Case 821F Service Manual

stuart pope
sp mechanical services ltd

Ings Lane
Doncaster
SERVICE MANUAL
DN10 4HE
United Kingdom (UK)
07970183838
spmechanicalservices@hotmail.co.uk
821G
821G 921G
921G Tier 2
Wheel Loader Wheel Loader
1/2 SERVICE MANUAL

Part number 48083741
Part number 48083741

English
July 2018
© 2018 CNH Industrial Italia S.p.A. All Rights Reserved.
SERVICE MANUAL
821G ZBAR - EH, NEW CAB TIER2

48083741_EN 31/07/2018
EN
Contents
INTRODUCTION
Engine....................................................................................... 10
[10.001] Engine and crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.1
[10.202] Air cleaners and lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.2
[10.400] Engine cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3
[10.414] Fan and drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.4
[10.310] Aftercooler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.5
[10.304] Engine lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.6
Transmission.............................................................................. 21
[21.113] Powershift transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.1
[21.155] Powershift transmission internal components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.2
[21.700] Torque converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.3
Four-Wheel Drive (4WD) system .................................................. 23

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

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

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

[33.202] Hydraulic service brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33.1
[33.110] Parking brake or parking lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33.2
Hydraulic systems....................................................................... 35
48083741_EN 31/07/2018
[35.000] Hydraulic systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.1
[35.300] Reservoir, cooler, and filters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.2
[35.106] Variable displacement pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.3
[35.359] Main control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.4
[35.357] Pilot system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.5
[35.204] Remote control valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.6
[35.752] Hydraulic fan drive cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.7
[35.701] Front loader arm hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.8
[35.723] Front loader bucket hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.9
[35.734] Tool quick coupler hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.10
Frames and ballasting ................................................................. 39

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

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

[55.100] Harnesses and connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.1
[55.301] Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.2
[55.302] Battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.3
[55.512] Cab controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.4
48083741_EN 31/07/2018
[55.050] Heating, Ventilation, and Air-Conditioning (HVAC) control system. . . . . . . . . . . . . . . . . 55.5
[55.415] Loader arm and bucket control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.6
[55.530] Camera. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.7
[55.DTC] FAULT CODES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.8
Front loader and bucket............................................................... 82

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

[90.150] Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.1
[90.120] Mechanically-adjusted operator seat. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.2
[90.124] Pneumatically-adjusted operator seat. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.3
[90.105] Machine shields and guards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.4
48083741_EN 31/07/2018
INTRODUCTION
48083741_EN 31/07/2018
1
Contents
INTRODUCTION
Safety rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Personal safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Basic instructions - Important notice regarding equipment servicing . . . . . . . . . . . . . . . . . . . . . . . . . 13
Basic instructions - How to use the maintenance standard and precautions . . . . . . . . . . . . . . . . . 14
Basic instructions - Precaution for disassembly and assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Basic instructions - Electrical equipment precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Torque - Minimum tightening torques for normal assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Consumables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Consumables - Biodiesel Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Hydraulic contamination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Product identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Product identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
48083741_EN 31/07/2018
2
INTRODUCTION
Safety rules
Personal safety
This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all
safety messages that follow this symbol to avoid possible death or injury.
Throughout this manual you will find the signal words DANGER, WARNING, and CAUTION followed by special in-
structions. These precautions are intended for the personal safety of you and those working with you.
Read and understand all the safety messages in this manual before you operate or service the machine.
DANGER indicates a hazardous situation that, if not avoided, will result in death or serious injury.
WARNING indicates a hazardous situation that, if not avoided, could result in death or serious injury.
CAUTION indicates a hazardous situation that, if not avoided, could result in minor or moderate injury.
FAILURE TO FOLLOW DANGER, WARNING, AND CAUTION MESSAGES COULD RESULT

IN DEATH OR SERIOUS INJURY.
Machine safety
NOTICE: Notice indicates a situation that, if not avoided, could result in machine or property damage.
Throughout this manual you will find the signal word Notice followed by special instructions to prevent machine or
property damage. The word Notice is used to address practices not related to personal safety.
Information
NOTE: Note indicates additional information that clarifies steps, procedures, or other information in this manual.
Throughout this manual you will find the word Note followed by additional information about a step, procedure, or
other information in the manual. The word Note is not intended to address personal safety or property damage.
48083741_EN 31/07/2018
3
INTRODUCTION
Personal safety
Carefully read this Manual before proceeding with main-
tenance, repairs, refuelling or other machine operations.
Repairs have to be carried out only by authorized and in-

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

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

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

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

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

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

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

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

maintenance in progress tag. This tag can be applied on
the left-hand control lever, safety lever or cab door.
48083741_EN 31/07/2018
4
INTRODUCTION
Emergency
Be prepared for emergencies. Always keep a fire extin-
guisher and first aid kit readily available. Ensure that the
fire extinguisher is serviced in accordance with the man-
ufacturer’s instructions.
SMIL12WEX0174AA 3
Equipment
Wear close fitting clothing and safety equipment appropri-
ate for the job:
• Safety helmet
• Safety shoes
• Heavy gloves
• Reflective clothing
• Wet weather clothing
If working conditions require, the following personal safety

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

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

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

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

gine is running.
Never lubricate the machine with the engine running.
TULI12WEX2009AA 5
48083741_EN 31/07/2018
5
INTRODUCTION
Pay attention to rotating components and do not allow

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

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

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

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

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

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

8
under pressure. TULI12WEX2012AA
Swallowing hydraulic oil is a severe health hazard.
48083741_EN 31/07/2018
6
INTRODUCTION
When hydraulic oil has been swallowed, avoid vomiting,

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

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

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

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

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

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

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

hydraulic hoses immediately on detecting any damaged
or moist areas.
Always store hydraulic oil in the original containers.
48083741_EN 31/07/2018
7
INTRODUCTION
Hoses and tubes

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

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

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

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

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

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

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

condition. Always lubricate new seal rings and O-rings
with hydraulic oil before installation to relevant seats.
This will prevent the O-rings from rolling over and twisting
during mounting which will jeopardize sealing.
48083741_EN 31/07/2018
8
INTRODUCTION
Battery
Batteries give off explosive gases.
Never handle open flames and unshielded light sources

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

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

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

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

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

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

the interests of environmental protection.
TULI12WEX2017AA 13
48083741_EN 31/07/2018
9
INTRODUCTION
Flammable liquids
When handling flammable liquids:
• Do not smoke.
• Keep away from unshielded light sources and open
flames.
Fuels often have a low flash point and are readily ignited.
Never attempt to extinguish burning liquids with water.

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

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

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

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

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

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

grinding or when working near an exposed flame.
TULI12WEX2019AA 16
48083741_EN 31/07/2018
10
INTRODUCTION
Tires
Before inflating the tires, always check the condition of
rims and the outer condition of tires for the presence of
dents, cuts, tears of reinforcement plies or other faults.
Before inflating a tire, make sure that there are no nearby
persons, then position yourself at tread side.
When inflating tires, ensure tire pressure does not exceed

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

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

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

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

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

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

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

penetration inside the cab.
48083741_EN 31/07/2018
11
INTRODUCTION
Waste disposal
Improperly disposing of waste can threaten the environ-
ment.
Each country has its own Regulations on this subject. It

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

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

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

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

someone into drinking from them. Do not pour waste onto
the ground, down a drain, or into any water source. Air
conditioning refrigerants escaping into the air can damage
the Earth’s atmosphere. Government regulations may re-
quire a certified air conditioning service centre to recover
and recycle used air conditioning refrigerants. Obtain in-
formation on the proper way to recycle or dispose of waste
from your local environmental or recycling centre, or from
your Dealer.
48083741_EN 31/07/2018
12
INTRODUCTION
Basic instructions - Important notice regarding equipment servicing

All repair and maintenance work listed in this manual must be carried out only by qualified dealership personnel,
strictly complying with the instructions given, and using, whenever possible, the special tools.
Anyone who performs repair and maintenance operations without complying with the procedures provided herein
shall be responsible for any subsequent damages.
The manufacturer and all the organizations of its distribution chain, including - without limitation - national, regional, or
local dealers, reject any responsibility for damages caused by parts and/or components not approved by the manu-
facturer, including those used for the servicing or repair of the product manufactured or marketed by the manufacturer.
In any case, no warranty is given or attributed on the product manufactured or marketed by the manufacturer in case
of damages caused by parts and/or components not approved by the manufacturer.
The information in this manual is up-to-date at the date of the publication. It is the policy of the manufacturer for
continuous improvement. Some information could not be updated due to modifications of a technical or commercial
type, or changes to the laws and regulations of different countries.
In case of questions, refer to your CASE CONSTRUCTION Sales and Service Networks.
48083741_EN 31/07/2018
13
INTRODUCTION
Basic instructions - How to use the maintenance standard and

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

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

PARTS LIABLE TO DEGRADE
Rubber products, such as, hydraulic hoses, O-rings, and oil seals deteriorate with time; replace them at regular inter-
vals or at overhauls.
48083741_EN 31/07/2018
14
INTRODUCTION
PARTS REQUIRING REGULAR REPLACEMENT
Critical hoses that are necessary to secure safety, we designate as Very Important Parts (V.I.P.) and recommend that
they should be replaced regularly.
INSPECTION AND REPLACEMENT OF OILS AND GREASES
In performing maintenance, it is necessary for the user to familiarize themselves with the machine and handle safely.
Use caution when inspecting and replacing oils and grease. Refer to the Operators Manuals as well.
48083741_EN 31/07/2018
15
INTRODUCTION
Basic instructions - Precaution for disassembly and assembly

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

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

• Impaired performance and function of hydraulic equipment after unauthorized service may not be covered under
warranty by the manufacturer. Consult your local dealer for service.
• If it is unavoidably necessary to disassemble and modify, it should be carried out by experts or personnel qualified
through service training.
• Make match mark on parts for reassembling.
• Before disassembling, read instructions in advance, and determine if the service is required to be performed by an
authorized dealer.
• Use appropriate specialty tools and jigs if required.
• If parts can not be removed as specified by the procedure, never force removal. Check for other failures that may
be causing binding or interference.
• Inspect parts for wear and clearance; record the measured values. Replace components if the values fall outside
of the recommended range.
• If an abnormality is detected, repair or replace the parts.
• When removing parts, use appropriate markings or labels to ensure they can be reinstalled in the correct order and
location without confusion.
• For common parts, pay attention to the quantity and locations of each group of components.
48083741_EN 31/07/2018
16
INTRODUCTION
Reassembling hydraulic equipment

• Clean parts in a well ventilated room.
• Remove residual oil with compressed air, and apply fresh hydraulic oil or gear oil to surfaces before reassembly.
• Replace removed o-rings, back-up rings and oil seals with new ones. Apply gear oil on them before reassembling.
• Thoroughly clean and dry surfaces on which liquid sealant must be reapplied.
• Before assembling, remove rust preventives on new parts.
• Use special tools to fit bearings, bushing and oil seal.
• Assemble parts matching to the marks.
• After completion, check that there is no omission of parts.
48083741_EN 31/07/2018
17
INTRODUCTION
Basic instructions - Electrical equipment precautions

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

• Handle equipment with care so as not to drop it or bump
it.
• Connector should be removed by unlocking while hold-
ing the connector.
• Never disconnect electrical plugs by pulling on the
wires. Always use only the electrical connectors to
make the disconnection.
• Check that connector is connected and locked com-
pletely.
• Engine key off before removing and connecting connec-
tor.
• Engine key off before touching terminals of starter and
alternator.
• Wash machine with care so as not to splash water on
electrical equipment and connector.
• If water has entered a sealed connection, thoroughly
dry both connectors before reconnecting
• Remove battery grounding terminal before beginning
work close to battery and battery relay with tools.
48083741_EN 31/07/2018
18
INTRODUCTION
Torque - Minimum tightening torques for normal assembly

Use the torques in this chart when special torques are not given. These torques apply to plain and zinc-dichromate
fasteners as received from suppliers dry, or when lubricated with engine oil. Not applicable if special graphite lubri-
cants, Molydisulfide greases, or other extreme pressure lubricants are used. A torque range of ± 10% is acceptable.
Grade 8.8 bolts, nuts, and studs

Size Nm lb ft
4 mm 4 N·m 3 lb ft
5 mm 7 N·m 5 lb ft
6 mm 12 N·m 9 lb ft
10 mm 57 N·m 42 lb ft
12 mm 100 N·m 74 lb ft
14 mm 159 N·m 117 lb ft
16 mm 248 N·m 183 lb ft
18 mm 352 N·m 260 lb ft
20 mm 500 N·m 369 lb ft
22 mm 681 N·m 502 lb ft
24 mm 865 N·m 638 lb ft
27 mm 1262 N·m 931 lb ft
30 mm 1719 N·m 1268 lb ft
36 mm 2999 N·m 2212 lb ft
Markings for Grade 8.8 hardware
Grade 10.9 bolts, nuts and studs

Size Nm lb ft
4 mm 5 N·m 4 lb ft
10 mm 82 N·m 60 lb ft
12 mm 143 N·m 105 lb ft
14 mm 227 N·m 168 lb ft
16 mm 354 N·m 261 lb ft
18 mm 487 N·m 359 lb ft
20 mm 690 N·m 509 lb ft
22 mm 942 N·m 695 lb ft
24 mm 1195 N·m 882 lb ft
27 mm 1749 N·m 1290 lb ft
30 mm 2377 N·m 1753 lb ft
36 mm 4149 N·m 3061 lb ft
48083741_EN 31/07/2018
19
INTRODUCTION
Grade 12.9 bolts, nuts, and studs

Torque values specified for grade 10.9 hardware can be used for grade 12.9 hardware.
48083741_EN 31/07/2018
20
INTRODUCTION
Consumables
821G Capacities and specifications
Engine
Type of oil CASE AKCELA UNITEK NO. 1™ SBL CJ-4
Technical specifications SAE 10W-40
API CJ-4
CASE CONSTRUCTION specifications MAT3521
Type of oil CASE AKCELA UNITEK NO. 1™ SSL CJ-4 SAE 0W-40
(cold weather)
API CJ-4
Capacity (with filter change) 13.25 L (14 US qt)
Total capacity in system 15.1 L (16 US qt)
Cooling system
Type of coolant CASE AKCELA ACTIFULL™ OT EXTENDED LIFE
COOLANT
System capacity 30 L (32 US qt)
Fuel system
System capacity 288 L (76 US gal)
Hydraulic system
Type of fluid CASE AKCELA HY-TRAN® ULTRACTION
Technical specifications ISO VG-46
CASE CONSTRUCTION specifications MAT 3540
Type of fluid CASE AKCELA HY-TRAN® ULTRACTION SSL
(low temperature)
Total system capacity 178 L (47 US gal)
Reservoir capacity 90.8 L (24 US gal)
Transmission
Type of oil CASE AKCELA NEXPLORE™ FLUID
Technical specifications SAE 10W - 30
API GL-4
ISO VG-32/46
Service capacity - with filter change 34.1 L (36 US qt)
Axles
Type of oil CASE AKCELA TRANSAXLE FLUID 80W-140
API GL-4
Front axle (Standard and Heavy Duty) 40 L (42.3 US qt)
Rear axle (Standard and Heavy Duty) 40 L (42.3 US qt)
Grease fittings, as required CASE AKCELA MOLY GREASE
CASE CONSTRUCTION specifications MAT3550 Grade C
48083741_EN 31/07/2018
21
INTRODUCTION
921G Capacities and specifications

Engine
Type of oil CASE AKCELA UNITEK NO. 1™ SBL CJ-4
Technical specifications SAE 10W40
API CJ-4
Type of oil CASE AKCELA UNITEK NO. 1™ SSL CJ-4 SAE 0W-40
(cold weather)
API CJ-4
Capacity (with filter change) 13.25 L (14 US qt)
Total capacity in system 15.1 L (16 US qt)
Cooling system
Type of coolant CASE AKCELA ACTIFULL™ OT EXTENDED LIFE
COOLANT
System capacity 30 L (32 US qt)
Fuel system
System capacity 288 L (76 US gal)
Hydraulic system
Type of fluid CASE AKCELA HY-TRAN® ULTRACTION
Technical specifications ISO VG-46
Type of fluid CASE AKCELA HY-TRAN® ULTRACTION SSL
(low temperature)
Total system capacity 200 L (53 US gal)
Reservoir capacity 110 L (29 US gal)
Transmission
Type of oil CASE AKCELA NEXPLORE™ FLUID
Technical specifications SAE 10W - 30
API GL-4
ISO VG-32/46
Service capacity - with filter change 34.1 L (36 US qt)
Axles
Type of oil CASE AKCELA TRANSAXLE FLUID 80W-140
API GL-4
Front axle 42 L (44.4 US qt)
Rear axle 40 L (42.3 US qt)
Grease fittings, as required CASE AKCELA MOLY GREASE
CASE CONSTRUCTION specifications MAT3550 Grade C
48083741_EN 31/07/2018
22
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 do 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 six months with biodiesel blends in the fuel system. DO NOT store
biodiesel fuel in on-site storage tanks for more than six 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 six 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.
48083741_EN 31/07/2018
23
INTRODUCTION
Hydraulic contamination
Contamination in the hydraulic system is a major cause of the malfunction of hydraulic components. Contamination
is any foreign material in the hydraulic oil.
Contamination can enter the hydraulic system in several ways:

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

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

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

• Particles of metal or dirt in the oil
• Air in the oil
• Dark or thick oil
• Oil with an odor of burned oil
• Water in the oil
If you find contamination, use a portable filter to clean the hydraulic system.
48083741_EN 31/07/2018
24
INTRODUCTION
Product identification
The terms right-hand, left-hand, front, and rear are used
in this manual to indicate the sides as they are seen from
the operator's seat.
1. Front
2. Right-hand
3. Rear
4. Left-hand
RCPH10WHL003BAH 1
48083741_EN 31/07/2018
25
INTRODUCTION
Product identification
LEIL16WHL2487FA 1
1. Roll Over Protection System (ROPS) cab 5. Steps

2. Cab door handle 6. Bucket (Z-bar version)
3. Timed disconnect switch and optional battery jump post 7. Loader lift arms
4. Battery access 8. Bucket cylinder
48083741_EN 31/07/2018
26
INTRODUCTION
LEIL16WHL2486FA 2
1. Pre-cleaner 5. Bucket (Z-bar version)

2. Sliding access panel 6. Cab air filter door
3. Cab side window 7. Windshield washer reservoir
4. Driving lights
48083741_EN 31/07/2018
27
INTRODUCTION
48083741_EN 31/07/2018
28
SERVICE MANUAL
Engine

48083741_EN 31/07/2018
10
Contents
Engine - 10
[10.001] Engine and crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.1
[10.202] Air cleaners and lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.2
[10.400] Engine cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3
[10.414] Fan and drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.4
[10.310] Aftercooler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.5
[10.304] Engine lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.6
48083741_EN 31/07/2018
10
Engine - 10
Engine and crankcase - 001

48083741_EN 31/07/2018
10.1 [10.001] / 1
Contents
Engine - 10
TECHNICAL DATA
Engine
General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SERVICE
Engine
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
(*) See content for specific models
48083741_EN 31/07/2018
10.1 [10.001] / 2
Engine - Engine and crankcase
Engine - General specification

821G ZBAR - EH, NEW CAB TIER2 ANZ --- APAC --- LA --- MEA
Engine with 4 Speed Transmission

A. Low idle 870 RPM to 930 RPM
Alternate low idle 670 RPM to 730 RPM
Alternate accelerated idle 1270 RPM to 1330 RPM
Working idle (setting from factory) 920 RPM to 980 RPM
B. Maximum No Load RPM 2065 RPM to 2185 RPM
C. Converter Stall 1775 RPM to 1975 RPM
D. Hydraulic Stall 1915 RPM to 2115 RPM
E. Converter & Hydraulic Stall 1410 RPM to 1610 RPM
Temperature of the torque converter oil 82 – 104 °C (180 – 219 °F)
Temperature of the hydraulic oil 54 – 57 °C (129 – 135 °F)

NOTE: hydraulic Stall and Converter and Hydraulic Stall RPM values are read while the lift arms are rising with the
bucket held rolled back and the engine at Wide Open Throttle (WOT) in max power mode with transmission in manual
mode and in 3rd gear.
Engine - General specification



48083741_EN 31/07/2018
10.1 [10.001] / 3
NOTE: hydraulic Stall and Converter and Hydraulic Stall RPM values are read while the lift arms are rising with the
bucket held rolled back and the engine at Wide Open Throttle (WOT) in max power mode with transmission in manual
mode and in 3rd gear.
48083741_EN 31/07/2018
10.1 [10.001] / 4
Engine - Remove
1. Park the machine on a level surface and lower the
bucket to the ground. Put the articulation lock in
LOCKED position and stop the engine.
LEIL16WHL0048AB 1
2. Actuate the brake pedal several times to discharge the

brake accumulators.
LEIL15WHL0564AA 2
3. Put the key switch to ON position.

Press the hydraulic functions lock-out button to unlock
all hydraulic functions.
Move the control lever(s) back and forth at least 30
times to release any pressure from the hydraulic circuit.
Put the key switch to OFF position.
LEIL16WHL1286AA 3
4. Raise the grill located above the cooler box just behind
the cab. Then slowly loosen the hydraulic reservoir
filler cap to release pressure in the reservoir.
LEIL17WHL0028AB 4
48083741_EN 31/07/2018
10.1 [10.001] / 5
5. Locate the timed disconnect switch and hood raise

switch in the battery box.
Raise the engine hood and put the timed disconnect
switch to OFF position.
RCPH10WHL106AAH 5
6. Unhook the rubber T-handle (1) and raise the upper

panel (2). Make sure that the security levers are
blocked.
LEIL13WHL0137AB 6
7. Raise the right-hand and left-hand side panels (1).

Then remove the thumb screws (2) and inner fender
panels (3).
NOTE: right–hand side of the machine is shown. The op-
eration is similar for the left–hand side.
LEIL17WHL0027AB 7
8. Place a suitable container below the radiator drain plug,

remove the radiator cap and the radiator drain plug
to drain the engine coolant. Then reinstall the radi-
ator drain plug and the radiator cap after coolant has
drained.
NOTE: see machine specifications for cooling system vol-
ume.
LEIL16WHL0198AA 8
48083741_EN 31/07/2018
10.1 [10.001] / 6
9. Place a suitable container below the engine oil drain

plug. Remove the engine oil drain plug and drain oil
into container. Then reinstall the engine oil drain plug.
NOTE: see machine specifications for engine oil sump vol-
ume.
LEIL16WHL0198AA 9
10. Remove the drain hose (1) from the frame bracket (2).
LEIL16WHL1250AB 10
11. Remove the engine hood (refer to Engine hood - Re-

move (90.105)).
LEIL17WHL0026AB 11
12. Remove the overflow tank of the engine coolant.
LEIL16WHL0574AB 12
48083741_EN 31/07/2018
10.1 [10.001] / 7
13. Remove the support bracket of the engine coolant

overflow tank.
LEIL16WHL0575AB 13
14. Remove the cooling fan guard.
LEIL17WHL0137AB 14
15. Loosen the four bolts to remove the engine guard (1).
LEIL17WHL0118AB 15
16. Disconnect the crankcase vent hose from the engine.
LEIL17WHL0136AB 16
48083741_EN 31/07/2018
10.1 [10.001] / 8
17. Remove the clamps (3) that secure the crankcase

vent hose (2) to the brackets (1). Remove the brack-
ets (1) from the engine.
LEIL17WHL0133AB 17
LEIL17WHL0119AB 18
18. Remove the clamp to disconnect the air cleaner from

the engine.
LEIL17WHL0135AB 19
19. Tag and disconnect the AFS2 connector (4) from the
air cleaner (3).
Remove the hardware (1) to unfix the air cleaner sup-
port bracket (2) from the rear chassis.
Remove the air cleaner assembly from the machine.
LEIL17WHL0120AB 20
48083741_EN 31/07/2018
10.1 [10.001] / 9
20. Remove the drive belt from the engine.
LEIL17WHL0117AB 21
21. Tag and disconnect the ACT connector from the air-
conditioning compressor clutch and ALT_5, ALT_B
connectors from the alternator.
Remove the alternator (2) and air-conditioning com-
pressor (1).
LEIL17WHL0116AB 22
22. Remove the clamp (2) that secures the heater supply
hose (1) to the flywheel cover.
Tag and disconnect the heater supply hose (1) from
the engine.
LEIL17WHL0115AB 23
23. Remove the clamps that secure the cables to the en-
gine.
LEIL16WHL0570AB 24
48083741_EN 31/07/2018
10.1 [10.001] / 10
24. Tag and disconnect the ST, CPWR and battery posi-
tive cables (1) from the engine starter.
Tag and disconnect the negative battery cable (2),
ground strap (3) and XM1C cable (4) from the engine
starter.
Tag and disconnect the GND_ENG1, GND_ENG3,
GND_ENG4 cables (5) and GND_CENG1,
GND_CENG2 cables (6) from the engine.
LEIL17WHL0114AB 25
25. Tag and disconnect the breather line (hose and vent-
ing check valve) from the engine.
LEIL17WHL0094AB 26
26. Remove the U-bolt clamp to unfix the top cooling line
from the muffler support structure.
LEIL17WHL0095AB 27
27. Remove the clamps (2) to disconnect the top cooling

line (1) from the elbow hose and engine. Tag the hose.
LEIL17WHL0093AB 28
48083741_EN 31/07/2018
10.1 [10.001] / 11
28. Remove the clamp (2) to disconnect the bottom en-

gine coolant line (1) from the engine. Tag the hose.
LEIL17WHL0092AB 29
29. Remove the clamps (2) to disconnect the turbo outlet

air cooling line (1) from the charge air cooler and en-
gine. Tag the hose.
LEIL17WHL0091AB 30
30. Remove the clamps (2) to disconnect the air intake

cooling line (1) from the charge air cooler and engine.
Tag the hose.
LEIL17WHL0090AB 31
48083741_EN 31/07/2018
10.1 [10.001] / 12
31. Tag and disconnect the fuel pre-filter to engine hose

(8) from the engine.
32. Remove the clamp (7) that secures the fuel tank suc-
tion hose to the rear muffler support.
33. Tag and disconnect the WIF connector (9) and WSH
connector (6) from the fuel pre-filter (4).
34. Tag and disconnect the fuel pre-filter (4) from the sup-
port bracket.
Tag the GRD_WIF wire (5).
35. Remove the fuel pre-filter support bracket (3) from the
rear muffler support.
LEIL17WHL0055AB 32
36. Remove the cable ties that secure the wires to the rear
muffler support.
Tag and disconnect the wires (2) from the alarm
back-up (1).
Remove the alarm back-up (1) from the rear muffler
support.
37. Remove the clamp (2) to disconnect the end of the
exhaust system pipe (1) from the engine.
LEIL17WHL0054AB 33
48083741_EN 31/07/2018
10.1 [10.001] / 13
38. Attach a suitable lifting device to the exhaust system

assembly (1) (including muffler, pipe, support brack-
ets).
Remove the hardware at the noted six locations to
unfix the exhaust system assembly (1) from the rear
chassis.
Lift and remove the exhaust system assembly (1) from
the machine.
NOTE: be sure all wire harness connections and hoses are
out of the way.
LEIL17WHL0053BB 34
LEIL17WHL0051AB 35
39. Remove the nuts (3) and studs (2) to disconnect the
engine starter (1) from the engine.
LEIL17WHL0052AB 36
48083741_EN 31/07/2018
10.1 [10.001] / 14
40. Tag and disconnect the EDC7 connector from the En-
gine Controller Unit (ECU).
LEIL17WHL0050AB 37
41. Tag and disconnect the FFH connector from the fuel
filter.
LEIL17WHL0049AB 38
42. Remove the clamp (1) to release the fuel return hose
(2). Tag and disconnect the fuel return hose (2) from
the fuel filter.
LEIL17WHL0046AB 39
43. At the noted location remove the clamp to release the

fuel tank suction hose.
LEIL17WHL0086AB 40
48083741_EN 31/07/2018
10.1 [10.001] / 15
44. Remove the upper and lower drive shaft dust covers.
LEIL17WHL0048AB 41
45. Remove the bolts to disengage the drive shaft from

the engine coupling.
LEIL17WHL0047AB 42
46. Connect a vacuum pump to the hydraulic reservoir

and turn it on. Tag and disconnect the suction hose
(2), pressure hose (4) and attenuator hose (3) from the
brake pump (1). Remove the brake pump (1) (refer to
Brake pump - Remove (33.202)). Turn off and dis-
connect the vacuum pump from the hydraulic reser-
voir.
LEIL17WHL0045AB 43
48083741_EN 31/07/2018
10.1 [10.001] / 16
47. Connect a suitable lifting equipment to the engine

mounts (1). Take up all slack in lifting equipment.
Remove the engine mount bolts (2).
48. Slowly raise the engine from the rear chassis. Make
sure all wire harness connections and hoses have
been disconnected and are clear of the engine. Guide
the oil drain hose from the frame as the engine is lifted.
Remove the engine from machine.
LEIL17WHL0034AA 44
LEIL17WHL0035AA 45
48083741_EN 31/07/2018
10.1 [10.001] / 17
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
RAIL12WEL0130FA 1
1. Engine mount bolt 5. Washers

2. Washer 6. Washer
3. Upper isolator 7. Nut
4. Lower isolator 8. Remote oil drain hose
1. Inspect the engine mounts. If the engine rubber isola-

tors require replacement, remove and discard the up-
per isolators (3) and lower isolators (4). Install new up-
per isolators (3) and new lower isolators (4).
48083741_EN 31/07/2018
10.1 [10.001] / 18
2. Attach a suitable lifting device to the engine mounts

(1) and slowly move the engine into position over the
rear chassis. Make sure all harness connections and
hoses are out of the way or positioned correctly for
reconnecting, before lowering the engine.
3. Fix the engine to the rear chassis. Torque the engine
mount bolts (2) to 244 – 298 N·m (180 – 220 lb ft).
4. Disconnect the lifting equipment from the engine
mounts.
LEIL17WHL0034AA 2
LEIL17WHL0035AA 3
5. Connect a vacuum pump to the hydraulic reservoir and

turn it on. Install the brake pump (1). Connect the
suction hose (2), pressure hose (4) and attenuator hose
(3) to the brake pump following the tags applied during
removal (refer to Brake pump - Install (33.202)). Turn
off and disconnect the vacuum pump from the hydraulic
reservoir.
LEIL17WHL0045AB 4
6. Connect the engine oil drain hose (1) to the frame

bracket (2).
LEIL16WHL1250AB 5
48083741_EN 31/07/2018
10.1 [10.001] / 19
7. Position the drive shaft on the engine coupling. In-

stall the six bolts (4–speed transmission) or eight bolts
(5–speed transmission) to secure the drive shaft to the
engine coupling.
NOTE: the figure shows the machine with 5–speed trans-
mission.
LEIL17WHL0047AB 6
8. Tighten to 86 – 94 N·m (63 – 69 lb ft) (821G, 4–speed

transmission).
Tighten to 85 – 94 N·m (63 – 69 lb ft) (621G, 721G,
921G, 4–speed transmission and 721G 5–speed trans-
mission).
Follow the bolt installation pattern in figure.
LEIL17WHL1383AA 7
9. Tighten to 130 – 140 N·m (96 – 103 lb ft) (621G, 821G,

921G, 5–speed transmission).
LEIL17WHL1382AA 8
10. Install the upper and lower drive shaft dust covers.
Torque to 20 – 27 N·m (15 – 20 lb ft).
LEIL17WHL0048AB 9
48083741_EN 31/07/2018
10.1 [10.001] / 20
11. At the noted location install additional spacer and

clamp to route the fuel tank suction hose.
LEIL17WHL0086AB 10
12. Install the clamp (1) to secure the fuel return hose (2).
13. Connect the fuel line (2) to the top of the fuel filter.
LEIL17WHL0046AB 11
14. Connect the FFH connector to the fuel filter.
LEIL17WHL0049AB 12
15. Connect the EDC7 connector to the Engine Controller

Unit (ECU).
NOTE: start the connector on the ECU with lever straight
out from ECU. Use a lever to pull connector into position.
LEIL17WHL0050AB 13
48083741_EN 31/07/2018
10.1 [10.001] / 21
16. Mount the engine starter (1). Firstly install the short
threaded portion of the three studs (2) into the flywheel
housing. Apply Loctite 747 primer to the studs and
holes. Apply two drops of LOCTITE® 271™ to each
hole and stud assemble and torque immediately to 19
– 29 N·m (14 – 21 lb ft). Allow Loctite adhesive to cure
20 min before installing the starter. Install the engine
starter (1). Torque the three starter mounting nuts (3)
to 40 – 50 N·m (29 – 37 lb ft).
LEIL17WHL0052AB 14
17. Connect a suitable lifting device to the exhaust system

assembly (1) (including muffler, pipe, support brack-
ets) and carefully lift it. Position and lower the exhaust
system assembly (1) over the rear chassis of the ma-
chine.
NOTE: be sure all wire harness connections and hoses are
out of the way.
18. Install the muffler support brackets to the rear chassis
with six bolts and washers (arrows).
LEIL17WHL0053BB 15
LEIL17WHL0051AB 16
48083741_EN 31/07/2018
10.1 [10.001] / 22
19. Fix the end of the exhaust system pipe (1) to the en-
gine with a new clamp (2). Tighten the clamp to 5.7 –
6.3 N·m (4.2 – 4.6 lb ft).
LEIL17WHL0054AB 17
20. Install the alarm back-up (1) to the rear muffler support
with four bolts, washers (under bolt head and nut) and
nuts. Connect wire O_JB of connector BU1 to “NEG”
and 35 A of connector BU2 to “H1” (2) of alarm back-
up. Secure the wire to the rear muffler support with
cable ties.
21. Install the fuel pre-filter support bracket (3) to the rear
muffler support with two bolts, washers (under bolt
head and nut) and nuts.
22. Install the fuel pre-filter (4) to the support bracket with
two bolts, washers (under bolt head and nut) and nuts.
At this time connect the GRD_WIF wire (5) by using
the same hardware. LEIL17WHL0055AB 18
23. Connect the WIF connector (9) and WSH connector

(6) to the fuel pre-filter.
24. Use the clamp (7) to secure the fuel tank suction hose
to the rear muffler support.
25. Connect the fuel pre-filter to engine hose (8) to the
engine.
26. Install the air intake cooling line (1) with clamps.
Torque the clamps (2) at the ends mating the charge
air cooler and engine to 10.1 – 11.3 N·m (7.4 – 8.3 lb
ft).
NOTE: ensure clearance of 16.5 – 26.5 mm between the
charge air intake tube and the muffler.
LEIL17WHL0090AB 19
48083741_EN 31/07/2018
10.1 [10.001] / 23
27. Install the turbo outlet air cooling line (1) with clamps.
Torque the clamp at the end mating the charge air
cooler to 10.1 – 11.3 N·m (7.4 – 8.3 lb ft). Install a
new O-ring at the end mating the engine and torque
the clamp (2) to 5.8 – 7.8 N·m (4.3 – 5.8 lb ft).
LEIL17WHL0091AB 20
28. Connect the bottom engine coolant line (1) to the en-
gine with the clamp (2). Torque the clamp to 10.1 –
11.3 N·m (7.4 – 8.3 lb ft).
LEIL17WHL0092AB 21
29. Install the top cooling line (1) with clamps (2). Torque
the clamps at the ends mating the elbow hose and
engine to 10.1 – 11.3 N·m (7.4 – 8.3 lb ft).
LEIL17WHL0093AB 22
30. Fix the top cooling line to the muffler support structure
with U-bolt clamp.
LEIL17WHL0095AB 23
48083741_EN 31/07/2018
10.1 [10.001] / 24
31. Install the breather line (hose and venting check valve)
to the engine. Tighten the clamp to 3.4 N·m (2.5 lb ft)
LEIL17WHL0094AB 24
32. Install the ST, CPWR and battery positive cables (1) to
the engine starter. Torque the nut to 22.5 – 29.4 N·m
(16.6 – 21.7 lb ft).
Install the negative battery cable (2), ground strap (3)
and XM1C cable (4) to the engine starter.
Install the GND_ENG1, GND_ENG3, GND_ENG4 ca-
bles (5) and GND_CENG1, GND_CENG2 cables (6)
to the engine. Torque the nuts to 22 – 24 N·m (16.2 –
17.7 lb ft).
LEIL17WHL0114AB 25
33. Secure the cables to the engine with clamps.
LEIL16WHL0570AB 26
34. Install the heater supply hose (1) to the engine. Se-
cure the hose to the flywheel cover with clamp (2) and
existing hardware.
LEIL17WHL0115AB 27
48083741_EN 31/07/2018
10.1 [10.001] / 25
35. Install the air-conditioning compressor (1) and the al-

ternator (2). Connect the ACT connector to the air-
conditioning clutch and the ALT_5, ALT_B connectors
to the alternator.
LEIL17WHL0116AB 28
36. Acting the automatic belt tensioner and install the

drive belt. Verify the correct tension using the tool
380001325. The correct tension for a new belt is:
623 – 712 N·m (459.5 – 525.1 lb ft). Tension for a
used belt is 400 – 534 N·m (295 – 393.9 lb ft) to be
squeezed 20 mm (0.8 in) maximum.
LEIL17WHL0117AB 29
37. Install the air cleaner assembly (3) to the machine.

Fix the bracket (2) to the rear chassis with fours bolts,
washers (under bolt head and nut), nuts (1) (only two
locations visible in figure).
Connect the AFS2 connector (4) to the air cleaner (3).
LEIL17WHL0120AB 30
38. Connect the air cleaner to the engine with clamp.

Torque the clamp to 3.5 – 4 N·m (2.6 – 3 lb ft).
LEIL17WHL0135AB 31
48083741_EN 31/07/2018
10.1 [10.001] / 26
39. Install the bracket (1) to the engine with two bolts,
washers, spacers (4) and two bolts, washers (5). Fix
the crankcase vent hose (2) to the bracket (2) with
clamp (3).
LEIL17WHL0134AB 32
40. Install the bracket (1) in place of the lift eye on the
engine. Fix the crankcase vent hose (2) to the bracket
(1) with clamp (3).
LEIL17WHL0133AB 33
41. Connect the crankcase vent hose to the engine.
LEIL17WHL0136AB 34
42. Install the engine guard (1) at the four locations.
LEIL17WHL0118AB 35
48083741_EN 31/07/2018
10.1 [10.001] / 27
43. Install the cooling fan guard.
LEIL17WHL0137AB 36
44. Install the support bracket of the engine coolant over-

flow tank.
LEIL16WHL0575AB 37
45. Install the overflow tank of the engine coolant.
LEIL16WHL0574AB 38
46. Follow the procedure in Engine hood - Install

(90.105) to install the engine hood.
LEIL17WHL0026AB 39
48083741_EN 31/07/2018
10.1 [10.001] / 28
47. Make sure the engine oil drain cap is secured. Refill
with suitable engine oil.
LEIL16WHL0198AA 40
48. Make sure the engine coolant drain cap is secured.

Refill the cooling system with a 50% CASE AKCELA
ACTIFULL™ OT EXTENDED LIFE COOLANT and
50% water solution. Install the radiator cap.
LEIL16WHL0198AA 41
49. Put the timed disconnect switch to the ON position.
RCPH10WHL106AAH 42
50. Start the engine and run it at low idle. Run the engine
at operating temperature for approximately 5 min 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 reser-
voir.
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.
48083741_EN 31/07/2018
10.1 [10.001] / 29
51. Install the left–hand and right–hand side inner fender

panels (3) using the thumb screws (2), then lower
left–hand and right–hand side panels (1). Close the
hood.
LEIL17WHL0027AB 43
52. Lower the upper panel (2) and hook the rubber T-han-
dle (1).
LEIL13WHL0137AB 44
48083741_EN 31/07/2018
10.1 [10.001] / 30
Engine - Test
During these tests the engine runs at full throttle and
works against the torque converter, the hydraulic sys-
tem, or both the torque converter and the hydraulic sys-
tem. The results of these tests will show if the cause of
poor performance is one or more of the following: (1)
engine, (2) torque converter or transmission, and (3)
hydraulic system.
48083741_EN 31/07/2018
10.1 [10.001] / 31
Index
Engine - 10

Engine - General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Engine - General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Engine - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Engine - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Engine - Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
48083741_EN 31/07/2018
10.1 [10.001] / 32
Engine - 10
Air cleaners and lines - 202

48083741_EN 31/07/2018
10.2 [10.202] / 1
Contents
Engine - 10
SERVICE
Air pre-cleaner
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Air cleaner
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
48083741_EN 31/07/2018
10.2 [10.202] / 2
Engine - Air cleaners and lines
Air pre-cleaner - Cleaning

NOTE: the following cleaning procedure refers to the full view precleaner.
1. Access to the pre-cleaner located on top of the engine
compartment hood.
2. Remove the wing nut.
LEIL16WHL0565AB 1
3. Remove the pre-cleaner assembly from the machine.
LEIL16WHL0696AA 2
4. Empty debris and wipe the pre-cleaner with a damp

clean cloth. Reassemble and install the assembly on
the machine.
LEIL16WHL0695AA 3
48083741_EN 31/07/2018
10.2 [10.202] / 3
Air cleaner - Remove

Primary/secondary filter element disassembly
1. Locate the timed disconnect switch and hood raise
switch in the battery box.
Raise the engine compartment hood. Locate the air
filter housing/element (arrow) on the left-hand side of
the engine.
Turn the timed disconnect switch to OFF position.
LEIL17WHL0138AB 1
2. Release all the clips (arrows) securing the housing

cover of the air filter element. Remove the cover (1)
from the housing of the air filter element.
LEIL17WHL0139AB 2
3. Remove the primary filter element. To do this, push the

filter element down to loosen the filter seal. Then pull
up the handle to lift the filter element out of the housing.
LEIL17WHL0140AB 3
4. Remove the 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.
LEIL13WHL0182AA 4
48083741_EN 31/07/2018
10.2 [10.202] / 4
Air cleaner - Install

1. Install a new secondary filter element.
NOTE: make sure that the filter element is positioned cor-
rectly in the slot and firmly seated into the housing.
LEIL13WHL0182AA 1
2. Install a new primary filter element by sliding it down

into housing. With the handle, pull the filter element
rearward to make the seal engage in the housing.
NOTE: make sure that the primary and the secondary filter
elements form an effective seal.
LEIL17WHL0140AB 2
3. Install the housing cover (1).

Lock the clips (arrows) to secure the filter housing
cover.
NOTE: if the cover does not fit properly, recheck the filter
element installation. The cover will be difficult to install if
the filter elements are not properly installed.
LEIL17WHL0139AB 3
4. Turn the timed disconnect switch to ON position. Lower

the engine hood.
Clear any fault codes. Start the machine and confirm
issue has been corrected.
LEIL17WHL0156AB 4
48083741_EN 31/07/2018
10.2 [10.202] / 5
Index
Engine - 10

Air cleaner - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Air cleaner - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Air pre-cleaner - Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
48083741_EN 31/07/2018
10.2 [10.202] / 6
Engine - 10
Engine cooling system - 400

48083741_EN 31/07/2018
10.3 [10.400] / 1
Contents
Engine - 10
SERVICE
Radiator
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
48083741_EN 31/07/2018
10.3 [10.400] / 2
Engine - Engine cooling system
Radiator - Remove
bucket to the ground. Shut down the engine. Place
the articulation lock in LOCKED position.
2. Put the timed disconnect switch to OFF position.
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.
LEIL17WHL0161AB 1
4. Remove the mounting screws for the left-hand side

panel. Remove the left-hand side panel.
RAIL12WEL0097AA 2
RAIL12WEL0098AA 3
48083741_EN 31/07/2018
10.3 [10.400] / 3
5. Remove the thumb screw and the washer (1) secur-

ing the left-hand inner fender panel (2). Remove the
fender.
LEIL17WHL0157AB 4
6. Remove the radiator cap (1).

7. Place a suitable container below the radiator drain cap
(arrow). Remove the drain cap and drain the coolant
into the container. Install and secure both caps after
coolant has drained.
8. Release the catch (2) and tilt the air conditioning con-
denser core up.
Disconnect the overflow hose (3) from radiator.
LEIL17WHL0159AB 5
LEIL16WHL0198AA 6
9. Loosen the clamp of the upper radiator hose. Remove

the hose from radiator.
LEIL17WHL0160AB 7
48083741_EN 31/07/2018
10.3 [10.400] / 4
10. Remove the coolant overflow tank.
LEIL16WHL0574AB 8
11. Remove the support bracket of the coolant overflow

tank.
LEIL16WHL0575AB 9
12. Remove the clamp that secures the electrical connec-

tor to the fan guard. Remove the fan guard.
LEIL17WHL0137AB 10
13. Loosen the clamp of the lower radiator hose. Remove

the lower radiator hose from the radiator.
LEIL17WHL0158AB 11
48083741_EN 31/07/2018
10.3 [10.400] / 5
14. Remove the bolts (1) and install suitable lifting eyes.
NOTE: for added lifting support, use bolts with a longer
thread than the bolts removed from the radiator.
15. Attach a suitable lifting equipment to the lifting eyes.
16. Remove the mounting bolts (2) to unfix the radiator
from the cooling frame.
LEIL17WHL0162AB 12
17. Carefully lift the radiator from the machine.
RAIL12WEL0114AA 13
48083741_EN 31/07/2018
10.3 [10.400] / 6
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.
Failure to comply could result in minor or moderate injury.
C0043A
1. Using a suitable lifting device, position the radiator

above the cooling box frame.
RAIL12WEL0114AA 1
2. Carefully lower the radiator while guiding it into position

on the cooling box frame. Install the bolts, washers and
nuts (2) to fix the radiator to the cooling box frame.
3. Disconnect the lifting equipment from lifting eyes. Re-
move the lifting eyes. Reinstall the original bolts (1).
LEIL17WHL0162AB 2
4. Connect the lower radiator hose to the radiator with

clamp. Torque the clamp to 10.1 – 11.3 N·m (89 –
100 lb in).
LEIL17WHL0158AB 3
48083741_EN 31/07/2018
10.3 [10.400] / 7
5. Install the fan guard. Install the clamp that secures the
electrical connector to the fan guard.
LEIL17WHL0137AB 4
6. Install the support bracket of the coolant overflow tank.
LEIL16WHL0575AB 5
7. Install the coolant overflow tank.
LEIL16WHL0574AB 6
8. Connect the upper radiator hose to the radiator with

clamp. Torque the clamp to 10.1 – 11.3 N·m (89 –
100 lb in).
LEIL17WHL0160AB 7
48083741_EN 31/07/2018
10.3 [10.400] / 8
9. Connect the overflow hose to the radiator.
LEIL17WHL0163AB 8
10. Position the inner fender so that it is behind the fender

mounting bolt.
RAIL12WEL0106AA 9
11. Align the hole in the inner fender panel on the bolt.
RAIL12WEL0108AA 10
48083741_EN 31/07/2018
10.3 [10.400] / 9
12. Align the slots in the inner fender panel with the tabs
on the machine chassis.
RAIL12WEL0110AA 11
13. Push the fender (2) towards the front of the machine
and secure it using the thumb screw and washer (1).
LEIL17WHL0157AB 12
48083741_EN 31/07/2018
10.3 [10.400] / 10
14. Apply LOCTITE® 242® to the threads, install the

mounting screws for the side panel and torque to 3.5
– 9.5 N·m (31 – 84 lb in).
RAIL12WEL0097AA 13
RAIL12WEL0098AA 14
15. Check that the coolant drain cap is tightened.
LEIL16WHL0198AA 15
16. Fill the engine coolant system with a pre-diluted solu-

tion of CASE AKCELA ACTIFULL™ OT EXTENDED
LIFE COOLANT. The cooling system capacity is
28.4 L (7.5 US gal).
48083741_EN 31/07/2018
10.3 [10.400] / 11
17. Install the radiator cap
LEIL17WHL0164AB 16
18. Fill the coolant tank up to the FULL mark on the reser-
voir.
LEIL16WHL0574AB 17

20. Start the engine and run the engine at low idle. Run
the engine at operating temperature for approximately
5 min to completely mix the CASE AKCELA ACTI-
FULL™ OT EXTENDED LIFE COOLANT. When the
coolant is at operating temperature, stop the engine.
When engine has cooled, check the coolant level at
the tank.
21. Close up all open body panels. Then put the articula-
tion lock in the OPERATING position.
48083741_EN 31/07/2018
10.3 [10.400] / 12
Index
Engine - 10

Radiator - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Radiator - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
48083741_EN 31/07/2018
10.3 [10.400] / 13
48083741_EN 31/07/2018
10.3 [10.400] / 14
Engine - 10
Fan and drive - 414

48083741_EN 31/07/2018
10.4 [10.414] / 1
Contents
Engine - 10
Fan and drive - 414
FUNCTIONAL DATA
Reverse fan control system

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

Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
48083741_EN 31/07/2018
10.4 [10.414] / 2
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 models 521G, 621G, 721G, 821G and 921G. The hydraulic reservoir is located at the
rear of the cab. The cooling system module includes the radiator, the engine charge air cooler, the hydraulic oil cooler,
the transmission oil cooler, the fuel cooler and the Air Conditioning (AC) condenser. The air flow enters the cooling
system module from both the right-hand and left-left sides of the machine as well as the top. On the small models the
air flow exits into the engine compartment.
Fan Hydraulic Function

The fan and brake pump (36) is used to charge the brake valve (13) and to drive the fan motor (43). 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.
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 ( 23 cm³) 43 – Fan motor ( 23 cm³ )
48083741_EN 31/07/2018
10.4 [10.414] / 3
RCPH11WHL032HAN 1
Non-Reversible Fan Circuit
48083741_EN 31/07/2018
10.4 [10.414] / 4
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. 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 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 Universal Control Module (UCM) controls the fan reverser valve. The AUTO function can be selected
within the display. The AUTO fan operating mode is activated in the Machine settings|Fan screen menu of the display.
In addition to the Auto Fan mode selection in the display, there is a Fan reverser switch in the keypad in the cab. This
switch allows the operator to override the auto fan reverse feature. The MANUAL position of the switch is momentary
contact. In the MANUAL position the operator controls how often that the fan reverses to clear debris. In the AUTO
mode the fan speed is regulated by a proportional solenoid valve (45B) depending on system temperatures. Also
with the switch in the AUTO position, the UCM will initiate a reverse fan cycle, as long as the engine speed is greater
than 1600 RPM and the fan reverser interval time limit has been met. In the OFF mode the fan will operate at full
speed and will not reverse unless manually selected. If either MANUAL or AUTO mode is selected, the fan reversal
is disabled if hydraulic oil temperature is below 10 °C (50 °F).
LEIL16WHL2621FB 2
NOTE: all multifunction keypad buttons are momentary switches with LED indicator of current status. When the LED
is ON the corresponding function is activated.
48083741_EN 31/07/2018
10.4 [10.414] / 5
1. Fan reverser
To use the fan reverser let the machine idle in NEUTRAL. Press and hold the fan reverser button and
press the throttle to high idle for a minimum of 10 s or until debris stops blowing out of the coolers.
Return the machine to idle and release the fan reverser button. Press the fan reverser function to
turn ON/OFF the automatic reversing function.
LED color: green.
→ Fan selections
Auto Fan
Fan Reverser Interval
Fan Reverser Duration
LEIL15WHL0532AA 3
When the display AUTO Fan mode is active:

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

• Fan speed is set to 100% for that particular model.
• Fan reversing by activating the MANUAL reverse switch on the keypad.
This reverser valve also has the ability to control the fan rotating speed. The UCM controls the fan reverser valve.
Based on a Pulse Width Modulated (PWM) electrical input from the UCM to the fan speed control solenoid valve
(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 UCM to the speed control solenoid (45B) varies based on temperature inputs to the UCM from the engine
coolant, engine intake air, transmission, hydraulic circuit temperatures and status of AC switch. The fan speed control
valve (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 UCM regulates the PWM signal to the speed control solenoid (45B). This
dampens the shocks as the blades reverse.
48083741_EN 31/07/2018
10.4 [10.414] / 6
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 ( 23 cm³) 43 – Fan motor ( 23 cm³)
RCPH11WHL043GAN 4
48083741_EN 31/07/2018
10.4 [10.414] / 7
Forward Fan Drive

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 UCM controls the fan reverser valve. The AUTO mode must be selected within
the display for the fan speed and auto reverse feature to function. The display AUTO fan operating mode is activated
in the Machine settings|Fan screen menu of the display.
contact. In the MANUAL position the operator controls how often that the fan reverses to clear debris. In the AUTO
mode the fan speed is regulated by a proportional solenoid valve (45B) depending on system temperatures. Also
with the switch in the AUTO position, the UCM will initiate a reverse fan cycle, as long as the engine speed is greater
than 1600 RPM and the fan reverser interval time limit has been met. In the OFF mode the fan will operate at full
speed and will not reverse unless manually selected. If either MANUAL or AUTO mode is selected, the fan reversal
is disabled if hydraulic oil temperature is below 10 °C (50 °F).
48083741_EN 31/07/2018
10.4 [10.414] / 8
RCPH11WHL033HAN 5
Fan Drive – Forward
13– Oil flow from brake valve 43 – Fan drive motor ( 23 cm³) 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
48083741_EN 31/07/2018
10.4 [10.414] / 9
Reverse Fan Drive

An electrical signal can be sent from the UCM 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 UCM controls the fan reverser valve. The AUTO fan mode must be
selected for the fan speed and auto reverse feature to function. The display AUTO fan operating mode is activated in
the Machine settings|Fan screen menu of the display.
contact. In the MANUAL position the operator controls how often that the fan reverses to clear debris. While holding
the MANUAL REVERSE position of the switch, if either the engine or hydraulic temperature increases by more than
3 °C (37.4 °F) the fan will revert back to the forward direction. In the AUTO mode the fan speed is regulated by a
proportional solenoid valve (45B) depending on system temperatures. Also with the switch in the AUTO position, the
UCM will send a reverse signal to the reverse solenoid valve (45A) to initiate a reverse fan cycle as long as the engine
speed is greater than 1600 RPM and the fan reverser interval time limit has been met. In the OFF position the fan will
operate at full speed for that model and will not reverse unless manually selected. If either MANUAL or AUTO mode
is selected, the fan reversal is disabled if hydraulic oil temperature is below 10 °C (50 °F).
48083741_EN 31/07/2018
10.4 [10.414] / 10
RCPH11WHL034HAN 6
Fan Drive – Reverse
13– Oil flow from brake valve 43 – Fan drive motor ( 23 cm³) 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
48083741_EN 31/07/2018
10.4 [10.414] / 11
Reverse fan control system - Remove

LOCKED position. Stop the engine.
2. With the engine NOT running, pump the brake repeat-
edly to be sure the brake accumulators have no hy-
draulic pressure, then move the loader control lever
back and forth several times to release any hydraulic
pressure in the pilot control circuit.
3. Slowly loosen the filler cap on the hydraulic reservoir
to release the air pressure in the reservoir. Connect
a vacuum pump to the hydraulic reservoir, turn on the
pump.
4. Raise the hood. Lift the left-hand hood panel.
5. Remove the fluted knob (1) with related hexagonal bolt
and washer to separate the left-hand inner fender panel
(2) from the rear chassis.
LEIL17WHL0157AB 1
6. Remove the bolt (1) with related washer. Remove the

left-hand inner fender panel (2) from the machine.
LEIL16WHL0823AB 2
7. Remove the clamp from the fan guard to release the

electrical connector.
LEIL17WHL0165AB 3
48083741_EN 31/07/2018
10.4 [10.414] / 12
8. Remove the fan guard.
LEIL17WHL0137AB 4
9. Remove the nut (1) and the related washer. Separate

the fan (2) from the fan drive motor. Move the fan (2)
in the engine compartment in order to obtain sufficient
access to the fan drive motor.
LEIL17WHL0166AB 5
10. Disconnect the fan forward hose (1) and the fan re-
verse hose (2). Install protective plugs to the hoses to
prevent entry of foreign matter into hydraulic system.
LEIL16WHL0816AB 6
11. Disconnect the fan motor drain tube (1). Install a pro-
tective plug to the hoses to prevent entry of foreign
matter into hydraulic system.
LEIL17WHL1438AB 7
48083741_EN 31/07/2018
10.4 [10.414] / 13
12. Disconnect the 90° elbow (1), the hydraulic connec-

tors (2), (3) and (4) from the fan drive motor (5). Dis-
connect the connector (6) from the speed sensor (7)
installed on the fan motor.
LEIL17WHL1437AB 8
13. Loosen the two bolts (1), with related washers to sep-
arate the fan drive motor (2) from the cooling frame.
LEIL17WHL1410AB 9
48083741_EN 31/07/2018
10.4 [10.414] / 14
Reverse fan control system - Install

1. Install the nuts (1) with the relevant washers to lock the
fan drive motor (2) on the cooling frame.
LEIL17WHL1410AB 1
2. Connect the hydraulic connectors (2), (3) and (4) to the

fan drive motor (5).
Connect the connector (6) to the speed sensor (7) in-
stalled on the fan drive motor.
3. Connect the 90° elbow (1) to the hydraulic connector
(2).
LEIL17WHL1437AB 2
4. Install the fan motor drain tube (1).
LEIL17WHL1438AB 3
5. Remove the protective plugs from the forward hose (1)

and the fan reverse hose (2). Connect the forward hose
(1) and the fan reverse hose (2). Tighten the hoses (1)
and (2) to 90 – 99 N·m (66.4 – 73 lb ft).
LEIL16WHL0816AB 4
48083741_EN 31/07/2018
10.4 [10.414] / 15
6. Install the nut (1) with the relevant washer to lock the
fan (2) on the cooling frame. Tighten the nut (2) to 50
– 55 N·m (36.9 – 40.6 lb ft).
LEIL17WHL0166AB 5
7. Install the fan guard on the cooling frame.
LEIL17WHL0137AB 6
8. Install the clamp to secure the electrical connector to

the fan guard.
LEIL17WHL0165AB 7
9. Place the left-hand inner fender panel (2) in the correct

position on the rear chassis. Install the fluted knob (1)
with related hexagonal bolt and washer.
LEIL17WHL0157AB 8
48083741_EN 31/07/2018
10.4 [10.414] / 16
10. Tighten the bolt (1) with related washer to fix the left-
hand inner fender panel (2).
LEIL16WHL0823AB 9
11. Install the left-hand inner fender panel.

Lower the engine hood.
48083741_EN 31/07/2018
10.4 [10.414] / 17
Reverse fan control system - Test

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

item. Press the enter/confirm key to access the selec-
tion screen.
LEIL16WHL0874AA 2
48083741_EN 31/07/2018
10.4 [10.414] / 18
5. Use up or down arrow to select the Fan Test item.
LEIL16WHL0899AA 3
6. Use left or right arrow to select the Fan speed %. Press

the enter/confirm key to start the Fan Test.
LEIL16WHL0899AA 4
For 821G, the fan speed with engine at full throttle

should be within the following range:
• Maximum fan speed at 100%: 1500 – 1550 RPM
For 921G, the fan speed with engine at full throttle
should be within the following range:
LEIL16WHL0901AA 5
7. Press the enter/confirm key to terminate the test and

return to the main menu.
48083741_EN 31/07/2018
10.4 [10.414] / 19
Index
Engine - 10
Fan and drive - 414

Reverse fan control system - Dynamic description - Cooling Fan System . . . . . . . . . . . . . . . . . . . . . . 3
Reverse fan control system - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Reverse fan control system - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Reverse fan control system - Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
48083741_EN 31/07/2018
10.4 [10.414] / 20
Engine - 10
Aftercooler - 310

48083741_EN 31/07/2018
10.5 [10.310] / 1
Contents
Engine - 10
Aftercooler - 310
SERVICE
Aftercooler
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Pressure test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
48083741_EN 31/07/2018
10.5 [10.310] / 2
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 the hood using controls located behind the ac-

cess cover.
2. After the hood is raised, turn the timed disconnect
3. On the underside of hood, remove the bolts (1) from
exhaust stack, then remove the plate (2).
4. Remove exhaust stack (3).
RAPH12WEL0194AA 1
5. Double up a nylon lifting strap. From the topside, slide

looped strap through the hood exhaust opening.
RAPH12WEL0170AA 2
48083741_EN 31/07/2018
10.5 [10.310] / 3
6. Place a solid steel bar through the strap loop (see ar-
row) 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.
RAPH12WEL0600AA 3
7. Disconnect the connector (5). Remove the cotter pin

(4) and the clevis pin (3) to separate the hood support
strut (2) from the lifting to separate the. Turn the timed
disconnect switch back to the ON position and run hood
strut up. Once strut is retracted, return the timed dis-
connect switch back to the OFF position.
LEIL16WHL1837BB 4
8. Remove the hood bracket bolts and move hood away

from back plate, allowing enough clearance to reach
the front bolts of the air cooler unit.
LEIL13WHL0183AA 5
48083741_EN 31/07/2018
10.5 [10.310] / 4
Turbocharger tube removal

9. Loosen the top left-hand side clamp of the air cooler
outlet hose.
NOTE: loosen only the clamp closest to the air cooler.
LEIL17WHL0168AB 6
10. Loosen the clamp at the elbow-turbocharger connec-

tion end. Remove tube and plug turbocharger.
LEIL17WHL0170AB 7
Intake port tube removal

11. Loosen the top right-hand side clamp of the air cooler
intake hose. Slide the hose back far enough to clear
the air cooler tube.
LEIL17WHL0169AB 8
12. Loosen the end clamp on the intake port side of the
engine. Remove the tube with the hose.
LEIL17WHL0181AB 9
48083741_EN 31/07/2018
10.5 [10.310] / 5
Screen cover removal

13. Unlatch the rubber T-handle from the screen cover.
NOTE: screen cover may be different from what is shown.
LEIL16WHL0488AB 10
14. Lift the screen cover part way. Pull the cotter pin and
the washer from the screen tab and locking bar prop-
erly.
LEIL16WHL0489AB 11
15. Open the screen cover completely and remove the

bolts. Lift and remove the cover.
NOTE: always use proper lifting devices.
NOTE: screen cover may be different than shown.
LEIL13WHL0204AB 12
Air cooler unit removal

NOTE: for Commodity King, include instruction 16.
48083741_EN 31/07/2018
10.5 [10.310] / 6
Commodity king only

16. Lift the side panels. Unbolt and remove left-hand and
right-hand beam seals, then lower the side panels.
NOTE: left–hand side shown.
LEIL16WHL0507AB 13
17. With a sharp cutting tool, make a slice in the gasket

(see the arrows) near the shoulder bolt.
RAPH12WEL0177AA 14
18. Remove the shoulder bolt, washers and nut (1) from
the air conditioner condenser unit (2).
RAPH12WEL0221AA 15
48083741_EN 31/07/2018
10.5 [10.310] / 7
19. Lift the air conditioner condenser up and angle toward

the back of the cab. Support in place if needed.
RAPH12WEL0146AA 16
20. Lift up the side panels. Remove the left-hand and

right-hand side bolt of air cooler unit.
LEIL13WHL0183AA 17
21. Remove the front bolts of air cooler unit.
LEIL17WHL0182AB 18
22. Remove air cooler unit out of cooler package frame-

work.
RAPH12WEL0172AA 19
48083741_EN 31/07/2018
10.5 [10.310] / 8
Aftercooler - Install
WARNING
Heavy objects!
Lift and handle all heavy components using lifting equipment with adequate capacity. Always support
units or parts with suitable slings or hooks. Make sure the work area is clear of all bystanders.
W0398A
1. Attach the frame to the air cooler assembly. Put 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 framework
with the tubes situated within the front plate cut–out,
facing the engine. Insert two bolts and partially set.
NOTE: do not tighten the bolts at this time.
LEIL17WHL0182AB 2
3. Raise the side panel and insert bolt into each side of
the air cooler unit. Run the bolt PART way.
4. Once the air cooler unit is semi–secured, tighten the
sides and front bolts, then lower the side panels.
LEIL13WHL0183AA 3
48083741_EN 31/07/2018
10.5 [10.310] / 9
5. Slide the air conditioner condenser unit back in place.
RAPH12WEL0145AA 4
6. Using a shoulder bolt, three washers and a nut (1),

secure the air conditioner condenser unit (2) in place.
RAPH12WEL0221AA 5
7. Flip latch closed on air conditioner condenser unit.
RAPH12WEL0179AA 6
8. Line up the screen cover and run the center bolt PART
way. Insert the outer bolts then securely tighten all
three bolts.
NOTE: screen cover may be different than shown.
NOTE: for Commodity King, continue with the following in-
structions.
LEIL13WHL0204AB 7
48083741_EN 31/07/2018
10.5 [10.310] / 10
Commodity king only

9. Lift the side panel. Attach the hood beam seal with
weather stripping shield facing up.
NOTE: left–hand side panel shown.
LEIL16WHL0507AB 8
10. Slide the beam seal onto the hood hinge stud and
tighten in place with the 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 the right–hand side.
LEIL16WHL0508AB 10
48083741_EN 31/07/2018
10.5 [10.310] / 11
Screen cover installation

12. Raise screen cover locking bar properly on left–hand
side.
LEIL16WHL0509AB 11
13. Partially lower screen cover, lining up screen tab with

locking bar prop.
LEIL16WHL0510AB 12
14. Place the washer on the outside of hinge followed with

a cotter pin to secure in place.
LEIL16WHL0489AB 13
15. Close the screen cover, locking in place with the rub-
ber T–handle.
LEIL16WHL0488AB 14
48083741_EN 31/07/2018
10.5 [10.310] / 12
Hood installation
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).
LEIL13WHL0183AA 15
17. Turn the timed disconnect switch to the ON position

and electrically lower the lifting motor cylinder, lining
up holes.
18. Return the timed disconnect switch to the OFF posi-
tion.
19. Insert the cotter pin (4) through the clever pin (3) to se-
cure the lifting motor cylinder (1) on the support hood
strut (2). Connect the wiring connector (5).
LEIL16WHL1837BB 16
20. Remove the hood lifting device.
RAPH12WEL0600AA 17
48083741_EN 31/07/2018
10.5 [10.310] / 13
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.
LEIL15WHL0033AB 18
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 19
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.
24. On the opposite end, make sure that O–ring is in el-
bow fitting.
RAPH12WEL0204AA 20
48083741_EN 31/07/2018
10.5 [10.310] / 14
25. Align O–ring end of tube to turbocharger.

26. Clamp in place. Torque to 10.1 – 11.3 N·m (7.4 –
8.3 lb ft).
LEIL17WHL0170AB 21
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 the direction of clamps.
LEIL17WHL0168AB 22
Intake port tube installation

28. Align opposite end of tube to the intake port manifold
side of the engine. Make sure there is clearance be-
tween hood and exhaust stack on both sides of tube.
Slide clamps in place and tighten. Torque to 10.1 –
11.3 N·m (7.4 – 8.3 lb ft).
LEIL17WHL0181AB 23
29. Line up top tube and slide hose over air cooler tube
until hose fits flush against the frame. Slide clamp in
place and tighten Torque to 10.1 – 11.3 N·m (7.4 –
8.3 lb ft).
NOTE: note the direction of clamps.
LEIL17WHL0169AB 24
48083741_EN 31/07/2018
10.5 [10.310] / 15
30. Turn power on (1), activate hood cylinder (2) and close
hood.
RCPH10WHL106AAH 25
48083741_EN 31/07/2018
10.5 [10.310] / 16
Aftercooler - Pressure test

CAUTION
Eye injury hazard!
Use caution when removing the cap due to possible air pressure.
C0056A
CAUTION
Eye injury hazard!
Always wear eye or full face protection when performing this procedure.
C0081A

bucket to the ground. Put the transmission in neutral,
apply the parking brake, then turn off engine.
2. Raise the hood. Remove the turbocharger outlet tube.
Plug the tube and the turbocharger.
NOTE: plug is dealer fabricated.
LEIL17WHL0170AB 1
3. Remove the inlet hose from manifold. Plug inlet hose

and with pressurized air, pressurize the system be-
tween 15 – 20 psi.
NOTE: always wear eye or full face protection when per-
forming this procedure.
NOTE: pressurized plug is dealer fabricated.
LEIL17WHL0181AB 2
4. For air leaks or lack of pressure, inspect cooler compo-

nents for damage or missing parts.
LEIL13WHL0211AB 3
48083741_EN 31/07/2018
10.5 [10.310] / 17
5. Inspect the flexible hose of the turbocharger top air

cooler outlet for leaks or holes and ensure that the
clamps are tightened.
LEIL17WHL0168AB 4
6. Inspect the flexible hose of the manifold top air cooler

inlet for leaks or holes and ensure that the clamp is
tighten.
LEIL17WHL0169AB 5
7. Visually inspect the top of air cooler for damage or

leaks.
NOTE: if the leak source has not been located, remove and
test the air cooler using Aftercooler - Testing (10.310).
RCPH10WHL139AAH 6
Pressure test – Reassemble

8. Unplug and remove pressurized air system from man-
ifold. 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).
LEIL17WHL0181AB 7
48083741_EN 31/07/2018
10.5 [10.310] / 18
9. Remove plug from turbocharger tube. Remove plug

from turbocharger. Make sure gasket remained inside
turbocharger tube.
RAPH12WEL0204AA 8
10. Align tube ends and secure in place with clamp.

Torque to 10.1 – 11.3 N·m (7.4 – 8.3 lb ft).
LEIL17WHL0170AB 9
11. Lower the hood.

12. Close screen and T-handle secure in place (if avail-
able). Put transmission in park and turn off.
LEIL16WHL0488AB 10
48083741_EN 31/07/2018
10.5 [10.310] / 19
Aftercooler - Test
1. Check the core for leaks by closing off the outlet
tube (1) and attaching regulated air pressure 550 kPa
(80 psi) to the inlet tube (2). Submerge the aftercooler
in water and check for air leakage.
2. If leakage is detected replace the aftercooler.
LEIL15WHL1549AB 1
48083741_EN 31/07/2018
10.5 [10.310] / 20
Index
Engine - 10
Aftercooler - 310
Aftercooler - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Aftercooler - Pressure test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Aftercooler - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Aftercooler - Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
48083741_EN 31/07/2018
10.5 [10.310] / 21
48083741_EN 31/07/2018
10.5 [10.310] / 22
Engine - 10
Engine lubrication system - 304

48083741_EN 31/07/2018
10.6 [10.304] / 1
Contents
Engine - 10
SERVICE
Crankcase ventilation system

Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
48083741_EN 31/07/2018
10.6 [10.304] / 2
Engine - Engine lubrication system
Crankcase ventilation system - Remove

1. Locate the blow-by recirculation system filter under the
hood on the engine, in back of the cooling fan. It can
be accessed from the right–hand side of the machine.
LEIL17WHL0167AB 1
2. Raise the hood using the controls located behind the

access cover. Then remove the inner fender panel.
3. Turn the timed disconnect switch to the OFF position.
4. Remove the screws on the filter housing cover plate. It
may be necessary to use an off-set screwdriver.
RAPH12WEL0089AA 2
5. Remove the filter housing cover plate.
RAPH12WEL0090AA 3
48083741_EN 31/07/2018
10.6 [10.304] / 3
6. Remove the filters from the filter housing and replace

them.
RCPH10WHL467AAH 4
48083741_EN 31/07/2018
10.6 [10.304] / 4
Crankcase ventilation system - Install

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
4. Turn the timed disconnect switch to ON position.

5. Install the inner fender panel. Then lower the hood
using the controls located behind the access cover.
48083741_EN 31/07/2018
10.6 [10.304] / 5
Index
Engine - 10

Crankcase ventilation system - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Crankcase ventilation system - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
48083741_EN 31/07/2018
10.6 [10.304] / 6
48083741_EN 31/07/2018
10.6 [10.304] / 7
CNH Industrial Italia S.p.A. viale delle Nazioni, 55 Modena Italy 41122
SERVICE - Technical Publications & Tools
PRINTED IN ITALY
© 2018 CNH Industrial Italia S.p.A. All rights reserved.
No part of the text or illustrations of this publication may be reproduced.
CNH Industrial Italia S.p.A reserves the right to make improvements in design and changes in specifications at
any time without notice and without incurring any obligation to install them on units previously sold. Specifications,
descriptions, and illustrative material herein are as accurate as known at the time of publication, but are subject
to change without notice.
Availability of some models and equipment builds varies according to the country in which the equipment is being
used. For exact information about any particular product, please consult your CASE CONSTRUCTION dealer.
CASE CONSTRUCTION is a trademark registered in the United States and many other countries, owned or
licensed to CNH Industrial N.V., its subsidiaries or affiliates.
Any trademarks referred to herein, in association with goods and/or services of companies, other than owned by or
licensed to CNH Industrial N.V., its subsidiaries or affiliates, are the property of those respective companies.
48083741_EN 31/07/2018
EN
SERVICE MANUAL
Transmission

48083741_EN 31/07/2018
21
Contents
Transmission - 21
[21.113] Powershift transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.1
[21.155] Powershift transmission internal components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.2
[21.700] Torque converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.3
48083741_EN 31/07/2018
21
Transmission - 21
Powershift transmission - 113

48083741_EN 31/07/2018
21.1 [21.113] / 1
Contents
Transmission - 21
TECHNICAL DATA
Powershift transmission
Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
SERVICE
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
DIAGNOSTIC
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
48083741_EN 31/07/2018
21.1 [21.113] / 2
Transmission - Powershift transmission
Powershift transmission - Special tools
LEIL13WHL0770FB 1
ITEM P/N Description

A 380001559 Transmission torque converter seal installation tool
B 380001560 Transmission input/output shaft seal installation tool
C CAS2885 Transmission valve adjustment tool set
D CAS2796 Nesting plate
E 380001556 Clutch pack holder and spring compressor tools
F CAS20801 Transmission mounting brackets
G CAS2802 Alignment dowel set
H CAS2798 Gear puller collet set
J 380001557 Clutch assembly holding knob set
K CAS2797 Lifting eyebolt set
48083741_EN 31/07/2018
21.1 [21.113] / 3
Powershift transmission - Torque

Oil pipes
Studs 9 N·m (80 lb in)
Socket head bolt 23 N·m (17 lb ft)
Screw plug 51 N·m (38 lb ft)
Clutch K1, K2, K3, K4 Stud 17 N·m (150 lb in)

Plugs 25 N·m (18 lb ft)
Output shaft
Output shaft bolts (apply Loctite 243 to threads) 23 N·m (17 lb ft)
Housing cover bolts (apply Loctite 574 to threads 46 N·m (34 lb ft)
Output flange bolts 68 N·m (50 lb ft)
Oil feed housing and transmission pump

Transmission pump bolts 46 N·m (34 lb ft)
Oil feed housing bolts 25 N·m (18 lb ft)
Engine connection and converter

Input shaft bolts 115 N·m (85 lb ft)
Converter housing bolts 68 N·m (50 lb ft)
Cover 23 N·m (17 lb ft)
Converter cover 46 N·m (34 lb ft)
Input flange 34 N·m (25 lb ft)
Duct plate
Bolts 25 N·m (18 lb ft)
Bolt plug 30 N·m (22 lb ft)
Hydraulic control unit 9.5 N·m (84 lb in)
Filter
Filter head bolts 25 N·m (18 lb ft)
Oil distribution cover bolts 25 N·m (18 lb ft)
Speed sensor and inductive transmitter

Speed sensor bolt 23 N·m (17 lb ft)
Inductive transmitter 30 N·m (22 lb ft)
Cover plate 23 N·m (17 lb ft)
Bolt plug 140 N·m (103 lb ft)
Powershift transmission - General specification

Clutch KV and KR plate clearance 2.65 – 2.95 mm (0.104 – 0.116 in)
Clutch K1plate clearance 2.35 – 2.65 mm (0.093 – 0.104 in)
Clutch K2 and K3 plate clearance 1.75 – 2.05 mm (0.069 – 0.081 in)
Clutch K4 plate clearance 1.35 – 1.65 mm (0.053 – 0.065 in)
48083741_EN 31/07/2018
21.1 [21.113] / 4
Powershift transmission - Remove

bucket to the ground. Stop the engine and apply the
parking brake.
2. Place the timed disconnect switch in the OFF position.
RCPH10WHL106AAH 1
3. Apply the articulation locking block to prevent acciden-

tal articulation of the machine.
LEIL16WHL0048AB 2
4. Remove ROPS cab.

5. Remove the hydraulic pump.
6. Put a suitable container under the transmission drain
plug. Remove the drain plug and drain the transmission
oil. Install the drain plug after oil has drained.
NOTE: follow the local regulations when handling trans-
mission oil.
7. Identify, tag, and disconnect the brake pump pressure
hose (15) and the brake to hydraulic reservoir hose
(16). Position the hoses away from the transmission.
Remove and discard O-ring face seals from fittings (17)
and (18). Plug the hoses and cap the fittings to prevent
entry of foreign matter into hydraulic system.
LEIL13WHL1435AB 3
48083741_EN 31/07/2018
21.1 [21.113] / 5
8. Disconnect transmission wiring harness connector (19)

from control valve connector. Remove socket head bolt
securing wiring harness clamp (20). Move the wiring
harness away from transmission.
LEIL13WHL1436AB 4
9. Just above where clamp (20) was installed, tag and dis-
connect the Connector TCOT – Torque Converter Out-
put temperature sender (21) from temperature sensor.
Move wiring harness away from transmission.
LEIL13WHL1437AB 5
10. Remove two socket head bolts (22)and (23) securing

transmission wiring harness clamps.
LEIL13WHL1438AB 6
11. Identify, tag, and disconnect transmission wiring har-

ness Connector ESS – Engine speed sensor (24),
Connector ISS – Intermediate Speed Sensor (25) and
the Connector TSS – Turbine Speed Sensor (26).
Move the transmission wiring harness away from the
transmission.
LEIL13WHL1439AB 7
48083741_EN 31/07/2018
21.1 [21.113] / 6
12. Remove the socket head bolt securing wiring harness

clamp (27). Move wiring harness away from transmis-
sion.
LEIL13WHL1440AB 8
13. Identify, tag, and disconnect transmission wiring har-

ness Connector FM – Filter Maintenance (28) and the
Connector OSS - Output Speed Sensor (29). Move
the transmission wiring harness away from the trans-
mission.
LEIL13WHL1441AB 9
14. Identify, tag, and disconnect the parking brake hose

(34) from the parking brake (35). Plug the hose and
cap the fitting to prevent entry of foreign matter into
hydraulic system. Move the hose away from the trans-
mission.
Loosen and remove the bolts (36) and the two straps
(37) that fasten the center drive shaft (38) to the trans-
mission output flange. Disconnect the center drive
shaft from the transmission.
NOTE: only for 821G Series machines.
LEIL13WHL1442AB 10
Identify, tag, and disconnect the parking brake hose

(34) from the parking brake (35). Plug the hose and
cap the fitting to prevent entry of foreign matter into hy-
draulic system. Move the hose away from the transmis-
sion.
Loosen and remove the four bolts (36). Disconnect the
center drive shaft (38) from the transmission.
NOTE: only for 921G Series machines use mechanical
style yokes (no bearing straps).
LEIL16WHL1758AB 11
48083741_EN 31/07/2018
21.1 [21.113] / 7
15. Loosen and remove the four bolts (39) and two straps
(40) that fasten the rear drive shaft (41) to the trans-
mission output flange.
NOTE: only for the 821G Series machines.
LEIL13WHL1443AB 12
Loosen and remove the four bolts (39) and two straps
(40) that fasten the rear drive shaft (41) to the transmis-
sion output flange.
NOTE: only for the 921G Series machines use mechanical
style yokes (no bearing straps)
LEIL16WHL1759AB 13
16. Remove the two bolts (45). Remove fill tube (46) with
cap and oil gauge assembled, two seals, and metal
strainer. Discard seals.
LEIL13WHL1444AB 14
17. Identify, tag, and disconnect the cooler hose (47) from
fitting (48) installed in thermo bypass valve located on
the left-hand side of the transmission. Install plugs
in hoses. Remove and discard O-ring face seal from
fittings (48).
LEIL13WHL1445AB 15
48083741_EN 31/07/2018
21.1 [21.113] / 8
18. Connect a lifting equipment to the transmission lifting

eyes (56). Take up all slack in lifting equipment.
LEIL13WHL1446AB 16
19. In the area between rear of transmission and engine,

remove four bolts (57) and two straps (58). Discard
the four bolts (57) and two straps (58). Use pry bar to
disconnect engine drive shaft (59) from the transmis-
sion. Remove the four bolts (60) and the related wash-
ers that secure the transmission to the top mounting
bracket (61).
LEIL13WHL1447AB 17
20. Remove the bolts (64) and the washers (65) that se-
cure the right-hand and left-hand mounting brackets
(63) to the rear chassis.
LEIL13WHL1448AB 18
21. Raise the transmission just enough to enable removal

of right-hand and left-hand mounting brackets (63).
Remove two bolts (62) and washers securing right-
hand and left-hand mounting brackets (63) to trans-
mission. Remove right-hand and left-hand mounting
brackets.
LEIL13WHL1449AB 19
48083741_EN 31/07/2018
21.1 [21.113] / 9
22. Slowly and carefully raise the transmission from

the machine. Be sure that the hoses, the electrical
connectors, and the wires have been disconnected
and nothing interferes with transmission removal.
Remove the transmission from the machine.
LEIL13WHL1450AA 20
23. If the top mounting bracket (61) requires removal,

remove bolt (66) and washer (67) then remove the
bracket.
LEIL13WHL1451AB 21
48083741_EN 31/07/2018
21.1 [21.113] / 10
Powershift transmission - Install

1. Check the isolators (68) for deterioration, tears, defor-
mation, or other damage.
2. If the top mounting bracket (61) was removed, put the
bracket in the correct position on the rear chassis trun-
nion. Use the bolt (66), the washers (67) and the
washer (68) to secure the top mounting bracket (61).
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.
LEIL16WHL0803BB 1
3. Attach a suitable lifting equipment to the engine lifting

brackets (1).
Move the transmission into position on the machine.
Slowly lower the transmission in the correct position on
the machine.
LEIL13WHL1450AA 2
4. Install the right-hand and left-hand side mounting

brackets (63) on the transmission with two washers
and bolts (62). Do not tighten the bolts.
LEIL13WHL1449AB 3
48083741_EN 31/07/2018
21.1 [21.113] / 11
5. Install the washers (65) and bolts (64) to secure the

right-hand side and left-hand mounting brackets (63)
to the rear chassis. Tighten the bolts (62) that secure
the right-hand side and left side mounting brackets to
transmission.
Torque to 481 – 590 Nm ( 355 – 435 lb.ft).
LEIL13WHL1448AB 4
6. Install the four washers and bolts (60) to secure the top
mounting bracket (61) to the transmission.
Torque the bolts (60) to 251 – 319 N·m (185 – 235 lb ft).
If bracket (61) had been removed, torque bolt (66) to
890 – 1000 N·m (656 – 738 lb ft). Connect the engine
drive shaft (59) to the transmission. Install two new
straps (58) and four new bolts (57).
Torque bolts (57) to 75 – 81 N·m (55 – 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.
LEIL13WHL1447AB 5
7. Torque bolts (64) to 890 – 1000 Nm ( 655 – 735 lb.ft)

that secure the right-hand and left-hand side mounting
brackets.
LEIL13WHL1452AB 6
8. Disconnect the lifting equipment from the transmission

lifting eyes (56).
LEIL13WHL1446AB 7
48083741_EN 31/07/2018
21.1 [21.113] / 12
9. Remove plugs in thermo bypass valve port. Install new

O-ring face seal in fitting on thermo bypass valve. Con-
nect the cooler hose (47) to the fitting following tag in-
stalled during removal. Remove and discard tag.
LEIL13WHL1453AB 8
10. Position the transmission fill tube (46), the two new
seals, and the metal strainer on the transmission;
(metal strainer is installed between seals). Torque the
two bolts (45) to 17 – 33 Nm ( 12 – 24 lb.ft) to secure
the transmission fill tube (46).
LEIL13WHL1444AB 9
11. Connect the rear drive shaft (41) to the transmission.

Install the two straps (40) and the four bolts (39).
Tighten the bolts to 75 – 81 N·m (55 – 60 lb ft).
LEIL13WHL1443AB 10
Connect the rear drive shaft (41) to the transmission.

Install the two straps (40) and the four bolts (39).
Tighten the bolts to 136 – 149 N·m (100 – 110 lb ft).
LEIL16WHL1759AB 11
48083741_EN 31/07/2018
21.1 [21.113] / 13
12. Connect the parking brake hose (34) to the parking

brake (35). Connect the center drive shaft (38) to the
transmission. Install and four bolts (36) and the two
straps (37).
LEIL13WHL1442AB 12
Connect the parking brake hose (34) to the parking

brake (35). Connect the center drive shaft (38) to the
transmission. Install and four bolts (39).
LEIL16WHL1758AB 13
13. Connect transmission wiring harness connectors

Connector FM – Filter Maintenance (28) and Connec-
tor OSS - Output Speed Sensor (29).
LEIL13WHL1441AB 14
14. Install the wiring harness clamp (27) with socket head
bolt.
LEIL13WHL1440AB 15
48083741_EN 31/07/2018
21.1 [21.113] / 14
15. Connect transmission wiring harness connectors

Connector ESS – Engine Speed Sensor (24), Con-
nector ISS – Intermediate Speed Sensor (25) and
the Connector TSS – Turbine Speed Sensor (26)
following tags installed during removal.
LEIL13WHL1439AB 16
16. Secure the transmission wiring harness clamps (22)

and (23) with two socket head bolts.
LEIL13WHL1438AB 17
17. Connect the Connector TCOT – Torque Converter

Output Temperature sender (21) following tag in-
stalled during removal. Remove and discard tag.
LEIL13WHL1437AB 18
18. Install socket head bolt to secure wiring harness

clamp (20). Connect the transmission wiring harness
connector (19) to control valve connector.
LEIL13WHL1436AB 19
48083741_EN 31/07/2018
21.1 [21.113] / 15
19. Install new O-ring face seals in fittings (17) and (18).
Connect brake to the hydraulic reservoir hose (16) and
the brake pump pressure hose (15) following tags in-
stalled during removal. Remove and discard tags.
LEIL13WHL1435AB 20
20. Check that transmission drain plug is tight.
LEIL13WHL1454AB 21
21. Fill the transmission to correct level shown in sight

glass, with approved transmission hydraulic oil.
22. Install the hydraulic pump.
23. Install the cab.
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 hy-
draulic oil until oil level is up to crosshatch region. Shut
down engine and put articulation lock in OPERATING
position.
48083741_EN 31/07/2018
21.1 [21.113] / 16
Powershift transmission - Disassemble

Electro-hydraulic control and oil filter (replaceable filter)
Removal oil filter

1. Fasten the transmission onto assembly stand with
CAS2801 or similar tool. Drain oil prior to starting
disassembly.
NOTICE: dispose of oil according to legal requirements.
LEIL13WHL0771BA 1
2. Remove and properly discard the filter (1).
LEIL13WHL0772AB 2
48083741_EN 31/07/2018
21.1 [21.113] / 17
3. Remove the Torx bolts (2) and separate the filter

head (1) from the transmission. Remove and discard
O-rings.
LEIL13WHL0773AB 3
Removal of electronic gear-shift control

1. Remove the gear-shift control (1). Remove the Torx
bolts (2) and separate the gear-shift control housing
from intermediate plate.
NOTE: for version with torque converter lock-up clutch So-
lenoid valve, go to the relevant steps.
LEIL13WHL0774AB 4
2. Remove the gear-shift control assembly (1) and the

sealing plate (2). Adjusting bolts M6 (S).
LEIL13WHL0775AB 5
48083741_EN 31/07/2018
21.1 [21.113] / 18
3. Remove the differential pressure switch (1) from fine

filter duct plate (4).
1. Switch with O-ring
2. Piston
3. Compression spring.
LEIL13WHL0776AB 6
4. Remove the hexagonal nuts and the Torx bolts. Sep-

arate the duct plate (1) and the seal (2) from the rear
housing.
LEIL13WHL0777AB 7
5. Remove converter safety valve (1) out of the housing

hole.
LEIL13WHL0778AB 8
6. Mark installation position of wiring harness (1) towards

the valve block (2).
LEIL13WHL0779AB 9
48083741_EN 31/07/2018
21.1 [21.113] / 19
7. Remove the Torx bolts (1).
LEIL13WHL0780AB 10
8. Separate the duct plate (1) and the sealing plate (2)
from the valve block (3).
LEIL13WHL0781AB 11
9. Remove the retaining clamp (1).
LEIL13WHL0782AB 12
10. Remove the Torx bolts (1) and the cover (2). Repeat
the procedure on the opposite end cover (3).
LEIL13WHL0783AB 13
48083741_EN 31/07/2018
21.1 [21.113] / 20
11. Remove wiring harness (1). Remove cylindrical bolts

(3), securing plates and pressure controllers (2).
LEIL13WHL0784AB 14
12. Remove cylindrical bolts, securing plates and pres-

sure controllers (1) on opposite side.
LEIL13WHL0785AB 15
13. Remove two Torx bolts (1) and temporarily attach

housing using 380001577 adjusting bolts (S). (Hous-
ing is spring-loaded.) Remove remaining Torx bolts.
LEIL13WHL0786AB 16
14. Loosen the adjusting bolts (S) equally releasing the

valve’s spring pressure. Remove the housing.
LEIL13WHL0787AB 17
48083741_EN 31/07/2018
21.1 [21.113] / 21
15. Remove individual parts including pressure reducing

valve (1), vibration dampers (2), and the follow-on
slide (3).
LEIL13WHL0788AB 18
16. Remove individual parts of opposite side including

main pressure valve (1), vibration dampers (2), and
the follow-on slide (3).
LEIL13WHL0789AB 19
Version with torque converter lock-up clutch solenoid valve

1. Loosen the nuts (1) and (2). Remove the system pres-
sure pipe (3) from the lock-up clutch valve to lock-up
clutch. Remove screw-in sleeve (4).
LEIL13WHL0790AB 20
2. Remove the hollow bolt (1) and the O-ring. Loosen the
bolt nut (2). Remove the system pressure to the lock-up
clutch valve pipe and the O-rings.
LEIL13WHL0791AB 21
48083741_EN 31/07/2018
21.1 [21.113] / 22
3. Mark installation position of the connecting housing (4)

towards valve block (5). Remove cylinder bolts (1) and
lock-up clutch valve. Remove bolt neck (2) and discard
O-rings. Remove the Torx bolts (3), and the connecting
housing.
LEIL13WHL0792AB 22
Inductive sensor Hall effect sensor, breather, oil filler and oil drain plug
1. Attach the transmission to assembly stand CAS2801.
Remove:
the oil drain plug (1),
the oil filler tube with oil dipstick (2),
the breather (3),
the inductive sensor - n central gear chain (4),
the inductive sensor - n turbine (5),
the inductive sensor - n engine (6).
LEIL13WHL0793BB 23
2. Remove the cylindrical bolt (1) and the Hall effect speed
sensor - n output and O-ring (2).
LEIL13WHL0794AB 24
48083741_EN 31/07/2018
21.1 [21.113] / 23
Engine connection, oil pressure pump, converter back-pressure valve and temperature
sensor
Engine connection (remote mount)

1. Remove the hexagonal bolts (1) and washer. Loosen
the cover/converter bell housing bolts (2).
NOTE: mark radial installation position of cover/converter
bell housing with center punch.
LEIL13WHL0795AB 25
2. Separate the cover from converter bell housing using a

suitable lifting device.
LEIL13WHL0796AA 26
3. Remove the output flange.
LEIL13WHL0797AA 27
48083741_EN 31/07/2018
21.1 [21.113] / 24
4. Press the input shaft and converter out of cover (ball

bearing).
LEIL13WHL0798AA 28
5. Remove the retaining ring (1) and the ball bearing (2).
LEIL13WHL0799AB 29
6. Remove the hexagonal bolts (1) and the flex plate (2)
from the converter.
LEIL13WHL0800AB 30
7. Remove the hexagonal bolts (1) and the flex plate (2)
from input shaft (3).
LEIL13WHL0801AB 31
48083741_EN 31/07/2018
21.1 [21.113] / 25
Oil pressure pump

1. Loosen the bolted connection (1) between the con-
verter bell housing and the oil feed housing. Remove
the converter bell housing (2).
LEIL13WHL0802AB 32
2. Remove the Torx bolts (1) from the oil feed housing
and front transmission housing. Remove the cylindri-
cal bolts (2) from the oil pressure pump and front trans-
mission housing.
NOTE: separate oil feed housing together with oil pressure
pump from front transmission housing.
LEIL13WHL0803AB 33
3. Separate the oil pressure pump (1) from the oil feed
housing (2).
LEIL13WHL0804AB 34
4. Remove the O-ring (1) and the cylindrical bolts (2).
LEIL13WHL0805AB 35
48083741_EN 31/07/2018
21.1 [21.113] / 26
5. Check oil gear pump for wear. In case of wear marks

on the pump housing, cover, inner rotor, or outer rotor;
replace the oil pressure pump.
1. Cover
2. Inner rotor
3. Outer rotor
4. Pump housing
LEIL13WHL0806AB 36
6. Remove the shaft seal (1) from the pump housing (2).
LEIL13WHL0807AB 37
Converter back-pressure valve

1. With a screwdriver, release the converter safety valve
(1) pressure and remove the locking plate (2).
LEIL13WHL0808AB 38
48083741_EN 31/07/2018
21.1 [21.113] / 27
2. Remove individual parts of converter safety valve

which are released.
1. Pressure plate
2. Compression spring
3. Piston
LEIL13WHL0809AB 39
3. Remove the temperature sensor (1).
LEIL13WHL0810AB 40
4. Remove the stator shaft (1). If applicable, remove the

pressure relief valve (2) out of the housing hole.
NOTE: the pressure relief valve is not mounted on all ver-
sions. Versions concerned, see the corresponding spare
parts list.
LEIL13WHL0811AB 41
48083741_EN 31/07/2018
21.1 [21.113] / 28
Emergency steering pump
Version without emergency steering pump

1. Remove the hexagonal bolts (1), the cover (2) and the
seals.
LEIL13WHL0812AB 42
Outputs and closure parts pump shaft (PTO-shaft)
Output flange on converter side (Standard version)

1. Remove the hexagonal bolts (1), the washer and
O-ring.
LEIL13WHL0813AB 43
2. Pull off output flange (1) and remove shaft seal (2).
LEIL13WHL0814AB 44
48083741_EN 31/07/2018
21.1 [21.113] / 29
Output flange on output side with parking brake FSG-88

1. Connect a hand-operated pump at port (see arrow) and
apply approximately 80 bar (1160 psi) pressure to the
hydraulically actuated parking brake (1) until the brake
disc (2) can be rotated by hand.
LEIL13WHL0815AB 45
2. Remove the hexagonal nut with open end wrench.
LEIL13WHL0816AA 46
3. Remove the hexagonal bolts (2), and the parking brake

(1).
LEIL13WHL0817AB 47
4. Remove the hexagonal bolts (1) of bolted brake disc/

output flange connection and remove the brake disc
(2).
LEIL13WHL0818AB 48
48083741_EN 31/07/2018
21.1 [21.113] / 30
5. Remove the hexagonal bolts (1), the washer and

O-ring. Remove the output flange (2) and the shaft
seal. Remove cylinder bolt with washer (3).
LEIL13WHL0819AB 49
Removal of input shaft, output shaft, pump shaft (PTO -shaft) and clutches
1. Force out both cylindrical pins (1). Loosen bolted con-
nection (2) between front and rear transmission hous-
ings. Use a suitable lifting device to separate housing
sections.
LEIL13WHL0820AB 50
2. Loosen the bolted connection (1) of the oil screen

sheets.
LEIL13WHL0821AB 51
3. Remove the output shaft (1) and the lower oil screen
sheet (2) from housing.
LEIL13WHL0822AB 52
48083741_EN 31/07/2018
21.1 [21.113] / 31
4. Remove all rectangular rings (1) from the clutches and

all O-rings (2) from the oil tubes.
LEIL13WHL0823AB 53
5. Use a suitable lifting device to lower rear housing sec-

tion (1) into contact position with front housing section
(2).
LEIL13WHL0824AB 54
6. Use the 380001557 handle (1) to secure clutches K1,

K2, K3 and K4.
NOTICE: clutches KV, KR and input shaft (2) are only se-
cured by the gear chain. Take care to ensure that these
non-secured components do not detach.
NOTE: due to the installation conditions, the removal of the
single clutches without using the special tool is not possi-
ble.
LEIL13WHL0825AB 55
7. Separate the rear housing section including clutches

from the front housing section using a suitable lifting
device and attach it to the assembly truck.
1. Clutch KV
2. Input shaft
3. Clutch KR
4. Pump shaft
NOTICE: clutches KV, KR and input shaft are only secured
by the gear chain. Care must be taken to ensure these
LEIL13WHL0826AB 56
48083741_EN 31/07/2018
21.1 [21.113] / 32
8. Remove the cylindrical bolts of oil tubes (1) from the

front housing.
NOTE: The suction tube (1) and the lubrication lines (2)
are rolled in and difficult to remove. In case of damage, use
special tools 380001285 (EU) or 380001286 (EU) for fitting
or replacing these components. North American Dealers
contact special tools.
LEIL13WHL0827AB 57
LEIL13WHL0828AB 58
9. Remove the bearing outer rings (arrows) from the front

housing.
NOTE: if contrary to recommendation, the tapered roller
bearings of clutches, input and output are not replaced, the
technician must ensure the previous pairing (bearing outer
ring/bearing inner ring). Mark the bearing outer ring and
the bearing inner ring.
LEIL13WHL0829AA 59
10. Disengage the retaining ring (1) and remove the pump
shafts (2).
LEIL13WHL0830AB 60
48083741_EN 31/07/2018
21.1 [21.113] / 33
11. Press the ball bearing (1) off the pump shaft. Snap
out rectangular ring (2).
LEIL13WHL0831AB 61
12. Lift the clutches out of the housing in numerical order

as described in the 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
LEIL13WHL0832AB 62
13. Remove the bearing outer rings (arrows) from the rear
housing.
NOTE: if contrary to recommendation, the tapered roller
bearings of clutches, input and 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.
NOTE: the lubrication lines (1) and (2) are rolled in and
difficult to remove. In case of damage, use special tool
380001285 (EU) for fitting or replacing these components.
North American Dealers contact special tools.
LEIL13WHL0833AA 63
LEIL13WHL0834AB 64
48083741_EN 31/07/2018
21.1 [21.113] / 34
Clutches KV/KR/K1/K2/K3/K4 input and output shaft

1. K1 clutch
2. K2 clutch
3. K3 clutch
4. K4 clutch
5. KR clutch
6. KV clutch
7. Input shaft
LEIL13WHL0835AB 65
KV clutch
1. Remove the stud bolt (1) and the snap out piston ring
(2).
LEIL13WHL0836AB 66
2. Pull tapered roller bearing off the shaft with the special
tool CAS2798.
LEIL13WHL0837AA 67
3. Snap out retaining ring (1).
LEIL13WHL0838AB 68
48083741_EN 31/07/2018
21.1 [21.113] / 35
4. Pull clutch (1) off the shaft.
LEIL13WHL0839AB 69
5. Use a cut-off device to secure the idler gear (1). Pull

the idler gear (1) off the clutch shaft.
LEIL13WHL0840AB 70
6. Snap the retaining ring (1) out of the idler gear (2) and
remove the ball bearing (3).
LEIL13WHL0841AB 71
7. Remove the needle cage (1) from the shaft (2).
LEIL13WHL0842AB 72
48083741_EN 31/07/2018
21.1 [21.113] / 36
8. Turn the shaft (2) 180° and snap out piston ring (1).
LEIL13WHL0843AB 73
9. Pull tapered roller bearing off shaft with special tool

CAS2798.
LEIL13WHL0844AA 74
10. Unsnap the snap ring (1).
LEIL13WHL0845AB 75
11. Remove the end shim (1) and the disc set (2) from the
disc carrier (3).
LEIL13WHL0846AB 76
48083741_EN 31/07/2018
21.1 [21.113] / 37
12. Preload the compression spring with special tool

380001556 and unsnap L-ring (1).
LEIL13WHL0847AB 77
13. Remove the support shim (1), the compression spring

(2) and the washer (3).
LEIL13WHL0848AB 78
14. Using compressed air, remove the piston (1) from the
disc carrier.
LEIL13WHL0849AB 79
15. Remove both O-rings (1) and (2).
LEIL13WHL0850AB 80
48083741_EN 31/07/2018
21.1 [21.113] / 38
KR clutch
1. Remove the stud bolt (1) and snap out piston ring (2).
LEIL13WHL0836AB 81
2. Pull tapered roller bearing off the shaft with special tool
CAS2798.
LEIL13WHL0837AA 82
LEIL13WHL0838AB 83
4. Pull the clutch (1) off the shaft.
LEIL13WHL0839AB 84
48083741_EN 31/07/2018
21.1 [21.113] / 39
5. Use a cut-off device to secure the idler gear (1). Pull

the idler gear (1) off the clutch shaft.
LEIL13WHL0840AB 85
6. Snap the retaining ring (1) out of the idler gear (2) and
remove the ball bearing (3).
LEIL13WHL0841AB 86
7. Remove needle cage (1) from the shaft (2).
LEIL13WHL0842AB 87
8. Turn the shaft 180° and snap out piston ring (1).
LEIL13WHL0843AB 88
48083741_EN 31/07/2018
21.1 [21.113] / 40
9. Pull tapered roller bearing off shaft with special tool

CAS2798.
LEIL13WHL0844AA 89
LEIL13WHL0845AB 90
disc carrier (3).
LEIL13WHL0846AB 91
12. Preload the compression spring with special tool

380001556 and unsnap L-ring (1).
LEIL13WHL0847AB 92
48083741_EN 31/07/2018
21.1 [21.113] / 41
13. Remove the support shim (1), the compression spring

(2) and the washer (3).
LEIL13WHL0848AB 93
14. Using compressed air, remove the piston (1) from the
disc carrier.
LEIL13WHL0849AB 94
LEIL13WHL0850AB 95
K1 clutch
LEIL13WHL0851AB 96
48083741_EN 31/07/2018
21.1 [21.113] / 42
CAS2798.
LEIL13WHL0852AA 97
LEIL13WHL0853AB 98
4. Remove the axial bearing assembly (1).
LEIL13WHL0854AB 99
5. Take off the idler gear (1). Remove the needle cage (2)
and the axial bearing assembly (3).
LEIL13WHL0855AB 100
48083741_EN 31/07/2018
21.1 [21.113] / 43
6. Pull clutch (1) off the shaft.
LEIL13WHL0856AB 101
7. Turn shaft (2) by 180° and snap out piston ring (1).
LEIL13WHL0857AB 102
CAS2798.
LEIL13WHL0858AA 103
LEIL13WHL0845AB 104
48083741_EN 31/07/2018
21.1 [21.113] / 44
disc carrier (3).
LEIL13WHL0846AB 105
11. Preload cup springs using special tool 380001556 and

unsnap L-ring (1).
LEIL13WHL0847AB 106
12. Remove the cup spring package (1).
LEIL13WHL0859AB 107
13. Use compressed air to remove the piston (1) from the
disc carrier.
LEIL13WHL0849AB 108
48083741_EN 31/07/2018
21.1 [21.113] / 45
LEIL13WHL0850AB 109
K2 clutch
LEIL13WHL0851AB 110
CAS2798.
LEIL13WHL0860AA 111
3. Snap out the retaining ring (1).
LEIL13WHL0861AB 112
48083741_EN 31/07/2018
21.1 [21.113] / 46
LEIL13WHL0862AB 113
5. Remove the idler gear (1), the needle cage (2) and axial
bearing assembly (3).
LEIL13WHL0863AB 114
LEIL13WHL0864AB 115
7. Turn the shaft (2)by 180° and snap out piston ring (1).
LEIL13WHL0865AB 116
48083741_EN 31/07/2018
21.1 [21.113] / 47
CAS2798.
LEIL13WHL0866AA 117
LEIL13WHL0845AB 118
disc carrier (3).
LEIL13WHL0846AB 119
11. Preload the cup springs with special tool 380001556

and unsnap L-ring (1).
LEIL13WHL0847AB 120
48083741_EN 31/07/2018
21.1 [21.113] / 48
LEIL13WHL0859AB 121
13. Use the compressed air to remove the piston (1) from
the disc carrier.
LEIL13WHL0849AB 122
LEIL13WHL0850AB 123
K3 clutch
1. Snap out the piston ring (1).
LEIL13WHL0867AB 124
48083741_EN 31/07/2018
21.1 [21.113] / 49
CAS2798.
LEIL13WHL0868AA 125
LEIL13WHL0869AB 126
4. Take off the idler gear (1), remove the needle cage (2)
and the axial bearing assembly (3).
LEIL13WHL0870AB 127
LEIL13WHL0871AB 128
48083741_EN 31/07/2018
21.1 [21.113] / 50
6. Remove stud bolt (1) and snap out piston ring (2).
LEIL13WHL0872AB 129
CAS2798.
LEIL13WHL0873AA 130
LEIL13WHL0845AB 131
disc carrier (3).
LEIL13WHL0846AB 132
48083741_EN 31/07/2018
21.1 [21.113] / 51
10. Use special tool 380001556 to preload the cup spring

and unsnap the L-ring (1).
LEIL13WHL0847AB 133
LEIL13WHL0859AB 134
disc carrier.
LEIL13WHL0849AB 135
LEIL13WHL0850AB 136
48083741_EN 31/07/2018
21.1 [21.113] / 52
K4 clutch
LEIL13WHL0874AB 137
CAS2798.
LEIL13WHL0875AA 138
LEIL13WHL0876AB 139
LEIL13WHL0877AB 140
48083741_EN 31/07/2018
21.1 [21.113] / 53
5. Remove the axial bearing assembly (1) and the idler

gear (2).
LEIL13WHL0878AB 141
6. Remove the needle cage (1) and the axial bearing as-
sembly (2).
NOTE: the gear (3) cannot be removed, it is a shrink fit.
LEIL13WHL0879AB 142
7. Turn shaft (2) by 180° and snap out piston ring (1).
LEIL13WHL0880AB 143
CAS2798.
LEIL13WHL0881AA 144
48083741_EN 31/07/2018
21.1 [21.113] / 54
LEIL13WHL0845AB 145
10. Remove the end shim (1) and the disc set (2) out of
the disc carrier (3).
LEIL13WHL0846AB 146
11. Preload cup springs with special tool 380001556 and

unsnap the L-ring (1).
LEIL13WHL0847AB 147
LEIL13WHL0859AB 148
48083741_EN 31/07/2018
21.1 [21.113] / 55
disc carrier.
LEIL13WHL0849AB 149
LEIL13WHL0850AB 150
Input shaft
1. Snap out piston ring (1). Turbine wheel shaft and drive
gear (2) are secured by a snap ring.
NOTE: when separated, the snap ring will be destroyed.
LEIL13WHL0882AB 151
2. Pull tapered roller bearing off drive gear using special

tool CAS2798.
LEIL13WHL0883AA 152
48083741_EN 31/07/2018
21.1 [21.113] / 56
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.
LEIL13WHL0884AB 153
Output shaft
1. Pull tapered roller bearing off of output shaft using spe-
cial tool CAS2798 and the remove oil sheet (1).
LEIL13WHL0885AB 154
2. Turn the output shaft 180° and pull off tapered roller
bearing with special tool CAS2798.
LEIL13WHL0886AA 155
48083741_EN 31/07/2018
21.1 [21.113] / 57
Powershift transmission - Assemble

Clutches KV/KR/K1/K2/K3/K4 input and output shaft
KV clutch
1. Heat the bearing to approximately 120 °C (248 °F).
LEIL13WHL0887AA 1
2. Mount the bearing (1) until contact is made. Adjust

bearing after it cools. Fit the rectangular ring (2).
NOTICE: always wear protective gloves to prevent burning
your hands when handling heated parts.
LEIL13WHL0888AB 2
3. Mount the bearing cage (1) onto the shaft and oil it.
LEIL13WHL0889AB 3
48083741_EN 31/07/2018
21.1 [21.113] / 58
4. Install the ball bearing (2) into the idler gear (1) until
contact occurs. Use the retaining ring (3) to secure the
bearing (2).
LEIL13WHL0890AB 4
5. Press the pre-assembled idler gear (1) onto the shaft

until contact occurs.
LEIL13WHL0891AB 5
6. Place both O-rings (1) and (2) into the piston grooves.
Oil the O-rings (1) and (2).
NOTE: check the function of the drain valve (3). The ball
must not jam.
LEIL13WHL0892AB 6
7. Place the piston (1) into the disc carrier.

NOTE: observe installation position.
LEIL13WHL0849AB 7
48083741_EN 31/07/2018
21.1 [21.113] / 59
8. Use special tool 380001556 (S) to place piston into the

disc carrier.
LEIL13WHL0893AB 8
9. Mount the inner installer (S) onto the disc carrier. Install
the disc (1), the compression spring (2), the support
shim (3) and the L-ring (4).
NOTE: for installation position of the support shim (3) and
L-ring (4) see the next two steps.
LEIL13WHL0894AB 9
10. Use special tool 380001556 (S1) and pressure piece

(S2) to preload compression spring until the L-Ring
has engaged into the annular grove.
NOTE: Always use a new L-ring.
LEIL13WHL0895AB 10
11. Disc carrier with piston retraction:

1. Washer
3. Support shim
4. L-Ring
5. Disc carrier
6. Drain valve (piston)
7. Piston with O-Rings
LEIL13WHL0896AB 11
48083741_EN 31/07/2018
21.1 [21.113] / 60
12. Install outer and inner discs into the disc carrier (4).
1. Friction disc - coated on one side (1 pcs)
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 20.
NOTE: different clutch disc arrangements with relevant
disc clearance can be installed depending on the parts list
version.
NOTE: the actual installed clutch and disc arrangement LEIL13WHL0897AB 12
must be taken from the corresponding spare parts list. The

spare parts list is binding.
13. Mount end plate (1) and secure disc package using
snap ring (2) e.g. thickness = 2.65 mm (0.104 in)/
recommended value.
LEIL13WHL0898AB 13
14. Press on end plate with a force of approximately 100 N

(22 lb) and set dial indicator to “zero”.
LEIL16WHL0606AB 14
15. Then press end plate against the snap ring (upwards)
and read disc clearance. Disc clearance should be:
2.65 – 2.95 mm (0.104 – 0.116 in).
NOTE: in cases of deviation, the disc clearance must be
corrected with the appropriate snap ring. Optional thick-
nesses range from 2.1 – 4.2 mm (0.083 – 0.165 in).
LEIL16WHL0579AB 15
48083741_EN 31/07/2018
21.1 [21.113] / 61
16. Heat clutch to approximately 120 °C (248 °F).
LEIL13WHL0901AA 16
17. Install the clutch until contact is made. Mount inner

discs onto the inner disc carrier using short left/right
rotations.
LEIL13WHL0902AB 17
18. Use the retaining ring (2) to secure the clutch (1).
LEIL13WHL0903AB 18
19. Heat bearing inner ring to approximately 120 °C

(248 °F).
LEIL13WHL0887AA 19
48083741_EN 31/07/2018
21.1 [21.113] / 62

bearing after it cools.
LEIL13WHL0904AB 20
21. Mount the stud bolt (1), torque to 17 N·m (150 lb in).
Fit rectangular ring (2).
LEIL13WHL0905AB 21
22. Use compressed air at the hole (see arrow) to check

clutch operation. Closing and opening of the clutch
must be clearly audible.
LEIL13WHL0906AB 22
23. Install the sealing cap on orifice (1).

NOTE: wet contact surface with LOCTITE® 262™.
NOTE: the sealing cap is not mounted on all versions. For
versions concerned, see the corresponding spare parts list.
LEIL13WHL0907AB 23
48083741_EN 31/07/2018
21.1 [21.113] / 63
KR clutch
1. Heat bearing to approximately 120 °C (248 °F).
LEIL13WHL0887AA 24

bearing after it cools. Fit rectangular ring (2).
LEIL13WHL0888AB 25
3. Mount needle bearing (1) onto the shaft and oil it.
LEIL13WHL0889AB 26
4. Install the ball bearing (2) into the idler gear (1) until
contact occurs. Use the retaining ring (3) to secure the
bearing (2).
LEIL13WHL0890AB 27
48083741_EN 31/07/2018
21.1 [21.113] / 64
5. Press in pre-assembled idler gear (1) onto the shaft

until contact occurs.
LEIL13WHL0891AB 28
NOTE: check function of the drain valve (3). The ball must
not jam.
LEIL13WHL0892AB 29

LEIL13WHL0849AB 30
8. Use special tool 380001556 (S) to place the piston into

the disc carrier.
LEIL13WHL0893AB 31
48083741_EN 31/07/2018
21.1 [21.113] / 65
the disc (1), the compression spring (2), the support
shim (3) and the L-ring (4).
NOTE: for installation position of the support shim (3), the
L-ring (4) and the inner installer (S), follow the next three
steps.
LEIL13WHL0894AB 32
10. Use special tool assembly 380001556 (S1) and pres-

sure piece (S2) to preload the compression spring un-
til the L-Ring has engaged the annular grove.
NOTE: always use a new L-ring.
LEIL13WHL0895AB 33

1. Washer
3. Support shim
4. L-Ring
5. Disc carrier
6. Drain valve (piston)
7. Piston with O-Rings
LEIL13WHL0896AB 34
12. Install the outer and inner discs into the disc carrier
(4).
version. LEIL13WHL0897AB 35
NOTE: the actual installed clutch and disc arrangement

48083741_EN 31/07/2018
21.1 [21.113] / 66
13. Mount the end plate (1) and secure the disc pack-
age with snap ring (2) e.g. thickness = 2.650 mm
(0.104 in)/recommended value.
LEIL13WHL0898AB 36
14. Press on the end plate with a force of approximately

100 N (22 lb) and set dial indicator to “zero”.
LEIL16WHL0606AB 37
15. Press the end plate against the snap ring (upwards)
and read the disc clearance. The disc clearance
should be 2.650 – 2.95 mm (0.104 – 0.116 in).
NOTE: correct the disc clearance with an appropriate snap
ring in cases of deviation. Optional thicknesses range from
2.1 – 4.2 mm (0.083 – 0.165 in).
LEIL16WHL0579AB 38

LEIL13WHL0901AA 39
48083741_EN 31/07/2018
21.1 [21.113] / 67
17. Install the clutch until contact is made. Mount the inner
discs onto the inner disc carrier using short left/right
rotations.
LEIL13WHL0908AB 40
18. Use the retaining ring (2) to secure the clutch (1).
LEIL13WHL0909AB 41
19. Heat bearing to approximately 120 °C (248 °F)

LEIL13WHL0887AA 42

LEIL13WHL0904AB 43
48083741_EN 31/07/2018
21.1 [21.113] / 68
21. Mount the stud bolt (1) and torque to 17 N·m (150 lb
in). Fit rectangular ring (2).
LEIL13WHL0905AB 44
22. Use the compressed air at the hole (see arrow) to

check clutch operation. Closing and opening of the
clutch must be clearly audible.
LEIL13WHL0906AB 45
23. Install sealing cap on orifice (1).

NOTE: wet contact surface with LOCTITE® 262™.
NOTE: the sealing cap is not mounted on all versions. Ver-
sions concerned, see corresponding spare parts list.
LEIL13WHL0907AB 46
Clutch K1
LEIL13WHL0887AA 47
48083741_EN 31/07/2018
21.1 [21.113] / 69

bearing after it cools. Fit rectangular ring (2).
LEIL13WHL0910AB 48
NOTE: Check function of the drain valve (3). The ball must
not jam.
LEIL13WHL0892AB 49

LEIL13WHL0849AB 50
28. Use special tool 380001556 (S) to place piston into

the disc carrier.
LEIL13WHL0893AB 51
48083741_EN 31/07/2018
21.1 [21.113] / 70
29. Mount the inner installer (S) onto the disc carrier. In-
stall cup spring package (1) and L-ring (2).
LEIL13WHL0911AB 52

(S2) to preload cup spring package until L-Ring has
engaged the annular grove.
LEIL13WHL0895AB 53

1. Cup spring package
2. L-Ring
3. Disc carrier
4. Piston with O-rings
LEIL13WHL0912AB 54
32. Install the outer and inner discs into the disc carrier (4)
.

48083741_EN 31/07/2018
21.1 [21.113] / 71
33. Mount end plate (1) and secure disc package using
snap ring (2) e.g. thickness = 2.65 mm (0.104 in)/
recommended value.
LEIL13WHL0898AB 56

100 N = 10 kg and set dial indicator to “zero”.
LEIL16WHL0606AB 57
should be 2.35 – 2.65 mm (0.093 – 0.104 in).
2.1 – 4.2 mm (0.083 – 0.165 in).
LEIL16WHL0579AB 58
36. Heat the clutch to approximately 120 °C (248 °F).
LEIL13WHL0901AA 59
48083741_EN 31/07/2018
21.1 [21.113] / 72
37. Install the clutch (1) until contact is made.

LEIL13WHL0914AB 60
38. Mount and oil the running disc (1), the axial cage (2)
and the axial washer (3).
NOTE: install chamfer of running disc (1) showing towards
the axial cage.
LEIL13WHL0915AB 61
39. Mount and oil the needle bearing (1).
LEIL13WHL0916AB 62
40. Install the (1) idler. Mount the inner discs onto the in-
ner disc carrier (idler) by using short left/right rotations.
LEIL13WHL0917AB 63
48083741_EN 31/07/2018
21.1 [21.113] / 73
41. Mount and oil the axial washer (1), the axial cage (2)
and the running disc (3).
NOTE: install chamfer of the running disc (3) showing to-
wards the axial cage.
LEIL13WHL0918AB 64
42. Secure the idler gear (1) and single parts with the re-
taining ring (2).
LEIL13WHL0919AB 65

LEIL13WHL0887AA 66

LEIL13WHL0920AB 67
48083741_EN 31/07/2018
21.1 [21.113] / 74
in). Fit the rectangular ring (2).
LEIL13WHL0921AB 68

LEIL13WHL0922AA 69
Clutch K2
LEIL13WHL0887AA 70

LEIL13WHL0923AB 71
48083741_EN 31/07/2018
21.1 [21.113] / 75
not jam.
LEIL13WHL0892AB 72

LEIL13WHL0849AB 73

disc carrier.
LEIL13WHL0893AB 74
the cup spring package (1) and L-ring (2)
NOTE: for installation position cup spring package (1) and
L-ring (2).
LEIL13WHL0911AB 75
48083741_EN 31/07/2018
21.1 [21.113] / 76
7. Preload cup spring package with the special tool

380001556 (S1) and the pressure piece (S2), until
L-Ring has engaged into the annular grove.
LEIL13WHL0895AB 76

2. L-Ring
3. Disc carrier
LEIL13WHL0912AB 77
version.

10. Mount the end plate (1) and secure disc package with
the snap ring (2) e.g. thickness = 2.65 mm (0.104 in)/
recommended value.
LEIL13WHL0898AB 79
48083741_EN 31/07/2018
21.1 [21.113] / 77

LEIL16WHL0606AB 80
should be 1.75 – 2.05 mm (0.069 – 0.081 in).
2.1 – 4.2 mm (0.083 – 0.165 in).
LEIL16WHL0579AB 81

LEIL13WHL0901AA 82
14. Mount the clutch (1) until contact is made.
LEIL13WHL0925AB 83
48083741_EN 31/07/2018
21.1 [21.113] / 78
NOTE: Install chamfer of running disc (1) showing towards
the axial cage.
LEIL13WHL0926AB 84
16. Mount the needle bearing (1). Oil the needle bearing
(1).
LEIL13WHL0927AB 85
17. Install the idler (1). Mount inner discs onto the inner
discs carrier (idler) by using short left/right rotations.
LEIL13WHL0928AB 86
the axial cage.
LEIL13WHL0929AB 87
48083741_EN 31/07/2018
21.1 [21.113] / 79
19. Use the retaining ring (2) to secure the idler gear (1)
and single parts.
LEIL13WHL0930AB 88

LEIL13WHL0887AA 89

LEIL13WHL0931AB 90
in). Fit the rectangular ring (2) .
LEIL13WHL0932AB 91
48083741_EN 31/07/2018
21.1 [21.113] / 80

LEIL13WHL0933AA 92
Clutck K3
1. Heat bearing to approximately +120 °C (+248 °F).
LEIL13WHL0887AA 93
2. Mount the bearing (1) until contact is made. Adjust the

bearing after it cools. Fit the rectangular ring (2). Mount
the stud bolt (3) and torque to 17 N·m (150 lb in).
LEIL13WHL0934AB 94
3. Place both O-rings (1) and (2) into the piston Oil the
O-rings (1) and (2).
not jam.
LEIL13WHL0892AB 95
48083741_EN 31/07/2018
21.1 [21.113] / 81

LEIL13WHL0849AB 96

disc carrier.
LEIL13WHL0893AB 97
the cup spring package (1) and L-ring (2).
NOTE: for installation position of cup spring package and
L-ring see next two steps.
LEIL13WHL0911AB 98

(S2), until L-Ring has engaged into the annular grove
to preload cup spring package.
LEIL13WHL0895AB 99
48083741_EN 31/07/2018
21.1 [21.113] / 82

2. L-Ring
3. Disc carrier
4. Piston with O-rings.
LEIL13WHL0912AB 100
version.

10. Mount the end plate (1) and secure disc package with
the snap ring (2) e.g. thickness = 2.65 mm (0.104 in)/
recommended value.
LEIL13WHL0898AB 102

LEIL16WHL0606AB 103
48083741_EN 31/07/2018
21.1 [21.113] / 83
should be 1.75 – 2.05 mm (0.069 – 0.081 in).
2.1 – 4.2 mm (0.083 – 0.165 in).
LEIL16WHL0579AB 104
13. Heat the clutch inner diameter to approximately

120 °C (248 °F).
LEIL13WHL0901AA 105
14. Mount the clutch (1) until contact is made.
LEIL13WHL0935AB 106
the axial cage.
LEIL13WHL0936AB 107
48083741_EN 31/07/2018
21.1 [21.113] / 84
LEIL13WHL0937AB 108
17. Install the idler (1). Mount inner discs onto the inner
disc carrier (idler) using short left/right rotations.
LEIL13WHL0938AB 109
the axial cage.
LEIL13WHL0939AB 110

LEIL13WHL0940AA 111
48083741_EN 31/07/2018
21.1 [21.113] / 85
LEIL13WHL0887AA 112

LEIL13WHL0941AB 113

LEIL13WHL0942AA 114
K4 clutch
LEIL13WHL0887AA 115
48083741_EN 31/07/2018
21.1 [21.113] / 86

bearing after it cools. Fit the angular ring (2).
LEIL13WHL0943AB 116
3. Cool the shaft (1) to approximately -80 °C (-112 °F),

heat the gear (2) to approximately +120 °C (+248 °F)
and mount until contact is made.
LEIL13WHL0944AB 117
4. Use the retaining ring (1) to secure the gear.
LEIL13WHL0945AB 118
5. Mount the lower and upper axial washers (1) and the
axial needle cage (2). Oil the axial needle cage (2).
NOTE: the upper and the lower axial washers are identical.
LEIL13WHL0946AB 119
48083741_EN 31/07/2018
21.1 [21.113] / 87
LEIL13WHL0947AB 120
7. Mount the idler gear (1).
LEIL13WHL0948AB 121
8. Mount and oil the axial washer (1), the axial needle
bearing (2) and running disc.
NOTE: mount running disc (3) with the chamfer pointing to
the needle cage.
LEIL13WHL0949AB 122
not jam.
LEIL13WHL0892AB 123
48083741_EN 31/07/2018
21.1 [21.113] / 88

LEIL13WHL0849AB 124
11. Use special tool 380001556 (S) to place the piston into
the disc carrier.
LEIL13WHL0893AB 125
12. Mount the inner installer (S) onto the disc carrier. In-
stall the cup spring package (1) and the L-ring (2).
NOTE: for installation position of cup spring package and
L-ring see the next two steps.
LEIL13WHL0911AB 126
13. Preload cup spring package using with the special tool
380001556 (S1) and pressure piece (S2), until the
L-Ring has engaged into the annular groove.
LEIL13WHL0895AB 127
48083741_EN 31/07/2018
21.1 [21.113] / 89

2. L-ring
3. Disc carrier
LEIL13WHL0912AB 128
15. Install the outer and inner discs into the disc carrier
(4).
1. Friction disc - coated on one side - (1pcs)

16. Mount the end plate (1) and secure the disc pack-
age with a snap ring (2) e.g. thickness = 2.65 mm
(0.104 in)/recommended value.
LEIL13WHL0898AB 130

LEIL16WHL0606AB 131
48083741_EN 31/07/2018
21.1 [21.113] / 90
should be 1.35 – 1.65 mm (0.053 – 0.065 in).
NOTE: Correct the disc clearance with an appropriate snap
2.1 – 4.2 mm (0.083 – 0.165 in).
LEIL16WHL0579AB 132
19. Heat the clutch inner diameter to approximately

120 °C (248 °F).
LEIL13WHL0901AA 133
20. Mount the clutch (1) until contact is made. Mount the
inner discs onto the inner disc carrier using short left/
right rotations.
LEIL13WHL0951AB 134
21. Use the retaining ring (1) to secure the clutch.
LEIL13WHL0952AB 135
48083741_EN 31/07/2018
21.1 [21.113] / 91
22. Heat bearing inner ring to approximately 120 °C

(248 °F).
LEIL13WHL0887AA 136

Fit the rectangular ring (2).
Torque the stud bolt (3) to 17 N·m (150 lb in).
LEIL13WHL0953AB 137

LEIL13WHL0954AA 138
Input shaft
1. Cool the input shaft (1) to approximately -80 °C
(-112 °F) and heat the drive gear (2) to approximately
+120 °C (+248 °F). Mount until contact is made.
LEIL13WHL0955AB 139
48083741_EN 31/07/2018
21.1 [21.113] / 92
2. Use the retaining ring (1) to secure the drive gear .
LEIL13WHL0956AB 140
3. Heat the bearing to approximately +120 °C (+248 °F).

LEIL13WHL0887AA 141

LEIL13WHL0957AB 142
LEIL13WHL0887AA 143
48083741_EN 31/07/2018
21.1 [21.113] / 93

LEIL13WHL0958AB 144
7. Install the snap ring (1) into the annular groove of the
turbine shaft (2).
LEIL13WHL0959AB 145
8. Mount the turbine shaft (1) until the snap ring engages
into the input shaft groove. Snap in and interlock rect-
angular ring (2).
NOTE: turbine shaft is axially secured.
LEIL13WHL0960AB 146
9. Version with lock-up clutch:

Mount the turbine shaft (1) until the snap ring engages
into the input shaft groove. Snap in and interlock rect-
angular rings (2) and (3).
NOTE: turbine shaft is axially secured.
LEIL13WHL0961AB 147
48083741_EN 31/07/2018
21.1 [21.113] / 94
Output shaft
LEIL13WHL0887AA 148

LEIL13WHL0962AB 149
3. Mount the screen sheet (1).
LEIL13WHL0963AB 150

LEIL13WHL0887AA 151
48083741_EN 31/07/2018
21.1 [21.113] / 95

LEIL13WHL0964AB 152
Installation of input shaft, output shaft, pump shaft (power-take off shaft) and clutches
NOTE: only for Europe market.
If the suction tube (1) in the front housing is to be re-
placed, use a special rolling tool 380001285 for the as-
sembly. Secure the tube with the cylindrical bolts (2).
Torque to 23 N·m (17 lb ft).
NOTE: oil the cylindrical bolts. Use always new cylindrical
bolts.
LEIL13WHL0965AB 153
The lubricating oil tube (1) is supplied as a complete

package with the front housing only. Single parts deliv-
ery are available only upon request.
NOTE: Assembly is only possible with special tool
380001287.
LEIL13WHL0966AB 154
48083741_EN 31/07/2018
21.1 [21.113] / 96
NOTE: only for North American market.

6. If the suction tube (1) in the front housing is to be re-
placed secure the tube with the cylindrical bolts (2).
NOTE: oil the cylindrical bolts. Use always new cylindrical
bolts.
LEIL13WHL0965AB 155
7. The lubricating oil tube (1) is supplied as a complete

package with the front housing only. Single parts deliv-
ery are available only upon request.
NOTE: North American Dealers contact CNH special tool
rental program from correct special tools.
LEIL13WHL0966AB 156
1. Mount the O-rings into the oil tube annular grooves (1)
and (2) and oil them. Insert tubes into the front housing.
Oil the cylindrical bolts (3) and (4).
Torque the cylindrical bolts (3) and (4) to 23 N·m (17 lb
ft).
NOTE: always use new cylindrical bolts.
LEIL13WHL0967AB 157
2. Mount and oil the O-rings into the oil tube annular
grooves (1) and (2). Insert the tubes into the front
housing.
LEIL13WHL0968AB 158
48083741_EN 31/07/2018
21.1 [21.113] / 97
3. The lubricating oil tubes (1) and (2) are supplied as a

complete package with the rear housing. Single parts
delivery available only upon request.
NOTE: for the European market: the assembly is only pos-
sible with special tool 380001287, for the North American
market, the dealers ask to CNHind for the correct special
tools.
LEIL13WHL0969AB 159
4. Insert all bearing outer rings into the bearing holes of

both housing sections.
Front housing.
1. Input
2. Output
3. Forward clutch
4. Reverse clutch
5. K1 = 1st gear clutch
6. K2 = 2nd gear clutch
7. K3 = 3rd gear clutch
LEIL13WHL0970AB 160
8. K4 = 4th gear clutch.
NOTE: for installation position, see the next two steps.
5. Place bearing outer rings into the bearing holes using
assembly grease.
NOTE: if contrary to manufacturer recommendation, the ta-
pered roller bearings of clutches, input and output are not
replaced, you must ensure the previous pairing (bearing in-
ner ring/bearing outer ring) - see disassembly instructions.
LEIL13WHL0971AB 161
6. Place KR clutch (1), AN input shaft (2) and KV clutch

(3) into the housing rear section at the same time.
NOTICE: risk of injury.
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.
LEIL13WHL0972AB 162
48083741_EN 31/07/2018
21.1 [21.113] / 98
7. Slightly lift the drive gear (1) and position the K4 clutch
(2).
LEIL13WHL0973AB 163
8. Mount the K3 clutch (1).
LEIL13WHL0974AB 164
9. Position the K2 clutch (1).
LEIL13WHL0975AB 165
10. Slightly lift the K4 clutch (1) and position the K1 clutch
(2).
LEIL13WHL0976AB 166
48083741_EN 31/07/2018
21.1 [21.113] / 99
11. Press the ball bearing (1) onto the pump shaft (2) un-
til contact is made. Mount the rectangular ring (3).
Grease and centrically align the rectangular ring.
LEIL13WHL0977AB 167
12. Mount the pump shaft (1) until contact is made. Attach
the pump shaft using the retaining ring (2).
LEIL13WHL0978AB 168
13. Secure clutches K1 (1), K2 (2), K3 (3) and K4 (4) by

using a special handle tool 380001557 (S). 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.
NOTICE: 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.
LEIL13WHL0979AB 169
14. Pivot rear housing 180° by using a suitable lifting de-

vice.
1. Clutch KV
2. Input shaft
3. Clutch KR
4. Pump shaft
NOTICE: clutches KV, KR and input shaft (2) are only se-
cured by the gear chain. Take care to ensure that these
LEIL13WHL0980AB 170
48083741_EN 31/07/2018
21.1 [21.113] / 100
15. Use the suitable lifting device to bring the rear hous-
ing into contact position with the front housing by cau-
tiously assembling the clutches. Then remove han-
dles.
LEIL13WHL0981AA 171
16. Remove the rear housing again.
LEIL13WHL0982AA 172
17. Position the screen sheet (1). Install the pre-assem-

bled output shaft (2).
LEIL13WHL0983AB 173
18. Oil the cylindrical bolts (1) and use them to attach
screen sheet (1). Torque to 23 N·m (17 lb ft). Mount
O-rings (2) into the annular grooves of the oil tubes
and oil them. Mount all rectangular rings (4), grease
and align them centrally. Wet mounting face (3) with
sealing agent LOCTITE® 574™.
NOTE: always use new cylindrical bolts.
LEIL13WHL0984AB 174
48083741_EN 31/07/2018
21.1 [21.113] / 101
19. Carefully bring the front housing into contact position

with the rear housing by using a suitable lifting device.
NOTE: be sure that both oil tubes are aligned with the holes
in the rear housing.
LEIL13WHL0985AA 175
20. Fit both cylindrical pins (1) centrically to the mounting

face.
LEIL13WHL0986AB 176
21. Check the clearance of the gear drive train. Position

driving element (S) and rotate KV clutch shaft. Driving
element can be fabricated by dealer.
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. Do this step on all clutch shafts.
LEIL13WHL0987AB 177
22. Join front and rear housing sections using cylindrical

bolts (1). Torque to 46 N·m (34 lb ft). Mount securing
plate (2). Mount stud bolts (3) and torque to 15 N·m
(133 lb in).
NOTE: wet bolt-in thread with LOCTITE® 243™.
LEIL13WHL0988AB 178
48083741_EN 31/07/2018
21.1 [21.113] / 102
23. The bolt plugs (1) must be mounted with a hydraulic

pneumatic pressing tool.
NOTE: in case of damage the pre-mounted rear transmis-
sion housing must be fully replaced.
LEIL13WHL0989AB 179
Outputs and closure parts pump shaft (PTO-shaft)
Output flange output side with brake FSG-88

1. Use driver tool 380001560 (S) to mount shaft seal with
the sealing lip showing to the oil sump. Fill the space
between sealing lip and dust lip with grease. Wet outer
diameter (rubber-coated) with mineral spirit.
NOTE: use of specified driver (S) ensures the exact instal-
lation position.
LEIL13WHL0990AB 180
2. Press the screen sheet (1) onto the output flange (2).
Mount the output flange (2) until contact is made.
LEIL13WHL0991AB 181
3. Insert the O-ring into the space between the output

flange and the shaft. Attach the output flange (1) the
washer (2) and the hexagonal bolts. Oil the hexagonal
bolts before the assembly.
Torque to 46 N·m (34 lb ft). Mount the cylindrical bolt
with washer (3) for stop of the parking brake set screw.
Tightening to torque 48 N·m (35 lb ft).
NOTE: always use new hexagonal bolts.
LEIL13WHL0992AB 182
48083741_EN 31/07/2018
21.1 [21.113] / 103
4. Secure the brake disc (1) at the output flange (2) using
hexagonal bolts and washers. Torque to 68 N·m (50 lb
ft). Connect a hand-operated pump at port and apply
approximately 80 bar (1160 psi) pressure to the park-
ing brake (3) and bring it in contact position.
LEIL13WHL0993AB 183
5. Attach the parking brake (1) on transmission housing

using the hexagonal bolt - guide pin (2).
LEIL13WHL0994AB 184
6. Secure the hexagonal nut on brake caliper using the

open end wrench insert. Torque to 230 N·m (170 lb ft).
LEIL13WHL0995AA 185
7. Insert setting gauge on both sides between base disc

and brake disc and hold in its position. Clearance: 0.5
– 1.5 mm (0.02 – 0.06 in), Nominal clearance: 1.0 mm
(0.04 in).
LEIL13WHL0996AA 186
48083741_EN 31/07/2018
21.1 [21.113] / 104
Output flange on converter side (Standard versions)

1. Use driver tool 380001560 (S) to mount shaft seal, with
the sealing lip showing to the oil sump.
NOTE: use of the specified driver (S) ensures the exact
installation position.
NOTE: fill space between sealing lip and dust lip with
grease.
LEIL13WHL0997AB 187
1. Shaft seal
2. Gearbox housing - rear section
3. Output shaft
4. Screen sheet
LEIL13WHL0998AB 188
2. Press the screen sheet (1) onto the input flange (2).
Mount the output flange (2) until contact is made.
LEIL13WHL0999AB 189
3. Insert the O-ring into the space between the output

flange and the shaft. Secure the output flange (1) with
the washer (2) and the hexagonal bolts (3). Oil the
hexagonal bolts before the assembly.
LEIL13WHL1000AB 190
48083741_EN 31/07/2018
21.1 [21.113] / 105
Reassembly: Engine connection, oil pressure pump, converter back-pressure valve and
temperature sensor
Converter back-pressure valve

1. The Step shows the single parts of the converter back-
pressure valve.
1. Oil feed housing
2. Piston
4. Pressure plate
5. Locking plate.
NOTE: install pressure plate (4), with the pin (6 mm diam-
eter) facing towards the locking plate (1).
LEIL13WHL1001AB 191
2. Assemble single parts, preload them with screwdriver

(1) and secure them with the locking plate (2).
LEIL13WHL1002AB 192
3. Mount the temperature sensor (1) with O-ring. Torque

to 25 N·m (18 lb ft).
NOTE: for version without a temperature sensor, fit a plug
(1) with O-ring and torque to 25 N·m (18 lb ft).
LEIL13WHL1003AB 193
48083741_EN 31/07/2018
21.1 [21.113] / 106
Oil pressure pump

4. Insert the pressure relief valve (1) into the housing hole
until contact is made. Mount two M8 adjusting bolts (S)
and position gasket (2) and oil feed housing (3). Use
assembly grease.
NOTE: the pressure relief valve is not mounted on all ver-
sions. Versions concerned, see the corresponding spare
parts list.
LEIL13WHL1004AB 194
5. Install two adjusting bolts (S) and mount stator shaft (1).
NOTE: pay attention to radial installation position.
LEIL13WHL1005AB 195
6. Install outer rotor with the chamfer (see arrow) facing

downwards.
NOTE: if there are wear marks in the pump housing or on
the control disc, replace the pump assembly.
LEIL13WHL1006AA 196
7. Install inner rotor with the teeth (see arrow) facing up-
wards.
LEIL13WHL1007AA 197
48083741_EN 31/07/2018
21.1 [21.113] / 107
8. Position control disc and secure it radially using two

cylindrical bolts (1). Place the O-ring (2) into the an-
nular groove. Oil the O-ring (2).
NOTE: do not tighten the cylindrical bolts - only turn them
in until contact is made and then turn them back by approx-
imately 1/2 a turn. Pay attention to the installation position
of the control disc in figure.
LEIL13WHL1008AB 198
9. With the sealing lip positioned facing downward, care-

fully insert the shaft seal (1) into the pump housing with
suitable driver (2) until contact is made.
NOTE: wet outer diameter of shaft seal with mineral spirits.
LEIL13WHL1009AB 199
10. Oil sliding bearing (see arrow) before assembly.

Mount the inner installer (S) onto the stator shaft.
Mount the pre-assembled transmission pump (1).
NOTE: pay attention to radial installation position.
LEIL13WHL1010AB 200
11. Mount the pre-assembled pump with driver (S) until

contact is made.
LEIL13WHL1011AB 201
48083741_EN 31/07/2018
21.1 [21.113] / 108
12. Grease the O-rings. Fit the O-rings to the cylindrical

bolts (1). Secure the transmission pump (2) with cylin-
drical bolts.
LEIL13WHL1012AB 202
13. Secure oil feed housing (1) equally using Torx bolts
(2). Torque to 23 N·m (17 lb ft). Secure plate (3) with
cylindrical bolts (4). Torque to 34 N·m (25 lb ft).
LEIL13WHL1013AB 203
14. Use the hexagonal bolts (2) to secure the converter

bell housing (1).
LEIL13WHL1014AB 204
Engine connection (remote mount)

1. Bolt input shaft (1) to flex plate (2) with hexagonal bolts
(3). Torque to 115 N·m (85 lb ft).
NOTE: wet threads of hex bolts with LOCTITE® 262™.
LEIL13WHL1015AB 205
48083741_EN 31/07/2018
21.1 [21.113] / 109
2. Use the hexagonal bolts (2) to secure the flex plate (1)
to the converter (3).
NOTE: Wet threads of hexagonal bolts with LOCTITE®
262™.
LEIL13WHL1016AB 206
3. Install the ball bearing (1). Secure the ball bearing (1)
with the V-ring (2).
LEIL13WHL1017AB 207
4. Put the cover (1) onto the converter. Press the cover
(1) until contact is made.
NOTE: support the pressure sleeve (S) on the bearing in-
ner ring.
LEIL13WHL1018AB 208
5. Press the screen sheet (1) onto the input flange (2).
LEIL13WHL1019AB 209
48083741_EN 31/07/2018
21.1 [21.113] / 110
6. Heat the flange inner diameter to approximately 120 °C

(248 °F).
LEIL13WHL1020AA 210
7. Mount the input flange (1) until contact is made.
LEIL13WHL1021AB 211
8. Use the washer (1) and the hexagonal bolts to secure

the input flange (3). Oil the hexagonal bolts before
assembly.
LEIL13WHL1022AB 212
9. Position the converter using a suitable lifting device un-

til the cover (1) is in contact with the converter bell hous-
ing (2) .
LEIL13WHL1023AB 213
48083741_EN 31/07/2018
21.1 [21.113] / 111
10. Secure the bolt converter bell housing (1) to the cover
(2) using the cylindrical bolts and the hexagonal nuts
(3). Torque to 46 N·m (34 lb ft).
NOTE: pay attention to radial installation position markings
made during disassembly (see arrows).
LEIL13WHL1024AB 214
Reassembly - Emergency steering pump
Version without emergency steering pump

11. Install the adjusting bolts (S). Assemble the seal (1)
and the cover (2).
LEIL13WHL1025AB 215
12. Attach the cover with hexagonal bolts (1).

LEIL13WHL1026AB 216
48083741_EN 31/07/2018
21.1 [21.113] / 112
Reassembly: Inductive sensor, Hall sensor, breather, oil filler and oil drain plug
1. Mount the inductive sensors (1) , (2) and (3) with
O-rings and torque to 30 N·m (22 lb ft).
1. Inductive sensor - turbine speed
2. Inductive sensor - speed/central gear chain
3. Inductive sensor - engine speed.
2. Mount the breather (4) and torque to 12 N·m (106 lb
in).
Mount he speed sensor (Hall sensor) - output speed
(5) with O-ring. Secure it with a cylindrical bolt (6) and
torque to 23 N·m (17 lb ft).
Mount the (7) with O-ring and torque to 80 N·m (59 lb
ft).
Attach the cover (8) with seal to the housing front
section securing it with hexagonal bolts (9), torque to
23 N·m (17 lb ft).
LEIL13WHL1027BB 217
3. Mount the oil drain plug with O-ring (1) and torque to
80 N·m (59 lb ft).
Attach the oil level tube (2) with seal to the housing front
section and secure it with hexagonal bolts (3). Torque
to 34 N·m (25 lb ft).
Fasten the dipstick (4) in oil level tube.
Attach the identification plate (5) to the housing front
section.
NOTE: use LOCTITE® (type No. MS 9360).
LEIL13WHL1028AB 218
48083741_EN 31/07/2018
21.1 [21.113] / 113
Reassembly Electro-hydraulic control with proportional valves
LEIL13WHL1029FB 219
1. Main pressure valve: 16 – 18 bar (232 – 261 psi) 4. Cover

2. Pressure reducing valve: 9 bar (130 psi) 5. Housing
3. Wiring harness 6. Valve block
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
electro-hydraulic control.
A. Proportional valve P5
B. Vibration damper
C. Follow-on side
D. Pressure controller
LEIL13WHL1030AB 220
48083741_EN 31/07/2018
21.1 [21.113] / 114
LEIL13WHL1031EB 221
A. Main pressure valve: 16+2 bar D. Pressure reducing valve: 9 bar

B. Valve block E. Duct plate
C. Wiring harness
Fitting of electric control

NOTICE: check all single parts for damage and replace if required. Ensure free travel of the moving parts in the valve
block before installation. Pistons can be exchanged individually. Before installation, oil single parts.
1. With the concave side facing upward, insert orifice (1)
until contact is made.
LEIL13WHL1032AB 222
2. This Step shows the following single parts:

1. Pressure reducing valve (1x, piston and compres-
sion spring)
2. Vibration damper (3x, piston and compression
spring)
3. Follow-on slide (3x, piston and compression
spring)
LEIL13WHL1033AB 223
48083741_EN 31/07/2018
21.1 [21.113] / 115
3. Install the single parts shown in above step. Preload

compression springs of the follow-on slides and tem-
porarily secure pistons using 5.0 mm (0.2 in) diameter
cylindrical pins (S).
LEIL13WHL1034AB 224
4. Fit adjusting bolts 380001577 (S). Mount seal (1) and

housing (2). Then position housing equally using the
adjusting bolts until contact is made.
LEIL13WHL1035AB 225
5. Bring housing (1) into contact position using the Torx

bolts. This preloads the pistons, allowing removal of
the cylindrical pins (assembly aid).
LEIL13WHL1036AB 226
6. Use the Torx bolts (1) to secure the housing.

Torque to 5.5 N·m (48.7 lb in).
LEIL13WHL1037AB 227
48083741_EN 31/07/2018
21.1 [21.113] / 116
7. Mount the pressure controllers with O-ring (1) and se-

cure them with the securing plates (2) and the Torx bolts
(3).
NOTE: install the securing plate with the claw side facing
downward. Pay attention to the radial installation position
of pressure controllers.
LEIL13WHL1038AB 228
8. Preassemble the opposite side with the following single

parts:
1. Main pressure valve (1x, Piston and compression
spring)
2. Vibration damper (3x, Piston and compression
spring)
3. Follow-on slide (3x, Piston and compression
spring).
LEIL13WHL1039AB 229
9. Install the single parts. Preload the compression

springs of the follow-on slides and temporarily fasten
the pistons using the 5.0 mm diameter cylindrical pins
(S).
Install two adjusting bolts (S). Assemble flat gasket (1)
and housing cover. Place the housing cover equally
until contact by using the adjusting bolts.
LEIL13WHL1040AB 230
10. Preload the pistons with Torx bolts and remove the
cylindrical pins (assembly aid) again. Then secure the
housing cover using Torx bolts (1). Torque to 5.5 N·m
(48.7 lb in).
LEIL13WHL1041AB 231
48083741_EN 31/07/2018
21.1 [21.113] / 117
11. Mount the pressure regulators with O-ring (1) and

fasten them using securing plates and cap screws.
NOTE: install the securing plate with the neck facing down-
ward. Observe radial installation position of the pressure
regulators.
LEIL13WHL1042AB 232
12. Assemble the wiring harness (1) and connect the

pressure regulators.
NOTE: pay attention to the installation position of the wiring
harness - see markings made during disassembly.
LEIL13WHL1043AB 233
13. Install the flat gasket (1) and assemble the plug
socket with the slot facing the lug of the cover until it
makes contact. Secure the cover using cap screws
and torque to 5.5 N·m (48.7 lb in).
LEIL13WHL1044AB 234
14. Secure the wiring harness using the retaining clamp

(1). Install the opposite cover.
LEIL13WHL1045AB 235
48083741_EN 31/07/2018
21.1 [21.113] / 118
Version with torque converter lock-up clutch solenoid valve

NOTE: Perform the following two steps only for version with torque converter lock-up clutch solenoid valve.
15. Position the seal (1) and secure connecting housing
(2) with Torx bolts (3).
NOTE: pay attention to installation position of connection
housing, see markings applied during disassembly.
LEIL13WHL1057AB 236
16. Use the cylindrical bolts (2) to secure the pressure

controller (1)
Torque to 10 N·m (89 lb in).
Fit the bolt necks (3) with O-ring and torque to 25 N·m
(18 lb ft). Fit the plug (4) with O-ring and torque to
10 N·m (89 lb in).
LEIL13WHL1058AB 237
17. Install the two adjusting bolts (S).
LEIL13WHL1046AB 238
18. Flush-mount screens (1) into the holes of the sealing

plate, see arrows.
NOTE: pay attention to the installation position, - screens
should face upwards toward the duct plate.
LEIL13WHL1047AB 239
48083741_EN 31/07/2018
21.1 [21.113] / 119
19. Attach the sealing plate (1) and duct plate (2).
Screens (3) should face upward.
NOTE: do not re-assemble the seal plate after opening the
threaded joint shift unit/duct plate. In case of repair, always
mount a new seal plate.
LEIL13WHL0781AB 240
20. Position duct plate (1) and secure it equally using Torx
bolts (2). Torque to 10.5 N·m (93 lb in).
LEIL13WHL1049AB 241
21. Install bolt plugs with O-rings (1) and torque them to
6 N·m (53 lb in).
LEIL13WHL1050AB 242
22. Insert the converter safety valve (1) into the housing
hole until contact is made.
LEIL13WHL1051AB 243
48083741_EN 31/07/2018
21.1 [21.113] / 120
23. Mount the stud bolts (1) and torque to 15 N·m (133 lb
in).
Position the seal (2) and the duct plate (3) on the rear
housing until contact is made.
NOTE: wet bolt-in thread with LOCTITE® 242®.
NOTE: use assembly grease.
LEIL13WHL1052AB 244
24. Secure the duct plate (1) using the Torx bolts (2)
and hexagonal nuts (3). Torque to 23 N·m (17 lb ft).
Mount the plug (4) with new O-ring and torque to
30 N·m (22 lb ft).
LEIL13WHL1053AB 245
48083741_EN 31/07/2018
21.1 [21.113] / 121
25. Mount the compression spring (4), the piston (3) and
the switch (2) with new O-ring. Torque to 30 N·m
(22 lb ft).
1. Filter differential pressure valve
2. Switch with O-ring
3. Piston
LEIL13WHL1054AB 246
26. Fit the two adjusting bolts (S). Mount the sealing plate
(1) and the electro-hydraulic control unit (2).
NOTE: do not re-assemble the seal plate after opening the
threaded joint of the shift unit/gearbox housing. In the case
of repair, a new seal plate must be mounted.
LEIL13WHL1055AB 247
27. Secure the electro-hydraulic control unit (1) evenly

using the Torx bolts (2) and torque them to 9.5 N·m
(84 lb in).
LEIL13WHL1056AB 248
Pipe - System pressure to lock-up clutch valve

1. Secure the pipe (1) with hollow bolt (2) and bolt nut (3).
Fit the O-ring on to hollow bolt (2), insert it into the eye
of the pipe and torque to 45 N·m (33 lb ft). Attach the
bolt nut (3) and torque to 35 N·m (26 lb ft).
LEIL13WHL1059AB 249
48083741_EN 31/07/2018
21.1 [21.113] / 122
Pipe - System pressure from lock-up clutch valve to lock-up clutch

1. Insert screw-in sleeve (1) and torque to 45 N·m (33 lb
ft).
NOTE: wet bolt-in thread with LOCTITE® 243™.
2. Secure the pipe (2) with nuts (3) and (4). Torque the
nut (3) to 35 N·m (26 lb ft). Torque nut (4) to 45 N·m
(33 lb ft).
LEIL13WHL1060AB 250
Fitting oil filter (pressure filter)

1. Secure the filter head (1) with new O-rings to the rear
housing using Torx bolts (2) . Torque to 34 N·m (25 lb
ft).
LEIL13WHL1061AB 251
2. Install new filter element.

NOTE: before putting the transmission into operation, fill it
with oil according to operators manual.
LEIL13WHL1062AA 252
48083741_EN 31/07/2018
21.1 [21.113] / 123
Powershift transmission - Testing

Test N°1
Test Point Condition
When the transmission reaches overheated condition, shift to Neutral and maintain engine RPM at a fast
idle ( 1250 – 1450 RPM ).
Check
Expected Result
Result Oil temperature returns to Normal - establish length of time (2 to 3 minutes).
Action
1. Check oil level, type and grade is correct.
2. Check operator’s gear selection is correct for conditions.
3. Make sure brakes are fully released.
4. Check the engine full throttle and stall speeds are correct as specified.
Other Action
Result Oil temperature remains overheated.
(Possible 1. Check for dirty radiator - airflow restricted.
Cause) 2. Check for engine overheating problem.
3. Check for faulty oil temperature gauge and sender or switch.
48083741_EN 31/07/2018
21.1 [21.113] / 124
Index
Transmission - 21

Powershift transmission - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Powershift transmission - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Powershift transmission - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Powershift transmission - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Powershift transmission - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Powershift transmission - Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Powershift transmission - Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
Powershift transmission - Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
48083741_EN 31/07/2018
21.1 [21.113] / 125
48083741_EN 31/07/2018
21.1 [21.113] / 126
Transmission - 21
Powershift transmission internal components - 155

48083741_EN 31/07/2018
21.2 [21.155] / 1
Contents
Transmission - 21
FUNCTIONAL DATA
Clutch
Dynamic description - Transmission Clutch Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
48083741_EN 31/07/2018
21.2 [21.155] / 2
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 1500 hours thereafter. The calibration needs to first be conducted to make up for the rapid
wear that happens as the initial break-in happens.
Multifunction Navigation Key Pad

The keypad is located on the right-hand external birder of the LCD multifunction display.
Use this keypad to move from one screen to another, to choose various selections, to monitor the machine functions,
and to 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 (B), (C), (D) and (E) to scroll to the desired selection, highlight that
selection and press the confirm/enter key (F).
Follow any screen prompts when given and use the confirm key to enter the selection. Use the escape key (A) to
return to the main menu. This will lock the chosen selection into memory.
You can access all functions in the same basic manner.
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 selections.
LEIL15WHL0581BB 1
48083741_EN 31/07/2018
21.2 [21.155] / 3
Accessing Clutch Calibration Feature

1. Park the machine on a level surface. Lower the bucket
to the ground.
Start the machine.
Move the transmission control lever in NEUTRAL.
Push the parking brake switch on the multifunction
keypad.
LEIL16WHL1125AA 2
2. Press the Machine Service key on the LCD multi-func-

tion display to access the Machine Service screen.
LEIL16WHL2335AB 3
3. Use up or down arrow to select the Calibration Set-

tings item. Press the enter/confirm key to access the
selection screen.
LEIL16WHL0874AA 4
4. The screen displays the three conditions to be satisfied

before starting the transmission clutch calibration.
• The transmission oil temperature must be within range

of 75 – 90 °C (167 – 194 °F).
• The transmission control lever must be in NEUTRAL.
• The Parking Brake must be activated.
If the three machine conditions are not correct, a red sig-

nal will appear near the not satisfied condition and the cal-
ibration procedure will not start.
Moreover on the display appears also the value of the
transmission. LEIL16WHL0905AA 5
If all conditions are verified a green signal appears near
each conditions. Press the enter/confirm key to start the
transmission clutch calibration.
48083741_EN 31/07/2018
21.2 [21.155] / 4
5. A progress bar slider appears on the display when the

transmission clutch calibration is in progress.
LEIL16WHL0906AA 6
6. A progress bar slider appears on the display when the

transmission clutch calibration is in progress.
LEIL16WHL0906AA 7
7. When calibration process is complete, the user will be

prompted to turn the engine Off and restart the ma-
chine.
LEIL16WHL0907AA 8
48083741_EN 31/07/2018
21.2 [21.155] / 5
Index
Transmission - 21

Clutch - Dynamic description - Transmission Clutch Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
48083741_EN 31/07/2018
21.2 [21.155] / 6
Transmission - 21
Torque converter - 700

48083741_EN 31/07/2018
21.3 [21.700] / 1
Contents
Transmission - 21
SERVICE
Torque converter
Service instruction - Procedure to heat the oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Service instruction - Performing stall tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
48083741_EN 31/07/2018
21.3 [21.700] / 2
Transmission - Torque converter
Torque converter - Service instruction - Procedure to heat the oil

Torque converter
1. Start the engine and run the engine at low idle.
2. Check the oil temperature through the display in the
cab (access to “Machine status” third screen).
LEIL16WHL2330AA 1
3. Make sure that the declutch function is deactivated

(LED indicator on declutch button OFF).
LEIL16WHL1125AA 2
4. Make sure that the transmission is in manual mode

(LED indicator on auto shift button OFF). Push down
and hold the brake pedal for the remainder of this pro-
cedure.
LEIL16WHL1125AA 3
5. Release the parking brake.

6. Move the transmission control lever to Forward and
turn the transmission control lever to 3rd gear.
7. Increase the engine speed to full throttle and run the
engine at this speed for 30 seconds.
8. Decrease the engine speed to low idle and move the
transmission control lever to the Neutral position for 15
seconds.
9. Repeat steps 6, 7, and 8 until the temperature of the
torque converter oil is 82 – 104 °C (180 – 219 °F).
48083741_EN 31/07/2018
21.3 [21.700] / 3
Hydraulic System
1. Apply the parking brake.
2. Start the engine and run at full throttle.
3. Check the oil temperature through the display in the
cab (access to “Machine service – Sensor Status – Hy-
draulics” screens).
LEIL16WHL0891AA 4
4. Hold the bucket control lever in the ROLLBACK posi-

tion while raising and lowering the lift arms from ground
level to full height.
5. Continue this procedure until the temperature of the
hydraulic oil is 54 – 57 °C (129 – 135 °F).
48083741_EN 31/07/2018
21.3 [21.700] / 4
Torque converter - Service instruction - Performing stall tests

Test No. 1 - Torque Converter and Hydraulic Stall together
NOTE: for converter, hydraulic and combined stall values, see “Engine – General specification” in this manual.
2. Press the brake pedal, release the park brake, shift into
Forward.
3. Run engine at low idle. Make sure the declutch function
is OFF. Put the transmission in manual mode. Push
down and hold the brake pedal for the remainder of this
procedure.
4. Turn the transmission control lever to third gear.
5. Increase the engine speed to full throttle.
tion and raise the lift arms.
NOTE: the stall speed must be read while the lift arms are in motion.
7. Check the engine speed.
8. Release the bucket control lever.
9. Decrease the engine speed to low idle.
10. Lower the bucket to the ground, place the transmis-
sion in neutral and apply the parking brake.
11. Stop the engine.
Understanding the Results of Test No. 1

1. If the engine speed is as specified, the engine, torque
converter, transmission and hydraulic system are prob-
ably good.
2. If the engine speed is not as specified, proceed to Test
No. 2 and 3.
48083741_EN 31/07/2018
21.3 [21.700] / 5
Test No. 2 - Torque Converter Stall

4. Press the brake pedal, release the park brake, shift into
Forward.
5. Run the engine at low idle.
6. Push down and hold the brake pedal for the remainder
of this test.
7. Turn the transmission control lever to third gear.
11. Place the transmission in neutral and apply the park-
ing brake.

1. If the engine speed is as specified, the engine, torque
converter and transmission are probably good.
2. If the engine speed is more than specified, the problem
can be in the torque converter or the transmission.
3. If the engine speed is less than specified, proceed to
Test No. 3.
Test No. 3 - Hydraulic Stall

tion and raise the lift arms.
NOTE: the stall speed must be read while the lift arms are in motion.
8. Release the bucket control lever.
10. Lower the bucket to the ground.

1. If the engine speed is as specified, the engine and hy-
draulic system are good.
2. If the engine speed is more or less than specified the
main relief setting may be too low or too high.
3. If the engine speed is less than specified in all tests,
the engine is probably the cause.
48083741_EN 31/07/2018
21.3 [21.700] / 6
Index
Transmission - 21

Torque converter - Service instruction - Performing stall tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Torque converter - Service instruction - Procedure to heat the oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
48083741_EN 31/07/2018
21.3 [21.700] / 7
PRINTED IN ITALY
48083741_EN 31/07/2018
EN
SERVICE MANUAL
Four-Wheel Drive (4WD) system

48083741_EN 31/07/2018
23
Contents
Four-Wheel Drive (4WD) system - 23
[23.314] Drive shaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23.1
48083741_EN 31/07/2018
23
Drive shaft - 314

48083741_EN 31/07/2018
23.1 [23.314] / 1
Contents
Drive shaft - 314
TECHNICAL DATA
Drive shaft
Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SERVICE
Drive shaft
Remove - Front Drive Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Install - Front Drive Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Remove - Center Drive Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Install - Center Drive Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Remove - Center bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Install - Center Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Remove - Rear Drive Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Install - Rear Drive Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Remove - Engine to transmission drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Install - Engine to transmission drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Drive shaft universal joint
Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
48083741_EN 31/07/2018
23.1 [23.314] / 2
Four-Wheel Drive (4WD) system - Drive shaft
Drive shaft - Torque

Center, Rear and Front Drive Shaft Bolts (821G) 75 – 81 Nm ( 55 – 60 lb.ft)
Center, Rear and Front Drive Shaft Bolts (921G) 136 – 149 N·m (100 – 110 lb ft)
Carrier Bearing Bolts (821G) 99 – 128 Nm ( 73 – 94 lb.ft)
Carrier Bearing Bolts (921G) 150 – 164 N·m (111 – 121 lb ft)
Lock Nut for Yoke on Front Drive Shaft 339 – 375 Nm ( 250 – 275 lb.ft)
Coupler to Flywheel Bolts 85 – 94 N·m (63 – 69 lb ft)
Engine Drive Shaft to Coupler Bolts (821G, 4–speed transmission) 86 – 94 N·m (63 – 69 lb ft)
Engine Drive Shaft to Transmission Bolt 75 – 81 Nm ( 55 – 60 lb.ft)
48083741_EN 31/07/2018
23.1 [23.314] / 3
Drive shaft - Remove - Front Drive Shaft

NOTE: the 921G Series machines use mechanical style yokes (no bearing straps) and may appear different from the
machine pictured.
1. Loosen and remove the bolts and straps that fasten the
center drive shaft to the yoke of the front drive shaft.
NOTICE: the bolts and straps that fasten the center drive
shaft to the front drive shaft must be replaced when re-
moved.
LEIL13WHL1063AB 1
2. Loosen and remove the lubrication hose from the cen-

ter bearing
LEIL13WHL1072AB 2
front drive shaft to the front axle.
LEIL13WHL1065AB 3
4. Loosen and remove the carrier bearing bolts.
LEIL16WHL1762AB 4
48083741_EN 31/07/2018
23.1 [23.314] / 4
5. Use a prybar to disengage the front drive shaft from

the front axle and remove the front drive shaft from the
machine.
NOTE: if necessary, use a brass hammer to drive the front
drive shaft out of the center bearing.
48083741_EN 31/07/2018
23.1 [23.314] / 5
Drive shaft - Install - Front Drive Shaft

machine pictured.
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.
821G: 75 – 81 N·m (55 – 60 lb ft)
921G: 136 – 149 N·m (100 – 110 lb ft)
LEIL13WHL1065AB 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).
LEIL13WHL1064AB 2
7. Tighten the set screws that secure the center bearing

to the front drive shaft alternately until they stop turning
and the hexagonal head socket wrench starts to spring.
Turn the set screw down to the shaft and then back it
off 1/4 turn and lock it with the jam nut.
NOTE: If installing new bearing, remove longer set screws
and jam nuts from the old bearing to reuse them on the new
bearing.
48083741_EN 31/07/2018
23.1 [23.314] / 6
8. Install the bolts and straps that fasten the front drive
shaft to the center drive shaft.
821G: 75 – 81 N·m (55 – 60 lb ft)
921G: 136 – 149 N·m (100 – 110 lb ft)
LEIL13WHL1063AB 3
48083741_EN 31/07/2018
23.1 [23.314] / 7
Drive shaft - Remove - Center Drive Shaft

machine pictured.
center drive shaft to the yoke of the front drive shaft.
moved.
LEIL13WHL1069AB 1
2. Use a prybar to disengage the center drive shaft from

the yoke of the front drive shaft.
center drive shaft to the transmission.
shaft to the transmission must be replaced when removed.
LEIL13WHL1070AB 2
4. Hold the center drive shaft and remove from the ma-
chine.
48083741_EN 31/07/2018
23.1 [23.314] / 8
Drive shaft - Install - Center Drive Shaft

machine pictured.
1. Hold the center drive shaft in position and install the
bolts and straps that fasten the center drive shaft to the
transmission.
821G: Tighten the bolts to 75 – 81 N·m (55 – 60 lb ft)
921G: Tighten the bolts to 136 – 149 N·m (100 – 110 lb
ft)
LEIL13WHL1070AB 1
2. Install the bolts and straps that fasten the center drive
shaft to the yoke of the front drive shaft.
ft)
LEIL13WHL1069AB 2
48083741_EN 31/07/2018
23.1 [23.314] / 9
Drive shaft - Remove - Center bearing

machine pictured.
center drive shaft to the front drive shaft.
moved.
LEIL13WHL1069AB 1
2. Loosen and remove the lubrication hose from the cen-

ter bearing
LEIL13WHL1072AB 2
3. Loosen and remove the lock nut that fastens the yoke
to the front drive shaft.
LEIL13WHL1064AB 3
4. Make an alignment mark on the yoke and the front drive

shaft to be sure that the yoke is installed correctly.
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
to the front drive shaft.
48083741_EN 31/07/2018
23.1 [23.314] / 10
8. Loosen and remove the bolts, washers and nuts that

fasten the bearing housing to the front frame.
LEIL13WHL1073AB 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.
48083741_EN 31/07/2018
23.1 [23.314] / 11
Drive shaft - Install - Center Bearing

machine pictured.
NOTE: the center bearing and the bearing housing are not serviced separately. If the center bearing is worn or dam-
aged or if the bearing housing is cracked, a new center bearing and bearing housing must be used.
1. Apply antiseize compound to the bearing area of the
front drive shaft.
2. Install the bearing housing so that the lubrication fitting
is at the top.
3. Apply LOCTITE® 242® to bolt threads. Install the bolts,
washers and nuts that fasten the bearing housing to the
front frame.
ft)
LEIL13WHL1073AB 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.
NOTE: If installing new bearings remove longer set screws
and jam nuts from old bearing to reuse on new bearing.
LEIL13WHL1074AA 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.
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).
LEIL13WHL1064AB 3
48083741_EN 31/07/2018
23.1 [23.314] / 12
8. Install the straps and bolts that fasten the center drive
shaft to the yoke on the front drive shaft.
ft)
LEIL13WHL1069AB 4
9. Install the lubrication hose into the fitting on the bearing

housing.
10. Lubricate the center bearing with the grease.
48083741_EN 31/07/2018
23.1 [23.314] / 13
Drive shaft - Remove - Rear Drive Shaft

machine pictured.
rear drive shaft to the transmission.
NOTICE: the bolts and straps that fasten the rear drive
LEIL13WHL1075AB 1
2. Use a prybar to disengage the rear drive shaft from the

transmission.
rear drive shaft to the rear axle.
shaft to the rear axle must be replaced when removed.
LEIL13WHL1076AB 2
4. Hold the rear drive shaft and remove from the machine.
48083741_EN 31/07/2018
23.1 [23.314] / 14
Drive shaft - Install - Rear Drive Shaft

machine pictured.
1. Hold the rear drive shaft into position and install the
bolts and straps that fasten the rear drive shaft to the
rear axle.
ft)
LEIL13WHL1076AB 1
2. Install the bolts and straps that fasten the rear drive
shaft to the transmission.
ft)
LEIL13WHL1075AB 2
48083741_EN 31/07/2018
23.1 [23.314] / 15
Drive shaft - Remove - Engine to transmission drive shaft

1. Remove and discard the bolts and straps that fasten
the engine drive shaft to the transmission.
NOTICE: the bolts and straps that fasten the engine drive
LEIL13WHL1066AB 1
2. Loosen and remove the six bolts that fasten the engine
drive shaft to the engine damper.
NOTICE: the bolts that fasten the engine drive shaft to the
engine must be replaced when removed.
LEIL13WHL1067AB 2
3. Remove the engine drive shaft from the machine.
48083741_EN 31/07/2018
23.1 [23.314] / 16
Drive shaft - Install - Engine to transmission drive shaft

1. Place the engine drive shaft into position on the trans-
mission and install new straps and bolts.
ft)
LEIL13WHL1066AB 1
2. Install new six bolts (4–speed transmission) or eight

bolts (5–speed transmission) that fasten the engine
drive shaft to the engine.
NOTE: the figure shows configuration with 4-speed trans-
mission.
LEIL13WHL1068AB 2
3. Tighten to 86 – 94 N·m (63 – 69 lb ft) (821G, 4–speed

transmission).
Tighten to 85 – 94 N·m (63 – 69 lb ft) (921G, 4–speed
transmission).
LEIL17WHL1383AA 3
4. Tighten to 130 – 140 N·m (96 – 103 lb ft) (821G, 921G,

5–speed transmission).
LEIL17WHL1382AA 4
48083741_EN 31/07/2018
23.1 [23.314] / 17
Drive shaft universal joint - Disassemble

machine pictured.
1. Remove the drive shaft from the machine.
2. Remove the ring (1) and the bearing (2) from the drive
shaft.
NOTE: the picture shows the drive shaft on the machine
and is for reference of the ring and bearing only.
LEIL13WHL1071AB 1
3. Remove the universal joint from the drive shaft.
48083741_EN 31/07/2018
23.1 [23.314] / 18
Drive shaft universal joint - Assemble

machine pictured.
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).
LEIL13WHL1071AB 1
3. Install the drive shaft.
48083741_EN 31/07/2018
23.1 [23.314] / 19
Index
Drive shaft - 314

Drive shaft - Install - Center Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Drive shaft - Install - Center Drive Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Drive shaft - Install - Engine to transmission drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Drive shaft - Install - Rear Drive Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Drive shaft - Install - Front Drive Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Drive shaft - Remove - Center bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Drive shaft - Remove - Engine to transmission drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Drive shaft - Remove - Rear Drive Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Drive shaft - Remove - Center Drive Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Drive shaft - Remove - Front Drive Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Drive shaft - Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Drive shaft universal joint - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Drive shaft universal joint - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
48083741_EN 31/07/2018
23.1 [23.314] / 20
48083741_EN 31/07/2018
23.1 [23.314] / 21
PRINTED IN ITALY
48083741_EN 31/07/2018
EN
SERVICE MANUAL
Front axle system

48083741_EN 31/07/2018
25
Contents
Front axle system - 25
[25.100] Powered front axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.1
[25.102] Front bevel gear set and differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.2
[25.108] Final drive hub, steering knuckles, and shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.3
48083741_EN 31/07/2018
25
Powered front axle - 100

48083741_EN 31/07/2018
25.1 [25.100] / 1
Contents
TECHNICAL DATA
Powered front axle

SERVICE
Powered front axle

Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Lubricate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
48083741_EN 31/07/2018
25.1 [25.100] / 2
Front axle system - Powered front axle
Powered front axle - General specification

Front Axle Model MT-L3095II - Limited Slip Differential
Front Axle Model MT-L3095II - Locking Differential
LEIL13WHL0573AA 1
OVERALL WIDTH 2483 mm (98 in)

DISTANCE FLANGE TO FLANGE 2314 mm (91 in)
WHEEL MOUNTING BOLT CIRCLE DIAMETER 425 mm (17 in)
WHEEL MOUNTING BOLTS (LIMITED SLIP
DIFFERENTIAL)/WHEEL MOUNTING STUDS 16 ( M22x1.5)
(LOCKING DIFFERENTIAL)
HUB RATIO 6.00:1
CROWN/PINION RATIO 4.11:1
OVERALL RATIO 24.67:1
CLOCKWISE INPUT ROTATION (FACING INPUT
–
FLANGE) FOR FORWARD TRAVEL
(*) AXLE TO BE EQUIPPED WITH LIMITED SLIP TYPE
45% TRANSFER
DIFFERENTIAL
(*) Only Front Axle Model MT-L3095II - Limited Slip Differential
48083741_EN 31/07/2018
25.1 [25.100] / 3
Powered front axle - General specification

Front Axle Model MT-L3105II - Open Differential
LEIL13WHL0574AA 1

WHEEL MOUNTING BOLTS (LIMITED SLIP
DIFFERENTIAL)/WHEEL MOUNTING STUDS 20 ( M22x1.5)
(LOCKING DIFFERENTIAL)
HUB RATIO 6.00:1
CLOCKWISE INPUT ROTATION (FACING INPUT
–
FLANGE) FOR FORWARD TRAVEL
48083741_EN 31/07/2018
25.1 [25.100] / 4
Powered front axle - Remove

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

safety strut. Lower the loader arm slowly until the safety
strut is supporting the loader arm.
BD03A092-01 2
3. Stop the engine. Actuate the brake pedal several

times to discharge the brake accumulators. Put the
key switch in ON position and move the loader control
lever back and forth at least 30 times to release any
pressure from the hydraulic circuit. Put the key switch
in OFF position.
4. Remove the four bolts (2) and two straps (1) securing
the front drive shaft (3) to the front axle.
NOTICE: the bolts and straps that fasten the front drive
shaft must be replaced when removed.
LEIL13WHL0571AB 3
48083741_EN 31/07/2018
25.1 [25.100] / 5
5. Remove the clamp securing the lubrication hose (1) to

the machine and nut securing the opposite end of the
hose (1). Remove the four bolts (5) and two straps
(6) securing the center drive shaft (7) to the front drive
shaft (3). Use a pry bar to separate the drive shafts.
While supporting the center bearing (4) and front drive
shaft (3), remove the four nuts and bolts (2) and eight
washers. Lower the center bearing and front drive shaft
from the mounting plate and remove from the machine.
LEIL13WHL0572AB 4
6. Disconnect the brake hose (1) from the elbow (2). Re-
move and discard the O-ring face seal from the elbow.
BD03A168-01 5
7. For machines with brake damping accumulators, dis-

connect the brake line from the elbow at the axle con-
nection. Remove and discard the O-ring face seal from
the elbow. For the accumulator removal, also discon-
nect the brake line and hose from the accumulator. Un-
bolt the accumulator from the machine frame.
LEIL13WHL0569AB 6
8. If equipped, disconnect the differential lock hose.
LEIL13WHL0570AB 7
48083741_EN 31/07/2018
25.1 [25.100] / 6
9. By using an acceptable hydraulic jack, raise one tire

from ground
BD01F298-01 8
10. Install an acceptable jack stand under the machine.
BD01D392-01 9
11. Repeat Step 9 to 10 to raise the other front axle tire

from ground.
12. Use an acceptable jack to hold the front axle.
BD01F297-01 10
13. Remove the bolts and washers from the front wheels
. Remove both wheels from the front axle.
LEIL13WHL0566AB 11
48083741_EN 31/07/2018
25.1 [25.100] / 7
14. Remove from each front axle side the four nuts (3),
four bolts (1) and eight washers (2) securing the front
axle to the machine.
BD01F296-01 12
15. Carefully lower the front axle and remove from under
the machine.
48083741_EN 31/07/2018
25.1 [25.100] / 8
Powered front axle - Install

1. Carefully move the front axle under the machine and
raise against by mounting pads on the machine.
2. Apply one drop of engine oil to the threads prior to the
assembly. Install at each front axle side four washers
(2) (on top side), bolts (1), washers (on bottom side)
and nuts (3) to secure the front axle to the machine.
BD01F296-01 1
3. Tighten the bolts to a torque of 1520 – 1712 N·m (1121

– 1263 lb ft) in the indicated sequence (front side of the
machine)
LEIL13WHL0565FB 2
4. Install both wheels to the front axle and secure by using

washers and bolts.
LEIL13WHL0566AB 3
48083741_EN 31/07/2018
25.1 [25.100] / 9
5. Tighten the bolts to a preliminary torque of 298 N·m

(220 lb ft) in the indicated sequence. Then, tighten to
a torque of 640 – 720 Nm ( 475 – 530 lb.ft) in the same
sequence.
821G Torque pattern
LEIL13WHL0567AB 4
921G Torque pattern
LEIL13WHL0568AB 5
6. Remove the jack from the front axle.
BD01F297-01 6
48083741_EN 31/07/2018
25.1 [25.100] / 10
7. By using an acceptable hydraulic jack, raise the front

axle from one side.
BD01F298-01 7
8. Remove the jack stand from under the machine.
BD01D392-01 8
9. Repeat Step 7 to 8 to remove the other jack stand from

under the machine.
10. Install a new O-ring face seal in the elbow (1). Con-
nect the brake hose (2) to the elbow.
BD03A168-01 9
11. For machines with brake damping accumulators, in-

stall a new O-ring face seal and connect the brake line
to the elbow at the axle connection. If the accumulator
was previously removed, bolt the accumulator to the
machine frame and connect the brake line and hose
to the accumulator.
LEIL13WHL0569AB 10
48083741_EN 31/07/2018
25.1 [25.100] / 11
12. If equipped, connect the differential lock hose.
LEIL13WHL0570AB 11
13. Place and support the center bearing (4) and front
drive shaft (3). Install eight washers, four bolts (2) and
nuts. Tighten the bolts (2) to a torque of 99 – 128 Nm
( 73 – 94 lb.ft). Install two straps (6) and four bolts
(5). Tighten the bolts (5) to a torque of 75 – 81 N·m
(55 – 60 lb ft). Secure the lubrication hose (1) to the
machine by using a clamp. Secure the opposite end
of the hose by using a nut.
LEIL13WHL0572AB 12
14. Secure the drive shaft (3) to the front axle by using
two straps (1) and four bolts (2). Tighten the bolts to
a torque of 75 – 81 N·m (55 – 60 lb ft).
LEIL13WHL0571AB 13
15. If needed, fill the axle with the specified gear lubricant.
See the front axle filling.
16. Bleed the brakes.
48083741_EN 31/07/2018
25.1 [25.100] / 12
17. Start the engine and raise the bucket. Have an assis-
tant to remove the safety strut. Lower the bucket to
ground and stop the engine.
BD03A092-01 14
18. Put the articulation lock in OPERATING position.
48083741_EN 31/07/2018
25.1 [25.100] / 13
Powered front axle - Lubricate

821G
LEIL13WHL1214AB 1
Front Axle Model MT-L3095II - Limited Slip Differential
Front Axle Model MT-L3095II - Locking differential
1. OIL DRAIN HOLE (AXLE CASING)

2. OIL DRAIN HOLE (OUTPUTS)
3. OIL FILLER HOLE
4. BRAKE BLEEDER
5. BLEEDER
921G
LEIL13WHL1215AB 2
Front Axle Model MT-L3105II - Open Differential
1. OIL DRAIN HOLE (AXLE CASING)

2. OIL DRAIN HOLE (OUTPUTS)
3. OIL FILLER HOLE
4. BRAKE BLEEDER
5. BLEEDER
48083741_EN 31/07/2018
25.1 [25.100] / 14
Index

Powered front axle - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Powered front axle - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Powered front axle - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Powered front axle - Lubricate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Powered front axle - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
48083741_EN 31/07/2018
25.1 [25.100] / 15
48083741_EN 31/07/2018
25.1 [25.100] / 16
Front bevel gear set and differential - 102

48083741_EN 31/07/2018
25.2 [25.102] / 1
Contents
SERVICE
Bevel gear set and differential carrier

Backlash - Models MT-L 3085 II / MT-L 3095 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Backlash Model 3105 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Differential
Remove - MT-L 3095 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Install - Model MT-L 3095 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Remove Model 3105 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Install Model 3105 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Disassemble - D Version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Assemble - D Version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Disassemble - DHL Version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Assemble - DHL Version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Disassemble - DL Version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Assemble - DL Version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
48083741_EN 31/07/2018
25.2 [25.102] / 2
Front axle system - Front bevel gear set and differential
Bevel gear set and differential carrier - Backlash - Models MT-L

3085 II / MT-L 3095 II
CAUTION
Burn hazard!
Always wear heat-resistant protective gloves when handling heated parts.
C0047A
1. Determine the shim thickness to obtain a correct con-

tact pattern. Read the dimension I from the axle drive
housing (1) . Dimension I e.g. 221.10 mm (8.705 in).
NOTE: if the crown wheel or input pinion are damaged,
both parts must be replaced together. When installing a
complete new bevel gear set, look for the identical mating
number of the input pinion and crown wheel.
NOTE: the measuring procedures must be done accu-
rately. Inaccurate measurements lead to an incorrect
contact pattern requiring additional disassembly and re-
assembly of the input pinion and differential.
RAIL11WEL0349BA 1
2. Read the dimension II from the pinion (1). Dimension

II e.g. 181.00 mm (7.126 in).
RAIL11WEL0350BA 2
3. Determine the dimension III (bearing width). Dimen-

sion III e.g. 39.10 mm (1.539 in).
RAIL11WEL0351BA 3
48083741_EN 31/07/2018
25.2 [25.102] / 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 the external bearing and insert it into the axle drive
housing until the contact is made.
RAIL11WEL0352BA 4
5. Insert the shim into the housing hole. Determined size

e.g. s = 1.00 mm (0.039 in).
RAIL11WEL0353BA 5
6. Cool the internal bearing outer ring and bring it into

the contact position in the housing hole by using the
380100001 bearing cup installer tool.
RAIL11WEL0354BA 6
48083741_EN 31/07/2018
25.2 [25.102] / 4
7. Heat the tapered roller bearing and insert it into the

input pinion until the contact is made.
RAIL11WEL0355BA 7
8. Set the rolling torque of the input pinion bearing (without

shaft seal) to 1.5 – 3.0 N·m (13 – 27 lb in). Insert a
spacer e.g. s = 8.18 mm (0.322 in).
NOTE: based on the experience, the needed rolling torque
is obtained by reusing the spacer removed during the dis-
assembly e.g. s = 8.18 mm (0.322 in).
NOTE: a later check of the rolling torque is needed.
RAIL11WEL0356BA 8
9. Insert the pre-assembled input pinion into the axle drive

housing. Insert the heated tapered roller bearing until
the contact is made.
RAIL11WEL0357BA 9
48083741_EN 31/07/2018
25.2 [25.102] / 5
10. Press the protection plate onto the input flange until
NOTE: do not fit the shaft seal until the contact pattern has
been checked.
RAIL11WEL0358BA 10
11. Insert the input flange and secure it with disk and
slotted nut. Torque to 1200 N·m (885 lb ft). Use
the CAS2842 slotted nut wrench and the 380001546
flange holder.
NOTE: temporarily mount the slotted nut without Loctite.
While tightening, rotate the input pinion several times in
both directions.
RAIL11WEL0359BA 11
12. Check the rolling torque. It must be 1.5 – 3.0 N·m (13
– 27 lb in) without shaft seal.
NOTE: when installing new bearings try to achieve the up-
per value of the rolling torque.
NOTE: in case of rolling torque measurement deviations,
correct with a corresponding spacer as specified in Step
8. Insufficient rolling torque - install a thinner spacer ring.
Excessive rolling torque - install a thicker spacer ring.
RAIL11WEL0360BA 12
48083741_EN 31/07/2018
25.2 [25.102] / 6
13. Grease the O-rings and insert them into the annular
grooves of the piston.
NOTE: this step is only needed for versions with DHL dif-
ferential.
RAIL11WEL0361BA 13
14. Insert the piston (see arrow) into the bearing housing
until the contact is made.
RAIL11WEL0362BA 14
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 the
read value (deviation/test dimension) and correspond-
ing specifications of the following table: (KRS - SET -
RIGHT) (KRS = bevel gear set) – see the crown wheel
rear side for deviation. The test dimension “101” is
stamped into the crown wheel rear side. If no +/- devi-
ation is indicated, this value corresponds to the actual
value “0” in the following table. According to this value,
the required shims are allocated in the table. Any +/-
deviation of the test dimension caused by the produc-
tion is also marked on the crown wheel rear side (e.g.
-20 or -10 or 10 or 20). In accordance with this devia-
tion, the required shims are allocated in the table.
RAIL11WEL0363BA 15
48083741_EN 31/07/2018
25.2 [25.102] / 7
16. 1. Axle housing

2. Shim (crown wheel side)
3. Shim (differential carrier side)
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.
Shim Crown wheel 1.3 1.2 1.1 1.0
side Shim thickness
Shim D/DL/DHL 2400 84476080 84330542 84330541 84330540
Order no.
17. Insert the selected shim e.g. s = 0.9 mm (0.035 in)

into the axle housing hole and adjust the bearing outer
ring (see arrow) until the contact is obtained.
RAIL11WEL0365BA 17
48083741_EN 31/07/2018
25.2 [25.102] / 8
18. Cover some drive and coast flanks of the crown wheel
with marking ink. Insert the pre-mounted differential
into the axle drive housing.
RAIL11WEL0366BA 18

ring until the contact is made.
RAIL11WEL0367BA 19
20. Mount two M20 locating pins (S) and bring the axle
housing into the contact position with the axle drive
housing by using a suitable lifting device. Temporarily
attach the axle housing with bolts. Torque to 560 N·m
(413 lb ft).
NOTE: test mount axle housing without O-ring.
RAIL11WEL0368BA 20
48083741_EN 31/07/2018
25.2 [25.102] / 9
21. Differential lock leak test. Pressurize the lock to p =

1 bar (15 psi), close the shutoff valve and remove the
air line. No noticeable pressure loss must occur within
10 seconds.
NOTE: this operation is only needed for versions with DHL
differential.
RAIL11WEL0369BA 21
22. Rotate the input flange, in both directions and several

times, to roll the crown wheel over the input pinion.
Remove the axle housing and lift the differential out
of the axle drive housing. Compare the obtained con-
tact pattern with the contact pattern examples at the
beginning of this section.
NOTE: if the tooth contact pattern differs, an incorrect shim
size was selected in 5. This must be corrected.
RAIL11WEL0370BA 22
48083741_EN 31/07/2018
25.2 [25.102] / 10
Bevel gear set and differential carrier - Backlash Model 3105 II

CAUTION
Burn hazard!
C0047A
1. Determine the shim thickness to obtain a correct gear

contact pattern. Read the dimension I (see arrow) from
the axle drive housing. Dimension I e.g. 245.60 mm
(9.67 in).
rately. Inaccurate measurements lead to an incorrect
contact pattern requiring additional disassembly and re-
assembly of the input pinion and differential.
RCIL11WHL087BAF 1
2. Read the dimension II from the pinion (see arrow). Di-

mension II e.g. 202.00 mm (7.95 in).
RCIL11WHL088BAF 2

sion III e.g. 42.60 mm (1.68 in). Calculation Example
“A”: Dimension I: 245.60 mm (9.67 in), Dimension
II: 202.00 mm (7.95 in), Dimension III: 42.60 mm
(1.68 in), Difference = shim s = 1.00 mm (0.04 in).
RCIL11WHL089BAF 3
48083741_EN 31/07/2018
25.2 [25.102] / 11
4. Cool the external bearing. With a driver tool, insert it

into the axle drive housing until the contact is made.
RCIL11WHL090BAF 4
5. Insert the shim into the housing hole. Determined size

e.g. s = 1.00 mm (0.04 in).
RCIL11WHL091BAF 5
6. Cool the internal bearing outer ring. Bring it into the

contact position within the housing hole by using the
380100001 bearing cup installer.
RCIL11WHL092BAF 6
48083741_EN 31/07/2018
25.2 [25.102] / 12
7. Heat the tapered roller bearing. Insert it onto the input

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

shaft seal to 1.5 – 3.0 N·m (13.3 – 26.6 lb in). Insert a
spacer (e.g. s= 8.18 mm (0.32 in)).
RCIL11WHL094BAF 8

RCIL11WHL095BAF 9
48083741_EN 31/07/2018
25.2 [25.102] / 13
10. Press the protection plate onto the input flange (see
arrow) until the contact is made.
been checked.
RCIL11WHL096BAF 10
11. Insert the input flange and secure it with disk and slot-
ted nut. Torque to 1200 N·m (885 lb ft) by using the
pinion locknut wrench CAS2842 and clamping device
380001564.
both directions.
RCIL11WHL097BAF 11
12. Check the rolling torque. It must be 1.5 – 3.0 N·m

(13.3 – 26.6 lb in) without shaft seal.
per value of rolling torque.
NOTE: In case of deviations from the needed rolling torque,
correct with a corresponding spacer as specified in Step
8. Insufficient rolling torque - install a thinner spacer ring.
Excessive rolling torque - install a thicker spacer ring.
RCIL11WHL098BAF 12
48083741_EN 31/07/2018
25.2 [25.102] / 14
13. Determine the required 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 in the following table: (KRS - SET -
RIGHT) (KRS = bevel gear set) – see the crown wheel
rear side for deviation. The test dimension “106” is
stamped into the rear side. If no + or - deviation is indi-
cated, the value corresponds to the actual value “0” in
the table. Based on this value, the required shims are
allocated in the table. Any + or - deviation of the test
dimension caused by the production will be marked on
the crown wheel rear side (e.g. - 20 or - 10 or 10 or
20). Based on the deviation, the required shims are
allocated in the table.
RCIL11WHL101BAF 13
14. 1. Axle housing

4. Axle housing
RCIL11WHL156BAF 14
Shims for differential in MT-L 3105 II axles

Crown wheel marking -20 -10 N/A 10
Deviation -0.2 -0.1 0 0.1
Shim diff. cage side 0.8 0.9 1.0 1.1
Shim thickness
side Shim thickness
15. Insert the selected shim e.g. s = 1.0 mm (0.04 in) into
the axle housing hole and adjust the bearing outer ring
(see arrow) until the contact is obtained.
RCIL11WHL102BAF 15
48083741_EN 31/07/2018
25.2 [25.102] / 15
RCIL11WHL103BAF 16
17. Insert the selected shim e.g. s = 1.0 mm (0.04 in) into
the axle housing hole and adjust the bearing outer ring
(see arrow) until the contact is made.
RCIL11WHL104BAF 17
18. Mount two locating pins and bring the axle housing
into the contact position with the axle drive housing
by using a suitable lifting device. Temporarily attach
the axle housing with bolts. Torque to 560 N·m (413 lb
ft).
RCIL11WHL105BAF 18
48083741_EN 31/07/2018
25.2 [25.102] / 16
19. Rotate the input flange, in both directions and several

times, to roll the crown wheel over the input pinion.
Remove the axle housing and lift the differential out of
the axle drive housing. Compare the obtained contact
pattern with the contact patter examples at the begin-
ning of this section.
NOTE: if a contact pattern deviation exists, the measuring
error was made during the shim size determination. This
must be corrected.
RCIL11WHL107BAF 19
48083741_EN 31/07/2018
25.2 [25.102] / 17
Bevel gear set and differential carrier - Check

Ideal tooth contact pattern
LEIL15WHL1223AA 1 LEIL15WHL1224AA 2
Coast side (concave) Drive side (convex)
Pinion distance must be increased
LEIL13WHL0577AA 3
48083741_EN 31/07/2018
25.2 [25.102] / 18
Pinion distance must be decreased
LEIL13WHL0580AA 6
48083741_EN 31/07/2018
25.2 [25.102] / 19
Differential - Remove - MT-L 3095 II

CAUTION
Burn hazard!
C0047A
1. Use a suitable lifting device and attach the axle to the

assembly stand.
NOTE: only the heavy duty axle version uses wheel mount-
ing studs.
RAIL11WEL0178BA 1
2. Remove the plug and drain the oil from the differential
carrier.
NOTE: use a suitable container for the oil collection and
abide by all local environmental laws for a proper handling
and disposal.
RAIL11WEL0179BA 2
3. Remove the plug and drain the oil from the outputs.
and disposal.
RAIL11WEL0180BA 3
48083741_EN 31/07/2018
25.2 [25.102] / 20
4. Remove the bleeder valve (1) to avoid damage during

the output and axle housing separation.
RAIL11WEL0181BA 4
5. Attach a suitable load carrying device to the output as-

sembly. Remove the bolts and separate the output from
the axle housing.
NOTE: attach the load carrying device with a wheel nut.
RAIL11WEL0182BA 5
6. Pull the stub shaft and sun gear shaft.

NOTE: watch for the loose shim(s).
RAIL11WEL0183BA 6
48083741_EN 31/07/2018
25.2 [25.102] / 21
7. Secure the axle housing to a suitable lifting device. Re-

move the bolts. Separate the axle housing from the
axle drive housing.
NOTE: watch out for the releasing differential.
RAIL11WEL0213BA 7
8. Loosen the threaded connections and remove the re-

leasing brake tube.
RAIL11WEL0214BA 8
9. Remove the screw neck.
RAIL11WEL0212BA 9
48083741_EN 31/07/2018
25.2 [25.102] / 22
10. Pull the bearing outer ring from the bearing hole and
remove the shim. Remove the O-ring (see arrow).
RAIL11WEL0233BA 10
11. Lift the differential from the axle drive housing by using
a suitable lifting device.
RAIL11WEL0232BA 11
12. Pull the bearing outer ring (see arrow) from the hous-
ing and remove the shim.
RAIL11WEL0233BA 12
48083741_EN 31/07/2018
25.2 [25.102] / 23
13. Remove the piston (see arrow) from the axle housing.
NOTE: step needed only for DHL version.
RAIL11WEL0234BA 13
14. Use compressed air to remove the piston.

NOTE: step needed only for DHL version.
RAIL11WEL0235BA 14
15. Heat the slotted nut with a hot air blower.

NOTE: slotted nut secured with LOCTITE® 262™.
RAIL11WEL0236BA 15
48083741_EN 31/07/2018
25.2 [25.102] / 24
16. Remove the slotted nut and shim behind it. Use the
slotted nut wrench CAS2842 and clamping device
380001546.
RAIL11WEL0237BA 16
17. Remove the input flange from the pinion. Use a lever
to remove the shaft seal.
RAIL11WEL0238BA 17
18. Press the input pinion from the axle drive housing and
remove the releasing tapered roller bearing.
RAIL11WEL0239BA 18
48083741_EN 31/07/2018
25.2 [25.102] / 25
19. Remove the spacer ring and pull the tapered roller
bearing from the input pinion.
RAIL11WEL0240BA 19
20. If needed, remove the bearing outer rings from the

axle drive housing.
RAIL11WEL0231BA 20
48083741_EN 31/07/2018
25.2 [25.102] / 26
Differential - Install - Model MT-L 3095 II

1. After the contact pattern check, insert the differential
into the axle drive housing again.
RAIL11WEL0371BA 1
2. Remove the slotted nut and pull the input flange from
the input pinion. Use the CAS2842 slotted nut wrench
and 380001546 clamping device.
RAIL11WEL0372BA 2
3. By using the CAS2841 driver tool, mount the shaft seal

with the seal lip facing the oil chamber.
NOTE: an exact installation position of the seal is obtained
by using the specified driver tool.
NOTE: wet the outer diameter of the shaft seal with mineral
spirits just before the installation. Fill the space between
the seal and the dust lip with grease.
RAIL11WEL0373BA 3
48083741_EN 31/07/2018
25.2 [25.102] / 27
4. Insert the input flange and secure it by using disc and

slotted nut. Torque to 1200 N·m (885 lb ft). Use the
CAS2842 slotted nut wrench and 380001546 clamping
device.
NOTE: cover the slotted nut threads with LOCTITE® 262™.
RAIL11WEL0348BA 4
5. Grease the O-ring and insert it into the axle housing.
RAIL11WEL0397BA 5
6. Mount two M20 locating pins and bring the axle housing
into the contact position with the axle drive housing by
using a suitable lifting device. Secure the axle housing
with bolts. Torque to 560 N·m (413 lb ft).
NOTE: after the axle housing assembly, secure the axle
with clamping brackets (S).
RAIL11WEL0398BA 6
48083741_EN 31/07/2018
25.2 [25.102] / 28
7. Mount the fitting and torque to 36 N·m (27 lb ft).
RAIL11WEL0399BA 7
8. Grease the O-ring. Insert it into the annular groove of

the parking brake tube.
RAIL11WEL0400BA 8
9. Mount the brake tube with the threaded connection and

nut. Torque to 100 N·m (74 lb ft).
RAIL11WEL0401BA 9
48083741_EN 31/07/2018
25.2 [25.102] / 29
10. Install the plug and new O-ring. Torque to 50 N·m

(37 lb ft).
RAIL11WEL0396BA 10
48083741_EN 31/07/2018
25.2 [25.102] / 30
Differential - Remove Model 3105 II

NOTE: the front axle is shown in the following images and may appear slightly different externally than the rear axle.
The use of the tools and disassembly/assembly of the axles are the same regardless of appearance.
assembly stand.
RCIL11WHL001BAF 1
carrier.
and disposal.
RCIL11WHL002BAF 2
3. Remove the plugs and drain the oil from the outputs.
and disposal.
RCIL11WHL003BAF 3
48083741_EN 31/07/2018
25.2 [25.102] / 31
4. Remove the bleeder valves to avoid damage during the

output and axle housing separation.
RCIL11WHL004BAF 4
5. Attach a suitable lifting device to the output assembly.

Remove the bolts and separate the output assembly
from the axle housing.
RCIL11WHL005BAF 5
6. Pull the stub shaft and sun gear shaft from the output.
RCIL11WHL006BAF 6
48083741_EN 31/07/2018
25.2 [25.102] / 32
7. Secure the axle housing with a suitable lifting device

and loosen bolts. Separate the axle housing from the
drive housing.
RCIL11WHL024BAF 7
8. Loosen the threaded connections and remove the

brake release tube.
RCIL11WHL025BAF 8
RCIL11WHL026BAF 9
48083741_EN 31/07/2018
25.2 [25.102] / 33
10. Pull the bearing outer ring and remove the shim be-
hind it. Remove the O-ring (see arrow).
RCIL11WHL027BAF 10
11. Use a suitable lifting device and pull the differential

from the axle drive housing.
NOTE: the differential disassembly is covered in a separate
section.
RCIL11WHL028BAF 11
RCIL11WHL029BAF 12
48083741_EN 31/07/2018
25.2 [25.102] / 34
13. Heat the slotted nut.

NOTE: the slotted nut is secured with LOCTITE® 262™.
RCIL11WHL032BAF 13
14. Remove the slotted nut and shim by using the pin-
ion locknut wrench CAS2842 and clamping device
380001546.
RCIL11WHL033BAF 14
15. Pull the input flange from the pinion. Use a lever to
remove the shaft seal.
RCIL11WHL034BAF 15
48083741_EN 31/07/2018
25.2 [25.102] / 35
RCIL11WHL035BAF 16
RCIL11WHL036BAF 17
18. If needed, remove both bearing outer rings from the

axle drive housing.
RCIL11WHL037BAF 18
48083741_EN 31/07/2018
25.2 [25.102] / 36
Differential - Install Model 3105 II

1. After the successful contact pattern check, reinsert the
differential into the axle drive housing.
RCIL11WHL108BAF 1
2. Loosen the slotted nut by using the pinion lock nut

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

the shaft seal with the seal lip facing the oil chamber.
by using the specified tool.
seal and dust lip with grease.
RCIL11WHL110BAF 3
48083741_EN 31/07/2018
25.2 [25.102] / 37
4. Insert the input flange and secure with disc and slotted
nut by using the pinion locknut wrench CAS2842 and
clamp device 380001546. Torque to 1200 N·m (885 lb
ft).
RCIL11WHL111BAF 4
5. Grease the O-ring (see arrow) and insert it into the axle
housing.
RCIL11WHL112BAF 5
6. Mount two M20 locating pins. Use a suitable lifting de-

vice and bring the axle housing into the contact position
with the axle drive housing. Secure the axle housing
with bolts. Torque to 560 N·m (413 lb ft).
with clamping brackets.
RCIL11WHL113BAF 6
48083741_EN 31/07/2018
25.2 [25.102] / 38
7. Mount the fitting. Torque to 36 N·m (27 lb ft).
RCIL11WHL114BAF 7

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

nut (see arrow). Torque to 100 N·m (74 lb ft).
RCIL11WHL116BAF 9
48083741_EN 31/07/2018
25.2 [25.102] / 39

(37 lb ft).
RCIL11WHL117BAF 10
48083741_EN 31/07/2018
25.2 [25.102] / 40
Differential - Disassemble - D Version

1. Pull both tapered roller bearings from the differential.
RCIL11WHL050BAF 1
2. Preload the differential by using a press. Remove the

bolts and releasing housing cover.
RCIL11WHL051BAF 2

locking bolts and housing cover.
RCIL11WHL052BAF 3
48083741_EN 31/07/2018
25.2 [25.102] / 41
4. Remove the axle bevel gear with the thrust washers

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

releasing spider gears with the thrust washers from the
differential housing.
RCIL11WHL055BAF 6
48083741_EN 31/07/2018
25.2 [25.102] / 42
7. Pull the long differential axle. Remove the releasing

spider gears with the thrust washers from the differen-
tial housing.
RCIL11WHL056BAF 7
8. Remove the axle bevel gear and shim.
RCIL11WHL057BAF 8
9. Press the crown wheel from the differential carrier.
RCIL11WHL058BAF 9
48083741_EN 31/07/2018
25.2 [25.102] / 43
Differential - Assemble - D Version

CAUTION
Burn hazard!
C0047A
1. Mount the locating pins and press the heated crown

wheel onto the differential housing until the contact is
made.
RCIL11WHL076BAF 1
2. Insert the thrust washer into the differential housing.
RCIL11WHL077BAF 2
3. Insert the axle bevel gear.
RCIL11WHL078BAF 3
48083741_EN 31/07/2018
25.2 [25.102] / 44
4. Insert the spider gears with the thrust washers into the
differential housing. Secure them with the long spider
shaft.
NOTE: the thrust washers must be positioned with the tabs
(see arrow) located in the differential housing recesses.
RCIL11WHL079BAF 4
differential housing. Secure them with the two short
spider shafts.
(1) located in the differential housing recesses. Pay atten-
tion to the radial installation position of the spider shaft se-
curing holes (2).
RCIL11WHL080BAF 5
6. Secure the short spider shafts with slotted pins.

NOTE: flush mount the slotted pins.
RCIL11WHL081BAF 6
48083741_EN 31/07/2018
25.2 [25.102] / 45
7. Mount the second axle bevel gear.
RCIL11WHL082BAF 7
8. Secure the thrust washers into the housing cover with

grease.
RCIL11WHL083BAF 8
9. Mount two adjusting bolts and insert the housing

cover until the contact with the differential housing is
obtained. Preload the differential by using a press.
Secure with new locking bolts. Torque to 400 N·m
(295 lb ft).
RCIL11WHL084BAF 9
48083741_EN 31/07/2018
25.2 [25.102] / 46
10. Attach the housing cover and preload the differential

with a suitable press. Secure the housing cover with
bolts and torque to 185 N·m (136 lb ft).
RCIL11WHL085BAF 10
11. Heat both tapered roller bearings and insert until the
contact is made. Adjust the tapered roller bearing af-
ter cooling down.
RCIL11WHL086BAF 11
48083741_EN 31/07/2018
25.2 [25.102] / 47
Differential - Disassemble - DHL Version

1. Remove the axial roller cage (see arrow).
LEIL13WHL0583AB 1
RCIL11WHL050BAF 2

bolts and releasing housing cover.
RCIL11WHL051BAF 3
48083741_EN 31/07/2018
25.2 [25.102] / 48
4. Preload the housing cover/compression spring by us-

ing a press. Disengage the retaining ring. Remove the
sliding sleeve and compression spring from the hous-
ing cover.
LEIL13WHL0584AA 4
5. Remove the single parts.

1. Pressure piece
2. Cage
3. Lever (12x)
4. Disk carrier
5. Disk package
LEIL13WHL0585AB 5

RCIL11WHL052BAF 6
48083741_EN 31/07/2018
25.2 [25.102] / 49
7. Remove the axle bevel gear with the thrust washers

from the differential housing.
RCIL11WHL053BAF 7
RCIL11WHL054BAF 8
9. Force out both short differential axles. Remove the

releasing spider gears with the thrust washers from the
differential housing.
RCIL11WHL055BAF 9
48083741_EN 31/07/2018
25.2 [25.102] / 50

spider gears with the thrust washers from the differen-
tial housing.
RCIL11WHL056BAF 10
RCIL11WHL057BAF 11
RCIL11WHL058BAF 12
48083741_EN 31/07/2018
25.2 [25.102] / 51
Differential - Assemble - DHL Version

CAUTION
Burn hazard!
C0047A

made.
RCIL11WHL076BAF 1
RCIL11WHL077BAF 2
RCIL11WHL078BAF 3
48083741_EN 31/07/2018
25.2 [25.102] / 52
differential housing. Secure them with the long spider
shaft.
(see arrow) located in the differential housing recesses.
RCIL11WHL079BAF 4
differential housing. Secure them with the two short
spider shafts.
(1) located in the differential housing recesses. Pay atten-
tion to the radial installation position of the spider shaft se-
curing holes (2).
RCIL11WHL080BAF 5

RCIL11WHL081BAF 6
48083741_EN 31/07/2018
25.2 [25.102] / 53
RCIL11WHL082BAF 7

grease.
RCIL11WHL083BAF 8

(295 lb ft).
RCIL11WHL084BAF 9
48083741_EN 31/07/2018
25.2 [25.102] / 54
10. Install the compression spring onto the sliding sleeve.
LEIL13WHL0586AA 10
11. Insert the premounted sliding sleeve into the housing

cover. Preload the compression spring with a press
and engage the retaining ring into the annular groove
of the sliding sleeve.
LEIL13WHL0584AA 11
12. Premount the single parts according to the 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 LEIL13WHL0587AB 12
NOTE: for the number of discs and disc arrangement, refer

to the related spare parts list.
13. Preload the disk package with an axial force of F =
50 +30 KN. Check the setting dimension A = 0.95 –
1.15 mm (0.04 – 0.05 in) from the collar of the differ-
ential cover to the plane face of the outer disc.
NOTE: any deviation from the specified setting dimension
must be corrected with a corresponding outer disk.
NOTE: the special tool pressure piece and load cell are to
be determined. Contact the special tools.
LEIL13WHL0588AA 13
48083741_EN 31/07/2018
25.2 [25.102] / 55
14. A = Setting dimension = 0.95 – 1.15 mm (0.04 –

0.05 in).
B = Contact face.
NOTE: to obtain a correct measuring result, the housing
cover may only be supported on the contact face (B). En-
sure that the assembly stand is only supported on the disk
package and not on the disk carrier.
LEIL13WHL0589AB 14
15. Place the housing cover onto the pressure piece. In-
sert two bolts into the housing cover to radially attach
the disc package.
LEIL13WHL0590AA 15
16. Use a suitable lifting device. Position the premounted

differential onto the housing cover and temporarily at-
tach with bolts.
LEIL13WHL0591AA 16

RCIL11WHL085BAF 17
48083741_EN 31/07/2018
25.2 [25.102] / 56
ter cooling down.
RCIL11WHL086BAF 18
19. Attach the axial roller cage to the sliding sleeve with
grease.
LEIL13WHL0583AB 19
48083741_EN 31/07/2018
25.2 [25.102] / 57
Differential - Disassemble - DL Version

1. Put both tapered roller bearings from the differential.
LEIL13WHL0592AA 1
2. Preload the differential with a press. Remove the lock-

ing screws and housing cover.
RCIL11WHL052BAF 2
3. Remove the axle bevel gear with the pressure ring, disc
package and thrust washers from the differential hous-
ing.
LEIL13WHL0593AA 3
4. Remove the spider shafts and axle bevel gears from

the differential housing.
LEIL13WHL0594AA 4
48083741_EN 31/07/2018
25.2 [25.102] / 58
5. Remove the second axle bevel gear.
RCIL11WHL057BAF 5
6. Remove the pressure ring, disc package and thrust

washers from the differential housing.
LEIL13WHL0595AA 6
RCIL11WHL058BAF 7
48083741_EN 31/07/2018
25.2 [25.102] / 59
Differential - Assemble - DL Version

1. Mount two M16 X 1.5 locating pins (S) and press the
heated crown wheel onto the differential housing until
LEIL13WHL0596AB 1
RCIL11WHL077BAF 2
3. Mount the outer and inner discs in alternating order

starting with an outer disk.
NOTE: the installation clearance of the 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).
LEIL13WHL0597AA 3
4. Install the pressure ring.
LEIL13WHL0598AA 4
48083741_EN 31/07/2018
25.2 [25.102] / 60
5. Install the axle bevel gear until the contact is made.

