is not free of corrosion, damage, abrasion and incorrect attachment. Repair or replace the
harness as required. Go to Step 1 to confirm elimination of the fault.
4. Check for ground circuit between filter bypass switch housing and filter head.
(1) Disconnect the signal wire from the filter restriction switch.
(2) Measure the resistance from the sensor to chassis ground. The resistance should be greater than 20,000
ohms.
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BD07F001-01 3
(1) Connector PHF

(2) Hydraulic Filter Restriction Switch
A. The resistance is less than 20,000 ohms, replace restriction switch. Return to Step 1 to confirm elimination
of fault.
B. The resistance is greater than 20,000 ohms, the filter restriction switch appears to be OK. Go to Step 5.
5. Measure the resistance from the signal wire to chassis ground.
(1) Measure the resistance from the filter restriction switch 31H wire to chassis ground. The resistance should
be greater than 20,000 ohms. Wiggle the harness during measurement to reveal an intermittent condition.
A. The resistance is less than 20,000 ohms. There is a short circuit in the wire to chassis ground. Repair or
replace the harness as required. Return to Step 1 to confirm elimination of fault.
B. The resistance is greater than 20,000 ohms. Temporarily replace the switch pad and retest. Go to Step 1
to confirm elimination of the fault.
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1311-Engine Air Filter Blocked

Possible failure modes:
1. Clogged air filter

3. Wiring or circuits shorted to minus battery or chassis ground.
4. Faulty reading from switch
5. Faulty Switch Panel
Solution:
rence.
B. Fault is not recorded again. OK for return to service.

2. Inspect Engine Air Filter.
(2) Inspect the engine air 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. Go to Step 1 to confirm elimination of the
fault.
(1) Inspect the Instrument Cluster, Switch Panel and Engine Air Filter Restriction Switch connections. All con-
nections should be secure, tight, free of corrosion, abrasion and damage.
RCPH11WHL001AAL 1
(2) Inspect the harness from the Switch Panel to the Engine Air Filter Restriction Switch. Verify that the harness
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RCPH11WHL006FAL 2
Schematic legend
(1) Switch pad connector, pin 5 (3) Sensor ground on engine block, near oil
filter
(2) Engine air filter restriction switch, All ma- (4) Cab T/ Trans Connector
chines
Normally Open, closes at –0.928 PSIG (
–6.4 kPaG)
4. Measure the resistance across the switch.
(1) Disconnect the signal wire from the filter restriction switch.
(2) Measure the resistance between pins 1 and 2 on the filter restriction switch. The resistance should be greater
than 20,000 ohms.
A. The resistance is less than 20,000 ohms, replace filter restriction switch. Return to Step 1 to confirm
elimination of fault.
B. The resistance is greater than 20,000 ohms, the filter restriction switch appears to be OK. Go to Step 5.
(1) Disconnect the switch panel connector.
(2) Measure the resistance from the filter restriction switch 31F wire (pin 1) to chassis ground. The resistance
should be greater than 20,000 ohms. Wiggle the harness during measurement to reveal an intermittent condi-
tion.
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1312-Hydraulic Oil Temperature Above Normal

Cause:
1. Low hydraulic oil level.

2. Connectors not mated fully, pins not pushed into connector, bent pin or broken wire at rear of connector.
Solution:
rence.
B. The fault is not recorded again. OK for return to service.

2. Check machine cooling operations.
(1) Run engine at 1500 RPM.
(2) Check fan operation.
(3) Check cooling core for clogs.
RCPH11WHL007AAL 1
A. The fan is not operational or the cooling core is dirty or clogged. Repair fan or clear clogs from cooling
core. Return to Step 1 to confirm elimination of fault.
B. The cooling core is clean and the fan is operational. Go to Step 3.

(1) Inspect the Instrument Cluster connections and Hydraulic Temperature Switch connections. All connections
should be secure, tight, free of corrosion, abrasion and damage.
(2) Inspect the harness from the Instrument Cluster connector 1 to the Hydraulic Temperature Switch. Verify
that the harness is free of damage, corrosion, abrasion or incorrect attachment.
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RCPH11WHL007FAL 2
Schematic legend
(1) AIC connector 1, pin 9 (3) Cab T/ Trans Connector
(2) Hydraulic oil temperature sender (4) Transmission Ground
3521 ohms at 20 °C (68 °F).
4. Measure the resistance across the temperature sender.
(2) Disconnect the hydraulic oil temperature connector.
(3) Measure the resistance across the sender terminals. The resistance should be approximately 3520 Ω at 20
°C (68 °F).
(4) Measure the resistance from pin 1 on the temperature sender to chassis ground. The resistance should be
greater than 20,000 ohms.
RCPH11WHL012AAL 3

(2) Hydraulic Oil Temperature Sender
A. The resistance measurements are within the specifications. Go to Step 5 to confirm elimination of fault.
B. The resistance measurements were not in the proper range. Temporarily replace the temperature sender
and retest. Go to Step 1.
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Wire harnesses - Electrical schematic frame 09 (55.100.DP-C.20.E.09)
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1313-Hydraulic Oil Temperature Too High

Cause:
1. Low hydraulic oil level.

Solution:
rence.

2. Check machine cooling operations.

(1) Inspect the Instrument Cluster connections and Hydraulic Temperature Switch connections. All connections
(2) Inspect the harness from the Instrument Cluster connector 1 to the Hydraulic Temperature Switch. Verify
that the harness is free of damage, corrosion, abrasion or incorrect attachment.
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RCPH11WHL007FAL 1
Schematic legend
(1) AIC connector 1, pin 9 (3) Cab T/ Trans Connector
(2) Hydraulic oil temperature sender (4) Transmission Ground
3521 ohms at 20 °C (68 °F).
4. Measure the resistance across the temperature sender.
(2) Disconnect the hydraulic oil temperature connector.
(3) Measure the resistance across the sender terminals. The resistance should be approximately 3520 Ω at 20
°C (68 °F).
(4) Measure the resistance from pin 1 on the temperature sender to chassis ground. The resistance should be
RCPH11WHL012AAL 2

(2) Hydraulic Oil Temperature Sender
A. The resistance measurements are within the specifications. Go to Step 5 to confirm elimination of fault.
B. The resistance measurements were not in the proper range. Temporarily replace the temperature sender
and retest. Go to Step 1.
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1314-Transmission Oil Temperature Above Normal

Cause:
1. Low transmission oil level.

2. Clogged transmission oil cooler.
5. Faulty reading from sender.
6. Faulty Transmission Control ( TECM ).
Solution:
rence.

2. Stop machine operations.

(2) Inspect the Instrument Cluster connections and Torque Converter Output temperature sender connections.
All connections should be secure, tight, free of corrosion, abrasion and damage.
(3) Inspect the harness from the Instrument Cluster connector 1 to the Torque Converter Output temperature
sender. Verify that the harness is free of damage, corrosion, abrasion or incorrect attachment.
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RCPH11WHL002FAL 1
Schematic legend
(1) TECM (4) Torque converter output temperature
sender
3521 ohms at 20 °C (68 °F).
(2) TRC Trans Control (5) Cab T/ Trans Connector
(3) Filter maintenance switch (6) 510 ohm resistor
4. Measure the resistance of the temp sender.
(1) Disconnect Connector TCOT from the Torque Converter Output temperature sending unit.
BD07F017-01 2
(1) Valve body

(2) Connector TRC
(3) Bell housing
(4) Connector TCOT
(2) Measure the resistance across pin A and B on the Torque Converter Output Temperature Sender. The
resistance should be approximately 3520 Ω at 20 °C (68.0 °F).
A. The resistance is not within the specifications. Temporarily replace sending unit and retest. Return to Step
1 to confirm elimination of fault.
47392461 19/06/2012
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B. The resistance is within the proper specifications. Go to Step 5.

5. Measure the resistance of the signal wire to chassis ground.
BD07E017 3
(1) Connector TECM

(2) Fuse and relay panels
(1) Disconnect the TECM connector.
(2) Measure the resistance between TECM connector pin 49 to chassis ground. The resistance should be
greater than 20,000 ohms. Wiggle the harness during measurement to reveal an intermittent condition.
(3) Measure the resistance between TECM connector pin 49 to and TECM connector, pin 46. The resistance
should be greater than 20,000 ohms. Wiggle the harness during measurement to reveal an intermittent condi-
tion.
A. The resistance is less than 20,000 ohms. There is a short circuit to chassis ground or the temp sender
common. Repair or replace the harness as required. Return to Step 1 to confirm elimination of fault.
B. The resistance measurements are greater than 20,000 ohms. Temporarily replace the TECM and retest.
Go to Step 1 to confirm elimination of the fault. .
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1315-Transmission Oil Temperature Too High

Cause:
1. Oil temperature high, oil degradation, damage to clutches.

2. Faulty reading from component.
4. Wiring or circuits open.
Solution:
rence.


3. Disconnect Connector TCOT from the Torque Converter Output temperature sending unit.
BD07F017-01 1
(1) Valve body

(2) Connector TRC
(3) Bell housing
(4) Connector TCOT
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(1) Measure the resistance across pin A and B on the Torque Converter Output Temperature Sender. The
resistance should be approximately 3520 Ω at 20 °C (68.0 °F).
A. The resistance is not within the specifications. Temporarily replace sending unit and retest. Return to Step
B. The resistance is within the proper specifications. Go to Step 4.

4. Check circuit 36R
BD07E017 2
(1) Connector TECM

(1) Check from pin 2 on Connector TCOT to pin 46 on Connector TECM.
(2) If circuit is open, check from pin 2 Connector TCOT to pin 12 Connector TRANS.
BD07E021-01 3
(1) Connector CAB-T

(2) Connector TRANS
(3) Check from pin 12 Connector CAB-T to pin 46 Connector TECM.
A. NOT OK – Determine the break between connector TCOT and TECM and repair. Return to Step 1 to
confirm elimination of fault.
B. OK - Go to Step 5.
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BD07E017 4
(1) Connector TECM

(1) Measure the resistance from the TCOT sender connector pin 1 to chassis ground. The resistance should be
(2) Measure the resistance from the TCOT sender connector pin 1 to TCOT sender connector pin 2. The resis-
tance should be greater than 20,000 ohms.
A. The resistance is less than 20,000 ohms. The signal wire is shorted to chassis ground or the temperature
return line. Repair or replace the harness as required. Go to Step. 1 to confirm elimination of fault.
B. The resistance is greater than 20,000 ohms. Temporarily replace the TECM and retest. Go to Step 1 to
confirm elimination of the fault.
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1316-Brake Pressure Too Low

Cause:
1. Loss of brake operation.

Solution:
rence.

(1) Bleed brakes, refer to Hydraulic service brakes - Bleed (33.202).
(2) Check brake system pressure, refer to Hydraulic service brakes - Pressure test Cut-in Cut-out (33.202).
A. The brake system pressure was low. Repair brake system as needed. Return to Step 1 to confirm elimi-
nation of fault.
B. The brake system pressure is Ok and the brakes did not need to be bled. Go to Step 3.
3. Disconnect Connector PBW from brake system pressure switches.
BD07E036-01 1
(1) Brake lamp switch

(2) Connector PBW
(3) Connector YPB
(1) Measure the resistance across the Brake Warning Pressure Switch. The resistance should be less than 10
ohms.
A. The resistance across the switch is less than 10 ohms. Go to Step 4.
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B. The resistance is greater than 10 ohms. Temporarily replace the switch and retest. Return to Step 1 to
4. Measure the resistance through the wires.
(1) Measure the resistance from PBW connector, pin 2 to chassis ground. The resistance should be less than
10 ohms. Wiggle the harness during measurement to reveal an intermittent condition.
(2) Measure the resistance from PBW connector, pin 1 to AIC connector 2, pin 5. The resistance should be less
than 10 ohms. Wiggle the harness during measurement to reveal an intermittent condition.
A. The resistance is less than 10 ohms. Temporarily replace the Instrument Cluster and retest. Go to Step1
B. NOT OK – Determine the break in the wire. Repair or replace the harness are required. Go to Step 1 to
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1317-Steering Pressure Too Low

NOTICE: Put articulation lock in the LOCKED position before proceeding.
NOTE: This fault only pertains to machines equipped with secondary steering.
Cause:
1. Steering pressure below a set range.

3. Wiring or circuits shorted to chassis ground or minus battery.
5. Faulty Instrument cluster.
Solution:
rence.
A. The fault is not recorded again. OK for return to service.
B. Fault code 1317 is recorded again. Go to Step 2.

(1) Check steering system pressures, refer to Hydraulic control components - Pressure test (41.200).
A. The steering system pressure is OK. Go to Step 3.
B. The steering system pressure is low. Repair steering system as needed. Return to Step 1 to confirm
(1) Inspect the Instrument Cluster, SSM Secondary Steering Module and the Secondary Steering Switch con-
nections. All connections should be secure, tight, free of corrosion, abrasion and damage.
(2) Inspect the harness from the Instrument Cluster l to the SSM Secondary Steering Module and the Secondary
Steering Switch. Verify that the harness is free of damage, corrosion, abrasion or incorrect attachment.
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RCPH11WHL005FAL 1
Schematic legend
(1) AIC connector 1, pin 6 (5) Hydraulic filter restriction switch, 1021F
only
kPaG)
(2) AIC connector 2, pin 4 (6) Hydraulic filter restriction switch, All ma-
chines
kPaG)
(3) Switch pad connector, pin 4 (7) Transmission Ground
(4) Cab T/ Trans Connector
4. Measure the resistance across the pressure switch.
BS07B176 2
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(1) Connector SPL-SEC-STR

(2) Pressure switch
(3) Connector PSS
(4) Connector SS-TR
(1) Disconnect Connector PSS.
(2) Inspect pins in connector PSS. clean connections.
(3) With engine stopped, measure the resistance across pin A and B on the secondary steering pressure switch.
The resistance should be greater than 20,000 ohms.
(4) Measure the resistance across pin B and C on the secondary steering pressure switch. The resistance
should be less than 10 ohms.
(5) With engine running, measure the resistance across pin A and B on the secondary steering pressure switch.
The resistance should be less than 10 ohms.
(6) Measure the resistance across pin B and C on the secondary steering pressure switch. The resistance
should be greater than 20,000 ohms.
A. The resistance measurements are OK. Go to Step 5.
B. The resistance measurements are not within the specifications. Temporarily replace the pressure switch
and retest. Return to Step 1 to confirm elimination of fault.
5. Measure the resistance through the wires.
(1) Turn the key switch OFF, engine OFF.
(2) Measure the resistance from pin C on Connector PSS to chassis ground. The resistance should be greater
than 20,000 ohms. Wiggle the harness during measurement to reveal an intermittent condition.
A. The resistance measurement is OK. Temporarily replace the Instrument Cluster and retest. Go to Step 1
B. The resistance measurement is less than 20,000 ohms. There is a short to chassis ground. Repair or
replace the harness as required. Go to Step 1 to confirm elimination of fault.
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1318-Engine Coolant Temperature Above Normal

NOTICE: Temporarily reduce the load on the engine to allow the cooling system to cool.
NOTICE: Verify proper coolant level when the system is cold.
Cause:
1. Low coolant level

5. Faulty Instrument Cluster.
Solution:
rence.

(2) Inspect the Instrument Cluster and the Radiator Coolant Temperature Sender connections. All connections
(3) Inspect the harness from the Instrument Cluster to the Radiator Coolant Temperature Sender. Verify that the
harness is free of damage, corrosion, abrasion or incorrect attachment.
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RCPH11WHL002GAL 1
Schematic legend
(1) AIC connector 1, pin 11 (4) Radiator Coolant Temperature Sensor
3521 ohms at 20 °C (68 °F)
(2) AIC connector 2, pin 24 (5) GND_ENG7
(3) Cab_E/ ENG connector
3. Measure the resistance of the temperature sender.
(1) Disconnect Connector RECT from coolant temperature sending unit.
(2) Measure the resistance across pins A and B on the sending unit. The resistance should be approximately
3521 Ω
at 20 °C (68.0 °F) and 221 Ω at 87.5 °C (189.5 °F).
(3) Measure the resistance from pin A to chassis ground. The resistance should be greater than 20,000 ohms.
A. All resistance measurement are OK. Go to Step 4.
B. One of the resistance measurements are not with the specified range. Temporarily replace the tempera-
ture sending unit and retest. Return to Step 1 to confirm elimination of fault.
(1) Disconnect Connector RECT.
(2) Disconnect the Instrument Cluster connector AIC-1.
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(3) Measure the resistance from pin A on Connector RECT to chassis ground. The resistance should be greater
A. The resistance is OK. Temporarily replace the Instrument Cluster and retest. Go to Step 1 to confirm
elimination of the fault.
B. The resistance measurement is less than 20,000 ohms. There is a short circuit to chassis ground. Repair
or replace the harness as required. Return to Step 1 to confirm elimination of fault.
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1319-Engine Coolant Temperature High - Critical

NOTICE: Turn the engine off to allow the engine and cooling system to cool down.
NOTICE: Verify proper coolant level when the system is cold.
Cause:
1. Low coolant level

5. Faulty Instrument Cluster.
Solution:
rence.

(2) Inspect the Instrument Cluster and the Radiator Coolant Temperature Sender connections. All connections
(3) Inspect the harness from the Instrument Cluster to the Radiator Coolant Temperature Sender. Verify that the
harness is free of damage, corrosion, abrasion or incorrect attachment.
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RCPH11WHL002GAL 1
Schematic legend
(1) AIC connector 1, pin 11 (4) Radiator Coolant Temperature Sensor
3521 ohms at 20 °C (68 °F)
(2) AIC connector 2, pin 24 (5) GND_ENG7
(3) Cab_E/ ENG connector
3. Measure the resistance of the temperature sender.
(1) Disconnect Connector RECT from coolant temperature sending unit.
(2) Measure the resistance across pins A and B on the sending unit. The resistance should be approximately
3521 Ω
at 20 °C (68.0 °F) and 221 Ω at 87.5 °C (189.5 °F).
(3) Measure the resistance from pin A to chassis ground. The resistance should be greater than 20,000 ohms.
A. All resistance measurement are OK. Go to Step 4.
B. One of the resistance measurements are not with the specified range. Temporarily replace the tempera-
ture sending unit and retest. Return to Step 1 to confirm elimination of fault.
(1) Disconnect Connector RECT.
(2) Disconnect the Instrument Cluster connector AIC-1.
47392461 19/06/2012
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(3) Measure the resistance from pin A on Connector RECT to chassis ground. The resistance should be greater
A. The resistance is OK. Temporarily replace the Instrument Cluster and retest. Go to Step 1 to confirm
elimination of the fault.
B. The resistance measurement is less than 20,000 ohms. There is a short circuit to chassis ground. Repair
or replace the harness as required. Return to Step 1 to confirm elimination of fault.
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1320-Engine Oil Pressure Too Low

NOTICE: Verify proper engine oil level before proceeding.
NOTE: See engine repair manual for electrical schematic information.
Cause:
1. Low engine oil level.

Solution:
1. Fault Code 1320 is a CAN Data Link message from the EDC7 Engine Controller to the Instrument Cluster. This
fault code is displayed on the Instrument Cluster to warn the operator of a low oil pressure condition. Refer to
the engine troubleshooting guide for more information.
2. Verify that the fault code is still active, refer to 0000 - Retrieving fault codes, Wheel Loaders
rence.
A. NOT OK – Fault code 1320 is recorded again. Go to Step 3.
B. OK – Fault is not recorded again. OK for return to service.

3. Disconnect connector from engine oil temp/pressure sending unit. NOTE: Remove belt cover to gain access to
sending unit connector.
BD07E022 1
(1) Connector engine oil temp/pressure sender

(2) Alternator
(1) Turn the ignition switch on to power the system.
(2) Take voltage reading at pin 3 on connector, a reading of 5 V should be obtained.
A. OK – Replace sending unit. Go to Step 2 to confirm elimination of fault.
B. NOT OK – Go to step 4.
4. Check circuit.
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BD07D130-01 2
(1) Connector C
(2) Connector A
(3) Connector EDC7
(1) If no voltage is present, disconnect connector C from engine controller.
(2) Check from pin 3 engine oil temp/pressure sending unit connector to pin 32 of connector C.
A. NOT OK – Determine the break between connectors and repair. Go to Step 2 to confirm elimination of
fault.
B. OK – Go to step 5.
5. Check input power.
BD07D130-01 3
(1) Connector C
(2) Connector A
(3) Connector EDC7
(1) Turn ignition OFF. Disconnect Connector EDC7 from engine controller. Turn the ignition ON.
(2) Check pins 2, 3, 8, and 9 of Connector EDC7 to ground, a reading of 24 V should be obtained.
A. NOT OK – Check fuse PRM D – F2. Go to Step 2 to confirm elimination of fault.
B. OK – Go to step 6.
6. Replace the engine control module.
(1) Remove and replace control module.
A. Return to Step 2 to confirm elimination of fault. If fault is recorded again, contact Technical Services Group
for assistance.
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1321-Engine Oil Pressure Below Normal

NOTICE: Check engine oil level before proceeding.
Cause:
1. Oil pressure to low, damage to engine.

Solution:
rence.

BD07E022 1

(2) Alternator
(1) Turn the ignition switch ON to power the system.
A. OK – Replace sending unit. Return to Step 1 to confirm elimination of fault.
B. NOT OK – Go to Step 3.
3. Check circuit.
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BD07D130-01 2
(1) Connector C
(2) Connector A
(3) Connector EDC7
(2) Check from 3 engine oil temp/pressure sending unit connector to pin 32 of connector C.
A. NOT OK – Determine the break between connectors and repair. Return to Step 1 to confirm elimination
of fault.
B. OK – Go to Step 4.
BD07D130-01 3
(1) Connector C
(2) Connector A
(3) Connector EDC7
A. NOT OK – Check fuse PRM D-F2. Return to Step 1 to confirm elimination of fault.
5. Replace engine control module.
A. Return to step 1 to confirm elimination of fault. If fault is recorded again, contact Technical Services Group
for assistance.
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1322-Engine Oil Pressure Above Normal

Cause:
1. Oil pressure to high, damage to engine.

Solution:
rence.

BD07E022 1

(2) Alternator
B. NOT OK – Go to step 3.
3. Check circuit.
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BD07D130-01 2
(1) Connector C
(2) Connector A
(3) Connector EDC7
(2) Check from 3 engine oil temp/pressure sending unit connector to pin 32 of connector C.
of fault.
BD07D130-01 3
(1) Connector C
(2) Connector A
(3) Connector EDC7
A. Return to step 1 to confirm elimination of fault. If fault is recorded again, contact Technical Services Group
for assistance.
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1323-Battery Voltage Too Low

Cause:

Solution:
rence.

(2) Inspect the Instrument Cluster connections, battery and alternator connections. All connections should be
secure, tight, free of corrosion, abrasion and damage.
(3) Inspect the harness from the Instrument Cluster to the battery and alternator. Verify that the harness is free
of damage, corrosion, abrasion or incorrect attachment.
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RCPH11WHL009FAL 1
Schematic legend
(1) Instrument Cluster key switch connec- (5) Instrument Cluster Power, AIC Power,
tions ECA-F3
7.5 Amp Fuse
(2) Instrument Cluster unswitched battery (6) CAB_E/ Trans connector
connections
(3) Instrument Cluster ground connections (7) GND_PDST1, Within 4 inches of the Instru-
ment Cluster
(4) Instrument Cluster Power, AIC Power,
ECC-F8
10 Amp Fuse
Instrument Cluster Connections

AIC 1 pin–1 19S_E Or-0.8 Key Switch B+
AIC 1 pin–6 0_DX Bk-0.8 Sensor Ground
AIC 1 pin–12 0_DW Bk-0.8 Ground
AIC 2 pin–14 19S-D Or-0.8 Unswitched Battery
AIC 2 pin–15 0_DB Bk-0.8 Ground
AIC 2 pin–20 19S-C Or-0.8 Unswitched Battery
AIC 2 pin–21 19S-F Or-0.8 Key Switch B+
AIC 2 pin–22 0_DA Bk-0.8 Chassis Ground
3. Measure the voltage at instrument cluster.
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BD07D128-01 2
(1) Connector AIC-2

(2) Connector AIC-1
(1) Disconnect AIC connector 2, AIC2.
(2) Inspect pins 14, 20, and 21 on AIC connector 2.
(3) Turn the key switch ON, engine ON.
(4) Measure the voltage from AIC connector 1, pin 1 to chassis ground. Measure the voltage from AIC con-
nector 2, pin 21 to chassis ground. The voltage should be approximately 24 volts. Wiggle the harness during
measurement to reveal an intermittent condition.
(5) Measure the voltage from AIC connector 2, pin 14 to chassis ground. Measure the voltage from AIC con-
nector 2, pin 20 to chassis ground. The voltage should be approximately 24 volts. Wiggle the harness during
A. The voltage measurement is correct. Temporarily replace the Instrument Cluster and retest. Go to Step
1.to confirm elimination of the fault.
B. The voltage is less than 5 volts. Check fuses ECC-F8 and ECA-F3. If the fuses test OK, there is a problem
with the battery supply to the instrument Cluster, repair or replace the harness as required. Return to Step
C. The voltage is less than 24 volts but greater than 5 volts. There is a problem with the alternator charging
system. Recharge the battery and retest. Refer to Alternator - Testing (55.301)
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1324-Battery Voltage High

Cause:

Solution:
rence.

2. Test alternator. Refer to Alternator - Testing (55.301)
A. NOT OK – Replace alternator. Return to Step 1 to confirm elimination of fault.
3. Replace the instrument cluster.
(1) Remove and replace instrument cluster.
for assistance.
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1325-Engine Oil Temperature Too High

Cause:
1. Oil pressure to high, damage to engine.

Solution:
rence.

BD07E022 1

(2) Alternator
3. Check circuit.
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BD07D130-01 2
(1) Connector C
(2) Connector A
(3) Connector EDC7
(2) Check from pin 3 engine oil temp/pressure sending unit connector to pin 32 of connector C.
of fault.
BD07D130-01 3
(1) Connector C
(2) Connector A
(3) Connector EDC7
for assistance.
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1331-Electrical charging system voltage too low, critical

Cause:
1. System shut down.

Solution:
rence.

2. Check voltage at instrument cluster.
BD07D128-01 1
(1) Connector AIC-2

(2) Connector AIC-1
(1) Disconnect AIC connector 2, AIC2 .
(2) Inspect pins 14, 20, and 21 on AIC connector 2. Clean connections.
(3) Clean female pins by installing and removing.
(4) Turn the ignition switch on and check for voltage at pin 14, 20, and 21, a reading of 24 V should be obtained.
A. NOT OK – Check fuses ECC-F8 and ECA-F3. Return to Step 1 to confirm elimination of fault.
3. Test alternator, refer to Alternator - Testing (55.301)
A. NOT OK – Replace alternator. Return to Step 1 to confirm elimination of fault.
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for assistance.
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1332-Water Detected In Fuel

NOTE: Drain fuel filter before proceeding.
Cause:
1. Engine fuel injection system damage.

Solution:
rence.

(1) Inspect the Instrument Cluster and Water In Fuel Switch connections. All connections should be secure,
tight, free of corrosion, abrasion and damage.
(2) Inspect the harness from the Instrument Cluster to the Water In Fuel sensor. Verify that the harness is free
of damage, corrosion, abrasion or incorrect attachment.
BD07D140-01 1
(1) Connector WIF

(2) Fuel filter
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RCPH11WHL010FAL 2
Schematic legend
(1) WIF Water In Fuel Sensor (3) Unswitched Power B+
(2) EDC7 Engine Controller (4) Sensor Ground
GND_ENG2 on engine block near starter
3. Disconnect water in fuel sensor.
A. Return to Step 1 to confirm elimination of fault.
C. OK – Replace water in fuel sensor.

4. Check ground circuit.
BD07D155-01 3
(1) Check from pin 2 Connector WIF to ENG-GRD #2.
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BD07D140-01 4
(1) Connector WIF

(2) Fuel filter
A. NOT OK – Determine the break between connector WIF and ENG-GRD #2 and repair. Return to Step 1
to confirm elimination of fault.
5. Check power circuit.
(1) Turn ignition switch ON.
(2) Check from pin 1 Connector WIF to ground, a reading of 24 V should be obtained.
(3) If no voltage is present, check fuse ECA-F9.
BD07E021-01 5
(1) Connector CAB-E

(2) Connector ENG
(4) Check from pin 1 Connector WIF to pin 14 Connector ENG.
BD07E018-01 6
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(1) Electrical Center A

(2) Electrical Center C
(3) Electrical Center B
(4) Electrical Center D
(5) Check from pin 14 Connector CAB-E to pin B2 Connector ECD.
A. NOT OK – Replace fuse or determine the break between connector WIF and ECD and repair. Return to
Step 1 to confirm elimination of fault.
6. Check circuit 35W.
BD07D130-01 7
(1) Connector C
(2) Connector A
(3) Connector EDC7
(1) Disconnect Connector EDC7.
(2) Inspect pin 42 on Connector EDC7. Clean connections.
(3) Check from pin 1 Connector WIF to pin 42 Connector EDC7.
A. NOT OK – Determine the break between connector WIF and EDC7 and repair. Return to Step 1 to confirm
7. Replace the engine controller.
(1) Remove and replace engine controller.
A. Return to Step 1 to confirm elimination of fault. If fault is recorded again contact Technical Services Group
for assistance.
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1333-Engine Overspeed
Cause:
1. Engine speeds too high, damage to engine.

Solution:
rence.

2. Disconnect connector from engine crankshaft speed sensor.
BD07D131-01 1
(1) Connector engine crankshaft speed sensor

(2) Crankshaft sensor
(1) Take Ohm reading between pins 1 and 2 to sensor, a reading of 900 Ω should be obtained.
A. NOT OK – Replace sensor. Return to Step 1 to confirm elimination of fault.
3. Check circuit.
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BD07D130-01 2
(1) Connector C
(2) Connector A
(3) Connector EDC7
(1) Disconnect connector C from engine controller and engine crankshaft speed sensor.
(2) Check from pin 1 engine crankshaft speed sensor to pin 19 of connector C.
(3) Check from pin 2 engine crankshaft speed sensor connector to pin 23 of connector C.
of fault.
for assistance.
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1334-Intake Manifold Temperature High - Critical

Cause:
1. Intake air temperature to high, damage to engine.

Solution:
rence.

(3) Check after cooler core for clogs or defects.
RCPH11WHL006AAL 1
A. NOT OK – Repair fan, clear clogs from after cooler core, repair/replace cooler core. Return to Step 1 to
3. Disconnect connector from engine intake manifold temperature sensor. Sensor is located behind air filter and
muffler mounting bracket.
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BD07D135-01 2
(1) Connector engine intake pressure/temperature sensor

(2) High pressure fuel pump
(1) Turn ignition switch on to power the system.
4. Check circuit.
BD07D130-01 3
(1) Connector C
(2) Connector A
(3) Connector EDC7
(2) Check from pin 3 engine intake manifold temperature sensor connector to pin 36 of connector C.
of fault.
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BD07D130-01 4
(1) Connector C
(2) Connector A
(3) Connector EDC7
for assistance.
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1335-Brake pressure too low, critical

1. Low brake fluid level.

Solution:
rence.

(1) Visually inspect the brakes, refer to Brake disks - Visual inspection Model 3105 II (33.202).
(2) Bleed brakes, refer to Brake disks - Visual inspection Model 3105 II (33.202) Hydraulic service brakes
- Bleed (33.202) if needed.
(3) Check brake system pressure, refer to Hydraulic service brakes - Check System performance (Stored
Energy) (33.202) and Hydraulic service brakes - Check System performance (Stored Energy) (33.202).
A. NOT OK – Repair brake system as needed. Return to Step 1 to confirm elimination of fault.
3. Disconnect Connector PBW from brake system pressure switches.
BD07E036-01 1
(1) Brake lamp switch

(2) Connector PBW
(3) Connector YPB
(1) Measure the resistance across the brake pressure switch, with brake system at pressure. The resistance
should be less than 10 Ω.
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A. OK – The resistance is less than 10 Ω. Go to Step 4.
B. NOT OK – The resistance is greater than 10 Ω. Replace bad pressure switch. Return to Step 1 to confirm
4. Check ground circuit.
(1) Measure the resistance from pin 2 Connector PBW to rear chassis ground GRD-FC.
BD07F016-01 2
(1) Ground GND-FC (Behind pedestal)
A. OK – The resistance is less than 10 Ω. Go to Step 5.
B. NOT OK – The resisatnce is greater than 10 Ω. Determine the break between connector PBW and
GRD-FC and repair. Return to Step 1 to confirm elimination of fault.
5. Check circuit from Connector PBW to instrument cluster Connector AIC-2.
(1) Check from pin 1 Connector PBW to pin 5 Connector AIC-2.
BD07D128-01 3
(1) Connector AIC-2

(2) Connector AIC-1
(2) If circuit is open, check from pin 1 Connector PBW to pin 25 Connector FRONT.
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BD07E021-01 4
(1) Connector CAB-F

(2) Connector FRONT
(3) Check from pin 25 Connector CAB-F to pin 5 Connector AIC-2.
A. NOT OK – Determine the break between connector PBW and AIC-2 and repair. Return to Step 1 to confirm
for assistance.
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1336-Transmission Oil Filter Blocked

Cause:
1. Filters clogged.
Solution:
rence.

2. Replace transmission filter.
C. OK – Fault is not recorded again. OK for return to service.

3. Disconnect Connector FM from transmission oil filter sending unit.
BD07F003-01 1
(1) Connector FM
(2) Left step
(1) Take Ohm reading on sending unit, a reading of 510 Ω should be obtained.
A. NOT OK – Replace filter maintenance switch. Return to Step 1 to confirm elimination of fault.
4. Check circuit 36R.
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BD07E017 2
(1) Connector TECM

(1) Check from pin 2 Connector FM to pin 46 Connector TECM.
BD07E021-01 3
(1) Connector CAB-T

(2) Connector TRANS
(2) If circuit is open, check from pin 2 Connector FM to pin 12 Connector TRANS.
A. NOT OK – Determine the break between connector FM and TECM and repair. Return to Step 1 to confirm
5. Check circuit 32F.
BD07E017 4
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(1) Connector TECM

BD07E021-01 5
(1) Connector CAB-T

(2) Connector TRANS
(2) If circuit is open, check from pin 1 Connector FM to pin 31 Connector TRANS.
A. NOT OK – Determine the break between connector FM and TECM and repair. Return to Step 1 to confirm
6. Replace the transmission control module.
for assistance.
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3004-Foot Throttle Sensor - No Signal

NOTICE: When available use special tool 380040185 harness diagnostic/repair kit and 380040188 electro injector
test fixture.
NOTE: The idle switch is internal to the throttle potentiometer.
Cause:
1. No throttle response.
Solution:
rence.
A. Fault is not recorded again. OK for return to service.

