621 F, 721 F Tier 4

621F
721F
Tier 4
Wheel Loader
from PIN NBF213602 and above
SERVICE MANUAL
Printed in U.S.A. Part number 84605841

1st edition English
Copyright © 2012 CNH America LLC. All Rights Reserved.
Case is a registered trademark of CNH America LLC. May 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
Engine cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.400
Fan and drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.414

Selective Catalytic Reduction (SCR) exhaust treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.500
Engine generic sub-group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.AAA
Transmission.............................................................................. 21
Powershift transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.113
Powershift transmission external controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.135
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
Rear bevel gear set and differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27.106
Planetary and final drives. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27.120
Brakes and controls .................................................................... 33

Hydraulic service brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33.202
Hydraulic systems....................................................................... 35
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Hydraulic systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.000
Variable displacement pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.106
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
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
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External lighting switches and relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.405
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
Selective Catalytic Reduction (SCR) electrical system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.988
FAULT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.DTC
Platform, cab, bodywork, and decals ............................................. 90

Pneumatically-adjusted operator seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.124
Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.150
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INTRODUCTION
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Contents
INTRODUCTION
Torque – 621F Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

621F WE, 621F NA
Torque – 721F Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

721F WE, 721F NA
Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
621F WE, 621F NA, 721F WE, 721F NA
Consumables - Biodiesel Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Hydraulic contamination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
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INTRODUCTION
Torque – 621F Torque Specifications

621F WE, 621F NA
Axle
Wheel mounting nuts 640 - 720 N·m (472 - 531 lb ft)
Front axle mounting bolts 651 - 678 N·m (480 - 500 lb ft)
Rear axle trunnion pin bolts 325 - 353 N·m (240 - 260 lb ft)
Chassis
Cab mounts 773 - 854 N·m (570 - 630 lb ft)
Exhaust stack to hood 36 - 44 N·m (27 - 32 lb ft)
Counterweight mounting bolts 955 - 1075 N·m (704 - 793 lb ft)
Articulation pivot pin bolts 224 - 278 N·m (165 - 205 lb ft)
Articulation mount pin retainer bolts 69 N·m (51 lb ft)
Seat mounting bolts 73 - 87 N·m (54 - 64 lb ft)
Steering wheel retaining nut 50 N·m (37 lb ft)
Hydraulic oil filter mounting bolts 23 - 27 N·m (17 - 20 lb ft)
Steering cylinder base end pin retaining bolt 290 - 375 N·m (214 - 277 lb ft)
Steering cylinder rod end pin retaining bolt Bolts must turn freely
Horn mounting bolt 53 - 62 N·m (39 - 46 lb ft)
Hood - rear grill bolts 9 - 11 N·m (7 - 8 lb ft)
Hood hinge bolts 65 - 79 N·m (48 - 58 lb ft)
Steps - lower entry strap bolts 27 - 31 N·m (20 - 23 lb ft)
Cooling
Fan to fan hub 40 - 48 N·m (30 - 35 lb ft)
Fan hub to motor shaft (no impact tools) 67 - 74 N·m (49 - 55 lb ft)
Radiator hose clamps 10.1 - 11.3 N·m (7.4 - 8.3 lb ft)
Hydraulic tank cover nuts 14 - 18 N·m (10 - 13 lb ft)
Hydraulic tank sight gauge 2.7 - 5.5 N·m (2.0 - 4.1 lb ft)
Diesel Exhaust Fluid (DEF) System

Heater valve bolts 17 - 19 N·m (13 - 14 lb ft)
Dosing module bolts 7 - 8 N·m (58 - 68 lb in)
DEF control module/pump assembly mounting bolts 20 - 28 N·m (15 - 21 lb ft)
Driveshafts
Coupling to flywheel 53 - 62 N·m (39 - 46 lb ft)
Driveshaft to coupling 53 - 62 N·m (39 - 46 lb ft)
Front driveshaft yoke nut 339 - 373 N·m (250 - 275 lb ft)
Carrier bearing mounting bolts 99 - 128 N·m (73 - 94 lb ft)
550R U-joints 75 - 81 N·m (55 - 60 lb ft)
410R U-joints 61 - 81 N·m (45 - 60 lb ft)
Dust cover mounting bolts 20 - 27 N·m (15 - 20 lb ft)
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INTRODUCTION
Engine
Engine mounting brackets 118 - 133 N·m (87 - 98 lb ft)
Engine rubber isolator mounts (Qty 4) 244 - 298 N·m (180 - 220 lb ft)
Brake pump to engine mounting 57 - 65 N·m (42 - 48 lb ft)
Brake pump gear nut (no impact tools) 70 - 79 N·m (52 - 58 lb ft)
Turbo to turbo exhaust elbow clamp 5 N·m (4 lb ft)
Muffler to turbo elbow exhaust clamp 20 - 25 N·m (15 - 18 lb ft)
Front muffler bracket to engine block 118 - 133 N·m (87 - 98 lb ft)
Muffler brackets to muffler 114 - 128 N·m (84 - 94 lb ft)
Charge Air Cooler (CAC) hose clamps (Qty 8) 10.1 - 11.3 N·m (7.4 - 8.3 lb ft)
Air cleaner to turbo hose clamp 10.1 - 11.3 N·m (7.4 - 8.3 lb ft)
Alternator pulley (no impact tools) 60 - 70 N·m (44 - 52 lb ft)
Starter mounting nuts 40 - 50 N·m (30 - 37 lb ft)
Loader
XT loader linkage bolts 650 - 732 N·m (479 - 540 lb ft)
XT guide link nuts 240 - 305 N·m (177 - 225 lb ft)
Loader link pin keeper 325 - 373 N·m (240 - 275 lb ft)
Transmission
Transmission rubber isolator mounts (Qty 3) 890 - 1000 N·m (656 - 738 lb ft)
Transmission upper mounting bracket bolts 251 - 319 N·m (185 - 235 lb ft)
Transmission lower mounting bracket bolts (Qty 2) 481 - 590 N·m (355 - 435 lb ft)
Hydraulic pump to transmission mounting 335 - 375 N·m (247 - 277 lb ft)
Cooler clamps 10.1 - 11.3 N·m (7.4 - 8.3 lb ft)
Hydraulic pump suction hose clamp flange 73 - 90 N·m (54 - 66 lb ft)
Steering priority manifold to pump 37 - 48 N·m (27 - 35 lb ft)
Transmission fill tube bolts 17 - 33 N·m (13 - 24 lb ft)
Transmission sight gauge bolts 2.7 - 5.5 N·m (2 - 4 lb ft)
Wheels
Wheel nuts Initial torque: 298 N·m (220 lb ft)
Final torque: 640 - 720 N·m (472 - 531 lb ft)
RCPH10WHL320AAH 1
Do the following initial and final torque procedures:
1. Tighten wheel nuts to an initial torque of 298 N·m (220 lb ft) in sequence shown in figure
2. Tighten wheel nuts to a final torque of 640 - 720 N·m (472 - 531 lb ft). in sequence shown in figure
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INTRODUCTION
Torque – 721F Torque Specifications

721F WE, 721F NA
Axle
Wheel mounting bolts 640 - 720 N·m (472 - 531 lb ft)
Front axle mounting bolts 765 - 855 N·m (564 - 631 lb ft)
Rear axle trunnion pin bolts 651 - 678 N·m (480 - 500 lb ft)
Chassis
Cab mounts 773 - 854 N·m (570 - 630 lb ft)
Exhaust stack to hood 36 - 44 N·m (27 - 32 lb ft)
Counterweight mounting bolts 955 - 1075 N·m (704 - 793 lb ft)
Articulation pivot pin bolts 224 - 278 N·m (165 - 205 lb ft)
Articulation mount pin retainer bolts 69 N·m (51 lb ft)
Seat mounting bolts 73 - 87 N·m (54 - 64 lb ft)
Steering wheel retaining nut 50 N·m (37 lb ft)
Hydraulic oil filter mounting bolts 23 - 27 N·m (17 - 20 lb ft)
Steering cylinder base end pin retaining bolt 290 - 375 N·m (214 - 277 lb ft)
Steering cylinder rod end pin retaining bolt Bolts must turn freely
Horn mounting bolt 53 - 62 N·m (39 - 46 lb ft)
Hood - rear grill bolts 9 - 11 N·m (7 - 8 lb ft)
Hood hinge bolts 65 - 79 N·m (48 - 58 lb ft)
Steps - lower entry strap bolts 27 - 31 N·m (20 - 23 lb ft)
Cooling
Fan to fan hub 40 - 48 N·m (30 - 35 lb ft)
Fan hub to motor shaft (no impact tools) 67 - 74 N·m (49 - 55 lb ft)
Radiator hose clamps 10.1 - 11.3 N·m (7.4 - 8.3 lb ft)
Hydraulic tank cover nuts 14 - 18 N·m (10 - 13 lb ft)
Hydraulic tank sight gauge 2.7 - 5.5 N·m (2.0 - 4.1 lb ft)
Diesel Exhaust Fluid (DEF) System

Heater valve bolts 17 - 19 N·m (13 - 14 lb ft)
Dosing module bolts 7 - 8 N·m (58 - 68 lb in)
DEF control module/pump assembly mounting bolts 20 - 28 N·m (15 - 21 lb ft)
Driveshafts
Coupling to flywheel 53 - 62 N·m (39 - 46 lb ft)
Driveshaft to coupling 53 - 62 N·m (39 - 46 lb ft)
Front driveshaft yoke nut 339 - 373 N·m (250 - 275 lb ft)
Carrier bearing mounting bolts 99 - 128 N·m (73 - 94 lb ft)
550R U-joints 75 - 81 N·m (55 - 60 lb ft)
Dust cover mounting bolts 20 - 27 N·m (15 - 20 lb ft)
Flex plate to flywheel bolts 33 - 41 N·m (24 - 30 lb ft)
Carrier bearing bolt 150 - 164 N·m (111 - 121 lb ft)
Drive line mounting bolts 136 - 149 N·m (100 - 110 lb ft)
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INTRODUCTION
Engine
Engine mounting brackets 118 - 133 N·m (87 - 98 lb ft)
Engine rubber isolator mounts (Qty 4) 244 - 298 N·m (180 - 220 lb ft)
Brake pump to engine mounting 57 - 65 N·m (42 - 48 lb ft)
Brake pump gear nut (no impact tools) 70 - 79 N·m (52 - 58 lb ft)
Turbo to turbo exhaust elbow clamp 5 N·m (4 lb ft)
Muffler to turbo elbow exhaust clamp 20 - 25 N·m (15 - 18 lb ft)
Muffler bracket to muffler 114 - 128 N·m (84 - 94 lb ft)
Charge Air Cooler (CAC) hose clamps (Qty 8) 10.1 - 11.3 N·m (7.4 - 8.3 lb ft)
Air cleaner to turbo hose clamp 10.1 - 11.3 N·m (7.4 - 8.3 lb ft)
Alternator pulley (no impact tools) 60 - 70 N·m (44 - 52 lb ft)
Starter mounting nuts 40 - 50 N·m (30 - 37 lb ft)
Loader
XT loader linkage bolts 650 - 732 N·m (479 - 540 lb ft)
XT guide link nuts 240 - 305 N·m (177 - 225 lb ft)
Loader link pin keeper 325 - 373 N·m (240 - 275 lb ft)
Transmission
Transmission rubber isolator mounts (Qty 3) 890 - 1000 N·m (656 - 738 lb ft)
Transmission upper mounting bracket bolts 251 - 319 N·m (185 - 235 lb ft)
Transmission lower mounting bracket bolts (Qty 2) 481 - 590 N·m (355 - 435 lb ft)
Cooler clamps 10.1 - 11.3 N·m (7.4 - 8.3 lb ft)
Hydraulic pump suction hose clamp flange 73 - 90 N·m (54 - 66 lb ft)
Steering priority manifold to pump 37 - 48 N·m (27 - 35 lb ft)
Transmission fill tube bolts 17 - 33 N·m (13 - 24 lb ft)
Transmission sight gauge bolts 2.7 - 5.5 N·m (2 - 4 lb ft)
Wheels
Wheel bolts Initial torque: 298 N·m (220 lb ft)
Final torque: 640 - 720 N·m (472 - 531 lb ft)
RCPH10WHL320AAH 1
Do the following initial and final torque procedures:
1. Tighten wheel bolts to an initial torque of 298 N·m (220 lb ft) in sequence shown in figure
2. Tighten wheel bolts to a final torque of 640 - 720 N·m (472 - 531 lb ft). in sequence shown in figure
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INTRODUCTION
Capacities
621F WE, 621F NA, 721F WE, 721F NA
621F Capacities and Specifications

Engine
Type of oil CASE AKCELA ENGINE OIL 15W-40
Capacity (with filter change) 13.25 l (14.0 US qt)
Total system capacity 15.1 l (16 US qt)
Cooling System
System capacity 26.8 l (28.4 US qt)
Hydraulic System
Type of fluid CASE AKCELA HY-TRAN® ULTRA™ HYDRAULIC TRANSMISSION
OIL
Total system capacity 147.6 l (39.0 US gal)
Reservoir capacity 90.8 l (24.0 US gal)
Fuel System
System capacity 246 l (65.0 US gal)
Transmission
Type of oil CASE AKCELA NEXPLORE™ FLUID
Service capacity (with filter change) 26.7 l (28.2 US qt)
Axles
Standard front axle 22 l (23.2 US qt)
Standard rear axle 22 l (23.2 US qt)
Optional front axle 35 l (37.0 US qt)
Optional rear axle 35 l (37.0 US qt)
Diesel Exhaust Fluid (DEF)
Total capacity 41.3 l (10.9 US gal)
Grease Fittings
As required CASE AKCELA MOLY GREASE
NOTE: Machines are shipped from the factory with break-in oil.
84605841 14/05/2012
7
INTRODUCTION
721F Capacities and Specifications

Engine
Type of oil CASE AKCELA ENGINE OIL 15W-40
Capacity (with filter change) 13.25 l (14.0 US qt)
Total system capacity 15.1 l (16 US qt)
Cooling System
System capacity 28.4 l (30.0 US qt)
Hydraulic System
Type of fluid CASE AKCELA HY-TRAN® ULTRA™ HYDRAULIC TRANSMISSION
OIL
Total system capacity 177.8 l (47.0 US gal)
Reservoir capacity 90.8 l (24.0 US gal)
Fuel System
System capacity 253 l (66.8 US gal)
Transmission
Service capacity (with filter change) 34 l (35.9 US qt)
Axles
Standard front axle 35 l (37.0 US qt)
Standard rear axle 23 l (24.3 US qt)
Optional front axle 35 l (37.0 US qt)
Optional rear axle 35 l (37.0 US qt)
Diesel Exhaust Fluid (DEF)
Total capacity 41.3 l (10.9 US gal)
Grease Fittings
As required CASE AKCELA MOLY GREASE
NOTE: Machines are shipped from the factory with break-in oil.
84605841 14/05/2012
8
INTRODUCTION
Engine Oil Viscosity/Temperature Range
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 Range
RCPH10WHL453BAH 2
84605841 14/05/2012
9
INTRODUCTION
Hydraulic/Brake System Temperature Range
RCPH10WHL006EAL 3
Coolant Solution
Only use 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.
NOTICE: Anti-rust additives and ethylene-glycol can mix and work against each other, reducing anti-corrosion pro-
tection, 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.
• For 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.
84605841 14/05/2012
10
INTRODUCTION
Hydraulic Fluid
CASE AKCELA HY-TRAN® ULTRA™ HYDRAULIC TRANSMISSION OIL is specifically designed for high pressure applica-
tions and for Case hydraulic systems. Your Case Dealer can provide hydraulic fluid to fulfill different climate/temper-
ature 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 AKCELA NEXPLORE™ FLUID. See charts at the beginning of this
section.
Grease
The type of grease to use depends on ambient temperature such as: CASE AKCELA MOLY GREASE.
Environment
Before servicing machine and disposing oil, fluids, and lubricants, follow all 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.
Engine Oil
CASE AKCELA ENGINE OIL 15W-40 is recommended for
your engine. This oil insures correct lubrication of your en-
gine in all working conditions. See charts at the beginning
of this section to choose the correct oil for climate/temper-
atures.
If CASE AKCELA ENGINE OIL 15W-40 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
84605841 14/05/2012
11
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.
84605841 14/05/2012
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.
84605841 14/05/2012
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CONSUMABLES INDEX
Consumable IU PAGE
CASE Akcela Engine oil Capacities 7
15W-40
CASE Akcela HY-TRAN® Capacities 7
Ultra™ hydraulic transmission
oil
CASE Akcela NEXPLORE™ Capacities 7
fluid
fluid
CASE Akcela Moly grease Capacities 7
15W-40
oil
fluid
fluid
oil
fluid
15W-40
15W-40
84605841 14/05/2012
14
SERVICE MANUAL
Engine
621F
721F
84605841 14/05/2012
10
Contents
Engine - 10
Engine and crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.001

621F , 721F
Air cleaners and lines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.202

621F , 721F
Engine lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.304

621F , 721F
Aftercooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.310
621F , 721F
Engine cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.400

621F , 721F
Fan and drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.414

621F , 721F
Selective Catalytic Reduction (SCR) exhaust treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.500

621F NA, 621F WE, 721F NA, 721F WE
Engine generic sub-group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.AAA

621F , 721F
84605841 14/05/2012
10
CONSUMABLES INDEX
Consumable IU PAGE
DEF/AdBlue® Engine - Remove 10.001 / 22
DEF/AdBlue® Engine - Install 10.001 / 33
CASE Akcela Engine oil Engine - Install 10.001 / 50
15W-40
Loctite® 242 Radiator - Install 10.400 / 16
DEF/AdBlue® Diesel Exhaust Fluid 10.500 / 20
DEF/AdBlue® Coolant control valve - Remove 10.500 / 29
DEF/AdBlue® Coolant control valve - Install 10.500 / 31
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10
84605841 14/05/2012
10
Engine - 10
Engine and crankcase - 001
621F
721F
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Contents
Engine - 10
SERVICE
Engine
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
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CONSUMABLES INDEX
Consumable IU PAGE
CASE Akcela Engine oil Engine - Install 10.001 / 50
15W-40
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10.001 / 3
Engine - Engine and crankcase
Engine - Remove
NOTE: Emissions sensors mounted in the exhaust stream are sensitive to extreme vibrations. Use of tools that gen-
erate extreme vibrations, such as impact wrenches and hammers, will result in damage to emission sensors. Avoid
using these tools during any service procedure in close proximity of emission sensors. If the use of these tools cannot
be avoided, remove the sensors using extreme caution prior to performing any service procedure.
1. Park machine on a level surface and lower the bucket
to the ground. Put articulation lock in LOCKED posi-
tion and stop the engine.
RCPH10WHL063BAL 1
2. Actuate the brake pedal several times to discharge

brake accumulators.
RCPH10WHL435AAH 2
3. Put key switch in ON position. Pilot control switch

must be in the ON position and then move loader
control lever(s) back and forth at least 30 times to
release any pressure from hydraulic circuit. Put key
switch in OFF position.
RCPH10WHL119BAL 3
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10.001 / 4
4. Raise grill located above the cooler box just behind

the cab. Then slowly loosen the hydraulic reservoir
filler cap to release pressure in the reservoir.
RCPH10WHL099BAL 4
5. Locate the master and hood raise switch by the bat-

tery box. Then raise the hood and put the master
disconnect switch in the OFF position.
RCPH10WHL106AAH 5
6. Raise both side panels (1). Then remove the thumb

screws (2) and inner fender panels (3).
NOTE: Left side of the machine is shown. The operation
is similar for the right side.
RAPH12WEL0597AA 6
7. Place a suitable container below radiator drain, re-

move radiator cap and coolant drain plug (arrow) to
drain engine coolant. Then reinstall drain plug and
radiator cap after coolant has drained.
NOTE: See machine specifications for cooling system vol-
ume.
RCPH10WHL054BAL 7
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10.001 / 5
8. Place a suitable container below engine oil drain.

Remove drain plug and drain oil into container. Then
reinstall drain plug.
NOTE: See machine specifications for engine oil sump vol-
ume.
RCPH10WHL054BAL 8
9. After oil drains, disconnect drain hose from frame by

removing jam nut (1). Then pull hose from frame in
preparation for engine removal. (2)
RAPH12WEL0598AA 9
10. Double up a nylon lifting strap (1) and slide through

the exhaust stack (2) on the hood.
RAPH12WEL0599AA 10
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10.001 / 6
11. Place a bar or pipe through the strap loop inside the
hood and attach the strap to a suitable lifting device.
Then raise the hood with the strap to release tension
on the lifting motor.
RAPH12WEL0600AA 11
12. Tag and disconnect the camera wire harness (if ma-
chine is equipped with a camera.)
RAPH12WEL0601AA 12
13. Cut wire ties and remove camera wire harness from
hood. Then place it off to the side in a safe location.
(If machine is equipped with a camera.)
RAPH12WEL0602AA 13
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14. Remove mount bolt (1) and backup alarm wiring har-
ness clamp from cooler housing. Then tag and re-
move hood ground wire (2) from cooler housing.
RAPH12WEL0603AA 14
15. Tag and disconnect hood wiring harness connector

from rear chassis wiring harness connector.
RAPH12WEL0604AA 15
16. Have another person balance the hood and

LOOSEN the hood hinge mounting bolts (arrows)
from the cooler frame.
NOTE: Do not remove the hood hinge mounting bolts at
this time.
RAPH12WEL0605AA 16
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17. Remove the pin from the bottom of the lifting motor
cylinder where it attaches to the loader frame.
RAPH12WEL0606AA 17
18. Put the master disconnect switch in the ON position.

Then, retract the lifting motor cylinder (2), replace pin
and disconnect wiring harness (1).
RAPH12WEL0062AA 18
19. Put master disconnect switch (1) in OFF position.

Remove the battery cover and disconnect ground
lead from the batteries (2). You may replace battery
cover if desired to give you a place to stand.
RAPH12WEL0608AA 19
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20. Have another person balance the hood and remove

the hood hinge mounting bolts (arrows) from the
cooler frame.
RAPH12WEL0605AA 20
21. Carefully raise and remove hood from loader. Lower

hood onto suitable platform and disconnect lifting
equipment.
NOTE: Radiator overflow hose may interfere with left hand
hood hinge movement and hood removal.
RAPH12WEL0609AA 21
22. Tag and disconnect engine wiring harness connector

from air filter restriction switch.
RAPH12WEL0610AA 22
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23. Tag and disconnect engine wiring harness connector

from air inlet humidity sensor.
RAPH12WEL0611AA 23
24. Loosen clamp (1) on the crankcase ventilation hose

(2) and disconnect hose.
RAPH12WEL0612AA 24
25. Loosen clamps on turbocharger and air filter hous-

ing. Then remove the intake air hose. Cover tur-
bocharger inlet to prevent debris entry.
RAPH12WEL0613AA 25
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26. Loosen the clamp on the turbocharger for the after

cooler inlet elbow.
RAPH12WEL0614AA 26
27. Loosen the clamp on the hose at the after cooler inlet
and remove the tube.
RAPH12WEL0615AA 27
28. Loosen clamp on the air inlet hose at the air filter
housing.
RAPH12WEL0616AA 28
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29. Remove bolts from the cooler box (1) and the cen-
ter support bracket (2) securing the air inlet hose
bracket. Then remove air inlet hose and bracket.
RAPH12WEL0617AA 29
30. Remove four the bolts securing the air filter housing
to the mounting support bracket. Then remove air
filter housing.
RAPH12WEL0618AA 30
31. Remove the four mounting bolts from the belt cover.
Then remove the cover.
NOTE: After removing the belt cover, remove the cover
mounting bracket from the left rear side of machine frame.
RAPH12WEL0619AA 31
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32. Remove the drive belt from the engine.
RAPH12WEL0620AA 32
33. If loader is equipped with air conditioning, identify,

tag, and disconnect the engine wiring harness con-
nectors from air compressor clutch connector (1) and
high pressure switch (2). Then remove the three
mounting bolts (3) for the compressor and carefully
set it on the left battery cover.
RAPH12WEL0621AA 33
34. Tag and disconnect the wiring from the alternator.
RAPH12WEL0622AA 34
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35. Remove SCR coolant return line.
RAPH12WEL0623AA 35
36. Tag and remove the wires from the starter solenoid
(1), the ground cable (2), and ground strap (3) from
the starter.
NOTE: Move the starter cables away from the engine.
RAPH12WEL0624AA 36
37. Remove bolts securing wiring harness clamps to en-

gine.
RAPH12WEL0625AA 37
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38. Remove ground wires from the engine.

NOTE: Move the wiring harness away from the engine.
RAPH12WEL0625AA 38
39. If the machine is so equipped, unplug the engine

block heater and set it aside.
RAPH12WEL0626AA 39
40. Loosen the exhaust clamp from the turbocharger.
RAPH12WEL0627AA 40
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41. Disconnect the engine coolant vent hose from the

engine.
RAPH12WEL0628AA 41
42. Loosen clamps and remove lower coolant hose from

the engine.
RAPH12WEL0629AA 42
43. Remove the radiator hose from the engine.
RAPH12WEL0630AA 43
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44. Remove the return radiator hose (1) and the engine
coolant vent hose (2) from the top of the radiator.
RAPH12WEL0631AA 44
45. Remove hood wire harness clamp from the fan

shroud.
RAPH12WEL0632AA 45
46. Remove engine coolant overflow bottle.
RAPH12WEL0633AA 46
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47. Remove engine coolant overflow bottle support

bracket.
RAPH12WEL0634AA 47
48. Remove cooling fan screen.
RAPH12WEL0635AA 48
49. Remove heater hose (1) and the SCR heater supply
line (2) from the engine.
RAPH12WEL0636AA 49
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50. Loosen the clamp on the intake manifold for the after
cooler output hose.
RAPH12WEL0637AA 50
51. Loosen the clamp on the after cooler, and remove

the after cooler outlet tube from the machine.
RAPH12WEL0638AA 51
52. Tag and disconnect the fuel filter heater wire (1) and
water sensor (2). Then drain fuel filter and discon-
nect inlet (3) and outlet (4) fuel lines from the fuel
filter head. Plug the lines and cap the fittings.
RAPH12WEL0639AA 52
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53. Remove ground wire and fuel filter head attachment

bolt (1). Then remove fuel line support clamp (2).
RAPH12WEL0640AA 53
54. Tag and disconnect the post SCR catalyst EGT sen-
sor from machine wire harness (1) and the post SCR
catalyst NOx sensor (2). Then tag and remove the
grid heater cable (3).
NOTE: Hold the rear nut with a second wrench to prevent
grid heater damage.
RAPH12WEL0063AA 54
55. Remove wire harness support clamp.
RAPH12WEL0064AA 55
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56. Tag and disconnect Pre-SCR catalyst EGT sensor

(1). Then remove tie wrap, wire harness bolts and
wire harness support clamp (2).
RAPH12WEL0065AA 56
57. Tag and disconnect wire harness from DEF/

ADBLUE® Dosing Module.
RAPH12WEL0066AA 57
58. Tag and disconnect wire harness from DEF/

ADBLUE® Control Module (1) and the coolant flow
control valve (2).
RAPH12WEL0067AA 58
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59. Tag and disconnect wire harness from primary fuel

filter.
RAPH12WEL0068AA 59
60. Remove DEF/ADBLUE® storage tank cover located

on the Right Hand side of the machine.
RAPH12WEL0069AA 60
61. Tag and disconnect wire harness and DEF/ADBLUE®

supply and return lines from the DEF/ADBLUE® stor-
age tank. Cap the supply lines.
RAPH12WEL0070AA 61
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62. Remove hood lift cylinder support bracket.
RAPH12WEL0071AA 62
63. Attach suitable lifting straps to the SCR Catalyst sup-

port structure.
RAPH12WEL0072AA 63
64. Remove bolts securing the SCR Catalyst support

structure at the front and rear of the structure. The
mounting points are positioned on the left and right
side in the front of the engine compartment, and in
the center at the rear of the engine compartment.
NOTE: The right front mount is shown.
RAPH12WEL0073AA 64
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65. Using suitable lifting device, carefully lift SCR cata-

lyst support structure (with SCR system components
attached) from the machine.
RAPH12WEL0075AA 65
66. Disconnect the wiring harness from the EDC 7 con-

troller.
NOTE: Lifting up on the lever will release the connector
from the controller.
RAPH12WEL0076AA 66
67. Remove the fuel line from the top of the primary fuel
filter, plug the line and cap the fitting.
NOTE: Make note on how fuel lines are routed.
RAPH12WEL0077AA 67
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68. Remove the fuel line support clamp.

NOTE: Make note on how fuel lines are routed.
RAPH12WEL0078AA 68
69. Remove the upper and lower covers for the drive
shaft.
RAPH12WEL0079AA 69
70. Remove the drive shaft bolts (1) from the flywheel.
Move the drive shaft clear of the flywheel.
RAPH12WEL0080AA 70
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71. Connect and turn on vacuum pump to hydraulic

reservoir. Tag and remove the hydraulic lines from
the brake system pump (arrow), plug the lines and
cap the fittings.
RAPH12WEL0081AA 71
72. Connect suitable lifting equipment to engine lifting

brackets. Take up all slack in lifting equipment. Re-
move the engine mounting bolts.
73. Slowly raise engine from rear chassis. Be sure all
wire harness connections and hoses have been dis-
connected and are clear of the engine. Guide the oil
drain hose from the frame as the engine is lifted. Re-
move engine from machine.
RAPH12WEL0082AA 72
Next operation:
Engine - Install (10.001)
84605841 14/05/2012
10.001 / 27
Engine - Install
WARNING
Hot liquid under pressure!
Never remove the filler cap or the recovery tank cap while the engine is running or the coolant is hot.
Let the system cool. Turn the filler cap to the first notch and allow any pressure to escape, and then
remove the filler cap. Loosen the recovery tank cap slowly to allow any pressure to escape.
Failure to comply could result in death or serious injury.
W0296A
Prior operation:
Engine - Remove (10.001)
NOTE: Emissions sensors mounted in the exhaust stream are sensitive to extreme vibrations. Use of tools that gen-
erate extreme vibrations, such as impact wrenches and hammers, will result in damage to emission sensors. Avoid
using these tools during any service procedure in close proximity of emission sensors. If the use of these tools cannot
be avoided, remove the sensors using extreme caution prior to performing any service procedure.
RAIL12WEL0130FA 1
1. Engine mount bolt 5. Washers

2. Washer 6. Washer
3. Isolator upper 7. Nut
4. Isolator lower 8. Remote oil drain hose
1. Inspect engine mounts. If engine rubber isolators re-
quire replacement, remove and discard isolators (3)
and (4). Install new rubber isolator (4), then rubber
isolator (3).
84605841 14/05/2012
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2. Attach suitable lifting device to the engine and slowly

move it into position over the rear chassis. Be sure
all harness connections and hoses are out of the way
or positioned correctly for reconnecting, before low-
ering engine.
RAPH12WEL0082AA 2
3. Tighten engine mounting bolts to a torque of 244 -

298 N·m (180 - 220 lb ft).
RAPH12WEL0080AA 3
4. Disconnect lifting equipment from engine lifting

brackets.
RAPH12WEL0082AA 4
84605841 14/05/2012
10.001 / 29
5. Connect vacuum pump to the hydraulic reservoir and

turn it on. Remove caps from fittings and plugs from
hoses. Connect hoses to brake pump following tags
installed during removal. Remove and discard tags.
Turn off and disconnect vacuum pump from hydraulic
reservoir.
RAPH12WEL0081AA 5
6. Connect engine oil drain hose (1) to frame bracket

(2).
RAPH12WEL0598AA 6
7. At front of engine, position drive shaft on engine cou-

pling. Install bolts to secure drive shaft to engine cou-
pling. Tighten the bolts to a torque of 53 - 62 N·m (39
- 46 lb ft).
RAPH12WEL0080AA 7
84605841 14/05/2012
10.001 / 30
8. Install the upper and lower drive shaft dust covers.

Torque to 20 - 27 N·m (15 - 20 lb ft).
NOTE: Attach p-clamp, securing coolant line.
RAPH12WEL0079AA 8
9. Install bolt and clamp for fuel return hose.
RAPH12WEL0078AA 9
10. Remove cap from fitting and plug from the hose.
Then connect fuel line to the top of the primary fuel
filter.
RAPH12WEL0077AA 10
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11. Connect wiring harness to EDC 7 controller.

NOTE: Start the connector on the EDC 7 with lever straight
out from EDC 7. Use lever to pull connector into position.
RAPH12WEL0076AA 11
12. Connect a suitable lifting device to the SCR catalyst

support structure and carefully lift it (with SCR sys-
tem components attached) and position it over the
rear chassis of the machine. Lower support struc-
ture into position on the machine.
NOTE: Be sure all wire harness connections and hoses are
out of the way or positioned correctly for reconnecting.
RAPH12WEL0075AA 12
13. Install bolts securing the SCR Catalyst support struc-

ture at the front (right hand side pictured) and rear
mounting points. Torque bolts to 125 - 150 N·m (92
- 111 lb ft).
NOTE: Emissions sensors mounted in the exhaust stream
are sensitive to extreme vibrations. Use of tools that gener-
ate extreme vibrations, such as impact wrenches and ham-
mers, will result in damage to emission sensors. Avoid us-
ing these tools during any service procedure in close prox-
imity of emission sensors. If the use of these tools can-
not be avoided, remove the sensors using extreme caution
prior to performing any service procedure.
RAPH12WEL0073AA 13
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14. Remove lifting straps from the SCR Catalyst support

structure.
RAPH12WEL0072AA 14
15. Install hood lift cylinder support bracket. Torque bolts

to 310 - 380 N·m (229 - 280 lb ft).
RAPH12WEL0071AA 15
16. Remove caps and plugs from lines and tag from wire
harness. Connect wire harness and DEF/ADBLUE®
supply and return lines to the DEF/ADBLUE® storage
tank.
RAPH12WEL0070AA 16
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17. Install DEF/ADBLUE® storage tank cover.
RAPH12WEL0069AA 17
18. Connect wire harness to the primary fuel filter.
RAPH12WEL0068AA 18
19. Connect the wire harness to the DEF/ADBLUE® Con-

trol Module (1) and the coolant flow control valve (2).
NOTE: Start the connector on the Control Module with
lever straight out from the Control Module. Use lever to
pull connector into position.
RAPH12WEL0067AA 19
84605841 14/05/2012
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20. Connect the wire harness to the DEF/ADBLUE® Dos-

ing Module.
RAPH12WEL0066AA 20
21. Connect the Pre-SCR catalyst EGT sensor (1). Then

secure with a tie wrap (2), and wire harness clamps
(3). Install wire harness support clamp.
RAPH12WEL0065AA 21
22. Attach wire harness support clamp.
RAPH12WEL0064AA 22
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23. Connect the post SCR catalyst EGT sensor (1) and
the post SCR catalyst NOx sensor (2) to the machine
wire harness. Then connect the grid heater cable (3)
NOTE: Hold the rear nut with a second wrench to prevent
grid heater damage.
RAPH12WEL0063AA 23
24. Connect the ground wire and attach fuel filter head
mounting bolt (1). Install fuel line support clamp (2).
RAPH12WEL0640AA 24
25. Connect the fuel filter heater wire (1) and water sen-
sor (2). Then remove the plugs and caps and con-
nect the fuel inlet line (3) and fuel outlet line (4) to the
fuel filter head.
RAPH12WEL0639AA 25
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26. Connect the after cooler outlet hose to the after

cooler and secure the clamp. Torque to 10.1 - 11.3
N·m (7.4 - 8.3 lb ft).
RAPH12WEL0638AA 26
27. Connect the after cooler outlet hose to the intake

manifold and secure clamp. Torque to 10.1 - 11.3
N·m (7.4 - 8.3 lb ft).
RAPH12WEL0637AA 27
28. Connect the heater hose (1) and the SCR heater sup-
ply line (2) to the engine and secure clamps. Torque
to 10.1 - 11.3 N·m (7.4 - 8.3 lb ft).
RAPH12WEL0636AA 28
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29. Install cooling fan screen.
RAPH12WEL0635AA 29
30. Install engine coolant overflow bottle support

bracket.
RAPH12WEL0634AA 30
31. Install engine coolant overflow bottle.
RAPH12WEL0633AA 31
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32. Install hood wire harness clamp on the fan shroud.
RAPH12WEL0632AA 32
33. Connect the radiator hose (1) and the engine coolant
vent hose (2) to the top of the radiator. Torque clamp
to 10.1 - 11.3 N·m (7.4 - 8.3 lb ft).
RAPH12WEL0631AA 33
34. Connect the radiator hose to the engine. Torque

clamp to 10.1 - 11.3 N·m (7.4 - 8.3 lb ft).
RAPH12WEL0630AA 34
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35. Connect lower coolant hose to the engine and tighten

clamps. Torque clamp to 10.1 - 11.3 N·m (7.4 - 8.3
lb ft).
RAPH12WEL0629AA 35
36. Connect the engine coolant vent hose to the engine

and secure clamp. Torque clamp to 10.1 - 11.3 N·m
(7.4 - 8.3 lb ft).
RAPH12WEL0628AA 36
37. Connect exhaust hose to the turbocharger and se-

cure clamp. Torque clamp to 5 N·m (4 lb ft).
RAPH12WEL0627AA 37
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38. Connect engine block heater if machine is so

equipped.
RAPH12WEL0626AA 38
39. Connect ground wires to the engine.
RAPH12WEL0625AA 39
40. Install bolts securing wiring harness clamps to the

engine.
RAPH12WEL0625AA 40
84605841 14/05/2012
10.001 / 41
41. Connect the wires to the starter solenoid (1), con-

nect the ground cable (2) and ground strap (3) to the
starter.
RAPH12WEL0624AA 41
42. Connect SCR coolant return line and secure clamp.

Torque to 10.1 - 11.3 N·m (7.4 - 8.3 lb ft).
RAPH12WEL0623AA 42
43. Connect the wiring harness to the alternator.
RAPH12WEL0622AA 43
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44. If loader is equipped with air conditioning, secure

compressor to support bracket with mounting bolts
(1). Then connect the engine wiring harness to the
high pressure switch (2) and air compressor clutch
connector (3).
RAPH12WEL0621AA 44
45. Install the drive belt.
RAPH12WEL0620AA 45
46. Secure belt cover mounting bracket to the machine

frame. Then Install the belt cover.
RAPH12WEL0619AA 46
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47. Position air filter housing on mounting support

bracket and secure it with four bolts.
RAPH12WEL0618AA 47
48. Position the air inlet hose, then install the center sup-
port bracket (2) attached to the air inlet hose and se-
cure it to the cooler box (1).
RAPH12WEL0617AA 48
49. Connect air inlet hose on the air filter housing and
secure clamp. Torque to 10.1 - 11.3 N·m (7.4 - 8.3
lb ft).
RAPH12WEL0616AA 49
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50. Connect hose on the after cooler inlet and secure

clamp. Torque to 10.1 - 11.3 N·m (7.4 - 8.3 lb ft).
RAPH12WEL0615AA 50
51. Connect the after cooler inlet hose to the tur-

bocharger and secure clamp. Torque to 10.1 - 11.3
N·m (7.4 - 8.3 lb ft).
RAPH12WEL0614AA 51
52. Connect the intake air hose to the turbocharger and

air filter housing. Secure clamps and torque to 10.1
- 11.3 N·m (7.4 - 8.3 lb ft).
RAPH12WEL0613AA 52
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10.001 / 45
53. Connect the crankcase ventilation hose (2). Secure

with clamp (1) and torque to 10.1 - 11.3 N·m (7.4 -
8.3 lb ft).
RAPH12WEL0612AA 53
54. Connect wiring harness to air inlet humidity sensor,

then remove tag.
RAPH12WEL0611AA 54
55. Connect engine wiring harness to air filter restriction

switch and remove tag.
RAPH12WEL0610AA 55
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56. Connect suitable lifting device to the hood. Carefully

raise the hood over the machine and lower it into
position.
NOTE: Radiator overflow hose may interfere with left hand
hood hinge movement and hood removal.
RAPH12WEL0609AA 56
57. Have another person balance the hood and install

the hood hinge mounting bolts to the cooler frame.
Torque bolts to 65 - 79 N·m (48 - 58 lb ft).
RAPH12WEL0605AA 57
58. Remove the battery cover and reconnect the ground

lead to batteries (2). Put the master disconnect
switch (1) in ON position.
RAPH12WEL0608AA 58
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59. Connect the hood lifting cylinder motor to the ma-

chine wiring harness (1). Extend the cylinder (2) and
remove pin from the bottom of the cylinder. Switch
the master disconnect switch to the OFF position.
RAPH12WEL0062AA 59
60. Attach lifting motor cylinder to the loader frame and

reinstall the pin at the bottom of the lifting motor cylin-
der.
RAPH12WEL0606AA 60
61. Remove lifting device from the hood.
RAPH12WEL0599AA 61
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62. Reconnect hood wiring harness to rear chassis

wiring harness connector. Remove tags.
RAPH12WEL0604AA 62
63. Attach backup alarm wiring harness clamp (1) and

hood ground wire (2) to the cooler housing. Then
remove marking tags.
RAPH12WEL0603AA 63
64. Reconnect the camera wire harness (if machine is

equipped with a camera). Remove marking tags.
RAPH12WEL0601AA 64
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65. Reattach camera wire harness to hood (if machine is

equipped with a camera).
RAPH12WEL0602AA 65
66. Be sure engine oil drain cap is secured. Refill engine

with CASE AKCELA ENGINE OIL 15W-40.
RCPH10WHL054BAL 66
67. Be sure engine coolant drain cap is secure. Refill

cooling system with a 50 % ethylene-glycol and 50
% water coolant solution. Install radiator cap.
RCPH10WHL054BAL 67
68. Switch the master disconnect switch to the ON posi-

tion.
RCPH10WHL106AAH 68
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69. Start the engine and run it at low idle. Run the en-
gine at operating temperature for approximately five
minutes to completely mix the Ethylene Glycol and
water. Check machine for fluid leaks. When coolant
is at operating temperature, recheck the coolant level
at the reservoir.
NOTE: Hot coolant can spray out if radiator cap is removed.
To remove radiator cap: Let system cool, turn cap to first
notch, then wait until all pressure is released. Scalding can
result from fast removal of radiator cap.
70. Install the left and right side inner fender panels (2),
then lower left and right hand side panels (1). Close
the hood.
NOTE: Left side of the machine is shown. This operation
is repeated for the right side.
RAPH12WEL0597AA 69
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Index
Engine - 10

Engine - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Engine - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
84605841 14/05/2012
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Engine - 10
Air cleaners and lines - 202
621F
721F
84605841 14/05/2012
10.202 / 1
Contents
Engine - 10
SERVICE
Air cleaner
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
84605841 14/05/2012
10.202 / 2
Engine - Air cleaners and lines
Air cleaner - Remove

1. Access pre-cleaner located on top of engine com-
partment hood.
RCPH11WHL663BAU 1
2. Remove wing nut.
RCPH11WHL720BAU 2
3. Remove pre-cleaner assembly from machine.
RCPH11WHL719BAU 3
84605841 14/05/2012
10.202 / 3
4. Empty debris and wipe pre-cleaner with a damp

clean cloth. Reassemble and install assembly on
the machine.
RCPH11WHL718BAU 4
Primary/secondary filter element disassembly

5. Raise engine compartment hood using controls lo-
cated behind access cover (1). Air filter housing/el-
ement (2) is located in main engine compartment on
operator’s left hand side of engine.
RCPH11WHL663BAU 5
6. Turn master electric switch “off”.
RCPH11WHL653BAU 6
84605841 14/05/2012
10.202 / 4
7. Release all clips securing air filter element housing

cover.
RCPH11WHL746BAU 7
8. Remove cover from air filter element housing.
RCPH11WHL747BAU 8
9. Remove the primary filter element. To do this, push

filter element down to loosen the filter seal. Then
pull up on the handle to lift the filter element out of
the housing.
RCPH11WHL748BAU 9
10. Remove secondary filter element from the right side

of the filter element housing. Remove debris from in-
side the housing before installing new filter elements.
NOTE: Do not clean the secondary filter element. It must
be replaced if damaged or clogged.
RCPH11WHL749BAU 10
Next operation:
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10.202 / 5
Air cleaner - Install (10.202)
84605841 14/05/2012
10.202 / 6
Air cleaner - Install

Prior operation:
Air cleaner - Remove (10.202)
1. Install new secondary filter element.

NOTE: Make sure filter element is positioned correctly in
slot and firmly seated into housing.
RCPH11WHL749BAU 1
2. Install new primary filter element by sliding it down

into housing. With the handle, pull filter element rear-
ward to make the seal engage in the housing.
NOTE: Make sure primary and secondary filter elements
form an effective seal.
RCPH11WHL748BAU 2
3. Install housing cover.
RCPH11WHL747BAU 3
84605841 14/05/2012
10.202 / 7
4. Lock clips to secure filter housing cover.

NOTE: If cover does not fit properly, recheck filter element
installation. Cover will be difficult to install if filter elements
are not properly installed.
RCPH11WHL745BAU 4
5. Turn master electric power switch “on”. Clear any

fault codes. Start machine and confirm issue has
been corrected.
RCPH11WHL653BAU 5
84605841 14/05/2012
10.202 / 8
Index
Engine - 10

Air cleaner - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Air cleaner - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
84605841 14/05/2012
10.202 / 9
84605841 14/05/2012
10.202 / 10
Engine - 10
Engine lubrication system - 304
621F
721F
84605841 14/05/2012
10.304 / 1
Contents
Engine - 10
SERVICE
Blowby re-circulation system

Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
84605841 14/05/2012
10.304 / 2
Engine - Engine lubrication system
Blowby re-circulation system - Remove

1. Locate the blowby recirculation system filter under
the hood on the engine in back of the cooling fan. It
can be accessed from the right side of the machine.
RCPH11WHL685BAU 1
2. Raise the hood using the controls located behind the

access cover. Then remove the inner fender panel.
RCPH11WHL663BAU 2
3. Turn the master electric switch to the “off” position.
RCPH11WHL653BAU 3
84605841 14/05/2012
10.304 / 3
4. Remove the screws on the filter housing cover plate.

It may be necessary to use an off-set screwdriver.
RAPH12WEL0089AA 4
5. Remove the filter housing cover plate.
RAPH12WEL0090AA 5
6. Remove the filters from the filter housing and replace

them.
RCPH10WHL467AAH 6
Next operation:
Blowby re-circulation system - Install (10.304)
84605841 14/05/2012
10.304 / 4
Blowby re-circulation system - Install

Prior operation:
Blowby re-circulation system - Remove (10.304)
1. Install the new filter elements into the filter housing.

Take care to fit the filter elements correctly.
RCPH10WHL467AAH 1
2. Install the filter housing cover plate.
RAPH12WEL0090AA 2
3. Secure the filter housing cover plate with screws. It

may be necessary to use an off-set screwdriver.
RAPH12WEL0089AA 3
84605841 14/05/2012
10.304 / 5
4. Turn the master electric switch to the “on” position.
RCPH11WHL653BAU 4
5. Install the inner fender panel. Then lower the hood

using the controls located behind the access cover.
RCPH11WHL663BAU 5
84605841 14/05/2012
10.304 / 6
Index
Engine - 10

Blowby re-circulation system - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Blowby re-circulation system - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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10.304 / 8
Engine - 10
Aftercooler - 310
621F
721F
84605841 14/05/2012
10.310 / 1
Contents
Engine - 10
Aftercooler - 310
SERVICE
Aftercooler
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Pressure test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
DIAGNOSTIC
Aftercooler
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
84605841 14/05/2012
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Engine - Aftercooler
Aftercooler - Remove
WARNING
Heavy objects!
Lift and handle all heavy components using lifting equipment with adequate capacity. Always support
units or parts with suitable slings or hooks. Make sure the work area is clear of all bystanders.
W0398A
1. Raise hood using controls located behind the access

cover.
RCPH11WHL652BAU 1
2. After hood is raised, turn master electric switch to the

off position.
RCPH11WHL653BAU 2
84605841 14/05/2012
10.310 / 3
3. On the underside of hood, remove bolts (1) from ex-

haust stack, then remove plate (2).
4. Remove exhaust stack (3).
RAPH12WEL0194AA 3
5. Double up a nylon lifting strap. From the topside,

slide looped strap through the hood exhaust opening.
RAPH12WEL0170AA 4
6. Place a solid steel bar through the strap loop (see

arrow) and tighten. Attach the other end of the strap
to a suitable lifting device and remove any slack in
the line.
NOTE: Note the position of the lifting bar strap. It is offset
to even out the weight distribution of the hood.
RAPH12WEL0193AA 5
84605841 14/05/2012
10.310 / 4
7. Remove cotter pin and pin from the lift cylinder. Turn
electrical master switch back on and run lift cylinder
up. Once cylinder is retracted, return the electrical
master switch back to the OFF position.
RAPH12WEL0191AA 6
8. Remove the hood bracket bolts and move hood away

from back plate, allowing enough clearance to reach
air cooler unit front bolts.
RAPH12WEL0169AA 7
Turbocharger tube removal

9. Loosen top left side clamp of the air cooler outlet
hose.
NOTE: Loosen only the clamp closest to the air cooler.
RAPH12WEL0207AA 8
84605841 14/05/2012
10.310 / 5
10. Loosen the clamp at the elbow-turbocharger connec-

tion end. Remove tube and plug turbocharger.
RAPH12WEL0206AA 9
Intake port tube removal

11. Loosen top right side clamps of the air cooler intake
hose. Slide hose back far enough to clear air cooler
tube.
RAPH12WEL0200AA 10
12. Loosen end clamp on intake port side of the engine.

Remove tube with hose.
RAPH12WEL0202AA 11
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10.310 / 6
Screen cover removal

13. Unlatch the rubber T-handle from the screen cover.
NOTE: Screen cover may be different from what is shown.
RAPH12WEL0190AA 12
14. Lift screen cover part way. Pull cotter pin and washer
from screen tab and locking bar prop.
RAPH12WEL0189AA 13
84605841 14/05/2012
10.310 / 7
15. Open screen cover completely and remove the bolts.

Lift and remove cover.
NOTE: Always use proper lifting devices.
RAPH12WEL0181AA 14
air cooler unit removal

NOTE: For Commodity King, include instruction 16. For Standard 721F omit instruction 16 and go to instruction 17.
Commodity king only

16. Lift side panels. Unbolt and remove left and right
beam seals, then lower side panels.
NOTE: Left side shown.
RAPH12WEL0222AA 15
84605841 14/05/2012
10.310 / 8
17. With a sharp cutting tool, make a slice in the gasket

(arrowed) near the shoulder bolt.
RAPH12WEL0177AA 16
18. Remove shoulder bolt, washers and nut (1) from air
conditioner condenser unit (2).
RAPH12WEL0221AA 17
19. Lift air conditioner condenser up and angle toward

the back of the cab. Support in place if needed.
RAPH12WEL0146AA 18
84605841 14/05/2012
10.310 / 9
20. Lift up side panels. Remove the left and right side
bolt of air cooler unit.
RAPH12WEL0169AA 19
21. Remove front bolts of air cooler unit.
RAPH12WEL0174AA 20
22. Remove air cooler unit out of cooler package frame-

work.
RAPH12WEL0172AA 21
Next operation:
Aftercooler - Testing (10.310)
84605841 14/05/2012
10.310 / 10
Aftercooler - Install
WARNING
Heavy objects!
Lift and handle all heavy components using lifting equipment with adequate capacity. Always support
units or parts with suitable slings or hooks. Make sure the work area is clear of all bystanders.
W0398A
Prior operation:
Aftercooler - Remove (10.310) Aftercooler - Testing (10.310)
1. Attach frame to air cooler assembly. Bolt in place

with four bolts and washers.
RAPH12WEL0172AA 1
2. Using proper lifting equipment, lift and position com-

pleted air cooler unit into the cooler package frame-
work with the tubes situated within the front plate
cut–out, facing the engine (1). Insert two bolts (2)
and partially set.
NOTE: Do not tighten bolts at this time.
RAPH12WEL0174AA 2
3. Raise side panel and insert bolt into each side of the
air cooler unit. Run bolt PART way.
4. Once air cooler unit is semi–secured, tighten sides
and front bolts, then lower side panels.
RAPH12WEL0169AA 3
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5. Slide air conditioner condenser unit back in place.
RAPH12WEL0145AA 4
6. Using a shoulder bolt, three washers and a nut (1),

secure air conditioner condenser unit (2) in place.
RAPH12WEL0221AA 5
7. Flip latch closed on air conditioner condenser unit.
RAPH12WEL0179AA 6
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8. Line up screen cover and run center bolt PART way

(1). Insert outer bolts (2) then securely tighten all
three bolts.
NOTE: Screen cover may be different than shown.
NOTE: For Commodity King, continue instructions. Stan-
dard 721F go to instruction 12.
RAPH12WEL0181AA 7
Commodity king only

9. Lift side panel. Attach hood beam seal with weather
stripping shield facing up.
NOTE: Left side panel shown.
RAPH12WEL0222AA 8
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10. Slide beam seal onto hood hinge stud and tighten in
place with washer and nut.
RAPH12WEL0184AA 9
11. Insert two bolts on opposite end of beam seal and

frame. Tighten in place with washers and nuts.
NOTE: Repeat procedure on right side.
RAPH12WEL0185AA 10
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Screen cover installed

12. Raise screen cover locking bar prop on left side.
RAPH12WEL0187AA 11
13. Partially lower screen cover, lining up screen tab with

locking bar prop.
RAPH12WEL0188AA 12
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14. Place washer on the outside of hinge followed with a

cotter pin to secure in place.
RAPH12WEL0189AA 13
15. Close screen cover, locking in place with the rubber

T–handle.
RAPH12WEL0190AA 14
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Hood installed
16. Line up hood hinge bolt holes to frame. Partially set
bolts to hold in place. Once hood lines up evenly,
tighten all bolts and torque to 65 - 79 N·m (48 - 58 lb
ft).
RAPH12WEL0169AA 15
17. Turn electrical master switch on and electrically lower

lift cylinder, lining up holes. Insert pin through both
holes.
18. Return electrical master switch to the off position.
RAPH12WEL0191AA 16
19. Insert cotter pin through rear of cylinder pin, securing

lift cylinder in place.
RAPH12WEL0192AA 17
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20. Remove hood lifting device.
RAPH12WEL0193AA 18
21. Replace exhaust stack. Insert stack studs through

the pre-drilled holes on the top of the hood.
NOTE: Exhaust stack opening faces toward the rear.
RAPH12WEL0195AA 19
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22. On underside of hood, place reinforce plate (1) over

stack studs (2), securing in place with washers and
nuts. Torque to 36 - 44 N·m (27 - 32 lb ft).
RAPH12WEL0194AA 20
Turbocharger tube installation

23. Remove plug from turbocharger. Place the upper
end of the hose onto the air cooler tube. DO NOT
CLAMP at this time.
NOTE: Note direction of clamps.
RAPH12WEL0207AA 21
24. On the opposite end, make sure that O–ring is in

elbow fitting.
RAPH12WEL0204AA 22
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25. Align O–ring end of tube to turbocharger.
RAPH12WEL0205AA 23
26. Clamp in place. Torque to 10.1 - 11.3 N·m (7.4 - 8.3

lb ft).
RAPH12WEL0206AA 24
27. Return to top air cooler tube connection and torque

clamp 10.1 - 11.3 N·m (7.4 - 8.3 lb ft) in place.
NOTE: Note direction of clamps.
RAPH12WEL0207AA 25
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Intake port tube installation

28. Lightly lubricate inside of hose (1). Slide hose over
top end of tube (2).
RAPH12WEL0199AA 26
29. Slide hose back far enough to clear right side air
cooler tube.
RAPH12WEL0200AA 27
30. Align opposite end of tube to the intake port manifold

side of the engine. Make sure there is clearance
between hood and exhaust stack on both sides of
tube.
RAPH12WEL0197AA 28
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31. Slide clamps in place and tighten. Torque to 10.1 -

11.3 N·m (7.4 - 8.3 lb ft).
RAPH12WEL0202AA 29
32. Line up top tube and slide hose over air cooler tube
until hose fits flush against the frame. Slide clamps
in place and tighten Torque to 10.1 - 11.3 N·m (7.4 -
8.3 lb ft).
NOTE: Note the direction of clamps.
RAPH12WEL0201AA 30
33. Turn power on (1), activate hood cylinder (2) and

close hood.
RCPH11WHL653BAU 31
Next operation:
Aftercooler - Pressure test (10.310)
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Aftercooler - Pressure test

CAUTION
Eye injury hazard!
Use caution when removing the cap due to possible air pressure.
Failure to comply could result in minor or moderate injury.
C0056A
CAUTION
Eye injury hazard!
Always wear eye or full face protection when performing this procedure.
C0081A
1. Park machine on a level surface and lower the bucket

to the ground. Put transmission in neutral, apply the
parking brake, then turn off engine.
RCPH10WHL350FAH 1
2. Raise hood. Remove the turbocharger outlet tube.

Plug tube and turbocharger.
NOTE: Plug is dealer fabricated.
RAPH12WEL0205AA 2
3. Remove inlet hose (1) from manifold (2). Plug inlet

hose and with pressurized air, pressurize the system
between 15 - 20 psi.
NOTE: Always wear eye or full face protection when per-
forming this procedure.
NOTE: Pressurized plug is dealer fabricated.
RAPH12WEL0202AA 3
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4. For air leaks or lack of pressure, inspect cooler com-

ponents for damage or missing parts.
RAPH12WEL0181AA 4
5. Inspect the turbocharger top air cooler outlet flex

hose for leaks or holes and ensure that the clamps
are tight.
RAPH12WEL0207AA 5
6. Inspect the manifold top air cooler inlet flex hose for
leaks or holes and ensure that the clamps are tight.
RAPH12WEL0201AA 6
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7. Visually inspect top of air cooler for damage or leaks.

NOTE: If the leak source has not been located, remove and
test the air cooler using Aftercooler - Testing (10.310).
RCPH10WHL139AAH 7
Pressure test reassemble

8. Unplug and remove pressurized air system from
manifold. Realign tube on manifold. Make sure
there is clearance between the hood and exhaust
stack on both sides of the tube. Tighten clamp and
torque to 10.1 - 11.3 N·m (7.4 - 8.3 lb ft).
RAPH12WEL0202AA 8
9. Remove plug from turbocharger tube. Remove plug

from turbocharger. Make sure gasket remained in-
side turbocharger tube.
RAPH12WEL0204AA 9
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10. Align tube ends and secure in place with clamp.

Torque to 10.1 - 11.3 N·m (7.4 - 8.3 lb ft).
RAPH12WEL0206AA 10
11. Lower hood.
RCPH11WHL653BAU 11
12. Close screen and T-handle secure in place (if avail-

able). Put transmission in park and turn off.
RAPH12WEL0190AA 12
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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 - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Aftercooler - Pressure test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Aftercooler - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Aftercooler - Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
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Engine - 10
Engine cooling system - 400
621F
721F
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Contents
Engine - 10
SERVICE
Radiator
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
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CONSUMABLES INDEX
Consumable IU PAGE
Loctite® 242 Radiator - Install 10.400 / 16
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Engine - Engine cooling system
Radiator - Remove
1. Park loader on level surface and lower bucket to
ground. Apply parking brake and shut down engine.
Then place articulation lock in locked position.
RCPH10WHL063BAL 1
2. Put master disconnect switch in OFF position.
RCPH11WHL653BAU 2
3. Raise the center cooler box cover (1). Have another

person lift and hold the cooler box side panel (2) up
into the raised position.
RAIL12WEL0099AA 3
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4. Remove the mounting screws for the side panel, and

remove the panel.
RAIL12WEL0097AA 4
RAIL12WEL0098AA 5
5. Remove the thumb screw and washer (1) securing

left hand inner fender panel (2) and remove fender.
RAIL12WEL0100AA 6
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6. Remove radiator cap.

NOTE: Machine pictured includes the heavy duty/high de-
bris cooling option. Your machine may differ slightly in ap-
pearance.
RAIL12WEL0103AA 7
7. Place a suitable container below radiator drain.

Then remove drain cap and drain coolant into con-
tainer. Install and secure both caps after coolant has
drained.
RCPH10WHL054BAL 8
8. Release catch and tilt air conditioning condenser

core up.
RAIL12WEL0101AA 9
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9. Loosen the upper radiator hose clamp and remove

the hose from radiator.
RAIL12WEL0102AA 10
10. Disconnect overflow hose from radiator.

pearance.
RAIL12WEL0103AA 11
11. Remove cooler box support brace bolts (1). Then

remove cooler box support brace (2).
NOTE: This step only required for machines equipped with
the heavy duty/high debris cooling option.
pearance.
RAIL12WEL0104AA 12
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12. Remove coolant overflow bottle.
RAIL12WEL0105AA 13
13. Remove coolant overflow bottle support bracket.
RAIL12WEL0107AA 14
14. Remove cooling fan screen shroud.
RAIL12WEL0109AA 15
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15. Loosen lower radiator hose clamp and remove the

lower radiator hose from the radiator.
RAIL12WEL0111AA 16
16. Remove bolts and install lifting eyes.

NOTE: For added lifting support, use bolts with a longer
thread than the bolts removed from the radiator.
RAIL12WEL0112AA 17
17. Attach suitable lifting equipment to lifting eyes.
RAIL12WEL0113AA 18
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18. Remove the four mounting bolts (two shown) and

carefully lift radiator from machine.
pearance.
NOTE: Machines with the standard cooling option use a
smaller radiator and a block-off plate attached to the ra-
diator at the top bottom and sides. Remove the radiator
and block-off plate as one assembly. Remove the block-off
plate from the radiator after the assembly is out of the ma-
chine.
RAIL12WEL0114AA 19
Next operation:
Radiator - Install (10.400)
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Radiator - Install
CAUTION
Burn hazard!
Hot coolant can spray out if you remove the filler cap while the system is hot. After the system has
cooled, turn the filler cap to the first notch and wait for all pressure to release before proceeding.
C0043A
Prior operation:
Radiator - Remove (10.400)
1. Using a suitable lifting device, position radiator above

cooling box frame.
pearance.
NOTE: Machines with the standard cooling option use a
smaller radiator and a block-off plate attached to the radi-
ator at the top bottom and sides. Install the radiator and
block-off plate as one assembly. Attach the block-off plate
to the radiator before the assembly is installed in the ma-
chine.
RAIL12WEL0114AA 1
2. Carefully lower radiator while guiding it into position

on cooling box frame. Install lock washers and bolts
to secure radiator.
pearance.
RAIL12WEL0113AA 2
3. Disconnect lifting equipment from lifting eyes (1). Re-

move lifting eyes and reinstall original bolts (2).
RAIL12WEL0112AA 3
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4. Connect lower radiator hose and tighten hose clamp

to a torque of 10.1 - 11.3 N·m (89 - 100 lb in).
RAIL12WEL0111AA 4
5. Install cooling fan screen shroud.
RAIL12WEL0109AA 5
6. Install coolant overflow bottle support bracket.
RAIL12WEL0107AA 6
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7. Install coolant overflow bottle.
RAIL12WEL0105AA 7
8. Install cooler box support brace.

NOTE: This step only required for machines equipped with
the heavy duty/high debris cooling option.
pearance.
RAIL12WEL0104AA 8
9. Connect overflow hose to radiator.

pearance.
RAIL12WEL0103AA 9
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10. Connect upper radiator hose and secure clamps.

Torque hose clamp to 10.1 - 11.3 N·m (89 - 100 lb
in).
RAIL12WEL0102AA 10
11. Position inner fender so that it is behind the fender

mounting bolt.
RAIL12WEL0106AA 11
12. Align the hole in the inner fender panel on the bolt.
RAIL12WEL0108AA 12
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13. Align the slots in the inner fender panel with the tabs
on the machine chassis.
RAIL12WEL0110AA 13
14. Push the fender towards the front of the machine and
secure it using thumb screw and washer.
RAIL12WEL0100AA 14
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15. Apply LOCTITE® 242 to the threads, install the mount-

ing screws for the side panel and torque to 3.5 - 9.5
N·m (31 - 84 lb in).
RAIL12WEL0097AA 15
RAIL12WEL0098AA 16
16. Check that coolant drain cap is tight.
RCPH10WHL054BAL 17
17. Fill engine coolant system with a solution of 50 %

Ethylene Glycol and 50 % water. Cooling system
capacity for the 621F is 26.8 l (28.3 US qt). Capacity
for the 721F is 28.4 l (30.0 US qt).
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18. Install the radiator cap

pearance.
RAIL12WEL0103AA 18
19. Fill the coolant reservoir up to the FULL mark on the

reservoir.
RAIL12WEL0105AA 19
20. Put master disconnect switch in ON position.
RCPH11WHL653BAU 20
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21. Start engine and run the engine at low idle. Run the
engine at operating temperature for approximately
five minutes to completely mix the Ethylene Glycol
and water. When the coolant is at operating tem-
perature, stop the engine. When engine has cooled,
check the coolant level at the reservoir.
NOTICE: WARNING: Hot coolant can spray out if radiator
cap is removed. To remove radiator cap: Let system cool,
turn to first notch, then wait until all pressure is released.
Scalding can result from fast removal of radiator cap.
22. Close up all open body panels. Then put articulation
lock in OPERATING position.
RCPH10WHL062BAL 21
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Index
Engine - 10

Radiator - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Radiator - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
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Engine - 10
Fan and drive - 414
621F
721F
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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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Engine - 10
Selective Catalytic Reduction (SCR) exhaust treatment - 500
621F NA
621F WE
721F NA
721F WE
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Contents
Engine - 10
FUNCTIONAL DATA
Selective Catalytic Reduction (SCR) exhaust treatment

Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
621F WE, 621F NA, 721F WE, 721F NA
SERVICE
Selective Catalytic Reduction (SCR) muffler and catalyst

Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Diesel Exhaust Fluid (DEF)/AdBlue® tank
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Coolant control valve
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
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CONSUMABLES INDEX
Consumable IU PAGE
DEF/AdBlue® Coolant control valve - Install 10.500 / 31
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Engine - Selective Catalytic Reduction (SCR) exhaust treatment
Selective Catalytic Reduction (SCR) exhaust treatment - Dynamic

description
621F WE, 621F NA, 721F WE, 721F NA
Wheel loaders built in 2011 and after can be equipped with Selective Catalytic Reduction (SCR) engine exhaust emis-
sion control system. With this system, the engines operate as efficiently as possible. During normal operation the
diesel engine generates certain pollutants. Federal law has regulated the levels of these exhaust components that a
vehicle is allowed to emit. Pollutants generated in the normal operation of the engines require after treatment. The
SCR system converts the pollutants to harmless nitrogen and water.
A diesel engine operates most efficiently at higher combustion temperatures. Unfortunately, the higher combustion
temperatures generate increased levels of nitrogen oxides (NOx). A sensor determines the NOx level in the exhaust
stream and reports this information to the Engine Controller. To reduce the NOx level the system adds a urea based
Diesel Exhaust Fluid (DEF) to reduce the pollutant. The NOx sensor monitors the exhaust to assure the system
meets regulations. An alarm sounds and a warning displays on the Advanced Instrument Cluster (AIC) if the system
malfunctions.
Operator Cautions
DEF fluid mishandling causes SCR system problems. It is preferable to dispense DEF directly from factory containers.
If refillable containers are required to handle DEF, make sure that it does not have traces of other contaminating
liquids. Water and oil do not mix. Petroleum contamination causes problems. Make sure that dirty containers are not
used. Replace the tank filler cap after filling. Dirty fluid causes premature filter plugging.
The SCR system requires the exhaust temperature to be above approximately 230 °C (446 °F) for proper function.
Operating units under light load conditions i.e. roading longer distances, idling or light duty cycle applications can
trigger alarms. For example, working for about 10 minutes and then idling for about 20 minutes can trigger an alarm.
Most of the sensors operate in adverse operating conditions and are designed to survive those. Damage can result
when a sensor is exposed to other conditions, For example, rain water can damage the NOx sensor. Operators should
be conscious of parking locations or consider covering the exhaust.
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SCR System Function

Beginning in 2011 the allowable emission level of nitrogen oxides (NOx) has been reduced. To meet these regulations
Wheel Loaders can be equipped with a SCR engine exhaust emission control system.
To reduce the NOx level the SCR system adds a Diesel Exhaust Fluid (DEF) to the catalyst to reduce the NOx pollu-
tant. Another term for DEF fluid is AdBlue. The NOx sensor monitors the exhaust to assure the system is functioning
correctly. A malfunction causes an audible alarm to sound and a warning to display on the AIC screen.
The machine consumes DEF fluid during operation. The ratio of DEF fluid to diesel fuel consumed varies depending
on the load on the engine and other factors. The machine typically consumes approximately 5 percent to 6 percent
as much DEF fluid as diesel fuel.
DEF fluid is required for the SCR System to function. This liquid consists of 32.5 percent urea mixed into deionized
water. This fluid has a limited shelf life. DEF degrades more rapidly when it is stored at temperatures above 30 °C
(86 °F) . DEF freezes at -11 °C (12 °F) and is usable when thawed. Contamination of the fluid can cause damage to
the system, which will then cause the engine power to derate causing machine performance complaints.
The machine has a separate DEF tank (1). In cold climates, the DEF tank can freeze. The plumbing between the
tank and the SCR control system can also freeze. To thaw the DEF fluid warm or hot engine coolant is circulated
through coiled tubing which is incorporated into the DEF tank level gauge. The coolant to the tank heater is bundled
with the DEF fluid supply and return hoses to thaw them as required. Elevated DEF fluid temperature is detrimental
to system performance. A solenoid operated ON-OFF valve controls the coolant flow to prevent overheating.
An inline filter (2) is connected between the tank and the system supply module. This filter is the first one in the
system and is subject to plugging. There also is a pre-filter (9) incorporated into the inlet port of the supply module.
A restriction in these filters limits the delivery of DEF fluid that will cause fault codes to be generated. Both of these
filters are serviceable.
The SCR system is electronically controlled. The Denox Controller Unit (DCU) (4) is incorporated into the supply
module located on the engine. This control unit receives signal inputs from many sensors. Based upon these inputs
the electronic control unit operates the supply pump (5), the reversing valve (6), the fluid heating system and the
dosing injector solenoid valve (12).
The supply module pump (5) provides a fluid pressure of approximately 5 bar (73 psi) to the dosing module (11).
Between the pumps and the dosing module (11), the fluid passes through a fine filter (10). This filter must be changed
at a scheduled interval. Non-serviceable filters are installed at both the inlet and return ports of the dosing module
(11).
To prevent fluid overheating at the dosing module there is a passage that allows a continuous bypass of fluid through
the dosing nozzle back to tank through the return flow valve (13). This back flow of fluid is connected to a flow
passage in the supply module. This connection through the supply module allows for both the DEF fluid supply and
return connections to the tank to come to one location on the engine.
The NOx in the exhaust is not visible. Removal of NOx requires a chemical reaction. This chemical reaction takes
place in the catalyst (15), which could be called a catalytic converter. Unlike automotive catalytic converter, the diesel
catalyst requires the injection of DEF fluid into the exhaust stream to function. The dosing module (11) injects the
required DEF fluid. The DCU receives sensor inputs and then controls the amount of DEF injected. The catalyst
requires about 230 °C (446 °F) for the chemical reaction to take place.
The DCU (4) monitors system function and will activate fault codes when it malfunctions. At exhaust temperatures
lower than about 230 °C (446 °F) the system does not function.
The DCU has an internal timer function that ignores what might be a malfunction for about ½ hour of operation. During
this time, the engine can operate at full power. A malfunction after the system is functioning causes an audible alarm
to sound and a warning message will display on the instrument cluster screen. If the malfunction continues, the engine
controller (22) will limit fuel delivery causing the engine power to derate. These derate conditions will likely cause a
customer complaint. Refer to the Electronic Service Tool (EST) or the Service Manual for additional information on
troubleshooting fault codes.
DEF fluid degrades at elevated temperatures. A two position 4-way solenoid controlled reversing valve (6) is con-
nected to the inlet and outlet of the DEF fluid pump (5). When the vehicle shuts down this valve activates reversing
the inlet and outlet of the pump. A control circuit in the DCU (4) keeps the pump running for a while after engine
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shutdown. This after run draws the DEF fluid from the system and sends it back to tank. Do not turn the master
disconnect off until the pump has stopped this after run cycle.
RCPH11WHL048GAN 1
SCR System Components
Graphic Legend
A – DEF fluid passage D – Heater
B – DEF fluid hose E – CAN wire
C – Electrical wiring F – Dosing module cooling
Components
1 – Diesel Exhaust Fluid (DEF) tank 14 – Mixer
2 – Inline filter 15 – Catalyst
3 – Supply module 16 – Humidity sensor
4 – Denox Controller Unit (DCU) 17 – DEF tank temperature sensor
5 – Pump 18 – DEF tank level sensor
6 – Reversing valve 19 – Catalyst inlet temperature sensor
7 – DEF temperature sensor 20 – Catalyst outlet temperature sensor
8 – DEF pressure sensor 21 – NOx sensor
9 – Prefilter 22 – Engine Controller Unit (EDC7UC31)
10 – Filter 23 – CAN wire (from NOx sensor to ECU)
11 – Dosing module 24 – CAN wire (between DCU and ECU)
12 – Dosing valve 25 – DEF tank heater solenoid
13 – Return flow valve
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The main components of SCR system are:
Fiat Powertrain (FPT) Vehicle Engine
DEF solution tank (1)

• A catalyst solution, DEF/Ad Blue is required for the system to operate. The vehicle typically consumes approx-
imately 5 percent to 6 percent as much DEF fluid as diesel fuel. This fluid consists of 32.5 percent urea mixed
into distilled water. Use of containers with traces of other liquids to handle DEF causes contamination that fouls
the system. Proper handling procedures are required. Use only American Petroleum Institute (API) certified
DEF fluid.
• Engine coolant circulates through the Tank Heater to thaw the DEF fluid. An On-Off solenoid valve controls the
coolant flow to prevent DEF fluid overheating.
• An inline DEF Filter (2) is installed between the tank and the inlet of the supply module. In extreme dirty condi-
tions, the vent can allow dirt to enter the tank and plug the filter. Clean this filter initially @ 100 hours and every
1500 hours thereafter.
Supply Module (3)

• The Denox Supply Module (3) is the supply and controller for the system. It consists of the following:
• The Denox Controller Unit (4), (DCU) receives input signals from the sensors. Based on this sensor input
it controls the flow of the DEF fluid into the system.
• A DEF fluid pump (5) delivers fluid from the supply tank to the dosing injection module.
• A reversing valve (6) returns flow from the system back to the DEF supply tank as the system is shutdown.
The pump may run up to 90 seconds after shutdown.
• The DEF fluid temperature sensor (7) monitors the temperature.
• The DEF fluid pressure sensor (8) monitors the fluid pressure to the dosing module.
• A pre-filter (9) at the module inlet screens out larger particles. This requires service as required.
• A main DEF filter (10) removes finer contamination. This filter requires service at 3000 hours.
• There is also a return flow passage within the supply module. This allows for both the DEF fluid supply
and return connections to the tank to come to one location on the engine.
Dosing Injection Module (11)

• The Dosing Injection Module mounted to the exhaust stream and injects a metered amount of DEF fluid to
reduce NOx level. It consists of the following components:
• The Dosing Valve (12) regulates the delivery of DEF fluid to the exhaust stream. The DCU in the supply
module controls this electric solenoid type valve.
• A Return Flow Valve (13) bypasses DEF fluid supply back to the tank to limit temperature build-up at the
dosing module. A check valve is part of this bypass. It allows DEF fluid to be evacuated from the dosing
module, as the vehicle is shutdown. Hot DEF fluid can cause deposits to build up causing blockages in
the system.
• Screens are located within both the inlet and return ports of the dosing module. These screens are not
expected to require service at any time.
• A mixer (14) is located in the exhaust flow at the inlet of the catalyst to assure distribution of the DEF fluid
to the catalyst.
SCR Catalyst (15)

• The SCR catalyst (15) would be called a catalytic converter on an automobile. In a SCR system, the catalyst
serves as the muffler as well as the device to remove NOx. All engine exhaust flow passes through the SCR
Catalyst. Within the catalyst, the urea based DEF fluid reacts with the higher concentrations of nitrogen oxides
(NOx) caused by the combustion cycle. This chemical reaction converts the NOx to nitrogen and water vapors
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that pass out the exhaust. The catalyst requires heat to function. The system requires a minimum temperature
of 230 °C (446 °F) to function.
RCPH11WHL048GAN 2
Graphic Legend
Components
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Control System Sensors

NOTE: Emissions sensors in the exhaust system and on the vehicle may be damaged by vibrations from use of impact
wrenches or hammers during service work. Avoid using these tools when servicing components close to the sensors.
Remove the sensors with care if use of these tools cannot be avoided.
• Humidity and Ambient Air Temperature sensor (16) at engine intake. Ambient air humidity impacts the amount
of NOx generated. This humidity level is reported directly to the EDC7UC31 engine controller (22) and the
information is then broadcast via the CAN network.
• DEF tank Temperature (17) and Level sensor (18)
• The temperature of the DEF fluid is important to the SCR control system. DEF fluid freezes at -11 °C (12
°F). It also degrades at elevated temperatures.
• If DEF fluid is not injected or if it has been contaminated reduced engine power results. A DEF fluid level
sensor is installed in the tank and the AIC screen displays that level.
• Fluid Temperature Sensor (7) in Supply Module
• A temperature sensor monitors the fluid temperature at the inlet of the main filter in the supply module.
• Fluid Pressure in Supply Module (8)
• A pressure sensor monitors the fluid pressure delivered to the dosing module.
• Catalyst Inlet Exhaust Temperature Sensor (19). A Temperature Sensor is installed upstream of the catalyst
to monitor exhaust temperature. For the catalyst to function efficiently the exhaust temperature needs to be
within a specific range. Too low a temperature restricts the catalyst function. The catalyst will be damaged if the
temperature exceeds a critical level.
• Catalyst Outlet Exhaust Temperature Sensor (20). A Temperature Sensor is installed downstream of the catalyst
to monitor exhaust temperature. For the catalyst to function efficiently the exhaust temperature needs to be
within a specific range. Too low a temperature restricts the catalyst function. The catalyst will be damaged if the
temperature exceeds a critical level.
• NOx sensor (21) downstream of the catalyst
• A NOx sensor is mounted downstream of the catalyst to monitor the emission level after the SCR process
has taken place.
• The NOx sensor is a two-part device. The sensor portion is directly in the exhaust stream downstream
of the catalyst. A cable connects from the sensor to an 8-pin connector on the CAN BUS module portion
of the NOx sensor. This module digitally communicates directly to the engine EDC7UC31 controller (22)
via a four wire CAN 2 network line (23). The CAN 2 line connects to the five pin connector on the sensor
module. The CAN 1 line (24) digitally communicates signals between the engine controller (22) and the
DCU (4).
Heaters
• DEF fluid freezes at -11 °C (12 °F). Many times these units operate in climates colder than this.
• A heating device incorporated within the DEF tank level sensor thaws the DEF. Engine coolant is circu-
lated through this heater to warm the fluid. The flow of coolant to this heater passes through a solenoid
controlled on-off valve (25). This prevents heating the DEF fluid once thawed.
• The plumbing between the tank and the supply module can also freeze. The coolant required to thaw the
tank is routed through a plumbing bundle to thaw the hoses.
• There are DEF fluid passages within the supply module that can freeze. Electric heaters incorporated in
the module thaw this fluid as required.
84605841 14/05/2012
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RCPH11WHL048GAN 3
Graphic Legend
Components
84605841 14/05/2012
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Selective Catalytic Reduction (SCR) muffler and catalyst - Remove

NOTICE: Emissions sensors in the exhaust system and on the vehicle may be damaged by vibrations from use of
impact wrenches or hammers during service work. Avoid using these tools when servicing components close to the
sensors. Remove the sensors with care if use of these tools cannot be avoided.
1. Raise the hood using controls located behind the ac-
cess cover.
RCPH11WHL663BAU 1
RCPH11WHL653BAU 2
3. Locate the catalyst (1) and its inlet temperature sen-

sor (2).
RCPH11WHL674BAU 3
84605841 14/05/2012
10.500 / 11
4. Loosen hex nut on sensor.
RCPH11WHL725BAU 4
5. Remove catalyst inlet temperature sensor.
RCPH11WHL676BAU 5
6. Locate NOx sensor (1) and catalyst outlet tempera-

ture sensor (2).
RCPH11WHL657BAU 6
84605841 14/05/2012
10.500 / 12
7. Loosen hex nut and remove catalyst outlet tempera-

ture sensor.
RCPH11WHL664BAU 7
8. Loosen hex nut on NOx sensor.
RCPH11WHL668BAU 8
9. Remove NOx sensor from exhaust system.
RCPH11WHL669BAU 9
84605841 14/05/2012
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10. Attach a suitable lifting device and lift strap to the

catalyst.
RCPH11WHL729BAU 10
11. Remove clamp, gasket and gasket alignment sleeve

from catalyst and mixing pipe connection. Discard
clamp and gasket.
NOTE: Gasket alignment sleeve may be attached to mixing
pipe. Gasket and clamp should be replaced every time the
connection is disassembled.
RCPH11WHL727BAU 11
12. Remove hex bolts and carriage head bolts from the
mounting support brackets securing the inlet end of
the catalyst and the air filter inlet hose.
RCPH11WHL728BAU 12
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10.500 / 14
13. Remove hex bolts securing mounting support

bracket to the rear of catalyst.
RCPH11WHL730BAU 13
14. Lift catalyst from machine.
RCPH11WHL731BAU 14
15. Remove mounting support bracket from front of cat-

alyst.
RCPH11WHL732BAU 15
Next operation:
Selective Catalytic Reduction (SCR) muffler and catalyst - Install (10.500)
84605841 14/05/2012
10.500 / 15
Selective Catalytic Reduction (SCR) muffler and catalyst - Install

Prior operation:
Selective Catalytic Reduction (SCR) muffler and catalyst - Remove (10.500)
1. Attach mounting support bracket to the inlet end of
the catalyst.
RCPH11WHL732BAU 1
2. Attach a suitable lifting device and lift strap to the

catalyst. Move the catalyst into position within the
machine.
RCPH11WHL731BAU 2
3. Install hex bolts into catalyst and attach rear mount-

ing support bracket.
NOTE: Leave hex bolts loose until final positioning of cat-
alyst is completed.
RCPH11WHL730BAU 3
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10.500 / 16
4. Install hex bolts and carriage head bolts connecting

the mounting support brackets securing the inlet end
of the catalyst and the air filter inlet hose.
NOTE: Leave hex bolts and carriage head bolts loose until
final positioning of the catalyst is obtained.
RCPH11WHL728BAU 4
5. Install new gasket and clamp at connection between

catalyst and mixing pipe. Clamp torque 6 N·m (53
lb in). Tighten all hex bolts to secure catalyst to
mounting support brackets.
NOTE: Gasket and clamp should be replaced every time
connection is disassembled. The gasket alignment sleeve
press fits into mixing pipe or muffler, whichever fits better.
NOTE: It might be necessary to loosen the turbo clamp,
brackets and U-bolts to gain proper alignment of compo-
nents.
RCPH11WHL727BAU 5
6. Install NOx sensor into exhaust pipe at catalyst out-

let. Sensor torque 40 - 60 N·m (30 - 44 lb ft).
RCPH11WHL669BAU 6
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7. Install catalyst outlet temperature sensor into ex-

haust pipe at catalyst outlet. Sensor torque 40 - 50
N·m (30 - 37 lb ft).
RCPH11WHL664BAU 7
8. Install catalyst inlet temperature sensor into mixing

pipe at the inlet of the catalyst. Sensor torque 40 -
50 N·m (30 - 37 lb ft).
RCPH11WHL675BAU 8

Clear any fault codes from the system. Start machine
and check for exhaust leaks. Confirm problem has
been corrected.
RCPH11WHL653BAU 9
84605841 14/05/2012
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Diesel Exhaust Fluid (DEF)/AdBlue® tank - Remove

CAUTION
Flying debris!
Compressed air can propel dirt, rust, etc. into the air. Wear eye and face protection when using com-
pressed air.
C0049A

cess cover.
RCPH11WHL663BAU 1
RCPH11WHL653BAU 2
3. Place a suitable container below radiator drain lo-

cated beneath the access cover at rear left hand side
of machine. Remove radiator cap. Remove drain
cap. Drain coolant. Install tank drain plug and radia-
tor cap after coolant has drained.
NOTE: Use compressed air and water to clean debris from
around drain plug area.
RCPH11WHL684BAU 3
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4. Loosen hex bolts and remove access cover below

supply tank to gain access to the drain.
NOTE: Use compressed air and water, to clean debris from
around drain plug area.
RCPH11WHL710BAU 4
5. Place a suitable container below DEF/ADBLUE®

supply tank drain plug. Remove filler neck cap
from supply tank. Loosen drain plug and drain
DEF/ADBLUE®. Install drain plug and access cover
after DEF/ADBLUE® has drained.
RCPH11WHL711BAU 5
6. Remove bolts securing filler neck screen assembly.