Install the inner discs with teeth.
RCIL11WHL078BAF 5
6. Preassemble the differential spider and insert it into the

differential housing/pressure ring.
LEIL13WHL0599AA 6
7. Install the second axle bevel gear.
LEIL13WHL0600AA 7
8. Install the second thrust ring into the differential hous-

ing.
LEIL13WHL1201AA 8
48083741_EN 31/07/2018
25.2 [25.102] / 61

starting with an inner disc.
rected by mounting outer discs of different thicknesses.
LEIL13WHL1202AA 9
10. Determine the installation clearance 0.2 – 0.7 mm

(0.008 – 0.028 in). Measure the 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).
LEIL13WHL1203AA 10
11. Measure the 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).
Calculation example:
Dimension I - 44.30 mm (1.744 in)
Dimension II - 43.95 mm (1.730 in)
Difference + disc clearance - 0.35 mm (0.014 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).
LEIL13WHL1204AA 11
grease.
LEIL13WHL1205AA 12
48083741_EN 31/07/2018
25.2 [25.102] / 62
13. Mount two M16 X 1.5 adjusting bolts and insert the
housing cover until the contact with the differential
housing is made. Preload the differential with a press.
Secure with new locking bolts and torque to 400 N·m
(295 lb ft).
LEIL13WHL1206AA 13
ter cooling down.
LEIL13WHL1207AA 14
48083741_EN 31/07/2018
25.2 [25.102] / 63
Index

Bevel gear set and differential carrier - Backlash - Models MT-L 3085 II / MT-L 3095 II . . . . . . . . . . 3
Bevel gear set and differential carrier - Backlash Model 3105 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Bevel gear set and differential carrier - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Differential - Assemble - D Version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Differential - Assemble - DHL Version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Differential - Assemble - DL Version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Differential - Disassemble - D Version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Differential - Disassemble - DHL Version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Differential - Disassemble - DL Version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Differential - Install - Model MT-L 3095 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Differential - Install Model 3105 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Differential - Remove - MT-L 3095 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Differential - Remove Model 3105 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
48083741_EN 31/07/2018
25.2 [25.102] / 64
Final drive hub, steering knuckles, and shafts - 108

48083741_EN 31/07/2018
25.3 [25.108] / 1
Contents
SERVICE
Wheel hub
Remove - Models MT-L 3085 II / MT-L 3095 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Install Model MT-L 3095 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Disassemble - Model MT-L 3095 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Visual inspection - Model MT-L 3095 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Assemble - MT-L 3095 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Remove Model 3105 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Disassemble Model 3105 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Visual inspection Model 3105 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Assemble Model 3105 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Install Model 3105 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
48083741_EN 31/07/2018
25.3 [25.108] / 2
Front axle system - Final drive hub, steering knuckles, and shafts
Wheel hub - Remove - Models MT-L 3085 II / MT-L 3095 II

assembly stand.
NOTE: only the heavy duty axle version uses the wheel
mounting studs.
RAIL11WEL0178BA 1
carrier.
and disposal.
RAIL11WEL0179BA 2
and disposal.
RAIL11WEL0180BA 3
48083741_EN 31/07/2018
25.3 [25.108] / 3

RAIL11WEL0181BA 4

the axle housing.
RAIL11WEL0182BA 5

RAIL11WEL0183BA 6
48083741_EN 31/07/2018
25.3 [25.108] / 4
Wheel hub - Install Model MT-L 3095 II

1. Set the axial play of the sun gear shaft to 0.5 – 2.0 mm
(0.020 – 0.079 in). Determine the dimension I, distance
from the mounting face of the brake housing to the
front face of the stop bolt. Dimension I e.g. 19.75 mm
(0.778 in).
RAIL11WEL0450BA 1
2. Insert the stub shaft into the teeth of the axle bevel gear
NOTE: be aware of the installation position. Mount the stub
shaft side with the long teeth towards the differential.
RAIL11WEL0451BA 2
3. Insert the sun gear shaft until the contact is made.
RAIL11WEL0452BA 3
48083741_EN 31/07/2018
25.3 [25.108] / 5
4. Measure the dimension II, from the front face of the sun
gear shaft to the mounting surface of the axle housing.
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 the sun gear shaft into the planetary carrier.
RAIL11WEL0454BA 5
6. Insert the shim(s) e.g. s = 1.60 mm (0.063 in) with

grease into the sun gear shaft.
RAIL11WEL0455BA 6
48083741_EN 31/07/2018
25.3 [25.108] / 6
7. Insert the O-ring with grease into the brake housing

countersink.
RAIL11WEL0456BA 7
8. Grease the O-ring and install it in the axle housing.
RAIL11WEL0457BA 8
9. Mount the adjusting bolts and use an acceptable lifting

device to bring the output into the contact position with
the axle housing. Secure the output by using bolts.
NOTE: attach the lifting device with wheel stud.
RAIL11WEL0458BA 9
48083741_EN 31/07/2018
25.3 [25.108] / 7
10. Mount the bleeder valve (see arrow).
RAIL11WEL0459BA 10
48083741_EN 31/07/2018
25.3 [25.108] / 8
Wheel hub - Disassemble - Model MT-L 3095 II

1. Attach the output to a suitable assembly stand.
RAIL11WEL0184BA 1
2. Use a lever to remove the output shaft cover.
RAIL11WEL0185BA 2
3. Remove the locking bolts and releasing cover.
RAIL11WEL0186BA 3
48083741_EN 31/07/2018
25.3 [25.108] / 9
4. Use a puller and press the planetary carrier out of the

output shaft profile.
RAIL11WEL0187BA 4
5. Use a suitable lifting device and lift the planetary carrier

out of the brake housing.
RAIL11WEL0188BA 5
6. With a suitable puller remove the tapered roller bearing

from the planetary carrier.
RAIL11WEL0189BA 6
48083741_EN 31/07/2018
25.3 [25.108] / 10
7. Remove the retaining rings.
RAIL11WEL0190BA 7
8. Pull off the planetary gears.
RAIL11WEL0191BA 8
9. Lift the end plate out of the brake housing.
RAIL11WEL0192BA 9
48083741_EN 31/07/2018
25.3 [25.108] / 11
10. Lift the disk package out of the brake housing.
RAIL11WEL0193BA 10
11. Remove the bolts, releasing cover and cup spring.
RAIL11WEL0194BA 11
12. Mount the bleeder valve. Use compressed air to re-

move the piston from the brake housing.
RAIL11WEL0195BA 12
48083741_EN 31/07/2018
25.3 [25.108] / 12
13. If needed, remove the guide ring, back-up rings and

grooved rings from the annular grooves of the brake
housing (see arrows).
RAIL11WEL0196BA 13
14. Note the installation position of the following individual

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 the brake housing

from the output shaft.
RAIL11WEL0198BA 15
48083741_EN 31/07/2018
25.3 [25.108] / 13
16. Depending on the version, use a lever to remove the

slide ring seal or shaft seal (combi seal version) from
the brake housing. If needed, remove both bearing
outer rings.
RAIL11WEL0199BA 16
17. For slide ring seal version, use a lever to remove the
slide ring seal from the output shaft. For combi seal
version, check the screening plate for the wear marks.
If required, separate it from the output shaft.
RAIL11WEL0200BA 17
18. Use a puller to remove the tapered roller bearing from

the output shaft.
RAIL11WEL0177BA 18
48083741_EN 31/07/2018
25.3 [25.108] / 14
Wheel hub - Visual inspection - Model MT-L 3095 II

NOTICE: do not use compressed air to dry bearings. Allow bearings to air dry.
NOTICE: wear face protection when using compressed air.
1. Clean all parts except the friction plates in the brake
disc pack by using a cleaning solvent. Use compressed
air to clear the passages in the planetary ring gear and
brake housing.
2. Inspect the bearing rollers for pitting, scoring, defor-
mation, or other damage. Check the inner face and
bearing cage for deformation, dents, and other dam-
age. Check the associated bearing cups for scratches,
grooves, or cracks. Check the bearings for rough spots
or binding by holding bearing and rotating. If the bear-
ing binds or action are not smooth, replace the bearing.
3. Inspect the 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 the planetary ring gear, planetary gears, and
planetary carrier gear teeth for cracks, breaks, chip-
ping, or other damage. Replace the part if any of these
conditions are seen. Check the planetary carrier shaft
splines for broken, cracked, or twisted condition. Re-
place if needed.
5. Check the wheel end shaft for cracked, broken, or
twisted splines. Replace if any of these conditions are
seen.
48083741_EN 31/07/2018
25.3 [25.108] / 15
Wheel hub - Assemble - MT-L 3095 II

CAUTION
Burn hazard!
C0047A
1. If needed, pull the wheel stud into the output shaft until
NOTE: a special tool may only be used for repairs when
exchanging the individual wheel studs with the mounted
output shaft. For new output shaft, use a press.
NOTE: only the heavy duty axle version uses the wheel
mounting studs.
RAIL11WEL0423BA 1
2. Heat the tapered roller bearing and insert it onto the

output shaft until the contact is made.
RAIL11WEL0424BA 2
3. Wet the O-ring of the slide ring seal and locating hole
with mineral spirits. Snap the new slide ring seal (part
1) into the output shaft.
NOTE: the step shows the version with slide ring seal.
RAIL11WEL0425BA 3
48083741_EN 31/07/2018
25.3 [25.108] / 16
4. Mount the new slide ring seal (part 2) into the brake
housing.
NOTE: the step shows the version with slide ring seal.
ATTENTION: risk of injury - metal rings have extremely
sharp edges. Wear protective gloves.
NOTE: the surface of the slide ring seal may not have any
grooves, scratches or other damage. Make sure the seal-
ing surface is parallel to the housing face. The O-rings
must be mounted evenly into the locating hole and must
not bulge out.
RAIL11WEL0426BA 4
5. Insert both bearing outer rings (see arrows) into the

brake housing until the contact is made.
RAIL11WEL0427BA 5
6. Refer to the illustration to see the 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.
The illustration shows the installation position of the combi
seal.
RAIL11WEL0428BA 6
48083741_EN 31/07/2018
25.3 [25.108] / 17
7. Heat the slide bushing and position it at the collar of

the output shaft. Position the slide bushing with the
pressure ring 381000106.
NOTE: an exact installation position is obtained when using
the specified pressure ring.
RAIL11WEL0429BA 7
8. Use the 381000073 driver tool to insert the shaft seal

into the brake housing.
NOTE: an exact installation position is obtained when us-
ing the specified driver tool. Make note of the installation
position (Step 6). Wet the outer diameter of the shaft seal
with mineral spirits before the assembly.
RAIL11WEL0430BA 8
9. Use a suitable lifting device and insert the premounted

brake housing over the output shaft until the contact is
made.
NOTE: before clamping the seal rings (slide ring seal) to
the installation dimension, clean the sliding surfaces and
apply an oil film. A leather cloth soaked in oil is recom-
mended for this step.
RAIL11WEL0431BA 9
48083741_EN 31/07/2018
25.3 [25.108] / 18
10. Insert the back-up rings and grooved rings into the
annular grooves of the brake housing (see arrows).
RAIL11WEL0432BA 10
11. Clean the annular groove of the brake housing with

mineral spirits. Insert the guide ring into the annular
grove (go to Step 12). Secure it with Loctite (type no.
415) at its ends (see arrows).
NOTE: the full circumference of the guide ring must be in
an exact contact position.
NOTE: upon the installation, the orifice of the guide ring
must show upwards - 12 o’clock position.
RAIL11WEL0433BA 11
12. Upon the installation, the orifice of the guide ring must
show upwards - 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
48083741_EN 31/07/2018
25.3 [25.108] / 19
13. Flush-mount the slotted pins into the piston holes.
RAIL11WEL0435BA 13
14. Insert the piston into the brake housing and install with
the fabricated fixing device until the contact is made.
NOTE: sufficiently oil the seal surface of the piston/back-up
rings, grooved rings and guide ring (W-10 oils are to be
used).
RAIL11WEL0436BA 14
15. Insert the disk and cup spring with the convex side
facing upwards into the piston.
RAIL11WEL0437BA 15
48083741_EN 31/07/2018
25.3 [25.108] / 20
16. Insert the cover and secure it by means of bolts.

RAIL11WEL0438BA 16
17. Insert the outer and inner disks.

NOTE: for the number of disks and disk arrangement, refer
RAIL11WEL0439BA 17
18. Insert the end plate.
RAIL11WEL0440BA 18
48083741_EN 31/07/2018
25.3 [25.108] / 21
19. Press the stop bolt (1) into the planetary carrier (2)
until the contact is obtained.
RAIL11WEL0461CA 19
20. Insert the cylindrical roller bearing into the planetary

gear by pressing the cylindrical roller bearing (1)
through the packaging sleeve (2) until the snap ring
(3) engages into the annular groove of the planetary
gear (4).
NOTE: use the packaging sleeve to facilitate the assembly.
RAIL11WEL0441BA 20
48083741_EN 31/07/2018
25.3 [25.108] / 22
21. Heat the bearing inner rings. Insert the premounted

planetary gears with the large radius facing the plan-
etary carrier (downwards) until the contact is made.
Secure the planetary gears by using retaining rings.
NOTE: adjust the bearing inner rings after cooling.
RAIL11WEL0442BA 21
22. Heat the tapered roller bearing and install it on the

planetary carrier until the contact is made.
RAIL11WEL0443BA 22
23. Wet the contact face of the bearing inner ring (1) and
profile teeth (2) in the output shaft with anti-corrosive
agent.
RAIL11WEL0444BA 23
48083741_EN 31/07/2018
25.3 [25.108] / 23
24. Align the disk package centrally and radially. Insert

the planetary carrier into the teeth of the output shaft
by using a suitable lifting device.
NOTE: MT-L 3095 planetary carrier has 4 planetary gears.
RAIL11WEL0445BA 24
25. Bring the planetary carrier into contact position with

the cover and the old locking screws which were re-
moved during disassembly. Then remove the locking
screws again.
RAIL11WEL0446BA 25
26. Pivot the output 90°.

Insert disk and fix planetary carrier with new locking
screws.
NOTE: Torque the locking screws successively to 200 N·m
(148 lb ft). Retighten locking screws to a torque of
500 N·m (369 lb ft).
RAIL11WEL0447BA 26
48083741_EN 31/07/2018
25.3 [25.108] / 24
27. Install a new O-ring (1) on the new cover. Wet contact
face (2) with TEROSTAT ® MS-9360.
NOTE: TEROSTAT ® MS-9360 has a curing period greater
than 24 h.
RAIL11WEL0448BA 27
28. Insert the cover into the output shaft until contact is
obtained.
RAIL11WEL0449BA 28
48083741_EN 31/07/2018
25.3 [25.108] / 25
Wheel hub - Remove Model 3105 II

NOTE: the front axle is shown in the following images and may appear slightly different externally than the rear axle.
The use of the tools and disassembly/assembly of the axles are the same regardless of appearance.
assembly stand.
RCIL11WHL001BAF 1
carrier.
and disposal.
RCIL11WHL002BAF 2
3. Remove the plugs and drain the oil from the outputs.
and disposal.
RCIL11WHL003BAF 3
48083741_EN 31/07/2018
25.3 [25.108] / 26
4. Remove the bleeder valves to avoid damage during the

RCIL11WHL004BAF 4
5. Attach an appropriate lifting device to the output as-

the axle housing.
ATTENTION: attach the load carrying device with a wheel
nut.
RCIL11WHL005BAF 5
6. Pull the stub shaft and sun gear shaft from the output.
RCIL11WHL006BAF 6
48083741_EN 31/07/2018
25.3 [25.108] / 27
Wheel hub - Disassemble Model 3105 II

1. Attach the output assembly to a suitable work stand.
RCIL11WHL007BAF 1
RCIL11WHL008BAF 2
RCIL11WHL009BAF 3
48083741_EN 31/07/2018
25.3 [25.108] / 28
4. Use a puller and press the planetary carrier from the

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

RCIL11WHL011BAF 5
6. Pull the tapered roller bearing from the planetary car-

rier.
RCIL11WHL012BAF 6
48083741_EN 31/07/2018
25.3 [25.108] / 29
RCIL11WHL013BAF 7
RCIL11WHL014BAF 8
RCIL11WHL015BAF 9
48083741_EN 31/07/2018
25.3 [25.108] / 30
RCIL11WHL016BAF 10
RCIL11WHL017BAF 11
12. Mount the bleeder valve and use compressed air to

remove the piston from the brake housing.
RCIL11WHL018BAF 12
48083741_EN 31/07/2018
25.3 [25.108] / 31

RCIL11WHL019BAF 13
1. Brake housing
2. Guide ring
3. Back-up ring
4. Piston seal
5. Piston seal
6. Back-up ring
7. Metal face seal (Heavy Duty Option) Combi seal
(Standard)
8. Output shaft
RCIL11WHL153BAF 14

RCIL11WHL020BAF 15
48083741_EN 31/07/2018
25.3 [25.108] / 32
15. Use levers to remove the slide ring seal from the brake
housing. If needed, remove both bearing outer rings.
RCIL11WHL021BAF 16
16. Use levers to remove the slide ring seal from the out-
put shaft.
RCIL11WHL022BAF 17
17. Pull the tapered roller bearing from the output shaft.
RCIL11WHL023BAF 18
48083741_EN 31/07/2018
25.3 [25.108] / 33
Wheel hub - Visual inspection Model 3105 II

NOTICE: do not use compressed air to dry bearings. Allow bearings to air dry.
NOTICE: wear face protection when using compressed air.
brake housing.
ing binds or action are not smooth, replace the bearing.
seen.
place if needed.
seen.
48083741_EN 31/07/2018
25.3 [25.108] / 34
Wheel hub - Assemble Model 3105 II

CAUTION
Burn hazard!
C0047A
1. Pull the wheel stud into the output shaft until the contact
is made.
NOTE: a special tool must be used for repairs when ex-
changing the individual wheel studs with a mounted output
shaft. On a new output shaft, mount the wheel studs with
a press.
RCIL11WHL118BAF 1
2. Heat the tapered roller bearing and place it onto the

output shaft.
RCIL11WHL119BAF 2
with mineral spirits. Snap new slide ring seal onto the
output shaft.
NOTE: the surface of the slide ring seal must not have any
grooves, scratches or other damage. Make sure that the
sealing surface is parallel to the housing face. The O-rings
not bulge out.
RCIL11WHL120BAF 3
48083741_EN 31/07/2018
25.3 [25.108] / 35
4. Mount new slide ring seal onto the brake housing.

grooves, scratches or other damage. Make sure that the
not bulge out.
RCIL11WHL121BAF 4

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

brake housing on output shaft.
RCIL11WHL123BAF 6
48083741_EN 31/07/2018
25.3 [25.108] / 36
7. Insert the back-up rings and grooved rings into the an-
nular grooves of the brake housing (see arrows).
RCIL11WHL124BAF 7

grove. Secure it with Loctite (type no. 415) at its ends
(see arrows).
the exact contact position.
RCIL11WHL125BAF 8
1. Brake housing
2. Guide ring
3. Back-up ring
4. Piston seal
5. Piston seal
6. Back-up ring
7. Metal Face Seal (Heavy Duty Option) Combi Seal
(Standard)
8. Output shaft
RCIL11WHL153BAF 9
48083741_EN 31/07/2018
25.3 [25.108] / 37
RCIL11WHL126BAF 10
the dealer fabricated fixing device until the contact is
made.
rings, grooved rings and guide ring with W-10 oils.
RCIL11WHL127BAF 11
showing upwards into the piston.
RCIL11WHL128BAF 12
48083741_EN 31/07/2018
25.3 [25.108] / 38
12. Insert the cover and secure it with bolts. Torque to

34 N·m (25 lb ft).
RCIL11WHL129BAF 13

RCIL11WHL130BAF 14
RCIL11WHL131BAF 15
48083741_EN 31/07/2018
25.3 [25.108] / 39
15. Press the stop bolt (1) into the planetary carrier (2).
RCIL11WHL158BAF 16

gear, by pressing the cylindrical roller bearing (1)
gear (4).
NOTE: use a packaging sleeve to facilitate the assembly.
RCIL11WHL132BAF 17
48083741_EN 31/07/2018
25.3 [25.108] / 40

planetary gears with the large radius facing the plane-
tary carrier (downwards). Secure the planetary gears
with the retaining rings.
RCIL11WHL133BAF 18
18. Heat the tapered roller bearing. Install it on the plan-

etary carrier.
RCIL11WHL134BAF 19
agent.
RCIL11WHL135BAF 20
48083741_EN 31/07/2018
25.3 [25.108] / 41
20. Align the disk package centrally and radially. Heat the
output shaft. Use a suitable lifting device to insert the
planetary carrier into the teeth of the output shaft.
RCIL11WHL136BAF 21
21. Bring the planetary carrier with the measuring disk

and three old locking bolts (removed during the disas-
sembly) into the contact position. Torque to 200 N·m
(148 lb ft).
RCIL11WHL137BAF 22
22. Pivot the output 180° and measure the gap width from
the output shaft to the planetary carrier. Remove the
locking bolts and measure the disk again.
NOTE: gap width e.g.: 0.21 mm (0.01 in).
RCIL11WHL159BAF 23
48083741_EN 31/07/2018
25.3 [25.108] / 42
1 = Planetary carrier
2 = Output shaft
X = Gap width
RCIL11WHL166BAF 24
23. Select the cover (optional) based on the following ta-

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

0.30 – 0.24 mm (0.012 – 0.009 in) 0.13 mm (0.005 in)
0.239 – 0.18 mm (0.009 – 0.007 in) 0.07 mm (0.003 in)
0.179 – 0.10 mm (0.007 – 0.004 in) 0.0 mm (0.000 in)
24. Pivot the output 90°. Insert the cover with the offset
e.g. 0.07 mm (0.003 in) showing towards the plane-
tary carrier and tighten with new locking bolts.
NOTE: when using the cover with offset of 0.07 mm
(0.003 in), the groove (arrow step 23) must be visible
when the cover is installed.
NOTE: torque the locking bolts successively to 200 N·m
(148 lb ft). Retorque to 500 N·m (369 lb ft).
RCIL11WHL138BAF 26
48083741_EN 31/07/2018
25.3 [25.108] / 43
25. Install new O-ring (1) and cover. Wet the contact face
(2) with TEROSTAT ® MS-9360.
NOTE: the curing period for TEROSTAT ® MS-9360 is
greater than 24-hours.
RCIL11WHL139BAF 27
26. Insert the cover into the output shaft until the contact
is made.
RCIL11WHL140BAF 28
48083741_EN 31/07/2018
25.3 [25.108] / 44
Wheel hub - Install Model 3105 II

1. Set the sun gear shaft axial play range to 0.5 – 2.0 mm
(0.02 – 0.08 in). Use a straight edge to determine the
dimension I, from the mounting face of the brake hous-
ing to the front face of the stop bolt. Dimension I e.g.
40.80 mm (1.61 in).
RCIL11WHL141BAF 1
2. Insert the stub shaft into the teeth of the axle bevel gear
NOTE: mount the stub shaft with the long teeth towards the
differential.
RCIL11WHL142BAF 2
RCIL11WHL143BAF 3
48083741_EN 31/07/2018
25.3 [25.108] / 45
4. By using a straight edge, measure the dimension II,

from the front face of the sun gear shaft to the mount-
ing surface of the axle housing. Dimension II e.g.
38.20 mm (1.50 in). CALCULATION EXAMPLE: Di-
mension I: 40.80 mm (1.61 in) Dimension II: 38.20 mm
(1.50 in) Difference: 2.60 mm (0.10 in) Required axial
play e.g.: 1.00 mm (0.04 in) Difference = shim e.g.: s
= 1.60 mm (0.06 in).
RCIL11WHL144BAF 4
RCIL11WHL145BAF 5

RCIL11WHL146BAF 6
48083741_EN 31/07/2018
25.3 [25.108] / 46
7. Attach the O-ring (see arrow) with grease into the brake
housing countersink.
RCIL11WHL147BAF 7
8. Grease the O-ring (see arrow) and install it in the axle

housing.
RCIL11WHL148BAF 8
9. Mount the adjusting bolts and use an appropriate lifting

device to bring the output into the contact position with
the axle housing. Secure the output by using bolts.
NOTE: attach the load carrying device with a wheel stud.
RCIL11WHL149BAF 9
48083741_EN 31/07/2018
25.3 [25.108] / 47
RCIL11WHL150BAF 10
48083741_EN 31/07/2018
25.3 [25.108] / 48
Index

Wheel hub - Assemble - MT-L 3095 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Wheel hub - Assemble Model 3105 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Wheel hub - Disassemble - Model MT-L 3095 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Wheel hub - Disassemble Model 3105 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Wheel hub - Install Model 3105 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Wheel hub - Install Model MT-L 3095 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Wheel hub - Remove - Models MT-L 3085 II / MT-L 3095 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Wheel hub - Remove Model 3105 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Wheel hub - Visual inspection - Model MT-L 3095 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Wheel hub - Visual inspection Model 3105 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
48083741_EN 31/07/2018
25.3 [25.108] / 49
PRINTED IN ITALY
48083741_EN 31/07/2018
EN
SERVICE MANUAL
Rear axle system

48083741_EN 31/07/2018
27
Contents
Rear axle system - 27
[27.100] Powered rear axle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27.1
[27.106] Rear bevel gear set and differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27.2
[27.120] Planetary and final drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27.3
48083741_EN 31/07/2018
27
Powered rear axle - 100

48083741_EN 31/07/2018
27.1 [27.100] / 1
Contents
TECHNICAL DATA
Powered rear axle

Rear axle - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SERVICE
Powered rear axle

Rear axle - Lubricate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Rear axle - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
48083741_EN 31/07/2018
27.1 [27.100] / 2
Rear axle system - Powered rear axle
Rear axle - General specification

821G
Rear Axle Model MT-L3085II - Limited Slip Differential
Rear Axle Model MT-L3095II - Open Differential
LEIL13WHL1208AA 1

WHEEL MOUNTING STUDS 16 (M22x1.5)
HUB RATIO 6.00:1
CCW INPUT ROTATION (FACING INPUT FLANGE)
–
FOR FORWARD TRAVEL
(*) AXLE TO BE EQUIPPED WITH LIMITED SLIP TYPE
45% TRANSFER
DIFFERENTIAL
(*) Only Front Axle Model MT-L3085II - Limited Slip Differential
48083741_EN 31/07/2018
27.1 [27.100] / 3
921G
LEIL13WHL1209AA 2

WHEEL MOUNTING STUDS 20 (M22x1.5)
HUB RATIO 6.00:1
CCW INPUT ROTATION (FACING INPUT FLANGE)
–
FOR FORWARD TRAVEL
48083741_EN 31/07/2018
27.1 [27.100] / 4
Rear axle - Lubricate

821G
Rear Axle Model MT-L3085II - Limited Slip Differential
LEIL13WHL1208AA 1
1. Oil drain hole (axle casing) 4. Brake bleeder

2. Oil drain hole (outputs) 5. Bleeder
3. Oil filler and check hole
48083741_EN 31/07/2018
27.1 [27.100] / 5
921G
LEIL13WHL1209AA 2
6. Oil drain hole (axle casing) 9. Brake bleeder

7. Oil drain hole (outputs) 10. Bleeder
8. Oil filler and check hole
48083741_EN 31/07/2018
27.1 [27.100] / 6
Rear axle - Remove

1. Park the machine on a level surface; make sure to al-
low an adequate space at the machine side for the rear
axle removal. Stop the engine. Actuate the brake pedal
several times to discharge the brake accumulators. Put
the key switch in ON position and move the loader con-
trol lever back and forth at least 30 times to release any
pressure from the hydraulic circuit.
2. Put the articulation lock in LOCKED position.
BD03A040-01 1
3. Install the wood blocks between the rear axle and the
chassis to prevent the rear axle from pivoting.
4. Remove the four bolts and two straps. Use a pry bar to
disconnect the rear drive shaft from the rear axle.
shaft must be replaced when removed.
BD03A162-01 2
5. Disconnect the brake hose from the elbow. Remove

and discard the O-ring face seal from the elbow.
BD03A169-01 3
48083741_EN 31/07/2018
27.1 [27.100] / 7
6. By using an acceptable hydraulic jack, raise one tire

from ground and install an acceptable jack stand under
the machine. Repeat this step for the other tire.
BD01F299-01 4
7. Use an acceptable jack to hold the rear axle.
LEIL13WHL1211AA 5
8. Remove the bolts and washers from the rear wheels.

Remove both wheels from the rear axle.
LEIL13WHL0566AB 6
9. At the front of the trunnion, remove the three Allen head

bolts and washers. Remove the front cap: if needed
use two M12 by 32 mm (1.26 in) bolts in the puller
holes (1); tighten the bolts evenly to pull the cap from
the axle and trunnion. Remove and discard the O-ring
from the cap. Repeat this step at the trunnion rear ex-
cept remove and retain the shim(s) after the rear cap
removal. Remove the pivot shaft by using an accept-
able sleeve or rod if needed.
LEIL13WHL1210AB 7
10. Carefully lower the rear axle and remove through the
machine side.
48083741_EN 31/07/2018
27.1 [27.100] / 8
11. Remove and discard the two seals from the rear axle
pivot point.
48083741_EN 31/07/2018
27.1 [27.100] / 9
Powered rear axle - Install

1. Assemble the pivot pin (10), the end cap front (4) and
the end cap rear (12) in the trunnion (1) without the rear
axle and without the shims.
Install one bolt (6) on each end. Tighten bolts securely.
2. Push assembled pivot pin and caps to rear of machine
as far as possible.
3. Measure and record the gap (A) between the rear cap
(12) and the trunnion (1). Select shims from the follow-
ing table:
RAPH12WEL0213AA 1
NOTE: shims are available in following sizes: 0.25 mm
(0.010 in), 0.50 mm (0.020 in), 1.00 mm (0.039 in) and
1.50 mm (0.059 in).
MEASURED GAP SHIM(S) REQUIRED

0.07 – 0.30 mm (0.003 – 0.012 in) None
0.31 – 0.55 mm (0.012 – 0.022 in) 0.25 mm (0.01 in)
0.56 – 0.840 mm (0.02 – 0.033 in) 0.5 mm (0.020 in)
0.85 – 1.09 mm (0.033 – 0.043 in) 0.5 mm (0.020 in) + 0.25 mm (0.01 in)
1.100 – 1.340 mm (0.043 – 0.053 in) 1 mm (0.039 in)
1.35 – 1.59 mm (0.053 – 0.063 in) 1 mm (0.039 in) + 0.25 mm (0.01 in)
1.6 – 1.84 mm (0.063 – 0.072 in) 1.5 mm (0.059 in) +
1.85 – 2.09 mm (0.073 – 0.083 in) 1.5 mm (0.059 in) + 0.25 mm (0.01 in)
2.1 – 2.34 mm (0.083 – 0.093 in) 1.5 mm (0.059 in) + 0.5 mm (0.020 in)
2.35 – 2.59 mm (0.093 – 0.102 in) 1.5 mm (0.059 in) + 0.5 mm (0.020 in) + 0.25 mm
(0.01 in)
2.6 – 3.02 mm (0.102 – 0.119 in) 1.0 mm (0.04 in) + 1.5 mm (0.059 in)
4. Loosen the bolts (6) to remove the pivot pin (10) and
the end caps (4) and (12).
48083741_EN 31/07/2018
27.1 [27.100] / 10
5. Clean the front (A) and the rear (B) pivot area of rear
axle where seals will be installed.
LEIL16WHL0562AB 2
LEIL16WHL0563AB 3
6. Use CASE AKCELA MOLY GREASE to lubricate

two new seals (2) and new O-rings. Install the seals,
smooth side out, into the front and rear of the 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).
LEIL16WHL0564AB 4
7. Carefully move the rear axle under machine. Raise the

axle into position in the trunnion. Align the pivot holes
in the trunnion with the pivot holes in the axle.
8. Lubricate the pivot pin (8) with CASE AKCELA MOLY
GREASE at the rear of the trunnion (B). Install the pivot
pin (8) into trunnion and axle (A).
9. Apply LOCTITE® 7471™ PRIMER T™ to the female
threads of the axle pivot pin and let dry for 70 s. Then,
apply LOCTITE® 243™to the female threads of the axle
pin.
10. Install the shim pack (7), the rear cap (6) with O-ring
installed, and two washers and bolts (5). Torque
RAPH12WEL0217AA 5
the end front cap (4) with O-ring, washers and bolts
(5). Tighten the bolts (5) to 575 – 600 N·m (424.1 –
442.5 lb ft).
48083741_EN 31/07/2018
27.1 [27.100] / 11
11. Connect the grease hoses to the rear axle.
LEIL17WHL2312AB 6
12. Try spinning the end cap by hand. If the hand cap
spins no shim is necessary.
LEIL17WHL1618AB 7
If the hand cap does not spin, remove one of the end
caps and add a shim (arrow). Re-assemble the end
cap and bolts. Torque the bolts again to 575 – 600 N·m
(424.1 – 442.5 lb ft).
Try spinning the end cap by hand. If the hand cap spins,
no further shim is required.
LEIL17WHL1619AB 8
If the hand cap does not spin, remove again one of the
end caps and add another shim.
Re-assemble the end cap and bolts. Try spinning the
end cap by hand. If the hand cap spins, no further ac-
tion is required. If the end cap does not spin, check all
parts in the pin/end cap/ axle assembly.
NOTE: DO NOT add more then 2 shims.
LEIL17WHL1620AB 9
48083741_EN 31/07/2018
27.1 [27.100] / 12
13. After the final assembly of the rear axle pin, apply
42.6 g (1.5 oz) of grease to both rear axle grease
lines. Apply the remaining grease quantity per axle
pin installation drawing via grease fitting mounted in
center of axle pin housing until grease is expelled from
seals.
14. Install both wheels on the rear axle and secure by
using washers and bolts.
BD01F295-01 10
15. Tighten the bolts to a preliminary torque of 298 N·m

(220 lb ft) in the indicated sequence. Then tighten
to a torque of 640 – 720 Nm ( 475 – 530 lb.ft) in the
same sequence.
821G Torque pattern
LEIL13WHL0567AB 11
921G Torque pattern
LEIL13WHL0568AB 12
48083741_EN 31/07/2018
27.1 [27.100] / 13
16. Remove the hydraulic jack supporting the rear axle

and the jack stands supporting loader.
BD01F302-01 13
17. Install a new O-ring face seal in elbow. Connect the

brake hose to the elbow.
BD03A169-01 14
18. Connect the rear drive shaft to the rear axle. Install
two straps and four bolts . Tighten bolts to a torque of
75 – 81 N·m (55 – 60 lb ft).
BD03A162-01 15
19. If necessary, fill the axle with the relevant lubricant.

20. Bleed the brakes.
21. Put the articulation lock in the OPERATING position.
48083741_EN 31/07/2018
27.1 [27.100] / 14
Index

Powered rear axle - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Rear axle - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Rear axle - Lubricate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Rear axle - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
48083741_EN 31/07/2018
27.1 [27.100] / 15
48083741_EN 31/07/2018
27.1 [27.100] / 16
Rear bevel gear set and differential - 106

48083741_EN 31/07/2018
27.2 [27.106] / 1
Contents
SERVICE
Bevel gear
Backlash - Models MT-L 3085 II / MT-L 3095 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Differential
Remove - Models MT-L 3085 II / MT-L 3095 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Install - Models MT-L 3085 II / MT-L 3095 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Disassemble - D Version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Assemble - D Version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Disassemble - DL Version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Assemble - DL Version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
48083741_EN 31/07/2018
27.2 [27.106] / 2
Rear axle system - Rear bevel gear set and differential
Bevel gear - Backlash - Models MT-L 3085 II / MT-L 3095 II

CAUTION
Burn hazard!
C0047A
1. Determine the shim thickness to obtain a correct con-

tact pattern. Read the dimension I from the axle drive
housing. Dimension I e.g. 221.10 mm (8.705 in)
rately. Inaccurate measurements lead to incorrect contact
pattern requiring additional disassembly and reassembly
of the input pinion and differential.
RAIL11WEL0349BA 1
2. Read the dimension II from the pinion. Dimension II

e.g. 181.00 mm (7.126 in).
RAIL11WEL0350BA 2

sion III e.g. 39.10 mm (1.539 in).
RAIL11WEL0351BA 3
48083741_EN 31/07/2018
27.2 [27.106] / 3
Calculation Example “A”:

Dimension I: -39.10 mm (1.54 in)
Dimension II: -181.00 mm (7.13 in)
Dimension III: -39.10 mm (1.54 in)
Difference = shim s = 1.00 mm (0.04 in)
4. Cool the external bearing and insert it into the axle drive
housing until the contact is made.
RAIL11WEL0352BA 4
5. Insert the shim into the housing hole size e.g. s =

1.00 mm (0.039 in).
RAIL11WEL0353BA 5
6. Cool the internal bearing outer ring and bring it into

the contact position in the housing hole by using the
380100001 bearing cup installer tool.
RAIL11WEL0354BA 6
48083741_EN 31/07/2018
27.2 [27.106] / 4
7. Heat the tapered roller bearing and insert it into the

input pinion until the contact is made.
RAIL11WEL0355BA 7
8. Set the rolling torque of the input pinion bearing (without

shaft seal) to 1.5 – 3.0 N·m (13 – 27 lb in). Insert a
spacer e.g. s = 8.18 mm (0.322 in).
RAIL11WEL0356BA 8

RAIL11WEL0357BA 9
48083741_EN 31/07/2018
27.2 [27.106] / 5
10. Press the protection plate onto the input flange until
been checked and verified.
RAIL11WEL0358BA 10
11. Insert the input flange and secure it with the disk and
CAS2842 slotted nut wrench and 380001546 flange
holder.
both directions.
RAIL11WEL0359BA 11
12. Check the rolling torque. It must be 1.5 – 3.0 N·m (13
– 27 lb in) without a shaft seal.
per value of the rolling torque.
NOTE: in case of rolling torque measurement deviations,
correct with a corresponding spacer as specified - go back
to 8. For an insufficient rolling torque, install a thinner
spacer ring. For an excessive rolling torque, install a
thicker spacer ring.
RAIL11WEL0360BA 12
48083741_EN 31/07/2018
27.2 [27.106] / 6
13. Grease the O-rings and insert them into the annular
grooves of the piston.
NOTE: this step is only needed for versions with DHL dif-
ferential.
RAIL11WEL0361BA 13
14. Insert the piston (see arrow) into the bearing housing
RAIL11WEL0362BA 14
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 the
read value (deviation/test dimension) and correspond-
ing 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 the actual value
“0” in the following table. According to this value, the
required shims are allocated in the table. Any +/- de-
viation of the test dimension caused by the 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
48083741_EN 31/07/2018
27.2 [27.106] / 7
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.

ring (see arrow) until the contact is obtained.
RAIL11WEL0365BA 17
48083741_EN 31/07/2018
27.2 [27.106] / 8
RAIL11WEL0366BA 18

ring until the contact is made.
RAIL11WEL0367BA 19
19. Mount two M20 locating pins (S) and bring the axle
housing into the contact position with the axle drive
housing by using a suitable lifting device. Temporarily
attach the axle housing with bolts. Torque to 560 N·m
(413 lb ft).
RAIL11WEL0368BA 20
48083741_EN 31/07/2018
27.2 [27.106] / 9
20. Leak test differential lock. Pressurize the lock to p =

1 bar (15 psi), close the shutoff valve and remove the
air line. No noticeable pressure loss must occur within
10 seconds.
NOTE: this operation is only needed for versions with DHL
differential.
RAIL11WEL0369BA 21
21. In both directions, several times, rotate the input

flange to roll the crown wheel over the input pinion.
Remove the axle housing and lift the differential out
of the axle drive housing. Compare the obtained
contact pattern with the contact pattern examples at
the beginning of this section.
NOTE: if the tooth contact pattern differs, an incorrect shim
size was selected in the previous steps. This must be cor-
rected.
RAIL11WEL0370BA 22
48083741_EN 31/07/2018
27.2 [27.106] / 10
Differential - Remove - Models MT-L 3085 II / MT-L 3095 II

CAUTION
Burn hazard!
C0047A

assembly stand.
ing studs.
RAIL11WEL0178BA 1
carrier.
and disposal.
RAIL11WEL0179BA 2
and disposal.
RAIL11WEL0180BA 3
48083741_EN 31/07/2018
27.2 [27.106] / 11

RAIL11WEL0181BA 4

the axle housing.
RAIL11WEL0182BA 5

RAIL11WEL0183BA 6
48083741_EN 31/07/2018
27.2 [27.106] / 12

move the bolts. Separate the axle housing from the
axle drive housing.
RAIL11WEL0213BA 7

leasing brake tube.
RAIL11WEL0214BA 8
RAIL11WEL0212BA 9
48083741_EN 31/07/2018
27.2 [27.106] / 13
RAIL11WEL0233BA 10
11. Lift the differential from the axle drive housing by using
a suitable lifting device.
RAIL11WEL0232BA 11
RAIL11WEL0233BA 12
48083741_EN 31/07/2018
27.2 [27.106] / 14
13. Remove the piston (see arrow) from the axle housing.
NOTE: this step is needed only for DHL version.
RAIL11WEL0234BA 13
14. Use compressed air to remove the piston.

NOTE: this step is needed only for DHL version.
RAIL11WEL0235BA 14
15. Heat the slotted nut with a hot air blower.

NOTE: the slotted nut is secured with LOCTITE® 262™.
RAIL11WEL0236BA 15
48083741_EN 31/07/2018
27.2 [27.106] / 15
16. Remove the slotted nut and shim behind it. Use the
slotted nut wrench CAS2842 and clamping device
380001546.
RAIL11WEL0237BA 16
17. Remove the input flange from the pinion. Use a lever
to remove the shaft seal.
RAIL11WEL0238BA 17
RAIL11WEL0239BA 18
48083741_EN 31/07/2018
27.2 [27.106] / 16
RAIL11WEL0240BA 19
20. If needed, remove the bearing outer rings from the

axle drive housing.
RAIL11WEL0231BA 20
48083741_EN 31/07/2018
27.2 [27.106] / 17
Differential - Install - Models MT-L 3085 II / MT-L 3095 II

1. After the contact pattern check, insert the differential
into the axle drive housing again.
RAIL11WEL0371BA 1
2. Remove the slotted nut and pull the input flange from
the input pinion. Use the CAS2842 slotted nut wrench
and 380001546clamping device.
RAIL11WEL0372BA 2
3. By using the CAS2841 driver tool, mount the shaft seal

with the seal lip facing oil chamber.
by using the specified driver tool.
seal and dust lip with grease.
RAIL11WEL0373BA 3
48083741_EN 31/07/2018
27.2 [27.106] / 18
4. Insert the input flange and secure it by using disc and

CAS2842 slotted nut wrench and 380001546 clamping
device.
RAIL11WEL0348BA 4
RAIL11WEL0397BA 5
6. Mount two M20 locating pins and bring the axle housing
into the contact position with the axle drive housing by
by using bolts. Torque to 560 N·m (413 lb ft).
with clamping brackets (S).
RAIL11WEL0398BA 6
48083741_EN 31/07/2018
27.2 [27.106] / 19
RAIL11WEL0399BA 7

RAIL11WEL0400BA 8
9. Mount the brake tube with threaded connection and

nut. Torque to 100 N·m (74 lb ft).
RAIL11WEL0401BA 9
48083741_EN 31/07/2018
27.2 [27.106] / 20

(37 lb ft).
RAIL11WEL0396BA 10
48083741_EN 31/07/2018
27.2 [27.106] / 21
Differential - Disassemble - D Version

RAIL11WEL0243BA 1

bolts and the releasing housing cover.
RAIL11WEL0244BA 2

RAIL11WEL0247BA 3
48083741_EN 31/07/2018
27.2 [27.106] / 22
4. Remove the axle bevel gear with thrust washers from

RAIL11WEL0248BA 4
RAIL11WEL0249BA 5
6. Force out both short differential axles. Remove the re-

leasing spider gears with thrust washers from the dif-
ferential housing.
RAIL11WEL0250BA 6
48083741_EN 31/07/2018
27.2 [27.106] / 23

spider gears with thrust washers from the differential
housing.
RAIL11WEL0251BA 7
RAIL11WEL0252BA 8
RAIL11WEL0241BA 9
48083741_EN 31/07/2018
27.2 [27.106] / 24
Differential - Assemble - D Version

CAUTION
Burn hazard!
C0047A

made.
RAIL11WEL0270BA 1
RAIL11WEL0271BA 2
RAIL11WEL0272BA 3
48083741_EN 31/07/2018
27.2 [27.106] / 25
4. Insert the spider gears with thrust washers into the dif-
ferential housing. Secure them with the long spider
shaft.
NOTE: the thrust washers must be positioned with tabs
(see arrow) located in the recesses of the differential hous-
ing.
RAIL11WEL0273BA 4
5. Insert the spider gears (1) with thrust washers into the
differential housing (2). Secure them with two short
spider shafts.
RAIL11WEL0274BA 5

RAIL11WEL0275BA 6
48083741_EN 31/07/2018
27.2 [27.106] / 26
RAIL11WEL0276BA 7

grease.
RAIL11WEL0277BA 8

(295 lb ft).
RAIL11WEL0278BA 9
48083741_EN 31/07/2018
27.2 [27.106] / 27

RAIL11WEL0298BA 10
ter cooling down.
RAIL11WEL0299BA 11
48083741_EN 31/07/2018
27.2 [27.106] / 28
Differential - Disassemble - DL Version

LEIL13WHL0592AA 1
2. Preload the differential with a press. Remove the lock-

ing screws and housing cover.
RCIL11WHL052BAF 2
3. Remove the axle bevel gear with pressure ring, disc

package and thrust washers from the differential hous-
ing.
LEIL13WHL0593AA 3
4. Remove the spider shafts and axle bevel gears from

LEIL13WHL0594AA 4
48083741_EN 31/07/2018
27.2 [27.106] / 29
5. Remove the second axle bevel gear.
RCIL11WHL057BAF 5
6. Remove the pressure ring, disc package and thrust

washers from the differential housing.
LEIL13WHL0595AA 6
RCIL11WHL058BAF 7
48083741_EN 31/07/2018
27.2 [27.106] / 30
Differential - Assemble - DL Version

1. Mount two M16 X 1.5 locating pins (S) and press the
heated crown wheel onto the differential housing until
LEIL13WHL0596AB 1
RCIL11WHL077BAF 2

starting with an outer disk.
rected by mounting the outer discs of different thicknesses.
LEIL13WHL0597AA 3
4. Install the pressure ring.
LEIL13WHL0598AA 4
48083741_EN 31/07/2018
27.2 [27.106] / 31
5. Install the axle bevel gear until the contact is made.

Then install the inner discs with teeth.
RCIL11WHL078BAF 5
6. Preassemble the differential spider and insert it into the

differential housing/pressure ring.
LEIL13WHL0599AA 6
7. Install the second axle bevel gear.
LEIL13WHL0600AA 7
8. Install the second thrust ring into the differential hous-

ing
LEIL13WHL1201AA 8
48083741_EN 31/07/2018
27.2 [27.106] / 32

starting with an inner disc.
rected by mounting the outer discs of different thicknesses.
LEIL13WHL1202AA 9
10. Determine the installation clearance 0.2 – 0.7 mm

(0.008 – 0.028 in). Measure the 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).
LEIL13WHL1203AA 10
11. Measure the Dimension II, from the contact face of the
outer disc to the mounting face on the housing cover.
Calculation Example:
Dimension I - 44.30 mm (1.744 in)
Dimension II - 43.95 mm (1.730 in)
Difference + disc clearance - 0.35 mm (0.014 in)
NOTE: any deviation from the required installation clear-
ance must be corrected with the 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 LEIL13WHL1204AA 11
left and right disc package is less than 0.1 mm (0.004 in).
grease.
LEIL13WHL1205AA 12
48083741_EN 31/07/2018
27.2 [27.106] / 33
13. Mount two M16 X 1.5 adjusting bolts and insert the
housing cover until the contact with the differential
housing is made. Preload the differential with a press.
Secure with new locking bolts and torque to 400 N·m
(295 lb ft).
LEIL13WHL1206AA 13
ter cooling down.
LEIL13WHL1207AA 14
48083741_EN 31/07/2018
27.2 [27.106] / 34
Index

Bevel gear - Backlash - Models MT-L 3085 II / MT-L 3095 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Differential - Assemble - D Version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Differential - Assemble - DL Version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Differential - Disassemble - D Version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Differential - Disassemble - DL Version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Differential - Install - Models MT-L 3085 II / MT-L 3095 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Differential - Remove - Models MT-L 3085 II / MT-L 3095 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
48083741_EN 31/07/2018
27.2 [27.106] / 35
48083741_EN 31/07/2018
27.2 [27.106] / 36
Planetary and final drives - 120

48083741_EN 31/07/2018
27.3 [27.120] / 1
Contents
SERVICE
Wheel hub
Remove - Models MT-L 3085 II / MT-L 3095 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Install - Models MT-L 3085 II / MT-L 3095 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Disassemble - Models MT-L 3085 II / MT-L 3095 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Visual inspection - Models MT-L 3085 II / MT-L 3095 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Assemble - Models MT-L 3085 II / MT-L 3095 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
48083741_EN 31/07/2018
27.3 [27.120] / 2
Rear axle system - Planetary and final drives
Wheel hub - Remove - Models MT-L 3085 II / MT-L 3095 II

assembly stand.
ing studs.
RAIL11WEL0178BA 1
carrier.
and disposal.
RAIL11WEL0179BA 2
and disposal.
RAIL11WEL0180BA 3
48083741_EN 31/07/2018
27.3 [27.120] / 3
4. Remove the bleeder valve to avoid damage during the

RAIL11WEL0181BA 4

the axle housing.
RAIL11WEL0182BA 5

RAIL11WEL0183BA 6
48083741_EN 31/07/2018
27.3 [27.120] / 4
Wheel hub - Install - Models MT-L 3085 II / MT-L 3095 II

1. Set the axial play of the sun gear shaft to 0.5 – 2.0 mm
(0.020 – 0.079 in). Determine the dimension I, distance
from the brake housing mounting face to the stop bolt
front face. Dimension I e.g. 19.75 mm (0.778 in).
RAIL11WEL0450BA 1
2. Insert the stub shaft into the axle bevel gear teeth until
NOTE: be aware of the installation position. Mount the stub
shaft side with the long teeth towards the differential.
RAIL11WEL0451BA 2
RAIL11WEL0452BA 3
48083741_EN 31/07/2018
27.3 [27.120] / 5
4. Measure the dimension II, from the sun gear shaft front
face to the axle housing mounting surface. Dimension
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)
RAIL11WEL0454BA 5

RAIL11WEL0455BA 6
48083741_EN 31/07/2018
27.3 [27.120] / 6
7. Insert the O-ring with grease into the brake housing

countersink.
RAIL11WEL0456BA 7
8. Grease the O-ring and install it in the axle housing.
RAIL11WEL0457BA 8
9. Mount adjusting bolts and use an acceptable lifting de-

vice to bring the output into the contact position with the
axle housing. Secure the output by using bolts. Torque
to 390 N·m (288 lb ft).
NOTE: attach the lifting device with wheel stud.
RAIL11WEL0458BA 9
48083741_EN 31/07/2018
27.3 [27.120] / 7
RAIL11WEL0459BA 10
48083741_EN 31/07/2018
27.3 [27.120] / 8
Wheel hub - Disassemble - Models MT-L 3085 II / MT-L 3095 II

RAIL11WEL0184BA 1
RAIL11WEL0185BA 2
RAIL11WEL0186BA 3
48083741_EN 31/07/2018
27.3 [27.120] / 9
4. Use a puller and press the planetary carrier out of the

RAIL11WEL0187BA 4
5. Use a suitable lifting device and lift the planetary carrier

RAIL11WEL0188BA 5
6. With a suitable puller remove the tapered roller bearing

from the planetary carrier.
RAIL11WEL0189BA 6
48083741_EN 31/07/2018
27.3 [27.120] / 10
RAIL11WEL0190BA 7
RAIL11WEL0191BA 8
RAIL11WEL0192BA 9
48083741_EN 31/07/2018
27.3 [27.120] / 11
RAIL11WEL0193BA 10
RAIL11WEL0194BA 11
12. Mount the bleeder valve. Use compressed air to re-

move the piston from the brake housing.
RAIL11WEL0195BA 12
48083741_EN 31/07/2018
27.3 [27.120] / 12

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
7. Slide ring seal (Metal face seal - HD option only
8. Output shaft
RAIL11WEL0197BA 14

RAIL11WEL0198BA 15
48083741_EN 31/07/2018
27.3 [27.120] / 13
16. Depending on the version, use a lever to remove the

slide ring seal or shaft seal (combi seal version) from
the brake housing. If needed, remove both bearing
outer rings.
RAIL11WEL0199BA 16
version, check the screening plate for wear marks. If
required, separate it from the output shaft.
RAIL11WEL0200BA 17

the output shaft.
RAIL11WEL0177BA 18
48083741_EN 31/07/2018
27.3 [27.120] / 14
Wheel hub - Visual inspection - Models MT-L 3085 II / MT-L 3095 II

disc pack by using cleaning solvent. Use compressed
brake housing.
NOTICE: wear face protection when using compresses air.

ing binds or action is not smooth, replace the bearing.
seen.
place if needed.
seen.
48083741_EN 31/07/2018
27.3 [27.120] / 15
Wheel hub - Assemble - Models MT-L 3085 II / MT-L 3095 II

CAUTION
Burn hazard!
C0047A
NOTE: a special tool may only be used for repairs when
exchanging the individual wheel studs with the mounted
output shaft. For new output shaft, use a press.
ing studs.
RAIL11WEL0423BA 1

output shaft until the contact is made.
RAIL11WEL0424BA 2
with mineral spirits. Snap the new slide ring seal (part
1) into the output shaft.
NOTE: this step shows the version with slide ring seal.
RAIL11WEL0425BA 3
48083741_EN 31/07/2018
27.3 [27.120] / 16
4. Then mount new slide ring seal (part 2) into the brake
housing.
grooves, scratches or other damage. Make sure the seal-
ing surface is parallel to the housing face. The O-rings
not bulge out.
RAIL11WEL0426BA 4

brake housing until the contact is made.
RAIL11WEL0427BA 5
6. Refer to the illustration to see the installation position

of the combi seal.
1. Output shaft
2. Brake housing
3. Combi seal consisting of: a = Shaft seal, b =
Screening plate.
NOTE: the steps 6 to 8 are for the version with combi seal.
The illustration shows the installation position of the combi
seal.
RAIL11WEL0428BA 6
48083741_EN 31/07/2018
27.3 [27.120] / 17
7. Heat the slide bushing and position it at the output shaft

collar. Then position the slide bushing with the pres-
sure ring 381000106.
NOTE: an exact installation position is obtained when using
the specified pressure ring.
RAIL11WEL0429BA 7
8. Use the 381000073 driver tool to insert the shaft seal

into the brake housing.
NOTE: an exact installation position is obtained when us-
position (Step 6). Wet the outer diameter of the shaft seal
RAIL11WEL0430BA 8
9. Use a suitable lifting device and insert the premounted

brake housing over the output shaft until the contact is
made.
RAIL11WEL0431BA 9
48083741_EN 31/07/2018
27.3 [27.120] / 18
annular grooves of the brake housing (see arrows).
RAIL11WEL0432BA 10

grove (go to 12). Secure it with Loctite (type no. 415)
at its ends (see arrows).
NOTE: upon the installation, the guide ring orifice must
show upwards - 12 o’clock position.
RAIL11WEL0433BA 11
12. Upon the installation, the guide ring orifice must show
upwards - 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
48083741_EN 31/07/2018
27.3 [27.120] / 19
RAIL11WEL0435BA 13
the fabricated fixing device until the contact is made.
used).
RAIL11WEL0436BA 14
RAIL11WEL0437BA 15
48083741_EN 31/07/2018
27.3 [27.120] / 20
16. Insert the cover and secure it by means of bolts.

RAIL11WEL0438BA 16

RAIL11WEL0439BA 17
RAIL11WEL0440BA 18
48083741_EN 31/07/2018
27.3 [27.120] / 21
until the contact is obtained.
RAIL11WEL0461CA 19

gear, by pressing the cylindrical roller bearing (1)
gear (4).
NOTE: use a packaging sleeve to facilitate the assembly.
RAIL11WEL0441BA 20
48083741_EN 31/07/2018
27.3 [27.120] / 22

planetary gears with the large radius facing the plan-
etary carrier (downwards) until the contact is made.
Secure the planetary gears by using retaining rings.
RAIL11WEL0442BA 21

planetary carrier until the contact is made.
RAIL11WEL0443BA 22
agent.
RAIL11WEL0444BA 23
48083741_EN 31/07/2018
27.3 [27.120] / 23
24. Align the disk package centrally and radially. Insert the
planetary carrier into the output shaft teeth by using a
suitable lifting device.
RAIL11WEL0445BA 24
25. Bring the planetary carrier with the measuring disk

and three old locking bolts removed during the disas-
sembly into the contact position. Torque the bolts to
200 N·m (148 lb ft).
RAIL11WEL0446BA 25

bolts.
NOTE: torque the locking bolts successively to 200 N·m
(148 lb ft). Retighten locking screws to a torque of
500 N·m (369 lb ft).
RAIL11WEL0447BA 26
48083741_EN 31/07/2018
27.3 [27.120] / 24
27. Install a new O-ring (1) on the cover and wet the con-
tact face (2) with the TEROSTAT ® MS-9360.
than 24 h.
RAIL11WEL0448BA 27
28. Install the cover onto the output shaft until fully seated.
RAIL11WEL0449BA 28
48083741_EN 31/07/2018
27.3 [27.120] / 25
Index

Wheel hub - Assemble - Models MT-L 3085 II / MT-L 3095 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Wheel hub - Disassemble - Models MT-L 3085 II / MT-L 3095 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Wheel hub - Install - Models MT-L 3085 II / MT-L 3095 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Wheel hub - Remove - Models MT-L 3085 II / MT-L 3095 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Wheel hub - Visual inspection - Models MT-L 3085 II / MT-L 3095 II . . . . . . . . . . . . . . . . . . . . . . . . . . 15
48083741_EN 31/07/2018
27.3 [27.120] / 26
48083741_EN 31/07/2018
27.3 [27.120] / 27
PRINTED IN ITALY
48083741_EN 31/07/2018
EN
SERVICE MANUAL
Brakes and controls

48083741_EN 31/07/2018
33
Contents
Brakes and controls - 33
[33.202] Hydraulic service brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33.1
[33.110] Parking brake or parking lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33.2
48083741_EN 31/07/2018
33
Hydraulic service brakes - 202

48083741_EN 31/07/2018
33.1 [33.202] / 1
Contents
TECHNICAL DATA
Hydraulic service brakes

Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Brake discs
Service limits - Models MT-L 3085 II / MT-L 3095 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Service limits Model 3105 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
FUNCTIONAL DATA

Component localization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Brake pedal control valve
Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Brake pump
Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
SERVICE

Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Bleed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Check - Brake modulation pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Check - Accumulator cut-in and cut-out pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Brakes
Leakage test - Models MT-L 3085 II / MT-L 3095 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Leakage test Model 3105 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Brake pedal control valve
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Brake pump
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
48083741_EN 31/07/2018
33.1 [33.202] / 2
Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Accumulator
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Discharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Brake discs
Disassemble - Models MT-L 3085 II / MT-L 3095 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Visual inspection - Models MT-L 3085 II / MT-L 3095 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Assemble - Models MT-L 3085 II / MT-L 3095 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Disassemble Model 3105 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Visual inspection Model 3105 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Assemble Model 3105 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Brake lines
Remove -Models MT-L 3085 II / MT-L 3095 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Install - Models MT-L 3085 II / MT-L 3095 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Remove Model 3105 II (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Install Model 3105 II (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
48083741_EN 31/07/2018
33.1 [33.202] / 3
Brakes and controls - Hydraulic service brakes
Hydraulic service brakes - General specification

Brake Pump Output 42 – 45 L/min (11 – 12 US gpm) at 172 bar (2494 psi)
Accumulator Nitrogen Charge Pressure 68 – 72 bar (986 – 1044 psi) at 21 °C (69.8 °F)
3.5 L Nitrogen Accumulator Pre-Charge Pressure 70 bar (1015 psi)
0.16 L Nitrogen Accumulator Pre-Charge Pressure 96 bar (1392 psi)
Accumulator Valve Cut-In Pressure 157 – 167 bar (2276 – 2422 psi)
Accumulator Valve Cut-Out Pressure 190 – 196 bar (2755 – 2842 psi)
Redundant Accumulator Pressure Switches – Rising < 91 bar (1319.5 psi)
Electrical Connectors PRB1, PRB2 Falling 70 – 84 bar (1015 – 1218 psi)
Low Brake Pressure Warning Switch Alarm OFF 138 bar (2001 psi) Increasing
Alarm ON 115 – 129 bar (1667.5 – 1870.5 psi) Decreasing
Brake Light Switch 4.1 bar (59.4 psi) Increasing
Front Axle Brakes – Modulation Pressure 76 – 86 bar (1100 – 1245 psi)
Rear Axle Brakes – Modulation Pressure 74 – 84 bar (1073 – 1218 psi)
NOTE: see hydraulic schematics for additional specifications.
48083741_EN 31/07/2018
33.1 [33.202] / 4
Hydraulic service brakes - Special tools

CAS-10899 Nitrogen charging kit used to check and
charge the accumulator with nitrogen.
A. Regulator
B. Valve
C. Valve
D. Valve
E. Gauge
F. Valve
LEIL13WHL1358AB 1
380001168 Accumulator charging adapter
G. Adapter
LEIL13WHL1230AB 2
CAS10280 Flow meter
LEIL13WHL1199AA 3
380001740 Flow meter fitting kit
LEIL13WHL1200AA 4
48083741_EN 31/07/2018
33.1 [33.202] / 5
Brake discs - Service limits - Models MT-L 3085 II / MT-L 3095 II

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.
1. Perform the wear measurement on both wheel end
sides.
2. Remove plug, actuate brake and determine dimension
(A) using a thickness gauge.
3. If the dimension (A) is:
○ less than or equal to 3.5 mm (0.138 in) for a

standard axle configuration with open differential
bronze discs or
○ less than or equal to 3.5 mm (0.138 in) for an
optional axle configuration with front differential
lock using sintered bronze discs
RCIL11WHL163BAF 1
replace the brake packs on both sides.
4. Replace O-ring when installing the plug.

5. Tighten plug to a torque of 70.0 N·m (51.6 lb ft).
RCIL11WHL164BAF 2
Brake discs - Service limits Model 3105 II

NOTICE: a wear measurement on the multi-disc brake must be made at least once a year. Wear measurement should
also be made if brake noise is heard, if braking power is reduced, or anytime it is suspected that braking function is
impaired.
NOTE: the images may differ slightly from your machine, the procedure is the same.
1. Perform the wear measurement on both wheel end
sides.
2. Remove plug, actuate brake and determine dimension
(A) using a thickness gauge.
3. If the dimension (A) is:
○ less or equal to 3.5 mm (0.138 in) a standard axle

configuration with open differential bronze discs or
○ less or equal to 3.5 mm (0.138 in) an optional
axle configuration with front differential lock using
sintered bronze discs
RCIL11WHL163BAF 1
48083741_EN 31/07/2018
33.1 [33.202] / 6
replace the lined discs on both output sides.
4. Replace O-ring when installing the plug.

5. Tighten the plug to a torque of 70.0 N·m (51.6 lb ft).
RCIL11WHL164BAF 2
48083741_EN 31/07/2018
33.1 [33.202] / 7
Hydraulic service brakes - Component localization
LEIL18WHL0906FB 1
1. Front Axle 6. Rear Brake Accumulator

2. Rear Axle 7. Brake Pump
3. Brake Valve 8. Connector to Fan Valve
4. Parking Brake Accumulator 9. Front Brake Damping Accumulator
5. Front Brake Accumulator 10. Rear Brake Damping Accumulator
48083741_EN 31/07/2018
33.1 [33.202] / 8
Brake pedal control valve - Component identification
LEIL18WHL0921FB 1
1. Brake Valve 6. Front Axle Brake Hose

2. Rear Brake Accumulator Hose 7. Rear Axle Brake Hose
3. Parking Brake Hose 8. Front Brake Accumulator Hose
4. Brake Valve Inlet 9. Return – Brake Valve to Tank Hose
5. Brake Valve Discharge Hose 10. Parking Brake Accumulator Hose
48083741_EN 31/07/2018
33.1 [33.202] / 9
Brake pump - Exploded view
LEIL13WHL1146GB 1
1. Retaining Ring 8. Backup Seal 15. Bolt

2. Seal Retainer 9. Channel Seal 16. Driven Gear
3. O-Ring 10. Dowel Pin 17. Drive Gear
4. Outer Lip Seal 11. Thrust Plate 18. Drive Screw
5. Inner Lip Seal 12. Gear Housing 19. Name Plate
6. Shaft End Cover Housing 13. Port End Cover Housing
7. Q–Ring 14. Washer
48083741_EN 31/07/2018
33.1 [33.202] / 10
Hydraulic service brakes - Test

1. Check the oil level in the hydraulic reservoir; add oil as
necessary.
2. Push and release the brake pedal several times with
the engine stopped to remove all hydraulic pressure
from the brake system until there is no pressure on the
pedal.
3. Install two 207 bar (3002 psi) pressure gauges to the
front and rear hydraulic brake accumulator test ports
TP6, TP7.
4. Make sure that the pressure gauge hoses are long
enough so the gauges can be read while sitting in the
operators seat.
NOTE: the gauges can not be connected to the test ports
if hydraulic pressure remains in the system.
5. Start the engine. Run the engine at low idle while read-
ing the pressure gauges. The alarms (buzzer, master
warning light and brake pressure warning light) should
shut off when the accumulator with the lowest pres-
sure reaches 115 – 129 bar (1667 – 1870 psi), approx-
imately 40 s at any engine speed.
6. After the alarms stop, run the machine at high idle to
finish charging the accumulators. The pressure must
increase on both gauges until 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.
7. With the engine running at high idle, push and re-
lease the brake pedal rapidly while reading the drop in
pressure on the gauges. The pressure drops may not
be equal, but as the lowest pressure reaches 157 –
167 bar (2276 – 2422 psi) , the system pressure must
start to increase. This is the valve cut-in pressure.
8. 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.
As the lowest pressure reaches 115 – 129 bar (1667
– 1870 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 sensors
and electrical circuit. If the warning lamp and alarm
buzzer actuate at a higher or lower pressure than spec-
ified, test the low brake pressure warning sensors and
replace as needed.
9. At cut-in pressure 157 bar (2276 psi), press the brake
pedal eight more times.
10. Record the readings on the pressure gauges. The
pressure gauges should read at or above 68 – 72 bar
(986 – 1044 psi).
11. If the pressures are at or above 68 – 72 bar (986 –
1044 psi), the test is complete.
48083741_EN 31/07/2018
33.1 [33.202] / 11
12. If the pressures are not within the required specifica-

tions, the brake system must be bled.
13. After bleeding the brake system, perform the brake
system check again.
14. Continue to very 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 accumulators.
If the pressure is below 68 – 72 bar (986 – 1044 psi)
at 21 °C (70 °F), 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.
48083741_EN 31/07/2018
33.1 [33.202] / 12
Hydraulic service brakes - Bleed

1. Check the hydraulic fluid level in the reservoir. Add fluid
to the reservoir if necessary.
NOTE: if the machine is equipped with quick-attached com-
ponents, disconnect them from the machine prior to pro-
ceeding.
2. Raise the loader arm and install the safety strut (1) for
a safe access to the front axle bleed screws.
3. Make sure the parking brake is applied.
4. Keep the engine speed at high idle until both brake
accumulators are fully charged.
NOTE: this will be approximately 30 seconds after the low LEIL13WHL1231AB 1
brake pressure light goes out.
5. Stop the engine.
6. Pump the brake pedal until there is no hydraulic pres-
sure in the brake system (approximately 20 pumps).
7. Remove the plastic and rubber caps (2) from each
wheel end and slowly open all four bleed screws (3).
NOTE: attach a hose to the bleed screws to prevent spilling
any fluids.
8. Start the engine and run at low idle.
9. Push the brake pedal all the way down and slowly re-
LEIL16WHL0659AA 2
lease for one cycle.
10. Close all four wheel end bleed screws.
11. Fully depress the brake pedal three times in 5 second
cycles.
12. With the brake pedal partially depressed, open the
bleed screw on the left front axle. Hold the brake pedal
in position until the oil is clear (no bubbles). Close the
bleed screw.
13. Open the bleed screw on the right front axle. Repeat
step 12.
14. Open the bleed screw on the left rear axle. Repeat
LEIL16WHL0660AA 3
step 12.
15. Open the bleed screw on the right rear axle. Repeat
step 12.
16. Replace all bleed screws, caps and plugs.
17. Check the hydraulic fluid and add as necessary.
48083741_EN 31/07/2018
33.1 [33.202] / 13
Hydraulic service brakes - Check - Brake modulation pressure

Testing the brake modulation pressure
1. Make sure the hydraulic accumulator cut-in and cut-out
pressures are correct.
2. Install the articulation lock before doing this test.
3. Stop the engine. Pump the brake pedal until there is
no pressure in the brake system.
4. Remove the cab skirts to gain access to the brake test
ports.
5. Connect two 207 bar (3002 psi) pressure gauges to
the front brake accumulator test port (1) and rear brake
accumulator test port (2).
6. Start the engine.
7. Operate the machine at low idle and watch the pressure
gauges on the brake accumulators until the gauges rise
above 170 bar (2465 psi).
8. Apply and hold the brakes for 10 – 15 s.
9. Make a note of the pressure on the gauges for the front
and rear brakes.
10. The front brake pressure should read 76 – 86 bar LEIL18WHL0922AA 1
(1100 – 1245 psi). This is the modulation pressure
for the front axle.
11. The rear brake pressure should read 74 – 84 bar
(1073 – 1218 psi). This is the modulation pressure
for the rear axle.
12. If the pressures are not within the specified range, it
will be needed to adjust the modulation pressures.
Adjusting the brake modulation pressure

NOTE: the adjusting bolt to adjust the modulation pres-
sure is located under the cab, under the brake pedal.
1. Remove the tamper evident cover (1) .

NOTE: this is a tamper evident cover and it will be needed
to install a new cover after the modulation pressure is ad-
justed.
2. Turn the adjusting bolt to adjust the modulation pres-
sure.
NOTE: the rear brake modulation pressure cannot be ad-
justed separately from the front brake modulation pressure.
3. Repeat steps 5 through 12 in the “Testing the brake
modulation pressure” procedure.
4. Repeat these steps until the brake modulation pressure LEIL13WHL1233AB 2
is within the specified range.
48083741_EN 31/07/2018
33.1 [33.202] / 14
Hydraulic service brakes - Check - Accumulator cut-in and cut-out

pressure
1. Check the hydraulic fluid level in the reservoir; add as
needed.
2. Install the articulation lock before doing this test.
3. Remove the left–hand side cab skirt to gain access to
the brake accumulator test ports.
4. Pump the brake pedal until there is no hydraulic pres-
sure in the brake system (approximately 20 pumps).
NOTE: pressure gauges can not be connected to the test
ports if hydraulic pressure remains in the system.
5. Connect two 207 bar (3002 psi) pressure gauges to
the test ports TP6 (1) and TP7 (2).
6. Start the engine. Run the engine at low idle while read-
ing the pressure gauges. The alarms (buzzer, master
warning light and brake pressure warning light) should
shut off when the accumulator with the lowest pres-
sure reaches 128 – 143 bar (1856 – 2074 psi), approx-
imately 40 s at any engine speed.
7. After the alarms off, run the machine at high idle until
both accumulators are fully charged. The accumulators
are fully charged when the pressure gauges reach 190
– 196 bar (2755 – 2842 psi). This is the accumulator
valve cut-out pressure. It is normal for the pressure to LEIL18WHL0922AA 1
drop slightly once the cut-out pressure is reached.

8. 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 (2276 – 2422 psi), the system pressure must
start to increase. This is the accumulator valve cut-in
pressure.
NOTE: the cut-in and cut-out pressures of the brake sys-
tem charge valve are factory preset and adjustable; how-
ever it is recommended do not touch the adjusting screw.
9. Stop the engine. Turn the ignition switch to the ON po-
sition. Push and release the brake pedal 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.
10. As the lowest pressure reaches 115 – 129 bar (1668
– 1870 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
sensors and electrical circuit. If the warning lamp and
alarm buzzer actuate at a higher or lower pressure
than range specified, test the low brake pressure
warning sensors and replace as needed.
48083741_EN 31/07/2018
33.1 [33.202] / 15
11. Continue to very 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, i.e. 68 – 72 bar (986 – 1044 psi). If the
pressure is below this range, charge or replace the
accumulator(s).
NOTE: be sure to bleed the brake system before the first
accumulator charge.
48083741_EN 31/07/2018
33.1 [33.202] / 16
Brakes - Leakage test - Models MT-L 3085 II / MT-L 3095 II

1. Check the brake hydraulics for leakage. Before starting
the test, bleed the hydraulic system. Pressurize the
brake temporarily five times with a maximum pressure
of p = 100 bar (1450 psi).
RAIL11WEL0460BA 1
High-pressure test:
Build up the test pressure to p = 100 bar (1450 psi)
maximum and close the 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 the test pressure to p = 5 bar (73 psi) and
close the shut-off valve. No pressure drop is al-
lowed during a 5 min test period.
Test media:
Engine oil SAE 10-W corresponds to MIL-L 2104
C, MIL-L 46152, API-CC, CD, SC, SD, SE, ATF-oils
type A.
48083741_EN 31/07/2018
33.1 [33.202] / 17
Brakes - Leakage test Model 3105 II

1. Check the brake hydraulics for leakage. Before starting
the test bleed the hydraulic system. Pressurize the
brake temporarily five times with a maximum pressure
of p = 100 bar (1450 psi).
RCIL11WHL151BAF 1
High-pressure test:
Build up the test pressure to p = 100 bar (1450 psi)
maximum and close the 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 the test pressure to p = 5 bar (73 psi) and
close the shut-off valve. No pressure drop is al-
lowed during a 5 min.
Test media:
Engine oil SAE 10-W corresponds to MIL-L 2104
C, MIL-L 46152, API-CC, CD, SC, SD, SE, ATF-oils
type A.
48083741_EN 31/07/2018
33.1 [33.202] / 18
Brake pedal control valve - Remove

loader bucket to the floor. Stop the engine.
2. Put the blocks on both sides of each tire to prevent the
machine movement.
3. Make sure the brake accumulators are completely dis-
charged. Push down and release the brake pedal sev-
eral times (at least 30 times).
5. Remove the cab skirts located under the cab.
6. To release the pressure on the parking brake accu-
mulator, the line at the accumulator must be slowly
cracked open. A pan will be needed to catch the hy-
draulic oil.
7. Connect a drain hose to the quick disconnect couplings
in each brake circuit to release any pressure in the
brake circuit.
8. Clean the brake pedal control valve (1) and lines.
9. Put identification tags on all electrical and hydraulic
lines that are connected to the brake valve.
LEIL16WHL1800AB 1
LEIL18WHL0923AB 2
48083741_EN 31/07/2018
33.1 [33.202] / 19
10. Disconnect the following electrical connectors from

the brake valve:
• X-PLB-PBD – Brake light/declutch pressure sen-
sor;
• X-PBW – Brake supply warning pressure sensor;
• X-YPB – Parking brake release solenoid;
• X-BPP – Brake angle sensor (only for 5 speed
brake valve).
11. Connect a vacuum pump to the hydraulic reservoir.
Start the vacuum pump.
12. Disconnect the following hoses from the brake pedal
control valve:
• brake valve inlet hose (4);
• rear brake accumulator hose (2);
• front brake accumulator hose (8);
• parking brake accumulator hose (10);
• parking brake hose (3);
• brake valve discharge hose (5);
• front axle brake hose (6);
• rear axle brake hose (7);
• return brake valve to tank hose (9).
Install protective plugs on the disconnected hoses.

13. Remove the four bolts M8x20 (2), the four screws
M8x16 (3), the two nuts M8 (4) and the gasket (5).
Remove the plates (6) and (7). Remove the brake
pedal control valve (1).
NOTE: the figures show the 5–speed brake valve; the
brake angle sensor connector is visible.
LEIL18WHL0944AB 3
48083741_EN 31/07/2018
33.1 [33.202] / 20
Brake pedal control valve - Install

1. Position the brake pedal control valve (1) from under
the cab floor. Position the gasket (5) and the plates (6)
and (7). Lock with the two nuts M8 (4), the four screws
M8x16 (3), the four bolts M8x20 (2).
NOTE: the figures show the 5–speed brake valve. The
brake angle sensor connector is visible.
LEIL18WHL0944AB 1
2. Remove the protective plugs from the hoses and con-

nect the following hoses to the brake pedal control
valve:
• brake valve inlet hose (4);
• rear brake accumulator hose (2);
• front brake accumulator hose (8);
• parking brake accumulator hose (10);
• parking brake hose (3);
• brake valve discharge hose (5);
• front axle brake hose (6);
LEIL16WHL1800AB 2
• rear axle brake hose (7);
• return brake valve to tank hose (9).
LEIL18WHL0923AB 3
3. Stop the vacuum pump and remove it.

4. Connect the following electrical connectors to the brake
valve:
• X-PLB-PBD – Brake light/declutch pressure sensor;
• X-PBW – Brake supply warning pressure sensor;
• X-YPB – Parking brake release solenoid;
• X-BPP – Brake angle sensor (only for 5 speed brake
valve).
5. Connect all the electrical connections.
6. Turn the timed disconnect switch to the ON position.
7. Bleed the brake system.
8. Install the cab skirts.
48083741_EN 31/07/2018
33.1 [33.202] / 21
9. Check the hydraulic reservoir oil level and add oil as

required.
48083741_EN 31/07/2018
33.1 [33.202] / 22
Brake pump - Remove
LEIL16WHL1801GB 1
1. Brake pump 6. Drive gear

2. Hexagonal screw, M12x35 7. Gear mounting washer
3. Washer 8. Hexagonal slotted nut
4. Brake pump suction hose 9. Cotter pin
5. Brake pump pressure hose 10. Brake Pump attenuator hose
48083741_EN 31/07/2018
33.1 [33.202] / 23

Lower the bucket to the ground.
Stop the engine.
machine from moving.
4. Clean the brake pump (1) and lines.
5. Put identification tags on the brake pump suction hose
(4), brake pump pressure hose (5) and brake pump
attenuator hose (10) that are connected to the brake
pump.
7. Disconnect the hoses (4), (5) and (10) from the brake
pump. Plug the open lines.
8. Remove the two M12x35 hexagonal screw (2) and
washers (3) from the brake pump. Remove the brake
pump.
9. Remove the cotter pin (9) and hexagonal slotted nut (8).
Remove the gear mounting washer (7) and the drive
gear (6).
48083741_EN 31/07/2018
33.1 [33.202] / 24
Brake pump - Install
LEIL16WHL1801GB 1
1. Brake pump 8. Hexagonal slotted nut

2. Hexagonal screw, M12x35 9. Cotter pin
3. Washer 10. Brake pump attenuator hose
4. Brake pump suction hose 11. Fitting
5. Brake pump pressure hose 12. 90° elbow
6. Drive gear 13. Tee
7. Gear mounting washer
48083741_EN 31/07/2018
33.1 [33.202] / 25
NOTE: do not use an impact tool when torquing the slotted nut for mounting the pump drive gear.
1. Install the drive gear (6) onto the pump shaft. Install the
gear mounting washer (7) and the hexagonal slotted
nut (8). Torque the nut to 70 – 79 N·m (52 – 58 lb ft).
2. Install the cotter pin (9).
3. Position the brake pump (1). Tighten the M12x35
hexagonal screws (2) and washers (3) to install the
brake pump. Torque to 57 – 65 N·m (42 – 48 lb ft).
4. Remove the caps or plugs from the open lines.
Connect the brake pump suction hose (4) to the fitting
(11). Torque the brake pump suction hose (4) to 246.0
– 256.0 N·m (181.4 – 188.8 lb ft).
Connect the brake pump pressure hose (5) and the
brake pump attenuator hose (10) to the tee (13).
required.
48083741_EN 31/07/2018
33.1 [33.202] / 26
Brake pump - Test

1. Connect the CAS10280 flow meter to the brake pump
as follows.
2. Connect the flow meter inlet hose in place of the brake
pump pressure hose (hose to brake valve).
3. Connect the flow meter outlet hose in place of the return
hose to the return oil filter manifold.
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 me-
ter and read the flow at 170 bar (2465 psi). Record
the flow reading.
6. Divide the flow reading at 170 bar (2465 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.
NOTE: if the unit is equipped with auxiliary steering a tee
fitting must be used instead of the straight connector.
48083741_EN 31/07/2018
33.1 [33.202] / 27
Brake pump - Disassemble

NOTE: refer to “Brake pump – Exploded view” for the callouts of this procedure.
1. Carefully secure the pump by the port end cover hous-
ing (13) in a vise.
2. Draw a line along the pump length to assist during the
assembly.
3. Loosen and remove the bolts (15).
4. Loosen the shaft end cover housing (6) by tapping with
a soft hammer. Remove the shaft end cover housing.
5. Remove the backup seal (8), channel seal (9) and
thrust plate (11).
6. Remove the drive gear (17) from the gear housing (12).
7. Remove the driven gear (16) from the gear housing.
8. Loosen the gear housing from the port end cover hous-
ing (13) by tapping with a soft hammer. Remove the
gear housing.
9. Remove the backup seal (8), channel seal (9) and
thrust plate (11).
10. Remove the retaining ring (1) form the shaft end cover
housing.
11. Remove the seal retainer (2), the O-ring (3), and the
outer lip seal (4) from the shaft end cover housing.
12. Remove the inner lip seal (5) from the shaft end cover
housing.
48083741_EN 31/07/2018
33.1 [33.202] / 28
Brake pump - Inspect

1. Discard all seals and quad rings. Clean all parts in a
proper cleaning solvent. Inspect all machined surfaces
for excessive wear or damage.
2. Measure the amount of wear caused by the gear teeth
in the gear pocket. Hold a straightedge across each
gear housing and use a feeler gauge to measure. If
the wear in any gear pocket is greater than 0.18 mm
(0.007 in), replace with a new gear housing.
3. Inspect the thrust plates for excessive wear or damage
(scoring, pitting, etc.). Replace as required.
4. Inspect gears for excessive wear or damage. Ensure
that no scoring is present on the gear hubs or on the
outside edges of the gear teeth. Ensure the wear in
the seal area of the drive shaft does not exceed more
than 0.05 mm (0.002 in). If any gear is damaged, the
pump must be replaced with a new hydraulic pump.
48083741_EN 31/07/2018
33.1 [33.202] / 29
Brake pump - Assemble

NOTE: refer to “Brake pump – Exploded view” for the callouts of this procedure.
1. Install a new lip seal (4) into the seal retainer (2) so the
lip of the seal will be facing away from the gears when
the seal retainer is installed into the shaft end cover
housing (6).
2. Install a new lip seal (5) into the shaft end cover housing
with the lip of the seal facing towards the gears.
3. Install a new O-ring (3) onto the seal retainer; lubricate
the O-ring with hydraulic oil.
4. Press the seal retainer into the shaft end cover housing
and install the retaining ring (1).
5. Carefully place and secure the shaft end housing face
down in a vise.
6. Install new backup seals (8) and channel seals (9) into
the thrust plates (11).
7. Install the thrust plate (11) onto the shaft end cover
housing.
NOTICE: make sure the thrust plate is installed onto the
shaft end cover housing as illustrated in “Brake pump –
Exploded view”.
8. Lubricate the driven gear (16) with hydraulic oil. Slide
the driven gear through the thrust plate into the shaft
end cover housing.
9. Lubricate the drive gear (17) with hydraulic oil. Slide
the drive gear through the thrust plate into the shaft end
cover housing.
10. Install a new Q-ring (7) into the gear housing (12).
Ensure the dowel pins (10) are in place either in the
gear housing or the shaft end cover housing.
11. Carefully place the gear housing onto the gears. Use
the marks made during the disassembly to aid in the
assembly.
12. Slide the remaining thrust plate (11) onto the shafts of
the gears.
NOTICE: make sure the thrust plate is installed onto the
shaft end cover housing as illustrated in “Brake pump –
Exploded view”.
13. Install a new Q-ring (7) into the gear housing (12).
Ensure the dowel pins (10) are in place either in the
gear housing or the port end cover housing (13).
14. Install the port end cover housing onto the gear hous-
ing.
15. Install the washers (14) and bolts (15) with clean and
dry threads. Torque the bolts to 186.5 – 197.5 N·m
(137.6 – 145.7 lb ft).
48083741_EN 31/07/2018
33.1 [33.202] / 30
Accumulator - Remove
LEIL18WHL0924GB 1
1. Brake Accumulator 5. Front Brake Accumulator Hose

2. Parking Brake Accumulator 6. Rear Brake Accumulator Hose
3. Mounting Nut 7. Accumulator Clamp
4. Parking Brake Accumulator Hose 8. Clamp Stud
48083741_EN 31/07/2018
33.1 [33.202] / 31

machine movement.
3. Make sure the brake accumulators (1), parking brake
accumulator (2) and brake damping accumulators are
completely discharged.
Push down and release the brake pedal several times
(at least 30 times).
5. Remove the left cab skirt located under the cab to gain
access to the accumulators.
6. To release the pressure in the parking brake accumula-
tor, the line at the accumulator must be slowly cracked
open. A pan will be needed to catch the hydraulic oil.
7. Connect a drain hose to the quick disconnect couplings
in each brake circuit to release any pressure in the
brake circuit.
8. Clean the brake accumulators (1), parking brake accu-
mulator (2), brake damping accumulators and lines.
9. Put an identification tag on the line that is connected to
the parking brake accumulator (2).
11. Disconnect the tubes from both brake accumulators
(1).
12. Loosen the clamp studs (8) on the accumulator
clamps (7).
13. Remove the accumulators (1) from the accumulator
clamps (7).
14. Install plugs in the hoses.
15. Disconnect the hose from the parking brake accumu-
lator (2).
16. Remove the nut (3) and the parking brake accumula-
tor (2).
17. Install a plug in the hose.
18. Disconnect the hose from the brake damping accumu-
lators.
19. Remove the brake damping accumulators from the
machine. Install plugs in the hoses.
48083741_EN 31/07/2018
33.1 [33.202] / 32
Accumulator - Install
LEIL18WHL0924GB 1
1. Brake Accumulator 5. Front Brake Accumulator Hose

2. Parking Brake Accumulator 6. Rear Brake Accumulator Hose
3. Mounting Nut 7. Accumulator Clamp
4. Parking Brake Accumulator Hose 8. Clamp Stud
48083741_EN 31/07/2018
33.1 [33.202] / 33
1. Mount the brake accumulators (1) in the accumulator

clamps (7); do not tighten the clamps at this time.
2. Connect the tubes to both brake accumulators (1) and
tighten them.
3. Tighten the accumulator clamp studs (8) to 17 N·m
(12.5 lb ft).
4. Install the parking brake accumulator (2) into the
bracket.
5. Install the nut (3) and tighten it.
6. Connect the line to the parking brake accumulator (2).
7. Install the brake damping accumulators.
8. Connect the lines to the brake damping accumulators.
10. Install the left cab skirt.
13. Perform the “Parking Brake or Parking Lock – Test”
procedure.
required.
48083741_EN 31/07/2018
33.1 [33.202] / 34
Accumulator - Discharging
1. Remove the cover from the accumulator charge port.
Loosen the Allen screw in the charge port.
NOTE: do not turn the Allen screw more than 1/8 of a turn
otherwise gas will escape uncontrolled.
2. Install the adapter 380001168 on the accumulator; use
the CAS-10899 nitrogen charging kit to discharge the
accumulator. The tool must be disconnected from the
nitrogen tank.
3. Close the valves (B), (C) and (D).
4. Adjust the regulator (A) to the minimum pressure set-
ting by turning the knob counterclockwise.
LEIL13WHL1358AB 1
5. Turn the T-handle on the valve (F) fully out.
6. Connect the valve (F) to the valve stem on the adapter.
7. Turn the T-handle inward the valve (F) to engage the
pin in the valve stem; open the valve (G).
8. Open the valve (D) and check the charge pressure on
the gauge (E).
9. To discharge the accumulator, partially open the valve
(B). The accumulator charge will bleed down through
the regulator.
10. Once the accumulator is fully discharged, disconnect
the valve (F) from the valve stem and remove the LEIL13WHL1230AB 2
adapter.
48083741_EN 31/07/2018
33.1 [33.202] / 35
Accumulator - Check
1. Make sure the oil side of the accumulator is completely
discharged by doing the following:
A. Stop the engine.
B. Push down and release the brake pedal several
times (at least 30 times) to release the pressure.
2. Connect a drain hose to the test connector in each
brake circuit to release any pressure in the brake cir-
cuit.
3. Close the valves (B) and (C) on the nitrogen charging
kit CAS-10899.
4. Turn the stem out of the valve (F) until the stem stops.
LEIL13WHL1358AB 1
5. Remove the cap from the accumulator. Loosen the
Allen screw in the charge port.
NOTE: do not turn the Allen screw more than 1/8 of a turn
otherwise gas will escape uncontrolled.
6. Connect the adapter 380001168 to the accumulator.
7. Connect the valve (F) to the adapter valve stem.
8. Make sure the valves (D) and (G) are open.
9. Turn the stem into the valve (F) and read the pressure
gauge (E).
10. If the pressure is too low, charge the accumulator with
dry nitrogen. LEIL13WHL1230AB 2
48083741_EN 31/07/2018
33.1 [33.202] / 36
Accumulator - Charging
NOTE: check the pressure in the accumulator according to the instructions in Checking the Nitrogen Charge in the
Accumulator. Keep the nitrogen charging kit CAS-10899 connected to the accumulator.
1. Close (turn counterclockwise) the valve (A) and open
the valve (B). Close the valves (C), (D) and (G).
2. Turn the stem out of the valve (F) until the stem stops
moving. Disconnect the valve (F) from the adapter
valve stem.
3. Connect the nitrogen charging kit to a dry nitrogen tank.
4. Slowly turn the valve (A) clockwise and read the gauge
(E) until the pressure is equal to the charge pressure
required for the accumulator being charged. Stop turn-
ing the valve (A).
5. If the pressure increases above the required pressure,
LEIL13WHL1358AB 1
quickly open and close the valve (D) and read the
gauge (E). If the pressure is still too high, close the
valve (A) (turn counterclockwise) a small amount and
quickly open and close the valve (D). The pressure
shown on the gauge (E) is the charge pressure.
6. Connect the valve (F) to the adapter valve stem. Turn
the stem into the valve (F) until the stem stops moving
and open the valves (G) and (D) to charge the accumu-
lator.
7. After the accumulator stops charging, turn the stem out
of the valve (F) until the stem stops moving and close
the valve (G).
8. Close the valve (B) and disconnect the nitrogen charg- LEIL13WHL1230AB 2
ing kit from the adapter valve stem; remove the adapter.
9. Torque the Allen screw to 20 N·m (15 lb ft); install the
cover on the accumulator valve stem.
TEMPERATURE CHARGE PRESSURE

10 °C (50 °F) 67.4 bar (977 psi)
13 °C (55 °F) 68.1 bar (987 psi)
16 °C (60 °F) 68.8 bar (998 psi)
18 °C (65 °F) 69.3 bar (1005 psi)
21 °C (70 °F) 70.0 bar (1015 psi)
24 °C (75 °F) 70.7 bar (1025 psi)
27 °C (80 °F) 71.4 bar (1036 psi)
29 °C (85 °F) 71.9 bar (1043 psi)
32 °C (90 °F) 72.6 bar (1053 psi)
35 °C (95 °F) 73.3 bar (1063 psi)
38 °C (100 °F) 74.0 bar (1073 psi)
48083741_EN 31/07/2018
33.1 [33.202] / 37
Brake discs - Disassemble - Models MT-L 3085 II / MT-L 3095 II

RAIL11WEL0184BA 1
RAIL11WEL0185BA 2
RAIL11WEL0186BA 3
48083741_EN 31/07/2018
33.1 [33.202] / 38
4. Use a puller to press the planetary carrier out of the

RAIL11WEL0187BA 4
5. Use a suitable lifting device to lift the planetary carrier

RAIL11WEL0188BA 5
6. Use a suitable puller to remove the tapered roller bear-

ing from the planetary carrier.
RAIL11WEL0189BA 6
48083741_EN 31/07/2018
33.1 [33.202] / 39
RAIL11WEL0190BA 7
RAIL11WEL0191BA 8
RAIL11WEL0192BA 9
48083741_EN 31/07/2018
33.1 [33.202] / 40
RAIL11WEL0193BA 10
11. Remove the hexagonal bolts, cover and cup spring.
RAIL11WEL0194BA 11
12. Mount a bleeder valve. Use compressed air to remove

the piston from the brake housing.
RAIL11WEL0195BA 12
48083741_EN 31/07/2018
33.1 [33.202] / 41

RAIL11WEL0196BA 13

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
8. Output shaft
RAIL11WEL0197BA 14
15. Use a suitable lifting device to lift the brake housing

RAIL11WEL0198BA 15
48083741_EN 31/07/2018
33.1 [33.202] / 42
16. Use a lever to remove the slide ring seal (slide ring
seal version) or shaft seal (combi seal version) from
the brake housing. If needed, force out both bearing
outer rings.
RAIL11WEL0199BA 16
version, check the screening plate for wear marks and
separate it from the output shaft if required.
RAIL11WEL0200BA 17

the output shaft.
RAIL11WEL0177BA 18
48083741_EN 31/07/2018
33.1 [33.202] / 43
Brake discs - Visual inspection - Models MT-L 3085 II / MT-L 3095 II

CAUTION
Eye injury hazard!
Wear protective goggles when using compressed air.
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

brake housing.
48083741_EN 31/07/2018
33.1 [33.202] / 44
Brake discs - Assemble - Models MT-L 3085 II / MT-L 3095 II

CAUTION
Burn hazard!
C0047A
contact 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.
NOTE: only heavy duty axle version uses wheel mounting
studs.
RAIL11WEL0423BA 1

output shaft until contact is made.
RAIL11WEL0424BA 2
with mineral spirits. Snap a new slide ring seal (part 1)
into the output shaft.
RAIL11WEL0425BA 3
48083741_EN 31/07/2018
33.1 [33.202] / 45
4. Mount a new slide ring seal (part 2) into the brake hous-
ing.
NOTE: the slide ring seal surface may not have any
grooves, scratches or other damage. Make sure the
not bulge out.
RAIL11WEL0426BA 4

brake housing until contact is made.
RAIL11WEL0427BA 5
6. Note the installation position of the combi seal.

1. Output shaft
2. Brake housing
3. Combi seal consisting of: A= Shaft seal, B=
Screening plate.
NOTE: the steps 6 to 8 are for the combi seal version; the
illustration shows the installation position of the combi seal.
RAIL11WEL0428BA 6
48083741_EN 31/07/2018
33.1 [33.202] / 46
7. Heat the slide bushing and position it at the output shaft

collar. Position the slide bushing with pressure ring
381000106.
NOTE: the exact installation position is obtained when us-
ing the specified pressure ring.
RAIL11WEL0429BA 7
8. Insert shaft seal into brake housing using 381000073

driver tool.
NOTE: the exact installation position is obtained when us-
position (step 6). Wet the outer diameter of the shaft seal
RAIL11WEL0430BA 8
9. Use a suitable lifting device and insert the pre-mounted

brake housing over the output shaft until contact is
made.
RAIL11WEL0431BA 9
48083741_EN 31/07/2018
33.1 [33.202] / 47
annular grooves of brake housing (see arrows). Clean
the annular groove of the brake housing with mineral
spirits. Insert the guide ring into the annular groove.
Secure it with LOCTITE® 415™ at its ends.
RAIL11WEL0432BA 10
11. Note the component installation position:

1. Brake housing
2. Guide ring
3. Back-up ring
4. Grooved ring
5. Grooved ring
6. Back-up ring
7. Slide ring seal
8. Output shaft
RAIL11WEL0434BA 11
12. Flush-mount the slotted pins into the holes of the pis-
ton.
RAIL11WEL0435BA 12
48083741_EN 31/07/2018
33.1 [33.202] / 48
13. Insert the piston into the brake housing and carefully
install with a dealer fabricated fixing device
used).
RAIL11WEL0436BA 13
RAIL11WEL0437BA 14
15. Insert the cover and secure it by means of hexagonal

bolts. Torque to 34 N·m (25 lb ft).
RAIL11WEL0438BA 15
48083741_EN 31/07/2018
33.1 [33.202] / 49

RAIL11WEL0439BA 16
RAIL11WEL0440BA 17
48083741_EN 31/07/2018
33.1 [33.202] / 50
until contact is obtained.
RAIL11WEL0461CA 18

gear by pressing the cylindrical roller bearing (1)
gear (4).
NOTE: use the packaging sleeve to facilitate the assembly.
RAIL11WEL0441BA 19
48083741_EN 31/07/2018
33.1 [33.202] / 51
20. Heat the bearing inner rings. Insert the pre-mounted

tary carrier (downwards) until contact is made. Secure
the planetary gears by using retaining rings.
RAIL11WEL0442BA 20

planetary carrier until contact is made.
RAIL11WEL0443BA 21
agent.
RAIL11WEL0444BA 22
48083741_EN 31/07/2018
33.1 [33.202] / 52
23. Align the disk package centrally and radially. Insert

the planetary carrier into the teeth of the output shaft
by using a suitable lifting device.
MT-L 3095 planetary carrier has 4 planetary gears.
RAIL11WEL0445BA 23
24. Bring the planetary carrier with a measuring disk and

three old locking bolts removed during the disas-
sembly into the contact position. Torque the bolts to
200 N·m (148 lb ft).
RAIL11WEL0446BA 24

bolts.
NOTE: tighten locking bolts successively with a tightening
torque of 200 N·m (148 lb ft). Then retighten the locking
screws successively with a tightening torque of 500 N·m
(369 lb ft).
RAIL11WEL0447BA 25
48083741_EN 31/07/2018
33.1 [33.202] / 53
26. Install a new O-ring (1) on the cover and wet the con-
tact face (2) with TEROSTAT ® MS-9360.
than 24 h.
RAIL11WEL0448BA 26
27. Install the cover onto the output shaft until fully seated.
RAIL11WEL0449BA 27
48083741_EN 31/07/2018
33.1 [33.202] / 54
Brake discs - Disassemble Model 3105 II

1. Attach the output to a suitable work stand.
RCIL11WHL007BAF 1
RCIL11WHL008BAF 2
RCIL11WHL009BAF 3
48083741_EN 31/07/2018
33.1 [33.202] / 55
4. Use a two-armed puller to press the planetary carrier

from the profile of the output shaft.
RCIL11WHL010BAF 4
5. Use a suitable lifting device to lift the planetary carrier

RCIL11WHL011BAF 5
6. Pull the tapered roller bearing from the planetary car-

rier.
RCIL11WHL012BAF 6
48083741_EN 31/07/2018
33.1 [33.202] / 56
RCIL11WHL013BAF 7
RCIL11WHL014BAF 8
RCIL11WHL015BAF 9
48083741_EN 31/07/2018
33.1 [33.202] / 57
RCIL11WHL016BAF 10
11. Remove the hexagonal bolts, releasing cover and cup

spring.
RCIL11WHL017BAF 11
12. Mount a bleeder valve. Use compressed air to remove

the piston from the brake housing.
RCIL11WHL018BAF 12
48083741_EN 31/07/2018
33.1 [33.202] / 58

RCIL11WHL019BAF 13

parts.
1. Brake housing
2. Guide ring
3. Back-up ring
4. Piston seal
5. Piston seal
6. Back-up ring
(Standard)
8. Output shaft
RCIL11WHL153BAF 14
48083741_EN 31/07/2018
33.1 [33.202] / 59
Brake discs - Visual inspection Model 3105 II

CAUTION
Eye injury hazard!
Wear protective goggles when using compressed air.
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

brake housing.
48083741_EN 31/07/2018
33.1 [33.202] / 60
Brake discs - Assemble Model 3105 II

1. Note the component installation position:
1. Brake housing
2. Guide ring
3. Back-up ring
4. Piston seal
5. Piston seal
6. Back-up ring
(Standard)
8. Output shaft
RCIL11WHL153BAF 1
2. Flush-mount the slotted pins into the holes of the piston.
RCIL11WHL126BAF 2
a dealer fabricated fixing device until contact is made.
rings, grooved rings and guide ring with W-10 oils.
RCIL11WHL127BAF 3
48083741_EN 31/07/2018
33.1 [33.202] / 61
showing upwards into the piston.
RCIL11WHL128BAF 4
5. Insert the cover and secure it with hexagonal bolts.

RCIL11WHL129BAF 5

RCIL11WHL130BAF 6
48083741_EN 31/07/2018
33.1 [33.202] / 62
RCIL11WHL131BAF 7
8. Press the stop bolt (1) into the planetary carrier (2).
RCIL11WHL158BAF 8
48083741_EN 31/07/2018
33.1 [33.202] / 63
9. Heat the bearing inner rings. Insert the pre-mounted

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

etary carrier until contact is made.
RCIL11WHL134BAF 10
agent.
RCIL11WHL135BAF 11
48083741_EN 31/07/2018
33.1 [33.202] / 64
12. Align the disk package centrally and radially. Heat the
output shaft. Use a suitable lifting device to insert the
planetary carrier into the teeth of the output shaft.
RCIL11WHL136BAF 12
13. Bring the planetary carrier with a measuring disk and

three old locking bolts (removed during the disassem-
bly) into contact position. Torque to 200 N·m (148 lb
ft).
RCIL11WHL137BAF 13
14. Pivot the output 180° and measure the gap width from
the output shaft to the planetary carrier – see next
sketch. Remove the locking bolts and measure the
disk again.
NOTE: gap width e.g.: 0.21 mm (0.01 in).
RCIL11WHL159BAF 14
48083741_EN 31/07/2018
33.1 [33.202] / 65
15. Legend to Sketch:

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

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

0.30 – 0.24 mm (0.012 – 0.009 in) 0.13 mm (0.005 in)
0.239 – 0.18 mm (0.009 – 0.007 in) 0.07 mm (0.003 in)
0.179 – 0.10 mm (0.007 – 0.004 in) 0.0 mm (0.000 in)
17. Pivot the output 90°. Insert the cover with the offset
e.g. 0.07 mm (0.003 in) showing towards the plane-
tary carrier and tighten with new locking bolts.
NOTE: when using the cover with an offset of 0.07 mm
(0.003 in), the groove (see arrow step 16) must be visible
when the cover is installed.
NOTE: tighten the locking bolts successively to a torque of
200 N·m (148 lb ft). Retighten successively to a torque of
500 N·m (369 lb ft).
RCIL11WHL138BAF 17
48083741_EN 31/07/2018
33.1 [33.202] / 66
18. Install a new O-ring (1) and cover. Wet the contact
face (2) with TEROSTAT ® MS-9360.
than 24-hours.
RCIL11WHL139BAF 18
19. Insert the cover into the output shaft until contact is
made.
RCIL11WHL140BAF 19
48083741_EN 31/07/2018
33.1 [33.202] / 67
Brake lines - Remove -Models MT-L 3085 II / MT-L 3095 II

move the hexagonal bolts. Separate the axle housing
from the axle drive housing.
RAIL11WEL0213BA 1

leasing brake tube.
RAIL11WEL0214BA 2
RAIL11WEL0215BA 3
48083741_EN 31/07/2018
33.1 [33.202] / 68
RAIL11WEL0212BA 4
48083741_EN 31/07/2018
33.1 [33.202] / 69
Brake lines - Install - Models MT-L 3085 II / MT-L 3095 II

RAIL11WEL0397BA 1
2. Mount two M20 locating pins and bring the axle hous-
ing into contact position with the axle drive housing by
by using hexagonal bolts. Torque to 560 N·m (413 lb
ft).
with clamping brackets (S) .
RAIL11WEL0398BA 2
RAIL11WEL0399BA 3
48083741_EN 31/07/2018
33.1 [33.202] / 70

RAIL11WEL0400BA 4

hexagonal nut. Torque to 100 N·m (74 lb ft).
RAIL11WEL0401BA 5

(37 lb ft).
RAIL11WEL0396BA 6
48083741_EN 31/07/2018
33.1 [33.202] / 71
Brake lines - Remove Model 3105 II

1. Secure the axle housing to a suitable lifting device.

Loosen the hexagonal bolts. Separate the axle hous-
ing from the drive housing.
NOTE: be aware of possible differential release.
RCIL11WHL024BAF 1
2. Loosen the threaded connections and remove the

brake release tube.
RCIL11WHL025BAF 2
RCIL11WHL026BAF 3
48083741_EN 31/07/2018
33.1 [33.202] / 72
4. Pull the bearing outer ring and remove the shim behind.
Remove the O-ring (see arrow).
RCIL11WHL027BAF 4
48083741_EN 31/07/2018
33.1 [33.202] / 73
Brake lines - Install Model 3105 II

1. Grease the O-ring (see arrow) and insert it into the axle
housing.
RCIL11WHL112BAF 1
2. Mount M20 locating pins. Use a suitable lifting device

and bring the axle housing into contact position with
the axle drive housing. Secure the axle housing with
hexagonal bolts. Torque to 560 N·m (413 lb ft).
NOTE: after the axle housing assembly secure the axle
with clamping brackets.
RCIL11WHL113BAF 2
3. Mount the fitting. Torque to 36 N·m (27 lb ft).
RCIL11WHL114BAF 3
48083741_EN 31/07/2018
33.1 [33.202] / 74

the brake tube (see arrow).
RCIL11WHL115BAF 4

hexagonal nut (see arrow). Torque to 100 N·m (74 lb
ft).
RCIL11WHL116BAF 5

(37 lb ft).
RCIL11WHL117BAF 6
48083741_EN 31/07/2018
33.1 [33.202] / 75
Index

Accumulator - Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Accumulator - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Accumulator - Discharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Accumulator - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Accumulator - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Brake discs - Assemble - Models MT-L 3085 II / MT-L 3095 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Brake discs - Assemble Model 3105 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Brake discs - Disassemble - Models MT-L 3085 II / MT-L 3095 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Brake discs - Disassemble Model 3105 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Brake discs - Service limits - Models MT-L 3085 II / MT-L 3095 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Brake discs - Service limits Model 3105 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Brake discs - Visual inspection - Models MT-L 3085 II / MT-L 3095 II . . . . . . . . . . . . . . . . . . . . . . . . . 44
Brake discs - Visual inspection Model 3105 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Brake lines - Install - Models MT-L 3085 II / MT-L 3095 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Brake lines - Install Model 3105 II (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Brake lines - Remove -Models MT-L 3085 II / MT-L 3095 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Brake lines - Remove Model 3105 II (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Brake pedal control valve - Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Brake pedal control valve - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Brake pedal control valve - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Brake pump - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Brake pump - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Brake pump - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Brake pump - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Brake pump - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Brake pump - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Brake pump - Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Brakes - Leakage test - Models MT-L 3085 II / MT-L 3095 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Brakes - Leakage test Model 3105 II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Hydraulic service brakes - Bleed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Hydraulic service brakes - Check - Accumulator cut-in and cut-out pressure . . . . . . . . . . . . . . . . . . . 15
Hydraulic service brakes - Check - Brake modulation pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Hydraulic service brakes - Component localization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
48083741_EN 31/07/2018
33.1 [33.202] / 76
Hydraulic service brakes - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Hydraulic service brakes - Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Hydraulic service brakes - Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
48083741_EN 31/07/2018
33.1 [33.202] / 77
48083741_EN 31/07/2018
33.1 [33.202] / 78
Parking brake or parking lock - 110

48083741_EN 31/07/2018
33.2 [33.110] / 1
Contents
TECHNICAL DATA
Parking brake or parking lock

SERVICE
Parking brake or parking lock

Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Service instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
48083741_EN 31/07/2018
33.2 [33.110] / 2
Brakes and controls - Parking brake or parking lock
Parking brake or parking lock - General specification

Spring Applied Hydraulic Released (SAHR) sliding calliper FSG 88
LEIL16WHL1151FB 1
1. Housing 8. Lining pad

2. Pressure ring 9. Guiding pin
3. Pressure bolt 10. Rubber buffer
4. Setting screw 11. Adjusting screw
5. Plate spring pack 12. Lining spring
6. Piston 13. Counter nut
7. Lining pad
The two identical lining pads (7) and (8) slide on the guide surfaces on the top of the housing (1) and are held in
position by a lining spring (12). The brake is directly fixed on the gearbox with the two guide pins (9).
The brake is positioned axially using the rubber buffers (10) between the brake housing and the guide pins (9), and
the setting screw (11).
When the brake is actuated (closed) a clamping force is created on the lining pads (7), (8) which is transmitted to
the brake disc. Under the force of the plate spring pack (5), the piston (6), together with the adjusting screw (4), the
pressure bolt (3) and the lining pad (7) are moved towards the brake disc. When the lining pad (7) comes into contact
with the brake disc, the reaction force displaces the brake on the guide pins (9), against the spring force of the rubber
buffers (10), until the second lining pad (8) is also pressed against the brake disc.
The braking effect (braking torque) is dependent upon the frictional values of the brake linings.
The brake is released by complete pre-tensioning of the plate spring pack (5). The piston (6) is moved back by the
required minimum release pressure to the stop on the pressure ring (2).
During this process the brake positions itself, depending upon the setting, by the two rubber buffers (10) up to contact
with the setting screw (11). An equal air gap must be guaranteed on both sides of the brake disc when set correctly.
The clamping force is reduced by wear of the lining pads (7), (8) and the brake disc. The brake must then be re-ad-
justed.
48083741_EN 31/07/2018
33.2 [33.110] / 3
Parking brake or parking lock - Disassemble

1. Park the machine on a hard level surface and lower the
loader bucket to the ground.
2. Place the wheel chocks on each wheel to prevent the
machine movement.
3. Install the articulation lock.
4. Place the timed disconnect switch to the OFF position.
5. Pump the brake pedal several times (at least 30 times)
to discharge the accumulators.
LEIL13WHL1236AA 1
6. Loosen and remove the cover from the parking brake.
LEIL13WHL1237AB 2
7. Loosen the jam nut, turn the adjusting bolt counter-

clockwise until the brake pads are loose.
LEIL13WHL1238AB 3
8. Remove the retainer pin and the brake pin.
LEIL13WHL1239AB 4
48083741_EN 31/07/2018
33.2 [33.110] / 4
9. Remove the two brake pads from the parking brake

assembly.
LEIL13WHL1240AA 5
48083741_EN 31/07/2018
33.2 [33.110] / 5
Parking brake or parking lock - Inspect

1. Clean and inspect all parts for wear and damage.
2. Inspect the brake disc for wear and damage.
3. Replace all parts that are worn or damaged.
48083741_EN 31/07/2018
33.2 [33.110] / 6
Parking brake or parking lock - Assemble

1. Install the two brake pads in the parking brake assem-
bly.
LEIL13WHL1240AA 1
2. Install the brake pins and retainer pins.

3. Place the timed disconnect switch to the on position.
Start the machine and run the engine at low idle with
the bucket resting on the ground.
NOTE: it will be necessary to have an assistant help for
this procedure. An operator must be present in the cab
at all times to apply the service brakes and shut down the
machine in the event of mechanical failure.
4. Disengage the parking brake. Make sure that the park-
ing brake button on the multifunction keypad is OFF.
Place the transmission back into neutral before pro-
ceeding. LEIL13WHL1239AB 2
NOTE: hydraulic pressure will not be applied to the parking

brake until the parking brake switch on the multifunctional
keypad is off, the service brakes applied and the transmis-
sion is put into gear.
5. Turn the adjusting bolt clockwise until both brake pads
contact the brake disc, then turn the adjusting bolt
counterclockwise one turn. Tighten the jam nut to
secure the adjusting bolt.
6. Install the cover on the parking brake.
7. Perform the Parking Brake Test Procedure as de-
scribed in this section.
8. Return the articulation lock to the operating position.
LEIL13WHL1238AB 3
48083741_EN 31/07/2018
33.2 [33.110] / 7
Parking brake or parking lock - Service instruction

Spring Applied Hydraulic Released (SAHR) sliding caliper FSG 88
LEIL16WHL1152FB 1
1. Locknut 7. Guiding bolt

2. Setting screw 8. Bleeding screw
3. Adjusting screw 9. Piston
4. Counter nut 10. Peg spanner (tool)
5. Screw cap 11. Ring spanner (tool)
6. Pressure bolt
NOTE: the fitting or adjusting must always be carried out

when the brake is cold.
Fitting the parking brake

1. Rotate the screw cap (5) in a counter-clockwise direc-
tion and unscrew it.
2. Release the locknut (1) and turn the adjusting screw (2)
counter-clockwise until the pressure bolt (6) contacts
the piston (9) with the flat surface.
3. Slide the brake over the brake disc in this condition.
NOTE: the point at which the brake disc is fitted is deter-

mined by the customer.
4. Screw the two guide pins (7) into the gearbox in accor-
dance with the fitting instructions provided by the man-
ufacturers of the gearbox.
48083741_EN 31/07/2018
33.2 [33.110] / 8
5. Connect the pressure.

6. Apply the required release pressure (minimum
130 bar) to the brake in order to pre-tension the plate
spring pack (10) completely, up to the stop.
7. Carry out bleeding of the brake using the bleed valve
(8).
Adjusting the parking brake

1. Place the machine on flat ground and secure with wheel
chocks and articulation lock to minimize the risk of in-
jury.
NOTE: an operator must be present in the cab at all times
to apply the service brakes and shut down the machine in
the event of mechanical failure.
2. Run the machine at low idle
3. Release the parking brake by application of the re-
quired release pressure (minimum 130 bar).
4. Rotate the screw cap (5) in a counter-clockwise direc-
tion and unscrew it.
5. Release the locknut (1) of the adjusting screw (2).
6. Insert a setting gauge on both sides between the brake
lining carrier and brake disc and hold them in position.
NOTE: the thickness of the setting gauge must be adjusted

to the desired air gap.
Type Clearance Setting gauge

Minimum 0.5 mm 0.25 mm (0.01 in)
(0.02 in)
FSG 88 Nominal clearance 0.5 mm (0.02 in)
1 mm (0.04 in)
Maximum 1.5 mm 0.75 mm (0.03 in)
(0.06 in)
7. Turn the adjusting screw (2) in a clockwise direction

until the two setting gauges are clamped between the
brake lining carriers and the brake disc.
8. Hold the adjusting screw (2) in position and lock using
the locknut (1).
NOTICE: the application pressure for clamping the setting

gauges must be selected so that both gauges can be re-
moved using a small amount of force after locking in posi-
tion.
9. Release the locknut (4) and then turn the setting screw
(3) in a clockwise direction until the end surface of the
setting screw (3) is in contact with the surface provided
for setting.
10. Hold the setting screw (3) in position and lock using
the locknut (4).
11. Remove the setting gauges from both sides of the
brake disc.
48083741_EN 31/07/2018
33.2 [33.110] / 9
12. Turn the screw cap (5) in a clockwise direction and

tighten hand-tight.
13. Actuate and release the brake several times to check
that it is functioning properly.
NOTE: DO NOT replace the knurled cover on a parking
brake which has been disabled. The cover can be severely
damaged if hydraulic pressure is applied to a disabled park-
ing brake. Store the cover in a safe place until the parking
brake is properly adjusted.
Emergency release of the parking brake

NOTE: in the event of a failure in pressure supply the park-
ing brake can be released mechanically in the following
way.

chocks and articulation lock.
2. Rotate the screw cap in a counter-clockwise direction
and unscrew it.
3. Release the locknut (1) and unscrew it back to the end
of the setting screw (2).
4. Rotate the setting screw (2) in a clockwise direction
until the brake disc is completely free.
NOTICE: for emergency release a torque of minimum

70 N·m is required on the setting screw.
5. Screw on the locknut (1) up to contact with the piston

and apply a slight locking force to the setting screw (2).
6. Screw on the screw cap in a clockwise direction by a
few threads (dirt ingress protection).
NOTICE: in this condition the machine has no parking

brake facility and thus must be protected from rolling away
by different means. The brake must be adjusted before
re-commissioning.
48083741_EN 31/07/2018
33.2 [33.110] / 10
Maintenance and replacement of the lining pads
LEIL16WHL1154FB 2
1. Locknut 5. Peg spanner (tool)

2. Setting screw 6. Screwdriver (tool)
3. Pressure bolt 7. Ring spanner (tool)
4. Piston
The brake, particularly the brake lining carriers, must be visually inspected at regular intervals. If the remaining
lining thickness is too thin, these intervals must be reduced accordingly to prevent extensive damage to the brake
or the brake disc. Once the minimum remaining lining thickness of 1 – 1.5 mm (0.04 – 0.06 in) per brake lining
carrier is reached, the brake lining carrier must be replaced in accordance with the following instructions.

and unscrew it.
4. Release the locknut (1) of the setting screw (2).
5. Rotate the setting screw (2) in an counter-clockwise di-
rection until the pressure bolt (3) can be pushed com-
pletely into the piston (4).
6. Unscrew (lever) the pressure bolt (3) with a suitable
screwdriver (6) until it contacts the piston (4).
48083741_EN 31/07/2018
33.2 [33.110] / 11
LEIL16WHL1155FB 3
1. Counter nut 4. Lining pad

2. Adjusting screw 5. Lining spring
3. Lining pad
7. Release the counter nut (1) and unscrew the setting

screw (2) from the brake housing
NOTICE: the lining spring (5) is pre-tensioned. The lining

spring (5) must be held in position with a suitable tool whilst
removing the setting screw (2).
8. Remove the lining spring (5).

9. Remove the two lining pads (3) and (4) from the lining
compartment in the brake housing.
10. Replace the lining pads (3) and (4).
11. The lining spring (5) must be pushed in position with
a suitable tool whilst screwing in the adjusting screw
(2).
NOTE: after changing the lining pads, the brake must be

adjusted in accordance with "Fitting the brake" procedure
from step 5.
48083741_EN 31/07/2018
33.2 [33.110] / 12
Replacing the seals
LEIL16WHL1156FB 4

NOTICE: if the brake cannot be pressurised with the re-

quired release pressure (minimum 130 bar) because of
excessive leaks, the parking brake must be released using
the “Emergency release of the parking brake” procedure.

and unscrew it.
4. Release the setting nut (3) of the setting screw (2).
5. Rotate the setting screw (2) in a counter-clockwise di-
rection until the pressure bolt (8) can be pushed com-
pletely into the piston (1).
6. Unscrew (lever) the pressure bolt (8) with a suitable
screwdriver until it contacts the piston (1).
7. Actuate the brake valve and dissipate the existing re-
lease pressure down to 0 bar.
NOTE: the plate spring pack (9) is now fully de-tensioned.

8. Unscrew the pressure line and remove the brake com-
pletely.
9. Remove the circlip (5) and remove the pressure ring (7)
from the housing (4).
10. Remove the plate spring pack (9) and the piston (1).
48083741_EN 31/07/2018
33.2 [33.110] / 13
11. Always replace both the seals (A) and (B).
NOTICE: observe the fitting direction of the grooved rings

and use a suitable fitting needle with rounded edges to fit
the new grooved rings. Take care - there is a danger of
injury.
NOTE: carry out re-fitting of the individual parts into the
brake in reverse order. Apply a light coat of fitting fluid
lubricant to the sliding and sealing surfaces of the piston
when fitting.
12. If necessary, also replace the dust protection cap (10).
NOTE: the dust protection cap (10) has a vulcanised-in

steel ring which is used to press it into the opening in the
brake housing (4). In order to replace this you will need
to lever it out with a suitable tool and then replace with a
fitting fixture by pressing it into the housing (4).
13. Fit the brake onto the gearbox in accordance with the
fitting instructions.
48083741_EN 31/07/2018
33.2 [33.110] / 14
Parking brake or parking lock - Test

1. While testing, the machine must be on a clear level
surface with the bucket in the travel position.
NOTICE: always know the location of all workers in your
area. Warn them before you start working the machine.
Always keep all other persons away from your area. Se-
rious injury or death can result if you do not follow these
instructions.
2. Start the machine. Move the transmission control lever
to neutral. Push the parking brake switch on the multi-
function keypad.
LEIL16WHL0936AA 1
3. The LCD multi-function display located above the mul-

tifunction keypad is on and displays the main menu.
4. Press the corresponding key to access the Machine
Service screen.
LEIL16WHL2335AB 2
5. Use up or down arrow to select the Calibration Settings

item. Press the enter/confirm key to access the selec-
tion screen.
LEIL16WHL0874AA 3
48083741_EN 31/07/2018
33.2 [33.110] / 15
6. Use up or down arrow to select the Park Brake Test

item.
7. The screen displays the two conditions to be satisfied
before starting the parking brake test.
8. The machine is already on with parking brake.
Place the transmission in 3rd gear forward to meet the
second condition needed for the test.
9. Press the enter/confirm key to start the parking brake
test.
LEIL16WHL0879AA 4
10. When the parking brake test is on, push the foot throt-
tle to increase the engine speed as suggested by the
screen.
11. If the machine moves, the test failed. The parking
brake must be adjusted (see procedures in this sec-
tion).
12. If the machine remains stationary, the test passed.
13. Reduce the engine speed to low idle. Return the
transmission to neutral.
14. Press the enter/confirm key to terminate the test.
LEIL16WHL0880AA 5
48083741_EN 31/07/2018
33.2 [33.110] / 16
Index

Parking brake or parking lock - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Parking brake or parking lock - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Parking brake or parking lock - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Parking brake or parking lock - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Parking brake or parking lock - Service instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Parking brake or parking lock - Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
48083741_EN 31/07/2018
33.2 [33.110] / 17
PRINTED IN ITALY
48083741_EN 31/07/2018
EN
SERVICE MANUAL
Hydraulic systems

48083741_EN 31/07/2018
35
Contents
Hydraulic systems - 35
[35.000] Hydraulic systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.1
[35.300] Reservoir, cooler, and filters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.2
[35.106] Variable displacement pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.3
[35.359] Main control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.4
[35.357] Pilot system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.5
[35.204] Remote control valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.6
[35.752] Hydraulic fan drive cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.7
[35.701] Front loader arm hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.8
[35.723] Front loader bucket hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.9
[35.734] Tool quick coupler hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.10
48083741_EN 31/07/2018
35

48083741_EN 31/07/2018
35.1 [35.000] / 1
Contents
TECHNICAL DATA
Hydraulic systems
Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
FUNCTIONAL DATA
Hydraulic systems
Hydraulic schema - 821G . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Hydraulic schema - 921G . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Component localization - Test ports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
SERVICE
Hydraulic systems
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Decontaminating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Service instruction - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
48083741_EN 31/07/2018
35.1 [35.000] / 2
Hydraulic systems - Hydraulic systems
Hydraulic systems - Special tools

CAS10162A, Portable filter unit
LEIL13WHL1194AA 1
CAS10192, Vacuum pump
LEIL13WHL1195AA 2
CAS10508, Fitting kit
LEIL13WHL1196AA 3
CAS1904-1, Pressure fitting kit
LEIL13WHL1197AA 4
48083741_EN 31/07/2018
35.1 [35.000] / 3
CAS10280, Flowmeter
LEIL13WHL1199AA 5
380001740, Flowmeter fitting kit
LEIL13WHL1200AA 6
5870 287 007, Hand pump
LEIL13WHL1227AA 7
CAS1804, Pressure fitting kit
LEIL13WHL1228AA 8
48083741_EN 31/07/2018
35.1 [35.000] / 4
Hydraulic systems - Hydraulic schema - 821G
48083741_EN 31/07/2018
35.1 [35.000] / 5
48083741_EN 31/07/2018
35.1 [35.000] / 6
Callout Description Callout Description Callout Description Callout Description

(1) Parking brake accumulator, 0.16 L (0.04 US gal), (2) Hydraulic gear pump, 25 cm³ (3) Brake dumping accumulator, 0.16 L (0.04 US gal), (4) Service brake accumulator, 3.5 L (0.92 US gal),
96 bar (1392 psi) precharge 7 bar (102 psi) precharge 70 bar (1015 psi) precharge
(5) Brake valve (for 4-speed transmission), 76 bar (6) Brake valve (for 5-speed transmission), 76 bar (7) Power steering, Orbitrol valve, 740 cm³ (8) Steering cylinder
(1102 psi) (1102 psi)
(9) Steering cylinder (10) Relief valve, 10 bar (145 psi) (11) Variable displacement pump, 63 cm³/rev (12) Steering priority valve
(13) Hydraulic oil filter (14) Hydraulic oil tank filter (15) Auxiliary steering pump, 11 cm³ (16) Auxiliary steering manifold (optional)
(17) Steering valve (18) Tee (19) Cut-off valve (20) Check valve fitting (M14x10 ORFS)
(21) Check valve (22) 2-function control valve (23) 3-function control valve (24) 4-function control valve
(25) 2-spool valve (Z-bar) (26) 3-function valve (Z-bar) (27) 4-function valve (Z-bar) (28) Lifting cylinder
(29) Bucket tilting cylinder (30) Bucket tilting cylinder (XR and LR version) (31) Ride control valve (32) Accumulator, 3.78 L (1.00 US gal), 10 bar (145 psi)
precharge
(33) Hydraulic oil tank filter (34) Hydraulic fan drive motor, 23 cm³ (35) Hydraulic oil tank neck (36) Hydraulic oil tank filter
(37) Fan relief valve (38) Fan reverse and variable fan speed control valve (39) Thermal by-pass valve (40) Transmission oil cooler
(41) Quick coupler locking valve (42) Quick coupler system (43) Quick coupler cylinder (44) Rear axle, open differential
(45) Front axle, locking differential (46) Rear axle, limited slip differential (47) Front axle, limited slip (48) Hydraulic tank breather valve, 0.28 bar (4.06 psi)
(49) Pilot supply accumulator, 0.32 L (0.08 US gal), (50) Brake pump attenuator hose
14 bar (203 psi) precharge
48083741_EN 31/07/2018
35.1 [35.000] / 7
48083741_EN 31/07/2018
35.1 [35.000] / 8
LEIL17WHL0946JB 1
48083741_EN 31/07/2018
35.1 [35.000] / 9
48083741_EN 31/07/2018
35.1 [35.000] / 10
Hydraulic systems - Hydraulic schema - 921G
48083741_EN 31/07/2018
35.1 [35.000] / 11
48083741_EN 31/07/2018
35.1 [35.000] / 12
Callout Description Callout Description Callout Description Callout Description

(1) Parking brake accumulator, 0.16 L (0.04 US gal), (2) Hydraulic gear pump, 25 cm³ (3) Service brake accumulator, 3.5 L (0.92 US gal), (4) Brake dumping accumulator, 0.16 L (0.04 US gal),
96 bar (1392 psi) precharge 70 bar (1015 psi) precharge 7 bar (102 psi) precharge
(5) Steering cylinder (6) Steering cylinder (7) Relief valve, 10 bar (145 psi) (8) Power steering, Orbitrol valve, 740 cm³
(9) Quick coupler locking valve (10) Hydraulic oil filter (11) Brake valve (for 5-speed transmission), 76 bar (12) Brake valve (for 4-speed transmission), 76 bar
(1102 psi) (1102 psi)
(13) Variable displacement pump, 85 cm³/rev / (14) Steering priority valve (15) Check valve fitting (M14x10 ORFS) (16) Auxiliary steering pump, 11 cm³
63 cm³/rev
(17) Auxiliary steering manifold (optional) (18) Hydraulic oil tank filter (19) Steering valve 100 L/min (20) Tee
(21) Cut-off valve (22) Hydraulic tank breather valve, 0.28 bar (4.06 psi) (23) Check valve (24) 2-function control valve
(25) 3-function control valve (26) 4-function control valve (27) 2-spool valve (Z-bar) (28) 3-function valve (Z-bar)
(29) 4-function valve (Z-bar) (30) Lifting cylinder (31) Bucket tilting cylinder (32) Bucket tilting cylinder (XR and LR version)
(33) Accumulator, 3.78 L (1.00 US gal), 10 bar (145 psi) (34) Ride control valve (35) Thermal by-pass valve (36) Fan reverse and variable fan speed control valve
precharge
(37) Fan relief valve (38) Transmission oil cooler (39) Hydraulic oil tank filter (40) Hydraulic fan drive motor, 23 cm³
(41) Hydraulic oil tank neck (42) Hydraulic oil tank filter (43) Front axle, locking differential (44) Front axle, open differential
(45) Rear axle, open differential (46) Quick coupler system (47) Quick coupler cylinder (48) Pilot supply accumulator, 0.32 L (0.08 US gal), 14 bar
(203 psi) precharge
(49) Brake pump attenuator hose
48083741_EN 31/07/2018
35.1 [35.000] / 13
48083741_EN 31/07/2018
35.1 [35.000] / 14
LEIL17WHL0947JB 1
48083741_EN 31/07/2018
35.1 [35.000] / 15
48083741_EN 31/07/2018
35.1 [35.000] / 16
Hydraulic systems - Dynamic description

The Wheel Loaders use a combination of:
• Variable displacement Pressure and Flow Compensated (PFC) piston type pump
• Open-center gear type pump
The closed center variable PFC hydraulic system supplies the oil flow requirements for:
• Priority flow divider manifold
• Steering
• Loader controls
• Loader lift
• Loader bucket
• Loader auxiliary system
• Loader valve pilot controls / EH manifold
The open center gear pump hydraulic system supplies, oil flow to the brakes, cooling fan, and oil cooler.
In a closed center variable displacement PFC system oil flow is minimal unless there is a hydraulic demand. In an
open-center system, oil is constantly pumped through the system regardless of hydraulic demand. When problems
are present in more than one steering or loader hydraulic function, consider that the problem could be within the
variable PFC hydraulic pump control system.
48083741_EN 31/07/2018
35.1 [35.000] / 17
Hydraulic Oil Supply Components

A single variable Pressure and Flow Compensated (PFC) hydraulic system controls both the steering (24) and the
loader control (22) systems on the Wheel Loaders. When it appears that there are malfunctions in both the steering
and loader control circuits consider there may be problems with one or both of the two pump PFC pumps (33) (34).
Oil flows from the reservoir to the PFC piston pump. The large wheel loaders have two piston type PFC pumps. Both
pumps directly supply oil to the steering priority valve (35). The steering priority valve (35) first supplies oil to steering
(24) with any excess flow then available to the loader valve (22). On units equipped with two PFC pumps, each
body of the piston pump has a compensator flow control system to deliver only the oil flow required by the hydraulic
system. On units equipped with a single PFC pump, a single compensator flow control system delivers only the oil
flow required by the hydraulic system. This control system requires a feedback signal (LS signal) from the loader
control valve (22) and/or from the steering valve (24) to deliver the oil required by the system.
The steering priority valve assembly (35) is located at the outlet of the 2nd pump. The function of this valve is to first
supply oil to the steering control system (24). The steering control valve (24) is located at the base of the steering
column.
The loader valve is mounted at the rear of the front chassis and can be accessed through the articulation joint or the
access cover at the front of the chassis. As the oil enters the loader valve, it supplies oil to the EH manifold circuit and
to the loader control spools. A pilot pressure regulator limits the maximum pilot pressure available to the EH manifold.
The bucket and loader lift sections are both included in the mono-block assembly. If the machine is equipped with
optional auxiliary hydraulic controls, each additional section consists of a separate section block. Each active spool
throughout the loader control valve generates a load sense (LS) signal pressure.
The LS feedback signal system sends the highest operating pressure signal requirement back to the compensator
flow regulator spool at the piston pump. The loader LS, as well as the steering LS signals, pass through the LS
shuttle check valve (35B) in the steering priority valve (35). From the LS shuttle check valve (35B) the LS signal is
then connected to flow regulator spools (33A) (34A) of the PFC pump assembly (32). This signals the pump to deliver
only the quantity of oil required by the hydraulic system.
The smaller wheel loaders use one variable displacement PFC pump to deliver flow to the steering priority valve (35),
the steering control valve (24), the loader valve (22), and the EH manifold (16). Included later in this section is a
detailed functional explanation of a single PFC pump.
The larger wheel loaders use two variable PFC pumps (35) to deliver flow to the steering priority flow divider (35), the
steering control valve (24), the loader valve (22) and the EH manifold (16). On units equipped with two PFC hydraulic
pumps, the first pump (34) is the only pump to supply the flow required to operate any of the hydraulic circuits at lower
flow requirements until it reaches maximum delivery. The second pump (33) only begins to deliver flow when the total
hydraulic flow requirements exceed the maximum capability of the first pump (34). The second pump (33) is idling at
no flow delivery until the first pump (34) reaches maximum delivery.
Both of the PFC pumps are mounted as an assembly (32) to the transmission towards the front of the wheel loader.
The first pump (34) is located closest to the transmission. The second pump (33) is mounted to the back of the first
pump (34) and is furthest from the transmission. The priority flow divider (35) is mounted directly to the second pump
(33). The outlet line from the first pump (34) is directly connected to the priority flow divider (35).
Component Flow Chart Legend

16 – EH manifold 34 – First pump
22 – Loader valve 34A – First pump compensator flow regulator spool
22A – Bucket 34B – First pump compensator pressure regulator spool
22B – Arm 35 – Steering priority valve
22C – Auxiliary 35A – Steering priority spool
24 – Steering orbitrol control valve 35B – Load sense (LS) signal shuttle check valve
24A – Steering isolation check valve 35C – Second pump isolation check valve
33 – Second pump 35D – Differential pressure relief valve
33A – Second pump compensator flow regulator spool 35E – Steering relief valve
33B – Second pump compensator pressure regulator
spool
48083741_EN 31/07/2018
35.1 [35.000] / 18
RCPH11WHL035HAN 1
Component Flow Chart
48083741_EN 31/07/2018
35.1 [35.000] / 19
Each of the hydraulic pumps are controlled by a compensator. Each of the compensators have two spools. The flow
regulator spools ( (33A) (34A)) control the output flow of each pump. The pressure regulator spools ( (33B) (34B))
control the maximum pressure that the pumps are capable of delivering. In the wheel loader hydraulic system, these
valves are adjusted higher than the maximum pressure in any of the circuits. Because of this higher adjustment, the
pressure regulator spools do not function. If one or both of these pressure regulator spools are adjusted too low, the
specified steering or loader relief valve pressures might not be able to be reached.
The priority flow divider (35) has many functions which require numerous components. The components of the
steering priority flow divider consists of the following components:
• Steering priority spool (35A)
• Load sense shuttle check valve (35B)
• Second pump isolation check valve (35C)
• Differential pressure relief valve (35D)
• Steering relief valve (35E)
Steering is more critical to the operation of the machine so the steering priority spool (35A) is in the circuit to provide
oil to the steering control valve (24) first. The priority spool (35A) is spring loaded to send all of the oil that the steering
system requires. Between the steering priority valve (35) and the steering orbitrol control valve (24), the oil flows
through the steering isolation check valve (24A). Once the steering circuit (24) is satisfied, all of the excess supply oil
then becomes available to the loader hydraulic system.
Both PFC pumps ( (33) (34)) require a load sense (LS) signal from the either the steering or loader systems, whichever
requires a higher pressure. The PFC pumps do not deliver flow until a command LS signal is received, Once a load
sense (LS) signal is received, the PFC pumps deliver as much flow as is required to satisfy the required LS pressure.
The LS signals from both the steering control system and the loader system are connected to the steering priority
valve. The LS signal shuttle check valve (35B) shifts away from the highest LS signal towards the lower LS signal. The
higher LS signal is then sent to the flow regulator spools of both of the PFC pumps. The higher pressure adjustment
of the first pump flow regulator (34A) causes that pump to begin to deliver flow first. The flow regulator pressure of
the first pump (34A) must be adjusted to specification. The adjustment of the flow regulator pressure of second pump
(33A) is lower than the first pump. If one compensator is adjusted, the opposite compensator must also be checked
and adjusted. The first pump flow regulator pressure must 3 – 4 bar (44 – 58 psi) higher than the adjustment of the
second pump flow regulator. It is preferable to use the same gauge to make both of these adjustments.
The second pump isolation check valve (35C) prevents pressurizing the second pump (33) from the outlet of the first
pump (34). Until the first pump (34) reaches full delivery, the second pump (33) is idling. The isolation valve (35C)
protects the second pump (33).
If the PFC pump control system malfunctions the pumps might deliver more flow than the hydraulic systems require,
causing excessive pressure at the pump outlet. A differential pressure relief valve (35D) is installed in the steering
priority valve limits this excessive pressure. The differential pressure relief (35D) provides a connection between the
PFC pump outlet flow and tank. The differential pressure relief valve is spring biased to the closed position. Pump
outlet pressure is ported to the non spring end of differential pressure relief valve spool. Load sense (LS) pressure is
ported to the spring end of the spool. The differential pressure relief opens when the pump outlet pressure is about
40 bar (580 psi) higher than load sense (LS) pressure.
The maximum steering pressure is lower than the maximum loader pressure. To limit this pressure in the steering
system, a steering pressure relief valve (35E) is connected between the steering LS signal (35B) in the steering priority
valve (35) and tank. This steering relief valve (35E) limits the maximum LS signal from the steering system and hence
limits the maximum steering pressure. The maximum pressure in the loader circuit is regulated by the loader relief
LS control valve located in the loader valve.
If only one of the complete steering or all of the loader circuits are malfunctioning, a quick check is to operate both
steering and loader at the same time. If both systems then operate, the PFC pumps should be OK. If only one circuit
of the loader valve malfunctions, the problem is in the loader valve only. If either the steering or all of the loader circuits
malfunction and both systems function when operated at the same time. A possible problem is then the shuttle check
valve (35B) in the steering priority valve (35).
48083741_EN 31/07/2018
35.1 [35.000] / 20
The piston pumps used in the wheel loaders have variable displacement and are pressure and flow compensated
(PFC).
The smaller wheel loaders have a single PFC pump to supply the hydraulic systems.
The large wheel loaders use a two PFC pump tandem assembly to deliver the required flow. The two pump system
operates the same as the single pump system. The first pump delivers all of the flow when under low flow require-
ments. The second pump is idling at no flow until the first pump reaches maximum flow.
The counterbalance spring (1) pushes the piston pump swash plate (3) to deliver maximum flow until the control piston
(2) reduces the pump output to what is required to satisfy system requirements. When the engine is off, the swash
plate rests at the full displacement position as shown.
The flow control spool (FR2) monitors the load sensing (LS) signal from the loader control valve to control the piston
pump so that it only delivers the flow required by the system.
The pressure control spool (FR1) can regulate the maximum pressure that the piston pump will deliver. On the wheel
loaders, the pressure regulator spool (FR1) does not function. If the pump outlet pressure exceeds the pressure
control spool setting, the displacement, and therefore outlet flow, of the piston pump will be reduced to only that
which is required to maintain the maximum pressure. On the wheel loaders the pressure regulator spool is set much
higher than the maximum pressure control, (main relief valve) located within the loader valve. The pressure regulator
spool (FR1) is not functional within these pumps unless it was incorrectly adjusted to a pressure lower than the main
relief valve. If either the steering and loader systems operate well at lower pressures but cannot be adjusted to the
maximum specified relief valve pressure, the pressure regulator spool may have been incorrectly adjusted.
1 – Counterbalance spring FR1 – Pressure regulator spool

2 – Control piston FR2 – Flow regulator spool
3 – Swash plate LS – Load sense signal pressure
4 – Pump outlet pressure L – Drain flow to reservoir
5– Flow regulator spring
48083741_EN 31/07/2018
35.1 [35.000] / 21
RCPH11WHL038GAN 2
48083741_EN 31/07/2018
35.1 [35.000] / 22
LEIL16WHL2705FB 3
48083741_EN 31/07/2018
35.1 [35.000] / 23
System Function Overview

This section provides a detailed explanation of how the Pressure and Flow Compensated (PFC) pump compensator
controls the pump.
When the engine is off, the pressure regulator spool (FR1) and the flow regulator spool (FR2) are spring loaded to
the closed position. The counterbalance spring pushes the swash plate to the full flow position. At start-up, pump
output flow is available to the steering and loader valve. The steering and loader control systems are closed center
design. The oil supply from the PFC pumps are blocked with the controls in neutral. With all controls in neutral, the LS
pressure will be vented to tank pressure. Pump outlet pressure is internally ported to the non spring end of the flow
regulator spool (FR2). Pump outlet pressure pushes on the left end of the flow regulator spool (FR2) overcoming the
flow regulator spring (5). Pump outlet pressure is then ported through the flow regulator spools to the control piston
(2). The control piston (2) then pushed the swash plate towards minimum displacement. The pump then delivers only
the flow required to maintain the flow regulator spring (5) pressure.
The flow regulator spring (5) is adjustable. Typically this spring does not require adjustment. If adjustment is required,
use the table below for the specifications. The flow regulator pressure of the first pump (34A) must be adjusted
to specification. The adjustment of the flow regulator pressure of second pump (33A) is lower than the first pump.
If one compensator is adjusted, the opposite compensator must also be checked and adjusted. Measure both the
pump outlet pressure and the LS pressure for the pump. Adjust the flow regulator spool to the pressure differential
specification. DO NOT activate any of the controls while making the adjustment, as the gauge may be damaged.
It is preferable to have a shutoff valve at the gauge to protect it from overpressure. The first pump flow regulator
pressure must 3 – 4 bar (44 – 58 psi) higher than the adjustment of the second pump flow regulator. It is preferable
to use the same gauge to make both of these adjustments to assure accuracy. The pump outlet pressure would be
approximately 24 – 35 bar (348 – 508 psi).
Model Pump 1 Delta P Pump 2 Delta P

521G and 621G 22 – 25 bar (319 – 362 psi) Not applicable
721G and 821G 28 – 30 bar (406 – 435 psi) 24 – 26 bar (348 – 377 psi)
921G 24 – 26 bar (348 – 377 psi) 21 – 23 bar (305 – 334 psi)
1021G and 1121G 25 – 27 bar (362 – 392 psi) 21 – 23 bar (305 – 334 psi)
When the steering or loader control system is activated, pump output pressure is available to the control spools. When
the loader circuit is activated, oil flow across the spool causes a pressure drop (Delta P) between the (PFC) pump
outlet pressure (4) and the LS signal pressure (6) back to the pump compensator. Pump output flow is delivered to
the inlet of the loader control valve through the steering priority valve.
When the pump outlet pressure (4) is higher than the LS signal pressure (6) plus the spring force (5), the flow regulator
spool (FR2) will gradually shift to send pump outlet oil (4) to the control piston (2) to reduce the output of the pump.
The flow regulator spool (FR2) will remain in balance between the pump outlet pressure (4) on the left end and the LS
pressure (6) plus the spring force (5) on the right end of the spool. The control piston (2) will move the swash plate
(3) so that the flow from the pump will maintain the specified differential pressure (Delta P).
The pressure at which the flow control spool (2) shuts the pump down is adjustable. The flow control spool of the
second pump is to be adjusted approximately 4 bar (58 psi) lower than the flow regulator on the first pump. Any time
that the pump is at less than full displacement, the flow control spool (2) will maintain the Delta P. At less than full
flow delivery of the 1st pump, the difference between pump outlet pressure and the LS pressure (Delta P) will be the
higher pressure setting of the 1st pump compensator. When the 1st pump is at maximum flow, the difference between
pump outlet pressure and the LS pressure (Delta P) will be the lower pressure setting of the 2nd pump. If the load
in the bucket would require 138 bar (2000 psi) pump outlet pressure to raise the load, the signal pressure would be
138 bar (2000 psi) minus Delta P.
The maximum pressure available to loader hydraulic system is controlled by loader main relief valve located in the
loader valve (7). The loader main relief connects between the LS signal pressure and the tank passage in the loader
valve (7). When the LS signal pressure is restricted, the pump will not be able to deliver flow above that pressure. The
steering signal relief valve located in the steering priority valve limits the maximum pressure available to the signal
line from steering control circuit to the spring end of the piston pump flow control spool (FR2).
48083741_EN 31/07/2018
35.1 [35.000] / 24
RCPH11WHL046GAN 4
1 – Counterbalance spring 6– Load sense signal pressure

2 – Control piston 7 – Loader valve
3 – Swash plate LS – Load sense signal pressure
4 – Pump outlet pressure L – Output port
5 – Flow regulator spring S – Sump
48083741_EN 31/07/2018
35.1 [35.000] / 25
Hydraulic systems - Component localization - Test ports

1. Brake test port
2. Brake test port
LEIL18WHL0925AA 1
3. Brake accumulator test port
4. Brake accumulator test port
LEIL18WHL0922AA 2
5. Steering priority valve test port
6. Steering priority valve test port
LEIL14WHL0221AB 3
7. Pilot pressure supply test port
LEIL16WHL1014AA 4
48083741_EN 31/07/2018
35.1 [35.000] / 26
8. Steering load sense test port
LEIL18WHL0926AB 5
For 821G
LEIL16WHL1011AA 6
For 921G
NOTE: see “Hydraulic systems - Hydraulic schema” in this manual for more information about the location of the test
ports.
48083741_EN 31/07/2018
35.1 [35.000] / 27
Hydraulic systems - Cleaning

Hydraulic system fluid contamination
Contamination in the hydraulic system is a major cause
of the malfunction of hydraulic components. Contami-
nation is any foreign material in the hydraulic oil. Con-
tamination can enter the hydraulic system in several
ways.
A. When you drain the oil or disconnect any line.
B. When you disassemble a component.
C. From normal wear of the hydraulic components.
D. From damaged or worn seals.
E. From a damaged component in the hydraulic sys-
tem.
All hydraulic systems operate with some contamination.
The design of the components in this hydraulic system
permits efficient operation with a small amount of con-
tamination. An increase in this amount of contamina-
tion can cause problems in the hydraulic system. The
following list includes some of these problems.
A. Cylinder rod seals leak.
B. Control valve spools do not return to neutral.
C. Movement of control valve spools is difficult.
D. Hydraulic oil becomes too hot.
E. Pump gears, housing, and other parts wear
rapidly.
F. Relief valves or check valves held open by dirt.
G. Quick failure of components that have been re-
paired.
H. Cycle times are slow; machine does not have
enough power.
If your machine has any of these problems, check the
hydraulic oil for contamination. See types of contamina-
tion below. If you find contamination, use the Portable
Filter to clean the hydraulic system.
There are two types of contamination, microscopic and
visible.
Microscopic contamination occurs when very fine par-
ticles of foreign material are in suspension in the hy-
draulic oil.
These particles are too small to see or feel. Microscopic
contamination can be found by identification of the fol-
lowing problems or by testing in a laboratory. Examples
of the problems:
A. Cylinder rod seal leak.
B. Control valve spools do not return to NEUTRAL.
C. The hydraulic system has a high operating temper-
ature.
48083741_EN 31/07/2018
35.1 [35.000] / 28
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.
NOTE: the hydrostatic system uses a third port bypass filter
system. If the filter becomes plugged it bypasses back to
the reservoir to stop contamination from entering the hydro-
static system. Upon completion of cleaning the hydraulic
system replace the hydrostatic system filter.
48083741_EN 31/07/2018
35.1 [35.000] / 29
Cleaning the hydraulic system

1. Prepare the portable filter by doing the following steps:
A. Remove all the hydraulic oil from the inlet and out-
let hoses for the portable filter.
B. Remove the filter element from the portable filter.
C. Remove all hydraulic oil from the portable filter.
D. Clean the inside of the housing for the filter ele-
ment.
2. You must know whether the contamination is micro-
scopic or visible.
3. If the contamination is microscopic:
A. Check the maintenance schedule for the machine
to learn if the hydraulic oil must be changed. If
needed, change the hydraulic oil. Change the hy-
draulic filter.
B. Do steps 6 through 35.
4. If the contamination is visible:
A. Change the hydraulic oil and hydraulic filter.
B. Do steps 5 through 35.
5. Check the amount of contamination in the hydraulic
system by doing the following steps:
A. Disassemble one cylinder in two different circuits.
Check for damage to seals, scoring of the cylinder
wall, etc. Repair the cylinders as necessary.
B. If, in your judgment, the damage to the cylinders
was caused by sever contamination and is not the
result of normal wear, it is necessary to remove,
clean and repair valves, pump, lines, cylinders, hy-
draulic reservoir, etc. in the hydraulic system.
6. Remove the breather from the reservoir and connect
the vacuum pump to the opening. Start the vacuum
pump.
7. Loosen and remove the drain plug from the reservoir.
8. Using the properly fitting kit, install the valve in the hole
for the drain plug. Make sure that the valve is closed.
9. Stop the vacuum pump.
10. Connect the inlet hose for the portable filter to the
valve that is installed in the hole for the drain plug.
48083741_EN 31/07/2018
35.1 [35.000] / 30
11. Disconnect the vacuum pump from the hydraulic

reservoir air breather hose. Remove the filler cap.
12. Install the outlet hose for the portable filter in the hy-
draulic reservoir filler neck.
13. Open the valve that is installed in the hole for the drain
plug.
14. Move the switch for the portable filter to the ON posi-
tion. Start and run the engine at 1500 RPM.
15. Run the portable filter for 10 minutes.
16. Continue to run the portable filter. Increase the engine
speed to full throttle. Heat the oil to operating temper-
ature by doing the following steps:
1. Hold the loader control in the bucket roll-back po-
sition for five seconds.
2. Return the blade control lever in the NEUTRAL
position for five seconds.
3. Repeat steps 1 and 2 until the oil in the hydraulic
system is at operating temperature.
17. Continue to run the engine at full throttle. Continue to
run the portable filter.
18. Operate each hydraulic circuit to completely extend
and retract the cylinders. Continue to operate each
hydraulic circuit two times, one after the other for 45
minutes.
20. Continue to run the portable filter for 10 minutes.
48083741_EN 31/07/2018
35.1 [35.000] / 31
21. Stop the portable filter.

23. Remove the hose from the hydraulic reservoir.
24. Close the valve that is installed in the hole for the drain
plug.
25. Disconnect the inlet hose for the portable filter from
the valve. Remove the outlet hose from the reservoir
filler neck and replace filler cap.
26. Connect a vacuum pump to the breather hose of the
hydraulic reservoir.
27. Start the vacuum pump.
28. Remove the valve from the hole for the drain plug.
29. Install the drain plug.
30. Stop the vacuum pump. Disconnect the vacuum
pump from the opening in the reservoir and install the
breather.
31. Remove the hydraulic filter elements from the ma-
chine.
32. Install new hydraulic filter elements on the machine.
33. Start the engine. Check for oil leakage around the new
hydraulic filters.
35. Check the oil level in the hydraulic reservoir. Add oil
as required.
48083741_EN 31/07/2018
35.1 [35.000] / 32
Hydraulic systems - Decontaminating

DANGER
Crushing hazard!
Always install the safety lock before working under the raised attachment.
Failure to comply will result in death or serious injury.
D0075A
1. Start and run the engine at 1500 rpm (r/min).

2. Completely retract the cylinders of all attachments on
the machine. Stop the engine
NOTICE: if retracting the cylinder rods causes the attach-
ment to be raised, block the attachment in place before
proceeding to the next step.
NOTE: any attachment or part of an attachment that is
raised must be supported with acceptable equipment to
prevent the attachment from falling.
3. Move each control lever in both directions to release
pressure in the hydraulic circuits.
4. Loosen and remove the filler cap from the reservoir.
LEIL16WHL0198AA 1
5. Drain the hydraulic oil from the reservoir.

A. Have available acceptable equipment to drain the
hydraulic oil.
B. 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 machine.
9. Install the drain cap in the remote drain.
10. Fill the hydraulic reservoir with hydraulic fluid.
11. Disconnect the line from the OPEN end and CLOSED
end of each cylinder.
12. Be sure all control levers are in the NEUTRAL posi-
tion.
13. Start and run the engine at low idle.
NOTICE: check the oil level in the hydraulic reservoir fre-
quently while doing step 13. Have another person hold a
container under the hydraulic lines while you do step 13.
48083741_EN 31/07/2018
35.1 [35.000] / 33
14. Slowly move each control lever in both directions until

oil begins to flow from the open line. Hold the control
lever in place until clean oil flows from the open line.
16. Connect the system line to the CLOSED end of each
cylinder.
17. Connect a suitable drain line to the OPEN end of each
cylinder and place the other end in an acceptable con-
tainer for contaminated oil.
19. Slowly and completely extend all cylinders. As the pis-
ton rod comes in/out of the cylinder, oil will be pushed
out of the OPEN end of the cylinders.
NOTE: any attachment or part of an attachment that is
raised must be supported with acceptable equipment to
prevent the attachment from falling.
20. Support any attachments that will be in the RAISED
position.
22. Disconnect the drain lines and connect the system
lines to the cylinders.
23. Check the oil level in the hydraulic reservoir. Add oil
as required.
24. Install the filler cap on the reservoir.
25. Remove the hydraulic filter elements from the ma-
chine.
27. Start and run the engine at 1500 rpm(r/min) , operate
each hydraulic circuit to completely extend and retract
the cylinders.
28. Stop the engine and check for leaks. Check the oil
level in the hydraulic reservoir. Add oil as required.
48083741_EN 31/07/2018
35.1 [35.000] / 34
Hydraulic systems - Service instruction - Troubleshooting

N° Test Point Expected Result Other Result (Possible Cause)
1 Condition Result Action
Visually check the machine for YES NO
oil leakage and damaged or Action Fill the hydraulic reservoir with
missing parts. Repair or replace Heat the oil in the hydraulic the hydraulic oil.
any damaged or missing parts. system to operating temperature.
Check the oil level in the hydraulic Operate the machine to find which
reservoir. Is the oil level correct? circuits have problems.
Problems in All Circuits YES NO
Replace the return line hydraulic Action Do the flow meter test of the
filter. Do the stall test to see Clean or replace the oil. hydraulic pump.
if the engine is good. Check
for contaminated oil. Is the oil
contaminated?
Problem in All Loader Circuits YES NO
Check the pressure setting of the Adjust the limit pressure
limit pressure in the loader control
valve. Is the pressure setting
correct?
Problem in the Braking Circuit YES NO
Action
Check the braking circuit.
Problem in a Single Loader Circuit YES NO
Start and run the engine at full Action The loader control valve is
throttle. Operate the control for Go to test 6 damaged.
the bad circuit. Does the cylinder Repair the loader control valve.
move in both directions?
Check the cylinder piston packing. YES NO
Is the packing good? Action Repair the cylinder.
Go to test 7
Check and adjust the circuit relief YES NO
valves. Then check the operation Action Disassemble the loader control
of the circuit again. Does the The problem is repaired. valve and check for worn or
circuit work correctly? damaged pars.
Problem in the Steering Circuit YES NO
Check the steering circuit. Is the Action Repair the component as
steering circuit good? Do the Steering Pump Limit necessary.
Pressure Test and Adjustment
Problem in the Ride Control YES NO
Lift arms rapidly and continuously Action See the Ride Control Test
sink towards the ground. Check the manual bleed valve for Procedure.
the ride control accumulator to be
sure that it is closed.
48083741_EN 31/07/2018
35.1 [35.000] / 35
Index

Hydraulic systems - Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Hydraulic systems - Component localization - Test ports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Hydraulic systems - Decontaminating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Hydraulic systems - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Hydraulic systems - Hydraulic schema - 821G . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Hydraulic systems - Hydraulic schema - 921G . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Hydraulic systems - Service instruction - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Hydraulic systems - Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
48083741_EN 31/07/2018
35.1 [35.000] / 36
Reservoir, cooler, and filters - 300

48083741_EN 31/07/2018
35.2 [35.300] / 1
Contents
SERVICE
Oil cooler/Heat exchanger

Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Thermal bypass valve
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
48083741_EN 31/07/2018
35.2 [35.300] / 2
Hydraulic systems - Reservoir, cooler, and filters
Oil cooler/Heat exchanger - Remove

parking brake.
3. Raise the engine hood and remove the shield on the
right side of the machine between the tire and the oil
cooler.
4. Have assistant hold side panel in raised position, re-
move two mounting screws, remove side panel.
5. Loosen the filler cap on the hydraulic reservoir to re-
lease the air pressure in the reservoir. Connect a vac-
uum pump to the hydraulic reservoir, turn on the pump.
LEIL13WHL1274AB 1
6. Disconnect the top hose and install a plug in the hose

and a cap on the fitting.
LEIL13WHL1275AB 2
7. Loosen and remove the bolt and washer that fasten the
oil cooler to the cooling frame.
LEIL13WHL1276AB 3
48083741_EN 31/07/2018
35.2 [35.300] / 3
8. Disconnect the hose from the bottom of the oil cooler.

Install a plug in the hose and a cap on the fitting. Re-
move the two mounting nuts, remove the oil cooler from
the machine.
LEIL13WHL1277AB 4
48083741_EN 31/07/2018
35.2 [35.300] / 4
Oil cooler/Heat exchanger - Install

1. Place the oil cooler in position in the cooling frame.
Connect the lower hose to the oil cooler, install and
tighten the two mounting nuts.
LEIL13WHL1277AB 1
2. Install the bolt and washer that fasten the oil cooler to
the cooling frame
LEIL13WHL1276AB 2
3. Connect the hose to the top of the oil cooler.
LEIL13WHL1275AB 3
4. Have assistant hold side panel in raised position, install

and tighten two mounting screws.
5. Turn off the vacuum pump and disconnect from the hy-
draulic reservoir.
6. Place the timed disconnect switch in the ON position.
7. Start the engine and run the engine at low idle for two
minutes. Stop the engine and check for hydraulic oil
leakage at the ports on the oil cooler.
8. Install the shield between the right rear tire and the oil
cooler and tighten the two bolts holding the shield.
9. Check the level of the hydraulic oil in the reservoir and LEIL13WHL1274AB 4
add hydraulic oil as required.
48083741_EN 31/07/2018
35.2 [35.300] / 5
Thermal bypass valve - Remove

parking brake.
NOTICE: put the ignition switch in the ON position then
move the joystick back and forth several times to release
any hydraulic pressure in the pilot control circuit, turn igni-
tion switch OFF.
3. Tag and disconnect the hoses from the thermal bypass
valve (A). Install a plug in the hoses and a cap on the
fittings.
4. Remove the mounting bolts from the thermal bypass
valve (A). Remove the thermal bypass valve (A) from
the machine.
LEIL13WHL1284AA 1
48083741_EN 31/07/2018
35.2 [35.300] / 6
Thermal bypass valve - Install

1. Place the thermal bypass valve (A) into position on the
machine.
2. Lubricate and install new O-rings in the fittings.
3. Install the bolts, washers and nuts. Tighten the nuts.
4. Connect the hoses to the thermal bypass valve (A),
remove and discard tags.
draulic reservoir.
6. Check the level of the hydraulic oil in the reservoir.
7. Start the engine and run the engine at low idle for two LEIL13WHL1284AA 1
minutes.
8. Stop the engine and check for hydraulic oil leakage at
the thermal bypass valve (A).
9. Check the level of the hydraulic oil in the reservoir and
add as required. Tighten the filler cap on the reservoir.
48083741_EN 31/07/2018
35.2 [35.300] / 7
Index

Oil cooler/Heat exchanger - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Oil cooler/Heat exchanger - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Thermal bypass valve - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Thermal bypass valve - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
48083741_EN 31/07/2018
35.2 [35.300] / 8
Variable displacement pump - 106

48083741_EN 31/07/2018
35.3 [35.106] / 1
Contents
TECHNICAL DATA
Pump
FUNCTIONAL DATA
Pump
Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
SERVICE
Variable displacement pump

Service instruction - Testing and adjusting the P1 pump differential pressure (*) . . . . . . . . . . . . . . . . . . . . 5
Service instruction - High pressure pump flow test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
48083741_EN 31/07/2018
35.3 [35.106] / 2
Hydraulic systems - Variable displacement pump
Pump - General specification

821G - Pump specifications
Manufacturer Bosch-Rexroth
High pressure pump (closest to transmission) 120 L/min (32 US gpm) at 172 bar (2494 psi), at
2000 RPM
Low pressure pump (furthest from transmission) 120 L/min (32 US gpm) at 172 bar (2494 psi), at
2000 RPM
Rotation Clockwise as seen from the end of the shaft
Special torques
Pump end cover bolts 165 N·m (122 lb ft)
Pump housing plug 127 N·m (94 lb ft)
Control piston plug 90 N·m (66 lb ft)
921G - Pump specifications

Manufacturer Bosch-Rexroth
High pressure pump (closest to transmission) 170 L/min (45 US gpm) at 24822 kPa (3600 psi), at
2000 RPM
Low pressure pump (furthest from transmission) 120 L/min (32 US gpm) at 24822 kPa (3600 psi), at
2000 RPM
Rotation Clockwise as seen from the end of the shaft
Special torques
Pump end cover bolts 165 N·m (122 lb ft)
Pump housing plug 127 N·m (94 lb ft)
Control piston plug 90 N·m (66 lb ft)
48083741_EN 31/07/2018
35.3 [35.106] / 3
Pump - Component identification
LEIL13WHL1298GB 1
1. Snap ring 11. Tapered bearing 21. Pressure pins

2. Seal 12. Bearing race 22. Backup plate
3. Main body 13. Shim 23. Spring
4. O-ring 14. Spring 24. Snap ring
5. Plug 15. Half bearing 25. Port plate
6. Control valve 16. Swash plate 26. Shim
7. Cap screw 17. Pistons 27. Tapered bearing
8. Piston rod 18. Retaining plate 28. Bearing race
9. Control piston 19. Ball 29. Dowel pin
10. Shaft 20. Cylinder 30. End cover
48083741_EN 31/07/2018
35.3 [35.106] / 4
Variable displacement pump - Service instruction - Testing and

adjusting the P1 pump differential pressure
Pressure check
2. Make sure that the temperature of the hydraulic oil is
at least 54 – 57 °C (129 – 135 °F). The following is the
procedure for heating the hydraulic oil.
● To measure the oil temperature with the instrument
cluster:
A. Press the up or down arrow key.
B. Stop at the info screen with the temperatures that
need to be monitored are on.
● 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 ROLLBACK posi-
tion while raising and lowering the lift arms from ground LEIL13WHL1236AA 1
C. Continue this procedure until the temperature of the
After heating oil to operating temperature, lower bucket
to the ground, turn off the engine, and relieve all pres-
sure in the hydraulic system.
3. Connect two test gauges, one to the test port (TP5) (2)
located on the “G1” port of the priority valve, and one
on the test port (TP3) (1) on the “LS1” port of the priority
valve.
NOTICE: Do not steer or operate loader controls while the
gauges are connected, gauges could be damaged.
5. Make sure all of the controls are in the neutral position
and record the readings on the test portes (1) and (2).
6. Subtract the reading of the test port (1) from the reading
of the test port (2).
LEIL18WHL0691AB 2
7. The difference between the two readings should be 28
– 30 bar (406 – 435 psi).
8. If this reading is more or less than specified, it will
be necessary to adjust the pump load-sense pressure.
Refer to procedure “High pressure pump differential
pressure adjustment".
Adjusting the P1 pump differential pressure

1. The load-sense adjusting screw is directly below the
load-sense pressure tap. Turn the screw clockwise to
increase the load-sense pressure. Turning the screw
counterclockwise will decrease the load-sense pres-
sure.
NOTE: one turn of the adjustment screw will change the
pressure approximately 16 bar (232 psi).
48083741_EN 31/07/2018
35.3 [35.106] / 5

Pressure check
cluster:
tion while raising and lowering the lift arms from ground LEIL13WHL1236AA 1
valve.
NOTICE: Do not steer or operate loader controls while the
and record the readings on the test portes (1) and (2).
LEIL18WHL0861AB 2
– 26 bar (348 – 377 psi).
Refer to procedure “High pressure pump differential
pressure adjustment".

sure.
48083741_EN 31/07/2018
35.3 [35.106] / 6

Pressure check
1. Install articulation lock.
cluster:
LEIL13WHL1236AA 1
valve.
NOTICE: do not steer or operate loader controls while the
and record the readings on the test gauges (1) and (2).
LEIL18WHL0692AB 2
– 26 bar (348 – 377 psi).
Adjusting the High Pressure Pump Differential Pres-
sure

sure.
48083741_EN 31/07/2018
35.3 [35.106] / 7

Pressure check
1. Install articulation lock.
cluster:
LEIL13WHL1236AA 1
valve.
NOTICE: do not steer or operate loader controls while the
and record the readings on the test gauges (1) and (2).
LEIL18WHL0862AB 2
– 23 bar (304.5 – 333.5 psi).
Adjusting the High Pressure Pump Differential Pres-
sure

sure.
48083741_EN 31/07/2018
35.3 [35.106] / 8
Variable displacement pump - Service instruction - High pressure

pump flow test
LEIL16WHL1809GB 1
1. Hydraulic return manifold 6. Pressure hose 11. Flow meter inlet hose
2. Flow meter return hose 7. Load sense hose 12. Cap
3. Flow meter 8. Needle valve 13. Split flange clamp
4. Pumps 9. Union 14. Loader valve
5. Priority valve 10. T fitting
NOTE: if unit is equipped with auxiliary steering a tee fitting will have to be used in the connection to the hydraulic
return manifold.
48083741_EN 31/07/2018
35.3 [35.106] / 9
NOTE: the pump differential pressure must be set before attempting any other tests.
1. Remove the split flange clamp (13) to disconnect the
pressure hose (6) from the loader valve (14).
2. Disconnect the load sense hose (7) from the loader
valve (14) and install a cap (12) to the fitting.
NOTE: this is the line that returns to the pump compensator
valve.
3. Mount the flow meter CAS10280 (3). Connect the flow
meter inlet hose (11) to the pressure hose (6) through
the T fitting (10). Use a union (9) and connect the open
port of T fitting (10) to the load sense hose (7) through
an in-line needle valve (8). Connect the flow meter
return hose (2) to the hydraulic return manifold (1).
4. Make sure that the flow meter valve and the installed
needle valve are in the open position. Start and run the
engine at high idle, slowly close the flow meter valve
until a pressure reading of 103 bar (1494 psi) is ob-
tained.
5. Using the temperature gauge on the flow meter, con-
tinue to run the engine at high idle until the temperature
of the hydraulic oil is at least 52 – 60 °C (126 – 140 °F).
6. Run the engine at low idle, fully open the flow meter
valve.
7. Open the needle valve (8) and operate the engine at
2000 RPM. At 0 bar (0 psi) the flow should be 250 –
255 L/min (66 – 67 US gpm).
8. Close the flow meter valve slowly and read the flow at
34.5 bar (500 psi) the flow should be 249 – 255 L/min
(66 – 67 US gpm).
9. Close the flow meter valve slowly and read the flow at
2000 RPM. The flow should read 244 – 247.5 L/min
(64 – 65 US gpm).
10. Continue slowly closing the flow meter valve until
227.6 bar (3300 psi) is reached. The flow should
read 231 L/min (61 US gpm).
11. If any of the pump flow readings are not within spec-
ifications, the pump may be out of calibration contact
your dealer.
48083741_EN 31/07/2018
35.3 [35.106] / 10
Variable displacement pump - Remove

LEIL13WHL1257GB 1
1. Main hydraulic pump 7. Suction hose 13. Loader high pressure hose
2. Mount bolts 8. Case drain hose 14. Steering priority valve
3. Drain hose 9. Steering high pressure hose 15. Clamps
4. Bolt 10. Clamps 16. Fittings
5. Split flange 11. Steering load sense hose
6. Tube 12. Loader load sense hose
NOTE: when disconnecting the hydraulic fittings, plug the hoses and cap the fittings to prevent entry of foreign matter
into the hydraulic system.
48083741_EN 31/07/2018
35.3 [35.106] / 11

bucket to the floor. Stop the engine and apply the park-
ing brake.
3. Drain the tank.
4. Remove the ROPS cab.
5. Remove the eight bolts (4) and the washers. Remove
the four split flanges (5). Disconnect the tubes (6) with
the suction hoses (7) from the hydraulic pump. Re-
move and discard the O-ring face seals from the flange
heads of the tubes.
6. Loosen the clamps (10). Tag and disconnect the suc-
tion hoses (7) from the hydraulic reservoir and remove
from the machine.
7. Tag and disconnect the case drain hoses (8) from the
fittings (16). Remove the hoses (8). Remove and dis-
card the O-ring face seals from the fittings.
8. Tag and disconnect the load sense hoses (11) and (12).
Remove and discard the O-ring face seals from the
fittings.
9. Tag and disconnect the drain hose (3). Remove and
discard the O-ring face seals from the fittings.
10. Tag and disconnect the pump pressure hoses (9) and
(13) from the steering priority valve (14). Remove and
discard the O-ring face seals from the flange heads of
the hoses.
11. Connect the lifting equipment to the hydraulic pump
(1). Take up all slack in a lifting equipment. Remove
the four mounting bolts (2) and the washers securing
the pump to the transmission. Pull the hydraulic pump
from the transmission and remove from the machine.
Remove and discard the O-ring from the pump.
48083741_EN 31/07/2018
35.3 [35.106] / 12
Variable displacement pump - Install

LEIL13WHL1257GB 1
1. Main hydraulic pump 7. Suction hose 13. Loader high pressure hose
2. Mount bolts 8. Case drain hose 14. Steering priority valve
3. Drain hose 9. Steering high pressure hose 15. Clamps
4. Bolt 10. Clamps 16. Fittings
5. Split flange 11. Steering load sense hose
6. Tube 12. Loader load sense hose
48083741_EN 31/07/2018
35.3 [35.106] / 13
NOTE: install new O-rings where required.

1. Install a new O-ring on the hydraulic pump flange.
Move the pump (1) into position and install to the
transmission. Install the four bolts (2) with the related
washers to secure the pump (1) to the transmission.
Tighten the bolts (2). Disconnect the lifting equipment
from the pump.
2. Connect the pump pressure hoses (9) and (13) to the
steering priority valve (14).
3. Connect the drain hose (3).
4. Connect the load sense hoses (11) and (12).
5. Install and connect the case drain hoses (8).
6. Install new O-rings in the flange heads of the tubes (6).
Install the suction hoses (7) with the tubes (6). Tighten
the clamps (10) to 10 – 11 N·m (7 – 8 lb ft).
7. Install the four split flanges (5). Install the eight bolts
(4) with the related washers. Tighten the bolts (4) to 73
– 90 N·m (54 – 66 lb ft).
8. Install the ROPS cab.
9. Add oil to hydraulic tank.
minutes.
NOTE: if any unusual vibration is heard coming from the
pump, stop the machine immediately and check for ob-
structions in the pump suction line.
the hydraulic pump.
48083741_EN 31/07/2018
35.3 [35.106] / 14
Variable displacement pump - Remove

LEIL16WHL0540GB 1
1. Main hydraulic pump 5. Split flange 9. Priority tank hose 13. Pressure hose
2. Mount bolts 6. Tube 10. Clamps 14. Steering priority valve
3. Split flange 7. Suction hose 11. Bolt 15. Clamps
4. Bolt 8. Drain hose 12. Load sense hose 16. O-ring
NOTE: when disconnecting the hydraulic fittings, plug the hoses and cap the fittings to prevent entry of foreign matter
into the hydraulic system.
48083741_EN 31/07/2018
35.3 [35.106] / 15

ing brake.
3. Drain the hydraulic tank.
4. Remove the ROPS cab.
5. Remove the eight bolts (4) and the washers. Remove
the four split flanges (5). Disconnect the tubes (6)
with the suction hoses (7) from the hydraulic pump.
Remove and discard the O-rings (16) from the flange
heads of the tubes (6).
6. Loosen the clamps (10). Tag and disconnect the suc-
tion hoses (7) from the hydraulic reservoir and remove
from the machine.
7. Tag and disconnect the drain hoses (8) from the hy-
draulic reservoir. Remove the case drain hoses (8)
from the main hydraulic pump (1).
8. Tag and disconnect the load sense hose (12). Remove
and discard the O-ring face seals from the fitting.
9. Remove the bolts (11) and the washers. Remove the
split flanges (3). Tag and disconnect the pressure hose
(13). Remove and discard the O-ring face seals from
the flange head of the hose
10. Tag and disconnect the priority tank hose (9) from the
steering priority valve (14). Remove and discard the
O-ring face seal from the flange head of the hose.
11. Connect the lifting equipment to the hydraulic pump
(1). Take up all slack in a lifting equipment. Remove
the four mounting bolts (2) and the washers securing
the pump to the transmission. Pull the hydraulic pump
from the transmission and remove from the machine.
Remove and discard the O-ring from the pump.
48083741_EN 31/07/2018
35.3 [35.106] / 16
Variable displacement pump - Install

LEIL16WHL0540GB 1
1. Main hydraulic pump 5. Split flange 9. Priority tank hose 13. Pressure hose
2. Mount bolts 6. Tube 10. Clamps 14. Steering priority valve
3. Split flange 7. Suction hose 11. Bolt 15. Clamps
4. Bolt 8. Drain hose 12. Load sense hose 16. O-ring
48083741_EN 31/07/2018
35.3 [35.106] / 17
NOTE: install new O-rings where required.

1. Install a new O-ring on the hydraulic pump flange.
Move the pump (1) into position and install to the
transmission. Install the four bolts (2) with the related
washers to secure the pump (1) to the transmission.
Tighten the bolts (2). Disconnect the lifting equipment
from the pump.
2. Connect the priority tank hose (9) to the steering priority
valve (14).
3. Connect the pressure hose (13) to the steering priority
valve (14). Install the split flanges (3). Install the bolts
(11) with the related washers. Tighten the bolts (11).
4. Connect the load sense hose (12).
5. Install and connect the drain hoses (8).
6. Install new O-rings (16) in the flange heads of the tubes
(6). Install the suction hoses (7) with the tubes (6).
Tighten the clamps (10) to 10 – 11 N·m (7 – 8 lb ft).
7. Install the four split flanges (5). Install the eight bolts
(4) with the related washers. Tighten the bolts (4) to 73
– 90 N·m (54 – 66 lb ft).
8. Install the ROPS cab.
9. Turn OFF the vacuum pump and disconnect from the
hydraulic tank. Add oil to hydraulic tank.
minutes.
NOTE: if any unusual vibration is heard coming from the
pump, stop the machine immediately and check for ob-
structions in the pump suction line.
the hydraulic pump.
48083741_EN 31/07/2018
35.3 [35.106] / 18
Index

Pump - Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Pump - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Variable displacement pump - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Variable displacement pump - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Variable displacement pump - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Variable displacement pump - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Variable displacement pump - Service instruction - High pressure pump flow test . . . . . . . . . . . . . . . 9
Variable displacement pump - Service instruction - Testing and adjusting the P1 pump differential
pressure (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
pressure (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
pressure (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
pressure (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
48083741_EN 31/07/2018
35.3 [35.106] / 19
48083741_EN 31/07/2018
35.3 [35.106] / 20
Main control valve - 359

48083741_EN 31/07/2018
35.4 [35.359] / 1
Contents
TECHNICAL DATA
Main control valve

FUNCTIONAL DATA
Main control valve

Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
SERVICE
Main control valve

Service instruction - Testing and adjusting the circuit relief valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Remove - Loader control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
48083741_EN 31/07/2018
35.4 [35.359] / 2
Hydraulic systems - Main control valve
Main control valve - General specification

Manufacturer Rexroth
Special Torques
End plate mounting bolts 70 N·m (52 lb ft)
Pressure relief, flow limit, and pilot pressure reducing 20 – 25 N·m (15 – 18 lb ft)
valves
Allen head plugs 240 N·m (177 lb ft)
Allen head locking screw. 100 N·m (74 lb ft)
Allen head cover screws (short) 10.4 N·m (8 lb ft)
Allen head cover screws (long) 6 N·m (4 lb ft)
Anticavitation valves 100 N·m (74 lb ft)
Combination anticavitation and circuit relief 200 N·m (148 lb ft)
Main relief valve pressure settings 248 – 252 bar (3596 – 3654 psi)
Circuit relief valve pressure setting
Auxiliary A and B port 290 bar (4205 psi)
Bucket A port 152 bar (2204 psi)
Bucket B port 290 bar (4205 psi)
48083741_EN 31/07/2018
35.4 [35.359] / 3
Main control valve - Exploded view

2 spool valve housing configuration
LEIL13WHL1335GB 1
1. Bolt 9. Load sense bleed down orifice 17. Spring

2. Washer 10. Flow compensator spool 18. Load check
3. Locking screws 11. Housing 19. Flow limit valve
4. Plate 12. Plug 20. Pressure relief valve
5. Regeneration relief valve 13. Float solenoid 21. Cone
6. O-rings 14. Plug 22. Locking screw
7. Load sense shuttle check 15. Regeneration check valve
8. Anticavitation and circuit relief 16. Locking screw
48083741_EN 31/07/2018
35.4 [35.359] / 4
2 spool configuration
LEIL13WHL1336FB 2
6. O-rings 27. Bolt 32. Bolt

23. Spring retainer 28. Piston 33. Cover
24. Spring 29. Piston 34. Adjusting rod
25. Spring 30. Cap nut 35. Spool
26. Cover 31. Piston
48083741_EN 31/07/2018
35.4 [35.359] / 5
3 spool mounting configuration
LEIL13WHL1337FB 3
36. Housing 37. Anticavitation and circuit relief
48083741_EN 31/07/2018
35.4 [35.359] / 6
4 spool mounting configuration
LEIL13WHL1338FB 4
38. Nut 39. Stud
48083741_EN 31/07/2018
35.4 [35.359] / 7
3 and 4 valve spool configuration
LEIL13WHL1339GB 5
6. O-rings 31. Piston

23. Spring retainer 32. Bolt
24. Spring 33. Cover
29. Cap nut 34. Adjusting rod
30. Jam nut 35. Spool
48083741_EN 31/07/2018
35.4 [35.359] / 8
Main control valve - Service instruction - Testing and adjusting the

circuit relief valves
Pressure check
1. Circuit relief valves are located as shown below.
1. Circuit relief valves
2. Pump limit pressure adjustment
3. Bucket spool
4. Lift spool
5. Auxiliary spool
6. Main control valve
2. Raise the lift arms and install the safety strut on the lift
arm cylinder.
3. Loosen and remove the bolts and washers that fasten
the access cover plate for the main control valve. Re-
move the cover plate.
4. Remove the safety strut and lower the bucket to the
floor. Shut off the engine. Find an easy place to dis-
connect the line for the circuit to be tested.
5. Connect the hand pump 5870 287 007 to the discon-
nected line that goes to the main control valve.
6. Make sure that the hand pump 5870 287 007 is full
of hydraulic oil and that the temperature of the oil is
approximately 21 °C (70 °F).
7. Operate the handle of the hand pump 5870 287 007
and read the highest pressure. Repeat this step sev-
LEIL13WHL1295BB 1
eral times to be sure of the reading.
8. Compare the reading to the specifications.
9. If the pressure is not correct, adjust the circuit relief
valve.
Adjustment
1. Loosen the lock nut. Turn the adjustment screw clock-
wise to increase the pressure or counterclockwise to
decrease the pressure.
NOTE: one turn of the adjusting screw will change the pres-
sure approximately 138 bar (2001 psi).
2. Check the pressure again. Repeat the adjustment as
necessary.
48083741_EN 31/07/2018
35.4 [35.359] / 9
Main control valve - Remove - Loader control valve

NOTICE: if the machine is equipped with quick-attached
components, disconnect them from the machine prior to
proceed.
arm cylinder.
3. Stop the engine and apply the parking brake.
NOTE: with the engine NOT running, pump the brake re-
peatedly to be sure the brake accumulators have no hy-
draulic pressure, put the ignition switch in the ON position
then move the loader control EH joystick back and forth
several times to release any hydraulic pressure in the pilot
control circuit, then turn the ignition switch to OFF.
LEIL13WHL1244AA 1
5. Relieve the pressure in the ride control accumulator

with the manual bleeder valve located on the top of the
ride control valve. Remove the plug and turn the valve
two turns counter-clockwise.
6. Loosen the filler cap on the reservoir to release the air
pressure in the reservoir.
7. Drain the hydraulic reservoir.
LEIL13WHL1245AB 2
8. Loosen and remove the bolts and the washers that fas-
ten the access cover plate for the loader control valve.
Remove the cover plate.
LEIL13WHL1246AB 3
NOTE: the following instructions refer to the 4–spool main control valve.
48083741_EN 31/07/2018
35.4 [35.359] / 10
9. Disconnect and tag the following hoses from the upper

side of the main control valve:
• (A) Pressure hose
• (B) Main valve return hose
• (C) Ride control hose
• (D) Tilt hose
• (E) Lifting arm hose
• (F) Auxiliary hose (left–hand)
• (G) Load sense hose
• (H) Auxiliary hose (right–hand)
• (I) Pilot pressure hose
• (J) Ride control hose
• (K) Tilt hose
NOTE: install a protective plug in the disconnected hoses
and a protective cap on the hydraulic fittings.
LEIL16WHL1015FA 4
Upper side of the main control valve
48083741_EN 31/07/2018
35.4 [35.359] / 11
10. Disconnect and tag the following hoses from the lower
side of the main control valve:
• (A) Ride control hose
• (B) Rollback hose (orange)
• (C) Pilot raise hose (yellow)
• (D) Third function hose (red-white)
• (E) Lift cylinder hose (raise)
• (F) Lift cylinder hose (lower)
• (G) Third function hose (yellow-white)
• (H) Pilot lower hose (red)
• (I) Pilot dump hose (green)
NOTE: install a protective plug in the disconnected hoses
and a protective cap on the hydraulic fittings.
LEIL16WHL1016FA 5
Lower side of the main control valve
48083741_EN 31/07/2018
35.4 [35.359] / 12
11. Install a proper lifting equipment to the main control

valve.
NOTE: the weight of the main control valve is approxi-
mately 75 kg (165 lb).
12. Loosen and remove the bolts, the spacers, and the
washers that hold the main control valve to the valve
mounting plate. Remove the main control valve.
LEIL13WHL1249AA 6
48083741_EN 31/07/2018
35.4 [35.359] / 13
Main control valve - Disassemble

1. Remove the main control valve from the machine.
NOTE: refer to Main control valve - Exploded view
(35.359) for the numbering in this procedure.
2. Remove the bolts (27), the cover (26), the springs (24)
and (25), and the spring retainer (23).
3. Remove the bolts (32), the covers (33), the spring (24),
and the spring retainer (23).
4. Use a wooden dowel or a brass drift and push the
spools (35) from the housing (11).
NOTICE: do not force the spools from the housing, if a
spool binds, work back and forth until the spool comes out
freely.
NOTE: repeat steps 3 and 4 for a 3 and 4 spool valve con-
figuration.
5. Remove the anti-cavitation valves (5), (8), (10) and
(13).
NOTE: repeat the step 5 for a 3 and 4 spool anti-cavitation
valves (37).
6. Remove the locking screw (22) and the cone (21).
7. Remove the pressure relief valve (20).
8. Remove the flow limit valve (19).
9. Remove the locking screw (16), the spring (17), and the
cone (18).
10. Remove the regeneration check valve (15).
11. Remove the locking screw (14).
12. Remove the load sense shuttle check valve (7).
13. Remove the locking screws (12).
14. Remove the pilot pressure reducing valve (9).
15. Remove the bolts (1) and the washers (2), remove the
plate (4) from the housing (11).
NOTE: for a 4 spool configuration remove the nut (38) from
the stud (39), remove the housings (36) from the housing
(11).
16. Remove and discard the O-rings (1) and the thrust
rings (2) from the pilot pressure reducing valve (9).
LEIL13WHL1340AB 1
48083741_EN 31/07/2018
35.4 [35.359] / 14
17. Remove and discard the O-rings (1) and the thrust
rings (2) from the flow limit valve (19).
LEIL13WHL1341AB 2
18. Remove and discard the O-rings (1) and the thrust ring
(2) from the locking screw (14).
LEIL13WHL1342AB 3
19. Remove and discard the O-rings (1), the thrust ring (2)
and the spool seal from the anti-cavitation valve (5).
LEIL13WHL1343AB 4
48083741_EN 31/07/2018
35.4 [35.359] / 15
20. Remove and discard the O-rings and the thrust rings
from the pressure relief valve (20).
LEIL13WHL1344FB 5
1. O-rings 2. Thrust rings
48083741_EN 31/07/2018
35.4 [35.359] / 16
from the anti-cavitation and pressure relief valves
(10).
LEIL13WHL1345FB 6
48083741_EN 31/07/2018
35.4 [35.359] / 17
from the anti-cavitation valve (13).
LEIL13WHL1346FB 7
1. O-rings 2. Coil
48083741_EN 31/07/2018
35.4 [35.359] / 18
from the anti-cavitation and circuit relief valves (8) and
(37).
LEIL13WHL1347FB 8
1. O-rings 3. Spool seal

2. Thrust rings 4. Lock nut
48083741_EN 31/07/2018
35.4 [35.359] / 19
Main control valve - Inspect

1. Discard all O-rings, thrust rings, and spool seals.
2. Clean all parts in cleaning solvent.
3. Inspect the spools and the spool bores for damage and
wear.
4. Inspect the following components for excessive wear or
damage. Replace with new components as required.
• Pressure relief valve
• Anticavitation valve
• Anticavitation and circuit relief valve
5. Inspect all other control valve components for exces-
sive wear or damage. Replace with new components
as required.
48083741_EN 31/07/2018
35.4 [35.359] / 20
Main control valve - Assemble

1. Install new O-rings and thrust rings on the anti-cavita-
tion and circuit relief valves (8) and (37). Torque the
relief valve (A) into the anti-cavitation valve to 200 N·m
(148 lb ft).
NOTE: spool seal mounting position is critical, the seal
must be mounted with the lip facing as shown above, pres-
sure is in the direction of the arrow.
LEIL13WHL1347FB 1
1. O-rings 3. Spool seal

2. Thrust ring 4. Lock nut
48083741_EN 31/07/2018
35.4 [35.359] / 21
2. Install new O-rings and thrust rings on the anti-cavita-

tion valve (13). Hand tighten the coil nut (A).
LEIL13WHL1348FB 2
1. O-rings 2. Coil
48083741_EN 31/07/2018
35.4 [35.359] / 22
3. Install new O-rings (1) and thrust rings (2) on the anti-
cavitation and pressure relief valves (10). Torque the
cap (A) to 100 N·m (74 lb ft).
LEIL13WHL1349FB 3
48083741_EN 31/07/2018
35.4 [35.359] / 23
4. Install new O-rings (1) and thrust rings (2) on the pres-
sure relief valve (20).
LEIL13WHL1350FB 4
5. Install new O-rings (1) and thrust rings (2) on the pilot
pressure reducing valve (9).
LEIL13WHL1340AB 5
48083741_EN 31/07/2018
35.4 [35.359] / 24
6. Install new O-rings (1) and thrust rings (2) on the flow
limit valve (19).
LEIL13WHL1341AB 6
7. Install new O-rings (1) and a new thrust ring (2) on the
locking screw (14).
LEIL13WHL1342AB 7
8. Install new O-rings (1), a new thrust ring (2) and a spool
seal (3) on the anti-cavitation valve (5).
LEIL13WHL1343AB 8
48083741_EN 31/07/2018
35.4 [35.359] / 25
9. Install and torque the regeneration check valve (15) to

100 N·m (74 lb ft).
10. Install and torque the locking screw (14) to 100 N·m
(74 lb ft).
11. Install and tighten the load sense shuttle check valve
(7).
12. Install and torque the locking screws (12) to 240 N·m
(177 lb ft).
13. Install and torque the pilot pressure reducing valve (9)
to 60 N·m (44 lb ft).
14. Install new O-rings on the housing (11). Install the
plate (4), the bolts (1) and the washers (2), onto the
housing (11). Torque the bolts to 70 N·m (52 lb ft).
NOTE: for a 4 spool configuration install new O-rings be-
tween the housings (36) and the housing (11), install the
nuts (38) on the studs (39). Torque the nuts to 70 N·m
(52 lb ft).
15. Install the anti-cavitation valves (5), (10) and (13) and
torque to 100 N·m (74 lb ft).
NOTE: repeat the step 15 for 3 and 4 spool anti-cavitation
valves (37).
16. Install the anti-cavitation valves (8) and torque to
200 N·m (148 lb ft).
17. Install and torque the flow limit valve (19) to 20 –
25 N·m (15 – 18 lb ft).
18. Install the cone (18), the spring (17), the locking screw
(16). Torque the locking screw to 100 N·m (74 lb ft).
19. Install the cone (21) and the locking screw (22).
Torque the locking screw to 40 N·m (30 lb ft).
20. Lubricate the spools with hydraulic oil and push the
spools (35) into the housing (11).
NOTE: do not force the spools into the housing.
21. Install the spring retainers (23), the springs (24), the
covers (33) and the bolts (32). Torque the bolts to
10.4 N·m (7.7 lb ft).
NOTE: repeat steps 18 and 19 for a 3 and 4 spool valve
configuration.
22. Install the spring retainers (23), the spring (24) and
(25), the cover (26) and the bolts (27). Torque the
bolts to 6 N·m (4 lb ft).
NOTE: circuit reliefs can be tested before the installation
on the machine.
23. Install the main control valve on the machine.
24. Check the loader limit pressure.
48083741_EN 31/07/2018
35.4 [35.359] / 26
Circuit relief pressure test

1. Connect the hand pump 5870 287 007 to the port for
the anti-cavitation and circuit relief valves (21).
NOTE: repeat the step for machines that are configured
with a 3 or 4 spool valve.
2. Make sure that the hand pump 5870 287 007 is full
of hydraulic oil and that the temperature of the oil is
approximately 21 °C (70 °F).
3. Operate the handle of the hand pump 5870 287 007
and read the highest pressure. Repeat this step sev-
eral times to be sure of the reading.
4. If the pressure is not correct, adjust the circuit relief
valve.
Circuit relief adjustment

1. Loosen the lock nut. Turn the adjustment screw clock-
wise to increase the pressure or counterclockwise to
decrease the pressure.
NOTE: one turn of the adjusting screw will change the pres-
sure approximately 138 bar (2001 psi).
2. Check the pressure again. Repeat the adjustment as
necessary.
48083741_EN 31/07/2018
35.4 [35.359] / 27
Main control valve - Install

NOTE: before installing the fittings or connecting the hoses to the fittings, install new O-rings on the fittings.
NOTE: remove the protective caps and the protective plugs from the fittings and hoses before installing.
1. Install a proper lifting equipment to the main control
valve.
NOTE: the weight of the main control valve is approxi-
mately 75 kg (165 lb).
2. Put the main control valve in position on the valve
mounting plate.
3. Install the bolts, the spacers, and the washers that fas-
ten the main control valve to the valve mounting plate.
Tighten the bolts.
4. Connect the following hoses to the lower side of the
main control valve:
LEIL13WHL1249AA 1
LEIL16WHL1016FA 2
Lower side of the main control valve
(A) Ride control hose (F) Lift cylinder hose (lower)

(B) Rollback hose (orange) (G) Third function hose (yellow-white)
(C) Pilot raise hose (yellow) (H) Pilot lower hose (red)
(D) Third function hose (red-white) (I) Pilot dump hose (green)
(E) Lift cylinder hose (raise)
48083741_EN 31/07/2018
35.4 [35.359] / 28
5. Connect the following hoses to the upper side of the

main control valve:
LEIL16WHL1015FA 3
Upper side of the main control valve
(A) Pressure hose (G) Load sense hose

(B) Main valve return hose (H) Auxiliary hose (right–hand)
(C) Ride control hose (I) Pilot pressure hose
(D) Tilt hose (J) Ride control hose
(E) Lifting arm hose (K) Tilt hose
(F) Auxiliary hose (left–hand)
6. Fill the hydraulic reservoir with oil.
7. Tighten the accumulator manual bleeder valve located
on the top of the ride control valve to a torque of 3.5 N·m
(2.6 lb ft). Install the plug and torque to 7 N·m (5 lb ft).
8. Place the timed disconnect switch to the ON position.
9. Raise the loader arms and remove the safety strut.
10. Run engine at half throttle.
11. Slowly and completely extend and retract all cylinders
at least 10 times to remove any air from the circuits.
12. Stop the engine and check for leaks.
13. Install the access cover on the front of the machine.
14. Check the level of the hydraulic oil and add hydraulic
oil as required.
LEIL13WHL1244AA 4
48083741_EN 31/07/2018
35.4 [35.359] / 29
Index

Main control valve - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Main control valve - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Main control valve - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Main control valve - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Main control valve - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Main control valve - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Main control valve - Remove - Loader control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Main control valve - Service instruction - Testing and adjusting the circuit relief valves . . . . . . . . . . . 9
48083741_EN 31/07/2018
35.4 [35.359] / 30
Pilot system - 357

48083741_EN 31/07/2018
35.5 [35.357] / 1
Contents
Pilot system - 357
TECHNICAL DATA
Pilot accumulator
SERVICE
Pilot solenoid valve block

Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
48083741_EN 31/07/2018
35.5 [35.357] / 2
Hydraulic systems - Pilot system
Pilot accumulator - General specification

Pilot accumulator fluid capacity: 0.75 liters ( 45 cu. inch)
Pre-charge pressure with dry nitrogen: 13 – 15 bar (188.5 – 217.5 psi) at 20 °C (68 °F)
Pilot accumulator maximum operating pressure: 210 bar ( 3046 psi)
NOTE: refer to the following table when check the pre-charge pressure.
Temperature Charge pressure

0 °C (32 °F) 13.0 bar (188.5 psi)
5 °C (41 °F) 13.3 bar (192.9 psi)
10 °C (50 °F) 13.5 bar (195.8 psi)
15 °C (59 °F) 13.8 bar (200.1 psi)
20 °C (68 °F) 14.0 bar (203.0 psi)
25 °C (77 °F) 14.2 bar (205.9 psi)
30 °C (86 °F) 14.5 bar (210.2 psi)
35 °C (95 °F) 14.7 bar (213.1 psi)
40 °C (104 °F) 15.0 bar (217.5 psi)
48083741_EN 31/07/2018
35.5 [35.357] / 3
Hydraulic systems - Pilot system
Pilot solenoid valve block - Check

Pressure check
NOTE: this pressure is factory preset and is not adjustable.
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:
B. Hold the bucket control lever in the ROLLBACK
position while raising and lowering the lift arms from
ground level to full height.
C. Continue this procedure until the temperature of
the hydraulic oil is 54 – 57 °C (129.2 – 134.6 °F) .
2. Raise lift arms to the top and turn off the engine. Turn
the ignition switch to the “RUN” position.
3. Repeatedly put the loader control lever into “FLOAT”
position and back to neutral. This should be done as
rapid as possible.
4. The system should allow a minimum of 10 actuations
into float and still cause the lift arms to come down.
NOTE: steps 1 through 4 are testing the pilot accumulator. If 10 full actuations cannot be made, an internal hydraulic
leak exists, proceed to next step.
5. Start the machine, lower the bucket to the ground, and
turn off the engine. Turn the ignition switch to the “RUN”
position and operate the pilot controls a minimum of 30
strokes to relieve any pressure in the system.
6. Open the right-hand side compartment to gain access
to the loader control valve.
7. Attach a gauge capable of reading 70 bar (1015.0 psi)
to the test port located on the loader control valve.
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 – 40 bar (421 – 580 psi)
should be obtained. If the pressure is not as specified,
replace the pilot pressure reducing valve. This valve is
part of the loader control valve. Retest as required.
10. Lower the bucket to the ground and turn off the engine.
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 and retest. If the accumulator
test is good, go to the next step.
12. Replace the pilot control valve and the loader control
valve and retest the system.
48083741_EN 31/07/2018
35.5 [35.357] / 4
Index
Pilot system - 357

Pilot accumulator - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Pilot solenoid valve block - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
48083741_EN 31/07/2018
35.5 [35.357] / 5
48083741_EN 31/07/2018
35.5 [35.357] / 6
Remote control valves - 204

48083741_EN 31/07/2018
35.6 [35.204] / 1
Contents
SERVICE
Electro-hydraulic control valve

Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
48083741_EN 31/07/2018
35.6 [35.204] / 2
Hydraulic systems - Remote control valves
Electro-hydraulic control valve - Remove

NOTICE: if machine is equipped with quick-attached com-
ponents, disconnect them from machine prior to proceed-
ing.
arm cylinder.
LEIL13WHL1244AA 1
3. Put the articulation lock in the LOCKED position.
RAPH12WEL1412AA 2

NOTE: with the engine NOT running, pump the brake re-
peatedly to be sure the brake accumulators have no hy-
draulic pressure, put the ignition switch to the ON position
and move the joystick all directions several times to release
any hydraulic pressure in the pilot control circuit. Turn the
ignition key to the OFF position.
5. Turn the timed disconnect switch in the OFF position.
LEIL13WHL1245AB 3
48083741_EN 31/07/2018
35.6 [35.204] / 3
7. Loosen the filler cap on the reservoir to release the air

pressure in the reservoir.
lease any air pressure in the reservoir. Connect the
vacuum pump CAS10192 to the hydraulic reservoir.
Turn on the vacuum pump CAS10192.
9. Loosen and remove the bolts and washers that fasten
the access cover plate for the electro-hydraulic control
valve. Remove the cover plate.
LEIL13WHL1246AB 4
10. Locate the electro-hydraulic control valve in the front

side of the machine.
LEIL17WHL1151AB 5
NOTE: the procedure showed from step 11 to step 20 refers to a machine equipped with a 4th function electro-hy-
draulic control valve, but it is similar also to the 3rd function electro-hydraulic control valve.
11. Disconnect the electrical connectors (1) ( A, B, C, D,
E, F, G, H connectors of the front chassis harness)
from the electro-hydraulic control valve.
Disconnect the electrical connector (2) ( PST connec-
tor of the front chassis harness) from the electro-hy-
draulic control valve.
LEIL17WHL1152AB 6
48083741_EN 31/07/2018
35.6 [35.204] / 4
12. Disconnect and plug the pilot tank hose (1) from the
electro-hydraulic control valve.
LEIL17WHL1153AB 7
13. Remove and cap the straight fitting (1) from the elec-
tro-hydraulic control valve.
LEIL17WHL1154AB 8
14. Disconnect and plug the following hoses from the

electro-hydraulic control valve:
• pilot 4th spool right-hand hose (1);
• pilot 4th spool left-hand hose (2);
• 3rd spool right-hand hose (3);
• 3rd spool left-hand hose (4);
• pilot lower hose (5).
LEIL17WHL1155AB 9
15. Remove and cap the following elbows and fittings from
the electro-hydraulic control valve:
• three 90° elbows (1);
• two 90° swivel elbows (2);
• two straight fittings (3).
LEIL17WHL1156AB 10
48083741_EN 31/07/2018
35.6 [35.204] / 5
16. Disconnect and plug the following hoses from the

electro-hydraulic control valve:
• pilot dump hose (1);
• pilot rollback hose (2);
• pilot raise hose (3).
LEIL17WHL1157AB 11
17. Remove and cap the following elbows and fittings from
the electro-hydraulic control valve:
• two straight fittings (1);
• 90° swivel elbow (2);
• 90° elbow (3).
LEIL17WHL1158AB 12
18. Disconnect and plug the pilot pressure hose (1) from
the electro-hydraulic control valve.
LEIL17WHL1159AB 13
19. Remove and cap the 90° elbow (1) from the electro-
hydraulic control valve.
LEIL17WHL1160AB 14
48083741_EN 31/07/2018
35.6 [35.204] / 6
20. Remove the three bolts (1) with relevant washers (2)
that secure the electro-hydraulic control valve to the
bracket (3).
Remove the electro-hydraulic control valve from the
machine.
LEIL17WHL1161AB 15
48083741_EN 31/07/2018
35.6 [35.204] / 7
Electro-hydraulic control valve - Install

NOTE: the procedure showed from step 1 to step 13 refers to a machine equipped with a 4th function electro-hydraulic
control valve, but it is similar also to the 3rd function electro-hydraulic control valve.
1. Place the electro-hydraulic control valve in the correct
position to the bracket (3). Tighten the three bolts (1)
with the relevant washers (2) to secure the electro-hy-
draulic control valve to the bracket (3).
LEIL17WHL1161AB 1
2. Remove the cap and install the straight fitting (1) to the
T port of the electro-hydraulic control valve.
LEIL17WHL1154AB 2
3. Unplug and connect the pilot tank hose (1) to the T port
of the electro-hydraulic control valve.
LEIL17WHL1153AB 3
4. Apply to the pilot tank hose (1) the angle orientation

shown in figure 4.
LEIL17WHL1162AB 4
48083741_EN 31/07/2018
35.6 [35.204] / 8
5. Remove the cap and install the following elbows and

fittings to the electro-hydraulic control valve:
• three 90° elbows (1) to the E2, F2 and H2 ports;
• two straight fittings (3) and two 90° swivel elbows (2)
to the B2 and G2 ports.
LEIL17WHL1156AB 5
6. Unplug and install the following hoses to the electro-

hydraulic control valve:
• pilot 4th spool right-hand hose (1) to the H2 port;
• pilot 4th spool left-hand hose (2) to the G2 port;
• 3rd spool right-hand hose (3) to the F2 port;
• 3rd spool left-hand hose (4) to the E2 port;
• pilot lower hose (5) to the B2 port.
LEIL17WHL1155AB 6
7. Apply to the pilot 4th spool right-hand hose (1), pilot 4th
spool left-hand hose (2), 3rd spool right-hand hose (3),
3rd spool left-hand hose (4) and pilot lower hose (5) the
angle orientation shown in figure 7.
LEIL17WHL1165AB 7
8. Remove the cap and install the following elbows and

fittings to the electro-hydraulic control valve:
• the straight fitting (1) to the A port;
• the straight fitting (1) and the 90° swivel elbow (2) to
the C port;
• the 90° elbow (3) to the D port.
LEIL17WHL1158AB 8
48083741_EN 31/07/2018
35.6 [35.204] / 9
9. Apply to the 90° swivel elbow (2) and 90° elbow (3) the
angle orientation shown in figure 9.
LEIL17WHL1163AB 9
10. Remove the cap and install the 90° elbow (1) to the
Pst port of the electro-hydraulic control valve.
LEIL17WHL1160AB 10
11. Unplug and connect the pilot pressure hose (1) to the
Pst port of the electro-hydraulic control valve.
LEIL17WHL1159AB 11
12. Apply to the pilot pressure hose (1) the angle orienta-
tion shown in figure 12.
LEIL17WHL1164AB 12
48083741_EN 31/07/2018
35.6 [35.204] / 10
13. Connect the electrical connectors (1) ( A, B, C, D, E,

F, G, H connectors of the front chassis harness) to the
electro-hydraulic control valve.
Connect the electrical connector (2) ( PST connector
of the front chassis harness) to the electro-hydraulic
control valve.
LEIL17WHL1152AB 13
14. Turn off the vacuum pump CAS10192. Disconnect

the vacuum pump CAS10192 from the hydraulic
reservoir.
15. Fill the hydraulic reservoir with hydraulic oil.
on the top of the ride control valve to a torque of
3.5 N·m (2.6 lb ft). Install the plug and torque to 7 N·m
(5 lb ft).
18. Lower the loader arms and remove the safety strut.
LEIL13WHL1244AA 14
19. Put the articulation lock in the operating (UNLOCKED)

position.
20. Run engine at half throttle.
21. Slowly and completely extend and retract all cylinders
at least 10 times to remove any air from the circuits.
22. Stop the engine and check for leaks.
48083741_EN 31/07/2018
35.6 [35.204] / 11
23. Install the access cover on the front of the machine.

Use the bolts and washers to fasten the access cover
plate.
LEIL13WHL1246AB 15
24. Check the level of the hydraulic oil and add hydraulic
oil as required.
48083741_EN 31/07/2018
35.6 [35.204] / 12
Index

Electro-hydraulic control valve - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Electro-hydraulic control valve - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
48083741_EN 31/07/2018
35.6 [35.204] / 13
48083741_EN 31/07/2018
35.6 [35.204] / 14
Hydraulic fan drive cooling system - 752

48083741_EN 31/07/2018
35.7 [35.752] / 1
Contents
SERVICE
Cooling fan valves

Remove - Variable speed and reversing fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Install - Variable speed and reversing fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
48083741_EN 31/07/2018
35.7 [35.752] / 2
Hydraulic systems - Hydraulic fan drive cooling system
Cooling fan valves - Remove - Variable speed and reversing fan

1. Park the machine on a level surface. Lower the bucket
to the ground. Stop the engine and apply the parking
brake.
NOTICE: with the engine NOT running, pump the brake
repeatedly to be sure the brake accumulators have no hy-
then move the joystick back and forth several times to re-
lease any hydraulic pressure in the pilot control circuit, turn
ignition switch OFF.
3. Disconnect the electrical connectors from the fan re-
versing valve.
LEIL16WHL2254AB 1
4. Tag and disconnect the fan forward hose (1) and the fan
reverse hose (2) from the fan reversing valve. Install a
plug in the hoses and a cap on the fittings.
LEIL16WHL2255AB 2
5. Tag and disconnect the fan-to-bypass hose (3) from the

fan reversing valve. Install a plug in the hose and a cap
on the fitting.
Tag and disconnect the fan valve tube (4) from the fan
reversing valve. Install a plug in the tube and a cap on
the fitting.
6. Loosen and remove the three bolts (5) with the relevant
washers and nuts.
7. Remove the fan reversing valve from the machine.
8. Remove and discard all O-rings from the fittings.
LEIL16WHL2256AB 3
48083741_EN 31/07/2018
35.7 [35.752] / 3
Cooling fan valves - Install - Variable speed and reversing fan

1. Place the fan reversing valve into position on the ma-
chine.
2. Lubricate and install new O-rings in the fittings.
3. Install the bolts (5) with the relevant washers and nuts.
Tighten the nuts.
4. Connect the fan valve tube (4) to the elbow on the fan
reversing valve.
Connect the fan-to-bypass hose (3) to the fitting on the
fan reversing valve.
LEIL16WHL2256AB 1
5. Connect the fan reverse hose (2) to the fitting on the

Connect the fan forward hose (1) to the elbow on the
LEIL16WHL2255AB 2
6. Make sure the fan reverse hose (2) is oriented as

shown in figure.
LEIL18WHL0518AB 3
48083741_EN 31/07/2018
35.7 [35.752] / 4
7. Connect the electrical connectors to the fan reversing

valve.
draulic reservoir.
9. Check the level of the hydraulic oil in the reservoir.
minutes.
the fan reversing valve.
add as required. Tighten the filler cap on the reservoir. LEIL16WHL2254AB 4
48083741_EN 31/07/2018
35.7 [35.752] / 5
Index

Cooling fan valves - Install - Variable speed and reversing fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Cooling fan valves - Remove - Variable speed and reversing fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
48083741_EN 31/07/2018
35.7 [35.752] / 6
Front loader arm hydraulic system - 701

48083741_EN 31/07/2018
35.8 [35.701] / 1
Contents
TECHNICAL DATA
Lift arm cylinder

Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Ride control solenoid valve block
General specification - Accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Torque - Accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Special tools - Accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
FUNCTIONAL DATA
Lift arm cylinder

Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
SERVICE
Front loader arm hydraulic system

Service instruction - Testing and adjusting the loader limit pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Service instruction - Testing and adjusting the loader pump cutoff pressure . . . . . . . . . . . . . . . . . . . . . . . 10
Lift arm cylinder
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Remove - Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Install - Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Bleed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Discharging - Accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Remove - Accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Install - Accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Charging - Accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
48083741_EN 31/07/2018
35.8 [35.701] / 2
Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
48083741_EN 31/07/2018
35.8 [35.701] / 3
Hydraulic systems - Front loader arm hydraulic system
Lift arm cylinder - General specification

Lift cylinder weight 156 kg (344 lb)
Tube diameter 139.6 mm (5.5 in)
Rod diameter 76.2 mm (3.0 in)
Lift arm cylinder - Torque

SEMS screw 1 1/2 x 3.5 for fixing the piston to piston rod 2830 – 3220 N·m (2087 – 2375 lb ft)
Locking screw for lift arm cylinder 2.3 N·m (20 lb in)
48083741_EN 31/07/2018
35.8 [35.701] / 4
Ride control solenoid valve block - General specification -

Accumulator
Nominal volume 3.8 L (1 US gal)
Ride control accumulator maximum operating pressure 280 bar (4060 psi)
Ride control accumulator pre-charge pressure (*) 17 bar (246 psi) at 20 °C (68 °F)
Ride control accumulator test pressure 310 bar (4495 psi)
Ride control accumulator weight Approximately 27 kg (59.5 lb)
NOTE: the accumulator is pre-charged with dry inert gas, as high purity nitrogen.
NOTE: (*) refer to the following table when check the pre-charge pressure at ambient temperature other than 20 °C
(68 °F).
Temperature Accumulator pre-charge pressure

10 °C (50 °F) 16.36 bar (237.22 psi)
13 °C (55 °F) 16.55 bar (239.98 psi)
16 °C (61 °F) 16.74 bar (242.73 psi)
18 °C (64 °F) 16.87 bar (244.62 psi)
21 °C (70 °F) 17.06 bar (247.37 psi)
24 °C (75 °F) 17.26 bar (250.27 psi)
27 °C (81 °F) 17.45 bar (253.02 psi)
29 °C (84 °F) 17.58 bar (254.91 psi)
32 °C (90 °F) 17.77 bar (257.66 psi)
35 °C (95 °F) 17.96 bar (260.42 psi)
38 °C (100 °F) 18.15 bar (263.17 psi)
Ride control solenoid valve block - Torque - Accumulator

Accumulator gas charging valve cap 20 N·m (177 lb in)
Accumulator drain screw (located on the ride control valve) 3.5 N·m (31 lb in)
Accumulator drain plug (located on the ride control valve) 5 N·m (44.3 lb in)
Ride control solenoid valve block - Special tools - Accumulator

CAS10088A Nitrogen accumulator charging kit
The nitrogen accumulator charging kit consists of:

• two gauges (C) and (E);
• three hoses (B);
• one shut off valve (F);
• one "T" handle service fitting (D).
380001737 High pressure regulator (A)
LEIL13WHL1358AB 1
48083741_EN 31/07/2018
35.8 [35.701] / 5
Lift arm cylinder - Exploded view
LEIL16WHL1023GB 1
1. Rod 4. Cylinder tube

2A. Piston assembly (piston, seal, wear ring) 5. Locking screw
2B. Gland assembly (gland, O-ring, wiper rod, bearing rod, seals) 6. Wiper rod
3. Bolt 1”1/2 x 3.50 7. Bushing
48083741_EN 31/07/2018
35.8 [35.701] / 6
Ride control solenoid valve block - Exploded view
LEIL13WHL1362FB 1
1. Plug 7. Spool 13. Orifice

2. Cap screw 8. Plug 14. Poppet
3. Bushing 9. Plug 15. Orifice
4. Spring carrier 10. Accumulator drain screw 16. Valve block
5. Spring 11. Plug 17. Relief valve
6. Spring 12. Solenoid
48083741_EN 31/07/2018
35.8 [35.701] / 7
Front loader arm hydraulic system - Service instruction - Testing

and adjusting the loader limit pressure
Pressure check
LEIL13WHL1236AA 1
2. Connect a 345 bar (5002 psi) test gauge to the test port
(1), located on the priority valve.
LEIL13WHL1289AB 2

54 – 57 °C (129 – 135 °F). The procedure to heat the
hydraulic oil is the following.
● Check the oil temperature through the display in the
● Heat the hydraulic oil:
C. Continue this procedure until the hydraulic oil tem-
perature is 54 – 57 °C (129 – 135 °F). After heating oil
to the operating temperature, lower the bucket to the LEIL16WHL0891AA 3
ground.
4. Run the engine at full throttle.
5. Roll the loader bucket back against the stops.
6. Record the reading on the test gauge.
7. Reading should be 248 – 255 bar (3596 – 3698 psi).
8. If this reading is more or less than specified, it will be
necessary to adjust the loader limit pressure.
48083741_EN 31/07/2018
35.8 [35.701] / 8
Adjusting the loader limit pressure

1. The limit adjusting screw is located on the left side of
the loader valve. Turn the screw clockwise to increase
the limit pressure. Turning the screw counterclockwise
will decrease the limit pressure.
LEIL13WHL1290AB 4
48083741_EN 31/07/2018
35.8 [35.701] / 9
Front loader arm hydraulic system - Service instruction - Testing

and adjusting the loader pump cutoff pressure
Pressure check
LEIL13WHL1236AA 1
2. Connect a 345 bar (5002 psi) test gauge to the test port
(1).
LEIL13WHL1289AB 2
3. Adjust the loader limit pressure to maximum by turning

clockwise the adjusting screw until stop is reached.
ground.
5. Roll the loader bucket back against the stops.
7. Reading should be 280 bar (4060 psi).
8. If this reading is more or less than specified, it will be
necessary to adjust the pump cutoff pressure.
48083741_EN 31/07/2018
35.8 [35.701] / 10
Adjusting the loader pump cutoff pressure

1. The unloading adjuster is the longer of the two ad-
justers on the loader pump. Turn the screw clockwise to
increase the cutoff pressure. Turning the screw coun-
terclockwise will decrease the cutoff pressure.
NOTE: the adjusting screw is located just above the steer-
ing priority valve on the pump furthest from the transmis-
sion.
2. Adjust the loader limit pressure back to 248 – 252 bar
(3596 – 3654 psi) per procedure.
LEIL13WHL1293AB 4
48083741_EN 31/07/2018
35.8 [35.701] / 11
Lift arm cylinder - Remove

ing brake.
then move the joystick or loader control back and forth sev-
eral times to release any hydraulic pressure in the pilot con-
trol circuit, turn ignition switch OFF.
2. Relieve the pressure in the Ride control accumulator
with the manual bleeder valve located at the rear of the
front chassis.
lease any pressure.
4. Remove the four bolts (1) and the washers (2) that se-
cure the lift rod tube (3) to the lift arm cylinder.
LEIL16WHL0590AB 1
821G
LEIL16WHL1820AB 2
921G
48083741_EN 31/07/2018
35.8 [35.701] / 12
5. Remove the four bolts (1) and the washers (2) that se-
cure the lift base tube (4) to the lift arm cylinder.
NOTE: for clarity, figure 3 does not show the side plate of
the front chassis.
LEIL16WHL0591AB 3
6. Remove the bolts (5), the washers (6) and the nuts (7).
Remove the two mounting blocks (8) and the two plates
(9).
7. Disconnect the lift rod tube (3) and the lift base tube (4)
from the lift base hoses and from the lift arm cylinder.
Remove and discard the O-rings from the flange heads
of the lift rod tube (3) and the lift base tube (4).
the front chassis.
LEIL16WHL0592BB 4
8. Remove the bolts (10), the washers (11) and the nuts
(12). Remove the bracket (13) from the lift arm cylinder.
the front chassis.
LEIL16WHL0593AB 5
48083741_EN 31/07/2018
35.8 [35.701] / 13
9. Loosen and remove the bolt, washer and spacer that

hold the pivot pin for the yoke.
LEIL13WHL1259AA 6
821G
LEIL16WHL1821AB 7
921G
10. Use a proper lifting device and secure a strap around

the lift cylinder.
LEIL13WHL1260AA 8
48083741_EN 31/07/2018
35.8 [35.701] / 14
11. Remove the pivot pin from the yoke end of the lift
cylinder.
LEIL13WHL1261AA 9
12. Loosen and remove the bolt, washer and spacer that
hold the pivot pin at the closed end of the lift cylinder.
LEIL13WHL1262AA 10
13. Remove the pivot pin from the closed end of the lift
cylinder.
14. Remove the lift cylinder from the machine.
LEIL13WHL1263AA 11
48083741_EN 31/07/2018
35.8 [35.701] / 15
Lift arm cylinder - Disassemble

NOTE: for the numbering, refer to Lift arm cylinder - Exploded view (35.701).
1. Clean exterior of cylinder. If hoses were removed with
cylinder, remove hoses from cylinder.
2. Fasten the cylinder tube (4) in a suitable repair stand or
other holding equipment. Do not damage the cylinder
tube (4).
3. Loosen and remove the locking screw (5).
4. Use a spanner wrench to loosen and remove the gland
(2B) from the cylinder tube (4).
5. Pull the rod (1) straight out of the cylinder tube (4) to
prevent damage to the tube.
6. Fasten the rod eye in a vise and put a support under
the rod (1) near the piston assembly (2A). Put a shop
cloth between the support and the piston rod to prevent
damage to the piston rod.
7. Use a suitable torque multiplier to remove the bolt (3)
that fastens the piston assembly (2A) to the piston rod
(1).
8. Remove the piston assembly (2A) from the piston rod
(1).
9. Remove the gland (2B) from the piston rod (1).
10. Remove and discard the seal and the wear ring from
the piston assembly (2A).
11. Remove and discard O-ring, the bearing, the wiper
rod, and the seas from the gland (2B).
48083741_EN 31/07/2018
35.8 [35.701] / 16
Lift arm cylinder - Remove - Bushing

1. Put the cylinder tube (4) and the rod (3) in a press.
2. Use an acceptable driver to press the wipers (1) and
the bushings (2) out of cylinder tube (4) eye.
3. Clean bore for bushings (2) in the cylinder tube (4) eye.
LEIL13WHL1355AB 1
48083741_EN 31/07/2018
35.8 [35.701] / 17
Lift arm cylinder - Inspect

NOTE: for the numbering in this procedure refer to Lift arm cylinder - Exploded view (35.701).
1. Clean all parts in cleaning solvent. Use only lint free
cloths for cleaning and drying.
2. Check to be sure that the piston rod (1) is straight. If
the piston rod is not straight, replace it with a new piston
rod.
3. Shine a light inside the cylinder tube (4) and check for
deep grooves and other damage. If there is any dam-
age to the tube, replace with a new tube.
4. Remove any small scratches on the piston rod (1) or
inside the cylinder tube (4) with emery cloth of medium
grit. Use emery cloth with a rotary motion.
5. Inspect the bushings (7) in the cylinder tube eye. Re-
place as required.
6. Inspect the gland (2B) for rust. Clean and remove rust
as necessary.
7. Inspect the gland end of tube for sharp edges that may
cut the gland O-ring and remove as necessary.
8. Inspect the piston (2A) for damage and wear. If the
piston is damaged or worn, replace with a new piston.
48083741_EN 31/07/2018
35.8 [35.701] / 18
Lift arm cylinder - Install - Bushing

1. Use an acceptable driver to press new bushings (2) into
the cylinder tube (4) eye. Bushings shall be recessed
8 mm (0.315 in) in the cylinder tube eye.
2. Use an acceptable driver to install wipers (1) until flush
with the cylinder tube (4) eye. The lips of wipers must
be toward outside of bore.
3. Remove the cylinder tube (4) and the rod (3) from the
press.
LEIL13WHL1355AB 1
48083741_EN 31/07/2018
35.8 [35.701] / 19
Lift arm cylinder - Assemble

NOTE: for the numbering, refer to Lift arm cylinder - Exploded view (35.701).
NOTE: if a new gland is being used, put the part number of the cylinder on the new gland.
1. Install the bushing in the gland (2B).
2. Install the rod seal in the gland (2B). Rod seal is to be
installed so that lips of seal are toward bearing.
NOTE: rd seal can be difficult to install.

