SM 695ST T4b 48090752

SERVICE MANUAL
580ST 580ST
590ST 590ST
695ST 695ST
Stage IV Stage IV
Tractor Backhoe Loader Tractor Backhoe Loader
SERVICE MANUAL
Part number 48090752
Part number 48090752

English
February 2017
© 2017 CNH Industrial America LLC. All Rights Reserved.

SERVICE MANUAL
580ST STAGE IV, SIDE-SHIFT (SS), FOUR-WHEEL DRIVE (4WD), MARBLE

CUTTING, 580ST STAGE IV, STRAIGHT LOADER ARM (SLA), SIDE SHIFT
(SS), FOUR-WHEEL DRIVE (4WD), 580ST STAGE IV, TOOL CARRIER (TC),
SIDE SHIFT (SS), TWO-WHEEL DRIVE (2WD), 590ST STAGE IV, TOOL
CARRIER (TC), SIDE SHIFT (SS), FOUR-WHEEL DRIVE (4WD), 695ST STAGE
IV, SIDE-SHIFT (SS), FOUR-WHEEL DRIVE (4WD), MARBLE CUTTING, 695ST
STAGE IV, TOOL CARRIER (TC), CENTER PIVOT (CP), 695ST STAGE IV, TOOL
CARRIER (TC), SIDE SHIFT (SS)
48090752 24/02/2017
EN
Link Product / Engine
Product Market Product Engine

580ST STAGE IV, SIDE-SHIFT Europe F5BFL413B*C002
(SS), FOUR-WHEEL DRIVE
(4WD), MARBLE CUTTING
580ST STAGE IV, STRAIGHT Europe F5BFL413B*C002
LOADER ARM (SLA), SIDE SHIFT
(4WD)
580ST STAGE IV, TOOL Europe F5BFL413B*C002
CARRIER (TC), SIDE SHIFT
(SS), TWO-WHEEL DRIVE (2WD)
590ST STAGE IV, TOOL Europe F5BFL413A*B001
CARRIER (TC), SIDE SHIFT
(4WD)
695ST STAGE IV, TOOL CARRIER Europe F5BFL413A*B001
(TC), CENTER PIVOT (CP)
695ST STAGE IV, SIDE-SHIFT Europe F5BFL413A*B001
(4WD), MARBLE CUTTING
695ST STAGE IV, TOOL CARRIER Europe F5BFL413A*B001
(TC), SIDE SHIFT (SS)
48090752 24/02/2017
Contents
INTRODUCTION
Engine....................................................................................... 10
[10.001] Engine and crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.1
[10.216] Fuel tanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.2
[10.206] Fuel filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3
[10.218] Fuel injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.4
[10.500] Selective Catalytic Reduction (SCR) exhaust treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.5
[10.400] Engine cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.6
[10.414] Fan and drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.7
Power coupling........................................................................... 19
[19.100] Drive shaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.1
Transmission.............................................................................. 21
[21.112] Power shuttle transmission. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.1
[21.134] Power shuttle transmission external controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.2
[21.154] Power shuttle transmission internal components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.3
[21.113] Powershift transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.4
[21.135] Powershift transmission external controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.5
[21.105] Powershift transmission hydraulic components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.6
[21.155] Powershift transmission internal components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.7
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
[25.400] Non-powered front axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.4
Rear axle system........................................................................ 27

[27.100] Powered rear axle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27.1
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[27.106] Rear bevel gear set and differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27.2
[27.120] Planetary and final drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27.3
[27.450] Rear-powered steerable axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27.4
Brakes and controls .................................................................... 33

[33.202] Hydraulic service brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33.1
[33.110] Parking brake or parking lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33.2
Hydraulic systems....................................................................... 35
[35.000] Hydraulic systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.1
[35.300] Reservoir, cooler, and filters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.2
[35.104] Fixed displacement pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.3
[35.106] Variable displacement pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.4
[35.102] Pump control valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.5
[35.350] Safety and main relief valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.6
[35.357] Pilot system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.7
[35.128] Auxiliary hydraulic function control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.8
[35.355] Hydraulic hand control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.9
[35.352] Hydraulic swing system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.10
[35.724] Front loader hydraulic system control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.11
[35.701] Front loader arm hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.12
[35.723] Front loader bucket hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.13
[35.726] Excavator and backhoe hydraulic controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.14
[35.736] Boom hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.15
[35.737] Dipper hydraulic system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.16
[35.738] Excavator and backhoe bucket hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.17
[35.739] Swing arm hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.18
[35.703] Stabilizer hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.19
[35.740] Telescopic arm hydraulic system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.20
Frames and ballasting ................................................................. 39
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[39.100] Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39.1
[39.140] Ballasts and supports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39.2
Steering..................................................................................... 41
[41.101] Steering control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.1
[41.106] Tie rods. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.2
[41.200] Hydraulic control components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.3
[41.216] Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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
[50.104] Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50.2
[50.200] Air conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50.3
Electrical systems ....................................................................... 55

[55.100] Harnesses and connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.1
[55.301] Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.2
[55.302] Battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.3
[55.011] Fuel tank system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.4
[55.012] Engine cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.5
[55.640] Electronic modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.6
[55.512] Cab controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.7
[55.991] Telematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.8
[55.DTC] FAULT CODES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.9
Front loader and bucket............................................................... 82

[82.100] Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82.1
[82.300] Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82.2
Booms, dippers, and buckets ....................................................... 84
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[84.114] Boom pivoting support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84.1
[84.910] Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84.2
[84.912] Dipper arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84.3
[84.100] Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84.4
Platform, cab, bodywork, and decals ............................................. 90

[90.105] Machine shields and guards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.1
48090752 24/02/2017
INTRODUCTION
48090752 24/02/2017
1
Contents
INTRODUCTION
Foreword - Important notice regarding equipment servicing (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Safety rules (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Safety rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Safety rules - Specific precautions to this machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Safety rules - Ductile iron . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Safety rules - Ecology and the environment (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Basic instructions - Support strut for loader lift arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Basic instructions - Engine hood . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Basic instructions - Organic Acid Technology (OAT) coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Torque - Minimum tightening torques for normal assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Torque - Standard torque data for hydraulic connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Torque - Hydraulic fittings and connectors - standard install procedures . . . . . . . . . . . . . . . . . . . . . 37
Basic instructions - Shop and assembly (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Swing tower - Basic instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Abbreviation Measurements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Capacities - 580ST and 590ST (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Capacities - 695ST (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
General specification - Diesel fuel (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
General specification - Biodiesel fuels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Recommended engine oil for operating temperature ranges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Consumables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Hydraulic contamination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
General specification - Hydraulic system component specifications . . . . . . . . . . . . . . . . . . . . . . . . . 59
General specification - Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Bucket - General specification - Front loader bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Bucket - General specification - Backhoe bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Product identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Component identification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
(*) See content for specific models

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2
INTRODUCTION
Foreword - Important notice regarding equipment servicing

580ST
590ST
695ST
All repair and maintenance work listed in this manual must be carried out only by qualified dealership personnel,
strictly complying with the instructions given, and using, whenever possible, the special tools.
Anyone who performs repair and maintenance operations without complying with the procedures provided herein
shall be responsible for any subsequent damages.
The manufacturer and all the organizations of its distribution chain, including - without limitation - national, regional, or
local dealers, reject any responsibility for damages caused by parts and/or components not approved by the manu-
facturer, including those used for the servicing or repair of the product manufactured or marketed by the manufacturer.
In any case, no warranty is given or attributed on the product manufactured or marketed by the manufacturer in case
of damages caused by parts and/or components not approved by the manufacturer.
The manufacturer reserves the right to make improvements in design and changes in specifications at any time without
notice and without incurring any obligation to install them on units previously sold. Specifications, descriptions, and
illustrative material herein are as accurate as known at time of publication but are subject to change without notice.
In case of questions, refer to your CASE CONSTRUCTION Sales and Service Networks.
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INTRODUCTION
Safety rules
580ST
590ST
695ST
Personal safety
This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all
safety messages that follow this symbol to avoid possible death or injury.
Throughout this manual you will find the signal words DANGER, WARNING, and CAUTION followed by special in-
structions. These precautions are intended for the personal safety of you and those working with you.
Read and understand all the safety messages in this manual before you operate or service the machine.
DANGER indicates a hazardous situation that, if not avoided, will result in death or serious injury.
WARNING indicates a hazardous situation that, if not avoided, could result in death or serious injury.
CAUTION indicates a hazardous situation that, if not avoided, could result in minor or moderate injury.
FAILURE TO FOLLOW DANGER, WARNING, AND CAUTION MESSAGES COULD RESULT

IN DEATH OR SERIOUS INJURY.
Machine safety
NOTICE: Notice indicates a situation that, if not avoided, could result in machine or property damage.
Throughout this manual you will find the signal word Notice followed by special instructions to prevent machine or
property damage. The word Notice is used to address practices not related to personal safety.
Information
NOTE: Note indicates additional information that clarifies steps, procedures, or other information in this manual.
Throughout this manual you will find the word Note followed by additional information about a step, procedure, or
other information in the manual. The word Note is not intended to address personal safety or property damage.
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INTRODUCTION
Safety rules
General safety rules
Use caution when you operate the machine on slopes. Raised equipment, full tanks and other loads will change the
center of gravity of the machine. The machine can tip or roll over when near ditches and embankments or uneven
surfaces.
Never permit anyone other than the operator to ride on the machine.
Never operate the machine under the influence of alcohol or drugs, or while you are otherwise impaired.
When digging or using ground-engaging attachments, be aware of buried cables. Contact local utilities to determine
the locations of services.
Pay attention to overhead power lines and hanging obstacles. High voltage lines may require significant clearance
for safety.
Hydraulic oil or diesel fuel leaking under pressure can penetrate the skin, causing serious injury or infection.
• DO NOT use your hand to check for leaks. Use a piece of cardboard or paper.
• Stop the engine, remove the key, and relieve the pressure before you connect or disconnect fluid lines.
• Make sure that all components are in good condition. Tighten all connections before you start the engine or pres-
surize the system.
• If hydraulic fluid or diesel fuel penetrates the skin, seek medical attention immediately.
• Continuous long term contact with hydraulic fluid may cause skin cancer. Avoid long term contact and wash the
skin promptly with soap and water.
Keep clear of moving parts. Loose clothing, jewelry, watches, long hair, and other loose or hanging items can become
entangled in moving parts.
Wear protective equipment when appropriate.
DO NOT attempt to remove material from any part of the machine while it is being operated or while components are
in motion.
Make sure that all guards and shields are in good condition and properly installed before you operate the machine.
Never operate the machine with shields removed. Always close access doors or panels before you operate the ma-
chine.
Dirty or slippery steps, ladders, walkways, and platforms can cause falls. Make sure these surfaces remain clean and
clear of debris.
A person or pet within the operating area of a machine can be struck or crushed by the machine or its equipment. DO
NOT allow anyone to enter the work area.
Raised equipment and/or loads can fall unexpectedly and crush persons underneath. Never allow anyone to enter
the area underneath raised equipment during operation.
Never operate the engine in enclosed spaces as harmful exhaust gases may build up.
Before you start the machine, be sure that all controls are in neutral or park lock position with the backhoe swing lock
pin in the lock position. The backhoe swing lock pin must be in the lock position when you are not using the backhoe.
Start the engine only from the operator’s seat. If you bypass the safety start switch, the engine can start with the
transmission in gear. Do not connect or short across terminals on the starter solenoid. Attach jumper cables as
described in the manual. Starting in gear may cause death or serious injury.
Always keep windows, mirrors, all lighting, and Slow-Moving Vehicle (SMV) emblem clean to provide the best possible
visibility while you operate the machine.
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INTRODUCTION
Operate controls only when seated in the operator’s seat, except for those controls expressly intended for use from
other locations.
From the operator's platform, install the backhoe swing lock pin when the backhoe is not in use and before all other
operation.
Before you leave the machine:

1. Park the machine on a firm, level surface.
2. Put all controls in neutral or park lock position.
3. Engage the parking brake. Use wheel chocks if required.
4. Lower the loader bucket or other front attachment to the ground.
5. Move the operator’s seat to the backhoe operating position and choose one of the following backhoe positions:
• Move the backhoe into the stowed position and from the operator's seat install the backhoe swing lock pin. See
Swing tower - Basic instructions () .
• Lower the backhoe bucket or other attachment to the ground.
6. Turn off the engine and remove the key.
7. Move the operator’s seat into the driving position.
When, due to exceptional circumstances, you decide to keep the engine running after you leave the operator’s station,
then you must follow these precautions:
1. Bring the engine to low idle speed.

2. Disengage all drive systems.
WARNING
Some components may continue to run down after you disengage drive systems.
Make sure all drive systems are fully disengaged.
Failure to comply could result in death or serious injury.
W0113A
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INTRODUCTION
3. Move the operator’s seat to the backhoe operating position and choose one of the following backhoe positions:
○ Move the backhoe into the stowed position and from the operator's seat install the backhoe swing lock pin. See
Swing tower - Basic instructions () .
○ Lower the backhoe bucket or other attachment to the ground.
4. Shift the transmission into neutral.
5. Apply the parking brake.
General maintenance safety
Do not attempt to clean, lubricate, clear obstructions, or make adjustments to the machine while it is in motion or while
the engine is running.
Keep the area used for servicing the machine clean and dry. Clean up spilled fluids.
Service the machine on a firm, level surface.
Install guards and shields after you service the machine.
Close all access doors and install all panels after servicing the machine.
Always make sure that working area is clear of tools, parts, other persons and pets before you start operating the
machine.
Unsupported hydraulic cylinders can lose pressure and drop the equipment, causing a crushing hazard. Do not leave
equipment in a raised position while parked or during service, unless the equipment is securely supported.
Jack or lift the machine only at jack or lift points indicated in this manual.
Incorrect towing procedures can cause accidents. When you tow a disabled machine follow the procedure in this
manual. Use only rigid tow bars.
Stop the engine, remove the key, and relieve pressure before you connect or disconnect fluid lines.
Stop the engine and remove the key before you connect or disconnect electrical connections.
Scalding can result from incorrect removal of coolant caps. Cooling systems operate under pressure. Hot coolant can
spray out if you remove a cap while the system is hot. Allow the system to cool before you remove the cap. When
you remove the cap, turn it slowly to allow pressure to escape before you completely remove the cap.
Replace damaged or worn tubes, hoses, electrical wiring, etc.
The engine, transmission, exhaust components, and hydraulic lines may become hot during operation. Take care
when you service such components. Allow surfaces to cool before you handle or disconnect hot components. Wear
protective equipment when appropriate.
When welding, follow the instructions in the manual. Always disconnect the battery before you weld on the machine.
Always wash your hands after you handle battery components.
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Wheels and tires
Make sure that tires are correctly inflated. Do not exceed any recommended load or pressure. Follow the instructions
in the manual for proper tire inflation.
Tires are heavy. Handling tires without proper equipment could cause death or serious injury.
Never weld on a wheel with a tire installed. Always remove the tire completely from the wheel prior to welding.
Always have a qualified tire technician service the tires and wheels. If a tire has lost all pressure, take the tire and
wheel to a tire shop or your dealer for service. Explosive separation of the tire can cause serious injury.
DO NOT weld to a wheel or rim until the tire is completely removed. Inflated tires can generate a gas mixture with
the air that can be ignited by high temperatures from welding procedures performed on the wheel or rim. Removing
the air or loosening the tire on the rim (breaking the bead) will NOT eliminate the hazard. This condition can exist
whether tires are inflated or deflated. The tire MUST be completely removed from the wheel or rim prior to welding
the wheel or rim.
Driving on public roads and general transportation safety
Comply with local laws and regulations.
Make sure that the backhoe swing lock pin is in the lock position. See Swing tower - Basic instructions () for more
information.
Use appropriate lighting to meet local regulations.
Make sure that the Slow-Moving Vehicle (SMV) emblem is visible.
Make sure that the brake pedal latch is engaged. You must lock brake pedals together for road travel.
Use safety chains for trailed equipment when safety chains are provided with machine or equipment.
Lift implements and attachments high enough above ground to prevent accidental contact with road.
When you transport equipment or a machine on a transport trailer, make sure that it is properly secured. Be sure the
Slow-Moving Vehicle (SMV) on the equipment or machine is covered while being transported on a trailer.
Be aware of overhead structures or power lines and make sure that the machine and/or attachments can pass safely
under.
Travel speed should be such that you maintain complete control and machine stability at all times.
Slow down and signal before turning.
Pull over to allow faster traffic to pass.
Follow correct towing procedure for equipment with or without brakes.
Fire and explosion prevention
Fuel or oil that is leaked or spilled on hot surfaces or electrical components can cause a fire.
Crop materials, trash, debris, bird nests, or flammable material can ignite on hot surfaces.
Always have a fire extinguisher on or near the machine.
Make sure that the fire extinguisher(s) is maintained and serviced according to the manufacturer’s instructions.
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INTRODUCTION
At least once each day and at the end of the day, remove all trash and debris from the machine especially around hot
components such as the engine, transmission, exhaust, battery, etc. More frequent cleaning of your machine may be
necessary depending on the operating environment and conditions.
At least once each day, remove debris accumulation around moving components such as bearings, pulleys, belts,
gears, cleaning fans, etc. More frequent cleaning of your machine may be necessary depending on the operating
environment and conditions.
Inspect the electrical system for loose connections and frayed insulation. Repair or replace loose or damaged parts.
Do not store oily rags or other flammable material on the machine.
Do not weld or flame cut any items that contain flammable material. Clean items thoroughly with non-flammable
solvents before welding or flame-cutting.
Do not expose the machine to flames, burning brush, or explosives.
Promptly investigate any unusual smells or odors that may occur during operation of the machine.
General battery safety
Always wear eye protection when you work with batteries.
Do not create sparks or have open flame near a battery.
Ventilate the area when you charge a battery or use a battery in an enclosed area.
Disconnect the negative (-) terminal first and reconnect the negative (-) terminal last.
When you weld on the machine, disconnect both terminals of the battery.
Do not weld, grind, or smoke near a battery.
When you use auxiliary batteries or connect jumper cables to start the engine, use the procedure shown in the oper-
ator’s manual. Do not short across terminals.
Follow the manufacturer’s instructions when you store and handle batteries.
Battery post, terminals, and related accessories contain lead and lead compounds. Wash hands after handling.
Battery acid causes burns. Batteries contain sulfuric acid. Avoid contact with skin, eyes, or clothing. Antidote (ex-
ternal): 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 immedi-
ately.
Keep out of reach of children and other unauthorized persons.
Reflectors and warning lights
You must use flashing amber warning lights when you operate equipment on public roads.
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INTRODUCTION
Seat belts
Seat belts must be worn at all times.
Seat belt inspection and maintenance:

• Keep seat belts in good condition.
• Keep sharp edges and items than can cause damage away from the belts.
• Periodically check belts, buckles, retractors, tethers, slack take-up system, and mounting bolts for damage and
wear.
• Replace all parts that have damage or wear.
• Replace belts that have cuts that can make the belt weak.
• Check that bolts are tight on the seat bracket or mounting.
• If the belt is attached to the seat, make sure that the seat or seat brackets are mounted securely.
• Keep seat belts clean and dry.
• Clean belts only with soap solution and warm water.
• Do not use bleach or dye on the belts because this can make the belts weak.
Fasten/release
1. Pull the right-hand belt strap from the retractor.
2. Insert the metal end into the latch mechanism of the
left-hand side of the seat.
RAIL14UTL0054BA 1
3. To release, press the red button on the latch mecha-

nism. The seat belt will automatically retract.
RAIL14UTL0054BA 2
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INTRODUCTION
Operator protective structure
Your machine is equipped with an operator protective structure, such as: a Roll Over Protective Structure (ROPS),
Falling Objects Protective Structure (FOPS), or a cab with a ROPS. A ROPS may be a can frame or a two-posted or
four-posted structure used for the protection of the operator to minimize the possibility of serious injury. The mounting
structure and fasteners forming the mounting connection with the machine are part of the ROPS.
The protective structure is a special safety component of your machine.
DO NOT attach any device to the protective structure for pulling purposes. DO NOT drill holes to the protective
structure.
The protective structure and interconnecting components are a certified system. Any damage, fire, corrosion, or
modification will weaken the structure and reduce your protection. If this occurs, THE PROTECTIVE STRUCTURE
MUST BE REPLACED so that it will provide the same protection as a new protective structure. Contact your dealer
for protective structure inspection and replacement.
After an accident, fire, tip over, or roll over, the following MUST be performed by a qualified technician before
returning the machine to field or job-site operations:
• The protective structure MUST BE REPLACED.
• The mounting or suspension for the protective structure, operator’s 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, DRILL HOLES, ATTEMPT TO STRAIGHTEN, OR REPAIR THE PROTECTIVE STRUCTURE. MOD-
IFICATION IN ANY WAY CAN REDUCE THE STRUCTURAL INTEGRITY OF THE STRUCTURE, WHICH COULD
CAUSE DEATH OR SERIOUS INJURY IN THE EVENT OF FIRE, TIP OVER, ROLL OVER, COLLISION, OR ACCI-
DENT.
Seat belts are part of your protective system and must be worn at all times. The operator must be held to the seat
inside the frame in order for the protective system to work.
Backup alarm system
The audible backup alarm system notifies others in the area that the machine will be or is moving in reverse
Place the directional lever in the reverse travel position and an audible alarm will sound repeatedly until the operator
moves the directional lever into the neutral position or the forward travel position.
Personal Protective Equipment (PPE)
Wear Personal Protective Equipment (PPE) such as hard hat, eye protection, heavy gloves, hearing protection, pro-
tective clothing, etc.
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INTRODUCTION
DCAPLT5NE020S2A 3
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INTRODUCTION
Do Not Operate tag
Before you start servicing the machine, attach a ‘Do Not Operate’ warning tag to the machine in an area that will be
visible.
RH99E029 4
Hazardous chemicals
If you are exposed to or come in contact with hazardous chemicals you can be seriously injured. The fluids, lubricants,
paints, adhesives, coolant, etc. required for the function of your machine can be hazardous. They may be attractive
and harmful to domestic animals as well as humans.
Material Safety Data Sheets (MSDS) provide information about the chemical substances within a product, safe han-
dling and storage procedures, first aid measures, and procedures to take in the event of a spill or accidental release.
MSDS are available from your dealer.
Before you service your machine check the MSDS for each lubricant, fluid, etc. used in this machine. This information
indicates the associated risks and will help you service the machine safely. Follow the information in the MSDS, and
on manufacturer containers, as well as the information in this manual, when you service the machine.
Dispose of all fluids, filters, and containers in an environmentally safe manner according to local laws and regulations.
Check with local environmental and recycling centers or your dealer for correct disposal information.
Store fluids and filters in accordance with local laws and regulations. Use only appropriate containers for the storage
of chemicals or petrochemical substances.
Keep out of reach or children or other unauthorized persons.
Applied chemicals require additional precautions. Obtain complete information from the manufacturer or distributor
of the chemicals before you use them.
Utility safety
When digging or using ground-engaging equipment, be aware of buried cables and other services. Contact your local
utilities or authorities, as appropriate, to determine the locations of services.
Make sure that the machine has sufficient clearance to pass in all directions. Pay special attention to overhead power
lines and hanging obstacles. High voltage lines may require significant clearance for safety. Contact local authorities
or utilities to obtain safe clearance distances from high voltage power lines.
Retract raised or extended components, if necessary. Remove or lower radio antennas or other accessories. Should
a contact between the machine and an electric power source occur, the following precautions must be taken:
• Stop the machine movement immediately.
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INTRODUCTION
• Apply the parking brake, stop the engine, and remove the key.
• Check if you can safely leave the cab or your actual position without contact with electrical wires. If not, stay in your
position and call for help. If you can leave your position without touching lines, jump clear of the machine to make
sure that you do not make contact with the ground and the machine at the same time.
• Do not permit anyone to touch the machine until power has been shut off to the power lines.
Electrical storm safety
Do not operate machine during an electrical storm.
If you are on the ground during an electrical storm, stay away from machinery and equipment. Seek shelter in a
permanent, protected structure.
If an electrical storm should strike during operation, remain in the cab. Do not leave the cab or operator’s platform.
Do not make contact with the ground or objects outside the machine.
Mounting and dismounting
Mount and dismount the machine only at designated locations that have handholds, steps, and/or or ladders.
Do not jump off of the machine.
Make sure that steps, ladders, and platforms remain clean and clear of debris and foreign substances. Injury may
result from slippery surfaces.
Face the machine when you mount and dismount the machine.
Maintain a three-point contact with steps, ladders, and handholds.
Never mount or dismount from a moving machine.
Do not use the steering wheel or other controls or accessories as handholds when you enter or exit the cab or oper-
ator’s platform.
Working at heights
When the normal use and maintenance of the machine requires you to work at heights:
• Correctly use installed steps, ladders, and railings.
• Never use ladders, steps, or railings while the machine is moving.
• Do not stand on surfaces that are not designated as steps or platforms.
Do not use the machine as a lift, ladder, or platform for working at heights.
Lifting and overhead loads
Never use loader buckets, forks, etc. or other lifting, handling, or digging equipment to lift persons.
Do not use raised equipment as a work platform.
Know the full area of movement of the machine and equipment and do not enter or permit anyone to enter the area
of movement while the machine is in operation.
Never enter or permit anyone to enter the area underneath raised equipment. Equipment and/or loads can fall unex-
pectedly and crush persons underneath it.
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INTRODUCTION
Do not leave equipment in raised position while parked or during service, unless securely supported. Hydraulic cylin-
ders must be mechanically locked or supported if they are left in a raised position for service or access.
Loader buckets, forks, etc. or other lifting, handling, or digging equipment and its load will change the center of gravity
of the machine. This can cause the machine to tip on slopes or uneven ground.
Load items can fall off the loader bucket or lifting equipment and crush the operator. Care must be taken when lifting
a load. Use proper lifting equipment.
Do not lift load higher than necessary. Lower loads to transport. Remember to leave appropriate clearance to the
ground and other obstacles.
Equipment and associated loads can block visibility and cause an accident. Do not operate with insufficient visibility.
Keep the load or tool as low as possible while moving the machine around the work site.
Release all hydraulic pressure before servicing the machine.
You must know which circuits have accumulators and how to release pressure properly.
Always use the lift arm support strut when servicing the machine with lift arms up.
Air-conditioning system
• The air-conditioning system is under high pressure. Do not disconnect any lines. The release of high pressure can
cause serious injury.
• The air-conditioning system contains gases that are harmful to the environment when released into the atmosphere.
Do not attempt to service or repair the system.
• Only trained service technicians can service, repair, and recharge the air-conditioning system.
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INTRODUCTION
Safety rules - Specific precautions to this machine
• From the operator's platform, install the backhoe swing lock pin when the backhoe is not in use and before all other
operation.
• When traveling on the road or working with the front loader keep the backhoe in the stowed position.
• Keep operator's platform clean. Never transport items in the operator's platform.
• Keep the load or tool as low as possible while moving the machine around the work site.
• Adjust the rear window before actuating the backhoe hydraulics. The rear window could come into contact with the
control lever.
• Pilot control machines are equipped with two backhoe control patterns. You must know which pattern the machine
is in, before operating the machine (actuating the hydraulics).
• Release all hydraulic pressure before servicing the machine.
• You must know which circuits have accumulators and how to release pressure properly.
• Always use the lift arm support strut when servicing the machine with lift arms up.
When using the backhoe:

• Position the stabilizer pads for maximum stability.
• Install a guard rail and warning signs to keep other persons away from the machine if operating in an area with
reduced visibility, such as a building.
• Place the direction control lever and the transmission in neutral and apply the parking brake before turning the
operator's seat around to the backhoe position.
• Ensure the seat is locked into position.
• Know which control pattern is engaged before actuating the hydraulics (pilot control machines only).
• Use caution when swinging the backhoe completely to the side to prevent contact with the stabilizers.
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INTRODUCTION
Safety rules - Ductile iron
DANGER
Altering cast ductile iron can cause it to weaken or break.
Before you weld, cut, or drill holes on any part of this machine, make sure that the part is not cast
ductile iron.
Failure to comply will result in death or serious injury.
D0148A
Altering cast ductile iron can cause it to weaken or break. Unauthorized modifications to cast ductile iron parts can
cause death or serious injury. Do not weld, cut, drill, repair, or attach items to cast ductile iron parts on this machine.
Before you weld, cut, or drill holes on any part of this machine, make sure that the part is not cast ductile iron. See
your dealer if you do not know if a part is cast ductile iron.
The following items are examples of cast ductile iron parts. There may also be other parts made of cast ductile
iron that are not on the list below.
• Two-wheel drive steering link
• Front axle
• Swing tower
• Air-Conditioning (A/C) compressor mounting bracket
Do not make any unauthorized modifications. Consult an authorized dealer before making any changes, additions,
or modifications to this machine.
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INTRODUCTION
Safety rules - Ecology and the environment

580ST
590ST
695ST
Soil, air, and water quality is important for all industries and life in general. When legislation does not yet rule the
treatment of some of the substances that advanced technology requires, sound judgment should govern the use and
disposal of products of a chemical and petrochemical nature.
Familiarize yourself with the relative legislation applicable to your country, and make sure that you understand this
legislation. Where no legislation exists, obtain information from suppliers of oils, filters, batteries, fuels, anti-freeze,
cleaning agents, etc., with regard to the effect of these substances on man and nature and how to safely store, use,
and dispose of these substances.
Helpful hints
• Avoid the use of cans or other inappropriate pressurized fuel delivery systems to fill tanks. Such delivery systems
may cause considerable spillage.
• In general, avoid skin contact with all fuels, oils, acids, solvents, etc. Most of these products contain substances
that may be harmful to your health.
• Modern oils contain additives. Do not burn contaminated fuels and or waste oils in ordinary heating systems.
• Avoid spillage when you drain fluids such as used engine coolant mixtures, engine oil, hydraulic fluid, brake fluid,
etc. Do not mix drained brake fluids or fuels with lubricants. Store all drained fluids safely until you can dispose of
the fluids in a proper way that complies with all local legislation and available resources.
• Do not allow coolant mixtures to get into the soil. Collect and dispose of coolant mixtures properly.
• The air-conditioning system contains gases that should not be released into the atmosphere. Consult an air-condi-
tioning specialist or use a special extractor to recharge the system properly.
• Repair any leaks or defects in the engine cooling system or hydraulic system immediately.
• Do not increase the pressure in a pressurized circuit as this may lead to a component failure.
• Protect hoses during welding. Penetrating weld splatter may burn a hole or weaken hoses, allowing the loss of oils,
coolant, etc.
Battery recycling
Batteries and electric accumulators contain several substances that can have a harmful
effect on the environment if the batteries are not properly recycled after use. Improper
disposal of batteries can contaminate the soil, groundwater, and waterways. CASE
CONSTRUCTION strongly recommends that you return all used batteries to a CASE
CONSTRUCTION dealer, who will dispose of the used batteries or recycle the used
batteries properly. In some countries, this is a legal requirement.
Mandatory battery recycling

NOTE: The following requirements are mandatory in Brazil.
Batteries are made of lead plates and a sulfuric acid solution. Because batteries contain heavy metals such as lead,
CONAMA Resolution 401/2008 requires you to return all used batteries to the battery dealer when you replace any
batteries. Do not dispose of batteries in your household garbage.
Points of sale are obliged to:

• Accept the return of your used batteries
• Store the returned batteries in a suitable location
• Send the returned batteries to the battery manufacturer for recycling
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INTRODUCTION
Basic instructions - Support strut for loader lift arm

WARNING
Crushing hazard!
If you service the machine with the loader lift arms raised, always use the support strut. Remove the
retaining pin and place the support strut onto the cylinder rod. Install the retaining pin into the support
strut. Lower the lift arms onto the support strut.
W0230A
Machines without the Tool Carrier (TC) option

Engage the loader arm support strut:
1. Empty the loader bucket.
2. Raise the loader lift arms to the maximum height.
3. Stop the engine and remove the starter switch key.
4. Remove the split pin (1) and the lock pin (2).
MOLI12LBB0260AB 1
5. Place the strut (3) on the cylinder rod and install the
pin (2) and the split pin (1) back into the holes in the
strut.
6. Lower the loader attachment until the safety strut is
firmly against the cylinder.
MOLI12LBB0261AB 2
Disengage the loader arm support strut:

3. Remove the split pin (1) and the lock pin (2).
MOLI12LBB0262AB 3
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INTRODUCTION
4. Remove the strut (3) from the attachment and install

the pin (1) and the split pin (2) back into the holes in
the strut.
5. Start the engine and lower the loader attachment.
MOLI12LBB0263AB 4
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INTRODUCTION
Machines with the Tool Carrier (TC) option

Engage the loader arm support strut:
1. Remove the split pins (1) and the safety strut (2) from
the storage position on the loader arm. Put the split
pins back in place.
2. Empty the loader bucket.
5. Place the strut (2) on the cylinder rod and fasten it by
means of the fastening flip (3).
6. Lower the loader attachment until the safety strut is
firmly against the cylinder. MOLI12LBB0264AB 5
MOLI12LBB0265AB 6
Disengage the loader arm support strut:

3. Remove the flip (3) and the strut (2) from the cylinder
rod.
MOLI12LBB0265AB 7
4. Start the engine and lower the loader attachment.

5. Stop the engine.
6. Install the safety strut (2) in the storage position on the
loader arm by means of the split pins (1).
MOLI12LBB0264AB 8
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Basic instructions - Engine hood

NOTICE: It is essential to install the loader attachment
support strut before any servicing work is done on the
engine.
Open the engine hood:

1. Insert the key (1) and turn counter-clockwise.
2. Push the key slot on the engine latch to release the
lock (2).
3. Use the engine hood lift handles (4), lift, and rotate the
hood (3) into the fully open position.
NOTICE: Before undertaking any road travel, make sure
the engine guard is properly locked.
Close and lock the engine hood (figures in reverse order):

RAIL15TLB0084AA 1
1. Push the hood down in to the closed position.
2. Push the engine latch (2) down into the lock position.
3. Insert the key (1) and turn clockwise.
RAIL15TLB0086AA 2
LEEN11T0072AA 3
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INTRODUCTION
Basic instructions - Organic Acid Technology (OAT) coolant

CASE CONSTRUCTION requires the use of a fully formulated Organic Acid Technology (OAT) based coolant. CASE
AKCELA ACTIFULL™ OT EXTENDED LIFE COOLANT is preferred. The coolant must meet the specifications
outlined in the CNH Industrial material specification MAT3624. Use of coolant not meeting this specification is not
allowed. Mixing of different coolant brands is not recommended.
NOTICE: OAT coolant is mandatory for all FPT engines compliant to Tier 4B (final) emissions using Selective Catalytic
Reduction (SCR). NEVER mix OAT coolant with conventional coolant. Under no circumstances should you top off a
cooling system with only water. You can use a refractometer to check the concentration level. You should not use
Supplemental Coolant Additives (SCA) when using CASE AKCELA ACTIFULL™ OT EXTENDED LIFE COOLANT.
Change the coolant solution at the recommended change interval.
The decal shown is located near the fill point of the cooling
system whenever the factory fill is CASE AKCELA ACT-
IFULL™ OT EXTENDED LIFE COOLANT. This decal is
available in three different sizes. See the table below for
the associated part numbers.
NOTE: Organic Acid Technology (OAT) appears yellow
in small quantities. OAT coolant can also appear yellow
when against translucent backgrounds. However, under
certain lighting conditions and backgrounds, such as look-
ing into the coolant overflow tank, OAT coolant may ap-
pear green. The green appearance is similar to the color
of ethylene glycol coolant. This color appearance is nor-
mal, which is not an indication of mixed coolant fill in new
units built after the implementation of OAT coolant.
CNH Industrial part Size

number
47757330 50 mm x 50 mm
47757331 75 mm x 75 mm
47757332 100 mm x 100 mm
47757330 1
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INTRODUCTION
You may notice the older version of the OAT decal (CNH
Industrial part number 47488993) on some applications.
Both decals convey the same message.
Definitions
Conventional coolant:
A coolant that relies on inorganic inhibitors such as sil-
icates, nitrites, and phosphates for corrosion and cavi-
tation protection.
Organic Acid Technology (OAT) coolant:

A coolant that relies on inhibitors such as organic acid
salts for corrosion and cavitation protection.
47488993 2
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INTRODUCTION
Torque - Minimum tightening torques for normal assembly

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

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

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

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

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

General information
• Hydraulic connections require a minimum assembly torque in order to provide zero leakage at rated pressure with
adequate fatigue resistance. Over-torquing of a hydraulic connection can also lead to leakage or failure. For some
connections, CASE CONSTRUCTION requires a different torque value than is listed in the ISO and SAE standards.
• The torque values in this document should be used whenever possible or applicable.
NOTICE: Always follow the instructions in this manual for specific torque values when you service components.
The information in this section is for general guidance only when a procedure contains no specific torque value.
Tolerance
• The tolerance for all torque values is ± 10%. This tolerance must include all assembly variation, not only the torque
wrench repeatability.
Lubrication
Application of grease or other lubricants to hydraulic connectors should be avoided. If clean hydraulic oil is already
on the connection, it is not required to remove the oil. Generally, application of grease:
• May cause a significant change in the torque required to properly tighten the connection.
• May reduce the connection’s resistance to vibration.
• Excessive grease may displace an elastomer seal during tightening.
• Grease extrusion when connection is tightened may be mistaken for leakage.
CASE CONSTRUCTION products generally use O-Ring Boss (ORB) connectors that have Teflon™-coated O-rings,
eliminating the need for O-ring lubrication during installation. For connections which are made into aluminum mani-
folds or with stainless steel connectors, it may be required to apply a lubricant to prevent galling.
Use of LOCTITE® and other thread-locking compounds is prohibited. These compounds:

• May cause a significant change in the torque required to properly tighten the connections.
• Reduce the serviceability of the joint.
• May prevent the O-ring from properly sealing if the compound gets on the O-ring.
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INTRODUCTION
Torque values for metric O-Ring Boss (ORB) port connections

S-Series * L-Series **
Metric Ferrous Non-Ferrous Ferrous Non-Ferrous
thread N·m (lb ft) ± 10% N·m (lb ft) ± 10% N·m (lb ft) ± 10% N·m (lb ft) ± 10%
M8 x 1 10.5 (7.7) 6.3 (4.6) 8.5 (6.3) 5 (3.7)
M10 x 1 21 (15.5) 12.5 (9.2) 15.5 (11.4) 9.3 (6.9)
M12 x 1.5 37 (27.3) 22 (16.2) 27 (19.9) 16 (11.8)
M14 x 1.5 47 (34.7) 28 (20.7) 37 (27.3) 22 (16.2)
M16 x 1.5 58 (42.8) 35 (25.8) 42 (31) 25 (18.4)
M18 x 1.5 74 (54.6) 44 (32.5) 47 (34.7) 28 (20.7)
M22 x 1.5 105 (77.4) 63 (46.5) 63 (46.5) 38 (28)
M27 x 2 178 (131.3) 107 (78.9) 105 (77.4) 63 (46.5)
M30 x 2 225 (166) 135 (99.6) 136 (100.3) 82 (60.5)
M33 x 2 325 (239.7) 195 (143.8) 168 (123.9) 101 (74.5)
M42 x 2 345 (254.5) 207 (152.7) 220 (162.3) 132 (97.4)
M48 x 2 440 (324.5) 264 (194.7) 273 (201.4) 164 (121)
M60 x 2 525 (387.2) 315 (232.3) 330 (243.4) 198 (146)
* S-Series connectors are used with O-Ring Face Seals (ORFS).
** L-Series connectors are used with 37° flare.
Torque values for metric O-Ring Boss (ORB) port plugs

Ferrous Non-ferrous
Metric Internal hex External hex
N·m (lb ft) ± 10%
thread N·m (lb ft) ± 10% N·m (lb ft) ± 10%
M8 x 1 8.5 (6.3) 10.5 (7.7) 6.3 (4.6)
M10 x 1 16 (11.8) 21 (15.5) 12.5 (9.2)
M12 x 1.5 23 (17) 37 (27.3) 22 (16.2)
M14 x 1.5 47 (34.7) 47 (34.7) 28 (20.7)
M16 x 1.5 58 (42.8) 58 (42.8) 35 (25.8)
M18 x 1.5 74 (54.6) 74 (54.6) 44 (32.5)
M22 x 1.5 105 (77.4) 105 (77.4) 63 (46.5)
M27 x 2 178 (131.3) 178 (131.3) 107 (78.9)
M30 x 2 225 (166) 225 (166) 135 (99.6)
M33 x 2 325 (239.7) 325 (239.7) 195 (143.8)
M42 x 2 345 (254.5) 345 (254.5) 207 (152.7)
M48 x 2 440 (324.5) 440 (324.5) 264 (194.7)
M60 x 2 525 (387.2) 525 (387.2) 315 (232.3)
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INTRODUCTION
Torque values for port connections (British Standard Pipe Parallel (BSPP) thread ports and stud ends)
Metric tube
Outside Diameter (OD) Ferrous Non-Ferrous
mm (in)
BSPP
thread S-Series L-Series S-Series L-Series
G- Gas; S-Series * L-Series ** N·m (lb ft) N·m (lb ft) N·m (lb ft) N·m (lb ft)
A- medium ± 10% ± 10% ± 10% ± 10%
coarse threads
G 1/8 A – 6 (0.236) – 21 (15.5) – 12.5 (9.2)
6 (0.236) 8 (0.315)
G 1/4 A or or 63 (46.5) 53 (39.1) 38 (28) 32 (23.6)
8 (0.315) 10 (0.394)
10 (0.394)
G 3/8 A or 12 (0.472) 95 (70.1) 84 (62) 57 (42) 50 (36.9)
12 (0.472)
15 (0.591)
G 1/2 A 16 (0.630) or 136 (100.3) 105 (77.4) 82 (60.5) 63 (46.5)
18 (0.709)
G 3/4 A 20 (0.787) 22 (0.866) 210 (154.9) 210 (154.9) 126 (92.9) 126 (92.9)
G1A 25 (0.984) 28 (1.102) 400 (295) 400 (295) 240 (177) 240 (177)
G 1 1/4 A 30 (1.181) 35 (1.378) 525 (387.2) 525 (387.2) 315 (232.3) 315 (232.3)
G 1 1/2 A 38 (1.496) 42 (1.654) 660 (486.8) 660 (486.8) 396 (292.1) 396 (292.1)
Torque values for metric port connections (Metric face-seal ports and stud ends)
Metric tube
Outside Diameter (OD) Ferrous Non-Ferrous
mm (in)
S-Series L-Series S-Series L-Series
Metric
S-Series * L-Series ** N·m (lb ft) N·m (lb ft) N·m (lb ft) N·m (lb ft)
thread
± 10% ± 10% ± 10% ± 10%
M10 x 1 – 4 (0.157) – 21 (15.5) – 12.5 (9.2)
M12 x 1.5 4 (0.157) 6 (0.236) 47 (34.7) 32 (23.6) 28 (20.7) 19 (14)
M14 x 1.5 5 (0.197) 7 (0.276) 63 (46.5) 53 (39.1) 38 (28) 32 (23.6)
M16 x 1.5 7 (0.276) 9 (0.354) 84 (62) 63 (46.5) 50 (36.9) 38 (28)
M18 x 1.5 8 (0.315) 11 (0.433) 105 (77.4) 84 (62) 63 (46.5) 50 (36.9)
M20 x 1.5 10 (0.394) – 147 (108.4) – 88 (64.9) –
M22 x 1.5 12 (0.472) 14 (0.551) 158 (116.5) 147 (108.4) 95 (70.1) 88 (64.9)
M26 x 1.5 – 18 (0.709) – 210 (154.9) – 126 (92.9)
M27 x 1.2 16 (0.630) – 210 (154.9) 126 (92.9) –
M33 x 2 20 (0.787) 23 (0.906) 400 (295) 400 (295) 240 (177) 240 (177)
M42 x 2 25 (0.984) 30 (1.181) 525 (387.2) 525 (387.2) 315 (232.3) 315 (232.3)
M48 x 2 32 (1.260) 36 (1.417) 630 (464.7) 630 (464.7) 396 (292.1) 396 (292.1)
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INTRODUCTION
Torque values for Inch O-Ring Boss (ORB) port non-adjustable connections
Ferrous Non- Ferrous Non-
Inch tube
SAE UN/UNF N·m (lb ft) Ferrous N·m (lb ft) Ferrous
OD
dash size thread size ± 10% N·m (lb ft) ± 10% N·m (lb ft)
mm (in)
± 10% ± 10%
2 5/16-24 3.18 (0.125) – – 8.5 (6.3) 5 (3.7)
3 3/8-24 4.76 (0.187) 15.5 (11.4) 9.3 (6.9) 10.5 (7.7) 6.3 (4.6)
4 7/16-20 6.35 (0.250) 37 (27.3) 22 (16.2) 19 (14) 11.5 (8.5)
5 1/2-20 7.94 (0.313) 42 (31) 25 (18.4) 26 (19.2) 15.5 (11.4)
6 9/16-18 9.52 (0.375) 47 (34.7) 28 (20.7) 32 (23.6) 19 (14)
8 3/4-16 12.7 (0.500) 89 (65.6) 53 (39.1) 53 (39.1) 32 (23.6)
10 7/8-14 15.88 (0.625) 121 (89.2) 73 (53.8) 63 (46.5) 38 (28)
12 1-1/16-12 19.05 (0.750) 178 (131.3) 107 (78.9) 100 (73.8) 60 (44.3)
14 1-3/16-12 22.22 (0.875) 225 (166) 135 (99.6) 131 (96.6) 79 (58.3)
16 1-5/16-12 25.4 (1.000) 283 (208.7) 170 (125.4) 156 (115.1) 94 (69.3)
20 1-5/8-12 31.75 (1.250) 300 (221.3) 180 (132.8) 210 (154.9) 126 (92.9)
24 1-7/8-12 38.1 (1.500) 388 (286.2) 233 (171.9) 220 (162.3) 132 (97.4)
32 2-1/2-12 50.8 (2.000) 388 (286.2) 233 (171.9) 315 (232.3) 189 (139.4)
Torque values for inch O-Ring Boss (ORB) port adjustable connections
Ferrous Non- Ferrous Non-
Inch tube
SAE UN/UNF N·m (lb ft) Ferrous N·m (lb ft) Ferrous
OD
dash size thread size ± 10% N·m (lb ft) ± 10% N·m (lb ft)
mm (in)
± 10% ± 10%
2 5/16-24 3.18 (0.125) – – 8.5 (6.3) 5 (3.7)
3 3/8-24 4.76 (0.187) 10.5 (7.7) 9.3 (6.9) 10.5 (7.7) 6.3 (4.6)
4 7/16-20 6.35 (0.250) 21 (15.5) 21 (15.5) 19 (14) 11.5 (8.5)
5 1/2-20 7.94 (0.313) 42 (31) 25 (18.4) 26 (19.2) 15.5 (11.4)
6 9/16-18 9.52 (0.375) 47 (34.7) 28 (20.7) 32 (23.6) 19 (14)
8 3/4-16 12.7 (0.500) 89 (65.6) 53 (39.1) 53 (39.1) 32 (23.6)
10 7/8-14 15.88 (0.625) 121 (89.2) 73 (53.8) 63 (46.5) 38 (28)
12 1-1/16-12 19.05 (0.750) 178 (131.3) 107 (78.9) 100 (73.8) 60 (44.3)
14 1-3/16-12 22.22 (0.875) 225 (166) 135 (99.6) 131 (96.6) 79 (58.3)
16 1-5/16-12 25.4 (1.000) 285 (210.2) 170 (125.4) 156 (115.1) 94 (69.3)
20 1-5/8-12 31.75 (1.250) 300 (221.3) 180 (132.8) 210 (154.9) 126 (92.9)
24 1-7/8-12 38.1 (1.500) 388 (286.2) 233 (171.9) 220 (162.3) 132 (97.4)
32 2-1/2-12 50.8 (2.000) 388 (286.2) 233 (171.9) 315 (232.3) 189 (139.4)
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INTRODUCTION
Torque values for inch O-Ring Boss (ORB) port plugs

Ferrous Non-Ferrous
Internal hex External hex
SAE UN/UNF N·m (lb ft)
N·m (lb ft) N·m (lb ft)
dash size thread size ± 10%
± 10% ± 10%
2 5/16-24 7.5 (5.5) 12.5 (9.2) 7.5 (5.5)
3 3/8-24 14.5 (10.7) 21 (15.5) 12.5 (9.2)
4 7/16-20 21 (15.5) 37 (27.3) 22 (16.2)
5 1/2-20 28 (20.7) 42 (31) 25 (18.4)
6 9/16-18 47 (34.7) 47 (34.7) 28 (20.7)
8 3/4-16 89 (65.6) 89 (65.6) 53 (39.1)
10 7/8-14 116 (85.6) 116 (85.6) 70 (51.6)
12 1-1/16-12 176 (129.8) 176 (129.8) 106 (78.2)
14 1-3/16-12 247 (182.2) 247 (182.2) 148 (109.2)
16 1-5/16-12 284 (209.5) 284 (209.5) 170 (125.4)
20 1-5/8-12 357 (263.3) 357 (263.3) 214 (157.8)
24 1-7/8-12 441 (325.3) 441 (325.3) 265 (195.5)
32 2-1/2-12 536 (395.3) 536 (395.3) 322 (237.5)
Torque values for four-bolt flange connections (Metric Screws, Class 10.9)
Code 61 Code 62
Metric size Imperial size Screw code Screw code
mm in 61 62
± 10% ± 10%
13 1/2 M8 x 1.25 34 (25.1) M8 x 1.25 34 (25.1)
19 3/4 M10 x 1.5 74 (54.6) M10 x 1.5 74 (54.6)
25 1 M10 x 1.5 74 (54.6) M12 x 1.75 137 (101)
M12 x 1.75 137 (101)
32 1-1/4 M10 x 1.5 74 (54.6)
M14 x 1.5 189 (139.4)
38 1-1/2 M12 x 1.75 137 (101) M16 x 2 310 (228.6)
51 2 M12 x 1.75 137 (101) M20 x 2.5 575 (424.1)
64 2-1/2 M12 x 1.75 137 (101) M24 x 3 575 (424.1)
76 3 M16 x 2 310 (228.6) M30 x 3.5 680 (501.5)
89 3-1/2 M16 x 2 310 (228.6) – –
102 4 M16 x 2 310 (228.6) – –
127 5 M16 x 2 310 (228.6) – –
Torque values for four-bolt flange connections (Metric Screws, Class 8.8)
Code 61 Code 62
mm in 61 62
± 10% ± 10%
13 1/2 M8 x 1.25 29 (21.4) M8 x 1.25 29 (21.4)
19 3/4 M10 x 1.5 57(42) M10 x 1.5 57(42)
25 1 M10 x 1.5 57(42) M12 x 1.75 100 (73.8)
M12 x 1.75 100 (73.8)
32 1-1/4 M10 x 1.5 57(42)
M14 x 1.5 160 (118)
38 1-1/2 M12 x 1.75 100 (73.8) M16 x 2 250 (184.4)
51 2 M12 x 1.75 100 (73.8) M20 x 2.5 500 (368.8)
64 2-1/2 M12 x 1.75 100 (73.8) M24 x 3 575 (424.1)
76 3 M16 x 2 250 (184.4) M30 x 3.5 680 (501.5)
89 3-1/2 M16 x 2 250 (184.4) – –
102 4 M16 x 2 250 (184.4) – –
127 5 M16 x 2 250 (184.4) – –
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INTRODUCTION
Torque values for four-bolt flange connections (Inch Screws, Grade 8)

Code 61 Code 62
mm in 61 62
± 10% ± 10%
13 1/2 5/16-18 34 (25.1) 5/16-18 34 (25.1)
19 3/4 3/8-16 63 (46.5) 3/8-16 63 (46.5)
25 1 3/8-16 63 (46.5) 7/16-14 97 (71.5)
32 1-1/4 7/16-14 97 (71.5) 1/2-13 158 (116.5)
38 1-1/2 1/2-13 158 (116.5) 5/8-11 310 (228.6)
51 2 1/2-13 158 (116.5) 3/4-10 473 (348.9)
64 2-1/2 1/2-13 158 (116.5) – –
76 3 5/8-11 310 (228.6) – –
89 3-1/2 5/8-11 310 (228.6) – –
102 4 5/8-11 310 (228.6) – –
127 5 5/8-11 310 (228.6) – –
Tapered thread connection tightening

British Standard Pipe Taper National Pipe Thread Fuel
Turns from finger tight
(BSPT) thread size (inch) (NPTF) thread size (inch)
1/8-28 1/8-27 2 - 3
1/4-19 1/4-18 2 - 3
3/8-19 3/8-18 2 - 3
1/2-14 1/2-14 2 - 3
3/4-14 3/4-14 2 - 3
1-11 1-11 1/2 1.5 - 2.5
1-1/4-11 1-1/4-11 1/2 1.5 - 2.5
1-1/2-11 1-1/2-11 1/2 1.5 - 2.5
2-11 2-11 1/2 1.5 - 2.5
Torque values for banjo bolt connections (Copper washer style)

Bolt thread (metric) Hex size (mm) Torque N·m (lb ft) ± 10%
M8 x 1.25 13 13 (9.6)
M10 x 1.25 17 16 (11.8)
M12 x 1.5 17 40 (29.5)
M14 x 1.5 19 45 (33.2)
M16 x 1.5 22 48 (35.4)
M18 x 1.5 24 50 (36.9)
M20 x 1.5 27 73 (53.8)
M22 x 1.5 32 73 (53.8)
M24 x 1.5 32 73 (53.8)
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INTRODUCTION
Torque values for O-Ring Face Seals (ORFS) connections

* **
Hex size
SAE Metric Swivel nut Swivel nut
UN/UNF Inch tube (mm)
dash tube torque torque
thread size OD (mm) (Reference
size OD (mm) N·m (lb ft) N·m (lb ft)
only)
± 10% ± 10%
4 9/16-18 6.35 6 17 27 (19.9) 27 (19.9)
5 5/8-18 7.94 8 19 34 (25.1) 34 (25.1)
6 11/16-16 9.52 10 22 44 (32.5) 44 (32.5)
8 13/16-16 12.7 12 24 65 (47.9) 65 (47.9)
10 1-14 15.88 16 30 100 (73.8) 100 (73.8)
12 1-3/16-12 19.05 20 36 150 (110.6) 131 (96.6)
14 1-5/16-12 22.23 22 41 163 (120.2) 131 (96.6)
16 1-7/16-12 25.4 25 41 210 (154.9) *** 131 (96.9)
20 1-11/16-12 31.75 30 50 280 (206.5) *** 178 (131.3)
24 2-12 38.1 38 60 375 (276.6) *** 210 (154.9)
* High/Medium-pressure applications > 50 bar (725 psi).
** Low-pressure applications < 50 bar (725 psi).
*** It is recommended to use a four-bolt flange connection instead of O-Ring Face Seals (ORFS) sizes "16" and up.
Torque values for 37° flare connections - Joint Industry Council (JIC)
SAE Metric
UN/UNF Inch tube Swivel nut torque
dash tube
thread size OD (mm) N·m (lb ft) ± 10%
size OD (mm)
2 5/16-24 – 3.18 8.25 (6.1)
3 3/8-24 – 4.76 11.5 (8.5)
4 7/16-20 6 6.35 15.5 (11.4)
5 1/2-20 8 7.94 20 (14.8)
6 9/16-18 10 9.52 25 (18.4)
8 3/4-16 12 12.7 52 (38.4)
10 7/8-14 16 15.88 81 (59.7)
12 1-1/16-12 20 19.05 112 (82.6)
14 1-3/16-12 – 22.22 133 (98.1)
16 1-5/16-12 25 25.4 155 (114.3)
20 1-5/8-12 30/32 31.75 180 (132.8)
24 1-7/8-12 38 38.1 225 (166)
32 2-1/2-12 50 50.8 348 (256.7)
Torque values for 30° flare, 60° cone connections

British Standard Pipe
Nominal Swivel nut torque
Parallel (BSPP) Hex size (mm)
size (mm) N·m (lb ft) ± 10%
thread size
5, 6, 6.3 G 1/4 17 25 (18.4)
8, 9, 10 G 3/8 19 34 (25.1)
12, 12.5 G 1/2 22 64 (47.2)
15, 16, 19 G 3/4 30 132 (97.4)
25 G1 36 196 (144.6)
31.5, 32 G 1-1/4 46 225 (166)
38 G 1-1/2 50 255 (188.1)
50, 51 G2 65 316 (223.1)
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INTRODUCTION
Torque - Hydraulic fittings and connectors - standard install

procedures
Installation of adjustable O-Ring Bosses (ORB) connectors
Adjustable port connectors are commonly found on
shaped connectors, which allow for orientation of the
connection. Adjustable port connectors utilize a locknut
and back-up washer.
NOTICE: Teflon coated O-rings do not require lubrication.
For connections which are made into aluminum manifolds
or with stainless steel connectors, it may be required to
apply a lubricant to prevent galling.
1. Remove protective connector caps only immediately

prior to assembly.
2. Inspect the components to ensure that the male and
female port threads and sealing surfaces are free of 23085659 1
burrs, nicks, and scratches, or any foreign material.

Do not use if impurities are found.
3. Make sure the washer (2) is on the fitting before the
O-ring (1).
4. Back off the lock nut as far as possible. Make sure that
the back-up washer is not loose and it is as far up on
the connector as possible.
5. Screw the connector into the port until the back-up
washer (2) or the retaining ring contacts the face of
the port (3). Light wrenching may be necessary.
6. Unscrew the connector until you achieve the correct
angle of the connector. Do not unscrew the connector
more than one full turn.
NOTICE: Do not over tighten the connector you may
damage the washer and increase the possibility of a
leak to occur.
7. Using two wrenches, hold the position of the connector
and tighten the locknut to the proper torque value. See
the torque tables for the proper torque value.
NOTICE: Make sure that the O-ring is not pinched and
that the washer is seated flat on the face of the port.
Do not over tighten and distort the back-up washer.
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INTRODUCTION
Installation of non-adjustable O-Ring Bosses (ORB) connectors

Non-adjustable port connectors are commonly found on
straight connectors, which do not require the installer to
adjust the orientation of the connection.
NOTICE: Teflon coated O-rings do not require lubrication.
For connections which are made into aluminum manifolds
or with stainless steel connectors, it may be required to
apply a lubricant to prevent galling.

prior to assembly.
RAIL15TLB0538AA 2
female port threads and sealing surfaces are free of
3. Install the connector by hand.
4. Tighten to the proper torque. See the torque tables for
the proper torque value.
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INTRODUCTION
Installation of tapered thread connectors

prior to assembly.
NOTICE: Pre-applied sealants, such as LOCTITE®
503™ VIBRA-SEAL® and/or powdered PTFE are the
preferred sealants for tapered thread connectors.
Non-preferred sealant types include PTFE tape, paste
sealants, and anaerobic liquids. PTFE tape and
paste sealants may contribute to hydraulic system
contamination.
RAIL15TLB0539AA 3
3. Apply the sealant/lubricant to the male pipe threads,
if not pre-applied. The first one or two threads should
not have sealant applied to them to avoid system con-
tamination.
NOTICE: If you require a specific orientation of a
shaped connector, take into consideration that final
position before you proceed with the next steps.
Never back off (loosen) tapered thread connectors to
achieve alignment you will increase the possibility of
leaks.
4. Screw the connector into the port to the finger tight
position.
5. Use a wrench to tighten the connector. See the torque
table for the proper number of Turns From Finger Tight
(TFFT).
NOTE: Normally, the total number of threads engaged
should be between 3.5 and 6. If more than 6 threads
are engaged, this may indicated an over-tightened
connection. If fewer than 3.5 threads are engaged,
this may indicate an under-tightened connection. For
an over-tightened connection, check both threads and
replace the part which has out-of-tolerance threads. If
the connection is under-tightened, it is acceptable to
tighten it further, but no more than one full turn.
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INTRODUCTION
Installation of flange connectors

Flange connections typically have four bolts, although
some flange connections may have more or fewer. The
flange connector consists of four main components:
• A body (flange head)
• An O-ring
• One “captive” or two “split” flange clamps
• Bolts and washers

prior to assembly.
3. Place the O-ring in the groove, the groove will be
either on the port side or the flange side.
4. Assemble the flange head and the clamps. RAIL15TLB0611BA 4
5. Position and hold the flange assembly over the port.

6. Finger tighten the bolt hardware evenly and in a
crossing pattern.
7. Tighten the bolt hardware to 60% of the torque value.
Use the same crossing pattern. See the torque tables
for the proper torque value.
NOTE: For bolt hardware that is not Metric Class 8.8
and 10.9 or Inch Grade 8 see the “Torque - Minimum
tightening torques for normal assembly” Torque -
Minimum tightening torques for normal assem-
bly.
8. Tighten the bolt hardware 1 and 2 to 100% of the
torque value.
9. Tighten the bolt hardware 3 and 4 to 100% of the
torque value.
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INTRODUCTION
Installation of O-Ring Face Seal (ORFS) connections

prior to assembly.
female threads and sealing surfaces are free of burrs,
nicks, and scratches, or any foreign material. Do not
use if impurities are found.
3. Check that the seal is properly installed in the groove
on the male connector. If the seal is not pre-installed
on the connector body, it must be installed using an
assembly tool:
A. Position the O-ring inside the assembly tool,
against the plunger.
B. Position the tool over the ORFS male end until it is 50011183 5
against the bottom of the tool.
C. Push the plunger of the tool until the O-ring is fully
seated into the groove on the connector.
4. Place the face of the female connector against the face
and O-ring of the male connector.
5. Thread the nut completely onto the male connector by
hand.
6. Complete steps 1 through 5 for both ends of the hose
or tube before continuing.
7. Hand-tighten any clamps that hold the position of the
hose or tube.
8. Tighten the ORFS connection to the proper torque
value. See the torque tables for the proper torque
value.
9. Complete tightening of any clamps that hold the hose
or tube only after both end fittings have been fully tight-
ened.
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INTRODUCTION
Installation of Flare-less Bite type and Flared connections

prior to assembly.
female threads and sealing surfaces are free of burrs,
nicks, and scratches, or any foreign material. Do not
use if impurities are found.
3. Place the face of the female connector against the face
and O-ring of the male connector.
4. Thread the nut completely onto the male connector by
hand. RAIL15TLB0541AA 6
5. Complete steps 1 through 5 for both ends of the hose

or tube before continuing.
6. Hand-tighten any clamps that hold the position of the
hose or tube.
7. Tighten the connection to the proper torque value. See
the torque tables for the proper torque value.
8. Complete tightening of any clamps that hold the hose
or tube only after both end fittings have been fully tight-
ened.
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INTRODUCTION
Basic instructions - Shop and assembly

580ST
590ST
695ST
Shimming
For each adjustment operation, select adjusting shims and measure the adjusting shims individually using a microm-
eter, then add up the recorded values. Do not rely on measuring the entire shimming set, which may be incorrect, or
the rated value shown on each shim.
Rotating shaft seals

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

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

• Operating in optimal technical conditions
• Obtaining the best results
• Saving time and effort
• Working in safe conditions
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INTRODUCTION
Swing tower - Basic instructions

Install the backhoe swing lock pin
Make sure the backhoe swing lock pin is in the LOCK
position whenever the backhoe is not in use. To install
the backhoe swing lock pin:
1. Place the seat in the backhoe operating position.
2. Center the backhoe over the rear of the machine.
3. Turn off the engine.
4. If applicable, open the rear window.
5. Remove the backhoe swing lock pin from the storage
location and place it in the LOCK position.
NOTE: View is from the operator seat facing the backhoe.
RAIL16TLB1504BA 1
RAIL16TLB1340BA 2
Remove the backhoe swing lock pin:

To remove the backhoe swing lock pin from the LOCK
position.
1. Turn off the machine.
2. Place the seat in the backhoe operating position.
3. If applicable, open the rear window.
4. Remove the backhoe swing lock pin from the LOCK
position and place it in the storage position.
NOTICE: After backhoe operations are complete make
sure that you put the backhoe in the stowed position with
the swing lock pin in the lock position.
NOTICE: Do NOT operate the machine if the backhoe
swing lock is missing or damaged. Before you operate
the machine, contact your dealer for a replacement.
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INTRODUCTION
Abbreviation Measurements
Typical applications Metric unit Imperial unit
Name Symbol Name Symbol
Area (Land area)

hectare ha acre ac
square meter m² square foot ft²
square inch in²
square millimeter mm² square inch in²
Electricity
ampere A ampere A
volt V volt V
microfarad µF microfarad µF
ohm Ω ohm Ω
Force
kilonewton kN pound lb
newton N pound lb
Force per length
newton per meter N/m pound per foot lb/ft
pound per inch lb/in
Frequency
megahertz MHz megahertz MHz
kilohertz kHz kilohertz kHz
hertz Hz hertz Hz
Frequency − Rotational
revolution per minute r/min revolution per minute r/min ª
rpm rpm
Length
kilometer km mile mi
meter m foot ft
centimeter cm inch in
millimeter mm inch in
micrometer µm
Mass
kilogram kg pound lb
gram g ounce oz
milligram mg
Power
kilowatt kW horsepower Hp
watt W Btu per hour Btu/hr
Btu per minute Btu/min
Pressure or stress (Force per area)
kilopascal kPa pound per square inch psi
inch of mercury inHg
pascal Pa inch of water inH2O
megapascal MPa pound per square inch psi
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INTRODUCTION
Typical applications Metric unit Imperial unit

Name Symbol Name Symbol
Temperature (other than Thermodynamic)

degrees Celsius °C degrees Fahrenheit °F
Time
hour h hour h
minute min minute min
second s second s
Torque (includes Bending moment, Moment of force, and Moment of a couple)
newton meter Nm pound foot lb ft
pound foot lb in
Velocity
kilometer per hour km/h mile per hour mph
meter per second m/s foot per second ft/s
millimeter per second mm/s inch per second in/s
meter per minute m/min foot per minute ft/min
Volume (includes Capacity)
cubic meter mm³ cubic yard yd³
cu yd
liter l cubic inch in³
liter l US gallon US gal
UK gallon UK gal
US quart US qt
UK quart UK qt
milliliter ml fluid ounce fl oz
Volume per time (includes Discharge and Flow rate)
cubic meter per m³/min cubic foot per minute ft³/min
minute
liter per minute l/min US gallon per minute US gal/min
milliliter per minute ml/min UK gallon per minute UK gal/min
Sound power level and Sound pressure level
decibel dB decibel dB
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INTRODUCTION
Capacities - 580ST and 590ST

580ST STAGE IV, SIDE-SHIFT (SS), FOUR-WHEEL DRIVE (4WD),
MARBLE CUTTING
580ST STAGE IV, STRAIGHT LOADER ARM (SLA), SIDE SHIFT (SS),
FOUR-WHEEL DRIVE (4WD)
580ST STAGE IV, TOOL CARRIER (TC), SIDE SHIFT (SS), TWO-WHEEL
DRIVE (2WD)
590ST STAGE IV, TOOL CARRIER (TC), SIDE SHIFT (SS), FOUR-WHEEL
DRIVE (4WD)
Engine crank case

Specification:
CASE AKCELA UNITEK NO. 1™ SBL CJ-4 SAE 10W-40
Capacity:
With filter change 8.0 L (8.5 US qt)
API CJ-4, MAT 3521
Fuel tank
Specification:
Ultra low sulfur Diesel fuel EN 590
Capacity: 131.0 L (34.6 US gal)
Emissions fluid tank

Specification:
DIESEL EXHAUST FLUID (DEF)/ADBLUE®
ES-BS001
Cooling system
Specification:
CASE AKCELA ACTIFULL™ OT EXTENDED LIFE COOLANT
( 50% concentrate and 50% distilled water)
Capacity:
With or without heater 24.0 L (25.4 US qt)
MAT3624, API CH-4, ACEA E5
Hydraulic system
Specification:
CASE AKCELA NEXPLORE™ FLUID or
CASE AKCELA HYDRAULIC EXCAVATOR FLUID BIO
Capacity:
Total system 111.2 L (29.4 US gal)
Reservoir refill to sight glass line 51.2 L (13.5 US gal)
Standard oil: API GL-4, ISO VG-32/46, NH 410B
Biodegradeable oil: ISO VG-46 DIN 51524 PART 2, NH 464 HBS
NOTE: CASE AKCELA HY-TRAN® ULTRACTION is an alternative to CASE AKCELA NEXPLORE™ FLUID.
Transmission
Specification:
CASE AKCELA NEXPLORE™ FLUID
Capacity:
Manual (powershuttle)
Two-Wheel Drive (2WD) Four-Wheel Drive (4WD)
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INTRODUCTION
Total system 18.5 L (19.5 US qt) 20.8 L (22.0 US qt)

Refill (with or without filter change) 11.9 L (12.6 US qt) 14.4 L (15.2 US qt)
MAT 3505
NOTE: The master brake cylinder receives fluid from the transmission.
Powershift
Four-Wheel Drive (4WD)
Total system 18.0 L (19.0 US qt)
Refill (with or without filter change) 11.4 L (12.0 US qt)
MAT 3505
Front drive axle - Four-Wheel drive (4WD)

Specification:
TUTELA TRANSAXLE FLUID SAE 80W-140
Capacity:
Differential 6.5 L (6.9 US qt)
Each planetary hub 0.7 L (0.7 US qt)
MAT 3505, ISO VG-46, ISO VG-32/46 NH410C
Rear axle (differential and hubs)

Specification:
Capacity: 21.2 L (22.4 US qt)
MAT 3505, ISO VG-46, ISO VG-32/46 NH410C
Various joints
Specification:
TUTELA MOLY GREASE GR-75
Capacity: As required
NLGI 2, QFK 585/GR
Extendable dipper
Specification:
TUTELA MULTI -PURPOSE EP GREASE 251H, GR-9
NLGI 2, QFK 587/GR
Air Conditioning (A/C) compressor

Specification:
PAG SP20
Capacity: 240.0 cm³ (14.6 in³)
Air Conditioning (A/C) refrigerant

Specification:
HFC R134A
Capacity: 1.2 kg (2.64 lb)
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INTRODUCTION
Capacities - 695ST
MARBLE CUTTING
695ST STAGE IV, TOOL CARRIER (TC), CENTER PIVOT (CP)
695ST STAGE IV, TOOL CARRIER (TC), SIDE SHIFT (SS)
Engine crank case

Specification:
CASE AKCELA UNITEK NO. 1™ SBL CJ-4 SAE 10W-40
Capacity:
With filter change 8.0 L (8.5 US qt)
API CJ-4, MAT 3521
Fuel tank
Specification:
Ultra low sulfur Diesel fuel EN 590
Emissions fluid tank

Specification:
DIESEL EXHAUST FLUID (DEF)/ADBLUE®
ES-BS001
Cooling system
Specification:
CASE AKCELA ACTIFULL™ OT EXTENDED LIFE COOLANT
( 50% concentrate and 50% distilled water)
Capacity:
With or without heater 24.0 L (25.4 US qt)
MAT3624, API CH-4, ACEA E5
Hydraulic system
Specification:
CASE AKCELA NEXPLORE™ FLUID or
CASE AKCELA HYDRAULIC EXCAVATOR FLUID BIO
Capacity:
Total system 111.2 L (29.4 US gal)
Reservoir refill to sight glass line 51.2 L (13.5 US gal)
Standard oil: API GL-4, ISO VG-32/46, NH 410B
Biodegradeable oil: ISO VG-46 DIN 51524 PART 2, NH 464 HBS
Transmission
Specification:
CASE AKCELA NEXPLORE™ FLUID
Powershift
Four-Wheel Drive (4WD)
Refill (with or without filter change) 11.4 L (12.0 US qt)
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INTRODUCTION
MAT 3505
Front drive axle - Four-Wheel drive (4WD)

Specification:
Capacity:
Wheel reduction gear (each) 1.3 L (1.4 US qt)
Rear axle - Four-Wheel Steer (4WS)

Specification:
Capacity:
Wheel reduction gear (each) 1.3 L (1.4 US qt)
Various joints
Specification:
TUTELA MOLY GREASE GR-75
NLGI 2, QFK 585/GR
Extendable dipper
Specification:
TUTELA MULTI -PURPOSE EP GREASE 251H, GR-9
NLGI 2, QFK 587/GR
Air Conditioning (A/C) compressor

Specification:
PAG SP20
Capacity: 240.0 cm³ (14.6 in³)
Air Conditioning (A/C) refrigerant

Specification:
HFC R134A
Capacity: 1.2 kg (2.64 lb)
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INTRODUCTION
General specification - Diesel fuel

580ST
590ST
695ST
Only use diesel fuel that conforms to European standard EN 590 or equivalent in your engine. Do not use any other
low grade diesel fuel.
NOTICE: Use of other low grade diesel fuels will result in loss of engine power, high fuel consumption, and damage
to the exhaust aftertreatment system (if equipped).
NOTE: When operating the machine in very cold climates, the use of winter blended fuel is permitted for a short period
of time. See your fuel supplier for winter fuel requirements in your area.
Fuel conditioner
Diesel fuel conditioner is available from your CASE CONSTRUCTION dealer. Instructions for the use of the fuel
conditioner is on the container.
The use of diesel fuel conditioner will:

• Clean fuel injectors, valves, and manifolds for increased service life
• Disperse insoluble gummy deposits that form in the fuel system
• Separate moisture from the fuel
• Stabilize fuel in storage
NOTICE: Use only CASE CONSTRUCTION approved biocide additives to prevent damage to the exhaust aftertreat-
ment system (if equipped).
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INTRODUCTION
General specification - Biodiesel fuels

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

FAME biodiesel, called biodiesel fuel in the following section, consists of a family of fuels derived from vegetable oils
treated with methyl esters.
There are two main biodiesel fuel types: Rapeseed Methyl Ester (RME) and Soybean Methyl Ester (SME). RME is a
blend of rapeseed and sunflower methyl ester, and is the preferred crop in Europe. SME is the preferred crop in the
United States.
Biodiesel fuel is a renewable alternative fuel source. Its use and development is promoted worldwide, especially in
Europe and in the United States.
NOTICE: Your emissions control system is compatible with up to 7% biodiesel fuel (B7). Be aware that the use of
biodiesel fuel that does not comply with the standards mentioned in this section could lead to severe damage to
the engine, fuel system or aftertreatment system of your machine. The use of non-approved fuels may void CASE
CONSTRUCTION Warranty coverage.
Biodiesel can be used to run Tier 4B (final) and Stage IV diesel engines only when blended with standard diesel fuel:
• B7: indicates the blend of 7% biodiesel and 93% diesel fuels.
• B20: indicates the blend of 20% biodiesel and 80% diesel fuels. Do not use.
Biodiesel fuel has several positive features in comparison with diesel fuel:
• Biodiesel adds lubricity to the fuel, which is beneficial in many circumstances, particularly as sulfur and aromatics
are removed from the fuel.
• Biodiesel has a greater cetane number and burns cleaner.
• Biodiesel produces less particulate matter and reduces smoke emissions.
• Biodiesel is fully biodegradable and non-toxic.
Diesel and biodiesel fuel specifications

Tier 4B (final) and Stage IV diesel fuel specifications are covered by the following:
• EN 590 - Specification of Diesel fuel. (10 ppm sulfur maximum.)
Biodiesel blends are covered by:

• European Diesel Fuel Specification EN 590 allows up to 7% biodiesel since 2009. European fuel suppliers are
allowed to use up to 7% biodiesel fuel (B7) to supply the network.
Pure biodiesel blend stock (B100) specification is covered by the following requirements:
• Europe: EN14214 - Automotive fuels. Fatty Acid Methyl Ester (FAME) for diesel engines. Requirements and test
methods.
• DIN V 51606 - German standard for biodiesel.
Before raw oil can be converted into usable biodiesel fuel, it must undergo transesterification to remove glycerides.
During the transesterification process, the oil reacts with an alcohol to separate the glycerine from the fat or vegetable
oil. This process leaves behind two products: methyl ester (the chemical name for biodiesel) and glycerine (a byprod-
uct usually sold for use in soaps or other products).
NOTICE: Biodiesel fuels approved for use in the CASE CONSTRUCTION equipment must be transesterified and
comply with the European Standard EN14214 or the German standard DIN V 51606.
NOTICE: Cold Pressed Biodiesel, Cold Pressed Oil, Straight Vegetable Oil (SVO), or more generally unrefined veg-
etable oils used as motor fuel, are fuels that are normally made from Rapeseed oil or similar high oil content crops.
These kinds of fuel are not transesterified, so they do not fulfil the EN14214 requirements. There is no recognized
quality standard available for these types of fuel. Therefore the use of Cold Pressed Biodiesel, Cold Pressed Oil,
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INTRODUCTION
Straight Vegetable Oil (SVO), or more generally unrefined vegetable oils used as motor fuel are NOT APPROVED at
any blend in any CASE CONSTRUCTION product.
NOTICE: Any engine and fuel injection equipment fitted to a CASE CONSTRUCTION vehicle found to have run with
any blend of NON-APPROVED fuel (fuel not fulfilling the specification described in the requirement EN14214) will no
longer be covered for Warranty by CASE CONSTRUCTION.
Biodiesel fuel usage conditions

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

• Filters and injector blockage caused by poor fuel quality.
• Wear and corrosion of internal components due to water content, which affects lubricity.
• Deterioration of some rubber sealing compounds in the fuel system.
• Biodiesel oxidation, which can lead to the formation of deposits that can harm the fuel injection system.
NOTICE: Any problem in the engine fuel injection equipment associated with non-compliance to the following condi-
tions for biodiesel fuel handling and maintenance will not be covered for Warranty by CASE CONSTRUCTION.
Purchase biodiesel fuel from a trusted supplier who understands the product and maintains acceptable fuel quality.
The use of biodiesel blends up to B7 will not void the CASE CONSTRUCTION warranty as long as the following
conditions for biodiesel fuel handling and maintenance are stringently followed:
Biodiesel fuel must be pre-blended by the supplier. Mixing biodiesel fuels on-site can result in an incorrect mixture
that could damage the engine and/or fuel system.
NOTICE: CASE CONSTRUCTION may void your warranty if the problem is associated with poor fuel quality due to
improper blending. It is the responsibility of the fuel supplier and/or yourself to ensure the right type of fuel and blend
is delivered and used.
Storage
The machine should not be stored for more than 6 months with biodiesel in the fuel system. For longer storage time,
it is strongly suggested that only regular EN 590 or #2 diesel fuel is used.
NOTE: If storage for longer than 6 months is necessary, the engine must be run on regular EN 590 or #2 diesel for a
minimum of 20 hours to flush the biodiesel fuel out of the fuel system prior to storage.
Biodiesel is highly hygroscopic and tends to collect water more than diesel fuel. This increases the risk of algae and
bacteria growth which can cause severe damage to the fuel injection system. Keep the machine fuel tanks and on-site
storage tanks as full as possible to limit the amount of air and water vapors inside the tank. Drain water from the tanks
at least once a week.
NOTICE: Use only CASE CONSTRUCTION approved biocide additives on Tier 4B (final) and Stage IV engines with
an exhaust aftertreatment system.
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INTRODUCTION
Recommended engine oil for operating temperature ranges

For machines using Stage IV engines
(H) 0W-40 CJ-4 UNITEK to CNH MAT3521 or ACEA E9

(H) 0W-40 API CJ-4* or ACEA E6*
(H) 5W-30 ACEA E6**
(H) 10W-40 CJ-4 UNITEK to CNH MAT3521 or ACEA E9

(H) 10W-40 API CJ-4* or ACEA E6*
(H) 15W-40 CJ-4 to CNH MAT3522* or ACEA E9

(H) 15W-40* API CJ-4* or ACEA E6*
-40 °C -30 °C -20 °C -10 °C 0 °C 10 °C 20 °C 30 °C 40 °C 50 °C

-40 °F -22 °F -4 °F 14 °F 32 °F 50 °F 68 °F 86 °F 104 °F 122 °F
(H) Engine oil pan or coolant block heater recommended in this range
* Requires a 50% reduction in oil change interval
**The use of 5W-30 CJ-4 engine oil is not recommended.
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INTRODUCTION
Consumables
Dye and black light procedure for detecting oil leaks
Oils and grease have natural phosphors and will illuminate differently under the black light. Oil, bluish-white, grease,
brilliant-white, anti-freeze, greenish-yellow, sealing compounds, red to orange.
Kit part number 380040182 consisting of:

Part Number Description Unit of Comments Usage
measurement
12 Volt Ultra Violet
380002254 Black Light — —
Light
Glows Green in Black Engine Oil /
380002357 Dye-uniglow F2HF 10 ml (0.34 US fl oz)
Light Crankcase
Glows Yellow in Black
380002358 Dye-uniglow F4HF 65 ml (2.2 US fl oz) Hydraulic Oil
Light
Glows Purple in Black
380002359 Dye-uniglow 1750 10 ml (0.34 US fl oz) Transmission Oil
Light
NOTE: Each dye is formulated to work in conjunction with a specific fluid, therefore the dyes are not interchangeable
and should only be used as described.
1. Prior to adding dye, connect the black light to the ma-
chines battery and investigate suspected areas.
2. Once suspected leak areas are found, attempt to trace
the leak completely to the origin.
NOTE: At the origin, the leak should be the brightest
in color.
3. After confirmation of the suspected leak, thoroughly
clean the area of the leak to remove any existing
fluids. Recheck the area with the black light to assure
the area is clean. Good cleaning is important for the
following reasons:
• Fluids captured by threaded joints or other cavities
will continue to show signs of leakage unless com-
pletely clean. RCPH10TLB245ACL 1
• Casting surfaces can hold residual oil.

4. Use the entire contents of the bottle of dye in the sys-
tem/systems of the suspected leak.
5. Run the unit for 5 to 10 minutes and cycle through sus-
pect system functions to ensure that the dye is avail-
able to all possible leak points.
NOTE: The hydraulic oil should be heated to 71 °C
(160 °F), engine at normal operating temperature, and
transmission should be in the normal operating range
on the gauge.
6. Use a clean cloth and wipe the dipstick or the inside
surface of the filler tube on each of the 3 sumps.
7. View traces of dyed fluid on the cloth under the black
light to ensure good samples.
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INTRODUCTION
8. Use these 3 samples as your baseline when inspecting

the unit with the black light.
NOTE: High hour engine oil can reduce the effective-
ness of the dye. In this event change the oil.
9. Avoid common errors.
• Fan airflow blowing leaking fluid.
• Gravity pulling leak paths down.
• When paint at a joint is not broken, the joint is not
leaking.
NOTE: It is not necessary to change oils after this
check.
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INTRODUCTION
Hydraulic contamination
Contamination in the hydraulic system is a major cause of the malfunction of hydraulic components. Contamination
is any foreign material in the hydraulic oil.
Contamination can enter the hydraulic system in several ways:

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

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

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

• Particles of metal or dirt in the oil
• Air in the oil
• Dark or thick oil
• Oil with an odor of burned oil
• Water in the oil
If you find contamination, use a portable filter to clean the hydraulic system.
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INTRODUCTION
General specification - Hydraulic system component specifications

Note: This table applies to Open-center hydraulic systems used on mechanical backhoe controls.
Component Subcomponent A(1) B(2) Notes

Fixed displacement Steering relief valve 177 bar +/- 1
dual tandem gear (2566 psi +/- 44)
pump
Priority flow divider 7 bar (102 psi)
spool spring
Pump stages 35.472 cm³/rev 35.472 cm³/rev 580ST – 154 L/min
— — (41 US gpm)
40.258 cm³/rev 35.472 cm³/rev 590ST and 695ST
– 165 L/min (44 US
gpm)
Clam valve Pressure reducing 35 bar (508 psi)
valve
PWM solenoid coil 5.4 Ω at 40.6 °C Two PWM solenoids
resistance (105.1 °F)
Loader quick coupler Pressure relief valve 189.7 bar
valve (2750.6 psi)
Glide ride (ride Accumulator 30 bar (435 psi) Pre-charge
control) valve
Uni-directional Pressure relief valve 200 bar (2900 psi) Adjustable. Do not
auxiliary valve exceed 210 bar
(3045 psi)
Solenoid coil 9 Ω at 20 – 25 °C (68
resistance – 77 °F)
Husco monoblock Inlet 210 bar +/- 2.5 Main relief valve
loader control valve (3045 psi +/- 35) Unload valve with
170 bar +/- 2.5 pilot override
(2465 psi +/- 35)
Bucket section 160 bar +/- 2.5 227 bar +/- 2.5 Circuit relief with
(2320 psi +/- 35) (3292 psi +/- 35) anti-cavitation
Lift section Anti-cavitation valve Anti-cavitation valve No circuit reliefs
Clam section None 241 bar +/- 2.5 Spool acrivated with
(3494 psi +/- 35) pilot pressure from
5 – 23.4 bar (72 –
340 psi)
Husco monoblock Inlet Regeneration check
backhoe control valve valve
Swing section 207 bar +/- 3 207 bar +/- 3 6.4 mm (0.3 in)
(3002 psi +/- 45) (3002 psi +/- 45) oriface upstream
of load check valve
Boom section 195 bar +/- 3 317 bar +/- 3 Regenerative flow
(2828 psi +/- 45) (4596 psi +/- 45) boom spool
Stabilizer section No port No port
Stabilizer section No port No port
Dipper section Plugged machined Plugged machined
port port
Bucket section Anti-cavitation valve 221 bar +/- 3
(3204 psi +/- 45)
Extend dipper / Aux 124 bar +/- 3 Plugged machined Max 7 spool valve.
section (1798 psi +/- 45) port Add either HED or
Aux section to 6 spool
monoblock.
Note: This table applies to Closed-center hydraulic systems used on pilot backhoe controls.
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INTRODUCTION
Component Subcomponent A(1) B(2) Notes

Variable volume axial Load Sense (LS) 20 bar (290 psi)
piston pump compensator margin
spring
High pressure cut-off 250 bar (3625 psi)
valve
Pump 71 cm³/rev 580ST 155 L/min Pump does not
— (41 US gpm) destroke to zero.
75 cm³/rev 590ST and 695ST Minimum pump output
— 165 L/min (44 US at low idle 900 RPM
7 cm³/rev minimum gpm) is 6.4 L/min (1.7 US
displacement gpm). At high full
load idle 2200 RPM
the minimum pump
output is 15 L/min
(4 US gpm) .
Rexroth sectional Inlet section Steering priority flow
loader control valve divider
Bucket section Spool 239 – 264 bar (3466 164 – 175 bar (2378
# HT118 – 3828 psi) – 2538 psi)
Lift section Spool # None None
HT121
Clam section Spool # None None
H014
Steering orbital Steering pressure 173 – 180 bar (2508
control valve relief valve – 2610 psi)
Rexroth sectional Inlet section 26 bar +/- 1 (377 psi Flushing valve
backhoe control valve +/- 14.5) .
— —
205 bar +/- 3 Load Sense (LS)
(2972 psi +/- 44) relief valve. Pressure
— measured at the
. backhoe inlet section
. M port.
— —
0.7 L/min (0.2 US LS drain. Continuous
gpm) and temperature
compensated.
HED section Spool # 123 – 134 bar (1784 None
H501 – 1943 psi)
Boom section Spool # 239 – 264 bar (3466 309 – 339 bar (4480
H451 – 3828 psi) – 4916 psi)
Swing section Spool 204 – 210 bar (2958 204 – 210 bar (2958
# HV173 – 3045 psi) – 3045 psi)
Bucket section Spool 219 – 242 bar (3176
# H470 – 3509 psi)
Dipper section Spool 239 – 264 bar (3466
# H452 – 3828 psi)
Stabilizer section None None
Spool # H399
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INTRODUCTION
General specification - Engine

580ST
Model Diesel, F5BFL413B*B003, Tier 4B (Final) emissions
compliant (base engine F5BFL413A*B007)
Type Four cylinder, turbocharged
Firing order 1-3-4-2
Bore and stroke 99 mm x 110 mm ( 3.90 in x 4.33 in)
Displacement 3.4 l (207.5 in³)
Compression ratio 17 to 1
Fuel injection Direct HPCR
Horsepower - rated at 2200 RPM
Gross 72 kW (98 Hp)
Net with viscous fan 71 kW (97 Hp)
Peak torque at 1400 RPM
Gross 459 N·m (339 lb ft)
Net with viscous fan 458 N·m (338 lb ft)
Maximum torque rise 45% ± 5 RPM
Engine speeds (with gear pump) First and second gear Third and fourth gear
Rated speed, full load 2200 RPM
Low idle 900 – 1000 RPM
High idle, no load 2320 – 2440 RPM
Converter stall 1870 – 2040 RPM 1900 – 2065 RPM
Backhoe stall 2150 – 2300 RPM
Loader stall 2150 – 2300 RPM
Combined stall
with unloading 1625 – 1825 RPM 1630 – 1855 RPM
without unloading 1350 – 1600 RPM
Engine speeds First and second gear Third and fourth gear
(with variable volume displacement
pump)
Combined stall 1850 – 2060 RPM 1890 – 2090 RPM
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INTRODUCTION
590ST and 695ST

Model Diesel, F5BFL413A*B006, Tier 4B (Final) emissions
compliant (base engine F5BFL413A*B007)
Type Four cylinder, turbocharged
Firing order 1-3-4-2
Bore and stroke 99 mm x 110 mm ( 3.90 in x 4.33 in)
Displacement 3.4 l (207.5 in³)
Compression ratio 17 to 1
Fuel injection Direct HPCR
Horsepower - rated at 2200 RPM
Gross 82 kW (111 Hp)
Net with viscous fan 81 kW (110 Hp)
Peak torque at 1400 RPM
Gross 467 N·m (344 lb ft)
Net with viscous fan 466 N·m (344 lb ft)
Maximum torque rise 30% ± 5 RPM
Engine speeds (with gear pump) First and second gear Third and fourth gear
Engine speeds First and second gear Third and fourth gear
(with variable volume displacement
pump)
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INTRODUCTION
Bucket - General specification - Front loader bucket

Bucket type 1 m³ (35.3 ft³) standard 4x1 6x1 (with forks)
Heaped capacity 1 m³ (35.3 ft³) 1 m³ (35.3 ft³) 1 m³ (35.3 ft³)
2WS
Width 2250 mm (88.6 in) 2250 mm (88.6 in) 2250 mm (88.6 in)
Weight 410 kg (904 lb) 800 kg (1764 lb) 960 kg (2116 lb)
Heaped capacity 1.15 m³ (40.6 ft³) 1.15 m³ (40.6 ft³) 1.15 m³ (40.6 ft³)
4WS Width 2400 mm (94.5 in) 2400 mm (94.5 in) 2400 mm (94.5 in)
Weight 426 kg (939 lb) 830 kg (1830 lb) 990 kg (2182 lb)
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INTRODUCTION
Bucket - General specification - Backhoe bucket

NOTE: Chart applies to models with an overlapping cylinder boom.
Type Width Weight

300 mm (12 in) 86 kg (190 lb)
400 mm (16 in) 104 kg (229 lb)
450 mm (18 in) 112 kg (247 lb)
Standard
600 mm (24 in) 130 kg (287 lb)
750 mm (30 in) 151 kg (333 lb)
900 mm (35 in) 171 kg (377 lb)
406 mm (16 in) 139 kg (306 lb)
457 mm (18 in) 149 kg (328 lb)
Heavy duty
610 mm (24 in) 176 kg (388 lb)
914 mm (36 in) 228 kg (503 lb)
Ditch cleaning 1500 mm (59 in) 160 kg (353 lb)
Backhoe buckets
NOTE: Chart applies to models with an in-line cylinder boom.
Type Width Weight

305 mm (12 in) 119 kg (262 lb)
457 mm (18 in) 138 kg (304 lb)
Standard 610 mm (24 in) 166 kg (366 lb)
762 mm (30 in) 217 kg (478 lb)
914 mm (36 in) 248 kg (547 lb)
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INTRODUCTION
Product identification
Record the Product Identification Numbers (PIN). If needed, give these numbers to your dealer when you need parts
or information for your machine. Keep a record of these numbers and your Manufacturer’s Statement of Origin in a
safe place. If the machine is stolen, report the numbers to your local law enforcement agency.
Machine
Model:
PIN:
Locate the Product Identification Number (PIN) plate on

the right-hand side beneath the loader lift cylinder pivot
point.
RAIL15TLB0039AA 1
NOTE: The PIN is also stamped on the right-hand side

chassis rail.
RAIL16TLB0369BA 2
580ST engine
Fiat Powertrain Technologies (FPT) 72 kW (98 Hp)
F5BFL413B.
PIN:
590ST and 695ST engine

Fiat Powertrain Technologies (FPT) 82 kW (111 Hp)
F5BFL413A.
PIN:
RAIL11TLB0009AA 3
NOTE: The PIN plate is located on the left-hand side of
the oil pan below the water separator.
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INTRODUCTION
Power shuttle transmission

Model:
PIN:
The PIN plate is on the lower right-hand side of the trans-

mission. View the PIN plate from under the machine.
LEEN11T0340AA 4
Powershift transmission
Model:
PIN:
The PIN plate is on the lower right-hand side of the trans-

mission. View the PIN plate from under the machine.
LEEN11T0341AA 5
Front axle
The same front axle housing is used for Two-Wheel Drive
(2WD) and Four-Wheel drive (4WD) models. Additional
components are required on the 4WD version.
Model:
PIN:
Ratio:
The PIN plate is on the right-hand back side of the axle.

View the PIN plate from under the machine.
LEEN11T0342AA 6
Front axle – Four-Wheel Steer (4WS)

Model:
PIN:
Ratio:
The PIN plate is on the right-hand back side of the axle.

LEEN11T0343AA 7
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INTRODUCTION
Rear axle – Two-Wheel Steer (2WS)

Model:
PIN:
Ratio:
The PIN plate is on the right-hand front side of the axle.

LEEN11T0344AA 8
Rear axle – Four-Wheel Steer (4WS)

Model:
PIN:
Ratio:
The PIN plate is on the left-hand front side of the axle.

LEEN11T0345AA 9
Cab
Cab with a certified Roll Over Protective Structure (ROPS)
and Falling Object Protective Structure (FOPS).
Model:
PIN:
LEEN11T0463AA_1 10
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INTRODUCTION
Canopy
Cab with a certified Roll Over Protective Structure (ROPS)
and Falling Object Protective Structure (FOPS).
Model:
PIN:
LEEN11T0463AA_1 11
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INTRODUCTION
Component identification
580ST
590ST
695ST
RAIL16TLB1343GA 1
580ST and 590ST with in-line cylinder boom*
1. Loader arm 13. Exhaust stack

2. Loader arm bucket 14. Hydraulic oil tank, battery box, and optional tool box
3. Loader arm bucket cylinder 15. Backhoe in-line cylinder boom* (shown)
4. Engine hood 16. Side shift carriage
5. Front driving light 17. Side shift stabilizer with pad
6. Front axle 18. Backhoe swing tower
7. Front work lights 19. Backhoe boom
8. Operator compartment 20. Backhoe bucket
9. Fuel tank and DIESEL EXHAUST FLUID 21. Backhoe bucket links with optional lift hook
(DEF)/ADBLUE® tank
10. Rear Axle 22. Backhoe bucket cylinder
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INTRODUCTION
11. Rearview side mirror 23. Backhoe dipper arm cylinder

12. Rear work lights 24. Backhoe standard dipper or Extendahoe® dipper
NOTE: Boom with overlapping cylinder* available as a standard option on most model configurations.
RAIL16TLB1344GA 2
695ST with in-line cylinder and side shift carriage
1. Backhoe standard dipper or Extendahoe® dipper 13. Backhoe swing tower

2. Loader arm bucket 14. Side-shift** stabilizers with pad
3. Fuel tank with DIESEL EXHAUST FLUID (DEF)/ADBLUE® tank 15. Exhaust stack
4. Loader arm bucket cylinder 16. Front driving light
5. Tool Carrier (TC) loader arm with safety support strut 17. Front axle – Four-Wheel Steer (4WS)
6. Rearview side mirror 18. Battery box
7. Front work lights 19. Tool box (optional)
8. Operator’s compartment 20. Hydraulic oil tank
9. Side work light 21. Rear axle – Four-Wheel Steer (4WS)
10. Backhoe dipper arm cylinder 22. Backhoe bucket links with optional lift hook
11. Backhoe boom 23. Backhoe bucket
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INTRODUCTION
12. Backhoe in-line cylinder boom* 24. Backhoe bucket cylinder

NOTE: Boom with overlapping cylinder boom* available as a standard option on most model configurations.
NOTE: Center pivot** available as a standard option on most model configurations.
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INTRODUCTION
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SERVICE MANUAL
Engine

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Contents
Engine - 10
[10.001] Engine and crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.1
[10.216] Fuel tanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.2
[10.206] Fuel filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3
[10.218] Fuel injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.4
[10.500] Selective Catalytic Reduction (SCR) exhaust treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.5
[10.400] Engine cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.6
[10.414] Fan and drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.7
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Engine - 10
Engine and crankcase - 001

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Contents
Engine - 10
TECHNICAL DATA
Engine
Speeds Stall test check sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SERVICE
Engine
Drain fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Prepare - Stall tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
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Engine - Engine and crankcase
Engine - Speeds Stall test check sheet

NOTE: The following specifications are for engines with more than 50 hours of operation.
NOTE: Engine RPM speed is based on the ISO 14396 Cetane number of at least 51 and density between 820 –
845 kg/m³ (1382 – 1424 lb/yd³). Fuel inlet 36.0 – 40.0 °C (96.8 – 104.0 °F).
Results from stall test procedure (fill in values accordingly)

ID RPM test valve Stall test component (specified value)
1 Loader hydraulic stall speed ( 2220 – 2330 RPM)
2 Backhoe hydraulic stall speed ( 2220 – 2330 RPM)
3 Torque converter stall speed ( 2150 – 2310 RPM)
4 Combined - loader hydraulic and torque converter - stall speed ( 1810 – 2090 RPM)
Stall test reference chart

ID RPM Results
1 2220 – 2330 RPM
2 2220 – 2330 RPM
All systems operating within normal specified RPM values.
3 2150 – 2310 RPM
4 1810 – 2090 RPM
1 Above 2330 RPM
2 2220 – 2330 RPM
Engine problem. Check engine speeds. Refer to the engine service manual.
3 Above 2310 RPM
4 Above 2090 RPM
1 Below 2220 RPM
2 2220 – 2330 RPM Engine problem. Check engine speeds. Replace the fuel and air filters Refer
3 Below 2150 RPM to the engine service manual.
4 Below 1810 RPM
1 Below 2220 RPM
2 2220 – 2330 RPM Hydraulic system problem(s). Check the setting of the main relief valve. Check the
3 2150 – 2310 RPM output of the hydraulic pump.
4 Below 1810 RPM
1 Above 2330 RPM
2 2220 – 2330 RPM Hydraulic system problem(s). Check the setting of the main relief valve. Check the
3 2150 – 2310 RPM output of the hydraulic pump. Check for leakage in the loader control valve.
4 Above 2090 RPM
1 2220 – 2330 RPM
2 Below 2200 RPM Hydraulic system problem(s). Check the setting of the main relief valve. Check the
4 1810 – 2090 RPM
1 2220 – 2330 RPM
2 Below 2220 RPM Hydraulic system problem(s). Check the setting of the main relief valve. Check the
4 1810 – 2090 RPM
1 2220 – 2330 RPM
2 2220 – 2330 RPM
Torque converter or transmission problems.
3 Above 2310 RPM
4 Above 2090 RPM
1 2220 – 2330 RPM
2 2220 – 2330 RPM
Torque converter or transmission problems.
3 Below 2150 RPM
4 Below 1810 RPM
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Engine - Drain fluid

WARNING
Avoid injury!
Avoid getting engine oil on your skin. In case of skin contact, wash with running water.
W1336B
WARNING
Pressurized system!
Never attempt to drain fluids or remove filters when the engine is running. Turn off the engine and
relieve all pressure from pressurized systems before servicing the machine.
W0905A
1. Move the machine to a level and firm ground.

2. Raise the loader attachment and install the safety sup-
port strut.
3. Place the backhoe attachment in the road travel posi-
tion.
4. Place the direction-of-travel lever and gearshift lever in
the NEUTRAL position.
5. Immobilize the machine with the parking brake.
7. Open and raise the engine guard. LEEN11T0354AA 1
8. Remove the cap (2) of the filler neck.

9. Remove the protection cap from the engine crankcase
drain valve.
10. Screw the connector of the extension drain hose
(stored in the toolbox) on the crankcase drain valve.
11. Place the opposite end into a container with sufficient
capacity.
NOTE: Drain the engine when it is still warm. The oil will
flow more easily.
12. Wait for the oil to completely flow out of the engine.
LEEN11T0356AA 2
13. Remove the extension drain hose and install the pro-
tection cap on the crankcase drain valve.
14. Place the extension drain hose in the toolbox.
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Engine - Remove
Prior operation:
Disconnect the battery, refer to Battery - Remove (55.302).
Prior operation:
Drain the engine oil, refer to Engine - Drain fluid (10.001).
Prior operation:
Remove engine hood, refer to Engine hood - Remove (90.105).
Prior operation:
Drain the hydraulic fluid, refer to Oil reservoir - Drain fluid (35.300)
Prior operation:
Drain the transmission fluid, refer to Power shuttle transmission - Drain fluid (21.112) (Power shuttle) or Power-
shift transmission - Drain fluid (21.113) (Powershift).
Prior operation:
Remove the cooling package, refer to Engine cooling system - Remove (10.400).
Prior operation:
If applicable discharge the Air Conditioning A/C system, refer to Air conditioning - Discharging (50.200).
1. Disconnect the air temperature sensor X-474.
RAIL15TLB0216AA 1
2. Remove the connector X-4 from 2-way air cleaner con-

nector.
RAIL15TLB0217AA 2
3. Remove the pipe connecting the air cleaner with tur-

bocharger.
RAIL15TLB0217AA 3
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4. Remove the aspirator tube. Remove the four mount-

ing bolts (1) securing the air cleaner. Remove the air
cleaner.
RAIL15TLB0218AA 4
5. Disconnect the connecting exhaust pipe from the tur-

bocharger
RAIL15TLB0230AA 5
6. Remove the connectors X-470 (1) and X-471 (2) from

the engine electronic control unit.
RAIL15TLB0237AA 6
7. Remove the ground strap.
RAIL15TLB0235AA 7
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8. Disconnect the fuel line (1) from the cylinder head. Dis-
connect the fuel lines from the fuel filter (2).
RAIL15TLB0240AA 8
9. Remove the alternator connector X-67 and connector

X-10.
RAIL15TLB0233AA 9
10. Disconnect the connector X-508 from the starter mo-

tor and the ignition connector.
RAIL15TLB0241AA 10
11. Remove the flywheel access cover.
LELI12TLB0080AA 11
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12. Use tool 380000988 to rotate the engine to access

flywheel flex plate hardware.
LELI12TLB0081AA 12
13. Remove the flywheel and flex plate hardware.
LELI12TLB0082AA 13
14. Attach a suitable lifting device.
RAIL15TLB0244AA 14
15. Remove engine mounting hardware.
RAIL15TLB0245AA 15
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16. Remove hardware which attaches the engine to the

transmission.
LELI12TLB0085AA 16
17. Make sure that all the harness connectors and hoses
have been disconnected and are clear of the engine.
Slowly raise the engine from the frame and remove
the engine from the machine.
RAIL15TLB0247AA 17
18. If necessary, see the engine service manual for more

specific details.
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Engine - Install
1. Carefully lower the engine on the frame.
RAIL15TLB0247AA 1
2. Attach the engine to the transmission with the hardware

removed earlier. Torque the hardware to 52 – 57 N·m
(38 – 42 lb ft).
LELI12TLB0085AA 2
3. Install the engine mounting hardware to the engine.

Torque the hardware to 89 – 107 N·m (66 – 79 lb ft).
RAIL15TLB0245AA 3
4. Secure engine mounts to the frame. Torque the hard-

ware to 178 – 240 N·m (131 – 177 lb ft).
5. Remove the lifting device.
RAIL15TLB0244AA 4
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6. Rotate the engine to access flywheel. Use tool

380000988.
LELI12TLB0081AA 5
7. Reinstall the flywheel and flex plate hardware. Torque

to 62 – 57 N·m (46 – 42 lb ft).
LELI12TLB0082AA 6
8. Install the flywheel access cover.
LELI12TLB0080AA 7
9. Connect the exhaust pipe to the turbocharger with the

clamp. Torque the hardware to 21 – 29 N·m (15 – 21 lb
ft).
RAIL15TLB0230AA 8
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10. Connect the connector X-508 on the starter motor and

the ignition connector.
RAIL15TLB0241AA 9
11. Connect the connectors X-67 and X-10 to the alterna-

tor.
RAIL15TLB0233AA 10
12. Connect the ground strap.
RAIL15TLB0235AA 11
13. Connect the fuel line (1) to the cylinder head. Connect
the fuel lines (2) to the fuel filter .
RAIL15TLB0240AA 12
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14. Connect the connectors X-470 (1) and X-471 (2) to the
electronic control unit.
RAIL15TLB0237AA 13
15. Install the air cleaner and secure with the bolts (1)
removed earlier. Connect the aspirator tube.
RAIL15TLB0218AA 14
16. Connect the hose to the turbocharger. Torque the

hardware to 3.4 – 4.5 N·m (30.1 – 39.8 lb in).
RAIL15TLB0217AA 15
17. Connect the connector X-4 to 2-way air cleaner con-

nector.
RAIL15TLB0217AA 16
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18. Connect the air temperature sensor connector.
RAIL15TLB0216AA 17
19. Top up the engine oil. Refer to Engine - Filling

(10.001).
20. Top up the hydraulic oil. Refer to Oil reservoir - Fill-
ing (35.300).
21. Top up the transmission oil. Refer to Power shut-
tle transmission - Filling (21.112) (Power Shuttle) or
Powershift transmission - Filling (21.113) (Power-
shift).
22. Install the cooling system. Refer to Engine cooling
system - Install (10.400).
23. Charge the Air Conditioning system. Refer to Air con-
ditioning - Charging (50.200)
24. Install the engine hood. Refer to Engine hood - In-
stall (90.105).
25. Connect the battery. Refer to Battery - Install
(55.302).
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Engine - Filling
WARNING
Avoid injury!
Avoid getting engine oil on your skin. In case of skin contact, wash with running water.
W1336B
WARNING
Pressurized system!
Never attempt to drain fluids or remove filters when the engine is running. Turn off the engine and
relieve all pressure from pressurized systems before servicing the machine.
W0905A
1. Open and raise the engine guard.

2. Remove the cap (2) of the filler neck.
LEEN11T0356AA 1
3. Fill the engine with new oil.

4. Run the engine for a few minutes and check for leaks.
5. Check the engine oil level by means of the dipstick (1).
NOTE: Always wait 15 min to allow the oil to return to the
engine sump before checking the oil level.
6. Reinstall the cap (2) on the filler neck.
7. Lower and lock the engine guard.
8. Remove the safety support strut and lower the loader
attachment.
LEEN11T0361AA 2
Oil specification and capacity

Use CASE AKCELA UNITEK 10W-40 MAT3521, en-
gine oil or an oil meeting the following specification:
• API CJ-4
• ACEA E9
NOTE: A higher quality oil is acceptable.
NOTICE: For machines operating in cold regions, see
Recommended engine oil for operating temperature
ranges (10.304).
Engine oil capacity (with filter): 8.0 L (7.0 UK qt)
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Engine - Prepare - Stall tests

Do the stall test to find the cause of poor performance.
The main relief valve must be set within specifications to achieve accurate readings when performing the following
stall tests.
The engine is run at full throttle and the transmission and hydraulic systems are engaged separately, and then to-
gether.
Comparing the engine speeds from the stall test with the check sheets in this section will help to find the cause of the
problem. It can be necessary to check a separate system to find the exact cause of the problem.
Use a photo tachometer or other tachometer of equal accuracy to get accurate results from the stall test.
The engine, transmission and hydraulic system must be at operating temperature before doing the stall test. Heat the
oil according to instructions in this section.
Machines with standard transmission (Power shuttle)

2. Move the transmission gear selector into fourth gear.
3. Lock the brake pedals together. Put your foot on the
service brakes and hold the machine with service
brakes.
4. Release the parking brake.
5. With the engine running at low idle, move the direction
control lever forward.
6. Slowly increase the engine speed to full throttle.
7. If the machine begins to move at any time, decrease
the engine speed to low idle and stop the engine.
Parking brake discs - Inspect (33.110), Parking
brake discs - Test (33.110) and Parking brake discs
- Check (33.110)
Machines with H-Type transmissions (Powershift)

2. Place the automatic/manual switch in the manual posi-
tion.
3. Select fourth gear on the range selector.
brakes.
6. With the engine running at low idle, move the direction
control lever forward.
7. Slowly increase the engine speed to full throttle.
8. If the machine begins to move at any time, decrease
the engine speed to low idle and stop the engine. Refer
to sections Parking brake discs - Inspect (33.110),
Parking brake discs - Test (33.110) and Parking
brake discs - Check (33.110).
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Procedure to heat the torque converter and the hydraulic oil

2. Start and run the engine at low idle.
3. Run the engine at full throttle, hold the loader control
lever in the rollback position for 15 seconds.
4. Return the loader control lever to neutral for 15 sec-
onds.
5. Return the boom control lever to neutral for 15 seconds.
6. Repeat steps 3 and 4 until the temperature of the oil
is 52 °C (126 °F). The side of the reservoir will be very
warm at this temperature.
7. With the engine running at low idle, move the trans-
mission control to fourth gear and the direction control
lever to forward.
8. Run the engine at full throttle for 15 seconds.
9. Decrease the engine speed to low idle and move the
direction control lever to neutral for 15 seconds.
10. Repeat steps 6 through 8 until the pointer in the gauge
for transmission oil temperature is in the center of the
green zone of the gauge for transmission oil temper-
ature.
Stall test procedure

1. Prepare the machine for the stall test according to in-
structions in this section.
2. Heat the oil according to instructions in this section.
3. Apply the parking brake and start the engine.
4. With the engine running at full throttle, hold the loader
control lever in the lift position and read the tachometer.
Record the reading on line 1 of the check sheet.
5. With the engine running at full throttle and boom in
travel lock, hold the dipper lever in the in position and
read the tachometer. Record the reading on line 2 of
the check sheet.
6. Decrease the engine speed to low idle.
7. Move the transmission control lever to fourth gear.
NOTE: For machines with H-Type transmissions, place the
automatic/manual switch in the manual position.
brakes.
10. Move the direction control lever to forward.
11. Slowly increase the engine speed to full throttle and
read the tachometer. Record the reading on line 3 on
the check sheet.
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12. With the transmission control lever in fourth gear, the

direction control lever in forward, and the engine run-
ning at full throttle, hold the loader control lever in the
lift position and read the tachometer. Record the read-
ing on line 4 on the check sheet.
13. Decrease the engine speed to low idle, move the di-
rectional control lever to neutral.
14. Run the engine at low idle for two minutes and then
stop the engine.
15. See the check sheet to understand the results of the
stall test.
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Index
Engine - 10

Engine - Drain fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Engine - Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Engine - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Engine - Prepare - Stall tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Engine - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Engine - Speeds Stall test check sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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Engine - 10
Fuel tanks - 216

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Contents
Engine - 10
Fuel tanks - 216
SERVICE
Fuel tank
Drain fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
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Engine - Fuel tanks
Fuel tank - Drain fluid

1. Move the machine to a level and firm surface.
2. Lower the loader attachment to the ground.
tion.
the neutral position.
5. Engage the parking brake.
7. Release any possible residual hydraulic pressure by
moving the control levers in all directions.
8. Place a container of the appropriate capacity under the
fuel tank located on the left side of the machine.
RAIL15TLB0037AA 1
9. Remove the drain plug from the fuel tank and drain the
contaminated fuel and sediment from the tank.
RAIL15TLB0035AA 2
10. When clean fuel flows from the drain, reinstall and
secure the drain plug.
11. Check the fuel level and refill the tank if necessary.
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Engine - Fuel tanks
Fuel tank - Remove

Prior operation:
Drain the fuel tank, see Fuel tank - Drain fluid (10.216).
Prior operation:
Drain the DIESEL EXHAUST FLUID (DEF)/ADBLUE® tank, see Diesel Exhaust Fluid (DEF)/AdBlue®/ARLA tank -
Drain fluid (10.500).
1. Remove the corner shroud.
RAIL15TLB0023AA 1
2. Remove the DEF/AdBlue® tank cover plate.
RAIL15TLB0022AA 2
3. Remove the fuel tank step plate.
RAIL15TLB0020AA 3
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Engine - Fuel tanks
4. Disconnect the DEF/ADBLUE® lines (2) and the coolant

lines (3).
5. Disconnect the level and quality sensor connector (3)
on the DEF/ADBLUE® tank.
RAIL15TLB0077AA 4
6. Disconnect the fuel inlet and return line (2) and the fuel
level sensor (1).
RAIL15TLB0018AA 5
7. Remove the three bolts from the panel to the right-hand

side of the step, in front of the rear tire.
RAIL14TLB0964BA 6
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Engine - Fuel tanks
8. Support the supply module with a tie strap. Make sure

that it is securely in place and that it will not catch on
anything when the tank is lowered.
RAIL15TLB0016AA 7
9. Place a suitable lifting device (such as a pallet jack) that

will evenly support the weight of the fuel tank under the
fuel tank.
RAIL15TLB0037AA 8
10. Support the fuel tank.

11. Remove the bolt hardware from each side of the fuel
tank.
12. Slowly lower the tank and remove it from the side of
the machine.
RAIL15TLB0037AA 9
Next operation:
Install the fuel tank, see Fuel tank - Install (10.216).
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Engine - Fuel tanks
Fuel tank - Install

1. Use a suitable lifting device and move the fuel tank into
position.
2. Slowly raise the tank to the mounting position on the
side of the machine.
3. Align and install the bolt hardware on each side of the
fuel tank.
RAIL15TLB0037AA 1
4. Place the supply module in the mounting position.
RAIL15TLB0016AA 2
5. Align and secure the supply module with the bolt hard-
ware to the right-hand side of the step, in front of the
rear tire.
RAIL14TLB0964BA 3
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Engine - Fuel tanks
6. Connect the fuel inlet and return line (2) and the fuel
level sensor (1).
7. Connect the level and quality sensor connector (3) on
the DEF/ADBLUE® tank.
RAIL15TLB0018AA 4
8. Connect the DEF/ADBLUE® lines (2) and the coolant

lines (3).
RAIL15TLB0077AA 5
9. Install the fuel tank step plate.
RAIL15TLB0020AA 6
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Engine - Fuel tanks
10. Install the DEF/AdBlue® tank cover plate.
RAIL15TLB0022AA 7
11. Install the corner shroud.
RAIL15TLB0023AA 8
Next operation:
Fill the fuel tank, see Fuel tank - Filling (10.216).
Next operation:
Fill the DIESEL EXHAUST FLUID (DEF)/ADBLUE® tank, see Diesel Exhaust Fluid (DEF)/AdBlue®/ARLA tank - Filling
(10.500).
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Engine - Fuel tanks
Fuel tank - Filling

1. Secure the drain plug on the back of the fuel tank.
RAIL15TLB0035AA 1
2. Remove the fuel tank cap.
RAIL15TLB0037AA 2
3. Fill the tank with ASTM D975 GRADE NO. 2-D S15.
Next operation:
Bleed air from the fuel system, see Fuel injection system - Bleed (10.218).
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Index
Engine - 10
Fuel tanks - 216

Fuel tank - Drain fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Fuel tank - Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Fuel tank - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Fuel tank - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
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Engine - 10
Fuel filters - 206

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Contents
Engine - 10
Fuel filters - 206
SERVICE
Fuel filters
Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Fuel-water separator filter
Drain fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
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Engine - Fuel filters
Fuel filters - Replace

port strut.
tion.
7. Open and raise the engine hood.
8. Place a container with suitable capacity under the fuel
filter.
9. Use a suitable tool and remove the fuel filter cartridge
(1).
LEEN11T0356AA 1
10. Apply a thin layer of clean oil on the seal (2) of the new
filter cartridge.
11. Install the new filter cartridge (1).
12. Manually tighten the filter cartridge until the seal
touches the filter head.
13. After contact, by hand, tighten the filter cartridge an
additional 3/4 of a turn.
NOTICE: Overtightening can damage the filter seal (2).
14. Bleed the fuel system.
LEEN11T0396AA 2
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Fuel filters - Replace

port strut.
tion.
7. Open and raise the engine hood.
8. Place a container with suitable capacity under the fuel
filter.
9. Use a suitable tool and remove the fuel filter cartridge
(1).
LEEN11T0356AA 1
10. Apply a thin layer of clean oil on the seal (2) of the new
filter cartridge.
11. Install the new filter cartridge (1).
12. Manually tighten the filter cartridge until the seal
touches the filter head.
13. After contact, by hand, tighten the filter cartridge an
additional 3/4 of a turn.
NOTICE: Overtightening can damage the filter seal (2).
14. Bleed the fuel system.
LEEN11T0396AA 2
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Fuel-water separator filter - Drain fluid

WARNING
Fire hazard! Avoid injury and/or machine damage!
During maintenance activities, make sure that the high-pressure fuel lines are not damaged. A fuel
leak from the high-pressure fuel lines can cause an accident and/or serious personal injury. If the fuel
lines are damaged, contact your dealer immediately.
W1335A

port strut.
tion.
7. Release any possible residual pressure from the hy-
draulic system by moving the control levers in all direc-
tions.
8. Wait the time necessary to allow the engine and the fuel
system to cool down.
9. Place a suitable container under the machine.
10. Unlock and raise the engine hood.
11. Locate the fuel filter (1) to drain the water and sed-
iments through the drain valve on the bottom of the
filter.
RAIL15TLB0027AA 1
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12. Remove the connector (2) from the bottom of the filter.
13. Install a drain pipe (about 1 m long 3.2 ft) on the drain
valve, (3) and put the other end of the pipe into the
container.
14. With engine inoperative, loosen the drain valve about
two turns and drain the water and sediment, until only
clean fuel runs out.
15. Tighten the drain valve without over tightening and
install the connector.
RAIL15TLB0028AA 2
16. If necessary bleed air from filter (see page Fuel injec-
tion system - Bleed (10.218))
NOTE: The drain interval can be increased or decreased, depending on the presence of water and the quantity of
fuel.
17. Lower and lock the engine hood.
attachment.
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Index
Engine - 10
Fuel filters - 206

Fuel filters - Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Fuel filters - Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Fuel-water separator filter - Drain fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
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Engine - 10
Fuel injection system - 218

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Contents
Engine - 10
SERVICE
Fuel injection system

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

WARNING
Pressurized system!
Only use the bleed screw to bleed air from the fuel system. DO NOT loosen the fuel or injector lines
to bleed air. Injury or damage can occur. Fuel or injector lines are under very high pressure.
W0285A

port strut.
tion.
neutral position.
5. Immobilize the machine by means of the parking brake.
7. Open and raise the engine tilt hood.
LEEN12T0566AA 1
8. From the bottom of the filter, remove the connector (3).

9. Place a container under the prefilter.
10. Open bleed screw (1) on prefilter only and activate
hand primer (2) until fuel flows freely from the bleed
screw.
11. This generally takes 35-45 pumps to fill the fuel lines
and the prefilter.
12. This can be done in about 30 s.
13. Tighten bleed screw.
14. Dry with cloth the prefilter. LEEN11T0355AA 2
15. Connect the electric connector under the prefilter.

16. Start the engine. Engine should start within 5 s.
17. Lower and lock the engine tilt hood.
attachment.
LEEN11T0370AA 3
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Index
Engine - 10

Fuel injection system - Bleed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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Engine - 10
Selective Catalytic Reduction (SCR) exhaust treatment - 500

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Contents
Engine - 10
FUNCTIONAL DATA
Selective Catalytic Reduction (SCR) exhaust treatment

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
General information Faults and their description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
SERVICE
Selective Catalytic Reduction (SCR) muffler and catalyst

Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Diesel Exhaust Fluid (DEF)/AdBlue®/ARLA tank
Cleaning filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Drain fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Coolant control valve
Replace - supply module filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Diesel Exhaust Fluid (DEF)/AdBlue®/ARLA lines
Cleaning filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
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Engine - Selective Catalytic Reduction (SCR) exhaust treatment
Selective Catalytic Reduction (SCR) exhaust treatment - Overview

What is Selective Catalytic Reduction (SCR)?
Your CASE CONSTRUCTION machine is equipped with additional components to comply with national and local
exhaust emissions requirements. The main components of the SCR system include the SCR catalyst, the Diesel
Exhaust Fluid (DEF)/AdBlue® dosing module, and the DEF/ADBLUE® tank.
How does Selective Catalytic Reduction (SCR) work?

During combustion, harmful nitrogen oxide (NOx ) molecules are formed in the exhaust. By injecting a DEF/ADBLUE®
solution into the exhaust prior to a catalyst, the NOx can be converted to harmless elemental nitrogen and water. This
happens when the NOx molecules react inside the catalyst with the heat generated by the engine and the ammonia
in the DEF/ADBLUE® solution.
NOTICE: Do not idle the machine with no load for more than 6 h, or damage to the SCR catalyst will occur.
During cold engine operation at low engine coolant and ambient air temperatures, water vapor will be visible from the
exhaust. This water vapor will resemble steam or light white smoke, and will dissipate as the engine and machine
components warm. This water vapor is considered normal.
NOTE: After engine shutdown, the SCR system will perform a purge cycle, which permits the supply module to con-
tinue to run for up to 90 seconds. This is considered normal and requires no action from the operator.
What is Exhaust Gas Recirculation (EGR) and how does it work?

Your CASE CONSTRUCTION machine is equipped with additional components to comply with national and local
exhaust emissions requirements. The main components of the EGR system include EGR valve, exhaust temperature
sensors, differential pressure sensor, and throttle valve actuator.
EGR works by recirculating a portion of the engine exhaust gasses back into the engine combustion chamber to lower
combustion temperatures.
What is Diesel Exhaust Fluid (DEF)/AdBlue®?

DEF/ADBLUE® is a clear, colorless, non-toxic, aqueous urea solution ( 32.5%) with a slight ammonia odor. It is used
to chemically reduce NOx emissions from heavy-duty diesel-powered vehicles. DEF/ADBLUE® is neither explosive
nor harmful to the environment. DEF/ADBLUE® is classified under the minimum-risk category of transportable fluids.
International standard ISO 22241-1 defines DEF/
ADBLUE® quality. The American Petroleum Insti-
tute (API®) has a voluntary certification program for
DEF/ADBLUE®. To ensure that DEF/ADBLUE® satis-
fies the requirements of ISO 22241, look for the API®
DEF Certification Mark™ whenever you purchase
DEF/ADBLUE®. API Diesel Exhaust Fluid Certification
Mark is a registered trademark of API in the United States
and or other countries.
Finding Diesel Exhaust Fluid (DEF)/AdBlue®

CASE CONSTRUCTION Customer Service:
Call 1-888-365-NHCE (1-888-365-6423) or email customerservice.na@cnh.com.
Storage, handling, and transport

NOTICE: Storage temperatures above 30 °C (86 °F) greatly reduces the shelf life of DEF/ADBLUE®.
DEF/ADBLUE® has a typical shelf life of 6-12 months. Refer to the SHELF LIFE table below. In order for
DEF/ADBLUE® to remain in a useable condition, storage requirements must be met.
• Store between -11 °C (12 °F) and 30 °C (86 °F).
• Use only an approved DEF/ADBLUE® container.
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• Keep container tightly closed.

• Keep container in a cool, well-ventilated area.
• Keep away from heat and direct sunlight.
If the machine will exceed a four month shut down period:

1. Key OFF.
NOTE: Allow 2 – 5 min after Key OFF before disconnecting the batteries.
2. Drain the DEF/ADBLUE® tank.
3. Flush the tank with deionized water.
4. Drain the deionized water.
NOTICE: Do not disconnect any electrical connections from the DEF/ADBLUE® system.
Machine start-up after extended shutdown:

1. Fill the DEF/ADBLUE® tank.
2. Replace the main filter in the supply module.
3. Start the machine.
In tank thawing
Thawing
• Your CASE CONSTRUCTION machine is equipped with an internal tank heater to thaw frozen DEF/ADBLUE®.
Your machine will still function until the DEF/ADBLUE® begins to flow. The SCR system will then function normally.
NOTE: You may notice a slight reduction in engine torque in high demand situations until the DEF/ADBLUE® is fully
thawed.
• Do not heat DEF/ADBLUE® for long periods of time at temperatures above 30 °C (86 °F). This causes the solution
to decompose, which very slowly decreases the expected shelf life.
NOTICE: Do not use an anti-gelling or freeze point improver in your DEF/ADBLUE®. The 32.5% solution is specifically
designed to provide the optimum NOx reduction properties. Any further blending or adjusting of the DEF/ADBLUE®
mixture will lessen its ability to perform correctly and may cause damage to the SCR components.
Handling and supply of additives, if any.

• Personal Protective Equipment (PPE) is not required under normal conditions. If splashing is likely, wear eye pro-
tection. For prolonged or repeated contact, impervious gloves are recommended. Follow the precautions listed in
the SAFETY INFORMATION chapter when handling any service fluid.
• No additives are required or recommended.
NOTICE: Contaminated DEF/ADBLUE® can affect the performance of your machine. Follow all instructions in this
manual when handling DEF/ADBLUE®.
Shelf life
Constant ambient storage temperature Minimum shelf life
Less than or equal to 10 °C (50 °F) 36 months
Less than or equal to 25 °C (77 °F) ¹ 18 months
Greater than 35 °C (95 °F) -²
¹ To prevent decomposition of DEF/ADBLUE®, prolonged transportation or storage above 25 °C (77 °F) should
be avoided.
² Significant loss of shelf life: check every batch before use.
NOTE: The main factors taken into account to define the shelf life in the table above are the ambient storage tem-
perature and the initial alkalinity of DEF/ADBLUE®. The difference in evaporation between vented and non-vented
storage containers is an additional factor.
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NOTE: The information in this table is for reference only and has been provided by the International Organization for
Standardization, Document number ISO 22241-3 Diesel engines - NOx reduction agent AUS 32 - Part 3: Handling,
transportation and storage.
NOTE: DEF/ADBLUE® that remains in the tank of the machine after the season does not require any special precau-
tions unless storage exceeds the shelf life table above.
Disposal
Dispose of DEF/ADBLUE® and any filter accumulations in accordance with all applicable Federal, State, and local
laws governing waste disposal.
Hydrocarbon management
If the engine operates at low idle speed for a prolonged period of time, hydrocarbons can accumulate in the SCR cat-
alyst. To manage this accumulation, your machine will monitor current conditions and increase idle speed or request
action from the operator in order to increase the temperature inside the SCR catalyst and eliminate the hydrocarbons.
NOTICE: Unless the Hydrocarbon (HC) level has reached the most critical level (SCR catalyst full ), running
the unit under load is advantageous for quickly reducing the HC levels.
There are three messages that can be displayed to inform you that hydrocarbon management is active:
Low Idle Increase Recommended

Display Audible alert Action
The Engine Control Unit (ECU) requires the operator to
3 consecutive beeps increase load on the engine or increase engine idle speed to a
minimum of 1350 RPM.
Low Idle Increase Active

The Engine Control Unit (ECU) will automatically increase
engine idle speed to 1350 RPM.
The Engine Control Module (ECU) will allow automatic

Hydrocarbon management only if the machine meets the
5 consecutive beeps following requirements for 10 min:
• the FORWARD-NEUTRAL-REVERSE (F-N-R) lever is kept
in the NEUTRAL position
• the park brake is engaged
• the engine idle speed is below 1350 RPM
NOTE: This automatic engine idle speed increase is inhibited if any of the conditions are not met or certain features
are active on the machine. For example: operating the hand or foot throttle.
NOTE: The operator is free to interrupt the auto idle increase and operate the machine. The display may change to
the low idle increase recommended , if the system determines that additional Hydrocarbon (HC) reduction
is required.
SCR Catalyst Full

1. Place the FORWARD-NEUTRAL-REVERSE (F-N-R) lever
in the NEUTRAL position.
2. Engage the park brake.
Constant audible alarm
3. Use the hand throttle and manually increase the engine
speed to 1500 RPM.
with illumination
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NOTE: The operator does not need to stay with the machine during the Hydrocarbon management procedure. Once
the procedure is complete the display message will disappear and the operator may resume machine operation.
NOTE: This procedure may take approximately 1 – 2 h to complete depending on the ambient air temperature.
NOTICE: Do not turn off the engine, drive the machine, or increase the load on the machine to avoid damage to the
catalyst.
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Selective Catalytic Reduction (SCR) exhaust treatment - General

information Faults and their description
Diesel Exhaust Fluid (DEF)/AdBlue® instrumentation warning
ATTENTION: The fuel system, exhaust after-treatment system, and engine on your machine are designed and built
to government emissions standards. Tampering by dealers, customers, operators, and users is strictly prohibited by
law. Failure to comply could result in government fines, rework charges, invalid warranty, legal action, and possible
confiscation of the machine until rework to original condition is completed. Engine service and/or repairs must be
done by a certified technician only!
Your CASE CONSTRUCTION machine is equipped with a warning system to inform the operator of the DEF/AdBlue®
level, system malfunctions, and engine power loss that may result from the SCR system for reducing exhaust emis-
sions.
Warning symbols
Engine power loss occurring SCR failure
DEF/AdBlue® Low DEF/AdBlue® level
Stop engine light Warning/Fault light
During normal operation of your CASE CONSTRUCTION machine, the instrument cluster displays the DEF/AdBlue®
fluid level (1) at all times.
Warning lights and indicators will be illuminated with a warning on the visual display (2). The display changes auto-
matically to allow the operator to view the warning indicator and display message.
RAIL15TLB0134AA 1
NOTICE: Avoid key-cycles when an active Selective Catalytic Reduction (SCR) exhaust treatment error occurs. Key
cycles with active errors will quickly increase the de-rate severity. Best practice is to move the machine to an area
that is easily accessible for service or for loading onto a transport vehicle.
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DEF level inducement displays

Display Description Warning lamps and Corrective action
alarms
DEF/AdBlue® level is less than Fill DEF/AdBlue® tank.
10% tank volume. No engine
power loss at this level.
One second audible
alarm every 3 min
and the DEF gauge
indicator is near or just
in the red zone.
DEF/AdBlue® level is less than Fill DEF/AdBlue® tank
5% of tank volume. Moderate immediately. Cycle the key
torque reduction and engine switch (or the POWER button)
+
speed reduction will occur. OFF then ON.
Continuous alarm
and the DEF gauge
indicator is in the red
zone.
DEF/AdBlue® level is empty. Fill DEF/AdBlue® tank
Severe torque reduction and immediately. Cycle the key
engine speed reduction will switch (or the POWER button)
+
occur. OFF then ON.
Continuous alarm
and the DEF gauge
indicator is on empty..
DEF quality inducement displays

alarms
DEF/AdBlue® quality / Drain the DEF/AdBlue® tank.
concentration is questionable. Fill the tank with approved
DEF/AdBlue®.
One second audible NOTE: If the problem continues
alarm every 3 min use the EST tool to check Fault
codes.
concentration is questionable Fill the tank with approved
60 min after the initial warning. DEF/AdBlue®.
+
Moderate torque reduction and
Continuous alarm NOTE: If the problem continues
engine speed reduction will
occur. use the EST tool to check Fault
codes.
concentration is questionable 4 h Fill the tank with approved
after the initial warning. Severe DEF/AdBlue®.
+
torque reduction and engine
Continuous alarm NOTE: If the problem continues
speed reduction will occur.
use the EST tool to check Fault
codes.
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DEF technical failure inducement

alarms
SCR fault/failure detected. NOTE: If the problem continues
Torque reduction and engine use the EST tool to check Fault
speed reduction will occur. codes.
One second audible
alarm every 3 min
SCR fault/failure detected NOTE: If the problem continues
60 min after the initial warning. use the EST tool to check Fault
Moderate torque reduction and codes.
+
engine speed reduction will
Continuous alarm
occur.
SCR fault/failure detected 4 h NOTE: If the problem continues
after the initial warning. Severe use the EST tool to check Fault
torque reduction and engine codes.
+
speed reduction will occur.
Continuous alarm
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DEF/AdBlue® level faults, failures, and engine power loss levels
NHPH14ENG0567HA 2
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DEF/AdBlue® quality faults, failures, and engine power loss levels
NHPH14ENG0693HA 3
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SCR system technical faults, failures, and engine power loss levels
There are two types of strategies that are applied to your machine based on the type of failure that occurs.
• For electrical failures, use figure 4.
• For failures that require the SCR system to be operational, use figure 5 and see the section on validation re-starts.
NOTE: You can restart the engine and receive full engine power up to two times at any point after the machine detects
a fault. However, if the machine detects the same fault within 40 operating hours, torque will be reduced to 50% and
the engine will be reduced to idle immediately. If you attempt a third restart, the engine will be locked at 50% torque
and engine idle. Reset the engine restart counter and resolve the fault causing the loss of productivity.
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NHPH14ENG0694JA 4
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NHPH14ENG0566JA 5
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Validation re-starts
Validation re-starts allow operation of the machine for up to 30 min without power loss after a poor DEF/AdBlue®
quality or SCR system fault has been detected. Up to three re-starts are permitted. Re-starts are counted if
either of the following conditions are met:
• Engine speed exceeds 1000 RPM
• Engine running time exceeds 5 min
Normal operation will resume if a reset is detected within the 30 min window.
If a reset is not detected within 30 min, power loss will occur as described in the flowcharts.
If all three validation re-starts have been used and the system has not been reset, the machine is limited to 50%
torque and engine idle only.
Follow the sequence in figure 6 to activate validation re-starts.
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NHPH14ENG0568HA 6
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Resetting the Selective Catalytic Reduction (SCR) system

For DEF/AdBlue® storage tank fluid level faults, failures that can cause engine power loss:
• The DEF/AdBlue® tank level must be raised above 12% total volume.
• The key switch must be cycled to the Off position or throttle returned to low idle position.
For DEF/AdBlue® quality and SCR system technical faults, failures that can cause engine power loss:
• To fully reset the system, the component/failure causing the fault must be repaired or replaced.
• Switching off the engine will reset the system and the engine will restart at full power.
• If the same failure is re-detected within 40 h of engine operation, the maximum engine power loss level will be
introduced.
• If the same failure is detected three consecutive times within 40 h of engine operation, maximum engine power loss
will remain active after engine restart until the system is repaired.
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Selective Catalytic Reduction (SCR) exhaust treatment - Overview
RAIL16TLB0545GA 1
(1) Intake air humidity and temperature sensor (9) Exhaust flap
(2) Air filter (10) Engine Control Unit (ECU)
(3) Supply module (11) SCR upstream temperature sensor
(4) DEF/AdBlue® level and temperature sensor (12) Selective Catalyst Reduction (SCR) catalyst
(5) DEF/AdBlue® quality sensor (13) SCR downstream temperature sensor
(6) Dosing module (14) NH3 sensor
(7) Mixer (15) Downstream NOx sensor
(8) Upstream NOx sensor (16) Engine
The humidity in the intake to the engine (16) affects the emissions in the exhaust stream. The intake air humidity
sensor (1) is located in the intake air piping to the engine between the air filter (2) and the intake manifold. The
information from this sensor is sent directly to the Engine Control Unit (ECU) (10).
Engine exhaust system temperature is critical to the catalytic reactions that take place in the emissions control com-
ponents. To quickly increase the catalyst temperature at initial start-up and light operating loads, there is an exhaust
flap (9) located in the exhaust stream near the turbocharger. The maximum temperature of the exhaust flap is critical,
therefore engine coolant is circulated through the core of this valve. Limiting NOx emissions in the exhaust stream is
one of the major goals of the emission control system on these engines. The upstream NOx sensor (8) is located in
the exhaust stream at the inlet to the dosing module (6). The NOx sensor transmits data to the ECU via the engine
CAN data bus.
DEF/AdBlue® fluid freezes at -11 °C (12 °F). A DEF/AdBlue® fluid level and temperature sensor (4) is installed in the
tank and the instrument cluster displays those levels. The DEF/AdBlue® quality sensor (5) monitors the quality of the
DEF/AdBlue® fluid.
To precisely control the quantity of DEF/AdBlue® fluid injected from the DEF/AdBlue® tank into the exhaust stream,
a DEF/AdBlue® dosing module (6) is integrated in the downpipe. The dosing valve is Pulse Width Modulation (PWM)
controlled by the ECU. The ECU determines the amount of DEF/AdBlue® fluid to inject based on inputs from sensors
in the exhaust stream. Pressurized DEF/AdBlue® fluid is supplied to the dosing module from the supply module (3)
at approximately 9 bar (130 psi).
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Removal of NOx requires a chemical reaction. This chemical reaction takes place in the SCR (12). DEF/AdBlue®
reacts with the SCR catalyst to convert NOx to harmless nitrogen and water vapor.
To assure that the emission system is functioning correctly, a downstream NOx sensor (15) is located in the exhaust
stream at the outlet of the SCR.
The NH3 sensor (14), located at the outlet of the SCR catalyst monitors ammonia (NH3) levels to ensure the proper
amount of DEF/AdBlue® is being used.
Temperature is very important to the chemical reactions that take place in the emission control system. An SCR
upstream temperature sensor (11) is located in the exhaust stream at the inlet of the SCR and compares the reading
of the SCR downstream temperature sensor (13) located in the exhaust stream at the outlet of the SCR. The catalyst
requires about 230 °C (446 °F) for the chemical reaction to take place.
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Selective Catalytic Reduction (SCR) exhaust treatment - Component

identification
Number Component
(1) Muffler, Select Catalytic Reduction (SCR)
(2) NH3 sensor (downstream)
(3) NOx sensor (downstream)
(4) Exhaust Gas Temperature (EGT), (upstream)
(5) Engine exhaust to Select Catalytic Reduction (SCR)
(6) DEF/ADBLUE® dosing module (injector)
(7) NOx sensor (upstream)
(8) DEF/ADBLUE® tank
(9) NOx sensor (upstream) module
(10) Heater valve
(11) DIESEL EXHAUST FLUID (DEF)/ADBLUE® tank cap with in-line screen filter
(12) DIESEL EXHAUST FLUID (DEF)/ADBLUE® tank heater coil and supply assembly
(13) DIESEL EXHAUST FLUID (DEF)/ADBLUE® supply module with filter
(14) Exhaust Gas Temperature (EGT), (downstream)
(15) NOx sensor (downstream) module
(16) NH3 sensor (downstream) module
RAIL16TLB1392UA 1
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Number Component
(1) Engine exhaust to Select Catalytic Reduction (SCR)
(2) NOx sensor (upstream)
(3) Coolant supply from DEF/ADBLUE® supply module
(4) Coolant return from DIESEL EXHAUST FLUID (DEF)/ADBLUE® dosing module (injector) to
engine
(5) Heater valve
(6) NOx sensor (upstream) module
(7) Coolant return from DIESEL EXHAUST FLUID (DEF)/ADBLUE® dosing module (injector) to
engine
(8) Coolant supply to heater valve from engine
(9) Heater valve DEF/ADBLUE® return to tank
(10) DEF/ADBLUE®supply from supply module to DEF/ADBLUE® dosing module (injector)
(11) DEF/ADBLUE® dosing module (injector)
RAIL16TLB1395UA 2
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Selective Catalytic Reduction (SCR) muffler and catalyst - Remove

1. Remove the three bolts (1) on the exhaust shield.
RAIL14TLB1308AA 1
2. Remove the exhaust shield.
RAIL14TLB1309AA 2
3. Remove the bolts.

4. Remove the selective catalyst reduction (SCR) cover.
5. Remove all necessary wire ties restraining the wire har-
ness.
RAIL14TLB1313AA 3
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6. Remove the mounting plate unplug the electrical con-

nector.
RAIL14TLB1314AA 4
7. Unplug the electrical connectors.
RAIL14TLB1315AA 5
8. Remove the two bolts and lift the plate out from the se-
lective catalyst reduction (SCR) muffler compartment.
9. Unplug the sensor.
RAIL14TLB1316AA 6
10. Loosen the exhaust clamp.
RAIL14TLB1317AA 7
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11. Remove the exhaust pipe.

NOTE: Use caution to prevent damage the sensors or sen-
sor wiring.
RAIL14TLB1318AA 8
12. Remove the bolts (1) under the selective catalyst re-
duction (SCR) muffler.
RAIL14TLB1320AA 9
13. Remove the three bolts (1) from the exhaust guard.
RAIL14TLB1321AA 10
14. Remove the exhaust guard.
RAIL14TLB1322AA 11
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15. Loosen the exhaust clamp.
RAIL14TLB1323AA 12
16. Pull the exhaust away from the selective catalyst re-
duction (SCR) muffler inlet.
RAIL14TLB1327AA 13
17. Use a plastic tie strap to hold the hydraulic hoses back
to prevent obstructing the selective catalyst reduction
(SCR) muffler during the next step.
RAIL14TLB1325AA 14
18. CAUTION
Heavy object!
The component is heavy. Use care not to drop
the component when installing, removing, or
handling.
Failure to comply could result in minor or mod-
erate injury.
C0095A
Lift the selective catalyst reduction (SCR) muffler out

of the compartment.
Next operation:
Selective Catalytic Reduction (SCR) muffler and catalyst - Install (10.500)
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Selective Catalytic Reduction (SCR) muffler and catalyst - Install

Prior operation:
Selective Catalytic Reduction (SCR) muffler and catalyst - Remove (10.500)
1. CAUTION
Heavy object!
The component is heavy. Use care not to drop
the component when installing, removing, or
handling.
erate injury.
C0095A
Carefully lower the selective catalyst reduction (SCR)

muffler into place.
2. Loosely install the four bolts (1) on the bottom of the
selective catalyst reduction (SCR) muffler.
RAIL14TLB1320AA 1
3. Loosely install the bolts, nuts and washers on the se-

lective catalyst reduction (SCR) cover.
4. Tighten the bolts from steps 2 and 3.
5. Move the exhaust pipe into position against the selec-
tive catalyst reduction (SCR) muffler inlet (1).
RAIL14TLB1327AA 2
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6. Tighten the exhaust clamp.
RAIL14TLB1323AA 3
7. Put the exhaust guard into position.
RAIL14TLB1322AA 4
8. Install and tighten the three bolts (1).
RAIL14TLB1321AA 5
9. Install the exhaust pipe.

NOTE: Use caution to prevent damage the sensors or sen-
sor wiring.
RAIL14TLB1318AA 6
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10. Tighten the exhaust clamp.
RAIL14TLB1317AA 7
11. Install the plate and tighten the two bolts.

12. Plug in the electrical connectors.
RAIL14TLB1315AA 8
13. Plug in the electrical connection and install the mount-

ing plate.
RAIL14TLB1314AA 9
14. Plug in the sensor.
RAIL14TLB1316AA 10
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15. Secure the wire harnesses with plastic wire ties.
RAIL14TLB1334AA 11
16. Put the selective catalyst reduction (SCR) cover into

position.
17. Install and tighten the bolts (1).
18. Put the exhaust shield into position.
RAIL14TLB1309AA 12
19. Tighten the three bolts (1) on the exhaust shield.
RAIL14TLB1308AA 13
20. If required, remove the plastic wire tie used to restrain

the hydraulic hoses.
RAIL14TLB1335AA 14
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Diesel Exhaust Fluid (DEF)/AdBlue®/ARLA tank - Cleaning filter

tion.
6. Stop the engine and remove the starter switch key
7. Switch the master disconnect to the off position.
RAIL15TLB0014AA 1
8. Remove the cap from the DEF/ADBLUE® tank.
RAIL15TLB0060AA 2
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9. Turn the screen filter counter-clockwise and remove.
RAIL15TLB0063AA 3
10. Rinse the screen filter with water.

11. Air or blow dry the screen filter.
RAIL15TLB0064AA 4
12. Fully Insert the screen filter and turn it clockwise.

13. Secure the cap on the tank.
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Diesel Exhaust Fluid (DEF)/AdBlue®/ARLA tank - Filling

Diesel Exhaust Fluid (DEF)/AdBlue® tank capacity: 13.5 L (3.6 US gal).
When theDiesel Exhaust Fluid (DEF)/AdBlue® low

fluid symbol appears in the display you will also notice
one of the following symbols illuminate on the instru-
ment cluster:
Warning symbol and an audible alert. The

system detects that the DEF/AdBlue® fluid is too
low.
Stop symbol with an audible alert. The system

detects that the DEF/AdBlue® fluid is extremely
low. The system will begin to de-rate engine speed
and torque.
RAIL14TLB1090AA 1
NOTE: When you refuel your machine also fill the DEF/
AdBlue®.
1. Remove the filler cap (1) on the DEF/AdBlue® tank.
RAIL15TLB0037AA 2
2. Fill the tank with DEF/AdBlue®.
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Diesel Exhaust Fluid (DEF)/AdBlue®/ARLA tank - Drain fluid

Diesel Exhaust Fluid (DEF)/AdBlue® tank capacity: 13.5 L (3.6 US gal).
When theDiesel Exhaust Fluid (DEF)/AdBlue® poor

quality symbol appears in the display you will also no-
tice one of the following symbols illuminate on the in-
strument cluster:
Warning symbol and an audible alert. The

system detects that the DEF/AdBlue® quality is
poor.
Stop symbol with a constant audible alert.

The system detects that the DEF/AdBlue® qual-
ity is poor. The system will begin to de-rate engine
speed and torque.
RAIL14TLB1163AA 1
1. Remove the filler cap (1) on the DEF/AdBlue® tank.
RAIL15TLB0037AA 2
2. Remove the cover plate below the DEF/AdBlue® tank

drain plug.
RAIL15TLB0034AA 3
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3. Place a suitable container below theDEF/AdBlue®

tank drain plug.
RAIL15TLB0033AA 4
4. Install the DEF/AdBlue® tank drain plug.

5. Install the cover plate.
6. If applicable, clean the “Diesel Exhaust Fluid (DEF)/Ad-
Blue® tank filler screen” Diesel Exhaust Fluid
(DEF)/AdBlue®/ARLA tank - Cleaning filter (10.500),
the “Diesel Exhaust Fluid (DEF)/AdBlue® in-line filter”
Diesel Exhaust Fluid (DEF)/AdBlue®/ARLA lines
- Cleaning filter (10.500), and replace the “Diesel
Exhaust Fluid (DEF)/AdBlue® supply module filter”
Coolant control valve - Replace - supply module
filter (10.500).
NOTE: Contact your authorized dealer if your current supply of DEF/AdBlue® is low or the quality is questionable.
7. Fill the DEF/AdBlue® with new DEF/AdBlue®.
8. Operate the machine and monitor. The system may
require a validation restart.
NOTICE: If the poor quality symbol continues to appear on the display contact your authorized dealer for assistance.
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Coolant control valve - Replace - supply module filter

1. To access the supply module, remove the corner
shroud.
RAIL15TLB0023AA 1
2. Remove the DEF/AdBlue® tank cover plate.
RAIL15TLB0022AA 2
3. Remove the fuel tank step plate.
RAIL15TLB0020AA 3
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4. Remove the three bolts from the panel to the right-hand

side of the step, in front of the rear tire.
RAIL14TLB0964BA 4
5. These bolts attach to a bracket that hold the supply

module in place.
RAIL14TLB0970BA 5
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NOTICE: Pay attention to the location of each tube in the

supply module. Also take care not to damage or loosen
the connectors on the lines. Tubes and connector that have
damage or fit loosely will not connect properly to the supply
module causing leaks and issues with the Selective Cata-
lyst Reduction (SCR) system.
6. Remove three tube quick connectors that attach to the
supply module.
NOTE: You will not be able to pull the supply module com-
pletely out to disconnect the tubes. You will need to reach
behind the supply module and disconnect the tubes.
RAIL14TLB0967BA 6
RAIL14TLB0968BA 7
7. Remove the filter cover.
RAIL14TLB0969BA 8
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8. Remove the equalizing element.
RAIL13GEN0027AA 9
9. Remove the filter tool from the new filter element.

Check the color of the filter (Grey or Black). Based on
the color of your filter element, insert the correct end
of the filter tool into the filter element.
NOTE: The filter tool comes with the new filter element.
RAIL13GEN0028AA 10
10. Insert the tool completely until a click is felt or heard.

This indicates that the tool is completely inserted.
RAIL13GEN0029AA 11
11. Pull the tool with the filter element out of the supply
module.
RAIL13GEN0030AA 12
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12. Clean the supply module filter housing and threads

with distilled water.
RAIL13GEN0031AA 13
13. Oil the O-rings on the new filter element. Insert the
filter element fully into the supply module.
RAIL13GEN0032AA 14
14. Install the new equalizing element.
RAIL13GEN0027AA 15
15. Install the filter cover. Torque to 15 – 25 N·m (11 –

18 lb ft)
RAIL13GEN0026AA 16
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16. Connect the three connections back to the supply

module. you will hear them snap in place.
RAIL14TLB0968BA 17
17. Install the bracket and secure the supply module in

place.
RAIL14TLB0970BA 18
RAIL14TLB0964BA 19
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Diesel Exhaust Fluid (DEF)/AdBlue®/ARLA lines - Cleaning filter

tion.
6. Stop the engine and remove the starter switch key
7. Switch the master disconnect to the off position.
RAIL15TLB0014AA 1
8. Remove the bolts from the cover plate to access the

sending unit.
RAIL15TLB0081AA 2
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9. Locate and remove the quick connect supply (suction)

tube.
RAIL15TLB0077AA 3
10. Use a flat needle-nose pliers and pull the filter directly
upward.
RAIL15TLB0079AA 4
11. Clean the filter with water.
RAIL15TLB0078AA 5
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12. Reinstall the filter.
RAIL15TLB0079AA 6
13. Connnect the supply (suction) tube. you will hear it

snap into place.
RAIL15TLB0080AA 7
14. Reinstall the cover for the sending unit.
RAIL15TLB0081AA 8
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Index
Engine - 10

Coolant control valve - Replace - supply module filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Diesel Exhaust Fluid (DEF)/AdBlue®/ARLA lines - Cleaning filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Diesel Exhaust Fluid (DEF)/AdBlue®/ARLA tank - Cleaning filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Diesel Exhaust Fluid (DEF)/AdBlue®/ARLA tank - Drain fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Diesel Exhaust Fluid (DEF)/AdBlue®/ARLA tank - Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Selective Catalytic Reduction (SCR) exhaust treatment - Component identification . . . . . . . . . . . . . 20
Selective Catalytic Reduction (SCR) exhaust treatment - General information Faults and their de-
scription . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Selective Catalytic Reduction (SCR) exhaust treatment - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Selective Catalytic Reduction (SCR) exhaust treatment - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Selective Catalytic Reduction (SCR) muffler and catalyst - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Selective Catalytic Reduction (SCR) muffler and catalyst - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
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Engine - 10
Engine cooling system - 400

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Contents
Engine - 10
FUNCTIONAL DATA
Engine cooling system

Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SERVICE
Engine cooling system

Change fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
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Engine - Engine cooling system
Engine cooling system - Component identification
LELI12TLB0037GB 1
1. Cooler charged air

2. Condenser
3. Radiator
4. Oil cooler
5. Cooler fuel
6. Washer
7. M12 X 30 hex screw
[tightening torque 90 – 110 N·m (66 – 81 lb ft)]
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Engine cooling system - Change fluid

CAUTION
Burn hazard!
Hot coolant can spray out if you remove the filler cap while the system is hot. After the system has
cooled, turn the filler cap to the first notch and wait for all pressure to release before proceeding.
Failure to comply could result in minor or moderate injury.
C0043A
NOTICE: NEVER mix OAT coolant with conventional coolant. Under no circumstances should you top off a cooling
system with only water. You can use a refractometer to check the concentration level. Supplemental Coolant Additives
(SCA) should not be used when using CASE AKCELA ACTIFULL™ OT EXTENDED LIFE COOLANT.
Drain, flush, and replace the engine coolant every 4000 h of operation or every year, whichever comes first.
Coolant fluid specification: CASE AKCELA ACTIFULL™ OT EXTENDED LIFE COOLANT
Coolant fluid capacities:
24.0 L (25.4 US qt)
1. Park the machine on level ground.

2. Raise the loader arm and engage the safety support.
3. Shut down the engine and place a 'Do Not Operate' tag
on the key switch.
4. Allow time for the engine and the coolant to cool.
5. Remove the front grille.
6. Place a piece of hose onto the radiator drain valve and
drain into a suitable container.
7. WARNING
Hot liquid under pressure!
Service when cool.
Failure to comply could result in death or seri-
ous injury.
W1187A
Open the filler cap on the de-aeration reservoir. Open

the filler cap by slowing turning the cap counter-clock-
wise until it is removed. It is not necessary to remove
the hoses in order to remove the cap.
RAIL14TLB0983BA 1
8. Remove the bolts that secure the coolers.

9. Swing the coolers out and clean of dirt and debris.
10. Check the hoses, elbows, and system components for
wear or damage.
11. After cleaning, swing the coolers back in and replace
the bolts.
12. After all the coolant has been drained, close the drain
valve. Do not detach the drain hose.
13. Pour approximately 24.0 L (25.4 US qt) of clean water
into the de-aeration reservoir until full.
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NOTE: In some situations air pockets in the coolant system

may prevent you from filling the system to capacity. If this
occurs remove the de-aeration valve cap this allows the air
to escape during the fill procedure. The de-aeration valve
cap is on the top right-hand side of the engine below the
air filter housing.
NOTE: Do not over fill the coolant system.
RAIL14TLB1164AA 2
14. Secure the filler cap on the de-aeration reservoir. If

applicable attach the de-aeration valve cap.
15. Start the engine and run for at least 30 min.
NOTE: Make sure that you activate the heating system (if
equipped) to circulate fluid through the heater core.
16. Remove the de-aeration filler cap.
17. Drain the water from the system.
18. Repeat Steps 13– 17 for a clean system flush.
19. After the radiator flush, close the radiator drain valve,
and detach the drain hose.
20. Pour coolant into the de-aeration reservoir until the
level reaches between the COLD MIN mark and the
HOT MAX mark on the tank.
21. Install the filler cap.
22. Start up the engine.
23. Run the engine for a few minutes and stop the engine
before it reaches operating temperature.
24. Check the system for leaks.
25. Start up the engine again and allow the engine to
reach operating temperature.
26. Shut down the engine.
27. Check the fluid level in the de-aeration reservoir.
28. If necessary, allow the components to cool and add
coolant to the reservoir.
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Engine cooling system - Remove

1. Remove the grill.
LELI12TLB0008AB 1
2. Lower the hood and attach the lifting device of ade-

quate capacity.
LELI12TLB0011AB 2
3. Remove the hood attaching hardware.
LELI12TLB0012AB 3
4. Remove the hood.
RAIL15TLB0181AA 4
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5. Disconnect the air inlet snorkel from the air cleaner.
RAIL15TLB0195AA 5
6. Remove the two mounting bolts (1) from the end of the
snorkel and remove.
RAIL15TLB0198AA 6
7. Disconnect the connector X-2 from the horn.
RAIL15TLB0191AA 7
8. Remove the four mounting bolts (1) for the hood sup-
port. Right side shown, repeat for left side. Remove
the support.
RAIL15TLB0199AA 8
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9. Remove the upper radiator hose.
LELI12TLB0025AA 9
10. Remove the intercooler hoses and pipes.
RAIL15TLB0185AA 10
11. Seal all the open ports to keep contaminates from en-
tering the system.
LELI12TLB0027AA 11
12. Remove the lower radiator hose.
LELI12TLB0028AA 12
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13. Disconnect the aspirator hose from the fan shroud.
RAIL15TLB0188AA 13
14. Tag and disconnect the front cooler lines and plug all
the open ports.
RAIL15TLB0193AA 14
15. Disconnect and cap the cooler lines, left side shown,
repeat for right side.
RAIL15TLB0191AA 15
16. Disengage the hose clamps (1), securing the cooler

hoses at the bottom of the cooling package.
RAIL15TLB0203AA 16
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17. Attach a suitable device.
RAIL15TLB0200AA 17
18. Remove the radiator mounting hardware.
RAIL15TLB0201AA 18
19. Make sure that all the harness connectors and hoses
have been disconnected and are clear of the radia-
tor. Slowly raise and remove the radiator from the ma-
chine.
RAIL15TLB0206AA 19
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Engine cooling system - Disassemble

1. Remove the fuel cooler mounting bolts.
RAIL15TLB0207AA 1
2. Remove the fuel cooler.
RAIL15TLB0208AA 2
3. Remove the air charge cooler mounting bolts (1) on

both sides of the radiator. Right side shown. Remove
the air charge cooler.
RAIL15TLB0209AA 3
4. Remove the oil cooler mounting bolts (1) on the right

side of the cooler.
RAIL15TLB0213AA 4
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5. Remove the oil cooler mounting bolts (1) on the left side
of the cooler.
RAIL15TLB0214AA 5
6. Remove the oil cooler.
RAIL15TLB0215AA 6
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Engine cooling system - Assemble

1. Install the oil cooler.
RAIL15TLB0215AA 1
2. Secure the cooler with the bolts (1) removed earlier.
RAIL15TLB0214AA 2
3. Install the air charge cooler with the bolts (1) removed
earlier.
RAIL15TLB0209AA 3
4. Install the fuel cooler.
RAIL15TLB0208AA 4
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5. Secure the fuel cooler with the bolts removed earlier.
RAIL15TLB0207AA 5
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Engine cooling system - Install

1. Carefully lower the radiator on its correct location.
RAIL15TLB0206AA 1
2. Install the radiator with the mounting hardware re-

moved earlier.
RAIL15TLB0201AA 2
3. Remove the lifting device.
RAIL15TLB0200AA 3
4. Connect the left-and right hand side cooler hoses.
RAIL15TLB0191AA 4
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5. Connect the front radiator hoses.
RAIL15TLB0193AA 5
6. Attach the lower radiator hose.
LELI12TLB0028AA 6
7. Connect the aspirator hose to the fan shroud.
RAIL15TLB0188AA 7
8. Install the intercooler hoses and ducts.
RAIL15TLB0185AA 8
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9. Install the upper radiator hose.
LELI12TLB0025AA 9
10. Install the hood support and secure with the bolts (1)
removed earlier.
RAIL15TLB0199AA 10
11. Connect the connector X-2 to the horn.
RAIL15TLB0191AA 11
12. Connect the air intake duct to the air filter.
RAIL15TLB0195AA 12
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13. Secure the air intake duct with the bolts (1) removed
earlier.
RAIL15TLB0198AA 13
14. Lower the hood into place.
RAIL15TLB0181AA 14
15. Secure the hood with the hardware removed earlier.
LELI12TLB0012AB 15
16. Install the grill.
LELI12TLB0008AB 16
17. Fill the cooling system with coolant.
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Index
Engine - 10

Engine cooling system - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Engine cooling system - Change fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Engine cooling system - Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Engine cooling system - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Engine cooling system - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Engine cooling system - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
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Engine - 10
Fan and drive - 414

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Contents
Engine - 10
Fan and drive - 414
SERVICE
Belt
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
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Engine - Fan and drive
Belt - Remove
Replace the fan drive belt as needed.
1. Loosen the lower alternator bolt (2).

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

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

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

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

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

Belt - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Belt - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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CNH Industrial America - Main 700 State Street Racine, Wisconsin United States 53404
SERVICE - Technical Publications & Tools
PRINTED IN U.S.A.
© 2017 CNH Industrial America LLC.
All rights reserved. No part of the text or illustrations of this publication may be reproduced.
CASE CONSTRUCTION policy is one of continuous improvement and the right to change prices, specification
or equipment at any time without notices is reserved.
All data given in this publication is subject to production variations. Dimensions and weight are approximate only
and the illustrations do not necessarily show products in standard condition. For exact information about any
particular product, please consult your CASE CONSTRUCTION Dealer.
48090752 24/02/2017
EN
SERVICE MANUAL
Power coupling

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19
Contents
Power coupling - 19
[19.100] Drive shaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.1
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Power coupling - 19
Drive shaft - 100

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Contents
Power coupling - 19
Drive shaft - 100
FUNCTIONAL DATA
Drive shaft
Detailed view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
SERVICE
Drive shaft
Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
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Power coupling - Drive shaft
Drive shaft - Detailed view

2WS
LELI12TLB2253FB 1
1. Front axle 5. Bracket

2. Front cardan shaft 6. Screw [tightening torque 35 – 41 N·m (26 – 30 lb
ft)]
3. Screw [tightening torque 33 – 39 N·m (24 – 29 lb 7. Rear cardan shaft
ft)]
4. Bracket 8. Rear axle
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4WS
LELI12TLB2254FB 2
1. Front axle 5. Bracket

2. Bracket 6. Screw [tightening torque 35 – 41 N·m (26 – 30 lb
ft)]
3. Screw [tightening torque 35 – 41 N·m (26 – 30 lb 7. Rear cardan shaft
ft)]
4. Front cardan shaft 8. Rear axle
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Drive shaft - Exploded view

Cardan joint
LELI12TLB0282GB 1
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Drive shaft - Disassemble

1. Remove the snap rings (3).
LELI12TLB0283AB 1
2. Use the V-block to support the coupling (5).

3. Adjust the screws in the V-block to hold the coupling
level.
4. Use a driver and press the bottom bearing cup against
the V-block.
LELI12TLB0284AB 2
5. Fasten the bearing cup in a vice and drive the coupling

off the bearing cup.
LELI12TLB0285AA 3
6. Use the V-block to support the coupling and press the

other bearing cup against the V-block.
LELI12TLB0286AA 4
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7. Remove the long axle shaft (2) from the coupling (5).
LELI12TLB0287AB 5
8. Remove the coupling (5) from the bearing cup.
LELI12TLB0288AB 6
9. Press the bottom bearing cup out of the yoke.
LELI12TLB0289AA 7
10. Remove the yoke from the bearing cup. DO NOT hit
the axle shaft in the seal area.
LELI12TLB0290AA 8
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11. Press the other bearing cup out of the yoke.
LELI12TLB0291AA 9
12. Remove the joint (4).
LELI12TLB0292AB 10
13. Press the bearing cup out of the yoke.
LELI12TLB0293AA 11
14. Press the bearing cup into the yoke until the top of
the bearing cup is 6 mm (0.24 in) above the top of the
yoke.
LELI12TLB0294AA 12
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Drive shaft - Assemble

1. Carefully install the cross in the bearing cap.
RCPH10TLB586ABL 1
2. Press the other bearing cap into the yoke until the top
of the bearing cap is 9 mm (0.35 in) above the top of
the yoke.
RCPH10TLB587ABL 2
3. Carefully raise the cross into the bearing cap so that

the cross is in both bearing caps.
RCPH10TLB588ABL 3
4. Hold the cross and press the bearing caps into the
yoke.
RCPH10TLB589ABL 4
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5. Use an acceptable driver and press a bearing cap into

the yoke so that a snap ring can be installed.
RCPH10TLB590ABL 5
6. Install a snap ring.
RCPH10TLB591ABL 6
7. Repeat for the other bearing cap.

8. Use a V-block to support the coupling and press a bear-
ing cap into the coupling even with the OD of the cou-
pling.
RCPH10TLB592ABL 7
RCPH10TLB595ABL 8
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10. Use an acceptable driver and press the other bearing

cap into the coupling until the top of the bearing cap
is 6 mm (0.24 in) above the top of the coupling.
RCPH10TLB597ABL 9
11. Carefully raise the cross into the top bearing cap so
that the cross is in both bearing caps.
RCPH10TLB598ABL 10
12. Hold the cross and press the bearing cap into the cou-
pling so that a snap ring can be installed.
RCPH10TLB600ABL 11
RCPH10TLB601ABL 12
14. Repeat for the other bearing cap.
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Index
Power coupling - 19
Drive shaft - 100

Drive shaft - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Drive shaft - Detailed view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Drive shaft - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Drive shaft - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
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PRINTED IN U.S.A.
48090752 24/02/2017
EN
SERVICE MANUAL
Transmission

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21
Contents
Transmission - 21
[21.112] Power shuttle transmission. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.1
[21.134] Power shuttle transmission external controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.2
[21.154] Power shuttle transmission internal components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.3
[21.113] Powershift transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.4
[21.135] Powershift transmission external controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.5
[21.105] Powershift transmission hydraulic components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.6
[21.155] Powershift transmission internal components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.7
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Transmission - 21
Power shuttle transmission - 112

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Contents
Transmission - 21
TECHNICAL DATA

General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
FUNCTIONAL DATA

Overview How it works (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Exploded view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Drawing Front view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Drawing Rear view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Drawing Right view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Drawing Top view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Sectional view Kinematic schematic (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Sectional view Transmission input shaft (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Hydraulic schema Transmission hydraulic schematic (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
SERVICE

Replace (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Drain fluid (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Filling (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Check Supply pump pressure (4WD only) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Test Checking converter in pressure (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Test Regulated clutch pressure (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Test Supply pump flow and relief pressure (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Test Converter out pressure (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Test Lubrication pressure (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Test Differential lock valve (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
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Pressure test 2 Wheel drive, test one engine at idle, 900 to 1100 RPM (*) . . . . . . . . . . . . . . . . . . . . . . . . . 45
Pressure test 2 Wheel drive, test two engine at 2200 RPM (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Tool connection 2 Wheel drive port identification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Tool connection Pressure test ports, 2 wheel drive (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Tool connection Pressure test ports, 4 wheel drive (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Tool connection 4 Wheel drive port identification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Pressure test 4 Wheel drive, test one engine at idle, 900 to 1100 RPM (*) . . . . . . . . . . . . . . . . . . . . . . . . . 51
Pressure test 4 Wheel drive, test two engine at 2200 RPM (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Transmission housing
Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Disassemble Shifter housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Disassemble Shift rods and shift forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Assemble Shifter housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Assemble Transmission housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
DIAGNOSTIC

Testing Machine will not move . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Testing Machine will not go into 4WD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Testing Machine hesitates when shifting between forward and reverse . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Testing Loss of power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Testing Transmission oil is too hot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Testing Problem in the parking brake system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
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Transmission - Power shuttle transmission
Power shuttle transmission - General specification

Type of transmission oil CASE AKCELA NEXPLORE™ FLUID
Clutch disc clearance 2.3 – 4.3 mm (0.1 – 0.2 in)
Capacity - Two wheel drive

Refill capacity with or without filter change 11.9 L (12.6 US qt)
Capacity - Four wheel drive

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

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

Pipe plug in end of four-wheel drive shaft 30 N·m (265.5 lb in)
Solenoid valve in four-wheel drive valve 22.0 N·m (194.7 lb in)
Nut for solenoid coils on transmission control valve 7 – 10 N·m (62.0 – 88.5 lb in)
Fittings for four-wheel drive clutch tube 30 N·m (265.5 lb in)
Allen head screws for valve plate on front housing 23 N·m (203.6 lb in)
Test port plugs 23 N·m (203.6 lb in)
Detent plugs 80 N·m (59.0 lb ft)
Bolts for rear cover 50 N·m (36.9 lb ft)
Bolt for output flange 139 N·m (102.5 lb ft)
Allen head screws for shifter assembly 23 N·m (203.6 lb in)
Hollow cap screws for tube on front housing 40 N·m (354.0 lb in)
Bolts to fasten front and rear housings 50 N·m (36.9 lb ft)
Bolts to fasten cover below four-wheel drive flange 23 N·m (203.6 lb in)
Bolt for four-wheel drive flange 139 N·m (102.5 lb ft)
Bolts for oil pump 23 N·m (203.6 lb in)
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Fitting for oil filter 50 N·m (36.9 lb ft)

Bolts to fasten four-wheel drive valve to front housing 23 N·m (203.6 lb in)
Bolts to fasten cover for oil screen 23 N·m (203.6 lb in)
Bolts for transmission control valve 23 N·m (203.6 lb in)
Drain plug 80 N·m (59.0 lb ft)
Allen head screws to fasten pump support to pump 10 N·m (88.5 lb in)
housing
Nut for four-wheel drive solenoid coil 8 N·m (70.8 lb in)
Allen head screws for modulation cover 11 N·m (97.4 lb in)
Solenoid plunger in transmission control valve 23 N·m (203.6 lb in)
Bolts to fasten pump mount to rear housing 50 N·m (36.9 lb ft)
Power shuttle transmission - Special tools

CAS1804 Pressure Fitting Kit
RCPH11TLB020BAL 1
CAS40033 Transmission Tool Kit
RCPH11TLB021BAL 2
380001740 Flowmeter Fitting Kit
RCPH11TLB022BAL 3
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380040161 - Teflon seal installation
RCPH10TLB828AAL 4
CAS2379 Input shaft holder and spring compressor
RCPH10TLB043ABL 5
CAS2381 Seal driver
RCPH10TLB045BL 6
CAS2771 - Teflon seal installation tool kit - 4 wheel drive

shaft
CAS2327 Pusher
RCPH10TLB688AAL 7
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Power shuttle transmission - Overview How it works

580ST
590ST
695ST
Refer to Power shuttle transmission - Hydraulic schema Transmission hydraulic schematic (21.112) for more
information.
Oil enters the transmission charge pump (31) from the transmission sump, through a 250 µm screen (1). Oil leaves
the supply pump and is filtered (29) prior to entering the pressure regulator valve (10). The pressure regulation valve
assured constant pressure is available to disengage the four-wheel drive. The charge pump cold relief valve (28)
protects the charge pump from overpressure.
4WD control
4WD pressure flows to the 4WD control valve (27) through a check valve. With no electrical signal to the 4WD valve,
the 4WD clutch supply passage is connected to the tank. The 4WD clutch is spring applied and engages with no
supply pressure. Use extreme caution when working around a running machine as the 4WD system can engage with
no power applied to the solenoid. The 4WD electrical switch is normally closed. When the contacts open to release
the clutch, the switch indicator light is on.
Oil exits the 4WD pressure regulator (10), after the regulated oil supply to the four-wheel drive circuit has been sat-
isfied.
Flow divider
Oil flow leaving the 4WD pressure regulator enters the control valve assembly at the flow divider (11). At this point,
flow is divided between the control valve and the torque converter/lubrication circuits. A 3.5 mm (0.138 in) orifice in
the flow divider spool allows oil to enter the open center area of the forward/reverse shuttle spool (16). When the oil
requirement of the transmission clutch circuit is met, the flow divider allows oil to enter the torque converter/lubrication
circuits. Torque converter inlet pressure is measures at port (9).
Clutch modulation
When the forward/reverse shuttle spool (16) is shifted forward, oil flow is now directed to the forward clutch pack (18).
To control the speed of clutch engagement, the modulator circuit is brought into play. Oil flows enters the modulator
piston (35) area through a 1 mm (0.039 in) orifice. To slow the rate of forward/reverse clutch pressure rise, there is
also a 0.6 mm (0.024 in) leak off orifice in the modulation piston. This orifice allows some of the flow supplied to the
piston to leak away. The pressure at the piston increases as the 1 mm (0.039 in) supply orifice is larger than the
0.6 mm (0.024 in) leak orifice. Oil pressure to the forward clutch pack gradually increases as the modulator piston
slowly compresses a multiple spring pack against the modulator spool (15). The modulation continues until the mod-
ulator piston bottoms out in its bore. At this point, the spring force on the modulation spool controls the maximum
clutch pressure. The modulator spool continues to regulate the clutch pressure by returning oil to the transmission
sump.
When the forward/reverse shuttle valve is returned to neutral, it is necessary to remove the clutch apply pressure to
minimum as quickly as possible. The check valve in the modulation circuit (14) dumps oil from behind the modulation
piston, returning the circuit flow to open center pressure. If the transmission is shifted into reverse, the forward/reverse
shuttle spool is actuated and the reverse clutch is engaged. All remaining modulation circuits function as previously
described.
Differential lock
The differential lock solenoid (6) also receives its oil supply from the oil sent to either the forward clutch or the reverse
clutch. If you are moving the machine through an area that is soft and muddy, make sure that the machine is moving
in a straight direction and the one of the rear wheels is not rotating faster than the other. Actuate the differential
lock switch on the loader control lever to activate the differential lock solenoid. This will activate the differential lock
solenoid (7) in the rear axle. Keep this switch activated while you are moving the machine through a soft or muddy
area. After you have moved through this area, release the differential lock switch.
NOTE: The differential lock will release automatically when the load on the axle is removed.
NOTICE: You may cause damage to the rear axle if you try to engage the differential lock when the machine is turning
or if one of the rear wheels is rotating faster than the other.
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Power shuttle transmission - Exploded view

MARBLE CUTTING
DRIVE (2WD)
DRIVE (4WD)
RAIL17TLB0067GA 1
Table 1
1. Transmission 8. M16 X 120 hex bolt
2. Anti-vibration 9. Washer
3. Left-hand side transmission support (welded on 10. M16 nut - torque 210 – 240 N·m (155 – 177 lb ft)
the chassis frame)
4. Right-hand side transmission support (welded on
the chassis frame)
5. Washer 11. Washer
6. M12 X 30 hex bolt - torque 90 – 110 N·m (66 – 12. Bracket transmission mounting
81 lb ft)
7. Washer
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LELI12TLB0344FB 2
Table 2
1. Transmission 5. Snap ring
2. Torque converter 6. Washer
3. Plate 7. M10 X 20 hex bolt - torque 52 – 57 N·m (38 –
42 lb ft)
4. Plate 8. M10 X 30 hex bolt - torque 52 – 57 N·m (38 –
42 lb ft)]
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LELI12TLB0345FB 3
Table 3
1. Fitting (apply LOCTITE® 567™ PST PIPE SEALANT) 4. M10 X 30 hex bolt - torque 52 – 57 N·m (38 –
2. Dipstick tube 42 lb ft)
3. Dipstick 5. Washer
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Power shuttle transmission - Drawing Front view

580ST
590ST
695ST
RAIL16TLB1307GA 1
1 Spin on filter 2 Oil pump

Nominal 10 µm Max pressure 16 bar (232 psi)
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Power shuttle transmission - Drawing Rear view

580ST
590ST
695ST
RAIL16TLB1308GA 1
1 Oil outlet port to brake power 2 Oil inlet port from brake power
@ 900 RPM 13.0 – 14.0 bar (188.5 –
203.0 psi)
@ 2200 RPM 13.0 – 15.5 bar (188.5 –
224.8 psi)
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Power shuttle transmission - Drawing Right view

580ST
590ST
695ST
RAIL16TLB1309GA 1
1 Oil inlet port from cooler 5 SAE 3 torque converter housing

2 Speed shift lever 6 Suction filter
Nominal 250 µm
3 Breather plug 7 Magnetic oil drain plug (SW 1/2”)
4 Oil outlet port to cooler
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Power shuttle transmission - Drawing Top view

580ST
590ST
695ST
RAIL16TLB1310GA 1
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1 Reverse clutch pressure check point 10 Oil outlet/inlet port to hydraulic differential lock
11.0 – 13.0 bar (159.5 – 188.5 psi)
Maximum pressure in neutral 0.3 bar (4.4 psi)
2 Reverse shift solenoid 11 4WD pressure check point
28 W 12 V @ 900 RPM 13.0 – 14.0 bar (188.5 –
203.0 psi)
@ 2200 RPM 13.0 – 15.5 bar (188.5 –
224.8 psi)
3 Eyebolt lifting holes 12 Hydraulic differential lock valve
20 W 12 V
4 Forward shift solenoid 13 Eyebolt lifting holes
28 W 12 V
5 Dipstick fitting hole 14 4WD shift solenoid valve
24 W 12 V
6 Converter pressure check point 15 Transmission temperature thermostat port
0.5 – 9.0 bar (7.2 – 130.5 psi)
7 Forward/reverse clutch pressure check point 16 Oil cooler back pressure check point
11.0 – 13.0 bar (159.5 – 188.5 psi) 0.5 – 3.5 bar (7.2 – 50.8 psi) in forward and
Maximum pressure in neutral 0.3 bar (4.4 psi) reverse clutch positions
0.5 – 5.0 bar (7.2 – 72.5 psi) in neutral clutch
positions
Oil outlet port to brake tank
8 Forward clutch pressure check point 17 Forward clutch pressure check point
11.0 – 13.0 bar (159.5 – 188.5 psi) 11.0 – 13.0 bar (159.5 – 188.5 psi)
Maximum pressure in neutral 0.3 bar (4.4 psi) Maximum pressure in neutral 0.3 bar (4.4 psi)
9 Reverse clutch pressure check point
11.0 – 13.0 bar (159.5 – 188.5 psi)
Maximum pressure in neutral 0.3 bar (4.4 psi)
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Power shuttle transmission - Sectional view Kinematic schematic

580ST
590ST
695ST
RAIL16TLB1338FA 1
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Power shuttle transmission - Sectional view Transmission input

shaft
580ST
590ST
695ST
RAIL16TLB1339FA 1
1 Input shaft 7 Forward clutch passage

2 Reverse gear 8 Lubrication oil passage
3 Reverse clutch pack 9 Forward clutch pressure
4 Forward clutch pack 10 Reverse clutch pressure
5 Forward gear 11 Lube pressure
6 Reverse clutch passage
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Power shuttle transmission - Hydraulic schema Transmission

hydraulic schematic
580ST
590ST
695ST
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RAIL16TLB1321HA 1
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1 Torque converter pressure relief valve, 19 Reverse clutch pack

located in the pump.
Opening pressure 3.5 – 5.5 bar (50.8 –
79.8 psi)
2 Torque converter 20 Reverse pressure check port
Three teeth removed on the torque converter 11.0 – 13.0 bar (159.5 – 188.5 psi)
3 Oil cooler 21 Bearing
4 Oil cooler back temperature thermostat port 22 Second gear
5 Oil cooler back shaft lubrication pressure 23 First gear
check port
Forward/reverse 0.5 – 3.5 bar (7.2 – 50.8 psi)
Neutral 0.5 – 5.0 bar (7.2 – 72.5 psi)
6 Hydraulic differential lock solenoid valve 24 Forth gear
7 Hydraulic differential lock engage/disengage 25 Third gear
8 Rear axle unit 26 4WD pressure check port
@ 900 RPM 13.0 – 15.0 bar (188.5 –
217.5 psi)
@ 2200 RPM 14.5 – 16.5 bar (210.2 –
239.2 psi)
9 Torque converter pressure check port 27 4WD disengagement solenoid
0.5 – 9.0 bar (7.2 – 130.5 psi)
10 Pressure regulator 28 Oil filter relief valve, located in the pump
Opens at 23.0 bar (333.5 psi)
11 Oil flow divider/pressure regulator valve 29 Spin-on delivery filter 10 µm
12 Forward/reverse main pressure check port 30 “Easy shift” 4WD engage/disengage
11.0 – 13.0 bar (159.5 – 188.5 psi)
13 Transmission control valve 31 Transmission oil pump 36 cm³/rev
14 Forward/reverse modulating valve 32 Suction filter 250 µm
15 Modulation relief valve 33 Bearing
16 Forward/reverse selection valve 34 Forward/reverse shaft lubrication
17 Forward pressure check port 35 First, second, third and forth gear shaft
11.0 – 13.0 bar (159.5 – 188.5 psi) lubrication
18 Forward clutch pack 36 Transmission sump
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Power shuttle transmission - Replace

580ST
590ST
695ST
Change the transmission fluid, replace the transmission filter, clean the transmission breather and inspect the suction
filter every 1000 h of operation.
Transmission fluid specifications – CASE AKCELA NEXPLORE™ FLUID
Severe Cold Weather Package (SCWP) transmission fluid specifications – CASE AKCELA HY-TRAN® ULTRAC-
TION SSL
Transmission capacity:
Two-Wheel Drive (2WD) 10.5 L (11.1 US qt). Four-Wheel Drive (4WD) 13.0 L (13.7 US qt)
1. Clean the area around the transmission dipstick area

and remove the dipstick.
RCPH11TLB027BAD 1
2. Clean the area around the transmission filter. The filter

is on the right-hand side, between the chassis and the
transmission.
3. Have a suitable container ready and remove the trans-
mission filter. Use a filter removal tool, if necessary.
RCPH10TLB023AAF 2
4. Clean the area around the transmission drain plug.

5. Place a suitable container under the transmission drain
plug and slowly remove the drain plug.
RCPH09TLB004AAF 3
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6. After all the fluid has drained from the system, inspect
the transmission oil suction filter.
A. Remove two cap screws.
B. Remove the plate and pull out the suction filter.
C. Inspect the filter for any type of debris.
NOTICE: If suction filter contains debris, investigate and
repair as necessary before proceeding with this procedure.
RCPH09TLB004AAF 4
7. Insert the suction filter, secure in place with plate and

bolts. Torque bolts to 23 N·m (17 lb ft).
8. Lubricate the new transmission filter gasket with clean
oil.
NOTICE: Never use a filter removal tool to install the filter.

9. Install the new filter and turn clockwise until the gasket
contacts the head of the filter assembly.
10. Continue to tighten the filter another 1/3 turn.
11. Install the transmission drain plug.
12. Fill the system to specification.
13. Install the transmission dipstick.
15. Check for leaks around the filter.
16. Operate the machine in first and second gear for sev-
eral minutes.
17. Park the machine on a level surface and, with the en-
gine running, check the fluid level.
18. Add fluid as needed.
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Power shuttle transmission - Drain fluid

580ST
590ST
695ST

RCPH11TLB027BAD 1

transmission.
RCPH10TLB023AAF 2

RCPH09TLB004AAF 3
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repair as necessary.
RCPH09TLB004AAF 4

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Power shuttle transmission - Remove

1. Position machine on a flat surface high enough to allow
transmission removal from underneath the machine.
2. Disconnect the battery.
3. Drain the transmission fluid.
4. Drain the hydraulic fluid.
5. Remove the hydraulic pump.
6. Remove the rear wheels.
7. Remove the fuel and SCR tank.
8. If applicable, remove front drive shaft hardware.
RCPH11TLB003AAL 1
9. Remove shaft from yoke.
RCPH11TLB004AAL 2
10. Remove front drive shaft.
RCPH11TLB005AAL 3
11. Identify, tag and disconnect the transmission cooler

lines.
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RCPH11TLB007AAL 4 RCPH11TLB008AAL 5
12. Disconnect the transmission control valve harness

connections on top of the transmission.
13. Disconnect the brake return line.
RCPH11TLB011AAL 6
14. Disconnect brake supply line.

15. Remove oil level dipstick tube.
16. Disconnect the oil temperature sensor.
RCPH11TLB014AAL 7
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17. Disconnect blue wire at switch (left-hand rear of trans-

mission).
RCPH11TLB015AAL 8
18. Disconnect black and white wire at switch (left-hand

rear top of transmission).
RCPH11TLB016AAL 9
19. Disconnect the differential lock line.
RCPH11TLB017AAL 10
20. Plug and cap all open ports.
RCPH11TLB018AAL 11
21. Disconnect starter ground and positive battery con-

nections.
22. Remove the starter.
23. Disconnect the ignition connection.
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24. Remove the access cover.
RCPH11TLB019AAL 12
25. Rotate engine to access flywheel hardware. Use tool

380000732 to rotate the engine.
RCPH11TLB062AAM 13
26. Rotate the engine to remove the flywheel to flex plate

hardware.
RCPH11TLB055AAM 14
27. Use an appropriate lifting device to support engine.
RCPH11TLB020AAL 15
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28. Support the transmission.
RCPH11TLB021AAL 16
29. Remove the engine to transmission hardware.
RCPH11TLB058AAM 17
30. Remove the right-hand and left-hand transmission

mount hardware.
31. Disconnect hydraulic reservoir hoses.
RCPH11TLB023AAL 18
32. Carefully lower and remove the transmission.
Next operation:
Power shuttle transmission - Install (21.112)
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Power shuttle transmission - Install

580ST
590ST
695ST
1. Move the transmission under the machine and raise it

into place.
2. Connect the hydraulic reservoir hoses.
RCPH11TLB023AAL 1
3. Install the right-hand and left-hand transmission mount

bracket hardware to the transmission. Torque to 90 –
110 N·m (66 – 81 lb ft).
• (1) Hex head bolt (bracket-to-frame)
• (2) Washer
• (3) Mounting bracket
• (4) Washer
• (5) Hex head bolt (bracket-to-transmission)
• (6) Washer
• (7) Anti-vibration spacer
• (8) Frame support (welded-to-frame
• (10) Washer
• (11) Nut
4. Install the transmission mount-to-frame hardware. Do
not torque at this time.
5. Install the transmission-to-engine bolt hardware.
Torque to 52 – 57 N·m (38 – 42 lb ft)
6. Torque transmission mount-to-frame hardware to 178
– 240 N·m (131 – 177 lb ft) RAIL17TLB0032BA 2
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7. Remove the transmission support.
RCPH11TLB021AAL 3
8. Remove engine supports.
RCPH11TLB020AAL 4
RCPH11TLB019AAL 5
10. Rotate the engine to access the flywheel mounting

holes. Use the 380000732 turning tool to rotate the
engine.
RCPH11TLB062AAM 6
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11. Install the flywheel flex plate hardware. Torque to 62

– 68 N·m (46 – 50 lb ft).
RCPH11TLB055AAM 7
12. Reconnect the ignition connection on the starter.

13. Reinstall starter.
14. Connect the starter ground and positive battery con-
nections.
15. Connect the differential lock line.
RCPH11TLB017AAL 8
16. Connect the black and white wire at the switch (left
hand rear top of transmission).
RCPH11TLB016AAL 9
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17. Connect the blue wire at the switch (left hand rear of
transmission).
RCPH11TLB015AAL 10
18. Connect the oil temperature sensor.
RCPH11TLB014AAL 11
19. Apply LOCTITE® 567™ PST PIPE SEALANT to the

threads of the transmission connector and install the
oil level dipstick tube.
20. Connect brake supply line.
RCPH11TLB012AAL 12
21. Connect the brake return line.
RCPH11TLB011AAL 13
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22. Reconnect the transmission control valve harness

connections.
23. Reconnect the transmission cooler lines.
24. Lubricate the splines on the axle and the inside of the
drive shaft coupling with TUTELA MULTI -PURPOSE EP
GREASE 251H, GR-9.
25. Install front drive shaft coupling yoke.
RCPH11TLB005AAL 16
26. Install shaft to the yoke. Tighten hardware to 33 –

39 N·m (24 – 29 lb ft)
RCPH11TLB004AAL 17
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27. Install front drive shaft hardware.
RCPH11TLB003AAL 18
28. Install wheels. Remove supports and lower machine.
NOTICE: Before staring the engine do the following

29. Make sure the transmission drain plug has been in-
stalled and tightened.
30. Fill the transmission, refer to Power shuttle trans-
mission - General specification (21.112)
NOTE: If removed, install the rear wheels.

31. Remove the stands from under the machine and lower
the machine to the floor.
32. With the machine parked on level ground and the en-
gine running at low idle, check the transmission oil
level. The oil level must be between the ADD and the
FULL marks on the dipstick. If the oil level is at the
ADD mark, add oil as required until the oil level is at
the FULL mark.
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Power shuttle transmission - Filling

580ST
590ST
695ST

TION SSL

RCPH11TLB027BAD 1
2. Clean the area around the transmission filter head on

the right-hand side, between the chassis and the trans-
mission.
oil.
RCPH10TLB023AAF 2

RCPH09TLB004AAF 3
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eral minutes.
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Power shuttle transmission - Check Supply pump pressure (4WD

only)
580ST
590ST
695ST
CAS-1804 Pressure Fitting Kit
NOTE: See Power shuttle transmission - Tool connection 2 Wheel drive port identification (21.112) for port
identification.
NOTE: Two wheel drive machines can only be tested by performing a flow meter test.
2. Start the engine. The oil should be at normal operating
temperatures.
3. Connect a 42 bar (600 psi) gauge to test port 10 (A),
see Power shuttle transmission - Tool connection 4
Wheel drive port identification (21.112).
4. Monitor the gauge and record the values for low idle,
see Power shuttle transmission - Pressure test 4
Wheel drive, test one engine at idle, 900 to 1100
RPM (21.112).
5. Monitor the gauge and record the values for full throttle,
Wheel drive, test two engine at 2200 RPM (21.112).
RCPH11TLB014BAL 1
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Power shuttle transmission - Test Checking converter in pressure

580ST
590ST
695ST
NOTE: See Power shuttle transmission - Tool connection 2 Wheel drive port identification (21.112) or Power
shuttle transmission - Tool connection 4 Wheel drive port identification (21.112) for test port locations.
temperatures.
3. Connect a 14 bar (200 psi) to test port 6 (A) for 2WD
or 4WD machines.
4. Place transmission controls in neutral.
RPM (21.112) or Power shuttle transmission - Pres-
sure test 4 Wheel drive, test one engine at idle, 900
to 1100 RPM (21.112).
Wheel drive, test two engine at 2200 RPM (21.112) or
Power shuttle transmission - Pressure test 4 Wheel
drive, test two engine at 2200 RPM (21.112).
RCPH11TLB015BAL 1
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Power shuttle transmission - Test Regulated clutch pressure

580ST
590ST
695ST
temperatures.
3. Connect a 42 bar (600 psi) gauge to test port 3 (A).
4. Move the direction control lever to forward.
to 1100 RPM (21.112).
RCPH11TLB016BAL 1
7. Repeat steps 5 and 6 with the control lever in reverse.
NOTE: Forward and reverse clutch pressure can be recorded separately using test port 5 (C) for Forward and test
port 4 (B) for Reverse.
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Power shuttle transmission - Test Supply pump flow and relief

pressure
580ST
590ST
695ST
CAS-1808 Flowmeter Fitting Kit

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

580ST
590ST
695ST
temperatures.
3. Connect a 20 bar (200 psi) to the service tee on test
port 8 (A).
4. Place the transmission in the neutral position.
to 1100 RPM (21.112).
RCPH11TLB018BAL 1
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Power shuttle transmission - Test Lubrication pressure

580ST
590ST
695ST
temperatures.
3. Connect a 42 bar (600 psi) gauge to test port 9 (A).
4. Place the transmission in neutral.
to 1100 RPM (21.112).
RCPH11TLB019BAL 1
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Power shuttle transmission - Test Differential lock valve

580ST
590ST
695ST
CAS-1804 Pressure Test Kit

CAS-1808 Flowmeter Fitting Kit
2. Place the transmission in neutral.
temperatures.
4. Connect a pressure test fitting and a 42 bar (600 psi)
gauge to test port 7 (A).
5. With the transmission shift lever in Neutral, put the di-
rectional control lever in Forward or Reverse.
6. Run the engine at 2200 RPM.
7. Press and hold the differential lock switch located in the
loader control valve.
to 1100 RPM (21.112).
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Power shuttle transmission - Pressure test 2 Wheel drive, test one

engine at idle, 900 to 1100 RPM
580ST
590ST
695ST
NOTE: All specifications shown were taken from a sampling of new production machines with less than 20 engine
hours, your figures may differ slightly.
Test Port Item Specifications - 2 wheel Actual

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

engine at 2200 RPM
580ST
590ST
695ST
Test Port Item Specifications — 2 wheel Actual

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

identification
580ST
590ST
695ST
RCPH11TLB002GAL 1
1. Flow meter adapter from charge pump to flow meter (Use CAS-2011). Connect the CAS-1029 Flow
meter or equivalent. Pump supply pressure on 2 Wheel Drive units can only be taken with a flow
meter connected to ports 1 and 2.
2. Return from flow meter to transmission (CAS-2383).
3. Regulated clutch pressure, common to forward and reverse. Use CAS-2745 and CAS-2746
4. Regulated reverse clutch pressure. Use CAS-2745 and CAS-2746
5. Regulated forward clutch pressure. Use CAS-2745 and CAS–2746
6. Torque Converter IN pressure. Use CAS-2745 and CAS-2746
7. Differential lock pressure. Use CAS-2744
8. Converter out to cooler. Use CAS-2747
9. Lubrication pressure, common to converter return. Use CAS-2745 and CAS-2746 or use CAS-2747
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Power shuttle transmission - Tool connection Pressure test ports,

2 wheel drive
580ST
590ST
695ST
RCPH11TLB004GAL 1
(1) Reverse Clutch Pressure (3) Regulated Clutch Pressure

(2) Forward Clutch Pressure (4) Torque Converter Pressure
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Power shuttle transmission - Tool connection Pressure test ports,

4 wheel drive
580ST
590ST
695ST
RCPH11TLB005GAL 1
(1) Supply Pump Pressure, Four Wheel Drive (4) Regulated Clutch Pressure
Only
(2) Reverse Clutch Pressure (5) Torque Converter Pressure
(3) Forward Clutch Pressure
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Power shuttle transmission - Tool connection 4 Wheel drive port

identification
580ST
590ST
695ST
RCPH11TLB003GAL 1
1. Flow meter adapter from charge pump to flow meter (Use CAS-2011). Connect the CAS-1029 Flow
meter or equivalent.
2. Return from flow meter to transmission (CAS-2383).
3. Regulated clutch pressure, common to forward and reverse. Use CAS-2745 and CAS-2746
4. Regulated reverse clutch pressure. Use CAS-2745 and CAS-2746
5. Regulated forward clutch pressure. Use CAS-2745 and CAS–2746
6. Torque Converter IN pressure. Use CAS-2745 and CAS-2746
7. Differential lock pressure. Use CAS-2744
8. Converter out to cooler. Use CAS-2747
9. Lubrication pressure, common to converter return. Use CAS-2745 and CAS-2746 or use CAS-2747
10. Pump supply pressure, 4 wheel drive only. Use CAS-2745 and CAS-2746
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Power shuttle transmission - Pressure test 4 Wheel drive, test one

engine at idle, 900 to 1100 RPM
580ST
590ST
695ST
NOTE: All specifications shown were taken from a sampling of new production machines with less than 20 engine
hours, your figures may differ slightly.

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

engine at 2200 RPM
580ST
590ST
695ST

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

1. Apply lithium grease to the ball of the shift lever. Install
the shift lever in the shifter housing.
RCPH10TLB017ABL 1
2. The correct alignment of the shift lever and the shifter

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

• Faulty transmission oil pump. Refer to Power shuttle transmission - Check Supply pump
pressure (4WD only) (21.112) or Power shuttle transmission - Test Supply pump flow and
relief pressure (21.112).
Test N°5
Test Point Check
Check the converter IN pressure. Refer to Power shuttle transmission - Test Checking converter in
pressure (21.112)
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Expected Result
Result The converter IN pressure is within specifications. Go to next step.
Other Action
Result The converter IN pressure is not within specifications. Check the transmission control valve. Repair or
(Possible replace as required.
Cause)
Test N°6
Test Point Check
Check the Forward and Reverse solenoid valve. Refer to Power shuttle transmission - Test Regulated
clutch pressure (21.112).
Expected Result
Result The regulated clutch pressures are within the specified range. Go to next step.
Other Action
Result The regulated clutch pressures are not within the specified range. Refer to Forward and Reverse solenoid
(Possible troubleshooting in the Service Manual. .
Cause)
Test N°7
Test Point Check
Check regulated clutch pressure at test port 3. Refer to Power shuttle transmission - Test Regulated
clutch pressure (21.112)
Expected Result
Result The regulated clutch pressure is within specifications. Refer to Power shuttle transmission - Pressure
test 2 Wheel drive, test one engine at idle, 900 to 1100 RPM (21.112) and Power shuttle trans-
mission - Pressure test 2 Wheel drive, test two engine at 2200 RPM (21.112) OR Power shuttle
transmission - Pressure test 4 Wheel drive, test one engine at idle, 900 to 1100 RPM (21.112) and
Power shuttle transmission - Pressure test 4 Wheel drive, test two engine at 2200 RPM (21.112).
Other Action
Result
(Possible The regulated clutch pressure is not within specifications. Possible causes include:
Cause) • Pressure remains zero in Forward, Neutral and Reverse. Check the control valve.
• Pressure is low, check the control valve. Inspect the transmission control valve.
• Pressure in Forward and Reverse are the same. Check the control valve.
• Forward and Reverse pressures are different. Inspect the individual clutch circuits.
Power shuttle transmission - Testing Machine will not go into 4WD

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

shifting between forward and reverse
Test N°1
Test Point Check
Expected Result
Other Action
Cause)
Test N°2
Check the pump supply pressure at test port 10 for 4WD machines. Refer to Power shuttle transmis-
sion - Check Supply pump pressure (4WD only) (21.112). 2WD machines, test the pressure on port
1 and port 2. Refer to Power shuttle transmission - Test Supply pump flow and relief pressure
(21.112)
Expected Result
Result The pressure are all within specifications. Go to next step.
Other Action
Result The pressures are not within specifications. Inspect the pressure regulator. Repair or replace as required.
(Possible
Cause)
Test N°3
Test Point Check
Check the regulated clutch pressure at test port 3. Refer to Power shuttle transmission - Test Regu-
lated clutch pressure (21.112)
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Expected Result
Result The pressures are within specifications.
Other Action
Result The pressures were not within specifications. Inspect the modulation spool and piston for sticking or
(Possible damage. Inspect the input shaft sealing rings and forward and reverse clutch piston seals. Repair or
Cause) replace as required.
Power shuttle transmission - Testing Loss of power

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

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

system
Test N°1
Test Point Check
Does the parking brake release?
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Expected Result
Result The parking brake will release. Inspect and test the parking brake disks. If the parking brake will not hold
the machine, repair or replace the disc brakes.
Other Action
Result
(Possible Check the electrical and hydraulic circuits.
Cause) • Check the differential lock pressure, refer to Power shuttle transmission - Test Differential lock
valve (21.112). The differential lock and the parking brake are on the same pressure circuit. If the
differential lock pressure is within specifications, refer to Power shuttle transmission - Pressure
test 2 Wheel drive, test one engine at idle, 900 to 1100 RPM (21.112) and Power shuttle
transmission - Pressure test 2 Wheel drive, test two engine at 2200 RPM (21.112) OR Power
shuttle transmission - Pressure test 4 Wheel drive, test one engine at idle, 900 to 1100 RPM
(21.112) and Power shuttle transmission - Pressure test 4 Wheel drive, test two engine at
2200 RPM (21.112).
• Check fuses, replace fuses as required.
• Check switch operation, repair or replace as required.
• Measure the solenoid resistance. The resistance should be approximately 9.8 Ω at 20 °C (68 °F).
Replace the solenoid as required.
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Index
Transmission - 21

Power shuttle transmission - Check Supply pump pressure (4WD only) (*) . . . . . . . . . . . . . . . . . . . . . 38
Power shuttle transmission - Drain fluid (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Power shuttle transmission - Drawing Front view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Power shuttle transmission - Drawing Rear view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Power shuttle transmission - Drawing Right view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Power shuttle transmission - Drawing Top view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Power shuttle transmission - Exploded view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Power shuttle transmission - Filling (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Power shuttle transmission - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Power shuttle transmission - Hydraulic schema Transmission hydraulic schematic (*) . . . . . . . . . . . 18
Power shuttle transmission - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Power shuttle transmission - Overview How it works (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Power shuttle transmission - Pressure test 2 Wheel drive, test one engine at idle, 900 to 1100 RPM
(*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Power shuttle transmission - Pressure test 2 Wheel drive, test two engine at 2200 RPM (*) . . . . . . 46
Power shuttle transmission - Pressure test 4 Wheel drive, test one engine at idle, 900 to 1100 RPM
(*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Power shuttle transmission - Pressure test 4 Wheel drive, test two engine at 2200 RPM (*) . . . . . . 52
Power shuttle transmission - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Power shuttle transmission - Replace (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Power shuttle transmission - Sectional view Kinematic schematic (*) . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Power shuttle transmission - Sectional view Transmission input shaft (*) . . . . . . . . . . . . . . . . . . . . . . 17
Power shuttle transmission - Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Power shuttle transmission - Test Checking converter in pressure (*) . . . . . . . . . . . . . . . . . . . . . . . . . 39
Power shuttle transmission - Test Converter out pressure (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Power shuttle transmission - Test Differential lock valve (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Power shuttle transmission - Test Lubrication pressure (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Power shuttle transmission - Test Regulated clutch pressure (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Power shuttle transmission - Test Supply pump flow and relief pressure (*) . . . . . . . . . . . . . . . . . . . . 41
Power shuttle transmission - Testing Loss of power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Power shuttle transmission - Testing Machine hesitates when shifting between forward and reverse 103
Power shuttle transmission - Testing Machine will not go into 4WD . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Power shuttle transmission - Testing Machine will not move . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
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Power shuttle transmission - Testing Problem in the parking brake system . . . . . . . . . . . . . . . . . . . . . 105
Power shuttle transmission - Testing Transmission oil is too hot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Power shuttle transmission - Tool connection 2 Wheel drive port identification (*) . . . . . . . . . . . . . . . 47
Power shuttle transmission - Tool connection 4 Wheel drive port identification (*) . . . . . . . . . . . . . . . 50
Power shuttle transmission - Tool connection Pressure test ports, 2 wheel drive (*) . . . . . . . . . . . . . 48
Power shuttle transmission - Tool connection Pressure test ports, 4 wheel drive (*) . . . . . . . . . . . . . 49
Power shuttle transmission - Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Transmission housing - Assemble Shifter housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Transmission housing - Assemble Transmission housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Transmission housing - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Transmission housing - Disassemble Shift rods and shift forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Transmission housing - Disassemble Shifter housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
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Transmission - 21
Power shuttle transmission external controls - 134

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Contents
Transmission - 21
FUNCTIONAL DATA
Transmission control valve

Exploded view Four wheel drive valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Exploded view Transmission control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Overview (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Overview Control valve in neutral with the engine running (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Overview Control valve shifted into forward, start of modulation (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Overview Control valve shifted into forward, clutch lock-up (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
SERVICE

Disassemble Four wheel drive valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Assemble Four wheel drive valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Disassemble Transmission control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Inspect Transmission control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Assemble Transmission control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
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Transmission - Power shuttle transmission external controls
Transmission control valve - Exploded view Four wheel drive valve
RCPH10TLB026GAL 1
1 Bolt 7 O-rings
2 Plug 8 Solenoid valve body
3 Copper washer 9 Solenoid coil
4 Solenoid valve body 10 Connector
5 Check valve 11 Nut
6 Gasket 12 Jumper wire
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Transmission control valve - Exploded view Transmission control

valve
RCPH10TLB027GAL 1
1 Nut 17 Snap ring-not removable

2 Seal 18 Ball
3 O-ring 19 Spring
4 Connector 20 Control valve body
5 Solenoid coil 21 Bolt
6 Solenoid plunger 22 Hex head plug
7 Allen head bolt 23 Copper washer
8 Modulation cover 24 Allen head plug
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9 Gasket 25 Plug
10 Plate 26 Spring spacer
11 Outer modulation piston 27 Forward/reverse spool
12 Small spring 28 Flow divider piston
13 Medium spring 29 Flow divider shaft
14 Large spring 30 Valve plate
15 Piston pin 31 Differential lock solenoid valve
16 Inner modulation piston 32 Snap ring
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Transmission control valve - Overview

580ST
590ST
695ST
RAIL16TLB1330GA 1
1 Forward clutch 7 0.7 mm

2 Reverse clutch 8 Modulator circuit housing
3 Forward/reverse shuttle spool 9 Modulator piston
4 Forward solenoid 10 Modulator spool
5 Reverse solenoid 11 Flow divider
6 1 mm 12 3.5 mm
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Transmission control valve - Overview Control valve in neutral with

the engine running
580ST
590ST
695ST
RAIL16TLB1333GA 1
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RAIL16TLB1332GA 2
1 Forward clutch 10 Modulator spool

2 Reverse clutch 11 Flow divider
3 Forward/reverse shuttle spool 12 3.5 mm
4 Forward solenoid 13 Charge pressure
5 Reverse solenoid 14 Supply to clutch
6 1 mm 15 Modulation pressure
7 0.7 mm 16 Converter pressure
8 Modulator circuit housing 17 Tank
9 Modulator piston
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Transmission control valve - Overview Control valve shifted into

forward, start of modulation
580ST
590ST
695ST
RAIL16TLB1334GA 1
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RAIL16TLB1335GA 2

9 Modulator piston
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Transmission control valve - Overview Control valve shifted into

forward, clutch lock-up
580ST
590ST
695ST
RAIL16TLB1336GA 1
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RAIL16TLB1337GA 2

9 Modulator piston
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Transmission control valve - Disassemble Four wheel drive valve

1. Remove the nut.
RCPH10TLB734AAL 1
2. Remove the solenoid coil.
RCPH10TLB737AAL 2
3. Remove the solenoid valve.
RCPH10TLB738AAL 3
4. Remove the check valve from the solenoid valve body.