(1) Inspect the Throttle Pedal Sensor and the EDC7 Engine Controller connections. All connections should be
RCPH11WHL013AAL 1
(2) Inspect the harness from the Throttle Pedal Sensor to the EDC7 Engine Controller. Verify that the harness
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RCPH11WHL011FAL 2
Schematic legend
(1) EDC7 Engine Controller (4) Connector BTM_E/ ENG_B
(2) Throttle Pedal (5) Digital Ground to EDC7 Engine Controller
Idle Validation Switch closes at 0.775 ± pin 29 and connector ENG/ CAB_E
0.1volt
Low idle = 0.35 V ± 0.1 volt
Wide Open Throttle = 4.0 V ± 0.1 volt
(3) Connector RTHP
EDC7 Connector Description Wire ID

29 Digital Ground 21F_B W-0.8 TXL
48 Low Idle Switch 24L W-0.8 TXL
77 Throttle Supply 24S W-0.8 TXL
78 Throttle Ground 24R W-0.8 TXL
79 Throttle Signal 24B W-0.8 TXL
3. Measure the voltage at the throttle sensor.
(1) Disconnect the RTHP connector from the throttle position sensor.
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RCPH11WHL014AAL 3
(2) Turn the key switch ON.
(3) Measure the voltage between RTPH pin 5 and RTPH pin 4. The voltage should be approximately 5 volts.
A. The voltage is approximately 5 volt. Go to Step 5.
B. The voltage is less than 5 volts. Go to Step 4.

4. Measure the voltage at the EDC7 connector.
(1) Use a breakout tee to measure the voltage between the EDC7 connector pin 77 and pin 78. The voltage
should be approximately 5 volts.
A. The voltage is approximately 5 volts at the EDC7 connector. There is a break in the harness between the
EDC7 engine control and the throttle sensor. Repair or replace the harness as required. Go to Step 1 to
B. The voltage is not approximately 5 volts. There is a problem with the EDC7 engine control. Temporarily
replace the EDC7 engine control and retest. Go to step 1 to confirm elimination of fault.
5. Measure the throttle signal.
(1) Fabricate a breakout tee and install it between the throttle sensor and RTHP connector.
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RCPH11WHL001GAL 4
Schematic legend
0.1volt
(3) Connector RTHP (6) Dealer supplied break out tee
(2) Measure the voltage between pins 3 and 4 while moving the throttle from the low idle position to the WOT
position. The voltage should be approximately 0.35 volts in the low idle position and approximately 4 volts at
the WOT position.
A. The voltage measurement is correct. Temporarily replace the EDC7 engine control and retest. Go to Step
1 to confirm elimination of the fault.
B. The voltage is less than 0.35 volts but greater than 0.1 volts at low idle or the voltage is greater than 4.0
volts but less than 5.0 volts at WOT. The throttle stops are out of adjustment. Reset the throttle stops and
retest. Go to step 1 to confirm elimination of fault.
C. The voltage is less that 0.35 volts or the voltage is greater than 4.0 volts at WOT and the throttle stops
are correct Temporarily replace the throttle position sensor and retest. Go to step 1 to confirm elimination
of fault.
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3006-Coolant Temperature Sensor - Signal Not Plausible

NOTE: See engine repair manual for electrical schematic information. Check coolant level before proceeding.
Cause:

Solution:
rence.

A. NOT OK – Repair fan or clear clogs from radiator. Return to Step 1 to confirm elimination of fault.
3. Disconnect connector from engine temperature sending unit.
BD07D153-01 1
(1) Connector engine temp sender

(2) Upper radiator hose
(1) Inspect pins on temperature sending unit and connector. Clean connections.
(2) Take Ohm reading on sending unit, 2500 Ω at 20 °C (68.0 °F).
A. NOT OK – Replace sending unit. Return to Step 1 to confirm elimination of fault.
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4. Check circuit.
BD07D130-01 2
(1) Connector C
(2) Connector A
(3) Connector EDC7
(1) Check from pin 2 of engine temperature sender to pin 26 of engine control module Connector C.
(2) Check from pin 1 of engine temperature sender to pin 15 of engine control module Connector C.
of fault.
(1) Remove and replace engine control module.
for assistance.
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3007-Coolant temperature signal - signal above range

Cause:
1. Coolant temperature sensor signal above a set range.

Solution:
rence.

(1) Run engine at 1500 r/min (rpm).
BD07D153-01 1

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4. Check circuit.
BD07D130-01 2
(1) Connector C
(2) Connector A
(3) Connector EDC7
(1) Check from pin 2 of engine temperature sender to pin 26 of engine controller Connector C.
of fault.
for assistance.
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3008-Coolant Temperature Signal - Signal Below Range Minimum

Cause:
1. Coolant temperature sensor signal low.

Solution:
rence.

BD07D153-01 1

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4. Check circuit.
BD07D130-01 2
(1) Connector C
(2) Connector A
(3) Connector EDC7
of fault.
for assistance.
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3009-Coolant Temperature Sensor Circuit Open Or Sensor

Disconnected
Cause:

Solution:
rence.

BD07D153-01 1

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4. Check circuit.
BD07D130-01 2
(1) Connector C
(2) Connector A
(3) Connector EDC7
of fault.
for assistance.
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3015-Fuel Temperature Sensor - Signal Above Maximum

Cause:
1. Fuel temperature signal above a set range.

Solution:
rence.

(3) Check fuel cooling core for clogs.
3. Disconnect connector from fuel temperature sensor.
BD07D132-01 1
(1) Connector fuel temp sender

(2) Fuel filter
(1) Inspect pins on fuel temperature sensor and connector. Clean connections.
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4. Check circuit.
BD07D130-01 2
(1) Connector C
(2) Connector A
(3) Connector EDC7
(1) Check from pin 2 of fuel temperature sensor to pin 18 of engine controller Connector C.
of fault.
for assistance.
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3016-Fuel Temperature Sensor - Signal Below Range Minimum

Cause:
1. Fuel temperature signal below a set range.

Solution:
rence.

(3) Check fuel cooling core for clogs.
3. Disconnect connector from fuel temperature sensor.
BD07D132-01 1
(1) Connector fuel temp sender

(2) Fuel filter
(1) Inspect pins on fuel temperature sensor and connector. Clean connections.
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4. Check circuit.
BD07D130-01 2
(1) Connector C
(2) Connector A
(3) Connector EDC7
of fault.
for assistance.
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3019-Boost Pressure Sensor - Signal Above Range Maximum

test fixture.
Cause:
1. Engine intake manifold pressure sensor signal above a set range.

Solution:
rence.

BD07D135-01 1

(1) Inspect connector and intake manifold temperature sensor pins. Clean connections.
(3) Take voltage reading at pin 3 on connector, a reading of 5 volts should be obtained.
A. OK — Replace sending unit. Return to step 1 to confirm elimination of fault.
B. NOT OK — Got to step 3.

3. Check circuit.
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BD07D130-01 2
(1) Connector C
(2) Connector A
(3) Connector EDC7
(1) If no voltage is present, disconnect Connector C from engine controller.
(2) Inspect pins on Connector C and controller. Clean connections.
(3) Check from pin 3 engine intake manifold temperature sensor connector to pin 36 of Connector C.
of fault.
BD07D130-01 3
(1) Connector C
(2) Connector A
(3) Connector EDC7
(1) Turn ignition OFF. Disconnect Connector EDC7 from engine controller.
(2) Inspect pins on Connector EDC7 and controller. Clean connections.
(3) Turn the ignition ON.
(4) Check pins 2, 3, 8, and 9 of Connector EDC7 to ground, a reading of 24 volts should be obtained.
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3021-Boost pressure sensor - (via CAN) no signal

Cause:
1. Engine intake manifold pressure sensor has no signal.

Solution:
rence.

BD07D135-01 1


3. Check circuit.
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BD07D130-01 2
(1) Connector C
(2) Connector A
(3) Connector EDC7
of fault.
BD07D130-01 3
(1) Connector C
(2) Connector A
(3) Connector EDC7
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3022-Boost Pressure Sensor - Signal Not Plausible

Cause:
1. Engine intake manifold pressure sensor signal not readable.

Solution:
rence.

BD07D135-01 1


3. Check circuit.
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BD07D130-01 2
(1) Connector C
(2) Connector A
(3) Connector EDC7
(1) If no voltage is present, disconnect Connector C rom engine controller.
of fault.
BD07D130-01 3
(1) Connector C
(2) Connector A
(3) Connector EDC7
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for assistance.
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3023-Atmospheric Pressure Sensor - Signal Not Plausible

NOTE: Atmospheric pressure sensor is inside the engine control module, replace ECU. (Not necessary if never run-
ning in high altitude and if turbocharger is without VGT).
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3024-Atmospheric Pressure Sensor - Signal Above Range Maximum

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3025-Atmospheric Pressure Sensor - Signal Below Range Minimum

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3028-Oil Pressure Too Low

NOTE: See engine repair manual for electrical schematic information. Check engine oil type and level before pro-
ceeding.
Context:
The Engine Control Unit (ECU) generated a fault associated with the oil press sensor. This fault is a result of a
plausibility check of the engine running extremely low oil pressure.
Cause:
The oil pressure sensor pressure signal to the ECU is operating at the extreme low end of the signal range.
1. Low engine oil level.

Solution:
rence.

2. Verify proper engine oil level.
A. The engine oil level is at the proper level. Go to Step 3.
B. The engine oil level is low. Fill oil to the proper level. Go to Step 1 to confirm elimination of fault.
3. Disconnect connector from engine oil temp/pressure sending unit. Remove belt cover to gain access to sending
unit connector.
BD07E022-01 1

(2) Alternator
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(1) Inspect pins on oil temp/pressure sending unit and connector. Clean connections.

4. Check circuit.
BD07D130-01 2
(1) Connector C
(2) Connector A
(3) Connector EDC7
(3) Check from pin 3 engine oil temp/pressure sending unit connector to pin 32 of Connector C.
A. OK – Go to Step 5.
B. NOT OK – Determine the break between connectors and repair. Return to Step 1 to confirm elimination
of fault.
BD07D130-01 3
(1) Connector C
(2) Connector A
(3) Connector EDC7
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B. NOT OK – Check fuse PRM D-F2. Return to Step 1 to confirm elimination of fault.
for assistance.
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3029-Oil Pressure Sensor - Short Circuit To Battery

Cause:

3. Faulty reading from EDC7 Engine Controller.
Solution:
rence.
A. OK – Fault is not recorded again. OK for return to service.
B. NOT OK – Fault code 3029 is recorded again. Go to Step 2.

unit connector.
BD07E022-01 1

(2) Alternator

3. Check circuit.
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BD07D130-01 2
(1) Connector C
(2) Connector A
(3) Connector EDC7
of fault.
BD07D130-01 3
(1) Connector C
(2) Connector A
(3) Connector EDC7
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for assistance.
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3030-Oil Pressure Sensor - Short Circuit To Ground

Cause:

Solution:
rence.

unit connector.
BD07E022-01 1

(2) Alternator

3. Check circuit.
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BD07D130-01 2
(1) Connector C
(2) Connector A
(3) Connector EDC7
of fault.
BD07D130-01 3
(1) Connector C
(2) Connector A
(3) Connector EDC7
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for assistance.
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3031-Oil Pressure Sensor - Hardware Error

ceeding.
Cause:

Solution:
rence.

unit connector.
BD07E022-01 1

(2) Alternator

3. Check circuit.
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BD07D130-01 2
(1) Connector C
(2) Connector A
(3) Connector EDC7
of fault.
BD07D130-01 3
(1) Connector C
(2) Connector A
(3) Connector EDC7
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for assistance.
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3032-Oil Pressure Sensor - Value Too High

ceeding.
Cause:
1. Engine oil pressure above a set range.

Solution:
rence.

unit connector.
BD07E022-01 1

(2) Alternator

3. Check circuit.
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BD07D130-01 2
(1) Connector C
(2) Connector A
(3) Connector EDC7
of fault.
BD07D130-01 3
(1) Connector C
(2) Connector A
(3) Connector EDC7
(4) Check pins 2, 3, 8, and 9 of EDC7 to ground, a reading of 24 volts should be obtained.
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for assistance.
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3033-Oil Temperature Sensor - Signal Not Plausible (Compared

With Coolant Temperature)
ceeding.
Cause:
1. Engine oil temperature sensor signal not readable.

Solution:
rence.

unit connector.
BD07E022-01 1

(2) Alternator

3. Check circuit.
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BD07D130-01 2
(1) Connector C
(2) Connector A
(3) Connector EDC7
of fault.
BD07D130-01 3
(1) Connector C
(2) Connector A
(3) Connector EDC7
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for assistance.
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3034-Oil Temperature Sensor - Signal Above Range Maximum

ceeding.
Cause:
1. Engine oil temperature sensor signal above a set range.

Solution:
rence.

unit connector.
BD07E022-01 1

(2) Alternator

3. Check circuit.
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BD07D130-01 2
(1) Connector C
(2) Connector A
(3) Connector EDC7
of fault.
BD07D130-01 3
(1) Connector C
(2) Connector A
(3) Connector EDC7
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for assistance.
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3035-Oil Temperature Sensor - Signal Below Range Minimum

ceeding.
Cause:
1. Engine oil temperature sensor signal below a set range.

Solution:
rence.

unit connector.
BD07E022-01 1

(2) Alternator

3. Check circuit.
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BD07D130-01 2
(1) Connector C
(2) Connector A
(3) Connector EDC7
of fault.
BD07D130-01 3
(1) Connector C
(2) Connector A
(3) Connector EDC7
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for assistance.
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3036-Oil temperature sensor circuit open or sensor disconnected

test fixture.
ceeding.
Cause:
1. Engine oil temperature sensor signal not received.

Solution:
rence.

unit connector.
BD07E022-01 1

(2) Alternator

3. Check circuit.
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BD07D130-01 2
(1) Connector C
(2) Connector A
(3) Connector EDC7
of fault.
BD07D130-01 3
(1) Connector C
(2) Connector A
(3) Connector EDC7
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for assistance.
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3037-Boost Pressure Sensor - Signal Low

Cause:
1. Engine intake manifold pressure below a set range.

Solution:
rence.

BD07D135-01 1


3. Check circuit.
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BD07D130-01 2
(1) Connector C
(2) Connector A
(3) Connector EDC7
of fault.
BD07D130-01 3
(1) Connector C
(2) Connector A
(3) Connector EDC7
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for assistance.
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3051-Battery Voltage To Engine Controller - Voltage Too High

test fixture.
Cause:
1. Battery voltage above a set range.

Solution:
rence.

BD07D130-01 1
(1) Connector C
(2) Connector A
(3) Connector EDC7
(1) Turn ignition OFF. Disconnect Engine Controller connector, EDC7 from engine controller.
(2) Inspect pins on connector EDC7 and controller. Clean connections.
3. Test alternator, refer to Alternator - Testing (55.301).
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B. NOT OK – Replace alternator. Return to Step 1 to confirm elimination of fault.

for assistance.
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3052-Battery Voltage To Engine Controller - Voltage Too Low

test fixture.
Cause:
1. Battery voltage below a set range.

Solution:
rence.

BD07D130-01 1
(1) Connector C
(2) Connector A
(3) Connector EDC7
(1) Turn ignition OFF. Disconnect Engine Controller connector EDC7 from engine controller.
3. Test alternator, refer to Alternator - Testing (55.301) .
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B. NOT OK – Replace alternator. Return to Step 1 to confirm elimination of fault.

for assistance.
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3060-Cylinder 1 - Unclassifiable Error In Injector

test fixture.
Context:
The engine control unit (ECU) has determined that an unclassifiable failure exists in the Cylinder #1 injector circuit.
A power stage component energizes the injection system transistors and simultaneously observes the current flow
in the high-side and low-side switching branch by sensing resistors. If there is a deviation from the expected current
flow the component detects specific errors and reports them to the ECU. This error message is then rearranged so
it holds information on performed injections, errors of cylinders on the same bank, bank specific errors and cylinder
specific errors. The rearranged error message is then compared to applicable error patterns and if there is a match
the failure corresponding to the matched pattern is output. If an error message doesn't match any pattern the defect
is treated as an unclassifiable error. Monitoring is performed once per camshaft revolution. This error is the result of
a failure in the Cylinder #1 injector circuit that is unclassifiable over 8 camshaft revolutions. As a result of this error an
individual cylinder or bank is shut off, based on parameters established in the ECU. Certain parameters, as currently
applied, are permanent (without a healing possibility, once tested by switching on the component to see if the defect
is still present). and others evoke an irreversible or reversible shut off of the engine to be executed.
Cause:
The Engine Control Unit (ECU) has determined that there is a fault associated with the injector output power driver
stage.
1. Faulty injection valve.

2. Faulty electrical wiring (damaged connector or conductor).
3. Faulty ECU, hardware or software.
Solution:
1. Verify this error code is still present and in an active state.
A. If the error is still present and active, continue with step 2.
B. If the error is no longer present or is in an inactive state, continue with step 3.

2. Visually check the electrical integrity of the injector circuit (Inspect connector housing body/latch, pins and wiring
harness for damage or corrosion).
A. If damage is determined after careful inspection, repair wiring and/or replace connector parts to ensure a
good and sound electrical connection.
B. If no damage is determined, the ECU or injector may have failed. Try reloading the ECU software. If the
fault reoccurs, try replacing the injector. If the fault reoccurs, replace the ECU.
3. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals
or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent
breaks or shorts in the wiring concerned. Operate the machine while monitoring the Display.
A. If damage is found or other than normal display readings are indicated, repair the damage discovered
during the inspection or locate and repair the other than normal display condition and verify that the error
has been resolved.
B. If no damage or other than normal display readings are indicated, erase the fault code and continue oper-
ation.
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3061-Cylinder 1 - Injector Cable Short Circuit (Low Side To Battery)

test fixture.
Context:
The Engine Control Unit (ECU) generated an error associated with the injector power driver stage. The power stage
component of the ECU energizes the injection system transistors and simultaneously observes the current flow (sense
resistors) in the high-side and low-side switching branches. If there is a deviation from the expected current flow, the
driver circuitry detects the specific error and reports it back to the ECU. The ECU will process the error message so
that it records information on performed injections, cylinder bank specific errors and cylinder specific errors. The error
message is then compared to applicable error patterns and if there is a match, a fault code is generated. If an error
message doesn't match any pattern, the error is treated as unclassifiable. This monitoring function is performed once
per camshaft revolution.
Cause:
The Engine Control Unit (ECU) has determined that there is a fault associated with the current monitoring of the
injector output power driver stage.
1. Faulty injection valve or shorted solenoid windings.

2. Faulty electrical wiring, short to high source or damaged wiring harness.
3. Faulty ECU, supply voltages or grounds.
Solution:
1. Operation: Electrical Inspection.

Vehicle Status: Key Off Engine Off.
Remove the following connector for electrical inspection:

1. ECU injector connector 3.
2. Valve cover connector VC1.
Inspect connector housing body/latch, pins and wiring harness for damage or corrosion.
B. If no damage is determined, proceed to step 2.

2. Operation: Injector Resistance Test Cylinder #1/2 injector connector VC1 to Cylinder #1/2 injector.
Remove connector VC1 and perform an injector resistance test on the Cylinder #1/2 injector connector VC1.
See test table below.
Test Type From To Expected Results

1. Resistance Cylinder #1/2 injector con- Cylinder #1/2 injector con- Approx. 0.4 - 0.5 ohms
nector VC1. connector nectorVC1 connector pin:
pin: 3 4
A. If resistance test was not successful, proceed to step 4
B. If resistance test was successful, reconnect connector VC1. Proceed to step 3.

3. Operation: Injector Resistance Test ECU harness side of connector 3 to Cylinder #1 injector.
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Remove ECU connector 3 and perform an injector resistance test. Use the spade style test leads from the Tier
II (NEF) Diagnostic Repair Kit # 380040185 when probing the ECU harness side of connector 3. See test table
below.

1. Resistance ECU harness connector 3, ECU harness connector 3, Approx. 0.4 - 0.5 ohms
pin: 4 pin: 13
A. If resistance test was not successful, repair wiring harness between ECU harness connector 3 and con-
nector VC1.
B. If resistance test was successful, proceed to step 5.

4. Operation: Standalone Injector Resistance Test.
Remove valve cover from the top of the head to allow access to the internal injector wiring harness. Remove the
Cylinder #1 injector connector (two flying leads with ring terminals). Perform a resistance test on the terminals
located on top of the solenoid portion of the injector. See test table below.

1. Resistance Cylinder #1 injector, con- Cylinder #1 injector, con- Approx. 0.4 - 0.5 ohms
nector INJ1, terminal #1 nector INJ1, terminal #2
A. If resistance test was successful, repair the internal harness between the Cylinder #1 injector and the
connector INJ1.
B. If resistance test was not successful, replace the Cylinder #1 injector.

5. Operation: Check for ECU Voltages and Ground Continuity.
Vehicle Status (when removing ECU connector 1) Key Off Engine Off.
Vehicle Status (when performing test) Key On Engine Off.
Vehicle Status (when replacing ECU connector 1) Key Off Engine Off.
Remove connector 1 from the ECU and check for voltage and continuity at the appropriate pins defined in the
test table below. Use the 0.43 mm (0.017 in) diameter test probes from the Tier II (NEF) Diagnostic Repair Kit
# 380040185 when connecting the DMM to the ECU connector 1.
Important Note: Check and verify that the Vehicle Status is correct for each operation. Potential ECU damage
could result when removing and replacing main ECU connectors if this is not followed.

1. Voltage ECU connector 1, pin 2, 3, Ground (engine block) Approx. 24 volts (DC)
8, 9, 40
2. Continuity ECU connector 1, pin 5, 6, Ground (engine block) Approx. 0.0 - 0.1 ohms
10, 11
A. If the voltages and ground paths are correct, proceed to step 6.
B. If the voltages and ground paths are not correct, refer to product schematic and determine root cause of
power and/or continuity problem(s).
6. Operation: Re-initialize the ECU.
Vehicle Status: Key On Engine Off.
Using the EST service tool, re-initialize the ECU and load the appropriate data-set for this engine type. Check
to see if the fault code has cleared.
A. If the fault code did not clear, Replace the ECU.
B. If fault code cleared, continue with operation of machine.
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3062-Cylinder 1 - Electronic injector , Low signal

WARNING
Escaping fluid!
Hydraulic fluid or diesel fuel leaking under pressure can penetrate the skin and cause infection or
other injury. To prevent personal injury: Relieve all pressure before disconnecting fluid lines or per-
forming work on the hydraulic system. Before applying pressure, make sure all connections are tight
and all components are in good condition. Never use your hand to check for suspected leaks under
pressure. Use a piece of cardboard or wood for this purpose. If injured by leaking fluid, see your
doctor immediately.
W0178A
WARNING
Fire hazard!
When handling diesel fuel, observe the following precautions:
1. Do not smoke.
2. Never fill the tank when the engine is running.
3. Wipe up spilled fuel immediately.
W0099A
test fixture.
NOTICE: Always turn ignition switch and master disconnect switch to the OFF position before removing or installing
connections to the engine controller.
Cause:

5. Connector pins corroded or dirty. When removing connectors inspect and clean pins. Clean female pins by
installing and removing.
Solution:
rence.
(1) Turn ignition switch to RUN position to power instrument cluster.
(2) Clear all fault codes from the cluster.

2. Check circuits from engine controller to injector connector.
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BD07F080-01 1
(1) Connector C
(2) Connector A
(3) Connector B
(1) Disconnect Engine Control Module (ECU) connector A and inspect pins, wiring and connectors for damage,
abrasion, corrosion or incorrect attachment.
(2) Disconnect injector connectors for cylinders 1 and 2. Inspect pins, wiring and connectors for damage, abra-
sion, corrosion or incorrect attachment.
BD08J015-01 2
(1) Rail pressure sensor

(2) Connector injectors (for cylinders 1 and 2)
(3) High pressure common rail
(3) Measure the resistance from ECU connector A, pin 4, to injector connector pin 1. The resistance should be
less than 10 ohms. Wiggle the harness during measurement to reveal an intermittent condition.
A. NOT OK— Determine the break between connectors and repair. Return to Step 1 to confirm elimination
of fault.
B. OK— Go to Step 3.
3. Check circuits from rocker housing connector to injector 1.
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BD08J013-01 3
(1) Injector cylinder 1 (4) Injector cylinder 4

(2) Injector cylinder 2 (5) Rocker housing connector for cylinders 3 and 4
(1) Remove engine valve cover.
NOTE: During installation of valve cover, tighten mounting nuts to a torque of 20 - 30 Nm (15 - 22 lb ft).
(2) Disconnect leads from number 1 injector.
NOTE: When installing leads on injectors, torque terminal nuts to general bolt torque specifications.
(3) Check for open circuit from injector 1 leads to pins 1 and 2 of connector in rocker housing, a reading of
continuity should be obtained.
(4) Check for short circuit between pins 1 and 2 of connector in rocker housing, an open circuit should be ob-
tained.
(5) Check for short circuit between pins 1 and 2 of connector in rocker housing and ground, an open circuit
should be obtained.
A. NOT OK— Determine the break or short between connectors and repair. Return to Step 1 to confirm
4. Check injector.
(2) Take an Ohm reading between terminals on number 1 injector, a reading of 0.5 - 1.0 Ω at 20 °C (68.0 °F)
should be obtained.
A. NOT OK— Replace injector as needed. Return to Step 1 to confirm elimination of fault.
Prior to changing the engine control module contact Technical Services Group for further assistance.
(2) Write symptom on failed engine control module.
for assistance.
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3063-Cylinder 1 - Injector Cable Short Circuit (High Side To Ground)

NOTE: This diagnostic procedure requires a good quality multi-meter to be able to take accurate resistance measure-
ments.
Context:
The engine control unit (ECU) has determined that a short circuit exists in the high side injector circuit for cylinder 1. A
power stage component energizes the unit injection system transistors and simultaneously observes the current flow
is treated as an unclassifiable error. Monitoring is performed once per camshaft revolution. This error is the result
of a short circuit of the high side to the low side or ground over 3 camshaft revolutions. As a result of this error an
Cause:
1. Faulty cylinder 1 solenoid windings.

2. Faulty electrical wiring, short high side to low side or ground (damaged wiring harness).
3. Faulty ECU hardware or software.
Solution:

2. Carefully disconnect the engine cylinder harness from the ECU at ECU cylinder harness connector 3. Use a
multi-meter to check the resistance, on the cylinder harness side of connector 3, between pins 4 and 13. There
should be 0.4 - 0.5 Ω.
A. If the resistance was within range, leave ECU cylinder connector 3 disconnected and continue with step 3
B. If the resistance was lower than range minimum, continue with step 6.
3. Use a multi-meter to check for continuity, on the ECU cylinder harness side of connector 3, from pin 4 to chassis
ground and pin 13 to chassis ground. There should not be continuity.
A. If there was continuity on either or both pins to chassis ground, continue with step 4
B. If there was no continuity on either pin to chassis ground, the ECU may have failed. Try reloading the ECU
software and if the fault reoccurs, replace the ECU .
4. Disconnect the engine cylinder harness from the injector (valve) cover at connector VC1. Use a multi-meter to
check for continuity, on the injector (valve) cover side of connector VC1 from pin A to chassis ground and pin B
to chassis ground. There should not be continuity.
A. If there was continuity on either or both pins to chassis ground, leave connector VC1 disconnected and
continue with step 5
B. If there was no continuity on either pin to chassis ground, there is a short to ground condition in the engine
cylinder harness between Valve cover connector VC1 and ECU to cylinder harness connector 3. Locate
and repair the grounded conductor.
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5. Remove the injector (valve) cover and disconnect the injector harness from Cylinder 1 injector at connector INJ1
terminal 1 (high side ring terminal) Use a multi-meter to check for continuity, on the injector, from terminal 1 to
chassis ground. There should not be continuity.
A. If there is continuity, Cylinder 1 injector's solenoid coil has failed, replace the injector.
B. If there is no continuity, there is a short to ground condition in Cylinder 1 injector circuit, between connector
INJ1 and connector VC1. Locate and repair the grounded conductor.
6. Disconnect the engine injector harness from the injector cover at Cylinder 1 /2 valve cover connector VC1 and
use a multi-meter to check the resistance on the injector cover side of Cylinder 1 /2 valve cover connector VC1
between pins A and B. There should be 0.4 - 0.5 Ω.
A. If the resistance was within range, there is a short circuit condition in the engine injector harness between
the Cylinder 1 / 2 valve cover connector VC1 and ECU cylinder harness connector 3, locate and repair the
short circuit.
B. If the resistance was lower than range minimum, continue with step7
7. Remove the injector (valve) cover and disconnect the injector harness from the Cylinder 1 injector at connector
INJ1 terminal 1 (high side ring terminal) Use a multi-meter to check for continuity, on the Cylinder 1 injector, from
terminal 1 to terminal 2. There should be 0.4 - 0.5 Ω.
A. If the resistance was within range, there is a short circuit condition in the injector harness, between Cylinder
1 injector connector INJ1 and connector VC1. Locate and repair the shorted conductors.
B. If the resistance was lower than minimum range, the Cylinder 1 injector solenoid coil has failed. Replace
the injector.
has been resolved.
ation.
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test fixture.
Context:
Cause:
stage.

Solution:

has been resolved.
ation.
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NOTE: This diagnostic procedure requires a good quality Digital Multi-meter (DMM) to be able to take accurate re-
sistance measurements.
Context:
Cause:

Solution:



Use the standard multi-meter test leads to access the connector pins. See test table below.

nector VC2 connector pin: nector VC2 connector pin:
3 4

Remove ECU connector 3 and perform an injector resistance test. Use the spade style test leads from the from
the Tier II (NEF) Diagnostic Repair Kit # 380040185 when probing the ECU harness side of connector 3. See
test table below.
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pin: 12 pin: 5
nector VC3.


nector INJ3 terminal #1 nector INJ3 terminal #2
connector INJ5.


8, 9, 40
10, 11
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Context:
The engine control unit (ECU) has determined that a short circuit exists in the high side injector circuit for cylinder 5.
Cause:

Solution:
1. Carefully disconnect the engine injector harness from the ECU at connector 3. Use a multi-meter to check the
resistance, on the ECU engine injector harness side of connector 3, between pins 1 and 16. There should be
0.4 - 0.5 Ω.
A. If the resistance was within range, leave ECU harness connector 3 disconnected, and continue with step
2.
2. Use a multi-meter to check for continuity, on the ECU engine injector harness side of connector 3, from pin 1 to
chassis ground and pin 16 to chassis ground. There should not be continuity.
A. If there was continuity on either or both pins to chassis ground, continue with step 3.
software and if the fault reoccurs, replace the ECU.
3. Disconnect the engine injector harness from the injector (valve) cover at connector VC3. Use a multi-meter to
check for continuity, on the injector (valve) cover side of connector VC3 from pin 3 to chassis ground and pin 4
continue with step 4.
injector harness between connector VC3 and ECU harness connector 3. Locate and repair the grounded
conductor.
4. Remove the injector (valve) cover and disconnect the injector harness from Cylinder #5 injector at connector
INJ5 terminal 1 (high side ring terminal) Use a multi-meter to check for continuity, on the Cylinder #5 injector,
from terminal 1 to chassis ground. There should not be continuity.
A. If there is continuity, the Cylinder #5 injector solenoid coil has failed, replace the injector.
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B. If there is no continuity, there is a short to ground condition in the Cylinder #5 injector circuit, between
connector INJ5 and connector VC3. Locate and repair the grounded conductor.
5. Disconnect the engine injector harness from the injector cover at connector VC3 and use a multi-meter to check
the resistance on the injector cover side of connector VC3 between pins 3 and 4. There should be 0.4 - 0.5 Ω.
connector VC3 and ECU harness connector 3, locate and repair the short circuit.
6. Remove the injector (valve) cover and disconnect the injector harness from the Cylinder #5 injector at connector
from terminal 1 to terminal 2. There should be 0.4 - 0.5 Ω.
A. If the resistance was within range, there is a short circuit condition in the injector harness, between con-
nector INJ5 and connector VC3. Locate and repair the shorted conductors.
B. If the resistance was lower than minimum range, the Cylinder #5 injector solenoid coil has failed. Replace
the injector.
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test fixture.
Context:
Cause:
stage.

Solution:

has been resolved.
ation.
47392461 19/06/2012
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Context:
Cause:

Solution:




3 4

the Tier II (NEF) Diagnostic Repair Kit # 380040185 when probing the ECU harness side of connector 3.See
test table below.
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pin: 12 pin: 5
nector VC2.


connector INJ3.


8, 9, 40
10, 11
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3070-Cylinder 3 - Electronic injector , Low signal

WARNING
Escaping fluid!
doctor immediately.
W0178A
WARNING
Fire hazard!
1. Do not smoke.
W0099A
test fixture.
Cause:
1. Engine misfires, runs erratic.

Solution:
rence.

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BD07F080-01 1
(1) Connector C
(2) Connector A
(3) Connector B
BD08J014-01 2

(3) Check for open circuit from ECU connector A, pin 16 to injector connector pin 1. The resistance should be
(4) Check for open circuit from ECU connector A, pin 1 to injector connector pin 2. The resistance should be
(5) Measure the resistance between pins 1 and 16 on ECU connector A. The resistance should be greater than
20,000 ohms. Wiggle the harness during measurement to reveal an intermittent condition.
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BD08J013-01 3

(3) Check for open circuit from injector 3 leads to pins 1 and 2 of connector in rocker housing, a reading of
(4) Check for short circuit between pins 1 and 2 of connector in rocker housing, an open circuit should be ob-
tained.
(5) Check for short circuit between pins 1 and 2 of connector in rocker housing and ground, an open circuit
should be obtained.
4. Check injector.
should be obtained.
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Context:
the failure corresponding to the matched pattern is output. If an error message does not match any pattern the defect
is still present) and others evoke an irreversible or reversible shut off of the engine to be executed.
Cause:

Solution:
0.4 - 0.5 Ω.
2.
2. Use a multi-meter to check for continuity, on the ECU engine injector harness side of connector 3, from pin 12
to chassis ground and pin 5 to chassis ground. There should not be continuity.
conductor.
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the injector.
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Context:
Cause:
stage.

Solution:

has been resolved.
ation.
47392461 19/06/2012
55.DTC / 150

Context:
Cause:

Solution:



Use the standard multi-meter test leads to access the connector pins. Make sure that the multi-meter's test
lead resistance is taken into account when resistance measurements are taken. Record the multi-meter's test
lead resistance by touching the leads together on the lowest Ohms scale and mentally recording the resistance
value. Subtract this value from the actual resistance measurement taken. See test table below.

1 2

Remove ECU connector 3 and perform an injector resistance test. Use the spade style test leads from the
from the Tier II (NEF) Diagnostic Repair Kit # 380040185 when probing the ECU harness side of connector 3.
Make sure that the multi-meter's test lead resistance is taken into account when resistance measurements are
47392461 19/06/2012
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taken. Record the multi-meter's test lead resistance by touching the leads together on the lowest Ohms scale
and mentally recording the resistance value. Subtract this value from the actual resistance measurement taken.