3. Install the buffer seal in the gland (2B). The side of
buffer seal with groove must be toward the bushing.
4. Install a new wiper in the gland (2B). Lips of wiper must
be toward outside end of the gland (2B).
5. Install a new O-ring in the groove on the outer diameter
of the gland (2B).
6. Fasten the piston rod (1) eye in a vise.
7. Remove any marks and sharp edges on chamfer at end
of piston rod (1). Make sure that the piston rod is clean.
8. Lubricate the bore of the gland (2B) and the piston rod
(13) with clean oil.
9. Push the gland (2B) onto the piston rod (1). If nec-
essary, use a soft hammer to drive the gland onto the
piston rod.
10. Put a support below and near end of the piston rod
(1). Use a shop cloth between support and the piston
rod to prevent damage to the piston rod.
11. Install the piston (2A) onto the piston rod (1).
12. Clean the threads on the end of the piston rod (1) and
the threads of the bolt (3) using LOCTITE® cleaning
solvent. Allow to dry.
Apply LOCTITE® 242® to piston rod threads 6.3 mm
(0.2 in) from open end of piston rod so that there is
13 mm (1 in) of LOCTITE® 242® on piston rod threads.
NOTE: DO NOT apply LOCTITE® to first 6.3 mm (0.2 in) of
piston rod threads.
13. Install the bolt (3) into the piston rod (1). Tighten the
bolt (3) to 2830 – 3220 N·m (2087 – 2375 lb ft). A
torque multiplier can be used to help torque the bolt.
14. Install a new wear ring in the wide groove on the out-
side of the piston (2A).
15. Install a new seal on the piston (2A).
16. Fasten the cylinder tube (4) in an acceptable repair
stand or other suitable holding equipment. Be careful
to prevent damage to the cylinder tube.
17. Lubricate inside of the cylinder tube (4) and piston
(2A) with clean oil.
18. Push the piston (2A) straight into the cylinder tube (4).
19. When the piston (2A) is in smooth part of the cylinder
tube (4), position the gland (2B) into the cylinder tube
(4).
48083741_EN 31/07/2018
35.8 [35.701] / 20
20. Lubricate the O-rings on the gland (2B) with clean oil.
21. Turn the gland (2B) into the cylinder tube (4).
22. If the original parts are being assembled:
A. Tighten the gland (2B) to 135 – 542 N·m (100 –
400 lb ft).
B. Install and tighten the locking screw (5) to a torque
of 2.3 N·m (1.7 lb ft)
C. If, after tightening gland, the locking screw (5)
holes are not aligned, a new hole for locking screw
must be drilled.
23. If a new gland (2B) or a new cylinder tube (4) are
being assembled:
A. Tighten the gland (2B) to 135 – 542 N·m (100 –
400 lb ft).
B. Use a No. 27 drill bit and drill a hole half in the
gland (2B) and half in the cylinder tube (4). Drill to
a depth of 11 mm (0 in). Do not drill within 13 mm
(1 in) of a hole for gland wrench.
C. Install and tighten the locking screw (5) to a
torque of 2.3 N·m (1.7 lb ft).
24. If hoses were removed with cylinder, install new
O-rings, if equipped, on hose fittings. Lubricate
O-rings with clean oil. Install the hoses.
48083741_EN 31/07/2018
35.8 [35.701] / 21
Lift arm cylinder - Install

1. Apply antiseize compound to the bores in the front
chassis and the yoke on the piston rod.
2. Use a proper lifting device and position the lift arm cylin-
der on the machine.
LEIL13WHL1264AA 1
3. Align the closed end of the lift arm cylinder with the front
chassis and install the pivot pin.
LEIL13WHL1263AA 2
4. Align the pivot pin with the front chassis and install the
spacer, washer and bolt. Tighten the bolt.
LEIL13WHL1262AA 3
5. Position the bracket (13) on the lift arm cylinder. Install

the bolts (10), the washers (11) and the nuts (12) to
secure the bracket (13) to the lift arm cylinder. Tighten
the nuts (12).
the front chassis.
LEIL16WHL0593AB 4
48083741_EN 31/07/2018
35.8 [35.701] / 22
6. Install a new O-ring in the flange heads of the lift rod

tube (3) and the lift base tube (4). Position the he lift
rod tube (3) and the lift base tube (4) on the lift arm
cylinder.
7. Connect the lift rod tube (3) and the lift base tube (4) to
the lift base hoses.
Install the two mounting blocks (8) and the two plates
(9). Install the bolts (5), the washers (6) and the nuts
(7) to secure the two mounting blocks (8) and the two
plates (9) to the lift rod tube (3) and the lift base tube
(4). Tighten the nuts (7).
the front chassis.
LEIL16WHL0592BB 5
8. Install the bolts (1) and the washers (2) to secure the lift
base tube (4) to the lift arm cylinder. Tighten the bolts
(1).
the front chassis.
LEIL16WHL0591AB 6
9. Install the bolts (1) and the washers (2) to secure the
lift rod tube (3) to the lift arm cylinder. Tighten the bolts
(1).
LEIL16WHL0590AB 7
821G
48083741_EN 31/07/2018
35.8 [35.701] / 23
LEIL16WHL1820AB 8
921G
10. If the yoke of the lift arm cylinder is not aligned with the
loader frame, have another person start and run the
engine at low idle and use the loader control lever to
SLOWLY move the yoke into alignment with the loader
frame.
11. Install the pivot pin for the yoke. Stop the engine.
LEIL13WHL1261AA 9
12. Align the pivot pin with the yoke and install the spacer,
washer and bolt. Tighten the bolt.
LEIL13WHL1259AA 10
821G
48083741_EN 31/07/2018
35.8 [35.701] / 24
LEIL16WHL1821AB 11
921G
13. SLOWLY extend and retract the piston rod three times
to remove any air from the lift cylinders.
14. Lubricate the pivot pins with molydisulfide grease.
15. Check the level of hydraulic oil in the reservoir and
add as required. Tighten the filler cap on the hydraulic
reservoir.
48083741_EN 31/07/2018
35.8 [35.701] / 25
Ride control solenoid valve block - Bleed

WARNING
Crushing hazard!
When doing stationary Power Take Off (PTO) work, install the articulation cylinder locking blocks to
prevent accidental articulation of the machine. Place the controls in the park lock position.
W0409A
WARNING
Chemical hazard!
When handling fuel, lubricants, and other service chemicals, follow the manufacturer's instructions.
Wear Personal Protective Equipment (PPE) as instructed. Do not smoke or use open flame. Collect
fluids in proper containers. Obey all local and environmental regulations when disposing of chemi-
cals.
W0371A
WARNING
Pressurized hydraulic fluid can penetrate the skin and cause severe injuries.
Hydraulic fluid is under extreme pressure. Rest the bucket or attachment on the ground. Shut the
engine off, turn the key on, and move the hydraulic control lever through all movements several times
to relieve residual pressure in the system.
W0161A
1. Park machine on a level surface and lower the bucket

to the ground. Put transmission in neutral, apply the
parking brake then turn off the engine.
2. Apply articulation locking blocks to prevent accidental
articulation of the machine.
LEIL16WHL0048AB 1
48083741_EN 31/07/2018
35.8 [35.701] / 26
3. Locate the Ride control valve behind the right-hand

side of the machine.
4. Place a small container underneath the Ride control
valve to collect the hydraulic fluid.
NOTE: hydraulic fluid will flow out of the Ride control valve
during the bleeding process.
5. Fill the hydraulic reservoir with correct hydraulic fluid.
6. Start the engine and cycle the lift arm without activating
the Ride control system. Turn off the engine.
NOTE: unintended lift arm movement may occur during this
procedure.
NOTE: do NOT activate the Ride control system until step
14.
RAPH12WEL0256AA 2
Required procedures
7. Verify that the hydraulic reservoir is at the correct level.
Add hydraulic fluid if necessary.
8. If hydraulic fluid was added, restart engine and cycle
lift arms again, otherwise go to next step.
9. Lower lift arms to lowest position and stop the engine.
10. Remove the Ride control valve plug and access to the
bleed screw. The bleed screw is located on the same
side of the valve as the solenoid. See picture 3.
LEIL18WHL0901AB 3
48083741_EN 31/07/2018
35.8 [35.701] / 27
11. With a proper tool, turn the Ride control valve bleeder
screw two turns counter clockwise to remove air and
fluid from the Ride control valve and line. Remove the
tool after opening the bleeder screw.
NOTE: pressurized air will escape. DO NOT retighten
bleeder screw at this time.
NOTE: some hydraulic fluid will flow out of the Ride control
valve.
RAPH12WEL0252AA 4
12. Start engine and cycle lift arms three times. Then,
lower lift arms to the lowest position and stop the en-
gine. Turn the Ride control valve bleeder screw two
turns clockwise to close it. Torque bleeder screw to
3.5 N·m (31.0 lb in).
13. Repeat steps 6 through 11 three more times.
14. Install the Ride control valve plug and torque to 5 N·m
(44 lb in).
RAPH12WEL0250AA 5
Spring chamber-Ride control valve bleeding

15. Start the engine and cycle lift arms to load the Ride
control valve. Lower the lift arms to the ground and
turn off the engine. Turn the ignition key to ON position
only then activate the Ride control (see the arrow in
figure).
LEIL16WHL1125AA 6
48083741_EN 31/07/2018
35.8 [35.701] / 28
16. On the side of the Ride control valve turn the spring
chamber bleed screw counter clockwise a maximum
of two turns to remove air from the spring chamber.
NOTE: some hydraulic fluid will escape.
RAPH12WEL0254AA 7
17. Retighten the spring chamber bleed screw once air

has bled out. Torque to 5 N·m (44 lb in) +/-10%
RAPH12WEL0262AA 8
18. Turn the ignition key off and remove articulation lock-
ing blocks.
48083741_EN 31/07/2018
35.8 [35.701] / 29
Ride control solenoid valve block - Discharging - Accumulator

Discharging the nitrogen charge on an accumulator
1. Use the CAS10088A nitrogen charging kit and the
380001737 high pressure regulator to discharge the
accumulator. The tool must be disconnected from the
nitrogen tank.
2. Close the valves (B), (C) and (D).
3. Adjust the regulator (A) to the minimum pressure set-
ting by turning the knob counterclockwise.
4. Turn the T-handle on the valve (F) fully out.
5. Remove the guard and the valve assembly cap from
the accumulator.
6. Connect the valve (F) to the valve stem on the accu- LEIL13WHL1358AB 1
mulator.
7. Turn the T-handle inward on valve (F) to engage the
pin in the valve stem.
8. Open the valve (D) and check the charge pressure on
gauge (E).
9. To discharge the accumulator, partially the open valve
(B). The accumulator charge will bleed down through
the regulator.
10. Once the accumulator is fully discharged, disconnect
the valve (F) from the valve stem.
48083741_EN 31/07/2018
35.8 [35.701] / 30
Ride control solenoid valve block - Remove - Accumulator

ing brake.
draulic pressure. Put the ignition switch in the ON position
then move the loader control valve back and forth several
times to release any hydraulic pressure in the pilot control
circuit. Turn the ignition switch to the OFF position.
LEIL13WHL1278AB 1
4. Disconnect the hose (1) from the elbow (2) located at

the bottom of the ride control accumulator (3). Install a
protective plug in the hose and a protective cap on the
fitting.
5. Loosen and remove the nuts (4) and the washers (5)
from the U-bolts (6) that fix the ride control accumula-
tor (3) to the right–hand side of the front chassis (7).
Remove the U-bolts (6).
6. Remove the ride control accumulator (3).
LEIL16WHL1027BA 2
48083741_EN 31/07/2018
35.8 [35.701] / 31
Ride control solenoid valve block - Install - Accumulator

1. Place the ride control accumulator (3) in position on the
right–hand side of the front chassis (7).
2. Install the U-bolts (6) that fix the ride control accumu-
lator (3) to the right–hand side of the front chassis (7)
and install the washers (5) and the nuts (4).
Tighten the nuts (4).
LEIL16WHL1027BA 1
3. Remove the protective cap and plug and connect the

hose (1) to the elbow (2) located at the bottom of the
ride control accumulator (3) .
NOTE: orient the elbow (2) and the hose (1) as indicated
in the figures.
4. Turn off and disconnect the vacuum pump from the hy-
draulic reservoir.
(2.6 lb ft). Install the plug and torque to 5 N·m (3.7 lb
ft).
LEIL16WHL1026AB 2
6. Properly charge the accumulator and check for leaks.
reservoir.
LEIL16WHL1025AB 3
48083741_EN 31/07/2018
35.8 [35.701] / 32
Ride control solenoid valve block - Charging - Accumulator

Charging the accumulator with nitrogen
1. Valve (C)
2. Connection to nitrogen tank
3. Valve (A)
4. Valve (B)
5. Valve (D)
6. Connection to accumulator
LEIL13WHL1361AB 1
NOTICE: use only nitrogen when charging the accumulator. Do not use air or oxygen that will cause an explosion.
NOTICE: do not drop the accumulator. A charged accumulator contains nitrogen compressed to 17 bar (246.5 psi).
If the charging valve breaks away from the accumulator, the escaping nitrogen will propel the accumulator at a dan-
gerous rate of speed.
NOTICE: do not expose the accumulator to temperatures above 80 °C (176 °F). A charged accumulator contains
nitrogen compressed to 17 bar (246.5 psi). High heat will cause the safety plug to blow out of the accumulator and
the escaping nitrogen will propel the accumulator at a dangerous rate of speed.
NOTICE: the four valves must be in the positions noted in the procedure before connecting the Nitrogen Accumulator
Charging Kit to the machine or nitrogen.
NOTICE: to help prevent equipment damage, the low pressure gauge valve (C) MUST BE SHUT OFF during high
pressure ( 10 bar (145 psi) and above) applications.
1. Close the valve (A) by turning it all the way to the left
(counterclockwise).
2. Open the valve (B) by turning it out all the way to the
left (counterclockwise).
3. Close the valve (C) by turning it all the way to the right
(clockwise).
4. Close the gauge valve (D) by turning it all the way to
the right (clockwise).
5. Connect the charging hose to the nitrogen supply tank.
6. SLOWLY turn the valve (A) clockwise while watch-
ing the high pressure gauge. Stop the turning valve
(A) when the needle on the gauge reaches 17 bar
(246.5 psi).
NOTE: If the needle goes over the needed pressure,
quickly open and close the valve (D) and check the pres-
sure setting again.
The charging kit is now ready to be installed on the ac-
cumulator.
7. Remove the cap screw from the accumulator.
8. Back off the needle valve on the accumulator end of
the charging hose by turning it counterclockwise to the
maximum amount. This prevents nitrogen from escap-
ing from the accumulator when the charging hose is
attached to the accumulator gas charging valve.
48083741_EN 31/07/2018
35.8 [35.701] / 33
9. Install the charging hose fitting onto the accumulator.

10. Tighten the needle valve by turning it clockwise.
Slowly open the gauge valve (D) and observe the
reading on the gauge. This reading is the nitrogen
pressure level inside the accumulator.
11. Open the valve (A) on the nitrogen supply tank. While
observing the pressure on the gauge, slightly open the
needle valve on the accumulator charge hose. By reg-
ulating the needle valve, fill the accumulator to pres-
sure according to temperature chart below. Close the
needle valve. Close the valve (A) on the nitrogen sup-
ply tank.
Temperature Accumulator pre-charge pressure

10 °C (50 °F) 16.36 bar (237.22 psi)
13 °C (55 °F) 16.55 bar (239.98 psi)
16 °C (61 °F) 16.74 bar (242.73 psi)
18 °C (64 °F) 16.87 bar (244.62 psi)
21 °C (70 °F) 17.06 bar (247.37 psi)
24 °C (75 °F) 17.26 bar (250.27 psi)
27 °C (81 °F) 17.45 bar (253.02 psi)
29 °C (84 °F) 17.58 bar (254.91 psi)
32 °C (90 °F) 17.77 bar (257.66 psi)
35 °C (95 °F) 17.96 bar (260.42 psi)
38 °C (100 °F) 18.15 bar (263.17 psi)
12. Close the valve (B) by turning to the right (clockwise).

After a few minutes, check the accumulator for leak-
age.
13. Back off the needle valve on the accumulator end of
the charging hose by turning it counterclockwise the
maximum amount. This will prevent nitrogen from es-
caping from the accumulator as the hose is removed.
Remove the charging hose from the accumulator.
14. Install the cap screws.
15. Remove the charging hose from the nitrogen supply
tank.
48083741_EN 31/07/2018
35.8 [35.701] / 34
Ride control solenoid valve block - Remove


ing brake.
LEIL13WHL1278AB 1
5. Disconnect the electrical connector on top of the ride

control valve (3).
LEIL16WHL1029AA 2
48083741_EN 31/07/2018
35.8 [35.701] / 35
6. Tag and disconnect the following hoses from the ride

control valve (3). Install protective plugs in the hoses
and protective caps on the fittings.
• (A) accumulator hose
• (B) return hose
• (C) ride control hose
• (D) ride control plated tube
LEIL16WHL1829FB 3
7. Loosen and remove the two bolts (1) and the four wash-
ers (2) that fasten the ride control valve (3) to the right-
hand side of the chassis.
NOTE: the weight of the ride control valve is approximately
15.5 kg (34.2 lb).
8. Remove the ride control valve (3) from the machine.
LEIL16WHL1024AA 4
48083741_EN 31/07/2018
35.8 [35.701] / 36
Ride control solenoid valve block - Remove


ing brake.
LEIL13WHL1278AB 1
5. Disconnect the electrical connector on top of the ride

control valve (3).
LEIL16WHL1029AA 2
48083741_EN 31/07/2018
35.8 [35.701] / 37
6. Tag and disconnect the following hoses from the ride

control valve (3). Install protective plugs in the hoses
and protective caps on the fittings.
• (B) return hose
• (C) left-hand cylinder hose
• (D) right-hand cylinder hose
LEIL16WHL1028FA 3
7. Loosen and remove the two bolts (1) and the four wash-
ers (2) that fasten the ride control valve (3) to the right-
hand side of the chassis.
NOTE: the weight of the ride control valve is approximately
15.5 kg (34.2 lb).
8. Remove the ride control valve (3) from the machine.
LEIL16WHL1024AA 4
48083741_EN 31/07/2018
35.8 [35.701] / 38
Ride control solenoid valve block - Disassemble

NOTE: refer to Ride control solenoid valve block - Exploded view (35.701) for the numbering of this procedure.
1. Remove the ride control valve.
2. Remove the plugs (1), (8), (9) and (11).
3. Remove the solenoid (12).
4. Remove the spool (7) from the valve block (16).
5. Remove the cap screw (2), the bushing (3), the spring
carrier (4), the springs (5) and (6) from the spool (7).
6. Remove the orifice (13), the poppet (14) and the orifice
(15).
7. Remove the accumulator drain screw (10).
8. Remove the pressure relief valve (17).
48083741_EN 31/07/2018
35.8 [35.701] / 39
Ride control solenoid valve block - Inspect

NOTE: Refer to Ride control solenoid valve block - Exploded view (35.701) for the numbering of this procedure.
1. Discard all the O-rings.
3. Check the spools and the spool bores for damage and
wear.
4. Check the parts of the pressure relief valve.
If any of the parts are damaged, install new parts.
48083741_EN 31/07/2018
35.8 [35.701] / 40
Ride control solenoid valve block - Assemble

NOTE: refer to Ride control solenoid valve block - Exploded view (35.701) for the numbering of this procedure.
1. Install new O-rings.
2. Install and torque the pressure relief valve (17) to
300 N·m (221 lb ft).
3. Install and torque the accumulator drain screw (10) to
3.5 N·m (2.6 lb ft). Install the plug for accumulator
drain screw and torque to 5 N·m (4 lb ft).
4. Install and torque the orifice (15) to 15 N·m (11 lb ft),
install poppet (14), install and torque orifice (13) to
15 N·m (11 lb ft).
5. Install and torque the solenoid valve (12) to 12 N·m
(9 lb ft).
6. Install the springs (5) and (6), the spring carrier (4), the
bushing (3), the cap screw (2) onto the spool (7) and
torque the cap screw (2) to 5.5 N·m (4.1 lb ft).
7. Install the spool (7) into the valve block (16).
8. Install and torque the plug (1) to 300 N·m (221 lb ft).
9. Install the plug (8) and torque to 140 N·m (103 lb ft).
Install the plug (9) and torque to 45 N·m (33 lb ft). In-
stall the plug (11) and torque to 90 N·m (66 lb ft).
10. Install the ride control valve in the machine.
11. Test the ride control system.
48083741_EN 31/07/2018
35.8 [35.701] / 41
Ride control solenoid valve block - Install

1. Install the ride control valve (3) in position on the front

frame.
2. Install the four washers (2) and bolts (1) to fix the ride
control valve (3) to the right-hand side of the chassis.
Tighten the bolts.
LEIL16WHL1024AA 1

ft).
LEIL13WHL1278AB 2
48083741_EN 31/07/2018
35.8 [35.701] / 42
4. Lubricate and install new O-rings. Connect the follow-

ing hoses to the ride control valve (3).
• (B) return hose
• (C) ride control hose
• (D) ride control plated tube
LEIL16WHL1829FB 3
5. Connect the electrical connector to the ride control

valve (3).
draulic reservoir.
8. Start and run the engine at low idle for two minutes.
the ride control valve.
reservoir. LEIL16WHL1029AA 4
11. Perform the ride control test procedure.
48083741_EN 31/07/2018
35.8 [35.701] / 43
Ride control solenoid valve block - Install

1. Install the ride control valve (3) in position on the front

frame.
2. Install the four washers (2) and bolts (1) to fix the ride
control valve (3) to the right-hand side of the chassis.
Tighten the bolts.
LEIL16WHL1024AA 1

ft).
LEIL13WHL1278AB 2
48083741_EN 31/07/2018
35.8 [35.701] / 44
4. Lubricate and install new O-rings. Connect the follow-

ing hoses to the ride control valve (3).
• (B) return hose
• (C) left-hand cylinder hose
• (D) right-hand cylinder hose
LEIL16WHL1028FA 3
5. Connect the electrical connector to the ride control

valve (3).
draulic reservoir.
8. Start and run the engine at low idle for two minutes.
the ride control valve.
reservoir. LEIL16WHL1029AA 4
11. Perform the ride control test procedure.
48083741_EN 31/07/2018
35.8 [35.701] / 45
Index

Front loader arm hydraulic system - Service instruction - Testing and adjusting the loader limit pres-
sure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Front loader arm hydraulic system - Service instruction - Testing and adjusting the loader pump
cutoff pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Lift arm cylinder - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Lift arm cylinder - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Lift arm cylinder - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Lift arm cylinder - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Lift arm cylinder - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Lift arm cylinder - Install - Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Lift arm cylinder - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Lift arm cylinder - Remove - Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Lift arm cylinder - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Lift arm cylinder - Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Ride control solenoid valve block - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Ride control solenoid valve block - Bleed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Ride control solenoid valve block - Charging - Accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Ride control solenoid valve block - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Ride control solenoid valve block - Discharging - Accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Ride control solenoid valve block - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Ride control solenoid valve block - General specification - Accumulator . . . . . . . . . . . . . . . . . . . . . . . 5
Ride control solenoid valve block - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Ride control solenoid valve block - Install - Accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Ride control solenoid valve block - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Ride control solenoid valve block - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Ride control solenoid valve block - Remove - Accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Ride control solenoid valve block - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Ride control solenoid valve block - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Ride control solenoid valve block - Special tools - Accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Ride control solenoid valve block - Torque - Accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
48083741_EN 31/07/2018
35.8 [35.701] / 46
Front loader bucket hydraulic system - 723

48083741_EN 31/07/2018
35.9 [35.723] / 1
Contents
TECHNICAL DATA
Loader bucket control cylinder

Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
FUNCTIONAL DATA

Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
SERVICE

Remove - Z-Bar loader . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Remove - Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Install - Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Install - Z-Bar loader . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
48083741_EN 31/07/2018
35.9 [35.723] / 2
Hydraulic systems - Front loader bucket hydraulic system
Loader bucket control cylinder - General specification

Bucket cylinder Approximate weight: 199.2 kg (439.2 lb)
Loader bucket control cylinder - Torque

Gland bolt of the bucket cylinder 420 – 500 N·m (310 – 369 lb ft)
48083741_EN 31/07/2018
35.9 [35.723] / 3
Loader bucket control cylinder - Exploded view
LEIL13WHL1352GB 1
1. Tube 7. Piston 13. Wide seal 19. Seal

2. Cap screw 8. Backup ring 14. Narrow seal 20. Bushing
3. Gland 9. O-ring 15. Backup ring
4. Piston rod 10. Retaining ring 16. O-ring
5. Wear ring 11. Pin 17. Bushing
6. Seal 12. Wiper 18. Hardened washer
48083741_EN 31/07/2018
35.9 [35.723] / 4
Loader bucket control cylinder - Remove - Z-Bar loader

parking brake.
2. With the engine stopped, move the bucket control lever
to release pressure in the bucket circuit.
3. Disconnect the tubes (5) and (6) from the bucket cylin-
der (1) performing the follow operations.
Remove the bolts (2), the washers (3), and the
nuts (4) to release the tubes (5) and (6) from the
brackets (7).
Disconnect the tubes (5) and (6) from the bucket
cylinder.
LEIL16WHL1022FB 1
4. Install protective plugs in the disconnected tubes and

on the fittings.
5. Use a suitable equipment to hold the bucket cylinder.
NOTE: the bucket cylinder weights approximately 200 kg
(440 lb).
6. Loosen and remove the bolt, the washer and the spacer
that fasten the pivot pin from both ends of the bucket
cylinder.
7. Remove the pivot pin from the rod end of the bucket
cylinder.
LEIL13WHL1271AA 2
48083741_EN 31/07/2018
35.9 [35.723] / 5
8. Remove the pivot pin from the head end of the bucket
cylinder.
NOTE: it is not necessary to remove the grease line from
the pivot pin unless the pivot pin is to be replaced.
9. Raise the bucket cylinder and remove the cylinder from
the machine.
LEIL13WHL1272AA 3
48083741_EN 31/07/2018
35.9 [35.723] / 6
Loader bucket control cylinder - Disassemble

1. Clean the outside of the cylinder. If the hoses were
removed with the cylinder, remove the hoses from the
cylinder.
NOTE: refer to “Loader bucket control cylinder - exploded
view” for the numbering of this procedure.
2. Fasten the tube (1) in a suitable repair stand or other
holding equipment. Do not damage the tube (1).
3. Loosen and remove the cap screws (2) and the hard-
ened washers (18) from the gland (3) and the tube (1).
4. Pull the piston rod (4) straight out of the tube (1) to
prevent damage to the tube (1).
5. Fasten the piston rod eye in a vise and put a support
under the piston rod (4) near the piston (7). Put a shop
cloth between the support and the piston rod (4) to pre-
vent damage to the piston rod (4).
6. Remove the retaining ring (10) that fastens the pin (11)
in the piston (7) and the piston rod (4).
7. Remove the pin (11) from the piston (7) and the piston
rod (4).
8. Turn the piston (7) off the piston rod (4) and remove the
piston (7).
9. Remove the gland (3) from the piston rod (4).
10. Remove the seal (6) from the outer diameter of the
piston (7).
11. Remove the wear ring (5) from the outer diameter of
the piston (7).
12. Remove the backup rings (8) and the O-ring (9) from
the inner diameter of the piston (7).
13. Remove the O-ring (16), the backup ring (15), the
wiper (12), the wide seal (13), the narrow seal (14),
and the bushing (17) from the gland (3).
48083741_EN 31/07/2018
35.9 [35.723] / 7
Loader bucket control cylinder - Remove - Bushing

1. Put piston rod eye (3) in a press.
2. Use an acceptable driver to press wipers (1) and bush-
ing (2) out of piston rod eye (3).
3. Put tube (4) in a press.
4. Use an acceptable driver to press bushings (2) out of
tube (4) eye.
5. Clean bore for bushings (2) in piston rod eye (3) and
tube (4) eye.
LEIL13WHL1356BB 1
48083741_EN 31/07/2018
35.9 [35.723] / 8
Loader bucket control cylinder - Inspect

1. Discard the parts that were removed from the piston
and the gland.
2. Clean all parts in cleaning solvent. Use only lint free
cloths for cleaning and drying.
3. Check to be sure that the piston rod is straight. If the
piston rod is not straight, replace it with a new piston
rod.
4. Illuminate the inside of the tube for deep grooves and
other damage. If there is any damage to the tube, re-
place it with a new tube.
5. Remove any small scratches on the piston rod or in-
side the tube with emery cloth of medium grit. Use the
emery cloth with a rotary motion.
6. Inspect the bushings in the piston rod eye or yoke and
the tube. Replace as required.
7. Inspect the gland for rust and clean and remove rust as
necessary.
8. Inspect the gland end of the tube for sharp edges that
will cut the gland O-ring and remove as necessary.
9. Inspect the piston for damage and wear. If the piston is
damaged or worn, replace it with a new piston.
48083741_EN 31/07/2018
35.9 [35.723] / 9
Loader bucket control cylinder - Install - Bushing

piston rod eye (3) until recessed 8 mm (0.315 in).
with piston rod eye (3). The lips of the wipers (1) must
be towards outside of bore.
tube (4) eye until recessed 8 mm (0.315 in).
with tube (4) eye. The lips of wipers (1) must be to-
wards outside of bore.
LEIL13WHL1356BB 1
48083741_EN 31/07/2018
35.9 [35.723] / 10
Loader bucket control cylinder - Assemble

NOTE: refer to “Loader bucket control cylinder - exploded view” for the numbering of this procedure.
1. Install the bushing (17) in the gland (3).
NOTE: If a new gland is being used, put the part number
of the cylinder on the new gland.
2. Install the wide seal (13) in the gland (3). The wide seal
(13) is to be installed so that the lips of the wide seal
(13) are toward the bushing (17).
NOTE: the wide seal (13) can be difficult to install.
3. Install a new wiper (12) in the gland (3). The lips of the
wiper (12) must be toward the outside end of the gland
(3).
4. Install the narrow seal (14) in the gland (3). The side
of the narrow seal (14) with the groove must be toward
the bushing (17).
5. Install a new backup ring (15) in the groove on the out-
side of the gland (3). If both sides of the backup ring
(15) are not flat, the side that is not flat must be toward
the small end of the gland (3).
6. Install the O-ring (16) next to the backup ring (15) in the
groove on the outside of the gland (3). The O-ring (16)
must be toward the small end of the gland (3).
7. Remove any marks and sharp edges on the chamfer at
the end of the piston rod (4). Make sure that the piston
rod (4) is clean.
8. Lubricate the bore of the gland (3) and the piston rod
(4) with clean oil.
9. Push the gland (3) onto the piston rod (4). If necessary,
use a soft hammer to drive the gland (3) onto the piston
rod (4).
10. Put a support below and near the end of the piston
rod (4). Use a shop cloth between the support and
the piston rod (4) to prevent damage to the piston rod
(4).
11. Install a new backup ring (8) in the groove in the inner
diameter of the piston (7). If both sides of the backup
ring (8) are not flat, the side that is not flat must be
toward the O-ring (9).
12. Install a new O-ring (9) in the groove in the inner di-
ameter of the piston (7) next to the backup ring (8).
13. Install the other new backup ring (8) in the groove in
the inner diameter of the piston (7) next to the O-ring
(9). If both sides of the backup ring (8) are not flat, the
side that is not flat must be toward the O-ring (9).
14. Lubricate the inner diameter of the piston (7) with
clean oil.
15. Start the piston (7) onto the piston rod (4). Turn the
piston (7) onto the piston rod (4) until the piston (7) is
seated against the shoulder of the piston rod (4).
48083741_EN 31/07/2018
35.9 [35.723] / 11
16. If none of the holes in the piston (7) align with the holes
in the piston rod (4), turn the piston (7) counterclock-
wise until one of the holes in the piston (7) aligns with
one of holes in the piston rod (4). Do not turn the pis-
ton (7) more than 90°.
17. Install the pin (11) in the piston (7) and the piston rod
(4).
18. Install the retaining ring (10) in the pin (11).
19. Install a new wear ring (5) in the wide groove on the
outer diameter of the piston (7).
20. Install a new seal (6) in the groove on the outer diam-
LEIL13WHL1353AB 1
eter of the piston (7).
21. Fasten the tube (1) in an acceptable repair stand or
other holding equipment. Be careful to prevent dam-
age to the tube (1).
22. Lubricate the inside of the tube (1) and the outside of
the piston (7) with clean oil.
23. Push the piston (7) straight into the tube (1).
24. Lubricate the O-ring (16) on the gland (3) with clean
oil.
25. Push the gland into the tube (1) and align the holes in
the tube (1).
26. Install the cap screws (2) and hardened washers (18).
27. Tighten the cap screws (2) in the sequence shown.
Torque to 420 – 500 N·m (310 – 369 lb ft).
LEIL13WHL1354AA 2
48083741_EN 31/07/2018
35.9 [35.723] / 12
Loader bucket control cylinder - Install - Z-Bar loader

1. Apply anti-seize compound to the holes in the front
frame and to the holes in the loader arm for the bucket
cylinder.
2. Use a suitable lifting equipment to lower the bucket
cylinder into position.
NOTE: the bucket cylinder weights approximately 200 kg
(440 lb).
3. Install the pivot pin to the head end of the bucket cylin-
der.
NOTE: if a new pivot pin is being installed, connect the
grease line to the pivot pin.
4. Install the spacer, the washer and the bolt that fasten
the pivot pins to the front frame. Tighten the bolts.
5. If the rod end of the bucket cylinder is not aligned with
the bellcrank, have another person to start the engine
and run the engine at low idle, and use the bucket con-
trol lever to SLOWLY move the piston rod eye into align-
ment with the bellcrank.
LEIL13WHL1272AA 1
6. Install the pivot pin and stop the engine.
7. Install the spacer, washer and bolt that fasten the pivot
pin to the bellcrank. Tighten the bolt.
LEIL13WHL1270AA 2
48083741_EN 31/07/2018
35.9 [35.723] / 13
8. Connect the tubes (5) and (6) to the bucket cylinder (1)
performing the follow operation.
Position the brackets (7) and install the bolts (2),
the washers (3), and the nuts (4) to fix the tubes
(5) and (6) to the brackets (7).
LEIL16WHL1022FB 3
9. SLOWLY extend and retract the piston rod three times

to remove any air from the bucket cylinder.
10. Lubricate the pivot pins with moly-disulfide grease.
reservoir.
48083741_EN 31/07/2018
35.9 [35.723] / 14
Index

Loader bucket control cylinder - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Loader bucket control cylinder - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Loader bucket control cylinder - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Loader bucket control cylinder - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Loader bucket control cylinder - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Loader bucket control cylinder - Install - Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Loader bucket control cylinder - Install - Z-Bar loader . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Loader bucket control cylinder - Remove - Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Loader bucket control cylinder - Remove - Z-Bar loader . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Loader bucket control cylinder - Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
48083741_EN 31/07/2018
35.9 [35.723] / 15
48083741_EN 31/07/2018
35.9 [35.723] / 16
Tool quick coupler hydraulic system - 734

48083741_EN 31/07/2018
35.10 [35.734] / 1
Contents
SERVICE
Solenoid valve
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
48083741_EN 31/07/2018
35.10 [35.734] / 2
Hydraulic systems - Tool quick coupler hydraulic system
Solenoid valve - Remove

3
lease any air in the reservoir. Connect a vacuum pump
to the hydraulic reservoir, turn on the pump.
4. Gain access to the solenoid valve (1) located on the
front chassis (A) of the machine.
5. Disconnect the pressure hose (2), the tank hose (3),
and the coupler hoses (4) from the solenoid valve (1).
LEIL16WHL1031BA 1
48083741_EN 31/07/2018
35.10 [35.734] / 3
6. Remove the two nuts (5), the two washers (6), the two
bolts (7) and the two washers (8) to release the bracket
(9) that fix the solenoid valve (1) to the front chassis (A).
7. Remove the solenoid valve (1).
LEIL16WHL1030BA 2
48083741_EN 31/07/2018
35.10 [35.734] / 4
Solenoid valve - Install

1. Position the solenoid valve (1) on the front chassis (A).
Install the bracket (9) and fix using the washers (8), the
bolts (7), the washers (6) and the nuts (5).
LEIL16WHL1030BA 1
2. Connect the coupler hoses (4), the tank hose (3), and
the pressure hose (2) to the solenoid valve (1).
3. Check the hydraulic fluid level and add hydraulic oil to
the system as required.
LEIL16WHL1031BA 2
48083741_EN 31/07/2018
35.10 [35.734] / 5
Index

Solenoid valve - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Solenoid valve - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
48083741_EN 31/07/2018
35.10 [35.734] / 6
48083741_EN 31/07/2018
35.10 [35.734] / 7
PRINTED IN ITALY
48083741_EN 31/07/2018
EN
SERVICE MANUAL
Frames and ballasting

48083741_EN 31/07/2018
39
Contents
Frames and ballasting - 39
[39.100] Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39.1
48083741_EN 31/07/2018
39
Frame - 100

48083741_EN 31/07/2018
39.1 [39.100] / 1
Contents
Frame - 100
TECHNICAL DATA
Articulation frame pivot

Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
FUNCTIONAL DATA

Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
SERVICE

Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
48083741_EN 31/07/2018
39.1 [39.100] / 2
Frames and ballasting - Frame
Articulation frame pivot - Torque

M16 bolt for upper pivot pin 224 – 278 N·m (165 – 205 lb ft)
M16 bolts for bearing retainers 224 – 278 N·m (165 – 205 lb ft)
M16 bolts for lower pin plate 224 – 278 N·m (165 – 205 lb ft)
M16 socket head bolts for lower pivot pin 168 – 209 N·m (124 – 154 lb ft)
Ferry head screws for the drive shaft 75 – 81 N·m (55 – 60 lb ft)
Articulation frame pivot - Special tools

1288730249 Hand pump (hydraulic ram)
CAS10193 Vacuum pump ( 12 volt)
48083741_EN 31/07/2018
39.1 [39.100] / 3
Articulation frame pivot - Exploded view
LEIL13WHL1365GB 1
Center pivot assembly
1. Bolt 9. Upper pivot bearing

2. Washer 10. Lower pivot pin
3. Spacer 11. Lower bearing spacer
4. Upper pivot pin 12. Lower pivot bearing
5. Rear chassis 13. Bearing retainer
6. Seal 14. Bottom spacer
7. Bearing retainer 15. Lower pin plate
8. Shim 16. Front chassis
48083741_EN 31/07/2018
39.1 [39.100] / 4
Articulation frame pivot - Disassemble

NOTE: refer to “Articulation frame pivot - Exploded view” for the numbering of this procedure.
1. Remove all dirt and grease from the area of the center
pivot. Park the machine on a level surface.
2. Lower the bucket until the bucket is flat on the floor.
4. Remove the covers from both sides of the machine.
5. Disconnect the front wiring harness from the cab floor.
6. Remove any tie straps that fasten the front wiring har-
ness to the chassis near the center pivot.
7. Loosen and remove the nut and washer that fasten the
chassis ground wire and cab ground wire to the studs.
8. Loosen and remove the bolt, lock washer, and nut that
fasten the clamp on the front wiring harness to the
bracket on the rear frame. Move the front wiring har-
ness out of the way.
9. Loosen and remove the fill cap for the hydraulic reser-
voir.
10. Connect the vacuum pump CAS10193 to the hy-
draulic reservoir. Start the vacuum pump.
11. Disconnect the brake hose from the backside of front
brake line bracket.
12. Install a plug in the tube and a cap on the fitting.
13. Disconnect the hoses for the steering cylinder.
14. Install caps on the fittings and plugs in the hoses.
15. Loosen and remove the bolts, lock washers, and self-
locking nuts that fasten the mounting bracket for the
hoses to the bracket on the front frame.
16. Loosen and remove the bolts, flat washers, and self-
locking nuts that fasten the bracket for the hoses to
the rear frame.
17. Disconnect the return hose.
18. Install the cap on the hose and a plug in the fitting.
19. Disconnect the supply hose.
20. Install a cap on the hose and a plug in the fitting.
21. Stop the vacuum pump CAS10193.
22. Loosen and remove the self-locking nut and bolt that
hold the pivot pin for the steering cylinder rod eye.
23. Remove the pivot pin from the rear frame and the
steering cylinder rod eye.
24. Remove the washer from the rear frame. Move the
steering cylinder out of the way.
25. Repeat steps for the other steering cylinder.
26. Loosen and remove the Ferry head screws and retain-
ers that fasten the drive shaft to the front yoke. Move
the drive shaft out of the way.
48083741_EN 31/07/2018
39.1 [39.100] / 5
27. Place two stands below and in contact with the front
frame.
28. Install blocks between the rear axle and the rear frame
on both sides of the machine to prevent the rear frame
from tipping.
29. Put a jack in contact with both sides of the rear frame
near the center pivot area. Use another jack at the
rear of the machine to prevent the rear frame from
tipping.
30. Loosen and remove the bolt (1), washer (2), and
spacer (3) that fasten the upper pivot pin (4) to the
rear chassis (5).
31. Use a prybar to remove the upper pivot pin (4).
32. Loosen and remove the bolts (1) and washers (2) that
fasten the lower pin plate (15) to the lower pivot pin
(10).
fasten the lower pin plate (15) to the bottom of the rear
chassis (5).
34. Use a suitable ram and hand pump 1288730249 to
remove the lower pivot pin (10).
35. Install the puller on the bottom spacer (14).
36. Remove the bottom spacer (14).
38. Use prybars to turn the left rear wheel backwards and
the right rear wheel forward to move the front of the
rear frame to the left for access to the bearings. Install
blocks under the wheels to prevent the rear frame from
moving.
40. Hold the bearing retainer (13) in place and loosen and
remove the bolts (1) and washers (2) that fasten the
bearing retainer (13) and shims (8) to the bottom of
the rear pivot.
41. Remove the bearing retainer (13) and shims (8).
42. Remove the lower bearing spacer (11) from the top of
the lower pivot.
fasten the bearing retainer (7) and shims (8) to the top
of the top pivot.
44. Remove the bearing retainer (7) and shims (8).
45. Use the puller to remove the seal (6) from the top of
the bottom pivot.
46. Use the puller to remove the seal (6) from the bottom
of the top pivot.
48083741_EN 31/07/2018
39.1 [39.100] / 6
47. Use an acceptable driver, the hydraulic ram, and the

hand pump to remove the upper pivot bearing (9) from
the top pivot.
NOTE: the spacers are matched to the bearing sets. Do
not mix the spacers. Do not use the old spacers if new
bearing sets are being installed.
48. Use an acceptable driver, the hydraulic ram, and the
hand pump to remove the lower pivot bearing (12)
from the bottom pivot.
NOTE: the spacers are matched to the bearing sets. Do
not mix the spacers. Do not use the old spacers if new
bearing sets are being installed.
49. Use an acceptable driver to press the seal (6) out of
each bearing retainer (7) and (13) .
48083741_EN 31/07/2018
39.1 [39.100] / 7
Articulation frame pivot - Assemble

1. Pack the bearing cones with grease. Be careful not to
mix the bearing cones.
2. Lubricate the bore in the top pivot with grease.
3. Install a bearing cup (20) in the top pivot (22).
4. Install the bearing driver (17) and plate (21).
LEIL13WHL1077AB 1
5. Tighten a nut (18) on the screw (19) until the bearing

cup (20) is seated in the bore of the top pivot (22).
Remove the bearing driver (17) and plate (21) from the
top pivot (22).
6. Install a bearing cone (25), spacer (24), the other bear-
ing cone (23), and the remaining bearing cup (26) in
the top pivot (22).
cup (26) is seated against the spacer (24). Remove
the bearing driver (17) and plate (21) from the top pivot
(22).
9. Put the bearing retainer (7) in place on the upper pivot
bearing (9).
LEIL13WHL1078AB 2
retainer (7) is tight against the upper pivot bearing (9).
12. Measure the gap (27) between the bearing retainer (7)
and the top pivot (22). Make a record of the measure-
ment. Subtract 0.076 – 0.102 mm (0.003 – 0.004 in)
from the measurement. Select shims (8) equal to that
value.
13. Remove the bearing driver (17), plate (21) and bearing
retainer (7) from the top pivot.
14. Install the shims (8) and the bearing retainer (7).
15. Install the washers (2) and bolts (1). Tighten the bolts
LEIL13WHL1079AB 3
(1) to 224 – 278 N·m (165 – 205 lb ft).
48083741_EN 31/07/2018
39.1 [39.100] / 8
16. Install the seal (6) in the bearing retainer (7). The top
of the seal (6) must be even with the top of the bearing
retainer (7).
17. Fill the other seal (6) for the top pivot with grease.
18. Use an acceptable driver to install the seal (6) in the
bottom of the top pivot.
LEIL13WHL1080AA 4
19. The bottom of the seal (6) must be even with the bot-
tom of the top pivot.
20. Apply grease to the upper pivot pin (4).
21. Install the upper pivot pin (4) in the top pivot.
22. Lubricate the top pivot until grease is forced out of the
seal (6).
23. Rotate the upper pivot pin (4) to check the bearing as-
sembly. The upper pivot pin (4) must rotate smoothly,
but not easily. Leave the upper pivot pin (4) in place
to keep dirt out of the upper pivot bearing (9).
24. Lubricate the bore for the bottom pivot with grease. LEIL13WHL1081AA 5
Install a bearing cup in the bottom pivot.
cup (28) is seated in the bore in the bottom pivot (29).
27. Remove the bearing driver (17) and plate (21) from
the bottom pivot (29).
28. Install a bearing cone (25), spacer (24), the other
bearing cone (23), and the remaining bearing cup (26)
in the bottom pivot (29).
LEIL13WHL1082AB 6

30. Tighten a nut (18) on the screw (19) until the bottom
bearing cup (26) is seated against the spacer (24).
31. Remove the bearing driver (17) and plate (21) from
the bottom pivot (29).
32. Put the bearing retainer (13) in place on the lower pivot
bearing (12).
LEIL13WHL1083AB 7
48083741_EN 31/07/2018
39.1 [39.100] / 9
33. Install the bearing driver and plate.

retainer (13) is tight against the lower pivot bearing
assembly (12).
35. Measure the gap (30) between the bearing retainer
(13) and the bottom pivot (29). Make a record of the
measurement. Subtract 0.0762 – 0.1016 mm (0.003
– 0.004 in) from the measurement. Select shims (8)
equal to that value.
36. Remove the bearing driver (17), plate (21) and bearing
retainer (13) from the bottom pivot.
LEIL13WHL1084AB 8
37. Install the shims (8), the bearing retainer (13), wash-
ers (2) and bolts (1).
38. Tighten the bolts (1) to 224 – 278 N·m (165 – 205 lb
ft).
39. Fill the seal (6) for the bearing retainer (13) with
grease.
40. Install the seal (6) in the bearing retainer (13). The
bottom of the seal (6) must be even with the bottom of
the bearing retainer (13).
LEIL13WHL1081AA 9
41. Install the other seal (6) in the bottom pivot. The top
of the seal (6) must be even with the top of the bottom
pivot.
42. Install the lower bearing spacer (11) and the bottom
spacer (14).
43. Apply grease to the lower pivot pin (10).
44. Install the lower pivot pin (10) in the bottom pivot.
45. Hold the bottom spacer (14) in place and lubricate the
bottom pivot until grease is forced out of the seal (6).
46. Rotate the lower pivot pin (10) to check the bearing as-
sembly. The lower pivot pin (10) must rotate smoothly, LEIL13WHL1080AA 10
but not easily.
47. Remove the lower pivot pin (10) and the upper pivot
pin (4).
48. Remove the bottom spacer (14).
48083741_EN 31/07/2018
39.1 [39.100] / 10
Articulation frame pivot - Install

Connecting the front frame to the rear frame
NOTE: refer to “Articulation frame pivot - Exploded view” for the numbering of this procedure.
2. Move the rear frame into alignment with the front frame.
3. Move the steering cylinders as required to move the
rear frame into alignment with the front frame.
5. Apply grease to the upper pivot pin (4).
6. Install the upper pivot pin (4), spacer (3), washer (2)
and bolt (1). Be careful not to damage the seal (6).
7. Tighten the bolt (1) to 224 – 278 N·m (165 – 205 lb ft).
8. Apply grease to the lower pivot pin (10). .
9. Install the lower pivot pin (10) in the frames. Be careful
not to damage the seal (6).
10. Use a suitable ram and hand pump 1288730249 to
install the bottom spacer (14).
11. Install the lower pin plate (15), three inner bolts (1),
and washers (2) that fasten the lower pin plate (15) to
the lower pivot pin (10).
12. Tighten the bolts (1) to 69 N·m (51 lb ft).
13. Measure the gap between the lower pin plate (15) and
the bottom pivot. Make a record of the measurement.
Subtract 0.0762 – 0.1016 mm (0.003 – 0.004 in) from
the measurement. Select shims equal to that value.
14. Remove the bolts (1) that fasten the lower pin plate
(15) to the lower pivot pin (10).
15. Install the shims (8).
16. Start the six outer bolts (1) into the lower pin plate (15)
and the bottom pivot.
17. Tighten the six outer bolts (1) to 224 – 278 N·m (165
– 205 lb ft).
18. Tighten the three inner bolts (1) to 168 – 209 N·m (124
– 154 lb ft). Apply one drop of LOCTITE® 243™ to
each socket head bolt for pivot pin.
19. Remove the jacks from the rear frame.
20. Remove the blocks from the rear axle.
21. Remove the stands from the front frame.
22. Put the drive shaft in position on the front yoke.
23. Install new Ferry head screws that fasten the drive
shaft to the front yoke.
24. Tighten the Ferry head screws to 75 – 81 N·m (55 –
60 lb ft).
25. Put the steering cylinder rod eye in position in the
frame. Install the washer between the steering cylin-
der rod eye and the rear frame.
48083741_EN 31/07/2018
39.1 [39.100] / 11
26. Align the hole in the pivot pin with the holes in the
steering cylinder rod eye, and install the pivot pin.
27. Install the bolt and self-locking nut that hold the pivot
pin.
28. Repeat steps 25, 26 and 27 for the other steering
cylinder.
30. Connect the return hose.
31. Connect the supply hose.
32. Put the bracket for the hoses in position on the rear
frame. Install the bolts, flat washers, and self-locking
nuts that fasten the bracket to the rear frame.
33. Put the bracket for the hoses in position on the front
frame.
34. Install the bolts, flat washers, and self-locking nuts
that fasten the bracket to the front frame.
35. Connect the hoses for the steering cylinders.
36. Connect the brake hose for the front brakes at the front
bracket.
38. Connect the front wiring harness to the rear wiring
harness.
39. Put the clamp on the wiring harness in position on
the bracket. Install the bolt, lock washer, and nut that
fasten the clamp on the wiring harness to the bracket.
40. Put the ground wire in position on the stud. Install the
washer and nut that fasten the ground wire to the stud.
41. Install a tie strap to fasten the wiring harness to the
tube.
42. Disconnect the vacuum pump from the hydraulic
reservoir.
43. Check the fluid level in the hydraulic reservoir. Add oil
as required.
44. Install the fill cap in the hydraulic reservoir.
45. Bleed air from the front axle bleed screws.
46. Lubricate the pivot pins for the steering cylinder rod
eyes.
47. Install the covers on both sides of the machine.
48083741_EN 31/07/2018
39.1 [39.100] / 12
Index
Frame - 100
Articulation frame pivot - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Articulation frame pivot - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Articulation frame pivot - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Articulation frame pivot - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Articulation frame pivot - Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Articulation frame pivot - Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
48083741_EN 31/07/2018
39.1 [39.100] / 13
PRINTED IN ITALY
48083741_EN 31/07/2018
EN
SERVICE MANUAL
Steering

48083741_EN 31/07/2018
41
Contents
Steering - 41
[41.101] Steering control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.1
[41.200] Hydraulic control components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.2
[41.216] Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.3
[41.910] Auxiliary steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.4
48083741_EN 31/07/2018
41
Steering - 41
Steering control - 101

48083741_EN 31/07/2018
41.1 [41.101] / 1
Contents
Steering - 41
SERVICE
Steering control
Service instruction - Steering limit pressure - Test and adjustment (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Service instruction - Steering limit pressure - Test and adjustment (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Steering column
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
48083741_EN 31/07/2018
41.1 [41.101] / 2
Steering - Steering control
Steering control - Service instruction - Steering limit pressure -

Test and adjustment
Pressure setting test

NOTICE: when performing the following pressure check
and adjustment, the articulation lock must be installed. Use
caution when working in or near the articulation area.
LEIL13WHL1236AA 1
2. Remove the dust cap from the test port (1) located
on the steering priority valve. Connect a 345 bar
(5002 psi) test gauge to the test port (1).
NOTE: make sure when you connect the pressure gauge
that you do so in a manner that you can read the pressure
gauge while sitting on the operator seat.
LEIL13WHL1289AB 2

ground.
5. Steer hard in either direction over the relief pressure.
48083741_EN 31/07/2018
41.1 [41.101] / 3
7. The pressure gauge must indicate 239 – 243 bar (3466

– 3524 psi).
In case of machine equipped with Joystick Steering
(JSS):
● with the engine at low idle, with all the controls in
neutral, JSS NOT active, a differential reading of 28 –
30 bar (406 – 435 psi) should be obtained;
● with the engine at low idle, with all the controls in neu-
tral, JSS ON and joystick in neutral, a differential read-
ing of 28 – 30 bar (406 – 435 psi) should be obtained;
neutral, JSS ON and joystick in full left or right turn,
a differential reading of 28 – 30 bar (406 – 435 psi)
should be obtained.
8. If the pressure is not correct, adjust the steering relief
valve.
Pressure setting adjustment

1. Use the steering relief valve (1) located on the priority
valve to adjust the steering limit pressure. Turn the
screw clockwise to increase the limit pressure. Turn the
screw counterclockwise to decrease the limit pressure.
LEIL13WHL1291AB 4
2. Repeat the pressure test procedure.

3. If necessary, adjust the limit valve again until within the
specified range.
4. Stop the engine before removing the pressure gauge.
48083741_EN 31/07/2018
41.1 [41.101] / 4
Steering control - Service instruction - Steering limit pressure -

Test and adjustment

LEIL13WHL1236AA 1
LEIL16WHL0911AA 2

ground.
48083741_EN 31/07/2018
41.1 [41.101] / 5

– 3524 psi).
(JSS):
should be obtained.
valve.
Pressure setting adjustment

LEIL16WHL0911AA 4

specified range.
48083741_EN 31/07/2018
41.1 [41.101] / 6
Steering column - Remove

1. Remove the floor mat (1).
LEIL18WHL0318AB 1
2. Remove the emblem plug (1).
LEIL18WHL0270AB 2
3. Unscrew the nut (1) with the relevant washer (2), and
remove the steering wheel (3).
LEIL18WHL0311AB 3
48083741_EN 31/07/2018
41.1 [41.101] / 7
4. Remove the four screws (1) that fix the top steering
column cover (2) to the left-hand and right-hand upper
steering column covers (3) and (4).
LEIL18WHL0312AB 4
LEIL18WHL0313AB 5
5. Remove the four screws (1) that hold the right-hand

upper steering column cover (2) to the left-hand upper
steering column cover. Remove the right-hand upper
steering column cover (2) from the machine.
LEIL18WHL0314AB 6
LEIL18WHL0315AB 7
48083741_EN 31/07/2018
41.1 [41.101] / 8
6. Remove the two screws (1) that hold the left-hand

upper steering column cover (2) to steering column
bracket.
LEIL18WHL0316AB 8
7. Disconnect the connector X-S_HZD (Receptacle) (2)

from the flasher switch.
Disconnect the connector X-TT (Receptacle) (3) from
the lamp indicator console.
Disconnect the connector X-SRWP (Receptacle) (4)
from the rear wiper switch.
Remove the two screws (1). Remove the top steering
column cover (5) from the machine.
LEIL18WHL0317AB 9
8. Remove the three screws (1) to remove the right-hand

lower steering column cover (2).
LEIL18WHL0326AB 10
9. Remove the two screws (1) to remove the (2) the left-
hand lower steering column cover (2).
LEIL18WHL0327AB 11
48083741_EN 31/07/2018
41.1 [41.101] / 9
10. Remove the eight screws (1) that fix the top front con-
sole (2). Remove the top front console (2) from the
machine.
LEIL18WHL0319AB 12
11. Disconnect the connector X-PED_2 (Plug) (1) from

the connector X-CAB_P2 (Receptacle) of the main
cab harness.
Disconnect the connector X-PED (Receptacle) (2)
from the connector X-CAB_P (Plug) of the main cab
harness.
Cut the cable tie (arrow).
LEIL18WHL0320AB 13
12. Disconnect the connector X-TS2 (Receptacle) (3)

and the connector X-GND_PED (Plug) (2).
Loosen the screw (1) to remove the transmission con-
trol lever (4).
LEIL18WHL0322AB 14
13. Disconnect the connector X-STLK (Receptacle) from

the right-hand multifunction lever (2).
Unscrew the three screws (1) to remove the multifunc-
tion lever (3).
LEIL18WHL0323AB 15
48083741_EN 31/07/2018
41.1 [41.101] / 10
14. Loosen and remove the bolts washers, and nuts that
fasten the right-hand rear cab skirt (1), the right-hand
cab skirt (2) and the center cab skirt (3) to have access
to the steering control valve bracket.
LEIL16WHL1189FB 16
15. Remove the four nuts (1) with the eight washers (un-
der bolt head and nut) and the four bolts to sepa-
rate the steering valve bracket (2) from the cab frame
steering column assembly (3).
Disengage the steering control valve (4) from the
steering shaft.
Remove the steering column (with the pedestal har-
ness) from the machine.
NOTE: the cab floor is NOT shown, for clarity.
LEIL18WHL0328AB 17
48083741_EN 31/07/2018
41.1 [41.101] / 11
16. Remove the ground strap (1) unscrewing the two fix-
ing screws and related washers.
Separate the connector X-TERM (Receptacle) from
the steering column (5).
Remove the three clamp (3).
Separate the pedestal harness (4) from the steering
column (5).
LEIL18WHL0324BB 18
LEIL18WHL0325BA 19
48083741_EN 31/07/2018
41.1 [41.101] / 12
Steering column - Install

1. Install the ground strap (1) on the steering column (5)
with two fixing screws.
Install the three clamp (3) to joint the pedestal harness
(4) to the steering column (5).
Fix the connector X-TERM (Receptacle) to the steer-
ing column (5).
LEIL18WHL0324BB 1
2. Engage the steering control valve (4) into the steering

shaft.
Tighten the four nuts (1) with the eight washers (under
bolt head and nut) and the four bolts to fasten the steer-
ing valve bracket (2) to the cab frame steering column
assembly (3).
NOTE: the cab floor is NOT shown, for clarity.
LEIL18WHL0328AB 2
48083741_EN 31/07/2018
41.1 [41.101] / 13
3. Install the bolts, washers, and nuts to mount the right-

hand rear cab skirt (1), the right-hand cab skirt (2) and
the center cab skirt (3) on the cab.
LEIL16WHL1189FB 3
4. Install the multifunction lever (3) with the three screws

(1).
Connect the connector X-STLK (Receptacle) (2) to the
right-hand multifunction lever (3).
LEIL18WHL0323AB 4
5. Install the transmission control lever (4) with the screw

(1).
Connect the connector X-TS2 (Receptacle) (3) and the
connector X-GND_PED (Plug) (2).
LEIL18WHL0322AB 5
48083741_EN 31/07/2018
41.1 [41.101] / 14
6. Connect the connector X-PED (Receptacle) (2) of the

pedestal harness to the connector X-CAB_P (Plug) of
the main cab harness.
Connect the connector X-PED_2 (Plug) (1) of the
pedestal harness to the connector X-CAB_P2 (Re-
ceptacle) of the main cab harness.
Install a new cable tie (arrow).
LEIL18WHL0320AB 6
7. Place the top front console (2) in the correct position.

Tighten the eight screws (1) to fix the top front console
(2).
LEIL18WHL0319AB 7
8. Install the top steering column cover (5) with the two
screws (1).
Connect the connector X-S_HZD (Receptacle) (2) to
the flasher switch.
Connect the connector X-TT (Receptacle) (3) to the
lamp indicator console.
Connect the connector X-SRWP (Receptacle) (4) to
the rear wiper switch.
LEIL18WHL0317AB 8
9. Install the left-hand lower steering column cover (2) to

the steering column bracket. Tighten the two screws
(1).
LEIL18WHL0327AB 9
48083741_EN 31/07/2018
41.1 [41.101] / 15
10. Install the right-hand lower steering column cover (2).

Tighten the three screws (1).
LEIL18WHL0326AB 10
11. Install the left-hand upper steering column cover (2) to

steering column bracket. Tighten the two screws (1).
LEIL18WHL0316AB 11
12. Install the right-hand upper steering column cover (2).

Tighten the four screws (1).
LEIL18WHL0314AB 12
LEIL18WHL0315AB 13
48083741_EN 31/07/2018
41.1 [41.101] / 16
13. Tighten the four screws (1) to fix the top steering col-
umn cover (2) to the left-hand and right-hand upper
steering column cover (3) and (4).
LEIL18WHL0312AB 14
LEIL18WHL0313AB 15
14. Install the steering wheel (3). Tighten the nut (1), with
the relevant washer (2), to 43.0 – 57.0 N·m (31.7 –
42.0 lb ft).
15. Install the emblem plug (1).
LEIL18WHL0270AB 16
16. Place the floor mat (1) in the cab.
LEIL18WHL0318AB 17
48083741_EN 31/07/2018
41.1 [41.101] / 17
Index
Steering - 41

Steering column - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Steering column - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Steering control - Service instruction - Steering limit pressure - Test and adjustment (*) . . . . . . . . . . 3
Steering control - Service instruction - Steering limit pressure - Test and adjustment (*) . . . . . . . . . . 5
48083741_EN 31/07/2018
41.1 [41.101] / 18
Steering - 41
Hydraulic control components - 200

48083741_EN 31/07/2018
41.2 [41.200] / 1
Contents
Steering - 41
TECHNICAL DATA
Hydraulic control components

Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
FUNCTIONAL DATA
Hydraulic steering system

Component identification - Standard steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Component identification - Standard steering with JSS (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Component identification - Steering system with Auxiliary Steering (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Component identification - Steering system with Auxiliary Steering and JSS (*) . . . . . . . . . . . . . . . . . . . . 22
Component identification - Standard steering (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Component identification - Standard steering with JSS (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Component identification - Steering system with Auxiliary Steering (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Component identification - Steering system with Auxiliary Steering and JSS (*) . . . . . . . . . . . . . . . . . . . . 42
SERVICE
Hydraulic steering system

Remove - Steering EHPS and cut-off valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Install - Steering EHPS and cut-off valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Service instruction (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Service instruction (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Steering valve
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Main priority valve
Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Test (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Test (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
48083741_EN 31/07/2018
41.2 [41.200] / 2
Adjust (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Adjust (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Steering circuit relief valve
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Auxiliary steering priority valve
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
48083741_EN 31/07/2018
41.2 [41.200] / 3
Steering - Hydraulic control components
Hydraulic control components - Special tools

CAS10280 Flow meter
LEIL13WHL0655AA 1
LEIL13WHL0656AA 2
CAS1804 Pressure test fitting kit
LEIL13WHL0657AA 3
48083741_EN 31/07/2018
41.2 [41.200] / 4
48083741_EN 31/07/2018
41.2 [41.200] / 5
Hydraulic steering system - Component identification - Standard

steering
HYDRAULIC COMPONENTS OF THE STANDARD STEERING SYSTEM - Sheet 1 of 2
1. Load Sense hose 10. Right-hand base hose

2. Steering supply hose 11. Block clamp
3. Right-hand rod hose 12. Clamp
4. Steering pump isolator 13. O-ring
5. Steel mount bushing 14. Orbitrol valve
6. Rubber mount bushing 15. Relief valve
7. BellevilLe washer, M10x22 16. Steering priority valve
8. Bolt, M10x30 CL 10.9 17. Check valve
9. Right-hand steering cylinder hose
48083741_EN 31/07/2018
41.2 [41.200] / 6
LEIL16WHL0536JB 1
48083741_EN 31/07/2018
41.2 [41.200] / 7
1. Load Sense hose 10. Right-hand base hose

2. Steering supply hose 11. Block clamp
3. Right-hand rod hose 12. Clamp
4. Steering pump isolator 13. O-ring
5. Steel mount bushing 14. Orbitrol valve
6. Rubber mount bushing 15. Relief valve
7. BellevilLe washer, M10x22 16. Steering priority valve
8. Bolt, M10x30 CL 10.9 17. Check valve
9. Right-hand steering cylinder hose
48083741_EN 31/07/2018
41.2 [41.200] / 8
LEIL17WHL1570JB 2
48083741_EN 31/07/2018
41.2 [41.200] / 9
Hydraulic steering system - Component identification - Standard steering with JSS

821G ZBAR - EH, NEW CAB TIER2 ANZ --- APAC --- LA --- MEA 13. Hydraulic connector 41. Nut M8
14. Washer, 9x21x2.5 mm 42. Washer, 6.6x12x1.6 mm
HYDRAULIC COMPONENTS OF THE STANDARD STEERING SYSTEM WITH JOYSTICK STEERING (JSS) - Sheet 15. Bolt, M8x20 CL 8.8 43. Bolt, M6x70 CL 10.9
1 of 2
16. T-joint 44. Nut M6
1. Steering EHPS valve 29. Hose (to tank) 17. Hose (to steering cylinder) 45. Right-hand steering cylinder head tube
2. Bracket 30. Steering pump isolator 18. Hose (to steering cylinder) 46. Block clamp
3. Hydraulic connector 31. Steel mount bushing 19. T-joint 47. Hose clamp
4. 90° elbow 32. Rubber mount bushing 20. T-joint 48. Right-hand base hose
5. 90° elbow 33. Steering angle sensor 21. Washer, 13.5x28x4 mm 49. O-ring
6. Hydraulic connector 34. Belleville washer, M10x22 22. Nut M12 50. Orbitrol valve
7. Hydraulic shuttle tee valve 35. Bolt, M10x30 CL 10.9 23. Bolt, M12x50 CL 10.9 51. Steering priority valve
8. 90° elbow 36. Bracket 24. Right-hand rod hose 52. Washer, 9x17x2 mm
9. Hydraulic connector 37. Bracket 25. Steering load sense hose 53. Bolt, M8x10 CL 8.8
10. Hydraulic connector 38. Washer, 6.6x12.5x2 mm 26. Steering supply hose 54. Washer, 9x16x1.6 mm
11. 90° elbow 39. Bolt, M8x20 CL 10.9 27. Steering load sense hose 55. Nut
12. Cut-off valve 40. Bolt, M8x25 CL 10.9 28. Suction valve hose 56. JSS sensor mounting bracket
48083741_EN 31/07/2018
41.2 [41.200] / 10
LEIL16WHL0538JB 1
48083741_EN 31/07/2018
41.2 [41.200] / 11
HYDRAULIC COMPONENTS OF THE STANDARD STEERING SYSTEM WITH JOYSTICK STEERING (JSS) - Sheet 14. Washer, 9x21x2.5 mm 42. Washer, 6.6x12x1.6 mm
2 of 2 15. Bolt, M8x20 CL 8.8 43. Bolt, M6x70 CL 10.9
16. T-joint 44. Nut M6
1. Steering EHPS valve 29. Hose (to tank)
17. Hose (to steering cylinder) 45. Right-hand steering cylinder head tube
2. Bracket 30. Steering pump isolator
18. Hose (to steering cylinder) 46. Block clamp
3. Hydraulic connector 31. Steel mount bushing
19. T-joint 47. Hose clamp
4. 90° elbow 32. Rubber mount bushing
20. T-joint 48. Right-hand base hose
5. 90° elbow 33. Steering angle sensor
21. Washer, 13.5x28x4 mm 49. O-ring
6. Hydraulic connector 34. Belleville washer, M10x22
22. Nut M12 50. Orbitrol valve
7. Hydraulic shuttle tee valve 35. Bolt, M10x30 CL 10.9
23. Bolt, M12x50 CL 10.9 51. Steering priority valve
8. 90° elbow 36. Bracket
24. Right-hand rod hose 52. Washer, 9x17x2 mm
9. Hydraulic connector 37. Bracket
25. Steering load sense hose 53. Bolt, M8x10 CL 8.8
10. Hydraulic connector 38. Washer, 6.6x12.5x2 mm
26. Steering supply hose 54. Washer, 9x16x1.6 mm
11. 90° elbow 39. Bolt, M8x20 CL 10.9
27. Steering load sense hose 55. Nut
12. Cut-off valve 40. Bolt, M8x25 CL 10.9
28. Suction valve hose 56. JSS sensor mounting bracket
13. Hydraulic connector 41. Nut M8
48083741_EN 31/07/2018
41.2 [41.200] / 12
LEIL16WHL1756JB 2
48083741_EN 31/07/2018
41.2 [41.200] / 13
Hydraulic steering system - Component identification - Steering system with Auxiliary Steering
821G ZBAR - EH, NEW CAB TIER2 ANZ --- APAC --- LA --- MEA 15. Bolt, M10x35 CL 10.9 45. Nut, M8
16. Steering pressure hose 46. Washer, 9x16x1.6 mm
HYDRAULIC COMPONENTS OF THE STEERING SYSTEM WITH AUXILIARY STEERING - Sheet 1 of 4 17. Auxiliary steering tank hose 47. Clamp
1. Orbitrol valve 31. Washer, 10.5x18x1.6mm 18. 45° elbow 48. Washer, 9x16x1.6 mm
2. Steering priority valve 32. 90° elbow 19. Filter manifold 49. Bolt, M8x25 CL 10.9
3. Right-hand rod hose 33. Auxiliary pressure hose 20. Auxiliary steering pressure hose 50. Bolt, M12x40 CL 10.9
4. Right-hand base hose 34. Hydraulic connector 21. Hydraulic connector 51. Tie hose
5. Block clamp 35. Hydraulic tank filter 22. 90° elbow 52. Cable tie strap
6. O-ring 36. Hydraulic tank 23. Hydraulic connector 53. Auxiliary steering module harness
7. Clamp 37. Pressure sensor 24. Nut, M6 54. Auxiliary steering cable
8. Right-hand steering cylinder hose 38. 45° elbow 25. Washer, 6.6x18x1.6 mm 55. Clamp
9. Auxiliary steering valve 39. 90° elbow 26. Hydraulic connector 56. Starter engine
10. Steering load sense hose 40. Bolt, M6x110 CL 10.9 27. Auxiliary pressure tube assembly 57. Electrical boot
11. Steering pump isolator 41. Washer, 6.6x18x1.6 mm 28. 90° elbow 58. Battery negative cable
12. Rubber mount bushing 42. Auxiliary steering bracket 29. Auxiliary steering pump 59. Tie strap
13. Steel mount bushing 43. Bolt, M10x30 CL 10.9 30. Nut, M10
14. Belleville washer, M10x22 44. Washer, 11x24x3 mm
48083741_EN 31/07/2018
41.2 [41.200] / 14
LEIL16WHL0805JB 1
48083741_EN 31/07/2018
41.2 [41.200] / 15
HYDRAULIC COMPONENTS OF THE STEERING SYSTEM WITH AUXILIARY STEERING - Sheet 2 of 4 16. Steering pressure hose 46. Washer, 9x16x1.6 mm
17. Auxiliary steering tank hose 47. Clamp
1. Orbitrol valve 31. Washer, 10.5x18x1.6mm
18. 45° elbow 48. Washer, 9x16x1.6 mm
2. Steering priority valve 32. 90° elbow
19. Filter manifold 49. Bolt, M8x25 CL 10.9
3. Right-hand rod hose 33. Auxiliary pressure hose
20. Auxiliary steering pressure hose 50. Bolt, M12x40 CL 10.9
4. Right-hand base hose 34. Hydraulic connector
21. Hydraulic connector 51. Tie hose
5. Block clamp 35. Hydraulic tank filter
22. 90° elbow 52. Cable tie strap
15. Bolt, M10x35 CL 10.9 45. Nut, M8
48083741_EN 31/07/2018
41.2 [41.200] / 16
LEIL16WHL0806JB 2
48083741_EN 31/07/2018
41.2 [41.200] / 17
15. Bolt, M10x35 CL 10.9 45. Nut, M8
48083741_EN 31/07/2018
41.2 [41.200] / 18
LEIL16WHL0925JB 3
48083741_EN 31/07/2018
41.2 [41.200] / 19
15. Bolt, M10x35 CL 10.9 45. Nut, M8
48083741_EN 31/07/2018
41.2 [41.200] / 20
LEIL16WHL0808JB 4
48083741_EN 31/07/2018
41.2 [41.200] / 21
Hydraulic steering system - Component identification - Steering system with Auxiliary Steering and JSS
821G ZBAR - EH, NEW CAB TIER2 ANZ --- APAC --- LA --- MEA 13. Hydraulic connector 40. Bolt, M8x25 CL 10.9
14. Washer, 9x21x2.5 mm 41. Block clamp
HYDRAULIC COMPONENTS OF THE STEERING SYSTEM WITH AUXILIARY STEERING AND JSS - Sheet 1 of 3 15. Bolt, M8x20 CL 8.8 42. Washer, 6.6x12x1.6 mm
1. Steering EHPS valve 28. Suction valve hose 16. Steering priority valve 43. Bolt, M6x70 CL 10.9
2. Bracket 29. Hose (to tank) 17. Hose (to steering cylinder) 44. Nut M6
3. Hydraulic connector 30. Steering pump isolator 18. Hose (to steering cylinder) 45. Steel mount bushing
4. 90° elbow 31. Rubber mount bushing 19. Hydraulic connector 46. Steering angle sensor
5. 90° elbow 32. 45° elbow 20. Right-hand base hose 47. Belleville washer, M10x22
6. Tee 33. Right-hand steering cylinder tube head 21. Washer, 13.5x28x4 mm 48. Bolt, M10x30 CL 10.9
7. Hydraulic shuttle tee valve 34. Clamp 22. Nut M12 49. Auxiliary steering valve
8. Hydraulic connector 35. O-ring 23. Bolt, M12x50 CL 10.9 50. Orbitrol valve
9. Hydraulic connector 36. Bracket 24. Right-hand rod hose 51. JSS sensor mounting bracket
10. Hydraulic connector 37. Bracket 25. Steering “LS” hose 52. Bolt, M8x10 CL 8.8
11. 90° elbow 38. Washer, 9x17x2 mm 26. Steering “LS” hose 53. Washer, 9x16x1.6 mm
12. Cut-off valve 39. Bolt, M8x20 CL 10.9 27. Tee 54. Nut
48083741_EN 31/07/2018
41.2 [41.200] / 22
LEIL16WHL0809JB 1
48083741_EN 31/07/2018
41.2 [41.200] / 23
HYDRAULIC COMPONENTS OF THE STEERING SYSTEM WITH AUXILIARY STEERING AND JSS - Sheet 2 of 3 14. Washer, 9x21x2.5 mm 41. Block clamp
15. Bolt, M8x20 CL 8.8 42. Washer, 6.6x12x1.6 mm
1. Steering EHPS valve 28. Suction valve hose
16. Steering priority valve 43. Bolt, M6x70 CL 10.9
2. Bracket 29. Hose (to tank)
17. Hose (to steering cylinder) 44. Nut M6
3. Hydraulic connector 30. Steering pump isolator
18. Hose (to steering cylinder) 45. Steel mount bushing
19. Hydraulic connector 46. Steering angle sensor
5. 90° elbow 32. 45° elbow
20. Right-hand base hose 47. Belleville washer, M10x22
6. Tee 33. Right-hand steering cylinder tube head
21. Washer, 13.5x28x4 mm 48. Bolt, M10x30 CL 10.9
7. Hydraulic shuttle tee valve 34. Clamp
22. Nut M12 49. Auxiliary steering valve
8. Hydraulic connector 35. O-ring
23. Bolt, M12x50 CL 10.9 50. Orbitrol valve
27. Tee 54. Nut
13. Hydraulic connector 40. Bolt, M8x25 CL 10.9
48083741_EN 31/07/2018
41.2 [41.200] / 24
LEIL16WHL1757JB 2
48083741_EN 31/07/2018
41.2 [41.200] / 25
1. Steering EHPS valve 28. Suction valve hose
5. 90° elbow 32. 45° elbow
27. Tee 54. Nut
48083741_EN 31/07/2018
41.2 [41.200] / 26
LEIL16WHL0811JB 3
48083741_EN 31/07/2018
41.2 [41.200] / 27
Hydraulic steering system - Component identification - Standard steering

1. Load Sense hose 9. Right-hand steering cylinder hose

2. Steering supply hose 10. Right-hand base hose
3. Right-hand rod hose 11. Block clamp
4. Steering pump isolator 12. Clamp
5. Steel mount bushing 13. O-ring
6. Rubber mount bushing 14. Orbitrol valve
7. BellevilLe washer, M10x22 15. Relief valve
48083741_EN 31/07/2018
41.2 [41.200] / 28
LEIL16WHL0918JB 1
48083741_EN 31/07/2018
41.2 [41.200] / 29
1. Load Sense hose 9. Right-hand steering cylinder hose

2. Steering supply hose 10. Right-hand base hose
3. Right-hand rod hose 11. Block clamp
4. Steering pump isolator 12. Clamp
5. Steel mount bushing 13. O-ring
6. Rubber mount bushing 14. Orbitrol valve
7. Belleville washer, M10x22 15. Relief valve
48083741_EN 31/07/2018
41.2 [41.200] / 30
LEIL16WHL0917JB 2
48083741_EN 31/07/2018
41.2 [41.200] / 31
Hydraulic steering system - Component identification - Standard steering with JSS

921G ZBAR - EH, NEW CAB TIER2 ANZ --- APAC --- LA --- MEA 12. Cut-off valve 38. Washer, 6.6x12.5x2 mm
HYDRAULIC COMPONENTS OF THE STANDARD STEERING SYSTEM WITH JOYSTICK STEERING (JSS) - Sheet 14. Washer, 9x21x2.5 mm 40. Bolt, M8x25 CL 10.9
1 of 2
15. Bolt, M8x20 CL 8.8 41. Nut, M8
1. Steering EHPS valve 27. JSS load sense hose 16. T-joint 42. Washer, 6.6x12x1.6 mm
2. Bracket 28. JSS pressure hose 17. Hose (to steering cylinder) 43. Bolt, M6x70 CL 10.9
3. Hydraulic connector 29. Hose (to tank) 18. Hose (to steering cylinder) 44. Nut, M6
4. 90° elbow 30. Steering pump isolator 19. Steering priority valve 45. Right-hand steering cylinder head tube
5. 45° elbow 31. Steel mount bushing 20. O-ring 46. Block clamp
6. Orbitrol valve 32. Rubber mount bushing 21. Washer, 13.5x28x4 mm 47. Hose clamp
7. Hydraulic shuttle tee valve 33. Steering angle sensor 22. Nut M12 48. Right-hand base hose
8. Tee 34. Belleville washer, M10x22 23. Bolt, M12x50 CL 10.9 49. Bolt, M8x30 CL 8.8
9. Hydraulic connector 35. Bolt, M10x30 CL 10.9 24. Right-hand rod hose 50. Washer, 9x16x1.6 mm
10. Hydraulic connector 36. Bracket 25. Steering load sense hose 51. Nut
11. 90° elbow 37. Bracket 26. Washer, 9x17x2 mm 52. JSS sensor mounting bracket
48083741_EN 31/07/2018
41.2 [41.200] / 32
LEIL16WHL0919JB 1
48083741_EN 31/07/2018
41.2 [41.200] / 33
HYDRAULIC COMPONENTS OF THE STANDARD STEERING SYSTEM WITH JOYSTICK STEERING (JSS) - Sheet 13. Hydraulic connector 39. Bolt, M8x20 CL 10.9
2 of 2 14. Washer, 9x21x2.5 mm 40. Bolt, M8x25 CL 10.9
15. Bolt, M8x20 CL 8.8 41. Nut, M8
1. Steering EHPS valve 27. JSS load sense hose
16. T-joint 42. Washer, 6.6x12x1.6 mm
2. Bracket 28. JSS pressure hose
17. Hose (to steering cylinder) 43. Bolt, M6x70 CL 10.9
3. Hydraulic connector 29. Hose (to tank)
18. Hose (to steering cylinder) 44. Nut, M6
4. 90° elbow 30. Steering pump isolator
19. Steering priority valve 45. Right-hand steering cylinder head tube
5. 45° elbow 31. Steel mount bushing
20. O-ring 46. Block clamp
6. Orbitrol valve 32. Rubber mount bushing
21. Washer, 13.5x28x4 mm 47. Hose clamp
7. Hydraulic shuttle tee valve 33. Steering angle sensor
22. Nut M12 48. Right-hand base hose
8. Tee 34. Belleville washer, M10x22
23. Bolt, M12x50 CL 10.9 49. Bolt, M8x30 CL 8.8
24. Right-hand rod hose 50. Washer, 9x16x1.6 mm
10. Hydraulic connector 36. Bracket
25. Steering load sense hose 51. Nut
11. 90° elbow 37. Bracket
26. Washer, 9x17x2 mm 52. JSS sensor mounting bracket
12. Cut-off valve 38. Washer, 6.6x12.5x2 mm
48083741_EN 31/07/2018
41.2 [41.200] / 34
LEIL16WHL1760JB 2
48083741_EN 31/07/2018
41.2 [41.200] / 35
Hydraulic steering system - Component identification - Steering system with Auxiliary Steering
921G ZBAR - EH, NEW CAB TIER2 ANZ --- APAC --- LA --- MEA 15. Bolt, M10x35 CL 10.9 45. Nut, M8
16. Steering pressure hose 46. Washer, 9x16x1.6 mm
HYDRAULIC COMPONENTS OF THE STEERING SYSTEM WITH AUXILIARY STEERING - Sheet 1 of 3 17. Auxiliary steering tank hose 47. Clamp
1. Orbitrol valve 31. Washer, 10.5x18x1.6mm 18. 45° elbow 48. Washer, 9x16x1.6 mm
2. Steering priority valve 32. 90° elbow 19. Filter manifold 49. Bolt, M8x25 CL 10.9
3. Right-hand rod hose 33. Auxiliary pressure hose 20. Auxiliary steering pressure hose 50. Bolt, M12x40 CL 10.9
4. Right-hand base hose 34. Hydraulic connector 21. Hydraulic connector 51. Tie hose
5. Block clamp 35. Hydraulic tank filter 22. 90° elbow 52. Cable tie strap
8. Right-hand steering cylinder hose 38. Clamp 25. Washer, 6.6x18x1.6 mm 55. Clamp
10. Steering load sense hose 40. Bolt, M6x110 CL 10.9 27. Auxiliary pressure tube assy 57. Electrical boot
11. Steering pump isolator 41. Washer, 6.6x18x1.6 mm 28. 90° elbow 58. Battery neg. cable
48083741_EN 31/07/2018
41.2 [41.200] / 36
LEIL16WHL0921JB 1
48083741_EN 31/07/2018
41.2 [41.200] / 37
15. Bolt, M10x35 CL 10.9 45. Nut, M8
48083741_EN 31/07/2018
41.2 [41.200] / 38
LEIL16WHL0922JB 2
48083741_EN 31/07/2018
41.2 [41.200] / 39
15. Bolt, M10x35 CL 10.9 45. Nut, M8
48083741_EN 31/07/2018
41.2 [41.200] / 40
LEIL16WHL0923JB 3
48083741_EN 31/07/2018
41.2 [41.200] / 41
Hydraulic steering system - Component identification - Steering system with Auxiliary Steering and JSS
921G ZBAR - EH, NEW CAB TIER2 ANZ --- APAC --- LA --- MEA 13. Hydraulic connector 40. Bolt, M8x25 CL 10.9
14. Washer, 9x21x2.5 mm 41. Block clamp
HYDRAULIC COMPONENTS OF THE STEERING SYSTEM WITH AUXILIARY STEERING AND JSS - Sheet 1 of 3 15. Bolt, M8x20 CL 8.8 42. Washer, 6.6x12x1.6 mm
1. Steering EHPS valve 28. JSS pressure hose 16. Steering priority valve 43. Bolt, M6x70 CL 10.9
2. Bracket 29. Hose (to tank) 17. Hose (to steering cylinder) 44. Nut M6
3. Hydraulic connector 30. Steering pump isolator 18. Hose (to steering cylinder) 45. Steel mount bushing
4. 90° elbow 31. Rubber mount bushing 19. Hydraulic connector 46. Steering angle sensor
5. 90° elbow 32. 45° elbow 20. Right-hand base hose 47. Belleville washer, M10x22
6. Tee 33. Right-hand steering cylinder tube head 21. Washer, 13.5x28x4 mm 48. Bolt, M10x30 CL 10.9
7. Hydraulic shuttle tee valve 34. Clamp 22. Nut M12 49. Auxiliary steering valve
8. Hydraulic connector 35. O-ring 23. Bolt, M12x50 CL 10.9 50. Orbitrol valve
10. Hydraulic connector 37. Bracket 25. Steering LS hose 52. Bolt, M8x10 CL 8.8
11. 90° elbow 38. Washer, 9x17x2 mm 26. Steering LS hose 53. Washer, 9x16x1.6 mm
12. Cut-off valve 39. Bolt, M8x20 CL 10.9 27. Tee 54. Nut
48083741_EN 31/07/2018
41.2 [41.200] / 42
LEIL16WHL0926JB 1
48083741_EN 31/07/2018
41.2 [41.200] / 43
1. Steering EHPS valve 28. JSS pressure hose
5. 90° elbow 32. 45° elbow
27. Tee 54. Nut
48083741_EN 31/07/2018
41.2 [41.200] / 44
LEIL16WHL1761JB 2
48083741_EN 31/07/2018
41.2 [41.200] / 45
1. Steering EHPS valve 28. JSS pressure hose
5. 90° elbow 32. 45° elbow
27. Tee 54. Nut
48083741_EN 31/07/2018
41.2 [41.200] / 46
LEIL16WHL0954JB 3
48083741_EN 31/07/2018
41.2 [41.200] / 47
48083741_EN 31/07/2018
41.2 [41.200] / 48
Hydraulic steering system - Remove - Steering EHPS and cut-off

valves
1. Clean all dirt and grease from the steering valves and
adjacent areas.
2. Remove the fill cap of the hydraulic reservoir. Attach a
vacuum pump to the reservoir. Start the pump.
3. Loosen and remove the steering LS hose (2) from the
steering EHPS valve (1).
4. Tag and disconnect the suction valve hose (3) and hose
(tank to) (4) from the steering EHPS valve (1). Plug the
hoses and cap the fittings.
5. Tag and disconnect the hose (to cylinder) (6) from the
cut-off valve (5) and the hose (to cylinder) (8) from the
cut-off valve (7). Plug the hoses and cap the fittings.
LEIL16WHL0824BA 1
6. Remove the two bolts M6x70 (7), washers (under bolt

head) (8), washers (under nut) (9) and nuts (10).
head) (12), washers (under nut) (13) and nuts (14),
paying attention to the release of bracket (4). Remove
the mounting bracket (4).
LEIL16WHL0913BB 2
48083741_EN 31/07/2018
41.2 [41.200] / 49

head) (16), washers (under nut) (17) and nuts (18).
9. Remove the two bolts M8x20 (19) and washers (20),
paying attention to the release of bracket (5). Remove
the mounting bracket (5).
LEIL16WHL0828BB 3
10. Remove the three bolts M8x20 (21) and washers (22).
Remove the steering EHPS valve and cut-off valves
assembly from the mounting bracket (6).
11. Remove the three bolts M12x50 (23), washers (under
bolt head) (24), washers (under nut) (25) and nuts
(26). Remove the mounting bracket (6) from the rear
chassis.
LEIL16WHL0829BB 4
48083741_EN 31/07/2018
41.2 [41.200] / 50
12. Disconnect the two cut-off valves (2) and (3) from the
steering EHPS valve (1). Unscrew all hydraulic con-
nectors and elbows from the steering EHPS valve (1)
and cut-off valves (2) and (3).
LEIL16WHL0830AB 5
48083741_EN 31/07/2018
41.2 [41.200] / 51
Hydraulic steering system - Install - Steering EHPS and cut-off

valves
NOTE: before assembling the steering valves, clean the parts with solvent and dry them.
1. Inspect each part for defects.
2. Replace all damaged or deformed parts with new ones.
3. Install the hydraulic connectors to the steering EHPS
valve (1):
A. install the fitting (2) to the LS port; tighten to 35 N·m
(26 lb ft);
B. connect the 90° elbow (3) to the T port; tighten to
60 N·m (44 lb ft);
C. connect the 90° elbow (4) to the P port; tighten to
90 N·m (66 lb ft).
LEIL16WHL0831AB 1
4. Install the two cut-off valves (7) and (8) to the steering
EHPS valve (1):
A. install the fitting (2) to the CL port of the steering
EHPS valve (1); tighten to 70 N·m (52 lb ft);
B. install the fitting (3) to the P1 port of the cut-off
valve (7); tighten to 100 N·m (74 lb ft);
C. connect the cut-off valve (7) to the fitting (2)
through the fitting (3); tighten to 60 N·m (44 lb ft);
D. install the 90° elbow (4) to the CR port of the
steering EHPS valve (1); tighten to 70 N·m (52 lb
ft);
E. install the fitting (6) to the P1 port of the cut-off
valve (8); tighten to 100 N·m (74 lb ft);
F. install the 90° elbow (5) to the 90° elbow (4);
tighten to 60 N·m (44 lb ft);
G. connect the cut-off valve (8) to the 90° elbow (5)
through the fitting (6); tighten to 60 N·m (44 lb ft);
H. install the fittings (9) and (10) to the P2 port of the
two cut-off valves. Tighten the fittings to 100 N·m
(74 lb ft).
LEIL16WHL0835BB 2
48083741_EN 31/07/2018
41.2 [41.200] / 52
5. Install the bracket (6) to the rear chassis by using three

bolts M12x50 (23), washers (under bolt head) (24),
washers (under nut) (25) and nuts (26).
6. Place the steering EHPS valve and cut-off valves as-
sembly onto the mounting bracket (6) and fix by using
three bolts M8x20 (21) and washers (22).
LEIL16WHL0829BB 3
7. Place and install the bracket (5) to the steering EHPS

valve (1) by using two bolts M8x20 (19) and washers
(20), and to the cut-off valve (2) with two bolts M6x70
(15), washers (under bolt head) (16), washers (under
nut) (17) and nuts (18).
LEIL16WHL0828BB 4
48083741_EN 31/07/2018
41.2 [41.200] / 53
8. Place and install the bracket (4) to the bracket (5) by

using two bolts M8x25 (11), washers (under bolt head)
(12), washers (under nut) (13) and nuts (14), and to
the cut-off valve (3) with two bolts M6x70 (7), washers
(under bolt head) (8), washers (under nut) (9) and nuts
(10).
LEIL16WHL0827BB 5
9. Connect the hose (to cylinder) (6) to the cut-off valve

(5) and the hose (to cylinder) (8) to the cut-off valve
(7). Tighten to 60 N·m (44 lb ft).
10. Connect the suction valve hose (3) to the 90° elbow
pre-mounted into the P port of the steering EHPS
valve (1). Tighten to 90 N·m (66 lb ft).
11. Connect the hose (tank to) (4) to the 90° elbow pre-
mounted into the T port of the steering EHPS valve
12. Connect the steering LS hose (2) to the fitting pre-
mounted into the LS port of the steering EHPS valve
LEIL16WHL0824BA 6
48083741_EN 31/07/2018
41.2 [41.200] / 54
Hydraulic steering system - Service instruction

A. Pressure setting test

LEIL13WHL1236AA 1
LEIL13WHL1289AB 2

ground.
48083741_EN 31/07/2018
41.2 [41.200] / 55

– 3524 psi).
(JSS):
should be obtained.
valve.
B. Pressure setting adjustment

LEIL13WHL1291AB 4

specified range.
C. Steering speed level setting

NOTICE: when performing the following procedure check
that the articulation of the unit is NOT locked.
The speed of steering is not constant but depends on
the speed reached by the vehicle. On reaching 20 km/h
(12.43 mph) the steering sensitivity is reduced by 80%
compared to the normal speed of steering.
The JSS can be set through the display in the cab on
three different levels of steering speed.
48083741_EN 31/07/2018
41.2 [41.200] / 56
The three speed levels are:

1. Slow - from 4.5 s to 5.5 s *
2. Medium - from 3.2 s to 4.5 s *
3. Fast - from 2.8 s to 3.2 s *
*(time to take the machine from all right to all left).
The purpose of this setting is to make steering the ma-
chine equipped with the JSS similar to the standard
steering system:
LEIL15WHL0533AA 5
1. With the engine at idle speed, with all the controls in

neutral and JSS ON, steer the machine completely to
the left.
2. Set a speed level (e.g. 1, 2 or 3).
3. Move the joystick completely to the right and at the
same time, with a chronometer, start measuring the
time. Stop the chronometer when the machine is com-
pletely steered on the right-hand side. Take the time to
compare it with the time specified in the table of speed
levels.
4. Move the joystick completely to the left and at the same
time, with a chronometer, start measuring the time.
Stop the chronometer when the machine is completely
steered on the left-hand side. Take the time to compare
it with the time specified in the table of speed levels. If
the value is not in the range shown in the table, follow
the system calibration procedure.
5. Repeat what is specified in point 1, 2, 3, and 4 with the
engine at high idle.
6. If the adjustments are not exact, verify the specifica-
tions given in paragraphs A and B.
48083741_EN 31/07/2018
41.2 [41.200] / 57
Hydraulic steering system - Service instruction

A. Pressure setting test

LEIL13WHL1236AA 1
LEIL16WHL0911AA 2

ground.
48083741_EN 31/07/2018
41.2 [41.200] / 58

– 3524 psi).
(JSS):
should be obtained.
valve.
B. Pressure setting adjustment

LEIL16WHL0911AA 4

specified range.
C. Steering speed level setting

NOTICE: when performing the following procedure check
that the articulation of the unit is NOT locked.
The speed of steering is not constant but depends on
the speed reached by the vehicle. On reaching 20 km/h
(12.43 mph) the steering sensitivity is reduced by 80%
compared to the normal speed of steering.
The JSS can be set through the display in the cab on
three different levels of steering speed.
48083741_EN 31/07/2018
41.2 [41.200] / 59
The three speed levels are:

1. Slow - from 4.5 s to 5.5 s *
2. Medium - from 3.2 s to 4.5 s *
3. Fast - from 2.8 s to 3.2 s *
*(time to take the machine from all right to all left).
The purpose of this setting is to make steering the ma-
chine equipped with the JSS similar to the standard
steering system:
LEIL15WHL0533AA 5
1. With the engine at idle speed, with all the controls in

neutral and JSS ON, steer the machine completely to
the left.
2. Set a speed level (e.g. 1, 2 or 3).
3. Move the joystick completely to the right and at the
same time, with a chronometer, start measuring the
time. Stop the chronometer when the machine is com-
pletely steered on the right-hand side. Take the time to
compare it with the time specified in the table of speed
levels.
4. Move the joystick completely to the left and at the same
time, with a chronometer, start measuring the time.
Stop the chronometer when the machine is completely
steered on the left-hand side. Take the time to compare
it with the time specified in the table of speed levels. If
the value is not in the range shown in the table, follow
the system calibration procedure.
5. Repeat what is specified in point 1, 2, 3, and 4 with the
engine at high idle.
6. If the adjustments are not exact, verify the specifica-
tions given in paragraphs A and B.
48083741_EN 31/07/2018
41.2 [41.200] / 60
Steering valve - Remove

1. Remove the cab skirts from the cab.
2. Remove all dirt and grease from the steering control
valve.
3. Remove the fill cap of the hydraulic reservoir, attach a
vacuum pump to the reservoir, start the pump.
4. Tag the hoses connected to the steering control valve.
5. Disconnect the hoses from the steering control valve,
cap or plug the fittings and the hoses, turn off the vac-
uum pump.
6. Loosen the four nuts (see arrows) to unfix the steering
valve bracket from the cab frame. Disengage the steer-
ing control valve from the steering shaft.
LEIL16WHL1122AA 1
7. Remove the four bolts (4), washers (5), steel bush-

ings and rubber bushings (not visible in figure) to un-
fix the steering control valve (3) from the steering valve
bracket (2). Pay attention to the release of the steering
isolator (1).
LEIL16WHL1171AA 2
48083741_EN 31/07/2018
41.2 [41.200] / 61
Steering valve - Install

1. Place the steering isolator (1) between the steering
control valve (3) and the steering valve bracket (2). Ori-
ent the steering isolator (1) with boss features towards
cab. Install and tighten the four mounting bolts (4) with
the washers (5), steel bushings and rubber bushings
(not visible in figure) to fix the steering control valve (3)
to steering valve bracket (2).
LEIL16WHL1171AA 1
2. Engage the steering control valve into the steering

shaft.
3. Tighten the four nuts (see arrows) to fix the steering
valve bracket to the cab frame.
4. Start the vacuum pump, remove the caps and plugs
from the fittings and hoses. Connect the hoses to the
steering control valve according to the tags installed
during removal. Remove and discard the tags.
LEIL16WHL1122AA 2
48083741_EN 31/07/2018
41.2 [41.200] / 62
Main priority valve - Remove

LEIL16WHL0851GB 1
1. Low pressure pump (loader pump) 7. Split flange

2. High pressure pump (steering pump) 8. Steering priority valve
3. O-ring 9. Hydraulic connector
4. Priority discharge tube 10. Priority tank hose
5. Bolt, M10x30 CL10.9 11. Diagnostic coupler
6. Washer, 11x20x2.0 mm 12. Bolt, M10x140 CL10.9
48083741_EN 31/07/2018
41.2 [41.200] / 63
1. Park the machine on a level ground and lower the

bucket to the ground. Put the transmission in NEU-
TRAL, apply the parking brake and shut down the en-
gine.
2. Put the timed disconnect switch to the OFF position.
3. Remove all dirt and grease from the steering priority
valve (8) and adjacent area.
4. Remove the hydraulic reservoir fill cap.
7. Tag and disconnect all hoses connected to the steering
priority valve (8).
8. Loosen and remove the four bolts (5) and washers (6)
joining the priority discharge tube (4) to the high pres-
sure pump (2).
9. Loosen and remove the four bolts (5), washers (6) and
two split flanges (7) joining the priority discharge tube
(4) to the steering priority valve (8).
10. Remove the priority discharge tube (4), discard the
two O-rings (3).
11. Support the steering priority valve (8), remove the four
mounting bolts (12) and washers (6). Discard the
O-ring (not shown).
12. Remove the steering priority valve (8) from the low
pressure pump (1).
48083741_EN 31/07/2018
41.2 [41.200] / 64
Main priority valve - Remove

LEIL16WHL0915GB 1

4. Priority discharge tube 11. Diagnostic coupler
5. Bolt, M14x75 CL10.9 12. Bolt, M10x145 CL10.9
6. Washer, spring lock 14 mm 13. Washer, spring lock 10 mm
7. Bolt, M14x45 CL10.9
48083741_EN 31/07/2018
41.2 [41.200] / 65
1. Park the machine on a level ground and lower the

bucket to the ground. Put the transmission in NEU-
TRAL, apply the parking brake and shut down the en-
gine.
3. Remove all dirt and grease from the steering priority
valve (9) and adjacent area.
7. Tag and disconnect all hoses connected to the steering
priority valve (9).
8. Loosen and remove the four bolts (5) and washers (6)
joining the priority discharge tube (4) to the high pres-
sure pump (2).
9. Loosen and remove the four bolts (7), washers (6) and
two split flanges (8) joining the priority discharge tube
(4) to the steering priority valve (9).
10. Remove the priority discharge tube (4), discard the
two O-rings (3).
11. Support the steering priority valve (9), remove the four
mounting bolts (12) and washers (13). Discard the
O-ring (not shown).
12. Remove the steering priority valve (9) from the low
pressure pump (1).
48083741_EN 31/07/2018
41.2 [41.200] / 66
Main priority valve - Install

LEIL16WHL0851GB 1

4. Priority discharge tube 10. Priority tank hose
5. Bolt, M10x30 CL10.9 11. Diagnostic coupler
6. Washer, 11x20x2.0 mm 12. Bolt, M10x140 CL10.9
48083741_EN 31/07/2018
41.2 [41.200] / 67
1. Install the four bolts (12) with washers (6) through the
steering priority valve (8). Install a new O-ring (not
shown) on the top of the steering priority valve. In-
stall the steering priority valve (8) onto the low pressure
pump (1). Tighten the bolts to 37 – 48 N·m (27 – 35 lb
ft).
2. Install two new O-rings (3) onto the priority discharge
tube (4).
3. Place the priority discharge tube (4) into position and
install to the steering priority valve (8) with the four bolts
(5), washers (6) and two split flanges (7). Tighten the
bolts.
4. Install the priority discharge tube (4) to the high pres-
sure pump (2) with the four bolts (5) and washers (6).
Tighten the bolts.
5. Connect all hoses as tagged to the steering priority
valve (8).
7. Disconnect the vacuum pump from the hydraulic reser-
voir.
8. Install the fill cap on the hydraulic reservoir.
Start the engine and run at low idle for 30 seconds.
Stop the engine and check for leaks.
10. Make sure the steering priority valve operates cor-
rectly.
as required.
48083741_EN 31/07/2018
41.2 [41.200] / 68
Main priority valve - Install

LEIL16WHL0915GB 1

4. Priority discharge tube 11. Diagnostic coupler
5. Bolt, M14x75 CL10.9 12. Bolt, M10x145 CL10.9
6. Washer, spring lock 14 mm 13. Washer, spring lock 10 mm
7. Bolt, M14x45 CL10.9
48083741_EN 31/07/2018
41.2 [41.200] / 69
1. Install the four bolts (12) with washers (13) through the
steering priority valve (9). Install a new O-ring (not
shown) on the top of the steering priority valve. In-
stall the steering priority valve (9) onto the low pressure
pump (1). Tighten the bolts to 37 – 48 N·m (27 – 35 lb
ft).
2. Install two new O-rings (3) onto the priority discharge
tube (4).
3. Place the priority discharge tube (4) into position and
install to the steering priority valve (9) with the four bolts
(7), washers (6) and two split flanges (8). Tighten the
bolts.
4. Install the priority discharge tube (4) to the high pres-
sure pump (2) with the four bolts (5) and washers (6).
Tighten the bolts.
5. Connect all hoses as tagged to the steering priority
valve (9).
7. Disconnect the vacuum pump from the hydraulic reser-
voir.
10. Make sure the steering priority valve operates cor-
rectly.
as required.
48083741_EN 31/07/2018
41.2 [41.200] / 70
Main priority valve - Test

NOTE: the loader/steering pump differential pressure must be properly adjusted before doing this test.

RCPH10WHL063BAL 1
LEIL13WHL1289AB 2

ground.
48083741_EN 31/07/2018
41.2 [41.200] / 71

– 3524 psi).
(JSS):
should be obtained.
valve.
48083741_EN 31/07/2018
41.2 [41.200] / 72
Main priority valve - Test

NOTE: the loader/steering pump differential pressure must be properly adjusted before doing this test.

RCPH10WHL063BAL 1
LEIL16WHL0911AA 2

ground.
48083741_EN 31/07/2018
41.2 [41.200] / 73

– 3524 psi).
(JSS):
should be obtained.
valve.
48083741_EN 31/07/2018
41.2 [41.200] / 74
Main priority valve - Adjust


LEIL18WHL0001AB 1

specified range.
48083741_EN 31/07/2018
41.2 [41.200] / 75
Main priority valve - Adjust


LEIL16WHL0911AA 1

specified range.
48083741_EN 31/07/2018
41.2 [41.200] / 76
Steering circuit relief valve - Remove
LEIL17WHL1697GB 1
1. Steering relief valve 7. Bolt, M6x100 CL10.9

2. Return manifold 8. Washer, 6.6x12x1.6 mm
3. Steering return hose 9. Clamp
4. Orbitrol valve 10. Washer, 6.6x18x1.6 mm
5. Return (to filters) hose 11. Nut, M6
6. Hydraulic connector 12. Spacer
48083741_EN 31/07/2018
41.2 [41.200] / 77
1. Remove the fill cap from the hydraulic reservoir to re-

lease the pressure in the reservoir; attach a vacuum
pump to the reservoir; start the pump.
2. Disconnect the return hose (3) and return (to filters)
hose (5) from the steering relief valve (1). Plug the
hoses and cup the fittings.
3. Remove the two bolts (7), washers (under bolt) (8), the
clamp (9), the two spacers (12), washers (under nut)
and nuts (11). Remove the steering relief valve from
the rear chassis.
48083741_EN 31/07/2018
41.2 [41.200] / 78
Steering circuit relief valve - Install
LEIL17WHL1697GB 1

48083741_EN 31/07/2018
41.2 [41.200] / 79
1. Fix the steering relief valve (1) to the rear chassis with
the two bolts (7), washers (under bolt) (8), the clamp
(9) (only one location), the two spacers (12), washers
(under nut) (10) and nuts (11). Tighten the bolts.
2. Install new O-rings onto the fittings of the hoses. Install
and tighten the return hose (3) and return (to filters)
hose (5) to the steering relief valve.
3. Stop the vacuum pump; install and tighten the reservoir
fill cap.
4. Start and run the machine at low idle; turn the steering
wheel from full left lock to full right lock, holding the
steering over relief.
5. Stop the machine and check for leaks.
as required.
48083741_EN 31/07/2018
41.2 [41.200] / 80
Steering circuit relief valve - Test

Pressure test
LEIL17WHL1697GB 1

1. Disconnect the return hose (3) from the hydraulic con-

nector (6).
2. Install a “T” fitting and connect a pressure gauge able
to read 35 bar (508 psi).
48083741_EN 31/07/2018
41.2 [41.200] / 81
3. Start and run the machine at high idle.

4. Turn the steering wheel and read the pressure.
5. The pressure should be 8 – 10 bar (116 – 145 psi).
6. If pressure is not as specified, replace the steering relief
valve (1).
NOTE: the relief valve is not adjustable.
48083741_EN 31/07/2018
41.2 [41.200] / 82
Auxiliary steering priority valve - Remove
LEIL13WHL0650FB 1
1. Steering LS hose (to priority valve) 6. Cap screws and nuts

2. Steering LS hose (to orbitrol valve) 7. Pressure hose
3. Pressure sensor 8. Steering solenoid
4. Suction port 9. Steering pressure hose
5. Pump out pressure tube fitting 10. Return hose (to tank)
1. Park the machine on level ground and lower the bucket

to ground. Put the transmission in NEUTRAL, apply the
parking brake and shut down the engine.
3. Remove all dirt and grease from the auxiliary steering
priority valve and adjacent area.
7. Tag and disconnect the suction hose from the suction
port (4), from the auxiliary steering pump and from the
motor. Install a cap on the fitting and a plug in the hose.
8. Tag and disconnect the return tube (to tank) (10) from
the auxiliary steering priority valve. Install a cap on the
elbow and a plug in the tube.
48083741_EN 31/07/2018
41.2 [41.200] / 83
10. Tag and disconnect the wiring from the steering sole-
noid (8).
11. Tag and disconnect the wiring from the pressure sen-
sor (3).
12. Tag and disconnect the steering LS hose (2) from the
auxiliary steering priority valve. Install a cap on the
elbow and a plug in the hose.
13. Tag and disconnect the steering LS hose (1) from the
auxiliary steering priority valve. Install a cap on the
elbow and a plug in the hose.
14. Tag and disconnect the steering pressure hose (9)
from the auxiliary steering priority valve. Install a cap
on the fitting and a plug in the hose.
15. Tag and disconnect the pressure hose (7) from auxil-
iary steering priority valve. Install a cap on the fitting
and a plug in the hose.
16. Loosen the fitting (5) connected to the elbow installed
in the auxiliary steering priority valve.
17. Support the auxiliary steering priority valve. Remove
the four nuts (6), the cap screws and the washers.
18. Remove the auxiliary steering priority valve.
48083741_EN 31/07/2018
41.2 [41.200] / 84
Auxiliary steering priority valve - Install
LEIL13WHL0650FB 1
1. Steering LS hose (to priority valve) 6. Cap screws and nuts

2. Steering LS hose (to orbitrol valve) 7. Pressure hose
3. Pressure sensor 8. Steering solenoid
4. Suction port 9. Steering pressure hose
5. Pump out pressure tube fitting 10. Return hose (to tank)
1. Connect and hand tighten the fitting (5) to the elbow in

the auxiliary steering priority valve.
2. Install the cap screws, the washers and the nuts (6).
3. Tighten the pressure tube fitting (5).
4. Tighten the nuts (6).
5. Connect and tighten the pressure hose (7).
6. Connect and tighten the steering pressure hose (9).
7. Connect and tighten the steering LS hose (1).
8. Connect and tighten the steering LS hose (2).
9. Connect the electrical connector to the pressure sensor
(3).
10. Connect the electrical connector to the steering sole-
noid (8).
12. Connect and tighten the return tube (to tank) (10).
48083741_EN 31/07/2018
41.2 [41.200] / 85
13. Connect and tighten the hose to the auxiliary steering

pump port (4).
14. Stop the vacuum pump. Disconnect the vacuum
pump from the hydraulic reservoir.
17. Check to make sure that auxiliary steering priority
valve operates correctly.
as required.
48083741_EN 31/07/2018
41.2 [41.200] / 86
Index
Steering - 41

Auxiliary steering priority valve - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Auxiliary steering priority valve - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Hydraulic control components - Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Hydraulic steering system - Component identification - Standard steering . . . . . . . . . . . . . . . . . . . . . 6
Hydraulic steering system - Component identification - Standard steering (*) . . . . . . . . . . . . . . . . . . . 28
Hydraulic steering system - Component identification - Standard steering with JSS (*) . . . . . . . . . . 10
Hydraulic steering system - Component identification - Standard steering with JSS (*) . . . . . . . . . . 32
Hydraulic steering system - Component identification - Steering system with Auxiliary Steering (*) 14
Hydraulic steering system - Component identification - Steering system with Auxiliary Steering (*) 36
Hydraulic steering system - Component identification - Steering system with Auxiliary Steering and
JSS (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Hydraulic steering system - Component identification - Steering system with Auxiliary Steering and
JSS (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Hydraulic steering system - Install - Steering EHPS and cut-off valves . . . . . . . . . . . . . . . . . . . . . . . . 52
Hydraulic steering system - Remove - Steering EHPS and cut-off valves . . . . . . . . . . . . . . . . . . . . . . 49
Hydraulic steering system - Service instruction (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Hydraulic steering system - Service instruction (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Main priority valve - Adjust (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Main priority valve - Adjust (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Main priority valve - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Main priority valve - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Main priority valve - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Main priority valve - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Main priority valve - Test (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Main priority valve - Test (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Steering circuit relief valve - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Steering circuit relief valve - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Steering circuit relief valve - Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Steering valve - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Steering valve - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
48083741_EN 31/07/2018
41.2 [41.200] / 87
48083741_EN 31/07/2018
41.2 [41.200] / 88
Steering - 41
Cylinders - 216

48083741_EN 31/07/2018
41.3 [41.216] / 1
Contents
Steering - 41
Cylinders - 216
SERVICE
Steering cylinder
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Test - Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
48083741_EN 31/07/2018
41.3 [41.216] / 2
Steering - Cylinders
Steering cylinder - Remove
LEIL13WHL0653GB 1
1. Grease hose 5. Pivot pin 9. Hose assembly 13. Cap screw

2. Hose assembly 6. Spacer 10. Hose assembly 14. Washer
3. Hose assembly 7. Washer 11. Steering cylinder 15. Locknut
4. Washer 8. Cap screw 12. Pin 16. Grease hose
48083741_EN 31/07/2018
41.3 [41.216] / 3
1. Loosen the fill cap for the hydraulic reservoir to release

the pressure in the reservoir, then tighten the fill cap.
2. Disconnect the grease hoses (1), (16) from the steering
cylinders (11).
3. Disconnect the hydraulic hoses (2), (3), (9) and (10)
from the steering cylinders (11).
4. Install a plug in each hose (2), (3), (9) and (10) to pre-
vent entry of foreign matter.
5. Remove the locknuts (15).
6. Remove the cap screws (13).
7. Remove the pins (12).
8. Remove the washers (14).
9. Remove the cap screws (8), the washers (7) and the
spacers (6) securing the pivot pins (5) at the rear of the
steering cylinders (11).
10. Use a suitable driver to drive the pivot pins (5) out of
the steering cylinders (11).
11. Remove the washers (4) from between the steering
cylinders (11) and the rear frame of the machine.
12. Remove the steering cylinders (11).
48083741_EN 31/07/2018
41.3 [41.216] / 4
Steering cylinder - Install
LEIL13WHL0653GB 1
1. Grease hose 5. Pivot pin 9. Hose assembly 13. Cap screw

2. Hose assembly 6. Spacer 10. Hose assembly 14. Washer
3. Hose assembly 7. Washer 11. Steering cylinder 15. Locknut
4. Washer 8. Cap screw 12. Pin 16. Grease hose
48083741_EN 31/07/2018
41.3 [41.216] / 5
1. Put the steering cylinders (11) in position on the ma-

chine. Make sure that the washers (4) are installed be-
tween the steering cylinders (11) and the rear frame.
NOTE: install a washer (4) at the top and bottom of the
steering cylinders (11) if possible. If only one washer (4)
can be installed, place the washer (4) at the bottom of the
steering cylinders (11).
2. Make sure the washers (14) are installed between the
steering cylinders (11) and the front frame of the ma-
chine.
3. Install the pivot pins (5) to secure the rear of the steer-
ing cylinders (11) to the machine frame. Install the
spacers (6), the washers (7) and the cap screws (8)
to secure the pivot pins (5).
4. Tighten the cap screws (8).
5. Install the pins (12) at the front of the steering cylinders
(11). Make sure that the washers (14) are installed in
correct position.
6. Install the cap screws (13) and new locknuts (15) in
the steering cylinders (11) rod end and the pins (12).
Tighten the locknuts (15).
NOTE: cap screws (13) should turn freely in the hole after
tightening.
7. Connect the hose assemblies (2), (3), (9) and (10) to
the steering cylinders (11).
8. Connect the grease hoses (1) and (16) to the steering
cylinders (11).
9. Tighten the hydraulic reservoir fill cap.
10. Start the engine.
11. Turn the steering wheel all the way to the right and
then to the left several times.
12. Stop the engine. Check the fluid level in the hydraulic
reservoir. Add oil as required.
48083741_EN 31/07/2018
41.3 [41.216] / 6
Steering cylinder - Test - Leaks

NOTE: make sure all persons are clear of the center pivot area and the center pivot is free from any obstructions.
2. Turn the machine all the way to the right.
4. Find the tube that is connected to the rod end of the
left-hand steering cylinder. Disconnect the tube from
the left-hand cylinder.
5. Install a plug in the tube.
6. Start and run the engine at 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 steering
cylinder.
10. Turn the machine all the way to the left.
12. Find the tube that is connected to the rod end of the
right-hand steering cylinder. Disconnect the tube from
the right-hand steering cylinder.
13. Install a plug in the tube.
14. Start and run the engine at 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 pis-
ton packing in the right-hand steering cylinder is dam-
aged. Repairs must be made.
17. Connect the tube to the rod end of the right-hand
steering cylinder.
48083741_EN 31/07/2018
41.3 [41.216] / 7
Steering cylinder - Disassemble
LEIL13WHL0664GB 1
1. Gland 8. Bolt and washer 15. Grease fitting

2. Rod wiper 9. Piston 16. Retaining ring
3. Rod seal 10. Ring cast iron 17. Bushing
4. Buffer seal 11. Wear ring 18. Tube
5. Bearing 12. Loader ring 19. Self-tapping screw
6. Backup ring 13. Seal
7. O-ring 14. Piston rod
48083741_EN 31/07/2018
41.3 [41.216] / 8
1. Fasten the tube (18) in a vise. Be careful not to damage

the tube.
2. Remove the gland (1) from the tube (18).
3. Pull the piston rod (14) and the piston (9) straight out
of the tube (18).
4. Fasten the piston rod (14) yoke in a vise and put a
support below the piston rod near the piston (9). Put
a shop cloth between the support and the piston rod to
prevent damage to the piston rod.
5. Loosen and remove the bolt and the washer (8) that
hold the piston (9).
6. Remove the piston (9) from the piston rod (14).
7. Remove and discard the seal (13), the loader ring (12),
the wear ring (11) and the cast iron ring (10) from the
piston (9).
8. Remove the gland (1) from the piston rod (14).
9. Remove and discard the O-ring (7), the backup ring (6),
the rod wiper (2), the rod seal (3), the buffer seal (4) and
the bearing (5) from the gland (1).
48083741_EN 31/07/2018
41.3 [41.216] / 9
Steering cylinder - Inspect

2. Check to be sure that piston rod (14) is straight. If the
piston rod is bent, install a new piston rod.
3. Inspect inside of the tube (18) for deep grooves and
other damage. If there is any damage to the tube, a
new tube must be used.
4. Remove small scratches on the piston rod (14) or inside
the tube (18) with emery cloth of medium grit. Use
emery cloth with a rotary motion.
5. Inspect the bushing (17). If the bushing requires re-
placement, remove the grease fitting (15) and retaining
rings (16), then press the bushing from the tube end.
48083741_EN 31/07/2018
41.3 [41.216] / 10
Steering cylinder - Assemble
LEIL13WHL0664GB 1
1. Gland 8. Bolt and washer 15. Grease fitting

2. Rod wiper 9. Piston 16. Retaining ring
3. Rod seal 10. Ring cast iron 17. Bushing
4. Buffer seal 11. Wear ring 18. Tube
5. Bearing 12. Loader ring 19. Self-tapping screw
6. Backup ring 13. Seal
7. O-ring 14. Piston rod
48083741_EN 31/07/2018
41.3 [41.216] / 11
1. Install the bearing (5) in the gland (1).

2. Install the buffer seal (4) in the gland (1) so that the seal
lips are toward the small end of the gland.
3. Install the rod seal (3) in the gland (1). The rod seal
must be installed so that the seal lips are toward the
small end of the gland. The seal can be difficult to
install. Use tools that will not damage the seal.
4. Install the rod wiper (2) in the gland (1) with the wiper
lips toward the large end of the gland (1).
5. Install the O-ring (7) on the gland (1).
6. Install the backup ring (6) on the gland (1). The backup
ring must be toward the large end of the gland (1). If
the backup ring is not flat on both sides, the side that is
not flat must be toward the O-ring (7).
7. Fasten the piston rod (14) yoke in a vise.
8. Lubricate the piston rod (15) and bore in the gland (1)
with clean hydraulic oil.
NOTE: if a new gland (1) is being installed, write the cylin-
der part number on the gland.
9. Push the gland (1) onto the piston rod (14) large end
first. If necessary, use a soft hammer to drive the gland
onto the piston rod.
10. Put a support below and near the end of the piston rod
(14). Put a cloth between the support and the piston
rod to prevent damaging the piston rod.
11. Install a new cast iron ring (10) on the piston (9).
12. Install a new wear ring (11) on the piston (9).
13. Install a new loader ring (12) on the piston (9).
14. Install a new seal (13) over the loader ring (12).
15. Clean the threads on the end of the piston rod (14)
and threads of the bolt (8) using Loctite cleaning sol-
vent. Allow to dry. Apply LOCTITE® 243™ to the pis-
ton rod threads 6.4 mm (0.3 in) from the open end
of the piston rod so that there is 12.7 mm (0.5 in) of
LOCTITE® 243™ on the piston rod threads. DO NOT
apply Loctite to the first 6.4 mm (0.3 in) of the piston
rod threads.
16. Install the bolt and hardened washer (8) in the piston
(9).
17. Install the piston (9) on the piston rod (14) and start
bolt (8) into the piston rod.
18. Tighten the bolt (8) to a torque of 810 – 925 N·m (597
– 682 lb ft).
19. Fasten the tube (18) in a vise. Be careful not to dam-
age the tube.
20. Apply petroleum jelly to the O-rings (7) and backup
ring (6) on the gland (1) and to the sealing surface in
the tube (18).
21. Lubricate the piston (9) and inside of the tube (18) with
clean hydraulic oil.
48083741_EN 31/07/2018
41.3 [41.216] / 12
22. Push the piston (9) straight into the tube (18). Be
careful not to damage the cast iron ring (10), the wear
ring (11) and the seal (13) on the piston (9).
23. When the piston (9) is in smooth part of the tube (18),
the start gland (1) is into the tube (18).
24. If the original parts are being assembled:
A. Tighten the gland to a torque of 339 – 475 N·m
(250 – 350 lb ft).
B. Install and tighten the self-tapping screw (19) to a
torque of 2.3 N·m (20.4 lb in).
C. If, after tightening the gland, the self-tapping screw
(19) holes are not aligned, a new hole for self-tap-
ping screw must be drilled.
25. If a new gland (1) or a new tube (18) are being assem-
bled.
A. Tighten the gland (1) to a torque of 339 – 475 N·m
(250 – 350 lb ft).
B. Use a No. 27 drill bit and drill a hole half in the
gland (1) and half in the tube (18). Drill to a depth
of 11 mm (0.4 in). Do not drill within 13 mm (1 in)
of a hole for gland wrench.
C. Install and tighten the self-tapping screw (19) to a
torque of 2.3 N·m (20.4 lb in).
26. If the hoses were removed with cylinder, install new
O-rings, if equipped, on the hose fittings. Lubricate
the O-rings with clean oil. Install the hoses.
48083741_EN 31/07/2018
41.3 [41.216] / 13
Index
Steering - 41
Cylinders - 216
Steering cylinder - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Steering cylinder - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Steering cylinder - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Steering cylinder - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Steering cylinder - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Steering cylinder - Test - Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
48083741_EN 31/07/2018
41.3 [41.216] / 14
Steering - 41
Auxiliary steering - 910

48083741_EN 31/07/2018
41.4 [41.910] / 1
Contents
Steering - 41
TECHNICAL DATA
Pump
Motor
SERVICE
Auxiliary steering
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Test - Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Test - Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Pump
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
48083741_EN 31/07/2018
41.4 [41.910] / 2
Steering - Auxiliary steering
Pump - General specification

Auxiliary steering pump
Maximum oil flow: 20.8 L/min (5.5 US gpm) at 104 bar (1508 psi) at 320 A.
Minimum oil flow: 14.8 L/min (3.9 US gpm) at 248 bar (3596 psi) at 615 A.
48083741_EN 31/07/2018
41.4 [41.910] / 3
Motor - General specification

Auxiliary steering motor
Maximum amperes: 30 A
Minimum armature speed: 6950 RPM
Motor: 24 V
48083741_EN 31/07/2018
41.4 [41.910] / 4
Auxiliary steering - Remove
LEIL16WHL0861GB 1
1. Ground cable 5. Pressure tube

2. Positive cable 6. Auxiliary steering priority valve
3. Nut (quantity 4) 7. Auxiliary steering pump and motor
4. Suction hose 8. Wiring harness
48083741_EN 31/07/2018
41.4 [41.910] / 5
1. Park the machine on level ground and lower the bucket

to ground. Put the transmission in NEUTRAL, apply the
parking brake and shut down the engine
2. Put the master disconnect switch in OFF position.
3. Tag and disconnect the two wiring harness (8) from the
solenoid of the auxiliary steering pump and the motor
(7).
4. Tag and disconnect the positive cable (2) from B+ stud
of auxiliary steering pump and motor (7).
5. Tag and disconnect the ground cable (1) from the
ground stud of the auxiliary steering pump and motor
(7).
9. Disconnect the suction hose (4) from the auxiliary
steering pump and motor (7). Install a plug in the
suction hose and cap on fitting.
11. Loosen the fittings on the pressure tube (5).
12. Support the auxiliary steering pump and motor (7).
Remove the nuts (3), the cap screws and the washers
securing the auxiliary steering pump and motor (7).
13. Remove the pressure tube (5) and the auxiliary steer-
ing pump and motor (7).
48083741_EN 31/07/2018
41.4 [41.910] / 6
Auxiliary steering - Install
LEIL16WHL0861GB 1
1. Ground cable 5. Pressure tube

2. Positive cable 6. Auxiliary steering priority valve
3. Nut (quantity 4) 7. Auxiliary steering pump and motor
4. Suction hose 8. Wiring harness
48083741_EN 31/07/2018
41.4 [41.910] / 7
1. Position the auxiliary steering pump and motor (7) on

its mounting plate while connecting and hand tightening
the pressure tube (5) to the auxiliary steering priority
valve (6).
2. While supporting the auxiliary steering pump and motor
(7) have an assistant who installs the cap screws, the
washers and the nuts (3) to secure the auxiliary steer-
ing pump and motor (7). Tighten the nuts.
3. Tighten the pressure tube (5) fittings securely.
5. Remove the plug from the suction hose (4) and cap
from the elbow. Connect the suction hose to the elbow
installed in the auxiliary steering pump and motor (7).
6. Stop and disconnect the vacuum pump. Install the fill
cap in the hydraulic reservoir.
7. Connect the ground cable (1) to the ground stud of the
auxiliary steering pump and motor (7) following the tag
installed during removal.
8. Connect the positive cable (2) to B+ stud of the auxiliary
steering pump and motor (7) following the tag installed
during removal.
9. Connect the wiring harness (8) to the auxiliary steering
pump and motor (7) following the tags applied during
removal.
10. Put the master disconnect switch in ON position.
11. Start and run the engine at low idle and raise the
bucket 500 mm (20 in) above ground. Check that the
auxiliary steering light on information center is OFF.
NOTICE: in following step, do not run the auxiliary steering
pump and the motor continuously for more than 20 seconds
at a time without a two minute cool down.
12. With the engine at low idle and the machine steering
straight ahead, turn the key switch to OFF position
to stop the engine and then immediately back to ON
position (not START position). The auxiliary steering
pump and motor should start operating immediately.
Check that the auxiliary steering light on the informa-
tion center is ON and the auxiliary steering pump and
motor are operating.
13. Turn the steering wheel all the way to the left and the
right to make sure that the auxiliary steering pump and
motor operates correctly.
14. Restart the engine. Check that the auxiliary steering
light on the information center stays ON and the aux-
iliary steering pump and motor are operating. After
about three seconds the motor should stop operating
and the auxiliary steering light should go out.
15. Let the engine runs and allows the batteries to
recharge for a minimum of 10 minutes.
48083741_EN 31/07/2018
41.4 [41.910] / 8
Auxiliary steering - Test - Pump

Test equipment
CAS10280 Flow meter
Test procedure
NOTE: when performing this pressure check, always be
sure the articulation lock is in place, especially when work-
ing in the articulation joint area.
RCPH10WHL063BAL 1
2. Loosen and remove the outlet hose to the auxiliary

steering pump from the auxiliary steering priority valve.
3. Install a plug into the auxiliary steering priority valve
fitting.
4. Connect the inlet of the flow meter to the outlet line of
the auxiliary steering pump.
5. Install the outlet hose of the flow meter in the hydraulic
reservoir and hold in place with wire.
6. Connect the ammeter clamp (1) to the cable as shown
in the illustration.
LEIL13WHL0658AB 2
7. Make sure that the parking brake is applied and the

bucket is on the floor.
8. Make sure that the oil is at the operating temperature.
9. Make sure that the load valve for the flow meter is open
(zero pressure).
10. Start and run the engine.
11. Stop the engine and turn the key back to the ON po-
sition.
12. Turn the steering wheel to activate the auxiliary steer-
ing pump.
48083741_EN 31/07/2018
41.4 [41.910] / 9
13. Turn the load valve on the flow meter towards

CLOSED until the pressure is 104 bar (1508 psi).
14. Read the flow meter and ammeter gauges and record
the readings.
15. The flow meter reading must not be less than 14.8 L/
min (3.9 US gpm). The ammeter reading must be
615 A.
16. Turn the key switch to the OFF position. If the flow
was less than the specification, or if the amperage was
more than 315 A, remove the auxiliary steering motor
and pump. Test the auxiliary steering motor. If the
motor is good, make repairs to the pump.
48083741_EN 31/07/2018
41.4 [41.910] / 10
Auxiliary steering - Test - Motor

Test equipment
1. A 24 V battery that is fully charged.
NOTE: a 24 V battery system (two 12 V batteries in a se-
ries) is used for this test. A 12 V battery system will cause
damage to the auxiliary steering motor.
2. A remote starter switch.
3. A tachometer to check the armature speed.
4. A Sun Electric VAT-33 Starting and Charging System
Tester.
Test procedure
NOTE: when performing this pressure check, always be
sure the articulation lock is in place, especially when work-
ing in the articulation joint area.
RCPH10WHL063BAL 1
2. Remove the connector that is between the terminals on

the magnetic switch and the auxiliary steering motor.
3. Remove the auxiliary steering motor from the auxiliary
steering pump.
4. Remove the drive coupling from the auxiliary steering
motor (3).
5. Connect the auxiliary steering motor (3), remote starter
switch (1) and tester (2) to the 24 volt battery system
(5) as shown in the illustration.
6. Push the button on the remote starter switch (1) and
look at the voltmeter in the tester.
LEIL13WHL0659AB 2
48083741_EN 31/07/2018
41.4 [41.910] / 11
7. Turn the load control (8) until the voltmeter (7) indicates
24 volts. Look at the ammeter (6) in the tester. Make a
record of the ammeter indication.
LEIL13WHL0660AB 3
8. Hold the tachometer against the armature shaft. Look

at the tachometer. Make a record of the indication.
9. Release the button on the remote starter switch (1).
Understanding the test results

1. If the ammeter indication in step 6 was 30 A or less and
the tachometer indication in step 7 was 6950 RPM or
more, the auxiliary steering motor is good.
2. If the armature speed was less than 6950 RPM and the
ammeter indication was higher than 30 A, replace the
motor.
48083741_EN 31/07/2018
41.4 [41.910] / 12
Auxiliary steering - Disassemble
LEIL13WHL0665GB 1
1. Motor 7. O-ring 13. Gasket 19. Driven gear

2. Bolt 8. Switch 14. Lock washer 20. Driven gear
3. Retaining ring 9. Cable 15. Screw 21. End plate
4. Seal 10. Screw 16. Wire 22. Pins
5. Backup ring 11. Lock washer 17. Plate 23. Wear plate
6. Seal 12. Washer 18. Body
48083741_EN 31/07/2018
41.4 [41.910] / 13
1. Make an alignment mark on the pump assembly and

the motor (1).
NOTE: the pump is the only component that is disassem-
bled. The switch (8) and the motor (1) are replaced as units
and are not serviced.
2. Loosen and remove the two screws (15) and the lock
washers (14) that hold the pump assembly to the motor
(1).
3. Remove and discard the mounting gasket (13), the re-
taining ring (3) and the seal (4) from the pump assem-
bly.
4. Loosen and remove the four bolts (2) that hold the
pump assembly together.
5. Remove the end plate (21) from the body (18).
6. Remove and discard the seal (6) and the backup ring
(5) from the end plate (21).
7. Remove the wear plate (23), the drive gear (20) and
the driven gear (19) from the body (18).
8. Remove the body (18) from the plate (17).
9. Remove and discard the O-rings (7) from the body (18).
10. Remove the pins (22) and the wear plate (23) from the
body (18).
11. Remove and discard the seal (6) and the backup ring
(5) from the plate (17).
NOTE: the only serviceable items on the pump assembly
are the seals (6), the backup rings (5), the O-rings (7), the
seal (4), the retaining ring (3) and the gasket (13). If any of
the other items are damaged, replace the pump assembly.
48083741_EN 31/07/2018
41.4 [41.910] / 14
Auxiliary steering - Inspect

1. Inspect the wear plates (23) for grooves, scoring and
pitting. In case of damage replace the pump assembly.
2. Inspect the drive gear (20) and driven gear (19). If the
shafts are worn or damaged, replace the pump assem-
bly.
3. Clean all parts in cleaning solvent and air dry.
4. Inspect the plate (17), end plate (21) and body (18).
Replace the pump assembly as necessary.
48083741_EN 31/07/2018
41.4 [41.910] / 15
Auxiliary steering - Assemble
LEIL13WHL0665GB 1
1. Motor 7. O-ring 13. Gasket 19. Driven gear

2. Bolt 8. Switch 14. Lock washer 20. Driven gear
3. Retaining ring 9. Cable 15. Screw 21. End plate
4. Seal 10. Screw 16. Wire 22. Pins
5. Backup ring 11. Lock washer 17. Plate 23. Wear plate
6. Seal 12. Washer 18. Body
48083741_EN 31/07/2018
41.4 [41.910] / 16
1. Lubricate all parts with clean hydraulic oil before the

assembly.
2. Lubricate and install a new seal (4) and retaining ring
(3) on the plate (17).
3. Lubricate and install a new backup ring (5) and seal (6)
on the plate (17).
4. Lubricate and install new O-rings (7) on the body (18).
5. Lubricate and install the pins (22), the drive gear (20),
the driven gear (19) and the wear plates (23) on the
body (18).
6. Lubricate and install a new backup ring (5) and a new
seal (6) on the end plate (21).
7. Align the marks made during the disassembly on the
end plate (21), the body (18) and the plate (17) and
install the four bolts (2). Tighten the four bolts (2).
8. Install a new gasket (13) on the pump assembly.
9. Align the marks made during the disassembly on the
pump assembly and the motor (1).
10. Install the lock washer (14) and screw (15). Torque
the screw (15) to 35 – 39 N·m (310 – 345 lb in).
48083741_EN 31/07/2018
41.4 [41.910] / 17
Pump - Test
Auxiliary steering pump flow test
NOTE: the following procedures is for the steering pump section flow test, readings will be much lower than that of a
combined flow test.
NOTE: if unit is equipped with auxiliary steering a tee fitting will have to be used in this location.
LEIL13WHL1364GB 1
1. Pump inlet hoses 8. Steering pressure hose

2. Filter inlet manifold 9. Steering pump section
3. Flowmeter outlet hose 10. Loader pump
4. Filters 11. Loader pressure hose
5. CAS10280 flowmeter 12. Check valve
6. Flowmeter inlet hose 13. Articulation pressure hose
7. Elbow 14. Priority valve
48083741_EN 31/07/2018
41.4 [41.910] / 18
1. Connect the flow meter to the filter manifold as shown.

2. Disconnect the steering pressure hose (8) from the el-
bow (7).
3. Cap the elbow (7) and connect the flow meter inlet hose
(6) to the steering pressure hose (8).
4. Make sure the load control of the flow meter is open.
Start the engine. Run the engine at full throttle. Make
sure the oil is at the operating temperature.
5. Measure the flow at 0 bar ( 0 psi). Record the flow
reading. Slowly close the load valve on the flow meter
and read the flow at 170 bar ( 2500 psi). Record the
flow reading.
6. Divide the flow reading at 170 bar ( 2500 psi) by the
reading at 0 bar ( 0 psi). Multiply the result by 100.
This is the percent efficiency of the pump. If the effi-
ciency of the pump is less than 85%, repair or replace
the pump.
7. Stop the engine. Remove the cap from the elbow (7).
8. Disconnect the flow meter inlet hose (6) from the steer-
ing pressure hose (8).
9. Connect the steering pressure hose (8) to the elbow
(7).
48083741_EN 31/07/2018
41.4 [41.910] / 19
Index
Steering - 41

Auxiliary steering - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Auxiliary steering - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Auxiliary steering - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Auxiliary steering - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Auxiliary steering - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Auxiliary steering - Test - Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Auxiliary steering - Test - Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Motor - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Pump - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Pump - Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
48083741_EN 31/07/2018
41.4 [41.910] / 20
48083741_EN 31/07/2018
41.4 [41.910] / 21
PRINTED IN ITALY
48083741_EN 31/07/2018
EN
SERVICE MANUAL
Wheels

48083741_EN 31/07/2018
44
Contents
Wheels - 44
[44.511] Front wheels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.1
[44.520] Rear wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.2
48083741_EN 31/07/2018
44
Wheels - 44
Front wheels - 511

48083741_EN 31/07/2018
44.1 [44.511] / 1
Contents
Wheels - 44
Front wheels - 511
TECHNICAL DATA
Front wheels
Tire pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SERVICE
Front wheels
Service instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
48083741_EN 31/07/2018
44.1 [44.511] / 2
Wheels - Front wheels
Front wheels - Tire pressure

Tire service
Service specifications – Normal Work Tire Inflations
821G Tire type Front pressure
23.5 x 25 L2 Bias 20 ply 3.4 bar (50 psi)
23.5 R25 L2 Radial 3.4 bar (50 psi)

921G Tire type Front pressure
48083741_EN 31/07/2018
44.1 [44.511] / 3
Front wheels - Service instruction

NOTE: this instruction is applicable both to the front and rear tires.
1. The wheel bolts must be tightened after every 20 hours
of operation until the wheel bolts stay tight:
A. if the machine is new.
B. if a wheel has been removed and installed.
NOTICE: the split rim wheels used on this machine can be
dangerous. When inflating a tire on the machine, use a
self-locking nozzle and stand at the front or rear of the tire.
When inflating a tire off the machine, put the wheel in a tire
inflation cage. The retaining ring and rim can come off with
enough force to result in death to a person in front of the
rim.
NOTICE: have a qualified tire mechanic service the split
rim wheels used on this machine. The correct tire equip-
ment, especially a tire inflation cage, is required. Using the
wrong procedure for a split rim wheel can result in death.
NOTE: when installing a Michelin tire, lubricate the tire
with a tire mounting lubricant and inflate the tire to 5.5 bar
(79.8 psi) to make sure that the tire is seated on the rim.
Then decrease the pressure to the specified pressure.
48083741_EN 31/07/2018
44.1 [44.511] / 4
Front wheels - Install

NOTE: this instruction is applicable both to the front and rear tires.
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 298 N·m (220 lb ft); then

tighten to a final torque of 640 – 720 N·m (472.0 –
531.0 lb ft) per the appropriate sequence shown.
LEIL13WHL0567AB 1
821G
LEIL13WHL0568AB 2
921G
48083741_EN 31/07/2018
44.1 [44.511] / 5
Index
Wheels - 44
Front wheels - 511

Front wheels - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Front wheels - Service instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Front wheels - Tire pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
48083741_EN 31/07/2018
44.1 [44.511] / 6
Wheels - 44
Rear wheels - 520

48083741_EN 31/07/2018
44.2 [44.520] / 1
Contents
Wheels - 44
Rear wheels - 520
TECHNICAL DATA
Rear wheels
Tire pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
48083741_EN 31/07/2018
44.2 [44.520] / 2
Wheels - Rear wheels
Rear wheels - Tire pressure

Tire service
821G Tire type Rear pressure

921G Tire type Rear pressure
48083741_EN 31/07/2018
44.2 [44.520] / 3
Index
Wheels - 44
Rear wheels - 520

Rear wheels - Tire pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
48083741_EN 31/07/2018
44.2 [44.520] / 4
48083741_EN 31/07/2018
44.2 [44.520] / 5
PRINTED IN ITALY
48083741_EN 31/07/2018
EN
SERVICE MANUAL
Cab climate control

48083741_EN 31/07/2018
50
Contents
Cab climate control - 50
[50.100] Heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50.1
[50.200] Air conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50.2
48083741_EN 31/07/2018
50
Heating - 100

48083741_EN 31/07/2018
50.1 [50.100] / 1
Contents
Heating - 100
SERVICE
Heater core
Remove - and water valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Install - and water valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
48083741_EN 31/07/2018
50.1 [50.100] / 2
Cab climate control - Heating
Heater core - Remove - and water valve

bucket to the ground.
2. Put the articulation lock in the locked position.
4. Put a suitable container below the radiator drain. Re-
move cap and drain coolant into container. Install cap
after coolant has drained.
5. Open the cab window to facilitate the removal of bolts
(arrows).
Remove the six bolts (arrows) and related washers to
unfix the HVAC cover.
LEIL16WHL1190AB 1
6. Loosen the clamps (1).

Remove the air intake hose (2).
LEIL16WHL1209AB 2
7. Disconnect the PRH2 connector (1) of the engine and

rear chassis harness. Remove the clamps (2) securing
the wire to the cab frame.
LEIL16WHL1193AB 3
48083741_EN 31/07/2018
50.1 [50.100] / 3
8. Loosen the clamp (2). Disconnect and plug the heater

hoses (1).
LEIL16WHL1241AB 4
9. Remove the grommet.
LEIL18WHL0452AB 5
10. Remove the three retaining knobs that hold the cab
air recirculation filter cover in place.
LEIL18WHL0453AB 6
11. Extract the cab air recirculation filter.
LEIL18WHL0454AB 7
48083741_EN 31/07/2018
50.1 [50.100] / 4
12. Position the cover case in place. Install the cover case
with 16 screws.
NOTE: for clarity, only one of the 16 screws is indicated in
figure 8.
LEIL18WHL0459AB 8
13. Disconnect the electrical connector.
LEIL18WHL0466AB 9
14. Remove the bolts (1) holding the heat exchanger (2)
on the cab heater case.
LEIL16WHL1247AB 10
15. Extract the heat exchanger as an assembly.
LEIL16WHL1248AA 11
48083741_EN 31/07/2018
50.1 [50.100] / 5
16. On bench, disassemble heat exchanger.

Remove the two clamps (3) to separate the heater
core (1) from the water valve (2). Remove the two
screws (4) to separate the bracket (5) to the water
valve (2).
LEIL18WHL0468FB 12
48083741_EN 31/07/2018
50.1 [50.100] / 6
Heater core - Install - and water valve
LEIL18WHL0468FB 1
1. On bench, install the heater core (1) to the water valve

(2) with two clamps (3).
Install the bracket (5) to the water valve (2) with the two
screws (4).
2. Insert the cab heater assembly in case.
Fix the cab heater assembly (2) with the bolts (1).
LEIL16WHL1247AB 2
48083741_EN 31/07/2018
50.1 [50.100] / 7
3. Connect the electrical connector.
LEIL18WHL0466AB 3

with 16 screws.
figure 4.
LEIL18WHL0459AB 4
5. Insert the cab air recirculation filter.
LEIL18WHL0454AB 5
6. Install the cab air recirculation filter cover with the three
retaining knobs.
LEIL18WHL0453AB 6
48083741_EN 31/07/2018
50.1 [50.100] / 8
7. Install the grommet.
LEIL18WHL0452AB 7
8. Remove plugs from the heater hoses (1). Tighten the

clamps (2).
LEIL16WHL1241AB 8
9. Connect the PRH2 connector (1) of the engine and rear

chassis harness. Install the clamps (2) securing the
wire to the cab frame.
LEIL16WHL1193AB 9
10. Install the air intake hose (2) with the clamps (1).
Tighten the clamps (1) to 3.4 N·m (30.1 lb in).
LEIL16WHL1209AB 10
48083741_EN 31/07/2018
50.1 [50.100] / 9
11. Open the cab window to facilitate the installation of

bolts (arrows). Tighten the six mounting bolts and
washers to install the HVAC cover.
LEIL16WHL1190AB 11
12. Put the timed disconnect switch to ON position

48083741_EN 31/07/2018
50.1 [50.100] / 10
Index
Heating - 100
Heater core - Install - and water valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Heater core - Remove - and water valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
48083741_EN 31/07/2018
50.1 [50.100] / 11
48083741_EN 31/07/2018
50.1 [50.100] / 12
Air conditioning - 200

48083741_EN 31/07/2018
50.2 [50.200] / 1
Contents
TECHNICAL DATA
Air conditioning
Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
FUNCTIONAL DATA
Air conditioning
Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
SERVICE
Air conditioning
Visual inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Service instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Service instruction - Safety procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Pressure test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Service instruction - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Air-conditioning compressor
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Air-conditioning condenser
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Receiver-dryer
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Air-conditioning evaporator
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
48083741_EN 31/07/2018
50.2 [50.200] / 2
Cab climate control - Air conditioning
Air conditioning - General specification

Pressure/Temperature chart
Ambient Temperature Normal Low Pressure Normal High Pressure Air Louver Maximum
Indication Indication Temperature
27 °C (80 °F) 0.62 – 0.83 bar (9 – 12 psi) 10.0 – 11.5 bar (145 – 14 °C (57 °F)
165 psi)
32 °C (90 °F) 0.76 – 1.00 bar (11 – 13.1 – 14.5 bar (190 – 18 °C (64 °F)
15 psi) 210 psi)
35 °C (95 °F) 1.10 – 1.24 bar (16 – 14.5 – 15.8 bar (210 – 20 °C (68 °F)
18 psi) 230 psi)
38 °C (100 °F) 1.17 – 1.31 bar (17 – 16.2 – 17.6 bar (235 – 22 °C (72 °F)
19 psi) 255 psi)
41 °C (106 °F) 1.38 – 1.45 bar (20 – 17.9 – 19.3 bar (260 – 23 °C (73 °F)
21 psi) 280 psi)
43 °C (109 °F) 1.90 – 2.14 bar (27 – 20.0 – 21.4 bar (290 – 25 °C (77 °F)
31 psi) 310 psi)
NOTE: the pressure / temperature chart is based on the following conditions:
(1) Engine operating at 1500 RPM. No engine load.

(2) Fan speed control in maximum position (full clockwise) and all louvers open.
(3) Cab temperature control set to maximum cooling (full counterclockwise).
(4) Air Conditioning switch ON. Both cab doors open.
(5) All panels and access doors installed and closed.
(6) Cab filters clean and installed. Heater valve at engine closed.
(7) Measurements taken 15 minutes after start-up.
Refrigerant charge 1.92 – 1.98 kg (4.23 – 4.37 lb)
Air conditioning - Special tools

380001325 Belt tension tool
LEIL13WHL1088AA 1
48083741_EN 31/07/2018
50.2 [50.200] / 3
OEM1598 Refrigerant recovery, recycling and charging

station
LEIL13WHL1085AA 2
380001327 Electronic leak detector
LEIL13WHL1086AA 3
Air conditioning - Torque

Tube connections torque chart
Description Parts to be Tube size Thread size Hexagonal size Material Torque
connected
Receiver/Dryer Dryer, HFC- 3/8 5/8-18 3/4 Steel to steel 31 – 36 N·m
outlet 134a (23 – 27 lb ft)
Low Pressure Switch for low - M10x1.25 - 6G 9/16 Steel to steel 8 – 10 N·m
Switch air conditioning (6 – 7 lb ft)
pressure
Cab air Tube for cab 3/8 5/8-18 3/4 Steel to steel 31 – 36 N·m
conditioning air conditioning (23 – 27 lb ft)
inlet liquid
Cab air Tube for cab 5/8 7/8-14 1 1/8 Steel to steel 45 – 52 N·m
conditioning air conditioning (33 – 38 lb ft)
outlet suction
Compressor Compressor - 1-14 1 1/8 Steel to 45 – 52 N·m
inlet aluminium (33 – 38 lb ft)
Compressor Compressor - 1-14 1 1/8 Steel to 45 – 52 N·m
outlet aluminium (33 – 38 lb ft)
High Pressure Switch for high - M10x1.25 - 6G 9/16 Steel to steel 8 – 10 N·m
Switch air conditioning (6 – 7 lb ft)
pressure
Condenser Condenser 3/8 5/8-18 3/4 Brass to steel 24 – 30 N·m
inlet hose (18 – 22 lb ft)
Condenser Condenser 3/8 5/8-18 3/4 Brass to steel 18 – 23 N·m
outlet (13 – 17 lb ft)
Receiver/Dryer Dryer, HFC- 3/8 5/8-18 3/4 Brass to steel 31 – 36 N·m
inlet 134a (23 – 27 lb ft)
48083741_EN 31/07/2018
50.2 [50.200] / 4
NOTE: When tightening air conditioning hose or pipe fittings, a second wrench serving as support must be used.
NOTE: Special care is required when tightening the fittings on the compressor, condenser and evaporator since these
connections are easily distorted. Overtightening connections may crush the O-rings and cause leaks.
NOTE: O-rings must be oiled and properly positioned prior to making the connection. Un-oiled O-rings may become
cut or misaligned.
48083741_EN 31/07/2018
50.2 [50.200] / 5
Air conditioning - Dynamic description

The refrigerant circuit of the air conditioning system contains five major components: compressor (3), condenser (4),
receiver-drier (5), expansion valve (1) and evaporator (2). These components are connected by tubes and hoses and
operate as a closed system. The air conditioner system is charged with HFC R134A refrigerant.
The compressor receives the refrigerant as a low pressure gas. The compressor then compresses the refrigerant
and sends it in the form of a high pressure gas to the condenser. The air flow through the condenser then removes
the heat from the refrigerant. As the heat is removed the refrigerant changes to a high pressure liquid.
The high pressure refrigerant liquid then flows from the condenser to the receiver-drier. The receiver-drier is a con-
tainer filled with moisture removing material, which removes any moisture that may have entered the air conditioner
system in order to prevent corrosion of the internal components of the air conditioner system.
The refrigerant, still in a high pressure liquid form, then flows from the receiver-drier to the expansion valve. The ex-
pansion valve then causes a restriction in flow of refrigerant to the evaporator core. The evaporator meters refrigerant
flow based on evaporator heat load.
As the refrigerant flows through the evaporator core, the refrigerant is heated by the air around and flowing through
the evaporator fins. The combination of increased heat and decreased pressure causes the air flow through the
evaporator fins to become very cool and the liquid refrigerant to become a low pressure gas. The cooled air then
passes from the evaporator to the cab for the operator’s comfort.
The electrical circuit of the air conditioning system consists of a fan speed control, temperature control, one relay, a
blower motor, blower resistor, Air Conditioning compressor clutch, Air Conditioning low pressure switch, Air Condi-
tioning high pressure switch, and Air Conditioning warning light.
LEIL15WHL0770FB 1
1. Expansion valve 4. Condenser B. Low pressure liquid

2. Evaporator 5. Dryer C. High pressure gas
3. Compressor A. Low pressure gas D. High pressure liquid
48083741_EN 31/07/2018
50.2 [50.200] / 6
Air conditioning - Exploded view
LEIL16WHL1209HB 1
48083741_EN 31/07/2018
50.2 [50.200] / 7
1. Cases assembly 16. Driver

2. Driver plate 17. Resistor
3. Evaporator 18. Harness
4. Heater 19. HVAC label
5. Drain water tank 20. Cover air filter O-ring
6. Blower 24 V 21. Cases O-ring
7. Air filter cover 22. Knobs
8. Air filter 23. Insert M6
9. Blower flange 24. Bushing
10. Gasket 25. Clamp
11. Drain water gasket 26. Plastic blocks
12. Cases gasket 27. Screws
13. Evaporator sensor 28. Insulation ring
14. Evaporator sensor bracket 29. Grommet
15. Blower flange gasket 30. Rubber washer
48083741_EN 31/07/2018
50.2 [50.200] / 8
Air conditioning - Visual inspection

Perform a visual inspection of the machine. Check the
following and correct as necessary:
1. Obtain service history if possible.
2. Is compressor drive belt in place and tensioned?
3. Are grille screens, fan blades, condenser, air filter and
evaporator unobstructed?
4. Are there any sharp bends or kinks in the hoses?
5. Are there heavy accumulations of oil, or oily dust
around the fittings, indicating refrigerant leakage?
6. Are air ducts undamaged, sealed properly and in posi-
tion?
7. Are the condensation drain hoses and the check valves
present and unobstructed?
48083741_EN 31/07/2018
50.2 [50.200] / 9
Air conditioning - Service instruction

Problem: no cooling
See pressure - temperature chart on Air conditioning
- General specification (50.200).
Temperature of low pressure gauge: very low
Temperature of high pressure gauge: very low
Indication of no refrigerant or low refrigerant charge:

1. Leak test the system. It may be necessary to
add refrigerant.
2. Evacuate and reclaim remaining refrigerant
from system.
A. Discharge air from evaporator is warm. 3. Repair system leaks as needed. Follow the
given repair procedure.
B. Compressor does not run, or cycles off Yes
rapidly after start-up. (Air conditioning 4. Check level of oil in compressor - possible for
warning light in cab should illuminate). compressor to have an oil loss.
5. Remove air and moisture from the system.
6. Charge system with new refrigerant.
7. Continue performance test for other possible
problems.

Temperature of low pressure gauge: high
Temperature of high pressure gauge: high
Indication of large quantity of air in the system:

1. Evacuate and reclaim refrigerant from
system.
Discharge air from evaporator is warm Yes
Condenser malfunctioning - Indications:

1. Check for loose or worn compressor or
engine fan belt and proper condenser fan
operation.
2. Check to see that condenser is clean and
unobstructed and that the fins are straight.
3. Check system for too much refrigerant.
Evacuate, reclaim and recharge refrigerant
until gauge pressure is normal.
A. Liquid line (between evaporator and
condenser) is very hot. 4. Remove and check condenser for restrictions
caused by oil or reduced heat transfer.
B. Discharge air from evaporator is warm.
A. Remove refrigerant from the system.
B. Use compressed air to remove oil from
condenser.
C. Replace receiver-drier.
D. Remove moisture and charge the system.
5. Continue the performance test for other
possible problems.
48083741_EN 31/07/2018
50.2 [50.200] / 10
Expansion valve malfunctioning - Indications:

A. Discharge air from heater/evaporator is
warm.
B. Excess condensation on suction hose at Replace the expansion valve.
compressor.
C. Excess condensation on evaporator outlet.
Refrigerant contamination:
1. See table below and check stable saturation
pressures at given temperature to determine
if contamination exists.
A. Measure pressure from gauge on
reclamation unit.
B. Measure temperature from refrigerant in
Refrigerant Contamination reclamation tank. If refrigerant has been
in reclamation unit for some time, use
ambient temperature. The numbers in
the table represent the boiling point for
R134A.
C. Pressure readings below range given in
chart indicate contaminated refrigerant.
NOTICE: do not use contaminated refrigerant or mix with uncontaminated refrigerant. Dispose of in accordance with
all applicable laws and local procedure.
48083741_EN 31/07/2018
50.2 [50.200] / 11
HFC-134a stable saturation pressure / temperature chart

Temperature °F (° C) Pressure PSIG (Bar)
50 (10) 45 (3.1)
55 (13) 51 (3.5)
60 (16) 57 (3.9)
65 (18) 64 (4.4)
70 (21) 71 (4.9)
75 (24) 78 (5.4)
80 (27) 88 (6.1)
85 (29) 95 (6.6)
90 (32) 104 (7.2)
95 (35) 114 (7.9)
100 (38) 124 (8.6)
102 (39) 129 (8.9)
104 (40) 133 (9.2)
106 (41) 138 (9.5)
108 (42) 142 (9.8)
110 (43) 147 (10.1)
112 (44) 152 (10.5)
114 (46) 157 (10.8)
116 (47) 162 (11.2)
118 (48) 167 (11.5)
120 (49) 172 (11.9)
Problem: not enough cooling

- General specification (50.200)
Temperature of low pressure gauge: normal to slightly
high
Temperature of high pressure gauge: normal
Air in the system - Indications:

1. Test system for leaks.
2. Discharge system of refrigerant.
A. Suction line is warm to the touch.
3. Repair system leak as necessary.
B. Discharge air from heater/evaporator is only
4. Check compressor oil level.
a little cool.

Temperature of low pressure gauge: low
Temperature of high pressure gauge: low
48083741_EN 31/07/2018
50.2 [50.200] / 12
Not enough refrigerant - Indications:

1. Leak test system - system has a loss of refrigerant.
A. If leak is found, go to Step 2.
B. If no leak is found, go to Step 6.
A. Discharge air from evaporator 2. Discharge refrigerant from system.
is either cool or warm - not
cold. 3. Repair system leaks as needed.
4. Check oil level in compressor - It is possible for compressor to lose oil.
NOTE: normally, the system will lose 1/2 – 1 ounce ( 14.7 – 29.5 grams ) of refrigerant between seasons.
High side restriction - Indications:

1. Discharge refrigerant from system-restriction
A. Discharge air from heater/evaporator is only in receiver-drier or liquid line must be
a little cool. removed.
B. Condensation or frost on receiver-drier. 2. Remove and replace part with restriction.
C. Liquid line to receive drier is cool, with frost 3. Remove air and moisture from the system.
or condensation present.
NOTE: the frost will form downstream from or at the point of the restriction.
Expansion valve not operating - Indications:

1. Expansion valve outlet with condensation or
frost present is an indication of a restriction
A. Discharge air from evaporator is either cool in the expansion valve. Replace expansion
or warm - not cold. valve.
B. Condensation or frost is present on 2. Inlet end of expansion valve is warm (not hot),
expansion valve outlet. indicating expansion valve is not completely
C. Inlet end of expansion valve is warm. open. If the valve is stuck closed, there will
be little or no flow of refrigerant through the
valve. Replace expansion valve.
See the pressure - temperature chart on Air condition-

ing - General specification (50.200).
Temperature of high pressure gauge: low
Compressor turning but not pumping properly - Indications:

1. Discharge refrigerant from system.
2. Remove the compressor from the machine.
A. System is fully charged. 3. Remove and replace compressor because
there is indication of internal leak in
B. Discharge air from evaporator is cool. compressor.
4. Replace compressor.
5. Charge the system with refrigerant.
48083741_EN 31/07/2018
50.2 [50.200] / 13
Expansion valve stuck open

Expansion Valve Stuck Open 1. Replace expansion valve.

Condenser not operating - Indications:

1. Check for loose or worn compressor belt and
proper condenser fan operation.
2. Check to see that condenser is clean and
that the fins are straight.
3. Check system for too much refrigerant.
A. Remove refrigerant from system until
gauge pressure is below normal.
B. Add refrigerant until gauge pressures are
A. Liquid line is very hot. normal.
B. Discharge air from evaporator is warm. C. If problem persists, see step 4.
4. Remove and inspect condenser for
restrictions caused by oil or reduced heat
transfer.
A. Discharge refrigerant from system.
B. Use compressed air to remove oil from
condenser.
C. Replace receiver-drier.
D. Charge system with new refrigerant.
Air in the system - Indications:

1. Discharge refrigerant from system.
2. Replace receiver-drier.
Discharge air from evaporator is warm.
48083741_EN 31/07/2018
50.2 [50.200] / 14
Problem: Intermittent cooling

Temperature of low pressure gauge: normal T
emperature of high pressure gauge: normal
Moisture in the system - Indications:

1. Discharge system of refrigerant. If too much
moisture enters the orifice of the expansion
valve, the freezing of this moisture can stop
refrigerant flow.
Cooling is acceptable during cool part of day but 2. Replace receiver-drier. The moisture
not acceptable during hot part of day. removing material could be full to capacity
with moisture.
NOTE: the time needed to remove a large amount of moisture will be two to three hours minimum.
Problem: Noise in system

Temperature of low pressure gauge: normal to high
Too much refrigerant in system - Indications:

1. Remove refrigerant from system until gauge
A. Discharge air from heater/evaporator is cool. readings are below normal.
B. Compressor makes noise. 2. Add new refrigerant until gauge readings are
normal.
48083741_EN 31/07/2018
50.2 [50.200] / 15
Air conditioning - Service instruction - Safety procedures

DANGER
Avoid injury!
Observe ALL precautions listed below when servicing the air-conditioning system and handling re-
frigerant.
Failure to comply will result in death or serious injury.
D0043A
Refrigerant HFC-134a is the most stable, and easiest to work with of the refrigerants now used in air conditioner
systems. Refrigerant HFC-134a does not contain any chlorofluorocarbons (CFC's) which are harmful to the earth's
ozone layer.
Safety procedures must be followed when working with Refrigerant HFC-134a to prevent possible personal injury.
NOTICE: only authorized technicians certified by an approved training and certification organization may service or
repair motor vehicle or mobile air conditioning systems. It is mandatory that all refrigerant must be RECOVERED and
RECYCLED when removed from a system during servicing.
1. Always wear safety goggles when doing any service
work near an air conditioner system. Liquid refrigerant
getting into the eyes can cause serious injury. Do the
following if you get refrigerant near or in your eyes:
A. Flush your eyes with water for 15 minutes.
B. See a physician immediately.
2. A drop of liquid refrigerant on your skin may cause frost-
bite. Open the fittings carefully and slowly when it is
necessary to service the air conditioner system. Your
skin must be treated for frostbite or a physician must
be seen if you get refrigerant on your skin.
3. Keep refrigerant containers in the correct upright po-
sition. Always keep refrigerant containers away from
heat and sunlight. The pressure in a container will in-
crease with heat.
4. Always reclaim refrigerant from the system, if you are
going to weld or steam clean near the air conditioner
system.
5. Always check the temperature and pressure of the air
conditioner system before reclaiming refrigerant and
when you test the system.
6. Dangerous gas can form when refrigerant comes in
contact with an open flame. Never permit fumes to be
inhaled.
7. Never leak test with compressed air or flame testers.
Tests have indicated that compressed mixtures of HFC-
134a and air can form a combustible gas.
8. Always reclaim refrigerant from the system before re-
moving any air conditioning component.
48083741_EN 31/07/2018
50.2 [50.200] / 16
Air conditioning - Pressure test

NOTICE: refer to .”Air conditioning – General specification”.
Manifold Gauge Set

NOTE: the gauge set is not accurate enough to optimize an
existing charge of HFC-134a. The best use of the gauge
set is to determine whether undercharge or overcharge ex-
ists, and then evacuate, reclaim and recharge system with
the recommended quantity (charge) of HFC-134a.
The manifold gauge set is the most important tool used
to service the air conditioning system. The manifold
gauge set is used to measure the high and low pres-
sures of the system, as a tool to troubleshoot for cor-
rect refrigerant charge quantity, system diagnosis, and
operating efficiency. The manifold gauge set can read
both the high (discharge) and low (suction) sides at the
same time, since pressure must be compared in order
to make a diagnosis of system operation.
LOW PRESSURE GAUGE - The low pressure gauge is
a compound gauge. It is best used to judge evacuation
effectiveness. A vacuum reading indicates a system
malfunction. For this reason, it is necessary to use a
compound gauge that will indicate both pressure and
vacuum.
During normal operation the low pressure gauge must
always indicate from 10 – 35 psi ( 0.7 – 2.4 bar) after
the system has run 10 – 15 minutes.
HIGH PRESSURE GAUGE - The high pressure gauge
is used to indicate pressures in the high side of the sys-
tem. The gauge must indicate from 0 – 400 psi ( 0 –
27.6 bar) minimum.
During normal operation, the high pressure gauge will
normally indicate from 120 – 310 psi ( 8.3 – 21.4 bar).
See pressure-temperature chart on ”Air conditioning –
General specification”.
Pressure Test Connection

Connect the manifold gauge set into the air conditioning
system as shown. Make sure that both valves in the
manifold gauge set are closed.
48083741_EN 31/07/2018
50.2 [50.200] / 17
Air conditioning - Charging

Recovery and charging station connections
1. Clean the external surfaces of the compressor and
hoses. Remove the caps from the service ports on the
suction and pressure hoses.
NOTICE: Do not steam clean any air conditioning system
parts while the system is charged. The heat will cause the
refrigerant to rise to a pressure that could cause the system
to explode.
2. Connect the hoses from the test gauges to the service
ports by turning the knurled knobs on the depressors.
3. Connect the hose from the low pressure gauge to the
port on the suction hose.
4. Connect the hose from the high pressure gauge to the
port on the discharge hose.
NOTICE: always wear safety goggles when working with
liquid refrigerant. Liquid refrigerant in your eyes could
cause blindness.
5. Make sure the charging station OEM1598 manifold
gauge valves are in the closed position.
6. Start the engine and run at 1500 RPM maximum
speed. Operate the air conditioner system at maximum
cooling setting and blower speed for 15 minutes with
the cab door open. Observe the test gauges and check
the chart on page 13 against the gauge readings.
48083741_EN 31/07/2018
50.2 [50.200] / 18
Air conditioner system refrigerant recovery

Recovered refrigerant passes through an oil separator
and a filter-drier before entering the refrigerant tank.
The moisture indicator will turn green when dry refrig-
erant passes over it. If possible, run the air condition-
ing system for ten minutes before starting the recovery
process. Turn the system off before proceeding.
1. Clean the external surfaces of the compressor and
hoses. Remove the caps from the service ports on the
suction and pressure hoses.
LEIL14WHL0219AA 1
2. With the charging station manifold gauge valves in the

closed position, connect the hoses from the test gauges
to the service ports. Connect the hose from the low
pressure gauge to the port on the suction hose. Turn
in valve depressor. Connect the hose from the high
pressure gauge to the port on the discharge hose. Turn
in valve depressor.
3. Open the high and low valves.
LEIL13WHL1092AA 2
4. Make certain the refrigerant tank gas and liquid valves

are open.
LEIL13WHL1093AA 3
48083741_EN 31/07/2018
50.2 [50.200] / 19
5. Connect the main power plug to a 115 V AC outlet.

Move the main power switch to the ON position and
depress the recovery start switch. The compressor
will shut OFF automatically when recovery is complete.
Wait for 5 minutes and observe the manifold pressure
gauges for a pressure rise. If pressure rises above
0 bar (0 psi), depress the hold/cont switch. Then wait
for the compressor to automatically shut OFF.
LEIL13WHL1094AA 4
6. Drain the oil separator of the Air Conditioning system

oil. Open the air purge valve long enough to let some of
the compressor discharge pressure back into the sep-
arator.
LEIL13WHL1095AA 5
7. Slowly open the oil drain valve and drain the oil into
the reservoir. When the oil stops draining, close the oil
drain valve completely.
LEIL13WHL1096AA 6
8. Fill the Air Conditioning compressor with fresh SP-20

PAG oil equal to the amount in the reservoir.
LEIL13WHL1097AA 7
9. Remove the hoses from the service ports and install

the caps.
48083741_EN 31/07/2018
50.2 [50.200] / 20
Air conditioner system evacuation and recharching

NOTE: replace the receiver-drier if one or more of the following conditions occurs before your remove the air and
moisture from the system
A. The system has been opened for service before.
B. Receiver-drier has operated two or more years.
C. Disassembly of compressor shows small particles
of moisture removing material (gold or brown par-
ticles).
D. Large system leak (broken hose, break in line).
E. Too much air or moisture in system.
F. Removal of compressor caused the system to be
open (uncapped) longer than 5 minutes.
10. With the charging station manifold gauge valves in
the closed position, connect the hoses from the test
gauges to the service ports as follows:
1. Connect the hose from the low pressure gauge to
the port on the suction hose.
2. Connect the hose from the high pressure gauge
to the port on the discharge hose.
3. Turn in both thumbscrews to depress the service
valves.
NOTE: the pump on the reclamation unit will not pull a suffi-
cient vacuum to remove air and moisture. Air and moisture
are removed from the system by a vacuum pump. A vac-
uum pump is the only equipment made to lower the pres-
sure enough to change the moisture to vapor that can be
removed from the system.
NOTE: refer to the vacuum pump manufacturer’s user
manual for additional information.
11. Connect the main power plug to a 115 V AC outlet.
Move the main power switch to the ON position. If
program and vacuum do not appear at the top of the
display press the vacuum key. Program a minimum of
45 minutes and press the Enter key. The display will
flash once indicating the programmed data has been
accepted.
LEIL13WHL1100AA 8
48083741_EN 31/07/2018
50.2 [50.200] / 21
12. Press the Charge key. “Program” and “Charge” will

appear on the display.
LEIL13WHL1101AA 9
13. Program 3.5 lbs and press the enter key. The display
will flash once indicating the programmed data has
been accepted.
LEIL13WHL1100AA 10
14. Fully open the low and high pressure valves.
LEIL13WHL1102AA 11
15. Open the red (vapor) and blue (liquid) valves on the
tank.
LEIL13WHL1093AA 12
48083741_EN 31/07/2018
50.2 [50.200] / 22
16. Press the Vacuum key. “Automatic” will appear on the

display. Vacuum will appear on the display and after a
slight delay, the vacuum pump will start. The display
will show the amount of time programmed and begin
a countdown to zero.
When the programmed time has elapsed, an auto-
matic hold occurs. Check the low pressure gauge
to see that the Air Conditioning system maintains a
28-29 in. of mercury (Hg). The low pressure gauge
must not increase faster than one inch of mercury (Hg)
in 10 min. A previously charged, leak-free system will
leach refrigerant from compressor oil and raise sys-
tem pressure under vacuum. If the system will not
hold vacuum, a leak exists that must be corrected be- LEIL13WHL1103AA 13
fore recharging can begin.
17. Press the charge key to begin refrigerant charging.
“Automatic” and “Charge” will appear on the display.
The display shows the programmed amount and
counts down to zero as charging proceeds. When
charging is completed, the display shows “CPL”.
LEIL13WHL1100AA 14
18. Completely close the high and low pressure manifold

valves.
NOTICE: check the OEM equipment manual before per-
forming Step 19 to avoid damaging the recovery unit. The
pressure reading should be obtainable with valves closed.
Damage may occur if the machine is started with the valves
accidently open or if either or both valves are opened while
the Air Conditioning system is operating.
LEIL13WHL1102AA 15
19. Start the engine and run at 1500 RPM. Operate the
air conditioner system at maximum cooling setting and
blower speed with the doors and windows open.
NOTE: the compressor will not operate if the system pres-
sure is too low or too high. The pressure indicator lamp will
illuminate when the relay is actuated by a low or high pres-
sure and the compressor clutch will disengage. To restart
the compressor, the air conditioner control or blower switch
must be turned to the OFF position and then to the ON po-
sition.
48083741_EN 31/07/2018
50.2 [50.200] / 23
20. Observe the pressure gauge readings to determine

that the correct amount of refrigerant has entered the
system.
LEIL13WHL1104AA 16
21. Stop the engine, close any open valves and carefully
remove the manifold gauge hoses.
22. Install the caps on the service ports on the suction and
discharge hoses.
48083741_EN 31/07/2018
50.2 [50.200] / 24
Air conditioning - Service instruction - Troubleshooting
Problem Possible Cause Correction

MECHANICAL See Mechanical Compressor Check
No Cooling (compressor doesn’t run) See Blower and Compressor Clutch
ELECTRICAL
Check
No Cooling (compressor runs) INTERNAL SYSTEM PROBLEM See Pressure Testing
Make sure the heater control is OFF
HEATER and that there is no coolant flow
through the heater core.
Make sure the sealing material is
SEAL
correctly in place.
Not Enough Cooling MECHANICAL See Mechanical Compressor Check
MECHANICAL See Evaporator Heater Core Check
See Blower and Compressor Clutch
ELECTRICAL
Check
REFRIGERANT See Cable Temperature Check
INTERNAL SYSTEM PROBLEM See Pressure Testing
See Blower and Compressor Clutch
ELECTRICAL
Check
Erratic Cooling ELECTRICAL Blower Motor Check
ELECTRICAL Blower Switch Check
ELECTRICAL Compressor Clutch Check
MECHANICAL See Blower Motor Check
System Makes Noise
ELECTRICAL See Compressor Clutch Check
Mechanical Compressor Check

Component Correction
Compressor and Fan Belts Too much belt wear - replace a worn belt, because a
worn belt will cause too much slippage.
Compressor Mounting Brackets 1. Loose bracket mounting bolts - tighten the bolts to the
correct torque.
2. Bracket has cracks or breaks - replace the bracket."
Compressor Clutch 1. The compressor belt will slip on the compressor pulley
if there is compressor seizure. Remove the compressor
for service or replacement.
2. Remove the dust cover and check the air gap on the
compressor clutch. The gap between the front plate
and pulley assembly must be 0.41 – 0.79 mm (0.02 –
0.03 in).
3. Use a socket wrench to slowly rotate the compressor
clockwise. Compressor rotation should be smooth and
not require much effort.
Pulley and Belt Alignment The compressor pulley and the compressor drive pulley
must be aligned within 1.6 mm (0.1 in) of each other.
Use a straight edge to check pulley alignment. Adjust the
compressor mounting bracket if needed.
48083741_EN 31/07/2018
50.2 [50.200] / 25
Blower and Compressor Clutch Check

Compressor Clutch NOTE: check supply voltage with compressor lead
plugged in and engaged. Voltage drops will not be ap-
parent without current flow.
1. If there is electrical system voltage to the clutch,
check for excessive voltage drop in the ground circuit,
and replace the compressor.
Low and High Pressure Switches Check the high and low pressure switches.
Blower Fuse ( 10 A) Check for damaged blower fuse.
Blower Fan Switch 1. Check switch operation. Switch must give four
different blower speeds: OFF, Low, High, and Purge.
2. Check for loose connections or broken wires. Repair
or replace as necessary.
3. Check resistor board.
Blower Motor 1. Check the wiring to the blower motor. Make repairs or
replace items as necessary.
2. Check motor ground wire. Make sure motor ground
wire is making good contact with mounting bracket.
Temperature Control Switch 1. With key in ON position, turn switch to maximum cold.
Compressor clutch must engage.
NOTE: blower must be operating, since electrical power
to temperature control switch is received from blower
switch.
2. Turn the blower off. Disconnect the wires from the
temperature control. Using an ohmmeter, check the
continuity between switch terminals. If continuity is not
present when switch is on maximum cold, replace switch.
Cab Temperature Check

Air Louvers 1. Make sure louvers and recirculation vents are fully
open for most efficient air conditioning operation. Defrost
louvers must be closed.
2. Check blower; blower must be running.
Air Conditioning NOTICE: use caution when feeling hoses. Hoses become
very hot. Check temperature by slowly reaching for hose
and touching briefly several times with finger tips, increas-
ing the duration with each touch.
1. Feel the air conditioning hoses. The high pressure
hoses (small line) must be warmer than the low pressure
hose (large line).
2. If no temperature difference, the system is low on
refrigerant, or compressor is not working correctly.
Duct Temperature 1. Put a thermometer in the air duct behind the seat
and run the compressor for f i ve minutes to make
temperature stable.
2. Duct temperature must be below 25 °C (77 °F) if the
system is operating at maximum efficiency.
3. If temperature is above 25 °C (77 °F), system is
low on refrigerant, there is a restr iction in the system,
compressor is not working correctly, or air ducts are not
sealed correctly.
NOTE: ambient temperature must be 27 – 43 °C (81 –
109 °F).
48083741_EN 31/07/2018
50.2 [50.200] / 26
Temperature Sensing Probe Check 1. Turn the engine OFF, key switch ON, blower switch
ON and temperature control switch turned fully clockwise.
2. Remove the temperature sensing probe from the
evaporator.
3. Put the end of the temperature sensing probe in a
container with ice and water.
4. When the sensing tube has cooled to the temperature
of the ice and water mixture, the temperature control
switch should interrupt the current flow to the compressor.
Check for current at the control switch terminals as on
previous page. If current is not interrupted then replace
the control switch.
Visual and Leak Check

Compressor Hoses 1. Make sure that all hose connections are tight.
2. Check hoses for bends or cracks. Replace all hoses
that have damage.
Leak Finding Check 1. Shut off the engine.
NOTICE: when refrigerant comes in contact with an open
flame, it can form dangerous gas. Never breathe these
fumes.
2. Use electronic leak detector 380001327 to inspect
all connections. Use instructions from manufacturer of
leak finding tool.
NOTE: when checking compressor seal for a leak, re-
move the dust cover and rotate the clutch shaft clockwise.
NOTE: to properly check the expansion valve for leaks,
remove the insulation tape.
3. Repair all leaks and recharge the system.
Condenser Make sure the condenser is clean and the seals are in
place. Make sure condenser fans run when temperature
control switch is ON.
Evaporator/Heater Core Check

Make sure heater valve is closed.
1. Inspect the fins on the evaporator/heater core. All the
fins that have bends or damage must be made straight.
2. Inspect the evaporator/heater core for restrictions.
If the core is dry, use compressed air or a brush and
vacuum cleaner. If the core is wet or filled with mud, flush
Evaporator/Heater Core the core with water using a hose without pressure. Make
sure the water drains freely from the evaporator/heater
core. DO NOT USE STEAM.
NOTICE: do not steam clean any air conditioning systems
parts while the system is charged. The heat will cause
the refrigerant to rise to a pressure that could cause the
system to explode
Evaporator/Heater Core Sealing Make sure seals are in place so blower will pull air only
through the evaporator/heater core and not around the
evaporator/heater core.
Filters Make sure the filters are clean.
48083741_EN 31/07/2018
50.2 [50.200] / 27
Air-conditioning compressor - Remove

2. Raise the engine hood.
3. Discharge the air conditioning system.
4. Remove the four bolts that hold the engine guard in
place. Remove the engine guard.
LEIL16WHL2490AA 1
LEIL16WHL2430AA 2
5. Remove the drive belt by releasing the automatic belt

tensioner.
LEIL16WHL2444AA 3
48083741_EN 31/07/2018
50.2 [50.200] / 28
6. Disconnect the high pressure hose (1) and low pres-

sure hose (2) located on the air-conditioning compres-
sor (3). Immediately install protective caps on the open
ports and lines.
NOTE: the air cleaner is NOT shown, for clarity.
LEIL17WHL0003AB 4
7. Loosen and remove the three mounting bolts M8x100

(1) and three washers (2). Remove the air-conditioning
compressor (3) from the machine.
LEIL16WHL1179AB 5
48083741_EN 31/07/2018
50.2 [50.200] / 29
Air-conditioning compressor - Install

1. Place the air-conditioning compressor (3) in the correct
position on the support.
2. Install the three washers (2) and three mounting bolts
M8x100 (1) to lock the air-conditioning (3) in position.
LEIL16WHL1179AB 1
3. Carefully remove the protective caps.

Install a new O-ring. Connect the high pressure hose
(1) to the discharge port of the air-conditioning com-
pressor (3).
Install a new O-ring. Connect the low pressure hose (2)
to the suction port of the air-conditioning compressor
(3).
Tighten the hoses (1) and (2) to the torque indicated in
the Air conditioning - Torque (50.200).
NOTE: apply the angle orientation to the hoses (1) and (2)
as indicated in figure.
NOTE: use caution when removing the protective caps.
The new compressors are internally pressurized when LEIL17WHL0001AB 2
shipped from the factory.

NOTE: the air cleaner is not shown for clarity.
LEIL17WHL0003AB 3
4. Acting the automatic belt tensioner and install the drive

belt.
Verify the correct tension using the tool 380001325.
The correct tension for a new belt is: 623 – 712 N·m
(459.5 – 525.1 lb ft). Tension for a used belt is: 400
– 534 N·m (295 – 393.9 lb ft) to be squeezed 20 mm
(0.8 in) maximum.
LEIL16WHL2444AA 4
48083741_EN 31/07/2018
50.2 [50.200] / 30
5. Install the engine guard, by using the four bolts.
LEIL16WHL2430AA 5
LEIL16WHL2490AA 6
6. Charge the air conditioning system according to spec-

ifications. Refer to Air conditioning - Charging
(50.200).
7. Lower the engine hood.
48083741_EN 31/07/2018
50.2 [50.200] / 31
Air-conditioning condenser - Remove

1. Park the machine on a firm, level surface. Lower the
3. Discharge the air conditioning system following the
specified procedures.
4. Open the cover (1) to gain access to the air-condition-
ing condenser (2).
RAPH12WEL2673AA 1
5. The air-conditioning condenser (2) is connected to a

plate (1) that pivots on the cooling frame. Pivot the
air-conditioning condenser to gain access to the hoses.
LEIL16WHL1204AB 2
6. Disconnect the condenser to dryer hose (1) and the

condenser to compressor hose (2) from the air-condi-
tioning condenser. Mark and tag the hoses (1) and (2)
to aid in reassembly.
7. Install plugs in the hoses (1) and (2). and caps on the
fittings.
LEIL16WHL1203AB 3
8. Loosen the four nuts (3) that fasten the air-conditioning

condenser to the plate. Pivot the air-conditioning con-
denser to remove the nuts (3), with the related washers
and nuts and the air conditioning condenser.
48083741_EN 31/07/2018
50.2 [50.200] / 32
Air-conditioning condenser - Install

1. Place the air-conditioning condenser (2) in the correct
position on the condenser plate (3).
2. Install the bolts (1), with related washers to secure the
air-conditioning condenser (2) to the condenser plate
(3). Pivot the air-conditioning condenser (2) down and
tighten the bolts.
LEIL16WHL1202AB 1
3. Pivot the air-conditioning condenser to gain access to

the hoses.
4. Carefully remove the protective caps. Install new
O-rings. Connect the compressor to dryer hose (1)and
the condenser to compressor hose (2) to the air-con-
ditioning condenser (3). Tighten the hoses (1) and (2)
to the torque indicated in Air conditioning - Torque
(50.200).
NOTE: apply the angle orientation to the hoses (1) and (2)
as indicated in figure.
LEIL16WHL1205BB 2
5. Pivot the air-conditioning condenser down and close

the cover.
6. Charge the air conditioning system. Refer to Air con-
ditioning - Charging (50.200).
LEIL16WHL1201AB 3
48083741_EN 31/07/2018
50.2 [50.200] / 33
Receiver-dryer - Remove
4. Locate the receiver-dryer under the machine, near the
rear axle.
LEIL16WHL1206AB 1
5. Fasten identification tags on the air-condenser to re-

ceiver-dryer hose (2) and on the receiver-dryer to cab
hose (1). Disconnect and plug the hoses (1) and (2)
from the receiver-dryer (3).Install caps on the fittings.
LEIL16WHL1207AB 2
6. Loosen the nuts (3), with related washers and bolts to

separate the receiver-dryer (1) from the brackets (2).
Remove the receiver-dryer (1) from the machine.
LEIL16WHL1208AB 3
48083741_EN 31/07/2018
50.2 [50.200] / 34
Receiver-dryer - Install
1. Locate the brackets (2), under the machine, near the
rear axle.
Place the receiver-dryer (1) in the correct position.
Loosen the nuts (3), with related washers and bolts to
secure the receiver-dryer (1) to the brackets
LEIL16WHL1208AB 1
2. Remove plugs from the receiver-dryer hose (2) and

from receiver-dryer to cab hose (1) hose. Remove caps
from the fittings. Install new O-rings.
Connect the receiver-dryer hose (2) and the receiver-
dryer to cab hose (1) hose to the receiver-dryer (3).
LEIL16WHL1207AB 2
3. Tighten the hoses (1) and (2) to the torque indicated in

Air conditioning - Torque (50.200).
4. Remove and discard identification tags that were used
during disassemble.
5. Charge the air conditioning system. Refer to Air con-
48083741_EN 31/07/2018
50.2 [50.200] / 35
Air-conditioning evaporator - Remove

4. Before changing any air conditioning components, be
sure to discharge the air conditioning system according
to procedures.
(arrows).
LEIL16WHL1190AB 1

LEIL16WHL1209AB 2
8. Disconnect the PRH2 connector (1) of the engine and

rear chassis harness. Remove the clamps (2) securing
LEIL16WHL1193AB 3
48083741_EN 31/07/2018
50.2 [50.200] / 36
9. Disconnect the drain hose (1).

Loosen the nut (4) and remove the clamp plate (3).
Disconnect and plug the air conditioning hoses (2) and
(3).
LEIL18WHL0464AB 4
LEIL18WHL0452AB 5
11. Remove the three retaining knobs that hold the cab
air recirculation filter cover in place.
LEIL18WHL0453AB 6
LEIL18WHL0454AB 7
48083741_EN 31/07/2018
50.2 [50.200] / 37
with 16 screws.
figure 8.
LEIL18WHL0459AB 8
14. Disconnect the electrical connectors (3) and (4).

Remove the three clamps (2) that hold the air condi-
tioning wire harness (1) on the water drain tank.
LEIL18WHL0465AB 9
15. Loosen the screws (1) and extract the water drain tank
from the cab heater assembly.
LEIL16WHL1245AB 10
16. Remove the case gasket (1) and the water drain tank
gasket (2). Remove the evaporator sensor bracket
(3).
LEIL16WHL1246AB 11
48083741_EN 31/07/2018
50.2 [50.200] / 38
17. Separate the air conditioning evaporator (1) from the

water drain tank (2).
LEIL16WHL1249AB 12
48083741_EN 31/07/2018
50.2 [50.200] / 39
Air-conditioning evaporator - Install

1. Insert the air conditioning evaporator (1) to the water
drain tank (2).
LEIL16WHL1249AB 1
2. Install the case gasket (1), the water drain tank gasket
(2) and the evaporator sensor bracket (3) to the air
conditioning evaporator.
LEIL16WHL1246AB 2
3. Insert the water drain tank (2) from the cab heater as-
sembly. Install the bolts (1) to secure the water drain
tank (2).
LEIL16WHL1245AB 3
4. Connect the electrical connectors (3) and (4).

Install the three clamps (2) holding the air conditioning
wire harness (1) on the water drain tank.
LEIL18WHL0465AB 4
48083741_EN 31/07/2018
50.2 [50.200] / 40

with 16 screws.
figure 5.
LEIL18WHL0459AB 5
LEIL18WHL0454AB 6
retaining knobs.
LEIL18WHL0453AB 7
LEIL18WHL0452AB 8
48083741_EN 31/07/2018
50.2 [50.200] / 41
9. Install the drain hose (1).

Remove the protective plugs from the air conditioning
hoses (2) and (3).Install the air conditioning hoses (2)
and (3)
Install the nut (4) and the clamp plate (3).
LEIL18WHL0464AB 9
10. Connect the PRH2 connector (1) of the engine and

rear chassis harness. Install the clamps (2) securing
LEIL16WHL1193AB 10
LEIL16WHL1209AB 11

LEIL16WHL1190AB 12
13. Charge the Air Conditioning system. Refer to Air con-

48083741_EN 31/07/2018
50.2 [50.200] / 42
14. Fill the engine cooling system.