DO NOT try to disassemble the check valve. There are
no serviceable parts. If there is a problem, use a new
check valve.
RCPH10TLB740AAL 4
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5. Remove the three O-rings from the solenoid valve.
RCPH10TLB741AAL 5
Next operation:
Transmission control valve - Assemble (21.134)
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Transmission control valve - Assemble Four wheel drive valve

1. Install the three new O-rings on the solenoid valve. Use
clean transmission oil to lubricate the O-rings.
RCPH10TLB741AAL 1
2. Install the check valve in the valve body as shown.
RCPH10TLB740AAL 2
3. Install the solenoid valve in the solenoid valve body.

Tighten the solenoid valve to a torque of 22.0 N·m
(194.7 lb in).
RCPH10TLB739AAL 3
4. Install the solenoid coil on the solenoid valve.
RCPH10TLB737AAL 4
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5. Install the nut.
RCPH10TLB736AAL 5
6. Tighten the nut to a torque of 8.0 N·m (70.8 lb in).
RCPH10TLB735AAL 6
Next operation:
Transmission control valve - Disassemble (21.134)
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Transmission control valve - Disassemble Transmission control

valve
NOTE: Some of the photos in the following procedure may not be the same as the model you are repairing. The
repair procedure is the same.
1. Remove the nut for the forward/reverse solenoid.
RCPH10TLB742AAL 1
2. Remove the seal.
RCPH10TLB744AAL 2
3. Remove the first solenoid coil.
RCPH10TLB747AAL 3
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4. Remove the O-ring from the either the solenoid coil or

the solenoid plunger.
RCPH10TLB748AAL 4
5. Remove the second solenoid coil.
RCPH10TLB749AAL 5
6. Remove the O-ring from the second solenoid coil.
RCPH10TLB750AAL 6
7. The remaining O-ring can stay with either the solenoid

coil or the solenoid plunger. Remove the remaining
O-ring.
RCPH10TLB751AAL 7
NOTE: Step 8 to 10 are for early production N Series 2 machines, current production have a 2 wire connector per
solenoid.
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8. Remove the retainer from the rear of the connector for

the solenoid coils.
RCPH10TLB005ABL 8
NOTE: Before removing any wires from the connector, you may want to record the locations of the wires for reference
during assembly.
9. Use a small punch to release the locking tab on the
terminal.
RCPH10TLB006ABL 9
10. Pull the wire and the terminal from the connector.
RCPH10TLB007ABL 10
11. Repeat steps 8 and 10 for the remaining wires and

terminals.
12. Remove the nut for the differential lock solenoid.
RCPH10TLB752AAL 11
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13. Remove the solenoid coil.
RCPH10TLB753AAL 12
14. Loosen and remove the solenoid plunger.
RCPH10TLB754AAL 13
15. Remove the O-rings from the solenoid plunger.
RCPH10TLB755AAL 14
16. Loosen and remove the solenoid plunger with the for-
ward/reverse spool attached.
RCPH10TLB756AAL 15
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17. Use a small screwdriver to push down the spring as

shown so that you can disengage the notched end of
the forward/reverse spool from the post on the end of
the solenoid plunger.
RCPH10TLB011ABL 16
18. Separate the solenoid plunger (1), the spring (2), the
spring spacer (3), and the forward/reverse spool (4).
RCPH10TLB009ABL 17
19. Remove the O-ring from the solenoid plunger.
RCPH10TLB010ABL 18
20. Remove the four Allen head bolts that fasten the mod-
ulation cover to the control valve body.
RCPH10TLB754AAL 19
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21. Remove the outer modulation piston (1) from the mod-
ulation cover (2). Remove the two cover gaskets (3)
and the spacer gasket (4). Remove the check ball (5)
and the spring (6). Remove the outer modulation pis-
ton spring (7), the inner spring (8) and the outer spring
(9), and the inner modulation piston pin (10) and the
piston (11).
RCPH10TLB758AAL 20
22. Loosen the plug at the opposite end of the bore.
RCPH10TLB759AAL 21
23. Remove the plug (1), the snap ring (2), the flow divider
shaft (3), the spring (4), and the flow divider piston (5)
from the bore.
RCPH10TLB764AAL 22
24. Remove the plug from the bore for the forward/reverse
spool.
RCPH10TLB760AAL 23
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25. Remove the spring from the bore for the forward/re-
verse solenoid.
RCPH10TLB761AAL 24
26. Remove the spring spacer.
RCPH10TLB762AAL 25
27. Remove the four hex head plugs (1) and the Allen
head plug (2) only if the plugs are damaged or leaking.
There are copper washers under the plugs.
RCPH10TLB763AAL 26
Next operation:
Transmission control valve - Inspect (21.134)
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Transmission control valve - Inspect Transmission control valve

1. Use cleaning solvent to clean all metal parts.
2. Check the springs for wear, cracks, heat distortion, and
other damage. Replace as necessary.
3. Inspect the spool and the pistons for damage or wear.
Make sure that the orifice in the outer modulation piston
is open. Use new parts as necessary.
4. Inspect the control valve body for cracks, corrosion,
and wear. Inspect the bores for wear. Find the bore
from which the ball was removed. There is a very small
orifice in one side of this bore. Make sure that this
orifice is open. If the control valve body is bad, you
must use a new transmission control valve.
5. Find the plate that held the ball in position. Put the ball
on the hole in the plate so that the ball is in contact with
the edge that has the radius. Hold the plate and the
ball up to a bright light and look at the bottom side of
the plate and the ball. There must be no light visible
between the plate and the ball. If light is visible, use a
new plate.
Next operation:
Transmission control valve - Assemble (21.134)
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Transmission control valve - Assemble Transmission control valve

NOTE: Some of the photos in the following procedure may not be the same as the model you are repairing. The
repair procedure is the same.
1. If the four hex head plugs (1) and the Allen head plug
(2) were removed, install the copper washers and the
plugs.
RCPH10TLB763AAL 1
2. Use clean transmission oil to lubricate the flow divider

shaft (1). Install the flow divider shaft (1). The closed
end of the flow divider piston (1) must be toward the
inside of the control valve body. Use clean transmission
oil to lubricate the flow divider piston (3). Install the
spring (2), flow divider piston (3), and the snap ring (4)
in the bore. Install a new O-ring on the plug (5). Use
clean transmission oil to lubricate the O-ring on the plug
(5). Install the plug (5).
RCPH10TLB764AAL 2
3. Tighten the plug at the in the bore.
RCPH10TLB759AAL 3
4. Lubricate the new inner modulation piston (11) with

clean transmission oil. Install the new inner piston (11)
so that the end with the deeper bore is towards the out-
side of the valve body. Install the spring (6) into the
small bore. Install one cover gasket (3) on the valve
body. Install the check ball (5) on top of the spring (6) in
the small bore. Install the spacer (4) so the coined (ra-
dius) side contacts the ball. Install the remaining cover
gasket (3) onto the spacer (4) Install the inner modula-
tion piston pin (10) the inner (8) and outer (9) spring and
the outer modulation piston spring (7) into the bore. Lu-
bricate the outer modulation piston (1) with clean trans-
mission oil and install the piston (1) into the modulation
cover (2) with the closed end towards the modulation RCPH10TLB758AAL 4
cover.
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5. Install the modulation cover onto the valve body. Install

the four Allen head bolts into the cover. Tighten the four
Allen head bolts to a torque of 11.0 N·m (97.4 lb in).
RCPH10TLB754AAL 5
6. Install a new O-ring on the solenoid plunger. Use clean

transmission oil to lubricate the O-ring.
RCPH10TLB010ABL 6
7. Assemble the solenoid plunger (1), the spring (2), the

spring spacer (3), and the forward/reverse spool (4) as
shown above. One side of the spring spacer (3) has a
chamfer in the bore. Install the spring spacer (3) so that
the chamfer is toward the forward/reverse spool (4).
RCPH10TLB009ABL 7
8. Use a small screwdriver to push down the spring as

shown so that you can engage the notched end of the
forward/reverse spool with the post on the end of the
solenoid plunger. When the notched end and the post
are fully engaged, release the spring to hold the for-
ward/reverse spool in position.
RCPH10TLB011ABL 8
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9. Install the solenoid plunger and the forward/reverse

spool in the control valve body.
RCPH10TLB757AAL 9
10. Tighten the solenoid plunger to a torque of 23.0 N·m

(203.6 lb in).
RCPH10TLB756AAL 10
NOTE: The following photos do not show the forward/reverse solenoid installed. The forward/reverse solenoid must
be installed before doing steps 11, 12 and 13.
11. Install the spring spacer in the bore as shown. One
side of the spring spacer has a chamfer in the bore.
Install the spring spacer so that the chamfer is toward
the inside of the control valve body. Make sure that
the end of the forward/reverse spool comes through
the hole in the spring spacer.
RCPH10TLB762AAL 11
RCPH10TLB761AAL 12
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13. Install a new O-ring on the plug. Use clean transmis-

sion oil to lubricate the O-ring. Install the plug in the
bore.
RCPH10TLB760AAL 13
14. Install new O-rings on the differential lock solenoid

plunger. Use clean transmission oil to lubricate the
O-rings.
RCPH10TLB755AAL 14
15. Install and tighten the differential lock solenoid plunger

to a torque of 15.0 N·m (132.8 lb in).
RCPH10TLB754AAL 15
NOTE: Step 16 to 18 are for early production N Series 2 machines, late production have a 2 wire connector per
solenoid.
16. Before inserting a terminal in the connector, use a
small screwdriver to push the locking tab out slightly
so that the locking tab will engage the plastic tab in
the connector when you insert the terminal.
RCPH10TLB008ABL 16
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17. Push each terminal into the connector until the locking
tab and the plastic tab engage, locking the terminal
into the connector.
RCPH10TLB007ABL 17
18. After all the terminals are in the connector, install the
retainer on the rear of the connector.
RCPH10TLB005ABL 18
19. Install the differential lock solenoid coil on the solenoid

plunger.
RCPH10TLB746AAL 19
20. Install the nut. Tighten the nut to a torque of 7.0 –

10.0 N·m (62.0 – 88.5 lb in).
RCPH10TLB745AAL 20
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21. Install a new O-ring on the solenoid plunger at the con-

trol valve body. Use clean transmission oil to lubricate
the O-ring.
RCPH10TLB751AAL 21
22. Install a new O-ring in the solenoid coil. Use clean

transmission oil to lubricate the O-ring.
RCPH10TLB750AAL 22
23. Install the solenoid coil on the solenoid plunger.
RCPH10TLB749AAL 23
24. Install a new O-ring on the solenoid plunger. Use

clean transmission oil to lubricate the O-ring.
RCPH10TLB748AAL 24
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25. Install the remaining solenoid coil on the solenoid

plunger.
RCPH10TLB747AAL 25
26. Install the sealing washer.
RCPH10TLB744AAL 26
27. Install the nut. Tighten the nut to a torque of 7.0 –

10.0 N·m (62.0 – 88.5 lb in).
RCPH10TLB743AAL 27
Next operation:
Transmission control valve - Disassemble (21.134)
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Index
Transmission - 21

Transmission control valve - Assemble Four wheel drive valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Transmission control valve - Assemble Transmission control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Transmission control valve - Disassemble Four wheel drive valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Transmission control valve - Disassemble Transmission control valve . . . . . . . . . . . . . . . . . . . . . . . . . 17
Transmission control valve - Exploded view Four wheel drive valve . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Transmission control valve - Exploded view Transmission control valve . . . . . . . . . . . . . . . . . . . . . . . 4
Transmission control valve - Inspect Transmission control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Transmission control valve - Overview (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Transmission control valve - Overview Control valve in neutral with the engine running (*) . . . . . . . 7
Transmission control valve - Overview Control valve shifted into forward, clutch lock-up (*) . . . . . . 11
Transmission control valve - Overview Control valve shifted into forward, start of modulation (*) . . 9
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Transmission - 21
Power shuttle transmission internal components - 154

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Contents
Transmission - 21
FUNCTIONAL DATA
Transmission drive and driven shafts

Exploded view Input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Exploded view Shift rod and forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Exploded view Secondary shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Exploded view Four wheel drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
SERVICE
Transmission drive and driven shafts

Disassemble Input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Inspect Input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Assemble Input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Disassemble Secondary shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Inspect Secondary shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Assemble Secondary shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Adjust Backlash adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Disassemble Primary shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Inspect Primary shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Assemble Primary shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Disassemble Reverse shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Inspect Reverse shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Assemble Reverse shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Disassemble Oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Inspect Oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Assemble Oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Disassemble Four wheel drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Inspect Four wheel drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Assemble Four wheel drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
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Transmission - Power shuttle transmission internal components
Transmission drive and driven shafts - Exploded view Input shaft
RCPH10TLB022GAL 1
1 Seal ring 16 Clutch piston

2 Snap ring 17 Seal ring
3 Bearing 18 Seal ring
4 Spacer 19 Inner shaft
5 Needle bearing 20 Split pin
6 Gear 21 Rivet
7 Thrust washer 22 Gear
8 Lock ring 23 Bearing
9 Clutch plate lock ring 24 Snap ring
10 Clutch drive plate (14) 25 Seal rings
11 Clutch plate (12) 26 Snap ring
12 Lock ring 27 Bearing
13 Lock-spring cover 28 Pump drive shaft
14 Spring 29 Seal ring
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15 Clutch sleeve
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Transmission drive and driven shafts - Exploded view Shift rod

and forks
RCPH10TLB024GAL 1
1 Boot 13 Detent ball

2 Band 14 Detent plug
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3 Shift lever 15 Washer

4 Pin 16 Detent spring
5 Allen head screw 17 Bolt
6 Shifter housing 18 Copper washer
7 O-ring 19 Shift rod for third and fourth gear
8 Spring 20 Shift rod for first and second gear
9 Bushing 21 Roll pin
10 Snap ring 22 Shift fork for third and fourth gear
11 Shift collar 23 Shift fork for first and second gear
12 Plate
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Transmission drive and driven shafts - Exploded view Secondary

shaft
RCPH10TLB023GAL 1
1 Bearing 15 Sleeve
2 Lock ring 16 Gear
3 Shim 17 Split pin
4 Thrust washer 18 Secondary shaft
5 Gear 19 Gear
6 Spacer 20 Clutch ring
7 Synchronizer ring 21 Synchronizer ring
8 Steel ring 22 Thrust washer
9 Coated ring 23 Bearing
10 Tapered friction ring 24 Seal
11 Hub 25 Flange
12 Spring 26 Washer
13 Ball 27 O-ring
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14 Lock spring plate 28 Bolt
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Transmission drive and driven shafts - Exploded view Four wheel

drive shaft
RCPH10TLB025GAL 1
1 Bolt 9 Special washer

2 Washer 10 Snap ring
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3 O-ring 11 Spacer
4 Four-wheel drive flange 12 Spring
5 Cover 13 Sleeve
6 Seal 14 Pipe plug
7 Bearing 15 Shaft
8 Teflon sealing ring 16 Four wheel drive clutch gear
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Transmission drive and driven shafts - Disassemble Input shaft

NOTE: Do steps 1 and 2 before you disassemble the input shaft. This will help to locate any problems. After you
assemble the input shaft, the tests will be done again to make sure that the input shaft is working correctly.
1. Apply compressed air of approximately 620.0 kPa
(89.9 psi) to the forward clutch passage. Listen to
hear the forward piston moving to lock the forward
clutch pack. Try to move the forward gear. The forward
gear must not turn on the input shaft. Try to move the
reverse gear. The reverse gear must turn freely on
the input shaft. If the clutches do not work correctly,
inspect the parts closely during disassembly so that
you can find and correct the problem.
(89.9 psi) to the reverse clutch passage. Listen to
hear the reverse piston moving to lock the reverse
clutch pack. Try to move the reverse gear. The reverse
gear must not turn on the input shaft. Try to move the
forward gear. The forward gear must turn freely on
the input shaft. If the clutches do not work correctly,
inspect the parts closely during disassembly so that
you can find and correct the problem.
3. Use the bottom piece of CAS-2379 special tool as
shown to fasten the input shaft in the vise so that the
reverse clutch is up.
RCPH10TLB786AAL 1
4. Remove the sealing ring.
RCPH10TLB788AAL 2
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5. Remove the snap ring above the bearing.
RCPH10TLB787AAL 3
6. Install a bearing separator under the gear as shown.

DO NOT install the bearing separator between the gear
and the bearing. Install a puller on the bearing sep-
arator. Use a shaft protector between the puller and
the end of the input shaft. Use molydisulfide grease to
lubricate the shaft protector and the end of the puller.
Make sure that you pull only until the bearing is free.
Pulling any farther can damage the parts.
RCPH10TLB789AAL 4
RCPH10TLB790AAL 5
8. Remove the spacer.
RCPH10TLB791AAL 6
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9. Remove the gear.
RCPH10TLB792AAL 7
10. Remove the needle bearing.
RCPH10TLB793AAL 8
11. Remove the thrust washer.
RCPH10TLB794AAL 9
12. Remove the roll pin.
RCPH10TLB795AAL 10
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13. Tap lightly on the thrust plate to move the thrust plate
down so that there is clearance between the snap ring
and the thrust plate.
RCPH10TLB796AAL 11
14. Tap lightly on the thrust plate to move the thrust plate
down so that there is clearance between the snap ring
and the thrust plate. Remove the snap ring.
RCPH10TLB797AAL 12
15. Install the top piece of the CAS-2379 special tool as

shown. Use the three threaded rods and nuts to fasten
the two pieces together.
RCPH10TLB798AAL 13
16. Tighten the nuts evenly to compress the spring. Com-

press the spring just enough to get access to the snap
ring.
RCPH10TLB800AAL 14
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RCPH10TLB799AAL 15
18. Loosen the nuts and the threaded rods to release the
tension from the spring. Remove the top piece of the
CAS-2379 special tool.
RCPH10TLB800AAL 16
19. Use pry bars to lift the thrust plate evenly.
RCPH10TLB922AAL 17
20. Lift the thrust plate and the steel discs and the friction
discs out of the housing as a complete unit. Set the
complete unit on top of the body.
RCPH10TLB809AAL 18
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21. Place a mark below the groove on the housing.
RCPH10TLB878AAL 19
22. Place a mark on each steel and friction disc and the
thrust plate. These marks will be used for reference
during the reassembly procedure.
RCPH10TLB879AAL 20
23. Place a mark on top of the thrust plate and each steel
and friction disc as they are removed. These marks
will be used for reference during the reassembly pro-
cedure.
RCPH10TLB880AAL 21
24. Remove the pressure plate and spring.
RCPH10TLB881AAL 22
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25. Remove the sleeve.
RCPH10TLB807AAL 23
NOTICE: Use an air hose with a safety on/off control nozzle with 2.1 bar (30.5 psi) maximum at the nozzle. Wear
face protection.
26. Use compressed air in the port shown to remove the
piston.
RCPH10TLB801AAL 24
27. Remove the piston.
RCPH10TLB802AAL 25
28. Put the input shaft in the bottom piece of the CAS-
2379 special tool as shown so that the forward clutch
is up.
RCPH10TLB923AAL 26
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29. Remove the four sealing rings (1)
RCPH10TLB819AAL 27
RCPH10TLB924AAL 28

DO NOT install the bearing separator between the
gear and the bearing. Install an acceptable puller on
the bearing separator. Use a shaft protector between
the puller and the end of the input shaft. Use moly-
disulfide grease to lubricate the shaft protector and
the end of the puller. Make sure that you pull only un-
til the bearing is free. Pulling any farther can damage
the parts.
RCPH10TLB925AAL 29
RCPH10TLB926AAL 30
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RCPH10TLB927AAL 31
NOTE: It is possible that the gear moved partially out of the clutch pack when the bearing was removed. If this occurs,
it can be difficult to remove the roll pin. Move the gear as necessary to remove the roll pin.
34. Remove the gear.
RCPH10TLB928AAL 32
RCPH10TLB929AAL 33
RCPH10TLB930AAL 34
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37. Tap lightly on the end plate to move the end plate down
so that there is clearance between the snap ring and
the end plate.
RCPH10TLB932AAL 35
RCPH10TLB931AAL 36
39. Use pry bars to lift the end plate evenly. Remove the
end plate.
RCPH10TLB933AAL 37
RCPH10TLB934AAL 38
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41. Install the top piece of the CAS-2379 special tool as

shown. Use the three threaded rods and nuts to fasten
the two pieces together.
RCPH10TLB935AAL 39
42. Tighten the nuts evenly to compress the spring. Com-

press the spring just enough to get access to the snap
ring.
RCPH10TLB936AAL 40
RCPH10TLB937AAL 41
CAS-2379 special tool.
RCPH10TLB938AAL 42
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45. Remove the retainer plate.
RCPH10TLB939AAL 43
RCPH10TLB940AAL 44
47. Lift the thrust plate and the steel discs and the friction
discs out of the housing as a complete unit. Set the
complete unit on top of the body.
RCPH10TLB941AAL 45
48. Follow the same procedure as Step 21and Step 22for

marking the top of the thrust plate and the steel and
friction discs as they are removed from the housing.
RCPH10TLB806AAL 46
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face protection.
50. Use compressed air in the port shown to remove the
piston.
RCPH10TLB803AAL 47
51. Remove the piston.
RCPH10TLB802AAL 48
52. Remove the sealing ring from the OD and the ID of

each piston.
RCPH10TLB805AAL 49
Next operation:
Transmission drive and driven shafts - Inspect (21.154)
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Transmission drive and driven shafts - Inspect Input shaft

1. Check the springs for broken or cracked coils. Com-
pare the heights of the two springs. If the two springs
are not approximately the same height, use new
springs. The correct spring height is approximately
85.5 mm (3.4 in). Use new parts as required.
2. Check the sealing ring grooves (large and small) for
wear and damage. Use new parts as required.
3. Check the teeth on the gears for wear and damage. If
a tooth is badly damaged, be sure to inspect the gear
or spline that is in mesh with the damaged gear. Use
new parts as required.
4. Check the splines on the output shaft for wear and dam-
age. Check the passages in the output shaft to be sure
that the passages are open and free of foreign mate-
rial. Use new parts as required.
5. Check the ball bearings and the needle bearings for
flat areas, pitting, and other damage. Use new parts
as required.
6. If the clutch discs are to be used again, keep the clutch
packs separate and record which clutch pack goes with
each clutch. Use new parts as required.
RCPH10TLB804AAL 1
RCPH10TLB942AAL 2
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7. Use a straight edge to check each steel disc (1) and

each friction disc (2) to be sure each part is flat. If
a steel disc (1) or a friction disc (2) is not flat, a new
part must be installed during assembly. If the friction
discs (2) are smooth or almost smooth, use new parts
during assembly. If the friction material is damaged or
appears burned, use new parts during assembly. Also,
check the splines for wear. Inspect the steel discs (1)
for pitting, scoring, or other damage. If there is any
damage, use new parts during assembly. If you will be
using new friction discs, soak the friction discs in clean
transmission oil for at least an hour before assembly. If
you are using the old friction discs, make sure that the
friction surfaces are coated with transmission oil before RCPH10TLB943AAL 3
assembly.
8. Inspect the bore and the shaft in the input shaft housing
for damage that will cause leakage when the clutch is
assembled. Check the slots in the side of the input shaft
housing for damage from the tangs on the steel discs.
Use new parts as required during assembly.
9. Inspect the end of the clutch pack housing line bore
holes, if a rivet is coming out of the housing (arrow),
replace the rivet.
RCPH10TLB818AAL 4
Next operation:
Transmission drive and driven shafts - Assemble (21.154)
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Transmission drive and driven shafts - Assemble Input shaft

1. Use clean transmission oil to lubricate the sealing rings.
Install new sealing rings in each piston.
RCPH10TLB805AAL 1
2. Slide the 380001926 piston installation tool on the input

shaft.
RCPH10TLB820AAL 2
3. Use clean transmission oil to lubricate the edge and

the bore of the piston. Install the piston. Remove the
380001926 piston installation tool from the input shaft.
4. Use clean transmission oil to lubricate the edge and the
bore of the piston. Install the piston.
RCPH10TLB806AAL 3
RCPH10TLB940AAL 4
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6. Install the retainer plate. The side that has a raised

area around the bore goes down.
RCPH10TLB939AAL 5
7. Install the top piece of the CAS-2379 special tool. Use

the three threaded rods and nuts to fasten the two
pieces together. Tighten the nuts evenly to compress
the spring just enough to get access to the snap ring
groove in the input shaft. Install the snap ring. Loosen
the nuts to relieve the spring tension and remove the
CAS-2379 special tool. Make sure that the outer edge
of the snap ring is seated in the groove in the retainer
plate.
RCPH10TLB961AAL 6
8. Install the pin.
RCPH10TLB962AAL 7
9. Use clean transmission oil to lubricate the thrust

washer. Install the thrust washer so that the notch in
the inner edge fits over the pin. Make sure that the
side with the oil grooves is up.
RCPH10TLB963AAL 8
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10. Use clean transmission oil to lubricate the needle

bearings. Install the needle bearing.
RCPH10TLB964AAL 9
11. To assemble the clutch pack, start with the gear on

the bench. Install the thrust plate so that the reference
mark on top of the plate made during disassembly is
facing towards the gear.
RCPH10TLB971AAL 10
12. Install one steel disc with reference mark on top of

the steel disc towards the gear followed by one friction
disc with the reference mark on top towards the gear.
RCPH10TLB972AAL 11
NOTE: If you will be using new friction discs, soak the friction discs in clean transmission oil for at least an hour before
assembly. If you are using the old friction discs, make sure that the friction surfaces are coated with transmission oil
before assembly.
13. Install one steel disc with reference mark on top of the
steel disc towards the gear.
RCPH10TLB048ABL 12
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14. Repeat steps 12 and 13 until all the clutch discs are
installed. The assembled clutch pack must contain
seven steel discs and six friction discs.
15. Make sure that the tabs with reference marks on all
the steel discs are aligned with each other. Hold the
clutch pack together so that the parts do not move
and rotate the clutch pack so that the clutch discs are
down. Put the clutch pack on the clutch housing as
shown so that the tabs with the reference marks on
the steel discs are almost ready to start into the slot in
the clutch housing with the reference mark.
RCPH10TLB965AAL 13
16. Use two screwdrivers in opposite slots in the clutch

housing to support the clutch pack as you start the
clutch pack into the clutch housing. Move the clutch
pack down slowly and evenly, making sure that all the
tabs are going into the slots. Make sure all of the
tabs with reference marks are aligned in the slot in
the housing with the reference mark. Also make sure
that the gear moves down with the clutch pack.
RCPH10TLB966AAL 14
17. When all the clutch discs are down, and the gear is
down as far as the thrust plate will permit, remove the
screwdrivers. Use a punch and a hammer to move the
thrust plate down evenly just far enough to get access
to the snap ring groove in the clutch housing.
RCPH10TLB967AAL 15
18. Install the snap ring.
RCPH10TLB968AAL 16
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19. Use two screwdrivers to move the thrust plate up until

the thrust plate is against the snap ring. There is a
recess in the outer edge of the thrust plate. When the
thrust plate is up all the way, the inner edge of the snap
ring will fit in this recess.
RCPH10TLB969AAL 17

side with the oil grooves is down.
RCPH10TLB927AAL 18
21. Use an acceptable driver to drive the bearing onto the

input shaft until the bearing makes contact with the
thrust washer.
RCPH10TLB970AAL 19
RCPH10TLB924AAL 20
NOTE: For clarity of the Teflon sealing ring installation procedure the following photos do not show the clutch pack,
gear, spacer, bearing, and snap ring installed on the input shaft. Steps 1 through 22 must be performed before in-
stalling the Teflon sealing ring on the input shaft.
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23. Place the 380001929 spacer into the 380001933 ex-

pander/protector.
RCPH10TLB821AAL 21
24. Slide the 380001933 expander/protector and the

spacer onto the shaft. Heat the Teflon sealing ring to
80 – 100 °C (176 – 212 °F). Install the Teflon sealing
ring onto the expander/protector.
RCPH10TLB831AAL 22

groove in the shaft. Remove the pusher, protector,
and spacer from the shaft.
RCPH10TLB838AAL 23

from the shaft.
RCPH10TLB839AAL 24
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15 min until the sealing ring has cooled and is prop-
erly sized and seated in the groove. After the sealing
ring has cooled, remove the seal compressor from the
shaft.
RCPH10TLB840AAL 25

pander/protector.
RCPH10TLB822AAL 26
29. Slide the expander/protector and the spacer onto the

shaft. Heat the Teflon sealing ring to 80 – 100 °C
(176 – 212 °F). Install the Teflon sealing ring onto the
expander/protector.
RCPH10TLB832AAL 27

groove in the shaft. Remove the pusher, expander/
protector, and spacer from the shaft.
RCPH10TLB837AAL 28
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from the shaft.
RCPH10TLB839AAL 29
shaft.
RCPH10TLB840AAL 30

pander/protector.
RCPH10TLB823AAL 31

expander/protector.
RCPH10TLB833AAL 32
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RCPH10TLB836AAL 33

from the shaft.
RCPH10TLB839AAL 34
shaft.
RCPH10TLB840AAL 35

pander/protector.
RCPH10TLB824AAL 36
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expander/protector.
RCPH10TLB834AAL 37

RCPH10TLB835AAL 38

from the shaft.
RCPH10TLB839AAL 39
shaft.
RCPH10TLB840AAL 40
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43. Put the input shaft in the bottom piece of the CAS2379
special tool so that the reverse clutch housing is up.
Slide the 380001926 piston installation tool on the in-
put shaft.
RCPH10TLB825AAL 41
44. Use clean transmission oil to lubricate the edge and

the bore of the piston. Install the piston. Remove the
piston installation tool.
45. Install the sleeve.
RCPH10TLB882AAL 42
46. Install the pressure plate and the spring. The raised
area around the bore of the pressure plate must go
down. The side that has the groove around the bore
should face up. The outer edge of the snap ring must
fit in the groove after the parts are assembled.
RCPH10TLB881AAL 43
47. Install the top piece of the CAS-2379 special tool. Use
the three threaded rods and nuts to fasten the two
pieces together. Tighten the nuts evenly to compress
the spring just enough to get access to the snap ring
groove in the input shaft. Install the snap ring. Loosen
the nuts to relieve the spring tension and remove the
CAS-2379 special tool. Make sure that the outer edge
of the snap ring is seated in the groove in the retainer
plate.
RCPH10TLB973AAL 44
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48. Install the pin.
RCPH10TLB974AAL 45

side with the oil grooves is up.
RCPH10TLB975AAL 46
50. Use clean transmission oil to lubricate the needle

bearing. Install the needle bearing.
RCPH10TLB793AAL 47
51. To assemble the clutch pack, start with the gear on

the bench. Install the thrust plate so that the reference
mark on top of the plate made during disassembly is
facing towards the gear.
RCPH10TLB971AAL 48
NOTE: If you will be using new friction discs, soak the friction discs in clean transmission oil for at least an hour before
assembly. If you are using the old friction discs, make sure that the friction surfaces are coated with transmission oil
before assembly.
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52. Install one steel disc with reference mark on top of

the steel disc towards the gear followed by one friction
disc with the reference mark on top towards the gear.
RCPH10TLB972AAL 49
53. Install one steel disc with reference mark on top of the
steel disc towards the gear.
RCPH10TLB048ABL 50
54. Repeat steps 52 and 53 until all the clutch discs are
installed. The assembled clutch pack must contain
seven steel discs and six friction discs.
55. Make sure that the tabs with reference marks on all
the steel discs are aligned with each other. Hold the
clutch pack together so that the parts do not move
and rotate the clutch pack so that the clutch discs are
down. Put the clutch pack on the clutch housing as
shown so that the tabs with the reference marks on
the steel discs are almost ready to start into the slot in
the clutch housing with the reference mark.
RCPH10TLB976AAL 51
56. Use two screwdrivers in opposite slots in the clutch

housing to support the clutch pack as you start the
clutch pack into the clutch housing. Move the clutch
pack down slowly and evenly, making sure that all the
tabs are going into the slots. Make sure all of the
tabs with reference marks are aligned in the slot in
the housing with the reference mark. Also make sure
that the gear moves down with the clutch pack.
RCPH10TLB977AAL 52
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57. When all the clutch discs are down, and the gear is
down as far as the thrust plate will permit, remove the
screwdrivers. Use a punch and a hammer to move the
thrust plate down evenly just far enough to get access
to the snap ring groove in the clutch housing.
RCPH10TLB978AAL 53
RCPH10TLB979AAL 54
59. Use two screwdrivers to move the thrust plate up until

the thrust plate is against the snap ring. There is a
recess in the outer edge of the thrust plate. When the
thrust plate is up all the way, the inner edge of the snap
ring will fit in this recess.
RCPH10TLB980AAL 55
60. Use clean transmission oil to lubricate the spacer (1)

and install the spacer (1) on the input shaft. Install the
bearing (2) onto the input shaft. Use an acceptable
driver (3) to drive the bearing onto the input shaft until
the bearing (2) makes contact with the spacer (1)
RCPH10TLB981AAL 56
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RCPH10TLB919AAL 57
NOTE: For clarity of the Teflon sealing ring installation procedure the following photos do not show the clutch pack,
gear, spacer, bearing, and snap ring installed on the input shaft. Steps 43 through 61 must be performed before
installing the Teflon sealing ring on the input shaft.
pander/protector.
RCPH10TLB826AAL 58
63. Slide the expander/protector and spacer onto the in-

put shaft. Heat the Teflon sealing ring to 80 – 100 °C
RCPH10TLB829AAL 59

RCPH10TLB830AAL 60
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from the shaft.
RCPH10TLB841AAL 61
shaft.
RCPH10TLB827AAL 62
67. Measure the clutch disc clearance for each clutch as-
sembly. The end cover must be all the way up against
the snap ring. Use a feeler gauge to measure the
distance between the end cover and the first metal
disc. The distance must be 2.300 – 4.300 mm (0.091
– 0.169 in). If the distance is not within specifica-
tion, the clutch is probably assembled wrong. Clutch
plate wear will not cause the distance to be outside
the specification.
RCPH10TLB982AAL 63
NOTE: The art shows a clutch pack without the PTO through shaft, the procedures for steps 68 and 69 are the same.
(89.9 psi) to the forward clutch passage. Listen to
hear the forward piston moving to lock the forward
clutch pack. Try to move the forward gear. The
forward gear must not turn on the input shaft. Try
to move the reverse gear. The reverse gear must
turn freely on the input shaft . If the clutches do not
work correctly, disassemble the clutches to find the
problem. RCPH10TLB054GAL 64
Clutch pack
1. Forward clutch passage 4. Forward clutch pack 7. Input shaft
2. Reverse clutch passage 5. Reverse clutch pack
3. Forward gear 6. Reverse gear
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(89.9 psi) to the reverse clutch passage. Listen to
hear the reverse piston moving to lock the reverse
clutch pack. Try to move the reverse gear. The
reverse gear must not turn on the input shaft. Try
to move the forward gear. The forward gear must
turn freely on the input shaft. If the clutches do not
work correctly, disassemble the clutches to find the
problem.
Next operation:
Transmission drive and driven shafts - Disassemble (21.154)
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Transmission drive and driven shafts - Disassemble Secondary

shaft
1. Support the secondary shaft on blocks on the bench as
shown.
RCPH10TLB765AAL 1

and the bearing. If the bearing separator has a beveled
edge, the beveled edge must be down. Do not tighten
the bearing separator so much that the bearing sepa-
rator pushes the synchronizer down. Install an accept-
able puller on the bearing separator. Use a shaft pro-
tector between the puller and the end of the secondary
shaft. Use molydisulfide grease to lubricate the shaft
protector and the end of the puller. Make sure that you
pull only until the bearing is free. Pulling any farther
can damage the parts .
RCPH10TLB766AAL 2
RCPH10TLB767AAL 3
RCPH10TLB768AAL 4
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5. Remove the third gear from the shaft.
RCPH10TLB769AAL 5
6. Remove the synchronizer assembly.
RCPH10TLB770AAL 6
7. Use a feeler gauge to measure the clearance between

the clutch ring (1) and the edge of the tapered friction
ring (2). This clearance (3) should be approximately
1.00 mm (0.04 in) with used parts in good condition.
If the clearance is 0.50 mm (0.02 in) or less, use new
parts as required. Repeat the measurement for the op-
posite side of the synchronizer assembly before disas-
sembly.
RCPH10TLB810AAL 7
8. Remove the clutch ring from each side of the synchro-

nizer assembly.
RCPH10TLB817AAL 8
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9. Remove the tapered friction ring from each side of the

synchronizer assembly.
RCPH10TLB816AAL 9
10. Inspect the clutch ring teeth for wear, wear in excess
of 0.50 mm (0.02 in) the ring must be replaced.
RCPH10TLB815AAL 10
NOTE: The parts may fly out of the hub when you do the following step. Putting the synchronizer assembly in a
cardboard box during this step can prevent loss of parts.
11. Remove the sleeve from the synchronizer hub. When
the sleeve is removed from the synchronizer hub the
spring plates, hub pins and hub springs will be re-
leased from the synchronizer hub. Be careful not to
lose any of these parts.
RCPH10TLB893AAL 11
12. This photo shows the relationship of the balls (1), the
spring plates (2), the springs (3), and the hub (4).
RCPH10TLB949AAL 12
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13. Remove fourth gear.
RCPH10TLB771AAL 13
14. Turn the secondary shaft over so that second gear is

at the top. You can use a vise with soft jaws to hold
the secondary shaft in position.
RCPH10TLB772AAL 14
15. Install a bearing separator under the bearing race as

shown. If the bearing separator has a beveled edge,
the beveled edge must be down. Do not tighten the
bearing separator so much that the bearing separator
pushes the synchronizer down. Install an acceptable
puller on the bearing separator. Use a shaft protector
between the puller and the end of the secondary shaft
. Use molydisulfide grease to lubricate the shaft pro-
tector and the end of the puller. Make sure that you
pull only until the bearing race is free. Pulling any far-
ther can damage the parts.
RCPH10TLB773AAL 15
16. Remove the bearing race from the shaft.
RCPH10TLB774AAL 16
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17. Remove the snap ring from the shaft.
RCPH10TLB775AAL 17
18. Remove the shim(s) and the thrust washer.
RCPH10TLB776AAL 18
19. Remove the pin.
RCPH10TLB777AAL 19
20. Remove second gear.
RCPH10TLB778AAL 20
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RCPH10TLB779AAL 21
22. Remove the synchronizer ring and the first-second

synchronizer as an assembly.
RCPH10TLB780AAL 22
23. Use a feeler gauge to measure the clearance between

the bottom of the teeth on the synchronizer ring and
the edge of the sleeve on the outside of the synchro-
nizer assembly. This clearance should be approxi-
mately 1.00 mm (0.04 in) with used parts in good con-
dition. If the clearance is 0.50 mm (0.02 in)or less,
use new parts as required. Repeat the measurement
for the opposite side of the synchronizer assembly be-
fore disassembly.
24. Remove the steel ring (1) and the bronze ring (2)to-
gether.
RCPH10TLB946AAL 23
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25. Remove the tapered friction ring.
RCPH10TLB947AAL 24
26. Turn the synchronizer assembly over and remove the

synchronizer ring from the other side.
RCPH10TLB945AAL 25
27. Remove the steel ring (1) and the bronze ring (2) to-
gether.
RCPH10TLB946AAL 26
28. Remove the tapered friction ring.
RCPH10TLB947AAL 27
NOTE: The parts will fly out of the hub when you do the following step. Putting the synchronizer assembly in a
cardboard box during this step can prevent loss of parts.
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29. Support the sleeve on blocks. Push down on the hub

while you use a punch to push the detent assemblies
out of the sleeve and hub. Remove the sleeve from
the hub.
RCPH10TLB948AAL 28
30. This photo shows the relationship of the balls (1), the
spring plates (2), the springs (3), and the hub (4).
RCPH10TLB949AAL 29
31. Remove first gear.
RCPH10TLB781AAL 30
32. If equipped with four wheel drive, remove the snap

ring from the four wheel drive gear.
RCPH10TLB782AAL 31
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33. Remove the four wheel drive gear, if equipped. On

two-wheel drive transmissions, there is a raised area
on the shaft.
RCPH10TLB783AAL 32
34. If equipped with four wheel drive, do not remove the

snap ring for the four wheel drive gear unless the snap
ring is damaged.
RCPH10TLB784AAL 33
Next operation:
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Transmission drive and driven shafts - Inspect Secondary shaft

or spline that is in mesh with the damaged gear.
2. Check the splines on the secondary shaft for wear and
damage. Check the passages in the secondary shaft to
be sure that the passages are open and free of foreign
material.
3. Check the bearings for flat areas, pitting, and other
damage. Replace as necessary.
4. Check the teeth in the synchronizer assemblies for
wear and damage. Replace as necessary.
5. Check for wear or damage to the steel rings and the
bronze rings from the synchronizer assemblies. Check
the springs in the synchronizer assemblies for wear,
cracks, heat distortion, and other damage. Replace as
necessary.
Next operation:
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Transmission drive and driven shafts - Assemble Secondary shaft

NOTE: Before each gear is installed on the secondary shaft, make sure that the bore of the gear and the outside
diameter of the secondary shaft are completely lubricated with clean transmission oil.
NOTE: When you install snap rings on the secondary shaft, make sure that the ends of each snap ring are seated in
the snap ring groove. Do not install a snap ring so that the ends extend into an axial slot on the secondary shaft.
1. If equipped with four wheel drive, if the snap ring was
removed from the shaft, install the snap ring as shown.
RCPH10TLB784AAL 1
2. Put the secondary shaft on the bench so that the first-

second gear end is up. You can use a vise with soft
jaws to hold the secondary shaft in position. Install the
four-wheel drive gear, if equipped.
RCPH10TLB783AAL 2
3. If equipped with four wheel drive, install the snap ring

for the four wheel drive gear.
RCPH10TLB782AAL 3
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4. Install first gear.
RCPH10TLB781AAL 4
5. This photo shows the correct relationship between the

hub and the sleeve for assembly of the first-second
synchronizer. The tabs (1) in the inside diameter of
the sleeve fit into the small recesses (2) in the outside
diameter of the hub. The large recesses (3) in the hub
are for the detent assemblies, that are not yet installed.
RCPH10TLB950AAL 5
6. This photo shows the correct positions of the hub, the

sleeve, the springs, the blocks, and the balls prior to
final assembly. The springs are installed in the hub,
and the blocks are on the springs. The blocks are not
yet pushed down into the sleeve and are holding the
hub up out of the sleeve. The balls are loose in the
recesses of the blocks.
RCPH10TLB951AAL 6
7. Use a punch or screwdriver to push the balls into the

blocks and to push the blocks down so that the balls
are on the flat faces of the teeth, but not into the detent
grooves. When all the balls are in position, push the
hub and the blocks down until the balls move into the
detent groove.
RCPH10TLB952AAL 7
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8. Install the tapered friction ring on the synchronizer as-

sembly.
RCPH10TLB947AAL 8
9. Use clean transmission oil to lubricate the bronze ring

(1) and the steel ring (2). Install the bronze ring (1) and
the steel ring (2) as shown.
RCPH10TLB946AAL 9
10. Install the synchronizer ring as shown. The flat sides

of the teeth must be up.
RCPH10TLB945AAL 10
11. Turn the synchronizer assembly over and install the

tapered friction ring on the other side.
RCPH10TLB947AAL 11
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12. Use clean transmission oil to lubricate the bronze ring

(1) and the steel ring (2). Install the bronze ring (1)
and the steel ring (2) as shown.
RCPH10TLB946AAL 12
13. Install the top synchronizer ring on the synchronizer

assembly. Make sure that the teeth on the top syn-
chronizer ring are aligned with the teeth on the inside
of the sleeve. Push the sleeve up until the sleeve
engages the teeth on the top synchronizer ring. To
do this, you must use enough force to overcome the
strength of the detent springs and balls. When the
synchronizer ring and the sleeve are completely en-
gaged, the detent must hold the sleeve in this posi-
tion. Push the sleeve back down to the neutral posi-
tion, turn the synchronizer assembly over, and repeat
the procedure with the bottom synchronizer ring. If the
sleeve does not engage the teeth smoothly or does
not stay in position when moved to any of the three
positions, the synchronizer assembly has damaged
parts or was not assembled correctly. Disassemble
the synchronizer assembly to find the problem.
14. Install the synchronizer ring and the first-second syn-
chronizer as an assembly. Make sure the top synchro-
nizer ring is installed so that the flat sides of the teeth
are up.
RCPH10TLB780AAL 13
NOTE: There is a groove in the bore at one end of the synchronizer hub. The synchronizer assembly must be installed
so that the groove is down.
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15. Install the spacer.
RCPH10TLB779AAL 14
16. Install and second gear. The teeth in the inside diame-
ter of the spacer must engage the teeth on the bottom
of second gear before second gear is installed.
RCPH10TLB778AAL 15
17. Install the pin.
RCPH10TLB777AAL 16
Next operation:
Transmission drive and driven shafts - Adjust (21.154)
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Transmission drive and driven shafts - Adjust Backlash adjustment

1. Install the thrust washer and snap ring.
RCPH10TLB775AAL 1
2. Use a feeler gauge and measure the backlash between

the gear and the thrust washer. Record this measure-
ment (a). Subtract the recorded measurement
(a) from 0.2000 – 0.4200 mm (0.0079 – 0.0165 in)
(b). Select the shim(s) required (c). Example: Use
0.8300 mm (0.0327 in) ± 0.1100 mm (0.0043 in) shim
(s).
a. 1.1400 mm (0.0449 in)

b. –0.3100 mm (–0.0122 in)
c. 0.8300 mm (0.0327 in)
3. Remove the snap ring and the thrust washer.
RCPH10TLB775AAL 2
4. Use clean transmission oil to lubricate the shim(s) and

the thrust washer. Install the shim(s). Install the thrust
washer on top of the shim(s). Make sure that the side
with the oil grooves is down.
RCPH10TLB776AAL 3
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5. Put the bearing race on the shaft.
RCPH10TLB774AAL 4
6. Use an acceptable driver to drive the bearing race onto

the secondary shaft until bearing race makes contact
with the snap ring.
RCPH10TLB785AAL 5
7. Turn the secondary shaft over so that second gear is at

the bottom. Use blocks to support the secondary shaft.
Install the fourth gear on the secondary shaft.
RCPH10TLB771AAL 6
8. This photo shows the correct relationship between the

hub and the sleeve for assembly of the third-fourth syn-
chronizer. The tabs (1) in the inside diameter of the
sleeve fit into the small recesses (2) in the outside di-
ameter of the hub. The large recesses (3) in the hub
are for the detent assemblies, shown installed.
RCPH10TLB811AAL 7
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9. Install the three sets of hub springs, hub pins, and

spring plates into the synchronizer hub. Use a punch
or screwdriver to push the spring plates as the synchro-
nizer hub is installed into the sleeve. Be sure that the
spring plates are aligned with the grooves in the sleeve.
RCPH10TLB952AAL 8
10. Install the friction ring on each side the synchronizer

assembly.
RCPH10TLB892AAL 9
11. Use clean transmission oil to lubricate and install the

clutch ring on each side of the synchronizer assembly.
RCPH10TLB891AAL 10
12. Install the top synchronizer ring on the synchronizer

assembly. Make sure that the teeth on the top syn-
chronizer ring are aligned with the teeth on the inside
of the sleeve. Push the sleeve up until the sleeve
engages the teeth on the top synchronizer ring. To
do this, you must use enough force to overcome the
strength of the detent springs and balls. When the
synchronizer ring and the sleeve are completely en-
gaged, the detent must hold the sleeve in this posi-
tion. Push the sleeve back down to the neutral posi-
tion, turn the synchronizer assembly over, and repeat
the procedure with the bottom synchronizer ring. If the
sleeve does not engage the teeth smoothly or does
not stay in position when moved to any of the three RCPH10TLB810AAL 11
positions, the synchronizer assembly has damaged

parts or was not assembled correctly. Disassemble
the synchronizer assembly to find the problem.
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13. Install the synchronizer assembly onto the shaft.
RCPH10TLB770AAL 12
14. Install the third gear on the shaft.
RCPH10TLB769AAL 13

washer. Install the thrust washer onto the shaft.
RCPH10TLB768AAL 14
16. Put the bearing in position on the secondary shaft.

Make sure that the snap ring groove is at the top.
RCPH10TLB767AAL 15
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secondary shaft until the bearing makes contact with
the thrust washer.
RCPH10TLB953AAL 16
NOTE: If the bearing is not very tight on the secondary shaft, parts could fall from the secondary shaft when you
install the secondary shaft in the rear housing. To prevent this, you can install a hose clamp on the output end of the
secondary shaft. This will keep the bearing in position during installation of the secondary shaft.
18. Check for correct operation of both synchronizer as-
semblies. If they do not shift smoothly, with the teeth
on the synchronizer ring aligned with the splines on
the sleeve, the re is a problem. Disassemble as nec-
essary, and correct the problem.
Next operation:
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Transmission drive and driven shafts - Disassemble Primary shaft

1. Put the primary shaft on the bench so that the end with
the bearing attached is up. Remove the snap ring.
RCPH10TLB954AAL 1

and the bearing. Install an acceptable puller on the
bearing separator. Use a shaft protector between the
puller and the end of the primary shaft. Use molydisul-
fide grease to lubricate the shaft protector and the end
of the puller. Pull the bearing from the primary shaft.
RCPH10TLB955AAL 2
RCPH10TLB956AAL 3
RCPH10TLB957AAL 4
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5. Install a bearing separator under the lip of the bearing

race as shown. Install an acceptable puller on the bear-
ing separator. Use a shaft protector between the puller
and the end of the primary shaft. Use molydisulfide
grease to lubricate the shaft protector and the end of
the puller. Pull the bearing race from the primary shaft.
RCPH10TLB958AAL 5
Next operation:
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Transmission drive and driven shafts - Inspect Primary shaft

or spline that is in mesh with the damaged gear.
2. Check the splines on the primary shaft for wear and
damage.
3. Check the bearings for flat areas, pitting, and other
damage. Replace as necessary.
Next operation:
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Transmission drive and driven shafts - Assemble Primary shaft

1. Use an acceptable driver to drive the bearing race all
the way onto the primary shaft.
RCPH10TLB959AAL 1

washer. Install the thrust washer so that the side with
the oil grooves is down.
RCPH10TLB957AAL 2
3. Put the bearing into position so that the snap ring

groove on the outside diameter of the bearing is at the
top.
RCPH10TLB956AAL 3

primary shaft until the bearing makes contact with the
thrust washer.
RCPH10TLB960AAL 4
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RCPH10TLB954AAL 5
Next operation:
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Transmission drive and driven shafts - Disassemble Reverse shaft

1. The bearings are the only serviceable parts on the re-
verse shaft. If you remove the bearings, use a shaft
protector between the puller and the end of the reverse
shaft. Use molydisulfide grease to lubricate the shaft
protector and the end of the puller. (1) Bearing, (2) Re-
verse shaft
RCPH10TLB050ABL 1
Next operation:
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Transmission drive and driven shafts - Inspect Reverse shaft

1. Check the teeth on the gears for wear and damage. If a
tooth is badly damaged, be sure to inspect the gear that
is in mesh with the damaged gear. Check the bearings
for flat areas, pitting, and other damage. Replace as
necessary.
Next operation:
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Transmission drive and driven shafts - Assemble Reverse shaft

1. Use an acceptable driver to drive each bearing onto the
reverse shaft until the bearing makes contact with the
shoulder on the reverse shaft.
Next operation:
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Transmission drive and driven shafts - Disassemble Oil pump

NOTE: Bolts (6), O-Rings, bushings and seals are the only serviceable components in the oil pump. Complete dis-
assembly of the oil pump is shown for reference only.
1. Remove the O-ring.
RCPH10TLB983AAL 1
2. Remove the two Allen head bolts that fasten the pump
support to the pump housing.
RCPH10TLB984AAL 2
3. Separate the pump support from the pump housing.
RCPH10TLB985AAL 3
4. Remove the large gear from the pump housing.
RCPH10TLB986AAL 4
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NOTE: Install a plastic plug in the bearings to keep the bearings from falling out when the small gear is removed from
the pump housing.
5. Remove the small gear from the pump housing.
RCPH10TLB987AAL 5
NOTE: Be careful when removing the plastic plug from the small gear the needle bearings will fall out. Make a record
of the number of needle bearings remove from the small gear for use during assembly.
6. Remove the seal from the pump housing.
RCPH10TLB988AAL 6
7. Turn the pump housing over and use blocks to support

the pump housing. Use an acceptable driver to drive
the bushing from the bore of the pump housing.
RCPH10TLB989AAL 7
8. Support the large gear on blocks as shown. Use a

punch and a hammer to drive the bushing from the
large gear.
RCPH10TLB994AAL 8
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9. Use an acceptable driver to push the needle bearing

out of the small gear.
RCPH10TLB996AAL 9
10. Remove the shaft for the small gear only if the shaft
is damaged. The shaft will probably be difficult to re-
move.
RCPH10TLB993AAL 10
11. Use a blind hole puller and a slide hammer to pull the
bushing from the shaft of the pump support.
RCPH10TLB997AAL 11
12. Remove the roll pin for the torque converter relief
valve.
RCPH10TLB999AAL 12
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13. Remove the plug, the spring, and the ball for the
torque converter relief valve.
RCPH10TLB001ABL 13
14. Remove the roll pin for the oil pump relief valve. Be
very careful because the large amount of spring ten-
sion will force the parts out when the roll pin is re-
moved.
RCPH10TLB002ABL 14
15. Remove the plug, the spring, the pin, and the plunger
for the oil pump relief valve.
RCPH10TLB038ABL 15
Next operation:
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Transmission drive and driven shafts - Inspect Oil pump

1. Inspect the large gear and the small gear for wear and
damage. If the teeth on a gear have scoring, excessive
wear, or sharp edges, use a new gear. Check for dam-
age to the lugs on the large gear. If there is damage,
check the hub on the torque converter for similar dam-
age. Replace the large gear and the torque converter
as necessary.
2. Inspect the gear pockets in the pump housing for wear
or damage. If the gear pockets have scoring or exces-
sive wear, use a new oil pump.
3. Inspect the splines on the shaft for wear and damage.
If you find damage, inspect the part that is installed on
the shaft.
4. Inspect all passages to be sure that the passages are
open and free of foreign material.
5. Check the needle bearing for wear, pitting, or other
damage.
6. Inspect the parts of the torque converter relief valve and
the oil pump relief valve for wear and damage.
Next operation:
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Transmission drive and driven shafts - Assemble Oil pump

1. Install the plunger for the oil pump relief valve.
RCPH10TLB042ABL 1
2. Install the pin for the oil pump relief valve. The ma-
chined end of the pin must be toward the plunger. Make
sure that the pin goes into the bore of the plunger.
RCPH10TLB041ABL 2
RCPH10TLB040ABL 3
4. Install the plug.
RCPH10TLB039ABL 4
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5. This step will be difficult because the spring will be un-

der heavy tension. Push the plug in until the plug is to
the inside of the hole for the roll pin. Install the roll pin.
RCPH10TLB002ABL 5
6. Install the ball, the spring, and the plug for the torque
converter relief valve. Make sure that the hole in the
plug is aligned with the hole for the roll pin.
RCPH10TLB001ABL 6
7. Install the roll pin through the holes in the pump support
and the hole in the plug.
RCPH10TLB003ABL 7
8. Use an acceptable driver to install a new bushing in the

shaft of the pump support.
RCPH10TLB998AAL 8
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9. Use an acceptable driver to install a new needle bear-

ing in the small gear. Push the needle bearing until the
needle bearing is approximately centered in the bore of
the gear.
RCPH10TLB996AAL 9
10. If the shaft for the small gear was removed, clean the
mating surfaces and apply either Loctite 640 (green)
or Loctite 642 (amber) before installation.
RCPH10TLB993AAL 10
11. Support the large gear on blocks so that the side with
the lugs is down. Use an acceptable driver to push
the new bushing to the end of the bore.
RCPH10TLB995AAL 11
12. Put a new bushing into position so that the recess (1)
in the bushing is aligned with the oil drain hole (2) in
the pump housing.
RCPH10TLB990AAL 12
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13. Use an acceptable driver to install the bushing.
RCPH10TLB992AAL 13
14. Use an acceptable driver to install a new seal in the

end of the pump housing.
RCPH10TLB991AAL 14
15. Use clean transmission oil to lubricate the small gear,

the needle bearing, and the bore in the pump housing.
Install the small gear on the shaft in the pump housing.
Install the same number of needle bearings that were
removed between the small gear and the shaft.
RCPH10TLB987AAL 15
16. Use clean transmission oil to lubricate the large gear,

the bushing in the large gear, and the bore in the pump
housing. Install the large gear so that the side with the
lugs is down.
RCPH10TLB986AAL 16
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17. Install the pump support on the pump housing. Make

sure that all the bolt holes are aligned.
RCPH10TLB985AAL 17
18. Install the two Allen head bolts to fasten the pump
support to the pump housing. Tighten the Allen head
bolts until they are just snug.
RCPH10TLB984AAL 18
19. Install a large worm gear clamp (radiator hose clamp)

around the outside of the pump housing and the pump
support. The clamp must cover the joint between the
two parts and be in contact with both parts. Tighten
the clamp. Tap the housing with a soft hammer.
Tighten the clamp again. Tap the housing again with
a soft hammer. Tighten the clamp again. Tighten
the Allen head bolts to 10 Nm (89 pound-inches).
Remove the clamp.
20. Put the oil pump on a clean work surface so that the
pump housing is up. Insert a small screwdriver or
punch through the hole in the torque converter hub
and rotate the large gear by pushing against one of
the lugs. The large gear must rotate freely. If the large
gear does not rotate freely, loosen the Allen head bolts
and repeat step 340. If the large gear rotates freely,
fill the oil pump with clean transmission oil and rotate
the large gear three revolutions before you install the
oil pump on the transmission.
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RCPH10TLB983AAL 19
Next operation:
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Transmission drive and driven shafts - Disassemble Four wheel

drive shaft
1. There is a pipe plug at the bottom of the hole in the end
of the shaft (see arrow). DO NOT remove the pipe plug
unless the pipe plug is damaged.
RCPH10TLB883AAL 1
2. Use an acceptable tool to press the spring retainer

down until you have access to the snap ring (see ar-
row). Remove the snap ring from the groove. Release
the tension and remove the tool.
RCPH10TLB884AAL 2
NOTE: The tool used in the photo above is a piece of round tubing with a rectangular access hole cut out to provide
access to the snap ring.
3. Remove the snap ring from the shaft.
RCPH10TLB885AAL 3
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RCPH10TLB886AAL 4
5. Remove the special washer.
RCPH10TLB887AAL 5
6. Remove the springs.
RCPH10TLB888AAL 6
RCPH10TLB889AAL 7
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8. Remove the two O-rings from the shaft.
RCPH10TLB890AAL 8
9. Remove the two Teflon sealing rings from the shaft.
RCPH10TLB890AAL 9
Next operation:
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Transmission drive and driven shafts - Inspect Four wheel drive

shaft
1. Inspect the lugs on the sleeve for peening or other dam-
age. If you find damage to the lugs, also inspect the
four-wheel drive clutch gear.
2. Check the splines on the shaft and inside the sleeve for
wear and damage.
3. Check the passages in the shaft to be sure that the
passages are open and free of foreign material.
4. Check the springs for wear, cracks, heat distortion, and
other damage. Replace as necessary.
Next operation:
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Transmission drive and driven shafts - Assemble Four wheel drive

shaft
NOTE: Special tools used up to step 6 are from the tool set CAS2771A, standard transmission without rear pump
drive.
1. Install new O-rings on the shaft. Use clean transmis-
sion oil to lubricate the O-rings.
RCPH10TLB890AAL 1
2. Install the CAS2771-2 expander/protector on the shaft.
RCPH10TLB894AAL 2
NOTE: For clarity, the following photo does not show the use of a heat resistant glove. To prevent injury be sure to
wear a heat resistant glove when installing the Teflon sealing ring.
3. Heat the Teflon sealing ring to 80 – 100 °C (176
– 212 °F). Install the Teflon sealing ring onto the
CAS2771-2 expander/protector.
RCPH10TLB895AAL 3
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4. Install the CAS2327 pusher over the expander/protec-

tor and slide the sealing ring until it reaches the groove
in the shaft. Remove the pusher and expander/protec-
tor from the shaft.
RCPH10TLB896AAL 4
5. Install the end of the CAS2771-7 seal compressor with

from the shaft.
RCPH10TLB897AAL 5
6. Turn the seal compressor around and slide the end with
the narrow chamfer over the shaft and over the sealing
ring. Leave the seal compressor in place for 15 min
until the sealing ring has cooled and is properly sized
and seated in the groove. After the sealing ring has
cooled, remove the seal compressor from the shaft.
RCPH10TLB898AAL 6
7. Place the CAS2771-3 spacer against the end of the

shaft.
RCPH10TLB899AAL 7
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8. Slide the CAS2771-2 expander/protector over the

CAS2771-3 spacer. The expander/protector will stop
in the correct position to install the sealing ring in the
groove.
RCPH10TLB900AAL 8
NOTE: For clarity, the following photo does not show the use of a heat resistant glove. To prevent injury be sure to
wear a heat resistant glove when installing the Teflon sealing ring.
CAS2771-2 expander/protector.
RCPH10TLB900AAL 9
10. Install the CAS2327 pusher over the expander/protec-

tor and slide the sealing ring until it reaches the groove
in the shaft. Remove the pusher, expander/protector,
RCPH10TLB902AAL 10
11. Install the end of the CAS2771-1 seal compressor with

from the shaft.
RCPH10TLB903AAL 11
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shaft.
RCPH10TLB904AAL 12
13. Install the sleeve on the shaft. Be careful not to dam-

age the Teflon sealing rings and the O-rings while in-
stalling the sleeve.
RCPH10TLB889AAL 13
14. Install the springs.
RCPH10TLB888AAL 14
15. Install the special washer.
RCPH10TLB887AAL 15
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16. Install the spacer onto the shaft.
RCPH10TLB886AAL 16
17. Install the snap ring onto the shaft.
RCPH10TLB885AAL 17
18. Use an acceptable tool to press the spring retainer

down until you have access to the snap ring groove
(see arrow). Install the snap ring in the groove. Re-
lease the tension and remove the tool. Make sure that
the snap ring is seated in the recess in the spring re-
tainer.
RCPH10TLB884AAL 18
NOTE: The tool used in the photo above is a piece of round tubing with a rectangular access hole cut out.
19. If the pipe plug at the bottom of the hole in the end
of the shaft (see arrow) was removed, apply Loctite
242 or Loctite 262 to the threads of the new pipe plug
before installation. Tighten the pipe plug to a torque
of 30.0 N·m (265.5 lb in).
RCPH10TLB004ABL 19
Next operation:
Transmission housing - Disassemble (21.112)
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Index
Transmission - 21

Transmission drive and driven shafts - Adjust Backlash adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Transmission drive and driven shafts - Assemble Four wheel drive shaft . . . . . . . . . . . . . . . . . . . . . . 86
Transmission drive and driven shafts - Assemble Input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Transmission drive and driven shafts - Assemble Oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Transmission drive and driven shafts - Assemble Primary shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Transmission drive and driven shafts - Assemble Reverse shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Transmission drive and driven shafts - Assemble Secondary shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Transmission drive and driven shafts - Disassemble Four wheel drive shaft . . . . . . . . . . . . . . . . . . . . 82
Transmission drive and driven shafts - Disassemble Input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Transmission drive and driven shafts - Disassemble Oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Transmission drive and driven shafts - Disassemble Primary shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Transmission drive and driven shafts - Disassemble Reverse shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Transmission drive and driven shafts - Disassemble Secondary shaft . . . . . . . . . . . . . . . . . . . . . . . . . 43
Transmission drive and driven shafts - Exploded view Four wheel drive shaft . . . . . . . . . . . . . . . . . . 9
Transmission drive and driven shafts - Exploded view Input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Transmission drive and driven shafts - Exploded view Secondary shaft . . . . . . . . . . . . . . . . . . . . . . . . 7
Transmission drive and driven shafts - Exploded view Shift rod and forks . . . . . . . . . . . . . . . . . . . . . . 5
Transmission drive and driven shafts - Inspect Four wheel drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . 85
Transmission drive and driven shafts - Inspect Input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Transmission drive and driven shafts - Inspect Oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Transmission drive and driven shafts - Inspect Primary shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Transmission drive and driven shafts - Inspect Reverse shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Transmission drive and driven shafts - Inspect Secondary shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
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Transmission - 21
Powershift transmission - 113

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Contents
Transmission - 21
TECHNICAL DATA
General specification H-type 4WD only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Special tools H-type 4WD only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
General specification - control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
General specification - dimensions and schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
General specification - port locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
General specification - gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
FUNCTIONAL DATA
Fault code index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
SERVICE
Drain fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Remove H-type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Disassemble H-type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Cleaning H-type - 4WD only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Inspect H-type - 4WD only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Assemble H-type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Install H-type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
Tool connection Test port and component locations, H-type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
Warm up Heating the oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
Service instruction - Torque and application of sealants/adhesives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
DIAGNOSTIC
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Testing Machine will not move, H-type and S-type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
Testing Loss of power, H-type and S-type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
Testing Wheels rotate when vehicle is raised, H-type and S-type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
Testing Transmission oil is too hot, H-type and S-type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
Testing Noisy transmission, H-type and S-type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
Testing Irregular clutch activation, H-type and S-type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
Testing Gear remains engaged, H-type and S-type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
Testing Will not go into 4WD, H-type and S-type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
Testing Problem in the parking brake system, H-type and S-type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
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Transmission - Powershift transmission
Powershift transmission - General specification H-type 4WD only

Lubricant
Total system capacity 18.0 L (19.0 US qt)
Refill capacity with or without filter change 11.4 l (11.4 US qt)
Type of fluid CASE AKCELA NEXPLORE™ FLUID
Powershift transmission - Special tools H-type 4WD only

380040161 - Teflon seal installation kit
RCPH10TLB828AAL 1
380002211 - Handle
RCPH10TLB059AAL 2
380040161 - Teflon seal ring protector and shims - 1st,

3rd, 4th, and 4WD shafts
RCPH10TLB080AAL 3
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380100081 - Teflon seal ring protector and shims - 2nd

gear
RCPH10TLB073AAL 4
380100082 - Teflon seal ring sizer - 2nd gear
RCPH10TLB074AAL 5
380100083 - Teflon seal ring protector - 1st gea r
RCPH10TLB072AAL 6
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380100084 - Teflon seal ring sizer - 1st gear
RCPH10TLB078AAL 7
380100085 - Teflon seal ring protector and shim - 1st gear

bushing
RCPH10TLB079AAL 8
380100086 - Teflon seal ring sizer - 1st gear bushing
RCPH10TLB075AAL 9
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380100087 - Holder bushing - 4WD shaft
RCPH10TLB076AAL 10
380100088 - Shaft puller/installer
RCPH10TLB077AAL 11
CAS2379 - Holder and spring compressor
RCPH10TLB043ABL 12
Powershift transmission - General specification - control valve

4WD/2WS transmission - Powershift (580ST / 590ST)
Model CARRARO TLB2 MPB 4WD
Type (4 x 4) 4 forward and 4 reverse travel gears
Torque converter ratio 2.38
Transmission ratios:
1st gear Forward travel 5.533:1 Reverse travel 4.549:1
2nd gear Forward travel 3.359:1 Reverse travel 2.762:1
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3rd gear Forward travel 1.553:1 Reverse travel 1.260:1

4th gear Forward travel 0.811:1 Reverse travel 0.677:1
4WD/4WS transmission - Powershift (695ST)

Model CARRARO TLB2 MPB 4WS
Type (4 x 4) 4 forward and 4 reverse travel gears
Torque converter ratio 2.38
Transmission ratios:
1st gear Forward travel 4.468:1 Reverse travel 3.657:1
2nd gear Forward travel 2.700:1 Reverse travel 2.220:1
3rd gear Forward travel 1.232:1 Reverse travel 1.013:1
4th gear Forward travel 0.652:1 Reverse travel 0.536:1
Hydraulic control valve
2/3 proportional solenoid valve specifications

Absorption: 10 W
Protection degree: IP69K
Solenoid resistance: 7.25 Ω [ 20 °C (68 °F)]
Power supply voltage: 12 V DC
2/3 solenoid valve specifications

Absorption: 1.68 A [ 20 °C (68 °F)]
2/4 solenoid valve specifications

Absorption: 1.68 A [ 20 °C (68 °F)]
Diagram
A. 2/3 proportional solenoid 2nd - 4th speed actuation
B. 2/3 proportional solenoid reverse speed
C. 2/3 proportional solenoid forward speed
D. 2/3 proportional solenoid 1st - 3rd speed actuation
E. 2/3 solenoid valve 4WD engagement
F. 2/4 solenoid valve 2nd or 4th speed selection
G. 2/3 solenoid valve differential lock engagement
H. 2/4 solenoid valve 1st or 3rd speed selection
PS. Supply pressure check port
HDL2. Differential lock engagement control port
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LELI12TLB0756HB 1
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Powershift transmission - General specification - dimensions and

schematics
2WS
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LELI12TLB0757JA 1
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4WS
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LELI12TLB0758JA 2
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Hydraulic diagram
2WS
LELI12TLB0759HB 3
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Ref. Description Notes

1. Suction filter 250 N·m (184.39 lb ft)
2. Pump 36 cm³/rev (2.20 in³/rev)
3. Oil filter relief valve 23 bar (334 psi)
4. Filter 10 N·m (7.4 lb ft)
5. Torque converter
6. Oil cooler
7. Torque converter relief valve 3.5 – 5.5 bar (51 – 80 psi)
8. Pressure regulator for sequential valve
9. Air breather
10. Forward gear pressure check port
11. Reverse gear pressure check port
12. Forward gear clutch
13. Reverse gear clutch
14. 4WD clutch
15. HDL
16. Shaft lubrication inlet
17. Brake oil return port
18. Transfer oil return port
19. Main pressure check port
20. Pressure check port of 1st gear clutch
21. Pressure check port of 2nd gear clutch
22. 1st gear clutch
23. 2nd gear clutch
24. 3rd gear clutch
25. 4th gear clutch
26. Main shaft lubrication
27. Output shaft lubrication
28. Temperature thermostat
29. Parking brake lubrication
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4WS
LELI12TLB0760HB 4
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Ref. Description Notes

1. Suction filter 250 N·m (184.39 lb ft)
2. Pump 36 cm³/rev (2.20 in³/rev)
3. Oil filter relief valve 23 bar (334 psi)
4. Spin-on filter 10 N·m (7.4 lb ft)
5. Torque converter
6. Oil cooler
7. Torque converter relief valve 3.5 – 5.5 bar (51 – 80 psi)
8. Pressure regulator for sequential valve
9. Air breather
10. Forward gear pressure check port
11. Reverse gear pressure check port
12. Forward gear clutch
13. Reverse gear clutch
14. 4WD clutch
15. HDL
16. Shaft lubrication inlet
17. Brake oil return port
18. Transfer oil return port
19. Main pressure check port
20. Pressure check port of 1st gear clutch
21. Pressure check port of 2nd gear clutch
22. 1st gear clutch
23. 2nd gear clutch
24. 3rd gear clutch
25. 4th gear clutch
26. Main shaft lubrication
27. Output shaft lubrication
28. Temperature thermostat
29. Parking handbrake lubrication
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Powershift transmission - General specification - port locations

2WS
LELI12TLB0761FB 1
Ref. Dimension Use Notes - miscellaneous

1. 7/8" - 14 UNF Oil inlet from cooler
2. 7/8" - 14 UNF Oil outlet to cooler
Check port for torque converter input
3. 9/16" - 18 UNF 3 – 9 bar (43.5 – 130.5 psi)
pressure
13.5 – 16.5 bar (196 – 239 psi)
4. 9/16" - 18 UNF Forward gear pressure check port 0.3 bar (4.4 psi) = maximum pressure in neutral
position
13.5 – 16.5 bar (196 – 239 psi)
5. 9/16" - 18 UNF Reverse gear pressure check port 0.3 bar (4.4 psi) = maximum pressure in neutral
position
6. Oil drain plug
Oil pressure delivery to differential
7. 9/16" - 18 UNF 14 – 17 bar (203 – 247 psi)
lock
Lubrication pressure check port (from
1 – 5 bar (14.5 – 72.5 psi) forward/reverse gear
8. 9/16" - 18 UNF cooler)
1 – 5 bar (14.5 – 72.5 psi) neutral position
Oil outlet to brake tank
9. 9/16" - 18 UNF Brake oil pressure delivery 14 – 17 bar (203 – 247 psi)
10. 9/16" - 18 UNF Oil return
11. 9/16" - 18 UNF Oil level check port
12. 9/16" - 18 UNF Oil main pressure check port 14 – 17 bar (203 – 247 psi)
13. 1/8" - BSP Lubrication check port
14. 1/8" - BSP Check port of 1st gear
15. 1/8" - BSP Check port of 2nd gear
16. 1/8" - BSP Check port of 4th gear
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4WS
LELI12TLB0761FB 2
Ref. Dimension Use Notes - miscellaneous

1. 7/8" - 14 UNF Oil inlet from cooler
2. 7/8" - 14 UNF Oil outlet to cooler
Check port for torque converter input
3. 9/16" - 18 UNF 3 – 9 bar (43.5 – 130.5 psi)
pressure
13.5 – 16.5 bar (196 – 239 psi)
4. 9/16" - 18 UNF Forward gear pressure check port 0.3 bar (4.4 psi) = maximum pressure in neutral
position
13.5 – 16.5 bar (196 – 239 psi)
5. 9/16" - 18 UNF Reverse gear pressure check port 0.3 bar (4.4 psi) = maximum pressure in neutral
position
6. Oil drain plug
Oil pressure delivery to differential
7. 9/16" - 18 UNF 14 – 17 bar (203 – 247 psi)
lock
Lubrication pressure check port (from
1 – 5 bar (14.5 – 72.5 psi) forward/reverse gear
8. 9/16" - 18 UNF cooler)
1 – 5 bar (14.5 – 72.5 psi) neutral position
Oil outlet to brake tank
9. 9/16" - 18 UNF Brake oil pressure delivery 14 – 17 bar (203 – 247 psi)
10. 9/16" - 18 UNF Oil return
11. 9/16" - 18 UNF Oil level check port
12. 9/16" - 18 UNF Oil main pressure check port 14 – 17 bar (203 – 247 psi)
13. 1/8" - BSP Lubrication check port
14. 1/8" - BSP Check port of 1st gear
15. 1/8" - BSP Check port of 2nd gear
16. 1/8" - BSP Check port of 4th gear
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Powershift transmission - General specification - gears
LELI12TLB1271FA 1
1nd Gear clutch

Disc number (each side) 6
Counterdisc number (each side) 6
Rated thickness of disc 2.15 – 2.25 mm (0.085 – 0.089 in)
Disc kit nominal thickness [with 163 kg (359.35 lb) of load] 27.50 – 27.70 mm (1.08 – 1.09 in)
Disc maximum wear (each side) 0.15 mm (0.006 in)
Pack maximum wear (each side) 1.8 mm (0.071 in)
2nd Gear clutch

Counter disc number (each side) 8
Disc kit nominal thickness [with 163 kg (359.35 lb) of
30.5 – 30.7 mm (1.20 – 1.21 in)
load]
3nd Gear clutch

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4nd Gear clutch

4WD clutch
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Powershift transmission - Fault code index

Fault code - Description Amber telltale
Red telltale LED
LED
4000 – Power supply (pin 2), forward FWD drive (pin 3), or RVS drive
X
(pin 4) drive shorted to ground
4001 – Power supply (pin 5), PWM 1 drive (pin 6), or PWM 2 drive (pin
X
7) drive shorted to ground
4002 – Power supply for digital outputs (pin 8) does not have power X
4004 – Battery voltage (Pin 34) voltage below 10 volts for 2.5 seconds
X
with engine speed above 900 rpm
4005 – Downshift delayed due to possible engine overspeed condition X
4006 – FWD input (Pin 12) feedback circuit is reading current with
X
command
4007 – FWD input (Pin 12) current is too low with command present X
4008 – FWD solenoid is drawing more current then commanded X
4009 – FWD solenoid is drawing less current than commanded X
4011 – RVS input (pin 40) feedback circuit is reading current with
X
command
4012 – RVS input (pin 40) current is too low with command present X
4013 – RVS solenoid is drawing more current than commanded X
4014 – RVS solenoid is drawing less current than commanded X
4016 – First and third shift modulation solenoid input (pin 13) feedback
X
circuit is reading current without command
4017 – First and third shift modulation solenoid input (pin 13) current
X
is too low with command present
4018 – First and third shift modulation solenoid is drawing more
X
current then commanded
4019 – First and third shift modulation solenoid is drawing less current
X
then commanded
4021 – Second and fourth shift modulation solenoid input (pin 41)
X
feedback circuit is reading current with command
4022 – Second and fourth shift modulation solenoid input (pin 41)
current is too low with command present
4023 – Second and fourth shift modulation solenoid is drawing more
X
4024 – Second and fourth shift modulation solenoid is drawing less
X
4026 – First / Third shift solenoid shorted to ground X
4027 – Second / Fourth shift solenoid shorted to ground X
4028 – Differential lock or 4 wheel drive solenoid shorted to ground X
4029 – Shifter Lever improperly connected, no power to pin 16, pin 18,
X
or pin 46 for more than 3 seconds
4030 – Shifter Lever malfunction: transmission in neutral receives
X
forward and neutral together
4031 – Shifter Lever malfunction: transmission in neutral receives
X
reverse and neutral together
4032 – Shifter Lever malfunction: transmission in forward receives
X
forward and reverse together
4033 – Shifter Lever malfunction: transmission in reverse receives
X
4034 – Shifter Lever malfunction: transmission in forward receives
X
neutral and forward together
4035 – Shifter Lever malfunction: transmission in reverse receives
X
neutral and reverse together
4036 – During transition from second to third gear, and Gear CMD_01
X
signal erratic or incorrect
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Fault code - Description Amber telltale

Red telltale LED
LED
4037 – During transition from first to second gear, and Gear CMD_02
X
4038 – During transition from third to fourth gear, and Gear CMD_02
X
4039 – Crab input erratic or incorrect X
4040 – Transmission Controller Driveline Configuration X
4041 – Transmission output shaft frequency above 3000 Hz detected X
4042 – Temperature signal erratic or incorrect X
4043 – Temperature sensor input (Pin 43) is shorted to a ground X
4044 – Temperature sensor input (Pin 43) is open circuit or shorted
X
to a voltage above 5 volts
4045 – Charge pressure is not detected when engine speed is above
X
700 rpm for 10 seconds
4046 – Charge pressure is not detected and vehicle speed is over 10
X
kph (6 mph)
4047 – Charge pressure switch is closed with no frequency input to
X
the TRAX controller
4100 – Missing EEC 1 message on CAN X
4101 – Internal TRAX failure, hardware measurement X
4102 – Internal TRAX failure, software timing X
4103 – Internal TRAX failure, software not running X
4105 – Internal TRAX failure, redundant flash memory X
4106 – Internal TRAX failure, sensor supply high X
4107 – Internal TRAX failure, sensor supply low X
4300 – Top Link Switch Not Fitted X
4301 – Side Link Switch Not Fitted X
4302 – Rear remote no. 6 - control message not plausible X
4303 – Rear remote no. 6 - EEPROM error X
4304 – Rear remote no. 6 - not commanded neutral on power-up X
4305 – Rear remote no. 6 - under voltage X
4306 – Rear remote no. 6 - over voltage X
4825 – Loss of TC1 message after 15 seconds X
4850 – Possible detection wrong transmission type for installed
X
software
4995 – Incorrect VCM configuration of transmission type X
4996 – Electronic transmission offline or incorrect VCM configuration
X
of transmission type
4997 – Loss of messaging from Trax controller X
4998 – Unknown transmission error code with amber lamp X
4999 – Unknown transmission error code with red lamp X
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Powershift transmission - Exploded view
LELI12TLB1016GB 1
Table 1
1. Transmission 8. M16 X 120 hex screw
2. Anti-vibration 9. Washer
3. Left transmission support 10. M16 nut
4. Right transmission support [tightening torque 210 – 240 N·m (155 – 177 lb ft)]
6. M12 X 30 hex screw 12. M12 X 30 hex screw
[tightening torque 90 – 110 N·m (66 – 81 lb ft)] [tightening torque 90 – 110 N·m (66 – 81 lb ft)]
7. Washer 13. Bracket transmission mounting
NOTE: Ensure chassis bolt on mount is seated against locating block on chassis. Some models will have the trans-
mission mount already welded to the chassis frame.
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LELI12TLB1017GB 2
Table 2
1. Transmission 8. M10 X 30 hex screw
2. Torque converter [tightening torque 52 – 57 N·m (38 – 42 lb ft)]
3. Plate 9. O-ring
4. Plate 10. Dipstick tube
5. Snap ring 11. Dipstick
7. M10 X 20 hex screw 13. M8 X 25 hex screw
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LELI12TLB1018GB 3
Table 3
1. Washer 4. Washer
2. M10 X 30 hex screw 5. M10X35 hex screw
3. Clamp
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Transmission housing - Exploded view
LELI12TLB0785GB 1
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Powershift transmission - Drain fluid

Four-Wheel Drive (4WD) 11.4 L (12.0 US qt)

RCPH11TLB027BAD 1

transmission.
RCPH10TLB023AAF 2

RCPH09TLB004AAF 3
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RCPH09TLB004AAF 4

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Powershift transmission - Remove H-type

1. Position machine on a flat surface high enough to allow
transmission removal from underneath the machine.
3. Drain the transmission fluid.
4. Drain the hydraulic fluid.
5. Remove the hydraulic pump.
7. Remove the fuel and SCR tank.
8. If applicable, remove front drive shaft hardware.
RCPH11TLB003AAL 1
9. Remove shaft from yoke.
RCPH11TLB004AAL 2
RCPH11TLB005AAL 3
11. Identify, tag and disconnect the transmission cooler

lines.
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12. Disconnect the transmission control valve harness

connections on top of the transmission.
13. Disconnect the brake return line.
RCPH11TLB011AAL 6
14. Disconnect brake supply line.

15. Remove oil level dipstick tube.
16. Disconnect the oil temperature sensor.
RCPH11TLB014AAL 7
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17. Disconnect blue wire at switch (left-hand rear of trans-

mission).
RCPH11TLB015AAL 8
18. Disconnect black and white wire at switch (left-hand

rear top of transmission).
RCPH11TLB016AAL 9
19. Disconnect the differential lock line.
RCPH11TLB017AAL 10
20. Plug and cap all open ports.
RCPH11TLB018AAL 11
21. Disconnect starter ground and positive battery con-

nections.
22. Remove the starter.
23. Disconnect the ignition connection.
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RCPH11TLB019AAL 12
25. Rotate engine to access flywheel hardware. Use tool

380000732 to rotate the engine.
RCPH11TLB062AAM 13
26. Rotate the engine to remove the flywheel to flex plate

hardware.
RCPH11TLB055AAM 14
27. Use an appropriate lifting device to support engine.
RCPH11TLB020AAL 15
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28. Support the transmission.
RCPH11TLB021AAL 16
29. Remove the engine to transmission hardware.
RCPH11TLB058AAM 17
30. Remove the right-hand and left-hand transmission

mount hardware.
31. Disconnect hydraulic reservoir hoses.
RCPH11TLB023AAL 18
32. Carefully lower and remove the transmission.
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Powershift transmission - Disassemble H-type

1. Clean the exterior of the transmission. Place the trans-
mission on a suitable stand.
2. Remove the drain plug. Drain the oil from the transmis-
sion.
RCPH10TLB081AAL 1
3. Remove the two cap screws which fasten the cover for
the oil suction filter.
RCPH10TLB082AAL 2
4. Remove the cover, the filter, and the O-ring.
RCPH10TLB083AAL 3
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5. Remove the filter.
RCPH10TLB249AAL 4
6. If necessary remove the connector for the filter.
RCPH10TLB092AAL 5
7. Loosen the oil filter bypass valve.
RCPH10TLB084AAL 6
8. Remove the filter bypass valve.
RCPH10TLB085AAL 7
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9. Remove the breather from the transmission only if the

breather is damaged or leaking.
RCPH10TLB086AAL 8
10. Remove the forward clutch test port plug. Replace

the O-ring, if the O-ring is leaking. Torque the forward
clutch test port plug to 30.0 N·m (22.1 lb ft).
RCPH10TLB087AAL 9
11. Remove the reverse clutch test port plug. Replace

the O-ring, if the O-ring is leaking. Torque the reverse
clutch test port plug to 30.0 N·m (22.1 lb ft).
RCPH10TLB088AAL 10
12. Remove the lubrication pressure test port plug. Re-

place the O-ring, if the O-ring is leaking. Torque the
lubrication pressure test port plug to 30.0 N·m (22.1 lb
ft).
RCPH10TLB089AAL 11
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13. Remove the speed sensor.
RCPH10TLB090AAL 12
14. Remove the thermostat.
RCPH10TLB091AAL 13
15. Remove the torque converter from the transmission.
RCPH10TLB093AAL 14
16. Remove the cap screws securing the pump in the

transmission.
RCPH10TLB094AAL 15
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17. Use two pry bars to loosen the pump from the trans-
mission.
RCPH10TLB251AAL 16
18. Remove the pump from the transmission.
RCPH10TLB252AAL 17
19. Remove the O-ring from the pump.
RCPH10TLB095AAL 18
20. Remove the seal from the pump.
RCPH10TLB096AAL 19
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21. Tag and remove the lubrication tube.
RCPH10TLB100AAL 20
22. Tag and remove the 4th gear tube (1), 2nd gear tube
(2), 3rd gear tube (3), and the 1st gear tube (4).
RCPH10TLB101AAL 21
23. Tag and remove the lubrication tube.
RCPH10TLB254AAL 22
24. Loosen the front flange cap screw.
RCPH10TLB596AAL 23
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25. Remove the cap screw and the front flange.
RCPH10TLB102AAL 24
26. Remove the seal from the housing.
RCPH10TLB103AAL 25
Parking Brake
27. Loosen the flange bolt.
RCPH10TLB596AAL 26
28. Remove the flange bolt and the washer.
RCPH10TLB868AAL 27
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29. Remove the O-ring and flange.
RCPH10TLB869AAL 28
NOTE: The transmission was removed from the machine for clarity only, it is not necessary to remove the transmis-
sion.
30. Loosen the brake housing bolts.
RCPH10TLB871AAL 29
31. Remove bolts (A), and alternately loosen bolts (B) to

release the load of bellville washers.
RCPH10TLB594AAL 30
NOTICE: The housing is under spring pressure, failure to follow these instructions could damage the transmission.
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32. Remove the brake cover from the transmission.
RCPH10TLB872AAL 31
33. Remove and discard the O-ring.
RCPH10TLB873AAL 32
34. Remove the back plate.
RCPH10TLB874AAL 33
35. Remove the springs. Remove the friction disc.
RCPH10TLB875AAL 34
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36. Remove the reaction plates.
RCPH10TLB876AAL 35
37. Remove the hub.
RCPH10TLB877AAL 36
38. Remove the retaining plate.
RCPH10TLB599AAL 37
39. Remove and discard the O-rings and backup ring from
the retaining plate.
RCPH10TLB600AAL 38
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40. Use CAS2379 to compress the bellville washers. Re-

move the retaining ring.
RCPH10TLB601AAL 39
41. Remove the piston from the brake housing.
RCPH10TLB602AAL 40
42. Remove and discard the O-rings and backup rings

from the piston.
RCPH10TLB603AAL 41
43. Remove the bellville washers from the brake housing.
RCPH10TLB604AAL 42
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44. Remove the seal from the brake housing.
RCPH10TLB605AAL 43
45. Remove and discard the O-ring from the brake hous-
ing.
RCPH10TLB606AAL 44
PTO Shaft
46. Remove the mounting screws for the pump flange.
RCPH10TLB255AAL 45
47. Remove the flange from the transmission.
RCPH10TLB104AAL 46
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48. Remove the PTO shaft from the transmission.
RCPH10TLB256AAL 47
49. Remove the teflon seal ring from the PTO shaft.
RCPH10TLB105AAL 48
50. Remove the snap ring from the PTO shaft.
RCPH10TLB257AAL 49
51. Use a suitable driver to remove the bearing from the

PTO shaft.
RCPH10TLB106AAL 50
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Housing separation
52. Remove the cap screws that fasten the front to the
rear housing
RCPH10TLB258AAL 51
53. Use pry bars in the slots to loosen the front housing
from the rear housing.
RCPH10TLB259AAL 52
54. Attach suitable lifting equipment to the front housing.

Remove it from the transmission.
RCPH10TLB260AAL 53
55. Remove and discard the O-rings from the rear hous-
ing.
RCPH10TLB107AAL 54
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56. Pull the input shaft and the reverse shaft together.
RCPH10TLB109AAL 55
57. Remove the cap screws and the shield from the 4
wheel drive clutch pack.
RCPH10TLB144AAL 56
58. Attach lifting bracket 380100088 to the shafts. Re-

move them from the transmission.
RCPH10TLB145AAL 57
Input shaft
59. Remove the teflon seal ring.
RCPH10TLB110AAL 58
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RCPH10TLB111AAL 59
61. Install a bearing puller under the gear as shown. Do

not install the bearing puller between the gear and the
bearing. Insert a shaft protector between the puller
and the end of the input shaft.
RCPH10TLB112AAL 60
RCPH10TLB113AAL 61
RCPH10TLB114AAL 62
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RCPH10TLB115AAL 63
RCPH10TLB116AAL 64
RCPH10TLB262AAL 65
RCPH10TLB262AAL 66
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68. Remove the lock ring.
RCPH10TLB117AAL 67
69. Use pry bars to lift and remove the thrust plate.
RCPH10TLB118AAL 68
70. Remove the clutch plates and the clutch discs.
RCPH10TLB119AAL 69
71. Place a mark below a groove on the clutch housing.
RCPH10TLB120AAL 70
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72. Place a mark on each thrust plate and the lock ring.
RCPH10TLB263AAL 71
73. Install the top piece of the CAS2379 special tool (not
shown). Use the three threaded rods and nuts to fas-
ten the two pieces together.
RCPH10TLB121AAL 72
RCPH10TLB264AAL 73
CAS2379 special tool (not shown).
RCPH10TLB121AAL 74
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76. Remove the pressure plate and the spring.
RCPH10TLB122AAL 75
RCPH10TLB265AAL 76
78. Use compressed air in the piston pressure port to re-

move the piston.
RCPH10TLB123AAL 77
face protection.
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79. Remove the piston seal rings and backup rings.
RCPH10TLB266AAL 78
80. Turn the clutch housing over, remove the teflon seal
rings.
RCPH10TLB124AAL 79
RCPH10TLB267AAL 80
82. Insert a shaft protector between the puller and the end
of the input shaft. Remove the bearing.
RCPH10TLB125AAL 81
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83. Remove the bearing and the thrust washer.
RCPH10TLB126AAL 82
RCPH10TLB303AAL 83
RCPH10TLB127AAL 84
86. Repeat steps 68 to 78 and disassemble the clutch.
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Reverse shaft
87. Insert a shaft protector between the puller and the end
of the reverse shaft. Remove the bearing.
RCPH10TLB128AAL 85
88. Turn the shaft over and insert a shaft protector be-
tween the puller and the end of the reverse shaft. Re-
move the bearing.
RCPH10TLB268AAL 86
Primary shaft
89. Remove the teflon seal ring from the primary shaft.
RCPH10TLB272AAL 87
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90. Install a puller on the gear as shown.
RCPH10TLB273AAL 88
91. Remove the bearing and gear.
RCPH10TLB146AAL 89
RCPH10TLB274AAL 90
RCPH10TLB147AAL 91
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RCPH10TLB275AAL 92
RCPH10TLB148AAL 93
96. Remove the needle bearings and the thrust washer.
RCPH10TLB149AAL 94
97. Remove the roll pin and the spacer.
RCPH10TLB150AAL 95
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98. Drive the thrust plate down away from the lock ring.
RCPH10TLB276AAL 96
RCPH10TLB277AAL 97
100. Remove the thrust plate from the clutch pack.
RCPH10TLB151AAL 98
101. Remove the discs and the plates from the clutch
pack.
RCPH10TLB278AAL 99
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shown). Use the three threaded rods and nuts to
fasten the two pieces together.
RCPH10TLB152AAL 100
RCPH10TLB279AAL 101
RCPH10TLB152AAL 102
105. Remove the retaining ring and the spring.
RCPH10TLB153AAL 103
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RCPH10TLB154AAL 104
107. Use compressed air and remove the piston from the
clutch pack.
RCPH10TLB155AAL 105
108. Remove the piston seal rings and the backup rings.
RCPH10TLB266AAL 106
109. Remove the teflon seal ring.
RCPH10TLB156AAL 107
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110. Use a puller to remove the bearing from the shaft.
RCPH10TLB157AAL 108
1st, 3rd, and 4th gear shaft

111. Use a puller to remove the bearing.
RCPH10TLB172AAL 109
112. Remove the bushing.
RCPH10TLB173AAL 110
113. Remove the gear and the clutch from the shaft.
RCPH10TLB174AAL 111
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114. Push down on the thrust plate.
RCPH10TLB284AAL 112
RCPH10TLB285AAL 113
116. Remove the thrust plate.
RCPH10TLB175AAL 114
pack.
RCPH10TLB176AAL 115
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fasten the two pieces together, remove the snap ring.
RCPH10TLB286AAL 116
RCPH10TLB177AAL 117
120. Remove the snap ring, the retaining ring, and the
spring.
RCPH10TLB287AAL 118
121. Use compressed air to remove the piston from the

clutch pack.
RCPH10TLB304AAL 119
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122. Remove the teflon ring and the O-ring from the pis-
ton.
RCPH10TLB178AAL 120
123. Remove the teflon seal ring and the O-ring from the
clutch housing.
RCPH10TLB179AAL 121
124. Use a puller to remove the gear.
RCPH10TLB180AAL 122
125. Remove the needle bearings and the spacer.
RCPH10TLB181AAL 123
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126. Remove the O-rings from inside the spacer.
RCPH10TLB182AAL 124
127. Remove the teflon rings from the outside of the

spacer.
RCPH10TLB183AAL 125
RCPH10TLB288AAL 126
RCPH10TLB184AAL 127
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RCPH10TLB071AAL 128
RCPH10TLB310AAL 129
RCPH10TLB185AAL 130
RCPH10TLB289AAL 131
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pack.
RCPH10TLB186AAL 132
RCPH10TLB187AAL 133
RCPH10TLB121AAL 134
RCPH10TLB264AAL 135
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RCPH10TLB121AAL 136
spring.
RCPH10TLB188AAL 137
140. Used compressed air to remove the piston.
RCPH10TLB305AAL 138
141. Remove the piston and the sleeve from the clutch
housing.
RCPH10TLB189AAL 139
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RCPH10TLB266AAL 140
143. Turn the shaft over and remove the teflon seal rings.
RCPH10TLB190AAL 141
144. Use a puller to remove the bearing.
RCPH10TLB191AAL 142
RCPH10TLB192AAL 143
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RCPH10TLB193AAL 144
147. Remove the needle bearing and the thrust washer.
RCPH10TLB194AAL 145
RCPH10TLB290AAL 146
RCPH10TLB310AAL 147
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RCPH10TLB185AAL 148
RCPH10TLB289AAL 149
pack.
RCPH10TLB186AAL 150
RCPH10TLB187AAL 151
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RCPH10TLB121AAL 152
RCPH10TLB264AAL 153
RCPH10TLB121AAL 154
spring.
RCPH10TLB188AAL 155
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158. Used compressed air to remove the piston.
RCPH10TLB305AAL 156
159. Remove the piston and the sleeve from the clutch
housing.
RCPH10TLB189AAL 157
RCPH10TLB195AAL 158
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4 wheel drive shaft

161. Remove the teflon seals.
RCPH10TLB221AAL 159
162. Use a puller to remove the bearing. Remove the

spacer.
RCPH10TLB297AAL 160
RCPH10TLB222AAL 161
RCPH10TLB298AAL 162
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165. Locally fabricate a pipe with a notch to access the

snap ring as shown. Remove the snap ring.
RCPH10TLB223AAL 163
166. Remove the shims and the thrust washer.
RCPH10TLB299AAL 164
167. Remove the bellville washers and the spacer.
RCPH10TLB224AAL 165
168. Push down on the thrust plate to remove the lock

ring.
RCPH10TLB225AAL 166
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169. Remove the thrust plate, the discs, and the plates
from the clutch pack.
RCPH10TLB226AAL 167
RCPH10TLB227AAL 168
171. Use a punch to remove the pistons.
RCPH10TLB228AAL 169
172. Remove the O-rings from the piston.
RCPH10TLB603AAL 170
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173. Remove the O-rings from the pistons.
RCPH10TLB229AAL 171
Next operation:
Powershift transmission - Cleaning (21.113)
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Powershift transmission - Cleaning H-type - 4WD only

Cleaning
1. Clean all parts thoroughly using solvent type cleaning
fluid. It is recommended that parts be immersed in
cleaning fluid and moved up and down slowly until all
old lubricant and foreign material is dissolved and parts
are thoroughly cleaned.
Bearings
2. Remove bearings from cleaning fluid and strike flat
against a block of wood to dislodge solidified particles
of lubricant. Immerse again in cleaning fluid to flush
out particles. Repeat above operation until bearings
are thoroughly clean. Dry bearings using moisture-free
compressed air. Be careful to direct air stream across
bearing to avoid spinning. Do not spin bearings when
drying. Bearings may be rotated slowly by hand to fa-
cilitate drying process.
Housings
3. Thoroughly clean the interior and the exterior of the
housings, the bearing caps, etc. Cast parts may be
cleaned in hot solution tanks with mild alkali solutions
providing these parts do not have ground or polished
surfaces. Parts should remain in solution long enough
to be thoroughly cleaned and heated. This will aid
the evaporation of the cleaning solution and rinse wa-
ter. Parts cleaned in solution tanks must be thoroughly
rinsed with clean water to remove all traces of alkali.
Cast parts may also be cleaned with steam cleaner. All
parts cleaned must be thoroughly dried immediately by
using moisture-free compressed air or soft, lint free ab-
sorbent wiping rags free of abrasive materials such as
metal fillings, contaminated oil, or lapping compound.
Next operation:
Powershift transmission - Inspect (21.113)
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Powershift transmission - Inspect H-type - 4WD only

Inspection
1. The importance of careful and thorough inspection of
all parts cannot be overstressed. Replacement of all
parts showing indication of wear or stress will eliminate
costly and avoidable failures at a later date.
Bearings
2. Carefully inspect all rollers, cages and cups for wear,
chipping, or nicks to determine fitness of bearings for
further use. Do not replace a bearing cone or cup in-
dividually without replacing the mating cup or cone at
the same time. After inspection, dip bearings in clean
transmission fluid and wrap in clean lint free cloth or
paper to protect them until installed.
Oil Seals, Gaskets, etc.

3. Replacement of spring load oil seals, O-rings, metal
sealing rings, gaskets, and snap rings is more econom-
ical when uni t is disassembled than premature over-
haul to replace these parts at a future time. Further loss
of lubricant through a worn seal may result in failure
of other more expensive parts of the assembly. Seal-
ing members should be handled carefully, particularly
when being installed. Cutting, scratching, or curling un-
der of lip of seal seriously impairs its efficiency. When
assembling new metal type sealing rings, same should
be lubricated with coat of chassis grease to stabilize
rings in their grooves for ease of assembly of mating
members. Lubricate all O-rings and seals with recom-
mended type transmission fluid before assembly.
Gears and Shafts

4. Examine teeth on all gears carefully for wear, pit-
ting, chipping, nicks, cracks, or scores. If gear teeth
show spots where case hardening is worn through or
cracked, replace with new gear. Small nicks may be
removed with suitable hone. Inspect shafts and quills
to make certain they are not sprung, bent, or splines
twisted, and that shafts are true.
Housing, Covers, etc.

5. Inspect housings, covers and bearing caps to be cer-
tain they are thoroughly clean and that mating surfaces,
bearing bores, etc., are free from nicks or burrs. Check
all parts carefully for evidence of cracks or condition
which would cause subsequent oil leaks or failures.
Clutches
6. Verify the total thickness of the clutch kit is within the
wear limits, if not, replace the clutch kit. Verify that
all the clutch plates do not appear burned or that the
friction material is not damaged and the splines are
intact. If using new clutch kit, soak the clutch plates
in clean transmission fluid for at least one hour before
assembly.
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Forward and Reverse Clutch Kits

Number of clutch plates 6
Number of steel plates 6
Nominal clutch plate thickness 2.4000 mm (0.0945 in) ± 0.0500 mm (0.0020 in)
Maximum clutch plate wear 0.250 mm (0.010 in)
Nominal clutch kit thickness * 29.0000 – 29.2000 mm (1.1417 – 1.1496 in)
Maximum clutch kit wear 3.000 mm (0.118 in)
*Measured under a load of 163 kgf (359 lbf)
1st Gear Clutch Kit

2nd Gear Clutch Kit

3rd Gear Clutch Kit

4th Gear Clutch Kit

4WD Gear Clutch Kit

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Powershift transmission - Assemble H-type

1. Install new seal rings on clutch piston.
RCPH10TLB603AAL 1
2. Install new O-rings on the pins.
RCPH10TLB229AAL 2
3. Install the pins on the clutch piston.
RCPH10TLB300AAL 3
4. Lubricate the piston and pin O- rings with transmission

fluid.
RCPH10TLB301AAL 4
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5. Use a soft faced hammer and drive the clutch piston

into the clutch housing.
RCPH10TLB230AAL 5
6. Turn the clutch housing over, install the counter disk in

the clutch housing with the tapered edge facing down.
RCPH10TLB231AAL 6
7. Install the clutch kit starting with a drive plate followed

by a clutch disc, continue to install until all clutch plates
and discs are installed.
RCPH10TLB232AAL 7
8. Install the thrust plate.
RCPH10TLB233AAL 8
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9. Install the retaining ring.
RCPH10TLB234AAL 9
10. Align the clutch discs using a screwdriver then install

the gear.
RCPH10TLB235AAL 10
11. Install the needle bearing and the spacer.
RCPH10TLB236AAL 11
12. Use a suitable driver and install the bearing.
RCPH10TLB237AAL 12
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13. Turn the clutch pack over. Make sure that the disk/
counter disk pack and the piston are seated.
RCPH10TLB238AAL 13
14. Install the spacer and washer.
RCPH10TLB239AAL 14
15. Using a thickness gauge measure the gap between

the washer and lock ring (X).
RCPH10TLB240AAL 15
16. Subtract 1.8 mm from X. The result is the shim thick-

ness required.
(X - 1.8 mm) = the required shim thickness.
RCPH10TLB241AAL 16
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17. Select the shim thickness value among the range of

available shims.
RCPH10TLB242AAL 17
NOTE: Verify that there is a stroke of 1.700 mm (0.067 in) to 1.900 mm (0.075 in) after shims are installed.
18. Remove the lock ring and washer from the shaft.
RCPH10TLB243AAL 18
19. Install the bellville washers, the washer must be in-

stalled with the outer rings touching and the inner rings
have a gap.
RCPH10TLB302AAL 19
20. Install the washer and the shim(s) that was deter-
mined in step 16.
RCPH10TLB244AAL 20
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21. Locally fabricate a pipe with notch to access the snap

ring as shown. Compress the bellville washers and
install the lock ring.
RCPH10TLB245AAL 21
RCPH10TLB246AAL 22
23. Use pusher 380001928 to install the teflon seal rings.

Using spacer and protector for the inner ring and
spacer for the outer ring from kit 380040161. Size the
seal rings using sizer 380001427.
RCPH10TLB247AAL 23
24. Mount a dial indicator as shown. Apply 10 bar

(145 psi) to the piston port, the stroke should be
between 2.3000 – 2.4000 mm (0.0906 – 0.0945 in).
RCPH10TLB248AAL 24
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1st Gear Clutch Pack

25. On the 1st gear clutch, install a new teflon seal ring
using protector 380100083 and pusher 380001928.
Install a new O-ring.
RCPH10TLB196AAL 25
26. Size the teflon seal ring using sizer 380100084.
RCPH10TLB197AAL 26
27. Install a new teflon seal ring and O-ring on the clutch
piston.
RCPH10TLB198AAL 27
28. Apply clean transmission fluid to the seal rings, install

the piston.
RCPH10TLB291AAL 28
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29. Insert the spring, thrust washer, and snap ring.
RCPH10TLB199AAL 29
30. Place the clutch in CAS2379 special tool (not shown),

and compress the spring.
RCPH10TLB177AAL 30
31. Install the snap ring, make sure the snap ring is prop-
erly seated.
RCPH10TLB286AAL 31
32. Remove the top plate of the spring compressor

CAS2379.
RCPH10TLB200AAL 32
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33. Starting with a reaction plate, install the six reaction

plates and the six friction discs. Then install the thrust
plate into the clutch housing.
RCPH10TLB201AAL 33
34. Install the retaining ring, make sure the retaining ring
is properly seated.
RCPH10TLB285AAL 34
35. Apply air pressure to the clutch pack to seat the thrust
plate against the retaining ring and release the air
pressure. Use a feeler gauge and measure the dis-
tance between the thrust plat and the first clutch disc,
a measurement of 1.7250 – 2.3750 mm (0.0679 –
0.0935 in) should be obtained. If the distance is not
within specification, check the clutch assembly.
RCPH10TLB202AAL 35
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4th Gear Clutch Pack

36. Install new O-rings and backup rings on the 4th gear
piston.
RCPH10TLB266AAL 36
37. Apply a thin film of grease on the piston rings.
RCPH10TLB160AAL 37
38. Use 380001926 clutch pack piston installer to protect

the inner seal and install the clutch piston.
RCPH10TLB280AAL 38
39. Install the spring sleeve.
RCPH10TLB161AAL 39
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40. Install the spring and thrust washer.
RCPH10TLB203AAL 40

RCPH10TLB162AAL 41
erly seated.
RCPH10TLB163AAL 42

CAS2379.
RCPH10TLB162AAL 43
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44. Install a new roll pin in the shaft.
RCPH10TLB204AAL 44
45. Apply a thin coat of grease to the bottom of the thrust

washer to keep the washer in place while turning the
shaft.
RCPH10TLB292AAL 45
46. Align the slot in the thrust washer with the roll pin.
RCPH10TLB293AAL 46
47. Starting with a reaction plate, install the nine reaction

plates and the nine friction discs.
RCPH10TLB205AAL 47
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48. Install the needle bearing and the thrust plate.
RCPH10TLB206AAL 48
is properly seated.
RCPH10TLB207AAL 49
pressure. Align the clutch disc splines.
RCPH10TLB208AAL 50
51. Use a feeler gauge and measure the distance be-

tween the thrust plat and the first clutch disc, a
measurement of 1.5000 – 1.9500 mm (0.0591 –
RCPH10TLB209AAL 51
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52. Install the clutch hub into the clutch pack, make sure
the clutch hub seats completely.
RCPH10TLB210AAL 52
Assembling 1st Gear Onto The Shaft

53. Put 1st gear clutch hub onto the shaft.
RCPH10TLB294AAL 53
54. Put 1st gear clutch pack onto 1st gear clutch hub,
make sure the clutch hub seats completely.
RCPH10TLB174AAL 54
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55. Use a suitable driver and install the bushing onto the
shaft, install the needle bearing.
RCPH10TLB211AAL 55
56. Remove the old teflon seal rings from the bushing.
RCPH10TLB212AAL 56
57. Install new teflon seal rings on the bushing with protec-
tor and shim set 380100085, use pusher 380001928.
RCPH10TLB307AAL 57
58. Size the teflon seal rings using 380100086 sizer.
RCPH10TLB308AAL 58
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59. Install the bushing into the clutch pack with the refer-
ence marks up.
RCPH10TLB213AAL 59
60. Use a suitable driver and install the bushing onto the
shaft, install the needle bearing.
RCPH10TLB214AAL 60
RCPH10TLB215AAL 61
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3rd Gear Clutch Pack

62. Install new O-rings and backup rings on the piston.
RCPH10TLB266AAL 62
RCPH10TLB160AAL 63

RCPH10TLB280AAL 64
RCPH10TLB216AAL 65
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RCPH10TLB295AAL 66

RCPH10TLB162AAL 67
erly seated.
RCPH10TLB163AAL 68

CAS2379.
RCPH10TLB162AAL 69
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70. Install a new roll pin.
RCPH10TLB296AAL 70
71. Starting with a reaction plate, install the eight reaction

plates and the eight friction discs.
RCPH10TLB205AAL 71
72. Install the thrust plate.
RCPH10TLB206AAL 72
is properly seated.
RCPH10TLB207AAL 73
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RCPH10TLB281AAL 74

RCPH10TLB209AAL 75
76. Install the thrust washer and roller bearing.
RCPH10TLB217AAL 76
77. Install the clutch hub, make sure the clutch hub seats
completely.
RCPH10TLB218AAL 77
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78. Install the thrust washer.
RCPH10TLB219AAL 78
RCPH10TLB220AAL 79
80. Install the teflon seal rings starting with the inner most
ring first. Use protector and shims as required from
380040161 and pusher 380001928. Size the seal
rings using sizer 380001427.
RCPH10TLB140AAL 80
2nd Gear Clutch Pack

RCPH10TLB158AAL 81
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82. Install the teflon seal ring. Use protector and shims
as required from 380040161 and pusher 380001928.
Size the seal rings using sizer 380001427.
RCPH10TLB159AAL 82
RCPH10TLB266AAL 83
RCPH10TLB160AAL 84

RCPH10TLB280AAL 85
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RCPH10TLB216AAL 86
RCPH10TLB295AAL 87

RCPH10TLB162AAL 88
erly seated.
RCPH10TLB163AAL 89
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CAS2379.
RCPH10TLB162AAL 90
91. Starting with a reaction plate, install the eight reaction

plates and the eight friction discs.
RCPH10TLB164AAL 91
92. Install the spacer and the roll pin.
RCPH10TLB165AAL 92
93. Align the slot on the thrust washer with the roll pin,
install the thrust washer and the needle bearing.
RCPH10TLB166AAL 93
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94. Install the thrust plate and drive it down evenly to the
clutch disc.
RCPH10TLB167AAL 94
is properly seated.
RCPH10TLB168AAL 95
RCPH10TLB281AAL 96
97. Install the clutch hub, make sure the clutch hub seats
completely.
RCPH10TLB169AAL 97
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98. Install the roll pin.
RCPH10TLB170AAL 98
install the thrust washer and the snap ring.
RCPH10TLB282AAL 99

RCPH10TLB209AAL 100
101. Install the gear with the large hub down, use a suit-
able driver and install the bearing.
RCPH10TLB283AAL 101
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102. Install the teflon seal rings starting with the inner most
ring first. Use protector and shims as required from
380040161 and pusher 380001928. Size the seal
rings using sizer 380001427.
RCPH10TLB171AAL 102
Reverse Shaft
103. Use a suitable driver and install a bearing on one end
of the shaft.
RCPH10TLB141AAL 103
104. Turn the shaft over and install a bearing on the other
end of the shaft.
RCPH10TLB142AAL 104
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Forward and Reverse Clutch Packs

RCPH10TLB266AAL 105
RCPH10TLB160AAL 106

RCPH10TLB280AAL 107
RCPH10TLB216AAL 108
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RCPH10TLB295AAL 109
110. Place the clutch in CAS2379 special tool (not

shown), and compress the spring.
RCPH10TLB162AAL 110
erly seated.
RCPH10TLB163AAL 111

CAS2379.
RCPH10TLB162AAL 112
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113. Install the roll pin.
RCPH10TLB129AAL 113
install the thrust washer.
RCPH10TLB130AAL 114
115. Install the needle bearing.
RCPH10TLB131AAL 115
116. Place the clutch hub on a bench, install the thrust

plate on the hub.
RCPH10TLB132AAL 116
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117. Starting with a friction disc, install the six friction discs
and the six reaction plates.
RCPH10TLB133AAL 117
118. Install the clutch pack in the clutch housing.
RCPH10TLB134AAL 118
is properly seated.
RCPH10TLB269AAL 119
120. Install the spacer.
RCPH10TLB114AAL 120
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121. Heat the bearing to 80 – 100 °C (176 – 212 °F), use

a suitable driver and install the bearing.
RCPH10TLB135AAL 121
RCPH10TLB136AAL 122

pander/protector.
RCPH10TLB826AAL 123
124. Slide the expander/protector and spacer onto the in-

put shaft. Heat the Teflon sealing ring to 80 – 100 °C
RCPH10TLB829AAL 124
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RCPH10TLB830AAL 125
126. Install the end of the 380001427 seal compressor

with the deep chamfer onto the shaft and over the
sealing ring. Use a back and forth twisting motion to
allow the seal compressor to slip over the top of the
sealing ring and seat the sealing ring into the groove.
Be careful not to damage the sealing ring. After the
sealing ring is seated in the groove, remove the seal
compressor from the shaft.
RCPH10TLB840AAL 126
15 minutes until the sealing ring has cooled and is
from the shaft.
RCPH10TLB827AAL 127

RCPH10TLB137AAL 128
129. Turn the shaft over and repeat steps 104 to 118 and
assemble the other clutch pack.
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130. Install the roll pin, align the slot on the thrust washer
with the roll pin, install the thrust washer.
RCPH10TLB270AAL 129
RCPH10TLB138AAL 130
RCPH10TLB139AAL 131

pander/protector.
RCPH10TLB821AAL 132
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134. Slide the 380001933 expander/protector and the

spacer onto the shaft. Heat the Teflon sealing ring to
80 – 100 °C (176 – 212 °F). Install the Teflon sealing
ring onto the expander/protector.
RCPH10TLB831AAL 133

groove in the shaft. Remove the pusher, protector,
RCPH10TLB838AAL 134

RCPH10TLB839AAL 135
sealing ring. Leave the seal compressor in place
for 15 min until the sealing ring has cooled and is
from the shaft.
RCPH10TLB840AAL 136
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pander/protector.
RCPH10TLB822AAL 137

expander/protector.
RCPH10TLB832AAL 138

RCPH10TLB837AAL 139

RCPH10TLB839AAL 140
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from the shaft.
RCPH10TLB840AAL 141

pander/protector.
RCPH10TLB823AAL 142

expander/protector.
RCPH10TLB833AAL 143

RCPH10TLB836AAL 144
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RCPH10TLB839AAL 145
from the shaft.
RCPH10TLB840AAL 146

pander/protector.
RCPH10TLB824AAL 147

expander/protector.
RCPH10TLB834AAL 148
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RCPH10TLB835AAL 149

RCPH10TLB839AAL 150
from the shaft.
RCPH10TLB840AAL 151
Transmission Housings
153. Lubricate the bores of the transmission housing that
house teflon sealing rings.
RCPH10TLB143AAL 152
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154. Attach lifting bracket 380100088 to the three shafts

as shown, install the shafts into the housing.
RCPH10TLB145AAL 153
155. Install the 4WD clutch cover as shown, apply Loc-

tite 542 to the threads and torque cap screws to
50.0 N·m (36.9 lb ft).
RCPH10TLB144AAL 154
156. Install the forward and reverse clutch pack and the
reverse shaft into the housing as an assembly.
RCPH10TLB109AAL 155
157. Start the bearing of the reverse shaft into its bore in
the housing and mesh the gears at the same time.
RCPH10TLB271AAL 156
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158. Apply a thin coat of Loctite 510 to the mating surface

of the transmission housing.
RCPH10TLB261AAL 157
159. Install new O-rings in the housing.
RCPH10TLB107AAL 158
160. Lubricate the bores of the front transmission housing

that house teflon sealing rings.
161. Attach lifting equipment to the front housing, lower
the front housing onto the rear housing.
RCPH10TLB260AAL 159
NOTE: Do not bind the shafts to prevent damaging the teflon seal rings.
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162. Install and hand tighten all of the transmission hous-

ing cap screws.
RCPH10TLB108AAL 160
163. Torque the housing cap screws to 50.0 N·m (36.9 lb

ft).
RCPH10TLB258AAL 161
PTO Shaft
164. Slide the expander/protector onto the pump drive
shaft.
RCPH10TLB842AAL 162

RCPH10TLB843AAL 163
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groove in the shaft. Remove the pusher and ex-
pander/protector from the shaft.
RCPH10TLB844AAL 164

RCPH10TLB845AAL 165
from the shaft.
RCPH10TLB846AAL 166
169. Install the bearing and snap ring on the PTO shaft.
170. Put the PTO shaft into the transmission.
RCPH10TLB256AAL 167
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171. Scrape all sealing material from the sealing surface

of the pump mount and rear cover. Prepare the seal-
ing surface by rubbing with a 3M Scotch-Brite fiber
pad or equivalent. DO NOT use steel wool or any-
thing that can leave material on the sealing surface.
Wipe the sealing surface with Loctite Safety Solvent
or equivalent. Apply a layer of Loctite 518 or Super
bond 539 to the sealing surface.
172. Clean the housing, use Loctite 518 sealer on the mat-
ing surfaces.
RCPH10TLB104AAL 168
173. Install the pump mount on the rear housing, torque

bolts to 50.0 N·m (36.9 lb ft).
RCPH10TLB255AAL 169
Parking Brake
174. Install a new O-ring on the brake housing.
RCPH10TLB607AAL 170
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175. Install the bellville washers as shown.
RCPH10TLB595AAL 171
176. Install the backup ring, install the seal ring.
RCPH10TLB608AAL 172
NOTE: Make sure that the seal ring does not twist during installation.
177. Lubricate the piston seals with transmission fluid, in-
stall the piston into the brake housing.
RCPH10TLB602AAL 173
178. Use CAS2379 and compress the bellville washers,

install the retaining ring.
RCPH10TLB601AAL 174
NOTICE: Make sure the retainer is properly seated before removing spring compressor.
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179. Install new O-rings and backup ring in the retaining

plate.
RCPH10TLB600AAL 175
180. Lubricate the O-rings on the retaining plate, install

the plate into the brake housing.
RCPH10TLB599AAL 176
181. Install the hub onto the output shaft as shown.
RCPH10TLB877AAL 177
182. Install a reaction plate first.
RCPH10TLB876AAL 178
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183. Install a friction plate and a wave spring, continue to

install a reaction plate, friction plate and wave spring
until all components are installed.
RCPH10TLB875AAL 179
184. Install the back plate as shown.
RCPH10TLB874AAL 180
RCPH10TLB873AAL 181
186. Install the brake housing.
RCPH10TLB872AAL 182
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187. Install the bolts, use an alternately tightening pattern

until the brake housing is tight against the transmis-
sion. Torque the bolts to 50.0 N·m (36.9 lb ft).
RCPH10TLB871AAL 183
188. Install the flange and a new O-ring.
RCPH10TLB869AAL 184
189. Install the bolt and washer.
RCPH10TLB868AAL 185
190. Torque bolt to 139.0 N·m (102.5 lb ft).
RCPH10TLB870AAL 186
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Lubrication and Clutch Tubes

191. Install tubes and torque to 30.0 N·m (22.1 lb ft).
RCPH10TLB254AAL 187
Pump
RCPH10TLB095AAL 188
193. Install the seal.
RCPH10TLB097AAL 189
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194. When installing the pump align the pump holes.
RCPH10TLB098AAL 190
195. Lubricate the teflon seal ring with clean transmission

fluid.
RCPH10TLB253AAL 191
196. Lubricate the O-ring with clean transmission fluid.
RCPH10TLB099AAL 192
197. Push the pump into position.
RCPH10TLB252AAL 193
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198. Install and torque bolts to 23.0 N·m (17.0 lb ft).
RCPH10TLB094AAL 194
199. Install the torque converter.
RCPH10TLB093AAL 195
200. Install a new suction filter.
RCPH10TLB250AAL 196
201. Install the cover and torque the bolts to 23.0 N·m
(17.0 lb ft).
RCPH10TLB082AAL 197
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202. Install and torque drain plugs to 80.0 N·m (59.0 lb ft).
RCPH10TLB081AAL 198
203. Install and torque the filter bypass to 23.0 N·m

(17.0 lb ft).
RCPH10TLB085AAL 199
204. Install and torque the speed sensor to 50.0 N·m

(36.9 lb ft).
RCPH10TLB090AAL 200
205. Install and torque the thermostat to 30.0 N·m (22.1 lb

ft).
RCPH10TLB091AAL 201
206. Install a new oil filter.
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207. Fill transmission with approved fluid, see specifica-

tions.
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Powershift transmission - Install H-type

1. Move the transmission under the machine and raise it
into place.
2. Connect the hydraulic reservoir hoses.
RCPH11TLB023AAL 1
3. Install the right-hand and left-hand transmission mount

bracket hardware to the transmission. Torque to 90 –
110 N·m (66 – 81 lb ft).
• (1) Hex head bolt (bracket-to-frame)
• (2) Washer
• (3) Mounting bracket
• (4) Washer
• (5) Hex head bolt (bracket-to-transmission)
• (6) Washer
• (8) Frame support (welded-to-frame
• (10) Washer
• (11) Nut
4. Install the transmission mount-to-frame hardware. Do
not torque at this time.
5. Install the transmission-to-engine bolt hardware.
Torque to 52 – 57 N·m (38 – 42 lb ft)
6. Torque transmission mount-to-frame hardware to 178
– 240 N·m (131 – 177 lb ft) RAIL17TLB0032BA 2
7. Remove the transmission support.
RCPH11TLB021AAL 3
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8. Remove engine supports.
RCPH11TLB020AAL 4
RCPH11TLB019AAL 5
10. Rotate the engine to access the flywheel mounting

holes. Use the 380000732 turning tool to rotate the
engine.
RCPH11TLB062AAM 6
11. Install the flywheel flex plate hardware. Torque to 62

– 68 N·m (46 – 50 lb ft).
RCPH11TLB055AAM 7
12. Reconnect the ignition connection on the starter.

13. Reinstall starter.
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14. Connect the starter ground and positive battery con-

nections.
15. Connect the differential lock line.
RCPH11TLB017AAL 8
16. Connect the black and white wire at the switch (left
hand rear top of transmission).
RCPH11TLB016AAL 9
17. Connect the blue wire at the switch (left hand rear of
transmission).
RCPH11TLB015AAL 10
18. Connect the oil temperature sensor.
RCPH11TLB014AAL 11
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19. Apply LOCTITE® 567™ PST PIPE SEALANT to the

threads of the transmission connector and install the
oil level dipstick tube.
20. Connect brake supply line.
RCPH11TLB012AAL 12
21. Connect the brake return line.
RCPH11TLB011AAL 13
22. Reconnect the transmission control valve harness

connections.
23. Reconnect the transmission cooler lines.
24. Lubricate the splines on the axle and the inside of the
drive shaft coupling with TUTELA MULTI -PURPOSE EP
GREASE 251H, GR-9.
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25. Install front drive shaft coupling yoke.
RCPH11TLB005AAL 16
26. Install shaft to the yoke. Tighten hardware to 33 –

39 N·m (24 – 29 lb ft)
RCPH11TLB004AAL 17
27. Install front drive shaft hardware.
RCPH11TLB003AAL 18
28. Install wheels. Remove supports and lower machine.
NOTICE: Before staring the engine do the following

29. Make sure the transmission drain plug has been in-
stalled and tightened.
30. Fill the transmission, refer to Powershift transmis-
sion - Filling (21.113)
NOTE: If removed, install the rear wheels.

31. Remove the stands from under the machine and lower
the machine to the floor.
32. With the machine parked on level ground and the en-
gine running at low idle, check the transmission oil
level. The oil level must be between the ADD and the
FULL marks on the dipstick. If the oil level is at the
ADD mark, add oil as required until the oil level is at
the FULL mark.
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Powershift transmission - Filling

TION SSL
Four-Wheel Drive (4WD) 11.4 L (12.0 US qt)

RCPH11TLB027BAD 1
2. Clean the area around the transmission filter head on

the right-hand side, between the chassis and the trans-
mission.
oil.
RCPH10TLB023AAF 2

RCPH09TLB004AAF 3

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eral minutes.
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Powershift transmission - Tool connection Test port and component

locations, H-type
RCPH11TLB006GAL 1
Left Side View
(1) Valve body (5) 1st check port

(2) Oil filter bypass valve (6) 2nd check port
(3) Speed sensor (7) Lubrication check port
(4) 4th check port (8) Torque converter inlet pressure test port
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RCPH11TLB007GAL 2
Front View
(9) Spin on Filter (11) Dip stick port

(10) Oil pump (3) Speed sensor
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RCPH11TLB008GAL 3
Right Side View
(12) Thermostat (16) 3rd check port

(13) Oil return from cooler (17) Drain plug
(14) Oil port to cooler (18) ID plate
(15) Suction filter
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RCPH11TLB009GAL 4
Rear View
(19) Booster port to vehicle brakes (22) Oil return port from vehicle brakes
(20) Hydraulic pump mount (23) Park brake pressure test port
(21) SAHR parking brake housing (24) Park brake release solenoid
(3) Speed sensor
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RCPH11TLB010GAL 5
Top View
(25) Pressure sensor (29) Reverse clutch test port

(26) Breather (30) Oil check port
(27) Lube pressure test port (31) Differential lock test port
(28) Forward clutch test port
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Powershift transmission - Warm up Heating the oil

1. Check the oil level and type before proceeding.
2. Activate the parking brake.
3. Start the engine.
4. Place the gear selector into 4th gear.
5. Put the FNR selector in forward.
6. Run the engine up to 1600 RPM ± 100 RPM for a period
of 30 seconds.
NOTE: Do not exceed 30 seconds.
7. Reduce the engine speed to low idle and place the FNR
lever in neutral for 15 seconds.
8. Repeat steps 6 and 7 until the oil temperature is be-
tween 78 °C (172 °F) and 82 °C (180 °F).
9. Perform an engine stall test before proceeding. Refer
to Engine - Speeds (10.001) .
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Powershift transmission - Service instruction - Torque and

application of sealants/adhesives
Some of the following pictures could not exactly show
your transmission, but the procedure is correct.
Tightening torques and application of sealants/adhesives

A. LOCTITE® 510™
B. LOCTITE® 542™
C. LOCTITE® 518™
D. LOCTITE® 638™
LELI12TLB1019GB 1
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LELI12TLB1020HB 2
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LELI12TLB1021HB 3
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Only 4WS
LELI12TLB1022GB 4
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Transmission housing - Disassemble

1. Remove the snap ring (16).
LEPH12TLB0786AB 1
2. Drain the transmission oil.

3. Remove the bolt (1) and the washer (3) from the flange
(2).
LEPH12TLB0787AB 2
LELI12TLB0789AB 3
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NOTICE: If necessary, use a screwdriver and the bolts to

prevent the flange from rotation.
LEPH12TLB0788AA 4
4. Remove the flange (2) and the O-ring (4).
LELI12TLB0790AB 5
5. Remove the seal ring (5).

NOTICE: The seal ring might get damaged during this op-
eration. If necessary, replace with a new one.
LEPH12TLB0791AB 6
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Only on machines with 4WS:

6. Remove the bolt (A) and the washer (B).
7. If necessary, replace the O-ring (E).
8. Remove the flange (D).
9. If necessary, replace the seal ring (G).
10. Loosen and remove the bolts (C).
11. Remove the hub (F).
LELI12TLB0792AB 7
On all machines:
12. Unscrew and remove the bolts (6) from the flange (7).
LEPH12TLB0793AB 8
13. Remove the flange (7).
LEPH12TLB0794AB 9
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14. Pull out the PTO transmission shaft (8).
LEPH12TLB0795AB 10
15. If necessary, replace the seal ring (9) with a new one.
LEPH12TLB0796AB 11
LEPH12TLB0797AB 12
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17. Take out the bearing (11) with the tool 380200190.
LEPH12TLB0798AB 13
18. Remove the bolts (12) from the rear (13) and the front
half box (14).
LEPH12TLB1604AB 14
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19. Insert a crowbar (L) in the special slot and remove the
cover.
NOTICE: Additional force may be required to remove the
cover, as the mating surfaces are installed with the sealant.
If necessary, use a plastic hammer to facilitate the separa-
tion of the half box.
LEPH12TLB1605AA 15
LEPH12TLB1606AB 16
20. Lift the front half box (14).

NOTICE: Do not lift the transmission shafts; the removal of
the shafts from their housings can damage the seal rings.
LEPH12TLB1607AB 17
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21. Remove the O-rings (15).
LEPH12TLB1610AB 18
22. Seal all oil recirculation holes with the protective plugs
(T).
LEPH12TLB1611AB 19
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Transmission housing - Assemble

1. Clean the edge of the rear half box.
2. Check the transmission housing and its internal com-
ponents for the possible presence of debris (dirt, filings
or burrs). Thoroughly clean all possible dirt.
LEPH12TLB1612AA 1
NOTICE: Only after a careful inspection of the whole transmission, proceed with the re-assembly.
3. Remove the old sealant from the mating surface of the

rear half box by means of a proper scraper.
NOTICE: Cover the internal components with a cover to
avoid debris getting into the transmission housing.
LEPH12TLB1613AA 2
4. We recommend the use of a sealant remover to remove

the old sealant.
LEPH12TLB1207AA 3
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5. Clean the O-ring seats.
LEPH12TLB1208AA 4
6. De-grease and dry the mating surface of the rear half

box.
NOTE: We suggest the use of a proper solvent.
LEPH12TLB1209AA 5
7. Apply sealant on the mating surface of the rear half box.
LEPH12TLB1210AA 6
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8. Spread the sealant uniformly.
LEPH12TLB1211AA 7
9. Prevent the penetration of the sealant in the O-ring

seats.
LEPH12TLB1212AA 8
10. Clean the O-ring seats.
LEPH12TLB1213AA 9
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11. Install the O-rings (15).

12. Do not lubricate the O-rings.
LEPH12TLB1214AB 10
13. Install the O-rings (15) in their seats with a buffer.
LEPH12TLB0853AB 11
14. Install the front half box (14) on the rear half box.
NOTICE: Make sure that the bearings of the shafts go
straight into the bores in the front box.
LEPH12TLB0854AB 12
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15. Push the front half box on the rear half box. Attach the
two half boxes together with the bolts (12). Torque the
bolts (12) to 50 N·m (37 lb ft).
LEPH12TLB0856AB 13
16. Install the snap ring (16).
LEPH12TLB0855AB 14
17. Install the seal ring (5) on the output of the front shaft
with the tool 380200226.
LEPH12TLB0857AB 15
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18. Install the flange (2) and a new O-ring (4).
LELI12TLB0858AB 16
19. Install the washer (3) and the bolt (1). Torque to
139 N·m (102.5 lb ft).
NOTICE: Use a screwdriver and bolts to prevent the flange
from rotating.
LELI12TLB0859AB 17
LEPH12TLB0860AB 18
20. Install the bearing (11) on the PTO transmission shaft

(8).
LEPH12TLB0861AB 19
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LEPH12TLB0862AB 20
22. To install the seal ring (9), use the following tools in
sequence:
• 380200257
• 380200225
• 380200214
LEPH12TLB0863AB 21
23. Insert the PTO transmission shaft (8) on the stroke

end.
LEPH12TLB0864AB 22
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24. Apply a thin layer of sealant on the flange (7). Align the
oil passage holes (P) on the housing and the flange as
shown in the Figure.
LEPH12TLB0865AB 23
25. Install the flange (7) with the bolts (6). Torque the bolts
(6) to 50 N·m (37 lb ft).
LEPH12TLB0866AB 24
Only machines with 4WS:

26. Install the hub (F) with the bolts (C). Torque the bolts
(C) to 50 N·m (37 lb ft).
27. Install the seal ring (G) with the tool 380200226.
28. Install the O-ring (E).
29. Install the flange (D).
30. Install the washer (B) and the bolt (A). Torque the bolt
(A) to 139 N·m (102.5 lb ft).
LELI12TLB0867AB 25
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Powershift transmission - Testing Machine will not move, H-type

and S-type
Test N°1
Test Point Check
Verify the transmission oil level. Refer to Powershift transmission - General specification (21.113).
Refer to the Operator’s Manual for the proper transmission fluid level.
Expected Result
Result The oil level is correct. Go to the next step.
Other Action
Result The transmission oil level is not correct. Check for leaks in the system. Fill the transmission oil to the
(Possible proper level. Refer to the Operator’s Manual for the proper transmission fluid level.
Cause)
Test N°2
Test Point Check
Does the SAHR parking brake release?
Expected Result
Result Yes, the SAHR parking brake does release. Go to the next step.
Other Action
Result No, the SAHR parking brake does not release. Check the transmission oil pressure and the electrical
(Possible supply to the solenoid. Repair as required.
Cause)
Test N°3
Test Point Check
Check for a broken universal joint or a broken drive shaft.
Expected Result
Result The drive shaft and the universal joint are free from damage. Go to the next step.
Other Action
Result The drive shaft or the universal joint is damaged. Repair as required.
(Possible
Cause)
Test N°4
Raise the rear wheels off the ground.
Check
Verify that the drive shaft turns when the transmission directional control lever (FNR) is moved into for-
ward or reverse.
Expected Result
Result The drive shaft turns when the transmission directional control lever (FNR) is moved into forward or re-
verse. Go to the next step.
Other Action
Result The drive shaft does not turn. Check the electrical connections to the transmission. Verify that there is
(Possible power to the clutch solenoids. Check fuse F-024.
Cause)
Test N°5
Test Point Check
Check the transmission pressure and the pump flow.
Expected Result
Result The transmission pressures and the pump flow are within specifications.
Other Action
Result
(Possible The transmission pressures and the pump flow are not within specifications. Possible causes include:
Cause) • Cold oil by-pass valve may be stuck or damaged.
• A faulty pressure regulator. Repair or replace as required.

• A faulty transmission oil pump. Repair or replace as required.
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Test N°6
Test Point Check
Check the converter IN pressure.
Expected Result
Result The converter IN pressure is within specifications. Go to the next step.
Other Action
Result The converter IN pressure is not within specifications. Check the transmission control valve. Repair or
(Possible replace as required.
Cause)
Test N°7
Test Point Check
Check the forward and the reverse solenoid valve.
Expected Result
Result The regulated clutch pressures are within the specified range. Go to the next step.
Other Action
Result The regulated clutch pressures are not within the specified range. Refer to the forward solenoid and the
(Possible reverse solenoid troubleshooting in the service manual.
Cause)
Test N°8
Test Point Check
Check regulated clutch pressure.
Expected Result
Result The regulated clutch pressure is within specifications.
Other Action
Result
(Possible The regulated clutch pressure is not within specifications. Possible causes include:
Cause) • If the pressure remains 0 kPa (0 psi) while the transmission is in forward, neutral or reverse, check
the control valve.
• If the pressure is low, check the control valve.
• The pressure in forward and reverse are the same, check the control valve.
• The forward pressure and the reverse pressure are different, inspect the individual clutch circuits.
Powershift transmission - Testing Loss of power, H-type and S-type

Test N°1
Test Point Check
Refer to the Operator’s Manual for the proper transmission fluid level.
Expected Result
Result The oil level is correct. Go to the next step.
Other Action
(Possible Refer to the Operator’s Manual for the proper transmission fluid level.
Cause)
Test N°2
Test Point Check
Verify that there is not a buildup of mud or foreign material on the inside of the wheel wells or along the
drive train.
Expected Result
Result The wheel wells and drive train are free of mud and debris. Go to the next step.
Other Action
Result There is mud and debris in the wheel well or along the drive train. Remove all mud and debris. If the
(Possible problem still exists, go to the next step.
Cause)
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Test N°3
Test Point Check
Perform a stall test according to the instructions in Power shuttle transmission - Test Regulated clutch
pressure (21.112).
Expected Result
Result The engine performed to specifications during the stall test. Go to next step.
Other Action
Result The engine did not perform to specifications during the stall test. Repair the engine as required.
(Possible
Cause)
Test N°4
Test Point Check
Check the regulated clutch pressure. Refer to Power shuttle transmission - Test Regulated clutch
pressure (21.112)
Expected Result
Result The pressures are within specifications. Go to Power shuttle transmission - Testing Machine will not
move (21.112)
Other Action
Result The pressure is out of range. Inspect the input shaft sealing rings and clutch piston seals. Inspect the
(Possible forward and reverse clutch friction discs. Repair or replace as required.
Cause)
Powershift transmission - Testing Wheels rotate when vehicle is

raised, H-type and S-type
Test N°1
Test Point Check
Verify the proper transmission oil type. Refer to Powershift transmission - General specification
(21.113). Refer to Transmission Fluid Level in the Operator’s Manual.
Expected Result
Result The oil type is correct. Go to next step.
Other Action
Result The transmission oil type is not correct. Drain and fill the transmission with the proper oil type. Refer to
(Possible Transmission Fluid Level in the Operator’s Manual.
Cause)
Test N°2
Test Point Check
Is the oil temperature low (high oil viscosity)
Expected Result
Result The oil is at the proper operating temperature, between 78 °C (172.4 °F) and 82 °C (179.6 °F). Go to next
step.
Other Action
Result The oil temperature is low. Refer to the warm-up procedure, Powershift transmission - Warm up Heat-
(Possible ing the oil (21.113).
Cause)
Test N°3
Test Point Check
Verify that the control valve is allowing pressure to the clutches while in the neutral position.
Expected Result
Result The control valve is not allowing pressure to the clutches while in neutral. Stop.
Other Action
Result The control valve is allowing pressure to the clutches while in neutral. Replace or repair as required.
(Possible
Cause)
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Powershift transmission - Testing Transmission oil is too hot,

H-type and S-type
Test N°1
Test Point Check
Expected Result
Other Action
Cause)
Test N°2
Test Point Check
Check the transmission oil cooler for air flow restrictions. Clean the exterior of the transmission oil cooler
as required.
Expected Result
Result The transmission oil cooler is clean. Go to next step.
Other Action
Result The transmission oil cooler is dirty and there are air flow restrictions. Clean the exterior of the transmis-
(Possible sion oil cooler as required. Go to the next step if the problem still exists.
Cause)
Test N°3
Test Point Check
pressure (21.112)
Expected Result
Other Action
Result The converter pressure is not within specifications. Refer to Power shuttle transmission - Testing
Cause)
Test N°4
Test Point Check
Check the converter OUT pressure. Refer to Power shuttle transmission - Test Converter out pres-
sure (21.112).
Expected Result
Result The converter OUT pressure is within specifications. Go to next step.
Other Action
Result The converter OUT pressure is not within specifications. Refer to Powershift transmission - Testing
(Possible Machine will not move, H-type and S-type (21.113)
Cause)
Test N°5
Test Point Check
Check the lube pressure. Refer to Powershift transmission - Tool connection Test port and compo-
nent locations, H-type (21.113).
Expected Result
Result The lube pressure is within specifications. STOP.
Other Action
Result
(Possible The pressure is not within specifications. If the torque converter pressure is high and the lube pressure
Cause) is low, possible causes include:
• Restriction in the oil cooler. Replace the oil cooler. The transmission oil cooler cannot be flushed or
cleaned out. The complete oil cooler must be replaced is a restriction is found.
• The oil cooler circuit is restricted. Inspect the oil cooler circuit and repair as required.
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Powershift transmission - Testing Noisy transmission, H-type and

S-type
Test N°1
Test Point Check
Expected Result
Other Action
Cause)
Test N°2
Test Point Check
Verify that the torque converter is not damaged.
Expected Result
Result The torque converter is not damaged. Go to next step.
Other Action
Result The torque converter is damaged. Repair or replace as required.
(Possible
Cause)
Test N°3
Test Point Check
Verify that the oil pump is not damaged.
Expected Result
Result The oil pump is not damaged. Go to next step.
Other Action
Result The oil pump is damaged. Repair or replace as required.
(Possible
Cause)
Test N°4
Test Point Check
Check for seized or broken gears, shafts, bearings, etc.
Expected Result
Result The gears, shafts, bearings, etc. are not seized or broken.
Other Action
Result A gear, shaft, bearing, etc. is seized or broken. Repair or replace as required.
(Possible
Cause)
Powershift transmission - Testing Irregular clutch activation, H-type

and S-type
Test N°1
Test Point Check
Expected Result
Other Action
Cause)
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Test N°2
Test Point Check
Check clutch pressure. Is the pressure in the specified range? Refer to Powershift transmission -
General specification H-type (21.113)
Expected Result
Result The clutch pressure is in the specified range. Go to next step.
Other Action
Result The clutch pressure is not in the specified range. Inspect the modulation spool and piston for sticking
(Possible and damage. Repair or replace as required.
Cause)
Test N°3
Test Point Check
Check for fault codes on the Trax Controller.
Expected Result
Result There are no fault codes associated with the Trax Controller. Check the electrical connections to the
clutch solenoids.
Other Action
Result The Trax Controller does have active fault codes. Troubleshoot and repair as required.
(Possible
Cause)
Powershift transmission - Testing Gear remains engaged, H-type

and S-type
Test N°1
Test Point Check
Expected Result
Other Action
Cause)
Test N°2
Test Point Check
Check clutch pressure. Is the pressure in the specified range? Refer to Powershift transmission -
General specification H-type (21.113)
Expected Result
Result The clutch pressure is in the specified range. Go to next step.
Other Action
Result The clutch pressure is not in the specified range. Inspect the modulation spool and piston for sticking
(Possible and damage. Repair or replace as required.
Cause)
Test N°3
Test Point Check
Expected Result
clutch solenoids.
Other Action
(Possible
Cause)
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Powershift transmission - Testing Will not go into 4WD, H-type and

S-type
Test N°1
Test Point Check
Check for broken universal joint or front drive shaft.
Expected Result
Result The universal joint and front drive shaft are functioning properly. Go to next step.
Other Action
Result The universal joint or front drive shaft is in need of repair. Repair or replace as required.
(Possible
Cause)
Test N°2
Raise the machine off of the ground. All four wheels should be able to rotate freely.
Check
Verify that the front and rear drive shafts turn when the transmission directional control lever (FNR) is
moved into Forward or Reverse.
Expected Result
Result The front drive shaft turns freely when the transmission control is in gear but the axle does not. There is
a problem in the front axle. Repair as required.
Other Action
Result The front drive shaft does not turn when the transmission control is in gear. Go to next step.
(Possible
Cause)
Test N°3
Test Point Check
Expected Result
clutch solenoids.
Other Action
(Possible
Cause)
Powershift transmission - Testing Problem in the parking brake

system, H-type and S-type
Test N°1
Test Point Check
Does the parking brake release?
Expected Result
Result The parking brake will release. Refer to Parking brake discs - Inspect (33.110) and Parking brake
discs - Test (33.110). If the parking brake will not hold the machine, repair or replace the disc brakes.
Other Action
Result
(Possible Check the electrical and hydraulic circuits.
Cause) • Check the differential lock pressure. The differential lock and the parking brake are on the
same pressure circuit. If the differential lock pressure is within specifications, refer to Powershift
transmission - General specification H-type (21.113).
• Check fuses, replace fuses as required.
• Check switch operation, repair or replace as required.
• Measure the solenoid resistance. The resistance should be approximately 9.8 Ω at 20 °C (68 °F).
Replace the solenoid as required.
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Powershift transmission - Troubleshooting

Problem Possible Cause Correction
The vehicle does not Control valve supply problem Check and, if necessary, replace the con-
move trol valves
Damaged connections of transmission and Repair and, if necessary, replace the wiring
vehicle wiring harness harness
Oxidation in the contacts of the electric ca- Clean the contacts
bles of the wiring harness
Interruption of the electric cable Replace the electric cable
Damage to the solenoids/solenoid valves Replace the solenoids
Damage to sensors Replace sensors
Short circuits or bad contact Check and, if necessary, replace the fuses
EGM/ECU gearshift electronic control op- Replace the electronic control of the EGM/
eration fault ECU gearshift
Incorrect oil level Restore the oil level
Check for possible oil leaks Eliminate the leaks and restore the oil level
Suction strainer restriction Clean the suction strainer
Damaged oil pump Replace the oil pump
Damaged oil pump pressure relief valve Replace the oil pump
Damaged/restricted filter Replace the filter
Damaged / stuck control valve Replace the control valve
Damaged converter Replace the converter
Oil temperature below 0 °C (32 °F) Wait for the operating temperature to be
reached (stall test)
Damaged rotary seal rings Replace the rotary seal rings
Stuck shuttle lever Repair the shuttle lever
Excessively worn-out clutch assembly Repair and, if necessary, replace the clutch
discs
Lack of motion transmission (broken gears, Check, repair and, if necessary, replace
shafts, bearings, etc.)
The brake does not release Check the general pressure of transmis-
sion
Check voltage
Check the operation of the solenoid valve
Check the mounting of the brake solenoid
valve block after operating on the brake
After the above-described verifications,
disassemble the brake cover and check the
condition of the parts for unlocking/locking
the brake (seal rings, belleville washers,
brake disc deformation, etc.)
The vehicle has a reduced Incorrect oil temperature Wait for the operating temperature to be
power transmission reached (stall test)
Transmission oil overheating Restore acceptable temperature values
Incorrect operating pressures Check the hydraulic circuit and replace (oil
pump, filters, control valve)
Worn-out clutch assembly Replace/repair
4WD Fails to engage Repair/replace the 4WD shaft assy
Overheated solenoids/solenoid valves Replace
Damaged connections of transmission and Repair and, if necessary, replace the wiring
vehicle wiring harness harness
Software of EGM/ECU gearshift electronic Replace EGM/ECU
control faulty
Damage to sensors Replace sensors
Overheating Damaged cooling system Repair the cooling system
Dirty heat exchanger Clean the heat exchanger
Unintentionally activated parking brake Deactivate the parking brake
Excessive soil deposit on axle wheel hubs Clean the axle wheel hubs
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Seizure (broken gears, shafts, bearings, Check, repair and, if necessary, replace
etc.)
Braking force external to transmission: axle Check and repair the axle
operating problem
Dragging of clutch discs Repair and, if necessary, replace the clutch
discs
Damaged oil thermostat Replace the oil thermostat
Worn-out oil pump Replace the oil pump
Wheel rotation with lifted Dragging of clutch discs Repair and, if necessary, replace the clutch
vehicle discs
Low oil temperature (high oil viscosity) Wait for the operating temperature to be
Incorrect oil gradient Change oil and filters
Damaged control valve Replace the control valve
Stuck shuttle lever. Repair and, if necessary, replace the shut-
tle lever
Noise Damaged converter Replace the converter
Damaged oil pump Replace the oil pump
Ventilation/Cavitation Check the oil level
Check the oil gradient
Seizure (broken gears, shafts, bearings, Check, repair and, if necessary, replace
etc.)
Worn-out clutch discs Replace the clutch discs
Irregular coupling Damaged hydraulic control valve Replace the control valves
Electric system fault Repair the electric system
Worn-out clutch discs Replace the clutch discs
Low oil temperature (high oil viscosity) Wait for the operating temperature to be
Overheating See “overheating”
EGM/ECU gearshift electronic control op- Replace EGM/ECU
eration fault
Damaged hydraulic system Repair the hydraulic system
Gear fails to engage Damaged clutch engagement assy Replace the clutch engagement assy
Damaged pressure sensors Check and, if necessary, replace the sen-
sors
eration fault
The gear remains engaged Damaged/stuck shuttle lever Repair and, if necessary, replace the shut-
tle lever
Damaged clutch assembly Repair and, if necessary, replace the clutch
assembly
eration fault
Lack of 4WD power Damaged 4WD connection assy Replace the 4WD coupling assy
transmission
Hydraulic system fault Repair the hydraulic system
Braking sensor fault Check and, if necessary, replace the brak-
ing sensors
eration fault
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Index
Transmission - 21

Powershift transmission - Assemble H-type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Powershift transmission - Cleaning H-type - 4WD only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Powershift transmission - Disassemble H-type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Powershift transmission - Drain fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Powershift transmission - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Powershift transmission - Fault code index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Powershift transmission - Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
Powershift transmission - General specification - control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Powershift transmission - General specification - dimensions and schematics . . . . . . . . . . . . . . . . . . 10
Powershift transmission - General specification - gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Powershift transmission - General specification - port locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Powershift transmission - General specification H-type 4WD only . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Powershift transmission - Inspect H-type - 4WD only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Powershift transmission - Install H-type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
Powershift transmission - Remove H-type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Powershift transmission - Service instruction - Torque and application of sealants/adhesives . . . . . 153
Powershift transmission - Special tools H-type 4WD only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Powershift transmission - Testing Gear remains engaged, H-type and S-type . . . . . . . . . . . . . . . . . . 177
Powershift transmission - Testing Irregular clutch activation, H-type and S-type . . . . . . . . . . . . . . . . 176
Powershift transmission - Testing Loss of power, H-type and S-type . . . . . . . . . . . . . . . . . . . . . . . . . . 173
Powershift transmission - Testing Machine will not move, H-type and S-type . . . . . . . . . . . . . . . . . . . 172
Powershift transmission - Testing Noisy transmission, H-type and S-type . . . . . . . . . . . . . . . . . . . . . . 176
Powershift transmission - Testing Problem in the parking brake system, H-type and S-type . . . . . . 178
Powershift transmission - Testing Transmission oil is too hot, H-type and S-type . . . . . . . . . . . . . . . . 175
Powershift transmission - Testing Wheels rotate when vehicle is raised, H-type and S-type . . . . . . 174
Powershift transmission - Testing Will not go into 4WD, H-type and S-type . . . . . . . . . . . . . . . . . . . . . 178
Powershift transmission - Tool connection Test port and component locations, H-type . . . . . . . . . . . 147
Powershift transmission - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
Powershift transmission - Warm up Heating the oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
Transmission housing - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
Transmission housing - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
Transmission housing - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
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Transmission - 21
Powershift transmission external controls - 135

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Contents
Transmission - 21
FUNCTIONAL DATA
Transmission hand lever

Dynamic description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Drawing H-type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Exploded view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
SERVICE

Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
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Transmission - Powershift transmission external controls
Transmission hand lever - Component identification

Controls
LELI12TLB0763GB 1
1. Powershift transmission gearshift and direction lever: It is possible to select four forward and four rearward travel
gears.
The lever has 3 positions, according to which the travel direction is defined:
F = Forward travel
N = Idle/neutral
R = Reverse
By turning the knob, instead, the following gears are selected:
1 = 1st gear
2 = 2nd gear
3 = 3rd gear
4 = 4th gear
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2. Kickdown switch: If the machine is in second gear and it is necessary to shift to the first gear to work with the loader
attachment, activating the kickdown switch to a lower ration allows the machine to instantly shift from second to
first gear.
When the reverse travel is activated, transmission reverts to second gear.
3. Horn button
4. Transmission disconnect button (on loader attachment control lever).
Kickdown (quick shifting to lower gear ratio)

The kickdown function (2nd to 1st gear only) instantly in-
creases the torque on the driving wheels and, hence, the
digging power. For example when the loader is pushing
into a pile and more torque is required at the wheels.
This is achieved by an instant gearshift from 2nd to 1st by

means of button (2) without activating the gearshift lever.
LELI12TLB0765AB 2
Transmission disconnection
The disconnect feature is useful when loading, for exam-
ple when pushing the loader attachment onto a pile of ma-
terial, with the bucket sufficiently filled.
For this purpose, press the disconnect switch (4) which

disengages the transmission, thus allowing the full power
of the engine to be directed to the hydraulic oil pump.
Disconnection is available in 1st and 2nd gear.

NOTE: Transmission disconnection is selectable when
the machine speed is lower than 5 km/h (3 mph), by
depressing the button on the loader lever, and remains
active until the switch is released.
LELI12TLB0766AB 3
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Transmission hand lever - Dynamic description

580ST
590ST
695ST
LELI12TLB0764GB 1
1. Gearshift and direction control lever: It is possible to select four forward and four rearward travel gears.
The lever has 3 positions, according to which the travel direction is defined:
F = Forward travel
N = Idle/neutral
R = Reverse
By turning the knob, instead, the following gears are selected:
1 = 1st gear
2 = 2nd gear
3 = 3rd gear
4 = 4th gear
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2. Kickdown switch: If the machine is in second gear and it is necessary to shift to the first gear to work with the loader
attachment, activating the kickdown switch to a lower ration allows the machine to instantly shift from second to
first gear.
When the reverse travel is activated, transmission reverts to second gear.
3. Transmission disconnect button (on loader attachment control lever).
Kickdown (quick shifting to lower gear ratio)

The kickdown function (2nd to 1st gear only) instantly in-
creases the torque on the driving wheels and, hence, the
digging power. For example when the loader is pushing
into a pile and more torque is required at the wheels.
This is achieved by an instant gearshift from 2nd to 1st by

means of button (2).
LELI12TLB0767AB 2
Transmission disconnection
The disconnect feature is useful when loading, for exam-
ple; when pushing the loader into a pile and you have
sufficient dirt in the bucket press the disconnect switch
(3) which disengages the transmission and allows the full
power of the engine to be directed to the hydraulic oil
pump.
Disconnection is available in 1st and 2nd gear.

NOTE: Transmission disconnection is selectable when
the machine speed is lower than 5 km/h, by depressing
the button on the loader lever, and remains active until
the switch is released.
LELI12TLB0768AB 3
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Transmission control valve - Drawing H-type
RCPH11TLB012FAL 1
Control Valve
1 Pulse Width Modulation 2/4 solenoid, port A 5 4WD solenoid, port E

2 Reverse solenoid, port B 6 2nd/4th solenoid, port F
3 Forward solenoid, port C 7 Differential lock solenoid, port G
4 Pulse Width Modulation 1/3 solenoid, port D 8 1st/3rd solenoid, port H
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Transmission control valve - Exploded view

580ST
590ST
695ST
Hydraulic control valve - Powershift transmission
LELI12TLB1127GB 1
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Transmission control valve - Disassemble

580ST
590ST
695ST
1. Disconnect cable (12).
LELI12TLB1128AB 1

3. Disconnect the electric connections.
4. Loosen all the fittings of the delivery pipes connected
with the control valve (2).
5. Remove the bolts (1).
LEPH12TLB1129AB 2
6. Remove the control valve (2).
LELI12TLB1130AB 3
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7. Remove the gasket (3).
LELI12TLB1131AB 4
8. Remove the pressure switch (4).
LEPH12TLB1132AB 5
9. Place the control valve on a workbench.

10. Remove the bolts (5) of the valves.
LEPH12TLB1133AB 6
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11. Remove the valves (6), (7) and (8).

NOTE: Use a screwdriver to remove the valves.
LEPH12TLB1134AB 7
12. Check the valves (6), (7) and (8) for damage and con-
dition.
LEPH12TLB1135AB 8
13. Remove the valve (9).
LEPH12TLB1136AB 9
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14. Check the valve (9) for damage and condition.

15. Clean the valve and, if necessary, replace the O-rings
(10) and (11).
LEPH12TLB1137AB 10
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Transmission control valve - Assemble

580ST
590ST
695ST
1. Clean the valve (9).

2. Install the O-rings (10) and (11).
LEPH12TLB1137AB 1
3. Install valve (9). Torque to 25 – 30 N·m (18 – 22 lb ft).
LEPH12TLB1136AB 2
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4. Install the “ON”/“OFF” valves (6) and (7) and the pro-
portional valves (8) in their correct position as shown in
the figures.
LELI12TLB1138BB 3
5. Install the pressure switch (4).
LEPH12TLB1132AB 4
6. Install the screws (5). Torque to 3 – 4 N·m (2 – 3 lb ft).
LEPH12TLB1133AB 5
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7. Install the gasket (3).
LELI12TLB1131AB 6
8. Install the control valve (2) with the bolts (1).
LELI12TLB1130AB 7
9. Torque the bolts (1) to 20 N·m (15 lb ft).
LEPH12TLB1139AB 8
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Index
Transmission - 21

Transmission control valve - Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Transmission control valve - Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Transmission control valve - Drawing H-type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Transmission control valve - Exploded view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Transmission hand lever - Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Transmission hand lever - Dynamic description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
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Transmission - 21
Powershift transmission hydraulic components - 105

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Contents
Transmission - 21
FUNCTIONAL DATA
Powershift transmission hydraulic components

Exploded view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Component identification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Identification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Powershift transmission - Exploded view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
SERVICE
Powershift transmission hydraulic components

Disassemble the filter, plugs and breather (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Assemble the filter, plugs and breather (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Powershift transmission - Disassemble the hydraulic system lines (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Powershift transmission - Assemble the hydraulic system lines (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Check (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Grease (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Transmission lubrication pump
Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
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Transmission - Powershift transmission hydraulic components
Powershift transmission hydraulic components - Exploded view

580ST
590ST
695ST
Plugs and filters
LELI12TLB1023GB 1
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Powershift transmission hydraulic components - Component

identification
580ST
590ST
695ST
LELI12TLB0769EB 1
1. Hole for filling and fastening of oil dipstick 3. Oil drain plug
2. Oil level plug 4. Breather
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Powershift transmission hydraulic components - Identification

580ST
590ST
695ST
Tecnolube POLYMER 400 grease
Transmission oil
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LELI12TLB1011HA 1
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Powershift transmission - Exploded view

580ST
590ST
695ST
Hydraulic system lines
LELI12TLB1140GB 1
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Powershift transmission hydraulic components - Disassemble the

filter, plugs and breather
580ST
590ST
695ST
1. Remove the oil drain plug (1) and drain the oil from the
transmission.
LEPH12TLB1024AB 1
LEPH12TLB1025AB 2
3. Remove the cover (3).

4. Remove the oil filter (4) and the O-ring (5).
LEPH12TLB1026AB 3
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5. Remove the oil filter (6).

6. If necessary, remove the fitting (7).
LEPH12TLB1027AB 4
LEPH12TLB1028AB 5
8. Check the valve (8).

9. Clean the valve.
10. If necessary, replace the O-rings (9) and (10).
LEPH12TLB1102AB 6
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11. If necessary, remove the breather (11).
LEPH12TLB1103AB 7
12. Remove the plug (12).

NOTE: This port enables you to check the supply pressure
for forward gear engagement.
LEPH12TLB1104AB 8

NOTE: This port enables you to check the supply pressure
for reverse gear engagement.
LEPH12TLB1105AB 9
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NOTE: This port enables you to check the lubrication pres-
sure.
LEPH12TLB1106AB 10
15. Remove the revolution sensor (15).
LEPH12TLB1107AB 11
16. Remove the oil temperature sensor (16).
LEPH12TLB1108AB 12
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Powershift transmission hydraulic components - Assemble the

filter, plugs and breather
580ST
590ST
695ST
1. Install the revolution sensor (15). Torque to 50 N·m

(37 lb ft).
LEPH12TLB1107AB 1
2. Install the oil temperature sensor (16). Torque to

30 N·m (22 lb ft).
LEPH12TLB1108AB 2
3. Install the plugs (12) and (13). Torque to 30 N·m (22 lb

ft).
LEPH12TLB1109AB 3
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4. Install the breather (11). To avoid damage to the

breather, do not torque the breather, tighten by hand.
LEPH12TLB1103AB 4
5. Clean the valve (8).

6. Install the O-rings (9) and (10) on the valve (8).
LEPH12TLB1102AB 5
7. Install the valve (8). torque to 28 N·m (21 lb ft).
LEPH12TLB1112AB 6
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8. If removed, reinstall the fitting (7). Torque to 50 N·m

(37 lb ft).
LEPH12TLB1110AB 7
9. Lubricate the gasket.

10. To instal the filter (6), tighten clockwise until the gasket
makes contact with its seat, then tighten further 2/3 of
a turn.
LEPH12TLB1111AB 8
11. Install the O-ring (5) on the filter (4).

12. Insert the filter (4).
LEPH12TLB1113AB 9
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13. Install the cover (3) with the bolts (2). Torque the bolts
to 23 N·m (17 lb ft).
LEPH12TLB1114AB 10
14. Install the oil drain plug (1). Torque to 30 N·m (22 lb
ft).
LEPH12TLB1115AB 11
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Powershift transmission - Disassemble the hydraulic system lines

580ST
590ST
695ST

2. Remove the 2nd gear tube (1).
LEPH12TLB1141AB 1
3. Remove the 4th gear tube (2).
LEPH12TLB1142AB 2
4. Remove the 3rd gear tube (3).
LEPH12TLB1143AB 3
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5. Remove the 1st gear tube (4).
LEPH12TLB1144AB 4
6. Remove the 4WD tube (5).
LEPH12TLB1145AB 5
7. Remove the lubrication tube (6).
LEPH12TLB1146AB 6
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8. Remove the lubrication tube (7).
LEPH12TLB1147AB 7
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Powershift transmission - Assemble the hydraulic system lines

580ST
590ST
695ST
1. Install the lubrication tube (7). Torque the fittings to

30 N·m (22 lb ft).
LEPH12TLB1147AB 1
2. Install the lubrication tube (6). Torque the fittings to

30 N·m (22 lb ft).
LEPH12TLB1146AB 2
3. Install the 4WD tube (5). Torque the fittings to 30 N·m

(22 lb ft).
LEPH12TLB1145AB 3
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4. Install the 1st gear tube (4). Torque the fittings to

30 N·m (22 lb ft).
LEPH12TLB1144AB 4
5. Install the 3rd gear tube (3). Torque the fittings to

30 N·m (22 lb ft).
LEPH12TLB1143AB 5
6. Torque the 4th gear tube (2). Torque the fittings to

30 N·m (22 lb ft).
LEPH12TLB1142AB 6
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7. Install the 2nd gear tube (1). Torque the fittings to

30 N·m (22 lb ft).
LEPH12TLB1141AB 7
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Powershift transmission hydraulic components - Check

580ST
590ST
695ST
1. The oil level check should be carried out with the engine
running at low speed and at normal operating temper-
ature.
3. Raise the loader attachment and assemble the safety
support strut.
tion.
neutral position.
6. Immobilize the machine with the parking brake. LELI12TLB0338AA 1
7. Open and raise the engine guard and lock it in opened

position by means of the safety lock on the left-hand
gas spring.
8. Extract the dipstick (1), clean it with a clean cloth and
completely insert it into the hose, then take it out again.
9. If the oil level is below the mini mark, top up.
10. Stop the engine.
11. Unlock the safety lock and close the engine guard.
LELI12TLB0771AB 2
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Powershift transmission hydraulic components - Grease

580ST
590ST
695ST
Transmission oil
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LELI12TLB1011HA 1
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Transmission lubrication pump - Remove

580ST
590ST
695ST

NOTICE: Mark the oil pump position with respect to the bell
housing before removing the bolts.
LEPH12TLB1117AB 1
2. Pull out the oil pump (2) with the crowbars (A).
LEPH12TLB1118AB 2
3. Remove the oil pump (2).

NOTICE: The O-ring may get damaged during this opera-
tion. Replace with a new one if necessary.
LEPH12TLB1119AB 3
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4. Remove the O-ring (3).

NOTICE: Do not disassemble the pump. Replace with a
new one if necessary.
LEPH12TLB1120AB 4
5. If necessary, remove the seal ring (4).

NOTICE: The seal ring may get damaged during this oper-
ation. Replace with a new one if necessary.
LEPH12TLB1121AB 5
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Transmission lubrication pump - Install

580ST
590ST
695ST
1. Install the seal ring (4) in the oil pump (2) with the tool
380200218 (T).
2. Lubricate the seal ring (4).
LELI12TLB1122AB 1
3. Install the O-ring (3).
LEPH12TLB1120AB 2
4. In case of a new pump, check that the oil passage

holes between pump and half box match. In case of
reinstallation of the existing pump, make sure that the
identification marks made during the removal coincide.
LEPH12TLB1123AA 3
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5. Lubricate the seal ring (4) to keep it centred, in order to

facilitate its introduction onto the oil pump.
LEPH12TLB1124AB 4
6. Lubricate the matching seat with the front half box.

7. Install the oil pump (2) with the bolts (1).
LEPH12TLB1125AB 5
LEPH12TLB1126AB 6
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Index
Transmission - 21

Powershift transmission - Assemble the hydraulic system lines (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Powershift transmission - Disassemble the hydraulic system lines (*) . . . . . . . . . . . . . . . . . . . . . . . . . 16
Powershift transmission - Exploded view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Powershift transmission hydraulic components - Assemble the filter, plugs and breather (*) . . . . . . 12
Powershift transmission hydraulic components - Check (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Powershift transmission hydraulic components - Component identification (*) . . . . . . . . . . . . . . . . . . 4
Powershift transmission hydraulic components - Disassemble the filter, plugs and breather (*) . . . 8
Powershift transmission hydraulic components - Exploded view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Powershift transmission hydraulic components - Grease (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Powershift transmission hydraulic components - Identification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Transmission lubrication pump - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Transmission lubrication pump - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
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Transmission - 21
Powershift transmission internal components - 155

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Contents
Transmission - 21
FUNCTIONAL DATA
Shaft assemblies
Exploded view H-type - reverse shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Exploded view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Clutch
Exploded view H-type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
SERVICE
Shaft assemblies
Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
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Transmission - Powershift transmission internal components
Shaft assemblies - Exploded view H-type - reverse shaft
RCPH10TLB019GAL 1
1 Bearing 21 Split pin

2 Bearing 22 Split pin
3 Teflon seal 23 Teflon seal ring
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4 Snap ring 24 O-ring

5 Bearing 25 Clutch piston
6 Spacer 26 Sleeve
7 Needle cage 27 Spring
8 Gear 28 Lock washer
9 Retaining plate 29 Snap ring
10 Lock ring 30 Clutch plates
11 Thrust plate 31 Clutch drive plates
12 Clutch drive plates 32 Thrust plate
13 Clutch plates 33 Lock ring
14 Snap ring 34 Retaining plate
15 Lock washer 35 Gear
16 Spring 36 Needle cage
17 Sleeve 37 Retaining plate
18 Clutch piston 38 Bearing
19 Teflon seal ring 39 Snap ring
20 O-ring 40 Teflon seal ring
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Shaft assemblies - Exploded view

580ST
590ST
695ST
(A) and (D) shafts
LELI12TLB1635GC 1
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B shaft
LELI12TLB0874GB 2
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C shaft
LELI12TLB1319GB 3
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E shaft
(Only for 2WS)
LELI12TLB0964FB 4
* = 4WD shaft set
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E shaft
(Only for 2WS)
LELI12TLB1059HB 5
* = 4WD shaft set
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E shaft
(Only 4WS)
LELI12TLB1160GB 6
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Clutch - Exploded view H-type
RCPH10TLB018GAL 1
1 Seal 14 Spacer
2 Seal 15 Snap ring
3 Bearing 16 Retaining washer
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4 Gear 17 Spring
5 Lock ring 18 Sleeve
6 Washer 19 Clutch piston
7 Roller retainer 20 Teflon seal ring
8 Gear 21 Teflon seal ring
9 Lock ring 22 Shaft
10 Thrust plate 23 Spring pin
11 Clutch discs 24 Bearing
12 Reaction plates 25 Teflon seal ring
13 Washer
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Shaft assemblies - Disassemble

580ST
590ST
695ST
Remove shafts (A) and (D)

1. Hold the shaft assembly (A) in place with the pliers.
Remove the shaft assembly (D).
LEPH12TLB1636AB 1
Disassembly of the shaft (A)

1. If necessary, remove the seal ring (1).
LEPH12TLB0576AB 2
LEPH12TLB0577AB 3
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3. Remove the bearing (3) as explained below:

A. Place a bearing separator under the gear as
shown. (do not assemble the bearing separator
between the gear and the bearing).
NOTICE: Do not place the bearing separator be-
tween the gear and bearing to avoid any damage
to the components.
B. Use the puller to lift the gear and bearing from the
shaft, till only the bearing (3) is out of the shaft.
C. Remove the bearing (3).
LEPH12TLB0578AA 4
LEPH12TLB0579AB 5
4. Remove the spacer (4).
LEPH12TLB0580AB 6
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5. Remove the gear (6).
LEPH12TLB0581AB 7
6. Remove the roller retainer (7).
LEPH12TLB0582AB 8
7. Remove the thrust washer (8).
LEPH12TLB0583AB 9
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8. Remove the pin (9).
LEPH12TLB0584AB 10
LEPH12TLB0585AB 11
10. Remove the retainer (11).
LEPH12TLB0586AB 12
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11. Remove the discs (18) and the counter discs (17).
LEPH12TLB0587AB 13
12. Place a mark below the groove on the clutch bell.
LEPH12TLB0578AA 14
13. Add identification mark on the snap ring (11), the discs
(18) and the counter discs (17) for reference during
assembly.
LEPH12TLB0588AB 15
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14. Lower the cover (13) by means of tool 380200215.
LEPH12TLB0589AB 16
LEPH12TLB0590AB 17
16. Loosen the knobs of the threaded bars to clear the

spring tension.
17. Remove the upper part of tool 380200215.
LEPH12TLB0591AA 18
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18. Remove the cover (13) and the spring (15).
LEPH12TLB0592AB 19
19. Remove the sleeve (5).
LEPH12TLB0593AB 20
CAUTION
Pinch point!
When using compressed air to remove pistons
from the caliper bore DO NOT place your hands
or fingers near the bore to catch or protect the
pistons.
erate injury.
C0021A
WARNING
Flying debris!
Compressed air can propel dirt, rust, etc. into
the air. Wear eye and face protection when us-
ing compressed air.
ous injury.
W0307A
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20. Remove the clutch piston (19) by blowing in com-

pressed air through the delivery hole.
LEPH12TLB0594AB 21
21. If necessary, remove the seal ring (20) with the inner
O-ring from the outside seat of the piston and the seal
ring (21) with the relevant O-ring from the inner seat
of the piston.
NOTICE: The seal rings and O-rings can be removed by
cutting them only. Replace with new once if removed.
LEPH12TLB0595AB 22
22. Turn the shaft.

23. If necessary, remove the seal rings (22).
LEPH12TLB0596AB 23
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LEPH12TLB0597AB 24
25. Use a puller to remove the bearing (24).
LEPH12TLB0598AB 25
26. Remove the bearing (24) and thrust washer (25).
LEPH12TLB0599AB 26
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27. Remove the gear (26) and roller retainer (12).
LEPH12TLB0600AB 27
28. For the disassembly of other parts, repeat the Steps

6 to 13.
LEPH12TLB0801AA 28
29. Check the seal ring grooves (large and small) for wear
or damage.
30. Check if the output shaft is worn or damaged.
31. Check oil passages in the output shaft to be sure that
they are open and free of foreign material.
flat areas, pitting or other damage.
33. If you are to re-use the clutch discs, observe the as-
sembly order.
LEPH12TLB0802AA 29
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34. Use a gauge to check that each counter disc (17) and
make sure that each clutch disc (18) is flat.
35. If they are not flat, replace them with new ones.
36. If the clutch discs (18) are nearly smooth, or if their
friction faces are damaged or burnt, they must be re-
placed.
37. Check the grooves for wear.
38. Check counter discs (17) for pitting, scoring or other
damage.
39. If you will be using new clutch discs, soak them in oil
for at least an hour before assembly.
40. If you are using the old clutch discs, make sure that the LEPH12TLB0803AB 30
contact surfaces are coated with transmission oil be-
fore assembly, check their wear condition (see chart
below).
41. If the wear exceeds the 50% of the rated value, re-
place them.
42. Verify the bore and the housing of the input shaft for
damage that will cause leakage during the assembly
of the clutch.
43. Check if the slots in the housing of the input shaft are
damaged by the tangs of the counter discs.
2WS forward - reverse gear clutch

29.00 – 29.20 mm (1.14 – 1.15 in)
load]
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LELI12TLB0870FB 31
A. Reverse
B. Forward
1. Clutch disc (No. 6)
2. Clutch counter disc (No. 3)
4WS forward gear clutch

33.90 – 34.10 mm (1.33 – 1.34 in)
load]
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LELI12TLB0871FB 32
A. Reverse
B. Forward
1. Clutch disc (No. 6)
4. Forward clutch disc (No. 7)
5. Forward clutch counter disc (No. 3)
6. Forward clutch counter disc (No. 4)
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Disassembly of the shaft (D)

1. Remove the bearing (16) from the shaft (D) with a
puller.
LEPH12TLB0804AB 33
2. Remove the bearing (37) from the shaft (D) with a

puller.
LEPH12TLB0805AB 34
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Disassembly of shaft (B)

1. Remove the bolts (28) and remove the 4WD oil bulk-
head (29).
LEPH12TLB0875AB 35
2. Install the tool 380200256 on the side of the shaft (C)

where the hub (27) is located.
LEPH12TLB0876AB 36
3. Lift the shaft assemblies (B), (C) and (E) simultane-

ously with the tool 380200239.
LEPH12TLB0877AA 37
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4. Do not remove the oil bulkhead (P) and the bolt (V).
LEPH12TLB0878AB 38
5. Remove the seal rings (1) and (2).

NOTICE: The seal rings might get damaged during this
operation. If necessary, replace with a new one.
LEPH12TLB0879AB 39
6. Remove the bearing (3) and the gear (4) with a puller.
LEPH12TLB0880AB 40
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7. Remove the bearing (3) and the gear (4).
LEPH12TLB0881AB 41
LEPH12TLB0882AB 42
LEPH12TLB0883AB 43
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LEPH12TLB0884AB 44
LEPH12TLB0885AB 45
12. Remove the roller retainer (7) and the thrust washer
(13).
LEPH12TLB0886AB 46
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13. Remove the pin (24) and the spacer (14).
LEPH12TLB0887AB 47
14. Push the thrust washer (10) slightly.
LEPH12TLB0888AB 48
LEPH12TLB0889AB 49
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LEPH12TLB0890AB 50
17. Remove the discs (11) and the counter discs (12).
LEPH12TLB0891AB 51
18. Lower the cover (16) with the tool 380200215.
LEPH12TLB0892AB 52
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LEPH12TLB0893AB 53

spring tension.
LEPH12TLB0894AA 54
22. Remove the cover (16) and the spring (17).
LEPH12TLB0895AB 55
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LEPH12TLB0896AB 56
CAUTION
Pinch point!
pistons.
erate injury.
C0021A
WARNING
Flying debris!
ing compressed air.
ous injury.
W0307A
24. Remove the piston (19) by blowing in compressed air

through the delivery hole.
LEPH12TLB0897AB 57
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of the piston.
LEPH12TLB0595AB 58
LEPH12TLB0898AB 59
27. Remove the bearing (25) with a puller.
LEPH12TLB0899AB 60
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or damage.
30. Check oil passages in the output shaft to be sure that
they are open and free of foreign material.
sembly order.
LEPH12TLB0802AA 61
33. At each disassembly check with a gauge that the total

thickness of the clutch disc kit remains within the wear
limits; otherwise replace the clutch disc kit (11) with a
new one.
34. Make sure that all the clutch discs are free from burns,
the friction surfaces are not damaged and the grooves
of the friction surfaces are well outlined.
35. Make sure that the counter discs (12) are perfectly flat,
without scrapes or pitting.
36. In case any of the discs shows even just one of the
above-mentioned faults, replace the clutch disc kit
with a new one.
37. If you are to use a new kit of clutch discs, let it soak LEPH12TLB0900AB 62
into a bath of oil for at least one hour before its use.
38. In any case, prior to assembling the clutch disc kit,
lubricate the contact surfaces of the counter discs with
oil.
39. Check that the hole of the input shaft on the rear half
box does not show damages that could cause leaks
when the clutch is assembled.
40. Check that the grooves of the input shaft are not dam-
aged by the steel discs.
2nd Gear clutch

30.5 – 30.7 mm (1.20 – 1.21 in)
load]
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Disassembly of shaft (C)

1. Remove the bolts (V1) to detach the 4WD oil bulkhead
(P1).
LEPH12TLB1320AB 63
2. Install the tool 380200256 on the rear end of the shaft

(C) where the hub (61) is located.
LEPH12TLB1215AB 64
3. Lift the shafts (B), (C) and (E) simultaneously with the
tool 380200239.
LEPH12TLB1216AA 65
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4. Do not remove the oil bulkhead (P2) and the screw

(V2).
LEPH12TLB1217AB 66
5. Remove the tool 380200256 and sleeve (62).
LEPH12TLB1218AB 67
LEPH12TLB1219AB 68
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LEPH12TLB1220AB 69
LEPH12TLB1221AB 70
9. On the other side of the shaft assembly, push the thrust

washer (39) downwards.
LEPH12TLB1222AB 71
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LEPH12TLB1223AB 72
LEPH12TLB1224AB 73
12. Remove the disc kit (40).
LEPH12TLB1225AB 74
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13. Lower the cover (42) with the tool 380200215 and re-
move the snap ring (41).
LEPH12TLB1226AB 75

spring tension.
LEPH12TLB1227AA 76
16. Remove the snap ring (41), the cover (42) and the
spring (43).
LEPH12TLB1228AB 77
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CAUTION
Pinch point!
pistons.
erate injury.
C0021A
WARNING
Flying debris!
ing compressed air.
ous injury.
W0307A
17. Remove the piston (44) by blowing in compressed air

through the delivery hole.
LEPH12TLB1229AB 78
18. If necessary, remove the seal ring (45) with the rele-
vant O-ring from the outer seat of piston (44).
LEPH12TLB1230AB 79
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19. If necessary, remove the seal ring (53) with the rele-
vant O-ring from the gear seat (54).
LEPH12TLB1231AB 80
20. Remove the gear (37) with a puller.
LEPH12TLB1232AA 81
21. Remove the bushings (47) and (56), the roller retain-
ers (46) and (55) and the spacer (50).
22. Check the condition of the removed components (46),
(47), (50), (55) and (56).
LEPH12TLB1233AB 82
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23. Remove the O-rings (48) and (52) from the bushing
(50).
LEPH12TLB1234AB 83
24. Check the seal rings (49) and (51) for wear and con-
dition.
25. If necessary, cut and discard the seal rings (49) and
(51) from the bushing (50).
LEPH12TLB1235AB 84
LEPH12TLB1236AB 85
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LEPH12TLB1237AB 86

LEPH12TLB1238AB 87
30. Lower the counter disc (33) slightly to release the snap
ring (34).
LEPH12TLB1239AB 88
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LEPH12TLB1240AB 89
LEPH12TLB1241AB 90
LEPH12TLB1242AB 91
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LEPH12TLB1243AB 92
LEPH12TLB1244AB 93
LEPH12TLB1245AB 94
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spring tension.
LEPH12TLB1246AA 95
39. Remove the snap ring (30), cover (29) and spring (28).
LEPH12TLB1247AB 96
CAUTION
Pinch point!
pistons.
erate injury.
C0021A
WARNING
Flying debris!
ing compressed air.
ous injury.
W0307A
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40. Remove the piston (26) from its seat by blowing in

compressed air through the delivery hole.
LEPH12TLB1248AA 97
41. Remove the bushing (27) and piston (26).
LEPH12TLB1249AB 98
of the piston.
LEPH12TLB1250AB 99
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43. On the other side of the shaft, remove the seal rings
(16), (17), (18) and (19) by cutting them.
LEPH12TLB1251AB 100
LEPH12TLB1252AB 101
LEPH12TLB1253AB 102
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LEPH12TLB1254AB 103
47. Remove the roller retainer (7) and thrust washer (8).
LEPH12TLB1255AB 104
LEPH12TLB1256AB 105
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49. Remove the roller retainer (7) and thrust washer (8).
LEPH12TLB1257AB 106
51. Slightly lower the thrust washer (5) to release the snap
ring (4).
LEPH12TLB1258AB 107
LEPH12TLB1259AB 108
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LEPH12TLB1260AB 109
LEPH12TLB1261AB 110
LEPH12TLB1262AB 111
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LEPH12TLB1263AB 112

spring tension.
LEPH12TLB1264AA 113
59. Remove the snap ring (9), cover (10) and spring (11).
LEPH12TLB1265AB 114
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CAUTION
Pinch point!
pistons.
erate injury.
C0021A
WARNING
Flying debris!
ing compressed air.
ous injury.
W0307A
60. Remove the piston (13) from its seat by blowing in

compressed air through the delivery hole.
LEPH12TLB1266AA 115
61. Remove the bushing (12) and piston (13).
LEPH12TLB1267AB 116
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62. If necessary, cut and discard the seal ring (15) with the
inner O-ring from the outside seat of the piston and the
seal ring (14) with the relevant O-ring from the inner
seat of the piston.
LEPH12TLB1268AB 117
or damage.
65. Check the oil passages in the output shaft to be sure
that they are open and free of foreign material.
sembly order.
LEPH12TLB1269AA 118
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thickness of the clutch discs remains in the wear limits;
otherwise replace the clutch disc kit (B) with a new
one.
69. Make sure that all clutch discs are free from burns,
friction surfaces are not damaged and grooves of the
friction surfaces are well outlined.
70. Make sure that the counter discs (A) are perfectly flat,
without scrapes or pitting.
with a new one.
oil.
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Disassembly of shaft (E) (2WS)

1. Remove the bolts to detach the 4WD oil bulkhead.
LEPH12TLB0965AA 120

(C) where the hub is located.
LEPH12TLB0966AA 121
tool 380200239.
LEPH12TLB0962AA 122
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4. Do not remove the oil bulkhead (P) and the screw (V).
LEPH12TLB0967AB 123
5. Cut and discard the seal rings (22) and (23).
LEPH12TLB0968AB 124
6. Remove the bearings (21) and (1) with a puller.

LEPH12TLB0969AB 125
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LEPH12TLB0970AB 126
LEPH12TLB0971AB 127
10. On the other side of the shaft, press the belleville

washers and remove the snap ring (2) with the tool
380200258.
LEPH12TLB0972AB 128
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11. Remove the shims (3) and the thrust washer (4).
LEPH12TLB0973AB 129
12. Remove the belleville washers (5) and the spacer (6).
LEPH12TLB0974AB 130
LEPH12TLB0975AB 131
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14. Remove the thrust washer (16) and the clutch disc kit
(15).
LEPH12TLB0976AB 132
15. Remove the counter disc (14).
LEPH12TLB0977AB 133
16. Take out the piston (8).
LEPH12TLB0978AB 134
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17. Remove the inner (7) and outer O-ring (9) from the
piston (8).
LEPH12TLB0979AB 135
18. Remove the pins (10) and the O-rings (11).
LEPH12TLB0980AB 136
sembly order.
LEPH12TLB1029AA 137
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20. Check each disc with a gauge and make sure that the
total thickness of the clutch discs remains in the wear
new one.
21. Make sure that all the clutch discs are free from burns,
the friction surfaces are not damaged and the grooves
of the friction surfaces are well outlined.
22. Moreover, verify that the counter discs (12) are per-
fectly flat, without scrapes or pitting.
with a new one.
oil.
4WD clutch
33.80 – 34.00 mm (1.33 – 1.34 in)
load]
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1. Unscrew and remove the screws to detach the 4WD oil
bulkhead.
LEPH12TLB1058AA 139

(C) where the hub is located.
LEPH12TLB1061AA 140
tool 380200239.
LEPH12TLB1057AA 141
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4. Do not remove the oil bulkhead (P) and the bolt (V).
LEPH12TLB1062AB 142
5. Remove the seal rings (25) and (26).
LEPH12TLB1063AB 143
6. Remove the bearings (1) and (24) with a puller.

LEPH12TLB1296AB 144
LEPH12TLB1297AB 145
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LEPH12TLB1298AB 146
LEPH12TLB1299AB 147
11. On the other side of the shaft, press the belleville

washers (5) and remove the snap ring (2) by means
of tool 380200258.
LEPH12TLB1300AB 148
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12. Remove the shims (3) and thrust washer (4).
LEPH12TLB1401AB 149
13. Remove the belleville washers (5) and spacer (6).
LEPH12TLB1402AB 150
14. On the other side of the shaft, remove the bell housing
assembly from the shaft.
LEPH12TLB1404AB 151
LEPH12TLB1405AB 152
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17. Remove the thrust washer (18) and the disc and
counter disc kit (15).
LEPH12TLB1406AB 153
18. Remove the 4WD disc and counter disc kit (17).
LEPH12TLB1407AB 154
LEPH12TLB1279AB 155
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20. Remove the piston (8) with the pins (10).
LEPH12TLB1280AB 156
21. Remove the inner (7) and outer O-ring (9) from the
piston (8).
LEPH12TLB1281AB 157
22. Remove the pins (10) and O-rings (11).
LEPH12TLB1282AB 158
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sembly order.
LEPH12TLB1269AA 159
24. Check each disc with a gauge and make sure that the
total thickness of the clutch discs remains in the wear
new one.
25. Verify that all clutch discs are free from burns, that
the friction surfaces are not damaged and that the
grooves of the friction surfaces are well outlined.
26. Moreover, verify that the counter discs (12) are per-
fectly flat, without scrapes or pitting.
with a new one.
oil.
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32. Remove the bolts and 4WD oil bulkhead.
LEPH12TLB1159AA 161
33. Lift the shafts (B), (C) and (E) with the tool 380200239.
LEPH12TLB1158AA 162
NOTICE: Do not remove the bolt (V) and oil bulkhead (P).
LEPH12TLB1161AB 163
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34. Remove the seal rings (24), (25) and (26).

35. Remove the bearing (23).
LEPH12TLB1162AB 164
LEPH12TLB1163AB 165
LEPH12TLB1164AB 166
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38. Remove the snap ring (19) and bearing (19).
LEPH12TLB1165AB 167
39. Remove the snap ring (16), thrust washer (18) and
disc and counter disc kit (14).
LEPH12TLB1166AB 168
LEPH12TLB1167AB 169
WARNING
Spring under tension!
Compressed springs have potentially danger-
ous stored energy. Always assemble and dis-
assemble properly.
ous injury.
W0356A
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41. Press the belleville washers (5) with the tool

380200258 and remove the snap ring (2).
LEPH12TLB1168AB 170
42. Remove the shims (3) and thrust washer (4).
LEPH12TLB1169AB 171
43. Remove the belleville washers (5) and spacer (6).
LEPH12TLB1170AB 172
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44. Remove the clutch housing (12) and O-ring (18) from
the shaft (17).
LEPH12TLB1171AB 173
45. To remove the piston (8), drive the pins (10) out with
a punch.
LEPH12TLB1172AB 174
46. Remove the O-rings (7) and (9) from the piston (8).
LEPH12TLB1173AB 175
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47. Remove the O-rings (11) from the pins (10).
LEPH12TLB1174AB 176
sembly order.
LEPH12TLB1175AA 177

thickness of the clutch discs remains in the wear limits;
otherwise replace the clutch disc kit with a new one.
50. Verify that all clutch discs (b) are free from burns, that
the friction surfaces are not damaged and that the
grooves of the friction surfaces are well outlined.
51. Moreover, verify that the counter discs (a) are perfectly
flat, without scrapes or pitting.
with a new one.
53. If you are to use a new kit of clutch discs, let it soak
into a bath of oil for at least one hour before its use. LEPH12TLB1176AB 178

oil.
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Shaft assemblies - Assemble

580ST
590ST
695ST
Assembly of the shaft (A)

1. Install the seal ring (20) with the relevant O-ring and
seal ring (21) with the relevant inner O-ring, respec-
tively in the outer and inner seat of the piston.
LEPH12TLB0595AB 1
2. Apply a thin film of oil on the seal rings.
LEPH12TLB0806AA 2
3. Insert the piston (19) with the tool 380001926 (T) to

protect the seal rings (21).
LEPH12TLB0807AB 3
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4. Install the sleeve (5).
LEPH12TLB0593AB 4
5. Install the spring (15) and cover (13).
LEPH12TLB0592AB 5
LEPH12TLB0589AB 6
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NOTE: Make sure that the snap ring (14) is correctly fitted
into its seat.
LEPH12TLB0590AB 7

spring tension.
9. Remove the tool 380200215.
LEPH12TLB0591AA 8
10. Install the pin (9).
LEPH12TLB0809AB 9
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11. Install the thrust washer (8).
LEPH12TLB0810AB 10
12. Insert the roller retainer (7).
LEPH12TLB0582AB 11
13. To assemble the clutch discs, place the gear (6) on

the bench and install the thrust washer (11) so that
the reference mark on top of the plate, made during
disassembly, is facing towards the gear.
LEPH12TLB0811AB 12
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14. Install the discs (18) and counter discs (17) on the
gear (6).
NOTE: The assembled clutch disc kit must contain 6 steel
discs and 6 friction discs.
LEPH12TLB0812AB 13
15. Install the disc kit on the housing.
LEPH12TLB0813AA 14
LEPH12TLB0814AB 15
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17. Install the spacer (4).
LEPH12TLB0580AB 16
18. Heat the bearing (3) to 80 – 100 °C (176 – 212 °F).

19. Install the bearing (3) with tool 380200190.
LEPH12TLB0815AB 17

NOTE: For clarity of the seal ring installation procedure,
the following photos do not show the disc kit, gear, spacer,
bearing, and snap ring installed on the input shaft.
LEPH12TLB0577AB 18
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21. Install the seal ring (1).
LEPH12TLB0816AB 19
22. Install the tool 380200224 on the input shaft with the
chamfered end facing inwards.
LEPH12TLB0817AA 20
23. Slide the tool 380200224 on the input shaft and above
the spacer.
NOTE: The tool will stop in the correct position to install the
seal ring in the groove.
LEPH12TLB0818AA 21
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24. Heat the seal ring to 60 – 80 °C (140 – 176 °F) for

5 min.
25. Place the seal ring on the tool 380200224.
LEPH12TLB0819AA 22
26. Push the tool 380200225 over the tool 380200224 and
slide the seal ring until it reaches the groove in the
shaft.
27. Remove the tools 380200224 and 380200225.
LEPH12TLB0820AA 23
28. Install the seal compressor 380200214 with the deep

chamfer end on the shaft and over the seal ring.
29. Use a back and forth twisting motion to allow the seal
compressor to slip over the top of the seal ring and
seat this the seal into the groove.
NOTICE: Be careful not to damage the seal ring.
30. After the seal ring is seated in the groove, remove the
seal compressor from the shaft.
LEPH12TLB0821AA 24
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seal ring.
32. Leave the seal compressor in place for 15 min until
the seal ring has cooled and is properly seated in the
groove.
33. After the seal ring has cooled, remove the seal com-
pressor from the shaft.
LEPH12TLB0822AA 25
34. Repeat steps 1 to 33 on the other side of the shaft.

35. Lubricate the thrust washer (25).
36. Install the thrust washer so that the notch in the inner
edge fits over the pin.
37. Make sure that the side with the oil grooves is down.
LEPH12TLB0823AB 26
38. Heat the bearing (24) to 80 – 100 °C (176 – 212 °F).

39. With the tool 380200197, install the bearing (24) on
the input shaft until it makes contact with the thrust
washer.
LEPH12TLB0824AB 27
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LEPH12TLB0825AB 28
41. Place the snap rings and place the spacer on the pro-
tection tool 380001933).
LEPH12TLB0826AA 29
42. Push the tool 380001933 on the shaft.

43. The tool will stop in the correct position to install the
seal ring in the groove.
LEPH12TLB0827AA 30
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44. Heat the seal ring to 60 – 80 °C (140 – 176 °F) for

5 min.
45. Place the seal ring on the tool 380001933.
LEPH12TLB0828AA 31
46. Insert the toll 380001928 over the tool 380001933 and
slide the seal ring until it reaches the groove in the
shaft.
47. Remove the tools 380001928 and 380001933.
LEPH12TLB0829AA 32
48. Insert e the end of tool 380001927 with the deep

chamfer on the shaft and over the seal ring.
49. Use a back and forth twisting motion to allow the seal
compressor to slip over the top of the seal ring and
seat this latter into the groove.
NOTICE: Be careful not to damage the seal ring.
50. After the seal ring is seated in the groove, remove the
seal compressor from the shaft.
LEPH12TLB0830AA 33
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51. Slide the seal compressor with the narrow chamfer

end over the shaft and over the seal ring.
52. Leave the seal compressor in place for 15 min until
the seal ring has cooled and is properly seated in the
groove.
53. After the seal ring has cooled, remove the seal com-
pressor from the shaft.
LEPH12TLB0831AA 34
54. In order to insert the other rings, repeat the operations

described previously, with the following spacer rings:
1. 380001933 for the 2nd ring.
2. 380001933 for the 3rd ring.
3. 380001933 for the 4th ring.
LELI12TLB0872EB 35
1. Lubrication oil passage

2. Forward gear clutch passage
3. Reverse gear clutch passage
4. Forward gear engagement
5. Forward gear disc kit
6. Reverse gear disc kit
7. Reverse gear engagement
8. Input shaft
55. Apply compressed air of approximately 6 bar (87 psi)

to the forward clutch passage.
56. Listen for the forward gear piston to move and to lock
the relevant disc kit.
57. Try to shift the forward travel gear.
58. It must not turn on the input shaft.
59. Try to shift the reverse travel gear.
60. It must turn freely on the input shaft.
61. If the clutches do not work correctly, disassemble
them to find the problem.
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62. Carry out the check procedure of the clutch disc kit
play on both sides of the clutch.
63. Position the shaft on a suitable support (S) and apply
load “F” on the counter disc (11) surface with a proper
buffer (T), as shown.
64. This operation clears any possible play.
LEPH12TLB0833AB 36
65. To check the backlash, supply the piston chamber with

compressed air at 6 bar (87 psi) and verify the actual
stroke “X” with a dial indicator.
66. Determine clearance “X”.
LEPH12TLB0834AA 37
Only for 4WS input shaft:

67. The piston stroke (19) and (38) must be such to en-
sure a play corresponding to
“X” = 1.60 – 2.45 mm (0.06 – 0.10 in)
“Y” = 1.90 – 2.75 mm (0.07 – 0.11 in)
68. If the distance is not within specification, the clutch is
probably wrongly installed.
69. Turn the clutch shaft upside down and repeat the op-
eration for the other clutch disc kit.
LELI12TLB0835AB 38
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Only for 2WS input shaft:

70. The piston stroke (19) and (38) must be such to en-
sure a play corresponding to
“X” = 1.60 – 2.45 mm (0.06 – 0.10 in)
72. Turn the clutch shaft upside down and repeat the op-
eration for the other clutch disc kit.
LELI12TLB0835AB 39
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Assembly of the shaft (D)

1. Install the bearing (16) on the shaft (D) with the tool
380200230.
LEPH12TLB0836AB 40
2. Install the bearing (37) on the shaft (D) with the tool
380200230.
LEPH12TLB0837AB 41
3. Lubricate the shaft seat “A”.
LEPH12TLB0838AA 42
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4. Install the shaft (D) and shaft (A).

5. The operation is correct only if both the shafts are fitted
at the same time.
LEPH12TLB0839AA 43
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Assembly of the shaft (B)

1. Install the bearing (25) with the tool 380200190.
LEPH12TLB1301AB 44
2. Install the seal ring (26) with the tool 380200224.
LEPH12TLB1302AA 45
3. Install the seal ring (20) with the relevant inner O-ring
and snap ring (21) with the relevant inner O-ring, re-
spectively in the outer and inner seat of the piston.
LEPH12TLB0595AB 46
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4. Apply a thin film of oil on the seal rings recently fitted.
LEPH12TLB0806AA 47
5. Insert the piston (19) with the tool 380001926 (T) to

protect the seal rings (21).
LEPH12TLB0807AB 48
LEPH12TLB0896AB 49
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LEPH12TLB0895AB 50
LEPH12TLB1303AB 51
LEPH12TLB1304AB 52
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spring tension.
LEPH12TLB0591AA 53
12. Install the disc kit.
LEPH12TLB1305AA 54
13. Install the spacer (14) and pin (24).
LEPH12TLB1306AB 55
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14. Install the thrust washer (13) and roller retainer (7).
LEPH12TLB1307AB 56
15. Install the thrust washer (10) and push it to end stroke
on disc kit.
LEPH12TLB1308AB 57
LEPH12TLB0889AB 58
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17. Apply compressed air at low pressure to the delivery

hole to push the thrust washer (10) against the snap
ring (9) and align the disc teeth.
LEPH12TLB1309AB 59
18. Install the gear (8) by paying attention not to let it slide
to stroke end.
LEPH12TLB1310AB 60
LEPH12TLB1311AB 61
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20. Install the thrust washer (6) and snap ring (5).
LEPH12TLB1312AB 62
21. Install the gear (4) paying attention to direct the pro-
truding end of the groove towards the clutch.
LEPH12TLB1313AB 63
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LELI12TLB1314FB 64
1. Lubrication oil passage 4. 2nd gear clutch disc kit

2. Oil passage for 2nd gear clutch 5. Input shaft
3. 2nd gear engagement
23. Try to turn the 2nd travel gear. It must turn on the input
shaft.
24. Apply compressed air at approximately 6 bar (87 psi)
to the 2nd gear clutch passage.
25. Listen for the 2nd gear piston to move and to lock the
related clutch disc kit.
26. Try to shift the 2nd travel gear. It must not turn on the
input shaft.
27. If the clutch does not work correctly, disassemble it to
find the problem.
backlash on both sides of the FWD-REV-clutch. Po-
sition the shaft on a suitable support and apply load F
on the counter disc (10) surface by means of a proper
buffer.
LEPH12TLB1315AB 65
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30. To check the backlash, supply the piston chamber (19)

with compressed air at 6 bar (87 psi) and verify the
actual stroke “X” with a dial indicator.
LEPH12TLB1316AA 66
32. The piston stroke (19) must be such to ensure a play

corresponding to:
X = 2.20 – 3.05 mm (0.09 – 0.12 in)
If the distance is not within specification, the clutch is
LELI12TLB1317AB 67
33. Install the seal rings (1) and (2).

34. In order to insert the seal rings, repeat the following
operations by means of:
• Spacer 380200240 for 1st and 2nd ring.
• Pusher 380200242 and compressor 380200241.
LEPH12TLB0877AA 68
35. Install the bulkhead (29) with the bolts (28).
LEPH12TLB1318AB 69
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Assembly of the shaft (C)

1. Install the seal ring (53) and relevant O-ring on gear
(54) with the tool 380200248.
LEPH12TLB1272AA 70
3. Adjust the seal ring (53) with the tool 380200250.
LEPH12TLB1273AA 71
4. Install the seal ring (45) and relevant O-ring on piston

(44).
LEPH12TLB1274AB 72
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5. Apply a thin film of grease on the outer edge and in the

inner part of the piston (44) and fit it to the gear (54).
LEPH12TLB1275AB 73
6. Insert the spring (43), cover (42) and snap ring (41).
LEPH12TLB1276AB 74
LEPH12TLB1277AB 75
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LEPH12TLB1226AB 76

spring tension.
LEPH12TLB1278AA 77
11. Install the kit (40) and thrust washer (39) into the gear
(54).
LEPH12TLB0908AB 78
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LEPH12TLB0909AB 79
13. Install the seal ring (25) and snap ring (24) with their
relevant O-rings, respectively in the outer and inner
seat of the piston (26).
LEPH12TLB0910AB 80
14. Apply a thin film of oil on the seal rings.
LEPH12TLB0911AA 81
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15. Install the piston (26) with the tool 380001926 to pro-
tect the seal rings.
LEPH12TLB0912AB 82
LEPH12TLB0913AB 83
LEPH12TLB0914AB 84
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LEPH12TLB0915AB 85
LEPH12TLB0916AB 86

spring tension.
LEPH12TLB0917AA 87
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LEPH12TLB0918AB 88
23. Install the thrust washer (31) on the shaft (23).