1. Resistance ECU harness connector 3 ECU harness connector 3 Approx. 0.4 - 0.5 ohms
pin: 2 pin: 15
nector VC3.

located on top of the solenoid portion of the injector. Make sure that the multi-meter's test lead resistance is taken
into consideration when resistance measurements are taken. Record the multi-meter's test lead resistance by
touching the leads together on the lowest Ohms scale and mentally recording the resistance value. Subtract
this value from the actual resistance measurement taken. See test table below.

connector VC3.


1. Voltage ECU connector 1, pin 2, 3, Ground (engine block) Approx. 12.0 volts (DC)
8, 9, 40
10, 11
Using the EST service tool, re-initialize the ECU and load the appropriate data-set for this engine type. A call
will have to be made to CNH TSS to get an authorization code for the ECU initialization download. Check to
see if the fault code has cleared.
47392461 19/06/2012
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Context:
Cause:

Solution:
0.4 - 0.5 Ω.
2.
conductor.
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the injector.
47392461 19/06/2012
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Context:
Cause:
stage.

3. Faulty ECU hardware or software.
Solution:

has been resolved.
ation.
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Context:
Cause:

Solution:




1 2

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test table below.

pin: 11 pin: 6
nector VC1.


connector INJ2 .


8, 9, 40
10, 11
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3078-Cylinder 2 - Electronic injector, Low signal

WARNING
Escaping fluid!
doctor immediately.
W0178A
WARNING
Fire hazard!
1. Do not smoke.
W0099A
test fixture.
Cause:

Solution:
rence.

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BD07F080-01 1
(1) Connector C
(2) Connector A
(3) Connector B
BD08J015-01 2

(3) Measure the resistance from ECU connector A, pin 2 to injector connector pin 2. The resistance should be
(4) Measure the resistance from ECU connector A, pin 15 to injector connector pin 4. The resistance should be
(5) Measure the resistance between ECU connector A pins 15 and 2. The resistance should be greater than
A. OK— Go to Step 3.
B. NOT OK— Determine the break or short between connectors and repair. Return to Step 1 to confirm
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BD08J013-01 3

(3) Measure the resistance from injector 2 leads to pins 3 and 4 of connector in rocker housing. The resistance
should be less than 10 ohms. Wiggle the harness during measurement to reveal an intermittent condition.
(4) Measure the resistance between pins 3 and 4 of connector in rocker housing. The resistance should be
(5) Measure the resistance between pins 3 and 4 of connector in rocker housing and ground (engine block).
The resistance should be greater than 20,000 ohms. Wiggle the harness during measurement to reveal an
B. NOT OK— Determine the break or short between connectors and repair. Return to Step 1 to confirm
4. Check injector.
(2) Measure the resistance between terminals on number 2 injector. The resistance should be between 0.5 -
1.0 Ω at 20 °C (68.0 °F).
B. NOT OK— Replace injector as needed. Return to Step 1 to confirm elimination of fault.
Prior to changing the engine control module contact Technical Services Group for further assistance.
47392461 19/06/2012
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Context:
Cause:

Solution:
0.4 - 0.5 Ω.
2.
2. Use a multi-meter to check for continuity, on the ECU engine injector harness side of connector 3, from pin 11
to chassis ground and pin 6 to chassis ground. There should not be continuity.
conductor.
47392461 19/06/2012
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connector VC1 and connector VC1. Locate and repair the grounded conductor.
the injector.
47392461 19/06/2012
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Context:
Cause:
stage.

Solution:

has been resolved.
ation.
47392461 19/06/2012
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test fixture.
Context:
Cause:

Solution:



Use the standard multi-meter test leads to access the connector pins. See test table below.

1 2

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test table below.

pin: 3 pin: 14
nector VC2.


connector INJ4.


8, 9, 40
10, 11
Using the EST service tool, re-initialize the ECU and load the appropriate data-set for this engine type. A call
will have to be made to CNH TSS to get an authorization code for the ECU initialization download. Check to
see if the fault code has cleared.
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3082-Cylinder 4 - Electronic injector, Low signal

WARNING
Escaping fluid!
doctor immediately.
W0178A
WARNING
Fire hazard!
1. Do not smoke.
W0099A
test fixture.
Cause:

Solution:
rence.

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BD07F080-01 1
(1) Connector C
(2) Connector A
(3) Connector B
BD08J014-01 2

(3) Measure the resistance from ECU connector A, pin 12, to injector connector pin 3. The resistance should
be less than 10 ohms. Wiggle the harness during measurement to reveal an intermittent condition.
(5) Measure the resistance between pins 5 and 12 on ECU connector A. The resistance should be greater than
47392461 19/06/2012
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BD08J013-01 3

(3) Measure the resistance from injector 4 leads to pins 3 and 4 of connector in rocker housing. The resistance
(4) Measure the resistance between pins 3 and 4 of connector in rocker housing. The resistance should be
(5) Measure the resistance between pins 3 and 4 of connector in rocker housing and ground (engine block).
4. Check injector.
(2) Measure the resistance between terminals on number 4 injector, a reading of 0.5 - 1.0 Ω at 20 °C (68.0 °F) .
47392461 19/06/2012
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Context:
Cause:

Solution:
0.4 - 0.5 Ω.
2.
injector harness between connector VC2 and ECU harness connector 3.Locate and repair the grounded
conductor.
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the injector.
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3088-Crankshaft sensor lost synchronization

test fixture.
Context:
The Engine Control Unit (ECU) has reported an error with the monitoring of the Increment speed (Crankshaft speed)
sensor. If the engine has a defective Crankshaft speed sensor it can run off the Segment speed (Camshaft speed)
sensor. This is referred to as BACKUP mode. Diagnostics of the SIG failure is only active if voltage is present at
terminal 15 (Ignition ON) and no errors are active for the sensor supply voltage.
Cause:
The ECU has determined that there is no signal from the Crankshaft speed sensor. The engine is now operating in
BACKUP mode.
1. Faulty electrical wiring and/or connections.

2. Faulty Crankshaft speed sensor.
3. Faulty ECU, or ECU supply voltages or grounds.
Solution:
rence.

BD07D131-01 1

(1) Inspect pins on crankshaft speed sensor and connector. Clean connections.
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3. Check circuit
BD07D130-01 2
(1) Connector C
(2) Connector A
(3) Connector EDC7
(1) Disconnect EDC connector C from engine controller.
(2) Inspect pins on EDC connector C and corresponding pins on the engine controller. Clean connections.
(3) Check from pin 1 engine crankshaft speed sensor connector to pin 19 of EDC connector C.
of fault.
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3089-Crankshaft Sensor - Invalid Signal

test fixture.
Context:
The Engine Control Unit (ECU) has reported an error with the monitoring of the Crankshaft speed sensor. If the engine
has a defective Crankshaft speed sensor it can run off the Camshaft speed sensor.
Cause:
The ECU has determined that there are errors in the signal from the Crankshaft speed sensor.

Solution:
rence.

BD07D131-01 1

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3. Check circuit
BD07D130-01 2
(1) Connector C
(2) Connector A
(3) Connector EDC7
of fault.
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3090-Camshaft Sensor - Lost Phase

test fixture.
Cause:
1. Loss of power.
Solution:
rence.

2. Disconnect connector from engine camshaft sensor.
BD07D136-01 1
(1) Connector engine camshaft sensor

(2) Camshaft sensor
(1) Inspect pins on camshaft sensor and connector. Clean connections.
3. Check circuit
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BD07D130-01 2
(1) Connector C
(2) Connector A
(3) Connector EDC7
(1) Disconnect Engine Controller connector C from engine controller.
(3) Check from pin 1 engine camshaft sensor connector to pin 10 of EDC connector C.
of fault.
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3091-Camshaft sensor phase synchronization failure

test fixture.
Cause:
5. Faulty Electronic Controller.
Solution:
rence.

BD07D136-01 1

(2) Camshaft sensor
(3) Measure the resistance between pins 1 and 2 on the sensor. The resistance should be approximately, 900
Ω ± 10%.
A. The resistance is not 900 Ω ± 10%. Temporarily replace sensor and retest. Return to Step 1 to confirm
B. The resistance value is within specifications. Go to Step 3.

3. Check circuit
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BD07D130-01 2
(1) Connector C
(2) Connector A
(3) Connector EDC7
(4) Measure the resistance from pin 1 engine camshaft sensor connector to pin 10 of EDC connector C. The
resistance should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition.
(5) Measure the resistance from pin 2 engine camshaft sensor connector to pin 9 of EDC connector C. The
resistance should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition.
A. The resistance is greater than 10 Ω. Determine the break between connectors and repair. Return to Step
B. The resistance is less than 10 Ω. Temporarily replace the engine control module and retest.
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3093-Offset Between Camshaft And Crankshaft - Outside

Boundaries
test fixture.
Cause:
1. Loss of power.
Solution:
rence.

BD07D136-01 1

(2) Camshaft sensor
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BD07D131-01 2

4. Check circuit
BD07D130-01 3
(1) Connector C
(2) Connector A
(3) Connector EDC7
(1) Disconnect EDC connector C from engine controller, engine camshaft, and crankshaft sensor.
(2) Inspect pins on connectors, camshaft, crankshaft, and EDC connector C and corresponding pins on the
engine controller. Clean connections.
(3) Check from pin 1 engine camshaft sensor connector to pin 10 of Connector C.
of fault.
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3095-Operating With Camshaft Sensor Only - Backup Mode

test fixture.
Cause:
1. Loss of power.
Solution:
rence.

BD07D131-01 1

3. Check circuit
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BD07D130-01 2
(1) Connector C
(2) Connector A
(3) Connector EDC7
of fault.
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3102-Rail Pressure Sensor CP3 - Signal Below Range Minimum

test fixture.
Context:
The engine control unit (ECU) has sensed that the Fuel Pressure sensor signal is too low. The signal voltage is less
than 0.25 V for period greater than 200 ms. While the fault is active the ECU will Once set the ECU will, substitute a
default value based on engine speed and injection quantity.
Cause:
The rail pressure signal is too low.
1. Rail pressure below set range.

Solution:
rence.

2. Disconnect connector from rail pressure sensor.
BD07D134-01 1

(2) Intake manifold
(1) Inspect pins on rail pressure sensor and connector. Clean connections.
(2) Take Ohm reading between pins 1 and 2 on the sensor, a reading of 45k Ω should be obtained.
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BD07D134-01 2

(2) Intake manifold
4. Check circuit
BD07D130-01 3
(1) Connector C
(2) Connector A
(3) Connector EDC7
(2) Inspect pins on Connector C and engine controller. Clean connections.
(3) Check from pin 3 rail pressure sensor connector to pin 13 of Connector C.
of fault.
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BD07D130-01 4
(1) Connector C
(2) Connector A
(3) Connector EDC7
(2) Inspect pins on EDC7 and engine controller. Clean connections.
6. Check circuit.
BD07D130-01 5
(1) Connector C
(2) Connector A
(3) Connector EDC7
(1) Disconnect Connector C from engine controller and connector at rail pressure sensor.
of fault.
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3104-Rail Pressure Relief Valve - Open

test fixture.
Cause:
1. Rail pressure below set range.

Solution:
rence.

BD07D134-01 1

(2) Intake manifold
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BD07D134-01 2

(2) Intake manifold
4. Check circuit
BD07D130-01 3
(1) Connector C
(2) Connector A
(3) Connector EDC7
of fault.
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BD07D130-01 4
(1) Connector C
(2) Connector A
(3) Connector EDC7
(2) Inspect pins on Connector EDC7 and engine controller. Clean connections.
6. Check circuit.
BD07D130-01 5
(1) Connector C
(2) Connector A
(3) Connector EDC7
of fault.
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3105-Rail Pressure Relief Valve - Pressure Shock Requested

test fixture.
Context:
The engine control unit (ECU) has determined that the Fuel Rail/System Pressure is too high and the Pressure Relief
Valve (PRV) did not open. Normally the fuel pressure in the rail is regulated by the metering unit of the high pressure
pump. However, if this component is malfunctioning the rail pressure can rise to critical levels. For this reason the
common rail has a Pressure Relief Valve (PRV) which is a mechanical safety valve (no electrical connectors) that
opens at a certain pressure level. An opening of the PRV is detected by evaluating the gradient of the rail pressure
(calculated by the ECU). If the PRV does not open on its own after exceeding the pressure threshold it can also be
forced open by a so-called 'kickoff' or pressure shock when the metering valve of the high pressure fuel pump is set to
maximum possible quantity. Rail pressure in excess of 148500 kPa (21538.1 psi) for 1 s evokes a kickoff (pressure
shock) request by the ECU. If the pressure shock (kickoff) does not immediately open the PRV, this error will occur.
This fault will only be cleared after an ECU reset.
1. Faulty ECU, improper data set.

2. Faulty PRV, mechanical valve does not function.
Solution:
1. Use the EST to flash the ECU with the appropriate data set.
A. If the error reoccurs, replace the PRV.
B. If the error does not reoccur, return the combine to service.
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3106-Rail Pressure Relief Valve - Did Not Open After Pressure

Shock
test fixture.
NOTICE: Replace pressure relief valve and restart machine.
Context:
The engine control unit (ECU) has determined that the Pressure Relief Valve (PRV) did not open after a pressure
shock (kickoff). Normally the fuel pressure in the rail is regulated by the metering unit of the high pressure pump.
However, if this component is malfunctioning the rail pressure can rise to critical levels. For this reason the common
rail has a Pressure Relief Valve (PRV) which is a mechanical safety valve (no electrical connectors) that opens at a
certain pressure level. An opening of the PRV is detected by evaluating the gradient of the rail pressure (calculated
by the ECU). If the PRV does not open on its own after exceeding the pressure threshold it can also be forced open
by a so-called 'kickoff' or pressure shock when the metering valve of the high pressure fuel pump is set to maximum
possible quantity. Rail pressure in excess of 148500 kPa (21538.1 psi) for 1 s evokes a kickoff (pressure shock)
request by the ECU. If the pressure shock (kickoff) request is present longer than 2 s and did not immediately open
the PRV, this error will occur. This fault will only be cleared after an ECU reset.
1. Faulty ECU, improper data set.

2. Faulty PRV, mechanical valve does not function.
Solution:
1. Use the EST to flash the ECU with the appropriate data set.
A. If the error reoccurs, replace the PRV.
B. If the error does not reoccur, return the combine to service.
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3107-Metering unit output short circuit to battery on low side

test fixture.
Context:
The engine control unit (ECU) has determined that a short to high source circuit condition exists in the fuel high pres-
sure pump low side circuit. The metering unit of the fuel high pressure pump regulates the pressure in the common
rail. The metering unit is closed-loop controlled by both main relay 1 (high side) and a low side power stage (Main
Relay 1 is an electronic control circuit within the ECU, providing source voltage to devices external to the ECU. The
low side power stage works in conjunction with the Main Relay 1 source, providing sensing and current limiting for the
circuit). The monitoring at low side is stopped if a short circuit to ground at the high side (main relay 1) is detected or it
is switched off for some reason. Failure detection of is only possible if the low side power stage is switched on. With
the current settings, the monitoring is shut off during after-run. This error is the result of the power stage hardware
report of 'short circuit to battery' (on the low side of the metering unit)
Cause:
Fuel high pressure pump circuit is shorted to a high source.
1. Faulty fuel high pressure pump control circuit, shorted to a high source.
Solution:

2. Disconnect the Engine Injector harness from the ECU at connector 3 and place the Key switch in the "On"
position. Use a multi-meter to test for voltage from the Engine Injector harness side of connector 3, pin 10 to
chassis ground. There should be no voltage.
A. If there is voltage, locate and repair the short to the voltage source.
B. If there is no voltage, continue with step 3

3. Disconnect the Engine Injector harness from the fuel high pressure pump at connector ZME and use a multi-
meter to check the resistance of the fuel high pressure pump solenoid coil. There should be a small amount of
resistance.
A. If there is a small amount of resistance, try reloading the ECU software and if the error reoccurs, replace
the ECU.
B. If there is no resistance, the fuel high pressure pump solenoid coil has failed, replace the solenoid.
has been resolved.
ation.
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3110-Rail Pressure Sensor Monitoring - Signal Above Range

Maximum
Context:
The engine control unit (ECU) has sensed that the Rail Pressure sensor offset signal is too high. This test is performed
during after-run and is aborted if the Key switch is switched "On" during after-run. During after-run the measured raw
value of the Rail Pressure sensor is compared to the atmospheric pressure sensor within the ECU. To ensure that the
rail pressure has depressurized sufficiently to atmospheric levels after engine shutoff, the monitoring is released only
if the delay time determined by the rail pressure dependent curve (ECU pre-programmed data) has elapsed and the
fuel temperature is above -0.04 °C (31.93 °F). If the raw value of the rail pressure sensor exceeds 0.65 V over 100
milliseconds during after-run, this error is set and will reset if the value goes below the limit for over 100 milliseconds.
Cause:
The Rail Pressure sensor after-run signal is too high.
1. Faulty circuit wiring or electrical connection.

2. Faulty sensor.
Solution:
1. Use EST to check for other Rail Pressure sensor errors.
A. If Rail Pressure sensor errors exist, follow troubleshooting procedure for existing Rail Pressure sensor
error.
B. If no Rail Pressure sensor errors exist, continue with step 2

2. Disconnect the Engine Sensor harness from the ECU at connector 2 and from the Rail Pressure sensor at
connector RDS4. Use a multi-meter to check for continuity from the Engine Sensor harness side of connector
2, pin 13 to the Engine Sensor harness side of connector RDS4, pin 3. There should be continuity.
A. If there is continuity, leave the connectors disconnected and continue with step 3
B. If there is no continuity, there is an open circuit condition in the sensor source wire. Locate and repair the
open circuit condition.
3. Use a multi-meter to check for continuity from the Engine Sensor harness side of connector 2, pin 14 to the
Engine Sensor harness side of connector RDS4, pin 2. There should be continuity.
B. If there is no continuity, there is an open circuit condition in the sensor ground reference wire. Locate and
repair the open circuit condition.
B. If there is no continuity, there is an open circuit condition in the sensor signal wire. Locate and repair the
5. Visually inspect both connectors for electrical integrity.
A. If damage or connectivity issues are discovered, repair, clean or replace as required.
B. If no damage or connectivity issues are discovered, replace the sensor.
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3111-Rail Pressure Sensor Monitoring - Signal Below Range

Minimum
Context:
The engine control unit (ECU) has sensed that the Rail Pressure sensor offset signal is too low. This test is performed
during after-run and is aborted if the Key switch is switched "On" during after-run. During after-run the measured raw
value of the Rail Pressure sensor is compared to the atmospheric pressure sensor within the ECU. To ensure that the
rail pressure has depressurized sufficiently to atmospheric levels after engine shutoff, the monitoring is released only
if the delay time determined by the rail pressure dependent curve (ECU pre-programmed data) has elapsed and the
fuel temperature is above -0.04 °C (31.93 °F). If the raw value of the rail pressure sensor is below 0.35 V over 100
milliseconds during after-run, this error is set and will reset if the value goes above the limit for over 100 milliseconds.
Cause:
The Rail Pressure sensor after-run signal is too low.
1. Faulty circuit wiring or electrical connection.

2. Faulty sensor.
Solution:
1. Use EST to check for other Rail Pressure sensor errors.
A. If Rail Pressure sensor errors exist, follow troubleshooting procedure for existing Rail Pressure sensor
error.
B. If no Rail Pressure sensor errors exist, continue with step 2

2. Disconnect the Engine Sensor harness from the ECU at connector 2 and from the Rail Pressure sensor at
connector RDS4. Use a multi-meter to check for continuity from the Engine Sensor harness side of connector
2, pin 13 to the Engine Sensor harness side of connector RDS4, pin 3. There should be continuity.
B. If there is no continuity, there is an open circuit condition in the sensor source wire. Locate and repair the
B. If there is no continuity, there is an open circuit condition in the sensor ground reference wire. Locate and
repair the open circuit condition.
B. If there is no continuity, there is an open circuit condition in the sensor signal wire. Locate and repair the
5. Visually inspect both connectors for electrical integrity.
A. If damage or connectivity issues are discovered, repair, clean or replace as required.
B. If no damage or connectivity issues are discovered, replace the sensor.
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3112-Rail Pressure Sensor CP3 - Signal Above Maximum Range

Context:
The engine control unit (ECU) has sensed that the Fuel Pressure sensor signal is too high. The test frequency of the
sensor is every 10 ms and if the signal is in excess of 4.86 V for over 200 ms, the error is set. Once set the ECU will,
instead of using the peak rail pressure value of the last 10 ms and the current rail pressure, output a substitute value
from a curve (MAP) in the ECU depending on engine speed and injection quantity.
Cause:
The Fuel Pressure sensor signal is too high.
1. Faulty Fuel Pressure sensor.

2. Faulty circuit wiring, shorted to high source.
Solution:
1. Disconnect the engine sensor harness from the ECU at ECU engine connector 2 and place the Key switch in
the "On" position. Using a multi-meter check the voltage on the ECU engine connector from pin 13 to pin 12.
There should be 5 V.
A. If there is 5 V reconnect ECU engine connector and continue with step 2
B. If there is greater than 5 V, there is a failure inside the ECU, replace the ECU.
2. Disconnect the engine sensor harness from the Rail Pressure sensor and place the Key switch in the "On"
position. Use a multi-meter check the voltage on the engine harness side of Rail pressure sensor connector
RDS4 from pin 3 to pin 2. There should be 5 V.
A. If there is 5 V leave the Rail pressure sensor connector disconnected and continue with step 3
B. If there is greater than 5 V, there is a short to high source in the sensor circuit wiring, leave the Rail pressure
sensor connector RDS4 disconnected and continue with step 4
3. Disconnect the engine sensor harness from the ECU at ECU engine connector 2. Use a multi-meter test for
voltage between the engine sensor harness side of ECU engine connector 2, pin 14 and ground and also be-
tween Rail pressure sensor connector RDS4, pin 1 and ground. There should be no voltage.
A. If there is voltage on either or both tests, there is a short to high source in the sensor signal wire, locate
and repair the short to high source.
B. If there is no voltage, either the sensor has failed or the ECU is faulty. Replace the Rail Pressure sensor
and if the fault reoccurs reload the ECU software. If the fault reoccurs after replacing the sensor and
reloading software, replace the ECU.
4. Disconnect the engine sensor harness from the ECU at ECU engine connector 2. Use a multi-meter test for
voltage between the engine sensor harness side of ECU engine connector 2, pin 13 and ground and also be-
tween Rail pressure sensor connector RDS4, pin 3 and ground. There should be no voltage.
A. If there is voltage, on either or both tests, there is a short to high source in the sensor source wire. Locate
and repair the short to high source.
B. If there is no voltage, on both tests, there is a short to high source in the sensor ground reference wire.
Locate and repair the short to high source.
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3113-Grid heater battery switch relay short circuit to battery

test fixture.
Cause:

5. Connector pins corroded or dirty. When removing connectors inspect and clean pins.
Solution:
rence.
(1) Use the Electronic Service Tool to clear all fault codes.

(2) Inspect the Grid Heater connections and Engine Control connections. All connections should be secure,
(3) Inspect the harness from the Grid Heater to the Engine Controller. Verify that the harness is free of damage,
corrosion, abrasion or incorrect attachment.
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RCIL11WHL054FAK 1
Schematic legend
1021F\1121F – 200 A
521F\621F\721F\821F\921F – 150 A
521F\621F\721F\821F\921F – 110 A ± Note 521F\621F\721F\821F\921F use
8% at 22 V 19mm squared wiring instead of 32mm
squared.
heater Switch

EDC7 pin 12 28G W-1.0 gxl Grid Heater Source voltage to Grid
Heater Relay
EDC7 pin 17 21H_A W-0.8 txl Crank Control Low
EDC7 pin 32 21E_A W-0.8 txl Key Switch Crank Request LSD
EDC7 pin 37 21G_A W-0.8 txl Crank Control Relay High
EDC7 pin 40 13MA Or-0.8 txl Key Switch Fused Power
EDC7 pin 75 0_BV Bk-0.8 txl Grid Heater Relay, low side
3. Check grid heater relay.
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BD08F244-01 2
(1) Grid heater relay

(2) Connector grid heater relay
(3) Battery terminal
(4) Grid heater terminal
(1) Disconnect the grid heater relay connector. Inspect pins, wiring and connectors for damage, abrasion, cor-
rosion or incorrect attachment.
(2) Measure the resistance from pin 1 on the grid heater relay to battery terminal and heater terminal studs.
(4) Measure the resistance between pin 1 and pin 2 on grid heater relay. The resistance should be approximately
15 - 40 Ω.
A. NOT OK – Replace relay. Return to Step 1 to confirm elimination of fault.
4. Check circuit.
BD08E032-01 3
(1) Connector C
(2) Connector A
(3) Connector B
(1) Disconnect ECU connector B and the grid heater relay connector. Inspect pins, wiring and connectors for
damage, abrasion, corrosion or incorrect attachment.
(2) Measure the resistance between ECU connector B pin 12 and pin 75. The resistance should be greater than
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(3) Measure the resistance from grid heater relay connector 1 to ECU connector B pin 12. The resistance should
(4) Measure the resistance from grid heater relay connector pin 2 to ECU connector B pin 75. The resistance
A. NOT OK – Determine the short circuit or break between connectors and repair. Return to Step 1 to confirm
5. Replace the engine control unit.
(1) Remove and replace engine control unit.
A. Return to Step 1to confirm elimination of fault.
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3114-Grid heater battery switch relay short circuit to ground

test fixture.
Cause:
1. Short circuit of grid heater relay to external ground.

Solution:
rence.

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RCIL11WHL054FAK 1
Schematic legend
1021F\1121F – 200 A
521F\621F\721F\821F\921F – 150 A
squared.
heater Switch

Heater Relay
3. Check grid heater relay.
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BD08F244-01 2

(1) Disconnect the grid heater relay connector. Inspect pins, wiring and connectors for damage, abrasion, cor-
(4) Measure the resistance between pin 1 and pin 2 on grid heater relay. The resistance should be approximately
15 - 40 Ω.
4. Check circuit.
BD08E032-01 3
(1) Connector C
(2) Connector A
(3) Connector B
(1) Disconnect ECU connector B and the grid heater relay connector. Inspect pins, wiring and connectors for
damage, abrasion, corrosion or incorrect attachment.
(2) Measure the resistance between ECU connector B pin 12 and pin 75. The resistance should be greater than
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(3) Measure the resistance from grid heater relay connector 1 to ECU connector B pin 12. The resistance should
(4) Measure the resistance from grid heater relay connector pin 2 to ECU connector B pin 75. The resistance
A. Return to Step 1to confirm elimination of fault.
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3118-ECM 12V sensor supply voltage high

NOTICE: When available use special tool 380040185 harness diagnostic/repair kit.
NOTICE: Check alternator output voltage, if above 28 V refer to Alternator - Testing (55.301) and troubleshoot
charging system before proceeding.
Cause:
1. Besides the 3 independent 5V voltage supplies the ECU also provides a 12V supply for the sensors. This 12V
supply is monitored to ensure it remains within a certain range. This is done by using an analog input of the
ECU. The lower and upper thresholds depend on the battery voltage.
Solution:
rence.

BD07D130-01 1
(1) Connector C
(2) Connector A
(3) Connector EDC7
(2) Inspect pins on Connector EDC7 and on engine controller. Clean connections.
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3119-ECM 12V sensor supply voltage low

test fixture.
NOTICE: Check alternator output voltage, refer to Alternator - Testing (55.301) and troubleshoot charging system
before proceeding.
Cause:
1. Besides the 3 independent 5V voltage supplies the ECU also provides a 12V supply for the sensors. This 12V
supply is monitored to ensure it remains within a certain range. This is done by using an analog input of the
ECU. The lower and upper thresholds depend on the battery voltage.
Solution:
rence.

BD07D130-01 1
(1) Connector C
(2) Connector A
(3) Connector EDC7
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3131-Grid Heater Always Switched On

test fixture.
Cause:
1. ECU monitoring grid heater as always on.

Solution:
rence.

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RCIL11WHL054FAK 1
Schematic legend
1021F\1121F – 200 A
521F\621F\721F\821F\921F – 150 A
squared.
heater Switch

Heater Relay
3. Disconnect connector from grid heater relay.
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BD07D146-01 2

(1) Inspect pins on grid heater relay and connector.
(2) Take Ohm reading from pins 1 and 2 at grid heater relay connector to battery terminal and heater terminal
studs at relay, circuit should be open.
4. Check circuit.
BD07D130-01 3
(1) Connector C
(2) Connector A
(3) Connector EDC7
(1) Disconnect Connector EDC7 from engine controller and connector at grid heater relay.
(3) Check from pin 12 to pin 75 at Connector EDC7, circuit should be open.
(4) Check from pin 1 grid heater relay connector to pin 12 of Connector EDC7.
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3137-Metering Unit - Open Load

test fixture.
Context:
The engine control unit (ECU) has determined that an open circuit condition exists in the Pump control valve (Metering
Unit - High Pressure Pump Regulator solenoid/valve) circuit. The metering unit of the fuel high pressure pump regu-
lates the pressure in the common rail. The metering unit is controlled by both main relay 1 high side and a low side
power stages (Main Relay 1 is an electronic control circuit within the ECU used to provide fixed and variable control
signals to devices external to the ECU). The monitoring at low side is stopped if a short circuit to ground at the high
side (main relay 1) is detected or it is switched off for some reason. Failure detection of an over current condition is
only possible if the low side power stage is switched on and the open circuit condition only if it is switched off. With
the current settings, the monitoring is shut off during after-run. This error is
Cause:
Pump control valve circuit is open.
1. Power stage hardware reports 'open load' in the metering unit longer than 200 ms, engine shut down.
Solution:
rence.

2. Disconnect connector from pressure regulator valve.
BD07D137-01 1
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(1) High pressure regulator valve

(2) High pressure pump
(1) Inspect pins on pressure regulator valve and connector. Clean connections.
(2) Take an Ohm reading between pins 1 and 2 at regulator valve, a reading of 3.2 Ω should be obtained.
A. NOT OK – Replace regulator valve. Return to Step 1 to confirm elimination of fault.
3. Check circuit
BD07D130-01 2
(1) Connector C
(2) Connector A
(3) Connector EDC7
(1) Disconnect EDC Connector C from engine controller and connector at rail pressure regulator valve.
(2) Inspect pins on EDC Connector C, pins on engine controller, rail pressure regulator valve, and connector.
Clean connections.
(3) Check from pin 9 to pin 10 at EDC connector C , circuit should be open.
(4) Check from pin 1 rail pressure regulator valve connector to pin 9 of EDC connector C.
(5) Check from pin 2 rail pressure regulator valve connector to pin 10 of EDC Connector C.
A. NOT OK – Determine the break or short circuit between connectors and repair. Return to Step 1 to confirm
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3138-Metering Unit - Signal Not Plausible

test fixture.
Cause:
1. Rail pressure regulator solenoid valve signal unreadable.

Solution:
rence.

2. Disconnect connector from pressure regulator solenoid valve.
BD07D137-01 1
(1) High pressure regulator solenoid valve

(1) Inspect pins on pressure regulator solenoid valve and connector. Clean connections.
(2) Take an Ohm reading between pins 1 and 2 at pressure regulator solenoid valve, a reading of 3.2 Ω should
be obtained.
3. Check circuit
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BD07D130-01 2
(1) Connector C
(2) Connector A
(3) Connector EDC7
(1) Disconnect Connector C from engine controller and connector at pressure regulator solenoid valve.
(2) Inspect pins on Connector C, pins on engine controller, pressure regulator solenoid valve, and connector.
Clean connections.
(3) Check from pin 9 to pin 10 at Connector C, circuit should be open.
(4) Check from pin 1 pressure regulator solenoid valve connector to pin 9 of Connector C.
(5) Check from pin 2 pressure regulator solenoid valve connector to pin 10 of Connector C.
of fault.
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3141-Set point of fuel volume flow through metering unit is lower

than calculated limit
Context:
The engine control unit (ECU) has determined that there is either Fuel System Leakage or the Metering Unit (High
Pressure Pump Regulator solenoid/valve) is jammed in closed position. The rail pressure is monitored by various fault
paths during active pressure control by the metering unit. The fault path at hand detects a leakage of fuel by monitoring
the set-point current used to control the metering unit. The monitoring is only active if the high pressure governor (High
Pressure Pump Regulator solenoid/valve) is operating in closed loop control, the rail pressure governor deviation is
within the range +/- 5000 kPa (725.2 psi) and the monitoring has not been inhibited by other faults. If the metering
unit current control set-point current is below a calculated minimum limit over 2.5 seconds this error will occur. [This
limit is calculated from various curves, maps and correction factors established by the ECU]. This error is the result
of an inaccurate Rail pressure sensor or defective high pressure pump in the high pressure system or Metering unit
reflux too low, fuel system leakage, or metering unit jammed in the closed position in the low pressure system.
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3147-Oil Temperature Sensor - Signal Above Normal Range

test fixture.
ceeding.
Cause:
1. Engine oil temperature sensor signal above a set range.

Solution:
rence.

unit connector.
BD07E022-01 1

(2) Alternator

3. Check circuit.
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BD07D130-01 2
(1) Connector C
(2) Connector A
(3) Connector EDC7
of fault.
BD07D130-01 3
(1) Connector C
(2) Connector A
(3) Connector EDC7
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3154-Grid Heater Relay - Short Circuit To Battery

Cause:
1. Short circuit of grid heater relay to external power source.

Solution:
rence.

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RCIL11WHL054FAK 1
Schematic legend
1021F\1121F – 200 A
521F\621F\721F\821F\921F – 150 A
squared.
heater Switch

Heater Relay
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BD07D146-01 2

BD07D130-01 3
(1) Connector C
(2) Connector A
(3) Connector EDC7
A. NOT OK – Determine the short circuit or the break between connectors and repair. Return to Step 1 to
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3155-Grid Heater Relay - Short Circuit To Ground

test fixture.
Cause:
1. Short circuit of grid heater relay to ground.

Solution:
rence.

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RCIL11WHL054FAK 1
Schematic legend
1021F\1121F – 200 A
521F\621F\721F\821F\921F – 150 A
squared.
heater Switch

Heater Relay
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BD07D146-01 2

BD07D130-01 3
(1) Connector C
(2) Connector A
(3) Connector EDC7
A. NOT OK – Determine the short circuit or the break between connectors and repair. Return to Step 1 to
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3156-Grid Heater Relay - No Load

NOTICE: When available use special tool 380040185 harness diagnostic/repair kit .
Cause:

Solution:
rence.