15. Put the timed disconnect switch to ON position
48083741_EN 31/07/2018
50.2 [50.200] / 43
Index

Air conditioning - Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Air conditioning - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Air conditioning - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Air conditioning - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Air conditioning - Pressure test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Air conditioning - Service instruction - Safety procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Air conditioning - Service instruction - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Air conditioning - Service instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Air conditioning - Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Air conditioning - Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Air conditioning - Visual inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Air-conditioning compressor - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Air-conditioning compressor - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Air-conditioning condenser - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Air-conditioning condenser - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Air-conditioning evaporator - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Air-conditioning evaporator - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Receiver-dryer - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Receiver-dryer - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
48083741_EN 31/07/2018
50.2 [50.200] / 44
48083741_EN 31/07/2018
50.2 [50.200] / 45
PRINTED IN ITALY
48083741_EN 31/07/2018
EN
SERVICE MANUAL
Electrical systems

48083741_EN 31/07/2018
55
Contents
Electrical systems - 55
[55.100] Harnesses and connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.1
[55.301] Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.2
[55.302] Battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.3
[55.512] Cab controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.4
[55.050] Heating, Ventilation, and Air-Conditioning (HVAC) control system. . . . . . . . . . . . . . . . . . . 55.5
[55.415] Loader arm and bucket control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.6
[55.530] Camera. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.7
[55.DTC] FAULT CODES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.8
48083741_EN 31/07/2018
55
Harnesses and connectors - 100

48083741_EN 31/07/2018
55.1 [55.100] / 1
Contents
FUNCTIONAL DATA
Electrical components
ECU description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Sensor description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Diode description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Fuse description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Voltage source description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Ground description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Speaker description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Power outlet description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Relay description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Load description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Lamp description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Motor description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Resistor description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Switch description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Solenoid description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Wiring harnesses
Electrical schematic sheet 03 SH03 - PWR DISTR-BATTERY / STARTER / KEY . . . . . . . . . . . . . . . . . . 36
Electrical schematic sheet 04 SH04 - POWER DISTRIBUTION SFB PWR AND GRNDS . . . . . . . . . . . 40
Electrical schematic sheet 06 SH06 - BATTERY PWR DISTR (FUSE BLOCK LC1) . . . . . . . . . . . . . . . . 42
Electrical schematic sheet 07 SH07 - BATTERY PWR DISTR (FUSE BLOCK LC2) . . . . . . . . . . . . . . . . 44
Electrical schematic sheet 08 SH08 - POWER DISTRIBUTION (FUSE BLOCK LC3) . . . . . . . . . . . . . . . 46
Electrical schematic sheet 09 SH09 - ACCESSORY PWR DIST (FUSE BLOCK LC4) . . . . . . . . . . . . . . 48
Electrical schematic sheet 10 SH10 - IGNITION PWR DISTR (FUSE BLOCK LC5) . . . . . . . . . . . . . . . . 50
Electrical schematic sheet 11 SH11 - PWR DISTR ENG COMPARTMENT (FUSE BLOCK LC6) . . . . . 52
Electrical schematic sheet 12 SH12 - POWER DISTRIBUTION 1 CLEAN GROUND BLK . . . . . . . . . . . 54
Electrical schematic sheet 13 SH13 - POWER DISTRIBUTION 2 CAB GROUND BLK . . . . . . . . . . . . . 56
Electrical schematic sheet 14 SH14 - CAB & CHASSIS GROUND PWR DISTR . . . . . . . . . . . . . . . . . . . 58
Electrical schematic sheet 15 SH15 - POWER DISTRIBUTION 4 ENGINE GROUND BLK . . . . . . . . . . 60
Electrical schematic sheet 16 SH16 - ENGINE CONTROL UNIT 1, GRID HEATER, FILTER HEATER 62
Electrical schematic sheet 17 SH17 - ENGINE CONTROL UNIT 2, AT . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Electrical schematic sheet 18 SH18 - ENGINE CONTROL UNIT 3, AT . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
48083741_EN 31/07/2018
55.1 [55.100] / 2
Electrical schematic sheet 19 SH19 - UCM PWR, GRND, INSTRUMENTATION . . . . . . . . . . . . . . . . . . . 68
Electrical schematic sheet 20 SH20 - UCM VEHICLE DRIVELINE / FAN CONTROL . . . . . . . . . . . . . . . 70
Electrical schematic sheet 21 SH21 - UCM-STEERING AUX JSS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Electrical schematic sheet 22 SH22 - UCM-LOADER BOOM CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . 74
Electrical schematic sheet 23 SH23 - PILOT LOADER CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Electrical schematic sheet 24 SH24 - CAN STRUCTURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Electrical schematic sheet 25 SH25 - GEAR CONTROL UNIT 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Electrical schematic sheet 26 SH26 - GEAR CONTROL UNIT 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Electrical schematic sheet 27 SH27 - LIGHTING DOME, MAP LIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Electrical schematic sheet 28 SH28 - LIGHTING HAZARD WARNING, BLINKERS, DRIVING . . . . . . . 86
Electrical schematic sheet 29 SH29 - LIGHTING REAR TAILS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Electrical schematic sheet 30 SH30 - OLD EURO LIGHTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Electrical schematic sheet 31 SH31 - LIGHTING WORKING LIGHTS CAB ROOF, FRONT AND REAR 92
Electrical schematic sheet 32 SH32 - CAB WIPER / WASHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Electrical schematic sheet 33 SH33 - HEATING BLOWER HEATER, HVAC . . . . . . . . . . . . . . . . . . . . . . . 96
Electrical schematic sheet 34 SH34 - MIRRORS, HORN BEACON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Electrical schematic sheet 35 SH35 - CABIN RADIO LOUDSPEAKER/12V CNVRTR . . . . . . . . . . . . . 100
Electrical schematic sheet 36 SH36 - REAR DEFROST, BACKUP ALARM . . . . . . . . . . . . . . . . . . . . . . 102
Electrical schematic sheet 37 SH37 - HOOD LIFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Electrical schematic sheet 38 SH38 - MISCELLANOUS, TELEMATICS . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Electrical schematic sheet 39 SH39 - MISCELLANOUS, REAR CAMERA . . . . . . . . . . . . . . . . . . . . . . . 108
Wire connectors
Component diagram 00 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Component diagram 100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263
48083741_EN 31/07/2018
55.1 [55.100] / 3
Electrical systems - Harnesses and connectors
Electrical components - ECU description

A-108F - ZF DIAGNOSTIC CONNECTOR (ECU)
Component Type ECU

Wiring frames SHEET 25 SH25 - GEAR CONTROL UNIT 1
Connectors X-ZF_DI (Plug) - DIAGNOSTIC [A-108F] (84364851)
A-AC CONTROL PANEL - DENSO (ECU)
Component Type ECU

Wiring frames SHEET 33 SH33 - HEATING BLOWER HEATER, HVAC
A-DIA - DIAGNOSTIC PLUG (ECU)
Component Type ECU

Wiring frames SHEET 24 SH24 - CAN STRUCTURE
Connectors X-DIA (Plug) - DIAGNOSTIC PORT [A-DIA] (87736919)
A-DISPLAY - (ECU)
Component Type ECU

Wiring frames SHEET 39 SH39 - MISCELLANOUS, REAR CAMERA
A-DRIVER 24V - DENSO (ECU)
Component Type ECU

A-DSP - DISPLAY (ECU)
Component Type ECU

Connectors X-DSP (Receptacle) - DISPLAY [A-DSP] (82016219)
A-ECU - ENGINE CONTROLLER (ECU)
Component Type ECU

Wiring frames SHEET 16 SH16 - ENGINE CONTROL UNIT 1, GRID HEATER, FILTER HEATER
SHEET 17 SH17 - ENGINE CONTROL UNIT 2, AT
SHEET 18 SH18 - ENGINE CONTROL UNIT 3, AT
Connectors X-ECU (Receptacle) - ECU CONNECTOR [A-ECU] (84300197)
A-EH_VLV - ELECTROHYDRAULIC VALVE (ECU)
Component Type ECU

Wiring frames SHEET 22 SH22 - UCM-LOADER BOOM CONTROL
Connectors X-PILOT_ENABLE (Receptacle) - PILOT ENABLE SOLENOID [SH28: A-1]
(87695582) X-BOOM_RAISE (Receptacle) - BOOM RAISE SOLENOID [A-EH_VLV]
(87695582) X-BOOM_LOWER (Receptacle) - BOOM LOWER SOLENOID
[A-EH_VLV] (87695582) X-BUCKET_ROLL (Receptacle) - BUCKET ROLL
SOLENOID [A-EH_VLV] (87695582) X-BUCKET_DUMP (Receptacle) - BUCKET
DUMP SOLENOID [A-EH_VLV] (87695582) X-AUX_1_LEFT (Receptacle) - AUX
1 LEFT [A-EH_VLV] (87695582) X-AUX_1_RIGHT (Receptacle) - AUX 1 RIGHT
[A-EH_VLV] (87695582) X-AUX_2_LEFT (Receptacle) - AUX 2 LEFT [A-EH_VLV]
(87695582) X-AUX_2_RIGHT (Receptacle) - AUX 2 RIGHT [A-EH_VLV] (87695582)
A-HVAC - DENSO (ECU)
Component Type ECU

48083741_EN 31/07/2018
55.1 [55.100] / 4
A-LIGHT HOLDER 2 - DENSO (ECU)
Component Type ECU

A-LIGHT HOLDER1 - DENSO (ECU)
Component Type ECU

A-MAIN JB CAB - JUNCTION BLOCK INTO CAB (ECU)
Component Type ECU

Wiring frames SHEET 03 SH03 - PWR DISTR-BATTERY / STARTER / KEY
SHEET 06 SH06 - BATTERY PWR DISTR (FUSE BLOCK LC1)
SHEET 07 SH07 - BATTERY PWR DISTR (FUSE BLOCK LC2)
SHEET 08 SH08 - POWER DISTRIBUTION (FUSE BLOCK LC3)
A-ORLACO CAMERA - REAR VIEW CAMERA (ECU)
Component Type ECU

Wiring frames SHEET 39 SH39 - MISCELLANOUS, REAR CAMERA
A-PFNR - PRIMARY FNR (ECU)
Component Type ECU

Wiring frames SHEET 20 SH20 - UCM VEHICLE DRIVELINE / FAN CONTROL
Connectors X-TS2 (Receptacle) - TRANS SHIFTER 2 [A-PFNR] (47702209) X-TS1 (Plug) -
TRANS SHIFTER1 [A-PFNR] (87692817)
A-PMP - DEF PUMP MODULE (ECU)
Component Type ECU

Wiring frames SHEET 18 SH18 - ENGINE CONTROL UNIT 3, AT
Connectors X-PUMP (Receptacle) - DENOX CONTROL UNIT [A-PMP] (47421681)
A-SFB - SMART FUSE BOX (ECU)
Component Type ECU

SHEET 04 SH04 - POWER DISTRIBUTION SFB PWR AND GRNDS
SHEET 24 SH24 - CAN STRUCTURE
SHEET 27 SH27 - LIGHTING DOME, MAP LIGHTS
SHEET 28 SH28 - LIGHTING HAZARD WARNING, BLINKERS, DRIVING
SHEET 29 SH29 - LIGHTING REAR TAILS
SHEET 31 SH31 - LIGHTING WORKING LIGHTS CAB ROOF, FRONT AND REAR
SHEET 32 SH32 - CAB WIPER / WASHER
SHEET 33 SH33 - HEATING BLOWER HEATER, HVAC
SHEET 34 SH34 - MIRRORS, HORN BEACON
SHEET 36 SH36 - REAR DEFROST, BACKUP ALARM
SHEET 39 SH39 - MISCELLANOUS, REAR CAMERA
Connectors X-X6 (Receptacle) - SFB [A-SFB] (47554341)
A-TELE - TELEMATIC MODULE (ECU)
Component Type ECU

Wiring frames SHEET 38 SH38 - MISCELLANOUS, TELEMATICS
Connectors X-X_TEL (Receptacle) - TELEMATICS [SH38: C-6] (87700156)
48083741_EN 31/07/2018
55.1 [55.100] / 5
A-TERM2 - TERMINATOR (ECU)
Component Type ECU

Connectors X-TERM2 (Receptacle) - TERMINATOR CAN [A-TERM2] (87695580)
A-TERM3 - TERMINATOR (ECU)
Component Type ECU

Connectors X-TERM3 (Receptacle) - TERMINATOR CAN [A-TERM3] (87695580)
A-TERMC - TERMINATOR FOR CAN (ECU)
Component Type ECU

Connectors X-TERM_C (Receptacle) - CONTROLLER AREA NETWORK [A-TERMC] (87695580)
A-TRANS - TRANSMISSION CONTROL UNIT (ECU)
Component Type ECU

SHEET 26 SH26 - GEAR CONTROL UNIT 2
Connectors X-TECM (Receptacle) - TRANS CONTROLLER [SH25: C-6] (84550089)
A-TRC - TRANS CONTROLLER ON TRANNY (ECU)
Component Type ECU

Connectors X-TRC (Receptacle) - TRANS CONTROLLER ON TRANNY CNH [A-TRC]
(47669071)
A-UCM - 47749442 WAS 84328725 (ECU)
Component Type ECU

Wiring frames SHEET 19 SH19 - UCM PWR, GRND, INSTRUMENTATION
SHEET 20 SH20 - UCM VEHICLE DRIVELINE / FAN CONTROL
SHEET 21 SH21 - UCM-STEERING AUX JSS
SHEET 22 SH22 - UCM-LOADER BOOM CONTROL
SHEET 23 SH23 - PILOT LOADER CONTROLS
Connectors X-UCM3B (Receptacle) - UCM [A-UCM] (84130760) X-UCM4B (Receptacle) - UCM
[A-UCM] (82028495) X-UCM2B (Receptacle) - UCM [A-UCM] (82028495)
48083741_EN 31/07/2018
55.1 [55.100] / 6
Electrical components - Sensor description

B-ACCEL - THROTTLE CONTROL (Sensor)
Component Type Sensor

Connectors X-THRTL (Receptacle) - THROTTLE CONTROL [B-ACCEL] (84403598)
B-BKT_ANG - BUCKET ANGLE (Sensor)

Connectors X-BUA (Receptacle) - BUCKET ANGLE SENSOR [B-BKT_ANG] (84403598)
B-BM_ANG - BOOM ANGLE (Sensor)

Connectors X-BOA (Receptacle) - BOOM ANGLE SENSOR [B-BM_ANG] (84403598)
B-BPP - BRAKE PEDAL ANGLE (Sensor)

Connectors X-BPP (Plug) - BRAKE PEDAL ANGLE [B-BPP] (87710588)
B-C_TS - DOC UPSTREAM TEMP SENSOR (Sensor)

Connectors X-CTS (Receptacle) - DOC UPSTREAM TEMP [B-C_TS] (84532147)
B-DEF_Q - DEF QUALITY SENSOR (Sensor)

Connectors X-DEFQ (Receptacle) - DEF QUALITY SENSOR (UQS) [B-DEF_Q] (84149219)
B-D_TS - SCR DOWNSTREAM TEMP SENSOR (Sensor)

Connectors X-DTS (Receptacle) - SCR DOWNSTREAM TEMP [B-D_TS] (84532147)
B-ES_S - ENGINE SPEED SENSOR (Sensor)

Connectors X-ESS (Receptacle) - SPEED SENSOR ENGINE [B-ES_S] (84364854)
B-FAX - FRONT AXLE OIL TEMP (Sensor)

Connectors X-FAX (Receptacle) - FRONT AXLE TEMP SENSOR [SH20: A-6] (87711966)
B-FM - FILTER MAINTENANCE (Sensor)

Connectors X-FM (Plug) - PRESSURE SWITCH OIL FILTER [B-FM] (82012083)
48083741_EN 31/07/2018
55.1 [55.100] / 7
B-FSS - FAN SPEED SENSOR (Sensor)

Connectors X-FSS (Receptacle) - FAN SPEED SENSOR [B-FSS] (47696743)
B-GOT - GEAR OIL TEMP (Sensor)

Connectors X-TCOT (Receptacle) - GEAR OIL TEMP [B-GOT] (84364854)
B-HOT - HYD OIL TEMP (Sensor)

Connectors X-HOT (Receptacle) - HYD OIL TEMP [B-HOT] (84607243)
B-HT - HUMIDITY AND AMB TEMP SENSOR (Sensor)

Connectors X-HTS (Receptacle) - HUMIDITY AND TEMP SENSOR [B-HT] (87709809)
B-IS_S - INTERMEDIATE SPEED SENSOR (Sensor)

Connectors X-ISS (Receptacle) - SPEED SENSOR MIDDLE WHEEL CHAIN [B-IS_S] (84364854)
B-JSS - LH JOYSTICK STEERING (Sensor)

Wiring frames SHEET 21 SH21 - UCM-STEERING AUX JSS
Connectors X-JSS_JOY (Receptacle) - JSS LEFT HAND JOYSTICK [B-JSS] (87700107)
B-JSS_CO_2 - JSS CUT OFF SENSOR 2 (Sensor)

Connectors X-JSS_CO_2 (Receptacle) - CUT OFF SENSOR [B-JSS_CO_2] (87694153)
B-NH3 - NH3 SENSOR (Sensor)

Connectors X-NH3 (Receptacle) - NH3 SENSOR [B-NH3] (84146686)
B-NOX_DU - DOC UPSTREAM NOX SENSOR (Sensor)

Connectors X-NOXD (Receptacle) - SCR DOWNSTREAM NOX SENSOR [B-NOX_DU]
(84190317)
B-NOX_SD - SCR DOWNSTREAM NOX SENSOR (Sensor)

Connectors X-NOXS (Receptacle) - DOC UPSTREAM NOX SENSOR [B-NOX_SD] (84190317)
48083741_EN 31/07/2018
55.1 [55.100] / 8
B-NTC SENSOR - DENSO (Sensor)

B-OSS - OUTPUT SPEED SENSOR (Sensor)

Connectors X-OSS (Plug) - SPEED SENSOR GEAR TRANS [B-OSS] (84062580)
B-PBBS - PARK BRAKE PR SENSOR FUTURE (Sensor)

Connectors X-PBBS (Plug) - PARK BRAKE PRES SENSR [B-PBBS]
B-PBL/PEDAL/DECLTCH - BRAKE PESSURE SENSOR (Sensor)

Connectors X-PLB-PBD (Receptacle) - BRAKE PRES SENSR [B-PBL/PEDAL/DECLTCH]
(84078681)
B-PBW - BRAKE SUPPLY PRESS (Sensor)

Connectors X-PBW (Receptacle) - BRAKE SUPPLY WARNING PRES [B-PBW] (84078681)
B-PRB1 - RED_BRAKE_FRNT (Sensor)

Connectors X-PRB1 (Receptacle) - REDUNDANT BRAKE SW 1 [B-PRB1] (84078681)
B-PRB2 - RED_BRAKE_REAR (Sensor)

Connectors X-PRB2 (Receptacle) - REDUNDANT BRAKE SW 2 [B-PRB2] (84078681)
B-PSS - AUX STEERING PRESSURE (Sensor)

Connectors X-PSS (Receptacle) - STEERING PRESSURE SENSOR [B-PSS] (84078681)
B-PXF - RETURN TO DIG PROX (Sensor)

Wiring frames SHEET 23 SH23 - PILOT LOADER CONTROLS
Connectors X-PXF (Plug) - RETURN TO DIG PROX [B-PXF] (87692858)
B-PXH - HEIGHT CONTROL PROX (Sensor)

Connectors X-PXH (Plug) - HEIGHT CNTRL PROX [B-PXH] (87644909)
48083741_EN 31/07/2018
55.1 [55.100] / 9
B-PXT - RTD FOR XT (Sensor)

Connectors X-PXT (Plug) - RTD XT [B-PXT] (87644909)
B-RECTD - COOLANT TEMP (Sensor)

Connectors X-RECT (Receptacle) - ENGINE COOLANT TEMP [B-RECTD] (84607243)
B-RFLG - FUEL LEVEL SENSOR (Sensor)

Connectors X-FL (Plug) - FUEL LEVEL [B-RFLG] (82012083)
B-ST_MTN - STEERING WHEEL MOTION (Sensor)

Connectors X-STW (Receptacle) - STEERING WHEEL MOTION SENSOR [B-ST_MTN]
(84563557)
B-TS_S - TURBINE SPEED SENSOR (Sensor)

Connectors X-TSS (Receptacle) - SPEED SENSOR TURBINE [B-TS_S] (84364854)
B-U_LVL - SENSOR TANK LEVEL & TEMP (Sensor)

Connectors X-DTLTS (Plug) - DEF LEVEL / TEMP [B-U_LVL] (84062580)
B-U_TS - SCR UPSTREAM TEMP SENSOR (Sensor)

Connectors X-UTS (Receptacle) - UPSTREAM OF SCR TEMP SENSOR [B-U_TS] (84532147)
B-WIF - WATER IN FUEL (Sensor)

Connectors X-WIF (Receptacle) - WATER IN FUEL [B-WIF] (87709663)
48083741_EN 31/07/2018
55.1 [55.100] / 10
Electrical components - Diode description

D-SS DIODE - SEC STRG FLYBACK DIODE (Diode)
Component Type Diode

Connectors X-SSD (Plug) - SS FLYBACK DIODE [D-SS DIODE] (87692858)
48083741_EN 31/07/2018
55.1 [55.100] / 11
Electrical components - Fuse description

F-1F1 - ACCESSORY (Fuse)
Component Type Fuse

Wiring frames SHEET 06 SH06 - BATTERY PWR DISTR (FUSE BLOCK LC1)
F-1F2 - IGNITION (Fuse)
Component Type Fuse

F-1F3 - SFB-D (Fuse)
Component Type Fuse

F-1F4 - SFB-A (Fuse)
Component Type Fuse

F-1F5 - SFB-B (Fuse)
Component Type Fuse

F-1F6 - SFB-A (Fuse)
Component Type Fuse

F-2F1 - UCM-VP (Fuse)
Component Type Fuse

F-2F10 - SPARE (Fuse)
Component Type Fuse

F-2F11 - CAMERA (Fuse)
Component Type Fuse

Component Type Fuse

Component Type Fuse

Component Type Fuse

48083741_EN 31/07/2018
55.1 [55.100] / 12
F-2F2 - UCM VF2/3 (Fuse)
Component Type Fuse

F-2F3 - UCM VF4/6 (Fuse)
Component Type Fuse

F-2F4 - UCM VS1/VLP (Fuse)
Component Type Fuse

Component Type Fuse

F-2F6 - TECM (Fuse)
Component Type Fuse

F-2F7 - DISPLAY (Fuse)
Component Type Fuse

F-2F8 - DIAGNOSTIC (Fuse)
Component Type Fuse

F-2F9 - HOOD LIFT (Fuse)
Component Type Fuse

F-3F1 - 12V PWR1 (Fuse)
Component Type Fuse

Wiring frames SHEET 08 SH08 - POWER DISTRIBUTION (FUSE BLOCK LC3)
F-3F2 - 12V SPARE (Fuse)
Component Type Fuse

F-3F3 - 12V RADIO (Fuse)
Component Type Fuse

F-3F4 - 12V SPARE (Fuse)
Component Type Fuse

48083741_EN 31/07/2018
55.1 [55.100] / 13
Component Type Fuse

Component Type Fuse

Component Type Fuse

F-3F8 - 12V CONVERTER (Fuse)
Component Type Fuse

F-4F1 - 24V CIGAR (Fuse)
Component Type Fuse

Wiring frames SHEET 09 SH09 - ACCESSORY PWR DIST (FUSE BLOCK LC4)
Component Type Fuse

Component Type Fuse

F-4F3 - A/C CLUTCH (Fuse)
Component Type Fuse

Component Type Fuse

Component Type Fuse

F-4F6 - BLOWER (Fuse)
Component Type Fuse

F-4F7 - SEAT (Fuse)
Component Type Fuse

48083741_EN 31/07/2018
55.1 [55.100] / 14
F-4F8 - REAR DEFROST (Fuse)
Component Type Fuse

Component Type Fuse

F-5F1 - DISPLAY WK (Fuse)
Component Type Fuse

Wiring frames SHEET 10 SH10 - IGNITION PWR DISTR (FUSE BLOCK LC5)
F-5F10 - STALK/DIFF (Fuse)
Component Type Fuse

F-5F2 - UCM (Fuse)
Component Type Fuse

F-5F3 - TECM (Fuse)
Component Type Fuse

F-5F4 - TELEMATICS (Fuse)
Component Type Fuse

F-5F5 - SEC STRG (Fuse)
Component Type Fuse

F-5F6 - IMP JOYSTICK (Fuse)
Component Type Fuse

F-5F7 - KEY PAD (Fuse)
Component Type Fuse

F-5F8 - JSS IGN (Fuse)
Component Type Fuse

F-5F9 - REAR PWR (Fuse)
Component Type Fuse

48083741_EN 31/07/2018
55.1 [55.100] / 15
F-GH - INLINE GH FUSE (Fuse)
Component Type Fuse

Connectors X-GH2 (Plug) - GRID HEATER [F-GH] (84140737) X-GH3 (Plug) - GRID HEATER
RING TERMINAL [F-GH] (84140737)
F-LC6F1 - MAIN ECU (Fuse)
Component Type Fuse

F-LC6F10 - TELE (Fuse)
Component Type Fuse

F-LC6F2 - KEY/HORN (Fuse)
Component Type Fuse

F-LC6F3 - ECU AUX (Fuse)
Component Type Fuse

F-LC6F4 - SCR SENSORS (Fuse)
Component Type Fuse

Wiring frames SHEET 11 SH11 - PWR DISTR ENG COMPARTMENT (FUSE BLOCK LC6)
F-LC6F5 - FFH (Fuse)
Component Type Fuse

F-LC6F6 - EVGT (Fuse)
Component Type Fuse

F-LC6F7 - ECU IGN (Fuse)
Component Type Fuse

F-LC6F9 - FAN (Fuse)
Component Type Fuse

F-MAIN CAB - FUSE (Fuse)
Component Type Fuse

48083741_EN 31/07/2018
55.1 [55.100] / 16
Electrical components - Voltage source description

G-001 - BATTERY (Voltage source)
Component Type Voltage source

Connectors X-563 (Plug) - BATTERY LUG [G-001] X-567 (Plug) - BATTERY LUG [G-001]
X-P5321 (Plug) - JUMP START [G-001]
G-002 - BATTERY (Voltage source)

Connectors X-564 (Plug) - BATTERY LUG [G-002] X-566 (Plug) - BATTERY POSITIVE [G-002]
X-P5320 (Plug) - JUMP START [G-002]
G-G1 - ALTERNATOR (Voltage source)

Connectors X-ALT (Receptacle) - ALTERNATOR [G-G1] (8602487)
48083741_EN 31/07/2018
55.1 [55.100] / 17
Electrical components - Ground description

GND-001 - (Ground)
Component Type Ground

GND-017 - (Ground)

Wiring frames SHEET 34 SH34 - MIRRORS, HORN BEACON
GND-018 - (Ground)

GND-019 - (Ground)

GND-025 - (Ground)

GND-029 - (Ground)

Wiring frames SHEET 31 SH31 - LIGHTING WORKING LIGHTS CAB ROOF, FRONT AND REAR
GND-069 - (Ground)

Wiring frames SHEET 36 SH36 - REAR DEFROST, BACKUP ALARM
48083741_EN 31/07/2018
55.1 [55.100] / 18
Electrical components - Speaker description

H-BU_ALRM - BACKUP ALARM (Speaker)
Component Type Speaker

Connectors X-BU2 (Plug) - BACK UP ALARM [H-BU_ALRM] (84426117) X-BU1 (Plug) - BACK
UP ALARM [H-BU_ALRM] (84426117)
H-HN - HORN (Speaker)

Connectors X-HN2 (Plug) - HORN_GRND [H-HN] (87697629) X-HN1 (Plug) - HORN_PWR
[H-HN] (87697629)
H-LSP1 - LOUDSPEAKER RT (Speaker)

Wiring frames SHEET 35 SH35 - CABIN RADIO LOUDSPEAKER/12V CNVRTR
Connectors X-XLP1 (Receptacle) - LOUDSPEAKER RT [H-LSP1] (84147089)
H-LSP2 - LOUDSPEAKER LF (Speaker)

Connectors X-XLP2 (Receptacle) - LOUDSPEAKER LF [H-LSP2] (84147089)
H-RADIO - 12V RADIO (Speaker)

Connectors X-SPK (Receptacle) - RADIO TO SPKRS [H-RADIO] (87709371) X-RAD
(Receptacle) - RADIO [H-RADIO] (87709660)
48083741_EN 31/07/2018
55.1 [55.100] / 19
Electrical components - Power outlet description

J-CNVRTR_24-12 - POWER CONVERTER (Power outlet)
Component Type Power outlet

Connectors X-CNV (Receptacle) - 24 TO 12 POWER CONVERTER [SH35: B-4] (87694112)
J-JS+ - JUMP START (Power outlet)

Connectors X-JS+ (Plug) - JUMP START STUD POS [J-JS+]
J-JS- - JUMP START STUD (Power outlet)

Connectors X-JS- (Plug) - JUMP START STUD NEG [J-JS-]
J-PO1 - RH CONSOLE 12V POWER OUTLET (Power outlet)

Connectors X-X-PO1 (Receptacle) - POWER OUTLET [J-PO1] (84398827)
48083741_EN 31/07/2018
55.1 [55.100] / 20
Electrical components - Relay description

K-3R1 - 12V CONVERTER (Relay)
Component Type Relay

K-3R2 - SEC STEERING (Relay)

K-3R3 - REAR DEFROST (Relay)

K-4KR1 - ACCESSORY (Relay)

K-5KR1 - IGNITION (Relay)

K-GH - GRID HEATER RELAY (Relay)

Connectors X-GHC (Plug) - GRID HEATER CONTROL [K-GH] (82012083)
K-ISOLATOR - ISOLATOR (Relay)

Connectors X-DC2 (Plug) - NON-DISC POWER STUD [K-ISOLATOR] (84140737) X-ISO (Plug)
- ISOLATOR [K-ISOLATOR] (87687242) X-D(S) (Plug) - MASTER DISCONNECT
SWITCHED [K-ISOLATOR] (84163398)
K-JSS_CO_1 - JSS CUT OFF SENSOR 1 (Relay)

Connectors X-JSS_CO_1 (Receptacle) - CUT OFF SENSOR [K-JSS_CO_1] (87694153)
K-LC3R4 - HORN RELAY (Relay)

Connectors X-LC3 (Receptacle) - LOADCENTER 3 [SH35: B-6] (84529039)
K-LC6F3_F4 - T2 OK TO START (Relay)

K-LC6KR3 - ECU AUX (Relay)

48083741_EN 31/07/2018
55.1 [55.100] / 21
K-LC6KR5 - AC CLUTCH (Relay)

K-LC6R1 - HOOD UP (Relay)

Wiring frames SHEET 37 SH37 - HOOD LIFT
Connectors X-LC6 (Receptacle) - LOADCENTER 6 [SH16: A-3] (84380518)
K-LC6R2 - HOOD DOWN (Relay)

K-LC6R4 - CRANK CONTROL (Relay)

K-LC7R1 - FF HEATER RELAY (Relay)

K-LC7R2 - STARTER RELAY (Relay)

48083741_EN 31/07/2018
55.1 [55.100] / 22
Electrical components - Load description

L-MH_L - MIRROR HEATER LH (Load)
Component Type Load

Connectors X-MH_L (Receptacle) - MIRROR HEATED LEFT [L-MH_L] (87695582)
L-NA-TAIL - LH REAR TAIL LT NA (Load)
Component Type Load

Wiring frames SHEET 29 SH29 - LIGHTING REAR TAILS
Connectors X-LH-TAIL (Receptacle) - LH REAR TAIL LIGHT NA [L-NA-TAIL] (87694101)
48083741_EN 31/07/2018
55.1 [55.100] / 23
Electrical components - Lamp description

LMP-BEA_RT - ROTATING BEACON / LED STROBE LIGHT (Lamp)
Component Type Lamp

Connectors X-BEA (Receptacle) - BEACON [LMP-BEA_RT] (84015523)
LMP-CIG_LTR - 24V CIGAR LIGHTER (Lamp)
Component Type Lamp

Connectors X-CL (Receptacle) - CIGAR LIGHTER [LMP-CIG_LTR] (84015523)
LMP-DM - EGRESS/DOME LAMP (Lamp)
Component Type Lamp

Wiring frames SHEET 27 SH27 - LIGHTING DOME, MAP LIGHTS
Connectors X-DM_G (Receptacle) - DOME LIGHT GROUND [LMP-DM] (87688695) X-DM_P
(Receptacle) - DOME LIGHT POSITIVE [LMP-DM] (84015523)
LMP-L-EURO-TAIL - LH REAR TAIL LT EURO (Lamp)
Component Type Lamp

Wiring frames SHEET 30 SH30 - OLD EURO LIGHTING
Connectors X-LH-REAR-TAIL-EURO (Receptacle) - LH REAR TAIL LIGHT EURO
[LMP-L-EURO-TAIL] (87694112)
LMP-LF0 - LEFT FRONT OPT WL (Lamp)
Component Type Lamp

Connectors X-LF2 (Receptacle) - WORK LIGHT OPT [LMP-LF0] (87695582)
LMP-LF_LT - LH FRONT COMBO LIGHT (Lamp)
Component Type Lamp

Wiring frames SHEET 28 SH28 - LIGHTING HAZARD WARNING, BLINKERS, DRIVING
Connectors X-LLF (Plug) - FRONT COMBO LAMP LEFT [LMP-LF_LT] (87694109)
LMP-LF_WL - LEFT FRONT WORK LIGHT (Lamp)
Component Type Lamp

Connectors X-LFWL (Receptacle) - LEFT FRONT WORK LIGHT [LMP-LF_WL] (87695582)
LMP-LPL - LICENSE PLATE LIGHT (Lamp)
Component Type Lamp

Connectors X-LPL (Plug) - LICENSE PLATE LIGHT [LMP-LPL] (87692855)
LMP-LR_WL - LEFT REAR WORK LIGHT (Lamp)
Component Type Lamp

Connectors X-LRWL (Receptacle) - LEFT REAR WORK LIGHT [LMP-LR_WL] (87695582)
48083741_EN 31/07/2018
55.1 [55.100] / 24
LMP-MH_R - MIRROR HEATER RH (Lamp)
Component Type Lamp

Connectors X-MH_R (Receptacle) - MIRROR HEATED RIGHT [LMP-MH_R] (87695582)
LMP-MPL - MAP LIGHT (Lamp)
Component Type Lamp

Connectors X-MAP (Receptacle) - MAP LIGHT [SH13: C-6] (84058093)
LMP-R-EURO-TAIL - RH REAR TAIL LT EURO (Lamp)
Component Type Lamp

Wiring frames SHEET 30 SH30 - OLD EURO LIGHTING
Connectors X-RH-REAR-TAIL-EURO (Receptacle) - RH-REAR-TAIL-EURO [LMP-R-EURO-TAIL]
(87694112)
LMP-R-NA-TAIL - RH REAR TAIL LT NA (Lamp)
Component Type Lamp

Wiring frames SHEET 29 SH29 - LIGHTING REAR TAILS
Connectors X-RH-TAIL (Receptacle) - RH REAR TAIL [LMP-R-NA-TAIL] (87694101)
LMP-RFO - RIGHT FRONT OPT WL (Lamp)
Component Type Lamp

Connectors X-RF2 (Receptacle) - WORK LIGHT OPTION [LMP-RFO] (87695582)
LMP-RF_LT - RH FRONT COMBO LIGHT (Lamp)
Component Type Lamp

Connectors X-LRF (Plug) - FRONT COMBO LAMP RT [LMP-RF_LT] (87694109)
LMP-RF_WL - RIGHT FRONT WORK LIGHT (Lamp)
Component Type Lamp

Connectors X-RFWL (Receptacle) - RIGHT FRONT WORK LIGHT [LMP-RF_WL] (87695582)
LMP-RR_WL - RIGHT REAR WORK LIGHT (Lamp)
Component Type Lamp

Connectors X-RRWL (Receptacle) - RIGHT REAR WORK LIGHT [LMP-RR_WL] (87695582)
LMP-TTI - TELL TALE INDICATOR (Lamp)
Component Type Lamp

Connectors X-TT (Receptacle) - TELL TALE INDICATOR [LMP-TTI] (87715979)
48083741_EN 31/07/2018
55.1 [55.100] / 25
Electrical components - Motor description

M-BLOWER 24V - DENSO (Motor)
Component Type Motor

M-FW_M - FRONT WASHER MOTOR (Motor)

Wiring frames SHEET 32 SH32 - CAB WIPER / WASHER
Connectors X-FWW (Receptacle) - FRONT WASHER MOTOR [M-FW_M] (84015523)
M-HD_L_M - HOOD LIFT MOTOR (Motor)

Connectors X-HDM (Receptacle) - HOOD MOTOR [M-HD_L_M] (87711966)
M-RW_M - REAR WASHER MOTOR (Motor)

Connectors X-RWW (Receptacle) - REAR WASHER MOTOR [M-RW_M] (84015523)
M-R_WPR_M - REAR WIPER MOTOR (Motor)

Connectors X-RWM (Plug) - REAR WIPER MOTOR [M-R_WPR_M] (87692862) X-RWM_G
(Plug) - REAR WIPER MOTOR GRND [SH13: C-2] (87693744)
M-SEC_STRG - SECONDARY STEERING MOTOR/PUMP (Motor)

Connectors X-S244 (Plug) - 20157 AUX STRG PWR RT ANGLE CONN [SH21: D-3] X-SSS
(Plug) - SECONDARY STEERING MOTOR [M-SEC_STRG] (84426118) X-S242
(Plug) - GROUND [M-SEC_STRG] (84401307)
M-STEPPER MOTOR 24V - DENSO (Motor)

M-STRT_MTR - STARTER MOTOR (Motor)

Connectors X-ST (Plug) - START SIGNAL TO STARTER [M-STRT_MTR] (84426134)
48083741_EN 31/07/2018
55.1 [55.100] / 26
Electrical components - Resistor description

R-022 - TERMINATOR (Resistor)
Component Type Resistor

Connectors X-TERM (Receptacle) - TERMINATOR [R-022] (87695580)
R-CERAMIC RESISTOR 24V - DENSO (Resistor)

R-RES-G_HTR - GRID HEATER (Resistor)

Connectors X-GH6 (Plug) - GRID HEATER [R-RES-G_HTR] (87744835) X-GH7 (Plug) - GRID
HEATER [R-RES-G_HTR] (87744835)
R-WND_HTR - REAR WINDSHIELD HEATER ELEMENT (Resistor)

Connectors X-RWHE1 (Receptacle) - REAR WINDOW HEATER [R-WND_HTR] (87688695)
X-RWHE2 (Receptacle) - REAR WINDOW HEATER [SH13: C-3] (87688695)
48083741_EN 31/07/2018
55.1 [55.100] / 27
Electrical components - Switch description

SW-AC SWITCH - DENSO (Switch)
Component Type Switch

SW-AFS2 - AIR FILTER SWITCH T2/T3 (Switch)

Connectors X-AFS2 (Receptacle) - AIR FILTER SWITCH T2/3 [SW-AFS2] (84607243)
SW-ARM_POS_DWN - LH ARMREST POSITION (Switch)

Connectors X-LH_ARM_DWN (Receptacle) - LH JSS ARM REST DOWN [SW-ARM_POS_DWN]
(84000405)
SW-ARM_POS_UP - LH ARMREST POSITION (Switch)

Connectors X-LH_ARM_UP (Receptacle) - LH JSS ARM REST DOWN [SW-ARM_POS_UP]
(84000405)
SW-A_F_S - AIR FILTER RSTCN SW (Switch)

Connectors X-AFS (Receptacle) - AIR FILTER RSTCN SW [SW-A_F_S] (84607243)
SW-BCK_U_SW - BACKUP ALRM CANCEL SW (Switch)

Connectors X-S_BU (Receptacle) - CANCEL BACKUP ALARM [SW-BCK_U_SW] (87716755)
SW-DEV6223 - JOYSTICK INTERNAL (Switch)

SW-DS - DOOR SWITCH (Switch)

Connectors X-DS (Receptacle) - DOOR SWITCH [SH27: C-6] (87382906)
SW-FNR - JOYSTICK INTERNAL (Switch)

Connectors X-P_JS (Plug) - PILOT LOADER JOYSTICK [SW-FNR] (87694152)
SW-HD_L_SW - HOOD LIFT SWITCH (Switch)

Connectors X-HD (Receptacle) - HOOD LIFT SWITCH [SH3: A-4] (84159859)
48083741_EN 31/07/2018
55.1 [55.100] / 28
SW-HN_RH_ARM - RH ARMREST HORN SWITCH (Switch)

SW-HN_STLK - RH STALK HORN SWITCH (Switch)

Connectors X-STLK (Receptacle) - STALK LEVER RH [SW-HN_STLK] (84426133)
SW-HORN - (Switch)

Connectors X-HN (Plug) - CAN [SW-HORN] (87311796)
SW-HZD_SW - HAZARD SWITCH (Switch)

Connectors X-S_HZD (Receptacle) - SWITCH HAZARD [SW-HZD_SW] (87716755)
SW-K/D - JOYSTICK INTERNAL (Switch)

SW-KD - KICK DOWN SW (Switch)

SW-KEY - IGNITION SWITCH (Switch)

Connectors X-KEY (Receptacle) - KEY SWITCH [SW-KEY] (87699176)
SW-LOW PRESSURE SWITCH N.C. - DENSO (Switch)

SW-MD - MASTER DISCONNECT (Switch)

SW-MH_SW - MIRROR HEATER SWITCH (Switch)

Connectors X-S_HMR (Receptacle) - SWITCH HEATED MIRRORS [SH13: D-4] (87716755)
SW-PD - SWITCH/KEY PAD (Switch)

Connectors X-SW_PD (Receptacle) - SWITCH PAD [SW-PD] (87694153)
48083741_EN 31/07/2018
55.1 [55.100] / 29
SW-PHF - HYDRAULIC FILTER SWITCH (Switch)

Connectors X-PHF (Plug) - HYDRAULIC FILTER SENSOR [SW-PHF] (84352277)
SW-POTENTIOMETER FOR MIX - DENSO (Switch)

SW-PRB - ROLL BACK PR SW (Switch)

Connectors X-PRB (Plug) - ROLL BACK PRESSURE SWITCH [SW-PRB] (87692877)
SW-PR_H2 - AC HIGH PRESS SW (Switch)

Connectors X-PRH2 (Plug) - HIGH PRESSURE SWITCH 2 [SH33: C-6] (87688788)
SW-RH_JS - RIGH HAND JOYSTICK or 3 lever (Switch)

SW-ROTARY FOR BLOWER - DENSO (Switch)

SW-R_DEF_SW - REAR DEFROST SWITCH (Switch)

Connectors X-S_RDF (Receptacle) - SWITCH REAR DEFROST [SW-R_DEF_SW] (87716755)
SW-SDM - DIFF LOCK FOOT SWITCH (Switch)

Connectors X-SDM (Plug) - SWITCH DIFF LOCK [SW-SDM] (82012083)
SW-STALK - STALK SWITCH (Switch)

SW-SW_JSS - SWITCH JSS ACTIVATION (Switch)

Connectors X-SW_JSS (Receptacle) - JOYSTICK STEERING SWITCH [SW-SW_JSS]
(87716755)
SW-WPR_SW - REAR WIPER SWITCH (Switch)

48083741_EN 31/07/2018
55.1 [55.100] / 30
Connectors X-SRWP (Receptacle) - SWITCH REAR WIPER [SW-WPR_SW] (87716755)
48083741_EN 31/07/2018
55.1 [55.100] / 31
Electrical components - Solenoid description

Y-ACT - AC COMPRESSOR CLUTCH (Solenoid)
Component Type Solenoid

Y-C0V_1 - JSS CUT OFF VALVE 1 (Solenoid)

Connectors X-COV1 (Receptacle) - CUT OFF VALVE SOL [Y-C0V_1] (87695582)
Y-COV_2 - JSS CUT OFF VALVE 2 (Solenoid)

Connectors X-COV2 (Receptacle) - CUT OFF VALVE SOL [Y-COV_2] (87695582)
Y-DL - DIFF LOCK SOLENOID (Solenoid)

Connectors X-YDL (Receptacle) - DIFF LOCK SOL [Y-DL] (87695582)
Y-DSV - DOSING VALVE (Solenoid)

Connectors X-DSR (Receptacle) - UREA DOSING VALVE [Y-DSV] (87709798)
Y-F_F_H - FILTER HEATER (Solenoid)

Connectors X-FFH (Receptacle) - FILTER HEATER [Y-F_F_H] (87679438)
Y-HC DET - (Solenoid)

Y-JSS_STRG_VLV - JOYSTICK STEERING VALVE (Solenoid)

Connectors X-JSV (Receptacle) - JOYSTICK STEERING VALVE [SH21: B-2] (87695592)
Y-RTD DET - (Solenoid)

Y-RTT DET - (Solenoid)

Connectors X-EM (Receptacle) - ELECTROMAGNETIC DETENTS [Y-RTT DET] (87694112)
48083741_EN 31/07/2018
55.1 [55.100] / 32
Y-SC - SEAT COMPRESSOR (Solenoid)

Connectors X-SC (Plug) - SEAT COMPRESSOR [Y-SC] (87692855)
Y-TNK_HTR - SCR TANK HEATING VALVE (Solenoid)

Connectors X-THV (Receptacle) - SCR TANK HEATING VALVE [Y-TNK_HTR] (84146685)
Y-W_S_H - WATER SEP HEATER (Solenoid)

Connectors X-WSH (Receptacle) - WATER SEPERATOR HEATER [Y-W_S_H] (87679438)
Y-YLS - LOCKUP SOLENOID (Solenoid)

Y-YLV - HEAT LOAD VALVE (Solenoid)

Connectors X-YLV (Receptacle) - HEAT LOAD VALVE [Y-YLV] (87695582)
Y-YPE - COUPLER VALVE SOL. (Solenoid)

Connectors X-YPE (Receptacle) - COUPLER VALVE [Y-YPE] (87695582)
Y-YRC - YRC RIDE CONTROL SOL (Solenoid)

Connectors X-YRC (Receptacle) - RIDE CONTROL SOLENOID [Y-YRC] (84607243)
Y-Y_FC - PWM FAN CONTROL (Solenoid)

Connectors X-YFN (Receptacle) - SOLENOID FAN CONTROL [Y-Y_FC] (87693821)
Y-Y_FR - FAN REVERSER (Solenoid)

Connectors X-YFR (Receptacle) - FAN REVESER SOLENOID [Y-Y_FR] (87695582)
Y-Y_PB - PARKING BRAKE SOLENOID (Solenoid)

Connectors X-YPB (Receptacle) - VALVE PARKING BRAKE [Y-Y_PB] (87695582)
48083741_EN 31/07/2018
55.1 [55.100] / 33
Y-Y_PL - PILOT LOCK (Solenoid)

Connectors X-YPP (Plug) - PILOT PRESSURE SOLENOID [Y-Y_PL] (87692855)
Y-Y_SS - SEC STEERING SOL. (Solenoid)

Connectors X-YSS (Receptacle) - SEC STEERING VALVE SOL [Y-Y_SS] (87695582)
48083741_EN 31/07/2018
55.1 [55.100] / 34
48083741_EN 31/07/2018
55.1 [55.100] / 35
Wiring harnesses - Electrical schematic sheet 03 SH03 - PWR

DISTR-BATTERY / STARTER / KEY
Type Component Connector / Link
ECU A-MAIN JB CAB - JUNCTION
BLOCK INTO CAB (ECU)
ECU A-SFB - SMART FUSE BOX X-X6 - SFB [A-SFB]
(ECU) (47554341)
Fuse F-GH - INLINE GH FUSE X-GH2 - GRID HEATER [F-GH]
(Fuse) (84140737) X-GH3 - GRID
HEATER RING TERMINAL
[F-GH] (84140737)
Fuse F-LC6F1 - MAIN ECU (Fuse)
Fuse F-LC6F10 - TELE (Fuse)
Fuse F-LC6F2 - KEY/HORN (Fuse)
Fuse F-LC6F3 - ECU AUX (Fuse)
Fuse F-LC6F5 - FFH (Fuse)
Fuse F-MAIN CAB - FUSE (Fuse)
Voltage source G-001 - BATTERY (Voltage X-563 - BATTERY LUG
source) [G-001] X-567 - BATTERY
LUG [G-001] X-P5321 - JUMP
START [G-001]
Voltage source G-002 - BATTERY (Voltage X-564 - BATTERY LUG [G-002]
source) X-566 - BATTERY POSITIVE
[G-002] X-P5320 - JUMP
START [G-002]
Voltage source G-G1 - ALTERNATOR (Voltage X-ALT - ALTERNATOR [G-G1]
source) (8602487)
Power outlet J-JS+ - JUMP START (Power X-JS+ - JUMP START STUD
outlet) POS [J-JS+]
Power outlet J-JS- - JUMP START STUD X-JS- - JUMP START STUD
(Power outlet) NEG [J-JS-]
Relay K-ISOLATOR - ISOLATOR X-DC2 - NON-DISC POWER
(Relay) STUD [K-ISOLATOR]
(84140737) X-ISO -
ISOLATOR [K-ISOLATOR]
(87687242) X-D(S) - MASTER
DISCONNECT SWITCHED
[K-ISOLATOR] (84163398)
Relay K-LC6R4 - CRANK CONTROL
(Relay)
Relay K-LC7R1 - FF HEATER
RELAY (Relay)
Relay K-LC7R2 - STARTER RELAY
(Relay)
Motor M-STRT_MTR - STARTER X-ST - START SIGNAL TO
MOTOR (Motor) STARTER [M-STRT_MTR]
(84426134)
Switch SW-KEY - IGNITION SWITCH X-KEY - KEY SWITCH
(Switch) [SW-KEY] (87699176)
Switch SW-MD - MASTER
DISCONNECT (Switch)
Connector X-563 X-563 - BATTERY LUG [G-001]
Connector X-566 X-566 - BATTERY POSITIVE
[G-002]
Connector X-ALT X-ALT - ALTERNATOR [G-G1]
(8602487)
Connector X-ALT_B X-ALT_B - ALTERNATOR B+
(84399576)
Connector X-B4 X-B4 - ALTERNATOR TO
STARTER B+ (84401309)
Connector X-BAT-GND X-BAT-GND - BATTERY
GROUND (84140737)
Connector X-CAB_E X-CAB_E - CAB TO ENGINE
[SH7: B-5] (84807216)
Connector X-CAB_E-2 X-CAB_E-2 - CAB TO ENG 2
[SH9: C-2] (87703902)
Connector X-CP X-CP - CAB POWER
(84401295)
48083741_EN 31/07/2018
55.1 [55.100] / 36

Connector X-CPWR X-CPWR - CAB POWER
(84401295)
Connector X-D(B) X-D(B) - MASTER
DISCONNECT BATTERY
(84140737)
Connector X-D(S) X-D(S) - MASTER
DISCONNECT SWITCHED
[K-ISOLATOR] (84163398)
Connector X-DC2 X-DC2 - NON-DISC POWER
STUD [K-ISOLATOR]
(84140737)
Connector X-ENG X-ENG - ENGINE TO CAB
[SH18: C-6] (87696948)
Connector X-ENG-2 X-ENG-2 - ENGINE TO CAB 2
(87703931)
Connector X-GH1 X-GH1 - GRID HEATER
(84140737)
Connector X-GH2 X-GH2 - GRID HEATER [F-GH]
(84140737)
Connector X-GH3 X-GH3 - GRID HEATER RING
TERMINAL [F-GH] (84140737)
Connector X-ISO X-ISO - ISOLATOR
[K-ISOLATOR] (87687242)
Connector X-JC1 X-JC1 - JUNCTION STUD OF
B+ IN REAR (84399576)
Connector X-JC2 X-JC2 - JUNCTION STUD
OF B+ IN REAR [SH3: C-4]
(84186853)
Connector X-JC3 X-JC3 - JUNCTION STUD OF
B+ IN REAR (84253168)
Connector X-JS+ X-JS+ - JUMP START STUD
POS [J-JS+]
Connector X-JS- X-JS- - JUMP START STUD
NEG [J-JS-]
Connector X-KEY X-KEY - KEY SWITCH
[SW-KEY] (87699176)
Connector X-LC6 X-LC6 - LOADCENTER 6
[SH16: A-3] (84380518)
Connector X-LC7 X-LC7 - LOAD CENTER 7
(84563565)
Connector X-P5320 X-P5320 - JUMP START
[G-002]
Connector X-P5321 X-P5321 - JUMP START
[G-001]
Connector X-ST X-ST - START SIGNAL TO
STARTER [M-STRT_MTR]
(84426134)
Connector X-SW_DISC X-SW_DISC - DISCONNECT
SWITCH [SH37: C-4]
(87694112)
Connector X-UCM2B X-UCM2B - UCM [A-UCM]
(82028495)
Connector X-X3 X-X3 - SFB [SH3: A-1]
(47554344)
Connector X-X4 X-X4 - SFB (47554343)
Connector X-X5 X-X5 - SFB [SH3: D-3]
(47554342)
(84538791)
Connector X-XM1B X-XM1B - STARTER LUG
FROM ISOLATOR (84596842)
Connector X-XM1C X-XM1C - STARTER
(84401295)
48083741_EN 31/07/2018
55.1 [55.100] / 37
48083741_EN 31/07/2018
55.1 [55.100] / 38
6 5 4 3 2 1
G-G1
ALTERNATOR
CHARGE X-ALT_B
INDICATOR B+
A
15
3 X-ENG
SH3: A-1 M10 PL10, PL23 84401295

PHASE 228 RD 0.8 26 26 228A RD 0.8
L 4 M12 MID 84426142
301 RD 13.0
D X-ALT
239 YE 0.8 17 17 239A YE 0.8 SH3: A-3
SH21: D-3 1
X-XM1C
STARTER MOTOR
D
1990 RD 62.0
X-CAB_E X-B4
K-ISOLATOR CABLE-004 RD 62.0
X-XM1B
X-D(B) ISOLATOR
235 RD 19.0 GND
1
X-CPWR M
IN OUT X-D(S)
1 1
X-DC2 X-ST
OPEN GND K-LC7R2
3 SH15: B-2 STARTER MOTOR GROUND
1 251 BK 0.8 STARTER RELAY
CLOSE M-STRT_MTR
2 X-ISO 7 6
229 RD 5.0 3 2 230 RD 5.0
K-LC6R4
X-ISO CRANK CONTROL 8 5
664 YE 0.8 4 1 197 BK 0.8 SH15: D-2
FROM UCM
32 35
SH20: D-1 663C YE 0.8 X-LC7 ENGINE SPACE X-LC7
SH16: C-3 619A YE 0.8 688A BL 0.8 SH16: C-3

36 31
SH16: B-2 619 YE 0.8 688 BL 0.8 SH16: B-2
FROM ECU
F-LC6F1 TO ECU
1 1 2 5
30.0 A 233 RD 5.0 SH16: D-6
CABLE-003 RD 62.0
MAIN ECU
TIER 4B K-LC7R1
3 1 2 7 F-LC6F3
212 RD 3.0 25.0 A 213 RD 3.0 SH11: A-6
C ECU AUX
FF HEATER RELAY
C
9 1 13 F-LC6F5 11 10
2
416 RD 5.0 30.0 A 417 RD 5.0 421 OR 5.0 SH16: A-2
216A RD 3.0
237A YE 0.8
FFH
ENGINE SPACE
X-LC6 X-LC6 12 9
SH16: A-2 627A RD 0.8 661 BK 0.8 SH16: A-2
SH11: A-6 ENGINE SPACE SH16: A-3

212A RD 3.0 661A BK 0.8
X-LC7 X-LC7 A-MAIN JB CAB
F-MAIN CAB JUNCTION BLOCK INTO CAB
X-JC2 FUSE M10

X-JC3
ENGINE SPACE M8
1
100A 240 RD 19.0
X-JC1 JC4 X-CP
F-GH
X-GH1 INLINE GH FUSE
1 2
CABLE 06 RD 32.0 150.0 A CABLE 05 RD 32.0 SH16: B-3 TO GRID HEATER SH6:A-6, SH7:B-6, SH8:C-6
CABLE09 RD 32.0 X-GH2 X-GH3
X-P5320
1
X-566 A-SFB
SMART FUSE BOX
POS
X-ENG-2
BATTERY
17
G-002
OUT_11_H
250A YE 0.8 F F 250 YE 0.8
ISOLATOR SET
NEG
X-X4
X-JS+ 8 OUT_09_H
G G 237 YE 0.8
X-564 ISOLATOR RESET
B SP-216A X-ENG
X-CAB_E-2
X-X7
B
JUMP START 216D RD 2.0 4 4 216E RD 2.0 SH7: B-5 TO HOOD LIFT MOTOR
CABLE-002 RD 62.0
J-JS+ X-CAB_E
F-LC6F10
TELE
X-ENG-2 217A RD 0.8 SH38: B-6 TO TELEMATICS
20 1 2 24
216B RD 1.0 7.5 A 217 RD 0.8 H H
11 VMCU
219C RD 0.8
F-LC6F2 NON-ISOLATED PWR
2 1 2 6
J-JS- 216C RD 1.0 10.0 A X-X4 8
SH34: C-6 OUT_02_H SH10: A-6
X-567 JUMP START STUD 219D RD 0.8 222 YE 0.8
KEY/HORN TO HORN Ignition Relay V+
RELAY
ENGINE SPACE
X-LC6 X-LC6 219E RD 0.8 SH34: C-6
POS
BATTERY
33 IN_DIG_01_H_WU
G-001
X-JS- ISOLATOR SHUTOFF DETECT

218 RD 0.8
OUT_01_H 11
NEG
226 YE 0.8 SH9: A-6

SW-KEY
Accessory Relay V+
SW-MD IGNITION SWITCH
X-563 X-P5321 MASTER DISCONNECT SP-219A START START 30
B IN_DIG_04_H_WU
220 YE 0.8
IN1 OUT1 B+ RUN KEY SWITCH: CRANK
CABLE08 BK 32.0 6 4 219 RD 0.8 J J 219A RD 0.8 219B RD 0.8 A
OFF RUN 15
5 533 RD 1.0 D 221 YE 0.8 OUT_06_H 192 OR 0.8 SH8: B-6
IN2 OUT2 ACC DC CONVERTER RELAY
SH11: C-2 510 OR 0.8 1 3 X-KEY
31 IN_DIG_03_H_WU
IGN X-CAB_E-2 START ACC
C
Key Switch: Ignition OUT_03_H
5
220B YE 0.8 SH20: D-5
PWR RUN CRANK SIGNAL
CABLE-001 BK 62.0
OFF 32 IN_DIG_02_H_WU
X-SW_DISC X-SW_DISC X-KEY 225 YE 0.8 X-X3
ACC Key Switch: Accesory
A SH37: C-4 A
669 OR 0.8 SH16: C-6
67 IN_ANA_15 OUT_07_H 4
SH3: D-3 239A YE 0.8 228A RD 0.8 SH3: D-3
ALT_CHARGE_INDICATOR ALTERNATOR_EXCITATION
669A OR 0.8 SH16: C-5
X-X7 X-X5
to ecu
IGN PWR
1
X-BAT-GND
ENG BLOCK GROUND
6 5 4 3 2 1
SHT_3 1
48083741_EN 31/07/2018
55.1 [55.100] / 39
Wiring harnesses - Electrical schematic sheet 04 SH04 - POWER

DISTRIBUTION SFB PWR AND GRNDS
(ECU) (47554341)
(84344499)
Connector X-X2 X-X2 - SFB [SH6: C-1]
(84344499)
(47554344)
48083741_EN 31/07/2018
55.1 [55.100] / 40
6 5 4 3 2 1
D D
C C
A-SFB
SMART FUSE BOX
GND_1 8
1002 BK 1.0 SH14: C-3
MODULE GROUND
GND_2 5
1006 BK 1.0 SH14: C-3
Redundant GND
X-X4
2 14
SH6: D-1 VSUPA PGND SH14: C-3
169 RD 8.0 1003 BK 1.0
X-X3
1
SH6: C-2 VSUPB
169 RD 8.0
X-X1
B 2
B
SH6: C-2 VSUPC
171 RD 8.0
1
SH6: C-1 VSUPD
172 RD 8.0
X-X2
A A
6 5 4 3 2 1
SHT_4 1
48083741_EN 31/07/2018
55.1 [55.100] / 41
Wiring harnesses - Electrical schematic sheet 06 SH06 - BATTERY PWR

DISTR (FUSE BLOCK LC1)
Fuse F-1F1 - ACCESSORY (Fuse)
Fuse F-1F2 - IGNITION (Fuse)
Fuse F-1F3 - SFB-D (Fuse)
Fuse F-1F4 - SFB-A (Fuse)
Fuse F-1F5 - SFB-B (Fuse)
Fuse F-1F6 - SFB-A (Fuse)
[SH10: A-6] (47728326)
Connector X-P1031 X-P1031 - B+ ON POWER
STUD (84140737)
48083741_EN 31/07/2018
55.1 [55.100] / 42
6 5 4 3 2 1
D LC1 D
A-MAIN JB CAB
JUNCTION BLOCK INTO CAB
F-1F6
SFB-A
F1
1 2
50 A 169 RD 8.0 SH4: B-6
F-1F5
SFB-B
E1
1 2
50 A 170 RD 8.0 SH4: B-5
1 1 F-1F4
518 RD 19.0 SFB-A
X-P1031 P1310 D1
1 2
50 A 171 RD 8.0 SH4: B-6
C C
F-1F3
SFB-D
C1
1 2
50 A 172 RD 8.0 SH4: B-5
F-1F2
IGNITION
1 2 B1
50 A 173 RD 5.0 SH10: A-6
F-1F1
ACCESSORY
1 2 A1
50 A 174 RD 5.0 SH9: A-6
B B
X-LC1
A A
SH3:B-1
X-LC1
6 5 4 3 2 1
SHT_6 1
48083741_EN 31/07/2018
55.1 [55.100] / 43
Wiring harnesses - Electrical schematic sheet 07 SH07 - BATTERY PWR

Fuse F-2F1 - UCM-VP (Fuse)
Fuse F-2F10 - SPARE (Fuse)
Fuse F-2F11 - CAMERA (Fuse)
Fuse F-2F2 - UCM VF2/3 (Fuse)
Fuse F-2F3 - UCM VF4/6 (Fuse)
Fuse F-2F4 - UCM VS1/VLP (Fuse)
Fuse F-2F6 - TECM (Fuse)
Fuse F-2F7 - DISPLAY (Fuse)
Fuse F-2F8 - DIAGNOSTIC (Fuse)
Fuse F-2F9 - HOOD LIFT (Fuse)
[SH7: B-3] (87733581)
Connector X-P1002 X-P1002 - B+ POWER STUD
(84140737)
(84140737)
48083741_EN 31/07/2018
55.1 [55.100] / 44
6 5 4 3 2 1
LC2
A-MAIN JB CAB
D JUNCTION BLOCK INTO CAB D
F-2F1
4.0 MAX UCM-VP
1B 1 1A
2 SH19: D-6
526 RD 1.0 20 A 465 RD 1.0
F-2F2
UCM VF2/3
1 2B 1 2A
2 SH19: D-6
527 RD 3.0 20 A 448 RD 3.0
X-P1196
F-2F3
UCM VF4/6
3B 1 2 3A
528 RD 3.0 20 A 454 RD 3.0 SH19: D-6
F-2F4
UCM VS1/VLP
4B 1 2 4A
529 RD 3.0 15 A 461 RD 3.0 SH19: D-6
C F-2F5
SPARE
C
5B 1 2 5A
0A
F-2F6
TECM
6B 1 2 6A
7.5 A 165 RD 1.0 SH25: D-6
F-2F7
DISPLAY
1 7B 1 2 7A
532 RD 3.0 10 A 805 RD 0.8 SH24: C-6
X-P1002
F-2F8
DIAGNOSTIC
8B 1 2 8A
5A 798 RD 0.8 SH24: C-5
SH3:B-1
F-2F9
HOOD LIFT
9B 1 2 9A
SH3: B-3 216E RD 2.0 20 A 205 RD 2.0 SH37: D-6
B F-2F10 B
SPARE
10B 1 2 10A
0A
F-2F11
CAMERA
1 2 11A
5A 125 OR 0.8 SH39: B-6
11B
F-2F12
SPARE
12B 1 2 12A
SH10: A-1 878C OR 3.0 0A
F-2F13
SPARE
13B 1 2 13A
0A
F-2F14
SPARE
1 2
0A
A A
X-LC2
X-LC2
20 FUSE SLOTS IN BOX
6 5 4 3 2 1
SHT_7 1
48083741_EN 31/07/2018
55.1 [55.100] / 45

DISTRIBUTION (FUSE BLOCK LC3)
Fuse F-3F1 - 12V PWR1 (Fuse)
Fuse F-3F2 - 12V SPARE (Fuse)
Fuse F-3F3 - 12V RADIO (Fuse)
Fuse F-3F4 - 12V SPARE (Fuse)
Fuse F-3F8 - 12V CONVERTER
(Fuse)
Relay K-3R1 - 12V CONVERTER
(Relay)
Relay K-3R2 - SEC STEERING
(Relay)
Relay K-3R3 - REAR DEFROST
(Relay)
[SH35: B-6] (84529039)
(84140737)
(47554344)
48083741_EN 31/07/2018
55.1 [55.100] / 46
6 5 4 3 2 1
SH35: B-4
LC3
A-MAIN JB CAB
JUNCTION BLOCK INTO CAB
F-3F1
D F1_9
12V PWR1 D
1 2 F1_13
10 A 750 OR 1.0 SH35: A-3
F-3F2
SP-6199 12V SPARE
F2_10
1 2 F2_14
20 A
F-3F3
12V RADIO
F3_11
1 2 F3_15
748 OR 2.0 10 A 753 OR 0.8 SH35: B-5
F-3F4
12V SPARE
F4_12
1 2 F4_16
20 A
F-3F5
SPARE
F5_5
2 F5_1
1
0A
F-3F6
SPARE
F6_6
F6_2
C 1
541 RD 2.0
1
0.0 A
2
C
X-P1009
F-3F7
SPARE
F7_7
2 F7_3
1
0A
F-3F8
12V CONVERTER
F8_8
SH3:B-1 1 2 F8_4
917 RD 3.0 20 A 191 RD 3.0 SH8: B-5
K-3R1
12V CONVERTER
87A R1_87A
R1_30
30
SH8: B-2 191 RD 3.0 R1_87
87
746 OR 3.0 SH35: B-6
R1_86 86 85 R1_85
SH3: A-1 192 OR 0.8 954F BK 0.8 SH13: A-2
K-3R2
SEC STEERING
87A R2_87A
B SH10: C-2 182 OR 0.8
R2_30 30
R2_87
B
87
441 OR 0.8 SH21: B-3
R2_86 86 85 R2_85
SH21: C-2 183 YE 0.8 954R BK 0.8 SH13: A-4
K-3R3
REAR DEFROST
87A R3_87A
R3_30 30
SH9: B-1 877 OR 2.0 R3_87
87
801 OR 2.0 SH36: D-2
R3_86 86 85 R3_85
SH36: D-3 120 YE 0.8 954M BK 0.8 SH13: A-3
3R4
HORN
87A
30
87
86 85 ON HORN SHT 34
A X-LC3
A
X-LC3
6 5 4 3 2 1
SHT_8 1
48083741_EN 31/07/2018
55.1 [55.100] / 47
Wiring harnesses - Electrical schematic sheet 09 SH09 - ACCESSORY

PWR DIST (FUSE BLOCK LC4)
Fuse F-4F1 - 24V CIGAR (Fuse)
Fuse F-4F3 - A/C CLUTCH (Fuse)
Fuse F-4F6 - BLOWER (Fuse)
Fuse F-4F7 - SEAT (Fuse)
Fuse F-4F8 - REAR DEFROST
(Fuse)
Relay K-4KR1 - ACCESSORY
(Relay)
[SH35: C-6] (87733595)
(47554344)
48083741_EN 31/07/2018
55.1 [55.100] / 48
6 5 4 3 2 1
874 OR 3.0
920 OR 3.0
919 OR 3.0
D D
LC4
F-4F1
24V CIGAR
1 2 1A
1B
4.0 MAX 15 A 743 OR 2.0 SH35: C-6
F-4F2
SPARE
SP-6201 2A
2B 1 2
0A
F-4F3
A/C CLUTCH
1 2 3A
3B 5A SH11: A-6
875 OR 1.0
F-4F4
SPARE
C 4B 1
0A
2 4A
C
F-4F5
SPARE
1 2 5A
5B 0A
F-4F6
BLOWER
1 2 6A
6B 25 A SH33: D-4
876 OR 3.0
F-4F7
SEAT
1 2 7A
7B 15 A SH35: D-6
742 OR 2.0
F-4F8
REAR DEFROST
1 2 8A
8B 20 A SH8: B-6
877 OR 2.0
B F-4F9 B
SPARE
1 2 9A
9B 0A
F-4F10
SPARE
10B 1 2 10A
0A
K-4KR1
ACCESSORY
87A
30 30
SH6: B-2
87 87
86 86 85 85
SH3: A-1 226 YE 0.8 954A BK 0.8 SH13: B-2
A X-LC4 X-LC4 A
6 5 4 3 2 1
SHT_9 1
48083741_EN 31/07/2018
55.1 [55.100] / 49
Wiring harnesses - Electrical schematic sheet 10 SH10 - IGNITION PWR

Fuse F-5F1 - DISPLAY WK (Fuse)
Fuse F-5F10 - STALK/DIFF (Fuse)
Fuse F-5F2 - UCM (Fuse)
Fuse F-5F3 - TECM (Fuse)
Fuse F-5F4 - TELEMATICS (Fuse)
Fuse F-5F5 - SEC STRG (Fuse)
Fuse F-5F6 - IMP JOYSTICK (Fuse)
Fuse F-5F7 - KEY PAD (Fuse)
Fuse F-5F8 - JSS IGN (Fuse)
Fuse F-5F9 - REAR PWR (Fuse)
Relay K-5KR1 - IGNITION (Relay)
[SH10: D-1] (87733595)
Connector X-ZF_DI X-ZF_DI - DIAGNOSTIC
[A-108F] (84364851)
48083741_EN 31/07/2018
55.1 [55.100] / 50
6 5 4 3 2 1
878B OR 3.0
878A OR 3.0
D D
LC5
F-5F1
DISPLAY WK
1B 1A
1 2
5A 806 OR 0.8 SH24: C-6
F-5F2
SH19: D-6
UCM
2B 2A
1 2
5A 466 OR 0.8
F-5F3
19D OR 0.8 SH20: C-4
TECM
3B 3A SP-19C
1 2
7.5 A 19C OR 2.0 19E OR 0.8 SH25: D-5
19F OR 0.8 SH25: C-2
F-5F4
19G OR 0.8 SH26: A-2
TELEMATICS
4B 4A
C 1
5A
2
168 OR 0.8 SH38: B-5 C
F-5F5
SEC STRG
5B 5A
1 2
7.5 A 182 OR 0.8 SH8: B-6
F-5F6
IMP JOYSTICK
6B 6A
1 2
7.5 A 792 OR 0.8 SH24: A-3
F-5F7
KEY PAD
7B 7A
1 2
5A 807 OR 0.8 SH24: D-5
F-5F8
JSS IGN
8B 8A SP-799
1 2
10 A 799 OR 0.8 799B OR 0.8 SH21: A-4
B F-5F9 799A OR 0.8 SH24: A-6

B
REAR PWR
9B 9A
1 2
15 A 850 OR 2.0 SH11: C-5
F-5F10
STALK/DIFF
SP-19H
10B 1 2 10A
5A 19H OR 0.8 19M OR 0.8 SH20: B-6
19J OR 0.8 SH24: C-5
878C OR 3.0 SH7: A-6

K-5KR1
IGNITION
87A
30 30
SH6: B-2 173 RD 5.0 SP-878
87 87
878 OR 5.0
86 86 85 85
SH3: B-1 222 YE 0.8 954H BK 0.8 SH13: A-4
A X-LC5 X-LC5 A
6 5 4 3 2 1
SHT_10 1
48083741_EN 31/07/2018
55.1 [55.100] / 51
Wiring harnesses - Electrical schematic sheet 11 SH11 - PWR DISTR ENG

COMPARTMENT (FUSE BLOCK LC6)
Fuse F-LC6F4 - SCR SENSORS
(Fuse)
Fuse F-LC6F6 - EVGT (Fuse)
Fuse F-LC6F7 - ECU IGN (Fuse)
Fuse F-LC6F9 - FAN (Fuse)
Relay K-LC6KR3 - ECU AUX (Relay)
Relay K-LC6KR5 - AC CLUTCH
(Relay)
[SH7: B-5] (84807216)
[SH9: C-2] (87703902)
[SH18: C-6] (87696948)
(87703931)
[SH16: A-3] (84380518)
Connector X-SW_DISC X-SW_DISC - DISCONNECT
SWITCH [SH37: C-4]
(87694112)
48083741_EN 31/07/2018
55.1 [55.100] / 52
6 5 4 3 2 1
LC6
IN ENGINE COMPARTMENT
LC6F1
MAIN ECU
1 2
30 A
LC6F2 SHOWN ON
KEYHORN
1 2
SHEET 3
D 10 A
D
LC6F3 LC6F3_F4_REF
ECU AUX TIER 2 OK TO START
1 2
3 25 A 7
30 87
4 7 SHOWN ON
SHEET 16
F-LC6F4 86 85
200J RD 3.0 SH18: A-6
SCR SENSORS 8 3
4 1 2 8
20 A 200 RD 3.0 SH18: A-6
LC6F5
FFH
1 2 SHOWN ON
30 A
SHEET 3
F-LC6F6
202A RD 1.0 SH18: B-5
10 EVGT
SP-214 14
1 2 TIER 2 ONLY
214A RD 3.0 20 A 202 RD 3.0 SH18: A-4
10 A EVGT
X-ENG SH17: D-4

850E OR 0.8
F-LC6F7
C IGN PWR SP-850A

11 1
ECU IGN
2 15
C
SH10: B-1 850 OR 2.0 1 1 850A OR 2.0 850B OR 0.8 5A 510 OR 0.8 SH3: A-6
F-LC6F8
X-CAB_E SPARE
12 1 2
-A
16
F-LC6F9 SH20: A-2

FAN 852B OR 0.8
SP-852
19 1 2 23
850D OR 0.8 7.5 A 852 OR 0.8 852C OR 0.8 SH20: B-2
F-LC6F10
TELE
SHOWN ON
1 2
7.5 A SHEET 3
X-LC6 X-LC6
214 RD 3.0
214C RD 3.0
LC6KR1 87A
HOOD UP 30
87
B 86 85 SHOWN ON B
SHEET 37
LC6KR2 87A
HOOD DOWN 30
87
86 85
SH3: C-4 212A RD 3.0

K-LC6KR3
TIER 2
ECU AUX PL2326 EVGT
30 30 87
SH3: C-2 213 RD 3.0 33
SH16: A-3 627F RD 0.8 29

34 86 85
SH16: B-3 620 WH 0.8 645 BK 0.8 SH16: B-3
SH16: A-2 627D RD 0.8 645A BK 0.8 SH16: B-3
LC6KR4
CRANK
CONTROL 30 87
SHOWN ON
SHEET 3
86 85
A A
X-CAB_E-2 X-ENG-2
ACC PWR
K-LC6KR5 87A
AC CLUTCH 187A YE 1.0 SH33: B-6
18 30
SH9: C-2 875 OR 1.0 K K 875A OR 1.0 25
87
187 YE 1.0 SH33: B-6
86 85 17
LOAD CENTER 7
26
SH33: C-6 211B YE 1.0 254 BK 0.8 SH12: A-4 SHOWN ON
SHEET 3
X-LC6 X-LC6
6 5 4 3 2 1
SHT_11 1
48083741_EN 31/07/2018
55.1 [55.100] / 53

DISTRIBUTION 1 CLEAN GROUND BLK
[SH7: B-5] (84807216)
[SH18: C-6] (87696948)
Connector X-GND_CENG1 X-GND_CENG1 - GROUND
CLEAN ENG BLOCK
(84140737)
Connector X-GND_CENG2 X-GND_CENG2 - GROUND
CLEAN ENG BLOCK [SH12:
A-4] (84140737)
Connector X-SP_PK_CLN X-SP_PK_CLN - SPLICE
PACK CLEAN GRND [SH25:
C-1] (87352746)
Connector X-TURBO_2 X-TURBO_2 - ENGINE
HARNESS INTERFACE T2
[SH18: B-5] (87694583)
48083741_EN 31/07/2018
55.1 [55.100] / 54
6 5 4 3 2 1
A
SH38: B-1 912 BK 0.8
B
SH24: D-5 916 BK 0.8
C
D SH24: B-6 871 BK 0.8 D
D
SH24: C-4 945 BK 0.8
E
SH33: D-4 256 BK 0.8
F
857 BK 2.0
G CLEAN
SH25: C-1 946 BK 0.8 GROUND
IN
CAB
H
SH25: D-2 856 BK 0.8
J
SH25: D-2 855 BK 0.8
C SH38: B-3 287 BK 0.8

K
C
M
X-ENG
3 3
X-SP_PK_CLN
X-CAB_E
B 857A BK 2.0
B
1
SH18: B-5 203A BK 1.0 X-GND_CENG1
SH18: A-4 203 BK 3.0
CHASSIS
CLEAN
GROUND
ON ENGINE
BLOCK
SH16: C-1 603 BK 5.0
SH11: A-2 254 BK 0.8

X-GND_CENG2
A SH18: A-6 201 BK 3.0 A

SH18: A-6 201K BK 3.0
6 5 4 3 2 1
SHT_12 1
48083741_EN 31/07/2018
55.1 [55.100] / 55

DISTRIBUTION 2 CAB GROUND BLK
Connector X-CG3 X-CG3 - CAB GROUND RH
HEADLINER [SH13: D-5]
(84149207)
Connector X-CG4 X-CG4 - CAB GROUND
[SH24: B-6] (84149207)
[SH35: B-6] (84529039)
48083741_EN 31/07/2018
55.1 [55.100] / 56
6 5 4 3 2 1
A
SH36: C-4 955A BK 0.8
B
SH34: A-4 955J BK 0.8
C
SH34: A-6 955K BK 0.8
D D
D
SH39: B-6 955AD BK 0.8
F
SH36: C-6 955R BK 0.8
H
SH27: C-2 955N BK 0.8
CAB
GROUND
SH27: C-6
J ROPS BACK
955P BK 0.8
TUBE
K
SH27: C-2 955Q BK 0.8
C C
L
SH32: C-1 955V BK 1.0
M
SH34: A-5 954B BK 0.8
SH31: C-3 X-CG3

949 BK 2.0
SH36: D-2 272 BK 2.0
1 RH HEADLINER
SH31: B-3 953 BK 2.0
CG1
STUD
SH33: C-2 903 BK 2.5
SH35: C-1 271 BK 0.8
SH36: C-4 958 BK 0.8

A
SH9: A-1 954A BK 0.8
B
SH21: A-3 955X BK 0.8
B SH35: D-1 955L BK 2.0

C B
D
SH28: C-3 954D BK 1.0
E
SH24: B-6 954E BK 0.8
F
SH8: B-1 954F BK 0.8
SH36: C-5 954T BK 0.8

SP-954L
G
SH36: B-5 954G BK 0.8 954L BK 0.8
SH36: B-6 955S BK 0.8

H
SH10: A-1 954H BK 0.8
CAB
GROUND
J
SH21: A-4 954J BK 0.8
A K A
SH24: A-3 954K BK 1.0
SH8: B-2 954R BK 0.8

SP-954S ROPS BACK
M
SH8: A-1 954M BK 0.8 954S BK 0.8
TUBE STUD
X-CG4
6 5 4 3 2 1
SHT_13 1
48083741_EN 31/07/2018
55.1 [55.100] / 57
Wiring harnesses - Electrical schematic sheet 14 SH14 - CAB & CHASSIS

GROUND PWR DISTR
Connector X-GND_FRNT X-GND_FRNT - CHASSIS
GROUND (84140737)
Connector X-GND_GRL X-GND_GRL - GROUND
GRILL TERMINAL (84140737)
Connector X-GND_PED X-GND_PED - GROUND
PEDESTAL RING [SH14: B-6]
(84140737)
Connector X-GND_RR X-GND_RR - CHASSIS
GROUND (84140737)
Connector X-GND_RR2 X-GND_RR2 - CHASSIS
GROUND [SH28: B-2]
(84426126)
Connector X-GND_RR3 X-GND_RR3 - SEC STRG
CHASSIS GRND [SH14: B-4]
(84426126)
Connector X-GND_RR4 X-GND_RR4 - (84140737)
Connector X-GRD_WIF X-GRD_WIF - WATER IN
FUEL GRND (84426120)
Connector X-SSG X-SSG - SECONDARY
STEERING GROUND RING
[SH21: C-1] (84401307)
Connector X-X31CF1-2 X-X31CF1-2 - CAB GROUND
BLOCK (84122130)
Connector X-X31CF1-3 X-X31CF1-3 - CAB GROUND
BLOCK (84122130)
Connector X-X31CF2-1 X-X31CF2-1 - STEERING
COLUMN GROUND
(84122130)
Connector X-X31CF2-2 X-X31CF2-2 - STEERING
COLUMN GROUND
(84122130)
Connector X-YSS X-YSS - SEC STEERING
VALVE SOL [Y-Y_SS]
(87695582)
48083741_EN 31/07/2018
55.1 [55.100] / 58
6 5 4 3 2 1
SH32: A-5 279 BK 2.0
CONTINUED ON
SHT 13
D D
SH35: A-1 275 BK 1.0
1
SH32: D-1 103 BK 2.0
CG2
SH35: C-1 957 BK 2.0
SH35: B-5 276 BK 2.0
CAB STUD
GROUND
SH35: B-5 277 BK 2.0
SH4: B-2 1002 BK 1.0
C 1 C
SH4: B-2 1006 BK 1.0
CG5
SH4: B-2 1003 BK 1.0

CONTINUED ON
SHT 19
1
STRAP1 - 50.0
X-X31CF2-1
BIG BRAIDED STRAP
CAB BOTTOM
GROUND
B B
1
1
SH28: D-1 X-X31CF2-2
955U BK 1.0 1
X-GND_PED SH21: C-1 185 BK 62.0
X-SSG
SH20: B-2 1
PEDESTAL 391A BK 1.0
X-GND_RR4
GROUND 1
SH21: B-1 184 BK 0.8 1 1
X-GND_RR3 CABLE_ENG_GRND BK 62.0
X-X31CF1-3 X-X31CF1-2
1 GRND CABLE
SH28: B-2 624D BK 2.0
X-GND_RR2
1
1
SH23: C-5 293 BK 0.8
RR4
1 GND_RR5 ENGINE BLOCK
GROUND
X-GND_RR REAR FRAME
GROUND
313 BK 2.0
1
SH15: C-2 281 BK 1.0
X-GRD_WIF
CONTINUED ON
X-GND_GRL 1
SHT 3, 12, AND 15
WATER IN FUEL
BODY GROUND
ON GRILL
A 1 A
061 BK 5.0
X-GND_FRNT
FRONT FRAME
GROUND
6 5 4 3 2 1
SHT_14 1
48083741_EN 31/07/2018
55.1 [55.100] / 59

DISTRIBUTION 4 ENGINE GROUND BLK
Connector X-BU1 X-BU1 - BACK UP ALARM
[H-BU_ALRM] (84426117)
Connector X-GND_ENG1 X-GND_ENG1 - GROUND
ENG BLOCK [SH16: A-1]
(84140737)
ENG BLOCK [SH15: C-3]
(84140737)
ENG BLOCK [SH29: B-3]
(84140737)
48083741_EN 31/07/2018
55.1 [55.100] / 60
6 5 4 3 2 1
SH16: A-1 195 BK 2.0

D D
1
SH3: C-2 197 BK 0.8
X-GND_ENG1
SH16: A-1 196 BK 2.0
SH16: B-5 198 BK 0.8
C C
SH14: A-5 281 BK 1.0
X-GND_ENG3
SH20: A-1 204 BK 0.8
1
SH37: C-1 208 BK 2.0
SH29: C-1 243 BK 0.8

ENG_EURO_PL10-20
B FROM PL10-20 BU SH36: C-1

ENG_PL10-20
244 BK 0.8
B
X-GND_ENG4
SH29: B-3 242 BK 1.0
1
SH3: D-5 251 BK 0.8
ENGINE BLOCK GROUND
A A
6 5 4 3 2 1
SHT_15 1
48083741_EN 31/07/2018
55.1 [55.100] / 61
Wiring harnesses - Electrical schematic sheet 16 SH16 - ENGINE

CONTROL UNIT 1, GRID HEATER, FILTER HEATER
ECU A-ECU - ENGINE X-ECU - ECU CONNECTOR
CONTROLLER (ECU) [A-ECU] (84300197)
Sensor B-ACCEL - THROTTLE X-THRTL - THROTTLE
CONTROL (Sensor) CONTROL [B-ACCEL]
(84403598)
Relay K-GH - GRID HEATER RELAY X-GHC - GRID HEATER
(Relay) CONTROL [K-GH] (82012083)
Relay K-LC6F3_F4 - T2 OK TO
START (Relay)
Resistor R-RES-G_HTR - GRID X-GH6 - GRID HEATER
HEATER (Resistor) [R-RES-G_HTR] (87744835)
X-GH7 - GRID HEATER
[R-RES-G_HTR] (87744835)
Connector X-001 X-001 - GRID HEATER
CABLE GRND ON ENGINE
(84398003)
[SH7: B-5] (84807216)
[SH9: C-2] (87703902)
Connector X-DIA X-DIA - DIAGNOSTIC PORT
[A-DIA] (87736919)
Connector X-ECU X-ECU - ECU CONNECTOR
[A-ECU] (84300197)
Connector X-EDC7 X-EDC7 - ENGINE
CONTROLLER T2/3 [SH18:
C-5] (84160698)
[SH18: C-6] (87696948)
(87703931)
Connector X-FFH X-FFH - FILTER HEATER
[Y-F_F_H] (87679438)
[R-RES-G_HTR] (87744835)
[R-RES-G_HTR] (87744835)
Connector X-GHC X-GHC - GRID HEATER
CONTROL [K-GH] (82012083)
[SH16: A-3] (84380518)
Connector X-THRTL X-THRTL - THROTTLE
CONTROL [B-ACCEL]
(84403598)
Connector X-WSH X-WSH - WATER
SEPERATOR HEATER
[Y-W_S_H] (87679438)
Solenoid Y-F_F_H - FILTER HEATER X-FFH - FILTER HEATER
(Solenoid) [Y-F_F_H] (87679438)
Solenoid Y-W_S_H - WATER SEP X-WSH - WATER
HEATER (Solenoid) SEPERATOR HEATER
[Y-W_S_H] (87679438)
48083741_EN 31/07/2018
55.1 [55.100] / 62
6 5 4 3 2 1
2
233F RD 1.0
3
233G RD 1.0
8
233H RD 1.0
9
233J RD 1.0
X-EDC7
5
D SH3: C-2
SP-233 A-ECU 603F BK 1.0 D
233 RD 5.0 233A RD 1.0 1 1 6
ENGINE CONTROLLER
603G BK 1.0
233B RD 1.0 25 25
10
233C RD 1.0 26 26 603H BK 1.0
11
233D RD 1.0 49 49 603J BK 1.0
233E RD 1.0 73 73
X-EDC7
3 3 603A BK 1.0
GROUND
5 5 603B BK 1.0
SH3: A-4 SP-603
669 OR 0.8 69 69
28 28 603C BK 1.0 603 BK 5.0 SH12: A-2
KEY SW POWER FROM DISCONNECT
SP-669A 40
SH3: A-4 669A OR 0.8 669B OR 0.8 29 29
669C OR 0.8 SH20: D-6 52 52 603D BK 1.0
SP-643F 75 75 603E BK 1.0 603K BK 0.8 SH17: D-5

29
643G BK 0.8 643F BK 0.8
76 76
B-ACCEL X-EDC7 X-ECU

X-ENG-2
THROTTLE CONTROL 643E BK 0.8
C X-ENG
C
F 643C BK 0.8 E E 643D BK 0.8 SH17: C-4 20 20 303 WH 0.8 SH24: B-4
60 160
D 408 WH 0.8 D D 408A WH 0.8 LOW IDLE POSITION SW
B 651H BL 0.8 C C 651K BL 0.8 80 180 X-CAB_E
89
THROTTLE PEDAL SNSR1 GND 303A WH 0.8
A 409 YE 0.8 A A 409A YE 0.8 79 179
C 471B PK 0.8 B B 471K PK 0.8 THROTTLE SIGNAL 1
37
619A YE 0.8 SH3: C-4
66 166
X-THRTL 48 5v SENSOR SUPPLY 2D
X-CAB_E-2 17
408B WH 0.8 688A BL 0.8 SH3: C-3
78 X-EDC7
651P BL 0.8 19 19 619 YE 0.8 SH3: C-4
CRANK CONTROL RELAY
79 88 88 688 BL 0.8 SH3: C-3
409B YE 0.8 CRANK CONTROL RELAY
77
471P PK 0.8
X-EDC7
FROM UCM SH20: D-1 663B YE 0.8 6363
OK TO START FROM VEHICLE
20 20 620 WH 0.8 SH11: A-5
AUX RELAY CONTROL
45 45 645 BK 0.8 SH11: A-2

32
K-LC6F3_F4 21E YE 0.8 AUX RELAY CONTROL
T2 OK TO START 51
B 4 87 X-EDC7
645A BK 0.8 SH11: A-2
B
30 7
X-EDC7
8 86 85 3
SH20: D-1 663D YE 0.8 198 BK 0.8 SH15: D-2
FROM UCM X-LC6 X-LC6
X-ECU K-GH
X-ECU
GRID HEATER RELAY
THESE PINS ARE ALSO USED SH3: B-3
ON SHT 3 FOR ECU AUX FUSE 87A
AND SHT 11 FOR SCR SENSOR 30
FUSE. TIER 4B MACHINES ONLY. CABLE 05 RD 32.0 R-RES-G_HTR
87 GH5
GH4 GRID HEATER
CABLE_06 RD 32.0
12 674A WH 0.8 86 85 P N
74 74 674 WH 0.8 1 2 CABLE_07 BK 32.0
GRID RELAY CNTRL HI
ENGINE CONTROLER CONNECTOR X-GHC ENGINE SPACE X-GHC X-GH6 X-GH7
IS 84595906 RIGHT EXIT ON PL23 83 83 683 BL 0.8
IS 84300197 LEFT EXIT ON ALL OTHERS. GRID RELAY CNTRL LO
75 683B BL 0.8 X-001
GROUND ON ENGINE
627F RD 0.8 SH11: A-5 BLOCK NEAR GRID HEATER
627D RD 0.8 SH11: A-5

Y-F_F_H GROUND
13 627E RD 0.8 FILTER HEATER
X-EDC7 SH3: C-1 SP-421
1 2
27 27 627 RD 0.8 627A RD 0.8 421 OR 5.0 421A OR 2.0 A B 196 BK 2.0 SH15: D-3
A B+ FOR AIR FILTER RS + FFH SIGNAL SP-627 SH3: C-2 A
TIER 2 AND TIER 3 ENGINES X-FFH X-FFH
627B RD 0.8 SH17: A-6
Y-W_S_H
FFH 61 61 661 BK 0.8 SH3: C-1 WATER SEP HEATER
1 2
X-ECU 421B OR 2.0 B A 195 BK 2.0 SH15: D-3
36 661A BK 0.8 SH3: C-1 X-WSH X-WSH

PL2326
NO FFH GROUND
X-EDC7
6 5 4 3 2 1
SHT_16 1
48083741_EN 31/07/2018
55.1 [55.100] / 63
Wiring harnesses - Electrical schematic sheet 17 SH17 - ENGINE CONTROL UNIT 2, AT

Type Component Connector / Link Type Component Connector / Link
ECU A-ECU - ENGINE X-ECU - ECU CONNECTOR Connector X-EDC7 X-EDC7 - ENGINE
CONTROLLER (ECU) [A-ECU] (84300197) CONTROLLER T2/3 [SH18:
Sensor B-C_TS - DOC UPSTREAM X-CTS - DOC UPSTREAM C-5] (84160698)
TEMP SENSOR (Sensor) TEMP [B-C_TS] (84532147) Connector X-HTS X-HTS - HUMIDITY AND
Sensor B-D_TS - SCR X-DTS - SCR DOWNSTREAM TEMP SENSOR [B-HT]
DOWNSTREAM TEMP TEMP [B-D_TS] (84532147) (87709809)
SENSOR (Sensor) Connector X-LEV1 X-LEV1 - INLINE TO DEF
Sensor B-HT - HUMIDITY AND AMB X-HTS - HUMIDITY AND LEVEL & TEMP (84062580)
TEMP SENSOR (Sensor) TEMP SENSOR [B-HT] Connector X-LEV2 X-LEV2 - INLINE TO DEF
(87709809) LEVEL & TEMP (87680689)
Sensor B-U_LVL - SENSOR TANK X-DTLTS - DEF LEVEL / TEMP Connector X-SCR1 X-SCR1 - INLINE TO SCR
LEVEL & TEMP (Sensor) [B-U_LVL] (84062580) SENSORS HARNESS
Sensor B-U_TS - SCR UPSTREAM X-UTS - UPSTREAM OF SCR (87695592)
TEMP SENSOR (Sensor) TEMP SENSOR [B-U_TS] Connector X-SCR2 X-SCR2 - INLINE FROM
(84532147) SCR SENSORS HARNESS
Sensor B-WIF - WATER IN FUEL X-WIF - WATER IN FUEL (87695724)
(Sensor) [B-WIF] (87709663) Connector X-THV X-THV - SCR TANK HEATING
Switch SW-A_F_S - AIR FILTER X-AFS - AIR FILTER RSTCN VALVE [Y-TNK_HTR]
RSTCN SW (Switch) SW [SW-A_F_S] (84607243) (84146685)
Connector X-AFS X-AFS - AIR FILTER RSTCN Connector X-UTS X-UTS - UPSTREAM OF SCR
SW [SW-A_F_S] (84607243) TEMP SENSOR [B-U_TS]
Connector X-CTS X-CTS - DOC UPSTREAM (84532147)
TEMP [B-C_TS] (84532147) Connector X-WIF X-WIF - WATER IN FUEL
Connector X-DSR X-DSR - UREA DOSING [B-WIF] (87709663)
VALVE [Y-DSV] (87709798) Solenoid Y-DSV - DOSING VALVE X-DSR - UREA DOSING
Connector X-DTLTS X-DTLTS - DEF LEVEL / TEMP (Solenoid) VALVE [Y-DSV] (87709798)
[B-U_LVL] (84062580) Solenoid Y-TNK_HTR - SCR TANK X-THV - SCR TANK HEATING
Connector X-DTS X-DTS - SCR DOWNSTREAM HEATING VALVE (Solenoid) VALVE [Y-TNK_HTR]
TEMP [B-D_TS] (84532147) (84146685)
[A-ECU] (84300197)
48083741_EN 31/07/2018
55.1 [55.100] / 64
6 5 4 3 2 1
42
613A YE 0.8
A-ECU
ENGINE CONTROLLER
B-WIF 696B TN 0.8 Y-DSV
X-EDC7 X-SCR2
WATER IN FUEL DOSING VALVE
1 2
1 MC18 MC18 MC19 MC19 IN OUT
1 613 YE 0.8 13 113 196 96
696 TN 0.8 5 5 696A TN 0.8
WATER IN FUEL SW O_T_RL10
D 2 2
603K BK 0.8 SH16: C-1 X-DSR X-DSR D
643B BK 0.8
123 623A WH 0.8
23 623 WH 0.8 6 6
O_T_RH01
MC19
3 3 850E OR 0.8 SH11: C-4 X-SCR1
623B WH 0.8
X-WIF
B-HT
643D BK 0.8 SH16: C-4
HUMIDITY AND AMB TEMP SENSOR
1 690 OR 0.8 90 190

COMMON SUPPLY
2 615 YE 0.8 15 115

HUMIDITY SENSOR
3 643A BK 0.8 643 BK 0.8 43 143

COMMON GROUND
SP-643
4 642 YE 0.8 40 140
AIR TEMPERATURE SENSOR
X-HTS
C 632 YE 0.8 32 132

I_A_AN24
C
B-U_TS
SCR UPSTREAM TEMP SENSOR
1 T 2
610A BK 0.8
P N
X-UTS X-UTS
609B YE 0.8
X-SCR2
109
609A YE 0.8 10 10 609 YE 0.8 9
I_A_AN22
B-D_TS
SCR DOWNSTREAM TEMP SENSOR
1 T 2
610C BK 0.8 9 9 610B BK 0.8
P N
X-DTS X-DTS 610G BK 0.8
B-C_TS
DOC UPSTREAM TEMP SENSOR 610F BK 0.8
1 2
T 10 110
610E BK 0.8 7 7 610D BK 0.8 610 BK 0.8
P N COMMON GROUND
SP-610
X-CTS X-CTS
B 616A YE 0.8 8 8 616 YE 0.8 16 116 B

I_A_AN13
X-SCR1
616B YE 0.8
B-U_LVL
SENSOR TANK LEVEL & TEMP
X-LEV1
31 131 I_A_AN12
1 1 631A YE 0.8 1 1 631 YE 0.8
SCR LEVEL SENSOR
8 108 I_A_AN25
3 3 608A PK 0.8 3 3 608 YE 0.8
SCR TEMP SENSOR
SP-639
2 2 639B BL 0.8 2 2 639A BL 0.8 39 139
639 BL 0.8
G_R_AN12
X-DTLTS X-LEV2
Y-TNK_HTR
639C BL 0.8 SH18: C-4
SCR TANK HEATING VALVE
O_S_RL12 172 672 BL 0.8 3 3 1 1

SW-A_F_S 72
SCR TANK HEATING VALVE
AIR FILTER RSTCN SW
X-THV X-THV
P
SH18: D-4 650C OR 0.8
1 IN OUT 2
SH16: A-2 627B RD 0.8 637 YE 0.8 37 137
MC17
I_S_DIG04
X-AFS X-AFS
A A
X-ECU X-ECU
PL2326 CIRCUITS
TIER 2 AND TIER 3 ENGINES
6 5 4 3 2 1
SHT_17 1
48083741_EN 31/07/2018
55.1 [55.100] / 65
Wiring harnesses - Electrical schematic sheet 18 SH18 - ENGINE

CONTROL UNIT 3, AT
ECU A-ECU - ENGINE X-ECU - ECU CONNECTOR
CONTROLLER (ECU) [A-ECU] (84300197)
ECU A-PMP - DEF PUMP MODULE X-PUMP - DENOX CONTROL
(ECU) UNIT [A-PMP] (47421681)
ECU A-TERMC - TERMINATOR X-TERM_C - CONTROLLER
FOR CAN (ECU) AREA NETWORK [A-TERMC]
(87695580)
Sensor B-DEF_Q - DEF QUALITY X-DEFQ - DEF QUALITY
SENSOR (Sensor) SENSOR (UQS) [B-DEF_Q]
(84149219)
Sensor B-NH3 - NH3 SENSOR X-NH3 - NH3 SENSOR
(Sensor) [B-NH3] (84146686)
Sensor B-NOX_DU - DOC X-NOXD - SCR
UPSTREAM NOX SENSOR DOWNSTREAM NOX
(Sensor) SENSOR [B-NOX_DU]
(84190317)
Sensor B-NOX_SD - SCR X-NOXS - DOC UPSTREAM
DOWNSTREAM NOX NOX SENSOR [B-NOX_SD]
SENSOR (Sensor) (84190317)
Connector X-CAN X-CAN - CAN (87696093)
Connector X-DEF1 X-DEF1 - INLINE TO
DEF QUALITY SENSOR
(87694153)
Connector X-DEF2 X-DEF2 - INLINE FROM
DEF QUALITY SENSOR
(87694154)
Connector X-DEFQ X-DEFQ - DEF QUALITY
SENSOR (UQS) [B-DEF_Q]
(84149219)
[A-ECU] (84300197)
Connector X-EDC7 X-EDC7 - ENGINE
CONTROLLER T2/3 [SH18:
C-5] (84160698)
[SH16: A-3] (84380518)
Connector X-NH3 X-NH3 - NH3 SENSOR
[B-NH3] (84146686)
Connector X-NOXD X-NOXD - SCR
DOWNSTREAM NOX
SENSOR [B-NOX_DU]
(84190317)
Connector X-NOXS X-NOXS - DOC UPSTREAM
NOX SENSOR [B-NOX_SD]
(84190317)
Connector X-PUMP X-PUMP - DENOX CONTROL
UNIT [A-PMP] (47421681)
Connector X-SCR1 X-SCR1 - INLINE TO SCR
SENSORS HARNESS
(87695592)
Connector X-SCR2 X-SCR2 - INLINE FROM
SCR SENSORS HARNESS
(87695724)
Connector X-TERM_C X-TERM_C - CONTROLLER
AREA NETWORK [A-TERMC]
(87695580)
Connector X-TURBO X-TURBO - INTERFACE
WIRING HARNESS PLUG C
[SH12: B-3] (84152563)
Connector X-TURBO_2 X-TURBO_2 - ENGINE
HARNESS INTERFACE T2
[SH18: B-5] (87694583)
48083741_EN 31/07/2018
55.1 [55.100] / 66
6 5 4 3 2 1
TERMC
ECU TERMINATOR FOR CAN
MC66 MC66
ENGINE CONTROLLER MC1 A
650A OR 0.8 CANC_HK YE 0.8 A
200G OR 1.0
B
PMP CANC_LK GN 0.8 B
DEF PUMP MODULE

TERM_C
MC15 84 184 O_T_RL13
D 10
684 YE 0.8
MC15 SCR PUMP MOTOR D
9
9 10
689 GY 0.8
8 89 189 G_G_RL13
8 SCR PUMP MOTOR
SCR PUMP MOTOR MC15 SP650
MC16 50 150 O_V_RH11
SH18: D-6 650B OR 0.8 650 OR 0.8
MC16 11 11 COMMON BATTERY PLUS
SH18: D-5 650B OR 0.8 650C OR 0.8 SH17: A-2
12 12 85 185 O_T_RL16
685 GY 0.8
SCR REVERTING VALVE
MC1
MC16
SCR REVERTING VALVE
PUMP NOX_SD
2 2 68 168 V_V_5VSS1D
668 PK 0.8 SCR DOWNSTREAM NOX SENSOR
4 COMMON SUPPLY
4 SH17: A-4
639C BL 0.8 1
3 3 1
200G OR 1.0
SCR PRESSURE SENSOR 7 107 I_A_AN23 2

607 YE 0.8 2
SCR PRESSURE SENSOR
MC3 MC3 4
PUMP CANC_HJ YE 0.8 4
CAN2_HC YE 0.8
SPL_CANC_HG
3
CANC_LJ GN 0.8 3
MC4
CAN2_LC GN 0.8
SPL_CANC_LG
NOXS
CANC_HG YE 0.8
CANC_LG GN 0.8
NOX_DU
CAN_1
MC14 MC14 46 146 DOC UPSTREAM NOX SENSOR
SH24: C-1 CAN_H YE 0.8 1
B_D_CANH0 200F OR 1.0 1
C SH24: C-1 CAN_L GN 0.8
47 147
2
C
35 201F BK 1.0 2
SH24: C-1 MC63 MC63 B_D_CANL0
CAN_H7 YE 0.8 5
201G BK 0.8 5
200G OR 1.0
34
MC4
SH24: C-1 CAN_L7 GN 0.8 MC5 4
200F OR 1.0
201H BK 1.0
CANC_HF YE 0.8 4
SPL_CANC_HE
EDC7
3
CANC_LF GN 0.8 3
MC6
MC5
SPL_CANC_LE NOXD
CANC_HE YE 0.8
CANC_LE GN 0.8
MC13 MC13 71 171
1 671 YE 0.8
B_D_CANH1
95 195
2 695 GN 0.8 B_D_CANL1
PROTOTYPES ONLY NH3
CAN ECU NH3 SENSOR
CAN SPL_200D 1
200E OR 1.0 101
MC65
CAN2_HB YE 0.8 53 4
SPL_201D 201E BK 1.0 104
MC6
CAN2_LB GN 0.8 52
MC7 MC7 2
SPL_CANC_HC CANC_HD YE 0.8 102
TIER 2, PL2326
ONLY EDC7 CANC_LD GN 0.8
3
103
MC65
SPL_CANC_LC NH3
200D RD 2.0
B B
201D BK 2.0
CANC_HC YE 0.8
SP2HC
CANC_LC GN 0.8
6
202A RD 1.0 SH11: C-2 SP2LC
CANC_HM YE 0.8
5
203A BK 1.0 SH12: B-2
MC64
201J BK 1.0
7 MC64
CAN2_HA YE 0.8
MC8
1
SCR2
CAN2_LA GN 0.8
CANC_LM GN 0.8
12 12
11 11
4
1 1
TURBO_2
4
12 PIN
MC12
SCR1
201B BK 2.0
200B RD 2.0
PL23PL26 ONLY
CANC_HB YE 0.8
SH11: D-2 200J RD 3.0 200H OR 1.0
CANC_LB GN 0.8
DEF_Q
DEF1
DEF QUALITY SENSOR
3 3
SH11: D-2 200 RD 3.0 200A OR 1.0 4 4 200C OR 1.0
SP200
CLEAN SH12: A-3 201K BK 3.0 SP201
6 6
GROUND SH12: A-3 201 BK 3.0 201A BK 1.0 1 1 201C BK 1.0
MC12
SPL_CAN_H1 MC11 MC9 MC9 4
1 4
202 RD 3.0 SH11: C-2 CANC_HA YE 0.8 3 3 CANC_HZ YE 0.8
5 5
2
CANC_LA GN 0.8 2 2 CANC_LZ GN 0.8
A TO FPT
203 BK 3.0 SH12: B-3
SPL_CAN_L1 DEF2 DEFQ
A
ENGINE
MC10
HARNESS
6 MC10
CANC_H YE 0.8
5
CANC_L GN 0.8
TURBO
6 5 4 3 2 1
SHT_18 1
48083741_EN 31/07/2018
55.1 [55.100] / 67
Wiring harnesses - Electrical schematic sheet 19 SH19 - UCM PWR, GRND, INSTRUMENTATION
ECU A-UCM - 47749442 WAS X-UCM3B - UCM [A-UCM] Connector X-LC2 X-LC2 - LOADCENTER 2
84328725 (ECU) (84130760) X-UCM4B - [SH7: B-3] (87733581)
UCM [A-UCM] (82028495) Connector X-PBW X-PBW - BRAKE SUPPLY
X-UCM2B - UCM [A-UCM] WARNING PRES [B-PBW]
(82028495) (84078681)
Sensor B-HOT - HYD OIL TEMP X-HOT - HYD OIL TEMP Connector X-PHF X-PHF - HYDRAULIC
(Sensor) [B-HOT] (84607243) FILTER SENSOR [SW-PHF]
Sensor B-PBL/PEDAL/DECLTCH - X-PLB-PBD - BRAKE PRES (84352277)
BRAKE PESSURE SENSOR SENSR [B-PBL/PEDAL/ Connector X-PHF23 X-PHF23 - HYDRAULIC
(Sensor) DECLTCH] (84078681) FILTER SENSOR PL23
Sensor B-PBW - BRAKE SUPPLY X-PBW - BRAKE SUPPLY (82012083)
PRESS (Sensor) WARNING PRES [B-PBW] Connector X-PLB-PBD X-PLB-PBD - BRAKE PRES
(84078681) SENSR [B-PBL/PEDAL/
Sensor B-PRB1 - RED_BRAKE_FRNT X-PRB1 - REDUNDANT DECLTCH] (84078681)
(Sensor) BRAKE SW 1 [B-PRB1] Connector X-PRB1 X-PRB1 - REDUNDANT
(84078681) BRAKE SW 1 [B-PRB1]
Sensor B-PRB2 - X-PRB2 - REDUNDANT (84078681)
RED_BRAKE_REAR (Sensor) BRAKE SW 2 [B-PRB2] Connector X-PRB2 X-PRB2 - REDUNDANT
(84078681) BRAKE SW 2 [B-PRB2]
Sensor B-RECTD - COOLANT TEMP X-RECT - ENGINE COOLANT (84078681)
(Sensor) TEMP [B-RECTD] (84607243) Connector X-RECT X-RECT - ENGINE COOLANT
Sensor B-RFLG - FUEL LEVEL X-FL - FUEL LEVEL [B-RFLG] TEMP [B-RECTD] (84607243)
SENSOR (Sensor) (82012083) Connector X-SP_PK1 X-SP_PK1 - SPLICE PACK
Switch SW-PHF - HYDRAULIC X-PHF - HYDRAULIC (87693718)
FILTER SWITCH (Switch) FILTER SENSOR [SW-PHF] Connector X-SP_PK2 X-SP_PK2 - SPLICE PACK
(84352277) (87693718)
Connector X-BTM X-BTM - BOTTOM TO CAB Connector X-TRANS X-TRANS - TRANSMISSION
STD (87704523) TO CAB (87696949)
Connector X-CAB_B X-CAB_B - CAB TO BOTTOM Connector X-UCM1A X-UCM1A - UCM (82016219)
[SH21: B-3] (87696945) Connector X-UCM1B X-UCM1B - UCM [SH22: A-6]
Connector X-CAB_E X-CAB_E - CAB TO ENGINE (87410946)
[SH7: B-5] (84807216) Connector X-UCM2A X-UCM2A - UCM (82028493)
Connector X-CAB_TR X-CAB_TR - CAB TO Connector X-UCM2B X-UCM2B - UCM [A-UCM]
TRANSMISSION [SH26: (82028495)
A-2] (87696944) Connector X-UCM3A X-UCM3A - UCM (84130757)
Connector X-ENG X-ENG - ENGINE TO CAB Connector X-UCM3B X-UCM3B - UCM [A-UCM]
[SH18: C-6] (87696948) (84130760)
Connector X-FL X-FL - FUEL LEVEL [B-RFLG] Connector X-UCM4A X-UCM4A - UCM (82028493)
(82012083)
Connector X-HOT X-HOT - HYD OIL TEMP (82028495)
[B-HOT] (84607243)
48083741_EN 31/07/2018
55.1 [55.100] / 68
6 5 4 3 2 1
A-UCM
47749442 WAS 84328725
6 A
GND_SIGNAL 1 937 BK 0.8
SP-448
7
SH7: C-2 448 RD 3.0 448A RD 1.0 24VF3 X-UCM1A
13 24VF3_1
448B RD 1.0 9 B
GND_SIGNAL_2 H
938 BK 0.8
X-UCM2A
1 X-UCM1B
448C RD 1.0 24VF2
8 24VF2_1
448D RD 1.0 26 C
D SP-454
X-UCM4A
GND_SIGNAL_4 939 BK 0.8 D
X-SP_PK1
7 X-UCM2A
SH7: C-3 454 RD 3.0 454A RD 1.0 24VF6
13 24VF6_1
454B RD 1.0 26 D
GND_SIGNAL_5 940 BK 0.8
X-UCM3A
SH7: C-1 461 RD 3.0
8
454C RD 1.0 24VF4
9 24VF4_1
SH7: D-1 465 RD 1.0 454D RD 1.0 34 E
GND_SIGNAL_6 941 BK 0.8
SP-461 2
SH10: C-2 466 OR 0.8 461A RD 1.0 24VS1
3 24VS1_1 X-UCM2B
461B RD 1.0
433A YE 0.8
X-UCM3B GND_SIGNAL_7 20 F
942 BK 0.8
2
B-RECTD 461C RD 1.0 24VLP
COOLANT TEMP GND_SIGNAL_8
X-UCM4B
1 T 2 20 26 G
482T BL 0.8 24 VP 943 BK 0.8
SUPPLY GND
X-RECT X-RECT SP-466 X-UCM3A X-SP_PK1
26 24 VB
466A OR 0.8
14 GND_SIGNAL_9 26 A
466B OR 0.8 24VA 929 BK 0.8
SH20: A-5 482N BL 0.8
X-UCM1A
X-ENG
12 34 B
B-RFLG 5 5 12 GND_SIGNAL_12
433 YE 0.8 930 BK 0.8
FUEL LEVEL SENSOR COOLANT TEMP H
SP-482R
482R BL 0.8 9 9 X-UCM3B
SIG GND
2 1 482M BL 0.8
C GND_SIGNAL_13 20
931 BK 0.8
C L C
X-FL X-FL
11
633A YE 0.8 8 8 633 YE 0.8 11
FUEL LEVEL M
26 D
GND_SIGNAL_14
634A YE 0.8 932 BK 0.8
X-SP_PK2
X-CAB_E
B-HOT X-UCM4A
HYD OIL TEMP
X-TRANS 32 E
GND_SIGNAL_15
1 933 BK 0.8
T 2
482S BL 0.8 18
SUPPLY GND 18
30 30 634 YE 0.8
HYD OIL TEMP
X-HOT X-HOT
34 F
GND_SIGNAL_16
934 BK 0.8
X-UCM4A
PL23/26 ONLY X-UCM4B
SW-PHF
HYDRAULIC FILTER SWITCH 2 236 YE 0.8
ECU_GND_SENSE 7 G
1 391G BK 0.8 935 BK 1.0
BODY P
GROUND X-PHF23 CAB GROUND
IN OUT 1 17 K STUD 2
636A YE 0.8 23 23 AN_33 950 BK 1.0
636 YE 0.8
X-PHF SWITCH, HYDRAULIC FILTER RES (PL23)
SH20: B-1 X-UCM3A
J
B-PRB1
482G BL 0.8
RED_BRAKE_FRNT 1
SP-482A UCM_GND
X-SP_PK2
PWR GND
SH19: A-1 486R PK 0.8 B A 482D BL 0.8 482A BL 0.8 3 3
B B
OUT 15
X-PRB1 C 443A YE 0.8 1 1 443 YE 0.8 AN_02
PRESSURE, BRAKE ACCUMULATOR PRB1
482B BL 0.8
X-PRB1
B-PRB2
RED_BRAKE_REAR
17
24 24 638 YE 0.8 AN_07
PWR GND PRESSURE, BRAKE ACCUMULATOR PRB2
SH19: A-1 486S PK 0.8 B A 482E BL 0.8
OUT X-CAB_TR
X-PRB2 C 638B YE 0.8
X-TRANS
TO FRONT X-PRB2
EH CNTRL SH22: C-5 482J BL 0.8 486R PK 0.8 SH19: B-6
1 GND_SIGNAL
482 BL 0.8 SP-486
SP-482 2
5V GND1 5VREF1 OUT
AUX SH21: D-4 482F BL 0.8 486 PK 0.8 486B PK 0.8 26 26 486N PK 0.8 486S PK 0.8 SH19: B-6
5VREF1 OUT
5VREF1
SP-486N
X-UCM1A
B-PBW
BRAKE SUPPLY PRESS X-CAB_TR
X-BTM
486A PK 0.8
SP-482H
PWR GND
SH19: A-1 486F PK 0.8 B A 482K BL 0.8 482H BL 0.8 10 10 482C BL 0.8
X-BTM
X-PBW
OUT 10 AN_03
486U PK 0.8 SH21: D-4 AUX
C 640A YE 0.8 6 6 640 YE 0.8
482L BL 0.8
PRESSURE, BRAKE SUPPLY PBW SP-486D

X-PBW 8 8 486D PK 0.8 486E PK 0.8 SH22: C-5
A B-PBL/PEDAL/DECLTCH X-UCM1A A
BRAKE PESSURE SENSOR
X-CAB_B
PWR GND
SH19: A-1 486G PK 0.8 B A 486F PK 0.8 SH19: A-6
X-UCM1B
X-PLB-PBD
OUT 20 AN_10
C 641A YE 0.8 7 7 641 YE 0.8
PRESSURE, BRAKE LIGHT /DECLUTCH PBL/PBD
486G PK 0.8 SH19: A-6
X-PLB-PBD
X-CAB_B
6 5 4 3 2 1
SHT_19 1
48083741_EN 31/07/2018
55.1 [55.100] / 69
Wiring harnesses - Electrical schematic sheet 20 SH20 - UCM VEHICLE DRIVELINE / FAN CONTROL
ECU A-PFNR - PRIMARY FNR X-TS2 - TRANS SHIFTER 2 Connector X-FRNT X-FRNT - FRONT TO
(ECU) [A-PFNR] (47702209) X-TS1 - BOTTOM STD (87704426)
TRANS SHIFTER1 [A-PFNR] Connector X-FSS X-FSS - FAN SPEED SENSOR
(87692817) [B-FSS] (47696743)
ECU A-UCM - 47749442 WAS X-UCM3B - UCM [A-UCM] Connector X-LC6 X-LC6 - LOADCENTER 6
84328725 (ECU) (84130760) X-UCM4B - [SH16: A-3] (84380518)
UCM [A-UCM] (82028495) Connector X-PBBS X-PBBS - PARK BRAKE PRES
X-UCM2B - UCM [A-UCM] SENSR [B-PBBS]
(82028495) Connector X-PED_2 X-PED_2 - PEDESTAL TO
Sensor B-BPP - BRAKE PEDAL X-BPP - BRAKE PEDAL CAB 2 (87705114)
ANGLE (Sensor) ANGLE [B-BPP] (87710588) Connector X-SDM X-SDM - SWITCH DIFF LOCK
Sensor B-FAX - FRONT AXLE OIL X-FAX - FRONT AXLE [SW-SDM] (82012083)
TEMP (Sensor) TEMP SENSOR [SH20: A-6] Connector X-TRANS X-TRANS - TRANSMISSION
(87711966) TO CAB (87696949)
Sensor B-FSS - FAN SPEED SENSOR X-FSS - FAN SPEED SENSOR Connector X-TS1 X-TS1 - TRANS SHIFTER1
(Sensor) [B-FSS] (47696743) [A-PFNR] (87692817)
Sensor B-PBBS - PARK BRAKE PR X-PBBS - PARK BRAKE PRES Connector X-TS2 X-TS2 - TRANS SHIFTER 2
SENSOR FUTURE (Sensor) SENSR [B-PBBS] [A-PFNR] (47702209)
Switch SW-AFS2 - AIR FILTER X-AFS2 - AIR FILTER SWITCH Connector X-UCM1A X-UCM1A - UCM (82016219)
SWITCH T2/T3 (Switch) T2/3 [SW-AFS2] (84607243)
Connector X-UCM2A X-UCM2A - UCM (82028493)
Switch SW-SDM - DIFF LOCK FOOT X-SDM - SWITCH DIFF LOCK
SWITCH (Switch) [SW-SDM] (82012083)
(82028495)
Connector X-AFS2 X-AFS2 - AIR FILTER SWITCH
T2/3 [SW-AFS2] (84607243)
Connector X-BPP X-BPP - BRAKE PEDAL
(84130760)
ANGLE [B-BPP] (87710588)
Connector X-BTM X-BTM - BOTTOM TO CAB
STD (87704523) Connector X-UCM4B X-UCM4B - UCM [A-UCM]
(82028495)
Connector X-BTM_F X-BTM_F - BOTTOM TO
FRONT STD (87696087) Connector X-YDL X-YDL - DIFF LOCK SOL
[Y-DL] (87695582)
Connector X-CAB_B X-CAB_B - CAB TO BOTTOM
[SH21: B-3] (87696945) Connector X-YFN X-YFN - SOLENOID FAN
CONTROL [Y-Y_FC]
(87693821)
[SH7: B-5] (84807216)
Connector X-YFR X-YFR - FAN REVESER
SOLENOID [Y-Y_FR]
[SH9: C-2] (87703902)
(87695582)
Connector X-CAB_P2 X-CAB_P2 - CAB TO
Connector X-YLV X-YLV - HEAT LOAD VALVE
PEDESTAL 2 [SH27: B-2]
[Y-YLV] (87695582)
(87705101)
Connector X-YPB X-YPB - VALVE PARKING
Connector X-CAB_TR X-CAB_TR - CAB TO
BRAKE [Y-Y_PB] (87695582)
TRANSMISSION [SH26:
A-2] (87696944) Solenoid Y-DL - DIFF LOCK SOLENOID X-YDL - DIFF LOCK SOL
(Solenoid) [Y-DL] (87695582)
[SH18: C-6] (87696948) Solenoid Y-YLV - HEAT LOAD VALVE X-YLV - HEAT LOAD VALVE
(Solenoid) [Y-YLV] (87695582)
(87703931) Solenoid Y-Y_FC - PWM FAN X-YFN - SOLENOID FAN
CONTROL (Solenoid) CONTROL [Y-Y_FC]
Connector X-FAN X-FAN - FAN SPEED SENSOR
(87693821)
JUMPER [SH11: C-1]
(87694112) Solenoid Y-Y_FR - FAN REVERSER X-YFR - FAN REVESER
(Solenoid) SOLENOID [Y-Y_FR]
Connector X-FAN2 X-FAN2 - FAN SPEED
(87695582)
SENSOR JUMPER
(87694152) Solenoid Y-Y_PB - PARKING BRAKE X-YPB - VALVE PARKING
SOLENOID (Solenoid) BRAKE [Y-Y_PB] (87695582)
Connector X-FAX X-FAX - FRONT AXLE
TEMP SENSOR [SH20: A-6]
(87711966)
48083741_EN 31/07/2018
55.1 [55.100] / 70
6 5 4 3 2 1
A-UCM
CRANK REQUEST
47749442 WAS 84328725
SH3: A-1 220B YE 0.8
TO ECU
14
AN_26
KEY SWITCH CRANK X-ENG
X-UCM3A SP-663A 663D YE 0.8 SH16: B-6
X-UCM2B
HSD_PWM_01 5
663 YE 0.8 15 15 663A YE 0.8 663B YE 0.8 SH16: B-5
CRANK REQUEST
D SW-AFS2
HSD_LP_05 7 X-CAB_E D
AIR FILTER SWITCH T2/T3
P X-ENG
HSD_LP_01 9
134 YE 0.8 SH28: D-3
1 IN OUT 2 17 WARNING INDICATOR LED
SH16: C-5 AN_17 SH3: C-4
669C OR 0.8 319A YE 0.8 18 18 319 YE 0.8 663C YE 0.8
AIR FILTER REST SW T2
X-UCM4B
X-AFS2 X-AFS2
X-CAB_E
CRANK CONTROL
RELAY PWR
A-PFNR
PRIMARY FNR
X-PED_2 11 AN_18
1 1 679 YE 0.8
A Stalk FNR R
3rd AND 4th B B 16 AN_19
407A YE 0.8 2 2 680 YE 0.8
C Stalk FNR N
1ST AND 4TH C 406A YE 0.8
D 10 AN_20
3 3 686 YE 0.8
Stalk FNR F
X-TS2 X-UCM2A
4 4 406 YE 0.8
5 5 407 YE 0.8
X-BTM
Y-Y_PB
C IGN PWR A1 A
B
4029 OR 0.8 6 6 19D OR 0.8 SH10: C-2
22 AN_25
Gear Select 1_4
PARKING BRAKE SOLENOID C
FORWARD SIGNAL B1
683A YE 0.8 27
REVERSE SIGNAL C1 C X-CAB_P2 HSD_HP_01 P N
679A YE 0.8 388 WH 0.8 18 18 388A WH 0.8 1 2
D PARK BRAKE SOLENOID
NEUTRAL SIGNAL D1 680A YE 0.8
21 AN_27 X-YPB X-YPB
X-UCM3B
X-TS1 Gear Select 3_4
B-BPP X-UCM2B
BRAKE PEDAL ANGLE
LSD_HP_04 22
GND 389 WH 0.8 19 19 389A BK 0.8
PWR PARK BRAKE RETURN
SH22: C-5 471E PK 0.8 2 1 651B BL 0.8 SH22: C-5
X-BTM
X-UCM1A
X-BPP
OUT 16
3 15 15 AN_04
402A YE 0.8 402 YE 0.8
ANGLE, BRAKE PEDAL BPP
X-CAB_B
X-BPP X-UCM1A
X-CAB_B Y-DL
DIFF LOCK SOLENOID
X-TRANS
HSD_HP_04 1 1 2
390 WH 0.8 27 27 390A WH 0.8
DIFF LOCK IN OUT
SW-SDM X-UCM3B X-YDL X-YDL
DIFF LOCK FOOT SWITCH
24 SP-391A
SIG GND
SH10: B-2 1 2 AN_37 SH14: B-3
19M OR 0.8 401 WH 0.8 391A BK 1.0 391B BK 0.8
DIFF LOCK FOOT SWITCH
X-SDM X-SDM
B X-UCM3B 391E BK 0.8 SH32: C-1
TO WASH B
MOTORS
391F BK 0.8 SH32: C-1
X-ENG-2 391G BK 0.8 PL23 HYD FILTER GRND SH19: B-6

X-FAN
B-FSS LSD_HP_06 22
X-ENG
FAN SPEED SENSOR HEAT LOAD VALVE 582 BR 0.8 M M 582A BR 0.8 1 1 582B BR 0.8
X-FAN SH21: C-5
677M PK 0.8 28 28 677L PK 0.8 Y-YLV
3 3 677N PK 0.8 3 3 30 HEAT LOAD VALVE
2 2 FIN_05
400B YE 0.8 4 4 400A YE 0.8 16 16 400 YE 0.8
FAN SPEED SENSOR IN OUT
852C OR 0.8 2 2 852A OR 0.8 1 2
1 1 482V BL 0.8 5 5 SH11: C-1
X-CAB_E X-YLV
X-UCM4B X-YLV
X-FAN2 X-FAN2
X-FSS
482N BL 0.8 SH19: C-6 NOT USING
B-PBBS
PARK BRAKE PR SENSOR FUTURE Y-Y_FR
FAN REVERSER
P X-BTM
maybe future SH11: C-2 852B OR 0.8 1
P N
2
1 2 5
1 2 AN_08
16 16 3686 YE 0.8
PRESSURE, PARK BRAKE X-YFR X-YFR
X-PBBS X-PBBS LSD_HP_07 21
X-UCM1A 692 BR 0.8 N N 692A BR 0.8
X-CAB_B FAN REVERSER
Y-Y_FC
PWM FAN CONTROL
A A
HSD_PWM_15 25 P N
B-FAX 392 YE 0.8 P P 392A YE 0.8 A B 392A YE 0.8
X-FRNT X-BTM FAN CONTROL
SH22: C-6 651N BL 0.8 FRONT AXLE OIL TEMP
2 X-UCM2A X-YFN X-YFN
1 1 17 X-CAB_E-2
2 T 17
SH22: C-6 651G BL 0.8 687B YE 0.8 A A 687A YE 0.8 17 17 687 YE 0.8
AXLE OIL TEMP
X-FAX X-FAX X-UCM4A

X-BTM_F X-CAB_B
PL2326 ONLY
6 5 4 3 2 1
SHT_20 1
48083741_EN 31/07/2018
55.1 [55.100] / 71
Wiring harnesses - Electrical schematic sheet 21 SH21 - UCM-STEERING AUX JSS

ECU A-UCM - 47749442 WAS X-UCM3B - UCM [A-UCM] Connector X-JSS_FR X-JSS_FR - JSS FRAME
84328725 (ECU) (84130760) X-UCM4B - HARNESS TO CAB
UCM [A-UCM] (82028495) (87694152)
X-UCM2B - UCM [A-UCM] Connector X-JSS_JOY X-JSS_JOY - JSS LEFT
(82028495) HAND JOYSTICK [B-JSS]
Sensor B-JSS - LH JOYSTICK X-JSS_JOY - JSS LEFT (87700107)
STEERING (Sensor) HAND JOYSTICK [B-JSS] Connector X-JSV X-JSV - JOYSTICK
(87700107) STEERING VALVE [SH21:
Sensor B-JSS_CO_2 - JSS CUT OFF X-JSS_CO_2 - CUT OFF B-2] (87695592)
SENSOR 2 (Sensor) SENSOR [B-JSS_CO_2] Connector X-LFT_2 X-LFT_2 - LEFT JS TO CAB
(87694153) (87700105)
Sensor B-PSS - AUX STEERING X-PSS - STEERING Connector X-LFT_A X-LFT_A - JSS TO CAB L
PRESSURE (Sensor) PRESSURE SENSOR [B-PSS] ARMREST (87700155)
(84078681) Connector X-LH_ARM_DWN X-LH_ARM_DWN - LH
Diode D-SS DIODE - SEC STRG X-SSD - SS FLYBACK DIODE JSS ARM REST DOWN
FLYBACK DIODE (Diode) [D-SS DIODE] (87692858) [SW-ARM_POS_DWN]
Relay K-JSS_CO_1 - JSS CUT OFF X-JSS_CO_1 - CUT OFF (84000405)
SENSOR 1 (Relay) SENSOR [K-JSS_CO_1] Connector X-LH_ARM_UP X-LH_ARM_UP - LH
(87694153) JSS ARM REST DOWN
Motor M-SEC_STRG - SECONDARY X-S244 - 20157 AUX STRG [SW-ARM_POS_UP]
STEERING MOTOR/PUMP PWR RT ANGLE CONN (84000405)
(Motor) [SH21: D-3] X-SSS - Connector X-PSS X-PSS - STEERING
SECONDARY STEERING PRESSURE SENSOR [B-PSS]
MOTOR [M-SEC_STRG] (84078681)
(84426118) X-S242 - GROUND Connector X-S242 X-S242 - GROUND
[M-SEC_STRG] (84401307) [M-SEC_STRG] (84401307)
Switch SW-ARM_POS_DWN - LH X-LH_ARM_DWN - LH Connector X-S244 X-S244 - 20157 AUX STRG
ARMREST POSITION (Switch) JSS ARM REST DOWN PWR RT ANGLE CONN
[SW-ARM_POS_DWN] [SH21: D-3]
(84000405) Connector X-S245 X-S245 - GROUND (84426118)
Switch SW-ARM_POS_UP - LH X-LH_ARM_UP - LH Connector X-SSD X-SSD - SS FLYBACK DIODE
ARMREST POSITION (Switch) JSS ARM REST DOWN [D-SS DIODE] (87692858)
[SW-ARM_POS_UP]
Connector X-SSS X-SSS - SECONDARY
(84000405)
STEERING MOTOR
Switch SW-SW_JSS - SWITCH JSS X-SW_JSS - JOYSTICK [M-SEC_STRG] (84426118)
ACTIVATION (Switch) STEERING SWITCH
Connector X-SST X-SST - SEC STRG TO
[SW-SW_JSS] (87716755)
TRANS (87694152)
Connector X-SW_JSS X-SW_JSS - JOYSTICK
STD (87704523)
STEERING SWITCH
Connector X-BTS X-BTS - BOTTOM TO SEC [SW-SW_JSS] (87716755)
STRG [SH19: A-1] (87694112)
[SH21: B-3] (87696945)
Connector X-CAB_JSS X-CAB_JSS - CAB TO JSS
(82028495)
FRAME HARNESS [SH24:
A-6] (87694112) Connector X-UCM3A X-UCM3A - UCM (84130757)
Connector X-CAB_L X-CAB_L - CAB TO JSS L Connector X-UCM3B X-UCM3B - UCM [A-UCM]
ARMREST (87700156) (84130760)
Connector X-CAB_L2 X-CAB_L2 - CAB TO LEFT Connector X-UCM4B X-UCM4B - UCM [A-UCM]
JSS (87696138) (82028495)
Connector X-COV1 X-COV1 - CUT OFF VALVE Connector X-YSS X-YSS - SEC STEERING
SOL [Y-C0V_1] (87695582) VALVE SOL [Y-Y_SS]
(87695582)
Connector X-COV2 X-COV2 - CUT OFF VALVE
SOL [Y-COV_2] (87695582) Solenoid Y-C0V_1 - JSS CUT OFF X-COV1 - CUT OFF VALVE
VALVE 1 (Solenoid) SOL [Y-C0V_1] (87695582)
Connector X-JSS_CO_1 X-JSS_CO_1 - CUT OFF
SENSOR [K-JSS_CO_1] Solenoid Y-COV_2 - JSS CUT OFF X-COV2 - CUT OFF VALVE
(87694153) VALVE 2 (Solenoid) SOL [Y-COV_2] (87695582)
Connector X-JSS_CO_2 X-JSS_CO_2 - CUT OFF Solenoid Y-Y_SS - SEC STEERING X-YSS - SEC STEERING
SENSOR [B-JSS_CO_2] SOL. (Solenoid) VALVE SOL [Y-Y_SS]
(87694153) (87695582)
48083741_EN 31/07/2018
55.1 [55.100] / 72
6 5 4 3 2 1
X-SST
486W PK 0.8 2 2 486U PK 0.8 SH19: A-1

B-PSS
AUX STEERING PRESSURE SH19: A-6 A-UCM
SH3: D-3
47749442 WAS 84328725
PWR GND
D B A 482P BL 0.8 3 3 482F BL 0.8
X-BTM
D
X-PSS
OUT 8 AN_01
C 176B YE 0.8 4 4 176A YE 0.8 11 11 176 YE 0.8
PRESSURE, AUXILIARY STEERING
X-PSS X-UCM1A
X-BTS X-CAB_B
K-JSS_CO_1
JSS CUT OFF SENSOR 1
1990 RD 62.0
GND
PWR
677G PK 0.8 1 2 967G BL 0.8
3 X-JSS_FR
OUT 12 AN_32
4 676A YE 0.8 2 2 676 YE 0.8
JSS COV SENSOR 1
X-JSS_CO_1 M-SEC_STRG
X-JSS_CO_1
B-JSS_CO_2 SECONDARY STEERING MOTOR/PUMP
JSS CUT OFF SENSOR 2 X-UCM3A
SP-677A GND SP-967A SP-967

1 PWR 2 20 GND_SIGNAL_3 1 PWR
677F PK 0.8 967F BL 0.8 967A BL 0.8 4 4 967 BL 0.8 967B BL 0.8 GND
5V REF GRND 3 1
X-S244 M 185 BK 62.0 SH14: B-3
X-UCM2A X-S242
3 1
OUT 4 15 AN_40 A 1
273A YE 0.8 6 6 273 YE 0.8 180A BK 1.0
JSS COV SENSOR 2
X-JSS_CO_2 X-JSS_CO_2 SP-677 X-S245
X-UCM3B X-SSS
677A PK 0.8 3 3 677 PK 0.8
4 5VREF3 OUT
X-CAB_JSS 677B PK 0.8
5VREF3
441D OR 1.0
C X-UCM1A
D-SS DIODE
SEC STRG FLYBACK DIODE
C
B-JSS N
X-JSS_JOY SH20: B-4 677L PK 0.8 441E OR 1.0 C
LH JOYSTICK STEERING P1
1 X-LFT_A A
677D PK 0.8 7 7 677C PK 0.8
P2
180 BK 1.0 B
3
967D BL 0.8 6 6 967C BL 0.8
X-SSD
HSD_LP_03 8
183 YE 0.8 SH8: B-6
X-UCM4B
X-BTM
Y-Y_SS
X-SST
6 SEC STEERING SOL.
651M BL 0.8 3 3 651L BL 0.8 SH22: C-5
P N
SH8: B-2 441 OR 0.8 12 12 441A OR 0.8 1 1 441B OR 1.0 441C OR 1.0 1 2
4
471L PK 0.8 1 1 471J PK 0.8 SH22: C-5
SP-441B
X-YSS X-YSS
2 18
184 BK 0.8
2 2 AN_15
670A YE 0.8 670 YE 0.8
JSS ACTIVIATION SW JSS JOYSTICK 1
INTERNAL 5 12 X-BTS
5 5 AN_16
630A YE 0.8 630 YE 0.8
JSS JOYSTICK 2 X-CAB_B
X-UCM2A
DEUTSCH_DTM SERIES_4-WAY_RECEP HSG

SW-ARM_POS_UP
SH14: B-4
LH ARMREST POSITION
OUT1
B 799K OR 0.8 1
IN
2
B
OUT2 12
3 4 4 AN_30
675A GY 0.8 675 GY 0.8 Y-COV_2
X-LH_ARM_UP JSS ARM UP
JSS CUT OFF VALVE 2
X-LH_ARM_UP
1 2
854B WH 0.8
SW-ARM_POS_DWN
LH ARMREST POSITION X-COV2 X-COV2
TO JSS
STRG VALVE SH24: A-5 854A WH 0.8 SP-854A
OUT1 Y-C0V_1
2 JSS CUT OFF VALVE 1
IN
799J OR 0.8 1 20
OUT2 AN_29 1 2
3 673A TN 0.8 8 8 673 TN 0.8 854 WH 0.8
X-LH_ARM_DWN JSS ARM DWN
X-LH_ARM_DWN X-UCM2B X-COV1 X-COV1
SP-799A
799G OR 0.8 10 10 799B OR 0.8 SH10: B-1
SW-SW_JSS
SWITCH JSS ACTIVATION
955AB BK 0.8
799H OR 0.8
SP-954
10 P N 9
954C BK 0.8 954 BK 0.8 11 11 954J BK 0.8 SH13: A-5 X-JSS_FR
16 955AC BK 0.8
1 3 AN_38
678A WH 0.8 9 9 678 WH 0.8 SP-955Y
JSS ACT NO
SH13: B-3 955X BK 0.8 5 5 955Y BK 0.8
2
A IN
A
2 1 23 AN_39 X-CAB_JSS TO STRG
682A YE 0.8 12 12 682 YE 0.8 955Z BK 0.8 SH24: A-5
JSS ACT NC WHEEL MOTION
8 P1 N1 7 X-CAB_L
954N BK 0.8 X-LFT_2
4 4 X-UCM3B 955AA BK 0.8 SH24: A-6 TO JSS
DEUTSCH_DTM SERIES_4-WAY_RECEP HSG STRG VALVE
3 3
X-SW_JSS X-SW_JSS
981K VT 0.8 2 2 981J VT 0.8 SH27: A-2
16 HSP_LP_04
691A WH 0.8 1 1 691 WH 0.8
JSS INDICATOR
X-CAB_L2
X-UCM4B SH19:A-4
6 5 4 3 2 1
SHT_21 1
48083741_EN 31/07/2018
55.1 [55.100] / 73
Wiring harnesses - Electrical schematic sheet 22 SH22 - UCM-LOADER BOOM CONTROL

ECU A-EH_VLV - ELECTROHY- X-PILOT_ENABLE - PILOT Connector X-BTM X-BTM - BOTTOM TO CAB
DRAULIC VALVE (ECU) ENABLE SOLENOID STD (87704523)
[SH28: A-1] (87695582) Connector X-BTM_EH X-BTM_EH - BOTTOM TO
X-BOOM_RAISE - BOOM CAB EH (84281075)
RAISE SOLENOID Connector X-BTM_F X-BTM_F - BOTTOM TO
[A-EH_VLV] (87695582) FRONT STD (87696087)
X-BOOM_LOWER - BOOM Connector X-BTM_FEH X-BTM_FEH - BOTTOM TO
LOWER SOLENOID FRONT EH (87700160)
[A-EH_VLV] (87695582)
Connector X-BUA X-BUA - BUCKET ANGLE
X-BUCKET_ROLL -
SENSOR [B-BKT_ANG]
BUCKET ROLL SOLENOID
(84403598)
[A-EH_VLV] (87695582)
X-BUCKET_DUMP - Connector X-BUCKET_DUMP X-BUCKET_DUMP -
BUCKET DUMP SOLENOID BUCKET DUMP SOLENOID
[A-EH_VLV] (87695582) [A-EH_VLV] (87695582)
X-AUX_1_LEFT - AUX 1 Connector X-BUCKET_ROLL X-BUCKET_ROLL - BUCKET
LEFT [A-EH_VLV] (87695582) ROLL SOLENOID [A-EH_VLV]
X-AUX_1_RIGHT - AUX (87695582)
1 RIGHT [A-EH_VLV] Connector X-CAB_B X-CAB_B - CAB TO BOTTOM
(87695582) X-AUX_2_LEFT [SH21: B-3] (87696945)
- AUX 2 LEFT [A-EH_VLV] Connector X-CAB_EH X-CAB_EH - CAB TO
(87695582) X-AUX_2_RIGHT BOTTOM EH (87700159)
- AUX 2 RIGHT [A-EH_VLV] Connector X-FAX X-FAX - FRONT AXLE
(87695582) TEMP SENSOR [SH20: A-6]
ECU A-UCM - 47749442 WAS X-UCM3B - UCM [A-UCM] (87711966)
84328725 (ECU) (84130760) X-UCM4B - Connector X-FRNT X-FRNT - FRONT TO
UCM [A-UCM] (82028495) BOTTOM STD (87704426)
X-UCM2B - UCM [A-UCM] Connector X-FRNT_EH X-FRNT_EH - FRONT TO
(82028495) BOTTOM EH (87700170)
Sensor B-BKT_ANG - BUCKET X-BUA - BUCKET ANGLE Connector X-PILOT_ENABLE X-PILOT_ENABLE - PILOT
ANGLE (Sensor) SENSOR [B-BKT_ANG] ENABLE SOLENOID [SH28:
(84403598) A-1] (87695582)
Sensor B-BM_ANG - BOOM ANGLE X-BOA - BOOM ANGLE Connector X-PRB X-PRB - ROLL BACK
(Sensor) SENSOR [B-BM_ANG] PRESSURE SWITCH
(84403598) [SW-PRB] (87692877)
Switch SW-PRB - ROLL BACK PR X-PRB - ROLL BACK Connector X-UCM1A X-UCM1A - UCM (82016219)
SW (Switch) PRESSURE SWITCH
Connector X-UCM1B X-UCM1B - UCM [SH22: A-6]
[SW-PRB] (87692877)
(87410946)
Connector X-AUX_1_LEFT X-AUX_1_LEFT - AUX 1 LEFT
[A-EH_VLV] (87695582)
(82028495)
Connector X-AUX_1_RIGHT X-AUX_1_RIGHT - AUX
1 RIGHT [A-EH_VLV]
(84130760)
(87695582)
Connector X-AUX_2_LEFT X-AUX_2_LEFT - AUX 2 LEFT
[A-EH_VLV] (87695582) Connector X-UCM4B X-UCM4B - UCM [A-UCM]
(82028495)
Connector X-AUX_2_RIGHT X-AUX_2_RIGHT - AUX
2 RIGHT [A-EH_VLV] Connector X-YPE X-YPE - COUPLER VALVE
(87695582) [Y-YPE] (87695582)
Connector X-BOA X-BOA - BOOM ANGLE Connector X-YRC X-YRC - RIDE CONTROL
SENSOR [B-BM_ANG] SOLENOID [Y-YRC]
(84403598) (84607243)
Connector X-BOOM_LOWER X-BOOM_LOWER - BOOM Solenoid Y-YPE - COUPLER VALVE X-YPE - COUPLER VALVE
LOWER SOLENOID SOL. (Solenoid) [Y-YPE] (87695582)
[A-EH_VLV] (87695582) Solenoid Y-YRC - YRC RIDE CONTROL X-YRC - RIDE CONTROL
Connector X-BOOM_RAISE X-BOOM_RAISE - BOOM SOL (Solenoid) SOLENOID [Y-YRC]
RAISE SOLENOID (84607243)
[A-EH_VLV] (87695582)
48083741_EN 31/07/2018
55.1 [55.100] / 74
6 5 4 3 2 1
A-UCM
47749442 WAS 84328725
D D
FRONT CHASSIS
X-BTM_FEH X-CAB_EH
B-BM_ANG
BOOM ANGLE
15 AN_14
R R R R A-EH_VLV
BOOM LIFT PRESSURE
N1 ELECTROHYDRAULIC VALVE
P1 X-CAB_EH X-BTM_FEH
B A 651F BL 0.8
OUT1 19 AN_09
C 647B YE 0.8 S S 647A YE 0.8 S S 647 YE 0.8 HSD_HP_02 18 344 WH 0.8 A A 344A WH 0.8 A A 344B WH 0.8 1
BOOM ANGLE 1 PILOT ENABLE PILOT ENABLE
SH28: A-1 624E BK 0.8 2 SOLENOID PST
P2 N2 X-UCM3B
F E 482X BL 0.8
X-PILOT_ENABLE
OUT2 22 AN_12
D 648B YE 0.8 T T 648A YE 0.8 T T 648 YE 0.8 X-BOOM_RAISE
471G PK 0.8
BOOM ANGLE 2
486K PK 0.8
X-BOA X-BOA X-BTM_EH HSD_PWM_10 1

7 340 WH 0.8 B B 340A WH 0.8 B B 340B WH 0.8 BOOM RAISE
BOOM RAISE D
482U BL 0.8 P P 339C BR 0.8 2 SOLENOID
X-UCM4A
SP-570E
486H PK 0.8 Q Q 482J BL 0.8 SH19: A-6 LSD_HP_01 2 339 BR 0.8 C C 339A BR 0.8 C C 339B BR 0.8 SP-339B
from std frnt BOOM ENABLE
X-FRNT_EH bulkhead X-UCM1B
486E PK 0.8 SH19: A-1 339D BR 0.8 2
SP-486F BOOM LOWER B
HSD_PWM_11 6 341 WH 0.8 D D 341A WH 0.8 D D 341B WH 0.8 1 SOLENOID
BOOM LOWER
SP-471F X-UCM4A X-BOOM_LOWER
SH21: B-4 651L BL 0.8
TO JSS
SH21: B-4 471J PK 0.8 HSD_PWM_16 17 346 WH 0.8 E E 346A WH 0.8 E E 346B WH 0.8 1 BUCKET ROLL
BUCKET ROLL SOLENOID C
347C BR 0.8 2
FRONT_PL23_PILOT X-UCM3B
C SH20: A-6 651N BL 0.8 471E PK 0.8 SH20: C-6
LSD_HP_02 30 347 BR 0.8 F F 347A BR 0.8 F F 347B BR 0.8 SP-347B
X-BUCKET_ROLL C
471H PK 0.8
SH20: A-6 TO BUCKET ENABLE

486L PK 0.8
651G BL 0.8
TO FAX SH20: C-5
BPP X-UCM1B
2
X-FRNT 651B BL 0.8 347D BR 0.8 BUCKET DUMP
HSD_PWM_17 SOLENOID A
25 350 WH 0.8 G G 350A WH 0.8 G G 350B WH 0.8 1
X-BTM X-UCM1B BUCKET DUMP
SP-651A SP-651
1 GND_SIGNAL_1 X-BUCKET_DUMP
B-BKT_ANG 651D BL 0.8 V V 651C BL 0.8 651A BL 0.8 3 3 651J BL 0.8 651 BL 0.8
SP-651D 5V GND2
BUCKET ANGLE X-BTM_F
HSD_PWM_18
SP-471 32 351 WH 0.8 H H 351A WH 0.8 H H 351B WH 0.8 1
3 5VREF2 OUT AUX1 LEFT AUX 1 LEFT SOLENOID E
471F PK 0.8 V V 471D PK 0.8 471C PK 0.8 4 4 471A PK 0.8 471 PK 0.8 X-UCM3B 352C BR 0.8 2
P1 N1 5V REF2
B A 651E BL 0.8 SP-471C
X-CAB_B X-UCM1A LSD_HP_03 X-AUX_1_LEFT
10 352 BR 0.8 J J 352A BR 0.8 J J 352B BR 0.8 SP-352B
OUT1 21 AN_11 AUX1 ENABLE
C 653B YE 0.8 W W 653A YE 0.8 W W 653 YE 0.8 BUCKET ANGLE 1 X-UCM1B
352D BR 0.8 2
P2 N2 HSD_PWM_19 AUX 1 RIGHT SOLENOID F
F E 482W BL 0.8 33 355 WH 0.8 K K 355A WH 0.8 K K 355B WH 0.8 1
AUX1 RIGHT
654B YE 0.8
OUT2 23 AN_13 X-UCM3B X-AUX_1_RIGHT
D X X 654A YE 0.8 X X 654 YE 0.8 BUCKET ANGLE 2
X-BUA
X-FRNT_EH X-BTM_FEH HSD_PWM_08
19 356 WH 0.8 L L 356A WH 0.8 L L 356B WH 0.8 1
X-BTM_EH X-CAB_EH X-UCM1B AUX2 LEFT AUX 2 LEFT SOLENOID G
X-BUA 357C BR 0.8 2
X-UCM4A
LSD_HP_05 X-AUX_2_LEFT
21 357 BR 0.8 M M 357A BR 0.8 M M 357B BR 0.8 SP-357B
AUX2 ENABLE
X-UCM1A
357D BR 0.8 2
HSD_PWM_09 AUX 2 RIGHT SOLENOID H
AUX2 RIGHT 13 360 WH 0.8 N N 360A WH 0.8 N N 360B WH 0.8 1
X-UCM4A X-AUX_2_RIGHT
X-BTM_EH X-FRNT_EH
B B
SW-PRB
ROLL BACK PR SW
P X-FRNT X-BTM
B 2 1 A 24
SH28: A-2 U U 13 13 FIN_DI_09
624F BK 0.8 291B YE 0.8 291A YE 0.8 291 YE 0.8
X-PRB X-PRB
X-BTM_F
X-UCM4B
X-CAB_B
XT MACHINES ONLY
REQUIRED WITH RIDE CONTROL SH28: A-2 624C BK 0.8
Y-YRC
X-FRNT
YRC RIDE CONTROL SOL
X-BTM
MC21 MC21 34 HSD_HP_06 6 OUT
SH24: C-1 CAN_HT YE 0.8
CAN1_HI
366 WH 0.8 5 5 366A WH 0.8 P P 366B WH 0.8 1 IN 2
CAN RIDE CONTROL VALVE
X-YRC X-YRC
25 Y-YPE
SH24: C-1 CAN1 LO COUPLER VALVE SOL.
CAN_LT GN 0.8
CAN
HSD_HP_05 7 IN OUT
X-UCM1B 367 WH 0.8 14 14 367A WH 0.8 R R 367B WH 0.8 1 2
COUPLER VALVE
X-YPE X-YPE
MC20 MC20 1
SH24: B-1 CAN2_HI
CANB_HK WH 0.8 4
CAN LSD_HP_08
COUPLER VALVE RETURN 368 BR 0.8 9 9 368A BR 0.8 S S 368B BR 0.8
10
A SH24: B-1 CANB_LK BL 0.8
CAN2_LO
CAN
X-UCM3B
X-CAB_B
A
X-UCM2B X-BTM_F
SH19:A-4
6 5 4 3 2 1
SHT_22 1
48083741_EN 31/07/2018
55.1 [55.100] / 75
Wiring harnesses - Electrical schematic sheet 23 SH23 - PILOT LOADER CONTROLS

ECU A-UCM - 47749442 WAS X-UCM3B - UCM [A-UCM] Connector X-EM X-EM - ELECTROMAGNETIC
84328725 (ECU) (84130760) X-UCM4B - DETENTS [Y-RTT DET]
UCM [A-UCM] (82028495) (87694112)
X-UCM2B - UCM [A-UCM] Connector X-FRNT X-FRNT - FRONT TO
(82028495) BOTTOM STD (87704426)
Sensor B-PXF - RETURN TO DIG X-PXF - RETURN TO DIG Connector X-HN X-HN - CAN [SW-HORN]
PROX (Sensor) PROX [B-PXF] (87692858) (87311796)
Sensor B-PXH - HEIGHT CONTROL X-PXH - HEIGHT CNTRL Connector X-KDD X-KDD - KICK DOWN SW
PROX (Sensor) PROX [B-PXH] (87644909) (84146428)
Sensor B-PXT - RTD FOR XT (Sensor) X-PXT - RTD XT [B-PXT] Connector X-KDS X-KDS - CAN (87311796)
(87644909) Connector X-PXF X-PXF - RETURN TO DIG
Switch SW-DEV6223 - JOYSTICK PROX [B-PXF] (87692858)
INTERNAL (Switch) Connector X-PXH X-PXH - HEIGHT CNTRL
Switch SW-FNR - JOYSTICK X-P_JS - PILOT LOADER PROX [B-PXH] (87644909)
INTERNAL (Switch) JOYSTICK [SW-FNR] Connector X-PXT X-PXT - RTD XT [B-PXT]
(87694152) (87644909)
Switch SW-HORN - (Switch) X-HN - CAN [SW-HORN] Connector X-P_JS X-P_JS - PILOT LOADER
(87311796) JOYSTICK [SW-FNR]
Switch SW-K/D - JOYSTICK (87694152)
INTERNAL (Switch) Connector X-UCM2B X-UCM2B - UCM [A-UCM]
Switch SW-KD - KICK DOWN SW (82028495)
(Switch) Connector X-UCM3B X-UCM3B - UCM [A-UCM]
Connector X-A_RT3 X-A_RT3 - RIGHT ARM PILOT (84130760)
(87694152) Connector X-UCM4B X-UCM4B - UCM [A-UCM]
Connector X-A_RT_2A X-A_RT_2A - ARM REST (82028495)
RIGHT PILOT 2 (84278761) Connector X-YPP X-YPP - PILOT PRESSURE
Connector X-A_RT_2B X-A_RT_2B - ARM REST SOLENOID [Y-Y_PL]
RIGHT PILOT 2 (84281913) (87692855)
Connector X-A_RT_P X-A_RT_P - ARM REST Solenoid Y-HC DET - (Solenoid)
RIGHT HAND PILOT Solenoid Y-RTD DET - (Solenoid)
(87694112) Solenoid Y-RTT DET - (Solenoid) X-EM - ELECTROMAGNETIC
Connector X-BTM X-BTM - BOTTOM TO CAB DETENTS [Y-RTT DET]
STD (87704523) (87694112)
Connector X-BTM_F X-BTM_F - BOTTOM TO Solenoid Y-Y_PL - PILOT LOCK X-YPP - PILOT PRESSURE
FRONT STD (87696087) (Solenoid) SOLENOID [Y-Y_PL]
Connector X-CAB_B X-CAB_B - CAB TO BOTTOM (87692855)
[SH21: B-3] (87696945)
48083741_EN 31/07/2018
55.1 [55.100] / 76
6 5 4 3 2 1
B-PXT
RTD FOR XT
C PWR GND B
792K OR 0.8 293C BK 0.8
A-UCM
X-PXT
D OUTPUT A
294C YE 0.8 D
X-PXT
B-PXF 47749442 WAS 84328725
RETURN TO DIG PROX X-FRNT

X-BTM
C PWR OUTPUT A 23 FIN_DI_08
792E OR 0.8 294B YE 0.8 B B 29 29
X-PXF
GROUND B
293A BK 0.8
X-PXF
SP-792D
792D OR 0.8 W W 30 30
B-PXH
HEIGHT CONTROL PROX
SP-293
C PWR GND B SH14: A-3
792F OR 0.8 293B BK 0.8 293 BK 0.8
X-PXH
OUTPUT A 3 FIN_DI_07
295B YE 0.8 X X 31 31
X-PXH
C C
X-BTM_F X-CAB_B
PILOT SINGLE AXIS X-UCM4B
1 310A LB 0.8
2 677K PK 0.8 OPTION NOT OFFERED

3 967K BL 0.8
X-A_RT_2B
FNR 4
SIGNAL SP-677H
5 677J PK 0.8 677H PK 0.8 9 9
SP-967H
SW-KD 6 967J BL 0.8 967H BL 0.8 10 10

KICK DOWN SW X-A_RT3
14 AN_42
11 11
IN OUT 1 FNR SIGNAL
2
22 AN_41
311A WH 0.8 12 12
2 FNR SIGNAL
4
X-UCM3B
X-KDD X-KDS
PILOT JOYSTICK
309B YE 0.8
SW-FNR
F 2 23 AN_23
B 306A WH 0.8 3 3
FORWARD B
IN N 3 16 AN_22
307A YE 0.8 4 4
NEUTRAL
R 4 24 AN_21
308A GY 0.8 5 5
REVERSE
X-A_RT_2B Y-RTD DET
3 P N 4
6 6 297A WH 0.8 954V BK 0.8
IN OUT 6 15 AN_24
309A YE 0.8 2 2
KICKDOWN
2 P N 5
7 7 298A WH 0.8 954W BK 0.8
X-P_JS Y-HC DET
SW-K/D
X-A_RT_2A SP-954U
N
1
P
X-P_JS
X-UCM2B 1 6
8 8 299A WH 0.8 954X BK 0.8
X-EM
Y-RTT DET X-EM
8
SH19:A-4
0.
BK
792H OR 0.8
4Y
95
1
792G OR 0.8
PILOT LOCK
SW-HORN TO RH ARM REST CAB_AR A P N B
2 SHEET 24 1 1 344E YE 0.8
1 5
4 2 113E BR 0.8
PIN 5 TO SHT 34 X-YPP Y-Y_PL X-YPP
X-HN
X-HN X-A_RT_2A
A 2
A
X-A_RT_P
954U BK 1.0
SOLID BLUE COMMON TO

JOYSTICK AND SINGLE AXIS
6 5 4 3 2 1
SHT_23 1
48083741_EN 31/07/2018
55.1 [55.100] / 77
Wiring harnesses - Electrical schematic sheet 24 SH24 - CAN STRUCTURE

ECU A-DIA - DIAGNOSTIC PLUG X-DIA - DIAGNOSTIC PORT Connector X-ENG X-ENG - ENGINE TO CAB
(ECU) [A-DIA] (87736919) [SH18: C-6] (87696948)
ECU A-DSP - DISPLAY (ECU) X-DSP - DISPLAY [A-DSP] Connector X-JSS_CAN X-JSS_CAN - CAN
(82016219) (87695580)
ECU A-SFB - SMART FUSE BOX X-X6 - SFB [A-SFB] Connector X-JSS_COM X-JSS_COM - JSS FRAME
(ECU) (47554341) TO CAB CAN (87695723)
ECU A-TERM2 - TERMINATOR X-TERM2 - TERMINATOR Connector X-JSS_FR X-JSS_FR - JSS FRAME
(ECU) CAN [A-TERM2] (87695580) HARNESS TO CAB
ECU A-TERM3 - TERMINATOR X-TERM3 - TERMINATOR (87694152)
(ECU) CAN [A-TERM3] (87695580) Connector X-JSV X-JSV - JOYSTICK
Sensor B-ST_MTN - STEERING X-STW - STEERING STEERING VALVE [SH21:
WHEEL MOTION (Sensor) WHEEL MOTION SENSOR B-2] (87695592)
[B-ST_MTN] (84563557) Connector X-PED X-PED - PEDESTAL TO CAB
Resistor R-022 - TERMINATOR X-TERM - TERMINATOR (87700156)
(Resistor) [R-022] (87695580) Connector X-SFB_XCP X-SFB_XCP - DIAG
Switch SW-PD - SWITCH/KEY PAD X-SW_PD - SWITCH PAD (87696093)
(Switch) [SW-PD] (87694153) Connector X-STLK X-STLK - STALK LEVER RH
Switch SW-RH_JS - RIGH HAND [SW-HN_STLK] (84426133)
JOYSTICK or 3 lever (Switch) Connector X-STW X-STW - STEERING
Switch SW-STALK - STALK SWITCH WHEEL MOTION SENSOR
(Switch) [B-ST_MTN] (84563557)
Connector X-A_RT X-A_RT - ARM REST RIGHT Connector X-SW_PD X-SW_PD - SWITCH PAD
(87694112) [SW-PD] (87694153)
Connector X-CAB_AR X-CAB_AR - CAB TO RH ARM Connector X-TERM X-TERM - TERMINATOR
REST (87694152) [R-022] (87695580)
Connector X-CAB_E X-CAB_E - CAB TO ENGINE Connector X-TERM2 X-TERM2 - TERMINATOR
[SH7: B-5] (84807216) CAN [A-TERM2] (87695580)
Connector X-CAB_JSS X-CAB_JSS - CAB TO JSS Connector X-TERM3 X-TERM3 - TERMINATOR
FRAME HARNESS [SH24: CAN [A-TERM3] (87695580)
A-6] (87694112) Connector X-X7 X-X7 - SFB [SH3: A-3]
Connector X-CAB_P X-CAB_P - CAB TO (84538791)
PEDESTAL [SH20: D-2] Connector X-X_TEL X-X_TEL - TELEMATICS
(87700155) [SH38: C-6] (87700156)
Connector X-DIA X-DIA - DIAGNOSTIC PORT Solenoid Y-JSS_STRG_VLV - X-JSV - JOYSTICK
[A-DIA] (87736919) JOYSTICK STEERING VALVE STEERING VALVE [SH21:
Connector X-DSP X-DSP - DISPLAY [A-DSP] (Solenoid) B-2] (87695592)
(82016219)
48083741_EN 31/07/2018
55.1 [55.100] / 78
6 5 4 3 2 1
SW-PD
SW-STALK SWITCH/KEY PAD

MC34
SH25: C-6
STALK SWITCH
SH10: B-1
TO TRANS
807 OR 0.8 1 1
IGN PWR CONTROLLER
916 BK 0.8 2 2
3
D D
8
GROUND SH25: C-6
MC28
X-STLK
3 3
CAN HI
MC24
955F BK 0.8
SH12: D-5 4 4
CAN LO
X-SW_PD
CAN_HE YE 0.8
19K OR 0.8
CAN_LE GN 0.8
MC36
CAN_HR YE 0.8
SH38: B-6
CAN_HK YE 0.8
TO
CAN_LR GN 0.8
SH28: D-1
TELEMATICS
CAN_LK GN 0.8
SH38: C-6
SH37
CAN_LC GN 0.8
CAN_HC YE 0.8
X-PED
TO
MC34
9 9 19J OR 0.8 SH10: A-1
ECU
R-022 X-ENG
TERMINATOR
SP-HP SP-HL SP-HJ MC30 SP-HF MC32 SP-HD SP-HB SP-HA SH18: C-6
MC22 MC25 MC29 SP-HH MC37 MC38 MC14
MC35
A CAN_HS YE 0.8 CAN_HP YE 0.8 10 10 CAN_HN YE 0.8 CAN_HL YE 0.8 CAN_HJ YE 0.8 CAN_HH YE 0.8 CAN_HF YE 0.8 CAN_HD YE 0.8 CAN_HB YE 0.8 CAN_HA YE 0.8 14 14 CAN_H YE 0.8
SP-LF SP-LD SP-LB
B CAN_LS GN 0.8 CAN_LP GN 0.8 11 11 CAN_LN GN 0.8 CAN_LL GN 0.8 CAN_LJ GN 0.8 CAN_LH GN 0.8 CAN_LF GN 0.8 CAN_LD GN 0.8 CAN_LB GN 0.8 CAN_LA GN 0.8 13 13 CAN_L GN 0.8
SP-LH
MC23 SP-LL MC26 SP-LJ SP-LA SH18: C-6
SP-LP
C CAN_LI GN 0.8
CAN_HM YE 0.8
CAN_HG YE 0.8
CAN_HT YE 0.8
CAN_LG GN 0.8
CAN_H7 YE 0.8
CAN_LM GN 0.8
X-CAB_P X-CAB_E
X-TERM CAN_HI YE 0.8 SH18: C-5
SH7: B-2
CAN_LT GN 0.8
798 RD 0.8 CAN_L7 GN 0.8
C
MC31
945 BK 0.8 SH12: D-3 CANB_HK WH 0.8 SH18: C-5 C
CANB_LK BL 0.8
X-DIA
MC33
MC27
A
B
MC21
X-X7
1
5
1
B
FUSED POWER
D
CAN LO
C
CAN HIGH
A
GROUND
A-DSP SH22: A-6
2 2
DISPLAY
6
13 13
CAN_A_L
CAN_A_H
CAN_A_T
SH7: B-1 805 RD 0.8 CAN CAN CAN SH22: A-6
B+
15
TO
15
SH10: D-1 806 OR 0.8
IGN WAKE
MC20 UCM
CANB_HK WH 0.8 SH22: A-6
11 11 A-SFB
SH12: D-4 871 BK 0.8 A-DIA
SIGNALGRND SMART FUSE BOX
DIAGNOSTIC PLUG
14 14
SH13: B-6 CANB_LK BL 0.8 SH22: A-5
CAN_B_T
CAN_B_H
CAN_B_L
954E BK 0.8
GROUND
CAN LO
CAN HI
X-DSP
CAN 2 LO
CAN 2 HI
ISO K
H
J
CAN CAN CAN
X-DIA
X-X7
5
E
J
F
5
3
2
1
6
X-DSP
CANB_LK BL 0.8
CANB_HK WH 0.8
MC44
MC42
303 WH 0.8
X-SFB_XCP
MC39
CANB_HD WH 0.8
CANB_LF BL 0.8 2
CANB_HB WH 0.8
CANB_LD BL 0.8
CANB_LB BL 0.8 CANB_HF WH 0.8 1
B SH16: C-1
B
MC20
MC39
A-TERM2
TERMINATOR SP-B_HJ
MC40 SP-B_HE MC50
MC41 MC41 MC46
A CANB_HA WH 0.8 CANB_HC WH 0.8 CANB_HE WH 0.8 CANB_HJ WH 0.8
SP-B_HC SP-B_HM
SP-B_LJ
B CANB_LA BL 0.8 CANB_LC BL 0.8 CANB_LE BL 0.8 CANB_LJ BL 0.8
C MC40 SP-B_LC SP-B_LE MC43 MC43 SP-B_LM
X-TERM2 X-A_RT SH34:D-5
MC47
X-JSS_FR
799F OR 0.8 MC47
799A OR 0.8 1 1 799C OR 0.8 SP-799C 3 3 CANB_HI WH 0.8
SW-RH_JS
SH10: B-2 3
799E OR 0.8 8
B-ST_MTN
X-CAB_JSS Y-JSS_STRG_VLV SH21: A-1 955Z BK 0.8 4 4 4 CANB_LI BL 0.8
SH21: A-1 955AA BK 0.8 7 6 854A WH 0.8 SH21: B-2 RIGH HAND JOYSTICK
JOYSTICK STEERING or 3 lever
VALVE STEERING WHEEL 1 1 792 OR 0.8 SH10: B-2
MC61 1 MOTION
MC62 MC68
5
10
2 2 2 954K BK 1.0 SH13: A-6
9 4
CANB_HR WH 0.8
CANB_HT WH 0.8
CANB_LR BL 0.8
X-JSV X-STW X-CAB_AR

X-JSV
CANB_LT BL 0.8
CANB_HW WH 0.8
A A
CANB_LW BL 0.8
MC68
A-TERM3 OPTION
X-JSS_CAN
TERMINATOR
MC60 MC60 SP-B_LS SP-B_LP MC51 MC51 MC50
MC59 SP-B_LV MC67
CANB_LU BL 0.8 CANB_LS BL 0.8 CANB_LV BL 0.8 CANB_LP BL 0.8 B B CANB_LO BL 0.8
B B
SP-B_HS MC67 SP-B_HP

A
A CANB_HU WH 0.8 CANB_HS WH 0.8 CANB_HV WH 0.8 CANB_HP WH 0.8 A A CANB_HO WH 0.8
C MC59 SP-B_HV C C
X-JSS_COM
X-TERM3
6 5 4 3 2 1
SHT_24 1
48083741_EN 31/07/2018
55.1 [55.100] / 79
Wiring harnesses - Electrical schematic sheet 25 SH25 - GEAR CONTROL

UNIT 1
ECU A-108F - ZF DIAGNOSTIC X-ZF_DI - DIAGNOSTIC
CONNECTOR (ECU) [A-108F] (84364851)
ECU A-TRANS - TRANSMISSION X-TECM - TRANS
CONTROL UNIT (ECU) CONTROLLER [SH25: C-6]
(84550089)
ECU A-TRC - TRANS X-TRC - TRANS
CONTROLLER ON TRANNY CONTROLLER ON TRANNY
(ECU) CNH [A-TRC] (47669071)
TRANSMISSION [SH26:
A-2] (87696944)
Connector X-SP_PK_CLN X-SP_PK_CLN - SPLICE
PACK CLEAN GRND [SH25:
C-1] (87352746)
Connector X-TECM X-TECM - TRANS
CONTROLLER [SH25: C-6]
(84550089)
Connector X-TRANS X-TRANS - TRANSMISSION
TO CAB (87696949)
Connector X-TRC X-TRC - TRANS
CONTROLLER ON TRANNY
CNH [A-TRC] (47669071)
Connector X-YLS X-YLS - TRANS LOCKUP
SOLENOID (82012083)
Connector X-ZF_DI X-ZF_DI - DIAGNOSTIC
[A-108F] (84364851)
Solenoid Y-YLS - LOCKUP SOLENOID
(Solenoid)
48083741_EN 31/07/2018
55.1 [55.100] / 80
6 5 4 3 2 1
A-TRANS
TRANSMISSION CONTROL UNIT
SP-165
23 23 1 1
SH7: C-3 165 RD 1.0 165A RD 0.8 856 BK 0.8 SH12: C-5
TECM B+ CLEAN GROUND
68 2
GROUNDS
68 2 SH12: C-4
165B RD 0.8 855 BK 0.8
TECM B+ CLEAN GROUND
D D
Y-YLS
X-TRANS
45 LOCKUP SOLENOID
SH10: C-2 19E OR 0.8 45
TECM IGN PWR 50
50 419 BR 0.8 15 15 419A BR 0.8 1
LOCKUP N P
SP-420C
53
53 420 WH 0.8 420C WH 0.8 25 25 420A WH 0.8 2
PWR VPSL
X-YLS
PLUG_2W_SUPERSEAL 1.5_BK_SLD_FEM TERMS
8 8
X-CAB_TR
420B WH 0.8
PWR_VSP2
946 BK 0.8 SH12: C-6
A-108F
ZF DIAGNOSTIC CONNECTOR
15
15 37D WH 0.8 2 2 3 3
DIAGNOSTIC SIG
18
18 167 SIL 0.8 4 4 1 1
C SH24: D-3
MC34
CAN_LE GN 0.8
MC34 26 26
CAN LO
DIAGNOSTIC SIG C
X-ZF_DI X-ZF_DI
25 25
SH24: D-3 CAN_HE YE 0.8
CAN HI
SH10: C-2 19F OR 0.8
67 67
43 43
64 64
65 65
63 63
A-TRC
TRANS CONTROLLER ON TRANNY
22 22
B B
PL2326 ONLY
X-TRANS
56 1
56 834A TN 0.8 1
834 TN 0.8 16 16
SOL Y1 CLUTCH K4
834B TN 0.8
10 836B TN 0.8 2
10 2
836 TN 0.8 17 17 836A TN 0.8
SOL Y2 CLUTCH KR
32 3
32 3
837 TN 0.8 18 18 837A TN 0.8
SOL Y3 CLUTCH K1
55 4
55 4
838 TN 0.8 19 19 838A TN 0.8
SOL Y4 CLUTCH K3
9 5
9 5
839 TN 0.8 20 20 839A TN 0.8
SOL Y5 CLUTCH KV
6 6
51 51 21 21 840A TN 0.8
SOL Y6 CLUTCH K2
SP-841
7 7
13 13 841 WH 0.8 841A WH 0.8 22 22 841C WH 0.8
SW PWR VPS1
VSP1 PWR
12 12 841B WH 0.8
A VSP1 PWR
A
842 YE 0.8 8 8
39 39 5 5 842A YE 0.8
TEMP SEND VALVE BODY TEMP SIG
9 9
VALVE BODY TEMP RET
X-CAB_TR
X-TRC
X-TECM X-TECM
697D BL 0.8 SH26: C-5
6 5 4 3 2 1
SHT_25 1
48083741_EN 31/07/2018
55.1 [55.100] / 81
Wiring harnesses - Electrical schematic sheet 26 SH26 - GEAR CONTROL

UNIT 2
ECU A-TRANS - TRANSMISSION X-TECM - TRANS
CONTROL UNIT (ECU) CONTROLLER [SH25: C-6]
(84550089)
Sensor B-ES_S - ENGINE SPEED X-ESS - SPEED SENSOR
SENSOR (Sensor) ENGINE [B-ES_S] (84364854)
Sensor B-FM - FILTER X-FM - PRESSURE SWITCH
MAINTENANCE (Sensor) OIL FILTER [B-FM] (82012083)
Sensor B-GOT - GEAR OIL TEMP X-TCOT - GEAR OIL TEMP
(Sensor) [B-GOT] (84364854)
Sensor B-IS_S - INTERMEDIATE X-ISS - SPEED SENSOR
SPEED SENSOR (Sensor) MIDDLE WHEEL CHAIN
[B-IS_S] (84364854)
Sensor B-OSS - OUTPUT SPEED X-OSS - SPEED SENSOR
SENSOR (Sensor) GEAR TRANS [B-OSS]
(84062580)
Sensor B-TS_S - TURBINE SPEED X-TSS - SPEED SENSOR
SENSOR (Sensor) TURBINE [B-TS_S]
(84364854)
TRANSMISSION [SH26:
A-2] (87696944)
Connector X-ESS X-ESS - SPEED SENSOR
ENGINE [B-ES_S] (84364854)
Connector X-FM X-FM - PRESSURE SWITCH
OIL FILTER [B-FM] (82012083)
Connector X-ISS X-ISS - SPEED SENSOR
MIDDLE WHEEL CHAIN
[B-IS_S] (84364854)
Connector X-OSS X-OSS - SPEED SENSOR
GEAR TRANS [B-OSS]
(84062580)
Connector X-TCOT X-TCOT - GEAR OIL TEMP
[B-GOT] (84364854)
Connector X-TECM X-TECM - TRANS
CONTROLLER [SH25: C-6]
(84550089)
TO CAB (87696949)
Connector X-TSS X-TSS - SPEED SENSOR
TURBINE [B-TS_S]
(84364854)
48083741_EN 31/07/2018
55.1 [55.100] / 82
6 5 4 3 2 1
TRANS CAB_T A-TRANS

TRANSMISSION CONTROL UNIT
X-TRANS
423A WH 0.8 31 31 423 WH 0.8 17 17

FILTER MAINTENANCE
B-FM
FILTER MAINTENANCE
D P
D
1 2
1 2
X-FM X-FM
697C BL 0.8
SH25: A-1 697D BL 0.8
B-GOT
GEAR OIL TEMP
SP-697A
1 1 2 2 697B BL 0.8 697A BL 0.8 12 12 697 BL 0.8 46 46
TRANS SIGNL RETURN
X-TCOT X-TCOT
425A WH 0.8 13 13 425 YE 0.8 49 49

TCO TEMP SENDER
C C
B-ES_S
ENGINE SPEED SENSOR
MC52 MC56
MC52 MC56
1 1 699A YE 0.8 7 7 699 YE 0.8 19 19
ENGINE SPEED
2 2 702D BL 0.8 2 2 702E BL 0.8
X-ESS
B-TS_S
TURBINE SPEED SENSOR
MC57
MC53 MC53 MC57
1 1 700A YE 0.8 8 8 700 YE 0.8 41 41
TURBINE SPEED
2 2 702C BL 0.8 14 14 702F BL 0.8
X-TSS
B-IS_S
INTERMEDIATE SPEED SENSOR
MC54 MC58 MC58
MC54
1 1 701A YE 0.8 9 9 701 YE 0.8 42 42
INTERMEDIATE SPEED
2 2 702B BL 0.8 11 11 702A BL 0.8 702 BL 0.8 3 3
SP-702A SPEED SENSOR GRND
X-ISS
B LOCATE SPLICE
NEAR TCU
B
B-OSS
OUTPUT SPEED SENSOR 28 28
PWR GND
3 1 703A BL 0.8 28 28 703 BL 0.8 4 4
OUTPUT SPEED GRND
X-OSS
OUT
2 578 YE 0.8 10 10 578A YE 0.8 62 62
OUTPUT SPEED SIGNAL
X-OSS
19T_H OR 0.8 29 29 19G OR 0.8 SH10: C-2
X-CAB_TR
A A
X-TECM
6 5 4 3 2 1
SHT_26 1
48083741_EN 31/07/2018
55.1 [55.100] / 83
Wiring harnesses - Electrical schematic sheet 27 SH27 - LIGHTING

DOME, MAP LIGHTS
(ECU) (47554341)
Lamp LMP-DM - EGRESS/DOME X-DM_G - DOME LIGHT
LAMP (Lamp) GROUND [LMP-DM]
(87688695) X-DM_P - DOME
LIGHT POSITIVE [LMP-DM]
(84015523)
Lamp LMP-LPL - LICENSE PLATE X-LPL - LICENSE PLATE
LIGHT (Lamp) LIGHT [LMP-LPL] (87692855)
Lamp LMP-MPL - MAP LIGHT X-MAP - MAP LIGHT [SH13:
(Lamp) C-6] (84058093)
Switch SW-DS - DOOR SWITCH X-DS - DOOR SWITCH [SH27:
(Switch) C-6] (87382906)
Connector X-AIR X-AIR - HVAC CONSOLE
[SH27: C-2] (84309048)
[SH7: B-5] (84807216)
Connector X-DM_G X-DM_G - DOME LIGHT
GROUND [LMP-DM]
(87688695)
Connector X-DM_P X-DM_P - DOME LIGHT
POSITIVE [LMP-DM]
(84015523)
Connector X-DS X-DS - DOOR SWITCH [SH27:
C-6] (87382906)
[SH18: C-6] (87696948)
Connector X-ENG_H X-ENG_H - ENGINE TO
HOOD (87700321)
Connector X-E_HD X-E_HD - ENGINE TO HOOD
EURO [SH29: B-1] (87692858)
Connector X-HD_E X-HD_E - HOOD EURO TO
EURO ENG HARN (87644909)
Connector X-HD_N X-HD_N - HOOD TO ENG
(87700325)
Connector X-LPL X-LPL - LICENSE PLATE
LIGHT [LMP-LPL] (87692855)
Connector X-MAP X-MAP - MAP LIGHT [SH13:
C-6] (84058093)
(47554344)
(47554342)
Connector X-X6 X-X6 - SFB [A-SFB]
(47554341)
(84538791)
48083741_EN 31/07/2018
55.1 [55.100] / 84
6 5 4 3 2 1
D D
A-SFB
SMART FUSE BOX
LMP-MPL
MAP LIGHT
OUT_05_H 18 P N
MAP LIGHT 147 VT 0.8 A C 955Q BK 0.8 SH13: C-6
X-X3
X-MAP X-MAP
SW-DS
DOOR SWITCH
IN OUT 80
IN_DIG_09_L_WU LMP-DM
SH13: C-5 955P BK 0.8 2 1 151 YE 0.8
LH Door Ajar Switch EGRESS/DOME LAMP
C X-DS X-DS X-X7
OUT_02_H_PWM
X-X6
17 1 P1
C
EGRESS/DOME LIGHT 148 VT 0.8 N
OUT_47_H_CS_L 12 1 955N BK 0.8 SH13: C-4
2 P2
DOME LAMP 149 OR 0.8
15 W X-DM_G
X-X5 X-DM_P
OUT_05_H_PWM 8
285 VT 0.8 SH33: D-3
Console Panel Illumination
X-X6
LMP-LPL
LICENSE PLATE LIGHT
X-ENG X-ENG_H
OUT_50_H_CS 17 P N
280 VT 0.8 25 25 280A VT 0.8 8 8 280B VT 0.8 A B
License Plate Light
X-X3 X-CAB_E SH29:B-3 X-HD_N X-LPL X-LPL
280C VT 0.8 280T VT 0.8
X-E_HD
ENG_EURO_PL10-20 ENG_EURO_PL10-20
242D BK 0.8
A A 280D VT 0.8
SH29: B-1 242T BK 0.8
C C 243D BK 0.8
B B ENG_EURO_PL10-20
X-HD_E
243C BK 0.8 SH29: C-1
ENG_EURO_PL10-20
B SP-981
B
SH29: B-1
OUT_01_H_PWM 2
981 VT 0.8 981E VT 0.8 SH36: C-6
Switch Back Lighting
X-X4
981D VT 0.8 SH32: C-5
981F VT 0.8 SH34: A-6
981G VT 0.8 SH36: C-6
COLOR:
GREEN NA PL10-26 ENGINE HARNESS 981J VT 0.8 SH21: A-4

A 3399FF
A
NA PL10-26 HOOD HARNESS
33CC00 EURO PL10-20 ENGINE HARNESS
BROWN EURO PL23-26 LIGHT/HOOD HARNESS
006600
PL23-26 ENGINE HARNESS
3399FF PL23-26 NA HOOD HARNESS
6 5 4 3 2 1
SHT_27 1
48083741_EN 31/07/2018
55.1 [55.100] / 85

HAZARD WARNING, BLINKERS, DRIVING
(ECU) (47554341)
Lamp LMP-LF_LT - LH FRONT X-LLF - FRONT COMBO
COMBO LIGHT (Lamp) LAMP LEFT [LMP-LF_LT]
(87694109)
Lamp LMP-RF_LT - RH FRONT X-LRF - FRONT COMBO
COMBO LIGHT (Lamp) LAMP RT [LMP-RF_LT]
(87694109)
Lamp LMP-TTI - TELL TALE X-TT - TELL TALE INDICATOR
INDICATOR (Lamp) [LMP-TTI] (87715979)
Switch SW-HZD_SW - HAZARD X-S_HZD - SWITCH HAZARD
SWITCH (Switch) [SW-HZD_SW] (87716755)
STD (87704523)
Connector X-BTM_F X-BTM_F - BOTTOM TO
FRONT STD (87696087)
[SH21: B-3] (87696945)
Connector X-CAB_P X-CAB_P - CAB TO
PEDESTAL [SH20: D-2]
(87700155)
Connector X-FRNT X-FRNT - FRONT TO
BOTTOM STD (87704426)
Connector X-LLF X-LLF - FRONT COMBO
LAMP LEFT [LMP-LF_LT]
(87694109)
Connector X-LRF X-LRF - FRONT COMBO
LAMP RT [LMP-RF_LT]
(87694109)
Connector X-PED X-PED - PEDESTAL TO CAB
(87700156)
Connector X-PG X-PG - PEDESTAL GROUND
[SH28: B-6] (87705607)
Connector X-SRWP X-SRWP - SWITCH REAR
WIPER [SW-WPR_SW]
(87716755)
Connector X-S_HZD X-S_HZD - SWITCH HAZARD
[SW-HZD_SW] (87716755)
Connector X-TT X-TT - TELL TALE INDICATOR
[LMP-TTI] (87715979)
(47554344)
(47554342)
(47554341)
(84538791)
48083741_EN 31/07/2018
55.1 [55.100] / 86
6 5 4 3 2 1
LMP-TTI
TELL TALE INDICATOR A 955T BK 0.8
X-CAB_P X-PED
B 955H BK 0.8 SH28: B-5
LEFT
188 VT 0.8 1 1 188A VT 0.8 2
C 955G BK 0.8 SH32: B-5
D 955F BK 0.8 SH24: D-6

RIGHT
2 2 189A VT 0.8 5
A-SFB E 955E BK 0.8 SH28: C-5
GND
D SMART FUSE BOX 1
SH32: B-5
D
WARNING F 955D BK 0.8
SH20: D-2 134 YE 0.8 5 5 134A YE 0.8 4 X-TT
G 955W BK 0.8 SH32: B-6
OUT_08_H
29 IN_DIG_05_L_WU 9 HIGH H 955U BK 1.0 SH14: B-6
DRIVING LIGHTS LOW BEAM LH TURN TELTALE
132C VT 0.8 3 3 132G VT 0.8 3
X-X7
78 IN_DIG_20_L K 955C BK 0.8 SH28: B-6
DRIVING LIGHTS HIGH BEAM
CAN INPUT
OUT_04_H X-TT
77 IN_DIG_21_L 16 189 VT 0.8 L 955M BK 0.8 SH32: B-6
DRIVING LIGHTS FLASH TO PASS RH TURN TELTALE
J
X-X5 PEDESTAL X-PG
954D BK 1.0 7 7 955B BK 1.0 LMP-LF_LT
LH FRONT COMBO LIGHT
SH13: B-5 X-BTM X-FRNT
OUT_09_H_CS 133B VT 0.8 LOW

21 133 VT 0.8 22 22 133A VT 0.8 F F 2
LH LOW BEAM LAMP
X-X5
27 IN_DIG_07_L_WU SP-132
POSITION TAIL LIGHTS SWITCH OUT_06_H_CS HIGH
4 132 VT 0.8 132A VT 0.8 20 20 132D VT 0.8 C C 132E VT 0.8 3
CAN INPUT LH HIGH BEAM LAMP
X-X4 GND
1
76 IN_DIG_22_L SP-127
LH TURN SWITCH OUT_16_H_CS POSTN X-LLF
6 127 VT 0.8 127A VT 0.8 23 23 127B VT 0.8 H H 127C VT 0.8 4
IN_DIG_23_L LH POSITION/TAIL
75
RH TURN SWITCH X-X6
C OUT_10_H_CS
LH FRONT TURN
12 136 VT 0.8 24 24 136B VT 0.8 J J 136C VT 0.8 5
TURN
C
X-LLF
X-X4
LMP-RF_LT
X-PED X-CAB_P RH FRONT COMBO LIGHT
SW-HZD_SW
HAZARD SWITCH LOW
OUT_04_H_CS 13 26
138 VT 0.8 26 138A VT 0.8 L L 138B VT 0.8 2
RH LOW BEAM LAMP
P1 N1
8 7 955E BK 0.8 SH28: D-1
X-X5
OUT1 IN_DIG_06_L_WU HIGH
OUT_02_H_CS 10 137B VT 0.8
3 141A YE 0.8 6 6 141 YE 0.8 28 137 VT 0.8 25 25 137A VT 0.8 K K 3
HAZARD SWITCH RH HIGH BEAM LAMP X-LRF
IN GND
2 X-X4 1
SP-130
OUT2 POSTN
OUT_17_H_CS 3 130 VT 0.8 130D VT 0.8 27 27 130E VT 0.8 M M 130F VT 0.8 4
X-X7 RH POSITION/TAIL
P2 N2
10 9 955H BK 0.8 SH28: D-1 X-X6
CAB BOTTOM FRONT_STD
981B VT 0.8
CAB HARNESS TURN

X-S_HZD X-S_HZD OUT_13_H_CS 15 135 VT 0.8 28 28 135D VT 0.8 N N 135E VT 0.8 5
RH FRONT TURN
X-X5 X-LRF
X-BTM_F
X-CAB_B
130A VT 0.8
OUT_01_H_CS_L
269 BK 0.8 8 8 269A BK 0.8 16
HAZARD INDICATOR
X-X3
B 955C BK 0.8 SH28: D-1

127D VT 0.8 SH29: C-5
B
TO TAIL
SH32: C-6 SH29: B-5 LIGHTS
TO BACKLIGHTING
624A BK 1.0
SP-624D
SH14: A-3 624D BK 2.0 624 BK 1.0
SH22: A-1 624C BK 0.8 624E BK 0.8 SH22: D-2
624B BK 0.8 SH34: D-2

SH22: B-6 624F BK 0.8
A A
NOTE:
MARKER LIGHTS = POSITION LIGHTS.
6 5 4 3 2 1
SHT_28 1
48083741_EN 31/07/2018
55.1 [55.100] / 87
Wiring harnesses - Electrical schematic sheet 29 SH29 - LIGHTING REAR

TAILS
(ECU) (47554341)
Load L-NA-TAIL - LH REAR TAIL LT X-LH-TAIL - LH REAR
NA (Load) TAIL LIGHT NA [L-NA-TAIL]
(87694101)
Lamp LMP-R-NA-TAIL - RH REAR X-RH-TAIL - RH REAR TAIL
TAIL LT NA (Lamp) [LMP-R-NA-TAIL] (87694101)
[SH7: B-5] (84807216)
[SH18: C-6] (87696948)
HOOD (87700321)
ENG BLOCK [SH29: B-3]
(84140737)
(87700325)
Connector X-LH-TAIL X-LH-TAIL - LH REAR
TAIL LIGHT NA [L-NA-TAIL]
(87694101)
Connector X-RH-TAIL X-RH-TAIL - RH REAR TAIL
[LMP-R-NA-TAIL] (87694101)
(47554344)
(47554342)
(47554341)
48083741_EN 31/07/2018
55.1 [55.100] / 88
6 5 4 3 2 1
D D
A-SFB
SMART FUSE BOX
ENG_EURO_PL10-20 FROM PL10-20 LPL

X-ENG L-NA-TAIL
126E VT 0.8 LH REAR TAIL LT NA
X-ENG_H PL10-PL26 243C BK 0.8 SH27: B-2
ENG_NA HOOD_NA 2
OUT_19_H_CS
2
126A VT 0.8
STOP ENG_EURO_PL10-20
126 VT 0.8 10 10 2 2 126B VT 0.8 SP-243
LH Brake 243A BK 0.8 243 BK 0.8
C X-X6 ENG_EURO_PL10-20 C
127J VT 0.8 3
ENG_EURO_PL10-20
TAIL GND
SH28: B-3 127D VT 0.8 12 12 127E VT 0.8 6 6 127F VT 0.8 1 SH15: B-2
ENG_EURO_PL10-20 X-LH-TAIL
18
128E VT 0.8 4 TURN
OUT_12_H_CS 128 VT 0.8 22 22 128A VT 0.8 3 3 128B VT 0.8
LH Rear Turn Lamp
X-X5
242C BK 1.0
X-LH-TAIL
LMP-R-NA-TAIL
RH REAR TAIL LT NA
ENG_EURO_PL10-20
129E VT 0.8 2
12 STOP
OUT_20_H_CS 129A VT 0.8 7 7 129B VT 0.8
RH Brake
129 VT 0.8 21 21 ENG_EURO_PL10-20
X-X3 ENG_EURO_PL10-20 243B BK 0.8
130J VT 0.8 3 TAIL GND HOOD_PL23
SH28: B-3 130A VT 0.8 11 11 130B VT 0.8 5 5 130C VT 0.8 1 242B BK 1.0 242F BK 0.8 SH36: C-1
SP-242A
ENG_EURO_PL10-20 X-RH-TAIL FROM PL2326 BU

131F VT 0.8 4 HOOD_NA
9 TURN
OUT_11_H_CS 131 VT 0.8 6 6 131A VT 0.8 4 4 131B VT 0.8 242D BK 0.8 SH27: B-1
RH Rear Turn Lamp
X-X4 X-RH-TAIL
FROM PL2326 LPL
X-CAB_E HOOD_NA
B 1 1 242A BK 1.0
242T BK 0.8 SH27: B-3
B
X-HD_N
TRKY
SH30:B-3, SH27:B-2
242 BK 1.0 SH15: B-3
COLOR:
GREEN NA PL10-26 ENGINE HARNESS

A 3399FF
A
33CC00
EURO PL10-20 ENGINE HARNESS
BROWN EURO PL23-26 LIGHTHOOD HARNESS
006600 PL23-26 ENGINE HARNESS
3399FF
PL23-26 NA HOOD HARNESS
6 5 4 3 2 1
SHT_29 1
48083741_EN 31/07/2018
55.1 [55.100] / 89
Wiring harnesses - Electrical schematic sheet 30 SH30 - OLD EURO

LIGHTING
Lamp LMP-L-EURO-TAIL - LH X-LH-REAR-TAIL-EURO
REAR TAIL LT EURO (Lamp) - LH REAR TAIL LIGHT
EURO [LMP-L-EURO-TAIL]
(87694112)
Lamp LMP-R-EURO-TAIL - RH X-RH-REAR-TAIL-EURO
REAR TAIL LT EURO (Lamp) - RH-REAR-TAIL-EURO
[LMP-R-EURO-TAIL]
(87694112)
[SH7: B-5] (84807216)
Connector X-EHD_23 X-EHD_23 - ENG TO PL23
HOOD (87694154)
[SH18: C-6] (87696948)
HOOD (87700321)
Connector X-HD_23 X-HD_23 - HOOD PL23
(87694153)
(87700325)
Connector X-LH-REAR-TAIL-EURO X-LH-REAR-TAIL-EURO
- LH REAR TAIL LIGHT
(87694112)
Connector X-RH-REAR-TAIL-EURO X-RH-REAR-TAIL-EURO
- RH-REAR-TAIL-EURO
[LMP-R-EURO-TAIL]
(87694112)
48083741_EN 31/07/2018
55.1 [55.100] / 90
6 5 4 3 2 1
LMP-L-EURO-TAIL
LH REAR TAIL LT EURO
1 STOP
126D VT 0.8
D 2 TURN
X-LH-REAR-TAIL-EURO D
GND
128D VT 0.8 5
3 TAIL
127H VT 0.8
4 REVERSE
X-LH-REAR-TAIL-EURO
EURO
PL23-PL26
SH29:B-3
X-ENG X-ENG_H
10 10 2 2
242L BK 0.8
C C
12 12 6 6
22 22 3 3
124K VT 0.8
CONTINUES ON CONTINUES ON 242M BK 0.8
PREVIOUS SHT PREVIOUS SHT
NO LONGER 21 21
11 11
7
5
7
5
SP-242H
B
USED. 6
X-CAB_E
6 4
1
4
242H BK 0.8
242J BK 0.8
B
X-HD_N
242K BK 0.8
X-EHD_23
2 2 124H VT 0.8
SP-124H
X-HD_23
SH36:C-2
LMP-R-EURO-TAIL
RH REAR TAIL LT EURO
129D VT 0.8
STOP
1
131E VT 0.8
TURN
2
GND
130H VT 0.8 5
TAIL X-RH-REAR-TAIL-EURO
3
124J VT 0.8
A 4
REVERSE
A
X-RH-REAR-TAIL-EURO
COLOR:
GREEN
NA PL10-26 ENGINE HARNESS
3399FF EURO PL10-20 ENGINE HARNESS
33CC00 EURO PL23-26 LIGHTHOOD HARNESS
TURKEY TO FOLLOW EU,
BROWN PL23-26 ENGINE HARNESS BUT WITH T3 ENGINE
006600
PL23-26 NA HOOD HARNESS
3399FF
6 5 4 3 2 1
SHT_30 1
48083741_EN 31/07/2018
55.1 [55.100] / 91

WORKING LIGHTS CAB ROOF, FRONT AND REAR
(ECU) (47554341)
Ground GND-029 - (Ground) GND-029
Lamp LMP-LF0 - LEFT FRONT OPTX-LF2 - WORK LIGHT OPT
WL (Lamp) [LMP-LF0] (87695582)
Lamp LMP-LF_WL - LEFT FRONT X-LFWL - LEFT FRONT
WORK LIGHT (Lamp) WORK LIGHT [LMP-LF_WL]
(87695582)
Lamp LMP-LR_WL - LEFT REAR X-LRWL - LEFT REAR
WORK LIGHT (Lamp) WORK LIGHT [LMP-LR_WL]
(87695582)
Lamp LMP-RFO - RIGHT FRONT X-RF2 - WORK LIGHT
OPT WL (Lamp) OPTION [LMP-RFO]
(87695582)
Lamp LMP-RF_WL - RIGHT FRONT X-RFWL - RIGHT FRONT
WORK LIGHT (Lamp) WORK LIGHT [LMP-RF_WL]
(87695582)
Lamp LMP-RR_WL - RIGHT REAR X-RRWL - RIGHT REAR
WORK LIGHT (Lamp) WORK LIGHT [LMP-RR_WL]
(87695582)
Connector X-CAB_R X-CAB_R - CAB TO ROOF
(87695891)
Connector X-LF2 X-LF2 - WORK LIGHT OPT
[LMP-LF0] (87695582)
Connector X-LFO X-LFO - WORK LIGHT
OPTION (87695584)
Connector X-LFWL X-LFWL - LEFT FRONT
WORK LIGHT [LMP-LF_WL]
(87695582)
Connector X-LRWL X-LRWL - LEFT REAR
WORK LIGHT [LMP-LR_WL]
(87695582)
Connector X-RF2 X-RF2 - WORK LIGHT
OPTION [LMP-RFO]
(87695582)
Connector X-RFO X-RFO - WORK LIGHT
OPTION (87695584)
Connector X-RFWL X-RFWL - RIGHT FRONT
WORK LIGHT [LMP-RF_WL]
(87695582)
Connector X-ROOF X-ROOF - ROOF TO CAB
(87700325)
Connector X-RRWL X-RRWL - RIGHT REAR
WORK LIGHT [LMP-RR_WL]
(87695582)
(47554344)
(84538791)
48083741_EN 31/07/2018
55.1 [55.100] / 92
6 5 4 3 2 1
A-SFB
D SMART FUSE BOX X-ROOF LMP-LF_WL D

LEFT FRONT WORK LIGHT
2 1 P N 2
OUT_26_H_CS
111 VT 1.0 1 1 111A VT 1.0 949C BK 1.0
LEFT FRONT WORK LIGHT
111D VT 1.0 X-LFWL X-LFWL 949F BK 1.0
1 1 2 2
OUT_27_H_CS 4 X-LFWL
X-LFWL X-LFO X-LFO
SP-6111D SP-949F
WORK LAMPS #2
111C VT 1.0 949E BK 1.0
LMP-LF0
LEFT FRONT OPT WL OPTIONAL
IN_DIG_25_L
73
WORK LAMPS SWITCH #1 1 P N 2
WORK LIGHT
111B VT 1.0 949D BK 1.0
X-LF2 X-LF2
IN_DIG_26_L LMP-RF_WL
72
WORK LAMPS SWITCH #2 RIGHT FRONT WORK LIGHT
1 P N 2
OUT_28_H_CS 1
724 VT 1.0 2 2 724A VT 1.0 949B BK 1.0
RIGHT FRONT WORK LIGHT
SWITCH PAD
111G VT 1.0 X-RFWL X-RFWL 949J BK 1.0
CAN
1 2
C 71
IN_DIG_27_L SP-111G X-RFO X-RFO
SP-949J C
WORK LAMPS SWITCH #4 111E VT 1.0 949G BK 1.0
LMP-RFO
RIGHT FRONT OPT WL
X-X3
OPTIONAL
P N 2
1 WORK LIGHT
66 IN_DIG_28_L 111F VT 1.0 949H BK 1.0
WORK LAMPS SWITCH #5
X-RF2 X-RF2 SP-949A
X-X7
SH13: C-4 949 BK 2.0 6 6 949A BK 2.0
SP-953A
SH13: B-5 953 BK 2.0 7 7 953A BK 2.0
SH34: C-1 953B BK 0.8
SH34: A-1 953C BK 1.0
SH34: A-1 953D BK 1.0
LMP-LR_WL
LEFT REAR WORK LIGHT
SP-859A
19 P N
OUT_29_H_CS 1 2
859 VT 1.0 5 5 859A VT 1.0 859B VT 0.8 953E BK 1.0
REAR WORK LIGHTS
B X-LRWL X-LRWL
B
X-X4 X-CAB_R
LMP-RR_WL
RIGHT REAR WORK LIGHT
P N
859C VT 0.8 1 2 953F BK 1.0
X-RRWL X-RRWL
A A
6 5 4 3 2 1
SHT_31 1
48083741_EN 31/07/2018
55.1 [55.100] / 93
Wiring harnesses - Electrical schematic sheet 32 SH32 - CAB WIPER

/ WASHER
(ECU) (47554341)
Motor M-FW_M - FRONT WASHER X-FWW - FRONT WASHER
MOTOR (Motor) MOTOR [M-FW_M]
(84015523)
Motor M-RW_M - REAR WASHER X-RWW - REAR WASHER
MOTOR (Motor) MOTOR [M-RW_M]
(84015523)
Motor M-R_WPR_M - REAR WIPER X-RWM - REAR WIPER
MOTOR (Motor) MOTOR [M-R_WPR_M]
(87692862) X-RWM_G -
REAR WIPER MOTOR GRND
[SH13: C-2] (87693744)
Switch SW-WPR_SW - REAR WIPER X-SRWP - SWITCH REAR
SWITCH (Switch) WIPER [SW-WPR_SW]
(87716755)
Connector X-CAB_P2 X-CAB_P2 - CAB TO
PEDESTAL 2 [SH27: B-2]
(87705101)
TRANSMISSION [SH26:
A-2] (87696944)
Connector X-FWM X-FWM - FRONT WIPER
MOTOR (87692862)
Connector X-FWM_G X-FWM_G - FRONT WIPER
GROUND [SH14: D-5]
(87693744)
Connector X-FWW X-FWW - FRONT WASHER
MOTOR [M-FW_M]
(84015523)
Connector X-PED_2 X-PED_2 - PEDESTAL TO
CAB 2 (87705114)
Connector X-PG X-PG - PEDESTAL GROUND
[SH28: B-6] (87705607)
Connector X-RWM X-RWM - REAR WIPER
MOTOR [M-R_WPR_M]
(87692862)
Connector X-RWM_G X-RWM_G - REAR WIPER
MOTOR GRND [SH13: C-2]
(87693744)
Connector X-RWW X-RWW - REAR WASHER
MOTOR [M-RW_M]
(84015523)
Connector X-SRWP X-SRWP - SWITCH REAR
WIPER [SW-WPR_SW]
(87716755)
TO CAB (87696949)
(47554341)
(84538791)
48083741_EN 31/07/2018
55.1 [55.100] / 94
6 5 4 3 2 1
A-SFB
SMART FUSE BOX
OUT_01_WIPER 6 100 TN 2.0 F_WPR_M

FRONT WIPER MOTOR HIGH
FRONT WIPER MOTOR
X-X4
A 53b (HIGH)
D D
B 53 (LOW)
OUT_02_WIPER 10 101 TN 1.0
FRONT WIPER MOTOR LOW
D 31b
IN_DIG_02_L X-X6
58 FRONT WASHER SWITCH
M
CAN INPUT C PARK
IN_DIG_01_L 53a
59 102 TN 0.8
FRONT WIPER MOTOR PARK
31 (GND) A
X-X7 X-FWM
103 BK 2.0 SH14: D-5
IN_ANA_01
19 FRONT WIPER LOW SWITCH M-FW_M
FRONT WASHER MOTOR X-FWM_G
X-X7 X-TRANS
1 2
OUT_01_H_CS_M 6 6 A M B SH20: B-1
16 104A TN 0.8 391F BK 0.8
FRONT WASHER MOTOR
X-FWW X-FWW
M-RW_M
REAR WASHER MOTOR
1 2
OUT_03_H_CS_M 9 4 4 M SH20: B-1
106 OR 0.8 106A OR 0.8 A B 391E BK 0.8
REAR WASHER MOTOR
X-CAB_TR X-RWW X-RWW

OUT_03_WIPER 12 108 TN 1.0
REAR WIPER MOTOR LOW
X-X6
M-R_WPR_M
SH27: B-2 IN_DIG_03_L 57
981D VT 0.8 109 TN 0.8
C REAR WIPER MOTOR PARK
B 53 (MOTOR +)
REAR WIPER MOTOR
C
X-X7
D 31b
M
C PARK
53a
SH28: B-6 981B VT 0.8 X-PED_2
31 (GND) A
SP-981A X-RWM
955V BK 1.0 SH13: C-2
981C VT 0.8 981A VT 0.8 12 12
X-RWM_G
SW-WPR_SW
REAR WIPER SWITCH
P N
8 7 955D BK 0.8 SH28: D-1
IN1
SH28: D-1 955W BK 0.8 5
2A 55 IN_DIG_05_L
6 727A YE 0.8 9 9 727 YE 0.8 REAR WASHER SWITCH
IN2
SH28: D-1 955M BK 0.8 2
B 2B
3 728A YE 0.8 8 8 728 YE 0.8
56 IN_DIG_04_L
REAR WIPER SWITCH
B
P1 N1 X-X7
10 9 955G BK 0.8 SH28: D-1
X-SRWP X-SRWP
3 OUT_49_H_CS
283A VT 0.8 11 11 283 VT 0.8 WIPER INDICATOR
X-X4
X-CAB_P2
5
SH14: D-4 WIPER_GND
279 BK 2.0
WIPER GROUND
X-X6
A A
6 5 4 3 2 1
SHT_32 1
48083741_EN 31/07/2018
55.1 [55.100] / 95
Wiring harnesses - Electrical schematic sheet 33 SH33 - HEATING BLOWER HEATER, HVAC
ECU A-AC CONTROL PANEL - Connector X-07 X-07 - DENSO (87692855)
DENSO (ECU) Connector X-08 X-08 - DENSO
ECU A-DRIVER 24V - DENSO Connector X-10A X-10A - DENSO
(ECU) Connector X-10B X-10B - DENSO
ECU A-HVAC - DENSO (ECU) Connector X-11A X-11A - DENSO
ECU A-LIGHT HOLDER 2 - DENSO Connector X-11B X-11B - DENSO
(ECU) Connector X-12 X-12 - DENSO (41200689)
ECU A-LIGHT HOLDER1 - DENSO Connector X-ACT X-ACT - AC CLUTCH
(ECU) (87687239)
ECU A-SFB - SMART FUSE BOX X-X6 - SFB [A-SFB] Connector X-ACT_10 X-ACT_10 - AIR
(ECU) (47554341) COMPRESSOR CLUTCH
Sensor B-NTC SENSOR - DENSO PL10 (87693744)
(Sensor) Connector X-AIR X-AIR - HVAC CONSOLE
Ground GND-001 - (Ground) GND-001 [SH27: C-2] (84309048)
Motor M-BLOWER 24V - DENSO Connector X-CAB_E-2 X-CAB_E-2 - CAB TO ENG 2
(Motor) [SH9: C-2] (87703902)
Motor M-STEPPER MOTOR 24V - Connector X-ENG-2 X-ENG-2 - ENGINE TO CAB 2
DENSO (Motor) (87703931)
Resistor R-CERAMIC RESISTOR 24V Connector X-HVAC X-HVAC - INTRCECT TO
- DENSO (Resistor) HVAC SYSTEM BY HVAC
Switch SW-AC SWITCH - DENSO [SH33: D-4] (87696573)
(Switch) Connector X-HVAC2 X-HVAC2 - HVAC MECHINISM
Switch SW-LOW PRESSURE (87696550)
SWITCH N.C. - DENSO Connector X-J1333 X-J1333 - DENSO
(Switch) Connector X-J1338 X-J1338 - DENSO
Switch SW-POTENTIOMETER FOR Connector X-LC6 X-LC6 - LOADCENTER 6
MIX - DENSO (Switch) [SH16: A-3] (84380518)
Switch SW-PR_H2 - AC HIGH PRESS X-PRH2 - HIGH PRESSURE Connector X-PRH2 X-PRH2 - HIGH PRESSURE
SW (Switch) SWITCH 2 [SH33: C-6] SWITCH 2 [SH33: C-6]
(87688788) (87688788)
Switch SW-ROTARY FOR BLOWER Connector X-X5 X-X5 - SFB [SH3: D-3]
- DENSO (Switch) (47554342)
Connector X-01 X-01 - DENSO Connector X-X7 X-X7 - SFB [SH3: A-3]
Connector X-02 X-02 - DENSO (84538791)
Connector X-04 X-04 - DENSO Solenoid Y-ACT - AC COMPRESSOR
Connector X-05 X-05 - DENSO CLUTCH (Solenoid)
Connector X-06 X-06 - DENSO
48083741_EN 31/07/2018
55.1 [55.100] / 96
6 5 4 3 2 1
A-AC CONTROL PANEL
YERD
1 1 258A YE 0.8 1 1
WHBK
2 2 262C WH 0.8 2 2
BKPRP
260A PRP 0.8 3 3
3 3
4 4
TO BACK
LIGHTING SW-POTENTIOMETER FOR MIX
X-10B
SH27: C-2 285 VT 0.8

X-11A DENSO
D 285A VT 0.8 1
D
4 4 1
2 A-LIGHT HOLDER1
GND5490 SH12: D-2 256 BK 0.8 256A BK 0.8 5 5 256D BK 0.8 2
SP-256
ACC PWR SH9: B-1 876 OR 3.0 X-08

YEGN 10B-1
873D OR 0.8 6
6 873E YE 0.8 1
7 10B-2
258D YE 0.8 258C YE 0.8 7 261A GY 0.8 2
GYRD 10B-3 SW-AC SWITCH
SP-258 3
A-SFB A/C
10B-4
SMART FUSE BOX
1 SP-873 OPTION
36 OUT_48_H_CS_L
IN_ANA_12
260 VT 0.8
873 OR 0.8
261 WH 0.8
A/C ON INPUT HVAC MOD PWR
262 YE 0.8
X-X7 X-X5
X-11B
256C BK 0.8
256J BK 0.8
258 YE 0.8
256E BK 0.8 1 1
A-LIGHT HOLDER 2
285B VT 0.8 2 2
873A OR 0.8
873B OR 0.8
SW-PR_H2 SH13: B-6
AC HIGH PRESS SW 10A-5
X-ENG-2 903A BK 2.5 1
903 BK 2.5 8 8
9 9 264A GY 1.0 2
10A-1 1 5
264 GY 1.0
10A-2 2
B P 265 GN 2.0 1010 265A GN 2.0 3
C SH11: A-6 211B YE 1.0
OUT IN A
246C YE 1.0 L L 246 YE 0.8 266 YE 2.0 1111 266A YE 2.0 4
10A-3
10A-4
3
4
SW-ROTARY FOR BLOWER
C
X-HVAC
267 WH 2.5 1212 267A GY 2.5 5
X-PRH2 X-PRH2
AC CLTCH RLY X-CAB_E-2 X-10A
D D
A A
S S
H H
N
J J
G G
K K
B B
C C
E E
R R
X-AIR
F F
X-12
M
N
P
L
X-HVAC2
267B GY 2.5
A-HVAC
264B GY 1.0
X-05
SP-267 5 R-CERAMIC RESISTOR 24V

267C GY 2.5 4 4 R3
266B YE 2.0 3 3 R2
265B GN 2.0 2 2 R1
264C GY 1.0 1 1
SP-264B
-
1 2
SH11: A-2 187 YE 1.0 Y-ACT 267D GY 2.5 2 2
M M-BLOWER 24V
AC COMPRESSOR CLUTCH 876H OR 3.0 1 1
X-ACT 1
X-06 +
X-J1333
A
SH11: A-2 187A YE 1.0 262B PRP 0.35 2 2
261B WH 0.35 25 25
X-ACT_10
260B YE 0.35 20 20
B GND-001
258E GY 0.35 8 8
B
BODY GROUND 873C GN 0.35 1 1
256F BK 0.8 15 15
A-DRIVER 24V
258F RD 0.35 14 14
5 5
264D GY 0.35 16 16
17 17
3 3
317 YE 0.35 6 6
29 29
27 27
28 28
26 26
X-01
268 PRP 0.35
315 OR 0.35
314 GY 0.35
288 BL 0.35 6 6
286 RD 0.35 5 5
284 BL 0.35 4 4
M-STEPPER MOTOR 24V
282 WH 0.35 3 3
2 2
1 1
X-02
A A
1 1
NTC B-NTC SENSOR
2 2
X-04
B 2
246B WH 0.35 A 1
X-07
X-J1338
SW-LOW PRESSURE SWITCH N.C.
6 5 4 3 2 1
SHT_33 1
48083741_EN 31/07/2018
55.1 [55.100] / 97
Wiring harnesses - Electrical schematic sheet 34 SH34 - MIRRORS, HORN BEACON

ECU A-SFB - SMART FUSE BOX X-X6 - SFB [A-SFB] Connector X-CAB_P X-CAB_P - CAB TO
(ECU) (47554341) PEDESTAL [SH20: D-2]
Ground GND-017 - (Ground) GND-017 (87700155)
Ground GND-018 - (Ground) GND-018 Connector X-CAB_R X-CAB_R - CAB TO ROOF
Ground GND-019 - (Ground) GND-019 (87695891)
Ground GND-025 - (Ground) GND-025 Connector X-CG3 X-CG3 - CAB GROUND RH
Speaker H-HN - HORN (Speaker) X-HN2 - HORN_GRND HEADLINER [SH13: D-5]
[H-HN] (87697629) X-HN1 (84149207)
- HORN_PWR [H-HN] Connector X-FRNT X-FRNT - FRONT TO
(87697629) BOTTOM STD (87704426)
Relay K-LC3R4 - HORN RELAY X-LC3 - LOADCENTER 3 Connector X-HN1 X-HN1 - HORN_PWR [H-HN]
(Relay) [SH35: B-6] (84529039) (87697629)
Load L-MH_L - MIRROR HEATER X-MH_L - MIRROR HEATED Connector X-HN2 X-HN2 - HORN_GRND [H-HN]
LH (Load) LEFT [L-MH_L] (87695582) (87697629)
Lamp LMP-BEA_RT - ROTATING X-BEA - BEACON Connector X-LC3 X-LC3 - LOADCENTER 3
BEACON / LED STROBE [LMP-BEA_RT] (84015523) [SH35: B-6] (84529039)
LIGHT (Lamp) Connector X-MH_L X-MH_L - MIRROR HEATED
Lamp LMP-MH_R - MIRROR X-MH_R - MIRROR HEATED LEFT [L-MH_L] (87695582)
HEATER RH (Lamp) RIGHT [LMP-MH_R] Connector X-MH_R X-MH_R - MIRROR HEATED
(87695582) RIGHT [LMP-MH_R]
Switch SW-HN_RH_ARM - RH (87695582)
ARMREST HORN SWITCH Connector X-PED X-PED - PEDESTAL TO CAB
(Switch) (87700156)
Switch SW-HN_STLK - RH STALK X-STLK - STALK LEVER RH Connector X-ROOF X-ROOF - ROOF TO CAB
HORN SWITCH (Switch) [SW-HN_STLK] (84426133) (87700325)
Switch SW-MH_SW - MIRROR X-S_HMR - SWITCH HEATED Connector X-STLK X-STLK - STALK LEVER RH
HEATER SWITCH (Switch) MIRRORS [SH13: D-4] [SW-HN_STLK] (84426133)
(87716755) Connector X-S_HMR X-S_HMR - SWITCH HEATED
Connector X-A_RT X-A_RT - ARM REST RIGHT MIRRORS [SH13: D-4]
(87694112) (87716755)
Connector X-BEA X-BEA - BEACON Connector X-X3 X-X3 - SFB [SH3: A-1]
[LMP-BEA_RT] (84015523) (47554344)
Connector X-BTM X-BTM - BOTTOM TO CAB Connector X-X4 X-X4 - SFB (47554343)
STD (87704523) Connector X-X5 X-X5 - SFB [SH3: D-3]
Connector X-BTM_F X-BTM_F - BOTTOM TO (47554342)
FRONT STD (87696087) Connector X-X7 X-X7 - SFB [SH3: A-3]
Connector X-CAB_AR X-CAB_AR - CAB TO RH ARM (84538791)
REST (87694152)
[SH21: B-3] (87696945)
48083741_EN 31/07/2018
55.1 [55.100] / 98
6 5 4 3 2 1
A-SFB
SMART FUSE BOX H-HN
SW-HN_STLK SH28:C-2 X-FRNT
X-PED X-BTM HORN
RH STALK HORN SWITCH
SP-113
2 1 26 IN_DIG_08_L_WU 1
1 113B BR 0.8 4 4 113A BR 0.8 113 BR 0.8 21 21 112A YE 0.8 T T 112B YE 0.8 P
Horn Switch
X-HN1
X-X7
INTERNAL TO 1
X-CAB_P SH28: A-1
STALK X-STLK X-CAB_B 624B BK 0.8 N
D X-HN2
D
113C BR 0.8
X-BTM_F
55 W
SW-HN_RH_ARM
X-A_RT SH24:A-3
RH ARMREST HORN SWITCH
2 1
113D BR 0.8 5 5
112 YE 0.8
INTERNAL TO RH
113F BR 0.8
EH ARMREST X-CAB_AR
A-SFB
SMART FUSE BOX
K-LC3R4
HORN RELAY X-ROOF
87A R4_87A
R4_30 30
SH3: B-3 219D RD 0.8 87 R4_87
LMP-BEA_RT
R4_86 ROTATING BEACON / LED STROBE LIGHT
86 85 R4_85
SH3: A-3 219E RD 0.8 2
OUT_21_H_CS 3 1 P N
851 VT 0.8 3 3 851A VT 0.8 953B BK 0.8 SH31: B-2
Rotating Beacon
CAN INPUT W
X-LC3 X-X3 X-BEA 70 X-BEA
X-LC3
C C
A-SFB
SMART FUSE BOX
B B
OUT_01_MIRR_COM 17
SW-MH_SW
Mirror LH Common
BACKLIGHTING MIRROR HEATER SWITCH
8 P1 N1 7
SH27: A-2 981F VT 0.8 954B BK 0.8 SH13: C-4
IN_DIG_12_L
2 IN OUT 3 48 Mirror Heat SW
SH13: D-4 955K BK 0.8 116 YE 0.8 L-MH_L
10 P2 N2 9 X-X7 MIRROR HEATER LH
955J BK 0.8 SH13: D-3 SP-114A
6
OUT_01_H_CS P N SH31: B-2
114 TN 1.0 4 4 114A TN 1.0 114B TN 1.0 1 2 953C BK 1.0
X-S_HMR Mirror Heat Supply LOAD
X-S_HMR
X-MH_L X-MH_L
13
114C TN 1.0
OUT_46_H_CS_L OUT_02_MIRR_COM 8 X-CAB_R
115 WH 0.8
Optional Output 4 Mirror RH Common
X-X4
RH HVAC LMP-MH_R
CONSOLE MIRROR HEATER RH
A X-X5 1 P N
LOAD
2 953D BK 1.0 SH31: B-2 A
X-MH_R X-MH_R
6 5 4 3 2 1
SHT_34 1
48083741_EN 31/07/2018
55.1 [55.100] / 99
Wiring harnesses - Electrical schematic sheet 35 SH35 - CABIN RADIO

LOUDSPEAKER/12V CNVRTR
Speaker H-LSP1 - LOUDSPEAKER RT X-XLP1 - LOUDSPEAKER RT
(Speaker) [H-LSP1] (84147089)
Speaker H-LSP2 - LOUDSPEAKER LF X-XLP2 - LOUDSPEAKER LF
(Speaker) [H-LSP2] (84147089)
Speaker H-RADIO - 12V RADIO X-SPK - RADIO TO SPKRS
(Speaker) [H-RADIO] (87709371)
X-RAD - RADIO [H-RADIO]
(87709660)
Power outlet J-CNVRTR_24-12 - POWER X-CNV - 24 TO 12 POWER
CONVERTER (Power outlet) CONVERTER [SH35: B-4]
(87694112)
Power outlet J-PO1 - RH CONSOLE 12V X-X-PO1 - POWER OUTLET
POWER OUTLET (Power [J-PO1] (84398827)
outlet)
Lamp LMP-CIG_LTR - 24V CIGARX-CL - CIGAR LIGHTER
LIGHTER (Lamp) [LMP-CIG_LTR] (84015523)
Connector X-CL X-CL - CIGAR LIGHTER
[LMP-CIG_LTR] (84015523)
Connector X-CNV X-CNV - 24 TO 12 POWER
CONVERTER [SH35: B-4]
(87694112)
[SH35: B-6] (84529039)
Connector X-RAD X-RAD - RADIO [H-RADIO]
(87709660)
Connector X-SC X-SC - SEAT COMPRESSOR
[Y-SC] (87692855)
Connector X-SPK X-SPK - RADIO TO SPKRS
[H-RADIO] (87709371)
Connector X-X-PO1 X-X-PO1 - POWER OUTLET
[J-PO1] (84398827)
Connector X-XLP1 X-XLP1 - LOUDSPEAKER RT
[H-LSP1] (84147089)
Connector X-XLP2 X-XLP2 - LOUDSPEAKER LF
[H-LSP2] (84147089)
Solenoid Y-SC - SEAT COMPRESSOR X-SC - SEAT COMPRESSOR
(Solenoid) [Y-SC] (87692855)
48083741_EN 31/07/2018
55.1 [55.100] / 100
6 5 4 3 2 1
Y-SC
D SEAT COMPRESSOR D
SH9: B-2 742 OR 2.0 A SUPPLY GND B 955L BK 2.0 SH13: B-6
X-SC X-SC
LMP-CIG_LTR
24V CIGAR LIGHTER
P1 N 2
SH9: D-2 743 OR 2.0 1 LOAD 957 BK 2.0 SH14: C-3
X-CL X-CL
C P2
C
271 BK 0.8 SH13: B-2
SH8: C-2 753 OR 0.8
SH8: B-2 746 OR 3.0

X-RAD
6 4 7 8
87709660
H-RADIO
12V RADIO
SP-746
24V+ 1 1
24 V 746A OR 2.0
2 2 8 7 2 1
24V+ 746B OR 2.0 X-SPK
J-CNVRTR_24-12
POWER CONVERTER 3 87709371
GRND 3
B 12V MEMORY 4 4
277 BK 2.0 SH14: C-4 H-LSP1
LOUDSPEAKER RT
B
5
12V+ SW 5 748 OR 2.0 SH8: D-5
12 V 6 1
6 SH14: C-4 P
GRND (OPT) 276 BK 2.0 LP1-1 BL 1.0
X-CNV
2
LP1-2 BK 1.0 N
X-XLP1
H-LSP2
1
LP2-1 WH 1.0 P
2
LP2-2 BR 1.0 N
X-XLP2
J-PO1 LOUDSPEAKER LF
RH CONSOLE 12V POWER OUTLET
P1 N
SH8: D-1 750 OR 1.0 A LOAD C 275 BK 1.0 SH14: D-4
P2
X-X-PO1
A X-X-PO1
A
ON RH
CONSOLE
6 5 4 3 2 1
SHT_35 1
48083741_EN 31/07/2018
55.1 [55.100] / 101
Wiring harnesses - Electrical schematic sheet 36 SH36 - REAR DEFROST,

BACKUP ALARM
(ECU) (47554341)
Ground GND-069 - (Ground) GND-069
Speaker H-BU_ALRM - BACKUP X-BU2 - BACK UP ALARM
ALARM (Speaker) [H-BU_ALRM] (84426117)
X-BU1 - BACK UP ALARM
[H-BU_ALRM] (84426117)
Resistor R-WND_HTR - REAR X-RWHE1 - REAR WINDOW
WINDSHIELD HEATER HEATER [R-WND_HTR]
ELEMENT (Resistor) (87688695) X-RWHE2 - REAR
WINDOW HEATER [SH13:
C-3] (87688695)
Switch SW-BCK_U_SW - BACKUP X-S_BU - CANCEL BACKUP
ALRM CANCEL SW (Switch) ALARM [SW-BCK_U_SW]
(87716755)
Switch SW-R_DEF_SW - REAR X-S_RDF - SWITCH REAR
DEFROST SWITCH (Switch) DEFROST [SW-R_DEF_SW]
(87716755)
[H-BU_ALRM] (84426117)
[H-BU_ALRM] (84426117)
[SH7: B-5] (84807216)
Connector X-EHD_23 X-EHD_23 - ENG TO PL23
HOOD (87694154)
[SH18: C-6] (87696948)
Connector X-HD_23 X-HD_23 - HOOD PL23
(87694153)
Connector X-RWHE1 X-RWHE1 - REAR WINDOW
HEATER [R-WND_HTR]
(87688695)
Connector X-RWHE2 X-RWHE2 - REAR WINDOW
HEATER [SH13: C-3]
(87688695)
Connector X-S_BU X-S_BU - CANCEL BACKUP
ALARM [SW-BCK_U_SW]
(87716755)
Connector X-S_RDF X-S_RDF - SWITCH REAR
DEFROST [SW-R_DEF_SW]
(87716755)
(47554344)
(84538791)
48083741_EN 31/07/2018
55.1 [55.100] / 102
6 5 4 3 2 1
D D
A-SFB
SMART FUSE BOX
R-WND_HTR
REAR WINDSHIELD HEATER ELEMENT
1
SH13: C-3 272 BK 2.0 N
SW-R_DEF_SW X-RWHE2
REAR DEFROST SWITCH 7 1
OUT_43_H_CS_L SH8: A-5 SH8: A-2 P
120 YE 0.8 801 OR 2.0
Rear Defrost
P1 N1 X-RWHE1
SH27: A-2 981G VT 0.8 8 7 958 BK 0.8 SH13: B-3 TO RELAY
IN OUT 68
SH13: C-2 2 IN_DIG_30_L
955R BK 0.8 3 117 YE 0.8
Rear Defrost Switch
P2 N2
10 9 955A BK 0.8 SH13: D-2
X-S_RDF X-S_RDF
HVAC PANEL X-X3
7 OUT_10_H
122 YE 0.8
Rear Defrost Indicator
H-BU_ALRM
X-X7
BACKUP ALARM
X-ENG
21 1
OUT_45_H_CS_L
121 OR 0.8 7 7 121A OR 0.8 P
Backup Alarm X-BU2
C X-CAB_E X-EHD_23 1
C
244 BK 0.8 N
121B OR 0.8 1 1 121C OR 0.8 X-BU1
1.2 A
SW-BCK_U_SW
BACKUP ALRM CANCEL SW
SH30:B-3 X-HD_23
242F BK 0.8 SH29: B-1
P1 N1
SH27: B-2 981E VT 0.8 8 7 954T BK 0.8 SH13: A-3
SH15: B-2
OUT1 50 IN_DIG_10_L
3 119 YE 0.8
Backup Alarm Cancel
IN X-X7 X-X4
SH13: A-6 955S BK 0.8 2
OUT2
P2 N2
10 9 SH13: A-3
954G BK 0.8 PL23-26 ENGINE HARNESS
X-S_BU X-S_BU
6 OUT_44_H_CS_L
118 YE 0.8
BU CANCEL INDICATOR
X-X3
B B
NOTE HIDDEN
COLOR:
GREEN NA PL10-26 ENGINE HARNESS
A 3399FF NA PL10-26 HOOD HARNESS A

33CC00 EURO PL10-20 ENGINE HARNESS
BROWN EURO PL23-26 LIGHTHOOD HARNESS
006600
PL23-26 ENGINE HARNESS
3399FF PL23-26 NA HOOD HARNESS
6 5 4 3 2 1
SHT_36 1
48083741_EN 31/07/2018
55.1 [55.100] / 103
Wiring harnesses - Electrical schematic sheet 37 SH37 - HOOD LIFT

Relay K-LC6R1 - HOOD UP (Relay) X-LC6 - LOADCENTER 6
[SH16: A-3] (84380518)
Relay K-LC6R2 - HOOD DOWN
(Relay)
Motor M-HD_L_M - HOOD LIFT X-HDM - HOOD MOTOR
MOTOR (Motor) [M-HD_L_M] (87711966)
Switch SW-HD_L_SW - HOOD LIFT X-HD - HOOD LIFT SWITCH
SWITCH (Switch) [SH3: A-4] (84159859)
[SH7: B-5] (84807216)
[SH18: C-6] (87696948)
Connector X-HD X-HD - HOOD LIFT SWITCH
[SH3: A-4] (84159859)
Connector X-HDM X-HDM - HOOD MOTOR
[M-HD_L_M] (87711966)
[SH7: B-3] (87733581)
[SH16: A-3] (84380518)
48083741_EN 31/07/2018
55.1 [55.100] / 104
6 5 4 3 2 1
X-ENG
D D
SH7: B-3 205 RD 2.0 2 2
X-CAB_E
HOOD LIFT
209 WH 2.0
205A RD 2.0
K-LC6R1
HOOD UP
87A 41
38 30 208A BK 2.0
87 45
46 86 85 37
208B BK 1.0
M-HD_L_M
SP-250A HOOD LIFT MOTOR
205B RD 2.0 X-LC6 X-LC6
SW-HD_L_SW 1 2
A M B
C HOOD LIFT SWITCH
OUT1 3
C
206 WH 1.0 X-HDM X-HDM
2 IN
SH3: A-4 533 RD 1.0
OUT2 1
X-HD SP-208 208 BK 2.0 SH15: C-2

X-HD
210 GY 2.0
207 GY 1.0
205D RD 2.0
K-LC6R2
HOOD DOWN
87A 43
30
208C BK 2.0
40
87 47
48 86 85 39
208D BK 1.0
X-LC6 X-LC6
B B
A A
6 5 4 3 2 1
SHT_37 1
48083741_EN 31/07/2018
55.1 [55.100] / 105
Wiring harnesses - Electrical schematic sheet 38 SH38 - MISCELLANOUS,

TELEMATICS
ECU A-TELE - TELEMATIC X-X_TEL - TELEMATICS
MODULE (ECU) [SH38: C-6] (87700156)
Connector X-DIAG_T X-DIAG_T - TELEMATICS
DIAGNOSTIC [SH38: B-1]
(87694101)
[SH10: D-1] (87733595)
Connector X-X_TEL X-X_TEL - TELEMATICS
[SH38: C-6] (87700156)
48083741_EN 31/07/2018
55.1 [55.100] / 106
6 5 4 3 2 1
D D
A-TELE
TELEMATIC MODULE
NON-ISOLATED B+
RS232RX
GROUND
RS232TX
DIAGNOSTICS
CAN LO
CAN HI
IGN B+
TELEMATICS CONNECTOR
C C
12
3
7
12
3
1
7
4
X-X_TEL X-DIAG_T
SH24: C-2 CAN_HC YE 0.8 CAN_TH TN 0.8
912 BK 0.8 SH12: D-6

CAN_TL LB 0.8
SH24: D-2 CAN_LC GN 0.8
SH3: B-3 217A RD 0.8
SH10: C-3 168 OR 0.8 287 BK 0.8 SH12: C-3
B B
A A
6 5 4 3 2 1
SHT_38 1
48083741_EN 31/07/2018
55.1 [55.100] / 107
Wiring harnesses - Electrical schematic sheet 39 SH39 - MISCELLANOUS,

REAR CAMERA
ECU A-DISPLAY - (ECU)
ECU A-ORLACO CAMERA - REAR
VIEW CAMERA (ECU)
(ECU) (47554341)
[SH7: B-5] (84807216)
Connector X-CAM X-CAM - REAR CAMERA
(87700107)
Connector X-CAM2 X-CAM2 - CAMERA CHORD
(87700106)
[SH18: C-6] (87696948)
[SH7: B-3] (87733581)
(47554341)
48083741_EN 31/07/2018
55.1 [55.100] / 108
6 5 4 3 2 1
D D
A-DISPLAY
A-ORLACO CAMERA
REAR VIEW CAMERA
DSP
FROM CAN COMMUNICATION
SHEET
C C
GRILL
GROMMET
CAB
REAR CHASSIS VGA-CABLE HOOD
AND PWR & GRND
MONITOR1 0.0
B B
X-CAM
SH7: B-2 125 OR 0.8 1 1
SH13: D-5 955AD BK 0.8 2 2
124B VT 0.8 3 3
X-CAM2
DEUTSCH_DTM SERIES_6-WAY_RECEP HSG
REAR
CAMERA
TRIGGER
A-SFB
A SMART FUSE BOX X-ENG A
SP-124
OUT_18_H_CS
1
124 VT 0.8
NOT USED
124A VT 0.8 19 19
Reverse Lights
X-CAB_E
X-X6
6 5 4 3 2 1
SHT_39 1
48083741_EN 31/07/2018
55.1 [55.100] / 109
48083741_EN 31/07/2018
55.1 [55.100] / 110
Wire connectors - Component diagram 00

X-001 - GRID HEATER CABLE GRND ON ENGINE (84398003) (Plug)
84398003
Pin From Wire Description Color-Size Frame
1 X-GH7 (Plug) pin 1 - GRID CABLE_07 GRID HEATER GROUND BK - 32.0 SHEET 16 SH16 - ENGINE CONTROL UNIT
HEATER [R-RES-G_HTR] CABLE 1, GRID HEATER, FILTER HEATER
(87744835)
X-01 - DENSO (Receptacle)

1 X-HVAC2 (Plug) pin F - HVAC 873C 873C GN - 0.35 SHEET 33 SH33 - HEATING BLOWER
MECHINISM (87696550) HEATER, HVAC
2 X-HVAC2 (Plug) pin P - HVAC 262B 262B PRP - 0.35
MECHINISM (87696550)
3 X-04 (Receptacle) pin 1 - 315 315 OR - 0.35
DENSO
5 X-07 (Receptacle) pin B - 268 268 PRP - 0.35
DENSO (87692855)
6 X-02 (Receptacle) pin 1 - 317 317 YE - 0.35
DENSO
8 X-HVAC2 (Plug) pin L - HVAC 258E 258E GY - 0.35
14 X-HVAC2 (Plug) pin K - HVAC 258F DENSO RD - 0.35
15 X-HVAC2 (Plug) pin C - HVAC 256F 256F BK - 0.8
16 SP-264B-P-X 264D 264D GY - 0.35
17 X-04 (Receptacle) pin 2 - 314 314 GY - 0.35
DENSO
20 X-HVAC2 (Plug) pin M - HVAC 260B 260B YE - 0.35
25 X-HVAC2 (Plug) pin N - HVAC 261B 261B WH - 0.35
26 X-02 (Receptacle) pin 6 - 288 288 BL - 0.35
DENSO
DENSO
28 X-02 (Receptacle) pin 5 - 286 286 RD - 0.35
DENSO
29 X-02 (Receptacle) pin 3 - 282 282 WH - 0.35
DENSO

1 X-01 (Receptacle) pin 6 - 317 317 YE - 0.35 SHEET 33 SH33 - HEATING BLOWER
DENSO HEATER, HVAC
3 X-01 (Receptacle) pin 29 - 282 282 WH - 0.35
DENSO
DENSO
5 X-01 (Receptacle) pin 28 - 286 286 RD - 0.35
DENSO
DENSO

1 X-01 (Receptacle) pin 3 - 315 315 OR - 0.35 SHEET 33 SH33 - HEATING BLOWER
DENSO HEATER, HVAC
2 X-01 (Receptacle) pin 17 - 314 314 GY - 0.35
DENSO
48083741_EN 31/07/2018
55.1 [55.100] / 111

1 SP-264B-P-X 264C 264C GY - 1.0 SHEET 33 SH33 - HEATING BLOWER
2 X-HVAC2 (Plug) pin S - HVAC 265B 265B GN - 2.0 HEATER, HVAC
3 X-HVAC2 (Plug) pin J - HVAC 266B 266B YE - 2.0
4 SP-267-P-X 267C 267C GY - 2.5

1 X-HVAC2 (Plug) pin A - HVAC 876H 876H OR - 3.0 SHEET 33 SH33 - HEATING BLOWER
2 SP-267-P-X 267D 267D GY - 2.5
X-07 - DENSO (87692855) (Receptacle)
87692855
A X-HVAC2 (Plug) pin B - HVAC 246B 246B WH - 0.35 SHEET 33 SH33 - HEATING BLOWER
B X-01 (Receptacle) pin 5 - 268 268 PRP - 0.35
DENSO

1 X-12 (Receptacle) pin 6 - 873E HVAC PWR YE - 0.8 SHEET 33 SH33 - HEATING BLOWER
DENSO (41200689) HEATER, HVAC
2 X-12 (Receptacle) pin 7 - 261A 261A GY - 0.8
DENSO (41200689)
X-ACT - AC CLUTCH (87687239) (Plug)
87687239
X-ACT_10 - AIR COMPRESSOR CLUTCH PL10 (87693744) (Plug)
87693744
A X-LC6 pin 25 - LOADCENTER 187A AC COMPRESSOR YE - 1.0 SHEET 33 SH33 - HEATING BLOWER
6 [SH16: A-3] (84380518) HEATER, HVAC
A Y-ACT-P-IN WIRE6222 WIRE6222
X-AFS - AIR FILTER RSTCN SW [ SW-A_F_S] (84607243) (Receptacle)
84607243
1 SP-627-P-X 627B RELAY FILTER HEATING RD - 0.8 SHEET 17 SH17 - ENGINE CONTROL UNIT
HI SIDE 2, AT
2 X-ECU (Receptacle) pin 37 - 637 AIR FILTER SWITCH YE - 0.8
ECU CONNECTOR [A-ECU]
(84300197)
X-AFS2 - AIR FILTER SWITCH T2/3 [ SW-AFS2] (84607243) (Receptacle)
84607243
1 SP-669A-P-X 669C IGN PWR FOR AIR FLTR OR - 0.8 SHEET 20 SH20 - UCM VEHICLE DRIVELINE
2 X-ENG (Plug) pin 18 - 319A AIR FILTER REST SW T2 YE - 0.8 / FAN CONTROL
ENGINE TO CAB [SH18: C-6]
(87696948)
48083741_EN 31/07/2018
55.1 [55.100] / 112
X-AIR - HVAC CONSOLE [ SH27: C-2] (84309048) (Receptacle)
84309048
1 X-HVAC (Receptacle) pin 262 TEMP SETTING YE - 0.8 SHEET 27 SH27 - LIGHTING DOME, MAP
M - INTRCECT TO HVAC LIGHTS
SYSTEM BY HVAC [SH33:
D-4] (87696573)
2 X-HVAC (Receptacle) pin 261 TEMP SETTING WH - 0.8
N - INTRCECT TO HVAC
D-4] (87696573)
3 X-HVAC (Receptacle) pin 260 TEMP SETTING VT - 0.8
P - INTRCECT TO HVAC
D-4] (87696573)
4 X-X6 (Receptacle) pin 8 - SFB 285 SWITCH BACK LIGHTING VT - 0.8
[A-SFB] (47554341)
5 SP-256-P-X 256A CAB CLEAN GRND BK - 0.8
6 SP-873-P-X 873D HVAC POWER OR - 0.8
7 SP-258-P-X 258C AC ON SIGNAL YE - 0.8
8 CG1-P-1 CAB GROUND RH 903 HVAC GROUND BK - 2.5
HEADLINER
9 X-HVAC (Receptacle) pin 264 BLOWER SPEED GY - 1.0
R - INTRCECT TO HVAC
D-4] (87696573)
10 X-HVAC (Receptacle) pin 265 BLOWER SPEED GN - 2.0
S - INTRCECT TO HVAC
D-4] (87696573)
11 X-HVAC (Receptacle) pin 266 BLOWER SPEED YE - 2.0
J - INTRCECT TO HVAC
D-4] (87696573)
12 X-HVAC (Receptacle) pin 267 BLOWER SPEED WH - 2.5
H - INTRCECT TO HVAC
D-4] (87696573)
X-ALT - ALTERNATOR [ G-G1] (8602487) (Receptacle)
8602487 8
8602487
3 X-ENG (Plug) pin 26 - 228 ALTERNATOR VOLTAGE RD - 0.8 SHEET 03 SH03 - PWR DISTR-BATTERY /
ENGINE TO CAB [SH18: C-6] STARTER / KEY
(87696948)
4 X-ENG (Plug) pin 17 - 239 ALT LAMP SIGNAL YE - 0.8
(87696948)
48083741_EN 31/07/2018
55.1 [55.100] / 113
X-ALT_B - ALTERNATOR B+ (84399576) (Plug)
84399576 9
84399576
1 X-XM1C (Plug) pin 1 - 301 ALTERNATOR B+ RD - 13.0 SHEET 03 SH03 - PWR DISTR-BATTERY /
STARTER (84401295) STARTER / KEY
X-AUX_1_LEFT - AUX 1 LEFT [ A-EH_VLV] (87695582) (Receptacle)
87695582 10
87695582
1 X-FRNT_EH (Receptacle) pin 351B AUX 1 LEFT WH - 0.8 SHEET 22 SH22 - UCM-LOADER BOOM
H - FRONT TO BOTTOM EH CONTROL
(87700170)
2 SP-352B-P-X 352C AUX 1 LEFT ENABLE BR - 0.8
X-AUX_1_RIGHT - AUX 1 RIGHT [ A-EH_VLV] (87695582) (Receptacle)
87695582 11
87695582
48083741_EN 31/07/2018
55.1 [55.100] / 114

1 X-FRNT_EH (Receptacle) pin 355B AUX 1 RIGHT WH - 0.8 SHEET 22 SH22 - UCM-LOADER BOOM
K - FRONT TO BOTTOM EH CONTROL
(87700170)
2 SP-352B-P-X 352D AUX 1 RIGHT ENABLE BR - 0.8
X-AUX_2_LEFT - AUX 2 LEFT [ A-EH_VLV] (87695582) (Receptacle)
87695582 12
87695582
1 X-FRNT_EH (Receptacle) pin 356B AUX 2 LEFT WH - 0.8 SHEET 22 SH22 - UCM-LOADER BOOM
L - FRONT TO BOTTOM EH CONTROL
(87700170)
2 SP-357B-P-X 357C AUX 2 LEFT ENABLE BR - 0.8
X-AUX_2_RIGHT - AUX 2 RIGHT [ A-EH_VLV] (87695582) (Receptacle)
87695582 13
87695582
1 X-FRNT_EH (Receptacle) pin 360B AUX 2 RIGHT WH - 0.8 SHEET 22 SH22 - UCM-LOADER BOOM
N - FRONT TO BOTTOM EH CONTROL
(87700170)
2 SP-357B-P-X 357D AUX 2 RIGHT ENABLE BR - 0.8
48083741_EN 31/07/2018
55.1 [55.100] / 115
X-A_RT - ARM REST RIGHT (87694112) (Receptacle)
87694112 14
87694112
5 SW-HN_RH_ARM-P-1 113D RH ARMREST HORN BR - 0.8 SHEET 34 SH34 - MIRRORS, HORN BEACON
SWITCH
X-A_RT3 - RIGHT ARM PILOT (87694152) (Plug)
87694152 15
87694152
1 X-A_RT_2B (Receptacle) pin 310A FORWARD REVERSE LB - 0.8 SHEET 23 SH23 - PILOT LOADER
11 - ARM REST RIGHT PILOT SIGNAL CONTROLS
2 (84281913)
2 SP-677H-P-X 677K 5V REF 3+ PK - 0.8
3 SP-967H-P-X 967K 5V REF3 GRND BL - 0.8
4 X-A_RT_2B (Receptacle) pin 311A FORWARD REVERSE WH - 0.8
12 - ARM REST RIGHT PILOT SIGNAL
2 (84281913)
5 SP-677H-P-X 677J 5V REF 3+ PK - 0.8
6 SP-967H-P-X 967J 5V REF3 GRND BL - 0.8
48083741_EN 31/07/2018
55.1 [55.100] / 116
X-A_RT_2A - ARM REST RIGHT PILOT 2 (84278761) (Plug)
84278761 16
84278761
X-A_RT_2B - ARM REST RIGHT PILOT 2 (84281913) (Receptacle)
84281913 17
84281913
48083741_EN 31/07/2018
55.1 [55.100] / 117