24. Apply a thin film of grease under the thrust washer
(31).
LEPH12TLB0919AB 89
LEPH12TLB0920AB 90
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26. Install the clutch disc kit (32) on the main shaft (23).
LEPH12TLB0922AB 91
27. Install the roller retainer (36) and thrust washer (33).
LEPH12TLB0923AB 92
LEPH12TLB0924AB 93
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29. Apply compressed air at low pressure into the hole (a)
to push the thrust washer (33) against the snap ring
(34).
LEPH12TLB0925AB 94
30. Install the gear (35).
LEPH12TLB0926AB 95
31. Install the gear (37) on the shaft (23).
LEPH12TLB0927AB 96
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32. Install the gear (54) on the shaft (23).
LEPH12TLB0928AB 97
33. Install the bushing (47) and bearing (46) with the tool
380200190.
LEPH12TLB0929AB 98
34. Install the O-rings (48) and (52) on the bushing (50).
LEPH12TLB0930AB 99
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35. Install new seal rings (49) and (51) on bushing

(50) with the tools 380200251, 380200252 and
380200253.
LELI12TLB0931AA 100
LELI12TLB0932A8 101
36. Install the bushing (50) and shaft (23) with the tool
380200190.
37. The reference marks must be directed upwards.
LEPH12TLB0933AB 102
38. Install the bushing (56) and bearing (55) with tool
380200190.
LEPH12TLB0934AB 103
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39. Install the spacer (57).
LEPH12TLB0935AB 104
LEPH12TLB0936AB 105
41. Install the tool 380200256 on the hub (61).
LEPH12TLB0937AB 106
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42. Turn the shaft.

43. Install the seal ring with relevant O-ring (14) in the
outer seat of piston (13).
44. Install the seal ring with relevant O-ring (15) in the
inner seat of piston (13).
LEPH12TLB0938AB 107
45. Apply a thin film of oil on the seal rings recently fitted.
LEPH12TLB0911AA 108
46. Install the piston (13) with the tool 380001926 to pro-
tect the seal rings.
LEPH12TLB0939AB 109
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LEPH12TLB0940AB 110
LEPH12TLB0941AB 111
LEPH12TLB0942AB 112
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LEPH12TLB0943AB 113

spring tension.
LEPH12TLB0944AB 114
LEPH12TLB0945AB 115
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54. Insert the disc kit (6) on the shaft (23).
LEPH12TLB0946AB 116
LEPH12TLB0947AB 117
LEPH12TLB0948AB 118
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57. Apply compressed air at low pressure into the supply

hole to push the thrust washer (5) against the snap
ring (4).
LEPH12TLB0949AB 119
58. Install the thrust washer (8) and roller retainer (7).
LEPH12TLB0950AB 120
59. Install the pin (22), thrust washer (8) and roller retainer
(7).
LEPH12TLB0951AB 121
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LEPH12TLB0952AB 122
LEPH12TLB0953AB 123
LEPH12TLB0954AB 124
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63. Install the seal rings (16), (17), (18) and (19) with the
tool 380200224.
LEPH12TLB0955AB 125
LELI12TLB0956FB 126
1. 1st gear clutch oil passage 7. 4th gear engagement

2. 3rd gear clutch oil passage 8. 1st gear engagement
3. 4th gear clutch oil passage 9. 1st gear disc kit
4. 3rd gear engagement 10. Main shaft
5. 3rd gear disc kit 11. Lubrication oil passage
6. 4th gear disc kit
64. Check that all gears turn freely on main shaft.

to the 1st gear clutch passage.
66. Listen for the 1st gear piston to move and to lock the
67. Try to shift the 1st travel gear.
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68. It must not turn on the main shaft.

find the problem.
to the 3rd gear clutch passage.
find the problem.
72. Listen for the 3rd gear piston to move and to lock the
73. Try to shift the 3rd travel gear.
find the problem.
to the 4th gear clutch passage.
77. Listen for the 4th gear piston to move and to lock the
related clutch disc kit. Try to shift the 4th travel gear.
play.
80. Position the shaft on a suitable support and apply load
“F” on the surface of the clutch counter disc with a
proper buffer (T).
LEPH12TLB0957AB 127
82. To check the backlash, supply the piston chamber (26)

with compressed air at 6 bar (87 psi) and verify the
actual stroke “X” with a dial indicator.
LEPH12TLB0958AA 128
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corresponding to:
X = 0.5 – 1.95 mm (0.020 – 0.077 in)
LELI12TLB0959AB 129

corresponding to:
X = 2.20 – 3.05 mm (0.09 – 0.12 in)
LELI12TLB0960AB 130

corresponding to:
X = 1.725 – 2.375 mm (0.068 – 0.094 in)
LELI12TLB0961AB 131
90. Lift the shafts (B), (C) and (E) with the tool 380200239.
91. Insert the shafts (B), (C) and (E) at the same time and
insert the assembly into the half box.
LEPH12TLB0962AA 132
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92. Install the bulkhead (P1) with the bolts (V1).
LEPH12TLB0963AB 133
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Assembly of the shaft (E) (2WS)

1. Insert the inner O-ring (7) and outer O-ring (9) on the
piston (8).
LEPH12TLB1031AB 134
2. Insert the O-rings (11) on the pins (10).
LEPH12TLB1032AB 135
3. Insert the pins (10) on the piston (8).
LEPH12TLB1033AB 136
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4. Apply a thin film of grease on the O-rings and position

the pins on piston (8) in order to match the holes of the
output shaft.
LEPH12TLB1034AB 137
5. Install the piston (8).
LEPH12TLB1035AB 138
6. Install the counter disc (14) with the chamfer down-

wards into the shaft (12).
LEPH12TLB1036AB 139
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7. Install the clutch disc kit starting with a counter disc (A)
followed by a disc (B).
LEPH12TLB1037AB 140
8. Install the thrust washer (16) on the shaft (12).
LEPH12TLB1038AB 141
LEPH12TLB1039AB 142
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LEPH12TLB1040AB 143
11. Install the roller retainer (19) and spacer (20).
LEPH12TLB1041AB 144
LEPH12TLB1042AB 145
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13. Turn the shaft (12).

14. Make sure that the disc, counter disc kit and piston
are correctly seated.
LEPH12TLB1043AB 146
15. Install the spacer (6), thrust washer (4) and snap ring
(2).
LEPH12TLB1044AB 147
16. With a thickness gauge determine the value of “X”

between the thrust washer (4) and snap ring (2).
LEPH12TLB1045AB 148
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17. To value “X” subtract the fixed measure “S1” of

1.80 mm (0.071 in) corresponding to the piston
stroke.
18. The resulting measure “S” corresponds to the height
of the shim that must be inserted between the thrust
washer (4) and snap ring (2).
S = X - S1 = X - 1.80 mm (0.071 in)
LELI12TLB1046AB 149
19. Choose the shim with value “S” from the shim range
available.
NOTE: In any case, choose the shim ensuring a piston
stroke of 1.70 – 1.90 mm (0.067 – 0.075 in).
Shim range:
• 0.1 mm (0.004 in)
• 0.3 mm (0.012 in)
• 0.5 mm (0.020 in)
LELI12TLB1047AA 150
20. Remove the thrust washer (4) and snap ring (2).
LEPH12TLB1048AB 151
21. Insert the belleville washers (5).

22. Check the proper orientation of the belleville washers
(5).
LEPH12TLB1049AB 152
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23. Install the thrust washer (4) and shims (3).
LEPH12TLB1050AB 153
24. Press the belleville washers and Install the snap ring
(2) with the tool 380200275.
NOTICE: The springs can cause damages to persons if the
snap ring is not assembled correctly.
LEPH12TLB1051AB 154
LEPH12TLB1052AB 155
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26. Install the seal rings (22) and (23) with the tool
380200224.
LEPH12TLB1053AA 156
27. Use the tool 380200223 to check piston operation and

verify correct adjustment.
LEPH12TLB1054AA 157
28. In order to check the sealing of rings (7) and (9), put
the piston chamber under pressure with oil at 10 bar
(145 psi) and verify with a dial gauge that the actual
stroke is 1.70 – 1.90 mm (0.067 – 0.075 in).
LEPH12TLB1055AA 158
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LELI12TLB1056FB 159
1. 4WD oil passage

2. 4WD gear
3. 4WD lubricant oil passage
4. Shaft
5. Belleville washers
29. Apply compressed air pressure of approximately

10 bar (145 psi) to the 4WD clutch passage.
30. Listen for the piston to move and to unlock the related
clutch disc kit.
31. The belleville washers compress themselves. Try to
shift the 4WD gear.
32. It must turn freely on the 4WD shaft.
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34. Lift the shafts (B), (C) and (E) at the same time and
insert the assembly into the half box with the tool
380200239.
LEPH12TLB1057AA 160
35. Install the bulkhead with the bolts.
LEPH12TLB1058AA 161
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1. Install the inner O-ring (7) and outer O-ring (9) on the
piston (8).
LEPH12TLB1281AB 162
2. Install the O-rings (11) on the pins (10).
LEPH12TLB1282AB 163
3. Install the pins (10) on the piston (8).
LEPH12TLB1284AB 164
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the pins on piston (8) in order to match the holes of the
output shaft (12).
LEPH12TLB1285AB 165
5. Install the piston (8) on the bell housing (12).
LEPH12TLB1286AB 166
6. Insert the brake counter disc (16) with the chamfer

downwards into the bell housing (12).
LEPH12TLB1287AB 167
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7. Install the clutch disc kit (17) starting with a counter disc
(A) followed by a disc (B).
LEPH12TLB1288AB 168
LEPH12TLB1289AB 169
LEPH12TLB1290AB 170
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LEPH12TLB1291AB 171
11. Install the shaft (13).
LEPH12TLB1292AB 172
12. Turn the shaft (13) and bell housing (12).

13. Make sure that the clutch disc kit and piston are cor-
rectly seated.
LEPH12TLB1293AB 173
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(2).
LEPH12TLB1295AB 174

LEPH12TLB1045AB 175

stroke.
S = X-S1 = X- 1.80 mm (0.071 in)
LELI12TLB118AB 176
available.
stroke of 1.70 – 1.90 mm (0.067 – 0.075 in).
Shim range
• Shims 0.1 mm (0.004 in)
• Shims 0.3 mm (0.012 in)
• Shims 0.5 mm (0.020 in)
LELI12TLB118AA 177
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LEPH12TLB1048AB 178
20. Insert the belleville washers (5).
LEPH12TLB1049AB 179
21. Check the proper orientation of the belleville washers

(5).
LELI12TLB1294AB 180
22. Install the thrust washer (4) and shims (3).
LEPH12TLB1050AB 181
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23. Press the belleville washers and fit the snap ring (2)
NOTICE: The springs can cause damages to persons if the
snap ring is not assembled correctly.
LEPH12TLB1148AB 182
LEPH12TLB1149AB 183
LEPH12TLB1150AB 184
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LEPH12TLB1151AB 185
27. Install the roller retainer (22) and spacer (23).
LEPH12TLB1152AB 186
LEPH12TLB1153AB 187
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29. Install the seal rings (25) and (26) with the tool
380200224.
LEPH12TLB1154AA 188
30. Use tool 380200223 to check piston operation and

LEPH12TLB1155AA 189
31. In order to check the sealing of the rings, put the piston
chamber under pressure with oil at 10 bar (145 psi)
and verify with a dial gauge that the actual stroke is
1.70 – 1.90 mm (0.067 – 0.075 in).
LEPH12TLB1156AA 190
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LELI12TLB1157FB 191
1. 4WD oil passage

2. 4WD gear
3. 4WD lubricant oil passage
4. Shaft
32. Apply compressed air pressure of approximately

clutch disc kit.
shift the 4WD gear.
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insert the assembly into the half box with the tool
380200239.
LEPH12TLB1158AA 192
38. Install the bulkhead with the bolts.
LEPH12TLB1159AA 193

1. Install the O-rings (7) and (9) on the piston (8).
LEPH12TLB1173AB 194
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LEPH12TLB1174AB 195
3. Install the pins (10) on the piston (8).
LEPH12TLB1177AB 196

the pins of the piston (8). This will help the pins to move
squarely into the holes of the clutch housing (12).
LEPH12TLB1178AB 197
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5. Install the piston (8) on the clutch housing (12).
LEPH12TLB1179AB 198
6. Install the brake counter disc (13) in the clutch housing

(12).
NOTICE: The chamfer on the counter disc should point
downwards
LEPH12TLB1180AB 199
7. Install the disc and counter disc kit (14) starting with a
counter disc (A) followed by a disc (B).
LEPH12TLB1181AB 200
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LEPH12TLB1182AB 201
9. Install the O-ring (18) on the shaft (17).

10. Install the shaft (17) on the clutch housing (12).
11. Make sure that the disc, counter disc kit and piston
are correctly seated.
LEPH12TLB1171AB 202
(2).
LEPH12TLB1184AB 203
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stroke.
16. S = X - S1 = X - 1.80 mm (0.071 in)
LEPH12TLB1185AB 204
LELI12TLB1186AB 205
available.
stroke of 1.70 – 1.90 mm (0.067 – 0.075 in).
Shim range
• Shims – 0.1 mm (0.004 in)
• Shims – 0.3 mm (0.012 in)
• Shims – 0.5 mm (0.020 in)
LELI12TLB1187AA 206
LEPH12TLB1188AB 207
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19. Install the belleville washers (5).
LEPH12TLB1189AB 208
20.
NOTICE: The orientation of the belleville washers (5)
should be as shown in the figure.
LELI12TLB1190AB 209
21. Install the thrust washer (4) and shims (3) with size “S”
previously calculated.
LEPH12TLB1191AB 210
WARNING
assemble properly.
ous injury.
W0356A
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22. Press the belleville washers with the tool 380200275

and install the snap ring (2).
LEPH12TLB1148AB 211

LEPH12TLB1192AB 212
LEPH12TLB1164AB 213
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LEPH12TLB1163AB 214
LEPH12TLB1193AB 215
LELI12TLB1194AB 216
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28. Install the seal rings (24), (25) and (26) with the tools
380200264 (T), 380001927 and 380001928.
LEPH12TLB1195AB 217
LEPH12TLB1154AA 218
LELI12TLB1196AB 219
29. Use tool 380200265 to check piston operation and

LELI12TLB1197AA 220
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30. Check the sealing of rings (7) and (9)

• Pressurize the piston chamber with oil at 10 bar
(145 psi).
• With a dial gauge, make sure that the actual stroke
is between 1.70 – 1.90 mm (0.067 – 0.075 in).
LEPH12TLB1198AA 221
LELI12TLB1199FB 222
1. 4WD oil passage

2. 4WD gear
3. Bearing lubrication
4. Shaft
6. Bearing
31. Apply compressed oil pressure of approximately
clutch disc kit.
shift the 4WD gear.
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position them in the half box with the tool 380200239.
LEPH12TLB1158AA 223
37. Install the bulkhead and tighten the screws.
LEPH12TLB1159AA 224
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Index
Transmission - 21

Clutch - Exploded view H-type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Shaft assemblies - Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Shaft assemblies - Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Shaft assemblies - Exploded view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Shaft assemblies - Exploded view H-type - reverse shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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PRINTED IN U.S.A.
48090752 24/02/2017
EN
SERVICE MANUAL
Front axle system

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25
Contents
Front axle system - 25
[25.100] Powered front axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.1
[25.102] Front bevel gear set and differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.2
[25.108] Final drive hub, steering knuckles, and shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.3
[25.400] Non-powered front axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.4
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25
Powered front axle - 100

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Contents
TECHNICAL DATA
Four-Wheel Drive (4WD) axle

General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
FUNCTIONAL DATA

Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Drawing - Front axle-four wheel drive- measuring toe-in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Axle housing
Exploded view Swivel housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
SERVICE

Drain fluid (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Filling (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Lubricate (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Axle housing
Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
DIAGNOSTIC
Powered front axle

Troubleshooting (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
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Front axle system - Powered front axle
Four-Wheel Drive (4WD) axle - General specification

MARBLE CUTTING
DRIVE (2WD)
DRIVE (4WD)
Specifications
Tie rod length securing nut 111 – 137 N·m (81.9 – 101.0 lb ft)
Tie rod ball joint nut 129 – 160 N·m (95.1 – 118.0 lb ft)
Tie rod ball joint 255 – 315 N·m (188.1 – 232.3 lb ft)
Breather 11 – 14 N·m (8.1 – 10.3 lb ft)
Beam drain plug/fill 54 – 66 N·m (39.8 – 48.7 lb ft)
Lube fitting, king pin 25 – 35 N·m (18.4 – 25.8 lb ft)
Planet carrier retention screw 21 – 26 N·m (15.5 – 19.2 lb ft)
King pin bolt 154 – 188 N·m (113.6 – 138.7 lb ft)
Differential cover bolt 96 – 118 N·m (70.8 – 87.0 lb ft)
Steering cylinder bolt 358 – 442 N·m (264.0 – 326.0 lb ft)
Steering stop nut 200 – 244 N·m (147.5 – 180.0 lb ft)
Sun shaft retention nut 358 – 442 N·m (264.0 – 326.0 lb ft)
Ring gear support bolt 55 – 68 N·m (40.6 – 50.2 lb ft)
Planet pin screw 95 – 105 N·m (70.1 – 77.4 lb ft)
Planetary drain plug 72 – 88 N·m (53.1 – 64.9 lb ft)
Bearing cap bolt 96 – 118 N·m (70.8 – 87.0 lb ft)
Ring nut retainer bolt 21 – 26 N·m (15.5 – 19.2 lb ft)
Bevel crown bolt 96 – 118 N·m (70.8 – 87.0 lb ft)
Pinion shaft bearing rolling torque 1.7 – 2.2 N·m (1.3 – 1.6 lb ft)
Differential bearing rolling torque 1.5 – 2.5 N·m (1.1 – 1.8 lb ft)
Wheel bearing with seal rolling torque 8 – 30 N·m (5.9 – 22.1 lb ft)
Open differential rolling torque (Internal diff gears) 0 – 1 N·m (0.0 – 0.7 lb ft)
Limited slip differential rolling torque (Internal diff gears) 1 – 5 N·m (0.7 – 3.7 lb ft)
Capacities
Differential 7.7 l (8.1 US qt) or bottom of fill hole.
Planetary 0.5 l (0.5 US qt) or fill to line.
Type of Fluid CASE AKCELA TRANSAXLE FLUID 80W-140
Lubricant CASE AKCELA MOLY GREASE or TUTELA
MULTI -PURPOSE EP GREASE 251H, GR-9
NOTE: All new or used hardware should have LOCTITE® 242® applied prior to installation. The manufacturer recom-
mends replacement of all hardware to include O-rings.

MARBLE CUTTING
Specifications
Tie rod length securing nut 111 – 137 N·m (81.9 – 101.0 lb ft)
Tie rod ball joint nut 129 – 160 N·m (95.1 – 118.0 lb ft)
Tie rod ball joint 255 – 315 N·m (188.1 – 232.3 lb ft)
Breather 11 – 14 N·m (8.1 – 10.3 lb ft)
Beam drain plug/fill 54 – 66 N·m (39.8 – 48.7 lb ft)
Lube fitting, king pin 25 – 35 N·m (18.4 – 25.8 lb ft)
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Specifications
Planet carrier retention screw 21 – 26 N·m (15.5 – 19.2 lb ft)
King pin bolt 154 – 188 N·m (113.6 – 138.7 lb ft)
Differential cover bolt 96 – 118 N·m (70.8 – 87.0 lb ft)
Steering cylinder bolt 358 – 442 N·m (264.0 – 326.0 lb ft)
Steering stop nut 200 – 244 N·m (147.5 – 180.0 lb ft)
Sun shaft retention nut 358 – 442 N·m (264.0 – 326.0 lb ft)
Ring gear support bolt 55 – 68 N·m (40.6 – 50.2 lb ft)
Planet pin screw 95 – 105 N·m (70.1 – 77.4 lb ft)
Planetary drain plug 72 – 88 N·m (53.1 – 64.9 lb ft)
Bearing cap bolt 96 – 118 N·m (70.8 – 87.0 lb ft)
Ring nut retainer bolt 21 – 26 N·m (15.5 – 19.2 lb ft)
Bevel crown bolt 96 – 118 N·m (70.8 – 87.0 lb ft)
Pinion shaft bearing rolling torque 1.7 – 2.2 N·m (1.3 – 1.6 lb ft)
Differential bearing rolling torque 1.5 – 2.5 N·m (1.1 – 1.8 lb ft)
Wheel bearing with seal rolling torque 8 – 30 N·m (5.9 – 22.1 lb ft)
Open differential rolling torque (Internal diff gears) 0 – 1 N·m (0.0 – 0.7 lb ft)
Limited slip differential rolling torque (Internal diff gears) 1 – 5 N·m (0.7 – 3.7 lb ft)
Capacities
Differential 10.5 L (11.1 US qt) or bottom of fill hole.
Planetary 1.3 L (1.4 US qt) or fill to line.
Type of Fluid CASE AKCELA TRANSAXLE FLUID 80W-140
Lubricant CASE AKCELA MOLY GREASE or TUTELA
MULTI -PURPOSE EP GREASE 251H, GR-9
NOTE: All new or used hardware should have LOCTITE® 242® applied prior to installation. The manufacturer recom-
mends replacement of all hardware to include O-rings.

MARBLE CUTTING
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4WS Front axle
LELI12TLB0657GA 1
Manufacturer CARRARO
Model 26.32
Differential ratio 2.75
Planetary hub ratio 6.92
Total reduction ratio 19.04
Lubrication angle 35° maximum (front and rear) - 35° maximum (from side
to side)
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Four-Wheel Drive (4WD) axle - Special tools

CAS1839 Pinion setting kit
1. Gauge tube
RCPH10TLB461ABL 1
2. Gauge block
3. Metric feeler gauge
4. Pilot
5. Handle
6. Stud
CAS1840C-1 Spanner wrench
RCPH10TLB468ABL 2
CAS2151A Wrench for pinion nut
RCPH10TLB465ABL 3
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Yoke to hold shaft
RCPH10TLB467ABL 4
CAS1842 Wheel stud removal and installation
RCPH10TLB466ABL 5
V-Block used to support coupling when replacing a uni-

versal joint
RCPH10TLB469ABL 6
CAS2369 - Seal protector
CAS2375 - Shaft adapter
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Four-Wheel Drive (4WD) axle - Exploded view
RCPH10TLB388ACL 1
(1) Axle (7) Retainer

(2) Bolt (8) Bolt
(3) Snap ring (9) Bolt
(4) Spacer (10) Washer
(5) Pivot pin (11) Drive shaft guard
(6) Drive shaft
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Four-Wheel Drive (4WD) axle - Drawing - Front axle-four wheel

drive- measuring toe-in
1. Mark around center of tire
2. Steering cylinder
3. Loosen the jam nut and turn the piston rod as required
4. Top axle measurement must be equal to or up to 5 mm (0.2 in) less than bottom axle measurement.
RCPH10TLB001FAL 1
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Axle housing - Exploded view Swivel housing
RCPH10TLB001GAL 1
1 Bushing 7 Bushing
2 Seal 8 Swivel housing
3 Grease fitting 9 Bellville washer
4 Bolt 10 Bottom king pin
5 Top king pin 11 Grease fitting
6 Belleville washer 12 Bolt
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Four-Wheel Drive (4WD) axle - Drain fluid

MARBLE CUTTING
DRIVE (2WD)
DRIVE (4WD)
1. Start up the engine and run until the front axle fluid is
at operating temperature.
2. Use the loader and raise the front wheels about 25 mm
(1 in) above the surface.
3. Rotate both front wheels so that the oil level plug is in
the drain position, as shown.
RAIL14FRK0089BA 1
4. Lower the loader to place the wheels on the surface.

5. Clean the areas around the planetary plugs.
6. Place a suitable container under the planetary drain
plugs and slowly remove the plugs.
7. Clean the areas around the check/fill plug (1) and the
drain plug (2) for the center bowl.
8. Slowly remove the check/fill plug.
9. Place a suitable container under the drain plug and
slowly remove the plug.
10. After the oil has drained from the axle, install the drain
plug.
RAIL14TLB0990BA 2
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Four-Wheel Drive (4WD) axle - Filling

MARBLE CUTTING
DRIVE (2WD)
DRIVE (4WD)
Axle and hub oil specification – TUTELA TRANSAXLE FLUID SAE 80W-140
Oil capacity (580N EP, 580N, and 580SN) – Differential 7.7 L (8.1 US qt). Each hub 0.5 L (0.5 US qt)
Oil capacity (580SN WT and 590SN) – Differential 8.6 L (9.1 US qt). Each hub 1.0 L (1.1 US qt)
1. Use the loader and raise the front wheels about 25 mm

(1 in) above the ground.
2. Rotate both front wheels to the check/fill position, as
shown.
RAIL14FRK0088BA 1
3. Lower the loader to place the wheels on the surface.

4. Confirm the drain plug (2) is installed.
5. Fill the axle at the center bowl check/fill plug (1)to spec-
ification. Fluid should just begin to flow out of the open-
ings, when at the proper level.
RAIL14TLB0990BA 2
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6. Fill the planetary check/fill plugs (1) to specification.

Fluid should just begin to flow out of the openings, when
at the proper level.
RAIL14FRK0088BA 3
7. Install the center bowl and the planetary check/fill

plugs.
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Four-Wheel Drive (4WD) axle - Remove

MARBLE CUTTING
DRIVE (2WD)
DRIVE (4WD)
4WD, 2WS
RCPH10TLB388ACL 1
1. Remove the bucket or attachment from the front loader

arm.
2. Move the machine to a level and firm ground, away
from any soft ground, excavations, and poorly shored
cavity.
3. Raise the loader arm and engage the safety support.
4. Turn off engine and release hydraulic pressure.
5. Use the master disconnect switch to disconnect power
from the batteries or disconnect the battery cables.
6. Remove the starter key and attach a “Do Not Operate”
tag.
7. Block the rear tires.
8. Use appropriate equipment to support the front of ma-
chine.
9. Use an appropriate support of lifting device to hold the
drive shaft (9) in place when removing.
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10. Loosen and remove the bolts (5) and the retainers
(6) that fasten the drive shaft (9) to the flange on the
transmission. Remove the drive shaft (9).
11. Install blocks between the axle stops and the frame to
prevent the axle from tilting.
RCPH11TLB136AAM 2
12. Identify, tag, and disconnect the steering hoses. Cap

all open ports.
RCPH11TLB146AAM 3
13. Remove the grease fitting form the pivot pin.

14. Place a floor jack under the axle to hold the axle in
position.
15. Remove the front snap ring (4) and the rear snap ring
(7) from the pivot pin (3).
RCPH11TLB141AAM 4
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16. Install a slide hammer into the pivot pin (3). Use the
slide hammer to pull the pivot pin (3) out of the frame.
RCPH11TLB143AAM 5
NOTICE: Take note of the quantity and orientation of the shims between the axle and the inside frame.
17. Gather the thrust washers and shims (2)/ (8) located
between the axle and the frame. Lower the axle (13)
and remove the washers (2).
RCPH11TLB144AAM 6
18. Remove the axle (13) from under the machine.
RCPH11TLB145AAM 7
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Four-Wheel Drive (4WD) axle - Install

MARBLE CUTTING
DRIVE (2WD)
DRIVE (4WD)
RCPH10TLB388ACL 1
1. Raise the axle into alignment with the frame.
RCPH11TLB140AAM 2
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2. Install the pivot pin (3) with the bolt hole end of the pivot
pin toward the front of the machine.
RCPH11TLB147AAM 3
3. Start the pivot pin (3) into the frame and axle.
4. Drive the pivot pin (3) into the rear pivot of the axle but
not through the rear pivot hole on the frame.
5. Install shims (8) between the rear of the axle and the
frame. Use enough shims to reduce the gap between
the frame and the rear of the axle.
6. Drive the pivot pin (3) through the rear pivot and the
frame.
7. Install the washer (8) and snap ring (7) on the pivot pin
(3).
8. Drive the pivot pin (3) toward the front of the machine
as far as possible.
9. Check the end play between the frame and the snap
ring (4) on the pivot pin (3) at the front of the ma-
chine. Use washers (2) as required to remove any end
play. Keep end play between 0.50 – 1.50 mm (0.02 –
0.06 in).
10. Install the grease fittings on the pivot pin.
11. Loosen and remove the plugs from the hoses and the
caps from the fittings for the steering cylinder.
RCPH11TLB146AAM 4
12. Connect the hoses to the steering cylinder.

13. Install the wheels.
14. Remove the stands and lower the wheels to the floor.
15. Lubricate the pivot pin (3) with TUTELA MULTI -PURPOSE
EP GREASE 251H, GR-9 for the axle.
16. Use TUTELA MULTI -PURPOSE EP GREASE 251H, GR-9
to grease the splines on the axle and the inside of drive
shaft coupling.
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17. Install the drive shaft (9). Install the bolts (5) and re-
tainers (6) that fasten the drive shaft (9) to the flange
on the transmission.
18. Tighten the bolts to 33 – 39 N·m (24 – 29 lb ft).
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Four-Wheel Drive (4WD) axle - Lubricate

MARBLE CUTTING
4WS - Lubrication and greasing

Differential 10.5 L (2.8 US gal)
Oil capacity
Final drive (each) 1.3 L (0.34 US gal)
Oil type CASE AKCELA TRANSAXLE FLUID 80W-140
LELI12TLB0658GB 1
1. Oil level plug 4. Oil drain plug

2. Air breather 5. Greasing points
3. Level, fill and drain plug for reduction gear oil
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WARNING
Pressurized system!
System is still under pressure. Release pres-
sure according to instructions in this manual.
ous injury.
W1044A
1. Before draining the oil from the axle body, use the
breather (2) to release any possible internal pressure.
LELI12TLB0659AB 2
2. To drain the oil from the central body remove the level
plug (1) and the drain plug (4).
3. Drain all oil.
4. Clean and install the drain plug (4).
5. Fill through the hole of the plug (1).
6. Check the level and, if necessary, top up.
7. Clean and install the plug (1).
LELI12TLB0660AB 3
8. Before draining the oil from the reduction gear, rotate it

so that the plug (3) is in the highest position (position
“A”) and partially loosen the plug to release any possi-
ble internal pressure.
9. Turn and bring the plug to the lowest position (position
“B”).
10. Remove the plug and drain the oil.
11. Now turn again and bring the hole of the plug (3) to
check and oil filling position (position “C”).
12. Carry out the filling.
13. Clean and install the plug (3). LELI12TLB0661AB 4
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Four-Wheel Drive (4WD) axle - Remove

MARBLE CUTTING
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
WARNING
Jack stands can slip or fall over. Dropping, tipping, or slipping of machine or its components is pos-
sible.
DO NOT work under a vehicle supported by jack stands only. Park machine on a level surface. Block
wheels. Support machine with safety stands.
W0069A
4WS
2. Place the backhoe attachment in the stowed position.
3. Completely raise the stabilizers and lock them mechan-
ically.
4. Rest the loader attachment on the ground in order to
unload the weight of the machine from the two front
wheels, then lift the front part of the machine off the
ground.
LELI12TLB0664AA 1
5. Secure the front end with safety support stands.

6. Use the locking pin (if provided) to lock the loader at-
tachment controls.
9. Stop the engine and remove the starter key.
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10. Release the hydraulic pressure by operating the con-

trol levers in all directions.
11. On hydraulically controlled machines, turn the key to
ON position without starting the machine, and release
the pressure by moving the hydraulic control levers in
all directions.
12. Place some wedges under the rear wheels so as to
prevent the machine from moving.
13. Place the master disconnect switch in the OFF posi-
tion.
14. Fasten the front axle (6) to a lifting hoist or to a sup-
port. Make sure that the lifting/support device is not
supporting the weight of the machine but that the lift-
ing/support device is supporting the weight of the axle.
15. Support and remove the two front wheels. Retain the
wheel nuts (7).
16. Disconnect the hoses of the steering cylinder, paying
attention to possible oil leaks, preventing spillage over
the ground using a container.
17. Support the weight of the four-wheel drive shaft (1).
LELI12TLB0663BB 2
18. Remove the bolts (2) and bracket (3) from the four-
wheel drive shaft yoke.
19. Loosen and remove the axle mount bolts (5) and
washers (4) from the front and rear of the axle.
20. Lower and remove the axle (6) from underneath the
machine.
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Four-Wheel Drive (4WD) axle - Install

MARBLE CUTTING
4WS
1. Move the front axle (6) into position underneath the
machine.
2. Install the front axle mounting bolts (5) and washers (4)
through the front axle mounting bracket to the chassis
frame. Tighten to a torque of 460 – 540 N·m (339 –
398 lb ft).
NOTE: Check the torque after 50 hours of operation, reset
the bolt torque if necessary.
3. Secure the four-wheel drive shaft (1) to the front axle
yoke with bolts (2) and bracket (3). Tighten to a torque
of 35.0 – 41.0 N·m (25.8 – 30.2 lb ft)
NOTICE: If necessary, replace O-rings or seals on hoses
or cylinder before attaching.
4. Secure hoses to the steering cylinder.
5. Install the front wheels.
6. Fill and lubricate the axle.
LELI12TLB0663BB 1
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Axle housing - Disassemble

1. See housing exploded view: Axle housing - Exploded
view (25.100)
NOTE: Steering stop screws are set per tires/loader combinations.

2. Do the necessary steps under disassembly of Plane-
tary Planetary drive and hub - Disassemble (25.108)
for access to the swivel housing.
3. Loosen the tie rod nut.
RCPH10TLB951ABL 1
4. Use a two jaw puller to loosen the ball joint. Remove

the tie rod nut and remove the ball joint from the swivel
housing. Remove the tie rod.
RCPH10TLB952ABL 2
NOTE: Remove and discard nut. DO NOT reuse.

5. Remove the nut and ball joint.
RCPH10TLB484ABL 3
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6. Fasten acceptable lifting equipment as shown.
RCPH10TLB390ACL 4
7. Remove the bolts (3)and use acceptable tools to re-

move the top king pin.
RCPH10TLB391ACL 5
8. Remove top king pin.
RCPH10TLB405ACL 6
9. Repeat steps 7 through 9 for the bottom king pin.

10. Remove the swivel housing.
RCPH10TLB956ABL 7
NOTE: Take care when removing shaft. Do not cut the seal and bushing the splines on the axle shaft.
11. Repeat steps1 through 11 for the other swivel housing.
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12. Remove the belleville washer from the top and bottom
of the axle housing.
RCPH10TLB699ABL 8
NOTE: Mark washers for reassembly.

13. Remove the top cylindrical bushing and bottom spher-
ical bushing. using an acceptable puller.
RCPH10TLB926ABL 9
14. Use an acceptable puller and remove the axle shaft

seal.
RCPH10TLB959ABL 10
15. Use an acceptable puller and remove the axle shaft

bushing.
RCPH10TLB492ABL 11
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16. Use a hammer and a chisel that has a long taper to

remove the bearing cone from the bottom king pin.
RCPH10TLB459ABL 12
Replacing a Universal Joint

17. Remove the four snap rings.
RCPH10TLB472ABL 13
18. Use the CAS1980 V-block to support the coupling.

Adjust the Allen bolts in the V-block to hold the cou-
pling level and use additional support as required.
Use an acceptable driver and press the bottom bear-
ing cap against the V-block.
RCPH10TLB599ABL 14
19. Fasten the bearing cap in a vise and drive the coupling
off the bearing cap.
RCPH10TLB473ABL 15
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20. Use the V-block to support the coupling and press the
other bearing cap against the V-block.
RCPH10TLB593ABL 16
21. Remove the long axle shaft (or short axle shaft) from
the coupling.
RCPH10TLB594ABL 17
22. Remove the coupling from the bearing cap.
RCPH10TLB596ABL 18
23. Use an acceptable support and driver to press the

bottom bearing cap out of the yoke as far as possible.
RCPH10TLB474ABL 19
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24. Remove the yoke from the bearing cap. DO NOT hit
the axle shaft in the seal area.
RCPH10TLB475ABL 20
25. Press the other bearing cap out of the yoke as far as
possible.
RCPH10TLB476ABL 21
26. Remove the cross.
RCPH10TLB477ABL 22
27. Use an acceptable driver and press the bearing cap

out of the yoke.
RCPH10TLB478ABL 23
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28. Press a bearing cap into the yoke until the top of the
bearing cap is 6 mm (0.24 in) above the top of the
yoke.
RCPH10TLB585ABL 24
RCPH10TLB586ABL 25
30. Press the other bearing cap into the yoke until the top
of the bearing cap is 9 mm (0.35 in) above the top of
the yoke.
RCPH10TLB587ABL 26
31. Carefully raise the cross into the bearing cap so that
the cross is in both bearing caps.
RCPH10TLB588ABL 27
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32. Hold the cross and press the bearing caps into the
yoke.
RCPH10TLB589ABL 28
33. Use an acceptable driver and press a bearing cap into

the yoke so that a snap ring can be installed.
RCPH10TLB590ABL 29
RCPH10TLB591ABL 30
35. Repeat steps 30 and 31 for the other bearing cap.

36. Use the V-block to support the coupling and press a
bearing cap into the coupling even with the OD of the
coupling.
RCPH10TLB592ABL 31
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RCPH10TLB595ABL 32
38. Use an acceptable driver and press the other bearing

cap into the coupling until the top of the bearing cap
is 6 mm (0.24 in) above the top of the coupling.
RCPH10TLB597ABL 33
39. Carefully raise the cross into the top bearing cap so
that the cross is in both bearing caps.
RCPH10TLB598ABL 34
40. Hold the cross and press the bearing cap into the cou-
pling so that a snap ring can be installed.
RCPH10TLB600ABL 35
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RCPH10TLB601ABL 36
42. Repeat steps 37 and 38 for the other bearing cap.
Next operation:
Axle housing - Assemble (25.100)
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Axle housing - Assemble

MARBLE CUTTING
DRIVE (4WD)
MARBLE CUTTING
1. Drive the bushing into the bore until the bushing is

3.175 mm (0.125 in) beyond the end of the bore. Then
install the seal. Use DMT100005 for the bushing and
DMT100006 for the seal.
RCPH10TLB994ABL 1
2. Install the cylindrical bushing for the top king pin on a

driver that has a pilot. Drive the bushing all the way into
the bore until fully seated.
RCPH10TLB490ABL 2
NOTE: Freezing of part to enable assembly is acceptable.

3. Repeat step 2 for the bottom bushing.
4. Insert shaft without cutting seal. Maneuver shaft to
align splines with the differential.
RCPH10TLB956ABL 3
NOTE: Take care not to cut seal during installation. It is necessary to rotate the input shaft to align splines.
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5. Install the belleville washer on the top of the axle hous-

ing. Then install the belleville washer on the bottom of
the axle housing. Make final adjustments of the swivel
housing to align king pins..
RCPH10TLB002ACL 4
6. Install the top king pin, and bolts. Tighten the bolts (3)
to a torque of 154 – 188 N·m (113.6 – 138.7 lb ft).
RCPH10TLB004ACL 5
7. Install the bottom king pin and bolts. Tighten the bolts
(3) to 154 – 188 N·m (113.6 – 138.7 lb ft). If bearing
cone is removed in the previous step replace with new
cone at this time.
RCPH10TLB497ABL 6
8. Install the ball joint and new nut.
RCPH10TLB005ACL 7
NOTE: Nut must be replaced with new nut each time it is removed.
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9. Tighten the nut for models 580N & 580SN to: 129 –
160 N·m (95.1 – 118.0 lb ft) Tighten the nut for mod-
els 580SN-WT & 590SN to: 162 – 200 N·m (119.5 –
147.5 lb ft).
RCPH10TLB006ACL 8
10. Repeat steps 1 through 9 for the opposite end of the

axle.
11. Lubricate the king pins.
12. Assemble the planetary according to instructions
Planetary drive and hub - Assemble (25.108).
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Powered front axle - Troubleshooting

695ST

Ring gear tooth broken on Excessive gear load compared to the one Replace bevel gear set
the outer side expected
Incorrect ring gear adjustment (excessive Follow carefully the recommended opera-
backlash) tions for the adjustment of the bevel gear
set backlash
Loose pinion nut Tighten the pinion nut
Ring gear tooth side Load bump Replace bevel gear set
broken
Incorrect ring gear adjustment (insufficient Follow carefully the recommended opera-
backlash) tions for the adjustment of the bevel gear
set backlash
Loose pinion nut Tighten the pinion nut
Worn pinion or ring gear Insufficient lubrication Replace bevel gear set
teeth
Contaminated oil Follow carefully the recommended opera-
tions for the adjustment of the bevel gear
set backlash
Incorrect lubrication or depleted additives Follow carefully the recommended opera-
tions for the adjustment of the bevel gear
set backlash
Worn out pinion bearings that cause an Use proper lubricants, fill up to the right lev-
incorrect pinion axle backlash and wrong els and replace at recommended intervals
contact between pinion and ring gear
Overheated ring gear and Prolonged operation at high temperatures Replace bevel gear set
pinion teeth
Check if ring gear teeth
are damaged
Inappropriate lubricant Use proper lubricants, fill up to the right
Low oil level level and replace at recommended inter-
Contaminated oil vals
Pinion teeth pitting Excessive use Replace bevel gear set
Insufficient lubrication Use correct lubrication, fill up to the right
level and substitute at recommended inter-
vals
Bent axle beam body Overloaded vehicle Replace the axle beam body
Damaged vehicle Replace the axle beam body
Worn out or pitted Insufficient lubrication Replace the bearings and top up oil
bearings
Contaminated oil Change the oil, fill up to right level and re-
place at recommended intervals
Excessive use Replace the bearings
Normal wear Replace the bearings
Oil leakage form the seals Prolonged operation with oil at a high tem- Replace the gasket or seal and matching
perature surface if damaged
Incorrectly installed seal Correctly lubricate and change oil and
seals at recommended intervals
Damaged seal lip Replace the seal
Contaminated oil Change the oil, fill up to right level and re-
place at recommended intervals
Excessive wear of input Use until worn Replace the flange
flange spline
Loose pinion nut Check that the pinion spline is not exces-
sively worn out
Pinion axle backlash Replace bevel gear set if required
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Fatigue failure of pinion Use until worn Replace bevel gear set
teeth. See if the fracture Continuous overload
line is well defined (wave
lines, straight lines)
Pinion and ring gear teeth Crash load of differential components Check and/or replace other differential
breakage components
Worn out side gear spline. Excessive use Replace differential gear group
Replace all scratched Replace the axle shaft if required
washers (excessive
backlash)
Worn out or scored thrust Excessive use Use correct lubrication and fill up to right
washer surface level
Inappropriate lubricant Replace at intervals recommended
Contaminated oil Replace all scratched washers and those
with a thickness by 0.1 mm (0.004 in) lower
than the new ones
Worn out inner diameter Excessive use Replace bearing
of tapered roller bearing
Excessive pinion axial backlash Check pinion axial backlash
Insufficient lubrication Use proper lubrication, fill up to right level
Contaminated oil and replace at recommended intervals
Bent or broken axle beam Intensive use of the vehicle or overloaded Replace the axle beam
vehicle
Axle shaft broken on Loose wheel support Replace the axle beam and check if the
wheel side wheel support is worn out or wrongly ad-
justed
Bent axle beam body Replace the axle beam and check if the
wheel support is worn out or wrongly ad-
justed
Wheel vibration and tire Incorrect installation Correct the installation
resistance
Faulty differential Inspect and repair the axle
Wrong weight distribution Distribute the weight differently
Overload Remove the excessive load
Incorrect tire rotation radius Replace the tire or adjust pressure on both
tires
Bent or broken axle shaft Replace the axle beam
Difficult steering; the Incorrect installation Correct the installation
machine travels in a
straight line while steering
Faulty differential Replace the differential
tires
Excessive noise Incorrect installation Correct the installation
tires
Incorrect wheel alignment Replace the parts and check that the bear-
ings are in good conditions
Incorrect axle part installation Check the installation
Uneven wear of tire Incorrect installation Correct the installation
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tires
Incorrect wheel adjustment Carry out the adjustment and check that the
bearings are in good conditions
Friction noise Incorrect installation Correct the installation
Damaged or worn axle parts Replace the parts and check that the bear-
ings are in good conditions
Presence of foreign objects Discard
Vibrations during travel Incorrect installation Correct the installation
tires
Intermittent noise Damaged ring gear Replace bevel gear
Differential box screws loose Tighten the screws to torque
Incorrect installation Correct the installation
tires
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Index

Axle housing - Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Axle housing - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Axle housing - Exploded view Swivel housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Four-Wheel Drive (4WD) axle - Drain fluid (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Four-Wheel Drive (4WD) axle - Drawing - Front axle-four wheel drive- measuring toe-in . . . . . . . . . 9
Four-Wheel Drive (4WD) axle - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Four-Wheel Drive (4WD) axle - Filling (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Four-Wheel Drive (4WD) axle - General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Four-Wheel Drive (4WD) axle - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Four-Wheel Drive (4WD) axle - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Four-Wheel Drive (4WD) axle - Lubricate (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Four-Wheel Drive (4WD) axle - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Four-Wheel Drive (4WD) axle - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Four-Wheel Drive (4WD) axle - Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Powered front axle - Troubleshooting (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
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Front bevel gear set and differential - 102

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Contents
FUNCTIONAL DATA
Differential
Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SERVICE
Differential
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Disassemble axle housing assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
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Front axle system - Front bevel gear set and differential
Differential - Exploded view

Differential
1. Differential Carrier 7. Crush sleeve 13. Side gear 19. Bolt 25. Bolts
2. Cover 8. Bearing 14. Thrust Washer 20. Bearing caps 26. Locking finger
bolts
3. O-ring 9. Spacer 15. Differential 21. Side gear 27. Locking pin for
housing diff. cross shaft
4. Seal 10. Pinion shaft 16. Bearing 22. Crown gear 28. Differential cross
shaft
5. Outboard bearing 11. Thrust Washer 17. Spanner nut 23. Bearing
6. Washer 12. Spider gear 18. Locking finger 24. Spanner nut
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RCPH10TLB171GAL 1
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Differential - Remove
NOTE: Some images may not represent your machine however the procedure is applicable to your machine.
Prior operation:
Drain the axle fluid. See Four-Wheel Drive (4WD) axle - Drain fluid (25.100).
Prior operation:
Remove the front wheels. See Front wheels - Remove (44.511).
Prior operation:
You may choose to remove the front axle but it is not necessary. See Four-Wheel Drive (4WD) axle - Remove
(25.100).
1. Loosen the tie rod nut.
RCPH10TLB951ABL 1
2. Use a two jaw puller to loosen the ball joint. Remove

the tie rod nut and remove the ball joint from the swivel
housing. Remove the tie rod.
RCPH10TLB952ABL 2
RCPH10TLB484ABL 3
NOTE: Remove and discard nut. DO NOT reuse.
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3. Remove the bolts and use acceptable tools to remove

the top king pin.
RCPH10TLB391ACL 4
4. Remove top king pin.
RCPH10TLB405ACL 5
5. Remove the bottom king pin bolts and use acceptable

tools to remove bottom king pin.
6. Remove the swivel housing.
RCPH10TLB956ABL 6
NOTICE: Take care when removing shaft. Do not cut the seal and bushing on the splines of the axle shaft. Replace
if necessary.
7. Repeat steps 1 through 6 for the other swivel housing.
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8. If applicable, remove the front drive shaft guard.
RCPH11TLB001AAL 7
RCPH11TLB002AAL 8
9. Remove the front drive shaft hardware.
RCPH11TLB003AAL 9
10. Remove the shaft from the yoke.
RCPH11TLB004AAL 10
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RCPH11TLB005AAL 11
12. Loosen and remove the steering cylinder bolts and

washers.
RCPH10TLB957ABL 12
13. Remove the differential carrier bolts.
RCPH10TLB958ABL 13
14. Use suitable lifting equipment and remove the differ-

ential carrier.
RCPH10TLB255ACL 14
Next operation:
Differential - Disassemble (25.102)
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Differential - Disassemble
1. See differential and differential carrier and exploded
view Differential - Exploded view (25.102)
2. Place the differential on an approved working area so
the differential gear is free to rotate.
RCPH10TLB962ABL 1
3. Prevent the pinion shaft from turning. Measure the

backlash of the ring gear. Record the reading.
RCPH10TLB963ABL 2
4. Make an identification mark on the bearing cap and leg

on one side of the differential carrier.
RCPH10TLB964ABL 3
5. Loosen the bolt.
RCPH10TLB964ABL 4
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6. Loosen both adjusting rings. Use DMT100002 tool or

suitable alternative, such as CAS1840C, if available.
RCPH10TLB964ABL 5
NOTE: Record the number of turns while removing the nuts.

7. Remove the bolts. Loosen the 2 bearing caps.
RCPH10TLB966ABL 6
8. Remove the adjusting rings, bearing cups and differen-

tial.
RCPH10TLB989ABL 7
9. If the bearing cups are to be used again, fasten an iden-

tification tag to one bearing cup for the current installa-
tion.
10. Remove the seal and cover.
RCPH10TLB972ABL 8
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11. Use a very narrow chisel/round end punch to unstake

the nut.
RCPH10TLB512ABL 9
12. Use special tool 380000468 and 380100102 or yolk to

remove the pinion nut.
RCPH10TLB263ACL 10
13. Remove the tab washer.
RCPH10TLB976ABL 11
14. Use a press and drive the pinion shaft out of the outer
bearing.
RCPH10TLB977ABL 12
NOTE: Take care to avoid pinion shaft falling on the ground.
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15. Remove the flat washers and crush sleeve. Discard

the crush sleeve. The crush sleeve MUST NOT be
used again.
RCPH10TLB978ABL 13
16. Press the pinion shaft out of the inner bearing.
RCPH10TLB979ABL 14
RCPH10TLB535ABL 15
18. Use a soft punch to remove the bearing cups only if

inspection indicates the need for new parts.
RCPH10TLB531ABL 16
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19. Use an acceptable puller to remove the seal from the

cover, if needed. Discard the seal.
RCPH10TLB713ABL 17
20. Remove and discard the O-ring from the cover.
RCPH10TLB974ABL 18
Next operation:
Differential - Disassemble (25.102)
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Differential - Disassemble axle housing assembly

1. Remove all the bolts (1) that secure the ring gear (3) to
the axle housing (2).
NOTE: You may choose to clamp the assembly in a vice to
hold the housing from turning.
RCPH10TLB967ABL 1
2. Use a soft faced hammer to remove the ring gear and

bushings.
RCPH10TLB968ABL 2
3. Remove the outer side gear and washer.
RCPH10TLB970ABL 3
4. Use a suitable punch to remove retaining pin.
RCPH10TLB928ABL 4
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5. Remove the differential cross pin (3), spider gears (2),

and washers (1).
RCPH10TLB930ABL 5
6. Remove the inner thrust gear (1) and washer (2).
RCPH10TLB931ABL 6
Next operation:
Differential - Inspect (25.102)
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Differential - Inspect
1. Clean all parts in cleaning solvent.
2. Inspect all bearing assemblies for flat areas, pitting,
scoring, and other damage. Also check the races for
damage. If any of these defects are found, a new wheel
bearing and bearing cup must be installed.
3. Inspect the teeth on the pinion gear and ring gear for
pitting, scoring, and broken teeth. The ring gear and
pinion gear must be replaced as a set.
4. Inspect the side gears, the cross pin, and the teeth of
the spider gears for pitting, scoring, and other damage.
Also inspect the thrust surfaces and the bore of each
spider gear. Check the splines (limited slip option only)
in the side gears for wear. Use new parts as required.
Differential gears must be replaced as a set.
5. Inspect the thrust washers for pitting, scoring, and other
damage. Use new parts as required.
6. Inspect the spider shaft for wear. If wear can be felt
with a finger nail, then replace.
Next operation:
Differential - Assemble (25.102)
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Differential - Assemble
1. Install the thrust gear (1) and washer (2) into the axle
housing (3).
RCPH10TLB931ABL 1
2. Install the differential cross pin (1) through both spider

gears (2) and washers (3). Washers are set between
the gear and the axle housing.
RCPH10TLB930ABL 2
3. Use a suitable punch to install the retaining pin (1)

through the differential cross pin (2).
RCPH10TLB928ABL 3
NOTE: Apply TUTELA TRANSAXLE FLUID SAE 80W-140 to all gear and plate contact surfaces before assembly.
4. Install the outer thrust gear (1) and washer (2).
5. Make sure that the mounting surfaces for the ring gear
(3) and axle housing (4) are clean.
RCPH10TLB970ABL 4
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6. Place the axle housing assembly (2) in a vise and po-

sition the ring gear (1) on the assembly.
7. Apply LOCTITE® 242® to the bolts.
RCPH10TLB987ABL 5
8. Install and tighten all the bolts in a star pattern. Torque

bolts to 96 – 118 N·m (70.8 – 87.0 lb ft).
RCPH10TLB988ABL 6
Next operation:
Differential - Assemble (25.102)
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Differential - Install
NOTE: Some images may not represent your machine however the procedure is applicable to your machine.
1. Use suitable lifting equipment and move the differential

carrier into place on the axle.
RCPH10TLB255ACL 1
2. Apply LOCTITE® 243™to the beginning bolt threads and

in a crossing pattern install the bolt hardware.
3. In a crossing pattern torque the bolts to 164 – 174 N·m
(121 – 128 lb ft).
RCPH10TLB958ABL 2
4. Apply LOCTITE® 243™ to the beginning bolt threads of

the steering cylinder bolts.
5. Position the steering cylinder and secure with bolts and
washers. Tighten to a torque of 98 – 118 N·m (72 –
87 lb ft)
RCPH10TLB957ABL 3
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6. Apply MOLYKOTE ® G-N METAL ASSEMBLY PASTE using

a brush application to the female end of the drive shaft
yoke and to the male end of the front axle spline shaft.
7. Slide drive shaft yoke on the spline shaft.
8. Tighten drive shaft dust seal by hand.
9. Install the front drive shaft.
RCPH11TLB005AAL 4
10. Install the shaft to the transmission yoke with bracket

and bolts. Tighten bolts to a torque of 33 – 39 N·m (24
– 29 lb ft).
RCPH11TLB003AAL 5
11. If applicable install the front drive shaft guard. Tighten

to a torque of 50 – 90 N·m (37 – 66 lb ft).
RCPH11TLB001AAL 6
RCPH11TLB002AAL 7
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12. If applicable, drive the bushing into the bore with spe-
cial tool DMT100005 until the bushing is 3.175 mm
(0.125 in) beyond the end of the bore.
13. If applicable, install the seal with special tool
DMT100006.
RCPH10TLB994ABL 8
14. Insert shaft without cutting seal. Maneuver shaft to

align splines with the differential.
NOTICE: Take care not to cut seal during installation. It is
necessary to rotate the input shaft to align splines.
RCPH10TLB956ABL 9
15. Place a belleville washer on the top of the axle hous-

ing.
RCPH10TLB002ACL 10
16. Align the steering knuckle assembly over the axle

housing.
17. Install the top king pin and secure with bolts. Tighten
the bolts to a torque of 154 – 188 N·m (113.6 –
138.7 lb ft).
RCPH10TLB004ACL 11
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18. Place a belleville washer on the bottom of the axle

housing and install the bottom king pin and bolts.
Tighten the bolts to 154 – 188 N·m (113.6 – 138.7 lb
ft).
RCPH10TLB497ABL 12
19. Install the ball joint and new nut.

NOTICE: Always use a new ball joint nut.
RCPH10TLB005ACL 13
20. Tighten the nut for models 580N & 580SN to: 129 –
160 N·m (95.1 – 118.0 lb ft) Tighten the nut for mod-
els 580SN-WT & 590SN to: 162 – 200 N·m (119.5 –
147.5 lb ft).
RCPH10TLB006ACL 14
21. Repeat steps 12 through 20 for the opposite end of

the axle.
22. Lubricate the king pins with TUTELA MULTI -PURPOSE
EP GREASE 251H, GR-9.
23. Fill the Four Wheel Drive (4WD) axle with oil TUTELA
TRANSAXLE FLUID SAE 80W-140. See Four-Wheel
Drive (4WD) axle - Filling (25.100).
24. Install the front wheels. See Front wheels - Install
(44.511).
25. Check the axle fluid level after the first 20 h of opera-
tion.
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Index

Differential - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Differential - Disassemble axle housing assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Differential - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Differential - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Differential - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Differential - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Differential - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
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Final drive hub, steering knuckles, and shafts - 108

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Contents
FUNCTIONAL DATA
Planetary drive and hub

Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SERVICE
Planetary drive and hub

Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
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Front axle system - Final drive hub, steering knuckles, and shafts
Planetary drive and hub - Exploded view

Planetary
1. Drain Plug 6. Planet pinion gear 11. Ring gear 16. Stud
w/needles
2. Drain Plug O-ring 7. Retainers 12. Hub 17. Seal
3. Allen head bolts 8. Bolts 13. Retaining ring
4. Planetary Carrier 9. T-dowels 14. Wheel Bearing
5. O-ring 10. Pinion nut 15. Wheel hub
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RCPH10TLB180GAL 1
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Planetary drive and hub - Disassemble

Prior operation:
Differential - Remove (25.102)
1. See planetary exploded view: Planetary drive and

hub - Exploded view (25.108)
NOTE: The following procedures show the axle already removed from the machine for ease of explanation.
2. Raise the wheel(s) off the floor and use acceptable sup-
ports to hold the machine in position.
3. Remove the bolts and hardened washers and remove
the wheel(s).
4. Drain the oil.
RCPH10TLB276ACL 1
5. Remove the two Allen head bolts 6mm that hold the
carrier.
RCPH10TLB946ABL 2
6. Separate the carrier from the planetary housing using

the 2 prybar slots.
RCPH10TLB277ACL 3
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Planetary Carrier
7. Remove the carrier from the planetary housing.
RCPH10TLB947ABL 4
NOTE: Take care when removing the cover. Pull the cover evenly on both sides to prevent gear damage. Capture
and discard residual oil from the cover.
8. Discard the O-ring.
RCPH10TLB275ACL 5
NOTE: Hub seal should be replaced.

9. Loosen 3 retaining screws 8 mm.
RCPH10TLB292ACL 6
NOTE: Use a hand wrench, not impact gun to avoid gear damage. Use care to avoid stripping socket in bolt head.
Replace bolt if needed. Easy out size 11/32" is effective for stripped bolt head hex sockets.
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10. Mark retainers, gears and pins.
RCPH10TLB360ACL 7
11. Remove retainers.
RCPH10TLB361ACL 8
12. Inspect retainers for dents or damage in roller contact

area.
RCPH10TLB362ACL 9
NOTE: Visually inspect. Also, inspect by running finger around the outer edge of the lower surface. Any detected
dents or damage will require rework to polish off rough edges.
13. During inspection, the use of a magnifying glass is
recommended.
RCPH10TLB363ACL 10
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14. Any dent or rough edge that can be felt or seen must
be reworked.
RCPH10TLB364ACL 11
15. Example of an unacceptable dent in the bearing con-

tact area.
RCPH10TLB365ACL 12
16. For slight damage rework retainer using 400 grit sand-
paper, as shown or replace, as required.
RCPH10TLB366ACL 13
17. Example of reworked retainer with the bearing contact

area removed.
RCPH10TLB367ACL 14
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18. Remove gear, as necessary. and place rollers into

individual containers for possible reuse.
RCPH10TLB360ACL 15
NOTE: . The drain plug has a powerful magnet. The technician may choose to cover the magnet with a rag, tape or
cardboard to allow rollers to be more easily removed from the carrier.
19. Ensure all rollers have been removed and wipe off any
contamination on the drain plug.
RCPH10TLB369ACL 16
NOTE: Thoroughly inspect entire carrier for rollers, including inside the threaded holes in the gear pins.
Hub
20. Use acceptable tools to loosen the crimping on the
nut.
RCPH10TLB279ACL 17
NOTE: Use a very narrow chisel/round end punch to unstake the nut. to avoid gear damage.
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21. Loosen nut. Use a 55mm socket or special tool

380000468.
RCPH10TLB961ABL 18
22. Remove the nut.
RCPH10TLB281ACL 19
23. Remove the bolts for the hub The axle will have either
10 bolts (M10) or 8 bolts (M12).
RCPH10TLB282ACL 20
24. Install two bolts in the two threaded holes in the hub.
Tighten the two bolts evenly until the ring gear is free
of the swivel housing. Use 2 bolts removed from step
22.
RCPH10TLB284ACL 21
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25. Remove the ring gear assembly. See section Axle

housing - Disassemble (25.100) for knuckle re-
moval.
RCPH10TLB285ACL 22
NOTE: Ensure you slide the axle shaft from the swivel housing assembly.
26. If necessary, remove the retaining ring which fastens
the hub in the ring gear.
RCPH10TLB289ACL 23
27. Separate the hub and ring gear.
RCPH10TLB290ACL 24
28. Press the T-dowels from the hub and discard.
RCPH10TLB625ABL 25
NOTE: Manufacturer recommends replacement of T-dowels if they are pressed out of the hub.
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29. Use an acceptable puller to remove the wheel hub

assembly from the swivel housing.
RCPH10TLB299ACL 26
30. Remove the outer wheel bearing.
RCPH10TLB300ACL 27
31. Remove the wheel hub assembly.
RCPH10TLB301ACL 28
32. Remove the cassette seal and bearing cups, as nec-

essary.
RCPH10TLB302ACL 29
NOTE: Cassette seal must be replaced. Replace bearing cups as necessary.
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33. Remove the wheel bearing from the swivel housing, if

necessary.
RCPH10TLB400ACL 30
34. Remove the axle shaft seal.
RCPH10TLB401ACL 31
RCPH10TLB261ACL 32
36. Remove axle shaft ball bearing.
RCPH10TLB260ACL 33
Next operation:
Planetary drive and hub - Inspect (25.108)
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Planetary drive and hub - Inspect

2. Inspect all bearing assemblies for flat areas, pitting,
scoring, and other damage. Also check the races for
damage. If any of these defects are found, a new wheel
bearing and bearing cup must be installed.
3. Inspect the planetary shafts for wear and damage.
4. Inspect the teeth of the planet gears, sun gear and ring
gear for wear, pitting, scoring, and other damage. Use
new parts as required.
Next operation:
Planetary drive and hub - Assemble (25.108)
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Planetary drive and hub - Assemble

Planetary Carrier
1. Install planetary gear over installation tool DMT100002
RCPH10TLB370ACL 1
2. Insert rollers between installation assembly tool and

gear as shown. Apply petroleum jelly to help retain
rollers.
RCPH10TLB371ACL 2
3. Ensure all rollers are installed.
RCPH10TLB372ACL 3
4. Install gears on the same pin they were removed from

using marks as a guide.
RCPH10TLB374ACL 4
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5. Push roller installation tool (DMT100002) off of gear as

gear & rollers engage pin.
RCPH10TLB375ACL 5
6. Confirm all lower rollers are properly installed. After all

3 gears are installed, confirm all lower rollers are prop-
erly installed. After all 3 gears are installed, reorient
planetary carrier horizontally.
RCPH10TLB376ACL 6
7. Install upper rollers into gears, as shown. Ensure all

rollers are installed.
RCPH10TLB402ACL 7
8. Where possible align retainers with the original pin us-

ing the marks applied previously. Align dowel with off-
set hole on retainer.
RCPH10TLB378ACL 8
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9. Use an 8mm allen wrench and tighten. Use torque

wrench Do not use an impact gun.
RCPH10TLB380ACL 9
NOTE: Apply 3 drops of Loctite 242.

10. Tighten to 95 – 105 N·m (70.1 – 77.4 lb ft)
NOTE: Apply approximately 5 drops of MS1317 oil at top of all rollers. Ensure gear has free end play by moving it up
and down. Should be approximately 1 mm play. Spin each gear to make sure they are free to rotate.
11. If bearing cups were removed, use an acceptable
driver to press new bearing cups into the planetary
housing. Special Tool DMT100004
RCPH10TLB578ABL 10
12. The words "OUTSIDE" on the seal must be facing up.

Use hub seal installation tool (DMT100004) to drive
the new seal into the wheel hub. . Use the flat side
of the hub seal installer. Do not damage the seal.
Lightly coat outside diameter of seal with Kluberplus..
Depth: 580N & 580SN 1.5 mm (0.059 in), 580SN-WT
& 590SN 6.5 mm (0.256 in)
RCPH10TLB622ABL 11
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13. Install two new T-dowels 180 degrees apart such that
they protrude 4 mm (0.157 in).
RCPH10TLB626ABL 12
14. Install the hub to the ring gear.
RCPH10TLB624ABL 13
15. Install the retaining ring. Ensure it is fully seated into

the groove.
RCPH10TLB998ABL 14
16. Install inner wheel bearing.
RCPH10TLB400ACL 15
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17. Install the hub. Use a press to pshl hub on evenly and
square to ensure proper seal seating. Seal ID must
have light coat of Kluberplus.
RCPH10TLB387ACL 16
18. Install a wheel bearing on the swivel housing. In-

stallation will be easier if you heat the wheel bearing
slightly. Do not heat the wheel bearing higher than
149 °C (300.2 °F). Use clean gear lubricant to lubri-
cate the wheel bearing.
RCPH10TLB388ACL 17
19. Install the axle shaft bearing. Install snap ring. Install
axle shaft seal to a depth of 6.1 mm (0.240 in).
RCPH10TLB261ACL 18
NOTE: Ensure proper seating of snap ring into groove.

20. Align the two bushings with two of the holes on the
swivel housing, then simultaneously press the heads
of the bushings to install the ring gear assembly.
RCPH10TLB285ACL 19
21. Press remaining T- dowels into place 2 at a time 180

degrees apart.
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22. Apply Loctite to bolts . Instal bolts l and tighten evenly

to pull the ring gear assembly against the swivel hous-
ing. Tighten the bolts in a star pattern to a final torque
of: 580N & 580SN 55 – 68 N·m (40.6 – 50.2 lb ft) and
580SN-WT & 590SN 96 – 118 N·m (70.8 – 87.0 lb ft).
RCPH10TLB282ACL 20
NOTE: Tighten bolts in a star pattern. Rotate hub while tightening bolts to avoid damage to wheel bearings.
23. Install the nut. Use 3 to 4 drops of Loctite 242. Tighten
to 358 – 442 N·m (264.0 – 326.0 lb ft). Use special
tool 380000468 to tighten. Stake the nut in 2 places
approximately 180 degrees apart.
RCPH10TLB961ABL 21
NOTE: Nut staking material should be crimped and not cracked or torn. Ensure opposite side of shaft is secure while
tightening nut.
24. Install a new O-ring on the planetary carrier.
RCPH10TLB275ACL 22
NOTE: Lubricate O-ring with oil prior to installation

25. Install the planetary carrier. Hold planetary carrier in
a level position. Do not force, it may be necessary to
turn input pinion.
RCPH10TLB947ABL 23
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26. Install and tighten the two Allen head bolts to a torque
of 21 – 26 N·m (15.5 – 19.2 lb ft)
RCPH10TLB945ABL 24
27. Lubricate the planetary Powered front axle - General

specification (25.100)
28. Install the wheel(s), hardened washers, and nuts.
Powered front axle - Install (25.100) Tighten the
nuts. Powered front axle - Install (25.100)
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Index

Planetary drive and hub - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Planetary drive and hub - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Planetary drive and hub - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Planetary drive and hub - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
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Non-powered front axle - 400

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Contents
TECHNICAL DATA
Front axle
Special tools (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Torque (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SERVICE
Front axle
Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Inspect (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
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Front axle system - Non-powered front axle
Front axle - Special tools

DRIVE (2WD)
CAS-1842 Wheel stud removal and installation
RCPH10TLB466ABL 1
CAS-2159 Wrench to loosen and tighten tie rods for steer-

ing cylinder
RCPH10TLB235ABL 2
Front axle - Torque

DRIVE (2WD)
Bolts for steering cylinder 335 N·m (247.1 lb ft)

Tie rod ball joint to steering cylinder 300 N·m (221.3 lb ft)
Tie rod to steering knuckle 165 N·m (121.7 lb ft)
Jam nut for tie rod 120 N·m (88.5 lb ft)
Bolts for king pin 120 N·m (88.5 lb ft)
Bolts for bearing caps 120 N·m (88.5 lb ft)
Bearing cap plug 15 N·m (11.1 lb ft)
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Front axle - Remove

DRIVE (2WD)
Prior operation:
Battery - Disconnect (55.302)
Prior operation:
Front wheels - Remove (44.511)
Prior operation:
Power shuttle transmission - Remove (21.112) Steps 2, 3, 4 and 5.
1. Raise and support the machine.

2. Install blocks.
RCPH11TLB136AAM 1
3. Identify, tag and disconnect steering hoses. Cap all

open ports.
RCPH11TLB146AAM 2
4. Remove pivot pin lube line.
RCPH11TLB139AAM 3
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5. Support the front axle.
RCPH11TLB140AAM 4
6. Remove rear pivot pin snap ring.
RCPH11TLB141AAM 5
7. Remove bolt and install slide hammer.
RCPH11TLB142AAM 6
8. Remove pivot pin.
RCPH11TLB143AAM 7
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9. Record and remove shims at the front and rear of the

axle pin tube.
RCPH11TLB144AAM 8
10. Carefully lower and remove the front axle.
RCPH11TLB145AAM 9
Next operation:
Front axle - Disassemble (25.400)
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Front axle - Disassemble

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

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

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

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

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

ing cup for the king pins.
RCPH10TLB611ABL 10
11. If required, remove the front and rear pivot seals and
bushings.
RCPH10TLB612ABL 11
Next operation:
Front axle - Inspect (25.400)
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Front axle - Inspect

DRIVE (2WD)
Prior operation:
Front axle - Disassemble (25.400)

2. Inspect the bearing cups and the rollers in the wheel
bearings for flat areas, pitting, scoring, and other dam-
age. Also check the bearing cones for damage. If any
of these defects are found, new wheel bearing cups
and cones must be installed.
3. Inspect king pin bushings and bearings for flat ar-
eas, pitting, scoring, and other damage. Replace as
needed.
4. Inspect axle pivot bushings and pivot pin for flat ar-
eas, pitting, scoring, and other damage. Replace as
needed.
5. Remove and discard all seals and O-rings.
Next operation:
Front axle - Assemble (25.400)
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Front axle - Assemble

DRIVE (2WD)
Prior operation:
Front axle - Inspect (25.400)
1. Install bushings and seals in the pivot on the axle beam.
RCPH10TLB612ABL 1
NOTE: To ease installation, cool bushings to -100 °C (-148.0 °F).

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

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

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

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

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

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

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

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

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

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

(121.7 lb ft).
RCPH10TLB603ABL 14
Toe-in Adjustment
15. Place two 1 m (39.37 in) bars on the wheel hubs with
500 mm (19.69 in) on each side of the center line of
the axle.
RCPH10TLB618ABL 15
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16. Use lug nuts to hold the bars into place on the wheel
hub.
RCPH10TLB619ABL 16
17. Measure the distance between the bars, adjust the

toe-in so that (A) is -12 – -24 mm (-0.47 – -0.94 in).
RCPH10TLB718ABL 17
18. Snug the jam nuts for the tie rods and recheck toe-in.
RCPH10TLB620ABL 18
19. Torque the jam nut to 120 N·m (88.5 lb ft).
RCPH10TLB621ABL 19
Next operation:
Front axle - Install (25.400)
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Front axle - Install

DRIVE (2WD)
Prior operation:
Front axle - Remove (25.400)
1. Raise the axle into alignment with the machine.
RCPH11TLB140AAM 1
2. Install a spacer (5) between the front of the axle and

the frame.
RCPH11TLB144AAM 2
3. Start the pivot pin (4) into the frame, spacer(s) (5) and
axle.
4. Drive the pivot pin (4) into the rear pivot of the axle but
not through the rear pivot.
5. Install the washer (2) between the rear of the axle and
the frame.
NOTE: Remove or install washer(s) (2) as required be-
tween the axle and the frame to remove any and play.
6. Drive the pivot pin (4) through the rear pivot and the
frame.
7. Install the bolt and snap rings.
RCPH11TLB142AAM 3
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8. Connect the lubrication hose (1) to the fitting.
RCPH11TLB139AAM 4
9. Loosen and remove the plugs from the hoses and the
caps from the fittings for the steering cylinder.
10. Connect the hoses to the steering cylinder.
RCPH11TLB146AAM 5
11. Install the wheels and wheel bolts. do not use an

impact wrench to tighten the wheel bolts. Refer to
Front wheels - Install (44.511).
12. Remove the stands and lower the wheels to the floor.
13. Lubricate the pivot pin (4) for the axle.
14. Check and adjust the toe-in according to Four-Wheel
Drive (4WD) axle - Drawing - Front axle-four wheel
drive- measuring toe-in (25.100).
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RCPH10TLB129GAL 6
(1) Remote grease hose (4) Pivot pin

(2) Washer thrust (5) Spacer
(3) Snap ring
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Index

Front axle - Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Front axle - Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Front axle - Inspect (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Front axle - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Front axle - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Front axle - Special tools (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Front axle - Torque (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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PRINTED IN U.S.A.
48090752 24/02/2017
EN
SERVICE MANUAL
Rear axle system

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27
Contents
Rear axle system - 27
[27.100] Powered rear axle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27.1
[27.106] Rear bevel gear set and differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27.2
[27.120] Planetary and final drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27.3
[27.450] Rear-powered steerable axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27.4
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27
Powered rear axle - 100

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Contents
TECHNICAL DATA
Powered rear axle

Rear axle
FUNCTIONAL DATA
Rear axle
Powered rear axle - Exploded view - Front flange (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
SERVICE
Powered rear axle

Lubricate (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Service instruction (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Disassemble - Front flange (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Assemble - Front flange (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
DIAGNOSTIC
Powered rear axle

Troubleshooting 2WS (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
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Rear axle system - Powered rear axle
Powered rear axle - General specification

580ST
590ST
695ST
2WS Rear axle

Model (580ST) CARRARO 28.44
Model (590ST) CARRARO 28.50
Type Rigid
4WS Rear axle (695ST)

Model CARRARO 26.32M
Type Steering
Differential lock Electric
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Rear axle - General specification

MARBLE CUTTING
DRIVE (2WD)
590ST
2WS rear axle
LELI12TLB1372GB 1
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27.1 [27.100] / 4
Model 28.50
Bevel gear reduction ratio 2.75/1
Epicyclic gear ratio 6.40/1
Total reduction ratio 17.6/1
Input rotation Clockwise
Dry weight 472 kg (1041 lb)
Differential type Mechanical and driven
Pressure for differential lock 12 – 35 bar (174 – 508 psi)
Bevel gear set backlash 0.20 – 0.35 mm (0.008 – 0.014 in)
Pinion bearing preload (*)
FPm= 10.0 – 12.0 daN (22.48 – 26.98 lbf)
(measured on Ø 39.7 mm (1.56 in) without seal ring)
Ring gear-pinion bearing total preload (*) FTm = (FPm + 2.76) ÷ (FPm + 4.16) daN
(measured on Ø 39.7 mm (1.56 in) without seal ring) [FTm = (FPm + 6.20) ÷ (FPm + 9.35) lbf]
Pinion bearing rolling torque (*) measured without seal
MPm = 2.0 – 2.4 N·m (1.48 – 1.77 lb ft)
ring
Total pinion-ring gear bearing rolling torque (*) measured MTm = (MPm + 0.55) ÷ (MPm + 0.83) Nm
without seal ring [MTm = (MPm + 0.40) ÷ (MPm + 0.61) lbf·ft]
(*) Only for new bearings
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Powered rear axle - Exploded view - Front flange

MARBLE CUTTING
DRIVE (2WD)
590ST
LELI12TLB0982GB 1
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Powered rear axle - Lubricate

MARBLE CUTTING
DRIVE (2WD)
590ST
Oil capacity (differential) 15.5 l (3.41 UK gal)

Oil type AMBRA TRX 80W -140 NH600 / TR
LELI12TLB1374FB 1
1. Level and fill plug for differential oil

2. Differential oil drain plug
3. Oil breather
4. Oil drain plug
5. Brake breather
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WARNING
Pressurized system!
ous injury.
W1044A
Before draining the oil from the axle body, use the
LELI12TLB1375AB 2
1. To drain the oil from the central body remove the level
plug (1) and the drain plug (2).
2. Drain all the oil.
3. Clean and install the plug (2). Torque to 80 N·m (59 lb
ft).
4. Fill through the hole of the plug (1).
6. Clean and install the plug (2). Torque to 80 N·m (59 lb
ft).
LELI12TLB1376AB 3
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Powered rear axle - Service instruction

MARBLE CUTTING
DRIVE (2WD)
590ST
Same of the following pictures may not exactly show

your axle, but the procedure is correct.

A. LOCTITE® 510™
B. LOCTITE® 270
C. LOCTITE® 638™
LELI12TLB1380GA 1
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Grease points
LELI12TLB0981GA 2
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Powered rear axle - Disassemble - Front flange

MARBLE CUTTING
DRIVE (2WD)
590ST
1. Remove the snap ring (1) and front flange (2).

2. Remove the shim (4) and O-ring (3).
LELI12TLB0983AB 1
3. Remove the seal ring (5) from the housing (6).

NOTICE: The seal ring can be damaged.
LELI12TLB0984AB 2
4. If necessary, remove the seal (7) from the front flange

(2).
LELI12TLB0985AB 3
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Powered rear axle - Assemble - Front flange

MARBLE CUTTING
DRIVE (2WD)
590ST
1. Install the seal (7) on the front flange (2) with the tool
380200277.
LELI12TLB0985AB 1
LELI12TLB0986AB 2
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2. Install a new seal ring (5) in the housing (6) with the tool
380200276.
LELI12TLB0984AB 3
LELI12TLB0987AB 4
3. Apply grease on the O-ring (3).

4. Install the washer (4), O-ring (3) and front flange (2) on
the pinion.
LELI12TLB0983AB 5
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Powered rear axle - Troubleshooting 2WS

MARBLE CUTTING
DRIVE (2WD)
590ST

Wheel vibrations Incorrect installation Correct the installation
Axle faulty Inspect and repair the axle
tires
Axle beam bent Replace the axle beam
Tire resistance Incorrect installation Correct the installation
Axle faulty Inspect and repair
tires
Broken axle shaft Incorrect installation Correct the installation
tires
Difficult steering; the Incorrect installation Correct the installation
machine travels in a
straight line while steering
tires
No differential action; Incorrect installation Correct the installation
jams during steering
Excessive noise Incorrect installation Correct the installation
tires
Incorrect wheel alignment Check that the structure and the bearings
are in good conditions
Excessive wear of the tire Incorrect installation Correct the installation
tires
Differential locked Check the installation
Excessive steering angle Reduce the steering angle
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Incorrect wheel alignment Check that the structure and the bearings
are in good conditions
Friction noise Incorrect installation Correct the installation
Damaged or worn axle parts Replace the damaged axle parts
Incorrect adjustment of the bevel gear set Adjust the bevel gear set
Vibrations during travel Incorrect installation Correct the installation
Outer tip of ring gear Excessive gear load compared to the one Replace bevel gear
tooth is broken expected
Gear adjustment wrong (excessive back- Follow carefully recommended adjustment
lash) operations of ring gear and pinion backlash
and of tooth marks detection
Pinion nut loose
Inner tip of ring gear tooth Crash load Replace bevel gear
is broken
Gear adjustment wrong (insufficient back- Follow carefully recommended adjustment
lash) operations of ring gear and pinion backlash
Pinion nut loose and of tooth marks detection
Ring gear teeth or pinion Insufficient lubrication Use proper lubricant, fill up to right level and
teeth damaged or scored replace at recommended intervals
Contaminated lubricant Use proper lubricant, fill up to right level and
Incorrect lubrication or poor additives replace at recommended intervals
Worn out pinion bearings that cause an Replace worn out pinion bearings that
incorrect pinion axle backlash and wrong cause an incorrect pinion axle backlash
contact between pinion and ring gear and wrong contact between pinion and ring
gear
Replace bevel gear
Ring gear teeth or pinion Prolonged operation at high temperature Replace bevel gear
teeth overheated. Check
if gear teeth have faded
Unsuitable lubricant Use proper lubricant, fill up to right level and
Oil level low replace at recommended intervals
Contaminated lubricant
Drive pinion teeth pitted Extremely intense use Replace bevel gear
Insufficient lubrication Use proper lubricant, fill up to right level and
replace at recommended intervals
Bent axle beam body Machine overloaded Replace the axle beam body
Damaged vehicle
Crash load
Bearings worn or pitted Insufficient lubrication Replace the bearings
Extremely intense use
Normal wear
Pinion nut loose
Gaskets leak oil Prolonged operation at excessive oil tem- Replace the gasket and matching surface
perature if damaged
Oil gasket wrongly installed Use proper lubricant, fill up to right level and
Gasket edge cut or scored Replace the gasket and matching surface
if damaged
Excessive wear of input Intense use Replace the flange
flange spline
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Pinion nut loose Check that the pinion spline is not exces-
sively worn out
Pinion axial backlash Replace bevel gear, if necessary
Pinion gear tooth fatigue Intense use Replace bevel gear
break
Check if the fracture Continuous overload
line is wavy or clearly
delineated (stop line)
Break of pinion teeth and Crash load of differential components Check and/or replace other differential
ring gear teeth components
Splines of planetary Intense use Replace differential gear assy
gear worn (excessive Replace axle beam, if necessary
backlash)
Worn or scored surfaces Insufficient lubrication Replace all scratched washers and those
of the scraper thrust Lubrication wrong with a 0.1 mm (0.004 in) thickness lower
washer than the new ones
Inner diameter of pinion Intense use Replace bearing
tapered roller bearing
worn out
Excessive pinion end play Check pinion axial backlash
Unsuitable lubrication Use proper lubricant, fill up to right level and
Contaminated lubricant replace at recommended intervals
Broken or bent axle beam Intense vehicle operation, overload Replace the axle beam
Broken axle beam at Loose wheel support Replace the axle beam
wheel flange
Bent axle beam body Check bending of axle beam body. En-
sure that wheel support is not worn out or
wrongly adjusted
Noise during travel Excessive backlash between ring gear and Adjust the backlash between the ring gear
pinion and the pinion
Pinion and ring gear worn Replace pinion and ring gear
Worn-out pinion bearings Replace pinion bearings
Loose pinion bearings Adjust pinion bearings
Excessive pinion end play Adjust the axial play of the pinion
Differential bearings worn out Replace differential bearings
Loose differential bearings Adjust the bearings
Ring gear excessively off-set Replace the ring gear
Low lubricant level Restore the level
Poor or wrong lubricant grade Change lubricant
Noise during idling Noises emitted by the axle when the ve- Adjust the backlash between the ring gear
hicle is moving are usually heard during and the pinion or replace pinion and ring
idling, even though they are not too loud gear
Wrong backlash between pinion and ring Adjust the play between the pinion and the
gear (the noise heard while decelerating ring gear
disappears when speed is increased)
Pinion spline or input flange worn Replace the pinion
Intermittent noise Damaged ring gear Replace bevel gear
Differential box screws loose Tighten the screws to torque
Constant noise Ring gear teeth or pinion teeth damaged Replace bevel gear
Worn bearings Replace the bearings
Pinion splines worn Replace the pinion
Noise while bending Differential planetary gears damaged Replace the planetary gears
Differential box and/or pins worn Replace the differential box
Worn differential thrust washers Replace the thrust washers
Worn-out axle beam splines Replace the axle beam
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Index

Powered rear axle - Assemble - Front flange (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Powered rear axle - Disassemble - Front flange (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Powered rear axle - Exploded view - Front flange (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Powered rear axle - General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Powered rear axle - Lubricate (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Powered rear axle - Service instruction (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Powered rear axle - Troubleshooting 2WS (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Rear axle - General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
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Rear bevel gear set and differential - 106

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Contents
FUNCTIONAL DATA
Bevel pinion
Exploded view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Differential
Exploded view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Differential housing
Exploded view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Differential lock
Exploded view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
SERVICE
Bevel pinion
Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Differential
Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Differential housing
Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Differential lock
Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
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Rear axle system - Rear bevel gear set and differential
Bevel pinion - Exploded view

MARBLE CUTTING
DRIVE (2WD)
590ST
LELI12TLB1435FB 1
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Differential - Exploded view

MARBLE CUTTING
DRIVE (2WD)
590ST
LELI12TLB1411GB 1
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Differential housing - Exploded view

MARBLE CUTTING
DRIVE (2WD)
590ST
LELI12TLB2125FB 1
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Differential lock - Exploded view

MARBLE CUTTING
DRIVE (2WD)
590ST
LELI12TLB2133FB 1
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Bevel pinion - Disassemble

MARBLE CUTTING
DRIVE (2WD)
590ST
2WS
1. Measure the starting preload FP0 of the pinion bearings
using a dynamometer whose cord is wound on the end
of the pinion shaft.
NOTICE: Note value FP0 that is necessary for assembling
the bearings.
LELI12TLB1344AA 1
2. Measure the rolling torque MP0 of the bearings, using

a torque wrench and tool 380200269.
NOTICE: Note value MP0 that is necessary for assembling
the bearings.
LEPH12TLB1345AA 2
3. Lock the differential assy in a vice.

4. Unscrew the ring nut (1) using special tools 380000268
and 380000269.
NOTE: This operation will irretrievably damage the lock nut
(1).
LEPH12TLB1346AB 3
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5. Remove the ring nut (1) and collect its washer (2).
LEPH12TLB1347AB 4
6. Tap the shaft end with a soft hammer to remove the

pinion (3).
7. Collect the washers (4) and (5), the spacer (6) and the
bearing (7).
LELI12TLB1348AB 5
8. Remove the bearing cups (7) and (8) from the differen-
tial support (9) using a buffer and a hammer.
LEPH12TLB1349AB 6
9. Remove the bearing (8) from the pinion (3) by means

of a puller.
10. Collect the shim (10).
LEPH12TLB1350AB 7
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11. Check the conditions of all pinion parts.

12. The ring nut (1) and the spacer (6) must be replaced
during assembly.
LELI12TLB1351AB 8
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Bevel pinion - Assemble

MARBLE CUTTING
DRIVE (2WD)
590ST
1. Place the differential housing (9) on a workbench.

2. Install the bearing cups (7) and (8) with the buffer
380200274 and a hammer.
LEPH12TLB1352AB 1
3. Install the bearings (7) and (8) into the relevant seats.
4. Install the tool 380200273 (a1) and ring nut (1).
5. Tighten the tool without exceeding the ring nut, until the
backlash is eliminated.
LELI12TLB1353AB 2
6. Install the tool 380200187 (T) on the differential box

seats (9).
LEPH12TLB1354AB 3
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7. Use a depth gauge to measure dimension (X) (distance

between bearing axis of differential box and leaning
point of pinion head or bearing base).
LEPH12TLB1355AA 4
8. To adjust the bevel gear, measure the distance (A) with

a depth gauge.
9. Determine the value (X) as follows:
X = (A + C) - B
where “B” and “C” are known values.
LELI12TLB1356AA 5
10. In order to determine the value (S) of the shim to be

placed between pinion and bearing, subtract from the
measured value (X) the value (V) engraved on pinion
head (V = prescribed distance).
S = (X - V)
LEPH12TLB1357AB 6
11. Select the shim (10) with value (S) from the range of
available shims, and fit it onto the shaft end under the
pinion head.
LEPH12TLB1358AB 7
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Shim range
Shims 2.5 mm ( 2.6 mm ( 2.7 mm ( 2.8 mm ( 2.9 mm ( 3.0 mm ( 3.1 mm ( 3.2 mm ( 3.3 mm ( 3.4 mm (
0.098 in) 0.102 in) 0.106 in) 0.110 in) 0.114 in) 0.118 in) 0.122 in) 0.126 in) 0.130 in) 0.134 in)
Qty. - - - - - - - - - -
12. Remove the tool 380200187 from the seats (9) of the
differential box.
13. Remove the ring nut, spacer, tool 380200273 and
bearings (7) and (8).
LELI12TLB1451AB 8
14. Install the suitable shim (10) on the pinion shaft with
the chamfer against the pinion head.
LELI12TLB1361AB 9
15. Install the bearing (8) on the pinion (3) using a press
and a buffer 380200220.
LEPH12TLB1362AB 10
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16. Insert the pinion (3) into the differential box (9). Insert
the shims (4) and (5) and spacer (6).
NOTE: Always use a new spacer (6).
LEPH12TLB1363AB 11
LELI12TLB1364AB 12
17. Install the bearing (7) on pinion shaft with buffer

LEPH12TLB1365AB 13
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18. Install the washer (2) and new ring nut (1) on the pin-
ion shaft. Torque the ring nut (1) using the wrench
380200268 and pinion retainer 380200269.
NOTICE: Lubricate the ring nut thread (1) and supporting
face of the washer (2) with oil.
NOTICE: Tighten the ring nut (1) until the preload on bear-
ings (7) and (8) is the same before disassembly.
NOTE: If the tightening is excessive, spacer (6) must be
replaced and procedure repeated.
19. Before checking the preload, strike the pinion end (3)
with a soft hammer. This will help the proper seating
of the bearings (7) and (8) in their seats.
LEPH12TLB1366AB 14
LEPH12TLB1346AB 15
20. If the bearings have not been replaced, to measure

the preload FPm of the bearings (7) and (8), use a dy-
namometer whose cord is wound on the end of pinion
shaft (3). The measured value should be within the
following range:
• FPm = FP0 ÷ (FP0 + 10) N
[FPm = FP0 ÷ (FP0 + 2.25) lbf]
LELI12TLB1344AA 16
21. If the bearings have not been replaced, it is possible

to measure the rolling torque MPm of the bearings (7)
and (8), using a torque wrench and tool 380200269.
The measured value should be the same of the start-
ing:
MPm = MP0
NOTE: Use this method only if the bearings are not re-
placed.
NOTE: All pre-loads must be measured without seal rings.
LEPH12TLB1345AA 17
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22. If the bearings (7) and (8) are new, to measure the
preload FPm of the bearings, use a dynamometer
whose cord is wound on tool 380200272, inserted on
the end of pinion shaft.
LELI12TLB1458AB 18
23. Measure the preload FPm with the tool 380200272

(gauge diameter Dm = 119.1 mm (4.69 in)). The mea-
sured value should be within the following range:
1. FPm = 33.3 – 40 N (7.49 – 8.99 lb)
NOTE: Values for new bearings.
LELI12TLB1368AA 19
24. In case you do not use the prescribed tool to measure

the preload, reference diameter is the diameter of pin-
ion shaft splined end. The measured value should be
within the following range:
• FPm = 100 – 120 N (22.48 – 26.98 lb)
LELI12TLB1344AA 20
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25. If the bearings are new, measure the rolling torque

MPm of the pinion shaft bearings with a torque meter
and wrench 380200269. The measured value MPm
should be within the following range:
1. MPm = 1.6 – 2.4 N·m (1.18 – 1.77 lb ft)
NOTE: All pre-loads must be measured without seal rings.
LEPH12TLB1369AA 21
LELI12TLB1370AA 22
26. Once the prescribed preload value is achieved, caulk

the ring nut (1) using a hammer and a punch.
LEPH12TLB1371AB 23
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Differential - Disassemble
MARBLE CUTTING
DRIVE (2WD)
590ST
1. Loosen and remove the screws (1).

2. Remove the ring gear (2).
LELI12TLB1412AB 1
3. If necessary, replace the differential bearings.

4. Remove the bearing cups (3) and (4).
LELI12TLB1413AB 2
LELI12TLB1414AB 3
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7. Open the cover (7) and remove the anti-rotation pin (8)
and the ring (9).
LELI12TLB1415AB 4
LELI12TLB1416AB 5
9. Remove the dowels (11).
LELI12TLB1417AB 6
10. Remove the pins (12).
LELI12TLB1418AB 7
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11. Slide the pin (13) until the gear (14) is free.
LELI12TLB1419AB 8
12. Remove the gear (14) and shoulder ring (15).
LELI12TLB1420AB 9
13. Remove the pin (13), gear (16) and shoulder ring (17).
LELI12TLB1421AB 10
14. Pull out the pins (18) partially and remove the spacer
(19).
LELI12TLB1422AB 11
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15. Remove the pins (18), gears (20) and shoulder rings
(21).
LELI12TLB1423AB 12
16. Remove the gear (22) and the relevant ring (23).
LELI12TLB1424AB 13
17. Remove the pins (25) locking the differential box (24).
LELI12TLB1425AB 14
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Differential - Assemble
MARBLE CUTTING
DRIVE (2WD)
590ST
LEPH12TLB1426AB 1
2. Install the pins (25) into the differential box (24).
LELI12TLB1425AB 2
3. Install the gear (22) and relevant ring (23).
LELI12TLB1424AB 3
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4. Install the gears (20) and shoulder rings (21). Insert the
pins (18) just enough to hold the gear in place.
NOTE: Align the flat face of the pins upwards.
LELI12TLB1423AB 4
5. Install the spacer (19) with the pins (18). Align the pin
holes with those of the differential box (24).
LELI12TLB1427AB 5
6. Install the gear (16) and shoulder ring (17) with the pin
(13).
NOTE: Align the flat face of the pin upwards.
LELI12TLB1421AB 6
7. Install the gear (14) and shoulder ring (15) with the pin
(13). Align the pin hole with that of the differential box
(24).
LELI12TLB1428AB 7
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8. Insert the studs (12) and nuts (11). Torque the nuts to
25 N·m (18.4 lb ft)
LELI12TLB1429AB 8
LELI12TLB1416AB 9
10. Apply a thin film of grease on the cover (7). Install the
ring (9) on the cover (7).
LELI12TLB1430AB 10
11. Install the anti-rotation pin (8) and cover (7) on the
differential box.
LELI12TLB1431AB 11
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12. Secure the cover (7) in place with the snap ring (6).
LELI12TLB1432AB 12

NOTE: To ease the installation, turn the gear (22).
LELI12TLB1433AB 13
14. Install the bearing cups (3) and (4) with drift
380200218.
NOTICE: Take care not to mix the bearing cups.
LELI12TLB1434AB 14
15. Install the ring gear (2) with the bolts (1). Torque the
bolts to 190 N·m (140 lb ft).
LELI12TLB1412AB 15
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Differential housing - Disassemble

MARBLE CUTTING
DRIVE (2WD)
590ST
1. Drain the oil completely from the differential.
LEPH12TLB2126AA 1
LEPH12TLB2127AB 2
3. Separate the differential housing (3) from the axle body

(2) using pry bars in slots.
LEPH12TLB0718AB 3
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4. Lift the differential housing (3) with a lifting device of

adequate capacity.
LEPH12TLB0719AB 4
5. Measure the rolling torque MT0 of the bearings (pinion-

ring gear system) with the torque wrench 380200269.
NOTE: The total rolling torque must be determined without
the pinion seal ring.
NOTICE: MT0 will be required for the reinstallation of the
bearings.
LEPH12TLB0720AA 5
6. Measure the total starting preload FT0 of the bearings

(pinion-ring gear system) using a dynamometer whose
cord is wound on the end of the pinion shaft.
NOTICE: FT0 will be required for the reinstallation of the
bearings.
LELI12TLB0721AA 6
7. Remove the bolts (4) which secures the ring nuts (5)
and (6).
LEPH12TLB0722AB 7
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8. Remove the ring nuts (5) and (6) with the tool
380200243.
LEPH12TLB0723AB 8
9. Remove the differential box (7) and bearing cups (8)

and (9).
NOTICE: Remove the bearing cups (8) and (9) along with
the differential box (7).
LEPH12TLB0724AB 9
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Differential housing - Assemble

MARBLE CUTTING
DRIVE (2WD)
590ST
1. Install the bearing cups (8) and (9) on the differential

box (7) with the drift 380200218.
LEPH12TLB0725AB 1
2. Install the differential box (7) with the bearings in the

differential housing (3).
LEPH12TLB0726AB 2
3. Install the ring nuts (5) and (6) with special tool
380200243. Tighten until the backlash is eliminated
and the bearings are slightly pre-loaded.
4. Check that the bearings are correctly seated.
LEPH12TLB2128AB 3
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5. Position a magnetic-base dial gauge on the differential

support, so that the feeler touches the surface of one
tooth of the ring gear with a 90° angle.
LEPH12TLB0727AA 4
6. Lock the pinion and move the ring gear, and note the
backlash between pinion and ring gear, measured with
the dial gauge.
7. Repeat the operation on two or more points (teeth), ro-
tating the ring gear, so that to obtain an average value.
8. Check if the measured backlash value is within 0.2 –
0.35 mm (0.008 – 0.014 in)
LEPH12TLB2129AB 5
9. If the backlash is not within specified limits, adjust the

ring nuts (5) and (6) with tool 380200243. Adjust as
follows until the backlash is within specified limits:
• If the measured backlash is less than the prescribed
tolerance range, loosen the ring nut (6) and tighten
the ring nut (5) by the same measure.
• If the measured backlash is more than the prescribed
tolerance range, loosen the ring nut (5) and tighten
the ring nut (6) by the same measure.
LELI12TLB0734AB 6
10. Once the pinion-ring gear backlash has been ad-

justed, if the bearings have not been replaced,
measure the total preload FTm of the bearings (pin-
ion-ring gear system), using a dynamometer whose
cord is wound on the end of the pinion shaft. The
measured value FTm should be within the following
range:
• FTm = FT0 ÷ (FT0 + 10) N
[FTm = FT0 ÷ (FT0 + 2.25) lbf]
NOTICE: Use this method only if the bearings are already
run in.
LELI12TLB0721AA 7
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justed, if the bearings have not been replaced,
measure the total rolling torque MTm of the bearings
(pinion-ring gear system) with a torque meter and
the special wrench 380200269. The measured value
MTm should be the same of the starting:
• MTm = MT0
LEPH12TLB0720AA 8
12. If the bearings have been replaced, measure the total

preload FTm of the bearings (pinion-ring gear system),
using a dynamometer whose cord is wound on tool
380200272 inserted on the pinion splined end.
LELI12TLB0730AA 9
13. Measure the pre-load FTm with the tool 380200272.

The measured value should be within the following
range:
• FTm = (FPm + 9.2) ÷ (FPm + 13.8) N
FTm = (FPm + 2.07) ÷ (FPm + 3.10) lbf
NOTE: FPm is the actual pre-load measured on tool
380200272 [gauge diameter Dm = 119.1 mm (4.69 in)].
NOTICE: All pre-loads must be measured without seal
rings.
LELI12TLB0731AA 10

justed, if the bearings have been replaced, measure
the total rolling torque MTm of the bearings (pinion-
ring gear system) with a torque meter and the wrench
380200269.
LELI12TLB0733AA 11
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15. If the pre-load is not within the requested range, adjust

the ring nuts (5) and (6) until the pre-load is within
specified range:
• If the total preload is less than the given range,
screw on the ring nuts (5) and (6) by the same mea-
sure, keeping the pinion-ring gear backlash value
unchanged.
screw on the ring nuts (5) and (6) with the same
measure, keeping the pinion-ring gear backlash
value unchanged.
LELI12TLB0734AB 12
16. Paint the ring gear with red lead paint and test the
marks of the bevel gear teeth. The contact mark test
should always be carried out on the ring gear teeth
and on both sides.
LELI12TLB0738AA 13
17. If the bevel gear is well adjusted, the mark on the teeth
surfaces will be regular.
• OK -> Correct contact
• Z -> Excessive contact on the tooth tip: Approach
the pinion to the ring bevel gear and then move
the ring bevel gear away from the pinion in order
to adjust the backlash.
• X -> Excessive contact at the tooth base: Move
the pinion away from the ring bevel gear and then
approach the ring bevel gear to the pinion in order
to adjust the backlash.
LELI12TLB0739AA 14
1. Move the pinion for type X contact adjustment.

2. Move the pinion for type Z contact adjustment.
LELI12TLB0740AB 15
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18. Once all the adjustment operations have been com-

pleted, secure the ring nuts (5) and (6) with the bolts
(4). Torque the bolts to 10 N·m (7.4 lb ft)
LEPH12TLB2130AB 16
19. Apply a film of sealant on the contact surface of the

axle body (2) and the differential support.
NOTICE: Before matching worked surfaces, make sure
they are perfectly clean, if not, clean with proper deter-
gents.
LEPH12TLB2131AB 17
20. Place the differential housing (3) on the axle body (2)
and install with the bolts (1). Torque the bolts (1) to
169 N·m (125 lb ft)
LEPH12TLB0737AB 18
LEPH12TLB2127AB 19
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Differential lock - Disassemble

MARBLE CUTTING
DRIVE (2WD)
590ST
1. Loosen plug (1) without removing it.
LELI12TLB1410AB 1
2. Push the yoke (2) downwards using the differential sup-

port as a retainer, then remove the plug (1).
LEPH12TLB1409AB 2
3. Insert the tool 380200259.
LELI12TLB0743AA 3
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4. Remove the snap ring (5) and tool 380200259.
LELI12TLB2132AB 4
5. Remove the bushing (6).
LEPH12TLB0746AB 5
LELI12TLB1381AB 6
7. Remove the springs (4) and (8) and spacer (9).
LELI12TLB1382AB 7
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8. Extract the rod assembly (3) from the differential hous-

ing.
LELI12TLB1383AB 8
9. Remove the O-ring (10) from the plug (1).

LEPH12TLB1384AB 9
11. Remove the O-ring (14) from the plug (7).
LELI12TLB1385AB 10
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Differential lock - Assemble

MARBLE CUTTING
DRIVE (2WD)
590ST
1. Install the O-ring (14) on the plug (7).
LELI12TLB1385AB 1
2. Install the O-rings (12) and (13) on the piston (11).

3. Install the O-ring (10) on the plug (1).
4. Lubricate the O-rings.
LEPH12TLB1384AB 2
5. Install the rod (3) and yoke (2) in the differential hous-
ing.
NOTE: Align the rod (3) with the outer groove (A) directed
towards the yoke (2).
LELI12TLB1386AB 3
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6. Install the springs (4) and (8) and spacer (9).
LELI12TLB1382AB 4
7. Install the plug (1) to the prescribed torque of 80 N·m

(59 lb ft).
LELI12TLB1387AB 5
8. Install the bushing (6).
LELI12TLB1388AB 6
9. Install the tool 380200259 (T1).
LELI12TLB1389AB 7
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10. Install the snap ring (5) with the tool 380200260 (T2).
11. Remove tools 380200259 (T1) and 380200260 (T2).
LELI12TLB1408AB 8
12. Push the yoke (2) downwards using the differential

support as a retainer.
13. Install the plug (1) by hand.
LEPH12TLB1409AB 9
14. Torque the plug (1) to 30 N·m (22 lb ft).
LELI12TLB1410AB 10
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Index

Bevel pinion - Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Bevel pinion - Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Bevel pinion - Exploded view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Differential - Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Differential - Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Differential - Exploded view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Differential housing - Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Differential housing - Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Differential housing - Exploded view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Differential lock - Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Differential lock - Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Differential lock - Exploded view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
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Planetary and final drives - 120

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Contents
FUNCTIONAL DATA
Planetary and final drives

Exploded view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Component localization (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Wheel hub
Exploded view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
SERVICE
Planetary and final drives

Disassemble the reduction gear (4WS) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Assemble the reduction gear (4WS) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Disassemble the wheel assembly and double joint (4WS) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Assemble the wheel assembly and double joint (4WS) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Replace the seal ring of the double joint (4WS) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Replace the bronze bushing of the double joint (4WS) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Wheel hub
Disassemble (2WS) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Assemble (2WS) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
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Rear axle system - Planetary and final drives
Planetary and final drives - Exploded view

MARBLE CUTTING
4WS - Reduction gear
LELI12TLB1640FB 1
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Planetary and final drives - Component localization

MARBLE CUTTING
4WS - Wheel assembly and double joint
LELI12TLB1594FB 1
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Wheel hub - Exploded view

MARBLE CUTTING
DRIVE (2WD)
590ST
2WS
LELI12TLB1524FB 1
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Planetary and final drives - Disassemble the reduction gear (4WS)

MARBLE CUTTING
1. Remove the plug (1) and drain oil from the reduction
gear.
LEPH12TLB1641AB 1
LELI12TLB1642AB 2
3. Remove the gear carrier (3) and O-ring (9)from the

wheel hub (10).
4. Position the gear carrier (3) on a workbench and check
for wear and condition.
LELI12TLB1643AB 3
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5. Removal of the gears (6):

• Remove the screw (8) of the gear (6).
• Remove the washer (7).
• Remove the gears (6) from the pins.
• Remove the bearings (5) and check their conditions.
• Remove the thrust washer (4).
LELI12TLB1644AB 4
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Planetary and final drives - Assemble the reduction gear (4WS)

MARBLE CUTTING
1. Install the gear carrier, thrust washers (4), gears (6),

needle bearings (5), washers (7) and bolts (8).
NOTICE: With new gears (6), use new bearings (5).
LELI12TLB1644AB 1
2. Position the planetary gears carrier (3) on a workbench.

3. Install the needle bearings (5) in the gears (6).
4. Grease the needle bearings (5).
5. Install the pins, thrust washer (4) and gears (6) with
needle bearing on the planetary gear carrier (3).
LEPH12TLB1645AB 2
6. Install the parts on the pins of the planetary gear carrier

(3) with the bolts (8) and washers (7).
LELI12TLB1646AB 3
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8. Install the new O-ring (9) on the wheel hub (10).
LELI12TLB1647AB 4
9. Install the reduction gear assembly on the wheel hub

with the bolts (2).
10. Torque the bolts (2) to 25 N·m (18.4 lb ft).
LELI12TLB1642AB 5
11. Refill the reduction gearbox with oil.

12. Install the plug (1). Torque to 60 N·m (44 lb ft).
LEPH12TLB1648AB 6
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Planetary and final drives - Disassemble the wheel assembly and

double joint (4WS)
MARBLE CUTTING
1. Drain the oil from the differential.

2. Remove the nut (1) and disconnect the tie rod (3) from
the swivel housing.
NOTICE: Do not hit the end of the threaded pin of the tie
rod (3) during disassembly.
NOTICE: Do not adjust the tie rod (3) with the relevant nut
(4) as this will affect the wheel toe-in.
LEPH12TLB1595AB 1
LEPH12TLB1596AB 2
3. Support the swivel housing on a lifting device of ade-

quate capacity.
4. Remove the bolts (5) and (9) from the upper (6) and
lower (10) king pins.
LELI12TLB1597AB 3
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5. Remove the king pins (6) and (10).
LELI12TLB1598AB 4
6. Remove the wheel hub assembly.
LELI12TLB1599AA 5
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Planetary and final drives - Assemble the wheel assembly and

double joint (4WS)
MARBLE CUTTING
1. Install the wheel hub assembly.
LELI12TLB1600AA 1
2. Grease the king pin seats (6) and (10).

3. Position the belleville washers on the king pin seats.
4. Install the lower (10) and the upper (6) king pins with the
bolts (9) and (5). Torque the bolts to 300 N·m (221 lb
ft).
LELI12TLB1901AB 2
LELI12TLB1902AB 3
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5. Turn the swivel housing as much as necessary and

insert the ball joint of the tie rod (3) into its seat on the
swivel housing (1).
NOTICE: Do not adjust the tie rod (3) with the relevant nut
(4) as this will affect the wheel toe-in.
LEPH12TLB1903AB 4
6. Install the nut (2). Torque to 260 N·m (192 lb ft).
LEPH12TLB1904AB 5
7. Check the differential oil level and top up if neces-

sary through the oil inlet plug (14). Torque the plug to
60 N·m (44 lb ft)
LELI12TLB1905AB 6
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Planetary and final drives - Replace the seal ring of the double
joint (4WS)
MARBLE CUTTING
1. Remove the wheel assembly and double joint (See

Planetary and final drives - Disassemble the wheel
assembly and double joint (4WS) (27.120)).
NOTICE: Do not damage the seat of the seal ring.
LELI12TLB1906AB 1
3. Install the new seal ring (11) with the tool 380002226
and a hammer.
4. Lubricate the seal ring.
LELI12TLB1907AB 2
5. Check the correct place of the seal ring (11) according

to the axle type.
LELI12TLB1908AB 3
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Planetary and final drives - Replace the bronze bushing of the

double joint (4WS)
MARBLE CUTTING
1. Remove the wheel assembly and the double joint (See

Planetary and final drives - Disassemble the wheel
assembly and double joint (4WS) (27.120)).
3. Remove the bronze bushing (13) with a puller.
NOTICE: Do not damage the seat.
LELI12TLB1909AB 1
4. Install the new bronze bushing (13) with the buffer

LELI12TLB1910AB 2
5. Install the seal ring (11).
LELI12TLB1907AB 3
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Wheel hub - Disassemble (2WS)

MARBLE CUTTING
DRIVE (2WD)
590ST
1. Remove the brake assembly.
LEPH12TLB1525AB 1
2. If disassembly of the planetary gear carrier for over-

hauling is not necessary, use a bearing puller to lift the
planetary gear carrier assembly.
LEPH12TLB1526AB 2
3. Release the snap ring (2) and simultaneously remove

the gear carrier (1).
LEPH12TLB1527AB 3
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4. If necessary, remove the snap rings (3), gears (4) and

bearings (5) from the gear carrier (1).
NOTE: The bearing (5) cannot be removed from the gear
(4).
NOTICE: If one gear must be replaced, replace the whole
pair.
LELI12TLB1528AB 4
5. Remove the ring nut (6) fastening the ring gear retain-
ing hub using tool 380200244.
LEPH12TLB0196AB 5
6. Separate the hub (7) from the wheel flange (8) with a
puller.
LEPH12TLB1530AB 6
7. Remove the hub (7) with a lifting device of adequate

capacity.
LEPH12TLB1531AB 7
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9. Remove the bearing cup (9) from the wheel hub (7).
LEPH12TLB1532AB 8
10. Remove the seal ring (10) from the wheel hub (7).
LEPH12TLB1533AB 9
11. Remove the bearing cup (11) from the wheel hub (7).
LEPH12TLB1534AB 10
12. Remove the spacer (12) from the wheel flange (8).
LEPH12TLB1535AB 11
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13. To remove the bearing (11), proceed as follows:

A. Use a disc grinder to cut the cage and to engrave
the ring.
B. Use a chisel to cut and remove the ring.
LEPH12TLB1536AB 12
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Wheel hub - Assemble (2WS)

MARBLE CUTTING
DRIVE (2WD)
590ST
1. Install the bearing cup (11) on the wheel hub (7) with
the tool 380200211.
2. Install the bearing cup (9) with the tool 380002222.
3. Install the seal ring (10) on the wheel hub (7) with the
tool 380200254.
LEPH12TLB1537AB 1
4. Use the tool 380200254 (T) for the assembly of the seal
ring (10) on the wheel hub (7).
LELI12TLB1538AB 2
5. Install the bearing (11) on the wheel flange (8) with a

press.
LEPH12TLB1536AB 3
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6. Install the spacer (12) on the wheel flange (8).
LEPH12TLB1535AB 4
7. Install the wheel hub (7) on the wheel flange (8) with a
lifting device of adequate capacity.
NOTICE: Clean the sealing surface of the flange.
NOTICE: Pay attention not to damage the seal ring (10).
LEPH12TLB1539AB 5
8. Install the bearing (9) and the ring nut (6). Torque
the ring nut (6) to 1200 N·m (885 lb ft) with the tool
380200244.
9. Rotate the hub one turn counterclockwise. Torque the
nut to 1200 N·m (885 lb ft).
10. Repeat steps 8 and 9 for a total of five times.
LEPH12TLB1540AB 6
LEPH12TLB1541AB 7
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11. Install the bearing (5) with tool 380200255 (T).
LEPH12TLB1542AB 8
12. Install the gears (4) and snap rings (3) on the gear
carrier (1).
NOTICE: Make sure that the chamfer of the bearings (5) is
directed towards the gear carrier (1).
LELI12TLB1543AB 9
13. Lift the gear carrier (1) with a lifting device of adequate
capacity and place it on the wheel hub (7).
LEPH12TLB1544AB 10
14. Align the gear carrier so that the tooth engages into
the ring nut (6).
LEPH12TLB1545AB 11
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15. In order to simplify the installation, align the hole on

the gear carrier with the ring nut (6).
NOTE: It may take several attempts to find the right com-
bination of alignment between teeth and hole of the gear
carrier and the ring nut, to get the locking tooth to engage.
LELI12TLB1546AB 12
16. Secure the gear carrier (1) with the snap ring (2).
LEPH12TLB1527AB 13
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Index

Planetary and final drives - Assemble the reduction gear (4WS) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Planetary and final drives - Assemble the wheel assembly and double joint (4WS) (*) . . . . . . . . . . . 12
Planetary and final drives - Component localization (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Planetary and final drives - Disassemble the reduction gear (4WS) (*) . . . . . . . . . . . . . . . . . . . . . . . . 6
Planetary and final drives - Disassemble the wheel assembly and double joint (4WS) (*) . . . . . . . . 10
Planetary and final drives - Exploded view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Planetary and final drives - Replace the bronze bushing of the double joint (4WS) (*) . . . . . . . . . . . 15
Planetary and final drives - Replace the seal ring of the double joint (4WS) (*) . . . . . . . . . . . . . . . . . 14
Wheel hub - Assemble (2WS) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Wheel hub - Disassemble (2WS) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Wheel hub - Exploded view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
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Rear-powered steerable axle - 450

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Contents
TECHNICAL DATA
Rear-powered steerable axle

FUNCTIONAL DATA

Exploded view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Exploded view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Differential carrier assembly
Exploded view - housing (4WS) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Exploded view - Bevel pinion (4WS) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Exploded view - Non-self-locking differential (4WS) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Exploded view - Limited slip differential (4WS) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Wheel hub
Exploded view - 4WS (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
SERVICE

Disassemble the beam assembly (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Assemble the beam assembly (4WS) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Service instruction (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Disassemble the front flange (4WS) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Assemble the front flange (4WS) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Lubricate (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Differential carrier assembly
Remove (4WS) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Disassemble - Bevel pinion (4WS) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Disassemble - Non-self locking differential (4WS) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Assemble - Non-self locking differential (4WS) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Disassemble - Limited slip differential (4WS) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
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Assemble - Limited slip differential (4WS) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Assemble - Bevel pinion (4WS) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Install (4WS) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Wheel hub
Disassemble (4WS) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Assemble (4WS) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
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Rear axle system - Rear-powered steerable axle
Rear-powered steerable axle - General specification

MARBLE CUTTING
4WS Rear axle
LELI12TLB1064GA 1
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Model 26.32M
Maximum steering angle 20-21°
Toe-in A±1
Bevel gear reduction ratio 2.750/1
Epicyclic gear ratio 6.923/1
Total reduction ratio 19.038/1
Input rotation clockwise
538 kg
Dry weight
(1186 lb)
Differential type Limited slip or open
0.15 – 0.30 mm
Bevel gear set backlash
(0.006 – 0.012 in)
Pinion bearing preload (*)
FP = 92 – 138 N (21 – 31 lb)
(measured on ø = 34.8 mm without seal ring)
Ring gear-pinion bearing total preload (*) FT = (FP + 33.4) - (FP + 50.2) N
(measured on ø = 34.8 mm without seal ring) [FT = (FP + 7.5) ÷ (FP + 11.29) lbf]
Pinion bearing rolling torque (*) measured without seal ring MP = 1.6 – 2.4 N·m (1.18 – 1.77 lb ft)
Total pinion-ring gear bearing rolling torque (*) measured without MT = (MP + 0.58) ÷ (MP + 0.87) Nm
seal ring [MT = (MP + 0.43) ÷ (MP + 0.64) lbf·ft]
(*) Only for new bearings
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Rear-powered steerable axle - Exploded view

MARBLE CUTTING
4WS - Beam assembly
LELI12TLB1463GB 1
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Rear-powered steerable axle - Exploded view

MARBLE CUTTING
4WS - Front flange
LELI12TLB1077FB 1
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Differential carrier assembly - Exploded view - housing (4WS)

MARBLE CUTTING
LELI12TLB1818FB 1
(1) Differential housing (central body) (6) Brake cylinder

(2) O-rings (7) Bolts
(3) Differential (8) Ring nut
(4) O-rings (9) Ring nut retainer
(5) Bearing cup (10) Ring nut retainer bolts
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Differential carrier assembly - Exploded view - Bevel pinion (4WS)

MARBLE CUTTING
LELI12TLB1555FB 1
(1) Pinion shaft (6) Washer

(2) Shim (7) Differential housing (central body)
(3) Bearing cup (8) Bearing
(4) Washer (9) Washer
(5) Spacer (10) Ring nut
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Differential carrier assembly - Exploded view - Non-self-locking

differential (4WS)
MARBLE CUTTING
LELI12TLB1846GB 1
(1) Bolts (8) Planetary gears

(2) Ring gear (9) Thrust washer
(3) Bearing (10) Gear
(4) Half box (11) Differential locking counter discs
(5) Differential locking counter discs (12) Half box
(6) Gear (13) Bearing
(7) Pins
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Differential carrier assembly - Exploded view - Limited slip

differential (4WS)
MARBLE CUTTING
LELI12TLB1547GB 1
(1) Bolts (9) Pins

(2) Ring gear (10) Planetary gears
(3) Bearing (11) Thrust washers
(4) Half box (12) Half box
(5) Differential locking counter discs (13) Bearing
(6) Differential locking discs (14) Bushings
(7) Friction discs (15) Pin
(8) Gears
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Wheel hub - Exploded view - 4WS

MARBLE CUTTING
LELI12TLB1649GB 1
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Rear-powered steerable axle - Disassemble the beam assembly

MARBLE CUTTING
1. Drain the oil from the axle.

3. Loosen the flare nuts (11) and remove the oil recircula-
tion line (12).
LELI12TLB1464AB 1
LELI12TLB1465AB 2
4. If necessary, remove the cover (1) from the drive shaft

(2).
LELI12TLB1466AB 3
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5. Remove the drive shaft (2).
LELI12TLB1467AB 4
6. Make alignment marks on the beam trumpets, on the

brake cylinders and on the axle central body.
LELI12TLB1468AA 5
7. Position the axle on supports suitable to hold it or se-

cure the assemblies separately to a lifting device.
LEPH12TLB1469AB 6
9. Remove the beam (8) and O-ring (9).

10. If the beam is removed, the brake assembly is re-
leased.
LELI12TLB1470AB 7
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12. If necessary, remove the bushing (4).
NOTICE: Be careful not to damage the seat.
LELI12TLB1471AB 8
13. If necessary, remove the bushing (5) and race (6) of

the ball joint from the seats using a puller.
LELI12TLB1472AB 9
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Rear-powered steerable axle - Assemble the beam assembly (4WS)

MARBLE CUTTING
1. With liquid nitrogen, bring down the temperature of the

bushing (5) and cup (6) to less than -100 °C (-148 °F).
2. Install the bushing (5) in the upper king pin seat with
the tool 380200196 and a hammer.
3. Install the cup (6) on the lower king pin seat with the
tool 380200196 and a hammer.
LELI12TLB2024AB 1
4. Install the bushing (4) with the tool 380200227 and a

hammer.
5. Install the seal ring (3) with the tool 380002226.
6. Lubricate the seal ring.
LELI12TLB1471AB 2
NOTICE: Make sure that the orientation of the seal ring (3)
is as shown in the figure.
LELI12TLB2025AB 3
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7. Install the O-ring (9) on the beam (8).
LELI12TLB2026AB 4
8. Support the assemblies properly as explained in the

disassembly precedure.
9. Install the beam (8) on the central axle body (10) with
the bolts (7). Use the reference marks made during
disassembly for proper alignment.
LELI12TLB1390AB 5
LELI12TLB1391AB 6
NOTICE: Tighten the screw (7) in the sequence shown.
LELI12TLB1392AA 7
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11. Install the drive shaft (2).

NOTICE: Make sure that you do not damage the seal ring.
LELI12TLB1467AB 8
12. Install the oil recirculation line (12) with the bolts (13).
Torque the bolts (13) to 23 N·m (17 lb ft)
13. Torque the flare nuts (11) to 60 N·m (44 lb ft).
LELI12TLB1465AB 9
LELI12TLB1393AB 10
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Rear-powered steerable axle - Service instruction

MARBLE CUTTING
4WS
Some of the following pictures could not exactly show
your axle, but the procedure is correct.

B. LOCTITE® 270
C. LOCTITE® 638™
LELI12TLB1074GA 1
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LELI12TLB1075GA 2
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Grease points
Grease AGIP GR MU EP2
LELI12TLB1076FA 3
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Rear-powered steerable axle - Remove

MARBLE CUTTING
4WS
from any soft ground, excavations and poorly shored
cavity.
3. Use the locking pin (if provided) to lock the loader at-
tachment controls.
4. Lower the backhoe attachment to the ground.
neutral position.
7. Lower the stabilizers until the rear wheels are slightly
lifted from the ground (they are free from machine
weight).
9. Release the hydraulic pressure by operating the control
levers in all directions.
On and release the pressure by moving the hydraulic
control levers in all directions.
11. Disconnect the electric system by disconnecting the
battery master switch.
12. Fasten the rear axle to a lifting hoist or to a support.
13. Now it is possible to carry out the disassembly of the
rear tires by loosening and removing the relevant fix-
ing nuts (9) [tightening torque = 700 N·m (516 lb ft)].
14. Disconnect the drive shaft (6) by removing the bolts
(7) and bracket (8).
15. Remove the bolts (2), nuts (4) and washers (3) and
(5) [tightening torque = 830 – 970 N·m (612 – 715 lb
ft)].
16. Remove the rear axle (1).
LELI12TLB1073BB 1
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Rear-powered steerable axle - Install

MARBLE CUTTING
WARNING
Heavy objects!
W0398A
4WS
1. Move the axle into position underneath the machine.
2. Raise the axle. Secure axle to the machine frame with
bolts (2), washers (3/5), and nuts (4).
NOTE: Center pivot machine shown. The procedure is the
same for side-shift machines.
3. Torque rear axle bolts to 830 – 970 N·m (612 – 715 lb
ft). Recheck bolt torque after 50 h of operation.
4. Secure the drive shaft (6) to the rear axle and transmis-
sion with yoke hardware (7/8). Torque hardware to 35
– 41 N·m (26 – 30 lb ft).
LELI12TLB1073BB 1
5. Fasten the steering hoses to the steering cylinder.
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6. Install the rear tires. Tighten the rear lug nuts (9) in a
alternating pattern sequence. Torque nuts to 700 N·m
(516 lb ft). Recheck nut torque after 10 h of operation
until torque setting is stabilized.
RAIL14FRK0031BA 2
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Rear-powered steerable axle - Disassemble the front flange (4WS)

MARBLE CUTTING
1. Drain the oil from the central body.

2. Remove the snap ring (1) from the pinion shaft (6).
3. Remove the front flange (2).
LELI12TLB1078AB 1
LELI12TLB1079AB 2
5. Remove the O-ring (3) and washer (4).
LELI12TLB1080AB 3
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Rear-powered steerable axle - Assemble the front flange (4WS)

MARBLE CUTTING
1. Install the washer (4) and O-ring (3).
LELI12TLB1080AB 1
2. Assemble the new seal ring (5) with tool 380200267

(T1) and a hammer.
LELI12TLB1081AB 2
LELI12TLB1082AB 3
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3. Install the front flange (2) and snap ring (1).

4. Refill the central body with oil.
LELI12TLB1083AB 4
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Rear-powered steerable axle - Lubricate

MARBLE CUTTING
4WS
Differential 11 L (2.42 US gal)
Oil capacity
Final drive (each) 1.3 L (0.29 US gal)
Oil type CASE AKCELA TRANSAXLE FLUID 80W-140 NH600 / TR
LELI12TLB1067FB 1
1. Level and fill plug for differential oil

2. Differential oil drain plug
3. Oil breather
4. Filler, level and drain plug for reduction gear oil
5. Greasing points
WARNING
Pressurized system!
ous injury.
W1044A
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1. Before draining the oil from the axle body, use the
LELI12TLB1068AB 2
2. Remove the level plug (1) and the drain plug (2) to drain
the oil from the central body.
3. Drain all oil.
5. Fill through the hole (1).
LELI12TLB1069AB 3
WARNING
Pressurized system!
ous injury.
W1044A
1. Before draining the oil from the reduction gear, turn

the gear so that the plug (4) is in the highest possible
position [position “A”].
2. Partially unscrew the plug (4) to release any possible
internal pressure.
3. Turn the plug (4) and bring it to its lowest position [po-
sition “B”].
4. Remove the plug and drain the oil.
5. Rotate again to bring the hole of the plug (4) to check
and oil filling position [position “C”].
6. Fill with oil. LELI12TLB1070AB 4
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Differential carrier assembly - Remove (4WS)

MARBLE CUTTING
1. Remove the brake.
LELI12TLB1819AA 1
2. Measure the starting preload FT0 of the bearings (pin-

ion-ring gear system) using a dynamometer whose
cord is wound on the end of the pinion shaft.
3. Make a note of the value FT0. This is necessary for
assembling the bearings.
LELI12TLB1820AA 2
4. Secure the brake cylinder (6) on a lifting device.

LELI12TLB1821AB 3
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6. Remove the brake cylinder (6) and O-rings (2) and (4).
LELI12TLB1822AB 4
7. Remove the differential (3) from the central body (1).
LELI12TLB1823AB 5
8. Remove the bolts (10) and the ring nut retainer (9) from
the brake cylinder (6).
LELI12TLB1824AB 6
9. Remove the ring nut (8) from the brake cylinder (6)
using tool 380200209.
LELI12TLB1825AB 7
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10. Remove the bearing cup (5) from the brake cylinder
(6) using a buffer and a hammer.
LELI12TLB1826AB 8
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Differential carrier assembly - Disassemble - Bevel pinion (4WS)

MARBLE CUTTING
1. Remove the differential assembly.

2. Measure the starting preload FP0 of the pinion bearings
using a dynamometer whose cord is wound on the end
of the pinion shaft.
NOTICE: Make a note of the value FP0. This is necessary
for assembling the bearings.
LELI12TLB1556AA 1
3. Remove the ring nut (10) with the wrench (T1) and
pinion retainer (T2) 380000020 (3/4” standard connec-
tion).
LELI12TLB1557AB 2
4. Tap the shaft end with a soft hammer and remove the
pinion (1).
LEPH12TLB1558AB 3
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5. Remove the washers (4), (6) and (9), spacer (5) and
bearing (8).
LEPH12TLB1559AB 4
6. Check the wear condition of the bearing cups.

7. Remove the bearing cups (3) and (8), if necessary.
LEPH12TLB1560AB 5
8. Remove the bearing (3) and shim (2) from the pinion
(1) with a puller.
LELI12TLB1561AB 6
9. Check the conditions of all parts.

NOTICE: The ring nut (10) and spacer (5) must be replaced
during assembly.
LELI12TLB1562AB 7
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Differential carrier assembly - Disassemble - Non-self locking

differential (4WS)
MARBLE CUTTING
1. Place the differential in a vice.

2. Loosen the screws (1) and remove the ring gear (2).
NOTICE: This operation also releases the two half boxes
of the differential.
LEPH12TLB1548AB 1
3. Remove the half boxes (4) and (12).

NOTICE: Make reference marks on the half boxes before
separating them.
4. Remove all parts and check for their operating status
and wear condition.
LELI12TLB1847AB 2
5. Take out the bearings (3) and (13) from the half boxes
(4) and (12) with a puller.
LELI12TLB1848AB 3
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Differential carrier assembly - Assemble - Non-self locking

differential (4WS)
MARBLE CUTTING
1. Install the bearings (3) and (13) on the half boxes (4)
and (12) with the tool 380200188 and a hammer.
LEPH12TLB1849AB 1
2. Place the half boxes (4) and (12) on a workbench and

carefully Install the parts:
• Differential locking counter discs (5)
• Gear (6)
• Pins (7)
• Planetary gears (8)
• Thrust washers (9)
3. Join the two half boxes (4) and (12), aligning the refer-
ence marks made during disassembly.
LELI12TLB1850AB 2
gents.
4. Place the ring gear (2) on the differential box.
5. Apply sealant on the screw thread (1).
6. Install the bolts (1). Torque the bolts to 155 N·m (114 lb
ft).
LEPH12TLB1851AB 3
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Differential carrier assembly - Disassemble - Limited slip differential

(4WS)
MARBLE CUTTING
1. Place the differential in a vice

2. Loosen the screws (1) and remove the ring gear (2).
NOTICE: This operation also releases the two half boxes
of the differential.
LEPH12TLB1548AB 1
3. Remove the half boxes (4) and (12).

NOTICE: Apply reference marks on the half boxes before
separating them.
4. Remove all the parts and check for their operating sta-
tus and wear condition.
LELI12TLB1549AB 2
5. Take out the bearings (3) and (13) from the half boxes
(4) and (12) using a puller.
LELI12TLB1550AB 3
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6. If necessary, take out the bushings (14) from the half

boxes (4) and (12).
NOTICE: Do not damage the bushing seats.
LELI12TLB1551AB 4
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Differential carrier assembly - Assemble - Limited slip differential

(4WS)
MARBLE CUTTING
1. If removed, install the bushings (14) in the half boxes

(4) and (12) using the tool 380200205 and a hammer.
LELI12TLB1551AB 1
2. Install the bearings (3) and (13) on the half boxes (4)
and (12) with the tool 380200188 and a hammer.
LEPH12TLB1552AB 2
3. Place the half boxes (4) and (12) on a workbench and

carefully assemble the parts:
• Differential locking counter discs (5)
• Differential locking discs (6) and (7)
• Gears (8)
• Pins (9)
• Planetary gears (10)
• Thrust washers (11)
NOTICE: The first disc (7) must be oriented with friction
face towards the discs and with smooth face towards the
gear (8). LELI12TLB1553AB 3
4. Join the half boxes (4) and (12), aligning the reference
marks made during disassembly.
gents.
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5. Place the ring gear (2) on the differential box.

6. Apply sealant on the screw thread (1).
7. Install the bolts (1). Torque to 155 N·m (114 lb ft).
LEPH12TLB1554AB 4
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Differential carrier assembly - Assemble - Bevel pinion (4WS)

MARBLE CUTTING
1. Position the axle central body onto a workbench.

2. Insert the bearing cups (3) and (8) on their seats using
the tool 380200216.
LEPH12TLB1563AB 1
3. Insert the bearing and the false pinion tool 380200202

on the seats.
4. Tighten the ring nut, until the backlash is eliminated.
LEPH12TLB1564AA 2
5. Check the correct place of the differential box supports

at the right and left side, using the reference marks
applied on the same and on the central body.
6. Install the brake cylinders with the relevant bolts.
LEPH12TLB1565AA 3
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7. Install the false differential box tool 380200217 in the

central axle body.
8. Check that the false differential box is inserted in both
seats of the differential supports.
LEPH12TLB1566AA 4
9. To adjust the bevel gear measure the distance (A) with

a depth gauge.
10. Determine the value (X) as follows:
X = (A + C) - B
where “B” and “C” are known values.
LELI12TLB1567AA 5
11. From the value (X) deduct the value (V) (stamped on
the pinion head) to get the value (S).
S=X-V
LELI12TLB1568AB 6
12. Choose the shim with value (S) from the shim range
available.
LELI12TLB1569AA 7
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Shim range
2.5 mm ( 2.6 mm ( 2.7 mm ( 2.8 mm ( 2.9 mm ( 3.0 mm ( 3.1 mm ( 3.2 mm ( 3.3 mm ( 3.4 mm (
Shims
0.098 in) 0.102 in) 0.106 in) 0.110 in) 0.114 in) 0.118 in) 0.122 in) 0.126 in) 0.130 in) 0.134 in)
Qty. - - - - - - - - - -
13. Remove the ring nut (10).

14. Remove the false pinion tool 380200202 and the bear-
ings (3) and (8) from the central body (7).
15. Remove the false differential box tool 380200217 from
the brake cylinders and remove the brake cylinders.
LELI12TLB1570AB 8
16. Install the shim(s) on the pinion shaft with the chamfer
against the pinion head.
LELI12TLB1571AB 9
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17. Install the bearing (3) on the pinion shaft (1) using a
press and tool 380200190.
18. Insert the shim (4), new spacer (5) and the shim (6).
LELI12TLB1572AB 10
LELI12TLB1573AB 11
19. Install the pre-assembled pinion (1) in the central

body. Install the bearing (8) on the pinion shaft.
20. Install the bearing (8) with tool 380200190 and a ham-
mer.
LEPH12TLB1574AB 12
21. Install the new ring nut (10) and retaining washer on
the pinion shaft.
22. Torque the ring nut (10) with wrench 380000021 (T1)
and the pinion retainer 380000020 (with 3/4" standard
connection) (T2).
NOTICE: The torque setting is given by the preload mea-
surement on bearings.
23. Tighten the ring nut (10) gradually.
NOTICE: Excessive tightening could damage the spacer
(5), that would need to be replaced and the procedure to
be repeated.
LELI12TLB1575AB 13
24. When you check the preload, strike the pinion ends
(1) with a soft hammer to seat the bearings.
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25. If the bearings have not been replaced, to measure

the preload FPm, use a dynamometer whose cord is
wound on the end of the pinion shaft. The measured
value should be within the following range:
• FPm = FP0 ÷ (FP0 + 10) N
[FPm = FP0 ÷ (FP0 + 2.25) lbf]
NOTICE: Use this method only if the bearings are not re-
placed.
LELI12TLB1556AA 14
26. If the bearings are new, to measure the preload FPm,

use a dynamometer whose cord is wound on tool
380200237, inserted on the end of pinion shaft.
LEPH12TLB1576AA 15
27. The actual preload FPm is measured on tool

380200237 [gauge diameter Dm = 114.4 mm
(4.50 in)].
range:
FPm = 31 – 46 N (6.97 – 10.34 lb)
LELI12TLB1577AA 16
28. In case you do not use the prescribed tool to measure

the preload, the reference diameter is the diameter of
pinion shaft splined end.
range:
FPm = 92 – 138 N (20.68 – 31.02 lb)]
LELI12TLB1556AA 17
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29. It is possible to measure the rolling torque MP of the

pinion shaft bearings with a torque meter and the
wrench 380000020.
NOTICE: All preloads must be measured without seal
rings.
LEPH12TLB1578AA 18
The measured value MP should be within this range:

MP = 1.6 – 2.4 N·m (1.18 – 1.77 lb ft) ]
LELI12TLB1579AA 19
30. Once the prescribed preload value is achieved, caulk

the ring nut (10) using a hammer and a punch.
LEPH12TLB1580AB 20
31. Install the differential assembly (3).
LELI12TLB1581AB 21
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Differential carrier assembly - Install (4WS)

MARBLE CUTTING
1. Before assembling the differential, install the pinion as-

sembly.
LELI12TLB1827AA 1
2. Lubricate and install the new O-ring (2) on each side of

the central body (1).
LELI12TLB1828AB 2
3. Place the brake cylinder (6) on a flat surface and install

the bearing cup (5) with the buffer 380200218.
LEPH12TLB1829AB 3
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4. Calculate the values of “R” as follows:

1. Measure the outer diameter (C) of the ring gear
installed on the differential.
2. With the value of “C”, calculate the value of “R” with
the formula:
R = “C” / 2 mm (0.079 in)
NOTE: This value is required for the backlash adjustment
between pinion and ring gear.
LELI12TLB1830AA 4
5. Lubricate and install a new O-ring (4) into the seat of

the brake cylinders (6).
LELI12TLB1831AB 5
6. Install the differential (3) in the central body (1).

NOTICE: The ring gear must be placed on the left side.
LELI12TLB1823AB 6
7. Install the brake cylinder (6) in the central body (1).

NOTICE: Check that the reference marks made during dis-
assembly between the brake cylinders and the central body
coincide.
LELI12TLB1832AB 7
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8. Install the bolts (7) in places (A). Torque the bolts to

80 N·m (59 lb ft)
9. Install the bolts (S) in place (B). Torque to 80 N·m (59 lb
ft).
LELI12TLB1833AB 8
10. Tighten the ring nuts (8) with the tool 380200209, till
the backlash is eliminated and slightly preload the dif-
ferential bearings.
LEPH12TLB1834AB 9
11. Install the tool 380200222 on the hole of the differen-

tial box.
12. Place a dial gauge and a feeler in contact and to 90°
with respect to the surface of the tool and in corre-
spondence of value (R).
LELI12TLB1835AA 10
13. Shift manually and alternately the tool 380200222

bracket installed on the hole of the differential box.
14. Determine and note the backlash between pinion and
ring gear.
15. Turn the ring gear 1/4 of turn, determine and note the
backlash between pinion and ring gear.
16. Repeat this operation to get several values of the
backlash.
17. Check if the average backlash is within the requested
range:
0.15 – 0.30 mm (0.006 – 0.012 in)
LEPH12TLB1836AA 11
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18. If the backlash is not within the requested range, carry

out adjustment as follows.
• Adjust the ring nuts (8) with tool 380200209.
• Unscrew and tighten both ring nuts of about 30°
each, then check the backlash.
LELI12TLB1837AB 12
19. Adjust the ring nuts (8):

• If the measured backlash is higher than the pre-
scribed tolerance range, tighten the ring nut on the
opposite side of the ring gear and loosen the oppo-
site ring nut by the same measure (A).
• If the measured backlash is lower than the pre-
scribed tolerance range, tighten the ring nut on the
ring gear side and loosen the opposite ring nut by
the same measure (B).
LELI12TLB1838AB 13
20. Check and make sure that there is a minimum preload

on the differential box bearings.
21. Repeat the whole sequence of the above mentioned
operations until the indicated conditions are reached.
LELI12TLB1839AA 14
22. If the bearings have not been replaced, measure the

total preload FTm of the bearings (pinion-ring gear sys-
tem), using a dynamometer whose cord is wound on
the end of the pinion shaft. The measured value FTm
FTm = FT0 ÷ (FT0 + 10) N
[FTm = FT0 ÷ (FT0 + 2.25) lbf]
NOTICE: Use this method only if the bearings are already
run in.
LELI12TLB1820AA 15
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23. If the bearings have been replaced, measure the total

preload FTm of the bearings (pinion-ring gear system),
using a dynamometer whose cord is wound on tool
380200237 inserted on the pinion splined end.
NOTICE: All pre-loads must be measured without seal ring.
LELI12TLB1840AA 16
24. The total preload FTm is measured by tool 380200237.

range:
FTm = (FPm + 11.1) ÷ (FPm + 16.7) N
[FTm = (FPm + 2.5) ÷ (FPm + 3.7) lbf]
NOTE: where FPm is the actual preload measured on tool
380200237 [gauge diameter Dm = 104.4 mm (4.11 in)].
LELI12TLB1841AA 17
25. If you do not use the prescribed tool to measure the

total preload FTm, the reference diameter is the diam-
eter of pinion shaft splined end. The measured value
FTm = (FPm + 33.4) ÷ (FPm + 50.2) N
[FTm = (FPm + 7.5) ÷ (FPm + 11) lbf]
NOTE: Where FPm is the preload of the pinion bearings.
LELI12TLB1820AA 18

justed, if the bearings have been replaced, measure
the total rolling torque MT of the bearings (pinion-ring
gear system) with a torque meter and the wrench
380000020.
NOTICE: All pre-loads must be measured without seal
rings.
LEPH12TLB1842AA 19
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27. The total torque MT should be within the following

range:
MTm = (MP + 0.58) ÷ (MP + 0.87) Nm
[MTm = (MP + 0.43) ÷ (MP + 0.64) lbf·ft]
NOTE: Where MP is the preload of the pinion bearings.
LELI12TLB1843AA 20
28. If the measure is not within the requested range,

check the assembly of each single component and
operate on the ring nuts of the differential support:
screw on the adjusting ring nuts by the same mea-
sure, keeping the pinion-ring gear backlash value
(A) unchanged.
• If the total preload is more than the given range, un-
screw the adjusting ring nuts by the same measure,
keeping the pinion-ring gear backlash value (B) un-
changed.
LELI12TLB1838AB 21
29. Once all adjustment operations have been performed,

assemble the ring nut retainers (9), fastening them
with the relevant screws (10).
30. Tighten the screws (10) to a tightening torque of
13 N·m (10 lb ft).
31. Turn the ring nuts (8) as little as possible to allow their
assembly.
LELI12TLB1844AB 22
32. Remove the two additional screws M16 X 130 (S) from
both sides.
LELI12TLB1845AB 23
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Wheel hub - Disassemble (4WS)

MARBLE CUTTING
1. Use a lever between the swivel housing and the axle

body to access the snap ring for removal.
NOTICE: With the lever push the double joint in the direc-
tion of the wheel hub.
NOTICE: Do not damage the double joint.
LEPH12TLB1650AA 1
2. Remove the snap ring (1), washer (2) and thrust

washer (3).
LELI12TLB1651AB 2
LELI12TLB1652AB 3
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4. To remove the ring gear carrier hub from its housing,

install two of the bolts (5) in the threaded extraction
holes as shown and tighten until the hub is separated
from the housing.
5. Remove the ring gear carrier hub (7) and ring gear (4).
LELI12TLB1653AB 4
6. Remove the snap ring (8) and separate the ring gear
carrier hub (7) from the ring gear (4).
7. If necessary, remove the bushes (6) from the ring gear
carrier with the tool 380200192 and a hammer.
LELI12TLB1654AB 5
8. Remove the wheel hub (11) from the swivel housing

(14). Remove the bearing (9).
LELI12TLB1655AB 6
9. Remove the wheel hub (11).

NOTICE: If necessary, use crowbars and a hammer.
LEPH12TLB1656AB 7
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10. Place the wheel hub (11) on a flat surface and remove
the seal ring (13).
11. Remove the bearing cups (9) and (12) with a drift and
a hammer.
LELI12TLB1657AB 8
12. Remove the bearing (12) from the swivel housing (14).
LELI12TLB1658AB 9
13. Remove the bolts (15) and (19) from the upper (16)
and lower (18) king pins.
NOTICE: Before removing the king pins (16) and (18), sup-
port the swivel housing (14) on a lifting device of adequate
capacity.
14. Remove the king pins (16) and (18).
LEPH12TLB1659AB 10
15. Remove the swivel housing (14).
LEPH12TLB1660AB 11
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16. Place the swivel housing (14) on a flat surface and

remove seal ring (25) with a puller.
17. Remove the bronze bushing (24) with a buffer and a
hammer.
LEPH12TLB1661AB 12
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Wheel hub - Assemble (4WS)

MARBLE CUTTING
1. If removed, reinstall the steering stop screw (23), nut

(22) and bushings (20) and (21).
2. Carry out the steering angle adjustment before you
torque the nut (22).
LELI12TLB1662AC 1
3. Install the bronze bushing (24) into the swivel housing

(14) with the tool 380000024 and a hammer.
4. Install the new seal ring (25) in the swivel housing (14)
with the tool 380200266 and a hammer.
LEPH12TLB1663AB 2
5. If removed, reinstall the ball bearing (17) on the lower

king pin (18) with the tool 380200195 under a press.
6. Grease the king pin seats (16) and (18).
7. Position the belleville washers (27) and (28) on the king
pin seats (16) and (18).
LEPH12TLB1664AB 3
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8. Support the swivel housing (14) on a lifting device of

adequate capacity.
NOTICE: Protect the splined end of the axle shaft by wind-
ing it with protective tape, to avoid damaging the seal ring.
9. Install the swivel housing (14) on the axle and com-
pletely remove the protective tape.
LEPH12TLB1660AB 4
10. Install the lower (18) and the upper (16) king pins with
the bolts (19) and (15). Torque the bolts to 300 N·m
(221 lb ft).
NOTICE: Make sure that the belleville washers stay in the
correct position.
LEPH12TLB1665AB 5
11. Check the indicated dimensions and make sure that

they are within limits provided below:
A. 10.090 – 10.140 mm (0.397 – 0.399 in)
B. 64.275 – 64.325 mm (2.531 – 2.532 in)
C. 27.000 – 27.100 mm (1.063 – 1.067 in)
NOTICE: The bearings installation does not require
preload or backlash adjustment.
LELI12TLB1666AA 6
12. Install the bearing cups (9) and (12) in the wheel hub
(11) with the tool 380200211 and a press.
13. Install the new seal ring (13) in the wheel hub (11) with
the tool 380200210 and a hammer.
LEPH12TLB1667AB 7
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15. Install the bearing (12) on the swivel housing (14).

16. Install the wheel hub (11) on the swivel housing (14)
and install the bearing (9).
LEPH12TLB1668AB 8
17. Place the ring gear hub (7) on a workbench and install
the bushings (6) with the tool 380200192.
NOTICE: At least two bushings (diametrically-opposed)
should be set slightly higher than the carrier surface level.
These raised bushings will be used as dowel pins.
LEPH12TLB1669AB 9
18. Install the ring gear carrier hub (7) on the ring gear (4)
with the snap ring (8).
LELI12TLB1670AB 10
19. Install the ring gear carrier hub assembly on the wheel
hub with the bolts. Use the two projecting bushings as
dowel pins.
LEPH12TLB1671AA 11
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20. Install all the bushings (6) up to stroke end with tool
LEPH12TLB1672AB 12
22. Use a lever between the swivel housing and the axle
body and install the thrust washer (3), washer (2) and
snap ring (1) at the end of the splined hub..
NOTICE: With the lever push the double joint in the direc-
tion of the wheel hub.
NOTICE: Do not damage the double joint.
LEPH12TLB1673AB 13
LELI12TLB1651AB 14
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Index

Differential carrier assembly - Assemble - Bevel pinion (4WS) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Differential carrier assembly - Assemble - Limited slip differential (4WS) (*) . . . . . . . . . . . . . . . . . . . . 39
Differential carrier assembly - Assemble - Non-self locking differential (4WS) (*) . . . . . . . . . . . . . . . . 36
Differential carrier assembly - Disassemble - Bevel pinion (4WS) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Differential carrier assembly - Disassemble - Limited slip differential (4WS) (*) . . . . . . . . . . . . . . . . . 37
Differential carrier assembly - Disassemble - Non-self locking differential (4WS) (*) . . . . . . . . . . . . . 35
Differential carrier assembly - Exploded view - Bevel pinion (4WS) (*) . . . . . . . . . . . . . . . . . . . . . . . . . 9
Differential carrier assembly - Exploded view - Non-self-locking differential (4WS) (*) . . . . . . . . . . . . 10
Differential carrier assembly - Exploded view - Limited slip differential (4WS) (*) . . . . . . . . . . . . . . . . 11
Differential carrier assembly - Exploded view - housing (4WS) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Differential carrier assembly - Install (4WS) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Differential carrier assembly - Remove (4WS) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Rear-powered steerable axle - Assemble the beam assembly (4WS) (*) . . . . . . . . . . . . . . . . . . . . . . . 16
Rear-powered steerable axle - Assemble the front flange (4WS) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Rear-powered steerable axle - Disassemble the beam assembly (*) . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Rear-powered steerable axle - Disassemble the front flange (4WS) (*) . . . . . . . . . . . . . . . . . . . . . . . . 25
Rear-powered steerable axle - Exploded view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Rear-powered steerable axle - Exploded view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Rear-powered steerable axle - General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Rear-powered steerable axle - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Rear-powered steerable axle - Lubricate (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Rear-powered steerable axle - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Rear-powered steerable axle - Service instruction (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Wheel hub - Assemble (4WS) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Wheel hub - Disassemble (4WS) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Wheel hub - Exploded view - 4WS (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
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PRINTED IN U.S.A.
48090752 24/02/2017
EN
SERVICE MANUAL
Brakes and controls

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33
Contents
Brakes and controls - 33
[33.202] Hydraulic service brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33.1
[33.110] Parking brake or parking lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33.2
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33
Hydraulic service brakes - 202

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Contents
TECHNICAL DATA
Hydraulic service brakes

FUNCTIONAL DATA

Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Brakes
Exploded view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Exploded view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Brake master cylinder
Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
SERVICE

Bleed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Brakes
Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Replace (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Brake master cylinder
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
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Brake discs
Check brake wear (4WS) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
DIAGNOSTIC

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Brakes and controls - Hydraulic service brakes
Hydraulic service brakes - General specification

During operation, the brake system of the machine can stop the machine at any time.
2WS
Type Wet multi-discs, 4 x axle (2 x half axle)
Braking surface 1236 cm² (192 in²)
4WS
Type Wet multi-discs, 6 x axle (3 x half axle)
Braking surface 1092 cm² (169 in²)

MARBLE CUTTING
DRIVE (2WD)
2WS
Brake type Wet disc brake
Brake operating temperature -20 – 150 °C (-4 – 302 °F)
Maximum operating pressure 43 bar (624 psi)
Oil displacement for brake actuation (each side) 16 cm³ (0.98 in³)
A. New counterdisc thickness = 7.95 – 8.05 mm (0.313
– 0.317 in)
B. New friction disc thickness = 6.63 – 6.83 mm (0.261 –
0.269 in)
Worn disc minimum thickness = 5.8 mm (0.23 in)
C. New counterdisc thickness = 4.95 – 5.05 mm (0.195
– 0.199 in)
LELI12TLB0141AB 1

DRIVE (4WD)
2WS
Maximum operating pressure 55 bar (798 psi)
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A. New counterdisc thickness = 7.95 – 8.05 mm (0.31 –

0.32 in)
0.27 in)
C. New counterdisc thickness = 4.95 – 5.05 mm (0.19 –
0.20 in)
LELI12TLB1373AB 1

MARBLE CUTTING
4WS
Brake actuation Hydraulic
Maximum operating pressure Mineral oil
Standard brake discs

A. New counterdisc thickness = 4.95 – 5.05 mm (0.19 –
0.20 in)
0.191 in)
C. New counterdisc thickness = 8.9 – 9.0 mm (0.350 –
0.354 in)
LELI12TLB1065AB 1
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“Limited slip” brake discs

A. New counterdisc thickness = 1.27 – 1.33 mm (0.050
– 0.052 in)
0.064 in)
C. New friction disc thickness = 2.65 – 2.75 mm (0.104 –
0.108 in)
Worn disc minimum thickness = 2.55 – 2.65 mm
(0.100 – 0.104 in)
LELI12TLB1066AB 2
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Hydraulic service brakes - Dynamic description

Operation
This system essentially consists of:
• Brake pedals (in the cab).
• Brake master cylinder and hydraulic hoses
• Hydraulically operated wet disc brakes in the rear axle.
LELI12TLB0421FB 1
The brake pedals (1) are provided with the locking pin (2) to lock the two pedals (1) together. Locking and unlocking
the brake pedals (1) together enables the following functions:
• The machine braking – When the pedals are locked together
• The machine turning – When the pedals are not locked together and by pushing only one pedal.
When the brake pedals (1) are pressed, the brake master cylinders (4) delivers pressurised hydraulic oil to the brake
unit (5) of the rear axle (6).
In the brake unit, when the pressure is applied to the brake piston (7), the piston (7) compress the brake friction discs
(9) and the brake separator plates (8). This prevents the axle drive shaft from rotating and the machine stops.
NOTE: This illustration shows the 2WS rear axle, the operation of the 4WS rear axle is the same.
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Brakes - Exploded view

MARBLE CUTTING
DRIVE (2WD)
DRIVE (4WD)
2WS
LELI12TLB0153FB 1
1. Bolt 11. Snap ring

2. Wheel hub assembly 12. Automatic slack adjuster assembly
3. Axle body 13. Snap rings
4. Drive shaft 14. Bushing
5. Brake separator plate 15. Brake piston Carrier
6. Brake friction disc 16. Brake piston O-ring
7. Dowel pins 17. Brake piston seal
8. Bolt 18. Brake piston seal
9. Return springs 19. Brake piston O-ring
10. Brake piston
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Brakes - Exploded view

MARBLE CUTTING
4WS
RAIL17TLB0068GA 1
1 Transmission sleeve 7 Outer seal ring

2 Drive plate 8 Piston
3 Brake disc 9 Self-adjusting seal kit with springs
4 Axle 10 Self-adjusting seal kit with belleville washers
5 Plug with washer 11 Drive plate
6 Inner seal ring
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Brake master cylinder - Dynamic description
RAIL14TLB0089GA 1
At rest
When no force is applied to the brake pedals:
1. Piston (3) is pushed to the right by the spring (4).
2. Oil from the reservoir passes through the port A and held at pressure inlet holes (Port C).
3. Pressure in the recuperation chamber (5), master cylinder chamber (6) and tank remains the same.
4. The master cylinder chamber (6) is vented to the atmosphere through the self bleed hole (7).
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Applying brakes
When the brake pedals are pressed:
1. Force is transmitted and plunger (8) is moved in the bore of the Piston (3).
2. Pressurised oil held at Port C enters the annular chamber (9) through the port C and boost chamber (10).
3. PTFE seal (11) of the plunger (8) blocks the port D and prevents the pressurised oil in the boost chamber to flow
to recuperation chamber (5).
4. This boost pressure pushes the piston (3) against the spring tension.
5. Piston seal (12) blocks the self bleed hole (7) and thus seals the master cylinder chamber (6) from the recuperation
chamber (5).
6. The piston (3) moves left and compresses the oil in the master cylinder chamber.
7. Check valve (13) seals the master cylinder chamber (6) as soon as it senses the oil pressure.
8. The oil in the master cylinder chamber (6) is compressed and forced through the port B to the brakes.
NOTE: If the optional trailer brake system is present, the pressure flows to the trailer brake valve.
NOTE: Screw (14) guides the movement of the piston. Do not alter the screw’s position.
Holding the brakes

Brake pedals pressed and held
1. Once the brakes are applied, pressure created in the master cylinder chamber acts against the piston.
2. The PTFE seal (15) of the plunger blocks the pressure inlet hole (Port C) and PTFE seal (11) seals the outlet port
D and maintains the boost pressure inside the boost chamber (10).
3. The boost chamber pressure counteracts the master cylinder chamber back pressure and keeps the brakes en-
gaged.
4. When boost pressure is more, piston (3) moves towards the master cylinder chamber (6) and increases the master
cylinder pressure.
5. If pressure in the master cylinder chamber is more, it causes the piston to move back and let the boost pressure
escape to the recuperation chamber thus reduces the master cylinder pressure.
6. The brake master cylinder alters the boost pressure and master cylinder chamber pressure several times a second
(as explained in the steps 4 and 5) and maintains the correct pressure on the brakes.
Releasing the brakes

When the force on the brake pedals is released:
1. Acted upon by the springs, plunger (8) returns to its original position, releasing the boost pressure to the recuper-
ation chamber (5).
2. Piston springs push the piston (4) returns to its original position.
3. Once the piston returns to its original position, check valve (13) balances the pressure between the master cylinder
chamber (6) and recuperation chamber (5).
4. Self bleed hole (7) allows oil flow to maintain a constant level in the master cylinder chamber (6) and removes any
air inside the brake master cylinder (1).
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Hydraulic service brakes - Bleed

The procedure to bleed the right-hand side brake is
given below. Use the same procedure to bleed the
left-hand side brakes. Differences (if any) are identi-
fied.
1. Raise the machine on the stabilizers. Support the ma-
chine with appropriate stands.
2. Apply the parking brakes.
3. Remove the right-hand side rear wheel.
4. Remove the bleeding port cover and attach the trans-
parent bleed hose to the bleeding port.
5. Loosen the bleed screw (1).
6. Start the engine. Run the engine at low idle speed.
NOTE: Make sure that the transmission oil level is correct.
Top-up with oil is necessary.
NOTE: The below operations would require two persons. RAIL14TLB0087BA 1
7. Press and release the right-hand side brake pedal for

approximately 15 times.
8. Press and hold the right-hand side brake pedal until
clear oil without bubbles flows through the bleed hose.
9. Reinstall the right-hand side rear wheel.
10. Repeat the bleeding procedure on the left-hand side
brake (if necessary).
11. Once the bleeding procedure is completed, release
the parking brake and drive the machine in an area
clear of pedestrians and personnel in 2nd gear with
the engine running at 1500 RPM.
12. Press the brake pedals until the gap between the floor
and the brake pedals “H” is as follows:
• On machines with floor mat: 30 mm (1.181 in)
• On machines without floor mat: 37 mm (1.457 in)
13. If the machine does not stop, repeat the bleeding pro-
cedure again.
14. If the machine stops, press and hold the pedals as
mentioned in Step 12 and make sure that the machine
does not move. If the machine moves, repeat the
bleeding procedure.
15. Shut down the engine.
16. Disconnect the bleed hose and replace the bleeding
port cover.
LELI12TLB0427BB 2
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Hydraulic service brakes - Test

NOTE: Refer to Brake master cylinder - Adjust (33.202) to check and adjust the brake pedal height and the free
play before carrying out the brake system testing.
1. Place the back hoe in travel position.
2. Raise the machine with the stabilizers until the wheels
are off the ground.
3. Support the machine on stands. Make sure that the
wheels are off the ground.
5. Disconnect the brake hoses from the axles. Plug the
axle fittings.
6. Attach the pressure gauges to the brake hoses.
NOTE: The pressure gauges should be capable of reading
pressures up to 3500 kPa (500 psi).
7. Lock the brake pedals together.
NOTE: The below operations would require two persons.

8. Press the brake pedals and make sure that the reading
is the same on both the sides.
A. Unequal pressure reading indicate brake master
cylinder malfunction. Replace the brake master
cylinder. Repeat the test.
B. If the reading are the same on both the gauges,
continue to Step 9.
9. Press and hold the brake pedals for about a minute.
A. If there is a drop in the pressure, replace the brake
master cylinder. Repeat the test.
B. If there is no drop in the pressure, continue to Step
10.
10. Remove the gauges from the hoses.
11. Connect a hand pump with appropriate gauge to the
right-hand side axle port.
12. Connect a transparent bleed hose to the bleeding port.
13. Loosen the bleed screw.
14. Pump the hand pump until bubbles free oil flow out
through the bleed hose.
15. Tighten the bleeder screw. Torque to 12 N·m (106 lb
in).
16. Apply a pressure of approximately 70 bar (1000 psi)
with the hand pump. Turn-off the hand pump valve
and wait for one minute.
A. If the pressure drops, it indicates the leaking pis-
ton seals. Replace the piston seals. Repeat the
test.
B. If there is no drop in the pressure, continue to
Step 17.
17. Repeat the Steps 11 to 16 on the left-hand side axle
port.
18. Connect the hoses to the axle ports.
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19. Refer to Hydraulic service brakes - Bleed (33.202)

and bleed the brake system.
20. Reinstall the rear wheels.
21. Remove the stand and lower the machine to ground.
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Brakes - Disassemble
MARBLE CUTTING
DRIVE (2WD)
2WS
LEPH12TLB0989AA 1

NOTICE: Leave two bolts in position to hold the hub in
place.
LEPH12TLB0990AB 2
3. Support the wheel hub (2) on a lifting device with ade-

quate lifting capacity.
4. Insert two rods (with opposed threads) on the hub to
guide the removal.
LEPH12TLB0991AB 3
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5. Remove the remaining bolts (1) and separate the wheel

hub assembly (2) from the axle body (3).
LEPH12TLB0992AB 4
6. Slowly remove the wheel hub assembly and the half

axle (4), make sure that the discs (5) and the counter
discs (6) stay on the wheel hub assembly.
LEPH12TLB0993AB 5
7. Place the wheel hub assembly vertically and mark the

counte rdisc (5) assembled to the axle body side (3).
8. Remove the discs (6), counter discs (5) and dowel pins
(7).
LEPH12TLB0994AB 6
9. Remove the half axle (4) from the wheel hub assembly
(2).
LEPH12TLB0995AB 7
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10. Remove the bolts (8) and belleville washers (9) from
LEPH12TLB0996AB 8
11. Check the bolts (8) and belleville washers (9) for dam-
age.
NOTE: If brake discs are replaced, replace screws and
springs also.
LEPH12TLB0997AB 9
12. Remove the snap ring (11) and self adjust kit assembly
(12).
LEPH12TLB0998AB 10
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13. Place the self adjust kit (12) on tool 380200245 and
remove the snap rings (13).
LEPH12TLB0999AB 11
14. Check the bushing (14) for wear.

15. Repeat the procedure for the other self adjust kits.
LEPH12TLB1000AB 12
16. Remove the brake cylinder assembly (10).
LEPH12TLB1501AB 13
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17. Remove the brake piston (15) from the brake cylinder
(10).
LEPH12TLB1502AB 14
18. Remove the O-rings (16) and (17) from the brake
cylinder (10).
LEPH12TLB1503AB 15
19. Remove the O-ring (18) from the brake piston (15).
LEPH12TLB1504AB 16
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LEPH12TLB1505AB 17
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Brakes - Assemble
MARBLE CUTTING
DRIVE (2WD)
2WS
1. Install the new O-ring (19).
LEPH12TLB1505AB 1
2. Install the O-ring (18) on the brake piston (15).
LEPH12TLB1506AB 2
3. Install the O-rings (16) and (17) on the brake cylinder

(10).
LEPH12TLB1503AB 3
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4. Lubricate the O-rings (16), (17) and (18).

5. Install the brake piston (15) in the brake cylinder (10).
LEPH12TLB1507AB 4
6. Lubricate the seat of the brake cylinder on the wheel

hub (2) and install the dowel pins (7).
LEPH12TLB1508AB 5
7. Install the brake cylinder assembly (10) and remove the

dowel pins (7).
LEPH12TLB1509AB 6
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8. Place the bushing (14) into the tool 380200245 with the
chamfer edge facing upwards.
LEPH12TLB1510AB 7
9. Install the snap rings (13) by turning them by 90° with

respect to the ring mounted before.
LEPH12TLB1511AB 8
10. Install the snap rings (13) with the tool 380200245.
Make sure that they are seated against the calibrated
disc.
LEPH12TLB1512AB 9
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12. Install the self adjust kits (12) in the brake cylinder,
paying attention to direct the chamfer edge of the
bushing (14) upwards.
LEPH12TLB1513AB 10
13. Install the snap rings (11).

NOTICE: Make sure that the teeth of the snap ring are
directed towards the self adjust kit.
LEPH12TLB1514AB 11
LELI12TLB1515AB 12
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14. Install the belleville washers (9) and bolts (8). Torque
the bolts to 15.3 N·m (11 lb ft).
NOTICE: Before applying the torque, make sure that the
belleville washers are aligned properly.
LEPH12TLB1516AB 13
LEPH12TLB1517AB 14
15. Install half shaft (4) and the dowel pins (7).
LEPH12TLB1518AB 15
16. Using the reference mark made during disassembly,

Install the counter disc (5).
LEPH12TLB1519AB 16
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17. Install the braking disc (6) and the counter disc (5).
18. If new brake discs (6) are to be used, soak them in oil
for at least 24 h prior to installation.
LEPH12TLB1520AB 17
19. Make sure that its slots of the last disc are aligned with
those of the first disc.
LEPH12TLB1521AB 18
20. Install the wheel hub (2) on the beam (3) with the bolts
(1). Torque the bolts to 226 N·m (167 lb ft).
LEPH12TLB1522AB 19
LEPH12TLB1523AB 20
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DRIVE (4WD)
2WS
LEPH12TLB0154AA 1

NOTICE: Leave two bolts in position to hold the hub in
place.
LEPH12TLB0155AB 2
3. Support the wheel hub (2) on a lifting device with ade-

quate lifting capacity.
4. Insert two rods (with opposed threads) on the how to
guide the removal.
LEPH12TLB0156AB 3
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5. Remove the remaining bolts (1) and separate the wheel

hub assembly (2) from the axle body (3).
LEPH12TLB0157AB 4
6. Slowly remove the wheel hub assembly and the half

axle (4), make sure that the discs (5) and the counter
discs (6) stay on the wheel hub assembly.
LEPH12TLB0158AB 5
7. Place the wheel hub assembly vertically and mark the

counter disc (5) assembled to the axle body side (3).
8. Remove the discs (6), counter discs (5) and dowel pins
(7).
LEPH12TLB0159AB 6
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9. Remove the half axle (4) from the wheel hub assy (2).
LEPH12TLB0160AB 7
NOTICE: In some cases the axle shaft are made up of two

parts.
LELI12TLB0161AA 8
10. Remove the bolts (8) and belleville washers (9) from
LEPH12TLB0162AB 9
11. Check the bolts (8) and belleville washers (9) for dam-
age.
NOTE: If brake discs are replaced, replace screws and
springs also.
LEPH12TLB0163AB 10
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12. Remove the snap ring (11) and self adjust kit assembly
(12).
LEPH12TLB0164AB 11
13. Place the self adjust kit (12) on tool 380200245 and
remove the snap rings (13).
LEPH12TLB0165AB 12
14. Check the bushing (14) for wear.

LEPH12TLB0166AB 13
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16. Remove the brake cylinder assembly (10).
LEPH12TLB0167AB 14
17. Remove the brake piston (15) from the brake cylinder
(10).
LEPH12TLB0168AB 15
18. Remove the O-rings (16) and (17) from the brake
cylinder (10).
LEPH12TLB0169AB 16
19. Remove the O-ring (18) from the brake piston (15).
LEPH12TLB0170AB 17
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LEPH12TLB0171AB 18
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Brakes - Assemble
DRIVE (4WD)
2WS
1. Install the new O-ring (19).
LEPH12TLB1505AB 1
2. Install the O-ring (18) on the brake piston (15).
LEPH12TLB1506AB 2
3. Install the O-rings (16) and (17) on the brake cylinder

(10).
LEPH12TLB1503AB 3
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4. Lubricate the O-rings (16), (17) and (18).

5. Install the brake piston (15) in the brake cylinder (10).
LEPH12TLB1507AB 4
6. Lubricate the seat of the brake cylinder on the wheel

hub (2) and install the dowel pins (7).
LEPH12TLB1508AB 5
7. Install the brake cylinder assembly (10) and remove the

dowel pins (7).
LEPH12TLB1509AB 6
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8. Place the bushing (14) into the tool 380200245 with the
chamfer edge facing upwards.
LEPH12TLB1510AB 7
9. Install the snap rings (13) by turning them by 90° with

respect to the ring mounted before.
LEPH12TLB1511AB 8
10. Install the snap rings (13) with the tool 380200245.
Make sure that they are seated against the calibrated
disc.
LEPH12TLB1512AB 9
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12. Install the self adjust kits (12) in the brake cylinder,
paying attention to direct the chamfer edge of the
bushing (14) upwards.
LEPH12TLB1513AB 10
13. Install the snap rings (11).

NOTICE: Make sure that the teeth of the snap ring are
directed towards the self adjust kit.
LEPH12TLB1514AB 11
LELI12TLB1515AB 12
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14. Install the belleville washers (9) and bolts (8). Torque
the bolts to 15.3 N·m (11 lb ft).
NOTICE: Before applying the torque, make sure that the
belleville washers are aligned properly.
LEPH12TLB1516AB 13
LEPH12TLB1517AB 14
15. Install half shaft (4) and the dowel pins (7).
LEPH12TLB1518AB 15
16. Using the reference mark made during disassembly,

Install the counter disc (5).
LEPH12TLB1519AB 16
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17. Install the braking disc (6) and the counter disc (5).
18. If new brake discs (6) are to be used, soak them in oil
for at least 24 h prior to installation.
LEPH12TLB1520AB 17
19. Make sure that its slots of the last disc are aligned with
those of the first disc.
LEPH12TLB1521AB 18
20. Install the wheel hub (2) on the beam (3) with the bolts
(1). Torque the bolts to 226 N·m (167 lb ft).
LEPH12TLB1522AB 19
LEPH12TLB1523AB 20
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MARBLE CUTTING
4WS
1. Remove the beam and the axle shaft.
LELI12TLB1395AB 1
2. Remove the brake components: counter discs (11),

discs (12), brake disc carrier hub (10), brake disc (9)
and brake counter disc (8).
NOTE: Mark the position of the hub for assembly.
LELI12TLB1396AB 2
3. Remove the brake piston return kit (7) and self-adjust

kit (6).
LELI12TLB1397AB 3
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4. Take out the brake piston (4) from the brake cylinder
(1).
5. If necessary, remove the plug (14) and O-ring (13).
LELI12TLB1398AB 4
6. Blow compressed air through the oil supply hole for

the brake to eject the piston (4), using the minimum
pressure required.
LELI12TLB1399AB 5
LELI12TLB1400AB 6
8. If necessary, remove the bushings (5) of the self-adjust

kit from the piston (4) with the tool 380200194 and a
hammer.
LELI12TLB1801AB 7
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Brakes - Assemble
MARBLE CUTTING
4WS
1. Install the piston (4).
2. Install the washers (5) in the self-adjust seats using tool
380200194 and a hammer. Align them with the piston
supporting inner surface.
LEPH12TLB1802AB 1
3. Align the bushings (5) with the inner supporting surface

of the piston (4).
LEPH12TLB1803AB 2
4. Install the new O-rings (2) and (3) on the piston (4).
5. Lubricate the O-rings.
LELI12TLB1400AB 3
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6. Install the piston (4) in the brake cylinder (1).
LELI12TLB1804AB 4
7. Install the tool 380200238 on the piston (4).

8. Instal the piston (4) in the brake cylinder (1) with one
slot aligned with the oil recirculation hole or with the
brake inspection hole.
NOTICE: Use a crowbar to insert the piston with a light
pressure.
LEPH12TLB1805AB 5
9. Install the big spring, the small spring and the bushing
of the piston return kit (7) as shown.
LEPH12TLB1806AB 6
10. Install the cover and the screw of the piston return kit
(7).
LEPH12TLB1807AB 7
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11. Install the bushing, washer and bolt of the self-adjust

kit (6).
LEPH12TLB1808AB 8
LEPH12TLB1809AA 9
NOTICE: If you are to replace the brake discs, you have to

restore the initial piston position.
LELI12TLB1810AA 10
13. Bring the piston (4) to stroke end with the tool
14. Place the tool carefully so as not to damage the piston.
LEPH12TLB1811AB 11
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15. Check that the brake discs and the counter discs do
not show any sign of burning. Replace if necessary.
NOTICE: If the new brake discs are installed, soak them in
oil before assembly.
LEPH12TLB1812AA 12
16. Install the brake counter disc (8), brake disc (9), brake
disc carrier hub (10), counterdiscs (11) and discs (12).
LELI12TLB1396AB 13
LELI12TLB1813AB 14
17. Reinstall the beam with the axle central body.
LEPH12TLB1814AA 15
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Brakes - Replace
MARBLE CUTTING
4WS
1. Remove the wheel hub assembly from the axle.
LELI12TLB1815AA 1
2. Remove the beam.
LELI12TLB1816AA 2
3. Remove the counter-discs (11), discs (12), brake disc

carrier hub (10), brake disc (9) and brake counter-disc
(8).
LELI12TLB1396AB 3
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4. Check that the brake discs and the counter-discs do not

show any sign of burning. Replace if necessary.
NOTICE: If new brake discs are to be installed, soak them
in oil before assembly.
LEPH12TLB1812AA 4
NOTICE: If you are to replace the brake discs, you have to

restore the initial piston position.
LELI12TLB1810AA 5
6. Bring the brake piston (4) to stroke end with the tool
NOTICE: Place the special tool carefully so as not to dam-
age the piston.
LEPH12TLB1817AB 6
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7. Install the brake counter-disc (8), brake disc (9), brake

disc carrier hub (10), counter-discs (11) and discs (12).
LELI12TLB1396AB 7
LELI12TLB1813AB 8
8. Install the beam on the axle central body.
LEPH12TLB1814AA 9
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Brake master cylinder - Remove

1. Park the machine on a level surface. Raise the loader
and lock the support strut to hold the loader.
2. Identify and tag the hoses (2), (3), (4) and (5). Discon-
nect the hoses from the brakes master cylinder (1).
LELI12TLB0423BB 1
3. From the inside of the cab, remove the steering column

cover (1).
LEPH12TLB0424AA 2
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4. Remove the cotter pins (1) and clevis pins (2) to detach
the push rods of the brake master cylinder from the
brake pedals.
LELI12TLB0425BB 3
5. From the engine compartment, secure the brake pump

to a lifting equipment.
6. Remove the nuts (1) and washers (2) that secures the
brake master cylinder (3) on the frame (4).
7. Remove the brake master cylinder (3) from the frame
(4).
LELI12TLB0426BB 4
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Brake master cylinder - Install

1. Install the brake master cylinder (3) on the frame (4)
with the washers (2) and nuts (1).
LELI12TLB0426BB 1
2. Connect the hoses (2), (3), (4) and (5) to brake master
cylinder (1).
NOTICE: Use identifying tags to make sure that you con-
nect the hoses to their respective ports.
LELI12TLB0423BB 2
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3. Install the push rods of the brake master cylinders on

the brake pedals with the clevis pins (2).
4. Adjust the brake pedals and the push rods as explained
in Brake master cylinder - Adjust (33.202). Once the
brake pedals and the push rods are adjusted, secure
the clevis pins (2) with the cotter pins (1).
LELI12TLB0425BB 3
5. Reinstall the steering column cover (1).
LEPH12TLB0424AA 4
6. Bleed the brake system as explained in Hydraulic ser-

vice brakes - Bleed (33.202).
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Brake master cylinder - Adjust

1. Using the adjustment bolts, adjust left and right pedals
to the height “H” shown:
2. H = 106 – 108 mm (4.17 – 4.25 in) for machine without
floor mats;
3. H = 126 – 128 mm (4.96 – 5.04 in) for machines with
floor mats.
NOTE: Dimensions shown are applicable before the floor
mat installation.
4. Once the brake pedal height is adjusted, use the push
rods clevis (1) to achieve 1 – 2 mm (0.039 – 0.079 in)
of free play measured at the brake pedals.
LELI12TLB0427BB 1
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Brake discs - Check brake wear (4WS)

MARBLE CUTTING
1. Actuate the service brake with machine stopped.
LEPH12TLB1911AB 1
2. Loosen the breather to release the internal system

pressure.
3. Remove the plug (1)
4. To check the wear condition of the brake disc friction
face, try to insert a pin of 4.08 mm (0.16 in) diameter
between the counter discs.
A. If the dowel can be inserted, the brake discs need
not be replaced.
B. If the pin cannot be inserted, the brake discs must
be replaced because worn out.
LEPH12TLB1912AA 2
5. Install the plug (1).

6. Carry out the check of the other brake assembly.
LEPH12TLB1913AB 3
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Hydraulic service brakes - Troubleshooting

MARBLE CUTTING
DRIVE (2WD)

Inefficient braking Contaminated/Improper oil Replace the brake fluid.
Leakage in the brake circuit Find and eliminate the cause for the leak
Worn brake disks Replace the discs (Refer to Brakes - Dis-
assemble (33.202) and Brakes - Assem-
ble (33.202))
Air in the system Bleed the system (Refer to Hydraulic ser-
vice brakes - Bleed (33.202))
Incorrect brake pedal adjustment Adjust the pedals to achieve the correct
free play (Refer to Brake master cylinder
- Adjust (33.202))
Brake system components failed Test the brake system components (Re-
fer to Hydraulic service brakes - Test
(33.202)) and replace failed components
Brake master cylinder failed Replace the brake master cylinder (Re-
fer to Brake master cylinder - Remove
(33.202) and Brake master cylinder -
Install (33.202))
Hard to operate Brake lines restricted or pinched / Improper Clean or replace the brake lines
flow
Brake master cylinder seized Replace the brake master cylinder (Re-
Install (33.202))
Pedal stroke too long Leakage in the brake circuit Eliminate the cause for the leak
Brake master cylinder seals worn/damaged Replace the brake master cylinder (Re-
Install (33.202))
Uneven braking Incorrect tire pressures Inflate tires to correct pressure
Leakage in the brake circuit Eliminate the cause for the leak
Brake lines restricted or pinched / Improper Clean or replace the brake lines
flow
Worn brake disks Replace the disks (Refer to Brakes - Dis-
ble (33.202))
Brake master cylinder failure Replace the brake master cylinder (Re-
Install (33.202))
Noisy brakes Worn brake disks Replace the disks (Refer to Brakes - Dis-
ble (33.202))

DRIVE (4WD)
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Worn brake disks Replace the discs (Refer to Brakes - Dis-
ble (33.202))
- Adjust (33.202))
Install (33.202))
flow
Install (33.202))
Install (33.202))
flow
ble (33.202))
fer to Hydraulic service brakes - Bleed
Install (33.202))
Noisy brakes Worn brake disks Replace the disks (Refer to Brakes - Dis-
ble (33.202))

MARBLE CUTTING

ble (33.202))
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- Adjust (33.202))
Install (33.202))
flow
Install (33.202))
Install (33.202))
flow
ble (33.202))
Install (33.202))
Noisy brakes Worn brake disks Replace the discs (Refer to Brakes - Dis-
ble (33.202))
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Index

Brake discs - Check brake wear (4WS) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Brake master cylinder - Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Brake master cylinder - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Brake master cylinder - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Brake master cylinder - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Brakes - Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Brakes - Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Brakes - Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Brakes - Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Brakes - Exploded view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Brakes - Exploded view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Brakes - Replace (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Hydraulic service brakes - Bleed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Hydraulic service brakes - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Hydraulic service brakes - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Hydraulic service brakes - General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Hydraulic service brakes - Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Hydraulic service brakes - Troubleshooting (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
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Parking brake or parking lock - 110

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Contents
TECHNICAL DATA
Parking brake or parking lock

FUNCTIONAL DATA

SERVICE

Disassemble (Power shuttle transmission) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Assemble (Power shuttle transmission) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Disassemble (Powershift transmission) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Assemble (Powershift transmission) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
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Brakes and controls - Parking brake or parking lock
Parking brake or parking lock - General specification

This device allows the immobilization of the machine each time it must be parked or stopped to carry out maintenance
work.
Technical specifications
Type Manual, with lever
Maximum lever pull 1650 N (371 lb)
Lever stroke 21 mm (0.83 in)
Maximum torque-Power-Shuttle 2000 N·m (1475 lb ft)
Maximum torque-Powershift 1500 N·m (1106 lb ft)
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Parking brake or parking lock - Dynamic description

Operation
The parking brake essentially consists of:
• Manual control lever
• Transmission brake
The lever (1) is located on the right side of the cab (seat
placed to loader attachment).
The lever position (1) is controlled by the sensor (2), when

the lever is lifted to immobilize the machine, the lamp (3)
indicating the parking brake activation and placed on the
side instrument panel (4), lights on.
NOTICE: If the gear is engaged when the parking brake is
activated, it will actuate the warning buzzer and the sym-
bol “parking brake alarm” will appear on the display.
By lifting the lever (1), by means of cable (5) and of the

relevant yoke (7), the brake is actuated inside transmis-
sion (6).
LELI12TLB0095CB 1
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Negative parking brake operation

Negative parking brake applied (A)
When the system is not under pressure, the belleville
washers (1) push on the parking brake piston (2) com-
pressing the brake discs (3).
This happens when the machine motor is stopped or be-

cause the operator has actuated the parking brake.
In order to move the machine disable the parking brake.
LELI12TLB0096AB 2
Negative brake released (B)

When the brake oil reaches the disengagement pres-
sure, the parking brake piston (2) is pushed against the
belleville washers (1) and the brake discs (3) are free.
This happens under normal operating condition, when the

operator disengages the parking brake.
LELI12TLB0097AB 3
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Parking brake or parking lock - Component identification
LELI12TLB0100GB 1
1. Screw 10. Piston

2. Washer 11. Snap ring
3. O-ring 12. O-ring
4. Flange 13. Stop plate
5. Screw 14. O-ring
6. Brake cover 15. Disc
7. O-ring 16. Brake discs
8. Belleville washer 17. Hub
9. O-ring
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Parking brake or parking lock - Disassemble (Power shuttle

transmission)
MARBLE CUTTING
DRIVE (2WD)
DRIVE (4WD)
LEPH12TLB0518AA 1
2. Remove the bolt (1) and the washer (2).

NOTICE: Use a lever and bolts to avoid the flange rotation.
3. Remove the flange (4) and O-ring (3).
LEPH12TLB0519AB 2
4. Remove the bolts (5), (6) and (7).

5. Remove the brake assembly (8).
6. Remove the O-ring (9) from the brake assembly (8).
LEPH12TLB0520AB 3
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NOTICE: The seal ring should be replaced with a new one
during assembly sequence.
LEPH12TLB0521AB 4
9. Remove the rings (10), brake discs (11) and counter

discs (12).
LEPH12TLB0522AB 5
10. Remove the hub (13).
LEPH12TLB0523AB 6
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Parking brake or parking lock - Assemble (Power shuttle

transmission)
MARBLE CUTTING
DRIVE (2WD)
DRIVE (4WD)
1. Install the hub (13).
LEPH12TLB0523AB 1
2. Check the discs as follows:

A. Use a gauge to check that all the counter discs (12)
and brake discs (11) are flat. If necessary, replace
them.
B. If the brake discs (11) are nearly smooth, replace
them.
C. If the friction material is damaged or appears
burned, replace it.
D. Check the grooves for wear. Check counter discs
(12) for pitting, scoring, or other damage. If nec-
essary, replace them.
E. If you will be using new brake discs, soak them in
oil for at least an hour before assembly.
LEPH12TLB0524AB 2
F. If you are using the old friction discs, make sure
that the contact surfaces are coated with oil before
assembly, check the wear condition. If this is 50%
compared to the nominal value, we suggest its re-
placement.
Brake disc kit

Brake disc number 5
Counter disc number 5
Nominal brake disc thickness 3.55 – 3.65 mm (0.140 – 0.144 in)
Brake disc kit nominal thickness [with 163 kg (359.35 lb) of load] 37.40 – 37.60 mm (1.47 – 1.48 in)
Brake disc maximum wear (each side) 0.65 mm (0.03 in)
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3. Install the counter disc (12), brake disc (11) and ring
(10).
4. Repeat the above operation until the brake disc kit is
complete.
LEPH12TLB0525AB 3

6. Lubricate and install the seal ring (15) on the brake (8)
LEPH12TLB0526AB 4
7. Install the O-ring (9) on the brake (8).

8. Install the brake assembly (8) on transmission with the
bolts (5), (6) and (7). Torque the bolts to 50 N·m (37 lb
ft).
LEPH12TLB0520AB 5
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9. Lubricate the O-ring (3). Install the flange (4) and

O-ring (3) with the washer (2) and bolt (1). Torque the
bolt to 139 N·m (102.5 lb ft).
NOTICE: Use a lever and bolts to prevent the flange from
rotation.
LEPH12TLB0519AB 6
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Parking brake or parking lock - Disassemble (Powershift

transmission)
1. Remove the oil drain plug (T) and drain the oil from the
transmission.
LEPH12TLB0774AB 1
2. Remove the bolt (1) and the washer (2).

NOTICE: Use a lever and bolts to avoid the flange rotation.
3. Remove the flange (4) and O-ring (3).
LEPH12TLB0775AB 2
4. Remove the bolts (6) and (7).
LEPH12TLB0776AB 3
Only machines 2WS

5. Remove the brake assembly (8).
6. Remove the O-ring (9) from the brake assembly (8).
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7. Remove the seal ring (15) and plug (5).

NOTICE: The seal ring should be replaced with a new one
during assembly sequence.
LEPH12TLB0777AB 4
8. Remove the rings (10), brake discs (11) and counter

discs (12).
LEPH12TLB0778AB 5
Only machines 4WS

9. Remove the brake and the disc kit.
10. Do not remove the plug (16).
LEPH12TLB0780AB 6
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Only machines 2WS

11. Remove the hub (13).
LEPH12TLB0779AB 7
Only machines 4WS

12. Remove the screw (17), washer (18) and hub (19).
LEPH12TLB0781AB 8
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Parking brake or parking lock - Assemble (Powershift transmission)

Only machines with 2WS
1. Install the hub (13).
LEPH12TLB0779AB 1
Only machines with 4WS

2. Assemble the hub (19), washer (18) and bolt (17).
Torque the bolt to 139 N·m (102.5 lb ft).
LEPH12TLB0781AB 2
All machines:
3. Check the discs as follows:
A. Use a gauge to check that all the counter discs (12)
and brake discs (11) are flat. If necessary, replace
them.
B. If the brake discs (11) are nearly smooth, replace
them.
C. If the friction material is damaged or appears
burned, replace it.
D. Check the grooves for wear. Check counter discs
(12) for pitting, scoring, or other damage. If nec-
essary, replace them.
E. If you will be using new brake discs, soak them in
oil for at least an hour before assembly. LEPH12TLB0782AB 3
F. If you are using the old friction discs, make sure

that the contact surfaces are coated with oil before
assembly, check the wear condition. If this is 50%
compared to the nominal value, we suggest its re-
placement.
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Brake disc kit

Brake disc number 5
Counter disc number 5
Nominal brake disc thickness 3.6 – 3.65 mm (0.5 – 0.14 in)
Brake disc kit nominal thickness [with 163 kg (359.35 lb)
37.40 – 37.60 mm (1.47 – 1.48 in)
of load]
Brake disc maximum wear (each side) 0.65 mm (0.03 in)
4. Install the counter disc (12), brake disc (11) and ring
(10).
5. Repeat this operation until the brake disc kit is com-
plete.
LEPH12TLB0778AB 4

7. Lubricate and install the seal ring (15) on the brake
(8)with the tool 380200226.
LEPH12TLB0783AB 5

8. Install the O-ring (9) on the brake (8).
9. Install the brake assembly (8) on the transmission with
the bolts (6) and (7). Torque the bolts to 50 N·m (37 lb
ft).
LEPH12TLB0776AB 6
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10. Install the brake disc kit and the brake assembly (8)
with the bolts (6) and (7). Torque the bolts to 50 N·m
(37 lb ft).
LEPH12TLB0784AB 7
All machines:
11. Lubricate the O-ring (3). Install the flange (4) and
O-ring (3) with the washer (2) and bolt (1). Torque
the bolts to 139 N·m (102.5 lb ft).
NOTICE: Use a lever and bolts to prevent the flange from
rotation.
LEPH12TLB0775AB 8
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Parking brake or parking lock - Adjust

To adjust the parking brake, place the brake pad in con-
tact with the disc to block the brake cable.
1. The brake cable movement (1) can be adjusted with
the locknut (2).
2. Adjust the parking brake so as to brake the machine
completely by lifting the brake lever up to the 4th
ratchet.
LELI12TLB0098AB 1
Mechanical parking brake adjustment procedure

3. Check operation of parking brake (the lever has to do
4/5 shots and the machine should start moving into 3rd
gear at 1700 RPM).
LELI12TLB0099FA 2
4. Bring the parking brake adjustment nut (Ref. 1) from

the position “1” to position “2” (nearly 50 mm).
5. Insert a 50 mm calibrated shim (Ref. 2) and set the
adjustment nut at end stroke position (to reach the cal-
ibrated shim wall).
6. Lock the adjustment nut in that position tightening the
lock nut (Ref. 3).
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Parking brake or parking lock - Inspect

2. Inspect the brake discs and plates for pitting, scoring,
excessive surface wear and other damage.
3. Inspect the belleville washer for cracking and excessive
surface wear at contact points.
4. Inspect brake pistons and housing for scratches on
their sliding surfaces and contact surfaces for pitting or
excessive wear.
5. Replace the O-rings.
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Index

Parking brake or parking lock - Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Parking brake or parking lock - Assemble (Power shuttle transmission) (*) . . . . . . . . . . . . . . . . . . . . . 9
Parking brake or parking lock - Assemble (Powershift transmission) . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Parking brake or parking lock - Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Parking brake or parking lock - Disassemble (Power shuttle transmission) (*) . . . . . . . . . . . . . . . . . . 7
Parking brake or parking lock - Disassemble (Powershift transmission) . . . . . . . . . . . . . . . . . . . . . . . . 12
Parking brake or parking lock - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Parking brake or parking lock - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Parking brake or parking lock - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
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PRINTED IN U.S.A.
48090752 24/02/2017
EN
SERVICE MANUAL
Hydraulic systems

48090752 24/02/2017
35
Contents
Hydraulic systems - 35
[35.000] Hydraulic systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.1
[35.300] Reservoir, cooler, and filters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.2
[35.104] Fixed displacement pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.3
[35.106] Variable displacement pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.4
[35.102] Pump control valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.5
[35.350] Safety and main relief valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.6
[35.357] Pilot system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.7
[35.128] Auxiliary hydraulic function control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.8
[35.355] Hydraulic hand control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.9
[35.352] Hydraulic swing system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.10
[35.724] Front loader hydraulic system control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.11
[35.701] Front loader arm hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.12
[35.723] Front loader bucket hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.13
[35.726] Excavator and backhoe hydraulic controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.14
[35.736] Boom hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.15
[35.737] Dipper hydraulic system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.16
[35.738] Excavator and backhoe bucket hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.17
[35.739] Swing arm hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.18
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[35.703] Stabilizer hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.19
[35.740] Telescopic arm hydraulic system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.20
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Contents
TECHNICAL DATA
Hydraulic systems
Speeds Engine specifications for the stall test (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
General specification Orientation of the pilot spools in the valve sections (*) . . . . . . . . . . . . . . . . . . . . . . . . 4
Technical Data Pump flow specifications (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
FUNCTIONAL DATA
Hydraulic systems
Excavator and backhoe bucket hydraulic system - Dynamic description (*) . . . . . . . . . . . . . . . . . . . . . . . . . 6
Excavator and backhoe bucket hydraulic system - Dynamic description (*) . . . . . . . . . . . . . . . . . . . . . . . . . 7
Overview Pilot manifold diagnostic port (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Overview Remote test ports (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Component localization (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Component localization Sectional compensators (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Component identification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Hydraulic schema Pilot control hydraulic line routing (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Component localization 20 amp fuse for the pilot controls (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Drawing Proportional control solenoid and switches (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Drawing Pilot control joystick valve (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Drawing Pilot circuit test point (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Drawing Pilot control relay (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Drawing Pilot controls enable switch (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Drawing Pattern change solenoid (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Overview (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Hydraulic systems
Hydraulic schematic frame 01 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
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SERVICE
Hydraulic systems
Check (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Cleaning (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Pressure test System pressure checks using the diagnostic port (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Visual inspection Bent joystick shaft (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Hydraulic systems
Depressurising . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
DIAGNOSTIC
Hydraulic systems
Troubleshooting - Hydraulic pump (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Troubleshooting - Swing system (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Troubleshooting - Control valves (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Troubleshooting - Loader (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Troubleshooting - Backhoe (Machines with “Rexroth” control valves) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Troubleshooting - Backhoe (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Testing Low pilot pressure (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Testing Low pilot pressure at the backhoe valve pilot port for the specific function. Bad joystick. (*) . . 62
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Hydraulic systems - Hydraulic systems
Hydraulic systems - Speeds Engine specifications for the stall test

580ST
590ST
695ST
Power Engine idle speed (Loader) Hydraulic Engine speed at stall

Min Max Transmission Combined
Power Powershift Power Powershift
shuttle shuttle
72.0 kW 900 RPM ± 2430 RPM ± 2400 RPM ± 1900 RPM ± 2000 RPM ± 1640 RPM ± 1730 RPM ±
(97.9 Hp) 50 RPM 50 RPM 25 RPM 25 RPM 25 RPM 35 RPM 35 RPM
82.0 kW 900 RPM ± 2430 RPM ± 2300 RPM ± 2015 RPM ± 2115 RPM ± 1765 RPM ± 1855 RPM ±
(111.5 Hp) 50 RPM 50 RPM 25 RPM 25 RPM 25 RPM 35 RPM 35 RPM
Hydraulic systems - General specification Orientation of the pilot

spools in the valve sections
580ST
590ST
695ST
Orientation of the pilot spools in the valve sections is critical to the machine performance.
Orient the spools with the groove at the work port end indicated as follows:
Function Groove
Swing N/A
Stabilizer B
Bucket A
Boom B
Dipper A
Extendahoe® A
Hydraulic systems - Technical Data Pump flow specifications

580ST
590ST
695ST
Model Pump type Pump size Flow at 2200 RPM Acceptable flow with
with no load load and volumetric
efficiency of 93%
580T Gear 70.9 155.88 L/min 144.97 L/min
(41.18 US gpm) (38.30 US gpm)
580ST Gear 70.9 155.88 L/min 144.97 L/min
(41.18 US gpm) (38.30 US gpm)
580ST Variable Piston 71.0 156.20 L/min 145.27 L/min
(41.26 US gpm) (38.38 US gpm)
590ST Gear 75.7 166.51 L/min 154.85 L/min
(43.99 US gpm) (40.91 US gpm)
(43.59 US gpm) (40.54 US gpm)
695ST Gear 75.7 166.51 L/min 154.85 L/min
(43.99 US gpm) (40.91 US gpm)
(43.59 US gpm) (40.54 US gpm)
B90 Gear 70.9 155.88 L/min 144.97 L/min
(41.18 US gpm) (38.30 US gpm)
B95 Gear 70.9 155.88 L/min 144.97 L/min
(41.18 US gpm) (38.30 US gpm)
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Model Pump type Pump size Flow at 2200 RPM Acceptable flow with
with no load load and volumetric
efficiency of 93%
B95 Variable Piston 71.0 156.20 L/min 145.27 L/min
(41.26 US gpm) (38.38 US gpm)
B100 Gear 70.9 155.88 L/min 144.97 L/min
(41.18 US gpm) (38.30 US gpm)
(41.26 US gpm) (38.38 US gpm)
B110 Gear 75.7 166.51 L/min 154.85 L/min
(43.99 US gpm) (40.91 US gpm)
(43.59 US gpm) (40.54 US gpm)
B115 Gear 75.7 166.51 L/min 154.85 L/min
(43.99 US gpm) (40.91 US gpm)
(43.59 US gpm) (40.54 US gpm)
Hydraulic systems - General specification

580ST
590ST
695ST
Gear pump
Pump 72 kW (98 Hp) (580ST)
Model CASAPPA KP 30.34 - 05 S6 - LMF
Type Double gear pump
Flow rate 35.427 cm³/rev (2.16 in³/rev) + 35.427 cm³/rev (2.16 in³/rev)
Pump 82 kW (111 Hp) (590ST - 695ST)
Type Double gear pump
Flow rate 40.258 cm³/rev (2.46 in³/rev) + 35.427 cm³/rev (2.16 in³/rev)
Variable-flow-rate pump
Pump 72 kW (98 Hp) (580ST)
Model DANFOSS J71C series 45
Type With axial pistons
Flow rate 71 cm³/rev (4.33 in³/rev)
Pump 82 kW (111 Hp) (590ST - 695ST)
Model DANFOSS J75C series 45
Flow rate 75 cm³/rev (4.58 in³/rev)
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Excavator and backhoe bucket hydraulic system - Dynamic

description
580ST
590ST
695ST
CONTROL VALVES
The hydraulic circuit is a load-sensing flow sharing system working together with a hydraulic pump.
This system has the advantage that at any time the distribution of flow to the services being operated is in proportion
to the openings of the control valve spools.
The flow distribution to the backhoe and loader control valves is independent of the load and it is therefore possible
to operate two or more spools at the same time.
Important components of the system are the pressure compensator valves in each control valve section, together with
the load-sensing line which connects all spools of the loader and backhoe attachment control valves.
With the fixed-flow-rate hydraulic pump, the load sensing line only connects the loader and backhoe attachment con-
trol valves and does not have any connection to the hydraulic pump.
The hydraulic pump draws oil from the tank and flow from the front pump is directed to the centre galleries of the
loader and backhoe control valves assemblies.
The flow coming from the rear section of the pump passes through the flow divider valve and sends the priority flow to
the steering system, while the remaining flow adds to the flow from the front pump, directed to the loader and backhoe
attachment systems.
The centre gallery of both the loader and backhoe control valves are blocked by the end plate.
Pressure in the supply system is controlled by the pump flow balancer valve in accordance with the pressure in the
load-sensing line.
Consequently, the higher the load sensing pressure is, the less flow is returned to the tank, with a corresponding
increase in flow/pressure to the hydraulic systems.
Maximum system pressure is limited by the load sense pressure relief valve which relieves pressure in the load sense
line when it reaches 210 bar (3045 psi).
Since the flow balancer valve is influenced by the load-sensing pressure, the valve diverts a sufficient quantity of oil
to the tank to maintain the maximum system pressure of 210 bar (3045 psi).
Loader control valve

The loader control valve is mounted on the right side of the machine adjacent to the pump.
The control valve assembly consists of a maximum of three sections and provides oil to the loader attachment, to the
bucket and to the 4x1 bucket, if installed.
Backhoe attachment control valve

The backhoe attachment control valve is located in the rear part of the machine.
The control valve consists of a maximum of 7 or 8 sections and provides the oil flow for operating the lifting, the
digging, the bucket, the stabilizers, the swing, the (optional) telescopic arm and the auxiliary services, if installed.
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Excavator and backhoe bucket hydraulic system - Dynamic

description
580ST
590ST
695ST
System diagram (backhoe attachment mechanical controls)
LELI12TLB1493GB 1
Hydraulic system oil Suction oil
Steering system oil Return to oil tank
Load-sensing line oil
1. Hydraulic tank 8. Backhoe hammer control valve

2. Hydraulic pump 9. Backhoe hammer
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3. Power steering 10. Oil cooler

4. Hand hammer control valve 11. Return line manifold
5. Hand hammer 12. Filter
6. Backhoe attachment control valve 13. Oil cooler by-pass valve
7. Loader attachment control valve
System diagram (backhoe attachment pilot controls)
LELI12TLB1494GB 2
Hydraulic system oil Suction oil
Steering system oil Return to oil tank
Load-sensing line oil Control circuit oil
1. Hydraulic tank 9. Backhoe hammer

2. Pump 10. Oil cooler
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3. Power steering 11. Return line manifold

4. Hand hammer control valve 12. Filter
5. Hand hammer 13. Oil cooler by-pass valve
6. Backhoe attachment control valve 14. Solenoid valve for piloting backhoe control valve
7. Loader attachment control valve 15. Hydraulic control lever
8. Backhoe hammer control valve 16. Accumulator
Oil flow operation
All loader/backhoe attachment systems are in neutral position

Each control valve section within the backhoe or loader control valve assemblies contains a spool, two check valves
and a load-sensing pressure compensator.
A load-sensing gallery connects the compensators in each control valve section.
When all control valves are in neutral position, the spools stop the oil flow in each system and the pressure of the
load-sensing line can bleed to the tank through the relevant return-to-tank port.
Because there is no load sense pressure being applied to the rear face of the flow balancer valve, the valve will move
against the spring and off its seat when pump pressure reaches 15 bar (218 psi). The pump flow is now diverted
back to the tank and the balancer valve maintains a stand-by pressure of 15 bar (218 psi) while the systems are in
neutral position.
LELI12TLB1495FB 3
Flow balancer valve operation - All spools in neutral
Pump stand-by pressure 15 bar (218 psi) Return to oil tank
1. Load sense bleed orifice 1 l/min (0.22 UK gpm) 5. Pump flow balancer (unload) valve
2. Load-sensing limiter 6. Pump flow IN
(system pressure relief valve)
3. Return to oil tank 7. To backhoe control valves
4. Load sense line
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LELI12TLB1496GB 4
Load sensing flow sharing - All spools in neutral
Pump pressure Return to oil tank
Trapped oil
1. Load non-return check valve 3. Pressure compensator

2. Load sense line 4. Spool
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One hydraulic circuit operating

When a single hydraulic circuit is operated the spool in the control valve section is moved allowing oil to flow past the
lands of the spool and apply pressure to the metering element of the pressure compensating valve.
The metering element moves upwards to allow oil to flow to the load check valve and at the same time uncovers the
drilling in the spool portion of the pressure compensator valve enabling operating pressure to be sensed in the load
sense gallery.
As pressure increases to open the check valve, the load-sensing pressure is applied to the spring side of the flow
balancer valve.
A higher pressure is now required to operate the flow balancer valve and pump pressure increase accordingly.
When pump pressure overcomes the pressure behind the load check valve, the valve opens allowing oil to flow into
the cylinder port.
Exhaust oil from the cylinder returns to tank through the other port in the control valve section.
If pressure in a load-sensing system reaches 195 bar (2828 psi), the relief valve is activated.
Pump pressure is now limited to 210 bar (3045 psi). This is the pressure required to overcome the pressure of the
flow balancing valve spring [ 15 bar (218 psi)] plus the load sensing pressure controlled at 195 bar (2828 psi).
LELI12TLB1497FB 5
Flow balancer valve operation - Hydraulic systems operating
Pump pressure
Load-sensing pressure
Return to oil tank
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2. Load-sensing limiter 6. Pump flow IN
(system pressure relief valve)
4. Load sense line
LELI12TLB1498GB 6
Load sensing flow sharing - One spool operating
Pump pressure
Trapped oil
Return to oil tank

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Two or more hydraulic systems operating

When two or more hydraulic systems operate, each system operates at a different pressure.
If pump flow to a specific system is not controlled, the system requiring a lower operating pressure will work faster
than the system requiring a higher pressure, because the flow will have to overcome less resistance.
To prevent this situation, the pressure compensating valve regulates the oil flow directed to the system operating at a
lower load.
When two spools are operated simultaneously pump pressure is applied to the metering element of the pressure
compensating valve in both valve sections.
Both metering elements therefore move upwards allowing oil to flow to the load check valves. At the same time, the
port in the spool section of the pressure compensating valve is uncovered to allow operating pressure to be sensed
in the load-sensing gallery.
Pump pressure will rise until it exceeds the pressure of the check valve of the system operating at the heaviest load
and the pressure in the load sensing line has a value similar to that of the high pressure.
The pressure required to operate the system with a lower load is now too high and, if not limited, it will result in this
system operating instead of and faster than the system with a higher load.
To compensate for this condition, the load sensing pressure moves the metering element of the pressure compensat-
ing valve in the system with a lower load downwards and restricts the flow to the system.
This balancing of flow and pressure according to the load ensures that both systems operate simultaneously and at
a balanced flow rate.
LELI12TLB1499FB 7
Load sense relief valve operating
Pump pressure at 210 bar (3045 psi) Return to oil tank
Load sense pressure at 195 bar (2828 psi)
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2. Load sense limiter (system relief valve) 6. Pump flow IN
4. Load sense line
LELI12TLB1500GB 8
Load sensing flow sharing - Two spools operating
1st spool operating pressure (higher) Trapped oil
2nd spool operating pressure (lower) Return to oil tank

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Hydraulic systems - Overview Pilot manifold diagnostic port

580ST
590ST
695ST
RAIL16TLB0175GA 1
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Hydraulic systems - Overview Remote test ports

580ST
590ST
695ST
RAIL16TLB0211BA 1
1 Loader and backhoe upper remote test port. Taps into the M2 port of the loader valve.
2 Steering system center remote test port. Taps into the CF port of the hydraulic pump.
3 Loader and backhoe lower remote test port. Taps into the M1 port of the loader valve.
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Hydraulic systems - Component localization

580ST
590ST
695ST
RAIL16TLB0212BA 1
1 Inlet compensator 4 Flow regulator

2 Secondary relief valves 5 Pilot endcaps
3 Load sense relief 6 Inlet section
Tightening torques
Load sense relief valve 41.0 – 50.0 N·m (30.2 – 36.9 lb ft)
Flow regulator 18.0 – 22.0 N·m (13.3 – 16.2 lb ft)
Inlet compensator 90.0 – 110.0 N·m (66.4 – 81.1 lb ft)
Pilot endcaps 9.0 – 11.0 N·m (6.6 – 8.1 lb ft)
Sectional compensator plug 54.0 – 66.0 N·m (39.8 – 48.7 lb ft)
Tie bolts 38 – 46.0 N·m (28 – 33.9 lb ft)
Secondary relief valves 63.0 – 77.0 N·m (46.5 – 56.8 lb ft)
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Hydraulic systems - Component localization Sectional

compensators
580ST
590ST
695ST
RAIL16TLB0213AA 1
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Hydraulic systems - Component identification

580ST
590ST
695ST
RAIL16TLB0214BA 1
1 Accumulator 5 Right-hand stabilizer solenoids

2 Pilot energizing solenoid 6 Pilot diagnostic port
3 Telescopic solenoids 7 Pressure reducing cartridge
4 Left-hand stabilizer solenoids 8 Pattern change solenoids
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Hydraulic systems - Hydraulic schema Pilot control hydraulic line

routing
580ST
590ST
695ST
1 Left joystick 14 Orange

2 Right stick 15 Hydraulic extendable dipper
3 Grey 16 Boom
4 Yellow 17 Swing
5 Black 18 Bucket
6 Blue 19 Dipper
7 Green 20 Left-hand stabilizer
8 Orange 21 Right-hand stabilizer
9 Red 22 A ports
10 Yellow 23 B ports
11 Brown 24 From the loader valve
12 White 25 Backhoe loader valve
13 Purple 26 Pilot control valve
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RAIL16TLB0289JA 1
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Hydraulic systems - Component localization 20 amp fuse for the

pilot controls
580ST
590ST
695ST
RAIL15TLB0257BA 1
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RAIL14TLB1180GA 2
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Hydraulic systems - Drawing Proportional control solenoid and

switches
580ST
590ST
695ST
RAIL16TLB0216AA 1
RAIL16TLB0217BA 2
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Hydraulic systems - Drawing Pilot control joystick valve

580ST
590ST
695ST
RAIL16TLB0219BA 1
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Hydraulic systems - Drawing Pilot circuit test point

580ST
590ST
695ST
RAIL16TLB0220BA 1
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Hydraulic systems - Drawing Pilot control relay

580ST
590ST
695ST
RAIL16TLB0221BA 1
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Hydraulic systems - Drawing Pilot controls enable switch

580ST
590ST
695ST
RAIL16TLB0337AA 1
RAIL16TLB0222BA 2
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Hydraulic systems - Drawing Pattern change solenoid

580ST
590ST
695ST
RAIL16TLB0223BA 1
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Hydraulic systems - Overview

580ST
590ST
695ST
Hydraulic cylinders
LELI12TLB1859GB 1
1. Loader attachment boom cylinder 7. Telescopic cylinder

2. Loader bucket cylinder 8. Swing backhoe cylinder
3. 4x1 loader bucket cylinder 9. Stabilizer cylinder (center pivot models)
4. Backhoe boom cylinder 10. Stabilizer cylinder (sideshift models)
5. Backhoe dipper cylinder 11. Backhoe sideshift locking cylinder (sideshift models)
6. Backhoe bucket cylinder
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Hydraulic systems - Hydraulic schematic frame 01

580ST
590ST
MARBLE CUTTING
2WS side shift mechanical models - With fixed-flow-rate gear pump
1. Front axle steering cylinder 18. Oil filter

2. Power steering 19. Back pressure valve
3. 4x1 bucket cylinders 20. Return manifold
21. Backhoe attachment travel lock cylinders
3A. Lock valve
(sideshift)
3B. 4x1 EH valve 22. Stabilizer right cylinder
4. Loader bucket cylinders 22A. Lock valve
4A. Lock valve 23. Stabilizer left cylinder
5. Boom cylinders 23A. Lock valve
5A. Lock valve 24. Dipper cylinder
6. Ride control valve (optional) 24A. Lock valve
7. Ride control accumulator (optional) 25. Bucket cylinder
8. Loader attachment control valve 26. Swing cylinders
9. Hand hammer control valve (optional) 27. Swing control valve
10. Backhoe hammer control valve (optional) 28. Boom cylinder
11. Hand hammer (optional) 28A. Lock valve
12. Backhoe hammer (optional) 29. Telescopic cylinder
13. Hydraulic fixed-flow-rate gear pump 30. Backhoe attachment control valve
14. Priority valve 31. Backhoe quick coupler (optional)
15. Oil cooler 32. Backhoe quick coupler control valve (optional)
16. Hydraulic tank 33. Diagnostic
17. Air filter
* Alternative diagram for non-reactive steering
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LELI12TLB0673JA 1
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580ST
590ST
CUTTING
With fixed-flow-rate gear pump - without backhoe attachment swing control valve

3A. Lock valve 21. Backhoe attachment travel lock cylinders (sideshift)
4. Loader bucket cylinders 22. Stabilizer right cylinder
4A. Lock valve 22A. Lock valve
5. Boom cylinders 23. Stabilizer left cylinder
6. Ride control valve (optional) 24. Dipper cylinder
7. Ride control accumulator (optional) 24A. Lock valve
8. Loader attachment control valve 25. Bucket cylinder
9. Hand hammer control valve (optional) 26. Swing cylinders
10. Backhoe hammer control valve (optional) 27. Diagnostic
11. Hand hammer (optional) 28. Boom cylinder
12. Backhoe hammer (optional) 28A. Lock valve
13. Hydraulic fixed-flow-rate gear pump 29. Telescopic cylinder
14. Priority valve 30. Backhoe attachment control valve
15. Oil cooler 31. Backhoe quick coupler (optional)
16. Hydraulic tank 32. Backhoe quick coupler control valve (optional)
17. Air filter
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LELI12TLB0674JA 1
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580ST
590ST
CUTTING
With variable-flow-rate piston pump

3B. 4x1 EH valve 22. Stabilizer right cylinder
5. Boom cylinders 23A. Lock valve
5A. Lock valve 24. Dipper cylinder
6. Ride control valve (optional) 24A. Lock valve
7. Ride control accumulator (optional) 25. Bucket cylinder
8. Loader attachment control valve 26. Swing cylinders
9. Hand hammer control valve (optional) 27. Diagnostic
10. Backhoe hammer control valve (optional) 28. Boom cylinder
11. Hand hammer (optional) 28A. Lock valve
12. Backhoe hammer (optional) 29. Telescopic cylinder
13. Hydraulic fixed-flow-rate piston pump 30. Backhoe attachment control valve
14. Priority valve 31. Bidirectional auxiliary attachment (optional)
15. Oil cooler 32. Backhoe quick coupler (optional)
16. Hydraulic tank 33. Backhoe quick coupler control valve (optional)
17. Air filter
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LELI12TLB0675JA 1
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580ST
590ST
695ST
2WS side shift pilot models – With fixed-flow-rate gear pump
1. Front axle steering cylinder 22. Stabilizer right cylinder

2. Power steering 22A. Lock valve
3. 4x1 bucket cylinders 23. Stabilizer left cylinder
3B. 4x1 EH valve 24. Dipper cylinder
4A. Lock valve 25. Bucket cylinder
5. Boom cylinders 26. Swing cylinders
5A. Lock valve 27. Swing control valve
6. Ride control valve (optional) 28. Boom cylinder
8. Loader attachment control valve 29. Telescopic cylinder
9. Hand hammer control valve (optional) 30. Backhoe attachment control valve
10. Backhoe hammer control valve (optional) 31. Bidirectional auxiliary attachment (optional)
11. Hand hammer (optional) 32. Backhoe quick coupler (optional)
12. Backhoe hammer (optional) 33. Backhoe quick coupler control valve (optional)
13. Hydraulic fixed-flow-rate piston pump 34. Diagnostic
14. Priority valve 35. Left-hand hydraulic control lever
15. Oil cooler 35A. Left hydraulic control lever - boom - dipper
16. Hydraulic tank 35B. Left hydraulic control lever - swing
17. Air filter 36. Right-hand hydraulic control lever
18. Oil filter 36A. Right hydraulic control lever - boom - dipper
19. Back pressure valve 36B. Right hydraulic control lever - swing
20. Return manifold 37. Pilot control manifold
21. Backhoe attachment travel lock cylinders (sideshift)
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LELI12TLB0676JA 1
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580ST
590ST
CUTTING
With variable-flow-rate piston pump
1. Front axle steering cylinder 21. Backhoe attachment travel lock cylinders (sideshift)
2. Power steering 22. Stabilizer right cylinder
3. 4x1 bucket cylinders 22A. Lock valve
3B. 4x1 EH valve 23A. Lock valve
4. Loader bucket cylinders 24. Dipper cylinder
5. Boom cylinders 25. Bucket cylinder
5A. Lock valve 26. Swing cylinders
6. Ride control valve (optional) 27. Swing control valve
7. Ride control accumulator (optional) 28. Boom cylinder
8. Loader attachment control valve 28A. Lock valve
9. Hand hammer control valve (optional) 29. Telescopic cylinder
10. Backhoe hammer control valve (optional) 30. Backhoe attachment control valve
11. Hand hammer (optional) 31. Bidirectional auxiliary attachment (optional)
12. Backhoe hammer (optional) 32. Backhoe quick coupler (optional)
13. Hydraulic fixed-flow-rate piston pump 33. Backhoe quick coupler control valve (optional)
14. Priority valve 34. Pilot control manifold
15. Oil cooler 35. Left-hand hydraulic control lever
16. Hydraulic tank 35A. Left hydraulic control lever - boom - dipper
17. Air filter 35B. Left hydraulic control lever - swing
18. Oil filter 36. Right-hand hydraulic control lever
19. Back pressure valve 36A. Right hydraulic control lever - boom - dipper
20. Return manifold 36B. Right hydraulic control lever - swing
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LELI12TLB0677JA 1
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695ST
4WS side shift mechanical models
1. Front axle steering cylinder 19. Air filter

2. Rear axle steering cylinder 20. Oil filter
3. 4WS steering control valve 21. Return manifold
4. Power steering 22. Backpressure valve
5. 4x1 bucket cylinders 23. Backhoe attachment control valve
5B. 4x1 EH valve 25. Bidirectional auxiliary attachment (optional)
6. Loader bucket cylinders 26. Stabilizer right cylinder
7. Boom cylinders 27. Stabilizer left cylinder
8. Ride control valve (optional) 28. Dipper cylinder
10. Loader attachment control valve 29. Bucket cylinder
11. Hand hammer control valve (optional) 30. Swing cylinders
12. Backhoe hammer control valve (optional) 31. Swing control valve
13. Hand hammer (optional) 32. Boom cylinder
14. Backhoe hammer (optional) 32A. Lock valve
15. Hydraulic variable-flow-rate pump 33. Telescopic dipper cylinder (optional)
16. Priority valve 34. Backhoe quick coupler (optional)
17. Oil cooler 35. Backhoe quick coupler control valve (optional)
18. Hydraulic tank
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LELI12TLB0678JA 1
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695ST
4WS side shift pilot models
1. Front axle steering cylinder 22. Return manifold

2. 4WS steering control valve 23. Backhoe attachment control valve
3. Rear axle steering cylinder 24. Bidirectional auxiliary attachment (optional)
4. Power steering 25. Stabilizer right cylinder
5. 4x1 bucket cylinders 25A. Lock valve
5B. 4x1 EH valve 26A. Lock valve
6. Loader bucket cylinders 27. Dipper cylinder
7. Boom cylinders 28. Bucket cylinder
7A. Lock valve 29. Swing cylinders
8. Ride control valve (optional) 30. Swing control valve
9. Ride control accumulator (optional) 31. Boom cylinder
10. Loader attachment control valve 31A. Lock valve
11. Hand hammer control valve (optional) 32. Telescopic dipper cylinder (optional)
12. Backhoe hammer control valve (optional) 33. Backhoe quick coupler (optional)
13. Hand hammer (optional) 34. Backhoe quick coupler control valve (optional)
14. Backhoe hammer (optional) 35. Left-hand hydraulic control lever
15. Hydraulic variable-flow-rate piston pump 36. Right-hand hydraulic control lever
16. Priority valve 36A. Boom or dipper right hydraulic control lever
17. Oil cooler 36B. Hydraulic control lever right-bucket
18. Hydraulic tank 37. Backhoe attachment control valve solenoid valve
19. Air filter 37A. Boom or dipper left hydraulic control lever
20. Oil filter 37B. Left hydraulic control lever - swing
21. Backpressure valve 38. Pilot control manifold
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LELI12TLB0679JA 1
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Hydraulic systems - Check

580ST
590ST
695ST
Troubleshooting preliminary checks

When troubleshooting, the pressure and flow rate test
must be carried out in a systematic manner and the
results analyzed.
In this way, the trouble may be identified immediately
and accurately.
If short-cuts, assumptions and guesses are made,
unnecessary component disassembly or replacement
could result.
Follow the step-by-step procedures outlined below.
As a first step in the fault finding procedure, several
preliminary checks should be made
These checks are important because, once they have
been performed, they need no longer be considered as
a possible cause of the immediate or reported malfunc-
tion.
Check that the hydraulic oil is at the correct level and of
the correct specification.
Check the loader, backhoe or any additional accessory
such as hydraulic bucket, hammers etc., for correct as-
sembly or installation and additionally for signs of ex-
ternal damage that might cause gross misalignment of
structural members.
Check in more detail for other mechanical damage such
as kinked, twisted, worn or decayed hoses, damaged
cylinders and bent elements.
Do not forget to check underneath the unit for damaged
steel tubes, particularly if the unit has been known to
have operated in arduous conditions, been grounded,
or bogged down.
Ensure optimum operating temperature of the hydraulic
oil is achieved.
Perform the system pressure and rear pump relief valve
pressure tests.
The above-described preliminary checks assume that
the failure is not linked to the engine performance.
Having performed these checks and failed to locate
the cause of the malfunction, the following procedures
should be adopted:
• If possible, operate the backhoe attachment and
make notes of its operating characteristics. Move
each cylinder control lever so that the cylinders
move from the fully extended to the fully retracted
position;
• Compare the operating characteristics in the preced-
ing stage with the malfunctions listed hereunder.
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Hydraulic systems - Cleaning

580ST
590ST
695ST
Special tools
CAS101162A, filter unit, portable.
RCPH10TLB306ABL 1
CAS10192, vacuum pump.
RCPH10TLB454ABL 2
CAS10508, fitting kit.
RCPH10TLB307ABL 3
General information
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.
1. When you drain the oil or disconnect any line.
2. When you disassemble a component.
3. From normal wear of the hydraulic components.
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4. From damaged or worn seals.