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RCIL11WHL054FAK 1
Schematic legend
1021F\1121F – 200 A
521F\621F\721F\821F\921F – 150 A
squared.
heater Switch

Heater Relay
3. Measure the resistance through the Grid Heater signal wires
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BD07D130-01 2
(1) Connector C
(2) Connector A
(3) Connector EDC7
(2) Inspect pins on Connector EDC7 Connector EDC7 and engine controller.
(3) Measure resistance from EDC7 connector pin 12 to the Grid Heater terminal 86. Wiggle the harness during
(4) Measure resistance from EDC7 connector pin 75 to the Grid Heater terminal 85. Wiggle the harness during
A. OK – The resistance is less than 10 Ω Go to Step 4.
B. NOT OK – The resistance is greater than 10 Ω. There is an open circuit in the Grid Heater Relay wires
from the EDC7 Engine Controller to the Grid Heater Relay. Repair as required. Return to Step 1 to confirm
4. Test the Grid Heater Relay
(1) Turn the key switch OFF. Disconnect the signal wires from Grid Heater Relay, terminal 86 and terminal 85.
(2) Fabricate two jumper wires that will reach from the battery to the Grid Heater Relay terminals.
(3) Connect one end of the first wire to the Minus Battery post. Connect the other end to the Grid Heater Relay,
terminal 85.
(4) Connect one end of the second wire to the Grid Heater Relay, terminal 86.
(5) Connect the other end to the positive battery post.
A. OK – The Grid Heater relay energized and the Grid Heater turned on. Temporarily replace the EDC7
Engine Controller and retest. Go to Step 1 to confirm elimination of the fault.
B. NOT OK – The Grid Heater relay did not energize. Temporarily replace the Grid Heater Relay and retest.
Return to Step 1 to confirm elimination of fault.
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3171-Fuel rail system pressure too low

WARNING
Escaping fluid!
doctor immediately.
W0178A
WARNING
Fire hazard!
1. Do not smoke.
W0099A
Cause:

Solution:
rence.

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BD07D134-01 1
(1) Rail pressure sender

(2) Intake manifold
3. Disconnect connector from rail pressure sending unit.
BD07D134-01 2

(2) Intake manifold
A. NOT OK – Go to Step 4.
B. OK – Replace sensor. Return to Step 1 to confirm elimination of fault.

4. Check circuit
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BD07D130-01 3
(1) Connector C
(2) Connector A
(3) Connector EDC7
(3) Check from pin 3 rail pressure sending unit connector to pin 13 of Connector C.
of fault.
BD07D130-01 4
(1) Connector C
(2) Connector A
(3) Connector EDC7
6. Check circuit.
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BD07D130-01 5
(1) Connector C
(2) Connector A
(3) Connector EDC7
of fault.
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3172-Fuel rail system pressure too high

WARNING
Escaping fluid!
doctor immediately.
W0178A
WARNING
Fire hazard!
1. Do not smoke.
W0099A
Cause:
1. Leakage in high pressure section, injection nozzle stuck in open position, worn high pressure pump, worn in-
jector, leaking pressure relieve valve.
Solution:
rence.

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BD07D134-01 1

(2) Intake manifold
BD07D134-01 2

(2) Intake manifold

4. Check circuit
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BD07D130-01 3
(1) Connector C
(2) Connector A
(3) Connector EDC7
of fault.
BD07D130-01 4
(1) Connector C
(2) Connector A
(3) Connector EDC7
6. Check circuit.
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BD07D130-01 5
(1) Connector C
(2) Connector A
(3) Connector EDC7
of fault.
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3173-Rail Pressure Governor Deviation Below Min. Limit for Speed

WARNING
Escaping fluid!
doctor immediately.
W0178A
WARNING
Fire hazard!
1. Do not smoke.
W0099A
test fixture.
Cause:
1. Pressure before gear pump too low, gear pump output too low (fuel filter clogged, leakage in low pressure side).
Solution:
rence.

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BD07D134-01 1

(2) Intake manifold
BD07D134-01 2

(2) Intake manifold

4. Check circuit
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BD07D130-01 3
(1) Connector C
(2) Connector A
(3) Connector EDC7
of fault.
BD07D130-01 4
(1) Connector C
(2) Connector A
(3) Connector EDC7
6. Check circuit.
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BD07D130-01 5
(1) Connector C
(2) Connector A
(3) Connector EDC7
of fault.
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3174-Rail Pressure Governor Deviation Exceeded Max. Limit

WARNING
Escaping fluid!
doctor immediately.
W0178A
WARNING
Fire hazard!
1. Do not smoke.
W0099A
test fixture.
Cause:
1. Pressure before gear pump too low, gear pump output too low (fuel filter clogged, leakage in low pressure side).
Solution:
rence.

2. Check fuel delivery system.
(1) Refer to the Engine Repair Manual for the following: Check and repair leaks in the high and low pressure
sides of the fuel system. Check for clogged fuel filter, worn or stuck injectors, and defective low and high pres-
sure pumps.
A. OK - Go to Step 3.
B. NOT OK - Repair fuel system leaks and/or repair worn or defective components. Return to Step 1 to
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3. Check rail pressure sensor.
BD08E030-01 1
(1) Connector fuel pressure sensor

(2) Common rail pressure sensor
(3) Common rail
(1) Disconnect rail pressure sensor connector. Inspect pins, wiring and connectors for damage, abrasion, cor-
(2). Disconnect rail pressure sensor connector. Turn the key switch ON. The rail pressure sensor fault code
should change to an Open Circuit fault while the sensor is disconnected.
(3) Fabricate a 6 inch jumper wire. Short the rail pressure signal wire to sensor common wire (Ground). The
fault code should change from an open circuit to a short circuit while the jumper is installed.
A. OK - Replace sensor. Go to Step 1 to confirm elimination of fault.
B. NOT OK - Go to step 4.
4. Check voltage at rail pressure sensor.
(1) Disconnect the Rail Pressure sensor connector.
(3) Measure the voltage between Fuel Pressure connector pin 3 to pin 1 (ground). The voltage should be ap-
proximately 5 V.
A. NOT OK - Go to Step 5.
B. OK - Replace sensor. Return to Step 1 to confirm elimination of fault.

5. Check rail pressure circuit.
BD08E032-01 2
(1) Connector C
(2) Connector A
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(3) Connector B
(1) Disconnect Electronic Control Unit (ECU) connector C. Inspect pins, wiring and connectors for damage,
(2) Measure the resistance from Rail Pressure sensor connector pin 1 to ECU connector C pin 12. The resis-
tance should be less than 10 ohms. Wiggle the harness during measurement to reveal an intermittent condition.
A. OK - Go to Step 6.
B. NOT OK - Determine the break between connectors and repair. Return to Step 1 to confirm elimination of
fault.
6. Check fuel high pressure regulator.
BD08F245-01 3
(1) Connector high pressure regulator

(1). Disconnect connector from fuel high pressure regulator. Inspect pins, wiring and connectors for damage,
(2). Measure the resistance between pins 1 and 2 on the high pressure regulator. The resistance should be
approximately 3.2 Ω.
A. NOT OK – Replace fuel high pressure regulator. Return to Step 1 to confirm elimination of fault.
7. Check high pressure regulator circuit.
BD08E032-01 4
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(1) Connector C
(2) Connector A
(3) Connector B
(1). Disconnect ECU connector A. Inspect pins, wiring and connectors for damage, abrasion, corrosion or in-
correct attachment.
(2). Measure the resistance between pin 9 to pin 10 on ECU connector A. The resistance should be greater
(3). Measure the resistance from high pressure regulator pin 1 to ECU connector A pin 9. The resistance should
(4). Measure the resistance from high pressure regulator pin 2 to ECU connector A pin 10. The resistance
A. NOT OK - Determine the break or short between connectors or wiring and repair as required. Return to
Step 1 to confirm elimination of fault.
B. OK - Go to Step 8.
for assistance.
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3175-Fuel system leak detected - large leak

WARNING
Escaping fluid!
doctor immediately.
W0178A
WARNING
Fire hazard!
1. Do not smoke.
W0099A
NOTICE: When available use special tool 380040185 harness diagnostic/repair kit. Check filters, lines, and low pres-
sure pump before proceeding, see engine repair manual.
Cause:
1. Leakage in high pressure section, injection nozzle stuck in open position, worn high pressure pump, worn in-
jector, leaking pressure relieve valve.
Solution:
rence.

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BD07D134-01 1

(2) Intake manifold
BD07D134-01 2

(2) Intake manifold

4. Check circuit
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BD07D130-01 3
(1) Connector C
(2) Connector A
(3) Connector EDC7
of fault.
BD07D130-01 4
(1) Connector C
(2) Connector A
(3) Connector EDC7
(1) Turn ignition OFF. Disconnect Connector EDC7 rom engine controller.
6. Check circuit.
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BD07D130-01 5
(1) Connector C
(2) Connector A
(3) Connector EDC7
of fault.
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3176-Fuel delivery exceeded threshold for pressure in overrun

mode
test fixture. Check filters, lines, and low pressure pump before proceeding, see engine repair manual.
Context:
The engine control unit (ECU) has determined that the Metering Unit (High Pressure Pump Regulator solenoid/valve)
has excessively opened to reach the desired Rail pressure. The rail pressure is monitored by various fault paths
during active pressure control by the metering unit. The fault path at hand detects an excessive leakage of fuel by
monitoring the set-point value of the fuel volume flow through the metering unit during overrun. The monitoring is
only active if the high pressure governor (High Pressure Pump Regulator solenoid/valve) is operating in closed loop
control, the engine is in overrun condition, the fuel injection quantity is zero and the monitoring has not been inhibited
by other faults. If the set-point value of the rail pressure governor for the fuel volume flow through the metering unit
exceeds an upper limit over 2.5 seconds this error will occur. [This limit is interpolated from the rail pressure dependent
curve, established by the ECU]. This error is the result of leakage in the high pressure section; injection nozzle stuck
in open position, worn or defective high pressure pump, worn injector, leaking pressure relief valve. or leakage in the
low pressure system; 'Zero delivery' is not active in metering unit (excessive leakage in metering unit).
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3178-Timeout of CAN Message BC2EDC1

Cause:
1. CAN controller of the EDC reports a reception time-out for the BC message BC2EDC1Iv over 100 ms.
Solution:
rence.

BD07D130-01 1
(1) Connector C
(2) Connector A
(3) Connector EDC7
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3179-Timeout of CAN Message BC2EDC2

Cause:
1. CAN controller of the EDC reports a reception time out for the BC message BC2EDC2Iv over 100 ms.
Solution:
rence.

BD07D130-01 1
(1) Connector C
(2) Connector A
(3) Connector EDC7
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3180-Timeout of CAN Message VCM2EDC

Cause:
1. CAN controller of the EDC reports a reception time-out for the VCM message VM2EDCIv over 100 ms.
Solution:
rence.

BD07D130-01 1
(1) Connector C
(2) Connector A
(3) Connector EDC7
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3188-Cylinder 1 - Open Load

WARNING
Pressurized fluid can penetrate the skin and cause severe injuries.
The fuel in the injector is pressurized. Never put your hands or arms in front of the spray. Follow the
test procedure exactly.
W0379A
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
test fixture.
Cause:
1. Injector cable open, load error is detected over 3 camshaft revolutions.

Solution:
rence.

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BD07F080-01 1
(1) Connector C
(2) Connector A
(3) Connector EDC7
(1) Disconnect EDC connector A from engine control module. Inspect pins.
(2) Disconnect the injector connector for cylinders 1 and 2. Inspect pins.
BD08J015-01 2

(3) Check for open circuit from EDC connector A, pin 4 to injector connector pin 1, a reading of continuity should
be obtained.
(4) Check for open circuit from EDC connector A, pin 13 to injector connector pin 2, a reading of continuity
should be obtained.
of fault.
3. Check circuits from rocker housing connector to injector.
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BD08J013-01 3

(3) Check for open circuit from injector 1 leads to pins 1 and 2 of connector in rocker housing. A reading of
of fault.
4. Check injector.
should be obtained.
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WARNING
W0379A
WARNING
W0904A
test fixture.
Cause:

Solution:
rence.

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BD07F080-01 1
(1) Connector C
(2) Connector A
(3) Connector EDC7
BD08J015-01 2

be obtained.
should be obtained.
of fault.
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BD08J013-01 3

of fault.
4. Check injector.
should be obtained.
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WARNING
W0379A
WARNING
W0904A
test fixture.
Cause:

Solution:
rence.
(2) Clear all fault code.

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BD07F080-01 1
(1) Connector C
(2) Connector A
(3) Connector EDC7
BD08J014-01 2

should be obtained.
be obtained.
of fault.
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BD08J013-01 3

of fault.
4. Check injector.
should be obtained.
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WARNING
W0379A
WARNING
W0904A
test fixture.
Cause:

6. Connector pins corroded or dirty. When removing connectors inspect and clean pins. .
Solution:
rence.

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BD07F080-01 1
(1) Connector C
(2) Connector A
(3) Connector EDC7
BD08J014-01 2

should be obtained.
be obtained.
of fault.
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BD08J013-01 3

of fault.
4. Check injector.
should be obtained.
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Context:
The engine control unit (ECU) has determined that an open circuit condition exists in the Cylinder 5 injector circuit. A
the failure corresponding to the matched pattern is output. If an error message doesn't match any pattern the defect is
treated as an unclassifiable error. Monitoring is performed once per camshaft revolution. This error is the result of an
open circuit failure being present for over 3 camshaft revolutions. As a result of this error an individual cylinder or bank
is shut off, based on parameters established in the ECU. Certain parameters, as currently applied, are permanent
(without a healing possibility, once tested by switching on the component to see if the defect is still present). and
others evoke an irreversible or reversible shut off of the engine to be executed.
Cause:
Cylinder 5 injector output power driver stage.
1. Faulty injection valve or open solenoid windings.

2. Faulty electrical wiring, open circuit (damaged wiring).
Solution:
B. If the error is no longer present or is in an inactive state, return machine to proper operation.
resistance, on the engine injector harness side of connector 3, between pins 1 and 16. There should be 0.4 -
0.5 Ω.
A. If the resistance is within range, the ECU may have failed. Try reloading the ECU software and if the fault
reoccurs, replace the ECU.
B. If the resistance was significantly greater than maximum range, continue with step 3
check resistance on the injector (valve) cover side of connector VC3 from pin 3 to pin 4. There should be 0.4 -
0.5 Ω.
A. If a small amount of resistance exists, there is open circuit condition in the engine injector harness between
connector 3 and connector VC3. Locate and repair the broken conductor.
terminal 1 (high side ring terminal) Use a multi-meter to check resistance, on the Cylinder 5 injector, from terminal
1 to terminal 2. There should be 0.4 - 0.5 Ω.
A. If the resistance is within range, there is an open circuit condition in the injector harness, between con-
nector VC3 and connector for injector 5. Locate and repair the broken conductor.
B. If the resistance was significantly greater than maximum range, the Cylinder 5 injector solenoid coil has
failed. Replace the injector.
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Context:
The engine control unit (ECU) has determined that an open circuit condition exists in the Cylinder 6 injector circuit. A
the failure corresponding to the matched pattern is output. If an error message doesn't match any pattern the defect is
treated as an unclassifiable error. Monitoring is performed once per camshaft revolution. This error is the result of an
open circuit failure being present for over 3 camshaft revolutions. As a result of this error an individual cylinder or bank
is shut off, based on parameters established in the ECU. Certain parameters, as currently applied, are permanent
(without a healing possibility, once tested by switching on the component to see if the defect is still present). and
others evoke an irreversible or reversible shut off of the engine to be executed.
Cause:
Cylinder 6 injector output power driver stage.
1. Faulty injection valve or open solenoid windings.

2. Faulty electrical wiring, open circuit (damaged wiring).
Solution:

resistance, on the engine injector harness side of connector 3, between pins 2 and 15. There should be 0.4 -
0.5 Ω.
A. If the resistance is within range, the ECU may have failed. Try reloading the ECU software and if the fault
check resistance on the injector (valve) cover side of connector VC3 from pin 1 to pin 2. There should be 0.4 -
0.5 Ω.
A. If a small amount of resistance exists, there is open circuit condition in the engine injector harness between
connector 3 and connector VC3. Locate and repair the broken conductor.
terminal 1 (high side ring terminal) Use a multi-meter to check resistance, on the Cylinder 6 injector, from terminal
1 to terminal 2. There should be 0.4 - 0.5 Ω.
A. If the resistance is within range, there is an open circuit condition in the injector harness, between con-
nector VC3 and connector for injector 6. Locate and repair the broken conductor.
B. If the resistance was significantly greater than maximum range, the Cylinder 6 injector solenoid coil has
failed. Replace the injector.
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has been resolved.
ation.
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3210-Bank 1 - General Short Circuit To Injector Cable

WARNING
W0379A
WARNING
W0904A
NOTE: This diagnostic procedure requires a good quality Digital Multi-meter (DMM) to accurately measure resistance.
test fixture.
Context:
The Engine Control Unit (ECU) has determined a short circuit exists in an injector cable in Bank 1 (Group A, Cylinders
1, 2, & 3). Monitoring is performed once per camshaft revolution. This error is a result of a general short circuit of the
high side to battery or ground over 4 camshaft revolutions. This error may shut off an individual cylinder or a bank of
injectors depending on how the Engine Control Unit (ECU) is programmed.
Cause:
The Engine Control Unit (ECU) has determined that there is a fault associated with the current monitoring of an injector
output power driver stage in Bank 1.

2. Faulty electrical wiring, short high side to high source, low side or ground (damaged wiring harness).
Solution:

2. Disconnect the engine injector harness from the ECU at connector 3. Use a DMM to check the resistance on
the engine injector harness side of connector 3.
From:
1. Pin 4 to pin 13
2. Pin 11 to pin 6
3. Pin 5 to pin 12
There should be 0.4 - 0.5 Ω.
A. If the resistance was within range, leave ECU connector 3 disconnected and continue to step 8.
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B. If the resistance was below range, record the pin numbers and continue to step 3.
3. Use a DMM to check for continuity on the engine injector harness side of connector 3, from pins 4, 11, and 5 to
chassis ground. There should not be continuity.
A. If there was continuity, record the pin number and continue to step 4.
B. If there was no continuity, continue to step 6.

4. Disconnect the engine injector harness from the injector (valve) cover at connector VC1 and connector VC2.
Use a DMM to check for continuity on the injector (valve) cover side of connector :
From:
1. Connector VC1 pin 4, if recorded pin in Step 3 was pin 4, to chassis ground
2. Connector VC1 pin 1, if recorded pin in Step 3 was pin 11, to chassis ground
3. Connector VC2 pin 4, if recorded pin in Step 3 was pin 5, to chassis ground.
There should not be continuity.
A. If there was continuity, leave connector VC1 and connector VC2 disconnected. Continue to step 5.
B. If there was no continuity, there is a short to ground condition in the engine injector harness between
connector VC1 pin 4 or 1, and ECU connector 3 pin 4, or 11
or between connector VC2 pin 4 and ECU connector 3, pin 5. Locate and repair the grounded conductor.
5. Remove the injector (valve) cover and disconnect the injector harness from the injector:
For:
1. Cylinder #1 injector at connector INJ1 terminal 1 (high side ring terminal) if recorded pin in Step 3
was pin 4
2. Cylinder #2 injector at connector INJ2 if recorded pin in Step 3 was pin 11
3. Cylinder #3 injector at connector INJ3 if recorded pin in Step 3 was pin 5
Use a DMM to check for continuity, on the injector, from terminal 1 to chassis ground. There should not be
continuity.
A. If there is continuity, the injector solenoid coil has failed: replace the injector.
B. If there is no continuity, there is a short to ground condition in the injector circuit, between connector INJ1
(if recorded pin in Step 3 was pin 4), or connector INJ2 (if recorded pin in Step 3 was pin 11), and connector
VC1, pin 4, or 1 and ECU connector 3, pin 4, or 11
or connector VC2 and connector INJ3 (if recorded pin in Step 3 was pin 5) and ECU connector 3, pin 5.
Locate and repair the grounded conductor.
6. Disconnect the engine injector harness from the injector cover at connector VC1 and VC2. Use a DMM to
measure the resistance on the injector cover side of connector :
From:
1. VC1, pin 4 to 3, if recorded pins in Step 2 were pins 4 and 13
2. VC1, pin 2 to 1, if recorded pins in Step 2 were pins 11 and 6
3. VC2, Pin 3 to 4, if recorded pins in Step 2 were pins 5 and 12
There should be 0.4 - 0.5 Ω.
connector VC1, pin 4, or 1, and ECU connector 3, pin 13, or 6
or connector VC2, pin 4 and ECU connector 3 pin 12. Locate and repair the short circuit.
B. If the resistance was below range, continue to step 7

7. Remove the injector (valve) cover and disconnect the injector harness from the injector:
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For:
1. Cylinder #1 injector at connector INJ1, terminal 1 (high side ring terminal), if recorded pins in Step
2 were pins 4 and 13
2. Cylinder #2 injector at connector INJ2, if recorded pins in Step 2 were pin 11 and 6
3. Cylinder #3 injector at connector INJ3, if recorded pins in Step 2 were pins 5 and 12
Use a DMM to check for continuity, on the injector, from terminal 1 to terminal 2. There should be 0.4 - 0.5 Ω.
nector INJ1 or INJ2 and connector VC1 pin 3, or 2, ECU connector 3 pin 13, or 6
or connector INJ3 and connector VC2 pin 3, ECU connector 3, pin 12. Locate and repair the shorted
conductors.
B. If the resistance was below range, the injector solenoid coil has failed. Replace the injector.
8. Use a DMM to check for continuity, on the engine injector harness side of ECU connector 3, from pins 4, 11,
and 5 to all other populated pins in connector 3. There should not be continuity.
A. If there is continuity, record the pin numbers and use to locate and repair the shorted conductors.
B. If there is no continuity, the ECU may have failed. Attempt reloading the ECU software. If the fault reoc-
curs, replace the ECU.
has been resolved.
ation.
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3211-Bank 1 - Injector cable Short Circuit Low Side to Ground

WARNING
W0379A
WARNING
W0904A
test fixture.
Context:
The Engine Control Unit (ECU) has determined a short circuit exists in an injector cable in Bank 1 (Group A, Cylinders
1, 2, & 3).This error is a result of a general short circuit of the high side to battery or ground over 4 camshaft revolutions.
This error shuts off an individual cylinder or bank, based on ECU parameters.
Cause:
injector output power driver stage in Bank 1.
1. Faulty injection valve (solenoid coil shorted to ground).

2. Faulty electrical wiring, short low side to ground (damaged wiring).
Solution:

2. Carefully disconnect the engine injector harness from the ECU at connector 3. Use a multi-meter to check for
continuity, on the engine injector harness side of ECU connector 3 from pins 13, 6 and 12 to chassis ground.
There should not be continuity.
A. If there is continuity on any of the pins to chassis ground, record the pin number and continue with step 3.
B. If there is no continuity, the ECU may have failed. Try reloading the ECU software and if the fault reoccurs,
replace the ECU.
3. Disconnect the engine injector harness from the injector (valve) cover at connector VC1 and VC2. Use a multi-
meter to check for continuity, on the injector (valve) cover side of connector VC1 from pin 3, if recorded pin in
Step 2 was pin 13, or pin 2, if recorded pin in Step 2 was pin 6
or connector VC2 pin 3, if recorded pin in Step 2 was pin 12, to chassis ground. There should not be continuity.
A. If there was continuity to chassis ground, leave connector VC1 and VC2 disconnected, and continue with
step 4
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B. If there was no continuity to chassis ground, there is a short to ground condition in the engine injector
harness between connector VC1 pin 3 or 2 and ECU connector 3 pin 13 or 6
or between connector VC2, pin 3 and ECU connector 3, pin 12. Locate and repair the grounded conductor.
INJ1 terminal 2 (low side ring terminal), if recorded pin in Step 2 was pin 13, or disconnect the injector harness
from the Cylinder #2 injector at connector INJ2, if recorded pin in Step 2 was pin 6 or disconnect the injector
harness from the Cylinder #3 injector at connector INJ3, if recorded pin in Step 2 was pin 12. Use a multi-meter
to check for continuity, on the injector, from terminal 2 to chassis ground. There should not be continuity.
A. If there is continuity, the injector solenoid coil has failed, replace the injector.
B. If there is no continuity, there is a short to ground condition in the injector circuit, between connector INJ1,
if recorded pin in Step 2 was pin 13, or connector INJ2 if recorded pin in Step 2 was pin 6 and connector
VC1 pin 2 or 3 and ECU connector 3 pin 6 or 13
or connector INJ3, if recorded pin in Step 2 was pin 12. and connector VC2, pin 3 and ECU connector 3,
pin 12. Locate and repair the grounded conductor.
has been resolved.
ation.
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3212-Bank 1 - No Signal
WARNING
W0379A
WARNING
W0904A
test fixture.
Cause:
1. A general short circuit of the injector cable is detected over 4 camshaft revolutions.
Solution:
1. Verify that fault code is still active, refer to 0000 - Retrieving fault codes, Wheel Loaders.
rence.

2. Check circuit.
BD07D130-01 1
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(1) Connector C
(2) Connector A
(3) Connector EDC7
(1) Disconnect EDC connector A from engine controller.
(2) Inspect all pins in EDC connector A and engine controller. Clean connections.
(3) Disconnect connector for cylinders 1 and 2.
BD07E030-01 2
(1) Connector cylinders 1 and 2

(4) Inspect pins 1, 2, 3, and 4 in Connector. Clean connections.
(5) Take an Ohm reading from pin 11 EDC connector A to pin 1 cylinders 1 and 2 Connector.
BD07E029-01 3

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BD07E028-01 4

of fault.
3. Check circuit.
BD07E034-01 5
(1) Injector cylinder 1

(2) Disconnect leads from number 1 and 2 injector.
(3) From injector leads to pins 1, 2, 3, and 4 at connector in rocker housing.
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BD07E033-01 6

BD07E032-01 7

of fault.
4. Check injector.
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BD07E034-01 8

(2) Take an Ohm reading between terminals on number 1 and number 2 injector, a reading of 0.5 - 1.0 Ω on
each injector at 20 °C (68.0 °F) should be obtained.
BD07E033-01 9

BD07E032-01 10

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A. NOT OK – Replace injectors as needed. Return to Step 1 to confirm elimination of fault.
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3213-Bank 1 - Unclassifiable Error

WARNING
W0379A
WARNING
W0904A
test fixture.
Cause:
1. An unclassifiable error in the injector cable is present over 9 camshaft revolutions.

Solution:
rence.

2. Check circuits from engine controller to injector connectors.
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BD07F080-01 1
(1) Connector C
(2) Connector A
(3) Connector EDC7
(2) Disconnect the injector connectors for cylinders 1 and 2. Inspect pins.
BD08J015-01 2

be obtained.
should be obtained.
be obtained.
should be obtained.
(7) Disconnect the injector connectors for cylinders 3 and 4. Inspect pins.
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BD08J014-01 3

(8) Check for open circuit from EDC connector, pin 16 to injector connector pin 1, a reading of continuity should
be obtained.
(9) Check for open circuit from EDC connector, pin 1 to injector connector pin 2, a reading of continuity should
be obtained.
should be obtained.
be obtained.
of fault.
3. Check circuits from rocker housing connector to injectors 1 and 2.
BD08J013-01 4

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(4) Check for short circuit between pins 1 and 2 of connector in rocker housing. An open circuit should be
obtained.
obtained.
(7) Check for short circuit between pins 1, 2, 3, and 4 of connector in rocker housing and ground. An open circuit
should be obtained.
BD08J013-01 5

obtained.
obtained.
should be obtained.
5. Check injectors.
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(1) Disconnect leads from number 1 and 2 injector. NOTE: When installing leads on injectors, torque terminal
nuts to general bolt torque specifications.
(2) Take an Ohm reading between terminals on number 1 and number 2 injectors, a reading of 0.5 - 1.0 Ω at 20
°C (68.0 °F) should be obtained across each injector.
(4) Take an Ohm reading between terminals on number 3 and 4 injectors, a reading of 0.5 - 1.0 Ω at 20 °C (68.0
°F) should be obtained across each injector.
A. NOT OK— Replace injectors as needed. Return to Step 1 to confirm elimination of fault.
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3218-Bank 2 - General Short Circuit On Injector Cable

WARNING
W0379A
WARNING
W0904A
test fixture.
Cause:

Solution:
rence.

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BD07F080-01 1
(1) Connector C
(2) Connector A
(3) Connector EDC7
(1) Disconnect EDC connector A, from engine control module. Inspect pins.
BD08J015-01 2

(3) Check for open circuit from pin 4 Connector A to pin 1 on the injector connector, a reading of continuity
should be obtained.
(4) Check for open circuit from pin 13 Connector A to pin 2 on the injector connector,a reading of continuity
should be obtained.
(5) Check for open circuit from pin 2 Connector A to pin 3 on the injector connector,a reading of continuity should
be obtained.
should be obtained.
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BD08J014-01 3

should be obtained.
(9) Check for open circuit from pin 1 Connector A to pin 2 on the injector connector,a reading of continuity should
be obtained.
should be obtained.
should be obtained.
of fault.
BD08J013-01 4

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obtained.
obtained.
should be obtained.
BD08J013-01 5

obtained.
obtained.
should be obtained.
5. Check injectors.
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3219-Bank 2 - Injector Cable Short Circuit Low Side To Ground

WARNING
W0379A
WARNING
W0904A
test fixture.
Context:
The Engine Control Unit (ECU) has determined a short circuit exists in an injector cable in Bank 2 (Group B, Cylin-
ders 4, 5, & 6). This error is a result of a general short circuit of the high side to battery or ground over 4 camshaft
revolutions. This error shuts off an individual cylinder or bank, based on ECU parameters.
Cause:
injector output power driver stage in Bank 2.

Solution:
rence.

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BD07F080-01 1
(1) Connector C
(2) Connector A
(3) Connector EDC7
BD08J015-01 2

be obtained.
should be obtained.
be obtained.
should be obtained.
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BD08J014-01 3

should be obtained.
be obtained.
should be obtained.
be obtained.
of fault.
BD08J013-01 4

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obtained.
obtained.
should be obtained.
BD08J013-01 5

obtained.
obtained.
should be obtained.
5. Check injectors.
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3220-Bank 2 No Signal
test fixture.
Cause:
1. A general short circuit of the injector cable is detected over 4 camshaft revolutions.
Solution:
rence.

2. Check circuit.
BD07D130-01 1
(1) Connector C
(2) Connector A
(3) Connector EDC7
(1) Disconnect EDC connector A from engine controller.
(2) Inspect all pins in EDC connector A and engine controller. Clean connections.
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BD07E030-01 2

BD07E029-01 3

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BD07E028-01 4

(19) Take an Ohm reading from pin 1 EDC connector to pin 3 cylinders 5 and 6 Connector.
of fault.
3. Check circuit.
BD07E034-01 5

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BD07E033-01 6

BD07E032-01 7

of fault.
4. Check injector.
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BD07E034-01 8

BD07E033-01 9

BD07E032-01 10

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A. NOT OK – Replace injectors as needed. Return to Step 1 to confirm elimination of fault.
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3221-Bank 2 - Unclassifiable Error

WARNING
W0379A
WARNING
W0904A
test fixture.
Cause:

Solution:
rence.