NOTE: Place a plug in filler neck hole to prevent loose
screws from entering the supply tank.
RCPH11WHL694BAU 6
7. Remove filler neck/screen assembly and O-ring from

supply tank by pulling upward while twisting assem-
bly left and right.
RCPH11WHL695BAU 7
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8. Remove hex bolts and panel to access supply tank.
RCPH11WHL703BAU 8
9. Remove rubber boot cover from liquid level/temp

sensor sending unit wires, DEF/ADBLUE® and en-
gine coolant supply lines. Mark wire and hose
connection positions.
top of DEF/ADBLUE® supply tank around liquid level/temp
sensor sending unit area.
RCPH11WHL704BAU 9
10. Unplug wiring harness. Disconnect engine coolant

lines and DEF/ADBLUE® lines by pushing coupling
together, squeezing tabs and then pulling connection
apart.
RCPH11WHL705BAU 10
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11. Pull wire and hose harness up and off to the side out
of the way.
NOTE: Plug all lines to prevent debris from entering the
system.
RCPH11WHL706BAU 11
12. Mark location of pickup unit within tank before re-

moval. Twist DEF/ADBLUE® level temperature sen-
sor unit counter clockwise to loosen it from tank.
RCPH11WHL707BAU 12
13. Lift DEF/ADBLUE® level/temp sensor unit out of tank.

NOTE: Cover tank opening to prevent debris entry.
RCPH11WHL744BAU 13
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10.500 / 22
14. Remove hex bolts from mounting support bracket

above tank and from bottom of tank. Lift tank up and
out of its cradle in the wheel loader frame.
RCPH11WHL709BAU 14
Next operation:
Diesel Exhaust Fluid (DEF)/AdBlue® tank - Install (10.500)
84605841 14/05/2012
10.500 / 23
Diesel Exhaust Fluid (DEF)/AdBlue® tank - Install

Prior operation:
Diesel Exhaust Fluid (DEF)/AdBlue® tank - Remove (10.500)
1. Install DEF/ADBLUE® supply tank into the machine

frame cradle and secure it using hex bolts and upper
support mounting bracket.
RCPH11WHL702BAU 1
2. Lower DEF/ADBLUE® level temp sensor and pick-up

unit into tank.
RCPH11WHL744BAU 2
84605841 14/05/2012
10.500 / 24
3. Use reference marks from disassembly procedure

to position DEF/ADBLUE® level temp sensor and
pick-up unit. Secure by turning it clockwise.
RCPH11WHL707BAU 3
4. Remove plugs from all lines. Reconnect DEF/

ADBLUE® supply/return and purge lines, engine
coolant supply/ return lines and liquid level gage
sensor wiring harness. To connect, push connec-
tions together all the way, and then pull back to lock.
RCPH11WHL705BAU 4
5. Replace rubber boot protective cover.
RCPH11WHL704BAU 5
84605841 14/05/2012
10.500 / 25
6. Replace access panel and secure using hex bolts.
RCPH11WHL703BAU 6
7. Lubricate O-ring with petroleum jelly. Reinstall the

O-ring onto the DEF/ADBLUE® supply tank with the
radius surface facing upward.
RCPH11WHL697BAU 7
8. Reinstall filler neck assembly onto supply tank.
RCPH11WHL695BAU 8
84605841 14/05/2012
10.500 / 26
9. Secure filler neck assembly using Torx bolts. Refill

DEF/ADBLUE® storage tank and engine cooling sys-
tem.
RCPH11WHL694BAU 9
10. Turn master electric power switch to “on” position.

Clear any fault codes. Start machine and check for
DEF/ADBLUE® and coolant leaks. Confirm that the
problem has been corrected.
RCPH11WHL653BAU 10
84605841 14/05/2012
10.500 / 27
Coolant control valve - Remove

CAUTION
Flying debris!
pressed air.
C0049A

cess cover.
RCPH11WHL663BAU 1
2. Turn master electric switch to the “off” position.
RCPH11WHL653BAU 2
3. Place a suitable container below radiator drain lo-

cated behind access cover. Remove radiator cap.
Remove drain cap and drain engine coolant. Install
tank drain plug and radiator cap after coolant has
drained.
around drain plug area prior to draining the system.
RCPH11WHL712BAU 3
84605841 14/05/2012
10.500 / 28
4. Locate DEF/ADBLUE® Heater Control valve next to

the DNOx Controller Unit on the right hand side of
the engine.
RCPH11WHL678BAU 4
5. Disconnect the machine wiring harness from the

DEF/ADBLUE® heater control valve.
RCPH11WHL679BAU 5
6. Using a small flat blade screw driver, pull up on the

fitting retaining clip and disconnect the coolant inlet/
outlet lines from the heater control valve.
RCPH11WHL680BAU 6
84605841 14/05/2012
10.500 / 29
7. Remove hex bolts securing heater control valve to

mounting support bracket.
RCPH11WHL681BAU 7
8. Remove heater control valve from machine.
RCPH11WHL682BAU 8
Next operation:
Coolant control valve - Install (10.500)
84605841 14/05/2012
10.500 / 30
Coolant control valve - Install

Prior operation:
Coolant control valve - Remove (10.500)
1. Position DEF/ADBLUE® heater control valve on the

mounting support bracket and secure it with hex
bolts.
RCPH11WHL681BAU 1
2. Reconnect coolant inlet/outlet lines and wiring har-

ness and refill engine cooling system.
RCPH11WHL679BAU 2
3. Turn master electric switch to the “on” position. Clear

any fault code. Start the machine and check for en-
gine coolant leaks. Confirm that problem has been
corrected.
RCPH11WHL653BAU 3
84605841 14/05/2012
10.500 / 31
Index
Engine - 10

Coolant control valve - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Coolant control valve - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Diesel Exhaust Fluid (DEF)/AdBlue® tank - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Diesel Exhaust Fluid (DEF)/AdBlue® tank - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Selective Catalytic Reduction (SCR) exhaust treatment - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
621F WE, 621F NA, 721F WE, 721F NA
Selective Catalytic Reduction (SCR) muffler and catalyst - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Selective Catalytic Reduction (SCR) muffler and catalyst - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
84605841 14/05/2012
10.500 / 32
Engine - 10
Engine generic sub-group - AAA
621F
721F
84605841 14/05/2012
10.AAA / 1
Contents
Engine - 10
TECHNICAL DATA
Engine generic sub-sub-group

General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SERVICE
Engine generic sub-sub-group

Remove - Engine to Transmission Drive Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Install - Engine to Transmission Drive Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
84605841 14/05/2012
10.AAA / 2
Engine - Engine generic sub-group
Engine generic sub-sub-group - General specification

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)
84605841 14/05/2012
10.AAA / 3
Engine generic sub-sub-group - 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 (10.AAA)
84605841 14/05/2012
10.AAA / 4
Engine generic sub-sub-group - Install - Engine to Transmission

Drive Shaft
Prior operation:
Drive shaft - Remove — Engine to Transmission Drive Shaft (10.AAA)
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
84605841 14/05/2012
10.AAA / 5
Index
Engine - 10

Engine generic sub-sub-group - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Engine generic sub-sub-group - Install - Engine to Transmission Drive Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Engine generic sub-sub-group - Remove - Engine to Transmission Drive Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
84605841 14/05/2012
10.AAA / 6
84605841 14/05/2012
10.AAA / 7
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.
84605841 14/05/2012
EN
SERVICE MANUAL
Transmission
621F
721F
84605841 14/05/2012
21
Contents
Transmission - 21
Powershift transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.113

621F , 721F
Powershift transmission external controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.135

621F , 721F
Powershift transmission internal components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.155

621F , 721F
84605841 14/05/2012
21
CONSUMABLES INDEX
Consumable IU PAGE
Loctite® 574 Powershift transmission - Assemble - 621F 21.113 / 49
Terostat® MS-9360 Powershift transmission - Assemble - 621F 21.113 / 64
Loctite® 574 Powershift transmission - Assemble - 4 Speed - 721F 21.113 / 92
Terostat® MS-9360 Powershift transmission - Assemble - 4 Speed - 721F 21.113 / 107
Loctite® 574 Powershift transmission - Assemble – 5 Speed - 712F 21.113 / 137
Terostat® MS-9360 Powershift transmission - Assemble – 5 Speed - 712F 21.113 / 152
Loctite® 243 Transmission control valve - Assemble - 621F 21.135 / 22
Loctite® 243 Transmission control valve - Assemble - 4 Speed - 721F 21.135 / 44
Loctite® 262 Clutch - Assemble - Forward clutch KV - 4 and 5 Speed - 721F 21.155 / 113
Loctite® 262 Clutch - Assemble - Reverse clutch KR - 4 and 5 Speed - 721F 21.155 / 127
84605841 14/05/2012
21
84605841 14/05/2012
21
Transmission - 21
Powershift transmission - 113
621F
721F
84605841 14/05/2012
21.113 / 1
Contents
Transmission - 21
FUNCTIONAL DATA
Powershift transmission
Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
SERVICE
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Disassemble - 621F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
621F
Assemble - 621F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
621F
Disassemble - 4 Speed - 721F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

721F
Assemble - 4 Speed - 721F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

721F
Disassemble - 5 Speed – 721F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111

721F
Assemble – 5 Speed - 712F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131

721F
DIAGNOSTIC
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
84605841 14/05/2012
21.113 / 2
CONSUMABLES INDEX
Consumable IU PAGE
Terostat® MS-9360 Powershift transmission - Assemble - 621F 21.113 / 64
Terostat® MS-9360 Powershift transmission - Assemble - 4 Speed - 721F 21.113 / 107
Terostat® MS-9360 Powershift transmission - Assemble – 5 Speed - 712F 21.113 / 152
84605841 14/05/2012
21.113 / 3
Transmission - Powershift transmission
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.
84605841 14/05/2012
21.113 / 4
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)
84605841 14/05/2012
21.113 / 5
RCPH11WHL039HAN 1
Transmission
84605841 14/05/2012
21.113 / 6
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

1. Park the machine on a level surface and lower the
bucket to the ground. Stop the engine and apply the
parking brake.
RCPH10WHL350FAH 1
2. Place the master disconnect switch in the OFF posi-

tion.
RCPH11WHL653BAU 2
3. Apply articulation locking block to prevent accidental

articulation of the machine.
RCPH10WHL063BAL 3
4. Refer to Roll Over Protective Structure (ROPS)

frame - Remove (90.114) and remove ROPS cab or
ROPS canopy.
5. Refer to Variable displacement pump - Remove
(35.106) and remove the hydraulic pump.
6. Put a 25.5 liter ( 27 quarts) container under trans-
mission drain plug. Remove drain plug and drain
transmission oil. Install drain plug after oil has
drained.
NOTE: Follow local regulations when handling transmis-
sion oil.
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7. Identify, tag, and disconnect brake pump pressure

hose (15) and brake to hydraulic reservoir hose (16).
Position hoses away from transmission. Remove
and discard O-ring face seals from fittings (17) and
(18). Plug hoses and cap fittings to prevent entry of
foreign matter into hydraulic system.
bd01d306 4
8. Disconnect transmission wiring harness connector

(19) from control valve connector. Remove socket
head bolt securing wiring harness clamp (20). Move
wiring harness away from transmission.
bd01d315 5
9. Just above where clamp (20) was installed, tag and

disconnect transmission wiring harness connector
(21) from temperature sensor. Move wiring harness
away from transmission.
bd01d317 6
10. Remove two socket head bolts (22)and (23) securing

transmission wiring harness clamps.
bd01d310 7
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11. Identify, tag, and disconnect transmission wiring har-

ness connectors from engine speed sensor (24), in-
termediate speed sensor (25), and turbine speed
sensor (26). Move transmission wiring harness away
from transmission.
bd01d312 8
12. Remove socket head bolt securing wiring harness

clamp (27). Move wiring harness away from trans-
mission.
bd01d316 9
13. Identify, tag, and disconnect transmission wiring har-

ness connectors from filter maintenance switch (28)
and output speed sensor (29). Move transmission
wiring harness away from transmission.
bd01d314 10
14. Identify, tag, and disconnect parking brake hose (34)

from parking brake (35). Plug hose and cap fitting to
prevent entry of foreign matter into hydraulic system.
Move hose away from transmission. Remove four
bolts (36) and two straps (37) securing center drive
shaft (38) to transmission output flange. Disconnect
center drive shaft from transmission.
bd03a165_496 11
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15. Remove four bolts (39) and two straps (40) securing
rear drive shaft (41) to transmission output flange.
Disconnect rear drive shaft from transmission.
bd03a161 12
16. Remove two bolts (45). Remove fill tube (46) with
cap and oil gauge assembled, two seals, and metal
strainer. Discard seals.
bd03a160 13
17. Identify, tag, and disconnect cooler hose (47) from

fitting (48) installed in thermo bypass valve located
on the left side of transmission. Install plugs in hoses.
Remove and discard O-ring face seal from fittings
(48).
RAPH12WEL0246AA 14
18. Connect lifting equipment to transmission lifting eyes

(56). Take up all slack in lifting equipment.
bd01d343 15
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19. In area between rear of transmission and engine, re-

move four bolts (57) and two straps (58). Discard.
Use pry bar to disconnect engine drive shaft (59)
from transmission. Using 3/4 in drive socket, ex-
tensions, and impact wrench, remove four bolts (60)
and washers securing transmission to top mounting
bracket (61).
bd01d342_497 16
20. Remove bolts (64) and washers (65) securing right

and left mounting brackets (63) to rear chassis.
bd03a163 17
21. Raise transmission just enough to enable removal of

right and left mounting brackets (63). Remove two
bolts (62) and washers securing right and left mount-
ing brackets (63) to transmission. Remove right and
left mounting brackets.
bd03a164 18
22. Slowly and carefully raise transmission from loader

while checking that all hoses, electrical connectors,
and wires have been disconnected and nothing in-
terferes with transmission removal. Remove trans-
mission from loader.
bd01d345 19
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21.113 / 18
23. If top mounting bracket (61) requires removal, re-

move bolt (66) and washer (67) then remove bracket.
bd01d361 20
Next operation:
Powershift transmission - Install (21.113)
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Powershift transmission - Install

Prior operation:
Powershift transmission - Remove (21.113)
1. Check isolators (68) for deterioration, tears, defor-

mation, or other damage. Replace as necessary:
refer to Powershift transmission - Detailed view
(21.113).
2. If top mounting bracket (61) was removed, put
bracket on rear chassis trunnion and secure using
washer (67) and bolt (66). Do not tighten bolt.
NOTE: Mounting hole use is base upon 4 speed and 5
speed installation. The 5 speed transmission installation
uses rear mounting holes.
bd01d361_533 1
3. Move transmission into position above loader.

Slowly lower transmission into loader.
bd01d345_534 2
4. Install right side and left side mounting brackets (63)

on transmission using two washers and bolts (62).
Do not tighten bolts.
bd03a164_535 3
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5. Loosely install washers (65) and bolts (64) to secure

right side and left side mounting brackets (63) to rear
chassis. Tighten bolts (62) securing right side and
left side mounting brackets to transmission. Torque
to 481 - 590 Nm ( 355 - 435 lb.ft).
bd03a163_536 4
6. Using 3/4 inch drive socket, extensions, and impact

wrench, install four washers and bolts (60) secure
top mounting bracket (61) to transmission. Torque
tighten bolts (60) to 251 - 319 Nm ( 185 - 235 lb.ft).
If bracket (61) had been removed, torque tighten bolt
(66) to 890 - 1000 Nm ( 655 - 735 lb.ft). Connect en-
gine drive shaft (59) to transmission. Install two new
straps (58) and four new bolts (57). Torque tighten
bolts (57) to 61 - 81 Nm ( 45 - 60 lb.ft).
NOTE: In this step, new straps (58) and bolts (57) must be
installed whenever these parts are removed. Bolts have a
nylon patch to maintain torque which requires new bolts.
bd01d342_537 5
7. Torque tighten bolts (64) to 890 - 1000 Nm ( 655 -

735 lb.ft) securing right side and left side mounting
brackets.
bd03a163_538 6
8. Disconnect lifting equipment from transmission lifting

eyes (56).
bd01d343_539 7
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9. Remove plugs in thermo bypass valve port. Install

new O-ring face seal in fitting on thermo bypass
valve. Connect cooler hose (47) to fitting following
tag installed during removal. Remove and discard
tag.
RAPH12WEL0246AA 8
10. Position fill tube (46), two new seals, and metal
strainer on transmission; (metal strainer is installed
between seals). Secure using two bolts (45). Torque
tighten bolts 17 - 33 Nm ( 12 - 24 lb.ft).
bd03a160_542 9
11. Connect rear drive shaft (41) to transmission then

install two straps (40) and four bolts (39). Torque
tighten bolts 61 - 81 Nm ( 45 - 60 lb.ft).
bd03a161_543 10
12. Connect center drive shaft (38) to transmission and

install two straps (37) and four bolts (36). Torque
tighten bolts 61 - 81 Nm ( 45 - 60 lb.ft). Connect
parking brake hose (34) to parking brake (35) follow-
ing tag installed during removal. Remove and dis-
card tag.
bd03a165_544 11
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13. Connect transmission wiring harness connectors

to output speed sensor (29) and filter maintenance
switch (28) following tags installed during removal.
Remove and discard tags.
bd01d314_546 12
14. Install socket head bolt to secure wiring harness

clamp (27).
bd01d316_547 13
15. Connect transmission wiring harness connectors to

turbine speed sensor (26), intermediate speed sen-
sor (25), and engine speed sensor (24) following tags
installed during removal. Remove and discard tags.
bd01d312_548 14
16. Install two socket head bolts to secure transmission

wiring harness clamps (22) and (23).
bd01d310_549 15
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21.113 / 23
17. Connect transmission wiring harness connector (21)

to torque converter output sender following tag in-
stalled during removal. Remove and discard tag.
bd01d317_550 16
18. Install socket head bolt to secure wiring harness

clamp (20). Connect transmission wiring harness
connector (19) to control valve connector.
bd01d315_551 17
19. At brake valve, install new O-ring face seals in fittings

(17) and (18). Connect brake to hydraulic reservoir
hose (16) and brake pump pressure hose (15) fol-
lowing tags installed during removal. Remove and
discard tags.
bd01d306_552 18
20. Check that transmission drain plug is tight.
bd03a177 19
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21.113 / 24
21. Fill transmission to correct level shown in sight glass,

with approved transmission hydraulic oil.
22. Refer to Variable displacement pump - Install
(35.106) and install the hydraulic pump.
23. Refer to Roll Over Protective Structure (ROPS)
frame - Install (90.114)
24. Start and run engine at idle speed with transmission
in neutral. If transmission oil level is at or below
bottom of cross hatch region, put articulation lock
in LOCKED position and add additional approved
transmission hydraulic oil until oil level is up to cross-
hatch region. Shut down engine and put articulation
lock in OPERATING position.
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21.113 / 25
Powershift transmission - Disassemble - 621F

621F
Removal of filter
1. Remove the fine filter from the filter head with an
appropriate filter wrench. Properly dispose of filter.
RCPH11WHL171BBU 1
2. Remove Torx bolts (1) and separate filter head (2)

from transmission housing.
3. Remove and dispose of O-rings.
RCPH11WHL172BBU 2
Removal of electric gear-shift control

4. Remove gear-shift control (1) by removing Torx bolts
(2) and separate the gear-shift control housing from
the intermediate plate.
RCPH11WHL173BBU 3
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5. Remove the gear-shift control assembly (1) and seal-

ing plate (2).
RCPH11WHL174BBU 4
6. Remove the differential pressure switch for the fine

filter from the duct plate (4) by removing the switch
with O-ring (1), piston (2), and compression spring
(3).
RCPH11WHL750BAU 5
7. Remove the hexagon nuts and Torx bolts. Separate

the duct plate (1) and seal (2) from transmissions rear
housing part.
RCPH11WHL751BAU 6
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8. Remove the converter safety valve (1) from housing

hole (2).
9. Remove the cylindrical screws (3) and speed sensor
(Hall sensor).
RCPH11WHL177BBU 7
10. Remove positioned parts:

• (1) screw plug (oil drain hole).
• (2) oil filler tube with oil dipstick.
• (3) breather.
• (4) inductive sensor n – central gear chain.
• (5) inductive sensor n – turbine.
• (6) inductive sensor n – engine.
RCPH11WHL770BAU 8
84605841 14/05/2012
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Engine connection (remote mount)

11. Remove hexagon bolts and washer (1).
12. Remove bolted connection (2) cover/converter bell-
housing.
NOTE: Mark radial installation position of cover/converter
bellousing by center punch.
RCPH11WHL149BBU 9
13. Separate cover from converter bell housing using an

appropriate lifting device.
RCPH11WHL150BBU 10
14. Pull off output flange.
RCPH11WHL151BBU 11
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15. Press input shaft and converter out of cover (ball

bearing).
RCPH11WHL152BBU 12
16. Snap out retaining ring (1) and remove ball bearing
(2).
RCPH11WHL153BBU 13
17. Remove hexagon bolts (1) and flex plate (2) from
converter.
RCPH11WHL154BBU 14
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18. Remove hexagon bolts (1) and flex plate (2) from
input shaft (3).
RCPH11WHL155BBU 15
Oil pressure pump

19. Remove the bolted connection (1) converter bell-
housing/oil feed housing and remove converter
bellhousing (2).
RCPH11WHL156BBU 16
20. Remove the Torx bolted connections (1) of the oil

feed housing/transmission front housing section and
the cylindrical bolted connections (2) of the oil pres-
sure pump/transmission front housing section.
NOTE: Separate oil feed housing together with oil pressure
pump from transmission housing front part.
RCPH11WHL157BBU 17
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21. Separate oil pressure pump (1) from oil feed housing
(2).
RCPH11WHL158BBU 18
22. Remove O-ring (1). Remove cylindrical screws (2).
RCPH11WHL159BBU 19
23. Check oil gear pump. If wear marks are present

in the pump housing (4), cover (1) or on the inner
(2) and outer rotor (3), the COMPLETE oil pressure
pump is to be replaced.
RCPH11WHL160BBU 20
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24. Remove shaft seal (1) from the pump housing (2).
RCPH11WHL161BBU 21
Converter back-pressure valve

25. Preload converter safety valve (1) using a screw
driver or other suitable tool and remove locking plate
(2).
RCPH11WHL785BAU 22
26. Remove the loosened individual parts of the con-

verter safety valve: pressure plate (1), compression
spring (2) and piston (3).
RCPH11WHL786BAU 23
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27. Remove temperature sensor.
RCPH11WHL178BBU 24
28. Remove stator shaft (1). Pull pressure relief valve (2)
out of the housing hole.
NOTE: The pressure relief valve is not mounted on all ver-
sions.
RCPH11WHL162BBU 25
Disassembly – emergency steering pump: version without emergency steering pump

29. Remove bolted connection (1) cover/front housing
section, cover, (2) and seal.
RCPH11WHL163BBU 26
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Disassembly – outputs and closure parts pump shaft (PTO – shaft)
Output flange on converter side

30. Remove hexagon bolts, washer, and O-ring.
RCPH11WHL179BBU 27
31. Pull off output flange (1) and remove shaft seal (2).
RCPH11WHL164BBU 28
Output flange on output side with parking brake FSG – 88

32. Connect HP pump (1) at port and apply approxi-
mately 6 bar (80 psi) pressure to the hydraulically
actuated parking brake until the brake disc (2) can
be rotated by hand.
RCPH11WHL181BBU 29
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33. Remove hexagon nut with open end wrench insert.
RCPH11WHL182BBU 30
34. Remove hexagon bolts (2) and remove parking

brake (1).
RCPH11WHL183BBU 31
35. Remove hexagon bolts (1) on the bolted brake disk/

output flange connection and remove brake disk (2).
RCPH11WHL184BBU 32
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36. Remove the hexagon bolts (1), washer and O ring.

37. Pull-off output flange (2) and remove shaft seal.
38. Remove cylinder bolt with washer (3).
RCPH11WHL165BBU 33
Removal of input shaft, output shaft, pump shaft (PTO – shaft) and clutches
39. Force out both cylindrical pins out (1). Remove
bolted connection (2) between housing front and
rear section and separate housing rear section with
appropriate lifting device.
RCPH11WHL186BBU 34
40. Remove bolted connection of the oil screen sheets.
RCPH11WHL187BBU 35
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41. Remove output shaft (1) and lower oil screen sheet
(2) from housing.
RCPH11WHL188BBU 36
42. Remove all rectangular rings (1) from the clutches

and all O-rings (2) from the oil tubes.
RCPH11WHL189BBU 37
43. Using an appropriate lifting device, reposition and

lower the rear housing section (1) onto the front hous-
ing section (2).
RCPH11WHL186BBU 38
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21.113 / 38
44. Secure clutches K1, K2, K3 and K4 (1) using handle

380001557.
NOTE: Clutches KV, KR and input shaft (2) are only se-
cured by the gear chain! Attention must be paid that the
non-fixed components of the gear chain do not get detach.
NOTE: Due to the installation conditions, the removal of
single clutches without using the special tool is not possi-
ble.
RCPH11WHL190BBU 39
45. Separate the rear housing section, including the

clutches from front housing section, and using an
appropriate lifting device, attach it to the assembly
truck.
NOTE: Clutch KV (1), clutch KR (2), and input shaft (3) are
only secured by the gear chain.
NOTE: Attention must be paid that the non-fixed compo-
nents of the gear chain do not get detach.
RCPH11WHL191BBU 40
46. Remove the cylindrical bolts from the oil tubes in the
front housing section.
RCPH11WHL192BBU 41
84605841 14/05/2012
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The suction tube (1) and the lubrication lines (2) are rolled
in and are highly difficult to remove. In case of damage,
use of the appropriate special rolling tool 380001285 is im-
perative for fitting or replacing these components.
NOTE: North America dealers contact CNH special tool
rental program.
RCPH11WHL166BBU 42
47. Remove bearing outer rings from the front housing

section.
NOTE: If the tapered roller bearings of clutches and input
and output are not replaced, it is imperative that the techni-
cian ensure the previous pairing (bearing outer ring/bearing
inner ring). Bearing outer ring and bearing inner ring must
be marked.
RCPH11WHL166BBU 43
48. Disengage retaining ring (1) and remove pump

shafts (2).
RCPH11WHL168BBU 44
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49. Press ball bearing (1) off the pump shaft. Snap out
rectangular ring (2).
RCPH11WHL167BBU 45
50. Lift the clutches out of the housing by the numerical

order as listed.
• (1) K1 clutch
• (2) K2 clutch
• (3) K3 clutch (version with emergency steering
pump)
• (4) K4 clutch
• (5) KR clutch
• (6) KV clutch
• (7) input shaft
RCPH11WHL169BBU 46
51. Remove bearing outer rings from the rear housing

section.
NOTE: If the tapered roller bearings of clutches, input and
output are not replaced, it is imperative that the technician
ensure the previous pairing (bearing outer ring/bearing in-
ner ring). Bearing outer ring and bearing inner ring must
be marked.
RCPH11WHL166BBU 47
84605841 14/05/2012
21.113 / 41
52. The lubrication lines (1) and (2) are rolled in and are
extremely difficult to remove. In case of damage, use
of the appropriate special rolling tool 380001285 is
imperative for fitting or replacing these components.
NOTE: North America dealers contact CNH special tool
rental program.
RCPH11WHL170BBU 48
Next operation:
Powershift transmission - Assemble — 621F (21.113).
84605841 14/05/2012
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Powershift transmission - Assemble - 621F

621F
WARNING
Heavy parts!
Support designated component(s) with adequate lifting equipment.
W1024A
CAUTION
Burn hazard!
Always wear heat-resistant protective gloves when handling heated parts.
C0047A
Prior operation:
Powershift transmission - Disassemble — 621F (21.113)
Installation of input shaft, output shaft, pump shaft, (power-takeoff shaft) and clutches
1. If the suction tube (1) in the housing front part is to be
replaced, special rolling tool 380001285 is needed
for assembly. Then attach tube with cylindrical bolt
(2).
2. Torque to 23 N·m (17 lb ft).
NOTE: North American dealers contact CNH special tool
rental program.
NOTE: Always use new cylindrical bolts.
RCPH11WHL214BBU 1
3. The spare parts service that supplies the lubricat-

ing oil tube come as a complete package with the
housing front part. Assemble using special tool
380001286.
NOTE: Single parts by request.
RCPH11WHL215BBU 2
84605841 14/05/2012
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4. Mount O-rings into the annular groove of the oil tubes

(1) and (2) and oil them.
5. Insert tubes into the housing front part, oil cylindrical
bolts (3) and torque to 23 N·m (17 lb ft).
RCPH11WHL216BBU 3
6. The spare parts service that supplies the lubricating

oil tube (1) and (2) come as a complete package with
the housing rear part. Assemble using special tool
380001287.
NOTE: Single parts by request.
RCPH11WHL170BBU 4
7. Insert all bearing outer rings into the bearing holes of

front housing according to the diagram.
Housing front parts
1. AN = Input
2. AB = Output
3. KV = Forward clutch
4. KR = Reverse clutch
5. K1 = 1st gear clutch
6. K2 = 2nd gear clutch
7. K3 = 3rd gear clutch
8. K4 = 4th gear clutch
output are not replaced, it is imperative that the technician RCPH11WHL166BBU 5
ensure the previous paring (bearing outer ring/bearing in-
ner ring). Bearing out ring and inner ring must be marked.
84605841 14/05/2012
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rear housing according to the diagram.
Housing rear parts
1. AN = Input
2. AB = Output
3. KV = Forward clutch
output are not replaced, it is imperative that the technician RCPH11WHL170BBU 6
ensure the previous paring (bearing outer ring/bearing in-
ner ring). Bearing out ring and inner ring must be marked.
9. Place KR clutch (1), AN input shaft (2) and KV clutch
(3) into the housing rear part at the same time.
NOTE: Due to the installation conditions, the installation of
ble.
NOTE: Housing rear part will be removed again later.
RCPH11WHL217BBU 7
10. Slightly lift drive gear (2) and position K4 clutch (4).
RCPH11WHL258BBU 8
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11. Mount K3 clutch (3).
RCPH11WHL259BBU 9
12. Position K2 clutch (2).
RCPH11WHL260BBU 10
13. Slightly lift K4 clutch (4) and position K1 clutch (1).
RCPH11WHL261BBU 11
84605841 14/05/2012
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14. Press ball bearing (1) onto the pump shaft (2) until
contact is made.
15. Mount rectangular ring (3).
16. Grease and centrically align rectangular ring.
RCPH11WHL021BBU 12
17. Mount pump shaft (1) until contact is made.

18. Secure pump shaft using retaining ring (2).
RCPH11WHL262BBU 13
19. Secure clutches K1 (1), K2 (2), K3 (3) and K4 (4)

using special handle tool 380001557 (8)
20. Check all rectangular rings, grease and align them
centrically.
NOTE: Clutches KV (5), KR (6) and input shaft (7) are se-
cured by the gear chain only.
RCPH11WHL263BBU 14
84605841 14/05/2012
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21. Pivot housing rear part 180 ° using proper lifting de-
vice.
1. Clutch KV
2. Input shaft
3. Clutch KR
4. Pump shaft
NOTE: Clutch KV, KR and input shaft are only secured
by the gear chain! Attention must be paid that the non-
secured components of the gear chain do not get loose.
RCPH11WHL264BBU 15
22. Use a suitable lifting device to bring the housing rear

part into contact position with the housing front part,
by cautiously aligning the clutches. Then remove the
handles.
RCPH11WHL265BBU 16
23. Remove housing rear part again.
RCPH11WHL186BBU 17
84605841 14/05/2012
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24. Put on screen sheet (1).

25. Install pre-assembled output shaft (2).
RCPH11WHL266BBU 18
26. Oil cylindrical bolts (1) and then secure them to

screen sheet. Torque to 23 N·m (17 lb ft).
27. Mount O-rings (2) into the annular groove of the oil
tubes and oil them.
28. Mount all rectangular rings, grease and align them
centrally.
29. Wet mounting face (3) with sealing agent LOCTITE®
574.
RCPH11WHL267BBU 19
30. Carefully bring the housing front part into contact po-
sition with the housing rear part by using a proper
lifting device.
NOTE: Be sure that both oil tubes are aligned with the holes
in the housing rear part.
RCPH11WHL186BBU 20
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31. Attach both cylindrical pins centrically to the mount-

ing face.
RCPH11WHL027BBU 21
32. Check the clearance of the gear drive train.

33. Position driving element (1) and rotate KV clutch
shaft crank handle (2).
NOTE: Driving element and crank handle are dealer fabri-
cated.
RCPH11WHL028BBU 22
34. Secure housing front and rear part using cylindrical

bolts (2). Torque to 46 N·m (34 lb ft).
35. Mount fixing plate (3).
36. Mount stud bolts (4). Torque to 15 N·m (133 lb in).
NOTE: Wet screw-in thread with LOCTITE® 243.
RCPH11WHL029BBU 23
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37. Mount the bolt plugs (1) WITH a hydraulic pneumatic

pressing tool.
NOTE: In case of damage the pre-mounted transmission
housing rear part must be fully replaced.
RCPH11WHL268BBU 24
Output flange on output side with brake FSG-88

38. Use driver to mount shaft seal with the sealing lip
showing to the oil sump.
NOTE: Fill space between sealing lip and dust lip with
grease. Wet outer diameter (rubber-coated) with mineral
spirits.
RCPH11WHL220BBU 25
39. Press screen sheet (1) onto the output flange (2).
40. Mount output flange until contact is made.
RCPH11WHL221BBU 26
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41. Insert O-ring into the space between output flange

and shaft.
42. Secure output flange (1)using a washer (2) and
hexagon bolts. Oil hexagon bolts before assembly.
Torque to 48 N·m (35 lb ft).
43. Mount cylindrical bolt with washer (3) for the stop of
the parking brake setting screw. Torque to 48 N·m
(35 lb ft).
RCPH11WHL222BBU 27
44. Secure brake disc (1) at output flange (2) using

hexagon bolts (3) and washers. Torque to 68 N·m
(50 lb ft).
45. Connect HP pump on port (5) and apply approxi-
mately 80 bar (1160 psi) pressure to parking brake
(4) and bring it in contact position.
RCPH11WHL223BBU 28
46. Secure parking brake (1) on transmission housing

using the hexagon bolt - guide pin (2). Torque to 60
N·m (44 lb ft).
RCPH11WHL224BBU 29
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47. Secure the hexagon nut on brake caliper using the

open end wrench insert. Torque to 195 N·m (144 lb
ft).
RCPH11WHL225BBU 30
48. Insert setting gauge on both sides between base disc

and brake disc and hold in position.
• Clearance: 0.5 – 1.5 mm 0.5 - 1.5 mm (0.0 -
0.1 in)
• Nom. clearance: 1.0 mm 0.0 - 1.0 mm
RCPH11WHL226BBU 31
Output flange on converter side

49. Use driver to mount shaft seal, with the sealing lip
showing to the oil sump.
spirit.
RCPH11WHL227BBU 32
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50. Mount output flange (1) until contact is made.
RCPH11WHL164BBU 33

and shaft.
52. Secure output flange (1) using washer (2) and
hexagon bolts (3). Oil hexagon bolts before the
assembly. Torque to 34 N·m (25 lb ft).
NOTE: Always use new hexagon bolts.
RCPH11WHL179BBU 34

53. Install pressure plate (4), with the pin ( 6 mm) show-
ing to the locking plate (5).
Legend
1. oil feed housing
2. piston
3. compression spring
4. pressure plate
5. locking plate
RCPH11WHL228BBU 35
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54. Assemble single parts (parts 2 to 4 from previous

step). Preload them with a screw driver (6) and se-
cure in place with locking plate (5).
RCPH11WHL229BBU 36
55. Mount temperature sensor with new O-ring. Torque

to 25 N·m (18 lb ft).
NOTE: Version without temperature sensor: Secure screw
plug with new O-ring and torque to 25 N·m (18 lb ft).
RCPH11WHL178BBU 37
Oil pressure pump

56. Insert pressure relief valve (1) into the housing hole
until contact is made.
57. Mount two adjusting screws (4) and insert gasket (2)
and oil feed housing (3).
NOTE: Adjusting screws are dealer fabricated.
sions.
RCPH11WHL230BBU 38
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58. Install two adjusting screws (4) and mount stator

shaft (1).
NOTE: Pay attention to radial installation position.
RCPH11WHL231BBU 39
59. Install outer rotor with chamfer (see arrow) facing

downward.
NOTE: In case of wear marks in the pump housing or on
the control disc, the pump assembly must be replaced.
RCPH11WHL232BBU 40
60. Install inner rotor with the teeth (see arrow) facing
upwards.
RCPH11WHL233BBU 41
84605841 14/05/2012
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61. Position control disc and secure it radially using two

cylindrical bolts (1).
62. Place O-ring (2) into the annular groove and oil it.
NOTE: Do not tighten the cylindrical bolts – just turn them
in until contact is obtained and then turn them back by ap-
proximately ½ rotation. Pay attention to the installation po-
sition of the control disc.
RCPH11WHL234BBU 42
63. With the sealing lip showing downwards, carefully

insert the shaft seal (1) into the pump housing (2)
with a suitable driver until contact is made.
NOTE: Wet outer diameter of shaft seal with mineral spirits.
RCPH11WHL235BBU 43
64. Oil sliding bearing (see arrow) before the assembly.

Mount inner installer (1) onto the stator shaft.
65. Mount pre-assembled transmission pump (2).
RCPH11WHL236BBU 44
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66. Mount pre-assembled pump with driver until contact

is made.
RCPH11WHL238BBU 45
67. Grease and secure O-rings to the cylindrical bolts.

Secure transmission pump (2) using cylindrical bolts
(1). Torque to 46 N·m (34 lb ft).
RCPH11WHL239BBU 46
68. Secure oil feed housing (1) equally using Torx bolts
(2). Torque these to 23 N·m (17 lb ft).
69. Fasten fixing plate (3)using cylindrical bolts (4).
Torque these to 34 N·m (25 lb ft).
RCPH11WHL240BBU 47
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70. Secure converter bell housing (1) using hexagon

RCPH11WHL241BBU 48

71. Bolt input shaft (1) to flex plate (2) using hexagon
NOTE: Wet threads of hexagon screws with LOCTITE® 262.
RCPH11WHL242BBU 49
72. Secure flex plate (1) to converter (3) using hexagon

NOTE: Wet threads of hexagon bolts with LOCTITE® 262.
RCPH11WHL243BBU 50
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73. Install ball bearing (1) and secure it using V-ring (2).
RCPH11WHL244BBU 51
74. Put cover (1) onto the converter and press it until
contact is made.
NOTE: Support the pressure sleeve (2) on the bearing IN-
NER ring.
RCPH11WHL245BBU 52
75. Press screen sheet (1) onto the input flange (2).
RCPH11WHL246BBU 53
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76. Heat up clutch inner diameter to approximately 120

°C (248 °F).
RCPH11WHL247BBU 54
77. Mount input flange (1) until contact is made.

NOTE: Always wear protective gloves to prevent burns
when handling heated parts.
RCPH11WHL248BBU 55
78. Secure input flange (3) using washer (1) and

hexagon bolts (2).
79. Oil hexagon bolts before the assembly. Torque to 34
N·m (25 lb ft).
RCPH11WHL249BBU 56
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80. Position converter using a suitable lifting device un-

til the cover (1) is in contact with the converter bell
housing (2).
RCPH11WHL250BBU 57
81. Bolt converter bell housing (1) to cover (3) using

cylindrical bolts and hexagon nuts (2). Torque to 46
N·m (34 lb ft).
NOTE: Pay attention to radial installation position markings
made during disassembly (arrows).
RCPH11WHL251BBU 58
Reassembly-emergency steering pump: version without emergency steering pump

82. Install adjusting bolts (1), seal (2) and cover (3).
RCPH11WHL252BBU 59
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83. Secure cover using hexagon bolts. Torque to 23 N·m

(17 lb ft).
RCPH11WHL253BBU 60
Reassembly: inductive sensor, Hall sensor, oil filter, and oil drain plug
84. Mount inductive sensors (1), (2), and (3) with new
O-rings. Torque to 30 N·m (22 lb ft).
Legend
1. inductive sensor-engine speed
2. inductive sensor-speed/cnntral gear chain
3. inductive sensor-turbine speed
85. Mount breather (4). Torque to 12 N·m (106 lb in).
RCPH11WHL254BBU 61
86. Mount speed sensor (Hall sensor) - output speed (1)

with O-ring and secure in place using a cylindrical
bolt (2). Torque to 23 N·m (17 lb ft).
87. Mount screw plug with O-ring. Torque to 80 N·m (59
lb ft).
RCPH11WHL255BBU 62
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88. Mount oil drain plug with O-ring (1). Torque to 80 N·m
(59 lb ft).
89. Bring oil level tube (2) with seal into contact position
with the housing front part and using hexagon bolts
(3), torque to 34 N·m (25 lb ft).
90. Fasten dipstick (4) in oil level tube.
91. Secure identification plate (5) to the housing front
part.
NOTE: Use TEROSTAT® MS-9360.
RCPH11WHL256BBU 63
92. Bring cover (1) with seal into contact position with the
housing front part and secure it using hexagon bolts
RCPH11WHL257BBU 64
93. Insert converter safety valve (1) into the housing hole
(2) until contact is made.
RCPH11WHL177BBU 65
84605841 14/05/2012
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NOTE: Wet bolt-in thread with LOCTITE® 243.
95. Position the seal (2) and duct plate (3) to the housing
rear part until contact is made.
NOTE: Use assembly grease.
RCPH11WHL004BBU 66
96. Secure duct plate (1) using Torx bolts (2) and
hexagon nuts (3). Torque to 23 N·m (17 lb ft).
97. Mount screw plug (4) with new O-ring. Torque to 30
N·m (22 lb ft).
RCPH11WHL005BBU 67
98. Mount a compression spring (4), piston (3) and

switch (2) with a new O-ring, to make up the filter
differential pressure valve.
99. Insert and torque to 30 N·m (22 lb ft).
RCPH11WHL006BBU 68
100. Install two adjusting screws 380001558 (1).

101. Mount sealing plate (2) and electro-hydraulic control
unit (3).
NOTE: Do not re-assemble the seal plate after opening the
threaded joint shift unit/gearbox housing. In case of repair
it is always necessary to mount a new seal plate.
RCPH11WHL174BBU 69
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102. Secure the electro-hydraulic control unit (1) evenly

using of Torx bolts (2). Torque to 9.5 N·m (84 lb in).
RCPH11WHL173BBU 70
Fitting of fine filter (pressure filter)

103. Secure filter head (1) with new O-rings to the housing
rear part using Torx screws (2). Torque to 34 N·m (25
lb ft).
RCPH11WHL172BBU 71
104. Install proper new filter for this equipment.

105. Slightly oil the filter seal.
106. Attach filter to the filter head and turn until seal makes
contact with surface. Tighten BY HAND approxi-
mately 1/3 to 1/2 rotation of the filter.
NOTE: Prior to putting transmission into operation, fill with
oil accordingly.
RCPH11WHL171BBU 72
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Powershift transmission - Disassemble - 4 Speed - 721F

721F
1. Fasten transmission onto assembly stand using

CAS2801 or similar tool. Drain oil prior to starting
disassembly.
NOTE: Dispose of oil according to legal requirements.
RAPH11WEL0216BA 1
Removal of filter
2. Remove and properly discard filter.
RAPH11WEL0217AA 2
84605841 14/05/2012
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from transmission. Remove and discard O-rings.
RAPH11WEL0218AA 3
Removal of electronic gear-shift control

4. Remove gear-shift control. Remove Torx bolts (1)
and separate gear-shift control housing (2) from in-
termediate plate.
RAPH11WEL0219AA 4
5. Remove gear-shift control assembly (1) and sealing

plate, and (2) adjusting bolts (3).
RAPH11WEL0220AA 5
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6. Remove differential pressure switch (1) from fine fil-

ter duct plate (4).
Legend
1. Switch with O-ring
2. Piston
3. Compression spring
4. Fine filter duct plate
RAPH11WEL0221AA 6
7. Remove hex nuts and Torx bolts. Separate the duct

plate (1) and seal (2) from rear housing.
RAPH11WEL0222AA 7
8. Remove converter safety valve (1) out of the housing

hole.
RAPH11WEL0223AA 8
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Inductive sensor, Hall sensor, breather, oil filter and oil drain plug
9. Securely attach transmission to assembly stand us-
ing CAS2801 or similar tool.
1. oil drain plug
2. oil filler tube with oil dipstick
3. breather
4. inductive sensor - n central gear chain
5. inductive sensor - n turbine
6. inductive sensor - n engine
RAPH11WEL0227BA 9
11. Remove cylindrical bolt (1) and remove Hall effect

speed sensor - n output and O-ring (2).
RAPH11WEL0228AA 10
84605841 14/05/2012
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12. Remove hex bolts (1) and washer. Loosen the cover/
converter bell housing bolts (2).
bell housing with center punch.
RAPH11WEL0229AA 11
13. Separate cover from converter bell housing using a

suitable lifting device.
RAPH11WEL0230AA 12
14. Remove output flange.
RAPH11WEL0313AA 13
84605841 14/05/2012
21.113 / 71

bearing).
RAPH11WEL0314AA 14
16. Remove retaining ring (1) and ball bearing (2).
RAPH11WEL0315AA 15
17. Remove hex bolts (1) and flex plate (2) from con-
verter.
RAPH11WEL0316AA 16
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18. Remove hex bolts (1) and flex plate (2) from input
shaft (3).
RCPH11WHL155BBU 17
Oil pressure pump

19. Loosen bolted connection (1) between converter bell
housing and oil feed housing. Remove converter bell
housing (2).
RAPH11WEL0318AA 18
20. Remove the Torx bolts (1) from the oil feed housing
and front transmission housing.
21. Remove cylindrical bolts (2) from the oil pressure
pump and front transmission housing.
pump from front transmission housing.
RAPH11WEL0319AA 19
84605841 14/05/2012
21.113 / 73
(2).
RAPH11WEL0320AA 20
23. Remove O-ring (1) and cylindrical bolts (2).
RAPH11WEL0321AA 21
24. Check oil gear pump for wear. In case of wear marks
on the pump housing, cover, inner rotor, or outer ro-
tor; replace the oil pressure pump.
Legend
1. Cover
2. Inner rotor
3. Outer rotor
4. Pump housing
RAPH11WEL0322AA 22
84605841 14/05/2012
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RAPH11WEL0323AA 23

26. With a screwdriver, release the converter back-pres-
sure safety valve (1) and remove the locking plate
(2).
RAPH11WEL0324BA 24
27. Remove the individual parts of the converter safety

valve.
Legend
1. pressure plate
3. piston
RAPH11WEL0325AA 25
84605841 14/05/2012
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RAPH11WEL0326AA 26
29. Remove stator shaft (1). If applicable, remove the

pressure relief valve (2) out of the housing hole.
sions.
RAPH11WEL0327AA 27
Emergency steering pump
Version without emergency steering pump

30. Remove hex bolts (1), cover (2) and seals.
RAPH11WEL0419AA 28
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Output flange on converter side (standard version)

31. Remove hex bolts (1), washer and O-ring.
RAPH11WEL0329AA 29
RAPH11WEL0330AA 30
Output flange on output side with parking brake FSG-88

33. Connect a hand-operated pump at port (1) and apply
approximately 80 bar (1160 psi) pressure to the hy-
draulically actuated parking brake (2) until the brake
disc (3) can be rotated by hand.
RAPH11WEL0331AA 31
84605841 14/05/2012
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34. Remove hex nut with open end wrench.
RAPH11WEL0332AA 32
35. Remove hex bolts (2) and parking brake (1).
RAPH11WEL0333AA 33
36. Remove hex bolts (1) of bolted brake disc/output

flange connection and remove brake disc (2).
RAPH11WEL0334AA 34
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37. Remove hex bolts (1), washer and O-ring. Remove

output flange (2) and shaft seal. Remove cylinder
bolt with washer (3).
RAPH11WEL0335AA 35
Removal of input shaft, output shaft, pump shaft (PTO-shaft) and clutches
38. Force out both cylindrical pins (1). Loosen bolted
connection (2) between front and rear transmission
housings. Separate housing sections using a suit-
able lifting device.
RAPH11WEL0336AA 36
39. Loosen bolted connection (1) of oil screen sheets.
RAPH11WEL0337AA 37
84605841 14/05/2012
21.113 / 79
(2) from housing.
RAPH11WEL0338AA 38

RAPH11WEL0339AA 39
42. Use a suitable lifting device to lower rear housing

section (1) into contact position with front housing
section (2).
RAPH11WEL0336AA 40
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43. Secure clutches K1, K2, K3 and K4 using special tool

handle 380001557 (1).
cured by the gear chain. Care must be taken to ensure
these non-secured components do not detach.
ble.
RAPH11WEL0340AA 41
44. Using a suitable lifting device, separate rear housing

section including clutches from front housing section
and attach it to the assembly truck.
Legend
1. Clutch KV
2. Clutck KR
3. Pump shaft
4. Input shaft
NOTE: Clutches KV, KR and input shaft are only secured
by the gear chain. Care must be taken to ensure these
non-secured components do not detach.
RAPH11WEL0341AA 42
45. Remove cylindrical bolts of oil tubes (1) from the front
housing.
RAPH11WEL0342AA 43
84605841 14/05/2012
21.113 / 81
46. The suction tube (1) and the lubrication lines (2) are
rolled in and difficult to remove. In case of damage,
in EU, use special tools 380001285 or 380001286 for
fitting or replacing these components. North Amer-
ican Dealers contact CNH special tool rental pro-
gram.
RAPH11WEL0343AA 44
47. Remove bearing outer rings (1) from the front hous-
ing.
output are not replaced, the technician MUST ensure the
previous pairing (bearing outer ring/bearing inner ring).
Bearing outer ring and bearing inner ring must be marked.
RAPH11WEL0343AA 45

shafts (2).
RAPH11WEL0344AA 46
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RAPH11WEL0345AA 47
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50. Lift the clutches out of the housing in the numerical

order listed in the legend.
RAPH11WEL0346EA 48
Legend
1. K1 clutch
2. K2 clutch
3. K3 clutch (Version with emergency steering
pump)
4. K4 clutch
5. KR clutch
6. KV clutch
7. Input shaft
51. Remove bearing outer rings (1) from the rear hous-
ing.
RAPH11WEL0347AA 49
84605841 14/05/2012
21.113 / 84
52. The lubrication lines (1) and (2) are rolled in and diffi-
cult to remove. In case of damage, in EU, use special
tool 380001285 for fitting or replacing these compo-
nents. North American Dealers contact CNH special
tool rental program.
RAPH11WEL0347AA 50
Next operation:
Powershift transmission - Assemble — 4 Speed - 721F (21.113)
84605841 14/05/2012
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Powershift transmission - Assemble - 4 Speed - 721F

721F
Prior operation:
Powershift transmission - Disassemble — 4 Speed - 721F (21.113)
Installation of input shaft, output shaft, pump shaft (power-take off shaft) and clutches
If the suction tube (1) in the front housing is to be replaced,
special rolling tool 380001285 (EU) must be used for as-
sembly. North American Dealers contact CNH special tool
rental program. Secure the tube with cylindrical bolt (2).
NOTE: Oil cylindrical bolt. Always use new cylindrical
bolts.
RAPH11WEL0374AA 1
The lubricating oil tube (1) is supplied as a complete pack-

age with the front housing only. Single parts delivery are
available only upon request.
NOTE: Assembly is only possible with special tool
380001286 (EU), North American Dealers contact CNH
special tool rental program.
RAPH11WEL0375AA 2
84605841 14/05/2012
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1. Mount O-rings into the oil tube annular grooves (1)

and (2) and oil them. Then insert tubes into the front
housing. Oil cylindrical bolts (3) and (4) and secure
them. Torque to 23 N·m (17 lb ft).
RAPH11WEL0376AA 3

housing.
RAPH11WEL0377AA 4
The lubricating oil tubes (1) and (2) are supplied as a com-
plete package with the rear housing. Single parts delivery
380001287 (EU). North American Dealers contact CNH
RAPH11WEL0347AA 5
84605841 14/05/2012
21.113 / 87

both housing sections.
Front and Rear Legend
1. Input
5. Output
8. Forward clutch
RAPH11WEL0343AA 6
4. Rear housing see legend in previous step. Place

bearing outer rings into the bearing holes using as-
sembly grease.
output are not replaced, it is imperative that the techni-
cian ensure the previous pairing (bearing inner ring/bear-
ing outer ring). Bearing outer ring and bearing inner ring
MUST be marked.
RAPH11WEL0347AA 7

(3) into the housing rear section at the same time.
NOTE: Due to installation conditions, the installation of sin-
gle clutches without using the special tool is not possible.
NOTE: Housing rear section will be removed again later.
RAPH11WEL0378AA 8
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RAPH11WEL0379AA 9
RAPH11WEL0380AA 10
RAPH11WEL0381AA 11
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RAPH11WEL0382AA 12
contact is made. Mount rectangular ring (3). Grease
and centrically align rectangular ring.
RAPH11WEL0383AA 13
11. Mount pump shaft (1) until contact is made. Secure

pump shaft using retaining ring (2).
RAPH11WEL0384AA 14
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12. Secure clutches K1 (1), K2 (2), K3 (3) and K4 (4) by

using a special handle tool 380001557 (8). Check all
rectangular rings, grease and align them centrically.
NOTE: This step shows the installation position of the indi-
vidual clutches in the rear housing.
NOTE: Clutches KV (5), KR (6) and input shaft AN (7) are
only secured by the gear chain. Care must be taken to
ensure these non-secured components do not detach.
RAPH11WEL0385AA 15
13. Pivot rear housing 180 ° by using a suitable lifting

device.
Legend
1. Clutch KV
2. Clutch KR
3. Pump shaft
4. Input shaft
RAPH11WEL0341AA 16
14. Use the suitable lifting device to bring the rear hous-
ing into contact position with the front housing by cau-
tiously aligning the clutches. Then remove handles.
RAPH11WEL0340AA 17
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15. Remove the rear housing again.
RAPH11WEL0336AA 18
16. Position screen sheet (1). Install pre-assembled out-

put shaft (2).
RAPH11WEL0338AA 19

tubes and oil them.
19. Mount all rectangular rings (4), grease and align
them centrally.
574.
RAPH11WEL0337AA 20
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lifting device.
RAPH11WEL0336AA 21
22. Attach both cylindrical pins (1) centrically to the

mounting face.
RAPH11WEL0386AA 22
23. Check the clearance of the gear drive train. Position

driving element (arrow) and rotate KV clutch shaft
crank handle.
cated.
NOTE: If interference of the movable parts (e.g. on the
screen sheet or on the oil tubes) is found, it must be cor-
rected. Check all clutch shafts and do this step on all of the
clutch shafts.
RAPH11WEL0387AA 23
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25. Mount securing plate (2).
RAPH11WEL0388BA 24

pressing tool.
RAPH11WEL0389AA 25
Output flange output side with brake FSG-88

28. Use driver tool 380001560 to mount shaft seal with
the sealing lip showing to the oil sump.
spirits.
RAPH11WEL0390AA 26
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RAPH11WEL0391AA 27

and shaft.
32. Secure output flange (1) using a washer (2) and
(35 lb ft).
NOTE: Always use new hex bolts.
RAPH11WEL0392AA 28
34. Secure brake disc (1) at output flange (2) using hex
bolts and washers. Torque to 68 N·m (50 lb ft).
35. Connect HP pump at port (see arrow) and apply ap-
proximately 80 bar (1160 psi) pressure to parking
brake (4) and bring it in contact position.
RAPH11WEL0334AA 29
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N·m (34 lb ft).
RAPH11WEL0333AA 30
37. Secure the hexagon nut on the brake caliper using

the open end wrench insert. Torque to 230 N·m (170
lb ft).
RAPH11WEL0332AA 31

• Clearance: 0.5 - 1.5 mm (0.020 - 0.059 in)
• Nominal clearance: 1.0 mm (0.039 in).
RAPH11WEL0393AA 32
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Output flange on converter side (Standard versions)

39. Use driver tool 380001560 to mount shaft seal, with
NOTE: Use of the specified driver ensures the exact instal-
lation position.
spirit.
RAPH11WEL0394AA 33
40. Installation position of shaft seal

Legend
1. Shaft seal
2. Gearbox housing - rear section
3. Roller bearing
4. Output shaft
5. Screen sheet
RAPH11WEL0395AA 34
Mount output flange (1) until contact is made.
RAPH11WEL0330AA 35
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and shaft. Secure output flange (1) using washer
and hex bolts (2). Oil hex bolts before the assembly.
RAPH11WEL0329AA 36
Reassembly: Engine connection, oil pressure pump, converter back-pressure valve and
temperature sensor

43. Install pressure plate (4), with the pin 6 mm (0.236
in) facing towards the locking plate (1).
1. Oil feed housing
2. Piston
4. Pressure plate
5. Locking plate
RCPH11WHL228BBU 37
44. Assemble single parts, preload them with an assem-

bly tool or screwdriver (1) and secure them with the
locking plate (2).
RCPH11WHL229BBU 38
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to 25 N·m (18 lb ft).
RAPH11WEL0402AA 39
Oil pressure pump

sions.
RAPH11WEL0403AA 40

shaft (1).
RAPH11WEL0404AA 41
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downward.
RAPH11WEL0405AA 42
upwards.
RAPH11WEL0406AA 43

RAPH11WEL0407AA 44
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RAPH11WEL0408AA 45
54. Oil sliding bearing (see arrow) before assembly.

RAPH11WEL0409AA 46

is made.
RAPH11WEL0410AA 47
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RCPH11WHL239BBU 48
58. Secure oil feed housing (1) equally using Torque

bolts (2). Torque these to 23 N·m (17 lb ft).
59. Fasten plate (3) using cylindrical bolts (4). Torque
these to 34 N·m (25 lb ft).
RCPH11WHL240BBU 49

RCPH11WHL241BBU 50
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RCPH11WHL242BBU 51

RAPH11WEL0411AA 52
RCPH11WHL244BBU 53
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contact is made.
NER ring.
RAPH11WEL0413AA 54
RAPH11WEL0414AA 55
66. Heat flange inner diameter to approximately 120 °C

(248 °F).
RAPH11WEL0415AA 56
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RAPH11WEL0416AA 57
68. Secure input flange (1) using washer and hexagon

bolts (2).
N·m (25 lb ft).
RAPH11WEL0417AA 58

housing (2).
RAPH11WEL0230AA 59
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N·m (34 lb ft).
RAPH11WEL0229AA 60
Reassembly - Emergency steering pump: Version without emergency steering pump

72. Install adjusting bolts (3) and assemble seal (2) and
cover (1).
RAPH11WEL0418AA 61

(17 lb ft).
RAPH11WEL0419AA 62
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Reassembly: Inductive sensor, Hall sensor, breather, oil filler and oil drain plug
Legend
1. Inductive sensor - turbine speed
2. Inductive sensor - speed/central gear chain
3. Inductive sensor - engine speed
4. Breather
5. Speed sensor (Hall sensor)
6. Bolt
7. Plug
8. Cover
9. Hex bolts
75. Mount breather (4) and torque to 12 N·m (106 lb in).
with O-ring. Secure it using a cylindrical bolt (6) and
torque to 23 N·m (17 lb ft).
RAPH11WEL0587BA 63
77. Mount plug (7) with O-ring and torque to 80 N·m (59
lb ft).
78. Attach cover (8) with seal to the housing front section
securing it with hex bolts (9), torque to 23 N·m (17 lb
ft).
79. Mount oil drain plug with O-ring (1) and torque to 80
N·m (59 lb ft).
Legend
1. oil drain plug
2. oil level tube
3. hex bolts
4. dipstick
5. identification plate
80. Attach oil level tube (2) with seal to the housing front
section and secure it using hex bolts (3). Torque to
34 N·m (25 lb ft).
82. Attach identification plate (5) to the housing front sec- RAPH11WEL0421AA 64
tion.
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RAPH11WEL0462AA 65

RAPH11WEL0222AA 66
87. Mount plug (4) with new O-ring. Torque to 30 N·m
(22 lb ft).
RAPH11WEL0588AA 67
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89. Insert the valve (1) and torque to 30 N·m (22 lb ft).
RAPH11WEL0221AA 68

unit (3).
RAPH11WEL0220AA 69

using Torx bolts (2). Torque to 9.5 N·m (84 lb in).
RAPH11WEL0219AA 70
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Fitting of filter (pressure filter)

93. Secure filter head (1) with new O-rings to the rear
housing using Torx bolts (2). Torque to 34 N·m (25
lb ft).
RAPH11WEL0218AA 71
94. Install new filter element.

NOTE: Before putting the transmission into operation, fill it
with oil according to operators manual.
RAPH11WEL0217AA 72
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Powershift transmission - Disassemble - 5 Speed – 721F

721F
1. Fasten transmission onto assembly stand using

CAS2801 or similar tool. Drain oil prior to starting
disassembly.
RAPH11WEL0216BA 1
Removal of filter
RAPH11WEL0217AA 2
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RAPH11WEL0218AA 3
4. Loosen nuts (1) and (2) and remove system pressure

pipe (3) from lock-up clutch valve to lock-up clutch.
5. Remove screw-in sleeve (4).
RAPH11WEL0463AA 4
6. Remove hollow bolt (1) and O-ring. Loosen bolt nut

(2). Remove system pressure to lock-up clutch valve
pipe and O-rings (3).
RAPH11WEL0582AA 5
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7. Remove gear-shift control. Remove Torx bolts (1)
and separate gear-shift control housing (2) from in-
termediate plate.
RAPH11WEL0219AA 6

plate, and (2) adjusting bolts (3).
RAPH11WEL0220AA 7

ter duct plate (4).
Legend
2. Piston
RAPH11WEL0221AA 8
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RAPH11WEL0222AA 9

hole.
RAPH11WEL0223AA 10
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Inductive sensor, Hall sensor, breather, oil filter and oil drain plug
12. Securely attach transmission to assembly stand us-
ing CAS2801 or similar tool.
1. oil drain plug
2. oil filler tube with oil dipstick
3. breather
4. inductive sensor - n central gear chain
5. inductive sensor - n turbine
6. inductive sensor - n engine
RAPH11WEL0227BA 11
14. Remove cylindrical bolt (1) and remove Hall effect

speed sensor - n output and O-ring (2).
RAPH11WEL0228AA 12
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15. Remove hex bolts (1) and washer. Loosen the cover/
converter bell housing bolts (2).
bell housing with center punch.
RAPH11WEL0229AA 13
16. Separate cover from converter bell housing using a

suitable lifting device.
RAPH11WEL0230AA 14
17. Remove output flange.
RAPH11WEL0313AA 15
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bearing).
RAPH11WEL0314AA 16
19. Remove retaining ring (1) and ball bearing (2).
RAPH11WEL0315AA 17
20. Remove hex bolts (1) and flex plate (2) from con-
verter.
RAPH11WEL0316AA 18
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21. Remove hex bolts (1) and flex plate (2) from input
shaft (3).
RCPH11WHL155BBU 19
Oil pressure pump

22. Loosen bolted connection (1) between converter bell
housing and oil feed housing. Remove converter bell
housing (2).
RAPH11WEL0318AA 20
23. Remove the Torx bolts (1) from the oil feed housing
and front transmission housing.
24. Remove cylindrical bolts (2) from the oil pressure
pump and front transmission housing.
pump from front transmission housing.
RAPH11WEL0319AA 21
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(2).
RAPH11WEL0320AA 22
26. Remove O-ring (1) and cylindrical bolts (2).
RAPH11WEL0321AA 23
27. Check oil gear pump for wear. In case of wear marks
on the pump housing, cover, inner rotor, or outer ro-
tor; replace the oil pressure pump.
Legend
1. Cover
2. Inner rotor
3. Outer rotor
4. Pump housing
RAPH11WEL0322AA 24
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RAPH11WEL0323AA 25

29. With a screwdriver, release the converter back-pres-
sure safety valve (1) and remove the locking plate
(2).
RAPH11WEL0324BA 26
30. Remove the individual parts of the converter safety

valve.
Legend
1. pressure plate
3. piston
RAPH11WEL0325AA 27
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RAPH11WEL0326AA 28
32. Remove stator shaft (1). If applicable, remove the

pressure relief valve (2) out of the housing hole.
sions.
RAPH11WEL0327AA 29
Version without emergency steering pump

33. Remove hex bolts (1), cover (2) and seals.
RAPH11WEL0419AA 30
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Output flange on converter side (standard version)

34. Remove hex bolts (1), washer and O-ring.
RAPH11WEL0329AA 31
RAPH11WEL0330AA 32
Output flange on output side with parking brake FSG-88

36. Connect a hand-operated pump at port (1) and apply
approximately 80 bar (1160 psi) pressure to the hy-
draulically actuated parking brake (2) until the brake
disc (3) can be rotated by hand.
RAPH11WEL0331AA 33
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37. Remove hex nut with open end wrench.
RAPH11WEL0332AA 34
38. Remove hex bolts (2) and parking brake (1).
RAPH11WEL0333AA 35
39. Remove hex bolts (1) of bolted brake disc/output

flange connection and remove brake disc (2).
RAPH11WEL0334AA 36
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40. Remove hex bolts (1), washer and O-ring. Remove

output flange (2) and shaft seal. Remove cylinder
bolt with washer (3).
RAPH11WEL0335AA 37
Removal of input shaft, output shaft, pump shaft (PTO-shaft) and clutches
41. Force out both cylindrical pins (1). Loosen bolted
connection (2) between front and rear transmission
housings. Separate housing sections using a suit-
RAPH11WEL0336AA 38
42. Loosen bolted connection (1) of oil screen sheets.
RAPH11WEL0337AA 39
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21.113 / 124
(2) from housing.
RAPH11WEL0338AA 40

RAPH11WEL0339AA 41
45. Use a suitable lifting device to lower rear housing

section (1) into contact position with front housing
section (2).
RAPH11WEL0336AA 42
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46. Secure clutches K1, K2, K3 and K4 using special tool

handle 380001557 (1).
cured by the gear chain. Care must be taken to ensure
these non-secured components do not detach.
ble.
RAPH11WEL0340AA 43
47. Using a suitable lifting device, separate rear housing

section including clutches from front housing section
and attach it to the assembly truck.
Legend
1. Clutch KV
2. Clutck KR
3. Pump shaft
4. Input shaft
RAPH11WEL0341AA 44
48. Remove cylindrical bolts of oil tubes (1) from the front
housing.
RAPH11WEL0342AA 45
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49. The suction tube (1) and the lubrication lines (2) are
rolled in and difficult to remove. In case of damage,
in EU, use special tools 380001285 or 380001286 for
fitting or replacing these components. North Amer-
ican Dealers contact CNH special tool rental pro-
gram.
RAPH11WEL0343AA 46
50. Remove bearing outer rings (1) from the front hous-
ing.
RAPH11WEL0343AA 47

shafts (2).
RAPH11WEL0344AA 48
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RAPH11WEL0345AA 49
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53. Lift the clutches out of the housing in the numerical

order listed in the legend.
RAPH11WEL0346EA 50
Legend
1. K1 clutch
2. K2 clutch
3. K3 clutch (Version with emergency steering
pump)
4. K4 clutch
5. KR clutch
6. KV clutch
7. Input shaft
54. Remove bearing outer rings (1) from the rear hous-
ing.
RAPH11WEL0347AA 51
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21.113 / 129
55. The lubrication lines (1) and (2) are rolled in and diffi-
cult to remove. In case of damage, in EU, use special
tool 380001285 for fitting or replacing these compo-
nents. North American Dealers contact CNH special
tool rental program.
RAPH11WEL0347AA 52
Next operation:
Powershift transmission - Assemble – 5 Speed - 712F (21.113)
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Powershift transmission - Assemble – 5 Speed - 712F

721F
Prior operation:
Powershift transmission - Disassemble — 5 Speed – 721F (21.113)
Installation of input shaft, output shaft, pump shaft (power-take off shaft) and clutches
If the suction tube (1) in the front housing is to be replaced,
special rolling tool 380001285 (EU) must be used for as-
sembly. North American Dealers contact CNH special tool
rental program. Secure the tube with cylindrical bolt (2).
NOTE: Oil cylindrical bolt. Always use new cylindrical
bolts.
RAPH11WEL0374AA 1
The lubricating oil tube (1) is supplied as a complete pack-

age with the front housing only. Single parts delivery are
380001286 (EU), North American Dealers contact CNH
RAPH11WEL0375AA 2
84605841 14/05/2012
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housing. Oil cylindrical bolts (3) and (4) and secure
them. Torque to 23 N·m (17 lb ft).
RAPH11WEL0376AA 3

housing.
RAPH11WEL0377AA 4
The lubricating oil tubes (1) and (2) are supplied as a com-
plete package with the rear housing. Single parts delivery
380001287 (EU). North American Dealers contact CNH
RAPH11WEL0347AA 5
84605841 14/05/2012
21.113 / 132

both housing sections.
Front and Rear Legend
1. Input
5. Output
8. Forward clutch
RAPH11WEL0343AA 6
4. Rear housing see legend in previous step. Place

bearing outer rings into the bearing holes using as-
sembly grease.
output are not replaced, it is imperative that the techni-
cian ensure the previous pairing (bearing inner ring/bear-
ing outer ring). Bearing outer ring and bearing inner ring
MUST be marked.
RAPH11WEL0347AA 7

(3) into the housing rear section at the same time.
NOTE: Due to installation conditions, the installation of sin-
gle clutches without using the special tool is not possible.
NOTE: Housing rear section will be removed again later.
RAPH11WEL0378AA 8
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RAPH11WEL0379AA 9
RAPH11WEL0380AA 10
RAPH11WEL0381AA 11
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RAPH11WEL0382AA 12
contact is made. Mount rectangular ring (3). Grease
and centrically align rectangular ring.
RAPH11WEL0383AA 13
11. Mount pump shaft (1) until contact is made. Secure

pump shaft using retaining ring (2).
RAPH11WEL0384AA 14
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12. Secure clutches K1 (1), K2 (2), K3 (3) and K4 (4) by

using a special handle tool 380001557 (8). Check all
rectangular rings, grease and align them centrically.
NOTE: This step shows the installation position of the indi-
vidual clutches in the rear housing.
NOTE: Clutches KV (5), KR (6) and input shaft AN (7) are
only secured by the gear chain. Care must be taken to
ensure these non-secured components do not detach.
RAPH11WEL0385AA 15
13. Pivot rear housing 180 ° by using a suitable lifting

device.
Legend
1. Clutch KV
2. Clutch KR
3. Pump shaft
4. Input shaft
RAPH11WEL0341AA 16
14. Use the suitable lifting device to bring the rear hous-
ing into contact position with the front housing by cau-
tiously aligning the clutches. Then remove handles.
RAPH11WEL0340AA 17
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15. Remove the rear housing again.
RAPH11WEL0336AA 18
16. Position screen sheet (1). Install pre-assembled out-

put shaft (2).
RAPH11WEL0338AA 19

tubes and oil them.
19. Mount all rectangular rings (4), grease and align
them centrally.
574.
RAPH11WEL0337AA 20
84605841 14/05/2012
21.113 / 137
lifting device.
RAPH11WEL0336AA 21
22. Attach both cylindrical pins (1) centrically to the

mounting face.
RAPH11WEL0386AA 22
23. Check the clearance of the gear drive train. Position

driving element (arrow) and rotate KV clutch shaft
crank handle.
cated.
NOTE: If interference of the movable parts (e.g. on the
screen sheet or on the oil tubes) is found, it must be cor-
rected. Check all clutch shafts and do this step on all of the
clutch shafts.
RAPH11WEL0387AA 23
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25. Mount securing plate (2).
RAPH11WEL0388BA 24

pressing tool.
RAPH11WEL0389AA 25
Output flange output side with brake FSG-88

28. Use driver tool 380001560 to mount shaft seal with
spirits.
RAPH11WEL0390AA 26
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21.113 / 139
RAPH11WEL0391AA 27

and shaft.
32. Secure output flange (1) using a washer (2) and
(35 lb ft).
RAPH11WEL0392AA 28
34. Secure brake disc (1) at output flange (2) using hex
bolts and washers. Torque to 68 N·m (50 lb ft).
35. Connect HP pump at port (see arrow) and apply ap-
proximately 80 bar (1160 psi) pressure to parking
brake (4) and bring it in contact position.
RAPH11WEL0334AA 29
84605841 14/05/2012
21.113 / 140

N·m (34 lb ft).
RAPH11WEL0333AA 30
37. Secure the hexagon nut on the brake caliper using

the open end wrench insert. Torque to 230 N·m (170
lb ft).
RAPH11WEL0332AA 31

• Clearance: 0.5 - 1.5 mm (0.020 - 0.059 in)
• Nominal clearance: 1.0 mm (0.039 in).
RAPH11WEL0393AA 32
84605841 14/05/2012
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Output flange on converter side (Standard versions)

39. Use driver tool 380001560 to mount shaft seal, with
NOTE: Use of the specified driver ensures the exact instal-
lation position.
spirit.
RAPH11WEL0394AA 33
40. Installation position of shaft seal

Legend
1. Shaft seal
2. Gearbox housing - rear section
3. Roller bearing
4. Output shaft
5. Screen sheet
RAPH11WEL0395AA 34
Mount output flange (1) until contact is made.
RAPH11WEL0330AA 35
84605841 14/05/2012
21.113 / 142

and shaft. Secure output flange (1) using washer
and hex bolts (2). Oil hex bolts before the assembly.
RAPH11WEL0329AA 36
Reassembly: Engine connection, oil pressure pump, converter back-pressure valve and
temperature sensor

43. Install pressure plate (4), with the pin 6 mm (0.236
in) facing towards the locking plate (1).
1. Oil feed housing
2. Piston
4. Pressure plate
5. Locking plate
RCPH11WHL228BBU 37
44. Assemble single parts, preload them with an assem-

bly tool or screwdriver (1) and secure them with the
locking plate (2).
RCPH11WHL229BBU 38
84605841 14/05/2012
21.113 / 143

to 25 N·m (18 lb ft).
RAPH11WEL0402AA 39
Oil pressure pump

sions.
RAPH11WEL0403AA 40

shaft (1).
RAPH11WEL0404AA 41
84605841 14/05/2012
21.113 / 144

downward.
RAPH11WEL0405AA 42
upwards.
RAPH11WEL0406AA 43

RAPH11WEL0407AA 44
84605841 14/05/2012
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RAPH11WEL0408AA 45
54. Oil sliding bearing (see arrow) before assembly.