5. From a damaged component in the hydraulic system.
All hydraulic systems operate with some contamination.
The design of the components in this hydraulic system
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.
1. Cylinder rod seals leak.
2. Control valve spools do not return to neutral.
3. Movement of control valve spools is difficult.
4. Hydraulic oil becomes too hot.
5. Pump gears, housing, and other parts wear rapidly.
6. Relief valves or check valves held open by dirt.
7. Quick failure of components that have been repaired.
8. Cycle times are slow; machine does not have enough
power.
If your machine has any of these problems, check the
hydraulic oil for contamination. See types of contamina-
tion below. If you find contamination, use the portable
filter to clean the hydraulic system.
Types of contamination
There are two types of contamination, microscopic and
visible.
1. Microscopic contamination occurs when very fine par-
ticles of foreign material are in suspension in the hy-
draulic oil.
2. These particles are too small to see or feel. Micro-
scopic contamination can be found by identification of
the following problems or by testing in a laboratory. Ex-
amples 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.
3. Visible contamination is foreign material that can be
found by sight, touch, or odor. Visible contamination
can cause a sudden failure of components. Examples
of visible contamination:
A. Particles of metal or dirt in the oil.

B. Air in the oil
C. The oil is dark and thick.
D. The oil has an odor of burned oil.
E. Water in the oil. See flushing water from the hy-
draulic system, step 23.
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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. See types of contamination .
3. If the contamination is microscopic:
A. Check the maintenance schedule for the machine

to learn when the hydraulic oil must be changed.
If needed, change the hydraulic oil.
B. Complete steps 6 through 35.
4. If the contamination is visible:
A. Change the hydraulic oil and hydraulic filter. Refer

to the Operator's manual for more details.
B. Complete 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 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.
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.
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15. Run the portable filter for 10 min.

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:
Complete this procedure on variable pump machines
when the temperature is below 40 degrees F (4 de-
grees C) and the engine has been warmed up.
1. Leave the boom in the transport position with the
transport pin installed.
2. Activate the pilot control switch, if equipped with
pilot controls.
3. Raise the engine speed between 1600 and 1800
rpm.
4. Place and hold the boom control in the down posi-
tion.
5. Cycle the functions for approximately 30 seconds.
6. Release the controls for approximately 15 sec-
onds.
7. Repeat steps until the desired oil temperature of
120 degrees F (48 degrees C) is reached.
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 min.
19. Decrease the engine speed to low idle.
20. Continue to run the portable filter for 10 min.
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.
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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. See Section 1002 for specifications.
Flushing water from the hydraulic system

1. Start and run the engine at 1500 RPM.
2. Completely retract the cylinders of all attachments on
the machine. Swing the boom to the right, the right
cylinder will be fully retracted and the left will be fully
extended.
NOTE: If retracting the cylinder rods causes the attachments to be raised, block the attachments in place before
proceeding to the next step!
NOTE: Any attachment or part of an attachment that is raised must be supported with acceptable equipment to prevent
the attachment from falling.
3. Stop the engine.
4. Turn the key switch to the ON position.
5. Turn the Pilot Controls switch to the ON position.
6. Move each Pilot Control lever in each direction to re-
lieve pressure.
7. Loosen and remove the filler cap from the reservoir.
8. Drain the hydraulic oil from the reservoir.
A. See capacity specifications.

B. Have available acceptable equipment to drain the
hydraulic oil.
C. Remove the drain plug from the bottom of the
reservoir.
9. Remove the hydraulic filter elements from the machine.
11. Install the drain plug in the bottom of the reservoir.
12. Fill the hydraulic reservoir with hydraulic fluid.
13. Disconnect the line from the open end and closed end
of each cylinder.
14. Be sure all control levers are in the neutral position.
NOTICE: Check the oil level in the hydraulic reservoir frequently while doing step 16. Have another person hold a
container under the hydraulic lines while you do step 16.
16. 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.
18. Connect the system line to the closed end of each
cylinder.
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19. 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.
20. Start the engine and run the engine at low idle.
21. 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.
22. Support any attachments that will be in the raised po-
sition.
24. Disconnect the drain lines and connect the system
lines to the cylinders.
25. Check the oil level in the hydraulic reservoir. Add oil
as required.
26. Install the filler cap on the reservoir.
27. Remove the hydraulic filter elements from the ma-
chine.
29. Start and run the engine at 1500 RPM, operate each
hydraulic circuit to completely extend and retract the
cylinders.
30. Stop the engine and check for leaks. Check the oil
level in the hydraulic reservoir. Add oil as required.
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Hydraulic systems - Pressure test System pressure checks using

the diagnostic port
580ST
590ST
695ST
Diagnostic ports
Refer to Hydraulic systems - Overview Pilot mani-
fold diagnostic port (35.000) for the location of the di-
agnostic ports.
Pressure readings
NOTE: For all pressure readings, unless otherwise specified, set the engine speed to 2200 RPM and warm the hy-
draulic oil to the normal operating temperature of 75 °C (167 °F).
Pressure reading Pressure Port

Steering standby Approximately 17.0 bar Engine speed set to Center remote test port
(246.5 psi) 1000 RPM gauge
Steering in neutral
Steering circuit relief for two Approximately 140.0 bar Full left-turn over relief Center remote test port
wheel steer (2WS) (2030.0 psi) Full right-turn over relief gauge
Steering circuit relief for Approximately 180.0 bar Full left-turn over relief Center remote test port
four wheel steer (4WS) (2610.0 psi) Full right-turn over relief gauge
Main system pressure relief 207.0 – 217.0 bar (3001.5 Loader bucket rollback over Upper remote test port
– 3146.5 psi) relief gauge
Pilot pressure relief 24.0 – 35.0 bar (348.0 – Any pilot function over relief Pilot manifold diagnostic
507.5 psi) port
Refer to Hydraulic
systems - Overview
Pilot manifold diagnostic
port (35.000)
Backhoe load sense relief 207.0 – 217.0 bar (3001.5 Any pilot function over relief Upper remote test port
– 3146.5 psi) gauge
Flow regulator stand-by 14.0 bar (203.0 psi) Engine speed set to Upper remote test port
pressure minimum 1000 RPM gauge
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Hydraulic systems - Visual inspection Bent joystick shaft

580ST
590ST
695ST
RCPH10TLB430ABL 1
RAIL16TLB0218BA 2
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Hydraulic systems - Depressurising

1. Park the machine on firm level ground.
2. Put all transmission controls in the Neutral position.
4. Lower the bucket to the ground but do not apply down
pressure; or raise the loader arm and engage the
loader arm safety support.
5. Rotate the operator seat into the backhoe operation
position.
6. Place the backhoe in the stowed position with swing
lock pin in the lock position. If applicable, insert the Ex-
tendahoe lock pin. You may choose to rest the backhoe
attachment on the ground.
7. Shut off the engine.
8. Turn the key switch to the ON position but DO NOT
start the engine.
9. Press the emblem end of the backhoe and stabilizer
control switch to activate all backhoe controls.
NOTE: When turning the backhoe and stabilizer control switch to the ON position, wait approximately half a second
before activating the stabilizers, Extendahoe® (if equipped) or bi-directional auxiliary hydraulics (if equipped). If an
operator attempts to operate the functions before the delay passes, the functions will not operate. Cycle the power
switch and wait for the delay to pass.
10. If equipped with combo auxiliaries, enable the bidirec-
tional switch on the right-hand side panel.
11. Cycle the bi-directional proportional control buttons on
the left-hand pilot control joystick.
12. Move each pilot backhoe control joystick in one com-
plete circle, stopping in the neutral (center) position.
13. Deactivate the backhoe and stabilizer control switch.
LEEN12T0487AA 1
14. Rotate the operator seat into the driving position.

15. Rotate the loader control joystick in one complete cir-
cle, stopping in the neutral (center) position.
16. If applicable, operate the bucket control switch.
17. Turn the key switch to the Off position.
LEEN12T0485AA 2
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Releasing hydraulic pressure on machines with mechanical backhoe controls

1. Park the machine on firm level ground.
2. Put all transmission controls in the Neutral position.
4. Lower the bucket to the ground but do not apply down
pressure; or raise the loader arm and engage the
loader arm safety support.
5. Rotate the operator seat into the backhoe operation
position.
6. Place the backhoe in the stowed position with swing
lock pin in the lock position. If applicable, insert the Ex-
tendahoe lock pin. You may choose to rest the backhoe
attachment on the ground.
7. Shut off the engine.
8. Turn the key switch to the ON position but DO NOT
start the engine.
9. If equipped with combo auxiliaries, enable the bi-direc-
tional switch on the right-hand side panel.
10. Cycle the bi-directional control lever or pedal.
11. Cycle each backhoe control lever in each direction
and then release in the neutral position.
RAIL14TLB0702AA 3
12. Rotate the operator seat into the driving position.

13. Rotate the loader control joystick in one complete cir-
cle, stopping in the neutral (center) position.
LEEN12T0485AA 4
14. If applicable, operate the bucket control switch.

15. Turn the key switch to the Off position.
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Hydraulic systems - Troubleshooting - Hydraulic pump

580ST
590ST
695ST

System noisy Worn or damaged pump gears or pressure Make a hydraulic pump performance test
plates
Aeration: Air entering the systems at: Suc- Make a hydraulic pump performance test
tion tube, pump shaft, fittings or cylinder
ring nuts
Cavitation: System restrictions in the suc- Make a visual check and/or a hydraulic
tion line or in the tank filter pump performance test
Water in the system Visual check
The system relief valve vibrates Check system relief valve, adjust/overhaul
as necessary
Vibrations in the lines Visual check
Cold hydraulic oil Check the hydraulic oil operating tempera-
ture
Wrong oil type Investigate/drain and top up
Hydraulic oil drain Tank overfilled Check hydraulic oil level
through tank breather
Aeration: Air entering the system at: suc- Make a hydraulic pump performance test
tion tube, pump shaft, fittings or cylinder
ring nuts
Cavitation: Restriction of the suction filter Make a visual check and/or a hydraulic
in the tank pump performance test
Oil heating Low oil quantity Fill the tank
Contaminated oil Drain the tank and refill with clean oil
Too high/low setting of the relief valve Drain the tank and refill with clean oil. Test
relief valves
Oil in system too light Drain the tank and refill with oil with the
correct viscosity
Oil cooler fins obstructed Clean the oil cooler
Oil leaks through the shaft Worn shaft seal Replace shaft seal and inspect pump
seal
Foamy oil Low oil level Fill the tank
Air in the suction system Check/tighten suction line
Wrong oil type Drain and refill with correct oil
Hydraulic systems - Troubleshooting - Swing system

580ST
590ST
695ST

Right or left swing is Swing system relief valves not seating, set Test the swing system relief valve
inoperative, is too slow or too low or seat leaking
loses power
Valve spool leaking Examine swing section of backhoe control
valve assembly for wear or scoring
Piston seals leaking or cylinder barrel dam- Examine/reseal piston and gland
aged
The swing fails to slow Built-in sliding limiter damaged Disassemble and inspect
down (bearing stop) at
stroke end
age
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The swing does not stop The system relief valve (return side) is Test the swing system relief valve
when the control lever stuck open, set to a too low value or there
returns to neutral (one is a leak in the seat
direction only)
Valve spool leaking Examine swing section of backhoe control
Cylinder leak (spools in Internal valve leak Examine appropriate valve section of back-
neutral) hoe control valve assembly for wear or
scoring
aged
A system temporarily Load check valve between control valve Disassemble and inspect
lowers when given the sections damaged
control to lift
Hydraulic systems - Troubleshooting - Control valves

580ST
590ST
695ST

All systems fail to operate Pump drive inoperative Check and repair as necessary
Low oil level Check and top up
Restricted pump suction line Inspect the suction line and the tank and
repair as necessary
Slow operation or loss of Worn pump Perform pump performance test and re-
power in all systems place/reseal as necessary
Restricted pump suction line Inspect the suction line and the tank and
repair as necessary
Load sensing pressure relief valve incor- Make a system pressure test
rectly adjusted
Hydraulic speed solenoid valve inoperative Make a system pressure test
Hydraulic systems - Troubleshooting - Loader

580ST
590ST
695ST

The lifting system fails to Valve spool leaking Examine lift section of loader control valve
operate, is slow or loses assembly for wear or scoring
power
aged
Bucket fails to operate, is The relief valves are stuck open, set to a Check the bucket system relief valve
slow or has loss of power too low value or there is a leak in the seat
Valve spool leaking Examine bucket section of loader control
age
Cylinder leak (spools in Damaged piston barrel Examine/reseal piston and gland
neutral)
Internal valve leak Examine appropriate valve section of
loader control valve assembly for wear or
scoring
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Hesitation in the raising Load check valve between control valve Disassemble and inspect
movement of the loader sections damaged
attachment or of the
bucket cylinders when
the control is initially
actuated
Hydraulic systems - Troubleshooting - Backhoe (Machines with

“Rexroth” control valves)
580ST
590ST
695ST

The lifting system is Lifting system relief valve stuck open, set Test the pressure of the lifting system relief
inoperative, is too slow, too low or seat leaking valve
loses power or does not
hold
Valve spool leaking Examine lift section of backhoe control
valve assembly for wear and scoring
aged
The digging control fails Digging system relief valve (piston end) Test the pressure of the digging system re-
to operate, is slow or stuck open, set too low or seat leaking lief valve
loses power
Valve spool leaking Examine digging section of backhoe con-
trol valve assembly for wear and scoring
aged
The digging control fails The bucket relief valve (rod end) is stuck Test the pressure of the bucket relief valve
to operate, is slow or open, set to a too low value or there is a
loses power leak in the seat
Valve spool leaking Examine bucket section of backhoe control
valve assembly for wear and scoring
aged
The telescopic dipper The telescopic dipper system relief valve Test the pressure of the telescopic dipper
fails to operate, is slow or (piston end) is stuck open, set to a too low relief valve
loses power value or there is a leak in the seat
Valve spool leaking Examine telescopic dipper section of back-
hoe control valve assembly for wear and
scoring
aged
Stabilizer pads leaking Stabilizer relief valve leaking Inspect and overhaul the stabilizer relief
valve
aged
Hydraulic systems - Troubleshooting - Backhoe

580ST
590ST
695ST

The lifting system fails to Valve spool leaking Examine lift section of loader control valve
operate, is slow or loses assembly for wear or scoring
power
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aged
Bucket fails to operate, is The relief valves are stuck open, set to a Check the bucket system relief valve
slow or has loss of power too low value or there is a leak in the seat
Valve spool leaking Examine bucket section of loader control
age
Cylinder leak (spools in Damaged piston barrel Examine/reseal piston and gland
neutral)
Internal valve leak Examine appropriate valve section of
loader control valve assembly for wear or
scoring
Hesitation in the raising Load check valve between control valve Disassemble and inspect
movement of the loader sections damaged
attachment or of the
bucket cylinders when
the control is initially
actuated
Hydraulic systems - Testing Low pilot pressure

580ST
590ST
695ST
Test N°1
Check the flow regulator stand-by pressure before activating any backhoe controls.
Before starting the machine, connect a 69.0 bar (1000.0 psi) gauge and a short hose with a quick discon-
nect fitting to the top test port (A). Refer to Hydraulic systems - Overview Remote test ports (35.000).
The check flow regulator standby pressure should be approximately 14.0 bar (203.0 psi).
Check
Check the pilot pressure by connecting a 69.0 bar (1000.0 psi) gauge and a short hose with a quick
disconnect fitting to the pilot control manifold. The pressure reading should be between 24.0 – 34.0 bar
(348.0 – 493.0 psi).
Expected Result
Result The pressure reading should be between 24.0
– 34.0 bar (348.0 – 493.0 psi).
If the pressure is low, then replace the pres-
sure reducing cartridge.
Action
Behind the pressure reducing cartridge is a
check valve and orifice fitting. These should
be inspected ONLY if a new pressure reduc-
ing cartridge does not solve the problem. The
check valve is removed using a 3 mm hex
wrench. A 4 mm hex wrench is used to re-
move the orifice fitting. The orifice fitting is in-
stalled first, followed by the check valve. Upon RCPH10TLB443ABL 1
installation of the check valve, make certain

that the circle of small holes on one end of the
valve face is to the rear of the manifold port.
This is a very important in order for the check
valve to function properly.
Other Action
Result Go to the next step Hydraulic systems - Delay in operation Backhoe functions are slow and not
(Possible working properly (35.000).
Cause)
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Hydraulic systems - Testing Low pilot pressure at the backhoe

valve pilot port for the specific function. Bad joystick.
580ST
590ST
695ST
Test N°1
Test Point Check
Install a test gauge by disconnecting the hy-
draulic pilot hose or the steel line from the
backhoe control valve for each of the circuits
that need to be tested. In some cases it is eas-
ier to disconnect the hoses from the manifold
valve base. Make sure that you stay within the
same circuit between the pilot manifold and
the backhoe control valve. Remember to work
on the pressure up-side for testing the pres-
sure.
Use a 69.0 bar (1000.0 psi) gauge for testing.
RAIL16TLB0220BA 1
Expected Result
Result The pressure at the pilot ports should be between 24.0 – 34.0 bar (348.0 – 493.0 psi) when the pilot
handles or proportional electric switches are fully shifted. For functions controlled with the hydraulic joy-
sticks, if the pressure is less than 24.0 bar (348.0 psi) and the pilot pressure at the pilot manifold is within
the range of 24.0 – 34.0 bar (348.0 – 493.0 psi), then replace the joystick control valve.
Other Action
Result If the function is electrically controlled, check
(Possible the electronic controller for error codes. If the
Cause) controller displays no error codes, then check
the appropriate proportional solenoid on the
multi-function pressure reducing valve mani-
fold.
If the problem is still not resolved, change
the complete multi-function pressure reducing
valve manifold.
RAIL16TLB0215BA 2
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Index

Hydraulic systems - Hydraulic schematic frame 02 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Excavator and backhoe bucket hydraulic system - Dynamic description (*) . . . . . . . . . . . . . . . . . . . . 6
Excavator and backhoe bucket hydraulic system - Dynamic description (*) . . . . . . . . . . . . . . . . . . . . 7
Hydraulic systems - Check (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Hydraulic systems - Cleaning (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Hydraulic systems - Component identification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Hydraulic systems - Component localization (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Hydraulic systems - Component localization 20 amp fuse for the pilot controls (*) . . . . . . . . . . . . . . . 23
Hydraulic systems - Component localization Sectional compensators (*) . . . . . . . . . . . . . . . . . . . . . . 18
Hydraulic systems - Depressurising . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Hydraulic systems - Drawing Pattern change solenoid (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Hydraulic systems - Drawing Pilot circuit test point (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Hydraulic systems - Drawing Pilot control joystick valve (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Hydraulic systems - Drawing Pilot control relay (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Hydraulic systems - Drawing Pilot controls enable switch (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Hydraulic systems - Drawing Proportional control solenoid and switches (*) . . . . . . . . . . . . . . . . . . . . 25
Hydraulic systems - General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Hydraulic systems - General specification Orientation of the pilot spools in the valve sections (*) . 4
Hydraulic systems - Hydraulic schema Pilot control hydraulic line routing (*) . . . . . . . . . . . . . . . . . . . 20
Hydraulic systems - Overview (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Hydraulic systems - Overview Pilot manifold diagnostic port (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Hydraulic systems - Overview Remote test ports (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Hydraulic systems - Pressure test System pressure checks using the diagnostic port (*) . . . . . . . . . 54
Hydraulic systems - Speeds Engine specifications for the stall test (*) . . . . . . . . . . . . . . . . . . . . . . . . . 4
Hydraulic systems - Technical Data Pump flow specifications (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Hydraulic systems - Testing Low pilot pressure (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
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Hydraulic systems - Testing Low pilot pressure at the backhoe valve pilot port for the specific func-
tion. Bad joystick. (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Hydraulic systems - Troubleshooting - Backhoe (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Hydraulic systems - Troubleshooting - Backhoe (Machines with “Rexroth” control valves) (*) . . . . . 60
Hydraulic systems - Troubleshooting - Control valves (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Hydraulic systems - Troubleshooting - Hydraulic pump (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Hydraulic systems - Troubleshooting - Loader (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Hydraulic systems - Troubleshooting - Swing system (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Hydraulic systems - Visual inspection Bent joystick shaft (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
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Reservoir, cooler, and filters - 300

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Contents
TECHNICAL DATA
Accumulator
SERVICE
Oil reservoir
Drain fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Accumulator
Service instruction - Maintenance (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Service instruction - Safety (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Check (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
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Hydraulic systems - Reservoir, cooler, and filters
Accumulator - General specification

580ST
590ST
695ST
Capacity (gas) 2 L (0.53 US gal)

Capacity (oil) 1.84 L (0.49 US gal)
Pre-charge 29 – 31 bar (421 – 450 psi)
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Oil reservoir - Drain fluid

Prior operation:
Release hydraulic system pressure. Refer to Hydraulic systems - Depressurising (35.000).
1. Place a container with suitable capacity under the hy-

draulic oil tank (1).
NOTE: When draining, it is ideal to have the hydraulic oil
must be at operating temperature.
RAIL15TLB0039AA 1
2. Clean the area around the hydraulic oil tank breather/

filler cap (2), and then loosen and remove the breather/
filler cap.
RAIL15TLB0083AA 2
3. Remove the hydraulic oil tank drain plug (3).

4. Drain the hydraulic oil into a suitable container and
clean the tank.
5. Reinstall and tighten the drain plug.
RAIL15TLB0179AA 3
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Oil reservoir - Filling

1. Make sure that the drain plug (1) is installed on the
bottom of the tank.
RAIL15TLB0039AA 1
2. Fill the hydraulic oil tank with CASE AKCELA NEX-

PLORE™ FLUID until the level reaches the middle of
the gauge (4) when oil is cold or at ambient tempera-
tures.
RAIL15TLB0039AA 2
3. Install and retighten the hydraulic oil tank breather/filler

cap (2).
RAIL15TLB0083AA 3
4. Start the engine and operate the loader attachment and

backhoe attachment functions for 3 to 4 minutes.
5. Lower the loader attachment back to the ground and
place the backhoe attachment in the road travel posi-
tion.
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7. Check the hydraulic oil level.

8. The oil must reach the middle of the gauge (4) when
cold or at ambient temperatures. If necessary, add
more oil.
NOTICE: Even when its level is insufficient, a small quan-
tity of hydraulic oil remains in the lower part of the gauge.
This does not mean that the level is sufficient.
RAIL15TLB0039AA 4
Oil specification and capacity

Use CASE AKCELA NEXPLORE™ FLUID, to refill the
hydraulic oil tank.
NOTE: CASE AKCELA HY-TRAN® ULTRACTION is an
acceptable alternative to CASE AKCELA NEXPLORE™
FLUID.
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Accumulator - Service instruction - Maintenance

580ST
590ST
695ST
Regularly check the gas pre-charge pressure during the

first few weeks of operation.
Then check at suitable intervals based on this initial ex-
perience.
Carry out a visual examination of the accumulator peri-
odically in order to detect any early signs of deteriora-
tion such as corrosion, deformation etc.
Comply with the regulatory provisions concerning the
monitoring of operational equipment.
Before removal, make sure that there is no residual
pressure in the accumulator.
Before carrying out any maintenance operation, dis-
charge the gas of the accumulator using a Parker UCA
charging and measuring device.
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Accumulator - Service instruction - Safety

580ST
590ST
695ST
Charging must be carried out by qualified personnel.

Before taking any readings or pressurizing with nitro-
gen, the accumulator must be isolated from the hy-
draulic system and the fluid side discharged in order
to depressurize it.
Use only nitrogen (N2) to pressurize the accumulator.
Danger of explosion - never charge with oxygen

The types of nitrogen permitted are:
• Type S (99.8% pure)
• Type R (99.99% pure)
• Type U (99.993% pure)
If the pressure of the gas contained in the nitrogen bot-
tle is greater than the maximum permissible operating
pressure of the accumulator, a pressure regulator must
be fitted to the nitrogen bottle.
The pre-charge should be checked during the first week
following commissioning of the system.
Thereafter, it should be checked every three months, or
at intervals determined by the Manufacturer.
Effect of temperature on pre-charge pressure

In order to compensate for the difference in pressure
at ambient and operating temperature, the precharge
pressure po should be adjusted according to the oper-
ating temperature of the system.
Stabilization
The process of charging or discharging an accumulator
with nitrogen causes a temperature change which is
transmitted to the surrounding air as the temperature
of the accumulator stabilizes.
To allow for the effects of temperature transfer, the ac-
cumulator should be allowed to stand for a minimum of
15 min before a final reading of the pre-charge pres-
sure is taken.
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Accumulator - Check
580ST
590ST
695ST
Checking and adjusting the pre-charge pressure

1. Check the pre-charge pressure of the accumulator with
the universal charging and measuring kit 380002714.
2. Connect the kit to the accumulator’s gas valve.
3. To increase the pre-charge pressure, connect the hose
supplied with the kit to nitrogen source.
NOTE: The kit includes two pressure gauges for readings
of 0 – 25 bar (0 – 363 psi) and 0 – 250 bar (0 – 3625 psi).If
a pressure gauge with different reading would be neces-
sary, use the only commercially available.
4. Parts of the kit 380002714 are as follows:
A. Inflation valve
B. Bleed valve
1. UCA
2. Adapter (long)
3. Adapter (short)
4. Adapter (insert)
5. Pressure gauge
6. Protective cap - gauge port
7. Collar - gas port
8. Protective cap - filling port
9. Hose (1/4) with O-ring
LELI12TLB1852BB 1
10. Valve
5. Remove the protective cap (11) from the accumulator,
to gain access to the gas valve (12).
6. Remove the protective cap (6) and connect the ap-
propriate pressure gauge (5) for the pressure to be
checked.
7. Turn the hand wheel in counter-clockwise direction until
the bleed valve (B) is fully closed and inflation valve (A)
is fully raised.
8. Install the short adapter and adapter insert (3) and
(4)on the gas valve (12) and hand tighten.
9. Install the UCA on the adapter.
LELI12TLB1853AB 2
10. Position the assembly to allow easy reading of the
gauge and hand tighten the collar (7).
11. Turn the hand wheel clockwise to open the inflation
valve (A) until the gauge reads the inflation pressure.
Readings and results

There are three possible conditions:
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Nitrogen po pressure is correct

12. Close the accumulator gas valve by turning the hand
wheel (A) counterclockwise.
13. Loosen the bleed valve (B) to release pressure in the
UCA.
14. Remove the UCA from the adapter.
15. Remove the adapters from the accumulator gas valve.
Nitrogen po pressure is too high

16. Loosen the bleed valve (B) to release nitrogen from
the accumulator until the desired pressure po is regis-
tered.
17. Tighten the bleed valve (B) once the desired filling
pressure is reached.
UCA.
20. Remove the UCA from the adapter.
Nitrogen po pressure is too low

22. Close the inflation valve (A) by turning the hand wheel
counterclockwise.
23. Remove the cap (8).
24. Connect the end of the hose (9) to the valve (10).
25. Connect the other end of the hose to the nitrogen
source.
26. Open the valve on the nitrogen source.
27. Turn the hand wheel (A) clockwise to let pressurized
gas in.
NOTICE: Use special care if the accumulator has smaller
capacity.
28. When pressure po is reached, close the valve on the
nitrogen source.
29. To allow for the effects of temperature transfer, the
accumulator should be allowed to stand for a minimum
of 15 min to allow the temperature to stabilize before
a final reading of the pre-charge pressure is taken.
UCA.
32. Remove the hose carefully, to release internal pres-
sure.
33. Refit the cap (8) on the valve (10).
34. Remove the UCA from the adapter(s).
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36. After removing the UCA and adapter(s), make sure

that the accumulator gas valve (12) is sealing effec-
tively.
37. Install the gas valve dust cover (12) and replace the
protective cover (11).
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Index

Accumulator - Check (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Accumulator - General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Accumulator - Service instruction - Maintenance (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Accumulator - Service instruction - Safety (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Oil reservoir - Drain fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Oil reservoir - Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
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Fixed displacement pump - 104

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Contents
TECHNICAL DATA
Fixed displacement pump

Torque (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
FUNCTIONAL DATA

Static description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Hydraulic schema (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
SERVICE

Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
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Hydraulic systems - Fixed displacement pump
Fixed displacement pump - General specification

580ST
590ST
695ST
72 kW - 97 HP pump
Type double gear pump
Displacement 35.427 cm³/rev (2.16 in³/rev) + 35.427 cm³/rev (2.16 in³/rev)
82 kW - 110 HP pump
Type double gear pump
Displacement 40.258 cm³/rev (2.46 in³/rev) + 35.427 cm³/rev (2.16 in³/rev)
Pump ( 97 Hp engine) 1st pump 2st pump

Direction of rotation (looking on drive
Clockwise (D)
shaft)
Displacement 35.427 cm³/rev 35.427 cm³/rev
(2.16 in³/rev) (2.16 in³/rev)
Inlet pressure range for pump 0.7 – 3 bar (10 – 44 psi)
Maximum continuous pressure P1 260 bar (3770 psi) 260 bar (3770 psi)
Maximum intermittent pressure P2 280 bar (4060 psi) 280 bar (4060 psi)
Maximum peak pressure P3 300 bar (4350 psi) 300 bar (4350 psi)
Operating temperature -25 – 80 °C (-13 – 176 °F)
Min P1 350 RPM
Speed
Max P1 3000 RPM
Recommended 12 – 100 mm (0.47 – 3.94 in) (cSt)
Viscosity range
Permitted Max 750 mm (29.53 in)(cSt)
Dp > 200 bar (2900 psi) 8 - Nas 1638
bx = 75 – 10 mm (2.95 – 19 / 17 /14 - ISO 4406
0.39 in)
Contamination class
Dp > 200 bar (2900 psi) 10 - Nas 1638
bx = 75 – 25 mm (2.95 – 21 / 19 /16 - ISO 4406
0.98 in)
Relief valve 174 – 180 bar (2523 – 2610 psi)
Stand by pressure load sensing valve 7 bar (102 psi)
Weight 30 kg (66 lb)

Direction of rotation (looking on drive
Clockwise (D)
shaft)
Displacement 40.258 cm³/rev 35.427 cm³/rev
(2.46 in³/rev) (2.16 in³/rev)
Inlet pressure range for pump 0.7 – 3 bar (10 – 44 psi)
Maximum continuous pressure P1 260 bar (3770 psi) 260 bar (3770 psi)
Maximum intermittent pressure P2 280 bar (4060 psi) 280 bar (4060 psi)
Maximum peak pressure P3 300 bar (4350 psi) 300 bar (4350 psi)
Min P1 350 RPM
Speed
Max P1 3000 RPM
Recommended 12 – 100 mm (0.47 – 3.94 in) (cSt)
Viscosity range
Permitted Max 750 mm (29.53 in)(cSt)
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Dp > 200 bar (2900 psi) 8 - Nas 1638
bx = 75 – 10 mm (2.95 – 19 / 17 /14 - ISO 4406
0.39 in)
Contamination class
Dp > 200 bar (2900 psi) 10 - Nas 1638
bx = 75 – 25 mm (2.95 – 21 / 19 /16 - ISO 4406
0.98 in)
Relief valve 174 – 180 bar (2523 – 2610 psi)
Stand by pressure load sensing valve 7 bar (102 psi)
Weight 30 kg (66 lb)
Fixed displacement pump - Torque

580ST
590ST
695ST
LELI12TLB0682EB 1
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Fixed displacement pump - Component identification

580ST
590ST
695ST
LELI12TLB0686FC 1
1. Screw 19. Bushing

2. Steering control valve 20. Gasket
3. Spool 21. Bushing
4. O-ring 22. Elastic retainer
5. Plug 23. Bearing
6. Valve 24. Gear
7. Filter 25. Gear
8. Fitting 26. Front pump body
9. Spring seat 27. Gasket
10. Spring 28. Gear
11. O-ring 29. Flange
12. Cover 30. Seal ring
13. Relief valve 31. Seal ring
14. O-ring 32. Snap ring
15. Poppet 33. Pressure seal
16. Spring 34. Gear
17. Seat 35. O-ring
18. Rear pump body 36. Screw
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Fixed displacement pump - Static description

580ST
590ST
695ST
The hydraulic pump is mounted on the rear part of the

transmission and is driven by a shaft directly connected
to the engine splined to the torque converter.
The pump consists of two pumping elements, the front

pump (1) and the rear pump (2), and a load sensing flow
divider valve (3) for the steering system.
Oil is drawn through the common inlet port into both pump-
ing elements.
The front pump flow is directed to the loader and backhoe

attachment control valve and also to the sideshift carriage
lock cylinders.
LELI12TLB0681AB 1
The rear pump flow passes through the flow divider valve,
which maintains priority oil flow to the steering system,
with the remaining flow used for the loader and backhoe
control valves.
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Fixed displacement pump - Hydraulic schema

580ST
590ST
695ST
Hydraulic diagram
LELI12TLB0683FB 1
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Fixed displacement pump - Remove

MARBLE CUTTING
DRIVE (2WD)
DRIVE (4WD)
1. Park the machine on a level surface. Put the backhoe

in the transport position. Lower the loader bucket to the
floor.
2. 2.Stop the engine. Turn the key switch and the pilot
control switch to the ON position.
3. 3.Operate the pilot controls and loader controls to re-
lieve any pressure in the system.
NOTE: Mark the location of each hose to aid in the installation process. Plug or cap all open ports.
4. Remove the Steering hose (2) from the pump tee fitting
(A).
5. Remove the diagnostic hose (1) from the pump tee fit-
ting (A).
RAIL17TLB0039BA 1
6. Remove the first pump supply hose hydraulic fitting (1)

from the pump fitting (A).
7. Remove the pump fitting (A).
RAIL17TLB0039BA 2
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8. Remove the second pump supply hose hydraulic fitting

(1) from the pump fitting (A).
RAIL17TLB0039BA 3
9. Remove the pump fitting (A).

10. Unscrew the two clamps (2) and disconnect the hose
(1) from the tube (A).
RAIL17TLB0039BA 4
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11. Remove the four screws (1) and the four washers (2)
and disconnect the gear pump (A) from the transmis-
sion (B).
RAIL17TLB0039BA 5
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Fixed displacement pump - Disassemble

580ST
590ST
To aid reassembly draw an alignment line along the total

length of the pump assembly.
Remove the screws (1).
LELI12TLB0687AB 1
Remove the load-sensing steering control valve (2).

Check and replace the O-rings (35), if necessary.
LELI12TLB0688AB 2
Do not disassemble the steering system relief valve (A)

if the valve’s pressure is to specification when pressure-
testing the pump prior to overhaul.
NOTE: If the steering system pressure relief valve is disas-
sembled, the valve must be reset as described in chapter
“Troubleshooting, pressure and flow testing”.
Wash all components in an approved degreasant and
check the following:
• The valve bore must be free from scoring or damage
to metering edges.
• The spool (3) should slide freely in the bore and must
be free from scoring or damage. LELI12TLB0689AB 3
• Ensure all orifices are clean.

• The valve seat must not show cavities or damage (a
small chamfer at the entrance of the bore is allowed).
• Examine the filter (7) mounted inside the outlet and
relief valves and replace the filter if dirty. Pressure
and flow test the pump.
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Fixed displacement pump - Install

MARBLE CUTTING
DRIVE (2WD)
DRIVE (4WD)
NOTICE: Replace all rings and seals before installation.
1. Secure the return hose (2) with hardware (1) to the

pump (A). Tighten to a torque of 20 N·m (15 lb ft).
RAIL17TLB0038BA 1
2. Connect the gear pump on the transmission (A) and

assemble the four washers (2) and the four screws (1).
Torque to 105 N·m (77 lb ft).
RAIL17TLB0038BA 2
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3. Install the tee fitting (1) on the pump in the orientation

shown.
RAIL17TLB0038BA 3
4. Secure the steering hose hydraulic fitting (1) and torque

to 65 N·m (48 lb ft).
5. Secure the diagnostic hose hydraulic fitting (2) and
torque to 44 N·m (32 lb ft)
RAIL17TLB0038BA 4
6. Assemble the first pump supply hose hydraulic fitting

(1) on the fitting (A). Torque to 150 N·m (111 lb ft).
RAIL17TLB0036BA 5
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7. Assemble the second pump supply hose hydraulic fit-

ting (1) on the fitting (A). Torque to 150 N·m (111 lb ft).
RAIL17TLB0036BA 6
8. Connect the hose (1) on the tube (A) and assemble the
two clamps (2). Torque to 12 N·m (106 lb in).
RAIL17TLB0039BA 7
9. Check the hydraulic oil. If necessary add hydraulic

fluid.
11. Run the machine at low idle for 3 - 4 minutes.
12. Increase engine speed to high idle for 1 minute.
13. Operate the loader controls for 2 - 3 minutes.
14. Operate the backhoe controls for 2 - 3 minutes.
15. Lower the loader attachment back to the ground and
place the backhoe attachment in the road travel posi-
tion.
17. Check the hydraulic oil level.
18. The oil must reach the middle of the gauge when cold
or at ambient temperatures. If necessary, add more
oil.
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Index

Fixed displacement pump - Component identification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Fixed displacement pump - Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Fixed displacement pump - General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Fixed displacement pump - Hydraulic schema (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Fixed displacement pump - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Fixed displacement pump - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Fixed displacement pump - Static description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Fixed displacement pump - Torque (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
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Variable displacement pump - 106

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Contents
TECHNICAL DATA
Variable displacement pump

FUNCTIONAL DATA

SERVICE

Remove Closed Center Axial Piston Pump (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Inspect (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Install Closed Center Axial Piston Pump (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
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Hydraulic systems - Variable displacement pump
Variable displacement pump - General specification

580ST
590ST
695ST
As an alternative to the fixed-flow-rate gear pump, the machine can be provided with a variable-flow rate pump.
72 kW (98 Hp) pump
Model DANFOSS J71C Series 45
Displacement 71 cm³/rev (4.33 in³/rev)
82 kW (111 Hp) pump
Model DANFOSS J75C Series 45
LELI12TLB0901GA 1
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Variable displacement pump - Component identification

580ST
590ST
695ST
LELI12TLB0902GB 1
1. Snap ring 28. O-ring

2. Seal ring 29. Load-sensing control valve
3. Pump body 30. Screw
4. O-ring 31. Piston
5. Plug 32. Piston disc
6. Plug 33. Articulation
7. O-ring 34. Pin
8. Bearing 35. Cylinder
9. Shaft 36. Washer
10. Cradle bearing 37. Spring
11. Pin 38. Washer
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12. Snap ring 39. Ring

13. Pin 43. Plug
14. Swash plate 44. O-ring
15. Spring 45. Spool
16. Piston 46. Valve body
17. Cylinder assy 47. O-ring
18. O-ring 48. Plug
19. Bearing 54. Plug
20. Pin 55. O-ring
21. Valve plate 56. Spring guide
22. Check valve 57. Spring
23. Spring 58. Spring
24. O-ring 59. Back-up ring
25. Plug 60. O-ring
26. Cover 61. Adjusting screw
27. Screw 62. Screw
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Variable displacement pump - Remove Closed Center Axial Piston

Pump
580ST
590ST
695ST
1. Park the machine on a level surface. Put the backhoe

in the transport position. Lower the loader bucket to the
floor.
2. Stop the engine. Turn the key switch and the pilot con-
trol switch to the ON position.
3. Operate the pilot controls and loader controls to relieve
any pressure in the system.
NOTE: Mark the location of each hose to aid in the installation process. Plug or cap all open ports.
4. Disconnect the LS hose (2) from fitting (4).
5. Disconnect the hammer LS hydraulic hose (5) from fit-
ting (3), if installed.
6. Disconnect the hand hammer LS hydraulic hose (1)
from fitting (3), if installed.
7. Remove fitting (3) and fitting (4) from the pump.
RAIL16TLB0121FA 1
8. Disconnect the pump drain hose (4) from fitting (3).

9. Disconnect the pilot valve drain hose (1) from fitting (2),
if installed.
10. Disconnect the 4x1 pilot valve drain hose (5) from fit-
ting (2), if installed.
11. Remove fitting (3) and fitting (2) from the pump.
RAIL16TLB0122FA 2
12. Disconnect the pump supply hose (1) from the hy-
draulic fitting (2).
13. Disconnect the hydraulic hose (3) from hydraulic fitting
(2)
14. Remove hydraulic fitting (2) from the pump.
RAIL16TLB0123FA 3
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15. Disconnect hose (1) from fitting (2).

16. Remove fitting (2) from the pump.
RAIL16TLB0124FA 4
17. Loosen the two clamps (4).

18. Disconnect hose (3) from tube (2).
19. Loosen the screws (1) securing the tube (2) to the
pump.
20. Remove tube (2).
RAIL16TLB0125FA 5
21. Loosen the four bolts (2).

22. Use a suitable lifting device to support the pump on
the engine.
23. Remove the four bolts (2), the four washers (3) that
secure the pump to the engine (1).
24. Carefully remove the pump from the engine (1).
RAIL16TLB0126FA 6
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Variable displacement pump - Disassemble

580ST
590ST
695ST
1. Remove bolts (30). Remove the load-sensing control

valve (29).
2. Remove and discard the O-rings (28).
LELI12TLB0903AB 1

4. Remove the end cap (26). Make sure that the valve
plate (21) does not fall.
5. Remove the bearing (19) and O-ring (18).
LELI12TLB0904BB 2
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6. Drain oil from the pump body.

7. Remove the cylinder assembly (17).
LELI12TLB0905AB 3
8. Turn the pump body (3) so that the shaft points down-
wards.
9. Remove the shaft (9).
10. Compress the spring (15) and rotate the piston (16)
towards the swash plate (14) and remove the swash
plate/piston assembly.
11. Remove the pin (13) and snap ring (12). Remove the
piston (16) and spring (15) from the swash plate (17).
LELI12TLB0906BB 4

13. Check the cradle bearings (10). If replacement is nec-
essary, remove the pins (11) and cradle bearings (10).
14. Make identification marks to enable easy re-installa-
tion.
LELI12TLB0907AB 5
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NOTICE: Additional force may be required to remove the
seal ring. Try to push the seal from the inside of the pump
body using a punch and hammer.
LELI12TLB1473BB 6
Disassembly of the load-sensing control valve (29)

1. Remove the plugs (43), (46) and (48) and O-rings (44)
and (47).
3. Remove the spool (45). Make a note of the bore each
spool came out of and orientation of the spools.
4. Remove the adjusting screw (61), O-ring (60) and
back-up ring (59).
5. Remove the springs (57) and (58) and spring guide
(56).
NOTE: When you reassemble the valve, the settings has
to be reset.
LELI12TLB1474BB 7
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Disassembly of the cylinder (17)

1. Identify the pistons and bores. Remove the piston disc
(32) and pistons (31) from the cylinder (35).
2. Remove the articulation (33).
NOTE: Perform this procedure only if the spring are to be
replaced.
4. Using a press, apply pressure on the washer (38).
Compress the spring (37) and remove the ring (39).
5. WARNING
assemble properly.
ous injury.
W0356A
Remove the washer (38), spring (37) and washer (36)

from the cylinder (35).
NOTICE: The spring (37) requires about 350 – 400 N (79
– 90 lb) force for compression.
NOTICE: Ensure that the spring is secure before attempt-
ing to remove the ring (39). Release the pressure slowly
after the ring (39) has been removed.
LELI12TLB1475BB 8
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Variable displacement pump - Inspect

580ST
590ST
695ST
1. Wash all parts (including the end cap and the pump
body) thoroughly with clean solvent and allow to air dry.
2. Clean the oil ducts in the pump body and the end cover
with compressed air.
3. Conduct inspection in a clean area and keep all parts
free from contamination.
4. Inspect the pistons (31) for damage and discoloration.
Discolored pistons may indicate excessive heat; do not
reuse.
5. Check the pistons and replace:
• Pistons with scored or excessively rounded edges
(running edges (A)).
• Pistons with foot thickness (B) less than 3.23 mm
(0.13 in).
• Pistons with axial end-play (C) of more than
0.05 mm (0.002 in).
LELI12TLB1476AB 1
6. Check the articulation (33) for nicks, scratches and

make sure that it is not excessively scored. Replace
if necessary.
7. Examine for discoloration that may indicate excessive
heat or lack of lubrication. Replace if necessary.
8. The piston disc (32) must be flat. The pistons must
align with a minimum side play. Replace if necessary.
9. Make sure that the pins (34) are straight. Replace if
necessary.
LELI12TLB1477AB 2
10. If the cylinder assembly was fully dissembled, visu-

ally inspect the cylinder block, spring (37) and wash-
ers (36), (38). Replace if cracks or other damage is
present.
LELI12TLB1478AB 3
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11. Examine the running face of the cylinder (35). The

surface should be smooth and free of nicks and burrs.
12. Ensure that no scratches or grooves exist; these may
drastically reduce output flow. Make sure that the di-
mensions “D” and “E” are as follows:
LELI12TLB1479AB 4
Minimum height (D) 62.25 mm (2.45 in)

Maximum bore diameter (E) 19.8 mm (0.78 in)
Inspection of the load-sensing control valve (29).

1. Carefully checks the plugs (43), (46) and (48) for signs
of wear.
2. Inspect all springs to make sure they are intact.
3. Check the inside and outside surfaces of the springs
for wear.
4. Check the spool (45) outside diameter for scratches
and/or burrs.
5. Clean and coat all spools, bores and seals with a light
coating of oil.
LELI12TLB1474BB 5
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6. Make sure that the shaft (9) and its splines are straight
and free of damage or heavy wear.
7. Inspect the shaft surface where it meets the seal ring.
8. Replace the shaft if a groove exists at the sealing land
surface that may let dirt into or hydraulic oil out of the
unit.
9. Clean the sealing area with non-abrasive material.
10. Lubricate the shaft with a light coat of oil.
LELI12TLB1480AB 6
11. Carefully inspect each surface of the swash plate (14)

for wear. All swash plate surfaces should be smooth.
12. Inspect the swash plate’s running surface for damage
and brass transfer.
13. Excessive transfer may indicate that the pistons
should be replaced.
14. Check the swash plate pin for scratches.
LELI12TLB1481AB 7
15. Inspect the cradle bearings (10) for damage or exces-

sive wear.
16. The polymer wear layer must be smooth and intact.
17. Replace if scratched or excessively worn.
18. Inspect the valve plate (21) for scratches or grooves.
19. Check the plate for evidence of any cavitation along
the running face.
20. If pitting from cavitation exists, replace the valve plate.
21. Check for excess wear on the running face. If discol-
oration or burn marks are observed, replace. LELI12TLB1482AB 8
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35.4 [35.106] / 14
22. Run a fingernail or a pencil tip across the diameter

of the sealing land surface. No deep or outstanding
grooves should be felt, as these may decrease pump
flow. Lap or replace if grooves or nicks are present.
23. Inspect the mating surfaces of the end cap and valve
plate for any possible contamination.
24. Measure the thickness of the valve plate (21).
25. Make sure that valve plate parallelism is equal to or
less than 0.025 mm (0.0010 in).
26. Appearance should be flat and smooth on both the
running face and the bottom surface.
LELI12TLB1483AB 9
27. The valve plate should be flat to 0.005 mm (0.0002 in)
convex.
28. Carry out a magnetic particle inspection to detect pos-
sible cracks.
29. The plate (21) must be replaced in case of cracks.
30. Check the cover (26).
31. Remove the check valve (22) to expose the spring
(23).
32. Check and record orientation of the pin (20). The split
in the pin should be facing into or out of the slot in the
valve plate.
33. Inspect the check valve (22) for wear on its sealing
face.
34. Make sure that the spring (23) is not damaged.
35. Replace any components if any sign of excessive
wear is present. LELI12TLB1484AB 10
36. Check that the piston assembly (16) and the cor-
responding end cap bore for any wear, damage or
galling.
LELI12TLB1485AB 11
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37. Inspect the pump body (3) to ensure that it is clean

and free of foreign material.
38. Inspect the surfaces of the cradle bearings and the
mating surfaces of the end cover.
LELI12TLB1486AB 12
39. Make sure the cup (B) and cone (A) of the bearings
(8) are free of excessive wear or contamination.
40. Rotate the bearing to check for smoothness.
41. If a contaminated bearing is suspected, clean with sol-
vent and lubricate with hydraulic oil.
42. Inspect for uneven wear.
LELI12TLB1487AB 13
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Variable displacement pump - Assemble

580ST
590ST
695ST
1. Coat the cradle bearings (10) with oil and install them
in the pump body (3).
2. Insert the pins (11) with a minimum of 0.5 mm (0.02 in)
below the bearing surface.
NOTICE: If the bearings (10) are reused, reinstall them in
their original position.
3. Install the bearing (8).
4. Before replacing the spring (15), coat the contact sur-
face of the swashplate (14) with oil.
5. Install the swashplate (14), piston (16) and spring (15)
in the pump body (3).
6. Rotate the piston (16) perpendicularly to the swash-
plate (14) and at the same time, compress the spring
(15) to fit it into the pump body (3).
7. Lubricate all sides of the piston (16), its relevant bore
and flat face of the swashplate with more oil to prevent
premature wear during start-up.
8. Install the shaft (9) through the bearing in the body.
NOTICE: To insert the shaft properly, rotate the swashplate
by pushing the piston.
LELI12TLB1488BB 1
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9. Lubricate all the components before assembly.
10. WARNING
assemble properly.
ous injury.
W0356A
Install the inner washer (36), spring (37) and outer

washer (38) in the cylinder (35). Compress the spring
enough to insert the ring (39).
NOTICE: Compressing the spring (37) requires about 350
– 400 N (79 – 90 lb). Use a press sufficient to maintain this
force.
NOTICE: Ensure that the spring is secure before attempt-
ing to assemble the ring (39).
11. Install the pins (34) and ball guide (33) in the cylinder
(35).
12. Install the pistons (31) in the piston disc (32).
13. Install the piston/disc assembly in the cylinder (35).
14. Make sure that the concave surface of the disc seats
correctly in the ball guide. If reusing the pistons, install
LELI12TLB1475BB 2
them to the original cylinder bores.
15. Lubricate the pistons (31), piston disc (32) and ball
guide (33) before assembly.
NOTICE: The concave side of the piston disc (32) should
mate correctly with the articulation (33) (convex side of the
ball guide).
16. Install the pre-assembled cylinder assembly (17) on
the shaft (9).
LELI12TLB1489AB 3
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17. Clean the valve plate (21) and end cap.

18. Install the pin (20) in the end cap (26). Make sure that
it is properly aligned with the split facing into or out of
the slot in the valve plate (21).
NOTICE: The pin should be 3.36 – 3.86 mm (0.13 –
0.15 in) above the valve plate (21) surface.
19. Apply a large quantity of grease to the backside of the
valve plate (21) surface to hold it in position.
20. Install the valve plate (21) on the pin (20).
21. Install the spring (23) and check valve (22).
22. Install the bearing cup (19).
NOTICE: For correct pump operation, it is extremely impor-
tant to guarantee that there is no contamination between
the end cap (26) and the valve plate (21).
LELI12TLB1490BB 4
23. Install the bearing race (19) on the shaft (9).

25. Install the cover (26) on the body (3) with the bolts
(27). Torque the bolts (27) to 127 – 155 N·m (94 –
114 lb ft).
LELI12TLB1491BB 5
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26. Lubricate the seal ring (2) with oil.

NOTICE: Place a protective sleeve over the shaft end (9)
to prevent damage to the seal ring during installation.
27. Install the seal ring (2) with the snap ring (1).
NOTICE: The concave side of the seal ring (2) should face
towards the shaft bearing.
LELI12TLB1492BB 6
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Variable displacement pump - Install Closed Center Axial Piston

Pump
580ST
590ST
695ST
1. Use an appropriate lifting device to lift the pump to the

machine.
2. Carefully fit the pump into the engine (1).
3. Secure the pump to the engine (1) using the four bolts
(2) and the four washers (3).
4. Tighten the bolts (2) to 105.0 N·m (77.4 lb ft).
RAIL16TLB0126FA 1
5. Install fitting (4) on to the pump. Install fitting (3) on to

the pump.
6. Connect the LS hose (2) to fitting (3). Tighten the hose
to 44.0 N·m (32.5 lb ft).
7. Connect the hammer LS hose (5) to fitting (4). Tighten
the hose to 44.0 N·m (32.5 lb ft).
8. Connect the hand hammer LS hose (1) to fitting (3).
Tighten the hose to 44.0 N·m (32.5 lb ft).
RAIL16TLB0121FA 2
9. Install fitting (2) on to the pump.

10. Connect the pump supply hose (1) on to the fitting (2).
11. Connect the pump supply hose (3) on to the fitting (2).
RAIL16TLB0122FA 3
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12. Install the fitting (2) on to the pump.

13. Connect the diagnostic hose (1) to fitting (2). Tighten
the hose to 16.0 N·m (11.8 lb ft).
RAIL16TLB0124FA 4
14. Fit the tube (2) to the pump. Secure the tube (2) to the
pump using the screws (1).
15. Slide the two clamps (4) over the tube (2).
16. Slide the hose (3) on to the tube (2).
17. Secure the hose (1) to the tube (2) using the two
clamps (4).
RAIL16TLB0125FA 5
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Index

Variable displacement pump - Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Variable displacement pump - Component identification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Variable displacement pump - Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Variable displacement pump - General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Variable displacement pump - Inspect (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Variable displacement pump - Install Closed Center Axial Piston Pump (*) . . . . . . . . . . . . . . . . . . . . . 21
Variable displacement pump - Remove Closed Center Axial Piston Pump (*) . . . . . . . . . . . . . . . . . . . 6
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Pump control valves - 102

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Contents
FUNCTIONAL DATA
Pump control valves

Fixed displacement pump - Component localization (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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Hydraulic systems - Pump control valves
Fixed displacement pump - Component localization

580ST
590ST
695ST
Load-sensing valve
LELI12TLB0684FB 1
1. Orifice 8. Steering relief valve

2. Rear systems (EF) 9. Relief valve adjuster
3. Filter 10. Poppet
4. Spool 11. Return to inlet pump port
5. To steering priority flow (CF) 12. Lock plug
6. Orifice 13. Load sensing signal (LS)
7. Inlet port from rear pump (IN) 14. Orifice
When the steering is in neutral the load sensing port is connected to the unload (through the steering) and the steering
inlet port (CF) is open.
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Hydraulic systems - Pump control valves
LELI12TLB0685EB 2
Load sensing valve with pump running - steering in neutral
Return to oil tank
Trapped oil
Pressure oil
1. Orifice 5. To steering priority flow (CF)

2. Rear systems (EF) 6. Orifice
3. Filter 7. Inlet port (from rear port)
4. Spool
The pressure on (CF) increases until the pressure value (stand-by pressure) is sufficient to move the spool valve in a
way to divert the flow toward (EF).
LELI12TLB0686EB 3
Load sensing valve with pump running - steering working
Trapped oil
Return to oil tank
1. Orifice 5. To steering priority flow (CF)

2. Rear systems (EF) 6. Orifice
3. Filte 7. Inlet port (from rear port)
4. Spool
During steering two actions are performed:
1. The fluid moves to the steering through (CF).

2. The (LS) signal is in communication to the steering.
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Index

Fixed displacement pump - Component localization (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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Safety and main relief valves - 350

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Contents
FUNCTIONAL DATA
Relief valve
SERVICE
Relief valve
Safety and main relief valves - Overhaul (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Safety and main relief valves - Service instruction (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Adjust (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
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Hydraulic systems - Safety and main relief valves
Relief valve - Static description

580ST
590ST
695ST
Relief valves
There are different relief valves installed on the loader and
backhoe attachment control valves.
The relief valves may be operated with anti-cavitation fea-

ture (1) or direct acting (2) and protect the single systems
from excessive pressure.
LELI12TLB1921AB 1
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Safety and main relief valves - Overhaul

580ST
590ST
695ST
Before removing the relief valves from the machine,

lower the loader and backhoe attachment to the
ground, stop the engine and relieve pressure in all
systems by moving the backhoe attachment, loader
attachment and telescopic dipper controls through all
operating positions. If the pressure relief valves are
suspected of contamination, they may be disassem-
bled and inspected for wear. During assembly, restore
the correct pressure.
During disassembly examine the poppet and seat in the
plunger assembly for a complete seating surface.
Pilot operated relief valve
LELI12TLB1929EB 1
1. Body 9. O-ring
2. Shutter 10. Nut
3. Spring 11. O-ring
4. Spring 12. Adjusting screw
5. O-ring 13. Spring
6. O-ring 14. Pilot valve
7. Valve 15. Poppet
8. Cover 16. Piston
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Direct acting circuit relief valve
LELI12TLB1930EB 2
1. Body 6. Cover
2. Poppet 7. O-ring
3. Spring 8. Nut
4. Spring 9. O-ring
5. Shim 10. Adjusting screw
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Loader bucket relief valve
LELI12TLB1931EB 3
1. Relief valve assembly 7. Piston

2. Spring 8. Poppet
3. Nut 9. Valve
4. Body 10. Inner body
5. Adjusting screw 11. Spring seat
6. Spring
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Safety and main relief valves - Service instruction

580ST
590ST
695ST
Operation
Relief valve inoperative

When the system is not subject to overload conditions
pressure in the system is insufficient to overcome pilot
valve spring pressure and move the valve of its seat.
System pressure sensed on the larger rear face of the
poppet valve maintains the poppet and sleeve firmly on
their seats.
1. Sleeve
2. Poppet valve
3. Pilot valve
4. Pilot valve body
5. Piston
LELI12TLB1922AB 1
6. Control valve (cylinder) exhaust gallery
7. Cylinder supply gallery
Exhaust oil
High pressure oil
Pilot valve operation

When the cylinder is subjected to shock forces, the
pressure increase in the cylinder supply gallery ex-
ceeds the pilot valve spring pressure: this valve lifts off
its seat.
System pressure on the rear face of the poppet valve
escapes to tank between the sleeve poppet and valve
body causing a pressure differential between the front
and rear face of the poppet valve.
The higher pressure in the cylinder supply gallery un-
seats the poppet valve and moves the piston to seat
against the pilot valve.
1. Sleeve
2. Poppet valve LELI12TLB1923AB 2
3. Pilot valve
4. Pilot valve body
5. Piston
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Exhaust oil
High pressure oil
Reduced pressure oil
Pilot and poppet valve operation

The excessive system pressure in the cylinder supply
gallery now flows past the poppet valve to the cylinder
exhaust gallery and back to tank.
NOTE: During this operation the sleeve poppet is held in
the fully seated position by pressure oil.
1. Sleeve
2. Poppet valve
3. Pilot valve
4. Pilot valve body
5. Piston
LELI12TLB1924AB 3
High pressure oil
Exhaust oil
Reduced pressure oil
Anti-cavitation operation
Relief valves with an anti-cavitation feature are fitted in
systems where a rapid extension of the cylinder could
create a void condition and permit the transfer of oil from
the high pressure side of a cylinder to the low pressure
(void) side.
When for example the boom is rapidly lowered and the
cylinder rod end circuit relief valve operates, oil has
been removed from the rod end of the cylinder and a
void created in the piston end. This oil is automatically
replenished by the anti-cavitation device in the opposite
circuit relief valve as follows:
The void creates a pressure lower in the cylinder supply
gallery and back pressure in the control valve exhaust
gallery acts on the outer face of the sleeve poppet mov-
ing it to the right.
Exhaust oil is then directed into the cylinder supply
gallery to stop cavitation.
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LELI12TLB1925FB 4
High pressure oil
Anti-cavitation oil supply to cylinder
Relief valve exhaust oil

1. Anti-cavitation system pressure relief valve
2. Cylinder rod
3. System pressure relief valve
4. Control valve exhaust gallery
5. Spool
Pilot-operated pressure relief valve with anti-cavitation feature subjected to overload and
fully relieving high-pressure oil
1. Sleeve
2. Poppet valve
3. Pilot valve
4. Pilot valve body
5. Piston
LELI12TLB1926AB 5
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Anti-cavitation cylinder resupply oil
Exhaust oil
Direct-acting pressure relief valve operation

High-pressure oil in the system is sensed in the cylinder
supply gallery and acts on the surface of the pressure
relief valve poppet.
When pressure in the system exceeds the pressure re-
lief valve setting, the oil pressure lifts the poppet, allow-
ing excess pressure in the overloaded cylinder to es-
cape to the drain gallery.
LELI12TLB1927AB 6
A. Direct acting circuit relief valve

Valve not subjected to overload conditions
B. Direct acting circuit relief valve
Valve subjected to overload conditions
1. Relief valve seat
2. Relief valve poppet
3. Valve pressure adjusting screw
4. Spring
5. Control valve exhaust gallery
6. Cylinder supply oil
LELI12TLB1928AB 7
Exhaust oil
High-pressure system oil
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Relief valve - Adjust

580ST
590ST
695ST
System pressure relief valve adjustment

1. After overhaul, the pressure relief valves of the sys-
tem must be tested and adjusted using a suitable hand
pump (1), a 275 bar (3988 psi) pressure gauge and a
test kit (2).
LELI12TLB1932AB 1
2. Attach the hand pump to the inlet port Ι and the drain
hose to the outlet port T of test block using suitable
adaptors.
NOTE: The pressure gauge may be connected to either
the hand pump or to the 3/8 UNF threaded port “G” in the
test block.
3. Remove the plug and insert the valve to be tested into
the appropriate port in the test block:
A. Stabilizer and backhoe relief valves
B. Loader bucket relief valves
C. Unload valve
LELI12TLB1933AB 2
NOTE: A special removable insert, which is part of the test

block, is installed in the bottom part of the port used for test-
ing the loader attachment valve. If difficulty is experienced
in screwing the loader valve into the test block, check that
the insert is fully seated and correctly installed. When cor-
rectly installed the O-ring (3) on the face of the insert should
be visible.
LELI12TLB1934AB 3
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4. Operate hand pump and record maximum pressure

reading on gauge. Compare pressure values with pre-
vious specifications.
NOTICE: Before removing the valve from the test block,
release the pressure in the system using the vent valve on
the hand pump.
LELI12TLB1935AA 4
5. Remove the valve cap, loosen locknut and turn adjuster

to obtain correct pressure.
NOTICE: Not applicable for the loader bucket relief valve.
NOTICE: Relief valves must not be set outside off the spec-
ified range.
LELI12TLB1936AA 5
Loader bucket relief valve adjustment

6. If the loader bucket circuit relief valve requires adjust-
ment, use the special adjusting tool supplied with the
test kit.
7. Hold relief valve in vice and using wrench supplied with
tool, remove the internal valve assembly from the valve
body.
8. Install the internal valve assembly (2) in the body of the
adjusting tool (1).
LELI12TLB1937AB 6
9. Install valve into test block and operate hand pump until
valve is pressurized to 170 bar (2465 psi).
10. Using the special wrench supplied, loosen the locknut
on the end of the valve and adjust pressure setting.
11. Operate hand pump and recheck pressure.
12. When pressure setting is correct tighten locknut and
release pressure in circuit using the vent valve on the
hand pump.
13. Remove the valve and, using a 3/8” UNC 16 UNC bolt,
remove the insert.
LELI12TLB1938AA 7
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14. Reinstall the valve and install it on the test block.

15. Operate hand pump and recheck pressure.
16. If pressure is now lower than that recorded with the
insert installed it is an indication that the anti-cavitation
feature of the valve is leaking and the valve requires
overhaul or replacement.
17. The insert isolates the anti-cavitation feature of the
valve. When reassembling the insert into the test
block ensure it is installed correctly. When correctly
installed the O-ring (3) on the face of the insert should
be visible.
LELI12TLB1939AB 8
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Index

Relief valve - Adjust (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Relief valve - Static description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Safety and main relief valves - Overhaul (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Safety and main relief valves - Service instruction (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
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Pilot system - 357

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Contents
Pilot system - 357
FUNCTIONAL DATA
Pilot system
Overview Introduction (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Overview Pilot electronic controller (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Overview Pilot manifold solenoids (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Overview Pilot enable switch (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Overview Control pattern change switch (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Overview Stabilizer switches (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Overview Extendahoe® and bi-directional auxiliary buttons (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
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Hydraulic systems - Pilot system
Pilot system - Overview Introduction

580ST
590ST
695ST
The Case N series loader backhoe has optional pilot backhoe controls available to the customer. The pilot controls
use a low pressure pilot oil to operate the backhoe control valve spools. This low pressure pilot oil is metered by the
pilot control joysticks for the boom, the dipper, the bucket, and the swing functions, or electrically controlled PWM
solenoids for the left stabilizer and the right stabilizer, the Extendahoe®, and the bi-directional auxiliary functions.
These PWM solenoids are actuated by a standalone electronic controller. This pilot controller interprets the operator
inputs from various control switches and buttons and then sends out a PWM signal to the appropriate solenoid on the
pilot manifold.
RAIL16TLB0175GA 1
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Pilot system - Overview Pilot electronic controller

580ST
590ST
695ST
The pilot control module, located under the machine cab, adjacent to the pilot manifold, controls all of the electronic
functions of the pilot control system. The pilot control module interprets the Hall Effect signal voltages from the sta-
bilizer, the Extendahoe®, or the bi-aux input proportional switches. The pilot control module then sends a variable
PWM signal in a range of 10% to 100% duty cycle at a frequency of 100 Hz to the appropriate solenoid coils located
on the pilot manifold. This variable PWM signal to the solenoid valve, located on the pilot manifold, controls the pilot
pressure signal applied to the backhoe valve control spools, providing proportional function control for the operator.
The pilot control module contains an LED status light next to the harness connector to communicate system operation
and faults. The LED status light will show the following conditions:
• LED light is off - no power or ground to the pilot controller.

• LED light is on continuously - controller is on, but there is a software problem with the pilot control module.
• LED light is flashing slowly, on for 3 s, then off for 0.2 s - this is an “OK” condition indicating that the pilot
control module is ready for use with no fault conditions present.
• LED light is flashing quickly, on for 0.25 s and off for 0.25 s - this is a fault condition, and there will be a
2 s pause between fault indications. If multiple fault codes are present, only the highest numeric flash code
will be generated.
The following four fault codes can occur:
Flash Code Condition

1 The input signal voltage is below the low threshold.
2 The input signal is above the high threshold.
3 The input signal is not in neutral upon power-up.
4 Output driver fault – A short circuit or an open circuit at the PWM output solenoids.
When the pilot control module is initially powered on, it immediately checks the status of the input switches and buttons
to ensure that they are all in a neutral position. This is a safety feature to prevent inadvertent actuation and movement
of the pilot electronic functions. If one of the input switches or buttons is not in neutral, the pilot control module will lock
out the actuation of that single function in both travel directions and it will communicate a fault condition (flash code
3) until the pilot control module is powered down, then powered up again. The other electronic functions will continue
to operate. If an electrical fault in the pilot control system occurs during operation, a flash code is generated, and
the function in which the faulty circuit is located will be locked out in both travel directions, until the fault condition is
corrected. Fault codes only occur while active, and there is no way for the technician to access any historic or inactive
fault codes. For troubleshooting, the knowledge of the active flash code indicated by the pilot control module and
which function is inoperative will serve to isolate the malfunction to one particular circuit (input signal voltage circuits
for flash codes 1, 2 and 3, or output coil driver circuits for flash code 4). See the sections regarding the individual
switches for more information on the low, high, and neutral voltage thresholds of each of the input circuits.
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Pilot control module harness connector
RAIL16TLB0196FA 1
Pin Wire ID Function

1 6013 Orange 12 V power supply
2 G153 Black Ground
3 6030 White PWM to left-hand stabilizer up solenoid
4 6040 White PWM to left-hand stabilizer down solenoid
5 6050 White PWM to right-hand stabilizer up solenoid
6 6060 White PWM to right-hand stabilizer down solenoid
7 6070 White PWM to Extendahoe® extend solenoid
8 6080 White PWM to Extendahoe® retract solenoid
9 6090 Yellow Left-hand stabilizer input signal voltage
10 6100 Yellow Right-hand stabilizer input signal voltage
11 6110 Yellow Extendahoe® retract input signal voltage
12 6120 Yellow Extendahoe® extend input signal voltage
13 6130 Yellow Left-hand stabilizer pressure switch input
Ground < 189.7 bar (2750.0 psi)
Open > 189.7 bar (2750.0 psi)
14 6140 Yellow Right-hand stabilizer pressure switch input
Ground < 189.7 bar (2750.0 psi)
Open > 189.7 bar (2750.0 psi)
15 0731 Yellow PWM to bi-aux forward solenoid
16 6161 Pink 5 V supply to Hall Effect input sensors
17 6170 Yellow Bi-aux forward input signal voltage
18 6180 Yellow Bi-aux reverse input signal voltage
19 Not used
20 Not used
21 0728 Blue Combo aux input
Ground for uni-aux
Open for bi-aux
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Pin Wire ID Function

22 0727 Blue Combo aux input
Ground for uni-aux
Open for bi-aux
23 6230 White PWM to bi-aux reverse solenoid
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Pilot system - Overview Pilot manifold solenoids

580ST
590ST
695ST
The pilot manifold contains all of the solenoid valves which the pilot control module will actuate based on input from
the operator. Three of the solenoids, the two pattern change solenoids and the joystick enable solenoid, are simple
on / off valves which are actuated by energizing the solenoid coil. Up to eight gold colored coils, the left and the right
stabilizer solenoids, the Extendahoe® solenoids, and the bi-aux solenoids are actuated by a variable PWM current
supplied by the pilot control module. The increasing PWM current across the solenoid coil results in a higher magnetic
field, which causes a rising pressure output from the solenoid valve. This variable pressure is applied to the backhoe
valve spools to provide accurate operator control of the hydraulic function.
The following table provides information regarding these coils found on the pilot manifold.
Solenoid Function Coil resistance

Joystick enable Activated by the pilot relay, when the Approximately 6 Ω.
coil is energized, pilot oil pressure is
sent to the joysticks, Extendahoe®
solenoids, and the bi-directional
solenoids.
Pattern change Both solenoids activate Approximately 6 Ω.
simultaneously to swap the boom
and dipper functions between the left
joystick and the right joystick. When
the solenoids are not energized, the
boom function is on the left joystick.
When the solenoids are energized,
the boom function is on the right
joystick.
Stabilizer, Extendahoe®, and Gold colored PWM solenoid pairs Approximately 6 Ω.
bi-directional aux activate to send pilot oil to each end
of the backhoe control spools. The
pilot control module will send a range
of 10% to 100%
12 V duty cycle at a frequency of
100 Hz.
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RAIL16TLB0197GA 1
1 Pattern change solenoids 7 Bi-directional auxiliary A port PWM

solenoid
2 Right-hand stabilizer retract solenoid 8 Extendahoe® extend PWM solenoid
3 Left-hand stabilizer retract solenoid 9 Left-hand stabilizer extend solenoid
4 Extendahoe® retract PWM solenoid 10 Right-hand stabilizer extend solenoid
5 Bi-directional auxiliary B port PWM 11 Joystick enable solenoid
solenoid
6 Extension block added for optional
Extendahoe® and bi-directional auxiliary
functions.
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Pilot system - Overview Pilot enable switch

580ST
590ST
695ST
The pilot controls are turned on by a three position switch located on the right hand pilot control tower. This switch
controls power to the pilot relay and the pilot control module. The pilot enable switch has three positions:
RAIL16TLB0198AA 1
Switch position Operation

OFF (down) All pilot controlled functions are off and non-functional.
ON (middle) The pilot control module gets 12 V at all times in this position. If the enable position of the
switch has not been activated first, the green light is off, and only the right stabilizer and the left
stabilizer functions will operate. If the enable position of the switch has first been activated, the
green light will remain on, and all pilot functions will operate.
ENABLE The pilot control relay is energized in this position. A latching circuit causes the relay to remain
(momentary) energized until the switch is turned to the off position, or the key switch is turned off. When
the pilot control relay is engaged, the enable solenoid of the pilot manifold is energized,
causing pressurized pilot oil to be sent to the hydraulic joysticks and to the Extendahoe®
and bi-directional aux solenoids (if equipped).
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RAIL16TLB0199FA 2
1 12 V from fuse F-015 or F-030 4 Pilot controls On/Off relay

2 Pilot controls On/Off switch 5 Pilot controls enable solenoid
3 To pilot control module connector pin 1
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Pilot system - Overview Control pattern change switch

580ST
590ST
695ST
The control pattern of the joysticks can be changed to suit the operator’s needs. The two position switch has a me-
chanical latching mechanism to prevent inadvertent switch movement. To move the switch the operator must slide the
latch toward the pivot point to allow switch movement. An orange indicator light is also incorporated into the switch.
RAIL16TLB0200FA 1
The switch receives power whenever the pilot control relay is energized. The boom and dipper functions will swap
from the left joystick to the right joystick depending on the switch position.
• In the upper switch position, the backhoe, or BHL, pattern is used. The orange indicator light on the switch
will not be on. The boom function is on the left joystick, and the dipper function is on the right joystick.
The pattern change solenoids are not energized.
• In the lower switch position, the excavator, or ISO, pattern is used. The orange indicator light on the switch
will be on. The dipper function is on the left joystick, and the boom function is on the right joystick. Both of the
pattern change solenoids are energized.
In the event of a malfunctioning electrical circuit or solenoid which results in only one of the pattern change solenoids
being activated, a “split” pattern can occur, where each joystick will contain one half of each of the two directions of
the boom and dipper functions.
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Pilot system - Overview Stabilizer switches

580ST
590ST
695ST
The left stabilizer switch (1) and the right stabilizer switch (2) are located on the left-hand pilot control tower. Pushing
the switch forward will lower the stabilizer. Pushing the switch rearward will raise the stabilizer.
RAIL16TLB0201FA 1
The stabilizer switches provide a Hall Effect type of proportional voltage signal to the pilot control module. The stabi-
lizer switches are powered with a 5 V sensor supply. The Hall Effect sensor in the switch will send a variable voltage
signal to the pilot control module based on the switch position. The following table shows the sensor voltage. The
voltage can be measured by back-probing the switch connectors or by installing a breakout harness.
Position Voltage range Fault threshold

Neutral 2.35 – 2.65 V Flash code 3,neutral fault code outside of listed range
Full lower 0.35 – 0.65 V Flash code 1, low threshold signal voltage < 0.25 V
Full raise 3.85 – 4.15 V N/A
Auto-up 4.35 – 4.65 V Flash code 2, high threshold signal voltage > 4.75 V
Stabilizer Auto-Up
An auto-up feature is also included in the stabilizer function. If the stabilizer switch is pushed rearward to the detent
position, the stabilizer will continue to move upward even when the switch is returned to neutral position. The auto-up
feature is stopped after a 10 s timer has passed (all models), the switch is moved to the stabilizer raise or lower
position again (all models), or a ground signal on the pilot control module pin 13 and pin 14 is interrupted by the
189.7 bar (2750.0 psi) pressure switch located in the stabilizer lock valve (model 580N only).
Stabilizer mud shake

A mud shake mode is also incorporated into the switch. In normal use, the actuation of the PWM solenoid by the
pilot controller undergoes a gradual acceleration and deceleration to ensure smooth operation. However, this makes
it impossible for the operator to shake mud and debris off of the stabilizers. If the stabilizer switch is moved rapidly
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from the raise position to the lower position three consecutive times, the PWM output will begin to go to full current in
either direction (no acceleration or deceleration), allowing the stabilizer cylinder to shake off the mud and debris.
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Pilot system - Overview Extendahoe® and bi-directional auxiliary

buttons
580ST
590ST
695ST
For the optional Extendahoe® function and the optional bi-directional auxiliary functions, a yellow proportional push
button is contained in the left-hand (bi-directional aux) joystick and the right-hand (Extendahoe®) joystick. These
yellow buttons operate similarly to the stabilizer switches. They are supplied with 5 V sensor supply from the pilot
control module. A Hall Effect sensor provides a variable voltage back to the pilot control module based on the switch
position.
RAIL16TLB0202AA 1
RAIL16TLB0203AA 2
However, these buttons activate a single function direction, instead of both directions in the case of the stabilizer
switches. These buttons are tested in the same manner as the stabilizer switches, by back-probe the connectors or
by installing a breakout harness. The following table lists the voltages for these buttons:
Position Voltage range

Neutral 0.85 – 1.15 V
Full engage 3.85 – 4.15 V
The following table lists the fault condition information for the Extendahoe® buttons and the bi-directional auxiliary
buttons:
Fault Flash code Voltage threshold

Low voltage 1 Less than 0.5 V
High voltage 2 Greater than 4.5 V
Neutral startup 3 Outside the range of 0.85 – 1.15 V
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Index
Pilot system - 357

Pilot system - Overview Control pattern change switch (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Pilot system - Overview Extendahoe® and bi-directional auxiliary buttons (*) . . . . . . . . . . . . . . . . . . . 14
Pilot system - Overview Introduction (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Pilot system - Overview Pilot electronic controller (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Pilot system - Overview Pilot enable switch (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Pilot system - Overview Pilot manifold solenoids (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Pilot system - Overview Stabilizer switches (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
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Auxiliary hydraulic function control - 128

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Contents
SERVICE
Control valve
Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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Hydraulic systems - Auxiliary hydraulic function control
Control valve - Remove

580ST
590ST
695ST

cavity.
neutral position.
5. Lower the stabilizers to the ground.
7. Release the hydraulic pressure by operating the control LELI12TLB2103AA 1
9. Place some wedges under the wheels so as to prevent
the machine from moving.
11. Drain oil from the hydraulic system.
13. Clean the area around the control valve.
14. Identify and disconnect the articulations, cables and
hoses and plug the hose ends.
15. A drip tray will be required to catch oil draining from
inside the hoses.
17. Remove the control valve assembly from the machine.
18. For installation, follow the removal procedure in re-
verse order.
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Index

Control valve - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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Hydraulic hand control - 355

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Contents
TECHNICAL DATA
Hand control
FUNCTIONAL DATA
Hand control
Hand control valve
SERVICE
Hand control
Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Hand control valve
Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
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Hydraulic systems - Hydraulic hand control
Hand control - General specification

580ST
590ST
695ST
Weight 5.1 – 5.3 kg (11.24 – 11.68 lb)

Spool stroke 7.55 mm (0.30 in)
Special torque settings
Maximum permissible on the hydraulic control lever 80 N·m (59 lb ft)
Control block retaining screw 30 N·m (22 lb ft)
Control block cardan joint 50 N·m (37 lb ft)
Control block nut 40 N·m (30 lb ft)
Lower body screw 50 N·m (37 lb ft)
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Hand control - Component identification

580ST
590ST
695ST
Right-hand hydraulic control lever
LELI12TLB2151GB 1
1. Valve 10. Half handle

2. Plate 11. Cover
3. Screw 12. Switches
4. Nut 13. Washer
5. Boot 14. Spacer
6. Connector 15. Clip
7. Wedge 16. Clip
8. Half handle 17. Plugs [if the switches (12) are not fitted]
9. Screw
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Left-hand control lever
LELI12TLB2152GB 2
1. Valve 11. Cover

2. Plate 12. Switch push button (horn)
3. Screw 13. Washer
4. Nut 14. Spacer
5. Boot 15. Clip
6. Connector 16. Clip
7. Wedge 17. Plugs [if the switches (18) are not fitted]
8. Half handle 18. Push-buttons (auxiliary bidirectional)
9. Screw 19. Connector
10. Half handle 20. Wedge
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Hand control - Component identification

580ST
590ST
695ST
Controls and operation
LELI12TLB2150FB 1
1. Control enable switch:

○ When set to On (control lamp On), this switch allows enabling all hydraulic controls of the backhoe attachment.
2. Left-hand hydraulic control lever:
○ The left-hand hydraulic control lever controls attachment swing and the boom or the dipper (depending on the
control pattern adopted).
3. Right-hand hydraulic control lever:
○ The right-hand hydraulic control lever controls the bucket and the boom or the dipper (depending on the control
pattern adopted).
NOTE: The operating speed depends on the angle of movement of the control levers. In intermediate position,
two movements may be obtained simultaneously.
4. Stabilizer controls:
○ The right-hand control is for the right-hand stabilizer and the left-hand control is for the left-hand stabilizer.
5. Control pattern change switch:
○ This switch is used for changing the standard control pattern to the ISO pattern.
6. Telescopic dipper controls (proportional controls):
○ Press the right-hand button to extend the telescopic dipper.
○ Press the left-hand button to retract the telescopic dipper.
7. Wrist rest:
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○ The wrist rests may be adjusted to the required height.

8. Control lever angle adjustment:
○ These controls are used for the fore/aft and left/right adjustment of the arm.
9. Horn button (momentary action control)
10. Auxiliary bidirectional attachment control:
○ Proportional buttons for the activation of the additional attachment.
11. Decelerator button:
○ By pressing this button, the engine RPM sets to low idle. During this phase, the accelerator knob and pedal
are disabled
○ By pressing the button again, the engine RPM is restored and the accelerator knob and pedal are functional
again.
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Hand control valve - Component identification

580ST
590ST
695ST
Control lever valve

P. Supply
T. Return to tank
Right valve (dipper/bucket)

1. Retracting the dipper
2. Opening the backhoe bucket
3. Extending the dipper
4. Closing the backhoe bucket
Left valve (backhoe attachment/swing)

1. Boom
2. Right swinging
3. Lowering
4. Left swinging
LELI12TLB2310BA 1
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1. cardan joint cam

2. Plate
3. Shim
4. Upper body
5. Rod guide
6. Seal ring
7. Seal ring
8. Rod
9. Spring guide
10. Spring
11. Shim
12. Cover
13. Safety ring
14. Spring
15. Spool
16. Shims
17. Valve
18. O-ring
19. Lower body
20. O-ring
LELI12TLB2311BB 2
21. O-ring
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Hand control - Disassemble

580ST
590ST
695ST
1. Turn the starter switch key to On position.

2. Turn pilot control enable switch to the On position.
3. Move the hydraulic control levers through all positions.
4. Turn the starter switch key to Off. Disconnect the neg-
ative battery cables.
5. Remove the knob (P) and support (S).
6. Only on the left-hand side control, remove the bracket
(O) and relevant bolts.
LEPH12TLB2153BB 1
7. Remove the decal (D), mounting plate (D1) and detach

the connectors (Q).
LELI12TLB2154AB 2
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8. Only on the right-hand side control, pull out both the

switches (I) and detach relevant connectors (Q1).
LELI12TLB2155AB 3
9. Remove the knob (P1) in the rear section of control

lever.
LEPH12TLB2156AB 4
10. Remove the bolts (V) and plate (N).
LEPH12TLB2157AB 5
11. Lift the rubber boot (RL) from the left-hand side control
and rubber boot (RR) from the right-hand side control.
LELI12TLB2158AB 6
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12. Tag all the hydraulic hoses (H) and disconnect them.
13. Tag and disconnect all the connectors (Q2).
LEPH12TLB2159AB 7
14. Remove the bolts (V1) and take out control lever from
the column.
LEPH12TLB2160AB 8

16. Remove the half handles (8) and (10).
18. Remove the wedge (7) from the connector (6).
19. Remove the wedge (20) from the connector (19).
20. Remove the connector housings (6) and (19).
21. Cut and discard the tie wraps (15) and (16). Remove
the grommet (13).
22. Remove the switches (12) and (18).
23. Remove the spacers (14). Remove the boots (5).
24. Remove the nut (4) and bolt (3).
25. Remove the plate (2).
LELI12TLB2161BB 9
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Hand control - Assemble

580ST
590ST
695ST
1. Install the plate (2), boot (5), nut (4), spacers (14) and
bolt (3) on the valve (1). Torque the nut (4) to 36 –
44 N·m (27 – 32 lb ft)
2. Install the wedges (7) and (20) on the connector hous-
ing (6) and (19).
3. Install the grommet (13) on the switches (12) and (18).
Secure the switches together with the cable ties (15)
and (16).
4. Instal the switches (12) and (18) on the cap (11).
5. Install the half handles (8) and (10) on the spacers (14)
with the bolts (9).
6. Install the caps (17) on the switches (12) and (18).
LELI12TLB2161BB 1
7. Install the pre-assembled control lever on the column

with the bolts (V1).
LEPH12TLB2160AB 2
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8. Connect all the connectors (Q2).

9. Reinstall all the hydraulic hoses (H).
LEPH12TLB2159AB 3
10. Reinstall the boots (RL) and (RR)
LELI12TLB2158AB 4
11. Install the plate (N) with the bolts (V).
LEPH12TLB2157AB 5
12. Install the knob (P1) on the rear of the control column.
LEPH12TLB2156AB 6
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13. Only on the right-hand side control, connect the con-

nectors (Q1) to the switches (I).
14. Install the switches (I) on the control.
LELI12TLB2155AB 7
15. Connect the connectors (Q) to the switches.

16. Install the mounting plate (D1).
17. Attach the decal (D).
LELI12TLB2154AB 8
18. Only on the left-hand side control, reinstall the bracket

(O) with the bolts removed earlier.
19. Reinstall the knob (P) and support (S).
LEPH12TLB2153BB 9
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Hand control valve - Disassemble

580ST
590ST
695ST
1. Make identification marks on all disassembled parts

about their orientation to enable easy reinstallation.
2. Remove the universal joint cam (1) using a key.
3. Remove the plate (2).
4. Remove the shim (3) from the upper body (4).
5. Remove the rod guide (5). Check and replace the seal
rings (6) and (7) if necessary.
6. Drive the pin (8) out.
7. Remove the spring guide (9), spring (10) and shims
(11).
8. Remove the spool assembly.
9. Secure the cover (12) and remove the safety ring (13).
10. Remove the spring (14) and spool (15).
11. Remove the shims (16).
NOTICE: Note down the thickness of the shims to enable
ease of assembly.
12. Remove all the other pins as explained in Steps 5 to
11.
13. Secure the upper body (4) in a vice.
14. Remove the valve (17). Check and replace the O-ring LELI12TLB2311BB 1
(18) if necessary.
15. Separate the upper (4) and lower (19) bodies. Check
and replace the seal rings (20) and (21) if necessary.
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Hand control valve - Assemble

580ST
590ST
695ST
1. To reassemble, proceed in the reverse order to that of

removal.
2. In the case of reassembly without changing the univer-
sal joint cam (1), put the same value of shims (3) as
those in place.
3. After changing the universal joint cam (1) adjust the
pressure of the cam on the rods.
4. Install a 2 mm (0.079 in) shim (3), check that the
recessing of the push-rods is less than 0.2 mm
(0.008 in), modify the shimming to more or less if
required.
5. Install the seal rings (6) and (7) and O-rings (18), (20)
and (21).
6. Lubricate all the moving parts.
7. Apply brake thread fluid on the threads of the universal
joint cam (1) and valve (17).
8. Torque the cam (1) to 50 N·m (37 lb ft).
9. Torque the valve (17) to 50 N·m (37 lb ft)
LELI12TLB2311BB 1
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Index

Hand control - Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Hand control - Component identification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Hand control - Component identification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Hand control - Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Hand control - General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Hand control valve - Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Hand control valve - Component identification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Hand control valve - Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
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Hydraulic swing system - 352

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Contents
FUNCTIONAL DATA
Hydraulic swing system

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Hydraulic systems - Hydraulic swing system
Hydraulic swing system - Static description

580ST
590ST
695ST
The hydraulic swing system has two versions:
Sideshift:
• It can shift laterally with the backhoe attachment as it is
installed directly on the side shift carriage.
Center pivot:
• It is fixed and cannot be shifted as it is installed directly
on the chassis.
The backhoe attachment may slew by 180° around the

main frame.
This movement is obtained by means of two hydraulic

cylinders (1) installed between the main chassis and the LEPH12TLB1855AB 1
backhoe attachment support.
The cylinders act directly on the backhoe attachment sup-

port, with no need for connections or bell cranks.
Each cylinder is free to rotate around the pivots (3), while
the rod comes out or retracts inside the cylinder body (2).
As each cylinder extends or retracts, the swing post and

the cylinders turn, pivoting on the headstocks within the
carriage.
Each cylinder is double-acting and as hydraulic oil is fed

to a cylinder to turn the post, one cylinder pushes and the
other cylinder pulls.
LELI12TLB1856AB 2
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Hydraulic swing system - Dynamic description

580ST
590ST
695ST
Hydraulic oil flow

Hydraulic feed to the swing cylinders is controlled by the swing section of the backhoe attachment control valve,
which contains pilot-operated pressure relief valves with anti-cavitation feature to protect the system and the cylinders,
should an overload condition occur.
The diagram illustrates the operation of the swing circuit when retracting the right-hand cylinder (4) and extending the
left-hand cylinder (5) in order to swing the backhoe attachment to the right.
When swinging the backhoe to the left the oil flows are reversed and exactly the same principle of operation applies.
The various operating stages for right swing are described below as an example.
When the swing control is operated the control valve directs oil flow to the rod end of the right hand cylinder.
The flow of oil at pump pressure lifts the one way restrictor (2) of its seat allowing the flow to continue unrestricted to
the inlet port of the piston end of the left hand cylinder.
System pressure increases causing the right hand cylinder to retract and the left hand cylinder to extend.
As the cylinders move, displaced oil on the piston side of the left hand cylinder flows towards the one way restrictor
(7) in the inlet port on the rod end of the right hand cylinder.
The oil flow moves the restrictor to the restrict position which limits the flow of oil and creates a back pressure (1st
stage restricted return oil) in the right hand cylinder.
The restricted flow of oil passes through restrictor (7) into the rod end of the left hand cylinder before returning to the
control valve and back to tank.
The spool in the swing control valve (1) is designed so that, during operation, oil can flow freely through the port
directing oil flow to the swing cylinders, but is restricted when going back to the tank.
This restriction is achieved using metering lands machined into the lands of the spool and creates a secondary back
pressure (2nd stage restricted return oil) in the rod end of the cylinder.
By allowing oil to flow unrestricted to the power side of the cylinder and be restricted on the exhaust side a smooth
controlled swing of the backhoe at optimum speed is achieved.
When the swing system reaches the last 20 - 25° of travel the sliding restrictor in the end of the piston rod touches
the outlet port in the cylinder barrel.
This further restricts the flow of oil drained from the cylinder. As the piston moves towards the end of its stroke, the
sliding restrictor is gently pushed down towards the centre of the cylinder rod, allowing a progressive and controlled
stop of the swing cycle.
If the swing control valve is suddenly returned to neutral mid-way through a full power swing the supply and exhaust
ports in the main control valve are totally blocked.
The momentum of the swinging backhoe assembly if not controlled will make the machine extremely unstable.
To prevent this from occurring, the system pressure relief valves operate and drain the oil until an excess pressure is
detected.
When the relief valve operates the cylinder rod will move and a void will be created in the low pressure side of the
cylinder.
The anti-cavitation feature in the relief valves prevents the void from creating by transferring the drain oil from the side
of the system where an excess pressure occurred to the low pressure side.
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LELI12TLB1857GB 1
Pump pressure oil
1st Stage restricted return oil
2nd Stage restricted return oil
Return to oil tank
1. Control valve swing section 5. Left hand cylinder

2. Limiter 6. Compressor rod
3. Cushioning rod 7. Limiter
4. Right hand cylinder
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Index

Hydraulic swing system - Dynamic description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Hydraulic swing system - Static description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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Front loader hydraulic system control - 724

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Contents
FUNCTIONAL DATA
Front loader hydraulic system control

Excavator and backhoe bucket hydraulic system - Static description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SERVICE
Front loader hydraulic system control

Excavator and backhoe bucket hydraulic system - Remove the loader control valve (*) . . . . . . . . . . . . . . 6
Disassemble the loader control valve (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Remove the backhoe attachment control valve (mechanical controls) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
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Hydraulic systems - Front loader hydraulic system control
Excavator and backhoe bucket hydraulic system - Static description

580ST
590ST
695ST
Loader control valve

The loader control valve is mounted on the right side of
the machine adjacent to the pump.
This control valve may be of 2 types, similar to each other,

according to the hydraulic pump assembled to the ma-
chine:
• Gear pump (with fixed flow rate)

• Piston pump (with variable flow rate)
The control valve consists of 2 or 3 sections, an end cover

and an inlet section.
The 3 control valve sections are:
• Loader attachment lifting

• Loader bucket
• 4x1 loader bucket
The loader attachment control valve has three sections

when the 4x1 bucket is installed on the machine.
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Loader attachment control valve with gear pump (with fixed flow rate)
LELI12TLB2101FB 1
A. 4x1 loader bucket section

B. Bucket section
C. Loader attachment lifting section
1. End cover
2. Bucket relief valve (rod side) - 240 bar (3480 psi)
3. Bucket relief valve (piston side) - 165 bar (2393 psi)
4. Hydraulic unloader relief valve - 165 bar (2393 psi)
5. 4x1 bucket relief valve - 240 bar (3480 psi)
6. Hydraulic unloader solenoid
7. Inlet section
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Loader attachment control valve with piston pump (with variable flow rate)
LELI12TLB2102FB 2
A. 4x1 loader bucket section

B. Bucket section
C. Loader attachment lifting section
1. End cover
2. Bucket relief valve (rod side) - 240 bar (3480 psi)
3. Bucket relief valve (piston side) - 165 bar (2393 psi)
4. 4x1 bucket relief valve - 240 bar (3480 psi)
5. Inlet section
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Excavator and backhoe bucket hydraulic system - Remove the

loader control valve
580ST
590ST
695ST

cavity.
neutral position.
7. Release the hydraulic pressure by operating the control LELI12TLB2103AA 1
14. Identify and disconnect the articulations, cables and
hoses and plug the hose ends.
15. A drip tray will be required to catch oil draining from
inside the hoses.
verse order.
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Front loader hydraulic system control - Disassemble the loader

control valve
580ST
590ST
695ST
1. Remove the nuts (1).

NOTICE: During assembly, torque the nuts to 25 – 29 N·m
(18.44 – 21.39 lb ft)
2. Remove the tie rods (2).
LELI12TLB2105AB 1
3. Remove the end cover (7).

4. Remove the control valve sections (4), (5) and (6) and
inlet section (3).
5. Check and replace the O-rings (8) located between the
different sections of the control valve if necessary.
LELI12TLB2104AB 2
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Front loader hydraulic system control - Remove the backhoe

attachment control valve (mechanical controls)
580ST
590ST
695ST

cavity.
2. Lower the loader attachment and the backhoe attach-
ment to the ground.
neutral position.
ON and release the pressure by moving the hydraulic
11. Drain oil from the hydraulic system. LELI12TLB2110AA 1

14. Identify the position of all hoses to be disconnected
and tag them.
15. Disconnect the hoses and plug their ends.
16. Disconnect the manual control levers.
verse order.
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Index

Excavator and backhoe bucket hydraulic system - Remove the loader control valve (*) . . . . . . . . . . 6
Excavator and backhoe bucket hydraulic system - Static description (*) . . . . . . . . . . . . . . . . . . . . . . . 3
Front loader hydraulic system control - Disassemble the loader control valve (*) . . . . . . . . . . . . . . . . 7
Front loader hydraulic system control - Remove the backhoe attachment control valve (mechanical
controls) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
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Front loader arm hydraulic system - 701

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Contents
TECHNICAL DATA
Lift arm cylinder

Boom cylinder - Dimension (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
FUNCTIONAL DATA
Lift arm cylinder

Exploded view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
SERVICE
Lift arm cylinder

Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
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Hydraulic systems - Front loader arm hydraulic system
Boom cylinder - Dimension

580ST
590ST
695ST
Loader attachment boom cylinder
2WS
LELI12TLB1676FA 1
1. Stroke
2. Completely retracted
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4WS
LELI12TLB1677FA 2
1. Stroke
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Lift arm cylinder - Exploded view

580ST
590ST
695ST
Loader attachment boom cylinder disassembly
LELI12TLB1692FB 1
1. Cylinder rod 9. Back-up ring

2. Bushing 10. O-ring
3. Wiper ring 11. Piston
4. Seal ring 12. Piston gasket
5. Seal ring 13. Piston guide rings
6. Guide bush 14. Screw
7. Cylinder gland 15. Cylinder tube
8. Safety screw 16. Bushing
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Lift arm cylinder - Remove

580ST
590ST
695ST

2. Sufficiently raise the loader attachment to allow the
boom cylinder pivot pin to be removed and securely
support the front and rear part of the bucket with stands
to prevent the loader attachment arms from lowering
when the cylinder is disconnected.
3. If the bucket cannot be safely supported, remove it and
support the loader attachment arms using a suitable
stand or hoist.
NOTICE: Always ensure that the loader is fully supported.
Do not work under or near an unsupported loader attach-
ment, to prevent the danger of personal injury. LELI12TLB1681AA 1
4. Relieve the residual pressure in the system by moving

the loader control lever through all operating positions.
5. Stop the engine.
6. Support the cylinder using sling and suitable hoist.
7. Disconnect the hoses.
8. Cap or plug all exposed openings.
LELI12TLB1682AA 2
9. Remove the snap ring (1) and spacer (2).
LEPH12TLB1683AB 3
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10. Remove the ring (3) and pin (4).

11. Use a hammer to extract the rod pin (5).
LEPH12TLB1687AB 4
12. Remove the loader arm cylinder.
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Lift arm cylinder - Disassemble

580ST
590ST
695ST
NOTICE: Cylinder weight (2WS): 32.5 kg (71.65 lb). Use a lifting device of adequate capacity.
Cylinder weight (4MS): 41.3 kg (91.05 lb). Use a lifting device of adequate capacity.
1. Lift and securely place the cylinder on a workbench.
NOTICE: Be sure that the cylinder is placed horizontally.
2. Drain hydraulic oil from the cylinder.
LELI12TLB1693AA 1
3. Support the cylinder rod (1).

4. Remove the bolt (8).
5. Use wrench 380000725 to loosen the cylinder gland
(7).
NOTE: If necessary gently heat the gland carrier to soften
the thread sealant applied during manufacture.
LELI12TLB1698AB 2
6. Remove the cylinder gland (7) from the cylinder barrel

(15) using a plastic hammer.
7. Remove the cylinder rod (1) and cylinder gland (7).
NOTICE: Be sure to pull the cylinder rod (1) straight so as
not to damage the sliding surfaces.
LELI12TLB1699AB 3
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9. Remove the piston (11) and cylinder gland (7) from the
cylinder rod (1).
LELI12TLB1696AB 4
10. Only if necessary:

• Remove the wiper ring (3), seal ring (4), ring (5),
guide bush (6), back-up ring (9) and O-ring (10)
from the cylinder gland (7).
• Remove the piston seal (12) and piston guide rings
(13) from the piston (11).
LELI12TLB2001AB 5
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Index

Boom cylinder - Dimension (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Lift arm cylinder - Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Lift arm cylinder - Exploded view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Lift arm cylinder - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
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Front loader bucket hydraulic system - 723

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Contents
TECHNICAL DATA
Loader bucket control cylinder

Dimension (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
FUNCTIONAL DATA

Exploded view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
SERVICE

Remove - 4x1 bucket cylinder (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
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Hydraulic systems - Front loader bucket hydraulic system
Loader bucket control cylinder - Dimension

580ST
590ST
695ST
2WS
LELI12TLB2004FA 1
1. Stroke
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4WS
LELI12TLB2005FA 2
1. Stroke
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Loader bucket control cylinder - Exploded view

580ST
590ST
695ST
Loader bucket cylinder disassembly
LELI12TLB1861FB 1
2. Cylinder rod 10. Piston
3. Wiper ring 11. Piston gasket
4. Seal ring 12. Piston guide
5. Seal ring 13. Screw
7. Snap ring 15. Bushing
8. Back-up ring
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Loader bucket control cylinder - Remove - 4x1 bucket cylinder

580ST
590ST
695ST

2. Place the bucket firmly on the ground.
the loader control lever through all operating positions.
LELI12TLB1874AA 1
4. Disconnect the hoses.

LEPH12TLB1879AA 2
6. Remove the bolts and cover (C).

7. Remove the cover (C).
LEPH12TLB1880AB 3
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9. Remove the rod pin (1) with a hammer.
LEPH12TLB1881AB 4
10. Remove the nut (6) and dowel (5).

11. Drive out the lower pin (7) with a hammer.
LEPH12TLB1882AB 5
12. Remove the 4x1 bucket cylinder.
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Loader bucket control cylinder - Disassemble

580ST
590ST
695ST
NOTICE: Cylinder weight: 32.5 kg (71.65 lb). Use a lifting device of adequate lifting capacity
LELI12TLB1945AA 1
3. Support the cylinder rod (2) and use the wrench

380000722 to loosen the cylinder gland (6).
LELI12TLB1865AB 2

(14) using a plastic hammer.
6. Remove the cylinder rod (2) and the cylinder gland (6).
LELI12TLB1867AB 3
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cylinder rod (2).
LELI12TLB1869AB 4
back-up ring (8) and O-ring (9) from the cylinder
gland (6).
• Remove the piston seal (11) and piston guide ring
LELI12TLB1871AB 5
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Index

Loader bucket control cylinder - Dimension (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Loader bucket control cylinder - Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Loader bucket control cylinder - Exploded view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Loader bucket control cylinder - Remove - 4x1 bucket cylinder (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
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Excavator and backhoe hydraulic controls - 726

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Contents
FUNCTIONAL DATA
Excavator and backhoe hydraulic controls

Dynamic description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Static description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Excavator and backhoe bucket hydraulic system - Static description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Excavator and backhoe bucket hydraulic system - Static description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . 27
SERVICE
Excavator and backhoe hydraulic controls

Excavator and backhoe bucket hydraulic system - Remove the backhoe attachment lock (*) . . . . . . . . 36
Remove the backhoe attachment control valve (mechanical controls) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Disassemble the backhoe attachment control valve (mechanical controls) (*) . . . . . . . . . . . . . . . . . . . . . . 38
Assemble the spool seals of the backhoe attachment valve (mechanical controls) (*) . . . . . . . . . . . . . . . 42
Remove the backhoe attachment control valve (pilot controls) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Disassemble the backhoe attachment control valve (pilot controls) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Disassemble the backhoe attachment control valve pilot solenoid valve (*) . . . . . . . . . . . . . . . . . . . . . . . . 48
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Hydraulic systems - Excavator and backhoe hydraulic controls
Excavator and backhoe hydraulic controls - Dynamic description

580ST
590ST
695ST
LELI12TLB2605FB 1
1. Control enable switch: When set to On (control lamp On), this switch allows enabling all hydraulic controls of the
backhoe attachment.
2. Left-hand hydraulic control lever: The left-hand hydraulic control lever controls attachment swing and the boom
or the dipper (depending on the control pattern adopted).
3. Right-hand hydraulic control lever: The right-hand hydraulic control lever controls the bucket and the boom or
the dipper (depending on the control pattern adopted).
NOTE: The operating speed depends on the angle of movement of the control levers. In intermediate position,
two movements may be obtained simultaneously.
4. Stabilizer controls: The right-hand control is for the right-hand stabilizer and the left-hand control is for the left-
hand stabilizer.
5. Control pattern change switch: This switch is used for changing the standard control pattern to the ISO pattern.
6. Telescopic dipper controls: (proportional controls): Press the right-hand button to extend the telescopic dipper.
Press the left-hand button to retract the telescopic dipper.
7. Wrist rests: The wrist rests may be adjusted to the required height.
8. Hydraulic control lever support angle adjustment: These controls are used for the fore/aft and left/right adjustment
of the arm.
9. Horn button (momentary action control).
10. Controls of auxiliary bidirectional attachment (If fitted): Proportional buttons for the activation of the additional
attachment.
11. Decelerator button: By pressing this button, the engine rpm sets to low idle.
During this phase, the accelerator knob and pedal are disabled.
By pressing the button again, the engine rpm is restored and the accelerator knob and pedal are functional again.
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Control enable switch

This control is located on the right-hand control lever.
This switch has three positions:
• Position “OFF”: (Lamp Off) All controls will deactivate;
• Position “1”: By pressing the upper side (lamp Off), the

stabilizers will activate;
• Position “2”: By pressing the upper side (lamp On)

again, all controls will activate.
ATTENTION: After using the attachment or before leaving
the machine, always tilt the switch to Off by pressing the
lower side of the switch (lamp Off). Never forget this basic LELI12TLB2603AB 2
safety requirement.
NOTE: When starting the engine, the position Off or dis-
abled controls is automatically selected.
Control pattern change switch (Boom Or dipper)

Located on the right-hand hydraulic control lever, this
switch is fitted with a locking device.
The switch is used to change from standard pattern to ISO

version, or vice versa.
To unlock the switch, push the locking device upwards and

at the same time press the top of the switch (1). In this
position, the switch turns on and the controls are in ISO
pattern.
The boom and dipper controls on the hydraulic control

levers are now inverted.
LELI12TLB2604AB 3
Press the bottom of the switch (1) to lock and return to
standard pattern operation.
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Backhoe attachment hydraulic controls
Standard configuration
Backhoe boom and backhoe attachment swing lefthand
hydraulic control lever
This hydraulic control lever has five positions:
Position “0”: Neutral/hold. This position enables the at-

tachment movement to be stopped. As soon as the hy-
draulic control lever is released, it automatically returns to
the neutral position “0” and the attachment remains in the
position where it was when movement stopped.
Position “A”: The boom lowers.
Position “B”: The boom rises.

LELI12TLB2606AB 4
Position “C”: The backhoe attachment swings to the left.
Position “D”: The backhoe attachment swings to the right.

Backhoe dipper and backhoe bucket right-hand control
lever
This hydraulic control lever has five positions:

tachment movement to be stopped. As soon as the hy-
draulic control lever is released, it automatically returns to
the neutral position “0” and the attachment remains in the
Position “E”: The backhoe dipper extends.
Position “F”: The backhoe dipper retracts.

LELI12TLB2607AB 5
Position “G”: The backhoe bucket closes.
Position “H”: The backhoe bucket opens.
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Stabilizer hydraulic controls

These controls are located on the left-hand hydraulic con-
trol lever and may be operated independently or simulta-
neously. These controls are proportional, and therefore,
the stabilizer speed may vary.
NOTICE: Whenever the backhoe attachment is used, the
machine must be resting on the stabilizers.
Left-hand stabilizer left-hand control lever

This lever has four positions:
Position “0”: Neutral. This position stops the movement

of the left-hand stabilizer. As soon as the lever is released
from positions “1” or “2”, it automatically returns to the neu-
tral position “0” and the left-hand stabilizer stops raising or
lowering.
When held in position “1”: The left-hand stabilizer lowers.
When held in position “2”: The left-hand stabilizer rises.
Position “3”: Stabilizer auto-up feature.

LELI12TLB2608AB 6
Right-hand stabilizer right-hand control lever

This lever has four positions:
Position “0”: Neutral. This position stops the movement

of the right-hand stabilizer. As soon as the lever is re-
leased from positions “1” or “2”, it automatically returns to
the neutral position “0” and the right-hand stabilizer stops
raising or lowering.
When held in position “1”: The right-hand stabilizer low-

ers.
When held in position “2”: The right-hand stabilizer rises.
Position “3”: Stabilizer auto-up feature.

LELI12TLB2609AB 7
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Auto-up feature (Center pivot version) (Optional)

Position “3”: When the levers are momentarily pulled back
to this position and then released, they return to the neu-
tral position and the stabilizers automatically rise to road
travel position, thereby leaving your hand free for other
duties. To stop the automatic rise at any time, push or
pull the levers; the rise of the stabilizers stops.
NOTE: The machines not provided with the optional
auto-up feature still have the relevant detent position, but
this does not affect the stabilizer operation in any way.
NOTICE: Before machine travel or before using the
loader attachment, make sure the stabilizers are com-
pletely raised.
LELI12TLB2609AB 8
NOTICE: During road travel, the stabilizers must be com-
pletely raised and immobilized by means of the pins pro-
vided for that purpose.
Telescopic dipper controls (Optional)

Press and hold down the right-hand button (1) to extend
the telescopic dipper. As soon as the button is released
the dipper stops and remains in the position it occupied
when the button was released.
Press and hold down the left-hand button (2) to retract the
telescopic dipper. As soon as the button is released the
dipper stops and remains in the position it occupied when
the button was released.
By pressing button (3), it is possible to set the engine RPM

to idle run disabling accelerator handle and accelerator
pedal. By pressing again button (3) the engine RPM are
restored and the accelerator handle and accelerator pedal LELI12TLB2610AB 9
as well.
Before using these controls, make sure the telescopic dip-

per is mechanically unlocked.
NOTE: Operating the backhoe attachment control levers
and these controls simultaneously will enable numerous
possibilities of progressive functioning.
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Auxiliary bi-directional controls (Optional)

Press and hold the left-hand button (1) to let the oil flow
out of the left-hand side of the boom.
Press and hold the left-hand button (2) to let the oil flow
out of the right-hand side of the boom.
LELI12TLB2611AB 10
Hydraulic control lever support adjustments
Fore and aft

Press the two levers (1), then tilt the hydraulic control
levers to the desired position.
Once the desired position is reached, release the two

levers (1).
LELI12TLB2612AB 11
Left and right

Loosen the two knobs (2) located in front of each hydraulic
control lever support, then tilt the supports to the required
position.
Once the adjustment has been carried out, tighten the two
knobs (2).
LELI12TLB2613AB 12
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Backhoe attachment sideshift (Sideshift version)

To dig alongside a building or fence, etc., it is possible to
shift the backhoe attachment sideways to the right or the
left.
Mechanical handling
Place the backhoe attachment to the left if you want to
shift the attachment to the right, or place it to the right if
you want to shift it to the left, then place the attachment
on the ground.
Press the backhoe attachment sideshift unlocking switch
(1). The switch lamp turns On (“ON” position).
A. Version with mechanical engines

B. Version with electric engines
LELI12TLB2616AB 13
Operate the backhoe attachment controls alternately so

as to slide the sideshift carriage sideways.
Once the attachment is in the side position required, swing

it round into alignment with the machine.
Work on the opposite side of the sideshift carriage as

much as possible. Otherwise, reduce the load in the
bucket for better stability.
Press the backhoe attachment sideshift locking switch (1)

. The switch lamp turns Off (“OFF” position).
NOTICE: Except when the sideshift carriage is being
moved, the switch (1) must always be in the “OFF” posi- LELI12TLB2617AA 14
tion. Never use the backhoe attachment with the sideshift

carriage unlocked.
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Hydraulic handling
A. Version with mechanical engines

B. Version with electric engines
LELI12TLB2616AB 15
For handling, press:
• the button (2) side with the symbol to move the backhoe
attachment to the left side of the track;
• the button (2) side without symbol to move the backhoe
attachment to the right side of the track.
NOTE: NOTE: Track sides are referred to the travel direc-
tion of the machine.
Press the backhoe attachment sideshift locking switch (1).
The switch lamp turns Off (“OFF” position).
moved, the switch (1) must always be in the “OFF” posi-
carriage unlocked.
LELI12TLB2619AB 16
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580ST
590ST
695ST
Controls
(A) Version with mechanical engines
(B) Version with electric engines
LELI12TLB2394AB 1
For handling, press:
- The button (2) side with the symbol to move the backhoe
attachment to the left side of the track.
- The button (2) side without symbol to move the backhoe

attachment to the right side of the track.
NOTE: Track sides are referred to the travel direction of
the machine.
Press the backhoe attachment sideshift locking switch
(1)The switch lamp turns Off (“OFF” position).
moved, the switch (1) must always be in the “OFF” posi-
carriage unlocked.
LELI12TLB2395AB 2
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Hydraulic diagram
LELI12TLB2396FB 3
A. Backhoe attachment control valve

B. Union tee of main load-sensing line from backhoe attachment control valve
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Excavator and backhoe hydraulic controls - Static description

580ST
590ST
695ST
Backhoe attachment controls

NOTE: The instruments represented may not exactly cor-
respond to the instruments on your machine.
NOTICE: Before using the backhoe attachment, make
sure that the sideshift carriage locking switch (1) is in the
“OFF” position and that the lock hook has been disen-
gaged, either by means of the lever (3) or the switch (2).
NOTICE: Whenever the backhoe attachment is used, the
machine must be resting on the stabilizers.
ATTENTION: Check control functions before operating
the machine. Failure to check control pattern before op-
erating can cause unexpected machine movement, death
or serious injury.
LELI12TLB2481AB 1
ATTENTION: Any uncontrolled movement of the machine

can cause an accident. Before turning the operator’s seat
to the backhoe attachment working position, it is essential
to place the direction-of-travel control lever and the pow-
ershuttle gearshift lever in the neutral position and immo-
bilize the machine by means of the parking brake lever.
ATTENTION: Before using the backhoe controls, make
sure that the operator’s seat is correctly adjusted in the
backhoe attachment position.
LELI12TLB2482AB 2
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580ST
590ST
695ST
Stabilizer mechanical controls

NOTICE: Whenever the backhoe attachment is used, the machine must be resting on the stabilizers.
Left-hand stabilizer left-hand control lever

This lever has three positions:
Position “0”: Neutral. This position stops the movement of

the left-hand stabilizer. As soon as the lever is released,
it automatically returns to the neutral position ”0” and the
left-hand stabilizer stops raising or lowering.
Position “1”: The left-hand stabilizer lowers.
Position “2”: The left-hand stabilizer rises.
Right-hand stabilizer right-hand control

lever
LELI12TLB2485AB 1
Position “0”: Neutral. This position stops the movement of

the right-hand stabilizer. As soon as the lever is released,
it automatically returns to the neutral position “0” and the
right-hand stabilizer stops raising or lowering.
Position “1”: The right-hand stabilizer lowers.
Position “2”: The right-hand stabilizer rises.

NOTE: To raise or lower the two stabilizers at the same
time, operate the two levers simultaneously.
NOTICE: Before machine travel or before using the
loader attachment, make sure the stabilizers are com-
pletely raised.
During road travel, the stabilizers must be completely

raised and immobilized by means of the pins provided for
that purpose.
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Locking the stabilizer mechanical controls

(specific to certain countries)
This pin (1), located in front of the stabilizer control levers,
is used to lock the stabilizer controls.
To lock the controls, extract the pin from its housing and
insert it into the specially provided hole of the lever sup-
port.
ATTENTION: Before leaving the operator’s compartment,
undertaking any road travel or working with the backhoe
attachment, place the pin in locking position.
LELI12TLB2486AB 2
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Attachment mechanical controls

These control levers are used to operate the backhoe at-
tachment. The speed of movement of each control de-
pends on the angle to which the lever is tilted. In the in-
termediate position, two movements can be obtained si-
multaneously.
Four backhoe attachment control configurations exist, de-

pending on the country concerned:
• standard configuration.
• ISO configuration.
• four lever pattern configuration.
• cross-pattern configuration.
The operating pattern of the control levers is different.

Check which configuration you have on your machine.
Standard configuration
Backhoe boom and backhoe attachment swing left-hand
control lever
This lever has five positions:

tachment movement to be stopped. As soon as the lever
is released, it automatically returns to the neutral position
“0” and the attachment remains in the position where it
was when movement stopped.
Backhoe dipper and backhoe bucket right-hand control

lever

”0” and the attachment remains in the position where it
Position ”H” : The backhoe bucket opens.
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LELI12TLB2488HB 3
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ISO configuration
Backhoe dipper and backhoe attachment swing left-hand
control lever

Position “A”: The backhoe dipper extends.
Position “B”: The backhoe dipper retracts.
Backhoe boom and backhoe bucket right-hand control

lever

Position “E”: The boom lowers.
Position “F”: The boom rises.
Position “G”: Tthe backhoe bucket closes.
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LELI12TLB2490HB 4
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Four-lever pattern configuration

Lever (1) for dipper

Position “A”: The backhoe dipper extends.
Position “B”: The backhoe dipper retracts.
Lever (2) for boom

Position “C”: The boom rises.
Position “D”: The boom lowers.
Lever (3) for backhoe bucket
Position “0”: neutral/hold. This position enables the at-

Position “E”: The backhoe bucket closes.
Position “F”: The backhoe bucket opens.
Lever (4) for backhoe attachment swing

Position “G”: The backhoe attachment swings to the right.
Position “H”: The backhoe attachment swings to the left.
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LELI12TLB2492GB 5
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Cross-pattern configuration
Backhoe boom and backhoe attachment swing left-hand
control lever


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LELI12TLB2494HB 6
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Telescopic dipper mechanical control

pedal (if fitted)
This pedal (A) has three positions:
Position “0”: Neutral. This position enables the movement

of the telescopic dipper to be stopped. This position is
selected automatically, as soon as the pedal is released.
Position “1”: The telescopic dipper extends.
Position “2”: The telescopic dipper retracts.
Before using this pedal make sure that the telescopic dip-
per is mechanically unlocked.
NOTE: Operating the backhoe attachment control levers
and this pedal simultaneously will enable numerous pos- LELI12TLB2498AB 7
sibilities of progressive functioning.
Auxiliary attachment control pedal (optional)

This pedal (1) is located to the right of the backhoe at-
tachment controls and is used for operating the auxiliary
attachment, such as a hydraulic hammer.
LELI12TLB2499AB 8
Backhoe attachment mechanical

control lock
(specific to certain countries)
This pin (1) , located in front of the stabilizer control levers,
is used to lock the backhoe attachment controls.
LELI12TLB2601AB 9
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To lock the controls, extract the pin from its housing and
insert it into the specially provided hole of the lever sup-
port.
ATTENTION: Before leaving the operator’s compartment,
undertaking any road travel or working with the backhoe
attachment, place the pin in locking position.
LELI12TLB2602AB 10
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580ST
590ST
695ST
Backhoe attachment lock (Side shift)

They are installed on the loader backhoe number 4 side
shift locking cylinders.
Their function is to lock the carriage once the backhoe

attachment is ready in the digging position.
The lock consists of:

1. Body
2. Cylinder
3. Gasket
LELI12TLB2147AB 1
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580ST
590ST
695ST
Backhoe attachment control valve

The backhoe attachment control valve is located in the rear part of the machine.
The backhoe attachment control valve may be of 2 types, similar to each other, according to the hydraulic pump
installed on the machine:
• Gear pump (with fixed flow rate)
• Piston pump (with variable flow rate)
Furthermore, the backhoe attachment control valves are divided into:

• Control valves for backhoe attachment mechanical controls.
• Control valves for backhoe attachment pilot controls.
The backhoe attachment control valve may consist of 6 or 7 or 8 sections, an end cover and an inlet section.
The possible 8 sections are:

• Right-hand stabilizer
• Left-hand stabilizer
• Boom
• Digging
• Swing
• Bucket
• Telescopic dipper (optional)
• Auxiliary attachment (only optional on control valves for backhoe attachment pilot controls).
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Excavator and backhoe hydraulic controls - Static description

580ST
590ST
695ST
Backhoe attachment control valve pilot solenoid valve
LELI12TLB0494GB 1
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Solenoid valve is located under the cab floor and is in-

stalled directly in the lower part of the chassis that sup-
ports the operating levers. The solenoid valve is installed
on loader backhoes with backhoe attachment pilot con-
trols and has the task to transform the electric controls, re-
ceived from the control levers, into hydraulic controls, and
to send them to the backhoe attachment control valve.
The module (A) is installed only on the machines versions
with telescopic dipper. If the machine is not equipped with
telescopic dipper, the solenoid valve installed is of type
(B); while if the telescopic dipper is installed the solenoid
valve can be of type (A) + (B).
LELI12TLB0495AB 2
If the loader backhoe is equipped with a telescopic dipper

and if the rear control valve contains an auxiliary section,
the solenoid valve consists of valve (B) and module (C).
LELI12TLB0496AB 3
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Excavator and backhoe hydraulic controls - Component

identification
580ST
590ST
695ST
Backhoe attachment mechanical controls

The backhoe attachment control valves for machines with backhoe attachment mechanical controls may have 6 or 7
sections (and not 8 sections).
With gear pump (with fixed flow rate)
LELI12TLB2107GB 1
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A. Right stabilizer section E. Swing section

B. Left stabilizer section F. Boom section
C. Dipper section G. Telescopic dipper section
D. Bucket section
1. End cover 6. Swing relief valve - 205 bar (2973 psi)

2. Inlet section 7. Boom relief valve (piston side) - 240 bar (3480 psi)
3. Dipper relief valve - 240 bar (3480 psi) 8. Boom relief valve (rod side) - 310 bar (4495 psi)
Bucket relief valve (piston side) - 260 bar
4. 9. Telescopic dipper relief valve - 124 bar (1798 psi)
(3770 psi)
Bucket relief valve (rod side) - 220 bar
5. 10. Pump flow rate balancer valve - 10 bar (145 psi)
(3190 psi)
With piston pump (with variable flow rate)
LELI12TLB2108GB 2
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A. Right stabilizer section E. Swing section

B. Left stabilizer section F. Boom section
C. Dipper section G. Telescopic dipper section
D. Bucket section
1. End cover 6. Swing relief valve - 205 bar (2973 psi)

2. Inlet section 7. Boom relief valve (piston side) - 240 bar (3480 psi)
3. Dipper relief valve - 240 bar (3480 psi) 8. Boom relief valve (rod side) - 310 bar (4495 psi)
Bucket relief valve (piston side) - 260 bar
4. 9. Telescopic dipper relief valve - 124 bar (1798 psi)
(3770 psi)
Bucket relief valve (rod side) - 220 bar
5. 10. Pump flow rate balancer valve - 10 bar (145 psi)
(3190 psi)
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Excavator and backhoe hydraulic controls - Component

identification
580ST
590ST
695ST
Backhoe attachment pilot controls

The backhoe attachment control valves for machines with backhoe attachment pilot controls may have 6 or 7 or 8
sections.
With gear pump (with fixed flow rate)
LELI12TLB2563GB 1
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A. Right stabilizer section 3. Dipper relief valve - 220 bar (3190 psi)
B. Left stabilizer section 4. Backhoe bucket relief valve (piston side) - 260 bar
(3770 psi)
C. Dipper section 5. Backhoe bucket relief valve (rod side) - 220 bar
(3190 psi)
D. Bucket section 6. Swing relief valve - 205 bar (2973 psi)
E. Swing section 7. Boom relief valve (piston side) - 124 bar (1798 psi)
F. Boom section 8. Boom relief valve (rod side) - 310 bar (4495 psi)
G. Telescopic dipper section 9. Telescopic dipper relief valve - 124 bar (1798 psi)
H. Auxiliary section 10. Auxiliary section relief valves - 220 bar (3190 psi)
1. End cover 11. Pump flow rate balancer valve - 10 bar (145 psi)
2. Inlet section 12. Load-sensing relief valve - 205 bar (2973 psi)
With piston pump (with variable flow rate)
LELI12TLB2563GC 2
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A. Right stabilizer section 3. Dipper relief valve - 220 bar (3190 psi)
B. Left stabilizer section 4. Backhoe bucket relief valve (piston side) - 260 bar
(3770 psi)
C. Dipper section 5. Backhoe bucket relief valve (rod side) - 220 bar
(3190 psi)
D. Bucket section 6. Swing relief valve - 205 bar (2973 psi)
E. Swing section 7. Boom relief valve (piston side) - 124 bar (1798 psi)
F. Boom section 8. Boom relief valve (rod side) - 310 bar (4495 psi)
G. Telescopic dipper section 9. Telescopic dipper relief valve - 124 bar (1798 psi)
H. Auxiliary section 10. Auxiliary section relief valves - 220 bar (3190 psi)
1. End cover 11. Pump flow rate balancer valve - 10 bar (145 psi)
2. Inlet section
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Excavator and backhoe bucket hydraulic system - Remove the

backhoe attachment lock
580ST
590ST
695ST
1. Park machine on a flat surface and position the bucket

on the ground.
2. Position the backhoe support in the centre of the ma-
chine and lower the backhoe on the ground.
the control levers through all operating positions.
LELI12TLB2148AA 1
5. Disconnect the line (1).

7. Remove the lock (3).
LEPH12TLB2149AB 2
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Excavator and backhoe hydraulic controls - Remove the backhoe

attachment control valve (mechanical controls)
580ST
590ST
695ST

cavity.
ment to the ground.
neutral position.
11. Drain oil from the hydraulic system. LELI12TLB2110AA 1

and tag them.
verse order.
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Excavator and backhoe hydraulic controls - Disassemble the

backhoe attachment control valve (mechanical controls)
580ST
590ST
695ST

NOTICE: During assembly, torque the nuts to 27.2 N·m
(20.06 lb ft).
LELI12TLB2112AB 1

4. Remove the control valve sections (4), (5), (6), (7), (8),
(9) and (10) and inlet section (11).
5. Check and replace the O-rings (12) located between
the different sections of the control valve if necessary.
LELI12TLB2113AB 2
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Inlet section disassembly

1. Remove the flow balancer valve (13).
NOTICE: During assembly, torque the valve to 100 N·m
(73.76 lb ft).
2. Remove the load-sensing relief valve (14).
(33.19 lb ft).
3. Remove the load sensing bleed valve (15).
4. Remove the plugs (16) and (17).
NOTICE: During assembly, torque the plug to 20 N·m
(15 lb ft).
LELI12TLB2114BB 3
Disassembly of the end cover

1. Remove the check valve (19).
LELI12TLB2117AC 4
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Disassemble the control valve sections
LELI12TLB2116FC 5
NOTE: The figure shows the stabilizer section, the valves may be different in the other sections.
1. Remove the check valves (21).
(22 lb ft).
(44 lb ft).
3. Remove the spool:
NOTICE: During assembly, torque the bolts to 10 N·m
(7.4 lb ft).
5. Remove the cover (24) and the seal (28).
NOTICE: During assembly, torque the pin to 10 N·m (7.4 lb
ft).
7. Remove the spring (27) with the relevant spring guides
(26).
8. Keep the seal (29).
9. Remove the yoke (30) with the protection (31).
NOTICE: During assembly, torque the yoke to 10 N·m
(7.4 lb ft).
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(7.4 lb ft).
11. Remove the flange (33) with the relevant seal (34).
12. Keep the seal (35).
13. Remove the spool (36).
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Excavator and backhoe hydraulic controls - Assemble the spool

seals of the backhoe attachment valve (mechanical controls)
580ST
590ST
695ST
1. Position the metal part of the seal (29) on the outside

of the spool (36).
2. The seal must be fitted on the end of the spool so that
its grooves (S) are not damaged and its tightness is not
jeopardized.
3. Let the seal slide perpendicularly onto the spool.
LELI12TLB2119AB 1
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Excavator and backhoe hydraulic controls - Remove the backhoe

attachment control valve (pilot controls)
580ST
590ST
695ST

cavity.
ment to the ground.
neutral position.
battery master switch. LELI12TLB1915AA 1

and tag them.
18. Remove the valve assembly from the machine.
verse order.
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backhoe attachment control valve (pilot controls)
580ST
590ST
695ST

NOTICE: During assembly, torque the nuts to 27.2 N·m
(20.06 lb ft).
LELI12TLB1916AB 1

4. Remove the control valve sections (4), (5), (6), (7), (8),
(9), (10) and (11) and inlet section (12).
5. Check and replace the O-rings (13) located between
the different sections of the control valve if necessary.
LELI12TLB1917AB 2
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Inlet section disassembly

(73.76 lb ft).
2. Remove the load-sensing relief valve (14).
(33.19 lb ft).
3. Remove the load sensing bleed valve (15).
4. Remove the plugs (16) and (17).
NOTICE: During assembly, torque the plug to 20 N·m
(15 lb ft).
LELI12TLB1918BB 3
Disassembly of the cover

1. Remove the check valve (21).
LELI12TLB1919AB 4
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Disassemble the control valve sections
LELI12TLB1920FB 5
NOTE: The figure shows the swing section, the valves may be different in the other sections.
1. Remove the check valves (22).
(22 lb ft).
(44 lb ft).
3. Remove the pressure relief valve (23).
(52 lb ft).
(7.4 lb ft).
6. If necessary, replace the O-ring (28).
7. Remove the spring (29) and the relevant spring guide
(30).
(7.4 lb ft).
10. If necessary, replace the O-ring (33).
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11. Remove the spring (34) and the relevant spring guide
(35).
12. Remove the spool (25).
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backhoe attachment control valve pilot solenoid valve
580ST
590ST
695ST
1. Remove the accumulator (1) from the solenoid valve

assembly (2).
LELI12TLB0497AB 1
2. Remove the bolts (3) and disassemble valve (4).

Check the O-rings (5). Replace if necessary.
LELI12TLB0498AB 2
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LELI12TLB0499GB 3
3. If necessary, it is possible to disassemble the various

solenoid valves:
• Remove the bolts (6) and remove the solenoid
valves (7).
• Remove and disassemble the valve (8). Check the
parts for condition. Replace if necessary.
• Remove and disassemble the solenoid valves (9)
and (10). Check the parts for condition. Replace
if necessary.
• Check the O-rings for condition. Replace the O-rings
if necessary.
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Index

Excavator and backhoe bucket hydraulic system - Remove the backhoe attachment lock (*) . . . . . 36
Excavator and backhoe hydraulic controls - Assemble the spool seals of the backhoe attachment
valve (mechanical controls) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Excavator and backhoe hydraulic controls - Component identification (*) . . . . . . . . . . . . . . . . . . . . . . 30
Excavator and backhoe hydraulic controls - Component identification (*) . . . . . . . . . . . . . . . . . . . . . . 33
Excavator and backhoe hydraulic controls - Disassemble the backhoe attachment control valve (me-
chanical controls) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Excavator and backhoe hydraulic controls - Disassemble the backhoe attachment control valve (pilot
controls) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Excavator and backhoe hydraulic controls - Disassemble the backhoe attachment control valve pilot
solenoid valve (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Excavator and backhoe hydraulic controls - Dynamic description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Excavator and backhoe hydraulic controls - Remove the backhoe attachment control valve (me-
chanical controls) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Excavator and backhoe hydraulic controls - Remove the backhoe attachment control valve (pilot
controls) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Excavator and backhoe hydraulic controls - Static description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Excavator and backhoe hydraulic controls - Static description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
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Boom hydraulic system - 736

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Contents
TECHNICAL DATA
Boom cylinder
Dimension (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
FUNCTIONAL DATA
Boom cylinder
Exploded view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
SERVICE
Boom cylinder
Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
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Hydraulic systems - Boom hydraulic system
Boom cylinder - Dimension

580ST
590ST
695ST
LELI12TLB1885EA 1
1. Stroke 590ST - 695ST

2. Completely retracted 580ST
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Boom cylinder - Exploded view

580ST
590ST
695ST
LELI12TLB1893FB 1
2. Bushing 10. Back-up ring

3. Cylinder rod 11. O-ring
6. Ring 14. Piston
8. Screw 16. Cylinder tube
9. Cylinder gland 17. Bushing
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Boom cylinder - Remove

580ST
590ST
695ST
NOTE: During this procedure hydraulic oil will be released. Keep a container to collect and dispose the fluid properly.
ATTENTION: While removing the boom cylinder ensure the safety of the cabin glasses.
1. Lower the backhoe attachment and rest it on the
ground.
PTIL13TLB0453AA 1
2. Attach a suitable lifting device to the boom cylinder (1).
PTIL13TLB0454AB 2
3. Remove the snap ring (1) and shim from the swing
frame end of the boom cylinder.
PTIL13TLB0455AB 3
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4. Tap and remove the pivot pin (1) from one side using
a wooden hammer and let the cylinder rest on the ma-
chine.
PTIL13TLB0456AB 4
5. Disconnect the cylinder from the center pivot point of

the boom.
6. Remove the bracket bolt (1).
7. Tap and remove the pivot pin from the other side to free
the boom cylinder from the machine.
NOTE: Ensure to collect all the shims and keep it aside for
easy retainment while installing.
PTIL13TLB0457AB 5
8. Using the lifting device place the boom cylinder aside

securely.
PTIL13TLB0452AA 6
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Boom cylinder - Remove

580ST
590ST
695ST
Backhoe attachment boom cylinder removal

3. Support the backhoe attachment elements for cylinder
removal using a suitable support.
NOTICE: Always support the structural members so that
they will be stable and safe to work around.
4. Stop the engine and move the backhoe attachment
control levers through all operating positions to relieve
any residual pressures in the system.
5. Support the cylinder with a lifting device of adequate
capacity. LELI12TLB1887AA 1
6. Disconnect the hoses (T).

8. Remove the snap ring (1) and spacers (2).
9. Remove the pin (3) with a hammer.
LELI12TLB1890AB 2
10. Disconnect the yoke of the lock cylinder (4) for trans-
port from the hook (5).
LELI12TLB1891AB 3
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12. Remove the hooks (5) and (8).
13. Remove the rod pin (7) with a hammer.
14. Remove the backhoe boom cylinder.
LELI12TLB1892AB 4
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Boom cylinder - Disassemble

580ST
590ST
695ST
NOTICE: Cylinder weight (with short dipper): 80.5 kg (177.47 lb). Use a lifting device of adequate capacity.
NOTICE: Cylinder weight (with long dipper): 93.1 kg (205.25 lb). Use a lifting device of adequate capacity.
NOTE: Be sure that the cylinder is placed horizontally.
LELI12TLB1894AA 1

5. Use the wrench 380000724 to loosen the cylinder gland
(9).
NOTICE: If necessary gently heat the gland carrier to
soften the thread sealant applied during manufacture.
LELI12TLB1895AB 2

(16) with a plastic hammer.
7. Remove the cylinder rod (3) and the cylinder gland (9).
LELI12TLB1896AB 3
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cylinder rod (3).
LELI12TLB1897AB 4

guide bush (7), the back-up ring (10) and O-ring
(11) from the cylinder gland (9).
• Remove the piston guide ring (13) and piston seal
LELI12TLB1898AB 5
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Boom cylinder - Install

580ST
590ST
695ST
1. Using the lifting device place the boom cylinder on the

boom.
PTIL13TLB0452AA 1
2. Place the bracket bolt (1) in the retainer bracket and

tap in the pivot pin to install the boom cylinder. Torque:
345 N·m (254 lb ft).
NOTE: Ensure to install all the shims, collected during re-
moval.
PTIL13TLB0457AB 2
3. Tap and install the pivot pin (1) from one side using a
wooden hammer.
PTIL13TLB0456AB 3
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4. Install the shim and snap ring (1) on the swing frame
end of the boom cylinder.
PTIL13TLB0455AB 4
5. Release the lifting device from the boom cylinder (1).
PTIL13TLB0454AB 5
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Index

Boom cylinder - Dimension (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Boom cylinder - Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Boom cylinder - Exploded view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Boom cylinder - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Boom cylinder - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Boom cylinder - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
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Dipper hydraulic system - 737

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Contents
TECHNICAL DATA
Dipper cylinder
Dimension (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
FUNCTIONAL DATA
Dipper cylinder
Exploded view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
SERVICE
Dipper cylinder
Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
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Hydraulic systems - Dipper hydraulic system
Dipper cylinder - Dimension

580ST
590ST
695ST
Backhoe attachment dipper cylinder
LELI12TLB1900EA 1
1. Stroke 590ST - 695ST

2. Completely retracted 580ST
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Dipper cylinder - Exploded view

580ST
590ST
695ST
LELI12TLB2208FB 1

6. Ring 14. Piston
8. Safety screw 16. Cylinder tube
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Dipper cylinder - Remove

580ST
590ST
695ST

removal using a suitable support.
5. Position a sling or other suitable lifting equipment
around the cylinder. LELI12TLB2202AA 1
6. Make sure that the dipper (A) and boom (B) are in a
safe position to prevent involuntary movements after
the removal of the dipper cylinder (1).
LEPH12TLB2205AB 2
7. Remove the snap rings (2) and spacers (3).

LELI12TLB2206AB 3
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9. Remove the snap rings (5) and spacers (6).

10. Drive out the rod pin (7) with a hammer.
11. Remove the backhoe dipper cylinder.
LELI12TLB2207AB 4
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Dipper cylinder - Remove

580ST
590ST
695ST
1. Lower the backhoe attachment and rest it on the
ground.
PTIL13TLB0453AA 1
2. Before proceeding to remove, attach a suitable lifting

device to the arm cylinder (1).
PTIL13TLB0447AB 2
3. De-clamp and remove the hydraulic lines (1) from the

cylinder and cap them immediately.
NOTE: Store the removed hoses and lines in a secure
place.
ATTENTION: Ensure not to damage the hydraulic pipes.
Failure to comply may affect oil flow during operations.
PTIL13TLB0448AB 3
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4. Remove the retainer bracket bolt (1) and washer.

NOTE: Ensure to collect all the shims for easy retainment
during installation.
PTIL13TLB0449AB 4
5. Tap and remove the retainer bracket pivot pin (1) using
a wooden hammer from the other side to free the cylin-
der from the boom end.
PTIL13TLB0450AB 5
6. Remove the retainer bracket bolt (1), washer and tap

the pivot pin from the other side using a wooden ham-
mer.
PTIL13TLB0451AB 6
7. Using the lifting device lift the cylinder and place it in a

secure location.
PTIL13TLB0452AA 7
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Dipper cylinder - Disassemble

580ST
590ST
695ST
NOTICE: Cylinder weight (580ST): 73.4 kg (161.82 lb). Use a lifting device with adequate capacity.
NOTICE: Cylinder weight (590T - 695ST): 74.6 kg (164.46 lb). Use a lifting device with adequate capacity.
LELI12TLB2210AA 1

5. Loosen the cylinder gland (9).
LELI12TLB2211AB 2

LELI12TLB2212AB 3
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cylinder rod (3).
LELI12TLB2213AB 4

from the cylinder gland (9).
LELI12TLB2214AB 5
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Dipper cylinder - Install

580ST
590ST
695ST
1. Using the lifting device lift the cylinder and place it on

the boom.
PTIL13TLB0452AA 1
2. Using a wooden hammer install the pivot pin and

tighten the retainer bracket bolt (1) and washer using
LOCTITE® 242®. Torque: 186 N·m (137 lb ft).
moval.
PTIL13TLB0451AB 2
3. Install the retainer bracket bolt (1) and washer us-

ing LOCTITE® 242® on the other end of the cylinder.
Torque: 186 N·m (137 lb ft).
PTIL13TLB0449AB 3
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4. Clamp and install the hydraulic lines (1) to the cylinder.

ATTENTION: Ensure not to damage the hydraulic pipes.
Failure to comply may affect oil flow during operations.
PTIL13TLB0448AB 4
5. Release the lifting device after installing the dipper

cylinder (1).
PTIL13TLB0447AB 5
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Index

Dipper cylinder - Dimension (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Dipper cylinder - Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Dipper cylinder - Exploded view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Dipper cylinder - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Dipper cylinder - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Dipper cylinder - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
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Excavator and backhoe bucket hydraulic system - 738

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Contents
TECHNICAL DATA
Bucket cylinder
Dimension (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
FUNCTIONAL DATA
Bucket cylinder
Exploded view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
SERVICE
Bucket cylinder
Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
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Hydraulic systems - Excavator and backhoe bucket hydraulic system
Bucket cylinder - Dimension

580ST
590ST
695ST
Backhoe bucket cylinder
LELI12TLB2021FA 1
1. Stroke 580ST
2. Completely retracted 590ST - 695ST
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Bucket cylinder - Exploded view

580ST
590ST
695ST
LELI12TLB2029FB 1

5. Seal ring 13 Piston guide
6. Ring .14. Piston
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Bucket cylinder - Remove

580ST
590ST
695ST

4. Support the cylinder with a lifting device of adequate
capacity.
LELI12TLB2022AA 1

7. If necessary use hydraulic power to very slowly retract
the cylinder.
LELI12TLB2023AB 2
8. Disconnect the hoses (T).

LEPH12TLB2028AB 3
12. Remove the backhoe bucket.
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Bucket cylinder - Remove

580ST
590ST
695ST
1. Lower the backhoe attachment and place the backhoe
bucket parallel to the ground.
PTIL13TLB0491AA 1
2. Attach a suitable lifting device to the bucket cylinder.
PTIL13TLB0492AA 2
3. De-clamp the hydraulic lines (1) from the cylinder ends.

4. Tag and cap the open plugs and hoses immediately.
5. Collect oil flowing from cylinder in a container.
PTIL13TLB0493AB 3
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6. Remove the wear ring (1), cotter pin and shims from
the cylinder end on both sides.
PTIL13TLB0494AB 4
7. Tap the pivot pin (1) from one end using a wooden
hammer and keep it resting on the arm.
PTIL13TLB0495AB 5
8. On the other side remove the pivot pin retainer bolt (1).
PTIL13TLB0496AB 6
9. Tap the pivot pin (1) out from other side to remove the
dipper cylinder completely from the machine.
PTIL13TLB0497AB 7
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10. Lift the suspended cylinder from the arm and place it
in a secure location.
PTIL13TLB0452AA 8
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Bucket cylinder - Disassemble

580ST
590ST
695ST
NOTICE: Cylinder weight: 50.1 kg (110.45 lb). Use a lifting device with adequate capacity.
LELI12TLB2041AA 1

(9).
LELI12TLB2031AB 2

LELI12TLB2032AB 3
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8. Remove the bolt (15). Remove the piston (14) and

cylinder gland (9) from the cylinder rod (3).
LELI12TLB2033AB 4
A. Remove the wiper ring (4), seal ring (5), ring (6),
guide bush (7), back-up ring (10) and O-ring from
the cylinder gland (9).
B. Remove the piston guide ring (13) and piston seal
LELI12TLB2034AB 5
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Bucket cylinder - Install

580ST
590ST
695ST
1. Lift the dipper bucket and place it on the arm.
PTIL13TLB0452AA 1
2. Tap the pivot pin (1) from outer side to install the dipper
bucket into the machine arm.
moval.
PTIL13TLB0497AB 2
3. Install the retainer bracket bolt (1) and washer using

LOCTITE® 242®. Torque: 186 N·m (137 lb ft)
PTIL13TLB0496AB 3
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4. Tap the pivot pin (1) into the bucket control cylinder end
using a wooden hammer.
PTIL13TLB0495AB 4
5. Install the shims, cotter pin and wear ring (1).
PTIL13TLB0494AB 5
6. Fix the hydraulic hoses to the plugs.

7. Clamp the hydraulic lines (1) to the cylinder.
PTIL13TLB0493AB 6
8. Release the lifting device from the bucket cylinder.
PTIL13TLB0492AA 7
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Index

Bucket cylinder - Dimension (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Bucket cylinder - Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Bucket cylinder - Exploded view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Bucket cylinder - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Bucket cylinder - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Bucket cylinder - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
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Swing arm hydraulic system - 739

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Contents
TECHNICAL DATA
Swing cylinder
Dimension (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
FUNCTIONAL DATA
Swing cylinder
Exploded view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
SERVICE
Swing cylinder
Stabilizer cylinder - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
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Hydraulic systems - Swing arm hydraulic system
Swing cylinder - Dimension

580ST
590ST
695ST
LELI12TLB2135FA 1
1. Stroke
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Swing cylinder - Exploded view

580ST
590ST
695ST
LELI12TLB2142FB 1
1. Bushing 10. Trunnion

2. Wiper ring 11. O-ring
6. Ring 15. Piston
7. Guide bush 16. Lock retaining piston
8. Bushing 17. Cylinder tube
9. Seal ring
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Stabilizer cylinder - Remove

580ST
590ST
695ST

removal using a suitable stand and a hoist.
LELI12TLB2138AA 1
5. Remove the nut (1) and bolt (2).

NOTICE: If necessary use a hammer to remove the pin (3).
LEPH12TLB2139AB 2
7. Disconnect the hoses from the cylinders and cap all

exposed openings.
8. Remove the nuts (4) and bolts (5).
9. Remove the support (6).
LEPH12TLB2141AB 3
10. Carefully lift and remove the swing cylinder.
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Swing cylinder - Disassemble

580ST
590ST
695ST
NOTE: Cylinder weight: 31 kg (68.34 lb). Use a lifting device of adequate capacity.
1. Lift and place the cylinder on a workbench and secure
it on a vice.
LELI12TLB2143AA 1
3. Use the wrench 380000725 to loosen the trunnion (10).

4. Remove the rod assembly with the trunnion and piston
assembly.
LELI12TLB2144AB 2
5. Remove the piston lock (16).

6. Remove the piston assembly (15) and cylinder rod (3)
from the trunnion (10).
7. Check the bushings (8) for wear and condition. Re-
place if necessary.
LELI12TLB2145AB 3
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from the king pin (10).
• Remove the piston seal (13) and piston guide ring
LELI12TLB2146AB 4
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Index

Stabilizer cylinder - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Swing cylinder - Dimension (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Swing cylinder - Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Swing cylinder - Exploded view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
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Stabilizer hydraulic system - 703

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Contents
TECHNICAL DATA
Stabilizer cylinder
Dimension (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Dimension (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
FUNCTIONAL DATA
Stabilizer cylinder
Exploded view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Exploded view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
SERVICE
Stabilizer cylinder
Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
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Hydraulic systems - Stabilizer hydraulic system
Stabilizer cylinder - Dimension

580ST
590ST
695ST
Center pivot
LELI12TLB2048FA 1
1. Stroke
Stabilizer cylinder - Dimension

580ST
590ST
695ST
Sideshift
LELI12TLB1940EA 1
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1. Stroke
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Stabilizer cylinder - Exploded view

580ST
590ST
695ST
Center pivot
LELI12TLB2052FB 1

3. Ring 10. Piston gasket
5. Guide bush 12. Piston
6. Safety screw 13. Screw
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Stabilizer cylinder - Exploded view

580ST
590ST
695ST
Sideshift
LELI12TLB1944GB 1

3. Seal ring 10. Piston
4. Ring 11. Piston guide
5. Guide bush 12. Piston gasket
6. Cylinder gland 13. Screw
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580ST
590ST
695ST
Center pivot
1. Make sure that the backhoe loader is locked in the
transfer position and the machine is parked in a safety
work position.
LELI12TLB2049AA 1
3. Support the cylinder safely with suitable belt and hoist.

4. Remove the snap ring (1) and shims (2).
5. Remove the pin (3) with a hammer. Using the hydraulic
power, retract the cylinder very slowly.
LELI12TLB2050AB 2
6. Stop the engine.

7. Release possible residual pressure by moving the con-
trol levers of the stabilizers.
8. Disconnect all the hoses.
10. Remove the snap ring (4) and shims (5).
11. Drive out the pin (6) with a hammer.
LELI12TLB2051AB 3
12. Remove the stabilizer cylinder.
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Stabilizer cylinder - Disassemble

580ST
590ST
695ST
Center pivot
NOTICE: Cylinder weight: 43 kg (94.80 lb). Use a lifting device with adequate capacity.
LELI12TLB2053AA 1

(7).
LELI12TLB2054AB 2

(14) by tapping it with a plastic hammer.
LELI12TLB2055AB 3
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cylinder rod (1).
LELI12TLB2056AB 4

guide bush (5), O-ring (9)and back-up ring (8) from
the cylinder gland (7).
LELI12TLB2057AB 5
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580ST
590ST
695ST
Side shift
LELI12TLB1941AA 1

4. Relieve possible residual pressures in the system by
moving the loader attachment control lever through all
operating positions.
5. Remove the screw (1) and nut (2).
6. Remove the pin (3) to release the cylinder rod.
LEPH12TLB1942AB 2
7. Disconnect the hydraulic tubes at the top of the stabi-

lizer leg.
8. Remove the snap ring (4) and pin (5).
9. Attach an eye bolt (6) on the cylinder and support the
cylinder with a lifting device of adequate capacity.
LEPH12TLB1943AB 3
10. Lift and remove the stabilizer cylinder.
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Stabilizer cylinder - Disassemble

580ST
590ST
695ST
Side shift
NOTICE: Cylinder weight: 34.6 kg (76.28 lb). Use a lifting device of adequate capacity.
1. Lift and place the cylinder on a workbench. Secure the
cylinder on a vice.
LELI12TLB1945AA 1

5. Use the wrench 380000721 to loose the cylinder gland
(7).
LELI12TLB2121AB 2

LELI12TLB2122AB 3
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cylinder rod (1).
LELI12TLB2123AB 4

• Remove the wiper ring (2), seal rings (3), ring (4),
guide bush (5), O-ring (9) and back-up ring (8) from
the cylinder gland (7);
LELI12TLB2124AB 5
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Index

Stabilizer cylinder - Dimension (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Stabilizer cylinder - Dimension (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Stabilizer cylinder - Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Stabilizer cylinder - Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Stabilizer cylinder - Exploded view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Stabilizer cylinder - Exploded view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
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Telescopic arm hydraulic system - 740

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Contents
TECHNICAL DATA
Telescopic arm cylinder

Dimension (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
FUNCTIONAL DATA

Exploded view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
SERVICE

Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
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Hydraulic systems - Telescopic arm hydraulic system
Telescopic arm cylinder - Dimension

580ST
590ST
695ST
LELI12TLB2038FA 1
1. Stroke 580ST
2. Completely retracted 590ST - 695ST
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Telescopic arm cylinder - Exploded view

580ST
590ST
695ST
LELI12TLB2042FB 1

3. Wiper ring 11. Piston
4. Ring 12. Piston gasket
8 Safety screw 16. Bushing
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Telescopic arm cylinder - Disassemble

580ST
590ST
695ST
The disassembly procedure described below is based

on the premise that the hydraulic hoses have already
been disconnected.
NOTE: Cylinder weight (580ST): 37.6 kg (82.89 lb).
Cylinder weight (590ST - 695ST): 41.9 kg (92.37 lb).
Lift and securely place the cylinder on a workbench.
Be sure that the cylinder is placed horizontally.
Drain hydraulic oil from the cylinder.
LELI12TLB2043AA 1
Support the cylinder rod (1).

Unscrew and remove the safety screw (8).
Loosen the cylinder gland (7).
If necessary gently heat the gland carrier to soften the
thread sealant applied during manufacture.
LELI12TLB1698AB 2
Extract the cylinder gland (7) from the cylinder barrel

Remove the cylinder rod (1) and the cylinder gland (7).
LELI12TLB1699AB 3
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Loosen and remove the screw (14).

Extract the piston (11) and the cylinder gland (7) from
the cylinder rod (1).
LELI12TLB1696AC 4
Only if necessary:
• Remove the wiper ring (2), the seal ring (3), the ring
(4), the guide bush (5) and the O-ring (9) with the
back-up ring (8) from the cylinder gland (7).
• Remove the piston guide ring (11) and the piston
seal (10) from the piston (12).
LELI12TLB2001AB 5
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Index

Telescopic arm cylinder - Dimension (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Telescopic arm cylinder - Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Telescopic arm cylinder - Exploded view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
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PRINTED IN U.S.A.
48090752 24/02/2017
EN
SERVICE MANUAL
Frames and ballasting

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39
Contents
Frames and ballasting - 39
[39.100] Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39.1
[39.140] Ballasts and supports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39.2
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39
Frame - 100

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Contents
Frame - 100
FUNCTIONAL DATA
Frame
Static description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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Frames and ballasting - Frame
Frame - Static description

The chassis of the Backhoe Loader is manufactured as a one-piece unit, on which the main assemblies are attached,
or which supports the main assemblies.
Types
Some kinds of chassis are available, which differ from each other according to some main characteristics of the Back-
hoe Loader.
Loader attachment:
• “Straight” loader arm (2WS).
• “Bent” loader arm (2WS-TC and 4WS).
Backhoe attachment:
• Center pivot: The backhoe attachment is directly connected to the chassis and cannot shift laterally.
• Side-shift: The backhoe attachment is installed on a side-shift support and can shift laterally on the chassis guides.
Steering:
• 2 wheel steering (2WS).
• 4 wheel steering (4WS).
2WS center pivot chassis
LELI12TLB1001A 1
4WS center pivot chassis
LELI12TLB1003A 2
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Frames and ballasting - Frame
2WS side-shift chassis
LELI12TLB1005A 3
2WS-TC side-shift chassis
LELI12TLB1007A 4
4WS side-shift chassis
LELI12TLB1009A 5
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Index
Frame - 100
Frame - Static description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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Ballasts and supports - 140

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Contents
TECHNICAL DATA
Counterweight
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Frames and ballasting - Ballasts and supports
Counterweight - General specification

Counterweight
LELI12TLB2255FB 1
It is installed under the chassis in the front section of the machine.
There are different types of counterweights:
2WS (A):
Counterweight Weight Front mounting Bottom mounting
hardware torque hardware torque
1. Standard 127.3 kg (281 lb) 205 N·m (151 lb ft) 330 N·m (243 lb ft)
2. Medium 370 kg (816 lb) 205 N·m (151 lb ft) 330 N·m (243 lb ft)
3. Heavy 483.7 kg (1066 lb) 205 N·m (151 lb ft) 330 N·m (243 lb ft)
4WS (B):
Counterweight Weight Front mounting
hardware torque
4. Standard 125.5 kg (277 lb) 205 N·m (151 lb ft)
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Index

Counterweight - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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PRINTED IN U.S.A.
48090752 24/02/2017
EN
SERVICE MANUAL
Steering

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41
Contents
Steering - 41
[41.101] Steering control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.1
[41.106] Tie rods. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.2
[41.200] Hydraulic control components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.3
[41.216] Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.4
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41
Steering - 41
Steering control - 101

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Contents
Steering - 41
FUNCTIONAL DATA
Steering control
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Steering - Steering control
Steering control - Component localization

MARBLE CUTTING
DRIVE (2WD)
DRIVE (4WD)
2WS steering system
LELI12TLB2064GB 1
1. Flow divider 5. Oil filter

2. Power steering 6. By-pass valve
3. Hydraulic tank 7. Radiator
4. Return manifold 8. Front axle
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Steering control - Static description

The steering system has the following features:
• Double-acting steering cylinder.

• Oil tank in common with the main hydraulic system.
• A hydraulic pump located on the rear part of the transmission.
• Steering (or power steering) control valve located on the steering wheel’s column.
The oil is taken from the tank and reaches the pump.
The front pump flow is directed to the loader and backhoe attachment control valves.
Thanks to the presence of a flow divider, the rear pump delivery guarantees priority oil delivery to the steering system.
The flow divider includes a load-sensing valve and a steering system pressure relief valve.
According to the machine model, the steering system can be of 2 types:
• 2WS steering system

• 4WS steering system
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Steering control - Dynamic description

MARBLE CUTTING
DRIVE (2WD)
DRIVE (4WD)
Power steering - neutral position
LELI12TLB2065GA 1
Pump pressure Trapped oil
Stand-by pressure Return to oil tank
When the steering wheel is held still, the leaf springs return and hold the power steering spool in neutral position. This
ensures that no more oil is supplied to the steering cylinder.
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The spool also traps the oil in the steering cylinder and allows the oil in the sensing lines to return to the tank, thus
allowing the priority flow divider to move to the left.
Power steering - turning right pump pressure
LELI12TLB2070GA 2
Pump pressure Trapped oil
Metered pressure Return to oil tank
When the steering wheel is turned, the movement of the power steering spool forms a series of passages.
During right turn, oil flows through the spool along a groove and into a passage in the housing which leads to the
metering unit. A gallery is also lined up to allow pressure oil to flow down the sensing line to the priority flow divider.
As the metering unit is turned by the drive shaft, it directs a measured quantity of oil along another set of passages in
the spool then from these to the steering cylinder.
Return oil from the other side of the cylinder is directed through the spool to a return passage in the housing.
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Steering control - Component localization

MARBLE CUTTING
4WS steering system
LELI12TLB2221GB 1
1. Flow divider 6. By-pass valve

2. Power steering 7. Radiator
3. Hydraulic tank 8. Front axle
4. Return manifold 9. 4WS steering control valve
5. Oil filter 10. Rear axle
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Steering control - Component identification

MARBLE CUTTING
4WS steering control valve

The valve is located on the rear axle.
Remove the four hoses and the two fastening screws.
Remove the valve.
Draw a diagonal line across the complete valve block this

will assist in the correct reassembly later.
The valve consists of a central manifold block which all

input and output pipes are attached to.
On each side of this block is a solenoid valve.
The solenoid valves have two positions: both of these LELI12TLB2222AA 1
positions are working positions and there is no neutral

point.
Each spool is detented and therefore the solenoids are

only energized momentarily to move the spool.
On the end of each solenoid is an emergency hand oper-

ating pin which moves the control spool without energizing
the solenoid.
The switching of the steering valve is normally controlled

by a microprocessor located underneath the right hand
side console.
Components
1. Solenoid knob
2. Solenoid
3. Control spool
4. Block
5. Central block
6. Fixing screws
7. Piston
8. O-ring
9. O-ring
LELI12TLB2223AB 2
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Steering control - Dynamic description

MARBLE CUTTING
4WS Steering system - Operation
LELI12TLB2074GB 1
In the position shown both spools have been moved by

solenoids (2b) and (3b).
The detents on the (a) side of the solenoid hold the spool
in this position until another solenoid is pulsed.
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The spool in valve (3) was last moved by solenoid (3b):

oil flowing in from P3 flows through the internal galleries
of the spool and exits at port A3.
From here, oil enters valve (2), whose spool was last
moved by solenoid (2b).
Oil flows through port P2 and exits through port T2, cutting
off flow to the rear steering cylinder.
Now the oil returns in valve (3), entering through port B3

and flowing out through port T3. From here, oil enters the
front steering cylinder.
The three modes of steering are as follows:
Front wheel only steering
Front and rear wheel steer
Front and rear wheel crab
LELI12TLB2075BA 2
The solenoids energized are shown in the table below.
These are also the pins which need to be pressed when

changing steering mode manually in an emergency.
X = Energized
O = Not Energized
3a 3b 2a 2b
2WS O X O X
2WS X O O X
4WS O X X O
CRAB X O X O
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Index
Steering - 41

Steering control - Component identification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Steering control - Component localization (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Steering control - Component localization (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Steering control - Dynamic description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Steering control - Dynamic description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Steering control - Static description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
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Steering - 41
Tie rods - 106

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Contents
Steering - 41
Tie rods - 106
FUNCTIONAL DATA
Steering control link

SERVICE
Steering control link

Check (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Adjust (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
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Steering - Tie rods
Steering control link - Component identification

MARBLE CUTTING
4WS front axle – Toe-in / steering angle
LELI12TLB0657GA 1
(1) Steering knuckle (5) Steering cylinder

(2) Ball joint (tie rod) (6) Steering stop
(3) Adjustable lock nut (7) Steering stop lock nut
(4) Ball joint (tie rod) (8) Steering stop bolt
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Steering - Tie rods
Steering control link - Component identification

MARBLE CUTTING
4WS rear axle - Toe-in / Steering angle
LELI12TLB1582FB 1
(1) Steering knuckle (5) Steering cylinder

(2) Ball joint (tie rod) (6) Steering stop bolt
(3) Adjustable lock nut (7) Steering stop lock nut
(4) Ball joint (tie rod) (8) Steering stop
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Steering - Tie rods
Steering control link - Check

MARBLE CUTTING
4WS - Toe-in / Steering angle

1. Install two identical, 1 m long linear bars on the wheel
sides and lock them with the nuts on the wheel hub stud
screws.
NOTICE: Align the two bars. The bars should be fixed on
their middle so that they are perfectly perpendicular to the
supporting surface and parallel to the pinion axis.
LEPH12TLB1583AA 1
2. Measure the distance “M” between bar ends.

NOTE: Keep the minimum value, swinging the measure-
ment point.
LEPH12TLB1584AA 2
3. Check that the difference between the measurements

at the ends of the wheel hub diameters is within the
required tolerance range.
4. The nominal toe-in “A” value is referred to the external
diameter of the wheel hubs flange, therefore the mea-
sured toe-in value “M” at the bar ends must be related
to the ratio between length of the bar and flange diam-
eter:
Nominal toe-in = A±1 → measured toe-in = M±3
LELI12TLB1585AA 3
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Steering - Tie rods
5. If toe-in is not correct, with two wrenches on the rods

(1) loosen and tighten the two tie rods (3) equally, till
the toe-in is within the requested tolerance.
LEPH12TLB1586AB 4
6. Once adjusted, tighten the nuts (2) of the bars (1).

Torque the nuts to 250 N·m (184 lb ft).
LEPH12TLB1587AB 5
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Steering - Tie rods
Steering control link - Adjust

MARBLE CUTTING
4WS - Toe-in / Steering angle

1. This procedure requires two straight bars attached to
the machine as follows:
A. Attach a 1 m (3.3 ft) long linear bars on the wheel
hub (See Steering control link - Check (41.106)
for more info).
B. Attach a long bar perfectly rested on the machined
part of the central body (pinion side).
NOTICE: Make sure that the two bars form an acute angle
when the wheel hub is turned to its maximum steering po-
sition.
2. Measure the angle between the two bars at the maxi-
mum steering angle.
3. The measure angle C should be within ± 2° of 90 – S, LEPH12TLB1588AA 1
where S is the standard steering angle.
LEPH12TLB1589AA 2
4. If the measured angle is not within specified range, the

steering angle needs to be adjusted as follows:
5. Set the bevel protractor to Angle of 90° - S (where S is
the standard steering angle).
6. Place the bevel protractor on the long bar.
LEPH12TLB1589AA 3
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Steering - Tie rods
7. Loosen the lock nuts (5) for the steering stops (4) on
both sides of the axle beam.
8. Adjust the hubs until angle formed by the two bars
matches the angle of the bevel protractor.
9. Apply the prescribed sealant on the screw threads of
the stops (4) and lock the stops in position with the lock
nuts (5). Torque the lock nuts to 150 N·m (111 lb ft)
LEPH12TLB1590AB 4
10. Check that the locks on the opposite sides are both in
contact with the axle beam.
LELI12TLB1591AA 5
11. Perform the above steps on the other wheel hub.
LEPH12TLB1592AA 6
LELI12TLB1593AA 7
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Index
Steering - 41
Tie rods - 106

Steering control link - Adjust (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Steering control link - Check (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Steering control link - Component identification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Steering control link - Component identification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
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Steering - 41
Hydraulic control components - 200

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Contents
Steering - 41
TECHNICAL DATA
Power steering system

FUNCTIONAL DATA
Power steering system

Power steering control valve
Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
SERVICE
Hydraulic control components

Disassemble the flow divider . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Power steering control valve
Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
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Steering - Hydraulic control components
Power steering system - General specification

(L) Left control port (steering cylinder)
(R) Right control port (steering cylinder)
(P) Inlet to steering pump
(T) Outlet to oil tank
(LS) Outlet to steering pump
LELI12TLB2229AA 1
LELI12TLB2230AA 2
2WS (with variable-flow-rate pump)

Model EATON P/N 403 -8754-04
Shock valve adjustment 235 bar (3408 psi)
Load-sensing pressure relief valve adjustment 175 bar (2538 psi)
2WS (with gear pump)

Load-sensing pressure relief valve adjustment No
4WS
Load-sensing pressure relief valve adjustment 175 bar (2538 psi)
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Power steering system - Static description

The power steering consists of a metering and
emergency pump that includes:
• A gearwheel with fixed stator with inner teeth and a rotor
with outer teeth.
• A 4-way rotary control valve consisting of an outer
sleeve and an inner selection rotor.
• A rotor connected to the steering wheel by means of
the steering column, which can be of two types, fixed
or adjustable.
• A cardan shaft which is mechanically tied to the gear-
wheel and to the outer sleeve, and allows the transmis-
sion’s movement.
• A set of centering springs between the outer sleeve and
the inner rotor.
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Power steering control valve - Exploded view

A. Anticavitation valve 19. Seal ring
B. Manual check valve 20. Gasket
C. Inlet check valve 21. O-ring
D. Cylinder relief valve 22. Seal
E. Load-sensing relief valve 23. Bearing cup
F. Inlet relief valve 24. Bearing
1. Screw 25. Bearing cup
2. Cover 26. Spring
3. O-ring 27. Spacer
4. Spring 28. Sleeve
5. Plug 29. Plug
6. Ball 30. O-ring
7. Rotor/stator gear 31. Spring
8. Plate 32. Poppet
9. Shaft 33. O-ring
10. Power steering unit 34. O-ring
11. Valve seat 35. Ball
12. Ball 36. Pin
13. Ball holder 37. Spacer
14. O-ring 38. Valve seat
15. Spring 39. Poppet
16. Plug 40. Spring
17. Cross pin 41. O-ring
18. Spool 42. Plug
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LELI12TLB2081HB 1
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Hydraulic control components - Disassemble the flow divider

1. Remove the rubber floor mat and the iron floor mat.
2. Release the possible residual pressure from the hy-
draulic system and tank.
3. Disconnect all hoses connected to the slewing motor.
TULI12EXN2578AB 1
4. Disconnect the grease hose (1).
TULI12EXN2579AB 2

6. Remove the screws (3) with the relevant washers (4).
7. Remove the slewing motor (5).
NOTICE: Slewing motor weighs 23 kg (51 lb). Use a lifting
device of adequate capacity.
TULI12EXN2580AB 3
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Power steering control valve - Disassemble

NOTICE: Cleanliness is extremely important when repairing the power steering control valve. Work in a clean area.
Before disconnecting the lines, thoroughly clean the area. Use a wire brush to remove foreign material and debris.
NOTICE: Use protective material on vice jaws. Power steering unit distortion can result if jaws are over-tightened.
1. Make an identification mark (M) on the pump to aid
reinstallation process.
LELI12TLB2082AB 1

LELI12TLB2083AB 2
5. Remove the rotor-stator gear (7).

6. Remove the spacer (37) and O-ring (34).
LELI12TLB2084AB 3
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7. Remove the shaft (9).

8. Remove the plate (8) and O-ring (33) from the power
steering unit (10).
LELI12TLB2085AB 4
9. Remove the anti-cavitation valve (A) and manual check

valve (B).
LELI12TLB2086AB 5
10. Remove the spool-sleeve assembly (18) from the

power steering unit (10).
NOTICE: Always store the spool-sleeve assembly (18) ver-
tically.
11. Remove the pin (17) from the spool (18) and sleeve
(28) assembly.
12.
NOTICE: Do not split the spool-sleeve assembly inside the
power steering unit (10). Slowly rotate the spool-sleeve
assembly to remove it from the power steering unit.
LELI12TLB2087AB 6
13. Remove the bearing race (25), bearing (24) and bear-
ing race (23) from the power steering unit (10).
LELI12TLB2088AB 7
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15. Partially push the spool (18) on the end of the sleeve,
then carefully remove the centering springs (26) from
the spool (18).
16. The power steering with low input torque uses four
centering springs (26) and two spacers (27).
17. The standard input torque power steering uses six
centering springs.
M = Mark
S1 = Low torque springs
S2 = Standard springs
NOTE: Do not remove any valves other than the manual LELI12TLB2089AB 8
check valve and the anti-cavitation valves. All other valves
are factory preset and are non-serviceable.
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Power steering control valve - Assemble

1. Check all the mating surfaces.
2. If any parts have scratches or burrs, the power steering
must be replaced.
NOTICE: Use of parts with scratches or burrs can cause
leakage and is therefore not recommended.
3. Clean all metal parts in clean solvent. Blow dry with air.
NOTICE: Do not wipe dry with cloth or paper towel because
lint or other matter can get into the hydraulic system and
cause damage.
4. Do not use grit paper or file or grind these parts.
5. Lubricate all seals, replace all old seals with new seals
and do not use an excessive quantity of lubricant on
the seals of the rotor / stator gear.
6. Carefully assemble the spool (18) and sleeve (28) so
that spring slots line up correctly. Rotate spool while
sliding parts together.
7. Test for free rotation. The spool should rotate smoothly
in the sleeve with finger tip force applied to its end.
8. Align the spool and the sleeve making reference to the
relevant marks (M).
LELI12TLB2090AB 1
9. Position centering springs (26) so that the notches line

up, and arched center sections are nested together.
Next, with spring notches facing sleeve, insert one end
of entire spring set into spring installation tool.
NOTICE: The centering springs (26) for power steering
with low input torque (S1) have four arched springs with
two flat spacers (27) in the center.
The centering springs (26) for power steering with standard
input torque (S2) have six arched springs.
LELI12TLB2091AB 2
10. Compress the extended end of the spring set and

push it into the spool - sleeve assembly (18).
11. Keep pressure on spring ends while withdrawing in-
stallation tool and pushing forward on springs at same
time.
12. Central springs set in spring slots. Seat springs down
evenly and flush with upper surface of spool (28) and
sleeve (18).
LELI12TLB2242AB 3
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13. Insert the pin (17) through the spool - sleeve assembly
(18) until the pin is within the outside diameter of the
sleeve.
LELI12TLB2243AB 4

15. Install the bearing races (23), (25) and bearing (24).
LELI12TLB2244AB 5
16. Position the spool (18) - sleeve (28) assembly so that

the splined end of the spool enters the power steering
body first.
NOTICE: While inserting the spool-sleeve assembly, make
sure that the parts do not tilt out of position. Gently push the
assembly into place with a slight rotation, holding the pin
so that it does not come out and gets stuck in the internal
groove.
17. Completely insert the spool-sleeve assembly into the
body.
18. With aligned spool-sleeve assembly, check for free
rotation by turning the assembly with fingertip force LELI12TLB2245AB 6
applied to the end.
19. Position the power steering unit (10) in a vice.
20. Lightly clamp on the edges of the mounting area; do
not over-tighten the jaws.
NOTE: Make sure that the spool and the sleeve are flush
or slightly below the unit’s surface.
21. Clean the upper surface of the unit.
LELI12TLB2246AB 7
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22. Install the anti-cavitation valves (A), the manual check

valve (B) and O-ring (33).
23. Install the plate (8). Align the holes in the plate (8) with
the threaded holes in the unit (10).
LELI12TLB2247AB 8
24. Rotate the spool and sleeve assembly until the pin is
parallel with the port’s face.
25. Install the shaft (9), making sure it is engaged with the
pin (17).
26. To guarantee proper alignment, mark the shaft (L2).
27. When marking the shaft, note the relationship be-
tween slotted end and splined end.
28. Lubricate and install the O-ring (34).
NOTE: The lubrication will hold the seal in place.
29. Reference lines L1, L2, L3 and L4 should be parallel LELI12TLB2248AB 9
to each other.
30. Lubricate and install the O-ring (3).
31. Install the cap (2) with the bolts (1). Apply a initial
torque of 17 N·m (13 lb ft)
NOTICE: Install the bolts in the sequence shown in Figure
11.
32. Once all the bolts are installed, torque the bolts to 35 –
45 N·m (26 – 33 lb ft) in the sequence shown in Figure
11.
LELI12TLB2249AB 10
LELI12TLB2250AB 11
33. Check for proper timing by turning the spool clockwise

and feeling pressure in the (R) port.
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Index
Steering - 41

Hydraulic control components - Disassemble the flow divider . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Power steering control valve - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Power steering control valve - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Power steering control valve - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Power steering system - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Power steering system - Static description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
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Steering - 41
Cylinders - 216

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Contents
Steering - 41
Cylinders - 216
TECHNICAL DATA
Steering cylinder
FUNCTIONAL DATA
Cylinders
Exploded view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
SERVICE
Cylinders
Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Steering cylinder
Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Inspect (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Check Piston packing (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
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Steering - Cylinders
Steering cylinder - General specification

MARBLE CUTTING
DRIVE (2WD)
DRIVE (4WD)
Four wheel drive steering cylinder mounting screws 120 N·m (89 lb ft)
Two wheel drive steering cylinder mounting screws 335 N·m (247 lb ft)
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Cylinders - Exploded view

MARBLE CUTTING
4WS - Rear axle steering cylinder
LELI12TLB1084GB 1
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Cylinders - Disassemble
MARBLE CUTTING
4WS – Rear axle steering cylinder

1. Remove the nuts (1) and (14). Remove the tie rods (3)
and (12) from the swivel housings (2) and (13).
NOTICE: Do not damage the end of the threaded pins.
2. Check and replace the nuts (1) and (14) if necessary.
LELI12TLB1085AB 1
3. Remove the clamps (15) and (18).

4. Remove the sensor (17), connector bracket (16) and
the clamps (15) and (18).
LELI12TLB1086AB 2
5. Loosen the nuts (4) and (11) and remove the tie rods
(3) and (12) from the cylinder rods. Check for wear and
condition.
6. Remove the ball joints (5) and (9).
LELI12TLB1087AB 3
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7. Remove the bolts (6) and (9).

8. Remove the bushings (7) with a puller.
LELI12TLB1088AB 4
9. Remove the steering cylinder (8).
LELI12TLB1089AB 5
10. Remove the snap rings (19) and (27) from the steering
cylinder (8).
LELI12TLB1090AB 6
11. Push the cylinder heads (21) and (25) inside the cylin-
der.
LELI12TLB1091AB 7
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12. Remove the snap rings (20) and (26).
LELI12TLB1092AB 8
13. Pull out the rod (23) as necessary and remove the
cylinder head (25).
NOTE: Do not extract the piston from the cylinder (22).
LELI12TLB1093AB 9
14. Push the rod (23) in the opposite direction and remove
it from the cylinder (22) with the head (21).
15. Remove the head (21) from the rod (23).
LELI12TLB1094AB 10
16. Remove all the seal rings from the rod (23) and from
the cylinder heads (21) and (25). Check for condition
and replace if necessary.
LELI12TLB1095AB 11
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Cylinders - Assemble
MARBLE CUTTING
4WS - Rear axle steering cylinder

1. Install the seal rings (24) on the heads (21) and (25).
LELI12TLB1096AB 1
2. Install the seal rings (24) on the rod (23).
LELI12TLB1097AB 2
LELI12TLB1098AB 3
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3. Install the heads (21) and (25) on the rod (23).
LELI12TLB1099AB 4
LELI12TLB1100AB 5
4. Insert the pre-assembled rod (23) into the cylinder body

(22).
LELI12TLB1700AB 6
5. Install the snap rings (20) and (26) in the relevant seats
of the cylinder body (22).
LELI12TLB1702AB 7
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6. Pull the rod (23) on each side and move the cylinder
heads (21) and (25) to the end of the stroke.
LELI12TLB1703AB 8
7. Install the snap rings (19) and (27) on the heads (21)
and (25).
LELI12TLB1704AB 9
LELI12TLB1705AA 10
8. Install the steering cylinder (8).
LELI12TLB1706AB 11
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9. Cool the bushes (7) at a temperature lower than

-100 °C (-148 °F) with liquid nitrogen.
10. Install the bushes (7) with a punch and a hammer.
LEPH12TLB1707AB 12
LELI12TLB1708AB 13
13. Install the ball joints (5) and (10) on the rod ends.
Torque to 300 N·m (221 lb ft).
14. Install the nuts (4) and (11) and the tie rods (3) and
(12) to the ball joints (5) and (10).
LELI12TLB1709AB 14
15. Align the swivel housing (2) with the axle.

16. Loosen the nut (4) and turn the tie rod (3) so that its
ball joint can be inserted into the swivel housing (2)
arm.
17. Repeat the above on the other side.
LEPH12TLB1710AB 15
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18. Install the ball joint of the tie rod (12) in its seat on the
swivel housing (13).
19. Install the nut (14). Torque to 260 N·m (192 lb ft).
20. Repeat the above steps on the other side.
LEPH12TLB1711AB 16
21. Install the nuts (4) and (11) of the tie rods (3) and (12)
only after the toe-in adjustment has been carried out.
LEPH12TLB1712AB 17
22. Install the sensor (17) and the connector bracket (16)
on the steering cylinder (8) with the clamps (15) and
(18).
LELI12TLB1713AB 18
23. Tighten the clamps (7) and (8) only after the toe-in
adjustment has been carried out.
LEPH12TLB1714AB 19
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Steering cylinder - Remove

MARBLE CUTTING
DRIVE (2WD)
DRIVE (4WD)
NOTE: The following photographs show the steering cylin-

der being removed from the axle with the axle removed
from the machine. It is not necessary to remove the axle
from the machine to remove the steering cylinder.
1. Clean the hose connections and the steering cylinder.
2. Fasten an identification tag to one of the hoses to the
steering cylinder.
3. Disconnect the hoses from the steering cylinder. Install
a plug is each hose and a cap on each fitting.
NOTE: Some of the photo may look different than your
machine. The procedure is the same.
4. Loosen the nut several turns. Do not remove the nut at
this time.
RCPH10TLB301ABL 1
5. Install the CAS10486 puller and tighten the screw to

loosen the ball joint.
6. Remove the nut and remove the ball joint from the arm.
RCPH10TLB302ABL 2
7. Repeat steps 4, 5 and 6 for the other end of the axle.
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8. Brace the flats of the piston rod and install a wrench

on the tie rod. Prevent the piston rod from turning and
loosen the tie rod.
RCPH10TLB303ABL 3
9. Remove the tie rod and ball joint assembly from the
piston rod.
10. Loosen and remove the bolts that fasten the steering
cylinder to the axle.
RCPH10TLB286ABL 4
11. A hose fitting will be installed in your steering cylinder.

Remove the hose fitting.
RCPH10TLB287ABL 5
12. Hit the steering cylinder with a soft hammer to drive

the steering cylinder out of the axle.
RCPH10TLB288ABL 6
13. Remove the steering cylinder from the axle.
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Next operation:
Steering cylinder - Install (41.216)
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Steering cylinder - Install

MARBLE CUTTING
DRIVE (2WD)
DRIVE (4WD)
1. Install the steering cylinder in the axle.

2. Install the bolts that fasten the steering cylinder to the
axle. Tighten the bolts to 120 N·m (89 lb ft).
RCPH10TLB286ABL 1
3. Start the ball joint assembly and tie rod onto the piston
rod.
4. Brace the flats of the piston rod and install a wrench on
the tie rod. Prevent the piston rod from turning the tie
rod. Tighten the tie rod to a torque of 300 N·m (221 lb
ft).
RCPH10TLB304ABL 2
5. Install the ball joint in the arm.
RCPH10TLB302ABL 3
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6. Install the nut on the ball joint and tighten the nut to
165 N·m (122 lb ft).
RCPH10TLB305ABL 4
7. Repeat steps 5, 6, and 7 for the other end of the axle.

8. Connect the hoses to the fittings in the steering cylinder.
10. Turn the steering wheel all the way to the right and
left several times to remove any air from the steering
system.
11. Stop the engine and check for oil leaks.
12. Check the level of the oil in the reservoir and add oil
as required.
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Steering cylinder - Disassemble

MARBLE CUTTING
DRIVE (2WD)
DRIVE (4WD)
1. Remove the tie rod ball joint assembly.

2. Fasten the tube in a vise or other holding equipment.
Do not damage the tube.
RCPH10TLB290ABL 1
3. Use a soft faced hammer and separate the gland from

the tube.
RCPH10TLB291ABL 2
4. Remove the gland from the piston rod assembly.
RCPH10TLB292ABL 3
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5. Use a soft faced hammer and drive the piston against

the gland, remove the gland from the tube.
RCPH10TLB293ABL 4
6. Pull the piston rod assembly straight out of the tube to

prevent damage to the tube.
RCPH10TLB294ABL 5
7. Remove the gland from the piston rod.
RCPH10TLB295ABL 6
8. Remove the wiper and the seal from the gland. Re-
move the seal ring from the gland. Repeat the proce-
dure for the other gland.
RCPH10TLB296ABL 7
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9. Remove the seals from the piston rod assembly.
RCPH10TLB297ABL 8
Next operation:
Steering cylinder - Inspect (41.216)
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Steering cylinder - Inspect

MARBLE CUTTING
DRIVE (2WD)
DRIVE (4WD)
Prior operation:
Steering cylinder - Assemble (41.216)
1. Discard the parts that were removed from the glands

and piston rod assembly.
3. Inspect the gland, piston rod assembly and the tube
for damage and wear. These parts are not serviced
separately, if these parts need to be replaced, a new
steering cylinder must be used.
Next operation:
Steering cylinder - Assemble (41.216)
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Steering cylinder - Assemble

MARBLE CUTTING
DRIVE (2WD)
DRIVE (4WD)
1. Install a new seal in the grooves of the piston rod as-

sembly.
RCPH10TLB299ABL 1
2. Install a new seal in the gland. The lip of the seal must
be toward the inside of the gland.
RCPH10TLB297ABL 2
3. Install a new wiper in the gland. The lip of the wiper

must be toward the outside of the gland.
RCPH10TLB298ABL 3
4. Install a new seal ring in the groove on the gland.

5. Lubricate the piston seals with clean oil.
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6. Fasten the tube in a vise with soft jaws. Start the piston
rod assembly into the tube, be careful not to damage
the seals.
RCPH10TLB294ABL 4
7. Push the piston rod assembly all the way into the tube,
use a soft faced hammer and drive the gland into the
tube.
8. Lubricate the wiper, seal, and seal ring on the gland
with clean oil.
9. Install the gland on the piston rod assembly and push
the gland against the tube, use a soft faced hammer
and drive the gland into the tube.
RCPH10TLB292ABL 5
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Steering cylinder - Check Piston packing

MARBLE CUTTING
DRIVE (2WD)
DRIVE (4WD)
Checking piston packing for the steering cylinder

1. Apply the parking brake and lower the loader bucket to
the floor.
2. Turn the steering wheel all the way to the right and stop
the engine.
3. Disconnect the hose at the left side of the steering cylin-
der.
4. Install a plug in the hose.
5. Start the engine and run the engine at full throttle.
6. Turn the steering wheel all the way to the right and
continue to turn the steering wheel to the right while
another person checks for leakage at the open fitting.
7. If there is constant leakage, the piston packing is dam-
aged and must be repaired.
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Index
Steering - 41
Cylinders - 216
Cylinders - Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Cylinders - Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Cylinders - Exploded view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Steering cylinder - Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Steering cylinder - Check Piston packing (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Steering cylinder - Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Steering cylinder - General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Steering cylinder - Inspect (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Steering cylinder - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Steering cylinder - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
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PRINTED IN U.S.A.
48090752 24/02/2017
EN
SERVICE MANUAL
Wheels

48090752 24/02/2017
44
Contents
Wheels - 44
[44.511] Front wheels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.1
[44.520] Rear wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.2
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44
Wheels - 44
Front wheels - 511

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44.1 [44.511] / 1
Contents
Wheels - 44
Front wheels - 511
SERVICE
Front wheels
Tire inflating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Service instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
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Wheels - Front wheels
Front wheels - Tire inflating

WARNING
Explosion hazard!
A tire can explode during inflation. Replace a tire if it has any defect(s). Replace a wheel rim that has
cracks, wear, or severe rust.
W0455A
WARNING
Explosion hazard!
When inflating tires, use a clip-on air chuck with a gauge, remote valve, and hose long enough to
allow you to stand to one side and NOT in front of or over the wheel assembly. Keep others out of the
DANGER AREA. Never inflate a tire beyond the maximum allowable pressure printed on the tire.
W0059A
WARNING
Explosion hazard!
Always maintain correct tire pressure as indicated in this manual. DO NOT inflate tires above the
recommended pressure. Excessive pressure could result in tire failure.
W0109A
NOTICE: Check pressure only with cold tires; when tires are warm, the pressure values detected are higher.
1. A too low pressure can reduce the machine’s stability
and overheat the tires, and could cause:
• Tire break
• Tire tread damage
• Internal damage
• Irregular wear and shortened life
2. An excessive pressure determines a higher sensitive-
ness to damage in case of shocks and, in extreme con-
ditions, the rim could get deformed or the tire may burst.
NOTICE: The tire inflating pressure varies according to the
load weighing on the axles. LEEN11T0371AA 1
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44.1 [44.511] / 3
Inflating procedure
tion.
neutral position.
7. Insert the self-locking spout of the inflating device (1)
into the tire valve.
8. The inflating device is equipped with a pressure gauge
(2) which enables, as soon as it is connected, to check
the pressure value.
9. If pressure is lower than the recommended pressure,
inflate.
LEEN11T0372AA 2
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Inflating pressure and allowed carrying capacity table

The following tables give the approximate carrying ca-
pacity at the indicated tire pressures.
Inflation pressure bar (psi)

1.5 1.7 1.9 2.3 2.5 2.8 3 3.1
Tire (21.7) (24.6) (27.5) (33.3) (36.2) (40.6) (43.5) (44.9)
Front size Profile
2WS 12.5/ SGI
Max load per tire kg (lb)
80–18
1550 1665 1780 2005 2120 2275 2380 2430
(3410) (3663) (3916) (4411) (4664) (5005) (5236) (5346)

1.5 1.8 2 2.1 2.3 2.5 2.8 2.9 3 3.1
Tire (21.7) (26.1) (29.0) (30.4) (33.3) (36.2) (40.6) (42.0) (43.5) (44.9)
Front size Profile
2WS 12.5/ SGL
80–18
1550 1720 1835 1890 2005 2120 2275 2325 2380 2430
(3410) (3784) (4037) (4158) (4411) (4664) (5005) (5115) (5236) (5346)

1 1.2 1.4 1.6 1.8 2.0 2.2 2.4 2.6 2.8 3 3.2
Tire (14.5) (17.4) (20.3) (23.2) (26.1) (29.0) (31.9) (34.8) (37.7) (40.6) (43.5) (46.4)
Front size
Profile
2WS 320/8
0R18
885 1015 1135 1225 1375 1510 1610 1715 1820 1975 2080 2205
(1947) (2233) (2497) (2695) (3025) (3322) (3542) (3773) (4004) (4345) (4576) (4851)

Tire 3.1 (44.9)
Front size Profile
2WS 12.5– SLR4
18
1700 (3740)

1.5 1.7 1.9 2.1 2.3 2.5
Tire (21.7) (24.6) (27.5) (30.4) (33.3) (36.2)
Front size Profile
2WS 16.0/ SGL
70–20
1565 1680 1796 1915 2050 3075
(3443) (3696) (3951) (4213) (4510) (6765)

1 1.5 1.7 2.0 2.2 2.6 2.9 3 3.3
Tire (14.5) (21.7) (24.6) (29.0) (31.9) (37.7) (42.0) (43.5) (47.8)
Rear size Profile
2WS 18.4– SGIT
26
2130 2390 2650 2765 3000 3225 3450 3590 4000
(4686) (5258) (5830) (6083) (6600) (7095) (7590) (7898) (8800)

1 1.2 1.4 1.5 1.7 1.9 2.1 2.2 2.5 2.8
Tire (1.45) (17.4) (20.3) (21.7) (24.6) (27.5) (30.4) (31.9) (36.2) (40.6)
Rear size Profile
2WS 16.9– SGIT
28
1760 2030 2295 2430 2665 2900 3065 3150 3450 3550
(3872) (4466) (5049) (5346) (5863) (6380) (6743) (6930) (7590) (7810)
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1 1.2 1.4 1.6 1.8 2.0 2.2 2.4 2.6 2.8 3 3.2
Tire (14.5) (17.4) (20.3) (23.2) (26.1) (29.0) (31.9) (34.8) (37.7) (40.6) (43.5) (46.4)
Rear size
Profile
2WS 480/8 Max load per tire kg (lb)
0–E26 4680
1975 2205 2455 2680 2910 3200 3485 3690 3900 4160 4420
(1029
(4345) (4851) (5401) (5896) (6402) (7040) (7667) (8118) (8580) (9152) (9724)
6)

Tire 2.5 (36.2)
Rear size Profile
2WS 18.4– SLR4
26
4160 (9152)

Tire 2.5 (36.2)
Rear size Profile
2WS 16.9– SLR4
28
3690 (8118)

Tire 1.4 1.6 1.8 2.0 2.2
size (20.3) (23.2) (26.1) (29.0) (31.9)
Rear Profile
19.9
2WS SGIT
–30 Max load per tire kg (lb)
IND 2486 2730 2990 3208 3380
(5469) (6006) (6578) (7057) (7436)

Tire Profile 1 1.2 1.4 1.6 1.8 2.0 2.2 2.4 2.6 2.8 3 3.2
Front
size IT520 (14.5) (17.4) (20.3) (23.2) (26.1) (29.0) (31.9) (34.8) (37.7) (40.6) (43.5) (46.4)
and
440/ GY
Rear
80– IT530 Max load per tire kg (lb)
4WS
R28 GY 1770 1975 2205 2455 2680 2910 3120 3275 3590 3795 4030 4160
(3894) (4345) (4851) (5401) (5896) (6402) (6864) (7025) (7898) (8349) (8866) (9152)

1.4 1.5 1.7 2.1 2.5
Front Tire (20.3) (21.7) (24.6) (30.4) (36.2)
and size Profile
Rear 16.9– ISG
4WS 24 EZ
2200 2325 2450 3910 3300
(4840) (5115) (5390) (6402) (7260)

1.4 1.5 1.7 2.1 2.5
Front Tire (20.3) (21.7) (24.6) (30.4) (36.2)
and size Profile
Rear 16.9– ISG
4WS 28 EZ
2325 2450 2765 3120 3500
(5115) (5390) (6083) (6864) (7)
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Front wheels - Service instruction

NOTICE: Small variations in the friction force between the wheel and the mounting hardware, such as lubricant, lack
of lubricant, paint, surface rust, thread variations, etc., will cause large variations in the clamping force. It has been
shown that the tension on fasteners or lug nuts is directly proportional to the angle of turn on a nut or bolt. Unlike
the automotive industry, our rims do not have a precision centering hub to locate and support the wheel and the low
length to diameter ratio of the studs make the preload even more critical.
NOTICE: Never use the minimum final torque value to set the torque for a wheel installation. Only use the torque
plus the additional degree angle turn provided in the procedure. The minimum final torque value is only for checking
the torque 10 h after a wheel installation or on a new machine.
Check the torque of the wheel nuts and bolts after the first 10 h of operation of a new machine or after a wheel install.
If the nuts and bolts are loose, tighten, and check after an additional 10 h of operation. Repeat until the nuts and bolts
remain tight.
Machine preparation
neutral position.
4. Stop the engine.
5. Slightly loosen (unlock) the wheel mounting hardware
when the tire is still holding the weight of the machine.
7. Use the loader attachment or the rear stabilizers to lift
the machine until the wheel that you will remove is just
off the ground.
9. Place wedges in front and rear of the tires that you will
not be removing.
10. If applicable, on both sides of the front axle wedge
blocks between the axle and the frame so the axle will
not swivel.
11. Remove all the wheel mounting hardware.
12. Remove the wheel.
13. Install a new wheel, observing the orientation of the
tread pattern.
Front wheels – Two-Wheel Steer (2WS)

NOTICE: Tighten wheel hardware in a crossing pattern (sequence), as shown.
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Front Two-Wheel Drive (2WD):

1. Tighten the eight mounting bolts with washers in
sequence until the wheel is snug again the axle
hub.
2. Tighten the bolts in sequence to final torque of 156
– 203 N·m (115 – 150 lb ft).
Front Four-Wheel Drive (4WD):
1. Tighten the eight mounting bolts in sequence until
the wheel is snug against the axle hub.
2. Tighten the bolts in sequence to a torque of 119 –
125 N·m (88 – 92 lb ft).
3. Tighten the bolts in sequence an additional 20° to
set the preload.
RAIL14FRK0032BA 1
Two-Wheel Drive (2WD) – front tires

Tire size Torque Minimum final torque value
for checking purposes only
11 x 16 156 – 203 N·m (115 – 150 lb ft) 156 N·m (115 lb ft)
Four-Wheel Drive (4WD) – front tires

Tire size Torque Minimum final torque value
for checking purposes only
12 x 16.5
119 – 125 N·m (88 – 92 lb ft) plus
12.5/80 x 18 271 N·m (200 lb ft)
an additional 20° to set the preload
14 x 17.5
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Front wheels - Service instruction

MARBLE CUTTING
remain tight.
Machine preparation
neutral position.
4. Stop the engine.
off the ground.
not be removing.
not swivel.
tread pattern.
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Four-Wheel Steer (4WS) – Front tires

1. Tighten the all mounting nuts in the sequence
shown until the wheel is snug against the axle hub.
2. Tighten the nuts in sequence to a torque of
800 N·m (516 lb ft).
RAIL14FRK0031BA 1
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Index
Wheels - 44
Front wheels - 511

Front wheels - Service instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Front wheels - Service instruction (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Front wheels - Tire inflating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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Wheels - 44
Rear wheels - 520

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Contents
Wheels - 44
Rear wheels - 520
SERVICE
Rear wheel
Tire inflating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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Wheels - Rear wheels
Rear wheel - Tire inflating

WARNING
Explosion hazard!
A tire can explode during inflation. Replace a tire if it has any defect(s). Replace a wheel rim that has
cracks, wear, or severe rust.
W0455A
WARNING
Explosion hazard!
When inflating tires, use a clip-on air chuck with a gauge, remote valve, and hose long enough to
allow you to stand to one side and NOT in front of or over the wheel assembly. Keep others out of the
DANGER AREA. Never inflate a tire beyond the maximum allowable pressure printed on the tire.
W0059A
WARNING
Explosion hazard!
Always maintain correct tire pressure as indicated in this manual. DO NOT inflate tires above the
recommended pressure. Excessive pressure could result in tire failure.
W0109A
NOTICE: Check pressure only with cold tires; when tires are warm, the pressure values detected are higher.
1. A too low pressure can reduce the machine’s stability
and overheat the tires, and could cause:
• Tire break
• Tire tread damage
• Internal damage
• Irregular wear and shortened life
2. An excessive pressure determines a higher sensitive-
ness to damage in case of shocks and, in extreme con-
ditions, the rim could get deformed or the tire may burst.
NOTICE: The tire inflating pressure varies according to the
load weighing on the axles. LEEN11T0371AA 1
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44.2 [44.520] / 3
Inflating procedure
tion.
neutral position.
7. Insert the self-locking spout of the inflating device (1)
into the tire valve.
8. The inflating device is equipped with a pressure gauge
(2) which enables, as soon as it is connected, to check
the pressure value.
9. If pressure is lower than the recommended pressure,
inflate.
LEEN11T0372AA 2
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Inflating pressure and allowed carrying capacity table

The following tables give the approximate carrying ca-
pacity at the indicated tire pressures.