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BD07F080-01 1
(1) Connector C
(2) Connector A
(3) Connector EDC7
(2) Disconnect injector connectors for cylinders 1 and 2. Inspect pins.
BD08J015-01 2

(3) Check for open circuit from EDC connector A, pin 4 to pin injector connector 1, a reading of continuity should
be obtained.
should be obtained.
be obtained.
should be obtained.
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BD08J014-01 3

should be obtained.
be obtained.
should be obtained.
be obtained.
of fault.
BD08J013-01 4

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obtained.
obtained.
should be obtained.
BD08J013-01 5

obtained.
obtained.
should be obtained.
5. Check injectors.
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55.DTC / 311
3227-Injection Processor Error - Internal Reset/Clock Loss/Voltage

Too Low
Context:
The engine control unit (ECU) has sensed a problem with the internal supply voltage for Fuel Injector Group “A”, the
fault path for errors in the power stage component of the unit injection system. The power stage monitors itself and
reports detected errors to the ECU. Monitoring is performed once per camshaft revolution. If an internal reset or parity
error is present longer than 3 camshaft revolutions , this error will occur. As a result of this error an individual cylinder
or bank is shut off. This shut off is currently applied to be permanent without a healing possibility by switching on the
component to see if the defect is still present. With either an irreversible or reversible shut off of the engine being
executed. The reason for this failure is a defective ECU. If the fault doesn't reset or reoccurs, replace the ECU.
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3228-Injection Processor Error - Unlocked/Initialization Error

Context:
reports detected errors to the ECU. Monitoring is performed once per camshaft revolution. If an internal program flow
error exists for longer than 3 camshaft revolutions , this error will occur. As a result of this error an individual cylinder
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3229-Injection Processor Error - Injections Limited By Software

Context:
reports detected errors to the ECU. Monitoring is performed once per camshaft revolution. If the YSEL signal is not
inverted as requested during injection for longer than 3 camshaft revolutions , this error will occur. As a result of this
error an individual cylinder or bank is shut off. This shut off is currently applied to be permanent without a healing
possibility by switching on the component to see if the defect is still present. With either an irreversible or reversible
shut off of the engine being executed. The reason for this failure is a defective ECU. If the fault doesn't reset or
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3230-Injection Processor Error - SPI Communication Failure

Context:
reports detected errors to the ECU. Monitoring is performed once per camshaft revolution. If the power stage compo-
nent On Time-out is present for at least one cylinder for longer than 3 camshaft revolutions , this error will occur. As a
result of this error an individual cylinder or bank is shut off. This shut off is currently applied to be permanent without
a healing possibility by switching on the component to see if the defect is still present. With either an irreversible or
reversible shut off of the engine being executed. The reason for this failure is a defective ECU. If the fault doesn't
reset or reoccurs, replace the ECU.
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3231-Injection Processor Error - Internal Reset/Clock Loss/Voltage

Too Low
Context:
The engine control unit (ECU) has sensed a problem with the internal supply voltage for Fuel Injector Group “B”, the
reports detected errors to the ECU. Monitoring is performed once per camshaft revolution. An internal reset or parity
error present longer than 3 camshaft revolutions, will produce this error. As a result of this error an individual cylinder
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3232-Injection Processor Error - Unlocked/Initialization Failure

Context:
The engine control unit (ECU) has sensed a problem with the internal supply voltage for Fuel Injector Group “B”, the
reports detected errors to the ECU. Monitoring is performed once per camshaft revolution. If an internal program flow
error exists for longer than 3 camshaft revolutions , this error will occur. As a result of this error an individual cylinder
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3233-Injection Processor Error - Test Mode

Context:
The engine control unit (ECU) has sensed a problem with the internal supply for Fuel Injector Group “B”, the fault
path for errors in the power stage component of the unit injection system. The power stage monitors itself and reports
detected errors to the ECU. Monitoring is performed once per camshaft revolution. If the power stage component
On Time-out is present for at least one cylinder for longer than 3 camshaft revolutions , this error will occur. As a
result of this error an individual cylinder or bank is shut off. This shut off is currently applied to be permanent without
a healing possibility by switching on the component to see if the defect is still present. With either an irreversible or
reversible shut off of the engine being executed. The reason for this failure is a defective ECU. If the fault doesn't
reset or reoccurs, replace the ECU.
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3234-Injection Processor Error - SPI Communication Failure

Context:
The engine control unit (ECU) has detected that injection time is too long. The sum of all torque-forming energizing
times of an individual cylinder exceeds the limit, calculated from the map (depending on the engine speed and the
time since the overrun monitoring is active) for more than 100 test events (test frequency every 10 ms). When the
engine is in overrun operation the monitoring becomes active and the current injection energizing time is compared
with a maximum permissible time limit. If the limit is exceeded an ECU recovery (reset ) is triggered and if the error
reoccurs in the same driving cycle, the torque-determining power stages are irreversibly shut off. The basic idea is
that the operator reacts to an unintentional torque increase, caused by a malfunction of the ECU, by releasing the
accelerator pedal (reducing engine speed) which causes the engine to enter the overrun operation mode. Overrun
monitoring is only released if various conditions are met, such as no accelerator pedal activation, no activated cruise
control, no intervention of the vehicle dynamic control or gearbox control is present, etc. This failure could be the
result of electronic disturbances, a requested torque increase via tester, the wrong application of injection relevant
parameters, or a defective ECU. If this failure persists, the ECU may need to be replaced.
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3238-Communication error of CJ940 processor

Context:
The engine control unit (ECU) has detected an internal communications error. Internal communications between
the micro-controller and each CJ940 module (peripheral integrated circuit) via the SPI bus is monitored cyclically
every 20 milliseconds by evaluating the corresponding communication error flag which is provided by the hardware
encapsulation. For every test an error counter is increased or decreased in steps of one. If the error counter for
defective SPI buss communications reaches or exceeds a value of 5 this error becomes active and will reset once the
error counter is equal to or below the value of 0 (zero). This error is caused by electrical disturbances or an internal
defect of the ECU. If failure remains present, replace the ECU.
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3242-Engine Controller (Locked) Recovery Occurred

Context:
The engine control unit (ECU) has detected, during system start up, a hardware or configuration problem. This triggers
an ECU recovery (reset of the CPU - Central Processing Unit) that is stored as protected. During a fresh ECU start
up different hardware tests are performed. If the error remains present even after reset, the software remains in the
boot-block and the driving software is not processed. If three recoveries are triggered within 4 seconds an irreversible
shut off of the system is carried out and the ECU is classified as permanently defective. In this case no error entry is
possible. If, however, the error leading to recovery is not detected repeatedly and the system is allowed to start up,
one of three recovery errors becomes active depending on the visibility of the recovery. This error can be the result
of electronic disturbances, various hardware defects (ECU internal) or configuration problems. If this error occurs
repeatedly, reprogram the ECU and if the error remains, replace the ECU.
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3243-Engine Controller Recovery (Suppressed) - Recovery

Occurred
Context:
an ECU recovery (reset of the CPU - Central Processing Unit) that is not stored. During a fresh ECU start up different
hardware tests are performed. If the error remains present even after reset, the software remains in the boot-block
and the driving software is not processed. If three recoveries are triggered within 4 seconds an irreversible shut
off of the system is carried out and the ECU is classified as permanently defective. In this case no error entry is
possible. If, however, the error leading to recovery is not detected repeatedly and the system is allowed to start up,
one of three recovery errors becomes active depending on the visibility of the recovery. This error can be the result
of electronic disturbances, various hardware defects (ECU internal) or configuration problems. If this error occurs
repeatedly, reprogram the ECU and if the error remains, replace the ECU.
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3244-Engine Controller Recovery (Visible) - Recovery Occurred

Context:
an ECU recovery (reset of the CPU - Central Processing Unit) that is visible in the error memory. During a fresh ECU
start up different hardware tests are performed. If the error remains present even after reset, the software remains
in the boot-block and the driving software is not processed. If three recoveries are triggered within 4 seconds an
irreversible shut off of the system is carried out and the ECU is classified as permanently defective. In this case no
error entry is possible. If, however, the error leading to recovery is not detected repeatedly and the system is allowed
to start up, one of three recovery errors becomes active depending on the visibility of the recovery. This error can be
the result of electronic disturbances, various hardware defects (ECU internal) or configuration problems. If this error
occurs repeatedly, reprogram the ECU and if the error remains, replace the ECU.
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3245-Engine Controller - Watchdog Not Plausible

Context:
The engine control unit (ECU) has detected a fault in the internal monitoring circuitry. The ECU contains a CPU (central
processing unit) and other microprocessor based circuitry one of which serves as a monitoring module (watchdog).
These two components communicate via the internal communications network (SPI-Bus). Both devices mutually
monitor one another for correct functioning. The watchdog initiates a query / response communication with the CPU,
which responds by starting a "command test" (test of the correct functioning of important processor commands) and
"program flow control" (monitors the correct execution of code segments of the monitoring). From the results of these
two procedures the response to the watchdog is composed. If this response does not correspond to the expected
value, an error counter is incremented. The CPU periodically sends incorrect responses (regarding response time
and value, respectively) as result of the watchdog query / response. The CPU then monitors if the above mentioned
counter is incremented or decremented in accordance with the incorrect or correct response. If the behavior of the
counter is implausible, a second counter is incremented. This monitoring process is executed every 80 ms. This error
is the result of one of the counters exceeding a count of 5 and will reset if both counters contain a value less than 5.
If the error exists only temporarily, it can be ignored and deleted in the fault memory. If the error is permanent, engine
injection will not be allowed and the ECU must be replaced.
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3246-Shutoff Paths During Initialization - Watchdog

Context:
The engine control unit (ECU) has detected an internal watchdog error. The ECU comprises redundant shutoff paths
(SOP) which deactivate all power stages relevant to injection if certain internal ECU errors are detected. The defects
which trigger SOP are the watchdog, over voltage and under voltage errors. In order to test the correct functioning
of the SOP procedure, every path is activated during ECU initialization and followed by activation of the fuel injection
power stage. Since the SOP is active, no injection should occur as it is blocked if the SOP procedure functions
properly. During a successful redundant SOP test an open circuit (no current flow) should be detected. The SOP test
can only be carried out if no errors, such as short circuits of the injection power stage, have been detected previously.
This fault is detected if injection occurred although internal SOP of the watchdog was active. If the failure remains
after ECU initialization, replace the ECU.
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3247-Shutoff Paths Failed During Initialization - Supply Voltage

Too High
Context:
The engine control unit (ECU) has detected that the internal supply voltage is too high. The ECU comprises redundant
shut-off paths (SOP) which deactivate all power stages relevant to injection if certain internal ECU errors are detected.
The defects which trigger SOP are the watchdog, over voltage and under voltage errors. In order to test the correct
functioning of the SOP procedure, every path is activated during ECU initialization and followed by activation of the
fuel injection power stage. Since the SOP is active, no injection should occur as it is blocked if the SOP procedure
functions properly. During a successful redundant SOP test an open circuit (no current flow) should be detected. The
SOP test can only be carried out if no errors, such as short circuits of the injection power stage, have been detected
previously. This fault is detected if injection occurred although internal SOP of the over-voltage was active. If the
failure remains after ECU initialization, replace the ECU.
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3248-Shutoff Paths During Initialization - Supply Voltage Too Low

Context:
The engine control unit (ECU) has detected that the internal supply voltage is too low. The ECU comprises redundant
shutoff paths (SOP) which deactivate all power stages relevant to injection if certain internal ECU errors are detected.
The defects which trigger SOP are the watchdog, over voltage and under voltage errors. In order to test the correct
functioning of the SOP procedure, every path is activated during ECU initialization and followed by activation of the
fuel injection power stage. Since the SOP is active, no injection should occur as it is blocked if the SOP procedure
functions properly. During a successful redundant SOP test an open circuit (no current flow) should be detected. The
SOP test can only be carried out if no errors, such as short circuits of the injection power stage, have been detected
previously. This fault is detected if injection occurred although internal SOP of the under-voltage was active. If the
failure remains after ECU initialization, replace the ECU.
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3253-ADC Monitoring - Reference Voltage Too Low

Cause:
1. Internal ECU error.
Solution:
rence.

2. Reset Engine Control Unit (ECU).
(1). Reset Engine Control Unit (ECU) by turning ignition switch OFF then back to the ON position.
B. NOT OK - Go to Step 3.
3. Replace ECU (Engine Control Unit).
(1). Remove and replace ECU (Engine Control Unit).
for assistance.
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3254-ADC Monitoring - Reference Voltage Too High

Cause:
1. Internal ECU error
Solution:
rence.

(1). Reset Engine Control Unit (ECU) by turning ignition switch OFF then back to the ON position.
(1). Remove and replace ECU (Engine Control Unit).
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3255-ADC Monitoring Test Impulse Error

Cause:
Solution:
rence.

2. Reset engine control module by turning ignition switch off then back on.
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55.DTC / 330
3256-ADC Monitoring Queue Error

Cause:
Solution:
rence.

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55.DTC / 331
3258-HS power stage hardware reports 'short circuit to battery'

longer than 500 ms.
test fixture.
Cause:
1. HS power stage hardware reports “short circuit to battery” longer than 500 ms.
Solution:
rence.

2. Remove crank control relay from Connector ECB (Electrical Center B).
BD07E018-01 1
(1) Electrical center A

(2) Electrical center C
(3) Electrical center B
(4) Electrical center D
(1) Inspect pins on crank control relay and relay panel. Clean connections.
(2) Disconnect Connector EDC7 from engine controller.
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BD07D130-01 2
(1) Connector C
(2) Connector A
(3) Connector EDC7
(4) Take Ohm reading from pin A9 at Connector ECB to pin 17 Connector EDC7.
(5) Take Ohm reading from pin AA10 at Connector ECB to pin 37 Connector EDC7.
BD07E021-01 3
(1) Connector CAB-E

(2) Connector ENG
(6) If circuit is open, check from pin A9 at Connector ECB to pin 4 of Connector CAB-E.
(7) From pin 4 of Connector CAB-E to pin 17 of Connector EDC7.
(8) Check from pin AA10 at Connector ECB to pin 3 of Connector CAB-E.
of fault.
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3259-HS power stage hardware reports 'short circuit to ground'

longer than 100 ms.
Cause:
1. HS power stage hardware reports 'short circuit to ground' longer than 100 ms.
Solution:
rence.

BD07E018-01 1

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BD07D130-01 2
(1) Connector C
(2) Connector A
(3) Connector EDC7
BD07E021-01 3
(1) Connector CAB-E

(2) Connector ENG
of fault.
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3260-LS power stage hardware reports 'open load' longer than

100 ms
Cause:
1. LS power stage hardware reports 'open load' longer than 100 ms.
Solution:
rence.

BD07E018-01 1

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BD07D130-01 2
(1) Connector C
(2) Connector A
(3) Connector EDC7
BD07E021-01 3
(1) Connector CAB-E

(2) Connector ENG
of fault.
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3261-LS power stage hardware reports 'short circuit to battery' or

'excess temperature' longer than 100 ms.
Cause:
1. LS power stage hardware reports 'short circuit to battery' or 'excess temperature' longer than 100 ms.
Solution:
rence.

BD07E018-01 1

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BD07D130-01 2
(1) Connector C
(2) Connector A
(3) Connector EDC7
BD07E021-01 3
(1) Connector CAB-E

(2) Connector ENG
of fault.
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3262-LS power stage hardware reports 'short circuit to ground'

longer than 100 ms.
Cause:
1. LS power stage hardware reports 'short circuit to ground' longer than 100 ms.
Solution:
rence.

2. Remove crank control relay from Connector ECB.
BD07E018-01 1

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BD07D130-01 2
(1) Connector C
(2) Connector A
(3) Connector EDC7
(4) Take Ohm reading from pin A9 at Connector ECB o pin 17 Connector EDC7.
BD07E021-01 3
(1) Connector CAB-E

(2) Connector ENG
of fault.
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3265-Energizing time exceeds limit of over run monitoring, injection

time too long
Context:
The engine control unit (ECU) has detected that injection time is too long. The sum of all torque-forming energizing
times of an individual cylinder exceeds the limit, calculated from the map (depending on the engine speed and the
time since the overrun monitoring is active) for more than 100 test events (test frequency every 10 ms). When the
engine is in overrun operation the monitoring becomes active and the current injection energizing time is compared
with a maximum permissible time limit. If the limit is exceeded an ECU recovery (reset ) is triggered and if the error
reoccurs in the same driving cycle, the torque-determining power stages are irreversibly shut off. The basic idea is
that the operator reacts to an unintentional torque increase, caused by a malfunction of the ECU, by releasing the
accelerator pedal (reducing engine speed) which causes the engine to enter the overrun operation mode. Overrun
monitoring is only released if various conditions are met, such as no accelerator pedal activation, no activated cruise
control, no intervention of the vehicle dynamic control or gearbox control is present, etc. This failure could be the
result of electronic disturbances, a requested torque increase via tester, the wrong application of injection relevant
parameters, or a defective ECU. If this failure persists, the ECU may need to be replaced.
Cause:
Internal ECU error
Solution:
rence.

(1) Reset Engine Control Unit (ECU) by turning ignition switch OFF then back to the ON position.
(1) Remove and replace ECU (Engine Control Unit).
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3266-Error in engine speed check, speed signal not plausible

Context:
The engine control unit (ECU) has determined that the speed signal is not plausible. In order to execute an overrun
monitoring, which checks if the injection energizing time is below a certain limit during overrun, the information of the
current engine speed is required. As the overrun monitoring is executed in layer 2 of the ECU monitoring concept (i.e.
function monitoring) in order to monitor the safety-relevant signal paths of the operational layer (layer 1, application
software) a redundant engine speed is additionally calculated in layer 2, independent of the engine speed information
of layer 1. If the absolute value of the deviation between engine speed (layer 1) and redundant segment speed (layer
2) exceeds 320 RPM over 800 ms (test frequency is every 40 ms), while the redundant segment speed is above 1000
RPM this error is activated, which triggers an ECU recovery (reset). If this failure persists after ECU re-initialization,
replace the ECU.
Cause:
1. Internal ECU error. .
Solution:
rence.

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3278-Engine Controller Internal Supply Voltage Too High

NOTE: Check alternator output voltage, if above 28 volts refer to Alternator - Testing (55.301) and troubleshoot
charging system before proceeding. See engine repair manual for electrical schematic information.
Cause:

Solution:
rence.

BD07D130-01 1
(1) Connector C
(2) Connector A
(3) Connector EDC7
(2) Inspect pins on EDC7 connector and control module. Clean connections.
A. NOT OK – Voltage is approximately equal to 0 volts. Check fuse F2 in PRM D(Power relay module D).
Return to Step 1 to confirm elimination of fault.
B. NOT OK – Voltage is greater than 28 volts, refer to Alternator - Testing (55.301) and troubleshoot the
charging system. Return to Step 1 to confirm elimination of fault.
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C. OK – Go to Step 3.
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3279-Engine Controller Internal Supply Voltage Too Low

NOTE: Check alternator output voltage, if lower than 10 volts refer to Alternator - Testing (55.301) and trouble shoot
Cause:

Solution:
rence.

BD07D130-01 1
(1) Connector C
(2) Connector A
(3) Connector EDC7
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3280-Sensor Supply Voltage 1 - High

test fixture.
Cause:
1. The ECU has detected the sensor voltage supply 1 has exceed the upper limit for a period greater than 100 ms.
Solution:
rence.

BD07D130-01 1
(1) Connector C
(2) Connector A
(3) Connector EDC7
(1) Turn ignition OFF. Disconnect Engine Controller connector EDC7. from engine controller.
(2) Inspect pins on EDC7 connector and controller. Clean connections.
(4) Check pins 2, 3, 8, and 9 of EDC7 connector to ground, a reading of 24 volts should be obtained.
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3281-Sensor Supply Voltage 1 - Low

test fixture.
NOTE: Check alternator output voltage, if below 24 volts refer to Alternator - Testing (55.301) and troubleshoot
Cause:
1. The hardware has detected the sensor voltage supply 1 to be below a lower limit over 100 ms.
Solution:
rence.

BD07D130-01 1
(1) Connector C
(2) Connector A
(3) Connector EDC7
(1) Turn ignition OFF. Disconnect EDC7 connector from the Engine Controller.
(2) Inspect pins on Engine Controller connector, EDC7.
(4) Check pins 2, 3, 8, and 9 on Engine Controller connector, EDC7 to ground, a reading of 24 volts should be
obtained.
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for assistance.
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test fixture.
Cause:
1. The hardware has detected the sensor voltage supply 2 to exceed an upper limit over 100 ms.
Solution:
rence.

BD07D130-01 1
(1) Connector C
(2) Connector A
(3) Connector EDC7
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test fixture.
Cause:
Solution:
rence.

BD07D130-01 1
(1) Connector C
(2) Connector A
(3) Connector EDC7
obtained.
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test fixture.
Cause:
1. The hardware has detected the sensor voltage supply 3 to exceed an upper limit over 100 ms.
Solution:
rence.

BD07D130-01 1
(1) Connector C
(2) Connector A
(3) Connector EDC7
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test fixture.
Cause:
Solution:
rence.

BD07D130-01 1
(1) Connector C
(2) Connector A
(3) Connector EDC7
obtained.
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3998-Unknown error
Cause:
1. An error has occurred that is not identified in the Instrument Cluster program.
Solution:
rence.
A. NOT OK – Fault code is recorded again. Go to Step 2.

BD07D130-01 1
(1) Connector C
(2) Connector A
(3) Connector EDC7
3. (1) Use the "EASY" program in the EST tool to bring up the fault.
(2) The fault number will be unique for the engine controller.
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(3) Use the fault description to analyze the error, contact TSG for further assistance.
(4) If no text or unique engine controller fault is found but the fault is still appears on the AIC, replace the Instru-
ment Cluster.
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3999-Unknown error
Cause:
1. An error has occurred that is not identified in the AIC program.

Solution:
rence.
A. NOT OK – Fault code is recorded again. Go to Step 2.

BD07D130-01 1
(1) Connector C
(2) Connector A
(3) Connector EDC7
3. (1) Use the "EASY" program in the EST tool to bring up the fault.
(2) The fault number will be unique for the engine controller.
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(3) Use the fault description to analyze the error, contact TSG for further assistance.
(4) If no text or unique engine controller fault is found but the fault is still appears on the AIC, contact TSG for
further assistance.
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4113-Logical error at FNR switch

NOTICE: Check fuses ECA F1 and ECC F10, replace as needed.
Cause:
1. FNR switch faulty.

Solution:
rence.

2. Check power circuit to FNR switch.
BD07D168-01 1
(1) Connector TS1

(2) Connector TS2
(1) Disconnect Connector TS1, turn ignition switch on.
(2) Inspect pin A on Connector TS1. Clean connections.
(3) Take a voltage reading at pin A Connector TS1, a reading of 24 volts should be obtained.
A. NOT OK — Check fuse ECA F1. Return to Step1 to confirm elimination of fault.
B. OK — Go to step 3.
3. Check circuit 19A.
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BD07E018-01 2

(1) Take an Ohm reading from pin A Connector TS1 to pin A1 Connector ECA.
(2) If circuit is open, take an Ohm reading from pin A Connector TS1 to pin M Connector SPL-TRNS-PWR.
BD07E035-01 3
(1) Connector SPL-TRNS-PWR

(2) Switch console
(3) From pin A Connector SPL-TRNS-PWR to pin A1 Connector ECA.
A. NOT OK — Determine the break between connectors and repair. Return to Step1 to confirm elimination
of fault.
4. Check gear selection at FNR switch.
BD07D168-01 4
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(1) Connector TS1

(2) Connector TS2
(1) Disconnect Connector TS1 and Connector TS2.
(2) Inspect all pins on Connector TS1 and Connector TS2. Clean connections.
(3) Take Ohm readings as listed below, continuity should be obtained.
(4) Place range selector in 1st gear, place FNR in F position. Pin A to pin B of Connector TS1, pin B and pin D
of Connector TS2.
(5) Place range selector in 1st gear, place FNR in R position. Pin A to pin C of Connector TS1, pin B and pin D
of Connector TS2.
(6) Place range selector in 2nd gear, place FNR in F position. Pin A to pin B of Connector TS1 and pin D of
Connector TS2.
(7) Place range selector in 2nd gear, place FNR in R position. Pin A to pin C of Connector TS1, and pin D of
Connector TS2.
(8) Place range selector in 3rd gear, place FNR switch F position. Pin A to pin B of Connector TS1, pin C and
pin D of Connector TS2.
(9) Place range selector in 3rd gear, place FNR in R position. Pin A to pin C of Connector TS1, pin C and pin D
of Connector TS2.
(10) Place range selector in 4th gear, place FNR in F position. Pin A to pin B of Connector TS1, pin B, pin C
and pin D of Connector TS2.
(11) Place the range selector in any gear, place the FNR in N position. Pin A to pin D of Connector TS1.
A. NOT OK — Replace FNR switch. Return to step1 to confirm elimination of fault.
5. Check for open circuit between FNR switch and transmission control module.
BD07D168-01 5
(1) Connector TS1

(2) Connector TS2
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BD07E019-01 6
(1) Transmission control module

(2) Flasher module
(3) Time delay module
(2) Disconnect Connector TECM from transmission control module.
(3) Inspect pins 22, 43, 63, 64, and 65 on Connector TECM. Clean connections.
(4) Check for continuity in the following circuits.
(5) Check for open circuit between pin B of Connector TS1 and pin 43 of Connector TECM.
(6) Check circuit between pin C of Connector TS1and pin 64 of Connector TECM.
(7) Check circuit between pin B of Connector TS2 and pin 65 of Connector TECM.
(8) Check circuit between pin C of Connector TS2 and pin 63 of Connector TECM.
(9) Check circuit between pin D of Connector TS2 and pin 22 of Connector TECM.
A. NOT OK — Determine break between connectors and repair. Return to Step 1 to confirm elimination of
fault.
B. OK — Go to Step 6.
(1). Remove and replace control module.

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4114-Logical error at direction select signal

Cause:

Solution:
rence.

BD07D168-01 1
(1) Connector TS1

(2) Connector TS2
(1) Disconnect Connector TS1, turn ignition switch on.
A. OK — Go to step 3.
B. NOT OK — Check fuse ECA F1 in (electrical center A). Return to Step1 to confirm elimination of fault.
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BD07E018-01 2

BD07E035-01 3

(2) Switch console
B. NOT OK — Determine the break between connectors and repair. Return to Step1 to confirm elimination
of fault.
BD07D168-01 4
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(1) Connector TS1

(2) Connector TS2
(3) Take Ohm readings as listed below, continuity should be obtained.
(4) Place range selector in 1st gear, place FNR in F position. Pin A to pin B of Connector TS1, pin B and pin D
of Connector TS2.
(5) Place range selector in 1st gear, place FNR in R position. Pin A to pin C of Connector TS1, pin B and pin D
of Connector TS2.
(6) Place range selector in 2nd gear, place FNR in F position. Pin A to pin B of Connector TS1 and pin D of
Connector TS2.
(7) Place range selector in 2nd gear, place FNR in R position. Pin A to pin C of Connector TS1, and pin D of
Connector TS2.
(8) Place range selector in 3rd gear, place FNR switch F position. Pin A to pin B of Connector TS1, pin C and
pin D of Connector TS2.
(9) Place range selector in 3rd gear, place FNR in R position. Pin A to pin C of Connector TS1, pin C and pin D
of Connector TS2.
(10) Place range selector in 4th gear, place FNR in F position. Pin A to pin B of Connector TS1, pin B, pin C
and pin D of Connector TS2.
(11) Place the range selector in any gear, place the FNR in N position. Pin A to pin D of Connector TS1.
B. NOT OK — Replace FNR switch. Return to step1 to confirm elimination of fault.

BD07D168-01 5
(1) Connector TS1

(2) Connector TS2
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BD07E019-01 6

(2) Flasher module
(4) Check for continuity in the following circuits.
B. NOT OK — Determine break between connectors and repair. Return to Step 1 to confirm elimination of
fault.
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4116-Logical error at park brake status

NOTICE: Check fuses F1 and F6 in ECA, check fuses in PRM-A, replace fuses as needed.
Cause:
1. Park brake switch faulty.

Solution:
1. Find out if the fault code is still active, refer to 0000 - Retrieving fault codes, Wheel Loaders.
rence.

2. Check park brake relay.
BD07E018-01 1

(1). Remove park brake relay K5 from Connector ECB (electrical center B).
(2). Replace park brake relay with a known good relay.
B. NOT OK — Go to Step 3.
C. OK — Replace defective relay.

3. Check power circuit park brake relay.
(1). Take voltage reading at pin B9 Connector ECB, a reading of 24 volts should be obtained.
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A. NOT OK — Check fuse ECA F1 in (electrical center A). Return to Step 1. to confirm elimination of fault.
4. Check function of park brake switch.
BD07E012-01 2
(1) Park brake switch

(2) Connector SPB
(1). Disconnect Connector SPB.
(2). Inspect all pins on Connector SPB. Clean connections.
(3). Place park brake switch in the release park brake position, measure between pins 2 and 3 on switch there
should be continuity.
A. NOT OK— Replace park brake switch. Return to Step 1 to confirm elimination of fault.
5. Check power circuit to park brake switch.
BD07E012-01 3

(2) Connector SPB
(2). Turn ignition switch on.
(3). Take a voltage reading at pin 2 Connector SPB, a reading of 24 volts should be obtained.
A. NOT OK— Check fuse F1 in Connector ECA, if fuse is not blown go to Step 6, if fuse is blown replace and
return to Step 1 to confirm elimination of fault.
B. OK— If you have power at the park brake switch go to Step 7.

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BD07E018-01 4

(1). Take an Ohm reading from pin 2 Connector SPB to pin A1 Connector ECA.
BD07E035-01 5

(2) Switch console
(2). If circuit is open, take an Ohm reading from pin 2 Connector SPB to pin L Connector SPL-TRNS-PWR.
(3). From pin A Connector SPL-TRNS-PWR to pin A1 Connector ECA.
of fault.
7. Check circuit between park brake switch and instrument cluster.
BD07E012-01 6
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(2) Connector SPB
BD07D128-01 7
(1) Connector AIC-2

(2) Connector AIC-1
(2). Disconnect Connector AIC-2 from instrument cluster.
(3). Inspect pin 6 on Connector AIC-2. Clean connections.
(4). Check circuit between pin 3 of Connector SPB and pin 6 of Connector AIC-2 there should be continuity.
A. NOT OK— Determine break between connectors and repair. Return to Step 1 to confirm elimination of
fault.
8. Check for open circuit between instrument cluster and park brake relay.
BD07D128-01 8
(1) Connector AIC-2

(2) Connector AIC-1
(1). Disconnect Connector AIC-1.
(2). Inspect pin 14 on Connector AIC-1. Clean connections.
(3). Check circuit between pin 10 of Connector ECB and pin 14 of Connector AIC-1 there should be continuity.
fault.
9. Check for open circuit between park brake relay and park brake solenoid.
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BD07E018-01 9

(1). Remove the park brake relay K5 from Connector ECB.
BD07F014-01 10
(1) Brake valve

(2) Brake warning switch
(3) Park brake solenoid
(4) Brake light switch
(2). Disconnect Connector YPB from park brake solenoid.
(3). Inspect pins on Connector YPB. Clean connections.
(4). Check for open circuit between pin B10 of Connector ECB and pin 1 of Connector YPB.
BD07E021-01 11
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(1) Connector Front

(2) Connector CAB-F
(5). If circuit is open check from pin B10 of Connector ECB to pin 24 of Connector CAB-F.
(6). From pin 1 of Connector YPB to pin 24 of Connector FRONT.
A. NOT OK— Determine break between connectors and repair. Return to 1 to confirm elimination of fault.
B. OK— Go to 10.
10. Check ground circuit of park brake solenoid.
BD07F014-01 12
(1) Brake valve

(3). Check for open circuit between pin 2 of Connector YPB and ground.
BD07F016-01 13
(4). If circuit is open check grounding stud connections at GND-FC.
A. NOT OK— Determine break between connectors and repair. Return to Step1 to confirm elimination of
fault.

11. Check park brake solenoid.
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BD07F014-01 14
(1) Brake valve

(2) Take an Ohm reading on the solenoid, a reading of 40.3 Ω at 20 °C (68.0 °F) should be obtained.
A. NOT OK— Replace solenoid. Return to Step 1 to confirm elimination of fault.

(1). Remove the instrument cluster.

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4117-Logic error at direction select signal 2

NOTICE: Check fuse F1 in ECA (electrical center A), and F10 in ECC (electrical center C), replace fuses as needed.
Cause:

Solution:
rence.

BD07D168-01 1
(1) Connector TS1

(2) Connector TS2
(1) Disconnect Connector TS1.
(3). Turn ignition switch on.
A. NOT OK — Check fuse ECA F1 in (electrical center A). Return to Step1 to confirm elimination of fault.
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BD07E018-01 2

BD07E035-01 3

(2) Switch console
of fault.
BD07D168-01 4
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(1) Connector TS1

(2) Connector TS2
(3) Take Ohm readings as listed in the following steps, continuity should be obtained.
(4) Place range selector in 1st gear, place FNR in F position. Pin A to pin B Connector TS1, pin B and pin D of
Connector TS2.
(5) Place range selector in 1st gear, place FNR in R position. Pin A to pin C Connector TS1, pin B and pin D of
Connector TS2
(6) Place range selector in 2nd gear, place FNR in F position. Pin A to pin B Connector TS1 and pin D of
Connector TS2.
(7) Place range selector in 2nd gear, place FNR in R position. Pin A to pin C Connector TS1 and pin D Connector
TS2.
(8) Place range selector in 3rd gear, place FNR switch F position. Pin A to pin B Connector TS1, pin C, and pin
D Connector TS2.
(9) Place range selector in 3rd gear, place FNR in R position. Pin A to pin C Connector TS1, pin C and pin D
Connector TS2.
(10) Place range selector in 4th gear, place FNR in F position. Pin A to pin B Connector TS1, pin B, pin C and
pin D Connector TS2.
(11) Place the range selector in any gear, place the FNR in N position. Pin A to pin D Connector TS1.
A. NOT OK — Replace FNR switch. Return to Step1 to confirm elimination of fault.
BD07D168-01 5
(1) Connector TS1

(2) Connector TS2
(1). Disconnect Connector TS1 and Connector TS2.
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BD07E019-01 6

(2) Flasher module
(2). Disconnect Connector TECM from transmission control module.
(3). Inspect pins 22, 43, 63, 64, and 65 on Connector TECM. Clean connections.
(4). The following readings should have continuity.
(5). Check circuit between pin B of Connector TS1 and pin 43 of Connector TECM.
(6). Check circuit between pin C of Connector TS1 and pin 64 of Connector TECM.
(7). Check circuit between pin B of Connector TS2 and pin 65 of Connector TECM.
(8). Check circuit between pin C of Connector TS2 and pin 63 of Connector TECM.
(9). Check circuit between pin D of Connector TS2 and pin 22 of Connector TECM.
A. NOT OK — Determine break between connectors and repair. Return to Step1 to confirm elimination of
fault.
(2) Return to Step 1 to confirm elimination of fault.

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4119-Short circuit to ground at ride control

NOTICE: Check fuse ECA F5, replace as needed.
Cause:
1. Ride control solenoid faulty.

Solution:
rence.

2. Check ride control relay in automatic (center) position on switch.
BD07E018-01 1

(1). Remove ride control relay K4 from Connector ECD (electrical center D)..
(2). Replace ride control relay with a known good relay.
B. NOT OK— Go to Step 3.
C. OK— Replace defective relay.

3. Check power circuit ride control relay.
(1). Take a voltage reading at pin B7 Connector ECD, a reading of 24 volts should be obtained.
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A. NOT OK— Check fuse F5 in Connector ECA. Return to Step 1 to confirm elimination of fault.
4. Check function of ride control switch.
BD07E035-01 2
(1) Right side console

(2) Switch panel
(1). Disconnect Connector SRC.
(2). Inspect all pins on Connector SRC. Clean connections.
(3). Place ride control switch in always on, (forward) position, check between pins 2 and 3 and pins 5 and 6 on
switch.
(4). Place ride control switch in automatic, (center) position, check between pins 2 and 3 and pins 4 and 5 on
switch.
(5). Place ride control switch in off (rear) position, check between pins 4 and 5 on switch.
A. NOT OK— Replace ride control switch. Return to Step 1 to confirm elimination of fault.
5. Check power to ride control switch.
BD07E035-01 3

(2) Switch panel
(1). Disconnect Connector SRC, turn ignition switch on.
(2). Take a voltage reading at pin 2 Connector SRC, a reading of 24 volts should be obtained.
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B. OK— If you have power at the switch go to Step 7.

6. Check circuit 19C
BD07E018-01 4

(1). Take an Ohm reading from pin 2 Connector SRC to pin A5 Connector ECA.
of fault.
7. Check for open circuit between switch and relay.
BD07E035-01 5

(2) Switch panel
(1). Disconnect Connector SRC.
(2). Check for open circuit between pin B7 of Connector ECD and pin 4 of Connector SRC.
(3). Check for open circuit between pin D8 of Connector ECD and pin 6 of Connector SRC.
fault.
8. Check circuit between relay and transmission control module.
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BD07E018-01 6

(1). Remove the relay from Connector ECD.
BD07E019-01 7

(2) Flasher module
(2). Disconnect Connector TECM from transmission control module.
(3). Inspect pins 8 and 57 on Connector TECM. Clean connections.
(4). Check circuit between pin D7 of Connector ECD and pin 8 of Connector TECM.
(5). Check circuit between pin B8 of Connector TS1 and pin 57 of Connector TECM.
fault.
9. Check circuit between ride control relay and solenoid.
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BD07E018-01 8

(1). Remove the ride control relay K4 from Connector ECD.
BD07F015-01 9
(1) Connector YRC

(2) Ride control valve
(2). Disconnect Connector YRC. from ride control solenoid.
(3). Inspect pins on Connector YRC. Clean connections.
(4). Check for open circuit between pin D8 of Connector ECD and pin 1 of Connector YRC.
BD07E021-01 10
(1) Connector front (2) Connector CAB-F
(5). If circuit is open check from pin D8 of Connector ECD to pin 21 of Connector CAB-F.
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(6). From pin B of Connector PRBF to pin 21 of Connector FRONT.
(7). From pin B of Connector 202M to pin A of Connector 202M.
(8). If circuit is open at Connector 202M, replace jumper wire or rollback pressure switch if equipped.
(9). From pin 1 of Connector YRC to pin A of Connector PRBF.
B. OK— Go to 10.
10. Check ground circuit of ride control solenoid.
BD07F015-01 11
(1) Connector YRC

(1). Disconnect Connector YRC from ride control solenoid.
(2). Check for open circuit between pin 2 of Connector YRC and ground.
BD07F016-01 12
(3). If circuit is open check grounding stud connections at GND_FC.
A. NOT OK— Determine brake between connectors and repair. Return to Step 1 to confirm elimination of
fault.

11. Check ride control solenoid.
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BD07F015-01 13
(1) Connector YRC

(1). Disconnect Connector YRC from ride control solenoid.
(2). Take an Ohm reading on the solenoid, a reading of 22.7 Ω at 20 °C (68.0 °F) should be obtained

12. (1). Replace control module if ride control does not work in automatic mode only.
(3). Return to Step 1 to confirm elimination of fault.