RAPH11WEL0409AA 46

is made.
RAPH11WEL0410AA 47
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RCPH11WHL239BBU 48
58. Secure oil feed housing (1) equally using Torque

bolts (2). Torque these to 23 N·m (17 lb ft).
59. Fasten plate (3) using cylindrical bolts (4). Torque
these to 34 N·m (25 lb ft).
RCPH11WHL240BBU 49

RCPH11WHL241BBU 50
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RCPH11WHL242BBU 51

RAPH11WEL0411AA 52
RCPH11WHL244BBU 53
84605841 14/05/2012
21.113 / 148
contact is made.
NER ring.
RAPH11WEL0413AA 54
RAPH11WEL0414AA 55
66. Heat flange inner diameter to approximately 120 °C

(248 °F).
RAPH11WEL0415AA 56
84605841 14/05/2012
21.113 / 149

RAPH11WEL0416AA 57
68. Secure input flange (1) using washer and hexagon

bolts (2).
N·m (25 lb ft).
RAPH11WEL0417AA 58

housing (2).
RAPH11WEL0230AA 59
84605841 14/05/2012
21.113 / 150

N·m (34 lb ft).
RAPH11WEL0229AA 60
Reassembly - Emergency steering pump: Version without emergency steering pump

72. Install adjusting bolts (3) and assemble seal (2) and
cover (1).
RAPH11WEL0418AA 61

(17 lb ft).
RAPH11WEL0419AA 62
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Reassembly: Inductive sensor, Hall sensor, breather, oil filler and oil drain plug
Legend
1. Inductive sensor - turbine speed
2. Inductive sensor - speed/central gear chain
3. Inductive sensor - engine speed
4. Breather
5. Speed sensor (Hall sensor)
6. Bolt
7. Plug
8. Cover
9. Hex bolts
75. Mount breather (4) and torque to 12 N·m (106 lb in).
with O-ring. Secure it using a cylindrical bolt (6) and
torque to 23 N·m (17 lb ft).
RAPH11WEL0587BA 63
77. Mount plug (7) with O-ring and torque to 80 N·m (59
lb ft).
78. Attach cover (8) with seal to the housing front section
securing it with hex bolts (9), torque to 23 N·m (17 lb
ft).
79. Mount oil drain plug with O-ring (1) and torque to 80
N·m (59 lb ft).
Legend
1. oil drain plug
2. oil level tube
3. hex bolts
4. dipstick
5. identification plate
80. Attach oil level tube (2) with seal to the housing front
section and secure it using hex bolts (3). Torque to
34 N·m (25 lb ft).
82. Attach identification plate (5) to the housing front sec- RAPH11WEL0421AA 64
tion.
84605841 14/05/2012
21.113 / 152
Attachment of control valve body

RAPH11WEL0462AA 65

RAPH11WEL0222AA 66
(22 lb ft).
RAPH11WEL0588AA 67
84605841 14/05/2012
21.113 / 153

RAPH11WEL0221AA 68

unit (3).
RAPH11WEL0220AA 69

RAPH11WEL0219AA 70
84605841 14/05/2012
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Pipe - System pressure to lock-up clutch valve

93. Secure pipe (1) with hollow bolt (2) and bolt nut (3).
94. Fit O-ring on to hollow bolt (2), insert it into the eye
of the pipe and torque to 45 N·m (33 lb ft).
95. Attach bolt nut (3) and torque to 35 N·m (26 lb ft).
RAPH11WEL0582AA 71
Pipe - System pressure from lock-up clutch valve to lock-up clutch

96. Insert screw-in sleeve (1) and torque to 45 N·m (33
lb ft).
97. Secure pipe (2) with nuts (3) and (4).
• Torque nut (3) to 26 N·m (19 lb ft).
RAPH11WEL0463AA 72

lb ft).
RAPH11WEL0218AA 73
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RAPH11WEL0217AA 74
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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.
84605841 14/05/2012
21.113 / 157
Index
Transmission - 21

Powershift transmission - Assemble - 4 Speed - 721F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
721F
Powershift transmission - Assemble - 621F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
621F
Powershift transmission - Assemble – 5 Speed - 712F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
721F
Powershift transmission - Disassemble - 4 Speed - 721F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
721F
Powershift transmission - Disassemble - 5 Speed – 721F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
721F
Powershift transmission - Disassemble - 621F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
621F
Powershift transmission - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Powershift transmission - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Powershift transmission - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Powershift transmission - Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
84605841 14/05/2012
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Transmission - 21
Powershift transmission external controls - 135
621F
721F
84605841 14/05/2012
21.135 / 1
Contents
Transmission - 21
SERVICE
Transmission control valve

Visual inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Disassemble - 621F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
621F
Assemble - 621F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
621F

721F
Assemble - 4 Speed - 721F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

721F

721F
Assemble - 5 Speed - 721F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

721F
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21.135 / 2
CONSUMABLES INDEX
Consumable IU PAGE
Loctite® 243 Transmission control valve - Assemble - 621F 21.135 / 22
84605841 14/05/2012
21.135 / 3
Transmission - Powershift transmission external controls
Transmission control valve - Visual inspection

WARNING
Flying debris!
pressed air.
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)
84605841 14/05/2012
21.135 / 4
Transmission control valve - Disassemble - 621F

621F
Electro-hydraulic control and fine filter (replaceable filter)

1. Attach transmission to an assembly truck stand.
NOTE: Drain oil prior to starting transmission disassembly.
Dispose of oil according to legal requirements.
RCPH11WHL765BAU 1
Removal of filter
2. Remove fine filter from the filter head with appropri-
ate filter wrench. Properly dispose of filter.
RCPH11WHL766BAU 2
84605841 14/05/2012
21.135 / 5

from transmission housing.
4. Remove and dispose of O-rings.
RCPH11WHL767BAU 3
Removal of electric gear-shift control

5. Remove gear-shift control (1) by removing Torx bolts
(2) and separate the gear-shift control housing from
the intermediate plate.
RCPH11WHL768BAU 4
6. Remove the gear-shift control assembly (1) and seal-

ing plate (2).
RCPH11WHL769BAU 5
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21.135 / 6
7. Remove the differential pressure switch for the fine

filter from the duct plate (4) by removing the switch
with o-ring (1), piston (2), and compression spring
(3).
RCPH11WHL750BAU 6
8. Remove the hexagon nuts and Torx bolts and sepa-

rate the duct plate (1) and seal (2) from transmissions
rear housing part.
RCPH11WHL751BAU 7
9. Remove the converter safety valve (1) from housing

hole (2).
RCPH11WHL752BAU 8
10. Mark the installation position of the wiring harness

(1) towards valve block (2).
NOTE: This is necessary for re-assemby.
RCPH11WHL753BAU 9
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21.135 / 7
11. Remove the Torx bolts.
RCPH11WHL754BAU 10
12. Separate the duct plate (1) and sealing plate (2) from
valve block (3).
RCPH11WHL755BAU 11
13. Remove the retaining clamp.
RCPH11WHL756BAU 12
14. Remove the Torx bolts (1) and cover (2). Repeat
procedure on the opposite side to remove cover (3).
RCPH11WHL757BAU 13
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21.135 / 8
15. Remove the wiring harness (1).

16. Remove the cylindrical bolts (3), the fixing plates and
the pressure controllers (2).
RCPH11WHL758BAU 14
17. Remove the cylindrical bolts, the fixing plates and the
pressure controllers on the opposite side.
RCPH11WHL759BAU 15
18. Remove TWO Torx bolts (1) and temporarily attach

the housing using adjusting screws 380001577 (2).
19. Remove the remaining Torx bolts.
NOTE: Housing is spring-loaded!
RCPH11WHL760BAU 16
20. Remove the housing from the valve housing by re-

moving the adjusting screws equally.
RCPH11WHL761BAU 17
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21.135 / 9
RCPH11WHL762BAU 18
21. Remove the following individual parts:

• (1) pressure reducing valve
• (2) three vibration dampers
• (3) follow-on slide
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21.135 / 10
22. On the opposite side, remove the following individual

parts as listed below.
RCPH11WHL764BAU 19
• (1) main pressure valve

• (2) three vibration dampers
Next operation:
Transmission control valve - Assemble — 621F (21.135)
84605841 14/05/2012
21.135 / 11
Transmission control valve - Assemble - 621F

621F
Prior operation:
Transmission control valve - Disassemble — 621F (21.135)
Electro-hydraulic control with proportional valves
RCPH11WHL980GAU 1
Electro-hydraulic control
(1) main pressure valve 16+2 bar (4) cover

(2) pressure reducing valve 9 bar (5) housing
(3) wiring harness (6) valve block
(A) main pressure valve (B) pressure controller-proportional valve P5
NOTE: Different versions regarding the wiring harness position are possible. Please observe the vehicle manufac-
turer's specifications.
The following sketches show the sectional views of the
above electro-hydraulic control.
1. Side view of the main pressure valve (A)
• (1) main pressure valve 1 bar (16 psi) + 0.1
bar (2 psi)
• (2) pressure reducing valve 0.6 bar (9 psi)
• (3) wiring harness
• (6) valve block
• (7) duct plate
RCPH11WHL982AAU 2
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21.135 / 12
2. Side view of the pressure controller (B).

• (8) proportional valve P5, with the vibration
damper
RCPH11WHL981BAU 3
Fitting of electric control

3. With the concave side showing upwards, insert ori-
fice (1) until contact is made.
NOTE: Check all single parts for damage and replaced,
if required. Ensure free travel of the moving parts in the
valve block prior to installation. Pistons can be exchanged
individually. Prior to installation, oil single parts.
RCPH11WHL983BAU 4
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21.135 / 13
RCPH11WHL213EBU 5
Electric control
Legend
1. main pressure valve (1x, piston and compres-
sion spring)
2. vibration damper (3x, piston and compression
spring)
3. follow-on slide (3x, piston and compression
spring) for insertion
4. Assemble and install the three individual vibration
dampers (2).
RCPH11WHL207BBU 6
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21.135 / 14
5. Assemble and install the main pressure valve (1) and

the three follow-on slides (3).
RCPH11WHL208BBU 7
6. Preload compression springs of the follow-on slides

and temporarily secure pistons using 0.5 mm cylin-
drical pins.
RCPH11WHL193BBU 8

8. Mount seal (2) and housing (3).
9. Then position the housing evenly using the adjusting
screws 380001577 until contact is made.
RCPH11WHL194BBU 9
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21.135 / 15
10. Bring housing into contact position by using the Torx

bolts. This will preload the pistons, and allow you to
remove the cylindrical pins.
RCPH11WHL195BBU 10
11. Seat housing using the Torx bolts. Tighten torque to

5.5 N·m (49 lb in).
RCPH11WHL196BBU 11
12. Mount pressure controllers with O-ring (1) and se-

cure in place using securing plates (2) and Torx bolts
(3). Torque bolts to 5.5 N·m (49 lb in).
NOTE: Install securing plate with the claw side facing
downward. Pay attention to the radial installation position
of pressure controllers.
RCPH11WHL197BBU 12
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21.135 / 16
Preassemble the opposite side of electric control
RCPH11WHL209FBU 13
Electric control
Legend
sion spring)
spring)
13. Assemble and insert three vibration dampers (2).
RCPH11WHL210BBU 14
84605841 14/05/2012
21.135 / 17
14. Install the assembled main pressure valves (1) and

the three follow-on slide (3)
RCPH11WHL212BBU 15
15. Preload the compression springs of the follow-on

slides (1) and secure the pistons temporarily using
the 5.5 N·m (49 lb in) cylindrical pins.
16. Install two adjusting screws 380001558 (2)
17. Assemble the flat gasket (3) and housing cover.
Then position the housing cover (4) using the ad-
justing screws 380001558 and evenly lower housing
cover until contact ismade.
RCPH11WHL198BBU 16
18. Preload the pistons with Torx bolts and remove the
cylinder pins.
19. Then secure the housing cover using the Torx bolts.
Tighten torque to 5.5 N·m (49 lb in).
RCPH11WHL199BBU 17
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21.135 / 18
20. Mount the pressure controllers with O-ring and fas-

ten in place, using the securing plates and cylindrical
screws. Tighten torque to 5.5 N·m (49 lb in)
NOTE: Install the securing plate with the neck facing down-
wards. Observe the radial installation position of the pres-
sure regulators.
RCPH11WHL200BBU 18
21. Assemble the wiring harness (1) and connect the

pressure controllers.
NOTE: Make sure that pressure regulators and wiring har-
ness are in the proper positions, as previously marked dur-
ing disassembly.
RCPH11WHL201BBU 19
22. Lay flat gasket (1) in place.

23. Insert the plug socket (2) with the slot showing toward
the lug on the cover until contact. Secure the cover
using cylindrical screws. Tighten torque to 5.5 N·m
(49 lb in)
RCPH11WHL202BBU 20
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21.135 / 19
24. Secure the wiring harness using a retaining clamp

25. Secure the opposite cover.
RCPH11WHL203BBU 21
26. Install two adjusting screws 380001558.
RCPH11WHL204BBU 22
27. Flush-mount screens (1) into the holes of the sealing

plate.
NOTE: Pay attention to the installation position. Screen
faces UPWARD, toward the duct plate.
RCPH11WHL205BBU 23
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21.135 / 20
28. Attach the sealing plate with the screens (1), and
duct plate (2) to the electro–hydraulic control (3).
NOTE: Verify that the screen is facing upward.
threaded joint shift unit/duct plate. In case of repair it is
always necessary to mount a new seal plate.
RCPH11WHL206BBU 24
29. Position duct plate (1) and secure it evenly using Torx
bolts (2). Tighten torque to 10.5 N·m (93 lb in).
RCPH11WHL001BBU 25
30. Install bolt plugs with O-rings and torque to 6 N·m (53
lb in).
RCPH11WHL002BBU 26
84605841 14/05/2012
21.135 / 21
RCPH11WHL177BBU 27

RCPH11WHL004BBU 28
35. Mount screw plug (4) with new O-ring. Torque to 30
N·m (22 lb ft).
RCPH11WHL005BBU 29
84605841 14/05/2012
21.135 / 22

37. Insert and torque to 30 N·m (22 lb ft).
RCPH11WHL006BBU 30

unit (3).
RCPH11WHL174BBU 31

using of Torx bolts (2). Torque to 9.5 N·m (84 lb in).
RCPH11WHL173BBU 32
84605841 14/05/2012
21.135 / 23
Fitting of fine filter (pressure filter)

41. Secure filter head (1) with new O-rings to the housing
rear part using Torx screws (2). Torque to 34 N·m (25
lb ft).
RCPH11WHL172BBU 33
42. Install proper new filter for this equipment.

43. Slightly oil the filter seal.
44. Attach filter to the filter head and turn until seal makes
contact with surface. Tighten BY HAND approxi-
mately 1/3 to 1/2 rotation of the filter.
NOTE: Prior to putting transmission into operation, fill with
oil accordingly.
RCPH11WHL171BBU 34
84605841 14/05/2012
21.135 / 24
Transmission control valve - Disassemble - 4 Speed - 721F

721F
Electro–hydraulic control and fine filter (replaceable filter)

1. Fasten transmission on assembly stand CAS2801 or
similar tool. Drain oil prior to starting disassembly.
RAPH11WEL0216BA 1
Removal of filter
RAPH11WEL0217AA 2
84605841 14/05/2012
21.135 / 25

RAPH11WEL0218AA 3

4. Remove gear-shift control (1). Remove Torx bolts
(2) and separate gear-shift control housing from in-
termediate plate.
RAPH11WEL0219AA 4

plate (2). Adjusting bolts (3).
RAPH11WEL0220AA 5
84605841 14/05/2012
21.135 / 26

ter duct plate (4).
2. Piston
RAPH11WEL0221AA 6

RAPH11WEL0222AA 7

hole.
RAPH11WEL0223AA 8
84605841 14/05/2012
21.135 / 27
9. Mark installation position of wiring harness (1) to-

wards the valve block (2).
RCPH11WHL753BAU 9
10. Remove Torx bolts.
RCPH11WHL001BBU 10
11. Separate duct plate (1) and sealing plate (2) from
valve block (3).
RCPH11WHL206BBU 11
84605841 14/05/2012
21.135 / 28
12. Remove retaining clamp.
RCPH11WHL203BBU 12
13. Remove Torx bolts (1) and cover (2). Repeat the
procedure on the opposite end cover (3).
RCPH11WHL203BBU 13
14. Remove wiring harness (1). Remove cylindrical bolts

(3), securing plates and pressure controllers (2).
RCPH11WHL758BAU 14
84605841 14/05/2012
21.135 / 29
15. Remove cylindrical bolts, securing plates and pres-

sure controllers (1) on opposite side.
RCPH11WHL200BBU 15
16. Remove two Torx bolts (1) and temporarily attach

housing using adjusting bolts 380001577 (2). Re-
move remaining Torx bolts.
NOTE: Housing is spring-loaded.
RAPH11WEL0225AA 16
17. Loosen the adjusting bolts equally releasing the

valve’s spring pressure. Remove the housing.
RCPH11WHL195BBU 17
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21.135 / 30
RCPH11WHL213EBU 18
Electric control
Legend
• (1) pressure reducing valve (1x, piston and
compression spring)
• (2) vibration damper (3x, piston and compres-
sion spring)
• (3) follow-on slide (3x, piston and compression
spring) for insertion.
18. Remove the three individual vibration dampers (2).
RCPH11WHL207BBU 19
84605841 14/05/2012
21.135 / 31
19. Remove the pressure reducing valve (1) and the

three follow-on slides (3).
RCPH11WHL208BBU 20
RCPH11WHL209FBU 21
Electric control
Legend
compression spring).
sion spring).
spring).
84605841 14/05/2012
21.135 / 32
20. Remove the three vibration dampers (2).
RCPH11WHL210BBU 22

RCPH11WHL212BBU 23
Next operation:
Transmission control valve - Assemble — 4 Speed - 721F (21.135).
84605841 14/05/2012
21.135 / 33
Transmission control valve - Assemble - 4 Speed - 721F

721F
Prior operation:
Transmission control valve - Disassemble — 4 Speed - 721F (21.135)
RCPH11WHL980GAU 1

bar (2 psi)
• (6) valve block
• (7) duct plate
RCPH11WHL982AAU 2
84605841 14/05/2012
21.135 / 34

damper
RCPH11WHL981BAU 3

RCPH11WHL983BAU 4
84605841 14/05/2012
21.135 / 35
RCPH11WHL213EBU 5
Electric control
Legend
1. Pressure reducing valve (1x, piston and com-
pression spring)
2. Vibration damper (3x, piston and compression
spring)
3. Follow-on slide (3x, piston and compression
spring)
dampers and compression springs (2).
RCPH11WHL207BBU 6
84605841 14/05/2012
21.135 / 36
5. Assemble and install the pressure reducing valve (1)

and the three follow-on slides (3).
RCPH11WHL208BBU 7

drical pins.
RCPH11WHL193BBU 8

RCPH11WHL194BBU 9
84605841 14/05/2012
21.135 / 37

RCPH11WHL195BBU 10

5.5 N·m (49 lb in).
RCPH11WHL196BBU 11

RCPH11WHL197BBU 12
84605841 14/05/2012
21.135 / 38
RCPH11WHL209FBU 13
Electric control
Legend
sion spring)
spring)
RCPH11WHL210BBU 14
84605841 14/05/2012
21.135 / 39

RCPH11WHL212BBU 15

cover until contact is made.
RCPH11WHL198BBU 16
cylinder pins.
RCPH11WHL199BBU 17
84605841 14/05/2012
21.135 / 40

sure regulators.
RCPH11WHL200BBU 18

ing disassembly.
RCPH11WHL201BBU 19

(49 lb in)
RCPH11WHL202BBU 20
84605841 14/05/2012
21.135 / 41

25. Secure the opposite cover.
RCPH11WHL203BBU 21
RCPH11WHL204BBU 22

plate.
RCPH11WHL205BBU 23
84605841 14/05/2012
21.135 / 42
RCPH11WHL206BBU 24
RCPH11WHL001BBU 25
lb in).
RCPH11WHL002BBU 26
84605841 14/05/2012
21.135 / 43
RAPH11WEL0462AA 27

RAPH11WEL0222AA 28
(22 lb ft).
RAPH11WEL0588AA 29
84605841 14/05/2012
21.135 / 44

RAPH11WEL0221AA 30

unit (3).
RAPH11WEL0220AA 31

RAPH11WEL0219AA 32
84605841 14/05/2012
21.135 / 45

lb ft).
RAPH11WEL0218AA 33

RAPH11WEL0217AA 34
84605841 14/05/2012
21.135 / 46
Transmission control valve - Disassemble - 5 Speed - 721F

721F
1. Fasten transmission on assembly stand CAS2801 or

similar tool. Drain oil prior to starting disassembly.
RAPH11WEL0216BA 1
Removal of filter
RAPH11WEL0217AA 2
84605841 14/05/2012
21.135 / 47

RAPH11WEL0218AA 3
4. Loosen nuts (1) and (2) and remove system pressure

pipe (3) from lock-up clutch valve to lock-up clutch.
5. Remove screw-in sleeve (4).
RAPH11WEL0463AA 4
6. Remove hollow bolt (1) and O-ring. Loosen bolt nut

(2). Remove system pressure to lock-up clutch valve
pipe and O-rings (3).
RAPH11WEL0582AA 5
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7. Remove gear-shift control (1). Remove Torx bolts
(2) and separate gear-shift control housing from in-
termediate plate.
NOTE: For version with WK – solenoid valve (5 – speed)
see Steps 22 through 25.
RAPH11WEL0219AA 6

plate (2). Adjusting bolts (3).
RAPH11WEL0220AA 7

ter duct plate (4).
2. Piston
RAPH11WEL0221AA 8
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RAPH11WEL0222AA 9

hole.
RAPH11WEL0223AA 10
12. Mark installation position of wiring harness (1) to-

wards the valve block (2).
RCPH11WHL753BAU 11
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13. Remove Torx bolts.
RCPH11WHL001BBU 12
14. Separate duct plate (1) and sealing plate (2) from
valve block (3).
RCPH11WHL206BBU 13
15. Remove retaining clamp.
RCPH11WHL203BBU 14
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16. Remove Torx bolts (1) and cover (2). Repeat the
procedure on the opposite end cover (3).
RCPH11WHL203BBU 15
17. Remove wiring harness (1). Remove cylindrical bolts

(3), securing plates and pressure controllers (2).
RCPH11WHL758BAU 16
WK - solenoid valve (5 - speed)

18. Mark installation position of connecting housing (4)
towards valve block (5).
19. Remove cylinder bolts (1) and lock-up clutch valve.
20. Remove bolt neck (2) and discard O-rings.
21. Remove Torx bolts (3), and the connecting housing.
RAPH11WEL0226AA 17
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22. Remove cylindrical bolts, securing plates and pres-

sure controllers (1) on opposite side.
RCPH11WHL200BBU 18
23. Remove two Torx bolts (1) and temporarily attach

housing using adjusting bolts 380001577 (2). Re-
move remaining Torx bolts.
NOTE: Housing is spring-loaded.
RAPH11WEL0225AA 19
24. Loosen the adjusting bolts equally releasing the

valve’s spring pressure. Remove the housing.
RCPH11WHL195BBU 20
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RCPH11WHL213EBU 21
Electric control
Legend
compression spring)
sion spring)
spring) for insertion.
25. Remove the three individual vibration dampers (2).
RCPH11WHL207BBU 22
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RCPH11WHL208BBU 23
RCPH11WHL209FBU 24
Electric control
Legend
compression spring).
sion spring).
spring).
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27. Remove the three vibration dampers (2).
RCPH11WHL210BBU 25

RCPH11WHL212BBU 26
Next operation:
Transmission control valve - Assemble — 5 Speed - 721F (21.135)
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Transmission control valve - Assemble - 5 Speed - 721F

721F
Prior operation:
Transmission control valve - Disassemble — 5 Speed — 721F (21.135)
RCPH11WHL980GAU 1

bar (2 psi)
• (6) valve block
• (7) duct plate
RCPH11WHL982AAU 2
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damper
RCPH11WHL981BAU 3

RCPH11WHL983BAU 4
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RCPH11WHL213EBU 5
Electric control
Legend
1. Pressure reducing valve (1x, piston and com-
pression spring)
2. Vibration damper (3x, piston and compression
spring)
3. Follow-on slide (3x, piston and compression
spring)
dampers and compression springs (2).
RCPH11WHL207BBU 6
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5. Assemble and install the pressure reducing valve (1)

and the three follow-on slides (3).
RCPH11WHL208BBU 7

drical pins.
RCPH11WHL193BBU 8

RCPH11WHL194BBU 9
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RCPH11WHL195BBU 10

5.5 N·m (49 lb in).
RCPH11WHL196BBU 11

RCPH11WHL197BBU 12
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RCPH11WHL209FBU 13
Electric control
Legend
sion spring)
spring)
RCPH11WHL210BBU 14
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RCPH11WHL212BBU 15

cover until contact is made.
RCPH11WHL198BBU 16
cylinder pins.
RCPH11WHL199BBU 17
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sure regulators.
RCPH11WHL200BBU 18

ing disassembly.
RCPH11WHL201BBU 19

(49 lb in)
RCPH11WHL202BBU 20
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RCPH11WHL203BBU 21
25. On reverse side, position seal (1) and secure con-

necting housing (2) using Torx bolts (3). Tightening
torque 5.5 N·m (49 lb in).
NOTE: Pay attention to installation position of connection
housing, see markings applied during disassembly.
RAPH11WEL0580AA 22
26. Secure pressure controller (1) using cylindrical bolts

(2) and torque to 10 N·m (89 lb in).
27. Fit bolt necks (4) with O-ring and torque to 25 N·m
(18 lb ft).
28. Fit plug (3) with O-ring and torque to 10 N·m (89 lb
in).
RAPH11WEL0583AA 23
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RCPH11WHL204BBU 24

plate.
RCPH11WHL205BBU 25
RCPH11WHL206BBU 26
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RCPH11WHL001BBU 27
lb in).
RCPH11WHL002BBU 28
RAPH11WEL0462AA 29
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RAPH11WEL0222AA 30
(22 lb ft).
RAPH11WEL0588AA 31

RAPH11WEL0221AA 32
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unit (3).
RAPH11WEL0220AA 33

RAPH11WEL0219AA 34
Pipe - System pressure to lock-up clutch valve

44. Secure pipe (1) with hollow bolt (2) and bolt nut (3).
45. Fit O-ring on to hollow bolt (2), insert it into the eye
of the pipe and torque to 45 N·m (33 lb ft).
46. Attach bolt nut (3) and torque to 35 N·m (26 lb ft).
RAPH11WEL0582AA 35
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Pipe - System pressure from lock-up clutch valve to lock-up clutch

47. Insert screw-in sleeve (1) and torque to 45 N·m (33
lb ft).
48. Secure pipe (2) with nuts (3) and (4).
RAPH11WEL0463AA 36

lb ft).
RAPH11WEL0218AA 37

RAPH11WEL0217AA 38
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Index
Transmission - 21

Transmission control valve - Assemble - 4 Speed - 721F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
721F
Transmission control valve - Assemble - 5 Speed - 721F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
721F
Transmission control valve - Assemble - 621F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
621F
Transmission control valve - Disassemble - 4 Speed - 721F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
721F
Transmission control valve - Disassemble - 5 Speed - 721F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
721F
Transmission control valve - Disassemble - 621F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
621F
Transmission control valve - Visual inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
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Transmission - 21
Powershift transmission internal components - 155
621F
721F
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Contents
Transmission - 21
FUNCTIONAL DATA
Clutch
Dynamic description – Transmission Clutch Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
SERVICE
Clutch
Disassemble - Forward clutch KV - 621F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
621F
Assemble - Forward clutch KV - 621F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

621F
Disassemble - Reverse clutch KR - 621F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

621F
Assemble - Reverse clutch KR - 621F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

621F
Disassemble - First gear clutch K1 - 621F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

621F
Assemble - First gear clutch K1 – 621F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

621F
Disassemble - Second gear clutch K2 - 621F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

621F
Assemble - Second gear clutch K2 - 621F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

621F
Disassemble - Third gear clutch K3 - 621F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

621F
Assemble - Third gear clutch K3 - 621F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

621F
Disassemble - Fourth gear clutch K4 - 621F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

621F
Assemble - Fourth gear clutch K4 - 621F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

621F
Disassemble - Input shaft - 621F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

621F
Assemble - Input shaft - 621F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

621F
Disassemble - Output shaft - 621F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96

621F
Assemble - Output shaft - 621F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

621F
Disassemble - Forward clutch KV – 4 and 5 Speed - 721F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

721F
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Assemble - Forward clutch KV - 4 and 5 Speed - 721F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
721F
Disassemble - Reverse clutch KR - 4 and 5 Speed - 721F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114

721F
Assemble - Reverse clutch KR - 4 and 5 Speed - 721F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120

721F
Disassemble - First gear clutch K1 – 4 and 5 Speed - 721F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128

721F
Assemble - First gear clutch K1 - 4 and 5 Speed - 721F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134

721F
Disassemble - Second gear clutch K2 - 4 and 5 Speed - 721F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142

721F
Assemble - Second gear clutch K2 - 4 and 5 Speed - 721F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148

721F
Disassemble - Third gear clutch K3 - 4 and 5 Speed – 721F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156

721F
Assemble - Third gear clutch K3 - 4 and 5 Speed - 721F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162

721F
Disassemble - Fourth gear clutch K4 - 4 and 5 Speed - 721F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170

721F
Assemble - Fourth gear clutch K4 - 4 and 5 Speed – 721F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176

721F
Disassemble - Input shaft - 4 and 5 Speed – 721F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185

721F
Assemble - Input shaft - 4 and 5 Speed - 721F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186

721F
Disassemble - Output shaft - 4 and 5 Speed – 721F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190

721F
Assemble - Output shaft - 4 and 5 Speed – 721F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191

721F
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CONSUMABLES INDEX
Consumable IU PAGE
Loctite® 262 Clutch - Assemble - Forward clutch KV - 4 and 5 Speed - 721F 21.155 / 113
Loctite® 262 Clutch - Assemble - Reverse clutch KR - 4 and 5 Speed - 721F 21.155 / 127
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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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21.155 / 5
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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21.155 / 6
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 - Forward clutch KV - 621F

621F
WARNING
Avoid injury!
When using compressed air, be sure to point the object being ejected away from others and self.
W0995A
CAUTION
Eye injury hazard!
Wear protective goggles when using compressed air.
C0035A
RCPH11WHL031FBU 1
Clutches KV, KR, K1, K3, K4, Input and output shaft
K1 clutch
K2 clutch
K3 clutch
K4 clutch
KR clutch
KV clutch
AN input shaft
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KV clutch
1. Remove stud bolt (1) and snap out piston ring (2).
RCPH11WHL085BBU 2
2. Pull tapered roller bearing (inner ring) off the shaft.
RCPH11WHL086BBU 3
3. Pull clutch off the shaft.
RCPH11WHL087BBU 4
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21.155 / 9
4. Snap out retaining ring.
RCPH11WHL046BBU 5
5. Secure idler gear (1) using a cut-off device and pull

it off the clutch shaft (2).
RCPH11WHL089BBU 6
6. Snap retaining ring (2) out of the idler gear (1) and
remove ball bearing (3).
RCPH11WHL090BBU 7
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7. Remove needle cage (1) from the shaft (2).
RCPH11WHL091BBU 8
8. Turn shaft (2) by 180 ° and snap out piston ring (1).
RCPH11WHL092BBU 9
RCPH11WHL093BBU 10
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21.155 / 11
10. Unsnap snap ring.
RCPH11WHL822BAU 11
11. Remove end shim (1) and disc set (2) out the disc
carrier (3).
RCPH11WHL095BBU 12
12. Preload compression spring with assembly aid tool

380001556 and unsnap L-Ring (1).
RCPH11WHL096BBU 13
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13. Remove support shim (1), compression spring (2)

and washer (3).
RCPH11WHL097BBU 14
14. Using compressed air, lift and remove piston from the
cylinder bore.
RCPH11WHL098BBU 15
15. Remove both O-rings (1) and (2).
RCPH11WHL099BBU 16
Next operation:
Clutch - Assemble — Forward clutch KV - 621F (21.155)
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Clutch - Assemble - Forward clutch KV - 621F

621F
CAUTION
Eye injury hazard!
C0035A
CAUTION
Hot area!
Use care when working near hot components. Wear protective gloves.
C0034A
Prior operation:
Clutch - Disassemble — Forward clutch KV - 621F (21.155)
1. Heat up bearing inner ring to approximately 49 °C

(120 °F).
RCPH11WHL131BBU 1
2. Mount bearing inner ring (1) until contact is obtained.

Secure rectangular ring (2).
NOTE: Wear protective gloves. Adjust bearing inner ring
after cooling down.
RCPH11WHL130BBU 2
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21.155 / 14
3. Mount needle bearing onto the shaft and oil it.
RCPH11WHL091BBU 3
4. Install ball bearing (2) into the idler gear (1) until con-
tact is obtained and secure it using a retaining ring
(3).
RCPH11WHL090BBU 4
5. Press in pre-assembled idler gear until contact is ob-

tained.
RCPH11WHL132BBU 5
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6. Secure the idler gear (1) using a retaining ring (2).
RCPH11WHL046BBU 6
7. Place O-rings (1) and (2) into the piston grooves and
oil them.
NOTE: Check the function of the drain valve (3). There
must be no jamming of the ball.
RCPH11WHL045BBU 7
8. Place piston into the disk carrier.

NOTE: Observe installation position.
RCPH11WHL072BBU 8
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9. Use special assembly tool 380001556 to place piston

into the disk carrier.
RCPH11WHL073BBU 9
10. Mount inner installer (1) onto the disk carrier.

11. Install disk (2), compression spring (3), support shim
(4) and L-ring (5).
NOTE: For mounting inner installer installation see 12
NOTE: For information on support shim and L-ring position
installation see step 13.
RCPH11WHL044BBU 10
12. Preload compression spring using special assem-

bly tool 380001556 (1) and pressure piece (2), until
L-ring has engaged into the annular groove.
NOTE: It is always necessary to mount a new L-ring.
RCPH11WHL134BBU 11
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13. Disk carrier with piston retraction

• (1) washer
• (2) compression spring
• (3) support shim
• (4) L-ring
• (5) disk carrier
• (6) drain valve (piston)
• (7) piston with O-rings
RCPH11WHL037BBU 12
14. Install outer and inner disks alternately into the disk
carrier (4) as shown in diagram.
NOTE: Take care that the uncoated (blank) side of the fric-
tion disk (1) is showing towards the piston or end plate.
Number of friction surfaces: 20.
Legend
• (1) friction disk – coated on one side (two
pieces)
• (2) outer disks (nine pieces)
• (3) inner disks (ten pieces)
• (4) disk carrier RCPH11WHL042BBU 13
15. Mount end plate (1) and secure the disk package
using a snap ring (2). A 2.65 mm (0.1 in) thickness
is recommended value.
RCPH11WHL135BBU 14
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16. Press on end plate with a force of approximately 100

N = 10 kg (22.5 lb) and set dial indicator to "zero“.
RCPH11WHL136BBU 15
17. Then press the end plate upward, against the snap
ring and read disk clearance. Disk clearance: 2.45
mm (0.10 in) to 2.75 mm as shown in step 14.
NOTE: In case of deviations, the disk clearance must be
corrected with an appropriate snap ring (optional thick-
nesses = 2.1 - 4.2 mm (0.1 - 0.2 in).
RCPH11WHL137BBU 16

°C (248 °F).
RCPH11WHL138BBU 17
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19. Install clutch until contact is obtained.

20. Mount inner disks onto the inner disk carrier using
short left/right rotations.
NOTE: Wear protective gloves.
RCPH11WHL139BBU 18

(248 °F).
RCPH11WHL131BBU 19
22. Mount bearing inner ring until contact is obtained.

NOTE: Adjust bearing inner ring after cooling-down.
RCPH11WHL140BBU 20
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23. Mount stud bolt (1). Tighten torque to 17 N·m (150

lb in).
24. Secure rectangular ring (2).
RCPH11WHL141BBU 21
25. Check the clutch operation using compressed air at

the hole. Closing and opening of the clutch must be
clearly audible.
RCPH11WHL141BBU 22
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Clutch - Disassemble - Reverse clutch KR - 621F

621F
WARNING
Avoid injury!
W0995A
CAUTION
Eye injury hazard!
C0035A
RCPH11WHL031FBU 1
K1 clutch
K2 clutch
K3 clutch
K4 clutch
KR clutch
KV clutch
AN input shaft
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RCPH11WHL085BBU 2
RCPH11WHL086BBU 3
RCPH11WHL087BBU 4
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RCPH11WHL046BBU 5
5. Secure idler gear (1) using a cut-off device and pull

it off the clutch shaft (2).
RCPH11WHL089BBU 6
RCPH11WHL090BBU 7
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RCPH11WHL091BBU 8
RCPH11WHL092BBU 9
RCPH11WHL093BBU 10
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RCPH11WHL822BAU 11
carrier (3).
RCPH11WHL095BBU 12

RCPH11WHL096BBU 13
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and washer (3).
RCPH11WHL097BBU 14
cylinder bore.
RCPH11WHL098BBU 15
RCPH11WHL099BBU 16
Next operation:
Clutch - Assemble — Reverse clutch KR - 621F (21.155)
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Clutch - Assemble - Reverse clutch KR - 621F

621F
CAUTION
Eye injury hazard!
C0035A
CAUTION
Hot area!
C0034A
Prior operation:
Clutch - Disassemble — Reverse clutch KR - 621F (21.155)

(120 °F).
RCPH11WHL131BBU 1

after cooling down.
RCPH11WHL130BBU 2
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3. Mount needle bearing onto the shaft and oil it.
RCPH11WHL091BBU 3
tact is obtained and secure it using a retaining ring
(3).
RCPH11WHL090BBU 4
5. Press in pre-assembled idler gear until contact is ob-

tained.
RCPH11WHL132BBU 5
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6. Secure the idler gear (1) using a retaining ring (2).
RCPH11WHL133BBU 6
7. Place O-rings (1) and (2) into the piston grooves and
oil them.
RCPH11WHL045BBU 7

RCPH11WHL072BBU 8
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RCPH11WHL073BBU 9
10. Mount inner installer (1) onto the disk carrier.

11. Install disk (2), compression spring (3), support shim
(4) and L-ring (5).
NOTE: For mounting inner installer installation see step 12
NOTE: For information on support shim and L-ring position
installation see step 13.
RCPH11WHL044BBU 10
12. Preload compression spring using special assem-

bly tool 380001556 (1) and pressure piece (2), until
L-ring has engaged into the annular groove.
NOTE: It is always necessary to mount a new L-ring.
RCPH11WHL134BBU 11
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13. Disk carrier with piston retraction

Legend
• (1) washer
• (2) compression spring
• (3) support shim
• (4) L-ring
• (6) drain valve (piston)
RCPH11WHL037BBU 12
carrier (4) as shown.
Number of friction surfaces: 20.
Legend
pieces)
• (2) outer disks (nine pieces)
• (3) inner disks (ten pieces)
• (4) disk carrier RCPH11WHL042BBU 13
RCPH11WHL135BBU 14
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RCPH11WHL136BBU 15
ring and read disk clearance. Disk clearance: 2.45
mm (0.10 in) to 2.75 mm as shown in step 14.
nesses = 2.1 - 4.2 mm (0.1 - 0.2 in).
RCPH11WHL137BBU 16

°C (248 °F).
RCPH11WHL138BBU 17
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19. Install clutch until contact is obtained.

RCPH11WHL139BBU 18

(248 °F).
RCPH11WHL131BBU 19

RCPH11WHL140BBU 20
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lb in).
RCPH11WHL141BBU 21
25. Check the clutch operation using compressed air at

the hole. Closing and opening of the clutch must be
clearly audible.
RCPH11WHL141BBU 22
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Clutch - Disassemble - First gear clutch K1 - 621F

621F
WARNING
Avoid injury!
W0995A
CAUTION
Eye injury hazard!
C0035A
RCPH11WHL031FBU 1
K1 clutch
K2 clutch
K3 clutch
K4 clutch
KR clutch
KV clutch
AN input shaft
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RCPH11WHL039BBU 2
RCPH11WHL101BBU 3
RCPH11WHL038BBU 4
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4. Remove axial bearing assembly.
RCPH11WHL100BBU 5
5. Take off idler gear (1), remove needle cage (2) and
axial bearing assembly (3).
RCPH11WHL102BBU 6
RCPH11WHL103BBU 7
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RCPH11WHL104BBU 8
RCPH11WHL105BBU 9
RCPH11WHL822BAU 10
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carrier (3).
RCPH11WHL095BBU 11

RCPH11WHL096BBU 12
12. Remove guide rings (1) and compression spring (2).
RCPH11WHL097BBU 13
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cylinder bore.
RCPH11WHL072BBU 14
RCPH11WHL099BBU 15
Next operation:
Clutch - Assemble — First gear clutch K1 – 621F (21.155)
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Clutch - Assemble - First gear clutch K1 – 621F

621F
CAUTION
Eye injury hazard!
C0035A
CAUTION
Hot area!
C0034A
Prior operation:
Clutch - Disassemble — First gear clutch K1 - 621F (21.155)

(120 °F).
RCPH11WHL131BBU 1

NOTE: Adjust bearing inner ring after cooling down.
RCPH11WHL130BBU 2
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3. Place both O rings (1) and (2) into the piston grooves
and oil them.
RCPH11WHL045BBU 3

RCPH11WHL072BBU 4

RCPH11WHL073BBU 5
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6. Mount guide rings (1) and compression spring (2).
RCPH11WHL047BBU 6
7. Preload pressure spring using special assembly aid

tool 380001556 and secure with retaining ring.
RCPH11WHL119BBU 7

Legend
pieces)
• (2) outer disks (eight pieces)
• (3) inner disks (nine pieces)
Number of friction surfaces: 18. RCPH11WHL041BBU 8
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RCPH11WHL135BBU 9

RCPH11WHL136BBU 10
ring and read disk clearance. Disk clearance: 2.5 -
2.8 mm (0.1 - 0.110 in).
nesses = 2.1 - 4.2 mm (0.1 - 0.2 in).
RCPH11WHL137BBU 11
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°C (248 °F).
RCPH11WHL138BBU 12
13. Mount clutch until contact is obtained.

RCPH11WHL142BBU 13
14. Mount running disk (1), axial cage (2), and axial
washer (3), then oil them.
NOTE: Install chamfer (see arrow) of running disk (1)
showing towards the axial cage.
RCPH11WHL143BBU 14
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15. Mount needle cage and oil it.
RCPH11WHL144BBU 15
16. Install (1) idler

17. Mount inner disks onto the inner disk carrier (idler)
using short left/right rotations.
RCPH11WHL145BBU 16
18. Mount axial washer (1), axial cage (2) and running
disk (3). Oil them.
RCPH11WHL146BBU 17
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19. Secure idler gear (1) and single parts using the re-
taining ring (2).
RCPH11WHL038BBU 18

(248 °F).
RCPH11WHL131BBU 19

RCPH11WHL147BBU 20
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22. Mount stud bolt (1). Tightening torque to 17 N·m (150

lb in). Secure rectangular ring (2).
RCPH11WHL039BBU 21
23. Check clutch operation using compressed air at the

hole. Closing and opening of the clutch must be
clearly audible.
RCPH11WHL039BBU 22
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Clutch - Disassemble - Second gear clutch K2 - 621F

621F
WARNING
Avoid injury!
W0995A
CAUTION
Eye injury hazard!
C0035A
RCPH11WHL031FBU 1
K1 clutch
K2 clutch
K3 clutch
K4 clutch
KR clutch
KV clutch
AN input shaft
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RCPH11WHL106BBU 2
RCPH11WHL107BBU 3
RCPH11WHL108BBU 4
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RCPH11WHL109BBU 5
RCPH11WHL110BBU 6
RCPH11WHL111BBU 7
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RCPH11WHL112BBU 8
RCPH11WHL105BBU 9
RCPH11WHL094BBU 10
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carrier (3).
RCPH11WHL095BBU 11

RCPH11WHL096BBU 12
RCPH11WHL097BBU 13
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cylinder bore.
RCPH11WHL072BBU 14
RCPH11WHL099BBU 15
Next operation:
Clutch - Assemble — Second gear clutch K2 - 621F (21.155)
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Clutch - Assemble - Second gear clutch K2 - 621F

621F
CAUTION
Eye injury hazard!
C0035A
CAUTION
Hot area!
C0034A
Prior operation:
Clutch - Disassemble — Second gear clutch K2 - 621F (21.155)

(120 °F).
RCPH11WHL131BBU 1
2. Mount bearing inner ring (1) until contact is made.

after cooling down.
RCPH11WHL112BBU 2
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and oil them.
RCPH11WHL045BBU 3

RCPH11WHL072BBU 4

RCPH11WHL073BBU 5
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RCPH11WHL047BBU 6

RCPH11WHL119BBU 7

Legend
pieces)
• (2) outer disks (seven pieces)
• (3) inner disks (eight pieces)
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RCPH11WHL135BBU 9

RCPH11WHL136BBU 10
2.30 mm
nesses = 2.1 - 4.2 mm (0.1 - 0.2 in).
RCPH11WHL137BBU 11
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°C (248 °F).
RCPH11WHL138BBU 12
13. Mount clutch until contact is made.

RCPH11WHL049BBU 13
14. Mount running disk (1), axial cage (2) and axial
RCPH11WHL050BBU 14
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RCPH11WHL051BBU 15

RCPH11WHL052BBU 16
disk (3). Oil them.
RCPH11WHL053BBU 17
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19. Secure idler gear (1) and single parts using the re-
taining ring (2).
RCPH11WHL054BBU 18
20. Heat up bearing inner ring 120 °C (248 °F).
RCPH11WHL131BBU 19
21. Mount bearing inner ring until contact is made.

22. Adjust bearing inner ring after cooling-down.
RCPH11WHL055BBU 20
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23. Mount stud bolt (1).Tighten torque to 17 N·m (150 lb

in).
RCPH11WHL056BBU 21
25. Using compressed air at the hole, check closing and

opening of the clutch. Closing and opening of the
clutch must be clearly audible.
RCPH11WHL056BBU 22
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Clutch - Disassemble - Third gear clutch K3 - 621F

621F
WARNING
Avoid injury!
W0995A
CAUTION
Eye injury hazard!
C0035A
RCPH11WHL031FBU 1
K1 clutch
K2 clutch
K3 clutch
K4 clutch
KR clutch
KV clutch
AN input shaft
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1. Snap out piston ring.
RCPH11WHL062BBU 2
RCPH11WHL113BBU 3
RCPH11WHL114BBU 4
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RCPH11WHL115BBU 5
RCPH11WHL116BBU 6
RCPH11WHL117BBU 7
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RCPH11WHL118BBU 8
RCPH11WHL094BBU 9
carrier (3).
RCPH11WHL095BBU 10
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RCPH11WHL119BBU 11
RCPH11WHL097BBU 12
cylinder bore.
RCPH11WHL072BBU 13
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RCPH11WHL099BBU 14
Next operation:
Clutch - Assemble — Third gear clutch K3 - 621F (21.155)
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Clutch - Assemble - Third gear clutch K3 - 621F

621F
CAUTION
Eye injury hazard!
C0035A
CAUTION
Hot area!
C0034A
Prior operation:
Clutch - Disassemble — Third gear clutch K3 - 621F (21.155)

(120 °F).
RCPH11WHL131BBU 1

lb in)
RCPH11WHL057BBU 2
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and oil them.
RCPH11WHL045BBU 3

RCPH11WHL072BBU 4

RCPH11WHL073BBU 5
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RCPH11WHL047BBU 6

RCPH11WHL119BBU 7
Legend
pieces)
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12. Mount end plate (1) and secure disk package using
snap ring (2). Recommended valued thickness =
2.65 mm (0.1 in).
RCPH11WHL135BBU 9

RCPH11WHL136BBU 10
2.30 mm
nesses = 2.1 - 4.2 mm (0.1 - 0.2 in).
RCPH11WHL137BBU 11
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°C (248 °F).
RCPH11WHL138BBU 12

RCPH11WHL049BBU 13
17. Mount running disk (1), axial cage (2) and axial
RCPH11WHL058BBU 14
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RCPH11WHL059BBU 15

RCPH11WHL060BBU 16
disk (3). Oil them.
RCPH11WHL061BBU 17
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22. Pay attention that the running disk is flush with the
shaft collar to ensure that all inner disks are mounted
on the idler gear teeth.
RCPH11WHL063BBU 18
23. Heat up bearing inner ring 120 °C (248 °F).
RCPH11WHL131BBU 19

RCPH11WHL062BBU 20
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26. Secure rectangular ring.
RCPH11WHL062BBU 21

RCPH11WHL064BBU 22
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Clutch - Disassemble - Fourth gear clutch K4 - 621F

621F
WARNING
Avoid injury!
W0995A
CAUTION
Eye injury hazard!
C0035A
RCPH11WHL031FBU 1
K1 clutch
K2 clutch
K3 clutch
K4 clutch
KR clutch
KV clutch
AN input shaft
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RCPH11WHL120BBU 2
RCPH11WHL033BBU 3
RCPH11WHL121BBU 4
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RCPH11WHL122BBU 5
5. Remove axial bearing assembly (1) and idler gear

(2).
RCPH11WHL123BBU 6
6. Remove needle cage (1) and axial bearing assembly

(2).
NOTE: Gear (3) is shrink fitted and cannot be removed.
RCPH11WHL124BBU 7
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RCPH11WHL035BBU 8
RCPH11WHL125BBU 9
RCPH11WHL094BBU 10
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carrier (3).
RCPH11WHL095BBU 11
11. Preload compression spring (1) with assembly aid

tool 380001556 and unsnap the snap ring.
RCPH11WHL119BBU 12
RCPH11WHL097BBU 13
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cylinder bore.
RCPH11WHL072BBU 14
RCPH11WHL099BBU 15
Next operation:
Clutch - Assemble — Fourth gear clutch K4 - 621F (21.155)
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Clutch - Assemble - Fourth gear clutch K4 - 621F

621F
CAUTION
Eye injury hazard!
C0035A
CAUTION
Hot area!
C0034A
Prior operation:
Clutch - Disassemble — Fourth gear clutch K4 - 621F (21.155)

(120 °F).
RCPH11WHL131BBU 1

RCPH11WHL065BBU 2
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5. Cool shaft (1) to approximately -80 °C (-112 °F) and

heat up gear (2) to approximately +120 °C (248 °F)
then mount gear down shaft until contact is obtained.
RCPH11WHL066BBU 3
7. Secure gear using retaining ring
RCPH11WHL067BBU 4
8. Mount lower axial washer (1) axial needle cage (2)

and upper axial washer, then oil it.
RCPH11WHL068BBU 5
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9. Mount needle cage, then oil it.
RCPH11WHL069BBU 6
10. Mount idler gear.
RCPH11WHL070BBU 7
11. Mount axial washer (1), axial needle (2), and running
disk (3), then oil it.
NOTE: Mount running disk (3) with the chamfer (see arrow)
showing to the needle cage.
RCPH11WHL071BBU 8
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and oil them.
RCPH11WHL045BBU 9

RCPH11WHL072BBU 10

RCPH11WHL073BBU 11
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RCPH11WHL047BBU 12

RCPH11WHL856BAU 13
Legend
pieces)
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18. Mount end plate (1) and secure disk package using
snap ring (2). Recommended valued thickness =
2.65 mm (0.1 in).
RCPH11WHL135BBU 15

RCPH11WHL136BBU 16
1.45 mm.
nesses = 2.1 - 4.2 mm (0.1 - 0.2 in).
RCPH11WHL137BBU 17
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°C (248 °F).
RCPH11WHL138BBU 18
22. Mount clutch (1) until contact is made.

RCPH11WHL148BBU 19
24. Secure clutch using retaining ring.
RCPH11WHL074BBU 20
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(248 °F).
RCPH11WHL131BBU 21

28. Mound stud bolt (3). Tighten torque to 17 N·m (150
lb in).
29. Adjust bearing inner ring after cooling down.
RCPH11WHL075BBU 22

RCPH11WHL075BBU 23
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Clutch - Disassemble - Input shaft - 621F

621F
1. Snap out piston ring (1). Turbine wheel shaft and

drive gear (2) are secured by a snap ring.
NOTE: When separated, the components will be de-
stroyed.
RCPH11WHL126BBU 1
2. Pull tapered roller bearing (inner ring) off the drive

gear.
RCPH11WHL127BBU 2
3. Pull tapered roller bearing (inner ring) off the drive

gear.
NOTE: Input shaft and gear (1) are shrink fitted and cannot
be separated.
RCPH11WHL128BBU 3
Next operation:
Clutch - Assemble — Input shaft - 621F (21.155)
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Clutch - Assemble - Input shaft - 621F

621F
CAUTION
Hot area!
C0034A
Prior operation:
Clutch - Disassemble — Input shaft - 621F (21.155)
1. Cool input shaft (1) to approximately -80 °C (-112

°F) and heat up drive gear (2) to approximately +120
°C (248 °F) and mount gear drive down shaft until
contact is complete.
RCPH11WHL076BBU 1
2. Secure drive gear using retaining ring.
RCPH11WHL077BBU 2
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(248 °F).
RCPH11WHL131BBU 3

RCPH11WHL078BBU 4

(248 °F).
RCPH11WHL131BBU 5
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RCPH11WHL079BBU 6
9. Install snap ring (1) into the annular groove (2) of the
turbine shaft.
RCPH11WHL080BBU 7
10. Mount turbine shaft (1) until the snap ring engages
into the input shaft groove.
11. Snap in and interlock rectangular ring (2).
NOTE: Turbine shaft is axially fixed.
RCPH11WHL081BBU 8
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Clutch - Disassemble - Output shaft - 621F

621F
1. Pull tapered roller bearing (inner ring) off the output

shaft and remove oil screen sheet (1).
RCPH11WHL036BBU 1
2. Turn output shaft by 180 ° and pull off tapered roller

bearing (inner ring).
RCPH11WHL129BBU 2
Next operation:
Clutch - Assemble — Output shaft - 621F (21.155)
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Clutch - Assemble - Output shaft - 621F

621F
CAUTION
Hot area!
C0034A
Prior operation:
Clutch - Disassemble — Output shaft - 621F (21.155)

(248 °F).
RCPH11WHL131BBU 1

RCPH11WHL082BBU 2
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4. Mount screen sheet.
RCPH11WHL083BBU 3

(248 °F).
RCPH11WHL131BBU 4
6. Mount bearing inner ring until contact is completed.

RCPH11WHL084BBU 5
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Clutch - Disassemble - Forward clutch KV – 4 and 5 Speed - 721F

721F
CAUTION
Eye injury hazard!
C0035A
RAPH11WEL0063AA 1
Clutches K1, K2, K3, K4, KR, KV, and Input
1 K1 clutch
2 K2 clutch
3 K3 clutch
4 K4 clutch
5 KR clutch
6 KV clutch
7 Input
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RAPH11WEL0064AA 2
2. Pull tapered roller bearing off the shaft using special

tool CAS2798.
RAPH11WEL0065AA 3
RAPH11WEL0066AA 4
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RCPH11WHL087BBU 5
5. Secure idler gear using a cut-off device and pull it off

the clutch shaft.
RAPH11WEL0067AA 6
RAPH11WEL0068AA 7
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RCPH11WHL091BBU 8
8. Turn shaft (2) a 180 ° degrees and snap out piston

ring (1).
RAPH11WEL0069AA 9
9. Pull tapered roller bearing off shaft with special tool

CAS2798.
RAPH11WEL0070AA 10
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RCPH11WHL094BBU 11
11. Remove end shim (1) and disc set (2) from the disc
carrier (3).
RCPH11WHL095BBU 12
12. Preload compression spring with special tool

380001556 and unsnap L-ring (1).
RCPH11WHL096BBU 13
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and washer (3).
RCPH11WHL097BBU 14
14. Using compressed air, remove the piston from the

disc carrier.
RCPH11WHL098BBU 15
15. Remove (both) O-rings (1) and (2).
RCPH11WHL099BBU 16
Next operation:
Clutch - Assemble — Forward clutch KV — 4 and 5 Speed - 721F (21.155)
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Clutch - Assemble - Forward clutch KV - 4 and 5 Speed - 721F

721F
CAUTION
Burn hazard!
C0047A
CAUTION
Eye injury hazard!
C0035A
Prior operation:
Clutch - Disassemble — Forward clutch KV – 4 and 5 Speed - 721F (21.155)
1. Heat bearing to approximately 120 °C (248 °F).
RCPH11WHL131BBU 1
2. Mount bearing (1) until contact is made. Adjust bear-

ing after it cools. Fit rectangular ring (2).
NOTE: Always wear protective gloves to prevent burning
your hands when handling heated parts.
RAPH11WEL0110AA 2
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3. Mount bearing cage (1) onto the shaft and oil it.
RAPH11WEL0111AA 3
tact occurs and secure it using retaining ring (2).
RAPH11WEL0112AA 4
5. Press pre-assembled idler gear onto the shaft until

contact occurs.
RAPH11WEL0113AA 5
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6. Place (both) O-rings (1) and (2) into the piston

grooves and oil them.
NOTE: Check function of the drain valve (see arrow). The
ball must not jam.
RAPH11WEL0114AA 6
7. Place piston into the disc carrier.

RAPH11WEL0115AA 7
8. Use special tool 380001556 to place piston into the

disc carrier.
RAPH11WEL0116AA 8
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9. Mount inner installer (1) onto the disc carrier.

10. Install disc (2), compression spring (3), support shim
(4) and L-ring (5).
NOTE: For installation position of support shim , L-ring and
inner installer, follow the next two steps.
RCPH11WHL044BBU 9
11. Preload compression spring using special tool

380001556 (2) and pressure piece (1), until L-ring
has engaged into the annular grove.
NOTE: Always use a new L-ring.
RCPH11WHL134BBU 10
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RCPH11WHL037BBU 11
Disc carrier with piston retraction
Legend
1. washer
2. compressor spring
3. support shim
4. L-ring
5. disc carrier
6. piston with O-rings
7. drain valve (piston)
12. Install outer and inner discs into the disc carrier (4).
Legend
• (1) Friction disc – coated on one side (1 pc)
• (2) Outer discs – (10 pcs)
• (3) Inner discs – (10 pcs)
NOTE: Make sure that the uncoated (blank) side of the
friction disc (1) is showing towards the piston. Number of
friction surfaces is 18.
RAPH11WEL0119AA 12
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13. Mount end plate (1) and secure disc package using
snap ring (2) (e.g. thickness = 2.65 mm (0.104 in.)
recommended value).
RCPH11WHL135BBU 13

RCPH11WHL136BBU 14
ring and read disc clearance. Disc clearance: 2.65 -
2.95 mm (0.104 - 0.116 in).
nesses = 2.1 - 4.2 mm (0.1 - 0.2 in).
RCPH11WHL137BBU 15
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°C (248 °F).
RCPH11WHL138BBU 16
17. Install clutch until contact is made. Mount inner discs

onto the inner disc carrier using short left/right rota-
tions.
RAPH11WEL0120AA 17
18. Secure clutch (1) using retaining ring (2).
RAPH11WEL0129AA 18
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(248 °F).
RCPH11WHL131BBU 19
20. Mount bearing until contact is made. Adjust bearing

after it cools.
RAPH11WEL0122AA 20
21. Mount stud bolt (1), tighten torque to 17 N·m (150 lb

in). Fit rectangular ring (2).
RAPH11WEL0123AA 21
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hole (see arrow). Closing and opening of the clutch
must be clearly audible.
RAPH11WEL0123AA 22
23. Install sealing cap on orifice (1).

NOTE: Wet contact surface with LOCTITE® 262.
NOTE: The sealing cap is not mounted on all versions.
RAPH11WEL0124AA 23
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Clutch - Disassemble - Reverse clutch KR - 4 and 5 Speed - 721F

721F
CAUTION
Eye injury hazard!
C0035A
RAPH11WEL0063AA 1
Clutches K1, K2, K3, K4, KR, KV and Input
1 K1 clutch
2 K2 clutch
3 K3 clutch
4 K4 clutch
5 KR clutch
6 KV clutch
7 Input
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RAPH11WEL0071AA 2
2. Pull tapered roller bearing off the shaft with special

tool CAS2798.
RAPH11WEL0072AA 3
RAPH11WEL0073AA 4
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RCPH11WHL087BBU 5
5. Secure idler gear using a cut-off device and pull it off

the clutch shaft.
RAPH11WEL0067AA 6
RAPH11WEL0068AA 7
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RCPH11WHL091BBU 8

ring (1).
RAPH11WEL0074AA 9
9. Pull tapered roller bearing off shaft using special tool

CAS2798.
RAPH11WEL0075AA 10
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RCPH11WHL094BBU 11
carrier (3).
RCPH11WHL095BBU 12

RCPH11WHL096BBU 13
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and washer (3).
RCPH11WHL097BBU 14

disc carrier.
RCPH11WHL098BBU 15
RCPH11WHL099BBU 16
Next operation:
Clutch - Assemble — Reverse clutch KR — 4 and 5 Speed - 721F (21.155)
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Clutch - Assemble - Reverse clutch KR - 4 and 5 Speed - 721F

721F
CAUTION
Burn hazard!
C0047A
CAUTION
Eye injury hazard!
C0035A
Prior operation:
Clutch - Disassemble — Reverse clutch KR — 4 and 5 Speed - 721F (21.155)
RCPH11WHL131BBU 1

RAPH11WEL0125AA 2
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tact occurs and secure it using retaining ring (2).
RCPH11WHL090BBU 3
4. Press pre-assembled idler gear (1) onto the shaft un-

til contact occurs.
RAPH11WEL0113AA 4

ball must not jam.
RAPH11WEL0114AA 5
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RAPH11WEL0115AA 6

disc carrier.
RAPH11WEL0116AA 7
8. Mount inner installer (1) onto the disc carrier.

9. Install disc (2), compression spring (3), support shim
(4) and L-ring (5).
RCPH11WHL044BBU 8
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RCPH11WHL134BBU 9
RCPH11WHL037BBU 10
Disk carrier with piston retraction
Legend
1. washer
2. compressor spring
3. support shim
4. L-ring
5. disk carrier
6. piston with O-rings
7. drain valve (piston)
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Legend
RAPH11WEL0119AA 11
recommended value).
RCPH11WHL135BBU 12

RCPH11WHL136BBU 13
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2.95 mm (0.104 - 0.116 in).
nesses = 2.1 - 4.2 mm (0.1 - 0.2 in).
RCPH11WHL137BBU 14

°C (248 °F).
RCPH11WHL138BBU 15
16. Install clutch until contact is made. Mount inner discs

onto the inner disc carrier using short left/right rota-
tions.
RAPH11WEL0120AA 16
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17. Secure clutch (1) using retaining ring (2).
RAPH11WEL0129AA 17

(248 °F).
RCPH11WHL131BBU 18

after it cools.
RAPH11WEL0122AA 19
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20. Mount stud bolt (1), tighten torque to 17 N·m (150 lb

in). Fit rectangular ring (2).
RAPH11WEL0123AA 20

RAPH11WEL0123AA 21
22. Install sealing cap on orifice (1).

NOTE: Wet contact surface with LOCTITE® 262.
NOTE: The sealing cap is not mounted on all versions.
RAPH11WEL0124AA 22
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Clutch - Disassemble - First gear clutch K1 – 4 and 5 Speed - 721F

721F
CAUTION
Eye injury hazard!
C0035A
RAPH11WEL0063AA 1
Clutches K1, K2, K3, K4, KR, KV, and Input
1 K1 clutch
2 K2 clutch
3 K3 clutch
4 K4 clutch
5 KR clutch
6 KV clutch
7 Input
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RAPH11WEL0076AA 2

tool CAS2798.
RAPH11WEL0077AA 3
RAPH11WEL0078AA 4
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RAPH11WEL0079AA 5
RAPH11WEL0080AA 6
6. Pull clutch off the shaft
RCPH11WHL087BBU 7
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ring (1).
RAPH11WEL0081AA 8

CAS2798
RAPH11WEL0082AA 9
RCPH11WHL094BBU 10
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carrier (3).
RCPH11WHL095BBU 11

RCPH11WHL096BBU 12
12. Remove cup spring package.
RAPH11WEL0090AA 13
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disc carrier.
RCPH11WHL098BBU 14
RCPH11WHL099BBU 15
Next operation:
Clutch - Assemble — First gear clutch K1 — 4 and 5 Speed - 721F (21.155)
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Clutch - Assemble - First gear clutch K1 - 4 and 5 Speed - 721F

721F
CAUTION
Burn hazard!
C0047A
CAUTION
Eye injury hazard!
C0035A
Prior operation:
Clutch - Disassemble — First gear clutch K1 – 4 and 5 Speed - 721F (21.155)
RCPH11WHL131BBU 1

RAPH11WEL0130AA 2
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ball must not jam.
RAPH11WEL0114AA 3

RAPH11WEL0115AA 4

disc carrier.
RAPH11WEL0116AA 5
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6. Mount inner installer (1) onto the disc carrier. Install

cup spring package (2) and L-ring (2).
NOTE: For installation position of cup spring package,
L-ring and inner installer, follow the next two steps.
RAPH11WEL0131AA 6
7. Preload cup spring package using special tool

RCPH11WHL134BBU 7
8. Disc carrier with piston retraction.

Legend
• (1) cup spring package
• (2) L-ring
• (4) disc carrier
RAPH11WEL0132AA 8
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RAPH11WEL0133AA 9
recommended value).
RCPH11WHL135BBU 10

RCPH11WHL136BBU 11
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2.65 mm (0.093 - 0.104 in).
NOTE: In case of deviations, the disc clearance must be
nesses = 2.1 - 4.2 mm (0.1 - 0.2 in).
RCPH11WHL137BBU 12

°C (248 °F).
RCPH11WHL138BBU 13
14. Install clutch until contact is made.

RAPH11WEL0134AA 14
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15. Mount running disc (1), axial cage (2) and axial
washer (3) and oil it.
NOTE: Install chamfer (see arrow) of running disc (1)
RAPH11WEL0135AA 15
16. Mount needle bearing (1) and oil it.
RAPH11WEL0136AA 16
17. Install idler (1). Mount inner discs onto the inner disc
carrier (idler) by using short left/right rotations.
RAPH11WEL0137AA 17
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disc (3) and oil it.
RAPH11WEL0138AA 18
19. Secure idler gear (1) and single parts using a retain-
ing ring (2).
RAPH11WEL0139AA 19

(248 °F).
RCPH11WHL131BBU 20
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ing after it cools.
RAPH11WEL0140AA 21
22. Mount stud bolt (1) and torque to 17 N·m (150 lb in).
Fit rectangular ring (2).
RAPH11WEL0141AA 22

RAPH11WEL0141AA 23
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Clutch - Disassemble - Second gear clutch K2 - 4 and 5 Speed - 721F

721F
CAUTION
Eye injury hazard!
C0035A
RAPH11WEL0063AA 1
1 K1 clutch
2 K2 clutch
3 K3 clutch
4 K4 clutch
5 KR clutch
6 KV clutch
7 Input
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RAPH11WEL0083AA 2

tool CAS2798.
RAPH11WEL0084AA 3
RAPH11WEL0085AA 4
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RAPH11WEL0086AA 5
5. Take off idler gear (1) , remove needle cage (2) and
RAPH11WEL0087AA 6
RCPH11WHL087BBU 7
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ring (1).
RAPH11WEL0088AA 8

CAS2798.
RAPH11WEL0089AA 9
RCPH11WHL094BBU 10
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carrier (3).
RCPH11WHL095BBU 11

RCPH11WHL096BBU 12
RAPH11WEL0090AA 13
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disc carrier.
RCPH11WHL098BBU 14
RCPH11WHL099BBU 15
Next operation:
Clutch - Assemble — Second gear clutch K2 — 4 and 5 Speed - 721F (21.155)
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Clutch - Assemble - Second gear clutch K2 - 4 and 5 Speed - 721F

721F
CAUTION
Burn hazard!
C0047A
CAUTION
Eye injury hazard!
C0035A
Prior operation:
Clutch - Disassemble — Second gear clutch K2 — 4 and 5 Speed - 721F (21.155)
RCPH11WHL131BBU 1

RAPH11WEL0142AA 2
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ball must not jam.
RAPH11WEL0114AA 3

RCPH11WHL098BBU 4

disc carrier.
RAPH11WEL0116AA 5
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RAPH11WEL0143AA 6

RCPH11WHL134BBU 7
8. Disc carrier with piston retraction:

1. Cup spring package
2. L-Ring
3. Piston with O-rings
4. Disc carrier
RAPH11WEL0132AA 8
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Legend
RCPH11WHL269BBU 9
recommended value).
RCPH11WHL135BBU 10

RCPH11WHL136BBU 11
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2.05 mm (0.07 - 0.08 in).
nesses = 2.1 - 4.2 mm (0.1 - 0.2 in).
RCPH11WHL137BBU 12

°C (248 °F).
RCPH11WHL138BBU 13

RAPH11WEL0145AA 14
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RAPH11WEL0146AA 15
16. Mount needle bearing cage (1) and oil it.
RAPH11WEL0147AA 16
17. Install (1) idler. Mount inner discs onto the inner discs
RAPH11WEL0148AA 17
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RAPH11WEL0146AA 18
19. Secure idler gear (1) and single parts using retaining
ring (2).
RAPH11WEL0149AA 19

(248 °F).
RCPH11WHL131BBU 20
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ing after it cools.
RAPH11WEL0150AA 21
22. Mount stud bolt (1), torque to 17 N·m (150 lb in). Fit
RAPH11WEL0151AA 22

RAPH11WEL0151AA 23
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Clutch - Disassemble - Third gear clutch K3 - 4 and 5 Speed – 721F

721F
CAUTION
Eye injury hazard!
C0035A
RAPH11WEL0063AA 1
1 K1 clutch
2 K2 clutch
3 K3 clutch
4 K4 clutch
5 KR clutch
6 KV clutch
7 Input
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1. Snap out piston ring (1).
RCPH11WHL062BBU 2

tool CAS2798.
RAPH11WEL0092AA 3
RAPH11WEL0093AA 4
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RAPH11WEL0094AA 5
RAPH11WEL0095AA 6
RAPH11WEL0096AA 7
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CAS2798.
RAPH11WEL0097AA 8
RCPH11WHL094BBU 9
carrier (3).
RCPH11WHL095BBU 10
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RCPH11WHL096BBU 11
RAPH11WEL0090AA 12

disc carrier.
RCPH11WHL098BBU 13
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RCPH11WHL099BBU 14
Next operation:
Clutch - Assemble — Third gear clutch K3 — 4 and 5 Speed - 721F (21.155)
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Clutch - Assemble - Third gear clutch K3 - 4 and 5 Speed - 721F

721F
CAUTION
Burn hazard!
C0047A
CAUTION
Eye injury hazard!
C0035A
Prior operation:
Clutch - Disassemble — Third gear clutch K3 — 4 and 5 Speed – 721F (21.155)
RCPH11WHL131BBU 1

3. Mount stud bolt and torque to 17 N·m (150 lb in).
RAPH11WEL0152AA 2
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ball must not jam.
RAPH11WEL0114AA 3

RCPH11WHL098BBU 4

disc carrier.
RAPH11WEL0116AA 5
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RAPH11WEL0131AA 6

RCPH11WHL134BBU 7

Legend
• (1) Cup spring package
• (2) L-Ring
• (3) Disc carrier
• (4) Piston with O-rings
RAPH11WEL0132AA 8
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Legend
RCPH11WHL269BBU 9
recommended value).
RCPH11WHL135BBU 10

RCPH11WHL136BBU 11
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ring and read disc clearance. Disc clearance: 1.75
mm (0.069 in) to 2.05 mm (0.081 in).
nesses = 2.1 - 4.2 mm (0.1 - 0.2 in).
RCPH11WHL137BBU 12

°C (248 °F).
RCPH11WHL138BBU 13
15. Mount clutch (1) until contact is made.

RAPH11WEL0154AA 14
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RAPH11WEL0155AA 15
RAPH11WEL0156AA 16
18. Install (1) idler. Mount inner discs onto the inner discs
RAPH11WEL0157AA 17
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RAPH11WEL0158AA 18
20. Make sure that the running disc is flush with the shaft
collar (see arrow) to ensure that all inner discs are
mounted on the idler gear teeth.
RAPH11WEL0159AA 19

(248 °F).
RCPH11WHL131BBU 20
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RAPH11WEL0160AA 21

RAPH11WEL0161AA 22
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Clutch - Disassemble - Fourth gear clutch K4 - 4 and 5 Speed - 721F

721F
CAUTION
Eye injury hazard!
C0035A
RAPH11WEL0063AA 1
1 K1 clutch
2 K2 clutch
3 K3 clutch
4 K4 clutch
5 KR clutch
6 KV clutch
7 Input
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RAPH11WEL0098AA 2

tool CAS2798.
RAPH11WEL0099AA 3
RAPH11WEL0100AA 4
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RCPH11WHL122BBU 5
5. Remove axial bearing assembly (1) and idler gear

(2).
RAPH11WEL0101AA 6
6. Remove needle cage (1) and axial bearing assembly

(2).
NOTE: The gear (3) cannot be removed, it is a shrink fit.
RAPH11WEL0102AA 7
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7. Turn shaft (2) by a 180 ° degrees and snap out piston

ring (1).
RAPH11WEL0103AA 8

CAS2798.
RAPH11WEL0104AA 9
RCPH11WHL094BBU 10
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carrier (3).
RCPH11WHL095BBU 11

RCPH11WHL096BBU 12
RAPH11WEL0090AA 13
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disc carrier.
RCPH11WHL098BBU 14
RCPH11WHL099BBU 15
Next operation:
Clutch - Assemble — Fourth gear clutch K4 — 4 and 5 Speed – 721F (21.155)
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Clutch - Assemble - Fourth gear clutch K4 - 4 and 5 Speed – 721F

721F
CAUTION
Burn hazard!
C0047A
CAUTION
Eye injury hazard!
C0035A
Prior operation:
Clutch - Disassemble — Fourth gear clutch K4 — 4 and 5 Speed - 721F (21.155)
RCPH11WHL131BBU 1

RAPH11WEL0163AA 2
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3. Cool shaft (1) to approximately -80 °C (-112 °F), heat

gear (2) to approximately + 120 °C (248 °F) and
mount until contact is made.
RAPH11WEL0164AA 3
4. Secure gear using retaining ring.
RAPH11WEL0165AA 4
5. Mount lower axial washer (1), axial needle cage (2)

and upper axial washer (3) and oil it.
NOTE: Upper and lower axial washers are identical.
RCPH11WHL270BBU 5
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RCPH11WHL271BBU 6
7. Mount idler gear.
RCPH11WHL272BBU 7
8. Mount axial washer (1), axial needle bearing (2) and

running disc (3) and oil it.
NOTE: Mount running disc (3) with the chamfer (see arrow)
pointing to the needle cage.
RCPH11WHL273BBU 8
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ball must not jam.
RAPH11WEL0114AA 9

RCPH11WHL098BBU 10

disc carrier.
RAPH11WEL0116AA 11
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RAPH11WEL0131AA 12

RCPH11WHL134BBU 13

Legend
1. Cup spring package
2. L-Ring
3. Disc carrier
4. Piston with O-rings
RAPH11WEL0132AA 14
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Legend
• (4) Disc carrier
RAPH11WEL0162AA 15
recommended value).
RCPH11WHL135BBU 16

RCPH11WHL136BBU 17
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1.65 mm (0.053 - 0.065 in).
nesses = 2.1 - 4.2 mm (0.1 - 0.2 in).
RCPH11WHL137BBU 18

°C (248 °F).
RCPH11WHL138BBU 19
20. Mount clutch (1) until contact is made. Mount inner

discs onto the inner disc carrier using short left/right
rotations.
RAPH11WEL0167AA 20
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21. Secure clutch using retaining ring.
RAPH11WEL0100AA 21

(248 °F).
RCPH11WHL131BBU 22

24. Mount stud bolt (3). Torque to 17 N·m (150 lb in).
RAPH11WEL0166AA 23
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RAPH11WEL0166AA 24
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Clutch - Disassemble - Input shaft - 4 and 5 Speed – 721F

721F
1. Snap out piston ring (1).