1 X-YPP (Plug) pin A - PILOT 344E PILOT ENABLE PILOT YE - 0.8 SHEET 23 SH23 - PILOT LOADER
PRESSURE SOLENOID CONTROLS
[Y-Y_PL] (87692855)
2 X-KDS (Plug) pin 2 - CAN 309B KICK DOWN SIGNAL YE - 0.8
(87311796)
2 X-P_JS (Plug) pin 6 - 309A KICK DOWN SIGNAL YE - 0.8
PILOT LOADER JOYSTICK
[SW-FNR] (87694152)
3 X-P_JS (Plug) pin 2 - 306A FOWARD SIGNAL WH - 0.8
[SW-FNR] (87694152)
4 X-P_JS (Plug) pin 3 - 307A NUETRAL SIGNAL YE - 0.8
[SW-FNR] (87694152)
5 X-P_JS (Plug) pin 4 - 308A REVERSE SIGNAL GY - 0.8
[SW-FNR] (87694152)
6 X-EM (Receptacle) pin 297A RTD DETENT WH - 0.8
3 - ELECTROMAGNETIC
DETENTS [Y-RTT DET]
(87694112)
7 X-EM (Receptacle) pin 298A HC DETENT WH - 0.8
2 - ELECTROMAGNETIC
DETENTS [Y-RTT DET]
(87694112)
8 X-EM (Receptacle) pin 299A RTT DETENT WH - 0.8
1 - ELECTROMAGNETIC
DETENTS [Y-RTT DET]
(87694112)
9 SP-677H-P-X 677H 5V REF 3+ PK - 0.8
10 SP-967H-P-X 967H 5V REF3 GRND BL - 0.8
11 X-A_RT3 (Plug) pin 1 - RIGHT 310A FORWARD REVERSE LB - 0.8
ARM PILOT (87694152) SIGNAL
12 X-A_RT3 (Plug) pin 4 - RIGHT 311A FORWARD REVERSE WH - 0.8
ARM PILOT (87694152) SIGNAL
X-A_RT_P - ARM REST RIGHT HAND PILOT (87694112) (Receptacle)
87694112 18
87694112
1 X-KDS (Plug) pin 4 - CAN 792H KICKDOWN SW PWR OR - 0.8 SHEET 23 SH23 - PILOT LOADER
(87311796) CONTROLS
1 X-P_JS (Plug) pin 1 - 792G IMP JOYSTICK IGN PWR OR - 0.8
[SW-FNR] (87694152)
2 SP-954U-P-X 954U CHASSIS GROUND BK - 1.0
5 X-HN (Plug) pin 2 - CAN 113E HORN BR - 0.8
[SW-HORN] (87311796)
48083741_EN 31/07/2018
55.1 [55.100] / 118
X-B4 - ALTERNATOR TO STARTER B+ (84401309) (Plug)
84401309 19
84401309
1 X-S244 (Plug) pin 1 - 20157 1990 AUX STEERING POWER RD - 62.0 SHEET 03 SH03 - PWR DISTR-BATTERY /
AUX STRG PWR RT ANGLE CABLE STARTER / KEY
CONN [SH21: D-3]
X-BAT-GND - BATTERY GROUND (84140737) (Plug)
84140737 20
84140737
1 X-563 (Plug) pin 1 - BATTERY CABLE-001 CABLE BATTERY BK - 62.0 SHEET 03 SH03 - PWR DISTR-BATTERY /
LUG [G-001] NEGATIVE STARTER / KEY
X-BEA - BEACON [ LMP-BEA_RT] (84015523) (Receptacle)
84015523 21
84015523
48083741_EN 31/07/2018
55.1 [55.100] / 119

1 X-ROOF (Receptacle) pin 3 - 851A ROTATING BEACON VT - 0.8 SHEET 34 SH34 - MIRRORS, HORN BEACON
ROOF TO CAB (87700325)
2 SP-953A-P-X 953B BEACON GND BK - 0.8
X-BOA - BOOM ANGLE SENSOR [ B-BM_ANG] (84403598) (Receptacle)
84403598 22
84403598
A SP-651D-P-X 651F 5V GND2 BL - 0.8 SHEET 22 SH22 - UCM-LOADER BOOM
B SP-471F-P-X 471G 5V REF2 PK - 0.8 CONTROL
C X-FRNT_EH (Receptacle) pin 647B BOOM ANGLE 1 YE - 0.8
S - FRONT TO BOTTOM EH
(87700170)
D X-FRNT_EH (Receptacle) pin 648B BOOM ANGLE 2 YE - 0.8
T - FRONT TO BOTTOM EH
(87700170)
E SP-570E-P-X 482X 5V GND1 BL - 0.8
F SP-486F-P-X 486K 5V REF1 PK - 0.8
X-BOOM_LOWER - BOOM LOWER SOLENOID [ A-EH_VLV] (87695582) (Receptacle)
87695582 23
87695582
1 X-FRNT_EH (Receptacle) pin 341B BOOM LOWER WH - 0.8 SHEET 22 SH22 - UCM-LOADER BOOM
D - FRONT TO BOTTOM EH CONTROL
(87700170)
2 SP-339B-P-X 339D BOOM LOWER ENABLE BR - 0.8
48083741_EN 31/07/2018
55.1 [55.100] / 120
X-BOOM_RAISE - BOOM RAISE SOLENOID [ A-EH_VLV] (87695582) (Receptacle)
87695582 24
87695582
1 X-FRNT_EH (Receptacle) pin 340B BOOM RAISE WH - 0.8 SHEET 22 SH22 - UCM-LOADER BOOM
B - FRONT TO BOTTOM EH CONTROL
(87700170)
2 SP-339B-P-X 339C BOOM RAISE ENABLE BR - 0.8
X-BPP - BRAKE PEDAL ANGLE [ B-BPP] (87710588) (Plug)
87710588 25
87710588
X-BTM - BOTTOM TO CAB STD (87704523) (Receptacle)
87704523 26
87704523
3 SP-651A-P-X 651A 5V GND2 BL - 0.8 SHEET 22 SH22 - UCM-LOADER BOOM
4 SP-471C-P-X 471C 5V REF2 PK - 0.8 CONTROL
5 X-BTM_F (Plug) pin P - 366A RIDE CONTROL SIG WH - 0.8
BOTTOM TO FRONT STD
(87696087)
48083741_EN 31/07/2018
55.1 [55.100] / 121

6 X-PBW (Receptacle) pin C - 640A BRAKE SUPPLY PRESS YE - 0.8 SHEET 19 SH19 - UCM PWR, GRND,
BRAKE SUPPLY WARNING INSTRUMENTATION
PRES [B-PBW] (84078681)
7 X-PLB-PBD (Receptacle) pin 641A BRAKE PRESS SENSOR YE - 0.8
C - BRAKE PRES SENSR
[B-PBL/PEDAL/DECLTCH]
(84078681)
8 SP-486D-P-X 486D 5V REF1 PK - 0.8
9 X-BTM_F (Plug) pin S - 368A COUPLER VALVE RTRN BR - 0.8 SHEET 22 SH22 - UCM-LOADER BOOM
BOTTOM TO FRONT STD CONTROL
(87696087)
10 SP-482H-P-X 482H 5V GRND1 BL - 0.8 SHEET 19 SH19 - UCM PWR, GRND,
INSTRUMENTATION
11 X-BTS (Receptacle) pin 4 176A AUX STRG PRESS YE - 0.8 SHEET 21 SH21 - UCM-STEERING AUX JSS
- BOTTOM TO SEC STRG SIGNAL
[SH19: A-1] (87694112)
12 X-BTS (Receptacle) pin 1 441A SEC STRG SOL PWR OR - 0.8
- BOTTOM TO SEC STRG
[SH19: A-1] (87694112)
13 X-BTM_F (Plug) pin U - 291A ROLL BACK PRESSURE YE - 0.8 SHEET 22 SH22 - UCM-LOADER BOOM
BOTTOM TO FRONT STD SW CONTROL
(87696087)
14 X-BTM_F (Plug) pin R - 367A COUPLER VALVE SIG WH - 0.8
BOTTOM TO FRONT STD
(87696087)
15 X-BPP pin 3 - BRAKE PEDAL 402A BRAKE PEDAL ANGLE YE - 0.8 SHEET 20 SH20 - UCM VEHICLE DRIVELINE
ANGLE [B-BPP] (87710588) / FAN CONTROL
17 X-BTM_F (Plug) pin A - 687A FRONT AXLE TEMP YE - 0.8
BOTTOM TO FRONT STD
(87696087)
18 X-YPB (Receptacle) pin 1 388A PARK BRAKE SOL WH - 0.8
- VALVE PARKING BRAKE
[Y-Y_PB] (87695582)
19 X-YPB (Receptacle) pin 2 389A PARK BRAKE SOL BK - 0.8
- VALVE PARKING BRAKE
[Y-Y_PB] (87695582)
20 X-BTM_F (Plug) pin C - 132D LH HIGH BEAM LAMP VT - 0.8 SHEET 28 SH28 - LIGHTING HAZARD
BOTTOM TO FRONT STD WARNING, BLINKERS, DRIVING
(87696087)
21 X-BTM_F (Plug) pin T - 112A HORN YE - 0.8 SHEET 34 SH34 - MIRRORS, HORN BEACON
BOTTOM TO FRONT STD
(87696087)
22 X-BTM_F (Plug) pin F - 133A LH LOW BEAM LAMP VT - 0.8 SHEET 28 SH28 - LIGHTING HAZARD
BOTTOM TO FRONT STD WARNING, BLINKERS, DRIVING
(87696087)
23 X-BTM_F (Plug) pin H - 127B LH POSITION VT - 0.8
BOTTOM TO FRONT STD
(87696087)
24 X-BTM_F (Plug) pin J - 136B LH FRONT TURN VT - 0.8
BOTTOM TO FRONT STD
(87696087)
25 X-BTM_F (Plug) pin K - 137A RH HIGH BEAM LAMP VT - 0.8
BOTTOM TO FRONT STD
(87696087)
26 X-BTM_F (Plug) pin L - 138A RH LOW BEAM LAMP VT - 0.8
BOTTOM TO FRONT STD
(87696087)
27 X-BTM_F (Plug) pin M - 130E RH POSITION VT - 0.8
BOTTOM TO FRONT STD
(87696087)
28 X-BTM_F (Plug) pin N - 135D RH FRONT TURN VT - 0.8
BOTTOM TO FRONT STD
(87696087)
48083741_EN 31/07/2018
55.1 [55.100] / 122
X-BTM_EH - BOTTOM TO CAB EH (84281075) (Receptacle)
84281075 27
84281075
A X-BTM_FEH (Plug) pin A 344A PILOT ENABLE WH - 0.8 SHEET 22 SH22 - UCM-LOADER BOOM
- BOTTOM TO FRONT EH CONTROL
(87700160)
B X-BTM_FEH (Plug) pin B 340A BOOM RAISE WH - 0.8
- BOTTOM TO FRONT EH
(87700160)
C X-BTM_FEH (Plug) pin C 339A BOOM ENABLE BR - 0.8
(87700160)
D X-BTM_FEH (Plug) pin D 341A BOOM LOWER WH - 0.8
(87700160)
E X-BTM_FEH (Plug) pin E 346A BUCKET ROLL WH - 0.8
(87700160)
F X-BTM_FEH (Plug) pin F 347A BUCKET ENABLE BR - 0.8
(87700160)
G X-BTM_FEH (Plug) pin G 350A BUCKET DUMP WH - 0.8
(87700160)
H X-BTM_FEH (Plug) pin H 351A AUX 1 LEFT WH - 0.8
(87700160)
J X-BTM_FEH (Plug) pin J 352A AUX 1 ENABLE BR - 0.8
(87700160)
K X-BTM_FEH (Plug) pin K 355A AUX 1 RIGHT WH - 0.8
(87700160)
L X-BTM_FEH (Plug) pin L 356A AUX 2 LEFT WH - 0.8
(87700160)
M X-BTM_FEH (Plug) pin M 357A AUX 2 ENABLE BR - 0.8
(87700160)
N X-BTM_FEH (Plug) pin N 360A AUX 2 RIGHT WH - 0.8
(87700160)
S X-BTM_FEH (Plug) pin S 647A BOOM ANGLE 1 YE - 0.8
(87700160)
T X-BTM_FEH (Plug) pin T 648A BOOM ANGLE 2 YE - 0.8
(87700160)
W X-BTM_FEH (Plug) pin W 653A BUCKET ANGLE 1 YE - 0.8
(87700160)
X X-BTM_FEH (Plug) pin X 654A BUCKET ANGLE 2 YE - 0.8
(87700160)
48083741_EN 31/07/2018
55.1 [55.100] / 123
X-BTM_F - BOTTOM TO FRONT STD (87696087) (Plug)
87696087 28
87696087
A X-BTM (Receptacle) pin 17 687A FRONT AXLE TEMP YE - 0.8 SHEET 20 SH20 - UCM VEHICLE DRIVELINE
- BOTTOM TO CAB STD / FAN CONTROL
(87704523)
C X-BTM (Receptacle) pin 20 132D LH HIGH BEAM LAMP VT - 0.8 SHEET 28 SH28 - LIGHTING HAZARD
- BOTTOM TO CAB STD WARNING, BLINKERS, DRIVING
(87704523)
F X-BTM (Receptacle) pin 22 133A LH LOW BEAM LAMP VT - 0.8
- BOTTOM TO CAB STD
(87704523)
H X-BTM (Receptacle) pin 23 127B LH POSITION VT - 0.8
- BOTTOM TO CAB STD
(87704523)
J X-BTM (Receptacle) pin 24 136B LH FRONT TURN VT - 0.8
- BOTTOM TO CAB STD
(87704523)
K X-BTM (Receptacle) pin 25 137A RH HIGH BEAM LAMP VT - 0.8
- BOTTOM TO CAB STD
(87704523)
L X-BTM (Receptacle) pin 26 138A RH LOW BEAM LAMP VT - 0.8
- BOTTOM TO CAB STD
(87704523)
M X-BTM (Receptacle) pin 27 130E RH POSITION VT - 0.8
- BOTTOM TO CAB STD
(87704523)
N X-BTM (Receptacle) pin 28 135D RH FRONT TURN VT - 0.8
- BOTTOM TO CAB STD
(87704523)
P X-BTM (Receptacle) pin 5 366A RIDE CONTROL SIG WH - 0.8 SHEET 22 SH22 - UCM-LOADER BOOM
- BOTTOM TO CAB STD CONTROL
(87704523)
R X-BTM (Receptacle) pin 14 367A COUPLER VALVE SIG WH - 0.8
- BOTTOM TO CAB STD
(87704523)
S X-BTM (Receptacle) pin 9 368A COUPLER VALVE RTRN BR - 0.8
- BOTTOM TO CAB STD
(87704523)
T X-BTM (Receptacle) pin 21 112A HORN YE - 0.8 SHEET 34 SH34 - MIRRORS, HORN BEACON
- BOTTOM TO CAB STD
(87704523)
U X-BTM (Receptacle) pin 13 291A ROLL BACK PRESSURE YE - 0.8 SHEET 22 SH22 - UCM-LOADER BOOM
- BOTTOM TO CAB STD SW CONTROL
(87704523)
V SP-651A-P-X 651C 5V GND2 BL - 0.8
48083741_EN 31/07/2018
55.1 [55.100] / 124
X-BTM_FEH - BOTTOM TO FRONT EH (87700160) (Plug)
87700160 29
87700160
A X-BTM_EH (Receptacle) pin 344A PILOT ENABLE WH - 0.8 SHEET 22 SH22 - UCM-LOADER BOOM
A - BOTTOM TO CAB EH CONTROL
(84281075)
B X-BTM_EH (Receptacle) pin 340A BOOM RAISE WH - 0.8
B - BOTTOM TO CAB EH
(84281075)
C X-BTM_EH (Receptacle) pin 339A BOOM ENABLE BR - 0.8
C - BOTTOM TO CAB EH
(84281075)
D X-BTM_EH (Receptacle) pin 341A BOOM LOWER WH - 0.8
D - BOTTOM TO CAB EH
(84281075)
E X-BTM_EH (Receptacle) pin 346A BUCKET ROLL WH - 0.8
E - BOTTOM TO CAB EH
(84281075)
F X-BTM_EH (Receptacle) pin 347A BUCKET ENABLE BR - 0.8
F - BOTTOM TO CAB EH
(84281075)
G X-BTM_EH (Receptacle) pin 350A BUCKET DUMP WH - 0.8
G - BOTTOM TO CAB EH
(84281075)
H X-BTM_EH (Receptacle) pin 351A AUX 1 LEFT WH - 0.8
H - BOTTOM TO CAB EH
(84281075)
J X-BTM_EH (Receptacle) pin 352A AUX 1 ENABLE BR - 0.8
J - BOTTOM TO CAB EH
(84281075)
K X-BTM_EH (Receptacle) pin 355A AUX 1 RIGHT WH - 0.8
K - BOTTOM TO CAB EH
(84281075)
L X-BTM_EH (Receptacle) pin 356A AUX 2 LEFT WH - 0.8
L - BOTTOM TO CAB EH
(84281075)
M X-BTM_EH (Receptacle) pin 357A AUX 2 ENABLE BR - 0.8
M - BOTTOM TO CAB EH
(84281075)
N X-BTM_EH (Receptacle) pin 360A AUX 2 RIGHT WH - 0.8
N - BOTTOM TO CAB EH
(84281075)
P SP-482H-P-X 482J 5V GRND1 BL - 0.8 SHEET 19 SH19 - UCM PWR, GRND,
INSTRUMENTATION
48083741_EN 31/07/2018
55.1 [55.100] / 125

Q SP-486D-P-X 486E 5V REF1 PK - 0.8 SHEET 22 SH22 - UCM-LOADER BOOM
S X-BTM_EH (Receptacle) pin 647A BOOM ANGLE 1 YE - 0.8 CONTROL
S - BOTTOM TO CAB EH
(84281075)
T X-BTM_EH (Receptacle) pin 648A BOOM ANGLE 2 YE - 0.8
T - BOTTOM TO CAB EH
(84281075)
V SP-471C-P-X 471D 5V REF2 PK - 0.8
W X-BTM_EH (Receptacle) pin 653A BUCKET ANGLE 1 YE - 0.8
W - BOTTOM TO CAB EH
(84281075)
X X-BTM_EH (Receptacle) pin 654A BUCKET ANGLE 2 YE - 0.8
X - BOTTOM TO CAB EH
(84281075)
X-BTS - BOTTOM TO SEC STRG [ SH19: A-1] (87694112) (Receptacle)
87694112 30
87694112
1 X-BTM (Receptacle) pin 12 441A SEC STRG SOL PWR OR - 0.8 SHEET 21 SH21 - UCM-STEERING AUX JSS
- BOTTOM TO CAB STD
(87704523)
2 SP-486D-P-X 486U 5V PWR REF 1 PK - 0.8
3 SP-482H-P-X 482F 5V GRND1 BL - 0.8 SHEET 19 SH19 - UCM PWR, GRND,
INSTRUMENTATION
4 X-BTM (Receptacle) pin 11 176A AUX STRG PRESS YE - 0.8 SHEET 21 SH21 - UCM-STEERING AUX JSS
- BOTTOM TO CAB STD SIGNAL
(87704523)
X-BU1 - BACK UP ALARM [ H-BU_ALRM] (84426117) (Plug)
84426117 31
84426117
48083741_EN 31/07/2018
55.1 [55.100] / 126

1 X-GND_ENG4 (Plug) pin 1 - 244 BACKUP ALARM GND BK - 0.8 SHEET 15 SH15 - POWER DISTRIBUTION 4
GROUND ENG BLOCK [SH29: ENGINE GROUND BLK
B-3] (84140737)
1 SP-242A-P-X 242F BACKUP ALARM GRND BK - 0.8
PL23 NA
X-BU2 - BACK UP ALARM [ H-BU_ALRM] (84426117) (Plug)
84426117 32
84426117
1 X-ENG (Plug) pin 7 - 121A BACKUP ALARM OR - 0.8 SHEET 36 SH36 - REAR DEFROST, BACKUP
ENGINE TO CAB [SH18: ALARM
C-6] (87696948)
1 X-HD_23 (Receptacle) pin 1 - 121C BACKUP ALARM PL23 OR - 0.8
HOOD PL23 (87694153)
X-BUA - BUCKET ANGLE SENSOR [ B-BKT_ANG] (84403598) (Receptacle)
84403598 33
84403598
A SP-651D-P-X 651E 5V GND2 BL - 0.8 SHEET 22 SH22 - UCM-LOADER BOOM
B SP-471F-P-X 471H 5V REF2 PK - 0.8 CONTROL
C X-FRNT_EH (Receptacle) pin 653B BUCKET ANGLE 1 YE - 0.8
W - FRONT TO BOTTOM EH
(87700170)
D X-FRNT_EH (Receptacle) pin 654B BUCKET ANGLE 2 YE - 0.8
X - FRONT TO BOTTOM EH
(87700170)
E SP-570E-P-X 482W 5V GND1 BL - 0.8
F SP-486F-P-X 486L 5V REF1 PK - 0.8
48083741_EN 31/07/2018
55.1 [55.100] / 127
X-BUCKET_DUMP - BUCKET DUMP SOLENOID [ A-EH_VLV] (87695582) (Receptacle)
87695582 34
87695582
1 X-FRNT_EH (Receptacle) pin 350B BUCKET DUMP WH - 0.8 SHEET 22 SH22 - UCM-LOADER BOOM
G - FRONT TO BOTTOM EH CONTROL
(87700170)
2 SP-347B-P-X 347D BUCKET DUMP ENABLE BR - 0.8
X-BUCKET_ROLL - BUCKET ROLL SOLENOID [ A-EH_VLV] (87695582) (Receptacle)
87695582 35
87695582
1 X-FRNT_EH (Receptacle) pin 346B BUCKET ROLL WH - 0.8 SHEET 22 SH22 - UCM-LOADER BOOM
E - FRONT TO BOTTOM EH CONTROL
(87700170)
2 SP-347B-P-X 347C BUCKET ROLL ENABLE BR - 0.8
X-CAB_AR - CAB TO RH ARM REST (87694152) (Plug)
87694152 36
87694152
48083741_EN 31/07/2018
55.1 [55.100] / 128

1 X-LC5 (Receptacle) pin 6A - 792 IMP JOYSTICK PWR OR - 0.8 SHEET 24 SH24 - CAN STRUCTURE
LOADCENTER 5 [SH10: D-1]
(87733595)
2 X-CG4 (Receptacle) pin K - 954K RH ARMREST JOYSTICK BK - 1.0
CAB GROUND [SH24: B-6] GND
(84149207)
3 SP-B_HJ-P-X CANB_HI CAN WH - 0.8
4 SP-B_LJ-P-X CANB_LI CAN BL - 0.8
5 SP-113-P-X 113C RH ARMREST HORN BR - 0.8 SHEET 34 SH34 - MIRRORS, HORN BEACON
SWITCH
X-CAB_B - CAB TO BOTTOM [ SH21: B-3] (87696945) (Plug)
87696945 37
87696945
3 SP-651-P-X 651J 5V GND2 BL - 0.8 SHEET 22 SH22 - UCM-LOADER BOOM
4 SP-471-P-X 471A 5V REF2 PK - 0.8 CONTROL
5 X-UCM3B (Receptacle) pin 6 366 RIDE CONTROL SIG WH - 0.8
- UCM [A-UCM] (84130760)
6 X-UCM1A (Receptacle) pin 640 BRAKE SUPPLY PRESS YE - 0.8 SHEET 19 SH19 - UCM PWR, GRND,
10 - UCM (82016219) INSTRUMENTATION
7 X-UCM1B (Receptacle) pin 20 641 BRAKE PRESSURE YE - 0.8
- UCM [SH22: A-6] (87410946)
8 SP-486-P-X 486A 5V PWR REF 1 PK - 0.8
9 X-UCM3B (Receptacle) pin 4 368 COUPLER VALVE RTRN BR - 0.8 SHEET 22 SH22 - UCM-LOADER BOOM
- UCM [A-UCM] (84130760) CONTROL
10 SP-482-P-X 482C 5V GRND1 BL - 0.8 SHEET 19 SH19 - UCM PWR, GRND,
INSTRUMENTATION
11 X-UCM1A (Receptacle) pin 8 176 AUX STRG PRESS YE - 0.8 SHEET 21 SH21 - UCM-STEERING AUX JSS
- UCM (82016219) SIGNAL
12 X-LC3 (Receptacle) pin 441 SEC STRG SOL PWR OR - 0.8 SHEET 08 SH08 - POWER DISTRIBUTION
R2_87 - LOADCENTER 3 (FUSE BLOCK LC3)
[SH35: B-6] (84529039)
13 X-UCM4B (Receptacle) pin 291 ROLL BACK PRESSURE YE - 0.8 SHEET 22 SH22 - UCM-LOADER BOOM
24 - UCM [A-UCM] (82028495) SW CONTROL
14 X-UCM3B (Receptacle) pin 7 367 COUPLER VALVE SIG WH - 0.8
- UCM [A-UCM] (84130760)
15 X-UCM1A (Receptacle) pin 402 BRAKE PEDAL ANGLE YE - 0.8 SHEET 20 SH20 - UCM VEHICLE DRIVELINE
16 - UCM (82016219) / FAN CONTROL
16 X-UCM1A (Receptacle) pin 5 3686 PARK BRAKE PRESS YE - 0.8
- UCM (82016219)
17 X-UCM4A (Receptacle) pin 687 FRONT AXLE TEMP YE - 0.8
17 - UCM (82028493)
18 X-UCM3B (Receptacle) pin 388 PARK BRAKE SOL WH - 0.8
27 - UCM [A-UCM] (84130760)
19 X-UCM1A (Receptacle) pin 389 PARK BRAKE SOL WH - 0.8
22 - UCM (82016219)
20 SP-132-P-X 132A LH HIGH BEAM LAMP VT - 0.8 SHEET 28 SH28 - LIGHTING HAZARD
WARNING, BLINKERS, DRIVING
21 X-LC3 (Receptacle) pin 112 HORN YE - 0.8 SHEET 34 SH34 - MIRRORS, HORN BEACON
R4_87 - LOADCENTER 3
[SH35: B-6] (84529039)
48083741_EN 31/07/2018
55.1 [55.100] / 129

22 X-X5 (Receptacle) pin 21 - 133 LH LOW BEAM LAMP VT - 0.8 SHEET 28 SH28 - LIGHTING HAZARD
SFB [SH3: D-3] (47554342) WARNING, BLINKERS, DRIVING
23 SP-127-P-X 127A LH POSITION VT - 0.8
24 X-X4 (Receptacle) pin 12 - 136 LH FRONT TURN VT - 0.8
SFB (47554343)
25 X-X4 (Receptacle) pin 10 - 137 RH HIGH BEAM LAMP VT - 0.8
SFB (47554343)
26 X-X5 (Receptacle) pin 13 - 138 RH LOW BEAM LAMP VT - 0.8
SFB [SH3: D-3] (47554342)
27 SP-130-P-X 130D RH POSITION VT - 0.8
28 X-X5 (Receptacle) pin 15 - 135 RH FRONT TURN VT - 0.8
SFB [SH3: D-3] (47554342)
X-CAB_E - CAB TO ENGINE [ SH7: B-5] (84807216) (Receptacle)
84807216 38
84807216
1 X-LC5 (Receptacle) pin 9A - 850 IGN PWR FOR REAR OR - 2.0 SHEET 11 SH11 - PWR DISTR ENG
LOADCENTER 5 [SH10: D-1] COMPARTMENT (FUSE BLOCK LC6)
(87733595)
2 X-LC2 (Receptacle) pin 9A - 205 HOOD LIFT RD - 2.0 SHEET 37 SH37 - HOOD LIFT
LOADCENTER 2 [SH7: B-3]
(87733581)
3 X-SP_PK_CLN (Receptacle) 857 CLEAN GROUND BK - 2.0 SHEET 12 SH12 - POWER DISTRIBUTION 1
pin X - SPLICE PACK CLEAN CLEAN GROUND BLK
GRND [SH25: C-1] (87352746)
4 X-LC2 (Receptacle) pin 9B - 216E HOOD LIFT NON-DISC RD - 2.0 SHEET 03 SH03 - PWR DISTR-BATTERY /
LOADCENTER 2 [SH7: B-3] PWR STARTER / KEY
(87733581)
5 X-UCM4A (Receptacle) pin 433 COOLANT TEMP YE - 0.8 SHEET 19 SH19 - UCM PWR, GRND,
6 X-X4 (Receptacle) pin 9 - SFB 131 RH REAR TURN LAMP VT - 0.8 SHEET 29 SH29 - LIGHTING REAR TAILS
(47554343)
7 X-X4 (Receptacle) pin 21 - 121 BACKUP ALARM OR - 0.8 SHEET 36 SH36 - REAR DEFROST, BACKUP
SFB (47554343) ALARM
8 X-UCM4A (Receptacle) pin 633 FUEL LEVEL YE - 0.8 SHEET 19 SH19 - UCM PWR, GRND,
9 SP-482-P-X 482G 5V GRND1 BL - 0.8
10 X-X6 (Receptacle) pin 2 - SFB 126 LH BRAKE LAMP VT - 0.8 SHEET 29 SH29 - LIGHTING REAR TAILS
[A-SFB] (47554341)
11 SP-130-P-X 130A RH TAIL LAMP VT - 0.8 SHEET 28 SH28 - LIGHTING HAZARD
12 SP-127-P-X 127D LH TAIL LAMP VT - 0.8 WARNING, BLINKERS, DRIVING
13 SP-LA-P-X CAN_LA CAN GN - 0.8 SHEET 24 SH24 - CAN STRUCTURE
14 SP-HA-P-X CAN_HA CAN YE - 0.8
15 X-UCM3A (Receptacle) pin 5 663 OK TO START YE - 0.8 SHEET 20 SH20 - UCM VEHICLE DRIVELINE
- UCM (84130757) / FAN CONTROL
16 X-UCM4B (Receptacle) pin 400 FAN SPEED SENSOR YE - 0.8
30 - UCM [A-UCM] (82028495) SGNL
17 X-X7 (Receptacle) pin 67 - 239A ALT LAMP SIGNAL YE - 0.8 SHEET 03 SH03 - PWR DISTR-BATTERY /
SFB [SH3: A-3] (84538791) STARTER / KEY
18 X-UCM2A (Receptacle) pin 319 AIR FILTER REST SW T2 YE - 0.8 SHEET 20 SH20 - UCM VEHICLE DRIVELINE
17 - UCM (82028493) / FAN CONTROL
19 SP-124-P-X 124A REVERSE LIGHTS VT - 0.8 SHEET 39 SH39 - MISCELLANOUS, REAR
CAMERA
48083741_EN 31/07/2018
55.1 [55.100] / 130

20 X-DIA (Plug) pin E - 303 ISO K LINE WH - 0.8 SHEET 16 SH16 - ENGINE CONTROL UNIT
DIAGNOSTIC PORT [A-DIA] 1, GRID HEATER, FILTER HEATER
(87736919)
21 X-X3 (Receptacle) pin 12 - 129 LH BRAKE LAMP VT - 0.8 SHEET 29 SH29 - LIGHTING REAR TAILS
SFB [SH3: A-1] (47554344)
22 X-X5 (Receptacle) pin 18 - 128 LH REAR TURN LAMP VT - 0.8
SFB [SH3: D-3] (47554342)
25 X-X3 (Receptacle) pin 17 - 280 LICENSE PLATE LIGHT VT - 0.8 SHEET 27 SH27 - LIGHTING DOME, MAP
SFB [SH3: A-1] (47554344) LIGHTS
26 X-X5 (Receptacle) pin 4 - SFB 228A ALTERNATOR VOLTAGE RD - 0.8 SHEET 03 SH03 - PWR DISTR-BATTERY /
[SH3: D-3] (47554342) STARTER / KEY
28 SP-677-P-X 677L FSS PWR PK - 0.8 SHEET 20 SH20 - UCM VEHICLE DRIVELINE
/ FAN CONTROL
X-CAB_E-2 - CAB TO ENG 2 [ SH9: C-2] (87703902) (Plug)
87703902 39
87703902
A X-THRTL (Receptacle) pin 409 THROTTLE PEDAL YE - 0.8 SHEET 16 SH16 - ENGINE CONTROL UNIT
A - THROTTLE CONTROL POSITION 1, GRID HEATER, FILTER HEATER
[B-ACCEL] (84403598)
B X-THRTL (Receptacle) pin 471B 5V REF2 PK - 0.8
C - THROTTLE CONTROL
[B-ACCEL] (84403598)
C X-THRTL (Receptacle) pin 651H 5V GND2 BL - 0.8
B - THROTTLE CONTROL
[B-ACCEL] (84403598)
D X-THRTL (Receptacle) pin 408 THROTTLE IDLE SW WH - 0.8
D - THROTTLE CONTROL
[B-ACCEL] (84403598)
E X-THRTL (Receptacle) pin 643C THROTTLE GRND BK - 0.8
F - THROTTLE CONTROL
[B-ACCEL] (84403598)
F X-X4 (Receptacle) pin 17 - 250 ISOLATOR SET YE - 0.8 SHEET 03 SH03 - PWR DISTR-BATTERY /
SFB (47554343) STARTER / KEY
G X-X7 (Receptacle) pin 8 - SFB 237 ISOLATOR RESET YE - 0.8
[SH3: A-3] (84538791)
H X-X_TEL (Receptacle) pin 12 217A TELE NON- RD - 0.8
- TELEMATICS [SH38: C-6] DISCONNECTED PWR
(87700156)
J SP-219A-P-X 219A NON ISOLATED PWR RD - 0.8
K X-LC4 (Receptacle) pin 3A - 875 AC CLUTCH PWR OR - 1.0 SHEET 11 SH11 - PWR DISTR ENG
LOADCENTER 4 [SH35: C-6] COMPARTMENT (FUSE BLOCK LC6)
(87733595)
L X-HVAC (Receptacle) pin 246 SIG_HVAC_A/C HIGH YE - 0.8 SHEET 33 SH33 - HEATING BLOWER
B - INTRCECT TO HVAC PRESSURE SW HEATER, HVAC
D-4] (87696573)
M X-UCM2A (Receptacle) pin 582 HEAT LOAD VALVE BR - 0.8 SHEET 20 SH20 - UCM VEHICLE DRIVELINE
22 - UCM (82028493) SIGNAL / FAN CONTROL
N X-UCM2A (Receptacle) pin 692 FAN REVERSER SGNL BR - 0.8
21 - UCM (82028493)
P X-UCM2A (Receptacle) pin 392 FAN CONTROL SGNL YE - 0.8
25 - UCM (82028493)
48083741_EN 31/07/2018
55.1 [55.100] / 131
X-CAB_EH - CAB TO BOTTOM EH (87700159) (Plug)
87700159 40
87700159
A X-UCM3B (Receptacle) pin 344 PILOT ENABLE WH - 0.8 SHEET 22 SH22 - UCM-LOADER BOOM
18 - UCM [A-UCM] (84130760) CONTROL
B X-UCM4A (Receptacle) pin 7 340 BOOM RAISE WH - 0.8
- UCM (82028493)
C X-UCM1B (Receptacle) pin 2 339 BOOM ENABLE BR - 0.8
- UCM [SH22: A-6] (87410946)
D X-UCM4A (Receptacle) pin 6 341 BOOM LOWER WH - 0.8
- UCM (82028493)
E X-UCM3B (Receptacle) pin 346 BUCKET ROLL WH - 0.8
17 - UCM [A-UCM] (84130760)
F X-UCM1B (Receptacle) pin 30 347 BUCKET ENABLE BR - 0.8
- UCM [SH22: A-6] (87410946)
G X-UCM3B (Receptacle) pin 350 BUCKET DUMP WH - 0.8
25 - UCM [A-UCM] (84130760)
H X-UCM3B (Receptacle) pin 351 AUX 1 LEFT WH - 0.8
32 - UCM [A-UCM] (84130760)
J X-UCM1B (Receptacle) pin 10 352 AUX 1 ENABLE BR - 0.8
- UCM [SH22: A-6] (87410946)
K X-UCM3B (Receptacle) pin 355 AUX 1 RIGHT WH - 0.8
33 - UCM [A-UCM] (84130760)
L X-UCM4A (Receptacle) pin 356 AUX 2 LEFT WH - 0.8
19 - UCM (82028493)
M X-UCM1A (Receptacle) pin 357 AUX 2 ENABLE BR - 0.8
21 - UCM (82016219)
N X-UCM4A (Receptacle) pin 360 AUX 2 RIGHT WH - 0.8
13 - UCM (82028493)
S X-UCM1B (Receptacle) pin 19 647 BOOM ANGLE 1 YE - 0.8
- UCM [SH22: A-6] (87410946)
T X-UCM1B (Receptacle) pin 22 648 BOOM ANGLE 2 YE - 0.8
- UCM [SH22: A-6] (87410946)
W X-UCM1B (Receptacle) pin 21 653 BUCKET ANGLE 1 YE - 0.8
- UCM [SH22: A-6] (87410946)
X X-UCM1B (Receptacle) pin 23 654 BUCKET ANGLE 2 YE - 0.8
- UCM [SH22: A-6] (87410946)
48083741_EN 31/07/2018
55.1 [55.100] / 132
X-CAB_JSS - CAB TO JSS FRAME HARNESS [ SH24: A-6] (87694112) (Receptacle)
87694112 41
87694112
1 SP-799-P-X 799A JSS PILOT DUMP OR - 0.8 SHEET 10 SH10 - IGNITION PWR DISTR
(FUSE BLOCK LC5)
2 X-UCM3A (Receptacle) pin 676 JSS PILOT PRESS SIG YE - 0.8 SHEET 21 SH21 - UCM-STEERING AUX JSS
12 - UCM (84130757)
3 SP-677-P-X 677 5V REF3 OUT PK - 0.8
5 X-CG4 (Receptacle) pin B - 955X JSS GROUND BK - 0.8
CAB GROUND [SH24: B-6]
(84149207)
6 X-UCM3B (Receptacle) pin 273 JSS CUTOFF SIG B YE - 0.8
15 - UCM [A-UCM] (84130760)
X-CAB_L - CAB TO JSS L ARMREST (87700156) (Receptacle)
87700156 42
87700156
48083741_EN 31/07/2018
55.1 [55.100] / 133

1 SP-471-P-X 471J 5V REF2 PK - 0.8 SHEET 21 SH21 - UCM-STEERING AUX JSS
2 X-UCM2A (Receptacle) pin 670 JSS JOYSTICK 1 YE - 0.8
18 - UCM (82028493)
3 SP-651-P-X 651L 5V GND2 BL - 0.8
4 X-UCM2B (Receptacle) pin 675 LH ARMREST POSITION GY - 0.8
12 - UCM [A-UCM] (82028495) UP
5 X-UCM2A (Receptacle) pin 630 JSS JOYSTICK 2 YE - 0.8
12 - UCM (82028493)
6 SP-967-P-X 967C 5 V REF GRND3 BL - 0.8
7 SP-677-P-X 677C 5V REF3 OUT PK - 0.8
8 X-UCM2B (Receptacle) pin 673 LH ARMREST POSITION TN - 0.8
20 - UCM [A-UCM] (82028495) DWN
9 X-UCM3B (Receptacle) pin 678 JSS ACTIVATION WH - 0.8
16 - UCM [A-UCM] (84130760)
10 SP-799-P-X 799B JSS IGNITION POWER OR - 0.8
11 X-CG4 (Receptacle) pin J - 954J LH JSS GND BK - 0.8
(84149207)
12 X-UCM3B (Receptacle) pin 682 JSS ACTIVATION NC YE - 0.8
23 - UCM [A-UCM] (84130760)
X-CAB_L2 - CAB TO LEFT JSS (87696138) (Receptacle)
87696138 43
87696138
1 X-UCM4B (Receptacle) pin 691 JSS INDICATOR WH - 0.8 SHEET 21 SH21 - UCM-STEERING AUX JSS
16 - UCM [A-UCM] (82028495)
2 SP-981-P-X 981J BACKLIGHTING VT - 0.8
X-CAB_P - CAB TO PEDESTAL [ SH20: D-2] (87700155) (Plug)
87700155 44
87700155
2 X-X5 (Receptacle) pin 16 - 189 RH TURN INDICATOR VT - 0.8 SHEET 28 SH28 - LIGHTING HAZARD
SFB [SH3: D-3] (47554342) WARNING, BLINKERS, DRIVING
3 SP-132-P-X 132C LH HIGH BEAM LAMP VT - 0.8
48083741_EN 31/07/2018
55.1 [55.100] / 134

4 SP-113-P-X 113A RH STALK HORN BR - 0.8 SHEET 34 SH34 - MIRRORS, HORN BEACON
SWITCH
5 X-UCM4B (Receptacle) pin 9 134 WARNING INDICATOR YE - 0.8 SHEET 20 SH20 - UCM VEHICLE DRIVELINE
- UCM [A-UCM] (82028495) LED / FAN CONTROL
6 X-X7 (Receptacle) pin 28 - 141 HAZARD SWITCH YE - 0.8 SHEET 28 SH28 - LIGHTING HAZARD
SFB [SH3: A-3] (84538791) WARNING, BLINKERS, DRIVING
7 X-CG4 (Receptacle) pin D - 954D PEDESTAL GND BK - 1.0
(84149207)
8 X-X3 (Receptacle) pin 16 - 269A HAZARD INDICATOR BK - 0.8
SFB [SH3: A-1] (47554344) LIGHT
9 SP-19H-P-X 19J IGN PWR OR - 0.8 SHEET 24 SH24 - CAN STRUCTURE
10 SP-HL-P-X CAN_HN CAN YE - 0.8
11 SP-LL-P-X CAN_LN CAN GN - 0.8
X-CAB_P2 - CAB TO PEDESTAL 2 [ SH27: B-2] (87705101) (Receptacle)
87705101 45
87705101
1 X-UCM2A (Receptacle) pin 679 STALK FNR R YE - 0.8 SHEET 20 SH20 - UCM VEHICLE DRIVELINE
11 - UCM (82028493) / FAN CONTROL
2 X-UCM2A (Receptacle) pin 680 STALK FNR N YE - 0.8
16 - UCM (82028493)
3 X-UCM2A (Receptacle) pin 686 STALK FNR F YE - 0.8
10 - UCM (82028493)
5 X-UCM2B (Receptacle) pin 407 GEAR SELECT 3_4 YE - 0.8
21 - UCM [A-UCM] (82028495)
6 SP-19C-P-X 19D IGN PWR OR - 0.8
8 X-X7 (Receptacle) pin 56 - 728 REAR WASHER SWITCH YE - 0.8 SHEET 32 SH32 - CAB WIPER / WASHER
SFB [SH3: A-3] (84538791)
9 X-X7 (Receptacle) pin 55 - 727 REAR WIPER SWITCH YE - 0.8
SFB [SH3: A-3] (84538791)
11 X-X4 (Receptacle) pin 3 - SFB 283 REAR WIPER INDICATOR VT - 0.8
(47554343)
12 SP-981-P-X 981D SWITCH BACK LIGHTING VT - 0.8 SHEET 27 SH27 - LIGHTING DOME, MAP
LIGHTS
48083741_EN 31/07/2018
55.1 [55.100] / 135
X-CAB_R - CAB TO ROOF (87695891) (Plug)
87695891 46
87695891
1 X-X3 (Receptacle) pin 2 - SFB 111 LEFT FRONT WORK VT - 1.0 SHEET 31 SH31 - LIGHTING WORKING
[SH3: A-1] (47554344) LIGHT LIGHTS CAB ROOF, FRONT AND REAR
2 X-X3 (Receptacle) pin 1 - SFB 724 RIGHT FRONT WORK VT - 1.0
[SH3: A-1] (47554344) LIGHT
3 X-X3 (Receptacle) pin 3 - SFB 851 ROTATING BEACON VT - 0.8 SHEET 34 SH34 - MIRRORS, HORN BEACON
[SH3: A-1] (47554344)
4 X-X5 (Receptacle) pin 6 - SFB 114 MIRROR HEAT SUPPLY TN - 1.0
[SH3: D-3] (47554342)
5 X-X4 (Receptacle) pin 19 - 859 REAR WORK LIGHTS VT - 1.0 SHEET 31 SH31 - LIGHTING WORKING
SFB (47554343) LIGHTS CAB ROOF, FRONT AND REAR
7 CG1-P-1 CAB GROUND RH 953 ROOF GND BK - 2.0
HEADLINER
X-CAB_TR - CAB TO TRANSMISSION [ SH26: A-2] (87696944) (Receptacle)
87696944 47
87696944
1 X-UCM1A (Receptacle) pin 443 BRAKE ACCUMULATOR YE - 0.8 SHEET 19 SH19 - UCM PWR, GRND,
15 - UCM (82016219) PRSR INSTRUMENTATION
2 SP-702A-P-X 702E SPEED SENSOR GRND BL - 0.8 SHEET 26 SH26 - GEAR CONTROL UNIT 2
3 SP-482-P-X 482B 5V GRND1 BL - 0.8 SHEET 19 SH19 - UCM PWR, GRND,
INSTRUMENTATION
4 X-X6 (Receptacle) pin 9 - SFB 106 REAR WASHER MOTOR OR - 0.8 SHEET 32 SH32 - CAB WIPER / WASHER
[A-SFB] (47554341)
5 X-TECM (Receptacle) pin 842 VALVE BODY TEMP SIG YE - 0.8 SHEET 25 SH25 - GEAR CONTROL UNIT 1
39 - TRANS CONTROLLER
[SH25: C-6] (84550089)
48083741_EN 31/07/2018
55.1 [55.100] / 136

7 X-TECM (Receptacle) pin 699 ENG SPEED SENSOR YE - 0.8 SHEET 26 SH26 - GEAR CONTROL UNIT 2
[SH25: C-6] (84550089)
8 X-TECM (Receptacle) pin 700 TURBINE SPEED YE - 0.8
41 - TRANS CONTROLLER SENSOR
[SH25: C-6] (84550089)
9 X-TECM (Receptacle) pin 701 INTERMEDIATE SPEED YE - 0.8
[SH25: C-6] (84550089)
10 X-TECM (Receptacle) pin 578A OUTPUT SPEED YE - 0.8
[SH25: C-6] (84550089)
11 SP-702A-P-X 702A SPEED SENSOR GRND BL - 0.8
12 X-TECM (Receptacle) pin 697 TRANS SIGNL RETURN BL - 0.8
[SH25: C-6] (84550089)
13 X-TECM (Receptacle) pin 425 GEAR OIL TEMP YE - 0.8
[SH25: C-6] (84550089)
14 SP-702A-P-X 702F SPEED SENSOR GRND BL - 0.8
15 X-TECM (Receptacle) pin 419 TRANS LOCKUP BR - 0.8 SHEET 25 SH25 - GEAR CONTROL UNIT 1
50 - TRANS CONTROLLER SOLENOID
[SH25: C-6] (84550089)
16 X-TECM (Receptacle) pin 834 K4 CLUTCH TN - 0.8
[SH25: C-6] (84550089)
17 X-TECM (Receptacle) pin 836 KR CLUTCH TN - 0.8
[SH25: C-6] (84550089)
[SH25: C-6] (84550089)
[SH25: C-6] (84550089)
20 X-TECM (Receptacle) pin 839 KV CLUTCH TN - 0.8
[SH25: C-6] (84550089)
22 SP-841-P-X 841A TRANS OUTPUT SW WH - 0.8
PWR VPS1
23 X-UCM3A (Receptacle) pin 636 HYD FILTER YE - 0.8 SHEET 19 SH19 - UCM PWR, GRND,
24 X-UCM1A (Receptacle) pin 638 RED BRAKE SW SIG YE - 0.8
17 - UCM (82016219)
25 SP-420C-P-X 420C TECM POWER WH - 0.8 SHEET 25 SH25 - GEAR CONTROL UNIT 1
26 SP-486-P-X 486B 5V PWR REF 1 PK - 0.8 SHEET 19 SH19 - UCM PWR, GRND,
INSTRUMENTATION
27 X-UCM3B (Receptacle) pin 1 390 DIFF LOCK SIGNAL WH - 0.8 SHEET 20 SH20 - UCM VEHICLE DRIVELINE
- UCM [A-UCM] (84130760) / FAN CONTROL
28 X-TECM (Receptacle) pin 703 OUTPUT SPEED BL - 0.8 SHEET 26 SH26 - GEAR CONTROL UNIT 2
[SH25: C-6] (84550089)
29 SP-19C-P-X 19G OUTPUT SP SENS IGN OR - 0.8 SHEET 10 SH10 - IGNITION PWR DISTR
PWR (FUSE BLOCK LC5)
30 X-UCM4A (Receptacle) pin 634 HYD OIL TEMP SIG YE - 0.8 SHEET 19 SH19 - UCM PWR, GRND,
31 X-TECM (Receptacle) pin 423 FILTER MAINTENANCE WH - 0.8 SHEET 26 SH26 - GEAR CONTROL UNIT 2
17 - TRANS CONTROLLER SIGNAL
[SH25: C-6] (84550089)
48083741_EN 31/07/2018
55.1 [55.100] / 137
X-CAM - REAR CAMERA (87700107) (Receptacle)
87700107 48
87700107
1 X-LC2 (Receptacle) pin 11A 125 REVERSE CAMERA OR - 0.8 SHEET 39 SH39 - MISCELLANOUS, REAR
- LOADCENTER 2 [SH7: B-3] POWER CAMERA
(87733581)
2 X-CG3 (Receptacle) pin 955AD CAMERA MONITOR BK - 0.8
D - CAB GROUND RH GROUND
(84149207)
3 SP-124-P-X 124B REVERSE SIGNAL VT - 0.8
X-CAM2 - CAMERA CHORD (87700106) (Plug)
87700106 49
87700106
X-CAN - CAN (87696093) (Receptacle)
87696093 50
87696093
48083741_EN 31/07/2018
55.1 [55.100] / 138

1 X-ECU (Receptacle) pin 71 - 671 CAN HI PROTO ONLY YE - 0.8 SHEET 18 SH18 - ENGINE CONTROL UNIT
ECU CONNECTOR [A-ECU] 3, AT
(84300197)
2 X-ECU (Receptacle) pin 95 - 695 CAN LO PROTO ONLY GN - 0.8
(84300197)
X-CG3 - CAB GROUND RH HEADLINER [ SH13: D-5] (84149207) (Receptacle)
84149207 51
84149207
A X-S_RDF (Receptacle) pin 9 955A REAR DEFROST SWITCH BK - 0.8 SHEET 13 SH13 - POWER DISTRIBUTION 2
- SWITCH REAR DEFROST IND GND CAB GROUND BLK
[SW-R_DEF_SW] (87716755)
B X-S_HMR (Receptacle) pin 9 955J MIRROR HEATER BK - 0.8
- SWITCH HEATED MIRRORS INDICATOR GND
[SH13: D-4] (87716755)
C X-S_HMR (Receptacle) pin 2 955K MIRROR HEATER SW BK - 0.8
- SWITCH HEATED MIRRORS GND
[SH13: D-4] (87716755)
D X-CAM (Receptacle) pin 2 - 955AD CAMERA MONITOR BK - 0.8
REAR CAMERA (87700107) GROUND
F X-S_RDF (Receptacle) pin 2 955R REAR DEFROST SWITCH BK - 0.8
- SWITCH REAR DEFROST GND
[SW-R_DEF_SW] (87716755)
H X-DM_G (Receptacle) pin 955N MAP LIGHT GND BK - 0.8
1 - DOME LIGHT GROUND
[LMP-DM] (87688695)
J X-DS (Receptacle) pin 2 - 955P LH DOOR AJAR SW GND BK - 0.8
DOOR SWITCH [SH27: C-6]
(87382906)
K X-MAP (Receptacle) pin C 955Q MAP LIGHT GND BK - 0.8
- MAP LIGHT [SH13: C-6]
(84058093)
L X-RWM_G (Plug) pin A - 955V REAR WIPER MOTOR BK - 1.0
REAR WIPER MOTOR GRND GND
[SH13: C-2] (87693744)
M X-S_HMR (Receptacle) pin 7 954B CAB GRND BK - 0.8
- SWITCH HEATED MIRRORS
[SH13: D-4] (87716755)
48083741_EN 31/07/2018
55.1 [55.100] / 139
X-CG4 - CAB GROUND [ SH24: B-6] (84149207) (Receptacle)
84149207 52
84149207
A X-LC4 (Receptacle) pin 85 - 954A ACCESSORY RELAY BK - 0.8 SHEET 13 SH13 - POWER DISTRIBUTION 2
LOADCENTER 4 [SH35: C-6] COIL GND CAB GROUND BLK
(87733595)
B X-CAB_JSS (Receptacle) 955X JSS GROUND BK - 0.8
pin 5 - CAB TO JSS FRAME
HARNESS [SH24: A-6]
(87694112)
C X-SC (Plug) pin B - SEAT 955L SEAT COMPRESSOR BK - 2.0
COMPRESSOR [Y-SC] GND
(87692855)
D X-CAB_P (Plug) pin 7 - CAB 954D PEDESTAL GND BK - 1.0
TO PEDESTAL [SH20: D-2]
(87700155)
E X-DSP (Receptacle) pin X - 954E DISPLAY GND BK - 0.8
DISPLAY [A-DSP] (82016219)
F X-LC3 (Receptacle) pin 954F SPARE RELAY COIL GND BK - 0.8
[SH35: B-6] (84529039)
G SP-954L-P-X 954L CAB GROUND BK - 0.8
H X-LC5 (Receptacle) pin 85 - 954H IGNITION RELAY COIL BK - 0.8
LOADCENTER 5 [SH10: D-1] GND
(87733595)
J X-CAB_L (Receptacle) pin 11 954J LH JSS GND BK - 0.8
- CAB TO JSS L ARMREST
(87700156)
K X-CAB_AR (Plug) pin 2 - CAB 954K RH ARMREST JOYSTICK BK - 1.0
TO RH ARM REST (87694152) GND
M SP-954S-P-X 954S GROUND BK - 0.8
X-CL - CIGAR LIGHTER [ LMP-CIG_LTR] (84015523) (Receptacle)
84015523 53
84015523
48083741_EN 31/07/2018
55.1 [55.100] / 140

1 X-LC4 (Receptacle) pin 1A - 743 24V CIGAR LIGHTER OR - 2.0 SHEET 35 SH35 - CABIN RADIO
LOADCENTER 4 [SH35: C-6] LOUDSPEAKER/12V CNVRTR
(87733595)
X-CNV - 24 TO 12 POWER CONVERTER [ SH35: B-4] (87694112) (Receptacle)
87694112 54
87694112
1 SP-746-P-X 746A POWER CONVERTER OR - 2.0 SHEET 35 SH35 - CABIN RADIO
ACC POWER LOUDSPEAKER/12V CNVRTR
2 SP-746-P-X 746B POWER CONVERTER OR - 2.0
ACC POWER
3 CG2-P-1 CAB GROUND 277 CAB GROUND BK - 2.0
BLOCK
5 X-LC3 (Receptacle) pin F3_11 748 12V ACC POWER OR - 2.0 SHEET 08 SH08 - POWER DISTRIBUTION
- LOADCENTER 3 [SH35: B-6] (FUSE BLOCK LC3)
(84529039)
6 CG2-P-1 CAB GROUND 276 CAB GROUND BK - 2.0 SHEET 14 SH14 - CAB & CHASSIS GROUND
BLOCK PWR DISTR
X-COV1 - CUT OFF VALVE SOL [ Y-C0V_1] (87695582) (Receptacle)
87695582 55
87695582
1 SP-854A-P-X 854 JSS COV WH - 0.8 SHEET 21 SH21 - UCM-STEERING AUX JSS
2 SP-955Y-P-X 955AB JSS GROUND BK - 0.8
48083741_EN 31/07/2018
55.1 [55.100] / 141
X-COV2 - CUT OFF VALVE SOL [ Y-COV_2] (87695582) (Receptacle)
87695582 56
87695582
1 SP-854A-P-X 854B JSS COV WH - 0.8 SHEET 21 SH21 - UCM-STEERING AUX JSS
2 SP-955Y-P-X 955AC JSS GROUND BK - 0.8
X-CP - CAB POWER (84401295) (Plug)
84401295 57
84401295
1 JC4-P-1 CAB POWER FROM 240 CAB POWER RD - 19.0 SHEET 03 SH03 - PWR DISTR-BATTERY /
REAR STUD STARTER / KEY
X-CPWR - CAB POWER (84401295) (Plug)
84401295 58
84401295
1 X-JC1 (Plug) pin 1 - 235 B+ TO REAR JUNCTION RD - 19.0 SHEET 03 SH03 - PWR DISTR-BATTERY /
JUNCTION STUD OF B+ BLOCK STARTER / KEY
IN REAR (84399576)
48083741_EN 31/07/2018
55.1 [55.100] / 142
X-CTS - DOC UPSTREAM TEMP [ B-C_TS] (84532147) (Receptacle)
84532147 59
84532147
1 X-SCR2 (Plug) pin 8 - INLINE 616A DOC UPSTREAM TEMP YE - 0.8 SHEET 17 SH17 - ENGINE CONTROL UNIT
FROM SCR SENSORS 2, AT
HARNESS (87695724)
1 X-ECU (Receptacle) pin 16 - 616B TEMP SENSOR DOC UP YE - 0.8
(84300197)
2 SP-610-P-X 610F TEMP SENSOR GRND BK - 0.8
2 X-SCR2 (Plug) pin 7 - INLINE 610E TEMP SENSOR GROUND BK - 0.8
FROM SCR SENSORS
HARNESS (87695724)
X-D(B) - MASTER DISCONNECT BATTERY (84140737) (Plug)
84140737 60
84140737
1 X-566 (Plug) pin 1 - BATTERY CABLE-003 BATTERY POWER RD - 62.0 SHEET 03 SH03 - PWR DISTR-BATTERY /
POSITIVE [G-002] STARTER / KEY
48083741_EN 31/07/2018
55.1 [55.100] / 143
X-D(S) - MASTER DISCONNECT SWITCHED [ K-ISOLATOR] (84163398) (Plug)
84163398 61
84163398
1 X-XM1B (Plug) pin 1 - CABLE-004 BATTERY CABLE RD - 62.0 SHEET 03 SH03 - PWR DISTR-BATTERY /
STARTER LUG FROM STARTER / KEY
ISOLATOR (84596842)
X-DC2 - NON-DISC POWER STUD [ K-ISOLATOR] (84140737) (Plug)
84140737 62
84140737
1 SP-216A-P-X 216A NON-DISCONNECT PWR RD - 3.0 SHEET 03 SH03 - PWR DISTR-BATTERY /
STARTER / KEY
X-DEF1 - INLINE TO DEF QUALITY SENSOR (87694153) (Receptacle)
87694153 63
87694153
48083741_EN 31/07/2018
55.1 [55.100] / 144

1 SP-201-P-X 201A SCR SENSORS CLEAN BK - 1.0 SHEET 18 SH18 - ENGINE CONTROL UNIT
GROUND 3, AT
1 SP-201D-P-X 201J SCR SENSORS CLEAN BK - 1.0
GROUND
2 SP-CAN_L1-P-X CANC_LA CAN GN - 0.8
3 SP-CAN_H1-P-X CANC_HA CAN YE - 0.8
4 SP-200-P-X 200A SCR SENSOR POWER OR - 1.0
4 SP-200D-P-X 200H SCR SENSOR POWER OR - 1.0
X-DEF2 - INLINE FROM DEF QUALITY SENSOR (87694154) (Plug)
87694154 64
87694154
1 X-DEFQ pin 6 - DEF QUALITY 201C SCR SENSORS CLEAN BK - 1.0 SHEET 18 SH18 - ENGINE CONTROL UNIT
SENSOR (UQS) [B-DEF_Q] GROUND 3, AT
(84149219)
2 X-DEFQ pin 5 - DEF QUALITY CANC_LZ CAN GN - 0.8
(84149219)
3 X-DEFQ pin 4 - DEF QUALITY CANC_HZ CAN YE - 0.8
(84149219)
4 X-DEFQ pin 3 - DEF QUALITY 200C SCR SENSOR POWER OR - 1.0
(84149219)
X-DEFQ - DEF QUALITY SENSOR (UQS) [ B-DEF_Q] (84149219) (Receptacle)
84149219 65
84149219
48083741_EN 31/07/2018
55.1 [55.100] / 145
X-DIA - DIAGNOSTIC PORT [ A-DIA] (87736919) (Plug)
87736919 66
87736919
A X-SP_PK_CLN (Receptacle) 945 CAB CLEAN GROUND BK - 0.8 SHEET 16 SH16 - ENGINE CONTROL UNIT
pin X - SPLICE PACK CLEAN DIAG 1, GRID HEATER, FILTER HEATER
GRND [SH25: C-1] (87352746)
B X-LC2 (Receptacle) pin 8A - 798 DIAGNOSTIC B+ RD - 0.8
(87733581)
C SP-HH-P-X CAN_HI CAN YE - 0.8
D SP-LH-P-X CAN_LI CAN GN - 0.8
E X-CAB_E (Receptacle) pin 20 303 ISO K LINE WH - 0.8
- CAB TO ENGINE [SH7: B-5]
(84807216)
H SP-B_HE-P-X CANB_HD CAN WH - 0.8
J SP-B_LE-P-X CANB_LD CAN BL - 0.8
X-DIAG_T - TELEMATICS DIAGNOSTIC [ SH38: B-1] (87694101) (Receptacle)
87694101 67
87694101
2 X-X_TEL (Receptacle) pin 7 CAN_TH CAN TN - 0.8 SHEET 38 SH38 - MISCELLANOUS,
- TELEMATICS [SH38: C-6] TELEMATICS
(87700156)
3 X-X_TEL (Receptacle) pin 6 CAN_TL CAN LB - 0.8
- TELEMATICS [SH38: C-6]
(87700156)
4 X-SP_PK_CLN (Receptacle) 912 CAB GROUND CLN BK - 0.8 SHEET 12 SH12 - POWER DISTRIBUTION 1
pin X - SPLICE PACK CLEAN CLEAN GROUND BLK
GRND [SH25: C-1] (87352746)
48083741_EN 31/07/2018
55.1 [55.100] / 146
X-DM_G - DOME LIGHT GROUND [ LMP-DM] (87688695) (Receptacle)
87688695 68
87688695
1 X-CG3 (Receptacle) pin 955N MAP LIGHT GND BK - 0.8 SHEET 27 SH27 - LIGHTING DOME, MAP
H - CAB GROUND RH LIGHTS
(84149207)
X-DM_P - DOME LIGHT POSITIVE [ LMP-DM] (84015523) (Receptacle)
84015523 69
84015523
1 X-X6 (Receptacle) pin 17 - 148 EGRESS/DOME LAMP B+ VT - 0.8 SHEET 27 SH27 - LIGHTING DOME, MAP
SFB [A-SFB] (47554341) LIGHTS
2 X-X5 (Receptacle) pin 12 - 149 DOME LAMP SW OR - 0.8
SFB [SH3: D-3] (47554342)
X-DS - DOOR SWITCH [ SH27: C-6] (87382906) (Receptacle)
87382906 70
87382906
48083741_EN 31/07/2018
55.1 [55.100] / 147

1 X-X7 (Receptacle) pin 80 - 151 LH DOOR AJAR SW YE - 0.8 SHEET 27 SH27 - LIGHTING DOME, MAP
SFB [SH3: A-3] (84538791) LIGHTS
2 X-CG3 (Receptacle) pin 955P LH DOOR AJAR SW GND BK - 0.8 SHEET 13 SH13 - POWER DISTRIBUTION 2
J - CAB GROUND RH CAB GROUND BLK
(84149207)
X-DSP - DISPLAY [ A-DSP] (82016219) (Receptacle)
82016219 71
82016219
X-DSR - UREA DOSING VALVE [ Y-DSV] (87709798) (Receptacle)
87709798 72
87709798
1 X-ECU (Receptacle) pin 96 - 696B DOSING VALVE TN - 0.8 SHEET 17 SH17 - ENGINE CONTROL UNIT
(84300197)
1 X-SCR2 (Plug) pin 5 - INLINE 696A DOSING VALVE TN - 0.8
FROM SCR SENSORS
HARNESS (87695724)
2 X-ECU (Receptacle) pin 23 - 623B DOSING VALVE WH - 0.8
(84300197)
2 X-SCR2 (Plug) pin 6 - INLINE 623A UREA DOSING VALVE 2 WH - 0.8
FROM SCR SENSORS
HARNESS (87695724)
48083741_EN 31/07/2018
55.1 [55.100] / 148
X-DTLTS - DEF LEVEL / TEMP [ B-U_LVL] (84062580) (Plug)
84062580 73
84062580
X-DTS - SCR DOWNSTREAM TEMP [ B-D_TS] (84532147) (Receptacle)
84532147 74
84532147
1 X-ECU (Receptacle) pin 9 - 609B TEMP SENSOR SCR UP YE - 0.8 SHEET 17 SH17 - ENGINE CONTROL UNIT
(84300197)
1 X-SCR2 (Plug) pin 10 - INLINE 609A SCR DOWNSTREAM YE - 0.8
FROM SCR SENSORS TEMP
HARNESS (87695724)
2 SP-610-P-X 610G TEMP SENSOR GROUND BK - 0.8
2 X-SCR2 (Plug) pin 9 - INLINE 610C TEMP SENSOR GROUND BK - 0.8
FROM SCR SENSORS
HARNESS (87695724)
X-ECU - ECU CONNECTOR [ A-ECU] (84300197) (Receptacle)
84300197 75
84300197
48083741_EN 31/07/2018
55.1 [55.100] / 149

1 SP-233-P-X 233A EDC FUSED POWER RD - 1.0 SHEET 16 SH16 - ENGINE CONTROL UNIT
3 SP-603-P-X 603A CLEAN GROUND BK - 1.0 1, GRID HEATER, FILTER HEATER
5 SP-603-P-X 603B CLEAN GROUND BK - 1.0
7 X-PUMP pin 3 - DENOX 607 DENOX CONTROL UNIT YE - 0.8 SHEET 18 SH18 - ENGINE CONTROL UNIT
CONTROL UNIT [A-PMP] 3 3, AT
(47421681)
8 X-LEV1 pin 3 - INLINE TO DEF 608 SCR LEVEL AND TEMP YE - 0.8 SHEET 17 SH17 - ENGINE CONTROL UNIT
LEVEL & TEMP (84062580) 2, AT
9 X-DTS (Receptacle) pin 1 - 609B TEMP SENSOR SCR UP YE - 0.8
SCR DOWNSTREAM TEMP
[B-D_TS] (84532147)
9 X-SCR1 (Receptacle) pin 10 609 SCR DOWNSTREAM YE - 0.8
- INLINE TO SCR SENSORS TEMP
HARNESS (87695592)
10 SP-610-P-X 610 TEMP SENSOR GROUND BK - 0.8
13 X-WIF (Receptacle) pin 1 613 WATER IN FUEL YE - 0.8
- WATER IN FUEL [B-WIF]
(87709663)
15 X-HTS (Receptacle) pin 2 615 HUMIDITY TEMP YE - 0.8
- HUMIDITY AND TEMP SENSOR
SENSOR [B-HT] (87709809)
16 X-SCR1 (Receptacle) pin 8 616 DOC UPSTREAM TEMP YE - 0.8
- INLINE TO SCR SENSORS
HARNESS (87695592)
16 X-CTS (Receptacle) pin 1 616B TEMP SENSOR DOC UP YE - 0.8
- DOC UPSTREAM TEMP
[B-C_TS] (84532147)
19 X-LC6 pin 36 - LOADCENTER 619 START CONTROL RELAY YE - 0.8 SHEET 16 SH16 - ENGINE CONTROL UNIT
6 [SH16: A-3] (84380518) 1, GRID HEATER, FILTER HEATER
20 X-LC6 pin 34 - LOADCENTER 620 ENG AUX WH - 0.8
6 [SH16: A-3] (84380518)
23 X-DSR (Receptacle) pin 623B DOSING VALVE WH - 0.8 SHEET 17 SH17 - ENGINE CONTROL UNIT
2 - UREA DOSING VALVE 2, AT
[Y-DSV] (87709798)
23 X-SCR1 (Receptacle) pin 6 623 UREA DOSING VALVE 2 WH - 0.8
HARNESS (87695592)
25 SP-233-P-X 233B EDC FUSED POWER RD - 1.0 SHEET 16 SH16 - ENGINE CONTROL UNIT
26 SP-233-P-X 233C EDC FUSED POWER RD - 1.0 1, GRID HEATER, FILTER HEATER
27 SP-627-P-X 627 RELAY FILTER HEATING RD - 0.8
HI SIDE
28 SP-603-P-X 603C CLEAN GROUND BK - 1.0
31 X-LEV1 pin 1 - INLINE TO DEF 631 SENSOR TANK LEVEL YE - 0.8 SHEET 17 SH17 - ENGINE CONTROL UNIT
LEVEL & TEMP (84062580) AND TEMP 2, AT
32 X-UTS (Receptacle) pin 632 SCR UPSTREAM TEMP YE - 0.8
1 - UPSTREAM OF SCR
TEMP SENSOR [B-U_TS]
(84532147)
37 X-AFS (Receptacle) pin 2 637 AIR FILTER SWITCH YE - 0.8
- AIR FILTER RSTCN SW
[SW-A_F_S] (84607243)
39 SP-639-P-X 639 SENSOR TANK LEVEL BL - 0.8
AND TEMP
40 X-HTS (Receptacle) pin 4 642 HUMIDITY TEMP YE - 0.8
- HUMIDITY AND TEMP SENSOR
SENSOR [B-HT] (87709809)
43 SP-643-P-X 643 HUMIDITY TEMP BK - 0.8
SENSOR
45 X-LC6 pin 29 - LOADCENTER 645 ENG AUX BK - 0.8 SHEET 16 SH16 - ENGINE CONTROL UNIT
6 [SH16: A-3] (84380518) 1, GRID HEATER, FILTER HEATER
46 X-ENG (Plug) pin 14 - CAN_H CAN YE - 0.8 SHEET 18 SH18 - ENGINE CONTROL UNIT
ENGINE TO CAB [SH18: C-6] 3, AT
(87696948)
47 X-ENG (Plug) pin 13 - CAN_L CAN GN - 0.8
(87696948)
49 SP-233-P-X 233D EDC FUSED POWER RD - 1.0 SHEET 16 SH16 - ENGINE CONTROL UNIT
1, GRID HEATER, FILTER HEATER
50 SP-650-P-X 650 DENOX CONTROL UNIT OR - 0.8 SHEET 18 SH18 - ENGINE CONTROL UNIT
9 3, AT
52 SP-603-P-X 603D CLEAN GROUND BK - 1.0 SHEET 16 SH16 - ENGINE CONTROL UNIT
60 X-ENG-2 (Receptacle) pin D - 408A THROTTLE PEDAL WH - 0.8 1, GRID HEATER, FILTER HEATER
ENGINE TO CAB 2 (87703931)
48083741_EN 31/07/2018
55.1 [55.100] / 150

61 X-LC7 pin 9 - LOAD CENTER 661 RELAY FILTER HEATING BK - 0.8 SHEET 03 SH03 - PWR DISTR-BATTERY /
7 (84563565) LOW SIDE STARTER / KEY
63 SP-663A-P-X 663B OK TO START YE - 0.8 SHEET 16 SH16 - ENGINE CONTROL UNIT
66 X-ENG-2 (Receptacle) pin B - 471K THROTTLE PEDAL PK - 0.8 1, GRID HEATER, FILTER HEATER
68 X-PUMP pin 2 - DENOX 668 DENOX CONTROL UNIT PK - 0.8 SHEET 18 SH18 - ENGINE CONTROL UNIT
(47421681)
69 X-SW_DISC (Receptacle) pin 669 ECU IGN PWR OR - 0.8 SHEET 16 SH16 - ENGINE CONTROL UNIT
3 - DISCONNECT SWITCH 1, GRID HEATER, FILTER HEATER
[SH37: C-4] (87694112)
71 X-CAN (Receptacle) pin 1 - 671 CAN HI PROTO ONLY YE - 0.8 SHEET 18 SH18 - ENGINE CONTROL UNIT
CAN (87696093) 3, AT
72 X-THV pin 3 - SCR 672 SCR TANK HEATING BL - 0.8 SHEET 17 SH17 - ENGINE CONTROL UNIT
TANK HEATING VALVE VALVE 2, AT
[Y-TNK_HTR] (84146685)
73 SP-233-P-X 233E EDC FUSED POWER RD - 1.0 SHEET 16 SH16 - ENGINE CONTROL UNIT
74 X-GHC pin 1 - GRID HEATER 674 GRID HEATER RELAY HI WH - 0.8 1, GRID HEATER, FILTER HEATER
75 SP-603-P-X 603E CLEAN GROUND BK - 1.0
79 X-ENG-2 (Receptacle) pin A - 409A THROTTLE PEDAL YE - 0.8
80 X-ENG-2 (Receptacle) pin C - 651K THROTTLE PEDAL BL - 0.8
83 X-GHC pin 2 - GRID HEATER 683 GRID HEATER RELAY LO BL - 0.8
84 X-PUMP pin 10 - DENOX 684 DENOX CONTROL UNIT YE - 0.8 SHEET 18 SH18 - ENGINE CONTROL UNIT
(47421681)
85 X-PUMP pin 12 - DENOX 685 DENOX CONTROL UNIT GY - 0.8
CONTROL UNIT [A-PMP] 12
(47421681)
88 X-LC6 pin 31 - LOADCENTER 688 START CONTROL RELAY BL - 0.8 SHEET 16 SH16 - ENGINE CONTROL UNIT
6 [SH16: A-3] (84380518) LOW SIDE 1, GRID HEATER, FILTER HEATER
89 X-PUMP pin 8 - DENOX 689 DENOX CONTROL UNIT GY - 0.8 SHEET 18 SH18 - ENGINE CONTROL UNIT
(47421681)
90 X-HTS (Receptacle) pin 1 690 HUMIDITY TEMP OR - 0.8 SHEET 17 SH17 - ENGINE CONTROL UNIT
- HUMIDITY AND TEMP SENSOR 2, AT
SENSOR [B-HT] (87709809)
95 X-CAN (Receptacle) pin 2 - 695 CAN LO PROTO ONLY GN - 0.8 SHEET 18 SH18 - ENGINE CONTROL UNIT
CAN (87696093) 3, AT
96 X-DSR (Receptacle) pin 696B DOSING VALVE TN - 0.8 SHEET 17 SH17 - ENGINE CONTROL UNIT
[Y-DSV] (87709798)
96 X-SCR1 (Receptacle) pin 5 696 UREA DOSING VALVE 1 TN - 0.8
HARNESS (87695592)
X-EDC7 - ENGINE CONTROLLER T2/3 [ SH18: C-5] (84160698) (Plug)
84160698 76
84160698
48083741_EN 31/07/2018
55.1 [55.100] / 151

2 SP-233-P-X 233F EDC FUSED POWER RD - 1.0 SHEET 16 SH16 - ENGINE CONTROL UNIT
3 SP-233-P-X 233G EDC FUSED POWER RD - 1.0 1, GRID HEATER, FILTER HEATER
5 SP-603-P-X 603F CLEAN GROUND BK - 1.0
6 SP-603-P-X 603G CLEAN GROUND BK - 1.0
8 SP-233-P-X 233H EDC FUSED POWER RD - 1.0
9 SP-233-P-X 233J EDC FUSED POWER RD - 1.0
10 SP-603-P-X 603H CLEAN GROUND BK - 1.0
11 SP-603-P-X 603J CLEAN GROUND BK - 1.0
12 X-GHC pin 1 - GRID HEATER 674A T2 GRID HTR HI WH - 0.8
13 SP-627-P-X 627E T2 EDC 7 PWR RD - 0.8
13 X-LC6 pin 34 - LOADCENTER 627F FUEL FILTER HTR T2 RD - 0.8
6 [SH16: A-3] (84380518)
17 X-LC6 pin 31 - LOADCENTER 688A START CONTROL RELAY BL - 0.8
6 [SH16: A-3] (84380518) LOW SIDE
29 SP-643F-P-X 643F EDC GRND BK - 0.8
32 X-LC6 pin 7 - LOADCENTER 21E T2 OK TO START FROM YE - 0.8
6 [SH16: A-3] (84380518) UCM
34 X-ENG (Plug) pin 13 - CAN_L7 CAN GN - 0.8 SHEET 18 SH18 - ENGINE CONTROL UNIT
ENGINE TO CAB [SH18: C-6] 3, AT
(87696948)
35 X-ENG (Plug) pin 14 - CAN_H7 CAN YE - 0.8
(87696948)
36 X-LC7 pin 9 - LOAD CENTER 661A FUEL FILTER HEATER BK - 0.8 SHEET 16 SH16 - ENGINE CONTROL UNIT
7 (84563565) 1, GRID HEATER, FILTER HEATER
37 X-LC6 pin 36 - LOADCENTER 619A START CONTROL RELAY YE - 0.8
6 [SH16: A-3] (84380518)
40 SP-669A-P-X 669B ECU IGN PWR OR - 0.8
42 X-WIF (Receptacle) pin 1 613A WATER IN FUEL SIGNAL YE - 0.8 SHEET 17 SH17 - ENGINE CONTROL UNIT
- WATER IN FUEL [B-WIF] T2 2, AT
(87709663)
48 X-ENG-2 (Receptacle) pin D - 408B THROTTLE PEDAL WH - 0.8 SHEET 16 SH16 - ENGINE CONTROL UNIT
ENGINE TO CAB 2 (87703931) 1, GRID HEATER, FILTER HEATER
51 X-LC6 pin 29 - LOADCENTER 645A T2 EVGT LSD BK - 0.8
6 [SH16: A-3] (84380518)
52 SP-2LC-P-X CAN2_LB CAN GN - 0.8 SHEET 18 SH18 - ENGINE CONTROL UNIT
53 SP-2HC-P-X CAN2_HB CAN YE - 0.8 3, AT
75 X-GHC pin 2 - GRID HEATER 683B T2 GRID HTR LOW BL - 0.8 SHEET 16 SH16 - ENGINE CONTROL UNIT
CONTROL [K-GH] (82012083) 1, GRID HEATER, FILTER HEATER
77 X-ENG-2 (Receptacle) pin B - 471P THROTTLE PEDAL PK - 0.8
78 X-ENG-2 (Receptacle) pin C - 651P THROTTLE PEDAL BL - 0.8
79 X-ENG-2 (Receptacle) pin A - 409B THROTTLE PEDAL YE - 0.8
89 X-ENG (Plug) pin 20 - 303A ISO K WH - 0.8
(87696948)
X-EHD_23 - ENG TO PL23 HOOD (87694154) (Plug)
87694154 77
87694154
48083741_EN 31/07/2018
55.1 [55.100] / 152

1 X-ENG (Plug) pin 7 - 121B BACKUP ALARM PL23 OR - 0.8 SHEET 36 SH36 - REAR DEFROST, BACKUP
ENGINE TO CAB [SH18: ALARM
C-6] (87696948)
X-EM - ELECTROMAGNETIC DETENTS [ Y-RTT DET] (87694112) (Receptacle)
87694112 78
87694112
1 X-A_RT_2B (Receptacle) pin 299A RTT DETENT WH - 0.8 SHEET 23 SH23 - PILOT LOADER
8 - ARM REST RIGHT PILOT CONTROLS
2 (84281913)
2 X-A_RT_2B (Receptacle) pin 298A HC DETENT WH - 0.8
7 - ARM REST RIGHT PILOT
2 (84281913)
3 X-A_RT_2B (Receptacle) pin 297A RTD DETENT WH - 0.8
2 (84281913)
4 SP-954U-P-X 954V CHASSIS GROUND BK - 0.8
5 SP-954U-P-X 954W CHASSIS GROUND BK - 0.8
6 SP-954U-P-X 954X CHASSIS GROUND BK - 0.8
X-ENG - ENGINE TO CAB [ SH18: C-6] (87696948) (Plug)
87696948 79
87696948
1 SP-850A-P-X 850A IGN PWR FOR REAR OR - 2.0 SHEET 11 SH11 - PWR DISTR ENG
2 SP-250A-P-X 205A HOOD LIFT RD - 2.0 SHEET 37 SH37 - HOOD LIFT
3 X-GND_CENG1 (Plug) pin 857A CAB CLEAN GRND BK - 2.0 SHEET 12 SH12 - POWER DISTRIBUTION 1
1 - GROUND CLEAN ENG CLEAN GROUND BLK
BLOCK (84140737)
4 SP-216A-P-X 216D HOOD LIFT NON-DISC RD - 2.0 SHEET 03 SH03 - PWR DISTR-BATTERY /
PWR STARTER / KEY
5 X-RECT (Receptacle) pin 1 433A COOLANT TEMP YE - 0.8 SHEET 19 SH19 - UCM PWR, GRND,
- ENGINE COOLANT TEMP INSTRUMENTATION
[B-RECTD] (84607243)
48083741_EN 31/07/2018
55.1 [55.100] / 153

6 X-RH-TAIL (Receptacle) 131F TURN RH EURO VT - 0.8 SHEET 29 SH29 - LIGHTING REAR TAILS
pin 4 - RH REAR TAIL
[LMP-R-NA-TAIL] (87694101)
6 X-ENG_H (Plug) pin 4 131A RH REAR TURN LAMP VT - 0.8
- ENGINE TO HOOD NA
(87700321)
7 X-BU2 (Plug) pin 1 - BACK 121A BACKUP ALARM OR - 0.8 SHEET 36 SH36 - REAR DEFROST, BACKUP
UP ALARM [H-BU_ALRM] ALARM
(84426117)
7 X-EHD_23 (Plug) pin 1 - ENG 121B BACKUP ALARM PL23 OR - 0.8
TO PL23 HOOD (87694154)
8 X-FL pin 2 - FUEL LEVEL 633A FUEL LEVEL YE - 0.8 SHEET 19 SH19 - UCM PWR, GRND,
[B-RFLG] (82012083) INSTRUMENTATION
9 SP-482R-P-X 482R 5V GRND REF1 BL - 0.8
10 X-ENG_H (Plug) pin 2 126A LH BRAKE LAMP NA VT - 0.8 SHEET 29 SH29 - LIGHTING REAR TAILS
- ENGINE TO HOOD
(87700321)
10 X-LH-TAIL (Receptacle) pin 126E STOP LH EURO VT - 0.8
2 - LH REAR TAIL LIGHT NA
[L-NA-TAIL] (87694101)
11 X-ENG_H (Plug) pin 5 130B RH TAIL LAMP NA VT - 0.8
- ENGINE TO HOOD
(87700321)
11 X-RH-TAIL (Receptacle) 130J TAIL RH EURO VT - 0.8
[LMP-R-NA-TAIL] (87694101)
12 X-LH-TAIL (Receptacle) pin 127J TAIL EURO VT - 0.8
[L-NA-TAIL] (87694101)
12 X-ENG_H (Plug) pin 6 127E LH TAIL LAMP NA VT - 0.8
- ENGINE TO HOOD
(87700321)
13 X-ECU (Receptacle) pin 47 - CAN_L CAN GN - 0.8 SHEET 18 SH18 - ENGINE CONTROL UNIT
(84300197)
13 X-EDC7 (Plug) pin 34 - CAN_L7 CAN GN - 0.8
ENGINE CONTROLLER T2/3
[SH18: C-5] (84160698)
14 X-ECU (Receptacle) pin 46 - CAN_H CAN YE - 0.8
(84300197)
14 X-EDC7 (Plug) pin 35 - CAN_H7 CAN YE - 0.8
[SH18: C-5] (84160698)
15 SP-663A-P-X 663A OK TO START YE - 0.8 SHEET 20 SH20 - UCM VEHICLE DRIVELINE
16 X-FAN (Receptacle) pin 400A FAN SPEED YE - 0.8 / FAN CONTROL
4 - FAN SPEED SENSOR
JUMPER [SH11: C-1]
(87694112)
17 X-ALT (Receptacle) pin 239 ALT LAMP SIGNAL YE - 0.8 SHEET 03 SH03 - PWR DISTR-BATTERY /
4 - ALTERNATOR [G-G1] STARTER / KEY
(8602487)
18 X-AFS2 (Receptacle) pin 2 319A AIR FILTER REST SW T2 YE - 0.8 SHEET 20 SH20 - UCM VEHICLE DRIVELINE
- AIR FILTER SWITCH T2/3 / FAN CONTROL
[SW-AFS2] (84607243)
20 X-EDC7 (Plug) pin 89 - 303A ISO K WH - 0.8 SHEET 16 SH16 - ENGINE CONTROL UNIT
ENGINE CONTROLLER T2/3 1, GRID HEATER, FILTER HEATER
[SH18: C-5] (84160698)
21 X-ENG_H (Plug) pin 7 129A RH BRAKE LAMP NA VT - 0.8 SHEET 29 SH29 - LIGHTING REAR TAILS
- ENGINE TO HOOD
(87700321)
21 X-RH-TAIL (Receptacle) 129E STOP RH EURO VT - 0.8
[LMP-R-NA-TAIL] (87694101)
22 X-ENG_H (Plug) pin 3 128A LH REAR TURN LAMP NA VT - 0.8
- ENGINE TO HOOD
(87700321)
22 X-LH-TAIL (Receptacle) pin 128E LH TURN EURO VT - 0.8
[L-NA-TAIL] (87694101)
48083741_EN 31/07/2018
55.1 [55.100] / 154

25 X-E_HD (Receptacle) pin A 280C LICENSE PLATE LIGHT VT - 0.8 SHEET 27 SH27 - LIGHTING DOME, MAP
- ENGINE TO HOOD EURO EURO LIGHTS
[SH29: B-1] (87692858)
25 X-ENG_H (Plug) pin 8 280A LICENSE PLATE LIGHT VT - 0.8
- ENGINE TO HOOD
(87700321)
26 X-ALT (Receptacle) pin 228 ALTERNATOR VOLTAGE RD - 0.8 SHEET 03 SH03 - PWR DISTR-BATTERY /
3 - ALTERNATOR [G-G1] STARTER / KEY
(8602487)
28 X-FAN (Receptacle) pin 677M 5V REF PWR1 PK - 0.8 SHEET 20 SH20 - UCM VEHICLE DRIVELINE
3 - FAN SPEED SENSOR / FAN CONTROL
JUMPER [SH11: C-1]
(87694112)
X-ENG-2 - ENGINE TO CAB 2 (87703931) (Receptacle)
87703931 80
87703931
A X-ECU (Receptacle) pin 79 - 409A THROTTLE PEDAL YE - 0.8 SHEET 16 SH16 - ENGINE CONTROL UNIT
ECU CONNECTOR [A-ECU] 1, GRID HEATER, FILTER HEATER
(84300197)
A X-EDC7 (Plug) pin 79 - 409B THROTTLE PEDAL YE - 0.8
[SH18: C-5] (84160698)
B X-ECU (Receptacle) pin 66 - 471K THROTTLE PEDAL PK - 0.8
(84300197)
B X-EDC7 (Plug) pin 77 - 471P THROTTLE PEDAL PK - 0.8
[SH18: C-5] (84160698)
C X-ECU (Receptacle) pin 80 - 651K THROTTLE PEDAL BL - 0.8
(84300197)
C X-EDC7 (Plug) pin 78 - 651P THROTTLE PEDAL BL - 0.8
[SH18: C-5] (84160698)
D X-EDC7 (Plug) pin 48 - 408B THROTTLE PEDAL WH - 0.8
[SH18: C-5] (84160698)
D X-ECU (Receptacle) pin 60 - 408A THROTTLE PEDAL WH - 0.8
(84300197)
E SP-643-P-X 643D THROTTLE PEDAL BK - 0.8
E SP-643F-P-X 643E EDC7 GRND BK - 0.8
F X-ISO pin 2 - ISOLATOR 250A ISOLATOR SET YE - 0.8 SHEET 03 SH03 - PWR DISTR-BATTERY /
[K-ISOLATOR] (87687242) STARTER / KEY
G X-ISO pin 1 - ISOLATOR 237A ISOLATOR RESET YE - 0.8
[K-ISOLATOR] (87687242)
H X-LC6 pin 24 - LOADCENTER 217 TELEMATICS/SFB PWR RD - 0.8
6 [SH16: A-3] (84380518)
J X-SW_DISC (Receptacle) pin 219 NON ISOLATED PWR RD - 0.8
4 - DISCONNECT SWITCH
[SH37: C-4] (87694112)
K X-LC6 pin 18 - LOADCENTER 875A AC CLUTCH ACC PWR OR - 1.0 SHEET 11 SH11 - PWR DISTR ENG
6 [SH16: A-3] (84380518) COMPARTMENT (FUSE BLOCK LC6)
48083741_EN 31/07/2018
55.1 [55.100] / 155

L X-PRH2 (Plug) pin A - HIGH 246C AC HIGH PRESS YE - 1.0 SHEET 33 SH33 - HEATING BLOWER
PRESSURE SWITCH 2 [SH33: HEATER, HVAC
C-6] (87688788)
M X-FAN (Receptacle) pin 582A HEAT LOAD VALVE BR - 0.8 SHEET 20 SH20 - UCM VEHICLE DRIVELINE
1 - FAN SPEED SENSOR / FAN CONTROL
JUMPER [SH11: C-1]
(87694112)
N X-YFR (Receptacle) pin 2 - 692A FAN REVERSER SGNL BR - 0.8
FAN REVESER SOLENOID
[Y-Y_FR] (87695582)
P X-YFN (Receptacle) pin A - 392A FAN CONTROL SGNL YE - 0.8
SOLENOID FAN CONTROL
[Y-Y_FC] (87693821)
X-ENG_H - ENGINE TO HOOD (87700321) (Plug)
87700321 81
87700321
1 X-GND_ENG4 (Plug) pin 1 - 242 TAIL LIGHT GROUND BK - 1.0 SHEET 29 SH29 - LIGHTING REAR TAILS
GROUND ENG BLOCK [SH29:
B-3] (84140737)
2 X-ENG (Plug) pin 10 - 126A LH BRAKE LAMP NA VT - 0.8
(87696948)
3 X-ENG (Plug) pin 22 - 128A LH REAR TURN LAMP NA VT - 0.8
(87696948)
4 X-ENG (Plug) pin 6 - 131A RH REAR TURN LAMP VT - 0.8
ENGINE TO CAB [SH18: NA
C-6] (87696948)
5 X-ENG (Plug) pin 11 - 130B RH TAIL LAMP NA VT - 0.8
(87696948)
6 X-ENG (Plug) pin 12 - 127E LH TAIL LAMP NA VT - 0.8
(87696948)
7 X-ENG (Plug) pin 21 - 129A RH BRAKE LAMP NA VT - 0.8
(87696948)
8 X-ENG (Plug) pin 25 - 280A LICENSE PLATE LIGHT VT - 0.8 SHEET 27 SH27 - LIGHTING DOME, MAP
ENGINE TO CAB [SH18: C-6] LIGHTS
(87696948)
48083741_EN 31/07/2018
55.1 [55.100] / 156
X-ESS - SPEED SENSOR ENGINE [ B-ES_S] (84364854) (Receptacle)
84364854 82
84364854
1 X-TRANS (Plug) pin 7 - 699A ENG SPEED SENSOR YE - 0.8 SHEET 26 SH26 - GEAR CONTROL UNIT 2
TRANSMISSION TO CAB
(87696949)
2 X-TRANS (Plug) pin 2 - 702D SPEED SENSOR GRND BL - 0.8
TRANSMISSION TO CAB
(87696949)
X-E_HD - ENGINE TO HOOD EURO [ SH29: B-1] (87692858) (Receptacle)
87692858 83
87692858
A X-ENG (Plug) pin 25 - 280C LICENSE PLATE LIGHT VT - 0.8 SHEET 27 SH27 - LIGHTING DOME, MAP
ENGINE TO CAB [SH18: C-6] EURO LIGHTS
(87696948)
A X-HD_N (Receptacle) pin 8 - 280T TRKY LICENSE PLT VT - 0.8
HOOD TO ENG (87700325) LIGHT
C SP-242A-P-X 242T TRKY LICENSE PLT BK - 0.8
LIGHT
C SP-243-P-X 243C LPL GRND EURO BK - 0.8
48083741_EN 31/07/2018
55.1 [55.100] / 157
X-FAN - FAN SPEED SENSOR JUMPER [ SH11: C-1] (87694112) (Receptacle)
87694112 84
87694112
1 X-ENG-2 (Receptacle) pin 582A HEAT LOAD VALVE BR - 0.8 SHEET 20 SH20 - UCM VEHICLE DRIVELINE
M - ENGINE TO CAB 2 / FAN CONTROL
(87703931)
2 SP-852-P-X 852C HEAT LOAD IGN PWR OR - 0.8 SHEET 11 SH11 - PWR DISTR ENG
3 X-ENG (Plug) pin 28 - 677M 5V REF PWR1 PK - 0.8 SHEET 20 SH20 - UCM VEHICLE DRIVELINE
ENGINE TO CAB [SH18: C-6] / FAN CONTROL
(87696948)
4 X-ENG (Plug) pin 16 - 400A FAN SPEED YE - 0.8
(87696948)
5 SP-482R-P-X 482N 5V GRND REF1 BL - 0.8 SHEET 19 SH19 - UCM PWR, GRND,
INSTRUMENTATION
X-FAN2 - FAN SPEED SENSOR JUMPER (87694152) (Plug)
87694152 85
87694152
1 X-YLV (Receptacle) pin 2 - 582B HEAT LOAD VALVE BR - 0.8 SHEET 20 SH20 - UCM VEHICLE DRIVELINE
HEAT LOAD VALVE [Y-YLV] SIGNAL / FAN CONTROL
(87695582)
2 X-YLV (Receptacle) pin 1 - 852A HEAT LOAD VALVE OR - 0.8
HEAT LOAD VALVE [Y-YLV]
(87695582)
3 X-FSS pin 3 - FAN SPEED 677N 5V REF PWR1 PK - 0.8
SENSOR [B-FSS] (47696743)
4 X-FSS pin 2 - FAN SPEED 400B FAN SPEED SENSOR YE - 0.8
SENSOR [B-FSS] (47696743) SGNL
5 X-FSS pin 1 - FAN SPEED 482V 5V GRND REF1 BL - 0.8
SENSOR [B-FSS] (47696743)
48083741_EN 31/07/2018
55.1 [55.100] / 158
X-FAX - FRONT AXLE TEMP SENSOR [ SH20: A-6] (87711966) (Receptacle)
87711966 86
87711966
1 X-FRNT (Receptacle) pin A 687B FRONT AXLE TEMP YE - 0.8 SHEET 20 SH20 - UCM VEHICLE DRIVELINE
- FRONT TO BOTTOM STD / FAN CONTROL
(87704426)
2 SP-651D-P-X 651G 5V REF2 BL - 0.8
2 X-FRNT (Receptacle) pin V 651N TEMP SENS PILOT BL - 0.8
- FRONT TO BOTTOM STD
(87704426)
X-FFH - FILTER HEATER [ Y-F_F_H] (87679438) (Receptacle)
87679438 87
87679438
A SP-421-P-X 421A FUEL FILTER HEATER OR - 2.0 SHEET 16 SH16 - ENGINE CONTROL UNIT
B X-GND_ENG1 (Plug) pin 1 - 196 FUEL FILTER HEATER BK - 2.0 1, GRID HEATER, FILTER HEATER
GROUND ENG BLOCK [SH16: GND
A-1] (84140737)
48083741_EN 31/07/2018
55.1 [55.100] / 159
X-FL - FUEL LEVEL [ B-RFLG] (82012083) (Plug)
82012083 88
82012083
X-FM - PRESSURE SWITCH OIL FILTER [ B-FM] (82012083) (Plug)
82012083 89
82012083
X-FRNT - FRONT TO BOTTOM STD (87704426) (Receptacle)
87704426 90
87704426
A X-FAX (Receptacle) pin 1 - 687B FRONT AXLE TEMP YE - 0.8 SHEET 20 SH20 - UCM VEHICLE DRIVELINE
FRONT AXLE TEMP SENSOR / FAN CONTROL
[SH20: A-6] (87711966)
B X-PXF (Plug) pin A - RETURN 294B RTD SIG YE - 0.8 SHEET 23 SH23 - PILOT LOADER
TO DIG PROX [B-PXF] CONTROLS
(87692858)
B X-PXT (Plug) pin A - RTD XT 294C RTD XT SIGNAL YE - 0.8
[B-PXT] (87644909)
48083741_EN 31/07/2018
55.1 [55.100] / 160

C X-LLF pin 3 - FRONT COMBO 132E LH HIGH BEAM LAMP VT - 0.8 SHEET 28 SH28 - LIGHTING HAZARD
LAMP LEFT [LMP-LF_LT] WARNING, BLINKERS, DRIVING
(87694109)
F X-LLF pin 2 - FRONT COMBO 133B LH LOW BEAM LAMP VT - 0.8
(87694109)
H X-LLF pin 4 - FRONT COMBO 127C LH POSITION VT - 0.8
(87694109)
J X-LLF pin 5 - FRONT COMBO 136C LH FRONT TURN VT - 0.8
(87694109)
K X-LRF pin 3 - FRONT COMBO 137B RH HIGH BEAM LAMP VT - 0.8
LAMP RT [LMP-RF_LT]
(87694109)
L X-LRF pin 2 - FRONT COMBO 138B RH LOW BEAM LAMP VT - 0.8
LAMP RT [LMP-RF_LT]
(87694109)
M X-LRF pin 4 - FRONT COMBO 130F RH POSITION VT - 0.8
LAMP RT [LMP-RF_LT]
(87694109)
N X-LRF pin 5 - FRONT COMBO 135E RH FRONT TURN VT - 0.8
LAMP RT [LMP-RF_LT]
(87694109)
P X-YRC (Receptacle) pin 1 - 366B RIDE CONTROL SOL WH - 0.8 SHEET 22 SH22 - UCM-LOADER BOOM
RIDE CONTROL SOLENOID PWR CONTROL
[Y-YRC] (84607243)
R X-YPE (Receptacle) pin 1 - 367B COUPLER SOL PWR WH - 0.8
COUPLER VALVE [Y-YPE]
(87695582)
S X-YPE (Receptacle) pin 2 - 368B COUPLER SOL RETURN BR - 0.8
COUPLER VALVE [Y-YPE]
(87695582)
T X-HN1 (Plug) pin 1 - 112B HORN YE - 0.8 SHEET 34 SH34 - MIRRORS, HORN BEACON
HORN_PWR [H-HN]
(87697629)
U X-PRB (Plug) pin A - ROLL 291B ROLL BACK PRESSURE YE - 0.8 SHEET 22 SH22 - UCM-LOADER BOOM
BACK PRESSURE SWITCH SW CONTROL
[SW-PRB] (87692877)
V SP-651D-P-X 651D 5V GND2 BL - 0.8
V X-FAX (Receptacle) pin 2 - 651N TEMP SENS PILOT BL - 0.8
FRONT AXLE TEMP SENSOR
[SH20: A-6] (87711966)
W SP-792D-P-X 792D PILOT TARGETS OR - 0.8 SHEET 23 SH23 - PILOT LOADER
X X-PXH (Plug) pin A - HEIGHT 295B HT CNTRL SIGNAL YE - 0.8 CONTROLS
CNTRL PROX [B-PXH]
(87644909)
X-FRNT_EH - FRONT TO BOTTOM EH (87700170) (Receptacle)
87700170 91
87700170
48083741_EN 31/07/2018
55.1 [55.100] / 161

A X-PILOT_ENABLE 344B PILOT ENABLE WH - 0.8 SHEET 22 SH22 - UCM-LOADER BOOM
(Receptacle) pin 1 - PILOT CONTROL
ENABLE SOLENOID [SH28:
A-1] (87695582)
B X-BOOM_RAISE 340B BOOM RAISE WH - 0.8
(Receptacle) pin 1 -
BOOM RAISE SOLENOID
[A-EH_VLV] (87695582)
C SP-339B-P-X 339B BOOM ENABLE BR - 0.8
D X-BOOM_LOWER 341B BOOM LOWER WH - 0.8
BOOM LOWER SOLENOID
[A-EH_VLV] (87695582)
E X-BUCKET_ROLL 346B BUCKET ROLL WH - 0.8
(Receptacle) pin 1 - BUCKET
ROLL SOLENOID [A-EH_VLV]
(87695582)
F SP-347B-P-X 347B BUCKET ENABLE BR - 0.8
G X-BUCKET_DUMP 350B BUCKET DUMP WH - 0.8
BUCKET DUMP SOLENOID
[A-EH_VLV] (87695582)
H X-AUX_1_LEFT (Receptacle) 351B AUX 1 LEFT WH - 0.8
pin 1 - AUX 1 LEFT
[A-EH_VLV] (87695582)
J SP-352B-P-X 352B AUX 1 ENABLE BR - 0.8
K X-AUX_1_RIGHT 355B AUX 1 RIGHT WH - 0.8
(Receptacle) pin 1 - AUX
1 RIGHT [A-EH_VLV]
(87695582)
L X-AUX_2_LEFT (Receptacle) 356B AUX 2 LEFT WH - 0.8
pin 1 - AUX 2 LEFT
[A-EH_VLV] (87695582)
M SP-357B-P-X 357B AUX 2 ENABLE BR - 0.8
N X-AUX_2_RIGHT 360B AUX 2 RIGHT WH - 0.8
(Receptacle) pin 1 - AUX
2 RIGHT [A-EH_VLV]
(87695582)
P SP-570E-P-X 482U 5V GND1 BL - 0.8
Q SP-486F-P-X 486H 5V REF1 PK - 0.8
S X-BOA (Receptacle) pin C 647B BOOM ANGLE 1 YE - 0.8
- BOOM ANGLE SENSOR
[B-BM_ANG] (84403598)
T X-BOA (Receptacle) pin D 648B BOOM ANGLE 2 YE - 0.8
- BOOM ANGLE SENSOR
[B-BM_ANG] (84403598)
V SP-471F-P-X 471F 5V REF2 PK - 0.8
W X-BUA (Receptacle) pin C - 653B BUCKET ANGLE 1 YE - 0.8
BUCKET ANGLE SENSOR
[B-BKT_ANG] (84403598)
X X-BUA (Receptacle) pin D - 654B BUCKET ANGLE 2 YE - 0.8
BUCKET ANGLE SENSOR
[B-BKT_ANG] (84403598)
48083741_EN 31/07/2018
55.1 [55.100] / 162
X-FSS - FAN SPEED SENSOR [ B-FSS] (47696743) (Receptacle)
47696743 92
47696743
X-FWM - FRONT WIPER MOTOR (87692862) (Plug)
87692862 93
87692862
A X-X4 (Receptacle) pin 6 - SFB 100 FRONT WIPER MOTOR TN - 2.0 SHEET 32 SH32 - CAB WIPER / WASHER
(47554343) HIGH
D X-X7 (Receptacle) pin 59 - 102 FRONT WIPER MOTOR TN - 0.8
SFB [SH3: A-3] (84538791) PARK
X-FWM_G - FRONT WIPER GROUND [ SH14: D-5] (87693744) (Plug)
87693744 94
87693744
A CG2-P-1 CAB GROUND 103 FRONT WIPER MOTOR BK - 2.0 SHEET 32 SH32 - CAB WIPER / WASHER
BLOCK GND
48083741_EN 31/07/2018
55.1 [55.100] / 163
X-FWW - FRONT WASHER MOTOR [ M-FW_M] (84015523) (Receptacle)
84015523 95
84015523
1 X-TRANS (Plug) pin 6 - 104A FRONT WASHER MOTOR TN - 0.8 SHEET 32 SH32 - CAB WIPER / WASHER
TRANSMISSION TO CAB
(87696949)
2 SP-391A-P-X 391F FRONT WASHER MOTOR BK - 0.8 SHEET 20 SH20 - UCM VEHICLE DRIVELINE
GND / FAN CONTROL
X-GH1 - GRID HEATER (84140737) (Plug)
84140737 96
84140737
1 X-GH2 (Plug) pin 1 - GRID CABLE 06 GRID HEATER CABLE RD - 32.0 SHEET 03 SH03 - PWR DISTR-BATTERY /
HEATER [F-GH] (84140737) STARTER / KEY
X-GH2 - GRID HEATER [ F-GH] (84140737) (Plug)
84140737 97
84140737
48083741_EN 31/07/2018
55.1 [55.100] / 164

1 X-GH1 (Plug) pin 1 - GRID CABLE 06 GRID HEATER CABLE RD - 32.0 SHEET 03 SH03 - PWR DISTR-BATTERY /
HEATER (84140737) STARTER / KEY
X-GH3 - GRID HEATER RING TERMINAL [ F-GH] (84140737) (Plug)
84140737 98
84140737
1 GH4-P-1 RELAY GRID CABLE 05 GRID HEATER POWER RD - 32.0 SHEET 03 SH03 - PWR DISTR-BATTERY /
HEATER (K1-7:87) CABLE STARTER / KEY
X-GH6 - GRID HEATER [ R-RES-G_HTR] (87744835) (Plug)
87744835 99
87744835
1 GH5-P-1 GRID HEATER FUSE CABLE_06 GRID HEATER POWER RD - 32.0 SHEET 16 SH16 - ENGINE CONTROL UNIT
CABLE 1, GRID HEATER, FILTER HEATER
X-GH7 - GRID HEATER [ R-RES-G_HTR] (87744835) (Plug)
87744835 100
87744835
48083741_EN 31/07/2018
55.1 [55.100] / 165

1 X-001 (Plug) pin 1 - GRID CABLE_07 GRID HEATER GROUND BK - 32.0 SHEET 16 SH16 - ENGINE CONTROL UNIT
HEATER CABLE GRND ON CABLE 1, GRID HEATER, FILTER HEATER
ENGINE (84398003)
X-GHC - GRID HEATER CONTROL [ K-GH] (82012083) (Plug)
82012083 101
82012083
X-GND_CENG1 - GROUND CLEAN ENG BLOCK (84140737) (Plug)
84140737 102
84140737
1 X-ENG (Plug) pin 3 - 857A CAB CLEAN GRND BK - 2.0 SHEET 12 SH12 - POWER DISTRIBUTION 1
ENGINE TO CAB [SH18: CLEAN GROUND BLK
C-6] (87696948)
1 X-TURBO_2 (Receptacle) 203A EVGT CLN GRND BK - 1.0
pin 5 - ENGINE HARNESS
INTERFACE T2 [SH18: B-5]
(87694583)
48083741_EN 31/07/2018
55.1 [55.100] / 166
X-GND_CENG2 - GROUND CLEAN ENG BLOCK [ SH12: A-4] (84140737) (Plug)
84140737 103
84140737
1 X-LC6 pin 17 - LOADCENTER 254 AC CLUTCH RELAY BK - 0.8 SHEET 11 SH11 - PWR DISTR ENG
6 [SH16: A-3] (84380518) GRND COMPARTMENT (FUSE BLOCK LC6)
1 SP-603-P-X 603 CLEAN GROUND BK - 5.0
1 SP-201D-P-X 201K SCR SENSOR GROUND BK - 3.0
1 SP-201-P-X 201 SCR SENSORS CLEAN BK - 3.0
GROUND
X-GND_ENG1 - GROUND ENG BLOCK [ SH16: A-1] (84140737) (Plug)
84140737 104
84140737
1 X-LC7 pin 1 - LOAD CENTER 197 ENG GROUND BK - 0.8 SHEET 03 SH03 - PWR DISTR-BATTERY /
7 (84563565) STARTER / KEY
1 X-WSH (Receptacle) pin 195 FUEL FILTER HTR GRND BK - 2.0
A - WATER SEPERATOR
HEATER [Y-W_S_H]
(87679438)
1 X-LC6 pin 3 - LOADCENTER 198 CHASSIS GRND T2 BK - 0.8
6 [SH16: A-3] (84380518)
1 X-FFH (Receptacle) pin B - 196 FUEL FILTER HEATER BK - 2.0
FILTER HEATER [Y-F_F_H] GND
(87679438)
48083741_EN 31/07/2018
55.1 [55.100] / 167
X-GND_ENG3 - GROUND ENG BLOCK [ SH15: C-3] (84140737) (Plug)
84140737 105
84140737
1 SP-208-P-X 208 HOOD LIFT GROUND BK - 2.0 SHEET 14 SH14 - CAB & CHASSIS GROUND
1 X-GRD_WIF (Plug) pin 1 281 WIF GROUND BK - 1.0 PWR DISTR
- WATER IN FUEL GRND
(84426120)
X-GND_ENG4 - GROUND ENG BLOCK [ SH29: B-3] (84140737) (Plug)
84140737 106
84140737
1 X-ISO pin 3 - ISOLATOR 251 ISOLATOR GRND BK - 0.8 SHEET 03 SH03 - PWR DISTR-BATTERY /
[K-ISOLATOR] (87687242) STARTER / KEY
1 X-ENG_H (Plug) pin 1 242 TAIL LIGHT GROUND BK - 1.0
- ENGINE TO HOOD
(87700321)
1 SP-243-P-X 243 TAIL LIGHTS GRND BK - 0.8
EURO
1 X-BU1 (Plug) pin 1 - BACK 244 BACKUP ALARM GND BK - 0.8
UP ALARM [H-BU_ALRM]
(84426117)
48083741_EN 31/07/2018
55.1 [55.100] / 168
X-GND_FRNT - CHASSIS GROUND (84140737) (Plug)
84140737 107
84140737
1 X-GND_RR (Plug) pin 061 CHASSIS GROUND BK - 5.0 SHEET 14 SH14 - CAB & CHASSIS GROUND
1 - CHASSIS GROUND PWR DISTR
(84140737)
X-GND_GRL - GROUND GRILL TERMINAL (84140737) (Plug)
84140737 108
84140737
1 GND_RR5-P-1 CHASSIS 313 HOOD GRILL GROUND BK - 2.0 SHEET 14 SH14 - CAB & CHASSIS GROUND
GROUND PWR DISTR
X-GND_PED - GROUND PEDESTAL RING [ SH14: B-6] (84140737) (Plug)
84140737 109
84140737
48083741_EN 31/07/2018
55.1 [55.100] / 169

1 X-PG (Receptacle) pin H - 955U PEDESTAL GND BK - 1.0 SHEET 14 SH14 - CAB & CHASSIS GROUND
PEDESTAL GROUND [SH28: PWR DISTR
B-6] (87705607)
X-GND_RR - CHASSIS GROUND (84140737) (Plug)
84140737 110
84140737
1 X-GND_FRNT (Plug) pin 061 CHASSIS GROUND BK - 5.0 SHEET 14 SH14 - CAB & CHASSIS GROUND
1 - CHASSIS GROUND PWR DISTR
(84140737)
X-GND_RR2 - CHASSIS GROUND [ SH28: B-2] (84426126) (Plug)
84426126 111
84426126
1 SP-624D-P-X 624D FRONT CHASSIS GND BK - 2.0 SHEET 14 SH14 - CAB & CHASSIS GROUND
PWR DISTR
48083741_EN 31/07/2018
55.1 [55.100] / 170
X-GND_RR3 - SEC STRG CHASSIS GRND [ SH14: B-4] (84426126) (Plug)
84426126 112
84426126
X-GND_RR4 - (84140737) (Plug)
84140737 113
84140737
1 SP-391A-P-X 391A DIFF LOCK BK - 1.0 SHEET 14 SH14 - CAB & CHASSIS GROUND
PWR DISTR
X-GRD_WIF - WATER IN FUEL GRND (84426120) (Plug)
84426120 114
84426120
1 X-GND_ENG3 (Plug) pin 1 - 281 WIF GROUND BK - 1.0 SHEET 14 SH14 - CAB & CHASSIS GROUND
GROUND ENG BLOCK [SH15: PWR DISTR
C-3] (84140737)
48083741_EN 31/07/2018
55.1 [55.100] / 171
X-HD - HOOD LIFT SWITCH [ SH3: A-4] (84159859) (Receptacle)
84159859 115
84159859
1 X-LC6 pin 48 - LOADCENTER 207 HOOD DOWN GY - 1.0 SHEET 37 SH37 - HOOD LIFT
6 [SH16: A-3] (84380518)
2 X-SW_DISC (Receptacle) pin 533 HOOD LIFT SIGNAL RD - 1.0
5 - DISCONNECT SWITCH
[SH37: C-4] (87694112)
3 X-LC6 pin 46 - LOADCENTER 206 HOOD UP WH - 1.0
6 [SH16: A-3] (84380518)
X-HDM - HOOD MOTOR [ M-HD_L_M] (87711966) (Receptacle)
87711966 116
87711966
1 X-LC6 pin 38 - LOADCENTER 209 HOOD UP WH - 2.0 SHEET 37 SH37 - HOOD LIFT
6 [SH16: A-3] (84380518)
2 X-LC6 pin 40 - LOADCENTER 210 HOOD DOWN GY - 2.0
6 [SH16: A-3] (84380518)
48083741_EN 31/07/2018
55.1 [55.100] / 172
X-HD_23 - HOOD PL23 (87694153) (Receptacle)
87694153 117
87694153
1 X-BU2 (Plug) pin 1 - BACK 121C BACKUP ALARM PL23 OR - 0.8 SHEET 36 SH36 - REAR DEFROST, BACKUP
UP ALARM [H-BU_ALRM] ALARM
(84426117)
2 SP-124H-P-X 124H REVERSE LIGHTS PL23 VT - 0.8 SHEET 30 SH30 - OLD EURO LIGHTING
X-HD_E - HOOD EURO TO EURO ENG HARN (87644909) (Plug)
87644909 118
87644909
A X-LPL (Plug) pin A - LICENSE 280D LICENSE PLATE LIGHT VT - 0.8 SHEET 27 SH27 - LIGHTING DOME, MAP
PLATE LIGHT [LMP-LPL] EURO LIGHTS
(87692855)
C X-LPL (Plug) pin B - LICENSE 243D LPL GRND EURO BK - 0.8
PLATE LIGHT [LMP-LPL]
(87692855)
48083741_EN 31/07/2018
55.1 [55.100] / 173
X-HD_N - HOOD TO ENG (87700325) (Receptacle)
87700325 119
87700325
1 SP-242H-P-X 242H HOOD GRND PL23 BK - 0.8 SHEET 29 SH29 - LIGHTING REAR TAILS
1 SP-242A-P-X 242A TAIL LIGHTS GRND NA BK - 1.0
2 X-LH-TAIL (Receptacle) pin 126B LH BRAKE LAMP NA VT - 0.8
[L-NA-TAIL] (87694101)
2 X-LH-REAR-TAIL-EURO 126D STOP PL23 EURO VT - 0.8
LH REAR TAIL LIGHT
(87694112)
3 X-LH-TAIL (Receptacle) pin 128B LH REAR TURN LAMP NA VT - 0.8
[L-NA-TAIL] (87694101)
3 X-LH-REAR-TAIL-EURO 128D TURN PL23 EURO VT - 0.8
LH REAR TAIL LIGHT
(87694112)
4 X-RH-REAR-TAIL-EURO 131E TAIL EURO VT - 0.8
RH-REAR-TAIL-EURO
[LMP-R-EURO-TAIL]
(87694112)
4 X-RH-TAIL (Receptacle) 131B RH REAR TURN LAMP VT - 0.8
pin 4 - RH REAR TAIL NA
[LMP-R-NA-TAIL] (87694101)
5 X-RH-REAR-TAIL-EURO 130H TA VT - 0.8
RH-REAR-TAIL-EURO
[LMP-R-EURO-TAIL]
(87694112)
5 X-RH-TAIL (Receptacle) 130C RH TAIL LAMP NA VT - 0.8
[LMP-R-NA-TAIL] (87694101)
6 X-LH-REAR-TAIL-EURO 127H TAIL PL23 EURO VT - 0.8
LH REAR TAIL LIGHT
(87694112)
6 X-LH-TAIL (Receptacle) pin 127F LH TAIL LAMP NA VT - 0.8
[L-NA-TAIL] (87694101)
7 X-RH-TAIL (Receptacle) 129B RH BRAKE LAMP NA VT - 0.8
[LMP-R-NA-TAIL] (87694101)
7 X-RH-REAR-TAIL-EURO 129D STOP PL23 EURO VT - 0.8
RH-REAR-TAIL-EURO
[LMP-R-EURO-TAIL]
(87694112)
48083741_EN 31/07/2018
55.1 [55.100] / 174

8 X-E_HD (Receptacle) pin A 280T TRKY LICENSE PLT VT - 0.8 SHEET 27 SH27 - LIGHTING DOME, MAP
- ENGINE TO HOOD EURO LIGHT LIGHTS
[SH29: B-1] (87692858)
8 X-LPL (Plug) pin A - LICENSE 280B LICENSE PLATE LIGHT VT - 0.8
PLATE LIGHT [LMP-LPL]
(87692855)
X-HN - CAN [ SW-HORN] (87311796) (Plug)
87311796 120
87311796
2 X-A_RT_P (Receptacle) pin 113E HORN BR - 0.8 SHEET 23 SH23 - PILOT LOADER
5 - ARM REST RIGHT HAND CONTROLS
PILOT (87694112)
X-HN1 - HORN_PWR [ H-HN] (87697629) (Plug)
87697629 121
87697629
1 X-FRNT (Receptacle) pin T 112B HORN YE - 0.8 SHEET 34 SH34 - MIRRORS, HORN BEACON
(87704426)
48083741_EN 31/07/2018
55.1 [55.100] / 175
X-HN2 - HORN_GRND [ H-HN] (87697629) (Plug)
87697629 122
87697629
1 SP-624D-P-X 624B HORN GND BK - 0.8 SHEET 34 SH34 - MIRRORS, HORN BEACON
X-HOT - HYD OIL TEMP [ B-HOT] (84607243) (Receptacle)
84607243 123
84607243
1 X-TRANS (Plug) pin 30 - 634A HYD OIL TEMP SIG YE - 0.8 SHEET 19 SH19 - UCM PWR, GRND,
TRANSMISSION TO CAB INSTRUMENTATION
(87696949)
2 SP-482A-P-X 482S HOT GRND BL - 0.8
X-HTS - HUMIDITY AND TEMP SENSOR [ B-HT] (87709809) (Receptacle)
87709809 124
87709809
48083741_EN 31/07/2018
55.1 [55.100] / 176

1 X-ECU (Receptacle) pin 90 - 690 HUMIDITY TEMP OR - 0.8 SHEET 17 SH17 - ENGINE CONTROL UNIT
ECU CONNECTOR [A-ECU] SENSOR 2, AT
(84300197)
2 X-ECU (Receptacle) pin 15 - 615 HUMIDITY TEMP YE - 0.8
ECU CONNECTOR [A-ECU] SENSOR
(84300197)
3 SP-643-P-X 643A HUMIDITY TEMP BK - 0.8
SENSOR
4 X-ECU (Receptacle) pin 40 - 642 HUMIDITY TEMP YE - 0.8
ECU CONNECTOR [A-ECU] SENSOR
(84300197)
X-HVAC - INTRCECT TO HVAC SYSTEM BY HVAC [ SH33: D-4] (87696573) (Receptacle)
87696573 125
87696573
A X-LC4 (Receptacle) pin 6A - 876 HVAC ACCESSORY OR - 3.0 SHEET 09 SH09 - ACCESSORY PWR DIST
LOADCENTER 4 [SH35: C-6] POWER (FUSE BLOCK LC4)
(87733595)
B X-CAB_E-2 (Plug) pin L - 246 SIG_HVAC_A/C HIGH YE - 0.8 SHEET 33 SH33 - HEATING BLOWER
CAB TO ENG 2 [SH9: C-2] PRESSURE SW HEATER, HVAC
(87703902)
C SP-256-P-X 256C CAB CLEAN GRND BK - 0.8
D SP-256-P-X 256J CAB CLEAN GRND BK - 0.8
E SP-873-P-X 873A HVAC POWER OR - 0.8
F SP-873-P-X 873B HVAC POWER OR - 0.8
H X-AIR (Receptacle) pin 12 - 267 BLOWER SPEED WH - 2.5
HVAC CONSOLE [SH27: C-2]
(84309048)
J X-AIR (Receptacle) pin 11 - 266 BLOWER SPEED YE - 2.0
(84309048)
L SP-258-P-X 258 HVAC ON SIGNAL YE - 0.8
M X-AIR (Receptacle) pin 1 - 262 TEMP SETTING YE - 0.8
(84309048)
N X-AIR (Receptacle) pin 2 - 261 TEMP SETTING WH - 0.8
(84309048)
P X-AIR (Receptacle) pin 3 - 260 TEMP SETTING VT - 0.8
(84309048)
R X-AIR (Receptacle) pin 9 - 264 BLOWER SPEED GY - 1.0
(84309048)
S X-AIR (Receptacle) pin 10 - 265 BLOWER SPEED GN - 2.0
(84309048)
48083741_EN 31/07/2018
55.1 [55.100] / 177
X-HVAC2 - HVAC MECHINISM (87696550) (Plug)
87696550 126
87696550
A X-06 (Receptacle) pin 1 - 876H 876H OR - 3.0 SHEET 33 SH33 - HEATING BLOWER
DENSO HEATER, HVAC
B X-07 (Receptacle) pin A - 246B 246B WH - 0.35
DENSO (87692855)
C X-01 (Receptacle) pin 15 - 256F 256F BK - 0.8
DENSO
F X-01 (Receptacle) pin 1 - 873C 873C GN - 0.35
DENSO
H SP-267-P-X 267B 267B GY - 2.5
J X-05 (Receptacle) pin 3 - 266B 266B YE - 2.0
DENSO
K X-01 (Receptacle) pin 14 - 258F DENSO RD - 0.35
DENSO
L X-01 (Receptacle) pin 8 - 258E 258E GY - 0.35
DENSO
M X-01 (Receptacle) pin 20 - 260B 260B YE - 0.35
DENSO
N X-01 (Receptacle) pin 25 - 261B 261B WH - 0.35
DENSO
P X-01 (Receptacle) pin 2 - 262B 262B PRP - 0.35
DENSO
R SP-264B-P-X 264B 264B GY - 1.0
S X-05 (Receptacle) pin 2 - 265B 265B GN - 2.0
DENSO
X-ISO - ISOLATOR [ K-ISOLATOR] (87687242) (Plug)
87687242 127
87687242
48083741_EN 31/07/2018
55.1 [55.100] / 178
X-ISS - SPEED SENSOR MIDDLE WHEEL CHAIN [ B-IS_S] (84364854) (Receptacle)
84364854 128
84364854
1 X-TRANS (Plug) pin 9 - 701A INTERMEDIATE SPEED YE - 0.8 SHEET 26 SH26 - GEAR CONTROL UNIT 2
TRANSMISSION TO CAB SENSOR
(87696949)
2 X-TRANS (Plug) pin 11 - 702B SPEED SENSOR GRND BL - 0.8
TRANSMISSION TO CAB
(87696949)
X-JC1 - JUNCTION STUD OF B+ IN REAR (84399576) (Plug)
84399576 129
84399576
1 X-CPWR (Plug) pin 1 - CAB 235 B+ TO REAR JUNCTION RD - 19.0 SHEET 03 SH03 - PWR DISTR-BATTERY /
POWER (84401295) BLOCK STARTER / KEY
X-JC2 - JUNCTION STUD OF B+ IN REAR [ SH3: C-4] (84186853) (Plug)
84186853 130
84186853
48083741_EN 31/07/2018
55.1 [55.100] / 179

1 X-LC6 pin 3 - LOADCENTER 212 B+ RD - 3.0 SHEET 03 SH03 - PWR DISTR-BATTERY /
6 [SH16: A-3] (84380518) STARTER / KEY
1 X-LC6 pin 30 - LOADCENTER 212A EVGT POWER RD - 3.0
6 [SH16: A-3] (84380518)
1 X-LC6 pin 9 - LOADCENTER 416 B+ RD - 5.0
6 [SH16: A-3] (84380518)
X-JC3 - JUNCTION STUD OF B+ IN REAR (84253168) (Plug)
84253168 131
84253168
1 X-LC7 pin 3 - LOAD CENTER 229 B+ RD - 5.0 SHEET 03 SH03 - PWR DISTR-BATTERY /
7 (84563565) STARTER / KEY
X-JS+ - JUMP START STUD POS [ J-JS+] (Plug)

PIN1 X-P5320 (Plug) pin PIN1 - CABLE09 JUMP START RD - 32.0 SHEET 03 SH03 - PWR DISTR-BATTERY /
JUMP START [G-002] STARTER / KEY
X-JS- - JUMP START STUD NEG [ J-JS-] (Plug)

PIN1 X-P5321 (Plug) pin PIN1 - CABLE08 JUMP START MINUS BK - 32.0 SHEET 03 SH03 - PWR DISTR-BATTERY /
JUMP START [G-001] STARTER / KEY
X-JSS_CAN - CAN (87695580) (Receptacle)
87695580 132
87695580
A SP-B_HM-P-X CANB_HO CAN WH - 0.8 SHEET 24 SH24 - CAN STRUCTURE
B SP-B_LM-P-X CANB_LO CAN BL - 0.8
48083741_EN 31/07/2018
55.1 [55.100] / 180
X-JSS_COM - JSS FRAME TO CAB CAN (87695723) (Plug)
87695723 133
87695723
A SP-B_HP-P-X CANB_HP CAN WH - 0.8 SHEET 24 SH24 - CAN STRUCTURE
B SP-B_LP-P-X CANB_LP CAN BL - 0.8
X-JSS_CO_1 - CUT OFF SENSOR [ K-JSS_CO_1] (87694153) (Receptacle)
87694153 134
87694153
1 SP-677A-P-X 677G 5V REF3 OUT PK - 0.8 SHEET 21 SH21 - UCM-STEERING AUX JSS
2 SP-967A-P-X 967G 5 V REF GRND3 BL - 0.8
4 X-JSS_FR (Plug) pin 2 - JSS 676A JSS PILOT PRESS SIG YE - 0.8
FRAME HARNESS TO CAB
(87694152)
X-JSS_CO_2 - CUT OFF SENSOR [ B-JSS_CO_2] (87694153) (Receptacle)
87694153 135
87694153
48083741_EN 31/07/2018
55.1 [55.100] / 181

1 SP-677A-P-X 677F 5V REF3 OUT PK - 0.8 SHEET 21 SH21 - UCM-STEERING AUX JSS
2 SP-967A-P-X 967F 5 V REF GRND3 BL - 0.8
4 X-JSS_FR (Plug) pin 6 - JSS 273A JSS CUTOFF SIG B YE - 0.8
FRAME HARNESS TO CAB
(87694152)
X-JSS_FR - JSS FRAME HARNESS TO CAB (87694152) (Plug)
87694152 136
87694152
1 SP-799C-P-X 799C JSS IGN PWR OR - 0.8 SHEET 24 SH24 - CAN STRUCTURE
2 X-JSS_CO_1 (Receptacle) 676A JSS PILOT PRESS SIG YE - 0.8 SHEET 21 SH21 - UCM-STEERING AUX JSS
pin 4 - CUT OFF SENSOR
[K-JSS_CO_1] (87694153)
3 SP-677A-P-X 677A 5V REF3 OUT PK - 0.8
4 SP-967A-P-X 967A 5 V REF GRND3 BL - 0.8
5 SP-955Y-P-X 955Y JSS GROUND BK - 0.8
6 X-JSS_CO_2 (Receptacle) 273A JSS CUTOFF SIG B YE - 0.8
pin 4 - CUT OFF SENSOR
[B-JSS_CO_2] (87694153)
X-JSS_JOY - JSS LEFT HAND JOYSTICK [ B-JSS] (87700107) (Receptacle)
87700107 137
87700107
48083741_EN 31/07/2018
55.1 [55.100] / 182

1 X-LFT_A (Plug) pin 7 - 677D 5V REF3 OUT PK - 0.8 SHEET 21 SH21 - UCM-STEERING AUX JSS
JSS TO CAB L ARMREST
(87700155)
2 X-LFT_A (Plug) pin 2 - 670A JSS JOYSTICK 1 YE - 0.8
(87700155)
3 X-LFT_A (Plug) pin 6 - 967D 5 V REF GRND3 BL - 0.8
(87700155)
4 X-LFT_A (Plug) pin 1 - 471L 5V REF2 PK - 0.8
(87700155)
5 X-LFT_A (Plug) pin 5 - 630A JSS JOYSTICK 2 YE - 0.8
(87700155)
6 X-LFT_A (Plug) pin 3 - 651M 5V GND2 BL - 0.8
(87700155)
X-JSV - JOYSTICK STEERING VALVE [ SH21: B-2] (87695592) (Receptacle)
87695592 138
87695592
4 SP-B_HV-P-X CANB_HW CAN WH - 0.8 SHEET 21 SH21 - UCM-STEERING AUX JSS
5 SP-B_LV-P-X CANB_LW CAN BL - 0.8
6 SP-854A-P-X 854A TO JSS CUTOFF VALVES WH - 0.8
7 SP-955Y-P-X 955AA JSS GROUND BK - 0.8
8 SP-799C-P-X 799E JSS IGN PWR OR - 0.8
9 SP-B_LS-P-X CANB_LT CAN BL - 0.8
10 SP-B_HS-P-X CANB_HT CAN WH - 0.8
X-KDD - KICK DOWN SW (84146428) (Receptacle)
84146428 139
84146428
48083741_EN 31/07/2018
55.1 [55.100] / 183
X-KDS - CAN (87311796) (Plug)
87311796 140
87311796
2 X-A_RT_2B (Receptacle) pin 309B KICK DOWN SIGNAL YE - 0.8 SHEET 23 SH23 - PILOT LOADER
2 (84281913)
4 X-A_RT_P (Receptacle) pin 792H KICKDOWN SW PWR OR - 0.8
1 - ARM REST RIGHT HAND
PILOT (87694112)
X-KEY - KEY SWITCH [ SW-KEY] (87699176) (Receptacle)
87699176 141
87699176
A SP-219A-P-X 219B NON-ISOLATED PWR RD - 0.8 SHEET 03 SH03 - PWR DISTR-BATTERY /
B X-X7 (Receptacle) pin 30 - 220 SIG_IGNITION YE - 0.8 STARTER / KEY
SFB [SH3: A-3] (84538791) SWITCH_START
C X-X7 (Receptacle) pin 32 - 225 SIG_IGNITION YE - 0.8
SFB [SH3: A-3] (84538791) SWITCH_ACC
D X-X7 (Receptacle) pin 31 - 221 SIG_IGNITION YE - 0.8
SFB [SH3: A-3] (84538791) SWITCH_RUN
48083741_EN 31/07/2018
55.1 [55.100] / 184
X-LC1 - LOADCENTER 1 [ SH10: A-6] (47728326) (Receptacle)
47728326 142
47728326
X-LC2 - LOADCENTER 2 [ SH7: B-3] (87733581) (Receptacle)
87733581 143
87733581
48083741_EN 31/07/2018
55.1 [55.100] / 185

1A F-2F1-P-2 WIRE6246 WIRE6246 SHEET 07 SH07 - BATTERY PWR DISTR
1A X-UCM1A (Receptacle) pin 465 CAB ISOLATED B+ RD - 1.0 (FUSE BLOCK LC2)
20 - UCM (82016219)
2A F-2F2-P-2 WIRE6247 WIRE6247
2A SP-448-P-X 448 CAB ISOLATED B+ RD - 3.0
6A SP-165-P-X 165 TECM_RH STALK B+ RD - 1.0
7A X-DSP (Receptacle) pin X - 805 DISPLAY B+ RD - 0.8
DISPLAY [A-DSP] (82016219)
8A X-DIA (Plug) pin B - 798 DIAGNOSTIC B+ RD - 0.8
DIAGNOSTIC PORT [A-DIA]
(87736919)
9A X-CAB_E (Receptacle) pin 2 205 HOOD LIFT RD - 2.0
(84807216)
11A F-2F11-P-2 WIRE6229 WIRE6229
11A X-CAM (Receptacle) pin 1 - 125 REVERSE CAMERA OR - 0.8
REAR CAMERA (87700107) POWER
12A F-2F12-P-2 WIRE6224 WIRE6224
13A F-2F13-P-2 WIRE6228 WIRE6228
1B X-P1196 (Plug) pin 1 - B+ 526 CAB ISOLATED B+ RD - 1.0
POWER STUD (84140737)
1B F-2F1-P-1 WIRE6245 WIRE6245
7B X-P1002 (Plug) pin 1 - B+ 532 CAB ISOLATED POWER RD - 3.0
7B SP-2F7-P-X WIRE6232 WIRE6232
9B X-CAB_E (Receptacle) pin 4 216E HOOD LIFT NON-DISC RD - 2.0
- CAB TO ENGINE [SH7: B-5] PWR
(84807216)
12B SP-878-P-X 878C IGN PWR OR - 3.0
12B SP-F12-P-X WIRE6223 WIRE6223
X-LC3 - LOADCENTER 3 [ SH35: B-6] (84529039) (Receptacle)
84529039 144
84529039
48083741_EN 31/07/2018
55.1 [55.100] / 186

F6_6 X-P1009 (Plug) pin 1 - B+ 541 CAB ISOLATED POWER RD - 2.0 SHEET 08 SH08 - POWER DISTRIBUTION
POWER STUD (84140737) (FUSE BLOCK LC3)
F6_6 SP-F6_6-P-X WIRE6256 WIRE6256
F8_4 F-3F8-P-2 WIRE6263 WIRE6263
F8_4 X-LC3 (Receptacle) pin 191 SWBAT_ISOLA- RD - 3.0
R1_30 - LOADCENTER 3 TOR_SPARE SUPPLY
[SH35: B-6] (84529039)
F8_8 F-3F8-P-1 WIRE6262 WIRE6262
F8_8 X-P1009 (Plug) pin 1 - B+ 917 CAB ISOLATED POWER RD - 3.0
F1_13 F-3F1-P-2 WIRE6261 WIRE6261
F1_13 X-X-PO1 (Receptacle) pin A 750 RH CONSOLE 12V PWR OR - 1.0
- POWER OUTLET [J-PO1] OUTLET
(84398827)
F3_11 X-CNV (Receptacle) pin 5 - 24 748 12V ACC POWER OR - 2.0
TO 12 POWER CONVERTER
[SH35: B-4] (87694112)
F3_11 SP-F3_11-P-X WIRE6250 WIRE6250
F3_15 F-3F3-P-2 WIRE6260 WIRE6260
F3_15 X-RAD (Receptacle) pin 7 - 753 12V FUSED ACC PWR OR - 0.8
RADIO [H-RADIO] (87709660)
R1_30 X-LC3 (Receptacle) pin F8_4 191 SWBAT_ISOLA- RD - 3.0
- LOADCENTER 3 [SH35: B-6] TOR_SPARE SUPPLY
(84529039)
R1_30 K-3R1-P-30 WIRE6264 WIRE6264
R1_85 X-LC3 (Receptacle) pin WIRE6266 WIRE6266
[SH35: B-6] (84529039)
R1_85 X-CG4 (Receptacle) pin F - 954F SPARE RELAY COIL GND BK - 0.8
(84149207)
R1_85 X-LC3 (Receptacle) pin WIRE6266 WIRE6266
[SH35: B-6] (84529039)
R1_86 K-3R1-P-86 WIRE6275 WIRE6275
R1_86 X-X3 (Receptacle) pin 15 - 192 SIG_DC_CONVERTER OR - 0.8
SFB [SH3: A-1] (47554344)
R1_87 K-3R1-P-87 WIRE6265 WIRE6265
R1_87 SP-746-P-X 746 POWER CONVERTER OR - 3.0
ACC POWER
R2_30 K-3R2-P-30 WIRE6274 WIRE6274
R2_30 X-LC5 (Receptacle) pin 5A - 182 SEC STRG IGN PWR OR - 0.8
LOADCENTER 5 [SH10: D-1]
(87733595)
R2_85 K-3R2-P-85 WIRE6268 WIRE6268
R2_85 SP-954S-P-X 954R SEC STRG SIG GRND BK - 0.8
R2_86 K-3R2-P-86 WIRE6273 WIRE6273
R2_87 K-3R2-P-87 WIRE6267 WIRE6267
R2_87 X-CAB_B (Plug) pin 12 - CAB 441 SEC STRG SOL PWR OR - 0.8
TO BOTTOM [SH21: B-3]
(87696945)
R3_30 K-3R3-P-30 WIRE6272 WIRE6272
R3_30 X-LC4 (Receptacle) pin 8A - 877 REAR DEFROST OR - 2.0
LOADCENTER 4 [SH35: C-6] ACCESSORY POWER
(87733595)
R3_85 K-3R3-P-85 WIRE6270 WIRE6270
R3_85 SP-954S-P-X 954M REAR DEFROST RELAY BK - 0.8
GND
R3_86 K-3R3-P-86 WIRE6271 WIRE6271
R3_86 X-X3 (Receptacle) pin 7 - SFB 120 REAR DEFROST YE - 0.8
[SH3: A-1] (47554344)
R3_87 K-3R3-P-87 WIRE6269 WIRE6269
R3_87 X-RWHE1 (Receptacle) pin 801 REAR DEFROST PWR OR - 2.0
1 - REAR WINDOW HEATER
[R-WND_HTR] (87688695)
R4_30 SP-219A-P-X 219D NON-ISOLATED PWR RD - 0.8 SHEET 03 SH03 - PWR DISTR-BATTERY /
STARTER / KEY
R4_85 SP-113-P-X 113F HORN SIGNAL BR - 0.8 SHEET 13 SH13 - POWER DISTRIBUTION 2
R4_86 SP-219A-P-X 219E NON-ISOLATED PWR RD - 0.8 CAB GROUND BLK
R4_87 X-CAB_B (Plug) pin 21 - CAB 112 HORN YE - 0.8
(87696945)
48083741_EN 31/07/2018
55.1 [55.100] / 187
X-LC4 - LOADCENTER 4 [ SH35: C-6] (87733595) (Receptacle)
87733595 145
87733595
30 K-4KR1-P-30 WIRE6289 WIRE6289 SHEET 09 SH09 - ACCESSORY PWR DIST
85 K-4KR1-P-85 WIRE6292 WIRE6292 (FUSE BLOCK LC4)
85 X-CG4 (Receptacle) pin A - 954A ACCESSORY RELAY BK - 0.8
CAB GROUND [SH24: B-6] COIL GND
(84149207)
86 K-4KR1-P-86 WIRE6290 WIRE6290
86 X-X3 (Receptacle) pin 11 - 226 ACCESSORY POWER YE - 0.8
SFB [SH3: A-1] (47554344)
87 X-LC4 (Receptacle) pin 2B - 919 ACCESSORY POWER OR - 3.0
LOADCENTER 4 [SH35: C-6]
(87733595)
(87733595)
87 K-4KR1-P-87 WIRE6291 WIRE6291
(87733595)
1A X-CL (Receptacle) pin 743 24V CIGAR LIGHTER OR - 2.0
1 - CIGAR LIGHTER
[LMP-CIG_LTR] (84015523)
3A X-CAB_E-2 (Plug) pin K - 875 AC CLUTCH PWR OR - 1.0
CAB TO ENG 2 [SH9: C-2]
(87703902)
6A X-HVAC (Receptacle) pin 876 HVAC ACCESSORY OR - 3.0
A - INTRCECT TO HVAC POWER
D-4] (87696573)
7A X-SC (Plug) pin A - SEAT 742 12V FUSED ACC PWR OR - 2.0
COMPRESSOR [Y-SC] FOR SEAT COMP
(87692855)
8A X-LC3 (Receptacle) pin 877 REAR DEFROST OR - 2.0 SHEET 08 SH08 - POWER DISTRIBUTION
R3_30 - LOADCENTER 3 ACCESSORY POWER (FUSE BLOCK LC3)
[SH35: B-6] (84529039)
2B SP-6201-P-X WIRE6276 WIRE6276 SHEET 09 SH09 - ACCESSORY PWR DIST
2B X-LC4 (Receptacle) pin 87 - 919 ACCESSORY POWER OR - 3.0 (FUSE BLOCK LC4)
(87733595)
6B X-LC4 (Receptacle) pin 87 - 920 ACCESSORY POWER OR - 3.0
(87733595)
8B X-LC4 (Receptacle) pin 87 - 874 ACCESSORY POWER OR - 3.0
(87733595)
8B SP-4F8-P-X WIRE6283 WIRE6283
48083741_EN 31/07/2018
55.1 [55.100] / 188
X-LC5 - LOADCENTER 5 [ SH10: D-1] (87733595) (Receptacle)
87733595 146
87733595
30 X-LC1 pin B1 - LOADCENTER 173 ISOLATED_SFB_IGNI- RD - 5.0 SHEET 10 SH10 - IGNITION PWR DISTR
1 [SH10: A-6] (47728326) TION SUPPLY (FUSE BLOCK LC5)
30 K-5KR1-P-30 WIRE6302 WIRE6302
85 X-CG4 (Receptacle) pin H - 954H IGNITION RELAY COIL BK - 0.8
(84149207)
85 K-5KR1-P-85 WIRE6296 WIRE6296
86 X-X3 (Receptacle) pin 8 - SFB 222 SIG_IGNITION YE - 0.8 SHEET 03 SH03 - PWR DISTR-BATTERY /
[SH3: A-1] (47554344) RELAY_COIL STARTER / KEY
86 K-5KR1-P-86 WIRE6308 WIRE6308
87 K-5KR1-P-87 WIRE6307 WIRE6307 SHEET 10 SH10 - IGNITION PWR DISTR
87 SP-878-P-X 878 IGNITION POWER OR - 5.0 (FUSE BLOCK LC5)
1A X-DSP (Receptacle) pin X - 806 DISPLAY WAKE-UP OR - 0.8
DISPLAY [A-DSP] (82016219) IGNITION POWER
2A SP-466-P-X 466 IGNITION POWR FOR OR - 0.8
UCM
3A SP-19C-P-X 19C IGN PWR OR - 2.0
4A X-X_TEL (Receptacle) pin 2 168 TELEMATICS IGN OR - 0.8
- TELEMATICS [SH38: C-6] POWER
(87700156)
5A X-LC3 (Receptacle) pin 182 SEC STRG IGN PWR OR - 0.8
[SH35: B-6] (84529039)
6A X-CAB_AR (Plug) pin 1 - CAB 792 IMP JOYSTICK PWR OR - 0.8
TO RH ARM REST (87694152)
7A X-SW_PD (Receptacle) pin 807 KEYPAD IGN POWER OR - 0.8
1 - SWITCH PAD [SW-PD]
(87694153)
8A SP-799-P-X 799 JSS IGNITION POWER OR - 0.8
9A X-CAB_E (Receptacle) pin 1 850 IGN PWR FOR REAR OR - 2.0
(84807216)
10A F-5F10-P-2 WIRE6309 WIRE6309
10A SP-19H-P-X 19H STALK/DIFF FUSED PWR OR - 0.8
3B SP-878-P-X 878A IGNITION POWER OR - 3.0
9B SP-878-P-X 878B IGN PWR OR - 3.0
48083741_EN 31/07/2018
55.1 [55.100] / 189
X-LC6 - LOADCENTER 6 [ SH16: A-3] (84380518) (Receptacle)
84380518 147
84380518
X-LC7 - LOAD CENTER 7 (84563565) (Receptacle)
84563565 148
84563565
X-LEV1 - INLINE TO DEF LEVEL & TEMP (84062580) (Plug)
84062580 149
84062580
48083741_EN 31/07/2018
55.1 [55.100] / 190
X-LEV2 - INLINE TO DEF LEVEL & TEMP (87680689) (Receptacle)
87680689 150
87680689
X-LF2 - WORK LIGHT OPT [ LMP-LF0] (87695582) (Receptacle)
87695582 151
87695582
1 SP-6111D-P-X 111B WORK LIGHT JUMPER VT - 1.0 SHEET 31 SH31 - LIGHTING WORKING
2 SP-949F-P-X 949D WORK LIGHT BK - 1.0 LIGHTS CAB ROOF, FRONT AND REAR
X-LFO - WORK LIGHT OPTION (87695584) (Plug)
87695584 152
87695584
1 SP-6111D-P-X 111C WORK LIGHT JUMPER VT - 1.0 SHEET 31 SH31 - LIGHTING WORKING
2 SP-949F-P-X 949E WORK LIGHT JUMPER BK - 1.0 LIGHTS CAB ROOF, FRONT AND REAR
48083741_EN 31/07/2018
55.1 [55.100] / 191
X-LFT_2 - LEFT JS TO CAB (87700105) (Plug)
87700105 153
87700105
1 X-SW_JSS (Receptacle) pin 691A JSS INDICATOR WH - 0.8 SHEET 21 SH21 - UCM-STEERING AUX JSS
10 - JOYSTICK STEERING
SWITCH [SW-SW_JSS]
(87716755)
2 X-SW_JSS (Receptacle) pin 981K BACKLIGHTING VT - 0.8
SWITCH [SW-SW_JSS]
(87716755)
X-LFT_A - JSS TO CAB L ARMREST (87700155) (Plug)
87700155 154
87700155
48083741_EN 31/07/2018
55.1 [55.100] / 192

1 X-JSS_JOY (Receptacle) 471L 5V REF2 PK - 0.8 SHEET 21 SH21 - UCM-STEERING AUX JSS
pin 4 - JSS LEFT HAND
JOYSTICK [B-JSS]
(87700107)
2 X-JSS_JOY (Receptacle) 670A JSS JOYSTICK 1 YE - 0.8
JOYSTICK [B-JSS]
(87700107)
3 X-JSS_JOY (Receptacle) 651M 5V GND2 BL - 0.8
JOYSTICK [B-JSS]
(87700107)
4 X-LH_ARM_UP (Receptacle) 675A LH ARMREST POSITION GY - 0.8
pin 3 - LH JSS ARM REST UP
DOWN [SW-ARM_POS_UP]
(84000405)
5 X-JSS_JOY (Receptacle) 630A JSS JOYSTICK 2 YE - 0.8
JOYSTICK [B-JSS]
(87700107)
6 X-JSS_JOY (Receptacle) 967D 5 V REF GRND3 BL - 0.8
JOYSTICK [B-JSS]
(87700107)
7 X-JSS_JOY (Receptacle) 677D 5V REF3 OUT PK - 0.8
JOYSTICK [B-JSS]
(87700107)
8 X-LH_ARM_DWN 673A LH ARMREST POSITION TN - 0.8
(Receptacle) pin 3 - LH DWN
JSS ARM REST DOWN
[SW-ARM_POS_DWN]
(84000405)
9 X-SW_JSS (Receptacle) pin 678A JSS ACTIVATION WH - 0.8
SWITCH [SW-SW_JSS]
(87716755)
10 SP-799A-P-X 799G JSS IGNITION POWER OR - 0.8
11 SP-954-P-X 954 LH JSS GND BK - 0.8
12 X-SW_JSS (Receptacle) pin 682A JSS ACTIVATION NC YE - 0.8
SWITCH [SW-SW_JSS]
(87716755)
X-LFWL - LEFT FRONT WORK LIGHT [ LMP-LF_WL] (87695582) (Receptacle)
87695582 155
87695582
1 X-ROOF (Receptacle) pin 1 - 111A LEFT FRONT WORK VT - 1.0 SHEET 31 SH31 - LIGHTING WORKING
ROOF TO CAB (87700325) LIGHT LIGHTS CAB ROOF, FRONT AND REAR
1 SP-6111D-P-X 111D WORK LIGHT JUMPER VT - 1.0
2 SP-949A-P-X 949C LEFT FRONT WORK BK - 1.0
LIGHT GND
2 SP-949F-P-X 949F WORK LIGHT JUMPER BK - 1.0
48083741_EN 31/07/2018
55.1 [55.100] / 193
X-LH-REAR-TAIL-EURO - LH REAR TAIL LIGHT EURO [ LMP-L-EURO-TAIL] (87694112) (Receptacle)
87694112 156
87694112
1 X-HD_N (Receptacle) pin 2 - 126D STOP PL23 EURO VT - 0.8 SHEET 30 SH30 - OLD EURO LIGHTING
HOOD TO ENG (87700325)
2 X-HD_N (Receptacle) pin 3 - 128D TURN PL23 EURO VT - 0.8
3 X-HD_N (Receptacle) pin 6 - 127H TAIL PL23 EURO VT - 0.8
4 SP-124H-P-X 124K REVERSE LIGHTS PL23 VT - 0.8
5 SP-242H-P-X 242L GRND BK - 0.8
X-LH-TAIL - LH REAR TAIL LIGHT NA [ L-NA-TAIL] (87694101) (Receptacle)
87694101 157
87694101
1 SP-243-P-X 243A TAIL LIGHTS GRND BK - 0.8 SHEET 29 SH29 - LIGHTING REAR TAILS
EURO
1 SP-242A-P-X 242C TAIL LIGHTS GRND NA BK - 1.0
2 X-ENG (Plug) pin 10 - 126E STOP LH EURO VT - 0.8
(87696948)
2 X-HD_N (Receptacle) pin 2 - 126B LH BRAKE LAMP NA VT - 0.8
3 X-HD_N (Receptacle) pin 6 - 127F LH TAIL LAMP NA VT - 0.8
3 X-ENG (Plug) pin 12 - 127J TAIL EURO VT - 0.8
(87696948)
4 X-ENG (Plug) pin 22 - 128E LH TURN EURO VT - 0.8
(87696948)
4 X-HD_N (Receptacle) pin 3 - 128B LH REAR TURN LAMP NA VT - 0.8
48083741_EN 31/07/2018
55.1 [55.100] / 194
X-LH_ARM_DWN - LH JSS ARM REST DOWN [ SW-ARM_POS_DWN] (84000405) (Receptacle)
84000405 158
84000405
1 SP-799A-P-X 799J JSS IGNITION POWER OR - 0.8 SHEET 21 SH21 - UCM-STEERING AUX JSS
3 X-LFT_A (Plug) pin 8 - 673A LH ARMREST POSITION TN - 0.8
JSS TO CAB L ARMREST DWN
(87700155)
X-LH_ARM_UP - LH JSS ARM REST DOWN [ SW-ARM_POS_UP] (84000405) (Receptacle)
84000405 159
84000405
1 SP-799A-P-X 799K JSS IGNITION POWER OR - 0.8 SHEET 21 SH21 - UCM-STEERING AUX JSS
3 X-LFT_A (Plug) pin 4 - 675A LH ARMREST POSITION GY - 0.8
JSS TO CAB L ARMREST UP
(87700155)
X-LLF - FRONT COMBO LAMP LEFT [ LMP-LF_LT] (87694109) (Plug)
87694109 160
87694109
48083741_EN 31/07/2018
55.1 [55.100] / 195
X-LPL - LICENSE PLATE LIGHT [ LMP-LPL] (87692855) (Plug)
87692855 161
87692855
A X-HD_E (Plug) pin A - HOOD 280D LICENSE PLATE LIGHT VT - 0.8 SHEET 27 SH27 - LIGHTING DOME, MAP
EURO TO EURO ENG HARN EURO LIGHTS
(87644909)
A X-HD_N (Receptacle) pin 8 - 280B LICENSE PLATE LIGHT VT - 0.8
B X-HD_E (Plug) pin C - HOOD 243D LPL GRND EURO BK - 0.8
EURO TO EURO ENG HARN
(87644909)
B SP-242A-P-X 242D LICENSE PLAT LIGHT BK - 0.8
GRND
X-LRF - FRONT COMBO LAMP RT [ LMP-RF_LT] (87694109) (Plug)
87694109 162
87694109
X-LRWL - LEFT REAR WORK LIGHT [ LMP-LR_WL] (87695582) (Receptacle)
87695582 163
87695582
48083741_EN 31/07/2018
55.1 [55.100] / 196

1 SP-859A-P-X 859B LEFT REAR WORK LIGHT VT - 0.8 SHEET 31 SH31 - LIGHTING WORKING
2 SP-953A-P-X 953E LEFT REAR WORK LIGHT BK - 1.0 LIGHTS CAB ROOF, FRONT AND REAR
GND
X-MAP - MAP LIGHT [ SH13: C-6] (84058093) (Receptacle)
84058093 164
84058093
A X-X3 (Receptacle) pin 18 - 147 MAP LAMP VT - 0.8 SHEET 27 SH27 - LIGHTING DOME, MAP
SFB [SH3: A-1] (47554344) LIGHTS
C X-CG3 (Receptacle) pin 955Q MAP LIGHT GND BK - 0.8 SHEET 13 SH13 - POWER DISTRIBUTION 2
K - CAB GROUND RH CAB GROUND BLK
(84149207)
X-MH_L - MIRROR HEATED LEFT [ L-MH_L] (87695582) (Receptacle)
87695582 165
87695582
1 SP-114A-P-X 114B MIRROR HEAT SUPPLY TN - 1.0 SHEET 34 SH34 - MIRRORS, HORN BEACON
LH
2 SP-953A-P-X 953C MIRROR HEAT GND LH BK - 1.0 SHEET 31 SH31 - LIGHTING WORKING
LIGHTS CAB ROOF, FRONT AND REAR
48083741_EN 31/07/2018
55.1 [55.100] / 197
X-MH_R - MIRROR HEATED RIGHT [ LMP-MH_R] (87695582) (Receptacle)
87695582 166
87695582
1 SP-114A-P-X 114C MIRROR HEAT SUPPLY TN - 1.0 SHEET 34 SH34 - MIRRORS, HORN BEACON
RH
2 SP-953A-P-X 953D MIRROR HEAT GND RH BK - 1.0
X-NH3 - NH3 SENSOR [ B-NH3] (84146686) (Receptacle)
84146686 167
84146686
X-NOXD - SCR DOWNSTREAM NOX SENSOR [ B-NOX_DU] (84190317) (Receptacle)
84190317 168
84190317
48083741_EN 31/07/2018
55.1 [55.100] / 198

1 SP-200D-P-X 200F SCR SENSOR POWER OR - 1.0 SHEET 18 SH18 - ENGINE CONTROL UNIT
2 SP-201D-P-X 201F SCR SENSORS CLEAN BK - 1.0 3, AT
GROUND
3 SP-CANC_LE-P-X CANC_LF CAN GN - 0.8
4 SP-CANC_HE-P-X CANC_HF CAN YE - 0.8
5 SP-201D-P-X 201G SCR SENSORS CLEAN BK - 0.8
GROUND
X-NOXS - DOC UPSTREAM NOX SENSOR [ B-NOX_SD] (84190317) (Receptacle)
84190317 169
84190317
1 SP-200D-P-X 200G SCR SENSOR POWER OR - 1.0 SHEET 18 SH18 - ENGINE CONTROL UNIT
2 SP-201D-P-X 201H SCR SENSORS CLEAN BK - 1.0 3, AT
GROUND
3 SP-CANC_LG-P-X CANC_LJ CAN GN - 0.8
4 SP-CANC_HG-P-X CANC_HJ CAN YE - 0.8
X-OSS - SPEED SENSOR GEAR TRANS [ B-OSS] (84062580) (Plug)
84062580 170
84062580
48083741_EN 31/07/2018
55.1 [55.100] / 199
X-PBBS - PARK BRAKE PRES SENSR [ B-PBBS] (Plug)
X-PBW - BRAKE SUPPLY WARNING PRES [ B-PBW] (84078681) (Receptacle)
84078681 171
84078681
A SP-482H-P-X 482K 5V GRND1 BL - 0.8 SHEET 19 SH19 - UCM PWR, GRND,
B SP-486D-P-X 486F 5V REF1 PK - 0.8 INSTRUMENTATION
C X-BTM (Receptacle) pin 6 640A BRAKE SUPPLY PRESS YE - 0.8
- BOTTOM TO CAB STD
(87704523)
X-PED - PEDESTAL TO CAB (87700156) (Receptacle)
87700156 172
87700156
1 X-TT (Receptacle) pin 2 188A LH TURN INDICATOR VT - 0.8 SHEET 28 SH28 - LIGHTING HAZARD
- TELL TALE INDICATOR WARNING, BLINKERS, DRIVING
[LMP-TTI] (87715979)
2 X-TT (Receptacle) pin 5 189A RIGHT TURN TELL TALE VT - 0.8
- TELL TALE INDICATOR
[LMP-TTI] (87715979)
3 X-TT (Receptacle) pin 3 132G LH HIGH BEAM LAMP VT - 0.8
- TELL TALE INDICATOR
[LMP-TTI] (87715979)
4 X-STLK (Receptacle) pin 113B RH STALK HORN BR - 0.8 SHEET 34 SH34 - MIRRORS, HORN BEACON
1 - STALK LEVER RH SWITCH
[SW-HN_STLK] (84426133)
48083741_EN 31/07/2018
55.1 [55.100] / 200

5 X-TT (Receptacle) pin 4 134A WARNING INDICATOR YE - 0.8 SHEET 28 SH28 - LIGHTING HAZARD
- TELL TALE INDICATOR LED WARNING, BLINKERS, DRIVING
[LMP-TTI] (87715979)
6 X-S_HZD (Receptacle) 141A HAZARD SWTICH YE - 0.8
pin 3 - SWITCH HAZARD
[SW-HZD_SW] (87716755)
7 X-PG (Receptacle) pin J - 955B PEDESTAL GND BK - 1.0
PEDESTAL GROUND [SH28:
B-6] (87705607)
8 X-S_HZD (Receptacle) pin 269 HAZARD INDICATOR BK - 0.8
10 - SWITCH HAZARD
[SW-HZD_SW] (87716755)
9 X-STLK (Receptacle) pin 19K IGN PWR OR - 0.8 SHEET 24 SH24 - CAN STRUCTURE
3 - STALK LEVER RH
[SW-HN_STLK] (84426133)
10 SP-HP-P-X CAN_HP CAN YE - 0.8
11 SP-LP-P-X CAN_LP CAN GN - 0.8
X-PED_2 - PEDESTAL TO CAB 2 (87705114) (Plug)
87705114 173
87705114
1 X-TS1 (Plug) pin C - 679A STALK FNR R YE - 0.8 SHEET 20 SH20 - UCM VEHICLE DRIVELINE
TRANS SHIFTER1 [A-PFNR] / FAN CONTROL
(87692817)
2 X-TS1 (Plug) pin D - 680A STALK FNR N YE - 0.8
TRANS SHIFTER1 [A-PFNR]
(87692817)
3 X-TS1 (Plug) pin B - 683A STALK FNR F YE - 0.8
(87692817)
4 X-TS2 pin C - TRANS 406A GEAR SELECT 1_4 YE - 0.8
SHIFTER 2 [A-PFNR]
(47702209)
5 X-TS2 pin B - TRANS 407A GEAR SELECT 3_4 YE - 0.8
SHIFTER 2 [A-PFNR]
(47702209)
6 X-TS1 (Plug) pin A - 4029 DW3 IGN PWR OR - 0.8
(87692817)
8 X-SRWP (Receptacle) pin 728A REAR WASHER SWITCH YE - 0.8 SHEET 32 SH32 - CAB WIPER / WASHER
3 - SWITCH REAR WIPER
[SW-WPR_SW] (87716755)
9 X-SRWP (Receptacle) pin 727A REAR WIPER SWITCH YE - 0.8
[SW-WPR_SW] (87716755)
11 X-SRWP (Receptacle) pin 283A REAR WIPER INDICATOR VT - 0.8
[SW-WPR_SW] (87716755)
12 SP-981A-P-X 981A SWITCH BACK LIGHTING VT - 0.8
48083741_EN 31/07/2018
55.1 [55.100] / 201
X-PG - PEDESTAL GROUND [ SH28: B-6] (87705607) (Receptacle)
87705607 174
87705607
A X-TT (Receptacle) pin 1 955T TELL TALE INDICATOR BK - 0.8 SHEET 28 SH28 - LIGHTING HAZARD
- TELL TALE INDICATOR GND WARNING, BLINKERS, DRIVING
[LMP-TTI] (87715979)
B X-S_HZD (Receptacle) 955H HAZARD SW GND BK - 0.8
[SW-HZD_SW] (87716755)
C X-SRWP (Receptacle) pin 955G REAR WIPER SW GND BK - 0.8
[SW-WPR_SW] (87716755)
D X-STLK (Receptacle) pin 955F LH TURN SW GND BK - 0.8
7 - STALK LEVER RH
[SW-HN_STLK] (84426133)
E X-S_HZD (Receptacle) 955E HAZARD SW INDICATOR BK - 0.8
pin 7 - SWITCH HAZARD GND
[SW-HZD_SW] (87716755)
F X-SRWP (Receptacle) pin 955D REAR WIPER SW BK - 0.8
7 - SWITCH REAR WIPER INDICATOR GND
[SW-WPR_SW] (87716755)
G X-SRWP (Receptacle) pin 955W PEDESTAL GROUND BK - 0.8
[SW-WPR_SW] (87716755)
H X-GND_PED (Plug) pin 1 - 955U PEDESTAL GND BK - 1.0
GROUND PEDESTAL RING
[SH14: B-6] (84140737)
J X-PED (Receptacle) pin 955B PEDESTAL GND BK - 1.0
7 - PEDESTAL TO CAB
(87700156)
K X-S_HZD (Receptacle) 955C PED GROUND BK - 0.8
[SW-HZD_SW] (87716755)
L X-SRWP (Receptacle) pin 955M GROUND BK - 0.8
[SW-WPR_SW] (87716755)
48083741_EN 31/07/2018
55.1 [55.100] / 202
X-PHF - HYDRAULIC FILTER SENSOR [ SW-PHF] (84352277) (Plug)
84352277 175
84352277
1 X-TRANS (Plug) pin 23 - 636A HYD FILTER SIGNAL YE - 0.8 SHEET 19 SH19 - UCM PWR, GRND,
TRANSMISSION TO CAB INSTRUMENTATION
(87696949)
X-PILOT_ENABLE - PILOT ENABLE SOLENOID [ SH28: A-1] (87695582) (Receptacle)
87695582 176
87695582
1 X-FRNT_EH (Receptacle) pin 344B PILOT ENABLE WH - 0.8 SHEET 22 SH22 - UCM-LOADER BOOM
A - FRONT TO BOTTOM EH CONTROL
(87700170)
2 SP-624D-P-X 624E PILOT ENABLE GRND BK - 0.8
X-PLB-PBD - BRAKE PRES SENSR [ B-PBL/PEDAL/DECLTCH] (84078681) (Receptacle)
84078681 177
84078681
48083741_EN 31/07/2018
55.1 [55.100] / 203

A SP-482H-P-X 482L 5V GRND1 BL - 0.8 SHEET 19 SH19 - UCM PWR, GRND,
B SP-486D-P-X 486G 5V REF1 PK - 0.8 INSTRUMENTATION
C X-BTM (Receptacle) pin 7 641A BRAKE PRESS SENSOR YE - 0.8
- BOTTOM TO CAB STD
(87704523)
X-PRB - ROLL BACK PRESSURE SWITCH [ SW-PRB] (87692877) (Plug)
87692877 178
87692877
A X-FRNT (Receptacle) pin U 291B ROLL BACK PRESSURE YE - 0.8 SHEET 22 SH22 - UCM-LOADER BOOM
- FRONT TO BOTTOM STD SW CONTROL
(87704426)
B SP-624D-P-X 624F PRB GRND BK - 0.8
X-PRB1 - REDUNDANT BRAKE SW 1 [ B-PRB1] (84078681) (Receptacle)
84078681 179
84078681
A SP-482A-P-X 482D 5V GRND1 BL - 0.8 SHEET 19 SH19 - UCM PWR, GRND,
B SP-486N-P-X 486R 5V PWR REF 1 PK - 0.8 INSTRUMENTATION
C X-TRANS (Plug) pin 1 - 443A RED BRAKE SW SIG YE - 0.8
TRANSMISSION TO CAB
(87696949)
48083741_EN 31/07/2018
55.1 [55.100] / 204
X-PRB2 - REDUNDANT BRAKE SW 2 [ B-PRB2] (84078681) (Receptacle)
84078681 180
84078681
A SP-482A-P-X 482E 5V GRND1 BL - 0.8 SHEET 19 SH19 - UCM PWR, GRND,
B SP-486N-P-X 486S 5V PWR REF 1 PK - 0.8 INSTRUMENTATION
C X-TRANS (Plug) pin 24 - 638B RED BRAKE SW SIG YE - 0.8
TRANSMISSION TO CAB
(87696949)
X-PRH2 - HIGH PRESSURE SWITCH 2 [ SH33: C-6] (87688788) (Plug)
87688788 181
87688788
A X-ENG-2 (Receptacle) pin L - 246C AC HIGH PRESS YE - 1.0 SHEET 33 SH33 - HEATING BLOWER
ENGINE TO CAB 2 (87703931) HEATER, HVAC
B X-LC6 pin 26 - LOADCENTER 211B A/C SIGNAL YE - 1.0 SHEET 11 SH11 - PWR DISTR ENG
48083741_EN 31/07/2018
55.1 [55.100] / 205
X-PSS - STEERING PRESSURE SENSOR [ B-PSS] (84078681) (Receptacle)
84078681 182
84078681
A X-SST (Plug) pin 3 - SEC 482P 5V GRND1 BL - 0.8 SHEET 21 SH21 - UCM-STEERING AUX JSS
STRG TO TRANS (87694152)
B X-SST (Plug) pin 2 - SEC 486W 5V PWR REF 1 PK - 0.8
STRG TO TRANS (87694152)
C X-SST (Plug) pin 4 - SEC 176B AUX STRG PRESS YE - 0.8
STRG TO TRANS (87694152) SIGNAL
X-PUMP - DENOX CONTROL UNIT [ A-PMP] (47421681) (Receptacle)
47421681 183
47421681
X-PXF - RETURN TO DIG PROX [ B-PXF] (87692858) (Plug)
87692858 184
87692858
48083741_EN 31/07/2018
55.1 [55.100] / 206

A X-FRNT (Receptacle) pin B 294B RTD SIG YE - 0.8 SHEET 23 SH23 - PILOT LOADER
- FRONT TO BOTTOM STD CONTROLS
(87704426)
B SP-293-P-X 293A RTD GRND BK - 0.8
C SP-792D-P-X 792E RTD IGN PWR OR - 0.8
X-PXH - HEIGHT CNTRL PROX [ B-PXH] (87644909) (Plug)
87644909 185
87644909
A X-FRNT (Receptacle) pin X 295B HT CNTRL SIGNAL YE - 0.8 SHEET 23 SH23 - PILOT LOADER
(87704426)
B SP-293-P-X 293B HT CNTRL GRND BK - 0.8
C SP-792D-P-X 792F HT_CNTRL IGN PWR OR - 0.8
X-PXT - RTD XT [ B-PXT] (87644909) (Plug)
87644909 186
87644909
A X-FRNT (Receptacle) pin B 294C RTD XT SIGNAL YE - 0.8 SHEET 23 SH23 - PILOT LOADER
(87704426)
B SP-293-P-X 293C RTD XT GRND BK - 0.8
C SP-792D-P-X 792K RTD XT PWR OR - 0.8
48083741_EN 31/07/2018
55.1 [55.100] / 207
X-P_JS - PILOT LOADER JOYSTICK [ SW-FNR] (87694152) (Plug)
87694152 187
87694152
1 X-A_RT_P (Receptacle) pin 792G IMP JOYSTICK IGN PWR OR - 0.8 SHEET 23 SH23 - PILOT LOADER
1 - ARM REST RIGHT HAND CONTROLS
PILOT (87694112)
2 X-A_RT_2B (Receptacle) pin 306A FOWARD SIGNAL WH - 0.8
2 (84281913)
3 X-A_RT_2B (Receptacle) pin 307A NUETRAL SIGNAL YE - 0.8
2 (84281913)
4 X-A_RT_2B (Receptacle) pin 308A REVERSE SIGNAL GY - 0.8
2 (84281913)
6 X-A_RT_2B (Receptacle) pin 309A KICK DOWN SIGNAL YE - 0.8
2 (84281913)
X-RAD - RADIO [ H-RADIO] (87709660) (Receptacle)
87709660 188
87709660
7 X-LC3 (Receptacle) pin 753 12V FUSED ACC PWR OR - 0.8 SHEET 35 SH35 - CABIN RADIO
F3_15 - LOADCENTER 3 LOUDSPEAKER/12V CNVRTR
[SH35: B-6] (84529039)
8 CG1-P-1 CAB GROUND RH 271 RADIO GRND BK - 0.8
HEADLINER
48083741_EN 31/07/2018
55.1 [55.100] / 208
X-RECT - ENGINE COOLANT TEMP [ B-RECTD] (84607243) (Receptacle)
84607243 189
84607243
1 X-ENG (Plug) pin 5 - 433A COOLANT TEMP YE - 0.8 SHEET 19 SH19 - UCM PWR, GRND,
ENGINE TO CAB [SH18: INSTRUMENTATION
C-6] (87696948)
2 SP-482R-P-X 482T COOLANT TEMP GRND BL - 0.8
X-RF2 - WORK LIGHT OPTION [ LMP-RFO] (87695582) (Receptacle)
87695582 190
87695582
1 SP-111G-P-X 111F WORK LIGHT JUMPER VT - 1.0 SHEET 31 SH31 - LIGHTING WORKING
2 SP-949J-P-X 949H WORK LIGHT JUMPER BK - 1.0 LIGHTS CAB ROOF, FRONT AND REAR
X-RFO - WORK LIGHT OPTION (87695584) (Plug)
87695584 191
87695584
48083741_EN 31/07/2018
55.1 [55.100] / 209

1 SP-111G-P-X 111E WORK LIGHT JUMPER VT - 1.0 SHEET 31 SH31 - LIGHTING WORKING
2 SP-949J-P-X 949G WORK LIGHT JUMPER BK - 1.0 LIGHTS CAB ROOF, FRONT AND REAR
X-RFWL - RIGHT FRONT WORK LIGHT [ LMP-RF_WL] (87695582) (Receptacle)
87695582 192
87695582
1 SP-111G-P-X 111G WORK LIGHT JUMPER VT - 1.0 SHEET 31 SH31 - LIGHTING WORKING
1 X-ROOF (Receptacle) pin 2 - 724A RIGHT FRONT WORK VT - 1.0 LIGHTS CAB ROOF, FRONT AND REAR
ROOF TO CAB (87700325) LIGHT
2 SP-949A-P-X 949B RIGHT FRONT WORK BK - 1.0
LIGHT GND
2 SP-949J-P-X 949J WORK LIGHT JUMPER BK - 1.0
X-RH-REAR-TAIL-EURO - RH-REAR-TAIL-EURO [ LMP-R-EURO-TAIL] (87694112) (Receptacle)
87694112 193
87694112
1 X-HD_N (Receptacle) pin 7 - 129D STOP PL23 EURO VT - 0.8 SHEET 30 SH30 - OLD EURO LIGHTING
2 X-HD_N (Receptacle) pin 4 - 131E TAIL EURO VT - 0.8
3 X-HD_N (Receptacle) pin 5 - 130H TA VT - 0.8
4 SP-124H-P-X 124J REVERSE LIGHTS PL23 VT - 0.8
5 SP-242H-P-X 242K GRND BK - 0.8
48083741_EN 31/07/2018
55.1 [55.100] / 210
X-RH-TAIL - RH REAR TAIL [ LMP-R-NA-TAIL] (87694101) (Receptacle)
87694101 194
87694101
1 SP-242A-P-X 242B TAIL LIGHTS GRND NA BK - 1.0 SHEET 29 SH29 - LIGHTING REAR TAILS
1 SP-243-P-X 243B TAIL LIGHTS GRND BK - 0.8
EURO
2 X-ENG (Plug) pin 21 - 129E STOP RH EURO VT - 0.8
(87696948)
2 X-HD_N (Receptacle) pin 7 - 129B RH BRAKE LAMP NA VT - 0.8
3 X-HD_N (Receptacle) pin 5 - 130C RH TAIL LAMP NA VT - 0.8
3 X-ENG (Plug) pin 11 - 130J TAIL RH EURO VT - 0.8
(87696948)
4 X-ENG (Plug) pin 6 - 131F TURN RH EURO VT - 0.8
ENGINE TO CAB [SH18:
C-6] (87696948)
4 X-HD_N (Receptacle) pin 4 - 131B RH REAR TURN LAMP VT - 0.8
HOOD TO ENG (87700325) NA
X-ROOF - ROOF TO CAB (87700325) (Receptacle)
87700325 195
87700325
1 X-LFWL (Receptacle) pin 1 - 111A LEFT FRONT WORK VT - 1.0 SHEET 31 SH31 - LIGHTING WORKING
LEFT FRONT WORK LIGHT LIGHT LIGHTS CAB ROOF, FRONT AND REAR
[LMP-LF_WL] (87695582)
2 X-RFWL (Receptacle) pin 1 - 724A RIGHT FRONT WORK VT - 1.0
RIGHT FRONT WORK LIGHT LIGHT
[LMP-RF_WL] (87695582)
3 X-BEA (Receptacle) pin 1 851A ROTATING BEACON VT - 0.8 SHEET 34 SH34 - MIRRORS, HORN BEACON
- BEACON [LMP-BEA_RT]
(84015523)
4 SP-114A-P-X 114A MIRROR HEAT SUPPLY TN - 1.0
48083741_EN 31/07/2018
55.1 [55.100] / 211

5 SP-859A-P-X 859A REAR WORK LIGHTS VT - 1.0 SHEET 31 SH31 - LIGHTING WORKING
6 SP-949A-P-X 949A FRONT WORK LIGHTS BK - 2.0 LIGHTS CAB ROOF, FRONT AND REAR
GND
7 SP-953A-P-X 953A ROOF GND BK - 2.0
X-RRWL - RIGHT REAR WORK LIGHT [ LMP-RR_WL] (87695582) (Receptacle)
87695582 196
87695582
1 SP-859A-P-X 859C RIGHTT REAR WORK VT - 0.8 SHEET 31 SH31 - LIGHTING WORKING
LIGHT LIGHTS CAB ROOF, FRONT AND REAR
2 SP-953A-P-X 953F RIGHT REAR WORK BK - 1.0
LIGHT GND
X-RWHE1 - REAR WINDOW HEATER [ R-WND_HTR] (87688695) (Receptacle)
87688695 197
87688695
1 X-LC3 (Receptacle) pin 801 REAR DEFROST PWR OR - 2.0 SHEET 36 SH36 - REAR DEFROST, BACKUP
R3_87 - LOADCENTER 3 ALARM
[SH35: B-6] (84529039)
48083741_EN 31/07/2018
55.1 [55.100] / 212
X-RWHE2 - REAR WINDOW HEATER [ SH13: C-3] (87688695) (Receptacle)
87688695 198
87688695
1 CG1-P-1 CAB GROUND RH 272 REAR DEFROST GND BK - 2.0 SHEET 36 SH36 - REAR DEFROST, BACKUP
HEADLINER ALARM
X-RWM - REAR WIPER MOTOR [ M-R_WPR_M] (87692862) (Plug)
87692862 199
87692862
B X-X6 (Receptacle) pin 12 - 108 REAR WIPER MOTOR TN - 1.0 SHEET 32 SH32 - CAB WIPER / WASHER
SFB [A-SFB] (47554341) LOW
X-RWM_G - REAR WIPER MOTOR GRND [ SH13: C-2] (87693744) (Plug)
87693744 200
87693744
48083741_EN 31/07/2018
55.1 [55.100] / 213

A X-CG3 (Receptacle) pin 955V REAR WIPER MOTOR BK - 1.0 SHEET 32 SH32 - CAB WIPER / WASHER
L - CAB GROUND RH GND
(84149207)
X-RWW - REAR WASHER MOTOR [ M-RW_M] (84015523) (Receptacle)
84015523 201
84015523
1 X-TRANS (Plug) pin 4 - 106A REAR WASHER MOTOR OR - 0.8 SHEET 32 SH32 - CAB WIPER / WASHER
TRANSMISSION TO CAB
(87696949)
2 SP-391A-P-X 391E WIPER GROUND BK - 0.8 SHEET 20 SH20 - UCM VEHICLE DRIVELINE
/ FAN CONTROL
X-SC - SEAT COMPRESSOR [ Y-SC] (87692855) (Plug)
87692855 202
87692855
A X-LC4 (Receptacle) pin 7A - 742 12V FUSED ACC PWR OR - 2.0 SHEET 35 SH35 - CABIN RADIO
LOADCENTER 4 [SH35: C-6] FOR SEAT COMP LOUDSPEAKER/12V CNVRTR
(87733595)
B X-CG4 (Receptacle) pin C - 955L SEAT COMPRESSOR BK - 2.0
(84149207)
48083741_EN 31/07/2018
55.1 [55.100] / 214
X-SCR1 - INLINE TO SCR SENSORS HARNESS (87695592) (Receptacle)
87695592 203
87695592
1 SP-201-P-X 201B SCR SENSORS CLEAN BK - 2.0 SHEET 18 SH18 - ENGINE CONTROL UNIT
GROUND 3, AT
4 SP-200-P-X 200B SCR SENSOR POWER RD - 2.0
5 X-ECU (Receptacle) pin 96 - 696 UREA DOSING VALVE 1 TN - 0.8 SHEET 17 SH17 - ENGINE CONTROL UNIT
(84300197)
6 X-ECU (Receptacle) pin 23 - 623 UREA DOSING VALVE 2 WH - 0.8
(84300197)
7 SP-610-P-X 610D TEMP SENSOR GROUND BK - 0.8
8 X-ECU (Receptacle) pin 16 - 616 DOC UPSTREAM TEMP YE - 0.8
(84300197)
9 SP-610-P-X 610B TEMP SENSOR GROUND BK - 0.8
10 X-ECU (Receptacle) pin 9 - 609 SCR DOWNSTREAM YE - 0.8
ECU CONNECTOR [A-ECU] TEMP
(84300197)
11 SP-CAN_H1-P-X CANC_HB CAN YE - 0.8 SHEET 18 SH18 - ENGINE CONTROL UNIT
12 SP-CAN_L1-P-X CANC_LB CAN GN - 0.8 3, AT
X-SCR2 - INLINE FROM SCR SENSORS HARNESS (87695724) (Plug)
87695724 204
87695724
1 SP-201D-P-X 201D SCR SENSORS CLEAN BK - 2.0 SHEET 18 SH18 - ENGINE CONTROL UNIT
GROUND 3, AT
4 SP-200D-P-X 200D SCR SENSOR POWER RD - 2.0
48083741_EN 31/07/2018
55.1 [55.100] / 215

5 X-DSR (Receptacle) pin 696A DOSING VALVE TN - 0.8 SHEET 17 SH17 - ENGINE CONTROL UNIT
[Y-DSV] (87709798)
6 X-DSR (Receptacle) pin 623A UREA DOSING VALVE 2 WH - 0.8
2 - UREA DOSING VALVE
[Y-DSV] (87709798)
7 X-CTS (Receptacle) pin 2 610E TEMP SENSOR GROUND BK - 0.8
- DOC UPSTREAM TEMP
[B-C_TS] (84532147)
8 X-CTS (Receptacle) pin 1 616A DOC UPSTREAM TEMP YE - 0.8
- DOC UPSTREAM TEMP
[B-C_TS] (84532147)
9 X-DTS (Receptacle) pin 2 - 610C TEMP SENSOR GROUND BK - 0.8
SCR DOWNSTREAM TEMP
[B-D_TS] (84532147)
10 X-DTS (Receptacle) pin 1 - 609A SCR DOWNSTREAM YE - 0.8
SCR DOWNSTREAM TEMP TEMP
[B-D_TS] (84532147)
11 SP-CANC_HC-P-X CANC_HC CAN YE - 0.8 SHEET 18 SH18 - ENGINE CONTROL UNIT
12 SP-CANC_LC-P-X CANC_LC CAN GN - 0.8 3, AT
X-SDM - SWITCH DIFF LOCK [ SW-SDM] (82012083) (Plug)
82012083 205
82012083
X-SFB_XCP - DIAG (87696093) (Receptacle)
87696093 206
87696093
1 X-X7 (Receptacle) pin 2 - SFB CANB_HF CAN WH - 0.8 SHEET 24 SH24 - CAN STRUCTURE
[SH3: A-3] (84538791)
2 X-X7 (Receptacle) pin 1 - SFB CANB_LF CAN BL - 0.8
[SH3: A-3] (84538791)
48083741_EN 31/07/2018
55.1 [55.100] / 216
X-SPK - RADIO TO SPKRS [ H-RADIO] (87709371) (Receptacle)
87709371 207
87709371
X-SP_PK1 - SPLICE PACK (87693718) (Receptacle)
87693718 208
87693718
X-SP_PK2 - SPLICE PACK (87693718) (Receptacle)
87693718 209
87693718
48083741_EN 31/07/2018
55.1 [55.100] / 217
X-SP_PK_CLN - SPLICE PACK CLEAN GRND [ SH25: C-1] (87352746) (Receptacle)
87352746 210
87352746
X-SRWP - SWITCH REAR WIPER [ SW-WPR_SW] (87716755) (Receptacle)
87716755 211
87716755
2 X-PG (Receptacle) pin L - 955M GROUND BK - 0.8 SHEET 28 SH28 - LIGHTING HAZARD
PEDESTAL GROUND [SH28: WARNING, BLINKERS, DRIVING
B-6] (87705607)
3 X-PED_2 (Plug) pin 8 - 728A REAR WASHER SWITCH YE - 0.8
PEDESTAL TO CAB 2
(87705114)
5 X-PG (Receptacle) pin G - 955W PEDESTAL GROUND BK - 0.8
B-6] (87705607)
6 X-PED_2 (Plug) pin 9 - 727A REAR WIPER SWITCH YE - 0.8
PEDESTAL TO CAB 2
(87705114)
7 X-PG (Receptacle) pin F - 955D REAR WIPER SW BK - 0.8
PEDESTAL GROUND [SH28: INDICATOR GND
B-6] (87705607)
8 SP-981A-P-X 981C SWITCH BACK LIGHTING VT - 0.8
9 X-PG (Receptacle) pin C - 955G REAR WIPER SW GND BK - 0.8
B-6] (87705607)
10 X-PED_2 (Plug) pin 11 283A REAR WIPER INDICATOR VT - 0.8
- PEDESTAL TO CAB 2
(87705114)
48083741_EN 31/07/2018
55.1 [55.100] / 218
X-SSD - SS FLYBACK DIODE [ D-SS DIODE] (87692858) (Plug)
87692858 212
87692858
A X-S245 (Plug) pin 1 - 180A SEC STRG FLYBACK BK - 1.0 SHEET 21 SH21 - UCM-STEERING AUX JSS
GROUND (84426118) GRND
B X-S245 (Plug) pin 1 - 180 SEC STRG FLYBACK BK - 1.0
GROUND (84426118) GRND
C X-SSS (Plug) pin 1 - 441E SEC STRG FLY BACK OR - 1.0
SECONDARY STEERING PWR
MOTOR [M-SEC_STRG]
(84426118)
X-SSG - SECONDARY STEERING GROUND RING [ SH21: C-1] (84401307) (Plug)
84401307 213
84401307
1 X-S242 (Plug) pin 1 - 185 AUX STEERING BK - 62.0 SHEET 14 SH14 - CAB & CHASSIS GROUND
GROUND [M-SEC_STRG] GROUND CABLE PWR DISTR
(84401307)
48083741_EN 31/07/2018
55.1 [55.100] / 219
X-SSS - SECONDARY STEERING MOTOR [ M-SEC_STRG] (84426118) (Plug)
84426118 214
84426118
1 X-SSD (Plug) pin C - SS 441E SEC STRG FLY BACK OR - 1.0 SHEET 21 SH21 - UCM-STEERING AUX JSS
FLYBACK DIODE [D-SS PWR
DIODE] (87692858)
1 SP-441B-P-X 441D SEC STRG IGN PWR OR - 1.0
X-SST - SEC STRG TO TRANS (87694152) (Plug)
87694152 215
87694152
1 SP-441B-P-X 441B SEC STRG IGN PWR OR - 1.0 SHEET 21 SH21 - UCM-STEERING AUX JSS
2 X-PSS (Receptacle) pin B 486W 5V PWR REF 1 PK - 0.8
- STEERING PRESSURE
SENSOR [B-PSS] (84078681)
3 X-PSS (Receptacle) pin A 482P 5V GRND1 BL - 0.8
- STEERING PRESSURE
4 X-PSS (Receptacle) pin C 176B AUX STRG PRESS YE - 0.8
- STEERING PRESSURE SIGNAL
48083741_EN 31/07/2018
55.1 [55.100] / 220
X-ST - START SIGNAL TO STARTER [ M-STRT_MTR] (84426134) (Plug)
84426134 216
84426134
1 X-LC7 pin 2 - LOAD CENTER 230 STARTER POWER RD - 5.0 SHEET 03 SH03 - PWR DISTR-BATTERY /
7 (84563565) STARTER / KEY
X-STLK - STALK LEVER RH [ SW-HN_STLK] (84426133) (Receptacle)
84426133 217
84426133
1 X-PED (Receptacle) pin 113B RH STALK HORN BR - 0.8 SHEET 34 SH34 - MIRRORS, HORN BEACON
4 - PEDESTAL TO CAB SWITCH
(87700156)
3 X-PED (Receptacle) pin 19K IGN PWR OR - 0.8 SHEET 24 SH24 - CAN STRUCTURE
9 - PEDESTAL TO CAB
(87700156)
4 SP-LP-P-X CAN_LR CAN GN - 0.8
5 SP-HP-P-X CAN_HR CAN YE - 0.8
7 X-PG (Receptacle) pin D - 955F LH TURN SW GND BK - 0.8
B-6] (87705607)
48083741_EN 31/07/2018
55.1 [55.100] / 221
X-STW - STEERING WHEEL MOTION SENSOR [ B-ST_MTN] (84563557) (Receptacle)
84563557 218
84563557
1 SP-B_HP-P-X CANB_HR CAN WH - 0.8 SHEET 24 SH24 - CAN STRUCTURE
2 SP-B_LP-P-X CANB_LR CAN BL - 0.8
3 SP-799C-P-X 799F JSS IGN PWR OR - 0.8
4 SP-955Y-P-X 955Z JSS GROUND BK - 0.8
X-SW_DISC - DISCONNECT SWITCH [ SH37: C-4] (87694112) (Receptacle)
87694112 219
87694112
1 X-LC6 pin 15 - LOADCENTER 510 ECU IGN PWR OR - 0.8 SHEET 03 SH03 - PWR DISTR-BATTERY /
6 [SH16: A-3] (84380518) STARTER / KEY
3 SP-669A-P-X 669A EDC7 IGN PWR OR - 0.8
3 X-ECU (Receptacle) pin 69 - 669 ECU IGN PWR OR - 0.8
(84300197)
4 X-ENG-2 (Receptacle) pin J - 219 NON ISOLATED PWR RD - 0.8
5 X-HD (Receptacle) pin 2 - 533 HOOD LIFT SIGNAL RD - 1.0
HOOD LIFT SWITCH [SH3:
A-4] (84159859)
6 X-LC6 pin 6 - LOADCENTER 218 KEY_NON_DISCONNECT RD - 0.8
6 [SH16: A-3] (84380518) PWR
48083741_EN 31/07/2018
55.1 [55.100] / 222
X-SW_JSS - JOYSTICK STEERING SWITCH [ SW-SW_JSS] (87716755) (Receptacle)
87716755 220
87716755
1 X-LFT_A (Plug) pin 12 - 682A JSS ACTIVATION NC YE - 0.8 SHEET 21 SH21 - UCM-STEERING AUX JSS
(87700155)
2 SP-799A-P-X 799H JSS IGNITION POWER OR - 0.8
3 X-LFT_A (Plug) pin 9 - 678A JSS ACTIVATION WH - 0.8
(87700155)
7 SP-954-P-X 954N LH JSS GND BK - 0.8
8 X-LFT_2 (Plug) pin 2 - LEFT 981K BACKLIGHTING VT - 0.8
JS TO CAB (87700105)
9 SP-954-P-X 954C LH JSS GND BK - 0.8
10 X-LFT_2 (Plug) pin 1 - LEFT 691A JSS INDICATOR WH - 0.8
JS TO CAB (87700105)
X-SW_PD - SWITCH PAD [ SW-PD] (87694153) (Receptacle)
87694153 221
87694153
1 X-LC5 (Receptacle) pin 7A - 807 KEYPAD IGN POWER OR - 0.8 SHEET 10 SH10 - IGNITION PWR DISTR
LOADCENTER 5 [SH10: D-1] (FUSE BLOCK LC5)
(87733595)
2 X-SP_PK_CLN (Receptacle) 916 CAB CLEAN GROUND BK - 0.8 SHEET 24 SH24 - CAN STRUCTURE
pin X - SPLICE PACK CLEAN SW PD
GRND [SH25: C-1] (87352746)
3 SP-HJ-P-X CAN_HK CAN YE - 0.8
4 SP-LJ-P-X CAN_LK CAN GN - 0.8
48083741_EN 31/07/2018
55.1 [55.100] / 223
X-S_BU - CANCEL BACKUP ALARM [ SW-BCK_U_SW] (87716755) (Receptacle)
87716755 222
87716755
2 SP-954L-P-X 955S BACKUP ALARM BK - 0.8 SHEET 36 SH36 - REAR DEFROST, BACKUP
CANCEL SWITCH GND ALARM
3 X-X7 (Receptacle) pin 50 - 119 BACKUP ALARM YE - 0.8
SFB [SH3: A-3] (84538791) CANCEL
7 SP-954L-P-X 954T BACK LIGHTING GRND BK - 0.8
8 SP-981-P-X 981E BU ALARM CANCEL VT - 0.8
9 SP-954L-P-X 954G BACKUP ALARM BK - 0.8
CANCEL INDICATOR
GND
10 X-X3 (Receptacle) pin 6 - SFB 118 BACKUP ALARM YE - 0.8
[SH3: A-1] (47554344) CANCEL IND
X-S_HMR - SWITCH HEATED MIRRORS [ SH13: D-4] (87716755) (Receptacle)
87716755 223
87716755
2 X-CG3 (Receptacle) pin 955K MIRROR HEATER SW BK - 0.8 SHEET 13 SH13 - POWER DISTRIBUTION 2
C - CAB GROUND RH GND CAB GROUND BLK
(84149207)
3 X-X7 (Receptacle) pin 48 - 116 MIRROR HEATER SW YE - 0.8 SHEET 34 SH34 - MIRRORS, HORN BEACON
SFB [SH3: A-3] (84538791)
7 X-CG3 (Receptacle) pin 954B CAB GRND BK - 0.8
M - CAB GROUND RH
(84149207)
8 SP-981-P-X 981F BACKLIGHTING VT - 0.8
9 X-CG3 (Receptacle) pin 955J MIRROR HEATER BK - 0.8 SHEET 13 SH13 - POWER DISTRIBUTION 2
B - CAB GROUND RH INDICATOR GND CAB GROUND BLK
(84149207)
10 X-X4 (Receptacle) pin 13 - 115 MIRROR HEATER WH - 0.8 SHEET 34 SH34 - MIRRORS, HORN BEACON
SFB (47554343) INDICATOR
48083741_EN 31/07/2018
55.1 [55.100] / 224
X-S_HZD - SWITCH HAZARD [ SW-HZD_SW] (87716755) (Receptacle)
87716755 224
87716755
2 X-PG (Receptacle) pin K - 955C PED GROUND BK - 0.8 SHEET 28 SH28 - LIGHTING HAZARD
PEDESTAL GROUND [SH28: WARNING, BLINKERS, DRIVING
B-6] (87705607)
3 X-PED (Receptacle) pin 141A HAZARD SWTICH YE - 0.8
6 - PEDESTAL TO CAB
(87700156)
7 X-PG (Receptacle) pin E - 955E HAZARD SW INDICATOR BK - 0.8
PEDESTAL GROUND [SH28: GND
B-6] (87705607)
8 SP-981A-P-X 981B SWITCH BACK LIGHTING VT - 0.8
9 X-PG (Receptacle) pin B - 955H HAZARD SW GND BK - 0.8
B-6] (87705607)
10 X-PED (Receptacle) pin 269 HAZARD INDICATOR BK - 0.8
8 - PEDESTAL TO CAB
(87700156)
X-S_RDF - SWITCH REAR DEFROST [ SW-R_DEF_SW] (87716755) (Receptacle)
87716755 225
87716755
48083741_EN 31/07/2018
55.1 [55.100] / 225

2 X-CG3 (Receptacle) pin 955R REAR DEFROST SWITCH BK - 0.8 SHEET 36 SH36 - REAR DEFROST, BACKUP
F - CAB GROUND RH GND ALARM
(84149207)
3 X-X7 (Receptacle) pin 68 - 117 REAR DEFROST SWITCH YE - 0.8
SFB [SH3: A-3] (84538791)
7 CG1-P-1 CAB GROUND RH 958 BACKLIGHTING REAR BK - 0.8
HEADLINER DEFROST SW
8 SP-981-P-X 981G BACKLIGHTING VT - 0.8
9 X-CG3 (Receptacle) pin 955A REAR DEFROST SWITCH BK - 0.8
A - CAB GROUND RH IND GND
(84149207)
10 X-X7 (Receptacle) pin 7 - SFB 122 REAR DEFROST SWITCH YE - 0.8
[SH3: A-3] (84538791) IND
X-TCOT - GEAR OIL TEMP [ B-GOT] (84364854) (Receptacle)
84364854 226
84364854
1 X-TRANS (Plug) pin 13 - 425A GEAR OIL TEMP WH - 0.8 SHEET 26 SH26 - GEAR CONTROL UNIT 2
TRANSMISSION TO CAB
(87696949)
2 SP-697A-P-X 697B OIL TEMP RETURN BL - 0.8
X-TECM - TRANS CONTROLLER [ SH25: C-6] (84550089) (Receptacle)
84550089 227
84550089
1 X-SP_PK_CLN (Receptacle) 856 TRANS CONTROLER BK - 0.8 SHEET 25 SH25 - GEAR CONTROL UNIT 1
pin X - SPLICE PACK CLEAN GRND
GRND [SH25: C-1] (87352746)
2 X-SP_PK_CLN (Receptacle) 855 TRANS CONTROLER BK - 0.8
pin X - SPLICE PACK CLEAN GRND
GRND [SH25: C-1] (87352746)
48083741_EN 31/07/2018
55.1 [55.100] / 226

3 SP-702A-P-X 702 SPEED SENSOR GRND BL - 0.8 SHEET 26 SH26 - GEAR CONTROL UNIT 2
4 X-CAB_TR (Receptacle) pin 703 OUTPUT SPEED BL - 0.8
28 - CAB TO TRANSMISSION SENSOR
[SH26: A-2] (87696944)
8 SP-420C-P-X 420B TECM PWR WH - 0.8 SHEET 25 SH25 - GEAR CONTROL UNIT 1
9 X-CAB_TR (Receptacle) pin 839 KV CLUTCH TN - 0.8
20 - CAB TO TRANSMISSION
[SH26: A-2] (87696944)
10 X-CAB_TR (Receptacle) pin 836 KR CLUTCH TN - 0.8
[SH26: A-2] (87696944)
12 SP-841-P-X 841B TRANS OUTPUT SW WH - 0.8
PWR VPS1
13 SP-841-P-X 841 TRANS OUTPUT SW WH - 0.8
PWR VPS1
15 X-ZF_DI (Plug) pin 2 - 37D DIAGNOSTIC WH - 0.8
DIAGNOSTIC [A-108F]
(84364851)
17 X-CAB_TR (Receptacle) pin 423 FILTER MAINTENANCE WH - 0.8 SHEET 26 SH26 - GEAR CONTROL UNIT 2
31 - CAB TO TRANSMISSION SIGNAL
[SH26: A-2] (87696944)
18 X-ZF_DI (Plug) pin 4 - 167 DIAGNOSTIC SIL - 0.8 SHEET 25 SH25 - GEAR CONTROL UNIT 1
DIAGNOSTIC [A-108F]
(84364851)
19 X-CAB_TR (Receptacle) pin 699 ENG SPEED SENSOR YE - 0.8 SHEET 26 SH26 - GEAR CONTROL UNIT 2
[SH26: A-2] (87696944)
23 SP-165-P-X 165A TECM B+ RD - 0.8 SHEET 25 SH25 - GEAR CONTROL UNIT 1
25 SP-HD-P-X CAN_HE CAN YE - 0.8 SHEET 24 SH24 - CAN STRUCTURE
26 SP-LD-P-X CAN_LE CAN GN - 0.8
32 X-CAB_TR (Receptacle) pin 837 K1 CLUTCH TN - 0.8 SHEET 25 SH25 - GEAR CONTROL UNIT 1
[SH26: A-2] (87696944)
39 X-CAB_TR (Receptacle) pin 842 VALVE BODY TEMP SIG YE - 0.8
[SH26: A-2] (87696944)
41 X-CAB_TR (Receptacle) pin 700 TURBINE SPEED YE - 0.8 SHEET 26 SH26 - GEAR CONTROL UNIT 2
[SH26: A-2] (87696944)
42 X-CAB_TR (Receptacle) pin 701 INTERMEDIATE SPEED YE - 0.8
[SH26: A-2] (87696944)
45 SP-19C-P-X 19E TECM IGN PWR OR - 0.8 SHEET 10 SH10 - IGNITION PWR DISTR
(FUSE BLOCK LC5)
46 X-CAB_TR (Receptacle) pin 697 TRANS SIGNL RETURN BL - 0.8 SHEET 26 SH26 - GEAR CONTROL UNIT 2
[SH26: A-2] (87696944)
49 X-CAB_TR (Receptacle) pin 425 GEAR OIL TEMP YE - 0.8
[SH26: A-2] (87696944)
50 X-CAB_TR (Receptacle) pin 419 TRANS LOCKUP BR - 0.8 SHEET 25 SH25 - GEAR CONTROL UNIT 1
15 - CAB TO TRANSMISSION SOLENOID
[SH26: A-2] (87696944)
53 SP-420C-P-X 420 TRANS LOCKUP WH - 0.8
SOLENOID
55 X-CAB_TR (Receptacle) pin 838 K3 CLUTCH TN - 0.8
[SH26: A-2] (87696944)
56 X-CAB_TR (Receptacle) pin 834 K4 CLUTCH TN - 0.8
[SH26: A-2] (87696944)
62 X-CAB_TR (Receptacle) pin 578A OUTPUT SPEED YE - 0.8 SHEET 26 SH26 - GEAR CONTROL UNIT 2
[SH26: A-2] (87696944)
68 SP-165-P-X 165B TECM B+ RD - 0.8 SHEET 25 SH25 - GEAR CONTROL UNIT 1
48083741_EN 31/07/2018
55.1 [55.100] / 227
X-TERM - TERMINATOR [ R-022] (87695580) (Receptacle)
87695580 228
87695580
A SP-HP-P-X CAN_HS CAN YE - 0.8 SHEET 24 SH24 - CAN STRUCTURE
B SP-LP-P-X CAN_LS CAN GN - 0.8
X-TERM2 - TERMINATOR CAN [ A-TERM2] (87695580) (Receptacle)
87695580 229
87695580
A SP-B_HC-P-X CANB_HA CAN WH - 0.8 SHEET 24 SH24 - CAN STRUCTURE
B SP-B_LC-P-X CANB_LA CAN BL - 0.8
X-TERM3 - TERMINATOR CAN [ A-TERM3] (87695580) (Receptacle)
87695580 230
87695580
A SP-B_HS-P-X CANB_HU CAN WH - 0.8 SHEET 24 SH24 - CAN STRUCTURE
B SP-B_LS-P-X CANB_LU CAN BL - 0.8
48083741_EN 31/07/2018
55.1 [55.100] / 228
X-TERM_C - CONTROLLER AREA NETWORK [ A-TERMC] (87695580) (Receptacle)
87695580 231
87695580
A SP-2HC-P-X CAN2_HC CAN YE - 0.8 SHEET 18 SH18 - ENGINE CONTROL UNIT
A SP-CANC_HG-P-X CANC_HK CAN YE - 0.8 3, AT
B SP-CANC_LG-P-X CANC_LK CAN GN - 0.8
B SP-2LC-P-X CAN2_LC CAN GN - 0.8
X-THRTL - THROTTLE CONTROL [ B-ACCEL] (84403598) (Receptacle)
84403598 232
84403598
A X-CAB_E-2 (Plug) pin A - 409 THROTTLE PEDAL YE - 0.8 SHEET 16 SH16 - ENGINE CONTROL UNIT
CAB TO ENG 2 [SH9: C-2] POSITION 1, GRID HEATER, FILTER HEATER
(87703902)
B X-CAB_E-2 (Plug) pin C - 651H 5V GND2 BL - 0.8
(87703902)
C X-CAB_E-2 (Plug) pin B - 471B 5V REF2 PK - 0.8
(87703902)
D X-CAB_E-2 (Plug) pin D - 408 THROTTLE IDLE SW WH - 0.8
(87703902)
F X-CAB_E-2 (Plug) pin E - 643C THROTTLE GRND BK - 0.8
(87703902)
48083741_EN 31/07/2018
55.1 [55.100] / 229
X-THV - SCR TANK HEATING VALVE [ Y-TNK_HTR] (84146685) (Receptacle)
84146685 233
84146685
X-TRANS - TRANSMISSION TO CAB (87696949) (Plug)
87696949 234
87696949
1 X-PRB1 (Receptacle) pin C - 443A RED BRAKE SW SIG YE - 0.8 SHEET 19 SH19 - UCM PWR, GRND,
REDUNDANT BRAKE SW 1 INSTRUMENTATION
[B-PRB1] (84078681)
2 X-ESS (Receptacle) pin 2 - 702D SPEED SENSOR GRND BL - 0.8 SHEET 26 SH26 - GEAR CONTROL UNIT 2
SPEED SENSOR ENGINE
[B-ES_S] (84364854)
3 SP-482A-P-X 482A 5V GRND1 BL - 0.8 SHEET 19 SH19 - UCM PWR, GRND,
INSTRUMENTATION
4 X-RWW (Receptacle) pin 1 106A REAR WASHER MOTOR OR - 0.8 SHEET 32 SH32 - CAB WIPER / WASHER
- REAR WASHER MOTOR
[M-RW_M] (84015523)
5 X-TRC (Receptacle) pin 8 842A VALVE BODY TEMP SIG YE - 0.8 SHEET 25 SH25 - GEAR CONTROL UNIT 1
- TRANS CONTROLLER
ON TRANNY CNH [A-TRC]
(47669071)
6 X-FWW (Receptacle) pin 1 104A FRONT WASHER MOTOR TN - 0.8 SHEET 32 SH32 - CAB WIPER / WASHER
- FRONT WASHER MOTOR
[M-FW_M] (84015523)
48083741_EN 31/07/2018
55.1 [55.100] / 230

7 X-ESS (Receptacle) pin 1 - 699A ENG SPEED SENSOR YE - 0.8 SHEET 26 SH26 - GEAR CONTROL UNIT 2
SPEED SENSOR ENGINE
[B-ES_S] (84364854)
8 X-TSS (Receptacle) pin 1 - 700A TURBINE SPEED YE - 0.8
SPEED SENSOR TURBINE SENSOR
[B-TS_S] (84364854)
9 X-ISS (Receptacle) pin 1 - 701A INTERMEDIATE SPEED YE - 0.8
SPEED SENSOR MIDDLE SENSOR
WHEEL CHAIN [B-IS_S]
(84364854)
10 X-OSS pin 2 - SPEED 578 OUTPUT SPEED YE - 0.8
SENSOR GEAR TRANS SENSOR SIGNAL
[B-OSS] (84062580)
11 X-ISS (Receptacle) pin 2 - 702B SPEED SENSOR GRND BL - 0.8
SPEED SENSOR MIDDLE
WHEEL CHAIN [B-IS_S]
(84364854)
12 SP-697A-P-X 697A TRANS SIGNL RETURN BL - 0.8
13 X-TCOT (Receptacle) pin 1 425A GEAR OIL TEMP WH - 0.8
- GEAR OIL TEMP [B-GOT]
(84364854)
14 X-TSS (Receptacle) pin 2 - 702C SPEED SENSOR GRND BL - 0.8
SPEED SENSOR TURBINE
[B-TS_S] (84364854)
15 X-YLS pin 1 - TRANS 419A TRANS LOCKUP BR - 0.8 SHEET 25 SH25 - GEAR CONTROL UNIT 1
LOCKUP SOLENOID SOLENOID
(82012083)
16 X-TRC (Receptacle) pin 1 834A K4 CLUTCH TN - 0.8
- TRANS CONTROLLER
(47669071)
16 X-TRC (Receptacle) pin 2 834B PL23_26 KR CLUTCH TN - 0.8
- TRANS CONTROLLER
(47669071)
17 X-TRC (Receptacle) pin 2 836A KR CLUTCH TN - 0.8
- TRANS CONTROLLER
(47669071)
17 X-TRC (Receptacle) pin 1 836B PL23_26 K4 CLUTCH TN - 0.8
- TRANS CONTROLLER
(47669071)
- TRANS CONTROLLER
(47669071)
- TRANS CONTROLLER
(47669071)
20 X-TRC (Receptacle) pin 5 839A KV CLUTCH TN - 0.8
- TRANS CONTROLLER
(47669071)
- TRANS CONTROLLER
(47669071)
22 X-TRC (Receptacle) pin 7 841C TRANS OUTPUT SW WH - 0.8
- TRANS CONTROLLER PWR VPS1
(47669071)
23 X-PHF (Plug) pin 1 - 636A HYD FILTER SIGNAL YE - 0.8 SHEET 19 SH19 - UCM PWR, GRND,
HYDRAULIC FILTER INSTRUMENTATION
SENSOR [SW-PHF]
(84352277)
23 X-PHF23 pin 2 - HYDRAULIC 236 HYDRAULIC OIL FILTER YE - 0.8
FILTER SENSOR PL23 SW
(82012083)
24 X-PRB2 (Receptacle) pin C - 638B RED BRAKE SW SIG YE - 0.8
REDUNDANT BRAKE SW 2
[B-PRB2] (84078681)
48083741_EN 31/07/2018
55.1 [55.100] / 231

25 X-YLS pin 2 - TRANS 420A TRANS LOCKUP WH - 0.8 SHEET 25 SH25 - GEAR CONTROL UNIT 1
LOCKUP SOLENOID SOLENOID
(82012083)
26 SP-486N-P-X 486N 5V PWR REF 1 PK - 0.8 SHEET 19 SH19 - UCM PWR, GRND,
INSTRUMENTATION
27 X-YDL (Receptacle) pin 1 390A DIFF LOCK SIGNAL WH - 0.8 SHEET 20 SH20 - UCM VEHICLE DRIVELINE
- DIFF LOCK SOL [Y-DL] / FAN CONTROL
(87695582)
28 X-OSS pin 1 - SPEED 703A OUTPUT SPEED BL - 0.8 SHEET 26 SH26 - GEAR CONTROL UNIT 2
SENSOR GEAR TRANS SENSOR
[B-OSS] (84062580)
29 X-OSS pin 3 - SPEED 19T_H OUTPUT SP SENS IGN OR - 0.8
SENSOR GEAR TRANS PWR
[B-OSS] (84062580)
30 X-HOT (Receptacle) pin 1 634A HYD OIL TEMP SIG YE - 0.8 SHEET 19 SH19 - UCM PWR, GRND,
- HYD OIL TEMP [B-HOT] INSTRUMENTATION
(84607243)
31 X-FM pin 2 - PRESSURE 423A FILTER MAINTENANCE WH - 0.8 SHEET 26 SH26 - GEAR CONTROL UNIT 2
SWITCH OIL FILTER [B-FM] SIGNAL
(82012083)
X-TRC - TRANS CONTROLLER ON TRANNY CNH [ A-TRC] (47669071) (Receptacle)
47669071 235
47669071
48083741_EN 31/07/2018
55.1 [55.100] / 232

1 X-TRANS (Plug) pin 17 - 836B PL23_26 K4 CLUTCH TN - 0.8 SHEET 25 SH25 - GEAR CONTROL UNIT 1
TRANSMISSION TO CAB
(87696949)
1 X-TRANS (Plug) pin 16 - 834A K4 CLUTCH TN - 0.8
TRANSMISSION TO CAB
(87696949)
2 X-TRANS (Plug) pin 17 - 836A KR CLUTCH TN - 0.8
TRANSMISSION TO CAB
(87696949)
2 X-TRANS (Plug) pin 16 - 834B PL23_26 KR CLUTCH TN - 0.8
TRANSMISSION TO CAB
(87696949)
TRANSMISSION TO CAB
(87696949)
TRANSMISSION TO CAB
(87696949)
5 X-TRANS (Plug) pin 20 - 839A KV CLUTCH TN - 0.8
TRANSMISSION TO CAB
(87696949)
TRANSMISSION TO CAB
(87696949)
7 X-TRANS (Plug) pin 22 - 841C TRANS OUTPUT SW WH - 0.8
TRANSMISSION TO CAB PWR VPS1
(87696949)
8 X-TRANS (Plug) pin 5 - 842A VALVE BODY TEMP SIG YE - 0.8
TRANSMISSION TO CAB
(87696949)
9 SP-697A-P-X 697D VALVE BODY TEMP BL - 0.8
RETURN
X-TS1 - TRANS SHIFTER1 [ A-PFNR] (87692817) (Plug)
87692817 236
87692817
A X-PED_2 (Plug) pin 6 - 4029 DW3 IGN PWR OR - 0.8 SHEET 20 SH20 - UCM VEHICLE DRIVELINE
PEDESTAL TO CAB 2 / FAN CONTROL
(87705114)
B X-PED_2 (Plug) pin 3 - 683A STALK FNR F YE - 0.8
PEDESTAL TO CAB 2
(87705114)
C X-PED_2 (Plug) pin 1 - 679A STALK FNR R YE - 0.8
PEDESTAL TO CAB 2
(87705114)
D X-PED_2 (Plug) pin 2 - 680A STALK FNR N YE - 0.8
PEDESTAL TO CAB 2
(87705114)
48083741_EN 31/07/2018
55.1 [55.100] / 233
X-TS2 - TRANS SHIFTER 2 [ A-PFNR] (47702209) (Receptacle)
47702209 237
47702209
X-TSS - SPEED SENSOR TURBINE [ B-TS_S] (84364854) (Receptacle)
84364854 238
84364854
1 X-TRANS (Plug) pin 8 - 700A TURBINE SPEED YE - 0.8 SHEET 26 SH26 - GEAR CONTROL UNIT 2
TRANSMISSION TO CAB SENSOR
(87696949)
2 X-TRANS (Plug) pin 14 - 702C SPEED SENSOR GRND BL - 0.8
TRANSMISSION TO CAB
(87696949)
X-TT - TELL TALE INDICATOR [ LMP-TTI] (87715979) (Receptacle)
87715979 239
87715979
48083741_EN 31/07/2018
55.1 [55.100] / 234