1.5 1.7 1.9 2.3 2.5 2.8 3 3.1
Tire (21.7) (24.6) (27.5) (33.3) (36.2) (40.6) (43.5) (44.9)
Front size Profile
2WS 12.5/ SGI
80–18
1550 1665 1780 2005 2120 2275 2380 2430
(3410) (3663) (3916) (4411) (4664) (5005) (5236) (5346)

1.5 1.8 2 2.1 2.3 2.5 2.8 2.9 3 3.1
Tire (21.7) (26.1) (29.0) (30.4) (33.3) (36.2) (40.6) (42.0) (43.5) (44.9)
Front size Profile
2WS 12.5/ SGL
80–18
1550 1720 1835 1890 2005 2120 2275 2325 2380 2430
(3410) (3784) (4037) (4158) (4411) (4664) (5005) (5115) (5236) (5346)

1 1.2 1.4 1.6 1.8 2.0 2.2 2.4 2.6 2.8 3 3.2
Tire (14.5) (17.4) (20.3) (23.2) (26.1) (29.0) (31.9) (34.8) (37.7) (40.6) (43.5) (46.4)
Front size
Profile
2WS 320/8
0R18
885 1015 1135 1225 1375 1510 1610 1715 1820 1975 2080 2205
(1947) (2233) (2497) (2695) (3025) (3322) (3542) (3773) (4004) (4345) (4576) (4851)

Tire 3.1 (44.9)
Front size Profile
2WS 12.5– SLR4
18
1700 (3740)

1.5 1.7 1.9 2.1 2.3 2.5
Tire (21.7) (24.6) (27.5) (30.4) (33.3) (36.2)
Front size Profile
2WS 16.0/ SGL
70–20
1565 1680 1796 1915 2050 3075
(3443) (3696) (3951) (4213) (4510) (6765)

1 1.5 1.7 2.0 2.2 2.6 2.9 3 3.3
Tire (14.5) (21.7) (24.6) (29.0) (31.9) (37.7) (42.0) (43.5) (47.8)
Rear size Profile
2WS 18.4– SGIT
26
2130 2390 2650 2765 3000 3225 3450 3590 4000
(4686) (5258) (5830) (6083) (6600) (7095) (7590) (7898) (8800)

1 1.2 1.4 1.5 1.7 1.9 2.1 2.2 2.5 2.8
Tire (1.45) (17.4) (20.3) (21.7) (24.6) (27.5) (30.4) (31.9) (36.2) (40.6)
Rear size Profile
2WS 16.9– SGIT
28
1760 2030 2295 2430 2665 2900 3065 3150 3450 3550
(3872) (4466) (5049) (5346) (5863) (6380) (6743) (6930) (7590) (7810)
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1 1.2 1.4 1.6 1.8 2.0 2.2 2.4 2.6 2.8 3 3.2
Tire (14.5) (17.4) (20.3) (23.2) (26.1) (29.0) (31.9) (34.8) (37.7) (40.6) (43.5) (46.4)
Rear size
Profile
2WS 480/8 Max load per tire kg (lb)
0–E26 4680
1975 2205 2455 2680 2910 3200 3485 3690 3900 4160 4420
(1029
(4345) (4851) (5401) (5896) (6402) (7040) (7667) (8118) (8580) (9152) (9724)
6)

Tire 2.5 (36.2)
Rear size Profile
2WS 18.4– SLR4
26
4160 (9152)

Tire 2.5 (36.2)
Rear size Profile
2WS 16.9– SLR4
28
3690 (8118)

Tire 1.4 1.6 1.8 2.0 2.2
size (20.3) (23.2) (26.1) (29.0) (31.9)
Rear Profile
19.9
2WS SGIT
–30 Max load per tire kg (lb)
IND 2486 2730 2990 3208 3380
(5469) (6006) (6578) (7057) (7436)

Tire Profile 1 1.2 1.4 1.6 1.8 2.0 2.2 2.4 2.6 2.8 3 3.2
Front
size IT520 (14.5) (17.4) (20.3) (23.2) (26.1) (29.0) (31.9) (34.8) (37.7) (40.6) (43.5) (46.4)
and
440/ GY
Rear
80– IT530 Max load per tire kg (lb)
4WS
R28 GY 1770 1975 2205 2455 2680 2910 3120 3275 3590 3795 4030 4160
(3894) (4345) (4851) (5401) (5896) (6402) (6864) (7025) (7898) (8349) (8866) (9152)

1.4 1.5 1.7 2.1 2.5
Front Tire (20.3) (21.7) (24.6) (30.4) (36.2)
and size Profile
Rear 16.9– ISG
4WS 24 EZ
2200 2325 2450 3910 3300
(4840) (5115) (5390) (6402) (7260)

1.4 1.5 1.7 2.1 2.5
Front Tire (20.3) (21.7) (24.6) (30.4) (36.2)
and size Profile
Rear 16.9– ISG
4WS 28 EZ
2325 2450 2765 3120 3500
(5115) (5390) (6083) (6864) (7)
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Rear wheel - Service instruction

MARBLE CUTTING
DRIVE (2WD)
DRIVE (4WD)
remain tight.
Machine preparation
neutral position.
4. Stop the engine.
off the ground.
not be removing.
not swivel.
tread pattern.
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44.2 [44.520] / 7
Rear wheel – Two-Wheel Steer (2WS)

1. Tighten the five mounting nuts in the sequence
136 N·m (100 lb ft).
3. Tighten the nuts a second time, in sequence, to a
torque of 271 N·m (200 lb ft).
4. Tighten the nuts in sequence an additional 30° to
set the preload.
5. Repeat the procedure on the remaining five mount-
ing nuts.
RAIL14FRK0031BA 1
Rear tire only

Torque
First sequence 136 N·m (100 lb ft)
Second sequence 271 N·m (200 lb ft)
Preload Additional 30°
Minimum final torque value for checking purposes only 813 N·m (600 lb ft)
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Rear wheel - Service instruction

MARBLE CUTTING
remain tight.
Machine preparation
neutral position.
4. Stop the engine.
off the ground.
not be removing.
not swivel.
tread pattern.
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Four-Wheel Steer (4WS) – Rear tires

1. Tighten the all mounting nuts in the sequence
800 N·m (516 lb ft).
RAIL14FRK0031BA 1
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Index
Wheels - 44
Rear wheels - 520

Rear wheel - Service instruction (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Rear wheel - Service instruction (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Rear wheel - Tire inflating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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PRINTED IN U.S.A.
48090752 24/02/2017
EN
SERVICE MANUAL
Cab climate control

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50
Contents
Cab climate control - 50
[50.100] Heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50.1
[50.104] Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50.2
[50.200] Air conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50.3
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50
Heating - 100

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Contents
Heating - 100
FUNCTIONAL DATA
Heating
Static description - Troubleshooting (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Cab heater
SERVICE
Heating
Overhaul (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Calibrate Stepper motor calibration in the water valve (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
DIAGNOSTIC
Heating
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Cab climate control - Heating
Heating - Static description

580ST
590ST
695ST
Cab heating
The cab is heated by a radiator mounted below the cab seat, which is supplied with hot water from the engine coolant
system.
A blower motor mounted behind the cab radiator is used to transfer the heat into the cab.
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Heating - Static description

580ST
590ST
695ST
Heater blower control

The three-speed blower is controlled by means of a knob
(1) on the instrument console, to the right of the operator’s
seat.
Turn clockwise to the first position for slow speed.
A further clockwise rotation selects medium and fast

speeds.
The blower draws outside air from beneath the cab floor
and blows it into the cab through a filter.
Temperature control
The temperature of the air coming from the radiator is ad-
justed by rotating the control knob (2), which opens or
closes the radiator valve, thus increasing or decreasing
the water flow as required.
Turn the knob clockwise to increase the temperature of

the air coming from the heater.
RAIL16TLB0451AA 1
By rotating the knob counter-clockwise, the temperature
is decreased.
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Heating - Dynamic description

580ST
590ST
695ST
Air flow diffusers

Air flow diffusers are connected to the heating unit and
receive air from the blower motor, to direct warm or cold
air onto the windscreen and side windows or into the cab
interior as required.
Each diffuser may be swivelled and adjusted to control the

flow of air.
To open a diffuser, press one side of the disc and turn it,
as required, to direct the air flow.
The diffusers are located as follows:

• Two on the top of the main dashboard (A).
• Two on the front edge of the front instrument panel (E).
• Two to the rear of the operator seat (C).
• Two under the seat, one in front, the other on the rear
(D).
• Two on the cab posts, right and left (B).
• Two on the ceiling, in front and back of operator’s head
(F).
NOTE: The diffusers (B) and (F) are mounted only when
air-conditioning (optional) is fitted.
LELI12TLB1949BB 1
LELI12TLB1950AB 2
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Heating - Static description - Troubleshooting

580ST
590ST
695ST
Items that may cause trouble are listed in the table in Heating - Troubleshooting (50.100). As a general rule, it is
recommended to carry out some preliminary checks.
Ensure water flow to the heater radiator is steady and that all air has been removed from the system.
Verify that the hoses are unrestricted and are not leaking.
Check that the electric connections are good and that the blower motor is operational.
Check that the operating cable to the heater valve is operational.
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Cab heater - Dynamic description

580ST
590ST
695ST
Electric heater valve

Each time the machine is started, the electric valve carries
out a momentary positioning of the valve to completely
closed and then returns to the position set by the temper-
ature control knob located on the control dashboard.
This enables the software to carry out a self-calibration on

the valve drive so as to always obtain an optimal regula-
tion of water flow.
This is part of the valve normal operation and is not to be

considered as a fault.
Valve release
NOTICE: The valve release procedure may have to be
performed if this machine remains idle for long periods.
Carry out this operation observing the following proce-
dure:
• Disconnect the electric connectors (1).

• Loosen the screws (2). Remove the electric valve (3)
from the evaporator.
• Loosen and remove the screws (4).
LEPH12TLB1951AB 1
• Separate the drive unit (5) from the valve (6).

• Use a wrench to turn the pin (A) of the valve to unlock
it.
NOTE: Once this operation is complete, reset pin (A) in
the correct starting position.
Reinstall the heater valve by repeating the previously op-

erations in reverse order.
LEPH12TLB1952AB 2
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Cab heater - Static description

580ST
590ST
695ST
Heater radiator
The heater radiator (1) is fitted in a housing under the cab
seat to guarantee a uniform distribution of warm and cold
air flow.
NOTICE: To ensure a good flow of air through the heater
radiator the filter should be cleaned more frequently when
operating in extremely dusty conditions.
RAIL16TLB0452AA 1
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Heating - Overhaul
580ST
590ST
695ST
NOTICE: When overhauling the heating system remember

that, with the engine running or shortly after it is turned Off,
the system will be at engine temperature and therefore the
water will be hot and under pressure.
To carry out the different checks and operations, it is
necessary to drain the system.
To drain the cooling system, disconnect either hose
at the union tee (1) found behind the engine oil filter,
mounted to the left-hand side of the engine.
LELI12TLB1953AB 1
Cab heater check

1. With the system drained, remove the heater radiator
hose connections. Remove the attaching screws and
remove the radiator from the vehicle.
2. Inspect the radiator (2).
3. Check that the water flows freely through the heater line
(otherwise, clear any obstruction).
4. The fins must be free from debris and not damaged:
clean and/or repair.
5. Clean the heater radiator using compressed air not ex-
ceeding 7 bar (102 psi) taking care not to damage the
radiator fins.
6. Make sure that the radiator is not leaking under pres-
sure.
7. Clean the chamber with a damp cloth. Reassemble the
housing filter element with the seal facing the inside of
the cover.
RAIL16TLB0452AA 2
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Blower motor check

1. The blower motor (3) can be removed by removing the
attaching screws and disconnecting the harness con-
nector.
2. Check that the fan operates correctly.
3. If the fan does not operate, then check the fuse and the
continuity of the fan motor. If the fan is defective, the
replace the blower unit as an assembly.
RAIL16TLB0453AA 3
Heating valve
1. To service the control valve (4), disconnect the hoses
and the control tie rod and remove it.
2. Check the control valve operation and replace it, if
worn.
RAIL16TLB0454AA 4
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Control panel
1. Check for the correct operation of the control knobs (5)
and (6).
RAIL16TLB0451AA 5
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Heating - Calibrate Stepper motor calibration in the water valve

580ST
590ST
695ST
1. Turn the ignition switch OFF.

2. Set the temperature control knob to the coldest setting.
RAIL16TLB0451AA 1
3. Turn the ignition switch ON.

4. Wait at least 2 s.
5. Turn the temperature control knob to the warmest set-
ting.
RAIL16TLB0455AA 2
6. Turn the temperature control knob to the coldest set-

ting.
ting.
ting.
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Heating - Troubleshooting
580ST
590ST
695ST

Dust enters the cab Improper seal around filter element Check the seal condition
Blocked filter Clean or replace the filter
Defective filter Replace the filter
Excessive air leak(s) around doors and Repair and seal air leak(s)
windows
Blower motor air flow low Blocked filter or recirculation filter Clean or replace the filter(s)
Heater radiator core blocked Clean radiator core thoroughly
Blower motor not working Fuse blown Replace fuse
Cab does not heat up Engine not reaching operating tempera- Replace the temperature switch
ture. Thermostat stuck open
Heater hose from engine to cab radiator, Ensure water flow to heater radiator is ad-
kinked or blocked equate and not restricted
Cab does not cool Heater control turned ON Turn the temperature control knob fully
counterclockwise for maximum cooling
Heater control valve stuck in open position Free up valve or change as required
Temperature not stable Low engine coolant Top up coolant recovery tank
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Index
Heating - 100
Cab heater - Dynamic description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Cab heater - Static description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Heating - Calibrate Stepper motor calibration in the water valve (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Heating - Dynamic description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Heating - Overhaul (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Heating - Static description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Heating - Static description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Heating - Static description - Troubleshooting (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Heating - Troubleshooting (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
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Ventilation - 104

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Contents
Ventilation - 104
FUNCTIONAL DATA
Air filter
SERVICE
Air filter
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Cab climate control - Ventilation
Air filter - Static description

580ST
590ST
695ST
The blower fan draws warm air from outside the cab
through the intake filter (2) below the cab floor and a
ready cooled dehumidified air through the recirculation
grille (1).
The air passes over the evaporator then into the cab
through the six louvered diffusers.
Two diffusers are located on the front instrument panel to

direct air onto the windshield.
Two are located at the base of the rear posts to direct air
onto the rear window.
Two additional vents are located at the front and rear of

the seat base to direct air at the operator’s feet.
RAIL15TLB0610BA 1
RAIL15TLB0552BA 2
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Air filter - Service instruction

580ST
590ST
695ST
NOTICE: In humid conditions do not switch on the blower prior to servicing the filter.
1. Park the machine on level ground.

3. Lift the grid cover (1) upward and remove it from the
filter housing.
RAIL15TLB0610BA 1
4. Remove the filter locking clip (1).
RAIL15TLB0607BA 2
5. Move the filter retaining bracket (2) away from the filter
(1).
RAIL15TLB0608BA 3
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6. Gently pull the top of the filter (1) away from the housing
and lift the filter out.
NOTE: Replace filter if damage occurs or excessive wear
is apparent.
7. Do not clean the filter (1) with air or water pressure.
8. Carefully shake off the filter (1) to remove the surface
dust.
NOTICE: Replace the filter (1) as needed or annually.
NOTICE: Dispose of all fluids filters, and containers in an
environmentally safe manner and in accordance with local
laws and regulations. Check with local environmental and
recycling centers or your dealer for correct disposal infor-
mation. RAIL15TLB0609BA 4
9. Clean the inside of the filter chamber with a damp lint-

free cloth.
10. Fully insert the filter (2).
11. Push and hold the retaining bracket (1) against the
filter (2).
RAIL15TLB0552BA 5
12. Secure the filter position with the locking clip (1).
RAIL15TLB0607BA 6
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13. Slide the grid cover over the filter housing. Make sure
that the sliding cover rails (1) engage with the filter
housing rails (2) on both sides.
14. Make sure that the grid cover is evenly and fully in the
down position.
RAIL15TLB0551BA 7
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Index
Ventilation - 104
Air filter - Service instruction (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Air filter - Static description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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Air conditioning - 200

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Contents
TECHNICAL DATA
Air conditioning
Air-conditioning compressor
FUNCTIONAL DATA
Air conditioning
Static description Temperature sensor (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Exploded view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Exploded view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Air-conditioning condenser
Receiver-dryer
Expansion valve
Air-conditioning evaporator
SERVICE
Air conditioning
Leakage test (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
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Discharging (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Flush (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Evacuate (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Charging (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Overhaul (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Overhaul (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Adjust (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Calibrate Stepper motor calibration in the water valve (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Overhaul (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Disassemble the clutch (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Assemble the clutch (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Compressor drive belt
Adjust (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Air-conditioning condenser
Cleaning (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Receiver-dryer
Replace (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Expansion valve
Replace (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Air-conditioning evaporator
DIAGNOSTIC
Air conditioning
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Cab climate control - Air conditioning
Air conditioning - General specification

580ST
590ST
695ST
Engine radiator coolant

Antifreeze - CASE AKCELA ACTIFULL™ OT 12.00 L (3.17 US gal)
EXTENDED LIFE COOLANT
Distilled water 12 l (3.17 US gal)
System type Pressurized FULL FLOW by-pass with expansion
chamber
Fan belt deflection

Natural suction 13 – 19 mm (0.51 – 0.75 in)
Turbocharged 10 – 16 mm (0.39 – 0.63 in)
Thermostat
Opening starts at 82 °C (180 °F)
Fully open at 95 °C (203 °F)
Radiator cap 0.90 bar (13 psi)
Mounting screw torque

Coolant/hot water hose connections 5 N·m (3.7 lb ft)
Air hose connections 5 N·m (3.7 lb ft)
Heater housing to floor fastening screws 6.2 N·m (4.6 lb ft)
Refrigerant
Type HFC R134A
Refrigerant quantity 1.2 kg (2.6 lb)
Compressor oil
Type PAG SP20 (PAG type, viscosity index 100)
Oil change amount 240 cm³ (14.65 in³)
Check conditions
Air inlet temperature 37.8 °C (100 °F)
Rated air inlet humidity 40%
Evaporation temperature 0 °C (32 °F)
Overheating 5 °C (41 °F)
Inlet air speed 1.0 m/s (3.3 ft/s) - 2.0 m/s (6.6 ft/s) - 3.0 m/s (9.8 ft/s)
Condensation temperature 58 °C (136 °F) ( 16 bar absolute)
Undercooling 2 °C (36 °F)
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Performance
Performance calculated at 1 m/s (3.28 ft/s) [ 191.72 m³ (6770.53 ft³)]
Exchanged heat 5.48 kW 4718.28 kcal/h
Air outlet temperature 5.64 °C (42.15 °F)
Air side load loss 0.0297 kPa (0.00431 psi) 0.030 cm H2O (0.012 in H2O)
Coolant side load loss 13.1 kPa 0.13 bar (1.9 psi)
Performance calculated at 2.0 m/s (6.56 ft/s) [ 383.4 m³ (13539.64 ft³)]

Performance calculated at 3.0 m/s (9.84 ft/s) [ 575.1 m³ (20309.46 ft³)]

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Air-conditioning compressor - General specification

580ST
590ST
695ST
Basic compressor specifications

Displacement 240 cm³ (14.65 in³)
Weight 9.9 kg (22 lb)
Oil type PAG SP20
Rotation CW (Clockwise only)
Compressor clutch and pulley air gap 0.8 – 0.9 mm (0.031 – 0.035 in)
Belt tension
Measure at the widest gap 10 mm (0.39 in) deflection with 1 kg (2.2 lb) force
applied midway between the pulleys
Speed rating
Constant 6000 RPM
Downshift 8000 RPM
Tightening torque
M8 armature retaining nut 14.8 – 20.6 N·m (10.9 – 15.2 lb ft)
M6 cylinder head screws 10.8 – 16.6 N·m (8 – 12.2 lb ft)
M8 cylinder head screws 29.4 – 39.2 N·m (21.7 – 28.9 lb ft)
Clutch dust cover screw 7 – 11 N·m (5.2 – 8.1 lb ft)
Oil filler plug 14.7 – 24.5 N·m (10.8 – 18.1 lb ft)
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Air conditioning - Static description

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Principles of air-conditioning
The function of the air-conditioning system is to improve
the operator’s comfort by cooling down the air tempera-
ture inside the cab and reducing the humidity level.
In order to achieve this heat transfer the following princi-

pals of heat generation and transfer are applied within the
air-conditioning system.
When two bodies with a different temperature come to-
gether, heat is transferred from one to the other. On
air-conditioning systems, an evaporator is used to main-
tain the low temperature of the coolant, which absorbs the
heat from the air within the cab.
LELI12TLB1958AA 1
When a gas is pressurized the temperature of the gas will

rise.
In air-conditioning systems the increase in pressure is

achieved using a compressor.
LELI12TLB1959AA 2
When a gas is cooled it will condense into a liquid.
In the air-conditioning system a condenser is used to cool

the gas and the resulting liquid is stored in a receiver dryer.
LELI12TLB1960AA 3
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When a liquid is atomized through an orifice, the temper-

ature of the resultant vapour will lower.
The low temperature of the atomized liquid will then ab-

sorb heat from its surrounding.
On air-conditioning systems, coolant is atomized using an

expansion valve.
LELI12TLB1961AA 4
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Air conditioning - Dynamic description

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Operating diagram
LELI12TLB1962GB 1
1. The expansion valve atomizes liquid coolant 3. The compressor compresses the coolant gas and raises
before passing to the evaporator. temperature of coolant gas.
2. The evaporator absorbs heat from air in the 4. The condenser and the receiver dryer convert coolant
cab. from a gas to a liquid.
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LELI12TLB1963GA 2
Air-conditioning flow diagram
It can now be seen that the principal components of an air-conditioning system are:
• Refrigerant
• Compressor
• Condenser
• Receiver dryer
• Expansion valve
• Evaporator
Refrigerant is drawn into the compressor as a cool, low pressure vapor which is compressed and then pumped out
as a hot, high pressure vapor to the condenser.
As the hot, high pressure vapor passes through the condenser core it gives off heat to the cooler outside air, being
drawn past the fins by the engine cooling fan.
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By giving off heat to the outside air, the vapor is condensed to a liquid which moves under high pressure to the receiver
dryer where it is stored until released to the evaporator by the temperature sensing expansion valve.
As liquid coolant passes through the metered orifice in the expansion valve the coolant changes from a high pressure
liquid to a low pressure atomized liquid with a lower temperature.
This low pressure, low temperature, atomized liquid enters the evaporator coils and absorbs heat from the cab warm
air blown across the coils and fins by the cab blower motor.
The coolant now changes from a cold low pressure atomized liquid to a warm low pressure vapor and leaves the
evaporator outlet, moving to the suction (low pressure) side of the compressor to repeat the cycle.
As this heat loss is taking place, moisture (humidity) in the cab air will condense on the outside of the evaporator and
drain off as water through the drain hoses attached to the evaporator drain pan, thereby reducing the humidity level
of the cab.
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Operation
Coolant
To achieve the absorption and the release of heat which is the function of an air-conditioning system, requires the use
of a suitable coolant. The coolant is a liquid that has a relatively low temperature boiling point, plus certain desirable
safety and stability features.
The coolant used in the air-conditioning system is coolant HFC R134A.

NOTE: To help protect the environment legislation has been introduced in most territories banning the release into
the atmosphere of refrigerants, including HFC R134A. All service procedures contained in this manual can be carried
out without the need to release coolant into the atmosphere.
In order to prevent the incorrect type of coolant being charged to the system, the service valves fitted to the machine
and necessary to connect up coolant recovery, evacuation and recycling/re-charging equipment will be of two different
sizes as recognized and specified by the air-conditioning industry.
NOTICE: Coolant HFC R134A is not compatible with coolant R12. Do not try to replace coolant HFC R134A with
coolant R12 or to test the system using instruments or tools previously used with R12, as the system could get dam-
aged.
HFC R134A coolant is stable at all operating temperatures and able to absorb great quantities of heat.
The boiling point of HFC R134A is -22 °C (-7.6 °F) at atmospheric pressure.
If the pressure is increased, HFC R134A will readily vaporize to absorb heat at temperatures between -11.7 °C
(10.94 °F) at 1.9 bar (28 psi) and 0 °C (32 °F) at 2.9 bar (42 psi) in the evaporator.
At higher pressures, HFC R134A will condense and give off heat at temperatures between 48 °C (118.4 °F) at 12.4 bar
(180 psi) and 58 °C (136.4 °F) at 15.85 bar (230 psi) in the condenser.
NOTICE: HFC R134A can be dangerous if improperly handled. Therefore it is important the following warning and
directions are adhered to.
Never expose any part of the air-conditioner system to flame or excessive heat because of risk of fire or explosion,
and the production of phosgene gas.
Never disconnect or disassemble any part of the air-conditioning system as escaping coolant can cause frostbite.
NOTICE: If coolant should contact the skin use the same treatment as for frostbite.
Warm the area with your hand or lukewarm water 32 °C (89.6 °F), cover the area loosely with a bandage to protect
affected area against infection and consult a doctor immediately.
If coolant should contact the eyes wash immediately in cold clean water for at least 5 min and consult a doctor im-
mediately.
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Air conditioning - Static description Temperature sensor

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The air-conditioner temperature adjusting sensor is

mounted on the blower motor.
It is a device which turns the compressor clutch On and Off

to maintain a constant average evaporator temperature
and senses the evaporator temperature using a thermistor
(1).
The sensor compares the voltage of the thermistor, which

depends on the temperature of the evaporator, with the
voltage across the potentiometer of the in-cab tempera-
ture control switch.
The switch upon comparing the two voltages determines

whether the compressor clutch should be switched on or
off in order to maintain the desired in cab temperature LEPH12TLB1967AB 1
control.
Low-pressure cut-out sensor

The low-pressure (1) sensor is on the upper part of the
filter, situated in front of the radiator.
The purpose of the sensor is to shut-off the compressor

in case of low pressure in the cooling system.
Low coolant pressure may occur due to a faulty expansion

valve, icing up of the expansion valve orifice or coolant
loss.
Low coolant pressure may result in damage to the com-

pressor pump.
The low-pressure sensor is set by the manufacturer.

LEPH12TLB1968AB 2
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Controls
The air-conditioning control can be adjusted to obtain the
desired temperature in the cab.
To activate air-conditioning, turn the selector (2) to ON.

Upon activation, the lamp (4) on the side instrument clus-
ter turns on. The selector (1) allows choosing the ideal
temperature according to your requirements.
Turn the selector (3) for air capacity according to your

requirements.
RAIL16TLB0450AA 1
NOTE: The air-conditioning can be operated only if the

fan speed (3) is set a position other than 0.
LELI12TLB1965AB 2
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Air-conditioning compressor - Dynamic description

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The compressor is mounted on the left-hand side of the

engine and is belt driven by the crankshaft pulley.
The compressor separates the low and high pressure

sides of the system and has two functions:
• Raising the coolant temperature by compressing to a

higher degree of temperature than the ambient (outside
air) temperature.
• Circulating the required volume of coolant through the
system.
The compressor is a 7-cylinder wobble plate unit, housed

in a die-cast aluminium housing.
LEPH12TLB1966AB 1
The drive to the wobble plate comes from the pulley,
through the clutch to the main driveshaft.
Attached to the driveshaft, there is a cam rotor which os-

cillates the wobble plate.
The wobble plate is prevented from rotating by a static

gear engaging with teeth formed in the face of the plate.
The seven pistons are connected to the wobble plate by

rods located in ball sockets.
Refrigerant is drawn in on the downward stroke of a piston

through the reed valves located either end of the cylinder
assembly.
Refrigerant enters the cylinder assembly through a gallery

in the outer circumference of the cylinder assembly.
During the upward stroke, the piston compresses the

coolant and expels it through another reed valve into an
inner gallery in the cylinder and, from here, out into the
coolant system.
The compressor is lubricated with a Polyalklene Glycol

(PAG) oil Type SP15. This oil can be mixed with coolant
and is carried around in the coolant system itself.
During the operation of the air conditioning system, the

compressor is activated by a clutch which engages or dis-
engages it as required.
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Air-conditioning compressor - Exploded view

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LELI12TLB2183GB 1
1. Bracket air-conditioning mounting
2. Stud dowel ring 10. M10 X 70 hex screw
3. Compressor air-conditioning 11. Nut
4. Bracket idler support
5. Pulley idler 13. Stud dowel ring
6. Belt 14. Bracket air-conditioning brace
7. Washer 15. M10 X 25 hex screw
8. M8 X 100 hex screw [tightening torque 37 –
41 N·m (27 – 30 lb ft)]
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Air-conditioning compressor - Exploded view

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LELI12TLB2200EB 1
1. Shaft key 6. Gasket

2. Ring 7. Plate
3. Snap ring 8. Head gasket
4. Gasket 9. Cylinder head
5. Plug 10. Screw
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Air-conditioning compressor - Component identification

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Clutch
LELI12TLB2188EB 1
1. Screw 6. Cover
2. Dust cover 7. Snap ring
3. Nut 8. Rotor
4. Plate 9. Snap ring
5. Shims 10. Coil
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Air-conditioning condenser - Static description

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The condenser (1) is located at the front of the machine in

front of the engine radiator. The condenser consists of a
number of turns of continuous coil mounted in a series
of thin cooling fins. This provides a maximum of heat
transfer in a minimum amount of space.
The condenser receives the hot, high pressure coolant

vapor from the compressor.
The hot vapor passes through the condenser coils and

outside air is drawn through the condenser by the engine
cooling fan.
Heat moves from the hot coolant vapor into the cooler
outside air flowing across the condenser coils and fins.
When the coolant vapor reaches the pressure and tem-

perature that will induce a change of state, a large quan-
tity of heat is transferred to the outside air and the coolant
changes to a high pressure warm liquid.
The warm liquid coolant continues onto the receiver/drier

where it is filtered and desiccated, to remove any mois-
ture, before passing through an outlet line to the thermo-
static expansion valve.
LEPH12TLB1969BB 1
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Receiver-dryer - Static description

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The receiver/dryer (1) stores the liquid coolant to make

sure that there is a steady flow of coolant to the expansion
valve over extremely different operating conditions.
The drier contains a desiccant (molecular sieve) which

absorbs any moisture within the system, and a filter which
prevents the entry of foreign particles.
NOTE: Any moisture in the air conditioning system is ex-
tremely harmful. Moisture not absorbed by the dehydrator
will circulate with the coolant and droplets may collect and
freeze in the thermostatic expansion valve orifice. This
action will block the coolant flow and stop the cooling ac-
tion. Moisture will also react with coolant HFC R134A and
the lubricant to form a corrosive acid.
LEPH12TLB1970AB 1
The desiccant can only absorb a limited amount of mois-

ture before reaching saturation point. Because of this, af-
ter any system component is replaced or repairs requir-
ing entry into the system, the receiver/dryer should be re-
placed.
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Expansion valve - Static description

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The expansion valve (1) is located underneath the

evaporator in the pressure line coming from the
receiver/dryer. The expansion valve performs the
following functions:
• Metering action
A metering orifice changes the liquid coolant from a
high-pressure low-temperature liquid to a low pressure,
lower-temperature atomized liquid.
• Modulating action
A thermostatically controlled valve within the expansion
valve body controls the volume of liquid coolant passing
through the orifice and makes sure that the coolant is
fully vaporized within the evaporator; the liquid coolant
could damage the compressor reed valves or freeze the LEPH12TLB1971AB 1
pistons.
• Control action
The valve responds to changes in the cooling require-
ments; when an increase in cooling is required, the
valve opens to increase the coolant flow, and when less
cooling is required, the valve closes to decrease the
coolant flow.
Operation
All of the needed temperature sensing and pressure sens-
ing functions are consolidated into the basic unit and no
external tubes are required for these purposes.
The coolant from the condenser and receiver dryer enters

the thermostatic expansion valve as a high pressure warm
liquid.
Upon passing through the ball and spring controlled me-

tering orifice, the pressure and temperature of the coolant
is reduced and the coolant leaves the thermostatic expan-
sion valve as a low pressure, lower temperature atomized
liquid.
LELI12TLB1972AA 2
The atomized liquid now passes through the evaporator
where it absorbs heat before returning via the expansion
valve to the compressor as a warm low pressure vapor.
There are two coolant passages in the valve.
One passage is in the coolant line from the condenser to

the evaporator. This passage contains the ball and spring
type orifice valve.
The other passage is in the coolant line from the evaporator to the compressor. This line contains the valve’s temper-
ature sensing element.
Liquid coolant flow from the condenser and receiver dryer is controlled by a push-rod forcing the orifice valve ball off
its seat. The spring exerts pressure on the ball to keep it on its seat.
During stabilized (vehicle shutdown) conditions, the pressure on the bottom of the expansion valve diaphragm rises
above the pressure on the top of the diaphragm allowing the valve spring to close the orifice.
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When the system is started, the pressure on the bottom of the diaphragm lowers rapidly, allowing the orifice to open
and metre atomized liquid coolant to the evaporator where it begins to vaporize.
Suction from the compressor draws the vaporized coolant out of the evaporator and back through a gallery in the top
of the valve.
The temperature sensor reacts to variations in coolant gas pressure returning from the evaporator.
When heat from the passenger compartment is absorbed by the coolant, the pressure of the gas increases causing
a differential pressure above and below the temperature sensor diaphragm.
The diaphragm reacts to this pressure differential and a push rod forces the ball in the expansion valve orifice further
off its seat.
This reaction allows an increase in the atomized coolant to flow through the valve, to the evaporator, so that more
heat can be absorbed by the air-conditioning system.
Similarly when the temperature of the gas returning from the evaporator decreases the pressure of the gas decreases.
This causes the diaphragm to react accordingly and allow the ball in the orifice to move closer towards its seat thus
reducing the flow of coolant through the valve to the evaporator.
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Air-conditioning evaporator - Static description

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The air conditioner temperature sensor (1) is mounted on

the blower motor.
It is a device which turns the compressor clutch on and off

to maintain a constant average evaporator temperature.
The sensor compares the voltage of the thermistor, which

depends on the temperature of the evaporator, with the
voltage across the potentiometer of the cab temperature
control switch.
The switch upon comparing the two voltages determines

whether the compressor clutch should be switched on or
off in order to maintain the desired in cab temperature
control.
LEPH12TLB1973AA 1
The low-pressure sensor (1) is on the upper part of the

filter, located in front of the radiator.
The purpose of the sensor is to shut-off the compressor

in case there is a low pressure in the cooling system.
Low coolant pressure may occur due to a faulty expansion

valve, icing up of the expansion valve orifice, or a low
coolant level.
Low coolant pressure may result in damage to the com-

pressor pump.
The low-pressure sensor is set by the manufacturer.

LEPH12TLB1968AB 2
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Air conditioning - Service instruction

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Troubleshooting and testing

Overhaul of the air-conditioning system should only be
undertaken by a certified specialist refrigeration engi-
neer using a comprehensive air-conditioning test kit,
including a gas leak detector, suitable for HFC R134A
coolant gas.
NOTICE: Before dismantling an air-conditioning system for
repair the gas within the system must be discharged and
recovered using a certified recovery unit designed for the
type of coolant gas used in the system.
NEVER release coolant gas into the atmosphere.
ALWAYS wear safety goggles and gloves when servicing
any part of the air-conditioning system.
To prevent the entry of any foreign material, it is neces-
sary to observe some precautions.
Ensure all tools, gauges, hoses and replacement parts
are kept clean and dry and are suitable for the type of
coolant gas used in the system.
Clean all hoses and fittings before disconnecting.
Cap or plug all openings when disconnected.
When adding lubricating oil to the system always uncap
and re-cap the oil container immediately before and af-
ter use. Always ensure the oil remains free of moisture.
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Preliminary checks
Always conduct the preliminary fault finding checks be-
fore performance testing the system.
Run the engine at 1000 – 1200 RPM for 10 min with the
air-conditioner set to maximum cooling and the blower
at high speed.
Check that the heater temperature control is switched
Off.
Check that the blower fan is operating at all speeds.
Check that the compressor clutch engages when the
temperature control switch is turned from Off to “ON”
position. A clicking sound indicates the clutch is engag-
ing. If the clutch fails to operate it may indicate an elec-
tric problem in the high low pressure cut out switches or
malfunction of the electric drive clutch on the compres-
sor.
Check the engine cooling fan is drawing cool air through
the condenser.
Check the compressor drive belt tension.
Check the condenser core and grid is clean and free of
obstruction.
Check the cab air filter is clean and free of obstruction.
Check the evaporator fins are not plugged or exces-
sively dirty.
LELI12TLB2168FB 1
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1. Low side gauge 6. Test hose to low side service connector

2. High side gauge 7. Shut-off valve
3. Shut-off valve 8. Low pressure (suction) side service valve
4. Test hose to high side service connector 9. High pressure (discharge) side service valve
5. Centre hose (not used)
Performance testing the air-conditioning system

The manifold gauge set is the most important tool used
in testing and servicing the air-conditioning system.
NOTE: For Dealers who posses the latest design level of
coolant recovery, recycling and recharging station, these
gauges are an integral part of the machine.
The following instructions for performance testing the
air-conditioning system is based on the use of the
gauge set shown. The principal of operation is however
similar when testing the system using a recovery and
recharging station with integral gauges.
When using this type of equipment always consult the
manufacturers operating instructions.
Operating precautions
NOTICE: Always ensure the shut-off valves are closed (turn clockwise until seated) during all test operations.
In the “closed” position, coolant circulates around the
valve stems to the gauges. Therefore, when the mani-
fold gauge set is connected into a system, pressure is
registered on both gauges.
• NEVER open the HIGH SIDE shut-off valve when the
system is operating.
• ALWAYS open the LOW SIDE shut-off valve when
adding coolant.
Attaching the gauge set to the loader backhoe

NOTICE: To avoid personal injury, stop the loader backhoe engine during connection of the manifold gauge set.
Check that the gauge set shut-off valves are closed
(turned fully clockwise).
Connect the high side gauge hose (normally red) to the
high pressure (discharge) side service valve and the
low side gauge hose (normally blue) to the low pressure
(suction) side service valve on the loader backhoe. En-
sure the hose connections are fully tightened.
NOTICE: Prior to connection of the manifold gauge set,
identify the suction (low pressure) and discharge (high
pressure) service gauge ports. The high pressure service
valve is always in the line from the compressor to the
condenser.
The high and low pressure service valves on the loader
backhoe are spring loaded valve and will be automati-
cally opened when the test hose is connected.
NOTE: The test hose must incorporate a valve depressor
to actuate this type of valve.
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The service valves have a protective cap. This cap

must be removed for test gauge connections and re-
placed when service operations are completed.
Test procedure
After the manifold gauge set has been connected and
before pressure tests can be made, the system must be
stabilized as follows:
Apply the parking brake, check the gearshift levers are
in neutral and close the cab windows and doors.
Re-check that both the high and low side shut-off valves
on the manifold gauge set are fully closed.
Run the engine at 1000 – 1200 RPM.
Turn the heater temperature control Off.
Operate the system at maximum cooling, with the
blower fan at high speed for 10 min to stabilize all
components.
Check the manifold low pressure gauge reading is
within the specified range of approximately 0.28 –
2.48 bar (4 – 36 psi).
Check the manifold high pressure gauge reading and
compare the reading to the pressure indicated on the
pressure temperature chart below.
Measure and compare the temperature of conditioned
air entering the cab through the louvered air diffusers
with the ambient air at the air intake filters on the outside
of the cab.
If the system is operating correctly the conditioned air
entering the cab should be 6 – 9 °C (42.8 – 48.2 °F)
cooler than the ambient temperature of the outside air.
If it is confirmed that the system is not operating cor-
rectly refer to the fault diagnostic charts and perfor-
mance test gauge reading examples on the following
pages for possible corrective action.
NOTICE: A significant amount of coolant vapor may have
condensed to a liquid at the service fitting at the high side
of the compressor. Use a cloth or other protective material
when disconnecting the manifold hose from this fitting to
prevent personal injury to hands and face.
Approximate high pressure gauge readings

Ambient air temperature High pressure gauge reading
27 °C (80.6 °F) 10.0 – 11.6 bar (145 – 168 psi)
29 °C (84.2 °F) 11.2 – 12.7 bar (162 – 184 psi)
32 °C (89.6 °F) 12.3 – 13.8 bar (178 – 200 psi)
35 °C (95.0 °F) 13.3 – 15.2 bar (193 – 220 psi)
38 °C (100.4 °F) 14.5 – 16.7 bar (210 – 242 psi)
41 °C (105.8 °F) 16.0 – 18.3 bar (232 – 265 psi)
43 °C (109.4 °F) 17.3 – 20.0 bar (251 – 290 psi)
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Air conditioning - Service instruction

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Examples of manifold gauge readings and interpretations

The following examples show typical low and high pres-
sure gauge readings obtained when performance test-
ing the air-conditioning system with an ambient temper-
ature of 35 °C (95 °F).
The recommended corrective action is based on a sim-
ilar fault as identified in the performance test diagnosis
charts.
Performance test example 1
LELI12TLB1977FB 1
1. High side low 5. Low side hose connected to low side service
2. High side hand valve closed connector
3. High side hose connected to high side service 6. Low side hand valve closed
connector 7. Low-pressure side low
4. Not used
Problem
Little or no cooling.
Cause
Coolant slightly low.
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Conditions*
Too low pressure on low-pressure side.
The gauge should read 1 – 2 bar (14.5 – 29 psi).
Too low pressure on high-pressure side.
The gauge should read 13.3 – 14.8 bar (193 – 215 psi).
Evaporator air not cold.
Corrective procedures
Leak test the system.
Repair leaks. Discharge and recover the coolant from
the system; replace lines or components.
Check compressor oil to ensure no loss.
Drain the system.
Charge the system.
Performance test the system.
Diagnostic
System coolant is low. May be caused by a small leak.
NOTE: * Test procedure based upon ambient temperature
of 35 °C (95 °F).
For proper high side gauge reading for other ambient tem-
peratures, refer to the pressure temperature chart.
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LELI12TLB1978FB 2
4. Not used
Problem
Insufficient cooling.
Cause
Refrigerant excessively low.
Conditions*
Low side pressure very low.
The gauge should read 1 – 2 bar (14.5 – 29 psi).
Too low pressure on high-pressure side.
The gauge should read 13.3 – 14.8 bar (193 – 215 psi).
Evaporator air warm.
Low pressure switch cutting out.
Leak test the system.
Discharge and recover the coolant from the system.
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Repair leaks.
Drain the system.
Charge the system.
Diagnostic
System coolant is extremely low. A serious leak is indi-
cated.
of 35 °C (95 °F).
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LELI12TLB1979FB 3
1. High side normal 5. Low side hose connected to low side service
4. Not used
Problem
Cause
Air in the system.
Conditions*
Low side pressure reading does not change when com-
pressor cycles ON and OFF.
High side pressure slightly high or slightly low. The
gauge should read 13.3 – 14.8 bar (193 – 215 psi).
Leak test the system. Give special attention to the com-
pressor seal area.
Repair leaks.
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Replace receiver/drier.
Drain the system.
Charge the system.
Diagnostic
Air or moisture in system. System not fully charged.
of 35 °C (95 °F).
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LELI12TLB1980FB 4
connector 7. Low side high
4. Not used
Problem
Cause
Compressor malfunction.
Conditions*
Low side pressure too high. The gauge should read 1
– 2 bar (14.5 – 29 psi).
Too low pressure on high-pressure side. The gauge
should read 13.3 – 14.8 bar (193 – 215 psi).
Replace the compressor.
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Diagnostic
Internal leak in compressor caused by worn or scored
pistons, rings, or cylinders.
of 35 °C (95 °F).
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LELI12TLB1981FB 5
1. High side high 5. Low side hose connected to low side service
connector 7. Low side high
4. Not used
Problem
Little or no cooling. Engine overheats in some cases.
Cause
Condenser not functioning properly.
Conditions*
– 2 bar (14.5 – 29 psi).
High side pressure too high. The gauge should read
13.3 – 14.8 bar (193 – 215 psi).
Liquid line hot.
High pressure switch cutting out.
Check belt. Loose or worn drive belts could cause ex-
cessive pressures in the compressor head.
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Look for clogged passages between the condenser fins

and coil, or other obstructions that could reduce con-
denser airflow.
If engine is overheating replace engine thermostat and
radiator pressure cap.
At this point, operate the system and check its perfor-
mance.
If still unsatisfactory, proceed as follows:
• Discharge and recover the coolant from the system.
• Remove the condenser, clean and flush it to ensure
a free flow of coolant. Otherwise, if the condenser
appears to be particularly dirty or obstructed, replace
it.
• Replace the receiver/drier.
• Drain the system and recharge it with the correct
quantity of coolant.
• Carry out the performance test of the system.
Diagnostic
Lack of cooling caused by pressure that is too high on
the high side, resulting from improper operation of con-
denser. (Coolant charge may be normal or excessive).
of 35 °C (95 °F).
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LELI12TLB1982FB 6
connector 7. Low-pressure side normal
4. Not used
Problem
Cause
Large amount of air in system.
Conditions*
– 2 bar (14.5 – 29 psi).
Replace receiver/drier.
Drain the system.
Charge the system.
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Diagnostic
Air in the system. Air and humidity contained in it con-
taminate the system: therefore, it will operate incor-
rectly.
of 35 °C (95 °F).
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LELI12TLB1983FB 7
1. High side high 5. Low side hose connected to low side service
connector 7. Low side hide
4. Not used
Problem
Cause
Improper operation of thermostatic expansion valve
(stuck open).
Conditions*
– 2 bar (14.5 – 29 psi).
High side pressure too high. The gauge should read
13.3 – 14.8 bar (193 – 215 psi).
Evaporator and suction hose (to compressor) surfaces
show considerable moisture.
Check for sticking expansion valve as follows:
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• Operate the system at maximum cooling.

• Check the low-pressure side gauge. The pressure
should lower slowly.
If the test indicates that the expansion valve is defec-
tive, proceed as follows:
• Replace the expansion valve.
• Drain the system.
• Charge the system.
Diagnostic
Thermostatic expansion valve is allowing too much
coolant to flow through the evaporator coils. Valve may
be stuck open.
of 35 °C (95 °F).
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LELI12TLB2162FB 8
4. Not used
Problem
Cause
Improper operation of thermostatic expansion valve
(stuck open).
Conditions*
Low side pressure too low (zero or vacuum). The gauge
should read 1 – 2 bar (14.5 – 29 psi).
High side pressure low. The gauge should read 13.3 –
14.8 bar (193 – 215 psi).
Evaporator air cool, but not sufficiently cold.
Evaporator inlet pipe surface shows considerable mois-
ture or frost.
Low pressure switch cutting out.
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Place finger on expansion valve to evaporator tube. If
too cold to touch, proceed as follows:
If the previous procedure indicates that the expansion
valve is defective, proceed as follows:
• Discharge the system.
Diagnostic
Expansion valve is not permitting a sufficient flow of
coolant. May be caused by valve stuck in restricted or
closed position.
of 35 °C (95 °F).
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LELI12TLB2163FB 9
4. Not used
Problem
Cause
Restriction in high side of system.
Conditions*
Too low pressure on low-pressure side. The gauge
should read 1 – 2 bar (14.5 – 29 psi).
NOTE: A normal or high reading of the high side pressure
gauge under these conditions indicates the system is over-
charged or the condenser or receiver/dryer is too small.
Evaporator only slightly cool.
Liquid line and receiver/dryer are cool to touch and
show frost or considerable moisture.
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Check for sticking expansion valve as follows:
If the test indicates that the expansion valve is defec-
tive, proceed as follows:
Diagnostic
Thermostatic expansion valve is allowing too much
coolant to flow through the evaporator coils. Valve may
be stuck open.
of 35 °C (95 °F).
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LELI12TLB2164FB 10
connector 7. Low side gauge
4. Not used Compressor cycles on at 2.3 bar (33.35 psi)
Compressor cycles off at 1.9 bar (27.55 psi)
Problem
Compressor cycles (cuts in and out) too rapidly.
Cause
Thermostatic switch defective.
Conditions*
Low-pressure side readings are too high during both
ON and OFF compressor cycles and between cycles.
Readings should be:
0.8 – 1.0 bar (11.60 – 14.50 psi) - OFF cycle
2.5 – 2.7 bar (36.25 – 39.15 psi) - ON cycle
1.7 – 1.9 bar (24.65 – 27.55 psi) - between cycles
The pressure on the high-pressure side is normal. The
gauge should read 13.3 – 14.8 bar (193 – 215 psi).
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Stop engine and shut-off air-conditioning.
Replace thermostatic switch with switch of same type.
Make sure the switch’s temperature sensor is installed
in the same position and depth (in evaporator core) as
previous.
Diagnostic
Defective thermostatic switch.
of 35 °C (95 °F).
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Air conditioning - Leakage test

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To perform a leak test if coolant leakage is suspected,

use a leak detector following the manufacturer’s instruc-
tions.
Leak detectors use light or sound dependent upon the
type used to alert the operator of a leak. If the leak de-
tector’s sensitivity is adjustable, be sure you calibrate
the detector according to the manufacturer’s instruc-
tions before use.
When using a leak detector, keep in mind that a very
slight amount of leakage in the compressor pulley area
is normal and does not necessarily indicate a repair is
required.
When a leak is located, follow these steps:
LELI12TLB2165AA 1
• Discharge the system using a certified coolant recov-
ery system.
• Repair the leak.
• Partially charge the system with 0.4 kg (0.88 lb) of
coolant.
• Check system for leaks.
• Fully charge the system.
Always check the system for leaks as a final test after
evacuating and before recharging. Refer to “Evacuat-
ing the system”.
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Air conditioning - Discharging

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Legislation has been introduced banning the release of

coolant into the atmosphere.
Whenever overhauling the air-conditioning system or
performing other tasks which require the air-condition-
ing system to be dismantled it is necessary to discharge
the coolant gas before commencing repair.
Before you can dismantle an air-conditioning system for
repairs, you must discharge and recover the coolant
using a certified recovery unit in accordance with the
manufacturer’s instructions.
Shown is a combined coolant recovery, evacuation and
recycling/charging station. This equipment removes
HFC 134a coolant from the air-conditioning system,
recycles and recharges all in one hook up.
The unit is designed to be used with the manifold gauge
set built into the control panel.
LELI12TLB2166BA 1
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LELI12TLB2167FB 2
1. Built in manifold gauge set

2. Recovery/recharging unit
3. Low side (suction) service valve (blue hose)
4. High side (discharge) service valve (red hose)
Other recovery systems are available where the man-
ifold gauges are not an integral part of the machine.
When this type of equipment is used a separate mani-
fold gauge set must be used.
The following is a summary of the steps for discharging
the system using a recovery/recycling unit.
NOTICE: Never discharge coolant gas into the atmos-
phere. Always wear safety goggles and gloves when
working with coolant. Only use authorized coolant tanks.
NOTICE: Always follow the manufactures instructions
when operating recovery equipment. Run the vehicle’s
air-conditioning system for a few minutes.
Set up the recovery unit following manufacturer’s in-
structions. Ensure that the units red (high side) hose
is connected to the high side (discharge) fitting and the
blue (low side) hose to the low side (suction) fitting.
NOTE: If a unit requiring the manifold gauge set is being
used, the low and high sides of the manifold set are con-
nected to the low and high sides of the loader backhoe
air-conditioning system. The hose from the recovery unit
is then connected to the manifold centre port.
To recover coolant, open both high and low side valves
on the control panel or the valves on the manifold gauge
set if being used.
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Open the valves labelled “gas” and “liquid” on the re-

covery unit coolant tank.
Plug in the unit’s power cord.
Operate the recovery system in accordance with the
manufacturers instructions.
The compressor will shut off automatically when the re-
covery is complete.
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Air conditioning - Flush

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Flushing the system
LELI12TLB2169FB 1
1. High side gauge 5. Low side hose

2. High side shut-off valve 6. Low side shut-off valve
3. High side hose 7. Low side gauge
4. Centre service hose
Air-conditioning systems may occasionally become

contaminated with solid particles. This contamination
may be the result of allowing dirt to enter the system
while it was open, from aluminium corrosion or sludge,
or from disintegrated compressor reed plates. Contam-
ination of this nature can result in plugged evaporators,
condensers and expansion valves.
Flush system with dry nitrogen.
Each individual component must be flushed after dis-
connecting every hose fitting.
The compressor and expansion valve can not be
flushed, therefore, the compressor should be disas-
sembled and cleaned or replaced and the expansion
valve should be replaced. When flushing the system
always replace the receiver/drier.
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NOTE: For flushing the air-conditioning system, never use

any solvent other than the special flushing solvent specifi-
cally produced for air-conditioning systems. Always follow
the manufacturer’s recommendations and directions for us-
ing the flushing equipment and solvent.
Re-assemble and evacuate the system to remove air
and moisture as described in Air conditioning - Evac-
uate (50.200).
LELI12TLB2170BA 2
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Air conditioning - Evacuate

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Draining the system

NOTICE: A system in which coolant has been recovered to
facilitate repairs must be drained before new coolant can
be added.
Air and moisture are removed by evacuating the system
using a vacuum pump.
The automatic recycling, recharge and evacuation
stations or evacuating and charging stations available
throughout the air-conditioning industry incorporate
a vacuum pump within the assembly. If this type of
equipment is not available a separate vacuum pump
and manifold gauge set must be used.
As the system is evacuated the boiling point of any
moisture within the system is similarly lowered. As
the vacuum increases the boiling reduces to below
that of the ambient temperate and the moisture is
subsequently boiled away.
The relationship of system vacuum to the boiling tem-
perature at which the water vapor is removed from the
system is as follows:
System
System vacuum
vacuum Temperature
of mercury
in mercury
28.0 71.0 cm (28.0 in) 38 °C (100.4 °F)
28.9 73.4 cm (28.9 in) 27 °C (80.6 °F)
29.4 74.6 cm (29.4 in) 16 °C (60.8 °F)
29.7 75.4 cm (29.7 in) 5 °C (41 °F)
29.8 75.7 cm (29.8 in) -7 °C (19.4 °F)
29.9 75.9 cm (29.9 in) -18 °C (-0.4 °F)
NOTE: For every 305 m (1001 ft) above sea level, the vac-
uum gauge reading must be corrected by adding 2.54 cm
(1 in) of mercury to compensate for the change in atmo-
spheric pressure.
NOTICE: Be sure the system is completely discharged as
coolant will damage the vacuum pump. If the manifold
gauge set is being used connect the low and high sides of
the manifold to the low and high sides of the vehicle air-con-
ditioning system as described for discharging the system.
Connect the manifold center hose to the vacuum pump
suction port as per the manufacturers instructions.
Fully open both the low and high side gauge shut off
valves.
If a combined recovery/evacuation unit is to be used
attach the unit to the air-conditioning system in accor-
dance with the manufacturers instructions. Be sure to
read all installation and operating instructions carefully
before starting the unit.
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After starting the evacuation cycle, note the low side

gauge to be sure the system pulls down into a vacuum.
Time the evacuation for a minimum of 30 min from the
point when lowest vacuum is attained.
Thirty minutes later when the low side gauge attains the
lowest steady vacuum, stop the evacuation process.
NOTE: The vacuum pump achieves ultimate vacuum with
the vented exhaust valve closed. Do not evacuate too
quickly as oil may be drawn from the system.
Check the system by closing the gauge shut-off valves,
turning the vacuum pump off and noting the low side
gauge reading. A loss of more than 5 cm (1.97 in) of
vacuum in 5 min indicates either a leak or moisture in
the system.
If the gauge needle remains stationary and the vacuum
is maintained for 3 – 5 min, close both the high and low
side manifold hand valves, turn off and disconnect the
centre hose from the pump. The system is now ready
for charging.
If a leak is detected, charge the system with approxi-
mately 0.4 kg (0.88 lb) of coolant, see charging the sys-
tem and locate the leak using a leak detector.
Once the leak is located discharge and recover the
coolant in the system, repair the leak, then repeat the
evacuation procedure.
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Air conditioning - Charging

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Charging the system

NOTICE: Make sure that there are no leaks in the system
and that the system has been fully drained. Observe
all safety recommendations when handling coolant HFC
R134A, see “Precautions when Handling coolant HFC
R134A” in this section.
Ensure the charging unit is correctly connected to the
loader backhoe air conditioning system in accordance
with the manufacturers instructions.
If a charging unit, in conjunction with the manifold gauge
set is used, open the high and low side hand valves on
the manifold.
Charge the system with 1.35 kg (2.98 lb) of coolant as
per the manufacturers instructions.
If the charging rate becomes very slow close the high
side valve carefully, start the loader backhoe and set
engine speed to idle. Turn ON the air conditioning
so that the compressor can pull the remainder of the
coolant into the system.
If the coolant charge will not completely transfer to the
air conditioning system, recover and recharge the sys-
tem.
Close the high and low side valves on the unit control
panel, or on the gauge assembly if being used, and
test the air conditioning as described in the paragraph
relevant to the performance test of the air conditioning
system.
NOTE: After charging a system, use the following start up
procedure to ensure the lubricating oil is properly dispersed
around the system.
• Ensure the air conditioning is switched OFF.
• Start the engine. Set the engine speed to idle.
• Turn the air conditioning ON and allow system to
operate for at least 1 min before increasing engine
speed.
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LELI12TLB2168FB 1
1. Built in manifold gauge set 3. Low side (suction) service valve (blue hose)
2. Recovery/recharging unit 4. High side (discharge) service valve (red hose)
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Air conditioning - Overhaul

580ST
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695ST
WARNING
Explosion hazard!
Air-conditioning refrigerant boils at -12 °C (10 °F)!
-NEVER expose any part of the air-conditioning system to a direct flame or excessive heat.
-NEVER disconnect or disassemble any part of the air-conditioning system.
Discharging refrigerant gas into the atmosphere is illegal in many countries.
W0340A
NOTICE: Before disconnecting components in the air-con-

ditioning system the coolant gas must be discharged and
recovered using a certified recovery system. Refer to Air
conditioning - Discharging (50.200). Do not discharge
the gas into the atmosphere.
If an air-conditioning component is to be replaced
during a system overhaul it is necessary to drain any
coolant oil that has collected in the component being
replaced into a clean calibrated container.
A volume of clean coolant oil equivalent to that removed
from the replaced component must then be added to the
new item before being installed onto the loader back-
hoe.
Upon completion of the repair evacuate, recharge, leak
test and performance test the system to ensure correct
operation.
Carry out the service and maintenance of the following
components:
1. Expansion valve: Expansion valve - Replace
(50.200)
2. Evaporator: Air-conditioning evaporator - Ser-
vice instruction (50.200)
3. Air-conditioning temperature sensor: Air condi-
tioning - Adjust (50.200)
4. Low pressure cut-out sensor: Air conditioning -
Overhaul (50.200)
5. Blower motor: Heating - Overhaul (50.100)
6. Receiver dryer: Receiver-dryer - Replace
(50.200)
7. Condenser: Air-conditioning condenser -
Cleaning (50.200)
8. Air filter: Air filter - Service instruction (50.104)
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Air conditioning - Overhaul

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Low-pressure cut-out sensor

With the engine OFF check continuity across the switch
contacts.
If the sensor (1) indicates an open circuit, replace it as
described below.
NOTICE: The sensor cannot be replaced without discharg-
ing the system.
Remove the sensor by unscrewing it from the valve.
Replace with new switch and connect to harness.
LEPH12TLB2173AB 1
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Air conditioning - Adjust

580ST
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695ST
Adjusting sensor of air-conditioner temperature

Remove the seat mounting plate.
The temperature adjusting sensor is mounted to the
side of the blower motor assembly.
Carefully disconnect the switch wiring at the harness
connector.
Remove the temperature control switch. Replace the
switch as required.
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Air conditioning - Calibrate Stepper motor calibration in the water

valve
580ST
590ST
695ST
1. Turn the ignition switch OFF.

2. Set the temperature control knob to the coldest setting.
RAIL16TLB0450AA 1
3. Turn the ignition switch ON.

4. Wait at least 2 s.
ting.
RAIL16TLB0456AA 2

ting.
ting.
ting.
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Air-conditioning compressor - Disassemble

580ST
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695ST
1. Drain the coolant oil from the compressor into a clean

graduated container.
2. Measure and record the quantity of oil obtained.
NOTICE: This information is required during installation of
the new or overhauled unit.
3. Remove the bolts (10) and cylinder head (9).
NOTE: Use a gasket cleaner and mallet to tap and free the
cylinder head.
LELI12TLB2306AB 1
4. If the plate (7) and/or cylinder head are to be reused,

carefully remove the gasket (8) using a suitable
scraper.
LELI12TLB2307AB 2
5. Gently pry the plate (7) free from the cylinder block
and remove the gasket (6). Inspect the plate (7) for
damage, replace if necessary.
LELI12TLB2308AB 3
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Air-conditioning compressor - Assemble

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1. Coat the top of the valve plate with clean coolant oil and
reassemble the cylinder head following the removal
procedure in reverse order.
2. When installing the gaskets and valve plate, make sure
that they are correctly positioned over the locating pins
in the cylinder block.
3. Install the cylinder head screws and tighten using the
sequence shown.
4. Torque to 20 N·m (14.8 lb ft).
5. When the overhaul is complete add oil to the compres-
sor.
LELI12TLB2309AB 1
NOTE: The filling quantity should match the drained oil
quantity.
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Air-conditioning compressor - Remove

580ST
590ST
695ST
LELI12TLB2183GB 1
1. Discharge the air-conditioning system.

2. Unplug the compressor harness from the engine har-
ness.
3. Disconnect tubing to compressor.
4. Remove the nut (11) and screw (10).
5. Remove the screws (9) from the belt tensioner’s (5)
support bracket (4).
6. Remove the belt (6).
7. Remove the screws (12), washers (7) and stud (2).
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8. Remove the support (1) complete with compressor (3).

9. Remove the screws (8) and stud (13) to detach the
compressor (3) from the support bracket (1).
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Air-conditioning compressor - Install

580ST
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695ST
1. To install, follow the removal procedure (See Air-con-

ditioning compressor - Remove (50.200)) in reverse
order.
2. Torque the bolts to 37 – 43 N·m (27.3 – 31.7 lb ft).
NOTE: It is recommended that a new receiver/drier assem-
bly is installed after any system component replacement or
any repair that requires entry into the system.
3. Drain the oil from the new compressor to be fitted into a
clean container, or if the old compressor is to be refitted,
obtain a new can of coolant oil.
4. Calculate the amount of oil to be added and refill the
LELI12TLB2184AA 1
compressor.
5. Reconnect the hoses to the compressor and tighten all
screws and hoses.
Torque the air compressor hoses to 55.0 N·m (40.6 lb
ft).
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Air-conditioning compressor - Overhaul

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Before any internal repair is done, drain the oil from the
compressor:
Remove the oil plug and drain as much oil as possible
into a suitable container.
Remove the caps (if present) from suction and dis-
charge ports.
Drain oil from the section and discharge ports into suit-
able container while turning the shaft clockwise only
with a socket wrench on the armature retaining nut.
LELI12TLB2186AA 1
Measure and record the amount of oil discharged.

Inspect the oil for signs of contamination such as dis-
coloration of foreign material.
LELI12TLB2187AA 2
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Air-conditioning compressor - Disassemble

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695ST
1. Remove the armature plate, as explained in Air-con-

ditioning compressor - Disassemble the clutch
(50.200).
2. Remove the shaft key (1) and ring (2) and remove the
expose the snap ring (3).
LELI12TLB2191AC 1
3. Remove and discard the seal (4) with the seal remover/
installer tool (A).
LELI12TLB2301AB 2
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Air-conditioning compressor - Assemble

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1. Thoroughly clean the seal cavity in the hub with a lint

free cloth.
2. Install the new shaft seal O-ring on the seal assembly.
3. Dip the new seal assembly in clean coolant oil.
LELI12TLB2302AA 1
4. Install the seal (4) with the seal remover/installer tool.

NOTE: If remover/installer tool (A) is not available, position
the seal squarely in the hub and tap gently until fully seated.
LELI12TLB2303AB 2

NOTICE: If the snap ring has a bevelled edge, this should
face outwards.
LELI12TLB2191AC 3
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6. Install the ring (2).
LELI12TLB2304AB 4
7. Position the shims on the shaft and reinstall the shaft

key.
8. Reinstall the plate (See Air-conditioning compressor
- Assemble the clutch (50.200)).
LELI12TLB2305AA 5
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Air-conditioning compressor - Disassemble the clutch

580ST
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695ST
NOTICE: All clutch servicing should be done with the compressor removed from the vehicle.
1. Support the compressor. If using a vice, do not hold on
to the housing.
2. If a dust cover (2) is present, remove the bolts (1) hold-
ing it in place and remove the cover.
3. If auxiliary sheet metal pulley is present, remove the
bolts holding it in place.
4. Remove the pulley.
5. Attach the tool to the cover in front of the clutch disc
and remove the nut (3) using a wrench.
LELI12TLB2189AB 1
6. Using the front plate tool and a crowbar, hold the clutch
plate stationary.
7. Remove the front plate with the tool and the bolt.
8. If the shims (5) are above the shaft key, remove the
shims..
9. If the shims (5) are below the shaft key, remove the key
and bearing dust cover before you remove the shims.
10. Remove the dust cover (6). Use caution to prevent
distorting cover when removing it.
11. Remove shaft key by tapping loose with a flat blade
screwdriver and hammer. LELI12TLB2190AB 2
12. Remove the shims (5).

13. Use a pointed tool and a small screwdriver to prevent
the shims from binding on the shaft.
14. Remove the snap ring (7), remove the shaft key and
lift the pulley assembly from the compressor.
LELI12TLB2191AB 3
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15. Check the rotor assembly (8) for wear and replace the
assembly as necessary.
LELI12TLB2192AB 4
16. Remove the field coil wire retaining clip.
LELI12TLB2193AA 5
17. Remove the snap ring (9) of the coil.
LELI12TLB2194AB 6
18. Lift the coil (10) from the housing and replace if re-
quired.
LELI12TLB2195AB 7
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Air-conditioning compressor - Assemble the clutch

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1. Install the coil (10) with the snap ring (9). Secure the
field coil wire with the retaining clamp.
LELI12TLB2196AB 1
2. Install the rotor (8) on the shaft.
LELI12TLB2197AB 2
LELI12TLB2191AB 3
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4. Install the plate (4) with the retaining nut (3). Torque
the nut to 18 N·m (13 lb ft).
LELI12TLB2189AB 4
5. Check the clearance between the plate (4) and the ro-
tor (8). This should be consistent around the circumfer-
ence and be between 0.4 – 0.8 mm (0.016 – 0.031 in).
NOTE: If the air gap is not consistent, lightly pry up on the
counter weighted front plate at the low spots or lightly tap
down at the high spots.
LELI12TLB2198AB 5
6. If the clearance is not within specification, the shims (5)

under the front plate should be added or removed, until
the correct clearance is obtained.
NOTE: New shims are available in the following sizes:
1 mm (0.039 in), 0.5 mm (0.020 in) and 0.125 mm
(0.005 in).
LELI12TLB2199AB 6
7. Install the dust cover (2). Install the bolts (1) (if appli-
cable).
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Compressor drive belt - Adjust

580ST
590ST
695ST
1. The compressor drive belt (1) can be tensioned by turn-

ing the bracket idler support (2).
2. Loosen the bracket idler support bolt and adjust the arm
to a belt deflection of 16 mm (0.63 in).
3. Once adjusted re-torque the bracket idler support bolt
to 37 – 41 N·m (27 – 30 lb ft).
LELI12TLB2185BB 1
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Air-conditioning condenser - Cleaning

580ST
590ST
695ST
1. Remove the bolts (2). Remove the front grill (1).
LELI12TLB2176AB 1
2. Remove the nuts (3) and (5), horn (4) and fuel cooler
(6).
LELI12TLB2177AB 2
3. Remove the upper nut (7) and loosen the lower nut.
Move the dryer filter (8) to the right side.
LELI12TLB2178AB 3
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LELI12TLB2179AB 4
5. Move the condenser (10) forward.

6. Clean the condenser (10) with compressor air.
LELI12TLB2180AB 5
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Receiver-dryer - Replace
580ST
590ST
695ST
1. The receiver/dryer (1) cannot be overhauled and must

be replaced as an assembly. The receiver/dryer as-
sembly should be replaced if it is suspected that mois-
ture is in the system.
2. The receiver dryer must also be replaced if the system
has been discharged and the air-conditioning joints dis-
connected.
3. Discharge and reclaim coolant gas using certified re-
covery systems.
4. Disconnect the hoses and switch and remove the dryer
from the loader backhoe.
5. Drain the coolant oil from the receiver dryer into a clean
1
calibrated container. Measure the quantity of oil ob- LEPH12TLB2175AB
tained and add the same quantity of new coolant oil

directly into the new item.
6. Cap and plug all fittings to prevent any dirt entering the
system.
7. Install a new receiver dryer.
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Expansion valve - Replace

580ST
590ST
695ST
1. The expansion valve is not a serviceable part and must

be replaced if defective.
2. Fully discharge the air-conditioning system.
3. Remove the seat to gain access to the valve.
4. To gain access to the expansion valve partially lift the
evaporator core from its position in the cab floor.
5. Remove the bolt securing the inlet and outlet connec-
tions to the valve and pull valve from tubing.
6. Replace the O-ring seals and lubricate with coolant oil
prior to installing the valve using disassembly proce-
dure in reverse. LELI12TLB2171AA 1
7. Evacuate, leak test and recharge the system.
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Air-conditioning evaporator - Service instruction

580ST
590ST
695ST
1. Discharge and recover coolant gas using certified re-

covery systems.
2. Remove the seat and cover plate to access the evapo-
rator assembly (1).
3. Remove temperature cycling control thermocouple.
4. Disconnect tubing to expansion valve.
5. Remove the evaporator.
6. Check the evaporator assembly fins for damage.
Straighten fins if necessary.
7. Clean the evaporator core of all foreign material to be
sure it is free of obstructions.
LEPH12TLB2172AB 1
8. Check the evaporator assembly for indications of
coolant leakage. If damage or leaks are evident,
replace the evaporator core.
9. If a new evaporator is to be installed drain the coolant
oil in the evaporator into a clean calibrated container.
10. Measure the quantity of oil obtained and add the same
quantity of new coolant oil directly into the replace-
ment evaporator core.
11. Install the evaporator using disassembly procedure in
reverse.
12. Evacuate, leak test and recharge the system.
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Air conditioning - Troubleshooting

580ST
590ST
695ST

Unusually high suction Valve plate test Replace or repair:
pressure with unusually Broken head or block gasket
low discharge pressure Broken or deformed reed valve
Foreign substance under reed valve or gas-
ket
Unusually low suction Check for low coolant charge Replace or repair:
and discharge pressure Shaft seal leak
Compressor leak check Cylinder head leak
Gasket leak
Leak check and diagnostic system Oil filler plug leak
Cracked cylinder block
Front housing O-ring leak
Intermittent or inoperative Check belt tension Replace
Check clutch air gap Adjust air gap
Check clutch volts, amps, coil lead wire Replace or repair:
Broken lead wire
Internal clutch coil defect
System ground (see system manual)
Difficult start Shaft turning smoothness test Internal compressor failure
Clutch engaged Check compressor mounting components Replace or repair
Check engine components Replace or repair
Check for intermittent or slipping clutch Adjust air gap - defective coil
Check for proper coolant charge Recharge and recheck
Check clutch bearing Replace rotor/armature assembly
Oil level procedure Fill to proper level
Shaft turning smoothness test Internal compressor failure
Remove valve plate and inspect Replace or repair:
Broken discharge valve reed or retainer
Broken suction valve reed
Broken gasket
“Chattering” disengaged Check air gap Replace or repair:
clutch Adjust air gap
Defective clutch pulley or front plate
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Index

Air conditioning - Adjust (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Air conditioning - Calibrate Stepper motor calibration in the water valve (*) . . . . . . . . . . . . . . . . . . . . . 61
Air conditioning - Charging (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Air conditioning - Discharging (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Air conditioning - Dynamic description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Air conditioning - Evacuate (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Air conditioning - Flush (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Air conditioning - General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Air conditioning - Leakage test (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Air conditioning - Overhaul (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Air conditioning - Overhaul (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Air conditioning - Service instruction (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Air conditioning - Service instruction (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Air conditioning - Static description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Air conditioning - Static description Temperature sensor (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Air conditioning - Troubleshooting (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Air-conditioning compressor - Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Air-conditioning compressor - Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Air-conditioning compressor - Assemble the clutch (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Air-conditioning compressor - Component identification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Air-conditioning compressor - Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Air-conditioning compressor - Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Air-conditioning compressor - Disassemble the clutch (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Air-conditioning compressor - Dynamic description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Air-conditioning compressor - Exploded view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Air-conditioning compressor - Exploded view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Air-conditioning compressor - General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Air-conditioning compressor - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Air-conditioning compressor - Overhaul (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Air-conditioning compressor - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Air-conditioning condenser - Cleaning (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
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Air-conditioning condenser - Static description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Air-conditioning evaporator - Service instruction (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Air-conditioning evaporator - Static description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Compressor drive belt - Adjust (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Expansion valve - Replace (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Expansion valve - Static description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Receiver-dryer - Replace (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Receiver-dryer - Static description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
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PRINTED IN U.S.A.
48090752 24/02/2017
EN
SERVICE MANUAL
Electrical systems

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55
Contents
Electrical systems - 55
[55.100] Harnesses and connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.1
[55.301] Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.2
[55.302] Battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.3
[55.011] Fuel tank system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.4
[55.012] Engine cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.5
[55.640] Electronic modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.6
[55.512] Cab controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.7
[55.991] Telematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.8
[55.DTC] FAULT CODES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.9
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Harnesses and connectors - 100

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Contents
FUNCTIONAL DATA
Harnesses and connectors

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Electrical schema index Components (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Electrical schema index Connectors (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Drawing Anti-tipping sensor switch harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Wiring harnesses
Electrical schematic sheet 01 Sheet 1 Engine cable (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Electrical schematic sheet 01 Sheet 1A Engine cable (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Electrical schematic sheet 01 Sheet 1B Engine cable (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Electrical schematic sheet 02 Sheet 2 Solenoid valves cable (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Electrical schematic sheet 04 Sheet 4 Lights cable (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Electrical schematic sheet 05 Sheet 5 Rear lights cable (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Electrical schematic sheet 06 Sheet 6 Work lights cable (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Electrical schematic sheet 07 Sheet 7 Windshield wiper/ washer cable (*) . . . . . . . . . . . . . . . . . . . . . . . . 60
Electrical schematic sheet 08 Sheet 8 Heater (radio) cable (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Electrical schematic sheet 09 Sheet 9 Quick coupler option (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Electrical schematic sheet 10 Sheet 10 Trax control module harness (*) . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Electrical schematic sheet 11 Sheet 11 Transmission (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Electrical schematic sheet 12 Sheet 12 Air conditioner kit (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Electrical schematic sheet 13 Sheet 13 Pilot control module (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Electrical schematic sheet 01 Sheet 1 Engine cable (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Electrical schematic sheet 01 Sheet 1A Engine cable (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Electrical schematic sheet 01 Sheet 1B Engine cable (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Electrical schematic sheet 04 Sheet 4 Lights cable (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
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Electrical schematic sheet 05 Sheet 5 Rear lights cable (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Electrical schematic sheet 06 Sheet 6 Work lights cable (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Electrical schematic sheet 07 Sheet 7 Windshield wiper/ washer cable (*) . . . . . . . . . . . . . . . . . . . . . . . . 90
Electrical schematic sheet 08 Sheet 8 Heater (radio) cable (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Electrical schematic sheet 09 Sheet 9 Quick coupler option (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Electrical schematic sheet 10 Sheet 10 Trax control module harness (*) . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Electrical schematic sheet 11 Sheet 11 Air conditioner kit (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Electrical schematic sheet 12 Sheet 12 Pilot control module (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Electrical schematic sheet 01 Sheet 1 Engine cable (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Electrical schematic sheet 01 Sheet 1A Engine cable (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Electrical schematic sheet 01 Sheet 1B Engine cable (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Electrical schematic sheet 02 Sheet 2 Solenoid valves cable (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Electrical schematic sheet 03 Sheet 3 solenoid valves cable (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Electrical schematic sheet 04 Sheet 4 Lights cable (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Electrical schematic sheet 05 Sheet 5 Rear lights cable (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Electrical schematic sheet 06 Sheet 6 Work lights cable (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Electrical schematic sheet 07 Sheet 7 Windshield wiper/ washer cable (*) . . . . . . . . . . . . . . . . . . . . . . . 118
Electrical schematic sheet 08 Sheet 8 Heater (radio) cable (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
Electrical schematic sheet 09 Sheet 9 Quick coupler option (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Electrical schematic sheet 10 Sheet 10 Air conditioner kit (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
Electrical schematic sheet 11 Sheet 11 Pilot control module (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
Wire connectors
Component diagram 00 Connectors power and ground (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
Component diagram 00 Connectors S01 to S99 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Component diagram 00 Connectors XST, XC, XX and X-00 to X-09 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . 139
Component diagram 01 Connectors X-010 to X-019 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
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Component diagram 00 Connectors fuses (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 264
Component diagram 00 Connectors BS1 to BS9 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265
Component diagram 00 Connectors H00 to H99 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267
Component diagram 00 Connectors relays K-00 to K-99 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269
Component diagram 00 Connector MC1 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270
Component diagram 00 Connectors S01 to S99 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271
Component diagram 00 Connectors XC, XST, and XX (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276
Component diagram 00 Connectors X-00 to X-09 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 283
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Component diagram 00 Pilot control connectors S1 and S2 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 382
Component diagram 00 Pilot control connectors XL, XR, and XX (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 383
Component diagram 00 Pilot control connectors YP3 to YP10 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 384
Component diagram 00 Pilot control connectors X-00 to X-09 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 385
Component diagram 01 Pilot control connectors X-010 to X-019 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 386
Component diagram 00 Connectors fuses (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 396
Component diagram 00 Connectors BS1 and BS2 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 397
Component diagram 00 Connectors H00 to H99 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 399
Component diagram 00 Connectors relays K-00 to K-99 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
Component diagram 00 Connector MC1 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
Component diagram 00 Connectors S01 to S101 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
Component diagram 00 Connectors XC, XST, and XX (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 408
Component diagram 00 Connectors X-00 to X-09 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 415
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Component diagram 00 Pilot control connectors S1 and S2 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 509
Component diagram 00 Pilot control connectors XL, XR, and XX (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 510
Component diagram 00 Pilot control connectors YP3 to YP10 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 511
Component diagram 00 Pilot control connectors X-01 to X-09 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 512
SERVICE
Fuse and relay box

Check - Power shuttle (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 516
Check - Powershift (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 523
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Electrical systems - Harnesses and connectors
Harnesses and connectors - Overview

Electrical failure modes
Short Circuit
A short circuit is a connection of comparatively low resistance between two points in an electrical circuit. Typically,
when a higher source (positive supply) short circuits to a ground circuit or a frame ground, it causes the circuit protec-
tion device, e.g. a fuse, to open and protect the wiring from damage. However, a short circuit can cause damage to
the wiring and machine. This damage can occur if a circuit is not properly protected with a circuit protection device.
The amount of current allowed to flow through a wire due to a short circuit can cause the wire to overheat. This
heat melts the insulation around the wire, adjacent wires, and may lead to a fire. Proper fusing reduces or eliminates
damage to the machine resulting from a short circuit. A short circuit may result when a cut, pinched or chafed wire
makes contact with a grounded component of the vehicle.
Open Circuit
An open circuit is a loss of connection between two points in a circuit. This condition creates infinite resistance
between two circuits and usually results in the malfunction of an electrical component.
An open circuit may result from:
• Pinched/cut wire(s)
• Terminal(s) improperly seated in a connector
• Poor/improper crimping
• Corroded terminal(s)
• Improperly connected Faston connector/ring terminal
Intermittent Circuit
An Intermittent circuit is a condition in the circuit that caused random or repeated failures, and is usually caused by
repeatedly opens or shorts in the circuit. In other words, the circuit makes and breaks contact intermittently.
An intermittent circuit may be caused by:
• Pinched wire
• Loose ring terminal
• Improper seating of terminal(s) in a connector
• Incomplete mating of connectors
• Corroded terminals
Examples of common electrical problems

Short circuit
• The wires are pinched between two objects, e.g. a
frame and bracket.
RAIL14SSL0590AA 1
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Open circuit
• A cut or broken wire.
RAIL14SSL0589AA 2
Open circuit
• There is no contact between the wire(s) and the termi-
nal due to the insulation not being properly removed
or positioned when the terminal was fastened to the
wire(s) .
RAIL14SSL0595AA 3
Open circuit
• Completely disconnected connectors do not make con-
tact with the terminals.
RAIL14SSL0600AA 4
Open circuit
• The terminal is not positioned properly or did not stay
inside the connector.
RAIL14SSL0601AA 5
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Open circuit
• A wire is missing from a connector.
RAIL14SSL0602AA 6
Open circuit
• A wire length that is shortened.
RAIL14SSL0603AA 7
Intermittent circuit
• The hardware used to secure the terminal is not com-
pletely tightened.
RAIL14SSL0593AA 8
• The ring terminal is not secured with hardware.
RAIL14SSL0594AA 9
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• The terminal is not crimped on the wire(s).
RAIL14SSL0596AA 10
• Bent pins may cause a short circuit if the two terminals
do not contact.
• The male and female connectors may not make contact
because of the bent pin.
RAIL14SSL0597AA 11
• Corrosion on the pin(s) is Indicated by a layer of green-
ish-white powder appearing on the pins.
• Corroded pins may overheat because of increased re-
sistance due to corrosion.
RAIL14SSL0598AA 12
• Partially disconnected connectors make contact with
only some terminals.
RAIL14SSL0599AA 13
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• Cracked, broken or melted connector cause improper
connections.
RAIL14SSL0605AA 14
• A ground terminal not fastened or loose on the machine.
RAIL14SSL0606AA 15
Chaffed wire
• A section of the wire’s insulation is rubbed away, expos-
ing the bare wire.
RAIL14SSL0591AA 16
Burned wire and/or melted insulation

• If the wire(s) are located near a heat source or over-
heated because of continuous, excessive current, the
insulation will be discolored and melt, exposing the
wire(s).
RAIL14SSL0592AA 17
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Cross connection
• Terminals that are connected in the wrong cavity will
result in system malfunction.
RAIL14SSL0604AA 18
Incorrect routing
• A wiring harness not routed properly can lead to prob-
lems.
RAIL14SSL0607AA 19
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Prevention of common electrical problems

In order to prevent common problems and to achieve a higher reliability, please follow the below procedures. Please
use harness diagnostic and repair kit, part number 380040185, to assist you with repairs to wires, harnesses, and
connectors.
Sealed connectors
Sealed connectors are designed with weather-proof seals that protect the connector’s terminals from moisture
and debris. This protection makes them ideal for use on the exterior. Two types of seals are available in these
types of connectors:
• A connector seal which provides an environmental seal between the mating connectors.
• A cable seal which seals the area where each wire enters the connector.
RAIL14SSL0609AA 20
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Unsealed connectors
Unsealed connectors are designed for the interior of the machine where connectors are free from contaminates. Do
not replace sealed connectors with unsealed connectors. Usage of unsealed connectors in place of sealed connectors
could lead to damage by environmental factors such as moisture and debris, and cause corrosion which can lead to a
poor connection. Corroded terminals create high resistance in the connection, which can cause intermittent or open
circuits.
RAIL14SSL0608AA 21
Assembly and disassembly of connectors:
Crimping wires on the terminals

The crimping procedure is the same for sealed and unsealed connectors. The differences are identified below.
Sealed connector
1. Slide the wire seal (1) on the wires.
RAIL14SSL0610AA 22
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2. Remove approximately 10 mm (3/8 in) insulation from

the wire ends.
3. Inspect wire strands for cuts and damage. Remove
the stripped portion of wire and strip again if necessary.
RAIL14SSL0611AA 23
4. Place the wire (1) on the terminal. Verify that the wire
seal (2) rests on the insulation barrel (3).
5. Verify that the wire core (4) is exposed to the wire
barrel (5).
RAIL14SSL0613AA 24
Unsealed connector
1. Remove approximately 10 mm (3/8 in) insulation from
the wire ends.
2. Inspect wire strands for cuts and damage. Remove
the stripped portion of wire and strip again if necessary.
RAIL14SSL0611AA 25
4. Place the wire (1) on the terminal. Verify that the insu-
lation lies on the insulation barrel (2).
5. Verify that the wire core (3) is exposed to the wire
barrel (4).
RAIL14SSL0612AA 26
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Sealed and unsealed connectors

6. Use the appropriate tools to crimp the barrels. Follow
these precautions while crimping:
A. Do not bend or crack the terminal.
B. Do not cut the wire strands with the barrel.
C. Verify that all wire strands are contained inside the
core barrel.
D. Wires must not fall out of the barrels once they
have been crimped.
RAIL14SSL0614AA 27
7. Solder all hand-crimped terminals.

8. Check circuit for electrical continuity.
RAIL14SSL0615AA 28
Installing terminals in the connectors

NOTICE: Installing the terminals do not require any special tools. Do not use excessive force to insert a terminal.
NOTICE: The connector pin/terminal number is read from the pin insertion side of the connector.
1. Orient the terminal to its proper relationship with the

connector body.
2. Insert the terminal into the correct connector cavity.
3. Push until the terminal “clicks” in place.
4. Gently pull the wire back to ensure the proper seating
of the terminal. Verify that the terminal will not back
out from the connector.
RAIL14SSL0616AA 29
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Wires are locked in place with a wire lock or a Terminal

Position Assurance (TPA) lock.
Wire locks or TPA locks are added in the connector to

avoid damage to the wires as the exposed/loose wires
are more prone to damage.
Wire locks and TPA locks vary in size and shape, depend-
ing on the type of connector being used.
Some connectors may not have wire or TPA locks.

NOTE: Image shows connector without wire lock.
RAIL14SSL0617AA 30
Sealed connector - wire lock
1. Install the wire lock after all terminals have been

seated in the connector.
2. Push the lock over the back of the connector until it
locks onto the connector.
RAIL14SSL0619AA 31
Unsealed connector - TPA lock
1. Install the TPA lock after all terminals have been

seated in the connector.
2. Push the lock into the back of the connector until it
locks into place.
RAIL14SSL0618AA 32
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Hinged wire lock
1. On connectors with a hinged wire lock, snap the wire

lock over back of the connector .
RAIL14SSL0620AA 33
Prior to mating the connectors, visually inspect the con-

nectors for damage. Verify that the connector pins are
straight.
RAIL14SSL0621AA 34
Bent pins will lead to damage to the connector and may

cause a short circuit.
RAIL14SSL0622AA 35
Once the terminals are installed and locked in place, apply

dielectric grease to the connector and on the pins to avoid
corrosion.
RAIL14SSL0623AA 36
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1. Push the connectors together until the connector’s

locks snaps into place.
2. If a manual latch is present, secure the manual latch.
3. Slightly pull the connectors to verify a proper connec-
tion.
NOTICE: Do not test the connectors by pulling the wires.
RAIL14SSL0624AA 37
RAIL14SSL0625AA 38
Precautions to be followed while connecting a connector:

• Verify that the connections are intact. Loose connec-
tions will lead to disconnection and corrosion damage.
RAIL14SSL0626AA 39
• Rubber seals on the connector prevents contamination.

Verify that the seal is present on the connectors before
mating the connectors.
RAIL14SSL0627AA 40
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• On connectors with a missing seal, the connection will

not be intact and may cause intermittent or open circuit.
RAIL14SSL0628AA 41
• Verify that the connectors without internal locks, the “T”

on the pins are flush with the bottom of the mating con-
nector to ensure a proper connection.
RAIL14SSL0629AA 42
• Image 43 shows properly mated connector.
RAIL14SSL0630AA 43
• In regards to Engine Control Unit (ECU) connectors,

verify that the connector is properly locked. Moving the
lever towards the controller locks the connector Moving
the lever away from the controller unlocks the connec-
tor. When the connector is properly locked, you should
be able to feel the lever “click” into place.
RAIL14SSL0631AA 44
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• Install the secondary locks or connector position assur-

ance (CPA) locks as required.
RAIL14SSL0632AA 45
RAIL14SSL0633AA 46
NOTICE: Missing and improperly installed secondary

locks will lead to faulty connections.
RAIL14SSL0634AA 47
Disconnecting connectors
1. Remove the secondary lock or CPA lock as follows:
○ Depress the tabs on either side of the lock
○ Pull the lock out of the connectors.
2. With your thumb and a small screwdriver or a pick, lift
the connector’s lock and pull the connectors apart.
NOTICE: Do not disconnect the connectors by pulling the
wires.
RAIL14SSL0635AA 48
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Unsealed connector – TPA lock removal

1. With a screwdriver or pick, depress the locking tabs of
the TPA lock and pull the lock from the connector.
NOTE: If the locks and connectors are to be used again,
verify that the locking mechanisms are not bent or de-
formed.
RAIL14SSL0636AA 49
Sealed connectors – Wire lock removal

1. With a screwdriver or pick, lift the secondary lock over
the locking tabs on either side of the connector and
remove the lock from the connector.
NOTE: If the locks and connectors are to be used again,
verify that the locking mechanisms are not bent or de-
formed.
RAIL14SSL0637AA 50
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Removal of terminals from the connectors

Special tools are required to remove the terminal without damaging it or the connector in which it is inserted. Please
use harness diagnostic and repair kit, part number 380040185, to assist you with repairs to wires, harnesses, and
connectors.
Because connectors are designed to firmly retain terminals, it is sometimes difficult to remove the terminals.
Different style terminals have different removal procedures, but the most common terminals can be removed by using
the procedure below.
A terminal removal tool (Ex: pick or safety pin) is required
to remove a push-to-seat terminal from a connector.
1. Disconnect the mating connector.
2. Remove any wire or TPA lock.
3. Grasp the wire (3) and push the terminal to the fore-
most position in the cavity of the connector (2). Hold
the terminal in this position.
4. The terminal locking tang should be separated from
the ridge inside the connector cavity. This makes it
easy for the terminal removal tool (1) to unseat the
terminal.
5. Locate the terminal lock tang in the connector cavity RAIL14SSL0638AA 51
channel by looking into the connector from the mating

end.
6. Insert an appropriately sized pick into the connector
cavity from the mating end of the connector.
7. Depress the lock tang with the pick or pin to unseat the
terminal.
8. Gently pull the wire to remove the terminal through the
back of the connector.
NOTICE: If force is required to remove the terminal, the
locking tang has not been properly depressed. Forcing a
terminal out of the connector can damage the cavity walls.
Splicing
To ensure a reliable connection, CNHi does not recommend the use of Quicksplice, Scotchlock, wire nuts, and/or
similar splicing devices.
A crimp and seal splice sleeve is recommended for splicing two wires together.
The advantages of using a crimp-and-seal splice sleeve are as follows:

• Easy to use.
• Only one part is required to complete the splice.
• Does not require soldering.
• Suitable for use in the interior and exterior of the machine.
• The bond between the splice and the wire, in addition to the wire crimp, creates a very strong splice.
When heated, these splices have a glue-lined sleeve that shrinks over the wires to seal them.
For reliable splicing, always select properly sized splice sleeve as per the wire gauge of the wires to be spliced.
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Recommended splicing procedure
Splicing single wires
1. Strip off approximately 10 mm (3/8 in) insulation from

the wire ends.
RAIL14SSL0639AA 52
2. Push the wire cores into the sleeve till they reach the
stop at the center of the sleeve.
RAIL14SSL0640AA 53
3. Individually crimp both the ends of the splice sleeve.
RAIL14SSL0641AA 54
4. With a hot air gun, apply heat to the splice sleeve.

5. Heat will melt the glue and adds a firm seal. When the
sleeve stops shrinking and glue appears at the ends
of the sleeve, remove the heat source.
6. Allow the splice to cool.
RAIL14SSL0642AA 55
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Splicing multiple wires

CNHi recommends the use of splice clip for splicing two or more wires together.
Splice clips are similar to terminal core grip wings, except that the splice clips accept more than one wire.
1. Strip off approximately 10 mm (3/8 in) insulation from

the wire ends.
RAIL14SSL0643AA 56
2. Place the stripped wires in the splice clip.
RAIL14SSL0644AA 57
3. Crimp the splice clip.

NOTICE: Do not crimp the insulation.
RAIL14SSL0645AA 58
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4. Heat the splice clip with a soldering iron and apply

solder to the splice clip.
5. Do not use too much solder. Too much solder might
lead to wicking and makes the wire brittle, resulting in
wire damage.
6. Check the continuity of the spliced wires.
7. Cover the splice with splice tape or heat shrink tubes.
RAIL14SSL0646AA 59
Harness routing guidelines

Proper harness routing must be performed to ensure the electrical system reliability. Improper routing of the harness
may lead to various electrical system malfunctions.
When repairing or replacing wire harnesses, verify that the harnesses are routed in their original position. Observe
the following safety precautions while routing the harness.
Location
Verify that the harness:
• Should not come in contact with any moving parts.
• Should be placed at least 125 mm (5 in) away from
sources of radiant heat
• Should be away from any potentially damaging sur-
faces, such as sharp or abrasive objects, sheet metal
holes, sharp metal flanges, etc.
• Should be placed at least 75 mm (3 in) away from bat-
tery vents
RAIL14SSL0647BA 60
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Verify that the bare wires (without conduit) do not contact

the hydraulic tubes and hoses.
RAIL14SSL0648AA 61
Verify that the bare wires are not secured with cable ties.
RAIL14SSL0649AA 62
Tension
Verify that the harness is not under tension. Tension is
when the strain on the harness between two fixing points
(clamps, brackets, connectors, grommets, etc) is larger
than the weight of the wiring harness.
Verify that the slack between two fixing points is not going
to cause interference with other objects/moving parts.
RAIL14SSL0650BA 63
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When the harness are to be bent, verify that the bend

radius is equal to or more than three time the harness
diameter.
RAIL14SSL0651AA 64
Image 65 is an example of a correct bend radius.
RAIL14SSL0652AA 65
Image 66 is an example of an incorrect bend radius.
RAIL14SSL0653AA 66
Harness fastening guidelines

The wiring harness must be fastened properly to avoid any possible harness damage such as incorrect routing, pinch-
ing, entrapment, and/or other conditions which would damage the wiring harness.
When installing the harness, follow their original routing positions and locations. Follow the guidelines below to verify
that the harness is fastened properly.
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Use the double tie to secure the wiring harness to isolated

points on the machine.
RAIL14SSL0654AA 67
RAIL14SSL0655AA 68
Use the dual clamp to secure the harnesses without any

contact.
RAIL14SSL0657AA 69
RAIL14SSL0658AA 70
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Grounding guidelines
A return path is necessary in an electrical circuit. In CNHi applications, the ground points are equivalent to the battery
negative terminal.
The electrical system should be properly grounded.
Use plated ground fasteners (studs, ring terminals, etc.) for better corrosion resistance.
The ground fasteners must be compatible with the ground terminals to reduce galvanic corrosion. Do not use rivets
or sheet metal screws for grounding.
Grounding surfaces must be free of sealants, paint and/or any non-conductive coatings.
Whenever possible, use ring terminals with an anti-rotation feature. In case of terminals without an anti-rotation fea-
ture, use lock washers.
RAIL14SSL0701AA 71
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Harnesses and connectors - Electrical schema index Components

MARBLE CUTTING
ID Description ID Description
A14 Antitheft unit K464 Main relay
A53 Radio (optional) K605 Side work lights relay
A95 Steering unit M1 Starter motor
A401 Trax control module M39 Rear windshield wiper motor
A461 ECU unit M41 Blower motor (optional)
A469 Glow plug control unit M49 Front windshield wiper motor
A605 DeNOx supply module M56 Front windshield washer
B4 Air filter pressure switch M57 Rear windshield washer
B5 Fuel level sender M473 Air conditioner compressor
B25 Foot throttle P125 Speedometer (optional)
B26 Bucket sender R460 CAN 2 termination relay
B30 Parking brake switch S2 4WD switch
B66 Transmission oil temperature switch S3 Hand hammer switch
B69 Air conditioning pressure switch S5 Ride control switch
B97 Front axle sensor S9 Light switch
B98 Rear axle sensor S15.1 Starting switch
B108 Transmission temperature sender S15 Beacon lamp switch
B109 Pressure switch S29 Front horn switch
B112 Speed sensor S32 Stop light switch
B463 Water in fuel sensor S33 Stop light switch
B474 Air temperature sensor S34 Left door switch
B606 Right-hand NOx sensor S35 Right door switch
B608 Urea tank S36 Rear hammer button (optional)
B608 Hand throttle S41 Windshield wiper/ lights steering column
switch
B618 Right-hand catalyst temperature sensor S42 Warning switch
B624 Left-hand NOx sensor S47 Steering switch
B633 DEF line heater 1 S48 Manual-Auto switch
B634 DEF line heater 2 S100 Optional quick coupler A switch
B805 Ride control pressure switch S101 Optional quick coupler B switch
BS1 Right speaker (optional) S135 Vertical rear lock switch
BS2 Left speaker (optional) S136 Up/down switch
E2 Left front light S137 Rear work light switch
E3 Right front light S138 Windshield washer/ wiper switch
E18 Cabin light S139 Display/ enter switch
E27 License plate light S140 Rear transport lock switch
E28 Left rear light S141 Front work light switch
E29 Right rear light S144 Rear horn button
E38 External rear work light S205a Disengage clutch button
E40 Internal rear work light S400 Gears steering column switch
E44 External front work light S604 Side work light switch
E45 Internal front work light SB1 Main switch
E46 Internal rear work light ST1 Side panel
E47 External rear work light ST3 4X1 joystick
E50 Internal front work light Y12 Proportional solenoid valves
E51 External front work light Y34 Ride control solenoid valve (optional)
E55 Socket lamp Y35 Hand hammer solenoid valve
E406 Beacon lamp Y91 Crab steering solenoid valve
E407 Right side work light Y92 Round steering solenoid valve
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E409 Left side work light Y93 4WS steering solenoid valve
E412 Beacon lamp Y94 2WS steering solenoid valve
F001 Switched battery fuse Y100 Forward speed solenoid valve
F002 Unswitched battery fuse Y102 PWM 1/3 solenoid valve
F953 Blower motor fuse Y103 PWM 2/4 solenoid valve
G1 Battery Y104 S13 solenoid valve
G67 Alternator Y105 Quick coupler solenoid valve
H2 Horn Y105 S24 solenoid valve
H3 Rear horn Y106 Load sensor solenoid valve
H7 Reverse buzzer Y113 4WD solenoid valve
H26 Backhoe transport lock light (optional) Y114 Differential gear lock solenoid valve
H606 Audible alarm Y202 Rear translation solenoid valve
K14 Transmission cut-off relay Y203 Backhoe transport lock solenoid valve
K227 4WD relay Y206 Bucket level solenoid valve
K230 Hand hammer relay Y207 Double delivery solenoid valve
K232 Ride control relay Y209 Rear hammer solenoid valve
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Harnesses and connectors - Electrical schema index Connectors

MARBLE CUTTING
X1 General cable/ engine cable connector X204 Pilot control horn button connector
X2 Chassis cable/ solenoid valves cable X205 Joystick button connector
connector
X7 Reverse speed buzzer connector X206 Crab level connector
X10 Solenoid valves cable/ general cable X207 Double delivery solenoid valve connector
connector
X12 General cable/ cabin cable connector X208 Joystick 4X1
X13 General cable/ front dashboard connector X209 Rear hammer solenoid valve connector
X14 Antitheft connector X210 Clutch shut off button connector
X15.1 Start switch connector X220 Air conditioner connector
X15.2 Start switch connector X262 Optional connector
X17 Seat connector X400 Gears steering column switch connector
X21 Horn/ left light connector X401 Trax control module connector
X22 Right light connector X402 Trax harness interface connector/ Carraro
harness interface connector
X23 General cable/ front dashboard connector X403 Trax harness interface connector/ Carraro
harness interface connector
X24 Lock valves switch connector X404 Trax harness interface connector/ front
dashboard interface connector
X25 Foot throttle connector X405 CAN bus interface connector
X26 Crab sender connector X406 Diode connector
X27 License plate light connector X406 Beacon lamp connector
X28 Right rear light connector X408 General harness/ front dashboard interface
connector
X29 Left rear light connector X409 Trax harness/ front dashboard interface
connector
X31 Fuse box general harness connector X412 Beacon lamp connector
X34 Ride control solenoid valve connector X420 Reverse speed buzzer connector
X35 Hand hammer solenoid valve connector X421 Fuel shut off diode connector
X36 Rear hammer button connector X-448 Fuse and relay connector
X38 Rear right work light connector X-449 Fuse connector
X39 Rear windshield wiper connector X450P Chassis harness/ engine harness interface
connection
X40 Rear right work light (optional) connector X-450S Chassis harness/ engine harness interface
connection
X41 Optional blower motor connector X451P Chassis harness/ engine harness interface
connection
X43 Beacon lamp connector X-451S Chassis harness/ engine harness interface
connection
X44 Front right work light connector X-460 CAN 2 termination resistor connector
X45 Front right work light (optional) connector X-461 ECU connector
X46 Rear left work light (optional) connector X-462 ECU connector
X47 Rear left work light connector X-463 Water in fuel sensor connector
X49 Front windshield wiper connector X-469 Glow control unit connector
X50 Front left work light (optional) connector X-470 Engine harness connector
X51 Front left work light connector X-471 Fuel injector connector
X53 Radio (brown color) connector X-473 Air conditioner clutch connector
X54 Radio (black color) connector X-474 Air temperature sensor connector
X55 Cigar lighter connector X-496 Front harness/ engine harness connector
X56 Front windshield washer connector X500 Telematics connector
X57 Rear windshield washer connector X501 Diagnostic connector
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X67A Alternator connector X-520 Lights output connector
X67B Alternator connector X600 General cable/ engine cable 1-pin connector
X-69 Air conditioner pressure switch X603 Quick coupler/ front dashboard connector
X72 Pilot control cable connector X603/1 Quick coupler kit connector
X87 Left side dashboard cable/ general cable X606 Buzzer connector
connector
X88 Right side dashboard cable/ general cable X607 Horn/ left light 7-pin connector
connector
X91 Crab steering solenoid valve X-607 Upstream NOx sensor connector
X92 Round steering solenoid valve X608 Hand throttle connector
X93 4WS steering solenoid valve X-611 SCR tank heat valve connector
X94 2WS steering solenoid valve X-612 HCU connector
X95 Steering unit connector X-617 Upstream catalyst temperature sensor
connector
X96 Steering unit connector X-622 Dosing valve connector
X97 Front axle sensor connector X-632 Unswitched battery connector
X98 Rear axle sensor connector X-636 Right-side pod connector
X100 Carraro harness solenoid valve connector X-637 Right-side pod connector
X101 Carraro harness solenoid valve connector X-638 Left-side pod 1 connector
X105 Carraro harness solenoid valve connector X800 Front harness/ engine harness interface
connector
X108 Carraro harness transmission temperature X801 Front harness/ general harness interface
sensor connector connector
X109 Carraro harness pressure switch connector X805 Ride control pressure switch connector
X110 Air conditioner connector XC1 Onboard 11-pin connector
X111 Air conditioner connector XC2 Onboard 7-pin connector
X112 Air conditioner fuse connector XC3 Onboard 21-pin connector
X113 Carraro harness solenoid valve connector XC4 Onboard 21-pin connector
X114 Carraro harness solenoid valve connector XC5 Onboard 17-pin connector
X125 Front panel connector XC6 Onboard 13-pin connector
X201.s One touch decel connector XX Diode connector
X201.p One touch decel connector XST1 Side multifunction panel 26-pin connector
X202 Rear translation lock solenoid valve XST2 Side multifunction panel 26-pin connector
X203 Excavator rear lock solenoid valve
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580ST STAGE IV, SIDE-SHIFT (SS), FOUR-WHEEL DRIVE (4WD), Transmission - Powershift transmission
MARBLE CUTTING
580ST STAGE IV, STRAIGHT LOADER ARM (SLA), SIDE SHIFT (SS), Transmission - Powershift transmission
580ST STAGE IV, TOOL CARRIER (TC), SIDE SHIFT (SS), TWO-WHEEL Transmission - Powershift transmission
DRIVE (2WD)
590ST STAGE IV, TOOL CARRIER (TC), SIDE SHIFT (SS), FOUR-WHEEL Transmission - Powershift transmission
DRIVE (4WD)
A14 Antitheft unit M1 Starter motor
A53 Radio (optional) M39 Rear windshield motor wiper
A461 ECU unit M41 Blower motor (optional)
A469 Glow plug control unit M49 Front windshield wiper
A605 DeNOx supply module M56 Front windshield washer
B4 Air filter pressure switch M57 Rear windshield washer
B5 Fuel level sender M473 Air conditioner compressor
B25 Foot throttle P125 Speedometer (optional)
B26 Bucket sender R460 CAN 2 termination relay
B30 Parking brake switch R608 Hand throttle
B66 Transmission oil temperature switch S2 4WD switch
B69 Air conditioner pressure switch S3 Hand hammer switch
B108 Transmission temperature sender S5 Ride control switch
B109 Pressure switch S9 Light switch
B112 Speed sensor S15.1 Starting switch
B463 Water in fuel sensor S15 Beacon lamp switch
B474 Air temperature sensor S29 Front horn switch
B606 Right-hand NOx sensor S32 Stop light switch
B608 Urea tank S33 Stop light switch
B618 Right-hand catalyst temperature sensor S34 Left door switch
B624 Left-hand NOx sensor S35 Right door switch
B633 DEF line heater 1 S36 Rear hammer button (optional)
B634 DEF line heater 2 S41 Windshield wiper/ lights steering column
switch
B805 Ride control pressure switch S42 Warning switch
BS1 Right speaker (optional) S48 Manual/ auto switch
BS2 Left speaker (optional) S100 Optional quick coupler A switch
E2 Left front light S101 Optional quick coupler B switch
E3 Right front light S135 Vertical rear lock switch
E18 Cabin light S136 Up/down switch
E27 License plate light S137 Rear work light switch
E28 Left rear light S138 Windshield washer/ wiper switch
E29 Right rear light S139 Display/ enter switch
E38 External rear work light S140 Rear transport lock switch
E40 Internal rear work light S141 Front work light switch
E44 External front work light S144 Rear horn button
E45 Internal front work light S205a Disengage clutch button
E46 Internal rear work light S205b Differential lock button
E47 External rear work light S400 Gears steering column switch
E50 Internal front work light S604 Side work lights switch
E51 External front work light SB1 Main switch
E55 Socket lamp ST1 Side panel
E406 Beacon lamp ST3 4X1 joystick
E407 Right side work light Y12 Proportional solenoid valves
E409 Left side work light Y34 Ride control solenoid valve (optional)
E412 Beacon lamp Y35 Hand hammer solenoid valve
F001 Switched battery fuse Y100 Forward speed solenoid valve
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F002 Unswitched battery fuse Y101 Reverse speed solenoid valve
F953 Blower motor fuse Y102 PWM 1/3 solenoid valve
G1 Battery Y103 PWM 2/4 solenoid valve
G67 Alternator Y104 S13 solenoid valve
H2 Horn Y105 Quick coupler solenoid valve
H3 Rear horn Y105 S24 solenoid valve
H7 Reverse buzzer Y106 Load sensor solenoid valve
H26 Backhoe transport lock light (optional) Y113 4WD solenoid valve
H606 Audible alarm Y114 Differential gear lock solenoid valve
K14 Transmission cut off relay Y202 Rear translation solenoid valve
K227 4WD relay Y203 Backhoe transport lock solenoid valve
K230 Hand hammer relay Y206 Bucket level solenoid valve
K232 Ride control relay Y207 Double delivery solenoid valve
K464 Main relay Y209 Rear hammer solenoid valve
K605 Side work lights relay
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MARBLE CUTTING
DRIVE (2WD)
DRIVE (4WD)
X1 General cable/ engine cable connector X208 Joystick 4X1
X2 Chassis cable/ solenoid valves cable X209 Rear hammer solenoid valve connector
connector
X7 Reverse speed buzzer connector X210 Clutch shut off button connector
X10 Solenoid valves cable/ general cable X220 Air conditioner connector
connector
X12 General cable/ cabin cable connector X262 Optional connector
X13 General cable/ front dashboard connector X400 Gears steering column switch connector
X14 Antitheft connector X401 Trax control module connector
X15.1 Start switch connector X402 Trax harness/ Carraro harness interface
connector
X15.2 Start switch connector X403 Trax harness/ Carraro harness interface
connector
X17 Seat connector X404 Trax harness/ front dashboard interface
connector
X21 Horn/ left light connector X405 CAN bus interface connector
X22 Right light connector X406 Diodes connector
X23 General cable/ front dashboard connector X406 Beacon lamp connector
X24 Lock valves switch connector X408 General harness/ front dashboard interface
connector
X25 Foot throttle connector X409 Trax harness/ front dashboard interface
connector
X26 Crab sender connector X412 Beacon lamp connector
X27 License plate light connector X420 Reverse speed buzzer connector
X28 Right rear light connector X421 Fuel shut off diode connector
X29 Left rear light connector X-448 Fuse and relay connector
X31 Fuse box general harness connector X-449 Fuse connector
X34 Ride control solenoid valve connector X450P Chassis harness/ engine harness interface
connection
X35 Hand hammer solenoid valve connector X-450S Chassis harness/ engine harness interface
connection
X36 Rear hammer button connector X451P Chassis harness/ engine harness interface
connection
X38 Rear right work light connector X-451S Chassis harness/ engine harness interface
connection
X39 Rear windshield wiper connector X-460 CAN 2 termination resistor connector
X40 Rear right work light (optional) connector X-461 ECU connector
X41 Optional blower motor connector X-462 ECU connector
X43 Beacon lamp connector X-463 Water in fuel sensor connector
X44 Front right work light connector X-469 Glow control unit connector
X45 Front right work light (optional) connector X-470 Engine harness connector
X46 Rear left work light (optional) connector X-471 Fuel injector connector
X47 Rear left work light connector X-473 Air conditioner clutch connector
X49 Front windshield wiper connector X-474 Air temperature sensor connector
X50 Front left work light (optional) connector X-496 Front harness/ engine harness connector
X51 Front left work light connector X500 Telematics connector
X53 Radio (brown color) connector X501 Diagnostic connector
X54 Radio (black color) connector X-520 Lights output connector
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X55 Cigar lighter connector X-600 General cable/ engine cable connector
X56 Front windshield washer connector X-603 Quick coupler/ front dashboard connector
X57 Rear windshield washer connector X-603/1 Quick coupler kit connector
X67A Alternator connector X-606 Buzzer connector
X67B Alternator connector X-607 Horn/ left light connector
X-69 Air conditioner pressure switch X-607 Upstream NOx sensor connector
X72 Pilot control cable connector X607 Diagnostic connector
X87 Left side dashboard cable/ general cable X-608 Hand throttle connector
connector
X88 Right side dashboard cable/ general cable X-611 SCR tank heat valve connector
connector
X100 Carraro harness solenoid valve connector X-612 HCU connector
X101 Carraro harness solenoid valve connector X-617 Upstream catalyst temperature sensor
connector
X102 Carraro harness solenoid valve connector X-622 Dosing valve connector
X103 Carraro harness solenoid valve connector X-632 Unswitched battery connector
X108 Carraro harness transmission temperature X-638 Left-side pod 1 connector
connector
X109 Carraro harness pressure switch connector X-639 Left-side pod 1 connector
X110 Air conditioner connector X-640 Left-side pod 2 connector
X111 Air conditioner connector X-641 Left-side pod 2 connector
X112 Air conditioner fuse connector X-800 Front harness/ engine harness interface
connector
X113 Carraro harness solenoid valve connector X-801 Front harness/ general harness interface
connector
X114 Carraro harness solenoid valve connector X-805 Ride control pressure switch connector
X125 Front panel connector XST1 Side multifunction panel connector
X201.S One touch decel connector XST2 Side multifunction panel connector
X201.P One touch decel connector XC1 Onboard connector
X202 Rear translation lock solenoid valve XC2 Onboard connector
X203 Excavator rear lock solenoid valve connector XC3 Onboard connector
X204 Pilot control horn button connector XC4 Onboard connector
X205 Joystick button connector XC5 Onboard connector
X206 Crab level connector XC6 Onboard connector
X207 Double delivery solenoid valve connector XX Diode connector
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580ST STAGE IV, SIDE-SHIFT (SS), FOUR-WHEEL DRIVE (4WD), Transmission - Power Shuttle
MARBLE CUTTING
580ST STAGE IV, STRAIGHT LOADER ARM (SLA), SIDE SHIFT (SS), Transmission - Power Shuttle
580ST STAGE IV, TOOL CARRIER (TC), SIDE SHIFT (SS), TWO-WHEEL Transmission - Power Shuttle
DRIVE (2WD)
590ST STAGE IV, TOOL CARRIER (TC), SIDE SHIFT (SS), FOUR-WHEEL Transmission - Power Shuttle
DRIVE (4WD)
A14 Antitheft unit K605 Side work lights relay
A53 Radio (optional) M1 Starter motor
A461 ECU unit M39 Rear windshield motor wiper
A469 Glow plug control unit M41 Blower motor (optional)
A605 DeNOx supply module M49 Front windshield wiper
B4 Air filter pressure switch M56 Front windshield washer
B5 Fuel level sender M57 Rear windshield washer
B25 Foot throttle M473 Air conditioner compressor
B26 Bucket sender P1 Side instrument panel
B30 Parking brake switch P125 Speedometer (optional)
B66 Transmission oil temperature switch R460 CAN 2 termination relay
B69 Air conditioning pressure switch R608 Hand throttle
B411 Speed sensor S2 4WD switch
B463 Water in fuel sensor S3 Hand hammer switch
B474 Air temperature sensor S5 Ride control switch
B606 Right-hand NOx sensor S9 Light switch
B608 Urea tank S15.1 Starting switch
B618 Right-hand catalyst temperature sensor S15 Beacon lamp switch
B624 Left-hand NOx sensor S32 Stop light switch
B633 DEF line heater 1 S33 Stop light switch
B634 DEF line heater 2 S34 Left door switch
B805 Ride control pressure switch S35 Right door switch
BS1 Left speaker (optional) S36 Rear hammer button (optional)
BS2 Right speaker (optional) S41 Windshield wiper/ lights steering column
switch
E2 Left front light S42 Warning switch
E3 Right front light S100 Optional quick coupler A switch
E18 Cabin light S101 Optional quick coupler B switch
E27 License plate light S132 Gear shift steering column switch
E28 Left rear light S135 Vertical rear lock switch
E29 Right rear light S136 Up/down switch
E38 External rear work light S137 Rear work light switch
E40 Internal rear work light (optional) S138 Rear windshield washer/ wiper switch
E44 External front work light S139 Display/enter switch
E45 Internal front work light (optional) S140 Rear transport lock switch (optional)
E46 Internal rear work light (optional) S141 Front work light switch
E47 External rear work light S144 Rear horn button
E50 Internal front work light (optional) S169 Transmission switch
E51 External front work light S205a Declutch button
E55 Cigar lighter S205b Differential lock button
E406 Beacon lamp S210 Disengage clutch button
E407 Right side work light S604 Side work light switch
E409 Left side work light SB1 Main switch
E412 Beacon lamp ST1 Side panel
F001 Switched battery fuse ST3 4X1 joystick
F002 Unswitched battery fuse Y6 Forward speed 2-pin connector
F953 Blower motor fuse Y8 4WD solenoid valve connector
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G1 Battery Y12 Proportional solenoid valves
G67 Alternator Y34 Ride control solenoid valve (optional)
H2 Horn Y35 Hand hammer solenoid valve
H3 Rear horn Y74 Differential gear lock solenoid valve
H7 Reverse buzzer Y105 Quick coupler solenoid valve
H26 Block control lamp Y106 Load sense solenoid valve
H606 Audible alarm Y200 Reverse speed solenoid valve
K224 Differential gear lock relay Y202 Rear translation solenoid valve
K226 4WD relay Y203 Backhoe transport lock solenoid valve
K230 Hand hammer relay Y206 Bucket level solenoid valve
K232 Ride control relay Y207 Double delivery solenoid valve
K464 Main relay Y261 Rear hammer solenoid valve
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MARBLE CUTTING
DRIVE (2WD)
DRIVE (4WD)
X1 General cable/ engine cable connector X206 Bucket level connector
X6 Forward solenoid valve connector X207 Double delivery solenoid valve connector
X7 Reverse speed buzzer connector X208 4X1 joystick connector
X8 4WD solenoid valve connector X209 Rear hammer solenoid valve connector
X10 Solenoid valves cable/ general cable X210 Clutch shut off button connector
connector
X12 General cable/ cabin connector X220 Air conditioner connector
X14 Antitheft connector X406 Rotating beacon lamp connector
X15.1 Starter switch connector X411 Speed sensor connector
X15.2 Starter switch connector X412 Rotating beacon lamp connector
X17 Seat optional connector X421 Fuel shut off diode connector
X19 Gears steering column connector X-448 Fuses and relays connector
X22 Right light connector X-449 Fuses connector
X24 Lock valves switch connector X450P Chassis harness/ engine harness interface
connector
X25 Foot throttle connector X-450S Chassis harness/ engine harness interface
connector
X26 Grab sender connector X451P Chassis harness/ engine harness interface
connector
X27 License plate light connector X-451S Chassis harness/ engine harness interface
connector
X28 Right rear light connector X-460 CAN 2 termination resistor
X29 Left rear light connector X-461 Electronic control unit connector
X31 Fuse box general harness connector X-462 Electronic control unit connector
X34 Ride control connector X-463 Water in fuel connector
X35 Hand hammer solenoid valve connector X-469 Glow plug control unit connector
X36 Rear hammer button connector X-470 Engine interface connector
X38 Rear right work light connector X-471 Fuel injector connector
X39 Rear windshield wiper motor connector X-473 Air conditioner clutch connector
X40 Rear right work light connector X-474 Air temperature sensor connector
X41 Fan motor connector X-496 Front harness/ engine harness interface
connector
X43 Beacon light connector X500 Telematics connector
X44 Front right work light connector X501 Diagnostic connector
X45 Front right work light connector X520 Light output connector
X46 Rear left work light connector X600 General cable/ engine cable connector
X47 Rear left work light connector X603 Quick coupler front dashboard
X49 Front windshield wiper connector X603/1 Quick coupler kit connector
X50 Front left work light connector X606 Buzzer connector
X51 Front left work light connector X-607 Upstream NOx sensor connector
X53 Radio connector X-607 Horn/ left light connector
X54 Radio connector X-607 Diagnostic plug connector
X55 Auxiliary 12V socket X-608 Hand throttle connector
X56 Front windshield washer pump connector X-611 SCR tank heat valve connector
X57 Rear windshield washer pump connector X-612 HCU connector
X67A Alternator connector X-617 Upstream catalysts temperature sensor
connector
X-069 Air conditioner pressure switch X-622 Dosing valve connector
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X72 Pilot control module connector X-632 Unswitched battery connector
X87 Left side dashboard/ general harness X-636 Right side pod connector
interface connector
X88 Right side dashboard/ general harness X-637 Right side pod connector
interface connector
X102 Diode connector X-638 Left side pod1 connector
X105 Quick coupler connection solenoid valve X-641 Left side pod2 connector
connector
X106 Cell load sensor solenoid valve connector X800 Front harness/ engine harness interface
connector
X110 Air conditioner connector X801 Front harness/ engine harness interface
connector
X111 Air conditioner connector X805 Ride control pressure switch connector
X112 Air conditioner fuse connector XST1 Side panel connector
X125 Front panel connector XST2 Side panel connector
X140 Diodes connector XC1 General/ fuses and relays unit harness
interface connector
X-200 Reverse speed solenoid valve connector XC2 General/ fuses and relays unit harness
interface connector
X201.s One touch decel connector XC3 General/ fuses and relays unit harness
interface connector
X201.p One touch decel connector XC4 General/ fuses and relays unit harness
interface connector
X202 Rear translation solenoid valve connector XC5 General/ fuses and relays unit harness
interface connector
X203 Bucket lock transport solenoid valve connector XC6 General/ fuses and relays unit harness
interface connector
X204 Pilot control horn switch connector XX Diodes connector
X205 Joystick button switch
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Harnesses and connectors - Drawing Anti-tipping sensor switch

harness
RAIL17TLB0293FA 1
Connector number/ pin Wire color/ size Function name Destination

number
X2.s pin A WH - 1.0 Buzzer (-) X4.2 pin 1
X2.s pin B GN - 1.0 Ground X7
X3 pin 1 LB - 1.0 Buzzer (pulse) X4.1 pin 1
X3 pin 2 RD - 1.0 Switched battery Splice
X3 pin 6 BK - 1.0 Ground X7
X4.1 pin 1 LB - 1.0 Buzzer (pulse) X3 pin 1
X4.1 pin 2 WH - 1.0 Buzzer - X2.s pin A
X5 pin 1 OR1 - 4.0 Switched battery fuse Fuse
X5 pin 2 OR2 - 4.0 Switched battery X6
X6 OR2 - 4.0 Switched battery X5 pin 2
X7 GN - 1.0 Ground X2.s pin B
BK - 1.0 Ground X3 pin 6
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Wiring harnesses - Electrical schematic sheet 01 Sheet 1 Engine

cable
MARBLE CUTTING
1 Seat option
2 Side panel
3 Diagnostic plug
4 Optional
5 Fuse panel
6 Telematics connector
7 Diagnostic
8 From pilot control cable sheet 13
9 One touch decel sheet 13
10 Connector X-450 connects to X-450P on sheet 1B
11 Not connected
12 Anti-theft
13 Jump start terminal
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RAIL17TLB0086JA 1
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Wiring harnesses - Electrical schematic sheet 01 Sheet 1A Engine cable

CUTTING
1 Connects to engine harness connector X-470

2 Glow control unit
3 X-611 SCR tank heat valve
4 X-617 Upstream catalyst temperature sensor
5 HCU
6 Right-hand NOx sensor
8 Right-hand catalyst temperature sensor
9 DEF line heater 2
10 DEF line heater 1
11 Urea tank
12 DeNOx supply module
13 R460 10 Ω 1 W resistor
14 Upstream NOx temperature sensor
15 Water in fuel sensor
16 Electric valve
17 Dosing valve
18 ECU unit
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RAIL17TLB0087JA 1
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Wiring harnesses - Electrical schematic sheet 01 Sheet 1B Engine cable

CUTTING
1 X-450P connects to X-450S on sheet 1
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RAIL17TLB0088JA 1
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Wiring harnesses - Electrical schematic sheet 02 Sheet 2 Solenoid

valves cable
CUTTING
1 Connects with sheet 10

2 Fuse panel
3 To pilot claxon switch
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RAIL17TLB0089JA 1
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valves cable
CUTTING
1 Optional speedometer
2 Valves block switch supply
3 Optional rear quick coupler see sheet 9
4 Bidirectional PWM driver
5 Proportional roller
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RAIL17TLB0090JA 1
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Wiring harnesses - Electrical schematic sheet 04 Sheet 4 Lights cable

CUTTING
1 Fuse panel
2 To pilot control module connects to page 13
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RAIL17TLB0091JA 1
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Wiring harnesses - Electrical schematic sheet 05 Sheet 5 Rear lights

cable
CUTTING
1 Fuse panel
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RAIL17TLB0092JA 1
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Wiring harnesses - Electrical schematic sheet 06 Sheet 6 Work lights

cable
CUTTING
1 Fuse panel
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RAIL17TLB0093JA 1
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Wiring harnesses - Electrical schematic sheet 07 Sheet 7 Windshield

wiper/ washer cable
CUTTING
1 Fuse panel
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RAIL17TLB0094JA 1
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Wiring harnesses - Electrical schematic sheet 08 Sheet 8 Heater (radio)

cable
CUTTING
1 Fuse panel
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RAIL17TLB0095JA 1
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Wiring harnesses - Electrical schematic sheet 09 Sheet 9 Quick coupler

option
CUTTING
1 Optional attachment
2 Connects to sheet 3
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RAIL17TLB0096JA 1
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Wiring harnesses - Electrical schematic sheet 10 Sheet 10 Trax control

module harness
CUTTING

2 TRAX control module
3 Unswitched battery
4 In-gear signal
5 Forward valve 1
6 Reverse valve 1
7 Switched battery
8 PWM 1
9 PWM 2
10 Switched battery
11 S13 valve
12 Differential lock solenoid
13 Forward valve 2
14 PWM 1
15 Neutral signal
16 Forward signal
17 Gear command 02
18 4-wheel steer signal
19 Declutch
20 4-wheel drive
21 Auto-manual
22 Speed sensor
23 CAN high
24 Speed sensor out
25 Ground
26 Switched battery
27 S24 valve
28 4WD solenoid
29 Reverse valve 2
30 PWM 2
31 Temperature signal
32 Pressure switch
33 Reverse signal
34 Gear command 01
35 Solenoid 3A
36 Kickdown
37 Stop switch out
38 Differential lock signal
39 W generator signal (from the alternator)
40 CAN low
41 Signal ground
42 X-901 console frame ground
43 Carraro transmission harness
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RAIL17TLB0166JA 1
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Wiring harnesses - Electrical schematic sheet 11 Sheet 11 Transmission

CUTTING
1 Steering crab valve

2 4WS switch
3 Round steering valve
4 +Front axle
5 +Rear axle
6 Steering wheel valve
7 Steering unit
8 Steering crab control lamp
9 Front axle signal
10 Steering crab control
11 Buzzer control
12 Round steering control
13 Steering power supply
14 Ground
15 Speed sensor 2
16 Rear axle signal
17 2 steering wheels valve
18 Round steering control lamp
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RAIL17TLB0098JA 1
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Wiring harnesses - Electrical schematic sheet 12 Sheet 12 Air 1 No connect

2 Evaporator signal
conditioner kit 3 Sensor ground
695ST STAGE IV, SIDE-SHIFT (SS), FOUR-WHEEL DRIVE (4WD), MARBLE 4 Analog ground
CUTTING
5 Switch battery
695ST STAGE IV, TOOL CARRIER (TC), SIDE SHIFT (SS) 6 Mix control
7 Mix control signal
8 A/C in
9 A/C request
10 Vel 1
11 HVAC
12 Electronic ground
13 Common phase B2
14 Common phase B1
15 Common phase A2
16 Stepper
17 Common phase A1
18 Customer side
19 Control panel
20 Legend
21 Name
22 HVAC
23 Control panel
24 Input / output
A HVAC
B Mix actuator
C Evaporator sensor
D Blower motor
E Resistor
F High speed relay
G Power supply relay
H Fuse folder
J Mix control
K A/C on/off rotary switch
L Blower motor speed control rotary switch
M Input/ output signal connector
N Input/ output signal connector
P Blower motor power connector
R Blower motor power connector
S Input/ output signal connector
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RAIL17TLB0099JA 1
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Wiring harnesses - Electrical schematic sheet 13 Sheet 13 Pilot control

module
CUTTING
1 To solenoid valves line sheet 1

2 Left joystick horn button
3 Safety switch
4 Pilot control kit
5 LVC
6 Retract
7 Right joystick
8 Extend
9 One touch decel switch
10 To solenoid valves line one touch decel
11 Pattern valve 2
12 Pattern valve 1
13 Right-hand stabilizer pressure switch
14 Left-hand stabilizer pressure switch
15 Right-hand stabilizer joystick
16 Left-hand stabilizer joystick
17 Plug 8 retract
18 Plug 7 extend
19 Plug 5 right-hand stabilizer down
20 Plug 6 right-hand stabilizer up
21 Plug 3 left-hand stabilizer down
22 Plug 4 left-hand stabilizer up
23 Manifold power
24 Horn jumper connection X-008 sheet 4
25 Plug 10 Auxiliary forward
26 Plug 9 Auxiliary reverse
27 Bidirectional reverse
28 Left joystick
29 Bidirectional forward
30 Pattern switch
31 Pilot control module On/Off switch
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RAIL17TLB0100JA 1
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Wiring harnesses - Electrical schematic sheet 01 Sheet 1 Engine cable

580ST STAGE IV, SIDE-SHIFT (SS), FOUR-WHEEL DRIVE (4WD), MARBLE Transmission - Powershift transmission
CUTTING
DRIVE (2WD)
DRIVE (4WD)
1 Seat option
2 Side panel
3 Diagnostic plug
4 Fuse panel
6 Diagnostic
7 One tough decel sheet 12
8 From pilot control module cable sheet 12
9 X-450S connects to X-450P on sheet 1B
10 Not connected
11 Antitheft
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RAIL17TLB0101JA 1
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CUTTING
DRIVE (2WD)
DRIVE (4WD)

2 Glow control unit
5 HCU
9 DEF line heater 2
11 Urea tank
16 Electric valve
17 Dosing valve
18 ECU unit
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RAIL17TLB0102JA 1
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CUTTING
DRIVE (2WD)
DRIVE (4WD)
1 X-450P connects to X-450S on sheet 1
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RAIL17TLB0103JA 1
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valves cable
CUTTING
DRIVE (2WD)
DRIVE (4WD)
1 Connects on page 10
2 Fuse panel
3 To pilot claxon switch
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RAIL17TLB0104JA 1
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valves cable
CUTTING
DRIVE (2WD)
DRIVE (4WD)
2 Valves block supply switch
3 Optional rear coupler see sheet 9
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RAIL17TLB0105JA 1
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CUTTING
DRIVE (2WD)
DRIVE (4WD)
1 Fuse panel
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RAIL17TLB0106JA 1
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cable
CUTTING
DRIVE (2WD)
DRIVE (4WD)
1 Fuse panel
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RAIL17TLB0107JA 1
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cable
CUTTING
DRIVE (2WD)
DRIVE (4WD)
1 Fuse panel
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RAIL17TLB0108JA 1
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wiper/ washer cable
CUTTING
DRIVE (2WD)
DRIVE (4WD)
1 Fuse panel
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RAIL17TLB0109JA 1
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cable
CUTTING
DRIVE (2WD)
DRIVE (4WD)
1 Fuse panel
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RAIL17TLB0110JA 1
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option
CUTTING
DRIVE (2WD)
DRIVE (4WD)
2 Connect to sheet 3
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RAIL17TLB0111JA 1
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Wiring harnesses - Electrical schematic sheet 10 Sheet 10 Trax control

module harness
CUTTING
DRIVE (2WD)
DRIVE (4WD)

2 TRAX control module
3 Unswitched battery
4 In-gear signal
5 Forward valve 1
6 Reverse valve 1
7 Switched battery
8 PWM 1
9 PWM 2
10 Switched battery
11 S13 valve
12 Differential lock solenoid
13 Forward valve 2
14 PWM 1
15 Neutral signal
16 Forward signal
17 Gear command 02
18 4-wheel steer signal
19 Declutch
20 4-wheel drive
21 Auto-manual
22 Speed sensor
23 CAN high
24 Speed sensor out
25 Ground
26 Switched battery
27 S24 valve
28 4WD solenoid
29 Reverse valve 2
30 PWM 2
31 Temperature signal
32 Pressure switch
33 Reverse signal
34 Gear command 01
35 Solenoid 3A
36 Kickdown
37 Stop switch out
38 Differential lock signal
39 W generator signal (from the alternator)
40 CAN low
41 Signal ground
42 X-901 console frame ground
43 Carraro transmission harness
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RAIL17TLB0112JA 1
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Wiring harnesses - Electrical schematic sheet 11 Sheet 11 Air conditioner 1 No connect

2 Evaporator signal
kit 3 Sensor ground
580ST STAGE IV, SIDE-SHIFT (SS), FOUR-WHEEL DRIVE (4WD), MARBLE Transmission - Powershift transmission 4 Analog ground
CUTTING
5 Switch battery
FOUR-WHEEL DRIVE (4WD) 6 Mix control
580ST STAGE IV, TOOL CARRIER (TC), SIDE SHIFT (SS), TWO-WHEEL Transmission - Powershift transmission 7 Mix control signal
DRIVE (2WD)
590ST STAGE IV, TOOL CARRIER (TC), SIDE SHIFT (SS), FOUR-WHEEL Transmission - Powershift transmission 8 A/C in
DRIVE (4WD) 9 A/C request
10 Vel 1
11 HVAC
13 Common phase B2
14 Common phase B1
15 Common phase A2
16 Stepper
17 Common phase A1
18 Customer side
19 Control panel
20 Legend
21 Name
22 HVAC
23 Control panel
24 Input / output
25 Not used
26 Fuse panel
A HVAC
B Mix actuator
C Evaporator sensor
D Blower motor
E Resistor
F High speed relay
H Fuse folder
J Mix control
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RAIL17TLB0113JA 1
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module
CUTTING
DRIVE (2WD)
DRIVE (4WD)

3 Safety switch
4 Pilot control kit
5 LVC
6 Retract
7 Right joystick
8 Extend
11 Pattern valve 2
12 Pattern valve 1
17 Plug 8 retract
18 Plug 7 extend
23 Manifold power
28 Left joystick
30 Pattern switch
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RAIL17TLB0114JA 1
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Wiring harnesses - Electrical schematic sheet 01 Sheet 1 Engine cable

580ST STAGE IV, SIDE-SHIFT (SS), FOUR-WHEEL DRIVE (4WD), MARBLE Transmission - Power Shuttle
CUTTING
DRIVE (2WD)
DRIVE (4WD)
1 Seat option
2 Side panel
3 Diagnostic plug
4 Fuse panel
6 Diagnostic
7 One touch decel sheet 11
8 From pilot control cable sheet 11
9 X-450P connects to X-450S sheet 1B
10 Not used
11 Antitheft
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RAIL17TLB0115JA 1
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CUTTING
DRIVE (2WD)
DRIVE (4WD)

2 Glow control unit
5 HCU
9 DEF line heater 2
11 Urea tank
16 Electric valve
17 Dosing valve
18 ECU unit
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RAIL17TLB0116JA 1
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CUTTING
DRIVE (2WD)
DRIVE (4WD)
1 X-450P connects to X-450S sheet 1
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RAIL17TLB0117JA 1
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valves cable
CUTTING
DRIVE (2WD)
DRIVE (4WD)
1 Fuse panel
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RAIL17TLB0118JA 1
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Wiring harnesses - Electrical schematic sheet 03 Sheet 3 solenoid

valves cable
CUTTING
DRIVE (2WD)
DRIVE (4WD)
2 Valves block switch supply
3 Optional rear quick coupler see sheet 9
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RAIL17TLB0119JA 1
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CUTTING
DRIVE (2WD)
DRIVE (4WD)
1 Fuse panel
2 Side console horn button
3 To pilot control connection sheet 11
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RAIL17TLB0120JA 1
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cable
CUTTING
DRIVE (2WD)
DRIVE (4WD)
1 Fuse panel
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RAIL17TLB0121JA 1
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cable
CUTTING
DRIVE (2WD)
DRIVE (4WD)
1 Fuse panel
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RAIL17TLB0122JA 1
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wiper/ washer cable
CUTTING
DRIVE (2WD)
DRIVE (4WD)
1 Fuse panel
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RAIL17TLB0123JA 1
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cable
CUTTING
DRIVE (2WD)
DRIVE (4WD)
1 Fuse panel
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RAIL17TLB0124JA 1
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option
CUTTING
DRIVE (2WD)
DRIVE (4WD)
2 Connect to sheet 3
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RAIL17TLB0125JA 1
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Wiring harnesses - Electrical schematic sheet 10 Sheet 10 Air 1 No connect

2 Evaporator signal
conditioner kit 3 Sensor ground
580ST STAGE IV, SIDE-SHIFT (SS), FOUR-WHEEL DRIVE (4WD), MARBLE Transmission - Power Shuttle 4 Analog ground
CUTTING
5 Switch battery
FOUR-WHEEL DRIVE (4WD) 6 Mix control
580ST STAGE IV, TOOL CARRIER (TC), SIDE SHIFT (SS), TWO-WHEEL Transmission - Power Shuttle 7 Mix control signal
DRIVE (2WD)
590ST STAGE IV, TOOL CARRIER (TC), SIDE SHIFT (SS), FOUR-WHEEL Transmission - Power Shuttle 8 A/C in
DRIVE (4WD) 9 A/C request
10 Vel 1
11 HVAC
13 Common phase B2
14 Common phase B1
15 Common phase A2
16 Stepper
17 Common phase A1
18 Customer side
19 Control panel
20 Legend
21 Name
22 HVAC
23 Control panel
24 Input / output
25 Fuse panel
A HVAC
B Mix actuator
C Evaporator sensor
D Blower motor
E Resistor
F High speed relay
H Fuse folder
J Mix control
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RAIL17TLB0126JA 1
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module
CUTTING
DRIVE (2WD)
DRIVE (4WD)

3 Safety switch
4 Pilot control kit
5 LVC
6 Retract
7 Right joystick
8 Extend
11 Pattern valve 2
12 Pattern valve 1
17 Plug 8 retract
18 Plug 7 extend
23 Manifold power
28 Left joystick
30 Pattern switch
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RAIL17TLB0127JA 1
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Wire connectors - Component diagram 00 Connectors power and

ground
MARBLE CUTTING
UNSWITCHED BATTERY CONNECTOR
RAIL17TLB0314AA 1
Pin From Wire Description Color-Size Frame

1 SA6 E3 Unswitched battery RD- 10.0 SHEET 01
SWITCHED BATTERY CONNECTOR
RAIL17TLB0315AA 2

1 X15.2 pin 6 C6 Switched battery DB - 6.0 SHEET 01
GND1 - GROUND CONNECTION
Located on harness 47872851
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RAIL17TLB0297AA 3

1 X4.2 pin 1 L2 Ground BK - 1.0 SHEET 01 SHEET 01 SHEET 04
X5 pin 2 X5 pin 2 C1 Ground BK - 1.0
U1 Ground BK - 2.5
GND2 - GROUND CONNECTION
RAIL17TLB0297AA 4

1 GND A3 Ground BK - 2.5 SHEET 01 SHEET 02 SHEET 03
S2 pin 4 E2 Ground BK - 1.0
S5 pin 9 P1 Ground BK - 1.0
GND - GROUND CONNECTOR
RAIL17TLB0316AA 5
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1 GND.1 V2 Ground BK - 1.5 SHEET 01
X10.p pin 2 Z Ground BK - 1.5
X10.p pin 3 A1 Ground BK - 1.5
SA103 O8 Ground BK - 1.0
GND.1 - GROUND CONNECTOR
RAIL17TLB0302AA 6

1 X607 pin A W2 Ground BK - 1.0 SHEET 01
H26.2 pin 1 C3 Ground BK - 1.0
XST2 pin 26 X2 Ground BK - 1.0
GND V2 Ground BK - 1.5
X23.s pin 2 T2 Ground BK - 1.5
X23.s pin 11 Z2 Ground BK - 1.5
X25 pin 1 R Ground BK - 1.0
X28 pin 1 A3 Ground BK - 1.0
X27 pin 1 B3 Ground BK - 1.0
X7 pin 1 D3 Ground BK - 1.0
X29 pin 1 U2 Ground BK - 1.0
RAIL17TLB0302AA 7

1 X110 pin 2 Q Ground BK - 4.0 SHEET 01
X30.2 pin 1 N2 Ground BK - 1.0
X605 pin 86 L2 Ground BK - 1.0
X88.p pin 14 R2 Ground BK - 1.0
X95 pin 8 Q2 Ground BK - 1.0
X1 pin 6 C2 Ground BK - 2.5
X606 pin B S2 Ground BK - 1.0
X14.s pin 3 M2 Ground BK - 1.0
X14.s pin 4 P2 Ground BK - 1.0
X88.p pin 6 O2 Ground BK - 1.0
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RAIL17TLB0302AA 8

1 X10.s pin 2 A1 Ground BK - 1.5 SHEET 01
X93 pin 2 V Ground BK - 1.0
X208.s pin 1 B1 Ground BK - 1.0
X209 pin 2 X Ground BK - 1.0
X91 pin 2 Z Ground BK - 1.0
X204 pin 1 W Ground BK - 1.0
RAIL17TLB0302AA 9

1 X10.s pin 3 O Ground BK - 1.5 SHEET 01
X34 pin 2 K Ground BK - 1.0
X92 pin 2 P Ground BK - 1.0
X94 pin 2 M Ground BK - 1.0
X95 pin C N Ground BK - 1.0
X206 pin 2 L Ground BK - 1.0
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RAIL17TLB0302AA 10

1 X207 pin 2 H Ground BK - 1.0 SHEET 01
X203 pin 2 D Ground BK - 1.0
X35 pin 2 G Ground BK - 1.0
97 pin C F Ground BK - 1.0
X26 pin B E Ground BK - 1.0
F-001 - FUSE
RAIL17TLB0317AA 11

1 X13.p pin 16 K8 Power supply RD/BK - 1.0 SHEET 01
2 X500.s pin 2 A9 Switched power OR - 1.0
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Wire connectors - Component diagram 00 Connectors S01 to S99

MARBLE CUTTING
S2 - 4WD SWITCH CONNECTOR
RAIL17TLB0309AA 1

1 - - - - SHEET 02
2 X404.p pin 4 M 4WD signal BR/GN - 1.0
3 XC1 pin 2 D2 Switched battery WH/RD - 1.0
4 GND2 E2 Switch lamp ground BK - 1.0
S3 pin 4 C2 BK - 1.0
5 - - - -
6 X23.p pin 13 F2 4WD relay signal WH - 1.0
S3 HAND HAMMER SWITCH CONNECTOR
RAIL17TLB0309AA 2

1 - - - - SHEET 02
2 X13.s pin 14 A2 Hand hammer relay RD/YE - 1.0
3 XC4 pin 11 B2 Hand hammer solenoid GY/BK - 1.0
valve
4 S2 pin 4 C2 Ground BK - 1.0
5 - - - -
6 - - - -
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S5 RIDE CONTROL SWITCH CONNECTOR
RAIL17TLB0308AA 3

1 - - - -
2 X125 pin 1 M1 Switched battery RD/GN - 1.0 SHEET 03
S5 pin 4 L3 Switched battery RD/GN - 1.0
3 X13.s pin 19 M3 Input ride control switch WH/YE - 1.0
4 X13.s pin 1 N1 Switched battery RD/GN - 1.0
S5 pin 2 L3 Switched battery RD/GN - 1.0
5 X13.s pin 29 N3 Input ride control switch Wh - 1.0
6 - - - -
7 X13.s pin 3 O1 Ride control switch lights LB/BK - 1.0 SHEET 03
8 - - - -
9 GND2 P1 Ground BK - 1.0 SHEET 03
S29 pin 5 J1 Ground BK - 1.0
10 - - - -
S15 ROTATING BEACON SWITCH CONNECTOR
RAIL17TLB0309AA 4

1 - - - -
2 XC4 pin 1 G1 Switched battery LB/YE - 1.5 SHEET 07
3 XC2 pin 1 H1 Rotating beacon LB/GN - 1.5
4 S29 pin 5 I1 Ground BK - 1.0
S48 pin 4 F1 Ground BK - 1.0
5 - - - -
6 - - - -
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S29 HORN SWITCH CONNECTOR
RAIL17TLB0309AA 5

1 - - - -
2 - - - -
3 - - - -
4 - - - -
5 S15 pin 4 I1 Ground BK - 1.0 SHEET 04
S5 pin 9 J1 Ground BK - 1.0
6 XC1 pin 1 K1 Horn OR - 1.0
X21 pin 6 L1 OR - 1.0
S41 WINDSHIELD WIPER/ LIGHTS SWITCH CONNECTOR (ON THE STEERING COLUMN)
RAIL17TLB0268AA 6

1 - - - - SHEET 07
2 X13.s pin 4 A Windshield washer pump DB/WH - 1.0
3 - - - -
4 XC2 pin 2 B Switched battery WH - 1.0
5 XC4 pin 8 C Head lights relay GN/BK - 1.5
6 XC4 pin 14 D Front windshield wiper WH - 1.0
7 XC4 pin 12 E Switched battery WH - 1.0
8 XC4 pin 15 F Front windshield wiper WH - 1.0
9 SA1 G Left turn signal DB - 1.0
10 SA2 H Right turn signal LB - 1.0
11 S42 pin 5 I 49a warning DB/BK - 1.0
12 - - - -
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S42 WARNING SWITCH CONNECTOR
RAIL17TLB0308AA 7

1 XC4 pin 3 Q1 Switched battery GY/RD - 1.0 SHEET 04
2 S42 pin 4 R1 Flasher GY/DB - 1.0
3 XC4 pin 13 S1 Unswitched battery WH - 1.0
4 XC4 pin 10 T1 Flasher GY/DB - 1.0
S42 pin 2 R1 Flasher GY/DB - 1.0
5 XC4 pin 9 U1 49a warning DB/BK - 1.0
S41 pin 11 I 49a warning DB/BK - 1.0
6 SA1 V1 Left turn signal DB - 1.0
7 SA2 W1 Right turn signal LB - 1.0
S47 STEERING SWITCH CONNECTOR
RAIL17TLB0311AA 8

1 X409.p pin 3 Z Round steering GN/BK - 1.0 SHEET 11
X13.s pin 11 H2 WH - 1.0
2 - - - -
3 X13.s pin 13 I2 Switched battery WH - 1.0
4 - - - -
5 X409.p pin 2 X Crab steering DB/RD - 1.0
X13.s pin 5 J2 DB/RD - 1.0
6 - - - -
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S48 TRAX AUTO/MANUAL SWITCH CONNECTOR
RAIL17TLB0309AA 9

1 X404.p pin 8 Q Auto/manual signal WH - 1.0 SHEET 02
2 XC1 pin 8 E1 Switched battery WH/RD - 1.0
3 - - - -
4 S15 pin 4 F1 Ground BK - 1.0 SHEET 02
5 - - - -
6 - - - -
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Wire connectors - Component diagram 00 Connectors XST, XC,

XX and X-00 to X-09
MARBLE CUTTING
MC1 - STARTER CONNECTION
RAIL17TLB0282AA 1

1 X450S pin 4 H2 Engine start OR - 4.0 SHEET 01
K14 - TRANSMISSION CUT-OFF RELAY
RAIL17TLB0261AA 2

30 X227 pin 30 I7 Switched battery WH/RD - 1.0 SHEET 02
X23.s pin 1 G5 WH/RD - 1.0
85 X232 pin 85 H7 Ground BK - 1.0
X-605 (Receptacle) pin 85 G7 Ground BK - 1.0
86 X10.p pin 20 R1 Transmission cut-off LB/RD - 1.0
87 X23.s pin 3 H5 Transmission cut-off signal DB/RD - 1.0
87a - - - -
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XST1 INSTRUMENT CLUSTER CONNECTOR (Receptacle)
82016219 3
82016219
RAIL16TLB0856FA 4
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1 - - - - SHEET 01
2 SA1 P3 Switched battery Red/ black
(1.0)
3 XC6 pin 6 A4 In gear signal Brown (1.0)
4 Splice SP-900 E4 Driving work lights Yellow (1.0)
5 - - - -
6 - - - -
7 X13.p pin 9 V4 Turn signals White (1.0)
8 X13.p pin 10 W4 High beams Green (1.0)
9 - - - -
10 X220 pin 11 M Air conditioner system Yellow/ green
pressure (1.0)
11 X88.p pin 10 S6 Display input switch Brown/ white
(1.0)
12 X88.p pin 11 T6 Enter input switch Brown/ black
(1.0)
13 X88.p pin 12 U6 Up input switch Dark blue/
black (1.0)
14 X88.p pin 13 V6 Down input switch Dark blue/
white (1.0)
15 X15.2 pin 9 E6 Crank signal White (1.0)
16 X1.p pin 15 J2 Air filter restriction switch Dark blue/
white (1.0)
17 - - - -
18 X30.1 pin 1 N6 Park brake White (1.0)
19 - - - -
20 X25 pin 6 V Idle validation switch Yellow (1.0)
21 X10.p pin 24 V1 One touch decel White/ Dark
blue (1.0)
22 X95 pin 1 F6 Crab steering White (1.0)
23 X95 pin 11 G6 Road steering Gray (1.0)
24 X95 pin 12 H6 Turn steering White (1.0)
25 - - - -
26 - - - -
82028493 5
82028493
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RAIL16TLB0856FA 6

1 X31 pin F3B J4 Unswitched battery Red (1.0) SHEET 01
2 - - - -
3 SA4 L9 CAN low signal Green (0.5)
4 SA3 W9 CAN high signal Yellow (0.5)
5 - - - -
6 X606 pin 1 P6 Audible alarm Orange (1.0)
7 - - - -
8 X232 pin 86 T8 Ride control relay White (1.0)
9 - - - -
10 - - - -
11 - - - -
12 - - - -
13 X1.p pin 14 I2 Fuel level signal Violet (1.0)
14 X1.p pin 3 A2 Transmission temperature Yellow/ red
(1.0)
15 - - - -
16 X25 pin 3 S Foot throttle signal; Green (1.0)
17 X608 pin B K6 Hand throttle signal Pink (1.0)
18 X25 pin 5 U Foot throttle 5V Red (1.0)
19 X608 pin A J6 Hand throttle 5V Red/ black
(1.0)
20 X25 pin 4 T Foot throttle sensor ground Green/ black
(1.0)
21 X608 pin C L6 Hand throttle sensor Brown (1.0)
ground
22 X13.p pin 19 A8 Ride control switch White/ yellow
(1.0)
23 X13.p pin 20 B8 Ride control switch White (1.0)
24 SA15 G2 Alternator Pink (1.0)
25 X10.p pin 28 M7 Ride control pressure White (1.0)
switch
26 GND.1 X2 Instrument cluster ground Black (1.0)
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XC1 FUSE PANEL CONNECTOR
RAIL17TLB0242AA 7

1 S29 pin 6 K1 Front horn switch Orange (1.0) SHEET 02
2 S2 pin 3 D2 Switched battery from
X23.p pin 1 E3 Fuse F1C White/ red
(1.0)
3 - - - -
4 Switched battery from fuse - SHEET 08
F2A
5 X33 pin 2 R2 Switched battery from fuse White (1.0) SHEET 05
F4A
6 - - - -
7 X32 pin 3 T2 Stop light switch Red/ black SHEET 05
X404.p pin 13 V (1.0)
Red/ black
(1.0)
8 S48 pin 2 E1 Switched battery from SHEET 02
X404.p pin 1 J Fuse F1C White/ red
(1.0)
9 - - - -
10 X13.s pin 9 F3 Turn signal White/ violet SHEET 04
(1.0)
11 - - - -
RAIL17TLB0243AA 8

1 S15 pin 3 H1 Rotating beacon Light blue/ SHEET 07
green (1.5)
2 S41 pin 4 B Switched battery from fuse Yellow/ red SHEET 02
F6C (1.0)
3 - - - -
4 - - -
5 XC2 pin 7 D3 Jumper to XC2 pin 7 Violet (1.0) SHEET 08
6 - - - -
7 XC2 pin 5 D3 Jumper to XC2 pin 5 Violet (1.0) SHEET 08
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RAIL17TLB0245AA 9

1 X10.p pin 4 B1 Hand hammer solenoid Brown/ black SHEET 02
valve (1.0)
2 X28 pin 2 L5 Rear left lamp Dark blue (1.0) SHEET 05
3 Splice SP-171 O9 Front light switch Yellow (1.0) SHEET 06
4 X87.p pin 1 N5 Front work light switch Pink/ Yellow
(1.0)
5 X14 pin 1 F5 Switched battery Dark blue/ SHEET 02
black (1.0)
6 - - - -
7 X10.p pin 23 U1 Switched battery from fuse White (1.0) SHEET 06
X87.p pin 2 O5 F3C White (1.0)
8 X262 pin 3 U3 Bucket level solenoid Gray/ red (1.0) SHEET 02
X10.p pin 5 C1 Gray/ red (1.0)
9 - - - -
10 - - - -
11 X10.p pin 6 D1 Rear horn Orange (1.0) SHEET 02
X88.p pin 5 P5 Orange (1.0)
12 X29 pin 2 Q5 Right rear light Light blue (1.0) SHEET 05
13 X27 pin 2 R5 Left rear light Yellow/ black
X28 pin 4 S5 (1.0)
Yellow/ black
(1.0)
14 Splice SP-172 Q9 Rear work light switch Yellow (1.0) SHEET 06
15 X87.p pin 11 U5 Rear work light switch Violet/ black
(1.0)
16 X10.p pin 8 F1 Bucket sender Red/ green SHEET 02
X230 pin 87 V1 (1.0)
Red/ green
(1.0)
17 X88.p pin 1 W5 Switched battery from fuse White (1.0) SHEET 07
F1A to windshield/ washer
switch and the rear wiper
motor
18 X13.p pin 13 A5 Switched battery from fuse White (1.0) SHEET 06
X88.p pin 9 X5 F4C to switch S140 White (1.0)
19 X10.p pin 25 W1 Bucket sender Light blue/ SHEET 02
yellow (1.0)
20 X29 pin 4 Z5 Right rear light Yellow (1.0) SHEET 05
21 X28 pin 3 A6 Right rear light and left rear Red/ black
X29 pin 3 B6 light (1.0)
Red/ black
(1.0)
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RAIL17TLB0245AA 10

1 S15 pin 2 G1 Switched battery from fuse Light blue/ SHEET 07
F6A to switch S15 yellow (1.5)
2 - - - -
3 S42 pin 1 Q1 Switched battery from fuse Gray/ red (1.0) SHEET 04
F6B to switch S42
4 - - - -
5 X13.s pin 8 G3 To switch S9 Gray/ black SHEET 04
(1.5)
6 S21 pin 3 M2 From fuse F3A to front Yellow (1.0) SHEET 04
lights
7 - - - -
8 S41 pin 5 C From the headlight switch Green/ black SHEET 04
(1.5)
9 S42 pin 5 U1 To the flasher unit from Dark blue/ SHEET 04
switch S42 black (1.0)
10 S42 pin 4 T1 To the flasher unit from Gray/ dark SHEET 04
switch S42 blue (1.0)
11 S3 pin 3 B2 Hand hammer switch Gray/ black SHEET 02
(1.0)
12 S41 pin 7 E Switched battery from fuse White (1.0) SHEET 07
F7C to switch S41
13 X13.s pin 6 H3 Unswitched battery from White (1.0) SHEET 04
S42 pin 3 S1 fuse F7A White (1.0)
14 S41 pin 6 D From switch S41 White (1.0) SHEET 07
15 S41 pin 8 F From switch S41 White (1.0) SHEET 07
16 X22 pin 4 X2 Head lights Gray (1.0) SHEET 04
X21 pin 4 N2 Gray/ black
(1.0)
17 SA1 C3 To switch S41 Dark blue (1.0) SHEET 05
18 X22 pin 3 W2 From fuse F3B to the head Yellow/ black SHEET 04
lights (1.0)
19 SA2 B3 To switch S41 Light blue (1.0) SHEET 05
20 X22 pin 5 Z2 High beams Green (1.0) SHEET 04
X21 pin 5 O2 Green/ black
(1.0)
21 X13.s pin 7 I3 From switch S9 Yellow (1.5) SHEET 04
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RAIL17TLB0248AA 11

1 X49 pin 3 A Switched battery from fuse White (1.0) SHEET 07
X41 pin 2 B F7C to the front windshield White (1.0)
wiper motor
2 - - - -
3 X49 pin 1 C Front windshield wiper White (1.0) SHEET 07
motor
4 X49 pin 4 D Front windshield wiper White (1.0)
motor
5 - - - -
6 X55.2 pin 1 F Socket lamp Yellow (1.0) SHEET 05
7 - - - -
8 - - - -
9 - - - -
10 X55.1 pin 1 L Unswitched battery from Red/ black SHEET 08
X18.2 pin 1 M fuse F7B to the cabin light, (1.5)
cigar lighter, and the radio White (1.0)
11 X40 pin 2 S Internal rear work light Green/ black SHEET 06
X46 pin 2 R (1.0)
Green/ black
(1.0)
12 X50 pin 2 U Internal front work light Green (1.0)
X45 pin 2 T Green (1.0)
13 X38 pin 2 N External rear work light Gray/ black
X47 pin 2 O (1.0)
Gray/ black
(1.0)
14 X44 pin 2 P External front work light Gray (1.0)
X51 pin 2 Q Gray (1.0)
15 - - - -
16 X43.s pin 2 V Switched battery from Light blue/ SHEET 07
fuse F1A to windshield yellow (1.5)
wiper switch and the rear
windshield wiper motor
17 - - - -
RAIL17TLB0249AA 12
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1 XX Diode pin 4 W3 Forward signal Brown/ black SHEET 02
X23.s pin 6 V3 (1.0)
Brown/ black
(1.0)
2 X95 pin 5 X3 Buzzer control Green/ white SHEET 05
(1.0)
3 X14.s pin 8 Z3 Switched battery from fuse Light blue (1.5) SHEET 01
F1B to the antitheft unit
4 - - - -
5 - - - -
6 XST1 (Receptacle) pin 3 A4 Start signal Brown (1.0) SHEET 01
X1.p pin 12 Z1 Green/ black
(1.0)
7 - - - -
8 X23.s pin 7 B4 Reverse signal Brown/ white SHEET 02
XX Diode pin 5 C4 (1.0)
Brown/ white
(1.0)
9 X262 pin 2 T3 Switched battery from fuse Gray (1.5) SHEET 01
F2C to the pilot control
module
10 X15.2 pin 5 D4 Switch battery from the Dark blue (1.5)
ignition switch
11 X520 pin 3 N9 To the diodes in connector Yellow (1.0) SHEET 05
X-520
12 SA1 S3 Switched battery from fuse Red/ black SHEET 08
F2A to the ride control (1.5)
pressure switch
13 SA1 Q3 Start signal to the starter Red/ black SHEET 01
relay (1.0)
XX DIODE CONNECTOR
RAIL17TLB0250AA 13

1 - - - -
2 - - - -
3 X10.p pin 19 Q1 Double delivery solenoid Dark blue/ SHEET 02
valve yellow (1.0)
4 XC6 pin 1 W3 Forward signal Brown/ black
(1.0)
5 X7 pin 2 E5 Reverse signal Brown/ white
XC6 pin 5 C4 Reverse buzzer (1.0)
Brown/ white
(1.0)
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X1.p ENGINE HARNESS CONNECTOR
RAIL17TLB0256AA 14

1 X15.1 pin 2 X1 Unswitched battery from RD - 6.0 SHEET 01
X601
2 XC6 pin 5 Z1 Starter interlock GN/BK - 1.0 SHEET 01
3 XST2 (Receptacle) pin 14 A2 Transmission oil YE/RD - 1.0 SHEET 01
temperature
4 X23.s pin 5 B2 Alternator signal LB/WH - 1.0 SHEET 01
5 X23.s pin 4 N7 Starter relay coil pin 85 GN - 1.0 SHEET 01
6 GND.1 C2 Ground BK - 2.5 SHEET 04
7 X15.2 pin 8 D2 Start signal WH - 1.0 SHEET 01
8 - - - -
9 X13.p pin 18 O7 Air conditioner compressor GN - 1.5 SHEET 01
10 X14.s pin 7 F2 Switched battery from fuse RD/BK - 1.0 SHEET 01
F2C
11 X220 pin 11 N Air conditioner relay pin 86 YE/GN - 1.5 SHEET 11
12 SA15 P8 D+ signal from the PK - 1.0 SHEET 01
alternator
13 X23.s pin 10 P7 Starter relay coil pin 86 DB - 1.0 SHEET 01
14 XST2 (Receptacle) pin 13 I2 Fuel level sender VT 1.0 SHEET 01
15 XST1 (Receptacle) pin 16 J2 Air filter pressure switch WH/YE - 1.0 SHEET 01
16 - - - -
17 - - - -
18 - - - -
X1.s ENGINE HARNESS CONNECTOR
RAIL17TLB0291AA 15

1 X601 pin 1 W1 Unswitched battery RD - 6.0 SHEET 01
2 X451S pin 3 J2 Starter interlock GN/BK - 1.0 SHEET 01
3 X66 pin 1 B1 Transmission oil YE/RD - 1.0 SHEET 01
temperature
4 X67B pin 1 X1 Alternator signal LB/WH - 1.0 SHEET 01
5 - - - -
6 GND.1 U1 Ground BK - 2.5 SHEET 04
7 X450S pin 3 G2 Start signal WH - 1.0 SHEET 01
8 - - - -
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9 - - - -
10 - - - -
11 X451S pin 2 R Air conditioner relay pin 86 YE/GN - 1.5 SHEET 11
12 X67A pin 1 A2 D+ signal from the PK - 1.0 SHEET 01
alternator
13 - - - -
14 X5 pin 1 D1 Fuel level sender VT 1.0 SHEET 01
15 X4.1 pin 1 M2 Air filter pressure switch WH/YE - 1.0 SHEET 01
16 - - - -
17 - - - -
18 - - - -
X2.p - UNSWITCHED BATTERY TO THE TELEMATICS UNIT
RAIL17TLB0287AA 16

1 X10.s pin 26 T1 Unswitched battery RD - 1.0 SHEET 01
X2.s - UNSWITCHED BATTERY TO THE TELEMATICS UNIT
RAIL17TLB0292AA 17

1 SA104 P2 Unswitched battery RD - 1.0 SHEET 01
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X4.1 AIR FILTER RESTRICTION SWITCH
RAIL17TLB0296AA 18

1 X1.s pin 15 M2 Air filter pressure YE - 1.0 SHEET 01
RAIL17TLB0296AA 19

1 GND.1 L2 Ground BK - 1.0 SHEET 01
X5 - FUEL LEVEL SENDER
RAIL17TLB0295AA 20

1 X1.s pin 14 D1 Fuel level sender RD - 1.0 SHEET 01
2 GND.1 C1 Ground BK - 1.0
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X7 REVERSE BUZZER
RAIL17TLB0269AA 21

1 GND.1 D3 Ground BK - 1.0 SHEET 02
2 XX Diode pin 5 E5 Reverse buzzer signal BR/WH - 1.0
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Wire connectors - Component diagram 01 Connectors X-010 to

X-019
MARBLE CUTTING
X10.p SERVICE HARNESS CONNECTOR
RAIL17TLB0255AA 1

1 X262 pin 1 X Power supply to the pilot GY - 1.5 SHEET 01
control module
2 GND.1 Z Ground BK - 1.5 SHEET 01
3 GND.1 A1 Ground BK - 1.5 SHEET 01
4 XC3 pin 1 B1 Service harness GY/BK -1.0 SHEET 02
5 XC3 pin 8 C1 Bucket level GY/RD - 1.0 SHEET 02
6 XC3 pin 11 D1 Horn OR - 1.0 SHEET 02
7 X230 pin 30 E1 Rear hammer button RD/YE - 1.0 SHEET 03
8 XC3 pin 16 F1 Bucket sensor supply RD/GN - 1.0 SHEET 02
9 X23.s pin 1 G1 Switched battery from fuse WH/RD - 1.0 SHEET 02
F1C
10 X232 pin 87 K7 Ride control solenoid LB/BK - 1.0 SHEET 03
11 X96 pin 6 I1 Rear axle sensor WH - 1.0 SHEET 11
12 SA10 J1 4WS steering solenoid WH - 1.0 SHEET 11
13 X95 pin 3 K1 Front axle sensor GY/DB - 1.0 SHEET 11
14 X95 pin 2 L1 Round steering solenoid WH - 1.0 SHEET 11
valve
15 X88.p pin 7 M1 Rear translation solenoid WH/BK - 1.0 SHEET 03
valve
16 X95 pin 10 N1 Rear axle sensor signal WH - 1.0 SHEET 11
17 X87.p pin 10 O1 Backhoe transport lock OR/WH - 1.0 SHEET 03
solenoid
18 X96 pin 8 P1 2WS WH - 1.0 SHEET 11
19 XX Diode pin 3 Q1 2WS DB/YE - 1.0 SHEET 02
20 K14 pin 86 R1 Disengage clutch button LB/RD - 1.0 SHEET 02
21 X96 pin 1 S1 Crab steering solenoid WH - 1.0 SHEET 11
valve
22 X96 pin 5 T1 Front axle sensor WH - 1.0 SHEET 11
23 XC3 pin 7 U1 Bucket quick coupler WH - 1.0 SHEET 03
24 XST1 (Receptacle) pin 21 V1 One touch decel WH/DB - 1.0 SHEET 01
25 XC3 pin 19 W1 Bucket sensor signal LB/YE - 1.0 SHEET 02
26 - - - -
27 SA1 L7 Switched battery to the ride RD/BK - 1.0 SHEET 03
control pressure switch
28 XST2 (Receptacle) pin 25 M7 Ride control pressure WH - 1.0 SHEET 03
switch signal
29 X500.s pin 12 W8 Switched battery to the RD - 1.0 SHEET 01
Telematics
30 - - - -
31 - - - -
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X10.s SERVICE HARNESS CONNECTOR
RAIL17TLB0283AA 2

1 X72.s pin 1 H1 Power supply to the pilot GY - 1.5 SHEET 01
control module
3 GND.1 O Ground BK - 1.5 SHEET 01
4 X35 pin 1 I Service harness GY/BK -1.0 SHEET 02
5 X206 pin A O1 Bucket level GY/RD - 1.0 SHEET 02
6 X204 pin 2 F1 Horn OR - 1.0 SHEET 02
7 X36.s pin 2 B Rear hammer button RD/YE - 1.0 SHEET 03
8 X26 pin A L1 Bucket sensor supply RD/GN - 1.0 SHEET 02
9 X205 pin D Q1 Switched battery from fuse WH/RD - 1.0 SHEET 02
F1C
10 X34 pin 1 J Ride control solenoid LB/BK - 1.0 SHEET 03
11 X98 pin B R Rear axle sensor WH - 1.0 SHEET 11
12 X93 pin 1 U 4WS steering solenoid WH - 1.0 SHEET 11
13 X97 pin A J1 Front axle sensor GY/DB - 1.0 SHEET 11
14 X92 pin 1 T Round steering solenoid WH - 1.0 SHEET 11
valve
15 X202 pin 1 E1 Rear translation solenoid WH/BK - 1.0 SHEET 03
valve
16 X95 pin 10 N1 Rear axle sensor signal WH - 1.0 SHEET 11
17 X203 pin 1 C Backhoe transport lock OR/WH - 1.0 SHEET 03
solenoid
18 X94 pin 1 S 2WS WH - 1.0 SHEET 11
19 X207 pin 1 N1 2WS DB/YE - 1.0 SHEET 02
20 X205 pin A P1 Disengage clutch button LB/RD - 1.0 SHEET 02
21 X91 pin 1 D1 Crab steering solenoid WH - 1.0 SHEET 11
valve
22 X97 pin B K1 Front axle sensor WH - 1.0 SHEET 11
23 X208 pin 2 I1 Bucket quick coupler WH - 1.0 SHEET 03
24 X201.s pin 1 G1 One touch decel WH/DB - 1.0 SHEET 01
25 X26 pin B M1 Bucket sensor signal LB/YE - 1.0 SHEET 02
26 - - - -
27 X805.s pin 1 R1 Switched battery to the ride RD/BK - 1.0 SHEET 03
control pressure switch
28 X805.s pin 2 S1 Ride control pressure WH - 1.0 SHEET 03
switch signal
29 X2.p pin 1 T1 Switched battery to the RD - 1.0 SHEET 01
Telematics
30 - - - -
31 - - - -
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X12.s CAB HARNESS CONNECTOR
RAIL17TLB0260AA 3

1 X88.p pin 3 W6 Windshield wiper ground WH - 1.0 SHEET 07
2 X88.p pin 2 X6 Rear windshield washer WH - 1.0
voltage supply
3 X13.p pin 4 Q4 Windshield washer pump DB/WH - 1.0
4 X88.p pin 4 Z6 Windshield wiper speed WH - 1.0
5 X88.p pin 1 A7 Rear windshield wiper WH - 1.0
voltage supply
6 X605 pin 87 B7 Right-side work light WH - 1.0
7 X605 pin 87 C7 Left-side work light WH - 1.0
8 - - - -
9 - - - -
X13.p POWER SUPPLY FRONT DASHBOARD HARNESS
RAIL17TLB0277AA 4

1 X31 pin F5B P4 Switched battery RD/GN - 1.0 SHEET 03
X232 pin 30 W7 Ride control RD/GN - 1.0
2 X15.2 pin 9 X7 Crank signal from the WH - 1.0 SHEET 01
ignition switch
3 X232 pin 87 H1 Ride control LB/BK - 1.0 SHEET 03
4 X12.s pin 3 Q4 Windshield washer pump DB/WH - 1.0 SHEET 07
5 X95 pin 4 R4 4WS DB/RD - 1.0 SHEET 11
6 X14.s pin 2 S4 Unswitched battery to the WH - 1.0 SHEET 04
antitheft system
7 X87.p pin 3 T4 Parking lights YE - 1.5 SHEET 04
8 X87.p pin 6 U4 Lights GY/BK - 1.5 SHEET 04
9 XST1 (Receptacle) pin 7 V4 Turn signals WH/GN - 1.0 SHEET 04
10 XST1 (Receptacle) pin 8 W4 Head lights GN - 1.0 SHEET 04
11 X95 pin 6 X4 Round steering control WH - 1.0 SHEET 11
12 X95 pin 9 Z4 Speed sensor 2 GY/DB - 1.0 SHEET 03
13 XC3 pin 18 A5 Steering selector supply WH - 1.0 SHEET 11
X95 pin 7 B5 Steering power supply WH - 1.0
14 X230 pin 30 C5 RD/YE - 1.0 SHEET 02
15 X230 pin 86 D5 Neutral GN/VT - 1.0 SHEET 02
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16 F-001 pin 1 K8 Power supply RD/BK -1.0 SHEET 01
X14.s pin 7 Z7 Power supply RD/BK - 1.0
17 X607 pin E E2 BR - 1.0 SHEET 01
18 X1.p pin 9 O7 Air conditioner compressor GN - 1.5 SHEET 01
19 XST2 (Receptacle) pin 22 A8 Ride control WH/YE - 1.0 SHEET 03
20 XST2 (Receptacle) pin 23 B8 Ride control WH - 1.0 SHEET 03
21 - - - -
X13.s POWER SUPPLY FRONT DASHBOARD HARNESS
RAIL17TLB0246AA 5

1 X24 pin 1 G2 Switched battery RD/GN - 1.0 SHEET 03
S5 pin 4 N1 Ride control RD/GN - 1.0
2 X-800 (Receptacle) pin D U3 Crank signal from the WH - 1.0 SHEET 01
ignition switch
3 S5 pin 7 O1 Ride control LB/BK - 1.0 SHEET 03
4 S41 pin 2 A Windshield washer pump DB/WH - 1.0 SHEET 07
5 S47 pin 5 J2 4WS DB/RD - 1.0 SHEET 11
6 X21 pin 7 Q2 Unswitched battery to the WH - 1.0 SHEET 04
XC4 pin 13 H3 antitheft system WH - 1.0
7 XC4 pin 21 I3 Parking lights YE - 1.5 SHEET 04
8 XC4 pin 5 G3 Lights GY/BK - 1.5 SHEET 04
9 XC1 pin 10 F3 Turn signals WH/GN - 1.0 SHEET 04
10 X21 pin 5 P2 Head lights GN - 1.0 SHEET 04
11 S47 pin 1 H2 Round steering control WH - 1.0 SHEET 11
12 X404.p pin 12 T Speed sensor 2 GY/DB - 1.0 SHEET 03
13 S47 pin 3 I2 Steering selector supply WH - 1.0 SHEET 11
14 S3 pin 2 A2 RD/YE - 1.0 SHEET 02
15 X409.p pin 5 B1 Neutral GN/VT - 1.0 SHEET 02
16 X-800 (Receptacle) pin C V3 Power supply RD/BK -1.0 SHEET 01
17 X-800 (Receptacle) pin B Q3 BR - 1.0 SHEET 01
18 X-800 (Receptacle) pin H R3 Air conditioner compressor GN - 1.5 SHEET 01
19 S5 pin 3 M3 Ride control WH/YE - 1.0 SHEET 03
20 S5 pin 5 N3 Ride control WH - 1.0 SHEET 03
21 - - - -
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X14.s ANTITHEFT SYSTEM
RAIL17TLB0263AA 6

1 XC3 pin 5 F5 Switched battery from fuse DB/BK - 1.0 SHEET 01
F4B
2 X13.p pin 6 S4 Unswitched battery from WH - 1.0
fuse F7A
3 GND.2 M2 Ground BK - 1.0
4 GND.2 P2 Ground BK - 1.0
5 - - - -
6 - - - -
7 X13.p pin 16 Z7 Switched battery RD/BK - 1.0
X1.p pin 10 F2 Switched battery RD/BK - 1.0
8 XC6 pin 3 Z3 Switched battery from fuse LB - 1.5
F1B
9 - - - -
10 - - - -
11 - - - -
X15.1 STARTING CONNECTOR
RAIL17TLB0273AA 7

1
2 X1.p pin 1 X1 Battery connection to the RD - 6.0 SHEET 01
ignition switch
3
4
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RAIL17TLB0272AA 8

5 X87.p pin 15 D6 Switched battery from the DB - 1.5 SHEET 01
XC6 pin 10 D4 ignition switch DB - 1.5
X31 pin F4A N4 DB - 1.5
6 Ignition switch C6 Switched battery from the DB - 6.0
ignition switch
7 - - - -
8 X1.p pin 7 D2 Start signal from the WH - 4.0
ignition switch
9 X13.p pin 2 X7 Start signal from the WH - 1.0
XST1 (Receptacle) pin 15 E6 ignition switch WH - 1.0
10 - - - -
X17 SEAT OPTION CONNECTOR
RAIL17TLB0281AA 9

1 X30.2 pin 1 M6 Ground BK - 1.0 SHEET 01
2 - - - -
3 - - - -
4 SA1 R3 Switched battery RD/BK - 1.0 SHEET 01
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X-029
MARBLE CUTTING
X21 - LEFT LIGHTS/ HORN CONNECTOR
RAIL17TLB0305AA 1

1 GND.1 K2 Ground BK - 1.5 SHEET 04
2 SA1 L2 Right turn signal DB - 1.0
3 XC4 pin 6 M2 Right parking light YE - 1.0
X125 pin 6 Z1 Backlight YE - 1.0
4 XC4 pin 16 N2 Right low beams GY - 1.0
5 X13.s pin 10 P2 Right bright lights GN - 1.0
XC4 pin 20 O2 GN - 1.0
6 S29 pin 6 L1 Unswitched battery to the OR - 1.0
horn
7 X13.s pin 6 Q2 Horn signal WH - 1.0
X22 - RIGHT LIGHTS CONNECTOR
RAIL17TLB0304AA 2

1 GND U2 Ground BK - 1.5 SHEET 04
2 SA2 V2 Right turn signal LB - 1.0
3 XC4 pin 18 W2 Right parking light YE/BK - 1.0
4 \ XC4 pin 16 X2 Right low beams GY/BK - 1.0
5 XC4 pin 20 Z2 Right bright lights GN/BK - 1.0
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X23.p - FRONT DASHBOARD CONNECTOR
RAIL17TLB0247AA 3

1 XC1 pin 2 E3 Switched battery WH/RD - 1.0 SHEET 02
2 X404.p pin 2 K Ground BK - 1.5 SHEET 02
3 X404.p pin 3 L Declutch DB/RD - 1.0 SHEET 02
4 X800.s pin F O3 Start relay coil terminal 85 GN - 1.0 SHEET 01
5 X404.p pin 5 N W signal from the alternator LB/WH - 1.0 SHEET 02
6 X404.p pin 6 O Forward signal BR/BK - 1.0 SHEET 02
7 X404.p pin 7 P Reverse signal BR/WH - 1.0 SHEET 02
8 X409.p pin 1 W Solenoid 3A WH - 1.0 SHEET 02
9 X404.p pin 9 R Unswitched battery RD - 1.0 SHEET 02
10 X800.s pin A P3 Start relay coil terminal 86 DB - 1.0 SHEET 01
11 X404.p pin 11 S Ground BK - 1.5 SHEET 02
12 X409.p pin 4 A1 4WD solenoid YE/RD - 1.0 SHEET 02
13 S2 pin 6 F2 4WD WH - 1.0 SHEET 02
X23.s - FRONT DASHBOARD CONNECTOR
RAIL17TLB0251AA 4

1 X10.p pin 9 G1 Switched battery WH/RD - 1.0 SHEET 02
K14 pin 30 G5 Switched battery WH/RD - 1.0
2 GND.1 T2 Ground BK - 1.5 SHEET 02
3 K14 pin 87 H5 Declutch DB/RD - 1.0 SHEET 02
4 X1.p pin 5 N7 Start relay coil terminal 85 GN - 1.0 SHEET 01
5 X1.p pin 4 B2 W signal from the alternator LB/WH - 1.0 SHEET 02
6 XC6 pin 1 V3 Forward signal BR/BK - 1.0 SHEET 02
7 XC6 pin 8 B4 Reverse signal BR/WH - 1.0 SHEET 02
8 SA10 I5 Solenoid 3A WH - 1.0 SHEET 02
9 X31 pin F3B K4 Unswitched battery RD - 1.0 SHEET 02
10 X1.p pin 13 P7 Start relay coil terminal 86 DB - 1.0 SHEET 01
11 GND.1 Z2 Ground BK - 1.0 SHEET 02
12 X227 pin 86 J5 4WD solenoid YE/RD - 1.0 SHEET 02
13 X227 pin 87a K5 4WD WH - 1.0 SHEET 02
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X24 - HAND HAMMER SWITCH CONNECTOR
RAIL17TLB0310AA 5

1 X13.s pin 1 G2 Switched battery RD/GN - 1.0 SHEET 03
X25 - FOOT THROTTLE CONNECTOR
RAIL17TLB0258AA 6
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RAIL16TLB0845FA 7

1 GND R Ground BK - 1.0 SHEET 01
2 - - - -
3 XST2 (Receptacle) pin 16 S Foot throttle signal GN - 1.0
4 XST2 (Receptacle) pin 20 T Sensor ground GN/BK - 1.0
5 XST2 (Receptacle) pin 18 U Foot throttle power +5V RD - 1.0
6 XST1 (Receptacle) pin 20 V Idle validation signal YE - 1.0
X26 - BUCKET SENSOR
RAIL17TLB0280AA 8

A X10.s pin 8 L1 Switched battery RD/GN - 1.0 SHEET 02
B GND.3 E Ground BK - 1.0
X10.s pin 25 M1 Sensor signal LB/YE - 1.0
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X27 - LICENSE PLATE LAMP CONNECTOR
RAIL17TLB0269AA 9

1 GND.1 B3 Ground BK - 1.0 SHEET 05
2 XC3 pin 13 R5 Lamp power YE/BK - 1.0
X28 - REAR LEFT LAMP CONNECTOR
RAIL17TLB0270AA 10

2 XC3 pin 2 L5 Left indicator rear lamp DB - 1.0
3 XC3 pin 21 A6 Left stop lamp RD/BK - 1.0
4 XC3 pin 13 S5 Left rear lamp YE/BK - 1.0
X29 - REAR RIGHT LAMP CONNECTOR
RAIL17TLB0270AA 11

2 XC3 pin 12 Q5 Right indicator rear lamp LB - 1.0
3 XC3 pin 21 B6 Right stop lamp RD/BK - 1.0
4 XC3 pin 20 Z5 Right rear lamp YE - 1.0
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X-039
MARBLE CUTTING
X30.1 PARKING BRAKE CONNECTOR
RAIL17TLB0282AA 1

1 XST1 (Receptacle) pin 18 N6 Parking brake WH - 1.0 SHEET 01
RAIL17TLB0282AA 2

1 GND.2 N2 Parking brake ground BK - 1.0 SHEET 01
X17 pin 1 M6 BK - 1.0
X31 FUSE CONNECTOR
RAIL17TLB0276AA 3
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F1A SA6 F3 Unswitched battery RD - 2.5 SHEET 01
X31 pin F2A G4 RD - 2.5
F1B X607 pin B F4 Unswitched battery RD - 1.0
F2A X31 pin F1A G4 Unswitched battery RD - 2.5 SHEET 07
X31 pin F3A H4 RD - 2.5
F2B X-605 (Receptacle) pin 30 I4 Unswitched battery RD/BK 2.5
F3A X31 pin F2A H4 Unswitched battery RD - 2.5 SHEET 01
F3B X23.s pin 9 K4 Unswitched battery RD - 1.0
X23.s pin 9 J4 RD - 1.0
X88.p pin 17 L4 RD - 1.0
F4A X31 pin F5A M4 Switched battery DB - 1.5 SHEET 03
X15.2 pin 5 N4 DB - 1.5
F4B X88.p pin 8 O4 Switched battery WH - 1.0
F5A X31 pin F4A M4 Switched battery DB - 1.5 SHEET 03
F5B X13.p pin 1 P4 Switched battery RD/GN - 1.0
F6A - - - -
F6B - - - -
X32 - STOP LIGHTS
RAIL17TLB0306AA 4

1 - - - -
2 X33 pin 3 S2 From switch S33 RD - 1.0 SHEET 05
3 XC1 pin 7 T2 Stop lights RD/BK - 1.0
4 - - - -
X33 - STOP LIGHTS
RAIL17TLB0306AA 5

1 - - - -
2 XC1 pin 5 R2 Switched battery WH - 1.0 SHEET 05
3 X32 pin 2 S2 To switch S32 RD - 1.0
4 - - - -
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X34 - RIDE CONTROL SOLENOID
RAIL17TLB0285AA 6

1 X10.s pin 10 J Ride control WH/BK - 1.0 SHEET 03
2 GND.2 K Ground BK - 1.0
X35 - HAND HAMMER SOLENOID
RAIL17TLB0290AA 7

1 X10.s pin 4 I Hand hammer solenoid GY/BK - 1.0 SHEET 02
2 GND.3 G Ground BK - 1.0
T - - - -
X36.s - REAR HAMMER SOLENOID
RAIL17TLB0252AA 8

1 X209 pin 1 A Ground RD/GN - 1.0 SHEET 03
2 X10.s pin 7 B Rear hammer RD/YE - 1.0
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X-049
MARBLE CUTTING
X40 - REAR RIGHT WORK LIGHT
RAIL17TLB0269AA 1

2 XC5 pin 11 S Rear right work light GN/BK - 1.0
X41 - BLOWER MOTOR
RAIL17TLB0319AA 2

1 GND.1 Q1 Ground BK - 1.0 SHEET 07
2 XC5 pin 11 B Blower motor WH - 1.0
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X43.p - WORK LIGHTS
RAIL17TLB0333AA 3

1 T1 Ground BK - 1.0 SHEET 07
2 X412 pin 1 V Work light switch LB/YE - 1.0
3 X407 pin 2 O1 Ground BK - 1.0
4 X407 pin 1 F1 Right work light WH - 1.0
5 X409.s pin 2 P1 Ground BK - 1.0
6 X409.s pin 1 G1 Left work light WH - 1.0
X43.s - ROTARY BEACON
RAIL17TLB0258AA 4

2 XC5 pin 16 V Rotary beacon switch LB/YE - 1.5
3 GND.1 O1 Ground BK - 1.0
4 X12.s pin 6 F1 Rotary beacon WH - 1.0
6 X12.s pin 7 G1 Rotary beacon WH - 1.0
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X44 - FRONT RIGHT WORK LIGHT
RAIL17TLB0269AA 5

2 XC5 pin 14 P Front right work light GY - 1.0
RAIL17TLB0269AA 6

2 XC5 pin 12 T Front right work light GN - 1.0
X46 - REAR LEFT WORK LIGHT
RAIL17TLB0269AA 7

2 XC5 pin 12 R Rear left work light GN - 1.0
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RAIL17TLB0269AA 8

1 GND.1 M1 Ground BK - 1.0 SHEET 06
2 XC5 pin 13 O Rear left work light GY-BK - 1.0
X49 - FRONT WIPER CONNECTOR
RAIL17TLB0321AA 9

1 XC5 pin 3 C Wiper switch WH - 1.0 SHEET 07
2 - - - -
3 XC5 pin 1 A Switched battery WH - 1.0
4 XC5 pin 4 D Wiper switch WH - 1.0
5 - - - -
6 H18.3 pin 1 F2 Ground BK - 1.0
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X-059
MARBLE CUTTING
X50 - FRONT LEFT WORK LIGHT
RAIL17TLB0252AA 1

1 GND.2 Ground BK - 1.0 SHEET 06
2 Front left work light
RAIL17TLB0252AA 2

2 XC5 pin 14 Q Front left work light GY - 1.0
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X53 - RADIO CONNECTOR
RAIL17TLB0323AA 3

1 - - - -
2 - - - -
3 BS1.1 pin 1 P2 Right speaker RD - 0.5 SHEET 08
4 BS1.2 pin 1 Q2 Right speaker BK - 0.5
5 BS2.1 pin 1 O2 Left speaker RD - 0.5
6 BS12.2 pin 1 N2 Left speaker BK - 0.5
7 - - - -
8 - - - -
RAIL17TLB0323AA 4

1 - - - -
2 - - - -
3 - - - -
4 X54 pin 7 M2 Unswitched battery from RD/BK - 1.0 SHEET 08
X55.1 pin 1 H2 fuse F7B RD/BK 1.0
5 - - - - -
6 - - - - -
7 X54 pin 3 M2 Unswitched battery from RD/BK 1.0 SHEET 08
fuse F7B
8 GND.2 B2 Ground BK - 1.0
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X55.1 - POWER POINT
RAIL17TLB0319AA 5

1 XC5 pin 10 L Unswitched battery from RD/BK - 1.5 SHEET 08
X54 pin 4 H2 fuse F7B RD/BK 1.0
2 X56 pin 2 I2 Ground BK - 1.0
GND.2 R1 BK - 1.0
X55.2 - POWER POINT
RAIL17TLB0325AA 6

1 XC5 pin 6 F Battery voltage YE - 1.0 SHEET 08
X56 - FRONT WASHER PUMP
RAIL17TLB0319AA 7

1 X12.p pin 3 C1 Pump signal DB/WH 1.0 SHEET 07
2 X55.1 pin 2 I2 Ground BK - 1.0
X57 pin 2 J2 BK - 1.0
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X57 - REAR WASHER PUMP
RAIL17TLB0319AA 8

1 X12.p pin 2 B1 Pump signal WH - 1.0 SHEET 07
2 X56 pin 2 J2 Ground BK - 1.0
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X-069
MARBLE CUTTING
X66 TRANSMISSION OIL TEMPERATURE SWITCH
RAIL17TLB0298AA 1

1 X1.s pin 3 B1 Transmission oil YE - 1.0 SHEET 01
temperature
X67A ALTERNATOR D+
RAIL17TLB0297AA 2

1 X1.s pin 12 A2 Alternator D+ signal PK - 1.0 SHEET 01
X67B ALTERNATOR W
RAIL17TLB0297AA 3
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1 X1.s pin 4 X1 Alternator W signal YE - 1.0 SHEET 01
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X-079
MARBLE CUTTING
X72.s - PILOT CONTROL
RAIL17TLB0288AA 1

1 X10.s pin 1 H1 Power supply to the pilot GY - 1.5 SHEET 01
control module
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X-089
MARBLE CUTTING
X87.p - LEFT POWER SUPPLY SIDE DASHBOARD HARNESS
RAIL17TLB0264AA 1

1 XC3 pin 4 N5 Power supply dashboard PK/YE - 1.0 SHEET 06
harness
2 XC3 pin 7 O5 Power supply switch WH - 1.0 SHEET 06
3 X13.p pin 7 T4 Parking lamp fuse YE - 1.5 SHEET 04
4 X605 pin 86 F7 Rear lights GN/VT - 1.0 SHEET 06
5 X15.2 pin 5 D6 Road and beam lights DB - 1.5 SHEET 04
switch
6 X13.p pin 8 U4 Road and beam lights GY/BK - 1.5 SHEET 04
7 X88.p pin 9 E7 Rear work light switch WH - 1.0 SHEET 06
8 SP-171 M5 Front work lights YE - 1.0 SHEET 06
9 H26.1 pin 1 O6 Rear work lights WH - 1.0 SHEET 03
10 X10.p pin 17 O1 Rear vertical lock OR/WH - 1.0 SHEET 03
11 XC3 pin 15 U5 Rear work lights VT/BK - 1.0 SHEET 06
12 X88.p pin 6 D7 Ground BK - 1.0 SHEET 06
13 SP-172 T5 Rear work lights YE - 1.0 SHEET 06
X88.p - RIGHT POWER SUPPLY SIDE DASHBOARD HARNESS
RAIL17TLB0265AA 2

1 X12.s pin 5 A7 Rear windshield wiper WH - 1.0 SHEET 07
XC3 pin 17 W5 WH - 1.0
2 X12.s pin 2 X6 Rear washer WH - 1.0 SHEET 07
3 X12.s pin 1 W6 Windshield wiper return WH - 1.0 SHEET 07
4 X12.s pin 4 Z6 Windshield wiper WH - 1.0 SHEET 07
5 XC3 pin 11 P5 Horn OR - 1.0 SHEET 02
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6 X87.p pin 12 D7 Ground BK - 1.0 SHEET 07
GND.2 O2 Ground BK - 1.0
7 X10.p pin 15 M1 WH/BK - 1.0 SHEET 06
8 X31 pin F4B O4 Switched battery WH - 1.0 SHEET 03
9 X87.p pin 7 E7 Rear work light switch WH - 1.0 SHEET 06
XC3 pin 18 X5 Rear work light switch WH - 1.0
10 XST1 (Receptacle) pin 11 S6 Display control BR/WH - 1.0 SHEET 03
11 XST1 (Receptacle) pin 12 T6 Enter control BR/BK - 1.0 SHEET 03
12 XST1 (Receptacle) pin 13 U6 Up control DB/BK - 1.0 SHEET 03
13 XST1 (Receptacle) pin 14 V6 Down control DB/WH - 1.0 SHEET 03
14 GND.2 R2 Ground BK - 1.0 SHEET 03
15 - - - -
16 - - - -
17 X31 pin F3B L4 Unswitched battery RD - 1.0 SHEET 03
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X-099
MARBLE CUTTING
X91 - CRAB STEERING SOLENOID
RAIL17TLB0289AA 1

1 X10.s pin 21 D1 Crab steering solenoid WH - 1.0 SHEET 11
2 GND.1 Z Ground BK - 1.0
T - - - -
X92 - ROUND STEERING SOLENOID
RAIL17TLB0289AA 2

1 X10.s pin 14 T Round steering solenoid WH - 1.0 SHEET 11
2 GND.2 P Ground BK - 1.0
T - - - -
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X93 - 4WS SOLENOID
RAIL17TLB0289AA 3

1 X10.s pin 12 U 4WS solenoid WH - 1.0 SHEET 11
2 GND.1 V Ground BK - 1.0
T - - - -
X94 - 2WS SOLENOID
RAIL17TLB0289AA 4

1 X10.s pin 18 S 2WS solenoid WH - 1.0 SHEET 11
2 GND.2 M Ground BK - 1.0
T - - - -
X95 CENTER 4WS CONNECTOR
RAIL17TLB0268AA 5
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1 XST1 (Receptacle) pin 22 Steering crab control lamp WH - 1.0 SHEET 11
2 - - - -
3 X10.p pin 13 K1 Front axle signal GY/DB - 1.0
4 X13.p pin 5 R4 Steering crab control DB/RD - 1.0
5 XC6 pin 2 X3 Buzzer control GN/WH - 1.0
6 X13.p pin 11 X4 Round steering control WH - 1.0
7 X13.p pin 13 B5 Center steering power WH - 1.0
supply
8 GND.2 Q2 Ground BK - 1.0
9 X13.p pin 12 Z4 Speed sensor 2 GY/DB - 1.0
10 X10.p pin 16 N1 Rear axle signal WH - 1.0
11 XST1 (Receptacle) pin 23 G6 2WS lamp GY - 1.0
12 XST1 (Receptacle) pin 24 H6 Round steering control WH - 1.0
lamp
X96 CENTER 4WS CONNECTOR
RAIL17TLB0271AA 6

1 X10.p pin 21 S1 Steering crab control WH - 1.0 SHEET 11
2 X10.p pin 14 L1 4WS WH - 1.0
3 SA10 I6 Round steering WH - 1.0
4 - - - -
5 X10.p pin 22 T1 Front axle sensor WH - 1.0
6 X10.p pin 11 I1 Rear axle sensor WH - 1.0
7 - - - -
8 X10.p pin 18 P1 2WS WH - 1.0
X97 - FRONT AXLE SENSOR
RAIL17TLB0280AA 7

A X10.s pin 13 J1 Front axle signal GY/DB - 1.0 SHEET 11
B X10.s pin 22 K1 +Front axle sensor WH - 1.0
C GND.3 F Ground BK - 1.0
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X98 - REAR AXLE SENSOR
RAIL17TLB0280AA 8

A X10.s pin 16 Q Rear axle signal WH - 1.0 SHEET 11
B X10.s pin 11 R +Rear axle sensor WH - 1.0
C GND.2 S Ground BK - 1.0
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X-109
MARBLE CUTTING
X-100 - FORWARD SOLENOID (Receptacle)
87695582 1
87695582
RAIL16TLB0877FA 2

1 X-403 (Receptacle) pin 1 305 Forward solenoid signal Orange (1.0) SHEET 10
2 X-403 (Receptacle) pin 2 307 Forward solenoid ground Orange/ black
(1.0)
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X-101 - REVERSE SOLENOID (Receptacle)
87695582 3
87695582
RAIL16TLB0877FA 4

1 X-403 (Receptacle) pin 3 306 Reverse solenoid signal Violet (1.0) SHEET 10
2 X-403 (Receptacle) pin 4 308 Reverse solenoid ground Violet/ black
(1.0)
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X-102 - 1/3 SOLENOID (Receptacle)
87695582 5
87695582
RAIL16TLB0877FA 6

1 X-403 (Receptacle) pin 5 304 1/3 solenoid signal Brown (1.0) SHEET 10
2 X-403 (Receptacle) pin 6 303 1/3 solenoid ground Brown/ black
(1.0)
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X-103 - 2/4 SOLENOID (Receptacle)
87695582 7
87695582
RAIL16TLB0877FA 8

1 X-403 (Receptacle) pin 7 359 2/4 solenoid signal White/ red SHEET 10
(1.0)
2 X-403 (Receptacle) pin 8 360 2/4 solenoid ground White/ dark
blue (1.0)
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X-104 - S13 SOLENOID (Receptacle)
87695582 9
87695582
RAIL16TLB0877FA 10

1 X-402 (Receptacle) pin 3 301 S13 solenoid signal Brown (1.0) SHEET 10
2 X-402 (Receptacle) pin 3 302 S13 solenoid ground Black (1.0)
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X-105 - S24 SOLENOID (Receptacle)
87695582 11
87695582
RAIL16TLB0877FA 12

1 X-402 (Receptacle) pin 5 25X S24 solenoid signal Pink (1.0) SHEET 10
2 X-402 (Receptacle) pin 4 30 S24 solenoid ground Black (1.0)
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X-108 - TRANSMISSION TEMPERATURE SENSOR (Receptacle)
84062580 13
84062580
RAIL16TLB0877FA 14