NOTE: Turbine wheel shaft and drive gear (2) are secured
by a snap ring. When separated, the snap ring will be de-
stroyed.
RCPH11WHL126BBU 1
2. Pull tapered roller bearing off drive gear using special

tool CAS2798.
RAPH11WEL0106AA 2
3. Pull tapered roller bearing off drive gear using special

tool CAS2798.
NOTE: It is not possible to separate the input shaft and
gear (1). It is a shrink fit.
RAPH11WEL0107AA 3
Next operation:
Clutch - Assemble — Input shaft — 4 and 5 Speed - 721F (21.155)
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Clutch - Assemble - Input shaft - 4 and 5 Speed - 721F

721F
CAUTION
Burn hazard!
C0047A
Prior operation:
Clutch - Disassemble — Input shaft — 4 and 5 Speed – 721F (21.155)
1. Cool input shaft (1) to approximately -80 °C (-112 °F),

heat gear (2) to approximately + 120 °C (248 °F) and
mount until contact is made.
RCPH11WHL076BBU 1
2. Secure drive gear using retaining ring.
RAPH11WEL0170AA 2
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RCPH11WHL131BBU 3
4. Mount bearing inner ring until contact is made. Ad-

just bearing after it cools.
RAPH11WEL0171AA 4
RCPH11WHL131BBU 5
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after it cools.
RAPH11WEL0172AA 6
7. Install snap ring (1) into the annular groove of the

turbine shaft (2).
RCPH11WHL080BBU 7

into the input shaft groove. Snap in and interlock
NOTE: Turbine shaft is axially secured.
RAPH11WEL0173AA 8
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Version with lock-up clutch

into the input shaft groove. Snap in and interlock
rectangular rings (2) and (3).
NOTE: Turbine shaft is axially secured.
RCPH11WHL274BBU 9
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Clutch - Disassemble - Output shaft - 4 and 5 Speed – 721F

721F
1. Pull tapered roller bearing off of output shaft using

special tool CAS2798 and remove oil sheet (1).
RAPH11WEL0108AA 1
2. Turn output shaft by a 180 ° and pull off tapered roller

bearing using special tool CAS2798.
RAPH11WEL0109AA 2
Next operation:
Clutch - Assemble — Output shaft — 4 and 5 Speed – 721F (21.155)
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Clutch - Assemble - Output shaft - 4 and 5 Speed – 721F

721F
CAUTION
Burn hazard!
C0047A
Prior operation:
Clutch - Disassemble — Output shaft — 4 and 5 Speed – 721F (21.155)
1. Heat bearing inner ring to approximately 120 °C (248

°F).
RCPH11WHL131BBU 1
2. Mount bearing inner ring until contact is made. Ad-

just bearing after it cools.
RAPH11WEL0174AA 2
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3. Mount screen sheet.
RAPH11WEL0175AA 3
4. Heat bearing inner ring to approximately 120 °C (248

°F).
RCPH11WHL131BBU 4

after it cools.
RAPH11WEL0176AA 5
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Index
Transmission - 21

Clutch - Assemble - Second gear clutch K2 - 4 and 5 Speed - 721F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
721F
Clutch - Assemble - Third gear clutch K3 - 4 and 5 Speed - 721F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
721F
Clutch - Assemble - First gear clutch K1 - 4 and 5 Speed - 721F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
721F
Clutch - Assemble - First gear clutch K1 – 621F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
621F
Clutch - Assemble - Forward clutch KV - 4 and 5 Speed - 721F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
721F
Clutch - Assemble - Forward clutch KV - 621F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
621F
Clutch - Assemble - Fourth gear clutch K4 - 4 and 5 Speed – 721F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
721F
Clutch - Assemble - Fourth gear clutch K4 - 621F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
621F
Clutch - Assemble - Input shaft - 4 and 5 Speed - 721F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
721F
Clutch - Assemble - Input shaft - 621F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
621F
Clutch - Assemble - Output shaft - 4 and 5 Speed – 721F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
721F
Clutch - Assemble - Output shaft - 621F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
621F
Clutch - Assemble - Reverse clutch KR - 4 and 5 Speed - 721F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
721F
Clutch - Assemble - Reverse clutch KR - 621F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
621F
Clutch - Assemble - Second gear clutch K2 - 621F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
621F
Clutch - Assemble - Third gear clutch K3 - 621F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
621F
Clutch - Disassemble - First gear clutch K1 – 4 and 5 Speed - 721F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
721F
Clutch - Disassemble - Output shaft - 4 and 5 Speed – 721F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
721F
Clutch - Disassemble - Reverse clutch KR - 4 and 5 Speed - 721F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
721F
Clutch - Disassemble - First gear clutch K1 - 621F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
621F
Clutch - Disassemble - Forward clutch KV - 621F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
621F
Clutch - Disassemble - Forward clutch KV – 4 and 5 Speed - 721F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
721F
Clutch - Disassemble - Fourth gear clutch K4 - 4 and 5 Speed - 721F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
721F
Clutch - Disassemble - Fourth gear clutch K4 - 621F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
621F
Clutch - Disassemble - Input shaft - 4 and 5 Speed – 721F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
721F
Clutch - Disassemble - Input shaft - 621F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
621F
Clutch - Disassemble - Output shaft - 621F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
621F
Clutch - Disassemble - Reverse clutch KR - 621F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
621F
Clutch - Disassemble - Second gear clutch K2 - 4 and 5 Speed - 721F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
721F
Clutch - Disassemble - Second gear clutch K2 - 621F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
621F
Clutch - Disassemble - Third gear clutch K3 - 4 and 5 Speed – 721F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
721F
Clutch - Disassemble - Third gear clutch K3 - 621F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
621F
Clutch - Dynamic description – Transmission Clutch Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
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PRINTED IN U.S.A.
84605841 14/05/2012
EN
SERVICE MANUAL
Four-Wheel Drive (4WD) system
621F
721F
84605841 14/05/2012
23
Contents
Four-Wheel Drive (4WD) system - 23
Drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23.314

621F , 721F
84605841 14/05/2012
23
CONSUMABLES INDEX
Consumable IU PAGE
Loctite® 242 Shaft support - Install - Carrier Bearing 23.314 / 13
84605841 14/05/2012
23
84605841 14/05/2012
23
Drive shaft - 314
621F
721F
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23.314 / 1
Contents
Drive shaft - 314
TECHNICAL DATA
Drive shaft
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
Shaft support
Remove - Carrier Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Install - Carrier Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Drive shaft universal joint
Disassemble - Universal Joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Assemble - Universal Joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
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23.314 / 2
CONSUMABLES INDEX
Consumable IU PAGE
Loctite® 242 Shaft support - Install - Carrier Bearing 23.314 / 13
84605841 14/05/2012
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)
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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
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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)
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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
end of the front drive shaft.
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.
84605841 14/05/2012
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
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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)
84605841 14/05/2012
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
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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
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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)
84605841 14/05/2012
23.314 / 12
Shaft support - Install - Carrier Bearing

Prior operation:
Drive shaft - Remove — Carrier Bearing (23.314)
NOTE: The center bearing and the bearing housing are not serviced separately. If the center bearing is worn or
damaged or if the bearing housing is cracked, a new center bearing and bearing housing must be used.
1. Apply antiseize compound to the bearing area of the
front drive shaft.
2. Install the bearing housing so that the lubrication 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.
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23.314 / 13
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.
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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)
84605841 14/05/2012
23.314 / 15
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.
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Index
Drive shaft - 314

Drive shaft - Install - Front Drive Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Drive shaft - Remove - Front Drive Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Drive shaft - Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Drive shaft universal joint - Assemble - Universal Joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Drive shaft universal joint - Disassemble - Universal Joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Front drive shaft - Install - Center Drive Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Front drive shaft - Remove - Center Drive Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Shaft support - Install - Carrier Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Shaft support - Remove - Carrier Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
84605841 14/05/2012
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PRINTED IN U.S.A.
84605841 14/05/2012
EN
SERVICE MANUAL
Front axle system
621F
721F
84605841 14/05/2012
25
Contents
Front axle system - 25
Powered front axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.100

621F , 721F
Front bevel gear set and differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.102

621F , 721F
Final drive hub, steering knuckles, and shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.108

621F , 721F
84605841 14/05/2012
25
CONSUMABLES INDEX
Consumable IU PAGE
Loctite® 262 Differential - Remove - Models MT-L 3065 II / MT-L 3075 II 25.102 / 22
Loctite® 262 Differential - Install - Models MT-L 3065 II / MT-L 3075 II 25.102 / 25
Loctite® 262 Differential - Install Models MT-L 3085 II / MT-L 3095 II 25.102 / 36
Loctite® 574 Wheel hub - Assemble - MT-L 3065 II / MT-L 3075 II 25.108 / 16
Terostat® MS-9360 Wheel hub - Assemble - MT-L 3065 II / MT-L 3075 II 25.108 / 22
Terostat® MS-9360 Wheel hub - Assemble - Models MT-L 3085 II / MT-L 3095 II 25.108 / 46
84605841 14/05/2012
25
84605841 14/05/2012
25
Powered front axle - 100
621F
721F
84605841 14/05/2012
25.100 / 1
Contents
FUNCTIONAL DATA
Powered front axle

External view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SERVICE
Powered front axle

Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
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Front axle system - Powered front axle
Powered front axle - External view
BS03B151 1
(1) Washer (4) Washer

(2) Bolt (5) Front Axle
(3) Nut
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25.100 / 3
Powered front axle - Remove

1. Park machine on level surface. Have assistant put
articulation lock in LOCKED position.
BD03A040-01 1
2. Raise bucket and have assistant install safety link.

Lower loader arms slowly until safety link is support-
ing loader arms.
BD03A092-01 2
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 four bolts (2) and two straps (1) securing
front drive shaft (3) to front axle.
BD03A167-01 3
84605841 14/05/2012
25.100 / 4
5. Remove clamp securing lubrication hose (1) to ma-

chine and nut securing opposite end of hose (1). Re-
move four bolts (5) and two straps (6) securing cen-
ter drive shaft (7) to front drive shaft (3). Use a pry
bar to separate drive shafts. While supporting cen-
ter bearing (4) and front drive shaft (3), remove four
nuts and bolts (2) and eight washers. Lower center
bearing and front drive shaft from mounting plate and
remove from machine.
BD03A166-01 4
6. Disconnect brake hose (1) from elbow (2). Remove

and discard O-ring face seal from elbow.
BD03A168-01 5
7. For machines with brake damping accumulators, dis-

connect brake line from elbow at axle connection. re-
move and discard O-ring face seal from elbow. To
remove accumulator, also disconnect brake line and
hose from accumulator. Unbolt accumulator from
machine frame.
RAPH12WEL0209AA 6
NOTE: 721F machines with heavy duty axles are equipped with brake damping accumulators.
84605841 14/05/2012
25.100 / 5
8. If equipped, disconnect differential lock hose.
RAPH12WEL0210AA 7
NOTE: Locking front differential is available on 721F machines equipped with heavy duty axles.
9. Using an acceptable hydraulic jack, raise one tire
from ground
BD01F298-01 8
10. Install an acceptable jack stand under machine.
BD01D392-01 9
11. Repeat Step 9 to 10 to raise other front axle tire from

ground.
84605841 14/05/2012
25.100 / 6
12. Use an acceptable jack to hold front axle.
BD01F297-01 10
13. Remove bolts and washers from front wheels . Re-

move both wheels from front axle.
BD01F295-01 11
14. Remove 4 nuts (3) bolts (1), and 8 washers (2) from
each side securing front axle to machine.
BD01F296-01 12
15. Carefully lower front axle and remove from under ma-
chine.
Next operation:
Powered front axle - Install (25.100)
84605841 14/05/2012
25.100 / 7
Powered front axle - Install

Prior operation:
Powered front axle - Remove (25.100)
1. Carefully move front axle under machine and raise

against mounting pads on machine.
2. Apply one drop of engine oil to threads prior to as-
sembly. Install four washers on the top side (2), four
bolts (1), four washers on the bottom side, and four
nuts (3) on each side of the axle to secure front axle
to machine. Tighten bolts to a torque of 765 - 855
Nm (564 - 631 lb ft).
BD01F296-01 1
3. Install both wheels on front axle and secure using

washers and bolts.
BD01F295-01 2
4. Tighten bolts to a preliminary torque of 278 Nm ( 205

lb.ft) in sequence indicated; then tighten to a torque
of 640 - 720 Nm ( 475 - 530 lb.ft) in same sequence.
b0987a88 3
84605841 14/05/2012
25.100 / 8
5. Remove jack from front axle.
BD01F297-01 4
6. Using an acceptable hydraulic jack, raise axle
BD01F298-01 5
7. Remove jack stand from under machine.
BD01D392-01 6
8. Repeat Step 6 to 7 to remove other jack stand from

under machine.
84605841 14/05/2012
25.100 / 9
9. Install a new O-ring face seal in elbow (1). Connect

brake hose (2) to elbow.
BD03A168-01 7
NOTE: 721F machines with heavy duty axles are equipped with brake damping accumulators.
10. For machines with brake damping accumulators, in-
stall a new O-ring face seal and connect brake line
to elbow at axle connection. If accumulator has been
removed, bolt accumulator to machine frame and
connect brake line and hose to accumulator.
RAPH12WEL0209AA 8
11. If equipped, connect differential lock hose.
RAPH12WEL0210AA 9
NOTE: Locking front differential is available on 721F machines equipped with heavy duty axles.
84605841 14/05/2012
25.100 / 10
12. Position and support center bearing (5) and front

drive shaft (4) and install eight washers and four bolts
(3) and nuts. Tighten bolts (3) to a torque of 99 - 128
Nm ( 73 - 94 lb.ft). Install two straps (6) and four
bolts (5). Tighten bolts (5) to a torque of 61 - 81 Nm (
45 - 60 lb.ft). Secure lubrication hose (4) to machine
using clamp; secure opposite end of hose using nut.
BD03A166-01 10
13. Secure drive shaft (3) to front axle using two straps
(1) and four bolts (2). Tighten bolts (1) to a torque of
61 - 81 Nm ( 45 - 60 lb.ft).
BD03A167-01 11
14. If necessary, fill axle with gear lubricant specified in

Capacities.
15. See front axle filling Powered front axle - Filling
(25.100).
16. Refer to Hydraulic service brakes - Bleed (33.202)
and bleed brakes.
17. Start engine and raise bucket. Have assistant re-
move safety link. Lower bucket to ground and stop
engine.
BD03A092-01 12
18. Put articulation lock in OPERATING position.
84605841 14/05/2012
25.100 / 11
Index

Powered front axle - External view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Powered front axle - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Powered front axle - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
84605841 14/05/2012
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Front bevel gear set and differential - 102
621F
721F
84605841 14/05/2012
25.102 / 1
Contents
SERVICE
Bevel gear set and differential carrier

Backlash - Models MT-L 3065 II / MT-L 3075 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
621F
Backlash - Models MT-L 3085 II / MT–L 3095 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

721F
Differential
Remove - Models MT-L 3065 II / MT-L 3075 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
621F
Install - Models MT-L 3065 II / MT-L 3075 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

621F

721F
Install Models MT-L 3085 II / MT-L 3095 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

721F
Limited slip differential

Disassemble - DZ-1200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
621F
Assemble - DZ-1200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
621F
Disassemble - DL-2400 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
721F
Assemble - DL-2400 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
721F
Differential lock
Disassemble - DHL-1200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
621F
Assemble - DHL-1200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
621F
Disassemble - DHL-2400 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
721F
Assemble - DHL-2400 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
721F
84605841 14/05/2012
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CONSUMABLES INDEX
Consumable IU PAGE
84605841 14/05/2012
25.102 / 3
Front axle system - Front bevel gear set and differential
Bevel gear set and differential carrier - Backlash - Models MT-L

3065 II / MT-L 3075 II
621F
CAUTION
Burn hazard!
C0047A
Prior operation:
Limited slip differential - Assemble — DZ-1200 (25.102)
Prior operation:
Differential lock - Assemble - DHL-1200 (25.102)
1. Determine shim thickness to obtain a correct contact

pattern. Read dimension I (arrow) from the axle drive
housing. Dimension I example is 182.8 mm (7.197
in).
RAIL11WEL0505BA 1
NOTE: If crown wheel or input pinion are damaged, both parts must be replaced together. In the case of a new
installation of a complete bevel gear set, pay attention to an identical mating number of input pinion and crown wheel.
NOTE: The following measuring procedures must be carried out accurately. Inaccurate measurements will lead to an
incorrect contact patter requiring additional disassembly and reassembly of input pinion and differential.
2. Read dimension II (pinion dimension). Dimension II
example is 148 mm (5.827 in).
RAIL11WEL0506BA 2
NOTE: A pinion dimension without + or — deviation value = 148 mm (5.827 in). A pinion dimension with an indication
of +0.1 deviation = 148.1 mm (5.831 in). A pinion dimension with an indiction of —0.1 deviation = 147.9 mm (5.823
in).
84605841 14/05/2012
25.102 / 4
3. Determine dimension III (bearing width). Dimension

II example = 33.6 mm (1.323 in).
RAIL11WEL0507BA 3
NOTE: Calculation Example “A”. Dimension I = 182.8 mm (7.197 in). Dimension II = 148 mm (5.827 in). Dimension
III = 33.6 mm (1.323 in). Difference = shim s = 1.2 mm (0.047 in).
4. Insert the correct shim into the housing hole. Exam-
ple = 1.2 mm (0.047 in).
RAIL11WEL0508BA 4
5. Cool the internal bearing outer ring and insert it into

the housing using assembly special tool.
RAIL11WEL0509BA 5
84605841 14/05/2012
25.102 / 5
6. Cool the external bearing outer ring and insert it into

RAIL11WEL0510BA 6
7. Heat the tapered roller bearing and place it on the

input pinion.
RAIL11WEL0511BA 7
8. Set the rolling torque of the input bearing to 1.0 - 5.0

N·m (9 - 44 lb in) without the shaft seal. To do this,
insert spacer example spacer is 8.7 mm (0.343 in).
RAIL11WEL0512BA 8
NOTE: Based on experience, the necessary rolling torque is reached when reusing the spacer that was removed
during disassemble. Spacer example is 8.7 mm (0.343 in). Checking input pinion bearing rolling torque is a must.
84605841 14/05/2012
25.102 / 6
9. Insert the preassembled input pinion into the axle

drive housing and insert the heated tapered roller
bearing until correct fit is obtained.
RAIL11WEL0513BA 9
10. Press the protection plate onto the input flange (see
arrow) until contact is made.
RAIL11WEL0514BA 10
NOTE: Do not fit the shaft seal until the contact pattern has been checked.
11. Insert the input flange and secure it using the disk
and hex nut. Torque to 700 N·m (516 lb ft).
NOTE: Do not use Loctite during preliminary mounting of
hex nut.
NOTE: While tightening the hex nut, rotate the input pinion
several times in both directions.
RAIL11WEL0515BA 11
12. Check rolling torque without shaft seal in place.

Rolling torque should be 1 - 5 N·m (9 - 44 lb in).
NOTE: When installing new bearings, try to reach the up-
per value of the rolling torque.
NOTE: In the case of rolling torque deviations, correct with
a different spacer. Insufficient rolling torque requires a thin-
ner spacer ring. Excessive rolling torque requires a thicker
spacer ring.
RAIL11WEL0516BA 12
84605841 14/05/2012
25.102 / 7
13. Determine the correct shims for setting the bear-

ing rolling torque (differential housing) and backlash
(bevel gear set). Select the shims based on the read
value (deviation/test dimension) and corresponding
specifications of the table below: (KRS — SET —
RIGHT) (KRS = bevel gear set). See the crown
wheel rear side for deviation. The test dimension
“77” is stamped into the crown wheel rear side. If no
+ or — deviation is indicated, this value corresponds
to the actual value “0” in the table below. Accord-
ing to this value, the required shims are allocated in
the table below. Any + or — deviation of the test di-
mension caused by production is also marked on the
crown wheel rear side (example —20 or — 10 or 10).
In accordance with this deviation, the required shims
are allocated in the table below. RAIL11WEL0517BA 13
14. Legend for sketch

1. Axle housing
2. Shim (crown wheel side)
3. Shim (differential carrier side)
4. Axle housing
RAIL11WEL0593BA 14
Shims for differential D / DZ and DHL — 1200 in MT-L 3065 / 3075 II Axles
Crown wheel marking —20 —10 — 10
Deviation —0.2 —0.1 0 0.1
Shim Differential cage 0.7 0.8 0.9 1.0
side shim thickness
Shim Crown wheel 1.3 1.2 1.1 1.0
side shim thickness
15. Insert the determined shim (example s = 0.9 mm

(0.035 in)) into the hole of the axle housing and ad-
just the bearing outer ring (see arrow) until contact is
obtained.
RAIL11WEL0518BA 15
84605841 14/05/2012
25.102 / 8
16. Cover some drive and coast flanks of the crown

wheel with marking ink. Then insert the premounted
differential into the axle drive housing using a suit-
RAIL11WEL0519BA 16
17. Grease both O-rings (arrows) and insert them into

the annular grooves of the piston.
NOTE: This operation only necessary for axle with locking
differential DHL.
RAIL11WEL0520BA 17
18. Insert the piston into the bearing housing.

differential DHL.
RAIL11WEL0521BA 18
19. Insert the selected shim (example s = 1.1 mm (0.043

in)) into the hole of the axle housing and adjust the
bearing outer ring (see arrow) until contact is made.
RAIL11WEL0522BA 19
84605841 14/05/2012
25.102 / 9
20. Connect the axle housing with the axle drive housing
using a suitable lifting device and secure them using
hex bolts. Torque bolts to 390 N·m (288 lb ft).
RAIL11WEL0523BA 20
21. Leak test the differential lock. Pressurize the lock to

1 bar (15 psi), close the shut-off valve and remove
air line. There should be no pressure loss within 10
seconds.
differential DHL.
RAIL11WEL0524BA 21
22. Rotate the input flange in both directions several

times to roll the crown wheel over the pinion. Then
remove the axle housing and lift the differential out
of the axle drive housing . Compare the observed
contact pattern with the contact pattern 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 by recalculating the shim size.
RAIL11WEL0525BA 22
Next operation:
Differential - Install — Models MT-L 3065 II / MT-L 3075 II (25.102)
84605841 14/05/2012
25.102 / 10
Bevel gear set and differential carrier - Backlash - Models MT-L

3085 II / MT–L 3095 II
721F
CAUTION
Burn hazard!
C0047A
Prior operation:
Limited slip differential - Assemble — DL-2400 (25.102)
Prior operation:
Differential lock - Assemble — DHL-2400 (25.102)
1. Determine the shim thickness to obtain a correct con-

tact pattern. Read dimension I from axle drive hous-
ing (1) . Dimension I e.g. 221.10 mm (8.705 in)
NOTE: If crown wheel or input pinion are damaged, both
parts must be replaced together. When installing a com-
plete new bevel gear set, look for identical mating number
of input pinion and crown wheel.
NOTE: Measuring procedures must be done accurately.
Inaccurate measurements lead to incorrect contact pattern
requiring additional disassembly and reassembly of input
pinion and differential.
RAIL11WEL0349BA 1
2. Read dimension II from pinion (1) . Dimension II e.g.

181.00 mm (7.126 in).
RAIL11WEL0350BA 2
84605841 14/05/2012
25.102 / 11

III e.g. 39.10 mm (1.539 in).
RAIL11WEL0351BA 3
Calculation Example “A”:

Dimension I: -39.10 (1.54 in)
Dimension II: -181.00 (7.13 in)
Dimension III: -39.10 (1.54 in)
Difference = shim s = 1.00 mm (0.04 in)
4. Cool external bearing and insert it into axle drive

housing until contact is made.
RAIL11WEL0352BA 4
5. Insert shim into housing hole size e.g. s = 1.00 mm

(0.039 in).
RAIL11WEL0353BA 5
84605841 14/05/2012
25.102 / 12
6. Cool internal bearing outer ring and bring it into con-

tact position in housing hole using 380100001 bear-
ing cup installer tool.
RAIL11WEL0354BA 6
7. Heat tapered roller bearing and insert it into input

pinion until contact is made.
RAIL11WEL0355BA 7
8. Set the rolling torque of the input pinion bearing (with-

out shaft seal) to 1.5 - 3.0 N·m (13 - 27 lb in). Insert
spacer e.g. s = 8.18 mm (0.322 in).
NOTE: Based on experience, necessary rolling torque is
obtained by reusing the spacer removed during disassem-
bly e.g. s = 8.18 mm (0.322 in).
NOTE: A later check of rolling torque is needed.
RAIL11WEL0356BA 8
84605841 14/05/2012
25.102 / 13
9. Insert pre-assembled input pinion into axle drive

housing. Insert heated tapered roller bearing until
contact is made.
RAIL11WEL0357BA 9
10. Press protection plate onto input flange until contact

is made.
NOTE: Do not fit shaft seal until contact pattern has been
checked and verified.
RAIL11WEL0358BA 10
11. Insert input flange and secure it with disk and slotted
nut. Torque to 1200 N·m (885 lb ft). Use CAS2842
slotted nut wrench and 380001546 flange holder.
NOTE: Temporarily mount slotted nut without Loctite.
While tightening, rotate input pinion several times in both
directions.
RAIL11WEL0359BA 11
84605841 14/05/2012
25.102 / 14
12. Check rolling torque. It should be 1.5 - 3.0 N·m (13 -

27 lb in) without a shaft seal.
NOTE: When installing new bearings try to achieve upper
value of rolling torque.
NOTE: In cases of rolling torque measurement deviations,
correct with a corresponding spacer as specified - go back
to 8. For insufficient rolling torque - install thinner spacer
ring. Excessive rolling torque - install a thicker spacer ring.
RAIL11WEL0360BA 12
13. Grease O-rings and insert them into annular grooves

of piston.
NOTE: This step is only need for versions with DHL differ-
ential.
RAIL11WEL0361BA 13
14. Insert piston (arrow) into bearing housing until con-

tact is made.
RAIL11WEL0362BA 14
84605841 14/05/2012
25.102 / 15
15. Determination the shims for setting the bearing

rolling torque (differential housing) and backlash
(bevel gear set). Determine the required shims on
the basis of read value (deviation/test dimension)
and corresponding specifications of the following
table: (KRS - SET - RIGHT) (KRS = bevel gear
set): Deviation see crown wheel rear side. The test
dimension “101” is stamped into the crown wheel
rear side. If no +/- deviation is indicated, this value
corresponds to actual value “0” in the following
table. According to this value, the required shims
are allocated in the table. Any +/- deviation of test
dimension caused by production is also 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 table.
RAIL11WEL0363BA 15
16. 1. Axle housing

4. Axle housing
RAIL11WEL0364BA 16
Shims for differential D/DL and DHL-2400 in ZF axles MT-L 3085/3095 II

Crown wheel marking —20 -10 10
Deviation -0.2 —0.1 0 0.1
Shim Diff. cage side 0.7 0.8 0.9 1.0
Shim thickness
Shim DHL 2400 Order 84395193 84354725 84354726 84354727
no.
Shim D/DL 2400 84476078 84330538 84330539 84330540
Order no.
side Shim thickness
Shim D/DL/DHL 2400 84476080 84330542 84330541 84330540
Order no.
84605841 14/05/2012
25.102 / 16
17. Insert selected shim e.g. s = 0.9 mm (0.035 in) into

hole of axle housing and adjust bearing outer ring
(arrow) until contact is obtained.
RAIL11WEL0365BA 17
18. Cover some drive and coast flanks of crown wheel

with marking ink. Insert pre-mounted differential into
axle drive housing.
RAIL11WEL0366BA 18

RAIL11WEL0367BA 19
84605841 14/05/2012
25.102 / 17
20. Mount two M20 locating pins (S) and bring axle hous-
ing into contact position with axle drive housing us-
ing a suitable 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.
RAIL11WEL0368BA 20
21. Leak test differential lock. Pressurize lock to p = 1

bar (15 psi), close the shutoff valve and remove air
line. No noticeable pressure loss should occur within
10 seconds.
NOTE: This operation is only necessary for version with
DHL differential.
RAIL11WEL0369BA 21
22. In both directions, several times, rotate input flange

to roll crown wheel over input pinion. Remove axle
housing and lift differential out of axle drive housing.
Compare obtained contact pattern with contact pat-
tern examples at the beginning of this section.
NOTE: If tooth contact pattern differs, an incorrect shim
size was selected in 5. This must be corrected.
RAIL11WEL0370BA 22
Next operation:
Differential - Install Models MT-L 3085 II / MT-L 3095 II (25.102)
84605841 14/05/2012
25.102 / 18
Differential - Remove - Models MT-L 3065 II / MT-L 3075 II

621F
1. Use a suitable lifting device and attach the axle to an

acceptable assembly stand.
RAIL11WEL0003BA 1
2. Remove plug from axle drive housing and drain oil.
RAIL11WEL0004BA 2
3. Remove plugs from axle outputs and drain oil.
RAIL11WEL0005BA 3
84605841 14/05/2012
25.102 / 19
4. Remove external brake tube if axle is so equipped.
RAIL11WEL0006BA 4
5. Attach output to a suitable lifting device, remove hex

bolts and separate the output assembly for the axle
housing.
RAIL11WEL0007BA 5
NOTE: Watch for releasing end plate and multiple discs.

6. Remove the stub shaft and sun gear shaft from the
output.
RAIL11WEL0008BA 6
NOTE: Watch for loose shims.
84605841 14/05/2012
25.102 / 20
7. Attach a suitable lifting device to the axle housing.

Then remove the hex bolts and separate the axle
housing from the axle drive housing.
RAIL11WEL0024BA 7
NOTE: Watch for possible release of differential.

8. Remove the bearing outer ring from the bearing hole
and the shim behind it. Then remove the O-ring (see
arrow).
RAIL11WEL0025BA 8
9. Remove the piston from the axle housing.
RAIL11WEL0026BA 9
NOTE: This step is only necessary for the version with DHL differential.
10. Loosen the threaded connections (2) and (4) and re-
move the brake releasing tube (3). Then remove
screw neck (1).
RAIL11WEL0061AA 10
84605841 14/05/2012
25.102 / 21
11. Attach a suitable lifting device to the differential and

lift differential out of the axle drive housing.
RAIL11WEL0028BA 11
12. Pull the bearing outer ring from the housing hole and
remove the shim behind it.
RAIL11WEL0029BA 12
13. Heat the hex nut with a suitable heat gun.
RAIL11WEL0030BA 13
NOTE: Hex nut is secured with LOCTITE® 262.

14. Remove hex nut and the shim behind it.
RAIL11WEL0031BA 14
84605841 14/05/2012
25.102 / 22
15. Pull the input flange from the input pinion and remove
the shaft seal behind from the axle drive housing.
RAIL11WEL0032BA 15
16. Remove the input pinion from the axle drive housing
with a suitable puller and then remove the tapered
roller bearing.
RAIL11WEL0033BA 16
17. Remove the spacer ring and pull the tapered roller
bearing from the input pinion.
RAIL11WEL0034BA 17
18. If needed, force both bearing outer rings out of the

axle drive housing.
RAIL11WEL0035BA 18
Next operation:
84605841 14/05/2012
25.102 / 23
Limited slip differential - Disassemble — DZ-1200 (25.102)

Next operation:
Differential lock - Disassemble — DHL-1200 (25.102)
84605841 14/05/2012
25.102 / 24
Differential - Install - Models MT-L 3065 II / MT-L 3075 II

621F
Prior operation:
Bevel gear set and differential carrier - Backlash — Models MT-L 3065 II / MT-L 3075 II (25.102)
1. After a successful contact pattern check, loosen the

hexagon nut and pull the input flange from the input
pinion.
RAIL11WEL0526BA 1
2. Mount the shaft seal with the seal lip showing to the
oil chamber.
NOTE: The exact installation position of the shaft seal is
obtained when using the specified driver tool.
NOTE: Wet the outer diameter of the shaft seal with mineral
spirits before installation and fill the space between the seal
and dust lip with grease.
RAIL11WEL0527BA 2
3. Insert the input flange and tighten by means of disk

and hex nut. Torque nut to 700 N·m (516 lb ft).
RAIL11WEL0528BA 3
NOTE: Cover the thread of the hexagon nut with LOCTITE® 262.
84605841 14/05/2012
25.102 / 25
4. Using a suitable lifting device, insert the differential

into the axle drive housing.
RAIL11WEL0529BA 4
5. Attach axial roller cage to the sliding sleeve using

grease.
RAIL11WEL0504BA 5
NOTE: This operation is only needed for axles with the DHL differential.
6. Grease O-ring and insert it into the annular groove of
the brake tube (see arrow).
RAIL11WEL0531BA 6
7. Mount fitting (1) and torque to 36 N·m (27 lb ft). Then

mount brake tube (2) with threaded connection (3)
and hex nut (4) and torque it to 100 N·m (74 lb ft).
RAIL11WEL0061AA 7
84605841 14/05/2012
25.102 / 26
8. Grease O-ring (see arrow) and insert it into the axle

housing.
RAIL11WEL0532BA 8
9. Using a suitable lifting device, attach axle housing to

axle drive housing and secure with hex nuts. Torque
hex nuts to 390 N·m (288 lb ft).
RAIL11WEL0533BA 9
Next operation:
Wheel hub - Install — Models MT-L 3065 II / 3075 II (25.108)
84605841 14/05/2012
25.102 / 27

721F
CAUTION
Burn hazard!
C0047A
1. Use a suitable lifting device and attach axle to as-

sembly stand.
NOTE: Only heavy duty axle version uses wheel mounting
studs.
RAIL11WEL0178BA 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.
RAIL11WEL0179BA 2
3. Remove plug and drain oil from outputs.

and disposal.
RAIL11WEL0180BA 3
84605841 14/05/2012
25.102 / 28
4. Remove bleeder valve (1) to avoid damage during

output and axle housing separation.
RAIL11WEL0181BA 4
5. Attach a suitable load carrying device to the output

assembly. Remove hex bolts and separate output
from axle housing.
NOTE: Attach load carrying device with a wheel nut.
RAIL11WEL0182BA 5
6. Pull stub shaft and sun gear shaft.

NOTE: Watch for loose shim(s).
RAIL11WEL0183BA 6
84605841 14/05/2012
25.102 / 29
7. Secure axle housing to suitable lifting device. Re-

move hex bolts. Separate axle housing from axle
drive housing.
NOTE: Watch out for releasing differential.
RAIL11WEL0213BA 7
8. Loosen threaded connections and remove releasing

brake tube.
RAIL11WEL0214BA 8
9. Remove screw neck.
RAIL11WEL0212BA 9
84605841 14/05/2012
25.102 / 30
10. Pull bearing outer ring from bearing hole and remove
shim. Remove O-ring (see arrow).
RAIL11WEL0233BA 10
11. Lift differential from axle drive housing using a suit-

RAIL11WEL0232BA 11
12. Pull bearing outer ring (arrow) from housing and re-
move shim.
RAIL11WEL0233BA 12
84605841 14/05/2012
25.102 / 31
13. Remove piston (arrow) from axle housing.

NOTE: Step is necessary only for DHL version.
RAIL11WEL0234BA 13
14. Use compressed air to remove piston.

RAIL11WEL0235BA 14
15. Heat slotted nut with a hot air blower.

NOTE: Slotted nut is secured with LOCTITE® 262.
RAIL11WEL0236BA 15
84605841 14/05/2012
25.102 / 32
16. Remove slotted nut and shim behind it. Use slot-
ted nut wrench CAS2842 and clamping device
380001546.
RAIL11WEL0237BA 16
17. Remove input flange from pinion. Use a lever to re-

move shaft seal.
RAIL11WEL0238BA 17
18. Press input pinion from axle drive housing and re-
move releasing tapered roller bearing.
RAIL11WEL0239BA 18
84605841 14/05/2012
25.102 / 33
19. Remove spacer ring and pull tapered roller bearing

from input pinion.
RAIL11WEL0240BA 19
20. If needed, remove bearing outer rings from axle drive

housing.
RAIL11WEL0231BA 20
Next operation:
Limited slip differential - Disassemble — DL-2400 (25.102)
Next operation:
Differential lock - Disassemble - DHL-2400 (25.102)
84605841 14/05/2012
25.102 / 34
Differential - Install Models MT-L 3085 II / MT-L 3095 II

721F
Prior operation:
Bevel gear set and differential carrier - Backlash — Models MT-L 3085 II / MT–L 3095 II (25.102)
1. After contact pattern check, insert differential into

axle drive housing again.
RAIL11WEL0371BA 1
2. Remove slotted nut and pull input flange from in-

put pinion. Use CAS2842 slotted nut wrench and
380001546clamping device.
RAIL11WEL0372BA 2
3. Using CAS2841 driver tool, mount shaft seal with

seal lip facing oil chamber.
NOTE: Exact installation position of seal is obtained using
specified driver tool.
NOTE: Wet outer diameter of shaft seal with mineral spirits
just before installation. Fill space between seal and dust lip
with grease.
RAIL11WEL0373BA 3
84605841 14/05/2012
25.102 / 35
4. Insert input flange and secure it using disc and

slotted nut. Torque to 1200 N·m (885 lb ft). Use
CAS2842 slotted nut wrench and 380001546 clamp-
ing device.
NOTE: Cover threads of slotted nut with LOCTITE® 262.
RAIL11WEL0348BA 4
5. Grease O-ring and insert it into axle housing.
RAIL11WEL0397BA 5
6. Mount two M20 locating pins and bring axle housing

into contact position with axle drive housing using a
suitable lifting device. Secure axle housing using hex
bolts. Torque to 560 N·m (413 lb ft).
NOTE: After axle housing assembly, secure axle with
clamping brackets (S).
RAIL11WEL0398BA 6
84605841 14/05/2012
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7. Mount fitting and torque to 36 N·m (27 lb ft).
RAIL11WEL0399BA 7
8. Grease O-ring. Insert it into annular groove of park-

ing brake tube.
RAIL11WEL0400BA 8
9. Mount brake tube with threaded connection and hex

nut (arrow). Torque to 100 N·m (74 lb ft).
RAIL11WEL0401BA 9
84605841 14/05/2012
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10. Install plug and new O-ring. Torque to 50 N·m (37 lb

ft).
RAIL11WEL0396BA 10
Next operation:
Wheel hub - Install Models MT-L 3085 II / MT-L 3095 II (25.108)
84605841 14/05/2012
25.102 / 38
Limited slip differential - Disassemble - DZ-1200

621F
Prior operation:
Differential - Remove — Models MT-L 3065 II / MT-L 3075 II (25.102)
1. Using a suitable puller to remove both tapered roller

bearings from the differential.
RAIL11WEL0050BA 1
2. Preload the differential using a press and then re-

move locking bolts and housing cover.
RAIL11WEL0051BA 2
3. Insert some locking bolts, position pressure plate and

then press differential carrier off the crown wheel.
RAIL11WEL0052BA 3
84605841 14/05/2012
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4. Remove the releasing disk package, thrust washer

and axle bevel gear.
RAIL11WEL0060BA 4
5. Force slotted pins out of both spider shaft halves

(split version). Then remove both spider shaft halves
in arrow direction and remove components from dif-
ferential carrier.
RAIL11WEL0053BA 5
84605841 14/05/2012
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6. Differential components
1. Spider shaft (one part)
2. Spider gear (four parts)
3. Thrust washer (four parts)
4. Spider shaft (split version)
5. Slotted pin (two parts)
RAIL11WEL0001BA 6
7. Remove the releasing axle bevel gear, thrust washer

and disc package.
RAIL12WEL0267CA 7
Next operation:
Limited slip differential - Assemble — DZ-1200 (25.102)
84605841 14/05/2012
25.102 / 41
Limited slip differential - Assemble - DZ-1200

621F
Prior operation:
Limited slip differential - Disassemble — DZ-1200 (25.102)
1. Observe component location for limited slip differen-

tial. Legend to sketch
1. Housing cover
2. Crown wheel
3. Spider shaft (split version) (two parts)
4. Slotted pins
5. Spider gear
6. Axle bevel gear
7. Differential carrier
8. Disk package “A”
9. Disk package “B”
NOTE: “A” Installation dimension = 18.6 mm - 0.2 mm.
NOTE: “B” installation dimension = 16.7 mm — 0.2 mm.
RAIL12WEL0220BA 1
2. Insert disk package (1) and thrust washer (2) into

differential carrier.
NOTE: The installation dimension “A” (18.6 mm —0.2 mm)
is determined by mounting outer disks with different thick-
nesses. Observe the installation position in the figure.
NOTE: The number of disks and the disk arrangement is
shown in the related spared parts list.
RAIL12WEL0219BA 2
84605841 14/05/2012
25.102 / 42
3. Insert axle bevel gear.
RAIL11WEL0467BA 3
4. Observe reassembly position of differential spider.

RAIL11WEL0497BA 4
5. Insert spider gears with thrust washers into the dif-

ferential housing and fix them with the long spider
shafts.
RAIL11WEL0498BA 5
NOTE: Position thrust washers with the tabs (see arrow) located in the recesses of the differential housing.
6. Insert spider gears with thrust washers into the differ-
ential housing and fix them with the two short spider
shafts.
NOTE: Position thrust washers with the tabs (see arrow 1)
located in the recesses of the differential housing.
NOTE: Observe the radial installation position (securing
holes, arrow 2) of the spider shafts.
RAIL11WEL0499BA 6
84605841 14/05/2012
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7. Secure short spider shafts with slotted pins. Slotted

pins should be flush mounted with openings installed
180 ° offset to each other.
RAIL11WEL0490BA 7
8. Mount second axle bevel gear.
RAIL11WEL0491BA 8
84605841 14/05/2012
25.102 / 44
9. Insert thrust washer and disk package into the differ-

ential carrier.
NOTE: The installation dimension “B” (16.7 mm —0.2 mm)
RAIL11WEL0060BA 9
10. Mount two locating pins and press the crown wheel
onto the differential housing.
RAIL11WEL0502BA 10
84605841 14/05/2012
25.102 / 45
11. Insert the housing cover until contact is made with the
crown wheel. Use a press to preload the differential
and secure with new locking bolts. Torque bolts to
400 N·m (295 lb ft).
RAIL11WEL0503BA 11
12. Heat both tapered roller bearings and install them on

the differential.
NOTE: Adjust tapered roller bearing after it cools.
RAIL11WEL0464BA 12
Next operation:
84605841 14/05/2012
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Limited slip differential - Disassemble - DL-2400

721F
Prior operation:
1. Pull both tapered roller bearings from differential.
RAIL11WEL0263BA 1
2. Preload differential with a press. Remove locking

screws and housing cover.
RAIL11WEL0264BA 2
3. Remove axle bevel gear with pressure ring, disc

package and thrust washers from differential hous-
ing.
RAIL11WEL0265BA 3
84605841 14/05/2012
25.102 / 47
4. Remove spider shafts and axle bevel gears from dif-

ferential housing.
RAIL11WEL0266BA 4
5. Remove second axle bevel gear.
RAIL11WEL0267BA 5
6. Remove pressure ring, disc package and thrust

washers from the differential housing.
RAIL11WEL0268BA 6
84605841 14/05/2012
25.102 / 48
7. Press crown wheel from the differential carrier.
RAIL11WEL0241BA 7
Next operation:
Limited slip differential - Assemble — DL-2400 (25.102)
84605841 14/05/2012
25.102 / 49
Limited slip differential - Assemble - DL-2400

721F
CAUTION
Burn hazard!
C0047A
Prior operation:
Limited slip differential - Disassemble — DL-2400 (25.102)
1. Mount two M16 x 1.5 locating pins (S) and press

heated crown wheel onto differential housing until
contact is made.
RAIL11WEL0270BA 1
2. Insert thrust washer into differential housing.
RAIL11WEL0271BA 2
84605841 14/05/2012
25.102 / 50
3. Mount outer and inner discs in alternating order start-

ing with an outer disk.
NOTE: The installation clearance of internal parts is cor-
rected by mounting outer discs of different thicknesses.
NOTE: The difference in thickness between the left and
right disc package must be less than 0.1 mm (0.004 in).
RAIL11WEL0302BA 3
4. Install pressure ring.
RAIL11WEL0303BA 4
5. Install axle bevel gear until contact is made. Then

install inner discs with teeth.
RAIL11WEL0304BA 5
84605841 14/05/2012
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6. Preassemble the differential spider and insert it into

the differential housing/pressure ring.
RAIL11WEL0305BA 6
7. Install second axle bevel gear.
RAIL11WEL0306BA 7
8. Install second thrust ring into differential housing.
RAIL11WEL0307BA 8
84605841 14/05/2012
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9. Mount outer and inner discs in alternating order start-

ing with an inner disc.
NOTE: The installation clearance of internal parts is cor-
rected by mounting outer discs of different thicknesses.
NOTE: The difference in thickness between the left and
right disc package must be less than 0.1 mm (0.004 in).
RAIL11WEL0308BA 9
10. Determine the installation clearance 0.2 - 0.7 mm

(0.008 - 0.028 in). Measure Dimension I from the
mounting face of the differential housing to the plane
face of the outer disc. Dimension I e.g. 44.30 mm
(1.744 in).
RAIL11WEL0309BA 10
11. Measure Dimension II, from the contact face of the

outer disc to the mounting face on the housing cover.
Dimension II e.g. 43.95 mm (1.730 in.)
NOTE: Any deviation from the required installation clear-
ance must be corrected with corresponding outer discs: s
= 2.7 mm (0.106 in), s = 2.9 mm (0.114 in), s = 3.0 mm
(0.118 in), s = 3.1 mm (0.122 in), s = 3.2 mm (0.126 in), s
= 3.3 mm (0.130 in), s = 3.5 mm (0.138 in) ).
NOTE: Make sure the difference in thickness between the
left and right disc package is less than 0.1 mm (0.004 in).
Calculation Example:
Dimension I 44.30 mm (1.744 in.)
Dimension II 43.95 mm (1.730 in.)
Difference + disc clearance 0.35 mm (0.013 in.)
84605841 14/05/2012
25.102 / 53
12. Secure thrust washers into housing cover with

grease.
RAIL11WEL0311BA 11
13. Mount two M16 x 1.5 adjusting bolts and insert

housing cover until contact with differential housing
is made. Preload differential with a press. Secure
with new locking bolts and torque to 400 N·m (295
lb ft).
RAIL11WEL0312BA 12
14. Heat both tapered roller bearings and insert until con-
tact is made. Adjust tapered roller bearing after cool-
ing down.
RAIL11WEL0269BA 13
Next operation:
84605841 14/05/2012
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Differential lock - Disassemble - DHL-1200

621F
Prior operation:
1. Pull both tapered roller bearings from the differential.
RAIL11WEL0036BA 1
2. Preload the differential using a press and loosen the

hexagon bolts.
RAIL11WEL0037BA 2
3. Remove the lid and single parts from the differential.

1. Lid
2. Cylindrical pins (6 components)
3. Cage
4. Pressure piece
5. Lever (12 components)
RAIL11WEL0038BA 3
84605841 14/05/2012
25.102 / 55
4. Preload the housing cover/compression spring using

the press and disengage the retaining ring. Then
remove the sliding sleeve and compression spring
from the housing cover.
RAIL11WEL0039BA 4
5. Remove the disc package and the disc carrier.
RAIL11WEL0040BA 5
6. Remove the crown wheel, axle bevel gear, thrust

washer and constant spacer.
2. Axle bevel gear
3. Crown wheel
4. Thrust washer
5. Constant spacer
RAIL11WEL0041BA 6

in arrow direction and take components out of the dif-
ferential carrier.
RAIL11WEL0042BA 7
84605841 14/05/2012
25.102 / 56
8. Differential carrier components are as follows:

2. Thrust washer (4 components)
3. Spider gear (4 components)
5. Slotted pin (3 components)
7. Spider shaft (1 piece)
8. Outer disc
9. Thrust washer
10. Constant spacer
11. Axle bevel gear
RAIL11WEL0059BA 8
Next operation:
Differential lock - Assemble - DHL-1200 (25.102)
84605841 14/05/2012
25.102 / 57
Differential lock - Assemble - DHL-1200

621F
Prior operation:
Differential lock - Disassemble — DHL-1200 (25.102)
1. Insert constant spacer into the differential carrier.
RAIL11WEL0465BA 1
2. Insert the steel outer disc (1) and thrust washer (2)
into the differential carrier. Note the installation posi-
tion.
RAIL11WEL0466BA 2
3. Insert the axle bevel gear.
RAIL11WEL0467BA 3
84605841 14/05/2012
25.102 / 58
4. Reassemble differential spider.

RAIL11WEL0468BA 4

ential housing and secure them with the long spider
shaft.
NOTE: Position the thrust washers with the tabs (arrow)
RAIL11WEL0469BA 5
6. Insert the spider gears with thrust washers into the

differential housing and secure them with the two
short spider shafts.
NOTE: Position the thrust washers with the tabs (1) located
in the recesses of the differential housing.
NOTE: Observe the radial installation position of the secur-
ing holes (2) on the spider shafts.
RAIL11WEL0470BA 6

RAIL11WEL0471BA 7
84605841 14/05/2012
25.102 / 59
RAIL11WEL0472BA 8
9. Insert the thrust washer (1) and constant spacer (2)

into the differential carrier.
NOTE: Pay attention to the installation positioning.
RAIL11WEL0473BA 9
10. Mount two locating pins (arrows) and press the crown
wheel onto the differential housing.
RAIL11WEL0474BA 10
11. Install compression spring onto the sliding sleeve.
RAIL11WEL0475BA 11
84605841 14/05/2012
25.102 / 60
12. Insert the premounted sliding sleeve into the housing

cover. Then preload the compression spring using a
press and engage the retaining ring into the annular
grove of the sliding sleeve.
RAIL11WEL0476BA 12
13. Premount the single parts to resemble the adjacent

sketch.
1. Lid
2. Pressure piece
3. Cage
4. Lever (12 components)
5. Pressure piece
NOTE: Be sure that the lid is supported only by the pres-
sure piece (5), but never on the sliding sleeve.
RAIL11WEL0591BA 13
14. Set the disc package by placing the cylindrical pins

(6 components) into the lid with grease.
RAIL11WEL0477BA 14
15. Insert the disc package into the lid. Pay attention to
the radial installation position of the outer disc. Lo-
cating grooves (1) of the outer disc are to be posi-
tioned over the cylindrical pins (2).
NOTE: For the number of disks and the disk arrangement,
refer to the related spare parts list.
RAIL11WEL0478BA 15
84605841 14/05/2012
25.102 / 61
16. Install the snap ring (arrow) in the annular groove of

the disc carrier. Then insert the preassembled disc
carrier so that all the inner discs are mounted.
RAIL11WEL0479BA 16
17. Preload disk package with an axial force of F=50 +

30 KN. Then check the setting dimension “A” = 0.8
+/- 0.1 mm from the collar of the lid to the plane face
of the outer disk (see also below sketch).
NOTE: Any deviation from the specified setting dimension
must be corrected with a corresponding outer disk.
RAIL11WEL0480BA 17
18. A = Setting dimension = 0.8 +/- 0.1 mm and F = 50

+30 KN.
1. Lid
2. Pressure piece
3. Sliding sleeve
4. Pressure piece
5. Disc package
6. Disc carrier
7. Load cell
NOTE: Ensure that lid (1) is only supported on the pressure
piece (2) but never on the sliding sleeve (3).
NOTE: Ensure that pressure piece (4) is seated only on
disc package (5), but not on disc carrier (6).
RAIL12WEL0061BA 18
84605841 14/05/2012
25.102 / 62
19. Position the premounted differential with the lifting

device onto the lid. Temporarily secure with new
locking bolts.
RAIL11WEL0481BA 19
20. Preload the differential with a press and the pressure

piece. Then tighten the housing cover with new lock-
ing bolts. Torque bolts to 400 N·m (295 lb ft).
RAIL11WEL0482BA 20
21. Heat both tapered roller bearings (arrows) and install

them on the differential.
RAIL11WEL0483BA 21
Next operation:
84605841 14/05/2012
25.102 / 63
Differential lock - Disassemble - DHL-2400

721F
Prior operation:
1. Remove axial roller cage (arrow).
RAIL11WEL0242BA 1
RAIL11WEL0243BA 2
3. Preload differential using a press. Remove hex bolts

and releasing housing cover.
RAIL11WEL0244BA 3
84605841 14/05/2012
25.102 / 64
4. Preload housing cover/compression spring using a

press. Disengage retaining ring. Remove sliding
sleeve and compression spring from housing cover.
RAIL11WEL0245BA 4
5. Remove the following single parts:.

1. Pressure piece
2. Cage
3. Lever (12x)
4. Disk carrier
5. Disk package
RAIL11WEL0246BA 5
6. Preload differential using a press. Remove locking

bolts and housing cover.
RAIL11WEL0247BA 6
84605841 14/05/2012
25.102 / 65
7. Remove axle bevel gear with thrust washers from

differential housing.
RAIL11WEL0248BA 7
8. Force out both slotted pins.
RAIL11WEL0249BA 8
9. Remove both short differential axles. Remove re-

leasing spider gears and thrust washers from differ-
ential housing.
RAIL11WEL0250BA 9
84605841 14/05/2012
25.102 / 66
10. Remove long differential axle, releasing spider gears

and thrust washers from differential housing.
RAIL11WEL0251BA 10
11. Remove axle bevel gear and shim.
RAIL11WEL0252BA 11
12. Press crown wheel from differential carrier.
RAIL11WEL0241BA 12
Next operation:
Differential lock - Assemble — DHL-2400 (25.102)
84605841 14/05/2012
25.102 / 67
Differential lock - Assemble - DHL-2400

721F
CAUTION
Burn hazard!
C0047A
Prior operation:
Differential lock - Disassemble - DHL-2400 (25.102)
1. Mount two M16 x 1.5 locating pins (S) and press

heated crown wheel onto differential housing until
contact is made.
RAIL11WEL0270BA 1
2. Insert thrust washers into differential housing.
RAIL11WEL0271BA 2
84605841 14/05/2012
25.102 / 68
RAIL11WEL0272BA 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.
RAIL11WEL0273BA 4
5. Insert spider gears with thrust washers into differ-

ential housing. Attach 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 attaching holes
(2).
RAIL11WEL0274BA 5
84605841 14/05/2012
25.102 / 69
6. Secure short spider shafts with slotted pins.

NOTE: Flush mount slotted pins.
RAIL11WEL0275BA 6
RAIL11WEL0276BA 7
8. Position thrust washers in housing cover with grease.
RAIL11WEL0277BA 8
84605841 14/05/2012
25.102 / 70
9. Mount M16 x 1.5 adjusting bolts and insert housing

cover until contact with differential housing is made.
Preload differential using a press and secure with
new locking bolts. Torque to 400 N·m (295 lb ft).
RAIL11WEL0278BA 9
10. Install compression spring onto sliding sleeve.
RAIL11WEL0279BA 10
11. Insert pre-mounted sliding sleeve into housing cover.

Preload compression spring with a press and engage
retaining ring into annular groove of sliding sleeve.
RAIL11WEL0280BA 11
84605841 14/05/2012
25.102 / 71
12. Pre-mount the single parts of the disc package ac-

cording to illustration.
1. Housing cover
2. Pressure piece
3. Cage
4. Lever (12x)
5. Disk carrier
6. Pressure ring
7. Inner discs
8. Outer discs (optional)
9. Snap ring.
NOTE: For number of discs and disc arrangement, refer to
related spare parts list.
RAIL11WEL0281BA 12
13. Preload disk package with an axial force of F = 50

+30 KN. Then check setting dimension “A” = 1.05
+/-0.1 mm (0.041 +/-0.004 in) from collar of differen-
tial cover to plane face of outer disc (also see sketch
in step 14).
NOTE: Any deviation from specified setting dimension
must be corrected with a corresponding outer disk.
NOTE: Special tools pressure piece and load cell are to be
determined. Contact special tools.
RAIL11WEL0282BA 13
14. A = Setting dimension = 1.05 +/- 0.1 mm (0.041

+/-0.004 in); B = Contact face.
NOTE: To obtain correct measuring result, housing cover
may only be supported on contact face (B). Ensure that
assembly stand is only supported on disk package and not
on disk carrier.
RAIL11WEL0283BA 14
84605841 14/05/2012
25.102 / 72
15. Position housing cover onto pressure piece (arrow).

Insert two hex bolts into housing cover to radially at-
tach disc package.
RAIL11WEL0284BA 15
16. Use a suitable lifting device. Position pre-mounted

differential onto housing cover and temporarily attach
with hex bolts.
RAIL11WEL0285BA 16
17. Preload differential with a press and pressure piece.

Final tighten housing cover with hex bolts. Torque to
185 N·m (136 lb ft).
RAIL11WEL0286BA 17
84605841 14/05/2012
25.102 / 73
ing down.
RAIL11WEL0287BA 18
19. Attach axial roller cage to sliding sleeve with grease.
RAIL11WEL0288BA 19
Next operation:
84605841 14/05/2012
25.102 / 74
Index

Bevel gear set and differential carrier - Backlash - Models MT-L 3065 II / MT-L 3075 II . . . . . . . . . . . . . . . . . . . . . . 4
621F
Bevel gear set and differential carrier - Backlash - Models MT-L 3085 II / MT–L 3095 II . . . . . . . . . . . . . . . . . . . . . 11
721F
Differential - Install - Models MT-L 3065 II / MT-L 3075 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
621F
Differential - Install Models MT-L 3085 II / MT-L 3095 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
721F
Differential - Remove - Models MT-L 3065 II / MT-L 3075 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
621F
721F
Differential lock - Assemble - DHL-1200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
621F
Differential lock - Assemble - DHL-2400 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
721F
Differential lock - Disassemble - DHL-1200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
621F
Differential lock - Disassemble - DHL-2400 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
721F
Limited slip differential - Assemble - DL-2400 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
721F
Limited slip differential - Assemble - DZ-1200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
621F
Limited slip differential - Disassemble - DL-2400 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
721F
Limited slip differential - Disassemble - DZ-1200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
621F
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Final drive hub, steering knuckles, and shafts - 108
621F
721F
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Contents
SERVICE
Wheel hub
Remove - Models MT-L 3065 II / MT-L 3075 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
621F
Install - Models MT-L 3065 II / 3075 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

621F
Disassemble - Models MT-L 3065 II / MT-L 3075 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

621F
Visual inspection - Models MT-L 3065 II / MT-L 3075 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

621F
Assemble - MT-L 3065 II / MT-L 3075 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

621F

721F

721F

721F
Visual inspection - Models MT-L 3085 II / MT–L 3095 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

721F
Assemble - Models MT-L 3085 II / MT-L 3095 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

721F
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CONSUMABLES INDEX
Consumable IU PAGE
84605841 14/05/2012
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Front axle system - Final drive hub, steering knuckles, and shafts
Wheel hub - Remove - Models MT-L 3065 II / MT-L 3075 II

621F

RAIL11WEL0003BA 1
RAIL11WEL0004BA 2
RAIL11WEL0005BA 3
84605841 14/05/2012
25.108 / 4
RAIL11WEL0006BA 4

housing.
RAIL11WEL0007BA 5

output.
RAIL11WEL0008BA 6
Next operation:
Wheel hub - Disassemble — Models MT-L 3065 II / MT-L 3075 II (25.108)
84605841 14/05/2012
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Wheel hub - Install - Models MT-L 3065 II / 3075 II

621F
CAUTION
Burn hazard!
C0047A
Prior operation:
Wheel hub - Assemble — MT-L 3065 II / MT-L 3075 II (25.108)
1. Set the sun gear shaft axial play range to 0.5 - 2.0
mm (0.020 - 0.079 in). Use a straight edge to deter-
mine dimension I from the mounting face of the brake
housing to the front face of the stop bolt. Dimension
I example 21.25 mm (0.837 in).
RAIL11WEL0557BA 1
2. Insert the stub shaft with sun gear into the teeth of
the axle bevel gear until it stops.
RAIL11WEL0558BA 2
3. Using a straight edge, measure dimension II from

the front face of the sun gear shaft to the mounting
surface of the axle housing. Dimension II example
19.00 mm (0.748 in).
NOTE: Calculation example: Dimension I 21.25 mm
(0.837 in) minus Dimension II 19.00 mm (0.748 in) equals
a difference of 2.25 mm (0.089 in) minus the required
axial play example of 1.25 mm (0.049 in) which leaves a
difference or required shim size of 1.00 mm (0.039 in).
RAIL11WEL0559BA 3
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25.108 / 6
4. Remove stub shaft with sun gear from the axle hous-
ing. Then insert the required shim (2) into the sun
gear shaft (1) and mount the stub shaft (3).
RAIL11WEL0560BA 4
5. Grease the O-ring (arrow) and install it into the axle

housing.
RAIL11WEL0561BA 5
6. Use a suitable lifting device and pick up the output.

Then secure disk package using the locating screw
assembly aid.
RAIL11WEL0562BA 6
7. Mount pre-assembled stub shaft into the teeth of the

planetary gears.
RAIL11WEL0563BA 7
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25.108 / 7
8. Bring the output assembly together with the axle

housing by mounting the stub shaft into the gearing
of the axle bevel gear.
NOTE: Pay attention to end plate positioning.
RAIL11WEL0564BA 8
9. Secure the output using hex bolts. Torque bolts to

390 N·m (288 lb ft).
RAIL11WEL0565BA 9
10. Install the screw neck (1) with new O-ring and torque
to 36 N·m (27 lb ft). Next mount breather valve (2)
and torque to 6 N·m (53 lb in). Then install the screw
plug (3) with new O-ring and torque to 50 N·m (37 lb
ft).
RAIL11WEL0566BA 10
11. Install the brake tube (1) with screw nut (2) and cylin-
drical screw (3). Torque the screw nut to 100 N·m (74
lb ft) and the cylindrical screw to 23 N·m (17 lb ft)
RAIL11WEL0567BA 11
Next operation:
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Brakes - Leakage test — Models MT-L 3065 II / MT–L 3075 II (33.202)
84605841 14/05/2012
25.108 / 9
Wheel hub - Disassemble - Models MT-L 3065 II / MT-L 3075 II

621F
Prior operation:
Wheel hub - Remove — Models MT-L 3065 II / MT-L 3075 II (25.108)
1. Attach output assembly to suitable work stand. Re-

move end plate (1), brake breather valve (2), and
screw neck (3).
RAIL11WEL0009BA 1
2. Remove the cover from the output shaft.
RAIL11WEL0010BA 2
3. Remove locking bolts and remove the releasing

cover.
RAIL11WEL0011BA 3
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4. With a suitable lifting device, lift the planetary carrier

out of the brake housing.
RAIL11WEL0012BA 4
NOTE: MT-L 3065 II planetary carrier uses 3 planetary gears.

5. Disengage the retaining ring.
RAIL11WEL0013BA 5
6. With a suitable puller, remove the planetary gears.
RAIL11WEL0014BA 6
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7. With a suitable puller, remove the roller bearing from

the planetary carrier.
RAIL11WEL0015BA 7
8. Lift the disk package out of the brake housing.
RAIL11WEL0016BA 8
9. Remove hexagon screws, remove releasing cover,

remove cup spring and washer.
RAIL11WEL0017BA 9
10. Lift piston off with suitable levers.
RAIL11WEL0018BA 10
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11. If needed, remove guide ring, back-up rings and

grooved rings from the annular grooves of the brake
housing (see arrows).
RAIL11WEL0019BA 11
12. Note installation position of the single parts.

1. Brake housing
2. Guide ring
3. Back-up ring
4. Grooved ring
5. Grooved ring
6. Back-up ring
RAIL11WEL0062BA 12
13. With a suitable lifting device, remove brake housing

from the output shaft.
RAIL11WEL0020BA 13
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14. Remove the shaft seal from the brake housing with
a suitable lever. Force out both bearing outer rings if
necessary.
RAIL11WEL0021BA 14
15. Remove tapered roller bearing from the output shaft

with suitable puller.
RAIL11WEL0022BA 15
16. Visually check the screening plate for wear marks

and if required, separate it from the output shaft.
RAIL11WEL0023BA 16
Next operation:
Wheel hub - Visual inspection — Models MT-L 3065 II / MT-L 3075 II (25.108)
84605841 14/05/2012
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Wheel hub - Visual inspection - Models MT-L 3065 II / MT-L 3075 II

621F
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:
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Wheel hub - Assemble - MT-L 3065 II / MT-L 3075 II

621F
CAUTION
Burn hazard!
C0047A
Prior operation:
1. Heat slide bushing and position it at the collar of the

output shaft. Then position the slide bushing with a
pressure ring special tool.
NOTE: Pay attention to installation position. Cover the con-
tact faces of the slide bushing/output shaft with LOCTITE®
574
NOTE: The exact installation position is obtained when us-
ing the specified pressure ring.
RAIL11WEL0535BA 1
2. Heat tapered roller bearing and insert it onto the out-

put shaft until fully seated.
RAIL11WEL0536BA 2
3. Insert shaft seal into the brake housing. Ensure seal

is installed and seated properly.
spirits before assembly.
RAIL11WEL0537BA 3
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4. Note the installation position of the combi seal.

1. Output shaft
2. Brake housing
3. Combi seal consisting of the shaft seal (a) and
screening plate (b).
RAIL11WEL0428BA 4
5. Carefully install outside bearing outer ring into brake

housing.
RAIL11WEL0538BA 5
6. Carefully install inside bearing outer ring into brake

housing.
RAIL11WEL0539BA 6
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7. Using a suitable lifting device, insert the pre-mounted

brake housing.
RAIL11WEL0540BA 7
8. Insert sealing elements (arrows) into annular

grooves of the brake housing. Pay attention to the
installation position and arrangement. To install
guide ring, clean annular groove of brake housing
with mineral spirits. Then insert guide ring into an-
nular grove (ensure contact of the guide ring around
its entire circumference) and attach guide ring end
points with LOCTITE® 415.
RAIL11WEL0541BA 8
9. Note component installation position.

1. Brake housing
2. Guide ring
3. Support ring
4. Grooved ring
5. Grooved ring
6. Support ring
RAIL11WEL0062BA 9
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10. Flush mount the slotted pins into the holes of the
piston.
RAIL11WEL0542BA 10
11. Insert the piston into the brake housing and carefully
install with a dealer fabricated fixing device.
NOTE: Sufficiently oil seal surface of piston/support rings,
grooved rings and guide ring with W-10 oils.
RAIL11WEL0543BA 11
12. Insert disc, cup spring and cover into the piston.
RAIL11WEL0544BA 12
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13. Confirm installation position of components.

1. Disc
2. Cup spring
3. Cover
4. Piston
5. Hex bolt
6. Brake housing
RAIL11WEL0589BA 13
14. Secure cover with hex bolts. Torque bolts to 34 N·m

(25 lb ft).
RAIL11WEL0545BA 14
15. Heat tapered roller bearing and install it in the plan-

etary carrier. Then wet the profile (1) and front face
(contact face of output shaft) (2) with anticorrosive
agent.
RAIL11WEL0546BA 15
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16. Press stop bolt into planetary carrier.
RAIL11WEL0547BA 16
17. Use a suitable lifting device to insert the planetary

carrier into the teeth of the output shaft.
RAIL11WEL0548BA 17
18. Install cover onto planetary carrier and secure with

old locking bolts that were removed during disassem-
bly. Then remove the locking bolts once again.
RAIL11WEL0549BA 18
19. Pivot output 90 ° then insert the disk and secure plan-
etary carrier with new locking bolts. Tighten locking
bolts crosswise with a tightening torque of 200 N·m
(148 lb ft) and re-torque bolts to 500 N·m (369 lb ft).
RAIL11WEL0550BA 19
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20. Install O-ring on cover (1). Then wet the contact face
(2) with TEROSTAT® MS-9360.
NOTE: Use a new cover and new O-ring.
NOTE: Curing time for TEROSTAT® MS-9360 is greater
than 24 h.
RAIL11WEL0551BA 20
21. Insert the cover into the output shaft.
RAIL11WEL0552BA 21
22. Mount outer and inner disks.

NOTE: For the number of disks and the arrangement,
please refer to the spare parts list.
RAIL11WEL0553BA 22
23. Insert end plate.

NOTE: Ensure radial installation position — driving tabs of
the end plate must be positioned in the grooves of the brake
housing.
RAIL11WEL0554BA 23
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24. 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
RAIL11WEL0555BA 24
25. Heat bearing inner rings and insert the premounted

planetary gears with large radius facing the planetary
carrier (downwards). Then fix planetary gears using
retaining rings.
NOTE: Adjust bearing inner rings after they cool.
RAIL11WEL0556BA 25
Next operation:
84605841 14/05/2012
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721F

sembly stand.
studs.
RAIL11WEL0178BA 1

and disposal.
RAIL11WEL0179BA 2

and disposal.
RAIL11WEL0180BA 3
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25.108 / 24
4. Remove bleeder valve (1) to avoid damage during

output and axle housing separation.
RAIL11WEL0181BA 4

from axle housing.
RAIL11WEL0182BA 5

RAIL11WEL0183BA 6
Next operation:
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Wheel hub - Install Models MT-L 3085 II / MT-L 3095 II

721F
Prior operation:
Wheel hub - Assemble — Models MT-L 3085 II / MT-L 3095 II (25.108)
1. Set axial play of sun gear shaft to 0.5 - 2.0 mm (0.020

- 0.079 in). Determine dimension I, distance from
mounting face of brake housing to front face of stop
bolt. Dimension I e.g. 19.75 mm (0.778 in).
RAIL11WEL0450BA 1
2. Insert stub shaft into teeth of axle bevel gear until

contact is made.
NOTE: Be aware of installation position. Mount stub shaft
side with long teeth towards differential.
RAIL11WEL0451BA 2
3. Insert sun gear shaft until contact is made.
RAIL11WEL0452BA 3
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4. Measure dimension II, from front face of sun gear

shaft to mounting surface of axle housing. Dimen-
sion II e.g. 17.15 mm (0.675 in).
RAIL11WEL0453BA 4
CALCULATION EXAMPLE:
Dimension I: 19.75 mm (0.778 in)
Dimension II: 17.15 mm (0.675 in)
Difference: 2.60 mm (0.102 in)
Required axial play e.g.: 1.00 mm (0.039 in)
Difference = shim e.g. s = 1.60 mm (0.06 in)
5. Insert sun gear shaft into planetary carrier.
RAIL11WEL0454BA 5
6. Insert shim(s) e.g. s = 1.60 mm (0.063 in) with

grease into sun gear shaft.
RAIL11WEL0455BA 6
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7. Insert O-ring with grease into countersink of brake

housing.
RAIL11WEL0456BA 7
8. Grease O-ring and install it in axle housing.
RAIL11WEL0457BA 8
9. Mount adjusting bolts and use acceptable lifting de-

vice to bring output into contact position with axle
housing. Secure output using hex bolts. Torque to
390 N·m (288 lb ft).
NOTE: Attach lifting device with wheel stud.
RAIL11WEL0458BA 9
84605841 14/05/2012
25.108 / 28
10. Mount bleeder valve (arrow).
RAIL11WEL0459BA 10
Next operation:
Brakes - Leakage test — Models MT-L 3085 II / MT-L 3095 II (33.202)
84605841 14/05/2012
25.108 / 29

721F
Prior operation:
1. Attach output to suitable assembly stand.
RAIL11WEL0184BA 1
2. Use a lever to remove output shaft cover.
RAIL11WEL0185BA 2
3. Remove locking bolts and releasing cover.
RAIL11WEL0186BA 3
84605841 14/05/2012
25.108 / 30
4. Use puller and press planetary carrier out of output

shaft profile.
RAIL11WEL0187BA 4
5. Use a suitable lifting device and lift planetary carrier

out of brake housing.
RAIL11WEL0188BA 5
6. With a suitable puller remove tapered roller bearing

from planetary carrier.
RAIL11WEL0189BA 6
84605841 14/05/2012
25.108 / 31
7. Remove retaining rings.
RAIL11WEL0190BA 7
8. Pull off planetary gears.
RAIL11WEL0191BA 8
9. Lift end plate out of brake housing.
RAIL11WEL0192BA 9
84605841 14/05/2012
25.108 / 32
10. Lift disk package out of brake housing.
RAIL11WEL0193BA 10
11. Remove hex bolts, releasing cover and cup spring.
RAIL11WEL0194BA 11
12. Mount bleeder valve. Use compressed air to remove

piston from brake housing.
RAIL11WEL0195BA 12
84605841 14/05/2012
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13. If necessary, remove guide ring, back-up rings and

grooved rings from annular grooves of brake housing
(arrows).
RAIL11WEL0196BA 13
14. Note the installation position of the following individ-

ual parts.
1. Brake housing
2. Guide ring
3. Back-up ring
4. Piston seal
5. Piston seal
6. Back-up ring
7. Slide ring seal (Metal face seal - HD option only
or combi seal standard version)
8. Output shaft
RAIL11WEL0197BA 14
15. Use a suitable lifting device. Lift brake housing from

output shaft.
RAIL11WEL0198BA 15
84605841 14/05/2012
25.108 / 34
16. Depending on version, use a lever to remove slide

ring seal or shaft seal (combi seal version) from brake
housing. If needed, remove both bearing outer rings.
RAIL11WEL0199BA 16
17. For slide ring seal version, use a lever to remove

slide ring seal from output shaft. For combi seal ver-
sion, check screening plate for wear marks. If re-
quired, separate it from output shaft.
RAIL11WEL0200BA 17
18. Use a puller to remove tapered roller bearing from

output shaft.
RAIL11WEL0177BA 18
Next operation:
Wheel hub - Visual inspection — Models MT-L 3085 II / MT–L 3095 II (25.108)
84605841 14/05/2012
25.108 / 35
Wheel hub - Visual inspection - Models MT-L 3085 II / MT–L 3095 II

721F
Prior operation:
are seen.
place if necessary.
are seen.
Next operation:
84605841 14/05/2012
25.108 / 36
Wheel hub - Assemble - Models MT-L 3085 II / MT-L 3095 II

721F
CAUTION
Burn hazard!
C0047A
Prior operation:
1. If needed, pull wheel stud into output shaft until con-

tact is made.
NOTE: Special tool may only be used for repairs when ex-
changing individual wheel studs with mounted output shaft.
For new output shaft, use a press.
studs.
RAIL11WEL0423BA 1
2. Heat tapered roller bearing and insert it onto output

shaft until contact is made.
RAIL11WEL0424BA 2
84605841 14/05/2012
25.108 / 37
3. Wet O-ring of slide ring seal and locating hole with

mineral spirits. Snap new slide ring seal (part 1) into
output shaft.
NOTE: Step shows version with slide ring seal.
RAIL11WEL0425BA 3
4. Then mount new slide ring seal (part 2) into brake

housing.
ATTENTION: Risk of injury - metal rings have extremely
sharp edges. Wear protective gloves.
NOTE: Surface of slide ring seal may not have any
grooves, scratches or other damage. Make sure seal-
ing surface is parallel to housing face. O-rings must be
mounted evenly into locating hole and must not bulge out.
RAIL11WEL0426BA 4
5. Insert both bearing outer rings (arrows) into brake

RAIL11WEL0427BA 5
84605841 14/05/2012
25.108 / 38
6. Refer to illustration to see installation position of the

combi seal.
1. Output shaft
2. Brake housing
3. Combi seal consisting of: a = Shaft seal, b =
Screening plate.
NOTE: Steps 6 to 8 are for the Version with combi seal
Illustration shows installation position of combi seal.
RAIL11WEL0428BA 6
7. Heat slide bushing and position it at collar of output

shaft. Then position slide bushing with pressure ring.
NOTE: Exact installation position is obtained when using
the specified pressure ring.
RAIL11WEL0429BA 7
8. Insert shaft seal into brake housing using CAS2880

driver tool.
specified driver tool. Make note of installation position
(Step 6). Wet outer diameter of shaft seal with mineral
RAIL11WEL0430BA 8
84605841 14/05/2012
25.108 / 39
9. Use suitable lifting device and insert premounted

brake housing over output shaft until contact is
made.
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.
RAIL11WEL0431BA 9
10. Insert back-up rings and grooved rings into annular

grooves of brake housing (arrows).
RAIL11WEL0432BA 10
11. Clean annular groove of brake housing with mineral

spirits. Insert guide ring into annular grove (go to step
12). 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.
RAIL11WEL0433BA 11
84605841 14/05/2012
25.108 / 40
12. Upon installation, orifice of guide ring must show up-

wards - 12 o’clock position.
1. Brake housing
2. Guide ring
3. Back-up ring
4. Grooved ring
5. Grooved ring
6. Back-up ring
7. Slide ring seal
8. Output shaft
RAIL11WEL0434BA 12
13. Flush-mount slotted pins into holes of piston.
RAIL11WEL0435BA 13
14. Insert piston into brake housing and install with fab-
ricated fixing device until contact is made.
NOTE: Sufficiently oil seal surface of piston/back-up rings,
grooved rings and guide ring (W-10 oils are to be used).
RAIL11WEL0436BA 14
84605841 14/05/2012
25.108 / 41
15. Insert disk and cup spring with convex side facing
upwards into piston.
RAIL11WEL0437BA 15
16. Insert cover and secure it by means of hex bolts.

RAIL11WEL0438BA 16
17. Insert outer and inner disks.