1 X-PG (Receptacle) pin A - 955T TELL TALE INDICATOR BK - 0.8 SHEET 28 SH28 - LIGHTING HAZARD
PEDESTAL GROUND [SH28: GND WARNING, BLINKERS, DRIVING
B-6] (87705607)
2 X-PED (Receptacle) pin 188A LH TURN INDICATOR VT - 0.8
1 - PEDESTAL TO CAB
(87700156)
3 X-PED (Receptacle) pin 132G LH HIGH BEAM LAMP VT - 0.8
3 - PEDESTAL TO CAB
(87700156)
4 X-PED (Receptacle) pin 134A WARNING INDICATOR YE - 0.8
5 - PEDESTAL TO CAB LED
(87700156)
5 X-PED (Receptacle) pin 189A RIGHT TURN TELL TALE VT - 0.8
2 - PEDESTAL TO CAB
(87700156)
X-TURBO - INTERFACE WIRING HARNESS PLUG C [ SH12: B-3] (84152563) (Receptacle)
84152563 240
84152563
X-TURBO_2 - ENGINE HARNESS INTERFACE T2 [ SH18: B-5] (87694583) (Receptacle)
87694583 241
87694583
1 SP-2LC-P-X CAN2_LA CAN GN - 0.8 SHEET 12 SH12 - POWER DISTRIBUTION 1
5 X-GND_CENG1 (Plug) pin 203A EVGT CLN GRND BK - 1.0 CLEAN GROUND BLK
1 - GROUND CLEAN ENG
BLOCK (84140737)
6 X-LC6 pin 14 - LOADCENTER 202A T2 EVGT RD - 1.0 SHEET 11 SH11 - PWR DISTR ENG
7 SP-2HC-P-X CAN2_HA CAN YE - 0.8 SHEET 12 SH12 - POWER DISTRIBUTION 1
CLEAN GROUND BLK
48083741_EN 31/07/2018
55.1 [55.100] / 235
X-UCM1A - UCM (82016219) (Receptacle)
82016219 242
82016219
1 SP-482-P-X 482 5V GRND1 BL - 0.8 SHEET 19 SH19 - UCM PWR, GRND,
2 SP-486-P-X 486 5V PWR REF 1 PK - 0.8 INSTRUMENTATION
3 SP-471-P-X 471 5V REF2 PK - 0.8 SHEET 22 SH22 - UCM-LOADER BOOM
CONTROL
4 SP-677-P-X 677B 5V REF3 OUT PK - 0.8 SHEET 21 SH21 - UCM-STEERING AUX JSS
5 X-CAB_B (Plug) pin 16 - CAB 3686 PARK BRAKE PRESS YE - 0.8 SHEET 20 SH20 - UCM VEHICLE DRIVELINE
TO BOTTOM [SH21: B-3] / FAN CONTROL
(87696945)
6 X-SP_PK1 (Receptacle) pin X 937 UCM CLEAN GROUND BK - 0.8 SHEET 19 SH19 - UCM PWR, GRND,
- SPLICE PACK (87693718) INSTRUMENTATION
7 X-SP_PK2 (Receptacle) pin X 935 UCM CLEAN GROUND BK - 1.0
- SPLICE PACK (87693718)
8 X-CAB_B (Plug) pin 11 - CAB 176 AUX STRG PRESS YE - 0.8 SHEET 21 SH21 - UCM-STEERING AUX JSS
TO BOTTOM [SH21: B-3] SIGNAL
(87696945)
10 X-CAB_B (Plug) pin 6 - CAB 640 BRAKE SUPPLY PRESS YE - 0.8 SHEET 19 SH19 - UCM PWR, GRND,
TO BOTTOM [SH21: B-3] INSTRUMENTATION
(87696945)
14 SP-466-P-X 466B IGNITION POWR FOR OR - 0.8
UCM
15 X-CAB_TR (Receptacle) pin 443 BRAKE ACCUMULATOR YE - 0.8
1 - CAB TO TRANSMISSION PRSR
[SH26: A-2] (87696944)
16 X-CAB_B (Plug) pin 15 - CAB 402 BRAKE PEDAL ANGLE YE - 0.8 SHEET 20 SH20 - UCM VEHICLE DRIVELINE
(87696945)
17 X-CAB_TR (Receptacle) pin 638 RED BRAKE SW SIG YE - 0.8 SHEET 19 SH19 - UCM PWR, GRND,
24 - CAB TO TRANSMISSION INSTRUMENTATION
[SH26: A-2] (87696944)
20 X-LC2 (Receptacle) pin 1A - 465 CAB ISOLATED B+ RD - 1.0
(87733581)
21 X-CAB_EH (Plug) pin M - CAB 357 AUX 2 ENABLE BR - 0.8 SHEET 22 SH22 - UCM-LOADER BOOM
TO BOTTOM EH (87700159) CONTROL
22 X-CAB_B (Plug) pin 19 - CAB 389 PARK BRAKE SOL WH - 0.8 SHEET 20 SH20 - UCM VEHICLE DRIVELINE
(87696945)
26 SP-466-P-X 466A IGNITION POWR FOR OR - 0.8 SHEET 19 SH19 - UCM PWR, GRND,
UCM INSTRUMENTATION
48083741_EN 31/07/2018
55.1 [55.100] / 236
X-UCM1B - UCM [ SH22: A-6] (87410946) (Receptacle)
87410946 243
87410946
1 SP-651-P-X 651 5V GND2 BL - 0.8 SHEET 22 SH22 - UCM-LOADER BOOM
2 X-CAB_EH (Plug) pin C - CAB 339 BOOM ENABLE BR - 0.8 CONTROL
TO BOTTOM EH (87700159)
10 X-CAB_EH (Plug) pin J - CAB 352 AUX 1 ENABLE BR - 0.8 SHEET 22 SH22 - UCM-LOADER BOOM
19 X-CAB_EH (Plug) pin S - CAB 647 BOOM ANGLE 1 YE - 0.8
20 X-CAB_B (Plug) pin 7 - CAB 641 BRAKE PRESSURE YE - 0.8 SHEET 19 SH19 - UCM PWR, GRND,
TO BOTTOM [SH21: B-3] INSTRUMENTATION
(87696945)
21 X-CAB_EH (Plug) pin W 653 BUCKET ANGLE 1 YE - 0.8 SHEET 22 SH22 - UCM-LOADER BOOM
- CAB TO BOTTOM EH CONTROL
(87700159)
22 X-CAB_EH (Plug) pin T - CAB 648 BOOM ANGLE 2 YE - 0.8
23 X-CAB_EH (Plug) pin X - CAB 654 BUCKET ANGLE 2 YE - 0.8
25 SP-LA-P-X CAN_LT CAN GN - 0.8
30 X-CAB_EH (Plug) pin F - CAB 347 BUCKET ENABLE BR - 0.8
34 SP-HA-P-X CAN_HT CAN YE - 0.8
82028493 244
82028493
48083741_EN 31/07/2018
55.1 [55.100] / 237

7 SP-448-P-X 448A CAB ISOLATED B+ RD - 1.0 SHEET 19 SH19 - UCM PWR, GRND,
INSTRUMENTATION
10 X-CAB_P2 (Receptacle) pin 3 686 STALK FNR F YE - 0.8 SHEET 20 SH20 - UCM VEHICLE DRIVELINE
- CAB TO PEDESTAL 2 [SH27: / FAN CONTROL
B-2] (87705101)
11 X-CAB_P2 (Receptacle) pin 1 679 STALK FNR R YE - 0.8
- CAB TO PEDESTAL 2 [SH27:
B-2] (87705101)
12 X-CAB_L (Receptacle) pin 5 630 JSS JOYSTICK 2 YE - 0.8 SHEET 21 SH21 - UCM-STEERING AUX JSS
(87700156)
13 SP-448-P-X 448B CAB ISOLATED B+ RD - 1.0 SHEET 19 SH19 - UCM PWR, GRND,
INSTRUMENTATION
16 X-CAB_P2 (Receptacle) pin 2 680 STALK FNR N YE - 0.8 SHEET 20 SH20 - UCM VEHICLE DRIVELINE
- CAB TO PEDESTAL 2 [SH27: / FAN CONTROL
B-2] (87705101)
17 X-CAB_E (Receptacle) pin 18 319 AIR FILTER REST SW T2 YE - 0.8
(84807216)
18 X-CAB_L (Receptacle) pin 2 670 JSS JOYSTICK 1 YE - 0.8 SHEET 21 SH21 - UCM-STEERING AUX JSS
(87700156)
20 SP-967-P-X 967B 5 V REF GRND3 BL - 0.8
21 X-CAB_E-2 (Plug) pin N - 692 FAN REVERSER SGNL BR - 0.8 SHEET 20 SH20 - UCM VEHICLE DRIVELINE
CAB TO ENG 2 [SH9: C-2] / FAN CONTROL
(87703902)
22 X-CAB_E-2 (Plug) pin M - 582 HEAT LOAD VALVE BR - 0.8
CAB TO ENG 2 [SH9: C-2] SIGNAL
(87703902)
25 X-CAB_E-2 (Plug) pin P - 392 FAN CONTROL SGNL YE - 0.8
(87703902)
X-UCM2B - UCM [ A-UCM] (82028495) (Receptacle)
82028495 245
82028495
48083741_EN 31/07/2018
55.1 [55.100] / 238

1 SP-B_HM-P-X CANB_HK CAN WH - 0.8 SHEET 03 SH03 - PWR DISTR-BATTERY /
10 SP-B_LM-P-X CANB_LK CAN BL - 0.8 STARTER / KEY
12 X-CAB_L (Receptacle) pin 4 675 LH ARMREST POSITION GY - 0.8
- CAB TO JSS L ARMREST UP
(87700156)
14 X-X3 (Receptacle) pin 5 - SFB 220B SIG_IGNITION YE - 0.8
[SH3: A-1] (47554344) SWITCH_START
20 X-CAB_L (Receptacle) pin 8 673 LH ARMREST POSITION TN - 0.8
- CAB TO JSS L ARMREST DWN
(87700156)
21 X-CAB_P2 (Receptacle) pin 5 407 GEAR SELECT 3_4 YE - 0.8
B-2] (87705101)
84130757 246
84130757
5 X-CAB_E (Receptacle) pin 15 663 OK TO START YE - 0.8 SHEET 20 SH20 - UCM VEHICLE DRIVELINE
- CAB TO ENGINE [SH7: B-5] / FAN CONTROL
(84807216)
INSTRUMENTATION
12 X-CAB_JSS (Receptacle) 676 JSS PILOT PRESS SIG YE - 0.8 SHEET 21 SH21 - UCM-STEERING AUX JSS
HARNESS [SH24: A-6]
(87694112)
13 SP-454-P-X 454B CAB ISOLATED B+ RD - 1.0 SHEET 19 SH19 - UCM PWR, GRND,
17 X-CAB_TR (Receptacle) pin 636 HYD FILTER YE - 0.8 INSTRUMENTATION
[SH26: A-2] (87696944)
48083741_EN 31/07/2018
55.1 [55.100] / 239
84130760 247
84130760
1 X-CAB_TR (Receptacle) pin 390 DIFF LOCK SIGNAL WH - 0.8 SHEET 20 SH20 - UCM VEHICLE DRIVELINE
27 - CAB TO TRANSMISSION / FAN CONTROL
[SH26: A-2] (87696944)
3 SP-461-P-X 461B CAB ISOLATED B+ RD - 1.0 INSTRUMENTATION
4 X-CAB_B (Plug) pin 9 - CAB 368 COUPLER VALVE RTRN BR - 0.8 SHEET 22 SH22 - UCM-LOADER BOOM
TO BOTTOM [SH21: B-3] CONTROL
(87696945)
6 X-CAB_B (Plug) pin 5 - CAB 366 RIDE CONTROL SIG WH - 0.8
(87696945)
7 X-CAB_B (Plug) pin 14 - CAB 367 COUPLER VALVE SIG WH - 0.8
(87696945)
8 SP-454-P-X 454C CAB ISOLATED B+ RD - 1.0 SHEET 19 SH19 - UCM PWR, GRND,
9 SP-454-P-X 454D CAB ISOLATED B+ RD - 1.0 INSTRUMENTATION
15 X-CAB_JSS (Receptacle) 273 JSS CUTOFF SIG B YE - 0.8 SHEET 21 SH21 - UCM-STEERING AUX JSS
HARNESS [SH24: A-6]
(87694112)
16 X-CAB_L (Receptacle) pin 9 678 JSS ACTIVATION WH - 0.8
(87700156)
17 X-CAB_EH (Plug) pin E - CAB 346 BUCKET ROLL WH - 0.8 SHEET 22 SH22 - UCM-LOADER BOOM
18 X-CAB_EH (Plug) pin A - CAB 344 PILOT ENABLE WH - 0.8
23 X-CAB_L (Receptacle) pin 12 682 JSS ACTIVATION NC YE - 0.8 SHEET 21 SH21 - UCM-STEERING AUX JSS
(87700156)
24 X-SDM pin 2 - SWITCH DIFF 401 DIFF LOCK WH - 0.8 SHEET 20 SH20 - UCM VEHICLE DRIVELINE
LOCK [SW-SDM] (82012083) / FAN CONTROL
25 X-CAB_EH (Plug) pin G - CAB 350 BUCKET DUMP WH - 0.8 SHEET 22 SH22 - UCM-LOADER BOOM
27 X-CAB_B (Plug) pin 18 - CAB 388 PARK BRAKE SOL WH - 0.8 SHEET 20 SH20 - UCM VEHICLE DRIVELINE
(87696945)
32 X-CAB_EH (Plug) pin H - CAB 351 AUX 1 LEFT WH - 0.8 SHEET 22 SH22 - UCM-LOADER BOOM
33 X-CAB_EH (Plug) pin K - CAB 355 AUX 1 RIGHT WH - 0.8
48083741_EN 31/07/2018
55.1 [55.100] / 240
82028493 248
82028493
INSTRUMENTATION
6 X-CAB_EH (Plug) pin D - CAB 341 BOOM LOWER WH - 0.8 SHEET 22 SH22 - UCM-LOADER BOOM
7 X-CAB_EH (Plug) pin B - CAB 340 BOOM RAISE WH - 0.8
8 SP-448-P-X 448D CAB ISOLATED B+ RD - 1.0 SHEET 19 SH19 - UCM PWR, GRND,
11 X-CAB_E (Receptacle) pin 8 633 FUEL LEVEL YE - 0.8 INSTRUMENTATION
(84807216)
12 X-CAB_E (Receptacle) pin 5 433 COOLANT TEMP YE - 0.8
(84807216)
13 X-CAB_EH (Plug) pin N - CAB 360 AUX 2 RIGHT WH - 0.8 SHEET 22 SH22 - UCM-LOADER BOOM
17 X-CAB_B (Plug) pin 17 - CAB 687 FRONT AXLE TEMP YE - 0.8 SHEET 20 SH20 - UCM VEHICLE DRIVELINE
(87696945)
18 X-CAB_TR (Receptacle) pin 634 HYD OIL TEMP SIG YE - 0.8 SHEET 19 SH19 - UCM PWR, GRND,
30 - CAB TO TRANSMISSION INSTRUMENTATION
[SH26: A-2] (87696944)
19 X-CAB_EH (Plug) pin L - CAB 356 AUX 2 LEFT WH - 0.8 SHEET 22 SH22 - UCM-LOADER BOOM
82028495 249
82028495
48083741_EN 31/07/2018
55.1 [55.100] / 241

INSTRUMENTATION
9 X-CAB_P (Plug) pin 5 - CAB 134 WARNING INDICATOR YE - 0.8 SHEET 20 SH20 - UCM VEHICLE DRIVELINE
TO PEDESTAL [SH20: D-2] LED / FAN CONTROL
(87700155)
16 X-CAB_L2 (Receptacle) 691 JSS INDICATOR WH - 0.8 SHEET 21 SH21 - UCM-STEERING AUX JSS
pin 1 - CAB TO LEFT JSS
(87696138)
24 X-CAB_B (Plug) pin 13 - CAB 291 ROLL BACK PRESSURE YE - 0.8 SHEET 22 SH22 - UCM-LOADER BOOM
TO BOTTOM [SH21: B-3] SW CONTROL
(87696945)
30 X-CAB_E (Receptacle) pin 16 400 FAN SPEED SENSOR YE - 0.8 SHEET 20 SH20 - UCM VEHICLE DRIVELINE
- CAB TO ENGINE [SH7: B-5] SGNL / FAN CONTROL
(84807216)
X-UTS - UPSTREAM OF SCR TEMP SENSOR [ B-U_TS] (84532147) (Receptacle)
84532147 250
84532147
1 X-ECU (Receptacle) pin 32 - 632 SCR UPSTREAM TEMP YE - 0.8 SHEET 17 SH17 - ENGINE CONTROL UNIT
(84300197)
2 SP-610-P-X 610A TEMP SENSOR GROUND BK - 0.8
X-WIF - WATER IN FUEL [ B-WIF] (87709663) (Receptacle)
87709663 251
87709663
48083741_EN 31/07/2018
55.1 [55.100] / 242

1 X-EDC7 (Plug) pin 42 - 613A WATER IN FUEL SIGNAL YE - 0.8 SHEET 17 SH17 - ENGINE CONTROL UNIT
ENGINE CONTROLLER T2/3 T2 2, AT
[SH18: C-5] (84160698)
1 X-ECU (Receptacle) pin 13 - 613 WATER IN FUEL YE - 0.8
(84300197)
2 SP-603-P-X 603K WIF GRND T2 BK - 0.8
2 SP-643-P-X 643B WATER IN FUEL BK - 0.8
3 SP-850A-P-X 850E KEY SWITCH FUSED OR - 0.8
POWER
X-WSH - WATER SEPERATOR HEATER [ Y-W_S_H] (87679438) (Receptacle)
87679438 252
87679438
A X-GND_ENG1 (Plug) pin 1 - 195 FUEL FILTER HTR GRND BK - 2.0 SHEET 16 SH16 - ENGINE CONTROL UNIT
GROUND ENG BLOCK [SH16: 1, GRID HEATER, FILTER HEATER
A-1] (84140737)
B SP-421-P-X 421B WATER SEP HEATER OR - 2.0
PWR
X-X-PO1 - POWER OUTLET [ J-PO1] (84398827) (Receptacle)
84398827 253
84398827
A X-LC3 (Receptacle) pin 750 RH CONSOLE 12V PWR OR - 1.0 SHEET 35 SH35 - CABIN RADIO
F1_13 - LOADCENTER 3 OUTLET LOUDSPEAKER/12V CNVRTR
[SH35: B-6] (84529039)
C CG2-P-1 CAB GROUND 275 RH CONSOLE 12V PWR BK - 1.0
BLOCK OUTLET GND
48083741_EN 31/07/2018
55.1 [55.100] / 243
X-X1 - SFB [ SH6: D-1] (84344499) (Receptacle)
84344499 254
84344499
2 X-LC1 pin F1 - LOADCENTER 169 SWBAT_ISOLATOR_SFB RD - 8.0 SHEET 04 SH04 - POWER DISTRIBUTION
1 [SH10: A-6] (47728326) SUPPLY A SFB PWR AND GRNDS
X-X2 - SFB [ SH6: C-1] (84344499) (Receptacle)
84344499 255
84344499
1 X-LC1 pin C1 - LOADCENTER 172 ISOLATED_SFB SUPPLY RD - 8.0 SHEET 04 SH04 - POWER DISTRIBUTION
1 [SH10: A-6] (47728326) D SFB PWR AND GRNDS
2 X-LC1 pin D1 - LOADCENTER 171 ISOLATED_SFB SUPPLY RD - 8.0
1 [SH10: A-6] (47728326) C
X-X3 - SFB [ SH3: A-1] (47554344) (Receptacle)
47554344 256
47554344
48083741_EN 31/07/2018
55.1 [55.100] / 244

1 X-CAB_R (Plug) pin 2 - CAB 724 RIGHT FRONT WORK VT - 1.0 SHEET 08 SH08 - POWER DISTRIBUTION
TO ROOF (87695891) LIGHT (FUSE BLOCK LC3)
2 X-CAB_R (Plug) pin 1 - CAB 111 LEFT FRONT WORK VT - 1.0
TO ROOF (87695891) LIGHT
3 X-CAB_R (Plug) pin 3 - CAB 851 ROTATING BEACON VT - 0.8
TO ROOF (87695891)
5 X-UCM2B (Receptacle) pin 220B SIG_IGNITION YE - 0.8 SHEET 03 SH03 - PWR DISTR-BATTERY /
14 - UCM [A-UCM] (82028495) SWITCH_START STARTER / KEY
6 X-S_BU (Receptacle) pin 10 118 BACKUP ALARM YE - 0.8 SHEET 08 SH08 - POWER DISTRIBUTION
- CANCEL BACKUP ALARM CANCEL IND (FUSE BLOCK LC3)
[SW-BCK_U_SW] (87716755)
7 X-LC3 (Receptacle) pin 120 REAR DEFROST YE - 0.8
[SH35: B-6] (84529039)
8 X-LC5 (Receptacle) pin 86 - 222 SIG_IGNITION YE - 0.8 SHEET 03 SH03 - PWR DISTR-BATTERY /
LOADCENTER 5 [SH10: D-1] RELAY_COIL STARTER / KEY
(87733595)
11 X-LC4 (Receptacle) pin 86 - 226 ACCESSORY POWER YE - 0.8
(87733595)
12 X-CAB_E (Receptacle) pin 21 129 LH BRAKE LAMP VT - 0.8 SHEET 08 SH08 - POWER DISTRIBUTION
- CAB TO ENGINE [SH7: B-5] (FUSE BLOCK LC3)
(84807216)
14 CG5-P-1 CAB GROUND 1003 GND_SFB_PGND BK - 1.0 SHEET 04 SH04 - POWER DISTRIBUTION
SFB PWR AND GRNDS
15 X-LC3 (Receptacle) pin 192 SIG_DC_CONVERTER OR - 0.8 SHEET 03 SH03 - PWR DISTR-BATTERY /
R1_86 - LOADCENTER 3 STARTER / KEY
[SH35: B-6] (84529039)
16 X-CAB_P (Plug) pin 8 - CAB 269A HAZARD INDICATOR BK - 0.8 SHEET 08 SH08 - POWER DISTRIBUTION
TO PEDESTAL [SH20: D-2] LIGHT (FUSE BLOCK LC3)
(87700155)
17 X-CAB_E (Receptacle) pin 25 280 LICENSE PLATE LIGHT VT - 0.8
(84807216)
18 X-MAP (Receptacle) pin A 147 MAP LAMP VT - 0.8
- MAP LIGHT [SH13: C-6]
(84058093)
X-X31CF1-2 - CAB GROUND BLOCK (84122130) (Plug)
84122130 257
84122130
1 X-X31CF1-3 (Plug) pin 1 CABLE_ENG_ GROUND CABLE ENG BK - 62.0 SHEET 14 SH14 - CAB & CHASSIS GROUND
- CAB GROUND BLOCK GRND BLCK TO REAR FRAME PWR DISTR
(84122130)
48083741_EN 31/07/2018
55.1 [55.100] / 245
X-X31CF1-3 - CAB GROUND BLOCK (84122130) (Plug)
84122130 258
84122130
1 X-X31CF1-2 (Plug) pin 1 CABLE_ENG_ GROUND CABLE ENG BK - 62.0 SHEET 14 SH14 - CAB & CHASSIS GROUND
- CAB GROUND BLOCK GRND BLCK TO REAR FRAME PWR DISTR
(84122130)
X-X31CF2-1 - STEERING COLUMN GROUND (84122130) (Plug)
84122130 259
84122130
1 X-X31CF2-2 (Plug) pin STRAP1 BIG BRAIDED STRAP - - 50.0 SHEET 14 SH14 - CAB & CHASSIS GROUND
1 - STEERING COLUMN CAB BTM TO REAR FRM PWR DISTR
GROUND (84122130)
X-X31CF2-2 - STEERING COLUMN GROUND (84122130) (Plug)
84122130 260
84122130
48083741_EN 31/07/2018
55.1 [55.100] / 246

1 X-X31CF2-1 (Plug) pin STRAP1 BIG BRAIDED STRAP - - 50.0 SHEET 14 SH14 - CAB & CHASSIS GROUND
1 - STEERING COLUMN CAB BTM TO REAR FRM PWR DISTR
GROUND (84122130)
X-X4 - SFB (47554343) (Receptacle)
47554343 261
47554343
2 SP-981-P-X 981 SWITCH BACK LIGHTING VT - 0.8 SHEET 27 SH27 - LIGHTING DOME, MAP
LIGHTS
3 X-CAB_P2 (Receptacle) pin 283 REAR WIPER INDICATOR VT - 0.8 SHEET 32 SH32 - CAB WIPER / WASHER
11 - CAB TO PEDESTAL 2
[SH27: B-2] (87705101)
4 SP-132-P-X 132 LH HIGH BEAM LAMP VT - 0.8 SHEET 28 SH28 - LIGHTING HAZARD
5 CG5-P-1 CAB GROUND 1006 GND_SFB_REDUNDANT BK - 1.0 SHEET 04 SH04 - POWER DISTRIBUTION
GND SFB PWR AND GRNDS
6 X-FWM (Plug) pin A - FRONT 100 FRONT WIPER MOTOR TN - 2.0 SHEET 32 SH32 - CAB WIPER / WASHER
WIPER MOTOR (87692862) HIGH
8 CG5-P-1 CAB GROUND 1002 GND_SFB_MODULE BK - 1.0 SHEET 04 SH04 - POWER DISTRIBUTION
GND SFB PWR AND GRNDS
9 X-CAB_E (Receptacle) pin 6 131 RH REAR TURN LAMP VT - 0.8 SHEET 29 SH29 - LIGHTING REAR TAILS
(84807216)
10 X-CAB_B (Plug) pin 25 - CAB 137 RH HIGH BEAM LAMP VT - 0.8 SHEET 28 SH28 - LIGHTING HAZARD
TO BOTTOM [SH21: B-3] WARNING, BLINKERS, DRIVING
(87696945)
11 SP-219A-P-X 219C PWR NON-ISOLATED RD - 0.8 SHEET 03 SH03 - PWR DISTR-BATTERY /
STARTER / KEY
12 X-CAB_B (Plug) pin 24 - CAB 136 LH FRONT TURN VT - 0.8 SHEET 28 SH28 - LIGHTING HAZARD
(87696945)
13 X-S_HMR (Receptacle) pin 10 115 MIRROR HEATER WH - 0.8 SHEET 34 SH34 - MIRRORS, HORN BEACON
- SWITCH HEATED MIRRORS INDICATOR
[SH13: D-4] (87716755)
17 X-CAB_E-2 (Plug) pin F - 250 ISOLATOR SET YE - 0.8 SHEET 03 SH03 - PWR DISTR-BATTERY /
CAB TO ENG 2 [SH9: C-2] STARTER / KEY
(87703902)
19 X-CAB_R (Plug) pin 5 - CAB 859 REAR WORK LIGHTS VT - 1.0 SHEET 31 SH31 - LIGHTING WORKING
TO ROOF (87695891) LIGHTS CAB ROOF, FRONT AND REAR
21 X-CAB_E (Receptacle) pin 7 121 BACKUP ALARM OR - 0.8 SHEET 36 SH36 - REAR DEFROST, BACKUP
- CAB TO ENGINE [SH7: B-5] ALARM
(84807216)
48083741_EN 31/07/2018
55.1 [55.100] / 247
X-X5 - SFB [ SH3: D-3] (47554342) (Receptacle)
47554342 262
47554342
1 SP-873-P-X 873 HVAC SFB POWER OR - 0.8 SHEET 33 SH33 - HEATING BLOWER
HEATER, HVAC
4 X-CAB_E (Receptacle) pin 26 228A ALTERNATOR VOLTAGE RD - 0.8 SHEET 03 SH03 - PWR DISTR-BATTERY /
- CAB TO ENGINE [SH7: B-5] STARTER / KEY
(84807216)
6 X-CAB_R (Plug) pin 4 - CAB 114 MIRROR HEAT SUPPLY TN - 1.0 SHEET 34 SH34 - MIRRORS, HORN BEACON
TO ROOF (87695891)
12 X-DM_P (Receptacle) pin 149 DOME LAMP SW OR - 0.8 SHEET 27 SH27 - LIGHTING DOME, MAP
2 - DOME LIGHT POSITIVE LIGHTS
[LMP-DM] (84015523)
13 X-CAB_B (Plug) pin 26 - CAB 138 RH LOW BEAM LAMP VT - 0.8 SHEET 28 SH28 - LIGHTING HAZARD
(87696945)
15 X-CAB_B (Plug) pin 28 - CAB 135 RH FRONT TURN VT - 0.8
(87696945)
16 X-CAB_P (Plug) pin 2 - CAB 189 RH TURN INDICATOR VT - 0.8
TO PEDESTAL [SH20: D-2]
(87700155)
18 X-CAB_E (Receptacle) pin 22 128 LH REAR TURN LAMP VT - 0.8 SHEET 29 SH29 - LIGHTING REAR TAILS
(84807216)
21 X-CAB_B (Plug) pin 22 - CAB 133 LH LOW BEAM LAMP VT - 0.8 SHEET 28 SH28 - LIGHTING HAZARD
(87696945)
X-X6 - SFB [ A-SFB] (47554341) (Receptacle)
47554341 263
47554341
1 SP-124-P-X 124 REVERSE VT - 0.8 SHEET 39 SH39 - MISCELLANOUS, REAR
LIGHTS_CAMERA CAMERA
2 X-CAB_E (Receptacle) pin 10 126 LH BRAKE LAMP VT - 0.8 SHEET 29 SH29 - LIGHTING REAR TAILS
(84807216)
48083741_EN 31/07/2018
55.1 [55.100] / 248

3 SP-130-P-X 130 RH TAIL LAMP VT - 0.8 SHEET 28 SH28 - LIGHTING HAZARD
5 CG2-P-1 CAB GROUND 279 WIPER GROUND BK - 2.0 SHEET 14 SH14 - CAB & CHASSIS GROUND
BLOCK PWR DISTR
6 SP-127-P-X 127 LH POSITION/TAIL VT - 0.8 SHEET 28 SH28 - LIGHTING HAZARD
8 X-AIR (Receptacle) pin 4 - 285 SWITCH BACK LIGHTING VT - 0.8 SHEET 27 SH27 - LIGHTING DOME, MAP
HVAC CONSOLE [SH27: C-2] LIGHTS
(84309048)
9 X-CAB_TR (Receptacle) pin 106 REAR WASHER MOTOR OR - 0.8 SHEET 32 SH32 - CAB WIPER / WASHER
[SH26: A-2] (87696944)
12 X-RWM (Plug) pin B - 108 REAR WIPER MOTOR TN - 1.0
REAR WIPER MOTOR LOW
[M-R_WPR_M] (87692862)
17 X-DM_P (Receptacle) pin 148 EGRESS/DOME LAMP B+ VT - 0.8 SHEET 27 SH27 - LIGHTING DOME, MAP
1 - DOME LIGHT POSITIVE LIGHTS
[LMP-DM] (84015523)
X-X7 - SFB [ SH3: A-3] (84538791) (Receptacle)
84538791 264
84538791
1 X-SFB_XCP (Receptacle) pin CANB_LF CAN BL - 0.8 SHEET 24 SH24 - CAN STRUCTURE
2 - DIAG (87696093)
2 X-SFB_XCP (Receptacle) pin CANB_HF CAN WH - 0.8
1 - DIAG (87696093)
4 SP-LF-P-X CAN_LG CAN GN - 0.8
5 SP-HF-P-X CAN_HG CAN YE - 0.8
7 X-S_RDF (Receptacle) pin 10 122 REAR DEFROST SWITCH YE - 0.8 SHEET 36 SH36 - REAR DEFROST, BACKUP
- SWITCH REAR DEFROST IND ALARM
[SW-R_DEF_SW] (87716755)
8 X-CAB_E-2 (Plug) pin G - 237 ISOLATOR RESET YE - 0.8 SHEET 03 SH03 - PWR DISTR-BATTERY /
CAB TO ENG 2 [SH9: C-2] STARTER / KEY
(87703902)
26 SP-113-P-X 113 HORN SWITCH BR - 0.8 SHEET 34 SH34 - MIRRORS, HORN BEACON
28 X-CAB_P (Plug) pin 6 - CAB 141 HAZARD SWITCH YE - 0.8 SHEET 28 SH28 - LIGHTING HAZARD
TO PEDESTAL [SH20: D-2] WARNING, BLINKERS, DRIVING
(87700155)
30 X-KEY (Receptacle) pin B 220 SIG_IGNITION YE - 0.8 SHEET 03 SH03 - PWR DISTR-BATTERY /
- KEY SWITCH [SW-KEY] SWITCH_START STARTER / KEY
(87699176)
31 X-KEY (Receptacle) pin D 221 SIG_IGNITION YE - 0.8
- KEY SWITCH [SW-KEY] SWITCH_RUN
(87699176)
32 X-KEY (Receptacle) pin C 225 SIG_IGNITION YE - 0.8
- KEY SWITCH [SW-KEY] SWITCH_ACC
(87699176)
36 SP-258-P-X 258D AC ON SIGNAL YE - 0.8 SHEET 33 SH33 - HEATING BLOWER
HEATER, HVAC
48 X-S_HMR (Receptacle) pin 3 116 MIRROR HEATER SW YE - 0.8 SHEET 34 SH34 - MIRRORS, HORN BEACON
- SWITCH HEATED MIRRORS
[SH13: D-4] (87716755)
48083741_EN 31/07/2018
55.1 [55.100] / 249

50 X-S_BU (Receptacle) pin 3 119 BACKUP ALARM YE - 0.8 SHEET 36 SH36 - REAR DEFROST, BACKUP
- CANCEL BACKUP ALARM CANCEL ALARM
[SW-BCK_U_SW] (87716755)
55 X-CAB_P2 (Receptacle) pin 9 727 REAR WIPER SWITCH YE - 0.8 SHEET 32 SH32 - CAB WIPER / WASHER
B-2] (87705101)
56 X-CAB_P2 (Receptacle) pin 8 728 REAR WASHER SWITCH YE - 0.8
B-2] (87705101)
59 X-FWM (Plug) pin D - FRONT 102 FRONT WIPER MOTOR TN - 0.8
WIPER MOTOR (87692862) PARK
67 X-CAB_E (Receptacle) pin 17 239A ALT LAMP SIGNAL YE - 0.8 SHEET 03 SH03 - PWR DISTR-BATTERY /
- CAB TO ENGINE [SH7: B-5] STARTER / KEY
(84807216)
68 X-S_RDF (Receptacle) pin 3 117 REAR DEFROST SWITCH YE - 0.8 SHEET 36 SH36 - REAR DEFROST, BACKUP
- SWITCH REAR DEFROST ALARM
[SW-R_DEF_SW] (87716755)
80 X-DS (Receptacle) pin 1 - 151 LH DOOR AJAR SW YE - 0.8 SHEET 27 SH27 - LIGHTING DOME, MAP
DOOR SWITCH [SH27: C-6] LIGHTS
(87382906)
X-XLP1 - LOUDSPEAKER RT [ H-LSP1] (84147089) (Receptacle)
84147089 265
84147089
1 X-SPK (Receptacle) pin X - LP1-1 LOUDSPEAKER RIGHT BL - 1.0 SHEET 35 SH35 - CABIN RADIO
RADIO TO SPKRS [H-RADIO] -1 LOUDSPEAKER/12V CNVRTR
(87709371)
2 X-SPK (Receptacle) pin X - LP1-2 LOUDSPEAKER RIGHT BK - 1.0
RADIO TO SPKRS [H-RADIO] -2
(87709371)
X-XLP2 - LOUDSPEAKER LF [ H-LSP2] (84147089) (Receptacle)
84147089 266
84147089
48083741_EN 31/07/2018
55.1 [55.100] / 250

1 X-SPK (Receptacle) pin X - LP2-1 LOUDSPEAKER LEFT -1 WH - 1.0 SHEET 35 SH35 - CABIN RADIO
RADIO TO SPKRS [H-RADIO] LOUDSPEAKER/12V CNVRTR
(87709371)
2 X-SPK (Receptacle) pin X - LP2-2 LOUDSPEAKER LEFT -2 BR - 1.0
RADIO TO SPKRS [H-RADIO]
(87709371)
X-XM1B - STARTER LUG FROM ISOLATOR (84596842) (Plug)
84596842 267
84596842
1 X-D(S) (Plug) pin 1 - MASTER CABLE-004 BATTERY CABLE RD - 62.0 SHEET 03 SH03 - PWR DISTR-BATTERY /
DISCONNECT SWITCHED STARTER / KEY
[K-ISOLATOR] (84163398)
X-XM1C - STARTER (84401295) (Plug)
84401295 268
84401295
1 X-ALT_B (Plug) pin 1 - 301 ALTERNATOR B+ RD - 13.0 SHEET 03 SH03 - PWR DISTR-BATTERY /
ALTERNATOR B+ (84399576) STARTER / KEY
48083741_EN 31/07/2018
55.1 [55.100] / 251
X-X_TEL - TELEMATICS [ SH38: C-6] (87700156) (Receptacle)
87700156 269
87700156
1 X-SP_PK_CLN (Receptacle) 287 TELE GRND BK - 0.8 SHEET 24 SH24 - CAN STRUCTURE
pin X - SPLICE PACK CLEAN
GRND [SH25: C-1] (87352746)
2 X-LC5 (Receptacle) pin 4A - 168 TELEMATICS IGN OR - 0.8
LOADCENTER 5 [SH10: D-1] POWER
(87733595)
3 SP-HB-P-X CAN_HC CAN YE - 0.8
4 SP-LB-P-X CAN_LC CAN GN - 0.8
6 X-DIAG_T (Receptacle) pin 3 CAN_TL CAN LB - 0.8
- TELEMATICS DIAGNOSTIC
[SH38: B-1] (87694101)
7 X-DIAG_T (Receptacle) pin 2 CAN_TH CAN TN - 0.8
- TELEMATICS DIAGNOSTIC
[SH38: B-1] (87694101)
12 X-CAB_E-2 (Plug) pin H - 217A TELE NON- RD - 0.8
CAB TO ENG 2 [SH9: C-2] DISCONNECTED PWR
(87703902)
X-YDL - DIFF LOCK SOL [ Y-DL] (87695582) (Receptacle)
87695582 270
87695582
1 X-TRANS (Plug) pin 27 - 390A DIFF LOCK SIGNAL WH - 0.8 SHEET 20 SH20 - UCM VEHICLE DRIVELINE
TRANSMISSION TO CAB / FAN CONTROL
(87696949)
2 SP-391A-P-X 391B DIFF LOCK BK - 0.8
48083741_EN 31/07/2018
55.1 [55.100] / 252
X-YFN - SOLENOID FAN CONTROL [ Y-Y_FC] (87693821) (Receptacle)
87693821 271
87693821
A X-ENG-2 (Receptacle) pin P - 392A FAN CONTROL SGNL YE - 0.8 SHEET 20 SH20 - UCM VEHICLE DRIVELINE
ENGINE TO CAB 2 (87703931) / FAN CONTROL
X-YFR - FAN REVESER SOLENOID [ Y-Y_FR] (87695582) (Receptacle)
87695582 272
87695582
1 SP-852-P-X 852B FAN IGN PWR OR - 0.8 SHEET 20 SH20 - UCM VEHICLE DRIVELINE
2 X-ENG-2 (Receptacle) pin N - 692A FAN REVERSER SGNL BR - 0.8 / FAN CONTROL
X-YLS - TRANS LOCKUP SOLENOID (82012083) (Plug)
82012083 273
82012083
48083741_EN 31/07/2018
55.1 [55.100] / 253
X-YLV - HEAT LOAD VALVE [ Y-YLV] (87695582) (Receptacle)
87695582 274
87695582
1 X-FAN2 (Plug) pin 2 - FAN 852A HEAT LOAD VALVE OR - 0.8 SHEET 20 SH20 - UCM VEHICLE DRIVELINE
SPEED SENSOR JUMPER / FAN CONTROL
(87694152)
2 X-FAN2 (Plug) pin 1 - FAN 582B HEAT LOAD VALVE BR - 0.8
SPEED SENSOR JUMPER SIGNAL
(87694152)
X-YPB - VALVE PARKING BRAKE [ Y-Y_PB] (87695582) (Receptacle)
87695582 275
87695582
1 X-BTM (Receptacle) pin 18 388A PARK BRAKE SOL WH - 0.8 SHEET 20 SH20 - UCM VEHICLE DRIVELINE
- BOTTOM TO CAB STD / FAN CONTROL
(87704523)
2 X-BTM (Receptacle) pin 19 389A PARK BRAKE SOL BK - 0.8
- BOTTOM TO CAB STD
(87704523)
48083741_EN 31/07/2018
55.1 [55.100] / 254
X-YPE - COUPLER VALVE [ Y-YPE] (87695582) (Receptacle)
87695582 276
87695582
1 X-FRNT (Receptacle) pin R 367B COUPLER SOL PWR WH - 0.8 SHEET 22 SH22 - UCM-LOADER BOOM
- FRONT TO BOTTOM STD CONTROL
(87704426)
2 X-FRNT (Receptacle) pin S 368B COUPLER SOL RETURN BR - 0.8
(87704426)
X-YPP - PILOT PRESSURE SOLENOID [ Y-Y_PL] (87692855) (Plug)
87692855 277
87692855
A X-A_RT_2B (Receptacle) pin 344E PILOT ENABLE PILOT YE - 0.8 SHEET 23 SH23 - PILOT LOADER
2 (84281913)
B SP-954U-P-X 954Y CHASSIS GROUND BK - 0.8
48083741_EN 31/07/2018
55.1 [55.100] / 255
X-YRC - RIDE CONTROL SOLENOID [ Y-YRC] (84607243) (Receptacle)
84607243 278
84607243
1 X-FRNT (Receptacle) pin P 366B RIDE CONTROL SOL WH - 0.8 SHEET 22 SH22 - UCM-LOADER BOOM
- FRONT TO BOTTOM STD PWR CONTROL
(87704426)
2 SP-624D-P-X 624C RIDE CONTROL GND BK - 0.8
X-YSS - SEC STEERING VALVE SOL [ Y-Y_SS] (87695582) (Receptacle)
87695582 279
87695582
1 SP-441B-P-X 441C SEC STRG IGN PWR OR - 1.0 SHEET 14 SH14 - CAB & CHASSIS GROUND
PWR DISTR
X-ZF_DI - DIAGNOSTIC [ A-108F] (84364851) (Plug)
84364851 280
84364851
48083741_EN 31/07/2018
55.1 [55.100] / 256

1 SP-19C-P-X 19F DIAG CON IGN PWR OR - 0.8 SHEET 10 SH10 - IGNITION PWR DISTR
2 X-TECM (Receptacle) pin 37D DIAGNOSTIC WH - 0.8 (FUSE BLOCK LC5)
[SH25: C-6] (84550089)
3 X-SP_PK_CLN (Receptacle) 946 CLEAN GROUND BK - 0.8
pin X - SPLICE PACK CLEAN
GRND [SH25: C-1] (87352746)
4 X-TECM (Receptacle) pin 167 DIAGNOSTIC SIL - 0.8
[SH25: C-6] (84550089)
48083741_EN 31/07/2018
55.1 [55.100] / 257

X-10A - DENSO (Receptacle)
1 X-12 (Receptacle) pin 8 - 903A 903A BK - 2.5 SHEET 33 SH33 - HEATING BLOWER
DENSO (41200689)
3 X-12 (Receptacle) pin 10 - 265A 265A GN - 2.0
DENSO (41200689)
4 X-12 (Receptacle) pin 11 - 266A 266A YE - 2.0
DENSO (41200689)
DENSO (41200689)
X-10B - DENSO (Receptacle)

1 X-12 (Receptacle) pin 1 - 258A 258A YE - 0.8 SHEET 33 SH33 - HEATING BLOWER
2 X-12 (Receptacle) pin 2 - 262C 262C WH - 0.8
DENSO (41200689)
3 X-12 (Receptacle) pin 3 - 260A 260A PRP - 0.8
DENSO (41200689)
X-11A - DENSO (Receptacle)

1 X-12 (Receptacle) pin 4 - 285A 285A VT - 0.8 SHEET 33 SH33 - HEATING BLOWER
2 X-12 (Receptacle) pin 5 - 256D 256D BK - 0.8
DENSO (41200689)
X-11B - DENSO (Receptacle)

1 X-12 (Receptacle) pin 5 - 256E 256E BK - 0.8 SHEET 33 SH33 - HEATING BLOWER
2 X-12 (Receptacle) pin 4 - 285B 285B VT - 0.8
DENSO (41200689)
X-12 - DENSO (41200689) (Receptacle)

1 X-10B (Receptacle) pin 1 - 258A 258A YE - 0.8 SHEET 33 SH33 - HEATING BLOWER
DENSO HEATER, HVAC
2 X-10B (Receptacle) pin 2 - 262C 262C WH - 0.8
DENSO
3 X-10B (Receptacle) pin 3 - 260A 260A PRP - 0.8
DENSO
4 X-11B (Receptacle) pin 2 - 285B 285B VT - 0.8
DENSO
4 X-11A (Receptacle) pin 1 - 285A 285A VT - 0.8
DENSO
5 X-11A (Receptacle) pin 2 - 256D 256D BK - 0.8
DENSO
5 X-11B (Receptacle) pin 1 - 256E 256E BK - 0.8
DENSO
6 X-08 (Receptacle) pin 1 - 873E HVAC PWR YE - 0.8
DENSO
DENSO
8 X-10A (Receptacle) pin 1 - 903A 903A BK - 2.5
DENSO
9 X-10A (Receptacle) pin 2 - 264A 264A GY - 1.0
DENSO
10 X-10A (Receptacle) pin 3 - 265A 265A GN - 2.0
DENSO
11 X-10A (Receptacle) pin 4 - 266A 266A YE - 2.0
DENSO
12 X-10A (Receptacle) pin 5 - 267A 267A GY - 2.5
DENSO
48083741_EN 31/07/2018
55.1 [55.100] / 258

X-PHF23 - HYDRAULIC FILTER SENSOR PL23 (82012083) (Plug)
82012083 1
82012083
48083741_EN 31/07/2018
55.1 [55.100] / 259

X-S242 - GROUND [ M-SEC_STRG] (84401307) (Plug)
84401307 1
84401307
1 X-SSG (Plug) pin 1 - 185 AUX STEERING BK - 62.0 SHEET 21 SH21 - UCM-STEERING AUX JSS
SECONDARY STEERING GROUND CABLE
GROUND RING [SH21: C-1]
(84401307)
X-S244 - 20157 AUX STRG PWR RT ANGLE CONN [ SH21: D-3] (Plug)
1 X-B4 (Plug) pin 1 - 1990 AUX STEERING POWER RD - 62.0 SHEET 03 SH03 - PWR DISTR-BATTERY /
ALTERNATOR TO STARTER CABLE STARTER / KEY
B+ (84401309)
X-S245 - GROUND (84426118) (Plug)
84426118 2
84426118
1 X-SSD (Plug) pin A - SS 180A SEC STRG FLYBACK BK - 1.0 SHEET 21 SH21 - UCM-STEERING AUX JSS
FLYBACK DIODE [D-SS GRND
DIODE] (87692858)
1 X-SSD (Plug) pin B - SS 180 SEC STRG FLYBACK BK - 1.0
FLYBACK DIODE [D-SS GRND
DIODE] (87692858)
48083741_EN 31/07/2018
55.1 [55.100] / 260

X-563 - BATTERY LUG [ G-001] (Plug)
1 X-BAT-GND (Plug) pin CABLE-001 CABLE BATTERY BK - 62.0 SHEET 03 SH03 - PWR DISTR-BATTERY /
1 - BATTERY GROUND NEGATIVE STARTER / KEY
(84140737)

1 X-567 (Plug) pin 1 - BATTERY CABLE-002 BATTERY CABLE RD - 62.0 SHEET 03 SH03 - PWR DISTR-BATTERY /
LUG [G-001] STARTER / KEY
X-566 - BATTERY POSITIVE [ G-002] (Plug)

1 X-D(B) (Plug) pin 1 - MASTER CABLE-003 BATTERY POWER RD - 62.0 SHEET 03 SH03 - PWR DISTR-BATTERY /
DISCONNECT BATTERY STARTER / KEY
(84140737)

1 X-564 (Plug) pin 1 - BATTERY CABLE-002 BATTERY CABLE RD - 62.0 SHEET 03 SH03 - PWR DISTR-BATTERY /
LUG [G-002] STARTER / KEY
48083741_EN 31/07/2018
55.1 [55.100] / 261

X-P5320 - JUMP START [ G-002] (Plug)
PIN1 X-JS+ (Plug) pin PIN1 - JUMP CABLE09 JUMP START RD - 32.0 SHEET 03 SH03 - PWR DISTR-BATTERY /
START STUD POS [J-JS+] STARTER / KEY
X-P5321 - JUMP START [ G-001] (Plug)

PIN1 X-JS- (Plug) pin PIN1 - JUMP CABLE08 JUMP START MINUS BK - 32.0 SHEET 03 SH03 - PWR DISTR-BATTERY /
START STUD NEG [J-JS-] STARTER / KEY
48083741_EN 31/07/2018
55.1 [55.100] / 262

X-P1002 - B+ POWER STUD (84140737) (Plug)
84140737 1
84140737
1 X-LC2 (Receptacle) pin 7B - 532 CAB ISOLATED POWER RD - 3.0 SHEET 07 SH07 - BATTERY PWR DISTR
LOADCENTER 2 [SH7: B-3] (FUSE BLOCK LC2)
(87733581)
84140737 2
84140737
1 X-LC3 (Receptacle) pin F8_8 917 CAB ISOLATED POWER RD - 3.0 SHEET 08 SH08 - POWER DISTRIBUTION
- LOADCENTER 3 [SH35: B-6] (FUSE BLOCK LC3)
(84529039)
1 X-LC3 (Receptacle) pin F6_6 541 CAB ISOLATED POWER RD - 2.0
- LOADCENTER 3 [SH35: B-6]
(84529039)
48083741_EN 31/07/2018
55.1 [55.100] / 263

X-P1031 - B+ ON POWER STUD (84140737) (Plug)
84140737 1
84140737
1 P1310-P-1 B+ ON LC1 518 B+ CAB POWER RD - 19.0 SHEET 06 SH06 - BATTERY PWR DISTR
(FUSE BLOCK LC1)
48083741_EN 31/07/2018
55.1 [55.100] / 264

84140737 1
84140737
1 X-LC2 (Receptacle) pin 2B - 527 CAB ISOLATED B+ RD - 3.0 SHEET 07 SH07 - BATTERY PWR DISTR
LOADCENTER 2 [SH7: B-3] (FUSE BLOCK LC2)
(87733581)
1 X-LC2 (Receptacle) pin 3B - 528 CAB ISOLATED B+ RD - 3.0
(87733581)
(87733581)
(87733581)
48083741_EN 31/07/2018
55.1 [55.100] / 265

X-J1333 - DENSO (Receptacle)
1 M-BLOWER 24V-P-1 WIRE4390 WIRE4390 SHEET 33 SH33 - HEATING BLOWER
2 M-BLOWER 24V-P-2 WIRE4389 WIRE4389 HEATER, HVAC
X-J1338 - DENSO (Receptacle)

1 SW-LOW PRESSURE WIRE4702 DENSO SHEET 33 SH33 - HEATING BLOWER
SWITCH N-P-1 HEATER, HVAC
2 SW-LOW PRESSURE WIRE4703 DENSO
SWITCH N-P-2
48083741_EN 31/07/2018
55.1 [55.100] / 266
Index

Electrical components - Diode description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Electrical components - ECU description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Electrical components - Fuse description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Electrical components - Ground description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Electrical components - Lamp description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Electrical components - Load description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Electrical components - Motor description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Electrical components - Power outlet description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Electrical components - Relay description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Electrical components - Resistor description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Electrical components - Sensor description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Electrical components - Solenoid description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Electrical components - Speaker description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Electrical components - Switch description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Electrical components - Voltage source description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Wire connectors - Component diagram 00 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Wire connectors - Component diagram 100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263
Wire connectors - Component diagram 119 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265
Wiring harnesses - Electrical schematic sheet 03 SH03 - PWR DISTR-BATTERY / STARTER / KEY
...................................................................................... 36
Wiring harnesses - Electrical schematic sheet 04 SH04 - POWER DISTRIBUTION SFB PWR AND
GRNDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Wiring harnesses - Electrical schematic sheet 06 SH06 - BATTERY PWR DISTR (FUSE BLOCK
LC1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Wiring harnesses - Electrical schematic sheet 07 SH07 - BATTERY PWR DISTR (FUSE BLOCK
LC2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Wiring harnesses - Electrical schematic sheet 08 SH08 - POWER DISTRIBUTION (FUSE BLOCK
LC3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
48083741_EN 31/07/2018
55.1 [55.100] / 267
Wiring harnesses - Electrical schematic sheet 09 SH09 - ACCESSORY PWR DIST (FUSE BLOCK
LC4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Wiring harnesses - Electrical schematic sheet 10 SH10 - IGNITION PWR DISTR (FUSE BLOCK
LC5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Wiring harnesses - Electrical schematic sheet 11 SH11 - PWR DISTR ENG COMPARTMENT (FUSE
BLOCK LC6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Wiring harnesses - Electrical schematic sheet 12 SH12 - POWER DISTRIBUTION 1 CLEAN
GROUND BLK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Wiring harnesses - Electrical schematic sheet 13 SH13 - POWER DISTRIBUTION 2 CAB GROUND
BLK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Wiring harnesses - Electrical schematic sheet 14 SH14 - CAB & CHASSIS GROUND PWR DISTR 58
Wiring harnesses - Electrical schematic sheet 15 SH15 - POWER DISTRIBUTION 4 ENGINE
GROUND BLK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Wiring harnesses - Electrical schematic sheet 16 SH16 - ENGINE CONTROL UNIT 1, GRID
HEATER, FILTER HEATER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Wiring harnesses - Electrical schematic sheet 17 SH17 - ENGINE CONTROL UNIT 2, AT . . . . . . . 64
Wiring harnesses - Electrical schematic sheet 18 SH18 - ENGINE CONTROL UNIT 3, AT . . . . . . . 66
Wiring harnesses - Electrical schematic sheet 19 SH19 - UCM PWR, GRND, INSTRUMENTATION 68
Wiring harnesses - Electrical schematic sheet 20 SH20 - UCM VEHICLE DRIVELINE / FAN CON-
TROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Wiring harnesses - Electrical schematic sheet 21 SH21 - UCM-STEERING AUX JSS . . . . . . . . . . . 72
Wiring harnesses - Electrical schematic sheet 22 SH22 - UCM-LOADER BOOM CONTROL . . . . . 74
Wiring harnesses - Electrical schematic sheet 23 SH23 - PILOT LOADER CONTROLS . . . . . . . . . 76
Wiring harnesses - Electrical schematic sheet 24 SH24 - CAN STRUCTURE . . . . . . . . . . . . . . . . . . 78
Wiring harnesses - Electrical schematic sheet 25 SH25 - GEAR CONTROL UNIT 1 . . . . . . . . . . . . 80
Wiring harnesses - Electrical schematic sheet 26 SH26 - GEAR CONTROL UNIT 2 . . . . . . . . . . . . 82
Wiring harnesses - Electrical schematic sheet 27 SH27 - LIGHTING DOME, MAP LIGHTS . . . . . . 84
Wiring harnesses - Electrical schematic sheet 28 SH28 - LIGHTING HAZARD WARNING, BLINK-
ERS, DRIVING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Wiring harnesses - Electrical schematic sheet 29 SH29 - LIGHTING REAR TAILS . . . . . . . . . . . . . . 88
Wiring harnesses - Electrical schematic sheet 30 SH30 - OLD EURO LIGHTING . . . . . . . . . . . . . . . 90
Wiring harnesses - Electrical schematic sheet 31 SH31 - LIGHTING WORKING LIGHTS CAB ROOF,
FRONT AND REAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Wiring harnesses - Electrical schematic sheet 32 SH32 - CAB WIPER / WASHER . . . . . . . . . . . . . . 94
Wiring harnesses - Electrical schematic sheet 33 SH33 - HEATING BLOWER HEATER, HVAC . . 96
Wiring harnesses - Electrical schematic sheet 34 SH34 - MIRRORS, HORN BEACON . . . . . . . . . . 98
Wiring harnesses - Electrical schematic sheet 35 SH35 - CABIN RADIO LOUDSPEAKER/12V CN-
VRTR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Wiring harnesses - Electrical schematic sheet 36 SH36 - REAR DEFROST, BACKUP ALARM . . . 102
Wiring harnesses - Electrical schematic sheet 37 SH37 - HOOD LIFT . . . . . . . . . . . . . . . . . . . . . . . . . 104
Wiring harnesses - Electrical schematic sheet 38 SH38 - MISCELLANOUS, TELEMATICS . . . . . . 106
Wiring harnesses - Electrical schematic sheet 39 SH39 - MISCELLANOUS, REAR CAMERA . . . . 108
48083741_EN 31/07/2018
55.1 [55.100] / 268
Alternator - 301

48083741_EN 31/07/2018
55.2 [55.301] / 1
Contents
Alternator - 301
SERVICE
Alternator
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
48083741_EN 31/07/2018
55.2 [55.301] / 2
Electrical systems - Alternator
Alternator - Remove
1. Park the machine on a level surface and lower bucket
to ground.
2. Raise the engine compartment with lifting motor. Place
the timed disconnect switch to the OFF position.
RCPH10WHL106AAH 1
3. Disconnect the two wires from the alternator.
LEIL16WHL0693AB 2
4. Remove the four bolts that hold the engine guard in

place. Remove the engine guard.
LEIL16WHL2490AA 3
LEIL16WHL2430AA 4
48083741_EN 31/07/2018
55.2 [55.301] / 3
5. Use a wrench to actuate the belt tensioner just enough

to release the tension on the drive belt. Remove the
drive belt.
LEIL16WHL2444AA 5
6. Remove the two bolts that hold the alternator in place.

Remove the alternator.
LEIL14WHL0532AB 6
48083741_EN 31/07/2018
55.2 [55.301] / 4
Alternator - Install
1. Place the alternator in the correct position on the en-
gine. Tighten the two bolts that fix the alternator.
LEIL14WHL0532AB 1
2. Use a wrench to actuate the belt tensioner Install the

drive belt.
NOTE: the belt routing instructions are on belt cover.
LEIL16WHL2444AA 2
3. Tighten the four bolts to install the engine guard.
LEIL16WHL2490AA 3
LEIL16WHL2430AA 4
48083741_EN 31/07/2018
55.2 [55.301] / 5
4. Connect the wires to the alternator, place the rubber

boot over the positive post.
LEIL16WHL0693AB 5

Lower the engine hood with the lifting motor.
RCPH10WHL106AAH 6
Belt without air conditioning
LEIL14WHL0533AA 7
48083741_EN 31/07/2018
55.2 [55.301] / 6
Belt with air conditioning
LEIL13WHL0632BA 8
48083741_EN 31/07/2018
55.2 [55.301] / 7
Index
Alternator - 301
Alternator - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Alternator - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
48083741_EN 31/07/2018
55.2 [55.301] / 8
Battery - 302

48083741_EN 31/07/2018
55.3 [55.302] / 1
Contents
Battery - 302
SERVICE
Battery
Visual inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
48083741_EN 31/07/2018
55.3 [55.302] / 2
Electrical systems - Battery
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 batter-
ies, 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.
48083741_EN 31/07/2018
55.3 [55.302] / 3
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 temperature or
a voltage regulator setting that is too high. Keep the
electrolyte level above the top of the plates in the bat-
tery 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 wa-
ter or other clean water until the electrolyte is 5 mm
(0.2 in) 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 bat-
tery.
5. Inspect the battery at regular intervals for dirt, corro-
sion, 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 termi-
nals, and the battery carrier. When available, use Bat-
tery Saver and Cleaner according to the instructions on
the container. Battery Saver and Cleaner also helps
prevent corrosion. If Battery Saver and Cleaner is not
available, use baking 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 Battery Saver and Cleaner
or Urethane Seal Coat to the cable terminals to pre-
vent corrosion. See the Parts Counter Catalog. Apply
Urethane Seal Coat to the cable terminals to prevent
corrosion. 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 min at 15 – 25 A to mix the water with
the electrolyte.
48083741_EN 31/07/2018
55.3 [55.302] / 4
Battery - Test
NOTE: to correctly test a battery, do each part of the battery test until you know the condition of the battery.
Visual Checks
1. Make sure the cable connections are clean and tight.
Clean foreign material from the top of the battery.
2. Inspect the battery case, the battery posts, and the ca-
bles for damage.
3. Check the electrolyte level.
4. If you have added water to the battery, the battery must
be charged for 15 minutes at 15 – 25 A to mix the water
with the electrolyte.
Specific Gravity Check

A hydrometer is used to check the specific gravity
(weight) of the electrolyte. The specific gravity is an
indication of the level of charge for each cell.
Hydrometers are made to show the correct specific
gravity when the temperature of the electrolyte is
26.7 °C (80.1 °F).
When you check the specific gravity, you must know
the temperature of the electrolyte. If your hydrome-
ter does not have a thermometer, get a thermometer
to check the temperature of the electrolyte. The ther-
mometer must indicate a high temperature of at least
52 °C (126 °F).
1. Remove enough electrolyte from a cell so that the float
is free in the tube.
NOTE: if the specific gravity cannot be checked without
first adding water to the cell, the battery must be charged
for 15 minutes at 15 to 25 amperes to mix the water with
the electrolyte. Then check the specific gravity.
2. Read the float.
3. Read the thermometer. If the reading is above 26.7 °C
(80.1 °F) add specific gravity points to the reading for
specific gravity. If the reading is below 26.5 °C (79.7 °F)
subtract specific gravity points from the reading for spe-
cific gravity. See the following illustration and add or
subtract specific gravity points as needed.
LEIL13WHL0634AB 1
48083741_EN 31/07/2018
55.3 [55.302] / 5
4. Make a record of the corrected specific gravity reading

for each cell.
5. If the difference between the high reading and the low
reading is 0.050 or more, charge the battery and check
the specific gravity again. If after charging, the differ-
ence is still 0.050 or more, install a new battery.
6. The corrected specific gravity reading shows the level
of charge for the cell. The level of charge must be at
least 75% in each of the cells. ln maintenance free bat-
teries the level of charge is at least 75% if the corrected
specific gravity reading is 1.240 or higher. In all other
batteries the level of charge is at least 75%if the cor-
rected specific gravity reading is 1.230 or higher.
reading is less than 0.050, and the level of charge is
at least 75% in all of the cells, do the Capacity (Load)
Test.
reading is less than 0.050, but the level of charge is
less than 75% in any of the cells, charge the battery
and check the specific gravity again. If after charging:
A. The level of charge is less than 75% in any of the
cells, discard the battery.
B. The level of charge is at least 75% in all of the cells,
do the Capacity (Load) Test.
Capacity (Load) Test

This test can be done using a variable load tester such
as the Sun Electric VAT-33. Other test equipment can
be used. Connect the test equipment according to the
instructions of the manufacturer of the equipment.
1. The level of charge of the battery must be at least 75%.
Do the Specific Gravity Check.
2. Prepare the tester for the test.
A. Select the voltmeter range that will measure 1 –
18 V.
B. Make sure the load control knob is in the OFF po-
sition.
C. Select the ammeter range that will measure 0 –
1000 A.
D. Move the volt lead switch to the ON position.
48083741_EN 31/07/2018
55.3 [55.302] / 6
3. Connect the tester to the battery as shown.

NOTE: never apply a load for longer than 15 s. After each
15 s, turn the load control knob to OFF for at least one
minute.
LEIL13WHL0635AB 2
4. Apply a 15 A load to the battery for 15 s. Wait at least

three minutes before applying the load again.
5. Check and make a record of the temperature of the
electrolyte.
6. Find the correct load for this test.
NOTE: the correct load is half of the cold cranking amperes
at -17 °C (1 °F).
7. Turn the load control knob until the ammeter indicates
the specified load. Keep the load for 15 s and read the
voltmeter. Turn the load control knob to OFF.
8. Compare the test reading and the temperature of the
electrolyte to the chart below.
Temperature of electrolyte Minimum voltage

21 °C (70 °F) and above 9.6
16 °C (61 °F) 9.5
10 °C (50 °F) 9.4
4 °C (39 °F) 9.3
-1 °C (30 °F) 9.1
-7 °C (19 °F) 8.9
-12 °C (10 °F) 8.7
-18 °C (0 °F) 8.5
A. If the test result is equal to or more than the voltage

shown, the battery is in good condition.
B. If the test result is less than the voltage shown, dis-
card the battery.
48083741_EN 31/07/2018
55.3 [55.302] / 7
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
Before you charge the battery, check the level of the

electrolyte.
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.
The charging rate must be decreased if:
48083741_EN 31/07/2018
55.3 [55.302] / 8
1. Too much gas causes the electrolyte to flow from

the cells.
2. The temperature of the electrolyte rises above
52 °C (126 °F).
NOTE: for the best charge, use the slow charging rates.
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.
Charging Guide For Maintenance Free Batteries

Recommended Rate* and Time for Fully Discharged Battery
Battery capacity – See Reserve Slow Charge Fast Charge
Capacity under Specifications
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 min to 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 min to 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
*initial rate for standard taper charger.
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 to get access to the battery caps, it is possible the words Maintenance
Free will have been removed from the decal.
48083741_EN 31/07/2018
55.3 [55.302] / 9
Charging Guide For Batteries Other Than Maintenance Free Batteries

Recommended Rate* and Time for Fully Discharged Battery
Battery capacity – See Reserve Slow Charge Fast Charge
Capacity under Specifications
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
Above 125 min to 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
Above 250 min 24 h at 10 A 6 h at 40 A
4 h at 60 A
*initial rate for standard taper charger.
Preparing a dry charged battery for use

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 in-
crease 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 (59.9 °F).
6. If necessary, fill each cell with electrolyte until the elec-
trolyte is just below split ring at the bottom of the cell
opening.
48083741_EN 31/07/2018
55.3 [55.302] / 10
Index
Battery - 302
Battery - Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Battery - Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Battery - Visual inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
48083741_EN 31/07/2018
55.3 [55.302] / 11
48083741_EN 31/07/2018
55.3 [55.302] / 12
Cab controls - 512

48083741_EN 31/07/2018
55.4 [55.512] / 1
Contents
Cab controls - 512
SERVICE
Joystick and Electric Hydraulic (EH) control

Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Remove (Two/three control levers) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Install (Two/three control levers) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
48083741_EN 31/07/2018
55.4 [55.512] / 2
Electrical systems - Cab controls
Joystick and Electric Hydraulic (EH) control - Remove

Joystick removal
bucket to the floor.
2. Stop the engine. Make sure the parking brake is ap-
plied.
3. Wait a few seconds and turn the ignition key to the ON
position. Move the joystick in both directions several
times to relieve pressure. Turn the ignition key to the
OFF position.
RCPH10WHL106AAH 1
5. Remove the three lower armrest mounting bolts (1) and

washers (2) on the right-hand side of the armrest (3).
6. Lift the arm pad to the top of its adjustment. Reach
the latch located under the arm pad and push the latch
forward to release the mechanism. Turn the arm pad
of 90° to access the two top mounting bolts (1) and
washers (2).
7. Remove the two top mounting bolts (1) and the washer
(2).
LEIL16WHL0484BB 2
48083741_EN 31/07/2018
55.4 [55.512] / 3
8. Remove the left-hand shell (1) by removing the three

mounting screws (2) and washers (3) located on the
outside of the left-hand shell.
9. Remove the bolt (4) under the arm pad.
LEIL16WHL0485AB 3
10. Remove the right-hand shell (1) by removing the four

mounting screws (2) and bolt (3) from the main sup-
port bracket (4).
LEIL16WHL0486AB 4
11. Remove the bezel (1) by removing the six screws (2)
from the back of the bezel.
Disconnect the wire harness from the back of bezel
(1).
LEIL16WHL0487AB 5
12. Remove the joystick (1) from the mounting bracket (2)
by removing the four flange nuts (3).
LEIL17WHL1627AB 6
48083741_EN 31/07/2018
55.4 [55.512] / 4
Joystick and Electric Hydraulic (EH) control - Install

1. Install the joystick (1) to the joystick mounting bracket
(2) by using the flange nuts (3).
LEIL17WHL1627AB 1
2. Install the bezel (1) to the joystick mounting bracket (2)

using the same six screws (3) previously removed.
3. Plug the wire harness into the joystick connector (see
the arrow).
LEIL16WHL0487AB 2
4. Install the right-hand shell (1) to the support bracket (4),

using the four mounting screws (2) and bolt (3).
LEIL16WHL0486AB 3
5. Reinstall the left-hand shell (1) reusing the bolt (4), and
then the three bolts (2) and washers (3).
LEIL16WHL0485AB 4
48083741_EN 31/07/2018
55.4 [55.512] / 5
6. Reinstall the two mounting bolts (1) and washers (2)

located on the top side of the armrest, and then the
three bolts (1) and washers (2) located on the lower
side of the armrest.
LEIL16WHL0489BB 5
RCPH10WHL106AAH 6
48083741_EN 31/07/2018
55.4 [55.512] / 6
Joystick and Electric Hydraulic (EH) control - Remove (Two/three

control levers)
bucket to the floor.
2. Stop the engine. Make sure the parking brake is ap-
plied.
3. Wait a few seconds and turn the ignition key to the
ON position. Move the two/three control levers in both
directions several times to relieve any pressure. Turn
the ignition key to the OFF position.
RCPH10WHL106AAH 1
5. Remove the three lower armrest mounting bolts (1) and

washers (2) on the right-hand side of the armrest (3).
6. Lift the arm pad to the top of its adjustment. Reach
the latch located under the arm pad and push the latch
forward to release the mechanism.
Turn the arm pad of 90° to access the two top mounting
bolts (1) and washers (2).
7. Remove the two top mounting bolts (1) and the washer
(2).
LEIL16WHL0483BB 2
48083741_EN 31/07/2018
55.4 [55.512] / 7
8. Remove the left-hand shell (1) by removing the three

mounting screws (2) and washers (3) located on the
outside of the left-hand shell.
9. Remove the bolt (4) under the arm pad.
LEIL16WHL0475AB 3
10. Remove the right-hand shell (1) by removing the four

mounting screws (2) and bolt (3) from the main sup-
port bracket (4).
LEIL16WHL0476AB 4
11. Disconnect the wire harness (1) from the main

bracket.
LEIL17WHL1624AB 5
12. Remove the control lever mounting bracket (1) from

the main bracket (2) by removing the bolts (3) and bolt
(4).
LEIL16WHL0478AB 6
48083741_EN 31/07/2018
55.4 [55.512] / 8
Two control levers

13. Take off the bezel (1) by removing the six screws (2)
LEIL17WHL1625AB 7
14. Disassemble the boom lever (1) and bucket lever (2)
from bracket (5) by removing the light screws (3) and
washers (4).
LEIL16WHL0480AB 8
Three control levers

13. Take off the bezel (1) by removing the six screws (2)
LEIL16WHL0481AB 9
14. Disassemble the boom lever (1) and bucket lever (2)
from the bracket (5), by removing the twelve screws
(3) and washers (4).
15. Unplug the harness from the auxiliary function control
lever (6), and then disassemble the auxiliary function
control lever (6) from bracket (5) as well.
LEIL17WHL1626AB 10
48083741_EN 31/07/2018
55.4 [55.512] / 9
Joystick and Electric Hydraulic (EH) control - Install (Two/three

control levers)
Two control levers
1. Reassemble the boom lever (1) and bucket lever (1) to
the mounting bracket (5), by using the eight screws (3)
and washers (4).
LEIL16WHL0480AB 1
2. Plug the harness (1) by mounting clips to the main

bracket.
LEIL17WHL1624AB 2
3. Install the bezel (1) to the mounting bracket by using

the six screws (2) from the back of bezel.
LEIL17WHL1625AB 3
48083741_EN 31/07/2018
55.4 [55.512] / 10
Three control levers

1. Install the boom lever (1), bucket lever (2) and auxiliary
function control lever (6) to the mounting bracket (5),
by using the twelve screws (3) and washers (4).
LEIL17WHL1626AB 4
2. Plug the harness (1) by mounting clips to the main

bracket, and than plug the auxiliary harness mounting
clip to the main bracket.
LEIL17WHL1624AB 5
3. Reinstall the bezel (1) to the mounting bracket by using

the six screws (2) from the back of bezel.
LEIL16WHL0481AB 6
4. Reinstall the right-hand shell (1) to the main support

bracket (4), by using the four screws (2) and bolt (3).
LEIL16WHL0476AB 7
48083741_EN 31/07/2018
55.4 [55.512] / 11
5. Reinstall the left-hand shell (1). Reuse the bolt (4) and
three bolts (2) and washers (3).
LEIL16WHL0475AB 8
6. Reinstall the armrest (3) to the seat. Reuse the five

bolts (1) and washers (2).
LEIL16WHL0483BB 9
RCPH10WHL106AAH 10
48083741_EN 31/07/2018
55.4 [55.512] / 12
Index
Cab controls - 512

Joystick and Electric Hydraulic (EH) control - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Joystick and Electric Hydraulic (EH) control - Install (Two/three control levers) . . . . . . . . . . . . . . . . . 10
Joystick and Electric Hydraulic (EH) control - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Joystick and Electric Hydraulic (EH) control - Remove (Two/three control levers) . . . . . . . . . . . . . . . 7
48083741_EN 31/07/2018
55.4 [55.512] / 13
48083741_EN 31/07/2018
55.4 [55.512] / 14
Heating, Ventilation, and Air-Conditioning (HVAC) control system -

050

48083741_EN 31/07/2018
55.5 [55.050] / 1
Contents
Heating, Ventilation, and Air-Conditioning (HVAC) control system - 050
SERVICE
Blower
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
48083741_EN 31/07/2018
55.5 [55.050] / 2
Electrical systems - Heating, Ventilation, and Air-Conditioning (HVAC) control system
Blower - Remove
Discharge the air conditioning system following the
2. Turn the timed disconnect switch to the OFF position
(arrows).
LEIL16WHL1190AB 1

LEIL16WHL1209AB 2
LEIL18WHL0452AB 3
48083741_EN 31/07/2018
55.5 [55.050] / 3
7. Remove the three retaining knobs that hold the cab air
recirculation filter cover in place.
LEIL18WHL0453AB 4
LEIL18WHL0454AB 5
9. Remove the 16 screws holding the cover case. Re-

move the cover case from the machine.
figure 6.
LEIL18WHL0459AB 6
10. Disconnect the electrical connector from the blower.
LEIL18WHL0460AB 7
48083741_EN 31/07/2018
55.5 [55.050] / 4
11. Remove the two screws to unfix the blower assembly.
LEIL18WHL0461AB 8
12. Extract not completely the blower assembly to discon-

nect the electrical connector.
Remove the blower assembly from the machine.
LEIL18WHL0467AB 9
13. On bench, remove the four screws to separate the

blower from the flange.
LEIL18WHL0462AB 10
14. Separate the blower.
LEIL18WHL0463AB 11
48083741_EN 31/07/2018
55.5 [55.050] / 5
Blower - Install
1. On bench, fasten the blower to the flange with four
screws.
LEIL18WHL0462AB 1
2. Insert not completely the blower assembly in the case.

Connect the electrical connector.
LEIL18WHL0467AB 2
3. Insert completely the blower assembly in the case. In-

stall the two screws to fix the blower assembly.
LEIL18WHL0461AB 3
4. Connect the electrical connector to the blower.
LEIL18WHL0460AB 4
48083741_EN 31/07/2018
55.5 [55.050] / 6

with 16 screws.
figure 5.
LEIL18WHL0459AB 5
LEIL18WHL0454AB 6
retaining knobs.
LEIL18WHL0453AB 7
LEIL18WHL0452AB 8
48083741_EN 31/07/2018
55.5 [55.050] / 7
LEIL16WHL1209AB 9

LEIL16WHL1190AB 10

12. Put the timed disconnect switch to ON position.
48083741_EN 31/07/2018
55.5 [55.050] / 8
Index
Heating, Ventilation, and Air-Conditioning (HVAC) control system - 050

Blower - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Blower - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
48083741_EN 31/07/2018
55.5 [55.050] / 9
48083741_EN 31/07/2018
55.5 [55.050] / 10
Loader arm and bucket control system - 415

48083741_EN 31/07/2018
55.6 [55.415] / 1
Contents
SERVICE
Loader arm and bucket control system

Remove - Electro-Hydraulic (EH) lift sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Disassemble - Electro-Hydraulic (EH) lift sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Assemble - Electro-Hydraulic (EH) lift sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Install - Electro-Hydraulic (EH) lift sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Check - Electro-Hydraulic (EH) lift sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Remove - Electro-Hydraulic (EH) tilt sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Disassemble - Electro-Hydraulic (EH) tilt sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Assemble - Electro-Hydraulic (EH) tilt sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Install - Electro-Hydraulic (EH) tilt sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Check - Electro-Hydraulic (EH) tilt sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
48083741_EN 31/07/2018
55.6 [55.415] / 2
Electrical systems - Loader arm and bucket control system
Loader arm and bucket control system - Remove - Electro-Hydraulic

(EH) lift sensor
ing brake.
2. With the engine stopped, move the joystick or control
lever(s) to release any pressure in the hydraulic circuit.
3. Locate the Electro-Hydraulic (EH) lift sensor assembly
on the right-hand of the front frame.
Disconnect the electrical connector X-BOA (arrow)
from the Electro-Hydraulic (EH) lift sensor (1).
LEIL16WHL2283AA 1
4. Loosen and remove the three bolts (5), washers (4) and
spacers (3) that fix the EH lift sensor assembly (1) to the
front frame.
5. Remove the hexagon socket screw (2) from the arm
fork of the EH lift sensor assembly (1). Remove the EH
lift sensor assembly (1) from the machine.
LEIL17WHL0540AB 2
48083741_EN 31/07/2018
55.6 [55.415] / 3
Loader arm and bucket control system - Disassemble -

Electro-Hydraulic (EH) lift sensor
LEIL17WHL0543FB 1
1. Loosen and remove the two bolts (6), the four washers
(4), the two spacers (2) and the two nuts (5). Separate
the Electro-Hydraulic (EH) lift sensor (1) from the cover
(3).
2. Loosen and remove the bolt (9), the two washers (8),
and the nut (10) to unfix the EH lift sensor (1) from the
arm fork (7).
48083741_EN 31/07/2018
55.6 [55.415] / 4
Loader arm and bucket control system - Assemble -

Electro-Hydraulic (EH) lift sensor
Prior operation:
Loader arm and bucket control system - Disassemble - Electro-Hydraulic (EH) lift sensor (55.415)
LEIL17WHL0543FB 1
1. Use the bolt (9), the two washers (8) and the nut (10) to
secure the Electro-Hydraulic (EH) lift sensor (1) to the
arm fork (7). Tighten to 2.9 – 4.0 N·m (2.14 – 2.95 lb
ft)
NOTE: after installation, make sure that the flat side of sen-
sor pin (see arrow) lines up with bottom of arm fork (7).
2. Use the two bolts (6), the four washers (4), the two
spacers (2) and the two nuts (5) to assembly the EH
lift sensor (1) to the sensor cover (3).
48083741_EN 31/07/2018
55.6 [55.415] / 5
Loader arm and bucket control system - Install - Electro-Hydraulic

(EH) lift sensor
parking brake
3. Fix the arm fork of the Electro-Hydraulic (EH) lift sensor
assembly (1) with the hexagonal socket screw (2) on
right-hand side of the front frame.
4. Use the three bolts (5), the three washers (4) and the
three spacers (3) to install the EH lift sensor assembly
(1) to the front frame.
LEIL17WHL0540AB 1
5. Connect the electrical connector X-BOA (arrow) to the

EH lift assembly sensor (1).
LEIL16WHL2283AA 2
48083741_EN 31/07/2018
55.6 [55.415] / 6
Loader arm and bucket control system - Check - Electro-Hydraulic

(EH) lift sensor
NOTE: set the input voltage according to the “Sensor I/O table”
Check the functional output of the Electro-Hydraulic
(EH) lift assembly sensor with the next steps:
1. Check the assembly output at 0°. Check the output
voltage (see “Sensor I/O Table”).
2. Rotate the assembly 45° counter-clockwise. Check
the output voltage (see “Sensor I/O Table”).
3. Rotate the assembly back to 0°. Check the output
Sensor I/O Table

Sensor input 5V ± 0.25 V
(A) 0° Output 50 % V ± 0.20 V
(B) 45°Clockwise Output 88.6 % V ± 0.20 V
(C) 45°Counter clockwise Output 11.4 % V ± 0.20 V
LEIL17WHL0542FB 1
48083741_EN 31/07/2018
55.6 [55.415] / 7
Loader arm and bucket control system - Remove - Electro-Hydraulic

(EH) tilt sensor
ing brake.
3. Locate the Electro-Hydraulic (EH) tilt sensor assembly
on the right-hand of the front frame.
LEIL17WHL0547AB 1
4. Disconnect the electrical connector X-BUA from the

Electro-Hydraulic (EH) tilt sensor.
LEIL17WHL2228AB 2
5. Loosen and remove the two bolts (5), washers (4), and
spacers (3) that fix the EH tilt sensor assembly (1) to
the front frame.
6. Remove the hexagon socket screw (2) from the arm
fork of the EH tilt sensor assembly (1). Remove the EH
tilt sensor assembly (1) from the machine.
LEIL17WHL0541AB 3
48083741_EN 31/07/2018
55.6 [55.415] / 8
Loader arm and bucket control system - Disassemble -

Electro-Hydraulic (EH) tilt sensor
LEIL17WHL2229FB 1
1. Loosen and remove the two bolts (8),the four washers

(7), and nuts (9). Separate the Electro-Hydraulic (EH)
tilt sensor (1) from the cover (6).
2. Loosen and remove the bolt (4), the two washers (3),
and the nut (5) to unfix the EH tilt sensor (1) from the
arm fork (2).
48083741_EN 31/07/2018
55.6 [55.415] / 9
Loader arm and bucket control system - Assemble -

Electro-Hydraulic (EH) tilt sensor
LEIL17WHL2229FB 1
1. Use the bolt (4), the two washers (3), and the nut (5) to
secure the Electro-Hydraulic (EH) tilt sensor (1) to the
arm fork (2).
Tighten to 2.9 – 4 N·m (2.14 – 2.95 lb ft).
NOTE: after installation, make sure that the flat side of sen-
sor pin (see arrow) lines up with the bottom of the arm fork
(2).
2. Use the two bolts (8), the four washers (7), and the two
nuts (9) to assembly the EH tilt sensor (1) to the sensor
cover (6).
48083741_EN 31/07/2018
55.6 [55.415] / 10
Loader arm and bucket control system - Install - Electro-Hydraulic

(EH) tilt sensor
bucket to the ground. Stop the engine and make sure
the parking brake is applied.
3. Fix the arm fork of the Electro-Hydraulic (EH) tilt sen-
sor assembly (1) to the front frame with the hexagonal
socket screw (2).
4. Use the two bolts (5), the two washers (4), and the two
spacers (3) to install the EH tilt sensor assembly (1) to
the front frame.
LEIL17WHL0541AB 1
5. Connect the electrical connector X-BUA to the EH tilt

sensor.
LEIL17WHL2228AB 2
48083741_EN 31/07/2018
55.6 [55.415] / 11
Loader arm and bucket control system - Check - Electro-Hydraulic

(EH) tilt sensor
NOTE: set the input voltage according to the “Sensor I/O Table”.
Check the functional output of the Electro-Hydraulic
(EH) tilt sensor with the next steps:
1. Check the assembly output at 0°. Check the output
2. Rotate the assembly 45° counter-clockwise. Check
the output voltage (see “Sensor I/O Table”).
3. Rotate the assembly back to 0°. Check the output
Sensor I/O Table

Sensor input 5V ± 0.25 V
(A) 0° Output 50% Vs ± 0.20 V
(B) 45°Clockwise Output 88.6% Vs ± 0.20 V
(C) 45°Counter clockwise Output 11.4% Vs ± 0.20 V
LEIL17WHL1661FB 1
48083741_EN 31/07/2018
55.6 [55.415] / 12
Index

Loader arm and bucket control system - Assemble - Electro-Hydraulic (EH) lift sensor . . . . . . . . . . 5
Loader arm and bucket control system - Assemble - Electro-Hydraulic (EH) tilt sensor . . . . . . . . . . 10
Loader arm and bucket control system - Check - Electro-Hydraulic (EH) lift sensor . . . . . . . . . . . . . 7
Loader arm and bucket control system - Check - Electro-Hydraulic (EH) tilt sensor . . . . . . . . . . . . . 12
Loader arm and bucket control system - Disassemble - Electro-Hydraulic (EH) lift sensor . . . . . . . . 4
Loader arm and bucket control system - Disassemble - Electro-Hydraulic (EH) tilt sensor . . . . . . . . 9
Loader arm and bucket control system - Install - Electro-Hydraulic (EH) lift sensor . . . . . . . . . . . . . . 6
Loader arm and bucket control system - Install - Electro-Hydraulic (EH) tilt sensor . . . . . . . . . . . . . . 11
Loader arm and bucket control system - Remove - Electro-Hydraulic (EH) tilt sensor . . . . . . . . . . . . 8
Loader arm and bucket control system - Remove - Electro-Hydraulic (EH) lift sensor . . . . . . . . . . . . 3
48083741_EN 31/07/2018
55.6 [55.415] / 13
48083741_EN 31/07/2018
55.6 [55.415] / 14
Camera - 530

48083741_EN 31/07/2018
55.7 [55.530] / 1
Contents
Camera - 530
SERVICE
Camera
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Monitor
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
48083741_EN 31/07/2018
55.7 [55.530] / 2
Electrical systems - Camera
Camera - Remove
bucket to the ground. Put the articulation lock in the
LOCKED position.
LEIL16WHL0048AB 1
2. Locate the rearview camera on the rear grill of the en-

gine hood.
LEIL16WHL0848AB 2
3. Raise the engine hood and turn the timed disconnect

switch to the OFF position.
RCPH10WHL106AAH 3
4. Remove the cable ties (2) to separate the extension

cable (3) of the rearview camera from the rear grill.
Disconnect the connector (1) of the extension cable (3)
of the rearview camera.
LEIL16WHL0849AB 4
48083741_EN 31/07/2018
55.7 [55.530] / 3
5. Loosen the four flange bolts (1), the eight washers (2)
and the four nuts (3) to remove the mounting bracket
(4) from the rear grill.
LEIL18WHL0864AB 5
6. Loosen the flange bolts (1) and the four nuts (3) to
remove the cover camera (4) from the rear grill.
LEIL18WHL0865AB 6
7. Remove the two hexagonal socket screw (1), the gas-

ket (2), the two washer (3) and the two nuts (4) to sepa-
rate the rearview camera (5) from the mounting bracket
(6).
8. Remove the grommet (7), installed on the cable (8)of
the rearview camera (5), from the mounting bracket (6).
LEIL18WHL0866AB 7
9. Remove the rearview camera.
LEIL16WHL0959AA 8
48083741_EN 31/07/2018
55.7 [55.530] / 4
Camera - Install
Prior operation:
Camera - Remove (55.530)
1. Place the grommet (7), installed on the cable (8) of

the rearview camera (5), on the hole in the mounting
bracket (6).
2. Use the two hexagonal socket screw (1), the gasket
(2), the two washer (3) and the two nuts (4) to fix the
rearview camera (5) to the mounting bracket (6).
Tighten the two hexagonal socket screw (1) to a torque
of 0.8 – 1.0 N·m (0.6 – 0.7 lb ft).
Tighten the two nuts (4) with a torque of 5.0 – 6.0 N·m
(3.7 – 4.4 lb ft).
NOTE: the gasket (2), the two washer (3) and the two nuts
(4) are provided with the camera.
LEIL18WHL0863AB 1
NOTE: the inclination of the installed rearview camera (3)

must be 80 – 84°.
Align dots (9) and (10) with indention on top bracket for
proper vertical and horizontal camera (3) alignment.
LEIL16WHL0846AB 2
3. Use the four flange bolts (1) , the eight washers (2) and
the four nuts (3) to install the mounting bracket (4), with
the rearview camera to the rear grill.
LEIL18WHL0864AB 3
4. Use the flange bolts (1) and the four nuts (3) to install
the cover camera (4) to the rear grill.
LEIL18WHL0865AB 4
48083741_EN 31/07/2018
55.7 [55.530] / 5
5. Route the extension cable (3) of the rearview camera

inside the engine hood. Connect the connector (1).
Use new cable ties (2) to secure the extension cable
(3) of the rearview camera to the rear grill inner side.
LEIL16WHL0849AB 5
6. Lower the engine hood. Turn the timed disconnect

switch to the ON position.
LEIL16WHL0848AB 6
48083741_EN 31/07/2018
55.7 [55.530] / 6
Monitor - Remove
1. Locate the multifunction display inside the cab.
LEIL16WHL0996AB 1
2. Disconnect the connector (4).

3. Remove the three bolts (2), the three washers (3) to
separate the multifunction display (1) from the related
support.
LEIL16WHL0854AB 2
48083741_EN 31/07/2018
55.7 [55.530] / 7
Monitor - Install
1. Connect the connector (4).
2. Tighten the three bolts (2) and the three washers (3) to
install the multifunction display (1) to the related sup-
port.
LEIL16WHL0854AB 1
48083741_EN 31/07/2018
55.7 [55.530] / 8
Index
Camera - 530
Camera - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Camera - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Monitor - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Monitor - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
48083741_EN 31/07/2018
55.7 [55.530] / 9
48083741_EN 31/07/2018
55.7 [55.530] / 10
FAULT CODES - DTC

48083741_EN 31/07/2018
55.8 [55.DTC] / 1
Contents
FAULT CODES - DTC
DIAGNOSTIC
91.19 - Engine Source Address Cyclic Timeout [UCM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

96-00 - Fuel Level Sensor Over Resistance [UCM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
96-01 - Fuel Level Sensor Under Resistance [UCM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
110-00 - Engine coolant temperature is very high [GHMI - Faults list] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
110-16 - Engine coolant temperature is high [GHMI - Faults list]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
158-03 - Short to Power at Key Switch Crank [UCM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
177-00 - Transmission oil temperature is very high [GHMI - Faults list] . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
177-16 - Transmission oil temperature is high [GHMI - Faults list] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
3997-03 - Electrical Accessory Power Relay - Short Circuit to B+ [SFB] . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
3997-05 - Electrical Accessory Power Relay - Open Circuit [SFB] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
3997-06 - Electrical Accessory Power Relay - Short Circuit to GND [SFB] . . . . . . . . . . . . . . . . . . . . . . . . . 28
5000-12 - Logical error at gear range signal [TCU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
5010-12 - Logical error at direction select signal [TCU]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
5110-03 - Short circuit to battery voltage or open circuit at transmission sump temperature sensor input
[TCU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
5110-04 - Short circuit to ground at transmission sump temperature sensor input [TCU] . . . . . . . . . . . . . 37
5120-03 - Short circuit to battery voltage or open circuit at retarder / torque converter temperature sensor
input [TCU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
5120-04 - Short circuit to ground at retarder / torque converter temperature sensor input [TCU] . . . . . . 41
5140-03 - Short circuit to battery voltage or open circuit at engine speed input [TCU] . . . . . . . . . . . . . . . 43
5140-04 - Short circuit to ground at engine speed input [TCU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
5140-12 - Logical error at engine speed input [TCU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
5150-03 - Short circuit to battery voltage or open circuit at turbine speed input [TCU] . . . . . . . . . . . . . . . 49
5150-04 - Short circuit to ground at turbine speed input [TCU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
5150-12 - Logical error at turbine speed input [TCU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
5160-03 - Short circuit to battery voltage or open circuit at internal speed input [TCU] . . . . . . . . . . . . . . . 55
5160-04 - Short circuit to ground at internal speed input [TCU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
5160-12 - Logical error at internal speed input [TCU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
5170-03 - Short circuit to battery voltage or open circuit at output speed input [TCU] . . . . . . . . . . . . . . . . 61
5170-04 - Short circuit to ground at output speed input [TCU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
5170-12 - Logical error at output speed input [TCU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
5180-02 - Output speed zero doesn't fit to other speed signals [TCU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
48083741_EN 31/07/2018
55.8 [55.DTC] / 2
5211-09 - Speedlimit_Prop1 Can message timeout [TCU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
5212-09 - Speedlimit_Prop2 Can message timeout [TCU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
521-03 - Inch Pedal Position Sensor over voltage [UCM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
521-04 - Inch Pedal Position Sensor under voltage [UCM]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
619-03 - Short to Power at Park Brake High Side Driver [UCM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
619-04 - Short to Ground at Park Brake High Side Driver [UCM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
619-05 - Open Circuit at Park Brake High Side Driver [UCM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
624-03 - Short to Power at Warning LED High Side Driver [UCM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
624-04 - Short to Ground at Warning LED High Side Driver [UCM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
624-05 - Open Circuit at Warning LED High Side Driver [UCM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
746-03 - Short to Power at Differential Lock Valve [UCM]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
746-04 - Short to Ground at Differential Lock Valve [UCM]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
746-05 - Open Circuit at Differential Lock Valve [UCM]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
1049-01 - Front Brake Accumulator Low Pressure [UCM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
1049-03 - Short to Power at Front Brake Accumulator Pressure Sensor [UCM]. . . . . . . . . . . . . . . . . . . . . 96
1049-04 - Short to Ground at Front Brake Accumulator Pressure Sensor [UCM]. . . . . . . . . . . . . . . . . . . . 97
1052-01 - Rear Brake Accumulator Low Pressure [UCM]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
1052-03 - Short to Power at Rear Brake Accumulator Pressure Sensor [UCM] . . . . . . . . . . . . . . . . . . . . 101
1052-04 - Short to Ground at Rear Brake Accumulator Pressure Sensor [UCM] . . . . . . . . . . . . . . . . . . . 103
1565-02 - Armrest Signals not plausible [UCM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
2580 - Low Brake Pressure [GHMI - Faults list] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
2661-14 - Roller X Hall cell plausibility error [Keypad and Joystick] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
2662-03 - Hall cell X1/X2 voltage abnormally high [Keypad and Joystick]. . . . . . . . . . . . . . . . . . . . . . . . . 113
2662-04 - Hall cell X1/X2 voltage abnormally low [Keypad and Joystick] . . . . . . . . . . . . . . . . . . . . . . . . . 114
2662-13 - Roller X out of neutral at power-up [Keypad and Joystick] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
2662-14 - Roller X Hall cell plausibility error [Keypad and Joystick] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
2663-03 - Hall cell Y1/Y2 voltage abnormally high [Keypad and Joystick]. . . . . . . . . . . . . . . . . . . . . . . . . 119
2663-04 - Hall cell Y1/Y2 voltage abnormally low [Keypad and Joystick] . . . . . . . . . . . . . . . . . . . . . . . . . 120
2663-13 - Roller Y out of neutral at power-up [Keypad and Joystick] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
2663-14 - Roller Y Hall cell plausibility error [Keypad and Joystick] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
2664-03 - Hall cell Z1/Z2 voltage abnormally high [Keypad and Joystick] . . . . . . . . . . . . . . . . . . . . . . . . . 123
2664-04 - Hall cell Z1/Z2 voltage abnormally low [Keypad and Joystick]. . . . . . . . . . . . . . . . . . . . . . . . . . 126
2664-13 - Roller Z out of neutral at power-up [Keypad and Joystick] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
2664-14 - Roller Z Hall cell plausibility error [Keypad and Joystick] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
3509-02 - 5V internal fault [Keypad and Joystick] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
3651-02 - Primary FNR Fault [UCM]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
5123-19 - Display Source Address Cyclic Timeout [UCM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
5220-09 - Brakes timeout [TCU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
5230-09 - Zftc1 Timeout [TCU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
5260-09 - Dct1 Timeout = Vehicle_1 Timeout [TCU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
5270-09 - Jss Timeout =Vehicle_2 Timeout [TCU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
5271-09 - DISPID1 CAN message timeout [TCU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
48083741_EN 31/07/2018
55.8 [55.DTC] / 3
5280-09 - Engine Conf timeout [TCU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
5290-09 - EEC1 Timeout [TCU]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
5300-09 - EEC3 Timeout [TCU]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
5310-09 - Engine speed limit function during gearshifts does not work properly [TCU]. . . . . . . . . . . . . . 151
5370-02 - Shift lever signal defective [TCU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
5390-02 - Aeb request signal defective [TCU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
5420-02 - Starting gear signal defective [TCU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
5430-02 - Enginge torque signal defective [TCU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
5431-09 - Engine speed limit function does not work properly during stall or output speed limit function
[TCU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
5440-02 - Reference engine torque signal defective [TCU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
5450-02 - Actual engine torque signal defective [TCU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
5460-02 - Nom friction torque signal defective [TCU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
5470-02 - EEC2 Timeout [TCU]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
5480-03 - Short circuit to battery voltage at clutch K1 [TCU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
5480-04 - Short circuit to ground at clutch K1 [TCU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
5480-05 - Open circuit at clutch K1 [TCU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
5520-03 - Short circuit to battery voltage at clutch Kv [TCU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
5520-04 - Short circuit to ground at clutch Kv [TCU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
5520-05 - Open circuit at clutch Kv [TCU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
5530-03 - Short circuit to battery voltage at clutch Kr [TCU]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
5530-04 - Short circuit to ground at clutch Kr [TCU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
5530-05 - Open circuit at clutch Kr [TCU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
5536-00 - Hydraulic oil temperature is very high [GHMI - Faults list] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
5536-16 - Hydraulic oil temperature is high [GHMI - Faults list] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
5540-03 - Short circuit to battery voltage at converter clutch (regulator valve) [TCU] . . . . . . . . . . . . . . . 195
5540-04 - Short circuit to ground at converter clutch (regulator valve) [TCU] . . . . . . . . . . . . . . . . . . . . . . 197
5540-05 - Open circuit at converter clutch (regulator valve) [TCU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
5560-03 - Short circuit to battery voltage at relay reverse warning alarm [TCU]. . . . . . . . . . . . . . . . . . . . 201
5560-05 - Open circuit at relay reverse warning alarm [TCU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
5657-02 - Incorrect Anti-tamper checksum sent by Engine Controller [UCM] . . . . . . . . . . . . . . . . . . . . . . 205
5657-09 - Anti-tamper checksum not sent by Engine Controller [UCM] . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
5660-02 - Slippage at clutch K1 [TCU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
5680-02 - Slippage at clutch Kv [TCU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
48083741_EN 31/07/2018
55.8 [55.DTC] / 4
5685-02 - Slippage at clutch Kr [TCU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
5700-00 - Overtemp Sump [TCU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
5710-00 - Overtemp Retarder [TCU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
5720-00 - Overspeed Engine [TCU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221
5730-00 - Differential pressure oil filter [TCU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223
5740-02 - Slippage at converter lockup clutch [TCU]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225
5745-15 - Overspeed output [TCU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226
5755-15 - Transmission input torque overload [TCU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228
5760-00 - Overtemp converter output [TCU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230
5810-03 - Short circuit to battery voltage at power supply for sensors [TCU] . . . . . . . . . . . . . . . . . . . . . . 231
5810-04 - Short circuit to ground at power supply for sensors [TCU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232
5820-03 - High voltage at battery [TCU]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233
5820-04 - Low voltage at battery [TCU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234
5830-02 - Error at valve power supply VPS1 [TCU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235
5840-02 - Error valve power supply VPS2 [TCU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236
5860-03 - Short circuit to battery voltage at display output [TCU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237
5860-04 - Short circuit to ground at display output [TCU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239
5880-02 - Illegal ID request via Can [TCU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241
5890-02 - General EEPROM fault [TCU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242
5900-13 - Configuration lost [TCU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243
5910-13 - Application error [TCU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244
5930-07 - Clutch failure [TCU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245
5930-13 - Clutch adjustment data lost or inchpedal calibration data lost [TCU] . . . . . . . . . . . . . . . . . . . . 246
5940-11 - Substitute clutch control [TCU]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247
65562-03 - Terminal 50 - Always On [ECU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248
65564-03 - Water detected in Fuel [ECU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249
65574-03 - Engine Controller battery voltage too High [ECU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251
65574-04 - Engine Controller battery voltage too Low [ECU]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253
65576-03 - Engine Controller High side supply #2 to Grid heater - Short to battery [ECU]. . . . . . . . . . . 255
65579-02 - Engine Controller Grid Heater relay circuit driver - No Load [ECU] . . . . . . . . . . . . . . . . . . . . 256
65579-03 - Engine Controller Grid Heater relay circuit driver - Short circuit to Battery [ECU] . . . . . . . . 258
65579-04 - Engine Controller Grid Heater relay circuit driver - Short circuit to Ground [ECU] . . . . . . . . 260
65585-03 - Engine Coolant Temperature Sensor - Signal Above Range Max [UCM] . . . . . . . . . . . . . . . 262
65585-04 - Engine Coolant Temperature Sensor - Signal Below Range Min [UCM] . . . . . . . . . . . . . . . . 264
65585-12 - Engine Coolant Temperature Sensor - Signal Not Plausible [UCM] . . . . . . . . . . . . . . . . . . . . 266
65596-03 - Ambient Air Temperature Sensor failure - Signal too high [UCM] . . . . . . . . . . . . . . . . . . . . . . 268
65596-04 - Ambient Air Temperature Sensor failure - Signal too low [UCM] . . . . . . . . . . . . . . . . . . . . . . . 270
65646-03 - Minimum Number of Injections Not Reached – Stop Engine [ECU] . . . . . . . . . . . . . . . . . . . . 272
65660-02 - Injection Processor (CY33X) Error – Injections Limited By Software [ECU] . . . . . . . . . . . . . 273
65660-03 - Injection Processor (CY33X) Error – Internal Reset / Clock Loss / Voltage Too Low [ECU] 274
65660-04 - Injection Processor (CY33X) Error – Unlocked / Initialization Failure [ECU] . . . . . . . . . . . . . 276
65660-12 - Injection Processor (CY33X) Error – SPI Communication Failure [ECU]. . . . . . . . . . . . . . . . 277
48083741_EN 31/07/2018
55.8 [55.DTC] / 5
65683-03 - Turbine speed - Signal too high [TCU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 278
65683-04 - Turbine speed - Signal too low [TCU]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280
65694-04 - Torque Reduction due to Smoke Limitation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282
65717-02 - Timeout of CAN Message VCM2EDC [ECU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 283
65734-03 - Timeout of CAN message TSC1-PE Torque (When Active) [ECU] . . . . . . . . . . . . . . . . . . . . . 286
65736-03 - Timeout of CAN message TSC1-VE Speed (When Active) [ECU] . . . . . . . . . . . . . . . . . . . . . 289
65745-03 - ECM Internal SPI Communication Error – CJ940 [ECU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 292
65747-12 - ECM (Locked) Recovery Occurred [ECU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 293
65748-12 - ECM Processor – Watchdog Not Plausible [ECU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 294
65749-02 - Shutoff Paths During Initialization – Supply Voltage Too High [ECU] . . . . . . . . . . . . . . . . . . . 295
65749-04 - Shutoff Paths During Initialization - Watchdog [ECU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 296
65749-12 - Shutoff Paths During Initialization – Supply Voltage Too Low [ECU] . . . . . . . . . . . . . . . . . . . 297
65750-12 - TPU Monitoring – Time Deviation between TPU and System Not Plausible [ECU] . . . . . . . 298
65752-12 - Controller Watchdog – SPI Communication Failure [ECU]. . . . . . . . . . . . . . . . . . . . . . . . . . . . 299
65753-02 - ADC Monitoring – Test Impulse Error [ECU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300
65753-03 - ADC Monitoring – Reference Voltage Too High [ECU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301
65753-04 - ADC Monitoring – Reference Voltage Too Low [ECU]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 302
65753-12 - ADC Monitoring – Queue Error [ECU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303
65763-03 - Overrun Monitoring – Injection Time Too Long [ECU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 304
65764-03 - Redundant Engine Speed in Overrun Monitoring – Speed Signal Not Plausible [ECU] . . . 305
65765-03 - Engine regulated 12 Volt sensor supply - Voltage High [ECU]. . . . . . . . . . . . . . . . . . . . . . . . . 306
65765-04 - Engine regulated 12 Volt sensor supply - Voltage Low [ECU] . . . . . . . . . . . . . . . . . . . . . . . . . 308
65766-03 - Sensor Supply Voltage 1 - High [ECU]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 310
65766-04 - Sensor Supply Voltage 1 - Low [ECU] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 312
65769-03 - ECM Internal Supply Voltage Too High – CJ940 Above Limit [ECU] . . . . . . . . . . . . . . . . . . . 322
65770-04 - ECM Internal Supply Voltage Too Low – CJ940 Below Limit [ECU] . . . . . . . . . . . . . . . . . . . . 324
131112-04 - Engine Controller High side supply #2 to Grid heater - Short to ground . . . . . . . . . . . . . . . 326
131122-12 - Coolant Temperature Test Failure [UCM]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 327
131151-03 - Emergency start time expired and shutdown initiated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 330
131196-02 - Injection Processor Error – Test Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 331
131196-03 - Injection Processor Error – Internal Reset / Clock Loss / Voltage Too Low [ECU] . . . . . . . 332
131196-04 - Injection Processor Error – Unlocked / Initialization Failure [ECU] . . . . . . . . . . . . . . . . . . . . 334
131196-12 - Injection Processor Error – SPI Communication Failure [ECU] . . . . . . . . . . . . . . . . . . . . . . . 335
131246-03 - Humidity Sensor possibly saturated with water droplets – Signal Ratio above Limit . . . . 336
131246-04 - Humidity Sensor possibly saturated with water droplets – Signal Ratio below Limit . . . . 337
131252-02 - Timeout of CAN Message BC2EDC2 [ECU]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 338
131270-02 - Timeout of CAN message TSC1-PE Torque (When Inactive) . . . . . . . . . . . . . . . . . . . . . . . . 341
131272-03 - Timeout of CAN Message TSC1-VR (When Active) [ECU] . . . . . . . . . . . . . . . . . . . . . . . . . . 344
48083741_EN 31/07/2018
55.8 [55.DTC] / 6
131283-12 - ECM Recovery which is suppressed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 347
196685-04 - Speed limitation activates torque limitation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 348
196766-04 - Torque limitation due to turbo charger protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 349
196804-02 - CAN message not received from XXXX1 (TSC1-AE passive) [ECU]. . . . . . . . . . . . . . . . . . 350
196808-02 - Timeout of CAN message TSC1-VE Speed (When Inactive) . . . . . . . . . . . . . . . . . . . . . . . . 353
196819-12 - ECU Recovery (Visible) - Recovery Occurred . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 356
262302-04 - Torque Limitation due to Engine Protection (Against Excessive Torque, Engine Overspeed
and Overheat) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 357
262344-02 - Timeout of CAN Message TSC1-VR (When Inactive) [ECU] . . . . . . . . . . . . . . . . . . . . . . . . . 358
393292-04 - Overheat protection activates torque limitation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 361
393374-04 - Torque Limitation due to Fuel Quantity Limitation because of Injection System Errors . . 362
517755-09 - EJM Message Timeout (AUX FNR, AUX I, AUX II) [UCM]. . . . . . . . . . . . . . . . . . . . . . . . . . . 363
517755-19 - BJM Message Timeout (Boom, Bucket, Kick down) [UCM] . . . . . . . . . . . . . . . . . . . . . . . . . . 365
518032-03 - Aux FNR Key Fault [Keypad and Joystick] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 367
518036-03 - Beacon Light Switch Key Fault [Keypad and Joystick] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 368
518047-03 - Declutch Key Fault [Keypad and Joystick] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 370
518052-03 - Differential Lock Up Key Fault [Keypad and Joystick] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 371
518056-03 - Fan Mode Key Fault [Keypad and Joystick] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 372
518058-03 - Float Key Fault [Keypad and Joystick] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 373
518063-03 - Implement Coupler Key Fault [Keypad and Joystick] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 374
518066-03 - Implement Enable Key Fault [Keypad and Joystick] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 375
518069-02 - Joystick Steering Activation Button Signals not plausible [UCM] . . . . . . . . . . . . . . . . . . . . . 376
518070-03 - Key_2 Key Fault [Keypad and Joystick] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 379
518074-03 - Key_18 Key Fault [Keypad and Joystick] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 380
518078-03 - Key_20 Key Fault [Keypad and Joystick] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 381
518083-03 - Park Brake Key Fault [Keypad and Joystick] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 382
518089-03 - Short to Power at Ride Control Valve High Side Driver [UCM] . . . . . . . . . . . . . . . . . . . . . . . 383
518089-04 - Short to Ground at Ride Control Valve High Side Driver [UCM] . . . . . . . . . . . . . . . . . . . . . . 385
518089-05 - Open Circuit at Ride Control Valve High Side Driver [UCM] . . . . . . . . . . . . . . . . . . . . . . . . . 387
518093-03 - Return ToTravel Key Fault [Keypad and Joystick] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 389
518101-03 - Torque Converter Lock Up Key Fault [Keypad and Joystick] . . . . . . . . . . . . . . . . . . . . . . . . . 390
518103-03 - Transmission Auto Mode Key Fault [Keypad and Joystick] . . . . . . . . . . . . . . . . . . . . . . . . . . 391
518106-03 - WorkLight 1 Key Fault [Keypad and Joystick]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 392
518108-03 - WorkLight 2 Key Fault [Keypad and Joystick]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 395
518110-02 - Boom Angle Sensor signals not plausible [UCM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 398
518110-03 - Boom Angle Sensor Channel 1 Over Voltage [UCM]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 399
518110-04 - Boom Angle Sensor Channel 1 Under Voltage [UCM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
518111-02 - Bucket Angle Sensor signals not plausible [UCM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
518111-03 - Bucket Angle Sensor Channel 1 Over Voltage [UCM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406
518111-04 - Bucket Angle Sensor Channel 1 Under Voltage [UCM]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 408
518112-01 - Radiator Coolant Temperature Sensor under resistance Short to Ground [UCM] . . . . . . . 411
518112.00 - Radiator Coolant Temperature Sensor over resistance Open Circuit/Short to Power [UCM]413
518113-02 - Low Brake Pressure [UCM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 415
48083741_EN 31/07/2018
55.8 [55.DTC] / 7
518113-03 - Short to Power at Brake Supply Line Pressure Sensor [UCM] . . . . . . . . . . . . . . . . . . . . . . . 416
518113-04 - Short to Ground at Brake Supply Line Pressure Sensor [UCM] . . . . . . . . . . . . . . . . . . . . . . 417
518114-03 - Short to Power at Brake Line (declutch) Pressure Sensor [UCM] . . . . . . . . . . . . . . . . . . . . . 420
518114-04 - Short to Ground at Brake Line (declutch) Pressure Sensor [UCM] . . . . . . . . . . . . . . . . . . . . 421
518115-01 - Auxiliary Steering lack of pressure [UCM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 424
518115-03 - Aux Steering Pressure Sensor Over Voltage [UCM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 425
518115-04 - Aux Steering Pressure Sensor Over Voltage [UCM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 427
518116-09 - Hydraulic Filter is Clogged [GHMI - Faults list] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 430
518119-03 - Short to Power at Implement Coupler High Side Driver [UCM] . . . . . . . . . . . . . . . . . . . . . . . 431
518119-04 - Short to Ground at Implement Coupler High Side Driver [UCM] . . . . . . . . . . . . . . . . . . . . . . 433
518119-05 - Open Circuit at Implement Coupler High Side Driver [UCM] . . . . . . . . . . . . . . . . . . . . . . . . . 435
518122-00 - Axle oil temperature is very high [GHMI - Faults list]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 437
518122-00 - Front Axle Oil Temp Sensor Over Resistance [UCM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 438
518122-01 - Front Axle Oil Temp Sensor Under Resistance [UCM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 441
518122-16 - Axle oil temperature high [GHMI - Faults list] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 444
518122-31 - Axle oil temperature sensor out of range [GHMI - Faults list] . . . . . . . . . . . . . . . . . . . . . . . . 445
518129-03 - Short to Power at Boom Raise Valve High Side Driver [UCM]. . . . . . . . . . . . . . . . . . . . . . . . 446
518129-04 - Short to Ground at Boom Raise Valve High Side Driver [UCM]. . . . . . . . . . . . . . . . . . . . . . . 448
518129-05 - Open Circuit at Boom Raise Valve High Side Driver [UCM]. . . . . . . . . . . . . . . . . . . . . . . . . . 450
518130-03 - Short to Power at Boom Lower Valve High Side Driver [UCM] . . . . . . . . . . . . . . . . . . . . . . . 453
518130-04 - Short to Ground at Boom Lower Valve High Side Driver [UCM] . . . . . . . . . . . . . . . . . . . . . . 455
518130-05 - Open Circuit at Boom Lower Valve High Side Driver [UCM] . . . . . . . . . . . . . . . . . . . . . . . . . 457
518131-03 - Short to Power/Open Circuit at Boom Valve Low Side Driver [UCM] . . . . . . . . . . . . . . . . . . 460
518131-04 - Short to Ground at Boom Valve Low Side Driver [UCM]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 462
518132-03 - Short to Power at Bucket Roll Valve High Side Driver [UCM] . . . . . . . . . . . . . . . . . . . . . . . . 464
518132-04 - Short to Ground at Bucket Roll Valve High Side Driver [UCM] . . . . . . . . . . . . . . . . . . . . . . . 466
518132-05 - Open Circuit at Bucket Roll Valve High Side Driver [UCM] . . . . . . . . . . . . . . . . . . . . . . . . . . 468
518133-03 - Short to Power at Bucket Dump Valve High Side Driver [UCM] . . . . . . . . . . . . . . . . . . . . . . 471
518133-04 - Short to Ground at Bucket Dump Valve High Side Driver [UCM] . . . . . . . . . . . . . . . . . . . . . 473
518133-05 - Open Circuit at Bucket Dump Valve High Side Driver [UCM]. . . . . . . . . . . . . . . . . . . . . . . . . 475
518134-03 - Short to Power/Open Circuit at Bucket Valve Low Side Driver [UCM] . . . . . . . . . . . . . . . . . 478
518134-04 - Short to Ground at Bucket Valve Low Side Driver [UCM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . 480
518135-03 - Boom Angle Sensor Channel 2 Over Voltage [UCM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 482
518135-04 - Boom Angle Sensor Channel 2 Under Voltage [UCM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 484
518136-03 - Bucket Angle Sensor Channel 2 Over Voltage [UCM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 487
518136-04 - Bucket Angle Sensor Channel 2 Under Voltage [UCM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 489
518137-03 - Short to Power at AUX 1 Left High Side Driver [UCM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 492
518137-04 - Short to Ground at AUX 1 Left High Side Driver [UCM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 494
518137-05 - Open Circuit at AUX 1 Left High Side Driver [UCM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 496
518138-03 - Short to Power at AUX 1 Right High Side Driver [UCM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 499
518138-04 - Short to Ground at AUX 1 Right High Side Driver [UCM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . 501
518138-05 - Open Circuit at AUX 1 Right High Side Driver [UCM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 503
48083741_EN 31/07/2018
55.8 [55.DTC] / 8
518139-03 - Short to Power/Open Circuit at AUX 1 Low Side Driver [UCM] . . . . . . . . . . . . . . . . . . . . . . . 506
518139-04 - Short to Ground at AUX 1 Low Side Driver [UCM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 508
518140-03 - Short to Power at AUX 2 Left High Side Driver [UCM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 510
518140-04 - Short to Ground at AUX 2 Left High Side Driver [UCM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 512
518140-05 - Open Circuit at AUX 2 Left High Side Driver [UCM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 514
518141-03 - Short to Power at AUX 2 Right High Side Driver [UCM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 517
518141-04 - Short to Ground at AUX 2 Right High Side Driver [UCM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . 519
518141-05 - Open Circuit at AUX 2 Right High Side Driver [UCM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 521
518142-03 - Short to Power/Open Circuit at AUX 2 Low Side Driver [UCM] . . . . . . . . . . . . . . . . . . . . . . . 524
518142-04 - Short to Ground at AUX 2 Low Side Driver [UCM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 526
518143-03 - Short to Power/Open Circuit at Implement Coupler Low Side Driver [UCM]. . . . . . . . . . . . 528
518143-04 - Short to Ground at Implement Coupler Low Side Driver [UCM] . . . . . . . . . . . . . . . . . . . . . . 530
518144-03 - Short to Power at Aux Steering Enable High Side Driver [UCM]. . . . . . . . . . . . . . . . . . . . . . 532
518144-04 - Short to Ground at Aux Steering Enable High Side Driver [UCM]. . . . . . . . . . . . . . . . . . . . . 534
518144-05 - Open Circuit at Aux Steering Enable High Side Driver [UCM]. . . . . . . . . . . . . . . . . . . . . . . . 536
518145-03 - Short to Power/Open Circuit at Park Brake Low Side Driver [UCM]. . . . . . . . . . . . . . . . . . . 538
518145-04 - Short to Ground at Park Brake Low Side Driver [UCM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 540
518146-03 - Short to Power at FAN Control High Side Driver [UCM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 542
518146-04 - Short to Ground at FAN Control High Side Driver [UCM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . 544
518146-05 - Open Circuit at FAN Control High Side Driver [UCM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 546
518147-03 - Short to Power FAN Reverser Low Side Driver [UCM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 548
518147-04 - Short to Ground at FAN Reverser Low Side Driver [UCM]. . . . . . . . . . . . . . . . . . . . . . . . . . . 550
518150-03 - Electrical Crank Power Relay- Short Circuit to B+ [SFB] . . . . . . . . . . . . . . . . . . . . . . . . . . . . 552
518150-03 - Electrical Ignition Power Relay- Short Circuit to B+ [SFB] . . . . . . . . . . . . . . . . . . . . . . . . . . . 554
518150-04 - Short to Ground at Crank Request High Side Driver [UCM] . . . . . . . . . . . . . . . . . . . . . . . . . 556
518150-05 - Electrical Crank Power Relay- Open Circuit [SFB] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 558
518150-05 - Electrical Ignition Power Relay- Open Circuit [SFB] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 560
518150-06 - Electrical Crank Power Relay- Short Circuit to GND [SFB] . . . . . . . . . . . . . . . . . . . . . . . . . . 562
518150-06 - Electrical Ignition Power Relay- Short Circuit to GND [SFB] . . . . . . . . . . . . . . . . . . . . . . . . . 564
518176-03 - Joystick Steering Signal 2 High voltage [UCM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 566
518176-04 - Joystick Steering Signal 2 Low voltage [UCM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 567
518176-09 - Joystick Steering Signals not plausible [UCM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 570
518176-15 - Joystick Steering Signal 1 High voltage [UCM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 572
518176-17 - Joystick Steering Signal 1 Low voltage [UCM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 574
518177-03 - Short to Power at Pilot Enable Valve High Side Driver [UCM] . . . . . . . . . . . . . . . . . . . . . . . . 576
518177-04 - Short to Ground at Pilot Enable Valve High Side Driver [UCM] . . . . . . . . . . . . . . . . . . . . . . . 578
518177-05 - Open Circuit at Pilot Enable Valve High Side Driver [UCM] . . . . . . . . . . . . . . . . . . . . . . . . . . 580
518267-02 - WatchDog Reset [Keypad and Joystick] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 583
518280-31 - Error at 5VREF1 Output [UCM]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 584
518283-31 - Error at 24VF2 Supply Rail [UCM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 590
48083741_EN 31/07/2018
55.8 [55.DTC] / 9
518287-31 - Error at 24VS1 Supply Rail [UCM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 598
518289-31 - Error at 24VA Supply Rail [UCM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 600
518290-31 - Error at 24VB Supply Rail [UCM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 602
518291-31 - Error at 24VLP Supply Rail [UCM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 604
518292-31 - Error at 24VP Supply Rail [UCM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 606
518293-31 - Error at 2.5V Ref1 Supply [UCM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 608
518294-31 - Error at 2.5V Ref2 Supply [UCM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 609
518296-31 - Error at 5VREFIN [UCM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 610
518390-00 - Hydraulic Oil Temp Sensor Over Resistance [UCM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 611
518390-01 - Hydraulic Oil Temp Sensor Under Resistance [UCM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 613
518498-00 - Engine oil temperature is very high [GHMI - Faults list] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 615
518499-18 - Engine Oil pressure Low [GHMI - Faults list] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 616
518501-09 - Air Filter Clogged [GHMI - Faults list]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 617
520332-19 - TCU Source Address Cyclic Timeout [UCM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 618
520333-19 - Keypad Source Address Cyclic Timeout [UCM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 620
520334-19 - Smart Fuse Box Source Address Cyclic Timeout [UCM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . 621
520335-19 - Joystick Steering Controller Source Address Cyclic Timeout [UCM] . . . . . . . . . . . . . . . . . . 622
520444-02 - Memory Integrity RAM [Keypad and Joystick] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 623
520444-31 - Memory Integrity ROM [Keypad and Joystick] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 624
520519-19 - Bus Off [Keypad and Joystick]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 625
520572-03 - 24v to 12v Converter Enable - Short Circuit to B+ [SFB] . . . . . . . . . . . . . . . . . . . . . . . . . . . . 627
520572-05 - 24v to 12v Converter Enable - Open Circuit [SFB] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 629
520572-06 - 24v to 12v Converter Enable - Short Circuit to GND [SFB] . . . . . . . . . . . . . . . . . . . . . . . . . . 631
520578-03 - Battery Isolator SET - Short Circuit to B+ [SFB]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 633
520578-03 - Battery Isolator RESET - Short Circuit to B+ [SFB] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 636
520578-06 - Battery Isolator SET - Short Circuit to GND [SFB] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 639
520578-06 - Battery Isolator RESET - Short Circuit to GND [SFB] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 642
520584-00 - Left Brake Indicator Light - Too many loads or faulty load [SFB]. . . . . . . . . . . . . . . . . . . . . . 645
520584-03 - Left Brake Indicator Light - Short circuit to B+ [SFB] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 647
520584-05 - Left Brake Indicator Light - Open Circuit [SFB] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 649
520584-06 - Left Brake Indicator Light - Short circuit to GND [SFB] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 651
520585-00 - Right Brake Indicator Light - Too many loads or faulty load [SFB] . . . . . . . . . . . . . . . . . . . . 653
520585-03 - Right Brake Indicator Light - Short circuit to B+ [SFB] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 655
520585-05 - Right Brake Indicator Light - Open Circuit [SFB] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 657
520585-06 - Right Brake Indicator Light - Short circuit to GND [SFB] . . . . . . . . . . . . . . . . . . . . . . . . . . . . 659
520588-03 - Alternator Excitation Driver - Short Circuit to B+ [SFB] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 661
520588-06 - Alternator Excitation Driver - Short Circuit to GND [SFB] . . . . . . . . . . . . . . . . . . . . . . . . . . . . 663
520591-00 - Backup Alarm - Too many loads or faulty load [SFB] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 665
520591-03 - Backup Alarm - Short circuit to B+ [SFB]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 668
48083741_EN 31/07/2018
55.8 [55.DTC] / 10
520591-05 - Backup Alarm - Open Circuit [SFB] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 671
520591-06 - Backup Alarm - Short circuit to GND [SFB]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 674
520596-03 - VSUP A - Out of Range - High [SFB] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 677
520596-04 - VSUP A - Out of Range - Low [SFB] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 679
520597-03 - VSUP B - Out of Range - High [SFB] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 681
520597-04 - VSUP B - Out of Range - Low [SFB] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 683
520598-03 - VSUP C - Out of Range - High [SFB]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 685
520598-04 - VSUP C - Out of Range - Low [SFB] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 687
520599-03 - VSUP D - Out of Range - High [SFB]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 689
520599-04 - VSUP D - Out of Range - Low [SFB] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 691
522809-02 - Memory Integrity EEPROM [Keypad and Joystick] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 693
522810-09 - Joystick Steering Cut Off Valves not plausible [UCM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 694
523438-31 - Joystick loss of communication [UCM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 698
524262-13 - Primary EEPROM configuration CRC validation fault [Keypad and Joystick] . . . . . . . . . . . 701
524263-13 - Redundant EEPROM configuration CRC validation fault [Keypad and Joystick] . . . . . . . . 702
524264-13 - Configuration parameter read error [Keypad and Joystick] . . . . . . . . . . . . . . . . . . . . . . . . . . 703
48083741_EN 31/07/2018
55.8 [55.DTC] / 11
Electrical systems - FAULT CODES
91.19 - Engine Source Address Cyclic Timeout

Control Module: UCM
Context:
The A-UCM does not receive messages from the Engine Source Address within the maximum interval time;
as a consequence:
• Use last ECU CAN message received;
• Disable cranking;
• KOER logic;
• Set engine speed to Standard Idle when EEC1.EngSpd not available.
Cause:
Incoming cycle time message interval > 10 times of maximum defined cycle time.
Possible failure modes:
1. The fault is intermittent and not currently active.

2. The harness of busses CAN 1 or CAN 2 is damaged.
3. The connectors X-UCM1B or X-UCM2B are damaged.
4. The A-UCM is damaged.
Solution:
1. Verify that the fault is present and active.
Use the Electronic Service Tool (EST) to check the status of this fault.
A. If the fault is present and active, continue with Step 2.
B. If the fault is no longer present or in an inactive state, the fault may be intermittent and not currently active.
2. Visually check the integrity of the harness of busses CAN 1 ( X-UCM1B).
A. If the harness is damaged, replace the harness.
B. If the harness is not damaged, continue with Step 3.


4. Check the integrity of connector X-UCM1B.
Disconnect the connector X-UCM1B from the A-UCM and visually check the integrity of pins 25 and 34.
A. If one pin is damaged, replace the harness.
B. If pins are not damaged, continue with Step 5.

B. If pins are not damaged, replace the A-UCM.
48083741_EN 31/07/2018
55.8 [55.DTC] / 12
Wiring harnesses - Electrical schematic sheet 22 (55.100)

48083741_EN 31/07/2018
55.8 [55.DTC] / 13
96-00 - Fuel Level Sensor Over Resistance

Control Module: UCM
Context:
The A-UCM detects a value of resistance of the FUEL LEVEL SENSOR ( B-RFLG) higher than the upper limit; as a
consequence the fuel level is not available:
Cause:
The A-UCM detects on pin 11 of connector X-UCM4A a resistance value > 269 Ω (last index is 254 Ω ± 5.0 Ω).

2. The harness between A-UCM and the FUEL LEVEL SENSOR is damaged.
3. The connectors X-CAB_E or X-ENG or X-FL or X-UCM4A are damaged.
4. The harness between connectors X-FL and ground is damaged.
5. The harness between connectors X-ENG and the FUEL LEVEL SENSOR is damaged.
6. The harness between connectors X-UCM4A and X-CAB_E is damaged.
7. The FUEL LEVEL SENSOR is damaged.
Solution:
2. Visually check the integrity of the harness between the connector X-UCM4A and the connector X-FL for any dam-
age.

3. Check the integrity of connector X-FL.
Disconnect the connector X-FL from the FUEL LEVEL SENSOR and visually check the integrity of pins 1 and 2
of the connector.
A. If one pin is damaged, replace the harness relevant to the connector.
B. If all pins are not damaged, continue with Step 4.

4. Check the integrity of harness between the connector X-FL and ground.
Disconnect the connector X-FL from the FUEL LEVEL SENSOR. Use a multimeter to perform the following check:
From To Value
Connector X-FL pin 2 Ground Short circuit
A. If the measurement is not correct, replace the harness.
B. If the measurement is correct, continue with Step 5.

5. Check the integrity of connectors X-ENG and X-CAB_E.
Disconnect the connector X-ENG from the connector X-CAB_E and visually check the integrity of pins 8 and 9 of
both connectors.
48083741_EN 31/07/2018
55.8 [55.DTC] / 14
A. If one pin is damaged, replace the harness relevant to the damaged connector.

6. Check the integrity of connector X-UCM4A.
Disconnect the connector X-UCM4A from the A-UCM and visually check the integrity of pin 11.
A. If the pin is damaged, replace the harness.
B. If the pin is not damaged, continue with Step 7.

7. Check the integrity of harness between the connector X-ENG and the FUEL LEVEL SENSOR.
Disconnect the connector X-FL from the FUEL LEVEL SENSOR.
Use a multimeter to perform the following check:
From To Value
Connector X-ENG pin 8 Connector X-FL pin 2 Short circuit

8. Check the integrity of harness between the connectors X-UCM4A and X-CAB_E.
From To Value
Connector X-UCM4A pin 11 Connector X-CAB_E pin 18 Short circuit

9. Replace the FUEL LEVEL SENSOR.
A. If the functionality is restored, the procedure ends.
B. If the functionality is not restored, replace the A-UCM.
48083741_EN 31/07/2018
55.8 [55.DTC] / 15
96-01 - Fuel Level Sensor Under Resistance

Control Module: UCM
Context:
The A-UCM detects a value of resistance of the FUEL LEVEL SENSOR ( B-RFLG) lower than the low limit; as a
consequence the fuel level is not available.
Cause:
The A-UCM detects on pin 11 of connector X-UCM4A a resistance value < 20 Ω 20 Ω (last index is 27.5 Ω ± 2.5 Ω).

2. The harness between A-UCM and the FUEL LEVEL SENSOR is damaged.
4. The connectors X-CAB_E or X-ENG or X-FL or X-UCM4A are damaged.
5. The harness of FUEL LEVEL SENSOR is damaged.
6. The harness between connectors X-ENG and X-FL is damaged.
7. The harness between connectors X-CAB_E and X-UCM4A is damaged.
Solution:
2. Visually check the integrity of the harness between the connector X-UCM4A and the connector X-FL for any dam-
age.

3. Replace the FUEL LEVEL SENSOR.
B. If the functionality is not restored, continue with Step 4.

4. Check the integrity of connector X-FL.
Disconnect the connector X-FL from the FUEL LEVEL SENSOR and visually check the integrity of pins 1 and 2.
B. If the pins are not damaged, continue with Step 5.

5. Check the integrity of harness of the FUEL LEVEL SENSOR.
Disconnect the connector X-FL from the FUEL LEVEL SENSOR.
From To Value
Connector X-FL pin 2 Connector X-FL pin 1 Open circuit
48083741_EN 31/07/2018
55.8 [55.DTC] / 16

6. Check the integrity of connectors X-ENG and X-CABLE_E.
Disconnect the connector X-ENG from the connector X-CABLE_E and visually check the integrity of pins 8 and 9
of both connectors.

7. Check the integrity of harness between the connector X-ENG and the FUEL LEVEL SENSOR.
Connect the connector X-FL to the FUEL LEVEL SENSOR.
From To Value
Connector X-ENG pin 8 Connector X-ENG pin 9 > 20 Ω


9. Check the integrity of harness between the connectors X-UCM4A and X-CAB_E.
Use a multimeter to perform the following checks:
From To Value
Connector X-UCM4A pin 11 Connector X-CAB_E pin 8 Short circuit
Connector X-CAB_E pin 9 Connector X-CAB_E pin 8 Open circuit
B. If the measurement is correct, replace the A-UCM.
48083741_EN 31/07/2018
55.8 [55.DTC] / 17
110-00 - Engine coolant temperature is very high

Control Module: GHMI - Faults list
Context:
The Universal Control Module (UCM) receives the engine coolant temperature signal from the coolant temperature
sensor B-RECTD. This fault occurs if the engine coolant temperature is higher than 110 °C.
Cause:
The UCM detected that the engine coolant temperature is higher than 110 °C.
1. Engine overheating.
2. The radiator doesn’t work properly.
3. Insufficient level of the coolant.
4. Defective engine coolant temperature sensor B-RECTD, internal failure.
5. Defective engine coolant temperature sensor B-RECTD circuit wiring, open circuit.
6. Defective UCM, software or internal failure.
Solution:
A. If the fault is no longer present or in an inactive state, the fault may be intermittent and not currently active.
B. If the fault is present and active, continue with Step 2.

2. Check the presence of the following related faults:
Electronic module - Malfunction (55.640)
A. If one or more of the listed faults is detected, resolve the fault. Then, repeat the Step 1.
B. If no other fault is detected, continue with Step 3.

3. Check the engine coolant for over-temperature (the temperature should be lower than 110 °C).
A. If the engine coolant temperature is too high, stop the engine and wait until the temperature falls within the
operative range. Then continue with Step 4.
B. If the engine coolant temperature is normal, continue with Step 6.

4. Clean the radiator or operate the fan reverser. Start the engine and wait until the coolant reaches the proper
temperature. Verify that the radiator works properly.
A. If the coolant temperature remains under 105 °C, clear the error and return to the machine to service.
B. If the coolant temperature rises over 110 °C, continue with Step 5.
5. Check the coolant level and add coolant if necessary. Start the engine and wait until the coolant reaches the
proper temperature.
A. If the coolant temperature remains under 105 °C, clear the error and return to the machine to service.
B. If the coolant temperature rises over 110 °C, continue with Step 6.
6. Check the integrity of the harness and the connectors.
48083741_EN 31/07/2018
55.8 [55.DTC] / 18
Visually inspect the relevant harness and connector for damage, bent or dislocated pins, corroded terminals or
broken wires. Verify that the connectors are fully installed. Flex the harness involved to reveal intermittent breaks
or shorts in the wiring concerned. Operate the machine while you monitor the display.
A. If you find damage or the display indicates other than normal display readings, then repair the damage discov-
ered during the inspection or locate and repair the other than normal display condition and verify that the error
has been resolved.
B. If you do not find damage and the display indicates only normal readings, then continue with Step 7.
7. Check the UCM for the appropriate software and re-flesh, if necessary.
A. If the fault has been resolved, return to the machine to service.
B. If the fault has not been resolved, continue with step 8.

8. Check the integrity of the coolant temperature sensor B-RECTD.
The key must be in the OFF position.
Disconnect the connector X-RECT and remove the sensor.
Use a multimeter to perform the resistance measurement of the sensor.
A. If Resistance > 2000 Ω, replace the B-RECTD COOLANT TEMP sensor.
B. If the resistance value is correct, leave the connector X-RECT disconnected and continue with Step 9.
9. Check the integrity of the harness.
Disconnect the connector X-UCM4A.
Use a multimeter to perform the following continuity checks:
From To Value
Connector X-RECT pin 1 Connector X-ENG pin 5 There should be continuity
Connector X-CAB_E pin 5 Connector X-UCM4A pin 12 There should be continuity
Connector X-RECT pin 2 Connector X-ENG pin 9 There should be continuity
Connector X-CAB_E pin 9 Chassis ground There should be continuity
A. If there is no continuity, there is an open circuit condition. Locate the fault and repair the conductor.
B. If there is continuity, replace the UCM.
48083741_EN 31/07/2018
55.8 [55.DTC] / 19
110-16 - Engine coolant temperature is high

Context:
Engine coolant temperature is high.
Cause:

2. The engine coolant temperature is between 105 – 110 °C.
Solution:
2. Idle the machine and monitor the temperature. Wait until the coolant temperature reach the proper temperature
and restart the machine.
A. If the coolant temperature rises again, idle the machine and continue with Step 3.
B. If the coolant temperature within proper range continue to work monitoring the temperature.
3. Clean the radiator or operate the fan reverser. Wait until the coolant temperature reach the proper temperature
A. If the coolant temperature rises again, idle the machine and continue with Step 4.
4. Check the coolant level and add coolant if necessary. Wait until the coolant temperature reach the proper temper-
ature and restart the machine.
A. If the coolant temperature rises again, idle the machine and replace the coolant temperature sensor.
48083741_EN 31/07/2018
55.8 [55.DTC] / 20
158-03 - Short to Power at Key Switch Crank

Control Module: UCM
Context:
The A-UCM detects a voltage on the Key Switch Crank greater than the expected one; as a consequence is disabled
the cracking request.
Cause:
The system detects, on 14 of connector X-UCM2B, a > 15 V.

2. The connector X-UCM2B is damaged.
3. The A-UCM component is damaged.
Solution:
2. Visually check the integrity of the harness between the connectors X-UCM2B and X-X3 for any damage.

Disconnect the connector X-UCM2B from the A-UCM and visually check the integrity of pin 14.
A. If the pin is damaged, replace the relevant harness.

4. Check the integrity of harness between the A-UCM and the connector X-X3.
From To Value
Connector X-UCM2B pin 14 Ground ≤ 15 V
A. If the measurement is correct, replace the A-UCM.
B. If the measurement is not correct, check the correct functioning of the circuit relevant to the SMART FUSE
BOX (see procedure 518150-03 – Electrical Crank Power Relay- Short Circuit to B+).

48083741_EN 31/07/2018
55.8 [55.DTC] / 21
177-00 - Transmission oil temperature is very high

Context:
Transmission oil temperature is very high.
Cause:

2. The transmission oil temperature is over 125 °C.
Solution:
2. Bring the machine to a safe stop, and turn the engine OFF immediately. Replace the transmission oil temperature
sensor.
48083741_EN 31/07/2018
55.8 [55.DTC] / 22
177-16 - Transmission oil temperature is high

Context:
Transmission oil temperature is high.
Cause:

2. The engine coolant temperature is between 120 – 125 °C.
Solution:
2. Idle the machine and monitor the temperature. Wait until the oil temperature goes below 90 °C and restart the
machine.
A. If the oil temperature rises again, idle the machine and 3.
B. If the oil temperature within range of 75 – 90 °C continue to work monitoring the temperature.
3. Clean the cooler or operate the fan reverser. Wait until the oil temperature goes below 90 °C and restart the
machine.
A. If the oil temperature rises again, idle the machine and continue with Step 4.
4. Wait until the oil temperature goes below 90 °C, restart the machine and use a lower gear.
A. If the oil temperature rises again, idle the machine and replace the transmission oil temperature sensor.
48083741_EN 31/07/2018
55.8 [55.DTC] / 23
3997-03 - Electrical Accessory Power Relay - Short Circuit to B+

Control Module: SFB
Context:
Electrical Accessory Power Relay - Short Circuit to B+.
Cause:
The Smart Fuse box detects a Short Circuit to B+ from the Electrical Accessory Power Relay ( X-X3 pin 11) when the
key is OFF.

2. The harness between Smart Fuse Box and Electrical Accessory Power Relay is damaged.
3. The X-LC4 connector (pin 86) is damaged.
4. The Smart Fuse Box connector ( X-X3 pin 11) is damaged.
5. The harness between Electrical Accessory Power Relay and Smart Fuse Box is defective.
6. The Electrical Accessory Power Relay is defective.
7. The Smart Fuse Box is defective.
Solution:
2. Check the integrity of the harness between Smart Fuse Box and Electrical Accessory Power Relay.
Visually check the integrity of the harness and check for any damage.

3. Check the integrity of the Electrical Accessory Power Relay connector.
Disconnect Electrical Accessory Power Relay ( X-LC4 pin 86) and visually check the integrity of the pin.
A. If the pin is damaged, replace the X-LC4 connector.

4. Check the integrity of the Smart Fuse Box connector.
Disconnect X-X3 connector and visually check the integrity of the pin 11.
A. If the pin is damaged, replace the X-X3 connector.

5. Check the Electrical Accessory Power Relay signal circuit.
48083741_EN 31/07/2018
55.8 [55.DTC] / 24
Use a multimeter to perform the following voltage check:
From To Value
Connector X-LC4 pin 86 Chassis ground There should not be voltage
A. If there is a battery voltage value, replace the Electrical Accessory Power Relay.
B. If there is not a voltage value, continue to Step 6.

6. Check the Smart Fuse Box signal circuit.
From To Value
Connector A-SFB pin OUT_01_H Chassis ground There should not be voltage
A. If there is a battery voltage value, replace the Smart Fuse Box.

48083741_EN 31/07/2018
55.8 [55.DTC] / 25
3997-05 - Electrical Accessory Power Relay - Open Circuit

Control Module: SFB
Context:
Electrical Accessory Power Relay - Open Circuit.
Cause:
The Smart Fuse box detects an Open Circuit from the Electrical Accessory Power Relay ( X-X3 pin 11) when the key
is OFF.

Solution:



48083741_EN 31/07/2018
55.8 [55.DTC] / 26
From To Value
Connector X-LC4 pin 86 Chassis ground There should be a resistance
A. If there is a battery voltage value, replace the Electrical Accessory Power Relay.
B. If there is not a voltage value, continue to Step 6.

From To Value
Connector A-SFB pin OUT_01_H Chassis ground There should be a resistance

48083741_EN 31/07/2018
55.8 [55.DTC] / 27
3997-06 - Electrical Accessory Power Relay - Short Circuit to GND

Control Module: SFB
Context:
Electrical Accessory Power Relay - Short Circuit to GND.
Cause:
The Smart Fuse box detects a Short Circuit to GND from the Electrical Accessory Power Relay ( X-X3 pin 11) when
the key is OFF.

Solution:



48083741_EN 31/07/2018
55.8 [55.DTC] / 28
From To Value
Connector X-LC4 pin 86 Chassis ground There should be an open circuit
A. If there is a short circuit to GND, replace the Electrical Accessory Power Relay.
B. If there is an open circuit, continue to Step 6.

From To Value
Connector A-SFB pin OUT_01_H Chassis ground There should be an open circuit

48083741_EN 31/07/2018
55.8 [55.DTC] / 29
5000-12 - Logical error at gear range signal

Control Module: TCU
Context:
The Transmission Control Unit A-TRANS detects a severe failure that disables control of the transmission.
The Transmission Control Unit A-TRANS shuts off the solenoid valves for the clutches and also the common power
supply (VPS1). Transmission shifts to neutral position. The park brake will operate normally, also the other functions
which use ADM 1 to ADM 8.
The operator has to slow down the vehicle. The transmission will stay in neutral.
Cause:
The Unit Control Module A-UCM detects a wrong signal combination for the gear range.

2. The harnesses or the connectors are damaged or the connectors are not installed.
3. The harness between the shift lever A-PFNR and the Unit Control Module A-UCM is defective.
4. The shift lever A-PFNR is defective.
5. The Unit Control Module A-UCM is defective.
Solution:
1. Verify that fault is present and active.
2. Check if the connector X-TS2 is connected to the shift lever A-PFNR.
Check if the connector X-PED_2 is connected to the connector X-CAB_P2.
Check if the connector X-UCM2B is connected to the Unit Control Module A-UCM.
A. If a problem is found, restore the connection.
B. If there are no problems,continue with Step 3.

3. Disconnect the connector X-TS2 from the shift lever A-PFNR.
Check the integrity of the connector X-TS2 and visually check for any damage to the connector and to the pins.
A. If a problem is found, replace the connector X-TS2.
B. If there are no problems, connect the connector X-TS2 to the shift lever A-PFNR and continue with Step 4.
4. Disconnect the connector X-PED_2 from the connector X-CAB_P2.
Check the integrity of the connectors X-PED_2 and X-CAB_P2, visually check for any damage to the connectors
and to the pins 4 and 5.
A. If a problem is found, replace the damaged connector.
B. If there are no problems, connect the connector X-PED_2 to the connector X-CAB_P2 and continue with Step
5.
5. Disconnect the connector X-UCM2B from the Unit Control Module A-UCM.
48083741_EN 31/07/2018
55.8 [55.DTC] / 30
Check the integrity of the connector X-UCM2B and visually check for any damage to the connector and to the pins
21 and 22.
A. If a problem is found, replace the connector X-UCM2B.
B. If there are no problems, connect the connector X-UCM2B to the Unit Control Module A-UCM and continue
with Step 6.
6. Check to see if the harness between the shift lever A-PFNR and the Unit Control Module A-UCM is defective.
A. If a problem is found, replace defective harness.
B. If there are no problems, continue with Step 7.

7. Check if the shift lever A-PFNR is defective.
Check the signal combinations of the shift lever A-PFNR positions for gear range.
Disconnect the connector X-UCM2B from the Unit Control Module A-UCM.
Use a multimeter to check the signal combination.
The key must be in the ON position.
Put the shift lever A-PFNR in 1ST and 4TH position.
Perform the following check:
From To Value
Connector X-UCM2B pin 22 Chassis ground There should be more then 0 V
Connector X-UCM2B pin 21 Chassis ground There should be 0 V
A. If are detected both the signals, replace the shift lever A-PFNR.
B. If is detected only the signal on the connector X-UCM2B pin 22, continue with Step 8.
8. Use a multimeter to check the signal combination.
Put the shift lever A-PFNR in 3RD and 4TH position.
From To Value
Connector X-UCM2B pin 22 Chassis ground There should be 0 V
Connector X-UCM2B pin 21 Chassis ground There should be more then 0 V
A. If are detected both the signals, replace the shift lever A-PFNR.
B. If is detected only the signal on the connector X-UCM2B pin 21, replace the Unit Control Module A-UCM.
48083741_EN 31/07/2018
55.8 [55.DTC] / 31
5010-12 - Logical error at direction select signal

Control Module: TCU
Context:
The Transmission Control Unit A-TRANS detects a severe failure that disables control of the transmission.
The Transmission Control Unit A-TRANS shuts off the solenoid valves for the clutches and also the common power
supply (VPS1). Transmission shifts to neutral position. The park brake will operate normally, also the other functions
which use ADM 1 to ADM 8.
The operator has to slow down the vehicle. The transmission will stay in neutral.
Cause:
The Unit Control Module A-UCM detects a wrong signal combination for the direction.

3. The harness between the shift lever A-PFNR and the Unit Control Module A-UCM is defective.
4. The shift lever A-PFNR is defective.
Solution:
2. Check if the connector X-TS1 is connected to the shift lever A-PFNR.
Check if the connector X-PED_2 is connected to the connector X-CAB_P2.
Check if the connector X-UCM2A is connected to the Unit Control Module A-UCM.

3. Disconnect the connector X-TS1 from the shift lever A-PFNR.
Check the integrity of the connector X-TS1 and visually check for any damage to the connector and to the pins.
A. If a problem is found, replace the connector X-TS1.
B. If there are no problems, connect the connector X-TS1 to the shift lever A-PFNR and continue with Step 4.
4. Disconnect the connector X-PED_2 from the connector X-CAB_P2.
Check the integrity of the connectors X-PED_2 and X-CAB_P2, visually check for any damage to the connectors
and to the pins 1, 2 and 3.
B. If there are no problems, connect the connector X-PED_2 to the connector X-CAB_P2 and continue with Step
5.
5. Disconnect the connector X-UCM2A from the Unit Control Module A-UCM.
48083741_EN 31/07/2018
55.8 [55.DTC] / 32
Check the integrity of the connector X-UCM2A and visually check for any damage to the connector and to the pins
11, 16 and 10.
A. If a problem is found, replace the connector X-UCM2A.
B. If there are no problems, connect the connector X-UCM2A to the Unit Control Module A-UCM and continue
with Step 6.
6. Check to see if the harness between the shift lever A-PFNR and the Unit Control Module A-UCM is defective.

7. Check if the shift lever A-PFNR is defective.
Check the signal combinations of the shift lever A-PFNR positions F-N-R.
Disconnect the connector X-UCM2A from the Unit Control Module A-UCM.
Use a multimeter to check the signal combination.
Put the shift lever A-PFNR in FORWARD position.
From To Value
Connector X-UCM2A pin 10 Chassis ground There should be more then 0 V
Connector X-UCM2A pin 11 Chassis ground There should be 0 V
A. If are detected other signals then the one on the connector X-UCM2A pin 10, replace the shift lever A-PFNR.
B. If is detected only the signal on the connector X-UCM2A pin 10, continue with Step 8.
Put the shift lever A-PFNR in NORMAL position.
From To Value
B. If is detected only the signal on the connector X-UCM2A pin 16, continue with Step 9.
Put the shift lever A-PFNR in REVERSE position.
From To Value
48083741_EN 31/07/2018
55.8 [55.DTC] / 33
B. If is detected only the signal on the connector X-UCM2A pin 11, replace the Unit Control Module A-UCM.
48083741_EN 31/07/2018
55.8 [55.DTC] / 34
5110-03 - Short circuit to battery voltage or open circuit at

transmission sump temperature sensor input
Control Module: TCU
Context:
The Transmission Control Unit A-TRANS uses the default temperature.
There is no failure detected in the transmission system or the failure has no or slight effects on the transmission
control.
The Transmission Control Unit A-TRANS works without or, in special cases, with little limitations.
Cause:
There is a short circuit to battery voltage or an open circuit at the supply circuit of the hydraulic oil temperature sensor
B-HOT. The measured voltage is too high.

3. The harness between hydraulic oil temperature sensor B-HOT and Unit Control Module A-UCM is defective.
4. The hydraulic oil temperature sensor B-HOT is defective.
Solution:
2. Check if the connector X-HOT is connected to the hydraulic oil temperature sensor B-HOT.
Check if the connector X-TRANS is connected to the connector X-CAB_TR.

3. Disconnect the connector X-HOT from the hydraulic oil temperature sensor B-HOT.
Check the integrity of the connector X-HOT and visually check for any damage to the connector and to the pins.
A. If a problem is found, replace the connector X-HOT.
B. If there are no problems, connect the connector X-HOT to the hydraulic oil temperature sensor B-HOT and
continue with Step 4.
4. Disconnect the connector X-TRANS from the connector X-CAB_TR.
Check the integrity of the connectors X-TRANS and X-CAB_TR, visually check for any damage to the connectors
and to the pin 30 and 3.
48083741_EN 31/07/2018
55.8 [55.DTC] / 35
B. If there are no problems, connect the connector X-CAB_TR to the connector X-TRANS and continue with Step
5.
Check the integrity of the connector X-UCM4A and visually check for any damage to the connector and to the pin
18.
with Step 6.
1.
with Step 7.
7. Check the harness between the hydraulic oil temperature sensor B-HOT and the Unit Control Module A-UCM for
a short circuit to battery voltage condition.
From To Value
Connector X-UCM4A pin 18 Chassis ground There should be no voltage
A. If there is a voltage, find and replace the wire 634 and/or 634A.
B. If there is no voltage, continue with Step 8.

an open circuit condition.
Disconnect the connector X-HOT from the hydraulic oil temperature sensor B-HOT.
From To Value
Connector X-UCM4A pin 18 Connector X-HOT pin 1 There should be continuity
A. If there is no continuity, find and repair or replace the wire 634 and/or 634A.
B. If there is continuity, continue with Step 9.

9. Check if the hydraulic oil temperature sensor B-HOT is defective.
A. If a problem is found, replace the hydraulic oil temperature sensor B-HOT.
B. If there are no problems, replace the Unit Control Module A-UCM.
48083741_EN 31/07/2018
55.8 [55.DTC] / 36
5110-04 - Short circuit to ground at transmission sump temperature

sensor input
Control Module: TCU
Context:
control.
Cause:
There is a short circuit to ground at the hydraulic oil temperature sensor B-HOT. The measured voltage is too low.

3. The harness between hydraulic oil temperature sensor B-HOT and the ground is defective.
Solution:
2. Check if the connector X-HOT is connected to the hydraulic oil temperature sensor B-HOT.

3. Disconnect the connector X-HOT from the hydraulic oil temperature sensor B-HOT.
Check the integrity of the connector X-HOT and visually check for any damage to the connector and to the pins.
A. If a problem is found, replace the connector X-HOT.
B. If there are no problems, connect the connector X-HOT to the hydraulic oil temperature sensor B-HOT and
and to the pin 30 and 3.
5.
48083741_EN 31/07/2018
55.8 [55.DTC] / 37
18.
with Step 6.
1.
with Step 7.
short circuit to ground condition.
From To Value
Connector X-UCM4A pin 18 Chassis ground There should be no continuity
A. If there is continuity, find and replace the wire 634 and/or 634A.
B. If there is no continuity, connect the connector X-UCM4A to the Unit Control Module A-UCM and continue with
Step 8.
8. Disconnect the X-HOT connector from the hydraulic oil temperature sensor B-HOT.
Check if the hydraulic oil temperature sensor B-HOT is defective.
A. If a problem is found, replace the hydraulic oil temperature sensor B-HOT.
48083741_EN 31/07/2018
55.8 [55.DTC] / 38
5120-03 - Short circuit to battery voltage or open circuit at retarder /

torque converter temperature sensor input
Control Module: TCU
Context:
control.
Cause:
There is a short circuit to battery voltage or an open circuit at the supply circuit of the gear oil temperature sensor
B-GOT. The measured voltage is too high.

3. The harness between the gear oil temperature sensor B-GOT and the Transmission Control Unit A-TRANS is
defective.
4. The gear oil temperature sensor B-GOT is defective.
5. The Transmission Control Unit A-TRANS is defective.
Solution:
2. Check if the connector X-TCOT is connected to the gear oil temperature sensor B-GOT.
Check if the connector X-TECM is connected to the Transmission Control Unit A-TRANS.

3. Disconnect the connector X-TCOT from the gear oil temperature sensor B-GOT.
Check the integrity of the connector X-TCOT and visually check for any damage to the connector and to the pins.
A. If a problem is found, replace the connector X-TCOT.
B. If there are no problems, connect the connector X-TCOT to the gear oil temperature sensor B-GOT and con-
tinue with Step 4.
48083741_EN 31/07/2018
55.8 [55.DTC] / 39
5.
5. Disconnect the connector X-TECM from the Transmission Control Unit A-TRANS.
Check the integrity of the connector X-TECM and visually check for any damage to the connector and to the pins
46 and 49.
A. If a problem is found, replace the connector X-TECM.

6. Check the harness between the gear oil temperature sensor B-GOT and the Transmission Control Unit A-TRANS
for a short circuit to battery voltage condition.
From To Value
Connector X-TECM pin 49 Chassis ground There should be no voltage

for an open circuit condition.
Disconnect the connector X-TCOT from the gear oil temperature sensor B-GOT.
From To Value
Connector X-TECM pin 49 Connector X-TCOT pin 1 There should be continuity

8. Check if the gear oil temperature sensor B-GOT is defective.
A. If a problem is found, replace the gear oil temperature sensor B-GOT.
B. If there are no problems, replace the Transmission Control Unit A-TRANS.
48083741_EN 31/07/2018
55.8 [55.DTC] / 40
5120-04 - Short circuit to ground at retarder / torque converter

temperature sensor input
Control Module: TCU
Context:
control.
Cause:
There is a short circuit to ground at the supply circuit of the gear oil temperature sensor B-GOT. The measured voltage
is too low.

defective.
Solution:

tinue with Step 4.
Check the integrity of the connector X-TRANS and X-CAB_TR, visually check for any damage to the connectors
48083741_EN 31/07/2018
55.8 [55.DTC] / 41
5.
46 and 49.

for a short circuit to ground condition.
From To Value
Connector X-TECM pin 49 Chassis ground There should be no continuity
B. If there is no continuity, connect the connector X-TECM from the Transmission Control Unit A-TRANS and
7. Disconnect the X-TCOT connector from the gear oil temperature sensor B-GOT.
Check if the gear oil temperature sensor B-GOT is defective.
48083741_EN 31/07/2018
55.8 [55.DTC] / 42
5140-03 - Short circuit to battery voltage or open circuit at engine

speed input
Control Module: TCU
Context:
The Transmission Control Unit A-TRANS can not change the gears or the direction under the control of the normal
clutch modulation. The Transmission Control Unit A-TRANS uses the substitute strategy for clutch control. All mod-
ulations are only time controlled.
Cause:
There is a short circuit to battery voltage or an open circuit at the supply circuit of the engine speed sensor B-ES_S.
The Transmission Control Unit A-TRANS measures a voltage higher than 7.00 V at speed input pin.

3. The harness between the engine speed sensor B-ES_S and the Transmission Control Unit A-TRANS is defective.
4. The engine speed sensor B-ES_S is defective.
Solution:
2. Check if the connector X-ESS is connected to the engine speed sensor B-ES_S.

3. Disconnect the connector X-ESS from the engine speed sensor B-ES_S.
Check the integrity of the connector X-ESS and visually check for any damage to the connector and to the pins.
A. If a problem is found, replace the connector X-ESS.
B. If there are no problems, connect the connector X-ESS to the engine speed sensor B-ES_S and continue with
Step 4.
5.
48083741_EN 31/07/2018
55.8 [55.DTC] / 43
3 and 19.

6. Check the harness between the engine speed sensor B-ES_S and the Transmission Control Unit A-TRANS for a
short circuit to battery voltage condition.
From To Value

7. Check the harness between the engine speed sensor B-ES_S and the Transmission Control Unit A-TRANS for
Disconnect the connector X-ESS from the engine speed sensor B-ES_S.
From To Value
Connector X-TECM pin 19 Connector X-ESS pin 1 There should be continuity

8. Check if the engine speed sensor B-ES_S is defective.
A. If a problem is found, replace the engine speed sensor B-ES_S.
48083741_EN 31/07/2018
55.8 [55.DTC] / 44
5140-04 - Short circuit to ground at engine speed input

Control Module: TCU
Context:
Cause:
There is a short circuit to ground at the supply circuit of the engine speed sensor B-ES_S. The Transmission Control
Unit A-TRANS measures a voltage lesser than 0.45 V at speed input pin.

Solution:

Step 4.
5.
48083741_EN 31/07/2018
55.8 [55.DTC] / 45
3 and 19.

From To Value
B. If there is no continuity, continue with Step 7.

7. Disconnect the X-ESS connector from the engine speed sensor B-ES_S.
Check if the engine speed sensor B-ES_S is defective.
48083741_EN 31/07/2018
55.8 [55.DTC] / 46
5140-12 - Logical error at engine speed input

Control Module: TCU
Context:
Cause:
There is a logical error at the supply circuit of the engine speed sensor B-ES_S. The Transmission Control Unit
A-TRANS measures an engine speed over the threshold value and the next moment the measured speed is zero.

4. The engine speed sensor B-ES_S gap has the wrong size.
Solution:

Step 4.
5.
48083741_EN 31/07/2018
55.8 [55.DTC] / 47
3 and 19.
B. If there are no problems, connect the connector X-TECM to the Transmission Control Unit A-TRANS and con-
tinue with Step 6.
6. Check if the harness between the engine speed sensor B-ES_S and the Transmission Control Unit A-TRANS is
defective.

7. Check the sensor gap at the engine speed sensor B-ES_S.
A. If a problem is found, adjust the gap or replace the engine speed sensor B-ES_S.

8. Disconnect the X-ESS connector from the engine speed sensor B-ES_S.
Check if the engine speed sensor B-ES_S is defective.
48083741_EN 31/07/2018
55.8 [55.DTC] / 48
5150-03 - Short circuit to battery voltage or open circuit at turbine

speed input
Control Module: TCU
Context:
If the failure is at the output speed, the system has strong limitations to transmission control. The Transmission Control
Unit A-TRANS can engage only one gear in each direction. In some cases only one direction will be possible.
The Transmission Control Unit A-TRANS will shift the transmission into neutral at the first occurrence of the failure.
First, the operator must shift the gear selector into neutral position.
If output speed is less than a threshold for neutral to gear and the operator shifts the gear selector into forward or
reverse, the Transmission Control Unit A-TRANS will select the limp-home gear.
If output speed is less than a threshold for reversal speed and the Transmission Control Unit A-TRANS has changed
into the limp-home gear and the operator selects a shuttle shift, the Transmission Control Unit A-TRANS will shift
immediately into the limp-home gear of the selected direction
If output speed is greater than the threshold, the Transmission Control Unit A-TRANS will shift the transmission into
neutral. The operator has to slow down the vehicle and must shift the gear selector into neutral position.
Cause:
There is a short circuit to battery voltage or an open circuit at the supply circuit of the turbine speed sensor B-TS_S.

3. The harness between the turbine speed sensor B-TS_S and the Transmission Control Unit A-TRANS is defective.
4. The turbine speed sensor B-TS_S is defective.
Solution:
2. Check if the connector X-TSS is connected to the turbine speed sensor B-TS_S.

3. Disconnect the connector X-TSS from the turbine speed sensor B-TS_S.
Check the integrity of the connector X-TSS and visually check for any damage to the connector and to the pins.
A. If a problem is found, replace the connector X-TSS.
48083741_EN 31/07/2018
55.8 [55.DTC] / 49
B. If there are no problems, connect the connector X-TSS to the turbine speed sensor B-TS_S and continue with
Step 4.
5.
3 and 41.

6. Check the harness between the turbine speed sensor B-TS_S and the Transmission Control Unit A-TRANS for a
From To Value

7. Check the harness between the turbine speed sensor B-TS_S and the Transmission Control Unit A-TRANS for
Disconnect the connector X-TSS from the turbine speed sensor B-TS_S.
From To Value
Connector X-TECM pin 41 Connector X-TSS pin 1 There should be continuity

8. Check if the turbine speed sensor B-TS_S is defective.
A. If a problem is found, replace the turbine speed sensor B-TS_S.
48083741_EN 31/07/2018
55.8 [55.DTC] / 50
5150-04 - Short circuit to ground at turbine speed input

Control Module: TCU
Context:
reverse, the Transmission Control Unit A-TRANS will select the limp-home gear .
immediately into the limp-home gear of the selected direction.
Cause:
There is a short circuit to ground at the supply circuit of the turbine speed sensor B-TS_S. The Transmission Control

Solution:

Step 4.
48083741_EN 31/07/2018
55.8 [55.DTC] / 51
5.
3 and 41.

6. Check the harness between the turbine speed sensor B-TS_S and the Transmission Control Unit A-TRANS for a
From To Value

7. Disconnect the X-TSS connector from the turbine speed sensor B-TS_S.
Check if the turbine speed sensor B-TS_S is defective.
48083741_EN 31/07/2018
55.8 [55.DTC] / 52
5150-12 - Logical error at turbine speed input

Control Module: TCU
Context:
reverse, the Transmission Control Unit A-TRANS will select the limp-home gear .
Cause:
There is a logical error at the supply circuit of the turbine speed sensor B-TS_S. The Transmission Control Unit
A-TRANS measures a turbine speed over the threshold value and the next moment the measured speed is zero.

4. The turbine speed sensor B-TS_S gap has the wrong size.
Solution:

Step 4.
48083741_EN 31/07/2018
55.8 [55.DTC] / 53
5.
3 and 41.
tinue with Step 6.
6. Check if the harness between the turbine speed sensor B-TS_S and the Transmission Control Unit A-TRANS is
defective.

7. Check the sensor gap at the turbine speed sensor B-TS_S.
A. If a problem is found, adjust the gap or replace the turbine speed sensor B-TS_S.

8. Disconnect the X-TSS connector from the turbine speed sensor B-TS_S.
Check if the turbine speed sensor B-TS_S is defective.
48083741_EN 31/07/2018
55.8 [55.DTC] / 54
5160-03 - Short circuit to battery voltage or open circuit at internal

speed input
Control Module: TCU
Context:
Cause:
There is a short circuit to battery voltage or an open circuit at the supply circuit of the intermediate speed sensor
B-IS_S. The Transmission Control Unit A-TRANS measures a voltage higher than 7.00 V at speed input pin.

3. The harness between the intermediate speed sensor B-IS_S and the Transmission Control Unit A-TRANS is de-
fective.
4. The intermediate speed sensor B-IS_S is defective.
Solution:
2. Check if the connector X-ISS is connected to the intermediate speed sensor B-IS_S.

3. Disconnect the connector X-ISS from the intermediate speed sensor B-IS_S.
Check the integrity of the connector X-ISS and visually check for any damage to the connector and to the pins.
A. If a problem is found, replace the connector X-ISS.
B. If there are no problems, connect the connector X-ISS to the intermediate speed sensor B-IS_S and continue
with Step 4.
5.
48083741_EN 31/07/2018
55.8 [55.DTC] / 55
3 and 42.

6. Check the harness between the intermediate speed sensor B-IS_S and the Transmission Control Unit A-TRANS
From To Value

Disconnect the connector X-ISS from the intermediate speed sensor B-IS_S.
From To Value
Connector X-TECM pin 42 Connector X-ISS pin 1 There should be continuity

8. Check if the intermediate speed sensor B-IS_S is defective.
A. If a problem is found, replace the intermediate speed sensor B-IS_S.
48083741_EN 31/07/2018
55.8 [55.DTC] / 56
5160-04 - Short circuit to ground at internal speed input

Control Module: TCU
Context:
Cause:
There is a short circuit to ground at the supply circuit of the intermediate speed sensor B-IS_S. The Transmission
Control Unit A-TRANS measures a voltage lesser than 0.45 V at speed input pin.

fective.
4. The intermediate speed sensor B-IS_S defective.
Solution:

with Step 4.
5.
48083741_EN 31/07/2018
55.8 [55.DTC] / 57
3 and 42.

for a short circuit to ground condition.
From To Value

7. Disconnect the X-ISS connector from the intermediate speed sensor B-IS_S.
Check if the intermediate speed sensor B-IS_S is defective.
48083741_EN 31/07/2018
55.8 [55.DTC] / 58
5160-12 - Logical error at internal speed input

Control Module: TCU
Context:
Cause:
There is a logical error at the supply circuit of the intermediate speed sensor B-IS_S. The Transmission Control Unit
A-TRANS measures an intermediate speed over the threshold value and the next moment the measured speed is
zero.

fective.
4. The intermediate speed sensor B-IS_S gap has the wrong size.
5. The intermediate speed sensor B-IS_S is defective.
Solution:

with Step 4.
4. Disconnect the connector A-TRANS from the connector X-CAB_TR.
5.
48083741_EN 31/07/2018
55.8 [55.DTC] / 59
3 and 42.
tinue with Step 6.
6. Check if the harness between the intermediate speed sensor B-IS_S and the Transmission Control Unit A-TRANS
is defective.

7. Check the sensor gap at the intermediate speed sensor B-IS_S.
A. If a problem is found, adjust the gap or replace the intermediate speed sensor B-IS_S.

8. Disconnect the X-ISS connector from the intermediate speed sensor B-IS_S.
Check if the intermediate speed sensor B-IS_S is defective.
48083741_EN 31/07/2018
55.8 [55.DTC] / 60
5170-03 - Short circuit to battery voltage or open circuit at output

speed input
Control Module: TCU
Context:
If the failure is at the turbine speed, the system has strong limitations to transmission control. The Transmission
Control Unit A-TRANS can engage only one gear in each direction. In some cases only one direction will be possible.
First, the operator must shift the gear selector into neutral position. If output speed is less than a threshold for neutral
to gear and the operator shifts the gear selector into forward or reverse, the Transmission Control Unit A-TRANS will
select the limp-home gear. If output speed is less than a threshold for reversal speed and the Transmission Control
Unit A-TRANS has changed into the limp-home gear and the operator selects a shuttle shift, the Transmission Control
Unit A-TRANS will shift immediately into the limp-home gear of the selected direction.
Cause:
There is a short circuit to battery voltage or an open circuit at the supply circuit of the output speed sensor B-OSS.

3. The harness between the output speed sensor B-OSS and the Transmission Control Unit A-TRANS is defective.
4. The output speed sensor B-OSS is defective.
Solution:
2. Check if the connector X-OSS is connected to the output speed sensor B-OSS.

3. Disconnect the connector X-OSS from the output speed sensor B-OSS.
Check the integrity of the connector X-OSS and visually check for any damage to the connector and to the pins.
A. If a problem is found, replace the connector X-OSS.
B. If there are no problems, connect the connector X-OSS to the output speed sensor B-OSS and continue with
Step 4.
48083741_EN 31/07/2018
55.8 [55.DTC] / 61
B. If there are no problems, connect the connector X-TRANS from the connector X-CAB_TR and continue with
Step 5.
4 and 62.

6. Check the harness between the output speed sensor B-OSS and the Transmission Control Unit A-TRANS for a
From To Value

7. Check the harness between the output speed sensor B-OSS and the Transmission Control Unit A-TRANS for an
open circuit condition.
Disconnect the connector X-OSS from the output speed sensor B-OSS.
From To Value
Connector X-TECM pin 62 Connector X-OSS pin 2 There should be continuity

8. Check if the output speed sensor B-OSS is defective.
A. If a problem is found, replace the output speed sensor B-OSS.
48083741_EN 31/07/2018
55.8 [55.DTC] / 62
5170-04 - Short circuit to ground at output speed input

Control Module: TCU
Context:
clutch modulation. The Transmission Control Unit A-TRANS uses the substitute strategy for clutch control. All modu-
lations are only time controlled. If the failure is at the turbine speed, the system has strong limitations to transmission
control. The Transmission Control Unit A-TRANS can engage only one gear in each direction. In some cases only
one direction will be possible.
Cause:
There is a short circuit to ground at the supply circuit of the output speed sensor B-OSS. The Transmission Control

Solution:
2. Check the fuse F-5F3 TECM ( 7.5 V).
A. If a problem is found, replace the fuse F-5F3 TECM ( 7.5 V).


48083741_EN 31/07/2018
55.8 [55.DTC] / 63
Step 5.
Step 6.
4 and 62.

From To Value

8. Disconnect the X-OSS connector from the output speed sensor B-OSS.
Check if the output speed sensor B-OSS is defective.
48083741_EN 31/07/2018
55.8 [55.DTC] / 64
5170-12 - Logical error at output speed input

Control Module: TCU
Context:
clutch modulation. The Transmission Control Unit A-TRANS uses the substitute strategy for clutch control. All modu-
lations are only time controlled. If the failure is at the turbine speed, the system has strong limitations to transmission
control. The Transmission Control Unit A-TRANS can engage only one gear in each direction. In some cases only
one direction will be possible.
Cause:
There is a logical error at the supply circuit of the output speed sensor B-OSS. The Transmission Control Unit
A-TRANS measures an output speed over the threshold value and the next moment the measured speed is zero.

4. The output speed sensor B-OSS gap has the wrong size.
Solution:

Step 4.
48083741_EN 31/07/2018
55.8 [55.DTC] / 65
Step 5.
4 and 62.
tinue with Step 6.
6. Check if the harness between the output speed sensor B-OSS and the Transmission Control Unit A-TRANS is
defective.

7. Check the sensor gap at the output speed sensor B-OSS.
A. If a problem is found, adjust the gap or replace the output speed sensor B-OSS.

48083741_EN 31/07/2018
55.8 [55.DTC] / 66
5180-02 - Output speed zero doesn't fit to other speed signals

Control Module: TCU
Context:
If the failure is at the turbine speed, the system has strong limitations to transmission control. The Transmission
Control Unit A-TRANS can engage only one gear in each direction. In some cases only one direction will be possible.
reverse, the Transmission Control Unit A-TRANS will select the limp-home gear. If output speed is less than a thresh-
old for reversal speed and the Transmission Control Unit A-TRANS has changed into the limp-home gear and the
operator selects a shuttle shift, the Transmission Control Unit A-TRANS will shift immediately into the limp-home gear
of the selected direction.
Cause:
The output speed is zero and does not fit to the other speed signals. If the transmission is not neutral and the shifting
has finished, the Transmission Control Unit A-TRANS measures an output speed equal to zero and a turbine speed
or an intermediate speed not equal to zero.

3. The output speed sensor B-OSS gap has the wrong size.
Solution:
2. Check if the harness between the output speed sensor B-OSS and the Transmission Control Unit A-TRANS is
defective.

3. Check the sensor gap at the output speed sensor B-OSS.
A. If a problem is found, adjust the gap or replace the output speed sensor B-OSS.

Check the signal of the output speed sensor B-OSS.
48083741_EN 31/07/2018
55.8 [55.DTC] / 67
48083741_EN 31/07/2018
55.8 [55.DTC] / 68
5211-09 - Speedlimit_Prop1 Can message timeout

Control Module: TCU
Context:
The Transmission Control Unit A-TRANS keeps the last valid sent Speed_Limit_Request.
Cause:
The Unit Control Module A-UCM does not send message like CAN-message SpeedLimit_Prop1.

2. The CAN connector or the harness are damaged or the connectors are not installed.
3. There are interference on the CAN-Bus .
Solution:
2. Check the integrity of the CAN-Bus harnesses and connectors.
Visually inspect the relevant harness and connectors for damage, bent or dislocated pins, corroded terminals or
broken wires. Verify that the connectors are fully installed. Flex the harness involved to revel intermittent breaks
A. f you find damage or the display indicates other than normal display readings, repair the damage discovered
during the inspection or locate and repair the other than normal display condition and verify that the error has
been resolved.
B. If you do not find damage and the display indicates only normal readings, continue with Step 3.
3. Check the wires of CAN-Bus for a contact to vehicle ground condition.
A. If a problem is found, find and replace the damaged wire.

4. Check the wires of CAN-Bus for a contact to battery voltage condition.

5. Check if there are interference on the CAN-Bus.
A. If a problem is found, repair or replace the defective component.

6. Check the harness and the connector of the CAN-Bus connected to the Unit Control Module A-UCM.
25 and 34.
48083741_EN 31/07/2018
55.8 [55.DTC] / 69
A. If a problem is found, replace the connector X-UCM1B.

48083741_EN 31/07/2018
55.8 [55.DTC] / 70
5212-09 - Speedlimit_Prop2 Can message timeout

Control Module: TCU
Context:
The Transmission Control Unit A-TRANS keeps the last valid sent Speed_Limit_Request.
Cause:
The Unit Control Module A-UCM does not send message like CAN-message SpeedLimit_Prop2.

3. There are interference on the CAN-Bus.
Solution:
A. If you find damage or the display indicates other than normal display readings, repair the damage discovered
been resolved.



6. Check the harness and the connector of the CAN-Bus connected to the Unit Control Module A-UCM.
1 and 10.
48083741_EN 31/07/2018
55.8 [55.DTC] / 71
B. If there are no problems, replace the connector X-UCM2B.

48083741_EN 31/07/2018
55.8 [55.DTC] / 72
521-03 - Inch Pedal Position Sensor over voltage

Control Module: UCM
Context:
The A-UCM detects a value from BRAKE PEDAL ANGLE ( B-BPP) out of higher limit.
Cause:
On pin 16 of connector X-UCM1A of A-UCM, the detected value is > 4.75 V.

2. The BRAKE PEDAL ANGLE ( B-BPP) is damaged.
Solution:
1. Power inch disabled.
Default position sensor to minimum value (0%).
Verify that the fault is present and active.
2. Check the BRAKE PEDAL ANGLE sensor integrity.
Remove the BRAKE PEDAL ANGLE sensor.
Use a multimeter to perform the B-BPP check:
From To Value
Connector X-BPP pin 2 Connector X-BPP pin 1 Resistance
A. If the resistance is an open circuit, replace the BRAKE PEDAL ANGLE.
B. If resistance value is correct, continue with Step 3.

3. Move the cursor of the sensor and, by using a multimeter, perform the B-BPP check:
From To Value
Connector X-BPP pin 2 Connector X-BPP pin 3 Resistance changing
A. If the value is a short circuit, replace the BRAKE PEDAL ANGLE.
B. If the resistance changes, replace the A-UCM.
48083741_EN 31/07/2018
55.8 [55.DTC] / 73
521-04 - Inch Pedal Position Sensor under voltage

Control Module: UCM
Context:
The A-UCM detects a value from BRAKE PEDAL ANGLE ( B-BPP) out of lower limit.
Cause:
On pin 16 of connector X-UCM1A of A-UCM, the detected value is < 0.25 V.
Power inch disabled

Default position sensor to minimum value (0%)
2. The harness between A-UCM and the B-BPP is damaged.
3. The BRAKE PEDAL ANGLE ( B-BPP) is not correctly supplied
4. The BRAKE PEDAL ANGLE ( B-BPP) is damaged.
5. The harness between BRAKE PEDAL ANGLE ( B-BPP) and A-UCM is damaged.
Solution:
2. Check the integrity of the harness between A-UCM and the BRAKE PEDAL ANGLE ( B-BPP).

3. Check the output voltage of A-UCM.
Disconnect the connector X-CAB_B from connector X-BTM.
Use a multimeter to perform the following Voltage check:
From To Value
Connector X-CAB_B pin 4 Connector X-CAB_B pin 3 (ref) Voltage = 5 V
A. If the value is correct, reconnect the connector and continue with Step 6.
B. If the value is not correct, continue with Step 4.

4. Check the integrity of the X-CAB_B connector.
Visually check the integrity of the pins 3 and 4.
B. If both pins are not damaged, continue with Step 5.

5. Check the harness of connector X-CAB_B for a proper condition.
48083741_EN 31/07/2018
55.8 [55.DTC] / 74
Use a multimeter to perform the following resistance check:
From To Value
Connector X-CAB_B pin 4 Connector X-UCM1A pin 3 Short circuit
Connector X-CAB_B pin 3 Connector X-UCM1B pin 1 Short circuit
A. If one value is not correct, replace the harness between the connector and the A-UCM.
B. If the value is correct, continue with Step 6.

6. Check the BRAKE PEDAL ANGLE sensor integrity.
Remove the BRAKE PEDAL ANGLE sensor.
Use a multimeter to perform the B-BPP check:
From To Value
Connector X-BPP pin 2 Connector X-BPP pin 1 Resistance
A. If the resistance is an open circuit, replace the BRAKE PEDAL ANGLE.

7. Move the cursor of the sensor and, by using a multimeter, perform the B-BPP check:
From To Value
Connector X-BPP pin 2 Connector X-BPP pin 3 Resistance changing
A. If the resistance does not change, replace the BRAKE PEDAL ANGLE.
B. If the resistance changes, continue with Step 8.

8. Check the integrity of the X-BTM connector.
Disconnect X-BTM connector and visually check the integrity of the pins 15 on both connectors.
A. If one pin is damaged, replace the relevant harness.

9. Check the B-BPP to X-BTM harness for a proper condition.
From To Value
Connector X-BPP pin 3 Connector X-BTM pin 15 Short circuit
A. If the value is not correct, replace the harness between the connector and the B-BPP.

10. Check the A-UCM to X-CAB_B harness for a proper condition.
From To Value
Connector X-UCM1A pin 16 Connector X-CAB_B pin 15 Short circuit
A. If the value is not correct, replace the harness.
B. If the value is correct, replace the A-UCM.
48083741_EN 31/07/2018
55.8 [55.DTC] / 75

48083741_EN 31/07/2018
55.8 [55.DTC] / 76
619-03 - Short to Power at Park Brake High Side Driver

Control Module: UCM
Context:
The A-UCM detects a value from Park Brake High Side Driver greater than the higher limit; as a consequence:
• If Vehicle moving TRUE
- None;
• If Vehicle moving FALSE
- Park Brake Function disabled ( PB always active)
- Open PB LSD
- Command PB HSD to OFF
- Set B.PBrakeAct = 01(Park Brake Actuator Active).
Cause:
The A-UCM detects, on pin 27 of connector X-UCM3B, a short circuit to power risen by BSP.

2. The harness between A-UCM and the PARKING BRAKE SOLENOID ( Y-Y_PB) is damaged.
3. The PARKING BRAKE SOLENOID is damaged.
4. The connectors X-BTM or X-CAB_B or X-YPB or X-UCM3B or X-UCM1A are damaged.
5. The harness between the connector X-BTM and the PARKING BRAKE SOLENOID is damaged.
6. The harness between the connector X-CAB_B and the A-UCM is damaged.
Solution:
2. Check the integrity of the harness between the A-UCM and the PARKING BRAKE SOLENOID.

3. Check the PARKING BRAKE SOLENOID integrity.
Remove the PARKING BRAKE SOLENOID sensor.
Use a multimeter to perform the resistance measurement of the solenoid.
A. If the resistance is an open circuit, replace the PARKING BRAKE SOLENOID.
B. If the resistance is not an open circuit, continue with Step 4.

4. Check the integrity of connectors X-BTM and X-CAB_B.
Disconnect the connector X-BTM from the connector X-CAB_B and visually check the integrity of pins 18 and 19
of both connectors.
48083741_EN 31/07/2018
55.8 [55.DTC] / 77

5. Check the integrity of harness between the connectors X-BTM and X-YPB.
From To Value
Connector X-BTM pin 18 Connector X-YPB pin 1 Short circuit
A. If one measurement is not correct, replace the harness.
B. If the measurements are correct, continue with Step 6.

Disconnect the connector X-UCM3B from the connector A-UCM and visually check the integrity of pin 27.
A. If the pin is damaged, replace the harness relevant to the damaged connector.

Disconnect the connector X-UCM1A from the connector A-UCM and visually check the integrity of pin 22.

8. Check the integrity of harness between the connector X-CAB_B and the A-UCM.
From To Value
A. If one measurement is not correct, replace the harness between the connector X-CAB_B and the A-UCM.
B. If the measurements are correct, replace the A-UCM.
48083741_EN 31/07/2018
55.8 [55.DTC] / 78
619-04 - Short to Ground at Park Brake High Side Driver

Control Module: UCM
Context:
The A-UCM detects a grounding at Park Brake High Side Driver; as a consequence:
• Park Brake Function disabled (PB always active)
- Open PB LSD
Cause:
The A-UCM detects, on pin 27 of connector X-UCM3B, a short circuit to ground risen by BSP.

Solution:

A. If the resistance is an open circuit, replace the PARKING BRAKE SOLENOID.

of both connectors.

5. Check the integrity of harness between the connectors X-BTM and X-YPB.
48083741_EN 31/07/2018
55.8 [55.DTC] / 79
From To Value



8. Check the integrity of harness between the connector X-CAB_B and the A-UCM.
From To Value
A. If one measurement is not correct, replace the harness between the connector X-CAB_B and the A-UCM.

9. Check the integrity of harness between connectors X-UCM3B and X-UCM1A.
Be sure the PARKING BRAKE SOLENOID sensor is installed and the connectors X-BTM and X-CAB_B are con-
nected.
From To Value
Connector X-UCM3B pin 27 Connector X-UCM1A pin 22 The PARKING BRAKE SOLENOID
resistance
48083741_EN 31/07/2018
55.8 [55.DTC] / 80
619-05 - Open Circuit at Park Brake High Side Driver

Control Module: UCM
Context:
The A-UCM detects a value of current from the Park Brake High Side Driver out of limit; as a consequence:
• Park Brake Function disabled (PB always active)
- Open PB LSD
Cause:
The A-UCM detects, on pin 27 of connector X-UCM3B, an open circuit or a low current risen by BSP.

4. The harness relevant to the A-UCM is damaged.
Solution:



5. Check the integrity of harness relevant to the A-UCM.
48083741_EN 31/07/2018
55.8 [55.DTC] / 81
From To Value
Connector X-UCM3B pin 27 Connector X-UCM1A pin 22 The PARKING BRAKE SOLENOID
resistance
B. If the measurement is not correct, continue with Step 6.

of both connectors.

7. Check the integrity of harness between connector X-CAB_B and the A-UCM.
From To Value
Connector X-UCM3B pin 27 Connector X-CAB_B pin 18 Short circuit

8. Check the integrity of harness between connectors X-BTM and X-YPB.
From To Value
B. If the measurements are correct, replace the PARKING BRAKE SOLENOID.
48083741_EN 31/07/2018
55.8 [55.DTC] / 82
624-03 - Short to Power at Warning LED High Side Driver

Control Module: UCM
Context:
The A-UCM, driving of the Warning LED, detects an output high level.
Cause:

2. The harness between A-UCM and the LED WARNING is damaged.
3. The LED WARNING is damaged.
4. The connectors X-CAB_B or X-PED or X-TT or X-UCM4B are damaged.
5. The harness between connectors X-TT and ground is damaged.
6. The harness between connectors X-PED and the TELL TALE INDICATOR ( LMP-TTI) is damaged.
7. The harness between connectors X-UCM4A and X-CAB_P is damaged.
Solution:
2. Visually check the integrity of the harness between the connector X-UCM4B and the connector X-XTT for any
damage.

3. Replace the LED WARNING.

4. Check the integrity of connector X-TT.
Disconnect the connector X-TT from the TELL TALE INDICATOR and visually check the integrity of pins 4 and 1
of the connector.

5. Check the integrity of harness of the connector X-TT.
Disconnect the connector X-TT from the TELL TALE INDICATOR.
From To Value
Connector X-TT pin 1 Ground Short circuit
48083741_EN 31/07/2018
55.8 [55.DTC] / 83

6. Check the integrity of connectors X-PED and X-CAB_B.
Disconnect the connector X-PED from the connector X-CAB_B and visually check the integrity of pin 5 of both
connectors.

7. Check the integrity of harness between the connector X-PED and the connector X-TT.
From To Value
Connector X-PED pin 5 Connector X-TT pin 4 Short circuit


9. Check the integrity of harness between the connectors X-UCM4B and X-CAB_P.
From To Value
Connector X-UCM4B pin 9 Connector X-CAB_P pin 5 Short circuit

48083741_EN 31/07/2018
55.8 [55.DTC] / 84
624-04 - Short to Ground at Warning LED High Side Driver

Control Module: UCM
Context:
The A-UCM, driving of the Warning LED, detects a short circuit to ground.
Cause:

Solution:
damage.


of the connector.

5. Check the integrity of harness of the connector X-TT.
From To Value
Connector X-TT pin 5 Connector X-TT pin 1 Open circuit
48083741_EN 31/07/2018
55.8 [55.DTC] / 85

connectors.

From To Value
Connector X-PED pin 5 Connector X-TT pin 1 Open circuit


From To Value
Connector X-CAB_P pin 5 Ground Open circuit

48083741_EN 31/07/2018
55.8 [55.DTC] / 86
624-05 - Open Circuit at Warning LED High Side Driver

Control Module: UCM
Context:
The A-UCM, driving of the Warning LED, detects an open circuit or a low current.
Cause:

Solution:
damage.

of the connector.

4. Check the integrity of harness between the connector X-TT and ground.
From To Value
Connector X-TT pin 1 Ground Short circuit

48083741_EN 31/07/2018
55.8 [55.DTC] / 87
connectors.

From To Value


From To Value


48083741_EN 31/07/2018
55.8 [55.DTC] / 88
746-03 - Short to Power at Differential Lock Valve

Control Module: UCM
Context:
The A-UCM detects the supply voltage on pin 3 of connector X-UCM3B.
Cause:
The DIFF LOCK SOLENOID is not correctly working.

2. The harness between A-UCM and the DIFF LOCK SOLENOID is damaged.
3. The DIFF LOCK SOLENOID is damaged.
4. The connector X-TRANS is damaged.
5. The harness between connector X-TRANS and component A-UCM is damaged.
Solution:
1. Disable Differential Lock function.

ZFTC1DisengageDifflockRequest = On (TBC if 2 is possible).
Icon and keypad LED blink (indicating always active) TBC.
Set the key in OFF position.
2. Check the integrity of the harness between A-UCM and the DIFF LOCK SOLENOID.

3. Check the DIFF LOCK SOLENOID integrity.
Remove the DIFF LOCK SOLENOID sensor.
A. If the resistance is an open circuit, replace the DIFF LOCK SOLENOID.

4. Check the integrity of connector X-TRANS.
Disconnect X-TRANS connector and visually check the integrity of pin 27.
A. If the pin is damaged, replace the harness of the connector.

5. Check the integrity of harness between connector X-TRANS and A-UCM.
48083741_EN 31/07/2018
55.8 [55.DTC] / 89
From To Value
Connector X-UCM3B pin 1 Connector X-TRANS pin 27 Short circuit
48083741_EN 31/07/2018
55.8 [55.DTC] / 90
746-04 - Short to Ground at Differential Lock Valve

Control Module: UCM
Context:
The A-UCM detects a grounding on pin 3 of connector X-UCM3B.
Cause:

Solution:


A. If the resistance is = 0, replace the DIFF LOCK SOLENOID.
B. If the resistance is > 0, continue with Step 4.


48083741_EN 31/07/2018
55.8 [55.DTC] / 91
From To Value
48083741_EN 31/07/2018
55.8 [55.DTC] / 92
746-05 - Open Circuit at Differential Lock Valve

Control Module: UCM
Context:
The A-UCM detects an open circuit or a low current on pin 3 of connector X-UCM3B.
Cause:

Solution:


A. If the resistance is an open circuit or too high, replace the DIFF LOCK SOLENOID.
B. If the resistance is > 0, continue with Step 4.


48083741_EN 31/07/2018
55.8 [55.DTC] / 93
From To Value
48083741_EN 31/07/2018
55.8 [55.DTC] / 94
1049-01 - Front Brake Accumulator Low Pressure

Control Module: UCM
Context:
The A-UCM detects a pressure value from Front Brake Accumulator lower than the expected one.
Cause:
Front Accumulator Pressure Mpa < 7.7 MPa.

2. The Front Brake Accumulator Pressure Sensor is not functioning.
3. The Front Brake Accumulator is not functioning.
Solution:
2. By performing the procedures 1049-03 – Short to Power at Front Brake Accumulator Pressure Sensor and
1049-04 – Short to Ground at Front Brake Accumulator Pressure Sensor, check the Front Brake Accumulator
Pressure Sensor is correctly functioning.
A. If the sensor is not functioning, replace sensor.
B. If the sensor is functioning, continue with Step 3.

3. Replace the Front Brake Accumulator.
A. If the functionality is restored, the procedure ends, replace the harness.
48083741_EN 31/07/2018
55.8 [55.DTC] / 95
1049-03 - Short to Power at Front Brake Accumulator Pressure

Sensor
Control Module: UCM
Context:
The A-UCM detects a value from RED_BRAKE_FRNT ( B-PRB1) out of higher limit.
Cause:

2. The RED_BRAKE_FRNT ( B-PRB1) is damaged.
Solution:
1. Set Front Accumulator Pressure to 0 bar

No Brake Pressure Warning available
2. Check the RED_BRAKE_FRNT ( B-PRB1) integrity.
Remove the RED_BRAKE_FRNT ( B-PRB1).
From To Value
Connector X-PRB1 pin B Connector X-PRB1 pin A Resistance
A. If the resistance is an open circuit, replace the RED_BRAKE_FRNT.

3. Move the cursor of the sensor and, by using a multimeter, perform the following check:
From To Value
Connector X-PRB1 pin B Connector X-PRB1 pin C Resistance changing
A. If the value is a short circuit, replace the RED_BRAKE_FRNT.
48083741_EN 31/07/2018
55.8 [55.DTC] / 96
1049-04 - Short to Ground at Front Brake Accumulator Pressure

Sensor
Control Module: UCM
Context:
The A-UCM detects a value from RED_BRAKE_FRNT ( B-PRB1) out of lower limit.
Cause:

2. The harness between A-UCM and B-PRB1 is damaged.
3. The RED_BRAKE_FRNT ( B-PRB1) is not correctly supplied
4. The RED_BRAKE_FRNT ( B-PRB1) is damaged.
5. The harness between RED_BRAKE_FRNT ( B-PRB1) and A-UCM is damaged.
Solution:
1. Set Front Accumulator Pressure to 0 bar

2. Check the integrity of the harness between A-UCM and RED_BRAKE_FRNT ( B-PRB1).

Disconnect the connector X-TRANS from connector X-CAB_TR.
From To Value
Connector X-CAB_TR pin 26 Connector X-CAB_TR pin 3 (ref) Voltage = 5 V
A. If the value is correct, reconnect the connectors and continue with Step 6.

4. Check the integrity of the X-CAB_TR connector.
Visually check the integrity of pins 26 and 3.
48083741_EN 31/07/2018
55.8 [55.DTC] / 97
5. Check the harness of connector X-CAB_TR for a proper condition.
From To Value
Connector X-CAB_TR pin 26 Connector X-UCM1A pin 2 Short circuit
A. If the value is not correct, replace the harness between the connector and the A-UCM.

6. Check the RED_BRAKE_FRNT sensor integrity.
Remove the RED_BRAKE_FRNT sensor.
From To Value
A. If the resistance is an open circuit, replace the RED_BRAKE_FRNT.

From To Value
A. If the resistance does not change, replace the RED_BRAKE_FRNT.

8. Check the integrity of the X-TRANS connector.
Disconnect the connector X-TRANS from the connector X-CAB_TR and visually check the integrity of the pins
1 on both connectors.

9. Check the X-PRB1 to X-TRANS harness for a proper condition.
From To Value
Connector X-PRB1 pin C Connector X-TRANS pin 1 Short circuit
A. If the value is not correct, replace the harness between the connector and the RED_BRAKE_FRNT.

10. Check the A-UCM to X-TRANS harness for a proper condition.
From To Value
Connector X-UCM1A pin 15 Connector X-CAB_TR pin 1 Short circuit
48083741_EN 31/07/2018
55.8 [55.DTC] / 98
48083741_EN 31/07/2018
55.8 [55.DTC] / 99
1052-01 - Rear Brake Accumulator Low Pressure

Control Module: UCM
Context:
The A-UCM detects a pressure value from Rear Brake Accumulator lower than the expected one.
Cause:
Rear Accumulator Pressure Mpa < 7.7 MPa.

2. The Rear Brake Accumulator Pressure Sensor is not functioning.
3. The Rear Brake Accumulator is not functioning.
Solution:
2. By performing the procedures 1052-03 – Short to Power at Rear Brake Accumulator Pressure Sensor and
1052-04 – Short to Ground at Rear Brake Accumulator Pressure Sensor, check the Rear Brake Accumulator
Pressure Sensor is correctly functioning.

3. Replace the Rear Brake Accumulator.
48083741_EN 31/07/2018
55.8 [55.DTC] / 100
1052-03 - Short to Power at Rear Brake Accumulator Pressure

Sensor
Control Module: UCM
Context:
The A-UCM detects a value from the rear brake accumulator pressure sensor ( B-PRB2) out of higher limit. As
reaction, the accumulator pressure is set to 0 bar. No brake pressure warning available.
Cause:

2. The rear brake accumulator pressure sensor ( B-PRB2) is damaged.
3. The rear brake accumulator pressure sensor circuit wiring is defective (open circuit or short circuit).
Solution:
2. Check the integrity of the rear brake accumulator pressure sensor ( B-PRB2) integrity.
Disconnect the connector X-PRB2 and remove the sensor ( B-PRB2).
Use a multimeter to perform the following resistance check on the sensor side:
From To Value
B-PRB2 pin C B-PRB2 pin A 5 kΩ < R < ∞
A. If the resistance is infinite, there is an internal open circuit, replace the sensor.
B. If resistance value is within the range, leave the connector disconnected and continue follows with Step 3.
3. Check the integrity of the rear brake accumulator pressure sensor ( B-PRB2).
Use a multimeter to perform the following resistance check on the sensor side:
From To Value
B-PRB2 pin C B-PRB2 pin B R>0Ω
A. If the resistance is about 0 Ω, there is an internal short circuit. Replace the sensor.
B. If the resistance s grater than 0 Ω, continue with Step 4.

4. Check the rear brake accumulator pressure sensor circuit for a short to high source condition.
Put the key in the ON position.
Use a multimeter to check the voltage between the following points on the harness side:
48083741_EN 31/07/2018
55.8 [55.DTC] / 101
From To Value
Connector X-PRB2 pin B Chassis ground There should be about 5 V
Connector X-PRB2 pin C Chassis ground There should be less than 5 V
Connector X-UCM1A pin 17 Chassis ground There should be less than 5 V
Connector X-UCM1A pin 2 Chassis ground There should be about 5 V
A. If there is more than 5 V, there is a short to high source condition.

Locate the fault and repair the shorted conductor.
B. If the voltage is correct, continue with Step 5.

5. Check the rear brake accumulator pressure sensor circuit for an open circuit condition.
Put the key in the OFF position.
Disconnect the B-PRB2 connector X-PRB2 and the A-UCM connector X-UCM1A.
Use a multimeter to check the continuity between the following points on the harness side:
From To Value
Connector X-PRB2 pin A Connector X-UCM1A pin 1 There should be continuity
Connector X-PRB2 pin B Connector X-UCM1A pin 2 There should be continuity
Connector X-PRB2 pin C Connector X-UCM1AA pin 17 There should be continuity
A. If there is no continuity, there is an open circuit. Locate the fault and repair the broken conductor.
B. If there is continuity, leave the connectors disconnected and continue to Step 6.

6. Check the rear brake accumulator pressure sensor circuit for a short circuit condition.
From To Value
Connector X-PRB2 pin C Connector X-PRB2 pin B There should be no continuity
Connector X-PRB2 pin C Connector X-UCM1A pin 1 There should be no continuity
Connector X-UCM1A pin 17 Connector X-UCM1A pin 1 There should be no continuity
A. If there is continuity, there is a short circuit condition.

Locate the fault and repair the shorted conductor.
B. If there is no continuity, check the A-UCM for the appropriate software and re-flash, if necessary. If the fault
recurs, replace the A-UCM.
48083741_EN 31/07/2018
55.8 [55.DTC] / 102
1052-04 - Short to Ground at Rear Brake Accumulator Pressure

Sensor
Control Module: UCM
Context:
The A-UCM detects a value from RED_BRAKE_REAR ( B-PRB2) out of lower limit.
Cause:

2. The harness between A-UCM and B-PRB2 is damaged.
3. The RED_BRAKE_REAR ( B-PRB2) is not correctly supplied
4. The RED_BRAKE_ REAR ( B-PRB2) is damaged.
5. The harness between RED_BRAKE_FRNT ( B-PRB1) and A-UCM is damaged.
Solution:
1. Set Rear Accumulator Pressure to 0 bar

2. Check the integrity of the harness between A-UCM and RED_BRAKE_REAR ( B-PRB2).

Disconnect the connector X-TRANS from connector X-CAB_TR.
From To Value
Connector X-CAB_TR pin 26 Connector X-CAB_TR pin 3 (ref) Voltage = 5 V

4. Check the integrity of the X-CAB_TR connector.
48083741_EN 31/07/2018
55.8 [55.DTC] / 103
5. Check the harness of connector X-CAB_TR for a proper condition.
From To Value
B. If the value is correct, replace A-UCM.

6. Check the RED_BRAKE_REAR sensor integrity.
Remove the RED_BRAKE_REAR sensor.
From To Value
A. If the resistance is an open circuit, replace the RED_BRAKE_REAR.
B. If resistance value is correct, continue to Step 7.

From To Value
A. If the resistance does not change, replace the RED_BRAKE_REAR.

8. Check the integrity of the X-TRANS connector.
Disconnect the connector X-TRANS from the connector X-CAB_TR and visually check the integrity of the pins
24 on both connectors.

9. Check the X-PRB2 to X-TRANS harness for a proper condition.
From To Value
Connector X-PRB2 pin C Connector X-TRANS pin 24 Short circuit
A. If the value is not correct, replace the harness between the connector and the RED_BRAKE_REAR.

10. Check the A-UCM to X-TRANS harness for a proper condition.
From To Value
48083741_EN 31/07/2018
55.8 [55.DTC] / 104
48083741_EN 31/07/2018
55.8 [55.DTC] / 105
1565-02 - Armrest Signals not plausible

Control Module: UCM
Context:
The A-UCM detects a value from LH ARMREST POSITION (UP and DWN) out of limits.
Cause:
The A-UCM detects one of the following conditions:

• voltage on pin 2B.12 > 15 V and 2B.20 > 15 V for T > 350 ms;
• voltage on pin 2B.12 < 10 V and 2B.20 < 10 V for T > 350 ms.

2. The harness between the A-UCM and the LH ARMREST POSITION (UP and DWN) is damaged.
3. The LH ARMREST POSITION (UP and DWN) is not supplied.
4. The harness between the connector X-CAB_L and the A-UCM is damaged.
5. The harness between the connector X-LFT_A and the LH ARMREST POSITION (UP and DWN) is damaged.
6. The LH ARMREST POSITION (UP and DWN) is damaged.
Solution:
1. If JSS is not Active:

- Prevent JSS Activation
If JSS is Active
- None (discuss if the fault shall be displayed) as soon as JSS get deactivated
- Set Joystick Position to Neutral
- Command PVED to cut Supply Pressure
A. f the fault is present and active, continue with Step 2.
2. Check the integrity of the harness between the A-UCM and the LH ARMREST POSITION (UP and DWN).

3. Check the LH ARMREST POSITION (UP and DWN) power supply.
Disconnect the connector X-LFT_A from the connector X-CAB_L.
From To Value
Connector X-CAB_L pin 10 + 24 V Ref. 24 V
A. If the value is not correct, connect the connector X-LFT_A to the connector X-CAB_L and continue with Step
4.
48083741_EN 31/07/2018
55.8 [55.DTC] / 106

4. Check the integrity of fuse F-5F8.
Remove the fuse F-5F8 from the LC5.
A. If the fuse is burned, replace the fuse.
B. If the fuse is not burned, check the harness between LC5 and the connector X-CAB_L.
5. Check the integrity of harness between the connector X-LFT_A and the LH ARMREST POSITION (UP and DWN).
Disconnect the connectors X-LH_ARM_UP and X-LH_ARM_DWN from the LH ARMREST POSITION (UP and
DWN).
From To Value
Connector X-LFT_A pin 10 Connector X-LH_ARM_UP pin 1 Short circuit
Connector X-LFT_A pin 10 Connector X-LH_ARM_DWN pin 1 Short circuit
A. If one measurement is not correct, replace the harness between the connector X-LFT_A and the LH-ARM-
REST POSITION (UP and DWN).

6. Check the integrity of harness between the connector X-CAB_L and the A-UCM.
Disconnect the connectors X-UCM2B from A-UCM. Use a multimeter to perform the following check:
From To Value
Connector X-UCM2B pin 12 Connector X-CAB_L pin 4 Short circuit
A. If one measurement is not correct, replace the harness between the connector X-CAB_L and the A-UCM.
B. If the measurements are correct, connect the connector X-UCM2B to the A-UCM and continue with Step 7.
7. Check the integrity of harness between the connector X-LFT_A and the LH ARMREST POSITION (UP and DWN).
Remove the connectors X-LH_ARM_UP and X-LH_ARM_DWN.
From To Value
Connector X-LFT_A pin 4 Connector X-LH_ARM_UP pin 3 Short circuit
Connector X-LFT_A pin 8 Connector X-LH_ARM_DWN pin 3 Short circuit
B. If all the measurements are correct, continue with Step 8.

8. Check the integrity of LH ARMREST POSITION (UP and DWN).
Replace the LH ARMREST POSITION UP and the LH ARMREST POSITION DWN.
48083741_EN 31/07/2018
55.8 [55.DTC] / 107

48083741_EN 31/07/2018
55.8 [55.DTC] / 108
2580 - Low Brake Pressure

Context:
Low Brake Pressure.
Cause:

2. The brake pressure is low.
Solution:
2. Bring the machine to a safe stop, and turn the engine OFF immediately. Replace the brake pressure sensor.
48083741_EN 31/07/2018
55.8 [55.DTC] / 109
2661-14 - Roller X Hall cell plausibility error

Control Module: Keypad and Joystick
Context:
The right hand joystick SW-RH_JS is connected to the Universal Control Module (UCM) via CAN2 bus. This fault
occurs if the UCM detects a plausibility error on the joystick roller X hall.
Cause:
The UCM has detected a plausibility error on the joystick roller X hall.
1. Defective harness or connectors, damaged or not fully installed.

2. Defective right hand joystick SW-RH_JS, internal failure.
3. Defective right hand joystick SW-RH_JS wiring harness.
Solution:
Use the diagnostic tool to check the status of this fault.

been resolved.
B. If the fault has not been resolved, continue with Step 4.

4. Check the mechanical integrity of the right hand joystick SW-RH_JS.
Visually inspect the right hand joystick for damage or mechanical defects.
Control the joystick movement and check the integrity of the FNR switch.
Verify that the joystick harness is long enough to allow joystick movement without causing strain on the wires.
A. If the right hand joystick is defective, or the joystick harness is not long enough, replace the component.
B. If the right hand joystick works properly, continue with Step 5.

5. Check the electrical integrity of the right hand joystick SW-RH_JS.
Disconnect X-CAB_AR connector.
48083741_EN 31/07/2018
55.8 [55.DTC] / 110
Use a multimeter to perform the following continuity checks on the right hand joystick side:
From To Value
X-CAB_AR (Plug) pin 1 All the other pins of X-CAB_AR There should be no continuity
A. If there is continuity, there is an internal short circuit. Replace the component.
B. If there is no continuity, leave the connector disconnected and continue with Step 6.
6. Verify the integrity of the fuse F-5F6.
Verify that the fuse F-5F6 is properly installed.
Visually check the fuse F-5F6.
Disconnect the connector X-LC5 of the fuse box LC5.
Use a multimeter to perform the following continuity check:
From To Value
X-LC5 (Receptacle) pin 9B X-LC5 pin 6A There should be continuity
A. If the fuse is broken or damaged or there is no continuity, replace the fuse.
B. If the fuse is ok, continue with Step 7.

7. Verify that the CAN2 bus is properly shielded.
From To Value
CAN2 bus shield Chassis ground There should be continuity
A. If there is no continuity, the CAN2 bus is not properly shielded. Locate the fault and repair the conductor.

8. Check the CAN2 bus for an open circuit condition.
Disconnect X-UCM2B connector.
From To Value
X-CAB_AR (Plug) pin 3 X-UCM2B (Receptacle) pin 1 There should be continuity
B. If there is continuity, leave both connectors disconnected and continue with Step 9.
9. Check the CAN2 bus for a short to ground condition.
48083741_EN 31/07/2018
55.8 [55.DTC] / 111
From To Value
X-CAB_AR (Plug) pin 3 Chassis ground There should be no continuity
A. If there is continuity, there is a short to ground condition. Locate the fault and repair the conductor.

10. Check the right hand joystick SW-RH_JS ground connection.
From To Value
X-CAB_AR (Plug) pin 2 Chassis ground There should be continuity
A. If there is no continuity, there is an open circuit. Locate the fault and repair the conductor.

11. Check the right hand joystick SW-RH_JS power supply connection.
From To Value
X-CAB_AR (Plug) pin 1 X-LC5 pin 6A There should be continuity
B. If there is continuity, check the UCM and replace if necessary. Then erase the fault and continue operation.

48083741_EN 31/07/2018
55.8 [55.DTC] / 112
2662-03 - Hall cell X1/X2 voltage abnormally high

Context:
Hall cell X1/X2 voltage abnormally high.
Cause:
Solution:
A. If the fault is present and active, make calibration.
48083741_EN 31/07/2018
55.8 [55.DTC] / 113
2662-04 - Hall cell X1/X2 voltage abnormally low

Context:
Hall cell X1/X2 voltage abnormally low.
Cause:
Solution:
48083741_EN 31/07/2018
55.8 [55.DTC] / 114
2662-13 - Roller X out of neutral at power-up

Context:
Roller X out of neutral at power-up.
Cause:
Solution:
48083741_EN 31/07/2018
55.8 [55.DTC] / 115
2662-14 - Roller X Hall cell plausibility error

Context:
occurs if the UCM detects a plausibility error on the joystick roller X hall.
Cause:
The UCM has detected a plausibility error on the joystick roller X hall.

Solution:

been resolved.

A. If the right hand joystick is defect, replace the component.

Use a multimeter to perform the following continuity checks on the right-hand joystick side:
48083741_EN 31/07/2018
55.8 [55.DTC] / 116
From To Value
X-CAB_AR (Plug) pin 1 All the other pins of X-CAB_AR There should be no continuity.
From To Value
X-LC5 (Receptacle) pin 9B X-LC5 (Receptacle) pin 6A There should be continuity

From To Value

From To Value
From To Value
48083741_EN 31/07/2018
55.8 [55.DTC] / 117

From To Value

From To Value
X-CAB_AR (Plug) pin 1 X-LC5 (Receptacle) pin 6A There should be continuity

48083741_EN 31/07/2018
55.8 [55.DTC] / 118
2663-03 - Hall cell Y1/Y2 voltage abnormally high

Context:
Hall cell Y1/Y2 voltage abnormally high.
Cause:
Solution:
48083741_EN 31/07/2018
55.8 [55.DTC] / 119
2663-04 - Hall cell Y1/Y2 voltage abnormally low

Context:
Hall cell Y1/Y2 voltage abnormally low
Cause:
Solution:
48083741_EN 31/07/2018
55.8 [55.DTC] / 120
2663-13 - Roller Y out of neutral at power-up

Context:
Roller Y out of neutral at power-up.
Cause:
Solution:
48083741_EN 31/07/2018
55.8 [55.DTC] / 121
2663-14 - Roller Y Hall cell plausibility error

Context:
Roller Y Hall cell plausibility error.
Cause:
Solution:
48083741_EN 31/07/2018
55.8 [55.DTC] / 122
2664-03 - Hall cell Z1/Z2 voltage abnormally high

Context:
occurs if the UCM detects a voltage abnormally high from the joystick hall cell Z1/Z2.
Cause:
The UCM has detected a voltage abnormally high from the joystick hall cell Z1/Z2.

Solution:


been resolved.


Disconnect the X-CAB_AR connector.
From To Value
48083741_EN 31/07/2018
55.8 [55.DTC] / 123
From To Value
X-LC5 (Receptacle) pin 9B X-LC5 pin 6A There should be continuity.
B. If the fuse is ok and there is continuity, continue with Step 7.

From To Value
X-CAB_AR (Plug) pin 1 X-LC5 pin 6A There should be continuity.
B. If there is continuity, leave the connector disconnected and continue with Step 8.
From To Value
X-CAB_AR (Plug) pin 2 Chassis ground There should be continuity.
From To Value
CAN2 bus shield Chassis ground There should be continuity.

From To Value
X-CAB_AR (Plug) pin 3 X-UCM2B (Receptacle) pin 1 There should be continuity.
A. If there is no continuity, there is an open circuit condition. Locate the fault and repair the conductor
11. Check the CAN2 bus for a short to high source condition.
48083741_EN 31/07/2018
55.8 [55.DTC] / 124
From To Value
A. If there is continuity, there is a short circuit condition to the joystick power supply. Locate the fault and repair
the conductor.
B. If there is continuity, check the UCM and replace if necessary. Then erase the fault and continue operation..

48083741_EN 31/07/2018
55.8 [55.DTC] / 125
2664-04 - Hall cell Z1/Z2 voltage abnormally low

Context:
Hall cell Z1/Z2 voltage abnormally low.
Cause:
Solution:
48083741_EN 31/07/2018
55.8 [55.DTC] / 126
2664-13 - Roller Z out of neutral at power-up

Context:
Roller Z out of neutral at power-up.
Cause:
Solution:
48083741_EN 31/07/2018
55.8 [55.DTC] / 127
2664-14 - Roller Z Hall cell plausibility error

Context:
The right-hand joystick SW-RH_JS is connected to the Universal Control Module (UCM) via CAN2 bus. This fault
occurs if the UCM detects a plausibility error on the joystick roller Z hall.
Cause:
The UCM has detected a plausibility error on the joystick roller Z hall

2. Defective right-hand joystick SW-RH_JS, internal failure.
3. Defective right-hand joystick SW-RH_JS wiring harness.
Solution:


been resolved.


From To Value
48083741_EN 31/07/2018
55.8 [55.DTC] / 128
From To Value
X-LC5 (Receptacle) pin 9B X-LC5 pin 6A There should be continuity.

From To Value
CAN2 bus shield Chassis ground There should be continuity.

From To Value
From To Value

From To Value

48083741_EN 31/07/2018
55.8 [55.DTC] / 129

From To Value
X-CAB_AR (Plug) pin 1 X-LC5 (Receptacle) pin 6A There should be continuity.

48083741_EN 31/07/2018
55.8 [55.DTC] / 130
3509-02 - 5V internal fault

Context:
5 V internal fault.
Cause:

2. The wirings to CAN BUS are damaged.
3. The wirings to external connection are damaged.
Solution:
2. Verify the wirings to CAN BUS.
A. If one or more wirings are damaged, proceed with the replacement.
B. If the wirings are intact and functioning, continue with Step 3.

3. Verify the wirings to external connection.
B. If the wiring are not damaged, verify that the fault code is not active.
48083741_EN 31/07/2018
55.8 [55.DTC] / 131
3651-02 - Primary FNR Fault

Control Module: UCM
Context:
The A-UCM detects a fail on the Primary FNR outputs.
Cause:
3 channel Low OR 2 channel High.

2. The harness between A-UCM and the PRIMARY FNR is damaged.
3. The connectors X-CAB_P2 and X-PED_2 are damaged.
4. The harness between connector X-CAB_P2 and component A-UCM is damaged.
5. The harness between connector X-PED_2 and component PFNR is damaged.
Solution:
1. Set Primary FNR to N.

2. Check the integrity of the harness between A-UCM and the PRIMARY FNR.

3. Check the integrity of connectors X-CAB_P2 and X-PED_2.
Disconnect X-CAB_P2 connector from X-PED_2 connector and visually check the integrity of the pins from 1 to
and 6 of both connectors.

4. Check the integrity of harness between connector X-CAB_P2 and component A-UCM.
From To Value
Connector X-UCM2A pin 11 Connector X-CAB_P2 pin 1 Short circuit
Connector X-UCM2B pin 22 Connector X-CAB_P2 pin 4 Short circuit
Connector X-UCM2B pin 21 Connector X-CAB_P2 pin 5 Short circuit
48083741_EN 31/07/2018
55.8 [55.DTC] / 132

5. Check the integrity of harness between connector X-PED_2 and component PFNR.
From To Value
Connector X-TS1 pin A Connector X-PED_2 pin 6 Short circuit
Connector X-TS1 pin B Connector X-PED_2 pin 3 Short circuit
Connector X-TS1 pin C Connector X-PED_2 pin 1 Short circuit
Connector X-TS1 pin D Connector X-PED_2 pin 2 Short circuit
Connector X-TS2 pin B Connector X-PED_2 pin 5 Short circuit
Connector X-TS2 pin C Connector X-PED_2 pin 4 Short circuit
B. If the measurements are correct, replace the component A-PFNR.
48083741_EN 31/07/2018
55.8 [55.DTC] / 133
5123-19 - Display Source Address Cyclic Timeout

Control Module: UCM
Context:
The Universal Control Module A-UCM is connected to the Display A-DSP via both CAN 1 and CAN 2 bus. This fault
occurs if the A-UCM does not receive any message from the Display Source Address within the maximum interval
time (3 times of maximum defined cycle time). As consequence, the UCM uses the last GHMI CAN message received.
Cause:
The A-UCM has detected a cycle time interval, of the CAN display messages, greater than 3 times of maximum
defined cycle time.

Solution:




48083741_EN 31/07/2018
55.8 [55.DTC] / 134
5220-09 - Brakes timeout

Control Module: TCU
Context:
control.
The Transmission Control Unit A-TRANS keeps the last state of parking brake.
Cause:
The Unit Control Module A-UCM does not send CAN message B from the parking brake.

Solution:
been resolved.



6. Check the wires of the CAN harness connected to the Engine Control Unit A-ECU, connector X-ECU pin 46 and
pin 47.
A. If a problem is found, repair or replace the damaged wire.
48083741_EN 31/07/2018
55.8 [55.DTC] / 135

48083741_EN 31/07/2018
55.8 [55.DTC] / 136
5230-09 - Zftc1 Timeout

Control Module: TCU
Context:
control.
The Transmission Control Unit A-TRANS shifts the transmission to neutral position.
Cause:
The Unit Control Module A-UCM does not send CAN message ZF-TransmissionControl from the transmission con-
troller on tranny A-TRC.

Solution:
been resolved.



6. Check the wire of the CAN harness connected to the Unit Control Module A-UCM, connector X-UCM1B pin 34
and pin 25.
48083741_EN 31/07/2018
55.8 [55.DTC] / 137

7. Check the wires of the CAN harness connected to the Unit Control Module A-UCM, connector X-UCM2B pin 1
and pin 10.

48083741_EN 31/07/2018
55.8 [55.DTC] / 138
5260-09 - Dct1 Timeout = Vehicle_1 Timeout

Control Module: TCU
Context:
control.
Cause:
There is a timeout of the CAN-message DTC1 from the display computer A-DSP.