1 X-402 (Receptacle) pin 9 343 Transmission temperature Dark blue/ SHEET 10
signal black (1.0)
2 X-402 (Receptacle) pin 12 40 Sensor ground Black (1.0)
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X-109 - TRANSMISSION PRESSURE SWITCH (Receptacle)
82012083 15
82012083
RAIL16TLB0877FA 16

1 X-402 (Receptacle) pin 11 344 Transmission pressure Yellow/ black SHEET 10
signal (1.0)
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X-119
MARBLE CUTTING
X110 - AIR CONDITIONER CONNECTOR
RAIL17TLB0259AA 1
84062580
1 SA6 P Unswitched battery to the RD - 4.0 SHEET 12
air conditioner fan
2 GND Q Ground BK - 4.0
X220 pin 10 L Ground BK - 4.0
3
RAIL17TLB0260AA 2
84062580
1 X220 pin 1 C YE - 1.5 SHEET 12
2 X220 pin 2 D RD - 1.5
3 X220 pin 3 E OR - 1.5
4 SA2 O Switched battery VT - 2.5
5 X220 pin 5 G GY - 1.0
6 X220 pin 6 H WH - 1.0
7 X220 pin 7 I GN - 1.0
8 X220 pin 8 J PK - 1.0
9 X220 pin 9 K LB - 1.0
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X-112 - TRANSMISSION SPEED SENSOR (Receptacle)
84062580 3
84062580
RAIL16TLB0877FA 4

1 X-402 (Receptacle) pin 7 330 Speed signal White/ black SHEET 10
(1.0)
3 X-402 (Receptacle) pin 8 21 Battery voltage Red (1.0)
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X-113 - 4WD SOLENOID (Receptacle)
87695582 5
87695582
RAIL16TLB0877FA 6

1 X-402 (Receptacle) pin 5 25X 4WD solenoid signal Yellow/ SHEET 10
red(1.0)
2 X-402 (Receptacle) pin 4 30 4WD solenoid ground Black (1.0)
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X-114 - DIFFERENTIAL LOCK SOLENOID (Receptacle)
87695582 7
87695582
RAIL16TLB0877FA 8

1 X-402 (Receptacle) pin 6 357 Differential lock solenoid Green/ black SHEET 10
signal (1.0)
2 X-402 (Receptacle) pin 4 30 Differential lock solenoid Black (1.0)
ground
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X-129
MARBLE CUTTING
X125 - OPTIONAL SPEEDOMETER CONNECTOR
RAIL17TLB0307AA 1

1 S5 pin 2 M1 Switched battery RD/GN - 1.0 SHEET 03
2 GND X1 Ground BK - 1.0
3 X404.p pin 12 U Speedometer GY/DB - 1.0
4 - - - -
5 - - - -
6 X21 pin 3 Z1 Backlight YE - 1.0
7 - - - -
8 - - - -
9 - - - -
10 - - - -
11 - - - -
12 - - - -
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X-209
MARBLE CUTTING
X201.s - ONE TOUCH DECEL
RAIL17TLB0287AA 1

1 X10.s pin 24 G1 Power supply to the one WH/DB - 1.0 SHEET 01
touch decel
X202 - SIDE-SHIFT SOLENOID
RAIL17TLB0285AA 2

1 X10.s pin 15 EN1 Side-shift solenoid WH/BK - 1.0 SHEET 03
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X203 - BOOM LOCK SOLENOID
RAIL17TLB0289AA 3

1 X10.s pin 17 C Boom lock solenoid OR/WH - 1.0 SHEET 03
2 GND.3 D Ground BK - 1.0
X204 - HORN CONNECTOR
RAIL17TLB0269AA 4

1 GND.1 W Ground BK - 1.0 SHEET 02
2 X10.s pin 6 F1 Horn signal OR - 1.0
X205 - TRANSMISSION CUT-OFF RELAY
RAIL17TLB0284AA 5

A X10.s pin 20 P1 Transmission cut-off signal LB/RD - 1.0 SHEET 02
B - - - -
C - - - -
D X10.s pin 9 Q1 Switched battery to the WH/RD - 1.0
transmission cut-off switch
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X206 - BUCKET LEVEL SOLENOID
RAIL17TLB0252AA 6

A X10.s pin 5 O1 Bucket level solenoid GY/RD - 1.0 SHEET 02
B GND.2 L Ground BK - 1.0
X207 - BI-DIRECTIONAL AUXILIARY SOLENOID
RAIL17TLB0285AA 7

1 X10.s pin 19 N1 Bi-directional auxiliary DB/YE - 1.0 SHEET 02
solenoid
2 GND.3 H Ground BK - 1.0
X208 - BUCKET QUICK COUPLER SOLENOID
RAIL17TLB0252AA 8

2 X10.s pin 23 I1 Bucket quick coupler WH - 1.0
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X209 - REAR HAMMER SOLENOID
RAIL17TLB0289AA 9

1 X36.s pin 1 A Rear hammer solenoid RD/GN - 1.0 SHEET 03
2 GND.1 X Ground BK - 1.0
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X-229
MARBLE CUTTING
RAIL17TLB0263AA 1
84062580
1 X111 pin 1 C +15 A/C YE - 1.5 SHEET 12
2 X111 pin 2 D +15 A/C RD - 1.5
3 X111 pin 3 E +15 A/C OR - 1.5
4 SA2 F +15 A/C VT - 2.5
5 X111 pin 5 G +15 A/C GY - 1.0
6 X111 pin 6 H +15 A/C WH - 1.0
7 X111 pin 7 I +15 A/C GN - 1.0
8 X111 pin 8 J +15 A/C PK - 1.0
9 X111 pin 9 K +15 A/C LB - 1.0
10 X111 pin 2 L Ground BK - 1.0
11 XST1 (Receptacle) pin 10 M Air conditioner lamp YE/GN - 1.0
X1.s pin 1 N Air conditioner relay pin 86 YE/GN - 1.5
X227 - 4WD RELAY
RAIL17TLB0261AA 2

30 K14 pin 30 I7 Relay signal WH/RD - 1.0 SHEET 02
85 X230 pin 85 J7 Ground BK - 1.0
86 X23.s pin 12 J5 Relay signal YE/RD - 1.0
87 - - - -
87a X23.s pin 13 K5 4WD signal WH - 1.0
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X-239
MARBLE CUTTING
X230 - HAND HAMMER RELAY
RAIL17TLB0261AA 1

30 X10.s pin 7 E1 Relay signal RD/YE - 1.0 SHEET 03
X13.p pin 14 C5 RD/YE - 1.0
85 X227 pin 85 J7 Ground BK - 1.0
86 X13.p pin 15 D5 Relay signal GN/VT - 1.0
87 XC3 pin 16 V5 Switched battery RD/GN - 1.0
87a - - - -
X232 - RIDE CONTROL RELAY
RAIL17TLB0261AA 2

30 X13.p pin 1 W7 Switched battery RD/GN - 1.0 SHEET 03
85 K14 pin 85 H7 Ground BK - 1.0
86 XST2 (Receptacle) pin 8 T8 Signal from the instrument WH - 1.0
cluster
87 X13.p pin 3 H1 Ride control solenoid LB/BK - 1.0
X10.p pin 10 K7 LB/BK - 1.0
87a - - - -
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X-269
MARBLE CUTTING
X262 - OPTIONAL CONNECTOR
RAIL17TLB0278AA 1 RAIL17TLB0279AA 2

1 X10.p pin 1 X Switched battery to the GY - 1.5 SHEET 01
pilot controls
2 XC6 pin 9 T3 Switched battery from fuse GY - 1.5
F2C
3 XC3 pin 8 U3 Bucket level GY/RD - 1.0
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X-409
MARBLE CUTTING
X-400 - FNR SWITCH (Receptacle)
84277215 1
84277215
RAIL16TLB0845FA 2
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1 - - - - SHEET 10
2 X-401 (Receptacle) pin 19 I1 Gear command 02 Violet (1.0)
3 X-401 (Receptacle) pin 47 Q1 Gear command 01 Green (1.0)
4 X-401 (Receptacle) pin 49 S1 Kick down signal Green/ white
(1.0)
5 X-406 pin 1 X1 Reverse signal Brown/ white
(1.0)
6 Splice SP-8361 G Neutral signal Green/ violet
(1.0)
7 X406.s pin 2 Z1 Forward signal Brown/ black
(1.0)
8 X404.s pin 1 A2 Switched battery to the White/ red
FNR switch (1.0)
X-401 - TRAX POWERSHIFT CONTROL MODULE (Receptacle)
RAIL17TLB0262FA 3
47715498
1 X404.s pin 9 F1 Unswitched battery Red (1.0) SHEET 02
2 X406.s pin 3 G1 In-gear signal White (1.0) SHEET 10
3 X-403 (Receptacle) pin 1 P Forward valve 1 Orange (1.0) SHEET 10
4 X-403 (Receptacle) pin 3 R Reverse valve 1 Violet (1.0) SHEET 10
5 Splice SP-8374 L Switched battery White/red (1.0) SHEET 10
SHEET 02
6 X-403 (Receptacle) pin 5 T PWM 1 Brown (1.0) SHEET 10
7 X-403 (Receptacle) pin 7 V PWM 2 White/ red SHEET 10
(1.0)
8 Splice SP-8374 J Switched battery White/ red SHEET 10
(1.0) SHEET 02
9 X-402 (Receptacle) pin 2 X S13 valve Brown (1.0) SHEET 10
10 - - - -
11 X-402 (Receptacle) pin 6 A1 Differential lock solenoid Green/ black SHEET 10
(1.0)
12 X-403 (Receptacle) pin 2 Q Forward valve 2 Orange/ black SHEET 10
13 X-403 (Receptacle) pin 6 U PWM 1 Brown/ black SHEET 10
(1.0)
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14 - - - -
15 - - - -
16 Splice SP-8361 E Neutral signal Green/ violet SHEET 10
(1.0) SHEET 02
17 X-402 (Receptacle) pin 12 F2 Signal ground Black (1.5) SHEET 10
18 X404.s pin 6 H1 Forward signal Brown/ black SHEET 02
(1.0)
19 X-400 (Receptacle) pin 2 I1 Gear command 2 Violet (1.0) SHEET 10
20 X406.s pin 6 J1 4WS signal Yellow/ dark SHEET 10
blue (1.0)
21 X404.s pin 3 K1 Declutch Dark blue/ red SHEET 10
(1.0)
22 X404.s pin 4 L1 4WD Brown/ green SHEET 02
(1.0)
23 X404.2 pin 8 M1 Auto/ manual White (1.0) SHEET 02
24 - - - -
25 X-402 (Receptacle) pin 7 B1 Speed sensor White/ black SHEET 10
(1.0)
26 - - - -
27 X405.2 pin 2 G2 CAN high signal Yellow (0.5) SHEET 02
28 X404.2 pin 12 O1 Speed sensor out Gray/ dark SHEET 02
blue (1.0)
29 Splice SP-8083 D Ground Black (1.0) SHEET 10
30 - - - -
31 - - - -
32 - - - -
33 - - - -
34 Splice SP-8374 I Switched battery White/ red SHEET 10
(1.0) SHEET 02
35 - - - -
36 - - - -
37 - - - -
38 X-402 (Receptacle) pin 3 Z S24 valve Pink (1.0) SHEET 10
39 Splice SP-8222 N 4WD solenoid Yellow/ red SHEET 10
(1.0) SHEET 02
40 X-403 (Receptacle) pin 4 S Reverse valve 2 Violet/ white SHEET 10
(1.0)
41 X-403 (Receptacle) pin 8 W PWM 2 White/ dark SHEET 10
blue (1.0)
42 - - - -
43 X-402 (Receptacle) pin 9 C1 Temperature signal Dark blue/ SHEET 10
black (1.0)
44 X-402 (Receptacle) pin 11 D1 Pressure signal Yellow/ black SHEET 10
(1.0)
45 - - - -
46 X404.s pin 7 P1 Reverse Brown/ white SHEET 02
(1.0)
47 X-400 (Receptacle) pin 3 Q1 Gear command 1 Green (1.0) SHEET 10
48 X409.s pin 1 R1 Solenoid 3A White (1.0) SHEET 02
49 X-400 (Receptacle) pin 4 S1 Kickdown Green/ white SHEET 10
(1.0)
50 X404.s pin 13 T1 Stop switch out Red/ black SHEET 02
(1.0)
51 X404.s pin 10 U1 Differential lock signal Violet/ white SHEET 02
(1.0)
52 - - - -
53 X404.2 pin 5 V1 W signal from the alternator Light blue/ SHEET 02
white (1.0)
54 - - - -
55 X405.s pin 1 H2 CAN low signal Green (0.5) SHEET 02
56 - - - -
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X-402 - POWERSHIFT JUMPER HARNESS (Receptacle)
84122168 4 84277218 5
RAIL16TLB0877FA 6

1 Splice SP-8083 A Solenoid ground Black (1.0) SHEET 10
2 X-401 (Receptacle) pin 9 X S13 solenoid Brown (1.0)
3 X-401 (Receptacle) pin 38 Z S24 solenoid Pink (1.0)
4 Splice SP-8083 B Solenoid ground Black (1.0)
5 Splice SP–8222 M 4WD solenoid Yellow/ red
(1.0)
6 X-401 (Receptacle) pin 11 A1 Differential lock solenoid Green/ black
(1.0)
7 X-401 (Receptacle) pin 25 B1 Transmission speed White/ black
sensor (1.0)
8 Splice SP-8374 H Switched battery Red (1.0)
9 X-401 (Receptacle) pin 43 H Transmission temperature Dark blue/
sensor signal black (1.0)
10 - - - -
11 X-401 (Receptacle) pin 44 D1 Transmission pressure Yellow/ black
switch (1.0)
12 X-401 (Receptacle) pin 17 F2 Transmission sensor Black (1.5)
ground
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X-403 - POWERSHIFT JUMPER HARNESS (Receptacle)
87700325 7 84277216 8
RAIL16TLB0877FA 9

1 X-401 (Receptacle) pin 3 P Forward valve 1 Orange (1.0) SHEET 10
2 X-401 (Receptacle) pin 12 Q Forward valve 2 Orange/ black
(1.0)
3 X-401 (Receptacle) pin 4 R Reverse valve 1 Violet (1.0)
4 X-401 (Receptacle) pin 40 S Reverse valve 2 Violet/ black
(1.0)
5 X-401 (Receptacle) pin 6 T PWM 1 Brown (1.0)
6 X-401 (Receptacle) pin 13 U PWM 1 Brown/ black
(1.0)
7 X-401 (Receptacle) pin 7 V PWM 2 White/ red
(1.0)
8 X-401 (Receptacle) pin 41 W PWM 2 White/ Dark
blue (1.0)
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X-404 - FRONT DASHBOARD INTERFACE CONNECTOR
RAIL17TLB0251AA 10
84277215
1 Splice SP-8374 K Switched battery from fuse White/ red SHEET 10
X-400 (Receptacle) pin 8 A2 F-1C (1.0)
White/ red
(1.0)
2 - - - -
3 X-401 (Receptacle) pin 21 K1 Declutch Dark blue/ red
(1.0)
4 X-401 (Receptacle) pin 22 L1 4WD Brown/ green
(1.0)
5 X-401 (Receptacle) pin 53 V1 Alternator signal Light blue/
white (1.0)
6 X406.s pin 2 C2 Forward signal Brown/ black
X-401 (Receptacle) pin 18 H1 (1.0)
Brown/ black
(1.0)
7 X406.s pin 1 B2 Reverse signal Brown/ white
X-401 (Receptacle) pin 46 P1 (1.0)
Brown/ white
(1.0)
8 X-401 (Receptacle) pin 23 M1 Auto/ manual White (1.0)
9 X-401 (Receptacle) pin 1 F1 Unswitched battery from Red (1.0)
X-23 pin 9
10 X-401 (Receptacle) pin 51 U1 Differential lock signal Violet/ white
(1.0)
11 - - - -
12 X-401 (Receptacle) pin 28 O1 Speed sensor out Brown/ dark
blue (1.0)
13 X-401 (Receptacle) pin 50 T1 Stop switch out Red/ black
(1.0)
X404.p - FRONT DASHBOARD INTERFACE CONNECTOR
RAIL17TLB0251AA 11
84277215
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1 XC1 pin 8 J Switched battery from fuse WH/RD - 1.0 SHEET 10
F-1C
2 X23.p pin 2 K Ground BK - 1.5
3 X23.p pin 3 L Declutch DB/RD - 1.5
4 S2 pin 2 M 4WD BR/GN - 1.0
5 X23.p pin 5 N Alternator signal LB/WH - 1.0
6 X23.p pin 6 O Forward signal BR/BK - 1.0
7 X23.p pin 7 P Reverse signal BR/WH - 1.0
8 S48 pin 1 Q Auto/ manual WH - 1.0
9 X23.p pin 9 R Unswitched battery from RD - 1.0
X-23 pin 9
10 - - - -
11 X23.p pin 11 S Ground BK - 1.5
12 X13.s pin 12 T Speed sensor out GY/DB - 1.0
X125 pin 3 GY/DB - 1.0
13 XC1 pin 7 U Stop switch out RD/BK - 1.0
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X-405 - CAN BUS INTERFACE CONNECTOR
RAIL17TLB0252AA 12
84277215
1 X-401 (Receptacle) pin 55 H2 CAN low to the Trax Green (0.5) SHEET 10
Control Module
2 X-401 (Receptacle) pin 27 G2 CAN high to the Trax Yellow (0.5)
Control Module
X405.p - CAN BUS INTERFACE CONNECTOR
RAIL17TLB0312AA 13
84277215
1 SA4 W3 CAN low GN -0.5 SHEET 10
2 SA3 A4 CAN high YE - 0.5
X-406 - DIODES CONNECTOR
RAIL17TLB0253AA 14
84277215
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1 X-400 (Receptacle) pin 5 X1 Reverse signal Brown/ SHEET 10
X404.s pin 7 B1 white(1.0)
Brown/
white(1.0)
2 X-400 (Receptacle) pin 7 Z1 Forward signal Brown/ black
X404.2 pin 6 C2 (1.0)
Brown/ black
(1.0)
3 X-401 (Receptacle) pin 2 G1 In-gear signal to the Trax White (1.0)
Control Module
4 X409.2 pin 2 D2 Signal from the steering Dark blue/ red
switch (1.0)
5 X409.2 pin 3 E2 Signal from the steering Green/ Black
switch (1.0)
6 X-401 (Receptacle) pin 20 J1 4WS signal Yellow/ Dark
blue (1.0)
7 - - - -
RAIL17TLB0312AA 15

1 SA3 C4 CAN high YE - 0.5 SHEET 01
2 SA4 Z3 CAN low GN - 0.5
X408.s - CAN BUS INTERFACE CONNECTOR
RAIL17TLB0252AA 16

1 SA13 E9 CAN low Green (0.5) SHEET 01
2 SA14 K9 CAN high Yellow (0.5)
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X409.s - FRONT DASHBOARD INTERFACE CONNECTOR
RAIL17TLB0254AA 17

1 X-401 (Receptacle) pin 48 R1 Solenoid 3A White (1.0) SHEET 10
2 X406.s pin 4 D2 4WS Dark blue (1.0)
3 X406.s pin 5 E2 4WS Green/ black
(1.0)
4 Splice SP-8222 O 4WD Yellow/ red
(1.0)
5 Splice SP-8361 F Neutral signal Green/ violet
(1.0)
RAIL17TLB0304AA 18

1 X23.p pin 8 W Solenoid 3A WH - 1.0 SHEET 10
2 S47 pin 5 X 4WS DB/RD - 1.0
3 S47 pin 1 Z 4WS GN/BK - 1.0
4 X23.p pin 12 A1 4WD YE/RD - 1.0
5 X13.s pin 15 B1 Neutral signal GN/VT - 1.0
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X-419
MARBLE CUTTING
X412 - ROTATING BEACON
RAIL17TLB0332AA 1

1 X43.p pin 2 B Signal LB/YE - 1.0 SHEET 07
X-406 pin 1 A LB/YE - 1.0
2 X43.p pin 1 E Ground BK - 1.0
X-406 pin 2 D BK - 1.0
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X-449
MARBLE CUTTING
X-448.p - RELAY/FUSE
1 Air conditioner relay K105 Air conditioner pressure SHEET 12
terminal 85 switch
2 Air conditioner relay K105 Unswitched battery from SHEET 12
terminal 30 fuse F007
3 Starter pilot relay K102 terminal Ground SHEET 01
85
4 Starter pilot relay K102 terminal Unswitched battery SHEET 01
30
5
6
7
8
9 Air conditioner relay K105 Air conditioner relay output SHEET 12
terminal 87
10 Air conditioner relay K105 Relay ground SHEET 12
terminal 86
11 Starter pilot relay K102 terminal Starter SHEET 01
87
12 Starter pilot relay K102 terminal Start signal SHEET 01
86
13 SCR main relay K107 terminal SHEET 01
85
14 SCR main relay K107 terminal Unswitched battery SHEET 01
30
15 Aux main relay K106 terminal SHEET 01
85
16 Aux main relay K106 terminal Unswitched battery SHEET 01
30
17
18
19
20
87
86
87
86
25
26 Air conditioner fuse F007 Unswitched battery SHEET 12
27 Starter interlock relay K103 SHEET 01
terminal 85
28 Starter interlock relay K103 From the start relay SHEET 01
terminal 30
29
31
32
33 Pump module fuse F008 SHEET 01
34 Tank heater valve and purge SHEET 01
module pump fuse F005
terminal 87
terminal 86
39 Starter relay K104 terminal 85 SHEET 01
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40 Starter relay K104 terminal 30 Start signal from the SHEET 01
ignition switch
41 Engine fuse F004 SHEET 01
42 SCR system fuse F003 SHEET 01
43
44
X-448.s - RELAY/FUSE
1 X-069.s pin B 1330 Air conditioner relay K105 YE - 1.0 SHEET 12
terminal 85
2 X-448.s pin 26 1360 Air conditioner relay K105 RD - 1.5 SHEET 12
terminal 30
3 Splice SP-002 G016 Ground BK - 0.75 SHEET 01
4 Splice SP-007 1022 Unswitched battery RD - 4.0 SHEET 01
5
6
7
8
9 X-473 (Plug) pin 1 60C6 Air conditioner relay K105 BR - 1.5 SHEET 12
terminal 87
10 X-451.p pin 2 1340 Air conditioner relay K105 YE - 1.0 SHEET 12
terminal 86
11 X-450.p pin 4 1170 Starter pilot relay K102 OR - 4.0 SHEET 01
terminal 87
12 X-448.s pin 35 1171 Starter pilot relay K102 OR - 0.75 SHEET 01
terminal 86
13 X-462 (Receptacle) pin 20 F200 SCR main relay K107 YE - 0.75 SHEET 01
terminal 85
14 Splice SP–007 1017 Unswitched battery RD - 4.0 SHEET 01
16 Splice SP-007 1016 Aux main relay K106 RD - 4.0 SHEET 01
terminal 30
17
18
19
20
21 Splice SP-021 IGN7 SCR main relay K107 OR - 4.0 SHEET 01
terminal 87
22 Splice SP-159 E05D SCR main relay K107 RD - 0.75 SHEET 01
terminal 86
23 X-449.s pin 1 IGN1 Aux main relay K106 OR - 4.0 SHEET 01
terminal 87
24 Splice SP-159 E05C Aux main relay K106 RD - 0.75 SHEET 01
terminal 86
25
26 Fuse F007 Air conditioner fuse F007 SHEET 12
28 X-448.s pin 47 1180 Starter relay K104 terminal OR - 0.75 SHEET 01
87
29
31
32
33 X-639 pin 3 IGNB Pump module fuse F008 OR - 1.5 SHEET 01
34 Splice SP-016 IGN9 Tank heater valve and OR - 1.5 SHEET 01
purge module pump fuse
F005
35 X-448.s pin 12 1171 Starter interlock relay K103 OR - 0.75 SHEET 01
terminal 87
36 X-451P pin 3 1191 Starter interlock relay K103 WH - 1.0 SHEET 01
terminal 86
37 Splice SP-021 IGNA Pump module fuse F008 OR - 1.5 SHEET 01
F005
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39 Starter relay K104 terminal SHEET 01
85
40 X-461 (Receptacle) pin 27 E270 Starter relay K104 terminal YE - 0.75 SHEET 01
30
41 X-461 (Receptacle) pin 1 E010 Engine fuse F004 RD - 2.5 SHEET 01
42 Splice SP-159 E058 SCR system fuse F003 RD - 1.0 SHEET 01
43
44
45 Splice SP-151 E054 Engine fuse F005 RD - 2.5 SHEET 01
46 Splice SP-151 E055 SCR system fuse F003 RD - 1 SHEET 01
87
86
1 Sensor power fuse F014 Sensor power fuse F014 SHEET 01
3 Spare fuse F013 Spare fuse F013 SHEET 01
5 Engine fuse f012 Engine fuse f012 SHEET 01
6 Engine fuse F012 Engine fuse F012 SHEET 01
7 DEF heater fuse F011 DEF heater fuse F011 SHEET 01
9
10
11 Glow plug fuse F010 Glow plug fuse F010 SHEET 01
1 X-448.s pin 23 IGN1 Sensor power fuse F014 OR - 4.0 SHEET 01
2 Splice SP-015 IGN2 Sensor power fuse F014 OR - 4.0 SHEET 01
3 X-450.p pin 1 1020 Spare fuse F013 RD - 4.0 SHEET 01
5 Splice SP-151 E05A Engine fuse f012 RD - 4.0 SHEET 01
7 X-612 (Receptacle) pin 11 1019 DEF heater fuse F011 RD - 10.0 SHEET 01
8 Splice SP-001 1018 DEF heater fuse F011 RD - 10.0 SHEET 01
9
10
11 Splice SP-001 Glow plug fuse F010 RD - 6.0 SHEET 01
12 X-469 (Receptacle) pin 4 1040 Glow plug fuse F010 RD - 6.0 SHEET 01
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X-459
MARBLE CUTTING
X450S TO ENGINE HARNESS
RAIL17TLB0299AA 1

1 - - - -
2 - - - -
3 X1.s pin 7 G2 Start signal OR - 4.0 SHEET 01
4 MC1 pin 1 H2 Engine start from the OR - 4.0
starter
RAIL17TLB0300AA 2

1 X601 U Air conditioner RD - 1.5 SHEET 12
2 X1.s pin 11 R Air conditioner relay pin 86 YE - 1.0
3 X1.s pin 2 J2 Starter interlock WH - 1.0 SHEET 01
4 - - - -
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X-469
MARBLE CUTTING
X-460 - CAN BUS TERMINATION RESISTOR (84058093) (Receptacle)
84058093 1
84058093
RAIL16TLB1513FA 2

A Splice SP-168 E45E CAN L CAN L TERMINATION GN - 0.5 SHEET 01
RESISTOR
B Splice Sp-169 E23E CAN H CAN H TERMINATION YE - 0.5
RESISTOR
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X-461 - ECU (Receptacle)
84474047 3
84474047
RAIL16TLB1513FA 4
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1 X-448 pin 5 E010 BATTERY VOLTAGE VIA RD - 2.5 SHEET 01
MAIN RELAY
2 SP-153-P-X G013 BATTERY MINUS 1 BK - 2.5
3 SP-158-P-X E051 BATTERY +B VIA MAIN RD - 2.5
RELAY
5 SP-158-P-X E050 BATTERY +C VIA MAIN RD - 2.5
RELAY
7 X-611 (Receptacle) pin 3 1070 SCR TANK HEATING YE - 0.8
TANK HEAT VALVE VALVE SIGNAL
8 X-496 E080 CRANK SIGNAL YE - 0.8
18 X-470 (Receptacle) pin 21 3210 EXHAUST GAS PRESS BL - 0.5
SENSE SIGNAL
19 X-474 (Receptacle) pin 1 E190 AIR TEMP SENSOR YE - 0.5
SIGNAL
20 X-474 (Receptacle) pin 2 E200 AIR TEMP SENSOR BK/WH - 0.5
GROUND
22 X-469 (Receptacle) pin 3 E220 GLOW PLUG FEEDBACK YE - 0.5
SIGNAL
23 SP-163-P-X CANH 2 5 CAN H 2 5 YE - 0.5
24 X-496 (Plug) pin K E241 CAN 1 HIGH YE - 0.5
25 X-496 (Plug) pin E E251 CAN 1 LOW GN - 0.5
26 X-469 (Receptacle) pin 8 E520 GLOW PLUG UNIT YE - 0.5
COMMAND SIGNAL
27 X-496 (Plug) pin F E270 CRANK ENABLE FROM YE - 0.5
ECU
28 X-464 (Receptacle) pin 1 E280 MAIN RELAY BL - 0.5
30 X-463 (Receptacle) pin 1 E300 WATER IN FUEL LEVEL YE - 0.8
SENSOR SIGNAL
SENSE GROUND
41 SP-203-P-X E410 GLOW PLUG UNIT BK - 0.8
GROUND
45 SP-162-P-X CANL 2 5 CAN L 2 5 GN - 0.5
53 X-496 (Plug) pin A E530 CRANK ENABLE FROM YE - 0.5
ECU
54 SP-154-P-X 1505 TERMINAL 15 SW BAT+ OR - 0.8
SENSE SIGNAL
68 X-496 (Plug) pin B E680 K LINE YE - 0.5
72 SP-111-P-X 1720 SUPPLY MOD PUMP YE - 0.8
CONTROL SIGNAL
73 X-151 pin 2 COLD START 1730 BY-PASS VALVE SIGNAL YE - 1.5
BY-PASS VALVE
76 SP-111-P-X 1760 SUPPLY MOD PUMP YE - 0.8
CONTROL SIGNAL
79 X-636 (Receptacle) pin 1 1791 CAT TEMP SENSE DS BL - 0.5
GROUND
80 X-636 (Receptacle) pin 2 1801 CAT TEMP SENSE DS YE - 0.5
SIGNAL
81 X-617 (Receptacle) pin 2 1810 CAT TEMP US GROUND BL - 0.5
CT
82 X-617 (Receptacle) pin 1 1820 CAT TEMP US GROUND YE - 0.5
CT
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84474053 5
84474053
RAIL16TLB1513FA 6

1 X-471 (Receptacle) pin D F010 INJECTOR 1 HIGH BANK WH - 1.5 SHEET 01
2
2 X-471 (Receptacle) pin H F020 INJECTOR 2 HIGH BANK WH - 1.5
2
3 X-622 (Receptacle) pin 2 F030 DOSING VALVE L YE - 1.5
4 X-470 (Receptacle) pin 27 F040 BOOST PRESSURE GY - 1.0
ACTUATOR 1
5 X-638 pin 8 F050 COMMON SIGNAL BL - 0.8
GROUND
6 X-470 (Receptacle) pin 3 F060 OIL PRESSURE SWITCH WH - 0.5
INPUT SIGNAL
7 X-638 pin 10 F070 PRESSURE SENSE PK - 0.8
SUPPLY
8 X-470 (Receptacle) pin 41 F080 TVA POSITION SENSOR PK - 0.5
SUPPLY
9 X-470 (Receptacle) pin 33 F090 EGR POSITION SENSOR PK - 0.5
SUPPLY
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10 X-470 (Receptacle) pin 17 F100 BOOST PRESSURE PK - 0.5
SENSOR SUPPLY
11 X-470 (Receptacle) pin 7 F110 RAIL PRESSURE PK - 0.5
SENSOR SUPPLY
13 X-470 (Receptacle) pin 12 F130 SEGMENT(CAMSHAFT) PK - 0.5
SPEED SENSOR SUPPLY
14 X-470 (Receptacle) pin 4 F140 SEGMENT(CAMSHAFT) YE - 0.5
SPEED SENSOR SIGNAL
15 X-470 (Receptacle) pin 1 F150 FUEL METERING UNIT WH - 1.0
SUPPLY
16 X-471 (Receptacle) pin A F160 INJECTOR 1 HIGH BANK WH - 1.5
1
17 X-471 (Receptacle) pin E F170 INJECTOR 2 HIGH BANK WH - 1.5
1
18 X-622 (Receptacle) pin 1 2180 DOSING VALVE H BL - 1.5
20 X-448 pin 37 2200 SCR MAIN RELAY YE - 0.8
23 X-470 (Receptacle) pin 15 F230 FUEL TEMPERATURE BL - 0.5
SENSOR GROUND
24 X-470 (Receptacle) pin 35 F240 EGR POSITION SENSOR BK/WH - 0.5
GROUND
25 X-470 (Receptacle) pin 19 F250 BOOST PRESSURE BK/WH - 0.5
SENSOR GROUND
26 X-470 (Receptacle) pin 5 F260 RAIL PRESSURE BL - 0.5
SENSOR GROUND
27 X-470 (Receptacle) pin 25 2270 INLET TURBINE TEMP BL - 0.5
SENSE GROUND
28 X-470 (Receptacle) pin 8 F280 SEGMENT(CAMSHAFT) BL - 0.5
SPEED SENSOR
GROUND
31 X-471 (Receptacle) pin C F310 INJECTOR 1 LOW BANK GY - 1.5
2
32 X-471 (Receptacle) pin B F320 INJECTOR 1 LOW BANK GY - 1.5
1
34 X-470 (Receptacle) pin 38 F340 TVA ACTUATOR MOTOR GY - 0.8
MINUS
35 X-470 (Receptacle) pin 30 F350 EGR ACTUATOR MOTOR GY - 0.8
MINUS
37 X-470 (Receptacle) pin 43 F370 TVA POSITION SENSOR BK/WH - 0.5
GROUND
38 X-470 (Receptacle) pin 16 F380 FUEL TEMPERATURE YE - 0.5
SENSOR SIGNAL
39 X-470 (Receptacle) pin 34 F390 EGR POSITION SENSOR YE - 0.5
SIGNAL
40 X-470 (Receptacle) pin 18 F400 BOOST PRESSURE YE - 0.5
SENSOR SIGNAL
41 X-470 (Receptacle) pin 6 F410 RAIL PRESSURE YE - 0.5
SENSOR SIGNAL
43 X-470 (Receptacle) pin 26 2430 INLET TURBINE TEMP YE - 0.5
SENSE SIGNAL
44 X-470 (Receptacle) pin 10 F440 CRANKSHAFT SPEED YE - 0.5
SENSOR SIGNAL MINUS
45 X-638 pin 6 F450 PURGING PUMP SIGNAL YE - 1.5
46 X-471 (Receptacle) pin G F460 INJECTOR 2 LOW BANK GY - 1.5
2
48 X-471 (Receptacle) pin F F480 INJECTOR 2 LOW BANK GY - 1.5
1
49 X-470 (Receptacle) pin 37 F490 TVA ACTUATOR MOTOR WH - 0.8
PLUS
50 X-470 (Receptacle) pin 29 F500 EGR ACTUATOR MOTOR WH - 0.8
PLUS
53 X-470 (Receptacle) pin 42 F530 TVA POSITION SENSOR YE - 0.5
SIGNAL
TEMPERATURE SENSOR
SIGNAL
56 X-638 pin 9 F561 PRESSURE SENSE YE - 0.8
SIGNAL
57 X-470 (Receptacle) pin 14 F570 COOLANT YE - 0.5
TEMPERATURE SENSOR
SIGNAL
58 X-470 (Receptacle) pin 13 F580 COOLANT BL - 0.5
TEMPERATURE SENSOR
GROUND
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SENSOR SIGNAL PLUS
60 X-470 (Receptacle) pin 2 F600 FUEL METERING UNIT GY - 1.0
X-463 - WATER IN FUEL SWITCH (Receptacle)
87709663 7
87709663
RAIL16TLB1513FA 8

1 X-461 (Receptacle) pin 30 E300 WATER IN FUEL LEVEL YE - 0.8 SHEET 01
SENSOR SIGNAL
3 SP-154-P-X 1504 TERMINAL 15 SW BAT+ OR - 0.8
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X-464 - MAIN RELAY (Receptacle)
84471904 9
84471904
RAIL16TLB1513FA 10

1 X-461 (Receptacle) pin 28 E280 MAIN RELAY BL - 0.5 SHEET 01
2 SP-157-P-X 1015 BAT+ RD - 0.5
3 SP-151-P-X E053 BAT+ RD - 6.0
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X-469 - GCU (Receptacle)
84356962 11
84356962
RAIL16TLB1513FA 12

1 X-470 (Receptacle) pin 58 1580 GLOW PLUG WH - 2.0 SHEET 01
2 X-470 (Receptacle) pin 61 1610 GLOW PLUG WH - 2.0
SIGNAL
4 Fuse F010 1040 BAT+ RD - 6.0
5 SP-203-P-X E411 GLOW PLUG UNIT BK - 5.0
GROUND
COMMAND SIGNAL
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X-479
MARBLE CUTTING
X-470 - ENGINE INTERFACE (Receptacle)
84154706 1
84154706
RAIL16TLB1513FA 2

1 X-462 (Receptacle) pin 15 F150 FUEL METERING UNIT WH - 0.75 SHEET 01
ECU SUPPLY
ECU
3 X-462 (Receptacle) pin 6 ECU F060 OIL PRESSURE SWITCH WH - 0.5
INPUT SIGNAL
ECU SPEED SENSOR SIGNAL
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5 X-462 (Receptacle) pin 26 F260 RAIL PRESSURE BL - 0.5
ECU SENSOR GROUND
ECU SENSOR SIGNAL
ECU SENSOR SUPPLY
8 X-462 (Receptacle) pin 28 F280 SEGMENT(CAMSHAFT) BL - 0.5
ECU SPEED SENSOR
GROUND
ECU SENSOR SIGNAL PLUS
ECU SENSOR SIGNAL MINUS
ECU SPEED SENSOR SUPPLY
13 X-462 (Receptacle) pin 58 F580 COOLANT BL - 0.5
ECU TEMPERATURE SENSOR
GROUND
SIGNAL
15 X-462 (Receptacle) pin 23 F230 FUEL TEMPERATURE BL - 0.5
ECU SENSOR GROUND
ECU SENSOR SIGNAL
ECU SENSOR SUPPLY
ECU SENSOR SIGNAL
19 X-462 (Receptacle) pin 25 F250 BOOST PRESSURE BK/WH - 0.5
ECU SENSOR GROUND
SIGNAL
21 X-461 (Receptacle) pin 18 E180 EXHAUST GAS PRESS BL - 0.5
ECU SENSE SIGNAL
ECU SENSE GROUND
ECU SENSE SIGNAL
25 X-462 (Receptacle) pin 27 F270 INLET TURBINE TEMP BL - 0.5
ECU SENSE GROUND
26 X-462 (Receptacle) pin 43 F430 INLET TURBINE TEMP YE - 0.5
ECU SENSE SIGNAL
27 X-462 (Receptacle) pin 4 ECU F040 BOOST PRESSURE GY - 0.75
ACTUATOR 1
28 SP-152-P-X E058 B+ TO EL.VALVE RD - 0.75
ECU PLUS
ECU MINUS
33 X-462 (Receptacle) pin 9 ECU F090 EGR POSITION SENSOR PK - 0.5
SUPPLY
ECU SIGNAL
35 X-462 (Receptacle) pin 24 F240 EGR POSITION SENSOR BK/WH - 0.5
ECU GROUND
ECU PLUS
ECU MINUS
41 X-462 (Receptacle) pin 8 ECU F080 TVA POSITION SENSOR PK - 0.5
SUPPLY
ECU SIGNAL
43 X-462 (Receptacle) pin 27 F370 TVA POSITION SENSOR BK/WH - 0.5
ECU GROUND
GCU
GCU
GCU
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GCU
X-471 - FUEL INJECTOR CONNECTOR (Receptacle)
87698252 3
87698252
RAIL16TLB1513FA 4
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A X-462 (Receptacle) pin 16 F160 INJECTOR 1 HIGH BANK WH - 1.5 SHEET 01
ECU 1
B X-462 (Receptacle) pin 32 F320 INJECTOR 1 LOW BANK GY - 1.5
ECU 1
C X-462 (Receptacle) pin 31 F310 INJECTOR 1 LOW BANK GY - 1.5
ECU 2
D X-462 (Receptacle) pin 1 ECU F010 INJECTOR 1 HIGH BANK WH - 1.5
2
E X-462 (Receptacle) pin 17 F170 INJECTOR 2 HIGH BANK WH - 1.5
ECU 1
F X-462 (Receptacle) pin 48 F480 INJECTOR 2 LOW BANK GY - 1.5
ECU 1
G X-462 (Receptacle) pin 46 F460 INJECTOR 2 LOW BANK GY - 1.5
ECU 2
H X-462 (Receptacle) pin 2 ECU F020 INJECTOR 2 HIGH BANK WH - 1.5
2
X-473 - A/C COMPRESSOR (Plug)
87679525 5
87679525
RAIL16TLB1513FA 6
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1 X-448 pin 9 60C6 A/C COMPRESSOR BR - 0.5 SHEET 12
OUTPUT
X-474 - AIR TEMP SENSOR (Receptacle)
84607243 7
84607243
RAIL16TLB1513FA 8

1 X-461 (Receptacle) pin 19 E190 AIR TEMP SENSOR YE - 0.5 SHEET 01
ECU SIGNAL
2 X-461 (Receptacle) pin 20 E200 AIR TEMP SENSOR BK/WH - 0.5
ECU GROUND
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X-499
MARBLE CUTTING
X-496 - TO FRONT HARNESS (CONNECTS TO X-800) [ SH5: C-1] (87698254) (Plug)
87698254 1
87698254
RAIL16TLB1513FA 2

A - - - -
B X-461 (Receptacle) pin 68 E680 K LINE YE - 0.5 SHEET 01
ECU
C SP-154-P-X 150A IGNITION OR - 0.8
D X-461 (Receptacle) pin 8 ECU E080 CRANK SIGNAL YE - 0.8
E X-461 (Receptacle) pin 25 CAN027 CAN 1 LOW GN - 0.5
ECU
F - - - -
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G - - - -
H - - - -
J - - - -
K X-461 (Receptacle) pin 24 CAN027 CAN 1 HIGH YE - 0.5 SHEET 01
ECU
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X-509
MARBLE CUTTING
X500.s - TELEMATICS CONNECTOR
RAIL17TLB0268AA 1

1 SA103 U8 Ground BK - 1.0 SHEET 01
2 F-001 pin 2 A9 Switched power to the OR - 1.0
Telematics control module
3 SA13 V9 CAN high YE - 0.5
4 SA14 X9 CAN low GN - 0.5
5 - - - -
6 X501 pin 3 B9 RS232 Tx DB - 1.0
7 X501 pin 2 C9 RS232 Rx VT - 1.0
8 SA15 S8 D+ PK - 1.0
9 - - - -
10 - - - -
11 - - - -
12 X10.p pin 29 W8 Unswitched battery to the RD - 1.0
X501 - TELEMATICS CONNECTOR
RAIL17TLB0270AA 2

1 SA103 V8 Ground BK - 1.0 SHEET 01
2 X500.s pin 7 C9 RS232 Tx VT - 1.0
3 X500.s pin 6 B9 RS232 Rx DB - 1.0
4 - - - -
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X502 UNSWITCHED BATTERY
RAIL17TLB0302AA 3

1 Fuse 002 pin 1 Q2 Unswitched battery OR- 4.0 SHEET 01
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X-529
MARBLE CUTTING
X520 - LIGHTS INPUT
RAIL17TLB0336AA 1

1 SP-171 P9 Front work lights YE - 1.0 SHEET 05
2 SP-900 S9 Front work lights YE - 1.0
3 XC6 pin 11 N9 Instrument lamps YE - 1.0
4 SP-900 T9 Instrument lamps YE - 1.0
5 SP-172 R9 Rear work lights YE - 1.0
6 SP-900 U9 Rear work lights YE - 1.0
7 - - - -
8 - - - -
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X-609
MARBLE CUTTING
X600.p UNSWITCHED BATTERY CONNECTOR
RAIL17TLB0257AA 1

1 SA6 W Unswitched battery RD - 16.0 SHEET 01
X600.s UNSWITCHED BATTERY CONNECTOR
RAIL17TLB0294AA 2

1 X601 pin 1 V1 Unswitched battery RD - 16.0 SHEET 01
X601 POWER
RAIL17TLB0301AA 3
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1 X451S pin 1 U Unswitched battery RD - 1.5 SHEET 01
X1.s pin 1 W1 Unswitched battery RD - 6.0
X600.s pin 1 V1 Unswitched battery RD - 16.0
X-605 - DNOX SUPPLY MODULE (Receptacle)
84152570 4
84152570
RAIL16TLB1513FA 5
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1 - - - SHEET 01
2 X-639 pin 2 E700 PUMP MOTOR CONTROL YE 1.5
SIGNAL
3 X-639 pin 3 IGNB IGNITION TO THE PUMP OR 1.5
MODULE
4 X-639 pin 4 G285 PUMP MODULE PIN 4 BK 1.5
5 X-639 pin 5 IG11 COMMON IGNITION OR 1.5
6 X-639 pin 6 F450 PURGING PUMP SIGNAL YE 1.5
7 - - -
8 X-639 pin 8 F050 PRESSURE SENSOR BL 0.8
GROUND
9 X-639 pin 9 F561 SCR PRESSURE YE 0.8
SENSOR
10 X-639 pin 10 F070 PRESSURE SENSOR PK 0.8
SUPPLY
11 X-639 pin 11 5050 OR 1.5
X-605 - SIDE WORK LIGHT RELAY (Receptacle)
RAIL17TLB0261AA 6

30 RD/BK - 2.5 SHEET 07
85 GND.2 L2 Ground BK - 1.0
K14 pin 85 G7 Ground BK - 1.0
86 X87.p pin 4 F7 GN/VT - 1.0
87 X12.s pin 6 B7 YE/RD - 1.0
X12.s pin 7 C7 YE/RD - 1.0
87a - - - -
X-606 - NOX SENSOR DOWNSTREAM (Receptacle)
47514978 7
47514978
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RAIL16TLB1514FA 8

1 X-637 (Plug) pin 7 IG02 IGN SCR DOWNSTREAM OR - 1.0 SHEET 01
NOx W/ECU
2 X-637 (Plug) pin 8 G229 BATT- 5 SCR BK - 1.0
DOWNSTREAM NOx
W/ECU
3 Splice SPp-170 CANL 2 7 CANL 2 7 SCR GN - 0.5
DOWNSTREAM NOx
W/ECU
4 Splice SP-171 CANH 2 7 CANH 2 7 SCR YE - 0.5
DOWNSTREAM NOx
W/ECU
X606 - OPTIONAL BUZZER
RAIL17TLB0266AA 9

1 XST2 (Receptacle) pin 6 P6 Buzzer OR/BK - 1.0 SHEET 01
2 GND.2 S2 Ground BK - 1.0
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X-607 - NOX SENSOR UPSTREAM (Receptacle)
47514978 10
47514978
RAIL16TLB1513FA 11

1 SP-015-P-X IGN6 IGN DOC UPSTREAM OR - 1.0 SHEET 01
NOx SENSOR w/ECU
2 SP-G03-P-X G219 BATT- 7 DOC UPSTREAM BK - 1.0
NOx SENSOR w/ECU
3 SP-168-P-X CANL 2 12 CANL 2 9 DOC GN - 0.5
UPSTREAM NOx
SENSOR w/ECU
4 SP-169-P-X CANH 2 12 CANH 2 9 DOC YE - 0.5
UPSTREAM NOx
SENSOR w/ECU
5 SP-G03-P-X G218 BATT- 6 DOC UPSTREAM BK - 0.5
NOx SENSOR w/ECU
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X607 DIAGNOSTIC CONNECTOR
RAIL17TLB0275AA 12

A GND.1 W2 Ground BK - 1.0 SHEET 01
B X31 pin F1B F4 Unswitched battery from RD - 1.0
fuse F1B
C SA3 G9 CAN high YE - 0.5
D SA4 M9 CAN low GN - 0.5
E X13.p pin 17 E2 K-line BR - 1.0
F - - - -
G - - - -
H - - - -
J - - - -
X-608 - UREA TANK (Receptacle)
87688719 13
87688719
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RAIL16TLB1513FA 14

1 X-641 pin 1 IG01 IGN UREA QUALITY OR - 0.8 SHEET 01
SENSOR
2 X-641 pin 2 G228 BATT- 9 BK - 0.8
4 X-641 pin 4 CANL CANL 2 10 QUALITY GN - 0.5
SENSOR
5 X-641 pin 5 CANH CANH 2 10 UREA YE - 0.5
QUALITY SENSOR
X608 - HAND THROTTLE CONNECTOR
RAIL17TLB0280AA 15

A XST2 (Receptacle) pin 19 J6 Voltage to the throttle RD/BK - 1.0 SHEET 02
sensor
B XST2 (Receptacle) pin 17 K6 Throttle signal PK - 1.0
C XST2 (Receptacle) pin 21 L6 Throttle sensor ground BR - 1.0
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X-619
MARBLE CUTTING
X-611 - SCR TANK HEATING VALVE (Receptacle)
84146685 1
84146685
RAIL16TLB1513FA 2

1 SPLICE SP-016 IGN10 COMMON IGNITION OR 0.8 SHEET 01
2 - - -
3 X-461 (Receptacle) pin 7 1070 SCR HEATING VALVE YE 0.8
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X-612 - HCU (Receptacle)
47514457 3
47514457
RAIL16TLB1513FA 4

1 X-638 pin 11 LSIDE POD 1 5051 IGN TO HEATER OR - 1.5 SHEET 01
2 X-640 pin 7 LSIDE POD 2 1205 DEF HTR1 WH - 1.5
4 X-640 pin 6LSIDE POD 2 1224 ADBLUE OUTLET WH - 1.5
6 SP-159-P-X E05E FUSED PWR FROM MAIN RD - 0.8
RLY
7 Splice SP-002 G292 HCU GROUND BK - 1.5
9 SP-166-P-X CANL CANL2 HCU GN - 0.5
10 SP-167-P-X CANH CANH2 HCU YE - 0.5
11 SP-017-P-X 1019 BATT+ FROM HCU FUSE RD - 10.0
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X-617 - UPSTREAM CATALYST TEMPERATURE SENSOR (Receptacle)
84532147 5
84532147
RAIL16TLB1513FA 6

1 X-461 (Receptacle) pin 82 1820 CAT TEMP US GND CT YE - 0.5 SHEET 01
ECU
2 X-461 (Receptacle) pin 8 ECU E080 CAT TEMP US GND CT BL - 0.5
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X-618 - DOWNSTREAM CATALYST TEMPERATURE SENSOR (Receptacle)
84532147 7
84532147
RAIL16TLB1513FA 8

1 X-637 (Plug) pin 2 E800 CATALYST TEMP DS T YE - 0.5 SHEET 01
2 X-637 (Plug) pin 1 E790 CATALYST TEMP DS OUT BL - 0.5
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X-629
MARBLE CUTTING
X-622 - DOSING VALVE (Receptacle)
87709793 1
87709793
RAIL16TLB1514FA 2

1 X-462 (Receptacle) pin 18 2180 DOSING VLV H BL - 1.5 SHEET 01
ECU
2 X-462 (Receptacle) pin 3 ECU F030 DOSING VLV L YE - 1.5
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X-624 - NH3 SENSOR DOWNSTREAM SENSOR (Receptacle)
84146686 3
84146686
RAIL16TLB1514FA 4

1 X-637 (Plug) pin 5 IGN5 SENSOR POWER OR 1.0 SHEET 01
2 SPLICE SP-164 CANH 2 9 CAN DATA LINK HIGH YE 0.5
3 SPLICE SP-165 CANL 2 9 CAN DATA LINK LOW GN 0.5
4 X-637 (Plug) pin 6 G217 SENSOR GROUND BK 1.0
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X-639
MARBLE CUTTING
X-633 - DEF LINE HEATER 1 (BLACK) (Receptacle)
84284795 1
84284795
RAIL16TLB1514FA 2

1 X-641 pin 7 1205 ADBLUE OUTLET WH - 1.5 SHEET 01
2 SP-181-P-X G337 DEF LINE HTR1 GND BK - 2.0
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X-634 - DEF LINE HEATER 2 (BLUE) (Plug)
47486930 3
47486930
RAIL16TLB1514FA 4

2 SP-181-P-X G338 GROUND BK - 2.0
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X-636 - RIGHT SIDE POD CONNECTOR (Receptacle)
47416270 5
47416270
RAIL16TLB1513FA 6
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1 X-618 (Receptacle) pin 2 E791 CATALYST BL - 0.5 SHEET 01
CATALYST DOWNSTREAM DOWNSTREAM
TEMPERATURE SENSOR TEMPERATURE SENSOR
2 X-618 (Receptacle) pin 1 E801 CATALYST YE - 0.5
CATALYST DOWNSTREAM DOWNSTREAM
TEMPERATURE SENSOR TEMPERATURE SENSOR
3 Splice SP-170 CAN037 CAN Low YE - 0.5
4 Splice SP-171 CAN High GN - 0.5
5 X-624 (Receptacle) pin 1 NH3 IGN NH3 SENSOR OR - 1.0
SENSOR - DS
6 X-624 (Receptacle) pin 4 NH3 G237 BATT- 11 NH3 SENSOR BK - 1.0
SENSOR - DS
7 X-606 (Receptacle) pin 1 IG02 IGN SCR DOWNSTREAM OR - 1.0
NOX SENSOR - DS NOx W/ECU
8 X-606 (Receptacle) pin 2 G229 BATT- 5 SCR BK - 1.0
NOX SENSOR - DS DOWNSTREAM NOx
W/ECU
9 - - - -
10 - - - -
12 Splice SP-173 CAN Low YE - 0.5
X-637 - RIGHT SIDE POD CONNECTOR (Plug)
47416278 7
47416278
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RAIL16TLB1513FA 8

1 X-461 (Receptacle) pin 79 E790 CAT TEMP SENSE DS BL - 0.5 SHEET 01
ECU GND
2 X-461 (Receptacle) pin 80 E800 CAT TEMP SENSE DS YE - 0.5
ECU SIG
5 SP-015-P-X IGN5 IGN NH3 SENSOR OR - 1.0
6 SP-003-P-X G217 BATT- 11 NH3 SENSOR BK - 1.0
7 SP-015-P-X IGN4 IGN SCR DOWNSTREAM OR - 1.0
NOx W/ECU
8 SP-G03-P-X G216 BATT- 5 SCR BK - 1.0
DOWNSTREAM NOx
W/ECU
9 - - - -
10 - - - -
11 Splice SP-167 CAN022 CAN High GN - 0.5
CANH
CANL
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X-638 - LEFT SIDE POD 1 CONNECTOR

1 - - - - SHEET 01
2 X-605 (Receptacle) pin 2 E701 PUMP MOTOR CONTROL YE -1.5
SIGNAL
3 X-605 (Receptacle) pin 3 IGNC IGNITION TO THE PUMP OR - 1.5
MODULE
4 X-605 (Receptacle) pin 4 G287 PUMP MODULE PIN 4 BK - 1.5
5 X-605 (Receptacle) pin 5 IG04 COMMON IGNITION OR - 1.5
6 X-605 (Receptacle) pin 6 F451 PURGING PUMP SIGNAL YE - 1.5
7 - - - -
8 X-605 (Receptacle) pin 8 F051 PRESSURE SENSOR Dark blue -
GROUND 0.75
9 X-605 (Receptacle) pin 9 F561 SCR PRESSURE YE - 0.75
SENSOR
10 X-605 (Receptacle) pin 10 F071 PRESSURE SENSOR PK - 0.75
SUPPLY
11 X-605 (Receptacle) pin 11 5051 OR - 1.5
12 X-605 (Receptacle) pin 12 G286 PUMP MODULE PIN 12 BL - 1.5

1 - - - - SHEET 01
2 Splice SP-111 E700 PUMP MOTOR CONTROL YE -1.5
SIGNAL
3 X-448 pin 33 IGNB IGNITION TO THE PUMP OR - 1.5
MODULE
4 Splice SP-002 G285 PUMP MODULE PIN 4 BK - 1.5
5 Splice SP-016 IG11 COMMON IGNITION OR - 1.5
ECU
7 - - - -
8 X-462 (Receptacle) pin 5 ECU F050 PRESSURE SENSOR Dark blue -
GROUND 0.75
ECU SENSOR
10 X-462 (Receptacle) pin 7 ECU F070 PRESSURE SENSOR PK - 0.75
SUPPLY
11 X-612 (Receptacle) pin 1 HCU 5050 OR - 1.5
12 Splice SP-002 G284 PUMP MODULE PIN 12 BL - 1.5
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X-649
MARBLE CUTTING

1 X-608 (Receptacle) pin 1 IG01 IGN UREA QUALITY OR - 1.0 SHEET 01
SENSOR
2 X-608 (Receptacle) pin 2 G228 BATT- 9 BK - 1.0
3 - - - -
4 X-608 (Receptacle) pin 4 CANL CANL 2 10 QUALITY GN - 0.5
SENSOR
5 X-608 (Receptacle) pin 5 CANH CANH 2 10 UREA YE - 0.5
QUALITY SENSOR
6 X-633 (Receptacle) pin 1 1224 ADBLUE OUTLET WH - 2.0
7 X-634 (Plug) pin 1 1205 ADBLUE OUTLET WH - 2.0
8 Splice SP-282 G289 GROUND BK - 2.0

1 Splice SP-015 IG01 IGN UREA QUALITY OR - 1.0 SHEET 01
SENSOR
2 Splice SP-003 G228 BATT- 9 BK - 1.0
3 - - - -
4 Splice SP-162 CANL CANL 2 10 QUALITY GN - 0.5
SENSOR
5 Splice SP-163 CANH CANH 2 10 UREA YE - 0.5
QUALITY SENSOR
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X-809
MARBLE CUTTING
X-800 - FRONT HARNESS (CONNECTS TO X-496) (Receptacle)
87698252 1
87698252
RAIL16TLB0845FA 2
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A - - - - SHEET 01
B X13.s pin 17 E682 K LINE YE - 0.5
C X408.s pin 1 150B IGNITION OR - 0.8
D X13.s pin 2 E081 CRANK SIGNAL YE - 0.8
E X408.s pin 2 E252 CAN 1 LOW GN - 0.5
F - - - -
G - - - -
H - - - -
J - - - -
K X408.s pin 1 E242 CAN 1 HIGH YE - 0.5
X805.s - RIDE CONTROL PRESSURE SWITCH
RAIL17TLB0252AA 3

1 X10 pin 27 R1 Switched battery GN/VT - 1.0 SHEET 03
2 X10.s pin 28 S1 Pressure switch out signal WH - 1.0
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ground
MARBLE CUTTING
DRIVE (2WD)
DRIVE (4WD)
UNSWITCHED BATTERY CONNECTOR
RAIL17TLB0314AA 1

1 SA6 D1 Unswitched battery RD- 10.0 SHEET 01
SWITCHED BATTERY CONNECTOR
RAIL17TLB0315AA 2

1 X15.2 pin 6 N5 Switched battery DB - 6.0 SHEET 01
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RAIL17TLB0316AA 3

1 X10.p pin 3 N1 Ground BK - 1.5 SHEET 01
SA103 H8 Ground BK - 1.0
GND.1 A3 Ground BK - 1.5
X10.p pin 2 M1 Ground BK - 1.5
RAIL17TLB0302AA 4

1 X4.2 pin 1 X2 Ground BK - 1.0 SHEET 01 SHEET 04
X5 pin 2 Z2 Ground BK - 1.0
X1.s pin 6 F3 Ground BK - 2.5
RAIL17TLB0302AA 5
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1 X29 pin 1 X2 Ground BK - 1.0 SHEET 01
X23.s pin 11 Z2 Ground BK - 1.5
X607 pin A F3 Ground BK - 1.0
X28 pin 1 E3 Ground BK - 1.0
X27 pin 1 B3 Ground BK - 1.0
X25 pin 1 G1 Ground BK - 1.0
X23.s pin 2 D3 Ground BK - 1.5
XST2 (Receptacle) pin 26 G3 Ground BK - 1.0
H26.2 pin 1 W2 Ground BK - 1.0
GND A3 Ground BK - 1.5
RAIL17TLB0302AA 6

1 X14.s pin 3 Q Ground BK - 1.0 SHEET 01
X110 pin 2 N2 Ground BK - 4.0
X1.p pin 6 L2 Ground BK - 2.5
X88.p pin 6 R2 Ground BK - 1.0
X605 (Receptacle) pin 86 Q2 Ground BK - 1.0
X30.2 pin 1 C2 Ground BK - 1.0
X606 pin 2 S2 Ground BK - 1.0
X14.s pin 4 M2 Ground BK - 1.0
X88.p pin 14 P2 Ground BK - 1.0
Ground
RAIL17TLB0302AA 7

1 X26 pin B Q Ground BK - 1.0 SHEET 01
X207 pin 2 T Ground BK - 1.0 SHEET 02
X10.s pin 2 C1 Ground BK - 1.5 SHEET 03
X208.s pin 1 A1 Ground BK - 1.0
X35 pin 2 B Ground BK - 1.0
X209 pin 2 M Ground BK - 1.0
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RAIL17TLB0302AA 8

1 X34 pin 2 D Ground BK - 1.0 SHEET 01
X206 pin B V Ground BK - 1.0 SHEET 02
X202 pin 2 L Ground BK - 1.0 SHEET 03
X203 pin 2 F Ground BK - 1.0
X10.s pin 3 D1 Ground BK - 1.
X204 pin 1 I Ground BK - 1.0
RAIL17TLB0327AA 9

1 X41 pin 1 Q1 Ground BK - 1.0 SHEET 06
X39 pin 4 H1 Ground BK - 1.0 SHEET 07
X43.s pin 3 O1 Ground BK - 1.0
X47 pin 1 M1 Ground BK - 1.0
X46 pin 1 K1 Ground BK - 1.
X38 pin 1 J1 Ground BK - 1.0
GND Z Ground BK - 2.5
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RAIL17TLB0327AA 10

1 X45 pin 1 V1 Ground BK - 1.0 SHEET 06
X54 pin 8 B2 Ground BK - 1.0 SHEET 07
X50 pin 1 W1 Ground BK - 1.0
H18.3 pin 1 A2 Ground BK - 1.0
X55.1 pin 2 R1 Ground BK - 1.0
RAIL17TLB0329AA 11

RAIL17TLB0327AA 12
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1 X125 pin 2 U1 Ground BK - 1.0 SHEET 03
X21 pin 1 F2 Ground BK - 1.5 SHEET 04
X22 pin 1 R2 Ground BK - 1.5
GND.2 W2 Ground BK - 2.5
GND2 - GROUND CONNECTOR
RAIL17TLB0329AA 13

1 S2 pin 4 C2 Ground BK - 1.0 SHEET 02
S5 pin 9 M1 Ground BK - 1.0 SHEET 03
GND W2 Ground BK - 2.5
RAIL17TLB0329AA 14

1 X406 pin 2 C Ground BK - 1.0 SHEET 07
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Wire connectors - Component diagram 00 Connectors fuses

MARBLE CUTTING
DRIVE (2WD)
DRIVE (4WD)
F-001 - FUSE
RAIL17TLB0317AA 1

1 X13.p pin 19 T7 Power supply RD/BK - 1.0 SHEET 01
2 X500.s pin 2 I8 Switched power OR - 1.0
F-002 - FUSE
RAIL17TLB0318AA 2

1 X502 pin 1 Q2 Unswitched battery OR1 - 4.0 SHEET 01
2 SA104 R2 Unswitched battery OR2 - 4.0
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Wire connectors - Component diagram 00 Connectors BS1 to BS9

MARBLE CUTTING
DRIVE (2WD)
DRIVE (4WD)
BS1.1 - RIGHT SPEAKER
RAIL17TLB0282AA 1

1 X53 pin 3 P2 Speaker RD - 0.5 SHEET 08
RAIL17TLB0326AA 2

1 X53 pin 4 Q2 Speaker BK - 0.5 SHEET 08
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BS2.1 - LEFT SPEAKER
RAIL17TLB0282AA 3

1 X53 pin 5 O2 Speaker RD - 0.5 SHEET 08
RAIL17TLB0326AA 4

1 X53 pin 6 N2 Speaker BK - 0.5 SHEET 08
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Wire connectors - Component diagram 00 Connectors H00 to H99

MARBLE CUTTING
DRIVE (2WD)
DRIVE (4WD)
H18.1 - DOME LAMP
RAIL17TLB0328AA 1

1 S34 pin 1 G2 Left door switch BR/BK - 1.0 SHEET 08
S35 pin 1 C2 Right door switch BR/BK - 1.0
H18.2 - DOME LAMP
RAIL17TLB0328AA 2

1 XC5 pin 10 M Unswitched battery from WH - 1.0 SHEET 08
fuse F7B
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H18.3 - DOME LAMP
RAIL17TLB0328AA 3

1 X49 pin 6 F2 Ground BK - 1.0 SHEET 08
GND.2 A2 Ground BK - 1.0
H26.1 - BLOCK CONTROL LAMP
RAIL17TLB0282AA 4

1 X87.p pin 9 V5 Rear block control lamp WH - 1.0 SHEET 03
RAIL17TLB0282AA 5

1 GND.1 W2 Ground BK - 1.0 SHEET 03
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Wire connectors - Component diagram 00 Connectors relays K-00

to K-99
MARBLE CUTTING
DRIVE (2WD)
DRIVE (4WD)
K14 - TRANSMISSION CUT-OFF RELAY
RAIL17TLB0261AA 1

30 X227 pin 30 P6 Switched battery WH/RD - 1.0 SHEET 02
X23.s pin 1 T4 WH/RD - 1.0
85 X605 (Receptacle) pin 85 N6 Ground BK - 1.0
86 X10.p pin 16 Z1 Transmission cut-off LB/RD - 1.0
87 X23.s pin 3 U4 Transmission cut-off signal DB/RD - 1.0
87a - - - -
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Wire connectors - Component diagram 00 Connector MC1

MARBLE CUTTING
DRIVE (2WD)
DRIVE (4WD)
RAIL17TLB0282AA 1

1 X405.s pin 1 H2 Engine start OR - 4.0 SHEET 01
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MARBLE CUTTING
DRIVE (2WD)
DRIVE (4WD)
RAIL17TLB0309AA 1

1 - - - - SHEET 02
2 X13.s pin 12 A2 4WD signal BR/GN - 1.0
3 XC1 pin 2 B2 Switched battery WH/RD - 1.0
4 GND2 C2 Switch lamp ground BK - 1.0
S3 pin 4 Z1 BK - 1.0
5 - - - -
6 X13.s pin 11 D2 4WD relay signal WH - 1.0
S3 - HAND HAMMER SWITCH CONNECTOR
RAIL17TLB0309AA 2

1 - - - - SHEET 02
2 X13.s pin 13 W1 Hand hammer relay RD/YE - 1.0
3 XC4 pin 11 X1 Hand hammer solenoid GY/BK - 1.0
valve
4 S2 pin 4 Z1 Ground BK - 1.0
5 - - - -
6 - - - -
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S5 - RIDE CONTROL SWITCH CONNECTOR
RAIL17TLB0331AA 3

1 - - - -
2 X125 pin 1 K1 Switched battery RD/GN - 1.0 SHEET 03
S5 pin 4 I3 Switched battery RD/GN - 1.0
3 X13.s pin 2 J3 Input ride control switch WH/YE - 1.0
4 X13.s pin 1 J1 Switched battery RD/GN - 1.0
S5 pin 2 I3 Switched battery RD/GN - 1.0
5 X13.s pin 14 K3 Input ride control switch WH - 1.0
6 - - - -
7 X13.s pin 3 L1 Ride control switch light LB/BK - 1.0
8 - - - -
9 GND2 M1 Ground BK - 1.0
S29 pin 5 G1 Ground BK - 1.0
10 - - - -
S15 - ROTATING BEACON SWITCH CONNECTOR
RAIL17TLB0309AA 4

1 - - - -
2 XC4 pin 1 D1 Switched battery LB/YE - 1.5 SHEET 07
3 XC2 pin 1 E1 Rotating beacon LB/GN - 1.5
4 S48 pin 4 C1 Ground BK - 1.0
5 - - - -
6 - - - -
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S29 - HORN SWITCH CONNECTOR
RAIL17TLB0309AA 5

1 - - - -
2 - - - -
3 - - - -
4 - - - -
5 S5 pin 9 G1 Ground BK - 1.0 SHEET 04
6 XC1 pin 1 H1 Horn OR - 1.0
X21 pin 6 I1 OR - 1.0
S34 - LEFT DOOR SWITCH
RAIL17TLB0282AA 6

1 H18.1 pin 1 G2 Door switch BR/BK - 1.0 SHEET 08
S35 - RIGHT DOOR SWITCH
RAIL17TLB0282AA 7

1 H18.1 pin 1 C2 Door switch BR/BK - 1.0 SHEET 08
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S41 - WINDSHIELD WIPER/ LIGHTS SWITCH CONNECTOR (ON THE STEERING COLUMN)
RAIL17TLB0268AA 8

1 - - - - SHEET 07
2 X23.p pin 28 A Windshield washer pump DB/WH - 1.0
3 - - - -
4 XC2 pin 2 B Switched battery WH - 1.0
5 XC4 pin 8 C Head lights relay GN/BK - 1.5
6 XC4 pin 14 D Front windshield wiper WH - 1.0
7 XC4 pin 12 E Switched battery WH - 1.0
8 XC4 pin 15 F Front windshield wiper WH - 1.0
9 SA1 G Left turn signal DB - 1.0
10 SA2 H Right turn signal LB - 1.0
12 - - - -
S42 - WARNING SWITCH CONNECTOR
RAIL17TLB0308AA 9

1 XC4 pin 3 N1 Switched battery GY/RD - 1.0 SHEET 04
2 S42 pin 4 O1 Flasher GY/DB - 1.0
3 XC4 pin 13 P1 Unswitched battery WH - 1.0
4 S42 pin 2 O1 Flasher GY/DB - 1.0
XC4 pin 10 Q1 Flasher GY/DB - 1.0
XC4 pin 9 R1 49a warning DB/BK - 1.0
6 SA1 S1 Left turn signal DB - 1.0
7 SA2 T1 Right turn signal LB - 1.0
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S48 - TRAX AUTO/MANUAL SWITCH CONNECTOR
RAIL17TLB0309AA 10

1 X404.p pin 8 Q Auto/manual signal WH - 1.0 SHEET 02
2 XC1 pin 8 B1 Switched battery WH/RD - 1.0
3 - - - -
4 S15 pin 4 C1 Ground BK - 1.0 SHEET 02
5 - - - -
6 - - - -
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Wire connectors - Component diagram 00 Connectors XC, XST,

and XX
MARBLE CUTTING
DRIVE (2WD)
DRIVE (4WD)
RAIL17TLB0242AA 1

1 S29 pin 6 H1 Front horn switch OR - 1.0) SHEET 02
2 S2 pin 3 B2 Switched battery from WH/RD - 1.0
X23.p pin 1 Z2 Fuse F1C WH/RD - 1.0
3 - - - -
4 - - - -
5 X33 pin 2 M2 Switched battery from fuse WH - 1.0 SHEET 05
F4A
6 - - - -
7 X32 pin 3 Q2 Stop light switch RD/BK - 1.0 SHEET 05
X404.p pin 13 V RD/BK - 1.0
8 S48 pin 2 B1 Switched battery from WH/RD - 1.0 SHEET 02
X404.p pin 1 J Fuse F1C WH/RD - 1.0
9 - - - -
10 X13.s pin 9 A3 Turn signal WH/GN - 1.0 SHEET 04
11 - - - -
RAIL17TLB0243AA 2

1 S15 pin 3 E1 Rotating beacon LB/GN - 1.5 SHEET 07
2 S41 pin 4 B Switched battery from fuse WH - 1.0 SHEET 02
F6C
3 - - - -
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4 - - -
5 XC2 pin 7 X2 Jumper to XC2 pin 7 VT - 1.0 SHEET 08
6 - - - -
7 XC2 pin 5 X2 Jumper to XC2 pin 5 VT - 1.0 SHEET 08
RAIL17TLB0245AA 3

1 X10.p pin 4 O1 Hand hammer solenoid GY/BK - 1.0 SHEET 02
valve
2 X28 pin 2 W4 Rear left lamp DB - 1.0 SHEET 05
3 Splice SP-171 W8 Front work lights YE - 1.0 SHEET 06
4 X87.p pin 1 Z4 PK/YE - 1.0
5 X14.s pin 2 S4 Switched battery DB/BK - 1.0 SHEET 02
6 - - - -
7 X87.p pin 2 A5 Switched battery from fuse WH - 1.0 SHEET 06
X10.p pin 17 A2 F3C WH - 1.0
Bucket quick coupler
8 X10.p pin 5 P1 Bucket level solenoid GY/RD - 1.0 SHEET 02
X262.s pin 3 M3 GY/RD - 1.0
9 - - - -
10 - - - -
11 X10.p pin 12 U1 Rear horn OR - 1.0 SHEET 02
X88.p pin 5 B5 Horn OR - 1.0
12 X29 pin 2 C4 Right rear turn signal LB - 1.0 SHEET 05
13 X28 pin 4 D5 Left rear light YE/BK - 1.0
X27 pin 2 E5 License plate light YE/BK - 1.0
14 Splice SP-172 X8 Rear work light switch YE - 1.0 SHEET 06
15 X87.p pin 11 G5 Rear work light switch VT/BK - 1.0
16 X10.p pin 7 Q1 Rear hammer pedal supply RD/GN - 1.0 SHEET 02
X230 pin 87 H5 Bucket sender RD/GN - 1.0
17 X88.p pin 1 I5 Switched battery from fuse WH - 1.0 SHEET 07
motor
18 X88.p pin 9 J5 Rear work light switch WH - 1.0 SHEET 06
19 X10.p pin 19 C2 Bucket sender LB/YE - 1.0 SHEET 02
20 X29 pin 4 K5 Right rear light YE - 1.0 SHEET 05
21 X28 pin 3 M5 Left stop lamp RD/BK - 1.0
X29 pin 3 L5 Right stop lampt RD/BK - 1.0
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RAIL17TLB0245AA 4

1 S15 pin 2 D1 Switched battery from fuse LB/YE - 1.5 SHEET 07
F6A to switch S15
2 - - - -
3 S42 pin 1 N1 Switched battery from fuse GY/RD - 1.0 SHEET 04
F6B to switch S42
4 - - - -
5 X13.s pin 8 B3 To switch S9 GY/BK - 1.5 SHEET 04
6 S21 pin 3 H2 From fuse F3A to front YE - 1.0 SHEET 04
lights
7 - - - -
8 S41 pin 5 C From the headlight switch GN/BK - 1.5 SHEET 04
9 S42 pin 5 R1 To the flasher unit from DB/BK - 1.0 SHEET 04
switch S42
10 S42 pin 4 Q1 To the flasher unit from GY/DB - 1.0 SHEET 04
switch S42
11 S3 pin 3 X1 Hand hammer switch GY/BK - 1.0 SHEET 02
12 S41 pin 7 E Switched battery from fuse WH - 1.0 SHEET 07
F7C to switch S41
13 X13.s pin 6 C3 Unswitched battery from WH - 1.0 SHEET 04
S42 pin 3 P1 fuse F7A WH - 1.0
14 S41 pin 6 D From switch S41 WH - 1.0 SHEET 07
15 S41 pin 8 F From switch S41 WH - 1.0 SHEET 07
16 X22 pin 4 U2 Head lights GY/BK - 1.0 SHEET 04
X21 pin 4 I2 GY - 1.0
17 SA1 D3 To switch S41 DB - 1.0 SHEET 05
18 X22 pin 3 T2 From fuse F3B to the head YE/BK - 1.0 SHEET 04
lights
19 SA2 E3 To switch S41 LB - 1.0 SHEET 05
20 X21 pin 5 K2 High beams GN - 1.0 SHEET 04
X22 pin 5 V2 GN/BK - 1.0
21 X13.s pin 7 F3 From switch S9 YE - 1.5 SHEET 04
RAIL17TLB0248AA 5
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1 X49 pin 3 A Switched battery from fuse WH - 1.0 SHEET 07
X41 pin 2 B F7C to the front windshield WH - 1.0
wiper motor
2 - - - -
3 X49 pin 1 C Front windshield wiper WH - 1.0 SHEET 07
motor
4 X49 pin 4 D Front windshield wiper WH - 1.0
motor
5 - - - -
6 X55.2 pin 1 F Socket lamp YE - 1.0 SHEET 05
7 - - - -
8 - - - -
9 - - - -
10 X55.1 pin 1 L Unswitched battery from RD/BK - 1.5 SHEET 08
H18.2 pin 1 M fuse F7B to the cabin light, WH - 1.0
cigar lighter, and the radio
11 X40 pin 2 S Internal rear work light GN/BK - 1.0 SHEET 06
X46 pin 2 R GN/BK - 1.0
12 X50 pin 2 U Internal front work light GN - 1.0
X45 pin 2 T GN - 1.0
13 X38 pin 2 N External rear work light GY/BK - 1.0
X47 pin 2 O GY/BK - 1.0
14 X44 pin 2 P External front work light GY - 1.0
X51 pin 2 Q GY - 1.0
15 - - - -
16 X43.s pin 2 V Switched battery from LB/YE - 1.0 SHEET 07
fuse F1A to windshield
17 - - - -
RAIL17TLB0249AA 6

1 XX pin 4 O3 Forward signal BR/BK - 1.0 SHEET 02
X23.s pin 6 N3 BR/BK - 1.0
2 - - - -
3 X14.s pin 8 P3 Switched battery from fuse LB - 1.5 SHEET 01
4 SA2 R Switched battery from fuse VT - 2.5 SHEET 11
F2B
5 - - - -
6 XST1 (Receptacle) pin 3 Q3 Start signal BR - 1.0 SHEET 01
X1.p pin 12 J7 GN/BK - 1.0
7 - - - -
8 XX pin 5 S3 Reverse signal BR/WH - 1.0 SHEET 02
X23.s pin 7 R3 BR/WH - 1.0
9 X262.s pin 2 L3 Switched battery from fuse GY - 1.5 SHEET 01
F2C to the pilot control
module
10 X15.2 pin 5 T3 Switch battery from the LB - 1.5
ignition switch
11 X520 pin 3 U3 To the diodes in connector YE - 1.0 SHEET 05
X-520
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12 SA1 H3 Switched battery from fuse RD/BK - 1.5 SHEET 08
F2A to the ride control
pressure switch
13 SA1 J3 Start signal to the starter RD/BK - 1.0 SHEET 01
relay
82016219 7
82016219
1 - - - - SHEET 01
2 SA1 I3 Switched battery RD/BK - 1.0
3 XC6 pin 6 Q3 In gear signal BR - 1.0
4 Splice SP-900 Z8 Driving work lights YE - 1.0
5 - - - -
6 - - - -
7 X13.p pin 9 M4 Turn signals WH - 1.0
8 X13.p pin 10 N4 High beams GN - 1.0
9 - - - -
10 X220 pin 11 M Air conditioner system YE/GN - 1.0
pressure
11 X88.p pin 10 A6 Display input switch BR/WH - 1.-
12 X88.p pin 11 B6 Enter input switch BR/BK - 1.0
13 X88.p pin 12 C6 Up input switch DB/BK - 1.0
14 X88.p pin 13 D6 Down input switch DB/WH - 1.0
15 X15.2 pin 9 P5 Crank signal WH - 1.0
16 X1.p pin 15 K7 Air filter restriction switch DB/WH - 1.0
17 - - - -
18 X30.1 pin 1 U5 Park brake WH - 1.0
19 - - - -
20 X25 pin 6 K1 Idle validation switch YE - 1.0
21 X10.p pin 15 X1 One touch decel WH/DB - 1.0
22 - - - -
23 - - - -
24 - - - -
25 - - - -
26 - - - -
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82028493 8
82028493
1 X31 pin F3B B4 Unswitched battery RD - 1.0 SHEET 01
2 - - - -
3 SA4 J9 CAN low signal GN - 0.5
4 SA3 K9 CAN high signal YE - 0.5
5 - - - -
6 X606 pin 1 W5 Audible alarm OR - 1.0
7 - - - -
8 X232 pin 86 D8 Ride control relay WH - 1.0
9 - - - -
10 - - - -
11 - - - -
12 - - - -
13 X1.p pin 14 N2 Fuel level signal VT - 1.0
14 X1.p pin 3 G2 Transmission temperature YE/RD - 1.0
15 - - - -
16 X25 pin 3 H1 Foot throttle signal; GN - 1.0
17 X608 pin B R5 Hand throttle signal PK - 1.0
18 X25 pin 5 J1 Foot throttle 5V RD - 1.0
19 X608 pin A Q5 Hand throttle 5V RD/BK - 1.0
20 X25 pin 4 I1 Foot throttle sensor ground GN/BK - 1.0
21 X608 pin C S5 Hand throttle sensor BR - 1.0
ground
22 X13.p pin 2 G7 Ride control switch WH/YE - 1.0
23 X13.p pin 14 H7 Ride control switch WH - 1.0
24 SA15 B8 Alternator PK - 1.0
25 X10.p pin 23 R7 Ride control pressure WH - 1.0
switch
26 GND.1 G3 Instrument cluster ground BK - 1.0
XX DIODE CONNECTOR
RAIL17TLB0250AA 9

1 - - - -
2 - - - -
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3 X10.p pin 13 V1 Bi-directional aux solenoid DB/YE - 1.0 SHEET 02
valve
4 XC6 pin 1 O3 Forward signal BR/BK - 1.0
5 XC6 pin 8 S3 Reverse signal BR/BK - 1.0
X7 pin 2 R4 Reverse buzzer BR/BK - 1.0
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Wire connectors - Component diagram 00 Connectors X-00 to X-09

MARBLE CUTTING
DRIVE (2WD)
DRIVE (4WD)
X1.p ENGINE HARNESS CONNECTOR
RAIL17TLB0256AA 1

1 X15.1 pin 2 E2 Unswitched battery from RD - 6.0 SHEET 01
X601
2 XC6 pin 6 J7 Starter interlock GN/BK - 1.0
3 XST2 (Receptacle) pin 14 G2 Transmission oil YE/RD - 1.0
temperature
4 X23.s pin 5 H2 Alternator signal LB/WH - 1.0
5 X13.p pin 16 B7 Starter relay coil pin 85 GN - 1.0
6 GND.2 I2 Ground BK - 2.5 SHEET 04
7 X15.2 pin 8 J2 Start signal WH - 1.0 SHEET 01
8 - - - -
9 X13.p pin 17 D7 Air conditioner compressor GN - 1.5 SHEET 01
10 X14.s pin 7 L2 Switched battery from fuse RD/BK - 1.0
F2C
11 X220 pin 11 N Air conditioner relay pin 86 YE/GN - 1.5 SHEET 10
12 SA15 M2 D+ signal from the PK - 1.0 SHEET 01
alternator
13 X13.p pin 18 F7 Starter relay coil pin 86 DB - 1.0
14 XST2 (Receptacle) pin 13 N2 Fuel level sender VT 1.0
15 XST1 (Receptacle) pin 16 K7 Air filter pressure switch WH/YE - 1.0
16 - - - -
17 - - - -
18 - - - -
X1.s ENGINE HARNESS CONNECTOR
RAIL17TLB0291AA 2
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1 X601 pin 1 W1 Unswitched battery RD - 6.0 SHEET 01
2 X450S pin 3 J2 Starter interlock WH - 1.0
3 X66 pin 1 B1 Transmission oil YE - 1.0
temperature
4 X67B pin 1 X1 Alternator signal YE - 1.0
5 - - - -
6 GND U1 Ground BK - 2.5 SHEET 04
7 X450S pin 3 G2 Start signal OR - 4.0 SHEET 01
8 - - - -
9 - - - -
10 - - - -
11 X451S pin 2 R Air conditioner relay pin 86 YE - 1.0 SHEET 11
12 X67A pin 1 A2 D+ signal from the PK - 1.0 SHEET 01
alternator
13 - - - -
14 X5 pin 1 D1 Fuel level sender YE - 1.0 SHEET 01
15 X4.1 pin 1 M2 Air filter pressure switch YE - 1.0
16 - - - -
17 - - - -
18 - - - -
RAIL17TLB0287AA 3

1 X10.s pin 27 G1 Unswitched battery RD - 1.0 SHEET 01
X2.s - INTERFACE CONNECTOR
RAIL17TLB0292AA 4

1 SA104 P2 Telematics unswitched RD - 1.0 SHEET 01
battery connector
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RAIL17TLB0296AA 5

1 X1.s pin 15 M2 Air filter pressure YE - 1.0 SHEET 01
RAIL17TLB0296AA 6

1 GND L2 Ground BK - 1.0 SHEET 01
RAIL17TLB0295AA 7

2 GND C1 Ground BK - 1.0
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X7 REVERSE BUZZER
RAIL17TLB0269AA 8

2 XX pin 5 R4 Reverse buzzer signal BR/WH - 1.0
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X-019
MARBLE CUTTING
DRIVE (2WD)
DRIVE (4WD)
X10.p - SERVICE HARNESS CONNECTOR
RAIL17TLB0255AA 1

1 X262.s pin 1 L1 Power supply to the pilot GY - 1.5 SHEET 01
control module
2 GND M1 Ground BK - 1.5
3 GND N1 Ground BK - 1.5
4 XC3 pin 1 O1 Hand hammer solenoid GY/BK - 1.0 SHEET 02
valve
5 XC3 pin 8 P1 Bucket level solenoid valve GY/RD - 1.0
6 - - - -
7 XC3 pin 16 Q1 Bucket sender RD/GN - 1.0 SHEET 02
8 X230 pin 30 R1 Rear hammer button RD/YE - 1.0 SHEET 03
9 - - - -
10 X232 pin 87 Z6 Ride control solenoid LB/BK - 1.0 SHEET 03
11 X88.p pin 7 T1 Rear translation solenoid WH/BK - 1.0
valve
12 XC3 pin 12 U1 Horn OR - 1.0 SHEET 02
13 XX pin 3 V1 Bi-directional aux DB/YE - 1.0
14 X87.p pin 10 W1 Backhoe transport lock OR/WH - 1.0 SHEET 03
solenoid
15 XST1 (Receptacle) pin 21 X1 One touch decel WH/DB - 1.0 SHEET 01
16 K14 pin 86 Z1 Transmission kick out LB/RD - 1.0 SHEET 02
button
17 XC3 pin 7 A2 Switched battery WH - 1.0 SHEET 03
18 X23.s pin 1 B2 Switched battery WH/RD - 1.0 SHEET 02
19 XC3 pin 19 C2 Bucket sender signal LB/YE - 1.0
20 - - - -
21 - - - -
22 SA1 I7 Switched battery RD/BK - 1.0 SHEET 03
23 XST2 (Receptacle) pin 25 R7 Ride control pressure WH - 1.0
switch
24 - - - -
25 - - - -
26 - - - -
27 X500.s pin 12 E8 Unswitched battery to the RD - 1.0 SHEET 01
Telematics module
28 X23.s pin 10 D2 Stop light switch WH - 1.0 SHEET 05
29 - - - -
30 - - - -
31 - - - -
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X10.s SERVICE HARNESS CONNECTOR
RAIL17TLB0283AA 2

1 X72.s pin 1 O Power supply to the pilot GY - 1.5 SHEET 01
control module
4 X35 pin 1 A Hand hammer solenoid GY/BK - 1.0 SHEET 02
valve
5 X206 pin A U Bucket level solenoid valve GY/RD - 1.0
6 - - - -
7 X26 pin A P Bucket sender RD/GN - 1.0 SHEET 02
8 X36.s pin 2 H Rear hammer button RD/YE - 1.0 SHEET 03
9 - - - -
10 X34 pin 1 C Ride control solenoid LB/BK - 1.0 SHEET 03
11 X202 pin 1 K Rear translation solenoid WH/BK - 1.0
valve
12 X204 pin 2 J Horn OR - 1.0 SHEET 02
13 X207 pin 1 S Bi-directional aux DB/YE - 1.0
14 X203 pin 1 E Backhoe transport lock OR/WH - 1.0 SHEET 03
solenoid
15 X201.s pin 1 N One touch decel WH/DB - 1.0 SHEET 01
16 X205 pin A W Transmission kick out LB/RD - 1.0 SHEET 02
button
17 X208.s pin 2 B1 Switched battery WH - 1.0 SHEET 03
18 X205 pin D Z Switched battery WH/RD - 1.0 SHEET 02
19 X26 pin C R Bucket sender signal LB/YE - 1.0
20 - - - -
21 - - - -
22 X805.s pin 1 E1 Switched battery RD/BK - 1.0 SHEET 03
23 X805.s pin 2 F1 Ride control pressure WH - 1.0
switch
24 - - - -
25 - - - -
26 - - - -
27 X2.p pin 1 G1 Unswitched battery to the RD - 1.0 SHEET 01
Telematics module
28 X205 pin C X Stop light switch WH - 1.0 SHEET 05
29 - - - -
30 - - - -
31 - - - -
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X12.p CAB HARNESS CONNECTOR
RAIL17TLB0260AA 3

1 X39 pin 3 A1 Windshield wiper ground WH - 1.0 SHEET 07
2 X57 pin 1 B1 Rear windshield washer WH - 1.0
voltage supply
3 X56 pin 1 C1 Windshield washer pump DB/WH - 1.0
4 X39 pin 2 D1 Windshield wiper speed WH - 1.0
5 X39 pin 1 E1 Rear windshield wiper WH - 1.0
voltage supply
6 X43.s pin 4 F1 Right-side work light WH - 1.0
7 X43.s pin 6 G1 Left-side work light WH - 1.0
8 - - - -
9 - - - -
X12.s CAB HARNESS CONNECTOR
RAIL17TLB0330AA 4

1 X88.p pin 3 E6 Windshield wiper ground WH - 1.0 SHEET 07
2 X88.p pin 2 F6 Rear windshield washer WH - 1.0
voltage supply
3 X23.s pin 8 V4 Windshield washer pump DB/WH - 1.0
4 X23.s pin 4 G6 Windshield wiper speed WH - 1.0
5 X23.s pin 1 H6 Rear windshield wiper WH - 1.0
voltage supply
6 X605 (Receptacle) pin 87 I6 Right-side work light WH - 1.0
7 X605 (Receptacle) pin 87 J6 Left-side work light WH - 1.0
8 - - - -
9 - - - -
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X13.p - POWER SUPPLY FRONT DASHBOARD HARNESS
RAIL17TLB0277AA 5

1 X31 pin F5B G4 Switched battery RD/GN - 1.0 SHEET 03
2 XST2 (Receptacle) pin 22 G7 Crank signal from the WH/YE - 1.0
ignition switch
3 X232 pin 87 S1 Ride control LB/BK - 1.0
4 X230 pin 86 H4 Neutral GN/VT - 1.0 SHEET 02
5 X227 pin 86 I4 4WD solenoid YE/RD - 1.0
6 X14.s pin 2 J4 Unswitched battery to the WH - 1.0 SHEET 04
antitheft system
7 X87.p pin 3 K4 Parking lights YE - 1.5
8 X87.p pin 6 L4 Lights GY/BK - 1.5
9 XST1 (Receptacle) pin 7 M4 Turn signals WH/GN - 1.0
10 XST1 (Receptacle) pin 8 N4 Head lights GN - 1.0
11 X227 pin 87a O4 4WD WH - 1.0 SHEET 02
12 X23.s pin 4 P4 4WD BR/GN - 1.0
13 X230 pin 30 Q4 RD/YE - 1.0
14 XST2 (Receptacle) pin 23 H7 WH - 1.0 SHEET 03
15 X607 pin E K2 GY - 1.0 SHEET 01
16 X1.p pin 5 B7 Start relay coil pin 85 GN - 1.0
17 X1.p pin 9 D7 Air conditioner compressor GN - 1.5
18 X1.p pin 13 F7 Start relay coil pin 86 DB - 1.0
19 X14.s pin 7 E7 Switched battery RD/BK - 1.0
F-001 pin 1 T7 Switched battery RD/BK - 1.0
20 X15.2 pin 8 C7
21 - - - -
X13.s - POWER SUPPLY FRONT DASHBOARD HARNESS
RAIL17TLB0246AA 6

1 S5 pin 4 J1 Switched battery RD/GN - 1.0 SHEET 03
X24 pin 1 E2 RD/GN - 1.0
2 S5 pin 3 J3 Crank signal from the WH/YE - 1.0
ignition switch
3 S5 pin 7 L1 Ride control LB/BK - 1.0
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4 X409.p pin 5 X Neutral GN/VT - 1.0 SHEET 02
5 X409.p pin 4 W 4WD solenoid YE/RD - 1.0
6 X21 pin 7 L2 Unswitched battery to the WH - 1.0 SHEET 04
XC4 pin 21 XC XC4 pin 13 C3 antitheft system WH - 1.0
7 XC4 pin 21 F3 Parking lights YE - 1.5
8 XC4 pin 5 B3 Lights GY/BK - 1.5
9 XC1 pin 10 A3 Turn signals WH/GN - 1.0
10 X21 pin 5 J2 Head lights GN - 1.0
11 S2 pin 6 D2 4WD WH - 1.0 SHEET 02
12 S2 pin 2 A2 4WD BR/GN - 1.0
13 S2 pin 3 W1 RD/YE - 1.0
14 S5 pin 5 K3 WH - 1.0 SHEET 03
15 X800.s (Receptacle) pin B N3 GY - 1.0 SHEET 01
16 X800.s (Receptacle) pin F O3 Start relay coil pin 85 GN - 1.0
17 X800.s (Receptacle) pin H P3 Air conditioner compressor GN - 1.5
18 X800.s (Receptacle) pin A Q3 Start relay coil pin 86 DB - 1.0
19 X800.s (Receptacle) pin C R3 Switched battery RD/BK - 1.0
20 X800.s (Receptacle) pin D S3 Crank signal from the WH - 1.0
ignition switch
21 - - - -
X14.s ANTITHEFT SYSTEM
RAIL17TLB0263AA 7

1 XC3 pin 5 F5 Switched battery from fuse DB/BK - 1.0 SHEET 01
F4B
2 X13.p pin 6 S4 Unswitched battery from WH - 1.0
fuse F7A
3 GND.2 M2 Ground BK - 1.0
5 - - - -
6 - - - -
7 X13.p pin 16 Z7 Switched battery RD/BK - 1.0
X1.p pin 10 F2 Switched battery RD/BK - 1.0
8 XC6 pin 3 Z3 Switched battery from fuse LB - 1.5
F1B
9 - - - -
10 - - - -
11 - - - -
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RAIL17TLB0273AA 8

1
2 X1.p pin 1 E2 Battery connection to the RD - 6.0 SHEET 01
ignition switch
3
4
RAIL17TLB0272AA 9

5 X87.p pin 15 D6 Switched battery from the DB - 1.5 SHEET 01
X31 pin F4A D4 ignition switch DB - 1.5
XC6 pin 10 N4 LB - 1.0
6 Ignition switch N5 Switched battery from the DB - 6.0
ignition switch
7 - - - -
8 X1.p pin 7 J2 Start signal from the WH - 4.0
X13.p pin 20 C7 ignition switch WH - 1.0
9 XST1 (Receptacle) pin 15 P5 Start signal from the WH - 1.0
ignition switch
10 - - - -
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X17 SEAT OPTION CONNECTOR
RAIL17TLB0281AA 10

1 X30.2 pin 1 T5 Ground BK - 1.0 SHEET 01
2 - - - -
3 - - - -
4 SA1 K3 Switched battery RD/BK - 1.0
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X-029
MARBLE CUTTING
DRIVE (2WD)
DRIVE (4WD)
RAIL17TLB0305AA 1

1 GND F2 Ground BK - 1.5 SHEET 04
2 SA1 G2 Right turn signal DB - 1.0
3 X125 pin 6 V1 Right parking light YE - 1.0
XC4 pin 6 H2 Backlight YE - 1.0
4 XC4 pin 16 I2 Right low beams GY - 1.0
5 XC4 pin 20 K2 Right bright lights GN - 1.0
X13.s pin 10 J2 GN - 1.0
6 S29 pin 6 I1 Unswitched battery to the OR - 1.0
horn
7 X13.s pin 6 L2 Horn signal WH - 1.0
RAIL17TLB0304AA 2

1 GND R2 Ground BK - 1.5 SHEET 04
2 SA2 S2 Right turn signal LB - 1.0
3 XC4 pin 18 T2 Right parking light YE/BK - 1.0
4 XC4 pin 16 U2 Right low beams GY/BK - 1.0
5 XC4 pin 20 V2 Right bright lights GN/BK - 1.0
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X23.p - FRONT DASHBOARD CONNECTOR
RAIL17TLB0247AA 3

1 XC1 pin 2 Z2 Switched battery WH/RD - 1.0 SHEET 02
4 X404.p pin 4 M 4WD BR/GN - 1.0
5 X404.p pin 5 N W signal from the alternator LB/WH - 1.0
8 S41 pin 2 A Windshield washer pump DB/WH - 1.0 SHEET 07
9 X404.p pin 9 R Unswitched battery RD - 1.0 SHEET 02
10 X32 pin 1 P2 Differential lock signal WH - 1.0 SHEET 05
11 X404.p pin 11 S Ground BK - 1.5 SHEET 02
12 - - - -
13 - - - -
X23.s - FRONT DASHBOARD CONNECTOR
RAIL17TLB0251AA 4

1 X10.p pin 18 B2 Switched battery WH/RD - 1.0 SHEET 02
K14 pin 30 T4 Switched battery WH/RD - 1.0
2 GND.1 D3 Ground BK - 1.5
3 K14 pin 87 U4 Declutch DB/RD - 1.0
4 X13.p pin 12 P4 4WD BR/GN - 1.0
5 X1.p pin 4 H2 W signal from the alternator LB/WH - 1.0
6 XC6 pin 1 N3 Forward signal BR/BK - 1.0
7 XC6 pin 8 R3 Reverse signal BR/WH - 1.0
8 X12.s pin 3 V4 Windshield washer pump DB/WH - 1.0 SHEET 07
9 X31 pin F3B C4 Unswitched battery RD - 1.0 SHEET 02
10 X10.p pin 28 D2 Differential lock signal WH - 1.0 SHEET 05
12 - - - -
13 - - - -
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RAIL17TLB0310AA 5

1 X13.s pin 1 E2 Switched battery RD/GN - 1.0 SHEET 03
RAIL17TLB0258AA 6

1 GND.1 G1 Ground BK - 1.0 SHEET 01
2 - - - -
3 XST2 (Receptacle) pin 16 H1 Foot throttle signal GN - 1.0
4 XST2 (Receptacle) pin 20 I1 Sensor ground GN/BK - 1.0
5 XST2 (Receptacle) pin 18 J1 Foot throttle power +5V RD - 1.0
6 XST1 (Receptacle) pin 20 K1 Idle validation signal YE - 1.0
X26 - BUCKET SENSOR
RAIL17TLB0280AA 7
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A X10.s pin 7 P Switched battery from fuse RD/GN - 1.0 SHEET 02
F4B
B GND.1 Q Ground BK - 1.0
X10.s pin 19 R Sensor signal LB/YE - 1.0
RAIL17TLB0269AA 8

2 XC3 pin 13 E5 Lamp power YE/BK - 1.0
RAIL17TLB0270AA 9

1 GND.1 E3 Ground BK - 1.0 SHEET 05
2 XC3 pin 2 W4 Left indicator rear lamp DB - 1.0
3 XC3 pin 21 M5 Left stop lamp RD/BK - 1.0
4 XC3 pin 13 D5 Left rear lamp YE/BK - 1.0
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RAIL17TLB0270AA 10

1 GND.1 X2 Ground BK - 1.0 SHEET 05
2 XC3 pin 12 C5 Right indicator rear lamp LB - 1.0
3 XC3 pin 21 L5 Right stop lamp RD/BK - 1.0
4 XC3 pin 20 K5 Right rear lamp YE - 1.0
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X-039
MARBLE CUTTING
DRIVE (2WD)
DRIVE (4WD)
RAIL17TLB0282AA 1

1 XST1 (Receptacle) pin 18 U5 Parking brake WH - 1.0 SHEET 01
RAIL17TLB0282AA 2

1 GND.2 V2 Parking brake ground BK - 1.0 SHEET 01
X17 pin 1 T5 BK - 1.0
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X31 FUSE CONNECTOR
RAIL17TLB0276AA 3

F1A X31 pin F2A W3 Unswitched battery RD - 2.5 SHEET 01
SA6 F1 RD - 2.5
F1B X607 pin B V3 Unswitched battery RD - 1.0
F2A X31 pin F3A X3 Unswitched battery RD - 2.5 SHEET 07
X31 pin F1A W3 RD - 2.5
F2B X605 (Receptacle) pin 30 Z3 Unswitched battery RD/BK 2.5
F3A X31 pin F2A X3 Unswitched battery RD - 2.5 SHEET 01
F3B X23.s pin 9 C4 Unswitched battery RD - 1.0
XST2 (Receptacle) pin 1 B4 RD - 1.0
X88.p pin 17 A4 RD - 1.0
F4A X31 pin F5A D4 Switched battery DB - 1.5 SHEET 03
X15.2 pin 5 E4 DB - 1.5
F4B X88.p pin 8 F4 Switched battery WH - 1.0
F5A X31 pin F4A D4 Switched battery DB - 1.5 SHEET 03
F5B X13.p pin 1 G4 Switched battery RD/GN - 1.0
F6A - - - -
F6B - - - -
X32 - STOP LIGHTS
RAIL17TLB0306AA 4

1 X23.p pin 10 P2 Differential lock signal WH - 1.0 SHEET 05
2 X33 pin 3 N2 From switch S33 RD - 1.0
3 XC1 pin 7 Q2 Stop lights RD/BK - 1.0
4 X33 pin 4 O2 S33 pin 4 OR - 1.0
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X33 - STOP LIGHTS
RAIL17TLB0306AA 5

1 X404.p pin 10 S Differential lock signal VT/WH - 1.0 SHEET 05
2 XC1 pin 5 M2 Switched battery WH - 1.0
3 X32 pin 2 N2 To switch S32 RD - 1.0
4 X32 pin 4 O2 Differential lock OR - 1.0
RAIL17TLB0285AA 6

1 X10.s pin 10 C Ride control WH/BK - 1.0 SHEET 03
RAIL17TLB0290AA 7

1 X10.s pin 4 A Hand hammer solenoid GY/BK - 1.0 SHEET 02
2 GND.1 B Ground BK - 1.0
T - - - -
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X36.s - REAR HAMMER SWITCH
RAIL17TLB0252AA 8

1 X209 pin 1 G Rear hammer solenoid RD/GN - 1.0 SHEET 03
2 X10.s pin 8 H Rear hammer relay RD/YE - 1.0
RAIL17TLB0269AA 9

1 GND.1 J1 Ground BK - 1.0 SHEET 06
2 XC5 pin 13 N Rear right work light GY/BK - 1.0
X39 - REAR WINDSHIELD WIPER
RAIL17TLB0322AA 10

1 X12.p pin 5 E1 Switched battery from fuse WH - 1.0 SHEET 07
F1A
2 X12.p pin 4 D1 Wiper switch WH - 1.0
3 X12.p pin 1 A1 Wiper switch WH - 1.0
4 GND.1 H1 Ground BK - 1.0
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X-049
MARBLE CUTTING
DRIVE (2WD)
DRIVE (4WD)
RAIL17TLB0269AA 1

X41 - BLOWER MOTOR
RAIL17TLB0319AA 2

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X43.p - WORK LIGHTS
RAIL17TLB0333AA 3

1 X412 pin 2 T1 Ground BK - 1.0 SHEET 07
5 X409.s pin 2 P1 Ground BK - 1.0
6 X409.s pin 1 G1 Left work light WH - 1.0
RAIL17TLB0258AA 4

4 X12.p pin 6 F1 Rotary beacon WH - 1.0
6 X12.p pin 7 G1 Rotary beacon WH - 1.0
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RAIL17TLB0269AA 5

RAIL17TLB0269AA 6

RAIL17TLB0269AA 7

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RAIL17TLB0269AA 8

RAIL17TLB0321AA 9

2 - - - -
5 - - - -
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X-059
MARBLE CUTTING
DRIVE (2WD)
DRIVE (4WD)
RAIL17TLB0252AA 1

1 GND.2 Ground BK - 1.0 SHEET 06
2 Front left work light
RAIL17TLB0252AA 2

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RAIL17TLB0323AA 3

1 - - - -
2 - - - -
7 - - - -
8 - - - -
RAIL17TLB0323AA 4

1 - - - -
2 - - - -
3 - - - -
X55.1 pin 1 H2 fuse F7B RD/BK 1.0
5 - - - - -
6 - - - - -
fuse F7B
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X55.1 - POWER POINT
RAIL17TLB0319AA 5

X54 pin 4 H2 fuse F7B RD/BK 1.0
GND.2 R1 BK - 1.0
X55.2 - POWER POINT
RAIL17TLB0325AA 6

RAIL17TLB0319AA 7

X57 pin 2 J2 BK - 1.0
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RAIL17TLB0319AA 8

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X-069
MARBLE CUTTING
DRIVE (2WD)
DRIVE (4WD)
X66 - TRANSMISSION OIL TEMPERATURE SWITCH
RAIL17TLB0298AA 1

1 X1.s pin 3 B1 Transmission oil YE - 1.0 SHEET 01
temperature
X67A - ALTERNATOR D+
RAIL17TLB0297AA 2

1 X1.s pin 12 A2 Alternator D+ signal PK - 1.0 SHEET 01
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X67B - ALTERNATOR W
RAIL17TLB0297AA 3

1 X1.s pin 4 X1 Alternator W signal YE - 1.0 SHEET 01
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X-079
MARBLE CUTTING
DRIVE (2WD)
DRIVE (4WD)
RAIL17TLB0288AA 1

1 X10.s pin 1 O Power supply to the pilot GY - 1.5 SHEET 01
control module
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X-089
MARBLE CUTTING
DRIVE (2WD)
DRIVE (4WD)
RAIL17TLB0264AA 1

1 XC3 pin 4 Z4 Power supply dashboard PK/YE - 1.0 SHEET 06
harness
2 X232 pin 30 A7 Unswitched battery WH - 1.0
XC3 pin 7 A5 Power supply switch WH - 1.0
3 X13.p pin 7 K4 Parking lamp fuse YE - 1.5 SHEET 04
4 X605 (Receptacle) pin 86 M6 Rear lights GN/VT - 1.0 SHEET 06
5 X15.2 pin 5 O5 Road and beam lights DB - 1.5 SHEET 04
switch
6 X13.p pin 8 L4 Road and beam lights GY/BK - 1.5
7 X88.p pin 9 L6 Rear work light switch WH - 1.0 SHEET 06
8 SP-171 A9 Front work lights YE - 1.0
9 H26.2 pin 1 V5 Rear work lights WH - 1.0 SHEET 03
10 X10.p pin 17 W1 Rear vertical lock OR/WH - 1.0
11 XC3 pin 15 G5 Rear work lights VT/BK - 1.0 SHEET 06
12 X88.p pin 6 K6 Ground BK - 1.0
13 SP-172 B9 Rear work lights YE - 1.0
RAIL17TLB0265AA 2
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1 XC3 pin 17 I5 Rear windshield wiper WH - 1.0 SHEET 07
X12.s pin 5 H6 WH - 1.0
2 X12.s pin 2 F6 Rear washer WH - 1.0
3 X12.s pin 1 E6 Windshield wiper return WH - 1.0
4 X12.s pin 4 G6 Windshield wiper WH - 1.0
5 XC3 pin 11 B5 Horn OR - 1.0 SHEET 02
6 GND.2 S2 Ground BK - 1.0 SHEET 07
X87.p pin 12 K6 Ground BK - 1.0
7 X10.p pin 11 T1 WH/BK - 1.0 SHEET 06
8 X31 pin F4B F4 Switched battery WH - 1.0 SHEET 03
9 X87.p pin 7 L6 Rear work light switch WH - 1.0 SHEET 06
XC3 pin 18 J5 Rear work light switch WH - 1.0
10 XST1 (Receptacle) pin 11 A6 Display control BR/WH - 1.0 SHEET 03
11 XST1 (Receptacle) pin 12 B6 Enter control BR/BK - 1.0
12 XST1 (Receptacle) pin 13 C6 Up control DB/BK - 1.0
13 XST1 (Receptacle) pin 14 D6 Down control DB/WH - 1.0
14 GND.2 T2 Ground BK - 1.0
15 - - - -
16 - - - -
17 X31 pin F3B A4 Unswitched battery RD - 1.0 SHEET 03
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X-119
MARBLE CUTTING
DRIVE (2WD)
DRIVE (4WD)
RAIL17TLB0259AA 1
84062580
1 SA6 P Unswitched battery to the RD - 4.0 SHEET 11
air conditioner fan
GND.2 Q Ground BK - 4.0
3
RAIL17TLB0260AA 2
84062580
1 X220 pin 1 A YE - 1.5 SHEET 11
2 X220 pin 2 D RD - 1.5
3 X220 pin 3 E OR - 1.5
4 SA2 O Switched battery VT - 2.5
5 X220 pin 5 G GY - 1.0
6 X220 pin 6 H WH - 1.0
7 X220 pin 7 I GN - 1.0
8 X220 pin 8 J PK - 1.0
9 X220 pin 9 K LB - 1.0
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X-129
MARBLE CUTTING
DRIVE (2WD)
DRIVE (4WD)
RAIL17TLB0307AA 1

1 S5 pin 2 K1 Switched battery RD/GN - 1.0 SHEET 03
2 GND U1 Ground BK - 1.0
3 X404.p pin 12 U Speedometer GY/DB - 1.0
4 - - - -
5 - - - -
6 X21 pin 3 V1 Backlight YE - 1.0
7 - - - -
8 - - - -
9 - - - -
10 - - - -
11 - - - -
12 - - - -
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X-209
MARBLE CUTTING
DRIVE (2WD)
DRIVE (4WD)
RAIL17TLB0287AA 1

1 X10.s pin 15 N Power supply to the one WH/DB - 1.0 SHEET 01
touch decel
RAIL17TLB0285AA 2

1 X10.s pin 11 K Side-shift solenoid WH/BK - 1.0 SHEET 03
2 GND.2 L Ground BK - 1.0
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RAIL17TLB0289AA 3

1 X10.s pin 14 E Boom lock solenoid OR/WH - 1.0 SHEET 03
2 GND.2 F Ground BK - 1.0
X204 - HORN CONNECTOR
RAIL17TLB0269AA 4

1 GND.2 I Ground BK - 1.0 SHEET 02
2 X10.s pin 12 J Horn signal OR - 1.0
X205 - TRANSMISSION CUT-OFF RELAY
RAIL17TLB0284AA 5

A X10.s pin 16 W Transmission cut-off signal LB/RD - 1.0 SHEET 02 SHEET 05
B - - - -
C X10.s pin 28 X Stop light switch WH - 1.0
D X10.s pin 18 Z Switched battery to the WH/RD - 1.0
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RAIL17TLB0252AA 6

A X10.s pin 5 U Bucket level solenoid GY/RD - 1.0 SHEET 02
B GND.2 V Ground BK - 1.0
RAIL17TLB0285AA 7

1 X10.s pin 19 S Bi-directional auxiliary DB/YE - 1.0 SHEET 02
solenoid
2 GND.1 T Ground BK - 1.0
X208.s - BUCKET QUICK COUPLER SOLENOID
RAIL17TLB0252AA 8

2 X10.s pin 17 B1 Bucket quick coupler WH - 1.0
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RAIL17TLB0289AA 9

1 X36.s pin 1 G Rear hammer solenoid RD/GN - 1.0 SHEET 03
T - - - -
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X-229
MARBLE CUTTING
DRIVE (2WD)
DRIVE (4WD)
RAIL17TLB0263AA 1
84062580
1 X111 pin 1 A +15 A/C YE - 1.5 SHEET 11
2 X111 pin 2 D +15 A/C RD - 1.5
3 X111 pin 3 E +15 A/C OR - 1.5
4 SA2 F +15 A/C VT - 2.5
5 X111 pin 5 G +15 A/C GY - 1.0
6 X111 pin 6 H +15 A/C WH - 1.0
7 X111 pin 7 I +15 A/C GN - 1.0
8 X111 pin 8 J +15 A/C PK - 1.0
9 X111 pin 9 K +15 A/C LB - 1.0
11 XST1 (Receptacle) pin 10 M Air conditioner lamp YE/GN - 1.0
X1.p pin 11 N Air conditioner relay pin 86 YE/GN - 1.5
X227 - 4WD RELAY
RAIL17TLB0261AA 2

30 K14 pin 30 P6 Relay signal WH/RD - 1.0 SHEET 02
85 X230 pin 85 Q6 Ground BK - 1.0
86 X13.p pin 5 I4 Relay signal YE/RD - 1.0
87 - - - -
87a X13.p pin 11 O4 4WD signal WH - 1.0
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X-239
MARBLE CUTTING
DRIVE (2WD)
DRIVE (4WD)
RAIL17TLB0261AA 1

30 X10.p pin 8 R1 Relay signal RD/YE - 1.0 SHEET 03
X13.p pin 13 Q4 RD/YE - 1.0
85 X232 pin 85 O6 Ground BK - 1.0
X227 pin 85 Q6 Ground BK - 1.0
86 X13.p pin 4 H4 Relay signal GN/VT - 1.0
87 XC3 pin 16 H5 Switched battery RD/GN - 1.0
87a - - - -
RAIL17TLB0261AA 2

30 X87.p pin 2 A7 Switched battery WH - 1.0 SHEET 03
85 K14 pin 85 R6 Ground BK - 1.0
X230 pin 85 O6 Ground BK - 1.0
86 XST2 (Receptacle) pin 8 D8 Signal from the instrument WH - 1.0
cluster
87 X13.p pin 3 S1 Ride control solenoid LB/BK - 1.0
X10.p pin 10 Z6 LB/BK - 1.0
87a - - - -
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X-269
MARBLE CUTTING
DRIVE (2WD)
DRIVE (4WD)
X262.p - OPTIONAL CONNECTOR
RAIL17TLB0279AA 1

1 X262.p pin 2 C Switched battery GY - 1.5 SHEET 01
2 X262.p pin 1 C Switched battery GY - 1.5
3 - - - -
X262.s - OPTIONAL CONNECTOR
RAIL17TLB0278AA 2

1 X10.p pin 1 L1 Switched battery to the GY - 1.5 SHEET 01
pilot controls
2 XC6 pin 9 L3 Switched battery from fuse GY - 1.5
F2C
3 XC6 pin 8 M3 Bucket level GY/RD - 1.0
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X-409
MARBLE CUTTING
DRIVE (2WD)
DRIVE (4WD)
X400 - FNR SWITCH (Receptacle)
84277215 1
84277215
RAIL16TLB0845FA 2
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1 - - - - SHEET 10
2 X401 (Receptacle) pin 19 I1 Gear command 02 VT - 1.0
3 X401 (Receptacle) pin 47 Q1 Gear command 01 GN - 1.0
4 X401 (Receptacle) pin 49 S1 Kick down signal GN/WH - 1.0
5 X406.s pin 1 X1 Reverse signal BR/WH - 1.0
6 Splice SP-8361 G Neutral signal GN/VT - 1.0
7 X406.s pin 2 Z1 Forward signal BR/BK - 1.0
8 X404.s pin 1 A2 Switched battery to the WH/RD - 1.0
FNR switch
X401 - TRAX POWERSHIFT CONTROL MODULE (Receptacle)
RAIL17TLB0262FA 3
47715498
1 X404.s pin 9 F1 Unswitched battery RD - 1.0 SHEET 02
2 X404.s pin 3 G1 In-gear signal WH - 1.0 SHEET 10
3 X404.s pin 1 P Forward valve 1 OR - 1.0
4 X403 (Receptacle) pin 3 R Reverse valve 1 VT - 1.0
5 Splice SP-8374 L Switched battery WH/RD - 1.0 SHEET 10
SHEET 02
6 X403 (Receptacle) pin 5 T PWM 1 BR - 1.0 SHEET 10
7 X403 (Receptacle) pin 7 V PWM 2 WH/RD - 1.0
8 Splice SP-8374 J Switched battery WH/RD - 1.0 SHEET 10
SHEET 02
9 X402 (Receptacle) pin 2 X S13 valve BR - 1.0 SHEET 10
10 - - - -
11 X402 (Receptacle) pin 6 A1 Differential lock solenoid GN/BK - 1.0 SHEET 10
12 X403 (Receptacle) pin 2 Q Forward valve 2 OR/BK - 1.0
13 X403 (Receptacle) pin 6 U PWM 1 BR/BK - 1.0
14 - - - -
15 - - - -
16 Splice SP-8361 E Neutral signal GN/VT - 1.0 SHEET 10
SHEET 02
17 X402 (Receptacle) pin 12 F2 Signal ground BK - 1.5 SHEET 10
18 X404.s pin 6 H1 Forward signal BR/BK - 1.0 SHEET 02
19 X400 (Receptacle) pin 2 I1 Gear command 2 VT - 1.0 SHEET 10
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20 X406.s pin 6 J1 4WS signal YE/DB - 1.0 SHEET 10
21 X404.s pin 3 K1 Declutch DB/RD - 1.0
22 X404.s pin 4 L1 4WD BR/GN - 1.0 SHEET 02
23 X404.s pin 8 M1 Auto/ manual WH - 1.0
24 - - - -
25 X402 (Receptacle) pin 7 B1 Speed sensor WH/BK - 1.0 SHEET 10
26 - - - -
27 X405.s pin 2 G2 CAN high signal YE - 0.5 SHEET 02
28 X404.s pin 12 O1 Speed sensor out GY/DB - 1.0
29 Splice SP-8083 D Ground BK - 1.0 SHEET 10
30 - - - -
31 - - - -
32 - - - -
33 - - - -
34 Splice SP-8374 I Switched battery WH/RD - 1.0 SHEET 10
SHEET 02
35 - - - -
36 - - - -
37 - - - -
38 X402 (Receptacle) pin 3 Z S24 valve PK - 1.0 SHEET 10
39 Splice SP-8222 N 4WD solenoid YE/RD - 1.0 SHEET 10
SHEET 02
40 X403 (Receptacle) pin 4 S Reverse valve 2 VT/WH - 1.0 SHEET 10
41 X403 (Receptacle) pin 8 W PWM 2 WH/DB - 1.0
42 - - - -
43 X402 (Receptacle) pin 9 C1 Temperature signal DB/BK - 1.0 SHEET 10
44 X402 (Receptacle) pin 11 D1 Pressure signal YE/BK - 1.0
45 - - - -
46 X404.s pin 7 P1 Reverse BR/WH - 1.0 SHEET 02
47 X400 (Receptacle) pin 3 Q1 Gear command 1 GN - 1.0 SHEET 10
48 X409.s pin 1 R1 Solenoid 3A WH - 1.0 SHEET 02
49 X400 (Receptacle) pin 4 S1 Kickdown GN/WH - 1.0 SHEET 10
50 X404.s pin 13 T1 Stop switch out RD/BK - 1.0 SHEET 02
51 X404.s pin 10 U1 Differential lock signal VT/WH - 1.0
52 - - - -
53 X404.s pin 5 V1 W signal from the alternator LB/WH - 1.0 SHEET 02
54 - - - -
55 X405.s pin 1 H2 CAN low signal GN - 0.5 SHEET 02
56 - - - -
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X402 - POWERSHIFT JUMPER HARNESS (Receptacle)
84277218 4
RAIL16TLB0877FA 5

1 Splice SP-8083 A Solenoid ground BK - 1.0 SHEET 10
2 X401 (Receptacle) pin 9 X S13 solenoid BR - 1.0
3 X401 (Receptacle) pin 38 Z S24 solenoid PK - 1.0
4 Splice SP-8083 B Solenoid ground BK - 1.0
5 Splice SP-8222 M 4WD solenoid YE/RD - 1.0
6 X401 (Receptacle) pin 11 A1 Differential lock solenoid GN/BK - 1.0
7 X401 (Receptacle) pin 25 B1 Transmission speed WH/BK - 1.0
sensor
8 Splice SP-8374 H Switched battery RD - 1.0
9 X401 (Receptacle) pin 43 H Transmission temperature DB/BK - 1.0
sensor signal
10 - - - -
11 X401 (Receptacle) pin 44 D1 Transmission pressure YE/BK - 1.0
switch
12 X401 (Receptacle) pin 17 F2 Transmission sensor BK - 1.5)
ground
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X403 - POWERSHIFT JUMPER HARNESS (Receptacle)
84277216 6
RAIL16TLB0877FA 7

1 X401 (Receptacle) pin 3 P Forward valve 1 OR - 1.0 SHEET 10
2 X401 (Receptacle) pin 12 Q Forward valve 2 OR/BK - 1.0
3 X401 (Receptacle) pin 4 R Reverse valve 1 VT - 1.0
4 X401 (Receptacle) pin 40 S Reverse valve 2 VT/BK - 1.0
5 X401 (Receptacle) pin 6 T PWM 1 BR - 1.0
6 X401 (Receptacle) pin 13 U PWM 1 BR/BK - 1.0
7 X401 (Receptacle) pin 7 V PWM 2 WH/RD - 1.0
8 X401 (Receptacle) pin 41 W PWM 2 WH/DB - 1.0
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RAIL17TLB0247AA 8

1 XC1 pin 8 J Switched battery from fuse WH/RD - 1.0 SHEET 02
F-1C
4 X23.p pin 4 M 4WD BR/GN - 1.0
5 X23.p pin 5 N Alternator signal LB/WH - 1.0
8 S48 pin 1 Q Auto/ manual WH - 1.0
9 X23.p pin 9 R Unswitched battery from RD - 1.0
X-23 pin 9
10 X33 pin 1 S Differential lock signal VT/WH - 1.0
11 X23.p pin 11 T Ground BK - 1.5
12 X125 pin 3 U Speedometer signal GY/DB - 1.0
13 XC1 pin 7 V Stop switch out RD/BK - 1.0
RAIL17TLB0251AA 9
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1 Splice SP-8374 K Switched battery from fuse White/ red SHEET 10
X400 (Receptacle) pin 8 A2 F-1C (1.0)
White/ red
(1.0)
2 - - - -
3 X401 (Receptacle) pin 21 K1 Declutch Dark blue/ red
(1.0)
4 X401 (Receptacle) pin 22 L1 4WD Brown/ green
(1.0)
5 X401 (Receptacle) pin 53 V1 Alternator signal Light blue/
white (1.0)
6 X406.s pin 2 C2 Forward signal Brown/ black
X401 (Receptacle) pin 18 H1 (1.0)
Brown/ black
(1.0)
7 X406.s pin 1 B2 Reverse signal Brown/ white
X401 (Receptacle) pin 46 P1 (1.0)
Brown/ white
(1.0)
8 X401 (Receptacle) pin 23 M1 Auto/ manual White (1.0)
9 X401 (Receptacle) pin 1 F1 Unswitched battery from Red (1.0)
X-23 pin 9
10 X401 (Receptacle) pin 51 U1 Differential lock signal Violet/ white
(1.0)
11 - - - -
12 X401 (Receptacle) pin 28 O1 Speed sensor out GY/DB - 1.0
13 X401 (Receptacle) pin 50 T1 Stop switch out RD/BK - 1.0
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RAIL17TLB0312AA 10
84277215
1 SA3 T3 CAN low GN - 0.5 SHEET 10
2 SA4 U3 CAN high YE - 0.5
RAIL17TLB0252AA 11
84277215
1 X401 (Receptacle) pin 55 H2 CAN low to the Trax GN - 0.5 SHEET 10
Control Module
2 X401 (Receptacle) pin 27 G2 CAN high to the Trax YE - 0.5
Control Module
RAIL17TLB0332AA 12
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1 X412 pin 1 A Signal LB/YE - 1.0 SHEET 07
2 GND C Ground BK - 1.0
X412 pin 2 D BK - 1.0
X406.s - DIODES CONNECTOR
RAIL17TLB0253AA 13

1 X400 (Receptacle) pin 5 X1 Reverse signal BR/WH - 1.0 SHEET 10
X404.s pin 7 B1 BR/WH - 1.0
2 X400 (Receptacle) pin 7 Z1 Forward signal BR/BK - 1.0
X404.s pin 6 C2 BR/BK - 1.0
3 X401 (Receptacle) pin 2 G1 In-gear signal to the Trax WH - 1.0
Control Module
4 X409.s pin 2 D2 Signal from the steering DB/RD - 1.0
switch
5 X409.s pin 3 E2 Signal from the steering GN/BK - 1.0
switch
6 X401 (Receptacle) pin 20 J1 4WS signal YE/DB - 1.0
7 - - - -
X407 - RIGHT WORK LIGHT CONNECTOR
RAIL17TLB0252AA 14

1 X43.p pin 4 G Side work light relay WH - 1.0 SHEET 07
2 X43.p pin 3 F Ground BK - 1.0
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RAIL17TLB0312AA 15

1 SA4 V3 CAN high YE - 0.5 SHEET 01
2 SA3 W3 CAN low GN - 0.5
RAIL17TLB0252AA 16

1 SA13 U8 CAN low GN - 0.5 SHEET 01
2 SA14 V8 CAN high YE - 0.5
X409 - LEFT WORK LIGHT CONNECTOR
RAIL17TLB0252AA 17

1 X43.p pin 6 I Side work light relay WH - 1.0 SHEET 07
2 X43.p pin 5 H Ground BK - 1.0
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RAIL17TLB0304AA 18

1 - - - -
2 - - - -
3 - - - -
4 Splice SP-8222 O 4WD YE/RD - 1.0 SHEET 02
5 Splice SP-8361 F Neutral signal GN/VT - 1.0
RAIL17TLB0254AA 19

1 X401 (Receptacle) pin 48 R1 Solenoid 3A WH - 1.0 SHEET 10
2 X406.s pin 4 D2 4WS DB/RD - 1.0
3 X406.s pin 5 E2 4WS GN/BK - 1.0
4 Splice SP-8222 O 4WD YE/RD - 1.0
5 Splice SP-8361 F Neutral signal GN/VT - 1.0
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X-419
MARBLE CUTTING
DRIVE (2WD)
DRIVE (4WD)
RAIL17TLB0332AA 1

X406 pin 1 A LB/YE - 1.0
X406 pin 2 D BK - 1.0
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X-449
MARBLE CUTTING
DRIVE (2WD)
DRIVE (4WD)
terminal 85 switch
2 Air conditioner relay K105 Unswitched battery from SHEET 11
85
4 Starter pilot relay K102 terminal Unswitched battery SHEET 01
30
5
6
7
8
terminal 87
10 Air conditioner relay K105 Relay ground SHEET 11
terminal 86
87
12 Starter pilot relay K102 terminal Start signal SHEET 01
86
85
14 SCR main relay K107 terminal Unswitched battery SHEET 01
30
85
16 Aux main relay K106 terminal Unswitched battery SHEET 01
30
17
18
19
20
87
86
87
86
25
terminal 85
28 Starter interlock relay K103 From the start relay SHEET 01
terminal 30
29
31
32
terminal 87
terminal 86
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40 Starter relay K104 terminal 30 Start signal from the SHEET 01
ignition switch
43
44
1 X-069.s pin B 1330 Air conditioner relay K105 YE - 1.0 SHEET 11
terminal 85
2 X-448.s pin 26 1360 Air conditioner relay K105 RD - 1.5 SHEET 11
terminal 30
4 Splice SP-007 1022 Unswitched battery RD - 4.0 SHEET 01
5
6
7
8
terminal 87
10 X-451.p pin 2 1340 Air conditioner relay K105 YE - 1.0 SHEET 11
terminal 86
terminal 87
12 X-448.s pin 35 1171 Starter pilot relay K102 OR - 0.75 SHEET 01
terminal 86
13 X-462 (Receptacle) pin 20 F200 SCR main relay K107 YE - 0.75 SHEET 01
terminal 85
14 Splice SP–007 1017 Unswitched battery RD - 4.0 SHEET 01
16 Splice SP-007 1016 Aux main relay K106 RD - 4.0 SHEET 01
terminal 30
17
18
19
20
terminal 87
22 Splice SP-159 E05D SCR main relay K107 RD - 0.75 SHEET 01
terminal 86
23 X-449.s pin 1 IGN1 Aux main relay K106 OR - 4.0 SHEET 01
terminal 87
24 Splice SP-159 E05C Aux main relay K106 RD - 0.75 SHEET 01
terminal 86
25
87
29
31
32
F005
35 X-448.s pin 12 1171 Starter interlock relay K103 OR - 0.75 SHEET 01
terminal 87
36 X-451P pin 3 1191 Starter interlock relay K103 WH - 1.0 SHEET 01
terminal 86
37 Splice SP-021 IGNA Pump module fuse F008 OR - 1.5 SHEET 01
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F005
39 Starter relay K104 terminal SHEET 01
85
30
41 X-461 (Receptacle) pin 1 E010 Engine fuse F004 RD - 2.5 SHEET 01
42 Splice SP-159 E058 SCR system fuse F003 RD - 1.0 SHEET 01
43
44
46 Splice SP-151 E055 SCR system fuse F003 RD - 1 SHEET 01
87
86
5 Engine fuse f012 Engine fuse f012 SHEET 01
6 Engine fuse F012 Engine fuse F012 SHEET 01
9
10
2 Splice SP-015 IGN2 Sensor power fuse F014 OR - 4.0 SHEET 01
5 Splice SP-151 E05A Engine fuse f012 RD - 4.0 SHEET 01
7 X-612 (Receptacle) pin 11 1019 DEF heater fuse F011 RD - 10.0 SHEET 01
8 Splice SP-001 1018 DEF heater fuse F011 RD - 10.0 SHEET 01
9
10
12 X-469 (Receptacle) pin 4 1040 Glow plug fuse F010 RD - 6.0 SHEET 01
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X-459
MARBLE CUTTING
DRIVE (2WD)
DRIVE (4WD)
RAIL17TLB0299AA 1

1 - - - -
2 - - - -
3 X1.s pin 7 G2 Start signal OR - 4.0 SHEET 01
4 MC1 pin 1 H2 Engine start from the OR - 4.0
starter
RAIL17TLB0300AA 2

1 X601 pin 1 U Air conditioner RD - 1.5 SHEET 11
2 X1.s pin 11 R Air conditioner relay pin 86 YE - 1.0
3 X1.s pin 2 J2 Starter interlock WH - 1.0 SHEET 01
4 - - - -
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X-469
MARBLE CUTTING
DRIVE (2WD)
DRIVE (4WD)
84058093 1
84058093
RAIL16TLB1513FA 2

RESISTOR
RESISTOR
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84474047 3
84474047
RAIL16TLB1513FA 4
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1 X-448.s pin 41 E010 BATTERY VOLTAGE VIA RD - 2.5 SHEET 01
MAIN RELAY
2 Splice SP-153 G013 BATTERY MINUS 1 BK - 2.5
3 Splice SP-158 E051 BATTERY +B VIA MAIN RD - 2.5
RELAY
5 Splice SP-158 E050 BATTERY +C VIA MAIN RD - 2.5
RELAY
7 X-611 (Receptacle) pin 3 1070 SCR TANK HEATING YE - 0.8
VALVE SIGNAL
8 X-496 (Plug) pin D E080 CRANK SIGNAL YE - 0.8
18 X-470 (Receptacle) pin 21 E180 EXHAUST GAS PRESS PK - 0.5
SENSE SIGNAL
SIGNAL
20 X-474 (Receptacle) pin 2 E200 AIR TEMP SENSOR WH - 0.5
GROUND
SIGNAL
23 Splice SP-163 CAN020 CAN HIGH YE - 0.5
24 X-496 (Plug) pin K CAN027 CAN HIGH YE - 0.5
25 X-496 (Plug) pin E CAN027 CAN LOW GN - 0.5
COMMAND SIGNAL
27 X-448.s pin 39 E270 CRANK ENABLE FROM YE - 0.75
ECU
28 X-464 (Receptacle) pin 2 E280 MAIN RELAY DB - 0.5
SENSOR SIGNAL
37 X-470 (Receptacle) pin 22 E370 EXHAUST GAS PRESS WH - 0.5
SENSE GROUND
41 Splice SP-203 E410 GLOW PLUG UNIT BK - 0.75
GROUND
45 Splice SP-162 CAN020 CAN LOW GN - 0.5
ECU
54 Splice SP-154 1505 TERMINAL 15 SW BAT+ OR - 0.75
57 X-470 (Receptacle) pin 23 E570 EXHAUST GAS PRESS YE - 0.5
SENSE SIGNAL
72 Splice SP-111 E720 SUPPLY MOD PUMP YE - 0.75
CONTROL SIGNAL
CONTROL SIGNAL
79 X-637 (Plug) pin 1 E790 CAT TEMP SENSE DS DB - 0.5
GROUND
80 X-637 (Plug) pin 2 E800 CAT TEMP SENSE DS YE - 0.5
SIGNAL
81 X-617 (Receptacle) pin 2 E810 CAT TEMP US GROUND DB - 0.5
CT
82 X-617 (Receptacle) pin 1 E820 CAT TEMP US GROUND YE - 0.5
CT
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84474053 5
84474053
RAIL16TLB1513FA 6

1 X-471 (Receptacle) pin D F010 INJECTOR 1 HIGH BANK 2 WH - 1.5 SHEET 01
2 X-471 (Receptacle) pin H F020 INJECTOR 2 HIGH BANK 2 WH - 1.5
4 X-470 (Receptacle) pin 27 F040 BOOST PRESSURE ACTUATOR 1 GY - 0.75
5 X-639 pin 8 F050 COMMON SIGNAL GROUND LB - 0.75
6 X-470 (Receptacle) pin 3 F060 OIL PRESSURE SWITCH INPUT WH - 0.5
SIGNAL
7 X-639 pin 10 F070 PRESSURE SENSE SUPPLY PK - 0.75
8 X-470 (Receptacle) pin 41 F080 TVA POSITION SENSOR SUPPLY PK - 0.5
9 X-470 (Receptacle) pin 33 F090 EGR POSITION SENSOR SUPPLY PK - 0.5
10 X-470 (Receptacle) pin 17 F100 BOOST PRESSURE SENSOR PK - 0.5
SUPPLY
11 X-470 (Receptacle) pin 7 F110 RAIL PRESSURE SENSOR SUPPLY PK - 0.5
13 X-470 (Receptacle) pin 12 F130 SEGMENT(CAMSHAFT) SPEED PK - 0.5
SENSOR SUPPLY
14 X-470 (Receptacle) pin 4 F140 SEGMENT (CAMSHAFT) SPEED YE - 0.5
SENSOR SIGNAL
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15 X-470 (Receptacle) pin 1 F150 FUEL METERING UNIT SUPPLY WH - 0.75
16 X-471 (Receptacle) pin A F160 INJECTOR 1 HIGH BANK 1 WH - 1.5
17 X-471 (Receptacle) pin E F170 INJECTOR 2 HIGH BANK 1 WH - 1.5
18 X-622 (Receptacle) pin 1 F180 DOSING VALVE H DB - 1.5
20 X-448.p pin 13 F200 SCR MAIN RELAY YE - 0.8
23 X-470 (Receptacle) pin 15 F230 FUEL TEMPERATURE SENSOR DB - 0.5
GROUND
24 X-470 (Receptacle) pin 35 F240 EGR POSITION SENSOR GROUND WH - 0.5
25 X-470 (Receptacle) pin 19 F250 BOOST PRESSURE SENSOR WH - 0.5
GROUND
26 X-470 (Receptacle) pin 5 F260 RAIL PRESSURE SENSOR GROUND DB - 0.5
27 X-470 (Receptacle) pin 25 F270 INLET TURBINE TEMP SENSE WH - 0.5
GROUND
28 X-470 (Receptacle) pin 8 F280 SEGMENT(CAMSHAFT) SPEED DB - 0.5
SENSOR GROUND
31 X-471 (Receptacle) pin C F310 INJECTOR 1 LOW BANK 2 GY - 1.5
32 X-471 (Receptacle) pin B F320 INJECTOR 1 LOW BANK 1 GY - 1.5
34 X-470 (Receptacle) pin 38 F340 TVA ACTUATOR MOTOR MINUS GY - 0.75
35 X-470 (Receptacle) pin 30 F350 EGR ACTUATOR MOTOR MINUS GY - 0.75
37 X-470 (Receptacle) pin 43 F370 TVA POSITION SENSOR GROUND WH - 0.5
38 X-470 (Receptacle) pin 16 F380 FUEL TEMPERATURE SENSOR YE - 0.5
SIGNAL
39 X-470 (Receptacle) pin 34 F390 EGR POSITION SENSOR SIGNAL YE - 0.5
40 X-470 (Receptacle) pin 18 F400 BOOST PRESSURE SENSOR SIGNAL YE - 0.5
41 X-470 (Receptacle) pin 6 F410 RAIL PRESSURE SENSOR SIGNAL YE - 0.5
43 X-470 (Receptacle) pin 26 F430 INLET TURBINE TEMP SENSE YE - 0.5
SIGNAL
44 X-470 (Receptacle) pin 10 F440 CRANKSHAFT SPEED SENSOR YE - 0.5
SIGNAL MINUS
46 X-471 (Receptacle) pin G F460 INJECTOR 2 LOW BANK 2 GY - 1.5
48 X-471 (Receptacle) pin F F480 INJECTOR 2 LOW BANK 1 GY - 1.5
49 X-470 (Receptacle) pin 37 F490 TVA ACTUATOR MOTOR PLUS WH - 0.75
50 X-470 (Receptacle) pin 29 F500 EGR ACTUATOR MOTOR PLUS WH - 0.75
53 X-470 (Receptacle) pin 42 F530 TVA POSITION SENSOR SIGNAL YE - 0.5
55 X-470 (Receptacle) pin 20 F550 BOOST PRESSURE TEMPERATURE YE - 0.5
SENSOR SIGNAL
56 X-639 pin 9 F561 PRESSURE SENSE SIGNAL YE - 0.8
57 X-470 (Receptacle) pin 14 F570 COOLANT TEMPERATURE SENSOR YE - 0.5
SIGNAL
58 X-470 (Receptacle) pin 10 F580 COOLANT TEMPERATURE SENSOR DB - 0.5
GROUND
59 X-470 (Receptacle) pin 9 F590 CRANKSHAFT SPEED SENSOR YE - 0.5
SIGNAL PLUS
87709663 7
87709663
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RAIL16TLB1513FA 8

SENSOR SIGNAL
84471904 9
84471904
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RAIL16TLB1513FA 10

1 Splice SP-157 1015 Unswitched battery DB - 0.5 SHEET 01
2 X-461 (Receptacle) pin 28 E280 Signal from ECU RD - 0.5
3 SP-151-P-X 1014 Unswitched battery RD - 6.0
5 Splice SP-151 E053 Relay signal out RD - 6.0
84356962 11
84356962
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RAIL16TLB1513FA 12

SIGNAL
4 X-449.s pin 12 1040 BAT+ RD - 6.0
5 Splice SP-203 E411 GLOW PLUG UNIT BK - 4.0
GROUND
COMMAND SIGNAL
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X-479
MARBLE CUTTING
DRIVE (2WD)
DRIVE (4WD)
84154706 1
84154706
RAIL16TLB1513FA 2

SUPPLY
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INPUT SIGNAL
SPEED SENSOR SIGNAL
5 X-462 (Receptacle) pin 26 F260 RAIL PRESSURE DB - 0.5
SENSOR GROUND
SENSOR SIGNAL
SENSOR SUPPLY
8 X-462 (Receptacle) pin 28 F280 SEGMENT(CAMSHAFT) DB - 0.5
SPEED SENSOR
GROUND
SENSOR SIGNAL PLUS
SENSOR SIGNAL MINUS
12 X-462 (Receptacle) pin 13 F130 SEGMENT (CAMSHAFT) PK - 0.5
SPEED SENSOR SUPPLY
13 X-462 (Receptacle) pin 58 F580 COOLANT DB - 0.5
TEMPERATURE SENSOR
GROUND
TEMPERATURE SENSOR
SIGNAL
15 X-462 (Receptacle) pin 23 F230 FUEL TEMPERATURE DB - 0.5
SENSOR GROUND
SENSOR SIGNAL
SENSOR SUPPLY
SENSOR SIGNAL
19 X-462 (Receptacle) pin 25 F250 BOOST PRESSURE WH - 0.5
SENSOR GROUND
TEMPERATURE SENSOR
SIGNAL
SENSE SIGNAL
SENSE GROUND
SENSE SIGNAL
25 X-462 (Receptacle) pin 27 F270 INLET TURBINE TEMP WH - 0.5
SENSE GROUND
SENSE SIGNAL
ACTUATOR 1
28 Splice SP-159 E058 B+ TO EL.VALVE RD - 0.75
PLUS
MINUS
SUPPLY
SIGNAL
35 X-462 (Receptacle) pin 24 F240 EGR POSITION SENSOR WH - 0.5
GROUND
PLUS
MINUS
SUPPLY
SIGNAL
43 X-462 (Receptacle) pin 37 F370 TVA POSITION SENSOR WH - 0.5
GROUND
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87698252 3
87698252
RAIL16TLB1513FA 4
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1
1
2
D X-462 (Receptacle) pin 1 F010 INJECTOR 1 HIGH BANK WH - 1.5
2
1
1
2
H X-462 (Receptacle) pin 2 F020 INJECTOR 2 HIGH BANK WH - 1.5
2
87679525 5
87679525
RAIL16TLB1513FA 6
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1 X-448.s pin 9 60C6 A/C COMPRESSOR BR - 1.5 SHEET 11
OUTPUT
84607243 7
84607243
RAIL16TLB1513FA 8

SIGNAL
GROUND
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X-499
MARBLE CUTTING
DRIVE (2WD)
DRIVE (4WD)
X-496 - TO FRONT HARNESS (Plug)
87698254 1
87698254
RAIL16TLB1513FA 2
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A - - - -
C Splice SP-154 150A IGNITION OR - 0.8
D X-461 (Receptacle) pin 8 E080 CRANK SIGNAL YE - 0.8
F - - - -
G - - - -
H - - - -
J - - - -
K X-461 (Receptacle) pin 24 CAN027 CAN 1 HIGH YE - 0.5
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X-509
MARBLE CUTTING
DRIVE (2WD)
DRIVE (4WD)
RAIL17TLB0268AA 1

1 SA103 L8 Ground BK - 1.0 SHEET 01
2 F-001 pin 2 I8 Switched power to the OR - 1.0
3 SA13 C9 CAN high YE - 0.5
4 SA14 D9 CAN low GN - 0.5
5 - - - -
6 X501 pin 3 M8 RS232 Tx DB - 1.0
7 X501 pin 2 N8 RS232 Rx VT - 1.0
8 SA15 C8 D+ PK - 1.0
9 - - - -
10 - - - -
11 - - - -
12 X10.p pin 27 E8 Unswitched battery to the RD - 1.0
RAIL17TLB0270AA 2

1 SA103 X7 Ground BK - 1.0 SHEET 01
2 X500.s pin 7 N8 RS232 Tx VT - 1.0
3 X500.s pin 6 M8 RS232 Rx DB - 1.0
4 - - - -
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X502 UNSWITCHED BATTERY
RAIL17TLB0302AA 3

1 F-002 pin 1 Q2 Unswitched battery OR- 4.0 SHEET 01
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X-529
MARBLE CUTTING
DRIVE (2WD)
DRIVE (4WD)
X520 - LIGHTS INPUT
RAIL17TLB0336AA 1

1 SP-171 E9 Front work lights YE - 1.0 SHEET 05
2 SP-900 H9 Front work lights YE - 1.0
3 XC6 pin 11 U3 Instrument lamps YE - 1.0
4 SP-900 G9 Instrument lamps YE - 1.0
5 SP-172 F9 Rear work lights YE - 1.0
6 SP-900 I9 Rear work lights YE - 1.0
7 - - - -
8 - - - -
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X-609
MARBLE CUTTING
DRIVE (2WD)
DRIVE (4WD)
X600.p - UNSWITCHED BATTERY CONNECTOR
RAIL17TLB0257AA 1

1 SA6 E1 Unswitched battery RD - 16.0 SHEET 01
X600.s - UNSWITCHED BATTERY CONNECTOR
RAIL17TLB0294AA 2

1 X601 pin 1 V1 Unswitched battery RD - 16.0 SHEET 01
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X601 POWER
RAIL17TLB0301AA 3

1 X451S pin 1 U Unswitched battery RD - 1.5 SHEET 01
X1.s pin 1 W1 Unswitched battery RD - 6.0
X600.s pin 1 V1 Unswitched battery RD - 16.0
X605 - SIDE WORK LIGHT RELAY (Receptacle)
RAIL17TLB0261AA 4

30 X31 pin F2B Z3 Power relay RD/BK - 2.5 SHEET 07
85 K14 pin 85 N6 Ground BK - 1.0
GND.2 Q2 Ground BK - 1.0
86 X87.p pin 4 M6 GN/VT - 1.0
87 X12.s pin 6 I6 WH - 1.0
X12.s pin 7 J6 WH - 1.0
87a - - - -
84152570 5
84152570
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RAIL16TLB1513FA 6

1 - - - SHEET 01
SIGNAL
3 X-638 pin 3 IGNC IGNITION TO THE PUMP OR 1.5
MODULE
7 - - -
GROUND
SENSOR
SUPPLY
11 X-638 pin 11 5051 OR 1.5
RAIL17TLB0266AA 7
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1 XST2 (Receptacle) pin 6 W5 Buzzer OR/BK - 1.0 SHEET 01
47514978 8
47514978
RAIL16TLB1514FA 9

1 X-636 (Receptacle) pin 7 IG02 IGN SCR DOWNSTREAM OR - 0.75 SHEET 01
NOx W/ECU
DOWNSTREAM NOx
W/ECU
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X607 DIAGNOSTIC CONNECTOR
RAIL17TLB0275AA 10

A GND.1 F3 Ground BK - 1.0 SHEET 01
B X31 pin F1B V3 Unswitched battery from RD - 1.0
fuse F1B
C SA3 S8 CAN high YE - 0.5
D SA4 O8 CAN low GN - 0.5
E X13.p pin 15 K2 K-line BR - 1.0
F - - - -
G - - - -
H - - - -
J - - - -
47514978 11
47514978
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RAIL16TLB1513FA 12

1 Splice SP-015 IGN6 IGN DOC UPSTREAM OR - 1.0 SHEET 01
NOx SENSOR w/ECU
2 Splice SP-G03 G219 BATT- 7 DOC UPSTREAM BK - 1.0
NOx SENSOR w/ECU
3 Splice SP-168 CAN024 CANL DOC UPSTREAM GN - 0.5
NOx SENSOR w/ECU
4 Splice SP-169 CAN024 CANH DOC UPSTREAM YE - 0.5
NOx SENSOR w/ECU
NOx SENSOR w/ECU
RAIL17TLB0280AA 13

A XST2 (Receptacle) pin 19 Q5 Voltage to the throttle RD/BK - 1.0 SHEET 02
sensor
B XST2 (Receptacle) pin 17 R5 Throttle signal PK - 1.0
C XST2 (Receptacle) pin 21 S5 Throttle sensor ground BR - 1.0
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87688719 14
87688719
RAIL16TLB1513FA 15

SENSOR
2 X-640 pin 2 G228 BATT- 9 BK - 1.0
4 X-640 pin 4 CAN040 CAN LOW GN - 0.5
5 X-640 pin 5 CAN040 CAN HIGH YE - 0.5
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X-619
MARBLE CUTTING
DRIVE (2WD)
DRIVE (4WD)
84146685 1
84146685
RAIL16TLB1513FA 2

2 - - -
3 X-461 (Receptacle) pin 7 E070 SCR HEATING VALVE YE 0.75
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47514457 3
47514457
RAIL16TLB1513FA 4

1 X-639 pin 11 5050 IGN TO HEATER OR - 1.5 SHEET 01
2 X-641 pin 7 1203 DEF HTR1 WH - 1.5
4 X-641 pin 6 1205 ADBLUE OUTLET WH - 1.5
6 Splice SP-159 E05E FUSED PWR FROM MAIN RD - 0.75
RLY
9 Splice SP-166 CAN025 CANL2 HCU GN - 0.5
10 Splice SP-167 CAN025 CANH2 HCU YE - 0.5
11 X-449.s pin 7 1019 BATT+ FROM HCU FUSE RD - 10.0
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84532147 5
84532147
RAIL16TLB1513FA 6

1 X-461 (Receptacle) pin 82 E820 CAT TEMP US GND CT YE - 0.5 SHEET 01
2 X-461 (Receptacle) pin 81 E810 CAT TEMP US GND CT BL - 0.5
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84532147 7
84532147
RAIL16TLB1513FA 8

1 X-636 (Receptacle) pin 2 E801 CATALYST TEMP DS T BL - 0.5 SHEET 01
2 X-636 (Receptacle) pin 1 E791 CATALYST TEMP DS OUT YE - 0.5
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X-629
MARBLE CUTTING
DRIVE (2WD)
DRIVE (4WD)
87709793 1
87709793
RAIL16TLB1514FA 2

1 X-462 (Receptacle) pin 18 F180 DOSING VLV H BL - 1.5 SHEET 01
2 X-462 (Receptacle) pin 3 F030 DOSING VLV L YE - 1.5
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84146686 3
84146686
RAIL16TLB1514FA 4

1 X-636 (Receptacle) pin 5 IG03 SENSOR POWER OR 1.0 SHEET 01
2 SPLICE SP-174 CAN039 CAN DATA LINK HIGH YE 0.5
3 SPLICE SP-173 CAN039 CAN DATA LINK LOW GN 0.5
4 X-636 (Receptacle) pin 6 G237 SENSOR GROUND BK 1.0
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X-639
MARBLE CUTTING
DRIVE (2WD)
DRIVE (4WD)
84284795 1
84284795
RAIL16TLB1514FA 2

2 Splice SP-182 G290 DEF LINE HTR1 GND BK - 2.0
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84284795 3
84284795
RAIL16TLB1514FA 4

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47416270 5
47416270
RAIL16TLB1513FA 6
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DOWNSTREAM
TEMPERATURE SENSOR
DOWNSTREAM
TEMPERATURE SENSOR
5 X-624 (Receptacle) pin 1 IG03 IGN NH3 SENSOR OR - 1.0
6 X-624 (Receptacle) pin 4 G237 BATT- 11 NH3 SENSOR BK - 1.0
NOx W/ECU
DOWNSTREAM NOx
W/ECU
9 - - - -
10 - - - -
47416278 7
47416278
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RAIL16TLB1513FA 8

GND
SIG
5 Splice SP-015 IGN5 IGN NH3 SENSOR OR - 1.0
6 Splice SP-003 G217 BATT- 11 NH3 SENSOR BK - 1.0
7 Splice SP-015 IGN4 IGN SCR DOWNSTREAM OR - 1.0
NOx W/ECU
8 Splice SP-003 G216 BATT- 5 SCR BK - 1.0
DOWNSTREAM NOx
W/ECU
9 - - - -
10 - - - -
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1 - - - - SHEET 01
SIGNAL
MODULE
7 - - - -
8 X-605 (Receptacle) pin 8 F051 PRESSURE SENSOR DB - 0.75
GROUND
SENSOR
SUPPLY

1 - - - - SHEET 01
SIGNAL
3 X-448.s pin 33 IGNB IGNITION TO THE PUMP OR - 1.5
MODULE
5 Splice SP-016 IGN11 COMMON IGNITION OR - 1.5
7 - - - -
GROUND
SENSOR
SUPPLY
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X-649
MARBLE CUTTING
DRIVE (2WD)
DRIVE (4WD)

SENSOR
3 - - - -
4 X-608 (Receptacle) pin 4 CAN040 CANL 2 10 QUALITY GN - 0.5
SENSOR
5 X-608 (Receptacle) pin 5 CAN040 CANH 2 10 UREA YE - 0.5
QUALITY SENSOR

1 Splice SP-015 IGN3 IGN UREA QUALITY OR - 1.0 SHEET 01
SENSOR
3 - - - -
4 Splice SP-162 CAN021 CANL 2 10 QUALITY GN - 0.5
SENSOR
5 Splice SP-163 CAN021 CANH 2 10 UREA YE - 0.5
QUALITY SENSOR
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X-809
MARBLE CUTTING
DRIVE (2WD)
DRIVE (4WD)
X800.s - FRONT HARNESS (Receptacle)
87698252 1
87698252
RAIL16TLB0845FA 2
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A X13.s pin 18 Q3 Starter relay coil terminal DB - 1.0 SHEET 01
86
B X13.s pin 15 N3 ISO K GY - 1.0
C X13.s pin 19 R3 Ignition RD/BK - 1.0
D X13.s pin 20 S3 Crank signal from ignition WH - 1.0
switch
E SA3 X3 CAN low GN - 0.5
F X13.s pin 16 O3 Starter relay coil terminal GN - 1.0
85
G - - - -
H X13.s pin 17 P3 Air conditioner clutch signal GN - 1.5
J - - - -
K SA4 Z3 CAN high YE - 0.5
RAIL17TLB0252AA 3

1 X10.s pin 22 E1 Switched battery GN/VT - 1.0 SHEET 03
2 X10.s pin 23 F1 Ride control pressure WH - 1.0
switch signal
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X-909
MARBLE CUTTING
DRIVE (2WD)
DRIVE (4WD)
X-901 - CONSOLE FRAME GROUND CONNECTOR
RAIL17TLB0302AA 1

1 Splice SP-8083 C Ground BK - 1.5
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Wire connectors - Component diagram 00 Pilot control connectors

S1 and S2
MARBLE CUTTING
DRIVE (2WD)
DRIVE (4WD)
S1 - PILOT CONTROL ON/OFF SWITCH CONNECTOR

2 X13.p pin 1 GY - 1.5 SHEET 12
3 X13.p pin 3 GY/YE - 1.5
5 X13.p pin 1 GY - 1.5
6 X13.p pin 2 GY/BK - 1.5
7 X13.p pin 5 GY/BK - 1.5
8 X13.p pin 2 BK - 1.5
S2 - PATTERN CHANGE SWITCH CONNECTOR

2 X13.p pin 2 GY/BK - 1.5 SHEET 12
3 X13.p pin 4 GY/RD - 1.5
7 X13.p pin 5 BK - 1.5
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XL, XR, and XX
MARBLE CUTTING
DRIVE (2WD)
DRIVE (4WD)
XL - LEFT-HAND STABILIZER JOYSTICK CONNECTOR

A X20 pin 16 Power WH/RD - 1.0 SHEET 12
B X20 pin 9 Signal LB/RD - 1.0
C Ground Ground BK - 1.0
XR - RIGHT-HAND STABILIZER JOYSTICK CONNECTOR

B X20 pin 10 Signal LB/BK - 1.0
XX - TO SOLENOID VALVES LINE/ ONE TOUCH DECEL

1 X73 pin 1 GY/DB - 1.0 SHEET 12
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YP3 to YP10
MARBLE CUTTING
DRIVE (2WD)
DRIVE (4WD)
YP3 - LEFT-HAND STABILIZER DOWN SOLENOID CONNECTOR

1 X20 pin 3 Signal YE/RD - 1.0 SHEET 12
2 Ground Ground BK - 1.0
YP4 - LEFT-HAND STABILIZER UP SOLENOID CONNECTOR

1 X20 pin 4 Signal DB/WH - 1.0 SHEET 12
YP5 - RIGHT-HAND STABILIZER DOWN SOLENOID CONNECTOR

1 X20 pin 6 Signal YE/BK - 1.0 SHEET 12
YP6 - RIGHT-HAND STABILIZER UP SOLENOID CONNECTOR

1 X20 pin 5 Signal DB/RD - 1.0 SHEET 12
YP7 - BOOM EXTEND SOLENOID CONNECTOR

1 X20 pin 7 Signal YE/GN - 1.0 SHEET 12
YP8 - BOOM RETRACT SOLENOID CONNECTOR

1 X20 pin 8 Signal DB/YE - 1.0 SHEET 12
YP9 - AUX FORWARD SOLENOID CONNECTOR

1 X20 pin 23 Signal BR/WH - 1.0 SHEET 12

1 X20 pin 15 Signal BR/BK - 1.0 SHEET 12
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X-00 to X-09
MARBLE CUTTING
DRIVE (2WD)
DRIVE (4WD)
X1 - PATTERN VALVE 1 CONNECTOR

A X13.s pin 4 Signal GY/RD - 1.5 SHEET 12
B Ground Ground BK - 1.0


1 X27 pin 1 BK - 1.0 SHEET 12
2 X27 pin 2 OR/BK - 1.0
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X-010 to X-019
MARBLE CUTTING
DRIVE (2WD)
DRIVE (4WD)
X11 - LEFT-HAND STABILIZER PRESSURE SWITCH CONNECTOR

1 X20 pin 13 Signal GN/WH - 1.0 SHEET 12
X12 - RIGHT-HAND STABILIZER PRESSURE SWITCH CONNECTOR

1 X20 pin 14 Signal GN/BK - 1.0 SHEET 12
X13.p - RIGHT-HAND TOWER LINE CONNECTOR

1 S1 pin 2 GY - 1.5 SHEET 12
S1 pin 5
2 S2 pin 2 GY/BK - 1.0
S1 pin 6
S1 pin 8
3 S1 pin 3 GY/YE - 1.5
4 S2 pin 3 GY/RD - 1.5
5 S2 pin 7 BK - 1.0
S1 pin 7
X13.s - RIGHT-HAND TOWER LINE CONNECTOR

1 X72 pin 1 GY - 1.5 SHEET 12
2 X23 pin A GY/BK - 1.0
3 X20 pin 1 GY/YE - 1.5
4 X1 pin A GY/RD - 1.5
X2 pin A
5 GROUND BK - 1.0
X14 - RIGHT-HAND JOYSTICK CONNECTOR

1 X20 pin 16 WH/RD - 1.0 SHEET 12
2 X20 pin 16 WH/RD - 1.0
3 GROUND BK - 1.0
4 GROUND BK - 1.0
5 X20 pin 12 WH/YE - 1.0
6 X20 pin 11 VT/WH - 1.0
X17 - MANIFOLD POWER CONNECTOR

1 X13.s pin 2 GY/BK - 1.0 SHEET 12
2 Ground BK - 1.0
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X-020 to X-029
MARBLE CUTTING
DRIVE (2WD)
DRIVE (4WD)
X20 - LVC UNIT CONNECTOR

1 X13.s pin 3 GY/YE - 1.5 SHEET 12
2 GROUND BK - 1.5
3 YP3 pin 1 YE/RD - 1.0
4 YP4 pin 1 DB/WH - 1.0
5 YP6 pin 1 DB/RD - 1.0
6 YP5 pin 1 YE/BK - 1.0
7 YP7 pin 1 YE/VT - 1.0
8 YP8 pin 1 DB/YE - 1.0
9 XL pin B LB/RD - 1.0
10 XR pin B LB/BK - 1.0
11 X14 pin 6 VT/WH - 1.0
12 X14 pin 5 WH/YE - 1.0
13 X11 pin 1 GN/WH - 1.0
14 X12 pin 1 GN/BK - 1.0
15 YP10 pin 1 BR/BK -
16 X14 pin 1 WH/RD - 1.0
X14 pin 2
17 X24 pin 5 LB - 1.0
18 X24 pin 6 DB - 1.0
19 - - - -
20 - - - -
21 - - - -
22 - - - -
23 YP9 pin 1 BR/WH - 1.0
X23 - SAFETY SWITCH CONNECTOR

A X17 pin 1 GY/BK - 1.0 SHEET 12
B Ground BK - 1.0
X24 - LEFT JOYSTICK CONNECTOR

1 X20 pin 16 WH/RD - 1.0 SHEET 12
2 X20 pin 16 WH/RD - 1.0
5 X20 pin 17 Signal LB - 1.0
6 X20 pin 18 Signal DB - 1.0
X27 - HORN JUMPER CONNECTOR

1 X4 pin 1 BK - 1.0 SHEET 12
2 X4 pin 2 OR/BK - 1.0
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X-070 to X-079
MARBLE CUTTING
DRIVE (2WD)
DRIVE (4WD)
X72 - TO SOLENOID VALVES CONNECTOR

1 X13.s pin 1 GY - 1.0 SHEET 12
X73 - ONE TOUCH DECEL CONNECTOR

1 XX pin 1 SIGNAL GY/DB - 1.0 SHEET 12
2 GROUND GROUND BK - 1.0
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ground
MARBLE CUTTING
DRIVE (2WD)
DRIVE (4WD)
UNSWITCHED BATTERY CONNECTOR +30
RAIL17TLB0314AA 1

1 SA6 C Unswitched battery RD- 10.0 SHEET 01
SWITCHED BATTERY CONNECTOR +15
RAIL17TLB0315AA 2

1 X15.2 pin 6 Q4 Switched battery DB - 6.0 SHEET 01
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RAIL17TLB0316AA 3

1 GND.1 R4 Ground BK - 1.5 SHEET 01
X10.p pin 2 T1 Ground BK - 1.5
X10.p pin 3 U1 Ground BK - 1.5
SA103 P7 Ground BK - 1.0
RAIL17TLB0327AA 4

1 X607 pin A I3 Ground BK - 1.0 SHEET 01
GND R4 Ground BK - 1.5 SHEET 01
X27 pin 1 F5 Ground BK - 1.0 SHEET 05
X25 pin 1 N1 Ground BK - 1.0
X29 pin 1 D5 Ground BK - 1.0
XST2 (Receptacle) pin 26 K5 Ground BK - 1.0
X224 pin 85 F6 Ground BK - 1.0
H26.2 pin 1 G5 Ground BK - 1.0
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RAIL17TLB0327AA 5

X46 pin 1 K1 Ground BK - 1.0
GND Z Ground BK - 2.5
RAIL17TLB0302AA 6

1 X41 pin 1 Q1 Ground BK - 2.5
RAIL17TLB0327AA 7
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X46 pin 1 K1 Ground BK - 1.0
X44 pin 1 Z Ground BK - 2.5
RAIL17TLB0327AA 8

1 X45 pin 1 V1 Ground BK - 1.0 SHEET 06
X50 pin 1 W1 Ground BK - 1.0
H18.3 pin 1 A2 Ground BK - 1.0
X55.1 pin 1 R1 Ground BK - 1.0
RAIL17TLB0302AA 9

1 X209 pin 2 C1 Ground BK - 1.0 SHEET 03
X26 pin B A1 Ground BK - 1.0 SHEET 08
X204.s pin 1 F1 Ground BK - 1.0
X203 pin 2 G1 Ground BK - 1.0
X411.s pin 2 D1 Ground BK - 1.0
X206 pin B W Ground BK - 1.0
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RAIL17TLB0302AA 10

1 X10.s pin 3 V1 Ground BK - 1.5 SHEET 03
X208.s pin 1 W1 Ground BK - 1.0
X10.s pin 2 R1 Ground BK - 1.5
X35 pin 2 T1 Ground BK - 1.0
RAIL17TLB0302AA 11

1 X8 pin 2 B1 Ground BK - 2.5 SHEET 01
X200 pin 2 Z Ground BK - 2.5 SHEET 02
X4.2 pin 1 T2 Ground BK - 2.5
X1.s pin 6 G Ground BK - 2.5
X74 pin 2 X Ground BK - 2.5
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RAIL17TLB0327AA 12

1 X125 pin 2 G1 Ground BK - 1.0 SHEET 03
X22 pin 1 G2 Ground BK - 1.5 SHEET 04
S5 pin 9 X Ground BK - 1.0
GND2 L2 Ground BK - 2.5
GND2 - GROUND CONNECTOR
RAIL17TLB0302AA 13

1 X19 pin 2 P Ground BK - 1.0 SHEET 02
S2 pin 4 O1 Ground BK - 1.0
GND L2 Ground BK - 2.5
RAIL17TLB0302AA 14
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1 X406 pin 2 C Ground BK - 1.0 SHEET 07
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Wire connectors - Component diagram 00 Connectors fuses

MARBLE CUTTING
DRIVE (2WD)
DRIVE (4WD)
F-001 - FUSE
RAIL17TLB0317AA 1

1 X802.p pin 3 H8 Power supply RD/BK - 1.0 SHEET 01
2 X500.s pin 2 J8 Switched power OR - 1.0
F-002 - FUSE
RAIL17TLB0318AA 2

1 X502 pin 1 V2 Unswitched battery OR1 - 4.0 SHEET 01
2 SA104 W2 Unswitched battery OR2 - 4.0
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Wire connectors - Component diagram 00 Connectors BS1 and BS2

MARBLE CUTTING
DRIVE (2WD)
DRIVE (4WD)
RAIL17TLB0282AA 1

1 X53 pin 3 P2 Speaker RD - 0.5 SHEET 08
RAIL17TLB0326AA 2

1 X53 pin 4 Q2 Speaker BK - 0.5 SHEET 08
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RAIL17TLB0282AA 3

1 X53 pin 5 O2 Speaker RD - 0.5 SHEET 08
RAIL17TLB0326AA 4

1 X53 pin 6 N2 Speaker BK - 0.5 SHEET 08
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Wire connectors - Component diagram 00 Connectors H00 to H99

MARBLE CUTTING
DRIVE (2WD)
DRIVE (4WD)
H18.1 - DOME LAMP
RAIL17TLB0328AA 1

1 S34 pin 1 G2 Left door switch/ right door BR/BK - 1.0 SHEET 08
switch
H18.2 - DOME LAMP
RAIL17TLB0328AA 2

1 XC5 pin 10 M Unswitched battery from WH - 1.0 SHEET 08
fuse F7B
H18.3 - DOME LAMP

1 X49 pin 3 F2 Ground BK - 1.0 SHEET 08
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RAIL17TLB0282AA 3

1 X87.p pin 9 H5 Rear block control lamp WH - 1.0 SHEET 03
RAIL17TLB0282AA 4

1 GND.1 G5 Ground BK - 1.0 SHEET 03
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Wire connectors - Component diagram 00 Connectors relays K-00

to K-99
MARBLE CUTTING
DRIVE (2WD)
DRIVE (4WD)
K1 - FORWARD/REVERSE SPEED SWITCH RELAY
RAIL17TLB0261AA 1

30 Fuse F4A Switched battery SHEET 02
85 Ground Ground
86 XC3 pin 9
87 - - - -
87a XC1 pin 5 Signal
K4 - BUCKET LEVEL SOLENOID VALVE RELAY
RAIL17TLB0261AA 2

30 Fuse F4B Switched battery SHEET 02
85 XC3 pin 19
86 Fuse F4B Switched battery
87 - - - -
87a XC3 pin 8 Signal
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K10 - REVERSE SPEED RELAY
RAIL17TLB0261AA 3

85 Ground Ground
86 XC1 pin 9
87 XC6 pin 8 Signal
87a - - - -
K11 - FORWARD SPEED RELAY
RAIL17TLB0261AA 4

85 Ground Ground
86 XC1 pin 3
87 XC6 pin 1 Signal
87a - - - -
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Wire connectors - Component diagram 00 Connector MC1

MARBLE CUTTING
DRIVE (2WD)
DRIVE (4WD)
RAIL17TLB0282AA 1

1 X450S pin 4 D3 Engine start OR - 4.0 SHEET 01
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MARBLE CUTTING
DRIVE (2WD)
DRIVE (4WD)
RAIL17TLB0309AA 1

1 - - - - SHEET 02
2 X13.s pin 10 M1 4WD signal WH - 1.0
3 XC4 pin 7 N1 Switched battery WH - 1.0
4 S3 pin 4 L1 Switch lamp ground BK - 1.0
5 - - - -
6 X13.s pin 7 P1 4WD relay signal GY - 1.0
S3 - HAND HAMMER SWITCH CONNECTOR
RAIL17TLB0309AA 2

1 - - - - SHEET 02
2 X13.s pin 15 J1 Hand hammer relay RD/YE - 1.0
3 XC4 pin 11 K1 Hand hammer solenoid GY/BK - 1.0
valve
4 S2 pin 4 L1 Ground BK - 1.0
5 - - - -
6 - - - -
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S5 - RIDE CONTROL SWITCH CONNECTOR
RAIL17TLB0331AA 3

1 - - - -
2 S5 pin 4 V2 Switched battery RD/GN - 1.0 SHEET 03
3 X13.s pin 2 W2 Input ride control switch WH/YE - 1.0
4 S5 pin 2 V2 Switched battery RD/GN - 1.0
5 X13.s pin 18 X2 Input ride control switch WH - 1.0
6 - - - -
7 X13.s pin 3 W Ride control switch light LB/BK - 1.0
8 - - - -
9 Ground T1 Ground BK - 1.0
10 - - - -
S15 - ROTATING BEACON SWITCH CONNECTOR
RAIL17TLB0309AA 4

1 - - - -
2 XC4 pin 1 R Switched battery LB/YE - 1.5 SHEET 07
3 XC2 pin 1 S Rotating beacon LB/GN - 1.5
4 Ground T Ground BK - 1.0
5 - - - -
6 - - - -
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S34 - LEFT DOOR SWITCH
RAIL17TLB0282AA 5

S35 - RIGHT DOOR SWITCH
RAIL17TLB0282AA 6

S41 - WINDSHIELD WIPER/ LIGHTS SWITCH CONNECTOR (ON THE STEERING COLUMN)
RAIL17TLB0268AA 7
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1 - - - - SHEET 07
2 X13.s pin 9 F Windshield washer pump DB/WH - 1.0
3 - - - -
4 XC2 pin 2 G Switched battery WH - 1.0
5 XC4 pin 8 H Head lights relay GN/BK - 1.5
6 XC4 pin 14 I Front windshield wiper WH - 1.0
7 XC4 pin 12 J Switched battery WH - 1.0
8 XC4 pin 15 K Front windshield wiper WH - 1.0
9 SA1 L Left turn signal DB - 1.0
10 SA2 M Right turn signal LB - 1.0
11 S42 pin 5 N 49a warning DB/BK - 1.0
12 - - - -
S42 - WARNING SWITCH CONNECTOR
RAIL17TLB0308AA 8

1 XC4 pin 3 Z Switched battery GY/RD - 1.0 SHEET 04
2 XC4 pin 10 A1 Flasher GY/DB - 1.0
3 XC4 pin 13 B1 Unswitched battery WH - 1.0
4 XC4 pin 10 C1 Flasher GY/DB - 1.0
5 XC4 pin 9 D1 49a warning DB/BK - 1.0
6 SA1 E1 Left turn signal DB - 1.0
7 SA2 F1 Right turn signal LB - 1.0
S100 - QUICK COUPLER SWITCH A

1 X102 pin 1 LB/BK - 1.0 SHEET 09
2 X603.p pin 1 DB/RD - 1.0
3 S101 pin 2 LB - 1.0
S101 - QUICK COUPLER SWITCH B

1 - - - - SHEET 09
2 S100 pin 3 LB - 1.0
3 X105 pin 1 BR - 1.0
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Wire connectors - Component diagram 00 Connectors XC, XST,

and XX
MARBLE CUTTING
DRIVE (2WD)
DRIVE (4WD)
XC1 - FUSE PANEL CONNECTOR
RAIL17TLB0242AA 1

1 X21 pin 6 X1 Front horn switch OR - 1.0 SHEET 02
2 X33 pin 2 B2 Switched battery from WH - 1.0 SHEET 05
Fuse F1C
3 X140.s pin 1 A BR/BK - 1.0 SHEET 02
4 - - - -
5 X19 pin 1 O Switched battery from fuse WH - 1.0 SHEET 02
F4A
6 - - - -
7 X32 pin 3 F2 Stop light switch RD/BK - 1.0 SHEET 05
8 - - - -
9 X140.s pin 2 C BR/WH - 1.0 SHEET 02
10 X13.s pin 14 R2 Turn signal WH/GN - 1.0 SHEET 04
11 - - - -
RAIL17TLB0243AA 2

1 S15 pin 3 S Rotating beacon LB/GN - 1.5 SHEET 07
2 S41 pin 4 G Switched battery from fuse WH - 1.0 SHEET 02
F6C
3 XC2 pin 4 O2 Jumper to XC2 pin 3 LB - 1.0 SHEET 08
4 XC2 pin 3 O2 Jumper to XC2 pin 4 LB - 1.0 SHEET 02
5 XC2 pin 7 P2 Jumper to XC2 pin 7 VT - 1.0 SHEET 08
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6 X13.s pin 17 Q2 4WD YE/RD - 1.0 SHEET 02
7 XC2 pin 5 P2 Jumper to XC2 pin 5 VT - 1.0 SHEET 08
RAIL17TLB0245AA 3

1 X10.p pin 4 V1 Hand hammer solenoid GY/BK - 1.0 SHEET 02
valve
2 X28 pin 2 C4 Rear left lamp DB - 1.0 SHEET 05
3 X87.p pin 8 D4 Front work lights YE - 1.0 SHEET 06 Sheet 6
4 X87.p pin 1 E4 PK/YE - 1.0
5 X14.s pin 1 Z3 Switched battery DB/BK - 1.0 SHEET 02
6 SA8 H WH/RD - 1.5
7 X10.p pin 17 H2 Bucket quick coupler WH - 1.0 SHEET 06
8 X10.p pin 7 W1 Bucket level solenoid GY/RD - 1.0 SHEET 02
9 X10.p pin 16 G2 Boom lock LB/RD - 1.0 SHEET 02
10 - - - -
11 X10.p pin 14 E2 Horn OR/BK - 1.0 SHEET 02
12 X29 pin 2 H4 Right rear turn signal LB - 1.0 SHEET 05
13 X27 pin 2 J4 License plate light YE/BK - 1.0
14 Splice SP-172 K4 Rear work light switch YE - 1.0 SHEET 06
15 X87.p pin 11 L4 Rear work light switch VT/BK - 1.0
16 X230 pin 87a M4 Power supply RD/GN - 1.0 SHEET 02
17 X88.p pin 1 N4 Switched battery from fuse WH - 1.0 SHEET 07
motor
18 X87.p pin 7 O4 Power supply WH - 1.0 SHEET 06
19 X10.p pin 19 J2 Bucket sender signal LB/YE - 1.0 SHEET 02
20 X29 pin 4 P4 Right rear position light YE - 1.0 SHEET 05
21 X28 pin 3 Z Left stop lamp RD/BK - 1.0
RAIL17TLB0245AA 4
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1 S15 pin 2 R Switched battery from fuse LB/YE - 1.5 SHEET 07
F6A to switch S15
2 - - - -
3 S42 pin 1 Z Switched battery from fuse GY/RD - 1.0 SHEET 04
F6B to switch S42
4 - - - -
5 X13.s pin 13 S2 To switch S9 GY/BK - 1.5 SHEET 04
6 X21 pin 3 T1 From fuse F3A to front YE - 1.0 SHEET 04
lights
7 S2 pin 3 N1 WH - 1.0 SHEET 02
8 S41 pin 5 H From the headlight switch GN/BK - 1.5 SHEET 04
9 S42 pin 5 D1 To the flasher unit from DB/BK - 1.0 SHEET 04
switch S42
10 S42 pin 4 C1 To the flasher unit from GY/DB - 1.0 SHEET 04
switch S42
11 S3 pin 3 K1 Hand hammer switch GY/BK - 1.0 SHEET 02
12 S41 pin 7 J Switched battery from fuse WH - 1.0 SHEET 07
F7C to switch S41
13 S42 pin 3 B1 Unswitched battery from WH - 1.0 SHEET 04
fuse F7A
14 S41 pin 6 I From switch S41 WH - 1.0 SHEET 07
15 S41 pin 8 K From switch S41 WH - 1.0 SHEET 07
16 X22 pin 4 J2 Head lights GY/BK - 1.0 SHEET 04
17 SA1 N2 To switch S41 DB - 1.0 SHEET 05
18 X22 pin 3 I2 From fuse F3B to the head YE/BK - 1.0 SHEET 04
lights
19 SA2 M2 To switch S41 LB - 1.0 SHEET 05
20 X21 pin 5 W1 High beams GN - 1.0 SHEET 04
21 X13.s pin 12 U2 From switch S9 YE - 1.5 SHEET 04
RAIL17TLB0248AA 5

1 X49 pin 3 A Switched battery from fuse WH - 1.0 SHEET 07
F7C to the front windshield
wiper motor
2 - - - -
3 X49 pin 1 C Front windshield wiper WH - 1.0 SHEET 07
motor
4 X49 pin 4 D Front windshield wiper WH - 1.0
motor
5 - - - -
6 X55.2 pin 1 F Socket lamp YE - 1.0 SHEET 05
7 - - - -
8 - - - -
9 - - - -
10 X55.1 pin 1 L Unswitched battery from RD/BK - 1.5 SHEET 08
fuse F7B to the cabin light,
cigar lighter, and the radio
11 X40 pin 2 S Internal rear work light GN/BK - 1.0 SHEET 06
12 X50 pin 2 U Internal front work light GN - 1.0
13 X38 pin 2 N External rear work light GY/BK - 1.0
14 X44 pin 2 P External front work light GY - 1.0
15 - - - -
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16 X43.s pin 2 V Switched battery from LB/YE - 1.0 SHEET 07
fuse F1A to windshield
17 - - - -
RAIL17TLB0249AA 6

1 XX pin 4 C3 Forward signal BR/BK - 1.0 SHEET 02
2 - - - -
3 X14.s pin 8 D3 Switched battery from fuse DB/BK - 1.5 SHEET 01
4 SA2 M Switched battery from fuse VT - 2.5 SHEET 10
F2B
5 - - - -
6 XST1 (Receptacle) pin 3 E3 Start signal BR - 1.0 SHEET 01
7 - - - -
8 X1.p pin 4 Q2 Reverse signal BR/WH - 1.0 SHEET 02
9 X10.p pin 1 S1 Switched battery to the GY - 1.5 SHEET 01
pilot control module
10 X15.2 pin 5 G3 Switch battery from the LB - 1.5
ignition switch
11 X520 pin 3 H3 Instrument lamp YE - 1.0 SHEET 05
12 SA1 O Switched battery from fuse RD/BK - 1.5 SHEET 08
F2A to the ride control
pressure switch
13 SA1 N Start signal to the starter RD/BK - 1.0 SHEET 01
relay
XST1 - INSTRUMENT CLUSTER CONNECTOR (Receptacle)
82016219 7
82016219
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RAIL16TLB0856FA 8

1 - - - - SHEET 01
2 SA1 P Switched battery RD/BK - 1.0
3 XC6 pin 6 E3 In gear signal BR - 1.0
4 Splice SP-900 B9 Driving work lights YE - 1.0
5 X1.p pin 9 H9 Transmission switch signal YE - 1.0
6 - - - -
7 X13.p pin 14 U3 Turn signal lamps WH/GN - 1.0
8 X13.p pin 16 W3 High beams GN - 1.0
9 - - - -
10 X220 pin 11 L1 Air conditioner lamp YE/GN - 1.0
11 X88.p pin 10 N5 Display input switch BR/WH - 1.-
12 X88.p pin 11 O5 Enter input switch BR/BK - 1.0
13 X88.p pin 12 P5 Up input switch DB/BK - 1.0
14 X88.p pin 13 Q5 Down input switch DB/WH - 1.0
15 X15.2 pin 9 U4 Crank signal WH - 1.0
16 X1.p pin 16 B7 Air filter restriction switch WH/YE - 1.0
17 - - - -
18 X30.1 pin 1 B5 Diode WH - 1.0
19 - - - -
20 X25 pin 6 R1 Idle validation switch YE - 1.0
21 X10.p pin 18 I2 One touch decel WH/DB - 1.0
22 - - - -
23 - - - -
24 - - - -
25 - - - -
26 - - - -
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XST2 - INSTRUMENT CLUSTER CONNECTOR (Receptacle)
82028493 9
82028493
RAIL16TLB0856FA 10
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1 X31 pin F3B I5 Unswitched battery VT/GN - 1.0 SHEET 01
2 - - - -
3 SA4 R8 CAN low signal GN - 0.5
4 SA3 M8 CAN high signal YE - 0.5
5 - - - -
6 X606 pin 1 J5 Audible alarm OR/BK - 1.0
7 - - - -
8 X232 pin 86 Z7 Ride control relay WH - 1.0
9 - - - -
10 X13.p pin 6 D7 Speedometer signal GY/DB - 1.0
11 - - - -
12 - - - -
13 X1.p pin 14 X2 Fuel level signal VT - 1.0
14 X1.p pin 3 P2 Transmission temperature YE/RD - 1.0
15 - - - -
16 X25 pin 3 O1 Foot throttle signal GN - 1.0
17 X608 pin B W4 Hand throttle signal PK - 1.0
18 X25 pin 5 Q1 Foot throttle 5V RD - 1.0
19 X608 pin A V4 Hand throttle 5V RD/BK - 1.0
20 X25 pin 4 P1 Foot throttle sensor ground GN/BK - 1.0
21 X608 pin C X4 Hand throttle sensor BR - 1.0
ground
22 X13.p pin 2 C7 Ride control switch WH/YE - 1.0
23 X13.p pin 18 W8 Ride control switch WH - 1.0
24 SA15 W8 Alternator PK - 1.0
25 X10.p pin 23 W6 Ride control pressure WH - 1.0
switch
26 GND.1 G3 Instrument cluster ground BK - 1.0
XX - DIODE CONNECTOR
RAIL17TLB0250AA 11

1 - - - -
2 - - - -
3 X10.p pin 15 F2 Bi-directional aux solenoid DB/YE - 1.0 SHEET 02
valve
4 XC6 pin 1 C3 Forward signal BR/BK - 1.0
5 XC6 pin 8 F3 Reverse signal BR/WH - 1.0
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Wire connectors - Component diagram 00 Connectors X-00 to X-09

MARBLE CUTTING
DRIVE (2WD)
DRIVE (4WD)
X1.p - ENGINE HARNESS CONNECTOR
RAIL17TLB0256AA 1

1 X15.1 pin 2 N2 Unswitched battery from RD - 6.0 SHEET 01
X601
2 XC6 pin 6 E3 Starter interlock GN/BK - 1.0
3 XST2 (Receptacle) pin 14 P2 Transmission oil YE/RD - 1.0
temperature
4 XC6 pin 8 Q2 Reverse BR/WH - 1.0 SHEET 02
5 X520 pin 8 G9 Transmission switched RD/BK - 1.0 SHEET 05
battery
6 GND.2 S2 Ground BK - 2.5 SHEET 02
7 X15.2 pin 8 T2 Start signal WH - 4.0 SHEET 01
8 - - - -
9 XST1 (Receptacle) pin 5 H9 Transmission switch signal YE - 1.5 SHEET 05
10 - - - -
11 X220 pin 11 K1 Air conditioner relay pin 86 YE/GN - 1.5 SHEET 10
12 SA15 W2 D+ signal from the PK - 1.0 SHEET 01
alternator
13 - - - -
14 XST2 (Receptacle) pin 13 X2 Fuel level sender VT 1.0 SHEET 01
15 X224 pin 87 R2 VT/WH - 1.0 SHEET 05
16 XST1 (Receptacle) pin 16 B7 Air filter pressure switch WH/YE - 1.0 SHEET 01
17 XC6 pin 1 A3 Forward BR/BK - 1.0 SHEET 02
18 X226 pin 87a B3 4WD BR/GN - 1.0
X1.s - ENGINE HARNESS CONNECTOR
RAIL17TLB0256AA 2
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1 X601 pin 1 A Unswitched battery from RD - 6.0 SHEET 01
X601
2 X451S pin 3 Z2 Starter interlock WH - 1.0
3 X66 pin 1 D Transmission oil YE - 1.0
temperature
4 X200 pin 1 E Reverse WH - 1.0 SHEET 02
5 X169 pin 1 E3 Transmission switched RD/BK - 1.0 SHEET 05
battery
6 GND G Ground BK - 2.5 SHEET 02
7 X450S pin 3 A3 Start signal OR - 4.0 SHEET 01
8 - - - -
9 X169 pin 2 F3 Transmission switch signal YE - 1.0 SHEET 05
10 - - - -
11 X451S pin 2 B3 Air conditioner relay pin 86 YE - 1.0 SHEET 10
12 X67A pin 1 L D+ signal from the YE - 1.0 SHEET 01
alternator
13 - - - -
14 X5 pin 1 N Fuel level sender YE - 1.0 SHEET 01
15 X74 pin 1 F WH - 1.0 SHEET 05
16 X4.1 pin 1 S2 Air filter pressure switch YE - 1.0 SHEET 01
17 X6 pin 1 Q Forward WH - 1.0 SHEET 02
18 X8 pin 1 R 4WD WH - 1.0
RAIL17TLB0287AA 3

1 X10.s pin 27 L1 Unswitched battery RD - 1.0 SHEET 01
X2.s - INTERFACE CONNECTOR
RAIL17TLB0292AA 4

1 SA104 X2 Telematics unswitched RD - 1.0 SHEET 01
battery connector
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X4.1 - AIR FILTER RESTRICTION SWITCH
RAIL17TLB0296AA 5

1 X1.s pin 16 S2 Air filter pressure YE - 1.0 SHEET 01
X4.2 - AIR FILTER RESTRICTION SWITCH
RAIL17TLB0296AA 6

1 GND L2 Ground BK - 1.0 SHEET 01
RAIL17TLB0295AA 7

2 GND C1 Ground BK - 1.0
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X6 - FORWARD SOLENOID
RAIL17TLB0269AA 8

1 X1.s pin 17 Q Forward solenoid WH - 1.0 SHEET 02
2 GND A1 Ground BK - 1.0
X7 - REVERSE BUZZER
RAIL17TLB0269AA 9

2 XX pin 5 K3 Reverse buzzer signal BR/WH - 1.0
X8 - 4WD SOLENOID
RAIL17TLB0269AA 10

1 X1.s pin 18 R 4WD solenoid WH - 1.0 SHEET 02
2 GND B1 Ground BK - 1.0
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X-019
MARBLE CUTTING
DRIVE (2WD)
DRIVE (4WD)
X10.p - SERVICE HARNESS CONNECTOR
RAIL17TLB0255AA 1

1 XC6 pin 6 S1 Power supply to the pilot GY - 1.5 SHEET 01
control module
2 GND T1 Ground BK - 1.5
3 GND U1 Ground BK - 1.5
4 XC3 pin 1 V1 Hand hammer solenoid GY/BK - 1.0 SHEET 02
valve
5 SA8 G Bucket level solenoid valve WH/RD - 1.0
6 SA8 I Power supply WH/RD - 1.0
7 XC3 pin 8 W1 Rear hammer pedal supply GY/RD - 1.0
8 XC3 pin 9 X1 Bucket sensor supply LB/RD - 1.0
9 XC3 pin 16 Z1 Power supply RD/GN - 1.0
10 X230 pin 30 A2 RD/YE - 1.0 SHEET 03
11 X232 pin 87 U6 Ride control LB/BK - 1.0
12 X87.p pin 10 C2 OR/WH - 1.0
13 X88.p pin 7 D2 RD/BK - 1.0
14 XC3 pin 11 E2 Horn OR/BK - 1.0 SHEET 02
15 XX pin 3 F2 DB/YE - 1.0
16 XC3 pin 9 G2 Book lock LB/RD - 1.0
17 XC3 pin 7 H2 Bucket quick coupler WH - 1.0 SHEET 03
18 XST1 (Receptacle) pin 21 I2 One touch decel WH/DB - 1.0 SHEET 01
19 XC3 pin 19 J2 Bucket sender signal LB/YE - 1.0 SHEET 02
20 X13.p pin 6 K2 Speedometer signal GY/DB - 1.0 SHEET 08
21 SA1 L2 Speed sensor RD/BK - 1.0
22 SA1 V6 Ride control pressure RD/BK - 1.0 SHEET 03
switch
23 XST2 (Receptacle) pin 25 W6 Ride control pressure WH - 1.0
switch
24 - - - -
25 - - - -
26 - - - -
27 X500.s pin 12 G8 Unswitched battery to the RD - 1.0 SHEET 01
Telematics module
28 X13.p pin 4 M2 WH - 1.0 SHEET 05
29 - - - -
30 - - - -
31 - - - -
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X10.s - SERVICE HARNESS CONNECTOR
RAIL17TLB0283AA 2

1 X72.s pin 1 A Power supply to the pilot GY - 1.5 SHEET 01
control module
2 GND.2 B Ground BK - 1.5 SHEET 01
3 GND.2 C Ground BK - 1.5 SHEET 01
4 X35 pin 1 D Hand hammer solenoid GY/BK - 1.0 SHEET 02
valve
5 X210 pin 1 E Bucket level solenoid valve WH/RD - 1.0 SHEET 02
6 X205 pin D F Power supply WH/RD - 1.0 SHEET 02
7 X206 pin A G Rear hammer pedal supply GY/RD - 1.0 SHEET 02
8 X205 pin A H Transmission kick-out LB/RD - 1.0 SHEET 02
button
9 X26 pin A I Power supply RD/GN - 1.0 SHEET 02
10 X36.s pin 2 J Power supply RD/YE - 1.0 SHEET 03
11 X34 pin 1 K Ride control solenoid LB/BK - 1.0 SHEET 03
12 X203 pin 1 L OR/WH - 1.0 SHEET 03
13 X202 pin 1 M Bi-directional aux WH/BK - 1.0 SHEET 03
14 X204.s pin 2 N Horn OR/WH - 1.0 SHEET 02
15 X207 pin 1 O One touch decel DB/YE - 1.0 SHEET 02
16 X210 pin 2 P Book lock LB/RD - 1.0 SHEET 02
17 X208.s pin 2 Q Bucket quick coupler WH - 1.0 SHEET 03
18 X201.s pin 1 R One touch decel WH/DB - 1.0 SHEET 01
19 X26 pin C S Bucket sender signal LB/YE - 1.0 SHEET 02
20 X411.s pin 1 T Speedometer signal GY/DB - 1.0 SHEET 08
21 X411.s pin 3 U Speed sensor WH - 1.0 SHEET 08
22 X805.s pin 1 J1 Ride control pressure GN/VT - 1.0 SHEET 03
switch
23 X805.s pin 2 K1 Ride control pressure WH - 1.0 SHEET 03
switch
24 - - - -
25 - - - -
26 - - - -
27 X2.p pin 1 L1 Unswitched battery to the RD - 1.0 SHEET 01
Telematics module
28 X205 pin C V Stop light switch WH - 1.0 SHEET 05
29 - - - -
30 - - - -
31 - - - -
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X12.p - CAB HARNESS CONNECTOR
RAIL17TLB0260AA 3

1 X39 pin 3 A1 Windshield wiper ground WH - 1.0 SHEET 07
2 X57 pin 1 B1 Rear windshield washer WH - 1.0
voltage supply
3 X56 pin 1 C1 Windshield washer pump DB/WH - 1.0
4 X39 pin 2 D1 Windshield wiper speed WH - 1.0
5 X39 pin 1 E1 Rear windshield wiper WH - 1.0
voltage supply
6 X43.s pin 4 F1 Right-side work light WH - 1.0
7 X43.s pin 6 G1 Left-side work light WH - 1.0
8 - - - -
9 - - - -
X12.s - CAB HARNESS CONNECTOR
RAIL17TLB0330AA 4

1 X88.p pin 3 U5 Windshield wiper ground WH - 1.0 SHEET 07
2 X88.p pin 2 T5 Rear windshield washer WH - 1.0
voltage supply
3 X13.p pin 9 P3 Windshield washer pump DB/WH - 1.0
4 X88.p pin 4 V5 Windshield wiper speed WH - 1.0
5 X88.p pin 1 S5 Rear windshield wiper WH - 1.0
voltage supply
6 X605 (Receptacle) pin 87 M6 Right-side work light WH - 1.0
7 X605 (Receptacle) pin 87 N6 Left-side work light WH - 1.0
8 - - - -
9 - - - -
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X13.p - POWER SUPPLY FRONT DASHBOARD HARNESS
RAIL17TLB0277AA 5

1 X31 pin F5B L3 Switched battery RD/GN - 1.0 SHEET 03
2 XST2 (Receptacle) pin 22 C7 Crank signal from the WH/YE - 1.0
ignition switch
3 X232 pin 87 B2 Ride control LB/BK - 1.0
4 X10.p pin 28 M2 WH - 1.0 SHEET 05
5 X224 pin 86 M3 WH - 1.0
6 XST2 (Receptacle) pin 10 D7 Speedometer signal GY/DB - 1.0 SHEET 03
7 X226 pin 87 N3 4WD GY - 1.5 SHEET 02
8 X14.s pin 2 O3 Antitheft system WH - 1.0 SHEET 04
9 X12.s pin 3 P3 Windshield washer pump DB/WH - 1.0 SHEET 07
10 X226 pin 86 Q3 WH - 1.0 SHEET 02
11 X230 pin 86 R3 Neutral GN/VT - 1.0
12 X87.p pin 3 S3 Parking lamp fuse YE - 1.5 SHEET 04
13 X87.p pin 6 T3 GY/BK - 1.5
14 XST1 (Receptacle) pin 7 U3 Indicator control lamp WH/GN - 1.0
15 X230 pin 30 V3 RD/YE - 1.0 SHEET 02
16 XST1 (Receptacle) pin 8 W3 Main beam light GN - 1.0 SHEET 04
17 X226 pin 30 X3 4WD YE/RD - 1.0 SHEET 02
18 XST2 (Receptacle) pin 23 W8 WH - 1.0 SHEET 03
19 X800_1 pin A DB - 1.0 SHEET 01
20 X607 pin E U2 BR - 1.0
21 X800_1 pin H GN - 1.5
X13.s - POWER SUPPLY FRONT DASHBOARD HARNESS
RAIL17TLB0246AA 6

1 S5 pin 4 Q1 Switched battery RD/GN - 1.0 SHEET 03
2 S5 pin 3 W2 Crank signal from the WH/YE - 1.0 SHEET 03
ignition switch
3 S5 pin 7 W Ride control LB/BK - 1.0 SHEET 03
4 X32 pin 1 E2 Neutral WH - 1.0 SHEET 05
5 X33 pin 1 A2 4WD solenoid WH - 1.0 SHEET 05
6 X125 pin 3 H1 Unswitched battery to the GY/DB - 1.0 SHEET 03
antitheft system
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7 S2 pin 6 P1 Parking lights GY - 1.5 SHEET 02
8 X21 pin 7 Z1 Lights WH - 1.0 SHEET 04
9 S41 pin 2 F Turn signals DB/WH - 1.0 SHEET 07
10 S2 pin 2 M1 Head lights WH - 1.0 SHEET 02
11 X140.s pin 3 E 4WD GN/VT - 1.0 SHEET 02
12 XC4 pin 21 U2 4WD YE- 1.5 SHEET 04
13 XC4 pin 5 S2 GY/BK - 1.5 SHEET 04
14 XC1 pin 10 R2 WH/GN - 1.0 SHEET 04
15 S3 pin 2 J1 RD/YE - 1.0 SHEET 02
16 X21 pin 5 V1 Start relay coil pin 85 GN - 1.0 SHEET 04
17 XC2 pin 6 Q2 Air conditioner compressor YE/RD - 1.5 SHEET 02
18 S5 pin 5 X2 Start relay coil pin 86 WH - 1.0 SHEET 03
19 X800.s pin A Z2 Switched battery DB - 1.0 SHEET 01
20 X800.s pin B A3 Crank signal from the BR - 1.0 SHEET 01
ignition switch
21 X800.s pin H B3 Air conditioner compressor GN - 1.5 SHEET 01
X14.p - ANTITHEFT SYSTEM
RAIL17TLB0337AA 7

1 - - - -
2 - - - -
3 - - - -
4 - - - -
5 - - - -
6 - - - -
7 X14.p pin 8 D Bridge BK - 1.5 SHEET 01
8 X14.p pin 7 D Bridge BK - 1.5
9 - - - -
10 - - - -
11 - - - -
X14.s - ANTITHEFT SYSTEM
RAIL17TLB0263AA 8
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1 XC3 pin 5 Z3 Switched battery from fuse DB/BK - 1.0 SHEET 01
F4B
2 X13.p pin 6 O3 Unswitched battery from WH - 1.0
fuse F7A
3 GND.2 A4 Ground BK - 1.0
5 - - - -
6 - - - -
7 X802.p pin 3 F7 Switched battery RD/BK - 1.0
8 XC6 pin 3 D3 Switched battery from fuse DB/BK - 1.5
F1B
9 - - - -
10 - - - -
11 - - - -
X15.1 - STARTING CONNECTOR
RAIL17TLB0273AA 9

1
2 X1.p pin 1 N2 Battery connection to the RD - 6.0 SHEET 01
ignition switch
3
4
X15.2 - STARTING CONNECTOR
RAIL17TLB0272AA 10

5 X87.p pin 5 T4 Switched battery from the DB - 1.5 SHEET 01
ignition switch
6 Ignition switch Q4 Switched battery from the DB - 6.0
ignition switch
7 - - - -
8 X802.p pin 2 G7 Start signal from the WH - 1.0
ignition switch
9 XST1 (Receptacle) pin 15 U4 Start signal from the WH - 1.0
ignition switch
10 - - - -
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X17 - SEAT OPTION CONNECTOR
RAIL17TLB0335AA 11

1 X30.2 pin 1 Z4 Ground BK - 1.0 SHEET 01
2 - - - -
3 - - - -
4 SA1 Q Switched battery RD/BK - 1.0
X19 - GEAR SHIFT STEERING COLUMN CONNECTOR
RAIL17TLB0258AA 12

1 XC1 pin 5 O WH - 1.0 SHEET 02
2 GND2 P BK - 1.0
3 XC1 pin 1 Q OR - 1.0
4 X140.s pin 2 D BR/WH - 1.0
5 - - - -
6 X140.s pin 1 B BR/BK - 1.0
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X-029
MARBLE CUTTING
DRIVE (2WD)
DRIVE (4WD)
RAIL17TLB0305AA 1

1 GND R1 Ground BK - 1.5 SHEET 04
2 SA1 S1 Right turn signal DB - 1.0
3 X125 pin 6 I1 Right parking light YE - 1.0
4 XC4 pin 16 U1 Right low beams GY - 1.0
5 XC4 pin 20 W1 Right bright lights GN - 1.0
6 XC1 pin 1 X1 Unswitched battery to the OR - 1.0
horn
7 X13.s pin 8 Z1 Horn signal WH - 1.0
RAIL17TLB0304AA 2

1 GND G2 Ground BK - 1.5 SHEET 04
2 SA2 H2 Right turn signal LB - 1.0
3 XC4 pin 18 I2 Right parking light YE/BK - 1.0
4 XC4 pin 16 J2 Right low beams GY/BK - 1.0
5 XC4 pin 20 K2 Right bright lights GN/BK - 1.0
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RAIL17TLB0310AA 3

1 X13.s pin 1 Q1 Switched battery RD/GN - 1.0 SHEET 03
RAIL17TLB0258AA 4
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RAIL16TLB0845FA 5

1 GND.1 N1 Ground BK - 1.0 SHEET 01
2 - - - -
3 XST2 (Receptacle) pin 16 O1 Foot throttle signal GN - 1.0
4 XST2 (Receptacle) pin 20 P1 Sensor ground GN/BK - 1.0
5 XST2 (Receptacle) pin 18 Q1 Foot throttle power +5V RD - 1.0
6 XST1 (Receptacle) pin 20 R1 Idle validation signal YE - 1.0
X26 - BUCKET SENSOR
RAIL17TLB0280AA 6

A X10.s pin 9 I Switched battery from fuse RD/GN - 1.0 SHEET 02
F4B
B GND.1 A1 Ground BK - 1.0
C X10.s pin 19 S Sensor signal LB/YE - 1.0
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RAIL17TLB0269AA 7

1 GND.1 F5 Ground BK - 1.0 SHEET 05
2 XC3 pin 13 J4 Lamp power YE/BK - 1.0
RAIL17TLB0270AA 8

1 GND.1 E5 Ground BK - 1.0 SHEET 05
2 XC3 pin 2 C4 Left indicator rear lamp DB - 1.0
3 XC3 pin 21 Z Left stop lamp RD/BK - 1.0
4 XC3 pin 13 I4 Left rear lamp YE/BK - 1.0
RAIL17TLB0270AA 9

1 GND.1 D5 Ground BK - 1.0 SHEET 05
2 XC3 pin 12 H4 Right indicator rear lamp LB - 1.0
3 XC3 pin 21 X Right stop lamp RD/BK - 1.0
4 XC3 pin 20 P4 Right rear lamp YE - 1.0
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X-039
MARBLE CUTTING
DRIVE (2WD)
DRIVE (4WD)
X30.1 - PARKING BRAKE CONNECTOR
RAIL17TLB0282AA 1

1 XST1 (Receptacle) pin 18 B5 Parking brake WH - 1.0 SHEET 01
X30.2 - PARKING BRAKE CONNECTOR
RAIL17TLB0282AA 2

1 X17 pin 1 Z4 Parking brake ground BK - 1.0 SHEET 01
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X31 - FUSE CONNECTOR
RAIL17TLB0276AA 3

F1A X31 pin F3A I6 Unswitched battery RD - 2.5 SHEET 01
F1B X607 pin B J3 Unswitched battery RD - 1.0
F2A X31 pin F3A J6 Unswitched battery RD - 2.5 SHEET 07
F2B X605 (Receptacle) pin 30 K6 Unswitched battery RD/BK 2.5
F3A X31 pin F1A J6 Unswitched battery RD - 2.5 SHEET 01
F3B XST2 (Receptacle) pin 1 I5 Unswitched battery VT/GN - 1.0
F4A X31 pin F5A L6 Switched battery DB - 1.5 SHEET 03
F4B X88.p pin 8 Z5 Switched battery WH - 1.0
F5A X15.2 pin 5 L6 Switched battery DB - 1.5 SHEET 03
F5B X13.p pin 1 L3 Switched battery RD/GN - 1.0
F6A - - - -
F6B - - - -
X32 - STOP LIGHTS
RAIL17TLB0306AA 4

1 X13.s pin 4 E2 Differential lock signal WH - 1.0 SHEET 05
2 X33 pin 3 C2 From switch S33 RD - 1.0
3 XC1 pin 7 F2 Stop lights RD/BK - 1.0
4 X33 pin 4 D2 S33 pin 4 OR - 1.0
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X33 - STOP LIGHTS
RAIL17TLB0306AA 5