NOTE: For number of disks and disk arrangement, refer to
RAIL11WEL0439BA 17
84605841 14/05/2012
25.108 / 42
RAIL11WEL0440BA 18
19. Press stop bolt (1) into planetary carrier (2) until con-
tact is obtained.
RAIL11WEL0461CA 19
84605841 14/05/2012
25.108 / 43
20. 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.
RAIL11WEL0441BA 20
21. Heat bearing inner rings. Insert premounted plane-

tary gears with large radius facing planetary carrier
(downwards) until contact is made. Secure plane-
tary gears using retaining rings.
NOTE: Adjust bearing inner rings after cooling.
RAIL11WEL0442BA 21
22. Heat tapered roller bearing and install it on planetary

carrier until contact is made.
RAIL11WEL0443BA 22
84605841 14/05/2012
25.108 / 44
23. Wet contact face of bearing inner ring (1) and profile
teeth (2) in output shaft with anti-corrosive agent.
RAIL11WEL0444BA 23
24. Align disk package centrally and radially. Insert plan-

etary carrier into teeth of output shaft using a suitable
lifting device.
NOTE: MT-L 3085 planetary carrier has 3 planetary gears.
RAIL11WEL0445BA 24
25. Bring planetary carrier wit measuring disk and three

old locking bolts removed during disassembly into
contact position. Torque bolts to 200 N·m (148 lb
ft).
RAIL11WEL0446BA 25
84605841 14/05/2012
25.108 / 45
26. Pivot output 180 ° and measure gap width from the
output shaft to the planetary carrier. Gap width ex-
ample is 0.21 mm (0.008 in). Then remove the lock-
ing bolts and the measuring disk.
RAIL11WEL0447BA 26
27. Make a note of the Planetary carrier (1), the Output

shaft (2) and the gap dimension to be measured “X”.
28. Select the cover (optional) on the basis of the follow-
ing table.
Determined gap width (Delta) Offset to be used on the cover ZF Part Number
0.30 - 0.24 mm (0.012 - 0.009 in) 0.13 mm +/- 0.01 mm ( 0.005 in 4474 353 172
0.0003 in)
0.239 - 0.18 mm (0.009 - 0.007 in) 0.07 mm +/- 0.01 mm ( 0.003 in 4474 353 172
0.0003 in)
0.179 - 0.10 mm (0.007 - 0.004 in) 0 mm (0.000 in) 4474 353 115
NOTE: Cover 4474 353 172 has an offset of 0.07 mm on one side and an offset of 0.13 mm on the other side.
NOTE: Offset of 0.13 mm is visibly marked with an annular groove (see arrow).
29. Insert the cover with the example 0.07 mm side
showing to the planetary carrier and tighten with new
locking bolts. Torque bolts successively to 200 N·m
(148 lb ft). Then retighten bolts successively to a
torque of 500 N·m (369 lb ft).
30. Install a new O-ring (1) on the cover and wet contact
face (2) with TEROSTAT® MS-9360.
NOTE: Terostat has a curing period of greater than 24
hours.
RAIL11WEL0448BA 27
84605841 14/05/2012
25.108 / 46
31. Install cover onto output shaft until fully seated.
RAIL11WEL0449BA 28
Next operation:
84605841 14/05/2012
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Index

Wheel hub - Assemble - MT-L 3065 II / MT-L 3075 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
621F
Wheel hub - Assemble - Models MT-L 3085 II / MT-L 3095 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
721F
Wheel hub - Disassemble - Models MT-L 3065 II / MT-L 3075 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
621F
721F
Wheel hub - Install - Models MT-L 3065 II / 3075 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
621F
Wheel hub - Install Models MT-L 3085 II / MT-L 3095 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
721F
Wheel hub - Remove - Models MT-L 3065 II / MT-L 3075 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
621F
Wheel hub - Remove - Models MT-L 3085 II / MT-L 3095 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
721F
Wheel hub - Visual inspection - Models MT-L 3065 II / MT-L 3075 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
621F
Wheel hub - Visual inspection - Models MT-L 3085 II / MT–L 3095 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
721F
84605841 14/05/2012
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84605841 14/05/2012
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PRINTED IN U.S.A.
84605841 14/05/2012
EN
SERVICE MANUAL
Rear axle system
621F
721F
84605841 14/05/2012
27
Contents
Rear axle system - 27
Powered rear axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27.100

621F , 721F
Rear bevel gear set and differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27.106

621F , 721F
Planetary and final drives. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27.120

621F , 721F
84605841 14/05/2012
27
CONSUMABLES INDEX
Consumable IU PAGE
Loctite® 243 Powered rear axle - Install 27.100 / 10
Loctite® 262 Differential - Remove Models MT-L 3065 II / MT-L 3075 II 27.106 / 23
84605841 14/05/2012
27
84605841 14/05/2012
27
Powered rear axle - 100
621F
721F
84605841 14/05/2012
27.100 / 1
Contents
TECHNICAL DATA
Rear axle control transmission shaft

Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
SERVICE
Powered rear axle

Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Rear axle control transmission shaft
Remove - Rear Drive Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Install - Rear Drive Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
84605841 14/05/2012
27.100 / 2
CONSUMABLES INDEX
Consumable IU PAGE
Loctite® 243 Powered rear axle - Install 27.100 / 10
84605841 14/05/2012
27.100 / 3
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)
84605841 14/05/2012
27.100 / 4
Powered rear axle - Remove

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. Put articulation lock in LOCKED position.
BD03A040-01 1
3. Install wood blocks between rear axle and chassis to

prevent rear axle from pivoting.
4. Remove four bolts and two straps. Use a pry bar to
disconnect rear drive shaft from rear axle.
BD03A162-01 2
5. Disconnect brake hose from elbow. Remove and

discard O-ring face seal from elbow.
BD03A169-01 3
84605841 14/05/2012
27.100 / 5
6. Using an acceptable hydraulic jack, raise one tire

from ground and install an acceptable jack stand un-
der machine. Repeat this step for other tire.
BD01F299-01 4
7. Use an acceptable jack to hold rear axle.
BD01F302-01 5
8. Remove bolts and washers from rear wheels.

Remove both wheels from rear axle.
NOTE: 721F heavy duty axles have wheel studs on the
axles and use wheel nuts.
BD01F295-01 6
9. At front of trunnion, remove three Allen head bolts

and washers. Remove front cap: if necessary use
two M12 by 32 mm (1.26 in) bolts in puller holes (A);
tighten bolts evenly to pull cap from axle and trun-
nion. Remove and discard O-ring from cap. Repeat
this step at rear of trunnion except remove and re-
tain shim(s) after removal of rear cap. Remove pivot
shaft using acceptable sleeve or rod if necessary.
RAPH12WEL0211AA 7
84605841 14/05/2012
27.100 / 6
10. Carefully lower rear axle and remove through side of

machine.
11. Remove and discard two seals from rear axle pivot
point.
Next operation:
Powered rear axle - Install (27.100)
84605841 14/05/2012
27.100 / 7
Powered rear axle - Install

Prior operation:
Powered rear axle - Remove (27.100)
NOTE: If shim(s) (11) have been lost or pivot pin (10) has been replaced, do Step 1 to determine required shim(s)
otherwise go to Step 3.
1. Install pivot pin (10) and caps (4) and (12) in trunnion
(1) without rear axle or shim(s). Install washers and
bolts (6). Tighten bolts securely. Push assembled
pivot pin and caps to rear of machine as far as pos-
sible. Measure and record gap (A) between rear cap
(12) and trunnion (1). Select shims from the follow-
ing:
NOTE: Shims are available in following sizes: 0.50 mm (
0.020 inch ), 1.0 mm ( 0.039 inch ), and 1.50 mm ( 0.059
inch ).
RAPH12WEL0213AA 1
MEASURED GAP SHIM(S) REQUIRED

.07 - .55 mm (0.003 - 0.022 in) None
.56 - 1.09 mm (0.022 - 0.043 in) 0.5 mm (0.020 in)
1.1 - 1.59 mm (0.043 - 0.063 in) 1 mm (0.039 in)
1.6 - 2.09 mm (0.063 - 0.082 in) 1.5 mm (0.059 in)
2.1 - 2.59 mm (0.083 - 0.102 in) .5 mm (0.020 in) plus 1.5 mm (0.059 in)
2.6 - 3.02 mm (0.102 - 0.119 in) 1.0 mm (0.04 in) plus 1.5 mm (0.059 in)
2. As necessary refer to Powered rear axle - External

view (27.100) for detailed view of component loca-
tion.
84605841 14/05/2012
27.100 / 8
3. Clean front (A) and rear (B) pivot area of rear axle
where seals will be installed.
RAPH12WEL0214AA 2
RAPH12WEL0215AA 3
84605841 14/05/2012
27.100 / 9
4. Lubricate two new seals (2) and new O-rings using

Molydisulfide Grease. Install seals, smooth side out,
into front and rear of axle housing (A) until flush with
housing or recessed 2.0 mm ( 0.079 inch ). Install
an O-ring in each cap (3) and (6).
RAPH12WEL0216AA 4
5. Carefully move rear axle under machine. Raise axle

into position in trunnion and align pivot holes in trun-
nion with pivot holes in axle.
6. Lubricate pivot pin (8) using Molydisulfide Grease. at
rear of trunnion (B), install pivot pin into trunnion and
axle (A). Install shim pack (7), rear cap (6) with O-ring
installed, and two washers and bolts (5). Apply Loc-
tite 747 primer and LOCTITE® 243 to bolts. At front of
trunnion install front cap (4) with O-ring installed and
two washers and bolts (5). Tighten bolts (5) on the
621F to a torque of 325 - 353 Nm (240 - 260 lb ft) or
on the 721F to a torque of 651 - 678 Nm ( 480 - 500
lb.ft).
RAPH12WEL0217AA 5
7. Install both wheels on rear axle and secure using 12

washers and bolts.
BD01F295-01 6
84605841 14/05/2012
27.100 / 10
8. Tighten bolts to a preliminary torque of 278 Nm ( 205

lb.ft) in sequence indicated; then tighten to a torque
of 640 - 720 Nm ( 475 - 530 lb.ft) in same sequence.
b0987a88_576 7
9. Remove hydraulic jack supporting rear axle and jack

stands supporting loader.
RAPH12WEL0218AA 8
10. Install a new O-ring face seal in elbow. Connect

brake hose to elbow.
BD03A169-01 9
84605841 14/05/2012
27.100 / 11
11. Connect rear drive shaft to rear axle. Install two

straps and four bolts . Tighten bolts to a torque of
61 - 81 Nm ( 45 - 60 lb.ft).
BD03A162-01 10
12. If necessary, fill axle with gear lubricant specified in

Capacities.
13. See Powered rear axle - Filling (27.100) for oil fill
plug location.
14. Refer to Hydraulic service brakes - Bleed (33.202)
and bleed brakes.
15. Put articulation lock in OPERATING position.
84605841 14/05/2012
27.100 / 12
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)
84605841 14/05/2012
27.100 / 13
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
84605841 14/05/2012
27.100 / 14
Index

Powered rear axle - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Powered rear axle - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Rear axle control transmission shaft - Install - Rear Drive Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Rear axle control transmission shaft - Remove - Rear Drive Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Rear axle control transmission shaft - Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
84605841 14/05/2012
27.100 / 15
84605841 14/05/2012
27.100 / 16
Rear bevel gear set and differential - 106
621F
721F
84605841 14/05/2012
27.106 / 1
Contents
SERVICE
Bevel gear
Backlash - Models MT-L 3065 II / MT-L 3075 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Backlash - Models MT-L 3085 II / MT–L 3095 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
721F
Differential
Remove Models MT-L 3065 II / MT-L 3075 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Disassemble - D-1200 Open differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
621F
Assemble - D–1200 Open Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

621F
Limited slip - Disassemble - DZ-1200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Limited slip - Assemble - DZ-1200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
721F

721F
Disassemble - D-2400 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
721F
Assemble - D-2400 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
721F
84605841 14/05/2012
27.106 / 2
CONSUMABLES INDEX
Consumable IU PAGE
Loctite® 262 Differential - Remove Models MT-L 3065 II / MT-L 3075 II 27.106 / 23
84605841 14/05/2012
27.106 / 3
Rear axle system - Rear bevel gear set and differential
Bevel gear - Backlash - Models MT-L 3065 II / MT-L 3075 II

CAUTION
Burn hazard!
C0047A
Prior operation:
Differential Limited slip - Assemble — DZ-1200 (27.106)
Prior operation:
Differential - Assemble - D–1200 Open Differential (27.106)
1. Determine shim thickness to obtain a correct contact

pattern. Read dimension I (arrow) from the axle drive
housing. Dimension I example is 182.8 mm (7.197
in).
RAIL11WEL0505BA 1
NOTE: If crown wheel or input pinion are damaged, both parts must be replaced together. In the case of a new
installation of a complete bevel gear set, pay attention to an identical mating number of input pinion and crown wheel.
NOTE: The following measuring procedures must be carried out accurately. Inaccurate measurements will lead to an
incorrect contact patter requiring additional disassembly and reassembly of input pinion and differential.
2. Read dimension II (pinion dimension). Dimension II
example is 148 mm (5.827 in).
RAIL11WEL0506BA 2
NOTE: A pinion dimension without + or — deviation value = 148 mm (5.827 in). A pinion dimension with an indication
of +0.1 deviation = 148.1 mm (5.831 in). A pinion dimension with an indiction of —0.1 deviation = 147.9 mm (5.823
in).
84605841 14/05/2012
27.106 / 4

II example = 33.6 mm (1.323 in).
RAIL11WEL0507BA 3
NOTE: Calculation Example “A”. Dimension I = 182.8 mm (7.197 in). Dimension II = 148 mm (5.827 in). Dimension
III = 33.6 mm (1.323 in). Difference = shim s = 1.2 mm (0.047 in).
4. Insert the correct shim into the housing hole. Exam-
ple = 1.2 mm (0.047 in).
RAIL11WEL0508BA 4
5. Cool the internal bearing outer ring and insert it into

RAIL11WEL0509BA 5
84605841 14/05/2012
27.106 / 5
6. Cool the external bearing outer ring and insert it into

RAIL11WEL0510BA 6
7. Heat the tapered roller bearing and place it on the

input pinion.
RAIL11WEL0511BA 7
8. Set the rolling torque of the input bearing to 1.0 - 5.0

N·m (9 - 44 lb in) without the shaft seal. To do this,
insert spacer example spacer is 8.7 mm (0.343 in).
RAIL11WEL0512BA 8
NOTE: Based on experience, the necessary rolling torque is reached when reusing the spacer that was removed
during disassemble. Spacer example is 8.7 mm (0.343 in). Checking input pinion bearing rolling torque is a must.
84605841 14/05/2012
27.106 / 6
9. Insert the preassembled input pinion into the axle

drive housing and insert the heated tapered roller
bearing until correct fit is obtained.
RAIL11WEL0513BA 9
10. Press the protection plate onto the input flange (see
arrow) until contact is made.
RAIL11WEL0514BA 10
NOTE: Do not fit the shaft seal until the contact pattern has been checked.
11. Insert the input flange and secure it using the disk
and hex nut. Torque to 700 N·m (516 lb ft).
NOTE: Do not use Loctite during preliminary mounting of
hex nut.
NOTE: While tightening the hex nut, rotate the input pinion
several times in both directions.
RAIL11WEL0515BA 11
12. Check rolling torque without shaft seal in place.

Rolling torque should be 1 - 5 N·m (9 - 44 lb in).
NOTE: When installing new bearings, try to reach the up-
per value of the rolling torque.
NOTE: In the case of rolling torque deviations, correct with
a different spacer. Insufficient rolling torque requires a thin-
ner spacer ring. Excessive rolling torque requires a thicker
spacer ring.
RAIL11WEL0516BA 12
84605841 14/05/2012
27.106 / 7
13. Determine the correct shims for setting the bear-

ing rolling torque (differential housing) and backlash
(bevel gear set). Select the shims based on the read
value (deviation/test dimension) and corresponding
specifications of the table below: (KRS — SET —
RIGHT) (KRS = bevel gear set). See the crown
wheel rear side for deviation. The test dimension
“77” is stamped into the crown wheel rear side. If no
+ or — deviation is indicated, this value corresponds
to the actual value “0” in the table below. Accord-
ing to this value, the required shims are allocated in
the table below. Any + or — deviation of the test di-
mension caused by production is also marked on the
crown wheel rear side (example —20 or — 10 or 10).
In accordance with this deviation, the required shims
are allocated in the table below. RAIL11WEL0517BA 13
14. Legend for sketch

1. Axle housing
4. Axle housing
RAIL11WEL0593BA 14
Shims for differential D / DZ and DHL — 1200 in MT-L 3065 / 3075 II Axles
Crown wheel marking —20 —10 — 10
Deviation —0.2 —0.1 0 0.1
Shim Differential cage 0.7 0.8 0.9 1.0
side shim thickness
side shim thickness
15. Insert the determined shim (example s = 0.9 mm

(0.035 in)) into the hole of the axle housing and ad-
just the bearing outer ring (see arrow) until contact is
obtained.
RAIL11WEL0518BA 15
84605841 14/05/2012
27.106 / 8
16. Cover some drive and coast flanks of the crown

wheel with marking ink. Then insert the premounted
differential into the axle drive housing using a suit-
RAIL11WEL0519BA 16
17. Grease both O-rings (arrows) and insert them into

the annular grooves of the piston.
differential DHL.
RAIL11WEL0520BA 17
18. Insert the piston into the bearing housing.

differential DHL.
RAIL11WEL0521BA 18
19. Insert the selected shim (example s = 1.1 mm (0.043

in)) into the hole of the axle housing and adjust the
bearing outer ring (see arrow) until contact is made.
RAIL11WEL0522BA 19
84605841 14/05/2012
27.106 / 9
20. Connect the axle housing with the axle drive housing
using a suitable lifting device and secure them using
hex bolts. Torque bolts to 390 N·m (288 lb ft).
RAIL11WEL0523BA 20
21. Leak test the differential lock. Pressurize the lock to

1 bar (15 psi), close the shut-off valve and remove
air line. Thee should be no pressure loss within 10
seconds.
differential DHL.
RAIL11WEL0524BA 21
22. Rotate the input flange in both directions several

times to roll the crown wheel over the pinion. Then
remove the axle housing and lift the differential out
of the axle drive housing . Compare the observed
contact pattern with the contact pattern 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 by recalculating the shim size.
RAIL11WEL0525BA 22
Next operation:
Differential - Install — Models MT-L 3065 II / MT-L 3075 II (27.106)
84605841 14/05/2012
27.106 / 10
Bevel gear - Backlash - Models MT-L 3085 II / MT–L 3095 II

721F
CAUTION
Burn hazard!
C0047A
Prior operation:
Differential - Assemble — D-2400 (27.106)
1. Determine the shim thickness to obtain a correct con-

tact pattern. Read dimension I from axle drive hous-
ing. Dimension I e.g. 221.10 mm (8.705 in)
NOTE: If crown wheel or input pinion are damaged, both
parts must be replaced together. When installing a com-
plete new bevel gear set, look for identical mating number
of input pinion and crown wheel.
NOTE: Measuring procedures must be done accurately.
Inaccurate measurements lead to incorrect contact pattern
requiring additional disassembly and reassembly of input
pinion and differential.
RAIL11WEL0349BA 1
2. Read dimension II from pinion. Dimension II e.g.

181.00 mm (7.126 in).
RAIL11WEL0350BA 2
84605841 14/05/2012
27.106 / 11

III e.g. 39.10 mm (1.539 in).
RAIL11WEL0351BA 3
Calculation Example “A”:

Dimension I: -39.10 (1.54 in)
Dimension II: -181.00 (7.13 in)
Dimension III: -39.10 (1.54 in)
Difference = shim s = 1.00 mm (0.04 in)
4. Cool external bearing and insert it into axle drive

RAIL11WEL0352BA 4
5. Insert shim into housing hole size e.g. s = 1.00 mm

(0.039 in).
RAIL11WEL0353BA 5
84605841 14/05/2012
27.106 / 12
6. Cool internal bearing outer ring and bring it into con-

tact position in housing hole using 380100001 bear-
ing cup installer tool.
RAIL11WEL0354BA 6
7. Heat tapered roller bearing and insert it into input

pinion until contact is made.
RAIL11WEL0355BA 7
8. Set the rolling torque of the input pinion bearing (with-

out shaft seal) to 1.5 - 3.0 N·m (13 - 27 lb in). Insert
spacer e.g. s = 8.18 mm (0.322 in).
NOTE: Based on experience, necessary rolling torque is
obtained by reusing the spacer removed during disassem-
bly e.g. s = 8.18 mm (0.322 in).
NOTE: A later check of rolling torque is needed.
RAIL11WEL0356BA 8
84605841 14/05/2012
27.106 / 13
9. Insert pre-assembled input pinion into axle drive

housing. Insert heated tapered roller bearing until
contact is made.
RAIL11WEL0357BA 9
10. Press protection plate onto input flange until contact

is made.
NOTE: Do not fit shaft seal until contact pattern has been
checked and verified.
RAIL11WEL0358BA 10
11. Insert input flange and secure it with disk and slotted
nut. Torque to 1200 N·m (885 lb ft). Use CAS2842
slotted nut wrench and 380001546 flange holder.
NOTE: Temporarily mount slotted nut without Loctite.
While tightening, rotate input pinion several times in both
directions.
RAIL11WEL0359BA 11
84605841 14/05/2012
27.106 / 14
12. Check rolling torque. It should be 1.5 - 3.0 N·m (13 -

27 lb in) without a shaft seal.
NOTE: When installing new bearings try to achieve upper
value of rolling torque.
NOTE: In cases of rolling torque measurement deviations,
correct with a corresponding spacer as specified - go back
to 8. For insufficient rolling torque - install thinner spacer
ring. Excessive rolling torque - install a thicker spacer ring.
RAIL11WEL0360BA 12
13. Grease O-rings and insert them into annular grooves

of piston.
NOTE: This step is only need for versions with DHL differ-
ential.
RAIL11WEL0361BA 13
14. Insert piston (arrow) into bearing housing until con-

tact is made.
RAIL11WEL0362BA 14
84605841 14/05/2012
27.106 / 15
15. Determination the shims for setting the bearing

rolling torque (differential housing) and backlash
(bevel gear set). Determine the required shims on
the basis of read value (deviation/test dimension)
and corresponding specifications of the following
table: (KRS - SET - RIGHT) (KRS = bevel gear
set): Deviation see crown wheel rear side. The test
dimension “101” is stamped into the crown wheel
rear side. If no +/- deviation is indicated, this value
corresponds to actual value “0” in the following
table. According to this value, the required shims
are allocated in the table. Any +/- deviation of test
dimension caused by production is also 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 table.
RAIL11WEL0363BA 15
16. 1. Axle housing

4. Axle housing
RAIL11WEL0364BA 16
Shims for differential D/DL and DHL-2400 in ZF axles MT-L 3085/3095 II

Crown wheel marking —20 -10 10
Deviation -0.2 —0.1 0 0.1
Shim Diff. cage side 0.7 0.8 0.9 1.0
Shim thickness
Shim DHL 2400 Order 84395193 84354725 84354726 84354727
no.
Shim D/DL 2400 84476078 84330538 84330539 84330540
Order no.
side Shim thickness
Shim D/DL/DHL 2400 84476080 84330542 84330541 84330540
Order no.
84605841 14/05/2012
27.106 / 16

(arrow) until contact is obtained.
RAIL11WEL0365BA 17
18. Cover some drive and coast flanks of crown wheel

with marking ink. Insert pre-mounted differential into
axle drive housing.
RAIL11WEL0366BA 18

RAIL11WEL0367BA 19
84605841 14/05/2012
27.106 / 17
20. Mount two M20 locating pins (S) and bring axle hous-
ing into contact position with axle drive housing us-
ing a suitable 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.
RAIL11WEL0368BA 20
21. Leak test differential lock. Pressurize lock to p = 1

bar (15 psi), close the shutoff valve and remove air
line. No noticeable pressure loss should occur within
10 seconds.
NOTE: This operation is only necessary for version with
DHL differential.
RAIL11WEL0369BA 21
22. In both directions, several times, rotate input flange

to roll crown wheel over input pinion. Remove axle
housing and lift differential out of axle drive housing.
Compare obtained contact pattern with contact pat-
tern examples at the beginning of this section.
NOTE: If tooth contact pattern differs, an incorrect shim
size was selected in 5. This must be corrected.
RAIL11WEL0370BA 22
Next operation:
Differential - Install Models MT-L 3085 II / MT-L 3095 II (27.106)
84605841 14/05/2012
27.106 / 18
Differential - Remove Models MT-L 3065 II / MT-L 3075 II

RAIL11WEL0003BA 1
RAIL11WEL0004BA 2
RAIL11WEL0005BA 3
RAIL11WEL0006BA 4
84605841 14/05/2012
27.106 / 19

housing.
RAIL11WEL0007BA 5

output.
RAIL11WEL0008BA 6

RAIL11WEL0024BA 7
84605841 14/05/2012
27.106 / 20

arrow).
RAIL11WEL0025BA 8
RAIL11WEL0026BA 9
screw neck (4).
RAIL11WEL0061AA 10
11. Disassemble bearing bushing of center pivot.
RAIL12WEL0148BA 11
84605841 14/05/2012
27.106 / 21
12. Press bearing busing from axle housing hole. If

needed, make a slot (bold line) in the bearing bush-
ing.
RAIL11WEL0590BA 12
NOTE: Bearing bushing will be destroyed and should be replaced.

13. Attach a suitable lifting device to the differential and
lift differential out of the axle drive housing.
RAIL11WEL0028BA 13
14. Pull the bearing outer ring from the housing hole and
remove the shim behind it.
RAIL11WEL0029BA 14
84605841 14/05/2012
27.106 / 22
15. Heat the hex nut with a suitable heat gun.
RAIL11WEL0030BA 15
NOTE: Hex nut is secured with LOCTITE® 262.

16. Remove hex nut and the shim behind it.
RAIL11WEL0031BA 16
17. Pull the input flange from the input pinion and remove
the shaft seal behind from the axle drive housing.
RAIL11WEL0032BA 17
18. Remove the input pinion from the axle drive housing
with a suitable puller and then remove the tapered
roller bearing.
RAIL11WEL0033BA 18
84605841 14/05/2012
27.106 / 23
19. Remove the spacer ring and pull the tapered roller
bearing from the input pinion.
RAIL11WEL0034BA 19
20. If needed, force both bearing outer rings out of the

axle drive housing.
RAIL11WEL0035BA 20
Next operation:
Differential Limited slip - Disassemble — DZ-1200 (27.106)
Next operation:
Differential - Disassemble — D-1200 Open differential (27.106)
84605841 14/05/2012
27.106 / 24
Differential - Install - Models MT-L 3065 II / MT-L 3075 II

Prior operation:
Bevel gear - Backlash — Models MT-L 3065 II / MT-L 3075 II (27.106)
1. After a successful contact pattern check, loosen the

hexagon nut and pull the input flange from the input
pinion.
RAIL11WEL0526BA 1
2. Mount the shaft seal with the seal lip showing to the
oil chamber.
NOTE: The exact installation position of the shaft seal is
obtained when using the specified driver tool.
spirits before installation and fill the space between the seal
and dust lip with grease.
RAIL11WEL0527BA 2
3. Insert the input flange and tighten by means of disk

and hex nut. Torque nut to 700 N·m (516 lb ft).
RAIL11WEL0528BA 3
NOTE: Cover the thread of the hexagon nut with LOCTITE® 262.
84605841 14/05/2012
27.106 / 25
4. Using a suitable lifting device, insert the differential

into the axle drive housing.
RAIL11WEL0529BA 4
5. Attach axial roller cage to the sliding sleeve using

grease.
RAIL11WEL0504BA 5
NOTE: This operation is only needed for axles with the DHL differential.
RAIL11WEL0531BA 6

RAIL11WEL0061AA 7
84605841 14/05/2012
27.106 / 26
8. Grease O-ring (see arrow) and insert it into the axle

housing.
RAIL11WEL0532BA 8
9. Using a suitable lifting device, attach axle housing to

axle drive housing and secure with hex nuts. Torque
hex nuts to 390 N·m (288 lb ft).
RAIL11WEL0533BA 9
10. Heat the hole in the axle drive housing with a hot air
blower.
RAIL12WEL0596BA 10
84605841 14/05/2012
27.106 / 27
11. Cool the bearing bushing and then insert it into the
axle drive housing with the grove in the front face
located in the 6 o’clock position.
RAIL12WEL0595BA 11
Next operation:
84605841 14/05/2012
27.106 / 28
Differential - Disassemble - D-1200 Open differential

621F
Prior operation:
Differential - Remove Models MT-L 3065 II / MT-L 3075 II (27.106)
1. Pull both tapered roller bearings from the differential.
RAIL11WEL0044BA 1
2. Preload the differential using a press. Remove lock-

ing bolts and housing cover.
RAIL11WEL0045BA 2

press differential carrier off the crown wheel.
RAIL11WEL0046BA 3
84605841 14/05/2012
27.106 / 29
4. 1. Differential carrier
2. Axle bevel gear
3. Crown wheel
4. Thrust washer
5. Constant spacer
RAIL11WEL0047BA 4

in the arrow direction and remove components from
RAIL11WEL0048BA 5
6. Differential carrier components are as follows:

7. Spider shaft (1 piece)
8. Outer disc
9. Thrust washer
10. Constant spacer
11. Axle bevel gear
RAIL11WEL0059BA 6
Next operation:
Differential - Assemble - D–1200 Open Differential (27.106)
84605841 14/05/2012
27.106 / 30
Differential - Assemble - D–1200 Open Differential

621F
Prior operation:
Differential - Disassemble — D-1200 Open differential (27.106)
1. Insert constant spacer into differential carrier.
RAIL11WEL0465BA 1
2. Insert steel outer disc (1) and thrust washer (2) into
RAIL11WEL0466BA 2
RAIL11WEL0467BA 3
84605841 14/05/2012
27.106 / 31
4. Reassembly differential spider.

1. Spider shaft.
2. Spider gears — 4 components
3. Thrust washer — 4 components
5. Slotted pin — 2 components
6. Slotted pin — 2 components
RAIL11WEL0468BA 4
5. Insert the spider gears with thrust washers into the

differential housing and secure them with the long
spider shaft. The thrust washers must be positioned
with the tabs (arrow) located in the recesses of the
RAIL11WEL0469BA 5
6. Insert the spider gears with the thrust washers into

the differential housing and secure them with the two
short spider shafts. The thrust washers must be po-
sitioned with the tabs (1) located in the recesses of
the differential housing. Note the radial installation
position of the holes in the spider shafts (2).
RAIL11WEL0470BA 6
7. Secure the short spider shafts with the slotted pins.
RAIL11WEL0471BA 7
NOTE: The pins must be flush mounted.
84605841 14/05/2012
27.106 / 32
NOTE: Install the openings of the slotted pins offset to each other by 180 °.
8. Install the second axle bevel gear.
RAIL11WEL0472BA 8
9. Insert the thrust washer (1) and constant spacer (2)

into the differential carrier.
NOTE: Note the installation position.
RAIL11WEL0473BA 9
10. Mount the two locating pins and press the crown
wheel onto the differential housing.
RAIL11WEL0474BA 10
11. Insert the housing cover until contact is made with

the crown wheel. Preload the differential using the
press and bolt with new locking bolts. Torque bolts
to 400 N·m (295 lb ft).
RAIL11WEL0494BA 11
84605841 14/05/2012
27.106 / 33
12. Heat both tapered roller bearings (arrows) and install

them on the differential.
RAIL11WEL0495BA 12
Next operation:
84605841 14/05/2012
27.106 / 34
Differential Limited slip - Disassemble - DZ-1200

Prior operation:
Differential - Remove Models MT-L 3065 II / MT-L 3075 II (27.106)
1. Using a suitable puller to remove both tapered roller

bearings from the differential.
RAIL11WEL0050BA 1
2. Preload the differential using a press and then re-

move locking bolts and housing cover.
RAIL11WEL0051BA 2

then press differential carrier off the crown wheel.
RAIL11WEL0052BA 3
84605841 14/05/2012
27.106 / 35
4. Remove the releasing disk package, thrust washer

and axle bevel gear.
RAIL11WEL0060BA 4

in arrow direction and remove components from dif-
ferential carrier.
RAIL11WEL0053BA 5
84605841 14/05/2012
27.106 / 36
6. Differential components
RAIL11WEL0001BA 6
7. Remove the releasing axle bevel gear, thrust washer

and disc package.
RAIL12WEL0267CA 7
Next operation:
Differential Limited slip - Assemble — DZ-1200 (27.106)
84605841 14/05/2012
27.106 / 37
Differential Limited slip - Assemble - DZ-1200

Prior operation:
Differential Limited slip - Disassemble — DZ-1200 (27.106)
1. Observe component location for limited slip differen-

tial. Legend to sketch
1. Housing cover
2. Crown wheel
3. Spider shaft (split version) (two parts)
4. Slotted pins
5. Spider gear
6. Axle bevel gear
8. Disk package “A”
9. Disk package “B”
NOTE: “A” Installation dimension = 18.6 mm - 0.2 mm.
NOTE: “B” installation dimension = 16.7 mm — 0.2 mm.
RAIL12WEL0220BA 1
2. Insert disk package (1) and thrust washer (2) into

NOTE: The installation dimension “A” (18.6 mm —0.2 mm)
RAIL12WEL0219BA 2
84605841 14/05/2012
27.106 / 38
RAIL11WEL0486BA 3
4. Observe reassembly position of differential spider.

RAIL11WEL0497BA 4
5. Insert spider gears with thrust washers into the dif-

ferential housing and fix them with the long spider
shafts.
RAIL11WEL0498BA 5
NOTE: Position thrust washers with the tabs (see arrow) located in the recesses of the differential housing.
ential housing and fix them with the two short spider
shafts.
NOTE: Position thrust washers with the tabs (see arrow 1)
NOTE: Observe the radial installation position (securing
holes, arrow 2) of the spider shafts.
RAIL11WEL0499BA 6
84605841 14/05/2012
27.106 / 39

RAIL11WEL0490BA 7
RAIL11WEL0491BA 8
84605841 14/05/2012
27.106 / 40
9. Insert thrust washer (1) and disk package (2) into the
NOTE: The installation dimension “B” (16.7 mm —0.2 mm)
RAIL11WEL0060BA 9
10. Mount two locating pins and press the crown wheel
onto the differential housing.
RAIL11WEL0502BA 10
84605841 14/05/2012
27.106 / 41
11. Insert the housing cover until contact is made with the
crown wheel. Use a press to preload the differential
and secure with new locking bolts. Torque bolts to
400 N·m (295 lb ft).
RAIL11WEL0503BA 11
12. Heat both tapered roller bearings and install them on

the differential.
RAIL11WEL0464BA 12
Next operation:
84605841 14/05/2012
27.106 / 42

721F
CAUTION
Burn hazard!
C0047A

sembly stand.
studs.
RAIL11WEL0178BA 1

and disposal.
RAIL11WEL0179BA 2

and disposal.
RAIL11WEL0180BA 3
84605841 14/05/2012
27.106 / 43
4. Remove bleeder valve to avoid damage during out-

put and axle housing separation.
RAIL11WEL0181BA 4

from axle housing.
RAIL11WEL0182BA 5

RAIL11WEL0183BA 6
84605841 14/05/2012
27.106 / 44

drive housing.
RAIL11WEL0213BA 7

brake tube.
RAIL11WEL0214BA 8
RAIL11WEL0212BA 9
84605841 14/05/2012
27.106 / 45
RAIL11WEL0233BA 10
11. Lift differential from axle drive housing using a suit-

RAIL11WEL0232BA 11
12. Pull bearing outer ring (arrow) from housing and re-
move shim.
RAIL11WEL0233BA 12
84605841 14/05/2012
27.106 / 46
13. Remove piston (arrow) from axle housing.

RAIL11WEL0234BA 13
14. Use compressed air to remove piston.

RAIL11WEL0235BA 14
15. Heat slotted nut with a hot air blower.

NOTE: Slotted nut is secured with LOCTITE® 262.
RAIL11WEL0236BA 15
84605841 14/05/2012
27.106 / 47
16. Remove slotted nut and shim behind it. Use slot-
ted nut wrench CAS2842 and clamping device
380001546.
RAIL11WEL0237BA 16
17. Remove input flange from pinion. Use a lever to re-

move shaft seal.
RAIL11WEL0238BA 17
18. Press input pinion from axle drive housing and re-
move releasing tapered roller bearing.
RAIL11WEL0239BA 18
84605841 14/05/2012
27.106 / 48
19. Remove spacer ring and pull tapered roller bearing

from input pinion.
RAIL11WEL0240BA 19
20. If needed, remove bearing outer rings from axle drive

housing.
RAIL11WEL0231BA 20
Next operation:
Differential - Disassemble — D-2400 (27.106)
84605841 14/05/2012
27.106 / 49
Differential - Install Models MT-L 3085 II / MT-L 3095 II

721F
Prior operation:
Bevel gear - Backlash — Models MT-L 3085 II / MT–L 3095 II (27.106)
1. After contact pattern check, insert differential into

axle drive housing again.
RAIL11WEL0371BA 1
2. Remove slotted nut and pull input flange from in-

put pinion. Use CAS2842 slotted nut wrench and
380001546clamping device.
RAIL11WEL0372BA 2
3. Using CAS2841 driver tool, mount shaft seal with

seal lip facing oil chamber.
NOTE: Exact installation position of seal is obtained using
specified driver tool.
NOTE: Wet outer diameter of shaft seal with mineral spirits
just before installation. Fill space between seal and dust lip
with grease.
RAIL11WEL0373BA 3
84605841 14/05/2012
27.106 / 50
4. Insert input flange and secure it using disc and

slotted nut. Torque to 1200 N·m (885 lb ft). Use
CAS2842 slotted nut wrench and 380001546 clamp-
ing device.
NOTE: Cover threads of slotted nut with LOCTITE® 262.
RAIL11WEL0348BA 4
RAIL11WEL0397BA 5

RAIL11WEL0398BA 6
84605841 14/05/2012
27.106 / 51
RAIL11WEL0399BA 7

ing brake tube.
RAIL11WEL0400BA 8

RAIL11WEL0401BA 9
84605841 14/05/2012
27.106 / 52

ft).
RAIL11WEL0396BA 10
Next operation:
84605841 14/05/2012
27.106 / 53
Differential - Disassemble - D-2400

721F
Prior operation:
RAIL11WEL0243BA 1
2. Preload differential using a press. Remove hex bolts

and releasing housing cover.
RAIL11WEL0244BA 2
3. Preload differential using a press. Remove locking

bolts and housing cover.
RAIL11WEL0247BA 3
84605841 14/05/2012
27.106 / 54
4. Remove axle bevel gear with thrust washers from

RAIL11WEL0248BA 4
5. Force out both slotted pins.
RAIL11WEL0249BA 5
6. Force out both short differential axles. Remove re-

leasing spider gears with thrust washers from differ-
ential housing.
RAIL11WEL0250BA 6
84605841 14/05/2012
27.106 / 55
7. Pull long differential axle. Remove releasing spider

gears with thrust washers from differential housing.
RAIL11WEL0251BA 7
8. Remove axle bevel gear and shim.
RAIL11WEL0252BA 8
9. Press crown wheel from differential carrier.
RAIL11WEL0241BA 9
Next operation:
Differential - Assemble — D-2400 (27.106)
84605841 14/05/2012
27.106 / 56
Differential - Assemble - D-2400

721F
CAUTION
Burn hazard!
C0047A
Prior operation:
Differential - Disassemble — D-2400 (27.106)
1. Mount locating pins and press heated crown wheel

onto differential housing until contact is made.
RAIL11WEL0270BA 1
2. Insert thrust washer into differential housing.
RAIL11WEL0271BA 2
84605841 14/05/2012
27.106 / 57
RAIL11WEL0272BA 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.
RAIL11WEL0273BA 4
5. Insert spider gears with thrust washers into differ-

ential housing. Secure them with two short spider
shafts.
RAIL11WEL0274BA 5
84605841 14/05/2012
27.106 / 58
6. Secure short spider shafts with slotted pins.

NOTE: Flush mount slotted pins.
RAIL11WEL0275BA 6
RAIL11WEL0276BA 7
8. Secure thrust washers into housing cover with

grease.
RAIL11WEL0277BA 8
84605841 14/05/2012
27.106 / 59
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).
RAIL11WEL0278BA 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).
RAIL11WEL0298BA 10
ing down.
RAIL11WEL0299BA 11
Next operation:
Bevel gear - Backlash — Models MT-L 3085 II / MT–L 3095 II (27.106)
84605841 14/05/2012
27.106 / 60
Index

Bevel gear - Backlash - Models MT-L 3065 II / MT-L 3075 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Bevel gear - Backlash - Models MT-L 3085 II / MT–L 3095 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
721F
Differential - Assemble - D-2400 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
721F
Differential - Assemble - D–1200 Open Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
621F
Differential - Disassemble - D-1200 Open differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
621F
Differential - Disassemble - D-2400 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
721F
Differential - Install - Models MT-L 3065 II / MT-L 3075 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Differential - Install Models MT-L 3085 II / MT-L 3095 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
721F
721F
Differential - Remove Models MT-L 3065 II / MT-L 3075 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Differential Limited slip - Assemble - DZ-1200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Differential Limited slip - Disassemble - DZ-1200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
84605841 14/05/2012
27.106 / 61
84605841 14/05/2012
27.106 / 62
Planetary and final drives - 120
621F
721F
84605841 14/05/2012
27.120 / 1
Contents
SERVICE
Wheel hub
Remove - Models MT-L 3065 II / MT-L 3075 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Install - Models MT-L 3065 II / 3075 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Disassemble - Models MT-L 3065 II / MT-L 3075 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
721F

721F

721F
Visual inspection - Models MT-L 3085 II / MT–L 3095 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

721F

721F
84605841 14/05/2012
27.120 / 2
CONSUMABLES INDEX
Consumable IU PAGE
84605841 14/05/2012
27.120 / 3
Rear axle system - Planetary and final drives

RAIL11WEL0003BA 1
RAIL11WEL0004BA 2
RAIL11WEL0005BA 3
RAIL11WEL0006BA 4
84605841 14/05/2012
27.120 / 4

housing.
RAIL11WEL0007BA 5

output.
RAIL11WEL0008BA 6
Next operation:
84605841 14/05/2012
27.120 / 5
Wheel hub - Install - Models MT-L 3065 II / 3075 II

CAUTION
Burn hazard!
C0047A
Prior operation:
1. Set the sun gear shaft axial play range to 0.5 - 2.0
mm (0.020 - 0.079 in). Use a straight edge to deter-
mine dimension I from the mounting face of the brake
housing to the front face of the stop bolt. Dimension
I example 21.25 mm (0.837 in).
RAIL11WEL0557BA 1
2. Insert the stub shaft with sun gear into the teeth of
the axle bevel gear until it stops.
RAIL11WEL0558BA 2
3. Using a straight edge, measure dimension II from

the front face of the sun gear shaft to the mounting
surface of the axle housing. Dimension II example
19.00 mm (0.748 in).
NOTE: Calculation example: Dimension I 21.25 mm
(0.837 in) minus Dimension II 19.00 mm (0.748 in) equals
a difference of 2.25 mm (0.089 in) minus the required
axial play example of 1.25 mm (0.049 in) which leaves a
difference or required shim size of 1.00 mm (0.039 in).
RAIL11WEL0559BA 3
84605841 14/05/2012
27.120 / 6
4. Remove stub shaft with sun gear from the axle hous-
ing. Then insert the required shim (2) into the sun
gear shaft (1) and mount the stub shaft (3).
RAIL11WEL0560BA 4
5. Grease the O-ring (arrow) and install it into the axle

housing.
RAIL11WEL0561BA 5
6. Use a suitable lifting device and pick up the output.

Then secure disk package using the locating screw
assembly aid.
RAIL11WEL0562BA 6
7. Mount pre-assembled stub shaft into the teeth of the

planetary gears.
RAIL11WEL0563BA 7
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8. Bring the output assembly together with the axle

housing by mounting the stub shaft into the gearing
of the axle bevel gear.
NOTE: Pay attention to end plate positioning.
RAIL11WEL0564BA 8
9. Secure the output using hex bolts. Torque bolts to

390 N·m (288 lb ft).
RAIL11WEL0565BA 9
10. Install the screw neck (1) with new O-ring and torque
to 36 N·m (27 lb ft). Next mount breather valve (2)
and torque to 6 N·m (53 lb in). Then install the screw
plug (3) with new O-ring and torque to 50 N·m (37 lb
ft).
RAIL11WEL0566BA 10
Next operation:
Brakes - Leakage test — Models MT-L 3065 II / MT–L 3075 II (33.202)
84605841 14/05/2012
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Prior operation:
Wheel hub - Remove - Models MT-L 3065 II / MT-L 3075 II (27.120)
1. Attach output assembly to suitable work stand.

Remove end plate (1), screw neck (2), and brake
breather valve (3).
RAIL11WEL0009BA 1
RAIL11WEL0010BA 2

cover.
RAIL11WEL0011BA 3
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RAIL11WEL0012BA 4

RAIL11WEL0013BA 5
RAIL11WEL0014BA 6
84605841 14/05/2012
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RAIL11WEL0015BA 7
RAIL11WEL0016BA 8

RAIL11WEL0017BA 9
RAIL11WEL0018BA 10
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RAIL11WEL0019BA 11

1. Brake housing
2. Guide ring
3. Back-up ring
4. Grooved ring
5. Grooved ring
6. Back-up ring
RAIL11WEL0062BA 12

RAIL11WEL0020BA 13
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necessary.
RAIL11WEL0021BA 14

RAIL11WEL0022BA 15

RAIL11WEL0023BA 16
Next operation:
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Wheel hub - Visual inspection - Models MT-L 3065 II / MT-L 3075 II

Prior operation:
are seen.
place if necessary.
are seen.
Next operation:
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Wheel hub - Assemble - MT-L 3065 II / MT-L 3075 II

CAUTION
Burn hazard!
C0047A
Prior operation:

574
RAIL11WEL0535BA 1

RAIL11WEL0536BA 2
3. Insert shaft seal into the brake housing. Ensure seal

is installed and seated properly.
RAIL11WEL0537BA 3
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1. Output shaft
2. Brake housing
RAIL11WEL0428BA 4

housing.
RAIL11WEL0538BA 5

housing.
RAIL11WEL0539BA 6
84605841 14/05/2012
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brake housing.
RAIL11WEL0540BA 7

RAIL11WEL0541BA 8

1. Brake housing
2. Guide ring
3. Support ring
4. Grooved ring
5. Grooved ring
6. Support ring
RAIL11WEL0062BA 9
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piston.
RAIL11WEL0542BA 10
RAIL11WEL0543BA 11
RAIL11WEL0544BA 12
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1. Disc
2. Cup spring
3. Cover
4. Piston
5. Hex bolt
6. Brake housing
RAIL11WEL0589BA 13

(25 lb ft).
RAIL11WEL0545BA 14

agent.
RAIL11WEL0546BA 15
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RAIL11WEL0547BA 16

RAIL11WEL0548BA 17

RAIL11WEL0549BA 18
RAIL11WEL0550BA 19
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than 24 h.
RAIL11WEL0551BA 20
RAIL11WEL0552BA 21

RAIL11WEL0553BA 22

housing.
RAIL11WEL0554BA 23
84605841 14/05/2012
27.120 / 21

gear.
2. Packaging sleeve
3. Snap ring
4. Planetary gear
RAIL11WEL0555BA 24

retaining rings.
RAIL11WEL0556BA 25
Next operation:
84605841 14/05/2012
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721F

sembly stand.
studs.
RAIL11WEL0178BA 1

and disposal.
RAIL11WEL0179BA 2

and disposal.
RAIL11WEL0180BA 3
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4. Remove bleeder valve to avoid damage during out-

put and axle housing separation.
RAIL11WEL0181BA 4

from axle housing.
RAIL11WEL0182BA 5

RAIL11WEL0183BA 6
Next operation:
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Wheel hub - Install Models MT-L 3085 II / MT-L 3095 II

721F
Prior operation:
1. Set axial play of sun gear shaft to 0.5 - 2.0 mm (0.020

- 0.079 in). Determine dimension I, distance from
mounting face of brake housing to front face of stop
bolt. Dimension I e.g. 19.75 mm (0.778 in).
RAIL11WEL0450BA 1
2. Insert stub shaft into teeth of axle bevel gear until

contact is made.
NOTE: Be aware of installation position. Mount stub shaft
side with long teeth towards differential.
RAIL11WEL0451BA 2
3. Insert sun gear shaft until contact is made.
RAIL11WEL0452BA 3
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4. Measure dimension II, from front face of sun gear

shaft to mounting surface of axle housing. Dimen-
sion II e.g. 17.15 mm (0.675 in).
RAIL11WEL0453BA 4
CALCULATION EXAMPLE:
Dimension I: 19.75 mm (0.778 in)
Dimension II: 17.15 mm (0.675 in)
Difference: 2.60 mm (0.102 in)
Required axial play e.g.: 1.00 mm (0.039 in)
Difference = shim e.g. s = 1.60 mm (0.06 in)
5. Insert sun gear shaft into planetary carrier.
RAIL11WEL0454BA 5
6. Insert shim(s) e.g. s = 1.60 mm (0.063 in) with

grease into sun gear shaft.
RAIL11WEL0455BA 6
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7. Insert O-ring with grease into countersink of brake

housing.
RAIL11WEL0456BA 7
8. Grease O-ring and install it in axle housing.
RAIL11WEL0457BA 8
9. Mount adjusting bolts and use acceptable lifting de-

vice to bring output into contact position with axle
housing. Secure output using hex bolts. Torque to
390 N·m (288 lb ft).
NOTE: Attach lifting device with wheel stud.
RAIL11WEL0458BA 9
84605841 14/05/2012
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10. Mount bleeder valve (arrow).
RAIL11WEL0459BA 10
Next operation:
Brakes - Leakage test — Models MT-L 3085 II / MT-L 3095 II (33.202)
84605841 14/05/2012
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721F
Prior operation:
RAIL11WEL0184BA 1
RAIL11WEL0185BA 2
RAIL11WEL0186BA 3
84605841 14/05/2012
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shaft profile.
RAIL11WEL0187BA 4

RAIL11WEL0188BA 5

RAIL11WEL0189BA 6
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RAIL11WEL0190BA 7
RAIL11WEL0191BA 8
RAIL11WEL0192BA 9
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RAIL11WEL0193BA 10
RAIL11WEL0194BA 11

RAIL11WEL0195BA 12
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(arrows).
RAIL11WEL0196BA 13
14. Note the installation position of the individual parts.

1. Brake housing
2. Guide ring
3. Back-up ring
4. Piston seal
5. Piston seal
6. Back-up ring
8. Output shaft
RAIL11WEL0197BA 14

output shaft.
RAIL11WEL0198BA 15
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RAIL11WEL0199BA 16

RAIL11WEL0200BA 17

output shaft.
RAIL11WEL0177BA 18
Next operation:
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Wheel hub - Visual inspection - Models MT-L 3085 II / MT–L 3095 II

721F
Prior operation:

are seen.
place if necessary.
are seen.
Next operation:
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Wheel hub - Assemble - Models MT-L 3085 II / MT-L 3095 II

721F
CAUTION
Burn hazard!
C0047A
Prior operation:

tact is made.
studs.
RAIL11WEL0423BA 1

RAIL11WEL0424BA 2
84605841 14/05/2012
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output shaft.
RAIL11WEL0425BA 3

housing.
RAIL11WEL0426BA 4

RAIL11WEL0427BA 5
84605841 14/05/2012
27.120 / 37

combi seal.
1. Output shaft
2. Brake housing
Screening plate.
RAIL11WEL0428BA 6

RAIL11WEL0429BA 7

driver tool.
RAIL11WEL0430BA 8
84605841 14/05/2012
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made.
this step.
RAIL11WEL0431BA 9

RAIL11WEL0432BA 10

12). Secure it with Loctite (type no. 415) at its ends
(arrows).
contact position.
RAIL11WEL0433BA 11
84605841 14/05/2012
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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
RAIL11WEL0434BA 12
RAIL11WEL0435BA 13
RAIL11WEL0436BA 14
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RAIL11WEL0437BA 15

RAIL11WEL0438BA 16

RAIL11WEL0439BA 17
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RAIL11WEL0440BA 18
tact is obtained.
RAIL11WEL0461CA 19
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RAIL11WEL0441BA 20

RAIL11WEL0442BA 21

RAIL11WEL0443BA 22
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RAIL11WEL0444BA 23

lifting device.
RAIL11WEL0445BA 24

ft).
RAIL11WEL0446BA 25
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RAIL11WEL0447BA 26

ing table.
0.30 - 0.24 mm (0.012 - 0.009 in) 0.13 mm +/- 0.01 mm ( 0.005 in 4474 353 172
0.0003 in)
0.239 - 0.18 mm (0.009 - 0.007 in) 0.07 mm +/- 0.01 mm ( 0.003 in 4474 353 172
0.0003 in)
0.179 - 0.10 mm (0.007 - 0.004 in) 0 mm (0.000 in) 4474 353 115
hours.
RAIL11WEL0448BA 27
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RAIL11WEL0449BA 28
Next operation:
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Index

Wheel hub - Assemble - MT-L 3065 II / MT-L 3075 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Wheel hub - Assemble - Models MT-L 3085 II / MT-L 3095 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
721F
Wheel hub - Disassemble - Models MT-L 3065 II / MT-L 3075 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
721F
Wheel hub - Install - Models MT-L 3065 II / 3075 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Wheel hub - Install Models MT-L 3085 II / MT-L 3095 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
721F
Wheel hub - Remove - Models MT-L 3065 II / MT-L 3075 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Wheel hub - Remove - Models MT-L 3085 II / MT-L 3095 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
721F
Wheel hub - Visual inspection - Models MT-L 3065 II / MT-L 3075 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Wheel hub - Visual inspection - Models MT-L 3085 II / MT–L 3095 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
721F
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PRINTED IN U.S.A.
84605841 14/05/2012
EN
SERVICE MANUAL
Brakes and controls
621F
721F
84605841 14/05/2012
33
Contents
Brakes and controls - 33
Hydraulic service brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33.202

621F , 721F
84605841 14/05/2012
33
CONSUMABLES INDEX
Consumable IU PAGE
DEXRON® Brakes - Leakage test - Models MT-L 3065 II / MT–L 3075 II 33.202 / 9
DEXRON® Brakes - Leakage test - Models MT-L 3085 II / MT-L 3095 II 33.202 / 10
Loctite® 574 Brake disks - Assemble - MT-L 3065 II / MT-L 3075 II 33.202 / 17
Terostat® MS-9360 Brake disks - Assemble - MT-L 3065 II / MT-L 3075 II 33.202 / 23
Loctite® 415 Brake disks - Assemble - Models MT-L 3085 II / MT-L 3095 II 33.202 / 35
Terostat® MS-9360 Brake disks - Assemble - Models MT-L 3085 II / MT-L 3095 II 33.202 / 41
84605841 14/05/2012
33
84605841 14/05/2012
33
Hydraulic service brakes - 202
621F
721F
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Contents
TECHNICAL DATA
Hydraulic service brakes

Brake pump
Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Accumulator
Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Brake disks
Service limits - Models MT-L 3065 II / MT-L 3075 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Service limits - Models MT-L 3085 II / MT-L 3095 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
721F
SERVICE
Brakes
Leakage test - Models MT-L 3065 II / MT–L 3075 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Leakage test - Models MT-L 3085 II / MT-L 3095 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
721F
Brake disks
721F

721F

721F
Brake lines
Install - Models MT-L 3065 II / 3075 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Remove -Models MT-L 3085 II / MT-L 3095 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
721F

721F
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CONSUMABLES INDEX
Consumable IU PAGE
DEXRON® Brakes - Leakage test - Models MT-L 3065 II / MT–L 3075 II 33.202 / 9
DEXRON® Brakes - Leakage test - Models MT-L 3085 II / MT-L 3095 II 33.202 / 10
Loctite® 415 Brake disks - Assemble - Models MT-L 3085 II / MT-L 3095 II 33.202 / 35
Terostat® MS-9360 Brake disks - Assemble - Models MT-L 3085 II / MT-L 3095 II 33.202 / 41
84605841 14/05/2012
33.202 / 3
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 (35.000)

621F Hydraulic systems - Hydraulic schematic frame 01 – 621F Tier 2\4 (35.000)
721F Hydraulic systems - Hydraulic schematic frame 01 – 721F 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 - Models MT-L 3065 II / MT-L 3075 II
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 4.0 mm (0.157 in) for a standard axle configuration with limited slip differential using paper linings or 3.5
mm (0.138 in) for a heavy duty axle configuration with front differential lock and open rear differential using sintered
bronze discs the lined discs on both output sides must be replaced. Replace O-ring when installing the plug. Tighten
plug to a torque of 50 N·m (37 lb ft) .
Brake disks - Service limits - Models MT-L 3085 II / MT-L 3095 II

721F
RCIL11WHL163BAF 1
84605841 14/05/2012
33.202 / 7
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 4.0 mm (0.157 in) the lined discs on both output sides must be replaced. Replace O-ring when installing the
plug. Tighten plug to a torque of 70 N·m (52 lb ft).
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Brakes - Leakage test - Models MT-L 3065 II / MT–L 3075 II

Prior operation:
Wheel hub - Install — Models MT-L 3065 II / 3075 II (25.108) Wheel hub - Install — Models MT-L 3065 II / 3075
II (27.120)
1. Check brake hydraulics for leakage. Before starting

test, bleed hydraulic system. Then pressurize brake
temporarily 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
RAIL11WEL0534BA 1
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.
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Brakes - Leakage test - Models MT-L 3085 II / MT-L 3095 II

721F
Prior operation:
Brake disks - Assemble — Models MT-L 3085 II / MT-L 3095 II (33.202)
1. Check brake hydraulics for leakage. Before starting

test, bleed hydraulic system. Then pressurize brake
temporarily five times with a maximum pressure of p
= 100 bar (1450 psi).
RAIL11WEL0460BA 1
High-pressure test:
Build up test pressure p = 100-10 bar maximum
and close connection to the 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 the shut-off valve. No pressure drop is
allowed during a 5 min test period.
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.
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Brake disks - Disassemble - Models MT-L 3065 II / MT-L 3075 II

Prior operation:
Wheel hub - Remove - Models MT-L 3065 II / MT-L 3075 II (27.120)
1. Attach output assembly to suitable work stand. Re-

move end plate (1), brake breather valve (2), and
screw neck (3).
RAIL11WEL0009BA 1
RAIL11WEL0010BA 2

cover.
RAIL11WEL0011BA 3
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RAIL11WEL0012BA 4

RAIL11WEL0013BA 5
RAIL11WEL0014BA 6
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33.202 / 12

RAIL11WEL0015BA 7
RAIL11WEL0016BA 8

RAIL11WEL0017BA 9
RAIL11WEL0018BA 10
84605841 14/05/2012
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RAIL11WEL0019BA 11

1. Brake housing
2. Guide ring
3. Back-up ring
4. Grooved ring
5. Grooved ring
6. Back-up ring
RAIL11WEL0062BA 12

RAIL11WEL0020BA 13
84605841 14/05/2012
33.202 / 14
necessary.
RAIL11WEL0021BA 14

RAIL11WEL0022BA 15

RAIL11WEL0023BA 16
Next operation:
Brake disks - Visual inspection — Models MT-L 3065 II / MT-L 3075 II (33.202)
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Brake disks - Visual inspection - Models MT-L 3065 II / MT-L 3075 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 — Models MT-L 3065 II / MT-L 3075 II (33.202)

pack using cleaning solvent. Use compressed air
to clear passages in planetary ring gear and brake
housing.
Next operation:
Brake disks - Assemble — MT-L 3065 II / MT-L 3075 II (33.202)
84605841 14/05/2012
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Brake disks - Assemble - MT-L 3065 II / MT-L 3075 II

CAUTION
Burn hazard!
C0047A
Prior operation:

574
RAIL11WEL0535BA 1

RAIL11WEL0536BA 2
3. Insert shaft seal into the brake housing. Use special

tool ?? for exact installation position of the seal.
RAIL11WEL0537BA 3
84605841 14/05/2012
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1. Output shaft
2. Brake housing
RAIL11WEL0428BA 4

housing.
RAIL11WEL0538BA 5

housing.
RAIL11WEL0539BA 6
84605841 14/05/2012
33.202 / 18

brake housing.
RAIL11WEL0540BA 7

RAIL11WEL0541BA 8

1. Brake housing
2. Guide ring
3. Support ring
4. Grooved ring
5. Grooved ring
6. Support ring
RAIL11WEL0062BA 9
84605841 14/05/2012
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piston.
RAIL11WEL0542BA 10
RAIL11WEL0543BA 11
RAIL11WEL0544BA 12
84605841 14/05/2012
33.202 / 20

1. Disc
2. Cup spring
3. Cover
4. Piston
5. Hex bolt
6. Brake housing
RAIL11WEL0589BA 13

(25 lb ft).
RAIL11WEL0545BA 14

agent.
RAIL11WEL0546BA 15
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RAIL11WEL0547BA 16

RAIL11WEL0548BA 17

RAIL11WEL0549BA 18
RAIL11WEL0550BA 19
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than 24 h.
RAIL11WEL0551BA 20
RAIL11WEL0552BA 21

RAIL11WEL0553BA 22

housing.
RAIL11WEL0554BA 23
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gear.
2. Packaging sleeve
3. Snap ring
4. Planetary gear
RAIL11WEL0555BA 24

retaining rings.
RAIL11WEL0556BA 25
Next operation:
Wheel hub - Install — Models MT-L 3065 II / 3075 II (25.108) Wheel hub - Install — Models MT-L 3065 II / 3075
II (27.120)
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Brake disks - Disassemble - Models MT-L 3085 II / MT-L 3095 II

721F
Prior operation:
Wheel hub - Remove — Models MT-L 3085 II / MT-L 3095 II (25.108) Wheel hub - Remove — Models MT-L 3085
II / MT-L 3095 II (27.120)
RAIL11WEL0184BA 1
RAIL11WEL0185BA 2
RAIL11WEL0186BA 3
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shaft profile.
RAIL11WEL0187BA 4

RAIL11WEL0188BA 5

RAIL11WEL0189BA 6
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RAIL11WEL0190BA 7
RAIL11WEL0191BA 8
RAIL11WEL0192BA 9
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RAIL11WEL0193BA 10
RAIL11WEL0194BA 11

RAIL11WEL0195BA 12
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(arrows).
RAIL11WEL0196BA 13
14. Note the installation position of the following individ-

ual parts.
1. Brake housing
2. Guide ring
3. Back-up ring
4. Piston seal
5. Piston seal
6. Back-up ring
8. Output shaft
RAIL11WEL0197BA 14

output shaft.
RAIL11WEL0198BA 15
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RAIL11WEL0199BA 16

RAIL11WEL0200BA 17

output shaft.
RAIL11WEL0177BA 18
Next operation:
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Brake disks - Visual inspection - Models MT-L 3085 II / MT-L 3095 II

721F
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 — Models MT-L 3085 II / MT-L 3095 II (33.202)

pack using cleaning solvent. Use compressed air
to clear passages in planetary ring gear and brake
housing.
Next operation:
Brake disks - Assemble — Models MT-L 3085 II / MT-L 3095 II (33.202)
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Brake disks - Assemble - Models MT-L 3085 II / MT-L 3095 II

721F
CAUTION
Burn hazard!
C0047A
Prior operation:

tact is made.
studs.
RAIL11WEL0423BA 1

RAIL11WEL0424BA 2
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output shaft.
RAIL11WEL0425BA 3

housing.
RAIL11WEL0426BA 4

RAIL11WEL0427BA 5
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combi seal.
1. Output shaft
2. Brake housing
Screening plate.
RAIL11WEL0428BA 6

RAIL11WEL0429BA 7

driver tool.
RAIL11WEL0430BA 8
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made.
this step.
RAIL11WEL0431BA 9

12). Secure it with LOCTITE® 415 at its ends (arrows).
contact position.
RAIL11WEL0432BA 10
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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
RAIL11WEL0434BA 11
RAIL11WEL0435BA 12
RAIL11WEL0436BA 13
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RAIL11WEL0437BA 14

RAIL11WEL0438BA 15

RAIL11WEL0439BA 16
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RAIL11WEL0440BA 17
tact is obtained.
RAIL11WEL0461CA 18
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RAIL11WEL0441BA 19

RAIL11WEL0442BA 20

RAIL11WEL0443BA 21
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RAIL11WEL0444BA 22

lifting device.
RAIL11WEL0445BA 23

ft).
RAIL11WEL0446BA 24
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RAIL11WEL0447BA 25

ing table.
0.30 - 0.24 mm (0.012 - 0.009 in) 0.13 mm +/- 0.01 mm ( 0.005 in 4474 353 172
0.0003 in)
0.239 - 0.18 mm (0.009 - 0.007 in) 0.07 mm +/- 0.01 mm ( 0.003 in 4474 353 172
0.0003 in)
0.179 - 0.10 mm (0.007 - 0.004 in) 0 mm (0.000 in) 4474 353 115
hours.
RAIL11WEL0448BA 26
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RAIL11WEL0449BA 27
Next operation:
Wheel hub - Install Models MT-L 3085 II / MT-L 3095 II (25.108) Wheel hub - Install Models MT-L 3085 II / MT-L
3095 II (27.120)
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Brake lines - Remove - Models MT-L 3065 II / MT-L 3075 II

Prior operation:

RAIL11WEL0024BA 1

arrow).
RAIL11WEL0025BA 2
RAIL11WEL0026BA 3
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screw neck (4).
RAIL11WEL0061AA 4
Next operation:
Brake lines - Install — Models MT-L 3065 II / 3075 II (33.202)
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Brake lines - Install - Models MT-L 3065 II / 3075 II

Prior operation:
Brake lines - Remove - Models MT-L 3065 II / MT-L 3075 II (33.202)

RAIL11WEL0531BA 1

RAIL11WEL0061AA 2
Next operation:
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Brake lines - Remove -Models MT-L 3085 II / MT-L 3095 II

721F
Prior operation:
Wheel hub - Remove — Models MT-L 3085 II / MT-L 3095 II (25.108) Wheel hub - Remove — Models MT-L 3085
II / MT-L 3095 II (27.120)

drive housing.
RAIL11WEL0213BA 1

brake tube.
RAIL11WEL0214BA 2
RAIL11WEL0215BA 3
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RAIL11WEL0212BA 4
Next operation:
Brake lines - Install — Models MT-L 3085 II / MT-L 3095 II (33.202)
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Brake lines - Install - Models MT-L 3085 II / MT-L 3095 II

721F
Prior operation:
Brake lines - Remove —Models MT-L 3085 II / MT-L 3095 II (33.202)
RAIL11WEL0397BA 1

RAIL11WEL0398BA 2
RAIL11WEL0399BA 3
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ing brake tube.
RAIL11WEL0400BA 4

RAIL11WEL0401BA 5

ft).
RAIL11WEL0396BA 6
Next operation:
Wheel hub - Install Models MT-L 3085 II / MT-L 3095 II (25.108) Wheel hub - Install Models MT-L 3085 II / MT-L
3095 II (27.120)
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Index

Accumulator - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Accumulator - Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Brake disks - Assemble - MT-L 3065 II / MT-L 3075 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Brake disks - Assemble - Models MT-L 3085 II / MT-L 3095 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
721F
Brake disks - Disassemble - Models MT-L 3065 II / MT-L 3075 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Brake disks - Disassemble - Models MT-L 3085 II / MT-L 3095 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
721F
Brake disks - Service limits - Models MT-L 3065 II / MT-L 3075 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Brake disks - Service limits - Models MT-L 3085 II / MT-L 3095 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
721F
Brake disks - Visual inspection - Models MT-L 3065 II / MT-L 3075 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Brake disks - Visual inspection - Models MT-L 3085 II / MT-L 3095 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
721F
Brake lines - Install - Models MT-L 3065 II / 3075 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Brake lines - Install - Models MT-L 3085 II / MT-L 3095 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
721F
Brake lines - Remove - Models MT-L 3065 II / MT-L 3075 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Brake lines - Remove -Models MT-L 3085 II / MT-L 3095 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
721F
Brake pump - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Brake pump - Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Brakes - Leakage test - Models MT-L 3065 II / MT–L 3075 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Brakes - Leakage test - Models MT-L 3085 II / MT-L 3095 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
721F
Hydraulic service brakes - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
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PRINTED IN U.S.A.
84605841 14/05/2012
EN
SERVICE MANUAL
Hydraulic systems
621F
721F
84605841 14/05/2012
35
Contents
Hydraulic systems - 35
Hydraulic systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.000

621F , 721F
Variable displacement pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.106

621F , 721F
Pilot system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.357

621F , 721F
Main control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.359

621F , 721F
Auxiliary hydraulic valves and lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.525

621F , 721F
Front loader arm hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.701

621F , 721F
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35
621F
721F
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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 – 621F Tier 2\4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
621F
Hydraulic schematic frame 01 – 721F Tier 2\4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

721F
SERVICE
Hydraulic systems
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Decontaminating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Test – Brake accumulator tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Test – Brake pump flow test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Test – First pump high pressure cut-off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Test – Auxiliary steering pump flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Test – Steering cylinder leakage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Test – Loader valve pilot pressure generation valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Test – Pilot pressure at end of loader valve spool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Test – Ride control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Test – Brake modulation pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Test – Ride control valve system function test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
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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.
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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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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 – 621F Tier 2\4

621F
Call- Description Call- Description

out # out #
(1) Rear Axle Brakes (2) Front Axle Brakes
Modulation Pressure 74 - 82 bar (1075 - 1190 psi) Modulation Pressure 76 - 84 bar (1100 - 1220 psi)
(3) Parking Brake (4) Brake Declutch Switch
Electrical Connector PBD
10 bar (145.0 psi)
(5) Brake Light Switch, (6) Parking Brake Accumulator
Electrical Connector PBL 4.1 bar (59.5 psi) 0.16 l (0.17 US qt)
Increasing 96 bar (1392.0 psi) Precharge
(7) Front Brake Accumulator (8) Rear Brake Accumulator
3.5 l (3.7 US qt) 3.5 l (3.7 US qt)
70 bar (1015.0 psi) Precharge 70 bar (1015.0 psi) Precharge
(9) Front Redundant Accumulator Pressure Switch (10) Rear Redundant Accumulator Pressure Switch
Electrical Connectors PRB1 Electrical Connectors PRB2
Rising < 91 bar (< 1320 PSI), Falling 70 - 84 bar Rising < 91 bar (< 1320 PSI), Falling 70 - 84 bar
(1015.0 - 1218.0 psi) (1015.0 - 1218.0 psi)
(11) Low Brake Pressure Warning Switch (12) Brake Valve
Alarm OFF 142 - 150 bar (2059.0 - 2175.0 psi)
Increasing
Alarm ON 118 - 126 bar (1711.0 - 1827.0 psi)
Decreasing
(12A) Parking Brake Solenoid (12B) Front Brake Valve
Electrical Connector YPB
(12C) Rear Brake Valve (12D) Accumulator Isolation Check Valve
(12E) Accumulator Charging Spool (12F) Priority Valve
Cut-In Pressure
157 - 167 bar (2276.5 - 2421.5 psi)
Cut-Out Pressure
190 - 196 bar (2755.0 - 2842.0 psi)
(13) Coupler locking valve (14) Coupler Locking Cylinders
Electrical Connection YPE
(15) Pilot Control Valve (15A) Pilot ON / OFF Solenoid
Electrical Connector YPP
(15B) Bucket Pilot Control (15C) Lift Pilot Control
(15D) Auxiliary Hydraulics Pilot Control 1 (15E) Auxiliary Hydraulics Pilot Control 2
(16) Pilot Control Accumulator (17) Bucket Cylinder Z-Bar / XR
0.75 l (0.79 US qt) 2 Bucket Cylinders XT
13.8 bar (200.1 psi) Precharge
(18) Lift Cylinders (19) Ride Control Valve
(19A) Ride Control Solenoid (19B) Ride Control Spool Valve
Electrical Connector YRC
(19C) Manual Bleed Valve (19D) Pressure Relief Valve
280 bar (4060.0 psi)
(20) Ride Control Accumulator (21) Loader Valve with Priority Flow Divider
3.78 l (4.0 US qt)
14.5 bar (210.3 psi) Precharge
(21A) Load Sense Check Valve (21B) Steering Relief Valve
239 - 243 bar (3465.5 - 3523.5 psi)
(21C) Pilot Pressure Reducing Valve (21D) Priority Flow Divider
29 - 40 bar (420.5 - 580.0 psi)
(21E) Loader Main Relief (21F) Load Sense Signal Bleed Down Orifice
248 - 255 bar (3596.0 - 3697.5 psi) 0.7 l/min (0.2 US gpm)
(21G) Circuit Relief Valve with Anti-Cavitation (6) (21H) Regeneration Check Valves (2)
(21J) Regeneration Relief Valve (21K) Differential Pressure Relief
6.7 bar (97.2 psi) 40 bar (580.0 psi)
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Call- Description Call- Description

out # out #
(21L) Flow Compensator (4) (21 Bucket Control Spool
M)
(21N) Lift Control Spool (21P) Auxiliary 1 Control Spool
(21Q) Auxiliary 2 Control Spool (21R) Shuttle Check Valves (6)
(22) Steering Cylinders (23) Steering Control Valve
(23A) Steering Spool (23B) Gerotor Pump
(23C) Circuit Relief Valve (24) Steering Back Pressure Valve
8 - 10 bar (116.0 - 145.0 psi)
(25) Steering Back Pressure Sensor, Joystick Steering (26) Joystick Steering Load Sense Resolver
Only
Electrical Connector JSSLSR
(27) Joystick Steering Valve (27A) Control Spool
(27B) Pressure Reducer (27C) Pilot Dump Valve
Electrical Connector PIL_DUMP
(28) Auxiliary Steering Control Valve (28A) Auxiliary Steering Activation Solenoid
Electrical Connector YSS
(28B) Relief Valve (28C) Priority Spool
240 bar (3480.0 psi)
(29) Auxiliary Steering Accumulator (30) Auxiliary Steering Pump
0.32 l (0.34 US qt)
60 bar (870.0 psi) Precharge
(31) Auxiliary Steering Pressure Switch (32) Pump
Electrical Connector PSS 170 l/min (44.9 US gpm)
Cut Off 280 bar (4060.0 psi)
Delta 22 - 25 bar (319.0 - 362.5 psi)
(32A) Compensator Differential Pressure Spool (32B) Compensator High Pressure Cutoff Spool
(32C) Control Piston with Spring (32D) Rotating Group with Swash Plate
(33) Brake Pump (34) 100 Mesh Strainers (2)
(35) Hydraulic Reservoir (36) Reservoir Vent
65 l (17.2 US gal) 100 Mesh
0.03 bar (0.4 psi) Check
0.35 bar (5.1 psi) Relief
(37) Filter (38) Oil Cooler Thermal Valve
Electrical Connector PHF Begin Opening 44 - 53 °C (111.2 - 127.4 °F)
10 micron media Full Open 63 °C (145.4 °F)
Bypass 3.4 bar (49.3 psi) 2.4 - 3.6 bar (34.8 - 52.2 psi) Bypass
Warning Switch 2.7 bar (39.2 psi)
(39) Hydraulic Oil Cooler (40) Oil Cooler Fan
(41) Standard Fan Valve (42) Fan Reversing and Variable Valve
197 bar (2856.5 psi)
(42A) Crossover Relief (42B) Reversing Spools
234 bar (3393.0 psi)
(42C) Pulse Width Modulation (PWM) Relief Valve (42D) ON / OFF Reversing Solenoid
165 bar (2392.5 psi) Electrical Connector YFR
Electrical Connector YFN
(43) Vent Check Valve TP1 Steering pressure
0.25 bar (3.6 psi)
TP3 Load sense signal TP5 Main pump pressure
TP6 Front brake accumulator TP7 Rear brake accumulator
TP9 Pilot pressure supply TP10 Front brake to axle
TP11 Rear brake to axle Note Optional check valve for Ride Control only
1
Note Check and relief valves (41) not used with Fan Note With Reverse option
2 Reverser 3
Note Without Reverse option
4
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Hydraulic systems - Hydraulic schematic frame 01 – 721F Tier 2\4

Callout Description Callout Description
721F # #
Callout Description Callout Description
(24A) Steering Spool (24B) Gerotor Pump
# #
(1) Rear Axle Brakes (2) Front Axle Brakes (24C) Circuit Relief Valve (25) Steering Back Pressure Valve
Modulation Pressure 68 - 75 bar (985 - 1090 psi) Modulation Pressure 70 - 77 bar (1015 - 1115 psi) 8 - 10 bar (116.0 - 145.0 psi)
(3) Brake Damping Accumulators (4) Parking brake (26) Steering Back Pressure Sensor, Joystick Steering Only (27) Joystick Steering Load Sense Resolver
Heavy duty option only (28) Joystick Steering Valve (28A) Control Spool
0.16 l (0.17 US qt) (28B) Pressure Reducer (28C) Pilot Dump Valve
7 bar (101.5 psi) (29) Auxiliary steering accumulator 0.32 l (0.34 US qt) (30) Auxiliary steering control valve
(5) Brake signal – 5 speed transmission (6) Brake Declutch Switch – 4 speed transmission 60 bar (870.0 psi) Precharge
Electrical connector PBD (30A) Auxiliary steering activation solenoid (30B) Relief valve
24 bar (350 psi) Electrical connector YSS 240 bar (3480.0 psi)
(7) Brake Light Switch, (8) Parking Brake Accumulator (30C) Priority spool (31) Auxiliary Steering Pump
Electrical Connector PBL 4.1 bar (59.5 psi) Increasing 0.16 l (0.17 US qt) (32) Auxiliary Steering Pressure Switch (33) Second Pump
96 bar (1392.0 psi) Precharge Electrical Connector PSS 86 l/min (22.7 US gpm)
(9) Front Brake Accumulator (10) Rear Brake Accumulator Cut Off 280 bar (4060.0 psi)
3.5 l (3.7 US qt) 3.5 l (3.7 US qt) Delta 24 - 26 bar (348.0 - 377.0 psi)
70 bar (1015.0 psi) Precharge 70 bar (1015.0 psi) Precharge (33A) Compensator Differential Pressure Spool (33B) Compensator High Pressure Cutoff Spool
(11) Redundant Accumulator Pressure Switches (12) Low Brake Pressure Warning Switch (33C) Control Piston with Spring (33D) Rotating Group with Swash Plate
Electrical Connectors PRB1, PRB2 Alarm OFF 138 bar (2001.0 psi) Increasing (34) First pump (34A) Compensator differential pressure spool
Rising < 91 bar (1319.5 psi) , Falling 70 - 84 bar (1015.0 - 1218.0 Alarm ON 115 - 129 bar (1667.5 - 1870.5 psi) Decreasing 120 l/min (31.7 US gpm)
psi) Cut Off 280 bar (4060.0 psi)
(13) Brake Valve (13A) Parking Brake Solenoid Delta 28 - 30 bar (406.0 - 435.0 psi)
Electrical Connector YPB (34B) Compensator high pressure cutoff spool (34C) Control piston with spring
(13B) Front Brake Valve (13C) Rear Brake Valve (34D) Rotating group with swash plate (35) Priority valve
(13D) Accumulator Isolation Check Valve (13E) Accumulator Charging Spool (35A) Priority spool (35B) Differential pressure relief
(13F) Priority valve 40 bar (580.0 psi)
Cut-In Pressure (35C) Steering relief (36) Brake pump
157 - 167 bar (2276.5 - 2421.5 psi) 214 bar (3103.0 psi)
Cut-Out Pressure
(37) 100 mesh strainers (38) Hydraulic reservoir
190 - 196 bar (2755.0 - 2842.0 psi)
90 l (95.1 US qt)
(14) Coupler locking valve (15) Coupler Locking Cylinders
(39) Reservoir vent (40) Filter
(16) Pilot Control Valve (16A) Pilot ON / OFF Solenoid 100 mesh Electrical connector PHF
Electrical Connector YPP 0.03 bar (0.4 psi) check 10 micron media
(16B) Bucket Pilot Control (16C) Lift Pilot Control 0.35 bar (5.1 psi) relief Bypass 3.4 bar (49.3 psi)
(16D) Auxiliary Hydraulics Pilot Control 1 (16E) Auxiliary Hydraulics Pilot Control 2 Warning switch 2.7 bar (39.2 psi)
(17) Pilot Control Accumulator (18) Bucket Cylinder Z-Bar / XR (41) Oil cooler thermal valve (42) Hydraulic oil cooler
0.75 l (0.79 US qt) 2 Bucket Cylinders XT 2.4 - 3.6 bar (34.8 - 52.2 psi) Bypass
13.8 bar (200.1 psi) Precharge (43) Oil cooler fan (44) Standard fan valve
(19) Lift Cylinders (20) Ride Control Valve 162 bar (2349.0 psi)
(20A) Ride Control Solenoid (20B) Ride Control Spool Valve (45) Fan reversing and variable valve (45A) Crossover relief
Electrical Connector YRC 234 bar (3393.0 psi)
(20C) Manual Bleed Valve (20D) Pressure Relief Valve (45B) Reversing spools (45C) Pulse width modulation (PWM) relief valve
280 bar (4060.0 psi) 165 bar (2392.5 psi)
(21) Ride Control Accumulator (22) Loader Valve (45D) ON \ OFF reversing solenoid TP1 Unloading pump pressure
3.78 l (4.0 US qt) Electrical connector YFR
14.5 bar (210.3 psi) Precharge TP3 Steering load sense TP5 Steering pump pressure
(22A) Load Sense Shuttle Valve (22B) Regeneration relief valve TP6 Front brake accumulator TP7 Rear brake accumulator
(22C) Flow compensator spool (22D) Regeneration check valve TP9 Pilot pressure supply TP10 Front brake to axle
(22E) Circuit relief valve with anti-cavitation (22F) Pilot pressure reducing valve TP11 Rear brake to axle
29 - 40 bar (420.5 - 580.0 psi)
(22G) Pilot pressure relief (22H) Load sense signal bleed down orifice
(22J) Loader main relief (22K) Shuttle check valve
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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.

bucket to the ground. Put the articulation lock (1) in
the locked position.
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 – Loader valve pilot pressure generation

valve
Pressure check steps
1. Make sure that the temperature of the hydraulic oil is
at least 54 - 57 °C (129.2 - 134.6 °F). To view the oil
temperature on the instrument cluster press the up or
down arrow key until your hydraulic oil temperature
is displayed.
• To heat the hydraulic oil do the following:
A. Start the engine and run at full throttle.
B. 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 tempera-
ture of the hydraulic oil is 54 - 57 °C (129.2 -
134.6 °F) .
2. Raise lift arms to the top and turn off the engine. Turn
the ignition switch to the “RUN” position..
3. Repeatedly put the loader control lever into “FLOAT”
position and back to neutral.
4. The system should allow a minimum of 10 actuations
into float and still cause the lift arms to come down.
NOTE: If 10 full actuations cannot be made, an internal hydraulic leak exists, proceed to next step.
5. Start machine, lower the bucket to the ground, and
turn off the engine. Turn the ignition switch to the
“RUN” position and operate the pilot controls a mini-
mum of 30 strokes to relieve any pressure in the sys-
tem.
6. Open the right side compartment to gain access to
the loader control handle.
7. Attach a gauge capable of reading 70 bar (1015.0
psi) to the test port under loader control handle.
This is TP9 on the schematic Hydraulic systems
- Hydraulic schematic frame 01 – 621F Tier
2\4 (35.000) or Hydraulic systems - Hydraulic
schematic frame 01 – 721F Tier 2\4 (35.000) .
8. Start and run the machine at low idle. Hold the bucket
control lever in the ROLLBACK position to increase
the system pressure.
9. A pressure reading of 29.5 - 39.5 bar (427.8 - 572.8
psi) should be obtained. If pressure is not as speci-
fied continue with the following steps.
10. Lower the bucket to the ground and turn off the en-
gine. Turn the ignition switch to the “RUN” position.
11. Operate the pilot controls several times until the
gauge pressure suddenly drops to 0 bar (0.0 psi).
The last pressure reading before the drop to 0 bar
(0.0 psi) is the nitrogen charge pressure in the
accumulator. If the pressure is below 13 - 15 bar
(188.5 - 217.5 psi) , replace the accumulator. If the
accumulator test is good, go to the next step.
12. Replace the pilot controls and retest the system. If
the test fails go to the next step.
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13. Replace the loader control valve and retest the sys-
tem.
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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 – Brake modulation pressure

1. Make sure the hydraulic accumulator cut-in and cut-
out pressures are correct.
2. Install the articulation lock (1) before doing this test.
BD03A040-01 1
3. Stop the engine. Pump the brake pedal until there is

no pressure in the brake system.
4. Remove the cab skirts to gain access to the brake
test ports.
BD06F145 2
(1) Front axle test port (3) Front brake accumulator test port
(2) Rear axle test port (4) Rear brake accumulator test port
5. Connect two 207 bar ( 3000 psi) pressure gauges to

the front axle test port (1) and the rear axle test port
(2).
6. Connect two 207 bar ( 3000 psi) pressure gauges to
the front brake accumulator test port (4) and the rear
brake accumulator test port (3).
7. Start the engine.
8. Operate the machine at low idle and watch the
pressure gauges on the brake accumulators until
the gauges rise above 170 bar ( 2645 psi).
9. Apply and hold the brakes for 10 - 15 seconds.
10. Make a note of the pressure on the gauges for the
front and rear brakes.
11. The front axle brake pressure should read . This is
the modulation pressure for the front axle.
12. The rear axle brake pressure should read . This is
the modulation pressure for the rear axle.
13. If the pressures are not within the specified range, it
will be necessary to adjust the modulation pressures.
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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 - Hydraulic schematic frame 01 – 721F Tier 2\4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
721F
Hydraulic systems - Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Hydraulic systems - Decontaminating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Hydraulic systems - Dynamic description – Hydraulic Oil Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Hydraulic systems - Hydraulic schematic frame 01 – 621F Tier 2\4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
621F
Hydraulic systems - Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Hydraulic systems - Test – Auxiliary steering pump flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Hydraulic systems - Test – Brake accumulator tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Hydraulic systems - Test – Brake modulation pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Hydraulic systems - Test – Brake pump flow test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Hydraulic systems - Test – First pump high pressure cut-off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Hydraulic systems - Test – Loader valve pilot pressure generation valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Hydraulic systems - Test – Pilot pressure at end of loader valve spool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Hydraulic systems - Test – Ride control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Hydraulic systems - Test – Ride control valve system function test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Hydraulic systems - Test – Steering cylinder leakage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
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Variable displacement pump - 106
621F
721F
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Contents
TECHNICAL DATA
Variable displacement pump

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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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Index

Variable displacement pump - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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Pilot system - 357
621F
721F
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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
621F
721F
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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
621F
721F
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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
621F
721F
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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
84605841 14/05/2012
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Index

Ride control solenoid valve block - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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PRINTED IN U.S.A.
84605841 14/05/2012
EN
SERVICE MANUAL
Steering
621F
721F
84605841 14/05/2012
41
Contents
Steering - 41
Auxiliary steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.910

621F , 721F
84605841 14/05/2012
41
Steering - 41
Auxiliary steering - 910
621F
721F
84605841 14/05/2012
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
84605841 14/05/2012
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
84605841 14/05/2012
41.910 / 5
Index
Steering - 41

Motor - Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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PRINTED IN U.S.A.
84605841 14/05/2012
EN
SERVICE MANUAL
Wheels
621F
721F
84605841 14/05/2012
44
Contents
Wheels - 44
Front wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.511

621F , 721F
84605841 14/05/2012
44
Wheels - 44
Front wheels - 511
621F
721F
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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.
84605841 14/05/2012
EN
SERVICE MANUAL
Cab climate control
621F
721F
84605841 14/05/2012
50
Contents
Cab climate control - 50
Air conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50.200

621F , 721F
84605841 14/05/2012
50
Air conditioning - 200
621F
721F
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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 compressor
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Air-conditioning condenser
Remove - Air conditioner condenser removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Install - Air conditioner condenser install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Air-conditioning evaporator
Visual inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
DIAGNOSTIC
Air conditioning
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
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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.
84605841 14/05/2012
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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.
84605841 14/05/2012
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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).
84605841 14/05/2012
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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).
84605841 14/05/2012
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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.
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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.
84605841 14/05/2012
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Air-conditioning compressor - Remove

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
1. Raise hood using controls located behind the access

cover.
RCPH11WHL652BAU 1
2. Turn master power switch to OFF.
RCPH11WHL653BAU 2
3. Evacuate the air conditioning system according to

instructions in Air conditioning - Connect (50.200).
84605841 14/05/2012
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4. Loosen the four bolts holding the protective shield.