4. The display computer A-DSP is defective.
Solution:
been resolved.

4. Check the harness to display computer and replace if necessary.


6. Check the wire of the CAN harness connected to the display computer A-DSP, connector X-DSP pins 1, 2, 5 and
6.
48083741_EN 31/07/2018
55.8 [55.DTC] / 139
B. If there are no problems, replace the display computer A-DSP.
48083741_EN 31/07/2018
55.8 [55.DTC] / 140
5270-09 - Jss Timeout =Vehicle_2 Timeout

Control Module: TCU
Context:
control.
The Transmission Control Unit A-TRANS shifts the transmission to neutral position while the joystick steering valve
Y-JSS_STRG_VLV is active.
Cause:
There is a timeout of the CAN-message JSS from the joystick steering valve Y-JSS_STRG_VLV.

4. The joystick steering valve Y-JSS_STRG_VLV is defective.
Solution:
been resolved.



6. Check the wire of the CAN harness connected to the joystick steering valve Y-JSS_STRG_VLV, connector X-JSV
pins 4, 5, 9 and 10.
48083741_EN 31/07/2018
55.8 [55.DTC] / 141
B. If there are no problems, replace the joystick steering valve Y-JSS_STRG_VLV.
48083741_EN 31/07/2018
55.8 [55.DTC] / 142
5271-09 - DISPID1 CAN message timeout

Control Module: TCU
Context:
The detected failure in the system has strong limitations to transmission control. The Transmission Control Unit
A-TRANS can engage only one gear in each direction. In some cases only one direction will be possible.
The Transmission Control Unit A-TRANS select the parameter set with ID0.
Cause:
There is a timeout of the CAN-message DISPID1 from the display computer A-DSP.

4. The display computer A-DSP is defective.
Solution:
been resolved.


48083741_EN 31/07/2018
55.8 [55.DTC] / 143

6. Check the wire of the CAN harness connected to the display computer A-DSP, connector X-DSP pins 1, 2, 5 and
6.
B. If there are no problems, replace the display computer A-DSP.
48083741_EN 31/07/2018
55.8 [55.DTC] / 144
5280-09 - Engine Conf timeout

Control Module: TCU
Context:
Cause:
There is a timeout of the CAN-message ENGINE CONF from the Engine Control Unit A-ECU.

4. The Engine Control Unit A-ECU is defective.
Solution:
been resolved.



6. Check the wire of the CAN harness connected to the Engine Control Unit A-ECU, connector X-ECU pin 46 and
pin 47.
48083741_EN 31/07/2018
55.8 [55.DTC] / 145
B. If there are no problems, replace the Engine Control Unit A-ECU.
48083741_EN 31/07/2018
55.8 [55.DTC] / 146
5290-09 - EEC1 Timeout

Control Module: TCU
Context:
Cause:
There is a timeout of the CAN-message EEC1 from the Engine Control Unit A-ECU.

Solution:
been resolved.



pin 47.
48083741_EN 31/07/2018
55.8 [55.DTC] / 147
48083741_EN 31/07/2018
55.8 [55.DTC] / 148

Control Module: TCU
Context:
Cause:

Solution:
been resolved.



pin 47.
48083741_EN 31/07/2018
55.8 [55.DTC] / 149
48083741_EN 31/07/2018
55.8 [55.DTC] / 150
5310-09 - Engine speed limit function during gearshifts does not

work properly
Control Module: TCU
Context:
control.
After the selection of the neutral position, only limited gears are available depending on applications.
Cause:
During gearshift, the engine speed limit function does not work properly.

Solution:
been resolved.

pin 47.

5. Check the efficiency of the Engine Control Unit A-ECU.
The Engine Control Unit A-ECU may ignore torque or speed limit command the Transmission Control Unit
A-TRANS via TSC1 message.
A. If a problem is found, replace the Engine Control Unit A-ECU.
48083741_EN 31/07/2018
55.8 [55.DTC] / 151
5370-02 - Shift lever signal defective

Control Module: TCU
Context:
control.
The Transmission Control Unit A-TRANS shifts the transmission to neutral position and uses informations from the
substitute shift lever.
Cause:
The CAN signal for the shift lever A-PFNR is defective

3. The I/O controller is defective.
Solution:
been resolved.

4. Check the harness of the I/O Controller.
A. If a problem is found, repair or replace the harness.
B. If there are no problems, replace the I/O Controller.
48083741_EN 31/07/2018
55.8 [55.DTC] / 152
5390-02 - Aeb request signal defective

Control Module: TCU
Context:
control.
The last selection of the transmission is kept from the Transmission Control Unit A-TRANS.
Cause:
The CAN signal for the Automatic Emergency Braking (AEB) request is defective.

Solution:
been resolved.

48083741_EN 31/07/2018
55.8 [55.DTC] / 153
5420-02 - Starting gear signal defective

Control Module: TCU
Context:
control.
The Transmission Control Unit A-TRANS uses the default starting gear.
Cause:
The CAN signal for the starting gear is defective.

Solution:
been resolved.

48083741_EN 31/07/2018
55.8 [55.DTC] / 154
5430-02 - Enginge torque signal defective

Control Module: TCU
Context:
Cause:
The CAN signal for the engine torque is defective.

Solution:
been resolved.

4. Check the harness of the Engine Control Unit A-ECU.

48083741_EN 31/07/2018
55.8 [55.DTC] / 155
5431-09 - Engine speed limit function does not work properly

during stall or output speed limit function
Control Module: TCU
Context:
control.
After the selection of the neutral position, only limited gears are available depending on applications.
Cause:
The engine speed limit function or output limit function do not work properly during stall.

Solution:
been resolved.

The Engine Control Unit A-ECU may ignore torque or speed limit command the Transmission Control Unit
A-TRANS via TSC1 message.

48083741_EN 31/07/2018
55.8 [55.DTC] / 156
5440-02 - Reference engine torque signal defective

Control Module: TCU
Context:
Cause:
The CAN signal for reference of the engine torque is defective.

Solution:
been resolved.


48083741_EN 31/07/2018
55.8 [55.DTC] / 157
5450-02 - Actual engine torque signal defective

Control Module: TCU
Context:
Cause:
The CAN signal for actual of the engine torque is defective.

Solution:
been resolved.


48083741_EN 31/07/2018
55.8 [55.DTC] / 158
5460-02 - Nom friction torque signal defective

Control Module: TCU
Context:
Cause:
The CAN signal for nominal friction torque is defective.

Solution:
been resolved.


48083741_EN 31/07/2018
55.8 [55.DTC] / 159

Control Module: TCU
Context:
control.
The Transmission Control Unit A-TRANS uses the default signal of the accelerator pedal in idle position.
Cause:

Solution:
been resolved.



pin 47.
48083741_EN 31/07/2018
55.8 [55.DTC] / 160
48083741_EN 31/07/2018
55.8 [55.DTC] / 161
5480-03 - Short circuit to battery voltage at clutch K1

Control Module: TCU
Context:
If a failure at another clutch is pending, the Transmission Control Unit A-TRANS detects a severe failure that disables
control of system.
The Transmission Control Unit A-TRANS shuts off all solenoid valves and also both common power supplies ( VPS1,
VPS2). The park brake is operating, also all functions which use ADM 1 to ADM 8 are disabled.
Cause:
There is a short circuit to battery voltage at clutch K1 of the transmission controller of tranny A-TRC. The measured
resistance value of the valve is out of limit, the voltage at K1 valve is too high.

3. The harness between the transmission controller of tranny A-TRC and the Transmission Control Unit A-TRANS
is defective.
4. The transmission controller of tranny A-TRC is defective.
Solution:
2. Check if the connector X-TRC is connected to the transmission controller of tranny A-TRC.

3. Disconnect the connector X-TRC from the transmission controller of tranny A-TRC.
Check the integrity of the connector X-TRC and visually check for any damage to the connector and to the pins.
A. If a problem is found, replace the connector X-TRC.
48083741_EN 31/07/2018
55.8 [55.DTC] / 162
B. If there are no problems, connect the connector X-TRC to the transmission controller of tranny A-TRC and
and to the pin 18.
5.
Check the integrity of the connector X-TECM and visually check for any damage to the connector and to the pin
32.

6. heck the harness between the transmission controller of tranny A-TRC and the Transmission Control Unit
A-TRANS for a short circuit to battery voltage condition.
From To Value
B. If there is no voltage, connect X-TECM to the Transmission Control Unit A-TRANS and continue with Step 7.
Check if the transmission controller of tranny A-TRC is defective.
Check the resistance of the transmission controller of tranny A-TRC.
A. If a problem is found, replace the transmission controller of tranny A-TRC.
48083741_EN 31/07/2018
55.8 [55.DTC] / 163
5480-04 - Short circuit to ground at clutch K1

Control Module: TCU
Context:
control of system.
Cause:
There is a short circuit to ground at clutch K1 of the transmission controller of tranny A-TRC. The measured resistance
value of the valve is out of limit, the voltage at K1 valve is too low.

is defective.
4. The harness between the Transmission Control Unit A-TRANS and the lockup solenoid Y-YLS is defective.
5. The lockup solenoid Y-YLS is defective (only for 5-speed models).
Solution:
2. Check if the connector X-TRC is properly connected to the transmission controller of tranny A-TRC.
Check if the connector X-TRANS is properly connected to the connector X-CAB_TR.
Check if the connector X-TECM is properly connected to the Transmission Control Unit A-TRANS.
Check if the connector X-YLS is properly connected to the lockup solenoid Y-YLS (only for 5-speed models).

48083741_EN 31/07/2018
55.8 [55.DTC] / 164
and to the pin 18.
B. If there are no problems, connect the connector X-CAB_TR to the connector X-TRANS and continue with
Step 5.
5. Disconnect the connector X-TECM from the Transmission Control Unit A-TRANS. Check the integrity of the con-
nector X-TECM and visually check for any damage to the connector and to the pin 32.

6. Disconnect the connector X-YLS from the lockup solenoid Y-YLS (only for 5-speed models).
Check the integrity of the connector X-YLS and visually check for any damage to the connector and to the pins
1 and 2.
A. If a problem is found,.replace the connector X-YLS.

7. Check the cables 419 and 420 of the lockup solenoid option (only for 4-speed models). Verify that the cables are
properly insulated from the other connectors.
A. If a problem is found, fix or replace the cable.

8. Check the harness between the transmission controller of tranny A-TRC and the Transmission Control Unit
A-TRANS for a short circuit to ground condition.
From To Value
Connector X-TECM (Receptacle) Chassis ground There should be no continuity
pin 32
Connector X-CAB_TR (Receptacle) Chassis ground There should be no continuity
pin 18
Connector X-TRANS (Plug) pin 18 Chassis ground There should be no continuity
Connector X-TRC (Receptacle) pin Chassis ground There should be no continuity
3
A. If there is a continuity, find and replace the wire 837 and/or 837A.

9. Check the electric insulation of the harness between the transmission controller of tranny A-TRC and the Trans-
mission Control Unit A-TRANS.
Disconnect the connector X-TRC from the transmission controller of tranny A-TRC.
48083741_EN 31/07/2018
55.8 [55.DTC] / 165
From To Value
Connector X-TECM (Receptacle) Connector X-TRC pin 1 There should be no continuity
pin 32
pin 32
Connector X-TECM (Receptacle) Connector X-TRC pin 3 There should be continuity
pin 32
Connector X-TECM pin 32 Connector X-TRC pin 4 There should be no continuity
pin 32
pin 32

10. Replace the transmission controller of tranny A-TRC.
A. If the problem has been solved, repeat the Step 1.
B. If the problem has not been solved, replace the Transmission Control Unit A-TRANS.
48083741_EN 31/07/2018
55.8 [55.DTC] / 166
5480-05 - Open circuit at clutch K1

Control Module: TCU
Context:
control of system.
Cause:
There is an open circuit at clutch K1 of the transmission controller of tranny A-TRC. The measured resistance value
of the valve is out of limit.

is defective.
Solution:

48083741_EN 31/07/2018
55.8 [55.DTC] / 167
and to the pin 18.
5.
32.

A-TRANS for an open circuit condition.
From To Value
Connector X-TECM pin 32 Connector X-TRC pin 3 There should be continuity

7. Check if the transmission controller of tranny A-TRC is defective.
48083741_EN 31/07/2018
55.8 [55.DTC] / 168

Control Module: TCU
Context:
control of system.
Cause:

is defective.
Solution:

48083741_EN 31/07/2018
55.8 [55.DTC] / 169
and to the pin 19.
5.
55.

From To Value
48083741_EN 31/07/2018
55.8 [55.DTC] / 170

Control Module: TCU
Context:
control of system.
Cause:

is defective.
Solution:

48083741_EN 31/07/2018
55.8 [55.DTC] / 171
and to the pin 19.
5.
55.

From To Value

From To Value

48083741_EN 31/07/2018
55.8 [55.DTC] / 172

Control Module: TCU
Context:
control of system.
Cause:

is defective.
Solution:

48083741_EN 31/07/2018
55.8 [55.DTC] / 173
and to the pin 19.
5.
55.

From To Value

48083741_EN 31/07/2018
55.8 [55.DTC] / 174

Control Module: TCU
Context:
control of system.
Cause:

is defective.
Solution:

48083741_EN 31/07/2018
55.8 [55.DTC] / 175
and to the pin 16.
5.
56.

From To Value
48083741_EN 31/07/2018
55.8 [55.DTC] / 176

Control Module: TCU
Context:
control of system.
Cause:

is defective.
Solution:

48083741_EN 31/07/2018
55.8 [55.DTC] / 177
and to the pin 16.
5.
56.

From To Value

From To Value

48083741_EN 31/07/2018
55.8 [55.DTC] / 178

Control Module: TCU
Context:
control of system.
Cause:

is defective.
Solution:

48083741_EN 31/07/2018
55.8 [55.DTC] / 179
and to the pin 16.
5.
56.

From To Value

48083741_EN 31/07/2018
55.8 [55.DTC] / 180
5520-03 - Short circuit to battery voltage at clutch Kv

Control Module: TCU
Context:
control of system.
Cause:
There is a short circuit to battery voltage at clutch Kv of the transmission controller of tranny A-TRC. The measured
resistance value of the valve is out of limit, the voltage at Kv valve is too high.

is defective.
Solution:

48083741_EN 31/07/2018
55.8 [55.DTC] / 181
and to the pin 20.
5.
Check the integrity of the connector X-TECM and visually check for any damage to the connector and to the pin 9.

From To Value
48083741_EN 31/07/2018
55.8 [55.DTC] / 182
5520-04 - Short circuit to ground at clutch Kv

Control Module: TCU
Context:
control of system.
Cause:
There is a short circuit to ground at clutch Kv of the transmission controller of tranny A-TRC. The measured resistance
value of the valve is out of limit, the voltage at Kv valve is too low.

is defective.
Solution:

48083741_EN 31/07/2018
55.8 [55.DTC] / 183
and to the pin 20.
5.

From To Value

From To Value

48083741_EN 31/07/2018
55.8 [55.DTC] / 184
5520-05 - Open circuit at clutch Kv

Control Module: TCU
Context:
control of system.
Cause:
There is an open circuit at clutch Kv of the transmission controller of tranny A-TRC. The measured resistance value

is defective.
Solution:

48083741_EN 31/07/2018
55.8 [55.DTC] / 185
and to the pin 20.
5.

A-TRANSS for an open circuit condition.
From To Value

48083741_EN 31/07/2018
55.8 [55.DTC] / 186
5530-03 - Short circuit to battery voltage at clutch Kr

Control Module: TCU
Context:
control of system. The Transmission Control Unit A-TRANS shuts off all solenoid valves and also both common power
supplies ( VPS1, VPS2). The park brake is operating, also all functions which use ADM 1 to ADM 8 are disabled.
Cause:
There is a short circuit to battery voltage at clutch Kr of the transmission controller of tranny A-TRC. The measured
resistance value of the valve is out of limit, the voltage at Kr valve is too high.

is defective.
Solution:
B. f there are no problems, continue with Step 3.

48083741_EN 31/07/2018
55.8 [55.DTC] / 187
and to the pin 17.
5.
10.

From To Value
48083741_EN 31/07/2018
55.8 [55.DTC] / 188
5530-04 - Short circuit to ground at clutch Kr

Control Module: TCU
Context:
control of system.
Cause:
There is a short circuit to ground at clutch Kr of the transmission controller of tranny A-TRC. The measured resistance
value of the valve is out of limit, the voltage at Kr valve is too low.

is defective.
Solution:

48083741_EN 31/07/2018
55.8 [55.DTC] / 189
and to the pin 17.
5.
10.

From To Value

From To Value

8. Check if the transmission controller of tranny A-TRC is defective. Check the resistance of the transmission con-
troller of tranny A-TRC.
48083741_EN 31/07/2018
55.8 [55.DTC] / 190
5530-05 - Open circuit at clutch Kr

Control Module: TCU
Context:
neutral. The operator has to slow down the vehicle and must shift the gear selector into neutral position. If a failure
at another clutch is pending, the Transmission Control Unit A-TRANS detects a severe failure that disables control of
system.
Cause:
There is an open circuit at clutch Kr of the transmission controller of tranny A-TRC. The measured resistance value

is defective.
Solution:

48083741_EN 31/07/2018
55.8 [55.DTC] / 191
and to the pin 17.
5.
10.

From To Value

48083741_EN 31/07/2018
55.8 [55.DTC] / 192
5536-00 - Hydraulic oil temperature is very high

Context:
Hydraulic oil temperature is very high.
Cause:

2. The hydraulic oil temperature is over 125 °C.
Solution:
2. Bring the machine to a safe stop, and turn the engine OFF immediately. Replace the hydraulic oil temperature
sensor.
48083741_EN 31/07/2018
55.8 [55.DTC] / 193
5536-16 - Hydraulic oil temperature is high

Context:
Hydraulic oil temperature is high.
Cause:

2. The Hydraulic oil temperature is between 110 – 115 °C.
Solution:
2. Idle the machine and monitor the temperature. Wait until the hydraulic oil temperature reach the proper tempera-
ture and restart the machine.
A. If the hydraulic oil temperature rises again, idle the machine and continue with Step 3.
B. If the hydraulic oil temperature within proper range continue to work monitoring the temperature.
3. Clean the radiator or operate the fan reverser. Wait until the hydraulic oil temperature reach the proper temperature
A. If the hydraulic oil temperature rises again, idle the machine and continue with Step 4.
4. Check the hydraulic oil level. Wait until the hydraulic oil temperature reach the proper temperature and restart the
machine.
A. If the hydraulic oil temperature rises again, idle the machine and replace the hydraulic oil temperature sensor.
48083741_EN 31/07/2018
55.8 [55.DTC] / 194
5540-03 - Short circuit to battery voltage at converter clutch

(regulator valve)
Control Module: TCU
Context:
control.
Cause:
There is a short circuit to battery voltage at the converter clutch.

is defective.
Solution:

and to the pin 5.
5.
48083741_EN 31/07/2018
55.8 [55.DTC] / 195
39.

From To Value
48083741_EN 31/07/2018
55.8 [55.DTC] / 196
5540-04 - Short circuit to ground at converter clutch (regulator

valve)
Control Module: TCU
Context:
control.
Cause:
There is a short circuit to ground at the converter clutch.

is defective.
Solution:

and to the pin 5.
5.
48083741_EN 31/07/2018
55.8 [55.DTC] / 197
39.

From To Value
B. If there is no continuity, connect X-TECM to the Transmission Control Unit A-TRANS and continue with Step 7.
48083741_EN 31/07/2018
55.8 [55.DTC] / 198
5540-05 - Open circuit at converter clutch (regulator valve)

Control Module: TCU
Context:
control.
Cause:
There is an opened circuit at the converter clutch.

is defective.
Solution:

and to the pin 5.
5.
48083741_EN 31/07/2018
55.8 [55.DTC] / 199
39.

From To Value

48083741_EN 31/07/2018
55.8 [55.DTC] / 200
5560-03 - Short circuit to battery voltage at relay reverse warning

alarm
Control Module: TCU
Context:
control.
Cause:
There is a short circuit to battery voltage at relay reverse warning alarm. The Transmission Control Unit A-TRANS
detected a wrong voltage at the output pin, that looks like a short circuit to battery voltage.

3. The backup alarm device H-BU_ALARM is defective.
4. The Smart Fuse Box A-SFB is defective.
Solution:
2. Check of the cable that connect the backup alarm device H-BU_ALARM.
been resolved.
3. Check the harness between the Smart Fuse Box A-SFB and the backup alarm device H-BU_ALARM for a short
circuit to battery voltage condition.
Disconnect the connector X-X4 form the Smart Fuse Box A-SFB.
From To Value
Connector X-X4 pin 21 Chassis ground There should be no voltage

4. Check if the backup alarm device H-BU_ALARM is defective.
Check the resistance of the backup alarm device.
48083741_EN 31/07/2018
55.8 [55.DTC] / 201
A. If a problem is found, replace the tbackup alarm device.
B. If there are no problems, replace the Smart Fuse Box A-SFB.
48083741_EN 31/07/2018
55.8 [55.DTC] / 202
5560-05 - Open circuit at relay reverse warning alarm

Control Module: TCU
Context:
control.
Cause:
There is a short circuit to battery voltage at relay reverse warning alarm. The Transmission Control Unit A-TRANS
detected a wrong voltage at the output pin, that looks like a short circuit to battery voltage.

3. The backup alarm device H-BU_ALARM is defective.
4. The Smart Fuse Box A-SFB is defective.
Solution:
2. Check of the cable that connect the backup alarm device H-BU_ALARM.
been resolved.
3. Check the harness between the Smart Fuse Box A-SFB and the backup alarm device H-BU_ALARM for a short
circuit to battery voltage condition.
Disconnect the connector X-X4 form the Smart Fuse Box A-SFB.
From To Value
Connector X-X4 pin 21 Chassis ground There should be no voltage

4. Check if the backup alarm device H-BU_ALARM is defective.
Check the resistance of the backup alarm device.
48083741_EN 31/07/2018
55.8 [55.DTC] / 203
A. If a problem is found, replace the tbackup alarm device.
B. If there are no problems, replace the Smart Fuse Box A-SFB.
48083741_EN 31/07/2018
55.8 [55.DTC] / 204
5657-02 - Incorrect Anti-tamper checksum sent by Engine Controller

Control Module: UCM
Context:
The A-UCM detects an error on the ECU messages checksum; as a consequence Limitation of Torque and Speed.
Cause:
Incorrect Anti-tamper checksum sent by engine ECU.

2. The harness of busses CAN 1 is damaged.
Solution:


48083741_EN 31/07/2018
55.8 [55.DTC] / 205
5657-09 - Anti-tamper checksum not sent by Engine Controller

Control Module: UCM
Context:
The A-UCM detects an error on the ECU messages checksum; as a consequence Limitation of Torque and Speed.
Cause:
Anti-tamper checksum not sent by engine ECU.

2. The harness of busses CAN 1 is damaged.
Solution:


48083741_EN 31/07/2018
55.8 [55.DTC] / 206
5660-02 - Slippage at clutch K1

Control Module: TCU
Context:
control of system.
VPS2).
The park brake is operating, also all functions which use ADM 1 to ADM 8 are disabled. The Transmission Control
Unit A-TRANS shifts the transmission to neutral position.
Cause:
The Transmission Control Unit A-TRANS calculates a differential speed at closed clutch K1. If this calculated value
is out of range, the Transmission Control Unit A-TRANS interprets this as a slipping clutch.

2. The pressure at clutch K1 is low.
3. The main pressure is low.
4. The intermediate speed sensor B-IS_S or the harness to the Transmission Control Unit A-TRANS or the connec-
tors are defective.
5. The output speed sensor B-OSS or the harness to the Transmission Control Unit A-TRANS or the connectors are
defective.
6. The clutch is defective.
Solution:
2. Check the pressure at clutch K1.
A. If a problem is found, repair the transmission as needed.

3. Check the main pressure into the transmission system.
A. If a problem is found, repair the system as needed.

4. Check for the following related faults:
48083741_EN 31/07/2018
55.8 [55.DTC] / 207
5160-12 - Logical error at internal speed input (55.640)
5170-12 - Logical error at output speed input (55.640)
5160-03 - Short circuit to battery voltage or open circuit at internal speed input (55.640)
5160-04 - Short circuit to ground at internal speed input (55.640)
5170-03 - Short circuit to battery voltage or open circuit at output speed input (55.640)
5170-04 - Short circuit to ground at output speed input (55.640)
A. If any of the listed faults are active, diagnose them first and then return to this fault.
B. If none of the listed faults are active, replace the clutch.
48083741_EN 31/07/2018
55.8 [55.DTC] / 208

Control Module: TCU
Context:
control of system.
Cause:

tors are defective.
defective.
Solution:


48083741_EN 31/07/2018
55.8 [55.DTC] / 209
48083741_EN 31/07/2018
55.8 [55.DTC] / 210

Control Module: TCU
Context:
control of system.
Cause:

tors are defective.
defective.
Solution:


48083741_EN 31/07/2018
55.8 [55.DTC] / 211
48083741_EN 31/07/2018
55.8 [55.DTC] / 212

Control Module: TCU
Context:
Cause:

tors are defective.
5. The turbine speed sensor B-TS_S or the harness to the Transmission Control Unit A-TRANS or the connectors
are defective.
Solution:


48083741_EN 31/07/2018
55.8 [55.DTC] / 213
5150-12 - Logical error at turbine speed input (55.640)
5150-03 - Short circuit to battery voltage or open circuit at turbine speed input (55.640)
5150-04 - Short circuit to ground at turbine speed input (55.640)
48083741_EN 31/07/2018
55.8 [55.DTC] / 214
5680-02 - Slippage at clutch Kv

Control Module: TCU
Context:
Cause:
The Transmission Control Unit A-TRANS calculates a differential speed at closed clutch Kv. If this calculated value

2. The pressure at clutch Kv is low.
tors are defective.
are defective.
Solution:
2. Check the pressure at clutch Kv.


48083741_EN 31/07/2018
55.8 [55.DTC] / 215
48083741_EN 31/07/2018
55.8 [55.DTC] / 216
5685-02 - Slippage at clutch Kr

Control Module: TCU
Context:
Cause:
The Transmission Control Unit A-TRANS calculates a differential speed at closed clutch Kr. If this calculated value

2. The pressure at clutch Kr is low.
tors are defective.
are defective.
Solution:
2. Check the pressure at clutch Kr.


48083741_EN 31/07/2018
55.8 [55.DTC] / 217
48083741_EN 31/07/2018
55.8 [55.DTC] / 218
5700-00 - Overtemp Sump

Control Module: TCU
Context:
control.
Cause:
The Transmission Control Unit A-TRANS measures a temperature in the oil sump that is over the allowed threshold.

2. Incorrect level of oil into the transmission.
Solution:
2. Cool down the machine.
Check the oil level of the transmission.
A. If a problem is found, restore the oil level of the transmission.

A. If a problem is found, replace the connector B-HOT.
48083741_EN 31/07/2018
55.8 [55.DTC] / 219
5710-00 - Overtemp Retarder

Control Module: TCU
Context:
control.
Cause:
The Transmission Control Unit A-TRANS measures a temperature in the retarder oil that is over the allowed threshold.

Solution:

48083741_EN 31/07/2018
55.8 [55.DTC] / 220
5720-00 - Overspeed Engine

Control Module: TCU
Context:
control.
Cause:
The Transmission Control Unit A-TRANS measures an engine speed above the defined threshold.

Solution:

Step 4.
5.
3 and 19.
48083741_EN 31/07/2018
55.8 [55.DTC] / 221

From To Value

7. Check the harness between the engine speed sensor B-ES_S and the Transmission Control Unit A-TRANS for
Disconnect the connector X-ESS from the engine speed sensor B-ES_S.
From To Value
Connector X-TECM pin 19 Connector X-ESS pin 1 There should be continuity

8. Check if the engine speed sensor B-ES_S is defective.
48083741_EN 31/07/2018
55.8 [55.DTC] / 222
5730-00 - Differential pressure oil filter

Control Module: TCU
Context:
control.
Cause:
The Transmission Control Unit A-TRANS measures a voltage at the differential pressure switch that is out of the
allowed range.

2. The hydraulic oil filter is polluted.
4. The hydraulic filter pressure switch SW-PHF is defective.
Solution:
Check the efficiency of the hydraulic oil filter.
A. If a problem is found, replace the hydraulic oil filter.

3. Check if the connector X-PHF is connected to the hydraulic filter pressure switch SW-PHF.

4. Disconnect the connector X-PHF from the hydraulic filter pressure switch SW-PHF.
Check the integrity of the connector X-PHF and visually check for any damage to the connector and to the pins.
A. If a problem is found, replace the connector X-PHF.
B. If there are no problems, connect the connector X-PHF to the hydraulic filter pressure switch SW-PHF and
and to the pin 23.
48083741_EN 31/07/2018
55.8 [55.DTC] / 223
6.
17.

7. Check the harness between the hydraulic filter pressure switch SW-PHF and the Unit Control Module A-UCM for
From To Value
Connector X-UCM3A pin 17 Chassis ground There should be no continuity

8. Check the harness between the hydraulic filter pressure switch SW-PHF and the Unit Control Module A-UCM for
a short circuit to battery voltage condition.
From To Value
Connector X-UCM3A pin 17 Chassis ground There should be no voltage
B. If there is no voltage, connect the connector X-UCM3A to the Unit Control Module A-UCM and continue with
Step 9.
9. Disconnect the connector X-PHF from the hydraulic filter pressure switch SW-PHF.
Check if the hydraulic filter pressure switch SW-PHF is defective.
A. If a problem is found, replace the hydraulic filter pressure switch SW-PHF.
48083741_EN 31/07/2018
55.8 [55.DTC] / 224
5740-02 - Slippage at converter lockup clutch

Control Module: TCU
Context:
The lockup clutch is disabled immediately by the system. After fault code was displayed, while the transmission is in
neutral position, the lockup clutch will be enabled again.
Cause:
The Transmission Control Unit A-TRANS calculates a differential speed at closed converter lockup clutch. If this
calculated value is out of range, the Transmission Control Unit A-TRANS interprets this as a slipping clutch.

2. The pressure at converter lock up clutch is low.
4. The engine speed sensor B-ES_S or the harness to the Transmission Control Unit A-TRANS or the connectors
are defective.
are defective.
Solution:
2. Check the pressure at converter lockup clutch.


5140-12 - Logical error at engine speed input (55.640)
5140-03 - Short circuit to battery voltage or open circuit at engine speed input (55.640)
5140-04 - Short circuit to ground at engine speed input (55.640)
48083741_EN 31/07/2018
55.8 [55.DTC] / 225
5745-15 - Overspeed output

Control Module: TCU
Context:
control.
Cause:
The Transmission Control Unit A-TRANS measures a transmission output speed above the defined threshold.

Solution:

Step 4.
Step 5.
4 and 62.
48083741_EN 31/07/2018
55.8 [55.DTC] / 226

From To Value

7. Check the harness between the output speed sensor B-OSS and the Transmission Control Unit A-TRANS for an
open circuit condition.
Disconnect the connector X-OSS from the output speed sensor B-OSS.
From To Value
Connector X-TECM pin 62 Connector X-OSS pin 2 There should be continuity

8. Check if the output speed sensor B-OSS is defective.
48083741_EN 31/07/2018
55.8 [55.DTC] / 227
5755-15 - Transmission input torque overload

Control Module: TCU
Context:
control.
Cause:
The Transmission Control Unit A-TRANS calculates a transmission input torque above the defined threshold.

defective.
Solution:

tinue with Step 4.
5.
48083741_EN 31/07/2018
55.8 [55.DTC] / 228
46 and 49.

From To Value

Disconnect the connector X-TCOT from the gear oil temperature sensor B-GOT.
From To Value
Connector X-TECM pin 49 Connector X-TCOT pin 1 There should be continuity

8. Check if the gear oil temperature sensor B-GOT is defective.
48083741_EN 31/07/2018
55.8 [55.DTC] / 229
5760-00 - Overtemp converter output

Control Module: TCU
Context:
control.
Cause:
The Transmission Control Unit A-TRANS measures an oil temperature at the gear oil temperature sensor B-GOT
output that is over the allowed threshold.

Solution:


48083741_EN 31/07/2018
55.8 [55.DTC] / 230
5810-03 - Short circuit to battery voltage at power supply for

sensors
Control Module: TCU
Cause:
There is a short circuit to battery voltage at the power supply for sensors. The Transmission Control Unit A-TRANS
measures more than 6 V at the pin AU1 (Sensor supply: 5 V).

2. The connector or the harness are damaged or the connectors are not installed.
Solution:
2. Check the integrity of harnesses and connectors of the sensors that are supplied from the power supply at pin
AU1.
been resolved.
3. Check the power supply at pin AU1 for a short circuit to battery voltage condition.
The voltage should be approximately 5 V.
A. If a problem is found, replace the defective component.
48083741_EN 31/07/2018
55.8 [55.DTC] / 231
5810-04 - Short circuit to ground at power supply for sensors

Control Module: TCU
Cause:
There is a short circuit to ground at the power supply for sensors. The Transmission Control Unit A-TRANS measures
less than 4 V at the pin AU1 (Sensor supply: 5 V).

Solution:
2. Check the integrity of harnesses and connectors of the sensors that are supplied from the power supply at pin
AU1.
been resolved.
3. Check the power supply at pin AU1 for a short circuit to ground condition.
The voltage should be approximately 5 V.
A. If a problem is found, replace the defective component.
48083741_EN 31/07/2018
55.8 [55.DTC] / 232
5820-03 - High voltage at battery

Control Module: TCU
Context:
The Transmission Control Unit A-TRANS detects a severe failure that disables control of system. The Transmission
Control Unit A-TRANS shuts off all solenoid valves and also both common power supplies ( VPS1, VPS2). The park
brake is operating, also all functions which use ADM 1 to ADM 8 are disabled.
Cause:
The Transmission Control Unit A-TRANS measures a voltage at power supply that is higher than 32.5 V (device
voltage: 24 V).

Solution:
2. Check the efficiency of the power supply batteries.
A. If a problem is found, replace the defective battery.

3. Check the integrity of harnesses and connectors that connect the batteries to the Transmission Control Unit
A-TRANS.
been resolved.
B. If you do not find damage and the display indicates only normal readings, replace the Transmission Control
Unit A-TRANS.
48083741_EN 31/07/2018
55.8 [55.DTC] / 233
5820-04 - Low voltage at battery

Control Module: TCU
Context:
Cause:
The Transmission Control Unit A-TRANS measures a voltage at power supply that is lower than 18 V (device voltage:
24 V).

Solution:
2. Check the efficiency of the power supply batteries.
A. If a problem is found, replace the defective battery.

3. Check the integrity of harnesses and connectors that connect the batteries to the Transmission Control Unit
A-TRANS.
been resolved.
B. If you do not find damage and the display indicates only normal readings, replace the Transmission Control
Unit A-TRANS.
48083741_EN 31/07/2018
55.8 [55.DTC] / 234
5830-02 - Error at valve power supply VPS1

Control Module: TCU
Context:
Cause:
The Transmission Control Unit A-TRANS switchs ON VPS1 and measures that VPS1 is OFF or Transmission Control
Unit A-TRANS switchs OFF VPS1 and measures that VPS1 is still ON.

3. The permanent power supply KL30 is missing.
Solution:
2. Check the integrity of harnesses and connectors that connect the gearbox to the Transmission Control Unit
A-TRANS.
been resolved.
3. Check the harnesses between the gearbox and the Transmission Control Unit A-TRANS for a short circuit to
battery voltage condition.
A. If a problem is found, find and replace the damaged component.

ground condition.
48083741_EN 31/07/2018
55.8 [55.DTC] / 235
5840-02 - Error valve power supply VPS2

Control Module: TCU
Context:
Cause:
The Transmission Control Unit A-TRANS switchs ON VPS2 and measures that VPS2 is OFF or Transmission Control
Unit A-TRANS switchs OFF VPS2 and measures that VPS2 is still ON.

3. The permanent power supply KL30 is missing.
Solution:
B. If the fault is no longer present or in an inactive state,the fault may be intermittent and not currently active.
2. Check the integrity of harnesses and connectors that connect the gearbox to the Transmission Control Unit
A-TRANS.
been resolved.

ground condition.
48083741_EN 31/07/2018
55.8 [55.DTC] / 236
5860-03 - Short circuit to battery voltage at display output

Control Module: TCU
Context:
control.
Cause:
The Transmission Control Unit A-TRANS sends data to the display A-DSP and measures always a high voltage level
on the connector X-DSP. There is a short circuit to battery voltage at the display A-DSP output.

3. The display A-DSP is defective.
Solution:
2. Check if the connector X-DSP is connected to the display A-DSP.

3. Disconnect the connector X-DSP from the display A-DSP.
Check the integrity of the connector X-DSP and visually check for any damage to the connector and to the pins.
A. If a problem is found, replace the connector X-DSP.

25 and 26.
tinue with Step 5.
5. Check the harness between the display A-DSP and the Transmission Control Unit A-TRANS for a short circuit to
48083741_EN 31/07/2018
55.8 [55.DTC] / 237
From To Value
Connector X-DSP pin 1 Connector X-DSP pin 13 There should be no continuity
A. If there is continuity, find and replace the damaged wire.
B. If there is no continuity, replace the display A-DSP.

48083741_EN 31/07/2018
55.8 [55.DTC] / 238
5860-04 - Short circuit to ground at display output

Control Module: TCU
Context:
control.
Cause:
The Transmission Control Unit A-TRANS sends data to the display A-DSP and measures always a high voltage level
on the connector X-DSP. There is a short circuit to ground at the display A-DSP output.

3. The display A-DSP is defective.
Solution:
2. Check if the connector X-DSP is connected to the display A-DSP.

3. Disconnect the connector X-DSP from the display A-DSP.
Check the integrity of the connector X-DSP and visually check for any damage to the connector and to the pins.
A. If a problem is found, replace the connector X-DSP.

25 and 26.
tinue with Step 5.
5. Check the harness between the display A-DSP and the Transmission Control Unit A-TRANS for a short circuit to
ground condition.
48083741_EN 31/07/2018
55.8 [55.DTC] / 239
From To Value
A. If there is continuity, find and replace the damaged wire.
B. If there is no continuity, replace the display A-DSP.

48083741_EN 31/07/2018
55.8 [55.DTC] / 240
5880-02 - Illegal ID request via Can

Control Module: TCU
Context:
The Transmission Control Unit A-TRANS detects a severe failure that disables control of system.
Cause:
Illegal ID Request via CAN.
48083741_EN 31/07/2018
55.8 [55.DTC] / 241
5890-02 - General EEPROM fault

Control Module: TCU
Context:
control.
Cause:
There is a general EEPROM fault. The Transmission Control Unit A-TRANS can not read the non volatile memory.

Solution:
A. If the fault is present and active, replace the Transmission Control Unit A-TRANS.
48083741_EN 31/07/2018
55.8 [55.DTC] / 242
5900-13 - Configuration lost

Control Module: TCU
Context:
Cause:
The Transmission Control Unit A-TRANS has lost the correct configuration and can not control the transmission.

2. Interference during the saving of the data on the non volatile memory.
3. The Transmission Control Unit A-TRANS is brand new.
4. The Transmission Control Unit A-TRANS is taken from another vehicle.
Solution:
A. If the fault is present and active, reprogram the correct configuration for the vehicle (e.g. with cluster controller,
...).
48083741_EN 31/07/2018
55.8 [55.DTC] / 243
5910-13 - Application error

Control Module: TCU
Context:
Cause:
There is an application error, something of the application is wrong.

Solution:
A. If the fault is present and active, replace the Transmission Control Unit A-TRANS.
48083741_EN 31/07/2018
55.8 [55.DTC] / 244
5930-07 - Clutch failure

Control Module: TCU
Context:
Cause:
The Automatic Emergency Braking (AEB) was not able to adjust the clutch filling parameters. One of the AEB-Values
is out of limit. The Transmission Control Unit A-TRANS shows also the affected clutch on the display.

Solution:
A. If the fault is present and active, check the clutch and repair or replace if necessary.
48083741_EN 31/07/2018
55.8 [55.DTC] / 245
5930-13 - Clutch adjustment data lost or inchpedal calibration data

lost
Control Module: TCU
Context:
control.
Cause:
The Transmission Control Unit A-TRANS is not able to read the correct clutch adjustment parameters.

2. Interference during the saving of the data on the non volatile memory.
3. The Transmission Control Unit A-TRANS is brand new.
Solution:
A. If the fault is present and active, execute the automatic calibration of shifting elements.
48083741_EN 31/07/2018
55.8 [55.DTC] / 246
5940-11 - Substitute clutch control

Control Module: TCU
Context:
Cause:
The transmission input torque is out of allowed range.

2. The engine retarder torque is wrong.
3. The engine torque is wrong.
4. The engine speed signal is defective.
Solution:
5120-03 - Short circuit to battery voltage or open circuit at retarder / torque converter temperature sensor
input (55.640)
5120-04 - Short circuit to ground at retarder / torque converter temperature sensor input (55.640)
5430-02 - Enginge torque signal defective (55.640)
5140-03 - Short circuit to battery voltage or open circuit at engine speed input (55.640)
5140-04 - Short circuit to ground at engine speed input (55.640)
5140-12 - Logical error at engine speed input (55.640)
48083741_EN 31/07/2018
55.8 [55.DTC] / 247
65562-03 - Terminal 50 - Always On

Control Module: ECU
Context:
The Engine Control Unit (ECU) has sensed that the raw battery voltage is greater than the high limit established in
the ECU for longer than 1 s. This fault should reset if battery voltage stays below threshold for longer than 0.5 s.
Cause:
Battery voltage at the ECU is too high.
1. Faulty wiring.
2. Faulty alternator / regulator.
Solution:
1. Verify the fault is still present and in an active state.
A. If fault is still present and active, continue with Step 2.
B. If the fault is not present, the fault may be intermittent. Check for an intermittent fault. If no faults are found,
clear fault code. Return machine to service.
2. Check ECU voltages. Verify the condition of the ECU wiring harness. The voltage reading should be between 22
– 26 V
A. If the voltage reading is greater than 26 V, there is a short to high source in the harness. Locate and repair
damage.
B. If the voltage reading is in range, continue with Step 3.

3. Start the combine engine. Use the Display Monitor diagnostics capability to view "Parameter" status, to check the
battery voltage range.
Increase the engine RPM to high idle (maximum) and check voltage range.
The acceptable voltage range for the module is 22 – 26 V volts when the engine is running.
A. If the voltage reading is greater than 26 V, the alternator and/or regulator has failed, and is producing excessive
voltage. Replace the alternator.
B. If the voltage reading is between 22 – 26 V, check for intermittent fault.
48083741_EN 31/07/2018
55.8 [55.DTC] / 248
65564-03 - Water detected in Fuel

Control Module: ECU
Context:
The fuel filter separates any water from the fuel and collects it in a special tank. This error path is set if this tank is
full and not emptied over a certain time.
Cause:
After preliminary debouncing, the fuel filter water level sensor signal is active.
1. Excess water in the fuel supply.

2. Faulty water in fuel sensor B-WIF, wiring or internal (mechanical and/or electrical) failure.
3. Faulty A-ECU, software.
Solution:
has been resolved.
3. Check fuel for water contamination.
A. If there is water contamination, continue with Step 4.
B. If there is no water contamination, continue with Step 5.

4. Verify proper water in fuel sensor B-WIF operation.
Purge fuel supply system, replace fuel filter(s) and refill with fuel that is free of water contamination.
Start and run engine for 5 min.
Check for code to return to active status.
A. If code returns in an active status, replace water in fuel sensor B-WIF.
B. If code remains inactive, return the machine to service.

5. Check for open, short and grounded circuit conditions in the water in fuel sensor B-WIF circuit.
Disconnect the connector X-WIF.
Disconnect the vehicle harness from the A-ECU at connector X-EDC7.
Disconnect the connector X-LC5 X- from the fuse box LC5.
48083741_EN 31/07/2018
55.8 [55.DTC] / 249
Use a multimeter to perform the following tests, on the vehicle harness:
From To Value
Connector X-WIF pin 1 Connector X-EDC7 (Plug) pin 42 There should be continuity
Connector X-WIF pin 2 Chassis ground There should be continuity
Connector X-WIF (Receptacle) pin Connector X-LC5 (Receptacle) pin There should be continuity
3 9A
Then use the multimeter to perform the following tests, on the vehicle harness:
From To Value
Connector X-WIF pin 1 Connector X-WIF pin 2 There should be no continuity
Connector X-WIF pin 1 Connector X-WIF (Receptacle) pin There should be no continuity
3
Connector X-WIF pin 2 Connector X-WIF (Receptacle) pin There should be no continuity
3
Then use the multimeter to perform the following tests, on the vehicle harness:
From To Value
Connector X-WIF pin 1 Chassis ground There should be no continuity
Connector X-WIF (Receptacle) pin Chassis ground There should be no continuity
3
A. If the results are not as expected for any of the wiring tests listed above, there is an open, short or grounded
circuit condition in the wiring. Locate the fault and repair the wiring.
B. If the results are as expected in all of the wiring tests listed above, the wiring is ok. Leave the connector X-WIF
disconnected and continue with Step 6.
6. Check for key switch voltage supply to water in fuel sensor B-WIF.
Put the key switch in the ON position.
Use a multimeter to perform the following test, on the vehicle harness side:
From To Value
Connector X-WIF (Receptacle) pin Chassis ground There should be key switch voltage
3
Connector X-WIF pin 1 Chassis ground There should be no key switch
voltage
A. If key switch voltage is not present in the first check or present in the second check, locate the fault and repair
the wiring.
B. If there is key switch voltage present in the first check and not present in the second check, continue with Step
7.
7. Replace the water in fuel sensor B-WIF.
Use the EST to verify the status of this fault.
B. If the fault has not been resolved, check the A-ECU for the appropriate software and re-flash, if necessary.
48083741_EN 31/07/2018
55.8 [55.DTC] / 250
65574-03 - Engine Controller battery voltage too High

Control Module: ECU
Context:
The Engine Control Unit ( A-ECU) receives the direct power supply from battery. If the A-ECU determines that battery
voltage is too high, this fault will occur.
Cause:
Battery voltage is too high.
1. Faulty battery
2. Faulty charging system
3. Faulty A-ECU supply wiring, open circuit
4. Faulty A-ECU, software
Solution:
has been resolved.
3. Check the battery voltage.
The engine must be running.
From To Value
Connector X-563 Connector X-566 There should be about 24 V
A. If there is more than 24 V, continue with Step 4
B. If there is about 24 V, continue with Step5.

4. Check the charging system for proper operation.
A. If the charging system is not functioning properly, repair the charging system as necessary.
B. If the charging system is functioning properly, check the A-ECU for the appropriate software and re-flash, if
necessary.
5. Verify the integrity of the F-LC6F1 fuse.
Verify that the fuse is properly installed.
48083741_EN 31/07/2018
55.8 [55.DTC] / 251
Visually check the fuse.
If necessary, use a multimeter to verify the continuity between the two poles of the fuse.
A. If the fuse is broken or damaged, replace the fuse.

6. Check the A-ECU supply wiring.
Disconnect the X-LC6 connector of the crank control.
Disconnect the X-EDC7 connector of the A-ECU.
From To Value
Connector X-LC6 (Receptacle) pin 5 Connector X-EDC7 (Plug) pin 2 There should be continuity
A. If there is no continuity on one or more checks, there is a failure in the A-ECU supply wiring. Locate and repair
the failed conductor.
B. If there is continuity on all checks, check the A-ECU for the appropriate software and re-flash, if necessary.

48083741_EN 31/07/2018
55.8 [55.DTC] / 252
65574-04 - Engine Controller battery voltage too Low

Control Module: ECU
Context:
The Engine Control Unit ( A-ECU) receives the direct power supply from battery. If the A-ECU determines that battery
voltage is too low, this fault will occur.
Cause:
Battery voltage is too low.
1. Faulty battery.
2. Engine cranked for extended period of time.
3. Faulty charging system.
4. Faulty A-ECU supply wiring.
Solution:
has been resolved.
From To Value
A. If there is less than 24 V, charge the battery and then perform a load test.
If the battery passes the load test, continue with Step 4.
If the battery fails the load test, continue with Step 7.
B. If there is about 24 V, continue with Step 4.

4. Check the voltage supply to the A-ECU.
Disconnect the connector X-EDC7.
48083741_EN 31/07/2018
55.8 [55.DTC] / 253
From To Value
Connector X-EDC7 (Plug) pin 2 Chassis ground There should be about 24 V
A. If there is less than 24 V on one or more checks, there is a failure in the A-ECU supply wiring. Locate and
repair the failed conductor.
B. If there is about 24 V on all checks, leave the connector X-EDC7 disconnected and continue with Step 5.
5. Check the ground connection of the A-ECU.
From To Value
Connector X-EDC7 (Plug) pin 5 Chassis ground There should be continuity
A. If there is no continuity on one or more the checks, there is a failure in the A-ECU ground wiring. Locate and
B. If there is continuity on all checks, continue with Step 6.

B. If the charging system is functioning properly, continue with Step 7.

7. Replace the battery.
A. If the fault has been resolved, perform a parasitic draw test to measure excessive current draw from the battery.
If an excessive draw is found, locate and repair as necessary and then return the machine to service.

48083741_EN 31/07/2018
55.8 [55.DTC] / 254
65576-03 - Engine Controller High side supply #2 to Grid heater -

Short to battery
Control Module: ECU
Context:
A short circuit to battery (SCB) of the main relay 1 can only be detected if it is switched off during after run (low side
actuators must also be deactivated). The monitoring of main relay 1 for an SCB error is stopped if a finalized short
circuit to ground of the main relay 1 is detected OR a low side actuator detects a 'no load' error (system ok, no SCB
possible) because both high and low side power stage are switched off.
Cause:
A 'short circuit to battery' longer than 100 ms is reported by the hardware.
1. Faulty of one of the component connected to main relay 1, internal failure.

2. Faulty main relay 1, internal failure.
Solution:
or shorts in the wiring concerned. Operate the machine while you monitor the display. Check all the components
connected to main relay 1.
has been resolved.
3. Check the ECU for the appropriate software and re-flash, if necessary.
B. If the fault has not been resolved, escalate an ASIST concern.
48083741_EN 31/07/2018
55.8 [55.DTC] / 255
65579-02 - Engine Controller Grid Heater relay circuit driver - No

Load
Control Module: ECU
Context:
The Engine Control Unit ( A-ECU) controls the grid heater relay activation on both high side and low side. If the
A-ECU detects an open circuit condition in the grid heater relay circuit, this fault will occur.
Cause:
The A-ECU has detected an open circuit condition in the grid heater relay circuit.
1. Faulty grid heater relay circuit wiring, open circuit.

2. Faulty grid heater relay, internal failure.
Solution:
has been resolved.
3. Verify the integrity of the inline GH fuse F-GH.

4. Check the grid heater relay K-GH circuit wiring for an open circuit condition.
Disconnect the A-ECU connector X-EDC7.
Disconnect the grid heater relay connector X-GHC.
Use a multimeter to perform the following continuity check on the vehicle harness:
48083741_EN 31/07/2018
55.8 [55.DTC] / 256
From To Value
Connector X-GHC pin 1 Connector X-EDC7 (Plug) pin 12 There should be continuity
Connector X-GHC pin 2 Connector X-EDC7 (Plug) pin 75 There should be continuity
A. If there is no continuity, there is an open circuit condition in the K-GH signal circuit. Locate the fault and repair
the shorted conductor.

5. Check the grid heater relay K-GH circuit wiring for an open circuit condition.
Disconnect the grid heater relay connectors GH4 and GH5 and the grid heater connector X-GH6.
Use a multimeter to perform the following continuity check on the vehicle harness:
From To Value
Connector GH5 Connector X-GH6 There should be continuity
Connector GH4 Battery + There should be continuity
A. If there is no continuity, there is an open circuit condition in the K-GH signal circuit. Locate the fault and repair

6. Replace the grid heater relay K-GH.

48083741_EN 31/07/2018
55.8 [55.DTC] / 257
65579-03 - Engine Controller Grid Heater relay circuit driver - Short

circuit to Battery
Control Module: ECU
Context:
A-ECU detects a short to high source condition in the high side supply of the grid heater relay, this fault will occur.
Cause:
The A-ECU has detected a short to high source condition in the grid heater relay high side control circuit.
1. Faulty grid heater relay circuit wiring, shorted to high source.

Solution:
has been resolved.
3. Check the grid heater relay K-GH circuit wiring for a short to high source condition.
Disconnect the A-ECU connector X-EDC7.
Disconnect the grid heater relay connector X-GHC.
Use a multimeter to perform the following voltage check on the vehicle harness:
From To Value
Connector X-GHC pin 1 Chassis ground There should be no voltage
A. If there is voltage, there is a short to high source condition in the K-GH signal circuit. Locate the fault and repair
B. If there is no voltage, leave the connectors disconnected and continue with Step 4.
4. Check the grid heater relay K-GH signal circuit at A-ECU side for a short to high source condition.
Use a multimeter to perform the following continuity check from the engine harness side:
48083741_EN 31/07/2018
55.8 [55.DTC] / 258
From To Value
Connector X-EDC7 (Plug) pin 12 Connector GH4 (pin 30) There should be no continuity
Connector X-EDC7 (Plug) pin 12 All the other pins of connector There should be no continuity
X-EDC7
A. If there is continuity, there is a short to high source condition. Locate and repair the shorted conductor.

48083741_EN 31/07/2018
55.8 [55.DTC] / 259
65579-04 - Engine Controller Grid Heater relay circuit driver - Short

circuit to Ground
Control Module: ECU
Context:
A-ECU detects a short to ground condition in the high side supply of the grid heater relay, this fault will occur.
Cause:
The A-ECU has detected a short to ground condition in the grid heater relay high side control circuit.
1. Faulty grid heater relay signal circuit, shorted to ground.

Solution:
has been resolved.
3. Check the integrity of the grid heater relay K-GH.
Remove the grid heater relay K-GH.
Use a multimeter to perform the following continuity check on the grid heater relay:
From To Value
GH5 (pin 87) Connector X-GHC (Plug) pin 2 (85) There should be no continuity
GH4 (pin 30) Connector X-GHC (Plug) pin 2 (85) There should be no continuity
A. If there is continuity, the grid heater relay is defective. Replace the component.
B. If there is no continuity, leave the grid heater relay removed and continue with Step 4.
4. Check the grid heater relay signal circuit for a short to ground condition.
Put the key switch in the OFF position.
Use a multimeter to perform the following continuity check on the engine harness side:
48083741_EN 31/07/2018
55.8 [55.DTC] / 260
From To Value
Connector X-GHC (Plug) pin 1 Chassis ground There should be no continuity
A. If there is continuity, there is a short circuit to ground in the signal circuit. Locate the fault and repair the shorted
conductor.

5. Check the grid heater relay signal circuit at ECU side for a short to ground condition.
Disconnect the X-EDC7 connector.
From To Value
Connector X-EDC7 (Plug) pin 12 Chassis ground There should be no continuity
Connector X-EDC7 (Plug) pin 12 All the other pins of connector There should be no continuity
X-EDC7
A. If there is continuity, there is a short to ground condition in the engine harness. Locate and repair the shorted
conductor.

48083741_EN 31/07/2018
55.8 [55.DTC] / 261
65585-03 - Engine Coolant Temperature Sensor - Signal Above

Range Max
Control Module: UCM
Context:
The Universal Control Module ( A-UCM) monitors the engine coolant temperature sensor B-RECTD circuit for a volt-
age higher than expected condition. If the A-UCM detects a voltage greater than 4.93 V in the B-RECTD circuit, this
fault will occur.
Cause:
The A-UCM has detected a voltage greater than 4.93 V in the engine coolant temperature sensor B-RECTD signal
circuit.
1. Faulty engine coolant temperature sensor B-RECTD circuit wiring, shorted to high source or open circuit.
2. Faulty engine coolant temperature sensor B-RECTD, internal failure.
3. Faulty A-UCM, software.
Solution:
has been resolved.
Use a multimeter to measure resistance on the coolant temperature sensor B-RECTD as follows:
From To Value
Connector X-RECT (Receptacle) Connector X-RECT (Receptacle) There should be measurable
pin 1 pin 2 resistance.
A. If the resistance is about 0 Ω or more than 1 MΩ, the coolant temperature sensor B-RECTD is defective. Re-
place the unit.
B. If there is measurable resistance, continue with Step 4.

4. Check the engine coolant temperature sensor B-RECTD signal circuit wiring for an open circuit condition.
Disconnect the connector X-RECT.
48083741_EN 31/07/2018
55.8 [55.DTC] / 262
From To Value
Connector X-RECT (Receptacle) Connector X-UCM4A (Receptacle) There should be continuity
pin 1 pin 12
pin 2 pin 1
A. If there is no continuity, there is an open circuit condition in the B-RECTD signal circuit. Locate the fault and
repair the broken conductor.
5. Check the engine coolant temperature sensor B-RECTD signal circuit for a short circuit condition.
From To Value
Connector X-UCM4A (Receptacle) All the other pins of connector There should be no continuity
pin 12 X-UCM4A
pin 1 X-UCM1A
A. If there is continuity, there is a short circuit condition in the B-RECTD signal circuit. Locate the fault and repair
B. If there is no continuity, leave both connectors disconnected and continue with Step 6.
6. Check the engine coolant temperature sensor B-RECTD signal circuit for a short key battery power condition.
From To Value
Connector X-UCM4A (Receptacle) Chassis ground There should be no voltage
pin 12
Connector X-UCM1A (Receptacle) Chassis ground There should be no voltage
pin 1
A. If there is voltage, there is a short to key batter power condition in the B-RECTD signal circuit. Locate the fault
and repair the shorted conductor.

7. Replace the engine coolant temperature sensor B-RECTD.
B. If the fault has not been resolved, check the A-UCM for the appropriate software and re-flash, if necessary.
48083741_EN 31/07/2018
55.8 [55.DTC] / 263
65585-04 - Engine Coolant Temperature Sensor - Signal Below

Range Min
Control Module: UCM
Context:
The Universal Control Module ( A-UCM) monitors the analog input value of the engine coolant temperature sensor
B-RECTD. If the coolant temperature sensor B-RECTD input signal is less than 200.39 mV, this fault will occur.
Cause:
The A-UCM is sensing an analog input signal less than 200.39 mV in the engine coolant temperature sensor B-RECTD
signal circuit.
1. Faulty engine coolant temperature sensor B-RECTD signal circuit, shorted to ground.
2. Faulty engine coolant temperature sensor B-RECTD, internal failure.
Solution:
has been resolved.
From To Value
pin 1 pin 2 resistance.
place the unit.

4. Check the coolant temperature sensor B-RECTD signal circuit for a short to ground condition.
From To Value
Connector X-RECT (Receptacle) Chassis ground There should be no continuity
pin 1
48083741_EN 31/07/2018
55.8 [55.DTC] / 264
A. If there is continuity, there is a short circuit to ground in the engine harness. Locate the fault and repair the
shorted conductor.

5. Check the coolant temperature sensor B-RECTD signal circuit at A-UCM side for a short to ground condition.
Disconnect the X-UCM4A connector.
From To Value
Connector X-UCM4A (Receptacle) Chassis ground There should be no continuity
pin 12
A. If there is continuity, there is a short to ground condition in the engine harness. Locate and repair the shorted
conductor.
B. If there is no continuity, check the A-UCM for the appropriate software and re-flash, if necessary.
48083741_EN 31/07/2018
55.8 [55.DTC] / 265
65585-12 - Engine Coolant Temperature Sensor - Signal Not

Plausible
Control Module: UCM
Context:
The Universal Control Module ( A-UCM) monitors the analog input value of the engine coolant temperature sensor
B-RECTD. If the coolant temperature sensor B-RECTD input signal is not plausible, this fault will occur.
Cause:
The A-UCM has detected an input signal of the coolant temperature sensor B-RECTD not plausible.
1. Faulty engine coolant temperature sensor B-RECTD signal circuit, shorted to ground, shorted to a high source or
open circuit.
2. Faulty engine coolant temperature sensor B-RECTD, failed internally.
Solution:
has been resolved.
From To Value
pin 1 pin 2 resistance
place the unit.

4. Check the engine coolant temperature sensor B-RECTD signal circuit wiring for a short to ground condition.
Use a multimeter to check for continuity on the engine harness as follows:
48083741_EN 31/07/2018
55.8 [55.DTC] / 266
From To Value
pin 1
A. If there is continuity, there is a short circuit to ground in the B-RECTD signal circuit. Locate the fault and repair
B. If there is no continuity, leave the connector X-RECT disconnected and continue with Step 5.
5. Check the engine coolant temperature sensor B-RECTD signal circuit for an open circuit condition.
Use a multimeter to check for continuity on the engine harness as follows:
From To Value
pin 1 pin 12
pin 2 pin 1
repair the conductor.
B. If there is continuity, leave the connector X-RECT disconnected and continue with Step 6.
6. Check the engine coolant temperature sensor B-RECTD signal circuit wiring for a voltage source condition.
Use a multimeter to check for voltage on the engine harness as follows:
From To Value
Connector X-RECT (Receptacle) Chassis ground There should be no voltage
pin 1
Connector X-RECT (Receptacle) Chassis ground There should be no voltage
pin 2
A. If there is voltage, there is a voltage source condition in the B-RECTD signal circuit. Locate the fault and repair
B. If there is no voltage, check the A-UCM for the appropriate software and re-flash, if necessary.
48083741_EN 31/07/2018
55.8 [55.DTC] / 267
65596-03 - Ambient Air Temperature Sensor failure - Signal too high

Control Module: UCM
Context:
The Engine Control Unit (ECU) monitors ambient air temperature by the humidity and ambient temperature sensor
B-HT. If the ECU detects a voltage greater than 4.90 V for more than 500 ms in the air temperature signal, this fault
will occur.
Cause:
The ECU has detected a voltage greater than 4.90 V for longer than 500 ms in the ambient air temperature signal of
the B-HT sensor.
1. Faulty ambient air temperature circuit wiring, short circuit, open circuit or shorted to external source.
2. Faulty humidity and ambient temperature sensor, internal failure.
3. Faulty ECU, software or internal failure.
Solution:
has been resolved.
3. Check the integrity of the humidity and ambient temperature sensor B-HT.
Put the key in the off position.
Disconnect the connector X-HTS and remove the B-HT sensor.
Use a multimeter to check the continuity between the following points on the component side:
From To Value
B-HT pin 4 B-HT pin 1 There should be no continuity
A. If there is continuity, there is an internal short circuit. Replace the sensor, then repeat the Step 1.
4. Check the humidity and ambient temperature sensor circuit wiring for an open circuit condition.
Disconnect the connector X-ECU.
48083741_EN 31/07/2018
55.8 [55.DTC] / 268
Use a multimeter to check the continuity between the following points on the engine harness side:
From To Value
Connector X-HTS (Receptacle) pin Connector X-ECU (Receptacle) pin There should be continuity
1 90
3 43
4 40
A. If there is no continuity, there is an open circuit condition in the B-HT circuit wiring. Locate the fault and repair
the broken conductor.
5. Check the humidity and ambient temperature sensor circuit wiring for a short circuit condition.
From To Value
Connector X-HTS (Receptacle) pin Connector X-ECU (Receptacle) pin There should be no continuity
1 40
4 90
Connector X-ECU (Receptacle) pin Connector X-ECU (Receptacle) pin There should be no continuity
40 90
Connector X-HTS (Receptacle) pin Connector X-HTS (Receptacle) pin There should be no continuity
1 4
A. If there is continuity, there is a short circuit condition in the B-HT circuit wiring. Locate the fault and repair the
shorted conductor.
6. Check the humidity and ambient temperature sensor circuit wiring for a short to key battery power condition.
Use a multimeter to check the voltage between the following points on the engine harness side:
From To Value
Connector X-HTS (Receptacle) pin Chassis ground There should be no voltage
4
Connector X-ECU (Receptacle) pin Chassis ground There should be no voltage
40
A. If there is voltage, there is a short to key batter power condition in the air temperature signal circuit. Locate the
fault and repair the shorted conductor.
B. If there is no voltage, check the ECU for the appropriate software and re-flash, if necessary.
48083741_EN 31/07/2018
55.8 [55.DTC] / 269
65596-04 - Ambient Air Temperature Sensor failure - Signal too low

Control Module: UCM
Context:
The Engine Control Unit (ECU) monitors ambient air temperature by the humidity and ambient temperature sensor
B-HT. If the ECU detects a voltage lower than 200.39 mV for more than 500 ms in the air temperature signal, this fault
will occur.
Cause:
The ECU has detected a voltage lower than 200.39 mV for longer than 500 ms in the ambient air temperature signal
of the B-HT sensor.
1. Faulty ambient air temperature circuit wiring, short circuit or shorted to ground.
Solution:
has been resolved.
3. Check the integrity of the humidity and ambient temperature sensor B-HT.
Put the key in the off position.
Disconnect the connector X-HTS and remove the B-HT sensor.
Use a multimeter to check the continuity between the following points on the component side:
From To Value
A. If there is continuity, there is an internal short circuit. Replace the sensor, then repeat the Step 1.
4. Check the humidity and ambient temperature sensor circuit wiring for an open circuit condition.
Disconnect the connector X-ECU.
48083741_EN 31/07/2018
55.8 [55.DTC] / 270
From To Value
1 90
3 43
4 40
A. If there is no continuity, there is an open circuit condition in the B-HT circuit wiring. Locate the fault and repair
the broken conductor.
5. Check the humidity and ambient temperature sensor circuit wiring for a short circuit condition.
From To Value
3 40
4 43
Connector X-ECU (Receptacle) pin Connector X-ECU (Receptacle) pin There should be no continuity
40 43
Connector X-HTS (Receptacle) pin Connector X-HTS (Receptacle) pin There should be no continuity
3 4
A. If there is continuity, there is a short circuit condition in the B-HT circuit wiring. Locate the fault and repair the
shorted conductor.
6. Check the humidity and ambient temperature sensor circuit wiring for a short to ground condition.
From To Value
Connector X-HTS (Receptacle) pin Chassis ground There should be no continuity
4
Connector X-HTS (Receptacle) pin Chassis ground There should be no continuity
1
A. If there is continuity, there is a short to key batter power condition in the air temperature signal circuit. Locate
the fault and repair the shorted conductor.
B. If there is no continuity, check the ECU for the appropriate software and re-flash, if necessary.
48083741_EN 31/07/2018
55.8 [55.DTC] / 271
65646-03 - Minimum Number of Injections Not Reached – Stop

Engine
Control Module: ECU
Context:
The injector shut-off function can switch off a single injector valve or an entire injection bank if a defect has been
detected in this component (monitoring is performed in other fault paths). If too many cylinders are shut down by the
shut-off function it is no longer possible to run the engine securely and it has to be shut down entirely. In this case
the fault path at hand is set.
Cause:
The number of cylinders with error or shut off exceeds 2 over 1 test cycles (injections).
1. Individual shut-off error of the injector/bank.

2. Faulty ECU, software.
Solution:
2. Check the presence of other related faults.
A. If one or more errors in injectors or banks is detected, resolve the fault. Then, repeat the Step 1.
B. If no other injector/bank fault is detected, continue with Step 3.

48083741_EN 31/07/2018
55.8 [55.DTC] / 272
65660-02 - Injection Processor (CY33X) Error – Injections Limited

By Software
Control Module: ECU
Context:
Fault path for errors in the power stage component of the common rail (or unit injection, for P342) system. The power
stage monitors itself and reports detected errors to the ECU. Monitoring is performed once per camshaft revolution.
Cause:
Power stage component is in 'TESTMODE' (used to test injection failures) longer than No 3 camshaft revolutions.

2. Faulty ECU, failed internally.
Solution:
48083741_EN 31/07/2018
55.8 [55.DTC] / 273
65660-03 - Injection Processor (CY33X) Error – Internal Reset /

Clock Loss / Voltage Too Low
Control Module: ECU
Context:
Cause:
An internal reset is present longer than No 3 camshaft revolutions.
1. Faulty ECU, clock error.

2. Faulty ECU, power supply voltage.
4. Faulty ECU, internal failure.
Solution:
has been resolved.

48083741_EN 31/07/2018
55.8 [55.DTC] / 274
From To Value
B. If there is about 24 V on all checks, leave the connector X-EDC7 disconnected and continue with step 5.

48083741_EN 31/07/2018
55.8 [55.DTC] / 275
65660-04 - Injection Processor (CY33X) Error – Unlocked /

Initialization Failure
Control Module: ECU
Context:
Cause:
After a reset the power stage component was not successfully initialized after No 3 camshaft revolutions.

Solution:
48083741_EN 31/07/2018
55.8 [55.DTC] / 276
65660-12 - Injection Processor (CY33X) Error – SPI Communication

Failure
Control Module: ECU
Context:
Cause:
Disturbed SPI communication, invalid command or a checksum error in the power stage message is present longer
than No 3 camshaft revolutions.

Solution:
48083741_EN 31/07/2018
55.8 [55.DTC] / 277
65683-03 - Turbine speed - Signal too high

Control Module: TCU
Context:
The Transmission Control Unit (TCU / A-TRANS) monitors the turbine speed sensor B-TS_S circuit for a voltage
higher than expected condition. If the A-TRANS detects a voltage too high of the turbine speed signal, this fault will
occur.
Cause:
The A-TRANS has detected a voltage too high of the turbine speed signal.
1. Faulty turbine speed sensor B-TS_S circuit wiring, shorted to high source or open circuit.
2. Faulty turbine speed sensor B-TS_S, internal failure.
3. Faulty A-TRANS, software.
Solution:
has been resolved.
3. Check the integrity of the turbine speed sensor B-TS_S.
Turn the key switch in the OFF position.
Disconnect the connector X-TSS and remove the turbine speed sensor.
Use a multimeter to measure resistance between the following points on the component side:
From To Value
B-TS_S pin 1 B-TS_S pin 2 There should be measurable
resistance
A. If the resistance is about 0 Ω or infinite, the turbine speed sensor B-TS_S is defective. Replace the component.
B. If there is measurable resistance, leave the connector disconnected and continue with Step 4.
4. Check the turbine speed sensor B-TS_S signal circuit wiring for an open circuit condition.
Disconnect the connector X-TECM.
48083741_EN 31/07/2018
55.8 [55.DTC] / 278
From To Value
Connector X-TSS (Receptacle) pin Connector X-TECM (Receptacle) There should be continuity
1 pin 41
Connector X-TSS (Receptacle) pin Connector X-TECM (Receptacle) There should be continuity
2 pin 3
A. If there is no continuity, there is an open circuit condition. Locate the fault and repair the broken conductor.
5. Check the turbine speed sensor B-TS_S signal circuit wiring for a short circuit condition.
From To Value
Connector X-TECM (Receptacle) All the other pins of connector There should be no continuity
pin 41 X-TECM
A. If there is continuity, there is a short circuit condition. Locate the fault and repair the shorted conductor.
6. Check the turbine speed sensor B-TS_S circuit wiring for a short key battery power condition.
Use a multimeter to check the voltage between the following points on the harness side:
From To Value
Connector X-TECM (Receptacle) Chassis ground There should be no voltage
pin 41
Connector X-TECM (Receptacle) Chassis ground There should be no voltage
pin 3
Connector X-TSS (Receptacle) pin Chassis ground There should be no voltage
1
Connector X-TSS (Receptacle) pin Chassis ground There should be no voltage
2
A. If there is voltage, there is a short to key batter power condition. Locate the fault and repair the shorted con-
ductor.

7. Replace the turbine speed sensor B-TS_S.
B. If the fault has not been resolved, check the A-TRANS for the appropriate software and re-flash, if necessary.
48083741_EN 31/07/2018
55.8 [55.DTC] / 279
65683-04 - Turbine speed - Signal too low

Control Module: TCU
Context:
The Transmission Control Unit (TCU / A-TRANS) monitors the analog input value of the turbine speed sensor B-TS_S.
If the turbine speed sensor B-TS_S input signal is too low, this fault will occur.
Cause:
The A-TRANS is sensing an analog input signal too low in the turbine speed sensor B-TS_S signal circuit.
1. Faulty turbine speed sensor B-TS_S signal circuit, shorted to ground.

2. Faulty turbine speed sensor B-TS_S, internal failure.
3. Faulty A-TRANS, software.
Solution:
has been resolved.
3. Check the integrity of the turbine speed sensor B-TS_S.
Disconnect the connector X-TSS and remove the turbine speed sensor.
Use a multimeter to measure resistance between the following points on the component side:
From To Value
B-TS_S pin 1 B-TS_S pin 2 There should be measurable
resistance
A. If the resistance is about 0 Ω or infinite, the turbine speed sensor B-TS_S is defective. Replace the component.
B. If there is measurable resistance, leave the connector disconnected and continue with Step 4.
4. Check the turbine speed sensor B-TS_S signal circuit for a short to ground condition.
Disconnect the connector X-TECM.
48083741_EN 31/07/2018
55.8 [55.DTC] / 280
From To Value
Connector X-TECM (Receptacle) Chassis ground There should be no continuity
pin 41
Connector X-TSS (Receptacle) pin Chassis ground There should be no continuity
1
A. If there is continuity, there is a short to ground condition. Locate the fault and repair the shorted conductor.
5. Check the turbine speed sensor B-TS_S signal circuit wiring for a short circuit condition.
From To Value
Connector X-TECM (Receptacle) Connector X-TSS (Receptacle) pin There should be no continuity
pin 41 2
Connector X-TECM (Receptacle) Connector X-TSS (Receptacle) pin There should be no continuity
pin 3 1
Connector X-TECM (Receptacle) All the other pins of connector There should be no continuity
pin 41 X-TECM
Connector X-TSS (Receptacle) pin Connector X-TSS (Receptacle) pin There should be no continuity
1 2
A. If there is continuity, there is a short circuit condition. Locate the fault and repair the shorted conductor.

6. Replace the turbine speed sensor B-TS_S.
B. If the fault has not been resolved, check the A-TRANS for the appropriate software and re-flash, if necessary.
48083741_EN 31/07/2018
55.8 [55.DTC] / 281
65694-04 - Torque Reduction due to Smoke Limitation

Context:
This fault path indicates that a power reduction due to smoke limitation is currently active which limits the engine
torque. In other words, this fault path is not used as an actual error status indicating a real defect but is used more for
information purposes for service personnel to determine the exact cause of the power limitation (in case a real defect
evokes a power reduction the triggering failure also has to be present in the failure memory).
Monitoring is only active if engine speed is above 500 RPM.
Cause:
A power reduction due to smoke limitation (via limiting torque) is active causing a torque limitation greater than 25%,
of the momentarily allowed maximum torque, or a high idle torque limitation greater than 5%.
1. Active power reduction due to smoke limitation.
Solution:
1. No actions necessary due to this failure alone. If power reduction occurred due to actual defect, the failure trig-
gering the torque limitation should also be in the failure memory. Follow troubleshooting of this root error.
48083741_EN 31/07/2018
55.8 [55.DTC] / 282
65717-02 - Timeout of CAN Message VCM2EDC

Control Module: ECU
Context:
The Engine Control Unit (ECU) is capable of connecting to and communicating on two separate Controller Area Net-
works (CAN). Proper configuration and monitoring of the two twisted pair configured networks is also a function of the
ECU. CAN Node 1 Bus is the main vehicle interface bus. The ECU provides a CAN termination resistor for the CAN
Node 1 Bus, internal to the ECU. The ECU receives and responds to proprietary idle speed, intermediate speed and
feedback information. If the ECU senses a message timeout, this fault will occur.
Cause:
The ECU has sensed a proprietary speed message timeout.
1. Faulty vehicle system, related CAN fault.

2. Faulty ECU supply voltage or ground, missing.
3. Faulty CAN 1 circuit wiring, open circuit, short to ground, or short circuit.
4. Faulty ECU, termination resistor or software.
Solution:
2. Check for other vehicle CAN faults.
Use the EST to determine if related vehicle CAN faults exist.
A. If other vehicle CAN faults do exist, resolve the vehicle CAN faults, then check if this fault is also resolved.
B. If other vehicle CAN faults do not exist, or this fault has not been resolved, continue with Step 3.
has been resolved.
48083741_EN 31/07/2018
55.8 [55.DTC] / 283
From To Value
Connector X-EDC7 (Plug) pin 3 Chassis ground Here should be about 24 V
A. If there is less than 24 V on one or more the checks, there is a failure in the A-ECU supply wiring.
Locate and repair the failed conductor.
From To Value
B. If there is continuity on all the checks, leave the connector X-EDC7 disconnected and continue with Step 7.
7. Check the ECU CAN 1 circuit for a short circuit condition.
Use a multimeter to perform the following continuity check on the engine harness:
From To Value
Connector X-EDC7 (Plug) pin 34 Connector X-EDC7 (Plug) pin 35 There should be no continuity
A. If there is continuity, there is a short circuit condition between the CAN H and CAN L wiring. Locate and repair
B. If there is no continuity, leave the connector X-EDC7 disconnected and continue with Step 8.
8. Check the ECU CAN 1 circuit for a short to ground condition.
From To Value
A. If there is continuity, there is a short circuit to ground condition in the CAN 1 circuit.
Locate and repair the shorted conductor.
48083741_EN 31/07/2018
55.8 [55.DTC] / 284
9. Check the ECU CAN 1 circuit for an open circuit condition.
Disconnect the diagnostic connector X-DIA.
Disconnect the UCM connector X-UCM1B.
From To Value
Connector X-EDC7 (Plug) pin 35 Connector X-DIA (Plug) pin C There should be continuity
Connector X-EDC7 (Plug) pin 34 Connector X-DIA (Plug) pin D There should be continuity
Connector X-EDC7 (Plug) pin 35 Connector X-UCM1B (Receptacle) There should be continuity
pin 34
pin 25
A. If there is no continuity, there is an open circuit condition in the CAN 1 circuit.

B. If there is continuity, check the ECU for the appropriate software and re-flash, if necessary.

48083741_EN 31/07/2018
55.8 [55.DTC] / 285
65734-03 - Timeout of CAN message TSC1-PE Torque (When Active)

Control Module: ECU
Context:
Node 1 Bus, internal to the ECU. The ECU receives and responds to Power take-off to Engine controller (PE) infor-
mation at two different rates (active and passive) dependent upon change request status. If the ECU is not sensing
the PE message at the active rate, this fault will occur.
Cause:
CAN controller of the EDC reports a reception timeout for the PTO message TSC1PEActIv while the override control
mode is active. Defect condition fulfilled continuously for more than 200.0 ms.

Solution:
has been resolved.
48083741_EN 31/07/2018
55.8 [55.DTC] / 286

From To Value
A. If there is less than 24 V on one or more the checks, there is a failure in the A-ECU supply wiring. Locate and
From To Value
From To Value
From To Value
A. If there is continuity, there is a short circuit to ground condition in the CAN 1 circuit. Locate and repair the
shorted conductor.
48083741_EN 31/07/2018
55.8 [55.DTC] / 287
From To Value
pin 34
pin 25


48083741_EN 31/07/2018
55.8 [55.DTC] / 288
65736-03 - Timeout of CAN message TSC1-VE Speed (When Active)

Control Module: ECU
Context:
works (CAN). Proper configuration and monitoring of the two twisted pair configured networks is also a function of
the ECU. CAN Node 1 Bus is the main vehicle interface bus. The ECU provides a CAN termination resistor for the
CAN Node 1 Bus, internal to the ECU. The ECU receives and responds to Torque/Speed Control (TSC) information
at two different rates (active and passive) dependent upon change request status. If the ECU is not sensing the TSC
message at the active rate, this fault will occur.
Cause:
CAN controller of the EDC reports a reception timeout for the VCM/BC message TSC1VEActIv while the override
control mode is active. Defect condition fulfilled continuously for more than 200 ms.

Solution:
has been resolved.
48083741_EN 31/07/2018
55.8 [55.DTC] / 289

From To Value
Connector X-EDC7 (Plug) pin 3 Chassis ground here should be about 24 V
From To Value
From To Value
From To Value
A. If there is continuity, there is a short circuit to ground condition in the CAN 1 circuit.
48083741_EN 31/07/2018
55.8 [55.DTC] / 290
From To Value
pin 34
pin 25


48083741_EN 31/07/2018
55.8 [55.DTC] / 291
65745-03 - ECM Internal SPI Communication Error – CJ940

Control Module: ECU
Context:
This fault monitors the internal communication between the microcontroller and some peripheral integrated circuit and
is set if a disturbance occurs. The communication with each CJ 940 module via SPI bus is monitored cyclically every
100 ms by evaluating the corresponding communication error flag which is provided by the hardware encapsulation.
For every test an error counter is in-/decremented depending if the evaluated error flag indicates a defect or not.
Cause:
The error counter for defective SPI bus communication reaches or exceeds the value of 5. Counter increment at
default detection by 1 step per event.

2. Faulty ECU, electric disturbances.
3. Faulty ECU, internal failure leading to a SPI bus communication error.
Solution:
48083741_EN 31/07/2018
55.8 [55.DTC] / 292
65747-12 - ECM (Locked) Recovery Occurred

Control Module: ECU
Context:
There are various failures of the ECU which trigger a recovery (reset of the CPU). During a fresh ECU start up different
hardware tests are performed. If the error remains present even after reset, the software remains in the bootblock and
the driving software is not processed. If 3 recoveries are triggered within 4 s an irreversible shut off of the system is
carried out and the ECU is classified as permanently defective. In this case no error entry is possible. If, however, the
error leading to the recovery is not detected repeatedly and the system is allowed to start up, one of three recovery
error becomes active (Locked, suppressed or visible) depending on the visibility of the recovery.
Cause:
During system start up a hardware error or configuration problem was detected which leads to a ECU recovery that
is stored as protected.
1. Faulty ECU, electronic disturbances.

2. Faulty ECU, software configuration.
Solution:
48083741_EN 31/07/2018
55.8 [55.DTC] / 293
65748-12 - ECM Processor – Watchdog Not Plausible

Control Module: ECU
Context:
Next to a CPU the ECU also contains a monitoring module (watchdog). These two components communicate via
a SPI-Bus with each other. Both devices mutually monitor each other for correct functioning. On the one hand, the
watchdog initiates a query/response communication with the CPU. Once the CPU receives the query it starts a 'com-
mand test' (tests the correct functioning of important processor commands) and a 'program flow control' (monitors
the correct execution of code segments of the monitoring). From the results of these two procedures the response
to the watchdog is composed. If this response does not correspond to the expected value an error counter (WD-
Com_dErrorCountForCntler_u8) is incremented. On the other hand, the CPU periodically sends incorrect responses
(regarding response time and value respectively) upon a received query of the watchdog. The CPU then monitors if
the above mentioned error counter of the watchdog is in-/decremented according to an incorrect/correct response. If
the behavior of the counter is implausible a second error counter (WDCom_dErrorCountForWD_u8) is incremented.
Cause:
One of the two error counters (WDCom_dErrorCountForCntler_u8 or WDCom_dErrorCountForWD_u8) exceeds the
value of 5.
1. Faulty ECU, defective monitoring module or CPU (e.g. impaired functioning of the CPU clock) of the EDC.
2. Faulty ECU, Disturbed SPI-Bus.
Solution:
48083741_EN 31/07/2018
55.8 [55.DTC] / 294
65749-02 - Shutoff Paths During Initialization – Supply Voltage Too

High
Control Module: ECU
Context:
The ECU comprises so-called redundant shut-off paths (SOP) which deactivate all power stages relevant to injection if
certain internal ECU errors are detected. The defects which trigger such a redundant shut-off are an internal watchdog
error (Dfp_Mon) and an over- or undervoltage error of the ECU (Dfp_HWEMonU%Supply, %= Max, Min). In order to
test the correct functioning of the SOP procedure every path is shortly activated during ECU initialization and following
this the fuel injection power stage is activated. Since, however, the SOP is active no injection should occur as it is
blocked if the SOP procedure functions correctly. During a successful redundant shut-off test an open circuit (=no
current flow) should be detected.
The SOP test can only be carried out once, during ECU initialization if no errors such as short circuits of the injection
power stage has been detected previously.
Cause:
Injection occurred although internal shut-off path of the overvoltage monitoring was active.

Solution:
48083741_EN 31/07/2018
55.8 [55.DTC] / 295
65749-04 - Shutoff Paths During Initialization - Watchdog

Control Module: ECU
Context:
error (Dfp_Mon) and an over- or undervoltage error of the ECU (Dfp_HWEMonU%Supply, %= Max, Min). In order to
test the correct functioning of the SOP procedure every path is shortly activated during ECU initialization and following
this the fuel injection power stage is activated. Since, however, the SOP is active no injection should occur as it is
blocked if the SOP procedure functions correctly. During a successful redundant shut-off test an open circuit (=no
current flow) should be detected.
Cause:
Injection occurred although internal shut-off path of the ECU watchdog was active.
1. Faulty ECU, watchdog switch off path defect.

Solution:
48083741_EN 31/07/2018
55.8 [55.DTC] / 296
65749-12 - Shutoff Paths During Initialization – Supply Voltage Too

Low
Control Module: ECU
Context:
error (Dfp_Mon) and an over- or undervoltage error of the ECU.
In order to test the correct functioning of the SOP procedure every path is shortly activated during ECU initialization
and following this the fuel injection power stage is activated. Since, however, the SOP is active no injection should
occur as it is blocked if the SOP procedure functions correctly. During a successful redundant shut-off test an open
circuit (=no current flow) should be detected.
Cause:
Injection occurred although internal shut-off path of the undervoltage monitoring was active.

Solution:
48083741_EN 31/07/2018
55.8 [55.DTC] / 297
65750-12 - TPU Monitoring – Time Deviation between TPU and

System Not Plausible
Control Module: ECU
Context:
Faultpath for monitoring of the time processing unit (TPU). As the time base of the CPU is checked according to
a query/response communication with the monitoring module (watchdog) it should be correct if no error has been
detected and therefore can be used to check the time base of the TPU. For this purpose the time bases of the TPU
and CPU are compared every 10 ms. After 100 ms the maximum and the minimum value, together with the absolute
value of the sum of the time differences are evaluated.
Cause:
If the maximum time difference between the TPU and CPU time base exceeds the threshold 81.00 ms
Or the minimum time difference is below the limit 81.00 ms
Or the absolute value of the sum of time differences is above 81.00 ms an error counter is incremented. If this counter
exceeds the value of 4, this fault path is set.

2. Faulty ECU, wrong TPU timebase.
Solution:
48083741_EN 31/07/2018
55.8 [55.DTC] / 298
65752-12 - Controller Watchdog – SPI Communication Failure

Control Module: ECU
Context:
Next to a CPU the ECU also contains a monitoring module (watchdog). These two components communicate via
a Serial Peripheral Interface (SPI) Bus with each other. Both devices mutually monitor each other for correct func-
tioning. If, however, the SPI communication between them fails this monitoring is impaired and an error counter is
incremented. If the error counter exceeds a limit the fault path at hand is activated. Communication status is checked
autonomously by the SPI driver component every 20 ms and reports a detected error to the EDC.
Cause:
Error counter for failed SPI communication between CPU and monitoring module exceeds 2 over 2x 20 ms (two tests).
1. Faulty ECU, defective monitoring module or CPU (e.g. impaired functioning of the CPU clock) of the EDC.
2. Faulty ECU, Disturbed SPI-Bus.
Solution:
48083741_EN 31/07/2018
55.8 [55.DTC] / 299
65753-02 - ADC Monitoring – Test Impulse Error

Control Module: ECU
Context:
This function monitors the analog-digital converter (ADC) of the microcontroller. The test pulse for the signal error
consists of cyclically setting the ADC channel of the accelerator pedal (APP2) to zero. Monitoring for no-load test
pulse is switched off (only allowed for poti/switch accelerator pedal).
Cause:
The converted test pulse voltage exceeds 5.20 V for longer than 10.92 min more than 65535.00 consecutive times.

Solution:
48083741_EN 31/07/2018
55.8 [55.DTC] / 300
65753-03 - ADC Monitoring – Reference Voltage Too High

Control Module: ECU
Context:
consists of cyclically setting the ADC channel of the accelerator pedal (APP2) to zero.
Cause:
The reference voltage exceeds 5.20 V.
1. Faulty ECU, short circuit to external source inside ECU.

Solution:
48083741_EN 31/07/2018
55.8 [55.DTC] / 301
65753-04 - ADC Monitoring – Reference Voltage Too Low

Control Module: ECU
Context:
Cause:
The reference voltage falls below 0.00 mV.
1. Faulty ECU, short circuit to ground inside ECU.

Solution:
48083741_EN 31/07/2018
55.8 [55.DTC] / 302
65753-12 - ADC Monitoring – Queue Error

Control Module: ECU
Context:
Cause:
An error is detected if not all ADC queues are converted within a time window. Time and engine speed synchronous
queues are monitored.
1. Faulty ECU buffer overrun.

Solution:
48083741_EN 31/07/2018
55.8 [55.DTC] / 303
65763-03 - Overrun Monitoring – Injection Time Too Long

Control Module: ECU
Context:
When the engine is in overrun operation the monitoring becomes active and the current injection energizing time is
compared with a maximum permissible time limit. If the limit is exceeded a recovery or even a shut off of injection
relevant power stages is triggered. The basic idea is that the driver reacts to an unintentional torque increase, caused
by a malfunction of the control unit, by releasing the accelerator pedal which causes the engine to enter the overrun
operation mode. Overrun monitoring is only released if various conditions are met, such as no accelerator pedal
activation, no activated cruise control, no intervention of the vehicle dynamic control or gearbox control is present
etc. The overrun monitoring is executed in layer 2 of the ECU monitoring concept, i.e. function monitoring, in order
to monitor the safety-relevant signal paths of the operational layer (layer 1, application software).
Cause:
The sum of all torque-forming energizing times of an individual cylinder exceeds the limit (calculated from the map
depending on the engine speed and the time since the overrun monitoring is active) for more than 100.00 test events
(test frequency every 10 ms).
1. Faulty fuel injectors, leakage.

2. Requested torque increase via tester.
4. Faulty ECU, wrong application of injection relevant parameters.
Solution:
48083741_EN 31/07/2018
55.8 [55.DTC] / 304
65764-03 - Redundant Engine Speed in Overrun Monitoring – Speed

Signal Not Plausible
Control Module: ECU
Context:
In order to execute an overrun monitoring, which checks if the injection energizing time is below a certain limit during
overrun, the information of the current engine speed is required. As the overrun monitoring is executed in layer 2 of the
ECU monitoring concept, i.e. function monitoring, in order to monitor the safety-relevant signal paths of the operational
layer (layer 1, application software) a redundant engine speed is additionally calculated in layer 2 independent of the
engine speed information of layer 1. If the engine speed information of the two layers varies excessively an error is
reported.
Cause:
The absolute value of the deviation between engine speed and redundant segment speed (layer 2) exceeds
320.00 RPM over 800.00 ms (event checked each 40 ms) while the redundant segment speed is above
1000.00 RPM.

Solution:
48083741_EN 31/07/2018
55.8 [55.DTC] / 305
65765-03 - Engine regulated 12 Volt sensor supply - Voltage High

Control Module: ECU
Context:
The Engine Control Unit ( A-ECU) provides independent 12 V voltage supply for the sensors. If the A-ECU detects
that the voltage sensor supply is too high, this fault will occur.
Cause:
The A-ECU has detected a sensor supply voltage too high.
1. Faulty battery
2. Faulty charging system
3. Faulty A-ECU supply wiring, open circuit
4. Faulty A-ECU, software
Solution:
has been resolved.
From To Value
A. If there is more than 24 V, continue with Step 4.

necessary.
48083741_EN 31/07/2018
55.8 [55.DTC] / 306

From To Value
A. If there is no continuity on one or more the checks, there is a failure in the A-ECU supply wiring. Locate and
B. If there is continuity on all the checks, check the A-ECU for the appropriate software and re-flash, if necessary.

48083741_EN 31/07/2018
55.8 [55.DTC] / 307
65765-04 - Engine regulated 12 Volt sensor supply - Voltage Low

Control Module: ECU
Context:
The Engine Control Unit ( A-ECU) provides independent 12 V voltage supply for the sensors. If the A-ECU detects
that the voltage sensor supply is too low, this fault will occur.
Cause:
The A-ECU has detected a sensor supply voltage too low.
1. Faulty battery.
2. Engine cranked for extended period of time.
3. Faulty charging system.
4. Faulty A-ECU supply wiring.
Solution:
has been resolved.

From To Value
48083741_EN 31/07/2018
55.8 [55.DTC] / 308
A. If there is less than 24 V, charge the battery and then perform a load test. If the battery passes the load test,
continue with Step 4. If the battery fails the load test, continue with Step 7.
B. If there is about 24 V, continue with step 5.

From To Value
From To Value
B. If there is continuity on all the checks, continue with Step 7.



48083741_EN 31/07/2018
55.8 [55.DTC] / 309
65766-03 - Sensor Supply Voltage 1 - High

Control Module: ECU
Context:
For reasons of safety the ECU provides 3 independent 5 V voltage supplies for the sensors. These sensor supply
voltages are monitored to ensure they remain within a given range. This check for voltage limits is done autonomously
by the hardware (thresholds not applicable). The error status is then reported via SPI-bus to the diagnostic system
management (DSM) where the error status is time-debounced before setting/healing the fault path.
Currently following sensors are connected to supply circuit 1:
- oil pressure/temperature,
- boost pressure/temperature,
- low fuel circuit pressure/temperature.
Cause:
The hardware has detected the sensor voltage supply 1 to exceed an upper limit.
1. Faulty battery, voltage too high.

2. Faulty ECU power supply, voltage too high.
3. Faulty ECU supply voltage 1 output wiring, defect in one of the connected components.
Solution:
has been resolved.
3. Check defects in one of the connected components.
One at a time, disconnect each component connected to the sensor supply voltage 1 and use the EST to monitor
the status of this fault.
A. If the fault is eliminated after a component disconnection, the relevant component has failed. Replace the
relevant component.
B. If the fault has not been eliminated after components disconnection, continue with Step 4.
48083741_EN 31/07/2018
55.8 [55.DTC] / 310
From To Value

necessary.

From To Value
Connector X-LC6 pin 5 Connector X-EDC7 (Plug) pin 2 There should be continuity

48083741_EN 31/07/2018
55.8 [55.DTC] / 311
65766-04 - Sensor Supply Voltage 1 - Low

Control Module: ECU
Context:
Currently following sensors are connected to supply circuit 1:
- oil pressure/temperature,
- boost pressure/temperature,
- low fuel circuit pressure/temperature.
Cause:
The hardware has detected the sensor voltage supply 1 to be below a lower limit.
1. Faulty battery, voltage too low.

2. Faulty ECU power supply, voltage too low.
Solution:
has been resolved.
relevant component.
48083741_EN 31/07/2018
55.8 [55.DTC] / 312
From To Value
A. If there is less than 24 V, continue with Step 5.

necessary.

From To Value

48083741_EN 31/07/2018
55.8 [55.DTC] / 313

Control Module: ECU
Context:
Cause:

Solution:
has been resolved.
relevant component.
From To Value
48083741_EN 31/07/2018
55.8 [55.DTC] / 314

necessary.

From To Value

48083741_EN 31/07/2018
55.8 [55.DTC] / 315

Control Module: ECU
Context:
Cause:

Solution:
has been resolved.
relevant component.
From To Value
48083741_EN 31/07/2018
55.8 [55.DTC] / 316

necessary.

From To Value

48083741_EN 31/07/2018
55.8 [55.DTC] / 317

Control Module: ECU
Context:
Cause:

Solution:
has been resolved.
relevant component.
From To Value
48083741_EN 31/07/2018
55.8 [55.DTC] / 318

necessary.

From To Value

48083741_EN 31/07/2018
55.8 [55.DTC] / 319

Control Module: ECU
Context:
Cause:

Solution:
has been resolved.
relevant component.
From To Value
48083741_EN 31/07/2018
55.8 [55.DTC] / 320

necessary.

From To Value

48083741_EN 31/07/2018
55.8 [55.DTC] / 321
65769-03 - ECM Internal Supply Voltage Too High – CJ940 Above

Limit
Control Module: ECU
Context:
Every CJ940 component of the EDC is monitored for sufficient voltage supply. If the voltage supply is outside of
an admissible range the hardware encapsulation registers this and sets an according error flag. These flags are
evaluated by the Diagnostic System Management (DSM) and depending on their value corresponding fault paths are
set. The monitoring procedure for overvoltage errors also takes the engine speed into account.
Cause:
A CJ940 has detected its voltage supply to be above an upper limit.

Solution:
has been resolved.
From To Value

necessary.
48083741_EN 31/07/2018
55.8 [55.DTC] / 322

From To Value

48083741_EN 31/07/2018
55.8 [55.DTC] / 323
65770-04 - ECM Internal Supply Voltage Too Low – CJ940 Below

Limit
Control Module: ECU
Context:
Every CJ940 component of the EDC is monitored for sufficient voltage supply. If the voltage supply is outside of
an admissible range the hardware encapsulation registers this and sets an according error flag. These flags are
evaluated by the Diagnostic System Management (DSM) and depending on their value corresponding fault paths are
set.
Cause:
A CJ940 has detected its voltage supply to be below a lower limit.

Solution:
has been resolved.

From To Value
48083741_EN 31/07/2018
55.8 [55.DTC] / 324
A. If there is less than 24 V, charge the battery and then perform a load test. If the battery passes the load test,
continue with Step 4. If the battery fails the load test, continue with Step 7.
B. If there is about 24 V, continue with step 5.

From To Value
From To Value
B. If there is continuity on all the checks, continue with Step 7.



48083741_EN 31/07/2018
55.8 [55.DTC] / 325
131112-04 - Engine Controller High side supply #2 to Grid heater

- Short to ground
Context:
A short circuit to ground (SCG) of the main relay 1 is only detected if it is switched on. If SCG error is detected the
main relay 1 is switched off automatically but is reactivated after 500.00 ms to check if error is permanent. If the
number of these reactivations exceeds 5 times the error is finalized. Error state is reset during ECU reset as well as
during interrupted after run.
Cause:
A 'short circuit to ground' is reported by the hardware, power stage is switched off and reactivated for a maximum of
5. If after that short circuit is still detected, power stage is permanently shut off.
1. Faulty of one of the component connected to main relay 1, internal failure.

2. Faulty main relay 1, internal failure.
Solution:
or shorts in the wiring concerned. Operate the machine while you monitor the display. Check all the components
connected to main relay 1.
has been resolved.
48083741_EN 31/07/2018
55.8 [55.DTC] / 326
131122-12 - Coolant Temperature Test Failure

Control Module: UCM
Context:
The Universal Control Module (UCM) monitors for a sufficient rise in engine coolant temperature. The start coolant
temperature is acquired after 60.00 s since engine start (engine in normal operation). If this start temperature is below
39.96 °C timer runs as long as engine speed > 1400.00 RPM and injection quantity > 16.00 mg/hub (mg/cyc).
Cause:
The coolant temperature does not reach the minimum threshold when the timer exceeds the maximum test time.
1. Extreme ambient conditions.

2. Faulty thermostat, blocked in open position.
3. Faulty coolant temperature sensor B-RECTD circuit wiring, shorted to ground or open circuit.
4. Faulty coolant temperature sensor B-RECTD, internal failure.
5. Faulty UCM, software.
Solution:
1. Ensure that the engine is not running in extreme ambient conditions.
A. If the engine is running in extreme ambient condition, wait until the conditions are within the normal operative
range, then continue with Step 3.
B. If the engine is not running in extreme ambient conditions, continue with Step 2.
2. Check that the thermostat is not blocked in open position.
A. If the thermostat is blocked in open position, restore the correct functionality of the thermostat or replace the
component. Then continue with Step 3.
B. If the thermostat works properly, continue with Step 3.

has been resolved.
5. Verify the integrity of the coolant temperature sensor B-RECTD.
Use a multimeter to measure the resistance between the following pins:
48083741_EN 31/07/2018
55.8 [55.DTC] / 327
From To Value
Connector X-RECT (Receptacle) Connector X-RECT (Receptacle) There should be 332 – 10.149 kΩ
pin 1 pin 2 depending on coolant temperature.
A. If the measured resistance is minimal or zero, the coolant temperature sensor B-RECTD has failed, internally.
Replace the sensor.
B. If the measured resistance is within the specified range, leave the connector X-RECT disconnected and con-
tinue with Step 6.
6. Check the coolant temperature sensor B-RECTD signal circuit for a short to ground condition.
From To Value
pin 1
Connector X-UCM4A (Receptacle) Chassis ground There should be no continuity
pin 12
A. If there is continuity, there is a short circuit to ground in the engine harness. Locate the fault and repair the
shorted conductor.
B. If there is no continuity, leave both connector disconnected and continue with Step 7.
7. Check the coolant temperature sensor B-RECTD signal circuit wiring for an open circuit condition.
From To Value
pin 1 pin 12
pin 2 pin 1
repair the broken conductor.
B. If there is continuity, leave all the connectors disconnected and continue with Step 8.
8. Check the coolant temperature sensor B-RECTD signal circuit for a short circuit condition.
From To Value
pin 12 X-UCM4A
pin 1 X-UCM1A
A. If there is continuity, there is a short circuit condition in the B-RECTD signal circuit. Locate the fault and repair

9. Replace the coolant temperature sensor B-RECTD.
48083741_EN 31/07/2018
55.8 [55.DTC] / 328
B. If the fault has not been resolved, check the UCM for the appropriate software and re-flash, if necessary.
48083741_EN 31/07/2018
55.8 [55.DTC] / 329
131151-03 - Emergency start time expired and shutdown initiated

Context:
This failure is used as 'Info-Failure'. Although the vehicle has run through the whole inducement procedure an engine
start (with full power) is permitted at every time. But the engine will run only for a certain time. After this time the
inducement is activated again and this info failure is set.
Cause:
If the vehicle is in final inducement condition an engine start (with full power) is permitted at every time. But only for
a limited time. After 30 s this info failure is set an the inducement will start again.
1. Only an Info-Failure signaling that engine shut down inducement is active.
Solution:
1. Check and repair failures which are activating inducement procedure.
48083741_EN 31/07/2018
55.8 [55.DTC] / 330
131196-02 - Injection Processor Error – Test Mode

Context:
Cause:
The 'YSEL' signal was not inverted as requested during injection for over No 3 camshaft revolutions.

Solution:
48083741_EN 31/07/2018
55.8 [55.DTC] / 331
131196-03 - Injection Processor Error – Internal Reset / Clock Loss

/ Voltage Too Low
Control Module: ECU
Context:
Cause:
Internal parity error is present longer than No 3 camshaft revolutions.
1. Faulty ECU, clock error.

Solution:
has been resolved.

48083741_EN 31/07/2018
55.8 [55.DTC] / 332
From To Value

48083741_EN 31/07/2018
55.8 [55.DTC] / 333
131196-04 - Injection Processor Error – Unlocked / Initialization

Failure
Control Module: ECU
Context:
Cause:
Internal program flow error longer than No 3 camshaft revolutions.

Solution:
48083741_EN 31/07/2018
55.8 [55.DTC] / 334
131196-12 - Injection Processor Error – SPI Communication Failure

Control Module: ECU
Context:
Cause:
Power stage component on timeout is present for at least 1 cylinder longer than No 3 camshaft revolutions.

Solution:
48083741_EN 31/07/2018
55.8 [55.DTC] / 335
131246-03 - Humidity Sensor possibly saturated with water droplets

– Signal Ratio above Limit
Context:
Undelayed signal range check of the humidity and ambient temperature sensor B-HT. In case of a Max failure the
sensor could be saturated with water droplets. If this is the case the failure will disappear after some time when the
engine is running.
Cause:
The ECU has detected a voltage greater than 3.6 V for a period greater than 500 ms after engine start caused by
water droplets into the humidity and ambient temperature sensor B-HT.
1. Faulty humidity and ambient temperature sensor B-HT, possibly saturated with water droplets.
2. Faulty ambient air temperature circuit wiring, short circuit, open circuit or shorted to external source.
Solution:
or shorts in the wiring concerned. Operate the machine while you monitor the display. Check the components
connected to the main relay 4 output.
has been resolved.
3. Check the presence of the following related fault:
65596-03 - Ambient Air Temperature Sensor failure - Signal too high (55.640).
A. If the fault is active, resolve the fault. Then, repeat the Step 1.
B. If the fault is not active, the humidity and ambient temperature sensor B-HT is experiencing a temporary short
circuit condition due to water droplets into the sensor. This fault should resolve itself after approximately 8 –
10 min of engine operation. If the fault remains active after approximately 8 – 10 min, replace the humidity and
ambient temperature sensor B-HT. If the fault recurs, check the ECU for the appropriate software and re-flash,
if necessary.
48083741_EN 31/07/2018
55.8 [55.DTC] / 336
131246-04 - Humidity Sensor possibly saturated with water droplets

– Signal Ratio below Limit
Context:
Undelayed signal range check of the humidity and ambient temperature sensor B-HT. In case of a Max failure the
sensor could be saturated with water droplets. If this is the case the failure will disappear after some time when the
engine is running.
Cause:
The raw value of the humidity and ambient temperature sensor B-HT is below 200.39 mV.
The ECU has detected a voltage lower than 200.39 mV for a period greater than 500 ms after engine start caused by
water droplets into the humidity and ambient temperature sensor B-HT.
1. Faulty humidity and ambient temperature sensor B-HT, possibly saturated with water droplets.
2. Faulty ambient air temperature circuit wiring, short circuit or shorted to ground.
Solution:
or shorts in the wiring concerned. Operate the machine while you monitor the display. Check the components
connected to the main relay 4 output.
has been resolved.
3. Check the presence of the following related fault:
65596-04 - Ambient Air Temperature Sensor failure - Signal too low (55.640).
A. If the fault is active, resolve the fault. Then, repeat the Step 1.
B. If the fault is not active, the humidity and ambient temperature sensor B-HT is experiencing a temporary short
circuit condition due to water droplets into the sensor. This fault should resolve itself after approximately 8 –
10 min of engine operation. If the fault remains active after approximately 8 – 10 min, replace the humidity and
ambient temperature sensor B-HT. If the fault recurs, check the ECU for the appropriate software and re-flash,
if necessary.
48083741_EN 31/07/2018
55.8 [55.DTC] / 337
131252-02 - Timeout of CAN Message BC2EDC2

Control Module: ECU
Context:
Node 1 Bus, internal to the ECU. The ECU receives and responds to proprietary Body Computer (BC) information. If
the ECU senses a message timeout, this fault will occur.
Cause:
The ECU has sensed a BC message timeout.

Solution:
has been resolved.
48083741_EN 31/07/2018
55.8 [55.DTC] / 338
From To Value
From To Value
From To Value
From To Value
shorted conductor.
48083741_EN 31/07/2018
55.8 [55.DTC] / 339
From To Value
pin 34
pin 25
A. If there is no continuity, there is an open circuit condition in the CAN 1 circuit. Locate and repair the shorted
conductor.

48083741_EN 31/07/2018
55.8 [55.DTC] / 340
131270-02 - Timeout of CAN message TSC1-PE Torque (When

Inactive)
Context:
Node 1 Bus, internal to the ECU. The ECU receives and responds to Power take-off to Engine controller (PE) infor-
mation at two different rates (active and passive) dependent upon change request status. If the ECU is not sensing
the PE message at the passive rate, this fault will occur.
Cause:
CAN controller of the EDC reports a reception timeout for the PTO message TSC1PEPasIv over 200.00 ms including
an additional 800.00 ms due to a longer CAN receiving cycle time because of an inactive override control mode.
Defect condition fulfilled continuously for more than 800.00 ms.

Solution:
has been resolved.
48083741_EN 31/07/2018
55.8 [55.DTC] / 341

From To Value
From To Value
From To Value
From To Value
shorted conductor.
48083741_EN 31/07/2018
55.8 [55.DTC] / 342
From To Value
pin 34
pin 25
conductor.

48083741_EN 31/07/2018
55.8 [55.DTC] / 343
131272-03 - Timeout of CAN Message TSC1-VR (When Active)

Control Module: ECU
Context:
CAN Node 1 Bus, internal to the ECU. The ECU receives and responds to Vehicle Retarder (VR) information at two
different rates (active and passive) dependent upon change request status. If the ECU is not sensing the VR message
at the active rate, this fault will occur.
Cause:
The ECU is not properly sensing the VR message.

Solution:
has been resolved.
48083741_EN 31/07/2018
55.8 [55.DTC] / 344
From To Value
From To Value
From To Value
From To Value
shorted conductor.
48083741_EN 31/07/2018
55.8 [55.DTC] / 345
From To Value
pin 34
pin 25
conductor.

48083741_EN 31/07/2018
55.8 [55.DTC] / 346
131283-12 - ECM Recovery which is suppressed

Context:
Cause:
is not stored.

Solution:
48083741_EN 31/07/2018
55.8 [55.DTC] / 347
196685-04 - Speed limitation activates torque limitation

Context:
This fault path indicates that a power reduction due to engine mechanics protection by speed limitation is currently
active which limits the engine torque. In other words, this fault path is not used as an actual error status indicating a
real defect but is used more for information purposes for service personnel to determine the exact cause of the power
limitation (in case a real defect evokes a power reduction the triggering failure also has to be present in the failure
memory).
Cause:
A power reduction due to engine mechanics protection (by speed limitation) is active. Torque demand is greater than
limitation torque, for engine mechanics protection by speed limitation, or high idle torque demand is greater than
limitation torque, for engine mechanics protection by speed limitation.
1. Active power reduction due to engine mechanics protection by speed limitation.
Solution:
48083741_EN 31/07/2018
55.8 [55.DTC] / 348
196766-04 - Torque limitation due to turbo charger protection

Context:
This fault path indicates that a power reduction due to turbo charger protection is currently active which limits the
engine torque. In other words, this fault path is not used as an actual error status indicating a real defect but is used
more for information purposes for service personnel to determine the exact cause of the power limitation (in case a
real defect evokes a power reduction the triggering failure also has to be present in the failure memory).
Cause:
A power reduction due to turbo charger protection is active causing a torque limitation greater than 25%, of the mo-
mentarily allowed maximum torque, or a high idle torque limitation greater than 25%.
1. Active power reduction due to turbo charger protection.
Solution:
48083741_EN 31/07/2018
55.8 [55.DTC] / 349
196804-02 - CAN message not received from XXXX1 (TSC1-AE

passive)
Control Module: ECU
Context:
The Engine Control Unit (ECU) receives and responds to AE information at two different rates (active and passive)
dependent upon change request status. If the ECU is not sensing the AE message at the passive rate, this fault will
occur.
Cause:
The ECU is not properly sensing the AE passive message.

Solution:
has been resolved.

48083741_EN 31/07/2018
55.8 [55.DTC] / 350
From To Value
From To Value
A. If there is no continuity on one or more checks, there is a failure in the A-ECU ground wiring. Locate and repair
From To Value
From To Value
shorted conductor.
48083741_EN 31/07/2018
55.8 [55.DTC] / 351
From To Value
pin 34
pin 25
conductor.

48083741_EN 31/07/2018
55.8 [55.DTC] / 352
196808-02 - Timeout of CAN message TSC1-VE Speed (When

Inactive)
Context:
CAN Node 1 Bus, internal to the ECU. The ECU receives and responds to Torque/Speed Control (TSC) information
at two different rates (active and passive) dependent upon change request status. If the ECU is not sensing the TSC
message at the passive rate, this fault will occur.
Cause:
CAN controller of the EDC reports a reception timeout for the VCM/BC message TSC1VEPasIv over 200.00 ms in-
cluding an additional 800.00 ms due to a longer CAN receiving cycle time because of an inactive override control
mode. Defect condition fulfilled continuously for more than 800.00 ms.

Solution:
has been resolved.
48083741_EN 31/07/2018
55.8 [55.DTC] / 353

From To Value
From To Value
A. If there is no continuity on one or more checks, there is a failure in the A-ECU ground wiring. Locate and repair
From To Value
From To Value
shorted conductor.
48083741_EN 31/07/2018
55.8 [55.DTC] / 354
From To Value
pin 34
pin 25
conductor.

48083741_EN 31/07/2018
55.8 [55.DTC] / 355
196819-12 - ECU Recovery (Visible) - Recovery Occurred

Context:
Cause:
is visible in the error memory.

Solution:
48083741_EN 31/07/2018
55.8 [55.DTC] / 356
262302-04 - Torque Limitation due to Engine Protection (Against

Excessive Torque, Engine Overspeed and Overheat)
Context:
This fault path indicates that a power reduction due to engine mechanics protection is currently active which limits the
Cause:
A power reduction due to engine mechanics protection (by torque limitation) is active. Torque demand is greater
than limitation torque for engine mechanics protection or high idle torque demand is greater than limitation torque for
engine mechanics protection.
1. Active power reduction due to engine mechanics protection.
Solution:
48083741_EN 31/07/2018
55.8 [55.DTC] / 357
262344-02 - Timeout of CAN Message TSC1-VR (When Inactive)

Control Module: ECU
Context:
CAN Node 1 Bus, internal to the ECU. The ECU receives and responds to Vehicle Retarder (VR) information at two
different rates (active and passive) dependent upon change request status. If the ECU is not sensing the VR message
at the passive rate, this fault will occur.
Cause:
The ECU is not properly sensing the VR message.

Solution:
has been resolved.
48083741_EN 31/07/2018
55.8 [55.DTC] / 358
From To Value
From To Value
From To Value
B. If there is no continuity, leave the connector X-EDC7 disconnected and continue with step 8.
From To Value
shorted conductor.
48083741_EN 31/07/2018
55.8 [55.DTC] / 359
From To Value
pin 34
pin 25
conductor.

48083741_EN 31/07/2018
55.8 [55.DTC] / 360
393292-04 - Overheat protection activates torque limitation

Context:
This fault path indicates that a power reduction due to engine overheat protection is currently active which limits the
Cause:
A power reduction due to engine overheat protection (via limiting torque) is active. Torque demand is greater than
limitation torque, for over heat protection, or high idle torque demand is greater than limitation torque, for over heat
protection.
1. Active power reduction due to engine overheat protection.
Solution:
48083741_EN 31/07/2018
55.8 [55.DTC] / 361
393374-04 - Torque Limitation due to Fuel Quantity Limitation

because of Injection System Errors
Context:
This fault path indicates that a power reduction due to limiting fuel quantity is currently active which limits the engine
torque. In other words, this fault path is not used as an actual error status indicating a real defect but is used more for
information purposes for service personnel to determine the exact cause of the power limitation (in case a real defect
evokes a power reduction the triggering failure also has to be present in the failure memory).
Cause:
A power reduction due to limiting fuel quantity (via limiting torque) is active causing a torque limitation greater than
25%, of the momentarily allowed maximum torque, or a high idle torque limitation greater than 5%.
1. Active power reduction due to limiting fuel quantity.
Solution:
48083741_EN 31/07/2018
55.8 [55.DTC] / 362
517755-09 - EJM Message Timeout (AUX FNR, AUX I, AUX II)

Control Module: UCM
Context:
The Universal Control Module A-UCM receives, from the right-hand joystick (SW-RH_JS) via CAN 2 bus, the Ex-
tended Joystick Message (EJM), that includes the AUX FNR, AUX I and AUX II messages. This fault occurs if, after
5 s from the key ON, the A-UCM does not receive any message from the Extended Joystick Message (EJM) within
the maximum interval time (3 times of maximum defined cycle time). As consequence, the A-UCM turns the default
AUX FNR signal to Neutral and AUX I / AUX II signals to 0%.
Cause:
The A-UCM has detected a cycle time interval, of the EJM message, greater than 3 times of maximum defined cycle
time.

2. The harness of CAN 2 bus is damaged.
4. The right-hand joystick connector X-CAB_AR (Plug) is damaged.
5. The right-hand joystick is not properly connected to the power supply or ground.
6. The right-hand joystick is damaged.
Solution:

A. If one pin is damaged, replace the connector or the harness.
B. f pins are not damaged, continue with Step 4.

4. Check the integrity of connector X-CAB_AR (Plug) .
Disconnect the connector X-CAB_AR (Plug) from the right hand joystick and visually check the integrity of the
pins.

5. Verify the integrity of the fuse 5F6.
48083741_EN 31/07/2018
55.8 [55.DTC] / 363

6. Check the electrical continuity between the following points:
• X-CAB_AR (Plug) pin 3 of right hand joystick and X-UCM2B (Receptacle) pin 1 of A-UCM
• X-CAB_AR (Plug) pin 1 of right hand joystick and F-LC5-6A of fuse box LC5
• X-CAB_AR (Plug) pin 2 of right hand joystick and chassis ground.
A. If there is no continuity, repair or replace the harness.

7. Check the right hand joystick and replace, if necessary.
A. If the fault has been solved, return to Step 1 to confirm elimination of fault.
B. If the fault has not been solved, check the A-UCM.

48083741_EN 31/07/2018
55.8 [55.DTC] / 364
517755-19 - BJM Message Timeout (Boom, Bucket, Kick down)

Control Module: UCM
Context:
The A-UCM does not receive messages from the Basic Joystick Message (BJM) within the maximum interval
time; as a consequence:
• Default Joystick Signal to Neutral or 0%;
• Default kick down to not pressed.
Cause:
After 5 s from key on incoming cycle time message interval > 3 times of maximum defined cycle time.

2. The harness of CAN 2 bus is damaged.
4. The right hand joystick connector X-CAB_AR (Plug) is damaged.
5. The right hand joystick is not properly connected to the power supply or ground.
6. The right hand joystick is damaged.
Solution:

B. f pins are not damaged, continue with Step 4.

4. Check the integrity of connector X-CAB_AR (Plug) .
Disconnect the connector X-CAB_AR (Plug) from the right hand joystick and visually check the integrity of the
pins.

5. Verify the integrity of the fuse 5F6.
48083741_EN 31/07/2018
55.8 [55.DTC] / 365

6. Check the electrical continuity between the following points:
• X-CAB_AR (Plug) pin 1 of right hand joystick and F-LC5-6A of fuse box LC5
• X-CAB_AR (Plug) pin 2 of right hand joystick and chassis ground.
A. If there is no continuity, repair or replace the harness.

7. Check the right hand joystick and replace, if necessary.
A. If the fault has been solved, return to Step 1 to confirm elimination of fault.
B. If the fault has not been solved, check the A-UCM.

48083741_EN 31/07/2018
55.8 [55.DTC] / 366
518032-03 - Aux FNR Key Fault

Context:
Aux FNR Key Fault.
Cause:

2. The Aux FNR Key is damaged.
Solution:
A. If the fault is present and active, replace the Aux FNR Key.
48083741_EN 31/07/2018
55.8 [55.DTC] / 367
518036-03 - Beacon Light Switch Key Fault

Context:
Beacon Light Switch Key Fault.
Cause:

2. The connector’s pin X-BEA are damaged.
3. The harness between the connector X-BEA and the ground is damaged.
4. The harness between the connector X-BEA and the connector X-ROOF is damaged.
5. The connector’s pin X-ROOF are damaged.
6. The connector’s pin X-CAB_R are damaged.
7. The harness between the connector X-CAB_R and the connector X-X3 is damaged
8. The connector’s pin X-X3 are damaged.
9. The LMP-BEA_RT is damaged.
10. The A-SFB is damaged.
Solution:
2. Check the integrity of connector X-BEA.
Disconnect the connector X-BEA from the ROTATING BEACON and visually check the integrity of pin 1 and 2.
A. If the pin is damaged, replace the harness relevant to the connector.

3. Check the integrity of the harness between the connector X-BEA and the ground.
From To Value
Connector X-BEA pin 2 Ground Short circuit

4. Check the integrity of connectors X-ROOF and X-CAB_R.
Disconnect the connector X-ROOF from the harness and visually check the integrity of pin of both connectors.
A. If the pin in damaged, replace the harness relevant to the connector.

5. Check the integrity of the harness between the connector X-BEA and the connector X-ROOF.
48083741_EN 31/07/2018
55.8 [55.DTC] / 368
From To Value
Connector X-BEA pin 1 Connector X-ROOF pin 3 Short circuit

6. Check the integrity of connectors X-X3.
Disconnect the connector X-X3 from the harness and visually check the integrity of pin 3.

7. Check the integrity of the harness between the connector X-CAB_R and the connector X-X3.
From To Value
Connector X-ROOF pin 3 Connector X-X3 pin 3 Short circuit

8. Replace the Rotating beacon LMP-BEA_RT.
A. If the fault is present, replace the A-SFB.
48083741_EN 31/07/2018
55.8 [55.DTC] / 369
518047-03 - Declutch Key Fault

Context:
Declutch Key Fault.
Cause:

2. The Declutch Key is damaged.
Solution:
A. If the fault is present and active, replace the Declutch Key.
48083741_EN 31/07/2018
55.8 [55.DTC] / 370
518052-03 - Differential Lock Up Key Fault

Context:
Differential Lock Up Key Fault.
Cause:

2. The Differential Lock Up key is damaged.
Solution:
A. If the fault is present and active, replace the Differential Lock Up key.
48083741_EN 31/07/2018
55.8 [55.DTC] / 371
518056-03 - Fan Mode Key Fault

Context:
Fan Mode Key Fault.
Cause:

2. The Fan Mode Key is damaged.
Solution:
A. If the fault is present and active, replace the Fan Mode Key.
48083741_EN 31/07/2018
55.8 [55.DTC] / 372
518058-03 - Float Key Fault

Context:
Float Key Fault.
Cause:

2. The Float Key is damaged.
Solution:
A. If the fault is present and active, replace the Float Key.
48083741_EN 31/07/2018
55.8 [55.DTC] / 373
518063-03 - Implement Coupler Key Fault

Context:
Implement Coupler Key Fault.
Cause:

2. The Implement Coupler key is damaged.
Solution:
A. If the fault is present and active, replace the Implement Coupler key.
48083741_EN 31/07/2018
55.8 [55.DTC] / 374
518066-03 - Implement Enable Key Fault

Context:
Implement Enable Key Fault.
Cause:

2. The Implement Enable key is damaged.
Solution:
A. If the fault is present and active, replace the Implement Enable key.
48083741_EN 31/07/2018
55.8 [55.DTC] / 375
518069-02 - Joystick Steering Activation Button Signals not

plausible
Control Module: UCM
Context:
The A-UCM detects a value from SWITCH JSS ACTIVATION (SW-SW_JSS) out of limits.
Cause:
The A-UCM detects one of the following conditions:

• Voltage on pin 3B.16 > 15 V and 3B.23 > 15 V for T > 350 ms;
• Voltage on pin 3B.16 < 10 V and 3B.23 < 10 V for T > 350 ms.

2. The harness between the A-UCM and the SWITCH JSS ACTIVATION is damaged.
3. The SWITCH JSS ACTIVATION is not supplied.
5. The harness between the connector X-LFT_A and the SWITCH JSS ACTIVATION is damaged.
6. The SWITCH JSS ACTIVATION is damaged.
Solution:
1. If JSS is not Active:

- Prevent JSS Activation
If JSS is Active
- None (discuss if the fault shall be displayed) as soon as JSS get deactivated:
2. Check the integrity of the harness between the A-UCM and the SWITCH JSS ACTIVATION.

3. Check the SWITCH JSS ACTIVATION power supply.
From To Value
Connector X-CAB_L pin 10 + 24 V Ref. 24 V
48083741_EN 31/07/2018
55.8 [55.DTC] / 376
A. If the value is not correct, connect the connector X-LFT_A to the connector X-CAB_L and continue with Step
4.

4. Check the integrity of fuse F-5F8.
Remove the fuse F-5F8 from the LC5.
A. If the fuse is burned, replace the fuse.
B. If the fuse is not burned, check the harness between LC5 and the connector X-CAB_L.
5. Check the integrity of harness between the connector X-LFT_A and the SWITCH JSS ACTIVATION.
Disconnect the connector X-SW_JSS from the SWITCH JSS ACTIVATION.
From To Value
Connector X-LFT_A pin 10 Connector X-SW_JSS pin 2 Short circuit
A. If the measurement is not correct, replace the harness between the connector X-LFT_A and the SWITCH JSS
ACTIVATION.

Disconnect the connectors X-UCM3B from A-UCM.
From To Value
A. If one measurement is not correct, replace the harness between the connector X-CAB_L and the A-UCM.
B. If the measurements are correct, connect the connector X-UCM2B to the A-UCM and continue with Step 7.
7. Check the integrity of harness between the connector X-LFT_A and the SWITCH JSS ACTIVATION.
Remove the connector X-SW_JSS.
From To Value

8. Check the integrity of SWITCH JSS ACTIVATION.
Replace the SWITCH JSS ACTIVATION.
48083741_EN 31/07/2018
55.8 [55.DTC] / 377

48083741_EN 31/07/2018
55.8 [55.DTC] / 378
518070-03 - Key_2 Key Fault

Context:
Key_2 Key Fault.
Cause:

2. The Key_2 Key is damaged.
Solution:
A. If the fault is present and active, replace the Key_2 Key.
48083741_EN 31/07/2018
55.8 [55.DTC] / 379
518074-03 - Key_18 Key Fault

Context:
Key_18 Key Fault.
Cause:

Solution:
48083741_EN 31/07/2018
55.8 [55.DTC] / 380
518078-03 - Key_20 Key Fault

Context:
Key_20 Key Fault.
Cause:

Solution:
48083741_EN 31/07/2018
55.8 [55.DTC] / 381
518083-03 - Park Brake Key Fault

Context:
Park Brake Key Fault.
Cause:

2. The park brake sensor is damaged.
3. The park brake key is damaged.
Solution:
2. Replace the parking brake sensor.
A. If the fault is present and active, replace the parking brake key.
48083741_EN 31/07/2018
55.8 [55.DTC] / 382
518089-03 - Short to Power at Ride Control Valve High Side Driver

Control Module: UCM
Context:
The A-UCM detects a high voltage from ride control solenoid ( Y-YRC).
Cause:
The A-UCM detects on pin 6 of connector X-UCM3B a short circuit to power risen by BSP.

2. The harness between A-UCM and the ride control solenoid ( Y-YRC) is damaged.
3. The YRC RIDE CONTROL SOL is damaged.
4. The harness between the connector X-FRNT and the connector X-YRC is damaged.
5. The harness between the connector X-BTM and the connector X-BTM_F is damaged.
Solution:
1. Ride Control Function Disabled (function forced active).
2. Check the integrity of the harness between the A-UCM and the ride control solenoid ( Y-YRC).

3. Check the UCM monitor voltage of the ride control solenoid.
Deactivate the ride control.
Disconnect the solenoid connector X-YRC.
From To Value
Connector X-YRC pin 1 Chassis ground 6V
A. If the measurement is not correct, continue with Step 6.
B. If the measurement is correct, leave the connector disconnected and continue with Step 4.
4. Check the and the ride control solenoid ( Y-YRC) ground circuit.
From To Value
Connector X-YRC pin 2 Chassis ground Short circuit
48083741_EN 31/07/2018
55.8 [55.DTC] / 383

5. Check the and the ride control solenoid ( Y-YRC) integrity.
Remove the and the ride control solenoid ( Y-YRC).
A. If the resistance is an open circuit, replace the and the ride control solenoid ( Y-YRC).

6. Check the integrity of connectors X-FRNT and X-BTM_F.
Disconnect the connector X-BTM_F from the connector X-FRNT and visually check the integrity of pins P of both
connectors.

7. Check the integrity of harness between the connector X-FRNT and the connector X-YRC.
Remove the connector X-YRC from the and the ride control solenoid ( Y-YRC).
From To Value
Connector X-FRNT pin P Connector X-YRC pin 1 Short circuit

8. Check the integrity of connectors X-CAB_B and X-BTM.
Disconnect the connector X-BTM from the connector X-CAB_B and visually check the integrity of pin 5 of both
connectors.

9. Check the integrity of harness between connectors X-BTM and X-BTM_F.
From To Value
Connector X-BTM pin 5 Connector X-BTM_F pin P Short circuit

10. Check the integrity of harness between connector X-CAB_B and A-UCM.
Disconnect the connector X-UCM3B from A-UCM and visually check the integrity of pin 6 of X-UCM3B.
From To Value
48083741_EN 31/07/2018
55.8 [55.DTC] / 384
518089-04 - Short to Ground at Ride Control Valve High Side Driver

Control Module: UCM
Context:
The A-UCM detects a grounding from YRC RIDE CONTROL SOL ( Y-YRC).
Cause:
The A-UCM detects on pin 6 of connector X-UCM3B a short circuit to ground risen by BSP.

2. The harness between A-UCM and the YRC RIDE CONTROL SOL is damaged.
Solution:
1. Ride Control Function Disabled.
2. Check the integrity of the harness between the A-UCM and the YRC RIDE CONTROL SOL.

3. Check the YRC RIDE CONTROL SOL integrity.
Remove the YRC RIDE CONTROL SOL sensor.
A. If the resistance is a short circuit, replace the YRC RIDE CONTROL SOL.

Disconnect the connector X-BTM_F from the connector X-FRNT and visually check the integrity of pin P of both
connectors.

Remove the connector X-YRC from YRC RIDE CONTROL SOL.
48083741_EN 31/07/2018
55.8 [55.DTC] / 385
From To Value

connectors.

From To Value

From To Value
48083741_EN 31/07/2018
55.8 [55.DTC] / 386
518089-05 - Open Circuit at Ride Control Valve High Side Driver

Control Module: UCM
Context:
The A-UCM detects an unexpected value of current from YRC RIDE CONTROL SOL ( Y-YRC).
Cause:
The A-UCM detects on pin 6 of connector X-UCM3B an Open Circuit or Low Current Error risen by BSP.

2. The harness between A-UCM and the YRC RIDE CONTROL SOL is damaged.
4. The YRC RIDE CONTROL SOL is not grounded.
Solution:
1. Ride Control Function Disabled.
2. Check the integrity of the harness between the A-UCM and the YRC RIDE CONTROL SOL.

3. Check the YRC RIDE CONTROL SOL integrity.
Remove the YRC RIDE CONTROL SOL sensor.
A. If the resistance is an open circuit or a value out of limit, replace the YRC RIDE CONTROL SOL.

4. Check the integrity of connectors X-YRC.
Disconnect the connector X-YRC from the YRC RIDE CONTROL SOL and visually check the integrity of pin
2.Disconnect the connector X-YRC from the YRC RIDE CONTROL SOL and visually check the integrity of pin 2.

5. Check the integrity of harness between the connector X-YRC and ground.
48083741_EN 31/07/2018
55.8 [55.DTC] / 387
From To Value
Connector X-YRC pin 2 Connector SP-624D Short circuit

Disconnect the connector X-BTM_F from the connector X-FRNT and visually check the integrity of pin P of both
connectors.

Remove the connector X-YRC from YRC RIDE CONTROL SOL.
From To Value

connectors.

From To Value

From To Value

48083741_EN 31/07/2018
55.8 [55.DTC] / 388
518093-03 - Return ToTravel Key Fault

Context:
Return ToTravel Key Fault
Cause:

2. The Return ToTravel Key is damaged.
Solution:
A. If the fault is present and active, replace the Return ToTravel Key.
48083741_EN 31/07/2018
55.8 [55.DTC] / 389
518101-03 - Torque Converter Lock Up Key Fault

Context:
Torque Converter Lock Up Key Fault.
Cause:

2. The Torque Converter Lock Up Key is damaged.
Solution:
A. If the fault is present and active, replace the Torque Converter Lock Up Key.
48083741_EN 31/07/2018
55.8 [55.DTC] / 390
518103-03 - Transmission Auto Mode Key Fault

Context:
Transmission Auto Mode Key Fault.
Cause:

2. The Transmission Auto Mode key is damaged.
Solution:
A. If the fault is present and active, replace the Transmission Auto Mode key.
48083741_EN 31/07/2018
55.8 [55.DTC] / 391
518106-03 - WorkLight 1 Key Fault

Context:
WorkLight 1 Key Fault.
Cause:

3. The harness between the connector X-X3 and the X-CAB_R is damaged.
6. The harness between the connector X-ROOF and the connector X-LFWL is damaged.
7. The connector’s pin X-LFWL are damaged.
8. The harness between the connector X-LFWL and SP-949A is damaged.
9. The LMP-LF_WL is damaged.
11. The harness between the connector X-ROOF and the connector X-RFWL is damaged.
12. The connector’s pin X-RFWL are damaged.
13. The harness between the connector X-RFWL and SP-949A is damaged.
14. The LMP-RF_WL is damaged.
15. The harness between SP-949A and the connector X-ROOF is damaged.
16. The harness between the connector X-CAB_R and CG1 is damaged.
Solution:
2. Check the integrity of connector X-X3.
Disconnect the connector X-X3 from the A-SFB (SMART FUSE BOX) and visually check the integrity of pin 1
and 2.

3. Check the integrity of the harness between the connector X-X3 and the X-CAB_R.
From To Value
Connector X-X3 pin 2 Connector X-CAB_R pin 1 Short circuit
48083741_EN 31/07/2018
55.8 [55.DTC] / 392

Disconnect the connectors X-ROOF and X-CAB_R from the harness and visually check the integrity of pin of
both connectors.

5. Check the integrity of the harness between the connector X-ROOF and the connector X-LFWL.
From To Value
Connector X-ROOF pin 1 Connector X-LFWL pin 1 Short circuit

6. Check the integrity of connectors X-LFWL.
Disconnect the connector X-LFWL from the LMP-LF_WL (LEFT FRONT WORK LIGHT) and visually check the
integrity of pin 1 and 2.

7. Check the integrity of the harness between the connector X-LFWL and SP-949A.
From To Value
Connector X-LFWL pin 2 Connector SP-949A Short circuit

8. Replace the LMP-LF_WL (LEFT FRONT WORK LIGHT).
A. If the fault is present, continue with Step 9.

From To Value

10. Check the integrity of the harness between the connector X-ROOF and the connector X-RFWL.
From To Value
Connector X-ROOF pin 2 Connector X-RFWL pin 1 Short circuit

11. Check the integrity of connectors X-RFWL.
48083741_EN 31/07/2018
55.8 [55.DTC] / 393
Disconnect the connector X-RFWL from the LMP-RF_WL (RIGHT FRONT WORK LIGHT) and visually check the

12. Check the integrity of the harness between the connector X-RFWL and SP-949A.
From To Value
Connector X-RFWL pin 2 Connector SP-949A Short circuit

13. Check the integrity of the harness between SP-949A and the connector X-ROOF.
From To Value
Connector SP-949A Connector X-ROOF pin 6 Short circuit

14. Replace the LMP-RF_WL (RIGHT FRONT WORK LIGHT).

15. Check the integrity of the harness between X-CAB_R and CG1.
From To Value
Connector X-CAB_R pin 6 Connector CG1 Short circuit
B. If the measurement is correct, replace the A-SFB (SMART FUSE BOX).

48083741_EN 31/07/2018
55.8 [55.DTC] / 394
518108-03 - WorkLight 2 Key Fault

Context:
WorkLight 2 Key Fault.
Cause:

6. The harness between the connector X-ROOF and SP-859A is damaged.
7. The harness between SP-859A and the connector X-LRWL is damaged.
8. The connector’s pin X-LRWL are damaged.
9. The harness between the connector X-LRWL and SP-953A is damaged.
10. The LMP-LR_WL is damaged.
11. The harness between SP-859A and the connector X-RRWL is damaged.
12. The connector’s pin X-RRWL are damaged.
13. The harness between the connector X-RRWL and SP-953A is damaged.
14. The LMP-RR_WL is damaged.
15. The harness between SP-953A and the connector X-ROOF is damaged.
16. The harness between the connector X-CAB_R and CG1 is damaged.
Solution:
2. Check the integrity of connector X-X4.
Disconnect the connector X-X4 from the A-SFB (SMART FUSE BOX) and visually check the integrity of pin 1
and 2.

From To Value
48083741_EN 31/07/2018
55.8 [55.DTC] / 395

Disconnect the connectors X-ROOF and X-CAB_R from the harness and visually check the integrity of pin of
both connectors.

5. Check the integrity of the harness between the connector X-ROOF and SP-859A.
From To Value
Connector X-ROOF pin 5 Connector SP-859A Short circuit

6. Check the integrity of the harness between SP-859A and the connector X-LRWL.
From To Value
Connector SP-859A Connector X-LRWL pin 1 Short circuit

7. Check the integrity of connectors X-LRWL.
Disconnect the connector X-LRWL from the LMP-LR_WL (LEFT REAR WORK LIGHT) and visually check the

8. Check the integrity of the harness between the connector X-LRWL and SP-953A.
From To Value
Connector X-LRWL pin 2 Connector SP-953A Short circuit

9. Replace the LMP-LR_WL (LEFT REAR WORK LIGHT).

10. Check the integrity of the harness between SP-859A and the connector X-RRWL.
From To Value
Connector SP-859A Connector X-RRWL pin 1 Short circuit

11. Check the integrity of connectors X-RRWL.
48083741_EN 31/07/2018
55.8 [55.DTC] / 396
Disconnect the connector X-RRWL from the LMP-RR_WL (RIGHT REAR WORK LIGHT) and visually check the

12. Check the integrity of the harness between the connector X-RRWL and SP-953A.
From To Value
Connector X-RRWL pin 2 Connector SP-953A Short circuit

13. Replace the LMP-RR_WL (RIGHT REAR WORK LIGHT).

14. Check the integrity of the harness between SP-953A and the connector X-ROOF.
From To Value
Connector SP-953A Connector X-ROOF pin 7 Short circuit

15. Check the integrity of the harness between X-CAB_R and CG1.
From To Value
Connector X-CAB_R pin 7 Connector CG1 Short circuit
B. If the measurement is correct, see procedure of 518106-03 fault.

48083741_EN 31/07/2018
55.8 [55.DTC] / 397
518110-02 - Boom Angle Sensor signals not plausible

Control Module: UCM
Context:
The A-UCM detects not plausible values from the BOOM ANGLE sensor; as a consequence, the advanced EH BOOM
features (RTT/Float and HC) is disabled.
Cause:
The A-UCM detects, on pins 19 and 22 of connector X-UCM1B, two not plausible signals (│5-(Sig1+Sig2)│ > 0.5 V).

2. The harness between the A-UCM and the BOOM ANGLE is visually damaged.
3. The output ANGLE 1 of the BOOM ANGLE is not correct.
4. The output ANGLE 2 of the BOOM ANGLE is not correct.
5. The A-UCM is not functioning.
Solution:
2. Visually check the integrity of the harness between the A-UCM and the BOOM ANGLE for any damage.

3. The output BOOM ANGLE 1 of the sensor is not functioning.
Be sure the voltage on pin 19 of connector X-UCM1B is 0.25 V < Voltage < 4.75 V.
A. If one value is not correct, check the correct functioning of the circuit by performing:
- the procedure 518110-04 – Boom Angle Sensor Channel 1 Under Voltage if the voltage is < 0.25 V;
- the procedure 518110-03 – Boom Angle Sensor Channel 1 Over Voltage if the voltage is > 4.75 V.
B. If both value are correct, continue with Step 4.

4. The output BOOM ANGLE 2 of the sensor is not functioning.
- the procedure 518135-04 – Boom Angle Sensor Channel 2 Under Voltage if the voltage is < 0.25 V;
- the procedure 518135-03 – Boom Angle Sensor Channel 2 Over Voltage if the voltage is > 4.75 V.
B. If both values are correct, continue with Step 5.

Replace the A-UCM.
48083741_EN 31/07/2018
55.8 [55.DTC] / 398
518110-03 - Boom Angle Sensor Channel 1 Over Voltage

Control Module: UCM
Context:
The A-UCM detects a value from the channel 1 of the BOOM ANGLE ( B-BKT_ANG) greater than the upper limit.
Cause:
The A-UCM detects, on pin 19 of connector X-UCM1B, a voltage > 4.75 V; as a consequence, the advanced EH
BOOM features (RTT/Float and HC) is disabled.

2. The harness between the A-UCM and the BOOM ANGLE is damaged.
3. The connectors X-BOA or X-FRNT_EH or X-BTM_FEH or X-BTM_EH or X-CAB_EH or X-UCM1B are damaged.
4. The BOOM ANGLE is damaged.
5. The harness relevant to the BOOM ANGLE is damaged.
Solution:
2. Check the integrity of the harness between the A-UCM and the BOOM ANGLE.

3. Check the BOOM ANGLE sensor integrity.
Remove the BOOM ANGLE sensor.
From To Value
BOOM ANGLE pin P1 BOOM ANGLE pin N1 The sensor resistance
A. If the resistance is an open circuit, replace the BOOM ANGLE.
B. If the resistance value is correct, continue with Step 4.

4. Use a multimeter to perform the following check:
From To Value
BOOM ANGLE pin P1 BOOM ANGLE pin OUT1 A resistance value
A. If the measurement is a short circuit, replace the BOOM ANGLE.

5. Check the integrity of the connectors X-UCM1B.
Disconnect the connector X-UCM1B from the A-UCM.
48083741_EN 31/07/2018
55.8 [55.DTC] / 399
Visually check the integrity of pin 19.

6. Check the integrity of the harness between the connector X-UCM1B and the power supply.
Mount the BOOM ANGLE sensor.
From To Value
Connector X-UCM1B pin 19 Ground < + 5V

7. Check the integrity of the connectors X-BTM_EH and X-CAB_EH.
Disconnect the connector X-BTM_EH from the connector X-CAB_EH.
Visually check the integrity of pin S of both connectors.

8. Check the harness between the connector X-BTM_EH and the power supply.
From To Value
Connector X-BTM_EH pin 5 Ground < + 5V
A. If the value is not correct, replace the harness between the connectors X-CAB_EH and X-UCM1B.

9. Check the integrity of the connectors X-FRNT_EH and X-BTM_FEH.
Disconnect the connector X-FRNT_EH from the connector X-BTM_FEH.
Visually check the integrity of pins S and V of both connectors.

10. Check the harness of the connector X-FRNT_EH.
From To Value
Connector X-FRNT_EH pin S Connector X-FRNT_EH pin V Open circuit
A. If the value is not correct, replace the harness between the connectors X-BOA and X-FRNT_EH.
B. If the value is correct, replace the harness between the connectors X-BTM_FEH and X-BTM_EH.
48083741_EN 31/07/2018
55.8 [55.DTC] / 400
518110-04 - Boom Angle Sensor Channel 1 Under Voltage

Control Module: UCM
Context:
The A-UCM detects a value from the channel 1 of the BOOM ANGLE ( B-BM_ANG) lower than the lower limit.
Cause:
The A-UCM detects, on pin 19 of connector X-UCM1B, a voltage < 0.25 V; as a consequence, the advanced EH

4. The BOOM ANGLE is not correctly supplied.
5. The BOOM ANGLE sensor is damaged.
6. The harness between the connectors X-BOA and X-FRNT_EH is damaged.
7. The harness between the connectors X-BTM_FEH and X-BTM_EH is damaged.
8. The harness between the connectors X-CAB_EH and X-UCM1B is damaged.
Solution:

3. Check the integrity of the connector X-BOA.
Disconnect the connector X-BOA from the BOOM ANGLE.
Visually check the integrity of pins A, B and C of the connector.

4. Check the BOOM ANGLE power supply.
From To Value
Connector X-BOA pin B Connector X-BOA pin A (Ref) + 5V
A. If the value is not correct, check the harness between the connectors X-BOA, X-FRNT_EH and X-FRNT.
48083741_EN 31/07/2018
55.8 [55.DTC] / 401
5. Replace the BOOM ANGLE sensor.


7. Check the harness between the connectors X-BOA and X-FRNT_EH.
From To Value
Connector X-BOA pin C Connector X-FRNT_EH pin S Short circuit


9. Check the harness between the connectors X-BTM_FEH and X-BTM_EH.
From To Value
Connector X-BTM_FEH pin S Connector X-BTM_EH pin S Short circuit
A. If the value is not correct, replace the harness between the connectors X-BTM_FEH and X-BTM_EH.

10. Check the integrity of the connector X-UCM1B.

11. Check the integrity of the harness between the connectors X-CAB_EH and X-UCM1B.
From To Value
Connector X-CAB_EH pin S Connector X-UCM1B pin 19 Short circuit
A. If the measurement is not correct, replace the harness between the connectors X-CAB_EH and X-UCM1B.
48083741_EN 31/07/2018
55.8 [55.DTC] / 402
48083741_EN 31/07/2018
55.8 [55.DTC] / 403
518111-02 - Bucket Angle Sensor signals not plausible

Control Module: UCM
Context:
The A-UCM detects not plausible values from the BUCKET ANGLE sensor; as a consequence, the advanced EH
bucket features ( RTD) is disabled.
Cause:
The A-UCM detects, on pins 21 and 23 of connector X-UCM1B, two not plausible signals (│5-(Sig1+Sig2)│ > 0.5 V).

2. The harness between the A-UCM and the BUCKET ANGLE is visually damaged.
3. The output ANGLE 1 of the BUCKET ANGLE is not correct.
4. The output ANGLE 2 of the BUCKET ANGLE is not correct.
Solution:
2. Visually check the integrity of the harness between the A-UCM and the BUCKET ANGLE for any damage.

3. The output BUCKET ANGLE 1 of the sensor is not functioning.
- the procedure 518111-04 – Bucket Angle Sensor Channel 1 Under Voltage if the voltage is < 0.25 V;
- the procedure 518111-03 – Bucket Angle Sensor Channel 1 Over Voltage if the voltage is > 4.75 V.

4. The output BUCKET ANGLE 2 of the sensor is not functioning.
- the procedure 518136-04 – Bucket Angle Sensor Channel 2 Under Voltage if the voltage is < 0.25 V;
- the procedure 518136-03 – Bucket Angle Sensor Channel 2 Over Voltage if the voltage is > 4.75 V.

Replace the A-UCM.
B. If the functionality is not restored, replace the harness.
48083741_EN 31/07/2018
55.8 [55.DTC] / 404
48083741_EN 31/07/2018
55.8 [55.DTC] / 405
518111-03 - Bucket Angle Sensor Channel 1 Over Voltage

Control Module: UCM
Context:
The A-UCM detects a value from the channel 1 of the BUCKET ANGLE ( B-BKT_ANG) greater than the upper limit.
Cause:

2. The harness between the A-UCM and the BUCKET ANGLE is damaged.
3. The connectors X-BUA or X-FRNT_EH or X-BTM_FEH or X-BTM_EH or X-CAB_EH or X-UCM1B are damaged.
4. The BUCKET ANGLE is damaged.
5. The harness relevant to the BUCKET ANGLE is damaged.
Solution:
2. Check the integrity of the harness between the A-UCM and the BUCKET ANGLE.

3. Check the BUCKET ANGLE sensor integrity.
Remove the BUCKET ANGLE sensor.
From To Value
BUCKET ANGLE pin P1 BUCKET ANGLE pin N1 The sensor resistance
A. If the resistance is an open circuit, replace the BUCKET ANGLE.

From To Value
BUCKET ANGLE pin P1 BUCKET ANGLE pin OUT1 A resistance value
A. If the measurement is a short circuit, replace the BUCKET ANGLE.

48083741_EN 31/07/2018
55.8 [55.DTC] / 406

Mount the BUCKET ANGLE sensor.
From To Value

Visually check the integrity of pin W of both connectors.

From To Value
Connector X-BTM_EH pin W Ground < + 5V

Visually check the integrity of pins W and V of both connectors.

From To Value
Connector X-FRNT_EH pin W Connector X-FRNT_EH pin V Open circuit
A. If the value is not correct, replace the harness between the connectors X-BUA and X-FRNT_EH.
48083741_EN 31/07/2018
55.8 [55.DTC] / 407
518111-04 - Bucket Angle Sensor Channel 1 Under Voltage

Control Module: UCM
Context:
The A-UCM detects a value from the channel 1 of the BUCKET ANGLE ( B-BKT_ANG) lower than the lower limit.
Cause:

4. The BUCKET ANGLE is not correctly supplied.
5. The BUCKET ANGLE sensor is damaged.
6. The harness between the connectors X-BUA and X-FRNT_EH is damaged.
Solution:

3. Check the integrity of the connector X-BUA.
Disconnect the connector X-BUA from the BUCKET ANGLE.

4. Check the BUCKET ANGLE power supply.
From To Value
Connector X-BUA pin B Connector X-BUA pin A (Ref) + 5V
A. If the value is not correct, check the harness between the connectors X-BUA, X-FRNT_EH and X-FRNT.
48083741_EN 31/07/2018
55.8 [55.DTC] / 408
5. Replace the BUCKET ANGLE sensor.


7. Check the harness between the connectors X-BUA and X-FRNT_EH.
From To Value
Connector X-BUA pin C Connector X-FRNT_EH pin W (Ref) Short circuit


From To Value
Connector X-BTM_FEH pin W Connector X-BTM_EH pin W Short circuit


From To Value
Connector X-CAB_EH pin W Connector X-UCM1B pin 21 Short circuit
48083741_EN 31/07/2018
55.8 [55.DTC] / 409
48083741_EN 31/07/2018
55.8 [55.DTC] / 410
518112-01 - Radiator Coolant Temperature Sensor under resistance

Short to Ground
Control Module: UCM
Context:
The resistance of the Radiator Coolant Temperature Sensor is < 500 Ω.
Cause:
On pin 12 of connector X-UCM4 of component A-UCM, the detected resistance is < 500 Ω.
Set the fan speed to max.

2. The harness between A-UCM and the B-RECTD COOLANT TEMP sensor is damaged.
3. The B-RECTD COOLANT TEMP sensor is damaged.
4. The connector X-ENG is damaged.
5. The B-RECTD COOLANT TEMP sensor hardness is damaged
6. The harness between connector X-ENG and component A-UCM is damaged.
Solution:
1. Set the fan speed to max.

2. Check the integrity of the harness between A-UCM and the B-RECTD COOLANT TEMP sensor.

3. Check the B-RECTD COOLANT TEMP sensor integrity.
Remove the B-RECTD COOLANT TEMP sensor.
A. If the resistance is < 500 Ω, replace the B-RECTD COOLANT TEMP sensor.

4. Check the integrity of the X-ENG connector.
Disconnect X-ENG connector and visually check the integrity of the pins 5 and 9.
48083741_EN 31/07/2018
55.8 [55.DTC] / 411

5. Check the B-RECTD COOLANT TEMP sensor harness for a proper condition.
From To Value
Connector X-ENG pin 5 Connector X-ENG pin 9 Resistance > 500 Ω
A. If the value is not correct, replace the harness between the connector and the sensor.
B. If the value is correct, continue to Step 6.

6. Check the integrity of harness between connector X-ENG and component A-UCM.
From To Value
Connector X-UCM4A pin 12 Connector X-ENG pin 5 Short circuit
Connector X-UCM4A pin 12 Connector X-ENG pin 9 Open circuit
B. If both measurements is are correct, replace the A-UCM component.
48083741_EN 31/07/2018
55.8 [55.DTC] / 412
518112.00 - Radiator Coolant Temperature Sensor over resistance

Open Circuit/Short to Power
Control Module: UCM
Context:
The resistance of the Radiator Coolant Temperature Sensor is > 2000 Ω.
Cause:
On pin 12 of connector X-UCM4 of component A-UCM, the detected resistance is > 2000 Ω.

2. The harness between A-UCM and the B-RECTD COOLANT TEMP ( B-RECTD) sensor is damaged.
3. The B-RECTD COOLANT TEMP ( B-RECTD) sensor is damaged.
4. The connector X-ENG is damaged.
5. The B-RECTD COOLANT TEMP ( B-RECTD) sensor hardness is damaged
6. The harness between connector X-ENG and component A-UCM is damaged.
Solution:
1. Set the fan speed to max.

2. Check the integrity of the harness between A-UCM and the B-RECTD COOLANT TEMP sensor.

3. Check the B-RECTD COOLANT TEMP sensor integrity.
Remove the B-RECTD COOLANT TEMP sensor.
A. If Resistance > 2000 Ω, replace the B-RECTD COOLANT TEMP sensor.

Disconnect X-ENG connector and visually check the integrity of the pins 5 and 9.

5. Check the B-RECTD COOLANT TEMP sensor harness for a proper condition.
48083741_EN 31/07/2018
55.8 [55.DTC] / 413
From To Value
Connector X-ENG pin 5 Connector X-ENG pin 9 Resistance < 2000 Ω
A. If the value is not correct, replace the harness between the connector and the sensor.
B. If the value is correct, continue to Step 6.

6. Check the integrity of harness between connector X-ENG and component A-UCM.
From To Value
Connector X-ENG pin 5 Connector X-UCM4A pin 12 Short circuit
A. If there is not a short circuit, replace the harness.
B. If there is a short circuit, replace the A-UCM component.
48083741_EN 31/07/2018
55.8 [55.DTC] / 414
518113-02 - Low Brake Pressure

Control Module: UCM
Context:
The A-UCM detects a value from Brake lower than the expected one; as a consequence:
• UCM: none
• GHMI:
- Low Brake Pressure Indicator = ON
- Red Master Indicator = ON
- Error Pop Up Message Displayed
- Buzzer = ON (Consistent with other RED warnings)
Cause:
• Key Switch = ON;

• Engine Running for 4 s;
• Brake Pressure < 12.2 for 3.0 s continuous.

2. The Brake Supply Line Pressure Sensor is not functioning.
3. The Brake Supply Line is not functioning.
Solution:
2. By performing the procedures 518113-03 – Short to Power at Brake Supply Line Pressure Sensor and
518113-04 – Short to Ground at Brake Supply Line Pressure Sensor, check the Brake Supply Line Pressure
Sensor is correctly functioning.

3. Replace the Brake Supply Line.
48083741_EN 31/07/2018
55.8 [55.DTC] / 415
518113-03 - Short to Power at Brake Supply Line Pressure Sensor

Control Module: UCM
Context:
The A-UCM detects a value from BRAKE SUPPLY PRESS ( B-PBW) out of higher limit.
Cause:

2. The BRAKE SUPPLY PRESS ( B-PBW) is damaged.
Solution:
1. Set Brake Supply Pressure to 0 bar

No Break Pressure Warning available
2. Check the BRAKE SUPPLY PRESS ( B-PBW) integrity.
Remove the BRAKE SUPPLY PRESS ( B-PBW). Use a multimeter to perform the PBW check:
From To Value
Connector X-PBW pin B Connector X-PBW pin A Resistance
A. If the resistance is an open circuit, replace the BRAKE SUPPLY PRESS.

3. Move the cursor of the sensor and, by using a multimeter, perform the PBW check:
From To Value
Connector X-PBW pin B Connector X-PBW pin C Resistance changing
A. If the value is a short circuit, replace the BRAKE SUPPLY PRESS.
48083741_EN 31/07/2018
55.8 [55.DTC] / 416
518113-04 - Short to Ground at Brake Supply Line Pressure Sensor

Control Module: UCM
Context:
The A-UCM detects a value from BRAKE SUPPLY PRESS ( B-PBW) out of lower limit.
Cause:

2. The harness between A-UCM and B-PBW is damaged.
3. The BRAKE SUPPLY PRESS ( B-PBW) is not correctly supplied
4. The BRAKE SUPPLY PRESS ( B-PBW) is damaged.
5. The harness between BRAKE SUPPLY PRESS ( B-PBW) and A-UCM is damaged.
Solution:
1. Set Brake Supply Pressure to 0 bar

2. Check the integrity of the harness between A-UCM and BRAKE SUPPLY PRESS ( B-PBW).

From To Value
Connector X-CAB_B pin 8 Connector X-CAB_B pin 10 Voltage = 5 V


48083741_EN 31/07/2018
55.8 [55.DTC] / 417
From To Value

6. Check the BRAKE SUPPLY PRESS sensor integrity.
Remove the BRAKE SUPPLY PRESS sensor.
Use a multimeter to perform the PBW check:
From To Value
Connector X-PBW pin B Connector X-PBW pin A Resistance
A. If the resistance is an open circuit, replace the BRAKE SUPPLY PRESS.

7. Move the cursor of the sensor and, by using a multimeter, perform the PBW check:
From To Value
Connector X-PBW pin B Connector X-PBW pin C Resistance changing
A. If the resistance does not change, replace the BRAKE SUPPLY PRESS.

8. Check the integrity of the connector X-BTM.
Disconnect the connector X-BTM from the connector X-CAB_B and visually check the integrity of the pins 6 on
both connectors.

9. Check the B-PBW to X-BTM harness for a proper condition.
From To Value
Connector X-PBW pin C Connector X-BTM pin 6 Short circuit
A. If the value is not correct, replace the harness between the connector and the BRAKE SUPPLY PRESS.

From To Value
48083741_EN 31/07/2018
55.8 [55.DTC] / 418
48083741_EN 31/07/2018
55.8 [55.DTC] / 419
518114-03 - Short to Power at Brake Line (declutch) Pressure

Sensor
Control Module: UCM
Context:
The A-UCM detects a value from PEDAL/DECLTCH ( B-PBL) out of higher limit.
Cause:
On pin 20 of connector X-UCM1B of A-UCM, the detected value is > 4.75 V.

2. The PEDAL/DECLTCH ( B-PBL) is damaged.
Solution:
1. Set Brake Line Pressure to 0 bar

CCO disabled (clutches will be immediately engaged if declutch was active)
Brake Light disabled (set error to SFB ) Default position sensor to minimum value (0%)
2. Check the PEDAL/DECLTCH ( B-PBL) integrity.
Remove the PEDAL/DECLTCH ( B-PBL).
Use a multimeter to perform the PBL check:
From To Value
Connector X-PLB-PBD pin B Connector X-PLB-PBD pin A Resistance
A. If the resistance is an open circuit, replace the PEDAL/DECLTCH.

3. Move the cursor of the sensor and, by using a multimeter, perform the PBL check:
From To Value
Connector X-PLB-PBD pin B Connector X-PLB-PBD pin C Resistance changing
A. If the value is a short circuit, replace the PEDAL/DECLTCH.
48083741_EN 31/07/2018
55.8 [55.DTC] / 420
518114-04 - Short to Ground at Brake Line (declutch) Pressure

Sensor
Control Module: UCM
Context:
The A-UCM detects a value from PEDAL/DECLTCH (B-PBL) out of lower limit.
Cause:
On pin 20 of connector X-UCM1B of A-UCM , the detected value is < 0.25 V.

2. The harness between A-UCM and B-PBL/PEDAL/DECLTCH is damaged.
3. The B-PBL/PEDAL/DECLTCH is not correctly supplied
4. The B-PBL/PEDAL/DECLTCH is damaged.
5. The harness between B-PBL/PEDAL/DECLTCH and A-UCM is damaged.
Solution:
1. Set Brake Line Pressure to 0 bar

CCO disabled (clutches will be immediately engaged if declutch was active)
Brake Light disabled (set error to SFB ) Default position sensor to minimum value (0%)
2. Check the integrity of the harness between A-UCM and B-PBL/PEDAL/DECLTCH.

From To Value
Connector X-CAB_B pin 8 Connector X-CAB_B pin 10 Voltage = 5 V

48083741_EN 31/07/2018
55.8 [55.DTC] / 421

From To Value

6. Check the PEDAL/DECLTCH sensor integrity.
Remove the PEDAL/DECLTCH sensor.
Use a multimeter to perform the PBL check:
From To Value
Connector X-PLB-PBD pin B Connector X-PLB-PBD pin A Resistance
A. If the resistance is an open circuit, replace the PEDAL/DECLTCH.

7. Move the cursor of the sensor and, by using a multimeter, perform the PBL check:
From To Value
Connector X-PLB-PBD pin B Connector X-PLB-PBD pin C Resistance changing
A. If the resistance does not change, replace the PEDAL/DECLTCH.

8. Check the integrity of the X-BTM connector.
Disconnect the connector X-BTM from the connector X-CAB_B and visually check the integrity of the pins 7 on
both connectors.

9. Check the B-PBL/PEDAL/DECLTCH to X-BTM harness for a proper condition.
From To Value
Connector X-PLB-PBD pin C Connector X-BTM pin 7 Short circuit
A. If the value is not correct, replace the harness between the connector and the PEDAL/DECLTCH.

48083741_EN 31/07/2018
55.8 [55.DTC] / 422
From To Value
48083741_EN 31/07/2018
55.8 [55.DTC] / 423
518115-01 - Auxiliary Steering lack of pressure

Control Module: UCM
Context:
The A-UCM detects a lack of pressure for the Auxiliary Steering.
Cause:
Engine Running is TRUE AND Steering Pressure < 240 kPa.

2. The Aux Steering Pressure Sensor is not functioning.
3. The Aux Steering is not functioning.
Solution:
2. By performing the procedures 518115-03 – Aux Steering Pressure Sensor Over Voltage and 518115-04 – Aux
Steering Pressure Sensor Over Voltage, check the Aux Steering Pressure Sensor is correctly functioning.

3. Replace the Aux Steering.
48083741_EN 31/07/2018
55.8 [55.DTC] / 424
518115-03 - Aux Steering Pressure Sensor Over Voltage

Control Module: UCM
Context:
The A-UCM detects a value from AUX STEERING PRESSURE ( B-PSS) greater than the upper limit.
Cause:
The A-UCM detects, on pin 8 of connector X-UCM1A, a voltage > 4.75 V.

2. The harness between the A-UCM and the AUX STEERING PRESSURE is damaged.
3. The AUX STEERING PRESSURE is damaged.
4. The harness relevant to the AUX STEERING PRESSURE is damaged.
Solution:
1. Disable Aux Steering Function.
2. Check the integrity of the harness between the A-UCM and the AUX STEERING PRESSURE.
The key must be in OFF position.

3. Check the AUX STEERING PRESSURE sensor integrity.
Remove the AUX STEERING PRESSURE sensor.
Use a multimeter to perform the AUX STEERING PRESSURE check:
From To Value
Connector X-PSS pin B Connector X-BPP pin A The sensor resistance
A. If the resistance is an open circuit, replace the AUX STEERING PRESSURE.

4. Move the cursor of the sensor and, by using a multimeter, perform the AUX STEERING PRESSURE check:
From To Value
Connector X-PSS pin B Connector X-PSS pin C Resistance changing
A. If the resistance does not change, replace the AUX STEERING PRESSURE.
48083741_EN 31/07/2018
55.8 [55.DTC] / 425
5. Check the integrity of the connectors X-SST and X-BTS.
Disconnect the connector X-SST from the connector X-BTS.
Visually check the integrity of pins 2, 3 and 4 of both connectors.

6. Check the integrity of the harness between the connector X-SST and the AUX STEERING PRESSURE.
From To Value
Connector X-PSS pin A Connector X-SST pin 3 Short circuit
Connector X-PSS pin C Connector X-SST pin 4 Short circuit
A. If one measurement is not correct, replace the harness between the connector X-SST and the AUX STEERING
PRESSURE.

7. Check the integrity of harness between the connector X-BTS and ground.
From To Value
Connector X-BTS pin 3 Ground Short circuit
A. If the measurement is not correct, replace the harness between the connector X-BTS and ground.

48083741_EN 31/07/2018
55.8 [55.DTC] / 426
518115-04 - Aux Steering Pressure Sensor Over Voltage

Control Module: UCM
Context:
The A-UCM detects a value from AUX STEERING PRESSURE ( B-PSS) lower than the upper limit.
Cause:
The A-UCM detects, on pin 8 of connector X-UCM1A, a voltage < 0.25 V.

2. The harness between the A-UCM and the AUX STEERING PRESSURE is damaged.
3. The AUX STEERING PRESSURE is not correctly supplied.
4. The harness relevant to the AUX STEERING PRESSURE is damaged.
5. The AUX STEERING PRESSURE is damaged.
Solution:
1. Disable Aux Steering Function.
2. Check the integrity of the harness between the A-UCM and the AUX STEERING PRESSURE.

3. Check the integrity of the connectors X-SST and X-BTS.
Disconnect the connector X-SST from the connector X-BTS.
Visually check the integrity of pins 2, 3 and 4 of both connectors.

4. Check the AUX STEERING PRESSURE power supply.
From To Value
Connector X-BTS pin 2 Connector X-BTS pin 3 (Ref) + 5V
A. If the value is not correct, replace the harness between the connector X-BTS and the connector X-BTM.

5. Check the harness between the AUX STEERING PRESSURE and the connector X-SST.
48083741_EN 31/07/2018
55.8 [55.DTC] / 427
Connect the connector X-BTS to the connector X-SST.
Remove the AUX STEERING PRESSURE sensor.
From To Value
Connector X-PSS pin B Connector X-PSS pin A + 5V
A. If the value is not correct, replace the harness between the connector X-SST and the connector X-PSS.

6. Check the integrity of the connectors X-BTM and X-CAB_B.
Disconnect the connector X-BTM from the connector X-CAB_B.
Visually check the integrity of the pin 11 of both connectors.

7. Check the integrity of the harness between the connector X-BTS and the connector X-BTM.
Disconnect the connector X-BTS from the connector X-SST.
From To Value
Connector X-BTS pin 4 Connector X-BTM pin 11 Short circuit
A. If the value is not correct, replace the harness between the connector X-BTS and the connector X-BTM.

8. Check the integrity of the connectors X-UCM1A.
Disconnect the connector X-UCM1A from the A-UCM.

9. Check the integrity of the harness between the connectors X-CAB_B and X-UCM1A.
From To Value
A. If the measurement is not correct, replace the harness between the connector X-CAB_B and the connector
X-UCM1A.

10. Check the AUX STEERING PRESSURE sensor integrity.
48083741_EN 31/07/2018
55.8 [55.DTC] / 428
Replace the AUX STEERING PRESSURE sensor.

48083741_EN 31/07/2018
55.8 [55.DTC] / 429
518116-09 - Hydraulic Filter is Clogged

Context:
Hydraulic Filter is Clogged.
Cause:

2. The hydraulic filter is clogged.
Solution:
2. Verify that the hydraulic filter is clean.
A. If the hydraulic filter is clean, replace the hydraulic filter sensor.
B. If the hydraulic filter is clogged, continue with Step 3.

3. Clean the hydraulic filter.
A. If the fault disappier after the cleaning, continue to work monitoring the fault.
B. If the fault is still present after the cleaning, bring the machine to a safe stop, and turn the engine OFF imme-
diately. Replace the air filter.
48083741_EN 31/07/2018
55.8 [55.DTC] / 430
518119-03 - Short to Power at Implement Coupler High Side Driver

Control Module: UCM
Context:
The A-UCM detects a malfunctioning from the COUPLER VALVE SOL. ( Y-YPE); as a consequence disable
implement coupler function (pin always engaged):
• Open Implement Coupler valve LSD
• Command Implement Coupler valve HSD to OFF
Cause:
The A-UCM detects on pin 7 of connector X-UCM3B a short circuit to power risen by BSP.

2. The harness between A-UCM and the COUPLER VALVE SOL. is damaged.
3. The connectors X-CAB_B or X-BTM or X-BTM_F or X-FRNT or X-UCM3B are damaged.
4. The harness between connectors X-BTM and X-FRNT is damaged.
5. The harness between connectors X-CAB_B and X-UCM3B is damaged.
6. The harness between connectors X-FRNT and X-YRC is damaged.
7. The COUPLER VALVE SOL. is damaged.
Solution:
2. Visually check the integrity of the harness between the connector X-UCM3B and the connector X-YPE for any
damage.

of both connectors.

4. Check the integrity of connectors X-BTM_F and X-FRNT.
Disconnect the connector X-BTM_F from the connector X-FRNT and visually check the integrity of pins R and S
of both connectors.

48083741_EN 31/07/2018
55.8 [55.DTC] / 431

6. Check the integrity of harness between the connector X-FRNT and the COUPLER VALVE SOL.
Remove the COUPLER VALVE SOL.
From To Value
Connector X-FRNT pin R Connector X-YPE pin 1 Short circuit
Connector X-FRNT pin S Connector X-YPE pin 2 Short circuit
Connector X-FRNT pin R Connector X-FRNT pin S Open circuit
Connector X-YPE pin 1 Connector X-YPE pin 2 Open circuit

7. Check the integrity of harness between the connectors X-BTM and X-BTM_F.
From To Value
Connector X-BTM pin 14 Connector X-BTM_F pin R Short circuit
Connector X-BTM pin 9 Connector X-BTM_F pin S Short circuit
Connector X-BTM pin 14 Connector X-BTM pin 9 Open circuit
Connector X-BTM_F pin R Connector X-BTM_F pin S Open circuit

8. Check the integrity of harness between the connectors X-UCM3B and X-CAB_B.
From To Value
Connector X-UCM3B pin 7 Connector X-UCM3B pin 4 Open circuit
Connector X-CAB_B pin 9 Connector X-CAB_B pin 14 Open circuit

9. Check the integrity of the COUPLER VALVE SOL.
Replace the COUPLER VALVE SOL.
48083741_EN 31/07/2018
55.8 [55.DTC] / 432
518119-04 - Short to Ground at Implement Coupler High Side Driver

Control Module: UCM
Context:
The A-UCM detects a grounding from the COUPLER VALVE SOL. ( Y-YPE); as a consequence disable implement
coupler function (pin always engaged):
Cause:

Solution:
damage.

3. Replace the COUPLER VALVE SOL.

of both connectors.

of both connectors.
48083741_EN 31/07/2018
55.8 [55.DTC] / 433


Remove the COUPLER VALVE SOL. Use a multimeter to perform the following check:
From To Value

From To Value

From To Value
48083741_EN 31/07/2018
55.8 [55.DTC] / 434
518119-05 - Open Circuit at Implement Coupler High Side Driver

Control Module: UCM
Context:
The A-UCM detects an open circuit or a low current absorption from the COUPLER VALVE SOL. ( Y-YPE); as a
consequence disable implement coupler function (pin always engaged):
Cause:
The A-UCM detects on pin 7 of connector X-UCM3B an Open Circuit or a Low Current Error risen by BSP.

Solution:
damage.

3. Replace the COUPLER VALVE SOL.

of both connectors.

of both connectors.
48083741_EN 31/07/2018
55.8 [55.DTC] / 435


From To Value

From To Value

From To Value
48083741_EN 31/07/2018
55.8 [55.DTC] / 436
518122-00 - Axle oil temperature is very high

Context:
Axle oil temperature is very high.
Cause:

2. The transmission oil temperature is very high.
Solution:
2. Bring the machine to a safe stop, and turn the engine OFF immediately. Replace the axle oil temperature sensor.
48083741_EN 31/07/2018
55.8 [55.DTC] / 437
518122-00 - Front Axle Oil Temp Sensor Over Resistance

Control Module: UCM
Context:
The A-UCM detects a value of resistance of the FRONT AXLE OIL TEMP ( B-FAX) higher than the upper limit;
as a consequence FAX Temperature not available:
• FAX warning disabled;
• Set PV_VC_STS.FAxOilTempWarn = 0x3 (out of range).
Cause:
The A-UCM detects on pin 17 of connector X-UCM4A a resistance value > 400 Ω.

2. The harness between A-UCM and the FRONT AXLE OIL TEMP is damaged.
3. The connectors X-CAB_B or X-BTM or X-BTM_F or X-FRNT or X-FAX or X-UCM4A are damaged.
4. The harness between connectors X-FAX and ground is damaged.
5. The harness between connectors X-FRNT and FRONT AXLE OIL TEMP is damaged.
6. The harness between connectors X-BTM and X-BTM_F is damaged.
7. The harness between connectors X-CAB_B and X-UCM4A is damaged.
8. The FRONT AXLE OIL TEMP is damaged.
Solution:
2. Visually check the integrity of the harness between the connector X-UCM4A and the connector X-FAX for any
damage.

3. Check the integrity of connector X-FAX.
Disconnect the connector X-FAX from the FRONT AXLE OIL TEMP and visually check the integrity of pins 1 and
2 of the connector.

4. Check the integrity of harness between the connector X-FAX and ground.
Remove the FRONT AXLE OIL TEMP.
From To Value
Connector X-FAX pin 2 Ground Short circuit
48083741_EN 31/07/2018
55.8 [55.DTC] / 438

connectors.

Disconnect the connector X-BTM_F from the connector X-FRNT and visually check the integrity of pin A of both
connectors.


8. Check the integrity of harness between the connector X-FRNT and the FRONT AXLE OIL TEMP.
From To Value
Connector X-FRNT pin A Connector X-FAX pin 1 Short circuit

From To Value
Connector X-BTM pin 17 Connector X-BTM_F pin A Short circuit

10. Check the integrity of harness between the connectors X-UCM4A and X-CAB_B.
From To Value

11. Replace the FRONT AXLE OIL TEMP.
48083741_EN 31/07/2018
55.8 [55.DTC] / 439
48083741_EN 31/07/2018
55.8 [55.DTC] / 440
518122-01 - Front Axle Oil Temp Sensor Under Resistance

Control Module: UCM
Context:
The A-UCM detects a value of resistance of the FRONT AXLE OIL TEMP ( B-FAX) lower than the low limit;
as a consequence FAX Temperature not available:
• FAX warning disabled;
• Set PV_VC_STS.FAxOilTempWarn = 0x3 (out of range).
Cause:
The A-UCM detects on pin 17 of connector X-UCM4A a resistance value < 25 Ω.

2. The harness between A-UCM and the FRONT AXLE OIL TEMP is damaged.
3. The FRONT AXLE OIL TEMP is damaged.
4. The connectors X-CAB_B or X-BTM or X-BTM_F or X-FRNT or X-FAX or X-UCM4A are damaged.
5. The harness of FRONT AXLE OIL TEMP is damaged.
6. The harness between connectors X-FRNT and X-FAX is damaged.
7. The harness between connectors X-BTM and X-BTM_F is damaged.
8. The hardness between connectors X-CAB_B and X-UCM4A is damaged.
Solution:
2. Visually check the integrity of the harness between the connector X-UCM4A and the connector X-FAX for any
damage.

3. Replace the FRONT AXLE OIL TEMP.

4. Check the integrity of connector X-FAX.
Disconnect the connector X-FAX from the FRONT AXLE OIL TEMP and visually check the integrity of pins 1 and
2.

5. Check the integrity of harness of the FRONT AXLE OIL TEMP.
48083741_EN 31/07/2018
55.8 [55.DTC] / 441
From To Value
Connector X-FAX pin 1 Ground Open circuit

Disconnect the connector X-BTM_F from the connector X-FRNT and visually check the integrity of pin A of both
connectors.

7. Check the integrity of harness between the connector X-FRNT and the FRONT AXLE OIL TEMP.
Connect the FRONT AXLE OIL TEMP.
From To Value
Connector X-FRNT pin A Ground > 25 Ω

connectors.

9. Check the integrity of harness between the connector X-BTM_F and the connector X-BTM.
Connect the connector X-FRNT to the connector X-BTM_F.
From To Value
Connector X-BTM pin 17 Ground > 25 Ω


11. Check the integrity of harness between the connectors X-UCM4A and X-CAB_B.
Connect the connector X-BTM to the connector X-CAB_B.
48083741_EN 31/07/2018
55.8 [55.DTC] / 442
From To Value
Connector X-UCM4A pin 17 Ground > 25 Ω
48083741_EN 31/07/2018
55.8 [55.DTC] / 443
518122-16 - Axle oil temperature high

Context:
Axle oil temperature high.
Cause:

2. The axle oil temperature is high.
Solution:
2. Idle the machine and monitor the temperature. Wait until the oil temperature reach the proper temperature and
restart the machine.
B. If the oil temperature within the proper range continue to work monitoring the temperature.
3. Clean the cooler or operate the fan reverser. Wait until the oil temperature reach the proper temperature and
restart the machine.
4. Wait until the oil temperature reach the proper temperature and restart the machine and use a lower gear.
A. If the oil temperature rises again, idle the machine and replace the axle oil temperature sensor.
48083741_EN 31/07/2018
55.8 [55.DTC] / 444
518122-31 - Axle oil temperature sensor out of range

Context:
Axle oil temperature sensor out of range.
Cause:

2. The axle oil temperature sensor out of range.
Solution:
2. Idle the machine and monitor the temperature. Wait until the axle oil temperature reach the proper temperature
3. Wait until the axle oil temperature reach the proper temperature and restart the machine and use a lower gear.
4. Bring the machine to a safe stop, and turn the engine OFF immediately. Replace the axle oil temperature sensor.
48083741_EN 31/07/2018
55.8 [55.DTC] / 445
518129-03 - Short to Power at Boom Raise Valve High Side Driver

Control Module: UCM
Context:
The A-UCM, driving the boom rise, detects a short circuit to power; as a consequence:
• Boom Function disabled;
• Open Boom LSD;
• Command Boom HSD PWM to 0%;
• Disabled advanced EH features (RTT/Float, HC).
Cause:
The A-UCM detects, on pin 7 of connector X-UCM4A, a short circuit to power risen by BSP.

2. The harness between A-UCM and the connector X-BOOM_RAISE is damaged.
3. The connectors X-BOOM_RAISE or X-FRNT_EH or X-BTM_FEH or X-BTM_EH or X-CAB_EH or X-UCM1B or
X-UCM4A are damaged.
5. The harness between connectors X-BTM_EH and X-BOOM_RAISE is damaged.
6. The harness between connectors X-FRNT_EH and X-BOOM_RAISE is damaged.
7. The BOOM_RAISE SOLENOID is damaged.
Solution:
2. Visually check the integrity of the harness between the connectors X-UCM4A, X-UCM1B and X-BOOM_RAISE
for any damage.



5. Check the integrity of harness between the A-UCM and the connector X-BOOM_RAISE.
48083741_EN 31/07/2018
55.8 [55.DTC] / 446
From To Value
Connector X-UCM4A pin 7 Connector X-UCM1B pin 2 < + 24 V

6. Check the integrity of connectors X-CAB_EH and X-BTM_EH.
Disconnect the connector X-CAB_EH from the connector X-BTM_EH and visually check the integrity of pins B
and C of both connectors.

7. Check the integrity of harness between the connectors X-BTM_EH and X-BOOM_RAISE.
From To Value
Connector X-BTM_EH pin B Connector X-BTM_EH pin C < + 24 V
A. If the measurement is correct, replace the harness between connector X-CAB_EH and the A-UCM.

8. Check the integrity of connectors X-BTM_FEH and X-FRNT_EH.
Disconnect the connector X-BTM_FEH from the connector X-FRNT_EH and visually check the integrity of pins
B and C of both connectors.

9. Check the integrity of harness between the connector X-FRNT_EH and the connector X-BOOM_RAISE.
From To Value
Connector X-FRNT_EH pin B Connector X-FRNT_EH pin C < + 24 V
A. If the measurement is correct, replace the harness between connectors X-BTM_EH and X-BTM_FEH.

10. Check the integrity of connector X-BOOM_RAISE.
Disconnect the connector X-BOOM_RAISE from the ELECTROHYDRAULIC VALVE ( A-EH_VLV) and visually
check the integrity of pins 1 and 2 of the connector.
B. If the pins are not damaged, replace the BOOM RAISE SOLENOID.
48083741_EN 31/07/2018
55.8 [55.DTC] / 447
518129-04 - Short to Ground at Boom Raise Valve High Side Driver

Control Module: UCM
Context:
The A-UCM, driving the boom rise, detects a short circuit to power; as a consequence:
• Open Boom LSD;
Cause:
The A-UCM detects, on pin 7 of connector X-UCM4A, a short circuit to ground risen by BSP.

5. The harness between connectors X-BTM_EH and X-BOOM_RAISE is damaged.
6. The harness between connectors X-FRNT_EH and X-BOOM_RAISE is damaged.
Solution:
for any damage.



5. Check the integrity of harness between the A-UCM and the connector X-BOOM_RAISE.
48083741_EN 31/07/2018
55.8 [55.DTC] / 448
From To Value
Connector X-UCM4A pin 7 Ground Open circuit
Connector X-UCM1B pin 2 Ground Open circuit


7. Check the integrity of harness between the connectors X-BTM_EH and X-BOOM_RAISE.
From To Value
Connector X-BTM_EH pin B Ground Open circuit
Connector X-BTM_EH pin C Ground Open circuit


9. Check the integrity of harness between the connector X-FRNT_EH and the connector X-BOOM_RAISE.
From To Value
Connector X-FRNT_EH pin B Ground Open circuit
Connector X-FRNT_EH pin C Ground Open circuit
A. If the measurements are correct, replace the harness between connectors X-BTM_EH and X-BTM_FEH.
B. If one measurement is correct, continue with Step 10.

48083741_EN 31/07/2018
55.8 [55.DTC] / 449
518129-05 - Open Circuit at Boom Raise Valve High Side Driver

Control Module: UCM
Context:
The A-UCM, driving the boom rise, detects an open circuit or a low current; as a consequence:
• Open Boom LSD;
Cause:
The A-UCM detects, on pin 7 of connector X-UCM4A, an open circuit or a low current risen by BSP.

4. The harness between connectors X-FRNT_EH and X-BTM_FEH is damaged.
5. The harness between connectors X-BTM_EH and X-BTM_FEH is damaged.
6. The harness between connectors A-UCM and the connector X-CAB_EH is damaged.
Solution:
for any damage.


48083741_EN 31/07/2018
55.8 [55.DTC] / 450

5. 5. Check the integrity of harness between the connector X-FRNT_EH and the connector X-BOOM_RAISE.
Disconnect the connector X-BOOM_RAISE from the ELECTROHYDRAULIC VALVE.
From To Value
Connector X-FRNT_EH pin B Connector X-BOOM_RAISE pin 1 Short circuit
Connector X-FRNT_EH pin C Connector X-BOOM_RAISE pin 2 Short circuit


7. Check the integrity of harness between the connectors X-BTM_FEH and X-BTM_EH.
From To Value
Connector X-BTM_FEH pin B Connector X-BTM_EH pin B Short circuit
Connector X-BTM_FEH pin C Connector X-BTM_EH pin C Short circuit



10. Check the integrity of harness between the A-UCM and the connector X-CAB_EH.
From To Value
Connector X-UCM4A pin 7 Connector X-CAB_EH pin B Short circuit
Connector X-UCM1B pin 2 Connector X-CAB_EH pin C Short circuit

11. Replace the BOOM RAISE SOLENOID.
48083741_EN 31/07/2018
55.8 [55.DTC] / 451
48083741_EN 31/07/2018
55.8 [55.DTC] / 452
518130-03 - Short to Power at Boom Lower Valve High Side Driver

Control Module: UCM
Context:
The A-UCM, driving the boom lower, detects a short circuit to power; as a consequence:
• Open Boom LSD;
Cause:

2. The harness between A-UCM and the connector X-BOOM_LOWER is damaged.
3. The connectors X-BOOM_LOWER or X-FRNT_EH or X-BTM_FEH or X-BTM_EH or X-CAB_EH or X-UCM1B or
5. The harness between connectors X-BTM_EH and X-BOOM_LOWER is damaged.
6. The harness between connectors X-FRNT_EH and X-BOOM_LOWER is damaged.
Solution:
2. Visually check the integrity of the harness between the connectors X-UCM4A, X-UCM1B and X-BOOM_LOWER
for any damage.



5. Check the integrity of harness between the A-UCM and the connector X-BOOM_LOWER.
48083741_EN 31/07/2018
55.8 [55.DTC] / 453
From To Value
Connector X-UCM4A pin 6 Connector X-UCM1B pin 2 < + 24 V

Disconnect the connector X-CAB_EH from the connector X-BTM_EH and visually check the integrity of pins D

7. Check the integrity of harness between the connectors X-BTM_EH and X-BOOM_LOWER.
From To Value
Connector X-BTM_EH pin D Connector X-BTM_EH pin C < + 24 V

D and C of both connectors.

9. Check the integrity of harness between the connector X-FRNT_EH and the connector X-BOOM_LOWER.
From To Value
Connector X-FRNT_EH pin D Connector X-FRNT_EH pin C < + 24 V

10. Check the integrity of connector X-BOOM_LOWER.
Disconnect the connector X-BOOM_LOWER from the ELECTROHYDRAULIC VALVE ( A-EH_VLV) and visually
48083741_EN 31/07/2018
55.8 [55.DTC] / 454
518130-04 - Short to Ground at Boom Lower Valve High Side Driver

Control Module: UCM
Context:
The A-UCM, driving the boom lower, detects a grounding connection; as a consequence:
• Open Boom LSD;
Cause:

5. The harness between connectors X-BTM_EH and X-BOOM_LOWER is damaged.
6. The harness between connectors X-FRNT_EH and X-BOOM_LOWER is damaged.
Solution:
for any damage.



5. Check the integrity of harness between the A-UCM and the connector X-BOOM_LOWER.
48083741_EN 31/07/2018
55.8 [55.DTC] / 455
From To Value
A. If the measurements are correct, replace the A-UCM.
B. If one measurement is not correct, continue with Step 6.

Disconnect the connector X-CAB_EH from the connector X-BTM_EH and visually check the integrity of pins D

7. Check the integrity of harness between the connectors X-BTM_EH and X-BOOM_LOWER.
From To Value
Connector X-BTM_EH pin D Ground Open circuit
Connector X-BTM_EH pin C Ground Open circuit


From To Value
Connector X-FRNT_EH pin D Ground Open circuit
Connector X-FRNT_EH pin C Ground Open circuit

48083741_EN 31/07/2018
55.8 [55.DTC] / 456
518130-05 - Open Circuit at Boom Lower Valve High Side Driver

Control Module: UCM
Context:
The A-UCM, driving the boom lower, detects an open circuit; as a consequence:
• Open Boom LSD;
Cause:
The A-UCM detects, on pin 6 of connector X-UCM4A, an open circuit risen by BSP.

4. The harness between X-FRNT_EH and X-BOOM_LOWER is damaged.
6. The harness between A-UCM and the connector X-CAB_EH is damaged.
Solution:
for any damage.


48083741_EN 31/07/2018
55.8 [55.DTC] / 457

Disconnect the connector X-BOOM_LOWER from the ELECTROHYDRAULIC VALVE.
From To Value
Connector X-FRNT_EH pin D Connector X-BOOM_LOWER pin 1 Short circuit
Connector X-FRNT_EH pin C Connector X-BOOM_LOWER pin 2 Short circuit

Disconnect the connector X-CAB_EH from the connector X-BTM_EHand visually check the integrity of pins D

From To Value
Connector X-BTM_FEH pin D Connector X-BTM_EH pin D Short circuit
Connector X-BTM_FEH pin C Connector X-BTM_EH pin C Short circuit


Disconnect the connector X-UCM1B from the A-UCMand visually check the integrity of pin 2.

From To Value
Connector X-UCM4A pin 6 Connector X-CAB_EH pin D Short circuit
Connector X-UCM1B pin 2 Connector X-CAB_EH pin C Short circuit

11. Replace the BOOM LOWER SOLENOID.
48083741_EN 31/07/2018
55.8 [55.DTC] / 458
48083741_EN 31/07/2018
55.8 [55.DTC] / 459
518131-03 - Short to Power/Open Circuit at Boom Valve Low Side

Driver
Control Module: UCM
Context:
The A-UCM detects a short circuit to power or an open circuit or a low current when drives a Boom Valve; as a
consequence:
• Open Boom LSD;
Cause:
The A-UCM detects, on pin 2 of connector X-UCM1B, a short circuit to power or an open circuit or a low current risen
by BSP.

2. The harness between the A-UCM and the connectors X-BOOM_RAISE and X-BOOM_LOWER is visually dam-
aged.
4. The harness between A-UCM and the connectors X-BOOM_RAISE and X-BOOM_LOWER is damaged.
Solution:
2. Visually check the integrity of the harness between the connectors X-UCM1B, X-BOOM_RAISE and
X-BOOM_LOWER for any damage.


4. Check the integrity of harness between the A-UCM and the connectors X-BOOM_RAISE and X-BOOM_LOWER.
From To Value
Connector X-UCM1B pin 2 Ground 0V
48083741_EN 31/07/2018
55.8 [55.DTC] / 460
B. If the measurement is not correct, check the correct functioning of the circuits relevant to:
- the Boom Raise Valve High Side Driver (see procedure 518129-03 – Short to Power at Boom Raise Valve
High Side Driver).
- the Boom Lower Valve High Side Driver (see procedure 518130-03 – Short to Power at Boom Lower Valve
High Side Driver).
48083741_EN 31/07/2018
55.8 [55.DTC] / 461
518131-04 - Short to Ground at Boom Valve Low Side Driver

Control Module: UCM
Context:
The A-UCM detects a grounding connection when drives a Boom Valve; as a consequence:
• Open Boom LSD;
Cause:

2. The harness between the A-UCM and the connectors X-BOOM_RAISE and X-BOOM_LOWER is visually dam-
aged.
4. The harness between A-UCM and the connectors X-BOOM_RAISE and X-BOOM_LOWER is damaged.
Solution:
2. Visually check the integrity of the harness between the connectors X-UCM1B, X-BOOM_RAISE and
X-BOOM_LOWER for any damage.


4. Check the integrity of harness between the A-UCM and the connectors X-BOOM_RAISE and X-BOOM_LOWER.
From To Value
- the Boom Raise Valve High Side Driver (see procedure 518129-04 – Short to Ground at Boom Raise Valve
High Side Driver).
48083741_EN 31/07/2018
55.8 [55.DTC] / 462
- the Boom Lower Valve High Side Driver (see procedure 518130-04 – Short to Ground at Boom Lower
Valve High Side Driver).
48083741_EN 31/07/2018
55.8 [55.DTC] / 463
518132-03 - Short to Power at Bucket Roll Valve High Side Driver

Control Module: UCM
Context:
The A-UCM, driving the bucket roll valve, detects a short circuit to power; as a consequence:
• Bucket Function disabled
• Open Bucket LSD
• Command Bucket HSD PWM to 0%
• Disabled advanced EH features ( RTD)
Cause:

2. The harness between A-UCM and the connector X-BUCKET_ROLL is damaged.
3. The connectors X-BUCKET_ROLL or X-FRNT_EH or X-BTM_FEH or X-BTM_EH or X-CAB_EH or X-UCM1B or
X-UCM3B are damaged.
5. The harness between connectors X-BTM_EH and X-BUCKET_ROLL is damaged.
6. The harness between connectors X-FRNT_EH and X-BUCKET_ROLL is damaged.
7. The BUCKET ROLL SOLENOID is damaged.
Solution:
2. Visually check the integrity of the harness between the connectors X-UCM3B, X-UCM1B and X-BUCKET_ROLL
for any damage.



5. Check the integrity of harness between the A-UCM and the connector X-BUCKET_ROLL.
48083741_EN 31/07/2018
55.8 [55.DTC] / 464
From To Value
Connector X-UCM3B pin 17 Connector X-UCM1B pin 30 < + 24 V

Disconnect the connector X-CAB_EH from the connector X-BTM_EH and visually check the integrity of pins E
and F of both connectors.

7. Check the integrity of harness between the connectors X-BTM_EH and X-BUCKET_ROLL.
From To Value
Connector X-BTM_EH pin E Connector X-BTM_EH pin F < + 24 V

E and F of both connectors.

9. Check the integrity of harness between the connector X-FRNT_EH and the connector X-BUCKET_ROLL.
From To Value
Connector X-FRNT_EH pin E Connector X-FRNT_EH pin F < + 24 V

10. Check the integrity of connector X-BUCKET_ROLL.
Disconnect the connector X-BUCKET_ROLL from the ELECTROHYDRAULIC VALVE ( A-EH_VLV) and visually
B. If the pins are not damaged, replace the BUCKET ROLL SOLENOID.
48083741_EN 31/07/2018
55.8 [55.DTC] / 465
518132-04 - Short to Ground at Bucket Roll Valve High Side Driver

Control Module: UCM
Context:
The A-UCM, driving the bucket roll valve, detects a grounding connection; as a consequence:
• Open Bucket LSD
• Command Bucket HSD PWM to 0%
• Disabled advanced EH features ( RTD)
Cause:

5. The harness between connectors X-BTM_EH and X-BUCKET_ROLL is damaged.
Solution:
for any damage.



5. Check the integrity of harness between the A-UCM and the connector X-BUCKET_ROLL.
48083741_EN 31/07/2018
55.8 [55.DTC] / 466
From To Value

Disconnect the connector X-CAB_EH from the connector X-CAB_EH and visually check the integrity of pins E

7. Check the integrity of harness between the connectors X-BTM_EH and X-BUCKET_ROLL.
From To Value
Connector X-BTM_EH pin E Ground Open circuit
Connector X-BTM_EH pin F Ground Open circuit
A. If the measurements are correct, replace the harness between connector X-CAB_EH and the A-UCM.


9. Check the integrity of harness between the connector X-FRNT_EH and the connector X-BUCKET_ROLL.
From To Value
Connector X-FRNT_EH pin E Ground Open circuit
Connector X-FRNT_EH pin F Ground Open circuit

B. If the pins are not damaged, replace the BUCKET ROLL SOLENOID.
48083741_EN 31/07/2018
55.8 [55.DTC] / 467
518132-05 - Open Circuit at Bucket Roll Valve High Side Driver

Control Module: UCM
Context:
• Open Boom LSD;
• Command Bucket HSD PWM to 0%;
• Disabled advanced EH features ( RTD).
Cause:

Solution:
for any damage.


48083741_EN 31/07/2018
55.8 [55.DTC] / 468

5. Check the integrity of harness between the connectors X-FRNT_EH and X-BUCKET_ROLL.
Disconnect the connector X-BUCKET_ROLL from the ELECTROHYDRAULIC VALVE.
From To Value
Connector X-FRNT_EH pin E Connector X-BUCKET_ROLL pin 1 Short circuit
Connector X-FRNT_EH pin F Connector X-BUCKET_ROLL pin 2 Short circuit

Disconnect the connector X-CAB_EH from the connector X-BTM_EH and visually check the integrity of pins E

From To Value
Connector X-BTM_FEH pin E Connector X-BTM_EH pin E Short circuit
Connector X-BTM_FEH pin F Connector X-BTM_EH pin F Short circuit


A. If the pin is damaged, replace the harness..

From To Value
Connector X-UCM3B pin 17 Connector X-CAB_EH pin E Short circuit
Connector X-UCM1B pin 30 Connector X-CAB_EH pin F Short circuit

11. Replace the BUCKET ROLL SOLENOID.
48083741_EN 31/07/2018
55.8 [55.DTC] / 469
48083741_EN 31/07/2018
55.8 [55.DTC] / 470
518133-03 - Short to Power at Bucket Dump Valve High Side Driver

Control Module: UCM
Context:
• Bucket Function disabled;
• Open Bucket LSD;
Cause:

2. The harness between A-UCM and the connector X-BUCKET_DUMP is damaged.
3. The connectors X-BUCKET_DUMP or X-FRNT_EH or X-BTM_FEH or X-BTM_EH or X-CAB_EH or X-UCM1B
or X-UCM3B are damaged.
5. The harness between connectors X-BTM_EH and X-BUCKET_DUMP is damaged.
6. The harness between connectors X-FRNT_EH and X-BUCKET_DUMP is damaged.
Solution:
2. Visually check the integrity of the harness between the connectors X-UCM3B, X-UCM1B and X-BUCKET_DUMP
for any damage.



5. Check the integrity of harness between the A-UCM and the connector X-BUCKET_DUMP.
48083741_EN 31/07/2018
55.8 [55.DTC] / 471
From To Value

Disconnect the connector X-CAB_EH from the connector X-BTM_EH and visually check the integrity of pins G

7. Check the integrity of harness between the connectors X-BTM_EH and X-BUCKET_DUMP.
From To Value
Connector X-BTM_EH pin G Connector X-BTM_EH pin F < + 24 V

G and F of both connectors.

9. Check the integrity of harness between the connector X-FRNT_EH and the connector X-BUCKET_DUMP.
From To Value
Connector X-FRNT_EH pin G Connector X-FRNT_EH pin F < + 24 V

10. Check the integrity of connector X-BUCKET_DUMP.
Disconnect the connector X-BUCKET_DUMP from the ELECTROHYDRAULIC VALVE ( A-EH_VLV) and visually
B. If the pins are not damaged, replace the BUCKET DUMP SOLENOID.
48083741_EN 31/07/2018
55.8 [55.DTC] / 472
518133-04 - Short to Ground at Bucket Dump Valve High Side Driver

Control Module: UCM
Context:
The A-UCM, driving the bucket dump valve, detects a grounding connection; as a consequence:
Cause:

5. The harness between connectors X-BTM_EH and X-BUCKET_DUMP is damaged.
Solution:
for any damage.



5. Check the integrity of harness between the A-UCM and the connector X-BUCKET_DUMP.
48083741_EN 31/07/2018
55.8 [55.DTC] / 473
From To Value


7. Check the integrity of harness between the connectors X-BTM_EH and X-BUCKET_DUMP.
From To Value
Connector X-BTM_EH pin G Ground Open circuit
Connector X-BTM_EH pin F Ground Open circuit


9. Check the integrity of harness between the connector X-FRNT_EH and the connector X-BUCKET_DUMP.
From To Value
Connector X-FRNT_EH pin G Ground Open circuit
Connector X-FRNT_EH pin F Ground Open circuit

B. If the pins are not damaged, replace the BUCKET DUMP SOLENOID.
48083741_EN 31/07/2018
55.8 [55.DTC] / 474
518133-05 - Open Circuit at Bucket Dump Valve High Side Driver

Control Module: UCM
Context:
The A-UCM, driving the bucket dump valve, detects an open circuit or a low current; as a consequence:
Cause:

7. The BUCKET DUMP SOLENOID is damaged.
Solution:
for any damage.


48083741_EN 31/07/2018
55.8 [55.DTC] / 475

5. Check the integrity of harness between the connectors X-FRNT_EH and X-BUCKET_DUMP.
Disconnect the connector X-BUCKET_DUMP from the ELECTROHYDRAULIC VALVE.
From To Value
Connector X-FRNT_EH pin G Connector X-BUCKET_DUMP pin 1 Short circuit
Connector X-FRNT_EH pin F Connector X-BUCKET_DUMP pin 2 Short circuit


From To Value
Connector X-BTM_FEH pin G Connector X-BTM_EH pin G Short circuit
Connector X-BTM_FEH pin F Connector X-BTM_EH pin F Short circuit



From To Value
Connector X-UCM3B pin 25 Connector X-CAB_EH pin G Short circuit
Connector X-UCM1B pin 30 Connector X-CAB_EH pin F Short circuit

11. Replace the BUCKET DUMP SOLENOID.
48083741_EN 31/07/2018
55.8 [55.DTC] / 476
48083741_EN 31/07/2018
55.8 [55.DTC] / 477
518134-03 - Short to Power/Open Circuit at Bucket Valve Low Side

Driver
Control Module: UCM
Context:
The A-UCM detects a short circuit to power or an open circuit or a low current when drives a Bucket Valve; as a
consequence:
Cause:
The A-UCM detects, on pin 30 of connector X-UCM1B, a short circuit to power or an open circuit or a low current
risen by BSP.

2. The harness between the A-UCM and the connectors X-BUCKET_ROLL and X-BUCKET_DUMP is visually dam-
aged.
4. The harness between A-UCM and the connectors X-BOOM_ROLL and X-BOOM_DUMP is damaged.
Solution:
2. Visually check the integrity of the harness between the connectors X-UCM1B, X-BUCKET_ROLL and
X-BUCKET_DUMP for any damage.


4. Check the integrity of harness between the A-UCM and the connectors X-BUCKET_ROLL and
X-BUCKET_DUMP.
From To Value
48083741_EN 31/07/2018
55.8 [55.DTC] / 478
- the Bucket Roll Valve High Side Driver (see procedure 518132-03 – Short to Power at Bucket Roll Valve
High Side Driver).
- the Bucket Dump Valve High Side Driver (see procedure 518133-03 – Short to Power at Bucket Dump
48083741_EN 31/07/2018
55.8 [55.DTC] / 479
518134-04 - Short to Ground at Bucket Valve Low Side Driver

Control Module: UCM
Context:
The A-UCM detects a grounding connection when drives a Bucket Valve; as a consequence:
Cause:

2. The harness between the A-UCM and the connectors X-BUCKET_ROLL and X-BUCKET_DUMP is visually dam-
aged.
4. The harness between A-UCM and the connectors X-BOOM_ROLL and X-BOOM_DUMP is damaged.
Solution:
2. Visually check the integrity of the harness between the connectors X-UCM1B, X-BUCKET_ROLL and
X-BUCKET_DUMP for any damage.


4. Check the integrity of harness between the A-UCM and the connectors X-BUCKET_ROLL and
X-BUCKET_DUMP.
From To Value
- the Bucket Roll Valve High Side Driver (see procedure 518132-04 – Short to Ground at Bucket Roll Valve
High Side Driver).
48083741_EN 31/07/2018
55.8 [55.DTC] / 480
- the Bucket Dump Valve High Side Driver (see procedure 518133-04 – Short to Ground at Bucket Dump
48083741_EN 31/07/2018
55.8 [55.DTC] / 481
518135-03 - Boom Angle Sensor Channel 2 Over Voltage

Control Module: UCM
Context:
The A-UCM detects a value from the Channel 2 of the BOOM ANGLE ( B-BKT_ANG) greater than the upper limit.
Cause:
The A-UCM detects, on pin 22 of connector X-UCM1B, a voltage > 4.75 V; as a consequence, the advanced CASE
CONSTRUCTION BOOM features (RTT/Float and HC) is disabled.

4. The BOOM ANGLE is damaged.
5. The harness relevant to the BOOM ANGLE is damaged.
Solution:

3. Check the BOOM ANGLE sensor integrity.
Remove the BOOM ANGLE sensor. Use a multimeter to perform the following check:
From To Value
BOOM ANGLE pin P2 BOOM ANGLE pin N2 The sensor resistance
A. If the resistance is an open circuit, replace the BOOM ANGLE.

From To Value
BOOM ANGLE pin P2 BOOM ANGLE pin OUT2 A resistance value
A. If the measurement is a short circuit, replace the BOOM ANGLE.

48083741_EN 31/07/2018
55.8 [55.DTC] / 482

Mount the BOOM ANGLE sensor.
From To Value

Visually check the integrity of pin T of both connectors.

From To Value
Connector X-BTM_EH pin T Ground < + 5V

Visually check the integrity of pins T and V of both connectors.

From To Value
Connector X-FRNT_EH pin T Connector X-FRNT_EH pin V Open circuit
48083741_EN 31/07/2018
55.8 [55.DTC] / 483
518135-04 - Boom Angle Sensor Channel 2 Under Voltage

Control Module: UCM
Context:
The A-UCM detects a value from the Channel 2 of the BOOM ANGLE ( B-BM_ANG) lower than the lower limit.
Cause:

4. The BOOM ANGLE is not correctly supplied.
5. The BOOM ANGLE sensor is damaged.
6. The harness between the connectors X-BOA and X-FRNT_EH is damaged.
Solution:

3. Check the integrity of the connector X-BOA.
Disconnect the connector X-BOA from the BOOM ANGLE.

4. Check the BOOM ANGLE power supply.
From To Value
Connector X-BOA pin F Connector X-BOA pin E (Ref) + 5V
A. If the value is not correct, check the harness between the connectors X-BOA, X-FRNT_EH and X-FRNT.
48083741_EN 31/07/2018
55.8 [55.DTC] / 484
5. Replace the BOOM ANGLE sensor.


7. Check the harness between the connectors X-BOA and X-FRNT_EH.
From To Value
Connector X-BOA pin D Connector X-FRNT_EH pin T Short circuit


From To Value
Connector X-BTM_FEH pin T Connector X-BTM_EH pin T Short circuit


From To Value
Connector X-CAB_EH pin T Connector X-UCM1B pin 22 Short circuit
48083741_EN 31/07/2018
55.8 [55.DTC] / 485
48083741_EN 31/07/2018
55.8 [55.DTC] / 486
518136-03 - Bucket Angle Sensor Channel 2 Over Voltage

Control Module: UCM
Context:
The A-UCM detects a value from the Channel 2 of the BUCKET ANGLE ( B-BKT_ANG) greater than the upper limit.
Cause:

4. The BUCKET ANGLE is damaged.
5. The harness relevant to the BUCKET ANGLE is damaged.
Solution:

3. Check the BUCKET ANGLE sensor integrity.
Remove the BUCKET ANGLE sensor.
From To Value
BUCKET ANGLE pin P2 BUCKET ANGLE pin N2 The sensor resistance
A. If the resistance is an open circuit, replace the BUCKET ANGLE.

From To Value
BUCKET ANGLE pin P2 BUCKET ANGLE pin OUT2 A resistance value
A. If the measurement is a short circuit, replace the BUCKET ANGLE.

48083741_EN 31/07/2018
55.8 [55.DTC] / 487

Mount the BUCKET ANGLE sensor.
From To Value

Visually check the integrity of pin X of both connectors.

From To Value
Connector X-BTM_EH pin X Ground < + 5V

Visually check the integrity of pins W and V of both connectors.

From To Value
Connector X-FRNT_EH pin X Connector X-FRNT_EH pin V Open circuit
48083741_EN 31/07/2018
55.8 [55.DTC] / 488
518136-04 - Bucket Angle Sensor Channel 2 Under Voltage

Control Module: UCM
Context:
The A-UCM detects a value from the Channel 2 of the BUCKET ANGLE ( B-BKT_ANG) greater than the lower limit.
Cause:

4. The BUCKET ANGLE is not correctly supplied.
5. The BUCKET ANGLE sensor is damaged.
6. The harness between the connectors X-BUA and X-FRNT_EH is damaged.
8. The harness between the connectors X-CAB_EH and X-UCM1B is damaged
Solution:

3. Check the integrity of the connector X-BUA.
Disconnect the connector X-BUA from the BUCKET ANGLE.
Visually check the integrity of pins F, E and D of the connector.

4. Check the BUCKET ANGLE power supply.
From To Value
Connector X-BUA pin F Connector X-BUA pin E + 5V
A. If the value is not correct, check the harness between the connectors X-BUA, X-FRNT_EH and X-FRNT.
48083741_EN 31/07/2018
55.8 [55.DTC] / 489
5. Replace the BUCKET ANGLE sensor.


7. Check the harness between the connectors X-BUA and X-FRNT_EH.
From To Value
Connector X-BUA pin D Connector X-FRNT_EH pin X Short circuit


From To Value
Connector X-BTM_FEH pin X Connector X-BTM_EH pin X Short circuit

A. If the pin is damaged, replace the relevant harness..

11. 11. Check the integrity of the harness between the connectors X-CAB_EH and X-UCM1B.
From To Value
Connector X-CAB_EH pin X Connector X-UCM1B pin 23 Short circuit
48083741_EN 31/07/2018
55.8 [55.DTC] / 490
48083741_EN 31/07/2018
55.8 [55.DTC] / 491
518137-03 - Short to Power at AUX 1 Left High Side Driver

Control Module: UCM
Context:
The A-UCM, driving the AUX 1 Left, detects a short circuit to power; as a consequence:
• AUX I Function disabled;
• Open AUX 1 LSD ;
• Command AUX I HSD PWMs to 0% Bucket Function disabled.
Cause:

2. The harness between A-UCM and the connector X-AUX_1_LEFT is damaged.
3. The connectors X-AUX_1_LEFT or X-FRNT_EH or X-BTM_FEH or X-BTM_EH or X-CAB_EH or X-UCM1B or
5. The harness between connectors X-BTM_EH and X-AUX_1_LEFT is damaged.
6. The harness between connectors X-FRNT_EH and X-AUX_1_LEFT is damaged.
7. The AUX 1 LEFT SOLENOID is damaged.
Solution:
2. Visually check the integrity of the harness between the connectors X-UCM3B, X-UCM1B and X-AUX_1_LEFT
for any damage.



5. Check the integrity of harness between the A-UCM and the connector X-AUX_1_LEFT.
48083741_EN 31/07/2018
55.8 [55.DTC] / 492
From To Value

Disconnect the connector X-CAB_EH from the connector X-BTM_EH and visually check the integrity of pins H
and J of both connectors.

7. Check the integrity of harness between the connectors X-BTM_EH and X-AUX_1_LEFT.
From To Value
Connector X-BTM_EH pin H Connector X-BTM_EH pin J < + 24 V

H and J of both connectors.

9. Check the integrity of harness between the connector X-FRNT_EH and the connector X-AUX_1_LEFT.
From To Value
Connector X-FRNT_EH pin H Connector X-FRNT_EH pin J < + 24 V

10. Check the integrity of connector X-AUX_1_LEFT.
Disconnect the connector X-AUX_1_LEFT from the ELECTROHYDRAULIC VALVE ( A-EH_VLV) and visually
B. If the pins are not damaged, replace the AUX 1 LEFT SOLENOID.
48083741_EN 31/07/2018
55.8 [55.DTC] / 493
518137-04 - Short to Ground at AUX 1 Left High Side Driver

Control Module: UCM
Context:
The A-UCM, driving the AUX 1 Left, detects a grounding connection; as a consequence:
Cause:

Solution:
for any damage.



48083741_EN 31/07/2018
55.8 [55.DTC] / 494
From To Value


From To Value
Connector X-BTM_EH pin H Ground Open circuit
Connector X-BTM_EH pin J Ground Open circuit


From To Value
Connector X-FRNT_EH pin H Ground Open circuit
Connector X-FRNT_EH pin J Ground Open circuit

48083741_EN 31/07/2018
55.8 [55.DTC] / 495
518137-05 - Open Circuit at AUX 1 Left High Side Driver

Control Module: UCM
Context:
The A-UCM, driving the AUX 1 Left, detects an open circuit or a low current; as a consequence:
Cause:

Solution:
for any damage.


48083741_EN 31/07/2018
55.8 [55.DTC] / 496
5. Check the integrity of harness between the connectors X-FRNT_EH and X-AUX_1_LEFT.
Disconnect the connector X-AUX_1_LEFT from the ELECTROHYDRAULIC VALVE.
From To Value
Connector X-FRNT_EH pin H Connector X-AUX_1_LEFT pin 1 Short circuit
Connector X-FRNT_EH pin J Connector X-AUX_1_LEFT pin 2 Short circuit


From To Value
Connector X-BTM_FEH pin H Connector X-BTM_EH pin H Short circuit
Connector X-BTM_FEH pin J Connector X-BTM_EH pin H Short circuit



From To Value
Connector X-UCM3B pin 32 Connector X-CAB_EH pin H Short circuit
Connector X-UCM1B pin 10 Connector X-CAB_EH pin J Short circuit

11. Replace the AUX 1 LEFT SOLENOID.
48083741_EN 31/07/2018
55.8 [55.DTC] / 497
48083741_EN 31/07/2018
55.8 [55.DTC] / 498
518138-03 - Short to Power at AUX 1 Right High Side Driver

Control Module: UCM
Context:
The A-UCM, driving the AUX 1 Right, detects a short circuit to power; as a consequence:
Cause:

2. The harness between A-UCM and the connector X-AUX_1_RIGHT is damaged.
3. The connectors X-AUX_1_RIGHT or X-FRNT_EH or X-BTM_FEH or X-BTM_EH or X-CAB_EH or X-UCM1B or
5. The harness between connectors X-BTM_EH and X-AUX_1_RIGHT is damaged.
6. The harness between connectors X-FRNT_EH and X-AUX_1_RIGHT is damaged.
7. The AUX 1 RIGHT SOLENOID is damaged.
Solution:
2. Visually check the integrity of the harness between the connectors X-UCM3B, X-UCM1B and X-AUX_1_RIGHT
for any damage.


4. Check the integrity of connector X-UCM1B

5. Check the integrity of harness between the A-UCM and the connector X-AUX_1_RIGHT.
48083741_EN 31/07/2018
55.8 [55.DTC] / 499
From To Value

Disconnect the connector X-CAB_EH from the connector X-BTM_EH and visually check the integrity of pins K

7. Check the integrity of harness between the connectors X-BTM_EH and X-AUX_1_RIGHT.
From To Value
Connector X-BTM_EH pin K Connector X-BTM_EH pin J < + 24 V

K and J of both connectors.

9. Check the integrity of harness between the connector X-FRNT_EH and the connector X-AUX_1_RIGHT.
From To Value
Connector X-FRNT_EH pin K Connector X-FRNT_EH pin J < + 24 V

10. Check the integrity of connector X-AUX_1_RIGHT.
Disconnect the connector X-AUX_1_RIGHT from the ELECTROHYDRAULIC VALVE ( A-EH_VLV) and visually
B. If the pins are not damaged, replace the AUX 1 RIGHT SOLENOID.
48083741_EN 31/07/2018
55.8 [55.DTC] / 500
518138-04 - Short to Ground at AUX 1 Right High Side Driver

Control Module: UCM
Context:
The A-UCM, driving the AUX 1 Right, detects a grounding connection; as a consequence:
Cause:

5. The hardness between connectors X-BTM_EH and X-AUX_1_RIGHT is damaged.
Solution:
for any damage.


4. Check the integrity of connector X-UCM1B

48083741_EN 31/07/2018
55.8 [55.DTC] / 501
From To Value


From To Value
Connector X-BTM_EH pin K Ground Open circuit
Connector X-BTM_EH pin J Ground Open circuit


From To Value
Connector X-FRNT_EH pin K Ground Open circuit
Connector X-FRNT_EH pin J Ground Open circuit

48083741_EN 31/07/2018
55.8 [55.DTC] / 502
518138-05 - Open Circuit at AUX 1 Right High Side Driver

Control Module: UCM
Context:
The A-UCM, driving the AUX 1 Right, detects an open circuit or a low current; as a consequence:
Cause:

Solution:
for any damage.