1 X13.s pin 5 A2 Differential lock signal VT/WH - 1.0 SHEET 05
2 XC1 pin 2 B2 Switched battery WH - 1.0
3 X32 pin 2 C2 To switch S32 RD - 1.0
4 X32 pin 4 D2 Differential lock OR - 1.0
RAIL17TLB0285AA 6

1 X10.s pin 11 K Ride control solenoid WH/BK - 1.0 SHEET 03
2 GND.1 E1 Ground BK - 1.0
RAIL17TLB0290AA 7

1 X10.s pin 4 D Hand hammer solenoid GY/BK - 1.0 SHEET 02
T - - - -
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X36.s - REAR HAMMER SWITCH
RAIL17TLB0252AA 8

1 X209 pin 1 B1 Rear hammer solenoid RD/GN - 1.0 SHEET 03
2 X10.s pin 10 J Rear hammer relay RD/YE - 1.0
RAIL17TLB0269AA 9

1 GND.1 J1 Ground BK - 1.0 SHEET 06
2 XC5 pin 13 N Rear right work light GY/BK - 1.0
X39 - REAR WINDSHIELD WIPER
RAIL17TLB0322AA 10

1 E1 Switched battery from fuse WH - 1.0 SHEET 07
F1A
2 X12.p pin 4 D1 Wiper switch WH - 1.0
3 X12.p pin 1 A1 Wiper switch WH - 1.0
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X-049
MARBLE CUTTING
DRIVE (2WD)
DRIVE (4WD)
RAIL17TLB0269AA 1

X41 - BLOWER MOTOR
RAIL17TLB0319AA 2

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X43.p - WORK LIGHTS
RAIL17TLB0333AA 3

1 X412 pin 2 T1 Ground BK - 1.0 SHEET 07
5 X409 pin 2 P1 Ground BK - 1.0
6 X409 pin 1 G1 Left work light WH - 1.0
RAIL17TLB0258AA 4

4 X12.p pin 6 F1 Rotary beacon WH - 1.0
6 X12.p pin 7 G1 Rotary beacon WH - 1.0
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RAIL17TLB0269AA 5

RAIL17TLB0269AA 6

RAIL17TLB0269AA 7

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RAIL17TLB0269AA 8

RAIL17TLB0321AA 9

2 - - - -
5 - - - -
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X-059
MARBLE CUTTING
DRIVE (2WD)
DRIVE (4WD)
RAIL17TLB0252AA 1

1 GND.2 W1 Ground BK - 1.0 SHEET 06
2 XC5 pin 12 U Front left work light VT - 1.0
RAIL17TLB0252AA 2

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RAIL17TLB0323AA 3

1 - - - -
2 - - - -
7 - - - -
8 - - - -
RAIL17TLB0323AA 4

1 - - - -
2 - - - -
3 - - - -
fuse F7B
5 - - - - -
6 - - - - -
fuse F7B
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X55.1 - POWER POINT
RAIL17TLB0319AA 5

fuse F7B
X55.2 - POWER POINT
RAIL17TLB0325AA 6

RAIL17TLB0319AA 7

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RAIL17TLB0319AA 8

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X-069
MARBLE CUTTING
DRIVE (2WD)
DRIVE (4WD)
X66 - TRANSMISSION OIL TEMPERATURE SWITCH
RAIL17TLB0298AA 1

1 X1.s pin 3 D Transmission oil YE - 1.0 SHEET 01
temperature
X67A - ALTERNATOR D+
RAIL17TLB0297AA 2

1 X1.s pin 12 L Alternator D+ signal YE - 1.0 SHEET 01
X69 - AIR CONDITIONER PRESSURE SWITCH CONNECTOR

A Ground G053 Ground BK - 1.0 SHEET 10
B X-448.s pin 1 1330 Air conditioner pressure YE - 1.0
fault
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X-079
MARBLE CUTTING
DRIVE (2WD)
DRIVE (4WD)
RAIL17TLB0288AA 1

1 X10.s pin 1 A Power supply to the pilot GY - 1.5 SHEET 01
control module
X74 - DIFFERENTIAL GEAR LOCK SOLENOID
RAIL17TLB0269AA 2

1 X10.s pin 15 F Solenoid signal WH - 1.0 SHEET 05
2 GND X Ground BK - 1.0
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X-089
MARBLE CUTTING
DRIVE (2WD)
DRIVE (4WD)
RAIL17TLB0264AA 1

1 XC3 pin 4 E4 Power supply dashboard PK/YE - 1.0 SHEET 06
harness
2 X232 pin 30 H7 Unswitched battery WH - 1.0
3 X13.p pin 7 S3 Parking lamp fuse YE - 1.5 SHEET 04
4 X605 (Receptacle) pin 86 D6 Rear lights GN/VT - 1.0 SHEET 06
5 X15.2 pin 5 T4 Road and beam lights DB - 1.5 SHEET 04
switch
6 X13.p pin 13 T3 Road and beam lights GY/BK - 1.5
7 X88.p pin 9 A6 Rear work light switch WH - 1.0 SHEET 06
8 SP-171 L5 Front work lights YE - 1.0
9 H26.1 pin 1 H5 Rear work lights WH - 1.0 SHEET 03
10 X10.p pin 12 C2 Rear vertical lock OR/WH - 1.0
11 XC3 pin 15 L4 Rear work lights VT/BK - 1.0 SHEET 06
12 X88.p pin 6 W5 Ground BK - 1.0
13 SP-172 A9 Rear work lights YE - 1.0
RAIL17TLB0265AA 2
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1 XC3 pin 17 N4 Rear windshield wiper WH - 1.0 SHEET 07
2 X12.s pin 2 T5 Rear washer WH - 1.0
3 X12.s pin 1 U5 Windshield wiper return WH - 1.0
4 X12.s pin 4 V5 Windshield wiper WH - 1.0
5 XC3 pin 11 G4 Horn OR - 1.0
6 X87.p pin 12 W5 Ground BK - 1.0
7 X10.p pin 11 D2 WH/BK - 1.0 SHEET 06
8 X31 pin F4B Z5 Switched battery WH - 1.0 SHEET 03
9 X87.p pin 7 A6 Rear work light switch WH - 1.0 SHEET 06
Rear work light switch
10 XST1 (Receptacle) pin 11 N5 Display control BR/WH - 1.0 SHEET 03
11 XST1 (Receptacle) pin 12 O5 Enter control BR/BK - 1.0
12 XST1 (Receptacle) pin 13 P5 Up control DB/BK - 1.0
13 XST1 (Receptacle) pin 14 Q5 Down control DB/WH - 1.0
15 - - - -
16 - - - -
17 X31 pin F3B C6 Unswitched battery RD - 1.0 SHEET 03
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X-109
MARBLE CUTTING
DRIVE (2WD)
DRIVE (4WD)
X102 - DIODE CONNECTOR

1 X103 pin 1 LB/BK - 1.0 SHEET 09
2 X105 pin 1 BR - 1.0
X103 - LOAD SENSOR SOLENOID FLYBACK DIODE CONNECTOR

1 X102 pin 1 LB/BK - 1.0 SHEET 09
2 X603.p pin 2 BK - 1.0
X104 - QUICK COUPLER FLYBACK DIODE CONNECTOR

1 X102 pin 2 BR - 1.0 SHEET 09
2 X603.p pin 2 BK - 1.0
X105 - QUICK COUPLER CONNECTOR

1 X102 pin 2 BR - 1.0 SHEET 09
2 X603.p pin 2 BK - 1.0
X106 - LOAD SENSOR SOLENOID CONNECTOR

1 X102 pin 1 LB/BK - 1.0 SHEET 09
2 X603.p pin 2 BK - 1.0
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X-119
MARBLE CUTTING
DRIVE (2WD)
DRIVE (4WD)
RAIL17TLB0259AA 1
84062580
1 SA6 E Unswitched battery to the RD - 4.0 SHEET 10
air conditioner fan
3 - - - -
RAIL17TLB0260AA 2
84062580
1 X220 pin 1 B1 YE - 1.5 SHEET 10
2 X220 pin 2 C1 RD - 1.5
3 X220 pin 3 D1 OR - 1.5
4 SA2 K Switched battery VT - 2.5
5 X220 pin 5 E1 GY - 1.0
6 X220 pin 6 F1 WH - 1.0
7 X220 pin 7 G1 GN - 1.0
8 X220 pin 8 H1 PK - 1.0
9 X220 pin 9 I1 LB - 1.0
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X-129
MARBLE CUTTING
DRIVE (2WD)
DRIVE (4WD)
RAIL17TLB0307AA 1

1 S5 pin 2 U Switched battery RD/GN - 1.0 SHEET 03
2 GND G1 Ground BK - 1.0
3 X13.s pin 6 H1 Speedometer GY/DB - 1.0
4 - - - -
5 - - - -
6 X21 pin 3 I1 Backlight YE - 1.0
7 - - - -
8 - - - -
9 - - - -
10 - - - -
11 - - - -
12 - - - -
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X-149
MARBLE CUTTING
DRIVE (2WD)
DRIVE (4WD)
X140.s - DIODE BRIDGE CONNECTOR
RAIL17TLB0278AA 1

1 XC1 pin 3 A Forward BR/BK - 1.0 SHEET 02
2 XC1 pin 9 D Reverse BR/WH - 1.0
3 X13.s pin 11 E Neutral GN/VT - 1.0
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X-169
MARBLE CUTTING
DRIVE (2WD)
DRIVE (4WD)
X169 - TRANSMISSION SWITCH
RAIL17TLB0269AA 1

1 X1.s pin 5 E3 Transmission switch B+ RD/BK - 1.0 SHEET 05
2 GND F3 Transmission switch signal YE - 1.0
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X-209
MARBLE CUTTING
DRIVE (2WD)
DRIVE (4WD)
X200 - REVERSE SOLENOID
RAIL17TLB0269AA 1

1 X1.s pin 4 E Reverse solenoid WH - 1.0 SHEET 02
2 GND Z Ground BK - 1.0
RAIL17TLB0287AA 2

1 X10.s pin 18 R Power supply to the one WH/DB - 1.0 SHEET 01
touch decel
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RAIL17TLB0285AA 3

1 X10.s pin 13 M Side-shift solenoid WH/BK - 1.0 SHEET 03
2 GND.2 I1 Ground BK - 1.0
RAIL17TLB0289AA 4

1 X10.s pin 12 L Boom lock solenoid OR/WH - 1.0 SHEET 03
2 GND.1 G1 Ground BK - 1.0
X204.s - HORN CONNECTOR
RAIL17TLB0269AA 5

1 GND.2 F1 Ground BK - 1.0 SHEET 02
2 X10.s pin 14 N Horn signal OR/BK - 1.0
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X205 - TRANSMISSION CUT-OFF SWITCH
RAIL17TLB0284AA 6

A X10.s pin 8 H Transmission cut-off signal LB/RD - 1.0 SHEET 02 SHEET 05
B - - - -
C X10.s pin 28 V Stop light switch WH - 1.0
D X10.s pin 6 F Switched battery to the WH/RD - 1.0
RAIL17TLB0252AA 7

A X10.s pin 7 G Bucket level solenoid GY/RD - 1.0 SHEET 02
B GND.2 W Ground BK - 1.0
RAIL17TLB0285AA 8

1 X10.s pin 7 O Bi-directional auxiliary DB/YE - 1.0 SHEET 02
solenoid
2 GND.1 X Ground BK - 1.0
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X208.s - BUCKET QUICK COUPLER SOLENOID
RAIL17TLB0252AA 9

2 X10.s pin 17 Q Bucket quick coupler WH - 1.0
RAIL17TLB0289AA 10

1 X36.s pin 1 G Rear hammer solenoid RD/GN - 1.0 SHEET 03
T - - - -
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X-219
MARBLE CUTTING
DRIVE (2WD)
DRIVE (4WD)
X210 - TRANSMISSION KICK-OUT SWITCH
RAIL17TLB0252AA 1

1 X10.s pin 5 E Switched battery WH/RD - 1.0 SHEET 02
2 X10.s pin 16 P Transmission kick-out LB/RD - 1.0
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X-229
MARBLE CUTTING
DRIVE (2WD)
DRIVE (4WD)
RAIL17TLB0263AA 1
84062580
1 X111 pin 1 B1 +15 A/C YE - 1.5 SHEET 10
2 X111 pin 2 C1 +15 A/C RD - 1.5
3 X111 pin 3 D1 +15 A/C OR - 1.5
4 SA2 L +15 A/C VT - 2.5
5 X111 pin 5 E1 +15 A/C GY - 1.0
6 X111 pin 6 F1 +15 A/C WH - 1.0
7 X111 pin 7 G1 +15 A/C GN - 1.0
8 X111 pin 8 H1 +15 A/C PK - 1.0
9 X111 pin 9 I1 +15 A/C LB - 1.0
11 X1.p pin 11 K1 Air conditioner relay pin 86 YE/GN - 1.5
X224 - DIFFERENTIAL GEAR LOCK RELAY
RAIL17TLB0261AA 2

85 X232 pin 85 I7 Ground BK - 1.0 SHEET 05
86 X13.p pin 5 M3 From the stop light switch WH - 1.0
30 SA8 J Switched battery WH/RD - 1.0
87 X1.p pin 15 R2 Signal VT/WH - 1.0
87a - - - -
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X226 - 4WD RELAY
RAIL17TLB0261AA 3

85 X230 pin 85 G6 Ground BK - 1.0 SHEET 02
86 X13.p pin 10 Q3 4WD switch WH - 1.0
30 X13.p pin 17 X3 Switched battery YE/RD - 1.0
87 X13.p pin 7 N3 GY - 1.0
87a X1.p pin 18 B3 4WD solenoid BR/GN - 1.0
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X-239
MARBLE CUTTING
DRIVE (2WD)
DRIVE (4WD)
RAIL17TLB0261AA 1

85 X232 pin 85 E6 Ground BK - 1.0 SHEET 03
86 X13.p pin 11 R3 Neutral GN/VT - 1.0
30 X13.p pin 15 V3 RD/YE - 1.0
87 - - - -
87a XC3 pin 16 M4 Power supply RD/GN - 1.0
RAIL17TLB0261AA 2

85 X224 pin 85 I7 Ground BK - 1.0 SHEET 03
86 XST2 (Receptacle) pin 8 Z7 Ride control switch WH - 1.0
30 X87.p pin 2 H7 Switched battery WH - 1.0
87 X13.p pin 3 B2 Ride control solenoid LB/BK - 1.0
87a - - - -
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X-409
MARBLE CUTTING
DRIVE (2WD)
DRIVE (4WD)
RAIL17TLB0332AA 1

1 X412 pin 1 A Signal LB/YE - 1.0 SHEET 07
2 X412 pin 2 D Ground BK - 1.0
X407 - RIGHT WORK LIGHT CONNECTOR
RAIL17TLB0252AA 2

1 X43.p pin 4 G Side work light relay WH - 1.0 SHEET 07
2 X43.p pin 3 F Ground BK - 1.0
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X409 - LEFT WORK LIGHT CONNECTOR
RAIL17TLB0252AA 3

1 X43.p pin 6 I Side work light relay WH - 1.0 SHEET 07
2 X43.p pin 5 H Ground BK - 1.0
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X-419
MARBLE CUTTING
DRIVE (2WD)
DRIVE (4WD)
X411.s - SPEED SENSOR
RAIL17TLB0338AA 1

1 X10.s pin 20 T Signal GY/LB - 1.0 SHEET 08
2 GND.1 D1 Ground BK - 1.0
3 X10.s pin 21 U Switched battery WH - 1.0
RAIL17TLB0332AA 2

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X-449
MARBLE CUTTING
DRIVE (2WD)
DRIVE (4WD)
terminal 85 switch
2 Air conditioner relay K105 Unswitched battery from
85
4 Starter pilot relay K102 terminal Unswitched battery
30
5
6
7
8
terminal 87
10 Air conditioner relay K105 Relay ground
terminal 86
87
12 Starter pilot relay K102 terminal Start signal
86
13 SCR main relay K107 terminal
85
14 SCR main relay K107 terminal Unswitched battery
30
15 Aux main relay K106 terminal
85
16 Aux main relay K106 terminal Unswitched battery
30
17
18
19
20
87
22 SCR main relay K107 terminal
86
87
86
25
terminal 85
28 Starter interlock relay K103 From the start relay
terminal 30
29
31
32
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34 Tank heater valve and purge
35 Starter interlock relay K103
terminal 87
36 Starter interlock relay K103
terminal 86
37 Pump module fuse F008
38 Tank heater valve and purge
39 Starter relay K104 terminal 85
40 Starter relay K104 terminal 30 Start signal from the
ignition switch
41 Engine fuse F004
42 SCR system fuse F003
43
44
46 SCR system fuse F003
1 X69 pin B 1330 Air conditioner relay K105 YE - 1.0 SHEET 10
terminal 85
2 X-448.s pin 26 1360 Air conditioner relay K105 RD - 1.5
terminal 30
4 Splice SP-007 1022 Unswitched battery RD - 4.0
5
6
7
8
terminal 87
10 X-451.p pin 2 1340 Air conditioner relay K105 YE - 1.0
terminal 86
terminal 87
12 X-448.s pin 35 1171 Starter pilot relay K102 OR - 0.75
terminal 86
13 X-462 (Receptacle) pin 20 F200 SCR main relay K107 YE - 0.75
terminal 85
14 Splice SP–007 1017 Unswitched battery RD - 4.0
15 Splice SP-002 G226 Ground BK - 0.75
16 Splice SP-007 1016 Aux main relay K106 RD - 4.0
terminal 30
17
18
19
20
terminal 87
22 Splice SP-159 E05D SCR main relay K107 RD - 0.75
terminal 86
23 X-449.s pin 1 IGN1 Aux main relay K106 OR - 4.0
terminal 87
24 Splice SP-159 E05C Aux main relay K106 RD - 0.75
terminal 86
25
28 X-448.s pin 47 1180 Starter relay K104 terminal OR - 0.75
87
29
31
32
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34 Splice SP-016 IGN9 Tank heater valve and OR - 1.5
F005
35 X-448.s pin 12 1171 Starter interlock relay K103 OR - 0.75
terminal 87
36 X-451P pin 3 1191 Starter interlock relay K103 WH - 1.0
terminal 86
37 Splice SP-021 IGNA Pump module fuse F008 OR - 1.5
38 Splice SP-021 IGN8 Tank heater valve and OR - 1.5
F005
39 Starter relay K104 terminal
85
40 X-461 (Receptacle) pin 27 E270 Starter relay K104 terminal YE - 0.75
30
41 X-461 (Receptacle) pin 1 E010 Engine fuse F004 RD - 2.5
42 Splice SP-159 E058 SCR system fuse F003 RD - 1.0
43
44
46 Splice SP-151 E055 SCR system fuse F003 RD - 1
47 X-448.s pin 28 1180 Starter relay K104 terminal OR - 0.75
87
48 X-461 (Receptacle) pin 53 E530 Starter relay K104 terminal YE - 0.75
86
2 Sensor power fuse F014 Sensor power fuse F014
3 Spare fuse F013 Spare fuse F013
4 Spare fuse F013 Spare fuse F013
5 Engine fuse f012 Engine fuse f012
6 Engine fuse F012 Engine fuse F012
7 DEF heater fuse F011 DEF heater fuse F011
8 DEF heater fuse F011 DEF heater fuse F011
9
10
12 Glow plug fuse F010 Glow plug fuse F010
2 Splice SP-015 IGN2 Sensor power fuse F014 OR - 4.0
3 X-450.p pin 1 1020 Spare fuse F013 RD - 4.0
4 X-450.p pin 2 1381 Spare fuse F013 RD - 4.0
5 Splice SP-151 E05A Engine fuse f012 RD - 4.0
6 Splice SP-158 E052 Engine fuse F012 RD - 4.0
7 X-612 (Receptacle) pin 11 1019 DEF heater fuse F011 RD - 10.0
8 Splice SP-001 1018 DEF heater fuse F011 RD - 10.0
9
10
12 X-469 (Receptacle) pin 4 1040 Glow plug fuse F010 RD - 6.0
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X-459
MARBLE CUTTING
DRIVE (2WD)
DRIVE (4WD)
RAIL17TLB0299AA 1

1 - - - -
2 - - - -
3 X1.s pin 7 A3 Start signal OR - 4.0 SHEET 01 Sheet 1
4 MC1 pin 1 D3 Engine start from the OR - 4.0
starter
RAIL17TLB0300AA 2

1 X601 pin 1 C3 Air conditioner RD - 1.5 SHEET 10
2 X1.s pin 11 B3 Air conditioner relay pin 86 YE - 1.0
3 X1.s pin 2 Z2 Starter interlock WH - 1.0 SHEET 01
4 - - - -
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X-469
MARBLE CUTTING
DRIVE (2WD)
DRIVE (4WD)
84058093 1
84058093
RAIL16TLB1513FA 2

RESISTOR
RESISTOR
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84474047 3
84474047
RAIL16TLB1513FA 4
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1 X-448.s pin 41 E010 BATTERY VOLTAGE VIA RD - 2.5 SHEET 01
MAIN RELAY
3 Splice SP-158 E051 BATTERY +B VIA MAIN RD - 2.5
RELAY
5 Splice SP-158 E050 BATTERY +C VIA MAIN RD - 2.5
RELAY
7 X-611 (Receptacle) pin 3 E070 SCR TANK HEATING YE - 0.75
VALVE SIGNAL
8 X-496 (Plug) pin D E080 CRANK SIGNAL YE - 0.5
SENSE SIGNAL
SIGNAL
GROUND
SIGNAL
24 X-496 (Plug) pin K CAN027 CAN HIGH YE - 0.5
25 X-496 (Plug) pin E CAN027 CAN LOW GN - 0.5
COMMAND SIGNAL
ECU
28 X-464 (Receptacle) pin 2 E280 MAIN RELAY DB - 0.5
SENSOR SIGNAL
SENSE GROUND
41 X-469 (Receptacle) pin 5 E410 GLOW PLUG UNIT BK - 0.75
GROUND
ECU
SENSE SIGNAL
CONTROL SIGNAL
CONTROL SIGNAL
79 X-637 (Plug) pin 1 E790 CAT TEMP SENSE DS DB - 0.5
GROUND
80 X-637 (Plug) pin 2 E800 CAT TEMP SENSE DS YE - 0.5
SIGNAL
81 X-617 (Receptacle) pin 2 E810 CAT TEMP US GROUND DB - 0.5
CT
82 X-617 (Receptacle) pin 1 E820 CAT TEMP US GROUND YE - 0.5
CT
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84474053 5
84474053
RAIL16TLB1513FA 6

1 X-471 (Receptacle) pin D F010 INJECTOR 1 HIGH BANK WH - 1.5 SHEET 01
2
2 X-471 (Receptacle) pin H F020 INJECTOR 2 HIGH BANK WH - 1.5
2
ACTUATOR 1
5 X-639 pin 8 F050 COMMON SIGNAL LB - 0.75
GROUND
INPUT SIGNAL
7 X-639 pin 10 F070 PRESSURE SENSE PK - 0.75
SUPPLY
SUPPLY
SUPPLY
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SENSOR SUPPLY
SENSOR SUPPLY
SPEED SENSOR SUPPLY
14 X-470 (Receptacle) pin 4 F140 SEGMENT (CAMSHAFT) YE - 0.5
SPEED SENSOR SIGNAL
15 X-470 (Receptacle) pin 1 F150 FUEL METERING UNIT WH - 0.75
SUPPLY
16 X-471 (Receptacle) pin A F160 INJECTOR 1 HIGH BANK WH - 1.5
1
17 X-471 (Receptacle) pin E F170 INJECTOR 2 HIGH BANK WH - 1.5
1
18 X-622 (Receptacle) pin 1 F180 DOSING VALVE H DB - 1.5
20 X-448.s pin 13 F200 SCR MAIN RELAY YE - 0.8
SENSOR GROUND
GROUND
SENSOR GROUND
SENSOR GROUND
SENSE GROUND
SPEED SENSOR
GROUND
31 X-471 (Receptacle) pin C F310 INJECTOR 1 LOW BANK GY - 1.5
2
32 X-471 (Receptacle) pin B F320 INJECTOR 1 LOW BANK GY - 1.5
1
MINUS
MINUS
GROUND
SENSOR SIGNAL
SIGNAL
SENSOR SIGNAL
SENSOR SIGNAL
SENSE SIGNAL
SENSOR SIGNAL MINUS
46 X-471 (Receptacle) pin G F460 INJECTOR 2 LOW BANK GY - 1.5
2
48 X-471 (Receptacle) pin F F480 INJECTOR 2 LOW BANK GY - 1.5
1
PLUS
PLUS
SIGNAL
TEMPERATURE SENSOR
SIGNAL
56 X-639 pin 9 F561 PRESSURE SENSE YE - 0.8
SIGNAL
TEMPERATURE SENSOR
SIGNAL
TEMPERATURE SENSOR
GROUND
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SENSOR SIGNAL PLUS
87709663 7
87709663
RAIL16TLB1513FA 8

SENSOR SIGNAL
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84471904 9
84471904
RAIL16TLB1513FA 10

1 Splice SP-157 1015 Unswitched battery DB - 0.5 SHEET 01
2 X-461 (Receptacle) pin 28 E280 Signal from ECU RD - 0.5
3 Splice SP-157 1014 Unswitched battery RD - 6.0
5 Splice SP-151 E053 Relay signal out RD - 6.0
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84356962 11
84356962
RAIL16TLB1513FA 12

SIGNAL
4 X-449.s pin 12 1040 BAT+ RD - 6.0
5 X-461 (Receptacle) pin 41 E411 GLOW PLUG UNIT BK - 4.0
GROUND
COMMAND SIGNAL
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X-479
MARBLE CUTTING
DRIVE (2WD)
DRIVE (4WD)
84154706 1
84154706
RAIL16TLB1513FA 2

SUPPLY
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INPUT SIGNAL
SPEED SENSOR SIGNAL
SENSOR GROUND
SENSOR SIGNAL
SENSOR SUPPLY
SPEED SENSOR
GROUND
SENSOR SIGNAL PLUS
SENSOR SIGNAL MINUS
12 X-462 (Receptacle) pin 13 F130 SEGMENT (CAMSHAFT) PK - 0.5
SPEED SENSOR SUPPLY
TEMPERATURE SENSOR
GROUND
TEMPERATURE SENSOR
SIGNAL
SENSOR GROUND
SENSOR SIGNAL
SENSOR SUPPLY
SENSOR SIGNAL
SENSOR GROUND
TEMPERATURE SENSOR
SIGNAL
SENSE SIGNAL
SENSE GROUND
SENSE SIGNAL
SENSE GROUND
SENSE SIGNAL
ACTUATOR 1
PLUS
MINUS
SUPPLY
SIGNAL
GROUND
PLUS
MINUS
SUPPLY
SIGNAL
GROUND
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87698252 3
87698252
RAIL16TLB1513FA 4

1
1
2
D X-462 (Receptacle) pin 1 F010 INJECTOR 1 HIGH BANK WH - 1.5
2
1
1
2
H X-462 (Receptacle) pin 2 F020 INJECTOR 2 HIGH BANK WH - 1.5
2
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87679525 5
87679525
RAIL16TLB1513FA 6

1 X-448.s pin 9 60C6 A/C COMPRESSOR BR - 1.5 SHEET 10
OUTPUT
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84607243 7
84607243
RAIL16TLB1513FA 8

SIGNAL
GROUND
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X-499
MARBLE CUTTING
DRIVE (2WD)
DRIVE (4WD)
X-496 - TO FRONT HARNESS (Plug)
87698254 1
87698254
RAIL16TLB1513FA 2
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A - - - -
C Splice SP-154 150A IGNITION OR - 0.8
D X-461 (Receptacle) pin 8 E080 CRANK SIGNAL YE - 0.8
F - - - -
G - - - -
H - - - -
J - - - -
K X-461 (Receptacle) pin 24 CAN027 CAN 1 HIGH YE - 0.5
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X-509
MARBLE CUTTING
DRIVE (2WD)
DRIVE (4WD)
RAIL17TLB0268AA 1

1 SA103 E8 Ground BK - 1.0 SHEET 01
2 F-001 pin 2 J8 Switched power to the OR - 1.0
3 SA13 Q8 CAN high YE - 0.5
4 SA14 V8 CAN low GN - 0.5
5 - - - -
6 X501 pin 3 K8 RS232 Tx DB - 1.0
7 X501 pin 2 L8 RS232 Rx VT - 1.0
8 SA15 I8 D+ PK - 1.0
9 - - - -
10 - - - -
11 - - - -
12 X10.p pin 27 G8 Unswitched battery to the RD - 1.0
RAIL17TLB0270AA 2

1 SA103 F8 Ground BK - 1.0 SHEET 01
2 X500.s pin 7 L8 RS232 Tx VT - 1.0
3 X500.s pin 6 K8 RS232 Rx DB - 1.0
4 - - - -
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X502 - UNSWITCHED BATTERY
RAIL17TLB0302AA 3

1 F-002 pin 1 V2 Unswitched battery OR- 4.0 SHEET 01
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X-529
MARBLE CUTTING
DRIVE (2WD)
DRIVE (4WD)
X520 - LIGHTS INPUT
RAIL17TLB0336AA 1

1 SP-171 X8 Front work lights YE - 1.0 SHEET 05
2 SP-900 C9 Front work lights YE - 1.0
3 XC6 pin 11 H3 Instrument lamps YE - 1.0
4 SP-900 D9 Instrument lamps YE - 1.0
5 SP-172 Z8 Rear work lights YE - 1.0
6 SP-900 E9 Rear work lights YE - 1.0
7 SA1 F9 Transmission switch B+ 5A RD/BK - 1.0
fuse
8 X1.p pin 5 G9 Transmission switch B+ 5A RD/BK - 1.0
fuse
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X-609
MARBLE CUTTING
DRIVE (2WD)
DRIVE (4WD)
X600.p - UNSWITCHED BATTERY CONNECTOR
RAIL17TLB0257AA 1

1 SA6 A Unswitched battery RD - 16.0 SHEET 01
X600.s - UNSWITCHED BATTERY CONNECTOR
RAIL17TLB0294AA 2

1 X601 pin 1 S Unswitched battery RD - 16.0 SHEET 01
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X601 POWER
RAIL17TLB0301AA 3

1 X600.s pin 1 S Unswitched battery RD - 16.0 SHEET 01
X603.p - OPTIONAL REAR QUICK COUPLER CONNECTOR

1 S100 pin 2 Switched battery DB/RD - 1.0 SHEET 09
2 X106 pin 2 BK - 1.0
X603.s - OPTIONAL REAR QUICK COUPLER CONNECTOR

1 X88.s pin 8 Switched battery DB/RD - 1.0 SHEET 03
2 X88.s pin 14 BK - 1.0
X605 - SIDE WORK LIGHT RELAY (Receptacle)
RAIL17TLB0261AA 4

85 X226 pin 85 H6 Ground BK - 1.0 SHEET 07
86 X87.p pin 4 D6 GN/VT - 1.0
30 X31 pin F2B K6 Unswitched battery RD/BK - 2.5
87 X12.s pin 7 N6 Side lights ON WH - 1.0
87a - - - -
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84152570 5
84152570
RAIL16TLB1513FA 6

1 - - - SHEET 01
SIGNAL
3 X-638 pin 3 IGNC IGNITION TO THE PUMP OR 1.5
MODULE
7 - - -
GROUND
SENSOR
SUPPLY
11 X-638 pin 11 5051 OR 1.5
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RAIL17TLB0266AA 7

1 XST2 (Receptacle) pin 6 J5 Buzzer OR/BK - 1.0 SHEET 01
2 GND.2 R5 Ground BK - 1.0
47514978 8
47514978
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RAIL16TLB1514FA 9

1 X-636 (Receptacle) pin 7 IG02 IGN SCR DOWNSTREAM OR - 0.75 SHEET 01
NOx W/ECU
DOWNSTREAM NOx
W/ECU
X607 - DIAGNOSTIC CONNECTOR
RAIL17TLB0275AA 10
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A GND.1 I3 Ground BK - 1.0 SHEET 01
B X31 pin F1B J3 Unswitched battery from RD - 1.0
fuse F1B
C SA3 N8 CAN high YE - 0.5
D SA4 S8 CAN low GN - 0.5
E X13.p pin 20 U2 K-line BR - 1.0
F - - - -
G - - - -
H - - - -
J - - - -
47514978 11
47514978
RAIL16TLB1513FA 12
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1 Splice SP-015 IGN6 IGN DOC UPSTREAM OR - 1.0 SHEET 01
NOx SENSOR w/ECU
NOx SENSOR w/ECU
3 Splice SP-168 CAN024 CANL DOC UPSTREAM GN - 0.5
NOx SENSOR w/ECU
4 Splice SP-169 CAN024 CANH DOC UPSTREAM YE - 0.5
NOx SENSOR w/ECU
NOx SENSOR w/ECU
RAIL17TLB0280AA 13

A XST2 (Receptacle) pin 19 V4 Voltage to the throttle RD/BK - 1.0 SHEET 02
sensor
B XST2 (Receptacle) pin 17 W4 Throttle signal PK - 1.0
C XST2 (Receptacle) pin 21 X4 Throttle sensor ground BR - 1.0
87688719 14
87688719
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RAIL16TLB1513FA 15

SENSOR
2 X-640 pin 2 G228 BATT- 9 BK - 1.0
4 X-640 pin 4 CAN040 CAN LOW GN - 0.5
5 X-640 pin 5 CAN040 CAN HIGH YE - 0.5
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X-619
MARBLE CUTTING
DRIVE (2WD)
DRIVE (4WD)
84146685 1
84146685
RAIL16TLB1513FA 2

2 - - -
3 X-461 (Receptacle) pin 7 E070 SCR HEATING VALVE YE 0.75
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47514457 3
47514457
RAIL16TLB1513FA 4

1 X-639 pin 11 5050 IGN TO HEATER OR - 1.5 SHEET 01
2 X-641 pin 7 1203 DEF HTR1 WH - 1.5
4 X-641 pin 6 1205 ADBLUE OUTLET WH - 1.5
6 Splice SP-159 E05E FUSED PWR FROM MAIN RD - 0.75
RLY
9 Splice SP-166 CAN025 CANL2 HCU GN - 0.5
10 Splice SP-167 CAN025 CANH2 HCU YE - 0.5
11 X-449.s pin 7 1019 BATT+ FROM HCU FUSE RD - 10.0
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84532147 5
84532147
RAIL16TLB1513FA 6

1 X-461 (Receptacle) pin 82 E820 CAT TEMP US GND CT YE - 0.5 SHEET 01
2 X-461 (Receptacle) pin 81 E810 CAT TEMP US GND CT BL - 0.5
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84532147 7
84532147
RAIL16TLB1513FA 8

1 X-636 (Receptacle) pin 2 E801 CATALYST TEMP DS T BL - 0.5 SHEET 01
2 X-636 (Receptacle) pin 1 E791 CATALYST TEMP DS OUT YE - 0.5
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X-629
MARBLE CUTTING
DRIVE (2WD)
DRIVE (4WD)
87709793 1
87709793
RAIL16TLB1514FA 2

1 X-462 (Receptacle) pin 18 F180 DOSING VLV H BL - 1.5 SHEET 01
2 X-462 (Receptacle) pin 3 F030 DOSING VLV L YE - 1.5
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84146686 3
84146686
RAIL16TLB1514FA 4

1 X-636 (Receptacle) pin 5 IG03 SENSOR POWER OR 1.0 SHEET 01
2 SPLICE SP-174 CAN039 CAN DATA LINK HIGH YE 0.5
3 SPLICE SP-173 CAN039 CAN DATA LINK LOW GN 0.5
4 X-636 (Receptacle) pin 6 G237 SENSOR GROUND BK 1.0
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X-639
MARBLE CUTTING
DRIVE (2WD)
DRIVE (4WD)
84284795 1
84284795
RAIL16TLB1514FA 2

2 X-640 pin 8 G290 DEF LINE HTR1 GND BK - 2.0
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84284795 3
84284795
RAIL16TLB1514FA 4

2 X-640 pin 8 G291 GROUND BK - 2.0
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47416270 5
47416270
RAIL16TLB1513FA 6
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DOWNSTREAM
TEMPERATURE SENSOR
DOWNSTREAM
TEMPERATURE SENSOR
5 X-624 (Receptacle) pin 1 IG03 IGN NH3 SENSOR OR - 1.0
6 X-624 (Receptacle) pin 4 G237 BATT- 11 NH3 SENSOR BK - 1.0
NOx W/ECU
DOWNSTREAM NOx
W/ECU
9 - - - -
10 - - - -
47416278 7
47416278
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RAIL16TLB1513FA 8

GND
SIG
5 Splice SP-015 IGN5 IGN NH3 SENSOR OR - 1.0
6 Splice SP-003 G217 BATT- 11 NH3 SENSOR BK - 1.0
7 Splice SP-015 IGN4 IGN SCR DOWNSTREAM OR - 1.0
NOx W/ECU
8 Splice SP-003 G216 BATT- 5 SCR BK - 1.0
DOWNSTREAM NOx
W/ECU
9 - - - -
10 - - - -
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1 - - - - SHEET 01
SIGNAL
MODULE
7 - - - -
GROUND
SENSOR
SUPPLY

1 - - - - SHEET 01
SIGNAL
3 X-448.s pin 33 IGNB IGNITION TO THE PUMP OR - 1.5
MODULE
5 Splice SP-016 IGN11 COMMON IGNITION OR - 1.5
7 - - - -
GROUND
SENSOR
SUPPLY
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X-649
MARBLE CUTTING
DRIVE (2WD)
DRIVE (4WD)

SENSOR
3 - - - -
4 X-608 (Receptacle) pin 4 CAN040 CANL 2 10 QUALITY GN - 0.5
SENSOR
5 X-608 (Receptacle) pin 5 CAN040 CANH 2 10 UREA YE - 0.5
QUALITY SENSOR

1 Splice SP-015 IGN3 IGN UREA QUALITY OR - 1.0 SHEET 01
SENSOR
3 - - - -
4 Splice SP-162 CAN021 CANL 2 10 QUALITY GN - 0.5
SENSOR
5 Splice SP-163 CAN021 CANH 2 10 UREA YE - 0.5
QUALITY SENSOR
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X-809
MARBLE CUTTING
DRIVE (2WD)
DRIVE (4WD)
X800.s - FRONT HARNESS
87698252 1
RAIL16TLB0845FA 2
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A X13.s pin 19 Z2 Starter relay coil terminal DB - 1.0 SHEET 01
86
B X13.s pin 20 A3 ISO K GY - 1.0
C X802.s pin 3 C3 Ignition RD/BK - 1.0
D X802.s pin 2 D3 Crank signal from ignition WH - 1.0
switch
E X801.s pin 2 G3 CAN low GN - 0.5
F X802.s pin 1 F3 Starter relay coil terminal GN - 1.0
85
G - - - -
H X13.s pin 21 B3 Air conditioner clutch signal GN - 1.5
J - - - -
K X801.s pin 1 H3 CAN high YE - 0.5
X801.p - CAN BUS CONNECTOR
RAIL17TLB0252AA 3

1 SA13 P8 CAN High YE - 0.5 SHEET 01
2 SA14 U8 CAN Low GN - 0.5
X801.s - CAN BUS CONNECTOR
RAIL17TLB0312AA 4

1 X800.s pin K H3 CAN High YE - 0.5 SHEET 01
2 X800.s pin E G3 CAN Low GN - 0.5
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X802.p - INLINE DASH CONNECTOR
RAIL17TLB0250AA 5

1 - - - -
2 X15.2 pin 8 G7 Unswitched battery WH - 1.0 SHEET 01
3 X14.s pin 7 F7 RD/BK - 1.0
4 - - - -
5 - - - -
X802.s - INLINE DASH CONNECTOR
RAIL17TLB0304AA 6

1 X800.s pin F F3 Start relay coil terminal 85 GN - 1.0 SHEET 01
2 X800.s pin D D3 Crank signal WH - 1.0
3 X800.s pin C C3 Ignition RD/BK - 1.0
4 - - - -
5 - - - -
RAIL17TLB0252AA 7
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1 X10.s pin 22 J1 Switched battery GN/VT - 1.0 SHEET 03
2 X10.s pin 23 K1 Ride control pressure WH - 1.0
switch signal
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S1 and S2
MARBLE CUTTING
DRIVE (2WD)
DRIVE (4WD)
S1 - PILOT CONTROL ON/OFF SWITCH CONNECTOR

2 X13.p pin 1 GY - 1.5 SHEET 11
3 X13.p pin 3 GY/YE - 1.5
5 X13.p pin 1 GY - 1.5
6 X13.p pin 2 GY/BK - 1.5
7 X13.p pin 5 GY/BK - 1.5
8 X13.p pin 2 BK - 1.5
S2 - PATTERN CHANGE SWITCH CONNECTOR

2 X13.p pin 2 GY/BK - 1.5 SHEET 11
3 X13.p pin 4 GY/RD - 1.5
7 X13.p pin 5 BK - 1.5
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XL, XR, and XX
MARBLE CUTTING
DRIVE (2WD)
DRIVE (4WD)
XL - LEFT-HAND STABILIZER JOYSTICK CONNECTOR

B X20 pin 9 Signal LB/RD - 1.0
XR - RIGHT-HAND STABILIZER JOYSTICK CONNECTOR

B X20 pin 10 Signal LB/BK - 1.0
XX - TO SOLENOID VALVES LINE/ ONE TOUCH DECEL

1 X73 pin 1 GY/DB - 1.0 SHEET 11
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YP3 to YP10
MARBLE CUTTING
DRIVE (2WD)
DRIVE (4WD)
YP3 - LEFT-HAND STABILIZER DOWN SOLENOID CONNECTOR

1 X20 pin 3 Signal YE/RD - 1.0 SHEET 11
YP4 - LEFT-HAND STABILIZER UP SOLENOID CONNECTOR

1 X20 pin 4 Signal DB/WH - 1.0 SHEET 11
YP5 - RIGHT-HAND STABILIZER DOWN SOLENOID CONNECTOR

1 X20 pin 6 Signal YE/BK - 1.0 SHEET 11
YP6 - RIGHT-HAND STABILIZER UP SOLENOID CONNECTOR

1 X20 pin 5 Signal DB/RD - 1.0 SHEET 11
YP7 - BOOM EXTEND SOLENOID CONNECTOR

1 X20 pin 7 Signal YE/GN - 1.0 SHEET 11
YP8 - BOOM RETRACT SOLENOID CONNECTOR

1 X20 pin 8 Signal DB/YE - 1.0 SHEET 11

1 X20 pin 23 Signal BR/WH - 1.0 SHEET 11

1 X20 pin 15 Signal BR/BK - 1.0 SHEET 11
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X-01 to X-09
MARBLE CUTTING
DRIVE (2WD)
DRIVE (4WD)


X4 - LEFT JOYSTICK HORN BUTTON CONNECTOR

1 X27 pin 1 BK - 1.0 SHEET 11
2 X27 pin 2 OR/BK - 1.0
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X-010 to X-019
MARBLE CUTTING
DRIVE (2WD)
DRIVE (4WD)
X11 - LEFT-HAND STABILIZER PRESSURE SWITCH CONNECTOR

1 X20 pin 13 Signal GN/WH - 1.0 SHEET 11
X12 - RIGHT-HAND STABILIZER PRESSURE SWITCH CONNECTOR

1 X20 pin 14 Signal GN/BK - 1.0 SHEET 11
X13.p - RIGHT-HAND TOWER LINE CONNECTOR

1 S1 pin 2 GY - 1.5 SHEET 11
2 S2 pin 2 GY/BK - 1.0
3 S1 pin 3 GY/YE - 1.5
4 S2 pin 3 GY/RD - 1.5
5 S1 pin 7 BK - 1.0
X13.s - RIGHT-HAND TOWER LINE CONNECTOR

1 X72 pin 1 GY - 1.5 SHEET 11
2 X23 pin A GY/BK - 1.0
3 X20 pin 1 GY/YE - 1.5
4 X1 pin A GY/RD - 1.5
5 GROUND BK - 1.0
X14 - RIGHT-HAND JOYSTICK CONNECTOR

1 X20 pin 16 WH/RD - 1.0 SHEET 11
2 X20 pin 16 WH/RD - 1.0
3 GROUND BK - 1.0
4 GROUND BK - 1.0
5 X20 pin 12 WH/YE - 1.0
6 X20 pin 11 VT/WH - 1.0
X17 - MANIFOLD POWER CONNECTOR

1 X13.s pin 2 GY/BK - 1.0 SHEET 11
2 Ground BK - 1.0
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X-020 to X-029
MARBLE CUTTING
DRIVE (2WD)
DRIVE (4WD)
X20 - LVC UNIT CONNECTOR

1 X13.s pin 3 GY/YE - 1.5 SHEET 11
2 GROUND BK - 1.5
3 YP3 pin 1 YE/RD - 1.0
4 YP4 pin 1 DB/WH - 1.0
5 YP6 pin 1 DB/RD - 1.0
6 YP5 pin 1 YE/BK - 1.0
7 YP7 pin 1 YE/VT - 1.0
8 YP8 pin 1 DB/YE - 1.0
9 XL pin B LB/RD - 1.0
10 XR pin B LB/BK - 1.0
11 X14 pin 6 VT/WH - 1.0
12 X14 pin 5 WH/YE - 1.0
13 X11 pin 1 GN/WH - 1.0
14 X12 pin 1 GN/BK - 1.0
15 YP10 pin 1 BR/BK -
16 X14 pin 2 WH/RD - 1.0
17 X24 pin 5 LB - 1.0
18 X24 pin 6 DB - 1.0
19 - - - -
20 - - - -
21 - - - -
22 - - - -
23 YP9 pin 1 BR/WH - 1.0
X23 - SAFETY SWITCH CONNECTOR

A X17 pin 1 GY/BK - 1.0 SHEET 11
B Ground BK - 1.0
X24 - LEFT JOYSTICK CONNECTOR

1 X20 pin 16 WH/RD - 1.0 SHEET 11
2 X20 pin 16 WH/RD - 1.0
5 X20 pin 17 Signal LB - 1.0
6 X20 pin 18 Signal DB - 1.0
X27 - HORN JUMPER CONNECTOR

1 X4 pin 1 BK - 1.0 SHEET 11
2 X4 pin 2 OR/BK - 1.0
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X-070 to X-079
MARBLE CUTTING
DRIVE (2WD)
DRIVE (4WD)
X72 - TO SOLENOID VALVES CONNECTOR

1 X13.s pin 1 GY - 1.0 SHEET 11
X73 - ONE TOUCH DECEL CONNECTOR

1 XX pin 1 SIGNAL GY/DB - 1.0 SHEET 11
2 GROUND GROUND BK - 1.0
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Fuse and relay box - Check - Power shuttle

MARBLE CUTTING
DRIVE (2WD)
DRIVE (4WD)
NOTICE: NEVER replace a fuse with a fuse of a different rating.
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Main fuse and relay panel

Remove the main fuse cover panel from the front right-
hand side console. The vehicle diagnostic connector
(1) and the four pin SiteWatch™ (Telematics) diagnos-
tic connector (2) are also found in this area.
RAIL16TLB0532BA 1
RAIL15TLB0257BA 2
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Fuses
Fuse No. Rating Function
F1A 15 A Rear windshield wiper and rear windshield washer
F1B 7.5 A Fuel shut off, +15 antitheft, key switch +15 ECU
F1C 10 A Stop lights switch
F2A 15 A Instrument power supply, speed sensor, start relay, pneumatic seat
F2B 15 A Air conditioning
F2C 15 A Pilot control
F3A 3A Rear right/front left side light, instrument illumination
F3B 3A Rear left/front right side lights, number plate light
F3C 10 A Working light switch, 4X1 joystick
F4A 5A Forward speed, reverse speed, reverse buzzer, speed switch
F4B 10 A Hand tool button, clam bucket level valve and sensor, clutch shut off button
F4C 10 A Rear excavator lock, side-shift lock ,working lights switch
F5A 15 A External front outer working lights
F5B 10 A Low beam fuse
F5C 15 A Main beam fuse
F6A 15 A Rotating beacon lamp
F6B 7.5 A (+15) flasher
F6C 7.5 A Hand tool, 4WD
F7A 10 A (+30) warning, horn
F7B 10 A Cigar lighter, radio, roof lamp
F7C 6A Front windshield wiper
F8A 15 A External rear outer work lights
F8B 15 A External front inner work lights
F8C 15 A External rear inner work lights
Relays
Relay reference Designation
K1 Forward-reverse speed switch relay
K3 Starting relay
K4 Bucket level solenoid valve relay
K5 Traffic and main beam lights relay
K6 External front outer work light relay
K7 External rear outer work light relay
K8 External front inner work light relay
K9 External rear inner work light relay
K10 Reverse speed relay
K11 Forward speed relay
K12 Flasher unit relay
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RAIL14TLB1183GA 3
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Side relay and fuse module

Remove the side instrument cluster panel to expose the
mini relay and fuse panel.
RAIL16TLB1503BA 4
RAIL15TLB0136AA 5
Fuse or relay reference Designation

K226 Four-Wheel Drive (4WD) relay X-225
K230 Hand hammer relay X-230
K232 Ride Control™ relay X-232
K224 Differential gear lock relay X-224
K605 Side working light relay X-605
F-001 +15 Switched fuse 5 A

X–31 +30 diagnostic plug 5 A (F1)
Side working light 15 A (F2)
+30 switches and +30 cluster 3 A (F3)
Quick coupler 7.5 A (F4)
Ride Control™, front panel, valve block 7.5 A (F5)
K464 Main relay X-464
X-520 Front working lamps – Diode 1 (D1)
Instrument lamp – Diode 2 (D2)
Rear working lamps – Diode 3 (D3)
Transmission switch B+ 5 A fuse F520
NOTE: The relays or fuses in this table are not attached to the fuse relay panel shown.
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Engine compartment fuse and relay panel

Open the engine hood and locate the fuse and relay
panel on the left-hand side of the engine.
• X-449 Fuse panel (1)
• X-448 Fuse and relay panel (2)
• Glow-Plug Control Unit (GCU) (3)
• Heater Control Unit (HCU) relay (4)
• Engine Control Unit (ECU) relay (5)
RAIL16TLB0366BA 6
X-449 fuse panel (1)

F-010 Glow-plug Control Unit (GCU) 60 A fuse
— not used
F-011 Heater Control Unit (HCU) 40 A fuse
F-012 Engine Control Unit (ECU) 20 A fuse
F-013 Spare 40 A fuse
F-014 Sensor power 25 A fuse

K-102 Starter pilot relay
K-103 Start interlock relay
K-104 Engine start relay
K-105 A/C compressor relay
K-106 AUX main relay
K-107 SCR main relay
F-003 SCR system ignition 7.5 A fuse
F-004 Engine Control Unit (ECU) 7.5 A fuse
F-005 Tank heater valve and purge module pump 10 A fuse
F-007 A/C 10 A fuse
F-008 Pump module 10 A fuse
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If the machine is equipped with Air-Conditioning (A/C).

On the right-hand side of the engine near the alternator
is a 40 A in-line harness blower fuse (F953/X-953).
RAIL16TLB0369BA 7
Main power fuse module

Open the battery compartment door and locate the 80 A
main power fuse.
NOTE: There is a in-line 5 A +30 unswitched fuse (F002)
in the SiteWatch™ (Telematics) harness near the positive
battery terminal.
RAIL15TLB0014AA 8
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Fuse and relay box - Check - Powershift

MARBLE CUTTING
DRIVE (2WD)
DRIVE (4WD)
MARBLE CUTTING
NOTICE: NEVER replace a fuse with a fuse of a different rating.
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Main fuse and relay panel

Remove the main fuse cover panel from the front right-
hand side console. The vehicle diagnostic connector
(1) and the four pin SiteWatch™ (Telematics) diagnos-
tic connector (2) are also found in this area.
RAIL16TLB0532BA 1
RAIL15TLB0257BA 2
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Fuses
Fuse No. Rating Function
F1A 15 A Rear windshield wiper and rear windshield washer
F1B 7.5 A Fuel shut off, +15 Antitheft, , +15 key switch ECU
F1C 10 A 4WD, automatic manual, TRAX, de-clutch transmission
F2A 15 A Side panel power supply, start relay, pneumatic seat
F2B 15 A Air-conditioning
F2C 15 A Pilot control
F3A 3A Rear right/front left side light, instrument illumination
F3B 3A Rear left/front right side lights, number plate light
F3C 10 A Front and side working light switches, 4X1 joystick
F4A 7.5 A Stop lights and TRAX
F4B 10 A Hand tool button, clam bucket level valve and sensor
F4C 10 A Rear excavator lock, side-shift lock, transport lock, rear working light switches
F5A 15 A External front inner working lights
F5B 10 A Traffic lights
F5C 15 A Main beam fuse
F6A 15 A Rotating beacon
F6B 7.5 A Warning supply
F6C 7.5 A +15 Steering column lights switchRapid attach
F7A 10 A (+30) warning, horn, antitheft
F7B 10 A Current intake, radio, roof lamp
F7C 6A Front windshield wiper
F8A 15 A External rear outer work lights
F8B 15 A External front outer work lights
F8C 15 A External rear Inner work lights
Relays
Relay reference Designation
K10 Optional relay
K1A Flasher relay
K3 Starting relay
K4 Bucket level solenoid valve relay
K5 Traffic and main beam lights relay
K6 External front inner work light relay
K7 External rear Inner work light relay
K8 External front outer work light relay
K9 External rear outer work light relay
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RAIL14TLB1180GA 3
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Fuse and relay module

Remove the side instrument cluster panel to expose the
mini relay and fuse panel.
NOTE: Four-Wheel Steer (4WS) machines will have less
relays then what is shown.
RAIL15TLB0258BA 4
RAIL15TLB0136AA 5

K225 Parking brake relay X-225 (not applicable to 4WS)
K227 4WD warning light relay X-227
K230 Hand hammer relay X-230
K232 Ride Control™ relay X-232
K231 Reset parking brake relay X-231 (not applicable to 4WS)
K228 Additional relay X-228 (not applicable to 4WS)
K14 Transmission cut-off relay X-14
F-001 +15 Switched fuse 5 A

X–31 +30 diagnostic plug 5 A (F1)
Side working light 15 A (F2)
+30 switches and +30 cluster 3 A (F3)
Quick coupler 7.5 A (F4)
Ride Control™, front panel, valve block 7.5 A (F5)
K464 Main relay X-464
X-520 Front working lamps – Diode 1 (D1)
Instrument lamp – Diode 2 (D2)
Rear working lamps – Diode 3 (D3)
NOTE: The relays or fuses in this table are not attached to the fuse relay panel shown.
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Engine compartment fuse and relay panel

Open the engine hood and locate the fuse and relay
panel on the left-hand side of the engine.
• X-449 Fuse panel (1)
• X-448 Fuse and relay panel (2)
• Glow-Plug Control Unit (GCU) (3)
• Heater Control Unit (HCU) relay (4)
• Engine Control Unit (ECU) relay (5)
RAIL16TLB0366BA 6

F-010 Glow-plug Control Unit (GCU) 60 A fuse
— not used
F-011 Heater Control Unit (HCU) 40 A fuse
F-012 Engine Control Unit (ECU) 20 A fuse
F-013 Spare 40 A fuse
F-014 Sensor power 25 A fuse

K-102 Starter pilot relay
K-103 Start interlock relay
K-104 Engine start relay
K-105 A/C compressor relay
K-106 AUX main relay
K-107 SCR main relay
F-003 SCR system ignition 7.5 A fuse
F-004 Engine Control Unit (ECU) 7.5 A fuse
F-005 Tank heater valve and purge module pump 10 A fuse
F-007 A/C 10 A fuse
F-008 Pump module 10 A fuse
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If the machine is equipped with Air-Conditioning (A/C).

On the right-hand side of the engine near the alternator
is a 40 A in-line harness blower fuse (F953/X-953).
RAIL16TLB0369BA 7
Main power fuse module

Open the battery compartment door and locate the 80 A
main power fuse.
NOTE: There is a in-line 5 A +30 unswitched fuse (F002)
in the SiteWatch™ (Telematics) harness near the positive
battery terminal.
RAIL15TLB0014AA 8
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Index

Wiring harnesses - Electrical schematic sheet 01 Sheet 1A Engine cable (*) . . . . . . . . . . . . . . . . . . . 46
Wiring harnesses - Electrical schematic sheet 01 Sheet 1B Engine cable (*) . . . . . . . . . . . . . . . . . . . 48
Wiring harnesses - Electrical schematic sheet 02 Sheet 2 Solenoid valves cable (*) . . . . . . . . . . . . . 50
Wiring harnesses - Electrical schematic sheet 04 Sheet 4 Lights cable (*) . . . . . . . . . . . . . . . . . . . . . 54
Wiring harnesses - Electrical schematic sheet 05 Sheet 5 Rear lights cable (*) . . . . . . . . . . . . . . . . . 56
Wiring harnesses - Electrical schematic sheet 06 Sheet 6 Work lights cable (*) . . . . . . . . . . . . . . . . . 58
Wiring harnesses - Electrical schematic sheet 07 Sheet 7 Windshield wiper/ washer cable (*) . . . . 60
Wiring harnesses - Electrical schematic sheet 08 Sheet 8 Heater (radio) cable (*) . . . . . . . . . . . . . . 62
Wiring harnesses - Electrical schematic sheet 09 Sheet 9 Quick coupler option (*) . . . . . . . . . . . . . . 64
Wiring harnesses - Electrical schematic sheet 10 Sheet 10 Trax control module harness (*) . . . . . . 66
Wiring harnesses - Electrical schematic sheet 11 Sheet 11 Transmission (*) . . . . . . . . . . . . . . . . . . . 68
Wiring harnesses - Electrical schematic sheet 12 Sheet 12 Air conditioner kit (*) . . . . . . . . . . . . . . . 70
Wiring harnesses - Electrical schematic sheet 13 Sheet 13 Pilot control module (*) . . . . . . . . . . . . . 72
Wiring harnesses - Electrical schematic sheet 01 Sheet 1 Engine cable (*) . . . . . . . . . . . . . . . . . . . . 74
Wiring harnesses - Electrical schematic sheet 10 Sheet 10 Trax control module harness (*) . . . . . . 96
Wiring harnesses - Electrical schematic sheet 11 Sheet 11 Air conditioner kit (*) . . . . . . . . . . . . . . . . 98
Wiring harnesses - Electrical schematic sheet 12 Sheet 12 Pilot control module (*) . . . . . . . . . . . . . 100
Wiring harnesses - Electrical schematic sheet 03 Sheet 3 solenoid valves cable (*) . . . . . . . . . . . . . 110
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Wiring harnesses - Electrical schematic sheet 10 Sheet 10 Air conditioner kit (*) . . . . . . . . . . . . . . . 124
Wiring harnesses - Electrical schematic sheet 11 Sheet 11 Pilot control module (*) . . . . . . . . . . . . . . 126
Fuse and relay box - Check - Power shuttle (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 516
Fuse and relay box - Check - Powershift (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 523
Harnesses and connectors - Drawing Anti-tipping sensor switch harness . . . . . . . . . . . . . . . . . . . . . . 43
Harnesses and connectors - Electrical schema index Components (*) . . . . . . . . . . . . . . . . . . . . . . . . . 31
Harnesses and connectors - Electrical schema index Connectors (*) . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Harnesses and connectors - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Wire connectors - Component diagram 00 Connector MC1 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270
Wire connectors - Component diagram 00 Connector MC1 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
Wire connectors - Component diagram 00 Connectors BS1 and BS2 (*) . . . . . . . . . . . . . . . . . . . . . . . 397
Wire connectors - Component diagram 00 Connectors BS1 to BS9 (*) . . . . . . . . . . . . . . . . . . . . . . . . 265
Wire connectors - Component diagram 00 Connectors H00 to H99 (*) . . . . . . . . . . . . . . . . . . . . . . . . 267
Wire connectors - Component diagram 00 Connectors H00 to H99 (*) . . . . . . . . . . . . . . . . . . . . . . . . 399
Wire connectors - Component diagram 00 Connectors S01 to S101 (*) . . . . . . . . . . . . . . . . . . . . . . . . 404
Wire connectors - Component diagram 00 Connectors S01 to S99 (*) . . . . . . . . . . . . . . . . . . . . . . . . . 134
Wire connectors - Component diagram 00 Connectors S01 to S99 (*) . . . . . . . . . . . . . . . . . . . . . . . . . 271
Wire connectors - Component diagram 00 Connectors X-00 to X-09 (*) . . . . . . . . . . . . . . . . . . . . . . . 283
Wire connectors - Component diagram 00 Connectors X-00 to X-09 (*) . . . . . . . . . . . . . . . . . . . . . . . 415
Wire connectors - Component diagram 00 Connectors XC, XST, and XX (*) . . . . . . . . . . . . . . . . . . . 276
Wire connectors - Component diagram 00 Connectors XC, XST, and XX (*) . . . . . . . . . . . . . . . . . . . 408
Wire connectors - Component diagram 00 Connectors XST, XC, XX and X-00 to X-09 (*) . . . . . . . . 139
Wire connectors - Component diagram 00 Connectors fuses (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 264
Wire connectors - Component diagram 00 Connectors fuses (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 396
Wire connectors - Component diagram 00 Connectors power and ground (*) . . . . . . . . . . . . . . . . . . 129
Wire connectors - Component diagram 00 Connectors relays K-00 to K-99 (*) . . . . . . . . . . . . . . . . . 269
Wire connectors - Component diagram 00 Connectors relays K-00 to K-99 (*) . . . . . . . . . . . . . . . . . 401
Wire connectors - Component diagram 00 Pilot control connectors S1 and S2 (*) . . . . . . . . . . . . . . . 382
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Wire connectors - Component diagram 00 Pilot control connectors S1 and S2 (*) . . . . . . . . . . . . . . . 509
Wire connectors - Component diagram 00 Pilot control connectors X-00 to X-09 (*) . . . . . . . . . . . . . 385
Wire connectors - Component diagram 00 Pilot control connectors X-01 to X-09 (*) . . . . . . . . . . . . . 512
Wire connectors - Component diagram 00 Pilot control connectors XL, XR, and XX (*) . . . . . . . . . . 383
Wire connectors - Component diagram 00 Pilot control connectors XL, XR, and XX (*) . . . . . . . . . . 510
Wire connectors - Component diagram 00 Pilot control connectors YP3 to YP10 (*) . . . . . . . . . . . . . 384
Wire connectors - Component diagram 00 Pilot control connectors YP3 to YP10 (*) . . . . . . . . . . . . . 511
Wire connectors - Component diagram 01 Connectors X-010 to X-019 (*) . . . . . . . . . . . . . . . . . . . . . 152
Wire connectors - Component diagram 01 Pilot control connectors X-010 to X-019 (*) . . . . . . . . . . . 386
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Wire connectors - Component diagram 11 Connectors X-110 to X-119 (*) . . . . . . . . . . . . . . . . . . . . . . 191
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Alternator - 301

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Contents
Alternator - 301
TECHNICAL DATA
Alternator
FUNCTIONAL DATA
Alternator
Component localization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
SERVICE
Alternator
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
DIAGNOSTIC
Alternator
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Electrical systems - Alternator
Alternator - General specification

Manufacturer Denso
Rated voltage 12 V
Polarity Negative terminal grounded
Current 120 A
Minimum charging speed 1400 RPM
Maximum speed 9000 RPM
Direction of rotation Clockwise seen from the pulley side
Regulated voltage at 5000 RPM with 10 A at 25 °C (77.00 °F) 14.2 – 14.8 V
Maximum load that can be applied at terminal L 12 V, 3.4 W x 6
Alternator - General specification

580ST
590ST
695ST
Rated voltage 14.5 V
Current 120 A
Swing speed 12000 – 13500 RPM
Operating temperature -30 – 90 °C (-22.0 – 194 °F)
Direction of rotation Clockwise seen from the pulley side
Regulated voltage at 5000 RPM with 10 A at 25 °C (77.0 °F) 14.2 – 14.8 V
Maximum load that can be applied at terminal L 12 V, 3.4 W*6
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LELI12TLB2706GA 1
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Alternator - Static description

Operation
The alternator, installed on the motor, on the front RH side
of the vehicle, is driven by the crankshaft pulley with the
help of a belt.
The alternator contains built-in regulators.
Current draw on the starter motor system

When the ignition key is turned, a current of low intensity is
sent by the battery to the field winding of the rotor (terminal
IG).
At this stage, the indicator lamp (terminal L) turns on and

the rotor is partially magnetized. LELI12TLB1984AB 1
When the motor starts and the partially magnetized rotor 1. Ground connection
rotates inside the stator, a three-phase alternating current 2. Terminal P: Motor tachometer
is generated (terminal B+). 3. Terminal L: Charge indicator
4. Terminal B+: charge +12 V
A constant portion of this current is transformed into a
direct current by three excitation diodes installed in the 5. Terminal IG: +12 V after ignition ( 10 A fuse)
rectifier.
The direct current is sent as reinforcement through the

field winding of the rotor.
Using this method an increase in the magnetic field of the

rotor is obtained, as well as a rapid rise in the voltage and
current generated at the output.
The luminosity of the indicator lamp decreases when the

voltage generated at the output is increasing (terminal L).
The indicator lamp goes out when the voltage at terminal

“L” is equal to that of the battery.
The voltage continues to increase up to the value prede-

fined by the regulator.
In case the alternator belt is broken, the voltage does not

accumulate in the alternator and the load indicator lamp
remains lighted to indicate the problem.
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Alternator - Static description

580ST
590ST
695ST
Operation
The alternator, installed on the motor, on the front RH side
of the vehicle, is driven by the crankshaft pulley with the
help of a belt.
The alternator contains built-in regulators.
Current draw on the starter motor system:

When the ignition key is turned, a current of low intensity is
sent by the battery to the field winding of the rotor (terminal
IG).
At this stage, the indicator lamp (terminal L) turns On and

the rotor is partially magnetized. LELI12TLB2707AB 1
When the motor starts and the partially magnetized rotor 1. Terminal W
rotates inside the stator, a three-phase alternating current 2. Terminal IG
is generated (terminal B+). 3. Terminal L
4. Terminal B
A constant portion of this current is transformed into a
direct current by three excitation diodes installed in the
rectifier.
The direct current is sent as reinforcement through the

field winding of the rotor.
Using this method an increase in the magnetic field of the

rotor is obtained, as well as a rapid rise in the voltage and
current generated at the output.
The luminosity of the indicator lamp decreases when the

voltage generated at the output is increasing (terminal L).
The indicator lamp goes out when the voltage at terminal

“L” is equal to that of the battery.
The voltage continues to increase up to the value prede-

fined by the regulator.
In case the alternator belt is broken, the voltage does not

accumulate in the alternator and the load indicator lamp
remains lighted to indicate the problem.
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Alternator - Component localization
LELI12TLB1985FB 1
1. Alternator 6. Battery
2. Output winding 7. Key switch
3. Rectifier 8. Charge indicator
4. Regulator 9. Speedometer
5. Starter motor
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Alternator - Component identification
LELI12TLB1986GB 1
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1. Front housing 16. Sealing ring

2. Rear housing 17. Sealing ring
3. Rectifier 18. Washer
4. Brush holder 19. Screw
5. Regulator 20. Electric terminal
6. Rear protective 21. Screw
7. Insulation ring 22. Bearing
8. Insulation ring 23. Flange
9. Screw 24. Flange
10. Screw 25. Stator
11. Nut 26. Stud screw
12. Nut 27. Bearing
13. Rotor 28. Plate
14. Pulley 29. Screw
15. Pulley nut
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Alternator - Remove
Disconnect the negative cable from the battery.
Disconnect the battery cable (1) from terminal B+ (2).
Disconnect the connector (3).
LEPH12TLB1987AB 1
Free the tension roller (4) using a suitable wrench, then

remove the belt (5).
Remove the screw (6) and the nut (7).
Remove the screw (8).
Remove the alternator (9).
LEPH12TLB1988AB 2
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Alternator - Check
Preliminary checks and tests
To prevent damage to components of the alternator
charging circuit, the following precautions must be
taken during maintenance:
• Never connect or disconnect a charging system con-
nection, including the battery, when the motor is run-
ning.
• Never dead short to ground any component of the
charging circuit.
• Always disconnect the ground cable from the battery
(negative) to recharge the battery on the vehicle us-
ing a battery charger.
• Always respect the polarity when installing the bat-
tery on the vehicle or when using an auxiliary battery
to start the motor.
NOTICE: Connect the positive cable to the positive termi-
nal and the negative cable to the negative terminal.
Preliminary checks
Before undertaking an electric inspection, check the
charging system and the electric system carefully.
Check the state of cables and the tightening of connec-
tions.
Battery check
Check each cell of the battery with a hydrometer.
The battery must be charged at least 70% and be in
good condition.
Drive belt check

Check that the belt and the pulley of the alternator are
clean, without any trace of oil and grease and that they
are in good condition.
Indicator lamp check

Turn the ignition key and check that the charge indicator
is well lit.
If it is not fully lighted, check its bulb.
If the bulb is OK, check the alternator wire connections
as described in the “Preliminary tests” section below.
If the indicator lamp is lighted, start the motor and run
it at a speed that is higher than the idling speed. The
indicator lamp must turn off.
If the indicator lamp does not turn off, turn off the motor
and disconnect the ground cable L.
If the indicator lamp goes out, an alternator component
is defective.
Follow the instructions given in the “Checking the alter-
nator components” section below.
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If the indicator lamp stays lighted, look for a dead short

to ground between the terminal “L” cable and the indi-
cator lamp.
Preliminary tests
The preliminary tests may be carried out without remov-
ing the charging system components; these tests help
check the following items:
• Connections of the alternator cables.
• Charging current and regulated voltage of the alter-
nator.
• Voltage drops in the alternator charging system.
• Maximum flow of the alternator.
Required devices:
• Voltmeter ( 0 – 30 V, moving coil)
• Millivoltmeter ( 0 – 1 V)
• Ammeter ( 0 – 110 A, moving coil)
• Variable resistance of 1.5 Ω, 110 A
NOTE: Most testing instruments sold in shops group to-
gether several measurement functions in a single device.
Use these devices in accordance with the manufacturer’s
instructions.
Checking the connections of the alternator cables

Disconnect the battery.
Disconnect the terminals B+ (2) and L (3) from the al-
ternator.
Reconnect the battery and turn the ignition key without
starting the motor. Connect a voltmeter (4) between
each terminal ( B+ or (L)) and the ground (1). The volt-
meter must show the battery voltage.
If there is no battery voltage, the external cable has a
continuity fault; in this case, check the entire system
and carry out the necessary repairs.
Connect the terminal L indicator lamp wire to the
ground. The indicator lamp should turn on.
Disconnect the battery and reconnect the cables to the
alternator. LELI12TLB1989AB 1
NOTE: If the indicator lamp does not turn on after recon-

necting the cable to the alternator, the regulator of the al-
ternator or the rotor systems are defective. Make sure that
terminal L is clean, then check the components of the al-
ternator as indicated in this chapter.
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Checking the charging current and the regulated voltage

Make sure that all electric components are powered off
and that the ignition is turned off (key on “OFF”).
Disconnect the negative terminal from the battery and
disconnect terminal B+ (4) from the alternator.
Connect an ammeter (1) between the disconnected ca-
ble (3) and terminal B+ of the alternator.
Connect a voltmeter (2) between terminal B+ of the al-
ternator and the ground.
Reconnect the battery. Start the motor and run it at a
speed of 2000 RPM. Observe the values shown on the
ammeter and the voltmeter.
The voltage shown on the voltmeter should at first be
very high and then should stabilize between 14.2 –
14.8 V when the value on the ammeter drops below LELI12TLB1990AB 2
10 A.
If the voltmeter stabilizes at a voltage greater than
14.8 V, the regulator of the alternator needs to be
replaced.
On the other hand, if the voltmeter stabilizes below
14.2 V, a component of the alternator is defective or the
resistance in the external connections of the charging
circuit is too high.
If the ammeter indicates zero amps, an alternator com-
ponent is defective.
Turn off the motor and carry out the operations de-
scribed in the “Checking the alternator components”.
Check of voltage drops in charging system
Voltage drop on insulated side

Make sure that the starter switch key is turned to OFF.
Disconnect the negative cable from the battery and dis-
connect cable B+ (1) from the alternator.
Connect a millivoltmeter (4) between the positive ter-
minal of the battery and cable B+ (5) (positive side on
cable).
Connect an ammeter (2) between terminal B+ of the
alternator and cable B+ (negative side on cable).
Reconnect the negative cable of the battery and con-
nect a variable resistance (3) between the battery ter-
minals by adjusting the cursor to the minimum current
draw (maximum resistance).
Start the motor and increase its speed to 2000 RPM.
Gradually reduce the resistance until the ammeter LELI12TLB1991AB 3
shows 90 A.
Observe the millivoltmeter, which must not indicate a
value that is greater than 400 mV.
If the value exceeds 400 mV, the resistance of the ex-
ternal system is too high. If the output value of the al-
ternator is not sufficient and the millivoltmeter indicates
a value that is less than 400 mV, an alternator compo-
nent is defective.
Carry out the operations described in the “Checking the
alternator components”.
Stop the engine.
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Voltage lower on ground side

Check the system as for the previous test, but connect
the millivoltmeter (4) between the negative terminal of
the battery and the alternator body (negative side to-
wards the body).
NOTE: Make sure that the variable resistance (3) is in the
minimum current draw position (maximum resistance).
Start the motor and increase its speed to 2000 RPM.
Gradually reduce the resistance until the ammeter (2)
shows 90 A.
Observe the millivoltmeter, which must not indicate a
value that is greater than 200 mV.
If the value exceeds 200 mV, the resistance of the ex-
LELI12TLB1992AB 4
ternal system is too high.
If the output value of the alternator is not sufficient and
the millivoltmeter indicates a value that is less than
200 mV, an alternator component is defective.
Stop the engine.
Checking the maximum output of the alternator

Disconnect the negative cable from the battery and dis-
connect cable B+ (5) from the alternator.
Connect an ammeter (2) between terminal B+ (1) of the
alternator and the disconnected cable B+ (negative side
towards the cable).
Connect a voltmeter (4) between terminal B+ of the al-
ternator and the ground.
Reconnect the battery, start the motor and increase its
speed to 2000 RPM.
Gradually reduce the resistance (3) until the ammeter
shows 90 A .
Observe the voltmeter, which must not indicate a value
that is less than 14.2 V.
If the value lowers below 14.2 V, an alternator compo- LELI12TLB1992AB 5
nent is defective.
Checking the alternator components

Checking of components must be done only if the PRE-
LIMINARY TESTS reveal an alternator defect which re-
lates to the following components:
• Regulator.
• Continuity of the rotor field winding.
• Brushes, springs and slip rings.
NOTE: These checks may be carried out without removing
the alternator from the vehicle.
The alternator must be removed to check the other com-
ponents of the alternator.
Refer to the “Removal” section in this chapter.
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NOTICE: Before disconnecting the cables from the alterna-

tor, make sure that the starter switch key is turned to OFF
and that the negative cable of the battery is disconnected.
Required devices:
• 12 V battery.
• Multimeter.
• 2.2 W test lamp.
Checking the rotor and the relevant field system

Disconnect all cables from the alternator.
Connect a 12 V battery and a 2.2 W test lamp (2) in
series between terminal L (1) and the alternator body
(negative side on body).
The test lamp must turn on.
If the lamp does not turn on, the rotor system is defec-
tive.
Check the brushes, the slip rings and the continuity of
the rotor field windings.
If the inspection reveals that these components are in
good condition, the defect may be due to the regulator.
LELI12TLB1994AB 6
Checking the continuity of the rotor field winding

Remove the regulator with the brush holder.
Connect an ohmmeter (3) between the two slip rings
(2). The resistance must be 2.6 Ω at 20 °C (68 °F).
If the resistance is not correct, replace the rotor (1) as
described in the “Removal” section below.
LELI12TLB1995AB 7
Rectifier-checking the positive/negative diodes

Check each of the six diodes separately.
Connect a multimeter (2) in series with one of the
diodes. Place one wire of the multimeter on the con-
necting pin (1) of the diode and the other wire on the
plate where the diode is installed.
Note down the value of the resistance indicated by the
multimeter. Reverse the wires of the multimeter.
The multimeter should indicate infinite resistance (open
circuit) only during the first half of the test. If this check
reveals that a diode is defective, replace the entire rec-
tifier.
LELI12TLB1996AB 8
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Rectifier-checking the excitation diodes
Check each of the excitation diodes separately.

Connect a multimeter (2) in series on the excitation
diode module. Place the negative wire on terminal L
(1) and the other wire on the connection of each exci-
tation diode (3).
Note down the value of the resistance indicated by the
multimeter. Reverse the wires of the multimeter.
The multimeter should indicate infinite resistance (open
circuit) only during the first half of the test. If this check
reveals that a diode is defective, replace the entire rec-
tifier.
LELI12TLB1997AB 9
Stator-checking the continuity of the winding

Check each excitation diode separately by proceeding
as follows:
Connect the wires of the ohmmeter (3) between wires
A, B and C (2). The resistance between each of the
wires must be low 0.1 W.
If the resistance is greater than this value, it indicates a
possible break in the winding, i.e. an open circuit.
A lower value (0.0. for example) indicates a short circuit
in the winding.
If the result of this check is not satisfactory, replace the
stator (1) and its casing.
LELI12TLB1998AB 10
Stator-checking the insulation

Check the insulation of each winding with respect to the
alternator casing.
There must not be any continuity between the winding
and the casing.
If the ohmmeter (2) indicates any value other than an
open circuit, replace the entire stator (1).
LELI12TLB1999AB 11
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Rotor check
Before checking the rotor components, inspect the slip
rings to make sure that they are in good condition.
• Check that the slip rings are clean and smooth.
If necessary, clean them with a cloth soaked in gaso-
line.
If the slip rings are burnt, scrape them with very fine
sandpaper (do not use emery cloth) and wipe them.
NOTE: Make sure that the sandpaper is sufficiently fine in
order to obtain a perfect finish of the slip ring surfaces and
avoid premature wear of the brushes.
• If the slip rings are excessively worn, replace the
rotor.
Rotor-checking the continuity of the field winding

Connect an ohmmeter (3) between the two slip rings
(2). The resistance must be 2.6 Ω at 20 °C (68 °F).
If the resistance is incorrect, replace the rotor (1).
LELI12TLB2000AB 12
Rotor-checking the insulation of the field winding

Using an ohmmeter (3), measure the resistance be-
tween each slip ring (2) and the rotor terminals (1).
The resistance should always be infinite.
If a resistance is not infinite, replace the rotor.
LELI12TLB2701AB 13
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Alternator - Troubleshooting
580ST
590ST
695ST

Not recharged Recharging system interrupted (warning Check the connections of the recharging
lamp, fuse, connector, etc.) system, clean and tighten the alternator
and battery terminals
Voltage regulator inefficient Replace the part
Rotor winder interrupted Replace the part
Worn brushes Replace the part
Recharge insufficient Slackened fan belt Supply the correct voltage
Voltage regulator faulty Replace the part
Excessive wear of rotor rings or brushes Replace the part
Short-circuited diodes Replace the part
Short-circuited stator winders or rotor Replace the part
winder
Excessive recharge Loose system connections Check the connections of battery terminals,
starter motor terminals and alternator
Voltage regulator inefficient Replace the part
Ground connection faulty Check connections for leaks
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Index
Alternator - 301
Alternator - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Alternator - Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Alternator - Component localization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Alternator - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Alternator - General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Alternator - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Alternator - Static description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Alternator - Static description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Alternator - Troubleshooting (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
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Battery - 302

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Contents
Battery - 302
TECHNICAL DATA
Battery
FUNCTIONAL DATA
Battery
SERVICE
Battery
Connect Assisted starting (Jump-starting) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Battery
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Double battery connecting cables
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
DIAGNOSTIC
Battery
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Electrical systems - Battery
Battery - General specification

580ST
590ST
695ST
For the loader backhoe models two different kinds of installation are provided:
• With one battery.
• With two batteries (for cold climates).
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Single battery
Voltage 12 V
Capacity ( 20 h) 95 A·h
Discharge current 900 A
Weight with electrolyte 25 kg (55 lb)
Double battery
Voltage 12 V
Capacity ( 20 h) 60 A·h
Discharge current 600 A
Weight with electrolyte 17 kg (37.5 lb)
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Battery - Dynamic description

580ST
590ST
695ST
All models feature one or two 12 V, negative ground, “maintenance free” lead calcium (Pb-Ca) type battery.
NOTICE: “Maintenance Free” means that under normal charging conditions the battery does not lose water from the
electrolyte. Conditions that may cause water loss include prolonged charging above 14.4 V where gassing occurs as
it approaches full charge. This can be caused by a faulty charging system or boost/recovery charging equipment.
The battery has four major functions:
• To provide a source of current for starting, lighting and instrumentation.

• To help control the voltage in the electric system.
• To provide current when the electric consumption exceeds the alternator output.
• To support quiescent loads from radio and microprocessor memory.
The battery is constructed in such a manner that each cell contains positive and negative plates placed alternatively
next to each other.
Each positive plate is separated from a negative plate by a non conducting porous envelope separator.
If any of the positive plates should make contact with negative plates within a cell, the cell will short circuit and suffer
irreparable damage.
All of the positive plates are welded to a bus-bar, forming a positive terminal and all of the negative plates are welded
to a similar bus-bar forming a negative terminal.
Each positive plate is composed of a lead grid with lead peroxide pasted into the grid openings.
The negative plates are composed of a lead grid with spongy lead pasted into the grid openings.
The plates are submerged in a liquid electrolyte solution of diluted sulphuric acid.
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Battery - Static description

580ST
590ST
695ST
NOTICE: Wait at least 60 seconds after you place the ig-

nition key in the OFF position before turning the master
disconnect switch to OFF. This allows the machine con-
trollers to shut down properly.
NOTICE: The battery master switch must be switched off
at the end of each working day, for machine service or
for any operations on the electric system. It acts as an
anti-theft device when the cab doors and windows are
locked.
The battery master switch (1) is located in the battery com-

partment and is used to completely disconnect the battery
from the electric system.
When the battery master switch has an inclination of 45°,

the circuit is disconnected. RAIL15TLB0014AA 1
When the master switch is in vertical position, the circuit

is connected.
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Battery - Connect Assisted starting (Jump-starting)

580ST
590ST
695ST
DANGER
Explosion hazard and/or run over hazard!
Read the procedure in the operator's manual before jump-start or service to avoid injury.
Failure to comply will result in death or serious injury.
D0149A
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
Explosive gas!
Batteries emit explosive hydrogen gas and other fumes while charging. Ventilate the charging area.
Keep the battery away from sparks, open flames, and other ignition sources. Never charge a frozen
battery.
W0005A
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
A high current flows on connection of the ground cable.

Connect the ground cable to the frame as far as possible away from the discharged battery.
During assisted starting operations (by means of an external battery), do not lean over the batteries. Wear goggles.
Only connect batteries (battery assemblies) with the same voltage.
Only use tested jumper cables with insulated terminal clips and an adequate lead diameter.
Ensure that the bodies of the supplying and receiving machines are not in contact. Otherwise a current flow might
result from connecting the positive poles.
When performing assisted starting, never use power supplies creating an over-voltage, such as, for example, two or
three batteries in series or devices generating voltages above 12 V.
Never use welding generators or welding transformers as power sources.
Position jumper cables in such a way that they cannot be caught by rotating engine components.
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Check whether the battery of the receiving machine

(discharged battery) is in working order:
1. Switch off electrical accessories (lights, fans).
2. Insert the ignition key, the warning lamps for the
instrument cluster must turn ON.
3. If warning lamps do not turn ON, the battery is
faulty (discharged or with a short-circuit inside). In
this case the machine must not be started, as the
alternator would then be damaged.
4. Install a functional battery before jump-starting.
Assisted starting connections

NOTE: Two persons are required for this procedure. Make sure the person making the connection is wearing hand
and face protection.
1. Switch off all electrical accessories in receiving ma-
chine and turn key switch to “0”.
2. Switch off all accessories in supplying machine
(booster battery) and shut off engine.
3. Open the engine hood.
4. Remove the red cap from the jump post (1) on the right-
hand side of the engine.
5. Connect the red jumper cable to the jump post (1) on
the right-hand of the machine with the discharged bat-
tery.
RAIL16TLB0368BA 1
6. Connect the other end of the red jumper cable to the

positive terminal on the booster battery.
7. Connect the black jumper cable to the negative terminal
on the booster battery.
8. Connect the other end of the black jumper cable to the
alternator frame (2) on the machine with the discharged
battery.
9. Start the engine of the supplying machine.
10. Increase RPM.
11. Start the engine of the receiving machine.
12. If the engine does not start up after 30 s, wait one
minute before restarting.
13. After the machine with the discharged battery starts,
activate some of the accessories with high current ab-
sorption, such as complete lighting and air-condition-
ing.
14. This prevents voltage peaks, which might damage
electronic modules, from occurring when the jumper
cables are disconnected.
15. Remove the black jumper cable from the alternator
frame.
16. Remove the other end of the black jumper cable from
the booster battery.
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17. Remove the red jumper cable from the jump post (1).
18. Remove the other end of the red jumper cable from
the booster battery.
19. Run the engine at moderate speed for about half an
hour. The batteries recharge partially.
20. Have the electrical system of the machine checked, to
determine why the batteries were dead.
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Battery - Remove
WARNING
Electrical shock hazard!
Do not reverse battery terminals. Connect positive cable ends to positive terminals (+) and negative
cable ends to negative terminals (-).
W0262A
WARNING
Battery gas can explode!
To prevent an explosion: 1. Always disconnect the negative (-) battery cable first. 2. Always connect
the negative (-) battery cable last. 3. Do not short circuit the battery posts with metal objects. 4. Do
not weld, grind, or smoke near a battery.
W0011A

tion.
7. Place the battery switch in the OFF position.
NOTE: Wait at least 60 seconds after key off before turning
battery switch to the off position. This allows the machine
controllers to shutdown properly.
8. Remove the fasteners (1) and the battery cover (2).
RAIL15TLB0073AA 1
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9. Remove the terminal covers and disconnect the cables,

first from the negative terminal (3) then the positive ter-
minal (4).
10. Remove the nuts and washers (5), the clamping bar
(6) and the battery (7).
RAIL15TLB0075AA 2
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Battery - Install
WARNING
W0262A
WARNING
W0011A
1. Install the battery (7).

2. Install the clamping bar (6) and the washers and nuts
(5).
3. Clean the cables and the connecting terminals and coat
them with grease.
4. Connect the cables, first to the positive terminal (4),
then the negative terminal (3) and install the terminal
covers.
RAIL15TLB0075AA 1
5. Reattach the battery cover (2) and secure it with the

fasteners (1).
RAIL15TLB0073AA 2
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Double battery connecting cables - Remove

WARNING
W0262A
WARNING
W0011A
1. Turn “OFF” the battery master disconnect switch.
RAIL16TLB0227AA 1
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2. Remove the toolbox if one has been installed.
RAIL16TLB0444CA 2
3. Remove the battery box cover.

4. Disconnect the negative battery cable.
RAIL16TLB0227AA 3
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5. Disconnect the negative battery cable (8) to both of the

negative battery terminals.
RAIL16TLB0407BA 4
6. Remove the positive terminal covers (6) from the top of

the batteries.
7. Remove the positive battery cable.
RAIL16TLB0407BA 5
8. Remove the positive battery cable (9) to both of the

positive battery terminals.
RAIL16TLB0407BA 6
9. Remove the battery hold down with J-bolt, washer, and

nut.
RAIL16TLB0408BA 7
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10. Remove the bolt (3), washers (2), and the nut (5) that
holds down the battery spacer plate (4)and battery
hold down bracket.
RAIL16TLB0446CA 8
RAIL16TLB0407BA 9
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11. Remove both of the batteries (1) from the battery box.
RAIL16TLB0408BA 10
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Double battery connecting cables - Install

WARNING
W0262A
WARNING
W0011A
1. Install both of the batteries (1) into the battery box.

NOTE: Position the batteries so that the positive terminals
will face toward the front of the machine.
RAIL16TLB0408BA 1
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2. Install the battery spacer plate (4) onto the, previously

removed, battery hold down bracket. Use bolt (3),
washers (2), and the nut (5).
RAIL16TLB0446CA 2
RAIL16TLB0407BA 3
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3. Install the battery hold down with the previously re-

moved J-bolt, washer, and nut.
NOTE: Position the batteries with a 37mm gap between
them to accept the new hold down spacer.
RAIL16TLB0408BA 4
4. Install the positive battery cable (9) to both of the posi-

tive battery terminals.
5. Install the positive battery cable, that was previously
removed from the single battery, to the new positive
battery cable (9).
RAIL16TLB0407BA 5
6. Install the positive terminal covers (6) by aligning the

pins on the covers with the holes in the top of the bat-
teries.
NOTE: When install properly the covers (6) will cover the
positive battery terminals.
RAIL16TLB0407BA 6
7. Install the negative battery cable (8) to both of the neg-

ative battery terminals.
8. Install the negative battery cable, that was previously
removed from the single battery, to the new negative
battery cable (8).
RAIL16TLB0407BA 7
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9. Install the battery box cover.
RAIL16TLB0408BA 8
10. Install the tool box if the machine was equipped with
one.
RAIL16TLB0408BA 9
11. Turn “ON” the battery master disconnect switch.
RAIL16TLB0408BA 10
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Battery - Troubleshooting
580ST
590ST
695ST

The electric system is Loose or oxidised battery connections Check that the battery voltage with open
inoperative circuit is at least 12.6 V
Clean and tighten the connections. Sul- Check the electrolyte level and density
phated batteries
Battery isolator switch off Restore the battery isolator switch
The main connection fuse of the machine Find the reason of the failure and replace
is blown the connection fuse
Starter motor speed too Loose or corroded connections Clean and tighten loose connections
low, the engine cranks
slowly
Low battery output voltage Check that the battery voltage with open
circuit is at least 12.6 V
Check the electrolyte level and density
Incorrect viscosity of the engine oil Use an oil with correct viscosity for the tem-
perature conditions
Starter motor inoperative Transmission gearshift lever engaged Move gearshift lever to neutral
Loose or corroded connections Clean and tighten loose connections
Dead batteries Charge or replace the batteries
The charge indicator lamp Low engine idle speed Increase idle speed
stays on with the engine
running
Loose belt Check belt tension
Malfunctioning battery Check that the battery voltage with open
circuit is at least 12.6 V. Check the elec-
trolyte level and density
Malfunctioning alternator Check the alternator and repair, if neces-
sary
Batteries will not charge Loose or corroded battery connections Clean and tighten the connections
Sulphated batteries Check that the battery voltage with open
circuit is at least 12.6 V
Check the electrolyte level and density
Loose or worn belt Check the automatic belt tensioner. If nec-
essary, replace the belt
The charge indicator Malfunctioning alternator Check the alternator and repair, if neces-
flashes, indicating sary
excessive charging
voltage
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Index
Battery - 302
Battery - Connect Assisted starting (Jump-starting) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Battery - Dynamic description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Battery - General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Battery - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Battery - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Battery - Static description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Battery - Troubleshooting (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Double battery connecting cables - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Double battery connecting cables - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
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Fuel tank system - 011

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Contents
FUNCTIONAL DATA
Fuel level sensor

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Electrical systems - Fuel tank system
Fuel level sensor - Dynamic description

580ST
590ST
695ST
When a certain low fuel level is reached, the relevant “low

fuel” lamp will be lit according to the following logic.
The filtering of the data read is obtained with a hysteresis

on the resistance value joined to a delay time of 2 s.
Ohmic parameter threshold and delay time value must be

kept in NVM.
Lamp activation depends on values used for needle

movement; this means that at key-on the low fuel level
warning is active if the cluster sees a resistance value
greater the table below.
LELI12TLB2336AA 1
Resistance values
The fuel level gauge will indicate the fuel level of the vehicle tank.
The gauge dial will be divided into two ranges: Red and green.
The red range will indicate a low fuel zone. The green range will indicate a non-low fuel zone.
This gauge will be connected to a sensor that will provide specific a resistance to correlate to a specific fuel tank level.
Red-green border
Tank size Empty value (X) Full value (Z) Indicated fuel level
(Y)
30% with 18 angular
133 l (35.13 US gal) 320 Ω 186 Ω 6.5 Ω degrees of gauge
motion
• X = empty. The centerline (CL) of the pointer will be at +0° / -2° angular degrees from the centerline of this empty
mark.
• Y = red - green threshold. The centerline (CL) of the pointer will be at +/-3 angular degrees from the centerline of
this “half” mark.
• Z = full. The centerline (CL) of the pointer will be at +4/-0 angular degrees from the centerline of this “full” mark.
In case the sender is disconnected, the gauge has to go down in empty position.
Reconnecting the sensor the gauge has to return to the correct position.
Both the movements have to be uniform.
A stepper motor will drive fuel level gauge.
The gauge accuracy should be less than or equal ±2%.
Needle calibration has never to be lost for any external condition.
During cranking, the needle movement shall be frozen in order to inhibit any spurious movement of it.
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Index

Fuel level sensor - Dynamic description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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Contents
FUNCTIONAL DATA
Engine coolant temperature sensor

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Electrical systems - Engine cooling system
Engine coolant temperature sensor - Dynamic description

580ST
590ST
695ST
A stepper motor will drive coolant temperature gauge. The gauge accuracy should be less than or equal 3 lb. Needle
calibration has never to be lost for any external condition.
Instrument Temperature
Gauge indication range 65 – 112 °C (149 – 234 °F)
Green field 65 – 106 °C (149 – 223 °F)
Red field 106 – 112 °C (223 – 234 °F)
The message to be used is engine temperature.
Engine temperature message Instrument position

00 => FD According to the logic above
FE Minimum value
FF Minimum value
An audible alarm must sound when the engine temperature exceeds 106 °C (223 °F).
In case the sender is disconnected, the gauge has to go to 65 °C (149 °F).
Reconnecting the sensor the gauge has to return to the correct position.
Both the movements have to be uniform.
The behavior of the gauge in case of faulty sensor will be to return to the parked position.
Since this signal is a function of the engine controller the appropriate warning lamp and lamp will be illuminated.
During cranking, the needle movement shall be frozen in order to inhibit any spurious movement of it.
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Electrical systems - Engine cooling system
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Index

Engine coolant temperature sensor - Dynamic description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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Electronic modules - 640

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Contents
FUNCTIONAL DATA
Electronic modules
Dynamic description Controller Area Network (CAN) data bus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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Electrical systems - Electronic modules
Electronic modules - Dynamic description Controller Area Network

(CAN) data bus
Introduction
CAN is an acronym for Controller Area Network. The bus connects controllers on a machine, and allows information
to be shared between the controllers. CAN was first developed by Bosch and Intel in 1984, and has been in use in
the automotive and truck industry since the late 1980‘s. Applications of CAN follow guidelines that are established in
SAE J1939.
Glossary of terms
Bus The network, e.g. the wires, connectors, and terminators
between the controllers.
CAN Controller Area Network. Generally refers to all parts of
the system -the controllers, wires, and terminators.
CAN HI A high priority, message carrying wire on the CAN bus.
CAN LO A low priority, message carrying wire on the CAN bus.
Controller Components that are connected by the bus and share
information. May also be referred to as processors,
control modules, units, or modules.
Terminator An electrical resistor or circuit placed at either end of the
bus. They may be passive or active type. They may be a
separate component or part of a controller. Terminators
prevent a message from rebounding along the bus, clear
the bus for the next message, and allow clear messages
to travel the bus.
Purpose
In the past, if a speed sensor‘s information was needed by a tachometer, an engine controller, and a transmission, the
three devices would need to be wired to the speed sensor. The complexity of wiring can be greatly reduced through
the use of a CAN bus system. A controller sends the speed sensor data onto the bus, and the other controllers on
the bus can read the data. Any controller on the bus that does not care about the data will ignores the message.
A CAN bus system also offers improved diagnostics with the use of the Electronic Service Tool (EST). The controllers
can detect errors, and fault codes can be displayed to the operator and technician. Onboard diagnostics may provide
the ability to test and monitor circuits during operation, aiding in troubleshooting.
The advantage of a CAN bus system are:

1. A decrease in the number of wires and overall length of the wiring harness.
2. Information is received by one controller which shares the information with the other controllers on the bus.
3. Less wiring and fewer connectors improve reliability and durability.
4. Improved diagnostics with the EST.
Operation
When the CAN bus is initially powered up (keyswitch on), each controller on the bus sends a message announcing its
existence and looks for messages from other controllers on the bus. After this initial message, each controller sends
data messages as necessary. The frequency of these messages is based on software programming, with important
messages broadcast more frequently than low priority messages.
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RAIL13TR03931FA 1
If a controller has not sent any messages within five seconds, it will broadcast a message that announces its existence.
This is done in order to monitor each controller’s status on the bus. If a certain controller has not transmitted any
messages for more than five seconds, then the other controllers on the bus will generate an alarm message indicating
that a controller is offline.
NOTE: This offline status condition may vary from one machine type to another. Some machines may need to be
configured to know that a specific controller is on the bus. However, this process of existence messages generally
holds true.
In a CAN system, controllers are positioned near the majority of their sensors and switches. For example, the Engine
Control Unit (ECU) is located in the engine compartment near the engine sensors. This results in less wiring, fewer
connections, and a reduction in the number of error sources.
The voltage signal from sensors and switches are processed by a controller, which converts the signal to a data
message. The data message is sent to the bus by the controller. Every controller that is connected to the bus can
read and process the data message as required. Each controller knows which information it needs based on the
software that is programmed into it.
The terminators absorb the voltage signals at either end of the bus. They are constantly trying to maintain of voltage
of 2.5 V on the bus. Terminators prevent a signal from rebounding along the bus, clear the bus for the next signal,
and allow clear messages to travel the bus.
Terminators
Terminators help eliminate the reflections that can occur when a message reaches the end of the bus. These re-
flections can cause interference (noise) on a CAN bus, creating communication problems between the controllers.
A good way to explain how terminators work is to think about dropping a stone into a pond. After the stone hits the
water, the waves travel to the edges of the pond and then rebound to the center. Terminators absorb the waves at
the edges and deny the rebound of the waves to the source.
Passive terminator or active terminator

1. Passive terminators are usually 120 Ω resistors placed at either end of the bus. Passive terminators are typically
used with a two wire CAN system. These resistors are connected between the CAN HI and CAN LO wires. Passive
termination is popular because it is a fraction of the cost of active terminators. Passive terminators act as snubbers
to kill reflections and work efficiently on systems with lower bus loading (low CAN bus traffic).
2. Active terminators are voltage regulators, and require a external voltage supply to operate. Active terminators are
typically used with a four wire CAN system. Active terminators produce 2.5 V on the CAN HI and CAN LO wires to
maintain the standard CAN wire voltage. This means they bring the wires to neutral. Active terminators are very
efficient, and are typically used on systems with high bus loading (high traffic).
Troubleshooting
The CAN system is capable of diagnosing itself and generating an alarm messages to the operator when problems
are present. The vehicle may continue to function when an alarm messages appears, but the systems related to that
controller may no longer function. When troubleshooting a vehicle with suspected CAN system failure, it is important
to determine if the problem is related to one or more controllers or if the bus is at fault.
CAN system problems will generally fall into two categories:
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1. Problems with individual controllers that affect certain functions, such as transmission or engine operation.
2. Problems with the bus. (The wires between the controllers.)
Some questions to answer are:

1. What functions are affected?
2. Are the affected functions related to a specific controller or several different controllers?
3. Are there any error codes or alarm messages active?
4. Are the error codes and/or alarm messages related to a specific controller or are they indicating a fault with the
entire system?
If only one or two controllers are affected on the vehicle, then those controllers should be tested for faults before
suspecting a CAN bus failure.
There are two general conditions that may cause an individual controller to go offline.
1. Loss of power or ground to the controller.
2. Controller related faults, such as a CAN controller failure, poor or failed CAN connector, or message errors.
Loss of power or ground

The controllers are not powered through the CAN bus wires. Each controller requires a power supply and ground
supply. If power or ground is lost, the controller will deactivate and will not be active on the bus. In addition, most
controllers require a minimal voltage level to activate, so weak batteries, a faulty charging system, or poor connections
may prevent controllers from properly activating.
Controller faults
Whenever a controller transmits or receives a fault message, it keeps a record of that error. After its error history fills,
the controller assumes that it is faulty, and will stop transmitting on the bus. We describe this situation as a controller
that has gone “bus off,” which may cause an alarm message to be displayed. This error history is erased and reset
at zero when the controller is deactivated.
There are several CAN related faults that may cause a controller to go offline:
1. External problems like bad or open connections to the CAN HI wires and CAN LO wires as a result of damaged
wiring. Inspect the wiring for damage, and use a multimeter to check for continuity to the wires.
2. Internal problems like a failure of the controller itself. If the controller is activating but never communicates on the
bus, the controller may have failed. If the controller is activating and is initially online but goes offline after a short
period of operation, it may be in a bus off state.
Faulty messages may result from:

1. Failed terminators (signal reflection occurring) on the CAN bus. Test the terminators for proper operation.
2. Bad connections (e.g. loose pins, corroded terminals, damaged wires) between the controller and the bus.
3. A problem with the controller.
If several controllers are offline or the vehicle will not start, there may be a problem with the actual CAN bus. The
wires may be shorted to 12 V, shorted to ground, open, or shorted together. Any of these problems can affect the
entire CAN bus.
Testing the CAN bus

There are several things to consider when testing CAN systems. The primary concern should be to confirm the in-
tegrity of the CAN bus circuit, after which you should check for shorts to battery voltage or to chassis ground.
You can easily test the CAN bus (CAN HI and CAN LO) for open circuits by conducting a circuit continuity check at
the vehicle’s diagnostic connector. However, for vehicles that use active terminators, it is necessary to unplug those
terminators, and replace them with jumper wires between the CAN HI wires and CAN LO wires.
For our machine, we deactivate all systems and use a multimeter (1) to check the resistance between pins C and D
of our vehicle’s diagnostic connector (2).
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NOTE: The CAN circuit that is being tested must be connected to the diagnostic connector.
RAIL13TR03932FA 2
The resistance across the CAN circuit between CAN HI (3) and CAN LO (4) should be approximately 54 – 66 Ω. A
reading of 54 – 66 Ω indicates that the passive terminators are good and confirms the integrity of the CAN bus circuit.
A reading of 70 – 150 Ω generally indicates that either a passive terminator has failed or there is an open circuit in
either the CAN HI wires or CAN LO wires. You must perform additional testing to isolate the source of the fault.
A reading of infinite resistance indicate that either both passive terminators have failed or there is an open circuit in
both CAN HI wires and CAN LO wires.
A reading of 53 Ω or less indicates poor connections in the circuit.
A reading of very low resistance indicates that the CAN HI wires and CAN LO wires are shorted together. Additional
testing must be completed to determine the location of the short.
Testing the terminators

If a passive terminator is suspected as a source of a CAN bus problem, disconnect the passive terminator from the
CAN bus and test the resistance of passive terminators with a multimeter. Passive terminators should have a resis-
tance of approximately 120 Ω.
NOTE: Some terminators may be an internal part of a controller. Disconnect the controller from the harness before
testing.
Testing the CAN bus voltage

A CAN circuit can be tested by measuring the voltage of the CAN HI wires and CAN LO wires while the system is
activated. This test may provide some indication if the CAN circuit is shorted to high voltage or to ground, but is not
conclusive of CAN system operation. If a fault is suspected, you must complete additional testing to locate the type
and source of the fault.
Use a multimeter to check the voltage between either the CAN HI wires or CAN LO wire and chassis ground.
1. The CAN HI circuit should read approximately 2.5 – 3.5 V.
2. The CAN LO circuit should read approximately 1.5 – 2.5 V.
Testing the CAN bus for shorts to battery voltage

If there is a short from a 12 V source to CAN HI or CAN LO, the controllers cannot send information on the CAN
system.
With the keyswitch on, use a multimeter to check the voltage from the circuit to ground. This needs to be carried out
for both the CAN HI and CAN LO wires. If data line voltage is at battery voltage, data can no longer be transmitted. If
such an error is found on a data line, localize the error by opening the circuit at intermediate connectors and repeating
this test.
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Testing the CAN bus for shorts between the wires

If there is a short between the CAN HI wires and CAN LO wires, the controllers cannot send information on the CAN
bus.
Turn the keyswitch off. Disconnect the terminators from the CAN HI wires and CAN LO wires, so the wires are open.
Use a multimeter to check for continuity between the CAN HI wires and CAN LO wires. If there is continuity, the two
wires are shorted together. If such an error is found, localize the error by opening the circuit at intermediate connectors
and repeating this test.
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Index

Electronic modules - Dynamic description Controller Area Network (CAN) data bus . . . . . . . . . . . . . 3
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Cab controls - 512

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Contents
Cab controls - 512
TECHNICAL DATA
Cab controls
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Electrical systems - Cab controls
Cab controls - General specification

Front instrument panel
LELI12TLB2416GB 1
1. Direction indicator lamp

This lamp turns On when the direction indicators are working.
2. Side light and low beam indicator lamp
This indicator lamp turns On when the side lights or the low beams are On.
3. Main beam indicator lamp
This indicator lamp turns On when the main beams are On.
4. “Four wheel steer” (4WS) steer indicator lamp
This lamp turns On when 4 wheel steer mode is selected and phased.
5. “Road” (4WS) steer indicator lamp
This lamp turns On when 2 wheel steer mode is selected and phased.
6. “Crab” (4WS) steer indicator lamp
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This lamp turns On when crab steer mode is selected and phased.
NOTE: If the three lamps turn On at once, this means there is a problem with the electric circuit. Consult your
Dealer.
7. Tachometer
The tachometer shows travel speed in kilometres per hour (km/h) and miles per hour (mph).
8. Rotating beacon switch
This switch is used to turn the rotating beacon On or Off.
9. Light switch
This switch has three positions:
• The first position is OFF (control lamp Off).
• Second position, by pressing the symbol side (first click) the instrument cluster panel is powered, the side lights
and the low beam indicator lamp are turned on (control lamp On).
• Third position, by pressing the symbol side again (second click), the high beams are enabled and the low beams
and the low beam indicator lamp are turned on (control lamp On).
10. Hazard light switch

Press the control down to locked position. The direction indicators and the control will flash simultaneously. Press
the control down again to turn Off the direction indicators and the indicator lamp.
11. Hand-held auxiliary hydraulic attachment switch (Optional)

This switch has two positions:
• The first position is OFF (control lamp On).
• The second position is ON and enables the auxiliary hydraulic attachments (control lamp Off).
12. Switch
This switch is used to engage or disengage the 4WD function.
• First position (powershuttle) (by pushing button on the right ):
Rear wheel drive and braking on rear wheels for all gears (lamp Off).
• First position (powershift) (by pushing button on the right ):
Rear wheel drive with braking only on rear wheels (only in first and second gear) (lamp Off).
Four wheel drive and braking (in third and fourth gear) (lamp On).
• Second position (by pushing button on the left ):
4 wheel drive and braking on 4 wheels (lamp On).
13. Manual mode selection switch (Powershift transmission)

In situations where manual gearshifting (up or downshift) is required, the automatic gearshift of the powershift
transmission can be overridden by means of this switch.
NOTE: Changing gears up or down must always be done using the powershift transmission lever.
When the manual mode is no longer required, place the
switch back to the OFF position to return to automatic gear
shifting.
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Calibration of speedometer
According to the model and tires fitted, it may be neces-
sary to calibrate the front instrument.
This calibration is required when fitting a new instrument

or if a change of tires takes place, and can be performed
by adjusting the settings of the switch block, mounted be-
hind the console.
LELI12TLB2421AA 2
Each switch numbered from 1 to 8 mounted in the block

should be turned ON = or OFF .
Switch positions:
1 = ON
0 = OFF
LELI12TLB2422AA 3
Tire–rolling circumference Frequency at 50 km/h Switch positions 1-2-3-4-5-6-7-8

4065-4335 2055 1-1-1-1-0-1-0-0
3810-3911 2245 1-1-1-0-1-0-1-0
4065-4335 2310 1-1-1-0-1-1-1-0
3810-3911 2522 1-1-0-0-0-0-0-1

580ST
590ST
MARBLE CUTTING
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Front control panels (580ST - 590ST)
LELI12TLB2417FB 1
1. Switch
• First position (Power-Shuttle), by pushing button on the left rear wheel drive and braking on rear wheels (for
all gears) (lamp Off).
• First position (Powershift), by pushing button on the left rear wheel drive with braking only on rear wheels
(only in first and second gear) (lamp Off);
• Second position (by pushing button on the right 4 wheel drive and braking on 4 wheels (lamp On).
1. Hand-held auxiliary hydraulic attachment switch (optional)

• The first position is “OFF”.
• The second position is “ON” and enables the auxiliary hydraulic attachments.
3. Loader attachment switch (optional)

4. Loader attachment locking switch (optional)
When operated, this switch prevents any movement of the loader attachment during travel.
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6.Roll-over protection switch (optional)
This switch is used to engage or disengage the roll-over protection device. When the operator is about to start working
with the backhoe attachment in conditions which could cause the machine to roll over, he/she must activate the roll-
over protection device by pressing the switch (“ON” position and lamp turned on). In this condition, the audible alarm
will sound by means of the buzzer when the pressure switch, installed on the backhoe attachment boom cylinder,
detects a pressure exceeding the following values:
2WS = 116 bar (1682 psi)
4WS = 126.5 bar (1834.3 psi)
7. “Auto glide ride” switch (optional)
The “auto glide ride” system control improves the machine comfort during travel, regardless of the type of terrain and
with the loader bucket full or empty. It reduces forward and rearward pitching when moving rearwards or forwards and
when carrying loads, at the same time increasing productivity and operator comfort. It also reduces impact forces to
the machine during operation. Do not use this system while operating the loader attachment.
ATTENTION: Never operate the “auto glide ride” system control when the loader arm and loader bucket are main-
taining the front of the machine raised off the ground. The machine could fall and cause serious or fatal injury.
In situations where manual gearshifting (up or downshift) is required, the automatic gearshift of the Powershift trans-
mission can be overridden by means of this switch.
NOTE: Changing gears up or down must always be done using the Powershift transmission lever.
When the manual mode is no longer required, place the switch back to the “OFF” position to return to automatic
gearshifting.
9. Horn button
This button operates the warning horn.
Press the control down to locked position. The direction indicators and the control will flash simultaneously.
Press the control down again to turn off the direction indicators and the lamp.

MARBLE CUTTING
DRIVE (2WD)
DRIVE (4WD)
695ST
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Front control panels (695ST)
LELI12TLB2425FB 1
1. Switch
• First position (Power-Shuttle), by pushing button on the left

rear wheel drive and braking on rear wheels (for all gears) (lamp Off).
• First position (Powershift), by pushing button on the left

Rear wheel drive and braking on rear wheels (for all gears) (lamp Off).
• First position (Powershift), by pushing button on the left
Rear wheel drive with braking only on rear wheels (only in first and second gear) (lamp Off);
• Second position (by pushing button on the right

4 wheel drive and braking on 4 wheels (lamp On).
2. Hand-held auxiliary hydraulic attachment switch (optional)
• The first position is “Off”.
• The second position is “On” and enables the auxiliary hydraulic attachments.
3. Loader attachment locking switch (optional)
When operated, this switch prevents any movement of the loader attachment during travel.
4. Steer mode switch
This switch has a locking cover and is used to select “Road”, “4 wheel steer” or “Crab steer”. This switch
has three positions:
• Position (a) = Road
• Position (b) = 4 wheel steer
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• Position (c) = Crab steer

NOTICE: Before undertaking any road travel, select “Road” mode and fold back the cover to lock the switch in
this position.
6. Roll-over protection switch (optional)
This switch is used to engage or disengage the roll-over protection device. When the operator is about to start
working with the backhoe attachment in conditions which could cause the machine to roll over, he/she must acti-
vate the roll-over protection device by pressing the switch (“On” position and lamp turned On).
In this condition, the audible alarm will sound by means of the buzzer when the pressure switch, installed on the
backhoe attachment boom cylinder, detects a pressure exceeding the following values:
2WS= 116 bar (1682 psi)
4WS = 126.5 bar (1834 psi)
7. “Auto glide ride” switch (optional)
The “auto glide ride” system control improves the machine comfort during travel, regardless of the type of terrain
and with the loader bucket full or empty.
It reduces forward and rearward pitching when moving rearwards or forwards and when carrying loads, at the
same time increasing productivity and operator comfort.
It also reduces impact forces to the machine during operation.
Do not use this system while operating the loader attachment.
NOTE: Never operate the “auto glide ride” system control when the loader arm and loader bucket are maintaining
the front of the machine raised off the ground. The machine could fall and cause serious or fatal injury.
In situations where manual gearshifting (up or downshift) is required, the automatic gearshift of the Powershift
transmission can be overridden by means of this switch.
NOTE: Changing gears up or down must always be done using the Powershift transmission lever.
When the manual mode is no longer required, place the switch back to the “Off” position to return to automatic
gearshifting.
9. Horn button
This button operates the warning horn.
Press the control down to locked position. The direction indicators and the control will flash simultaneously.
Press the control down again to turn Off the direction indicators and the lamp.
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Index
Cab controls - 512

Cab controls - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Cab controls - General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Cab controls - General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
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Telematics - 991

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Contents
Telematics - 991
FUNCTIONAL DATA
Telematics
Overview with Case SiteWatch™ (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SERVICE
Telematics
Replace (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
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Electrical systems - Telematics
Telematics - Overview with Case SiteWatch™

580ST
590ST
695ST
NOTE: The CASE CONSTRUCTION SiteWatch™ website (www.casesitewatch.com) will not be accessible until the
CASE CONSTRUCTION SiteWatch™ subscription for this machine is registered.
This machine may be equipped with a Telematics system. This is an asset-monitoring system that combines Inter-
net, cellular, and GPS technologies. A transponder unit is mounted on the equipment that wirelessly communicates
with the user interface CASE CONSTRUCTION SiteWatch™ at www.casesitwatch.com. Using cellular technology,
the transponder can send equipment data, including location, on/off status, usage and production metrics, diagnostic
data, movement alarms, unauthorized usage and monitor machine maintenance to the user interface CASE CON-
STRUCTION SiteWatch™. The system will help cut costs and keep accurate records.
The Light Emitting Diode (LED) display panel is the con-
troller’s minimum interface used to display and control
data input and output.
LED display showing normal operation with the ignition

key in the ON position:
• (1A) Phone or connectivity — RED (steady)
• (1B) CAN traffic — RED (blinking)
• (1C) GPS — RED (steady)
• (1D) Power — GREEN (steady)
RAIL12GEN0174AA 1
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Additional Information on the LED display

(1A) The GSM/GPRS LED (Red) displays the
GSM/GPRS status:
• Off — No GSM or GPRS coverage or the device is in
“stand-by” mode.
• Slowly Blinking — GSM coverage only. The system can
receive SMS, but the connection with the website is not
available.
• Blinking Fast — GPRS coverage, but the website con-
nection is not available for any reason.
• On — GPRS coverage and server connection. RAIL12GEN0174AA 2
(1B) The CAN LED (Red) displays the CAN status:

• Off — The CAN is not available or the device is in
• Blinking — CAN messages on the BUS.
(1C) The GPS LED (red) displays the GPS status:

• Off — Before the GPS initialization or the device is in
• Blinking — Searching for GPS signal.
• On — GPS fix 2D or 3D.
(1D) The Power LED (Green) displays the power status:

• Off — No power supply
• Blinking — Downloading files or firmware from the
server or waiting for the application firmware.
• On — Power supply and standard work or the device is
in “stand-by” mode.
• Green (fixed) — indicates that power supply is on.
Special LED Configuration

NOTE: Four LEDs ON indicates both the loader and the
firmware are not presently on board. The board is waiting
for the download of the loader.
NOTE: Power LED (Green) ON and the three Red LEDs
blinking indicate problems with the GPRS modem (no SIM
or modem initialization failed).
Troubleshooting
Condition Solution
No Power Check the fuse.
If no power light is on, check power (both constant power
and switched power must be correct and functioning
between 9 – 32 V).
Make sure that grounding is solid (when in doubt, use a
solid chassis ground).
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Condition Solution
GPRS is NOT Solid Red Antenna is installed incorrectly or placed in a poor
reception area (For example, under a metal hood or
headliner). You should be able to see the antenna from
the sky.
Power net work coverage area.
Antenna is defective (replace antenna).
GPRS antenna connector failure (test with ohmmeter).
GPS is NOT Solid Red Current GPS coverage is poor (no Satellite coverage).
Antenna is defective (replace antenna).
Antenna is installed incorrectly or placed in a poor
reception area (For example, under a metal hood or
headliner). You should be able to see the antenna from
the sky.
GPS antenna connector failure (test with ohmmeter).
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Telematics - Replace
580ST
DRIVE (4WD)
MARBLE CUTTING
NOTE: If your machine is equipped with a Telematics system, your machine will have two additional 5 A fuse locations.
1. The first in-line fuse location.

A. Remove the side instrument cluster panel.
B. Locate the 5 A fuse in the harness.
C. Remove the fuse cover (1).
D. Check the 5 A fuse and replace if necessary.
RAIL13TLB0209BA 1
2. The second in-line fuse location.

A. Remove the battery cover plate.
B. Locate the 5 A fuse in the harness.
C. Remove the fuse cover (1).
D. Check the 5 A fuse and replace if necessary.
RAIL13TLB0099BA 2
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Index
Telematics - 991
Telematics - Overview with Case SiteWatch™ (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Telematics - Replace (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
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FAULT CODES - DTC

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Contents
FAULT CODES - DTC
DIAGNOSTIC
1001 - Engine Air Filter Blocked . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

1002 - Engine coolant temperature too high, critical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1003 - Air conditioning pressure too high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
1009 - Transmission oil temperature too high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
1010 - Foot throttle signal out of range, IVS not changing state in 300 ms . . . . . . . . . . . . . . . . . . . . . . . . . 22
1011 - Foot throttle signal out of range, throttle above 95% of input for 5 seconds . . . . . . . . . . . . . . . . . . 25
1012 - Foot throttle signal out of range, throttle below 5% of input for 5 seconds . . . . . . . . . . . . . . . . . . . 28
1013 - Foot throttle signal out of range, signal unusable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
1014 - Battery charge voltage too high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
1015 - Battery charge voltage too low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
1018 - Boost air temperature too high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
1019 - Engine coolant temperature too high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
1020 - Transmission oil temperature above normal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
1021 - Fuel temperature above normal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
1022 - Water in fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
1023 - Foot throttle supply voltage too high, over 5.2 volts for 5 seconds . . . . . . . . . . . . . . . . . . . . . . . . . 43
1024 - Foot throttle supply voltage too low, under 4.8 volts for 5 seconds . . . . . . . . . . . . . . . . . . . . . . . . . 45
1025 - Foot throttle sensor voltage over 5.3 volts for 5 seconds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
1026 - Foot throttle sensor voltage under 200 mV for 5 seconds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
1032 - Hand throttle supply voltage too low, under 4.8 volts for 5 seconds . . . . . . . . . . . . . . . . . . . . . . . . 53
1033 - Hand throttle sensor voltage over 5.3 volts for 5 seconds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
1034 - Hand throttle sensor voltage under 200 mV for 5 seconds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
1035 - Hand throttle sensor signal above 95% of input for 5 seconds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
1036 - Hand throttle sensor signal below 5% of input for 5 seconds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
1037 - Hand throttle sensor out of range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
1039 - Hand throttle sensor voltage under 200 mV for 5 seconds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
1040 - Engine overspeed warning, Engine speed greater than 2750 RPM for 5 seconds . . . . . . . . . . . . 72
1041 - Engine overspeed fault, Engine speed greater than 3000 RPM for 5 seconds . . . . . . . . . . . . . . . 73
1044 - Fuel level sensor below 2.0 ohm for 5 seconds, shorted low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
1045 - Fuel level sensor open circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
1047 - Transmission Temperature Sensor is Shorted Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
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1050 - Alternator L+ terminal under 1.5 volts for 5 seconds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
1051 - Timeout of CAN message EEC1, 5 seconds without message . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
1052 - Timeout of CAN message EEC3, 5 seconds without message . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
1053 - Timeout of CAN message CNFBAM, 25 seconds without message . . . . . . . . . . . . . . . . . . . . . . . . 87
1054 - Timeout of CAN message engine temperature, 5 seconds without message . . . . . . . . . . . . . . . . 88
1055 - Timeout of CAN message inlet/exhaust, 5 seconds without message . . . . . . . . . . . . . . . . . . . . . . 89
1056 - Timeout of CAN message DPFC1, 5 seconds without message . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
1057 - Timeout of CAN message vehicle electrical, 5 seconds without message . . . . . . . . . . . . . . . . . . . 91
1058 - Timeout of CAN message EDC2BC, 5 seconds without message . . . . . . . . . . . . . . . . . . . . . . . . . 92
1059 - Timeout of CAN message DM1, 5 seconds without message . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
1060 - Timeout Of CAN Message EGRIND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
1090 - Vehicle Model ID in VCM is UNCONFIGURED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
3007 (DTC 1113) - Engine coolant temperature sensor voltage is higher than expected . . . . . . . . . . . . . 97
3008 (DTC 2213) - Engine coolant temperature sensor voltage is lower than expected . . . . . . . . . . . . 100
3010 (DTC 2474) - Intake manifold temperature sensor voltage is lower than expected . . . . . . . . . . . . 102
3015 (DTC 1C15) - Fuel temperature sensor voltage is higher than expected . . . . . . . . . . . . . . . . . . . . 104
3016 (DTC 2D15) - Fuel temperature sensor voltage is lower than expected . . . . . . . . . . . . . . . . . . . . . 107
3019 (DTC 1D64) - Intake manifold pressure sensor voltage is higher than expected . . . . . . . . . . . . . . 109
3024 (DTC 13C4) - ECU internal failure - Ambient pressure sensor voltage is higher than expected . 112
3025 (DTC 24C4) - ECU internal failure - Ambient pressure sensor voltage is lower than expected . . 113
3027 (DTC 34D3) - Defect fault check for plausibility from digital sensor . . . . . . . . . . . . . . . . . . . . . . . . . 114
3028 (DTC 26D3) - Oil pressure is too low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
3037 (DTC 2E64) - Intake manifold pressure sensor voltage is lower than expected . . . . . . . . . . . . . . . 118
3051 (DTC 1161) - Battery voltage is higher than expected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
3052 (DTC 2261) - Battery voltage is lower than expected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
3059 (DTC 4661) - Main relay stuck error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
3063 (DTC 6226) - Short circuit error of injector in cylinder 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
3088 (DTC 4512) - Crankshaft speed sensor values are not plausible . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
3089 (DTC 4412) - Crankshaft speed sensor pattern is not plausible . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
3090 (DTC 4212) - Camshaft speed sensor values are not plausible . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
3091 (DTC 4112) - Camshaft speed sensor pattern is not plausible . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
3093 (DTC 3312) - Compared camshaft and crankshaft speed sensor values are not plausible . . . . . 149
3096 (DTC 951B) - CAN A Bus off failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
3097 (DTC 961B) - CAN B Bus off failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
3102 (DTC 2525) - Fuel rail pressure sensor voltage is lower than expected . . . . . . . . . . . . . . . . . . . . . 154
3104 (DTC F445) - Fuel pressure relief valve is open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
3105 (DTC F245) - Fuel pressure relief valve is forced to open, perform pressure increase . . . . . . . . 157
3106 (DTC 1145) - Fuel pressure relief valve reached maximum allowed opening count . . . . . . . . . . . 158
3107 (DTC 6655) - Fuel metering unit is shorted to battery voltage at the low side . . . . . . . . . . . . . . . . 159
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3108 (DTC 7755) - Fuel metering unit is shorted to ground at the low side . . . . . . . . . . . . . . . . . . . . . . . 161
3112 (DTC 1425) - Fuel rail pressure sensor voltage is higher than expected . . . . . . . . . . . . . . . . . . . . . 163
3137 (DTC 5255) - Fuel metering unit has an open load error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
3141 (DTC 4465) - Fuel pump pressure has exceeded desired pressure limits . . . . . . . . . . . . . . . . . . . 168
3146 (DTC 4415) - Water in fuel detected or water in fuel circuit failure . . . . . . . . . . . . . . . . . . . . . . . . . . 169
3170 (DTC 38CB) - NH3 sensor signal is not changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
3173 (DTC F623) - Engine coolant temperature has exceeded the warning threshold . . . . . . . . . . . . . 172
3176 (DTC 3B65) - High pressure pump fuel delivery quantity in over run exceeds a maximum threshold
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
3177 (DTC F1A2) - Engine over speed condition detected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
3179 (DTC 956B) - CAN communication failure between vehicle controller and ECU - BC2ECU2 message
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
3180 (DTC 9B7B) - CAN communication error between vehicle controller to ECU . . . . . . . . . . . . . . . . . 177
3188 (DTC 5316) - Open load error of injector in cylinder 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
3210 (DTC 7116) - Injection bank 1 short circuit failure (all injectors of the same bank can be affected) 187
3218 (DTC 7216) - Injection bank 2 short circuit failure (all injectors of the same bank can be affected) 189
3235 (DTC F936) - Exceeded the number of injections for a given engine speed . . . . . . . . . . . . . . . . . 191
3236 (DTC F836) - Number of injections is limited by system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
3237 (DTC 1636) - Number of desired injections exceeds threshold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
3245 (DTC E51D) - ECU internal failure - Query/response communication errors . . . . . . . . . . . . . . . . . 195
3252 (DTC E61D) - ECU internal failure - SPI communication error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
3253 (DTC E41D) - ECU internal failure - Voltage ratio in ADC monitoring . . . . . . . . . . . . . . . . . . . . . . . 197
3255 (DTC E31D) - ECU internal failure - ADC test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
3256 (DTC E21D) - ECU internal failure - NTP error in ADC monitoring . . . . . . . . . . . . . . . . . . . . . . . . . 199
3258 (DTC 6722) - Starter relay high side driver circuit short to battery failure . . . . . . . . . . . . . . . . . . . . 200
3259 (DTC 7822) - Starter relay high side driver circuit short to ground failure . . . . . . . . . . . . . . . . . . . . 202
3260 (DTC 5922) - Starter relay low side driver circuit open failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
3261 (DTC 6B22) - Starter relay low side driver circuit short to battery failure . . . . . . . . . . . . . . . . . . . . . 206
3262 (DTC 7C22) - Starter relay low side driver circuit short to ground failure . . . . . . . . . . . . . . . . . . . . 208
3265 (DTC E4DD) - Fuel injection requested during overrun . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
3283 (DTC E32D) - ECU internal failure - Sensor 5 volt supply 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
3285 (DTC E42D) - ECU internal failure - Sensor 5 volt supply 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
3293 (DTC 2265) - Fuel rail pressure has exceeded maximum positive deviation limits . . . . . . . . . . . . 215
3301 (DTC 1565) - Fuel rail pressure has exceeded maximum negative deviation limits . . . . . . . . . . . 216
3305 (DTC 2765) - Fuel rail pressure has exceeded minimum limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
3309 (DTC 1865) - Fuel rail pressure has exceeded maximum limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
3334 (DTC 98BB) - CAN communication failure between vehicle controller and ECU controller - TSC1_PE
message . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
3338 (DTC 91CB) - CAN communication failure between vehicle controller and ECU controller - TSC1_VE
message . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221
3339 - Timeout of CAN Message TSC1 Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223
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3358 (DTC 962B) - CAN transmit error - EEC1 message (Electronic Engine Control 1 message - Torque,
accelerator pedal, engine speed, and other signals) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227
3361 (DTC E16D) - ECU internal failure - EEPROM write/read error . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229
3368 (DTC F6EF) - Torque limitation caused by performance limiter . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230
3369 (DTC F8EF) - Torque limitation caused by smoke limitation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231
3370 (DTC F2EF) - Strong torque limitation from engine protection active . . . . . . . . . . . . . . . . . . . . . . . 232
3371 (DTC F3EF) - Strong torque limitation from injection system active . . . . . . . . . . . . . . . . . . . . . . . . . 233
3403 (DTC 8A22) - Starter relay low side ECU driver circuit over temperature failure . . . . . . . . . . . . . . 234
3409 (DTC 23D3) - Defect fault check for minimum oil pressure from digital sensor . . . . . . . . . . . . . . . 236
3425 (DTC 1438) - Turbocharger boost pressure is higher than expected . . . . . . . . . . . . . . . . . . . . . . . . 239
3436 (DTC FBBF) - Inducement system is locked due to 3 detections in 40 hours. The system must be
reset using the dealer service tool screen "Engine Restart Counter Reset" . . . . . . . . . . . . . . . . . . . . . . . 240
3449 (DTC E812) - ECU internal failure - Calculated engine speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241
3457 (DTC 1374) - Intake manifold temperature sensor voltage is higher than expected . . . . . . . . . . . 242
3461 (DTC E69D) - ECU internal failure - Timeout in the shut off path test error . . . . . . . . . . . . . . . . . . 245
3462 (DTC E79D) - ECU internal failure - Overvoltage monitoring error . . . . . . . . . . . . . . . . . . . . . . . . . . 246
3501 (DTC ED1D) - ECU internal failure - Software resets in DSM 0 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247
3502 (DTC EE1D) - ECU internal failure - Software resets in DSM 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248
3503 (DTC EF1D) - ECU internal failure - Software resets in DSM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249
3507 (DTC 4761) - Engine cranked for too long or keyswitch failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250
3508 (DTC FAEF) - Torque limitation active . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 252
3517 (DTC 19C4) - Ambient temperature sensor voltage is higher than expected . . . . . . . . . . . . . . . . . 253
3518 (DTC 2AC4) - Ambient temperature sensor voltage is lower than expected . . . . . . . . . . . . . . . . . 255
3525 (DTC E18E) - Downstream NOx sensor internal failure (open circuit error) . . . . . . . . . . . . . . . . . . 257
3526 (DTC E28E) - Downstream NOx sensor internal failure (short circuit error) . . . . . . . . . . . . . . . . . . 259
3528 (DTC 319E) - Downstream NOx sensor values are not plausible . . . . . . . . . . . . . . . . . . . . . . . . . . . 261
3529 (DTC E16E) - Downstream NOx sensor internal failure (heater open circuit error) . . . . . . . . . . . . 262
3530 (DTC E26E) - Downstream NOx sensor internal failure (heater short circuit error) . . . . . . . . . . . . 264
3531 (DTC A36E) - Downstream NOx sensor internal failure (heater performance plausibility error) . 266
3533 (DTC 9D6E) - CAN timeout error from downstream NOx sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . 268
3581 (DTC FD8F) - Torque limitation is active . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270
3616 (DTC F1EF) - Torque limitation caused by turbo charger protection . . . . . . . . . . . . . . . . . . . . . . . . 271
3623 (DTC 3CAE) - Downstream NOx sensor lambda signal deviation - NOx sensor possible removal
detected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272
3652 (DTC 911B) - CAN A Bus off passive failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274
3680 (DTC E536) - Engine speed limitation via fuel injection cut off is active . . . . . . . . . . . . . . . . . . . . . 276
3703 (DTC 2B36) - The minimum rail pressure value necessary to allow fuel injection has not been reached
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277
3735 (DTC 8355) - Fuel metering unit has an over temperature error . . . . . . . . . . . . . . . . . . . . . . . . . . . . 278
3738 (DTC E71D) - ECU internal failure - ROM error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280
3739 (DTC E13D) - ECU internal failure - Loss of synchronization to MM from CPU . . . . . . . . . . . . . . . 281
3740 (DTC E23D) - ECU internal failure - ECU shutdown test failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282
3741 (DTC E33D) - ECU internal failure - Wrong set response time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 283
3742 (DTC E43D) - ECU internal failure - SPI errors during MoCSOP execution . . . . . . . . . . . . . . . . . . 284
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3743 (DTC E53D) - ECU internal failure - Undervoltage monitoring error . . . . . . . . . . . . . . . . . . . . . . . . 285
3745 (DTC E63D) - ECU internal failure - WDA is not working correctly . . . . . . . . . . . . . . . . . . . . . . . . . 286
3746 (DTC E73D) - ECU internal failure - Alarm task period error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 287
3747 (DTC E83D) - ECU internal failure - Positive test failed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 288
3749 (DTC E5B1) - ECU internal failure - Accelerator pedal position sensor . . . . . . . . . . . . . . . . . . . . . . 289
3750 (DTC EC36) - ECU internal failure - Fuel injection energizing time not plausible . . . . . . . . . . . . . 290
3751 (DTC ED36) - ECU internal failure - Fuel injection energizing phase is not plausible . . . . . . . . . . 291
3752 (DTC EE36) - Fuel injection correction has exceeded a minimum limit . . . . . . . . . . . . . . . . . . . . . . 292
3753 (DTC E5DD) - ECU internal failure - Injection quality correction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 293
3754 (DTC E6DD) - ECU internal failure - Rail pressure plausibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 294
3755 (DTC E7DD) - ECU internal failure - Torque request comparison . . . . . . . . . . . . . . . . . . . . . . . . . . 295
3756 (DTC E1DD) - ECU internal failure - Post injection quality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 296
3757 (DTC E2DD) - ECU internal failure - Post injection shut off failure . . . . . . . . . . . . . . . . . . . . . . . . . . 297
3759 (DTC E8DD) - ECU internal failure - Torque request due to fuel pressure exceeds maximum torque
limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 298
3760 (DTC E9DD) - ECU internal failure - Torque request due to air control exceeds maximum torque limit
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 299
3761 (DTC EADD) - ECU internal failure - Torque request exceeds maximum torque limit . . . . . . . . . . 300
3764 (DTC F561) - ECU after run power interruption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301
3767 (DTC E81D) - ECU internal failure - 'WDA active' reported due to errors in query/response commu-
nication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 304
3768 (DTC E91D) - ECU internal failure - 'ABE active' reported due to undervoltage detection . . . . . . 305
3769 (DTC EA1D) - ECU internal failure - 'ABE active' report due to overvoltage detection . . . . . . . . . 306
3770 (DTC EB1D) - ECU internal failure - 'WDA/ABE active' reported . . . . . . . . . . . . . . . . . . . . . . . . . . . 307
3773 (DTC 2838) - Turbocharger boost pressure is lower than expected . . . . . . . . . . . . . . . . . . . . . . . . . 308
3794 (DTC 3B64) - Plausibility check for air pressure at the upstream of intake valve sensor . . . . . . . 309
3795 (DTC 3C64) - Plausibility check for air pressure at the upstream of intake valve sensor . . . . . . . 310
3799 (DTC F345) - Fuel pressure relief valve is forced to open, perform pressure shock . . . . . . . . . . . 311
3838 (DTC 2999) - Upstream oxidation catalyst temperature sensor voltage is lower than expected . 312
3906 (DTC 4736) - Number of injections is limited by quantity balance of high pressure pump . . . . . . 314
3910 (DTC 4155) - Fuel metering unit intermittent electrical connection failure . . . . . . . . . . . . . . . . . . . . 315
3915 (DTC 3645) - Averaged rail pressure is outside the expected tolerance range . . . . . . . . . . . . . . . 317
3916 (DTC 1745) - Fuel pressure relief valve has reached maximum allowed open time . . . . . . . . . . . 318
3959 (DTC 17A4) - Intake throttle valve position is higher than expected . . . . . . . . . . . . . . . . . . . . . . . . 319
3960 (DTC 28A4) - Intake throttle valve position is lower than expected . . . . . . . . . . . . . . . . . . . . . . . . . 321
3961 (DTC ED2D) - CAN communication failure - External torque/speed checksum and counter . . . . 323
3985 (DTC 1758) - Exhaust gas pressure sensor voltage is higher than expected . . . . . . . . . . . . . . . . . 325
3986 (DTC 2858) - Exhaust gas pressure sensor voltage is lower than expected . . . . . . . . . . . . . . . . . 327
3998 - Unknown error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 329
3999 - Unknown error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 331
4029 - Shifter Lever improperly connected, no power to pin 16, pin 18, or pin 46 for more than 3 seconds
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 333
4030 - Shifter Lever malfunction: transmission in neutral receives forward and neutral together . . . . . 336
4031 - Shifter Lever malfunction: transmission in neutral receives reverse and neutral together . . . . . 339
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4032 - Shifter Lever malfunction: transmission in forward receives forward and reverse together . . . . 342
4033 - Shifter Lever malfunction: transmission in reverse receives forward and reverse together . . . . 345
4034 - Shifter Lever malfunction: transmission in forward receives neutral and forward together . . . . 348
4035 - Shifter Lever malfunction: transmission in reverse receives neutral and reverse together . . . . 351
4036 - During transition from second to third gear, and Gear CMD_01 signal erratic or incorrect . . . . 354
4037 - During transition from first to second gear, and Gear CMD_02 signal erratic or incorrect . . . . . 357
4038 - During transition from third to fourth gear, and Gear CMD_02 signal erratic or incorrect . . . . . 360
9001 - Hour meter plausibility, internal error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 363
9002 - Hour meter RAM checksum failure, internal error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 364
9003 - J1939 receive buffer overflow, internal error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 365
9004 - EEPROM checksum failure, hour meter location 1, internal error . . . . . . . . . . . . . . . . . . . . . . . . . 366
9007 - Abnormal reset watchdog time-out, internal error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 369
9008 - A/D fault foot throttle, internal error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 370
9009 - A/D fault foot throttle power, internal error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 371
9010 - A/D fault hand throttle, internal error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 372
9011 - A/D fault foot throttle, internal error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 373
9012 - A/D fault, internal error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 374
9013 - Cluster Type Checksum Error: Location 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 375
17195 (DTC 921B) - CAN B Bus off passive failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 378
17297 (DTC 3167) - EGR valve will not close during after run . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 380
17301 (DTC 1567) - EGR valve will not open to commanded position . . . . . . . . . . . . . . . . . . . . . . . . . . . 381
17302 (DTC 2667) - EGR valve will not close to commanded position . . . . . . . . . . . . . . . . . . . . . . . . . . . 382
17303 (DTC 5767) - EGR valve control circuit open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 383
17305 (DTC 8967) - EGR valve control circuit over current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 385
17306 (DTC 6A67) - EGR valve control circuit high side shorted to battery . . . . . . . . . . . . . . . . . . . . . . . 387
17307 (DTC 6B67) - EGR valve control circuit low side shorted to battery . . . . . . . . . . . . . . . . . . . . . . . . 389
17308 (DTC 7C67) - EGR valve control circuit high side shorted to ground . . . . . . . . . . . . . . . . . . . . . . . 391
17309 (DTC 7D67) - EGR valve control circuit low side shorted to ground . . . . . . . . . . . . . . . . . . . . . . . 393
17310 (DTC 1E67) - EGR valve control circuit over load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 395
17322 (DTC 1B97) - EGR valve position sensor voltage is higher than expected . . . . . . . . . . . . . . . . . . 398
17323 (DTC 2C97) - EGR valve position sensor voltage is lower than expected . . . . . . . . . . . . . . . . . . 400
17337 (DTC 9E8C) - Hydrocarbon level 2 exceeded . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 402
17345 (DTC 4652) - DFC for faulty diagnostic data transmission or protocol error . . . . . . . . . . . . . . . . . 403
17347 (DTC 5852) - No load error for Low Voltage System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405
17348 (DTC 8952) - Over temperature error on ECU powerstage for Glow plug Low Voltage System 407
17349 (DTC 6A52) - Short circuit to battery error for Low Voltage System . . . . . . . . . . . . . . . . . . . . . . . . 409
17350 (DTC 7B52) - Short circuit to ground error for Low Voltage System . . . . . . . . . . . . . . . . . . . . . . . 411
17359 (DTC 7562) - Glow plug 1 control circuit shorted to ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 413
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17377 (DTC 21A6) - MI1 injection quantity is low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 421
17378 (DTC 22A6) - MI1 energizing time is low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 422
17379 (DTC 43A6) - Measured injection closing time exceeds a limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 423
17383 (DTC F976) - IMA type mismatch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 427
17384 (DTC FA76) - IMA type mismatch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 428
17385 (DTC FB76) - IMA type mismatch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 429
17386 (DTC FC76) - IMA type mismatch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 430
17387 (DTC E196) - Chip error in the Injector CY33x power stage component . . . . . . . . . . . . . . . . . . . 431
17403 (DTC 31B6) - Reporting Error if Relay is stuck at closed position . . . . . . . . . . . . . . . . . . . . . . . . . 432
17404 (DTC 32B6) - Reporting Error if Relay is stuck at open position . . . . . . . . . . . . . . . . . . . . . . . . . . . 434
17405 (DTC 1E4A) - DFC used to evaluate filter clog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 436
17409 (DTC 53B6) - Reporting the leakage in the system during no dosing . . . . . . . . . . . . . . . . . . . . . . 437
17410 (DTC 3F9A) - Error in dosing valve plausibility at low voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . 438
17411 (DTC FEBA) - Defective pressure reduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 440
17412 (DTC 14B6) - High threshold for pressure sensor plausibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 441
17413 (DTC 25B6) - Low threshold for pressure sensor plausibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 442
17414 (DTC 56B6) - DEF/AdBlue Supply module supply voltage control relay circuit open . . . . . . . . . 443
17415 (DTC 87B6) - DEF/AdBlue Supply module supply voltage control relay short circuit . . . . . . . . . 445
17416 (DTC 68B6) - DEF/AdBlue Supply module supply voltage control relay short circuit to battery 447
17417 (DTC 79B6) - DEF/AdBlue Supply module supply voltage control relay short circuit to ground 449
17420 (DTC 1BB6) - SRC high for Urea Pump Module Pressure Sensor . . . . . . . . . . . . . . . . . . . . . . . . 450
17421 (DTC 2CB6) - SRC low for Urea Pump Module Pressure Sensor . . . . . . . . . . . . . . . . . . . . . . . . . 452
17422 (DTC EA2D) - Timer error of ECU off time counter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 453
17427 (DTC 1634) - SRC high for air temperature sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 454
17428 (DTC 2734) - SRC low for air temperature sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 456
17429 (DTC F542) - DFC is set if the cold start is detected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 458
17442 (DTC 1EA4) - Permanent governor deviation for valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 459
17443 (DTC 2FA4) - Permanent governor deviation for valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 460
17444 (DTC 3DB4) - Open load error for powerstage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 461
17446 (DTC 8FB4) - Over temperature error for H-bridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 463
17447 (DTC 61E4) - Short circuit to battery on Out1 error for H-bridge . . . . . . . . . . . . . . . . . . . . . . . . . . 465
17448 (DTC 62E4) - Short circuit to battery on Out2 error for H-bridge . . . . . . . . . . . . . . . . . . . . . . . . . . 467
17449 (DTC 73E4) - Short circuit to ground on Out1 error for H-bridge . . . . . . . . . . . . . . . . . . . . . . . . . . 469
17450 (DTC 74E4) - Short circuit to ground on Out2 error for H-bridge . . . . . . . . . . . . . . . . . . . . . . . . . . 471
17451 (DTC 15E4) - Short circuit over load error for H-bridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 473
17453 (DTC 27E4) - Under voltage error for H-bridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 475
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17465 (DTC 5DB6) - Open Load error in powerstage of Urea dosing valve actuator . . . . . . . . . . . . . . . 476
17466 (DTC 6EB6) - Short circuit to battery error in powerstage of Urea dosing valve actuator . . . . . 478
17467 (DTC 6FB6) - Short circuit to battery error in highside powerstage of Urea dosing valve actuator
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 480
17468 (DTC 71C6) - Short circuit to ground error in lowside powerstage of Urea dosing valve actuator 482
17469 (DTC 72C6) - Short circuit to ground error in highside powerstage of Urea dosing valve actuator
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 484
17470 (DTC E3C6) - FET error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 486
17476 (DTC 49C6) - Diagnostic Fault Check for Supply Module temperature Duty cycle in failure range
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 487
17477 (DTC 1AC6) - Diagnostic Fault Check for Supply Module temperature Duty cycle in failure range
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 490
17478 (DTC 2BC6) - Diagnostic Fault Check for Supply Module temperature Duty cycle in failure range
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 492
17479 (DTC 1CC6) - Diagnostic Fault Check for Supply Module temperature Duty cycle in failure range
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 494
17480 (DTC 2DC6) - Diagnostic Fault Check for Supply Module temperature Duty cycle in failure range
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 496
17481 (DTC 1EC6) - Diagnostic Fault Check for Supply Module temperature Duty cycle in failure range
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 498
17482 (DTC 2FC6) - Diagnostic Fault Check for Supply Module temperature Duty cycle in failure range
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 500
17483 (DTC 11D6) - Diagnostic Fault Check for Supply Module temperature Duty cycle in failure range
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 502
17484 (DTC 22D6) - Diagnostic Fault Check for Supply Module temperature Duty cycle in failure range
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 504
17485 (DTC 53D6) - No load error on low powerstage for Urea back flow pump . . . . . . . . . . . . . . . . . . 506
17486 (DTC 84D6) - Over temperature error on low powerstage for Urea back flow pump . . . . . . . . . 507
17487 (DTC 65D6) - Short circuit to battery error on low powerstage for Urea back flow pump . . . . . . 509
17488 (DTC 76D6) - Short circuit to ground error on low powerstage for Urea back flow pump . . . . . 511
17494 (DTC 624E) - Short circuit to Battery (reported via CAN frame ComRx_CRI1) . . . . . . . . . . . . . . 512
17495 (DTC 734E) - Short circuit to Ground (reported via CAN Frame ComRx_CRI1) . . . . . . . . . . . . . 513
17498 (DTC 464E) - Sensor internal fault (via CAN Frame ComRx_CRI1) . . . . . . . . . . . . . . . . . . . . . . . 514
17500 (DTC 684E) - Short to Battery of the temperature sensor located in the Urea Quality sensor (re-
ported via CAN Frame ComRx_CRI1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 515
17501 (DTC 794E) - Short to Ground of the temperature sensor located in the Urea Quality sensor (re-
ported via CAN Frame ComRx_CRI1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 516
17504 (DTC 4C4E) - Signal fault of the temperature sensor located in the Urea Quality sensor (reported
via CAN Frame ComRx_CRI1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 517
17524 (DTC 31E9) - Hydrocarbon level 1 exceeded . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 518
17525 (DTC 3E27) - EGR OBD Monitoring error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 519
19001 (DTC 1361) - Battery voltage is higher than expected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 520
19002 (DTC 2461) - Battery voltage is lower than expected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 521
19008 (DTC E7DE) - NH3 sensor open or short in ground circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 523
19009 (DTC 18DE) - NH3 sensor short in heater circuit causing overheating . . . . . . . . . . . . . . . . . . . . . 524
19010 (DTC 161A) - Downstream SCR catalyst temperature sensor voltage is higher than expected 526
19011 (DTC 271A) - Downstream SCR catalyst temperature sensor voltage is lower than expected . 528
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19012 (DTC E9DE) - NH3 sensor open in heater circuit causing underheating . . . . . . . . . . . . . . . . . . . 530
19013 (DTC EADE) - NH3 sensor open or short in temperature cell circuit . . . . . . . . . . . . . . . . . . . . . . . 532
19014 (DTC EBDE) - NH3 sensor open or short in trim resistor circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . 533
19015 (DTC 4CDE) - NH3 sensor heater control failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 535
19016 (DTC 37EE) - NH3 sensor heater performance failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 536
19017 (DTC 38EE) - NH3 sensor signal out of range failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 538
19018 (DTC 4DDE) - NH3 sensor power supply failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 539
19019 (DTC 1A1A) - Upstream SCR catalyst temperature sensor voltage is higher than expected . . 541
19020 (DTC 2B1A) - Upstream SCR catalyst temperature sensor voltage is lower than expected . . . 543
19023 (DTC 4EDE) - NH3 sensor controller failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 545
19024 (DTC 92EE) - CAN timeout error from NH3 sensor - NH3Sens message . . . . . . . . . . . . . . . . . . 546
19036 (DTC 3F1C) - SCR downstream temperature sensor signal drift at cold start . . . . . . . . . . . . . . . 548
19040 (DTC 352C) - Upstream SCR temperature sensor comparison to a calculated temperature value
failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 550
19041 (DTC 362C) - Downstream SCR temperature sensor comparison to a calculated temperature value
failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 552
19042 (DTC 372C) - Downstream SCR temperature sensor comparison to a calculated temperature value
failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 554
19045 (DTC 94BE) - Timeout Error of Message from ECU to NOx downstream Sensor . . . . . . . . . . . . 556
19050 (DTC 478E) - Downstream NOx sensor supply voltage is out of range . . . . . . . . . . . . . . . . . . . . 558
19051 (DTC E46E) - Upstream NOx sensor internal failure (heater open circuit error) . . . . . . . . . . . . . 560
19052 (DTC 256E) - Upstream NOx sensor internal failure (heater short circuit error) . . . . . . . . . . . . . 562
19053 (DTC A66E) - Upstream NOx sensor internal failure (Heater Performance Plausibility Error) . 564
19054 (DTC E48E) - Upstream NOx sensor internal failure (open circuit error) . . . . . . . . . . . . . . . . . . . 566
19059 (DTC 258E) - Upstream NOx sensor internal failure (Short Circuit Error) . . . . . . . . . . . . . . . . . . . 568
19060 (DTC 9E6E) - CAN timeout error from upstream NOx sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . 570
19061 (DTC 32BE) - Upstream NOx sensor lambda signal deviation - NOx sensor possible removal de-
tected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 572
19062 (DTC E98E) - Upstream NOx sensor values are not plausible . . . . . . . . . . . . . . . . . . . . . . . . . . . . 573
19063 (DTC 4A8E) - Upstream NOx sensor supply voltage is out of range . . . . . . . . . . . . . . . . . . . . . . . 574
19064 (DTC 563A) - Open Load error of DEF/AdBlue Supply Module Heater Actuator powerstage . . 576
19066 (DTC 1899) - Upstream oxidation catalyst temperature sensor voltage is higher than expected 578
19071 (DTC 2DDA) - SCR catalyst efficiency lower than first NOx production threshold level . . . . . . . 580
19077 (DTC 334A) - DEF/AdBlue pressure stabilization failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 584
19079 (DTC 1A4A) - DEF/AdBlue over pressure failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 585
19080 (DTC 294A) - DEF/AdBlue under pressure failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 586
19085 (DTC 857A) - DEF/AdBlue dosing valve ECU driver over temperature failure . . . . . . . . . . . . . . . 587
19086 (DTC 3DBA) - DEF/AdBlue pressure line heater failure and DEF/AdBlue tank temperature is too
low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 589
19087 (DTC 8DAA) - DEF/AdBlue tank temperature is not within acceptable limits . . . . . . . . . . . . . . . . 590
19090 (DTC 3C3A) - Error DEF/AdBlue supply module heater temperature sensor cold start plausibility
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 591
19095 (DTC 2F3A) - DEF/AdBlue tank temperature sensor plausibility failure . . . . . . . . . . . . . . . . . . . . 593
19103 (DTC 643A) - Short Circuit to Battery of DEF/AdBlue Supply Module Heater Actuator powerstage
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 594
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19104 (DTC 753A) - Short Circuit to Ground of DEF/AdBlue Supply Module Heater Actuator powerstage
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 596
19105 (DTC 879A) - DEF/AdBlue tank heater ECU driver over temperature failure . . . . . . . . . . . . . . . . 598
19106 (DTC 759A) - DEF/AdBlue tank heater actuator short circuit to ground failure . . . . . . . . . . . . . . 600
19107 (DTC 515A) - DEF/AdBlue supply module pump motor open load failure . . . . . . . . . . . . . . . . . . 602
19108 (DTC 613A) - DEF/AdBlue supply module pump motor short circuit to battery failure . . . . . . . . 603
19111 (DTC 723A) - DEF/AdBlue supply module pump motor short circuit to ground failure . . . . . . . . 605
19126 (DTC FF9F) - SCR Inducement: Warning, triggered by tampering fault . . . . . . . . . . . . . . . . . . . . 607
19140 (DTC 4BCA) - DEF/AdBlue concentration is out of range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 608
19141 (DTC 4CCA) - DEF/AdBlue quality sensor detects diesel fuel in DEF/AdBlue tank . . . . . . . . . . 609
19144 (DTC 9AEA) - CAN timeout error from DEF/AdBlue quality sensor . . . . . . . . . . . . . . . . . . . . . . . . 610
19155 (DTC 345A) - DEF/AdBlue Supply Module Pump Motor Speed Deviation . . . . . . . . . . . . . . . . . . 612
19156 (DTC 335A) - DEF/AdBlue supply module pump motor severe speed deviation . . . . . . . . . . . . . 613
19210 (DTC 57BA) - Open Load error of DEF/AdBlue Backflow Line Heater Actuator powerstage . . 614
19253 (DTC 69BA) - Short Circuit to Battery of DEF/AdBlue Pressure Line heater Actuator powerstage
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 616
19255 (DTC 5BBA) - Open Load error of DEF/AdBlue Pressure Line Heater Actuator powerstage . . 618
19262 (DTC 649A) - DEF/AdBlue tank heater actuator short circuit to battery failure . . . . . . . . . . . . . . 620
19264 (DTC 569A) - DEF/AdBlue tank heater actuator open load failure . . . . . . . . . . . . . . . . . . . . . . . . . 622
19267 (DTC F2AF) - Engine idle shutdown commanded from SCR inducement . . . . . . . . . . . . . . . . . . 624
19323 (DTC 94FB) - External engine shutdown request received . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 625
19335 (DTC 224A - Pressure build-up error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 626
19336 (DTC 354A) - DEF/AdBlue general pressure check failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 627
19337 (DTC 344A) - DEF/AdBlue dosing system backflow line pressure too high plausibility failure . 628
19345 (DTC 9ECA) - Timeout error of CAN receive frame HCU Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 630
19346 (DTC BFBA) - Timeout error of CAN receive frame HCU Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 632
19356 (DTC 3FDE) - Downstream NOx sensor signal and NH3 sensor signal plausibility check failure 634
19402 (DTC 9AAA) - CAN timeout error - Urea tank level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 635
19415 (DTC FABF) - Remaining DEF/AdBlue is below the empty threshold . . . . . . . . . . . . . . . . . . . . . . 637
19421 (DTC 33BE) - Downstream NOx sensor failed negative drift test monitoring . . . . . . . . . . . . . . . . 638
19422 (DTC 43CE) - Downstream NOx sensor signal is stuck at a constant value . . . . . . . . . . . . . . . . 639
19423 (DTC 3CDA) - Upstream NOx sensor comparison to a calculated NOx value failure . . . . . . . . . 640
19434 (DTC E26D) - ECU internal failure - EEPROM erase error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 641
19435 (DTC E36D) - ECU internal failure - EEPROM read error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 642
19436 (DTC E46D) - ECU internal failure - EEPROM write error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 643
19496 (DTC 184A) - Monitoring of over pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 644
19523 (DTC 49AA) - DEF/AdBlue tank temperature failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 645
19559 (DTC F18F) - DEF/AdBlue level too low warning is active - Stage 1 . . . . . . . . . . . . . . . . . . . . . . . 646
19568 (DTC F28F) - DEF/AdBlue level too low warning is active - Stage 2 . . . . . . . . . . . . . . . . . . . . . . . 647
19748 (DTC 833A) - DEF/AdBlue supply module pump motor ECU driver over temperature failure . . 648
19787 (DTC F49F) - SCR Inducement: Level 1 (Torque reduction), triggered by DEF/AdBlue dosing inter-
ruption fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 650
19788 (DTC F59F) - SCR Inducement: Level 3 (creep mode), triggered by DEF/AdBlue dosing interruption
fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 651
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19789 (DTC F69F) - SCR Inducement: Warning, triggered by DEF/AdBlue dosing interruption fault . 652
19797 (DTC FA9F) - SCR Inducement: Level 1 (torque reduction), triggered by DEF/AdBlue quality fault
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 653
19798 (DTC FB9F) - SCR Inducement: Level 3 (creep mode), triggered by DEF/AdBlue Quality fault 654
19799 (DTC FC9F) - SCR Inducement: Warning, triggered by DEF/AdBlue Quality fault . . . . . . . . . . . 655
19800 (DTC FD9F) - SCR Inducement: Level 1 (Torque reduction), triggered by Tampering fault . . . 656
19801 (DTC FE9F) - SCR Inducement: Level 3 (creep mode), triggered by Tampering fault . . . . . . . . 657
19817 (DTC 377A) - DEF/AdBlue dosing valve is blocked . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 658
19835 (DTC 5468) - Open load temperature error on the Turbocharger PWM output powerstage . . . 659
19836 (DTC 8368) - Over temperature error on the Turbocharger PWM output powerstage . . . . . . . . 661
19837 (DTC 6168) - SCB error on the Turbocharger PWM output powerstage . . . . . . . . . . . . . . . . . . . . 663
19838 (DTC 7268) - SCG error on the Turbocharger PWM output powerstage . . . . . . . . . . . . . . . . . . . 665
19858 (DTC 1748) - SRC High for turbine upstream temperature sensor . . . . . . . . . . . . . . . . . . . . . . . . 667
19859 (DTC 2848) - SRC low for turbine upstream temperature sensor . . . . . . . . . . . . . . . . . . . . . . . . . 670
19862 (DTC E86A) - Power stage error in HCU for DEF/AdBlue Back flow line Heater . . . . . . . . . . . . 672
19865 (DTC 65BA) - Short Circuit to Battery of DEF/AdBlue Backflow Line Heater Actuator powerstage
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 673
19866 (DTC 66BA) - Short Circuit to Ground of DEF/AdBlue Backflow Line Heater Actuator powerstage
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 675
19870 (DTC 7ABA) - Short Circuit to Ground of DEF/AdBlue Pressure Line Heater Actuator powerstage
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 677
19872 (DTC E96A) - Power stage error in HCU for DEF/AdBlue Supply Module Heater . . . . . . . . . . . 679
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Electrical systems - FAULT CODES
1001 - Engine Air Filter Blocked

Context:
The instrument cluster detects a signal to ground on XST1 pin 16, indicating that the air filter restriction switch has
been tripped. The instrument cluster will illuminate the air filter restriction lamp while this fault is active.
Cause:
The instrument cluster detects a signal to ground indicating that the air filter restriction switch has been tripped.
Possible failure modes:
1. Clogged air filter.

2. Signal wire short circuit to minus battery or chassis ground.
3. Faulty air filter restriction switch.
4. Faulty instrument cluster.
Solution:
1. Verify that the fault code is active.
Connect the Electronic Service Tool to the service tool connector.
To check for fault codes: Start and operate the machine.
A. The fault code is not recorded again. Go to step 7.
B. Fault code 1001 – Engine Air Filter Blocked is recorded again. Go to step 2.
2. Inspect the engine air filter.
Inspect the engine air filter. Replace the filter if needed.
A. The filter is OK and does not need to be replaced. Go to step 3.
B. The filter is in poor condition or is clogged. Replace the filter. Return to step 1 to confirm elimination of the fault.
3. Verify that the wiring and connectors are free of damage.
Inspect the instrument cluster and the air filter restriction switch connections. All connections should be secure,
tight, free of corrosion, abrasion and damage.
Inspect the harness from the instrument cluster and the air filter restriction switch. Verify that the harness is free
of damage, corrosion, abrasion and incorrect attachment.
A. The connectors are secure and the harness is free of damage. Go to step 3.
B. The connectors or the harness has damage. Repair or replace the harness or connectors as required. Return
to step 1 to confirm elimination of fault.
4. Check the air filter restriction circuit.
Disconnect the signal wire from air filter restriction switch.
Turn the ignition switch ON, engine OFF.
Access the fault code screen on the Electronic Service Tool. The air filter restriction fault code should no longer
be active.
A. The fault code is no longer active. Go to step 4.
B. Fault code 1001 is still active. Go to step 5.

5. Check air filter restriction switch.
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Remove the air filter restriction switch from the air filter housing.
Measure the resistance across the switch. The resistance should be greater than 20,000 Ω .
A. The resistance is greater than 20,000 Ω. Inspect the wiring around the sensor. Go to step 5.
B. The resistance is less than 20,000 Ω. Replace the air filter restriction switch. Return to step 1 to confirm
elimination of the fault.
6. Measure the resistance of the signal wire.
Measure the resistance between XST1 pin 16 and chassis ground. The resistance should be greater than
20,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition.
A. The resistance is greater than 20,000 Ω. Temporarily replace the instrument cluster and retest. Return to step
1 to confirm elimination of the fault.
B. The resistance is less than 20,000 Ω. There is a short circuit to chassis ground in the signal wire. Repair or
replace the wire as required. Return to step 1 to confirm elimination of fault.
7. Check the harness for intermittent connections.
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.
Wiggle the harnesses to reveal an intermittent connection or a short circuit in the wiring.
Operate the machine while you monitor the instrument cluster and EST.
A. If you find damage or the display indicates other than normal display readings, then repair the damage discov-
ered during the inspection or locate and repair the other than normal display condition and verify that the error
has been resolved.
B. If you do not find damage and the display indicates only normal readings, then erase the fault code and return
the machine to service.
Wiring harnesses - Electrical schematic sheet 01 Sheet 1 Engine cable (55.100.DP-C.20.E.01)
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1002 - Engine coolant temperature too high, critical

NOTICE: Check coolant level before proceeding.
Context:
The instrument cluster has detected a coolant temperature above 111 °C (232 °F) for a period greater than 5 s. The
instrument cluster will illuminate the coolant temperature icon and the danger icon. The audible alarm will sound
continuously while this fault is active.
Cause:
The coolant temperature signal is above normal. The instrument cluster has detected a coolant temperature above
111 °C (232 °F) for a period greater than 5 s.
1. Low coolant level.

2. Wiring or circuits shorted to ground.
3. Faulty reading from component.
Solution:
To check for fault code: Start and operate machine.
B. Fault code 1002 is recorded again. Go to step 2.

Inspect the Engine Control Unit (ECU) and the coolant temperature sensor connections. All connections should
be secure, tight, free of corrosion, abrasion and damage.
Inspect the harness from the ECU to the coolant temperature sensor. Verify that the harness is free of damage,
corrosion, abrasion and incorrect attachment.
3. Measure the resistance through the circuit.
Turn the ignition switch OFF.
Disconnect the engine harness from the ECU at connector X-462.
Disconnect the engine harness from the coolant temperature sensor.
Fabricate a jumper wire that will connect between the coolant temperature sensor connector pin 1 and pin 2.
Connect the jumper wire between pin 1 and pin 2.
Measure the resistance between X-462 pin 57 and X-462 pin 58. The resistance should be less than 10 Ω. Wiggle
the harness during measurement to reveal an intermittent condition.
A. The resistance is less than 10 Ω. Go to step 4.
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B. The resistance is greater than 10 Ω. There is an open circuit in the wiring. Repair or replace the harness as
required. Return to step 1 to confirm elimination of fault.
4. Measure the voltage on the signal wire.
Disconnect the engine harness from the ECU at connector X-462.
Disconnect the engine harness from the coolant temperature sensor.
Turn the ignition switch ON.
Measure the voltage between X-462 pin 57 and chassis ground. The chassis ground connection must be clean
and free of paint, oil, and dirt. The voltage should be less than 0.5 V. Wiggle the harness during measurement to
reveal an intermittent condition.
Measure the voltage between X-462 pin 58 and chassis ground. The chassis ground connection must be clean
and free of paint, oil, and dirt. The voltage should be less than 0.5 V. Wiggle the harness during measurement to
A. Both voltage measurements are less than 0.5 V. Go to step 5.
B. One or both voltage measurements are greater than 0.5 V. There is a short circuit to another voltage source in
the wiring. Repair or replace the harness as required. Return to step 1 to confirm elimination of fault.
5. Test the ECU.
Reconnect ECU connector X-462.
Leave the coolant temperature sensor disconnected.
Fabricate a jumper wire that will connect between the coolant temperature sensor connector pin 1 and pin 2.
Access the EST fault code screen. Fault code 3006 should no longer be active. Fault code 3008 is now active.
A. Fault code 3006 is no longer active. Fault code 3008 is now present and active. Temporarily replace the sensor
and retest. Return to step 1 to confirm elimination of the fault.
B. Fault code 3006 is still present and active. Fault code 3008 did not become active. Temporarily replace the
ECU and retest. Return to step 1 to confirm elimination of fault.
or broken wires.
has been resolved.
Wiring harnesses - Electrical schematic sheet 01 Sheet 1A Engine cable (55.100.DP-C.20.E.01)
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1003 - Air conditioning pressure too high

Context:
The Instrument Cluster measures 12 V on connector XST1 pin 10. The instrument cluster will illuminate the air condi-
tioning icon while the fault is active and will sound the alarm for 1 s on the next system power up following the event.
Cause:
The instrument cluster has detected the air conditioning pressure to be greater than 27.6 bar (400 psi).
1. Air conditioning pressure is greater than 27.6 bar (400 psi).

2. Faulty reading from pressure switch.
3. Wiring or circuit shorted to positive battery.
4. Connectors not mated fully, pins not seated properly in connector, bent pin or broken wires at rear of connector.
5. Faulty A/C relay.
Solution:
A. The fault code is not recorded again. OK to return the machine to service.

2. Verify the harness is not damaged.
Inspect the instrument cluster and A/C high pressure switch and the A/C relay connections. All connections should
Inspect the harness between the instrument cluster and the A/C high pressure switch. Verify that the harness is
free of damage, corrosion, abrasion or incorrect attachment.
Inspect the harness between the instrument cluster and the A/C relay. Verify that the harness is free of damage,
corrosion, abrasion or incorrect attachment.
A. The wiring is free of corrosion, damage, abrasion, and incorrect attachment. Go to step 3.
B. The wiring is not free of corrosion, damage, abrasion, and incorrect attachment. Repair or replace the harness
as required. Go to step 1 to confirm elimination of the fault.
3. Check the air conditioning system pressure.
Install a gauge capable of measuring a minimum of 27.6 bar (400 psi) on the A/C high side test port.
Turn the A/C temperature control to the coldest position. Set the blower switch to the high position.
Measure the pressure at the high side test port. The pressure should be less than 27.6 bar (400 psi).
A. The pressure is below 27.6 bar (400 psi). Go to step .4.
B. The pressure is above 27.6 bar (400 psi). The pressure is too high. Repair or replace air conditioning system
as required. Return to step 1 to confirm elimination of fault.
4. Test the instrument cluster.
Start the engine.
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Disconnect the A/C pressure switch. The fault code 1003 should no longer be active.
A. The fault code 1003 is not active when the pressure switch is disconnected. The fault code 1003 is active when
the switch is reconnected. Replace the switch. Return to step 1 to confirm elimination of the fault.
B. The fault code is active while the switch is disconnected. Go to step 5.

5. Check instrument cluster signal pin.
Disconnect the A/C high pressure switch input pin to the instrument cluster.
Remove XST1 pin 10.
Turn the ignition switch to the ON position.
A. The fault code 1003 is not active when the pin is removed. Reinstall the A/C fault signal wire into instrument
cluster connector XST1 pin 10. Go to step 6.
B. Fault code 1003 is still active. Temporarily replace the instrument cluster and retest. Return to step 1 to confirm
elimination of fault.
6. Check the A/C Relay
Turn ignition switch to the OFF position.
Remove the A/C relay. Inspect the pins and wiring to the relay.
Turn the key switch ON.
Turn the A/C temperature control to the coldest position. Set the blower switch to the high position. Fault code
1003 should not be active.
A. The fault code is not active when the relay is removed. Replace the relay. Return to step 1 to confirm elimination
of the fault code.
B. The fault code 1003 is active with relay removed. There is a short circuit to positive battery in the wiring harness.
Repair or replace the harness as needed. Return to step 1 to confirm elimination of the fault code. .
Wiring harnesses - Electrical schematic sheet 12 Sheet 12 Air conditioner kit (55.100.DP-C.20.E.12)
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1009 - Transmission oil temperature too high

Context:
The instrument cluster monitored a transmission oil temperature greater than 115 °C (239 °F) for a period greater than
5 s. The instrument cluster will illuminate the stop lamp and the audible alarm will sound continuously while the fault
is active.
The fuel level sensor/transmission temperature sensor error icon will illuminate while the fault is active.
The fault will reset once the transmission oil temperature drops below 107 °C (225 °F) for a period greater than 5 s.
Cause:
The transmission oil temperature is above 115 °C (239 °F) for a period greater than 5 s.
1. Low transmission oil level.

2. Faulty fan operation.
3. Clogged cooling core.
4. Faulty reading from the sensor.
Solution:

2. Verify the transmission oil level.
Check the transmission oil level. Add oil as required. Refer to Operator's Manual for more details.
A. The oil level is correct and the fault is not recorded again. OK for return to service.
B. The oil level is correct but the fault is recorded again. Go to step 3.
3. Check the cooling system.
Run engine at 1500 RPM.
Check fan operation.
Check cooling core for clogs.
A. The cooling system is operating properly. Go to step 4.
B. The cooling system is not operating properly or the cooling core is clogged. Repair fan or clear clogs from
cooling core. Repair as required. Return to step 1 to confirm elimination of fault.
4. Check temperature sender.
Disconnect terminal connector from the transmission temperature sender.
Turn the ignition switch ON. Fault code 1009 should no longer be active.
A. Fault code 1009 is no longer active. Temporarily replace the transmission oil temperature sensor and retest.
Return to step 1 to confirm elimination of the fault.
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B. Fault code 1009 is still active. Go to step 5.

5. Check wiring to Instrument Cluster
Disconnect the instrument cluster connector XST2.
Measure the resistance between the transmission temperature sender connector XST2 pin 14 and chassis ground.
The resistance should be greater than 20,000 Ω. Wiggle the harness during measurement to reveal an intermittent
condition.
A. The resistance measurement is greater than 20,000 Ω. Temporarily replace the Instrument Cluster and retest.
B. The resistance is less than 20,000 Ω. There is a short circuit to chassis ground in the wire. Repair or replace
the wire as required. Return to step 1 to confirm elimination of fault.
or broken wires.
has been resolved.
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1010 - Foot throttle signal out of range, IVS not changing state in
300 ms
Context:
The IVS (idle validation signal) did not change from a high state 12 V to a low state 0 V when the throttle moved off of
low idle. The instrument cluster will illuminate the warning lamp and will sound the alarm for one second on the next
system power up following the event.
Cause:
The IVS did not change state in 0.3 s after the throttle was moved off of low idle.
1. Faulty wiring or connections.

2. Faulty reading from foot throttle sensor.
Solution:

Inspect the instrument cluster and the throttle sensor connections. All connections should be secure, tight, free of
corrosion, abrasion and damage.
Inspect the harness from the instrument cluster to the throttle sensor . Verify that the harness is free of damage,
3. Measure the voltage at throttle sensor.
Turn the ignition switch to the OFF position.
Disconnect the foot throttle connector X25.
Measure the voltage between X25 pin 5 and X25 pin 6. The voltage should be between 4.8 V and 5.2 V. Wiggle
A. The voltage is correct. Go to step 4.
B. The voltage is greater than 5.2 V. Go to procedure 1023 - Foot throttle supply voltage too high, over 5.2
volts for 5 seconds (55.408).
C. The voltage is less than 4.8 V. Go to procedure 1024 - Foot throttle supply voltage too low, under 4.8 volts
for 5 seconds (55.408).
4. Check idle validation circuit
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RCPH10TLB018GAM 1
Throttle Signal Legend

(1) Idle Validation Signal (3) Throttle movement in degrees of travel. 0
degrees equals low idle. 20 degrees equals
WOT (Wide Open Throttle).
(2) Throttle Signal Voltage
This step is used to monitor the throttle validation signal. The sensor must be connected and active in order to
continue. The dealer must provide a breakout harness or use connector back probes in order to complete this
procedure.
Turn the ignition switch ON, engine OFF. Measure the voltage from X25 pin 4 to X25 pin 1. The voltage should
be approximately 12 V.
Move the throttle approximately 3 degrees. The idle validation signal should change from 12 V to 0 V.
A. The voltage changed from 12 V to 0 V. Go to step 5.
B. The voltage was not correct or the voltage did not change from 12 V to 0 V as the throttle moved off of low idle.
Replace the sensor and retest. Return to step 1 to confirm elimination of fault.
5. Check the wire harness from the throttle sensor to the instrument cluster.
Remove the breakout harness and reconnect the sensor to the instrument cluster harness.
Remove the foot throttle signal wire XST2 pin 20.
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Measure the voltage between the removed wire, XST2 pin 20 and XST1 pin 20. Move the throttle approximately
3 degrees. The idle validation signal should change from 12 V to 0 V. The signal should stay at 0 V as the throttle
is moved to WOT (wide open throttle).
A. The voltage changed from 12 V to 0 V when the throttle was moved. Temporarily replace the instrument cluster
B. The voltage was not correct or voltage did not change from 12 V to 0 V as the throttle moved off of low idle.
There is a problem with the idle validation signal wire from the sensor to the instrument cluster. Repair or
or broken wires.
has been resolved.
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1011 - Foot throttle signal out of range, throttle above 95% of input
for 5 seconds
Context:
The instrument cluster measured a foot throttle signal greater than 4.75 V. The instrument cluster will illuminate the
warning lamp and will sound the alarm for one second on the next system power up following the event.
Cause:
The instrument cluster monitored a throttle signal greater than 4.75 V 95% for a period greater than 5 s.

Solution:

corrosion, abrasion, and damage.
Inspect the harness from the instrument cluster to the throttle sensor. Verify that the harness is free of damage,
3. Check voltage at throttle sensor.
4. Check the throttle signal from the sensor.
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RCPH10TLB017GAM 1

procedure.
Connect the breakout harness and measure the voltage between X025 pin 3 and X025 pin 6.
Measure the voltage between X025 pin 3 and X025 pin 6. Move the throttle from low idle to WOT (wide open
throttle). The voltage should change from approximately 0.55 V at low idle to 4.2 V at WOT.
A. The voltage measurement is correct. Go to step 5.
B. The voltage was not between 0.55 V and 4.2 V as the throttle moved from low idle to WOT or the voltage was
greater than 4.75 V at WOT. Temporarily replace the sensor and retest. Return to step 1 to confirm elimination
of fault.
5. Measure the throttle signal from the sensor to the instrument cluster.
Remove foot throttle switch wire from connector XST2 pin 16.
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Measure the voltage between the removed wire, XST2 pin 16 and XST1 pin 20. Move the throttle from low idle to
WOT (wide open throttle). The voltage should change from approximately 0.55 V at low idle to 4.2 V at WOT.
A. The voltage changed from approximately 0.55 V to 4.2 V. Temporarily replace the instrument cluster and retest.
B. The voltage did not change between 0.55 V and 4.2 V as the throttle moved from low idle to WOT or the voltage
was greater than 4.75 V at WOT. There is a problem in the throttle signal wire from the sensor to the instrument
cluster. Repair or replace the wire as required. Return to step 1 to confirm elimination of fault.
or broken wires.
has been resolved.
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1012 - Foot throttle signal out of range, throttle below 5% of input

for 5 seconds
Context:
The instrument cluster measures a foot throttle signal less than 0.5 V. The instrument cluster will illuminate the warning
lamp and will sound the alarm for one second on the next system power up following the event.
Cause:
The instrument cluster monitored a throttle signal less than 0.5 V 5% for a period greater than 5 s.
1. Faulty wiring or connections shorted to ground.

Solution:

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RCPH10TLB017GAM 1

procedure.
Measure the voltage between X25 pin 3 and X25 pin 6. Move the throttle from low idle to WOT (wide open throttle).
The voltage should change from approximately 0.55 V at low idle to 4.2 V at WOT.
was less than 0.5 V at low idle. Replace the sensor and retest. Return to step 1 to confirm elimination of fault.
5. Measure the throttle signal from the sensor to the Instrument Cluster.
Remove the foot throttle switch wire from connector XST2 pin 16.
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Measure the voltage between XST2 pin 16 and XST1 pin 20. Move the throttle from low idle to WOT (wide open
A. The voltage changed from approximately 0.55 V to 4.2 V. Temporarily replace the instrument cluster and retest.
was less than 0.5 V at low idle. There is a problem in the throttle signal wire from the sensor to the instrument
or broken wires.
has been resolved.
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1013 - Foot throttle signal out of range, signal unusable

Context:
The instrument cluster measures a foot throttle signal that is unstable. The instrument cluster will illuminate the warn-
ing lamp and will sound the alarm for one second on the next system power up following the event.
Cause:
The instrument cluster monitors a fluctuation in the throttle signal that is not possible.

Solution:

4. Measure the throttle signal from the sensor.
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RCPH10TLB017GAM 1

procedure.
The voltage should change from approximately 0.55 V at low idle to 4.2 V at WOT. Wiggle the sensor harness to
B. The voltage did not change between 0.55 V volts and 4.2 V as the throttle moved from low idle to WOT or there
were voltage fluctuations or spikes as the throttle was moved. Replace the sensor. Return to step 1 to confirm
Remove the foot throttle switch wire from connector XST2 pin 16.
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Measure the voltage between removed wire,XST1 pin 16 and XST1 pin 20. Move the throttle from low idle to WOT
(wide open throttle). The voltage should change from approximately 0.55 V at low idle to 4.2 V at WOT.
A. The throttle signal voltage changed between 0.55 V volts and 4.2 V. Temporarily replace the instrument cluster
B. The voltage did not change between 0.55 V and 4.2 V as the throttle moved from low idle to WOT or there were
voltage fluctuations or spikes as the throttle was moved. There is a problem in the throttle signal wire from the
sensor to the instrument cluster. Replace the wire. Return to step 1 to confirm elimination of fault.
or broken wires.
has been resolved.
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1014 - Battery charge voltage too high

Context:
The instrument cluster measured an alternator voltage greater than 16 V for a period greater than 5 s. The instrument
cluster will illuminate the battery warning symbol indicating that it has detected a problem in the battery charging
system.
Cause:
The alternator output is greater than 16 V.
1. Faulty alternator, the alternator output is greater than 16 V.

Solution:

Inspect the instrument cluster and the alternator connections. All connections should be secure, tight, free of
Inspect the harness from the instrument cluster to the alternator. Verify that the harness is free of damage, corro-
sion, abrasion and incorrect attachment.
3. Measure the alternator output.
Start the engine.
Set engine speed to low idle and measure the voltage at the alternator. The voltage should be approximately
14.5 V.
A. The voltage is approximately 14.5 V. Go to step 3.
B. The voltage is greater than 16 V. Replace the alternator. Go to test step 1 to confirm elimination of fault.
4. Measure the voltage at instrument cluster.
Measure the voltage between XST2 pin 24 and chassis ground. The chassis ground connection must be clean and
free of paint, oil , and dirt. The voltage should be approximately 14.5 V. Wiggle the harness during measurement
to reveal an intermittent condition.
A. The voltage is approximately 14.5 V. Temporarily replace the instrument cluster and retest. Return to step 1
to confirm elimination of the fault code.
B. The voltage is greater than 16 V. There is a problem in the alternator charging circuit. Repair or replace the
alternator as required. Return to step 1 to confirm elimination of fault.
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or broken wires.
has been resolved.
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1015 - Battery charge voltage too low

Context:
The instrument cluster measured an alternator voltage less than 11 V for a period greater than 5 s. The instrument
cluster will illuminate the battery warning symbol indicating that it has detected a problem in the battery charging
system.
Cause:
The alternator output is less than 11 V.
1. The instrument cluster signal wire shorted to chassis ground.

2. Faulty alternator, the alternator output is less than 11 V.
Solution:

Inspect the instrument cluster and the alternator connections. All connections should be secure, tight, free of
Inspect the harness from the instrument cluster to the alternator. Verify that the harness is free of damage, corro-
sion, abrasion and incorrect attachment.
B. The connectors or the harness has damage. Repair or replace the harness or the connectors as required.
Return to step 1 to confirm elimination of fault.
3. Measure the alternator output.
Start the engine. Set engine speed to low idle.
Measure the voltage at the alternator. The voltage should be approximately 14.5 V.
A. The voltage is approximately 14.5 V. Go to step 4.
B. The voltage is less than 11 V. There is a problem in the charging system. Repair as required. Return to step
1 to confirm elimination of fault.
Measure the voltage on XST2 pin 24 to chassis ground. The chassis ground must be clean and free of paint,
oil, and dirt. The voltage should be approximately 14.5 V. Wiggle the harness during measurement to reveal an
intermittent condition.
A. The voltage measurement is correct. Temporarily replace the instrument cluster and retest. Return to step 1
to confirm elimination of the fault code.
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B. The voltage is less than 11 V. There is a problem in the alternator charging system. Repair as required. Return
or broken wires.
has been resolved.
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1018 - Boost air temperature too high

Cause:
The engine inlet air temperature is greater than 95 °C (203 °F) for a period greater than 5 s. The instrument cluster
will illuminate the amber warning light while the fault is active.
Solution:
1. Fault Code 1018 is a CAN bus message from the Engine Control Unit (ECU) to the instrument cluster. This fault
code is displayed on the instrument cluster to warn the operator of a high boost temperature warning. Refer to 3019
(DTC 1D64) - Intake manifold pressure sensor voltage is higher than expected (55.640) for more information.
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1019 - Engine coolant temperature too high

Cause:
The coolant temperature is greater than 107 °C (224 °F) for a period greater than 5 s. The instrument cluster will
illuminate the amber warning light while the fault is active.
Solution:
1. This is an information fault code only. The fault code is logged and indicates that the coolant temperature is
approaching the fault code trigger point.
2. Verify proper coolant level.
3. Fault code 1019 is a CAN bus message from the ECU to the instrument cluster. This fault code is displayed on
the instrument cluster to warn the operator of a high coolant temperature warning. Refer to 3007 (DTC 1113) -
Engine coolant temperature sensor voltage is higher than expected (55.640) for more information.
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1020 - Transmission oil temperature above normal

Context:
The transmission oil temperature is greater than 105 °C (221 °F) for a period greater than 5 s. The instrument cluster
will illuminate the amber warning light while the fault is active. The fuel level sensor/transmission temperature sensor
error icon will illuminate while the fault is active.
Cause:
The transmission oil temperature is greater than 105 °C (221 °F) for a period greater than 5 s.
Solution:
1. This is an information fault code only. The fault code is logged and indicates that the transmission oil temperature
is approaching the fault code trigger point.
2. Verify proper transmission oil level.
3. Fault code 1020 is a CAN bus message from the Engine Control Unit (ECU) to the instrument cluster. This fault
code is displayed on the instrument cluster to warn the operator of a high transmission oil temperature warning.
Refer to 1009 - Transmission oil temperature too high (55.408) for more information.
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1021 - Fuel temperature above normal

Context:
The fuel temperature is greater than 82 °C (180 °F) for a period greater than 5 s. The instrument cluster will illuminate
the amber warning light while the fault is active.
Cause:
The fuel temperature is greater than 82 °C (180 °F) for a period greater than 5 s.
Solution:
1. Fault code 1021 is a CAN bus message from the ECU to the instrument cluster. This fault code is displayed on
the instrument cluster to warn the operator of a high fuel temperature warning. Refer to 3015 (DTC 1C15) - Fuel
temperature sensor voltage is higher than expected (55.640) for more information.
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1022 - Water in fuel

Context:
The instrument cluster has detected excess water in the fuel system. The instrument cluster will illuminate the amber
warning light while this fault is active.
Cause:
Fault code 1022 is a CAN bus message from the Engine Control Unit (ECU) to the instrument cluster. This fault code
is displayed on the instrument cluster to warn the operator that the ECU has detected excess water in the fuel system.
Refer to 3146 (DTC 4415) - Water in fuel detected or water in fuel circuit failure (55.640) for more information.
Solution:
1. Drain the fuel filter of excess water.
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1023 - Foot throttle supply voltage too high, over 5.2 volts for 5
seconds
Context:
The instrument cluster detects a voltage greater than 5.2 V on the throttle 5 V supply line, connector XST2 pin 18.
The instrument cluster will illuminate the Warning Lamp and will sound the alarm for 1 s on the next system power up
following the event.
Cause:
The instrument cluster detects a voltage greater than 5.2 V on the throttle 5 V supply line, connector XST2 pin 18.
1. Throttle supply wire short circuit to battery.

2. Wiring open circuit.
Solution:

2. Verify that the wiring and the connectors are free of damage.
corrosion, abrasion, and damage.
corrosion, abrasion, and incorrect attachment.
3. Measure the voltage at the foot throttle connector.
Disconnect the foot throttle sensor.
Measure the voltage between X25 pin 5 and X25 pin 6. The voltage should be approximately 5 V.
A. The voltage is between 4.8 V and 5.2 V. There is an intermittent condition in the wiring to the instrument cluster.
Inspect the wiring and connectors for damage. Repair as required. Return to 1 to confirm elimination of fault.
B. The voltage is greater than 5.2 V. Go to step 4.

4. Measure the voltage at the instrument cluster.
Remove wire 18 from connector XST2.
Insert a test wire into pin 18.
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Measure the voltage between XST2 pin 18 and chassis ground. The chassis ground connection must be clean
and free of paint, oil, and dirt. The voltage should be approximately 5 V.
A. The voltage is between 4.8 V and 5.2 V. There is a problem in the wiring harness from the instrument cluster
to the foot throttle. Repair or replace the harness as required. Return to step 1 to confirm elimination of fault.
B. The voltage is greater than 5.2 V. There is a problem in the instrument cluster. Temporarily replace the instru-
ment cluster and retest. Return to step 1 to confirm elimination of fault.
or broken wires.
has been resolved.
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1024 - Foot throttle supply voltage too low, under 4.8 volts for
5 seconds
Context:
The instrument cluster detects a voltage less than 4.8 V on the throttle 5 V supply line, connector XST2 pin 18. The
instrument cluster will illuminate the warning lamp and will sound the alarm for one second on the next system power
up following the event.
Cause:
The instrument cluster detects a voltage less than 4.8 V on the throttle 5 V supply line, connector XST2 pin 18.
1. Throttle supply wire short circuit to minus battery or a short circuit chassis ground.
2. Faulty throttle sensor.
Solution:

3. Measure the voltage at the foot throttle connector.
Disconnect the foot throttle sensor.
Measure the voltage between X25 pin 5 and X25 pin 6. The voltage should be approximately 5 V. Wiggle the
harness during measurement to reveal an intermittent condition.
A. The voltage is between 4.8 V and 5.2 V. There is an intermittent condition in the wiring to the instrument cluster.
Inspect the wiring and connectors for damage. Repair as required. Return to step 1 to confirm elimination of
fault.
B. The voltage is less than 4.8 V. Go to step 4.

Remove the wire from connector XST2 pin 18.
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Insert a test wire into the empty cavity in XST2 pin 18.
and free of paint, oil, and dirt. The voltage should be between 4.8 V and 5.2 V.
to the foot throttle. Replace or repair the harness. Return to step 1 to confirm elimination of fault.
B. The voltage is less than 4.8 V. There is a problem in the instrument cluster. Temporarily replace the instrument
cluster and retest. Return to step 1 to confirm elimination of fault.
or broken wires.
has been resolved.
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1025 - Foot throttle sensor voltage over 5.3 volts for 5 seconds
Context:
The instrument cluster measures a foot throttle signal greater than 5.3 V for a period greater than 5 s. The instrument
cluster will illuminate the warning lamp and will sound the alarm for 1 s on the next system power up following the
event.
Cause:
The instrument cluster measures a foot throttle signal greater than 5.3 V for a period greater than 5 s.
1. Faulty wiring harness. Wiring or circuits shorted to positive battery.

2. Faulty reading from sensor.
Solution:

3. Check the voltage at the throttle sensor.
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RCPH10TLB017GAM 1

procedure.
Connect the breakout harness between the two connectors of connector X25.
A. The voltage changed between 0.55 V and 4.2 V. Go to step 5.
B. The voltage did not change between 0.5 V and 4.2 V as the throttle moved from low idle to WOT or the volt-
age was greater than 4.75 V at WOT. Temporarily replace the sensor and retest. Return to step 1 to confirm
Remove the wire from XST2 pin 16.
Insert a test wire into the empty cavity in XST2 pin 16.
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and free of paint, oil, and dirt. Move the throttle from low idle to WOT (wide open throttle). The voltage should
change from approximately 0.5 V at low idle to 4.2 V at WOT.
A. The voltage changed between 0.5 V and 4.2 V. Temporarily replace the instrument cluster and retest. Return
to step 1 to confirm elimination of the fault.
was greater than 4.75 V at WOT. There is a problem in the throttle signal wire from the sensor to the instrument
or broken wires.
has been resolved.
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1026 - Foot throttle sensor voltage under 200 mV for 5 seconds

Context:
The instrument cluster measures a foot throttle signal less than 200 mV. The instrument cluster will illuminate the
warning lamp and will sound the alarm for 1 s on the next system power up following the event.
Cause:
The instrument cluster measures a foot throttle signal less than 200 mV.
1. Faulty wiring harness. Wiring or circuits shorted to negative battery.

Solution:

3. Check the voltage at the throttle sensor.
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RCPH10TLB017GAM 1

procedure.
Connect the breakout tee between connector X25.
B. The voltage did not change between 0.55 V and 4.2 V as the throttle moved from low idle to WOT or the volt-
age was less than 0.5 V at low idle. Temporarily replace the sensor and retest. Return to step 1 to confirm
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or broken wires.
has been resolved.
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1032 - Hand throttle supply voltage too low, under 4.8 volts for 5
seconds
Context:
The instrument cluster detects a voltage less than 4.8 V on the hand throttle 5 V supply line XST2 pin 19. The instru-
ment cluster will illuminate the warning lamp and will sound the alarm for 1 s on the next system power up following
the event.
Cause:
The instrument cluster detects a voltage less than 4.8 V on the hand throttle 5 V supply line XST2 pin 19.
1. Throttle supply wire shorted to minus battery or chassis ground.

Solution:

3. Measure the voltage at the hand throttle connector.
Disconnect the hand throttle sensor.
Measure the voltage between X608 pin A and X608 pin C. The voltage should be approximately 5 V.
A. The voltage is between 4.8 V and 5.2 V. Temporarily replace the hand throttle and retest. Return to step 1 to
confirm elimination of fault.
B. The voltage is less than 4.8 V. Go to step 4.

Insert a test wire into the open cavity on XST2 pin 19.
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Measure the voltage between XST2 pin 19 and chassis ground. The voltage should be approximately 5 V.
to the foot throttle. Replace or repair the harness as required. Return to step 1 to confirm elimination of fault.
or broken wires.
has been resolved.
Wiring harnesses - Electrical schematic sheet 02 Sheet 2 Solenoid valves cable (55.100.DP-C.20.E.02)
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1033 - Hand throttle sensor voltage over 5.3 volts for 5 seconds
Context:
The instrument cluster detects a voltage greater than 5.3 V on the hand throttle 5 V supply line, connector XST2 pin
19. The instrument cluster will illuminate the warning lamp and will sound the alarm for 1 s on the next system power
Cause:
The instrument cluster detects a voltage greater than 5.3 V on the hand throttle 5 V supply line, connector XST2 pin
19.
1. Throttle supply wire has an open circuit or is shorted to battery supply or another voltage source.
Solution:

A. The voltage is between 4.8 V and 5.2 V. Temporarily replace the hand throttle and retest. Return to step 1 to
B. The voltage is greater than 5.2 V. Go to step 4.

Insert a test wire into the open cavity on XST2 pin 19.
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and free of paint, oil, and dirt. The voltage should be approximately 5 V.
to the foot throttle. Replace or repair the harness as required. Return to step 1 to confirm elimination of fault.
or broken wires.
has been resolved.
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1034 - Hand throttle sensor voltage under 200 mV for 5 seconds

Context:
The instrument cluster detects a throttle signal less than 0.2 V on the hand throttle signal line, connector XST2 pin
17. The instrument cluster will illuminate the warning lamp and will sound the alarm for 1 s on the next system power
Cause:
The instrument cluster detects a throttle signal less than 0.2 V on the hand throttle signal line, connector XST2 pin 17.
1. Hand throttle signal wire is shorted to chassis ground.

Solution:

B. The voltage is greater than 5.2 V. Go to procedure 1033 - Hand throttle sensor voltage over 5.3 volts for 5
seconds (55.408).
C. The voltage is less than 4.8 V. Go to procedure 1032 - Hand throttle supply voltage too low, under 4.8 volts
4. Measure the resistance of the signal wire to chassis ground.
Turn the key switch OFF.
Disconnect the harness from the hand throttle sensor.
Disconnect connector XST2 from the instrument cluster.
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Measure the resistance between XST2 pin 17 and chassis ground. The chassis ground connection must be clean
and free of paint, oil, and dirt. The resistance should be greater than 20,000 Ω. Wiggle the harness during mea-
surement to reveal an intermittent condition.
A. The resistance is greater than 20,000 Ω. Go to step 3.
B. The resistance is less than 20,000 Ω. There is a short circuit to chassis ground. Repair or replace the harness
as required. Return to step 3 to confirm elimination of the fault.
5. Measure the resistance through the signal wire.
Measure the resistance between XST2 pin 17 and X608 pin B. The resistance should be less than 10 Ω. Wiggle
A. The resistance measurement is less than 10 Ω. Go to step 3.
B. The resistance is greater than 10 Ω. There is an open circuit in the throttle signal wire. Repair or replace the
harness as required. Return to step 3 to confirm elimination of the fault.
RCPH10TLB053FAM 1

(2) Throttle movement in degrees of travel. 0 degrees equals low idle. 20
degrees equals WOT (Wide Open Throttle).
Connect the breakout tee between connector X608.
Measure the voltage between X608 pin B and X608 pin C. Move the throttle from low idle to WOT (wide open
throttle). The voltage should change from approximately 0.55 V at low idle and 4.2 V at WOT.
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was less than 0.5 V at low idle. Replace the sensor. Return to step 1 to confirm elimination of fault.
Insert a test wire in the open cavity inXST2 pin 17.
A. The voltage changed between 0.55 V and 4.2 V. Temporarily replace the instrument cluster. Return to step 1
to confirm elimination of the fault.
cluster. Replace the wire. Return to step 1 to confirm elimination of fault.
or broken wires.
has been resolved.
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1035 - Hand throttle sensor signal above 95% of input for 5 seconds
Context:
The Instrument Cluster detects a throttle signal greater than 4.75 V on the hand throttle signal line, connector XST2
pin 17. The instrument cluster will illuminate the warning lamp and will sound the alarm for 1 s on the next system
power up following the event.
Cause:
The instrument cluster detects a throttle signal greater than 4.75 V on the hand throttle signal line, XST2 pin 17.
1. Hand throttle signal wire is shorted to another voltage source or there is an open circuit in the wire or connections.
Solution:

seconds (55.408).
Disconnect the throttle sensor from the harness X608.
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RCPH10TLB053FAM 1

Connect the breakout harness between connector X608.
Measure the voltage between X608 pin B and X608 pin C. Move the throttle from low idle to WOT (wide open
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Insert a test wire in the open cavity in XST2 pin 17.
or broken wires.
has been resolved.
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1036 - Hand throttle sensor signal below 5% of input for 5 seconds

Context:
The instrument cluster detects a throttle signal less than 0.25 V on the hand throttle signal line, XST2 pin 17. The
instrument cluster will illuminate the warning lamp and will sound the alarm for 1 s on the next system power up
Cause:
The instrument cluster detects a throttle signal less than 0.25 V on the hand throttle signal line, XST2 pin 17.

Solution:

seconds (55.408).
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Disconnect the throttle sensor from the harness.
Disconnect instrument cluster connector XST2.
Measure the resistance between XXST2 pin 17 and X608 pin B. The resistance should be less than 10 Ω. Wiggle
RCPH10TLB053FAM 1

Connect the breakout harness between throttle connector X608.
Measure the voltage between X608 pin C and X608 pin B. Move the throttle from low idle to WOT (wide open
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Remove the breakout harness and reconnect the hand throttle sensor to the instrument cluster harness.
Insert a test wire in the open cavity on XST2 pin 17.
or broken wires.
has been resolved.
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1037 - Hand throttle sensor out of range

Context:
Cause:

2. Hand throttle signal wire is shorted to battery supply or another voltage source.
3. Open circuit in the hand throttle signal wire.
Solution:

seconds (55.408).
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Disconnect the hand throttle sensor from the harness.
Disconnect instrument cluster connector XST2.
RCPH10TLB053FAM 1

Connect the breakout harness between the hand throttle connector X608.
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7. Measure the throttle signal from the sensor to the Instrument Cluster.
or broken wires.
has been resolved.
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1039 - Hand throttle sensor voltage under 200 mV for 5 seconds

Context:
Cause:

Solution:

seconds (55.408).
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RCPH10TLB053FAM 1

Connect the breakout harness between connector X608.
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Remove the breakout harness and reconnect the hand throttle sensor to the instrument cluster harness.
or broken wires.
has been resolved.
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1040 - Engine overspeed warning, Engine speed greater than 2750

RPM for 5 seconds
Cause:
The instrument cluster has detected an engine speed greater than 2750 RPM for a period greater than 5 s. The warn-
ing lamp will illuminate amber and the LCD backlight will change from the normal backlight to amber. The instrument
cluster will sound the alarm for 1 s upon activation per key cycle.
Solution:
1. Fault Code 1040 is displayed on the instrument cluster to warn the operator that the engine speed has exceeded
2750 RPM. For more information refer to 3177 (DTC F1A2) - Engine over speed condition detected (55.640).
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1041 - Engine overspeed fault, Engine speed greater than 3000

RPM for 5 seconds
NOTICE: Always stop the machine and shut down the engine whenever the danger lamp illuminates.
Cause:
The instrument cluster has detected an engine speed greater than 3000 RPM for a period greater than 5 s. The
danger lamp will illuminate red and the LCD backlight will change from the normal backlight to red. The instrument
cluster will sound the alarm continuously.
Solution:
1. Stop the engine.

2. Fault Code 1041 is displayed on the instrument cluster to warn the operator that the engine speed has exceeded
3000 RPM.
Stop the engine. For more information refer to 3177 (DTC F1A2) - Engine over speed condition detected
(55.640).
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1044 - Fuel level sensor below 2.0 ohm for 5 seconds, shorted low
Context:
The instrument cluster has detected the fuel level sender resistance is below 2 Ω for a period greater than 2 s. The
instrument cluster will illuminate the warning lamp and will sound the alarm for one second on the next system
Cause:
The instrument cluster has detected the fuel level sender resistance below 2 Ω for a period greater than 2 s.
1. Wiring or circuits shorted to minus battery or chassis ground.

2. Faulty fuel level sensor.
Solution:

Inspect the instrument cluster and the fuel level sensor connections. All connections should be secure, tight, free
of corrosion, abrasion and damage.
Inspect the harness from the instrument cluster to the fuel level sensor. Verify that the harness is free of damage,
3. Measure the resistance of the fuel level signal to chassis ground.
Disconnect the fuel level sensor connector X005.
Measure the resistance between X005 pin a and X005 pin 2.

Refer to the fuel tank level. The resistance should between 4.5 Ω and 330 Ω.
Level Resistance
Full 2.5 Ω to 6.5 Ω
Empty 320 Ω to 340 Ω
A. The resistance measurements were within tolerances. Go to step 4.
B. The resistance values did not match the values from the table or the resistance was less than 2.5 Ω. Replace
the fuel level sensor. Go to step 1 to confirm elimination of the fault code.
4. Measure the resistance at the fuel level sensor.
Tilt the cab and remove the fuel level sender from the tank.
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Disconnect the harness from the sender.
Move the fuel level float from the low to high position while measuring the resistance of the sender. The resistance
should change linearly from approximately 4.5 Ω at the full tank position to approximately 340 Ω at the empty tank
position. The resistance should change linearly without any fluctuations to a higher or lower resistance.
A. The resistance measurements from the sensor are within specifications. Go to step 5.
B. The resistance readings from the sensor are not steady or the values are not accurate. Temporarily replace
sensor and retest. Return to step 1 to confirm elimination of fault.
5. Check fuel level wiring.
Measure the resistance between X005 pin 2and chassis ground. The resistance should be less than 10 Ω. Wiggle
Measure the resistance between X005 pin 1 and the instrument cluster connector XST2 pin 13. The resistance
should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition.
A. The resistance measurements are within specifications. Temporarily replace the instrument cluster and retest.
Go to step 1 to confirm elimination of the fault.
B. The resistance readings were not with the limits defined in the step. Repair or replace the harness as required.
or broken wires.
has been resolved.
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1045 - Fuel level sensor open circuit

Context:
The instrument cluster has detected an open circuit in the fuel sender signal. The instrument cluster will illuminate
the warning lamp and will sound the alarm for 1 s on the next system power up following the event.
Cause:
The instrument cluster has detected an open circuit in the fuel sender signal.
1. Open circuit in the fuel level sender signal wire.

2. Faulty fuel level sensor.
Solution:

Inspect the instrument cluster and the fuel level sensor connections. All connections should be secure, tight, free
of corrosion, abrasion and damage.
Inspect the harness from the instrument cluster to the fuel level sensor. Verify that the harness is free of damage,
3. Measure the resistance of the fuel level signal to chassis ground.
Disconnect the fuel level sensor connector X005.
Measure the resistance between X005 pin 1 and X005 pin 2.