Remove the shield.
RCPH10WHL070AAH 3
5. Insert wrench into the belt tension (1). Pull to left,

releasing tension and remove the belt (2).
RAPH12WEL0157AA 4
6. Disconnect high pressure (1) and low pressure (2)

lines and ground (3) to compressor. Cap and plug
lines.
RAPH12WEL0162AA 5
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7. Remove three compressor mounting bolts.

8. Remove compressor.
RAPH12WEL0163AA 6
Next operation:
Air-conditioning compressor - Install (50.200)
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Air-conditioning compressor - Install

WARNING
Explosion hazard!
W0340A
Prior operation:
Air-conditioning compressor - Remove (50.200)
NOTICE: Refer to Environmental Control air conditioning system — Service instruction Air conditioning - Charging
(50.200)
1. Position compressor on the machine, lining up bolt
holes. Insert three bolts to mount the compressor.
Torque tighten to 37 - 43 N·m (27 - 32 lb ft).
RAPH12WEL0163AA 1
2. Remove caps and plugs. Connect the ground wire

(3). Install NEW lubricated O-rings in the high pres-
sure line (1) and low pressure (2) line, then attach
both pressure lines to the compressor.
NOTE: Use caution when removing caps as new compres-
sors have internal pressure when shipped.
RAPH12WEL0162AA 2
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3. Install belt.
RAPH12WEL0158AA 3
4. Install protective shield, bolting in place.
RCPH10WHL070AAH 4
5. Charge air conditioning system according to the in-

structions in Air conditioning - Charging (50.200).
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Air-conditioning condenser - Remove - Air conditioner condenser

removal
WARNING
Explosion hazard!
W0340A
NOTICE: HFC R134A

bucket to the ground.
RCPH10WHL350FAH 1
2. Turn master switch to the OFF position.
RCPH11WHL653BAU 2
3. Discharge the air conditioning system according

to the instructions in Air conditioning - Connect
(50.200).
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4. Open screen cover (1). Unlatch air conditioning con-

denser (2).
RCPH10WHL139AAH 3
5. Pivot condenser to gain access to the hoses.

6. Fasten identification tags on the hoses and discon-
nect them from the condensers.
7. Plugs the hoses and cap the fittings.
RAPH12WEL0145AA 4
8. Lay condenser down and remove bolts (1) that fas-

ten the condenser to the bracket. Remove the air
conditioning condenser.
RCPH10WHL139AAH 5
Next operation:
Air-conditioning condenser - Install — Air conditioner condenser install (50.200).
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Air-conditioning condenser - Install - Air conditioner condenser

install
WARNING
Explosion hazard!
W0340A
Prior operation:
Air-conditioning condenser - Remove — Air conditioner condenser removal (50.200)
NOTICE: HFC R134A

1. Position the air conditioning condenser on the
bracket.
2. Install the bracket bolts and partially tighten. Lower
the air conditioning condenser and tighten the bolts
(1) completely.
RCPH10WHL139AAH 1
3. Pivot the air conditioning condenser to gain access

to the hoses.
4. Install new O-rings. Remove the plugs and caps from
the hoses and fittings and reconnect the hoses to the
fittings.
NOTE: Lubricate O-rings.
RAPH12WEL0146AA 2
5. Lower the air conditioning condenser and re-latch.

Then close and secure the screen cover with the rub-
ber T-handle.
RCPH10WHL139AAH 3
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6. Charge the air conditioning system according to the

instructions in Air conditioning - Charging (50.200)
7. Place the master disconnect switch to the ON posi-
tion.
RCPH11WHL653BAU 4
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Air-conditioning evaporator - Visual inspection

WARNING
Explosion hazard!
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 -
84605841 14/05/2012
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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).
84605841 14/05/2012
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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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Air conditioning - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Air-conditioning compressor - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Air-conditioning compressor - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Air-conditioning condenser - Install - Air conditioner condenser install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Air-conditioning condenser - Remove - Air conditioner condenser removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Air-conditioning evaporator - Visual inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
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PRINTED IN U.S.A.
84605841 14/05/2012
EN
SERVICE MANUAL
Electrical systems
621F
721F
84605841 14/05/2012
55
Contents
Electrical systems - 55
Electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.000

621F , 721F
Fuel tank system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.011

621F , 721F
Engine cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.012

621F , 721F
Engine control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.015

621F , 721F
Service brake electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.030

621F , 721F
Parking brake electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.031

621F , 721F
Hydraulic system control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.036

621F , 721F
Steering control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.047

621F , 721F
Heating, Ventilation, and Air-Conditioning (HVAC) control system . . . . . . . . . . . . . . . . . . . . . . . . . 55.050

621F , 721F
Cab Heating, Ventilation, and Air-Conditioning (HVAC) controls . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.051

621F , 721F
Harnesses and connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.100

621F , 721F
Engine starting system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.201

621F , 721F
Cold start aid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.202

621F , 721F
Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.301
621F , 721F
84605841 14/05/2012
55
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.302
621F , 721F
External lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.404

621F , 721F
External lighting switches and relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.405

621F , 721F
Warning indicators, alarms, and instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.408

621F , 721F
Loader arm and bucket control system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.415

621F , 721F
Cab/Platform harnesses and connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.510

621F , 721F
Cab controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.512

621F , 721F
Cab lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.514

621F , 721F
Wiper/Washer system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.518

621F , 721F
Cab brake controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.519

621F , 721F
Cab controls (Lift arm, Boom, Dipper, Bucket) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.524

621F , 721F
Selective Catalytic Reduction (SCR) electrical system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.988

621F NA, 621F WE, 721F NA, 721F WE
FAULT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.DTC

621F , 721F
84605841 14/05/2012
55
CONSUMABLES INDEX
Consumable IU PAGE
DEF/AdBlue® Selective Catalytic Reduction 55.988 / 6
84605841 14/05/2012
55
Electrical system - 000
621F
721F
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55.000 / 1
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
621F
721F
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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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621F
721F
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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
621F
721F
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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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Service brake electrical system - 030
621F
721F
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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
621F
721F
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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
621F
721F
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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
621F
721F
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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
621F
721F
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Contents
Heating, Ventilation, and Air-Conditioning (HVAC) control system - 050
DIAGNOSTIC
Air-conditioning system pressure switch

High pressure - Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Temperature sensor
Testing - Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
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Electrical systems - Heating, Ventilation, and Air-Conditioning (HVAC) control system
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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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. Measure
the voltage from DNS_Thermo-
stat_2 connector ( DNS78 Y-0.5 ) to
chassis ground.
Turn the key switch OFF. Fabri- The A/C system should turn on and There is a problem in the HVAC
cate a jumper wire 15 cm (6 in) operate properly. Relay Circuit. Refer to Heating,
long. Disconnect the thermostat Action Ventilation, and Air-Conditioning
connector DNS_Thermostat_1 and Replace the thermostat and retest. (HVAC) control system - Testing
DNS_Thermostat_2. Turn the key A/C System Test (55.050)
switch ON.
Check
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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RCPH11WHL007GAL 1
(1) HVAC1 connector, DNS_HVAC1_S (4) DNS A/C Switch

(2) HVAC2 connector, DNS_HVAC2_S (5) DNS Thermostat
(3) DNS Fan Speed Selector Switch
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Index
Heating, Ventilation, and Air-Conditioning (HVAC) control system - 050

Air-conditioning system pressure switch High pressure - Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Temperature sensor - Testing - Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
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Cab Heating, Ventilation, and Air-Conditioning (HVAC) controls -

051
621F
721F
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Contents
Cab Heating, Ventilation, and Air-Conditioning (HVAC) controls - 051
DIAGNOSTIC
Heat command switch

Fan speed switch - Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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Electrical systems - Cab Heating, Ventilation, and Air-Conditioning (HVAC) controls
Heat command switch Fan speed 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 should be approximately 24 The voltage is less than 10 volts
DNS_SPEED_SELECTOR switch volts. there is a problem with the supply
pin 1 to chassis ground. voltage from HVAC2 connector. Re-
pair or replace as required.
Turn the fan selector switch to the The voltage should be approximately There is a problem in the wiring to
first position. 24 volts. the DNS_RESISTOR. Repair as re-
Check quired.
Measure the voltage from DNS_RE-
SISTOR pin 1 to chassis ground.
second position. 24 volts. the DNS_RESISTOR. Repair as re-
Check quired.
third position. 24 volts. the DNS_RESISTOR. Repair as re-
Check quired.
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
RCPH11WHL009GAL 1
(1) HVAC2 Connector, DNS_HVAC2_S (4) DNS_RESISTOR

(2) DNS_SPEED_SELECTOR, Fan Speed (5) DNS_ELECTRIC_FAN
(3) DNS_AC_SWITCH , Not Used on Heater (6) 24 V supply to thermostat
Only Unit
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Index
Cab Heating, Ventilation, and Air-Conditioning (HVAC) controls - 051

Heat command switch Fan speed switch - Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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Harnesses and connectors - 100
621F
721F
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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 - Lighting 1, 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Component diagram 05 - Machine controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Component diagram 06 - Transmission controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Component diagram 09 - Instrument cluster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Component diagram 10 - Instrument cluster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Component diagram 11 - Backup alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Component diagram 12 - Lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Component diagram 15 - Engine / Lighting / Backup alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Component diagram 16 - Wiper / Washer system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Component diagram 17 - Secondary steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
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Component diagram 18 - Diagnostic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Component diagram 19 - Radio power / converter / Heated mirrors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Component diagram 20 - Air seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Component diagram 21 - Cigar lighter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Component diagram 22 - HVAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Component diagram 23 - HVAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Component diagram 24 - Hood lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Component diagram 25 - Engine controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
Component diagram 26 - Joystick Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
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Electrical systems - Harnesses and connectors
Wire harnesses - Electrical schematic frame 01 -Index of functions

Function Sheet
Air seat 12
Can Communication 12
Cold start 4
Engine control 5
Hood lift 11
HVAC 12, 14
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
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
Schematic applies to Wheel Loaders after serial # NBF213602
# 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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RAIL11WEL0201JA 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
161 NOX sensor
162 Humidity and ambient temperature sensor
163 NOX sensor (NOXS)
164 Tank heater control valve
165 Def level and tank temperature
166 Upstream temperature sensor
167 Downstream temperature sensor
168 Doser metering valve
169 DNOX controller
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RAIL11WEL0202JA 1
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Wire harnesses - Electrical schematic frame 06 - Lighting 1, Backup

Alarm
Schematic applies to Wheel Loaders after serial #NBF213602
# Component
78 Backup alarm relay
79 Backup alarm disable switch
90 Brake light pressure switch
91 Brake lights relay
92 Flasher module
93 Hazard switch
94 Turn signal, high-low beam, and horn switch
95 Driving lights switch
96 Left hand front combination lights
97 Right hand front combination lights
100 Right hand rear combination lights
101 Left hand rear combination lights
102 License plate light
103 Backup alarm
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RAIL11WEL0203JA 1
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Wire harnesses - Electrical schematic frame 07 - Lighting 2

# Component
80 Work lights switch
81 Door switch
82 Rotating beacon (optional)
83 Dome light
84 Rotating beacon switch (optional)
85 Left hand front work light
86 Right hand front work light
87 Left hand rear work light
88 Right hand rear work light
89 Diodes
170 Rear view camera / monitor
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RAIL11WEL0204JA 1
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Wire harnesses - Electrical schematic frame 08 - Transmission Controls

# Component
45 Output speed sensor
46 Transmission control — 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 \ Lockup switch
61 Diagnostic connector
171 Differential lock switch (manual)
172 Differential lock switch
173 Differential lock solenoid
174 Lockup solenoid
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RAIL11WEL0205JA 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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RAIL11WEL0206JA 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 Pressure 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
34 Pin engage 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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RAIL11WEL0207JA 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
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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RAIL11WEL0208JA 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 Timer relay
136 Mirror heat switch
137 Mirror heater
138 Mirror heater
139 Telematics
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RAIL11WEL0209JA 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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RAIL11WEL0210JA 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+ (L1) J10 DNOX switch B+
(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
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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 DEFDM - Doser metering valve
87709793 3
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(1) 38 Doser valve B+ (2) 38A Doser valve ground
Connector DIA-2 - Diagnostic
87736919 4

(A) 0D-C Diag2 ground (D) CAN-LX CAN2 LO, Diag2
(B) 18K-B Diagnostic fused B+ (E) 23J-B DNOX2 K-line
(C) CAN-HO CAN2 HI, Diag2
Connector DISC - Disconnect engine
245482C1 5

(A) 13C Fuel Shutoff Fused Power (B) 13M Fuel Shutoff Fused Power
Connector DNOX2 - NOX controller
87713291 6

(1) 38D Tank heat B+ (17) 0E-A EXHT up signal
(2) Not used (18) 38B DEF level signal
(3) 18U-D DCU B+ non-disconnected (19) 0-T DEF sensor ground
(4) 18U-B DCU B+ non-disconnected (20) Not used
(5) Not used (21) Not used
(7) CAN-HQ CAN HI, DNOX2 (23) 38C Tank heat ground
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(8) CAN-LK CAN LO, DNOX2 (24) 18T-A DNOX2 switch B+
(9) Not used (25) 0-U EXHT temperature downstream
ground
(10) Not used (26) 38E EXHT temperature downstream B+
(11) 38A Doser valve ground (27) Not used
(12) 38 Doser valve B+ (28) 38F EXHT up signal
(13) Not used (29) 38G DEF temperature signal
(14) 0-LB DNOX2 module ground (30) Not used
(15) 0-LC DNOX2 module ground (31) 38H DNOX2 K-line
(16) Not used
Connector DTLTS - DEF tank level temperature sensor
84062580 7

(1) 38B-A DEF level signal (3) 38G-A DEF temperature signal
(2) 0–TA DEF sensor ground
Connector DTS - Downstream temperature sensor
87709793 8

(1) 38E EXHT temperature downstream B+ (2) 0–U EXHT temperature downstream
ground
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Connector EDC7 - Engine controller
BOSCH-89-POLE 9

(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
(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
CAN-LS CAN2 LO, NOX
(13) 31 EDC relay control (53) CAN-H3 CAN2 HI, NOX
CAN-HS CAN2 HI, NOX
(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
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Connector ENG-B -CAB bottom
NO_IMAGE 10

(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 11

(A) 13C-A Fuel Shutoff Fused Power (B) 13M-B WIF ignition power
Connector EVGT-3 - EVGT fuse
NO_IMAGE 12

(A) 1-T EVGT-3 power (B) 1-B EVGT relay power
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Connector EVGT-4 - EVGT
NO_IMAGE 13

(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 14

(1) 23K-A Temperature / Humidity B+ (3) 23K-E Temperature / Humidity Humidity
(2) 23K-B Temperature / Humidity (4) 23K-C Temperature / Humidity ground
Temperature
Connector NOXS - NOX sensor
84190317 15

(1) 23A-A Temperature / Humidity B+ (4) CAN-HU Temperature / Humidity Humidity
(2) 23D-D Temperature / Humidity (5) Not used
Temperature
(3) CAN-LU Temperature / Humidity
Temperature
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Connector RTHP - Throttle pedal
225351C1 16

(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 17

(A) CAN-L2 CAN2 LO, TERM (B) CAN-H2 CAN2 HI, TERM
CAN-LV CAN2 LO, TERM CAN-HV CAN2 HI, TERM
Connector THV - Tank heater control valve
CNH_84192117AAO 18

(1) 38C Tank heat ground (2) 38D Tank heat B+
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Connector UBJ - DEF level temperature
84062580 19

(1) 38B DEF level signal (3) 38G DEF temperature signal
(2) 0-T DEF sensor ground
Connector UBJM - DEF level temperature
RCPH11WHL018EAK 20

(1) 38B-A DEF level signal (3) 38G-A DEF temperature signal
(2) 0–TA DEF sensor ground
Connector UTS - Upstream temperature sensor
87709793 21

(1) 38F EXHT up signal (2) 0E-A EXHT temperature up ground
Connector WIF - Water in fuel sensor
8602416-01 22
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(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 (B7) 58T Ride control relay switched power
(A8) 23B-A NOX sensor B+ (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+ (D4) 63C2 Front wiper park control
(AA8) 23B-D NOX relay B+ (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
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+ (M) 18F-A Left hand position / tail fused power
(B) 18U-C DCU B+ non-disconnected (N) 18G-F Right hand position / tail fused power
(C) 23B-B NOX sensor B+ (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 (S) 44A-A Brake light relay output
(F) 23B-A NOX sensor B+ (T) 19Y-C Hood switch fused power
(G) 1–NL Power non-disconnect (U) 60D Hood down relay output
(H) 18T DNOX switch B+ (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+ (M) 18F-AN Left hand position / tail fused power
18F-B Left hand position / tail fused power
(B) 18U-D DCU B+ non-disconnected (N) 18G-H Right hand position / tail fused power
18G-HN Right hand position / tail fused power
(C) 23A-A DNOX2 module B+ (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 (S) 44A-D Brake light relay output
44A-DN Brake light relay output
(F) 23B-E NOX sensor B+ (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+ (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 (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 DNS AC switch

(1) DNS72 (3)
(2) DNS68 (4) DNS71
Connector DNS actuator

(5) DNS48 (6) DNS49
Connector DNS control panel light

(1) DNS69 (2) DNS70
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
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Connector DNS - HVAC1-S
225326C1 2

(1) DNS67 (3) DNS69
(2) DNS76 (4) DNS77
Connector DNS - HVAC2-S
225315C1 3

(1) DNS74 (2) DNS75
Connector DNS recirculating switch

(1) DNS51 (2) DNS53
Connector DNS resistor

(1) DNS61 (3) DNS63
(2) DNS62 (4) DNS64
Connector DNS speed selector

(1) DNS74 (4) DNS63
(2) DNS61 (5) DNS73
(3) DNS62
Connector DNS thermostat 1

(1) DNS67
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Connector DNS thermostat 2

(1) DNS78
Connector DNS Water valve pot

(1) DNS55 (2) DNS54
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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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Index

Wire harnesses - Electrical schematic frame 05 - Engine Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Wire harnesses - Electrical schematic frame 06 - Lighting 1, 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
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Wire connectors - Component diagram 05 - Machine controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Wire connectors - Component diagram 06 - Transmission controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Wire connectors - Component diagram 09 - Instrument cluster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Wire connectors - Component diagram 10 - Instrument cluster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Wire connectors - Component diagram 11 - Backup alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Wire connectors - Component diagram 12 - Lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Wire connectors - Component diagram 15 - Engine / Lighting / Backup alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Wire connectors - Component diagram 16 - Wiper / Washer system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Wire connectors - Component diagram 17 - Secondary steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Wire connectors - Component diagram 18 - Diagnostic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Wire connectors - Component diagram 19 - Radio power / converter / Heated mirrors . . . . . . . . . . . . . . . . . . . . . 109
Wire connectors - Component diagram 20 - Air seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Wire connectors - Component diagram 21 - Cigar lighter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Wire connectors - Component diagram 22 - HVAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Wire connectors - Component diagram 23 - HVAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Wire connectors - Component diagram 24 - Hood lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
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Wire connectors - Component diagram 25 - Engine controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
Wire connectors - Component diagram 26 - Joystick Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
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
621F
721F
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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
621F
721F
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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
621F
721F
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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
621F
721F
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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
621F
721F
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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
621F
721F
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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
621F
721F
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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
Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
621F WE, 621F NA, 721F WE, 721F NA
Digital instrument cluster - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
DIAGNOSTIC
Buzzer
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Backup/Reverse alarm relay
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Instrument cluster
Digital instrument cluster - Testing - Advanced Instrument Cluster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
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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
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.
7. Verify machine does not move.
8. Reduce engine speed to low idle. Return transmis-
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
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
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
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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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 - Exploded view

621F WE, 621F NA, 721F WE, 721F NA
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-criticall) 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 Low engine oil
Bring the machine to a safe stop, and turn the engine OFF immediately.
pressure pressure
Brake
Low brake pressure Bring the machine to a safe stop, and turn the engine OFF immediately.
pressure
Steering
pressure
Low steering pressure Bring the machine to a safe stop, and turn the engine OFF immediately.
(w/auxiliary
steering)
Coolant High engine coolant Bring the machine to a safe stop, and turn the engine OFF immediately.
temperature temperature Check the coolant levels after allowing the engine and the coolant to cool.
Hydraulic oil High hydraulic oil
temperature temperature
Transmission High transmission oil
oil temperature temperature
DEF level below
DEF tank
minimum acceptable Refill the DEF (diesel exhaust fluid) tank immediately.
empty
level
DEF injection
failed. Technical failure
If machine continues to operate for over 5 hours, the engine may stop.
Engine may detected
stop
SCR fault/failure
detected. Engine
SCR failure See SCR section
will shut down after
two minutes of idling.
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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 engaged and
Parking brake machine shifted forward or Release the parking brake. Check parking brake system.
reverse
Coolant High engine coolant 1. Idle machine and monitor temperature.

temperature temperature 2. Clean radiator or operate fan reverser (If equipped).
3. Check coolant level and add coolant if necessary.
1. Idle machine and monitor temperature.

Hydraulic
High hydraulic temperature 2. Clean cooler or operate fan reverser (If equipped).
temperature
3. Check hydraulic fluid level.
4. Check hydraulic system.
Transmission High transmission 1. Idle machine and monitor temperature.

temperature 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
1. Check electrical system.

Alternator Alternator malfunction
2. Voltages are out of range.
3. Check alternator
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Display Description Corrective action

DEF level is less than 15%
DEF level low of tank volume. No engine Fill DEF tank.
power loss at this level
DEF level is less than 5% of
DEF level low tank volume. There will be
Fill DEF tank.
Power limited moderate engine power level
loss.
Poor DEF quality
High NOx level detected. Drain tank. Replace DEF.
detected
After engine has run for 3
hours with high NOX level
DEF injection failed Drain tank. Replace DEF.
detected there will be a
torque and speed reduction.
After engine has run for an
Poor DEF quality extended period of time with
Drain tank. Replace DEF.
detected high NOX level detected, the
engine may stop.
DEF injection
failed. Technical failure detected. Check DEF injection system
Torque limited
DEF injection Technical failure detected.
failed. Torque reduction may be Check DEF injection system
Power limited experienced.
DEF injection Technical failure detected.
failed. Torque reduction may be Check DEF injection system
Torque limited experienced.
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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

The key pad is located on the console just below the steer-
ing wheel. Use this key pad to move from one screen to
another, choose various selections, monitor the machine
functions, and retrieve information.
All selections made with the computerized technology of

the LCD screen are essentially programmed in the same
manner.
When using the screen, use the arrow keys (C) and (D) to
scroll to the desired selection, highlight that selection and
press the confirm/enter key (B).
Follow any screen prompts when given and use the con-
firm key to enter the selection. Use the escape key (A) to
return to the main menu. This will lock the chosen selec-
tion into memory.
All functions can be accessed in the same basic manner. RCIL10WHL182BAL 1
A. Escape key - Use this key to exit and return to the

driving screen. This key can be used anytime to
start over and begin again or to exit a field. It can
also be used to electronically check fault codes.
B. Enter/confirm key - Use this key to confirm selec-
tions: After selections have been highlighted, use
the enter/confirm key to choose selections.
C. Up arrow key - Use this key to scroll up to selections.
D. Down arrow key - Use this key to scroll down to
selections.
NOTE: Arrows on the screen will indicate if selections are
up or down from the current selection.
Using the arrow keys

At any time during operation or with the key switch ON, the
operator may scroll through four information screens and
two trip screens by using the arrow keys. These screens
are in a circular loop and may be accessed by pressing
the up or down key. The following sequence shown uses
the down key only.
NOTE: Pressing the escape key will return the LCD back
to the normal driving screen. In order to lock the changes
into memory, the operator must press the confirm key,
then use the escape key to return to the main screen.
Turning the machine off will also lock the settings into
memory.
From the driving screen, push the down arrow, as shown. RCPH10WHL021BAL 2
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Viewing screens
Info 1 is the first information screen displayed when using
the down arrow from the driving screen. It displays engine
RPM's, speed, fuel level, and the DEF fluid level.
RCPH10WHL349AAH 3
Press the down key again to display Info 2 screen. This

screen will display coolant temperature, engine oil tem-
perature, oil pressure, and DEF fluid level. Temperature
can be displayed in either Fahrenheit or Celsius.
RCPH10WHL350AAH 4
Push the down key again to display the Info 3 screen. This
screen displays the temperature in Fahrenheit or Celsius
of the transmission oil, hydraulic oil, sump oil, and DEF
fluid level.
RCPH10WHL351AAH 5
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Push the down key again to display the Info 4 screen. This
screen displays voltage, the temperature in Fahrenheit or
Celsius of the turbocharger air, DEF fluid, and DEF fluid
level.
RCPH10WHL352AAH 6
Entering the service screens

After the machine has been started or the key switch has
been turned to ON, the operator or service technician
may use the main menu to adjust machine configurations
to working conditions, to test components, view faults that
may have occurred, or to select preferences. Languages
can be set at the beginning of the menu configuration to
allow the operator to work in the language of choice.
Menu
Press and hold the confirm key for two seconds to arrive
at the main menu. The arrow keys can be used to scroll
through menu selections.
Items and selections in this menu are:

Settings
Display
Diagnostics
Service
RCPH10WHL355AAH 7
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Settings
Selections at the setting menu include:
Engine
Transmission
Joystick steering (Option - will display only if machine is
joystick steering equipped)
RCPH10WHL366BAH 8
Service
Highlight the desired election and press confirm. The
tests in the configuration menu should be performed only
by a qualified operator or technician, as some tests re-
quire the engine to be running at high RPM's.
Items and selections in this menu are:

Calibration (Park brake and pedal calibration)
Select Tires (tire size)
RCPH10WHL376BAH 9
Diagnostics
Highlight the desired election and press confirm. The di-
agnostic area should be used by a trained service techni-
cian.
NOTE: Pressing the escape key will return the LCD back
to the normal driving screen. In order to lock the changes
into memory, the operator must press the confirm key,
then use the escape key to return to the main screen.
Turning the machine off will also lock the settings into
memory.
RCPH10WHL447AAH 10
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Software legend
RCPH10WHL060HAH 11
Parking Brake Indicator
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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 normal operating temperature, 20 ° to 120 ° C ( 68 ° to 248 ° F).
Red Zone:
NOTE: The machine must not be operated when the temperature is in the red zone.
1. Transmission oil temperature continues to increase, 125 ° C and above ( 257 ° F and above).
2. The warning alarm sounds continuously.
Transmission Oil Temperature Indicator
Illuminates when transmission oil temperature exceeds 125 ° C ( 257 ° F).
Fuel Level
Displays the fuel level in percent remaining in the tank.
Fuel Reserve Indicator
The tank is almost empty, 5 percent and below.
Engine Oil Pressure Indicator
The engine oil pressure indicator will illuminate if 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 normal operating temperature, 20 ° to 105 ° C ( 68 ° to 221 ° F).
Red Zone:
NOTE: The machine must not be operated when the temperature is in the red zone.
1. Engine coolant temperature continues to increase, 110 ° C or above ( 230 ° F or above).
Engine Coolant Temperature Indicator
Illuminates when coolant temperature exceeds 110 ° C ( 230 ° F).
Hourmeter
The hourmeter displays the accumulated running time of the engine in hours and tenths of an hour with an “hour
glass” symbol.
Tachometer
The tachometer displays the engine speed in revolutions per minute along with a “r/min” symbol.
Speedometer
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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.
Battery Charge Indicator
Illuminates when the battery charge is insufficient.
Requested Gear
The gear position on shift lever, shown in the center:
1 1st gear
2 2nd gear
3 3rd gear
4 4th gear
Brake Pressure Indicator
Illuminates when brake pressure is below 110 bar +/- 5 ( 1595 psi +/- 73).
Emergency Steering Indicator
Illuminates when emergency steering pump is actuated.
High Beam Indicator
Illuminates when road lights are placed into high beam.
Turning Indicator Lamps
When the turning light control lever is moved toward the turning direction desired, the relevant lights and indicator
illuminate.
General Warning Indicator
Illuminates when a fault is detected and machine must be shut down and problem repaired.
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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
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Index

Backup/Reverse alarm relay - Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Buzzer - Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Instrument cluster - Dynamic description - Brake pedal calibration (5-speed transmission) . . . . . . . . . . . . . . . . . . . 3
Instrument cluster - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
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 - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
621F WE, 621F NA, 721F WE, 721F NA
Instrument cluster Digital instrument cluster - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Instrument cluster Digital instrument cluster - Testing - Advanced Instrument Cluster . . . . . . . . . . . . . . . . . . . . . . . 43
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Loader arm and bucket control system - 415
621F
721F
84605841 14/05/2012
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Contents
DIAGNOSTIC
Load travel stabilization system

Control solenoid - Testing - Ride Control Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
84605841 14/05/2012
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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.
84605841 14/05/2012
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Index

Load travel stabilization system Control solenoid - Testing - Ride Control Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . 3
84605841 14/05/2012
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Cab/Platform harnesses and connectors - 510
621F
721F
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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
621F
721F
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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
621F
721F
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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
621F
721F
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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
84605841 14/05/2012
55.518 / 3

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
84605841 14/05/2012
55.518 / 7
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
84605841 14/05/2012
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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
621F
721F
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55.519 / 1
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
84605841 14/05/2012
55.519 / 3
Electrical systems - Cab brake controls

kPa (1600 psi)
AIC connector 2
AIC connector 1
84605841 14/05/2012
55.519 / 4
Index

Parking brake control Button switch - Testing - Parking Brake Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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Cab controls (Lift arm, Boom, Dipper, Bucket) - 524
621F
721F
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55.524 / 1
Contents
SERVICE
Lift arm lifting controls

Proximity switch - Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
DIAGNOSTIC
Load travel stabilization switch

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
RCPH10WHL202GAH 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.
84605841 14/05/2012
55.524 / 3
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 6.8
N·m (5.0 lb ft).
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 RCPH10WHL208BAH 2
the target per the table. Tighten the target in this

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
621F Z-Bar 44 mm (1.7 in) 380 mm (15.0 in) 38 mm (1.5 in) 3302 mm (130 in)
621F XT 78 mm (3.1 in) 496 mm (19.5 in) 54 mm (2.1 in) 3302 mm (130 in)
721F Z-Bar 54 mm (2.1 in) 380 mm (15.0 in) 48 mm (1.9 in) 3302 mm (130 in)
721F XT 51 mm (2.0 in) 403 mm (15.9 in) 43 mm (1.7 in) 3302 mm (130.0 in)
721F XR 58 mm (2.3 in) 461 mm (18.1 in) 54 mm (2.1 in) 4000 mm (157.48 in)
84605841 14/05/2012
55.524 / 4
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.
84605841 14/05/2012
55.524 / 5
Index

Lift arm lifting controls Proximity switch - Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Load travel stabilization switch - Testing - Ride Control Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
84605841 14/05/2012
55.524 / 6
Selective Catalytic Reduction (SCR) electrical system - 988
621F NA
621F WE
721F NA
721F WE
84605841 14/05/2012
55.988 / 1
Contents
SERVICE
Selective Catalytic Reduction (SCR) supply module

Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Filter - Remove DNOx supply module controller unit filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Filter - Install - DNOx supply module controller unit filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Filter - Remove - Supply tank filler neck screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Filter - Install - Supply tank filler neck screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Filter - Remove - Supply line screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Filter - Install - Supply line screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Selective Catalytic Reduction (SCR) dosing module
Dosing valve - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Dosing valve - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Selective Catalytic Reduction (SCR) humidity sensor
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Selective Catalytic Reduction (SCR) temperature sensors
Remove - Catalyst inlet temperature sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Install - Catalyst inlet temperature sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Remove - Catalyst outlet temperature sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Install - Catalyst outlet temperature sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
NOx sensor
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Selective Catalytic Reduction (SCR) heated level sensor
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
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CONSUMABLES INDEX
Consumable IU PAGE
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Electrical systems - Selective Catalytic Reduction (SCR) electrical system
Selective Catalytic Reduction (SCR) supply module - Remove

CAUTION
Flying debris!
pressed air.
C0049A

cess cover.
RCPH11WHL652BAU 1
RCPH11WHL653BAU 2
84605841 14/05/2012
55.988 / 4
3. Open the grill located above the radiator/charge air

cooler/oil cooler/hydraulic cooler package located
just behind the cab.
RCPH11WHL685BAU 3
4. Raise the right hand side engine compartment side

panel.
RCPH11WHL733BAU 4
5. Remove thumb screw securing the right hand side

inner fender panel.
RCPH11WHL734BAU 5
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55.988 / 5
6. Remove right hand side inner fender panel.
RCPH11WHL735BAU 6
7. Mark supply and return line connection locations for

reference during reassembly.
RCPH11WHL737BAU 7
8. Disconnect DEF/ADBLUE® supply and return lines

from underneath DNOx supply module controller
unit.
NOTE: To disconnect fittings, squirt water into the fitting
connection to lubricate the O-ring. Squeeze the locking
tabs together while slightly pushing the fitting ends together
and then pulling them apart. If the fitting will not release,
but is free to rotate, the O-ring is likely stuck and additional
water should be used.
supply and return line connections.
RCPH11WHL742BAU 8
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55.988 / 6
9. Remove hex bolts securing the DNOx supply module

controller unit to the mounting support bracket.
RCPH11WHL738BAU 9
10. Partially remove DNOx supply module controller unit

from its mounting support bracket to gain access to
the wiring harness (1). Open the lever (2) and dis-
connect wiring harness from DNOx supply module
controller unit.
RCPH11WHL741BAU 10
11. Remove DNOx supply module controller unit from

the machine.
RCPH11WHL739BAU 11
Next operation:
Selective Catalytic Reduction (SCR) supply module - Install (55.988)
84605841 14/05/2012
55.988 / 7
Selective Catalytic Reduction (SCR) supply module - Install

Prior operation:
Selective Catalytic Reduction (SCR) supply module - Remove (55.988)
1. Position the DNOx supply module control unit on its

mounting support bracket. Connect wiring harness
to back of unit. Be sure the lever (1) is fully engaged
and the plug (2) is fully seated.
RCPH11WHL740BAU 1
2. Fit the DNOx supply module into mounting support

bracket and secure with hex bolts.
RCPH11WHL738BAU 2
3. Reconnect supply and return lines underneath DNOx

supply module control unit. To connect, push the two
fitting ends together until an audible snap is heard.
NOTE: Test fitting connections to be sure they are secure.
Match supply and return markings to ensure correct con-
nections are made.
RCPH11WHL742BAU 3
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55.988 / 8
4. Check wire harness and supply lines for proper po-

sitioning.
NOTE: Make sure wire harness and supply lines do not
contact anything that would cause damage.
RCPH11WHL736BAU 4
5. Turn master electric switch to “on” position. Clear

any fault codes. Start engine. Check for fluid leaks at
connections. Confirm problem has been corrected.
RCPH11WHL653BAU 5
6. Reinstall inner fender panel and secure using thumb-

screw.
RCPH11WHL735BAU 6
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55.988 / 9
7. Lower right hand side engine compartment side

panel. Lower grill above radiator/charge air cooler/oil
cooler/hydraulic cooler package located just behind
cab. Close engine compartment hood.
RCPH11WHL733BAU 7
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Selective Catalytic Reduction (SCR) supply module Filter - Remove

DNOx supply module controller unit filter
CAUTION
Flying debris!
pressed air.
C0049A
1. Locate the DEF/ADBLUE® supply filter inside the

DNOx supply module control unit under the hood
on the right side of the engine at the rear of the
machine.
RCPH11WHL685BAU 1
2. Raise the hood using the controls located behind the

access cover.
RCPH11WHL663BAU 2
RCPH11WHL653BAU 3
84605841 14/05/2012
55.988 / 11
4. Locate the DNOx supply module controller unit (1).

The filter element assembly (2) is located on the un-
derside of the unit.
NOTE: Clean dirt and debris from the filter element housing
using compressed air and water.
RCPH11WHL686BAU 4
5. Squirt water into the fitting connections to lubricate

the O-rings. Disconnect the fittings by pushing them
together while squeezing the locking tabs. Then pull
the fitting down and off.
NOTE: If a fitting will not release, but is free to rotate, the
O-ring is likely stuck and lubrication of the O-ring should be
repeated.
RCPH11WHL692BAU 5
6. Remove the DEF/ADBLUE® filter element assembly

from DNOx supply module controller unit by turning it
counter clockwise. Pull straight down and away from
unit.
NOTE: Use a suitable container to catch any fluid dis-
charged during disassembly.
RCPH11WHL688BAU 6
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7. Remove the filter element (1) from the filter housing

(2) by turning it counter clockwise. Discard the fil-
ter element following local environmental and waste
regulations.
RCPH11WHL691BAU 7
Next operation:
Selective Catalytic Reduction (SCR) supply module Filter - Install — DNOx supply module controller unit filter
(55.988)
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Selective Catalytic Reduction (SCR) supply module Filter - Install -

DNOx supply module controller unit filter
Prior operation:
Selective Catalytic Reduction (SCR) supply module Filter - Remove DNOx supply module controller unit filter
(55.988)
1. Lubricate the filter element O-ring (1) on the hous-

ing side with petroleum jelly. Lubricate the housing
O-ring (2). Install the filter element hand tight onto
the housing by turning it clockwise.
RCPH11WHL691BAU 1
2. Lubricate the filter element O-ring on control module

side with petroleum jelly.
RCPH11WHL690BAU 2
3. Insert the filter housing assembly into the DNOx

supply module controller unit. Turn it clockwise to
tighten. Torque to 20 - 25 N·m (15 - 18 lb ft).
RCPH11WHL689BAU 3
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55.988 / 14
4. Reinstall the DEF/ADBLUE® supply line. Push the

connection together and then pull it back to make
sure it is secure.
RCPH11WHL692BAU 4

Clear any fault codes. Start the engine and check
connections for leaks. Confirm that the problem has
been corrected.
RCPH11WHL653BAU 5
84605841 14/05/2012
55.988 / 15

- Supply tank filler neck screen
CAUTION
Flying debris!
pressed air.
C0049A
1. Locate the DEF/ADBLUE® supply tank on the right

hand side of the machine beneath the access cover.
RCPH11WHL685BAU 1

cess cover.
RCPH11WHL663BAU 2
3. Turn off the master electric switch to the “off” position.
RCPH11WHL653BAU 3
84605841 14/05/2012
55.988 / 16
4. Open the access cover and remove the filler cap from
filler neck of supply tank.
NOTE: Before opening filler cap, use compressed air and
water, to clean debris from around filler cap/neck area.
RCPH11WHL693BAU 4
5. Remove the bolts securing the filler neck/cap screen

assembly.
NOTE: Place a stopper into filler neck hole to prevent loose
screws and debris from entering supply tank.
RCPH11WHL694BAU 5
6. Remove the filler neck/cap screen assembly and

O-ring. Pull upwards while twisting assembly left
and right.
NOTE: Cap opening of supply tank to prevent debris from
entering tank.
RCPH11WHL695BAU 6
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7. Remove the plug from the filler neck and rinse screen
with water to remove accumulated debris. Reinstall
plug into filler hole.
NOTE: If the screen is damaged, replace it. To replace,
remove bolts and separate filler neck from screen. Attach
new screen to filler neck and secure with bolts.
RCPH11WHL699BAU 7
Next operation:
Selective Catalytic Reduction (SCR) supply module Filter - Install — Supply tank filler neck screen (55.988)
84605841 14/05/2012
55.988 / 18

Supply tank filler neck screen
Prior operation:
Selective Catalytic Reduction (SCR) supply module Filter - Remove — Supply tank filler neck screen (55.988)
1. Lubricate the O-ring with petroleum jelly. Reinstall

O-ring (1) onto the supply tank (2) with the radius
surface facing upward.
RCPH11WHL697BAU 1
2. Reinstall the filler neck/cap screen assembly (1) onto

the supply tank (2).
RCPH11WHL698BAU 2
3. Secure the assembly with bolts and remove the stop-

per from the filler neck hole. Reinstall the supply tank
filler neck cap.
RCPH11WHL694BAU 3
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55.988 / 19
4. Close the side cover concealing the supply tank.

Turn the master electric switch to the “on” position.
Lower engine compartment hood.
RCPH11WHL653BAU 4
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55.988 / 20

- Supply line screen
CAUTION
Flying debris!
pressed air.
C0049A
1. Locate the DEF/ADBLUE® supply line screen under

the engine hood on the right side of engine at rear of
machine.
RCPH11WHL685BAU 1

cess cover.
RCPH11WHL663BAU 2
3. Turn master electric switch to “off” position.
RCPH11WHL653BAU 3
84605841 14/05/2012
55.988 / 21
4. Locate supply line filter screen housing within sup-

ply line between supply tank (1) and DNOx supply
module control unit (2) mounted on right hand side
of engine.
around screen assembly.
RCPH11WHL686BAU 4
5. Open the supply line fitting. To open fitting, push fit-

ting together, squeeze locking tabs slightly and then
pull apart.
NOTE: Squirt water into the fitting connection to lubricate
O-ring. If the fitting will not release, but is free to rotate, the
O-ring is likely stuck and additional water should be used
to free the connection.
NOTE: Use a suitable container to catch any fluid dis-
charged during hose and filter disassembly.
RCPH11WHL701BAU 5
6. Remove the filter screen from housing. Rinse filter

screen with water to remove accumulated debris.
NOTE: If filter screen is damaged, replace it.
RCPH11WHL700BAU 6
Next operation:
Selective Catalytic Reduction (SCR) supply module Filter - Install — Supply line screen (55.988)
84605841 14/05/2012
55.988 / 22

Supply line screen
Prior operation:
Selective Catalytic Reduction (SCR) supply module Filter - Remove — Supply line screen (55.988)
1. Install the filter screen into the supply line filter hous-
ing.
RCPH11WHL700BAU 1
2. Reconnect the supply line coupling.
RCPH11WHL701BAU 2

any fault codes. Start the engine and check connec-
tions for leaks. Confirm problem has been corrected.
RCPH11WHL653BAU 3
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Selective Catalytic Reduction (SCR) dosing module Dosing valve -

Remove
cess cover.
RCPH11WHL663BAU 1
RCPH11WHL653BAU 2
3. Clean dirt and debris from around engine air intake

pipe connections and DEF/ADBLUE® dosing valve.
NOTE: The dosing valve is located in the exhaust system
before the SCR catalyst and after the turbocharger.
RCPH11WHL656AAU 3
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4. Remove intake pipe (1) connecting turbocharger and

charge air cooler. Remove intake pipe (2) connecting
air filter housing inlet and support bracket.
NOTE: Cover openings to prevent debris entering system.
RCPH11WHL655AAU 4
5. Remove engine coolant line mounting bracket (1) for

easier access to dosing valve (2).
NOTE: Mark the location and routing of coolant lines for
reference during reassembly.
RCPH11WHL661BAU 5
6. Disconnect dosing valve wiring harness.
RCPH11WHL654AAU 6
7. Mark the location of the DEF/ADBLUE® supply and

return lines for reference during reassembly. Re-
move the DEF/ADBLUE® supply and return lines.
Cap the lines to prevent debris from entering the
system.
NOTE: To separate connections, squirt water into fittings
to lubricate O-rings. Squeeze fitting locking tabs slightly
and push fitting together then pull it apart. If fitting will not
release, but is free to rotate, the O-ring is likely stuck and
additional water should be applied.
RCPH11WHL657AAU 7
84605841 14/05/2012
55.988 / 25
8. Remove bolts securing dosing valve into mixing pipe.
RCPH11WHL659AAU 8
9. Remove dosing valve. Cover opening of mixing pipe

to prevent debris from entering the exhaust system.
RCPH11WHL660BAU 9
10. Inspect dosing valve and service or replace as rec-

ommended.
RCPH11WHL662BAU 10
Next operation:
Selective Catalytic Reduction (SCR) dosing module Dosing valve - Install (55.988)
84605841 14/05/2012
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Selective Catalytic Reduction (SCR) dosing module Dosing valve

- Install
Prior operation:
Selective Catalytic Reduction (SCR) dosing module Dosing valve - Remove (55.988)
1. Remove cover from exhaust system and install dos-
ing valve.
NOTE: Use markings made during disassembly to deter-
mined proper positioning.
RCPH11WHL660BAU 1
2. Secure dosing valve to exhaust pipe. Torque screws

to 7 N·m (62.0 lb in) +/- 0.5 N·m (4 lb in).
RCPH11WHL659AAU 2
3. Connect DEF/ADBLUE® supply and return lines and

wiring harness to dosing valve.
NOTE: Use marks made during disassembly to determine
proper positioning.
RCPH11WHL658AAU 3
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55.988 / 27
4. Secure engine coolant line hold down bracket.
RCPH11WHL661BAU 4
5. Remove covers from air intake pipe openings. Install

air intake pipe (1) connecting air filter housing inlet
and support bracket. Install air intake pipe (2) con-
necting turbocharger inlet side and charge air cooler.
RCPH11WHL656AAU 5
6. Turn master electric switch to “on”. Clear any

fault code. Start machine. Check for leaks at
DEF/ADBLUE®, exhaust and intake system connec-
tions. Confirm problem has been corrected.
RCPH11WHL653BAU 6
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Selective Catalytic Reduction (SCR) humidity sensor - Remove

1. Raise the engine compartment hood using controls
located behind the access cover.
RCPH11WHL652BAU 1
RCPH11WHL653BAU 2
84605841 14/05/2012
55.988 / 29
3. Locate the humidity sensor on air intake pipe be-

tween the air filter housing and turbocharger.
RCPH11WHL721BAU 3
4. Disconnect the wiring harness plug.
RCPH11WHL722BAU 4
5. Remove the hex bolts.
RCPH11WHL723BAU 5
84605841 14/05/2012
55.988 / 30
6. Remove the sensor.

NOTE: Cover hole in the intake pipe to prevent debris from
entering the system.
RCPH11WHL724BAU 6
Next operation:
Selective Catalytic Reduction (SCR) humidity sensor - Install (55.988)
84605841 14/05/2012
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Selective Catalytic Reduction (SCR) humidity sensor - Install

Prior operation:
Selective Catalytic Reduction (SCR) humidity sensor - Remove (55.988)
1. Remove plug covering hole in intake pipe and insert
sensor.
RCPH11WHL724BAU 1
2. Secure sensor with hex bolts. Sensor torque 15 - 19

N·m (11 - 14 lb ft).
RCPH11WHL723BAU 2
3. Reconnect wiring harness plug.
RCPH11WHL722BAU 3
84605841 14/05/2012
55.988 / 32
4. Turn master electric switch “on”. Clear any fault

codes. Start machine and confirm that problem has
been corrected.
RCPH11WHL653BAU 4
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55.988 / 33
Selective Catalytic Reduction (SCR) temperature sensors - Remove

- Catalyst inlet temperature sensor
cess cover.
RCPH11WHL663BAU 1
RCPH11WHL653BAU 2
3. Locate the catalyst inlet temperature sensor (1) on

the exhaust system before the catalyst (2).
RCPH11WHL674BAU 3
84605841 14/05/2012
55.988 / 34
4. Loosen hex nut on the sensor.
RCPH11WHL675BAU 4
5. Remove sensor from the exhaust system.
RCPH11WHL676BAU 5
6. Remove wire ties securing wire harness to support

brackets. Unplug sensor from machine wiring har-
ness and remove it.
RCPH11WHL677BAU 6
Next operation:
Selective Catalytic Reduction (SCR) temperature sensors - Install — Catalyst inlet temperature sensor (55.988)
84605841 14/05/2012
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Selective Catalytic Reduction (SCR) temperature sensors - Install -

Catalyst inlet temperature sensor
Prior operation:
Selective Catalytic Reduction (SCR) temperature sensors - Remove — Catalyst inlet temperature sensor
(55.988)
1. Install catalyst inlet temperature sensor into exhaust
pipe.
RCPH11WHL676BAU 1
2. Secure sensor into exhaust pipe. Sensor torque 40 -

50 N·m (30 - 37 lb ft). Reconnect sensor to wire har-
ness and secure harness to support brackets using
new wire ties.
RCPH11WHL675BAU 2
84605841 14/05/2012
55.988 / 36

any fault code. Start engine and check to see if prob-
lem has been corrected.
RCPH11WHL653BAU 3
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Selective Catalytic Reduction (SCR) temperature sensors - Remove

- Catalyst outlet temperature sensor
cess cover.
RCPH11WHL663BAU 1
RCPH11WHL653BAU 2
3. Locate the catalyst outlet temperature sensor (1) on

exhaust system after catalyst (2).
RCPH11WHL657BAU 3
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4. Loosen hex nut and remove sensor from exhaust

system.
RCPH11WHL664BAU 4
5. Loosen hex nut and remove clamp securing sensor

wiring harness to catalyst mounting support bracket.
Remove any wire ties securing sensor wiring har-
ness to the machine.
RCPH11WHL665BAU 5
6. Disconnect sensor from wiring harness.
RCPH11WHL666BAU 6
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7. Remove sensor and wiring harness.
RCPH11WHL667BAU 7
Next operation:
Selective Catalytic Reduction (SCR) temperature sensors - Install — Catalyst outlet temperature sensor
(55.988)
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Selective Catalytic Reduction (SCR) temperature sensors - Install -

Catalyst outlet temperature sensor
Prior operation:
Selective Catalytic Reduction (SCR) temperature sensors - Remove — Catalyst inlet temperature sensor
(55.988)
1. Install temperature sensor into exhaust system. Se-
cure sensor by tightening hex nut. Sensor torque 40
- 50 N·m (30 - 37 lb ft).
RCPH11WHL664BAU 1
2. Install hex nut and clamp holding sensor wiring har-

ness to catalyst mounting support bracket.
RCPH11WHL665BAU 2
3. Reconnect sensor to machine wiring harness.
RCPH11WHL666BAU 3
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RCPH11WHL653BAU 4
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NOx sensor - Remove

cess cover.
RCPH11WHL663BAU 1
RCPH11WHL653BAU 2
3. Locate NOx sensor (1) on outlet of the catalyst (2).
RCPH11WHL657BAU 3
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4. Loosen hex nut and remove the clamp (1) holding

the sensor wiring harness to the catalyst mounting
support bracket (2).
RCPH11WHL665BAU 4
5. Loosen hex nut on NOx sensor.
RCPH11WHL668BAU 5
6. Remove NOx sensor from exhaust system.
RCPH11WHL669BAU 6
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7. Locate NOx sensor module (1) on the backside of the

catalyst mounting support bracket (2).
RCPH11WHL670BAU 7
8. Disconnect NOx sensor module from machine wiring

harness.
RCPH11WHL673BAU 8
9. Remove hex bolts securing NOx sensor module to

mounting support bracket and remove module.
RCPH11WHL672BAU 9
10. Remove wire ties securing NOx sensor wiring har-

ness to machine and remove sensor assembly.
RCPH11WHL671AAU 10
Next operation:
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NOx sensor - Install (55.988)
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NOx sensor - Install

Prior operation:
NOx sensor - Remove (55.988)
1. Install NOx sensor into exhaust system.
RCPH11WHL669BAU 1
2. Secure NOx sensor with hex nut. Sensor torque 40

- 60 N·m (30 - 44 lb ft).
RCPH11WHL668BAU 2
3. Install NOx sensor module and secure it to mounting

support bracket using hex bolts. NOx sensor module
torque 10.5 - 14.5 N·m (8 - 11 lb ft).
RCPH11WHL672BAU 3
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55.988 / 47
4. Reconnect machine wiring harness to NOx sensor

module.
RCPH11WHL673BAU 4
5. Secure NOx sensor wire harness with clamp (1)

to catalyst mounting support bracket (2) using hex
bolts. Secure wire harness with wire ties where
appropriate.
RCPH11WHL665BAU 5

RCPH11WHL653BAU 6
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Selective Catalytic Reduction (SCR) heated level sensor - Remove

CAUTION
Flying debris!
pressed air.
C0049A

cess cover.
RCPH11WHL663BAU 1
2. Turn master electric switch to “off” position.
RCPH11WHL653BAU 2
3. Place a suitable container below the radiator drain

under the access cover at the left rear of the ma-
chine. Remove radiator cap. Remove drain cap and
drain engine coolant. Install tank drain plug and ra-
diator cap after coolant has drained.
around drain plug area before draining system.
RCPH11WHL684BAU 3
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4. Loosen hex bolts and remove cover on right rear of

machine to access the DEF/ADBLUE® supply tank.
RCPH11WHL703BAU 4
5. Use compressed air or water to clean dirt and de-

bris from the DEF/ADBLUE® supply tank around filler
cap/neck (1) and level/temp sensor pickup heater el-
ement (2).
RCPH11WHL713BAU 5
6. Remove the rubber cover from the DEF/ADBLUE®

level/temp sensor pickup heater wires and supply/re-
turn lines. Mark hose and wire connection position-
ing.
RCPH11WHL704BAU 6
7. Unplug the wiring harness. Disconnect engine

coolant lines and the DEF/ADBLUE® lines. Discon-
nect the lines by pushing coupling together all the
way to unlock. Squeeze tabs and pull coupling apart
to break connections.
RCPH11WHL705BAU 7
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8. Move wiring harness, engine coolant, and

DEF/ADBLUE® supply/return and purge line harness
off to the side. Plug all lines to prevent debris entry
into the system.
RCPH11WHL706BAU 8
9. Mark positioning of the DEF/ADBLUE® level temp

sensor pickup heater unit within the tank. Turn unit
counter clockwise to loosen it from tank.
RCPH11WHL707BAU 9
10. Lift the DEF/ADBLUE® level/temp sensor pickup

heater unit out of tank. Cover the tank opening to
prevent debris entry.
RCPH11WHL744BAU 10
Next operation:
Selective Catalytic Reduction (SCR) heated level sensor - Install (55.988)
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Selective Catalytic Reduction (SCR) heated level sensor - Install

Prior operation:
Selective Catalytic Reduction (SCR) heated level sensor - Remove (55.988)
1. Insert the DEF/ADBLUE® tank level/temp sensor

pickup heater unit into the supply tank.
RCPH11WHL744BAU 1
2. Twist the DEF/ADBLUE® tank level/temp sensor pick

up heater unit clockwise to secure it to the tank.
NOTE: Use markings made during disassembly to position
the unit correctly in the tank.
RCPH11WHL707BAU 2
3. Remove the plugs from all lines. Reconnect the DEF/

ADBLUE® purge and supply/return lines. Reconnect
the engine coolant supply/return lines. Reconnect
the liquid level and temperature sensor wiring har-
ness.
NOTE: Test the connections by pushing them together all
the way and then pull back to be sure they are secure.
RCPH11WHL705BAU 3
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4. Replace the protective rubber cover. Refill the en-

gine cooling system.
RCPH11WHL713BAU 4

any fault codes. Start the machine and check for
engine coolant and DEF/ADBLUE® leaks. Confirm
that the problem has been corrected.
RCPH11WHL653BAU 5
6. Replace tank access cover and secure with hex

bolts.
RCPH11WHL685BAU 6
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Index

NOx sensor - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
NOx sensor - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Selective Catalytic Reduction (SCR) dosing module Dosing valve - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Selective Catalytic Reduction (SCR) dosing module Dosing valve - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Selective Catalytic Reduction (SCR) heated level sensor - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Selective Catalytic Reduction (SCR) heated level sensor - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Selective Catalytic Reduction (SCR) humidity sensor - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Selective Catalytic Reduction (SCR) humidity sensor - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Selective Catalytic Reduction (SCR) supply module - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Selective Catalytic Reduction (SCR) supply module - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Selective Catalytic Reduction (SCR) supply module Filter - Install - DNOx supply module controller unit filter . . 14
Selective Catalytic Reduction (SCR) supply module Filter - Install - Supply line screen . . . . . . . . . . . . . . . . . . . . . 23
Selective Catalytic Reduction (SCR) supply module Filter - Install - Supply tank filler neck screen . . . . . . . . . . . . 19
Selective Catalytic Reduction (SCR) supply module Filter - Remove - Supply line screen . . . . . . . . . . . . . . . . . . . 21
Selective Catalytic Reduction (SCR) supply module Filter - Remove - Supply tank filler neck screen . . . . . . . . . 16
Selective Catalytic Reduction (SCR) supply module Filter - Remove DNOx supply module controller unit filter . 11
Selective Catalytic Reduction (SCR) temperature sensors - Install - Catalyst inlet temperature sensor . . . . . . . . 36
Selective Catalytic Reduction (SCR) temperature sensors - Install - Catalyst outlet temperature sensor . . . . . . . 41
Selective Catalytic Reduction (SCR) temperature sensors - Remove - Catalyst inlet temperature sensor . . . . . . 34
Selective Catalytic Reduction (SCR) temperature sensors - Remove - Catalyst outlet temperature sensor . . . . 38
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FAULT CODES - DTC
621F
721F
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Contents
FAULT CODES - DTC
DIAGNOSTIC
0000-Retrieving fault codes, Wheel Loaders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

1310-Hydraulic Filter Blocked . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1311-Engine Air Filter Blocked . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
1312-Hydraulic Oil Temperature Above Normal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
1313-Hydraulic Oil Temperature Too High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
1314-Transmission Oil Temperature Above Normal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
1315-Transmission Oil Temperature Too High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
1316-Brake Pressure Too Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
1317-Steering Pressure Too Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
1318-Engine Coolant Temperature Above Normal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
1319-Engine Coolant Temperature High - Critical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
1320-Engine Oil Pressure Too Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
1321-Engine Oil Pressure Below Normal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
1322-Engine Oil Pressure Above Normal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
1323-Battery Voltage Too Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
1324-Battery Voltage High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
1325-Engine Oil Temperature Too High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
1331-Electrical charging system voltage too low, critical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
1332-Water Detected In Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
1333-Engine Overspeed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
1334-Intake Manifold Temperature High - Critical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
1335-Brake pressure too low, critical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
1336-Transmission Oil Filter Blocked . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
19001-Battery voltage evaluation - Above upper limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
19002-Battery voltage evaluation - Below lower limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
19003-Battery voltage sensing (electrical) - Above upper limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
19004-Battery voltage sensing (electrical) - Below lower limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
19010-Catalyst Temperature Sensor Circuit High - After Catalyst . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
19011-Catalyst Temperature Sensor Circuit Low - After Catalyst . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
19019-Catalyst Temperature Sensor Circuit High - Before Catalyst . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
19020-Catalyst Temperature Sensor Circuit Low - Before Catalyst . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
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19021-Temperature sensor before catalyst (electrical) - signal above high error threshold . . . . . . . . . . . 79
621F WE, 621F NA, 721F WE, 721F NA
19022-Temperature sensor before catalyst (electrical) - signal below low error threshold . . . . . . . . . . . . 80
621F WE, 621F NA, 721F WE, 721F NA
19037-Reagent - pressure sensor - Short circuit high (high supply voltage) . . . . . . . . . . . . . . . . . . . . . . . 81

19038-Reagent - pressure sensor - Short circuit low (low supply voltage) . . . . . . . . . . . . . . . . . . . . . . . . . 82
19046-Reagent - pressure sensor - Open circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
19047-Reagent - pressure sensor - Short circuit high (signal high) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
19048-Reagent - pressure sensor - Short circuit low (signal low) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
19055-Reagent - temperature sensor of pump module - Short circuit high . . . . . . . . . . . . . . . . . . . . . . . . 86
19056-Reagent - temperature sensor of pump module - Short circuit low . . . . . . . . . . . . . . . . . . . . . . . . . 87
19057-UREA Temperature sensor in box (electrical) - signal above high error threshold Out of range . 88
621F WE, 621F NA, 721F WE, 721F NA
19058-UREA Temperature sensor in box (electrical) - signal below low error threshold Out of range . . 89
621F WE, 621F NA, 721F WE, 721F NA
19064-Voltage supply internal heaters 1 (UB1) electrical - Internal heating Open circuit . . . . . . . . . . . . . 90
19065-Pump module - Internal heating - Short circuit high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
19073-Voltage supply 2 - tube heaters (UB2) electrical - Short circuit high . . . . . . . . . . . . . . . . . . . . . . . . 92
621F WE, 621F NA, 721F WE, 721F NA
19074-Voltage supply 2 - tube heaters (UB2) electrical - Short circuit low . . . . . . . . . . . . . . . . . . . . . . . . . 93

621F WE, 621F NA, 721F WE, 721F NA
19075-Reagent - suction tube heating -Open Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

19082-Vent valve (Reductant Purge Control Valve) - Short circuit high . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
621F WE, 621F NA, 721F WE, 721F NA
19083-Voltage supply 3 - Coolant control valve and reverting valve (UB3) electrical - Short circuit low 96
621F WE, 621F NA, 721F WE, 721F NA
19084-Vent valve (Reductant Purge Control Valve) - Short circuit low . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

621F WE, 621F NA, 721F WE, 721F NA
19091-12 Volt supply for dosing module - Above upper limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98

19092-12 Volt supply for dosing module - Below lower limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
19093-Dosing valve/Pump motor - Above upper limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
621F WE, 621F NA, 721F WE, 721F NA
19094-Dosing valve/Pump motor - Below lower limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105

621F WE, 621F NA, 721F WE, 721F NA
19100-UREA level sensor (electrical) - supply voltage error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106

19101-Reagent - tank level sensor - Short circuit high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
19102-Reagent - tank level sensor - Short circuit low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
19109-Reagent - tank temperature sensor (temperature of the Reagent - solution in the tank) - Short circuit
high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
19110-Reagent - tank temperature sensor (temperature of the Reagent - solution in the tank) - Short circuit
low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
19145-Reductant Injector Circuit High - Dosing Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
19146-Reductant Injector Circuit Low - Dosing Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
19147-Reductant Injector Circuit/Open - Dosing Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
19148-Reagent - dosing nozzle - Pressure too high - Dosing Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
19149-Dosing Valve (electrical) - short circuit to ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
19150-Dosing Valve (electrical) - Dosing valve permanent "ON" - Pressure too high . . . . . . . . . . . . . . . 116
19154-Reagent-pump - Not delivering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
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19155-Reagent-pump motor blocked . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
19156-Reagent-pump - Over speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
19157-Reagent-pump - Not delivering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
19163-Vent valve (Cooling Control Valve) - Short circuit high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
621F WE, 621F NA, 721F WE, 721F NA
19164-Vent valve (Cooling Purge Control Valve) - Open circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122

621F WE, 621F NA, 721F WE, 721F NA
19172-Vent valve (Cooling Purge Control Valve) - Short circuit low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
621F WE, 621F NA, 721F WE, 721F NA
19181-Vent valve (Reverting Purge Control Valve) - Short circuit high . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
19182-Vent valve (Reverting Purge Control Valve) - Short circuit low . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
19183-Vent valve (Reverting Purge Control Valve) - Open circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
19184-Reverting valve electrically - 'Short circuit to ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
621F WE, 621F NA, 721F WE, 721F NA
19262-Tank Heating Valve - Short Circuit High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128

621F WE, 621F NA, 721F WE, 721F NA
19263-Tank Heating Valve - Short Circuit Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129

621F WE, 621F NA, 721F WE, 721F NA
19264-Tank Heating Valve - Open Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130

621F WE, 621F NA, 721F WE, 721F NA
19265-Tank Heating Valve - Short Circuit To Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131

621F WE, 621F NA, 721F WE, 721F NA
19289-Temperature After Catalyst Too Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132

621F WE, 621F NA, 721F WE, 721F NA
19290-Catalyst Temperature Sensor Circuit Range / Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133

19298-Reagent Pump Not Delivering - Urea Pressure Too Low At System Start . . . . . . . . . . . . . . . . . . 134
19307-Reagent Pressure Above Threshold - Urea Pressure Not Plausible (Urea Pressure Too High) 135
19316-Reagent Temperature Sensor Of Pump Module - Out Of Range . . . . . . . . . . . . . . . . . . . . . . . . . . 136
19325-Reagent Tank Temperature Sensor - (Temperature of the Reagent Solution in the Tank) Tempera-
ture Out Of Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
621F WE, 621F NA, 721F WE, 721F NA
19334-Defreezing Mode and Detection Errors (Inlet Line Defreezing Failed) . . . . . . . . . . . . . . . . . . . . . 138
621F WE, 621F NA, 721F WE, 721F NA
19335-Defreezing Mode and Detection Errors (Pressure Line Defreezing Failed) . . . . . . . . . . . . . . . . . 139
621F WE, 621F NA, 721F WE, 721F NA
19336-Defreezing Mode and Detection Errors (Pressure Build-up in Detection Mode Failed) Pump Module
Internal Heating - Open Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
621F WE, 621F NA, 721F WE, 721F NA
19337-Defreezing Mode and Detection Errors (Back-flow Line Defreezing Failed) . . . . . . . . . . . . . . . . 141
621F WE, 621F NA, 721F WE, 721F NA
19343-Coolant Control Valve Mechanically - Mechanical Defective Blocked Open . . . . . . . . . . . . . . . . 142

621F WE, 621F NA, 721F WE, 721F NA
19344-Coolant Control Valve Mechanically - Mechanical Defective Blocked Closed . . . . . . . . . . . . . . . 143

621F WE, 621F NA, 721F WE, 721F NA
19352-Vent Valve (Reductant Purge Control Valve) - Open Circuit, Reverting Control Valve . . . . . . . . 144
19361-Battery Voltage Evaluation - Above Upper Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
19362-Battery Voltage Evaluation - Below Lower Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
19370-Pump Motor Error During Commissioning - Urea Pressure Too Low . . . . . . . . . . . . . . . . . . . . . . 147
19379-Urea temperature too low during commissioning - temperatures not plausible during commissioning
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
19415-Empty Urea Tank - Fluid Level In Tank Too Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
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19496-Pressure - Above threshold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
621F WE, 621F NA, 721F WE, 721F NA
19505-Plausibility of pump module temp. sensor ; dynamic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152

19514-Plausibility of urea tank temp. sensor ; dynamic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
621F WE, 621F NA, 721F WE, 721F NA
19532-Back Flow Line Blocked, Dosing Valve - Short Circuit Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
19541-Vent Valve Test - Plausibility Test (Start Up) Cooling Control Valve . . . . . . . . . . . . . . . . . . . . . . . . 155
621F WE, 621F NA, 721F WE, 721F NA
19550-Dosing Nozzle - Pressure Too High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156

19559-Low Urea Level 1 - Too Low (Warning) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
19568-Fluid Level In Tank - Too Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
19577-CAN Receive Frame E2SCR (Urea Quantity Not In Range) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
19578-CAN Receive Frame E2SCR (Dosing Status Not In Range) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
19579-CAN Receive Frame E2SCR Timeout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
19580-CAN Receive Frame E2SCR Too Many Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
19581-CAN Receive Frame E2SCR Serial Communication Link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
19595-CAN Receive Frame EEC1 (Engine Torque Not In Range) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
19596-CAN Receive Frame EEC1 (Engine Speed Not In Range) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
19597-CAN Receive Frame EEC1 - Timeout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
19598-CAN Receive Frame EEC1 - Too Many Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
19599-CAN Receive Frame EEC1 (Torque Driver Demand Not In Range) . . . . . . . . . . . . . . . . . . . . . . . 168
19604-CAN Receive Frame ET1 (Oil Temperature Not In Range) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
19605-CAN Receive Frame ET1 - Timeout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
19606-CAN Receive Frame ET1 - Too Many Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
19607-CAN Receive Frame ET1 (Water Temperature Not In Range) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
19649-Tank Level Sensor - Open Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
19650-Tank Level Sensor - Short Circuit High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
19651-Tank Level Sensor - Short Circuit Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
19652-UREA Tank level error (CAN message or electrical with real sensor) - (TIMEOUT) . . . . . . . . . . 176
621F WE, 621F NA, 721F WE, 721F NA
19653-UREA Tank level error (too many CAN messages) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178

621F WE, 621F NA, 721F WE, 721F NA
19654-UREA Tank level error - Open circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179