48083741_EN 31/07/2018
55.8 [55.DTC] / 503
5. Check the integrity of harness between the connectors X-FRNT_EH and X-AUX_1_RIGHT.
Disconnect the connector X-AUX_1_RIGHT from the ELECTROHYDRAULIC VALVE.
From To Value
Connector X-FRNT_EH pin K Connector X-AUX_1_RIGHT pin 1 Short circuit
Connector X-FRNT_EH pin J Connector X-AUX_1_RIGHT pin 2 Short circuit

A. If one pin is damaged, rreplace the harness relevant to the damaged connector.

From To Value
Connector X-BTM_FEH pin K Connector X-BTM_EH pin K Short circuit
Connector X-BTM_FEH pin J Connector X-BTM_EH pin J Short circuit



From To Value
Connector X-UCM3B pin 33 Connector X-CAB_EH pin K Short circuit
Connector X-UCM1B pin 10 Connector X-CAB_EH pin J Short circuit

11. Replace the AUX 1 RIGHT SOLENOID.
48083741_EN 31/07/2018
55.8 [55.DTC] / 504
48083741_EN 31/07/2018
55.8 [55.DTC] / 505
518139-03 - Short to Power/Open Circuit at AUX 1 Low Side Driver

Control Module: UCM
Context:
The A-UCM detects a short circuit to power or an open circuit or a low current when drives an AUX 1 Solenoid;
as a consequence:
• AUX I Function disabled
• Open AUX 1 LSD
• Command AUX I HSD PWMs to 0%
Cause:
The A-UCM detects, on pin 10 of connector X-UCM1B, a short circuit to power or an open circuit or a low current
risen by BSP.

2. The harness between the A-UCM and the connectors X-AUX_1_LEFT and X-AUX_1_RIGHT is visually damaged.
4. The harness between A-UCM and the connectors X-AUX_1_LEFT and X-AUX_1_RIGHT is damaged.
Solution:
2. Visually check the integrity of the harness between the connectors X-UCM1B, X-AUX_1_LEFT and
X-AUX_1_RIGHT for any damage.


4. Check the integrity of harness between the A-UCM and the connectors X-AUX_1_LEFT and X-AUX_1_RIGHT.
From To Value
- the AUX 1 Left High Side Driver (see procedure 518137-03 – Short to Power at AUX 1 Left High Side
Driver).
48083741_EN 31/07/2018
55.8 [55.DTC] / 506
- the AUX 1 Right High Side Driver (see procedure 518138-03 – Short to Power at AUX 1 Right High Side
Driver).
48083741_EN 31/07/2018
55.8 [55.DTC] / 507
518139-04 - Short to Ground at AUX 1 Low Side Driver

Control Module: UCM
Context:
The A-UCM detects a grounding connection when drives an AUX 1 Solenoid; as a consequence:
• Open AUX 1 LSD
Cause:

Solution:
2. Visually check the integrity of the harness between the connectors X-UCM1B, X-AUX_1_LEFT and


From To Value
- the AUX 1 Left High Side Driver (see procedure 518137-04 – Short to Ground at AUX 1 Left High Side
Driver).
- the AUX 1 Right High Side Driver (see procedure 518138-04 – Short to Ground at AUX 1 Right High Side
Driver).
48083741_EN 31/07/2018
55.8 [55.DTC] / 508
48083741_EN 31/07/2018
55.8 [55.DTC] / 509
518140-03 - Short to Power at AUX 2 Left High Side Driver

Control Module: UCM
Context:
The A-UCM, driving the AUX 2 Left, detects a short circuit to power; as a consequence:
• AUX II Function disabled;
• Open AUX II LSD;
• Command AUX II HSD PWMs to 0 °/s Bucket Function disabled.
Cause:

3. The connectors X-AUX_2_LEFT or X-FRNT_EH or X-BTM_FEH or X-BTM_EH or X-CAB_EH or X-UCM1A or
6. The harness between X-FRNT_EH and X-AUX_2_LEFT is damaged.
Solution:
2. Visually check the integrity of the harness between the connectors X-UCM4A, X-UCM1A and X-AUX_2_LEFT
for any damage.



48083741_EN 31/07/2018
55.8 [55.DTC] / 510
From To Value
Connector X-UCM4A pin 19 Connector X-UCM1A pin 21 < + 24 V

Disconnect the connector X-CAB_EH from the connector X-BTM_EH and visually check the integrity of pins L
and M of both connectors.

From To Value
Connector X-BTM_EH pin L Connector X-BTM_EH pin M < + 24 V

L and M of both connectors.

From To Value
Connector X-FRNT_EH pin L Connector X-FRNT_EH pin M < + 24 V

48083741_EN 31/07/2018
55.8 [55.DTC] / 511
518140-04 - Short to Ground at AUX 2 Left High Side Driver

Control Module: UCM
Context:
The A-UCM, driving the AUX 2 Left, detects a grounding connection; as a consequence:
Cause:

6. The harness between X-FRNT_EH and X-AUX_2_LEFT is damaged.
Solution:
for any damage.



48083741_EN 31/07/2018
55.8 [55.DTC] / 512
From To Value


From To Value
Connector X-BTM_EH pin L Ground Open circuit
Connector X-BTM_EH pin M Ground Open circuit


From To Value
Connector X-FRNT_EH pin L Ground Open circuit
Connector X-FRNT_EH pin M Ground Open circuit

48083741_EN 31/07/2018
55.8 [55.DTC] / 513
518140-05 - Open Circuit at AUX 2 Left High Side Driver

Control Module: UCM
Context:
The A-UCM, driving the AUX 2 Left, detects an open circuit or a low current; as a consequence:
Cause:

Solution:
for any damage.


48083741_EN 31/07/2018
55.8 [55.DTC] / 514
5. Check the integrity of harness between the connectors X-FRNT_EH and X-AUX_2_LEFT.
Disconnect the connector X-AUX_2_LEFT from the ELECTROHYDRAULIC VALVE.
From To Value
Connector X-FRNT_EH pin L Connector X-AUX_2_LEFT pin 1 Short circuit
Connector X-FRNT_EH pin M Connector X-AUX_2_LEFT pin 2 Short circuit


From To Value
Connector X-BTM_FEH pin L Connector X-BTM_EH pin L Short circuit
Connector X-BTM_FEH pin M Connector X-BTM_EH pin M Short circuit



From To Value
Connector X-UCM4A pin 19 Connector X-CAB_EH pin L Short circuit
Connector X-UCM1A pin 21 Connector X-CAB_EH pin M Short circuit

11. Replace the AUX 2 LEFT SOLENOID.
48083741_EN 31/07/2018
55.8 [55.DTC] / 515
48083741_EN 31/07/2018
55.8 [55.DTC] / 516
518141-03 - Short to Power at AUX 2 Right High Side Driver

Control Module: UCM
Context:
The A-UCM, driving the AUX 2 Right, detects a short circuit to power; as a consequence:
Cause:

3. The connectors X-AUX_2_RIGHT or X-FRNT_EH or X-BTM_FEH or X-BTM_EH or X-CAB_EH or X-UCM1A or
6. The harness between X-FRNT_EH and X-AUX_2_RIGHT is damaged.
Solution:
2. Visually check the integrity of the harness between the connectors X-UCM4A, X-UCM1A and X-AUX_2_RIGHT
for any damage.



48083741_EN 31/07/2018
55.8 [55.DTC] / 517
From To Value
Connector X-UCM4A pin 13 Connector X-UCM1A pin 21 < + 24 V

Disconnect the connector X-CAB_EH from the connector X-BTM_EH and visually check the integrity of pins N

From To Value
Connector X-BTM_EH pin N Connector X-BTM_EH pin M < + 24 V

N and M of both connectors.

From To Value
Connector X-FRNT_EH pin N Connector X-FRNT_EH pin M < + 24 V

48083741_EN 31/07/2018
55.8 [55.DTC] / 518
518141-04 - Short to Ground at AUX 2 Right High Side Driver

Control Module: UCM
Context:
The A-UCM, driving the AUX 2 Right, detects a grounding connection; as a consequence:
Cause:

Solution:
for any damage.



48083741_EN 31/07/2018
55.8 [55.DTC] / 519
From To Value


From To Value
Connector X-BTM_EH pin N Ground Open circuit
Connector X-BTM_EH pin M Ground Open circuit


From To Value
Connector X-FRNT_EH pin N Ground Open circuit
Connector X-FRNT_EH pin M Ground Open circuit

48083741_EN 31/07/2018
55.8 [55.DTC] / 520
518141-05 - Open Circuit at AUX 2 Right High Side Driver

Control Module: UCM
Context:
The A-UCM, driving the AUX 2 Right, detects an open circuit or a low current; as a consequence:
Cause:

6. The harness between A-UCM and X-CAB_EH is damaged.
Solution:
for any damage.


4. Check the integrity of connector X-BTM_FEH and X-FRNT_EH.
48083741_EN 31/07/2018
55.8 [55.DTC] / 521
5. Check the integrity of harness between the connectors X-FRNT_EH and X-AUX_2_RIGHT.
Disconnect the connector X-AUX_2_RIGHT from the ELECTROHYDRAULIC VALVE.
From To Value
Connector X-FRNT_EH pin N Connector X-AUX_2_RIGHT pin 1 Short circuit
Connector X-FRNT_EH pin M Connector X-AUX_2_RIGHT pin 2 Short circuit


From To Value
Connector X-BTM_FEH pin N Connector X-BTM_EH pin N Short circuit
Connector X-BTM_FEH pin M Connector X-BTM_EH pin M Short circuit



From To Value
Connector X-UCM4A pin 13 Connector X-CAB_EH pin N Short circuit
Connector X-UCM1A pin 21 Connector X-CAB_EH pin M Short circuit

11. Replace the AUX 2 RIGHT SOLENOID.
48083741_EN 31/07/2018
55.8 [55.DTC] / 522
48083741_EN 31/07/2018
55.8 [55.DTC] / 523
518142-03 - Short to Power/Open Circuit at AUX 2 Low Side Driver

Control Module: UCM
Context:
The A-UCM detects a short circuit to power or an open circuit or a low current when drives an AUX 2 Solenoid;
as a consequence:
• AUX II Function disabled
• Open AUX II LSD
• Command AUX II HSD PWMs to 0%
Cause:
The A-UCM detects, on pin 21 of connector X-UCM1A, a short circuit to power or an open circuit or a low current
risen by BSP.

3. The connector X-UCM1A is damaged.
Solution:
2. Visually check the integrity of the harness between the connectors X-UCM1A, X-AUX_2_LEFT and


From To Value
Connector X-UCM1A pin 21 Ground 0V
- the AUX 2 Left High Side Driver (see procedure 518140-03 – Short to Power at AUX 2 Left High Side
Driver).
48083741_EN 31/07/2018
55.8 [55.DTC] / 524
- the AUX 2 Right High Side Driver (see procedure 518141-03 – Short to Power at AUX 2 Right High Side
Driver).
48083741_EN 31/07/2018
55.8 [55.DTC] / 525
518142-04 - Short to Ground at AUX 2 Low Side Driver

Control Module: UCM
Context:
The A-UCM detects a grounding connection when drives an AUX 2 Solenoid; as a consequence:
• AUX II Function disabled
• Open AUX II LSD
• Command AUX II HSD PWMs to 0%
Cause:

3. The connector X-UCM1A is damaged.
Solution:
2. Visually check the integrity of the harness between the connectors X-UCM1A, X-AUX_2_LEFT and


From To Value
- the AUX 2 Left High Side Driver (see procedure 518140-04 – Short to Ground at AUX 2 Left High Side
Driver).
- the AUX 2 Right High Side Driver (see procedure 518141-04 – Short to Ground at AUX 2 Right High Side
Driver).
48083741_EN 31/07/2018
55.8 [55.DTC] / 526
48083741_EN 31/07/2018
55.8 [55.DTC] / 527
518143-03 - Short to Power/Open Circuit at Implement Coupler Low

Side Driver
Control Module: UCM
Context:
The A-UCM detects a malfunctioning from the COUPLER VALVE SOL. ( Y-YPE); as a consequence disable
implement coupler function (pin always engaged):
Cause:
The A-UCM detects on pin 4 of connector X-UCM3B a Short circuit to power or an Open Circuit or a Low Current
risen by BSP.

4. The connectors X-CAB_B or X-BTM or X-BTM_F or X-FRNT are damaged.
Solution:
A. f the fault is present and active, continue with Step 2.
damage.

By means of a multimeter, measure the resistance between pin 1 and pin 2 of the COUPLER VALVE SOL. con-
nector.
A. If the resistance is an open circuit, replace COUPLER VALVE SOL.

of both connectors.
48083741_EN 31/07/2018
55.8 [55.DTC] / 528

of both connectors.

From To Value


From To Value

From To Value
48083741_EN 31/07/2018
55.8 [55.DTC] / 529
518143-04 - Short to Ground at Implement Coupler Low Side Driver

Control Module: UCM
Context:
The A-UCM detects a grounding from the COUPLER VALVE SOL. ( Y-YPE); as a consequence disable implement
coupler function (pin always engaged):
Cause:

3. The connectors X-CAB_B or X-BTM or X-BTM_F or X-FRNT are damaged.
Solution:
damage.

of both connectors.

of both connectors.

48083741_EN 31/07/2018
55.8 [55.DTC] / 530
From To Value


From To Value

From To Value

Replace the COUPLER VALVE SOL.
48083741_EN 31/07/2018
55.8 [55.DTC] / 531
518144-03 - Short to Power at Aux Steering Enable High Side Driver

Control Module: UCM
Context:
The A-UCM detects a value from X-LC3 greater than the upper limit, as a consequence:
• Disable Aux Steering function;
• Aux steering function forced to activate.
Cause:

2. The harness between the connector X-UCM4B and the connector X-LC3 is damaged.
3. The relay SEC STEERING ( K-3R2) of LC3 is damaged.
Solution:
2. Visually check the integrity of the harness between the connector X-UCM4B and the connector X-LC3 for any
damage.

3. Replace the relay SEC STEERING ( K-3R2) of LC3.

Disconnect the connector X-UCM4B from A-UCM.
Visually check the integrity of pin 8 of the connector.

5. Check the integrity of the connector X-LC3.
Disconnect the connector X-LC3 from the LC3.
Visually check the integrity of pins R2_30, R2_85, R2_86 and R2_87 of the connector.
48083741_EN 31/07/2018
55.8 [55.DTC] / 532
6. Check the integrity of the harness between the connector X-UCM4B and the connector X-LC3.
From To Value
Connector X-UCM4B pin 8 Connector X-LC3 pin R2_86 Short circuit
A. If the measurement is not correct, replace the harness between the connector X-UCM4B and the connector
X-LC3.

48083741_EN 31/07/2018
55.8 [55.DTC] / 533
518144-04 - Short to Ground at Aux Steering Enable High Side

Driver
Control Module: UCM
Context:
The A-UCM detects a grounding from X-LC3, as a consequence:

• Disable Aux Steering function.
Cause:

Solution:
damage.



5. Check the integrity of the harness relevant to the connector X-LC3.
From To Value
Connector X-LC3 pin R2_86 Connector X-LC3 pin R2_85 Open circuit
48083741_EN 31/07/2018
55.8 [55.DTC] / 534
X-LC3.

48083741_EN 31/07/2018
55.8 [55.DTC] / 535
518144-05 - Open Circuit at Aux Steering Enable High Side Driver

Control Module: UCM
Context:
The A-UCM detects an open circuit with respect to X-LC3, as a consequence:

• Disable Aux Steering function.
Cause:
The A-UCM detects, on pin 8 of connector X-UCM4B, an open circuit or a low current error risen by BSP.

Solution:
damage.


4. Check the integrity of the harness between the connector X-UCM4B and the connector X-LC3.
From To Value
Connector X-LC3 pin R2_86 Connector X-UCM4B pin 8 Short circuit
X-LC3.

48083741_EN 31/07/2018
55.8 [55.DTC] / 536

48083741_EN 31/07/2018
55.8 [55.DTC] / 537
518145-03 - Short to Power/Open Circuit at Park Brake Low Side

Driver
Control Module: UCM
Context:
The A-UCM detects a value from PARKING BRAKE SOLENOID ( Y-Y_BP) out of higher limit.
Cause:
The A-UCM detects on pin 22 of connector X-UCM1A a short circuit to power.

2. The harness between A-UCM and the PARKING BRAKE SOLENOID is damaged.
4. The connectors X-BTM and X-CAB_B are damaged.
Solution:
1. Park Brake Function disabled (PB always active)

- Open PB LSD
- Set B.PBrakeAct = 01 (Park Brake Actuator Active)

A. If the resistance is a short circuit, replace the PARKING BRAKE SOLENOID.
B. If the resistance is not short circuit, continue with Step 4.

of both connectors.
48083741_EN 31/07/2018
55.8 [55.DTC] / 538

5. Check the integrity of harness of connector X-BTM.
From To Value

6. Check the integrity of harness of connector X-CAB_B.
Disconnect the connectors X-UCM3B and X-UCM1A from A-UCM
From To Value
48083741_EN 31/07/2018
55.8 [55.DTC] / 539
518145-04 - Short to Ground at Park Brake Low Side Driver

Control Module: UCM
Context:
The A-UCM detects a grounding from PARKING BRAKE SOLENOID ( Y-Y_BP).
Cause:
The A-UCM detects on pin 22 of connector X-UCM1A a short circuit to ground.

2. The harness between A-UCM and the PARKING BRAKE SOLENOID is damaged.
4. The connectors X-BTM and X-CAB_B are damaged.
5. The harness of connector X-BTM is damaged.
6. The harness of connector X-CAB_B is damaged.
Solution:
1. Set the key in OFF position.

A. If the resistance is a short circuit, replace the PARKING BRAKE SOLENOID.
B. If the resistance is not short circuit, continue with Step 4.

of both connectors.

5. Check the integrity of harness of connector X-BTM.
48083741_EN 31/07/2018
55.8 [55.DTC] / 540
From To Value
Connector X-BTM pin 19 Ground Open circuit

6. Check the integrity of harness of connector X-CAB_B.
From To Value
Connector X-CAB_B pin 19 Ground Open circuit
48083741_EN 31/07/2018
55.8 [55.DTC] / 541
518146-03 - Short to Power at FAN Control High Side Driver

Control Module: UCM
Context:
The A-UCM, driving the PWM FAN CONTROL ( Y-Y_FC), detects a short circuit to power; as a consequence the FAN
Functions are disabled.
Cause:

2. The harness between A-UCM and the connector X-YFN is damaged.
3. The connectors X-CAB_E-2 or X-ENG-2 or X-YFN or X-UCM2A are damaged.
4. The harness between A-UCM and the power supply is damaged.
5. The harness between connector X-BTM_EH and the power supply is damaged.
6. The harness between connector X-YFN and the power supply is damaged.
7. The PWM FAN CONTROL is damaged.
Solution:
2. Visually check the integrity of the harness between the connectors X-UCM2A and X-YFN for any damage.


4. Check the integrity of harness between the A-UCM and the power supply.
From To Value
Connector X-UCM2A pin 25 Ground < + 24 V

5. Check the integrity of connectors X-CAB_E-2 and X-ENG-2.
Disconnect the connector X-CAB_E-2 from the connector X-ENG-2 and visually check the integrity of pin P of
both connectors.
48083741_EN 31/07/2018
55.8 [55.DTC] / 542

6. Check the integrity of harness between the connectors X-ENG-2 and the power supply.
From To Value
Connector X-ENG-2 pin P Ground < + 24 V
A. If the measurement is correct, replace the harness between connector X-CAB_E-2 and the A-UCM.

7. Check the integrity of connector X-YFN.
Disconnect the connector X-YFN from the PWM FAN CONTROL and visually check the integrity of pins A and B
of the connector.

8. Check the integrity of harness between the connector X-YFN and the power supply.
From To Value
Connector X-YFN pin A Ground < + 24 V
A. If the measurement is not correct, replace the harness of connector X-YFN.
B. If the measurement is correct, replace the PWM FAN CONTROL.
48083741_EN 31/07/2018
55.8 [55.DTC] / 543
518146-04 - Short to Ground at FAN Control High Side Driver

Control Module: UCM
Context:
The A-UCM, driving the PWM FAN CONTROL ( Y-Y_FC), detects a grounding connection; as a consequence the
FAN Functions are disabled.
Cause:

4. The harness between A-UCM and ground is damaged.
5. The harness between connector X-ENG-2 and ground is damaged.
6. The harness between connector X-ENG-2 and X-YFN is damaged.
Solution:


4. Check the integrity of harness between the A-UCM and the ground.
From To Value
Connector X-UCM2A pin 25 Ground The PWM FAN CONTROL resistance

both connectors.
48083741_EN 31/07/2018
55.8 [55.DTC] / 544

6. Check the integrity of harness between the connectors X-ENG-2 and ground.
From To Value
Connector X-ENG-2 pin P Ground The PWM FAN CONTROL resistance
B. If one measurement is not correct,continue with Step 7.

of the connector.

8. Check the integrity of harness between the connectors X-ENG-2 and X-YFN.
From To Value
Connector X-ENG-2 pin P Connector X-YFN pin B Open circuit
A. If the measurement is not correct, replace the harness of connector X-YFN.
B. If the measurement is correct, replace the PWM FAN CONTROL.
48083741_EN 31/07/2018
55.8 [55.DTC] / 545
518146-05 - Open Circuit at FAN Control High Side Driver

Control Module: UCM
Context:
The A-UCM, driving the PWM FAN CONTROL ( Y-Y_FC), detects an open circuit or a low current; as a consequence
the FAN Functions are disabled.
Cause:
The A-UCM detects, on pin 25 of connector X-UCM2A, an open circuit or a low current error risen by BSP.

4. The harness between connector X-YFN and ground is damaged.
5. The harness between connector X-ENG-2 and X-YFN is damaged.
6. The harness between the A-UCM and the connector X-CAB_E-2 is damaged.
Solution:

of the connector.

4. Check the integrity of harness between the X-YFN and the ground.
Disconnect the connector X-YFN from the PWM FAN CONTROL.
From To Value
Connector X-YFN pin B Ground Short circuit

48083741_EN 31/07/2018
55.8 [55.DTC] / 546
both connectors.

6. Check the integrity of harness between the connectors X-ENG-2 and X-YFN.
Disconnect the connector X-YFN from the PWM FAN CONTROL.
From To Value
Connector X-ENG-2 pin P Connector X-YFN pin A Short circuit


8. Check the integrity of harness between the A-UCM and the connector X-CAB_E-2.
From To Value
Connector X-UCM2A pin 25 Connector X-CAB_E-2 pin P Short circuit

9. Replace the PWM FAN CONTROL.
48083741_EN 31/07/2018
55.8 [55.DTC] / 547
518147-03 - Short to Power FAN Reverser Low Side Driver

Control Module: UCM
Context:
The A-UCM, driving the FAN REVERSER ( Y-Y_FR), detects a short circuit to power; as a consequence the FAN
Cause:
The A-UCM detects, on pin 21 of connector X-UCM2A, a short circuit to power or a low current risen by BSP.

2. The harness between A-UCM and the connector X-YFR is damaged.
3. The connectors X-CAB_E-2 or X-ENG-2 or X-YFR or X-UCM2A are damaged.
5. The harness between connector X-ENG-2 and the power supply is damaged.
6. The FAN REVERSER is damaged.
Solution:


From To Value
Connector X-UCM2A pin 21 Ground < + 24 V

Disconnect the connector X-CAB_E-2 from the connector X-ENG-2 and visually check the integrity of pin N of
both connectors.
48083741_EN 31/07/2018
55.8 [55.DTC] / 548

6. Check the integrity of harness between the connectors X-ENG-2 and the power supply.
From To Value
Connector X-ENG-2 pin N Ground < + 24 V

7. Check the integrity of connector X-YFR.
Disconnect the connector X-YFR from the FAN REVERSER and visually check the integrity of pins 1 and 2 of the
connector.
B. If the pins are not damaged, replace the FAN REVERSER.
48083741_EN 31/07/2018
55.8 [55.DTC] / 549
518147-04 - Short to Ground at FAN Reverser Low Side Driver

Control Module: UCM
Context:
The A-UCM, driving the FAN REVERSER ( Y-Y_FR), detects a grounding connection; as a consequence the FAN
Cause:

3. The connectors X-CAB_E-2 or X-ENG-2 or X-YFR or X-UCM2A are damaged.
4. The harness between A-UCM and ground is damaged.
5. The harness between the connector X-ENG-2 and ground is damaged.
6. The FAN REVERSER is damaged.
Solution:
2. Visually check the integrity of the harness between the connectors X-UCM2A and X-YFR for any damage.


4. Check the integrity of harness between the A-UCM and the ground.
From To Value

Disconnect the connector X-CAB_E-2 from the connector X-ENG-2 and visually check the integrity of pin N of
both connectors.
48083741_EN 31/07/2018
55.8 [55.DTC] / 550

6. Check the integrity of harness between the connectors X-ENG-2 and ground.
From To Value
Connector X-ENG-2 pin N Ground Open circuit

7. Check the integrity of connector X-YFR.
Disconnect the connector X-YFR from the FAN REVERSER and visually check the integrity of pins 1 and 2 of the
connector.
B. If the pins are not damaged, replace the FAN REVERSER.
48083741_EN 31/07/2018
55.8 [55.DTC] / 551
518150-03 - Electrical Crank Power Relay- Short Circuit to B+

Control Module: SFB
Context:
Short Circuit to B+ of the Electrical Crank Power Relay.
Cause:
The Smart Fuse box measure a Short Circuit to B+ Electrical Crank Power Relay ( X3-5) when the key is OFF.

2. The harness between Smart Fuse Box and UCM is damaged.
3. The key switch Crank connector is damaged.
4. The Smart Fuse Box connector is damaged.
5. The Crank Power Relay is defective.
Solution:
2. Check the integrity of the harness between Smart Fuse Box and key switch Crank ( X-UCM2B pin 14).

3. Check the integrity of the key switch Crank connector ( X-UCM2B pin 14).
Disconnect key switch Crank connector and visually check the integrity of the pin.
A. If the pin is damaged, replace the connector.

A. If the pin 5 is damaged, replace the X-X3 connector.
B. If the pin 5 is not damaged, continue with Step 5.

5. Check the signal circuit for an open circuit condition on the harness between key switch Crank pin ( X-UCM2B pin
14) and + 5 V voltage.
48083741_EN 31/07/2018
55.8 [55.DTC] / 552
From To Value
Connector X-UCM2B pin 14 + 5V There should be an open circuit
A. If there is a short circuit, replace the harness.

6. Check the Smart Fuse Box signal circuit for an open circuit.
From To Value
Connector A-SFB pin OUT_03_H + 5V There should be an open circuit
A. If there is a short circuit, replace the Smart Fuse Box.

48083741_EN 31/07/2018
55.8 [55.DTC] / 553
518150-03 - Electrical Ignition Power Relay- Short Circuit to B+

Control Module: SFB
Context:
Open circuit Electrical Ignition Power Relay.
Cause:
The Smart Fuse box measure a Short Circuit to B+ of Electrical Ignition Power Relay ( X3-8) when the key is OFF.

2. The harness between Smart Fuse Box and key switch Ignition is damaged.
3. The key switch Ignition connector is damaged.
5. The Electrical Ignition Power Relay is defective.
Solution:
2. Check the integrity of the harness between Smart Fuse Box and Ignition Power Relay ( X-LC5 pin 86).

3. Check the integrity of the Ignition Power Relay connector ( X-LC5 pin 86).
Disconnect Ignition Power Relay connector and visually check the integrity of the pin.


5. Check the signal circuit for a Short Circuit to B+ condition on the harness between Electrical Ignition Power Relay
pin ( X-LC5 pin 86) and Smart Fuse Box.
48083741_EN 31/07/2018
55.8 [55.DTC] / 554
From To Value
Connector X-UCM2B pin14 Connector X-X3 pin 8 There should be a short circuit
Connector X-X3 pin 8 + 5V There should be an open circuit
Connector X-UCM2B pin14 + 5V There should be an open circuit
A. If there is an open circuit in the first measure, replace the harness.
B. If there is not voltage, continue to Step 6.

6. Check the Electrical Ignition Power Relay pin ( X-LC5 pin 86) circuit for a short circuit to B+.
From To Value
Connector X-LC5 pin 86 GND There should be a short circuit
A. If there is an open circuit, replace the Electrical Ignition Power Relay.

7. Check the Smart Fuse Box signal circuit for short circuit to B+.
From To Value
A. If there is a voltage, replace the Smart Fuse Box.

48083741_EN 31/07/2018
55.8 [55.DTC] / 555
518150-04 - Short to Ground at Crank Request High Side Driver

Control Module: UCM
Context:
The A-UCM detects a grounding connection at Crank Request; as a consequence the cranking request is disabled.
Cause:

2. The harness between Smart Fuse Box and UCM is visually damaged.
3. The connectors X-UCM3A or X-CAB_E or E-ENG or X-ECU or X-LC6 are damaged.
4. The harness relevant to A-UCM is damaged.
5. The harness relevant to connector E-ENG is damaged.
Solution:
2. Visually check the integrity of the harness between the A-UCM (connector X-UCM3A), the CRANK CONTROL
(connector X-LC6) and the A-ECU (connector X-ECU).


4. Check the integrity of the harness between the connector X-UCM3A and ground.
From To Value

5. Check the integrity of connectors X-CAB_E and E-ENG.
Disconnect the connectors X-CAB_E and E-ENG and visually check the integrity of pin 15.

6. Check the integrity of the harness between the connector X-ENG and ground.
48083741_EN 31/07/2018
55.8 [55.DTC] / 556
From To Value
Connector X-ENG pin 15 Ground Open circuit
A. If the measurement is correct, replace the harness between connectors X-UCM3A and X-CAB_E.

7. Check the integrity of connector X-LC6.
Disconnect the connector X-LC6 from the CRANK CONTROL (connector X-LC6) and visually check the integrity
of pin 32.

8. Check the integrity of the harness relevant to connector X-ENG.
From To Value
A. If the measurement is correct, replace the CRANK CONTROL.

9. Check the integrity of connector X-ECU.
Disconnect the connector X-ECU from the A-ECU and visually check the integrity of pin 63.

10. Check the integrity of the harness relevant to connector X-ENG.
From To Value
A. If the measurement is correct, replace the A-ECU.
B. If the measurement is not correct, replace the harness relevant to the connector X-ENG.

48083741_EN 31/07/2018
55.8 [55.DTC] / 557
518150-05 - Electrical Crank Power Relay- Open Circuit

Control Module: SFB
Context:
Open circuit Electrical Crank Power Relay.
Cause:
The Smart Fuse box measure an open circuit Electrical Crank Power Relay ( X3-5) when the key is OFF.

2. The harness between Smart Fuse Box and key switch Crank is damaged.
5. The Electrical Crank Power Relay is defective.
Solution:



5. Check the signal circuit for an open circuit condition on the harness between Electrical Crank Power Relay pin (
X-UCM2B pin 14) and Smart Fuse Box.
48083741_EN 31/07/2018
55.8 [55.DTC] / 558
From To Value
Connector X-UCM2B pin 14 Ground There should be a short circuit
A. If there is an open circuit, replace the harness.

From To Value

48083741_EN 31/07/2018
55.8 [55.DTC] / 559
518150-05 - Electrical Ignition Power Relay- Open Circuit

Control Module: SFB
Context:
Cause:
The Smart Fuse box measure an open circuit Electrical Ignition Power Relay ( X3-8) when the key is OFF.

Solution:



5. Check the signal circuit for an open circuit condition on the harness between Electrical Ignition Power Relay pin (
X-LC5 pin 86) and Smart Fuse Box.
48083741_EN 31/07/2018
55.8 [55.DTC] / 560
From To Value
Connector X-LC5 pin 86 Connector X-X3 pin 8 There should be a short circuit

6. Check the Electrical Ignition Power Relay pin ( X-LC5 pin 86) circuit for an open circuit.
From To Value
Connector X-LC5 pin 86 Connector X-LC5 pin 85 There should be a short circuit
Connector X-LC5 pin 85 Ground There should be a short circuit

From To Value

48083741_EN 31/07/2018
55.8 [55.DTC] / 561
518150-06 - Electrical Crank Power Relay- Short Circuit to GND

Control Module: SFB
Context:
Short Circuit to GND of the Electrical Crank Power Relay.
Cause:
The Smart Fuse box measure a Short Circuit to GND Electrical Crank Power Relay ( X3-5 ) on SCG when ON.

2. The harness between Smart Fuse Box and UCM is damaged.
5. The Crank Power Relay is defective.
Solution:



5. Check the signal circuit for an open circuit condition on the harness between key switch Crank pin ( X-UCM2B pin
14) and Smart Fuse Box.
48083741_EN 31/07/2018
55.8 [55.DTC] / 562
From To Value
Connector X-UCM2B pin 14 Ground There should be a short circuit

From To Value

48083741_EN 31/07/2018
55.8 [55.DTC] / 563
518150-06 - Electrical Ignition Power Relay- Short Circuit to GND

Control Module: SFB
Context:
Cause:
The Smart Fuse box measure a Short Circuit to GND of Electrical Ignition Power Relay ( X3-8) when the key is ON.

Solution:



5. Check the signal circuit for a Short Circuit to GND condition on the harness between Electrical Ignition Power
Relay pin ( X-LC5 pin 86) and Smart Fuse Box.
48083741_EN 31/07/2018
55.8 [55.DTC] / 564
From To Value
Connector X-LC5 pin 86 Connector X-X3 pin 8 There should be a short circuit
Connector X-X3 pin 8 GND There should be an open circuit
Connector X-LC5 pin 86 GND There should be an open circuit
A. If there is an open circuit in the first measure, replace the harness.

6. Check the Electrical Ignition Power Relay pin ( X-LC5 pin 86) circuit for a short circuit to GND.
From To Value
Connector X-LC5 pin 86 GND There should be a short circuit

7. Check the Smart Fuse Box signal circuit for short circuit to GND.
From To Value

48083741_EN 31/07/2018
55.8 [55.DTC] / 565
518176-03 - Joystick Steering Signal 2 High voltage

Control Module: UCM
Context:
The A-UCM detects a value from LH JOYSTICK STEERING ( B-JSS) out of higher limit.
Cause:
The A-UCM detects on pin 18 of connector X-UCM2A a voltage < 4.75 V for T> 250 ms.

2. The harness between A-UCM and the LH JOYSTICK STEERING ( B-JSS) is damaged.
3. The LH JOYSTICK STEERING is damaged.
Solution:
1. JSS Function Disabled

2. Check the integrity of the harness between the A-UCM and the LH JOYSTICK STEERING ( B-JSS).

3. Check the integrity of the LH JOYSTICK STEERING.
Replace the LH JOYSTICK STEERING.
48083741_EN 31/07/2018
55.8 [55.DTC] / 566
518176-04 - Joystick Steering Signal 2 Low voltage

Control Module: UCM
Context:
The A-UCM detects a value from LH JOYSTICK STEERING ( B-JSS) out of lower limit.
Cause:
The A-UCM detects on pin 18 of connector X-UCM2A a voltage < 0.25 V for T> 250 ms.

3. The LH JOYSTICK STEERING is not supplied.
4. The harness between the connector X-LFT_A and the LH JOYSTICK STEERING is damaged.
Solution:
1. JSS Function Disabled

2. Check the integrity of the harness between the A-UCM and the LH JOYSTICK STEERING ( B-JSS).

3. Check the LH JOYSTICK STEERING ( B-JSS) power supply.
From To Value
Connector X-CAB_L pin 7 Connector X-CAB_L pin 6 (Ref) 5V
A. If the value is not correct, continue with Step 5.

From To Value
Connector X-CAB_L pin 1 Connector X-CAB_L pin 3 (Ref) 5V
A. If the value is not correct, continue with Step 6.
48083741_EN 31/07/2018
55.8 [55.DTC] / 567

Disconnect the connectors X-UCM2A and the connector X-UCM1A from A-UCM.
From To Value
Connector X-UCM1A pin 4 Connector X-UCM2A pin 20 (Ref) 5V
A. If the value is not correct, replace the A-UCM.
B. If the value is correct, replace the harness between the connector X-CAB_L and the A-UCM.
6. Check the integrity of harness from the connector X-CAB_L and the A-UCM.
Disconnect the connectors X-UCM1B and the connector X-UCM1A from A-UCM.
From To Value
Connector X-UCM1A pin 3 Connector X-UCM2A pin 1 (Ref) 5V
A. If the value is not correct, replace the A-UCM.
B. If the value is correct, replace the harness between the connector X-CAB_L and the A-UCM.
7. Check the integrity of harness from the connector X-LFT_A and the LH JOYSTICK STEERING ( B-JSS).
Remove the connector X-JSS_JOY from the LH JOYSTICK STEERING.
From To Value
Connector X-JSS_JOY pin 1 Connector X-LFT_A pin 7 Short circuit

8. Check the integrity of harness from the connector X-CAB_L and the A-UCM.
Remove the connectors X-UCM2A from the A-UCM.
From To Value
Connector X-CAB_L pin 2 Connector X-UCM2A pin 18 Short circuit
Connector X-CAB_L pin 5 Connector X-UCM2A pin 12 Short circuit
B. If all the measurements are correct, replace the A-UCM.
C. Continue with Step 9.

9. Check the LH JOYSTICK STEERING integrity.
48083741_EN 31/07/2018
55.8 [55.DTC] / 568
B. If the functionality is not restored, replace the LH JOYSTICK STEERING.

48083741_EN 31/07/2018
55.8 [55.DTC] / 569
518176-09 - Joystick Steering Signals not plausible

Control Module: UCM
Context:
The A-UCM detects not plausible values from the Joystick; as a consequence, the function JSS is disabled:
• Set Joystick Position to Neutral
• Command PVED to cut Supply Pressure
Cause:
The A-UCM detects, on pins 12 and 18 of connector X-UCM2A, two not plausible signals (│5-( (Sig 1 Normalized +
Sig 2 Normalized)| ≤ 0.8 V T> 250 ms).

2. The harness between the A-UCM and the LH JOYSTICK STEERING is visually damaged.
3. The output JSS JOYSTICK 1 of the LH JOYSTICK STEERING is not correct.
4. The output JSS JOYSTICK 2 of the LH JOYSTICK STEERING is not correct.
Solution:
2. Visually check the integrity of the harness between the A-UCM and the LH JOYSTICK STEERING for any damage.

3. The output JSS JOYSTICK 1 of the Joystick is not functioning.
Be sure the voltage on pin 12 of connector X-UCM2A is 0.25 V < Voltage < 4.75 V.
- the procedure 518176-17 if the voltage is < 0.25 V;
- the procedure 518176-15 if the voltage is > 4.75 V.

4. The output JSS JOYSTICK 2 of the Joystick is not functioning.
Be sure the voltage on pin 18 of connector X-UCM2A is 0.25 V < Voltage < 4.75 V.
- the procedure 518176-04 – Joystick Steering Signal 2 Low voltage if the voltage is < 0.25 V;
- the procedure 518176-03 – Joystick Steering Signal 2 High voltage if the voltage is > 4.75 V.

Replace the A-UCM.
48083741_EN 31/07/2018
55.8 [55.DTC] / 570
B. If the functionality is not restored, replace the harness.
48083741_EN 31/07/2018
55.8 [55.DTC] / 571
518176-15 - Joystick Steering Signal 1 High voltage

Control Module: UCM
Context:
The A-UCM detects a value from LH JOYSTICK STEERING ( B-JSS) out of higher limit; as a consequence the
JSS Function is Disabled:
Cause:
The A-UCM detects, on pin 12 of connector X-UCM2A, a voltage > 4.75 V for T> 250 ms.

2. The harness between A-UCM and the LH JOYSTICK STEERING ( B-JSS) is visually damaged.
3. The connectors X-UCM2A or X-LFT_A or X-CAB_L or X-JSS_JOY are damaged.
4. The harness between A-UCM and the connector X-CAB_L is damaged.
5. The harness between the connectors X-JSS_JOY and X-LFT_A is damaged.
Solution:
2. Visually check the integrity of the harness between the A-UCM and the connector X-JSS_JOY.


4. Check the integrity of harness between the A-UCM and the LH JOYSTICK STEERING.
From To Value
Connector X-UCM2A pin 12 Ground 4.75 V

5. Check the integrity of connectors X-LFT_A and X-CAB_L.
Disconnect the connector X-LFT_A from the X-CAB_L and visually check the integrity of pin 5 of both connectors.
48083741_EN 31/07/2018
55.8 [55.DTC] / 572

6. Check the integrity of harness between the A-UCM and the connector X-CAB_L.
From To Value
Connector X-UCM2A pin 12 Connector X-CAB_L pin 5 Short circuit

7. Check the integrity of connector X-JSS_JOY.
Disconnect the connector X-JSS_JOY from the LH JOYSTICK STEERING and visually check the integrity of pin
5.

8. Check the integrity of harness between the connectors X-JSS_JOY and X-LFT_A.
From To Value
B. If the measurement is correct, replace the LH JOYSTICK STEERING.
48083741_EN 31/07/2018
55.8 [55.DTC] / 573
518176-17 - Joystick Steering Signal 1 Low voltage

Control Module: UCM
Context:
The A-UCM detects a value from LH JOYSTICK STEERING ( B-JSS) out of lower limit; as a consequence the
JSS Function is Disabled:
Cause:
The A-UCM detects, on pin 12 of connector X-UCM2A, a voltage < 0.25 V V for T> 250 ms.

3. The connectors X-UCM2A or X-LFT_A or X-CAB_L or X-JSS_JOY are damaged.
4. The LH JOYSTICK STEERING is not supplied.
5. The harness between the connectors X-LFT_A and X-JSS_JOY is damaged.
Solution:
2. Visually check the integrity of the harness between the A-UCM and the connector X-JSS_JOY.

3. Check the LH JOYSTICK STEERING is not supplied by the 5VREF3.
Disconnect the connector X-JSS_JOY from the LH JOYSTICK STEERING.
From To Value
Connector X-JSS_JOY pin 1 Connector X-JSS_JOY pin 2 (Ref) 5V
A. If the value is not correct, check for the absence of the power supply 5VREF3 (see procedure 518282-31 –
Error at 5VREF3 Output).

4. Check the LH JOYSTICK STEERING is not supplied by the 5VREF2.
Disconnect the connector X-JSS_JOY from the LH JOYSTICK STEERING.
48083741_EN 31/07/2018
55.8 [55.DTC] / 574
From To Value
Connector X-JSS_JOY pin 4 Connector X-JSS_JOY pin 6 (Ref) 5V
A. If the value is not correct, check for the absence of the power supply 5VREF2 (see procedure 518282-31 –
Error at 5VREF3 Output).

5. Check the integrity of connector X-JSS_JOY.
Disconnect the connector X-JSS_JOY from the LH JOYSTICK STEERING and visually check the integrity of pin
5.

Disconnect the connector X-LFT_A from the X-CAB_L and visually check the integrity of pin 5 of both connectors.

7. Check the integrity of harness between the connectors X-JSS_JOY and X-LFT_A.
From To Value


From To Value
Connector X-UCM2A pin 12 Connector X-CAB_L pin 5 Short circuit

10. Replace the LH JOYSTICK STEERING.
48083741_EN 31/07/2018
55.8 [55.DTC] / 575
518177-03 - Short to Power at Pilot Enable Valve High Side Driver

Control Module: UCM
Context:
The A-UCM, driving the Pilot Enable Valve, detects a short circuit to power; as a consequence:
• Pilot Lock valve disabled;
• Command Pilot lock Valve HSD PWM to 0% Bucket Function disabled.
Cause:

2. The harness between A-UCM and the connector X-PILOT_ENABLE is damaged.
3. The connectors X-PILOT_ENABLE or X-FRNT_EH or X-BTM_FEH or X-BTM_EH or X-CAB_EH or X-UCM3B
are damaged.
5. The harness between connectors X-BTM_EH and X-PILOT_ENABLE is damaged.
6. The harness between connectors X-FRNT_EH and X-PILOT_ENABLE is damaged.
7. The PILOT ENABLE SOLENOID is damaged.
Solution:
2. Visually check the integrity of the harness between the connectors X-UCM3B and X-PILOT_ENABLE for any
damage.


4. Check the integrity of harness between the A-UCM and the connector X-PILOT_ENABLE.
From To Value
Connector X-UCM3B pin 18 Ground < + 24 V

48083741_EN 31/07/2018
55.8 [55.DTC] / 576
Disconnect the connector X-CAB_EH from the connector X-BTM_EH and visually check the integrity of pin A of
both connectors.

6. Check the integrity of harness between the connectors X-BTM_EH and X-PILOT_ENABLE.
From To Value
Connector X-BTM_EH pin A Ground < + 24 V
A. If the measurement is correct, replace the harness between connector X-BTM_EH and the A-UCM.

Disconnect the connector X-BTM_FEH from the connector X-FRNT_EH and visually check the integrity of pin A
of both connectors.

8. Check the integrity of harness between the connector X-FRNT_EH and the connector X-PILOT_ENABLE.
From To Value
Connector X-FRNT_EH pin A Ground < + 24 V

9. Check the integrity of connector X-PILOT_ENABLE.
Disconnect the connector X-PILOT_ENABLE from the ELECTROHYDRAULIC VALVE ( A-EH_VLV) and visually
B. If the pins are not damaged, replace the PILOT ENABLE SOLENOID.
48083741_EN 31/07/2018
55.8 [55.DTC] / 577
518177-04 - Short to Ground at Pilot Enable Valve High Side Driver

Control Module: UCM
Context:
The A-UCM, driving the Pilot Enable Valve, detects a grounding connection; as a consequence:
Cause:

are damaged.
5. The harness between connectors X-BTM_EH and X-PILOT_ENABLE is damaged.
6. The harness between connectors X-FRNT_EH and X-PILOT_ENABLE is damaged.
Solution:
damage.


4. Check the integrity of harness between the A-UCM and the connector X-PILOT_ENABLE.
From To Value

48083741_EN 31/07/2018
55.8 [55.DTC] / 578
both connectors.

6. Check the integrity of harness between the connectors X-BTM_EH and X-PILOT_ENABLE.
From To Value
Connector X-BTM_EH pin A Ground Open circuit

of both connectors.

8. Check the integrity of harness between the connector X-FRNT_EH and the connector X-PILOT_ENABLE.
From To Value
Connector X-FRNT_EH pin A Ground Open circuit

B. If the pins are not damaged, replace the PILOT ENABLE SOLENOID.
48083741_EN 31/07/2018
55.8 [55.DTC] / 579
518177-05 - Open Circuit at Pilot Enable Valve High Side Driver

Control Module: UCM
Context:
The A-UCM, driving the Pilot Enable Valve, detects an open circuit or a low current; as a consequence:
Cause:

are damaged.
4. The harness between X-FRNT_EH and ground is damaged.
5. The harness between connector X-PILOT_ENABLE is damaged.
Solution:
damage.


of both connectors.
48083741_EN 31/07/2018
55.8 [55.DTC] / 580
5. Check the integrity of harness between the connectors X-FRNT_EH and X-PILOT_ENABLE.
Disconnect the connector X-PILOT_ENABLE from the ELECTROHYDRAULIC VALVE.
From To Value
Connector X-FRNT_EH pin A Connector X-PILOT_ENABLE pin 1 Short circuit

6. Check the integrity of harness between the connector X-PILOT_ENABLE and ground.
Disconnect the connector X-PILOT_ENABLE from the ELECTROHYDRAULIC VALVE. Use a multimeter to per-
form the following check:
From To Value
Connector X-PILOT_ENABLE pin 2 Ground Short circuit

both connectors.

From To Value
Connector X-BTM_FEH pin A Connector X-BTM_EH pin A Short circuit


From To Value
Connector X-UCM3B pin 18 Connector X-CAB_EH pin A Short circuit
48083741_EN 31/07/2018
55.8 [55.DTC] / 581
11. Replace the PILOT ENABLE SOLENOID.
48083741_EN 31/07/2018
55.8 [55.DTC] / 582
518267-02 - WatchDog Reset

Context:
WatchDog Reset.
Cause:

Solution:

3. Verify the wirings to external connection.
48083741_EN 31/07/2018
55.8 [55.DTC] / 583
518280-31 - Error at 5VREF1 Output

Control Module: UCM
Context:
The A-UCM detects the 5VREF1 is not within the limits; as a consequence:
• Set Brake Supply Pressure to 0 bar
• Set Front Accumulator Pressure to 0 bar
• Set Rear Accumulator Pressure to 0 bar
• No Brake Pressure Warning available
• Set Brake Line Pressure to 0 bar
• CCO disabled (clutches will be immediately engaged if declutch was active)
• Brake Light disabled
• Disable Aux Steering Function
• Disabled advanced EH features ( RTT/Float, RTD, HC)
• If 2-Lever or 3-Lever Pilot Joystick is installed
• Set Aux FNR = N
• Disable Aux FNR
Cause:
The A-UCM detects, on pin 2 of connector X-UCM1A, a voltage > 5.2 V or < 4.8 V.

2. The connectors X-CAB_TR or X-TRANS or X-CAB_B or X-BTM or X-UCM1A are damaged.
4. One circuit connected to the A-UCM is not functioning.
Solution:
2. Check the integrity of connectors X-CAB_TR and X-TRANS.
Disconnect the connector X-CAB_TR from the connector X-TRANS and visually check the integrity of pin 26 of
both connectors.

Disconnect the connector X-CAB_B from the connector X-BTM and visually check the integrity of pin 8 of both
connectors.
48083741_EN 31/07/2018
55.8 [55.DTC] / 584
From To Value
Connector X-CAB_TR pin 26 Ground 4.8 V < Value < 5.2
A. If the value is out of the limits, continue with Step 5.
B. If the value is within the limits, continue with Step 6.

5. Replace the harness relevant to the connectors X-UCM1A, X-CAB_B and X-CAB_TR.

6. Connect the connectors X-CAB_B and X-BTM.
From To Value
Connector X-CAB_TR pin 26 Ground 4.8 V < Value < 5.2
A. If the value is within the limits, check the correct functioning of the circuit relevant to:
- the Front Brake Accumulator Pressure Sensor (see procedure 1049-04);
- the Rear Brake Accumulator Pressure Sensor (see procedure 1052-04).
B. If the value is out of the limits, check the correct functioning of the circuit relevant to:
- the Brake Supply Line Pressure Sensor (see procedure 518113-04);
- the Brake Line (declutch) Pressure Sensor (see procedure 518114-04);
- the Aux Steering Pressure Sensor (see procedure 518115-04);
- the Boom Angle Sensor Channel 2 (see procedure 518135-04);
- the Bucket Angle Sensor Channel 2 (see procedure 518136-04).
48083741_EN 31/07/2018
55.8 [55.DTC] / 585

Control Module: UCM
Context:
• Disabled advanced EH features ( RTT/Float, RTD, EH)
• Power Inch disabled
• Default Angle Position sensor to minimum value ( 0%)
• Disabled JSS
• Only if Model is PL23 or PL26
• FAX Temperature not available
• FAX warning disabled
• Set PV_VC_STS.FAxOilTempWarn = 0x3 (out of range)
• Only if 2-Lever or 3-Lever Pilot Joystick is installed
• Set Aux FNR = N
• Disable Aux FNR
Cause:

2. The connectors X-CAB_B or X-BTM or X-LFT_A or X-CAB_L or X-FRNT_EH or X-BTM_FEH or X-UCM1A are
damaged.
Solution:
Disconnect the connector X-CAB_B from the connector X-BTM and visually check the integrity of pin 4 of both
connectors.

3. Check the integrity of harness between the A-UCM and the connector X-CAB_B.
From To Value
Connector X-CAB_B pin 4 Ground 4.8 V < Value < 5.2
A. If the value is out of the limits, continue with Step 4.
B. If the value within the limits, continue with Step 7.
48083741_EN 31/07/2018
55.8 [55.DTC] / 586
Disconnect the connector X-LFT_A from the connector X-CAB_L and visually check the integrity of pin 1 of both
connectors.

From To Value
Connector X-CAB_B pin 4 Ground 4.8 V < Value < 5.2
A. If the value within the limits, check the correct functioning of the circuit relevant to:
- the Joystick Steering Signal 2 Low voltage (see procedure 518176-04);
- the Joystick Steering Signal 1 Low voltage (see procedure 518176-17).
B. If the value is out of the limits, continue with Step 6.

6. Replace the harness relevant to the connectors X-UCM1B, X-CAB_B and X-CAB_L.

Connect the connectors X-CAB_B and X-BTM.
Disconnect the connector X-BTM_FEH from the connector X-FRNT_EH and visually check the integrity of pin V
of both connectors.

8. Check the integrity of harness between the connectors X-BTM_EH and X-BTM_FEH.
From To Value
Connector X-BTM_FEH pin V Ground 4.8 V < Value < 5.2
A. If the value is out of the limits, check the correct functioning of the circuit relevant to the Inch Pedal Position
Sensor (see procedure 521-04).
B. If the value within the limits, check the correct functioning of the circuit relevant to:
- the Bucket Angle Sensor Channel 1 (see procedure 518111-04);
- the Boom Angle Sensor Channel 1 (see procedure 518110-04).
48083741_EN 31/07/2018
55.8 [55.DTC] / 587

Control Module: UCM
Context:
• Disabled JSS;
• Command the FAN as open loop.
Cause:

2. The connectors X-CAB_JSS or X-JSS_FR or X-LFT_A or X-CAB_L or X-CAB_E or X-ENG or X-UCM1A are
damaged.
Solution:
Disconnect the connector X-LFT_A from the connector X-CAB_L and visually check the integrity of pin 7 of both
connectors.

From To Value
Connector X-CAB_L pin 7 Ground 4.8 V < Value < 5.2
- the Joystick Steering Signal 2 Low voltage (see procedure 518176-04);
- the Joystick Steering Signal 1 Low voltage (see procedure 518176-17).

4. Check the integrity of connectors X-JSS_FR and X-CAB_JSS.
Disconnect the connector X-JSS_FR from the connector X-CAB_JSS and visually check the integrity of pin 3 of
both connectors.
48083741_EN 31/07/2018
55.8 [55.DTC] / 588
5. Check the integrity of harness between the A-UCM and the connector X-CAB_JSS.
From To Value
Connector X-CAB_JSS pin 3 Ground 4.8 V < Value < 5.2
- the JSS CUT OFF SENSOR 1 (see procedure TBD);
- the JSS CUT OFF SENSOR 2 (see procedure TBD).

6. Check the integrity of connectors X-ENG and X-CAB_E.
Disconnect the connector X-ENG from the connector X-CAB_E and visually check the integrity of pin 28 of both
connectors.

7. Check the integrity of harness between the A-UCM and the connector X-CAB_E.
From To Value
Connector X-CAB_E pin 28 Ground 4.8 V < Value < 5.2
A. If the value within the limits, check the correct functioning of the circuit relevant to the FAN SPEED SENSOR
(see procedure TBD).

8. Replace the harness relevant to the connectors X-UCM1A, X-CAB_E, X-CAB_JSS and X-CAB_L.
48083741_EN 31/07/2018
55.8 [55.DTC] / 589
518283-31 - Error at 24VF2 Supply Rail

Control Module: UCM
Context:
The A-UCM detects the absence of the 24VF2 power supply; as a consequence:
• AUX II Function disabled:
• Open AUX II LSD
• Command AUX II HSD PWMs to 0%:
• Boom Function disabled:
• Open Boom LSD
• Command Boom HSD PWMs to 0%;
• Disabled advanced EH Boom features (RTT/Float, HC).
Cause:
The A-UCM detects, on pins 1 and 8 of connector X-UCM4A, a voltage < 19.6 V (Note: only one input is available in
CCS ).

2. The harness between A-UCM and the LC2 is damaged.
3. The connectors X-LC2 or X-UCM4A are damaged.
4. The harness between A-UCM and the connector X-LC2 is damaged.
5. The UCM VF2/3 ( F-2F2) is burnt.
6. The harness between the LC2 and the power supply is damaged.
Solution:
2. Visually check the integrity of the harness between the connectors X-UCM4A and X-LC2 for any damage.

Disconnect the connector X-UCM4A from the A-UCM and visually check the integrity of pins 1 and 8.

From To Value
Connector X-UCM4A pin 1 Ground ≥ + 19.6 V
48083741_EN 31/07/2018
55.8 [55.DTC] / 590
B. If the measurements are not correct, continue with Step 5.

Disconnect the connector X-LC2 from LC2 and visually check the integrity of pins 2A and 2B.

6. Check the integrity of harness between the connectors X-LC2 and X-UCM4A.
From To Value
Connector X-LC2 pin A Ground ≥ + 19.6 V
A. If the measurement is correct, replace the harness between the connectors X-LC2 and X-UCM4A.

7. Check the integrity of fuse UCM VF2/3 ( F-2F2) of LC2.
Remove the fuse from the LC2 and, by means of a multimeter, check the status of the fuse.
A. If the fuse is burnt (open circuit between the terminals), replace the fuse UCM VF2/3 .
B. If the fuse is integer (short circuit between the terminals), continue with Step 8.
8. Check the integrity of harness between LC2 and the power supply.
From To Value
Connector X-P1196 Ground ≥ + 19.6 V
A. If the measurement is correct, replace the harness between the LC2 and the JUNCTION BLOCK INTO CAB (
A-MAIN JB CAB).
B. If the measurement is not correct, check the circuits generating the + 24 V.

48083741_EN 31/07/2018
55.8 [55.DTC] / 591

Control Module: UCM
Context:
The A-UCM detects the absence of the 24VF3 power supply; as a consequence the FAN is disabled.
Cause:
The A-UCM detects, on pins 7 and 13 of connector X-UCM2A, a voltage < 19.6 V (Note: only one input is available
in CCS).

5. The UCM VF2/3 ( F-2F2) is burnt
7. Supply voltage to be checked.
Solution:


From To Value

48083741_EN 31/07/2018
55.8 [55.DTC] / 592

From To Value
Connector X-LC2 pin A Ground ≥ + 19.6 V

From To Value
A-MAIN JB CAB).

48083741_EN 31/07/2018
55.8 [55.DTC] / 593

Control Module: UCM
Context:
The A-UCM detects the absence of the 24VF4 power supply; as a consequence:
• Open AUX I LSD
• Open Boom LSD
• Command Bucket HSD PWMs to 0%
• Disabled advanced EH Bucket features ( RTD)
Cause:
The A-UCM detects, on pins 8 and 9 of connector X-UCM3B, a voltage < 19.6 V (Note: only one input is available in
CCS).

3. The connectors X-LC2 or X-UCM3B are damaged.
5. The UCM VF4/6 ( F-2F3) is burnt
Solution:
2. Visually check the integrity of the harness between the connectors X-UCM3B and X-LC2 for any damage.


From To Value
Connector X-UCM3B pin 1 Ground ≥ + 19.6 V
48083741_EN 31/07/2018
55.8 [55.DTC] / 594


6. Check the integrity of harness between the connectors X-LC2 and X-UCM3B.
From To Value
Connector X-LC2 pin 3A Ground ≥ + 19.6 V
A. If the measurement is correct, replace the harness between the connectors X-LC2 and X-UCM3B.

From To Value
A-MAIN JB CAB).

48083741_EN 31/07/2018
55.8 [55.DTC] / 595

Control Module: UCM
Context:
The A-UCM detects the absence of the 24VF6.
Cause:
The A-UCM detects, on pins 7 and 13 of connector X-UCM3A, a voltage < 19.6 V (Note: only one input is available
in CCS).

5. The UCM VF4/6 ( F-2F3) is burnt.
Solution:


From To Value

48083741_EN 31/07/2018
55.8 [55.DTC] / 596

From To Value

From To Value
A-MAIN JB CAB).

48083741_EN 31/07/2018
55.8 [55.DTC] / 597
518287-31 - Error at 24VS1 Supply Rail

Control Module: UCM
Context:
The A-UCM detects the absence of the 24VS1 power supply; as a consequence the following functions are disabled:
• Park Brake (engaged);
• Differential Lock (disengaged);
• Implement Coupler (engaged);
• Ride Control (disengaged);
• Pilot Lock (disengaged).
Cause:
The A-UCM detects, on pins 2 and 3 of connector X-UCM3B, a voltage < 19.6 V (Note: only one input is available in
CCS).

5. The UCM VS1/VLP ( F-2F4) is burnt.
Solution:


From To Value
48083741_EN 31/07/2018
55.8 [55.DTC] / 598


From To Value
A. If the measurement is correct, replace the harness between the connectors X-LC2 and X-UCM3B.

7. Check the integrity of fuse UCM VS1/VLP ( F-2F4) of LC2.
A. If the fuse is burnt (open circuit between the terminals), replace the fuse UCM VS1/VLP .
From To Value
A-MAIN JB CAB).

48083741_EN 31/07/2018
55.8 [55.DTC] / 599
518289-31 - Error at 24VA Supply Rail

Control Module: UCM
Context:
The A-UCM detects the absence of the 24VA power supply; as a consequence the UCM disable all functions.
Cause:
The A-UCM detects, on pin 14 of connector X-UCM1A, a voltage < 10 V.

5. The fuse UCM ( F-5F2) is burnt.
Solution:

B. B. If the pin is not damaged, continue with Step 4.

From To Value
Connector X-UCM1A pin 14 Ground + 10 V
A. If the voltage is correct, replace the A-UCM.
B. If the voltage is not correct, continue with Step 5.


48083741_EN 31/07/2018
55.8 [55.DTC] / 600
From To Value
Connector X-LC5 pin 2A Connector X-UCM1A pin 26 Short circuit
A. If the measurement is not correct, replace the harness between the connectors X-LC5 and X-UCM1A.

7. Check the integrity of fuse UCM ( F-5F2) of LC5.
A. If the fuse is burnt (open circuit between the terminals), replace the fuse UCM.
B. If the fuse is integer (short circuit between the terminals), continue the troubleshooting by performing the pro-
cedure 520567-05.

48083741_EN 31/07/2018
55.8 [55.DTC] / 601
518290-31 - Error at 24VB Supply Rail

Control Module: UCM
Context:
The A-UCM detects the absence of the 24VB power supply; as a consequence the UCM disable all functions.
Cause:
The A-UCM detects, on pin 26 of connector X-UCM1A, a voltage < 10 V ( UCM shutdown at 8 V).

5. The fuse UCM ( F-5F2) is burnt.
Solution:


From To Value
Connector X-UCM1A pin 26 Ground > + 10 V
A. If the voltage is correct, replace the A-UCM.
B. If the voltage is not correct, continue with Step 5.


48083741_EN 31/07/2018
55.8 [55.DTC] / 602
From To Value

7. Check the integrity of fuse UCM ( F-5F2) of LC5.
A. If the fuse is burnt (open circuit between the terminals), replace the fuse UCM.
B. If the fuse is integer (short circuit between the terminals), continue the troubleshooting by performing the pro-
cedure 520567-05.

48083741_EN 31/07/2018
55.8 [55.DTC] / 603
518291-31 - Error at 24VLP Supply Rail

Control Module: UCM
Context:
The A-UCM detects the absence of the 24VLP power supply; as a consequence the following functions are disabled:
• Warning LED disabled;
• Aux Steering Disabled;
• FAN Commanded in Open Loop.
Cause:
The A-UCM detects, on pin 2 of connector X-UCM4B, a voltage < 10 V.

5. The UCM VS1/VLP ( F-2F4) is burnt.
Solution:


From To Value
Connector X-UCM4B pin 2 Ground ≥ + 10 V

48083741_EN 31/07/2018
55.8 [55.DTC] / 604

From To Value
Connector X-LC2 pin 4A Connector X-UCM4B pin 2 Short circuit
A. If the measurement is not correct, replace the harness between the connectors X-LC2 and X-UCM4B.

7. Check the integrity of fuse UCM VS1/VLP ( F-2F4) of LC2.
A. If the fuse is burnt (open circuit between the terminals), replace the fuse UCM VS1/VLP.
From To Value
Connector X-P1196 Ground ≥ + 10 V
A-MAIN JB CAB).

48083741_EN 31/07/2018
55.8 [55.DTC] / 605
518292-31 - Error at 24VP Supply Rail

Control Module: UCM
Context:
The A-UCM detects the absence of the 24VP power supply; as a consequence the UCM functions are all disabled.
Cause:
The A-UCM detects, on pin 20 of connector X-UCM1A, a voltage < + 10 V.

5. The UCM VP ( F-2F1) is burnt.
Solution:


From To Value
Connector X-UCM1A pin 2 Ground ≥ + 10 V


48083741_EN 31/07/2018
55.8 [55.DTC] / 606
From To Value

7. Check the integrity of fuse UCM VP ( F-2F1) of LC2.
A. If the fuse is burnt (open circuit between the terminals), replace the fuse UCM VP.
From To Value
Connector X-P1196 Ground ≥ + 10 V
A-MAIN JB CAB).

48083741_EN 31/07/2018
55.8 [55.DTC] / 607
518293-31 - Error at 2.5V Ref1 Supply

Control Module: UCM
Context:
The A-UCM detects an error on the 2.5 V Ref1; as a consequence:

• Loss of FIN_1, FIN_2, FIN_3, FIN_4;
Cause:
IcVREF_2V5REF1_mV <= 2350 mV or IcVREF_2V5REF1_mV >= 2650 mV

Solution:
A. If the fault is present and active, replace, and send to manufacturer per repairing if possible, the UCM.
48083741_EN 31/07/2018
55.8 [55.DTC] / 608
518294-31 - Error at 2.5V Ref2 Supply

Control Module: UCM
Context:
The A-UCM detects an error on the 2.5 V Ref2; as a consequence:

• Loss of FIN_1, FIN_2, FIN_3, FIN_4;
Cause:
IcVREF_2V5REF2_mV <= 2350 mV or IcVREF_2V5REF2_mV >= 2650 mV

Solution:
48083741_EN 31/07/2018
55.8 [55.DTC] / 609
518296-31 - Error at 5VREFIN

Control Module: UCM
Context:
The A-UCM detects an error on the 5VREFIN; as a consequence:

• Loss of RIN_01, RIN_02, RIN_03, RIN_04)
- Set fan speed to max
- FAX Temperature not available
• FAX warning disabled
• Set PV_VC_STS.FAxOilTempWarn = 0x3 (out of range)
- Fuel Level Not Available
- Hydraulic Oil Temperature not available
Cause:
IcVREF_5VREFIN_mV <= 4800 mV or IcVREF_5VREFIN_mV <= 5200 mV

Solution:
48083741_EN 31/07/2018
55.8 [55.DTC] / 610
518390-00 - Hydraulic Oil Temp Sensor Over Resistance

Control Module: UCM
Context:
The A-UCM detects a value of resistance of the HYD OIL TEMP ( B-HOT) higher than the upper limit; as a
consequence:
• the Hydraulic Oil Temperature is not available;
• the Hydraulic Oil Temperature is set to - 50 °C.
Cause:
The A-UCM detects on pin 18 of connector X-UCM4A a resistance value > 2000 Ω (About 250 °C).

2. The harness between A-UCM and the HYD OIL TEMP is damaged.
3. The connectors X-TRANS or X-HOT or X-CAB_TR or X-UCM4A are damaged.
4. The harness between connectors X-HOT and ground is damaged.
5. The harness between connectors X-TRANS and the HYD OIL TEMP is damaged.
6. The harness between connectors X-UCM4A and X-CAB_TR is damaged.
Solution:
2. Visually check the integrity of the harness between the connectors X-UCM4A and connector X-HOT for any dam-
age.

3. Check the integrity of connector X-HOT.
Disconnect the connector X-HOT from the HYD OIL TEMP and visually check the integrity of pins 1 and 2 of the
connector.

4. Check the integrity of harness between the connector X-HOT and ground.
Disconnect the connector X-HOT from the HYD OIL TEMP.
From To Value
Connector X-HOT pin 2 Ground Short circuit
48083741_EN 31/07/2018
55.8 [55.DTC] / 611

5. Check the integrity of connectors X-TRANS and X-CAB_TR.
Disconnect the connector X-TRANS from the connector X-CAB_TR and visually check the integrity of pins 30 and
3 of both connectors.

6. Check the integrity of harness between the connector X-TRANS and the HYD OIL TEMP.
From To Value
Connector X-TRANS pin 30 Connector X-HOT pin 1 Short circuit


8. Check the integrity of harness between the connectors X-UCM4A and X-CAB_TR.
From To Value

9. Replace the HYD OIL TEMP.
48083741_EN 31/07/2018
55.8 [55.DTC] / 612
518390-01 - Hydraulic Oil Temp Sensor Under Resistance

Control Module: UCM
Context:
The A-UCM detects a value of resistance of the HYD OIL TEMP ( B-HOT) lower than the low limit; as a consequence:
• the Hydraulic Oil Temperature is not available;
• the Hydraulic Oil Temperature is set to - 50 °C.
Cause:
The A-UCM detects on pin 18 of connector X-UCM4A a resistance value > 500 Ω (About - 100 °C).

2. The harness between A-UCM and the HYD OIL TEMP is damaged.
3. The HYD OIL TEMP is damaged.
4. The connectors X-TRANS or X-HOT or X-CAB_TR or X-UCM4A are damaged
5. The harness of HYD OIL TEMP is damaged.
6. The harness between connectors X-TRANS and X-HOT is damaged.
7. The harness between connectors X-CAB_TR and X-UCM4A is damaged.
Solution:
2. Visually check the integrity of the harness between the connectors X-UCM4A and connector X-HOT for any dam-
age.

3. Replace the HYD OIL TEMP.

4. Check the integrity of connector X-HOT.
Disconnect the connector X-HOT from the HYD OIL TEMP and visually check the integrity of pins 1 and 2.

5. Check the integrity of harness of the HYD OIL TEMP.
48083741_EN 31/07/2018
55.8 [55.DTC] / 613
From To Value
Connector X-HOT pin 2 Connector X-HOT pin 1 Open circuit

6. Check the integrity of connectors X-TRANS and X-CAB_TR.
Disconnect the connector X-TRANS from the connector X-CAB_TR and visually check the integrity of pins 30 and
3 of both connectors.

7. Check the integrity of harness between the connector X-TRANS and the HYD OIL TEMP.
Connect the connector X-HOT to the HYD OIL TEMP.
From To Value
Connector X-TRANS pin 30 Connector X-TRANS pin 3 > 500 Ω


9. Check the integrity of harness between the connectors X-UCM4A and X-CAB_TR.
From To Value
Connector X-CAB_TR pin 3 Connector X-CAB_TR pin 30 Open circuit
48083741_EN 31/07/2018
55.8 [55.DTC] / 614
518498-00 - Engine oil temperature is very high

Context:
Engine oil temperature is very high.
Cause:

2. The UCM reports that engine oil temperature is over.
Solution:
2. Bring the machine to a safe stop, and turn the engine OFF immediately. Replace the engine oil temperature
sensor.
48083741_EN 31/07/2018
55.8 [55.DTC] / 615
518499-18 - Engine Oil pressure Low

Context:
Engine Oil pressure Low.
Cause:

2. The UCM reports that engine oil pressure is over.
Solution:
2. Bring the machine to a safe stop, and turn the engine OFF immediately. Replace the engine oil pressure sensor.
48083741_EN 31/07/2018
55.8 [55.DTC] / 616
518501-09 - Air Filter Clogged

Context:
Air Filter Clogged.
Cause:
Air Filter switch shall be considered clogged when AN_17 Voltage > 15 V and not clogged when Voltage < 10 V.

2. The air filter is clogged.
Solution:
2. Verify that the air filter is clean.
A. If the air filter is clean, replace the air filter sensor..
B. If the air filter is clogged, continue with Step 3.

3. Clean the air filter.
A. If the fault disappier after the cleaning, continue to work monitoring the fault.
B. If the fault is still present after the cleaning, bring the machine to a safe stop, and turn the engine OFF imme-
diately. Replace the air filter.
48083741_EN 31/07/2018
55.8 [55.DTC] / 617
520332-19 - TCU Source Address Cyclic Timeout

Control Module: UCM
Context:
The A-UCM does not receive messages from the TCU Source Address within the maximum interval time; as a
consequence:
• Use last TCU CAN message received;
• (sump temp blank when timeout);
• ( EPAS use TRF1.TransmOilTemp);
• Disable Differential Lock Function;
• Disable Torque Converter Lock Up Function;
• Disable CCO and ICCO.
Cause:

Solution:



48083741_EN 31/07/2018
55.8 [55.DTC] / 618

48083741_EN 31/07/2018
55.8 [55.DTC] / 619
520333-19 - Keypad Source Address Cyclic Timeout

Control Module: UCM
Context:
The A-UCM does not receive messages from the Keypad Source Address within the maximum interval time; as a
consequence use last keypad CAN message received.
Cause:

2. The harness of busses CAN 1 or CAN 2 is visually damaged.
Solution:




48083741_EN 31/07/2018
55.8 [55.DTC] / 620
520334-19 - Smart Fuse Box Source Address Cyclic Timeout

Control Module: UCM
Context:
The A-UCM does not receive messages from the Smart Fuse Box Source Address within the maximum interval time;
as a consequence last SFB CAN message received.
Cause:

Solution:




48083741_EN 31/07/2018
55.8 [55.DTC] / 621
520335-19 - Joystick Steering Controller Source Address Cyclic

Timeout
Control Module: UCM
Context:
The A-UCM does not receive messages from Joystick Steering Controller Source Address within the maximum
interval time; as a consequence the JSS function is disabled:
• Set Joystick Position to Neutral;
• Command PVED to cut Supply Pressure.
Cause:

Solution:




48083741_EN 31/07/2018
55.8 [55.DTC] / 622
520444-02 - Memory Integrity RAM

Context:
Memory Integrity RAM.
Cause:

Solution:

3. Verify the wirings to external connection, if one or more wirings are damaged, proceed with the replacement.
48083741_EN 31/07/2018
55.8 [55.DTC] / 623
520444-31 - Memory Integrity ROM

Context:
Memory Integrity ROM.
Cause:

Solution:

3. Verify the wirings to external connection, if one or more wirings are damaged, proceed with the replacement.
48083741_EN 31/07/2018
55.8 [55.DTC] / 624
520519-19 - Bus Off

Context:
The Keypad unit is capable of connecting to and communicating on separate Controller Area Networks ( CAN).
Cause:
Keypad unit has sensed a “Bus Off” state to be present.
1. Faulty supply voltage or ground, missing.

2. Faulty CAN circuit wiring, open circuit, short to ground, or short circuit.
3. Faulty Keypad termination resistor or software.
Solution:
B. If the fault is no longer present or is in an inactive state, the fault may be intermittent and not currently active.
Continue with Step 6.
Use the EST to determine if vehicle CAN faults exist.
A. If other vehicle CAN faults do exist, resolve the vehicle CAN faults, then check to see that this fault is also
resolved.
B. If other vehicle CAN faults do not exist, continue with Step 3.

3. Check the Keypad unit supply voltage.
Disconnect the vehicle ( VE) harness from the Keypad unit at connector. With the key switch in the “ON” position,
use a multimeter to check for voltage on the vehicle ( VE) harness side:
From To Value
Power Supply pins Chassis ground There should be 12.0 V
A. If the voltage is present on all of the checks, leave connector disconnected and continue with Step 4.
B. If the voltage is not present for one or more of the checks, refer to the appropriate vehicle service manual and
electrical schematics to locate and restore supply power to the Keypad unit.
4. Check the Keypad unit grounding.
With the key switch in the “OFF” position, use a multimeter to check for continuity on the vehicle ( VE) harness
side:
From To Value
GND pins Chassis ground There should be continuity
A. If there is continuity on all of the checks, leave connector disconnected and continue with Step 5.
B. If there is no continuity for one or more of the checks, refer to the electrical schematics to locate and restore
the grounding circuit to the Keypad unit.
5. Determine the condition of the Keypad unit CAN circuit.
48083741_EN 31/07/2018
55.8 [55.DTC] / 625
With the key switch in the “OFF” position, use a multimeter to measure the resistance of the CAN connection on
the vehicle (VE) harness side:
From To Value
Connector X-ECU pin 46 Connector X-ECU pin 47 There should be 120 Ω
Connector X-ECU pin 46 Chassis ground There should not be continuity
Connector X-ECU pin 47 Chassis ground There should not be continuity
Use a multimeter to measure the resistance of the CAN termination resistor, internal to the Keypad unit:
From To Value
Connector X-ECU pin 46 Connector X-ECU pin 47 There should be 120 Ω
A. If the measured resistances are correct and neither conductor is grounded, check the Keypad unit for the
appropriate software and re-flash, if necessary.
B. If the measured resistances are not correct or one or both of the conductors is grounded, refer to the appropriate
vehicle service manual and electrical schematics to locate and restore the termination resistance to the CAN
circuit.
6. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals,
or broken wires.
Verify that the connectors are fully installed.
Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned.
Operate the machine while you monitor the display.
has been resolved.
B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue
operation.
48083741_EN 31/07/2018
55.8 [55.DTC] / 626
520572-03 - 24v to 12v Converter Enable - Short Circuit to B+

Control Module: SFB
Context:
24 V to 12 V Converter Enable (Short Circuit to B+).
Cause:
The Smart Fuse box detects a Short Circuit to B+ from the DC converter Relay signal ( X-X3 pin 15) when the key is
OFF.

2. The harness between Smart Fuse Box and DC converter Relay is damaged.
3. The X-LC3 connector (pin RI_86) is damaged.
5. The harness between DC converter Relay and Smart Fuse Box is defective.
6. The DC converter Relay is defective.
Solution:
2. Check the integrity of the harness between Smart Fuse Box and DC converter Relay.

3. Check the integrity of the DC converter Relay connector.
Disconnect DC converter Relay connector ( X-LC3 pin R1-86) and visually check the integrity of the pin.


5. Check the DC converter Relay signal circuit.
48083741_EN 31/07/2018
55.8 [55.DTC] / 627
From To Value
Connector K-3R1 pin 86 Chassis ground There should be an open circuit
A. If there is a voltage, replace the 24 V to 12 V Converter.

From To Value
A. If there is an open circuit, replace the Smart Fuse Box.

48083741_EN 31/07/2018
55.8 [55.DTC] / 628
520572-05 - 24v to 12v Converter Enable - Open Circuit

Control Module: SFB
Context:
24 V to 12 V Converter Enable (Open Circuit)
Cause:
The Smart Fuse box detects an Open Circuit from the DC converter Relay signal ( X-X3 pin 15) when the key is OFF.

Solution:



48083741_EN 31/07/2018
55.8 [55.DTC] / 629
From To Value
Connector K-3R1 pin 86 Chassis ground There should be a resistance
A. If there is an open circuit, replace the 24 V to 12 V Converter.
B. If there is a resistance value, continue to Step 6.

From To Value
Connector A-SFB pin OUT_06_H Chassis ground There should be a resistance
A. If there is an open circuit, replace the Smart Fuse Box.

48083741_EN 31/07/2018
55.8 [55.DTC] / 630
520572-06 - 24v to 12v Converter Enable - Short Circuit to GND

Control Module: SFB
Context:
24 V to 12 V Converter Enable (Short Circuit to GND).
Cause:
The Smart Fuse box detects a Short Circuit to GND from the DC converter Relay signal ( X-X3 pin 15) when the key
is ON.

Solution:



48083741_EN 31/07/2018
55.8 [55.DTC] / 631
From To Value
Connector K-3R1 pin 86 Chassis ground There should be an open circuit
A. If there is an short circuit, replace the 24 V to 12 V Converter.

From To Value

48083741_EN 31/07/2018
55.8 [55.DTC] / 632
520578-03 - Battery Isolator SET - Short Circuit to B+

Control Module: SFB
Context:
Battery voltage on K Isolator set (short circuit to B+).
Cause:
The Smart Fuse box detects a battery voltage on K isolator signal ( X-X4 pin 17) when the key is ON.

2. The harness between Smart Fuse Box and Battery Isolator is damaged.
3. The Battery Isolator connector is damaged.
4. The X-ENG-2 connector is damaged.
5. The X-CAB_E-2 connector is damaged.
6. The Smart Fuse Box connector is damaged. x
7. The Battery isolator is defective.
8. The harness between Battery Isolator and X-ENG-2 connector is defective.
9. The harness between Smart Fuse Box and X-CAB_E-2 connector is defective.
Solution:
2. Check the integrity of the harness between Smart Fuse Box and Battery Isolator.

3. Check the integrity of the Battery Isolator connector.
Disconnect Battery Isolator connector X-ISO and visually check the integrity of the pin 2.
A. If the pin 1 is damaged, replace the X-ISO connector.

4. Check the integrity of the X-ENG-2 connector.
Disconnect X-ENG-2 connector and visually check the integrity of the pin F.
A. If the pin F is damaged, replace the X-ENG-2 connector.
B. If the pin F is not damaged, continue with Step 5.
48083741_EN 31/07/2018
55.8 [55.DTC] / 633
5. Check the integrity of the X-CAB_E-2 connector.
Disconnect X-CAB_E-2 connector and visually check the integrity of the pin F.
A. If the pin F is damaged, replace the X-CAB_E-2 connector.


7. Check the Battery Isolator signal circuit for a short key battery power condition.
From To Value
Connector X-ISO pin 2 Chassis ground There should be an open circuit
A. If there is a short circuit to B+, replace the Battery Isolator relay.

8. Check the signal circuit for a short key battery power condition on the harness between Battery Isolator and
X-ENG-2 connector.
From To Value
Connector X-ENG-2 pin F Chassis ground There should be an open circuit
A. If there is a Short Circuit, replace the harness.

9. Check the signal circuit for a short key battery power condition on the harness between Smart Fuse Box and
X-CAB_E-2 connector.
From To Value
Connector X-X4 pin 17 Chassis ground There should be an open circuit

10. Check the Smart Fuse Box signal circuit for a short key battery power condition.
48083741_EN 31/07/2018
55.8 [55.DTC] / 634
From To Value
A. If there is a Short Circuit to B+, replace the Smart Fuse Box.
48083741_EN 31/07/2018
55.8 [55.DTC] / 635
520578-03 - Battery Isolator RESET - Short Circuit to B+

Control Module: SFB
Context:
Battery voltage on K Isolator reset (short circuit to B+).
Cause:
The Smart Fuse box detects a battery voltage on K isolator signal ( X-X7 pin 8) when the key is OFF.

Solution:


Disconnect X-ENG-2 connector and visually check the integrity of the pin G.
A. If the pin G is damaged, replace the X-ENG-2 connector.
B. If the pin G is not damaged, continue with Step 5.
48083741_EN 31/07/2018
55.8 [55.DTC] / 636
Disconnect X-CAB_E-2 connector and visually check the integrity of the pin G.
A. If the pin G is damaged, replace the X-CAB_E-2 connector.


From To Value
A. If there is a voltage, replace the Battery Isolator relay.

X-ENG-2 connector.
From To Value
Connector X-ENG-2 pin G Chassis ground There should be an open circuit

From To Value

48083741_EN 31/07/2018
55.8 [55.DTC] / 637
From To Value
Connector A-SFB pin OUT_09_H Chassis ground There should be Short Circuit
A. If there is a Short Circuit, replace the Smart Fuse Box.
48083741_EN 31/07/2018
55.8 [55.DTC] / 638
520578-06 - Battery Isolator SET - Short Circuit to GND

Control Module: SFB
Context:
Battery voltage on K Isolator set (short circuit to GND).
Cause:
The Smart Fuse box detects a short circuit to GND on K isolator signal ( X-X4 pin 17) when the key is ON.

Solution:


Disconnect X-ENG-2 connector and visually check the integrity of the pin F.
A. If the pin F is damaged, replace the X-ENG-2 connector.
48083741_EN 31/07/2018
55.8 [55.DTC] / 639
Disconnect X-CAB_E-2 connector and visually check the integrity of the pin F.
A. If the pin F is damaged, replace the X-CAB_E-2 connector.


From To Value
A. If there is a short circuit to GND, replace the Battery Isolator relay.

X-ENG-2 connector.
From To Value
Connector X-ENG-2 pin F Chassis ground There should be an open circuit
A. If there is a Short Circuit to GND, replace the harness.

From To Value
A. If there is a Short Circuit to GND, replace the harness.

48083741_EN 31/07/2018
55.8 [55.DTC] / 640
From To Value
A. If there is a Short Circuit to GND, replace the Smart Fuse Box.
48083741_EN 31/07/2018
55.8 [55.DTC] / 641
520578-06 - Battery Isolator RESET - Short Circuit to GND

Control Module: SFB
Context:
Battery voltage on K Isolator reset (short circuit to GND).
Cause:
The Smart Fuse box detects a short circuit to GND on K isolator signal ( X-X7 pin 8) when the key is ON.

Solution:


Disconnect X-ENG-2 connector and visually check the integrity of the pin G.
A. If the pin G is damaged, replace the X-ENG-2 connector.
48083741_EN 31/07/2018
55.8 [55.DTC] / 642
Disconnect X-CAB_E-2 connector and visually check the integrity of the pin G.
A. If the pin G is damaged, replace the X-CAB_E-2 connector.


From To Value
Connector X-ISO pin 1 Chassis ground There should be open circuit
A. If there is a short circuit, replace the Battery Isolator relay.

X-ENG-2 connector.
From To Value
Connector X-ENG-2 pin G Chassis ground There should be open circuit

From To Value
Connector X-X7 pin 8 Chassis ground There should be open circuit

48083741_EN 31/07/2018
55.8 [55.DTC] / 643
From To Value
Connector A-SFB pin OUT_09_H Chassis ground There should be open circuit
48083741_EN 31/07/2018
55.8 [55.DTC] / 644
520584-00 - Left Brake Indicator Light - Too many loads or faulty

load
Control Module: SFB
Context:
Too many loads or faulty load on Left Brake Indicator Light.
Cause:
The Smart Fuse box measure Too many loads or faulty load on Left Brake Indicator Light ( X6-2) with a current value
> 2.365 A when the key is ON.

3. The Left Brake Indicator Light connector is damaged.
5. The Left Brake Indicator Light is defective.
Solution:
2. Check the integrity of the harness between Smart Fuse Box and L-NA-TAIL ( X-LH-TAIL pin 2).

3. Check the integrity of the L-NA-TAIL connector ( X-LH-TAIL pin 2).


5. Check the signal circuit for an short circuit to GND condition on the harness between L-NA-TAIL pin ( X-LH-TAIL
pin 2) and Smart Fuse Box.
48083741_EN 31/07/2018
55.8 [55.DTC] / 645
From To Value
Connector X-CAB_E pin 10 GND There should be an open circuit
Connector X-ENG pin 10 GND There should be an open circuit
Connector X-ENG_H pin 2 GND There should be an open circuit
A. If there is an short circuit to GND, replace the harness.

6. Check the Electrical Ignition Power Relay pin ( L-NA-TAIL pin 2) circuit for an short circuit to GND.
From To Value
Connector L-NA-TAIL pin 2 GND There should be an open circuit
A. If there is an short circuit to GND, replace the Electrical Ignition Power Relay.

7. Check the Smart Fuse Box signal circuit for an short circuit to GND.
From To Value
Connector A-SFB pin GND There should be an open circuit to
OUT_19_H_CS GND
48083741_EN 31/07/2018
55.8 [55.DTC] / 646
520584-03 - Left Brake Indicator Light - Short circuit to B+

Control Module: SFB
Context:
Short circuit to B+ on Left Brake Indicator Light.
Cause:
The Smart Fuse box measure an short circuit to B+ on Left Brake Indicator Light ( X6-2) when the key is ON.

Solution:



5. Check the signal circuit for an short circuit to B+ condition on the harness between L-NA-TAIL pin ( X-LH-TAIL pin
48083741_EN 31/07/2018
55.8 [55.DTC] / 647
From To Value
Connector X-CAB_E pin 10 + 5V There should be an open circuit
Connector X-ENG pin 10 + 5V There should be an open circuit
Connector X-ENG_H pin 2 + 5V There should be an open circuit
A. If there is an short circuit to B+, replace the harness.

6. Check the Electrical Ignition Power Relay pin ( L-NA-TAIL pin 2) circuit for an short circuit to B+.
From To Value
Connector L-NA-TAIL pin 2 + 5V There should be an open circuit
A. If there is an short circuit to B+, replace the Electrical Ignition Power Relay.

7. Check the Smart Fuse Box signal circuit for an short circuit to B+.
From To Value
Connector A-SFB pin + 5V There should be an open circuit to B+
OUT_19_H_CS
48083741_EN 31/07/2018
55.8 [55.DTC] / 648
520584-05 - Left Brake Indicator Light - Open Circuit

Control Module: SFB
Context:
Short circuit to B+ on Left Brake Indicator Light.
Cause:
The Smart Fuse box measure an open circuit on Left Brake Indicator Light ( X6-2) when the key is OFF or a Current
value < 35 mA when ON.

Solution:



5. Check the signal circuit for an open circuit condition on the harness between L-NA-TAIL pin ( X-LH-TAIL pin 2)
and Smart Fuse Box.
48083741_EN 31/07/2018
55.8 [55.DTC] / 649
From To Value
Connector X-X6 pin 2 Connector X-CAB_E pin 10 There should be a short circuit
Connector X-CAB_E pin 10 Connector X-ENG pin 10 There should be a short circuit
Connector X-ENG pin 10 Connector X-ENG_H pin 2 There should be a short circuit
Connector X-ENG_H pin 2 Connector X-LH-TAIL pin 2 There should be a short circuit
B. If there is a short circuit, continue to Step 6.

6. Check the Electrical Ignition Power Relay pin ( L-NA-TAIL pin 2) circuit for an open circuit.
From To Value
Connector L-NA-TAIL pin 2 Connector X-LH-TAIL pin 1 There should be a short circuit
A. If there is an open circuit, replace the L-NA-TAIL.
48083741_EN 31/07/2018
55.8 [55.DTC] / 650
520584-06 - Left Brake Indicator Light - Short circuit to GND

Control Module: SFB
Context:
Short circuit to GND on Left Brake Indicator Light.
Cause:
The Smart Fuse box measure an short circuit to GND on Left Brake Indicator Light ( X6-2) when the key is ON.

Solution:



5. Check the signal circuit for an over current condition on the harness between L-NA-TAIL pin ( X-LH-TAIL pin 2)
and Smart Fuse Box.
48083741_EN 31/07/2018
55.8 [55.DTC] / 651
From To Value

6. 6. Check the Electrical Ignition Power Relay pin ( L-NA-TAIL pin 2) circuit for over current.
From To Value

7. Check the Smart Fuse Box signal circuit for an over current.
From To Value
OUT_19_H_CS GND
48083741_EN 31/07/2018
55.8 [55.DTC] / 652
520585-00 - Right Brake Indicator Light - Too many loads or faulty

load
Control Module: SFB
Context:
Too many loads or faulty load on Right Brake Indicator Light.
Cause:
The Smart Fuse box measure Too many loads or faulty load on Right Brake Indicator Light ( X-X3 pin 12) with a
current value > 2.365 A when the key is ON.

3. The Right Brake Indicator Light connector is damaged.
5. The Right Brake Indicator Light is defective.
Solution:
2. Check the integrity of the harness between Smart Fuse Box and LMP-R-NA-TAIL ( X-RH-TAIL pin 2).

3. Check the integrity of the LMP-R-NA-TAIL connector ( X-RH-TAIL pin 2).


5. Check the signal circuit for an short circuit to GND condition on the harness between LMP-R-NA-TAIL pin ( X-RH-
TAIL pin 2) and Smart Fuse Box.
48083741_EN 31/07/2018
55.8 [55.DTC] / 653
From To Value

6. Check the Electrical Ignition Power Relay pin ( LMP-R-NA-TAIL pin 2) circuit for an short circuit to GND.
From To Value

7. Check the Smart Fuse Box signal circuit for an short circuit to GND.
From To Value
OUT_20_H_CS GND
48083741_EN 31/07/2018
55.8 [55.DTC] / 654
520585-03 - Right Brake Indicator Light - Short circuit to B+

Control Module: SFB
Context:
Short circuit to B+ on Right Brake Indicator Light.
Cause:
The Smart Fuse box measure an short circuit to B+ on Right Brake Indicator Light ( X6-2) when the key is ON.

Solution:



5. Check the signal circuit for an short circuit to B+ condition on the harness between LMP-R-NA-TAIL pin ( X-RH-
TAIL pin 2) and Smart Fuse Box.
48083741_EN 31/07/2018
55.8 [55.DTC] / 655
From To Value
Connector X-CAB_E pin 21 + 5V There should be an open circuit
Connector X-ENG pin 7 + 5V There should be an open circuit
Connector X-ENG_H pin 7 + 5V There should be an open circuit
A. If there is an short circuit to B+, replace the harness.

6. Check the Electrical Ignition Power Relay pin ( L-NA-TAIL pin 2) circuit for an short circuit to B+.
From To Value
Connector LMP-R-NA-TAIL pin 2 + 5V There should be an open circuit
A. If there is an short circuit to B+, replace the Electrical Ignition Power Relay.

7. Check the Smart Fuse Box signal circuit for an short circuit to B+.
From To Value
Connector A-SFB pin + 5V There should be an open circuit to B+
OUT_20_H_CS
48083741_EN 31/07/2018
55.8 [55.DTC] / 656
520585-05 - Right Brake Indicator Light - Open Circuit

Control Module: SFB
Context:
Short circuit to B+ on Right Brake Indicator Light.
Cause:
The Smart Fuse box measure an open circuit on Right Brake Indicator Light ( X-X3 pin 12) when the key is OFF or a
Current value < 35 mA when ON.

Solution:



5. Check the signal circuit for an open circuit condition on the harness between LMP-R-NA-TAIL pin ( X-RH-TAIL pin
48083741_EN 31/07/2018
55.8 [55.DTC] / 657
From To Value
Connector X-X3 pin 12 Connector X-CAB_E pin 21 There should be a short circuit
Connector X-CAB_E pin 21 Connector X-ENG pin 21 There should be a short circuit
Connector X-ENG pin 21 Connector X-ENG_H pin 7 There should be a short circuit
Connector X-ENG_H pin 7 Connector X-RH-TAIL pin 2 There should be a short circuit
B. If there is a short circuit, continue to Step 6.

6. Check the Electrical Ignition Power Relay pin ( LMP-R-NA-TAIL pin 2) circuit for an open circuit.
From To Value
Connector LMP-R-NA-TAIL pin 2 LMP-R-NA-TAIL pin 1 There should be a short circuit
A. If there is an open circuit, replace the L-NA-TAIL.
48083741_EN 31/07/2018
55.8 [55.DTC] / 658
520585-06 - Right Brake Indicator Light - Short circuit to GND

Control Module: SFB
Context:
Short circuit to GND on Right Brake Indicator Light.
Cause:
The Smart Fuse box measure an short circuit to GND on Right Brake Indicator Light ( X-X3-pin 12) when the key is
ON.

Solution:



5. Check the signal circuit for an over current condition on the harness between LMP-R-NA-TAIL pin ( X-RH-TAIL
pin 2) and Smart Fuse Box.
48083741_EN 31/07/2018
55.8 [55.DTC] / 659
From To Value

6. Check the Electrical Ignition Power Relay pin ( LMP-R-NA-TAIL pin 2) circuit for over current.
From To Value
Connector LMP-R-NA-TAIL pin 2 GND There should be an open circuit

7. Check the Smart Fuse Box signal circuit for an over current.
From To Value
OUT_20_H_CS GND
48083741_EN 31/07/2018
55.8 [55.DTC] / 660
520588-03 - Alternator Excitation Driver - Short Circuit to B+

Control Module: SFB
Context:
Alternator Excitation Driver (Short Circuit to B+).
Cause:
The Smart Fuse box detects a Short Circuit to B+ from the Alternator Excitation Driver signal ( X-X5 pin 4) when the
key is OFF.

2. The harness between Smart Fuse Box and Alternator is damaged.
3. The X-ALT connector (pin 3) is damaged.
5. The harness between Alternator and Smart Fuse Box is defective.
6. The Alternator is defective.
Solution:
2. Check the integrity of the harness between Smart Fuse Box and Alternator.

3. Check the integrity of the Alternator connector.
Disconnect Alternator connector ( X-ALT pin 3) and visually check the integrity of the pin.


5. Check the Alternator signal circuit.
48083741_EN 31/07/2018
55.8 [55.DTC] / 661
From To Value
Connector G-G1 pin 15 Chassis ground There should be an open circuit
A. If there is a short circuit to B+, replace Alternator.

From To Value
A. If there is a short circuit to B+, replace the Smart Fuse Box.
48083741_EN 31/07/2018
55.8 [55.DTC] / 662
520588-06 - Alternator Excitation Driver - Short Circuit to GND

Control Module: SFB
Context:
Alternator Excitation Driver (Short Circuit to GND).
Cause:
The Smart Fuse box detects a Short Circuit to GND from the Alternator Excitation Driver signal ( X-X5 pin 4) when
the key is ON.

2. The harness between Smart Fuse Box and Alternator is damaged.
3. The X-ALT connector (pin 3) is damaged.
5. The harness between Alternator and Smart Fuse Box is defective.
6. The Alternator is defective.
Solution:
2. Check the integrity of the harness between Smart Fuse Box and Alternator.

3. Check the integrity of the Alternator connector.
Disconnect Alternator connector ( X-ALT pin 3) and visually check the integrity of the pin.


5. Check the Alternator signal circuit.
48083741_EN 31/07/2018
55.8 [55.DTC] / 663
From To Value
Connector G-G1 pin 15 Chassis ground There should be an open circuit
A. If there is a short circuit to GND, replace Alternator.

From To Value
A. If there is a short circuit to ground, replace the Smart Fuse Box.
48083741_EN 31/07/2018
55.8 [55.DTC] / 664
520591-00 - Backup Alarm - Too many loads or faulty load

Control Module: SFB
Context:
Over load of the Backup Alarm Signal (Too many loads or faulty load).
Cause:
The Smart Fuse box measure a current > 5.5 A on Backup Alarm signal ( X4 pin 21) when the SCG is ON.

2. The harness between Smart Fuse Box and Backup Alarm is damaged.
3. The Backup Alarm connector is damaged.
4. The X-ENG connector is damaged.
5. The X-CAB_E connector is damaged.
7. The Backup Alarm is defective.
8. The harness between Backup Alarm and X-ENG connector is defective.
9. The harness between Smart Fuse Box and X-CAB_E connector is defective.
Solution:
2. Check the integrity of the harness between Smart Fuse Box and Backup Alarm.

3. Check the integrity of the Backup Alarm connector.
Disconnect Backup Alarm connector X-BU2 and visually check the integrity of the pin P.
A. If the pin P is damaged, replace the X-BU2 connector.
B. If the pin P is not damaged, continue with Step 4.

4. Disconnect Backup Alarm connector X-BU1 and visually check the integrity of the pin N.
A. If the pin N is damaged, replace the X-BU1 connector.
B. If the pin N is not damaged, continue with Step 5.

48083741_EN 31/07/2018
55.8 [55.DTC] / 665
Disconnect X-ENG connector and visually check the integrity of the pin 7.
A. If the pin 7 is damaged, replace the X-ENG connector.

6. Check the integrity of the X-CAB_E connector.
Disconnect X-CAB_E connector and visually check the integrity of the pin 7.
A. If the pin 7 is damaged, replace the X-CAB_E connector.


8. Check the Backup Alarm signal circuit for an over current condition.
Use a multimeter to perform the following voltage check on the BACKUP ALARM connector:
From To Value
Connector N Connector P There should be an open circuit
A. If there is continuity, replace the Backup Alarm

9. Check the signal circuit for an over current condition on the harness between Backup Alarm and X-ENG connec-
tor.
From To Value
Connector X-ENG Connector X-BU2 There should be a short circuit
B. If there is a voltage, continue to Step 10.

10. Check the signal circuit for an over current condition on the harness between Smart Fuse Box and X-CAB_E
connector.
From To Value
Connector X-X4 pin 21 Connector X-CAB_E There should be a short circuit

11. Check the Smart Fuse Box signal circuit for an over current condition.
48083741_EN 31/07/2018
55.8 [55.DTC] / 666
From To Value
Connector A-SFB pin Chassis ground There should be an open circuit
OUT_45_H_CS_L
A. If there is a short circuit to ground, replace the Smart Fuse Box.
48083741_EN 31/07/2018
55.8 [55.DTC] / 667
520591-03 - Backup Alarm - Short circuit to B+

Control Module: SFB
Context:
Battery voltage on Backup Alarm (Short circuit to B+).
Cause:
The Smart Fuse box measure a battery voltage on Backup Alarm signal ( X4 pin 21) when the key is OFF.

Solution:



48083741_EN 31/07/2018
55.8 [55.DTC] / 668



8. Check the Backup Alarm signal circuit for an open circuit condition.
From To Value
Connector X-BU1 Connector X-BU2 There should be an open circuit
A. If there is continuity, replace the Backup Alarm.

9. Check the signal circuit for an open circuit condition on the harness between Backup Alarm and X-ENG connector.
From To Value

10. Check the signal circuit for an open circuit condition on the harness between Smart Fuse Box and X-CAB_E
connector.
From To Value

48083741_EN 31/07/2018
55.8 [55.DTC] / 669
From To Value
Connector A-SFB pin Chassis ground There should be not voltage
OUT_45_H_CS_L
48083741_EN 31/07/2018
55.8 [55.DTC] / 670
520591-05 - Backup Alarm - Open Circuit

Control Module: SFB
Context:
Low current on Backup Alarm (open circuit).
Cause:
The Smart Fuse box measure a current < 35 mA on Backup Alarm signal ( X4 pin 21) when the key is ON.

Solution:



48083741_EN 31/07/2018
55.8 [55.DTC] / 671



8. Check the Backup Alarm signal circuit for an open circuit condition.
From To Value
Connector X-BU1 Connector X-BU2 There should be an open circuit

9. Check the signal circuit for an open circuit condition on the harness between Backup Alarm and X-ENG connector.
From To Value

10. Check the signal circuit for an open circuit condition on the harness between Smart Fuse Box and X-CAB_E
connector.
From To Value

From To Value
OUT_45_H_CS_L
48083741_EN 31/07/2018
55.8 [55.DTC] / 672
48083741_EN 31/07/2018
55.8 [55.DTC] / 673
520591-06 - Backup Alarm - Short circuit to GND

Control Module: SFB
Context:
No Signal on Backup Alarm (Short circuit to GND).
Cause:
The Smart Fuse box measure a GND voltage on Backup Alarm signal ( X4 pin 21) when the SCG is ON.

Solution:



48083741_EN 31/07/2018
55.8 [55.DTC] / 674



8. Check the Backup Alarm signal circuit for a short circuit to GND condition.
Use a multimeter to perform the following voltage check on the BACKUP ALARM connector:
From To Value
Connector N Connector P There should be an open circuit

9. Check the signal circuit for a short circuit to GND condition on the harness between Backup Alarm and X-ENG
connector.
From To Value

10. Check the signal circuit for a short circuit to GND condition on the harness between Smart Fuse Box and X-CAB_E
connector.
From To Value

11. Check the Smart Fuse Box signal circuit for a short circuit to GND.
48083741_EN 31/07/2018
55.8 [55.DTC] / 675
From To Value
OUT_45_H_CS_L
A. If there is a short circuit to GND, replace the Smart Fuse Box.
48083741_EN 31/07/2018
55.8 [55.DTC] / 676
520596-03 - VSUP A - Out of Range - High

Control Module: SFB
Context:
VSUP A signal is out of range, too high level.
Cause:
The Smart Fuse box measure a high level of VSUP A signal (out of range), voltage > 32 V.

2. The harness between Smart Fuse Box and the Battery Isolator is damaged.
4. The Battery Isolator is defective.
Solution:
2. Check the integrity of the harness between Smart Fuse Box X-X1 pin 2 and the Junction Block into the cab pin
X-P1031.

3. Check the integrity of the Smart Fuse Box X-X1 connector pin 2.
Visually check the integrity of the pin.

4. Check the integrity of the Smart Fuse Box X-LC1 connector pin 1.

5. Check the integrity of the fuse.
Visually check the integrity of the fuse F-1F6 ( 50 A).
48083741_EN 31/07/2018
55.8 [55.DTC] / 677
A. If the fuse is damaged, replace the fuse.
B. If the fuse is not damaged, continue with Step 6.

6. Check the Battery K Isolator.
From To Value
Connector X-ISO pin 3 Chassis ground There should be a short
A. Verify the Battery K Isolator Power supply (pin X-D)
B. If Battery K Isolator is right functioning, replace the Smart Fuse Box.

48083741_EN 31/07/2018
55.8 [55.DTC] / 678
520596-04 - VSUP A - Out of Range - Low

Control Module: SFB
Context:
VSUP A signal is out of range, too Low level.
Cause:
The Smart Fuse box measure a Low level of VSUP A signal (out of range), voltage <20 and not cranking.

Solution:
X-P1031.



48083741_EN 31/07/2018
55.8 [55.DTC] / 679

From To Value
A. Verify the Battery K Isolator Power supply (pin X-D).

48083741_EN 31/07/2018
55.8 [55.DTC] / 680
520597-03 - VSUP B - Out of Range - High

Control Module: SFB
Context:
VSUP B signal is out of range, too high level.
Cause:
The Smart Fuse box measure a high level of VSUP B signal (out of range), voltage > 32 V.

Solution:
X-P1031.



48083741_EN 31/07/2018
55.8 [55.DTC] / 681

From To Value
A. Verify the Battery K Isolator Power supply (pin X-D).

48083741_EN 31/07/2018
55.8 [55.DTC] / 682
520597-04 - VSUP B - Out of Range - Low

Control Module: SFB
Context:
VSUP B signal is out of range, too Low level.
Cause:
The Smart Fuse box measure a Low level of VSUP B signal (out of range), voltage <20 and not cranking.

Solution:
X-P1031.



48083741_EN 31/07/2018
55.8 [55.DTC] / 683

From To Value

48083741_EN 31/07/2018
55.8 [55.DTC] / 684
520598-03 - VSUP C - Out of Range - High

Control Module: SFB
Context:
VSUP C signal is out of range, too high level.
Cause:
The Smart Fuse box measure a high level of VSUP C signal (out of range), voltage > 32 V.

Solution:
X-P1031.



48083741_EN 31/07/2018
55.8 [55.DTC] / 685

From To Value

48083741_EN 31/07/2018
55.8 [55.DTC] / 686
520598-04 - VSUP C - Out of Range - Low

Control Module: SFB
Context:
VSUP C signal is out of range, too Low level.
Cause:
The Smart Fuse box measure a Low level of VSUP C signal (out of range), voltage <20 and not cranking.

Solution:
X-P1031.



48083741_EN 31/07/2018
55.8 [55.DTC] / 687

From To Value

48083741_EN 31/07/2018
55.8 [55.DTC] / 688
520599-03 - VSUP D - Out of Range - High

Control Module: SFB
Context:
VSUP D signal is out of range, too high level.
Cause:
The Smart Fuse box measure a high level of VSUP D signal (out of range), voltage > 32 V.

Solution:
X-P1031.



48083741_EN 31/07/2018
55.8 [55.DTC] / 689

From To Value

48083741_EN 31/07/2018
55.8 [55.DTC] / 690
520599-04 - VSUP D - Out of Range - Low

Control Module: SFB
Context:
VSUP D signal is out of range, too Low level.
Cause:
The Smart Fuse box measure a high level of VSUP D signal (out of range), voltage <20 and not cranking.

Solution:
X-P1031.



48083741_EN 31/07/2018
55.8 [55.DTC] / 691

From To Value

48083741_EN 31/07/2018
55.8 [55.DTC] / 692
522809-02 - Memory Integrity EEPROM

Context:
Memory Integrity EEPROM.
Cause:

Solution:
B. If the wirings are intact and functioning, verify the wirings to external connection, if one or more wirings are
damaged, proceed with the replacement.
48083741_EN 31/07/2018
55.8 [55.DTC] / 693
522810-09 - Joystick Steering Cut Off Valves not plausible

Control Module: UCM
Context:
The A-UCM detects not plausible values from the Joystick; as a consequence, the function JSS is disabled:
Cause:
The A-UCM detects, on pins 12 of connector X-UCM2A and 15 of connector X-UCM3B, one of the following
conditions:
• COV_A is closed and COV_B is open;
• COV_B is closed and COV_A is open;
• COV_A is closed and COV_B is closed and STAT_MSG_OP_X.OperationState_X = 0x11;
• COV_A is open and COV_B is open and STAT_MSG_OP_X.OperationState_X = 0x00

2. The harness between the A-UCM, the JSS CUT OFF SENSOR 1 and the JSS CUT OFF SENSOR 2 is visually
damaged.
3. The harness between the PVED-CLS, the valve JSS COV 1 and the valve JSS COV 2 is visually damaged.
4. The PVED-CLS is not functioning.
5. The integrity of the connectors X-JSS_FR or X-CAB_JSS or X-JSS_CO_1 or X-JSS_CO_2 or X-UCM3A or
X-UCM2A or X-UCM3B or X-UCM1A is damaged.
6. The JSS CUT OFF SENSOR 1 and the JSS CUT OFF SENSOR 2 are not supplied.
7. The harness between the connectors X-JSS_CO_1 or X-JSS_CO_2 and the connector X-JSS_FR is damaged.
8. The JSS CUT OFF SENSOR 1 or the JSS CUT OFF SENSOR 2 is damaged.
9. The harness between the PVED-CLS and the A-UCM (bus CAN 2) is visually damaged.
10. The harness between the connector X-CAB_JSS and the A-UCM is damaged.
Solution:
2. Visually check the integrity of the harness between the A-UCM, the JSS CUT OFF SENSOR 1 and the JSS CUT
OFF SENSOR 2 for any damage.

3. Visually check the integrity of the harness between the PVED-CLS and the valves JSS COV 1 and JSS COV 2
for any damage.
48083741_EN 31/07/2018
55.8 [55.DTC] / 694

4. Check the PVED-CLS correctly commands the valves JSS COV 1 and the JSS COV 2.
A. If the PVED-CLS does command the valves, replace the PVED-CLS.
B. If the PVED-CLS correctly commands the valves, continue with Step 5.

5. Check the integrity of the connectors X-JSS_FR and X-CAB_JSS.
Disconnect the connector X-SST from the connector X-BTS and visually check the integrity of pins 2, 3, 4 and 6
of both connectors.

6. Check the JSS CUT OFF SENSOR 1 and JSS CUT OFF SENSOR 2 power supply.
From To Value
Connector X-CAB_JSS pin 3 Connector X-CAB_JSS pin 4 (Ref) + 5 V
A. If the value is not correct, replace the harness between the connector X-CAB_JSS and the A-UCM.

7. Check the integrity of connectors X-JSS_CO_1 and X-JSS_CO_2.
Remove the connector X-JSS_CO_1 from the JSS CUT OFF SENSOR 1 and the connector X-JSS_CO_2 from
the JSS CUT OFF SENSOR 2 and visually check the integrity of pins 1, 2 and 4 of both connectors.

8. Check the harness between the connectors X-JSS_CO_1 and the connector X-JSS_FR.
From To Value
Connector X-JSS_CO_1 pin 1 Connector X-JSS_FR pin 3 Short circuit
A. If one value is not correct, replace the harness between the connector X-JSS_FR and the connector
X-JSS_CO_1.

9. Check the harness between the connectors X-JSS_CO_2 and the connector X-JSS_FR.
From To Value
A. If one value is not correct, replace the harness between the connector X-JSS_FR and the connector
X-JSS_CO_2.

10. Check the JSS CUT OFF SENSOR integrity.
Install the JSS CUT OFF SENSOR 1.
48083741_EN 31/07/2018
55.8 [55.DTC] / 695
From To Value
Connector X-JSS_CO_1 pin 1 Connector X-JSS_CO_1 pin 2 The sensor resistance
A. If the resistance is an open circuit, replace the JSS CUT OFF SENSOR 1.

From To Value
Connector X-JSS_CO_1 pin 1 Connector X-JSS_CO_1 pin 4 Resistance value between maximum
and minimum
A. If the resistance value is not valid, replace the JSS CUT OFF SENSOR 1.
B. If the resistance is correct, continue with Step 12.

12. Check the JSS CUT OFF SENSOR 2 integrity.
Install the JSS CUT OFF SENSOR 2.
From To Value
Connector X-JSS_CO_2 pin 1 Connector X-JSS_CO_2 pin 2 The sensor resistance
A. If the resistance is an open circuit, replace the JSS CUT OFF SENSOR 2.

From To Value
Connector X-JSS_CO_2 pin 1 Connector X-JSS_CO_2 pin 4 Resistance value between maximum
and minimum
A. If the resistance value is not valid, replace the JSS CUT OFF SENSOR 1.
B. If the resistance correct, continue with Step 14.

14. Visually check the integrity of the harness between the PVED-CLS and the A-UCM ( CAN 2) for any damage.
A. If the harness is damaged, replace the bus CAN 2.

A. If the pin is damaged, replace the harness between the connectors X-UCM3A and X-CAB_JSS.

A. If the pin is damaged, replace the harness between the connectors X-UCM3B and X-CAB_JSS.

48083741_EN 31/07/2018
55.8 [55.DTC] / 696


19. Check the integrity of harness between the connector X-CAB_JSS and the A-UCM.
From To Value
Connector X-CAB_JSS pin 2 Connector X-UCM3A pin 12 Short circuit
Connector X-CAB_JSS pin 6 Connector X-UCM3B pin 15 Short circuit
A. If the measurement is not correct, replace the harness between the connector X-BTS and the A-UCM.
48083741_EN 31/07/2018
55.8 [55.DTC] / 697
523438-31 - Joystick loss of communication

Control Module: UCM
Context:
occurs if the UCM detects a loss of communication of the joystick. The bootloader will output this message when
active.
Cause:
The UCM has detected a loss of communication of the joystick.

Solution:

been resolved.


48083741_EN 31/07/2018
55.8 [55.DTC] / 698
From To Value
From To Value
X-LC5 (Receptacle) pin 9B X-LC5 pin 6A There should be continuity

From To Value

From To Value
48083741_EN 31/07/2018
55.8 [55.DTC] / 699
From To Value

10. Check the CAN2 bus for a short circuit condition.
From To Value
X-UCM2B (Receptacle) pin 10 X-CAB_AR (Plug) pin 3 There should be no continuity
A. If there is continuity, there is a short circuit condition. Locate the fault and repair the conductor.

From To Value

From To Value
X-CAB_AR (Plug) pin 1 X-LC5 pin 6A There should be continuity

48083741_EN 31/07/2018
55.8 [55.DTC] / 700
524262-13 - Primary EEPROM configuration CRC validation fault

Context:
Primary EEPROM configuration CRC validation fault.
Cause:

Solution:
48083741_EN 31/07/2018
55.8 [55.DTC] / 701
524263-13 - Redundant EEPROM configuration CRC validation fault

Context:
Redundant EEPROM configuration CRC validation fault.
Cause:

Solution:
48083741_EN 31/07/2018
55.8 [55.DTC] / 702
524264-13 - Configuration parameter read error

Context:
Configuration parameter read error .
Cause:

Solution:
48083741_EN 31/07/2018
55.8 [55.DTC] / 703
Index
FAULT CODES - DTC

1049-01 - Front Brake Accumulator Low Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
1049-03 - Short to Power at Front Brake Accumulator Pressure Sensor . . . . . . . . . . . . . . . . . . . . . . . 96
1049-04 - Short to Ground at Front Brake Accumulator Pressure Sensor . . . . . . . . . . . . . . . . . . . . . . 97
1052-01 - Rear Brake Accumulator Low Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
1052-03 - Short to Power at Rear Brake Accumulator Pressure Sensor . . . . . . . . . . . . . . . . . . . . . . . 101
1052-04 - Short to Ground at Rear Brake Accumulator Pressure Sensor . . . . . . . . . . . . . . . . . . . . . . 103
110-00 - Engine coolant temperature is very high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
110-16 - Engine coolant temperature is high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
131112-04 - Engine Controller High side supply #2 to Grid heater - Short to ground . . . . . . . . . . . . . 326
131122-12 - Coolant Temperature Test Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 327
131151-03 - Emergency start time expired and shutdown initiated . . . . . . . . . . . . . . . . . . . . . . . . . . . . 330
131196-02 - Injection Processor Error – Test Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 331
131196-03 - Injection Processor Error – Internal Reset / Clock Loss / Voltage Too Low . . . . . . . . . . 332
131196-04 - Injection Processor Error – Unlocked / Initialization Failure . . . . . . . . . . . . . . . . . . . . . . . 334
131196-12 - Injection Processor Error – SPI Communication Failure . . . . . . . . . . . . . . . . . . . . . . . . . . 335
131246-03 - Humidity Sensor possibly saturated with water droplets – Signal Ratio above Limit . . 336
131246-04 - Humidity Sensor possibly saturated with water droplets – Signal Ratio below Limit . . 337
131252-02 - Timeout of CAN Message BC2EDC2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 338
131270-02 - Timeout of CAN message TSC1-PE Torque (When Inactive) . . . . . . . . . . . . . . . . . . . . . 341
131272-03 - Timeout of CAN Message TSC1-VR (When Active) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 344
131283-12 - ECM Recovery which is suppressed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 347
1565-02 - Armrest Signals not plausible . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
158-03 - Short to Power at Key Switch Crank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
177-00 - Transmission oil temperature is very high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
177-16 - Transmission oil temperature is high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
196685-04 - Speed limitation activates torque limitation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 348
196766-04 - Torque limitation due to turbo charger protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 349
196804-02 - CAN message not received from XXXX1 (TSC1-AE passive) . . . . . . . . . . . . . . . . . . . . . 350
196808-02 - Timeout of CAN message TSC1-VE Speed (When Inactive) . . . . . . . . . . . . . . . . . . . . . . 353
196819-12 - ECU Recovery (Visible) - Recovery Occurred . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 356
2580 - Low Brake Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
262302-04 - Torque Limitation due to Engine Protection (Against Excessive Torque, Engine Over-
speed and Overheat) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 357
262344-02 - Timeout of CAN Message TSC1-VR (When Inactive) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 358
48083741_EN 31/07/2018
55.8 [55.DTC] / 704
2661-14 - Roller X Hall cell plausibility error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
2662-03 - Hall cell X1/X2 voltage abnormally high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
2662-04 - Hall cell X1/X2 voltage abnormally low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
2662-13 - Roller X out of neutral at power-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
2662-14 - Roller X Hall cell plausibility error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
2663-03 - Hall cell Y1/Y2 voltage abnormally high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
2663-04 - Hall cell Y1/Y2 voltage abnormally low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
2663-13 - Roller Y out of neutral at power-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
2663-14 - Roller Y Hall cell plausibility error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
2664-03 - Hall cell Z1/Z2 voltage abnormally high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
2664-04 - Hall cell Z1/Z2 voltage abnormally low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
2664-13 - Roller Z out of neutral at power-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
2664-14 - Roller Z Hall cell plausibility error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
3509-02 - 5V internal fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
3651-02 - Primary FNR Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
393292-04 - Overheat protection activates torque limitation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 361
393374-04 - Torque Limitation due to Fuel Quantity Limitation because of Injection System Errors 362
3997-03 - Electrical Accessory Power Relay - Short Circuit to B+ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
3997-05 - Electrical Accessory Power Relay - Open Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
3997-06 - Electrical Accessory Power Relay - Short Circuit to GND . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
5000-12 - Logical error at gear range signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
5010-12 - Logical error at direction select signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
5110-03 - Short circuit to battery voltage or open circuit at transmission sump temperature sensor
input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
5110-04 - Short circuit to ground at transmission sump temperature sensor input . . . . . . . . . . . . . . . 37
5120-03 - Short circuit to battery voltage or open circuit at retarder / torque converter temperature
sensor input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
5120-04 - Short circuit to ground at retarder / torque converter temperature sensor input . . . . . . . . 41
5123-19 - Display Source Address Cyclic Timeout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
5140-03 - Short circuit to battery voltage or open circuit at engine speed input . . . . . . . . . . . . . . . . . 43
5140-04 - Short circuit to ground at engine speed input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
5140-12 - Logical error at engine speed input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
5150-03 - Short circuit to battery voltage or open circuit at turbine speed input . . . . . . . . . . . . . . . . . 49
5150-04 - Short circuit to ground at turbine speed input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
5150-12 - Logical error at turbine speed input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
5160-03 - Short circuit to battery voltage or open circuit at internal speed input . . . . . . . . . . . . . . . . . 55
5160-04 - Short circuit to ground at internal speed input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
5160-12 - Logical error at internal speed input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
5170-03 - Short circuit to battery voltage or open circuit at output speed input . . . . . . . . . . . . . . . . . . 61
5170-04 - Short circuit to ground at output speed input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
5170-12 - Logical error at output speed input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
517755-09 - EJM Message Timeout (AUX FNR, AUX I, AUX II) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 363
48083741_EN 31/07/2018
55.8 [55.DTC] / 705
517755-19 - BJM Message Timeout (Boom, Bucket, Kick down) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 365
5180-02 - Output speed zero doesn't fit to other speed signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
518032-03 - Aux FNR Key Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 367
518036-03 - Beacon Light Switch Key Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 368
518047-03 - Declutch Key Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 370
518052-03 - Differential Lock Up Key Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 371
518056-03 - Fan Mode Key Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 372
518058-03 - Float Key Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 373
518063-03 - Implement Coupler Key Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 374
518066-03 - Implement Enable Key Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 375
518069-02 - Joystick Steering Activation Button Signals not plausible . . . . . . . . . . . . . . . . . . . . . . . . . 376
518070-03 - Key_2 Key Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 379
518074-03 - Key_18 Key Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 380
518078-03 - Key_20 Key Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 381
518083-03 - Park Brake Key Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 382
518089-03 - Short to Power at Ride Control Valve High Side Driver . . . . . . . . . . . . . . . . . . . . . . . . . . . 383
518089-04 - Short to Ground at Ride Control Valve High Side Driver . . . . . . . . . . . . . . . . . . . . . . . . . . 385
518089-05 - Open Circuit at Ride Control Valve High Side Driver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 387
518093-03 - Return ToTravel Key Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 389
518101-03 - Torque Converter Lock Up Key Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 390
518103-03 - Transmission Auto Mode Key Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 391
518106-03 - WorkLight 1 Key Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 392
518108-03 - WorkLight 2 Key Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 395
518110-02 - Boom Angle Sensor signals not plausible . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 398
518110-03 - Boom Angle Sensor Channel 1 Over Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 399
518110-04 - Boom Angle Sensor Channel 1 Under Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
518111-02 - Bucket Angle Sensor signals not plausible . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
518111-03 - Bucket Angle Sensor Channel 1 Over Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406
518111-04 - Bucket Angle Sensor Channel 1 Under Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 408
518112-01 - Radiator Coolant Temperature Sensor under resistance Short to Ground . . . . . . . . . . . 411
518112.00 - Radiator Coolant Temperature Sensor over resistance Open Circuit/Short to Power . 413
518113-02 - Low Brake Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 415
518113-03 - Short to Power at Brake Supply Line Pressure Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . 416
518113-04 - Short to Ground at Brake Supply Line Pressure Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . 417
518114-03 - Short to Power at Brake Line (declutch) Pressure Sensor . . . . . . . . . . . . . . . . . . . . . . . . 420
518114-04 - Short to Ground at Brake Line (declutch) Pressure Sensor . . . . . . . . . . . . . . . . . . . . . . . 421
518115-01 - Auxiliary Steering lack of pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 424
518115-03 - Aux Steering Pressure Sensor Over Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 425
518115-04 - Aux Steering Pressure Sensor Over Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 427
518116-09 - Hydraulic Filter is Clogged . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 430
518119-03 - Short to Power at Implement Coupler High Side Driver . . . . . . . . . . . . . . . . . . . . . . . . . . 431
518119-04 - Short to Ground at Implement Coupler High Side Driver . . . . . . . . . . . . . . . . . . . . . . . . . 433
48083741_EN 31/07/2018
55.8 [55.DTC] / 706
518119-05 - Open Circuit at Implement Coupler High Side Driver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 435
518122-00 - Axle oil temperature is very high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 437
518122-00 - Front Axle Oil Temp Sensor Over Resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 438
518122-01 - Front Axle Oil Temp Sensor Under Resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 441
518122-16 - Axle oil temperature high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 444
518122-31 - Axle oil temperature sensor out of range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 445
518129-03 - Short to Power at Boom Raise Valve High Side Driver . . . . . . . . . . . . . . . . . . . . . . . . . . . 446
518129-04 - Short to Ground at Boom Raise Valve High Side Driver . . . . . . . . . . . . . . . . . . . . . . . . . . 448
518129-05 - Open Circuit at Boom Raise Valve High Side Driver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 450
518130-03 - Short to Power at Boom Lower Valve High Side Driver . . . . . . . . . . . . . . . . . . . . . . . . . . . 453
518130-04 - Short to Ground at Boom Lower Valve High Side Driver . . . . . . . . . . . . . . . . . . . . . . . . . . 455
518130-05 - Open Circuit at Boom Lower Valve High Side Driver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 457
518131-03 - Short to Power/Open Circuit at Boom Valve Low Side Driver . . . . . . . . . . . . . . . . . . . . . 460
518131-04 - Short to Ground at Boom Valve Low Side Driver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 462
518132-03 - Short to Power at Bucket Roll Valve High Side Driver . . . . . . . . . . . . . . . . . . . . . . . . . . . . 464
518132-04 - Short to Ground at Bucket Roll Valve High Side Driver . . . . . . . . . . . . . . . . . . . . . . . . . . . 466
518132-05 - Open Circuit at Bucket Roll Valve High Side Driver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 468
518133-03 - Short to Power at Bucket Dump Valve High Side Driver . . . . . . . . . . . . . . . . . . . . . . . . . . 471
518133-04 - Short to Ground at Bucket Dump Valve High Side Driver . . . . . . . . . . . . . . . . . . . . . . . . . 473
518133-05 - Open Circuit at Bucket Dump Valve High Side Driver . . . . . . . . . . . . . . . . . . . . . . . . . . . . 475
518134-03 - Short to Power/Open Circuit at Bucket Valve Low Side Driver . . . . . . . . . . . . . . . . . . . . 478
518134-04 - Short to Ground at Bucket Valve Low Side Driver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 480
518135-03 - Boom Angle Sensor Channel 2 Over Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 482
518135-04 - Boom Angle Sensor Channel 2 Under Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 484
518136-03 - Bucket Angle Sensor Channel 2 Over Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 487
518136-04 - Bucket Angle Sensor Channel 2 Under Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 489
518137-03 - Short to Power at AUX 1 Left High Side Driver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 492
518137-04 - Short to Ground at AUX 1 Left High Side Driver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 494
518137-05 - Open Circuit at AUX 1 Left High Side Driver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 496
518138-03 - Short to Power at AUX 1 Right High Side Driver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 499
518138-04 - Short to Ground at AUX 1 Right High Side Driver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 501
518138-05 - Open Circuit at AUX 1 Right High Side Driver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 503
518139-03 - Short to Power/Open Circuit at AUX 1 Low Side Driver . . . . . . . . . . . . . . . . . . . . . . . . . . 506
518139-04 - Short to Ground at AUX 1 Low Side Driver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 508
518140-03 - Short to Power at AUX 2 Left High Side Driver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 510
518140-04 - Short to Ground at AUX 2 Left High Side Driver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 512
518140-05 - Open Circuit at AUX 2 Left High Side Driver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 514
518141-03 - Short to Power at AUX 2 Right High Side Driver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 517
518141-04 - Short to Ground at AUX 2 Right High Side Driver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 519
518141-05 - Open Circuit at AUX 2 Right High Side Driver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 521
518142-03 - Short to Power/Open Circuit at AUX 2 Low Side Driver . . . . . . . . . . . . . . . . . . . . . . . . . . 524
518142-04 - Short to Ground at AUX 2 Low Side Driver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 526
48083741_EN 31/07/2018
55.8 [55.DTC] / 707
518143-03 - Short to Power/Open Circuit at Implement Coupler Low Side Driver . . . . . . . . . . . . . . . 528
518143-04 - Short to Ground at Implement Coupler Low Side Driver . . . . . . . . . . . . . . . . . . . . . . . . . . 530
518144-03 - Short to Power at Aux Steering Enable High Side Driver . . . . . . . . . . . . . . . . . . . . . . . . . 532
518144-04 - Short to Ground at Aux Steering Enable High Side Driver . . . . . . . . . . . . . . . . . . . . . . . . 534
518144-05 - Open Circuit at Aux Steering Enable High Side Driver . . . . . . . . . . . . . . . . . . . . . . . . . . . 536
518145-03 - Short to Power/Open Circuit at Park Brake Low Side Driver . . . . . . . . . . . . . . . . . . . . . . 538
518145-04 - Short to Ground at Park Brake Low Side Driver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 540
518146-03 - Short to Power at FAN Control High Side Driver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 542
518146-04 - Short to Ground at FAN Control High Side Driver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 544
518146-05 - Open Circuit at FAN Control High Side Driver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 546
518147-03 - Short to Power FAN Reverser Low Side Driver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 548
518147-04 - Short to Ground at FAN Reverser Low Side Driver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 550
518150-03 - Electrical Crank Power Relay- Short Circuit to B+ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 552
518150-03 - Electrical Ignition Power Relay- Short Circuit to B+ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 554
518150-04 - Short to Ground at Crank Request High Side Driver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 556
518150-05 - Electrical Crank Power Relay- Open Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 558
518150-05 - Electrical Ignition Power Relay- Open Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 560
518150-06 - Electrical Crank Power Relay- Short Circuit to GND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 562
518150-06 - Electrical Ignition Power Relay- Short Circuit to GND . . . . . . . . . . . . . . . . . . . . . . . . . . . . 564
518176-03 - Joystick Steering Signal 2 High voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 566
518176-04 - Joystick Steering Signal 2 Low voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 567
518176-09 - Joystick Steering Signals not plausible . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 570
518176-15 - Joystick Steering Signal 1 High voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 572
518176-17 - Joystick Steering Signal 1 Low voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 574
518177-03 - Short to Power at Pilot Enable Valve High Side Driver . . . . . . . . . . . . . . . . . . . . . . . . . . . 576
518177-04 - Short to Ground at Pilot Enable Valve High Side Driver . . . . . . . . . . . . . . . . . . . . . . . . . . 578
518177-05 - Open Circuit at Pilot Enable Valve High Side Driver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 580
518267-02 - WatchDog Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 583
518280-31 - Error at 5VREF1 Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 584
518283-31 - Error at 24VF2 Supply Rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 590
518287-31 - Error at 24VS1 Supply Rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 598
518289-31 - Error at 24VA Supply Rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 600
518290-31 - Error at 24VB Supply Rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 602
518291-31 - Error at 24VLP Supply Rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 604
518292-31 - Error at 24VP Supply Rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 606
518293-31 - Error at 2.5V Ref1 Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 608
518294-31 - Error at 2.5V Ref2 Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 609
48083741_EN 31/07/2018
55.8 [55.DTC] / 708
518296-31 - Error at 5VREFIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 610
518390-00 - Hydraulic Oil Temp Sensor Over Resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 611
518390-01 - Hydraulic Oil Temp Sensor Under Resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 613
518498-00 - Engine oil temperature is very high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 615
518499-18 - Engine Oil pressure Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 616
518501-09 - Air Filter Clogged . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 617
520332-19 - TCU Source Address Cyclic Timeout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 618
520333-19 - Keypad Source Address Cyclic Timeout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 620
520334-19 - Smart Fuse Box Source Address Cyclic Timeout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 621
520335-19 - Joystick Steering Controller Source Address Cyclic Timeout . . . . . . . . . . . . . . . . . . . . . . 622
520444-02 - Memory Integrity RAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 623
520444-31 - Memory Integrity ROM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 624
520519-19 - Bus Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 625
520572-03 - 24v to 12v Converter Enable - Short Circuit to B+ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 627
520572-05 - 24v to 12v Converter Enable - Open Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 629
520572-06 - 24v to 12v Converter Enable - Short Circuit to GND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 631
520578-03 - Battery Isolator RESET - Short Circuit to B+ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 636
520578-03 - Battery Isolator SET - Short Circuit to B+ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 633
520578-06 - Battery Isolator RESET - Short Circuit to GND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 642
520578-06 - Battery Isolator SET - Short Circuit to GND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 639
520584-00 - Left Brake Indicator Light - Too many loads or faulty load . . . . . . . . . . . . . . . . . . . . . . . . 645
520584-03 - Left Brake Indicator Light - Short circuit to B+ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 647
520584-05 - Left Brake Indicator Light - Open Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 649
520584-06 - Left Brake Indicator Light - Short circuit to GND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 651
520585-00 - Right Brake Indicator Light - Too many loads or faulty load . . . . . . . . . . . . . . . . . . . . . . . 653
520585-03 - Right Brake Indicator Light - Short circuit to B+ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 655
520585-05 - Right Brake Indicator Light - Open Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 657
520585-06 - Right Brake Indicator Light - Short circuit to GND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 659
520588-03 - Alternator Excitation Driver - Short Circuit to B+ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 661
520588-06 - Alternator Excitation Driver - Short Circuit to GND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 663
520591-00 - Backup Alarm - Too many loads or faulty load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 665
520591-03 - Backup Alarm - Short circuit to B+ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 668
520591-05 - Backup Alarm - Open Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 671
520591-06 - Backup Alarm - Short circuit to GND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 674
520596-03 - VSUP A - Out of Range - High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 677
520596-04 - VSUP A - Out of Range - Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 679
520597-03 - VSUP B - Out of Range - High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 681
520597-04 - VSUP B - Out of Range - Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 683
520598-03 - VSUP C - Out of Range - High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 685
520598-04 - VSUP C - Out of Range - Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 687
520599-03 - VSUP D - Out of Range - High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 689
520599-04 - VSUP D - Out of Range - Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 691
48083741_EN 31/07/2018
55.8 [55.DTC] / 709
521-03 - Inch Pedal Position Sensor over voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
521-04 - Inch Pedal Position Sensor under voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
5211-09 - Speedlimit_Prop1 Can message timeout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
5212-09 - Speedlimit_Prop2 Can message timeout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
5220-09 - Brakes timeout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
522809-02 - Memory Integrity EEPROM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 693
522810-09 - Joystick Steering Cut Off Valves not plausible . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 694
5230-09 - Zftc1 Timeout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
523438-31 - Joystick loss of communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 698
524262-13 - Primary EEPROM configuration CRC validation fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . 701
524263-13 - Redundant EEPROM configuration CRC validation fault . . . . . . . . . . . . . . . . . . . . . . . . . 702
524264-13 - Configuration parameter read error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 703
5260-09 - Dct1 Timeout = Vehicle_1 Timeout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
5270-09 - Jss Timeout =Vehicle_2 Timeout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
5271-09 - DISPID1 CAN message timeout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
5280-09 - Engine Conf timeout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
5290-09 - EEC1 Timeout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
5300-09 - EEC3 Timeout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
5310-09 - Engine speed limit function during gearshifts does not work properly . . . . . . . . . . . . . . . . . 151
5370-02 - Shift lever signal defective . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
5390-02 - Aeb request signal defective . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
5420-02 - Starting gear signal defective . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
5430-02 - Enginge torque signal defective . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
5431-09 - Engine speed limit function does not work properly during stall or output speed limit func-
tion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
5440-02 - Reference engine torque signal defective . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
5450-02 - Actual engine torque signal defective . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
5460-02 - Nom friction torque signal defective . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
5470-02 - EEC2 Timeout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
5480-03 - Short circuit to battery voltage at clutch K1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
5480-04 - Short circuit to ground at clutch K1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
5480-05 - Open circuit at clutch K1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
5520-03 - Short circuit to battery voltage at clutch Kv . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
5520-04 - Short circuit to ground at clutch Kv . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
5520-05 - Open circuit at clutch Kv . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
5530-03 - Short circuit to battery voltage at clutch Kr . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
48083741_EN 31/07/2018
55.8 [55.DTC] / 710
5530-04 - Short circuit to ground at clutch Kr . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
5530-05 - Open circuit at clutch Kr . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
5536-00 - Hydraulic oil temperature is very high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
5536-16 - Hydraulic oil temperature is high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
5540-03 - Short circuit to battery voltage at converter clutch (regulator valve) . . . . . . . . . . . . . . . . . . 195
5540-04 - Short circuit to ground at converter clutch (regulator valve) . . . . . . . . . . . . . . . . . . . . . . . . . 197
5540-05 - Open circuit at converter clutch (regulator valve) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
5560-03 - Short circuit to battery voltage at relay reverse warning alarm . . . . . . . . . . . . . . . . . . . . . . . 201
5560-05 - Open circuit at relay reverse warning alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
5657-02 - Incorrect Anti-tamper checksum sent by Engine Controller . . . . . . . . . . . . . . . . . . . . . . . . . 205
5657-09 - Anti-tamper checksum not sent by Engine Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
5660-02 - Slippage at clutch K1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
5680-02 - Slippage at clutch Kv . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
5685-02 - Slippage at clutch Kr . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
5700-00 - Overtemp Sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
5710-00 - Overtemp Retarder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
5720-00 - Overspeed Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221
5730-00 - Differential pressure oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223
5740-02 - Slippage at converter lockup clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225
5745-15 - Overspeed output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226
5755-15 - Transmission input torque overload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228
5760-00 - Overtemp converter output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230
5810-03 - Short circuit to battery voltage at power supply for sensors . . . . . . . . . . . . . . . . . . . . . . . . . 231
5810-04 - Short circuit to ground at power supply for sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232
5820-03 - High voltage at battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233
5820-04 - Low voltage at battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234
5830-02 - Error at valve power supply VPS1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235
5840-02 - Error valve power supply VPS2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236
5860-03 - Short circuit to battery voltage at display output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237
5860-04 - Short circuit to ground at display output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239
5880-02 - Illegal ID request via Can . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241
5890-02 - General EEPROM fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242
5900-13 - Configuration lost . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243
5910-13 - Application error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244
5930-07 - Clutch failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245
5930-13 - Clutch adjustment data lost or inchpedal calibration data lost . . . . . . . . . . . . . . . . . . . . . . . 246
5940-11 - Substitute clutch control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247
619-03 - Short to Power at Park Brake High Side Driver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
619-04 - Short to Ground at Park Brake High Side Driver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
48083741_EN 31/07/2018
55.8 [55.DTC] / 711
619-05 - Open Circuit at Park Brake High Side Driver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
624-03 - Short to Power at Warning LED High Side Driver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
624-04 - Short to Ground at Warning LED High Side Driver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
624-05 - Open Circuit at Warning LED High Side Driver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
65562-03 - Terminal 50 - Always On . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248
65564-03 - Water detected in Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249
65574-03 - Engine Controller battery voltage too High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251
65574-04 - Engine Controller battery voltage too Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253
65576-03 - Engine Controller High side supply #2 to Grid heater - Short to battery . . . . . . . . . . . . . . 255
65579-02 - Engine Controller Grid Heater relay circuit driver - No Load . . . . . . . . . . . . . . . . . . . . . . . . 256
65579-03 - Engine Controller Grid Heater relay circuit driver - Short circuit to Battery . . . . . . . . . . . 258
65579-04 - Engine Controller Grid Heater relay circuit driver - Short circuit to Ground . . . . . . . . . . . 260
65585-03 - Engine Coolant Temperature Sensor - Signal Above Range Max . . . . . . . . . . . . . . . . . . . 262
65585-04 - Engine Coolant Temperature Sensor - Signal Below Range Min . . . . . . . . . . . . . . . . . . . . 264
65585-12 - Engine Coolant Temperature Sensor - Signal Not Plausible . . . . . . . . . . . . . . . . . . . . . . . 266
65596-03 - Ambient Air Temperature Sensor failure - Signal too high . . . . . . . . . . . . . . . . . . . . . . . . . 268
65596-04 - Ambient Air Temperature Sensor failure - Signal too low . . . . . . . . . . . . . . . . . . . . . . . . . . 270
65646-03 - Minimum Number of Injections Not Reached – Stop Engine . . . . . . . . . . . . . . . . . . . . . . . 272
65660-02 - Injection Processor (CY33X) Error – Injections Limited By Software . . . . . . . . . . . . . . . . 273
65660-03 - Injection Processor (CY33X) Error – Internal Reset / Clock Loss / Voltage Too Low . . . 274
65660-04 - Injection Processor (CY33X) Error – Unlocked / Initialization Failure . . . . . . . . . . . . . . . . 276
65660-12 - Injection Processor (CY33X) Error – SPI Communication Failure . . . . . . . . . . . . . . . . . . . 277
65683-03 - Turbine speed - Signal too high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 278
65683-04 - Turbine speed - Signal too low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280
65694-04 - Torque Reduction due to Smoke Limitation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282
65717-02 - Timeout of CAN Message VCM2EDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 283
65734-03 - Timeout of CAN message TSC1-PE Torque (When Active) . . . . . . . . . . . . . . . . . . . . . . . . 286
65736-03 - Timeout of CAN message TSC1-VE Speed (When Active) . . . . . . . . . . . . . . . . . . . . . . . . 289
65745-03 - ECM Internal SPI Communication Error – CJ940 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 292
65747-12 - ECM (Locked) Recovery Occurred . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 293
65748-12 - ECM Processor – Watchdog Not Plausible . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 294
65749-02 - Shutoff Paths During Initialization – Supply Voltage Too High . . . . . . . . . . . . . . . . . . . . . . 295
65749-04 - Shutoff Paths During Initialization - Watchdog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 296
65749-12 - Shutoff Paths During Initialization – Supply Voltage Too Low . . . . . . . . . . . . . . . . . . . . . . 297
65750-12 - TPU Monitoring – Time Deviation between TPU and System Not Plausible . . . . . . . . . . 298
65752-12 - Controller Watchdog – SPI Communication Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 299
65753-02 - ADC Monitoring – Test Impulse Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300
65753-03 - ADC Monitoring – Reference Voltage Too High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301
65753-04 - ADC Monitoring – Reference Voltage Too Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 302
65753-12 - ADC Monitoring – Queue Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303
65763-03 - Overrun Monitoring – Injection Time Too Long . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 304
65764-03 - Redundant Engine Speed in Overrun Monitoring – Speed Signal Not Plausible . . . . . . 305
48083741_EN 31/07/2018
55.8 [55.DTC] / 712
65765-03 - Engine regulated 12 Volt sensor supply - Voltage High . . . . . . . . . . . . . . . . . . . . . . . . . . . . 306
65765-04 - Engine regulated 12 Volt sensor supply - Voltage Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . 308
65766-03 - Sensor Supply Voltage 1 - High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 310
65766-04 - Sensor Supply Voltage 1 - Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 312
65769-03 - ECM Internal Supply Voltage Too High – CJ940 Above Limit . . . . . . . . . . . . . . . . . . . . . . 322
65770-04 - ECM Internal Supply Voltage Too Low – CJ940 Below Limit . . . . . . . . . . . . . . . . . . . . . . . 324
746-03 - Short to Power at Differential Lock Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
746-04 - Short to Ground at Differential Lock Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
746-05 - Open Circuit at Differential Lock Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
91.19 - Engine Source Address Cyclic Timeout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
96-00 - Fuel Level Sensor Over Resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
96-01 - Fuel Level Sensor Under Resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
48083741_EN 31/07/2018
55.8 [55.DTC] / 713
PRINTED IN ITALY
48083741_EN 31/07/2018
EN
SERVICE MANUAL
Front loader and bucket

48083741_EN 31/07/2018
82
Contents
Front loader and bucket - 82
[82.100] Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82.1
[82.300] Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82.2
48083741_EN 31/07/2018
82
Arm - 100

48083741_EN 31/07/2018
82.1 [82.100] / 1
Contents
Arm - 100
FUNCTIONAL DATA
Front loader arm

Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SERVICE
Front loader arm

Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
48083741_EN 31/07/2018
82.1 [82.100] / 2
Front loader and bucket - Arm
Front loader arm - Exploded view
LEIL17WHL1569GB 1
1. Lift Arm 11. Bellcrank Pin 21. Lube Fitting

2. Bellcrank 12. Dump Link Pin 22. 90° Elbow
3. Dump Assy Link 13. Spacer 23. Clamp
4. Wiper Rod 95.3 14. Washer 24. Nut
5. Wiper Rod 82.5 15. Bolt, M16x50 CL 10.9 25. Dump Link Washer
6. Wiper Rod 88.9 16. Bolt, M16x40 CL 10.9 26. Hardened Washer
7. Lift Arm Pin 17. Bolt, M16x60 CL 10.9 27. Hardened Washer
8. Lift Cylinder/Chassis Pin 18. Bolt, M16x90 CL 10.9 28. Wiper Rod 107.95
9. Lift Cylinder/Arm Pin 19. Nut 29. Wire Tie
10. Tilt Cylinder Pin 20. Lube Fitting 30. Grease Hose
48083741_EN 31/07/2018
82.1 [82.100] / 3
Front loader arm - Remove

1. Park the machine on a level surface and apply the park-
ing brake. Roll the bucket all the way forward and lower
the bucket to the floor. Stop the engine.
2. Loosen the filler plug in the reservoir to release the air
in the reservoir.
3. Fasten a chain hoist to the cross member of the loader
frame (1).
4. Loosen and remove the bolt (16), flat washer (14), and
spacer (13) that fasten the pivot pin (9) to the piston rod
yoke of the right-hand lift cylinder.
5. Use an acceptable driver and drive the pivot pin (9) out
of the piston rod yoke of the right-hand lift cylinder. Do
not remove the driver.
6. Repeat steps 4 and 5 for the left-hand lift cylinder.
7. Start the engine. Roll the bucket back and lower the
bucket so that the bucket is flat on the floor and fasten
the chain hoist to one of the lift cylinders.
8. Raise the lift cylinder slightly and remove the driver.
9. Repeat steps 7 and 8 for the other lift cylinder.
10. Connect the chain hoist to the bucket cylinder.
11. Loosen and remove the bolt (15), flat washer (14), and
spacer (13) that fasten the pivot pin (10) for the piston
rod eye of the bucket cylinder to the bell crank (2).
12. Use an acceptable driver and drive the pivot pin (10)
out of the piston rod eye of the bucket cylinder.
13. Raise the bucket cylinder and use a chain or other ac-
ceptable holding equipment to hold the bucket cylin-
der in place.
14. If the machine is equipped with auxiliary hydraulics,
disconnect the two hoses from the tubes at the bracket
on the right side of the loader frame (1). Install caps
on the hoses and plugs in the tube fittings.
15. If the machine is equipped with front lamps, loosen
and remove the cap screws and lock washers that
fasten the lamp brackets to the front frame. Discon-
nect electrical connector and position harness to avoid
damage. Put the lamp brackets on the fenders.
16. Connect the chain hoist to the loader frame (1).
48083741_EN 31/07/2018
82.1 [82.100] / 4
17. Disconnect the electrical connector (31) from the lift

EH sensor (32) (right-hand side of machine).
LEIL16WHL1792AA 1
18. Remove the lift EH sensor assembly to access the

pivot pin (7).
LEIL17WHL2085AB 2
19. Loosen and remove the bolt (15), flat washer (14) and
spacer (13) that fasten the pivot pin (7) to the front
frame.
20. Raise the loader frame slightly. Use an acceptable
driver and drive the pivot pin (7) out of the front frame.
Do not lose the washers (25), (26), (27) between the
front frame and the loader frame (1). Keep the washer
shim packs together and note the location from which
they were removed.
21. Repeat Steps 19 and 20 for the pivot pin on the left-
hand side.
22. Raise the loader frame (1) out of the front frame. Care-
fully move the machine out of the loader frame (1).
48083741_EN 31/07/2018
82.1 [82.100] / 5
Front loader arm - Install

1. Apply antiseize compound to the inner bores and outer
bores for the pivot pins of the front frame.
2. Move the machine into alignment with the loader frame
(1).
3. Lower the loader frame (1) into alignment with the front
frame.
4. Apply antiseize compound to the pivot pin (7) and that
one on the opposite side that fasten the loader frame
(1) to the front frame.
5. Start the two pivot pins into the front frame. Install the
washers (25), (26), (27) between the loader frame (1)
and the front frame. Install washer shim packs in the
exact location from which they were removed.
6. Install the pivot pins all the way.
7. Install the bolt (15), washer (14) and spacer (13) that
fasten the pivot pin (7). Tighten the bolt. Repeat this
step on the other side.
8. Install the lift EH sensor assembly (right-hand side of
machine).
LEIL17WHL2087AB 1
9. Connect the electrical connector (31)to the lift EH sen-

sor (32).
LEIL16WHL1792AA 2
10. Disconnect the chain hoist from the loader frame (1).
11. If the machine is equipped with front lamps, hold the
front lamps in place and install the cap screws and
lock washers that fasten the front lamps to the front
frame. Tighten the cap screws. Reconnect electrical
connectors.
remove the plugs from the tube fittings and the caps
from the hoses. Connect the hoses to the tubes.
48083741_EN 31/07/2018
82.1 [82.100] / 6
13. Connect the chain hoist to the bucket cylinder and

lower the bucket cylinder.
15. Have another person help you at this time. Move the
bucket control lever as required to align the piston rod
eye of the bucket cylinder with the bell crank (2). Stop
the engine.
NOTICE: do not use your fingers to check the alignment of
the cylinder rod . Personal injury can be the result.
16. Install the pivot pin (10) in the bell crank (2) and the
piston rod eye of the bucket cylinder.
17. Install the bolt (15), washer (14), and spacer (13) that
fasten the pivot pin (10). Tighten the bolt.
18. Disconnect the chain hoist from the bucket cylinder.
19. Fasten the chain hoist to one of the lift cylinders.
20. Raise the piston rod yoke of the lift cylinder so the
piston rod yoke is aligned with the loader frame (1).
21. Install a driver in the piston rod yoke and the loader
frame (1).
22. Repeat steps 19, 20, and 21 for the other lift cylinder.
23. Disconnect the chain hoist from the lift cylinder.
24. Start the engine. Raise the loader frame and roll the
bucket all the way forward. Lower the bucket to the
floor. Stop the engine.
25. Fasten the chain hoist to the cross member of the
loader frame (1).
27. Have another person help you at this time. Move the
lift control lever as required to align the piston rod yoke
of one of the lift cylinders with the loader frame (1).
NOTICE: do not use your fingers to check the alignment of
the cylinder rod . Personal injury can be the result.
28. Remove the driver and install the pivot pin (9).
29. Install the bolt (16), washer (14), and spacer (13) that
fasten the pivot pin (9). Tighten the bolt.
30. Repeat Steps 27, 28, and 29 for the other lift cylinder.
Stop the engine.
31. Lubricate the pivot pins with molydisulfide grease.
32. Disconnect the chain hoist from the cross member of
the loader frame (1).
33. Tighten the filler plug in the reservoir.
start the engine and run the engine at low idle.
35. Slowly extend and retract the clam cylinders four times
to remove air from the auxiliary circuit.
36. Stop the engine, check the level of the oil in the reser-
voir, and check for leaks. Add oil to the reservoir as
required.
48083741_EN 31/07/2018
82.1 [82.100] / 7
Index
Arm - 100
Front loader arm - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Front loader arm - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Front loader arm - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
48083741_EN 31/07/2018
82.1 [82.100] / 8
Bucket - 300

48083741_EN 31/07/2018
82.2 [82.300] / 1
Contents
Bucket - 300
SERVICE
Bucket
Replace - Bucket teeth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
48083741_EN 31/07/2018
82.2 [82.300] / 2
Front loader and bucket - Bucket
Bucket - Replace - Bucket teeth

Replacement of the Tooth Points
1. Use a hammer and punch to drive the retaining pin (1)
for the tooth point (2) out of the tooth shank (3), refer to
the illustration on this page.
NOTE: if equipped with SMART FIT teeth, rotate the pin
locking tab with a socket wrench prior to attempting to re-
move the pin.
2. Remove the tooth point (2).
3. Install a new tooth point (2) on the tooth shank (3).
4. Install the retaining pin (1) into the tooth point (2) and
tooth shank (3). Make sure the shoulder on the retain-
ing pin is toward the cutting edge. Use a hammer to
hit the retaining pin (1) until the retaining pin (1) is even
with the outside of the tooth shank (3).
NOTE: if equipped with SMART FIT teeth, install the pin to
a depth that allows the pin locking tab to be rotated with a
socket wrench. The tooth point is now secure and the use
of a hammer is not required.
LEIL13WHL1147BB 1
Replacement of the Bucket Teeth

1. Loosen and remove the nuts (4), hardened washers
(5), and bolts (6) from the bucket teeth.
NOTE: if wear of the bolt or nut makes removal difficult, the
bolt or nut can be cut off.
2. Remove the tooth.
3. Install the new tooth on the bucket cutting edge (7).
4. Use new nuts (4), hardened washers (5), and bolts (6)
for the tooth being installed.
5. Tighten the nuts (4) to 1315 – 1480 N·m (970 – 1092 lb
ft).
48083741_EN 31/07/2018
82.2 [82.300] / 3
Front loader and bucket - Bucket
Replacement of the Bucket Corner Teeth

1. Loosen and remove the nuts (9), hardened washers
and bolts (8) from the bucket corner teeth (10).
NOTE: if wear of the bolt or nut makes removal difficult, the
bolt or nut can be cut off.
2. Remove the corner tooth (10).
3. Install the new corner tooth (10) on the bucket cutting
edge (7).
4. Use new nuts (9), hardened washers and bolts (8) for
the corner tooth being installed.
5. Tighten the nuts (9) to 1315 – 1480 N·m (970 – 1092 lb
ft).
48083741_EN 31/07/2018
82.2 [82.300] / 4
Index
Bucket - 300
Bucket - Replace - Bucket teeth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
48083741_EN 31/07/2018
82.2 [82.300] / 5
PRINTED IN ITALY
48083741_EN 31/07/2018
EN
SERVICE MANUAL
Platform, cab, bodywork, and decals

48083741_EN 31/07/2018
90
Contents
Platform, cab, bodywork, and decals - 90
[90.150] Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.1
[90.120] Mechanically-adjusted operator seat. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.2
[90.124] Pneumatically-adjusted operator seat. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.3
[90.105] Machine shields and guards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.4
48083741_EN 31/07/2018
90
Cab - 150

48083741_EN 31/07/2018
90.1 [90.150] / 1
Contents
Cab - 150
FUNCTIONAL DATA
Cab
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SERVICE
Cab
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
48083741_EN 31/07/2018
90.1 [90.150] / 2
Platform, cab, bodywork, and decals - Cab
Cab - Overview
Rollover Protective Structure (ROPS)
NOTICE: the Rollover Protective Structure (ROPS) is a special safety component of your machine. DO NOT attach
any device to the ROPS for pulling purposes. The ROPS is a certified structural support and any damage, fire, corro-
sion or modification will weaken the structure and reduce your protection. If this occurs, the ROPS MUST be replaced
so that it will provide the same protection as a new ROPS.
After an accident, fire or rollover, the following MUST be performed before returning the machine to field or job site
operation:
• The ROPS structure MUST be replaced.

• The ROPS mounting or suspension, operator seat and suspension, seat belts and mounting components and wiring
within the operator’s protective system MUST be carefully inspected for damage.
• All damaged parts MUST be replaced.
DO NOT WELD, ATTEMPT TO STRAIGHTEN OR REPAIR THE ROPS.
Maintenance and inspection of the Rollover Protective Structure (ROPS)

After every 500 hours of operation or every six months, whichever comes first, do the following:
1. Check the torque on the ROPS mounting bolts; torque should be 561 – 758 N·m (413.8 – 559.1 lb ft) for ROPS
retaining bolts and 200 – 285 N·m (147.5 – 210.2 lb ft) for viscous mount bolts. If necessary, tighten the bolts to
the correct torque.
2. Check that seat belt mounting hardware is tight and seat belt is not cut or frayed. Check the torque on operators
seat mounting bolts; torque should be 38 – 44 N·m (28 – 32 lb ft). If necessary, tighten the bolts to the correct
torque. Replace parts that are worn or damaged.
NOTICE: class 10.9 hardware is used to mount and anchor the ROPS. Parts used for replacement must be those
shown in the parts catalog.
NOTICE: do not install attachments that will make the total weight of the machine more than the weight shown in the
maximum gross vehicle weight section of the ROPS serial number plate.
NOTICE: do not change the ROPS in any way. Changes made to the ROPS which are not authorized, such as
welding, drilling or cutting will make the ROPS weaker and decrease your protection. Replace the ROPS if it becomes
damaged in any way. DO NOT TRY TO MAKE REPAIRS TO THE ROPS.
48083741_EN 31/07/2018
90.1 [90.150] / 3
Cab - Remove
Rollover Protective Structure (ROPS)
Stop the engine.
Actuate the brake pedal several times to discharge the
brake accumulators.
2. Put the key switch to ON position and move the joystick
to the raise and to the lower position in order to release
any hydraulic pressure in the hydraulic circuit.
3. Slowly loosen the filler cap on the hydraulic oil tank to
release air pressure.
4. Put the key switch to OFF position.
6. Put the timed disconnect switch to OFF position.
8. Discharge and recover the air-conditioning refrigerant.
Refer to Air conditioning - Charging (50.200).
9. Remove the right-hand rear fender and steps (if
equipped).
10. Remove the relevant bolts, washers, and nuts to dis-
assemble:
• the right-hand rear cab skirt (1);

• the right-hand cab skirt (2);
• the center cab skirt (3);
• the left-hand cab skirt (4).
LEIL16WHL1189FB 1
48083741_EN 31/07/2018
90.1 [90.150] / 4
11. Put identification tags and disconnect all the hoses

and electrical connectors from the steering control
valve (1) and brake pedal control valve (2). Refer to
Brake pedal control valve - Remove (33.202) and
Steering valve - Remove (41.200).
Install protective caps to the hoses and fittings to pre-
vent entry of foreign matter into hydraulic system.
LEIL16WHL1195AB 2
12. Remove the bolts and washers to unfix the HVAC

cover.
LEIL16WHL1190AB 3
13. Disconnect the PRH2 connector (1) (Ref: Engine and

rear chassis harness).
Remove the clamps (2) securing the wire to the cab
frame.
LEIL16WHL1193AB 4
14. Disconnect the ground strap from the cab weld stud.
LEIL16WHL1185AB 5
48083741_EN 31/07/2018
90.1 [90.150] / 5
15. Disconnect the FRNT connector (1) and FRNT_EH

connector (2) (Ref: Front chassis harness).
LEIL16WHL1187AB 6
16. Remove the clamps (1) and (6) securing wires to

bracket.
Disconnect the following electrical connectors:
(Ref: Engine and rear chassis harness)
• ENG connector (4);
• ENG-2 connector (3);
• CP connector (2);
(Ref: Transmission harness)
• TRANS connector (7);
(Ref: Rear view camera harness)
• connector (5).
NOTE: if the machine is equipped with Joystick Steering
(JSS), disconnect also the JSS_COM and JSS_FR con- LEIL16WHL1194AB 7
nectors (Ref: Joystick steering harness).
17. If machine is equipped with auxiliary steering system,
disconnect the BTS connector (Ref: Bottom cab har-
ness).
LEIL16WHL1191AB 8
18. Remove the two clamps that secure the heater hoses
and air-conditioning hoses to the cab frame.
LEIL16WHL1192AB 9
48083741_EN 31/07/2018
90.1 [90.150] / 6
19. Disconnect and plug the following hoses:

• heater hoses (1), (2);
• air-conditioning hoses (3), (4) (after removal of clamp
plate (6));
• drain hose (5).
LEIL16WHL1186AB 10
20. Disconnect and plug the front and rear wiper hoses.
LEIL16WHL1197AB 11
LEIL16WHL1196AB 12
21. Remove the fours bolts to disassemble the roof cab

cover.
LEIL16WHL1183AB 13
48083741_EN 31/07/2018
90.1 [90.150] / 7
22. Install lifting eyes at the four cab lifting points.
LEIL16WHL1184AB 14
23. Attach the cab to a suitable lifting equipment at the

cab lifting eyes. Take up all slack in lifting equipment.
LEIL16WHL1198AA 15
24. Remove the following relevant items that fix the cab
to the rear chassis at four points:
• spacers (1);
• washers (2);
• M22x160 bolts (3);
• viscous mounts (4);
• washers (5);
• M10x35 bolts (6);
• washers (7);
• M16x55 bolts (8);
LEIL18WHL0857BB 16
48083741_EN 31/07/2018
90.1 [90.150] / 8
25. Slowly raise the cab from the rear chassis.

Check that all the tie straps and clamps have been
removed.
Check that all the hoses, tubes, and connectors are
disconnected and free.
26. Remove the cab and position it onto wood blocks to
prevent damage.
48083741_EN 31/07/2018
90.1 [90.150] / 9
Cab - Install
1. Connect a suitable lifting equipment to the cab lifting
eyes. Take up all slack in the lifting equipment.
2. Position the cab over the rear chassis and slowly lower
the cab making sure the mounting holes in cab are
aligned to the associated holes in rear chassis.
LEIL16WHL1198AA 1
3. Check the viscous mounts (4) for deterioration, tears,

deformation, or other damage; replace them as neces-
sary.
4. Fix the viscous mounts (4) to the cab. Install the
M10x35 bolts (6), washers (5), and nuts; tighten the
bolts to a torque of 70 – 94 N·m (51.6 – 69.3 lb ft).
5. Fix the viscous mounts (4) to the rear chassis.
Apply the LOCTITE® 243™ to bolts threads (8). Install
the M16x55 bolts and washers (7). Tighten the bolts
(8) to a torque of 300 – 348 N·m (221.3 – 256.7 lb ft).
6. Install the M22x160 bolts (3), washers (2), and spac-
ers (1); tighten the bolts to a torque of 561 – 758 N·m
(413.8 – 559.1 lb ft).
LEIL18WHL0857BB 2
7. Disconnect the lifting equipment from the cab.

8. Remove the cab lifting eyes from the cab.
LEIL16WHL1184AB 3
48083741_EN 31/07/2018
90.1 [90.150] / 10
9. Before to install the roof cab cover, ensure that the roof
foam (1) and the four roof support foams (2) are not
damaged.
LEIL18WHL0873AB 4
10. Install the bolts to fix the roof cab cover.
LEIL16WHL1183AB 5
11. Connect the front and rear wiper hoses.
LEIL16WHL1197AB 6
LEIL16WHL1196AB 7
48083741_EN 31/07/2018
90.1 [90.150] / 11
12. Unplug and connect the following hoses:

• heater hoses (1), (2);
• air-conditioning hoses (3), (4) (fix the clamp plate
(6));
• drain hose (5).
LEIL16WHL1186AB 8
13. Secure with two clamps the heater hoses and air-con-
ditioning hoses to the cab frame.
LEIL16WHL1192AB 9
14. If machine is equipped with auxiliary steering system,

connect the BTS connector (Ref: Bottom cab har-
ness).
LEIL16WHL1191AB 10
15. Connect the following electrical connectors:

(Ref: Engine and rear chassis harness)
• ENG connector (4);
• ENG-2 connector (3);
• CP connector (2);
(Ref: Transmission harness)
• TRANS connector (7);
(Ref: Rear view camera harness)
• connector (5).
Secure with the clamps (1) and (6) the wires to
bracket.
NOTE: if the machine is equipped with Joystick Steering
(JSS), connect also the JSS_COM and JSS_FR connec- LEIL16WHL1194AB 11
tors (Ref: Joystick steering harness).
48083741_EN 31/07/2018
90.1 [90.150] / 12
16. Connect the FRNT connector (1) and FRNT_EH con-

nector (2) (Ref: Front chassis harness).
LEIL16WHL1187AB 12
17. Connect the ground strap to the cab weld stud.
LEIL16WHL1185AB 13
18. Connect the PRH2 connector (1) (Ref: Engine and

rear chassis harness).
Secure with the clamps (2) the wire to the cab frame.
LEIL16WHL1193AB 14
19. Install the mounting bolts and washers for the HVAC
cover.
LEIL16WHL1190AB 15
48083741_EN 31/07/2018
90.1 [90.150] / 13
20. Remove the protective plugs from the hydraulic sys-

tem hoses and caps from fittings on steering control
valve and brake pedal control valve. With the aid
of the identification tags put in cab removal phase,
connect all the hoses and electrical connectors to
the steering control valve (1) and brake pedal control
valve (2). Refer to Brake pedal control valve - In-
stall (33.202) and Steering valve - Install (41.200).
LEIL16WHL1195AB 16
21. Install the bolts, washers, and nuts to mount:
• the right-hand rear cab skirt (1);

• the right-hand cab skirt (2);
• the center cab skirt (3);
• the left-hand cab skirt (4).
LEIL16WHL1189FB 17

23. Fill the engine cooling system.
48083741_EN 31/07/2018
90.1 [90.150] / 14
24. Fill the hydraulic system.

25. Put the timed disconnect switch to ON position.
26. Start engine and run engine at low idle. Run engine
at operating temperature for approximately 5 min.
When coolant is at operating temperature, stop en-
gine. When engine has cooled, check coolant level
at reservoir.
NOTICE: hot coolant can spray out if radiator cap is re-
moved. To remove radiator cap: let system cool, turn to
first notch, then wait until all pressure is released. Scald-
ing can result from fast removal of radiator cap.
48083741_EN 31/07/2018
90.1 [90.150] / 15
Index
Cab - 150
Cab - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Cab - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Cab - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
48083741_EN 31/07/2018
90.1 [90.150] / 16
Mechanically-adjusted operator seat - 120

48083741_EN 31/07/2018
90.2 [90.120] / 1
Contents
FUNCTIONAL DATA
Operator seat
Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SERVICE
Mechanically-adjusted operator seat

Remove - Standard operator seat - Mechanical suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Install - Standard operator seat - Mechanical suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
48083741_EN 31/07/2018
90.2 [90.120] / 2
Platform, cab, bodywork, and decals - Mechanically-adjusted operator seat
Operator seat - Exploded view

Standard operator seat – Mechanical suspension
LEIL17WHL0726GB 1
48083741_EN 31/07/2018
90.2 [90.120] / 3
LEIL17WHL1602GB 2
Item Description
(1) Seat base assembly
(2) Damper
(3) Knob and slotted spring
(4) Shock absorbers
(5) Roller
(6) Rollers and bushings
(7) Backrest cushion
(8) Seat cushion
(9) Left-hand and right-hand adjusters assembly
(10) Console adjusters
(11) Left-hand armrest
(12) Literature box
(13) Pivot cover
48083741_EN 31/07/2018
90.2 [90.120] / 4
Mechanically-adjusted operator seat - Remove - Standard operator

seat - Mechanical suspension
1. Remove the joystick. Joystick and Electric Hy-
draulic (EH) control - Remove (55.512) or Joystick
and Electric Hydraulic (EH) control - Remove
(Two/three control levers) (55.512).
2. Remove the 8 bolts (1) with the relevant washers (1)
that secure the console (2) to the machine.
LEIL18WHL0740AB 1
NOTE: have another person help you at this time.

3. Attach a suitable lifting device to the seat.
4. Lift the seat.
5. Remove carefully the seat from the cab.
LEIL18WHL0722AA 2
48083741_EN 31/07/2018
90.2 [90.120] / 5
Mechanically-adjusted operator seat - Install - Standard operator

seat - Mechanical suspension
2. Lift the seat.
3. Carefully move the seat inside the cab.
4. Place the seat on the correct position inside the cab.
5. Remove the lifting device.
LEIL18WHL0722AA 1
6. Install the 8 bolts (1) with the relevant washers to se-

cure the console (2) of the seat.
7. Torque to 38.0 – 44.0 N·m (336.3 – 389.4 lb in) the 8
bolts.
LEIL18WHL0740AB 2
8. Install the joystick. Joystick and Electric Hydraulic

(EH) control - Install (55.512) or Joystick and Elec-
tric Hydraulic (EH) control - Install (Two/three con-
trol levers) (55.512).
48083741_EN 31/07/2018
90.2 [90.120] / 6
Index

Mechanically-adjusted operator seat - Install - Standard operator seat - Mechanical suspension . . 6
Mechanically-adjusted operator seat - Remove - Standard operator seat - Mechanical suspension 5
Operator seat - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
48083741_EN 31/07/2018
90.2 [90.120] / 7
48083741_EN 31/07/2018
90.2 [90.120] / 8
Pneumatically-adjusted operator seat - 124

48083741_EN 31/07/2018
90.3 [90.124] / 1
Contents
FUNCTIONAL DATA
Pneumatically-adjusted operator seat

Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Seat pneumatic lift system
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Overview - Upper suspension part . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Overview - Lower suspension part . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
SERVICE
Pneumatically-adjusted operator seat

Remove - Optional operator seat - Air suspension, heated seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Install - Optional operator seat - Air suspension, heated seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Remove - Optional premium operator seat - Air suspension, heated seat . . . . . . . . . . . . . . . . . . . . . . . . . 15
Install - Optional premium operator seat - Air suspension, heated seat . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Seat pneumatic lift system
Remove - Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Install - Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Remove - Upper suspension part . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Install - Upper suspension part . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Remove - Lower suspension part . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Install - Lower suspension part . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Remove - Air-spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Install - Air-spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Operator seat rubber bellows
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
48083741_EN 31/07/2018
90.3 [90.124] / 2
Platform, cab, bodywork, and decals - Pneumatically-adjusted operator seat
Pneumatically-adjusted operator seat - Exploded view

Optional operator seat – Air suspension, heated seat
LEIL17WHL0727GB 1
48083741_EN 31/07/2018
90.3 [90.124] / 3
LEIL17WHL1604GB 2
48083741_EN 31/07/2018
90.3 [90.124] / 4
Item Description
(1) Seat base assembly
(2) Damper
(3) Compressor
(4) Air valve assembly
(5) Air spring assembly
(6) Bumper
(7) Rollers and bushings
(8) Backrest cushion
(9) Seat cushion
(10) Left-hand and right-hand adjusters assembly
(11) Console adjusters
(12) Left-hand armrest
(13) Literature box
(14) Pivot cover
(15) Heater switch
(16) Harness
48083741_EN 31/07/2018
90.3 [90.124] / 5
Pneumatically-adjusted operator seat - Exploded view

Optional premium operator seat – Air suspension, heated seat
48083741_EN 31/07/2018
LEIL17WHL1605HB 1
90.3 [90.124] / 6
Item Description
1 Cover
2 Control lever
3 Suspension
4 Harness
5 Air spring
6 Reservoir
7 Suspension
8 Lower suspension
9 Bellows
10 Air compressor
11 Handle
12 Triggering assembly
13 Loop sewn
14 Handle
15 Locking lever control
16 Shock absorber
17 Shock absorber
18 Console
48083741_EN 31/07/2018
90.3 [90.124] / 7
LEIL17WHL1606HB 2
48083741_EN 31/07/2018
90.3 [90.124] / 8
Item Description
1 Backrest cushion
2 Seat cushion
3 Headrest cushion
4 Headrest guide
5 Support
6 Backrest handle
7 Actuator for backrest
8 Backrest assembly
9 Seat operator angle adjuster
10 Swivel lever
11 Leaf spring
12 Bracket
13 Cover
14 Seat operator depth adjuster
15 Rail adjustment assembly
16 Armrest
17 Armrest
18 Cover
19 Cover
20 Armrest
21 Harness
22 Harness
23 Climate distributor
24 Link
48083741_EN 31/07/2018
90.3 [90.124] / 9
Seat pneumatic lift system - Overview
LEIL18WHL0521GA 1
Component Description
(1) Compressor
(2) Cable tie
(3) Lower suspension part
(4) Compressed-air hose (*)
(5) Hose nozzle
(6) Pad
(7) Compressor cable
(8) Electrical connector X-SC
(9) Lifting structure
(10) Cable tie
(11) Air intake hose
NOTE: (*) Use a sharp knife for cutting into lengths.
48083741_EN 31/07/2018
90.3 [90.124] / 10
Seat pneumatic lift system - Overview - Upper suspension part
LEIL18WHL0689GA 1
(1) Upper suspension part
(2) Guiding rail
(3) Rear roller
(5) Front roller
48083741_EN 31/07/2018
90.3 [90.124] / 11
Seat pneumatic lift system - Overview - Lower suspension part
LEIL18WHL0690GA 1
(1) Lower suspension part
(2) Guiding rail
(3) End stop
(4) Buffer
(5) Fixed bearing
(7) Roller
(8) Upper suspension part
(9) Collar screw
(10) Hexagon nut
(11) Screw
48083741_EN 31/07/2018
90.3 [90.124] / 12
Pneumatically-adjusted operator seat - Remove - Optional operator

seat - Air suspension, heated seat
2. Disconnect the connector X-SC from the seat harness.
LEIL18WHL0721AB 1
3. Remove the 8 bolts (1) with the relevant washers (1)

LEIL18WHL0740AB 2

5. Lift the seat.
LEIL18WHL0722AA 3
48083741_EN 31/07/2018
90.3 [90.124] / 13
Pneumatically-adjusted operator seat - Install - Optional operator

seat - Air suspension, heated seat
2. Lift the seat.
LEIL18WHL0722AA 1
6. Install the 8 bolts (1) with the relevant washers to se-

cure the console (2) of the seat.
7. Torque to 38.0 – 44.0 N·m (336.3 – 389.4 lb in) the 8
bolts.
LEIL18WHL0740AB 2
8. Connect the connector X-SC to the seat harness.
LEIL18WHL0721AB 3

48083741_EN 31/07/2018
90.3 [90.124] / 14
Pneumatically-adjusted operator seat - Remove - Optional premium

operator seat - Air suspension, heated seat
2. Disconnect the connector X-SC from the seat harness.
LEIL18WHL0721AB 1
3. Remove the four bolts (1) with the relevant washers (1)
LEIL18WHL0725AA 2

5. Lift the seat.
LEIL18WHL0722AA 3
48083741_EN 31/07/2018
90.3 [90.124] / 15
Pneumatically-adjusted operator seat - Install - Optional premium

operator seat - Air suspension, heated seat
2. Lift the seat.
LEIL18WHL0722AA 1
6. Install the four bolts (1) with the relevant washers to

secure the console (2) of the seat.
7. Torque to 38.0 – 44.0 N·m (336.3 – 389.4 lb in) the four
bolts.
LEIL18WHL0725AA 2
8. Connect the connector X-SC to the seat harness.
LEIL18WHL0721AB 3

48083741_EN 31/07/2018
90.3 [90.124] / 16
Seat pneumatic lift system - Remove - Compressor

Prior operation:
Operator seat rubber bellows - Remove (90.124)
NOTE: use a suitable spacer to support the structure of the operator seat.
1. To remove the compressor (1) move the seat suspen-
sion to the highest position and secure it at the rear
between the lifting structure and the lower suspension
part.
NOTE: open the vent valve of the pneumatic system before
remove the compressor (1).
LEIL18WHL0522AA 1
2. Mark the point where the hose nozzle (5) and the intake
hose (11) are fastened with cable tie (10) and remove
the cable tie (10).
LEIL18WHL0523AA 2
3. Mark the two electrical connectors (8) and disconnect

the electrical connectors (8) from the compressor (1).
4. Disconnect the hose nozzle (5) from the compressor
(1) and push it backwards at the compressed-air hose
(4).
NOTICE: be careful that you do not damage the com-
pressed-air hose (4)
NOTE: do not lift off the compressed-air hose (4) at the
connection of the compressor (1) (for example by means
of a screwdriver or similar tools).
5. Pull off the hose nozzle (5) from compressed-air hose
LEIL18WHL0524AA 3
(4).
6. Mark the places where the compressor (1) is attached
to the lower suspension part (3) by means of two cable
ties (2). Cut the two cable ties (2).
NOTICE: be careful that you do not cause damage the
compressor (1).
48083741_EN 31/07/2018
90.3 [90.124] / 17
7. Remove the compressor (1) from the front of the seat.
LEIL18WHL0522AA 4
8. Remove the compressor (1) from the pad (6).
LEIL18WHL0524AA 5
48083741_EN 31/07/2018
90.3 [90.124] / 18
Seat pneumatic lift system - Install - Compressor

NOTICE: use a suitable spacers to support the operator's seat structure.
1. To install the compressor (1) move the seat suspension
to the highest position and secure it at the rear between
the lifting structure and the lower suspension part.
LEIL18WHL0522AA 1
2. Install the compressor (1) from the front part.
LEIL18WHL0522AA 2
3. Place the pad (6) between the lower suspension part

(3) and the compressor (1) so that the compressor (1)
is not in contact with the lower suspension part (3).
4. Align the compressor (1) in the correct position to pre-
vent collision with the lifting structure (9).
5. Install the cable tie (2) in the slots of the pad (6).
NOTE: guide the cable ties (2) through the slots located on
the lower suspension part (3) , so that the locking head of
the cable ties (2) points forwards.
6. Pull the cable tie (2) to 360 N by means of pliers.
LEIL18WHL0524AA 3
NOTE: use a sharp knife to perform a clean cut to the com-

pressed-air hose (4) (if necessary).
NOTE: the compressed-air hose (4) can be cut only one
time. Mark the correct position before perform the cut on
the compressed-air hose (4) in order to cut it one time.
7. Install the hose nozzle (5) to the compressed air hose
(4).
8. Connect the compressed air hose (4) to the compres-
sor (1).
LEIL18WHL0524AA 4
48083741_EN 31/07/2018
90.3 [90.124] / 19
Seat pneumatic lift system - Remove - Upper suspension part

1. Remove the seat suspension.
LEIL18WHL0673AA 1
2. Remove the front cover.
LEIL18WHL0674AA 2
3. Remove the top cover.
LEIL18WHL0675AA 3
4. Push up the bellows and fasten it to the upper suspen-

sion part. Operator seat rubber bellows - Remove
(90.124)
LEIL18WHL0676AA 4
48083741_EN 31/07/2018
90.3 [90.124] / 20
5. Remove the Bowden pull wire (1) and the handle for
vertical shock absorber adjustment (2) at the upper
suspension part.
NOTE: the Bowden pull wire for the vertical shock absorber
(1) remains installed at the vertical shock absorber (2).
LEIL18WHL0678AA 5
6. Remove the longitudinal horizontal shock absorber.
LEIL18WHL0679AA 6
7. Remove the fore/aft isolator unit from the upper sus-

pension part.
LEIL18WHL0680AA 7
8. Remove the locking mechanism of the fore/aft isolator

if it is not preassembled.
NOTE: the clamp remains attached to the lifting structure.
LEIL18WHL0681AA 8
9. Remove the holder for height adjustment.
48083741_EN 31/07/2018
90.3 [90.124] / 21
10. Remove the Bowden pull wire for height adjustment in

downward direction at the upper suspension part.
NOTE: remove the Bowden pull wire for height adjustment
in downward direction at the clamp (if installed) and pull
inwards through the opening of the U-shaped rail.
NOTE: the Bowden pull wire for height adjustment in down-
ward direction remains installed at the level control.
LEIL18WHL0682AA 9
11. Remove the cable harness for vehicle connection.
LEIL18WHL0683AA 10
12. Remove the cable harness (1) of the seat suspension

with the U-profile (2) at the upper suspension part and
do the preservation for the part.
NOTE: the cable harness of the seat suspension remains
installed at the level control and at the compressor.
LEIL18WHL0684AA 11
13. Remove the secondary belt from the upper suspen-

sion part.
LEIL18WHL0685AA 12
48083741_EN 31/07/2018
90.3 [90.124] / 22
14. Remove the level control at the upper suspension part

and do the preservation for the part.
NOTE: the belt retractor of the level control is tensioned;
hold the level control and carefully guide it down.
NOTE: the cable harness of the seat suspension remains
installed at the level control.
LEIL18WHL0686AA 13
15. Remove the air distributor from the upper suspension

part and do the preservation for the part.
NOTE: the air hoses remain attached at the air distributor.
LEIL18WHL0687AA 14

16. Push the upper suspension part (1) forwards until the
cut-outs on the left and right sides at the guiding rails
(2) are located at the same height with the front rollers
(5).
17. Lift the upper suspension part (1) over the front rollers
(5).
LEIL18WHL0695BA 15
48083741_EN 31/07/2018
90.3 [90.124] / 23
18. Turn counterclockwise the upper suspension part (1)

by approximately of 45°.
19. Lift the upper suspension part (1) above ad forward
the rear roller (3).
20. Pull and remove the two front rollers (5) and two rear
rollers (3) from the lifting structure (4).
LEIL18WHL0696AA 16
48083741_EN 31/07/2018
90.3 [90.124] / 24
Seat pneumatic lift system - Install - Upper suspension part

1. Install the two front rollers (5) and two rear rollers (3)
on the lifting structure (4).
Push the parts in the lifting structure (4).
2. Lubricate the two guiding rails (2), the two front rollers
(5) and two rear rollers (3) with acid-free multi-purpose.
3. Hold the upper suspension part (1) over the front rollers
(5) and over the rear rollers (3).
LEIL18WHL0696AA 1
4. Put the upper suspension part (1) into the left and right
sides at the guiding rails (2) and push until it is fit in the
correct position.
LEIL18WHL0697BA 2

5. Install the air distributor and the air hoses at the upper
suspension part.
LEIL18WHL0687AA 3
48083741_EN 31/07/2018
90.3 [90.124] / 25
6. Install the level control and the cable harness of the

seat suspension part.
LEIL18WHL0686AA 4
7. Install the secondary belt to the upper suspension part.

NOTE: the belt retractor of the level control must be ten-
sioned.
LEIL18WHL0685AA 5
8. Install the cable harness (1) of the seat suspension with

the U-profile (2) on the upper suspension.
LEIL18WHL0684AA 6
NOTE: the cable harness of the seat suspension is already installed at the level control and on the compressor.
9. Install the cable harness for vehicle connection.
LEIL18WHL0683AA 7
48083741_EN 31/07/2018
90.3 [90.124] / 26
10. Install the Bowden pull wire for height adjustment in

forward direction at the upper suspension part.
NOTE: install the Bowden pull wire for height adjustment
in downward direction at the clamp (if installed) and push
forwards in the opening of the U-shaped rail.
NOTE: the Bowden pull wire for height adjustment in down-
ward direction remains installed at the level control.
LEIL18WHL0682AA 8
11. Install the holder for height adjustment.

12. Install the locking mechanism for the fore/aft isolator
not preassembled.
NOTE: the clamp is still attached to the lifting structure.
LEIL18WHL0681AA 9
13. Install the fore/aft isolator unit on the upper suspen-

sion part.
LEIL18WHL0680AA 10
14. Install the longitudinal horizontal shock absorber.
LEIL18WHL0679AA 11
48083741_EN 31/07/2018
90.3 [90.124] / 27
15. Install the Bowden pull wire (1) and the handle for
vertical shock absorber adjustment (2) on the upper
suspension part.
NOTE: the Bowden pull wire for the vertical shock absorber
is still installed at the vertical shock absorber.
LEIL18WHL0678AA 12
16. Lift down the bellows to the upper suspension part.

Operator seat rubber bellows - Install (90.124)
LEIL18WHL0676AA 13
17. Install the top cover.
LEIL18WHL0675AA 14
18. Install the front cover.
LEIL18WHL0674AA 15
48083741_EN 31/07/2018
90.3 [90.124] / 28
19. Install the seat suspension.
LEIL18WHL0673AA 16
48083741_EN 31/07/2018
90.3 [90.124] / 29
Seat pneumatic lift system - Remove - Lower suspension part

1. Push up the bellows and fasten it to the upper suspen-
sion part. Operator seat rubber bellows - Remove
(90.124)
LEIL18WHL0676AA 1
2. Remove the compressor. Seat pneumatic lift system

- Remove - Compressor (90.124).
NOTE: if the compressed air hose remain installed at the
compressor, the compressor must be fixed at the lifting
structure to prevent damage.
3. Remove the webbing of the level control from the lower
suspension part.
LEIL18WHL0699AA 2
4. Remove the secondary belt from the lower suspension

part.
LEIL18WHL0685AA 3
5. Remove the air spring. Seat pneumatic lift system -

Remove - Air-spring (90.124).
48083741_EN 31/07/2018
90.3 [90.124] / 30
6. Loosen and discard the two micro-encapsulated

hexagonal nuts (10) from the lower suspension part
(1).
7. Loosen the two screws (11) from fixed bearing (5).
8. Push the lifting structure (6) backwards until the two
fixed bearings (5) at the lifting structure (6) fit through
the end of the left and right guiding rail (2) of the lower
suspension part (1).
LEIL18WHL0698BA 4
9. Lift the lifting structure (6) with the two fixed bearings
(5) out of the guiding rails (2) of the lower suspension
part (1) at the front.
10. Loosen the two collar screws (9).
Remove the end stops (3) with the buffer (4) from the
guiding rails (2).
11. Turn laterally the lifting structure (6) with the attached
upper suspension part (8) of approximately 45° to pull
the two rollers (7) out of the guiding rails (2).
Lift the suspension part (8) in upward direction.
12. Remove the upper suspension part (8).
LEIL18WHL0698BA 5
48083741_EN 31/07/2018
90.3 [90.124] / 31
Seat pneumatic lift system - Install - Lower suspension part

1. Install the two guiding rails (2) on the lower suspension
part (1).
2. Torque the two screw (11) and the two micro-encapsu-
lated hexagonal nuts (10) to 25.0 N·m (18.4 lb ft).
3. Lubricate with acid-free multi-purpose the side of the
two guiding rails (2) where the rollers are moved.
4. Put the end stop (3) with the buffer (4) into the guiding
rails (2).
LEIL18WHL0698BA 1
5. Torque to 6.0 N·m (53.1 lb in) the collar screw (9).

6. Insert the two rollers (7) into the two guiding rails (2).
7. The two rollers (7) are attached to the suspension part
(8) through the lifting structure (6).
8. Engage the two fixed bearings (5) to the lower suspen-
sion part (1).
9. With the structure in front of you, push from the back
to the front the two fixed bearings (5) on the correct
position until they stop.
LEIL18WHL0698BA 2

10. Install the air spring. Seat pneumatic lift system -
Install - Air-spring (90.124).
48083741_EN 31/07/2018
90.3 [90.124] / 32
11. Install the webbing of the level control on the lower

suspension part.
LEIL18WHL0699AA 3
12. Install the secondary belt on the lower suspension

part.
LEIL18WHL0685AA 4
13. Install the compressor. Seat pneumatic lift system -

Install - Compressor (90.124).
14. Lift down the bellows to the upper suspension part.
Operator seat rubber bellows - Install (90.124).
LEIL18WHL0676AA 5
48083741_EN 31/07/2018
90.3 [90.124] / 33
Seat pneumatic lift system - Remove

1. Push the upper seat part (1) in backward position.
LEIL18WHL0724AA 1
2. Mark the position of the screws (2) located in the front

side of the guides (3).
3. Remove and discard the screws (2).
4. Remove the end stop (5) (if equipped).
LEIL18WHL0534AA 2
5. Mark the position of the screw (2) located in the rear

side of the guides (3).
6. Remove and discard the screws (2).
7. Remove the end stop (7) (if equipped).
LEIL18WHL0543BA 3
48083741_EN 31/07/2018
90.3 [90.124] / 34
8. Lift and hold the upper seat part (1) that is attached to
the seat suspension (4).
NOTE: make sure you do not overstretch the cable harness
(8).
LEIL18WHL0543BA 4
9. Mark the point where the cable harness (8) is attached

to the center cover (6).
10. Cut the cable tie (9).
11. Disconnect the electrical connection between the
socket (10) and the plug (11).
LEIL18WHL0535AA 5
48083741_EN 31/07/2018
90.3 [90.124] / 35
Seat pneumatic lift system - Install

1. Hold the upper seat part (1) on the seat suspension (4).
LEIL18WHL0543BA 1
2. Follows the mark to find the point where the cable har-
ness (8) must be attached to the center cover (6).
3. Connect the electrical connection between the socket
(10) and the plug (11).
4. Lock the cable harness (8) with a cable tie (9).
NOTE: install the cable harness (8) in is correct position to
avoid overstretch.
LEIL18WHL0535AA 2
48083741_EN 31/07/2018
90.3 [90.124] / 36
5. Pull the upper seat part (1) in forward position.
LEIL18WHL0543BA 3
NOTE: follows the indication mark to find the correct posi-

tion of the end stop (7) (if equipped).
6. Install the end stop (7) (if equipped) on the guides (3).
LEIL18WHL0543BA 4
7. Install the screws (2) to attach the upper seat part (1).to
the guides (3).
Tighten the screws (2) to 25.0 N·m (18.4 lb ft).
48083741_EN 31/07/2018
90.3 [90.124] / 37
8. Push the upper seat part (1) in backward position.
LEIL18WHL0543BA 5
NOTE: follows the indication mark to find the correct posi-

tion of the end stop (5) (if equipped).
9. Install the end stop (5) (if equipped) on the guides (3).
LEIL18WHL0534AA 6
10. Install the screws (2) to attach the upper seat part (1)
to the guides (3).
Tighten the screws (2) to 25.0 N·m (18.4 lb ft).
48083741_EN 31/07/2018
90.3 [90.124] / 38
Seat pneumatic lift system - Remove - Air-spring

1. Remove the operator’s seat from the cab. Refer to
Pneumatically-adjusted operator seat - Remove -
Optional premium operator seat - Air suspension,
heated seat (90.124).
2. Remove the bellows. Refer to Operator seat rubber
bellows - Remove (90.124).
NOTE: use a suitable spacer to support the operator's seat structure.

3. Move the seat suspension to the highest position to
remove the air spring (2).
Secure the seat suspension at the rear between the
lifting structure (3) and the lower suspension part (1).
LEIL18WHL0544BA 1
NOTE: vent the pneumatic system before remove the air spring (2).
4. Pull the catch spring (5) out of the air spring (2).
5. Pull to disconnect the two quick couplings (6) of the air
intake hose (7) and the compressed-air hose (8) from
the air spring (2).
LEIL18WHL0806AA 2
48083741_EN 31/07/2018
90.3 [90.124] / 39
6. Loosen the screw (4) on the bottom of the lower sus-

pension part (1).
7. Turn the air spring (2) 90 °C clockwise until the bayonet
fits through the longitudinal hole in the lifting structure
(3).
8. Push the air spring (2) down.
Pull and disengage the air spring (2) from the lifting
structure (3).
LEIL18WHL0807BA 3
9. Remove the air spring (2) from the seat suspension.
48083741_EN 31/07/2018
90.3 [90.124] / 40
Seat pneumatic lift system - Install - Air-spring

1. Move the seat suspension to the highest position and
secure it at the rear between the lifting structure (3) and
the lower suspension part (1).
2. Hold the air spring (2) into the seat suspension.
LEIL18WHL0544BA 1
3. Push the air spring (2) to the lifting structure (3) until
you hear a click.
4. Turn the air spring (2) 90° counterclockwise until the
bayonet fits through the longitudinal hole into the lifting
structure (3).
5. Torque the screw (4) to 6.0 N·m (53.1 lb in).
NOTE: the internal thread collar of the bottom of the air
spring (2) must lie flush in the drill hole of the lower sus-
pension part (1).
LEIL18WHL0807BA 2
48083741_EN 31/07/2018
90.3 [90.124] / 41
6. Connect the two quick couplings (6) of the air intake

hose (7) and the compressed-air hose (8) into the air
spring (2).
7. Lock the catch spring (5).
LEIL18WHL0806AA 3
8. Install the bellows. Refer to Operator seat rubber bel-

lows - Install (90.124).
9. Install the operator’s seat in the cab. Refer to Pneu-
matically-adjusted operator seat - Install - Optional
premium operator seat - Air suspension, heated
seat (90.124).
48083741_EN 31/07/2018
90.3 [90.124] / 42
Operator seat rubber bellows - Remove

1. Remove the 16 bellows pins (3) that attach the upper
suspension part (2) to the bellows (1).
LEIL18WHL0530BA 1
2. Remove the six bellows pins (3) that attach the lower
suspension part (2) to the bellows (1).
3. Lift the bellows (1) over the handle (4) for vertical shock
absorber adjustment.
LEIL18WHL0532BA 2
48083741_EN 31/07/2018
90.3 [90.124] / 43
4. Make sure that the wire insert (5) is not damaged. Re-
place the wire insert (5) if damaged.
LEIL18WHL0531AA 3
48083741_EN 31/07/2018
90.3 [90.124] / 44
Operator seat rubber bellows - Install

1. Install the wire insert (5) in the middle fold of the bellows
(1).
NOTE: the correct position to install the wire insert (5) is
with the welding joint in the front of the bellows (1) (see the
arrow).
LEIL18WHL0531AA 1
2. Lower the bellows (1) from the handle for vertical shock
absorber adjustment (4).
3. Install the six bellows pins (3) that attach the lower sus-
pension part (2) to the bellows (1).
LEIL18WHL0532BA 2
48083741_EN 31/07/2018
90.3 [90.124] / 45
4. Install the 16 bellows pins (3) that attach the upper sus-
pension part (2) to the bellows (1).
LEIL18WHL0530BA 3
48083741_EN 31/07/2018
90.3 [90.124] / 46
Index

Operator seat rubber bellows - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Operator seat rubber bellows - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Pneumatically-adjusted operator seat - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Pneumatically-adjusted operator seat - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Pneumatically-adjusted operator seat - Install - Optional operator seat - Air suspension, heated seat
...................................................................................... 14
Pneumatically-adjusted operator seat - Install - Optional premium operator seat - Air suspension,
heated seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Pneumatically-adjusted operator seat - Remove - Optional operator seat - Air suspension, heated
seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Pneumatically-adjusted operator seat - Remove - Optional premium operator seat - Air suspension,
heated seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Seat pneumatic lift system - Install - Air-spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Seat pneumatic lift system - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Seat pneumatic lift system - Install - Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Seat pneumatic lift system - Install - Lower suspension part . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Seat pneumatic lift system - Install - Upper suspension part . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Seat pneumatic lift system - Overview - Lower suspension part . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Seat pneumatic lift system - Overview - Upper suspension part . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Seat pneumatic lift system - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Seat pneumatic lift system - Remove - Air-spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Seat pneumatic lift system - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Seat pneumatic lift system - Remove - Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Seat pneumatic lift system - Remove - Lower suspension part . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Seat pneumatic lift system - Remove - Upper suspension part . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
48083741_EN 31/07/2018
90.3 [90.124] / 47
48083741_EN 31/07/2018
90.3 [90.124] / 48
Machine shields and guards - 105

48083741_EN 31/07/2018
90.4 [90.105] / 1
Contents
SERVICE
Engine hood
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
48083741_EN 31/07/2018
90.4 [90.105] / 2
Platform, cab, bodywork, and decals - Machine shields and guards
Engine hood - Remove

LOCKED position.
LEIL16WHL0048AB 1
2. Locate the timed disconnect switch (1) and hood raise

switch (2) in the battery box.
Raise the engine hood and put the timed disconnect
RCPH10WHL106AAH 2
3. Double up a nylon lifting strap and slide through the

exhaust stack (1) on the engine hood.
LEIL17WHL0026AB 3
4. Place a solid steel bar or pipe through the strap loop

inside the engine hood and attach the strap to a suitable
lifting device.
Raise the engine hood with the strap to release tension
on the lifting motor.
RAPH12WEL0600AA 4
48083741_EN 31/07/2018
90.4 [90.105] / 3
5. If machine is equipped with a rearview camera, tag and

disconnect the connector (1) of the rearview camera
wire harness (3). Cut the wire ties (2) that hold the
rearview camera wire harness (3) to the rear grill.
LEIL16WHL0849AB 5
6. Cut the wire ties and remove the rearview camera wire
harness from the engine hood.
Place the rearview camera wire harness off to the side
in a safe location.
LEIL13WHL0140AB 6
7. Remove the engine hood wire harness clamp (1) from

the cooler housing.
Tag and remove the engine hood ground wire (2) from
the cooler housing.
8. Tag and disconnect the engine hood connector from the
rear chassis connector (3).
Remove the engine hood wire harness clamp (4) from
the fan guard.
LEIL17WHL0033AB 7
48083741_EN 31/07/2018
90.4 [90.105] / 4
9. Have another person to balance the hood and

LOOSEN the hood hinge mounting bolts (arrows) from
the cooler frame.
NOTE: do not remove the engine hood hinge mounting
bolts at this time.
LEIL17WHL0029AB 8
LEIL17WHL0031AB 9
10. Remove the cotter pin (4) from the clever pin (3) at the
bottom of the lifting motor cylinder (1). Separate the
lifting motor cylinder (1) from the support hood strut
(2).
11. Put the timed disconnect switch to ON position. Then,
retract the lifting motor cylinder (1), and disconnect the
wiring harness (5).
LEIL16WHL1837BB 10
48083741_EN 31/07/2018
90.4 [90.105] / 5
12. Put the timed disconnect switch (1) to OFF position.

Remove the battery cover and disconnect the ground
lead from the batteries (2).
RAPH12WEL0608AA 11
13. Loosen the nuts (arrows) and separate the forward

muffler support bracket (1) from the front muffler sup-
port bracket (2).
LEIL17WHL0030AB 12
14. Remove the bolts and washers (arrows) to unfix the

air intake bracket from the cooler frame.
LEIL17WHL0032AB 13
48083741_EN 31/07/2018
90.4 [90.105] / 6
15. Have another person to balance the hood and re-

move the hood hinge mounting bolts (arrows) from the
cooler frame.
LEIL17WHL0029AB 14
LEIL17WHL0031AB 15
16. Carefully raise and remove the engine hood from the
machine. Lower the engine hood onto a suitable plat-
form and disconnect lifting equipment from the ex-
haust stack.
NOTE: radiator overflow hose may interfere with left-hand
hood hinge movement and engine hood removal.
48083741_EN 31/07/2018
90.4 [90.105] / 7
Engine hood - Install

1. Connect a suitable lifting device to the hood and to the
exhaust stack (1). 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.
LEIL17WHL0026AB 1
2. Have another person to balance the engine hood and

install the engine hood hinge mounting bolts to the
cooler frame.
LEIL17WHL0029AB 2
LEIL17WHL0031AB 3
3. Install the four bolts and washers to fix the air intake
bracket to the cooler frame.
LEIL17WHL0032AB 4
48083741_EN 31/07/2018
90.4 [90.105] / 8
4. Fix the forward muffler support bracket (1) to the front

muffler support bracket (2).
LEIL17WHL0030AB 5
5. Connect the air inlet hose to the air intake bracket with
clamp. Torque the clamp to 3.5 – 4 N·m (2.6 – 3 lb ft).
6. Remove the battery cover and reconnect the ground
lead to batteries (2). Put the timed disconnect switch
(1) to ON position.
RAPH12WEL0608AA 6
48083741_EN 31/07/2018
90.4 [90.105] / 9
7. Connect the wiring harness (5). Extend the lifting mo-

tor cylinder (2) and remove pin from the bottom of the
cylinder. Switch the timed disconnect switch to OFF
position.
8. Install the cotter pin (4) on the clever pin (2) to attach
the lifting motor cylinder (1) to the support hood strut
(2).
Remove the lifting device from the engine hood.
LEIL16WHL1837BB 7
9. Reconnect the engine hood wiring harness to the rear

chassis wiring harness connector (3). Remove tags.
Fix the engine hood wire harness with clamp (4) to the
fan guard.
10. Attach the hood ground wire (2) to the cooler housing.
Then remove marking tags.
Fix the hood ground wire with clamp (1) to the cooler
housing.
LEIL17WHL0033AB 8
11. If machine is equipped with a rear view camera, re-

connect the connector (1) of the rearview camera wire
harness (3). Remove the tag.
Use the wire ties (2) to hold the rearview camera wire
harness (3) to the rear grill.
LEIL16WHL0849AB 9
48083741_EN 31/07/2018
90.4 [90.105] / 10
12. Attach the rearview camera wire harness to the engine

hood (if machine is equipped with a rearview camera).
LEIL13WHL0140AB 10
13. Reconnect the wire harness connector of the rear

lights and remove the marking tags.
14. Switch the timed disconnect switch to ON position.
Lower the engine hood.
48083741_EN 31/07/2018
90.4 [90.105] / 11
Index

Engine hood - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Engine hood - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
48083741_EN 31/07/2018
90.4 [90.105] / 12
48083741_EN 31/07/2018
90.4 [90.105] / 13
PRINTED IN ITALY
48083741_EN 31/07/2018
EN
SPECIAL TOOL INDEX
Genuine Reference PAGE

380001325 [Compressor Belt Engine - Install 10.1 / 26
Tension Checking Tool]
380001560 [Input / Output Powershift transmission - Special tools 21.1 / 3
Shaft Seal Installer]
CAS2798 [Gear Puller Collet Powershift transmission - Special tools 21.1 / 3
Set]
CAS2797 [Eyebolt Lifting Set] Powershift transmission - Special tools 21.1 / 3
CAS2801 [Transmission Powershift transmission - Disassemble 21.1 / 17
Mounting Brackets]
380001577 [Valve Adjustment Powershift transmission - Disassemble 21.1 / 21
Tool Set]
380001285 [Front Housing Powershift transmission - Disassemble 21.1 / 33
Suction Tube Removal Tool]
Lubrication Line Removal
Tool]
CAS2798 [Gear Puller Collet Powershift transmission - Disassemble 21.1 / 35
Set]
Set]
Set]
Set]
Set]
Set]
Set]
Set]
Set]
Set]
Set]
Set]
Set]
Set]
Set]
Set]
380001285 [Front Housing Powershift transmission - Assemble 21.1 / 96
Tool]
48083741_EN 31/07/2018
Tool]
380001560 [Input / Output Powershift transmission - Assemble 21.1 / 103
380001560 [Input / Output Powershift transmission - Assemble 21.1 / 105
380001577 [Valve Adjustment Powershift transmission - Assemble 21.1 / 116
Tool Set]
380100001 [Bearing Cup Bevel gear set and differential carrier - Backlash - Models MT-L 25.2 / 4
Installer ] 3085 II / MT-L 3095 II
CAS2842 [Pinion Locknut Bevel gear set and differential carrier - Backlash - Models MT-L 25.2 / 6
Wrench] 3085 II / MT-L 3095 II
380001546 [Flange Holder] Bevel gear set and differential carrier - Backlash - Models MT-L 25.2 / 6
3085 II / MT-L 3095 II
380100001 [Bearing Cup Bevel gear set and differential carrier - Backlash Model 3105 II 25.2 / 12
Installer ]
CAS2842 [Pinion Locknut Bevel gear set and differential carrier - Backlash Model 3105 II 25.2 / 14
Wrench]
380001564 [Brake Housing Bevel gear set and differential carrier - Backlash Model 3105 II 25.2 / 14
Puller Bridge]
CAS2842 [Pinion Locknut Differential - Remove - MT-L 3095 II 25.2 / 25
Wrench]
380001546 [Flange Holder] Differential - Remove - MT-L 3095 II 25.2 / 25
CAS2842 [Pinion Locknut Differential - Install - Model MT-L 3095 II 25.2 / 27
Wrench]
380001546 [Flange Holder] Differential - Install - Model MT-L 3095 II 25.2 / 27
CAS2841 [Pinion Shaft Seal Differential - Install - Model MT-L 3095 II 25.2 / 27
Installer ]
CAS2842 [Pinion Locknut Differential - Install - Model MT-L 3095 II 25.2 / 28
Wrench]
380001546 [Flange Holder] Differential - Install - Model MT-L 3095 II 25.2 / 28
CAS2842 [Pinion Locknut Differential - Remove Model 3105 II 25.2 / 35
Wrench]
380001546 [Flange Holder] Differential - Remove Model 3105 II 25.2 / 35
CAS2842 [Pinion Locknut Differential - Install Model 3105 II 25.2 / 37
Wrench]
380001564 [Brake Housing Differential - Install Model 3105 II 25.2 / 37
Puller Bridge]
CAS2841 [Pinion Shaft Seal Differential - Install Model 3105 II 25.2 / 37
Installer ]
CAS2842 [Pinion Locknut Differential - Install Model 3105 II 25.2 / 38
Wrench]
380001546 [Flange Holder] Differential - Install Model 3105 II 25.2 / 38
381000106 [PRESSING Wheel hub - Assemble - MT-L 3095 II 25.3 / 18
DEVICE]
381000073 [SEAL RING Wheel hub - Assemble - MT-L 3095 II 25.3 / 18
FITTER]
380100001 [Bearing Cup Bevel gear - Backlash - Models MT-L 3085 II / MT-L 3095 II 27.2 / 4
Installer ]
CAS2842 [Pinion Locknut Bevel gear - Backlash - Models MT-L 3085 II / MT-L 3095 II 27.2 / 6
Wrench]
380001546 [Flange Holder] Bevel gear - Backlash - Models MT-L 3085 II / MT-L 3095 II 27.2 / 6
CAS2842 [Pinion Locknut Differential - Remove - Models MT-L 3085 II / MT-L 3095 II 27.2 / 16
Wrench]
380001546 [Flange Holder] Differential - Remove - Models MT-L 3085 II / MT-L 3095 II 27.2 / 16
CAS2842 [Pinion Locknut Differential - Install - Models MT-L 3085 II / MT-L 3095 II 27.2 / 18
Wrench]
380001546 [Flange Holder] Differential - Install - Models MT-L 3085 II / MT-L 3095 II 27.2 / 18
CAS2841 [Pinion Shaft Seal Differential - Install - Models MT-L 3085 II / MT-L 3095 II 27.2 / 18
Installer ]
48083741_EN 31/07/2018
CAS2842 [Pinion Locknut Differential - Install - Models MT-L 3085 II / MT-L 3095 II 27.2 / 19
Wrench]
380001546 [Flange Holder] Differential - Install - Models MT-L 3085 II / MT-L 3095 II 27.2 / 19
381000106 [PRESSING Wheel hub - Assemble - Models MT-L 3085 II / MT-L 3095 II 27.3 / 18
DEVICE]
381000073 [SEAL RING Wheel hub - Assemble - Models MT-L 3085 II / MT-L 3095 II 27.3 / 18
FITTER]
CAS-10899 [Nitrogen Hydraulic service brakes - Special tools 33.1 / 5
Charging Kit]
380001168 [Nitrogen Hydraulic service brakes - Special tools 33.1 / 5
Accumulator Charging
Adapter]
CAS10280 [75 GPM In-Line Hydraulic service brakes - Special tools 33.1 / 5
Hydraulic Tester]
380001740 [Flowmeter Fitting Hydraulic service brakes - Special tools 33.1 / 5
Kit]
CAS10280 [75 GPM In-Line Brake pump - Test 33.1 / 27
Hydraulic Tester]
380001168 [Nitrogen Accumulator - Discharging 33.1 / 35
Adapter]
CAS-10899 [Nitrogen Accumulator - Discharging 33.1 / 35
Charging Kit]
CAS-10899 [Nitrogen Accumulator - Check 33.1 / 36
Charging Kit]
380001168 [Nitrogen Accumulator - Check 33.1 / 36
Adapter]
CAS-10899 [Nitrogen Accumulator - Charging 33.1 / 37
Charging Kit]
381000106 [PRESSING Brake discs - Assemble - Models MT-L 3085 II / MT-L 3095 II 33.1 / 47
DEVICE]
381000073 [SEAL RING Brake discs - Assemble - Models MT-L 3085 II / MT-L 3095 II 33.1 / 47
FITTER]
CAS1904-1 [Tool Kit] Hydraulic systems - Special tools 35.1 / 3
CAS10280 [75 GPM In-Line Hydraulic systems - Special tools 35.1 / 4
Hydraulic Tester]
380001740 [Flowmeter Fitting Hydraulic systems - Special tools 35.1 / 4
Kit]
5870 287 007 [HD Hand Hydraulic systems - Special tools 35.1 / 4
Pump]
CAS1804 [Pressure Test Hydraulic systems - Special tools 35.1 / 4
Fitting Kit]
CAS10280 [75 GPM In-Line Variable displacement pump - Service instruction - High pressure 35.3 / 10
Hydraulic Tester] pump flow test
5870 287 007 [HD Hand Main control valve - Service instruction - Testing and adjusting 35.4 / 9
Pump] the circuit relief valves
5870 287 007 [HD Hand Main control valve - Assemble 35.4 / 27
Pump]
Pump]
Pump]
CAS10088A [Nitrogen Ride control solenoid valve block - Special tools - Accumulator 35.8 / 5
Accumulator Charging Kit]
CAS10088A [Nitrogen Ride control solenoid valve block - Discharging - Accumulator 35.8 / 30
Accumulator Charging Kit]
48083741_EN 31/07/2018
1288730249 [Hand Pump Articulation frame pivot - Special tools 39.1 / 3
Assembly]
1288730249 [Hand Pump Articulation frame pivot - Disassemble 39.1 / 6
Assembly]
1288730249 [Hand Pump Articulation frame pivot - Install 39.1 / 11
Assembly]
CAS10280 [75 GPM In-Line Hydraulic control components - Special tools 41.2 / 4
Hydraulic Tester]
380001740 [Flowmeter Fitting Hydraulic control components - Special tools 41.2 / 4
Kit]
CAS1804 [Pressure Test Hydraulic control components - Special tools 41.2 / 4
Fitting Kit]
CAS10280 [75 GPM In-Line Auxiliary steering - Test - Pump 41.4 / 9
Hydraulic Tester]
380001740 [Flowmeter Fitting Auxiliary steering - Test - Pump 41.4 / 9
Kit]
380001325 [Compressor Belt Air conditioning - Special tools 50.2 / 3
380001327 [Electronic Leak Air conditioning - Special tools 50.2 / 4
Detector]
380001325 [Compressor Belt Air-conditioning compressor - Install 50.2 / 30
OEM Reference PAGE
OEM1598 [A/C Refrigerant Air conditioning - Special tools 50.2 / 4
Recovery Station - Clean
(Same as OEM1415)]
OEM1598 [A/C Refrigerant Air conditioning - Charging 50.2 / 18
Recovery Station - Clean
(Same as OEM1415)]
Kit Reference PAGE
CAS10162A [Portable Filter Hydraulic systems - Special tools 35.1 / 3
Caddy]
CAS10192 [Vacuum Pump] Hydraulic systems - Special tools 35.1 / 3
CAS10508 [Fitting Kit For Hydraulic systems - Special tools 35.1 / 3
Unions]
CAS10192 [Vacuum Pump] Electro-hydraulic control valve - Remove 35.6 / 4
CAS10192 [Vacuum Pump] Electro-hydraulic control valve - Remove 35.6 / 4
CAS10192 [Vacuum Pump] Electro-hydraulic control valve - Install 35.6 / 11
CAS10192 [Vacuum Pump] Electro-hydraulic control valve - Install 35.6 / 11
380001737 [Nitrogen Ride control solenoid valve block - Special tools - Accumulator 35.8 / 5
Charging Kit With High
Pressure Regulator And
Hoses Complete]
380001737 [Nitrogen Ride control solenoid valve block - Discharging - Accumulator 35.8 / 30
Charging Kit With High
Pressure Regulator And
Hoses Complete]
CAS10193 [ Kit For Vacuum Articulation frame pivot - Special tools 39.1 / 3
Pump]
CAS10193 [ Kit For Vacuum Articulation frame pivot - Disassemble 39.1 / 5
Pump]
CAS10193 [ Kit For Vacuum Articulation frame pivot - Disassemble 39.1 / 5
Pump]
48083741_EN 31/07/2018
48083741_EN 31/07/2018
PRINTED IN ITALY
48083741_EN 31/07/2018
EN

Case 821F Service Manual

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Case 821F Service Manual

Uploaded by

Copyright:

Available Formats

stuart pope

sp mechanical services ltd

1/2 SERVICE MANUAL

Part number 48083741

821G ZBAR - EH, NEW CAB TIER2

[10.202] Air cleaners and lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.2

[10.400] Engine cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3

[10.414] Fan and drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.4

[10.310] Aftercooler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.5

[10.304] Engine lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.6

[21.155] Powershift transmission internal components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.2

[21.700] Torque converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.3

Four-Wheel Drive (4WD) system .................................................. 23

Front axle system ....................................................................... 25

[25.102] Front bevel gear set and differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.2

[25.108] Final drive hub, steering knuckles, and shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.3

Rear axle system........................................................................ 27

[27.106] Rear bevel gear set and differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27.2

[27.120] Planetary and final drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27.3

Brakes and controls .................................................................... 33

[33.110] Parking brake or parking lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33.2

[35.300] Reservoir, cooler, and filters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.2

[35.106] Variable displacement pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.3

[35.359] Main control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.4

[35.357] Pilot system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.5

[35.204] Remote control valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.6

[35.752] Hydraulic fan drive cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.7

[35.701] Front loader arm hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.8

[35.723] Front loader bucket hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.9

[35.734] Tool quick coupler hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.10

Frames and ballasting ................................................................. 39

[41.200] Hydraulic control components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.2

[41.216] Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.3

[41.910] Auxiliary steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.4

[44.520] Rear wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.2

Cab climate control ..................................................................... 50

[50.200] Air conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50.2

Electrical systems ....................................................................... 55

[55.301] Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.2

[55.302] Battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.3

[55.512] Cab controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.4

[55.415] Loader arm and bucket control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.6

[55.530] Camera. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.7

[55.DTC] FAULT CODES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.8

Front loader and bucket............................................................... 82

[82.300] Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82.2

Platform, cab, bodywork, and decals ............................................. 90

[90.120] Mechanically-adjusted operator seat. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.2

[90.124] Pneumatically-adjusted operator seat. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.3

[90.105] Machine shields and guards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.4

FAILURE TO FOLLOW DANGER, WARNING, AND CAUTION MESSAGES COULD RESULT

Repairs have to be carried out only by authorized and in-

Non-authorized persons are not allowed to repair or carry

Ask your employer about the safety instructions in force

Nobody should be allowed in the cab during machine

If it is necessary to move the equipment to carry out re-

Stop the engine and ensure that all pressure is relieved

All repair and maintenance operations should be carried

Service stairs and platforms used in a workshop or in the

Before performing any work on the machine, attach a

If working conditions require, the following personal safety

• Ear plugs or acoustic ears protections

Do not wear rings, wristwatches, jewelry, unbuttoned or