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4120-Short circuit to battery voltage at ride control

NOTICE: Check fuse F5 in ECA (electrical center A) replace as needed.
Cause:

Solution:
rence.
A. NOT OK – Fault code 4120- is recorded again. Go to Step 2.

BD07E018-01 1

(1). Remove ride control relay K4 from connector ECD.
(2). Replace ride control relay with a known good relay.

(1). Take a voltage reading at pin B7 on connector ECD, a reading of 24 volts should be obtained.
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A. NOT OK— Check fuse F5 in connector ECA. Return to Step 1 to confirm elimination of fault.
BD07E035-01 2

(2) Switch panel
(1). Disconnect connector SRC.
(2). Inspect all pins on connector SRC. Clean connections.
(3). Place ride control switch in always on, (forward) position, check between pins 2 and 3 and pins 5 and 6 on
switch.
(4). Place ride control switch in automatic, (center) position, check between pins 2 and 3 and pins 4 and 5 on
switch.
(5). Place ride control switch in off (rear) position, check between pins 4 and 5 on switch.
BD07E035-01 3

(2) Switch panel
(1). Disconnect connector SRC, turn ignition switch on.
(2). Take a voltage reading at pin 2 connector SRC, a reading of 24 volts should be obtained.
A. NOT OK— Check fuse F5 in connector ECA, if fuse is not blown go to Step 6, if fuse is blown replace and
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BD07E018-01 4

(1). Take an Ohm reading from pin 2 on connector SRC to pin A5 connector ECA.
of fault.
7. Check circuit between switch and relay.
BD07E035-01 5

(2) Switch panel
(1). Disconnect connector SRC.
(2). Check circuit between pin B7 of connector ECD and pin 4 of connector SRC.
(3). Check circuit between pin D8 on connector ECD and pin 6 of connector SRC.
fault.
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BD07E018-01 6

(1). Remove the relay from connector ECD.
BD07E019-01 7

(2) Flasher module
(2). Disconnect connector TECM from transmission control module.
(3). Inspect pins 8 and 57 on connector TECM. Clean connections.
(4). Check circuit between pin D7 of connector ECD and pin 8 of connector TECM.
(5). Check circuit between pin B8 of connector TS1 and pin 57 of connector TECM.
fault.
9. Check for open circuit between ride control relay and solenoid.
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BD07E018-01 8

(1). Remove the ride control relay K4 from connector ECD.
BD07F015-01 9
(1) Connector YRC

(2). Disconnect connector YRC. from ride control solenoid.
(3). Inspect pins on connector YRC. Clean connections.
(4). Check circuit between pin D8 of connector ECD and pin 1 of connector YRC.
BD07E021-01 10
(5). If circuit is open check from pin D8 of connector ECD to pin 21 of connector CAB-F.
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(6). From pin B of connector PRBF to pin 21 of connector FRONT.
(7). From pin B of connector 202M to pin A of connector 202M.
(8). If circuit is open at Connector 202M, replace jumper wire or rollback pressure switch if equipped.
(9). From pin 1 of connector YRC to pin A of connector PRBF.
B. OK— Go to 10.
BD07F015-01 11
(1) Connector YRC

(1). Disconnect connector YRC from ride control solenoid.
(2). Check circuit between pin 2 of connector YRC and ground.
BD07F016-01 12
fault.

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BD07F015-01 13
(1) Connector YRC

(1). Disconnect connector YRC from ride control solenoid.
(2). Take an Ohm reading on the solenoid, a reading of 22.7 Ω at 20 °C (68.0 °F) should be obtained

12. (1). Replace control module if ride control does not work in automatic mode only.
(3). Return to Step 1 to confirm elimination of fault.

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4121-Open circuit at ride control

Cause:

Solution:
rence.

BD07E018-01 1

(1) Remove ride control relay K4 from Connector ECD.
(2) Replace ride control relay with a known good relay.

(1) Take a voltage reading at pin B7 Connector ECD, a reading of 24 volts should be obtained.
A. NOT OK— Check fuse F5 in Connector ECA. Return to Step 1 to confirm elimination of fault.
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BD07E035-01 2

(2) Switch panel
(1) Disconnect Connector SRC.
(2) Inspect all pins on Connector SRC. Clean connections.
(3) Place ride control switch in always on, (forward) position, check between pins 2 and 3 and pins 5 and 6 on
switch.
(4) Place ride control switch in automatic, (center) position, check between pins 2 and 3 and pins 4 and 5 on
switch.
(5) Place ride control switch in off (rear) position, check between pins 4 and 5 on switch.
BD07E035-01 3

(2) Switch panel
(1) Disconnect Connector SRC, turn ignition switch on.
(2) Take a voltage reading at pin 2 Connector SRC, a reading of 24 volts should be obtained.
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BD07E018-01 4

(1) Take an Ohm reading from pin 2 Connector SRC to pin A5 Connector ECA.
of fault.
7. Check circuit between switch and relay.
BD07E035-01 5

(2) Switch panel
(1) Disconnect Connector SRC.
(2) Check circuit between pin B7 of Connector ECD and pin 4 of Connector SRC.
(3) Check circuit between pin D8 of Connector ECD and pin 6 of Connector SRC.
fault.
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BD07E018-01 6

(1) Remove the relay from Connector ECD.
BD07E019-01 7

(2) Flasher module
(3) Inspect pins 8 and 57 on Connector TECM. Clean connections.
(4) Check circuit between pin D7 of Connector ECD and pin 8 of Connector TECM.
(5) Check circuit between pin B8 of Connector TS1 and pin 57 of Connector TECM.
fault.
9. Check circuit between ride control relay and solenoid.
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BD07E018-01 8

(1) Remove the ride control relay K4 from Connector ECD.
BD07F015-01 9
(1) Connector YRC

(2) Disconnect Connector YRC. from ride control solenoid.
(3) Inspect pins on Connector YRC. Clean connections.
(4) Check for open circuit between pin D8 of Connector ECD and pin 1 of Connector YRC.
BD07E021-01 10
(5) If circuit is open check from pin D8 of Connector ECD to pin 21 of Connector CAB-F.
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(6) From pin B of Connector PRBF to pin 21 of Connector FRONT.
(7) From pin B of Connector 202M to pin A of Connector 202M.
(8) If circuit is open at Connector 202M, replace jumper wire or rollback pressure switch if equipped.
(9) From pin 1 of Connector YRC to pin A of Connector PRBF.
B. OK— Go to 10.
BD07F015-01 11
(1) Connector YRC

(1) Disconnect Connector YRC from ride control solenoid.
(2) Check circuit between pin 2 of Connector YRC and ground.
BD07F016-01 12
(3) If circuit is open check grounding stud connections at GND_FC.
fault.

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BD07F015-01 13
(1) Connector YRC

(1) Disconnect Connector YRC from ride control solenoid.
(2) Take an Ohm reading on the solenoid, a reading of 22.7 Ω at 20 °C (68.0 °F) should be obtained

12. (1) Replace control module if ride control does not work in automatic mode only.
(3) Return to Step 1 to confirm elimination of fault.

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4133-Short circuit to battery voltage or open circuit at transmission

sump temperature sensor input
Cause:
1. Failed thermocouple.
Solution:
rence.

2. Disconnect Connector TRC at the valve body.
BD07F017-01 1
(1) Valve body

(2) Connector TRC
(3) Bell housing
(4) Connector TCOT
(1) Take an Ohm reading at the valve body from pin 8 to pin 9, a reading of 988 Ω at 27 °C (80.6 °F) and 1.44 k
Ω at 80 °C (176.0 °F) should be obtained.
A. NOT OK – Replace valve body, internal harness. Return to Step 1 to confirm elimination of fault.
B. OK – Go to Step .3.
3. Check circuit.
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BD07E019-01 2

(2) Flasher module
(1). Disconnect Connector TECM from the transmission control module.
(3). Check from pin 8 Connector TRC to pin 39 Connector TECM.
BD07E021-01 3
(1) Connector CAB-T

(2) Connector TRANS
(5). If circuit is open, check from pin 8 Connector TRC to pin 5 Connector TRANS.
(6). From pin 5 Connector CAB-T to pin 39 Connector TECM.
(7). If circuit is open check from pin 9 Connector TRC to pin 12 Connector TRANS.
of fault.

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4134-Short circuit to ground at transmission sump temperature

sensor input
Cause:
1. Failed thermocouple.
Solution:
rence.

2. Disconnect connector at the valve body.
BD07F017-01 1
(1) Valve body

(2) Connector TRC
(3) Bell housing
(4) Connector TCOT
3. Check circuit.
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BD07E019-01 2

(2) Flasher module
BD07E021-01 3
(1) Connector CAB-T

(2) Connector TRANS
(5). If circuit is open, check from pin 8 Connector TRC to pin 5 Connector TRANS.
(7). If circuit is open check from pin 9 Connector TRC to pin 12 Connector TRANS.
of fault.
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4135-Short circuit to battery voltage or open circuit at retarder/

torque converter temperature sensor input
Cause:
1. Failed temperature sensor.

Solution:
rence.

BD07F017-01 1
(1) Valve body

(2) Connector TRC
(3) Bell housing
(4) Connector TCOT
3. Check circuit.
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BD07E019-01 2

(2) Flasher module
(3). Check from pin 1 Connector TCOT to pin 49 Connector TECM.
BD07E021-01 3
(1) Connector CAB-T

(2) Connector TRANS
(5). If circuit is open, check from pin 1 Connector TCOT to pin 13 Connector TRANS.
(7). If circuit is open check from pin 2 Connector TCOT to pin 12 Connector TRANS.
of fault.
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4136-Short circuit to ground at retarder/ torque converter

temperature sensor input
Cause:
1. Failed temperature sensor.

Solution:
rence.

2. Disconnect Connector TCOT from torque converter output temperature sensor.
BD07F017-01 1
(1) Valve body

(2) Connector TRC
(3) Bell housing
(4) Connector TCOT
(1) Take an Ohm reading at the torque converter output temperature sensor. A reading of 60 k Ω at 20 °C (68
°F) and 6.53 k Ω at 93 °C (200 °F) should be obtained.
3. Check circuit.
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BD07E019-01 2

(2) Flasher module
BD07E021-01 3
(1) Connector CAB-T

(2) Connector TRANS
(5). If circuit is open, check from pin 1 Connector TCOT to pin 13 Connector TRANS.
(7). If circuit is open check from pin 2 Connector TCOT to pin 12 Connector TRANS.
of fault.
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4137-Short circuit to battery voltage or open circuit at parking

brake sensor input
NOTICE: Check fuses F1 and F6 in ECA (electrical center A), check fuses in PRM-A, replace fuses as needed.
Cause:
1. Park brake switch faulty.

Solution:
rence.

2. Check park brake relay.
BD07E018-01 1

(1) Remove park brake relay K5 from ECB (electrical center B).
(2) Replace park brake relay with known good relay.
C. OK – Replace defective relay.

3. Check power circuit park brake relay.
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(1) Take a voltage reading at pin B9 Connector ECB, a reading of 24 V should be obtained.
A. NOT OK – Check fuse ECA F1 in (electrical center A). Return to Step 1 to confirm elimination of fault.
4. Check function of park brake switch.
BD07E012-01 2

(2) Connector SPB
(1) Disconnect Connector SPB.
(2) Inspect all pins on Connector SPB. Clean connections.
(3) Place park brake switch in the release park brake position, Ohm between pins 2 and 3 on park brake switch,
A. NOT OK – Replace park brake switch. Return to Step 1 to confirm elimination of fault.
5. Check power circuit to park brake switch.
BD07E012-01 3

(2) Connector SPB
(1) Disconnect Connector SPB, turn ignition switch on.
(2) Take a voltage reading at pin 2 Connector SPB, a reading of 24 V should be obtained.
A. NOT OK – Check fuse ECA F1 in (electrical center A), if fuse is not blown go to Step 6. If fuse is blown,
replace and return to Step .1 to confirm elimination of fault.
B. OK – If you have power at the park brake switch, go to Step 7.

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BD07E018-01 4

(1) Take an Ohm reading from pin 2 Connector SPB to pin A1 Connector ECA.
BD07E035-01 5

(2) Switch console.
(2) If circuit is open, take an Ohm reading from pin 2 Connector SPB to pin L Connector SPL-TRNS-PWR.
of fault.
7. Check circuit between park brake switch and instrument cluster.
BD07E012-01 6
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(2) Connector SPB
(1) Disconnect Connector SPB.
BD07D128-01 7
(1) Connector AIC-2

(2) Connector AIC-1
(2) Disconnect Connector AIC-2 from instrument cluster.
(3) Inspect pin 6 on Connector AIC-2. Clean connections.
(4) Check circuit between pin 3 of Connector SPB and pin 6 of Connector AIC-2.
of fault.
8. Check circuit between instrument cluster and park brake relay.
BD07D128-01 8
(1) Connector AIC-2

(2) Connector AIC-1
(1) Disconnect Connector AIC-1.
(2) Inspect pin 14 on Connector AIC-1. Clean connections.
(3) Check circuit between pin 10 of Connector ECB and pin 14 of Connector AIC-1.
of fault.
9. Check for open circuit between park brake relay and park brake solenoid.
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BD07E018-01 9

(1). Remove the park brake relay K5 from Connector ECB.
BD07F014-01 10
(1) Brake valve

(4). Check for open circuit between pin B10 of Connector ECB and pin 1 of Connector YPB.
BD07E021-01 11
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(1) Connector Front

(2) Connector CAB-F
(5). If circuit is open check from pin B10 of Connector ECB to pin 24 of Connector CAB-F.
(6). From pin 1 of Connector YPB to pin 24 of Connector FRONT.
B. OK— Go to 10.
10. Check ground circuit of park brake solenoid.
BD07F014-01 12
(1) Brake valve

(2). Check for open circuit between pin 2 of Connector YPB and ground.
BD07F016-01 13
A. NOT OK— Determine break between connectors and repair. Return to Step1 to confirm elimination of
fault.

11. Check park brake solenoid.
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BD07F014-01 14
(1) Brake valve

(2) Take an Ohm reading on the solenoid, a reading of 40.3 Ω at 20 °C (68.0 °F) should be obtained.


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4145-Short circuit to battery voltage or open circuit at engine speed

input
Cause:
1. Failed speed sensor.

Solution:
rence.

2. Check circuit.
BD07F020-01 1
(1) Main hydraulic pump

(2) Connector ESS
(1) Disconnect Connector ESS.
(2) Inspect pins on Connector ESS. Clean connections.
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BD07E019-01 2

(2) Flasher module
(3) Disconnect Connector TECM from the transmission control module.
(5) Check from pin 1 Connector ESS to pin 19 Connector TECM.
BD07E021-01 3
(1) Connector CAB-T

(2) Connector TRANS
(7) If circuit is open, check from pin 1 Connector ESS to pin 7 Connector TRANS.
(8) From pin 7 Connector CAB-T to pin 19 Connector TECM.
(9) If circuit is open check from pin 2 Connector ESS to pin 11 Connector TRANS.
of fault.
3. Replace the engine speed sensor.
B. NOT OK— If fault is recorded again go to Step 4.

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A. Remove and replace transmission control module.
B. Return to Step 1 to confirm elimination of fault.

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4146-Short circuit to ground at engine speed input

Cause:

Solution:
rence.

2. Check circuit.
BD07F020-01 1

(2) Connector ESS
(1). Disconnect Connector ESS.
(2). Inspect pins on Connector ESS. Clean connections.
(3). Clean female pins by installing and removing.
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BD07E019-01 2

(2) Flasher module
(6). Clean female pins by installing and removing.
(7). Check from pin 1 Connector ESS to pin 19 Connector TECM.
BD07E021-01 3
(1) Connector CAB-T

(2) Connector TRANS
(9). If circuit is open, check from pin 1 Connector ESS to pin 7 Connector TRANS.
(11). If circuit is open check from pin 2 Connector ESS to pin 11 Connector TRANS.
of fault.
A. Remove and replace engine speed sensor. Return to Step 1 to confirm elimination of fault.
B. NOT OK— If fault is recorded again go to 4.
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B. Return to Step 1 to confirm elimination of fault. If fault is recorded again contact Technical Services Group
for assistance.
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4147-Logical error at engine speed input

NOTE: This fault code is reset after power up of the TCM (transmission control module). It is also reset if the signal
is above zero speed threshold.
Cause:

Solution:
rence.

2. Check circuit.
BD07F020-01 1

(2) Connector ESS
(1). Disconnect Connector ESS.
(2). Inspect pins on Connector ESS. Clean connections.
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BD07E019-01 2

(2) Flasher module
BD07E021-01 3
(1) Connector CAB-T

(2) Connector TRANS
(7). If circuit is open, check from pin 1 Connector ESS to pin 7 Connector TRANS.
(9). If circuit is open check from pin 2 Connector ESS to pin 11 Connector TRANS.
of fault.
A. Remove and replace engine speed sensor.
C. NOT OK— If fault is recorded again go to 4.
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4148-Short circuit to battery voltage or open circuit at turbine

speed input
Cause:
1. Failed turbine speed sensor.

Solution:
rence.

2. Check circuit.
BD07F019-01 1
(1) Connector TSS

(2) Connector ISS
(1) Disconnect Connector TSS at turbine speed sensor.
(2) Inspect pins on Connector TSS. Clean connections.
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BD07E019-01 2

(2) Flasher module
(5) Check from pin 1 Connector TSS to pin 19 Connector TECM.
BD07E021-01 3
(1) Connector CAB-T

(2) Connector TRANS
(7) If circuit is open, check from pin 1 Connector TSS to pin 8 Connector TRANS.
(9) If circuit is open check from pin 2 Connector TSS to pin 11 Connector TRANS.
of fault.
3. Replace the turbine speed sensor.
A. Remove and replace turbine speed sensor.
C. NOT OK— If fault is recorded again go to 4.
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4149-Short circuit to ground at turbine speed input

Cause:

Solution:
rence.

2. Check circuit.
BD07F019-01 1
(1) Connector TSS

(2) Connector ISS
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BD07E019-01 2

(2) Flasher module
BD07E021-01 3
(1) Connector CAB-T

(2) Connector TRANS
of fault.
(1) Remove and replace speed sensor.
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4150-Logical error at turbine speed input

NOTE: This fault code is reset after power up of the TCM (transmission control module).
Cause:

Solution:
rence.

2. Check circuit.
BD07F019-01 1
(1) Connector TSS

(2) Connector ISS
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BD07E019-01 2

(2) Flasher module
(4) Inspect pins 3 and 41 on Connector TECM Clean connections.
BD07E021-01 3
(1) Connector CAB-T

(2) Connector TRANS
of fault.
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4151-Short circuit to battery voltage or open circuit at internal

speed input
Cause:
1. Failed intermediate speed sensor.

Solution:
rence.

2. Check circuit.
BD07F019-01 1
(1) Connector TSS

(2) Connector ISS
(1) Disconnect Connector ISS at intermediate speed sensor.
(2) Inspect pins on Connector ISS. Clean connections.
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BD07E019-01 2

(2) Flasher module
(5) Check from pin 1 Connector ISS to pin 42 Connector TECM.
BD07E021-01 3
(1) Connector CAB-T

(2) Connector TRANS
(7) If circuit is open, check from pin 1 Connector ISS to pin 9 Connector TRANS.
(9) If circuit is open check from pin 2 Connector ISS to pin 11 Connector TRANS.
of fault.
3. Replace the intermediate speed sensor.
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4152-Short circuit to ground at internal speed input

Cause:
1. Failed intermediate speed sensor.

Solution:
rence.

2. Check circuit.
BD07F019-01 1
(1) Connector TSS

(2) Connector ISS
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BD07E019-01 2

(2) Flasher module
BD07E021-01 3
(1) Connector CAB-T

(2) Connector TRANS
of fault.
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4153-Logical error at internal speed input

NOTE: This fault code is reset after power up of the TCM (transmission control module).
Cause:
1. Intermediate speed reading erratic.

Solution:
rence.

2. Check circuit.
BD07F019-01 1
(1) Connector TSS

(2) Connector ISS
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BD07E019-01 2

(2) Flasher module
(4) Inspect pins 3 and 42 on Connector TECM Clean connections.
BD07E021-01 3
(1) Connector CAB-T

(2) Connector TRANS
of fault.
(1) Remove and replace intermediate speed sensor.
B. NOT OK— go to 4.
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55.DTC / 445
4154-Short circuit to battery voltage or open circuit at output speed

input
NOTICE: Check fuse ECA F1.
Cause:
1. Output speed reading erratic.

Solution:
rence.

2. Check power to output speed sensor.
BD07F018-01 1
(1) Connector OSS
(1) Disconnect Connector OSS at output speed sensor.
(2) Inspect pins on Connector OSS. Clean connections.
(4) Take a voltage reading at pin 3 Connector OSS, a reading of 24 V should be obtained.
A. NOT OK— Check fuse ECA F1. Return to Step 1 to confirm elimination of fault.
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3. Check power circuit
BD07E018-01 2

(1) Take an Ohm reading from pin 3 Connector OSS to pin A1 Connector ECA.
BD07E035-01 3

(2) Switch console
(2) If circuit is open, take an Ohm reading from pin 3 Connector OSS to pin K Connector SPL-TRNS-PWR.
(3) Check from pin A Connector SPL-TRNS-PWR to pin A1 Connector ECA.
of fault.
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4. Check Circuit.
BD07F018-01 4
(1) Connector OSS
BD07E019-01 5

(2) Flasher module
(4) Check from pin 1 Connector OSS to pin 4 Connector TECM.
BD07E021-01 6
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(1) Connector CAB-T

(2) Connector TRANS
(6) If circuit is open check from pin 1 Connector OSS to pin 28 Connector TRANS.
fault.
5. Replace the output speed sensor.
(1) Remove and replace output speed sensor.

(1). Remove and replace transmission control module.
A. Return to Step 1 to confirm the elimination of fault.

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4155-Short circuit to ground at output speed input

Cause:

Solution:
rence.

BD07F018-01 1
(1) Connector OSS
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BD07E018-01 2

(1). Take an Ohm reading from pin 3 Connector OSS to pin A1 Connector ECA.
BD07E035-01 3

(2) Switch console
of fault.
4. Check Circuit.
47392461 19/06/2012
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BD07F018-01 4
(1) Connector OSS
BD07E019-01 5

(2) Flasher module
BD07E021-01 6
(1) Connector CAB-T

(2) Connector TRANS
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fault.

(1) Remove and replace transmission control module.

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55.DTC / 453
4156-Logical error at output speed input

Cause:

Solution:
rence.

BD07F018-01 1
(1) Connector OSS
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BD07E018-01 2

BD07E035-01 3

(2) Switch console
of fault.
4. Check Circuit.
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55.DTC / 455
BD07F018-01 4
(1) Connector OSS
BD07E019-01 5

(2) Flasher module
BD07E021-01 6
(1) Connector CAB-T

(2) Connector TRANS
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55.DTC / 456
fault.


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4158-Output speed zero, doesn't fit to other speed signals

Cause:

Solution:
rence.

BD07F018-01 1
(1) Connector OSS
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BD07E018-01 2

BD07E035-01 3

(2) Switch console
of fault.
4. Check Circuit.
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55.DTC / 459
BD07F018-01 4
(1) Connector OSS
BD07E019-01 5

(2) Flasher module
BD07E021-01 6
(1) Connector CAB-T

(2) Connector TRANS
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fault.

B. NOT OK— If fault is recorded again contact Technical Services Group for assistance.
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55.DTC / 461
4160-Invalid gear range restriction (CAN)

NOTICE: Check fuse F1 in ECA (electrical center A)
Cause:
1. Failed instrument cluster.

Solution:
rence.

2. Check CAN circuit.
BD07D128-01 1
(1) Connector AIC-2

(2) Connector AIC-1
(2) Inspect pins in Connector AIC-1. Clean connections.
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BD07E019-01 2

(2) Flasher module
(4) Inspect pins 25, 26 and 27 on Connector TECM. Clean connections.
(5) Check from pin 3 Connector AIC-1 to pin 25 Connector TECM.
(6) Check from pin 4 Connector AIC-1 to pins 26 and 27 Connector TECM.
of fault.
3. Replace instrument cluster.

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4186-Invalid park brake status (CAN)

NOTICE: Check fuse F1 in ECA (electrical center A)
Cause:

Solution:
rence.

BD07D128-01 1
(1) Connector AIC-2

(2) Connector AIC-1
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BD07E019-01 2

(2) Flasher module
(4) Inspect pins 25, 26 and 27 on Connector TECM. Clean connections.
(6) Check from pin 4 Connector AIC-1 to pins 26 and 27 Connector TECM.
of fault.


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4209-Short circuit to battery voltage at clutch K1

Cause:
1. K1 clutch not functioning, transmission goes into limp home mode.

Solution:
rence.

BD07F017-01 1
(1) Valve body

(2) Connector TRC
(3) Bell housing
(4) Connector TCOT
(1) Take Ohm reading at the valve body from pin 3 to pin 7, a reading of 19 Ω at 27 °C (80.6 °F) should be
obtained.
A. NOT OK – Replace Y3 solenoid. Return to Step 1 to confirm elimination of fault.
3. Check circuit.
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BD07E019-01 2

(2) Flasher module
(2) Inspect pin 32 on Connector TECM. Clean connections.
(3) Check from pin 3 Connector TRC to pin 32 Connector TECM.
BD07E021-01 3
(1) Connector CAB-T

(2) Connector TRANS
(4) If circuit is open check from pin 3 Connector TRC to pin 18 Connector TRANS.
of fault.

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4210-Short circuit to ground at clutch K1

Cause:

Solution:
rence.

BD07F017-01 1
(1) Valve body

(2) Connector TRC
(3) Bell housing
(4) Connector TCOT
obtained.
3. Check circuit.
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BD07E019-01 2

(2) Flasher module
BD07E021-01 3
(1) Connector CAB-T

(2) Connector TRANS
of fault.

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4211-Open circuit at clutch K1

Cause:

Solution:
rence.

BD07F017-01 1
(1) Valve body

(2) Connector TRC
(3) Bell housing
(4) Connector TCOT
obtained.
3. Check circuit.
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BD07E019-01 2

(2) Flasher module
BD07E021-01 3
(1) Connector CAB-T

(2) Connector TRANS
of fault.

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Cause:

Solution:
rence.

BD07F017-01 1
(1) Valve body

(2) Connector TRC
(3) Bell housing
(4) Connector TCOT
obtained.
3. Check circuit.
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BD07E019-01 2

(2) Flasher module
BD07E021-01 3
(1) Connector CAB-T

(2) Connector TRANS
of fault.

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Cause:

Solution:
rence.

BD07F017-01 1
(1) Valve body

(2) Connector TRC
(3) Bell housing
(4) Connector TCOT
obtained.
3. Check circuit.
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BD07E019-01 2

(2) Flasher module
BD07E021-01 3
(1) Connector CAB-T

(2) Connector TRANS
of fault.

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Cause:

Solution:
rence.

BD07F017-01 1
(1) Valve body

(2) Connector TRC
(3) Bell housing
(4) Connector TCOT
obtained.
3. Check circuit.
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BD07E019-01 2

(2) Flasher module
BD07E021-01 3
(1) Connector CAB-T

(2) Connector TRANS
of fault.

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Cause:

Solution:
rence.

BD07F017-01 1
(1) Valve body

(2) Connector TRC
(3) Bell housing
(4) Connector TCOT
(1) Take an Ohm reading at the valve body from pin 4 to pin 7, a reading of 19 Ω at 27 °C (80.6 °F) should be
obtained.
3. Check circuit.
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BD07E019-01 2

(2) Flasher module
(2) Inspect pin 55 on Conenector TECM . Clean connections.
(3) Check from pin 4 Connector TRC to pin 55 .
BD07E021-01 3
(1) Connector CAB-T

(2) Connector TRANS
(5) From pin 19 Connector CAB-T to pin 55 Connector TECM. .
of fault.

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Cause:

Solution:
rence.

BD07F017-01 1
(1) Valve body

(2) Connector TRC
(3) Bell housing
(4) Connector TCOT
obtained.
3. Check circuit.
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BD07E019-01 2

(2) Flasher module
BD07E021-01 3
(1) Connector CAB-T

(2) Connector TRANS
of fault.

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Cause:

Solution:
rence.

BD07F017-01 1
(1) Valve body

(2) Connector TRC
(3) Bell housing
(4) Connector TCOT
obtained.
3. Check circuit.
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BD07E019-01 2

(2) Flasher module
BD07E021-01 3
(1) Connector CAB-T

(2) Connector TRANS
of fault.

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Cause:

Solution:
rence.

BD07F017-01 1
(1) Valve body

(2) Connector TRC
(3) Bell housing
(4) Connector TCOT
obtained.
3. Check circuit.
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BD07E019-01 2

(2) Flasher module
BD07E021-01 3
(1) Connector CAB-T

(2) Connector TRANS
of fault.

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Cause:

Solution:
rence.

BD07F017-01 1
(1) Valve body

(2) Connector TRC
(3) Bell housing
(4) Connector TCOT
obtained.
3. Check circuit.
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BD07E019-01 2

(2) Flasher module
BD07E021-01 3
(1) Connector CAB-T

(2) Connector TRANS
of fault.
A. Return to Step 1 to confirm elimination of fault. .

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Cause:

Solution:
rence.

BD07F017-01 1
(1) Valve body

(2) Connector TRC
(3) Bell housing
(4) Connector TCOT
obtained.
3. Check circuit.
47392461 19/06/2012
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BD07E019-01 2

(2) Flasher module
BD07E021-01 3
(1) Connector CAB-T

(2) Connector TRANS
of fault.

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4228-Short circuit to battery voltage at clutch KV

Cause:
1. KV clutch not functioning, transmission goes into limp home mode.

Solution:
rence.

BD07F017-01 1
(1) Valve body

(2) Connector TRC
(3) Bell housing
(4) Connector TCOT
obtained.
3. Check circuit.
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BD07E019-01 2

(2) Flasher module
BD07E021-01 3
(1) Connector CAB-T

(2) Connector TRANS
of fault.

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4229-Short circuit to ground at clutch KV

Cause:

Solution:
rence.

BD07F017-01 1
(1) Valve body

(2) Connector TRC
(3) Bell housing
(4) Connector TCOT
obtained.
3. Check circuit.
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BD07E019-01 2

(2) Flasher module
BD07E021-01 3
(1) Connector CAB-T

(2) Connector TRANS
of fault.

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4230-Open circuit at clutch KV

Cause:

Solution:
rence.

BD07F017-01 1
(1) Valve body

(2) Connector TRC
(3) Bell housing
(4) Connector TCOT
obtained.
3. Check circuit.
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BD07E019-01 2

(2) Flasher module
BD07E021-01 3
(1) Connector CAB-T

(2) Connector TRANS
of fault.

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4231-Short circuit to battery voltage at clutch KR

Cause:
1. KR clutch not functioning, transmission goes into limp home mode.

Solution:
rence.

BD07F017-01 1
(1) Valve body

(2) Connector TRC
(3) Bell housing
(4) Connector TCOT
obtained.
3. Check circuit.
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BD07E019-01 2

(2) Flasher module
BD07E021-01 3
(1) Connector CAB-T

(2) Connector TRANS
of fault.

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4232-Short circuit to ground at clutch KR

Cause:

Solution:
rence.

BD07F017-01 1
(1) Valve body

(2) Connector TRC
(3) Bell housing
(4) Connector TCOT
obtained.
3. Check circuit.
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BD07E019-01 2

(2) Flasher module
BD07E021-01 3
(1) Connector CAB-T

(2) Connector TRANS
of fault.

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4233-Open circuit at clutch KR

Cause:

Solution:
rence.

BD07F017-01 1
(1) Valve body

(2) Connector TRC
(3) Bell housing
(4) Connector TCOT
obtained.
3. Check circuit.
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BD07E019-01 2

(2) Flasher module
BD07E021-01 3
(1) Connector CAB-T

(2) Connector TRANS
of fault.

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4241-Short circuit to ground at backup alarm relay

Cause:
1. Backup alarm does not work.

Solution:
rence.

2. Check relay.
(1) Remove backup alarm relay.
(2) Replace relay with known good relay.

BD07E018-01 1

(1) Check for voltage at pin A10 Connector ECD, a reading of 24 V should be obtained.
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(2) If there is no voltage, remove relay and fuse ECA F14.
(3) Check from pin C4 Connector ECA to pin A10 Connector ECD.
of fault.
4. Check control circuit.
BD07E019-01 2

(2) Flasher module
(1) Turn the ignition switch on, place the FNR selector in the R position, release parking brake and press foot
brake.
(2) Check for ground at pin A9 Connector ECD, a reading of continuity should be obtained.
(5) Check from pin A9 Connector ECD to pin 7 Connector TECM.
of fault.
BD07E018-01 3

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(1) Check for voltage at pin AA10 Connector ECD, a reading of 24 V should be obtained.
(3) Take an Ohm reading from pin A1 Connector ECA to pin AA10 Connector ECD.
BD07E035-01 4

(2) Switch console
(4) If circuit is open, take an Ohm reading from pin AA10 Connector ECD to pin G Connector SPL-TRNS-PWR.
of fault.

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4242-Short circuit to battery voltage at backup alarm relay

Cause:

Solution:
rence.

2. Check relay.

BD07E018-01 1

47392461 19/06/2012
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of fault.
BD07E019-01 2

(2) Flasher module
brake.
of fault.
BD07E018-01 3

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BD07E035-01 4

(2) Switch console
of fault.

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4243-Open circuit at backup alarm relay

Cause:

Solution:
rence.

2. Check relay.

BD07E018-01 1

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of fault.
BD07E019-01 2

(2) Flasher module
brake.
of fault.
BD07E018-01 3

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BD07E035-01 4

(2) Switch console
of fault.

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4273-Slippage at clutch K1
NOTICE: Check clutch pressures refer to Powershift transmission - General specification Pressures (21.113)
and Clutch - Dynamic description – Transmission Clutch Calibration (55.408).
Cause:

Solution:
rence.

2. Refer to Powershift transmission - General specification Pressures (21.113) to perform pressure checks
and transmission troubleshooting.
A. OK – No errors were found during troubleshooting. Go to Step 3.
B. NOT OK – Repair transmission as needed.

3. Refer to 4153 - Logical error at intermediate speed sensor input and troubleshoot intermediate speed sen-
sor. Do not replace the transmission control module at this time.
A. OK – Go to Step.4.
4. Refer to 4156 - Logical error at output speed sensor input and troubleshoot output speed sensor.

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55.DTC / 511
Cause:

Solution:
rence.



47392461 19/06/2012
55.DTC / 512
Cause:

Solution:
rence.



47392461 19/06/2012
55.DTC / 513
Cause:

Solution:
rence.



47392461 19/06/2012
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4277-Slippage at clutch KV
Cause:

Solution:
rence.


sor. Note: Do not replace the transmission control module at this time.