621F WE, 621F NA, 721F WE, 721F NA
19676-Ambient Temperature CAN Receive Signal (Ambient Air Temperature Not In Range) . . . . . . . . 181
19677-Ambient Air Temperature Sensor Range/ Performance - CAN Timeout . . . . . . . . . . . . . . . . . . . . 182
19678-Ambient Air Temperature Sensor Range/ Performance - Too Many CAN Messages . . . . . . . . . 183
19679-Ambient Temperature CAN Receive Signal (Barometric Pressure Not In Range) . . . . . . . . . . . 184
19721-EEPROM/ Checksum Failures - EEPROM Write Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
19722-EEPROM/ Checksum Failures - No Corresponding Variant Number Error . . . . . . . . . . . . . . . . . 186
19723-EEPROM/ Checksum Failures - EEPROM Communication Error . . . . . . . . . . . . . . . . . . . . . . . . . 187
19724-EEPROM/ Checksum Failures - EEPROM Detection Error or Codierwort Error . . . . . . . . . . . . . 188
19725-EEPROM/ Checksum Failures - Wrong EEPROM Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
19730-Ignition on signal K15 - digital input ignition on not sensed during initialization - P2530 ignition switch
- plausibility error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
19739-ECM/PCM Power Relay Control Circuit Open - Main Relay Shut Off Too Late . . . . . . . . . . . . . . 191
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19740-ECM/PCM Power Relay Control Circuit Open - Main Relay Short Circuit . . . . . . . . . . . . . . . . . . 192
19741-ECM/PCM Power Relay Control Circuit Open - Main Relay Open Circuit . . . . . . . . . . . . . . . . . . 193
19742-ECM/PCM Power Relay Control Circuit Open - Main Relay Shut Off Too Early . . . . . . . . . . . . . 194
19748-Temperature Sensor of Pump Module - Out of Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
19749-Dynamic Urea Leakage Test - Leak Detected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
19757-Reagent Pump Not Delivering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
19766-Compressed Air Regulation Valve - Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
19775-Plausibility of Catalyst Temperature Sensors - Plausibility Error . . . . . . . . . . . . . . . . . . . . . . . . . . 199
19784-NOx Trap Efficiency Below Threshold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
19793-Fluid Level In Tank Too Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
19802-Urea Tank Temperature -Temp Over CAN Timeout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
19803-Urea Tank Temperature -Temp Over CAN - SAE J1939 Too Many Messages . . . . . . . . . . . . . . 203
19804-Urea Tank Temperature -Temp Over CAN - SAE J1939 Erroneous Signal, Open Circuit . . . . . 204
19805-Urea Tank Temperature -SCR High - Short Circuit High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
19806-Urea Tank Temperature -SCR Low - Short Circuit Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
19807-Urea Tank Temperature -SCR High - Urea Temperature Too High - Out Of Range . . . . . . . . . . 207
19808-Urea Tank Temperature -SCR Low - Urea Temperature Too Low - Out Of Range . . . . . . . . . . . 208
19813-Reagent Pump - Not Delivering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
19817-Dosing Valve - Blocked (stuck open) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
621F WE, 621F NA, 721F WE, 721F NA
19818-Plausibility of UDV (urea dosing valve) stuck - P202D dynamic urea leakage test - leakage detected
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
621F WE, 621F NA, 721F WE, 721F NA
19822-Dynamic Urea Leakage Test - Leak Detected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212

621F WE, 621F NA, 721F WE, 721F NA
19999-Unknown SCR Controller Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213

621F WE, 621F NA, 721F WE, 721F NA
3004-Foot Throttle Sensor - No Signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214

3006-Coolant Temperature Sensor - Signal Not Plausible . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
3007-Coolant temperature signal - signal above range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
3008-Coolant Temperature Signal - Signal Below Range Minimum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
3009-Coolant Temperature Sensor Circuit Open Or Sensor Disconnected . . . . . . . . . . . . . . . . . . . . . . . 224
3015-Fuel Temperature Sensor - Signal Above Maximum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226
3016-Fuel Temperature Sensor - Signal Below Range Minimum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228
3019-Boost Pressure Sensor - Signal Above Range Maximum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230
3021-Boost pressure sensor - (via CAN) no signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233
3022-Boost Pressure Sensor - Signal Not Plausible . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236
3023-Atmospheric Pressure Sensor - Signal Not Plausible . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239
3024-Atmospheric Pressure Sensor - Signal Above Range Maximum . . . . . . . . . . . . . . . . . . . . . . . . . . . 240
3025-Atmospheric Pressure Sensor - Signal Below Range Minimum . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241
3028-Oil Pressure Too Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242
3029-Oil Pressure Sensor - Short Circuit To Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245
3030-Oil Pressure Sensor - Short Circuit To Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248
3031-Oil Pressure Sensor - Hardware Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251
3032-Oil Pressure Sensor - Value Too High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 254
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3033-Oil Temperature Sensor - Signal Not Plausible (Compared With Coolant Temperature) . . . . . . . 257
3034-Oil Temperature Sensor - Signal Above Range Maximum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260
3035-Oil Temperature Sensor - Signal Below Range Minimum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263
3036-Oil temperature sensor circuit open or sensor disconnected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266
3037-Boost Pressure Sensor - Signal Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269
3051-Battery Voltage To Engine Controller - Voltage Too High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272
3052-Battery Voltage To Engine Controller - Voltage Too Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274
3060-Cylinder 1 - Unclassifiable Error In Injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276
3061-Cylinder 1 - Injector Cable Short Circuit (Low Side To Battery) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277
3062-Cylinder 1 - Electronic injector , Low signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 279
3063-Cylinder 1 - Injector Cable Short Circuit (High Side To Ground) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282
3070-Cylinder 3 - Electronic injector , Low signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 292
3078-Cylinder 2 - Electronic injector, Low signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 305
3082-Cylinder 4 - Electronic injector, Low signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 313
3088-Crankshaft sensor lost synchronization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 318
3089-Crankshaft Sensor - Invalid Signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 320
3090-Camshaft Sensor - Lost Phase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 322
3091-Camshaft sensor phase synchronization failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 324
3093-Offset Between Camshaft And Crankshaft - Outside Boundaries . . . . . . . . . . . . . . . . . . . . . . . . . . 326
3095-Operating With Camshaft Sensor Only - Backup Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 329
3102-Rail Pressure Sensor CP3 - Signal Below Range Minimum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 331
3104-Rail Pressure Relief Valve - Open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 335
3105-Rail Pressure Relief Valve - Pressure Shock Requested . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 339
3106-Rail Pressure Relief Valve - Did Not Open After Pressure Shock . . . . . . . . . . . . . . . . . . . . . . . . . . 340
3107-Metering unit output short circuit to battery on low side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 341
3110-Rail Pressure Sensor Monitoring - Signal Above Range Maximum . . . . . . . . . . . . . . . . . . . . . . . . . 342
3111-Rail Pressure Sensor Monitoring - Signal Below Range Minimum . . . . . . . . . . . . . . . . . . . . . . . . . . 343
3112-Rail Pressure Sensor CP3 - Signal Above Maximum Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 344
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3113-Grid heater battery switch relay short circuit to battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 345
3114-Grid heater battery switch relay short circuit to ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 349
3118-ECM 12V sensor supply voltage high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 353
3119-ECM 12V sensor supply voltage low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 355
3131-Grid Heater Always Switched On . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 357
3137-Metering Unit - Open Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 361
3138-Metering Unit - Signal Not Plausible . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 363
3141-Set point of fuel volume flow through metering unit is lower than calculated limit . . . . . . . . . . . . . 365
3147-Oil Temperature Sensor - Signal Above Normal Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 366
3154-Grid Heater Relay - Short Circuit To Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 369
3155-Grid Heater Relay - Short Circuit To Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 373
3156-Grid Heater Relay - No Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 377
3171-Fuel rail system pressure too low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 380
3172-Fuel rail system pressure too high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 384
3173-Rail Pressure Governor Deviation Below Min. Limit for Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 388
3174-Rail Pressure Governor Deviation Exceeded Max. Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 392
3175-Fuel system leak detected - large leak . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 396
3176-Fuel delivery exceeded threshold for pressure in overrun mode . . . . . . . . . . . . . . . . . . . . . . . . . . . 400
3178-Timeout of CAN Message BC2EDC1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
3179-Timeout of CAN Message BC2EDC2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
3180-Timeout of CAN Message VCM2EDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405
3188-Cylinder 1 - Open Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 407
3210-Bank 1 - General Short Circuit To Injector Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 422
3211-Bank 1 - Injector cable Short Circuit Low Side to Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 425
3212-Bank 1 - No Signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 427
3213-Bank 1 - Unclassifiable Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 433
3218-Bank 2 - General Short Circuit On Injector Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 438
3219-Bank 2 - Injector Cable Short Circuit Low Side To Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 443
3220-Bank 2 No Signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 448
3221-Bank 2 - Unclassifiable Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 454
3227-Injection Processor Error - Internal Reset/Clock Loss/Voltage Too Low . . . . . . . . . . . . . . . . . . . . . 459
3228-Injection Processor Error - Unlocked/Initialization Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 460
3229-Injection Processor Error - Injections Limited By Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 461
3230-Injection Processor Error - SPI Communication Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 462
3231-Injection Processor Error - Internal Reset/Clock Loss/Voltage Too Low . . . . . . . . . . . . . . . . . . . . . 463
3232-Injection Processor Error - Unlocked/Initialization Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 464
3233-Injection Processor Error - Test Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 465
3234-Injection Processor Error - SPI Communication Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 466
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3238-Communication error of CJ940 processor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 467
3242-Engine Controller (Locked) Recovery Occurred . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 468
3243-Engine Controller Recovery (Suppressed) - Recovery Occurred . . . . . . . . . . . . . . . . . . . . . . . . . . . 469
3244-Engine Controller Recovery (Visible) - Recovery Occurred . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 470
3245-Engine Controller - Watchdog Not Plausible . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 471
3246-Shutoff Paths During Initialization - Watchdog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 472
3247-Shutoff Paths Failed During Initialization - Supply Voltage Too High . . . . . . . . . . . . . . . . . . . . . . . . 473
3248-Shutoff Paths During Initialization - Supply Voltage Too Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 474
3253-ADC Monitoring - Reference Voltage Too Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 475
3254-ADC Monitoring - Reference Voltage Too High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 476
3255-ADC Monitoring Test Impulse Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 477
3256-ADC Monitoring Queue Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 478
3258-HS power stage hardware reports 'short circuit to battery' longer than 500 ms. . . . . . . . . . . . . . . 479
3259-HS power stage hardware reports 'short circuit to ground' longer than 100 ms. . . . . . . . . . . . . . . 481
3260-LS power stage hardware reports 'open load' longer than 100 ms . . . . . . . . . . . . . . . . . . . . . . . . . 483
3261-LS power stage hardware reports 'short circuit to battery' or 'excess temperature' longer than 100
ms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 485
3262-LS power stage hardware reports 'short circuit to ground' longer than 100 ms. . . . . . . . . . . . . . . 487
3265-Energizing time exceeds limit of over run monitoring, injection time too long . . . . . . . . . . . . . . . . 489
3266-Error in engine speed check, speed signal not plausible . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 490
3278-Engine Controller Internal Supply Voltage Too High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 491
3279-Engine Controller Internal Supply Voltage Too Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 493
3280-Sensor Supply Voltage 1 - High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 495
3281-Sensor Supply Voltage 1 - Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 497
3998-Unknown error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 507
3999-Unknown error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 509
4113-Logical error at FNR switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 511
4114-Logical error at direction select signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 515
4116-Logical error at park brake status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 519
4117-Logic error at direction select signal 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 526
4119-Short circuit to ground at ride control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 530
4120-Short circuit to battery voltage at ride control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 537
4121-Open circuit at ride control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 544
4133-Short circuit to battery voltage or open circuit at transmission sump temperature sensor input . 551
4134-Short circuit to ground at transmission sump temperature sensor input . . . . . . . . . . . . . . . . . . . . . 553
4135-Short circuit to battery voltage or open circuit at retarder/ torque converter temperature sensor input
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 555
4136-Short circuit to ground at retarder/ torque converter temperature sensor input . . . . . . . . . . . . . . . 557
4137-Short circuit to battery voltage or open circuit at parking brake sensor input . . . . . . . . . . . . . . . . . 559
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4145-Short circuit to battery voltage or open circuit at engine speed input . . . . . . . . . . . . . . . . . . . . . . . . 566
4146-Short circuit to ground at engine speed input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 569
4147-Logical error at engine speed input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 572
4148-Short circuit to battery voltage or open circuit at turbine speed input . . . . . . . . . . . . . . . . . . . . . . . 575
4149-Short circuit to ground at turbine speed input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 578
4150-Logical error at turbine speed input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 581
4151-Short circuit to battery voltage or open circuit at internal speed input . . . . . . . . . . . . . . . . . . . . . . . 584
4152-Short circuit to ground at internal speed input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 587
4153-Logical error at internal speed input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 590
4154-Short circuit to battery voltage or open circuit at output speed input . . . . . . . . . . . . . . . . . . . . . . . . 593
4155-Short circuit to ground at output speed input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 597
4156-Logical error at output speed input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
4158-Output speed zero, doesn't fit to other speed signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 605
4160-Invalid gear range restriction (CAN) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 609
4186-Invalid park brake status (CAN) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 611
4209-Short circuit to battery voltage at clutch K1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 613
4210-Short circuit to ground at clutch K1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 615
4211-Open circuit at clutch K1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 617
4228-Short circuit to battery voltage at clutch KV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 637
4229-Short circuit to ground at clutch KV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 639
4230-Open circuit at clutch KV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 641
4231-Short circuit to battery voltage at clutch KR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 643
4232-Short circuit to ground at clutch KR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 645
4233-Open circuit at clutch KR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 647
4241-Short circuit to ground at backup alarm relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 649
4242-Short circuit to battery voltage at backup alarm relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 652
4243-Open circuit at backup alarm relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 655
4273-Slippage at clutch K1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 658
4277-Slippage at clutch KV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 662
4278-Slippage at clutch KR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 663
4279-Overtemp sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 664
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4281-Engine overspeed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 667
4282-TCM sensed a voltage at oil filter maintenance switch out of the allowed range (dirty filter) . . . . 670
4284-Overspeed output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 673
4290-Transmission input torque overload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 677
4291-Overtemp converter output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 678
4292-Short circuit to ground at joystick status indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 681
4293-Short circuit to battery voltage at joystick status indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 685
4294-Open circuit at joystick status indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 689
4305-Short circuit to battery voltage at power supply for sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 693
4306-Short circuit to ground at power supply for sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 694
4307-Low voltage at battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 695
4308-High voltage at battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 696
4309-Error at valve power supply VPS1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 697
4310-Error valve power supply VPS2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 698
4325-VehicleID#1 timeout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 699
4326-Illegal ID request via CAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 702
4337-General EEPROM fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 703
4338-Configuration error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 704
4339-Application error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 705
4341-Clutch failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 706
4342-Clutch adjustment data lost . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 707
9128-CAN Timed Out During Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 708
9160-Hour Meter Failure - Both Copies Are Wrong . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 717
9161-Hour Meter Failure - One Of Two Copies Are Wrong . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 718
9162-Hour Meter Failure - Pre-crank And After-crank Checks Are Wrong . . . . . . . . . . . . . . . . . . . . . . . . 719
[EDC] - 3001-Foot Throttle Sensor - Signal Not Plausible . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 720
[EDC] - 3002-Foot Throttle Sensor - Signal Above Range Maximum . . . . . . . . . . . . . . . . . . . . . . . . . . . . 725
[EDC] - 3003-Foot Throttle Sensor - Signal Below Range Minimum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 729
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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.
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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.
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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
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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19001-Battery voltage evaluation - Above upper limit

1. Faulty electrical wiring or connections.

2. Faulty DCU.
Solution:
1. Verify error is still present and in an active state.
A. If error is still present and active, continue with step 2.
B. If the error is no longer present or inactive, continue with step 3.

2. Verify voltage supply to the DCU. Disconnect the wiring harness from the DCU and with the ignition switch ON,
use a multi-meter to check for voltage between pin24 of the DCU connector and ground. Also check voltage
on the unswitched power between pins 3 and 4 of the DCU connector and ground. The voltage should be
approximately 24 V on all three pins.
A. If the voltage is greater than 28 V, there is a problem in the battery charging system, refer to Battery -
Visual inspection (55.302), Battery - Check (55.302) and Battery - Electrical test (55.302)
B. If the voltage is approximately 24 V , there is an internal failure of the DCU. Temporarily replace the DCU
and retest.
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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19002-Battery voltage evaluation - Below lower limit


2. Faulty DCU.
Solution:

use a multi-meter to check for voltage between pin24 of the DCU connector and ground. The voltage should be
approximately 24 V.
A. If the voltage is less than 11 V, there is a problem in the battery charging system, refer to Battery - Visual
inspection (55.302), Battery - Check (55.302) and Battery - Electrical test (55.302)
B. If the voltage is approximately 24 V , there is an internal failure of the DCU. Temporarily replace the DCU
and retest.
has been resolved.
ation.
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19003-Battery voltage sensing (electrical) - Above upper limit

Context:
The Dosing control unit (DCU) has detected a high voltage condition in the voltage supply circuit. The fault becomes
active when the supply voltage is greater than 36.738 V (36.738 V) for at least 0.3 s (0.3 s). The code will not longer
be active when the supply voltage returns to less than 36.738 V (36.738 V) for 0.8 s (0.8 s).
Cause:
The supply voltage to the DCU is greater than 36.738 V (36.738 V).

2. Faulty Power converter
3. Faulty DCU.
Solution:

2. Verify voltage supply to the DCU. Disconnect the wiring harness from the DCU and with the ignition switch
ON, use a multi-meter to check for voltage between pin24 of the DCU connector and ground. Also check the
unswitched power supply to pins 3 and 4 of the DCU connector and ground. There should be 24 V (24 V) on
all three pins.
A. If there is greater than 36.738 V (36.738 V), use the product schematics to diagnose the wiring.
B. If there is 24 V (24 V), there is an internal failure of the DCU. Replace the DCU
has been resolved.
ation.
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19004-Battery voltage sensing (electrical) - Below lower limit

Context:
The Dosing control unit (DCU) has detected a low voltage condition in the voltage supply circuit. The fault becomes
active when the supply voltage is less than 13.143 V (13.143 V) for at least 0.3 s (0.3 s). The code will heal if the
supply voltage returns to greater than 13.143 V (13.143 V) for 0.8 s (0.8 s).
Cause:
The supply voltage to the DCU is less than 13.143 V (13.143 V).

2. Faulty DCU.
Solution:

use a multi-meter to check for voltage between pin24 of the DCU connector and ground. Also check unswitched
power between pins 3 and 4 of the DCU connector and ground. There should be 24 V (24 V) on all three pins.
A. If there is less than 13.143 V (13.143 V), use the product schematics to diagnose the wiring and ensure
the master disconnect switch is turned on..
B. If there is 24 V (24 V), there is an internal failure of the DCU. Replace the DCU
has been resolved.
ation.
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19010-Catalyst Temperature Sensor Circuit High - After Catalyst

Context:
A second temperature sensor is used downstream of the selective catalytic reduction (SCR) muffler to monitor muffler
operating efficiency. This error will occur when the signal voltage is higher than 2.2 V for more than 0.7 s.
Cause:
There is an open circuit in the downstream temperature sensor circuit.
1. Faulty sensor.
2. Faulty electrical wiring or connection.
3. Faulty denox module.
Solution:
1. Verify this error 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 inactive, return unit to field operation..

2. Make sure the machine is fully cooled down to ambient temperature. Disconnect the wiring harness from the
downstream temperature sensor at connector DTS. Measure the resistance on the sensor from pin 1 to pin 2.
There should be approximately 200 - 250 Ω.
A. If the resistance is within range, continue with step 3.
B. If the resistance is infinite or 0.0 Ω the sensor has failed. Replace the sensor.
3. Test the wiring harness end of the downstream temp sensor connector DTS to the denox module.
Check the resistance between connector DTS pin 1 and pin 2. Expected reading is approximately 1000 - 1600
Ω.
A. If wiring harness test is good, . contact ASIST for further information.
B. If the resistance reading out of range, continue with step 4.

4. Test the wiring harness end of the downstream temp sensor for good ground.
Check the resistance between connector DTS pin 2 and ground. Expected reading is less than 1.0 Ω.
B. If the resistance is infinite, locate bad ground connection and repair..

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19011-Catalyst Temperature Sensor Circuit Low - After Catalyst

Context:
A second temperature sensor is used downstream of the selective catalytic reduction (SCR) muffler to monitor muffler
operating efficiency. This error will occur when the signal voltage is less than 0.71 V for more than 0.7 s.
Cause:
There is a short circuit in the downstream temperature sensor circuit in the selective catalytic reduction (SCR) muffler.
1. Faulty sensor.
Solution:
1. Verify this error is still present and in an active state.

2. Make sure the machine is fully cooled down. Disconnect the wiring harness from the downstream temperature
sensor at connector DTS. Measure the resistance on the sensor from pin 1 to pin 2. There should be approxi-
mately 175 - 250 Ω.
A. If the resistance is within 175 - 250 Ω, continue with step 3.
3. Test the wiring harness end of the downstream temp sensor connector DTS to the denox module.
Check the resistance between connector DTS. pin 1 and pin 2. Expected reading is approximately 1000 - 1600
Ω.

4. Test the wiring harness end of the downstream temp sensor for good ground.
Check the resistance between connector DTS pin 2 and ground. Expected reading is less than 1.0 Ω. between
pin 2 and ground. .
A. If wiring harness test is good, contact ASIST for further information.

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19019-Catalyst Temperature Sensor Circuit High - Before Catalyst

Context:
This is the first temperature sensor used upstream of the selective catalytic reduction (SCR) muffler to monitor muffler
operating efficiency. This error will occur when the signal voltage is higher than 2.2 V for more than 0.7 s.
Cause:
There is an open circuit in the upstream temperature sensor circuit.
1. Faulty sensor.
Solution:

2. Make sure the machine is fully cooled down to ambient temperature. Disconnect the wiring harness from the
upstream temperature sensor at connector UTS. Measure the resistance on the sensor from pin 1 to pin 2.
There should be approximately 175 - 250 Ω.
3. Test the wiring harness end of the upstream temp sensor connector UTS to the denox module.
Check the resistance between connector UTS pin 1 and pin 2. Expected reading is approximately 1000 - 1600
Ω.

4. Test the wiring harness end of the upstream temp sensor for good ground.
Check the resistance between connector UTS pin 2 and ground. Expected reading is less than 1.0 Ω.

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19020-Catalyst Temperature Sensor Circuit Low - Before Catalyst

Context:
This is the first temperature sensor used upstream of the selective catalytic reduction (SCR) muffler to monitor muffler
operating efficiency. This error will occur when the signal voltage is less than 0.71 V for more than 0.7 s.
Cause:
There is a short circuit in the upstream temperature sensor circuit.
1. Faulty sensor.
3. Faulty denox module/supply module.
Solution:

2. Make sure the machine is fully cooled down. Disconnect the wiring harness from the upstream temperature
sensor at connector UTS. Measure the resistance on the sensor from pin 1 to pin 2. There should be approxi-
mately 175 - 250 Ω.
3. Test the wiring harness end of the upstream temp sensor connector UTS to the denox module.
Check the resistance between connector UTS pin 1 and pin 2. Expected reading is approximately 1000 - 1600
Ω.

4. Test the wiring harness end of the upstream temp sensor for good ground.
Check the resistance between connector UTS pin 2 and ground. Expected reading is less than 1.0 Ω.

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19021-Temperature sensor before catalyst (electrical) - signal above

high error threshold
621F WE, 621F NA, 721F WE, 721F NA
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19022-Temperature sensor before catalyst (electrical) - signal below

low error threshold
621F WE, 621F NA, 721F WE, 721F NA
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19037-Reagent - pressure sensor - Short circuit high (high supply

voltage)
Context:
The denox module/supply module has detected a high supply voltage for urea pressure sensors, located inside the
denox module/supply module. Attempt to clear the code. If this code reoccurs, there is a problem with the supply
voltage internal to denox module/supply module. Replace the denox module/supply module.
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19038-Reagent - pressure sensor - Short circuit low (low supply

voltage)
Context:
The denox module/supply module has detected a low supply voltage for urea pressure sensors, located inside the
denox module/supply module. Attempt to clear the code. If this code reoccurs, there is a problem with the supply
voltage internal to denox module/supply module. Replace the denox module/supply module.
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19046-Reagent - pressure sensor - Open circuit

Context:
The denox module/supply module has detected a failure of the urea pressure sensor, located inside the denox module.
This error occurs when the sensor signal level has reached its internal limit. This error is corrected if sensor returns
to its normal output. Ensure all connectors are secured properly on the denox module/supply module and all lines are
in operable condition. If the fault does not reset or reoccurs, replace the denox module/supply module.
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19047-Reagent - pressure sensor - Short circuit high (signal high)

Context:
The sensor signal level is above 5.0 V for over 700 ms. This fault will reset if the raw signal level goes below 5.0 V for
over 1000 ms. Attempt to clear the code. If this code reoccurs, the sensor is defective and the denox module should
be replaced.
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19048-Reagent - pressure sensor - Short circuit low (signal low)

Context:
This error occurs when the sensor signal level is below 0.152 V for over 700 ms. This error is corrected if sensor
returns to normal output for greater than 1.0 s. Ensure all connectors are secured properly on the denox module and
all lines are in operable condition. If the fault does not reset or reoccurs, replace the denox module.
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19055-Reagent - temperature sensor of pump module - Short circuit

high
Context:
The denox module/supply module has detected a failure of the urea temperature sensor, located inside the denox
module. The sensor signal level is above 5.0 V for over 700 ms. This fault will reset if the raw signal level goes below
5.0 V for over 1000 ms. If the sensor is defective the denox module should be replaced.
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19056-Reagent - temperature sensor of pump module - Short circuit

low
Context:
The denox module/supply module has detected a failure of the urea temperature sensor, located inside the denox
module. This error occurs when the sensor signal level is below 0.283 V for over 700 ms. This error is corrected
if sensor returns to normal output for greater than 1.0 s. Ensure all connectors are secured properly on the denox
module and all lines are in operable condition. If the fault does not reset or reoccurs, replace the denox module.
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19057-UREA Temperature sensor in box (electrical) - signal above

high error threshold Out of range
621F WE, 621F NA, 721F WE, 721F NA
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19058-UREA Temperature sensor in box (electrical) - signal below

low error threshold Out of range
621F WE, 621F NA, 721F WE, 721F NA
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19064-Voltage supply internal heaters 1 (UB1) electrical - Internal

heating Open circuit
Context:
The denox module/supply module has sensed a fault with the voltage supply for the internal heaters, located in the
supply module. Ensure all connectors are secured properly on the denox module/supply module and all lines are in
operable condition. If the fault does not reset or reoccurs, replace the supply module.
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19065-Pump module - Internal heating - Short circuit high

Context:
operable condition. If the fault does not reset or reoccurs, replace the supply module.
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19073-Voltage supply 2 - tube heaters (UB2) electrical - Short circuit

high
621F WE, 621F NA, 721F WE, 721F NA
Context:
denox module/supply module. Ensure all connectors are secured properly on the denox module/supply module and
all lines are in operable condition. If the fault does not reset or reoccurs, replace the denox module/supply module.
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19074-Voltage supply 2 - tube heaters (UB2) electrical - Short circuit

low
621F WE, 621F NA, 721F WE, 721F NA
Context:
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19075-Reagent - suction tube heating -Open Circuit

Context:
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19082-Vent valve (Reductant Purge Control Valve) - Short circuit

high
621F WE, 621F NA, 721F WE, 721F NA
Context:
The denox module/supply module has sensed a fault with the voltage supply for the coolant control valve and the
reverting valve, located in the denox module/supply module. Ensure all connectors are secured properly on the denox
module/supply module and all lines are in operable condition. If the fault does not reset or reoccurs, replace the denox
module/supply module.
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19083-Voltage supply 3 - Coolant control valve and reverting valve

(UB3) electrical - Short circuit low
621F WE, 621F NA, 721F WE, 721F NA
Context:
The denox module/supply module has sensed a fault with the voltage supply for the coolant control valve and the
reverting valve, located in the denox module/supply module. Ensure all connectors are secured properly on the denox
module/supply module and all lines are in operable condition. If the fault does not reset or reoccurs, replace the denox
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19084-Vent valve (Reductant Purge Control Valve) - Short circuit low

621F WE, 621F NA, 721F WE, 721F NA
Context:
If this error has occurred, there is a failure in denox module/supply module. Ensure all connectors are secured prop-
erly on the denox module/supply module and all lines are in operable condition. If fault does not reset or reoccurs,
replace denox module/supply module.
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19091-12 Volt supply for dosing module - Above upper limit

1. Wire harness short to battery or to another voltage source.

2. Denox module/supply module internal failure.
Solution:
rence.

(2) Inspect the NOX Controller connections and Doser Metering Valve connections. All connections should be
(3) Inspect the harness from the NOX Controller connections to the Doser Metering Valve. Verify that the har-
ness is free of damage, corrosion, abrasion or incorrect attachment.
RCPH11WHL025FAL 1
Schematic Legend
(1) Unswitched Battery, 24 V from Relay (7) Tank Heater Control Valve
Module PRM_A
Fuse DCU PWR F2 , 20 A
(2) Switched Battery, 24 V (8) DEF Level and Tank Temperature
Fuse DNOX CNTRLR ECA-F10 , 5 A
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Schematic Legend
(3) DNOX2 NOX Controller (9) Upstream Temperature Sensor
(4) Doser Metering Valve (10) UBJ/ UBJM Connector
(5) CAN Data Link Signal, CAN_2 (11) GND_ENG7 Chassis Ground
(6) Downstream Temperature Sensor (12) Diagnostic ISO K Line
DNOX2 NOX Controller Description Wire ID

Connections
1 Battery + Via Main Relay 38D Or-0.8
3 Battery + 18U_D Or-3.0
4 Battery + 18U_B Or-3.0
7 CAN 2 High CAN_HQ Y-0.8
8 CAN 2 Low CAN_LK G-0.8
11 DEF Dosing Module 38A LU-0.8
12 DEF Dosing Module Supply 38 R-0.8
14 Battery Minus O_LB Bk-1.0
15 Battery Minus O_LC Bk-1.0
17 Catalyst Upstream Temp Sensor OE_A Bk-0.8
Ground
18 DEF Tank Level Signal 38B Y-0.8
19 DEF Tank Level Temp Sensor O_T Bk-0.8
Ground
23 DEF Tank Heating 38C LU-0.8
24 Switched + Battery 18T_A Or-1.0
25 Catalyst Downstream Temp Sensor O_U Bk-0.8
Ground
26 Catalyst Downstream Temp Sensor 38E Y-0.8
Signal
28 Catalyst Upstream Temp Sensor 38F Y-0.8
Signal
29 DEF Tank Temp Signal 38G Y-0.8
31 ISO K Interface 38H W-0.8
3. Measure the voltage at the Doser Metering Valve harness
(1) Turn the key switch OFF. Disconnect the Doser Metering Valve from the NOX Controller harness.
(2) Turn the key switch ON.
(3) Measure the voltage from DEFDM connector pin 1 to chassis ground.
A. The voltage should be less than 12 V. Temporarily replace the NOX Controller and retest. Go to Step 1 to
confirm elimination of the fault.
B. The voltage is greater than 13 V Go to Step 4.

4. Measure the resistance through the harness to battery voltage.
(1) Disconnect the Doser Metering Valve from the NOX Controller harness. Disconnect the DNOX2 connector
from the NOX Controller. Turn the key switch ON.
(2) Measure the voltage from DEFDM connector pin 1 to chassis ground. Wiggle the harness during measure-
ment to reveal an intermittent condition.
A. The voltage is less than 1 V. Temporarily replace the NOX Controller and retest. Go to Step 1 to confirm
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B. The voltage is greater than 1 V. There is a short circuit to another voltage source. Repair or replace the
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19092-12 Volt supply for dosing module - Below lower limit

1. Problem battery or charging system.

2. Denox module/supply module internal failure.
Solution:
rence.

(2) Inspect the NOX Controller connections and Doser Metering Valve connections. All connections should be
(3) Inspect the harness from the NOX Controller connections to the Doser Metering Valve. Verify that the har-
ness is free of damage, corrosion, abrasion or incorrect attachment.
RCPH11WHL025FAL 1
Schematic Legend
(1) Unswitched Battery, 24 V from Relay (7) Tank Heater Control Valve
Module PRM_A
Fuse DCU PWR F2 , 20 A
(2) Switched Battery, 24 V (8) DEF Level and Tank Temperature
Fuse DNOX CNTRLR ECA-F10 , 5 A
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Schematic Legend
(3) DNOX2 NOX Controller (9) Upstream Temperature Sensor
(4) Doser Metering Valve (10) UBJ/ UBJM Connector
(5) CAN Data Link Signal, CAN_2 (11) GND_ENG7 Chassis Ground
(6) Downstream Temperature Sensor (12) Diagnostic ISO K Line
DNOX2 NOX Controller Description Wire ID

Connections
1 Battery + Via Main Relay 38D Or-0.8
3 Battery + 18U_D Or-3.0
4 Battery + 18U_B Or-3.0
7 CAN 2 High CAN_HQ Y-0.8
8 CAN 2 Low CAN_LK G-0.8
11 DEF Dosing Module 38A LU-0.8
12 DEF Dosing Module Supply 38 R-0.8
14 Battery Minus O_LB Bk-1.0
15 Battery Minus O_LC Bk-1.0
17 Catalyst Upstream Temp Sensor OE_A Bk-0.8
Ground
18 DEF Tank Level Signal 38B Y-0.8
19 DEF Tank Level Temp Sensor O_T Bk-0.8
Ground
23 DEF Tank Heating 38C LU-0.8
24 Switched + Battery 18T_A Or-1.0
25 Catalyst Downstream Temp Sensor O_U Bk-0.8
Ground
26 Catalyst Downstream Temp Sensor 38E Y-0.8
Signal
28 Catalyst Upstream Temp Sensor 38F Y-0.8
Signal
29 DEF Tank Temp Signal 38G Y-0.8
31 ISO K Interface 38H W-0.8
3. Measure the voltage at the Doser Metering Valve harness
(1) Turn the key switch OFF. Disconnect the Doser Metering Valve from the NOX Controller harness.
(3) Measure the voltage from DEFDM connector pin 1 to chassis ground.
A. The voltage is greater than 1 V. Temporarily replace the NOX Controller and retest. Go to Step 1 to confirm
B. The voltage is less than 1 V Go to Step 4.

4. Measure the resistance through the harness to chassis ground.
(1) Disconnect the Doser Metering Valve from the NOX Controller harness. Disconnect the DNOX2 connector
from the NOX Controller. Turn the key switch ON.
(2) Measure the resistance from DEFDM connector pin 1 to chassis ground. Wiggle the harness during mea-
surement to reveal an intermittent condition.
A. The resistance is greater than 20000 Ω. Temporarily replace the NOX Controller and retest. Go to Step
1 to confirm elimination of the fault.
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B. The resistance is less than 10 Ω. There is a short circuit to chassis ground. Repair or replace the harness
as required. Go to Step 1 to confirm elimination of the fault.
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19093-Dosing valve/Pump motor - Above upper limit

621F WE, 621F NA, 721F WE, 721F NA
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19094-Dosing valve/Pump motor - Below lower limit

621F WE, 621F NA, 721F WE, 721F NA
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19100-UREA level sensor (electrical) - supply voltage error

Context:
The dosing control unit (DCU) has detected a failure of the Internal level sensor, located inside the DCU. This error
occurs when there is a short circuit or broken supply wire inside the denox module/supply module. Ensure all connec-
tors are secured properly on the DCU and all lines are in operable condition. If the fault does not reset or reoccurs,
replace the DCU.
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19101-Reagent - tank level sensor - Short circuit high

Context:
The dosing control unit has sensed the level of AdBlue™/Def drops below a predetermined level. If the signal is higher
than 4.7 V for 0.5 s.
Cause:
There is a short circuit in the AdBlue™/Def level sensor circuit.
1. Faulty Sensor.
3. Faulty DCU.
Solution:
1. Verify this error code is still present, and in an active state.
B. If the error is no longer present or is in an inactive state, return unit to field operation.
2. Check level sensor resistance . Disconnect connector DTLTS at the top of DEF/AdBlue® tank. Use a multi-
meter to measure the resistance of the level sensor from pin 1 to pin 2. The resistance should be approximately
16000 Ω when the tank is filled. The resistance should be approximately 100 Ω when the tank is empty.
A. If resistance is correct continue with step 3.
B. If the resistance is not correct, replace the level sensor.

3. Check for a short to power between denox module/supply module and tank sensor. Disconnect connector
DTLTS from tank sensor. Turn the ignition switch to the on position. Check for greater than 4.7 V between
connector DTLTS pin 1 and ground.
A. If reading shows short to power, repair or replace harness as required. Return unit to field operation.
B. If the reading does not indicate a short , contact ASIST before replacing denox module/supply module.
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19102-Reagent - tank level sensor - Short circuit low

Context:
The Dosing Control Unit (DCU) has sensed the level of AdBlue™/Def has dropped below a predetermined level. If
the signal is lower than 0.2 V for 0.5 s this error will occur.
Cause:
There is an short to ground in the AdBlue™/Def level sensor circuit.
1. Faulty sensor.
3. Faulty DCU.
Solution:
2. Check level sensor resistance . Disconnect connector DTLTS at top of DEF/AdBlue® tank. Use a multi-meter
to measure the resistance of the level sensor from pin 1 to pin 2. The resistance should be approximately 16000
Ω when the tank is filled. The resistance should be approximately 100 Ω when the tank is empty.

3. Check for a short to ground between denox module/supply module and tank sensor. Disconnect connector
DTLTS from tank sensor. Check for continuity between connector DTLTS pin 1 and ground.
A. If reading is less than 1.0 Ω there is short to ground, repair or replace harness as required. Return unit to
field operation.
B. If the reading does not indicate a short to ground, contact ASIST before replacing denox module/supply
module.
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19109-Reagent - tank temperature sensor (temperature of the

Reagent - solution in the tank) - Short circuit high
1. Faulty wiring
2. DEF/AdBlue® tank temperature sensor is faulty.
Solution:
2. Check temperature sensor resistance. Disconnect connector DTLTS at top of DEF/AdBlue® tank. Use a mul-
timeter to measure the resistance of the level sensor from pin 2 to pin 3. See expected resistance at given
temperatures in table below.
-30 °C (-22.0 °F) 12850 Ω

-20 °C (-4.0 °F) 7500 Ω
0 °C (32.0 °F) 2800 Ω
20 °C (68.0 °F) 1215 Ω
30 °C (86.0 °F) 825 Ω
50 °C (122.0 °F) 410 Ω

DTLTS from tank sensor. Turn the ignition switch to the on position. Check for short to power between connec-
tor DTLTS pin 3 and ground.
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19110-Reagent - tank temperature sensor (temperature of the

Reagent - solution in the tank) - Short circuit low
1. Faulty wiring
Solution:
-30 °C (-22.0 °F) 12850 Ω

-20 °C (-4.0 °F) 7500 Ω
0 °C (32.0 °F) 2800 Ω
20 °C (68.0 °F) 1215 Ω
30 °C (86.0 °F) 825 Ω
50 °C (122.0 °F) 410 Ω

DTLTS from tank sensor. Check for short to ground between connector DTLTS pin 3 and ground.
A. If reading shows short to ground, repair or replace harness as required. Return unit to field operation.
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19145-Reductant Injector Circuit High - Dosing Valve

1. Dosing valve harness short to power.

2. Denox module/supply module is faulty
Solution:
1. Disconnect the dosing valve connector DEFDM. Turn the ignition switch on. Use multimeter to check for power
at both pins 1 and 2.
A. Check indicates constant power at connector DEFDM. Locate and repair short to power in dosing circuit
harness.
B. Check indicates no power at connector DEFDM. See step 2.

A. If error is still present and active, replace the denox module/supply module..

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19146-Reductant Injector Circuit Low - Dosing Valve

1. Dosing valve harness short to ground.

Solution:
1. Disconnect the dosing valve connector DEFDM. Use multimeter to check for short to ground at both harness
end pins 1 and 2.
A. Check indicates a short to ground (less than 10 Ω) at connector DEFDM. Locate and repair short to ground
in dosing circuit harness.
B. Check indicates no short to ground at connector DEFDM. See step 2.

2. Check the dosing valve resistance. Disconnect dosing valve connector DEFDM. Use a multi-meter to measure
the resistance directly at dosing valve connector pins 1 and 2. The resistance should be less than 5 Ω .
B. If the resistance is not correct, replace the dosing valve.


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19147-Reductant Injector Circuit/Open - Dosing Valve

NOTE: After the repair has been completed, the code will still be present and active until it has been determined that
the selective catalytic reduction (SCR) system is operating properly. The engine must be brought to normal operating
temperature and run under load until the fault clears. If the code is still present and active after running the engine for
30 minutes, further diagnostics is necessary.
1. Dosing valve harness open circuit.

2. Dosing valve solenoid open circuit.
3. Denox module/supply module is faulty.
Solution:
1. Visually inspect the wiring harness between the denox module/supply module and dosing valve solenoid for
damage or loose connections.
A. Damage or loose connections not found. Go to Step 2.
B. Damage or loose connection found. Repair or correct the problem. Clear all fault codes, and return unit
to field operation.
2. Disconnect the dosing valve connector DEFDM. Use multimeter to check resistance between pins 1 and 2 on
dosing valve solenoid. Expected resistance should be approximately 1.0 Ω.
A. Expected resistance not found. Replace the dosing valve assembly. Clear all fault codes, and return unit
to field operation.
B. Expected resistance found. Go to Step 3.

3. Check for an open circuit in dosing valve wiring. Disconnect connector DEFDM from dosing valve. Disconnect
DNOX2 from the denox module/supply module.
Measure the resistance between connector DEFDM pin 1 and connector DNOX2 pin 12.
Measure the resistance between connector DEFDM pin 2 and connector DNOX2 pin 11.
Reading should be less than 1.0 Ω.
A. Expected reading is not found. Repair open circuit or replace harness.Return unit to field operation.
B. Expected reading found. There is not an open circuit between denox module/supply module and dosing
valve solenoid.Replace the denox module/supply module..
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19148-Reagent - dosing nozzle - Pressure too high - Dosing Valve

1. Dosing valve faulty.

Solution:
1. Check the dosing valve resistance. Disconnect dosing valve connector DEFDM . Use a multi-meter to measure
the resistance directly at dosing valve connector. The resistance should be less than 2 Ω .

A. If error is still present and active, replace the denox valve module..

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19149-Dosing Valve (electrical) - short circuit to ground

Context:
The dosing module, which is fed with AdBlue™/DEF, is an injector located on the exhaust pipe.
Cause:
There is a short circuit in the dosing module circuit.

2. Faulty dosing valve.
3. Faulty Denox \ supply module..
Solution:
A. If error is still present, and active, continue with step 2.

end pins 1 and 2.



has been resolved.
ation.
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19150-Dosing Valve (electrical) - Dosing valve permanent "ON" -

Pressure too high
Context:
The dosing control unit (DCU) has detected an error with the dosing module.
Cause:
There is a short circuit in the dosing module circuit.

2. Faulty dosing valve.
3. Faulty Denox \ supply module..
Solution:

end pins 1 and 2.



has been resolved.
ation.
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19154-Reagent-pump - Not delivering

Context:
The supply module/denox module has detected a urea pump speed sensor fault. This error occurs when the supply
module/denox module has sensed all three hall sensors outputs are high for greater than 7 s. This error is corrected
if all three sensors return to normal output for greater than 1 s. Ensure all connectors are secured properly on the
supply module/denox module and all lines are in operable condition. If the fault does not reset or reoccurs, replace
the supply module/denox module.
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19155-Reagent-pump motor blocked

Context:
The denox module/supply module has detected this failure because the averaged pump flow is less than a predeter-
mined flow rate, and pump control duty cycle is greater than expected as determined by the denox module/supply
module. The pump is blocked internally because of contamination, frozen DEF/AdBlue®, damaged pump motor, or
damaged pump flow measurement. Ensure all connectors are secured properly to the denox module/supply module
and all lines are in operable condition. If fault does not reset, replace the denox module/supply module.
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19156-Reagent-pump - Over speed

Context:
The denox module/supply module has detected this failure because the averaged pump flow is greater than a prede-
termined value for over 7.0 s. Check hose from DEF/AdBlue® tank to pump module. If hose is detached, reconnect
hose and secure to pump. If hose is defective, replace the hose. Ensure all connectors are secured properly on the
denox module/supply module and all lines are in operable condition. Replace denox module/supply module if fault
reoccurs.
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19157-Reagent-pump - Not delivering

Context:
The supply module/denox module has detected a urea pump speed sensor fault. This error occurs when the supply
module/denox module has sensed all three hall sensor outputs are low for greater than 7 s. This error is corrected
if all three sensors return to normal output for greater than 1 s. If the fault does not reset or reoccurs, replace the
supply module/denox module.
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19163-Vent valve (Cooling Control Valve) - Short circuit high

621F WE, 621F NA, 721F WE, 721F NA
Context:
The dosing control unit (DCU) has detected a failure of the SCR Coolant control valve. If this error is detected, the
power stage is switched OFF and ON again and the check is repeated for ten times. Failure is reported if test fails
each time. Ensure all connectors are secured properly on the DCU and all lines are in operable condition. If fault
does not reset or reoccurs, replace the DCU.
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19164-Vent valve (Cooling Purge Control Valve) - Open circuit

621F WE, 621F NA, 721F WE, 721F NA
Context:
The dosing control unit (DCU) has detected a failure of the SCR Coolant control valve. If this error is detected, there
is a short internal to the pump module. Ensure all connectors are secured properly on the DCU and all lines are in
operable condition. If fault does not reset or reoccurs, replace the DCU.
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19172-Vent valve (Cooling Purge Control Valve) - Short circuit low

621F WE, 621F NA, 721F WE, 721F NA
Context:
The dosing control unit (DCU) has detected a failure of the SCR Coolant control valve. If this error is detected, there
is a internal failure to the pump module. Ensure all connectors are secured properly on the DCU and all lines are in
operable condition. If fault does not reset or reoccurs, replace the DCU.
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19181-Vent valve (Reverting Purge Control Valve) - Short circuit

high
Context:
The denox module/supply module has detected a failure of the reverting valve, located inside the denox module/
operable condition. If the fault does not reset or reoccurs, replace the denox module/supply module.
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19182-Vent valve (Reverting Purge Control Valve) - Short circuit low

Context:
The dosing control unit (DCU) has detected a failure of the reverting valve, located inside the supply module. Ensure
all connectors are secured properly on the DCU and all lines are in operable condition. If the fault does not reset or
reoccurs, replace the supply module.
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19183-Vent valve (Reverting Purge Control Valve) - Open circuit

Context:
The denox module/supply module has detected a failure of the reverting valve, located inside the denox module/
operable condition. If the fault does not reset or reoccurs, replace the denox module/supply module.
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19184-Reverting valve electrically - 'Short circuit to ground

621F WE, 621F NA, 721F WE, 721F NA
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19262-Tank Heating Valve - Short Circuit High

621F WE, 621F NA, 721F WE, 721F NA
Context:
A valve remote from the storage tank is used to control coolant to prevent DEF/AdBlue® from freezing in cold tem-
peratures. The valve will respond to a signal from the denox module/supply module based on temperature signals
from the temperature sensor.
Cause:
A open circuit has been detected in the tank heater control valve circuit.
1. Faulty DEF tank heater control valve

2. Faulty electrical wiring or connection
3. Faulty denox module/supply module
Solution:
B. If the error is no longer present or inactive, return unit to field operation.

2. Disconnect the DEF tank heater control valve located at top front of engine compartment.
Use multimeter to check resistance between pins 1 and 2 on tank heating valve/coolant flow solenoid. Expected
resistance should be approximately 30.0 Ω.
A. Expected resistance not found. Replace the tank heating valve/coolant flow solenoid assembly. Clear all
fault codes, and return unit to field operation.

3. Turn the ignition switch on. Use multimeter to check for power at both harness end pins 1 and 2 on connector
C197.
A. Check indicates constant power at valve connector . Locate and repair short to power in tank heating
valve/coolant flow solenoid circuit harness.
B. Check indicates no power at valve connector . See step 4.

A. If error is still present and active, replace the denox module/supply module.

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19263-Tank Heating Valve - Short Circuit Low

621F WE, 621F NA, 721F WE, 721F NA
Context:
A valve remote from the storage tank is used to control coolant to prevent AdBlue™/DEF from freezing in cold temper-
atures. The valve will respond to a signal from the DCU based on temperature signals from the temperature sensor.
Cause:
A short circuit has been detected in the tank heater control valve (coolant flow solenoid valve) circuit.
1. Faulty tank heater control valve

3. Faulty DCU
Solution:
B. If the error is no longer present or inactive, troubleshooting complete..

2. Check the tank heater control valve (coolant flow solenoid valve) connector .
A. Ensure the connector is connected, not damaged, the pins are in the correct position and that the fit is
tight. Repair or replace as required.
B. If the connector is okay, continue to step 3

3. Disconnect the tank heating valve/coolant flow solenoid connector located at top front of engine compartment.

4. Check for a short to ground. Ignition switch in off position.
A. Check between valve connector: pin 1 and ground

If a short to ground is indicated, repair or replace the harness as required.
B. Check indicates no short to ground. See step 5.

A. If error is still present and active, replace the denox module/supply module.

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19264-Tank Heating Valve - Open Circuit

621F WE, 621F NA, 721F WE, 721F NA
Context:
Cause:
A open circuit has been detected in the DEF tank heater control valve circuit.
1. Faulty DEF tank heating control valve

Solution:

2. Disconnect the DEF tank heating control valve connector located at top front of engine compartment.
A. Expected resistance not found. Replace the DEF tank heating control valve. Clear all fault codes, and
return unit to field operation.

3. Check for an open circuit in DEF tank heating control valve wiring. Disconnect connector from DEF tank heating
control valve. Disconnect connector from the denox module/supply module.
Measure the resistance between valve connector pin 1 and module connector pin 23.
Measure the resistance between valve connector pin 2 and module connector pin 1.
Reading should be less than 1.0 Ω.
A. Expected reading is not found. Repair open circuit or replace harness.Return unit to field operation.
B. Expected reading found. There is not an open circuit between denox module/supply module and DEF tank
heating control valve.Replace the denox module/supply module.
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19265-Tank Heating Valve - Short Circuit To Ground

621F WE, 621F NA, 721F WE, 721F NA
Context:
Cause:
A short circuit has been detected in the DEF tank heater control valve circuit.
1. Faulty DEF tank heating control valve

Solution:

2. Disconnect the DEF tank heating control valve connector C197 located at top front of engine compartment.
Use multimeter to check resistance between pins 1 and 2 on DEF tank heating control valve. Expected resis-
tance should be approximately 30.0 Ω.
A. Expected resistance not found. Replace the DEF tank heating control valve. Clear all fault codes, and
return unit to field operation.

3. Check for a short to ground in DEF tank heating control valve wiring. Disconnect connector C197 from DEF
tank heating control valve.
Measure the resistance between harness end connector C197 pin 2 and ground.
Expected reading is no continuity, or overload/ infinite resistance.
A. Expected reading is not found. Repair short to ground, or replace harness.Return unit to field operation.
B. Expected reading found. There is no short to ground in DEF tank heating control valve circuit.Contact
ASIST before replacing the denox module/supply module.
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19289-Temperature After Catalyst Too Low

621F WE, 621F NA, 721F WE, 721F NA
Context:
Cause:
A short circuit has been detected in the tank heater control valve circuit.
1. Faulty tank heating valve/coolant flow solenoid

Solution:

2. Disconnect the tank heating valve/coolant flow solenoid connector located at top front of engine compartment.

3. Check for a short to ground in tank heating valve/coolant flow solenoid wiring. Disconnect connector from tank
heating valve/coolant flow solenoid.
Measure the resistance between harness end connector pin 1 and ground.
Expected reading is no continuity, or overload/ infinite resistance.
A. Expected reading is not found. Repair short to ground, or replace harness.Return unit to field operation.
B. Expected reading found. There is no short to ground in tank heating valve/coolant flow circuit.Contact
ASIST before replacing the denox module/supply module.
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19290-Catalyst Temperature Sensor Circuit Range / Performance

Context:
The dosing control module (DCU) has sensed the Downstream temperature sensor is giving an implausible reading.
This occurs when the DCU senses the Downstream temperature sensor reading is less than 110 °C (230 °F) for longer
than 450 s (450 s) with engine speed of greater than 800 RPM (800.0 RPM) and an engine load of at least 15 % (15.0
%).
Cause:
The DCU has sensed a low Downstream temperature sensor reading.
1. Downstream temperature sensor not installed properly
Solution:
1. Verify this fault code is still present and in an active state.
A. If the fault is still present and remains active, continue with step 2.
B. If the fault is no longer present or is now in an inactive state, continue with step 4.
2. Verify sensor operation. Make sure the machine is fully cooled down to ambient temperature. Disconnect the
wiring harness from the downstream temperature sensor. Measure the resistance on the sensor from pin 1 to
pin 2. There should be approximately 200 - 250 Ω.
A. If the resistance is within range, continue with step 3.
3. Verify proper installation of the sensor. Ensure the downstream temperature sensor is installed in the exhaust
pipe, after the SCR muffler, and the connector is securely seated.
A. Downstream temperature sensor is installed correctly and the connector is securely seated. Continue with
step 4.
B. Downstream temperature sensor is no installed correctly or connector was disconnected.Properly install

the Downstream temperature sensor and ensure the connector is seated properly.
has been resolved.
ation.
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19298-Reagent Pump Not Delivering - Urea Pressure Too Low At

System Start
Context:
The denox module/supply module has detected the DEF/AdBlue® pressure has not reached 500 kPa within 2.5 min.
Manually check DEF/AdBlue® level is filled to operating level. Check feeding tubes, connectors and O-rings in con-
nectors for any air leaks. If error is still present, use the electronic service tool (EST) to run urea dosing system test
(UDST) to troubleshoot the system further.
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19307-Reagent Pressure Above Threshold - Urea Pressure Not

Plausible (Urea Pressure Too High)
Context:
The denox module/supply module has detected the DEF/AdBlue® pressure exceeds 6.5 bar for 30 s. Reasons for
failure could be internal control valve blocked or pump speed to high. These are indications of internal failure of supply
module. Use the electronic service tool (EST) to run the urea dosing system test (UDST) to monitor the DEF/AdBlue®
pressure and pump speed. DEF/AdBlue® pressure should not exceed 500 kPa, and the pump speed should not
exceed 6000 RPM. Replace denox module/supply module if values are out of range.
84605841 14/05/2012
55.DTC / 135
19316-Reagent Temperature Sensor Of Pump Module - Out Of

Range
Context:
The denox module/supply module has detected the DEF/AdBlue® temperature in module box is less than 75 °C (167
°F) or greater than 9 °C (48 °F), and system is not in defreezing mode. This error occurs if, in the previous driving
cycle, box temperature was less than 85 °C (185 °F) and in shutdown mode. If during the actual driving cycle the box
temperature remains less than 70 °C (158 °F)for more than 10.0 s, the system goes into emergency shutdown and
will not start until EEPROM is cleared. Use the electronic service tool (EST) to clear code. Verify tank heater codes
are not present, and there is no temperature plausibility errors. If other errors are present, correct as well.
84605841 14/05/2012
55.DTC / 136
19325-Reagent Tank Temperature Sensor - (Temperature of the

Reagent Solution in the Tank) Temperature Out Of Range
621F WE, 621F NA, 721F WE, 721F NA
Context:
The DEF/AdBlue® temperature in tank is greater than 75.0 °C (167.0 °F)for 300 s and system is not in defreezing
mode. This code will heal when the temperature returns below 75.0 °C (167.0 °F)for 1.0 s.
Cause:
The DEF/AdBlue® tank temperature is out of range.
1. Tank heating valve stuck open

2. Check for other DEF tank heater control valve related error codes
Solution:
1. Verify error is present and in an active state.
B. If the error is no longer present or inactive, continue normal operation.

2. Disconnect the wiring harness from the DEF tank heater control valve connector . Check to see if the heater
valve is stuck open.
A. If heating valve is stuck open, replace heater valve.
B. If heating valve is in normal operation, erase the fault code and continue operation. The DEF tank heater
control valve may stick intermittently. If the fault returns repeatedly, replace DEF tank heater control valve.
84605841 14/05/2012
55.DTC / 137
19334-Defreezing Mode and Detection Errors (Inlet Line Defreezing

Failed)
621F WE, 621F NA, 721F WE, 721F NA
Context:
The denox module/supply module has detected this failure when ambient temperature is below 17.0 °F at system
start up. If DEF/AdBlue® pressure does not reach 390 kPa within 2.5 min the inlet line is frozen. This failure is stored
after 30 repetitions with 2.5 min heating phases between the checks.
Cause:
The denox module/supply module has detected this error because of no DEF/AdBlue® pressure.
1. AdBlue™/DEF tank empty

2. Inlet line broken
3. Pump does not feed
4. DEF/AdBlue® box heater does not work correctly
Solution:
B. If the error is no longer present or is in an inactive state, continue with step 6.

2. Verify if fault code 19262, 19263 or 19264 are present.
A. If no other errors are present, continue with step 3.
B. If any errors are present, correct those errors first. Then check to see if original error has been corrected.
3. Check the DEF/AdBlue® tank. Manually check the level of the DEF/AdBlue® in the tank.
A. If the DEF/AdBlue® level is in normal operating range, continue with step 4.
B. If the DEF/AdBlue® level is not correct, fill tank to proper operating level.
4. Check the inlet line tube. Inspect inlet line tube for any damage.
A. If the inlet tube is in working condition, continue with step 5.
B. If there is any damage to the inlet tube, repair/replace the inlet tube.
5. Actuate pump by using the electronic service tool (EST) to 100 % pump capacity: DEF/AdBlue® pressure should
read greater than 300 kPa after about 1.0 min.
A. If pump does not work correctly, check operation of the box heater.
B. If error is corrected, the line was frozen.

has been resolved.
ation.
84605841 14/05/2012
55.DTC / 138
19335-Defreezing Mode and Detection Errors (Pressure Line

Defreezing Failed)
621F WE, 621F NA, 721F WE, 721F NA
Context:
start up, and inlet line is detected open. If DEF/AdBlue® pressure does not drop to 350 kPa within 40 s with the
dosing valve open to 99.0 %, the pressure line is frozen. This failure is stored after 28 repetitions with 2.5 min heating
phases between the checks.
Cause:
The denox module/supply module has detected this error because of no DEF/AdBlue® injection.
1. Dosing valve does not open

2. Pressure line blocked
3. Injection nozzle blocked
4. Faulty box heater
Solution:
1. Verify this error code is still present and in an active state.

2. Check dosing valve operation. Use the electronic service tool (EST) to run the urea dosing system test (UDST)
to start pump and stop it when DEF/AdBlue® pressure has reached 300 kPa. Open the dosing valve.
A. If pressure drops immediately, continue with step 4.
B. If pressure does not drop down, continue with step 3.

3. Check injection nozzle. Open the air valve to 100 %, the air pressure must be 800 kPa. Close the air valve all
the way.
A. If air pressure drops down to ambient pressure, continue with step 4.
B. If air pressure does not drop to ambient pressure, injection nozzle is clogged. Clean injection nozzle.
4. Check the pressure line. Disconnect the pressure line from dosing valve and start the pump.
A. If DEF/AdBlue® does not flow through the line, the line is clogged. Clean/replace pressure line.
B. If DEF/AdBlue® flows through the tube, the line is clear. Dosing valve does not open. Check operation of
dosing valve.
C. If pressure line and dosing valve are operating normally, check the box heater for incorrect operation.
has been resolved.
ation.
84605841 14/05/2012
55.DTC / 139
19336-Defreezing Mode and Detection Errors (Pressure Build-up

in Detection Mode Failed) Pump Module Internal Heating - Open
Circuit
621F WE, 621F NA, 721F WE, 721F NA
Context:
The dosing control unit (DCU) has detected this failure when ambient temperature is below 17.0 °F at system start up.
The pressure line and inlet line is detected open. If DEF/AdBlue® pressure does not reach 390 kPa within 40 s with
full pump speed, the system is not unfrozen. This failure is stored after 26 repetitions with 2.5 min heating phases
between the checks. Check if the internal heater is working correctly.
84605841 14/05/2012
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19337-Defreezing Mode and Detection Errors (Back-flow Line

Defreezing Failed)
621F WE, 621F NA, 721F WE, 721F NA
Context:
start up. The inlet and pressure line is detected open and pressure build up was OK. If DEF/AdBlue® pressure does
not drop to 140 kPa within 50 s with the vent valve open to 100 %, the back flow line is frozen. This failure is stored
after 24 repetitions with 2.5 min heating phases between the checks.
Cause:
The denox module/supply module has detected this error because of no DEF/AdBlue® back flow line is frozen.
1. DEF/AdBlue® tank ventilation clogged

2. Back flow line clogged
3. Ventilation valve does not open
4. Back flow line frozen
Solution:

2. Actuate the pump. Use the electronic service tool (EST) to run the urea dosing system test (UDST) to start
pump and stop it when DEF/AdBlue® pressure has reached 300 kPa. Open the ventilation valve with the EST.
A. If pressure does not drop down, continue with step 3.
B. If the pressure drops down to ambient pressure immediately, the line was frozen.
3. Check DEF/AdBlue® tank. Use the electronic service tool (EST) to run urea dosing system test (UDST) to start
pump and stop it when DEF/AdBlue® pressure has reached 300 kPa. Open the ventilation valve via EST.
A. If pressure does not drop down, continue with step 4.
B. If pressure does drop, DEF/AdBlue® tank ventilation was clogged.

4. Check back flow line. Disconnect the back flow line from the box. Use the electronic service tool (EST) to run
urea dosing system test (UDST) to start pump and stop it when DEF/AdBlue® pressure has reached 300 kPa.
Open the ventilation valve via EST.
A. If DEF/AdBlue® flows, back flow line is clogged. Replace/repair the line.
B. If DEF/AdBlue® does not flow, ventilation valve does not open. Replace the DEF/AdBlue® tank.
has been resolved.
ation.
84605841 14/05/2012
55.DTC / 141
19343-Coolant Control Valve Mechanically - Mechanical Defective

Blocked Open
621F WE, 621F NA, 721F WE, 721F NA
Context:
The dosing control unit (DCU) has detected a short circuit. If at normal operating speed the AdBlue™/DEF pressure
is greater than 450 kPa, and the cooling valve is closed from 100 - 0 %, the AdBlue™/DEF pressure must rise at least
15 kPa within 2 s. Ensure all connections and connectors are secured to the DCU properly. If error is still present,
there is an internal failure of the box. Replace the DCU.
84605841 14/05/2012
55.DTC / 142
19344-Coolant Control Valve Mechanically - Mechanical Defective

Blocked Closed
621F WE, 621F NA, 721F WE, 721F NA
Context:
The dosing control unit (DCU) has detected a open circuit. If at normal operating speed the AdBlue™/DEF pressure
is greater than 450 kPa, and the cooling valve is open from 0 - 100 %, the AdBlue™/DEF pressure must drop at least
15 kPa within 2 s. Ensure all connections and connectors are secured to the DCU properly. If error is still present,
there is an internal failure of the box. Replace the DCU.
84605841 14/05/2012
55.DTC / 143
19352-Vent Valve (Reductant Purge Control Valve) - Open Circuit,

Reverting Control Valve
1. Valve is mechanically stuck

2. System was empty, needs primed
Solution:

2. Check DEF/AdBlue® tank. Verify that the tank level is filled to the proper capacity.
A. If the tank level is full, continue with step 3.
B. If the level is empty or below capacity, fill the tank to the proper level.
3. Prime the system. Start the pump with the electronic service tool (EST). Open the ventilation valve by 50 %
with the EST until DEF/AdBlue® pressure reaches 60 kPa. Close the ventilation valve. DEF/AdBlue® pressure
should reach 300 kPa within 2 min.
A. If the system will not prime, continue with step 4.
B. If the system primes, continue operation of machine.

4. Check operation of pump. Start the pump with the EST. Listen for pump operation.
A. Pump operation can be heard, continue with step 5.
B. Pump operation cannot be heard, replace the denox module/supply module.

5. Check for blocked, or kinked lines.
A. Pump operation can be heard, lines are okay and tank level is good. Reverting valve is stuck in purge
position. Replace the denox module/supply module.5.
B. A blocked line was located and repaired. Erase the fault code and continue operation.
has been resolved.
ation.
84605841 14/05/2012
55.DTC / 144
19361-Battery Voltage Evaluation - Above Upper Limit

1. Problem with battery or charging system

2. Denox module/supply module internal failure
Solution:
1. Machine running, use the display to check the battery voltage.
A. Battery voltage is below 21 V. Test the alternator and the battery.
B. Battery voltage is 22 - 26 V, continue to step 2

2. Delete fault code. If the fault code continually reoccurs replace the denox module/supply module.
84605841 14/05/2012
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19362-Battery Voltage Evaluation - Below Lower Limit

1. Problem battery or charging system

2. Denox module/supply module internal failure
Solution:
1. Machine running, use the display to check the battery voltage.
A. Battery voltage is above 25 V. Test the alternator and the battery.
B. Battery voltage is 22 - 24 V, continue to step 2

2. Delete fault code. If the fault code continually reoccurs replace the denox module/supply module.
84605841 14/05/2012
55.DTC / 146
19370-Pump Motor Error During Commissioning - Urea Pressure

Too Low
Context:
During operation, the ventilation valve is fully opened, the pump is then set to 100 % operation until DEF/AdBlue®
pressure has reached 500 kPa. The ventilation valve is then closed. If DEF/AdBlue® pressure does not reach 500
kPa within 2.5 min, this error occurs.
Cause:
The denox module/supply module has detected the pump motor is not delivering.
1. No DEF/AdBlue® in tank
3. Faulty pump
4. Faulty feeding line
Solution:

3. Prime the system. Start the pump with the electronic service tool (EST). Open the ventilation valve by 50 % with
the EST until DEF/AdBlue® pressure reaches 60 kPa. Close ventilation valve. DEF/AdBlue® pressure should
reach 300 kPa within 2 min.

4. Check operation of pump. Start pump with the EST. Listen for pump operation.

5. Check for air leak. Disconnect any hoses on the denox module/supply module. Check hoses for any cracks or
holes in the lines. Check all connections that use O-rings are not missing or broken.
A. No air leaks are found, continue with step 6.
B. If any holes or cracks are found, repair/replace hose. If any O-rings are missing or broken, replace the
O-rings.
breaks or shorts in the wiring concerned. Operate the machine while monitoring the display.
has been resolved.
84605841 14/05/2012
55.DTC / 147
ation.
84605841 14/05/2012
55.DTC / 148
19379-Urea temperature too low during commissioning -

temperatures not plausible during commissioning
Context:
The denox module/supply module has detected the temperatures are not correct within 30 min of operation. The
module box temperature is less than -9 °C (16 °F) or greater than 75 °C (167 °F), or the DEF/AdBlue® tank is less
than -17 °C (2 °F) or greater than 75 °C (167 °F). Bring temperature to a normal level, between 0 - 30 °C (32 - 86 °F).
1. Extreme cold ambient conditions

2. DEF/AdBlue® tank temperature sensor is faulty
Solution:
B. If the error is no longer present or is in an inactive state, return machine to service.

2. Check to see if other DEF/AdBlue® temperature sensor fault codes are present.
B. If errors are present, correct these errors first. Verify original error has been corrected.
3. Check temperature sensor resistance. Disconnect connector at top of DEF/AdBlue® tank. Use a multi-meter to
measure the resistance of the level sensor from pin 2 to pin 3. See expected resistance at given temperatures
in table below.
-30 °C (-22.0 °F) 12850 Ω

-20 °C (-4.0 °F) 7500 Ω
0 °C (32.0 °F) 2800 Ω
20 °C (68.0 °F) 1215 Ω
30 °C (86.0 °F) 825 Ω
50 °C (122.0 °F) 410 Ω

4. If the machine is operating in an extreme cold environment, shutdown and restart for another warm up cycle.
A. If no other errors are present after warm up return unit to field operation.
B. If same fault code error is present, contact ASIST before replacing denox module/supply module.
84605841 14/05/2012
55.DTC / 149
19415-Empty Urea Tank - Fluid Level In Tank Too Low

Cause:
The denox module/supply module has detected the DEF/AdBlue® level is constantly less than 0.1 % for more than
25 s.
1. Tank is empty
2. Faulty level sensor
Solution:
B. If the error is no longer present or is in an inactive state, return unit to field operation.6.
2. Check to see if other DEF/AdBlue® level sensor fault codes are present.
4. Check DEF/AdBlue® tank float. Verify the DEF/AdBlue® float is not stuck or is obstructed by any foreign object.
A. If float moves freely, continue with step 5.
B. If float is stuck, clean foreign objects from around float.

5. Check level sensor resistance . Disconnect connector at top of DEF/AdBlue® tank. Use a multimeter to mea-
sure the resistance of the level sensor from pin 1 to pin 2. The resistance should be approximately 16000 Ω
when the tank is filled. The resistance should be approximately 100 Ω when the tank is empty.

6. Fill the DEF/AdBlue® tank.
A. If the fault code does not reoccur return unit to field operation.
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19496-Pressure - Above threshold

621F WE, 621F NA, 721F WE, 721F NA
84605841 14/05/2012
55.DTC / 151
19505-Plausibility of pump module temp. sensor ; dynamic

84605841 14/05/2012
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19514-Plausibility of urea tank temp. sensor ; dynamic

621F WE, 621F NA, 721F WE, 721F NA
84605841 14/05/2012
55.DTC / 153
19532-Back Flow Line Blocked, Dosing Valve - Short Circuit Low

Context:
The denox module/supply module has generated this fault because it has sensed the back flow line is clogged. This
fault occurs when the denox module/supply module performs a test and determines: DEF/AdBlue® pressure is greater
than 345 kPa (50 psi), pump speed greater than 300 RPM, downstream temperature is greater than 60 °C (140 °F),
and dosing is greater than 6 % for 20 s. If these parameters are met, the cooling valve is closed, the DEF/AdBlue®
pump is stopped and the dosing valve is fully opened and the pressure is rechecked by the denox module/supply
module. If the pressure is less than 30 kPa (4.35 psi), the back flow line is clogged. Ensure the lines are open and
free flowing. If the lines are free of blockage, replace the denox module/supply module.
84605841 14/05/2012
55.DTC / 154
19541-Vent Valve Test - Plausibility Test (Start Up) Cooling Control

Valve
621F WE, 621F NA, 721F WE, 721F NA
Context:
The denox module/supply module has detected at start up , after opening the coolant control valve for 40 s, DEF/
AdBlue® pressure is less than 150 kPa. First check that pressure and back flow line are not frozen or clogged. If all
lines are open and in proper operation, the denox module/supply module has failed. Replace the denox module/supply
module.
84605841 14/05/2012
55.DTC / 155
19550-Dosing Nozzle - Pressure Too High

1. Dosing nozzle blocked.

2. Crimped , or collapsed supply line to dosing nozzle.
Solution:
A. If error is still present and active, inspect for crimped , or collapsed supply line. If supply line is good
inspect and clean out dosing nozzle..
84605841 14/05/2012
55.DTC / 156
19559-Low Urea Level 1 - Too Low (Warning)

Context:
The denox module/supply module has detected low DEF/AdBlue® level. This error occurs when the DEF/AdBlue®
fluid level is too low or level sensor has faults present. Ensure the heated level sensor is connected properly. Check
DEF/AdBlue® tank level is full. If fluid level is low, fill tank to proper capacity. Check for any other errors that may be
present. Correct those errors first, then recheck original error has been corrected. Ensure all connectors are secured
properly on the denox module/supply module and all lines are in operable condition. If the fault does not reset or
reoccurs, replace the denox module/supply module.
84605841 14/05/2012
55.DTC / 157
19568-Fluid Level In Tank - Too Low

Context:
The denox module/supply module has detected low DEF/AdBlue® level. This error occurs when the DEF/AdBlue®
fluid level is too low or level sensor has faults present. Ensure the heated level sensor is connected properly. Check
DEF/AdBlue® tank level is full. If fluid level is low, fill tank to proper capacity. Check for any other errors that may be
present. Correct those errors first, then recheck original error has been corrected. Ensure all connectors are secured
properly on the denox module/supply module and all lines are in operable condition. If the fault does not reset or
reoccurs, replace the denox module/supply module.
84605841 14/05/2012
55.DTC / 158
19577-CAN Receive Frame E2SCR (Urea Quantity Not In Range)

1. Controller communication error
Solution:
1. Check for other error codes being displayed. Are there other codes displayed referring to low DEF/AdBlue®
level. Are there other can bus communication error issues.
A. If any other error code is being displayed, resolve that code.
B. If no other error code is displayed, continue to step 2.

2. Ensure all connectors are secured properly on the denox module/supply , the denox terminator connector bus
(located on top right front fender) and engine control module . Check for damage, loose connections or broken
can bus wires.
A. A connector/wiring issue was located and corrected. Erase fault code and return unit to field operation.
B. No connector/wiring issues were located. Continue with step3.

3. Check the can bus terminators. Disconnect denox bus terminator connector . Check the terminators resistance
from pin 1 to pin 2. The expected reading is 120 Ω.
A. Expected reading is not found. Replace denox terminator. Erase fault code and return unit to field oper-
ation.
B. Reading is as expected. Continue with step 4.

4. Check the harness end resistance on the connector from pin 1 to pin 2. This will be checking the engine control
modules internal terminator. The expected reading is 120 Ω.
A. Expected reading not found. There may be a short to ground, or open wire between the denox terminator
and engine control module connector , or the engine control module terminator is faulty. Troubleshoot the
wiring harness make repairs, or replace engine control module.
B. Reading is as expected. Erase fault code. If the fault code reoccurs contact ASIST.
84605841 14/05/2012
55.DTC / 159
19578-CAN Receive Frame E2SCR (Dosing Status Not In Range)

Solution:
1. Check for other error codes being displayed. Are there other codes displayed referring to dosing valve solenoid.
Are there other can bus communication error issues.
A. If any other error code is being displayed, continue to these tests.
B. If no other error code is displayed, continue to step 2

2. Ensure all connectors are secured properly on the denox module/supply module connector , the denox termi-
nator connector (located on top of right front fender) and engine control module connector . Check for damage,
loose connections or broken can bus wires.
B. No connector/wiring issues were located. Continue with step3

3. Check the can bus terminators. Disconnect denox terminator connector . Check the terminators resistance from
pin 1 to pin 2. The expected reading is 120 Ω.
ation.
B. Reading is as expected. Continue with step4

4. Next, check the harness end resistance on connector from pin 1 to pin 2. This will be checking the engine control
A. Expected reading not found. There may be a short to ground, or open wire between the denox terminator
84605841 14/05/2012
55.DTC / 160
19579-CAN Receive Frame E2SCR Timeout

Solution:
1. Check for other error codes being displayed. Are there other codes displayed referring to time out of communi-
cation link. Are there other can bus communication error issues.

nator connector (located on top right front fender) and engine control module connector . Check for damage,

ation.

4. Next, check the harness end resistance on the denox terminator connector from pin 1 to pin 2. This will be
checking the engine control modules internal terminator. The expected reading is 120 Ω.
A. Expected reading not found. There may be a short to ground, or open wire between denox terminator
and engine control module connector , or the engine control module terminator is faulty. Trouble shoot the
84605841 14/05/2012
55.DTC / 161
19580-CAN Receive Frame E2SCR Too Many Messages

Solution:
1. Check for other error codes being displayed. Are there other error codes displayed . Are there other can bus
communication error issues.


ation.
B. Reading is as expected. Continue with step4.

4. Next, check the harness end resistance on denox module connector from pin 1 to pin 2. This will be checking
the engine control modules internal terminator. The expected reading is 120 Ω.
84605841 14/05/2012
55.DTC / 162
19581-CAN Receive Frame E2SCR Serial Communication Link

Solution:
1. Check for other error codes being displayed. Are there other can bus communication error issues.

nator connector (located top right front fender) and engine control module connector . Check for damage, loose
connections or broken can bus wires.

ation.

4. Next, check the harness end resistance on denox terminator from pin 1 to pin 2. This will be checking the engine
control modules internal terminator. The expected reading is 120 Ω.
84605841 14/05/2012
55.DTC / 163
19595-CAN Receive Frame EEC1 (Engine Torque Not In Range)

Solution:
1. Check for other error codes being displayed. Are there other engine error codes displayed . Are there other can
bus communication error issues.

nator connector (located top right front fender) and engine control module connector . Check for damage, loose

ation.

84605841 14/05/2012
55.DTC / 164
19596-CAN Receive Frame EEC1 (Engine Speed Not In Range)

Solution:
1. Check for other error codes being displayed. Are there other codes displayed referring to time out of communi-
cation link. Are there other can bus communication error issues.

nator connector and the engine controller connector . The denox terminator connector is located behind cover
at SCR muffler in NOX sensor harness. Check for damage, loose connections or broken can bus wires.

3. Check the denox system can bus terminators. Disconnect denox terminator connector . Check the terminator
resistance from pin 1 to pin 2. The expected reading is 120 Ω.
ation.

84605841 14/05/2012
55.DTC / 165
19597-CAN Receive Frame EEC1 - Timeout

Solution:
1. Check for other error codes being displayed. Are there other time out error codes displayed . Are there other
can bus communication error issues.


ation.

4. Next, check the harness end resistance on the denox terminator from pin 1 to pin 2. This will be checking the
engine control modules internal terminator. The expected reading is 120 Ω.
84605841 14/05/2012
55.DTC / 166
19598-CAN Receive Frame EEC1 - Too Many Messages

Solution:
1. Check for other error codes being displayed. Are there other can bus communication error issues.


ation.

84605841 14/05/2012
55.DTC / 167
19599-CAN Receive Frame EEC1 (Torque Driver Demand Not In

Range)
Solution:
1. Check for other error codes being displayed. Are there other engine related error codes displayed. Are there
other can bus communication error issues.

2. Ensure all connectors are secured properly on the denox module/supply module connector , the denox termina-
tor connector (located top of right front fender) and engine control module connector . Check for damage, loose

ation.

84605841 14/05/2012
55.DTC / 168
19604-CAN Receive Frame ET1 (Oil Temperature Not In Range)

Solution:
1. Check for other error codes being displayed. Are there other engine temperature related error codes displayed
. Are there other can bus communication error issues.


ation.

84605841 14/05/2012
55.DTC / 169
19605-CAN Receive Frame ET1 - Timeout

Solution:
1. Check for other error codes being displayed. Are there other time out error codes displayed . Are there other
can bus communication error issues.


ation.