47392461 19/06/2012
55.DTC / 515
4278-Slippage at clutch KR
Cause:

Solution:
rence.



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4279-Overtemp sump
NOTICE: Check transmission oil level, check oil type, refer to Capacities ()
Cause:
1. Transmission temperature is above set value.

Solution:
rence.

A. NOT OK – Repair fan or clear clogs from cooling core. Return to Step 1 to confirm elimination of fault.
BD07F017-01 1
(1) Valve body

(2) Connector TRC
(3) Bell housing
(4) Connector TCOT
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(1) Take an Ohm reading at the valve body from pin 8 to pin 9, a reading of 988 Ω at 27 °C (80.6 °F), 1.44k Ω
at 80 °C (176.0 °F) should be obtained.
A. NOT OK – Replace valve body internal harness. Return to Step 1 to confirm elimination of fault.
4. Check circuit.
BD07E019-01 2

(2) Flasher module
BD07E021-01 3
(1) Connector CAB-T

(2) Connector TRANS
of fault.
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4281-Engine overspeed
Cause:
1. Engine speed reading erratic.

Solution:
rence.

2. Check circuit.
BD07F020-01 1

(2) Connector ESS
(1) Disconnect Connector ESS at engine speed sensor.
(2) Inspect pins on Connector ESS. Clean connections.
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BD07E019-01 2

(2) Flasher module
BD07E021-01 3
(1) Connector CAB-T

(2) Connector TRANS
of fault.
B. NOT OK – Fault is recorded again, Go to Step 4.
47392461 19/06/2012
55.DTC / 521

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4282-TCM sensed a voltage at oil filter maintenance switch out of

the allowed range (dirty filter)
Cause:
1. Filter clogged.
Solution:
rence.

2. Replace filter.
C. OK – Fault is not recorded again. OK for return to service.

3. Disconnect Connector FM at transmission filter maintenance switch.
BD07F003-01 1
(1) Connector FM
(2) Left step
(1) Inspect pins on Connector FM and filter maintenance switch. Clean connections.
(2) Take an Ohm reading at the filter maintenance switch, a reading of 510 Ω at 20 °C (68.0 °F) should be
obtained.
A. NOT OK – Replace switch. Return to Step 1 to confirm elimination of fault.
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4. Check circuit.
BD07E019-01 2

(2) Flasher module
BD07E021-01 3
(1) Connector CAB-T

(2) Connector TRANS
(5) If circuit is open check from pin 1 Connector FM to pin 31 Connector TRANS.
(7) If circuit is open check from pin 2 Connector FM to pin 12 Connector TRANS.
A. NOT OK – Determine break between connectors and repair. Return to Step 1 to confirm elimination of
fault.
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4284-Overspeed output
Cause:

Solution:
rence.

BD07F018-01 1
(1) Connector OSS
A. NOT OK— Go to Step 3.
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BD07E018-01 2

(1) Take an Ohm reading from pin 3 Connector OSS to pin K Connector SPL-TRNS-PWR. Check buss bar
terminal K for correct tension or corrosion, test buss bar from pin to pin for continuity.
BD07E035-01 3

(2) Switch console
(2) If circuit is open, take an Ohm reading from pin 3 Connector OSS to pin 29 Connector TRANS.
(3) From pin K Connector SPL-TRNS-PWR to pin 29 Connector CAB-T.
of fault.
4. Check Circuit.
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BD07F018-01 4
(1) Connector OSS
BD07E019-01 5

(2) Flasher module
BD07E021-01 6
(1) Connector CAB-T

(2) Connector TRANS
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(6) If circuit is open, check from pin 1 Connector OSS to pin 28 Connector TRANS.
(8) If circuit is open, check from pin 2 Connector OSS to pin 10 Connector TRANS.
fault.


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4290-Transmission input torque overload

Cause:
1. TECM calculates a transmission input torque above the defined thresholds.

Solution:
rence.

2. Calibrate clutches.
(1) Calibrate clutches accord to instructions. Refer to Clutch - Dynamic description – Transmission Clutch
Calibration (55.408).
A. OK – Return to Step 1 to confirm the elimination of fault.
B. NOT OK – Repair or replace transmission as needed.

3. Perform engine stall test.
(1) Check engine stall speeds according to instructions in Engine - Test (10.001).
B. NOT OK – Repair or replace engine or transmission as needed.


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4291-Overtemp converter output

NOTICE: Check transmission oil level, check oil type, refer to Capacities ().
Cause:
1. Transmission temperature reading above set limit.

Solution:
rence.

A. NOT OK – Repair fan or clear clogs from cooling core. Return to Step 1 to confirm elimination of fault.
3. Disconnect Connector TCOT at torque converter output temperature sensor.
BD07D167 1
(1) Connector TCOT

(2) Transmission control valve harness
(1) Take an Ohm reading at the sensor, a reading of 60k Ω at 20 °C (68 °F), 6.53k Ω at 93 °C (199.4 °F) should
be obtained.
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4. Check circuit.
BD07E019-01 2

(2) Flasher module
(3) Check from pin 1 Connector TCOT to pin 49 Connector TECM.
(4) Check from pin 2 Connector TCOT to pin 46 Connector TECM.
BD07E021-01 3
(1) Connector CAB-T

(2) Connector TRANS
(5) If circuit is open check from pin 1 Connector TCOT to pin 13 Connector TRANSConnector TRANS.
(7) If circuit is open check from pin 2 Connector TCOT to pin 12 Connector TRANS.
A. NOT OK – Determine break between connectors and repair. Return to Step 1 to confirm elimination of
fault.
47392461 19/06/2012
55.DTC / 532

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4292-Short circuit to ground at joystick status indicator

Cause:
1. Vehicle transmission operations stopped, can not select gears.

Solution:
rence.

BD07D168-01 1
(1) Connector TS1

(2) Connector TS2
(4) Take a voltage reading at pin A Connector TS1, a reading of 24 V should be obtained.
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BD07E018-01 2

BD07E035-01 3

(2) Switch console
of fault.
BD07D168-01 4
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(1) Connector TS1

(2) Connector TS2
(4) Place range selector in 1st gear, place FNR in F position. Pin A to pin B Connector TS1, pin B, and pin D
Connector TS2.
(5) Place range selector in 1st gear, place FNR in R position. Pin A to pin C Connector TS1, pin B, and pin D
Connector TS2.
(6) Place range selector in 2nd gear, place FNR in F position. Pin A to pin B Connector TS1, and pin D Connector
TS2.
TS2.
D Connector TS2.
(9) Place range selector in 3rd gear, place FNR in R position. Pin A to pin C Connector TS1, pins C, and D
Connector TS2.
(10) Place range selector in 4th gear, place FNR in F position. Pin A to pin B Connector TS1, pin B, pin C, and
BD07D168-01 5
(1) Connector TS1

(2) Connector TS2
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BD07E019-01 6

(2) Flasher module
fault.

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4293-Short circuit to battery voltage at joystick status indicator

NOTICE: Check fuses ECA F1 and ECC F10, replace as needed
Cause:

Solution:
rence.

BD07D168-01 1
(1) Connector TS1

(2) Connector TS2
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BD07E018-01 2

BD07E035-01 3

(2) Switch console
of fault.
BD07D168-01 4
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(1) Connector TS1

(2) Connector TS2
Connector TS2.
Connector TS2.
TS2.
TS2.
D Connector TS2.
Connector TS2.
BD07D168-01 5
(1) Connector TS1

(2) Connector TS2
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BD07E019-01 6

(2) Flasher module
fault.

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4294-Open circuit at joystick status indicator

NOTICE: Check fuses ECA F1 and ECC F10, replace as needed
Cause:
1. Burnt-out indicator light in the FNR enable switch.

Solution:
rence.

2. If equipped, activate the forward-neutral-reverse (FNR) auxiliary enable switch on the side console by pushing
down at the top of the switch.
(1) Operate the auxiliary FNR switch at the loader controls.
(2) Observe the light in the auxiliary enable switch on the side console, does the light illuminate.
A. NOT OK — Replace the switch. Return to Step 1 to confirm elimination of fault.
BD07D168-01 1
(1) Connector TS1

(2) Connector TS2
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BD07E018-01 2

BD07E035-01 3

(2) Switch console
of fault.
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BD07D168-01 4
(1) Connector TS1

(2) Connector TS2
Connector TS2.
Connector TS2.
TS2.
TS2.
D Connector TS2.
Connector TS2.
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BD07D168-01 5
(1) Connector TS1

(2) Connector TS2
BD07E019-01 6

(2) Flasher module
fault.

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4305-Short circuit to battery voltage at power supply for sensors

Cause:
1. Over voltage to TCM (Transmission Control Module).

Solution:
rence.

2. Check equipment voltage.
(1) Start and run engine at high idle.
(2) Check output voltage of alternator.
A. NOT OK – Repair electrical system as needed. Return to Step 1 to confirm elimination of fault.

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4306-Short circuit to ground at power supply for sensors

Cause:

Solution:
rence.


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4307-Low voltage at battery

Cause:
1. Under voltage to TCM (Transmission Control Module).

Solution:
rence.


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4308-High voltage at battery

Cause:

Solution:
rence.


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4309-Error at valve power supply VPS1

Cause:

Solution:
rence.


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55.DTC / 550
4310-Error valve power supply VPS2

Cause:

Solution:
rence.


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4325-VehicleID#1 timeout
NOTICE: Check fuse F8 in ECC (electrical center C)
Cause:

2. Blown fuse ECC F8.
Solution:
1. The EST will have to be used to retrieve and transmission faults do to lack of communication with the AIC from
the TECM. Verify that the fault code is still active, refer to 0000 - Retrieving fault codes, Wheel Loaders. Prior
to clearing fault codes write down all fault codes, number of occurrences, and engine hours at last occurrence.
(2) Clear all fault codes, the EST will have to used to read and clear fault codes from the TECM.

2. Verify voltage at fuse ECC - F8.
BD07D128-01 1
(1) Connector AIC-2

(2) Connector AIC-1
(3) Check for voltage at pins 14 and 20 of Connector AIC-2.
(4) If no voltage or low voltage, check for corrosion or loose terminal tension at pins 14 and 20.
(5) Check from pins 14 and 20 of Connector AIC-2 to pin A8 Connector ECC.
of fault.
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BD07D128-01 2
(1) Connector AIC-2

(2) Connector AIC-1
BD07E019-01 3

(2) Flasher module
(5) Check from pin 3 Connector AIC-1. to pin 25 Connector TECM.
of fault.
4. Check grounding circuit.
(1) Disconnect Connector AIC-1 and Connector AIC-2.
(2). Inspect pins 6 and 12 in Connector AIC-1 and pins 15 and 22 in Connector AIC-2. Clean connections.
(3) Check circuit from pins 6 and 12 in Connector AIC-1 and pin 15 in Connector AIC-2 to ground, a reading of
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(4) If circuit is open check circuit from pin 15 Connector AIC-2 to pin 20 Connector CAB-E.
(5) Check circuit from pin 20 of Connector ENG to ground.
(6) Check circuit from pin 6 Connector AIC-1 to pin 17 Connector CAB-E.
(7) Check circuit from pin 17 of Connector ENG to ground on engine near oil filter.
(8) Check circuit from pin 12 Connector AIC-1 to pin 19 Connector CAB-E.
(9) Check circuit from pin 19 of Connector ENG to ground on engine near oil filter.
(10) Check circuit from pin 22 Connector AIC-1 to ground on the steering pedestal.
A. NOT OK— Determine the break and repair. Return to Step 1 to confirm elimination of fault.

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4326-Illegal ID request via CAN

Cause:
1. CAN communication interrupted during normal operation.

Solution:
rence.

2. Check configuration of the AIC and TECM using the EST.
A. NOT OK – Update AIC or TECM as required, return to Step 1 to confirm elimination of fault.
3. Replace the transmission controller.
(1) Remove and replace TECM.
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4337-General EEPROM fault

Cause:
1. Failed TCM (Transmission Control Module).
Solution:
rence.

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4338-Configuration error
Cause:
Solution:
rence.

2. (1) Reprogram the correct configuration for the vehicle.

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4339-Application error
Cause:
Solution:
rence.

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4341-Clutch failure
Cause:

2. Clutch calibration lost from memory.
Solution:
rence.

2. (1) Calibrate the clutches.

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4342-Clutch adjustment data lost

Cause:

2. Clutch adjustment data lost from memory.
Solution:
rence.

2. (1) Calibrate clutches.

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9128-CAN Timed Out During Operation

Cause:

Solution:
rence.

2. Check circuit.
(1) Disconnect Connector QSM11.
BD07F007-01 1
(1) Connector QSM11
(2) Disconnect connector TECM.
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BD07E019-01 2

(2) Flasher module
(3) Disconnect connector AIC-1.
BD07D128-01 3
(1) Connector AIC-2

(2) Connector AIC-1
(4) Disconnect connector SW-PD.
BD07E012-01 4
(1) Switch pad

(2) Connector SW-PD
(5) From pin C at the diagnostic connector, Connector DIA, take Ohm reading to pin 3 Connector AIC-1, take
an Ohm reading to pin 46 Connector QSM11, take and Ohm reading to pin 25 Connector TECM, and take an
Ohm reading to pin 7 Connector SW-PD.
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(6) From pin D at the diagnostic connector, Connector DIA, take Ohm reading to pin 4 Connector AIC-1, take
an Ohm reading to pin 37 Connector QSM11, take and Ohm reading to pin 26 and 27 Connector TECM, and
take an Ohm reading to pin 8 Connector SW-PD.
A. NOT OK – Determine the break and repair. Return to Step 1 to confirm elimination of fault.
for assistance.
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Cause:

Solution:
rence.

2. Check circuit.
BD07F007-01 1
(1) Connector QSM11
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BD07E019-01 2

(2) Flasher module
BD07D128-01 3
(1) Connector AIC-2

(2) Connector AIC-1
BD07E012-01 4
(1) Switch pad

(2) Connector SW-PD
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for assistance.
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Cause:

Solution:
rence.

2. Check circuit.
BD07F007-01 1
(1) Connector QSM11
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BD07E019-01 2

(2) Flasher module
BD07D128-01 3
(1) Connector AIC-2

(2) Connector AIC-1
BD07E012-01 4
(1) Switch pad

(2) Connector SW-PD
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for assistance.
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9160-Hour Meter Failure - Both Copies Are Wrong

Cause:
1. Instrument Cluster internal failure
Solution:
rence.

(1). Remove and replace instrument cluster.
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9161-Hour Meter Failure - One Of Two Copies Are Wrong

Cause:
Solution:
rence.

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9162-Hour Meter Failure - Pre-crank And After-crank Checks Are

Wrong
Cause:
Solution:
rence.

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3001-Foot Throttle Sensor - Signal Not Plausible

Control Module : EDC
NOTE: The idle switch is internal to the throttle sensor assembly.
Cause:
1. Faulty wiring or connections.

2. Faulty reading from foot throttle sensor.
3. Faulty engine control.
Solution:
rence.

RCPH11WHL013AAL 1
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RCPH11WHL011FAL 2
Schematic legend
0.1volt
(3) Connector RTHP

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RCPH11WHL014AAL 3

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RCPH11WHL001GAL 4
Schematic legend
0.1volt
the WOT position.
A. The voltage measurement is correct. Go to Step 6.
of fault.
6. Test the idle validation switch.
(1) Install the dealer supplied breakout tee.
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(2) Turn the key switch ON, engine OFF. Leave the throttle is the low idle position. Measure the voltage between
pin 6 and pin 1. The voltage should be approximately 12 volts.
(3) Move the throttle approximately 3 degrees. The idle validation switch should change from 12 volts to 0 volts
and stay at 0 volts as the throttle is moved to WOT.
B. The voltage stayed at 12 volts, was sporadic or did not change at the low idle position. Temporarily replace
the throttle position sensor and retest. Go to step 1 to confirm elimination of fault.
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3002-Foot Throttle Sensor - Signal Above Range Maximum

Cause:

Solution:
rence.

RCPH11WHL013AAL 1
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RCPH11WHL011FAL 2
Schematic legend
0.1volt
(3) Connector RTHP

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RCPH11WHL014AAL 3

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RCPH11WHL001GAL 4
Schematic legend
0.1volt
the WOT position.
of fault.
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3003-Foot Throttle Sensor - Signal Below Range Minimum

Cause:

Solution:
rence.

RCPH11WHL013AAL 1
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RCPH11WHL011FAL 2
Schematic legend
0.1volt
(3) Connector RTHP

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RCPH11WHL014AAL 3

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RCPH11WHL001GAL 4
Schematic legend
0.1volt
the WOT position.
of fault.
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Index
FAULT CODES - DTC

0000-Retrieving fault codes, Wheel Loaders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1310-Hydraulic Filter Blocked . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1311-Engine Air Filter Blocked . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1312-Hydraulic Oil Temperature Above Normal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1313-Hydraulic Oil Temperature Too High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
1314-Transmission Oil Temperature Above Normal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
1315-Transmission Oil Temperature Too High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
1316-Brake Pressure Too Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
1317-Steering Pressure Too Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
1318-Engine Coolant Temperature Above Normal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
1319-Engine Coolant Temperature High - Critical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
1320-Engine Oil Pressure Too Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
1321-Engine Oil Pressure Below Normal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
1322-Engine Oil Pressure Above Normal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
1323-Battery Voltage Too Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
1324-Battery Voltage High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
1325-Engine Oil Temperature Too High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
1331-Electrical charging system voltage too low, critical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
1332-Water Detected In Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
1333-Engine Overspeed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
1334-Intake Manifold Temperature High - Critical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
1335-Brake pressure too low, critical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
1336-Transmission Oil Filter Blocked . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
3001-Foot Throttle Sensor - Signal Not Plausible . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 573
3002-Foot Throttle Sensor - Signal Above Range Maximum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 578
3003-Foot Throttle Sensor - Signal Below Range Minimum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 582
3004-Foot Throttle Sensor - No Signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
3006-Coolant Temperature Sensor - Signal Not Plausible . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
3007-Coolant temperature signal - signal above range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
3008-Coolant Temperature Signal - Signal Below Range Minimum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
3009-Coolant Temperature Sensor Circuit Open Or Sensor Disconnected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
3015-Fuel Temperature Sensor - Signal Above Maximum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
3016-Fuel Temperature Sensor - Signal Below Range Minimum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
3019-Boost Pressure Sensor - Signal Above Range Maximum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
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3021-Boost pressure sensor - (via CAN) no signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
3022-Boost Pressure Sensor - Signal Not Plausible . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
3023-Atmospheric Pressure Sensor - Signal Not Plausible . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
3024-Atmospheric Pressure Sensor - Signal Above Range Maximum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
3025-Atmospheric Pressure Sensor - Signal Below Range Minimum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
3028-Oil Pressure Too Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
3029-Oil Pressure Sensor - Short Circuit To Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
3030-Oil Pressure Sensor - Short Circuit To Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
3031-Oil Pressure Sensor - Hardware Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
3032-Oil Pressure Sensor - Value Too High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
3033-Oil Temperature Sensor - Signal Not Plausible (Compared With Coolant Temperature) . . . . . . . . . . . . . . . 110
3034-Oil Temperature Sensor - Signal Above Range Maximum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
3035-Oil Temperature Sensor - Signal Below Range Minimum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
3036-Oil temperature sensor circuit open or sensor disconnected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
3037-Boost Pressure Sensor - Signal Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
3051-Battery Voltage To Engine Controller - Voltage Too High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
3052-Battery Voltage To Engine Controller - Voltage Too Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
3060-Cylinder 1 - Unclassifiable Error In Injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
3061-Cylinder 1 - Injector Cable Short Circuit (Low Side To Battery) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
3062-Cylinder 1 - Electronic injector , Low signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
3063-Cylinder 1 - Injector Cable Short Circuit (High Side To Ground) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
3070-Cylinder 3 - Electronic injector , Low signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
3078-Cylinder 2 - Electronic injector, Low signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
3082-Cylinder 4 - Electronic injector, Low signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
3088-Crankshaft sensor lost synchronization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
3089-Crankshaft Sensor - Invalid Signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
3090-Camshaft Sensor - Lost Phase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
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3091-Camshaft sensor phase synchronization failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
3093-Offset Between Camshaft And Crankshaft - Outside Boundaries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
3095-Operating With Camshaft Sensor Only - Backup Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
3102-Rail Pressure Sensor CP3 - Signal Below Range Minimum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
3104-Rail Pressure Relief Valve - Open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
3105-Rail Pressure Relief Valve - Pressure Shock Requested . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
3106-Rail Pressure Relief Valve - Did Not Open After Pressure Shock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
3107-Metering unit output short circuit to battery on low side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
3110-Rail Pressure Sensor Monitoring - Signal Above Range Maximum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
3111-Rail Pressure Sensor Monitoring - Signal Below Range Minimum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
3112-Rail Pressure Sensor CP3 - Signal Above Maximum Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
3113-Grid heater battery switch relay short circuit to battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
3114-Grid heater battery switch relay short circuit to ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
3118-ECM 12V sensor supply voltage high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
3119-ECM 12V sensor supply voltage low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
3131-Grid Heater Always Switched On . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
3137-Metering Unit - Open Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
3138-Metering Unit - Signal Not Plausible . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
3141-Set point of fuel volume flow through metering unit is lower than calculated limit . . . . . . . . . . . . . . . . . . . . . 218
3147-Oil Temperature Sensor - Signal Above Normal Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
3154-Grid Heater Relay - Short Circuit To Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
3155-Grid Heater Relay - Short Circuit To Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226
3156-Grid Heater Relay - No Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230
3171-Fuel rail system pressure too low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233
3172-Fuel rail system pressure too high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237
3173-Rail Pressure Governor Deviation Below Min. Limit for Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241
3174-Rail Pressure Governor Deviation Exceeded Max. Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245
3175-Fuel system leak detected - large leak . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249
3176-Fuel delivery exceeded threshold for pressure in overrun mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253
3178-Timeout of CAN Message BC2EDC1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 254
3179-Timeout of CAN Message BC2EDC2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 256
3180-Timeout of CAN Message VCM2EDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258
3188-Cylinder 1 - Open Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260
3210-Bank 1 - General Short Circuit To Injector Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 275
3211-Bank 1 - Injector cable Short Circuit Low Side to Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 278
3212-Bank 1 - No Signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280
3213-Bank 1 - Unclassifiable Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 286
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3218-Bank 2 - General Short Circuit On Injector Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 291
3219-Bank 2 - Injector Cable Short Circuit Low Side To Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 296
3220-Bank 2 No Signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301
3221-Bank 2 - Unclassifiable Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 307
3227-Injection Processor Error - Internal Reset/Clock Loss/Voltage Too Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 312
3228-Injection Processor Error - Unlocked/Initialization Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 313
3229-Injection Processor Error - Injections Limited By Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 314
3230-Injection Processor Error - SPI Communication Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 315
3231-Injection Processor Error - Internal Reset/Clock Loss/Voltage Too Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 316
3232-Injection Processor Error - Unlocked/Initialization Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 317
3233-Injection Processor Error - Test Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 318
3234-Injection Processor Error - SPI Communication Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 319
3238-Communication error of CJ940 processor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 320
3242-Engine Controller (Locked) Recovery Occurred . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 321
3243-Engine Controller Recovery (Suppressed) - Recovery Occurred . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 322
3244-Engine Controller Recovery (Visible) - Recovery Occurred . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 323
3245-Engine Controller - Watchdog Not Plausible . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 324
3246-Shutoff Paths During Initialization - Watchdog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 325
3247-Shutoff Paths Failed During Initialization - Supply Voltage Too High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 326
3248-Shutoff Paths During Initialization - Supply Voltage Too Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 327
3253-ADC Monitoring - Reference Voltage Too Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 328
3254-ADC Monitoring - Reference Voltage Too High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 329
3255-ADC Monitoring Test Impulse Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 330
3256-ADC Monitoring Queue Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 331
3258-HS power stage hardware reports 'short circuit to battery' longer than 500 ms. . . . . . . . . . . . . . . . . . . . . . . 332
3259-HS power stage hardware reports 'short circuit to ground' longer than 100 ms. . . . . . . . . . . . . . . . . . . . . . . 334
3260-LS power stage hardware reports 'open load' longer than 100 ms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 336
3261-LS power stage hardware reports 'short circuit to battery' or 'excess temperature' longer than 100 ms. . 338
3262-LS power stage hardware reports 'short circuit to ground' longer than 100 ms. . . . . . . . . . . . . . . . . . . . . . . 340
3265-Energizing time exceeds limit of over run monitoring, injection time too long . . . . . . . . . . . . . . . . . . . . . . . . 342
3266-Error in engine speed check, speed signal not plausible . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 343
3278-Engine Controller Internal Supply Voltage Too High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 344
3279-Engine Controller Internal Supply Voltage Too Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 346
3280-Sensor Supply Voltage 1 - High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 348
3281-Sensor Supply Voltage 1 - Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 350
3998-Unknown error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 360
3999-Unknown error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 362
4113-Logical error at FNR switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 364
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4114-Logical error at direction select signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 368
4116-Logical error at park brake status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 372
4117-Logic error at direction select signal 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 379
4119-Short circuit to ground at ride control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 383
4120-Short circuit to battery voltage at ride control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 390
4121-Open circuit at ride control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 397
4133-Short circuit to battery voltage or open circuit at transmission sump temperature sensor input . . . . . . . . . 404
4134-Short circuit to ground at transmission sump temperature sensor input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406
4135-Short circuit to battery voltage or open circuit at retarder/ torque converter temperature sensor input . . . 408
4136-Short circuit to ground at retarder/ torque converter temperature sensor input . . . . . . . . . . . . . . . . . . . . . . . 410
4137-Short circuit to battery voltage or open circuit at parking brake sensor input . . . . . . . . . . . . . . . . . . . . . . . . . 412
4145-Short circuit to battery voltage or open circuit at engine speed input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 419
4146-Short circuit to ground at engine speed input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 422
4147-Logical error at engine speed input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 425
4148-Short circuit to battery voltage or open circuit at turbine speed input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 428
4149-Short circuit to ground at turbine speed input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 431
4150-Logical error at turbine speed input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 434
4151-Short circuit to battery voltage or open circuit at internal speed input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 437
4152-Short circuit to ground at internal speed input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 440
4153-Logical error at internal speed input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 443
4154-Short circuit to battery voltage or open circuit at output speed input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 446
4155-Short circuit to ground at output speed input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 450
4156-Logical error at output speed input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 454
4158-Output speed zero, doesn't fit to other speed signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 458
4160-Invalid gear range restriction (CAN) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 462
4186-Invalid park brake status (CAN) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 464
4209-Short circuit to battery voltage at clutch K1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 466
4210-Short circuit to ground at clutch K1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 468
4211-Open circuit at clutch K1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 470
4228-Short circuit to battery voltage at clutch KV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 490
4229-Short circuit to ground at clutch KV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 492
4230-Open circuit at clutch KV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 494
4231-Short circuit to battery voltage at clutch KR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 496
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4232-Short circuit to ground at clutch KR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 498
4233-Open circuit at clutch KR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 500
4241-Short circuit to ground at backup alarm relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 502
4242-Short circuit to battery voltage at backup alarm relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 505
4243-Open circuit at backup alarm relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 508
4273-Slippage at clutch K1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 511
4277-Slippage at clutch KV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 515
4278-Slippage at clutch KR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 516
4279-Overtemp sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 517
4281-Engine overspeed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 520
4282-TCM sensed a voltage at oil filter maintenance switch out of the allowed range (dirty filter) . . . . . . . . . . . . 523
4284-Overspeed output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 526
4290-Transmission input torque overload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 530
4291-Overtemp converter output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 531
4292-Short circuit to ground at joystick status indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 534
4293-Short circuit to battery voltage at joystick status indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 538
4294-Open circuit at joystick status indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 542
4305-Short circuit to battery voltage at power supply for sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 546
4306-Short circuit to ground at power supply for sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 547
4307-Low voltage at battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 548
4308-High voltage at battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 549
4309-Error at valve power supply VPS1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 550
4310-Error valve power supply VPS2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 551
4325-VehicleID#1 timeout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 552
4326-Illegal ID request via CAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 555
4337-General EEPROM fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 556
4338-Configuration error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 557
4339-Application error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 558
4341-Clutch failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 559
4342-Clutch adjustment data lost . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 560
9128-CAN Timed Out During Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 561
9160-Hour Meter Failure - Both Copies Are Wrong . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 570
9161-Hour Meter Failure - One Of Two Copies Are Wrong . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 571
9162-Hour Meter Failure - Pre-crank And After-crank Checks Are Wrong . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 572
47392461 19/06/2012
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PRINTED IN U.S.A.
47392461 19/06/2012
EN
SERVICE MANUAL
Platform, cab, bodywork, and decals
1021F
1121F
47392461 19/06/2012
90
Contents
Platform, cab, bodywork, and decals - 90
Machine shields and guards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.105

1021F , 1121F
Protections and footboards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.118

1021F , 1121F
Pneumatically-adjusted operator seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.124

1021F , 1121F
Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.150
1021F , 1121F
47392461 19/06/2012
90
Machine shields and guards - 105
1021F
1121F
47392461 19/06/2012
90.105 / 1
Contents
SERVICE
Engine hood
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
47392461 19/06/2012
90.105 / 2
Platform, cab, bodywork, and decals - Machine shields and guards
Engine hood - Remove

1. Remove side panels.
2. Remove bolts (1) from the screen (2) and panel (3)
located on top of the engine.
RCPH11WHL017BAQ 1
3. Remove nuts (1) from the electric roller hood strut

(2).
RCPH11WHL018BAQ 2
4. Attach lifting straps (1) to the hood frame (2).
RCPH11WHL019BAQ 3
47392461 19/06/2012
90.105 / 3
5. Manually raise the hood to the up position
RCPH11WHL020BAQ 4
6. Tag and disconnect hood wiring harness connector

from rear chassis wiring harness connector.
RCPH11WHL021BAQ 5
7. Mark washer (1) and hinge (2) for reposition during

assembly. Remove bolts and washers securing hood
to the machine.
RCPH11WHL022BAQ 6
NOTE: A punch may be used to hold washer and bolt from turning while removing the input from inside.
47392461 19/06/2012
90.105 / 4
8. Mark and remove plate tooth.
RCPH11WHL023BAQ 7
9. Carefully raise and remove hood from loader. Lower

the hood onto a suitable platform and disconnect lift-
ing equipment.
47392461 19/06/2012
90.105 / 5
Engine hood - Install

1. Carefully move and align hood over the loader.
2. Install and align plate tooth with previous marks from
removal procedure.
RCPH11WHL023BAQ 1
NOTE: A punch may be used to hold washer and bolt from turning while installing the input from inside.
3. Align washer (1) and hinge (2) with previous marks
from removal procedure. Install bolts and washers
securing hood to the machine.
RCPH11WHL022BAQ 2
4. Connect hood wiring harness connector to the

tagged connector on the rear chassis wiring har-
ness. Remove tag.
RCPH11WHL021BAQ 3
47392461 19/06/2012
90.105 / 6
5. Manually lower the hood into the down position
RCPH11WHL020BAQ 4
6. Remove lifting straps (1) from the hood frame (2).
RCPH11WHL019BAQ 5
7. Secure the electric roller hood strut (2) with nuts (1) .
RCPH11WHL018BAQ 6
47392461 19/06/2012
90.105 / 7
8. Position screen (2) and panels (3) on top of the hood

and secure with bolts (1).
RCPH11WHL017BAQ 7
9. Install side panels.
Next operation:
Engine hood - Alignment (90.105)
47392461 19/06/2012
90.105 / 8
Engine hood - Alignment

1. Measure the distance at location (1) and location (2).
This distance is the distance between the hydraulic
oil tank and the outside edge of the chassis. If the
values are within the ranges specified in table 1, the
hydraulic tank is centered in the chassis. If the differ-
ence of the two measured values from the left side
of the machine is less than 2mm, then the hydraulic
tank is parallel to the chassis.
RCPH11WHL115AAR 1
Table 1. Hydraulic oil tank centering values

Model Max Min
1021F 27 mm 23 mm
1121F 36 mm 32 mm
2. If the hydraulic tank is not centered in the chassis

or parallel to the chassis, adjust the position of the
hydraulic oil tank and measure again. Repeat this
step until the hydraulic oil tank measurements are
within the specified parameters.
3. Measure the gap between the left hand hood panel
(1) and the rear screen (2).
4. Measure the gap between the right hand hood panel
(3) and the rear screen (2).
5. If the measured gap is between 0.5 mm and 3 mm,
then no further adjustment is necessary.
RCPH11WHL100AAR 2
47392461 19/06/2012
90.105 / 9
6. If the gap is less than 0.5 mm add one washer (3) be-
tween the iso-mount plate (1) and the hood structure
(2) at each mounting point. Repeat this step until the
left and right hood panel measurements are within
the specified parameters.
7. If the measured gap is greater than 3 mm, remove
one washer (3) between the iso-mount plate (1) and
the hood structure (2) at each mounting point. Re-
peat this step until the left and right hood panel mea-
surements are within the specified parameters.
RCPH11WHL101AAR 3
8. Align the left panel (1) and right panel (not called out)
with the edge of the rear screen (2).
9. Tighten the mounting hardware.
RCPH11WHL098AAR 4
10. Raise and lower the engine hood. If the engine hood
has trouble clearing the cooling box, the engine hood
will need to be adjusted using the adjustable tooth
washers (1) in the hood pivot joint. If the hood needs
to move to the right, move the right side pivot joint
tooth washer to the rear of the hood frame slot (2), or
move the left side pivot joint tooth washer to the front
of the hood frame slot. If the hood needs to move to
the left, move the right side pivot joint tooth washer to
the front of the hood frame slot, or move the left side
pivot joint tooth washer to the rear of the hood frame
slot. Make these adjustments one notch at a time
until the hood clears the cooling frame when closing.
RCPH11WHL023BAQ 5
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90.105 / 10
11. Measure the distance at location 1 and location 2. If

the distance at location 1 or location 2 is between 0.0
mm and 14 mm, no further adjustment is required.
12. If the distance at location 1 or location 2 is more than
14 mm, refer to step 10. Adjust the hood until the
distance at location 1 and location 2 is between 0.0
mm and 14 mm.
RCPH11WHL105AAR 6
13. Measure the distance from the top, left of the coun-
terweight (4) to the top, left of the rear frame (1) and
measure the distance from the top, right of the coun-
terweight (3) to the top, right of the rear frame (2).
The difference between the two distances should be
no greater than 3 mm. If the differences between
the two distances is greater than 3 mm, readjust the
counterweight.
RCPH11WHL107AAR 7
14. Fully close the engine hood. Remove the access

panel (1) on the top engine hood screen to gain ac-
cess to the hood actuator shaft jam nut and flange
nut.
RCPH11WHL017BAQ 8
47392461 19/06/2012
90.105 / 11
15. Loosen the jam nut (1). Turn the flange nut (2) left
or right until only one of the bumpers (3) touches the
counterweight.
RCPH11WHL116AAR 9
RCPH11WHL110AAR 10
16. Measure the distance (1) from the bottom of the en-
gine hood to the top of the counterweight.
RCPH11WHL110AAR 11
47392461 19/06/2012
90.105 / 12
17. Adjust the flange nut (2) until the distance between
the engine hood and counterweight is 5 mm less than
the measurement recorded in step 16.
18. Tighten the jam nut (1).
RCPH11WHL116AAR 12
19. Using the hood actuator switch, lift or lower the en-
gine hood until the second bumper (1) touches the
counterweight.
RCPH11WHL113AAR 13
20. Measure the distance (1) between the engine hood

and the counterweight.
RCPH11WHL113AAR 14
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90.105 / 13
21. Fully lower the hood.