84605841 14/05/2012
55.DTC / 170
19606-CAN Receive Frame ET1 - Too Many Messages

Solution:


ation.

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55.DTC / 171
19607-CAN Receive Frame ET1 (Water Temperature Not In Range)

Solution:


ation.

84605841 14/05/2012
55.DTC / 172
19649-Tank Level Sensor - Open Circuit

Cause:
There was an open circuit detected in the DEF/AdBlue® level sensor circuit.
1. Faulty Sensor
3. Faulty DCU
Solution:

3. Check for an open circuit between denox module/supply module and tank sensor. Disconnect connector DNOX2
from denox module/supply module and connector DTLTS from tank sensor. Check for continuity between con-
nector DTLTS pin 1 and connector DNOX2 pin 18, and between connector DTLTS pin 2 and connector DNOX2
pin 19.
A. If either reading shows no continuity, repair or replace harness as required. Return unit to field operation.
B. If both readings show continuity/resistance of less than 1.0 Ω, contact ASIST before replacing denox mod-
ule/supply module.
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19650-Tank Level Sensor - Short Circuit High

Cause:
There was a short to power detected in the DEF/AdBlue® level sensor circuit.
1. Faulty Sensor
3. Faulty DCU
Solution:
2. Check level sensor resistance . Disconnect connector DTLTS at top of DEF/AdBlue® tank. Use a multimeter to
measure the resistance of the level sensor from pin 1 to pin 2. The resistance should be approximately 16000

DTLTS from tank sensor. Turn the ignition switch to the on position. Check for 12 volt power between connector
DTLTS pin 1 and ground.
B. If reading the reading does not indicate a short , contact ASIST before replacing denox module/supply
module.
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55.DTC / 174
19651-Tank Level Sensor - Short Circuit Low

Cause:
There was a short to ground detected in the DEF/AdBlue® level sensor circuit.
1. Faulty Sensor
3. Faulty DCU
Solution:

DTLTS from tank sensor. Check for short to ground (continuity) between connector DTLTS pin 1 and ground.
B. If reading the reading does not indicate a short to ground, contact ASIST before replacing denox module/
supply module.
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19652-UREA Tank level error (CAN message or electrical with real

sensor) - (TIMEOUT)
621F WE, 621F NA, 721F WE, 721F NA
Cause:
Faulty signal to the DNOX controller.
1. Faulty wiring or connections.

2. Faulty DEF level sensor.
3. Faulty DNOX controller.
Solution:
1. Verify that the fault code is still active..

Prior to clearing fault codes, write down all fault codes, the number of occurrences and engine hours of last
occurrence.
(1) Use the Electronic Service Tool to clear all fault codes.
(2) To check for fault code: Start and operate machine. Wiggle the harness to reveal an intermittent condition.
A. If the fault is not recorded again. OK to return the machine to service.
B. If the fault code 19652 is recorded again. Go to Step 2.

2. Check voltage at DEF level and tank temperature sensor.
RCIL11WHL052FAK 1
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(1) DNOX controller (6) Doser metering valve

(2) 24 Volt switched power from fuse ECA-F10, (7) DEF level and tank temperature
5 amp. sensor
(3) CAN high (8) Downstream temperature sensor
(4) CAN low (9) Upstream temperature sensor
(5) Tank heater control valve
(1) Turn the key switch OFF. Remove connector DTLTS and inspect pins.
(2) Turn the ignition switch to the ON position.
(3) Measure the voltage from pin 1 to pin 2. The voltage should be between 4.8 volts and 5.2 volts. Wiggle the
harness during measurement to reveal an intermittent condition.
A. If the voltage is correct, replace DEF level sensor..
B. If the voltage is greater than 5.2 volts check the supply voltage on the DNOX controller between pins 3, 4,
, 24 and chassis ground. This should be 24 V. If supply voltage is OK, replace DNOX controller.
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19653-UREA Tank level error (too many CAN messages)

621F WE, 621F NA, 721F WE, 721F NA
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19654-UREA Tank level error - Open circuit

621F WE, 621F NA, 721F WE, 721F NA
Cause:
Faulty signal or wiring to the DNOX controller.

2. Faulty DEF level sensor.
3. Faulty DNOX controller.
Solution:
1. Verify that the fault code is still active.

Prior to clearing fault codes, write down all fault codes, the number of occurrences, and engine hour of last
occurrence.
(2) To check for fault code: Start and operate machine. Wiggle the harness to reveal an intermittent condition.
A. If the fault is not recorded again, OK to return the machine to service.
B. If the fault code 19654 is recorded again Go to Step 2

2. Turn the ignition key switch OFF and remove connectors DTLTS and DNOX2. Measure the resistance between
DTLTS pin 2 and DNOX2 pin 19.
A. If the resistance is greater than 10 Ω or an open circuit is indicated, repair or replace connectors or wiring
as necessary. Otherwise proceed with step 3
3. If the DEF level ground is OK, check the resistance on the supply wire from connector DTLTS pin 1 and DNOX2
pin 18. If wiring is good replace DEF level sensor. If the error code persists, replace the DNOX module. Other
possibilities: CAN communication on DNOX controller pin 7 and 8.
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RCIL11WHL052FAK 1
(1) DNOX controller (6) Dosing metering valve

(2) 24 Volt switched power from fuse ECA- (7) DEF level and tank temperature sensor
F10, 5 amp
(3) CAN high (8) Downstream temperature sensor
(4) CAN low (9) Upstream temperature sensor
(5) Tank heater control valve
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19676-Ambient Temperature CAN Receive Signal (Ambient Air

Temperature Not In Range)
Cause:
There was a short to ground detected in the DEF/AdBlue® level sensor circuit.
1. Faulty Sensor.
3. Faulty DCU.
Solution:

DTLTS from tank sensor. Check for short to ground (continuity) between connector DTLTS pin 1 and ground.
B. If reading the reading does not indicate a short to ground, contact ASIST before replacing denox module/
supply module.
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19677-Ambient Air Temperature Sensor Range/ Performance - CAN

Timeout
Context:
The denox module/supply module has detected this failure because the ambient air temperature has timed out. En-
sure all connectors are secured properly to the denox module/supply module and all lines are in operable condition.
If fault does not reset, replace the denox module/supply module.
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19678-Ambient Air Temperature Sensor Range/ Performance - Too

Many CAN Messages
Context:
The denox module/supply module has detected this failure because the ambient air temperature has faulty can bus
signal. Ensure all connectors are secured properly to the denox module/supply module and all lines are in operable
condition. If fault does not reset, replace the denox module/supply module.
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19679-Ambient Temperature CAN Receive Signal (Barometric

Pressure Not In Range)
Context:
The denox module/supply module has detected this failure because the ambient air temperature has faulty sensor
range. Ensure all connectors are secured properly to the denox module/supply module and all lines are in operable
condition. If fault does not reset, replace the denox module/supply module.
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19721-EEPROM/ Checksum Failures - EEPROM Write Error

Context:
The denox module/supply module has suffered a detection error. This error indicates a defect in the dataset that is
presently loaded in the denox module/supply module. If this error is present and active, reload the software dataset.
If this error then reoccurs, replace the denox module/supply module.
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19722-EEPROM/ Checksum Failures - No Corresponding Variant

Number Error
Context:
The denox module/supply module has an internal cycle counter to check if the afterrun is correctly finished. This
cycle counter data is then stored in the EEPROM memory. This error indicates the denox module/supply module has
attempted to store this data in a protected area of memory. If this error is present and active, first verify the denox
module/supply module and other components have not been tampered with and reload the software. If this error
reoccurs replace the denox module/supply module.
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19723-EEPROM/ Checksum Failures - EEPROM Communication

Error
Context:
The denox module/supply module memory in EEPROM is not correct or a SPI communication error has occurred. This
error indicates an internal denox module/supply module error. If this error is present and active, ensure all electrical
connectors are secure and reload the denox module/supply module software. If this error reoccurs, replace the denox
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19724-EEPROM/ Checksum Failures - EEPROM Detection Error

or Codierwort Error
Context:
The denox module/supply module has an internal error in software. If the code is present and active, reload the
software. If this error reoccurs, replace the denox module/supply module.
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19725-EEPROM/ Checksum Failures - Wrong EEPROM Size

Context:
The denox module/supply module has the incorrect EEPROM installed. This error would only occur during initial
startup when the denox module/supply module has previously been replaced. Replace the denox module/supply
module.
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19730-Ignition on signal K15 - digital input ignition on not sensed

during initialization - P2530 ignition switch - plausibility error
1. Faulty connector
2. Faulty ignition switch
Solution:
1. Before proceeding clear the error code with the approved diagnostic equipment. Run the machine under normal
conditions and retest.
A. If the error code is not indicated, check that the system is operating correctly.
B. If the error code is indicated, continue to step 2.

2. Check for 24 V. input on denox module/supply module. Backprobe denox module/supply module connector
DNOX2 pin 24. Turn the ignition switch on.
A. If 24 V is indicated, erase the fault code and return unit to field operation.
B. If 24 V is not indicated, continue with step 3.

3. Check fuse ECA—F10 for 24 V and replace if necessary.
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19739-ECM/PCM Power Relay Control Circuit Open - Main Relay

Shut Off Too Late
Context:
The denox module/supply module has detected the main relay is not switched off within 2 s.
Cause:
The main relay is shutting off too late.
1. Faulty relay
3. Denox module/supply module error
Solution:
B. If the error is no longer present or is in an inactive state, continue with normal operation of machine.
2. Check the cab switched power relays. Use a multimeter to measure the resistance between pin 86 to pin 85.
There should be approximately 50 - 200 Ω. Also, check for continuity from pin 30 to pin 87. There should be no
continuity
A. If the resistance and continuity readings are correct, continue with step 3.
B. If there is infinite resistance or no continuity; the relay coil is open or grounded internally. Replace the
relay.
3. Check the denox module/supply module. Use the electronic service tool (EST) to flash the denox module/supply
module.
A. If flashing the denox module/supply module does not correct the error, replace the denox module/supply
module.
B. If flashing corrects error, verify error is not still active or present. Continue with normal operation of ma-
chine.
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Short Circuit
Cause:
Switched power relay control circuit open.
1. Faulty relay
Solution:
continuity
relay.
module.
module.
chine.
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Open Circuit
Cause:
Switched power relay control circuit high.
1. Faulty relay
Solution:
continuity
relay.
module.
module.
chine.
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Shut Off Too Early
Cause:
Switched power relay control circuit open.
1. Faulty relay
Solution:
There should be approximately 50 - 200 Ω. Also, check for continuity from pin 30 to pin 87. There should be
no continuity.
relay.
module.
module.
chine.
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19748-Temperature Sensor of Pump Module - Out of Range

Cause:
High urea temperature in pump module.
1. Tank heating valve stuck open.

2. Check for other tank heating valve/coolant flow solenoid related error codes.
Solution:
1. Verify error is present, and in an active state.

2. Disconnect the wiring harness from the tank heating valve/coolant flow solenoid. Check to see if the heater
valve is stuck open.
B. If heating valve is in normal operation, erase the fault code and continue operation. The tank heating
valve/coolant flow solenoid may stick intermittently. If the fault returns repeatedly replace tank heating
valve/coolant flow solenoid.
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19749-Dynamic Urea Leakage Test - Leak Detected

Cause:
High urea temperature in pump module.
1. Tank heating valve stuck open.

2. Check for other tank heating valve/coolant flow solenoid related error codes.
Solution:
1. Verify error is present, and in an active state.

2. Disconnect the wiring harness from the tank heating valve/coolant flow solenoid connector THV. Check to see
if the heater valve is stuck open.
B. If heating valve is in normal operation, erase the fault code and continue operation. The tank heating
valve/coolant flow solenoid may stick intermittently. If the fault returns repeatedly replace tank heating
valve/coolant flow solenoid.
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19757-Reagent Pump Not Delivering

Context:
The dosing control unit (DCU) has activated this fault due to other fault codes associated with the DEF / AdBlue®
injection control being active. Diagnose those fault codes to clear this fault. If this fault is active without any other
codes active, reload the software in the DCU or replace the DCU.
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19766-Compressed Air Regulation Valve - Error

Context:
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19775-Plausibility of Catalyst Temperature Sensors - Plausibility

Error
Context:
injection temperature being active. Diagnose those fault codes to clear this fault. If this fault is active without any
other codes active, reload the software in the DCU or replace the DCU.
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19784-NOx Trap Efficiency Below Threshold

Context:
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19793-Fluid Level In Tank Too Low

Context:
system urea low tank level. Confirm the urea tank is full. Diagnose those fault codes to clear this fault. If this fault is
active without any other codes active, reload the software in the DCU or replace the DCU.
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19802-Urea Tank Temperature -Temp Over CAN Timeout

Context:
The denox module/supply module has detected the urea tank temperature and denox module/supply module temper-
ature are not in agreement.
1. Can communication error.

Solution:
2. Check to see if other DEF/AdBlue® temperature sensor or can communication error fault codes are present.
-30 °C (-22.0 °F) 12850 Ω

-20 °C (-4.0 °F) 7500 Ω
0 °C (32.0 °F) 2800 Ω
20 °C (68.0 °F) 1215 Ω
30 °C (86.0 °F) 825 Ω
50 °C (122.0 °F) 410 Ω

4. If the machine is operating in an extreme cold or extreme hot environment, shutdown and restart.
A. If no other errors are present after restart return unit to field operation.
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19803-Urea Tank Temperature -Temp Over CAN - SAE J1939 Too

Many Messages
Context:
1. Extreme cold ambient conditions.

Solution:
B. If the error is no longer present or is in an inactive state, return unit to the field.
-30 °C (-22.0 °F) 12850 Ω

-20 °C (-4.0 °F) 7500 Ω
0 °C (32.0 °F) 2800 Ω
20 °C (68.0 °F) 1215 Ω
30 °C (86.0 °F) 825 Ω
50 °C (122.0 °F) 410 Ω

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19804-Urea Tank Temperature -Temp Over CAN - SAE J1939

Erroneous Signal, Open Circuit
Context:

Solution:
B. If the error is no longer present or is in an inactive state, return machine to the field.
-30 °C (-22.0 °F) 12850 Ω

-20 °C (-4.0 °F) 7500 Ω
0 °C (32.0 °F) 2800 Ω
20 °C (68.0 °F) 1215 Ω
30 °C (86.0 °F) 825 Ω
50 °C (122.0 °F) 410 Ω

A. If no other errors are present after warm up return unit to the field.
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19805-Urea Tank Temperature -SCR High - Short Circuit High

Context:
1. Extreme hot ambient conditions.

Solution:
B. If the error is no longer present or is in an inactive state, return machine to the field.
-30 °C (-22.0 °F) 12850 Ω

-20 °C (-4.0 °F) 7500 Ω
0 °C (32.0 °F) 2800 Ω
20 °C (68.0 °F) 1215 Ω
30 °C (86.0 °F) 825 Ω
50 °C (122.0 °F) 410 Ω

4. If the tractor is operating in an extreme hot environment, shutdown for a period for cool down.
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19806-Urea Tank Temperature -SCR Low - Short Circuit Low

Context:

Solution:
B. If the error is no longer present or is in an inactive state, return unit to the field.
-30 °C (-22.0 °F) 12850 Ω

-20 °C (-4.0 °F) 7500 Ω
0 °C (32.0 °F) 2800 Ω
20 °C (68.0 °F) 1215 Ω
30 °C (86.0 °F) 825 Ω
50 °C (122.0 °F) 410 Ω

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19807-Urea Tank Temperature -SCR High - Urea Temperature Too

High - Out Of Range
Context:
1. Extreme hot ambient conditions.

Solution:
B. If the error is no longer present or is in an inactive state, return machine to operation.

-30 °C (-22.0 °F) 12850 Ω

-20 °C (-4.0 °F) 7500 Ω
0 °C (32.0 °F) 2800 Ω
20 °C (68.0 °F) 1215 Ω
30 °C (86.0 °F) 825 Ω
50 °C (122.0 °F) 410 Ω

4. If the machine is operating in an extreme hot environment, shutdown for a period for cool down.
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19808-Urea Tank Temperature -SCR Low - Urea Temperature Too

Low - Out Of Range
Context:

Solution:
-30 °C (-22.0 °F) 12850 Ω

-20 °C (-4.0 °F) 7500 Ω
0 °C (32.0 °F) 2800 Ω
20 °C (68.0 °F) 1215 Ω
30 °C (86.0 °F) 825 Ω
50 °C (122.0 °F) 410 Ω

4. If the tractor is operating in an extreme cold environment, shutdown and restart for another warm up cycle.
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19813-Reagent Pump - Not Delivering

Context:
During operation, the ventilation valve is fully opened, the pump is then set to 100 % operation until DEF/AdBlue®
pressure has reached 500 kPa. The ventilation valve is then closed. If DEF/AdBlue® pressure does not reach 500
kPa within 2.5 min, this error occurs.
Cause:
The denox module/supply module has detected the pump motor is not delivering.
1. No DEF/AdBlue® in tank
3. Faulty pump
4. Faulty feeding line
Solution:

3. Prime the system. Start the pump with the electronic service tool (EST). Open the ventilation valve by 50 % with
the EST until DEF/AdBlue® pressure reaches 60 kPa. Close ventilation valve. DEF/AdBlue® pressure should
reach 300 kPa within 2 min.

4. Check operation of pump. Start pump with the EST. Listen for pump operation.

5. Check for an air leak. Disconnect any hoses on the denox module/supply module. Check hoses for any cracks
or holes in the lines. Check all connections for missing or broken O-rings.
A. No air leaks are found, continue with step 6.
B. If any holes or cracks are found, repair/replace hose. If any O-rings are missing or broken, replace the
O-rings.
has been resolved.
ation.
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19817-Dosing Valve - Blocked (stuck open)

621F WE, 621F NA, 721F WE, 721F NA
Context:
The denox module/supply module has detected the DEF/AdBlue® pressure exceeds 6.5 bar for 30 s. Reasons for
failure could be internal control valve blocked, blocked dosing valve nozzle or too high a pump speed. These are
indications of internal failure of supply module. Use the electronic service tool (EST) to run the Urea dosing system
test (UDST) to monitor the DEF/AdBlue® pressure and pump speed. DEF/AdBlue® pressure should not exceed 500
kPa, and the pump speed should not exceed 6000 RPM. Replace denox module/supply module if values are out of
range.
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19818-Plausibility of UDV (urea dosing valve) stuck - P202D

dynamic urea leakage test - leakage detected
621F WE, 621F NA, 721F WE, 721F NA
Context:
The denox module/supply module has detected leakage. Visual inspect all urea lines and connections for leakage.
These are indications of internal leakage of supply module. Use the electronic service tool (EST) to run the urea
dosing system test (UDST) to monitor the DEF/AdBlue® pressure and pump speed. DEF/AdBlue® pressure should
not exceed 500 kPa , and lower values can indicate leakage, and the pump speed should not exceed 6000 RPM.
Replace denox module/supply module if values are out of range.
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19822-Dynamic Urea Leakage Test - Leak Detected

621F WE, 621F NA, 721F WE, 721F NA
Context:
The denox module/supply module has detected leakage. Visual inspect all urea lines and connections for leakage.
These are indications of internal leakage of supply module. Use the electronic service tool (EST) to run the urea
dosing system test (UDST) to monitor the DEF/AdBlue® pressure and pump speed. DEF/AdBlue® pressure should
not exceed 500 kPa , and lower values can indicate leakage, and the pump speed should not exceed 6000 RPM.
Replace denox module/supply module if values are out of range.
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19999-Unknown SCR Controller Error

621F WE, 621F NA, 721F WE, 721F NA
NOTE: When the cause of the error code has been rectified, clear the error code and test the system for normal
operation.
Solution:
1. Before proceeding clear the error code with the approved diagnostic equipment. Run the machine under normal
conditions and retest.
A. If the error code is not indicated, check that the system is operating correctly.
B. If the error code is indicated, continue to step 2.

2. Check for other engine related error codes.
A. If other engine related error codes are displayed, continue to these tests.
B. If no other engine related error codes are displayed, continue to step 3.

3. EasyEngine software and the electronic service tool (EST) will be needed to troubleshoot code.
A. Contact ASIST for instruction.
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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
(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
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:

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.
has been resolved.
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.
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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.
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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
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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.
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Context:
Cause:

Solution:
0.4 - 0.5 Ω.
2.
conductor.
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the injector.
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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.
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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.
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connector VC1 and connector VC1. Locate and repair the grounded conductor.
the injector.
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Context:
Cause:
stage.

Solution:

has been resolved.
ation.
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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
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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) .
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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.

(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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55.DTC / 402
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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55.DTC / 456
obtained.
obtained.
should be obtained.
BD08J013-01 5

obtained.
obtained.
should be obtained.
5. Check injectors.
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55.DTC / 457
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55.DTC / 458
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.
84605841 14/05/2012
55.DTC / 459
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
84605841 14/05/2012
55.DTC / 460
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
84605841 14/05/2012
55.DTC / 461
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.
84605841 14/05/2012
55.DTC / 462
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
84605841 14/05/2012
55.DTC / 463
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
84605841 14/05/2012
55.DTC / 464
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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55.DTC / 465
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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55.DTC / 466
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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55.DTC / 467
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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55.DTC / 468
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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55.DTC / 469
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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55.DTC / 470
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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55.DTC / 471
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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55.DTC / 472
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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55.DTC / 473
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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55.DTC / 474
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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55.DTC / 476
3255-ADC Monitoring Test Impulse Error

Cause:
Solution:
rence.

2. Reset engine control module by turning ignition switch off then back on.
84605841 14/05/2012
55.DTC / 477
3256-ADC Monitoring Queue Error

Cause:
Solution:
rence.

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55.DTC / 478
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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55.DTC / 480
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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55.DTC / 482
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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55.DTC / 484
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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55.DTC / 486
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

84605841 14/05/2012
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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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55.DTC / 488
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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55.DTC / 489
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.
84605841 14/05/2012
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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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84605841 14/05/2012
55.DTC / 502

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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55.DTC / 556
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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55.DTC / 558
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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55.DTC / 577
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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55.DTC / 580
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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55.DTC / 586
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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55.DTC / 589
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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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.
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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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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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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.


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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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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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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.
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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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55.DTC / 636
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

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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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Cause:

Solution:
rence.



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Cause:

Solution:
rence.



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Cause:

Solution:
rence.



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4277-Slippage at clutch KV
Cause:

Solution:
rence.


sor. Note: Do not replace the transmission control module at this time.

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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.
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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.
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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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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.
84605841 14/05/2012
55.DTC / 716
9160-Hour Meter Failure - Both Copies Are Wrong

Cause:
1. Instrument Cluster internal failure
Solution:
rence.

(1). Remove and replace instrument cluster.
84605841 14/05/2012
55.DTC / 717
9161-Hour Meter Failure - One Of Two Copies Are Wrong

Cause:
Solution:
rence.

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55.DTC / 718
9162-Hour Meter Failure - Pre-crank And After-crank Checks Are

Wrong
Cause:
Solution:
rence.

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55.DTC / 719
3001-Foot Throttle Sensor - Signal Not Plausible

Control Module : EDC
NOTE: The idle switch is internal to the throttle sensor assembly.
Cause:

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
84605841 14/05/2012
55.DTC / 725
RCPH11WHL011FAL 2
Schematic legend
0.1volt
(3) Connector RTHP

84605841 14/05/2012
55.DTC / 726
RCPH11WHL014AAL 3

84605841 14/05/2012
55.DTC / 727
RCPH11WHL001GAL 4
Schematic legend
0.1volt
the WOT position.
of fault.
84605841 14/05/2012
55.DTC / 728
3003-Foot Throttle Sensor - Signal Below Range Minimum

Cause:

Solution:
rence.

RCPH11WHL013AAL 1
84605841 14/05/2012
55.DTC / 729
RCPH11WHL011FAL 2
Schematic legend
0.1volt
(3) Connector RTHP

84605841 14/05/2012
55.DTC / 730
RCPH11WHL014AAL 3

84605841 14/05/2012
55.DTC / 731
RCPH11WHL001GAL 4
Schematic legend
0.1volt
the WOT position.
of fault.
84605841 14/05/2012
55.DTC / 732
Index
FAULT CODES - DTC

0000-Retrieving fault codes, Wheel Loaders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1310-Hydraulic Filter Blocked . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1311-Engine Air Filter Blocked . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
1312-Hydraulic Oil Temperature Above Normal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
1313-Hydraulic Oil Temperature Too High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
1314-Transmission Oil Temperature Above Normal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
1315-Transmission Oil Temperature Too High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
1316-Brake Pressure Too Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
1317-Steering Pressure Too Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
1318-Engine Coolant Temperature Above Normal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
1319-Engine Coolant Temperature High - Critical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
1320-Engine Oil Pressure Too Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
1321-Engine Oil Pressure Below Normal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
1322-Engine Oil Pressure Above Normal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
1323-Battery Voltage Too Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
1324-Battery Voltage High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
1325-Engine Oil Temperature Too High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
1331-Electrical charging system voltage too low, critical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
1332-Water Detected In Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
1333-Engine Overspeed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
1334-Intake Manifold Temperature High - Critical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
1335-Brake pressure too low, critical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
1336-Transmission Oil Filter Blocked . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
19001-Battery voltage evaluation - Above upper limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
19002-Battery voltage evaluation - Below lower limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
19003-Battery voltage sensing (electrical) - Above upper limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
19004-Battery voltage sensing (electrical) - Below lower limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
19010-Catalyst Temperature Sensor Circuit High - After Catalyst . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
19011-Catalyst Temperature Sensor Circuit Low - After Catalyst . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
19019-Catalyst Temperature Sensor Circuit High - Before Catalyst . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
19020-Catalyst Temperature Sensor Circuit Low - Before Catalyst . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
19021-Temperature sensor before catalyst (electrical) - signal above high error threshold . . . . . . . . . . . . . . . . . . . 79
621F WE, 621F NA, 721F WE, 721F NA
19022-Temperature sensor before catalyst (electrical) - signal below low error threshold . . . . . . . . . . . . . . . . . . . . 80
621F WE, 621F NA, 721F WE, 721F NA
19037-Reagent - pressure sensor - Short circuit high (high supply voltage) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
84605841 14/05/2012
55.DTC / 733
19038-Reagent - pressure sensor - Short circuit low (low supply voltage) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
19046-Reagent - pressure sensor - Open circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
19047-Reagent - pressure sensor - Short circuit high (signal high) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
19048-Reagent - pressure sensor - Short circuit low (signal low) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
19055-Reagent - temperature sensor of pump module - Short circuit high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
19056-Reagent - temperature sensor of pump module - Short circuit low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
19057-UREA Temperature sensor in box (electrical) - signal above high error threshold Out of range . . . . . . . . . 88
621F WE, 621F NA, 721F WE, 721F NA
19058-UREA Temperature sensor in box (electrical) - signal below low error threshold Out of range . . . . . . . . . . 89
621F WE, 621F NA, 721F WE, 721F NA
19064-Voltage supply internal heaters 1 (UB1) electrical - Internal heating Open circuit . . . . . . . . . . . . . . . . . . . . . 90
19065-Pump module - Internal heating - Short circuit high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
19073-Voltage supply 2 - tube heaters (UB2) electrical - Short circuit high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
621F WE, 621F NA, 721F WE, 721F NA
19074-Voltage supply 2 - tube heaters (UB2) electrical - Short circuit low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
621F WE, 621F NA, 721F WE, 721F NA
19075-Reagent - suction tube heating -Open Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
19082-Vent valve (Reductant Purge Control Valve) - Short circuit high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
621F WE, 621F NA, 721F WE, 721F NA
19083-Voltage supply 3 - Coolant control valve and reverting valve (UB3) electrical - Short circuit low . . . . . . . . 96
621F WE, 621F NA, 721F WE, 721F NA
19084-Vent valve (Reductant Purge Control Valve) - Short circuit low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
621F WE, 621F NA, 721F WE, 721F NA
19091-12 Volt supply for dosing module - Above upper limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
19092-12 Volt supply for dosing module - Below lower limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
19093-Dosing valve/Pump motor - Above upper limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
621F WE, 621F NA, 721F WE, 721F NA
19094-Dosing valve/Pump motor - Below lower limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
621F WE, 621F NA, 721F WE, 721F NA
19100-UREA level sensor (electrical) - supply voltage error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
19101-Reagent - tank level sensor - Short circuit high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
19102-Reagent - tank level sensor - Short circuit low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
19109-Reagent - tank temperature sensor (temperature of the Reagent - solution in the tank) - Short circuit high
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
19110-Reagent - tank temperature sensor (temperature of the Reagent - solution in the tank) - Short circuit low 110
19145-Reductant Injector Circuit High - Dosing Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
19146-Reductant Injector Circuit Low - Dosing Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
19147-Reductant Injector Circuit/Open - Dosing Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
19148-Reagent - dosing nozzle - Pressure too high - Dosing Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
19149-Dosing Valve (electrical) - short circuit to ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
19150-Dosing Valve (electrical) - Dosing valve permanent "ON" - Pressure too high . . . . . . . . . . . . . . . . . . . . . . . 116
19154-Reagent-pump - Not delivering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
19155-Reagent-pump motor blocked . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
19156-Reagent-pump - Over speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
19157-Reagent-pump - Not delivering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
19163-Vent valve (Cooling Control Valve) - Short circuit high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
621F WE, 621F NA, 721F WE, 721F NA
19164-Vent valve (Cooling Purge Control Valve) - Open circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
621F WE, 621F NA, 721F WE, 721F NA
19172-Vent valve (Cooling Purge Control Valve) - Short circuit low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
621F WE, 621F NA, 721F WE, 721F NA
19181-Vent valve (Reverting Purge Control Valve) - Short circuit high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
19182-Vent valve (Reverting Purge Control Valve) - Short circuit low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
84605841 14/05/2012
55.DTC / 734
19183-Vent valve (Reverting Purge Control Valve) - Open circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
19184-Reverting valve electrically - 'Short circuit to ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
621F WE, 621F NA, 721F WE, 721F NA
19262-Tank Heating Valve - Short Circuit High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
621F WE, 621F NA, 721F WE, 721F NA
19263-Tank Heating Valve - Short Circuit Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
621F WE, 621F NA, 721F WE, 721F NA
19264-Tank Heating Valve - Open Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
621F WE, 621F NA, 721F WE, 721F NA
19265-Tank Heating Valve - Short Circuit To Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
621F WE, 621F NA, 721F WE, 721F NA
19289-Temperature After Catalyst Too Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
621F WE, 621F NA, 721F WE, 721F NA
19290-Catalyst Temperature Sensor Circuit Range / Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
19298-Reagent Pump Not Delivering - Urea Pressure Too Low At System Start . . . . . . . . . . . . . . . . . . . . . . . . . . 134
19307-Reagent Pressure Above Threshold - Urea Pressure Not Plausible (Urea Pressure Too High) . . . . . . . . 135
19316-Reagent Temperature Sensor Of Pump Module - Out Of Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
19325-Reagent Tank Temperature Sensor - (Temperature of the Reagent Solution in the Tank) Temperature Out Of
Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
621F WE, 621F NA, 721F WE, 721F NA
19334-Defreezing Mode and Detection Errors (Inlet Line Defreezing Failed) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
621F WE, 621F NA, 721F WE, 721F NA
19335-Defreezing Mode and Detection Errors (Pressure Line Defreezing Failed) . . . . . . . . . . . . . . . . . . . . . . . . . 139
621F WE, 621F NA, 721F WE, 721F NA
19336-Defreezing Mode and Detection Errors (Pressure Build-up in Detection Mode Failed) Pump Module Internal
Heating - Open Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
621F WE, 621F NA, 721F WE, 721F NA
19337-Defreezing Mode and Detection Errors (Back-flow Line Defreezing Failed) . . . . . . . . . . . . . . . . . . . . . . . . 141
621F WE, 621F NA, 721F WE, 721F NA
19343-Coolant Control Valve Mechanically - Mechanical Defective Blocked Open . . . . . . . . . . . . . . . . . . . . . . . . 142
621F WE, 621F NA, 721F WE, 721F NA
19344-Coolant Control Valve Mechanically - Mechanical Defective Blocked Closed . . . . . . . . . . . . . . . . . . . . . . . 143
621F WE, 621F NA, 721F WE, 721F NA
19352-Vent Valve (Reductant Purge Control Valve) - Open Circuit, Reverting Control Valve . . . . . . . . . . . . . . . . 144
19361-Battery Voltage Evaluation - Above Upper Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
19362-Battery Voltage Evaluation - Below Lower Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
19370-Pump Motor Error During Commissioning - Urea Pressure Too Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
19379-Urea temperature too low during commissioning - temperatures not plausible during commissioning . . 149
19415-Empty Urea Tank - Fluid Level In Tank Too Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
19496-Pressure - Above threshold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
621F WE, 621F NA, 721F WE, 721F NA
19505-Plausibility of pump module temp. sensor ; dynamic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
19514-Plausibility of urea tank temp. sensor ; dynamic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
621F WE, 621F NA, 721F WE, 721F NA
19532-Back Flow Line Blocked, Dosing Valve - Short Circuit Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
19541-Vent Valve Test - Plausibility Test (Start Up) Cooling Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
621F WE, 621F NA, 721F WE, 721F NA
19550-Dosing Nozzle - Pressure Too High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
19559-Low Urea Level 1 - Too Low (Warning) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
19568-Fluid Level In Tank - Too Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
19577-CAN Receive Frame E2SCR (Urea Quantity Not In Range) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
19578-CAN Receive Frame E2SCR (Dosing Status Not In Range) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
19579-CAN Receive Frame E2SCR Timeout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
19580-CAN Receive Frame E2SCR Too Many Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
19581-CAN Receive Frame E2SCR Serial Communication Link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
19595-CAN Receive Frame EEC1 (Engine Torque Not In Range) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
19596-CAN Receive Frame EEC1 (Engine Speed Not In Range) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
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19597-CAN Receive Frame EEC1 - Timeout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
19598-CAN Receive Frame EEC1 - Too Many Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
19599-CAN Receive Frame EEC1 (Torque Driver Demand Not In Range) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
19604-CAN Receive Frame ET1 (Oil Temperature Not In Range) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
19605-CAN Receive Frame ET1 - Timeout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
19606-CAN Receive Frame ET1 - Too Many Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
19607-CAN Receive Frame ET1 (Water Temperature Not In Range) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
19649-Tank Level Sensor - Open Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
19650-Tank Level Sensor - Short Circuit High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
19651-Tank Level Sensor - Short Circuit Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
19652-UREA Tank level error (CAN message or electrical with real sensor) - (TIMEOUT) . . . . . . . . . . . . . . . . . . 176
621F WE, 621F NA, 721F WE, 721F NA
19653-UREA Tank level error (too many CAN messages) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
621F WE, 621F NA, 721F WE, 721F NA
19654-UREA Tank level error - Open circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
621F WE, 621F NA, 721F WE, 721F NA
19676-Ambient Temperature CAN Receive Signal (Ambient Air Temperature Not In Range) . . . . . . . . . . . . . . . . 181
19677-Ambient Air Temperature Sensor Range/ Performance - CAN Timeout . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
19678-Ambient Air Temperature Sensor Range/ Performance - Too Many CAN Messages . . . . . . . . . . . . . . . . . 183
19679-Ambient Temperature CAN Receive Signal (Barometric Pressure Not In Range) . . . . . . . . . . . . . . . . . . . 184
19721-EEPROM/ Checksum Failures - EEPROM Write Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
19722-EEPROM/ Checksum Failures - No Corresponding Variant Number Error . . . . . . . . . . . . . . . . . . . . . . . . . 186
19723-EEPROM/ Checksum Failures - EEPROM Communication Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
19724-EEPROM/ Checksum Failures - EEPROM Detection Error or Codierwort Error . . . . . . . . . . . . . . . . . . . . . 188
19725-EEPROM/ Checksum Failures - Wrong EEPROM Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
19730-Ignition on signal K15 - digital input ignition on not sensed during initialization - P2530 ignition switch - plau-
sibility error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
19739-ECM/PCM Power Relay Control Circuit Open - Main Relay Shut Off Too Late . . . . . . . . . . . . . . . . . . . . . . 191
19740-ECM/PCM Power Relay Control Circuit Open - Main Relay Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . 192
19741-ECM/PCM Power Relay Control Circuit Open - Main Relay Open Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . 193
19742-ECM/PCM Power Relay Control Circuit Open - Main Relay Shut Off Too Early . . . . . . . . . . . . . . . . . . . . . 194
19748-Temperature Sensor of Pump Module - Out of Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
19749-Dynamic Urea Leakage Test - Leak Detected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
19757-Reagent Pump Not Delivering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
19766-Compressed Air Regulation Valve - Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
19775-Plausibility of Catalyst Temperature Sensors - Plausibility Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
19784-NOx Trap Efficiency Below Threshold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
19793-Fluid Level In Tank Too Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
19802-Urea Tank Temperature -Temp Over CAN Timeout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
19803-Urea Tank Temperature -Temp Over CAN - SAE J1939 Too Many Messages . . . . . . . . . . . . . . . . . . . . . . 203
19804-Urea Tank Temperature -Temp Over CAN - SAE J1939 Erroneous Signal, Open Circuit . . . . . . . . . . . . . 204
19805-Urea Tank Temperature -SCR High - Short Circuit High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
19806-Urea Tank Temperature -SCR Low - Short Circuit Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
19807-Urea Tank Temperature -SCR High - Urea Temperature Too High - Out Of Range . . . . . . . . . . . . . . . . . . 207
19808-Urea Tank Temperature -SCR Low - Urea Temperature Too Low - Out Of Range . . . . . . . . . . . . . . . . . . . 208
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19813-Reagent Pump - Not Delivering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
19817-Dosing Valve - Blocked (stuck open) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
621F WE, 621F NA, 721F WE, 721F NA
19818-Plausibility of UDV (urea dosing valve) stuck - P202D dynamic urea leakage test - leakage detected . . 211
621F WE, 621F NA, 721F WE, 721F NA
19822-Dynamic Urea Leakage Test - Leak Detected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
621F WE, 621F NA, 721F WE, 721F NA
19999-Unknown SCR Controller Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
621F WE, 621F NA, 721F WE, 721F NA
3001-Foot Throttle Sensor - Signal Not Plausible . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 720
3002-Foot Throttle Sensor - Signal Above Range Maximum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 725
3003-Foot Throttle Sensor - Signal Below Range Minimum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 729
3004-Foot Throttle Sensor - No Signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
3006-Coolant Temperature Sensor - Signal Not Plausible . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
3007-Coolant temperature signal - signal above range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
3008-Coolant Temperature Signal - Signal Below Range Minimum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
3009-Coolant Temperature Sensor Circuit Open Or Sensor Disconnected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
3015-Fuel Temperature Sensor - Signal Above Maximum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226
3016-Fuel Temperature Sensor - Signal Below Range Minimum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228
3019-Boost Pressure Sensor - Signal Above Range Maximum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230
3021-Boost pressure sensor - (via CAN) no signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233
3022-Boost Pressure Sensor - Signal Not Plausible . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236
3023-Atmospheric Pressure Sensor - Signal Not Plausible . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239
3024-Atmospheric Pressure Sensor - Signal Above Range Maximum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240
3025-Atmospheric Pressure Sensor - Signal Below Range Minimum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241
3028-Oil Pressure Too Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242
3029-Oil Pressure Sensor - Short Circuit To Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245
3030-Oil Pressure Sensor - Short Circuit To Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248
3031-Oil Pressure Sensor - Hardware Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251
3032-Oil Pressure Sensor - Value Too High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 254
3033-Oil Temperature Sensor - Signal Not Plausible (Compared With Coolant Temperature) . . . . . . . . . . . . . . . 257
3034-Oil Temperature Sensor - Signal Above Range Maximum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260
3035-Oil Temperature Sensor - Signal Below Range Minimum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263
3036-Oil temperature sensor circuit open or sensor disconnected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266
3037-Boost Pressure Sensor - Signal Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269
3051-Battery Voltage To Engine Controller - Voltage Too High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272
3052-Battery Voltage To Engine Controller - Voltage Too Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274
3060-Cylinder 1 - Unclassifiable Error In Injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276
3061-Cylinder 1 - Injector Cable Short Circuit (Low Side To Battery) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277
3062-Cylinder 1 - Electronic injector , Low signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 279
3063-Cylinder 1 - Injector Cable Short Circuit (High Side To Ground) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282
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3070-Cylinder 3 - Electronic injector , Low signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 292
3078-Cylinder 2 - Electronic injector, Low signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 305
3082-Cylinder 4 - Electronic injector, Low signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 313
3088-Crankshaft sensor lost synchronization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 318
3089-Crankshaft Sensor - Invalid Signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 320
3090-Camshaft Sensor - Lost Phase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 322
3091-Camshaft sensor phase synchronization failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 324
3093-Offset Between Camshaft And Crankshaft - Outside Boundaries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 326
3095-Operating With Camshaft Sensor Only - Backup Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 329
3102-Rail Pressure Sensor CP3 - Signal Below Range Minimum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 331
3104-Rail Pressure Relief Valve - Open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 335
3105-Rail Pressure Relief Valve - Pressure Shock Requested . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 339
3106-Rail Pressure Relief Valve - Did Not Open After Pressure Shock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 340
3107-Metering unit output short circuit to battery on low side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 341
3110-Rail Pressure Sensor Monitoring - Signal Above Range Maximum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 342
3111-Rail Pressure Sensor Monitoring - Signal Below Range Minimum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 343
3112-Rail Pressure Sensor CP3 - Signal Above Maximum Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 344
3113-Grid heater battery switch relay short circuit to battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 345
3114-Grid heater battery switch relay short circuit to ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 349
3118-ECM 12V sensor supply voltage high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 353
3119-ECM 12V sensor supply voltage low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 355
3131-Grid Heater Always Switched On . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 357
3137-Metering Unit - Open Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 361
3138-Metering Unit - Signal Not Plausible . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 363
3141-Set point of fuel volume flow through metering unit is lower than calculated limit . . . . . . . . . . . . . . . . . . . . . 365
3147-Oil Temperature Sensor - Signal Above Normal Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 366
3154-Grid Heater Relay - Short Circuit To Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 369
3155-Grid Heater Relay - Short Circuit To Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 373
3156-Grid Heater Relay - No Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 377
3171-Fuel rail system pressure too low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 380
3172-Fuel rail system pressure too high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 384
3173-Rail Pressure Governor Deviation Below Min. Limit for Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 388
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3174-Rail Pressure Governor Deviation Exceeded Max. Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 392
3175-Fuel system leak detected - large leak . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 396
3176-Fuel delivery exceeded threshold for pressure in overrun mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 400
3178-Timeout of CAN Message BC2EDC1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
3179-Timeout of CAN Message BC2EDC2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
3180-Timeout of CAN Message VCM2EDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405
3188-Cylinder 1 - Open Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 407
3210-Bank 1 - General Short Circuit To Injector Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 422
3211-Bank 1 - Injector cable Short Circuit Low Side to Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 425
3212-Bank 1 - No Signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 427
3213-Bank 1 - Unclassifiable Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 433
3218-Bank 2 - General Short Circuit On Injector Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 438
3219-Bank 2 - Injector Cable Short Circuit Low Side To Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 443
3220-Bank 2 No Signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 448
3221-Bank 2 - Unclassifiable Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 454
3227-Injection Processor Error - Internal Reset/Clock Loss/Voltage Too Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 459
3228-Injection Processor Error - Unlocked/Initialization Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 460
3229-Injection Processor Error - Injections Limited By Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 461
3230-Injection Processor Error - SPI Communication Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 462
3231-Injection Processor Error - Internal Reset/Clock Loss/Voltage Too Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 463
3232-Injection Processor Error - Unlocked/Initialization Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 464
3233-Injection Processor Error - Test Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 465
3234-Injection Processor Error - SPI Communication Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 466
3238-Communication error of CJ940 processor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 467
3242-Engine Controller (Locked) Recovery Occurred . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 468
3243-Engine Controller Recovery (Suppressed) - Recovery Occurred . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 469
3244-Engine Controller Recovery (Visible) - Recovery Occurred . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 470
3245-Engine Controller - Watchdog Not Plausible . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 471
3246-Shutoff Paths During Initialization - Watchdog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 472
3247-Shutoff Paths Failed During Initialization - Supply Voltage Too High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 473
3248-Shutoff Paths During Initialization - Supply Voltage Too Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 474
3253-ADC Monitoring - Reference Voltage Too Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 475
3254-ADC Monitoring - Reference Voltage Too High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 476
3255-ADC Monitoring Test Impulse Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 477
3256-ADC Monitoring Queue Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 478
3258-HS power stage hardware reports 'short circuit to battery' longer than 500 ms. . . . . . . . . . . . . . . . . . . . . . . 479
3259-HS power stage hardware reports 'short circuit to ground' longer than 100 ms. . . . . . . . . . . . . . . . . . . . . . . 481
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3260-LS power stage hardware reports 'open load' longer than 100 ms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 483
3261-LS power stage hardware reports 'short circuit to battery' or 'excess temperature' longer than 100 ms. . 485
3262-LS power stage hardware reports 'short circuit to ground' longer than 100 ms. . . . . . . . . . . . . . . . . . . . . . . 487
3265-Energizing time exceeds limit of over run monitoring, injection time too long . . . . . . . . . . . . . . . . . . . . . . . . 489
3266-Error in engine speed check, speed signal not plausible . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 490
3278-Engine Controller Internal Supply Voltage Too High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 491
3279-Engine Controller Internal Supply Voltage Too Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 493
3280-Sensor Supply Voltage 1 - High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 495
3281-Sensor Supply Voltage 1 - Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 497
3998-Unknown error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 507
3999-Unknown error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 509
4113-Logical error at FNR switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 511
4114-Logical error at direction select signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 515
4116-Logical error at park brake status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 519
4117-Logic error at direction select signal 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 526
4119-Short circuit to ground at ride control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 530
4120-Short circuit to battery voltage at ride control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 537
4121-Open circuit at ride control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 544
4133-Short circuit to battery voltage or open circuit at transmission sump temperature sensor input . . . . . . . . . 551
4134-Short circuit to ground at transmission sump temperature sensor input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 553
4135-Short circuit to battery voltage or open circuit at retarder/ torque converter temperature sensor input . . . 555
4136-Short circuit to ground at retarder/ torque converter temperature sensor input . . . . . . . . . . . . . . . . . . . . . . . 557
4137-Short circuit to battery voltage or open circuit at parking brake sensor input . . . . . . . . . . . . . . . . . . . . . . . . . 559
4145-Short circuit to battery voltage or open circuit at engine speed input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 566
4146-Short circuit to ground at engine speed input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 569
4147-Logical error at engine speed input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 572
4148-Short circuit to battery voltage or open circuit at turbine speed input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 575
4149-Short circuit to ground at turbine speed input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 578
4150-Logical error at turbine speed input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 581
4151-Short circuit to battery voltage or open circuit at internal speed input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 584
4152-Short circuit to ground at internal speed input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 587
4153-Logical error at internal speed input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 590
4154-Short circuit to battery voltage or open circuit at output speed input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 593
4155-Short circuit to ground at output speed input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 597
4156-Logical error at output speed input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
4158-Output speed zero, doesn't fit to other speed signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 605
4160-Invalid gear range restriction (CAN) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 609
4186-Invalid park brake status (CAN) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 611
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4209-Short circuit to battery voltage at clutch K1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 613
4210-Short circuit to ground at clutch K1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 615
4211-Open circuit at clutch K1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 617
4228-Short circuit to battery voltage at clutch KV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 637
4229-Short circuit to ground at clutch KV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 639
4230-Open circuit at clutch KV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 641
4231-Short circuit to battery voltage at clutch KR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 643
4232-Short circuit to ground at clutch KR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 645
4233-Open circuit at clutch KR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 647
4241-Short circuit to ground at backup alarm relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 649
4242-Short circuit to battery voltage at backup alarm relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 652
4243-Open circuit at backup alarm relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 655
4273-Slippage at clutch K1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 658
4277-Slippage at clutch KV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 662
4278-Slippage at clutch KR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 663
4279-Overtemp sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 664
4281-Engine overspeed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 667
4282-TCM sensed a voltage at oil filter maintenance switch out of the allowed range (dirty filter) . . . . . . . . . . . . 670
4284-Overspeed output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 673
4290-Transmission input torque overload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 677
4291-Overtemp converter output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 678
4292-Short circuit to ground at joystick status indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 681
4293-Short circuit to battery voltage at joystick status indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 685
4294-Open circuit at joystick status indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 689
4305-Short circuit to battery voltage at power supply for sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 693
4306-Short circuit to ground at power supply for sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 694
4307-Low voltage at battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 695
4308-High voltage at battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 696
4309-Error at valve power supply VPS1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 697
4310-Error valve power supply VPS2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 698
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4325-VehicleID#1 timeout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 699
4326-Illegal ID request via CAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 702
4337-General EEPROM fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 703
4338-Configuration error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 704
4339-Application error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 705
4341-Clutch failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 706
4342-Clutch adjustment data lost . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 707
9128-CAN Timed Out During Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 708
9160-Hour Meter Failure - Both Copies Are Wrong . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 717
9161-Hour Meter Failure - One Of Two Copies Are Wrong . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 718
9162-Hour Meter Failure - Pre-crank And After-crank Checks Are Wrong . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 719
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PRINTED IN U.S.A.
84605841 14/05/2012
EN
SERVICE MANUAL
Platform, cab, bodywork, and decals
621F
721F
84605841 14/05/2012
90
Contents
Platform, cab, bodywork, and decals - 90
Pneumatically-adjusted operator seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.124

621F , 721F
Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.150
621F , 721F
84605841 14/05/2012
90
Pneumatically-adjusted operator seat - 124
621F
721F
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Contents
DIAGNOSTIC
Seat pneumatic lift system

Compressor - Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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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-
ment. Repair as required.
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
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Index

Seat pneumatic lift system Compressor - Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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Cab - 150
621F
721F
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Contents
Cab - 150
SERVICE
Cab
Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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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.
84605841 14/05/2012
90.150 / 3
Index
Cab - 150
Cab - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
84605841 14/05/2012
90.150 / 4
84605841 14/05/2012
90.150 / 5
PRINTED IN U.S.A.
84605841 14/05/2012
EN
SPECIAL TOOL INDEX
Genuine IU PAGE
380001285 [Front Housing Powershift transmission - Assemble - 621F 21.113 / 43
Suction Tube Removal Tool]
Lubrication Line Removal
Tool]
Tool]
CAS2801 [Transmission Powershift transmission - Disassemble - 4 Speed - 721F 21.113 / 67
Mounting Brackets]
CAS2801 [Transmission Powershift transmission - Disassemble - 4 Speed - 721F 21.113 / 70
Mounting Brackets]
380001285 [Front Housing Powershift transmission - Disassemble - 4 Speed - 721F 21.113 / 82
Tool]
380001285 [Front Housing Powershift transmission - Assemble - 4 Speed - 721F 21.113 / 86
Tool]
Tool]
CAS2801 [Transmission Powershift transmission - Disassemble - 5 Speed – 721F 21.113 / 111
Mounting Brackets]
CAS2801 [Transmission Powershift transmission - Disassemble - 5 Speed – 721F 21.113 / 115
Mounting Brackets]
380001285 [Front Housing Powershift transmission - Disassemble - 5 Speed – 721F 21.113 / 127
Tool]
380001285 [Front Housing Powershift transmission - Assemble – 5 Speed - 712F 21.113 / 131
Tool]
Tool]
380001577 [Valve Adjustment Transmission control valve - Assemble - 621F 21.135 / 15
Tool Set]
380001577 [Valve Adjustment Transmission control valve - Assemble - 621F 21.135 / 15
Tool Set]
CAS2801 [Transmission Transmission control valve - Disassemble - 4 Speed - 721F 21.135 / 25
Mounting Brackets]
380001577 [Valve Adjustment Transmission control valve - Disassemble - 4 Speed - 721F 21.135 / 30
Tool Set]
380001577 [Valve Adjustment Transmission control valve - Assemble - 4 Speed - 721F 21.135 / 37
Tool Set]
Tool Set]
14/05/2012
7
Genuine IU PAGE
CAS2801 [Transmission Transmission control valve - Disassemble - 5 Speed - 721F 21.135 / 47
Mounting Brackets]
380001577 [Valve Adjustment Transmission control valve - Disassemble - 5 Speed - 721F 21.135 / 53
Tool Set]
Tool Set]
Tool Set]
CAS2798 [Gear Puller Collet Clutch - Disassemble - Forward clutch KV – 4 and 5 Speed - 721F 21.155 / 100
Set]
CAS2798 [Gear Puller Collet Clutch - Disassemble - Forward clutch KV – 4 and 5 Speed - 721F 21.155 / 102
Set]
CAS2798 [Gear Puller Collet Clutch - Disassemble - Reverse clutch KR - 4 and 5 Speed - 721F 21.155 / 115
Set]
CAS2798 [Gear Puller Collet Clutch - Disassemble - Reverse clutch KR - 4 and 5 Speed - 721F 21.155 / 117
Set]
CAS2798 [Gear Puller Collet Clutch - Disassemble - First gear clutch K1 – 4 and 5 Speed 21.155 / 129
Set] - 721F
CAS2798 [Gear Puller Collet Clutch - Disassemble - First gear clutch K1 – 4 and 5 Speed 21.155 / 131
Set] - 721F
CAS2798 [Gear Puller Collet Clutch - Disassemble - Second gear clutch K2 - 4 and 5 Speed 21.155 / 143
Set] - 721F
CAS2798 [Gear Puller Collet Clutch - Disassemble - Second gear clutch K2 - 4 and 5 Speed 21.155 / 145
Set] - 721F
CAS2798 [Gear Puller Collet Clutch - Disassemble - Third gear clutch K3 - 4 and 5 Speed 21.155 / 157
Set] – 721F
CAS2798 [Gear Puller Collet Clutch - Disassemble - Third gear clutch K3 - 4 and 5 Speed 21.155 / 159
Set] – 721F
CAS2798 [Gear Puller Collet Clutch - Disassemble - Fourth gear clutch K4 - 4 and 5 Speed 21.155 / 171
Set] - 721F
CAS2798 [Gear Puller Collet Clutch - Disassemble - Fourth gear clutch K4 - 4 and 5 Speed 21.155 / 173
Set] - 721F
CAS2798 [Gear Puller Collet Clutch - Disassemble - Input shaft - 4 and 5 Speed – 721F 21.155 / 185
Set]
CAS2798 [Gear Puller Collet Clutch - Disassemble - Input shaft - 4 and 5 Speed – 721F 21.155 / 185
Set]
CAS2798 [Gear Puller Collet Clutch - Disassemble - Output shaft - 4 and 5 Speed – 721F 21.155 / 190
Set]
CAS2798 [Gear Puller Collet Clutch - Disassemble - Output shaft - 4 and 5 Speed – 721F 21.155 / 190
Set]
380100001 [Bearing Cup Bevel gear set and differential carrier - Backlash - Models MT-L 25.102 / 13
Installer ] 3085 II / MT–L 3095 II
CAS2842 [Pinion Locknut Bevel gear set and differential carrier - Backlash - Models MT-L 25.102 / 14
Wrench] 3085 II / MT–L 3095 II
380001546 [Flange Holder] Bevel gear set and differential carrier - Backlash - Models MT-L 25.102 / 14
3085 II / MT–L 3095 II
CAS2842 [Pinion Locknut Differential - Remove - Models MT-L 3085 II / MT-L 3095 II 25.102 / 33
Wrench]
380001546 [Flange Holder] Differential - Remove - Models MT-L 3085 II / MT-L 3095 II 25.102 / 33
CAS2842 [Pinion Locknut Differential - Install Models MT-L 3085 II / MT-L 3095 II 25.102 / 35
Wrench]
380001546 [Flange Holder] Differential - Install Models MT-L 3085 II / MT-L 3095 II 25.102 / 35
CAS2841 [Pinion Shaft Seal Differential - Install Models MT-L 3085 II / MT-L 3095 II 25.102 / 35
Installer ]
Wrench]
380100001 [Bearing Cup Bevel gear - Backlash - Models MT-L 3085 II / MT–L 3095 II 27.106 / 13
Installer ]
CAS2842 [Pinion Locknut Bevel gear - Backlash - Models MT-L 3085 II / MT–L 3095 II 27.106 / 14
Wrench]
14/05/2012
8
Genuine IU PAGE
380001546 [Flange Holder] Bevel gear - Backlash - Models MT-L 3085 II / MT–L 3095 II 27.106 / 14
CAS2842 [Pinion Locknut Differential - Remove - Models MT-L 3085 II / MT-L 3095 II 27.106 / 48
Wrench]
380001546 [Flange Holder] Differential - Remove - Models MT-L 3085 II / MT-L 3095 II 27.106 / 48
Wrench]
CAS2841 [Pinion Shaft Seal Differential - Install Models MT-L 3085 II / MT-L 3095 II 27.106 / 50
Installer ]
Wrench]
380040185 [Harness 3061-Cylinder 1 - Injector Cable Short Circuit 55.DTC / 278
Diagnostic /Repair Kit (NEF)]
14/05/2012
9
PRINTED IN U.S.A.
84605841 14/05/2012
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
19.0
19.0
9
11
10
19.0
1
24
158
16 19.0
150 A
19.0 6
159
17 110
160
19.0
CONNECTOR LIST 3 COLD START POWER DISTRIBUTION IGNITION SWITCH 4

ELECTRICAL SCHEMATIC SIDE 1
621F, 721F, 821F, 921F TIER 4 WHEEL LOADER
Additional copies of this schematic can be ordered through Technical Publications Distribution System. Part # RAC 84564192
22
24
92
133 90
162
161
Relay in
Relay in location
location F9\F10
93
F1/F2
95
78
91
North American models

European and International models
101 100 101 100
23 163
Turn
Signal
Driving
Lights
Light/
Horn
79
Horn
169
94
164
168
103
165
96 97
167
166 102
ENGINE CONTROL 5 LIGHTING 1 BACKUP ALARM 6
89
172
54
173 171
81
57
59
56
88
721F-921F: 24 bar (350 PSI)
621F : 10 bar (145 PSI)
87
55 174
80
46
86
47
61
48 45
58
49
85
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
74
72
27
67
99
65 JUMPER 821F ONLY
69
39
73
115 bar (1668 psi)
approx 70 bar (1015 psi)
75 28
JUMPER 821F ONLY 40
38 34
approx 70 bar (1015 psi)
66 30
76
44 41
42
43
821F
134
INSTRUMENT CLUSTER 9 MACHINE CONTROLS 10
121
127
113 122
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 113 139
SWITCH
136 138
157
110
118
CAN
13 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
153
149 150
182
152
180
821F ONLY 183
151
186
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
15 4 POWER RELAY MODULE C 73 9 HYDRAULIC OIL TEMPERATURE SENDER 132
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
23 5 THROTTLE POTENTIOMETER 81 7 DOOR SWITCH 139 12 TELEMATICS
24 4, 5 ENGINE CONTROLLER 82 7 ROTATING BEACON (OPTIONAL) 140
25 10 RETURN TO TRAVEL FLOAT SWITCH 83 7 DOME LAMP 141
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
621F, 721F, 821F, 921F Tier 4 Wheel Loader 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
ELECTRICAL SCHEMATIC 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
34 92 6 FLASHER MODULE 150 14 AIR CONDITIONING SWITCH
35 10 RIDE CONTROL SWITCH (OPTION) 93 6 HAZARD SWITCH 151 14 CONTROL PANEL LAMPS
LEGEND 36 10 RIDE CONTROL RELAY (OPTION) 94 6 TURN SIGNAL, HIGH-LOW BEAM, AND HORN SWITCH 152 14 WATER VALVE POTENTIOMETER
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
INDICATES CONSTANT POWER 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 157 11 HOOD MOTOR
SWITCH IS ON 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
INDICATES POWER WHEN KEY 44 10 FAN REVERSE SOLENOID (OPTION) 102 6 LICENSE PLATE LAMP 160 4 START LOCKOUT
SWITCH IS IN START POSITION 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
47 8 FILTER MAINTENANCE SWITCH 105 11 WIPER CUTOUT RELAY 163 5 NOX SENSOR (NOXS)
POWER RELAY A 48 8 TORQUE CONVERTER OUTPUT TEMPERATURE SENDER 106 11 FRONT WIPER LOW SPEED RELAY 164 5 TANK HEATER CONTROL VALVE
POWER RELAY B 49 8 ENGINE SPEED SENSOR 107 11 REAR WIPER AND WASHER SWITCH 165 5 DEF LEVEL AND TANK TEMPERATURE
50 8 INTERMEDIATE SPEED SENSOR 108 11 FRONT WIPER AND WASHER SWITCH 166 5 UPSTREAM TEMPERATURE SENSOR
POWER RELAY C 51 8 TURBINE SPEED SENSOR 109 11 FRONT WIPER MOTOR 167 5 DOWNSTREAM TEMPERATURE SENSOR
52 8 TRANSMISSION SHIFTER 110 11 REAR WIPER MOTOR 168 5 DOSER METERING VALVE
POWER RELAY D 53 8 TRANSMISSION ELECTRONIC CONTROL MODULE 111 11 REAR WASHER MOTOR 169 5 DNOX CONTROLLER
ILLUMINATION 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

4
))
)) ))
))
3
))
))
3
))
3
))
COMPONENTS
1 Rear Axle Brakes 3.5 liter (3.7 quart) Cut-Out Pressure 19A Ride Control Solenoid 21G Circuit Relief Valve with Anti-Cavitation (6) 25 Steering Back Pressure Sensor Electrical Connector PSS Bypass 3.4 bar (50 PSI)
Modulation Pressure 70 bar (1015 PSI) Precharge 190 to 196 bar (2755 to 2845 PSI) Electrical Connector YRC 290 bar (4200 PSI) Joystick Steering Only 32 Pump Warning Switch 2.7 bar (40 PSI)
74 to 82 bar (1075 to 1190 PSI) 9 Front Redundant Accumulator Pressure Switch 12F Priority Valve 19B Ride Control Spool Valve 21H Regeneration Check Valves (2) Electrical Connector JSSLSR 170 LPM (45 GPM) 38 Oil Cooler Thermal Valve
2 Front Axle Brakes Electrical Connector PRB1 13 Coupler Locking Valve 19C Manual Bleed Valve 21J Regeneration Relief Valve 26 Joystick Steering Load Sense Resolver Cut Off 280 bar (4060 PSI) Begin Opening 44° to 53° C (112° to 128 ° F)
Modulation Pressure Rising < 91 bar (< 1320 PSI) , Falling 70 to 84 bar (1015 to 1220 PSI) Electrical Connection YPE 19D Pressure Relief Valve 6.7 bar (100 PSI) 27 Joystick Steering Valve Delta 22 to 25 bar (320 to 365 PSI) Full Open 63° C (145° F)
76 to 84 bar (1100 to 1220 PSI) 10 Rear Redundant Accumulator Pressure Switch 14 Coupler Locking Cylinders 280 bar (4060 PSI) 21K Differential Pressure Relief 27A Control Spool 32A Compensator Differential Pressure Spool 2.4 to 3.6 bar (35 to 52 PSI) Bypass
3 Parking Brake Electrical Connector PRB2 15 Pilot Control Valve 20 Ride Control Accumulator 40 bar (580 PSI) 27B Pressure Reducer 32B Compensator High Pressure Cutoff Spool 39 Hydraulic Oil Cooler
4 Brake Declutch Switch Rising < 91 bar (< 1320 PSI) , Falling 70 to 84 bar (1015 to 1220 PSI) 15A Pilot ON/OFF Solenoid 3.78 liter (4 quart) 21L Flow Compensator (4) 27C Pilot Dump Valve 32C Control Piston with Spring 40 Oil Cooler Fan
Electrical Connector PBD 11 Low Brake Pressure Warning Switch Electrical Connector YPP 14.5 bar (210 PSI) Precharge 21M Bucket Control Spool Electrical Connector PIL_DUMP 32D Rotating Group with Swash Plate 41 Standard Fan Valve
10 bar (150 PSI) Alarm OFF 142 to 150 bar (2060 to 2175 PSI) Increasing 15B Bucket Pilot Control 21 Loader Valve with Priority Flow Divider 21N Lift Control Spool 28 Auxiliary Steering Control Valve 33 Brake Pump 197 bar (2860 PSI)
5 Brake Light Switch Alarm ON 118 to 126 bar (1711 to 1827 PSI) Decreasing 15C Lift Pilot Control 21A Load Sense Check Valve 21P Auxiliary 1 Control Spool 28A Auxiliary Steering Activation Solenoid 34 100 Mesh Strainers (2) 42 Fan Reversing and Variable Valve
CONVERSION INFORMATION Electrical Connector PBL 12 Brake Valve 15D Auxiliary Hydraulics Pilot Control 1 21B Steering Relief Valve 21Q Auxiliary 2 Control Spool Electrical Connector YSS 35 Hydraulic Reservoir 42A Crossover Relief 234 bar (3395 PSI)
4.1 bar (60 PSI) Increasing 12A Parking Brake Solenoid 15E Auxiliary Hydraulics Pilot Control 2 239 to 243 bar (3465 to 3525 PSI) 21R Shuttle Check Valves (6) 28B Relief Valve 65 liter (17 GAL) 42B Reversing Spools
1 bar = 14.5 pounds per square inch (PSI)
6 Parking Brake Accumulator Electrical Connector YPB 16 Pilot Control Accumulator 21C Pilot Pressure Reducing Valve 22 Steering Cylinders 240 bar (3480 PSI) 36 Reservoir Vent 42C Pulse Width Modulation (PWM) Relief Valve
1 liter per minute = .264 gallons per minute
0.16 liter (0.17 quart) 12B Front Brake Valve 0.75 liter (0.79 quart) 29 to 40 bar (420 to 580 PSI) 23 Steering Control Valve 28C Priority Spool 100 mesh 165 bar (2390 PSI)
96 bar (1390 PSI) Precharge 12C Rear Brake Valve 13.8 bar (200 PSI) Precharge 21D Priority Flow Divider 23A Steering Spool 29 Auxiliary Steering Accumulator 0.03 bar check (0.4 PSI) Electrical Connector YFN
7 Front Brake Accumulator 12D Accumulator Isolation Check Valve 17 Bucket Cylinder Z-Bar / XR 21E Loader Main Relief 23B Gerotor Pump 0.32 liter (0.34 quart) 0.35 bar relief (5 PSI) 42D ON/OFF Reversing Solenoid
3.5 liter (3.7 quart) 12E Accumulator Charging Spool 2 Bucket Cylinders XT 248 to 255 bar (3595 to 3700 PSI) 23C Circuit Relief Valve 60 bar (870 PSI) Precharge 37 Filter Electrical Connector YFR
CIRCUIT DIAGRAM LEGEND CIRCUIT PUMP SUPPLY NOTES 70 bar (1015 PSI) Precharge Cut-In Pressure 18 Lift Cylinders 21F Load Sense Signal Bleed Down Orifice 24 Steering Back Pressure Valve 30 Auxiliary Steering Pump Electrical Connector PHF 43 Vent Check Valve
8 Rear Brake Accumulator 157 to 167 bar (2275 to 2420 PSI) 19 Ride Control Valve 0.7 LPM (0.2 GPM) 8 to 10 bar (115 to 145 PSI) 31 Auxiliary Steering Pressure Switch 10 micron media 0.25 bar (4 PSI)
COMPONENT RETURN TO TANK \SUMP Note 1: Optional check valve for Ride Control only
SHOWS CIRCUIT Note 2: Check and relief valves (41) not used with Fan Reverser HYDRAULIC SCHEMATIC
CROSSING SHOWS CIRCUIT AUX\OPTIONAL REGULATED PRESSURE Note 3: With Reverse option 621F WHEEL LOADER TIER 2 / 4
NOT CONNECTED CONNECTED CHECK VALVE RESTRICTOR FILTER OR SCREEN OIL COOLER
Note 4: Without Reverse option Additional copies of this Schematic can be ordered through Technical Publications Distribution System. Part # RAC 84564198.
TEST POINTS LOAD SENSE
LINE TYPES
1 2 9
15 18 19
16 21
11 YPP
UNLOCK
20
P T X1
LOCK
8 16B MX
16A
20D
12 20A
T 280 bar
14
16C
20C
R R1 F
13 YRC
4
13A 2
20B
X 16D
3 13F
1
13E B A
5 P 2
13D 16E
13B
1
3 T1
T1'
240±20 L/min
240±20 L/min
6 B
a2
BUCKET
N 22K
B2 230+20 L/min
22K
BOOM
a3
OPTION
B1 240±10 L/min
A2 20+10 L/min
868050
868050
13C
ø0.8
ø0.8
ø2.0
ø2.0
Pst
T2 22A
0.6
a1
A1
A3
B3
P
R2 765876
LS
Mp
1.2
R901047887
22F
Pst
17
528789
528789
528789
7 11 22H
30 bar
22C
R901007569
T
22C )(
22C
22G
847160
10
224±3 bar
R901007569
TP11: REAR BRAKE TO AXLE
859551
R900756264
22J
8-10.8 bar
TP10: FRONT BRAKE TO AXLE 22D
329140
MT1
TP6: FRONT BRAKE ACCUMULATOR 22B
S1
TP7: REAR BRAKE ACCUMULATOR
737012
936718
290 bar
290 bar
290 bar
936718
936718
290 bar
936718
TP3: STEERING LOAD SENSE
936725
TP2: IMPLEMENT LOAD SENSE
TP5: STEERING PUMP PRESSURE 22D 22D 22E

22E 22E 22E
TP1: UNLOADING PUMP PRESSURE
S2
22
TP9: PILOT PRESSURE SUPPLY
A2
A1
b1
B2
899039
868050
ø2.0
ø0.8
ø2.0
ø0.8
240±10
L/min
M2 45C
P
b2
b3
22K 22K
45B
44 45A 45
42 43 234
M2 136.2 BAR IN bar
23cc 234
TANK 35 EF 24
M1 bar
CF
35A
L
Note 2 45B 45D G1 0.025
LS
P 24A 24B
T .71
M1 G2 24C
35C LS 23
35B
T
34 X
R
27
33 2 T
1
34A 33A 30
LS SLS ST CF 32
34B 0.7 R L
33B 3 28
36 30A
40
Note 1 240 bar
0.6 mm LS
23cc 34C 33C 0.31
0.31
30B
41 P T
29 28A
34D 33D 1.6 mm P

30C
p 28C
T P 26 28B
31
39
11 cc
25
T
38
COMPONENTS
1 Rear Axle Brakes 11 Redundant Accumulator Pressure Switches 17 Pilot Control Accumulator 23 Steering Cylinders 33 Second Pump (Farthest from Transmission) 39 Reservoir Vent
Modulation Pressure Electrical Connectors PRB1, PRB2 0.75 liter (0.79 quart) 24 Steering Control Valve 86 LPM (22.5 GPM) 100 mesh
68 to 75 bar (985 to 1090 PSI) Rising < 91 bar (< 1320 PSI) 13.8 bar (200 PSI) Precharge 24A Steering Spool Cut Off 280 bar (4060 PSI) 0.03 bar check
2 Front Axle Brakes Falling 70 to 84 bar (1015 to 1220 PSI) 18 Bucket Cylinder Z-Bar 24B Gerotor Pump Delta 24 to 26 bar (350 to 375 PSI) 0.35 bar relief
Modulation Pressure 12 Low Brake Pressure Warning Switch 2 Bucket Cylinders XT
24C Circuit Relief Valve 33A Compensator Differential Pressure Spool 40 Filter
Alarm OFF 138 bar (2000 PSI) Increasing 19 Lift Cylinders
37 37 70 to 77 bar (1015 to 1115 PSI)
Alarm ON 115 to 129 bar (1670 to 1870 PSI) Decreasing 20 Ride Control Valve
25 Steering Back Pressure Valve 33B Compensator High Pressure Cutoff Spool Electrical Connector PHF
3 Brake Damping Accumulators 8 to 10 bar (115 to 145 PSI) 33C Control Piston with Spring 10 micron media
13 Brake Valve 20A Ride Control Solenoid
Heavy Duty Option Only 13A Parking Brake Solenoid 26 Steering Back Pressure Sensor 33D Rotating Group with Swash Plate Bypass 3.4 bar (50 PSI)
Electrical Connector YRC
0.16 liter (0.17 quart) Electrical Connector YPB 20B Ride Control Spool Valve Joystick Steering Only 34 First Pump (Closest to Transmission) Warning Switch 2.7 bar (40 PSI)
7 bar (102 PSI) Precharge 13B Front Brake Valve 20C Manual Bleed Valve 27 Joystick Steering Load Sense Resolver 120 LPM (31.6 GPM) 41 Oil Cooler Thermal Valve
4 Parking Brake 13C Rear Brake Valve 20D Pressure Relief Valve 28 Joystick Steering Valve Cut Off 280 bar (4060 PSI) 2.4 to 3.6 bar (35 to 52 PSI) Bypass
5 Brake Signal, 5-speed transmission 13D Accumulator Isolation Check Valve 280 bar (4060 PSI) 28A Control Spool Delta 28 to 30 bar (405 to 435 PSI) 42 Hydraulic Oil Cooler
6 Brake Declutch Switch, 4-speed transmission 13E Accumulator Charging Spool 21 Ride Control Accumulator 28B Pressure Reducer 34A Compensator Differential Pressure Spool 43 Oil Cooler Fan
Electrical Connector PBD 13F Priority Valve 3.78 liter (4 quart) 28C Pilot Dump Valve 34B Compensator High Pressure Cutoff Spool
44 Standard Fan Valve
24 bar (350 PSI) Cut-In Pressure 14.5 bar (210 PSI) Precharge 29 Auxiliary Steering Accumulator 34C Control Piston with Spring
157 to 167 bar (2275 to 2420 PSI) 22 Loader Valve
162 bar (2350 PSI)
7 Brake Light Switch 0.32 liter (0.34 quart) 34D Rotating Group with Swash Plate
Cut-Out Pressure 22A Load Sense Shuttle Valve 45 Fan Reversing and Variable Valve
4.1 bar (60 PSI) Increasing 60 bar (870 PSI) Precharge 35 Priority Valve
190 to 196 bar (2755 to 2845 PSI) 22B Regeneration Relief Valve 45A Crossover Relief 234 bar (3395 PSI)
8 Parking Brake Accumulator 30 Auxiliary Steering Control Valve 35A Priority Spool
14 Coupler Locking Valve 22C Flow Compensator Spool 45B Reversing Spools
0.16 liter (0.17 quart) 30A Auxiliary Steering Activation Solenoid 35B Differential Pressure Relief
15 Coupler Locking Cylinders 22D Regeneration Check Valve 45C Pulse Width Modulation (PWM) Relief Valve
96 bar (1390 PSI) Precharge Electrical Connector YSS 40 bar (580 PSI)
16 Pilot Control Valve 22E Circuit Relief Valve with Anti-Cavitation 165 bar (2390 PSI)
9 Front Brake Accumulator 16A Pilot ON/OFF Solenoid 22F Pilot Pressure Reducing Valve
30B Relief Valve 35C Steering Relief
3.5 liter (3.7 quart)
45D ON/OFF Reversing Solenoid
Electrical Connector YPP 29 to 40 bar (420 to 580 PSI) 240 bar (3480 PSI) 214 bar (3100 PSI)
70 bar (1015 PSI) Precharge 30C Priority Spool 36 Brake Pump Electrical Connector YFR
16B Bucket Pilot Control 22G Pilot Pressure Relief
10 Rear Brake Accumulator, 3.5 liter, 70 bar precharge 16C Lift Pilot Control 22H Load Sense Signal Bleed Down Orifice 31 Auxiliary Steering Pump 37 100 Mesh Strainers
3.5 liter (3.7 quart) 16D Auxiliary Hydraulics Pilot Control 1 22J Loader Main Relief 32 Auxiliary Steering Pressure Switch 38 Hydraulic Reservoir
70 bar (1015 PSI) Precharge 16E Auxiliary Hydraulics Pilot Control 2 22K Shuttle Check Valve Electrical Connector PSS 90 liter
CIRCUIT DIAGRAM LEGEND NOTES CONVERSION INFORMATION

HYDRAULIC SCHEMATIC
PUMP SUPPLY
Note 1 : Optional Check Valve for Ride Control Only 1 bar = 14.5 pounds per square inch (PSI) 721F WHEEL LOADER
# CIRCUIT LOAD SENSE Note 2 : Check and Relief Valves not used with Fan Reverser 1 liter per minute = .264 gallons per minute
Additional copies of this Schematic can be ordered through Technical Publications Distribution System. Part # RAC 84419916.
SHOWS CIRCUIT COMPONENT PILOT
CROSSING SHOWS CIRCUIT COMPONENT
NOT CONNECTED CONNECTED NUMBER CHECK VALVE RESTRICTOR FILTER OR SCREEN OIL COOLER LINE TYPES

621 F, 721 F Tier 4

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621 F, 721 F Tier 4

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621F

Printed in U.S.A. Part number 84605841

Air cleaners and lines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.202

Fan and drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.414

Engine generic sub-group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.AAA

Four-Wheel Drive (4WD) system .................................................. 23

Front axle system ....................................................................... 25

Final drive hub, steering knuckles, and shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.108

Rear axle system........................................................................ 27

Planetary and final drives. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27.120

Brakes and controls .................................................................... 33

Variable displacement pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.106

Pilot system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.357

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

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

Warning indicators, alarms, and instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.408

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

Selective Catalytic Reduction (SCR) electrical system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.988

FAULT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.DTC

Platform, cab, bodywork, and decals ............................................. 90

Torque – 621F Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Torque – 721F Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Consumables - Biodiesel Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Torque – 621F Torque Specifications

Diesel Exhaust Fluid (DEF) System

Torque – 721F Torque Specifications

Diesel Exhaust Fluid (DEF) System

621F Capacities and Specifications

721F Capacities and Specifications

Engine Oil Viscosity/Temperature Range

Transmission Oil Viscosity/Temperature Range

Hydraulic/Brake System Temperature Range

Transmission Component Oil

If CASE AKCELA ENGINE OIL 15W-40 cannot be obtained,

Consumables - Biodiesel Fuel

Biodiesel Fuel Usage Conditions

Engine and crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.001

Air cleaners and lines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.202

Engine lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.304

Engine cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.400

Fan and drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.414

Selective Catalytic Reduction (SCR) exhaust treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.500

Engine generic sub-group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.AAA

Engine and crankcase - 001

Engine and crankcase - 001

2. Actuate the brake pedal several times to discharge

3. Put key switch in ON position. Pilot control switch