22. Measure the distance (1) between the engine hood
and the counterweight. This new measurement
needs to be 3 mm less than the recorded measure-
ment in step 20.
23. If the new measurement is less than 3 mm, the coun-
terweight or the engine hood will need to be read-
justed.
RCPH11WHL114AAR 15
47392461 19/06/2012
90.105 / 14
Index

Engine hood - Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Engine hood - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Engine hood - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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Protections and footboards - 118
1021F
1121F
47392461 19/06/2012
90.118 / 1
Contents
SERVICE
Ladder
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
47392461 19/06/2012
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Platform, cab, bodywork, and decals - Protections and footboards
Ladder - Remove
RCPH11WHL039AAH 1
Left step and ladder assembly

2. Remove the accumulator cover (1).
RCPH11WHL070AAR 2
3. Remove the bolts (1) that secure the hydraulic oil

tank drain line to the stairs.
RCPH11WHL071AAR 3
47392461 19/06/2012
90.118 / 3
4. Attaching lifting equipment to the step and ladder as-

sembly.
RCPH11WHL069AAR 4
5. Remove the step and ladder assembly (1).
RCPH11WHL072AAR 5
Right step and ladder assembly

1. Remove the upper panel (1) behind the step and lad-
der assembly.
RCPH11WHL076AAR 6
47392461 19/06/2012
90.118 / 4
2. Remove the lower panel (1) behind the step and lad-
der assembly.
RCPH11WHL077AAR 7
3. Remove the washer reservoir cover (1).
RCPH11WHL074AAR 8
4. Label the washer pump electrical connectors (1).

Disconnect the washer pump electrical connectors
(1).
5. Label the washer pump supply hoses (2). Discon-
nect the washer pump supply hoses (2).
RCPH11WHL075AAR 9
47392461 19/06/2012
90.118 / 5

sembly.
RCPH11WHL095AAR 10
7. Remove the step and ladder assembly (1).
RCPH11WHL078AAR 11
47392461 19/06/2012
90.118 / 6
Ladder - Install
Left step and ladder assembly
sembly.
RCPH11WHL069AAR 1
2. Install the step and ladder assembly (1).
RCPH11WHL072AAR 2
3. Install the bolts (1) that secure the hydraulic oil tank
drain line to the stairs.
RCPH11WHL071AAR 3
47392461 19/06/2012
90.118 / 7
4. Install the accumulator cover (1).
RCPH11WHL070AAR 4
Right step and ladder assembly

sembly.
RCPH11WHL078AAR 5
3. Connect the washer pump electrical connectors (1).

4. Connect the washer pump supply hoses (2).
RCPH11WHL075AAR 6
47392461 19/06/2012
90.118 / 8
5. Install the washer reservoir cover (1).
RCPH11WHL074AAR 7
6. Install the lower panel (1) behind the step and ladder
assembly.
RCPH11WHL077AAR 8
7. Install the upper panel (1) behind the step and ladder
assembly.
RCPH11WHL076AAR 9
47392461 19/06/2012
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Index

Ladder - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Ladder - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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Pneumatically-adjusted operator seat - 124
1021F
1121F
47392461 19/06/2012
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Contents
DIAGNOSTIC
Seat pneumatic lift system

Compressor - Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
47392461 19/06/2012
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Platform, cab, bodywork, and decals - Pneumatically-adjusted operator seat
Seat pneumatic lift system Compressor - Testing

Turn the key switch OFF. Disconnect The resistance should be less than The resistance is greater than 10 Ω.
the Seat Compressor connector. 10 Ω. There is an open circuit in the chas-
Check sis ground connection to the Air Seat
Measure the resistance from the Compressor. Verify that the wire and
Seat Compressor connector pin B to connection points are free of abra-
chassis ground. sion, corrosion or incorrect attach-
Check 24 volts. is a problem with the battery supply
Measure the voltage across the Seat Action to the Air Seat Compressor. Check
Compressor pin A and pin B. Temporarily replace the Air Seat fuse ECA-F16.
Compressor Motor and retest.
RCPH11WHL020FAL 1
(1) Switched Battery, 24 V (4)

(2) Seat Compressor, ECA-F16 (5) Seat Compressor connector
15 A
(3) Seat Compressor Motor, Air Seat Option (6) GND_CAB_SPL , pin J
Only
47392461 19/06/2012
90.124 / 3
Index

Seat pneumatic lift system Compressor - Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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Cab - 150
1021F
1121F
47392461 19/06/2012
90.150 / 1
Contents
Cab - 150
SERVICE
Cab
Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Cab suspension
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
47392461 19/06/2012
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Platform, cab, bodywork, and decals - Cab
Cab - Inspect
DANGER
Crushing hazard!
Do not change the Roll Over Protective Structure (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 damage of any kind occurs. DO NOT TRY TO REPAIR THE ROPS.
D0037A
After an accident, fire, tip over, or roll over, have a qualified

technician inspect and replace cab or ROPS canopy and
other protective structure components (such as the seat
belt), before returning the machine to operation.
1. Replace the cab or ROPS canopy.
2. Inspect the mounting and suspension for the cab
or ROPS canopy, the operator's seat and suspen-
sion, the seat belt and mounting components, and
the wiring for damage. Replace damaged parts.
3. Tighten all bolts and mounted equipment to specifi-
cations.
47392461 19/06/2012
90.150 / 3
Cab suspension - Install

1. Attach lifting equipment to the cab. Carefully lower
the cab onto the chassis.
RCPH11WHL093AAR 1
2. Install the cab mounting bolts (1). Tighten the cab

mounting bolts (1) to a torque of 773 - 854 N·m (570
- 630 lb ft).
RCPH11WHL089AAR 2
3. Connect the cab ground (1).
RCPH11WHL090AAR 3
47392461 19/06/2012
90.150 / 4
4. Connect the electrical connector (1).
RCPH11WHL091AAR 4
5. Connect the heater core hoses (1) to the heater core.

6. Install the A/C lines (2).
RCPH11WHL088AAR 5
7. Attaching lifting equipment to the right step and lad-

der assembly.
RCPH11WHL095AAR 6
47392461 19/06/2012
90.150 / 5
8. Install the right step and ladder assembly (1).
RCPH11WHL078AAR 7
9. Connect the washer pump electrical connectors (1).

10. Connect the washer pump supply hoses (2).
RCPH11WHL075AAR 8
11. Install the washer reservoir cover (1).
RCPH11WHL074AAR 9
47392461 19/06/2012
90.150 / 6
12. Install the lower panel (1) behind the right step and
ladder assembly.
RCPH11WHL077AAR 10
13. Install the upper panel (1) behind the right step and
ladder assembly.
RCPH11WHL076AAR 11

sembly.
RCPH11WHL069AAR 12
47392461 19/06/2012
90.150 / 7
RCPH11WHL072AAR 13
16. Install the bolts (1) that secure the hydraulic oil tank
drain line to the stairs.
RCPH11WHL071AAR 14
17. Install the accumulator cover (1).
RCPH11WHL070AAR 15
47392461 19/06/2012
90.150 / 8
18. Connect all the hydraulic lines located inside the con-
sole.
RCPH11WHL085AAR 16
19. Install the hydraulic hoses rubber grommet .
RCPH11WHL087AAR 17
20. Connect the P-clamps (1) that secure the wiring har-
ness to the cab.
RCPH11WHL086AAR 18
47392461 19/06/2012
90.150 / 9
21. Connect all the electrical connectors located inside

the console.
22. Install the wire harness rubber grommet (2).
23. Install the rubber grommet hold-down panel (1).
RCPH11WHL084AAR 19
24. Position the steering control valve on the steering

shaft spline shaft. Support the steering control valve.
Install the steering control valve mounting bolts (1)
that fasten the steering control valve assembly to the
bottom of the pedestal.
25. Install the steering column lower trim (1).
26. Install the steering column upper trim (1).
27. Support the brake valve. Install the brake valve
mounting bolts (1) that fasten the brake valve as-
sembly to the bottom of the pedestal.
28. Install the right brake pedal (1).
29. Install the left brake pedal (1)
30. Install the pivot rod (1) from the left brake pedal.
31. Install the set screws (1) on the left brake pedal.
32. Install the cotter pin (1) in the pivot rod. Pull the
rubber brake pedal cover over the left brake pedal.
33. Install the left cab skirt (1).
RCPH11WHL080AAR 20
47392461 19/06/2012
90.150 / 10
34. Install the right cab skirt (1).
RCPH11WHL079AAR 21
35. Install the front cab skirt (1).
RCPH11WHL081AAR 22
47392461 19/06/2012
90.150 / 11
Index
Cab - 150
Cab - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Cab suspension - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
47392461 19/06/2012
90.150 / 12
47392461 19/06/2012
90.150 / 13
PRINTED IN U.S.A.
47392461 19/06/2012
EN
SPECIAL TOOL INDEX
Genuine IU PAGE
CAS2268 [Puller] Powershift transmission - Disassemble 21.113 / 23
CAS2268 [Puller] Powershift transmission - Disassemble 21.113 / 27
380100001 [Bearing Cup Bevel gear set and differential carrier - Backlash Model 3105 II 25.102 / 9
Installer ]
CAS2842 [Pinion Locknut Bevel gear set and differential carrier - Backlash Model 3105 II 25.102 / 10
Wrench]
CAS2842 [Pinion Locknut Differential - Remove Model 3105 II 25.102 / 27
Wrench]
380001546 [Flange Holder] Differential - Remove Model 3105 II 25.102 / 27
CAS2842 [Pinion Locknut Differential - Install Model 3105 II 25.102 / 36
Wrench]
CAS2841 [Pinion Shaft Seal Differential - Install Model 3105 II 25.102 / 36
Installer ]
CAS2842 [Pinion Locknut Differential - Install Model 3105 II 25.102 / 37
Wrench]
380001546 [Flange Holder] Differential - Install Model 3105 II 25.102 / 37
380040185 [Harness 3061-Cylinder 1 - Injector Cable Short Circuit 55.DTC / 131
Diagnostic /Repair Kit (NEF)]
19/06/2012
15
PRINTED IN U.S.A.
47392461 19/06/2012
EN
INDEX OF FUNCTIONS
62 ECD ENG ENGINE-CAB1
LARGE CONNECTOR LIST PIN SHEET PIN NAME SHEET PIN NAME SHEET PIN NAME SHEET PIN NAME SHEET PIN SHEET PIN SHEET
NAME DESCRIPTION SHEET

4, 7, 9, 10
4, 6, 7, 9, 10
4, 5, 9, 10, 11, 12
6, 10
13
4, 5, 6, 7, 8, 9, 10, 11
4, 6, 9, 10, 12
4, 6, 7, 8, 9, 10, 11
4, 5, 6, 10, 11, 12
4, 5, 9, 10, 11, 12
6, 10
71
6, 9, 10, 12 70
PIN SHEET PIN SHEET
COLOR ABBREVIATIONS
TRANS-CAB
PIN SHEET
ENG2 ENG BULKHD2

PIN SHEET
INDEX / WIRE INFORMATION 1 CONNECTOR LIST 2
18
21 13
14 15
20
32.0
32.0
9
11
32.0 10
1
24
158
16 32.0
200 A
32.0 6
159
17 150
160
32.0
CONNECTOR LIST 3 COLD START POWER DISTRIBUTION IGNITION SWITCH 4

ELECTRICAL SCHEMATIC SIDE 1
1021F, 1121F TIER 2 WHEEL LOADER
Additional copies of this schematic can be ordered through Technical Publications Distribution System. Part # RAC 47388802
22
24
92
90
133
161
93
95
78
91
North American models

European and International models
101 100 101 100
79
23
94
132
131
103
96 97
102
ENGINE CONTROL 5 LIGHTING 1 BACKUP ALARM 6
89
172
54
81 173 171
57
59
56
88
87
80 55 174
46
86
47
61
48 45
58
85 49
84
50
51
52
170
53
83
60
82
LIGHTING 2 7 TRANSMISSION CONTROLS 8

35
25
36
26
63
29
33
64
32 31
37
98
68
72 74
27
67
99
65
69
39
73
75 28
40
38
76 30
66
44 42 41
43
134
INSTRUMENT CLUSTER 9 MACHINE CONTROLS 10
121
127
122
113
126
155 129
122
154
104
128
108
105 130
114 125
123
106 124
119
107
117
115 109
156 135
111
116 137
BLUE BROWN
DOWN UP
112
LIMIT LIMIT
SWITCH 113
SWITCH 139
136 138
157
110
118
CAN
COMMUNICATION
SECONDARY STEERING HOOD LIFT WIPER/WASHER SYSTEM 11 HVAC AIR SEAT RADIO POWER/CONVERTER 12
145
144
143
146
184
177
175
147
185
176 148
179
178
181
186
182 152
149 153
180 150 151
183
JOYSTICK STEERING 13 STANDARD HVAC 14

COMPONENT NUMBERS
# SHT COMPONENT # SHT COMPONENT # SHT COMPONENT # SHT COMPONENT
1 4 STARTING RELAY 61 8 DIAGNOSTIC CONNECTOR 119 12 DIAGNOSTIC CONNECTOR 177 13 ARM POS
2 4 RESISTOR - 75 OHM 62 1 INSTRUMENT CLUSTER CONNECTOR 1 121 12 POWER CONVERTER - 24 TO 12 VOLT 178 13 FNR SWITCH (OPTION)
3 4 ALTERNATOR 63 9 WARNING BUZZER 122 12 12 VOLT POWER OUTLETS (OPTION) 179 13 FNR RELAY
4 4 CRANK CONTROL RELAY 64 9 PARKING BRAKE RELAY 123 12 RADIO 180 13 PILOT DUMP VALVE
5 4 BATTERIES 65 9 FUEL LEVEL SENDER 124 12 RIGHT SPEAKER 181 13 JSS VALVE
6 4 CRANK REQUEST RELAY 66 9 AIR FILTER RESTRICTION SWITCH 125 12 LEFT SPEAKER 182 13 LOAD SENSE PRESSURE SENSOR
8 4 MASTER DISCONNECT SWITCH 67 9 PARKING BRAKE SOLENOID 126 12 AIR SEAT 183 13 PILOT PRESSURE SWITCH
9 4 STARTER 68 9 RADIATOR COOLANT TEMPERATURE SENDER 127 12 CIGAR LIGHTER 184 13 JSS RELAY
10 4 IGNITION SWITCH 69 9 BRAKE PRESSURE WARNING SWITCH 128 12 AIR CONDITIONING CLUTCH RELAY 185 13 JOYSTICK STR SWITCH (OPTION)
11 4 NEUTRAL START RELAY 70 1 SWITCH PAD 129 12 AIR CONDITIONING HIGH-LOW PRESSURE SWITCH 186 13 JSS CONTROLLER
13 4 POWER RELAY MODULE A 71 1 INSTRUMENT CLUSTER CONNECTOR 2 130 12 AIR CONDITIONING COMPRESSOR CLUTCH
14 4 POWER RELAY MODULE B 72 9 HYDRAULIC FILTER RESTRICTION SWITCH 131 5 EVGT RELAY
15 4 POWER RELAY MODULE C 73 9 HYDRAULIC OIL TEMPERATURE SENDER 132 5 TURBO CONTROLLER
16 4 GRID HEATER RELAY 74 9 PARK BRAKE SWITCH 133 5 DIA-2 DIAGNOSTIC CONNECTOR
17 4 GRID HEATER 75 9 REDUNDANT BRAKE PRESSURE SWITCH 1 134 10 HEAT LOAD VALVE SOLENOID
18 4 POWER RELAY MODULE D 76 9 REDUNDANT BRAKE PRESSURE SWITCH 2 135 12 MIRROR HEAT TIMER RELAY
20 4 WATER SEPARATOR HEATER 78 6 BACKUP ALARM RELAY 136 12 MIRROR HEAT SWITCH
21 4 FUEL FILTER HEATER 79 6 BACKUP ALARM DISABLE SWITCH 137 12 MIRROR HEAT RIGHT
22 5 WATER IN FUEL SENSOR 80 7 WORK LAMPS SWITCH 138 12 MIRROR HEAT LEFT
5 THROTTLE POTENTIOMETER
1021F, 1121F Tier 4 Wheel Loader 23
24 4, 5 ENGINE CONTROLLER
81
82
7
7
DOOR SWITCH
ROTATING BEACON (OPTIONAL)
139
140
12 TELEMATICS
25 10 RETURN TO TRAVEL FLOAT SWITCH 83 7 DOME LAMP 141

ELECTRICAL SCHEMATIC 26 10 HEIGHT CONTROL SWITCH 84 7 ROTATING BEACON SWITCH (OPTIONAL) 142
27 10 ELECTROMAGNETIC DETENTS 85 7 LEFT HAND FRONT WORK LAMP 143 14 ACTUATOR
28 10 RETURN TO DIG PROXIMITY SWITCH 86 7 RIGHT HAND FRONT WORK LAMP 144 14 DRIVER
29 10 PILOT CONTROL RELAY ECD-K3 87 7 LEFT HAND REAR WORK LAMP 145 14 ELECTRONIC WATER VALVE
30 10 HEIGHT CONTROL AND RETURN TO TRAVEL PROXIMITY SW 88 7 RIGHT HAND REAR WORK LAMP 146 14 BLOWER FAN RESISTOR
LEGEND 31 10 RETURN TO DIG SWITCH 89 7 DIODES 147 14 BLOWER MOTOR
32 10 PIN ENGAGE SWITCH (OPTION) 90 6 BRAKE LAMP SWITCH 148 14 THERMOSTAT
33 10 PILOT PRESSURE SOLENOID 91 6 BRAKE LAMP RELAY 149 14 FAN SPEED SWITCH
INDICATES CONSTANT POWER 34
35 10 RIDE CONTROL SWITCH (OPTION)
92
93
6
6
FLASHER MODULE
HAZARD SWITCH
150
151
14
14
AIR CONDITIONING SWITCH
CONTROL PANEL LAMPS
36 10 RIDE CONTROL RELAY (OPTION) 94 6 TURN SIGNAL, HIGH-LOW BEAM, AND HORN SWITCH 152 14 WATER VALVE POTENTIOMETER
INDICATES POWER WHEN KEY 37 10 FAN CONTROL SWITCH (OPTION) 95 6 DRIVING LAMPS SWITCH 153 14 AIR RECIRCULATING SWITCH
38 10 FAN REVERSE RELAY (OPTION) 96 6 LEFT HAND FRONT COMBINATION LAMPS 154 11 HOOD UP RELAY
SWITCH IS ON 39 10 PILOT CONTROL SWITCH 97 6 RIGHT HAND FRONT COMBINATION LAMPS 155 11 HOOD DOWN RELAY
40 10 RIDE CONTROL SOLENOID (OPTION) 98 10 HORN RELAY 156 11 HOOD SWITCH
INDICATES POWER WHEN KEY 41 10 ROLLBACK PRESSURE SW (XT WITH RIDE CONTROL ONLY) 99 10 HORN RELAY 157 11 HOOD MOTOR
SWITCH IS IN START POSITION 42 10 ROLLBACK JUMPER 100 6 RIGHT HAND REAR COMBINATION LAMPS 158 4 IGNITION POWER LATCH
43 10 FAN PWM SOLENOID 101 6 LEFT HAND REAR COMBINATION LAMPS 159 4 IGNITION POWER CONTROL
44 10 FAN REVERSE SOLENOID (OPTION) 102 6 LICENSE PLATE LAMP 160 4 START LOCKOUT
POWER RELAY A 45 8 OUTPUT SPEED SENSOR 103 6 BACKUP ALARM 161 5 NOX SENSOR
46 8 TRANSMISSION SOLENOID VALVE AND TEMP SENDER 104 11 FRONT WIPER HIGH SPEED RELAY 162 5 HUMIDITY AND AMBIENT TEMPERATURE SENSOR
POWER RELAY B 47 8 FILTER MAINTENANCE SWITCH 105 11 WIPER CUTOUT RELAY 163 5 NOX SENSOR (NOXS)
8 TORQUE CONVERTER OUTPUT TEMPERATURE SENDER
POWER RELAY C 48
49 8 ENGINE SPEED SENSOR
106
107
11
11
FRONT WIPER LOW SPEED RELAY
REAR WIPER AND WASHER SWITCH
164
165
5
5
TANK HEATER CONTROL VALVE
DEF LEVEL AND TANK TEMPERATURE
8 INTERMEDIATE SPEED SENSOR
POWER RELAY D 50
51 8 TURBINE SPEED SENSOR
108
109
11
11
FRONT WIPER AND WASHER SWITCH
FRONT WIPER MOTOR
166
167
5
5
UPSTREAM TEMPERATURE SENSOR
DOWNSTREAM TEMPERATURE SENSOR
ILLUMINATION 52 8 TRANSMISSION SHIFTER 110 11 REAR WIPER MOTOR 168 5 DOSER METERING VALVE
53 8 TRANSMISSION ELECTRONIC CONTROL MODULE 111 11 REAR WASHER MOTOR 169 5 DNOX CONTROLLER
54 8 TRANSMISSION ENABLE SWITCH 112 11 FRONT WASHER MOTOR 170 7 REAR VIEW CAMERA/MONITOR
55 8 FNR SWITCH FOR JOYSTICK CONTROLS 113 11 DIODES 171 8 DIFFERENTIAL LOCK SWITCH (MANUAL)
56 8 TRANSMISSION KICK DOWN SWITCH 114 11 SECONDARY STEERING DIODES 172 8 DIFFERENTIAL LOCK SWITCH
57 8 FNR SWITCH FOR SINGLE AXIS CONTROLS 115 11 SECONDARY STEERING SOLENOID 173 8 DIFFERENTIAL LOCK SOLENOID
58 8 TRANSMISSION AUTO SWITCH 116 11 SECONDARY STEERING MODULE 174 8 LOCKUP SOLENOID
59 8 BRAKE DECLUTCH PRESSURE SWITCH 117 11 SECONDARY STEERING MOTOR 175 13 JOYSTICK PVRES
60 8 DECLUTCH SWITCH 118 11 SECONDARY STEERING PRESSURE SWITCH 176 13 TRANSMISSION KICK DOWN SWITCH
ELECTRICAL WIRING INFORMATION 15 COMPONENT NUMBERING INFORMATION 16

1 2 21
9 13 19
18
16
20 X1 X2
T
11 MX
PP
16B
8 20D
16A 20A
12
TT 20C
R R1 F
4 16C
15A 15
3
20B
X 15F
22
15E
16D
B A
5 P 11
15D
22
3 15B
T1 16E
11
6 T1'
7 N B
Q=240±8%L/min
Q=240±8%L/min
Q=20±8%L/min
Q=20±8%L/min
15C 22J
T2 22J
b4
b2
b3
b1
22J
BOOM
Ø2.0
Ø2.0
Ø0.8
Ø0.8
22
Ø2.0
Ø0.8
T2
R2
A2
A1
B2
B1
22E 22E 22D
11
22M 22L 22G 22D 22D 22B
pst
TP10: REAR BRAKE TO AXLE
22C 22C 22C 22C
TP11: FRONT BRAKE TO AXLE
22K
)(
TP7: FRONT BRAKE ACCUMULATOR 10 14 22H 22K

TP6: REAR BRAKE ACCUMULATOR 22F
TP9: PILOT PRESSURE SUPPLY
Ø0.8
Ø0.8
Ø2.0
Ø2.0
A3
B3
P
A4
P2
B4
Ø0.6
Ø1.2
T
Q=360±8% L/min
Q=360±8% L/min
AUX. 1
TP3: LOAD SENSE SIGNAL 17
22J
BUCKET
Q=240±8%
Q=240±8%
L/min
a1
L/min
a3
a4
22J
LS
Ø0.8
Ø2.0
TP5: PUMP 1 PRESSURE 22A
TP1: PUMP 2 PRESSURE 22J
a2
52
M2 52C
P
24
51 52B
52A
L
50 24A
P 24B
M2 IN
49 23cc 24C
M1 37 LS EF LS IMPL LS 23
TANK 25
CF
0.8
1.1 LS1
R
Note 1
52B 52D 1.2 0.47 30 T
LS2 2
T
M1 37A 1.2
T 3
G1 0.76
36 37B 37C 35
X1 G2 X2 34 32 R L
LS SLS ST CF 1 26
48 47 0.7 0.8
34A 1.1 LS
36A 35A
14cc 0.8
0.31
0.31
2.9 27 P T
34B 26A
38 31 P
16cc
41 36B 36C 35C 35B
34C 26C
26B
46 46 16cc 19cc 21cc T P 29 p
36D 35D
11cc M
28
33 T
L1 L2 S1 S2 L4 L3
40
45 45 39 COMPONENTS
39A 9 Front Brake Accumulator 15 Brake Valve 18 Bucket Cylinder 22G Loader Main Relief 35A Compensator Differential Pressure Spool 39A Hydraulic Oil Filter Assembly
1 Rear Axle Brakes 28 Steering Back Pressure Valve 48 Oil Cooler Thermal Valve
Modulation Pressure 3.5 liter (3.7 quart) 15A Parking Brake Solenoid 19 Lift Cylinders 219-226 bar (3175-3275 PSI) 8 to 10 bar (115 to 145 PSI) 35B Compensator High Pressure Cutoff Spool 10 micron media 2.4 to 3.6 bar (35 to 52 PSI) Bypass
68 to 75 bar (985 to 1090 PSI) 70 bar (1015 PSI) Precharge Electrical Connector YPB 20 Ride Control Valve 22H Load Sense Signal Bleed Down Orifice 29 Steering Back Pressure Sensor 35C Control Piston with Spring 3.4 bar (50 PSI) bypass 49 Hydraulic Oil Cooler
10 Rear Brake Accumulator 15B Front Brake Valve 20A Ride Control Solenoid 0.7 LPM (0.2 GPM) Joystick Steering Only 35D Rotating Group with Swash Plate 39B 100 Mesh Strainers (4) 50 Oil Cooler Fan
44 44 2 Front Axle Brakes
Modulation Pressure 3.5 liter (3.7 quart) 15C Rear Brake Valve Electrical Connector YRC 22J Shuttle Check Valves (6) 30 Joystick Steering Load Sense Resolver 36 First Pump (Closest to Transmission) 40 Reservoir Vent 51 Standard Fan Valve
39B
70 to 77 bar (1015 to 1115 PSI) 70 bar (1015 PSI) Precharge 15D Accumulator Isolation Check Valve 20B Ride Control Spool Valve 22K Lift Circuit Spool Valves (2) 31 Auxiliary Steering Accumulator 190 LPM (50.2 GPM) 100 mesh 162 bar (2350 PSI)
42 43 11 Redundant Brake Accumulator Pressure Switches 15E Accumulator Charging Spool 20C Manual Bleed Valve 22L Bucket Circuit Spool Valve Cut Off 280 bar (4060 PSI) 0.03 bar check
3 Brake Damping Accumulators (2) 0.32 liter (0.34 quart) 52 Fan Reversing and Variable Valve
0.16 liter (0.17 quart) Electrical Connectors PRB1 (Front), PRB2 (Rear) 15F Priority Valve 20D Pressure Relief Valve 22M Auxiliary Circuit Spool Valve 60 bar (870 PSI) Precharge Delta 25 to 27 bar (360 to 390 PSI) 0.35 bar relief 52A Crossover Relief 234 bar (3395 PSI)
7 bar (102 PSI) Precharge Rising < 91 bar (< 1320 PSI) Cut-In Pressure 280 bar (4060 PSI) 23 Steering Cylinders 32 Auxiliary Steering Pressure Switch 36A Compensator Differential Pressure Spool 41 Filter Warning Switch 52B Reversing Spools (2)
4 Parking Brake Falling 70 to 84 bar (1015 to 1220 PSI) 157 to 167 bar (2275 to 2420 PSI) 21 Ride Control Accumulators (2) 24 Steering Control Valve Electrical Connector PSS 36B Compensator High Pressure Cutoff Spool Electrical Connector PHF 52C Pulse Width Modulation (PWM) Relief Valve
5 Brake Signal, HVT transmission 12 Low Brake Pressure Warning Switch Cut-Out Pressure 3.78 liter (4 quart) 24A Steering Spool 33 Auxiliary Steering Pump 36C Control Piston with Spring 2.7 bar (40 PSI) 165 bar (2390 PSI)
6 Brake Declutch Switch, 4-speed transmission Alarm OFF 138 bar (2000 PSI) Increasing 190 to 196 bar (2755 to 2845 PSI) 14.5 bar (210 PSI) Precharge 24B Gerotor Pump 34 Auxiliary Steering Control Valve 36D Rotating Group with Swash Plate 42 Rear Axle 52D ON/OFF Reversing Solenoid
Electrical Connector PBD Alarm ON 115 to 129 bar (1670 to 1870 PSI) Decreasing 16 Pilot Control Valve 22 Loader Valve 24C Circuit Relief Valve 34A Auxiliary Steering Activation Solenoid 37 Priority Valve 43 Front Axle Electrical Connector YFR
24 bar (350 PSI) 13 Additional Front Brake Accumulator 16A Pilot ON/OFF Solenoid 22A Load Sense Shuttle Valve 25 Steering Cylinder Relief Valve Electrical Connector YSS 37A Priority Spool 44 Axle Cooler Anti-Caviation Valves (2)
7 Brake Light Switch PL23-Heavy Duty and PL26 Electrical Connector YPP 22B Regeneration Relief Valve 345 bar (5000 PSI) 34B Relief Valve 10 bar (145 PSI) 0.3 bar (5 PSI)
4.1 bar (60 PSI) Increasing 2.8 liter (3.0 quart) 16B Bucket Pilot Control 8-10.8 bar (115-155 PSI) 26 Joystick Steering Valve 240 bar (3480 PSI) 37B Differential Pressure Relief 45 Air-to-Oil Axle Coolers (2)
8 Parking Brake Accumulator 70 bar (1015 PSI) Precharge 16C Lift Pilot Control 22C Flow Compensator Spools (4) 26A Control Spool 34C Priority Spool 40 bar (580 PSI) 46 Axle Oil Filters (2)
0.16 liter (0.17 quart) 14 Additional Rear Brake Accumulator 16D Auxiliary Hydraulics Pilot Control 1 22D Regeneration Check Valves (4) 26B Pressure Reducer 35 Second Pump (Farthest from Transmission) 37C Steering Relief Electrical Connectors PRA, PFA
96 bar (1390 PSI) Precharge PL26 Only 16E Auxiliary Hydraulics Pilot Control 2 22E Circuit Relief Valves with Anti-Cavitation (4) 26C Pilot Dump Valve PL23: 162 LPM (42.7 GPM) 216 bar (3130 PSI) 3.4 bar (50 PSI) bypass
CIRCUIT DIAGRAM LEGEND PUMP SUPPLY NOTES CONVERSION INFORMATION
2.8 liter (3.0 quart) 17 Pilot Control Accumulator 22F Pilot Pressure Generation Valve 27 Joystick Steering Load Sense Accumulator
0.32 liter (0.34 quart)
PL26: 190 LPM (50.2 GPM) 38 Brake and Fan Pumps 47 Axle Cooler Motor-Pump-Pump Combination
70 bar (1015 PSI) Precharge 0.75 liter (0.79 quart) 29 to 40 bar (420 to 580 PSI) Cut Off 280 bar (4060 PSI) 39 Hydraulic Reservoir 55 bar (800 PSI) bypass
13.8 bar (200 PSI) Precharge 60 bar (870 PSI) Precharge Delta 21 to 23 bar (305 to 335 PSI) 134 liter (35.4 GAL)
CIRCUIT LOAD SENSE Note 1 : Check and Relief Valves not used with Fan Reverser 1 bar = 14.5 pounds per square inch (PSI)
SHOWS CIRCUIT 1 liter per minute = .264 gallons per minute HYDRAULIC SCHEMATIC
CROSSING SHOWS CIRCUIT COMPONENT PILOT 1021F/1121F WHEEL LOADER
NOT CONNECTED CONNECTED CHECK VALVE RESTRICTOR FILTER OR SCREEN OIL COOLER Additional copies of this Schematic can be ordered through Technical Publications Distribution System. Part # RAC 84527196.
LINE TYPES

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1021F

Printed in U.S.A. Part number 47392461

Air cleaners and lines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.202

Powershift transmission internal components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.155

Four-Wheel Drive (4WD) system .................................................. 23

Front axle system ....................................................................... 25

Final drive hub, steering knuckles, and shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.108

Rear axle system........................................................................ 27

Brakes and controls .................................................................... 33

Hydraulic service brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33.202

Variable displacement pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.106

Reservoir, cooler, and filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.300

Main control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.359

Front loader arm hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.701

Cab climate control ..................................................................... 50

Electrical systems ....................................................................... 55

Fuel tank system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.011

Engine cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.012

Engine control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.015

Transmission control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.024

Service brake electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.030

Parking brake electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.031

Hydraulic system control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.036

Steering control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.047

Heating, Ventilation, and Air-Conditioning (HVAC) control system . . . . . . . . . . . . . . . . . . . . . . . 55.050

Cab Heating, Ventilation, and Air-Conditioning (HVAC) controls . . . . . . . . . . . . . . . . . . . . . . . . . 55.051

Harnesses and connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.100

Cold start aid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.202

External lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.404

External lighting switches and relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.405

Loader arm and bucket control system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.415

Cab/Platform harnesses and connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.510

Wiper/Washer system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.518

Cab brake controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.519

FAULT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.DTC

Platform, cab, bodywork, and decals ............................................. 90

Protections and footboards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.118

Consumables - Biodiesel Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Fuel sender mounting bolts 6 - 8 N·m (53 - 71 lb in)

1021F Capacities and specifications

* Machines are shipped from the factory with break-in oil.

1121F Capacities and specifications

* Machines are shipped from the factory with break-in oil.

Engine oil viscosity/Temperature ranges

Transmission oil viscosity/Temperature ranges

Hydraulic/Brake system - temperature range

Transmission component oil

If Case Akcela engine oil cannot be obtained, use only oil

Consumables - Biodiesel Fuel

Biodiesel Fuel Usage Conditions

Engine and crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.001

Air cleaners and lines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.202

Engine lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.304

Fan and drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.414

Engine and crankcase - 001

Engine and crankcase - 001

2. Key in the run position, engine off, place the pilot

3. Move the loader hydraulic control handle to the raise

8. Put the master disconnect switch (1) in the off posi-

9. Drain the engine radiator coolant.

12. Remove the mounting bolts on the exhaust stack

13. Remove the muffler assembly.

14. Disconnect the deaeration tank overflow hose (2).