Refer to the fuel tank level. The resistance should between 4.5 Ω and 330 Ω.
Level Resistance
Full 2.5 Ω to 6.5 Ω
Empty 320 Ω to 340 Ω
A. The resistance measurements were within tolerances. Go to step 4.
B. The resistance values did not match the values from the table or the resistance was less than 2.5 Ω. Replace
the fuel level sensor. Go to step 1 to confirm elimination of the fault code.
4. Measure the resistance at the fuel level sensor.
Tilt the cab and remove the fuel level sender from the tank.
Disconnect the harness from the fuel level sender.
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Move the fuel level float from the low position to high position while measuring the resistance of the sender. The
resistance should change linearly from approximately 4.5 Ω at the full tank position to approximately 340 Ω at the
empty tank position. The resistance should change linearly without any fluctuations to a higher or lower resistance.
A. The resistance measurements from the sensor were within specifications. Go to step 5.
B. The resistance readings from the sensor were not steady or the values were not accurate. Temporarily replace
sensor and retest. Return to step 1 to confirm elimination of fault.
5. Check fuel level wiring.
Measure the resistance between X005 pin 2 and chassis ground. The resistance should be less than 10 Ω. Wiggle
Measure the resistance between X005 pin 1 and instrument cluster connector XST2 pin 13. The resistance should
be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition.
A. The resistance measurements from the sensor were within specifications. Temporarily replace the instrument
cluster and retest. Return to step 1 to confirm elimination of the fault.
B. The resistance readings were not with the limits defined in the step. Repair or replace the harness as required.
or broken wires.
has been resolved.
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1047 - Transmission Temperature Sensor is Shorted Low

Context:
The instrument cluster measures a resistance less than 3 Ω on the transmission oil temperature input, XST2 pin 14.
The instrument cluster will illuminate the warning lamp and will sound the alarm for one second on the next system
The fuel level sensor/transmission oil temperature sensor error icon will illuminate while the fault is active.
The fault will reset once the resistance is greater than 10 Ω for a period greater than 5 s.
Cause:
The instrument cluster measures a resistance less than 3 Ω for a period greater than 5 seconds.
1. Wiring or circuits shorted to minus battery or chassis ground.

3. Faulty reading from instrument cluster.
Solution:
B. Fault code 1047 – Transmission Temperature Sensor is Shorted Low is recorded again. Go to step 2.
Inspect the instrument cluster and the transmission oil temperature sender connections. All connections should
Inspect the harness from the instrument cluster to the transmission oil temperature sender. Verify that the harness
is free of damage, corrosion, abrasion or incorrect attachment.
Schematic Legend
(1) Instrument cluster connector XST2 (2) Transmission oil temperature sender
connector X66
3. Measure the resistance across the sensor.
Disconnect the transmission oil temperature sensor connector X66.
Measure the resistance across the transmission oil temperature sensor. The resistance should be between 30 Ω
and 68.7k Ω. Refer to the chart for more details.
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Temperature Resistance Temperature Resistance

-35 °C 68634 Ω 65 °C 456 Ω
-25 °C 35440 Ω 75 °C 321 Ω
-15 °C 19116 Ω 85 °C 230 Ω
-5 °C 10721 Ω 90 °C 168 Ω
5 °C 10721 Ω 105 °C 124 Ω
15 °C 3756 Ω 115 °C 93 Ω
25 °C 2336 Ω 125 °C 71 Ω
35 °C 1496 Ω 135 °C 55 Ω
45 °C 983 Ω 145 °C 43 Ω
55 °C 662 Ω 155 °C 34 Ω
A. The resistance values are within range. Go to step 1.
B. The resistance measurements are not within range. Temporarily replace the sender and retest. Return to step
1 to confirm elimination of the fault.
Disconnect the transmission oil temperature sender from the harness.
Measure the resistance between XST2 pin 14 and chassis ground. Wiggle the harness during measurement to
reveal an intermittent condition. The resistance should be greater than 20,000 Ω.
A. The resistance is greater than 20,000 Ω. Temporarily replace the instrument cluster and retest. Return to step
B. The resistance is less than 20,000 Ω. There is a short circuit in the signal wire to chassis ground. Repair or
or broken wires.
has been resolved.
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1050 - Alternator L+ terminal under 1.5 volts for 5 seconds

NOTE: The battery must be at full charge, and all connections must be clean and tight before testing the electrical
system.
Context:
The instrument cluster measures a voltage less than 1.5 V for a period greater than 5 s on connector XST2 pin 24.
The instrument cluster will illuminate the battery warning symbol when it detects a problem in the battery charging
system. The instrument cluster will illuminate the warning lamp and will sound the alarm for one second on the next
system power up following the event.
Cause:
The instrument cluster measures a voltage less than 1.5 V for a period greater than 5 s on connector XST2 pin 24.
1. Wiring or circuits open.

2. Alternator output voltage is less than 11 V.
3. Faulty reading from the instrument cluster.
Solution:

Inspect the alternator and battery connections. All connections should be secure, tight, free of corrosion, abrasion,
and damage.
Inspect the harness from the alternator and the battery to the instrument cluster. Verify that the harness is free of
damage, corrosion, abrasion, or incorrect attachment.
A. All connections are secure and the harness is free of damage. Go to step 3.
to step1 to confirm elimination of the fault.
3. Test the alternator output.
Measure the voltage at the alternator output. The voltage should be approximately 14.5 V.
A. The alternator voltage is less than 11 V. Temporarily replace the alternator and retest. Return to step 1 to
B. The alternator output voltage is approximately 14.5 V. Go to step 4.

Measure the voltage between XST2 pin 24 and chassis ground. The voltage should be approximately 14.5 V.
Wiggle the harness during measurement to reveal an intermittent condition.
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A. The measured voltage is approximately 14.5 V. Temporarily replace the instrument cluster and retest. Return
to step 1 to confirm elimination of the fault code.
B. The measured voltage is less than 11 V. Temporarily replace the alternator and retest. Return to step 1 to
or broken wires.
has been resolved.
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1051 - Timeout of CAN message EEC1, 5 seconds without message

Context:
CAN bus communications between the instrument cluster and the Engine Control Unit (ECU) have been lost. The
instrument cluster did not receive the EEC1 message from the ECU. This fault code may be displayed with other CAN
bus fault code messages. The instrument cluster will illuminate the danger lamp and will continually sound the audible
alarm.
Cause:
The instrument cluster has stopped receiving CAN messages from the ECU. CAN bus communications between the
instrument cluster and the ECU have been lost.
1. CAN data link wiring or circuits open.

2. CAN data link wiring or circuits shorted.
4. Faulty ECU.
Solution:

If three or more fault codes are active, 3096, 3334,1051 through 1059, this is an indication of a problem in the
CAN Data Link circuit, continue with this procedure. If one or two CAN Data Link fault codes are active, this is
an indication of an intermittent connection in the CAN circuit. Check all wires and connectors to verify they are
secure and free of damage, corrosion, abrasion or incorrect attachment.
A. CAN Data Link fault codes are not recorded again and are no longer ACTIVE. OK to return the machine service.
B. CAN Data Link fault codes are present and ACTIVE. Go to step 2.
Verify the connections to the ECU, instrument cluster, diagnostic connector, Trax control (if installed) and the op-
tional Telematics unit are tight and secure.
Verify the harness is free of damage, abrasion, corrosion and incorrect attachment from the ECU to the instrument
cluster. Verify all data link drops are free of damage, abrasion, corrosion and incorrect attachment.
A. The CAN Data Link harness is not damaged and all connections are secure. Go to step 3.
B. The harness is damaged or the connectors are loose or damaged. Repair or replace the harness as required.
Go to step 1 to confirm the elimination of the fault code.
3. Measure the resistance through the CAN Data Link harness.
Measure the resistance between the Diagnostic Port connector, CAN 1 High and CAN 1 Low pins, pins C and D.
The resistance should be approximately 60 Ω. Wiggle the harness during measurement to reveal an intermittent
condition.
A. The resistance is between 54 Ω and 66 Ω. Go to step 4.
B. The resistance is less than 50 Ω. Go to Step6.
C. The resistance is greater than 70 Ω. Go to step 7.
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4. Measure the harness resistance to chassis ground.
Disconnect the instrument cluster connector, XST2.
Disconnect all devices connected to the CAN Data Link.
Measure the resistance between XST2 pin 3 and chassis ground. The resistance should be greater than 20,000 Ω.
A. Both resistance measurements are greater than 20,000 Ω. Go to step 5.
B. One or both resistance measurements are less than 20,000 Ω. There is a short circuit in the CAN Data Link.
Temporarily replace the CAN Data Link wires and retest. Repair or replace the harness as required. Return to
step 1 to confirm the elimination of the fault code.
5. Check the stray voltages on the harness. .
Measure the voltage between XST2 pin 3 and chassis ground. The voltage should be less than 0.5 V. Wiggle the
A. Both voltage measurements are less than 0.5 V. Verify the ECU is powered and operational. Verify that all
minus battery and chassis ground connections to the CAN Bus modules are clean and secure. Return to step
1.
B. One or both voltage measurements are greater than 0.5 V. There is a short circuit to another voltage source
in the CAN Data Link. Temporarily replace the CAN Data Link wires and retest. Repair or replace the harness
as required. Return to step 1 to confirm the elimination of the fault code.
6. Measure the resistance between the CAN High and CAN Low lines.
Disconnect all modules on the CAN bus.
Measure the resistance between CAN High X-607 pin C and CAN Low X-607 pin D.
A. The resistance is greater than 20,000 Ω. Connect each component to the CAN Bus one at a time. The re-
sistance should be greater than 60 Ω. Replace the module that drops the CAN Bus resistance below 60 Ω.
Return to step 1 to confirm the elimination of the fault code.
B. The resistance is less than 56 Ω. There is a short circuit between the CAN High and CAN Low wires. Repair
or replace the harness as required. Return to test step 1 to confirm the elimination of the fault code.
7. Measure the resistance through the CAN Data Link circuit.
Turn the key switch OFF. Disconnect all components connected to the CAN Bus.
Fabricate a jumper that will connect between X-461 pin 24 and X-461 pin 25.
Connect the jumper between X-461 pin 24 and X-461 pin 25.
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Measure the resistance between connector X-607 pin C and X-607 pin D. The resistance should be less than
10 Ω. Wiggle the harness during measurement to reveal an intermittent condition.
RCPH11TLB074FAL 1
(1) Digital volt meter set to measure (5) CAN Bus to instrument cluster
resistance CAN High XST2 pin 4
CAN Low XST2 pin 3
(2) Diagnostic Port X-607 (6) CAN Bus to ECU
CAN High X-461 pin 24
CAN Low X-461 pin 25
(3) Jumper wire installed between the CAN (7) CAN Bus to Telematics (optional)
High and CAN Low pins CAN High X500 pin 3
CAN Low X500 pin 4
(4) CAN Bus to Trax Control
CAN High X401 pin 27
CAN Low X401 pin 55
Measure the resistance between the Telematics connector pins C and D. The resistance should be less than 10 Ω.
Measure the resistance between the Trax connector X401 pin 27 and X401 pin 55. The resistance should be less
than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition.
Measure the resistance between instrument cluster connector XST2 pin 4 and XST2 pin 3. The resistance should
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RCPH11TLB072FAL 2
CAN Low XST2 pin 3
(2) Diagnostic Port X607 (6) CAN Bus to ECU
CAN Low X500 pin 4
CAN Low X401 pin 55
A. All resistance measurements are less than 10 Ω. Temporarily replace the ECU and retest. Return to step 1 to
confirm the elimination of the fault code.
B. A resistance measurement is greater than 20,000 Ω. There is an open circuit in the wiring to the ECM. Repair
or replace the harness as required. Return to step 1 to confirm the elimination of the fault code.
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1052 - Timeout of CAN message EEC3, 5 seconds without message

Context:
instrument cluster did not receive the EEC3 message from the ECU. This fault code may be displayed with other CAN
alarm.
Cause:

4. Faulty ECU.
Solution:
To check for fault code: Start and operate the machine.
If three or more fault codes are active, such as 1051 through 1059 or 3096, 3334, 3339 or 3358, this is an indication
of a problem in the CAN bus circuit, continue with this procedure. If one or two CAN bus fault codes are active,
this is an indication of an intermittent connection in the CAN circuit. Check all wire and connector to verify they
are secure and free of damage, corrosion, abrasion or incorrect attachment.
A. CAN Data Link fault codes are not recorded again and are no longer active. OK to return the machine to
service.
B. CAN Data Link fault codes are present and ACTIVE. Continue with 1051 - Timeout of CAN message EEC1,
5 seconds without message (55.408) .
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1053 - Timeout of CAN message CNFBAM, 25 seconds without

message
Context:
instrument cluster did not receive the CNFBAM message from the ECU. This fault code may be displayed with other
CAN bus fault code messages. The instrument cluster will illuminate the danger lamp and will continually sound the
audible alarm.
Cause:

4. Faulty ECU.
Solution:
service.
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1054 - Timeout of CAN message engine temperature, 5 seconds

without message
Context:
instrument cluster did not receive the engine temperature message from the ECU. This fault code may be displayed
with other CAN bus fault code messages. The instrument cluster will illuminate the danger lamp and will continually
sound the audible alarm.
Cause:

4. Faulty ECU.
Solution:
service.
5 seconds without message (55.408).
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1055 - Timeout of CAN message inlet/exhaust, 5 seconds without

message
Context:
instrument cluster did not receive the inlet exhaust message from the ECU. This fault code may be displayed with
other CAN bus fault code messages. The instrument cluster will illuminate the danger lamp and will continually sound
the audible alarm.
Cause:

4. Faulty ECU.
Solution:
this is an indication of an intermittent connection in the CAN circuit. Check all wires and connectors to verify they
service.
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1056 - Timeout of CAN message DPFC1, 5 seconds without

message
Context:
instrument cluster did not receive the DPFC1 message from the ECU. This fault code may be displayed with other
audible alarm.
Cause:

4. Faulty ECU.
Solution:
service.
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1057 - Timeout of CAN message vehicle electrical, 5 seconds

without message
Context:
instrument cluster did not receive the vehicle electrical message from the ECU. This fault code may be displayed with
other CAN bus fault code messages. The instrument cluster will illuminate the danger lamp and will continually sound
the audible alarm.
Cause:

4. Faulty ECU.
Solution:
service.
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1058 - Timeout of CAN message EDC2BC, 5 seconds without

message
Context:
instrument cluster did not receive the EDC2BC message from the ECU. This fault code may be displayed with other
audible alarm.
Cause:

4. Faulty ECU.
Solution:
service.
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1059 - Timeout of CAN message DM1, 5 seconds without message

Context:
instrument cluster did not receive the DM1 message from the ECU. This fault code may be displayed with other CAN
alarm.
Cause:

4. Faulty ECU.
Solution:
service.
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1060 - Timeout Of CAN Message EGRIND

Context:
CAN bus communications between the instrument cluster and the ECU may have been interrupted. The instrument
cluster did not receive the EGRIND message from the ECU. This fault code may be displayed with other CAN bus
fault messages. The instrument cluster will illuminate the stop lamp and will continually sound the audible alarm while
this fault is active.
Cause:
The instrument cluster did not receive a CAN message from the ECU. CAN bus communications between the instru-
ment cluster and the ECU may have been interrupted.
1. CAN bus wiring open circuit.

2. CAN bus wiring short circuit.
4. Faulty ECU.
Solution:
A. Fault code is not recorded again. Go to step 2.
B. Fault code is recorded again. There may be one or two other CAN bus fault codes associated with 1051 –
Expected CAN Message Not Received (EEC1). Go to step 2.
C. Fault code 1060 – Timeout Of CAN Message EGRIND is recorded along with other CAN data link faults such
as 1051-1059, and/or 3096, 3179 and 3180. Go to 1051 - Timeout of CAN message EEC1, 5 seconds
without message (55.408) step 3.
2. Verify that the CAN bus circuit is functioning properly.
Verify the connections to the ECU, instrument cluster, diagnostic connector, and the optional Telematics unit are
tight and secure. Check for CAN bus fault codes while wiggling the harness.
Measure the resistance between XST2 pin 3 and XST2 pin 4 on the instrument cluster. The resistance should be
between 108 Ω and 132 Ω.
Disconnect ECU connector X-461.
Measure the resistance between X-461 pin 25 and X-461 pin 24 on the ECU. The resistance should be between
108 Ω and 132 Ω.
A. All connections are secure. Both resistance measurements are within range. OK to return the machine to
service.
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C. One or both resistance measurements are less than 108 Ω or greater than 132 Ω. Replace the control that
has the bad resistance value. Return to step 1 to confirm elimination of fault.
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1090 - Vehicle Model ID in VCM is UNCONFIGURED

Cause:
The Vehicle Model ID is not programmed in the instrument cluster. One or more parameters in the instrument cluster
are not programmed.
1. The instrument cluster is not configured properly.
Solution:
1. Connect the Electronic Service Tool and configure all programmable parameters in the instrument cluster.
RAIL14FRK0188FA 1
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3007 (DTC 1113) - Engine coolant temperature sensor voltage is

higher than expected
Context:
The Engine Control Unit (ECU) monitors the engine coolant temperature sensor signal circuit. If the ECU A-9000
determines that voltage is higher than expected in the engine coolant temperature sensor signal circuit, this fault will
occur. If this fault is active, the ECU will set the engine coolant temperature value to a fixed replacement value of
89.96 °C (193.93 °F).
Cause:
The engine coolant temperature sensor signal voltage is greater than 4.93 V.
1. Faulty engine coolant temperature sensor, internal failure.

2. Faulty engine coolant temperature sensor circuit wiring, open circuit or short to a voltage source.
3. Faulty ECU, software.
Solution:
1. Verify fault is present and active.
Use the Electronic Service Tool (EST) to check the status of this fault.
A. If the fault is present and active, continue with step 2.
B. If the fault is no longer present or in an inactive state, the fault may be intermittent and not currently active.
Continue with step 5.
2. Check the coolant temperature sensor for an internal failure.
Disconnect the engine harness (EN) from the coolant temperature sensor.
Use a multimeter to measure the resistance of the coolant temperature sensor on the sensor pins :
From To Value
Coolant temperature sensor pin 1 Coolant temperature sensor pin 2 At approximately 20.0 °C (68.0 °F)
there should be between 2,000 –
3,000 Ω .
NOTE: The coolant temperature sensor is a Negative Temperature Coefficient (NTC) thermistor. The thermistor’s
conductivity increases with increasing temperature and resistance decreases with increasing temperature.
A. If the resistance value is relative, based on temperature, leave the coolant temperature sensor disconnected
and continue to step 3.
B. If the resistance value is not relative, based on temperature, then the coolant temperature sensor has failed.
Replace the coolant temperature sensor and retest.
3. Check the coolant temperature sensor engine harness (EN) circuit wiring.
Disconnect the vehicle harness (VE) from the engine interface at connector X-9138.
Use a multimeter to check for an open circuit in the engine harness (EN) side :
From To Value
Coolant temperature sensor X-470 pin 14 There should be continuity.
connector pin 1
Coolant temperature sensor X-470 pin 13 There should be continuity.
connector pin 2
Use a multimeter to check for a short circuit to another voltage source in the engine harness (EN) side :
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From To Value
X-470 pin 14 All pins in connector X-470 There should be no continuity.
With the key in the OFF position, use a multimeter to check for a short circuit to battery voltage in the engine
harness (EN) side :
From To Value
Coolant temperature sensor Chassis ground There should be no voltage.
connector pin 1
With the key in the ON position, use a multimeter to perform the following voltage check, for a short to switched
battery voltage condition, on the engine harness (EN) side :
From To Value
Coolant temperature sensor Chassis ground There should be no voltage.
connector pin 1
A. If the specified values are measured, then leave connector X-470 disconnected. Leave the coolant temperature
sensor disconnected and continue to step 4.
B. If the specified values are not measured, then there is a failure in the coolant temperature sensor circuit wiring
in the engine harness (EN). Locate and repair the failed conductor or conductors. Repair or replace the harness
as required.
4. Check the coolant temperature sensor vehicle harness (VE) circuit wiring.
Disconnect the vehicle harness (VE) from the ECU at connector X-462.
Use a multimeter to check for an open circuit in the vehicle harness (VE) side :
From To Value
X-470 pin 14 X-462 pin 57 There should be continuity.
Use a multimeter to check for a short circuit to another voltage source in the vehicle harness (VE) side :
From To Value
X-462 pin 57 all other pins in connector X-462 There should be no continuity.
With the key switch in the OFF position, use a multimeter to check for a short circuit to battery voltage in the vehicle
harness (VE) side :
From To Value
X-462 pin 57 Chassis ground There should be no voltage.
With the key switch in the ON position, use a multimeter to check for a short circuit to switched battery voltage in
the vehicle harness (VE) side :
From To Value
A. If the specified values are not measured, then there is a fault in the coolant temperature sensor circuit wiring
in the vehicle harness (VE). Locate and repair the damaged conductor or conductors. Repair or replace the
harness as required.
B. If the specified values are measured, then check the ECU for the appropriate software and re-flash, if neces-
sary.
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5. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals,
or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent
breaks or shorts in the wiring concerned. Operate the machine while you monitor the display.
has been resolved.
B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue
operation.
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3008 (DTC 2213) - Engine coolant temperature sensor voltage is

lower than expected
Context:
The Engine Control Unit (ECU) monitors the engine coolant temperature sensor signal circuit. If the ECU determines
that voltage is lower than expected in the engine coolant temperature sensor signal circuit, this fault will occur. If
this fault is active, the ECU will set the engine coolant temperature value to a fixed replacement value of 89.96 °C
(193.93 °F).
Cause:
The engine coolant temperature sensor signal voltage is less than 0.198 V.
1. Faulty engine coolant temperature sensor, internal failure.

2. Faulty engine coolant temperature sensor circuit wiring, short to ground condition.
Solution:
B. If the fault is no longer present or in an inactive state, then the fault may be intermittent and not currently active.
2. Check the coolant temperature sensor for an internal failure.
Disconnect the engine harness (EN) from the coolant temperature sensor.
Use a multimeter to measure the resistance of the coolant temperature sensor on the sensor pins :
From To Value
Coolant temperature sensor pin 1 Coolant temperature sensor pin 2 At approximately 20.0 °C (68.0 °F)
there should be between 2,000 –
3,000 Ω.
NOTE: The coolant temperature sensor is a Negative Temperature Coefficient (NTC) thermistor. The thermistor’s
A. If the resistance value is relative based on temperature, then leave the coolant temperature sensor discon-
nected and continue to step 3.
B. If the resistance value is not relative, based on temperature, then the coolant temperature sensor has failed.
Replace the coolant temperature sensor and retest.
3. Check the coolant temperature sensor engine harness (EN) wiring for a short circuit to ground.
Use a multimeter to perform the following continuity check on the engine harness side :
To From Value
Coolant temperature sensor Coolant temperature sensor There should be no continuity.
connector pin 1 connector pin 2
Coolant temperature sensor Chassis ground There should be no continuity.
connector pin 1
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A. If there is no continuity, then leave the coolant temperature sensor disconnected. Leave connector X-470
disconnected and continue to step 3.
B. If there is continuity, then there is a short circuit to ground in the coolant temperature sensor engine harness
(EN) wiring. Locate and repair the damaged conductor or conductors. Repair or replace the harness as re-
quired.
4. Check the coolant temperature sensor vehicle harness (VE) wiring for a short circuit to ground.
Use a multimeter to perform the following continuity check on the vehicle harness (VE) side :
From To Value
X-470 pin 14 Chassis ground There should be no continuity.
A. If there is no continuity, check the ECU for the appropriate software and re-flash, if necessary.
B. If there is continuity, then there is a short to ground condition in the coolant temperature sensor vehicle har-
ness (VE) wiring. Locate and repair the damaged conductor or conductors. Repair or replace the harness as
required.
has been resolved.
operation.
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3010 (DTC 2474) - Intake manifold temperature sensor voltage is

lower than expected
Context:
The Engine Control Unit (ECU) monitors the intake manifold temperature sensor. If the ECU determines that the
intake manifold temperature sensor signal circuit voltage is less than 202.80 mV, then this fault will occur. If this fault
is active, the intake manifold temperature value will be frozen at the last valid value for a preliminary failure or jump
to a fixed replacement value of 0.98 bar (14.21 psi) if the failure is validated.
Cause:
The ECU has determined that the intake manifold temperature sensor signal circuit voltage is less than 202.80 mV.
1. Faulty intake manifold temperature sensor wiring, short circuit to ground.

2. Faulty intake manifold temperature sensor, internal failure.
Solution:
A. If the fault is present and active, then continue with step 2.
2. Check the intake manifold temperature sensor wiring in the engine harness (EN) for a short circuit to ground.
Disconnect the engine harness (EN) from the intake manifold temperature sensor.
With the key in the OFF position, use a multimeter to perform the following continuity check on the engine harness
(EN) side :
From To Value
Intake manifold temperature sensor Chassis ground There should be no continuity.
connector pin 2
Intake manifold temperature sensor Intake manifold temperature sensor There should be no continuity.
A. If there is continuity, then there is a short circuit in the intake manifold temperature sensor wiring in the engine
harness (EN). Locate and repair the shorted conductor. Repair or replace the harness as required.
B. If there is no continuity, then leave the intake manifold temperature sensor disconnected. Leave connector
X–470 disconnected and continue to step 3.
3. Check the intake manifold temperature sensor wiring in the vehicle harness (VE) for a short circuit to ground.
Disconnect the vehicle harness from the ECU at connector X-462.
With the key in the OFF position, use a multimeter to perform the following continuity check on the vehicle harness
(VE) side :
From To Value
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A. If there is continuity, then there is a short circuit in the intake manifold temperature sensor wiring in the vehicle
harness (VE).Locate and repair the shorted conductor. Repair or replace the harness as required.
B. If there is no continuity, then leave the intake manifold temperature sensor disconnected and continue to step
4.
4. Replace the intake manifold temperature sensor and retest.
A. If the fault is no longer active, then return the machine to service.
B. If the fault is still active, then check the ECU for the appropriate software and re-flash, if necessary.
has been resolved.
operation.
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3015 (DTC 1C15) - Fuel temperature sensor voltage is higher than

expected
Context:
The Engine Control Unit (ECU) monitors the fuel temperature sensor signal circuit voltage. If the ECU detects a
voltage greater than 4.93 V in the signal circuit, this fault will occur. If this fault is not inhibited by another fault, the
ECU will freeze the fuel temperature value to 39.96 °C (103.93 °F).
Cause:
The fuel temperature sensor signal circuit voltage is greater than 4.93 V.
1. Faulty fuel temperature sensor, internal failure.

2. Faulty fuel temperature sensor circuit wiring, open circuit or short to a voltage source.
Solution:
2. Check the fuel temperature sensor for an internal failure.
Disconnect the engine harness from the fuel temperature sensor.
Use a multimeter to measure the resistance of the fuel temperature sensor on the sensor pins :
From To Value
Fuel temperature sensor pin 1 Fuel temperature sensor pin 1 At approximately 20.0 °C (68.0 °F),
there should be between 2351 –
2648 Ω.
NOTE: The fuel temperature sensor is a Negative Temperature Coefficient (NTC) thermistor. The thermistor’s
A. If the resistance value is relative, based on temperature, then leave the fuel temperature sensor disconnected
B. If the resistance value is not relative, based on temperature, then the fuel temperature sensor has failed. Re-
place the fuel temperature sensor and retest.
NOTE: Due to internal circuit configuration, the ECU can not distinguish between an open circuit and a short circuit
to another voltage source. Therefore a very high to infinite fuel temperature sensor internal resistance could cause
this fault.
3. Check the fuel temperature sensor circuit wiring in the engine harness (EN).
With the key in the OFF position, use a multimeter to check for an open circuit in the engine harness (EN) side :
From To Value
Fuel temperature sensor connector X-470 pin 16 There should be continuity.
pin 1
Fuel temperature sensor connector X-470 pin 15 There should be continuity.
pin 2
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With the key in the OFF position, use a multimeter to check for a short circuit to another circuit in the engine
harness (EN) side :
From To Value
With the key in the OFF position, use a multimeter to check for a short circuit to battery voltage source in the
engine harness (EN) side :
From To Value
Fuel temperature sensor connector Chassis ground There should be no voltage.
pin 1
With the key in the ON position, use a multimeter to check for a short circuit to switched battery voltage in the
From To Value
Fuel temperature sensor connector Chassis ground There should be no voltage.
pin 1
A. If the specified values are measured, then leave the fuel temperature sensor disconnected. Leave connector
X-470 disconnected and continue to step 4.
B. If the specified values are not measured, then there is a failure in the fuel temperature sensor circuit wiring in
the engine harness (EN). Locate and repair the failed conductor or conductors. Repair or replace the harness
as required.
4. Check the fuel temperature sensor circuit wiring in the vehicle harness (VE).
With the key in the OFF position, use a multimeter to check for an open circuit in the vehicle harness (VE) side :
From To Value
With the key in the OFF position, use a multimeter to check for a short circuit to another circuit in the vehicle
harness (VE) side :
From To Value
With the key in the OFF position, use a multimeter to check for a short circuit to battery voltage in the vehicle
harness (VE) side :
From To Value
With the key in the ON position, use a multimeter to check for a short circuit to switched battery in the vehicle
harness (VE) side :
From To Value
A. If the specified values are not measured, then there is a fault in the fuel temperature sensor circuit wiring in the
vehicle harness (VE). Locate and repair the damaged conductor or conductors. Repair or replace the harness
as required.
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B. If the specified values are measured, then check the ECU for the appropriate software and re-flash, if neces-
sary.
or broken wires.
Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned.
Operate the machine while you monitor the display.
has been resolved.
operation.
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3016 (DTC 2D15) - Fuel temperature sensor voltage is lower than

expected
Context:
The Engine Control Unit (ECU) monitors the fuel temperature sensor signal circuit voltage. If the ECU detects a volt-
age less than 0.198 V in the signal circuit, then this fault will occur. If this fault is not inhibited by another fault, then the
ECU will freeze the fuel temperature value to 39.96 °C (103.93 °F). For information regarding the functional operation
of the fuel temperature sensor, refer to the engine service manual Fuel injection system - Overview (10.218).
Cause:
The fuel temperature sensor signal circuit voltage is less than 0.198 V.
1. Faulty fuel temperature sensor, internal failure.

2. Faulty fuel temperature sensor circuit wiring, short to ground condition.
Solution:
2. Check the fuel temperature sensor for an internal failure.
Disconnect the engine harness (EN) from the fuel temperature sensor.
Use a multimeter to measure the resistance of the fuel temperature sensor on the sensor pins :
From To Value
Fuel temperature sensor pin 1 Fuel temperature sensor pin 2 At approximately 20.0 °C (68.0 °F),
there should be between 2351 –
2648 Ω.
NOTE: The fuel temperature sensor is a Negative Temperature Coefficient (NTC) thermistor. The thermistor’s
A. If there the resistance is greater than 100 Ω, then leave the fuel temperature sensor disconnected and continue
to step 3.
B. If there is not a nominal resistance value, 0 Ω, then the fuel temperature sensor has failed. Replace the fuel
temperature sensor and retest.
3. Check the fuel temperature sensor engine harness (EN) wiring for a short circuit to ground.
With the key in the OFF position, use the a multimeter to check for a short circuit to ground in the engine harness
(EN) side :
From To Value
Fuel temperature sensor connector Fuel temperature sensor connector There should be no continuity.
pin 1 pin 2
Fuel temperature sensor connector Chassis ground There should be no continuity.
pin 1
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A. If there is no continuity, then leave the fuel temperature sensor disconnected. Leave connector X-470 discon-
B. If there is continuity, then there is a short circuit in the fuel temperature sensor wiring in the engine harness
(EN). Locate and repair the failed conductor or conductors. Repair or replace the harness as required.
4. Check the fuel temperature sensor vehicle harness (VE) wiring for a short circuit to ground.
With the key in the OFF position use the a multimeter to perform the check for a short circuit to ground in the
vehicle harness (VE) side :
From To Value
X-470 pin 16 X-470 pin 15 There should be no continuity.
A. If there is continuity, then there is a fault in the fuel temperature sensor vehicle harness (VE) wiring. Locate
and repair the failed conductor. Repair or replace the harness as required.
B. If there is no continuity, then check the ECU for the appropriate software and re-flash, if necessary.
has been resolved.
operation.
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3019 (DTC 1D64) - Intake manifold pressure sensor voltage is

Context:
The Engine Control Unit (ECU) monitors the intake manifold temperature sensor signal circuit. If the ECU determines
that the intake manifold temperature sensor signal circuit voltage is greater than 4.94 V, then this fault will occur.
Cause:
The ECU has determined that the intake manifold temperature sensor signal circuit voltage is greater than 4.94 V.
1. Faulty intake manifold temperature sensor wiring, short circuit to another voltage source.
2. Faulty intake manifold temperature sensor wiring, open circuit.
Solution:
2. Check the intake manifold temperature sensor wiring for a short circuit to battery.
With the key in the OFF position, use a multimeter to perform the following voltage check on the engine harness
(EN) side :
From To Value
Intake manifold temperature sensor Chassis ground There should be no voltage.
connector pin 1
With the key in the ON position, use a multimeter to perform the following voltage check on the engine harness
(EN) side :
From To Value
Intake manifold temperature sensor Chassis ground There should be less than 5.5 V.
connector pin 1
A. If the specified values are not measured, then there is a short circuit to another voltage source in the intake
manifold temperature sensor signal circuit. Locate and repair the shorted conductor. Repair or replace the
B. If the specified values are measured, then leave the intake manifold temperature sensor disconnected and
continue to step 3.
3. Check the intake manifold temperature sensor wiring for an open circuit.
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From To Value
Intake manifold temperature sensor X-470 pin 20 There should be continuity.
connector pin 1
connector pin 2
NOTE: Wiggle the harness during measurement to reveal an intermittent electrical connection.
From To Value
NOTE: Wiggle the harness during measurement to reveal an intermittent electrical connection.
A. If there is no continuity, then there is an open circuit in the intake manifold temperature sensor wiring. Locate
and repair the broken conductor. Repair or replace the harness as required.
B. If there is continuity, then leave connector X-470 and X-462 disconnected and continue to step 4.
4. Check the intake manifold temperature sensor engine harness (EN) wiring for a short circuit.
(EN) side :
From To Value
A. If there is continuity, then there is a short circuit in the intake manifold temperature sensor in the engine harness
(EN) wiring. Locate and repair the shorted conductor. Repair or replace the harness as required.
B. If there no continuity, then continue to step 5.

5. Check the intake manifold temperature sensor vehicle harness (VE) wiring.
(VE) side :
From To Value
A. If there is continuity, then there is a short circuit in the intake manifold temperature sensor in the vehicle harness
(VE) wiring. Locate and repair the shorted conductor. Repair or replace the harness as required.
B. If there no continuity, then continue to step 6.

has been resolved.
operation.
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3024 (DTC 13C4) - ECU internal failure - Ambient pressure sensor

voltage is higher than expected
Context:
The Engine Control Unit monitors ambient pressure by the ambient pressure sensor which is internal to the ECU. If
the ECU detects a voltage greater than 4.88 V for a period greater than 0.8 s, then this fault will occur. If this fault
occurs, then the ambient pressure will be frozen at the last valid ambient pressure value for a preliminary failure and
a replacement ambient pressure of 0.8 bar (11.6 psi) if the failure is validated. As this fault can occur from abnormal
altitude, verify that the machine is not being operated at extreme altitude before diagnosing this fault.
Solution:
1. Check the ECU for the appropriate software and re-flash, if necessary.
A. If the fault has been resolved, then return the machine to service.
B. If the fault has not been resolved, then escalate an ASIST concern.
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3025 (DTC 24C4) - ECU internal failure - Ambient pressure sensor

voltage is lower than expected
Context:
The Engine Control Unit (ECU) monitors ambient pressure by the ambient pressure sensor which is internal to the
ECU. If the ECU detects a voltage less than 0.190 V for a period greater than 0.8 s, then this fault will occur. If this
fault occurs, then the ambient pressure will be frozen at the last valid ambient pressure value for a preliminary failure
and a replacement ambient pressure of 0.8 bar (11.6 psi) if the failure is validated. As this fault can occur from higher
than normal altitude, verify that the machine is not being operated at extreme altitude before diagnosing this fault.
Solution:
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3027 (DTC 34D3) - Defect fault check for plausibility from digital
sensor
Context:
The Engine Control Unit (ECU) monitors the oil pressure switch for proper operation. The oil pressure switch changes
from its off to an on state between 0.6 – 0.9 bar (8.7 – 13.0 psi). If the oil pressure switch does not return to its off
state once the engine is switched OFF, then this fault will occur.
Cause:
The ECU has sensed that the oil pressure switch did not return to its off state.
1. Faulty oil pressure switch, failed internally.

2. Faulty oil pressure switch circuit wiring, open circuit.
Solution:
1. Verify that the fault is present and active.
2. Check the condition of the oil pressure switch.
Disconnect the engine harness (EN) from the oil pressure switch.
Use a multimeter to check for continuity on the component side :
From To Result
Oil pressure switch pin 1 Chassis ground There should be continuity.
A. If there is continuity, leave the oil pressure switch disconnected and continue with step 3.
B. If there is no continuity, then the oil pressure switch has failed internally. Replace the switch and retest.
3. Check the oil pressure switch circuit for an open circuit.
Place a jumper wire between connector X-462 pin 6 and chassis ground.
Use a multimeter to check for continuity on the engine harness (EN) side :
From To Result
Oil pressure switch connector pin 1 Chassis ground There should be continuity.
A. If there is no continuity, then leave the jumper wire in place. Leave the oil pressure switch disconnected. Leave
connector X-462 disconnected and continue with step 4.
B. If there is continuity, then check the ECU for the appropriate software and re-flash, if necessary.
4. Locate the open circuit.
Disconnect the vehicle harness (VE) from the engine interface connector X-470.
Use a multimeter to check for continuity on the vehicle harness (VE) side :
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From To Result
X-470 pin 3 Chassis ground There should be continuity.
A. If there is continuity, then the open circuit condition is the engine harness (EN) between connector X-470 pin
3 and the oil pressure switch connector pin 1Locate and repair the broken conductor. Repair or replace the
B. If there is no continuity, then the open circuit condition is in the vehicle harness (VE) between connector X-470
pin 3 and X-462 pin 6. Locate and repair the broken conductor. Repair or replace the harness as required.
or broken wires.
has been resolved.
operation.
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3028 (DTC 26D3) - Oil pressure is too low

Context:
The Engine Control Unit (ECU) has detected a low oil pressure condition.
Cause:
Engine speed is greater than 500 RPM and the oil pressure switch did not close. The oil pressure switch will close to
indicate to the ECU that the engine is running with the proper oil pressure.
1. Low engine oil level.

2. Faulty engine lubrication system.
3. Faulty electrical wiring, open circuit in the signal wire to the ECU.
4. Faulty oil press switch.
5. Faulty ECU.
Solution:
A. The fault is not recorded again. OK to return the machine to service.
B. Fault code 3028 (DTC 26D3) – Oil pressure is too low is recorded again. Go to step 2.
2. Check the engine oil level.
Check the engine oil level. Refer to the operators manual for the proper oil level.
A. The oil level is correct. Go to step 3.
B. The oil level is not correct. Refer to the operators manual for the proper oil level. Repair as required. Return
Inspect the ECU and the oil pressure switch connections. All connections should be secure, tight, free of corrosion,
abrasion and damage.
Inspect the harness from the ECU to the oil pressure switch. Verify that the harness is free of damage, corrosion,
abrasion and incorrect attachment.
to step 1 to confirm the elimination of the fault.
Disconnect ECU connector X-462 and the oil pressure switch connector.
Fabricate a jumper wire that will connect between the oil pressure switch connector, pin 1 and chassis ground.
The chassis ground connection should be clean and free of oil, paint and dirt.
Connect the jumper wire between the oil pressure switch connector, pin 1 and chassis ground.
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Measure the resistance between X-462 pin 6 and chassis ground. The resistance should be less than 10 Ω.
A. The resistance is less than 10 Ω. Go to step 5.
B. The resistance is greater than 10 Ω. There is an open circuit in the signal wire. Repair as required. Return to
step 1 to confirm the elimination of the fault.
5. Measure the resistance through the oil pressure switch.
Disconnect the oil pressure switch connector.
Start the engine. Set engine speed to 800 RPM.
While the engine is running, measure the resistance through the switch to chassis ground. The chassis ground
connection should be clean and free of oil, paint and dirt. The resistance should be less than 10 Ω.
A. The resistance is less than 10 Ω. Temporarily replace the ECU and retest. Return to step 1 to confirm elimi-
nation of the fault.
B. The resistance is greater than 10 Ω. There is a problem with the oil pressure switch. Temporarily replace the
oil pressure switch and retest. Return to step 1 to confirm the elimination of the fault.
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3037 (DTC 2E64) - Intake manifold pressure sensor voltage is lower

than expected
Context:
The Engine Control Unit (ECU) monitors the intake manifold temperature sensor signal circuit. If the ECU determines
that the intake manifold temperature sensor signal circuit voltage is less than 266.40 mV, then this fault will occur.
Cause:
The ECU has determined that the intake manifold temperature sensor signal circuit voltage is less than 266.40 mV.
1. Faulty intake manifold temperature sensor wiring, short circuit to ground.

Solution:
2. Check the intake manifold temperature sensor engine harness (EN) wiring.
(EN) side :
From To Value
Intake manifold temperature sensor Chassis ground There should be no continuity.
connector pin 1
A. If there is continuity, then there is a short circuit in the intake manifold temperature sensor in the engine harness
B. If there no continuity, then leave the intake manifold temperature sensor disconnected. Leave connector X-470
3. Check the intake manifold temperature sensor vehicle harness (VE) wiring.
(VE) side :
From To Value
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A. If there is continuity, then there is a short circuit in the intake manifold temperature sensor in the vehicle harness
B. If there no continuity, then leave the intake manifold temperature sensor disconnected and continue to step 4.
has been resolved.
operation.
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3051 (DTC 1161) - Battery voltage is higher than expected

Context:
The Electronic Control Unit (ECU) monitors the battery voltage. If the ECU determines that battery voltage has ex-
ceeded 16.1 V, then this fault will occur.
Cause:
The battery voltage is greater than 16.1 V.
1. Faulty charging system.

Solution:
2. Check the battery voltage.
The engine must be running.
Use a multimeter to perform the following voltage check :
From To Value
Battery (+) terminal Battery (–) terminal There should be approximately 12 V.
A. If there is not approximately 12 V, then continue to step 3.
B. If there is approximately 12 V, then check the ECU for the appropriate software and re-flash, if necessary.
3. Check the charging system for proper operation.
A. If the charging system is not functioning properly, then repair the charging system as necessary.
B. If the charging system is functioning properly, then check the ECU for the appropriate software and re-flash, if
necessary.
has been resolved.
operation.
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3052 (DTC 2261) - Battery voltage is lower than expected

Context:
The Electronic Control Unit (ECU) monitors battery voltage. If the ECU determines that battery voltage is less than
10.2 V, then this fault will occur.
Cause:
The battery voltage is less than 10.2 V.
1. Faulty Battery.
2. Engine cranked for extended period of time.
3. Faulty supply wiring.
Solution:
From To Value
A. If there is not approximately 12 V, then charge the battery and then perform a load test on the battery. If the
battery passes the load test, continue to step 3. If the battery fails the load test, continue to step 4.
B. If there is approximately 12 V, then continue to step 3.

B. If the charging system is functioning properly, then continue to step 4.

4. Replace the battery and retest.
Use the Electronic Service Tool (EST) to verify the status of this fault.
A. If the fault has been resolved, then 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.
B. If the fault has not been resolved, then check the ECU for the appropriate software and re-flash, if necessary.
has been resolved.
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operation.
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3059 (DTC 4661) - Main relay stuck error

Context:
The Engine Control Unit controls the main relay. The main relay is powered on by the ECU to achieve after-run. The
main relay is powered off once after-run is completed. If the ECU determines that the main relay is “stuck” or will not
shut off as commanded, this fault will occur.
Cause:
The ECU has determined that the main relay will not shut off as commanded.
1. Faulty main relay, wiring.

2. Faulty main relay, internal failure.
Solution:
2. Check the main relay coil for an internal failure.
Remove the main relay.
Use a multimeter to measure the resistance on the main relay pins :
From To Value
Main relay pin 85 Main relay pin 86 There should be approximately 70 –
130 Ω.
A. If there is approximately 70 – 130 Ω, then leave the main relay disconnected and continue to step 3.
B. If there is not approximately 70 – 130 Ω, then the main relay has failed. Replace the main relay and retest.
3. Check the main relay low side driver wiring for a short circuit to ground.
With the key in the OFF position, use a multimeter to perform the check for a short circuit to ground on the vehicle
harness (VE) side :
From To Value
Main relay connector pin 85 Chassis ground There should be no continuity.
A. If there is continuity, then there is a short circuit in the main relay wiring in the vehicle harness (VE). Locate
and repair the shorted conductor. Repair or replace the harness as required.
B. If there is no continuity, then leave the main relay disconnected and continue to step 4.
4. Check the main relay low side driver wiring for a short circuit.
With the key in the OFF position, use a multimeter to perform to check for a short circuit in the vehicle harness
(VE) side :
From To Value
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A. If there is continuity, then there is a short circuit in the main relay wiring in the vehicle harness (VE). Locate
B. If there is no continuity, then leave the main relay and connector X-461 disconnected. Continue to step 5.
5. Check the ECU voltage supply wiring for a short circuit to another voltage source.
With the key in the OFF position, use a multimeter to perform to check for a short circuit to another voltage source
in the vehicle harness (VE) side :
From To Value
A. If there is voltage, then there is a short circuit to another voltage source in the ECU voltage supply wiring.
Locate and repair the shorted conductor. repair or replace the harness as required.
B. If there is no voltage, then leave the main relay and connector X-461 disconnected. Continue to step 6.
6. Check the ECU voltage supply wiring for a short circuit to another voltage source.
Re-connect the main relay.
With the key in the OFF position, use a multimeter to perform a check for a short circuit to another voltage source
in the vehicle harness (VE) side :
From To Value
A. If there is voltage, then the main relay has failed. Replace the main relay and retest.
B. If there is no voltage, then check the ECU for the appropriate software and re-flash, if necessary.
has been resolved.
operation.
Wiring harnesses - Electrical schematic sheet 01 Sheet 1B Engine cable (55.100.DP-C.20.E.01)
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3063 (DTC 6226) - Short circuit error of injector in cylinder 1

Context:
The Engine Control Unit (ECU) monitors the fuel injector power stages for a short circuit. If the ECU detects a short
circuit in the injector number 1 circuit, then this fault will occur.
Cause:
The ECU has detected a short circuit in the fuel injector number 1 circuit.
1. Faulty fuel injector number 1, wiring.

2. Faulty fuel injector number 1, internal failure.
Solution:
1. Verify this fault code is still present and in an active state.
Use the Easy Engine software provided on the Electronic Service Tool (EST) to check the fault status and to
perform the cylinder cut-out test.
A. If the fault is still present and active, then continue with step 2.
B. If the fault is no longer present or is in an inactive state, then the fault may be intermittent and not currently
active. Continue with step 8.
2. Check the fuel injector number 1 internal resistance.
Disconnect the injector harness (INJ) from fuel injector number 1.
Use a multimeter to measure the resistance of fuel injector number 1 on the injector pins :
From To Value
Fuel injector number 1 pin 1 Fuel injector number 1 pin 2 There should be between .03 – .05 Ω
A. If there is between .03 – .05 Ω, then leave fuel injector number 1 disconnected and continue to step 3.
B. If the resistance is not between .03 – .05 Ω, then fuel injector number 1 solenoid coil has failed. Replace fuel
injector number 1 and retest.
3. Check the fuel injector number 1 injector harness (INJ) wiring for a short circuit to another voltage source.
With the key in the OFF position, use a multimeter to perform the following voltage check on the injector harness
(INJ) side :
From To Value
Fuel injector number 1 connector pin Chassis ground There should be no voltage.
1
2
With the key in the ON position, use a multimeter to perform the following voltage check on the injector harness
(INJ) side :
From To Value
1
2
A. If there is no voltage, then leave fuel injector number 1 disconnected and continue to step 4.
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B. If there is voltage, then there is a short circuit to battery or a short circuit switched battery in the fuel injector
number 1 wiring in the injector harness (INJ). Locate and repair the shorted conductor. Repair or replace the
4. Check the fuel injector number 1 injector harness (INJ) wiring for a short circuit to ground.
With the key in the OFF position, use a multimeter to perform the following continuity checks on the injector harness
(INJ) side :
From To Value
Fuel injector number 1 connector pin Fuel injector number 1 connector pin There should be no continuity.
1 2
Fuel injector number 1 connector pin Chassis ground There should be no continuity.
1
2
X-471 pin A All pins in connector X-471 There should be no continuity.
X-471 pin B All pins in connector X-471 There should be no continuity.
A. If there is no continuity, then leave fuel injector number 1 disconnected. Leave connector X-471 disconnected
B. If there is continuity, then there is a short circuit in the fuel injector number 1 wiring in the injector harness (INJ).
Locate and repair the shorted conductor. Repair or replace the harness as required.
5. Check the fuel injector number 1 vehicle harness (VE) wiring for a short circuit.
With the key in the OFF position, use a multimeter to perform the following continuity checks on vehicle harness
(VE) side :
From To Value
X-471 pin A X-471 pin B There should be no continuity
X-471 pin A Chassis ground There should be no continuity
X-471 pin B Chassis ground There should be no continuity
X-471 pin A All pins in connector X-471 There should be no continuity
X-471 pin B All pins in connector X-471 There should be no continuity
A. If there is continuity, then there is a short circuit in the fuel injector number 1 wiring in the vehicle harness
(VE).Locate and repair the shorted conductor. Repair or replace the harness as required.
B. If there is no continuity, then continue with step 6.

6. Check the ECU voltage supply wiring.
Place a jumper wire between X-461 pin 28 and chassis ground. This will energize the main relay .
With the key in the ON position, use a multimeter to perform the following voltage checks from the vehicle harness
(VE) side :
From To Value
X-461 pin 1 Chassis ground There should be approximately
12.0 V
12.0 V
12.0 V
A. If there is approximately 12.0 V, then leave connector X-461 disconnected and continue to step 7.
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B. If there is not approximately 12.0 V, then there is a problem with the battery supply to the ECU. Locate and
repair the failed conductor. Repair or replace the harness as required.
7. Check the ECU ground supply.
(VE) side :
From To Value
A. If there is no continuity, then there is a problem in the ECU ground connections. Locate and repair the failed
conductor. Repair or replace the harness as required.
has been resolved.
operation.
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Context:
Cause:

Solution:
From To Value
(INJ) side :
From To Value
1
2
(INJ) side :
From To Value
1
2
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B. If there is voltage, then there is a short circuit to battery or a short circuit to switched battery in the fuel injector
(INJ) side :
From To Value
1 2
1
2
X-471 pin H All pins in connector X-471 There should be no continuity.
X-471 pin G All pins in connector X-471 There should be no continuity.
(VE) side :
From To Value
X-471 pin H X-471 pin G There should be no continuity
X-471 pin H Chassis ground There should be no continuity
X-471 pin G Chassis ground There should be no continuity
X-471 pin H All pins in connector X-471 There should be no continuity
X-471 pin G All pins in connector X-471 There should be no continuity

Place a jumper wire between X-461 pin 28 and chassis ground. This will energize the main relay.
(VE) side :
From To Value
12.0 V
12.0 V
12.0 V
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B. If there is not approximately 12.0 V, then there is a problem in the battery supply to the ECU. Locate and repair
the failed conductor. Repair or replace the harness as required.
(VE) side :
From To Value
A. If there is no continuity, then there is a problem in the ECU ground circuit. Locate and repair the failed conduc-
tor. Repair or replace the harness as required.
has been resolved.
operation.
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Context:
Cause:

Solution:
From To Value
(INJ) side :
From To Value
1
2
(INJ) side :
From To Value
1
2
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(INJ) side :
From To Value
1 2
1
2
X-471 pin E All pins in connector X-471 There should be no continuity.
X-471 pin F All pins in connector X-471 There should be no continuity.
(VE) side :
From To Value
X-471 pin E X-471 pin F There should be no continuity.
X-471 pin E Chassis ground There should be no continuity.
X-471 pin F Chassis ground There should be no continuity.
X-471 pin E All pins in connector X-471 There should be no continuity.
X-471 pin F All pins in connector X-471 There should be no continuity.

(VE) side :
From To Value
12.0 V.
12.0 V.
12.0 V.
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(VE) side : :
From To Value
A. If there is no continuity, then there is a problem in the ground connections to the ECU. Locate and repair the
failed conductor. Repair or replace the harness as required.
has been resolved.
operation.
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Context:
Cause:

Solution:
From To Value
Fuel injector number 3 pin 1 Fuel injector number 3 pin 2 There should be between .03 –
.05 Ω.
(INJ) side :
From To Value
1
2
(INJ) side :
From To Value
1
2
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(INJ) side :
From To Value
1 2
1
2
X-471 pin D All pins in connector X-471 There should be no continuity.
X-471 pin C All pins in connector X-471 There should be no continuity.
(VE) side :
From To Value
X-471 pin C X-471 pin D There should be no continuity
X-471 pin D Chassis ground There should be no continuity
X-471 pin C Chassis ground There should be no continuity
X-471 pin D All pins in connector X-471 There should be no continuity
X-471 pin C All pins in connector X-471 There should be no continuity
A. If there is continuity, then there is a short circuit in the fuel injector number 3 wiring in the vehicle harness (VE).

Place a jumper wire between X-461 pin 28 and chassis ground. This will energize the main relay .
(VE) side :
From To Value
12.0 V.
12.0 V.
12.0 V.
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(VE) side : :
From To Value
A. If there is no continuity, then there is a problem in the ground connection to the ECU. Locate and repair the
has been resolved.
operation.
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3088 (DTC 4512) - Crankshaft speed sensor values are not plausible
Context:
The Engine Control Unit (ECU) monitors the crankshaft position sensor characteristics for angle, speed determination,
signal plausibility, and quality. If the ECU determines that there are no crankshaft position signals detected for at least
4 engine revolutions, then this fault will occur.
Cause:
The ECU has determined that there are no crankshaft position signals detected for at least 4 engine revolutions.
1. Faulty crankshaft tone wheel, damaged or misaligned.

2. Faulty crankshaft position sensor, not fully seated or loose.
3. Faulty crankshaft position sensor circuit wiring, open or grounded or shorted to another circuit.
4. Faulty crankshaft position sensor, internal failure.
Solution:
2. Check the physical integrity of the crankshaft position sensor and the crankshaft tone wheel.
Remove the crankshaft position sensor and inspect the crankshaft tone wheel.
The tone wheel should not be damaged or loose.
The crankshaft position sensor should be fully seated and mounted tightly.
A. If the tone wheel or the sensor is damaged or the sensor is not mounted/secured properly, then repair as
required.
B. If the tone wheel and sensor are not damaged and the sensor is mounted/secured properly, then continue to
step 3.
3. Check the crankshaft position sensor internal resistance.
Disconnect the engine harness (EN) from the crankshaft position sensor.
Use a multimeter to measure the resistance of the crankshaft position sensor on the sensor side :
From To Value
Crankshaft position sensor pin 1 Crankshaft position sensor pin 2 There should be between 774 –
946 Ω.
A. If there is between 774 – 946 Ω, then leave the crankshaft position sensor disconnected and continue to step
4.
B. If there is not between 774 – 946 Ω, then the crankshaft position sensor has failed. Replace the crankshaft
position sensor and retest.
4. Check the crankshaft position sensor circuit wiring for a short circuit to another voltage source.
(EN) side :
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From To Value
(EN) side :
From To Value
A. If there is no voltage, then leave the crankshaft position sensor disconnected and continue to step 5.
B. If there is voltage, then there is a short circuit to battery or a short circuit to the key switched battery voltage in
the crankshaft position sensor circuit wiring. Locate and repair the shorted conductors. Repair or replace the
5. Check the crankshaft position sensor engine harness (EN) circuit wiring.
Disconnect the vehicle harness (VE) connector from the engine interface at connector X-470.
With the key in the OFF position, use a multimeter to check for a short circuit in the engine harness (EN) side :
From To Value
Crankshaft position sensor connector Crankshaft position sensor connector There should be no continuity.
pin 1 pin 2
Crankshaft position sensor connector Chassis ground There should be no continuity.
pin 1
pin 2
With the key in the OFF position, use a multimeter to checks for an open circuit in the engine harness (EN) side :
From To Value
Crankshaft position sensor connector X-470 pin 9 There should be continuity.
pin 1
pin 2
With the key in the OFF position, use a multimeter to check for a short circuit to another circuit in the engine
harness (EN) side :
From To Value
A. If the specified values are measured, then leave the crankshaft position sensor disconnected. Leave connector
B. If the specified values are not measured, then there is a problem in the crankshaft position sensor circuit wiring
in the engine harness (EN). Locate and repair the failed conductor or conductors. Repair or replace the harness
as required.
6. Check the crankshaft position sensor vehicle harness (VE) circuit wiring.
With the key in the OFF position, use a multimeter to check for a short circuit in the vehicle harness (VE) side :
From To Value
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From To Value
From To Value
A. If the specified values are measured, then leave the crankshaft position sensor disconnected and continue to
step 7.
B. If the specified values are not measured, then there is a problem in the crankshaft position sensor circuit wiring
in the vehicle harness (VE). Locate and repair the failed conductor or conductors. Repair or replace the harness
as required.
7. Replace the crankshaft position sensor and retest.
Use the Electronic Service Tool (EST) to verify the status of this fault, 3088 – Crankshaft speed sensor values
are not plausible.
has been resolved.
operation.
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3089 (DTC 4412) - Crankshaft speed sensor pattern is not plausible

Context:
The Engine Control Unit (ECU) monitors the crankshaft position sensor characteristics for angle, speed determination,
signal plausibility, and quality. If the ECU detects greater than 80 crankshaft position signal plausibility errors, then
this fault will occur.
Cause:
The ECU has detected more than 80 crankshaft position signal plausibility errors.
1. Faulty crankshaft tone wheel, damaged or misaligned.

2. Faulty crankshaft position sensor, not fully seated or loose.
3. Faulty crankshaft position sensor circuit wiring, open or grounded or shorted to another circuit.
4. Faulty crankshaft position sensor, internal failure.
Solution:
2. Check the physical integrity of the crankshaft position sensor and the crankshaft tone wheel.
Remove the crankshaft position sensor and inspect the crankshaft tone wheel.
The tone wheel should not be damaged or loose.
The crankshaft position sensor should be fully seated and mounted tightly.
A. If the tone wheel or the sensor is damaged or the sensor is not mounted/secured properly. Repair as required.
B. If the tone wheel and the sensor are not damaged and the sensor is mounted/secured properly, then continue
to step 3.
3. Check the crankshaft position sensor internal resistance.
Disconnect the engine harness (EN) from the crankshaft position sensor.
Use a multimeter to measure the resistance of the crankshaft position sensor on the sensor side :
From To Value
Crankshaft position sensor pin 1 Crankshaft position sensor pin 2 There should be between 774 –
946 Ω.
A. If there is between 774 – 946 Ω, then leave the crankshaft position sensor disconnected and continue to step
4.
B. If there is not between 774 – 946 Ω, then the crankshaft position sensor has failed. Replace the crankshaft
position sensor and retest.
4. Check the crankshaft position sensor circuit wiring for a short circuit to another voltage source.
(EN) side :
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From To Value
(EN) side :
From To Value
A. If there is no voltage, then leave the crankshaft position sensor disconnected and continue to step 5.
B. If there is voltage, then there is a short circuit to battery or a short circuit key switched battery voltage in the
crankshaft position sensor wiring. Locate and repair the shorted conductors. Repair or replace the harness as
required.
5. Check the crankshaft position sensor engine harness (EN) circuit wiring.
Disconnect the vehicle harness (VE) connector from the engine interface at connector X-470.
From To Value
Crankshaft position sensor connector Crankshaft position sensor connector There should be no continuity.
pin 1 pin 2
pin 1
pin 2
From To Value
pin 1
pin 2
With the key in the OFF position, use a multimeter to perform the following continuity checks, for a short to another
circuit condition, on the engine harness (EN) side :
From To Value
A. If the specified values are measured, the leave the crankshaft position sensor disconnected. Leave X-470
B. If the specified values are not measured, then there is a problem in the crankshaft position sensor wiring in the
engine harness (EN). Locate and repair the failed conductor or conductors. Repair or replace the harness as
required.
6. Check the crankshaft position sensor vehicle harness (VE) circuit wiring.
With the key in the OFF position, use a multimeter to perform the following continuity check, for a short circuit
condition, on the vehicle harness (VE) side :
From To Value
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From To Value
With the key in the OFF position, use a multimeter to check for a short circuit to another circuit in the vehicle
harness (VE) side :
From To Value
A. If the specified values are measured, then leave the crankshaft position sensor disconnected and continue to
step 7.
B. If the specified values are not measured, then there is a fault in the crankshaft position sensor circuit wiring in
the vehicle harness (VE). Locate and repair the failed conductor or conductors. Repair or replace the harness
as required.
7. Replace the crankshaft position sensor.
Use the Electronic Service Tool (EST) to verify the status of this fault, DTC 4512 – Crankshaft speed sensor
values are not plausible.
has been resolved.
operation.
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3090 (DTC 4212) - Camshaft speed sensor values are not plausible
Context:
The Engine Control Unit (ECU) monitors the camshaft position sensor characteristics for angle, speed determination,
signal plausibility, and quality. If the ECU determines that no camshaft edge is detected for at least four crankshaft
revolutions, then this fault will occur.
Cause:
The ECU has detected no camshaft edge for at least four crankshaft revolutions.
1. Faulty camshaft position sensor, improperly seated or mounted.

2. Faulty camshaft position sensor circuit wiring, open or grounded or shorted to another circuit.
3. Faulty camshaft position sensor, internal failure.
Solution:
2. Check the physical integrity of the camshaft speed sensor.
The sensor should be fully seated and mounted tightly.
A. If the sensor is not mounted/secured properly, then repair as required.
B. If the sensor is not damaged and is mounted/secured properly, then continue to step 3.
3. Check the camshaft position sensor circuit wiring in the engine harness (EN).
Disconnect the engine harness (EN) from the camshaft position sensor.
From To Value
Camshaft position sensor connector X-470 pin 4 There should be continuity.
pin 2
pin 1
pin 3
With the key in the OFF position, use a multimeter to check for a short circuit to ground condition in the engine
harness (EN) side :
From To Value
Camshaft position sensor connector Chassis ground There should be no continuity.
pin 2
With the key in the OFF position, use a multimeter to check for a short circuit to another circuit condition in the
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From To Value
With the key in the ON position, use a multimeter to check for a short circuit to another voltage source in the engine
harness (EN) side :
From To Value
Camshaft position sensor connector Chassis ground There should be no voltage.
pin 2
A. If the specified values are measured, then the camshaft position sensor disconnected. Leave connector X-470
B. If the specified values are not measured, then there is a problem in the camshaft position sensor. Locate and
repair the failed conductor or conductors. Repair or replace the harness as required.
4. Check the camshaft position sensor circuit wiring in the vehicle harness (VE).
From To Value
With the key in the OFF position, use a multimeter to check for a short circuit to ground in the engine harness (EN)
side :
From To Value
From To Value
With the key in the ON position, use a multimeter to check for a short circuit to another voltage source in the vehicle
harness (VE) side :
From To Value
A. If the specified values are measured, then leave connector the camshaft position sensor disconnected and
continue to step 5.
B. If the specified values are not measured, then there is a problem in the camshaft position sensor wiring. Locate
and repair the failed conductor or conductors. Repair or replace the harness as required.
5. Replace the camshaft position sensor and retest.
Use the Electronic Service Tool (EST) to verify the status of this fault, 3090 – Camshaft speed sensor values
are not plausible.
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has been resolved.
operation.
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3091 (DTC 4112) - Camshaft speed sensor pattern is not plausible

Context:
The Engine Control Unit (ECU) monitors the camshaft position sensor characteristics for angle, speed determination,
signal plausibility, and quality. If the ECU determines that the camshaft signal does not match the expected pattern
(edge, distance, level) or not all expected camshaft edges are detected during an engine revolution, then this fault
will occur.
Cause:
The ECU has detected a camshaft pattern signal error.
1. Faulty camshaft position sensor, improperly seated or mounted.

2. Faulty camshaft position sensor circuit wiring, open or grounded or shorted to another circuit.
3. Faulty camshaft position sensor, internal failure.
Solution:
2. Check the physical integrity of the camshaft speed sensor.
The sensor should be fully seated and mounted tightly.
A. If the sensor is not mounted/secured properly, then repair as required.
B. If the sensor is not damaged and is mounted/secured properly, then continue to step 3.
3. Check the camshaft position sensor circuit wiring in the engine harness (EN).
Disconnect the engine harness (EN) from the camshaft position sensor.
From To Value
pin 4
With the key in the OFF position, use a multimeter to check for a short circuit to ground in the engine harness (EN)
side :
From To Value
Camshaft position sensor connector Chassis ground There should be no continuity.
pin 2
From To Value
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With the key in the ON position, use a multimeter to check for a short circuit to another voltage source in the engine
harness (EN) side :
From To Value
Camshaft position sensor connector Chassis ground There should be no voltage.
pin 2
A. If the specified values are measured, then leave the camshaft position sensor disconnected. Leave connector
4. Check the camshaft position sensor circuit wiring in the vehicle harness (VE).
From To Value
With the key in the OFF position, use a multimeter to check for a short circuit to ground in the vehicle harness (VE)
side :
From To Value
From To Value
With the key in the ON position, use a multimeter to check for a short circuit to another voltage source in the vehicle
harness (VE) side :
From To Value
A. If the specified values are measured, then leave the camshaft position sensor disconnected and continue to
step 5.
5. Replace the camshaft position sensor and retest.
Use the Electronic Service Tool (EST) to verify the status of this fault, 3091 – Camshaft speed sensor pattern
is not plausible.
has been resolved.
operation.
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3093 (DTC 3312) - Compared camshaft and crankshaft speed

sensor values are not plausible
Context:
The Engine Control Unit (ECU) monitors the camshaft position sensor and crankshaft position sensor for angle and
speed determination, signal plausibility and quality. If the ECU determines that the compared values between the two
sensors are implausible, then this fault will occur.
1. Faulty camshaft gear, loose or damaged.

2. Faulty camshaft position sensor, improperly mounted or not fully seated.
3. Faulty crankshaft tone wheel, loose or damaged.
4. Faulty crankshaft position sensor, improperly mounted or not fully seated.
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3096 (DTC 951B) - CAN A Bus off failure

Context:
The Engine Control Unit (ECU) A-9000 is capable of connecting to and communicating on two separate Controller
Area Networks (CAN). Proper configuration and monitoring of the two twisted pair configured networks is also a func-
tion of the ECU A-9000. CAN Node A Bus is the main vehicle interface bus. The ECU A-9000 provides a CAN
termination resistor for the CAN Node A Bus, internal to the ECU A-9000. If the ECU A-9000 senses that CAN Node
A Bus is not functioning properly, this fault will occur.
Cause:
ECU A-9000 has sensed a Bus Off state to be present at the CAN Node A.
1. Faulty supply voltage or ground, missing.

2. Faulty CAN circuit wiring, open circuit, short to ground, or short circuit.
3. Faulty ECU A-9000, termination resistor or software.
Solution:
1. Verify fault is present and in active state.
2. Check for other vehicle CAN faults.
Use the EST to determine if vehicle CAN faults exist.
A. If other vehicle CAN faults exist, resolve the vehicle CAN faults, then check to see that 3096 – CAN A Bus off
failure is also resolved.
B. If other vehicle CAN faults do not exist, then continue with step 3.
3. Check the ECU supply voltage.
Disconnect the vehicle (VE) harness from the ECU at connector X-461.
Place a jumper wire between the vehicle harness (VE) side of connector X-461 pin 28 and chassis ground. This
will energize the main relay.
Use a multimeter to check for voltage on the vehicle (VE) harness side :
From To Value
X-461 pin 1 Chassis ground There should be 12.0 V.
A. If the voltage is present on all of the checks, then leave connector X-461 disconnected and continue with step
4.
B. If the voltage is not present for one or more of the checks, then there is a problem with the battery supply to
the ECU. Repair or repalce the harness as required.
4. Check the ECU ground circuits.
Use a multimeter to check for continuity on the vehicle (VE) harness side:
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From To Value
A. If there is continuity on all of the checks, then leave connector X-461 disconnected and continue with step 5.
B. If there is no continuity for one or more of the checks, then there is a problem with the ground connection to
the ECU. Repair or replace the harness as required.
5. Determine the condition of the ECU CAN circuit.
With the key switch in the OFF position, use a multimeter to measure the resistance of the CAN connection on the
vehicle (VE) harness side :
From To Value
X-461 pin 24 X-461 pin 25 There should be 120 Ω.
X-461 pin 24 Chassis ground There should not be continuity.
Use a multimeter to measure the resistance of the CAN termination resistor, internal to the ECU :
From To Value
A. If the measured resistances are correct and neither conductor is grounded, then check the ECU for the appro-
priate software and re-flash, if necessary.
B. If the measured resistances are not correct or one or both of the conductors is grounded, then locate and
restore the termination resistance to the CAN circuit.
has been resolved.
operation.
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3097 (DTC 961B) - CAN B Bus off failure

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 B Bus is the engine devices communications bus. The ECU provides a CAN termination resistor for
the CAN Node B Bus, internal to the ECU. If the ECU senses that CAN Node B Bus is not functioning properly, then
Cause:
ECU has sensed a “Bus Off” state to be present at the CAN Node B.

3. Faulty ECU, termination resistor or software.
Solution:
2. Check for other engine Selective Catalytic Reduction (SCR) device CAN faults.
Use the EST to determine if SCR device CAN faults exist.
A. If other SCR device CAN faults exist, resolve the SCR device CAN faults, then check to see that 3097 – CAN
B Bus off failure is also resolved.
B. If other SCR device CAN faults do not exist, then continue with step 3.
Use a multimeter to check for voltage on the vehicle (VE) harness side:
From To Value
4.
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From To Value
B. If there is no continuity for one or more of the checks, then there is a problem in the ground circuit to the ECU.
Repair or replace the harness as required.
With the key switch in the “OFF” position, use a multimeter to measure the resistance of the CAN connection on
the vehicle (VE) harness side :
From To Value
From To Value
B. If one or both of the conductors is grounded or the measured resistances are not correct, then locate and repair
the damage to the CAN circuit or to restore the termination resistance or replace the ECU.
has been resolved.
operation.
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3102 (DTC 2525) - Fuel rail pressure sensor voltage is lower than
expected
NOTE: If the rail pressure sensor is replaced, it is necessary to perform the Replacement of the Rail Pressure sensor -
Reset ECU Data with the Electronic Service Tool (EST) before you return the machine to service. Refer to the engine
service manual Common rail pressure sensor - Configure - Reset ECU data (Rail pressure sensor) (55.010), if
necessary.
Context:
The Engine Control Unit (ECU) monitors the rail pressure sensor. If the ECU detects a voltage less than 342.20 mV
in the rail pressure sensor signal circuit, then this fault will occur.
Cause:
The ECU has detected a voltage less than 342.20 mV in the rail pressure sensor signal circuit.
1. Faulty rail pressure sensor wiring, short circuit to ground.

2. Faulty rail pressure sensor , internal failure.
Solution:
2. Check the rail pressure sensor engine harness (EN) wiring for a short circuit.
Disconnect the engine harness (EN) from the rail pressure sensor.
(EN) side :
From To Value
Rail pressure sensor connector pin 2 Chassis ground There should be no continuity.
Rail pressure sensor connector pin 2 Rail pressure sensor connector pin 1 There should be no continuity.
A. If there is continuity, then there is a short circuit in the rail pressure sensor engine harness (EN) wiring. Locate
B. If there is no continuity, then leave the rail pressure sensor disconnected. Leave connector X-470 disconnected
3. Check the rail pressure sensor vehicle harness (VE) wiring for a short circuit.
(VE) side :
From To Value
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A. If there is continuity, then there is a short circuit in the rail pressure sensor vehicle harness (VE) wiring. Locate
B. If there is no continuity, then continue to step 4.

4. Replace the rail pressure sensor and retest.
has been resolved.
operation.
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3104 (DTC F445) - Fuel pressure relief valve is open

NOTE: If the Pressure Relief Valve (PRV) is replaced, it is necessary to perform the Replacement of the Rail Pressure
Relief Valve (PRV) - Reset ECU Data with the Electronic Service Tool (EST) before you return the machine to service.
Refer to the engine service manual Common rail Relief valve - Configure - Reset ECU data (10.218), if necessary.
necessary.
Context:
The Engine Control Unit (ECU) monitors the Pressure Relief Valve (PRV). If the ECU determines that the PRV is open,
then this fault will occur. Other active faults may have caused this fault to occur. For more information regarding fuel
system troubleshooting, refer to the engine service manual Fuel injection system - Troubleshooting (10.218).
Cause:
The ECU has determined that the PRV is open.
1. Faulty fuel metering unit, stuck open.

2. Faulty rail pressure sensor, drifted signal.
3. Faulty PRV, opening pressure too low.
4. Faulty fuel back-flow, clogged or damaged.
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3105 (DTC F245) - Fuel pressure relief valve is forced to open,

perform pressure increase
necessary.
Context:
The Engine Control Unit (ECU), if necessary, will set the engine into limp home mode. This process is achieved in
two steps by the ECU, a pressure increase and a pressure shock. The ECU will execute step one by a fuel pressure
increase. This is achieved by fully opening the fuel metering unit, thus allowing maximum fuel delivery. If this fault is
active, the ECU has performed step one for achieving limp home mode, a fuel pressure increase. Other active faults
may have caused this fault to occur. For more information regarding fuel system troubleshooting, refer to the engine
service manual Fuel injection system - Troubleshooting (10.218).
Cause:
The ECU has performed a fuel pressure increase to achieve limp home mode.
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3106 (DTC 1145) - Fuel pressure relief valve reached maximum

allowed opening count
necessary.
Context:
The Engine Control Unit (ECU) monitors the fuel Pressure Relief Valve (PRV). If the ECU determines that the PRV
has exceeded its maximum open count, 50 times, then this fault will occur. If the PRV has opened more than 50
times, then the PRV must be replaced. Other active faults may have caused this fault to occur. For more information
regarding fuel system troubleshooting, refer to the engine service manual Fuel injection system - Troubleshooting
(10.218).
Cause:
The ECU has determined that the PRV has opened more than 50 times.

3. Faulty PRV, opening pressure too low.
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3107 (DTC 6655) - Fuel metering unit is shorted to battery voltage

at the low side
Context:
The Engine Control Unit (ECU) monitors the fuel metering unit signal circuit. If the ECU detects a short circuit to
another voltage source in the fuel metering unit low side driver circuit, then this fault will occur.
Cause:
There is a short circuit to another voltage source in the fuel metering unit low side driver circuit.
1. Faulty fuel metering unit wiring, short circuit to another voltage source.
2. Faulty fuel metering unit, internal failure.
Solution:
2. Test the fuel metering unit internal resistance.
Disconnect the engine harness (EN) from the fuel metering unit.
Use a multimeter to measure the resistance on the fuel metering unit pins :
From To Value
Fuel metering unit pin 1 Fuel metering unit pin 2 There should be between 2.6 – 3.2 Ω
at approximately 20.0 °C (68.0 °F).
A. If there is between 2.6 – 3.2 Ω, then leave the fuel metering unit pin disconnected and continue to step 3.
B. If there is not between 2.6 – 3.2 Ω, then the fuel metering unit has failed. Replace the fuel metering unit and
retest.
3. Check the fuel metering unit low side driver wiring for a short circuit to battery.
(EN) side :
From To Value
Fuel metering unit connector pin 2 Chassis ground There should be no voltage.
(EN) side :
From To Value
Fuel metering unit connector pin 2 Chassis ground There should be no voltage.
A. If there is voltage, then there is a short circuit to battery or a short circuit to switched battery in the fuel metering
unit low side driver circuit wiring. Locate and repair the shorted conductor. Repair or replace the harness as
required.
B. If there is no voltage, then leave the fuel metering unit disconnected and continue to step 4.
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4. Check the fuel metering unit low side driver engine harness (EN) wiring for a short circuit.
(EN) side :
From To Value
A. If there is no continuity, then leave connector X-470 disconnected and continue to step 5.
B. If there is continuity, then there is a short circuit in the fuel metering unit low side driver engine harness (EN)
wiring. Locate and repair the shorted conductor. Repair or replace the harness as required.
5. Check the fuel metering unit low side driver vehicle harness (VE) wiring for a short circuit.
With the key in the OFF position, use a multimeter to perform the following continuity check from the vehicle
harness (VE) side :
From To Value
A. If there is continuity, then there is a short circuit in the fuel metering unit low side driver vehicle harness (VE)
has been resolved.
operation.
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3108 (DTC 7755) - Fuel metering unit is shorted to ground at the

low side
Context:
The Engine Control Unit (ECU) monitors the fuel metering unit low side driver circuit. If the ECU detects a short circuit
to ground in the fuel metering unit low side driver circuit, then this fault will occur.
Cause:
The ECU has detected a short circuit to ground in the fuel metering unit low side driver circuit.
1. Faulty fuel metering unit wiring, short circuit to ground.

Solution:
B. If the fault is no longer present or in an inactive state, then the fault may be intermittent and not currently
active.Continue with step 5.
2. Test the fuel metering unit internal resistance and test for a short circuit to ground.
Use a multimeter to perform the following continuity and resistance check on the fuel metering unit pins :
From To Value
Fuel metering unit pin 2 Chassis ground There should be no continuity.
at approximately 20 °C (68 °F).
A. If there is between 2.6 – 3.2 Ω and there is no continuity to ground, then leave the fuel metering unit discon-
B. If the specified values are not measured, then the fuel metering unit has a grounded condition or has failed
internally. Replace the fuel metering unit and retest.
3. Check the fuel metering unit engine harness (EN) wiring for a short circuit to ground.
With the key switch in the OFF position, use a multimeter to perform the following continuity check on the engine
harness (EN) side :
From To Value
A. If there is continuity, then there is a short circuit in the fuel metering unit engine harness (EN) wiring. Locate
B. If there is no continuity, then leave connector X-470 disconnected and continue to step 4.
4. Check the fuel metering unit vehicle harness (VE) wiring for a short circuit to ground.
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With the key switch in the OFF position, use a multimeter to perform the following continuity check on the vehicle
harness (VE) side :
From To Value
A. If there is continuity, then there is a short circuit in the fuel metering unit vehicle harness (VE) wiring. Locate
B. If there is no continuity, then check the ECU for the appropriate service manual and re-flash, if necessary.
has been resolved.
operation.
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3112 (DTC 1425) - Fuel rail pressure sensor voltage is higher than
expected
necessary.
Context:
The Engine Control Unit (ECU) monitors the rail pressure sensor. If the ECU detects a voltage greater than 4.90 V in
the rail pressure sensor signal circuit, then this fault will occur.
Cause:
The ECU has detected a voltage greater than 4.90 V in the rail pressure sensor B-9004 signal circuit.
1. Faulty rail pressure sensor wiring, short to a voltage source.

2. Faulty rail pressure sensor wiring, open circuit.
3. Faulty rail pressure sensor, internal failure.
Solution:
2. Check the rail pressure sensor wiring for a short circuit.
Disconnect the engine harness (EN) from the rail pressure sensor.
(EN) side :
From To Value
Rail pressure sensor connector pin 2 Chassis ground There should be no voltage.
(EN) side :
From To Value
Rail pressure sensor connector pin 2 Chassis ground There should be less than 5.5 V.
A. If the specified values are not measured, then there is a short circuit to battery or a short circuit switched battery
in the rail pressure sensor wiring. Locate and repair the shorted conductor. Repair or replace the harness as
required.
B. If the specified values are measured, then leave the rail pressure sensor disconnected and continue to step 3.
3. Check the rail pressure sensor engine harness (EN) wiring for an open circuit.
(EN) side :
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From To Value
Rail pressure sensor connector pin 2 X-470 pin 6 There should be continuity.
Rail pressure sensor connector pin 3 X-470 pin 7 There should be continuity.
(VE) side :
From To Value
A. If there is no continuity, then there is an open circuit in the rail pressure sensor vehicle harness (VE) wiring.
Locate and repair the broken conductor. Repair or replace the harness as required.
B. If there is continuity, then leave the rail pressure sensor disconnected. Leave connectors X-470 and X-462
4. Check the rail pressure sensor engine harness (EN) wiring for a short circuit to another voltage source.
(EN) side :
From To Value
Rail pressure sensor connector pin 2 Rail pressure sensor connector pin 3 There should be no continuity.
A. If there is continuity, then there is a short circuit in the rail pressure sensor engine harness (EN) wiring.Locate
B. If there is no continuity, then leave the rail pressure sensor disconnected. Leave connectors X-470 and X-462
5. Check the rail pressure sensor vehicle harness (VE) wiring for a short circuit to another voltage source.
(VE) side :
From To Value
A. If there is continuity, then there is a short circuit in the rail pressure sensor vehicle harness (VE) wiring. Locate
B. If there is no continuity, then leave the rail pressure sensor disconnected and continue to step 6.
6. Replace the rail pressure sensor and retest.
has been resolved.
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operation.
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3137 (DTC 5255) - Fuel metering unit has an open load error
Context:
The Engine Control Unit (ECU) monitors the fuel metering unit signal circuit. If the ECU detects an open circuit error
in the fuel metering unit signal circuit, then this fault will occur.
Cause:
There is open circuit detected in the fuel metering unit signal circuit.
1. Faulty fuel metering unit wiring, open circuit.

Solution:
From To Value
A. If there is between 2.6 – 3.2 Ω, then leave fuel metering unit disconnected and continue to step 3.
retest.
3. Check the fuel metering unit engine harness (EN) wiring for an open circuit.
(EN) side :
From To Value
Fuel metering unit connector pin 1 X-470 pin 1 There should be continuity.
NOTE: Wiggle the harness during the check to promote an intermittent electrical connection.
A. If there is continuity, then leave connector X-470 disconnected and continue to step 4.
B. If there is no continuity, then there is an open circuit in the fuel metering unit engine harness (EN) wiring. Locate
4. Check the fuel metering unit vehicle harness (VE) wiring for an open circuit.
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(VE) side :
From To Value
NOTE: Wiggle the harness during the check to promote an intermittent electrical connection.
A. If there is no continuity, then there is an open circuit in the fuel metering unit vehicle harness (VE) wiring.Locate
has been resolved.
operation.
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3141 (DTC 4465) - Fuel pump pressure has exceeded desired

pressure limits
necessary.
Context:
The Engine Control Unit (ECU) monitors fuel rail pressure. If the ECU determines that the requested fuel pressure
can not be reached, a leakage in the fuel system is assumed and this fault will occur. For more information regarding
fuel system troubleshooting, refer to the engine service manual Fuel injection system - Troubleshooting (10.218).
Cause:
The ECU has determined that a fuel system leakage is present.
1. Faulty fuel filters, clogged.

2. Faulty low pressure fuel lines, clogged or damaged.
3. Faulty high pressure fuel lines, clogged or damaged.
4. Faulty electric fuel pump (if equipped).
5. Faulty charge gear pump, low efficiency.
6. Faulty high pressure pump, low efficiency or excessive leak-off.
7. Faulty fuel injectors, external or internal leakage.
8. Faulty Pressure Relief Valve (PRV), leaking or stuck open.
9. Faulty rail pressure sensor or sensor leaking.
10. Faulty fuel metering unit.
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3146 (DTC 4415) - Water in fuel detected or water in fuel circuit

failure
NOTE: This fault code is for the Water in Fuel switch with black connector housing.
Context:
The Engine Control Unit (ECU) monitors the voltage output from the water in fuel switch to determine if water is present
in the fuel supply. If water is detected in the fuel, warnings will be displayed to alert the operator of potential engine
damage if operation continues. High voltage signal from the water in fuel switch indicates water present.
Cause:
This fault code is displayed to warn the operator that the ECU has detected excess water in the fuel system or a fault
in the water in fuel switch circuit.
1. Excess water in the fuel supply.

2. Faulty water in fuel switch, wiring or internal (mechanical and/or electrical) failure.
Solution:
Use the Electronic Service Tool (EST) to check the fault status.
A. If the fault is still present and active, continue with step 2.
B. If the fault is no longer present or is in an inactive state, continue with step 7.

2. Check fuel for water contamination.
A. If there is water contamination, then continue with step 3.
B. If there is no water contamination, then continue with step 4.

3. Verify proper water in fuel switch operation.
Purge fuel supply system, replace fuel filter(s) and refill with fuel that is free of water contamination.
Start and run engine for 5 minutes.
Check for code to return to active status.
A. If code returns in an active status, then replace water in fuel switch.
B. If code remains inactive, then return the machine to service.

4. Check for an open circuit or a short circuit in the water in fuel switch circuit.
Disconnect the water in fuel switch.
With the key switch in the OFF position, use a multimeter to perform the following tests on the vehicle (VE) harness
from :
From To Value
Water in fuel switch connector pin 1 X-461 pin 30 There should be continuity.
Water in fuel switch connector pin 2 Chassis ground There should be continuity.
Water in fuel switch connector pin 3 X-461 pin 54 There should be continuity.
Then use the multimeter to perform the following tests on the vehicle (VE) harness from :
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From To Value
X-463 pin 1 X-463 pin 2 There should be no continuity
Then use the multimeter to perform the following tests, on the vehicle (VE) harness from :
From To Value
X-463 pin 1 Chassis ground There should be no continuity
X-463 pin 3 Chassis ground There should be no continuity
A. If the results are not as expected for any of the wiring tests listed above, then there is a problem in the wiring
harness. Repair or replace the harness as required.
B. If the results are as expected in all of the wiring tests listed above, then the wiring is okay. Leave the water in
fuel sensor disconnected. Leave connector X-461 disconnected and continue with step 5.
5. Check for key switch voltage supply to water in fuel switch.
With the key switch in an ON position, use a multimeter to perform the following test on the vehicle (VE) harness
side from :
From To Value
X-463 pin 3 Chassis ground There should be key switch voltage.
X-463 pin 1 Chassis ground There should be no key switch
voltage.
A. If there is key switch voltage present in the first check and not present in the second check, then continue with
step 6.
B. If key switch voltage is not present in the first check or present in the second check, then there is a problem in
the wiring. Repair or replace the harness as required.
6. Replace the water in fuel switch and retest, then check to see if this fault has been resolved.
A. If the fault is resolved, then return the machine to service.
B. If the fault is not resolved, then check the ECU for the appropriate software and re-flash, if necessary.
A. If you find damage or the display indicates other than normal readings, then repair the damage discovered
during the inspection or locate and repair the other than normal display condition and verify that the error has
been resolved.
operation.
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3170 (DTC 38CB) - NH3 sensor signal is not changing

NOTE: Because this fault causes inducement, it is necessary to perform the SCR Fault Repair Verification Test once
the fault has been resolved. Refer to the engine service manual Selective Catalytic Reduction (SCR) exhaust
treatment - Service instruction - SCR fault repair verification test (10.500) if necessary.
NOTE: Because this fault causes inducement, it is necessary to perform the Engine Restart Counter Reset / Unlock
Inducement configuration with the Electronic Service Tool (EST) before you return the machine to service. Refer to
the engine service manual Selective Catalytic Reduction (SCR) exhaust treatment - Configure - Engine restart
counter reset (10.500) if necessary.
Context:
For information regarding the functional operation of the NH3 sensor and the NH3 control unit, refer to the engine
service manual Ammonia (NH3) sensor - Dynamic description (55.988). The NH3 control unit is required to report
information at regular intervals to the Engine Control Unit (ECU) via the Controller Area Network (CAN). This fault will
occur when the NH3 sensor signal is not changing over time or if the NH3 control unit is not reporting a change.
Cause:
The NH3 control unit has reported to the ECU that the NH3 sensor signal is not changing over time.
1. A missing NH3 sensor or a sensor that is improperly installed.

2. A damaged NH3 sensor.
3. A faulty NH3 control unit.
Solution:
1. Verify the condition of the NH3 sensor.
Remove the NH3 sensor.
Inspect the NH3 sensor for debris accumulation, a broken sensing tip, or other damage.
There should be no accumulation of debris. The sensor should not be damaged.
A. If accumulation of debris or a damage sensor is found, then replace the NH3 sensor. Then use the EST,
refer to the engine service manual Selective Catalytic Reduction (SCR) exhaust treatment - Configure -
Engine restart counter reset (10.500) if necessary, to perform the Engine Restart Counter Reset / Unlock
Inducement configuration. Then perform the SCR Fault Repair Verification Test, refer to the engine service
manual Selective Catalytic Reduction (SCR) exhaust treatment - Service instruction - SCR fault repair
verification test (10.500), if necessary. Then return the machine to service.
B. If no accumulation of debris or no damage is found, then continue with step 2.

2. As there is no method for field testing or re-flashing the sensor controller, replace the NH3 control unit.
Then use the EST, refer to the engine service manual Selective Catalytic Reduction (SCR) exhaust treatment
- Configure - Engine restart counter reset (10.500) if necessary, to perform the Engine Restart Counter Reset
/ Unlock Inducement configuration.
Then perform the SCR Fault Repair Verification Test, refer to the engine service manual Selective Catalytic
Reduction (SCR) exhaust treatment - Service instruction - SCR fault repair verification test (10.500), if nec-
essary.
Then check to see if the fault is resolved.
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3173 (DTC F623) - Engine coolant temperature has exceeded the

warning threshold
Context:
The Engine Control Unit (ECU) monitors the engine coolant temperature. Two engine temperature thresholds are
monitored by the ECU, a pre-warning, and a warning. If the ECU monitors a temperature greater than 111.96 °C
(233.53 °F), a warning is set and this fault will occur. For more information regarding cooling system troubleshooting,
refer to the engine service manual Engine cooling system - Troubleshooting (10.400).
Cause:
A coolant temperature level warning has been set by the ECU.
1. Coolant level low.

2. Faulty cooling system, leakage or blockage.
3. Extremely high environmental temperature or heavy machine use.
4. Faulty coolant temperature sensor, wiring or internal failure of sensor.
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3176 (DTC 3B65) - High pressure pump fuel delivery quantity in

over run exceeds a maximum threshold
necessary.
Context:
The Engine Control Unit (ECU) monitors fuel rail pressure using the rail pressure sensor. If the ECU determines
that the measured rail pressure is greater than desired by more than a dependent engine speed value, this fault will
occur. For more information regarding fuel system troubleshooting, refer to the engine service manual Fuel injection
system - Troubleshooting (10.218).
Cause:
The ECU has determined that the measured rail pressure is greater than desired by more than a dependent engine
speed value.
1. Faulty fuel metering unit, stuck open or internal failure.

2. Faulty fuel back-flow lines, blocked or damaged.
3. Faulty Pressure Relief Valve (PRV), stuck closed or mechanically unable to open.
4. Faulty high pressure pump, zero delivery throttle valve clogged.
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3177 (DTC F1A2) - Engine over speed condition detected

Context:
This fault is intended for information purposes only and does not require any further action. Other active faults may
have caused this fault to occur. The Engine Control Unit (ECU) monitors for an engine overspeed condition. An engine
overspeed condition can occur from such conditions as downhill travel. If an engine speed of at least 3100 RPM has
been detected for at least 0.05 s, then this fault will occur.
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3179 (DTC 956B) - CAN communication failure between vehicle

controller and ECU - BC2ECU2 message
Context:
works (CAN). Proper configuration and monitoring of the two twisted pair configured networks is also a function of
the ECU. CAN Node A Bus is the main vehicle interface bus. The ECU provides a CAN termination resistor for the
CAN Node A Bus, internal to the ECU. The ECU A-9000 receives and responds to proprietary Body Computer (BC)
information. If the ECU senses a message timeout, then this fault will occur.
Cause:
ECU has sensed a BC message timeout.
1. Faulty vehicle system, related CAN fault.

Solution:
B. If the fault is no longer present or is in an inactive state, the fault may be intermittent and not currently active.
A. If other vehicle CAN faults exist, resolve the vehicle CAN faults, then check to see that this fault is also resolved.
From To Value
4.
B. If the voltage is not present for one or more of the checks, then there is a problem in the battery supply to the
ECU. Repair or replace the harness as required.
Use a multimeter to check for continuity on the vehicle (VE) harness side :
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From To Value
A. If there is continuity on all of the checks, then leave connector X-461 disconnected. Continue with step 5.
B. If there is no continuity for one or more of the checks, then there is a problem in the ground connection to the
With the key switch in the “OFF” position, use a multimeter to measure the resistance of the CAN connection on
the vehicle (VE) harness side:
From To Value
From To Value
has been resolved.
operation.
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3180 (DTC 9B7B) - CAN communication error between vehicle

controller to ECU
Context:
The Engine Control Unit (ECU) is capable of connecting to and communicating on two or more separate Controller
Area Networks (CAN). Proper configuration and monitoring of these twisted pair configured networks is also a function
of the ECU. CAN Node A Bus is the main vehicle interface bus. The ECU provides a CAN termination resistor for the
CAN Node A Bus, internal to the ECU. The ECU receives and responds to proprietary information like low and high
idle or intermediate speed set points and parameters or feedback. If the ECU does not receive the message every
0.050 s, then this fault will occur.
Cause:
ECU has sensed a timeout of required vehicle controller data provided on CAN Node A.

Solution:
From To Value
4.
4. Check the ECU grounding.
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From To Value
vehicle (VE) harness side:
From To Value
From To Value
restore the termination resistance to the CAN circuit or replace the ECU.
has been resolved.
operation.
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3188 (DTC 5316) - Open load error of injector in cylinder 1

Context:
The Engine Control Unit (ECU) monitors the fuel injector number 1 circuit. If the ECU determines that there is an open
circuit condition in the fuel injector number 1 circuit, then this fault will occur.
Cause:
The ECU has detected an open circuit in the fuel injector number 1 circuit.

2. Faulty fuel injector number 1 wiring, open circuit.
Solution:
2. Check fuel injector number 1 for an internal failure.
Disconnect fuel injector number 1.
Use a multimeter to perform the following resistance check on the fuel injector pins :
From To Value
Fuel injector number 1 pin 1 Fuel injector number 1 pin 2 There should be approximately 0.3
– 0.5 Ω.
A. If the resistance is significantly greater than the specified range, then the fuel injector has failed. Replace fuel
B. If the specified range is measured, then leave fuel injector number 1 disconnected and continue to step 3.
3. Check the fuel injector number 1 engine harness (EN) wiring for an open circuit.
Disconnect connector X-471 from the engine interface connector.
Use a multimeter to perform the following continuity check on the injector harness (INJ) side :
From To Value
X-471 pin A Fuel injector number 1 pin 1 There should be continuity.
X-471 pin B Fuel injector number 1 pin 2 There should be continuity.
A. If there is no continuity, then there is an open circuit in the fuel injector number 1 injector harness (INJ) wiring.
B. If there is continuity, then leave fuel injector number 1 disconnected. Leave connector X-471 disconnected and
continue to step 4.
4. Check the fuel injector number 1 vehicle harness (VE) wiring for an open circuit.
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From To Value
X-471 pin A X-462 pin 16 There should be continuity.
X-471 pin B X-462 pin 32 There should be continuity.
A. If there is no continuity, there is an open circuit in the fuel injector number 1 vehicle harness (VE) wiring. Locate
has been resolved.
operation.
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Context:
circuit condition in the fuel injector number 4 circuit, then this fault will occur.
Cause:

Solution:
Disconnect fuel injector number 4.
From To Value
– 0.5 Ω.
A. If the resistance is significantly greater than the specified range, then the fuel injector has failed. Replace the
fuel injector number 4 and retest.
3. Check the fuel injector number 4 injector harness (INJ) wiring for an open circuit.
Disconnect the engine interface connector, X-471.
From To Value
X-471 pin E Fuel injector number 4 connector pin There should be continuity.
1
X-471 pin F Fuel injector number 4 connector pin There should be continuity.
2
continue to step 4.
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From To Value
X-471 pin E X-462 pin 17 There should be continuity.
X-471 pin F X-462 pin 48 There should be continuity.
A. If there is no continuity, then there is an open circuit in the fuel injector number 4 vehicle harness (VE) wiring.
has been resolved.
operation.
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Context:
circuit in the fuel injector number 3 circuit, then this fault will occur.
Cause:

Solution:
Disconnect fuel injector number 3 from the injector harness.
From To Value
Fuel injector number 3 pin 1 X-9031 Fuel injector number 3 pin 2 There should be approximately 0.3
pin 1 – 0.5 Ω.
From To Value
X-471 pin D Fuel injector number 3 connector pin There should be continuity.
1
X-471 pin C Fuel injector number 3 connector pin There should be continuity.
2
continue to step 4.
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From To Value
X-471 pin D X-462 pin 1 There should be continuity.
X-471 pin C X-462 pin 31 There should be continuity.
has been resolved.
operation.
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Context:
circuit in the fuel injector number 2 circuit, then this fault will occur.
Cause:

Solution:
Disconnect fuel injector number 2 from the injector harness.
From To Value
– 0.5 Ω.
Use a multimeter to perform the following continuity check on the engine harness (EN) side :
From To Value
X-471 pin H Fuel injector number 2 connector pin There should be continuity.
1
X-471 pin G Fuel injector number 2 connector pin There should be continuity.
2
continue to step 4.
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From To Value
X-471 pin G X-462 pin 2 There should be continuity.
X-471 pin G X-462 pin 46 There should be continuity.
has been resolved.
operation.
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3210 (DTC 7116) - Injection bank 1 short circuit failure (all injectors
of the same bank can be affected)
Context:
The Engine Control Unit (ECU) monitors the fuel injector harness for a short circuit. If the ECU detects a short circuit
pattern in the fuel injector harness of both bank 1 fuel injections, then this fault will occur. The bank 1 fuel injectors
are fuel injector number 1 and fuel injector number 4.
Cause:
The ECU has detected a short circuit pattern between both bank 1 fuel injectors.
1. Faulty fuel injector wiring, short circuit.

2. Fault ECU, software.
Solution:
2. Use the Electronic Service Tool (EST) to check if the following related faults are active:
3063 – Short circuit error of injector in cylinder 1
A. If any of the related faults are active, then diagnose them first and then return to this fault.
B. If none of the related faults are active, then continue to step 3.

3. Check the fuel injector harness (INJ) for a short circuit.
Use a multimeter to perform the following continuity check on the fuel injector harness (INJ) side :
From To Value
X-471 pin A X-471 pin E There should be no continuity.
X-471 pin A X-471 pin F There should be no continuity.
X-471 pin B X-471 pin E There should be no continuity.
X-471 pin B X-471 pin F There should be no continuity.
A. If there is continuity, then there is a short circuit in the fuel injector number 1 and fuel injector number 4 control
circuits in the fuel injector harness (INJ) wiring. Locate and repair the damaged conductors. Repair or replace
the harness as required.
B. If there is no continuity, leave the engine interface connector X-9139 disconnected and continue to step 4.
4. Check the vehicle harness (VE) for a short circuit condition.
harness (VE) side :
From To Value
X-471 pin A X-471 pin E There should be no continuity.
X-471 pin A X-471 pin F There should be no continuity.
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From To Value
X-471 pin B X-471 pin E There should be no continuity.
X-471 pin B X-471 pin F There should be no continuity.
A. If there is continuity, then there is a short circuit in the fuel injector number 1 and fuel injector number 4 vehicle
harness (VE) wiring. Locate and repair the damaged conductors. Repair or replace the harness as required.
has been resolved.
operation.
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3218 (DTC 7216) - Injection bank 2 short circuit failure (all injectors
of the same bank can be affected)
Context:
The Engine Control Unit (ECU) monitors the fuel injector harness for a short circuit condition. If the ECU detects a
short circuit pattern in the fuel injector harness of both bank 2 fuel injections, then this fault will occur. The bank 2 fuel
injectors are fuel injector number 2 and fuel injector number 3.
Cause:
The ECU has detected a short circuit pattern between both bank 2 fuel injectors.
1. Faulty bank fuel injector wiring, short circuit.

2. Fault ECU, software.
Solution:
2. Use the Electronic Service Tool (EST) to check if the following related faults are active:
A. If any of the related faults are active, then diagnose them first and then return to this fault.
B. If none of the related faults are active, then continue to step 3.

3. Check the fuel injector harness (INJ) for a short circuit.
From To Value
X-471 pin D X-471 pin H There should be no continuity.
X-471 pin D X-471 pin G There should be no continuity.
X-471 pin C X-471 pin H There should be no continuity.
X-471 pin C X-471 pin G There should be no continuity.
A. If there is continuity, then there is a short circuit in the fuel injector harness (INJ) wiring. Locate and repair the
shorted conductors. Repair or replace the harness as required.
B. If there is no continuity, then leave the engine interface connector X-471 disconnected and continue to step 4.
4. Check the fuel injector vehicle harness (VE) for a short circuit.
harness (VE) side :
From To Value
X-471 pin D X-471 pin H There should be no continuity.
X-471 pin D X-471 pin G There should be no continuity.
X-471 pin C X-471 pin H There should be no continuity.
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From To Value
X-471 pin C X-471 pin G There should be no continuity.
A. If there is continuity, then there is a short circuit in the fuel injector vehicle harness (VE) wiring. Locate and
repair the shorted conductors. Repair or replace the harness as required.
has been resolved.
operation.
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3235 (DTC F936) - Exceeded the number of injections for a given

engine speed
Context:
The Engine Control Unit monitors the compatibility between the number of injections and the current capability of the
injection system for fulfilling the number of injections requested at various engine speeds. If the number of requested
injections is greater than the maximum number of injections, established by the ECU, for the current engine speed,
then this fault will occur.
Solution:
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3236 (DTC F836) - Number of injections is limited by system

Context:
The Engine Control Unit (ECU) monitors the difference between the requested number of fuel injections and the
current capability of the fuel injection system fulfilling that requested number. If the difference between the number of
requested injections and actual injection is five injections, then this fault will occur.
Solution:
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3237 (DTC 1636) - Number of desired injections exceeds threshold

Context:
The Engine Control Unit (ECU) monitors the requested number of fuel injections. If the ECU determines that the
number of requested injections is greater than the current capability of the fuel injection system, then this fault will
occur.
Cause:
The ECU has determined that the number of requested fuel injections has exceeded the current capability of the fuel
injection system.
1. Faulty battery, low voltage.

2. Faulty ECU power supply.
Solution:
1. Check battery voltage.
Load test the battery. There should be approximately 12.0 V.
A. If the battery passes the load test, then continue to step 2.
B. If the battery fails the load test, then the battery has failed. Replace the battery and retest.
2. Check the ECU power supply wiring.
Disconnect connector X-461 from the ECU.
Use a multimeter to check for voltage on the vehicle harness (VE) side :
From To Value
12.0 V.
12.0 V.
12.0 V.
A. If there is approximately 12.0 V, then leave the connector X-461 disconnected and continue to step 3.
3. Check the ECU ground supply wiring.
Use a multimeter to perform the following continuity check.
From To Value
A. If there is no continuity, then there is a problem in the ground connection to the ECU. Locate and repair the
B. If there is continuity, then continue to step 4.
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3245 (DTC E51D) - ECU internal failure - Query/response

communication errors
Context:
The Engine Control Unit (ECU) monitors internal communications with the power stage controllers over Serial Pe-
ripheral Interface (SPI) bus. If no response or erroneous response is detected, the ECU will reset and monitor again
seven times. If the error is still detected, then this fault will occur.
Solution:
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3252 (DTC E61D) - ECU internal failure - SPI communication error

Context:
The Engine Control Unit (ECU) tests the correct functioning of the fuel injection path shut off procedure. During this
test, each injection path is shortly activated during ECU initialization. If a Serial Peripheral Interface (SPI) communi-
cation error is detected during this test, then this fault will occur.
Solution:
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3253 (DTC E41D) - ECU internal failure - Voltage ratio in ADC

monitoring
Context:
The Engine Control Unit (ECU) monitors the efficiency of the Analog to Digital Converter (ADC) using a voltage ratio
conversion test. The will count each time the voltage ratio is out of the desired range. If the count exceeds 15 times,
Solution:
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3255 (DTC E31D) - ECU internal failure - ADC test

Context:
The Engine Control Unit (ECU) monitors the efficiency of the Analog to Digital Converter (ADC). A fixed test input
voltage is sent to and converted by the ADC. The test voltage value must be between 4.73 – 4.83 V. The ECU monitors
this test and counts each time the value is not recorded in the specified range. If the counter exceeds 15 times, then
Solution:
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3256 (DTC E21D) - ECU internal failure - NTP error in ADC

monitoring
Context:
The Engine Control Unit (ECU) uses a No-load Test Pulse (NTP) operation to check the efficiency of the Analog to
Digital Converter (ADC). If an error is detected during this test, then this fault will occur.
Solution:
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3258 (DTC 6722) - Starter relay high side driver circuit short to
battery failure
Context:
The Engine Control Unit (ECU) controls the starter control relay using a low side and high side driver. If the ECU
detects a short circuit to battery in the high side driver circuit, then this fault will occur.
Cause:
The ECU has detected a short circuit to battery in the starter control relay high side driver circuit.
1. Faulty starter control relay wiring, short to a voltage source.

2. Faulty starter control relay, internal failure.
Solution:
2. Check the starter control relay coil for an internal failure.
Remove the starter control relay.
Use a multimeter to measure the relay coil resistance on the starter control relay pins :
From To Value
Starter control relay coil pin 85 Starter control relay coil pin 86 There should be approximately 70 –
130 Ω.
A. If there is approximately 70 – 130 Ω, then leave the starter control relay disconnected and continue to step 3.
B. If there is not approximately 70 – 130 Ω, then the relay has failed. Replace the starter control relay and retest.
3. Check the starter control relay high side driver vehicle harness (VE) wiring for a short circuit to another voltage
source.
With the key in the OFF position, use a multimeter to check for short circuit to another voltage source on the vehicle
harness (VE) side :
From To Value
Starter control relay coil connector Chassis ground There should be no voltage.
pin 85
With the key in the ON position, use a multimeter to check for short circuit to another voltage source on the vehicle
harness (VE) side :
From To Value
Starter control relay coil connector Chassis ground There should be no voltage.
pin 85
A. If there is voltage, then there is a short circuit to another voltage source in the starter control relay wiring in the
vehicle harness (VE). Locate and repair the shorted conductor. Repair or replace the harness as required.
B. If there is no voltage, then continue to step 4.
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4. Check the starter control relay high side driver vehicle harness (VE) wiring for a short circuit.
With the key in the OFF position, use a multimeter to check for short circuit on the vehicle harness (VE) side :
From To Value
A. If there is continuity, then there is a short circuit in the starter control relay wiring in the vehicle harness (VE).
has been resolved.
operation.
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3259 (DTC 7822) - Starter relay high side driver circuit short to
ground failure
Context:
detects a short circuit to ground in the high side driver circuit, then this fault will occur.
Cause:
The ECU has detected a short circuit to ground in the starter control relay high side driver circuit.
1. Faulty starter control relay wiring, short circuit to ground.

Solution:
From To Value
130 Ω.
B. If there is not approximately 70 – 130 Ω, then the relay has failed. Replace the starter control relay.
3. Check the starter control relay high side driver vehicle harness (VE) wiring for a short circuit to ground.
With the key in the OFF position, use a multimeter to check for a short circuit to ground on the vehicle harness
(VE) side :
From To Value
Starter control relay coil connector Chassis ground There should be no continuity.
pin 85
Starter control relay coil connector Starter control relay coil connector There should be no continuity.
pin 85 pin 86
A. If there is continuity, then there is a short circuit to ground in the starter control relay wiring in the vehicle harness
(VE). Locate and repair the shorted conductor. Repair or replace the harness as required.

4. Check the starter control relay high side driver vehicle harness (VE) wiring for a short circuit.
With the key in the OFF position, use a multimeter to check for a short circuit to ground on the vehicle harness
(VE) side :
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From To Value
A. If there is continuity, then there is a short circuit to ground in the starter control relay wiring in the vehicle harness
(VE). Locate and repair the shorted conductor. Repair or replace the harness as required.
has been resolved.
operation.
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3260 (DTC 5922) - Starter relay low side driver circuit open failure
Context:
The Engine Control Unit (ECU) controls the starter control relay using a low side driver and a high side driver. If the
ECU detects an open circuit in the high side driver circuit, then this fault will occur.
Cause:
The ECU has detected an open circuit in the starter control relay high side driver circuit.
1. Faulty starter control relay wiring, open circuit.

Solution:
From To Value
130 Ω.
3. Check the starter control relay vehicle harness (VE) wiring for an open circuit.
With the key in the OFF position, use a multimeter to check for an open circuit on the vehicle harness (VE) side :
From To Value
Starter control relay coil connector X-461 pin 53 There should be continuity.
pin 85
Starter control relay coil connector X-461 pin 27 There should be continuity.
pin 86
NOTE: Wiggle the harness during the measurement to reveal an intermittent electrical connection.
A. If there is no continuity, then there is an open circuit in the starter control relay wiring in the vehicle harness
(VE). Locate and repair the broken conductor. Repair or replace the harness as required.
B. If there is continuity, then check the ECU for the appropriate service manual and re-flash, if necessary.
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has been resolved.
operation.
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3261 (DTC 6B22) - Starter relay low side driver circuit short to
battery failure
Context:
detects a short circuit to battery in the low side driver circuit, then this fault will occur.
Cause:
The ECU has detected a short circuit to battery in the starter control relay low side driver circuit.
1. Faulty starter control relay wiring, short circuit to another voltage source.
Solution:
From To Value
Starter control relay pin 85 Starter control relay pin 86 There should be approximately 70 –
130 Ω.
3. Check the starter control relay low side driver vehicle harness (VE) wiring for a short circuit to another voltage
source.
With the key in the OFF position, use a multimeter to perform the following voltage check for a short circuit to
another voltage source in the vehicle harness (VE) side :
From To Value
Starter control relay connector pin 86 Chassis ground There should be no voltage.
With the key in the ON position, use a multimeter to perform the following voltage check for a short to a voltage
source on the vehicle harness (VE) side :
From To Value
A. If there is voltage, then there is a short circuit to another voltage source in the starter control relay low side driver
wiring in the vehicle harness (VE). Locate and repair the shorted conductor. Repair or replace the harness as
required.
B. If there is no voltage, then leave the starter control relay disconnected and continue to step 4.
4. Check the starter control relay low side driver vehicle harness (VE) wiring for a short circuit.
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(VE) side :
From To Value
Starter control relay connector pin 86 Starter control relay connector pin 85 There should be no continuity.
A. If there is continuity, then there is a short circuit in the starter control relay wiring in the vehicle harness (VE).
has been resolved.
operation.
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3262 (DTC 7C22) - Starter relay low side driver circuit short to
ground failure
Context:
detects a short circuit to ground in the low side driver circuit, then this fault will occur.
Cause:
The ECU has detected a short circuit to ground in the starter control relay low side driver circuit.
1. Faulty starter control relay wiring, short to ground.

Solution:
2. Check the starter control relay coil internal resistance.
Using a multimeter, to measure the resistance on the starter control relay pins :
From To Value
130 Ω.
A. If there is approximately 70 – 130 Ω, then leave the relay disconnected and continue to step 3.
B. If there is not approximately 70 – 130 Ω, then the relay starter control relay has failed. Replace the starter
control relay and retest.
3. Check the starter control relay low side driver vehicle harness (VE) wiring for a short circuit.
(VE) side :
From To Value
Starter control relay connector pin 86 Chassis ground There should be no continuity.
Disconnect the ECU connector X-461.
(VE) side :
From To Value
A. If there is continuity, then there is a short circuit in the starter control relay vehicle harness (VE) wiring. Locate
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has been resolved.
operation.
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3265 (DTC E4DD) - Fuel injection requested during overrun

Context:
The Engine Control Unit (ECU), during after run, monitors fuel injector actuation time by calculating the demanded
fuel injection quantity of actual injection and actual fuel pressure. If the ECU determines that energizing time is greater
than engine speed, then this fault will occur.
Solution:
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3283 (DTC E32D) - ECU internal failure - Sensor 5 volt supply 2

Context:
The Engine Control Unit (ECU) provides three independent five volt sensor supplies. The ECU monitors each sensor
supply voltage to ensure they operate within a given range. If the ECU determines that the voltage for sensor supply
2 is out of range, then this fault will occur.
The ECU pin numbers associated with sensor supply 2 are X-461 pin 12, X-461 pin 13, X-461 pin 14, X-461 pin 15,
and X-461 pin 16.
Cause:
The ECU has determined that the sensor supply 2 voltage is out of range.
1. Faulty battery voltage.

2. Faulty ECU supply voltage.
3. Faulty ECU sensor supply 2 pins.
4. Faulty ECU connector X-461, corrosion or damage.
Solution:
Charge the battery, then, perform a load test on the battery.
With the key in the ON position, use a multimeter to perform the following voltage check on the vehicle harness
(VE) side :
From To Value
X-461 pin 1 X-461 pin 2 There should be approximately 12 V.
A. If there is approximately 12 V, then leave connector X-461 disconnected and continue to step 4.
B. If there is not approximately 12 V, then there is a problem with the battery supply to the ECU. Repair or replace
4. Check the following pins listed below on the ECU and in connector X-461.
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Pin Physical condition

X461 pin 12 The pin and connector should be free of corrosion or
damage.
damage.
damage.
damage.
damage.
A. If a pin or connector shows signs of corrosion or damage, then repair as required.
B. If a pin or connector shows no signs of corrosion or damage, then continue to step 5.

has been resolved.
operation.
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3285 (DTC E42D) - ECU internal failure - Sensor 5 volt supply 3

Context:
The Engine Control Unit (ECU) provides three independent five volt sensor supplies. The ECU monitors each sensor
supply voltage to ensure they operate within a given range. If the ECU determines that the voltage for sensor supply
3 is out of range, then this fault will occur.
The ECU pin numbers associated with sensor supply 3 are X-461 pin 17, X-461 pin 18, and X-462 pin 29.
Cause:
The ECU has determined that the sensor supply 3 voltage is out of range.
1. Faulty battery voltage.

2. Faulty ECU, supply voltage.
3. Faulty ECU sensor supply 3 pins.
4. Faulty ECU connector X-461 or X-462, corrosion or damage.
Solution:
Charge the battery, then perform a load test on the battery.
(VE) side :
From To Value
A. If there is approximately 12 V, then leave connector X-461 disconnected and continue to step 4.
B. If there is not approximately 12 V, then there is a failure in the ECU supply wiring.Locate and repair the failed
4. Disconnect the vehicle harness (VE) from the ECU at connector X-462.
Check the following pins listed below on the ECU and in connectors X-461 and X-461.
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Pin Physical condition

X-461 pin 17 The pin and connector should be free of corrosion or
damage.
damage.
damage.
A. If a pin or connector shows signs of corrosion or damage, then repair as required.
B. If a pin or connector shows no signs of corrosion or damage, then ontinue to step 5.

A. If you find damage or the display indicates other than normal display readings, Then, repair the damage dis-
covered during the inspection or locate and repair the other than normal display condition and verify that the
error has been resolved.
B. If you do not find damage and the display indicates only normal readings, Then, erase the fault code and
continue operation.
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3293 (DTC 2265) - Fuel rail pressure has exceeded maximum

positive deviation limits
NOTE: If the rail pressure sensor B-9004 is replaced, it is necessary to perform the Replacement of the Rail Pressure
sensor - Reset ECU Data with the Electronic Service Tool (EST) before you return the machine to service. Refer to
the engine service manual Common rail pressure sensor - Configure - Reset ECU data (Rail pressure sensor)
(55.010), if necessary.
Context:
The Engine Control Unit (ECU) A-9000 monitors fuel rail pressure. If the measured rail pressure is lower than the de-
sired pressure by 100 bar (1450 psi) depending on engine speed, this fault will occur. For more information regarding
fuel system troubleshooting, refer to the engine service manual Fuel injection system - Troubleshooting (10.218).
Cause:
The ECU A-9000 has determined that the measured rail pressure is 100 bar (1450 psi) lower than desired fuel pres-
sure based on engine speed.
1. Faulty fuel metering unit Y-9000, internal failure.

4. Faulty low pressure fuel supply lines, clogged or damaged.
5. Faulty high pressure fuel supply lines, clogged or damaged.
6. Faulty Pressure Relief Valve (PRV), leakage.
7. Faulty high pressure fuel pump, low efficiency.
8. Faulty fuel injectors, worn, clogged or internal leakage.
9. Faulty rail pressure sensor B-9004, drifted or leaking.
10. Faulty ECU A-9000, software.
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3301 (DTC 1565) - Fuel rail pressure has exceeded maximum

negative deviation limits
necessary.
Context:
The Engine Control Unit (ECU) monitors fuel rail pressure. If the ECU determines that fuel pressure is higher than the
desired fuel pressure, depending on engine speed, this fault will occur. For more information regarding fuel system
troubleshooting, refer to the engine service manual Fuel injection system - Troubleshooting (10.218).
Cause:
The ECU has determined that the fuel rail pressure is higher than desired based on engine speed.

3. Faulty Pressure Relief Valve (PRV), stuck or blocked.
4. Faulty rail pressure sensor, drifted.
5. Faulty high pressure pump.
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3305 (DTC 2765) - Fuel rail pressure has exceeded minimum limit
necessary.
Context:
The Engine Control Unit (ECU) monitors fuel rail pressure using the rail pressure sensor. If the ECU determines that
the measured rail pressure is less than a dependent engine speed value, this fault will occur. Other active faults
Cause:
The ECU has determined that the measured rail pressure is less than a dependent engine speed value.

2. Faulty low pressure fuel lines, clogged or damaged.
3. Faulty high pressure fuel lines, clogged or damaged.
6. Faulty high pressure pump, low efficiency or excessive leak-off.
7. Faulty fuel injectors, excessive or leaking internally.
8. Faulty Pressure Relief Valve (PRV), leaking or stuck open.
9. Faulty rail pressure sensor or sensor leaking.
10. Faulty fuel metering unit.
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3309 (DTC 1865) - Fuel rail pressure has exceeded maximum limit
necessary.
Context:
The Engine Control Unit (ECU) monitors fuel rail pressure using the rail pressure sensor. If the ECU determines
that the measured rail pressure is greater than desired by more than a dependent engine speed value, this fault will
occur. For more information regarding fuel system troubleshooting, refer to the engine service manual Fuel injection
system - Troubleshooting (10.218).
Cause:
The ECU has determined that the measured rail pressure is greater than desired by more than a dependent engine
speed value.
1. Faulty fuel metering unit, stuck open or internal failure.

2. Faulty fuel back-flow lines, blocked or damaged.
3. Faulty Pressure Relief Valve (PRV), stuck closed or mechanically unable to open.
4. Faulty high pressure pump, zero delivery throttle valve clogged.
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3334 (DTC 98BB) - CAN communication failure between vehicle

controller and ECU controller - TSC1_PE message
Context:
Area Networks (CAN). Proper configuration and monitoring of the these twisted pair configured networks is also a
function of the ECU. CAN Node A Bus is the main vehicle interface bus. The ECU provides a CAN termination resistor
for the CAN Node A Bus, internal to the ECU. The ECU receives and responds to Power take-off to Engine controller
(PE) information 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:
The ECU is not properly sensing the PE message.

Solution:
2. Check for related vehicle CAN faults.
A. If related vehicle CAN faults exist, resolve the vehicle CAN faults, then check to see that 3334 – CAN com-
munication failure between vehicle controller and ECU controller - TSC1_PE message is also resolved.
B. If related vehicle CAN faults do not exist, then continue with step 3.
From To Value
A. If the voltage is present on all of the checks, leave connector X-461 disconnected and continue with step 4.
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From To Value
From To Value
X-461 pin 24 Chassis ground There should not be continuity
X-461 pin 25 Chassis ground There should not be continuity
From To Value
restore the termination resistance to the CAN circuit or replace the ECU.
has been resolved.
operation.
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3338 (DTC 91CB) - CAN communication failure between vehicle

controller and ECU controller - TSC1_VE message
Context:
Area Networks (CAN). Proper configuration and monitoring of these twisted pair configured networks is also a function
of the ECU. CAN Node A Bus is the main vehicle interface bus. The ECU provides a CAN termination resistor for the
CAN Node A Bus, internal to the ECU. The ECU receives and responds to Torque/Speed Control (TSC) information
at two different rates (active and passive) dependant upon change request status. If the ECU is not sensing the TSC
message at the passive rate, this fault will occur.
Cause:
ECU has sensed a timeout of required vehicle controller data provided on CAN Node A.

Solution:
From To Value
4.
ECU. Repair or repalce the harness as required.
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From To Value
From To Value
From To Value
B. If the measured resistances are not correct or one or both of the conductors is grounded, then there is a problem
in the ground connection to the ECU. Repair or replace the harness as required.
has been resolved.
operation.
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3339 - Timeout of CAN Message TSC1 Torque

Context:
CAN Data Link communications from the Engine Control Unit (ECU) have been lost.
Cause:
CAN Data Link communications from the ECU have been lost. This fault code will be displayed with other CAN Data
Link fault messages. The engine may go into Limp Home Mode and engine speed will be set to 1500 RPM

4. Faulty ECU.
Solution:

If three or more fault codes are active, 3096, 3334,1051 through 1059, this is an indication of a problem in the
CAN Data Link circuit, continue with this procedure. If one or two CAN Data Link fault codes are active, this is
an indication of an intermittent connection in the CAN circuit. Check all wires and connectors to verify they are
secure and free of damage, corrosion, abrasion or incorrect attachment.
A. CAN Data Link fault codes are not recorded again and are no longer ACTIVE. OK to return the machine service.
B. CAN Data Link fault codes are present and ACTIVE. Go to step 2.
Verify the connections to the ECU, instrument cluster, diagnostic connector, Trax control (if installed) and the op-
tional Telematics unit are tight and secure.
Verify the harness is free of damage, abrasion, corrosion and incorrect attachment from the ECU to the instrument
cluster. Verify all data link drops are free of damage, abrasion, corrosion and incorrect attachment.
A. The CAN Data Link harness is not damaged and all connections are secure. Go to step 3.
Go to step 1 to confirm the elimination of the fault code.
3. Measure the resistance through the CAN Data Link harness.
Measure the resistance between the Diagnostic Port connector, CAN 1 High and CAN 1 Low pins, pins C and D.
The resistance should be approximately 60 Ω. Wiggle the harness during measurement to reveal an intermittent
condition.
A. The resistance is between 54 Ω and 66 Ω. Go to step 4.
B. The resistance is less than 50 Ω. Go to Step6.
C. The resistance is greater than 70 Ω. Go to step 7.

4. Measure the harness resistance to chassis ground.
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A. Both resistance measurements are greater than 20,000 Ω. Go to step 5.
B. One or both resistance measurements are less than 20,000 Ω. There is a short circuit in the CAN Data Link.
Temporarily replace the CAN Data Link wires and retest. Repair or replace the harness as required. Return to
step 1 to confirm the elimination of the fault code.
5. Check the stray voltages on the harness. .
A. Both voltage measurements are less than 0.5 V. Verify the ECU is powered and operational. Verify that all
minus battery and chassis ground connections to the CAN Bus modules are clean and secure. Return to step
1.
B. One or both voltage measurements are greater than 0.5 V. There is a short circuit to another voltage source
in the CAN Data Link. Temporarily replace the CAN Data Link wires and retest. Repair or replace the harness
as required. Return to step 1 to confirm the elimination of the fault code.
6. Measure the resistance between the CAN High and CAN Low lines.
Disconnect all modules on the CAN bus.
Measure the resistance between CAN High X-607 pin C and CAN Low X-607 pin D.
A. The resistance is greater than 20,000 Ω. Connect each component to the CAN Bus one at a time. The re-
sistance should be greater than 60 Ω. Replace the module that drops the CAN Bus resistance below 60 Ω.
Return to step 1 to confirm the elimination of the fault code.
B. The resistance is less than 56 Ω. There is a short circuit between the CAN High and CAN Low wires. Repair
or replace the harness as required. Return to test step 1 to confirm the elimination of the fault code.
7. Measure the resistance through the CAN Data Link circuit.
Turn the key switch OFF. Disconnect all components connected to the CAN Bus.
Fabricate a jumper that will connect between X-461 pin 24 and X-461 pin 25.
Connect the jumper between X-461 pin 24 and X-461 pin 25.
Measure the resistance between connector X-607 pin C and X-607 pin D. The resistance should be less than
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RCPH11TLB074FAL 1
CAN Low XST2 pin 3
(2) Diagnostic Port X-607 (6) CAN Bus to ECU
CAN Low X500 pin 4
CAN Low X401 pin 55
Measure the resistance between the Telematics connector pins C and D. The resistance should be less than 10 Ω.
Measure the resistance between the Trax connector X401 pin 27 and X401 pin 55. The resistance should be less
than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition.
Measure the resistance between instrument cluster connector XST2 pin 4 and XST2 pin 3. The resistance should
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RCPH11TLB072FAL 2
CAN Low XST2 pin 3
(2) Diagnostic Port X607 (6) CAN Bus to ECU
CAN Low X500 pin 4
CAN Low X401 pin 55
A. All resistance measurements are less than 10 Ω. Temporarily replace the ECU and retest. Return to step 1 to
confirm the elimination of the fault code.
B. A resistance measurement is greater than 20,000 Ω. There is an open circuit in the wiring to the ECM. Repair
or replace the harness as required. Return to step 1 to confirm the elimination of the fault code.
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3358 (DTC 962B) - CAN transmit error - EEC1 message (Electronic

Engine Control 1 message - Torque, accelerator pedal, engine
speed, and other signals)
Context:
ECU. CAN Node A Bus is the main vehicle interface bus. The ECU provides a CAN termination resistor for the CAN
Node A Bus, internal to the ECU. If the EEC1 message, from the vehicle control module, is not communicated within
an allotted time frame this ECU fault will occur.
Cause:
The ECU has reported, via CAN bus, that a timeout of the EEC1 message has occurred.

2. Faulty CAN circuit wiring, open circuit, or short circuit.
Solution:
From To Value
4.
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From To Value
B. If there is no continuity for one or more of the checks, then there is a problem with the ground circuit to the
From To Value
From To Value
A. If the measured resistances are correct and neither conductor is grounded, check the ECU for the appropriate
software and re-flash, if necessary.
has been resolved.
operation.
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3361 (DTC E16D) - ECU internal failure - EEPROM write/read error

Context:
The Engine Control Unit (ECU) has the capability of reading and writing values to flash or Electrically Erasable Pro-
grammable Read Only Memory (EEPROM). The ECU monitors the reading and writing capability of this function. If
the ECU determines that calibrated parameters for baud rate cannot be read from EEPROM during this monitoring,
Solution:
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3368 (DTC F6EF) - Torque limitation caused by performance limiter

Context:
This fault has set due to a performance limitation, engine power and speed reduction greater than 25%, because of
too high NOx emission for longer than 120 s. This fault code is for information only and does not require any further
action. If the power / speed reduction occurred due to an actual defect, the failure triggering the torque limitation
should also be in failure memory. Follow the troubleshooting procedure for the other fault.
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3369 (DTC F8EF) - Torque limitation caused by smoke limitation

Context:
Torque is limited during acceleration to prevent smoke emissions due to a lean mixture. Therefore the fuel quantity
is limited to a minimum air/fuel ratio, depending on the actual engine speed and the actual air flow. This reduction is
usual and the duration normally less than 1.00 s. If there was a power reduction greater than 25% or an engine speed
limitation greater than 25% due to smoke limitation for more than 120.00 s a fault code was stored. This fault code is
for information only and does not require any further action. That there was an active performance limitation due to
smoke limitation, which lasted longer than usually expected. If no other failure is stored in memory concerning Exhaust
Gas Recirculation (EGR) or intake manifold pressure control or if failure occurred at high altitude 1800 m (5906 ft)
(less than 0.78 bar (11.31 psi) ambient pressure), no action is needed. Check applicable actuators of EGR, intake
manifold pressure and exhaust flap control for sticking. Check turbocharger for correct efficiency. Check applicable
air flow and intake manifold pressure sensors for correct measuring. If other fault codes are present concerning EGR
or intake manifold pressure that could influence smoke limitation, those faults could pinpoint an actual failure. Follow
the troubleshooting procedure for the other fault.
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3370 (DTC F2EF) - Strong torque limitation from engine protection

active
Context:
The engine is protected against too high air intake gas temperature (VGT protection), too high coolant temperature,
too high oil temperature, and too high fuel temperature by reducing the torque. If any one of the temperatures exceeds
the dedicated limit established by parameters programmed within the Engine Control Unit (ECU) the torque is reduced.
If there is a power reduction greater than 25.00% or an engine speed limitation greater than 25.00%, depending
on engine speed, for more than 120.00 s, a failure is stored as confirmation that there was an active performance
limitation. This is not caused by the failure of a component or system, but by an extreme working condition. This
failure is a confirmation of a temporary power limitation. This failure does not ask for any action except, to check if
other failures concerning the engine protection/engine speed are present in the failure memory. No actions necessary
due to this failure alone. If power reduction occurred due to actual defect, the failure triggering the torque limitation
should also be in the failure memory. Follow troubleshooting of the actual defect.
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3371 (DTC F3EF) - Strong torque limitation from injection system

active
Context:
This fault has set due to a performance limitation to protect the high pressure fuel pump from high temperatures. If
there was a power reduction greater than 25.00% or an engine speed limitation greater than 25.00% is required by
the high pressure pump, depending on engine speed, for more than 120.00 s a fault code was stored. This fault
code is for information only and does not require any further action. That there was an active performance limitation
due to the high pressure fuel pump protection against too high fuel temperature, which was not caused by a failure,
but an extreme working condition. If other fault codes are present that could influence the high pressure fuel pump
temperatures, those faults could pinpoint an actual failure. Follow the troubleshooting procedure for the other fault.
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3403 (DTC 8A22) - Starter relay low side ECU driver circuit over
temperature failure
Context:
detects an over temperature/current condition in the high side driver circuit, this fault will occur.
Cause:
The ECU has detected an over temperature/current condition in the starter control relay high side driver circuit.
1. Faulty starter control relay wiring, short circuit.

Solution:
From To Value
Starter control relay pin 85 Starter control relay pin 86 There should be approximately 70 –
130 Ω.
3. Check the starter control relay high side driver vehicle harness (VE) wiring for a short circuit to ground.
With the key in the OFF position, use a multimeter to perform the following continuity check for short circuit to
ground on the vehicle harness (VE) side :
From To Value
Starter control relay connector pin 85 Starter control relay connector pin 86 There should be no continuity.
Starter control relay connector pin 85 Chassis ground There should be no continuity.
A. If there is continuity, then there is a short circuit to ground in the starter control relay high side driver circuit in
the vehicle harness (VE).Locate and repair the shorted conductor. Repair or replace the harness as required.
B. If there is no continuity, then leave the starter control relay disconnected and continue to step 4.
source.
With the key in the OFF position, use a multimeter to check for a short circuit to another voltage source on the
From To Value
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With the key in the ON position, use a multimeter to perform the following voltage check for a short to a voltage
source on the vehicle harness (VE) side :
From To Value
A. If there is voltage, then there is a short circuit to another voltage source in the starter control relay high side
driver circuit in the vehicle harness (VE). Locate and repair the shorted conductor. Repair or replace the har-
ness as required.

source.
From To Value
A. If there is continuity, then there is a short circuit in the starter control relay high side driver circuit in the vehicle
harness (VE). Locate and repair the shorted conductor. Repair or replace the harness as required.
has been resolved.
operation.
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3409 (DTC 23D3) - Defect fault check for minimum oil pressure from
digital sensor
Context:
The Engine Control Unit (ECU) monitors the oil pressure switch for proper operation. The oil pressure switch changes
from its off to on state between 0.6 – 0.9 bar (8.7 – 13.0 psi). If the oil pressure switch does actuate once the engine
has been running for 6.0 s at greater than 500.0 RPM, then this fault will occur.
Cause:
The ECU has determined that the oil pressure switch did not actuate.
1. Faulty oil level, too low.

2. Faulty oil pressure switch, failed internally.
3. Faulty oil pressure switch circuit wiring, shorted to chassis ground.
4. Faulty oil pressure, too low or blockage.
5. Faulty ECU, hardware or software.
Solution:
2. Check the oil level.
Use the appropriate operator or service manual to determine if the lubrication system has the appropriate amount
of oil.
There should be at least the minimum acceptable level of oil.
A. If there is at least the minimum acceptable level of oil, then continue with step 3.
B. If there is less than the minimum acceptable level of oil, use the appropriate operator or service manual to
determine the type and quantity of oil required to re-fill the oil system.
3. Check the condition of the oil pressure switch.
Disconnect the engine harness (EN) from the oil pressure switch.
With the engine not running, use a multimeter to check for continuity on the component side :
From To Result
Oil pressure switch pin 1 Chassis ground There should be continuity.
Start the engine and allow it to run at a speed greater than 500 RPM for at least 6.0 s.
While the engine is running at a speed greater than 500 RPM, use a multimeter to check for continuity on the
component side :
From To Result
Oil pressure switch pin 1 Chassis ground There should be no continuity.
A. If the specified values are measured, leave the oil pressure switch disconnected and continue with step 4.
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B. If the oil pressure switch did not change state, then leave the oil pressure switch disconnected and continue
with step 7.
4. Check the oil pressure switch circuit for a short circuit to ground.
With the key switch in the OFF position, use a multimeter to check for continuity on the engine harness (EN) side :
From To Result
Oil pressure switch connector pin 1 Chassis ground There should be no continuity.
A. If there is continuity, then leave the oil pressure switch disconnected and continue with step 5.
5. Locate the short circuit to ground.
With the key switch in the OFF position, use a multimeter to check for continuity on the vehicle harness (VE) side :
From To Result
A. If there is continuity, then leave connector X-470 disconnected and continue with step 6.
B. If there is no continuity, then the short circuit to ground is in the engine harness (EN) between the oil pressure
switch connector pin 1 and connector X-470 pin 3. Locate and repair the grounded conductor. Repair or
replace the harness as required.
Carefully disconnect the vehicle harness (VE) from the ECU at connector X-462.
From To Result
A. If there is continuity, then the short circuit to chassis ground is in the vehicle harness (VE) between connector
X-462 pin 6 and X-470 pin 3. Locate and repair the grounded conductor. Repair or replace the harness as
required.
B. If there is no continuity, then the ECU has failed internally. Replace the ECU and retest.
7. Check lubrication system for blockage.
Refer to the engine service manual Engine lubrication system - Test (10.304) to determine if the lubrication
system has the appropriate amount of oil pressure.
Between 0.6 – 0.9 bar (8.7 – 13.0 psi) is required to actuate the oil pressure switch.
There should be at least the minimum acceptable level of oil pressure.
A. If there is adequate oil pressure, then the oil pressure switch has failed internally. Replace the switch and
retest.
B. If there less than the minimum acceptable level of oil pressure, then locate and restore oil pressure to the
lubrication system.
or broken wires.
has been resolved.
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operation.
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3425 (DTC 1438) - Turbocharger boost pressure is higher than

expected
Context:
The Engine Control Unit (ECU) monitors boost pressure using the intake manifold pressure sensor. If the ECU de-
termines that boost pressure is higher than expected, this fault will occur. For more information regarding the trou-
bleshooting of an over-boost condition, refer to the engine service manual Turbocharger Boost - Troubleshooting
(10.250).
Cause:
The ECU has determined that boost pressure is higher than expected.
1. Faulty wastegate pressure modulator valve, if applicable.

2. Faulty wastegate, sticking or broken linkage.
3. Faulty intake manifold pressure sensor, signal drifted.
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3436 (DTC FBBF) - Inducement system is locked due to 3 detections

in 40 hours. The system must be reset using the dealer service tool
screen "Engine Restart Counter Reset"
NOTE: Since this fault is part of the inducement strategy and has resulted in an inducement lock condition, it may
be necessary to perform the Engine Restart Counter Reset / Unlock Inducement configuration and the SCR Fault
Repair Verification Test with the Electronic Service Tool (EST) before you return the machine to service. Refer to
counter reset (10.500) and Selective Catalytic Reduction (SCR) exhaust treatment - Service instruction - SCR
fault repair verification test (10.500) , if necessary. If the machine is still locked in final inducement after following
the above procedures, you must use the Easy Engine software provided with the Electronic Service Tool (EST) to
clear all faults.
Context:
This failure path is only for information. One or more of the inducement blocks has been detected as active at least
three times in the last 40 h by the Engine Control Unit (ECU) which has caused the inducement system to lock. The
failure causing the inducement must be located, resolved and reset prior to reset of this fault. The Electronic Service
Tool (EST) is required to release inducement.
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3449 (DTC E812) - ECU internal failure - Calculated engine speed

Context:
The Engine Control Unit (ECU) monitors engine speed in multiple software levels. If the ECU determines that there
is plausibility error in the engine speed monitoring, this fault will occur.
Solution:
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3457 (DTC 1374) - Intake manifold temperature sensor voltage is

Context:
The Engine Control Unit (ECU) monitors the intake manifold temperature sensor. If the ECU determines that the
intake manifold temperature sensor signal circuit voltage is greater than 4.92 V, then this fault will occur. If this fault
is active, then the intake manifold temperature value will be frozen at the last valid value for a preliminary failure or
jump to a fixed replacement value of 0.98 bar (14.21 psi) if the failure is validated.
Cause:
The ECU has determined that the intake manifold temperature sensor signal circuit voltage is greater than 4.92 V.
1. Faulty intake manifold temperature sensor wiring, short circuit to another voltage source.
2. Faulty intake manifold temperature sensor wiring, open circuit.
Solution:
2. Check the intake manifold temperature sensor wiring for a short circuit to another voltage source.
side :
From To Value
Intake manifold temperature sensor Chassis ground There should be no voltage.
connector pin 2
side :
From To Value
Intake manifold temperature sensor Chassis ground There should be less than 5.5 V.
connector pin 2
A. If there is voltage, then there is a short circuit to battery or a short circuit switched battery in the intake manifold
temperature sensor wiring. Locate and repair the shorted conductor. Repair or replace the harness as required.
B. If there is no voltage, then leave connector disconnected and continue to step 3.

3. Check the intake manifold temperature sensor wiring in the engine harness (EN) for an open circuit.
(EN) side :
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From To Value
connector pin 2
connector pin 1
NOTE: Wiggle the harness during measurement to reveal an intermittent condition.
(VE) side :
From To Value
A. If there is no continuity, then there is an open circuit in the intake manifold temperature sensor wiring in the
engine harness (EN). Locate and repair the broken conductor. Repair or replace the harness as required.
B. If there is continuity, then leave the intake manifold temperature sensor disconnected. Leave connectors X-462
and X-470 disconnected and continue to step 4.
4. Check the intake manifold temperature sensor wiring in the engine harness (EN) for a short circuit to another
voltage source.
(EN) side :
From To Value
A. If there is continuity, then there is a short circuit in the intake manifold temperature sensor wiring in the engine
harness (EN). Locate and repair the shorted conductor. Repair or replace the harness as required.
B. If there is no continuity, then leave the intake manifold temperature sensor disconnected. Leave connectors
X-462 and X-470 disconnected and continue to step 5.
5. Check the intake manifold temperature sensor wiring in the vehicle harness (VE) for a short circuit.
(VE) side :
From To Value
A. If there is continuity, then there is a short circuit in the intake manifold temperature sensor wiring in the vehicle
B. If there is no continuity, then leave the intake manifold temperature sensor disconnected and continue to step
6.
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has been resolved.
operation.
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3461 (DTC E69D) - ECU internal failure - Timeout in the shut off
path test error
Context:
The Engine Control Unit (ECU) performs shut off paths which deactivate all power stages relevant to fuel injection
if certain internal ECU errors are detected. In order to test this function, every path is shortly activated during ECU
initialization. Since the shut off is active, no fuel injection should occur during this test. If a time-out error in the power
stage feedback is detected during this test, this fault will occur.
Solution:
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3462 (DTC E79D) - ECU internal failure - Overvoltage monitoring

error
Context:
initialization. Since the shut off is active, no fuel injection should occur during this test. If a voltage higher than
expected condition is detected during this test, this fault will occur.
Solution:
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3501 (DTC ED1D) - ECU internal failure - Software resets in DSM 0

Context:
The Engine Control Unit (ECU) monitors for a possible error to the ECU internal software. If the ECU detects a
software failure, a software reset will be performed and this fault will occur. During a software reset, all instrument
panel lights could flash (power on test) and the instruments could momentarily read zero.
Solution:
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3502 (DTC EE1D) - ECU internal failure - Software resets in DSM 1

Context:
The Engine Control Unit (ECU) will perform a software reset if a software failure is detected. If this fault is active, a
software failure has been reported and a software reset has occurred.
Solution:
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3503 (DTC EF1D) - ECU internal failure - Software resets in DSM

Context:
The Engine Control Unit (ECU) will perform a software reset if a software failure is detected. If this fault is active, a
software failure has been reported and a software reset has occurred.
Solution:
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3507 (DTC 4761) - Engine cranked for too long or keyswitch failure
Context:
The Engine Control Unit (ECU) is notified of a request for engine cranking at connector X-461 pin 8. If the request for
cranking signal exists for longer than 80.0 s, then the ECU assumes a mechanical failure in the ignition key module
or start relay or a short circuit to another voltage source exists in the input circuit and this fault occurs.
Cause:
The engine cranking signal has exceeded the signal ON time established be the ECU.
1. Faulty vehicle cranking circuit component, key switch or crank / start relay.
2. Faulty cranking circuit wiring, short circuit to another voltage source.
Solution:
1. Verify that the fault present and active.
2. Check the cranking circuit wiring for a short circuit to another voltage source.
With the key switch in the ON position, use a multimeter to check for voltage on the vehicle harness (VE) side :
From To Value
A. If there is voltage, then locate the short circuit in the harness. Repair or replace the harness as required.
B. If there is no voltage, then leave connector X-461 X-9122 disconnected and continue with step 3.
3. Check the cranking circuit wiring for a short circuit.
From To Result
X-461 pin 8 to all other pins in connector X-461 There should be no continuity.
A. If there is continuity, then there is a short circuit to another voltage source in the vehicle harness (VE). Locate
and repair the shorted conductors. Repair or replace the harness as required.
or broken wires.
has been resolved.
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operation.
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3508 (DTC FAEF) - Torque limitation active

Context:
This failure path is only for information, that there was an active performance limitation. One or more torque reductions
are present. No actions necessary due to this failure alone. If power reduction occurred due to actual defect, the
failure triggering the torque limitation should also be in the failure memory. Follow troubleshooting of the actual defect.
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3517 (DTC 19C4) - Ambient temperature sensor voltage is higher

than expected
Context:
The Engine Control Unit (ECU) monitors the intake air temperature sensor. If the ECU determines that the intake air
temperature sensor signal circuit voltage is greater than 4.93 V, then this fault will occur. Once this fault occurs, the
intake air temperature value is frozen by the ECU A-9000 at the last valid value for a preliminary failure or jumps to a
fixed replacement value of 29.96 °C (85.93 °F) if the failure is validated.
Cause:
The intake air temperature sensor signal circuit voltage is greater than 4.93 V.
1. Faulty intake air temperature sensor wiring, short circuit to another voltage source.
2. Faulty intake air temperature sensor, internal failure.
Solution:
2. Check the intake air temperature sensor wiring for a short circuit to battery.
Disconnect the vehicle harness from the intake air temperature sensor.
With the key in the OFF position, use a multimeter to perform the following voltage check on the vehicle harness
(VE) side :
From To Value
(VE) side :
From To Value
X-474 pin 1 Chassis ground There should be less than 5.5 V.
A. If the specified values are measured, then leave the intake air temperature sensor disconnected and continue
to step 3.
B. If the specified values are not measured, then there is a short circuit to another voltage source in the intake
temperature sensor signal circuit in the vehicle harness (VE). Locate and repair the shorted conductor. Repair
or replace the harness as required.
3. Check the intake air temperature sensor wiring for an open circuit.
(VE) side :
From To Value
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A. If there is continuity, then leave the intake air temperature sensor disconnected. Leave connector X-462 dis-
connected and continue to step 4.
B. If there is no continuity, then there is an open circuit in the intake temperature sensor signal circuit vehicle
harness (VE) wiring. Locate and repair the broken conductor. Repair or replace the harness as required.
4. Check the intake air temperature sensor wiring for a short circuit.
With the key in the OFF position, use a multimeter to perform the following continuity check at the vehicle harness
(VE) side of the connector from :
From To Value
A. If there is continuity, then there is a short circuit to another circuit in the intake temperature sensor signal cir-
cuit in the vehicle harness (VE). Locate and repair the shorted conductor. Repair or replace the harness as
requested.
B. If there is no continuity, then leave the intake air temperature sensor disconnected and continue to step 5.
5. Replace the intake temperature sensor and retest.
has been resolved.
operation.
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3518 (DTC 2AC4) - Ambient temperature sensor voltage is lower

than expected
Context:
temperature sensor signal circuit voltage is less than 0.198 V, then this fault will occur. Once this fault occurs, the
intake air temperature value is frozen by the ECU at the last valid value for a preliminary failure or jumps to a fixed
replacement value of 29.96 °C (85.93 °F) if the failure is validated.
Cause:
The intake air temperature sensor signal circuit voltage is less than 0.198 V.
1. Faulty intake air temperature sensor wiring, short circuit to ground.

Solution:
2. Check the intake air temperature sensor vehicle harness (VE) wiring for a short circuit to ground.
Disconnect the vehicle harness (VE) from the intake air temperature sensor at connector X-474.
(VE) side :
From To Value
A. If there is continuity, then there is a short circuit to ground in the air temperature sensor signal circuit vehicle
harness (VE) wiring. Locate and repair the grounded conductor. Repair or replace the harness as required.
3. Check the intake air temperature sensor vehicle harness (VE) wiring for a short circuit to ground.
From To Value
A. If there is continuity, then there is a short circuit in the air temperature sensor signal circuit vehicle harness
4. Replace the intake temperature sensor and retest.
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Use the EST to check to see that this fault has been resolved.
has been resolved.
operation.
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3525 (DTC E18E) - Downstream NOx sensor internal failure (open

circuit error)
counter reset (10.500), if necessary.
Context:
For information regarding the functional operation of the smart Selective Catalytic Reduction (SCR) downstream NOx
sensor, refer to the engine service manual Nitrogen Oxide (NOx) sensor - Dynamic description (55.988). The SCR
downstream NOx sensor has internal monitoring for an open circuit or a short circuit and sends an error status in case
of a detected failure. This failure is the result of an open circuit error in the sensor NOx and/or Oxygen level circuit.
Cause:
The SCR downstream NOx sensor has reported, via CAN, to the ECU that an open circuit exists in the NOx and/or
Oxygen level circuit.
1. Faulty SCR downstream NOx sensor, hardware or firmware.

Solution:
2. As there is no method for field testing or re-flashing the sensor controller, replace the SCR downstream NOx sensor
and retest.
- Configure - Engine restart counter reset (10.500), if necessary, to perform the Engine Restart Counter Reset
Then check to see that this fault is resolved.
A. If this fault is resolved, then return the machine to service.
B. If this fault is not resolved, then check the ECU for the appropriate software and re-flash, if necessary.
has been resolved.
operation.
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3526 (DTC E28E) - Downstream NOx sensor internal failure (short

circuit error)
Context:
sensor, refer to the engine service manual Nitrogen Oxide (NOx) sensor - Dynamic description (55.988). The
SCR downstream NOx sensor has internal monitoring for open wire or short circuit and sends an error status in case
of a detected failure. This failure is the result of a short circuit error in the sensor NOx and/or Oxygen level circuit.
Cause:
The SCR downstream NOx sensor has reported, via CAN, to the ECU that a short circuit exists in the NOx and/or

Solution:
2. As there is no method for field testing or re-flashing the sensor controller, replace the SCR downstream NOx
sensor.
Then use the EST, refer to the engine service manual Nitrogen Oxide (NOx) sensor - Configure - Reset ECU
data (Downstream sensor) (55.988), if necessary, to perform the Replacement of Nox Downstream Sensor -
Reset ECU Data configuration.
Then perform the SCR Fault Verification Test, refer to the engine service manual Selective Catalytic Reduction
(SCR) exhaust treatment - Service instruction - SCR fault repair verification test (10.500), if necessary.
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has been resolved.
operation.
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3528 (DTC 319E) - Downstream NOx sensor values are not plausible
Context:
SCR downstream NOx sensor delivers information about its error status and the results of self diagnosis procedure,
via CAN, to the Engine Control Unit (ECU). If the SCR downstream NOx sensor sends the message Lambda or NOx
signal not plausible, this fault will occur.
Cause:
The SCR downstream NOx sensor has reported, via CAN, to the ECU that the Lambda or NOx signal is not plausible.
Solution:
1. Check for related fault.
Use the Electronic Service Tool (EST) to check for fault DTC 2DDA – SCR catalyst efficiency lower than first
NOx production threshold level.
A. If fault 19071 – SCR catalyst efficiency lower than first NOx production threshold level is present, the
SCR downstream NOx sensor is poisoned. Replace the SCR downstream NOx sensor. Then use EST, refer
to the engine service manual Nitrogen Oxide (NOx) sensor - Configure - Reset ECU data (Downstream
sensor) (55.988), if necessary, to perform the Replacement of NOx Downstream Sensor - Reset ECU Data
configuration.
B. If fault 19071 – SCR catalyst efficiency lower than first NOx production threshold level is not present,
ignore fault 3528 – Downstream NOx sensor values are not plausible.
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3529 (DTC E16E) - Downstream NOx sensor internal failure (heater

open circuit error)
Context:
of a detected failure. This failure is the result of an open circuit error in the sensor heater circuit.
Cause:
The SCR downstream NOx sensor has reported, via CAN, to the Engine Control Unit (ECU) that an open circuit exists
in the heater control circuit.

Solution:
sensor.
data (Downstream sensor) (55.988), if necessary, to perform the Replacement of the Nox Downstream Sensor
- Reset ECU Data configuration.
B. If this fault is not resolved, then heck the ECU for the appropriate software and re-flash, if necessary.
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has been resolved.
operation.
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3530 (DTC E26E) - Downstream NOx sensor internal failure (heater

short circuit error)
Context:
of a detected failure. This failure is the result of a short circuit error in the sensor heater circuit.
Cause:
The SCR downstream NOx sensor has reported, via CAN, to the Engine Control Unit (ECU) that a short circuit con-
dition exists in the heater control circuit.

Solution:
sensor.
data (Downstream sensor) (55.988), if necessary, to perform the Replacement of Nox Downstream Sensor -
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has been resolved.
operation.
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3531 (DTC A36E) - Downstream NOx sensor internal failure (heater

performance plausibility error)
Context:
The SCR downstream NOx sensor has internal monitoring and delivers information about its error status and the
results of self diagnosis procedure, via CAN, to the Engine Control Unit (ECU). One of the monitored conditions is
whether or not the SCR downstream NOx sensor reached the appropriate operating temperature within the allotted
time. Once the dew point has been reached, the sensor has 3.0 min to reach heat up. If the sensor heat up is not
completed in time, this fault will occur. For information regarding the functional operation of the smart Selective Cat-
alytic Reduction (SCR) downstream NOx sensor, refer to the engine service manual Nitrogen Oxide (NOx) sensor
- Dynamic description (55.988).
Cause:
The SCR downstream NOx sensor has reported, via CAN, to the ECU that the sensor failed to reach heater working
temperature in the allotted time.

Solution:
2. Check for other relevant faults.
Use the EST to check for the presence of fault 19050 – Downstream NOx sensor supply voltage is out of
range.
A. If fault 19050 – Downstream NOx sensor supply voltage is out of range is present, then resolve fault
19050 – Downstream NOx sensor supply voltage is out of range. Then check to see that fault 3531 –
Downstream NOx sensor internal failure (Heater Performance Plausibility Error) is also resolved.
B. If fault 19050 – Downstream NOx sensor supply voltage is out of range is not present, then continue with
step 3.
sensor.
Run the machine and use the EST capability to view parameters to verify that the sensor has reached dew point.
has been resolved.
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operation.
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3533 (DTC 9D6E) - CAN timeout error from downstream NOx sensor
Context:
The Selective Catalytic Reduction (SCR) downstream NOx sensor is required to report information at regular intervals
to the Engine Control Unit (ECU) via Controller Area Network (CAN). If this information is not communicated within the
allotted time frame, this ECU timeout fault will occur. For information regarding the functional operation of the smart
Diesel Oxidation Catalyst (DOC) upstream NOx sensor, refer to the engine service manual Nitrogen Oxide (NOx)
sensor - Dynamic description (55.988).
Cause:
The ECU has reported, via the engine sensor CAN bus, that a SCR downstream NOx sensor timeout of the SCR
downstream NOx sensor message has occurred.
1. Faulty supply voltage, out of required range.

2. Faulty CAN wiring, open or short circuit.
Solution:
2. Check for the presence of supply voltage fault.
Use EST to determine the presence of fault 19050 – Downstream NOx sensor supply voltage is out of range.
A. If fault 19050 – Downstream NOx sensor supply voltage is out of range is present, resolve the 19050 –
Downstream NOx sensor supply voltage is out of range fault. Then determine if this fault is also resolved.
B. If fault 19050 – Downstream NOx sensor supply voltage is out of range is not present, continue with step 3.
3. Determine the condition of the SCR downstream NOx sensor CAN circuit.
Disconnect the vehicle (VE) harness from the SCR downstream NOx sensor.
Use a multimeter to measure the resistance of the CAN circuit on the vehicle (VE) harness side:
From To Value
SCR downstream NOx sensor SCR downstream NOx sensor There should be 60 Ω.
A. If the measured resistance is correct, then continue with step 4.
B. If the measured resistance is not correct, then continue with step 5.

sensor.
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data (Downstream sensor) (55.988) if necessary, to perform the Replacement of Nox Downstream Sensor -
A. If this fault is resolved, use the EST, refer to the engine service manual Selective Catalytic Reduction (SCR)
exhaust treatment - Configure - Engine restart counter reset (10.500) if necessary, to perform the Engine
Restart Counter Reset / Unlock Inducement configuration. Then return the machine to service.
5. Check for other engine SCR CAN faults.
Use EST to determine if other SCR CAN faults exist.
A. If other faults exist, then locate and repair the faulted condition. Repair or replace the harness as required.
B. If no other faults exist, then the vehicle (VE) harness wiring is damaged between the network harness splice
and the SCR downstream NOx sensor connector SCR downstream NOx sensor connector pin 3 and SCR
downstream NOx sensor connector pin 4. Locate and repair the damage to the CAN circuit wiring.
has been resolved.
operation.
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3581 (DTC FD8F) - Torque limitation is active

NOTE: Since this fault is part of the inducement strategy, it may be necessary to perform the Engine Restart Counter
Reset / Unlock Inducement configuration with the Electronic Service Tool (EST) before you return the machine to
service, unless this was accomplished as part of the resolution of the fault causing this fault. Refer to the engine
service manual Selective Catalytic Reduction (SCR) exhaust treatment - Configure - Engine restart counter
reset (10.500), if necessary.
Context:
This fault is only for informational purposes and requires no action other than the resolution of the active fault causing
this fault to occur. Any one of many Selective Catalytic Reduction (SCR) not displayed faults that remains active for
an Engine Control Module (ECU) predetermined length of time will trigger this fault.
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3616 (DTC F1EF) - Torque limitation caused by turbo charger

protection
Context:
This failure path is only for information. This failure does not require any further action except to check if another failure
related to turbocharger is stored in fault memory. If there is a failure present, follow the troubleshooting procedure for
that fault. This failure confirms there was a temporary torque limitation present.
Cause:
One or more of the following failure modes may be the reason for the occurrence of this fault.
1. Air filter issue.

2. Excessive fueling.
3. Injector issue.
4. Boost pressure is too high.
5. Waste gate stuck, if equipped.
6. Turbine over speed.
7. High altitude operation.
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3623 (DTC 3CAE) - Downstream NOx sensor lambda signal

deviation - NOx sensor possible removal detected
Context:
sensor refer to the engine service manual Nitrogen Oxide (NOx) sensor - Dynamic description (55.988). The SCR
downstream NOx sensor has internal monitoring for operating conditions and reports status along with sensed data.
If the sensor lambda data value is outside the values established by the minimum/maximum curves specified in the
Engine Control Unit (ECU), dependent on the lambda value itself, this fault will occur.
Cause:
The ECU has determined that the SCR downstream NOx sensor is not measuring correct lambda values.

Solution:
1. Determine proper installation of the SCR downstream NOx sensor.
Remove and re-install, if necessary, the SCR downstream NOx sensor to assure that it is properly aligned and
securely installed.
Use EST, refer to the engine service manual Selective Catalytic Reduction (SCR) exhaust treatment - Config-
ure - Engine restart counter reset (10.500), if necessary, to perform the Engine Restart Counter Reset / Unlock
Inducement configuration.
essary.
Then check to see that the fault is resolved.
A. If the fault is resolved, return the machine to service.
B. If the fault is not resolved, continue with Step 2.

sensor.
data (Downstream sensor) (55.988) if necessary, to perform the Replacement of Nox Downstream Sensor -
essary.
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B. If the fault is not resolved, check the ECU for the appropriate software and re-flash, if necessary.
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3652 (DTC 911B) - CAN A Bus off passive failure

Context:
ECU. CAN Node A Bus is the main vehicle interface bus. The ECU provides a CAN termination resistor for the CAN
Node A Bus, internal to the ECU. If the ECU senses that CAN Node A Bus is not functioning properly, this fault will
occur.
Cause:
ECU has sensed a Bus Off state to be present at the CAN Node A.

2. Faulty CAN circuit wiring, an open circuit, or a short circuit.
Solution:
A. If other vehicle CAN faults exist, resolve the vehicle CAN faults, then check to see that 3652 – CAN A Bus off
passive failure is also resolved.
From To Value
4.
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From To Value
From To Value
From To Value
B. If the measured resistances are not correct or one or both of the conductors is grounded, Locate and restore
the termination resistance to the CAN circuit.
has been resolved.
operation.
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3680 (DTC E536) - Engine speed limitation via fuel injection cut
off is active
Context:
The Engine Control Unit (ECU) will perform an injection cut-off to limit the engine speed to a controllable range, if
needed. Implausible signals from certain parameters such as accelerator pedal signal, fuel injection parameters or
engine speed can cause an injection cut-off. If torque or injection quantity are not plausible and engine speed is
greater than 1200 RPM, this fault will occur. Other active faults may have caused this fault to occur.
Solution:
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3703 (DTC 2B36) - The minimum rail pressure value necessary to

allow fuel injection has not been reached
necessary.
Context:
The Engine Control Unit (ECU) monitors fuel rail pressure. If the ECU determines that fuel rail pressure is less than
130.0 bar (1885.0 psi) or below a limit value from an ECU calculated curve, this fault will occur. Other active faults
Cause:
The ECU has determined that fuel rail pressure is too low to continue engine operation.
1. Faulty fuel metering unit, stuck closed or internal failure.

2. Faulty high pressure pump, low efficiency.
5. Faulty fuel lines, leakage or blockage.
7. Faulty fuel injectors, internal leakage or stuck open.
9. Faulty rail pressure sensor drifted signal or leaking.
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3735 (DTC 8355) - Fuel metering unit has an over temperature error
Context:
The Engine Control Unit (ECU) monitors the fuel metering unit signal circuit for an over temperature/current condition.
If the ECU detects an over temperature/current condition in the fuel metering unit signal circuit, this fault will occur.
Cause:
The ECU has detected an over temperature/current condition in the fuel metering unit signal circuit.
1. Faulty fuel metering unit wiring, short circuit to another voltage source.
Solution:
From To Value
A. If there is between 2.6 – 3.2 Ω, then leave the fuel metering unit disconnected and continue to step 3.
retest.
3. Check the fuel metering unit low side driver wiring for a short circuit to battery.
(EN) side :
From To Value
Fuel metering unit pin 2 Chassis ground There should be no voltage.
(EN) side :
From To Value
Fuel metering unit pin 2 Chassis ground There should be no voltage.
A. If there is voltage, then there is a short circuit to battery or a short circuit switched battery in the fuel metering
unit low side driver circuit wiring. Locate and repair the shorted conductor. Repair or replace the harness as
required.
B. If there is no voltage, then leave the fuel metering unit disconnected and continue to step 4.
4. Check the fuel metering unit low side driver engine harness (EN) wiring for a short circuit.
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(EN) side :
From To Value
B. If there is continuity, there is a short circuit in the fuel metering unit low side driver engine harness (EN) wiring.
5. Check the fuel metering unit low side driver vehicle harness (VE) wiring for a short circuit.
harness (VE) side :
From To Value
A. If there is continuity, then there is a short circuit in the fuel metering unit low side driver vehicle harness (VE)
has been resolved.
operation.
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3738 (DTC E71D) - ECU internal failure - ROM error

Context:
The Engine Control Unit (ECU) performs a Read-Only Memory (ROM) check during after run. If ROM memory blocks
are detected during this check, power stages will be shut off and this fault will occur.
Solution:
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3739 (DTC E13D) - ECU internal failure - Loss of synchronization to

MM from CPU
Context:
The Engine Control Unit (ECU) performs shut off paths which deactivate all power stages relevant to injection if certain
internal ECU errors are detected. In order to test the correct functioning of the shut off procedure, every path is shortly
activated during ECU initialization to activate the fuel injection power stage. Since the ECU has activated the shut off,
no fuel injection should occur during this test. If the wrong response from the processor to the power stage supply is
detected during the shut off path test, this fault occur.
Solution:
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3740 (DTC E23D) - ECU internal failure - ECU shutdown test failure
Context:
test, each injection path is shortly activated during ECU initialization. If at least one error is detected during this test
occurs, then this fault will occur.
Solution:
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3741 (DTC E33D) - ECU internal failure - Wrong set response time
Context:
test, each injection path is shortly activated during ECU initialization. If a time-out error occurs during this test, this
fault will occur.
Solution:
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3742 (DTC E43D) - ECU internal failure - SPI errors during MoCSOP
execution
Context:
test, each injection path is shortly activated during ECU initialization. If a Serial Peripheral Interface (SPI) communi-
cation error is detected during this test, this fault will occur.
Solution:
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3743 (DTC E53D) - ECU internal failure - Undervoltage monitoring

error
Context:
initialization. Since the shut off is active, no fuel injection should occur during this test. If a voltage lower than expected
condition is detected during this test, this fault will occur.
Solution:
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3745 (DTC E63D) - ECU internal failure - WDA is not working

correctly
Context:
initialization. Since the shut off is active, no fuel injection should occur during this test. If an implausible response in
the power stage feedback is detected during this test, this fault will occur.
Solution:
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3746 (DTC E73D) - ECU internal failure - Alarm task period error
Context:
initialization. Since the shut off is active, no fuel injection should occur during this test. If a time-out error during the
shut off path test is detected and the alarm task cannot be set or reset, this fault will occur.
Solution:
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3747 (DTC E83D) - ECU internal failure - Positive test failed

Context:
The Engine Control Unit (ECU) performs shut off paths which deactivate all power stages relevant to injection if certain
internal ECU errors are detected. In order to test the correct functioning of the shut off procedure, every path is shortly
activated during ECU initialization to activate the fuel injection power stage. Since the ECU has activated the shut off,
no fuel injection should occur during this test. If an error is detected during this test, this fault will occur.
Solution:
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3749 (DTC E5B1) - ECU internal failure - Accelerator pedal position

sensor
Context:
The Engine Control Unit (ECU) performs a diagnostic evaluation of the accelerator pedal position. If there is an error
detected using this process, this fault will occur.
Solution:
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3750 (DTC EC36) - ECU internal failure - Fuel injection energizing

time not plausible
Context:
The Engine Control Unit (ECU) monitors injector energizing time. If the ECU determines that the energizing time for
either the pilot injection, main injection or post injection is implausible, this fault will occur.
Solution:
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3751 (DTC ED36) - ECU internal failure - Fuel injection energizing

phase is not plausible
Context:
The Engine Control Unit (ECU) monitors for injector energizing start time. If the ECU determines that the energizing
start time for either the pilot injection, main injection or post injection is implausible, this fault will occur.
Solution:
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3752 (DTC EE36) - Fuel injection correction has exceeded a

minimum limit
Context:
The Engine Control Unit (ECU) checks the plausibility of the Zero Fuel Quantity Calibration (ZFC) energizing time.
The ZFC is used to correct pilot injection quantity. If the ECU determines the energizing time of the ZFC is implausible,
Solution:
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3753 (DTC E5DD) - ECU internal failure - Injection quality correction

Context:
Engine performance is assisted by the addition of pilot injections, main injections and three post injections. The Engine
Control Unit (ECU) monitors the efficiency of these injections and provides injection quantity corrections, if necessary.
If the ECU determines that excessive corrections to injection quantity are being made, there is a calibration error and
Solution:
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3754 (DTC E6DD) - ECU internal failure - Rail pressure plausibility

Context:
The Engine Control Unit (ECU) monitors fuel rail pressure for proper engine performance as well as safety concerns.
Fuel rail pressure is monitored by the ECU to check if the ECU is functioning properly. If the ECU detects an implau-
sible rail pressure during monitoring, the ECU is not functioning correctly and this fault will occur.
Solution:
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3755 (DTC E7DD) - ECU internal failure - Torque request comparison

Context:
The Engine Control Unit (ECU) determines engine torque based on the requests of many vehicle functions. The total
requested engine torque is compared to the maximal engine torque allowed. If the total requested torque is greater
than the maximal allowed torque, the ECU has a calibration error and this fault will occur.
Solution:
A. If the fault has been resolved, return the machine to service.
B. If the fault has not been resolved, escalate an ASIST concern.
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3756 (DTC E1DD) - ECU internal failure - Post injection quality

Context:
Engine performance is assisted by the addition of pilot injections, main injections and three post injections. The
Engine Control Unit (ECU) monitors the start angle and efficiency of post Injection 2. If the ECU determines that the
post Injection 2 is not within a plausible value, a calibration error has occurred and this fault will occur.
Solution:
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3757 (DTC E2DD) - ECU internal failure - Post injection shut off
failure
Context:
Engine performance is assisted by the addition of pilot injections, main injections and three post injections. The Engine
Control Unit (ECU) monitors the post Injection 2 shut off quantity in normal mode. If the ECU detects that the post
Injection 2 shut off quantity has exceeded the 655.34 mg limit in normal mode, this fault will occur.
Solution:
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3759 (DTC E8DD) - ECU internal failure - Torque request due to fuel
pressure exceeds maximum torque limit
Context:
The Engine Control Unit (ECU) determines engine torque based on the requests of many vehicle functions. The
total requested engine torque is compared to the maximal engine torque allowed. Fuel pressure is dependent on
requested torque. Therefore, torque is calculated separately, called “Lead torque.” If this fault has occurred, the ECU
has detected that the requested Lead torque value has exceeded the maximum torque allowed.
Solution:
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3760 (DTC E9DD) - ECU internal failure - Torque request due to air
control exceeds maximum torque limit
Context:
requested engine torque is compared to the maximal engine torque allowed. Air control is dependent on requested
torque. Therefore, air control is calculated separately, called “Lead torque.” If this fault has occurred, the ECU has
detected that the requested Lead torque value has exceeded the maximum torque allowed.
Solution:
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3761 (DTC EADD) - ECU internal failure - Torque request exceeds

maximum torque limit
Context:
requested engine torque is compared to the maximal engine torque allowed. If the total requested torque is greater
than the maximal allowed torque, the ECU has a calibration error and this fault will occur.
Solution:
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3764 (DTC F561) - ECU after run power interruption

Context:
The Engine Control Unit controls the main relay. The main relay is powered on by the ECU to achieve after-run. The
main relay is powered off once after-run is completed. If the ECU determines that the main relay has shut off before
commanded, then this fault will occur.
Cause:
The ECU has determined that the main relay has shut off before commanded to shut off.
1. Faulty main relay, wiring.

2. Faulty main relay, internal failure.
Solution:
active.Continue with step 9.
2. Check the main relay coil for an internal failure.
Remove the main relay.
Use a multimeter to measure the resistance on the main relay pins :
From To Value
Main relay pin 85 Main relay pin 86 There should be approximately 70 –
130 Ω.
A. If there is approximately 70 – 130 Ω, leave the main relay disconnected and continue to step 3.
B. If there is not approximately 70 – 130 Ω, the main relay has failed. Replace the main relay and retest.
3. Check the main relay vehicle harness (VE) wiring for a short circuit to another voltage source.
From To Value
Main relay connector pin 85 Chassis ground There should be no voltage.
With the key in the ON position, use a multimeter to check for a short circuit to another voltage source on the
From To Value
Main relay connector pin 85 Chassis ground There should be no voltage.
A. If there is voltage, then there is a short circuit to another voltage source in the main relay wiring in the vehicle
B. If there is no voltage, then leave the main relay disconnected and continue to step 4.
4. Check the main relay vehicle harness (VE) wiring for a short circuit to ground.
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side :
From To Value
Main relay connector pin 85 Chassis ground There should be no continuity.
A. If there is continuity, then there is a short circuit to ground in the main relay wiring in the vehicle harness (VE).
Locate and repair the broken or damaged conductor. Repair or replace the harness as required.
B. If there is no continuity, then leave the main relay disconnected and continue to step 5.
5. Check the main relay vehicle harness (VE) wiring for an open circuit.
From To Value
Main relay connector pin 85 X-461 pin 28 There should be continuity.
A. If there is no continuity, then there is an open circuit in the main relay wiring in the vehicle harness (VE). Locate
and repair the broken or damaged conductor. Repair or replace the harness as required.
B. If there is continuity, then leave the main relay disconnected. Leave connector X-461 disconnected and con-
tinue to step 6.
6. Check the main relay wiring for a short circuit.
From To Value
Main relay connector pin 85 Main relay connector pin 86 There should be no continuity.
X-461 pin 28 All pins in connectorX-461 There should be no continuity.
A. If there is continuity, then there is a short circuit in the main relay vehicle harness (VE) wiring. Locate and repair
the shorted conductor. Repair or replace the harness as required.
B. If there is no continuity, then leave the main relay disconnected. Leave connector X-461 disconnected and
continue to step 7.
7. Check the main relay load-side wiring.
With the key in the ON position, use a multimeter to perform the following voltage checks on the vehicle harness
(VE) side :
From To Value
Main relay connector pin 86 Chassis ground There should be approximately
12.0 V.
Main relay connector pin 30 Chassis ground There should be approximately
12.0 V.
A. If there is not approximately 12.0 V, then there is a failure in the main relay load-side wiring. Locate and repair
B. If there is approximately 12.0 V, then leave the main relay disconnected. Leave connector X-461 disconnected
8. Check the main relay load-side wiring.
With the key in the OFF position, use a multimeter to perform the following continuity checks on the vehicle harness
(VE) side :
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From To Value
A. If there is no continuity, then there is an open circuit in the main relay load-side wiring or fuse. Locate and
repair the shorted conductor or open fuse. Repair or replace the harness as required.
has been resolved.
operation.
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3767 (DTC E81D) - ECU internal failure - 'WDA active' reported due
to errors in query/response communication
Context:
The Engine Control Unit (ECU) monitors the communication, internal to the ECU, between the power stages and the
power stage voltage supplier. If an unexpected communication (a wire is active when it should not be) is detected
during this monitoring, this fault will occur.
Solution:
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3768 (DTC E91D) - ECU internal failure - 'ABE active' reported due
to undervoltage detection
Context:
power stage voltage supplier. This fault occurs if the ECU detects a low voltage condition while the battery voltage is
greater than 8.00 V and the shut off path test is not active.
Solution:
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3769 (DTC EA1D) - ECU internal failure - 'ABE active' report due
to overvoltage detection
Context:
The Engine Control Unit (ECU) monitors the communication, internal to the ECU , between the power stages and the
power stage voltage supplier. If the ECU detects a high voltage condition while the shut off path test is not active, this
fault will occur.
Solution:
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3770 (DTC EB1D) - ECU internal failure - 'WDA/ABE active' reported

Context:
power stage voltage supplier. Monitoring is performed continuously as long as the battery voltage is greater than
8.00 V and the shut off path test is not active. If the WDA/ABE communication wire becomes active, then this fault
will occur.
Solution:
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3773 (DTC 2838) - Turbocharger boost pressure is lower than

expected
Context:
The Engine Control Unit (ECU) monitors boost pressure using the intake manifold pressure sensor. If the ECU de-
termines that boost pressure is lower than expected, this fault will occur. For more information regarding the trou-
bleshooting of an under-boost condition, refer to the engine service manual Turbocharger Boost - Troubleshooting
(10.250).
Cause:
The ECU has determined that boost pressure is lower than expected.
1. Faulty intake plumbing, boost leakage.

2. Faulty air filter, clogged.
3. Faulty wastegate pressure modulator valve, if applicable.
4. Faulty boost pressure accumulator, if applicable.
5. Faulty wastegate, sticking.
6. Faulty turbocharger, low efficiency.
7. Faulty intake manifold pressure sensor, drifted signal.
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3794 (DTC 3B64) - Plausibility check for air pressure at the

upstream of intake valve sensor
Context:
The Engine Control Unit (ECU) monitors boost pressure. Boost pressure is compared to environmental pressure by
the ECU. If the ECU determines that the difference between measured boost pressure and environmental pressure
is greater than 0.1 bar (1.5 psi), then this fault will occur.
Cause:
The ECU has determined that boost pressure is greater than environmental pressure by 0.1 bar (1.5 psi).
1. Faulty intake manifold pressure sensor, internal failure.

Solution:
2. Use the Electronic Service Tool (EST) to check for related faults :
A. If any faults are active, then diagnose them first and then return to this fault.
B. If none of the listed faults are active, then continue to step 3.

3. Replace the intake manifold pressure sensor and retest.
Use the EST to verify the status of this fault.
has been resolved.
operation.
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3795 (DTC 3C64) - Plausibility check for air pressure at the

upstream of intake valve sensor
Context:
The Engine Control Unit (ECU) monitors boost pressure. Boost pressure is compared to environmental pressure by
the ECU. If the ECU determines that the boost pressure is less than environmental pressure by 0.1 bar (1.5 psi), then
Cause:
The ECU has determined that boost pressure is less than environmental pressure by 0.1 bar (1.5 psi).
1. Faulty intake manifold pressure sensor, internal failure.

Solution:
2. Use the Electronic Service Tool (EST) to check for related faults :
A. If any faults are active, then diagnose them first and then return to this fault.

3. Replace the intake manifold pressure sensor.
B. If the fault is still active, check the ECU for the appropriate software and re-flash, if necessary.
has been resolved.
operation.
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3799 (DTC F345) - Fuel pressure relief valve is forced to open,

perform pressure shock
Context:
This fault is intended for information purposes only. Other active faults may have caused this fault to occur. The
Engine Control Unit (ECU), if necessary, will set the engine into limp home mode. This process is achieved in two
steps by the ECU, a pressure increase and a pressure shock. The ECU will execute step two by a fuel pressure
shock. This is achieved by setting injection quantity to zero. If this fault is active, the ECU has performed step two for
achieving limp home mode, a fuel pressure shock.
Cause:
The ECU has performed a fuel pressure shock to achieve limp home mode.
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3838 (DTC 2999) - Upstream oxidation catalyst temperature sensor

Context:
The Engine Control Unit (ECU) monitors the Diesel Oxidation Catalyst (DOC) upstream temperature sensor. If the
ECU detects a voltage less than 459.40 mV in the DOC upstream temperature sensor signal circuit, then this fault
will occur.
Cause:
The ECU has detected a voltage less than 459.40 mV in the DOC upstream temperature sensor signal circuit. For
more information regarding the technical specifications of the DOC upstream temperature sensor, refer to the engine
service manual Exhaust Gas Recirculation (EGR) temperature sensors Diesel Oxidation Catalyst (DOC) inlet
temperature sensor - Technical Data (55.989).
1. Faulty DOC upstream temperature sensor wiring, short circuit to ground.

2. Faulty DOC upstream temperature sensor, internal failure.
Solution:
2. Check the DOC upstream temperature sensor for an internal failure.
Disconnect the vehicle harness (VE) from the DOC upstream temperature sensor.
Use a multimeter to measure the resistance on the DOC upstream temperature sensor :
From To Value
DOC upstream temperature sensor DOC upstream temperature sensor There should be between 170.2 –
pin 1 pin 2 849.7 Ω.
A. If there is between 170.2 – 849.7 Ω, leave connector X-9106 disconnected and continue to step 3.
B. If there is not between 170.2 – 849.7 Ω, the DOC upstream temperature sensor has failed. Replace the DOC
upstream temperature sensor and retest.
3. Check the DOC upstream temperature sensor vehicle harness (VE) wiring for a short circuit.
(VE) side :
From To Value
DOC upstream temperature sensor DOC upstream temperature sensor There should be no continuity.
pin 1 pin 2
DOC upstream temperature sensor Chassis ground There should be no continuity.
pin 1
A. If there is continuity, then there is a short circuit in the DOC upstream temperature sensor vehicle harness (VE)
B. If there is no continuity, then leave the DOC upstream temperature sensor disconnected and continue to step
4.
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(VE) side :
From To Value
A. If there is continuity, there is a short circuit in the DOC upstream temperature sensor vehicle harness (VE)
has been resolved.
operation.
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3906 (DTC 4736) - Number of injections is limited by quantity

balance of high pressure pump
Context:
The ECU monitors the requested number of fuel injections and the current capability of the fuel injection system to
fulfill that request. If the ECU determines that the number of requested fuel injections is greater than the current
capability of the fuel injection system, this fault will occur. For more information regarding the troubleshooting of the
fuel system, refer to the engine service manual Fuel injection system - Troubleshooting (10.218).
Cause:
The ECU has determined that the number of requested fuel injections is greater than the current capability of the fuel
injection system to fulfill that request.
1. Faulty fuel back-flow, excessive.

2. Faulty high pressure pump, worn or ageing.
3. Faulty fuel metering unit, unable to open.
4. Faulty fuel temperature, too high.
5. Faulty fuel injectors, worn or internal leakage.
9. Faulty rail pressure sensor, drifted signal or leakage.
10. Faulty fuel injection system, leaking or blocked lines.
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3910 (DTC 4155) - Fuel metering unit intermittent electrical

connection failure
Context:
The Engine Control Unit (ECU) monitors the fuel metering unit signal circuit. If the ECU detects an intermittent con-
nection in the fuel metering unit signal circuit, this fault will occur.
Cause:
The ECU has detected a intermittent connection in the fuel metering unit signal circuit.
1. Faulty fuel metering unit wiring, open circuit or intermittent open circuit.
Solution:
From To Value
A. If there is between 2.6 – 3.2 Ω, then leave the fuel metering unit disconnected and continue to step 3.
retest.
3. Check the fuel metering unit engine harness (EN) wiring for an open circuit.
With the key in the OFF position, use a multimeter to check for an open circuit on the engine harness (EN) side :
From To Value
A. If there is continuity, then leave connector X-470 disconnected and continue to step 4.
B. If there is no continuity, there is an open circuit condition in the fuel metering unit Y-9000 engine harness (EN)
wiring. Locate and repair the broken conductor.
4. Check the fuel metering unit vehicle harness (VE) wiring for an open circuit.
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(VE) side :
From To Value
A. If there is no continuity, then there is an open circuit in the fuel metering unit vehicle harness (VE) wiring. Locate
has been resolved.
operation.
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3915 (DTC 3645) - Averaged rail pressure is outside the expected

tolerance range
necessary.
Context:
The Engine Control Unit (ECU) monitors fuel rail pressure using the rail pressure sensor. After a fuel pressure evalu-
ation, if the ECU suspects that the Pressure Relief Valve (PRV) should be open but has not opened, this fault occur.
If this fault is active, the ECU has performed step one for achieving limp home mode, a fuel pressure increase. Other
active faults may have caused this fault to occur. For more information regarding fuel system troubleshooting, refer
to the engine service manual Fuel injection system - Troubleshooting (10.218).
Cause:
The ECU has determined that the PRV should be open but is not open.
1. Faulty PRV, unable to open or partially open.

2. Faulty PRV fuel back-flow, clogged or damaged.
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3916 (DTC 1745) - Fuel pressure relief valve has reached maximum
allowed open time
Context:
The Engine Control Unit (ECU) monitors the fuel Pressure Relief Valve (PRV). If the ECU determines that the PRV
has been open for too long, then this fault will occur. The PRV opening duration is monitored by the ECU and stored in
the EEPROM during after run. This fault is for informational purposes only. If this fault is active, then other fuel system
faults may be active that caused this fault to occur. For more information regarding fuel system troubleshooting, refer
to the engine service manual Fuel injection system - Troubleshooting (10.218).
Cause:
The ECU has determined that the PRV has reached its maximum allowed open time.
1. Faulty PRV, stuck open or worn.

4. Faulty rail pressure sensor, internal failure.
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3959 (DTC 17A4) - Intake throttle valve position is higher than

expected
Context:
The Engine Control Unit (ECU) monitors the throttle valve actuator position sensor signal circuit. If the ECU detects
a voltage greater than 4.75 V in the throttle valve actuator position sensor signal circuit, this fault will occur.
Cause:
The ECU has detected a voltage greater than 4.75 V in the throttle valve actuator Z-9001 position sensor signal circuit.
1. Faulty throttle valve actuator wiring, short circuit to another voltage source.
2. Faulty throttle valve actuator, internal failure.
Solution:
2. Check the throttle valve actuator position sensor wiring for a short circuit to battery condition.
Disconnect the engine harness (EN) from the throttle valve actuator.
(EN) side :
From To Value
Throttle valve actuator position Chassis ground There should be no voltage.
sensor pin 5
A. If there is voltage, then there is a short circuit to battery in the throttle valve actuator position sensor signal
circuit. Locate and repair the shorted conductor. Repair or replace the harness as required.
B. If there is no voltage, then leave the throttle valve actuator position sensor disconnected. Leave connectors
X-470 and X-462 disconnected. Continue to step 3.
3. Check the throttle valve actuator position sensor wiring for an open circuit.
With the key in the OFF position, use a multimeter to perform the following continuity check on the harness side :
From To Value
Throttle valve actuator position X-470 pin 42 There should be continuity.
sensor connector pin 5
NOTE: Wiggle the harness during the reveal an intermittent condition.
A. If there is no continuity, then there is an open circuit in the throttle valve actuator position sensor signal circuit.
B. If there is continuity, then continue to step 4.
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4. Check the throttle valve actuator position sensor engine harness (EN) wiring for a short circuit.
(EN) side :
From To Value
Throttle valve actuator position Throttle valve actuator position There should be no continuity.
sensor connector pin 5 sensor connector pin 6
A. If there is continuity, then there is a short circuit in the throttle valve actuator engine harness (EN) position
sensor signal circuit. Locate and repair the shorted conductor. Repair or replace the harness as required.

5. Check the throttle valve actuator position sensor vehicle harness (VE) wiring for a short circuit.
(VE) side :
From To Value
A. If there is continuity, then there is a short circuit in the throttle valve actuator position sensor signal circuit in the
vehicle harness (VE).Locate and repair the shorted conductor. Repair or replace the harness as required.

6. Replace the throttle valve actuator and retest. .
B. If the fault is still active, then check the ECU for the appropriate service manual and re-flash, if necessary.
has been resolved.
operation.
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3960 (DTC 28A4) - Intake throttle valve position is lower than

expected
Context:
The Engine Control Unit (ECU) monitors the throttle valve actuator position sensor signal circuit. If the ECU detects
a voltage less than 0.25 V in the throttle valve actuator position sensor signal circuit, then this fault will occur.
Cause:
The ECU has detected a voltage less than 0.25 V in the throttle valve actuator position sensor signal circuit.
1. Faulty throttle valve actuator wiring, short circuit to ground.

Solution:
2. Check the throttle valve actuator position sensor engine harness (EN) wiring for a short circuit to ground.
(EN) side :
From To Value
Throttle valve actuator position Chassis ground There should be no continuity.
A. If there is continuity, then there is a short circuit to ground in the throttle valve actuator position sensor signal
circuit in the engine harness (EN). Locate and repair the shorted conductor. Repair or replace the harness as
required.
B. If there is no continuity, then leave the throttle valve actuator position sensor disconnected. Leave connector
3. Check the throttle valve actuator position sensor vehicle harness (VE) wiring for a short circuit to ground.
(VE) side :
From To Value
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A. If there is continuity, then there is a short circuit to ground in the throttle valve actuator position sensor signal
circuit in the vehicle harness (VE). Locate and repair the shorted conductor. Repair or replace the harness as
required.
B. If there is no continuity, then leave the throttle valve actuator position sensor disconnected and continue to step
4.
4. Replace the throttle valve actuator and retest.
has been resolved.
operation.
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3961 (DTC ED2D) - CAN communication failure - External

torque/speed checksum and counter
Context:
ECU. The ECU monitors the throttle speed control function via CAN. If an error is detected during this monitoring, this
fault will occur.
Cause:
ECU has sensed an error during throttle speed control monitoring.

Solution:
From To Value
4.
the ECU. repair or replace the harness as required.
With the key switch in the OFF position, use a multimeter to check for continuity on the vehicle (VE) harness side:
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From To Value
From To Value
From To Value
A. If the measured resistances are correct and neither conductor is grounded, check the ECU A-9000 for the
appropriate software and re-flash, if necessary.
B. If the measured resistances are not correct or one or both of the conductors is grounded, refer to the service
manual and electrical schematics to locate and restore the termination resistance to the CAN circuit.
has been resolved.
operation.
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3985 (DTC 1758) - Exhaust gas pressure sensor voltage is higher

than expected
Context:
The Engine Control Unit (ECU) monitors the exhaust gas absolute pressure sensor. If the ECU detects a voltage
greater than 4.74 V in the exhaust gas absolute pressure sensor signal circuit, then this fault will occur. The sensor
value will be frozen at the last valid value for a preliminary failure or jump to a fixed replacement value of 0.500 bar
(7.250 psi) if the failure is validated.
Cause:
The ECU has detected a voltage greater than 4.74 V in the exhaust gas absolute pressure sensor signal circuit.
1. Faulty exhaust gas absolute pressure sensor, wiring to internal failure.

Solution:
2. Check the exhaust gas absolute pressure sensor engine harness (EN) wiring.
Disconnect the exhaust gas absolute pressure sensor.
With the key in the ON position, use a multimeter to perform the following voltage check at the engine harness
(EN) side of the connector from :
From To Value
Gas absolute pressure sensor Chassis ground There should be no voltage.
connector pin 3
A. If there is voltage, then there is a short circuit in the exhaust gas absolute pressure sensor signal circuit engine
harness (EN) wiring. Locate and repair the shorted conductor. Repair or replace the harness as required.
B. If there is no voltage, then leave the gas absolute pressure sensor disconnect and continue to step 3.
Disconnect the engine interface connector X-470.
With the key in the OFF position, use a multimeter to perform the following continuity check at the engine harness
From To Value
A. If there is continuity, then there is a short circuit in the exhaust gas absolute pressure sensor signal circuit en-
gine harness (EN) wiring.Locate and repair the shorted conductor. Repair or replace the harness as required.
B. If there is no continuity, then leave the gas absolute pressure sensor disconnect and continue to step 4.
4. Check the exhaust gas absolute pressure sensor vehicle harness (VE) wiring.
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From To Value
A. If there is continuity, then there is a short circuit in the exhaust gas absolute pressure sensor signal circuit ve-
hicle harness (VE) wiring.Locate and repair the shorted conductor. Repair or replace the harness as required.
5. Replace the exhaust gas absolute pressure sensor and retest.
has been resolved.
operation.
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3986 (DTC 2858) - Exhaust gas pressure sensor voltage is lower

than expected
Context:
The Engine Control Unit (ECU) monitors the exhaust gas absolute pressure sensor . If the ECU detects a voltage
less than 427.00 mV in the exhaust gas absolute pressure sensor signal circuit, then this fault will occur. The sensor
value will be frozen at the last valid value for a preliminary failure or jump to a fixed replacement value of 0.500 bar
(7.250 psi) if the failure is validated.
Cause:
The ECU has detected a voltage less than 427.00 mV in the exhaust gas absolute pressure sensor signal circuit.
1. Faulty exhaust gas absolute pressure sensor, wiring to internal failure.

Solution:
Disconnect the exhaust gas absolute pressure sensor from the engine harness.
From To Value
Gas absolute pressure sensor Gas absolute pressure sensor There should be no continuity.
gine harness (EN) wiring. Locate and repair the shorted conductor. Repair or replace the harness as required.
Disconnect the engine interface connector X-470.
From To Value
gine harness (EN) wiring. Locate and repair the shorted conductor. Repair or replace the harness as required.
4. Check the exhaust gas absolute pressure sensor vehicle harness (VE) wiring.
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From To Value
A. If there is continuity, then there is a short circuit in the exhaust gas absolute pressure sensor signal circuit vehi-
cle harness (VE) wiring. Locate and repair the shorted conductor. Repair or replace the harness as required.
5. Replace the exhaust gas absolute pressure sensor and retest.
has been resolved.
operation.
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3998 - Unknown error

Context:
The ECU has encountered an unknown error.
Cause:
1. CAN communication interrupted during normal operation.

4. Wiring or circuits shorted.
Solution:
A. The fault is not recorded again. OK for return to service.
B. Fault code 3998 – Unknown error is recorded again. Go to step 2.

2. Measure the ECU unswitched input voltage.
Disconnect the Engine Control Unit (ECU) connector X-461 from engine controller.
Inspect the pins on connector X-461.
Inspect the pins on the engine controller.
Fabricate a jumper wire that will connect between X-461 pin 28 and chassis ground.
Connect the jumper wire between X-461 pin 28 and chassis ground. This will supply the ground to the main power
relay.
Measure the voltage between connector X-461 pin 1 and chassis ground. The voltage should be between 11 V
and 14.5 V. Wiggle the harness during measurement to reveal an intermittent condition.
Remove the jumper wire between X-461 pin 28 and chassis ground.
A. The voltage is less than 11 V. There is a problem in the wiring to the ECU. Check the fuses and the wiring to
the ECU. Repair as required. Return to step 1 to confirm the elimination of the fault.
B. The voltage is between 11 V and 14.5 V. Go to step 3.

3. Measure the resistance through the ground wires.
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Measure the resistance between connector X-461 pin 2 and chassis ground. The resistance should be less than
A. The resistance is greater than 10 Ω. There is a problem in the wiring to the ECU. Repair or replace the harness
B. The voltage is less than 10 Ω. Go to step 4.

4. Use the "EASY" program in the EST tool to bring up the fault.
The fault number will be unique for the engine controller.
Use the fault description to analyze the error, contact Technical Services Group for assistance.
If no text or unique engine controller fault is found, but the fault still appears on the AIC, contact Technical Services
Group for assistance.
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3999 - Unknown error

Context:
Cause:
1. CAN communication interrupted during normal operation.

4. Wiring or circuits shorted.
Solution:
A. The fault is not recorded again. OK for return to service.
B. Fault code 3999 – Unknown error is recorded again. Go to step 2.

2. Measure the ECU unswitched input voltage.
Disconnect the Engine Control Unit (ECU) connector X-461 from engine controller.
Inspect the pins on connector X-461.
Inspect the pins on the engine controller.
Fabricate a jumper wire that will connect between X-461 pin 28 and chassis ground.
Connect the jumper wire between X-461 pin 28 and chassis ground. This will supply the ground to the main power
relay.
Remove the jumper wire between X-461 pin 28 and chassis ground.
A. The voltage is less than 11 V. There is a problem in the wiring to the ECU. Check the fuses and the wiring to
the ECU. Repair as required. Return to step 1 to confirm the elimination of the fault.
B. The voltage is between 11 V and 14.5 V. Go to step 3.

3. Measure the resistance through the ground wires.
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A. The resistance is greater than 10 Ω. There is a problem in the wiring to the ECU. Repair or replace the harness
B. The voltage is less than 10 Ω. Go to step 4.

4. Use the "EASY" program in the EST tool to bring up the fault.
The fault number will be unique for the engine controller.
Use the fault description to analyze the error, contact Technical Services Group for assistance.
If no text or unique engine controller fault is found, but the fault still appears on the AIC, contact Technical Services
Group for assistance.
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4029 - Shifter Lever improperly connected, no power to pin 16, pin

18, or pin 46 for more than 3 seconds
Context:
The shift lever is improperly connected. There is no voltage on pin 16, pin 18, or pin 46 for a period greater than 3 s.
Cause:
The Trax control module is powered ON, but it is not receiving a signal on X-300 pin 16, pin 18, or pin 46. If the Trax
control module does not receive a signal on either of these pins for a period greater than 3 s, the Trax control module
will log the fault code and then shift the transmission into neutral.
1. Faulty wiring or connectors to the FNR shift lever.

2. Faulty wiring or connectors from the FNR shift lever to the Trax control module.
3. A faulty FNR shift lever.
4. A faulty Trax control module.
Solution:

Inspect the Trax control module connector X-300 and the FNR shift lever connections. All connections should be
secure and free of corrosion, abrasion, and damage.
Inspect the harness from the Trax control module to the FNR shift lever. Verify that the harness is free of damage,
3. Measure the voltage at the FNR shift lever.
Use backprobes or a breakout harness (as shown below) to measure the voltage at the FNR switch.
BD08E055-01 1
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RCPH11TLB027GAL 2
1 FNR (Forward-Neutral-Reverse) switch 3 Engine harness

2 Dealer provided breakout harness
Measure the voltage between FNR connector pin 8 and chassis ground. The voltage should be approximately
12 V.
A. The voltage is between 11 V and 14.8 V. Go to step 4.
B. The voltage is less than 11 V. There is a problem with the voltage supply to the FNR switch. Verify that splices
SP-062 and SP-067 are OK. Verify that the connections at connector X-040/150 and connector X-012 are
secure and free of damage. Verify that fuse F-009 is not blown. Repair or replace as required. Return to step
4. Measure the voltage of the switch output.
Place the FNR switch in the neutral position.
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Measure the voltage between pin 6 and chassis ground. The voltage should be approximately 12 V.
Place the FNR switch in the forward position.
Place the FNR switch in the reverse position.
A. For all voltage measurements, the voltage is between 11 V and 14.8 V. Go to step 5.
B. One or more voltage reading is less than 11 V. There is a problem in the FNR shift lever. Temporarily replace
the FNR shift lever and retest. Return to step 1 to confirm elimination of fault.
5. Measure the voltage at the Trax Control connector.
Measure the voltage between X-300 pin 16 and chassis ground (X-300 pin 29). The voltage should be approxi-
mately 12 V.
mately 12 V.
mately 12 V.
A. For all voltage measurements, the voltage is between 11 V and 14.8 V. Temporarily replace the Trax control
module and retest. Return to step 1 to confirm elimination of the fault.
B. One or more voltage reading is less than 11 V. There is a problem in the harness between the FNR shift lever
and the Trax control module. Repair or replace the harness as required. Return to step 1 to confirm elimination
of fault.
Wiring harnesses - Electrical schematic sheet 06 Powershift transmission inputs (55.100.DP-C.20.E.06)
Wiring harnesses - Electrical schematic sheet 23 Trax SPS - PS controller (55.100.DP-C.20.E.23)
Wiring harnesses - Electrical schematic sheet 22 Powershift transmission harness (55.100.DP-C.20.E.22)
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4030 - Shifter Lever malfunction: transmission in neutral receives

forward and neutral together
Context:
There is a malfunction in the shift lever. The transmission is in the neutral position, but receives a forward signal and
a neutral signal together. This fault has occurred for a period greater than 5 s.
Cause:
There is a malfunction in the shift lever. The transmission is in neutral position but receives a forward signal and a
neutral signal together. This fault has occurred for a period greater than 5 s. The Trax control module will log the fault
code and keep the transmission in the neutral position while the fault is active.
Solution:

BD08E055-01 1
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Use a wire removal tool to remove the wire from pin 6 and from pin 7 in the FNR connector.
RCPH11TLB030GAL 2
1 FNR (Forward-Neutral-Reverse) switch 4 Remove wires from pin 6 and pin 7.

2 Dealer provided breakout harness 5 Digital volt meter
3 Engine harness 6 Chassis ground
Measure the voltage between pin 6 and chassis ground. The voltage should be less than 0.5 V.
A. The voltage on pin 6 is less than 0.5 V and the voltage on pin 7 is between 11 V and 14.8 V. Go to step 4.
B. The voltage on pin 6 is between 11 V and 14.8 V and the voltage on pin 7 is between 11 V and 14.8 V. Tem-
porarily replace the FNR shift lever and retest. Return to step 1 to confirm elimination of fault.
4. Measure the resistance through the harness.
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Disconnect connector X-300 from the Trax control module.
Measure the resistance between X-300 pin 16 and X-300 pin 18. The resistance should be greater than 20,000 Ω.
B. The resistance is less than 20,000 Ω. There is a short circuit between connector X-300 pin 16 and connector
X-300 pin 18. Repair or replace the harness as required. Return to step 1 to confirm elimination of fault.
5. Measure the voltage at the Trax control module connector.
Remove the breakout harness between the harness and the FNR switch.
Reinstall pin 6 and pin 7 into the FNR connector.
Reconnect the FNR harness connector to the FRN switch.
Measure the voltage between X-300 pin 18 and chassis ground. The voltage should be less than 0.5 V. Wiggle
Measure the voltage between X-300 pin 16 and chassis ground. The voltage should be approximately 12 V. Wiggle
A. The voltage on pin 18 is less than 0.5 V and the voltage on pin 16 is between 11 V and 14.8 V. Temporarily
replace the Trax control module and retest. Return to step 1 to confirm elimination of the fault.
B. The voltage on pin 18 is between 11 V and 14.8 V and the voltage on pin 16 is between 11 V and 14.8 V. There
is a short circuit between connector X-300 pin 18 and connector X-300 pin 16. Repair or replace the harness
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4031 - Shifter Lever malfunction: transmission in neutral receives

reverse and neutral together
Context:
There is a malfunction in the shift lever. The transmission is in the neutral position, but receives a reverse signal and
Cause:
There is a malfunction in the shift lever. The transmission is in the neutral position, but receives a reverse signal and
a neutral signal together. This fault has occurred for a period greater than 5 s. The Trax control module will log the
fault code and keep the transmission in the neutral position while the fault is active.
Solution:

BD08E055-01 1
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RCPH11TLB030GAL 2

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Measure the resistance between connector X-300 pin 16 and connector X-300 pin 46. The resistance should be
greater than 20,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition.
Remove the breakout harness that is between the harness and the FNR switch.
Reconnect the FNR harness connector to the FRN switch.
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4032 - Shifter Lever malfunction: transmission in forward receives

Context:
There is a malfunction in the shift lever. The transmission is in the forward position and receives a forward signal and
a reverse signal together. This fault has occurred for a period greater than 5 s.
Cause:
a reverse signal together. This fault has occurred for a period greater than 5 s. The Trax control module will log the
Solution:

3. Measure the voltage at the FNR Shift Lever.
BD08E055-01 1
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RCPH11TLB030GAL 2

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Reinstall pin 5 and pin 7 in the FNR connector.
Reconnect the FNR harness connector to the FNR switch.
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4033 - Shifter Lever malfunction: transmission in reverse receives

Context:
There is a malfunction in the shift lever. The transmission is in the reverse position, but receives a forward signal and
a reverse signal together. This fault has occurred for a period greater than 5 s.
Cause:
There is a malfunction in the shift lever. The transmission is in the reverse position, but receives a forward signal and
a reverse signal together. This fault has occurred for a period greater than 5 s. The Trax control module will log the
Solution:

BD08E055-01 1
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RCPH11TLB030GAL 2

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4034 - Shifter Lever malfunction: transmission in forward receives

neutral and forward together
Context:
Cause:
Solution:

BD08E055-01 1
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RCPH11TLB030GAL 2

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4035 - Shifter Lever malfunction: transmission in reverse receives

neutral and reverse together
Context:
There is a malfunction in the shift lever. The transmission is in the reverse position, but receives a reverse signal and
Cause:
There is a malfunction in the shift lever. The transmission is in the reverse position, but receives a reverse signal and
Solution:

3. Measure the voltage at the FNR Shift Lever.
Use back probes or a breakout harness (as shown below) to measure the voltage at the FNR switch.
BD08E055-01 1
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RCPH11TLB030GAL 2

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Remove the breakout harness that is connected between the harness and the FNR switch.
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4036 - During transition from second to third gear, and Gear

CMD_01 signal erratic or incorrect
Context:
The Trax control module measured 12 V on the gear command 1 (X-300 pin 19) when the shifting from 2nd gear to
3rd gear.
Cause:
During the shift from 2nd gear to 3rd gear, the Trax control module measured 12 V on the gear command 1 (X-300
pin 19) when it should have measured 0 V. The Trax control module will log the fault code and shift into limp home
mode (2nd gear) while the fault is active.
Solution:

3. Measure the voltage at the FNR shift lever while in second gear.
BD08E055-01 1
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RCPH11TLB031GAL 2

Place the FNR switch into second gear.
A. The voltage on pin 2 is less than 0.5 V and the voltage on pin 3 is less than 0.5 V. Go to step 4.
B. The voltage on pin 2 is between 11 V and 14.8 V or the voltage on pin 3 is between 11 V and 14.8 V. Temporarily
replace the FNR shift lever and retest. Return to step 1 to confirm elimination of fault.
4. Measure the voltage at the FNR shift lever while in third gear.
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Place the FNR switch into third gear.
5. Measure the resistance through the harness
Disconnect the Trax control module connector X-300.
Measure the resistance between connector X-300 pin 47 and connector X-300 pin 19. Wiggle the harness during
measurement to reveal an intermittent condition. The resistance should be greater than 20,000 Ω.
A. The resistance is greater than 20,000 Ω. Temporarily replace the Trax control module and retest. Return to
step 1 to confirm elimination of the fault.
B. The resistance is less than 20,000 Ω. There is a short circuit in the harness. Repair or replace the harness as
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4037 - During transition from first to second gear, and Gear CMD_02
Context:
The Trax control module measured 12 V on gear command 2 (X-300 pin 47) when shifting from 1st gear to 2nd gear.
Cause:
During the shift from 1st gear to 2nd gear, the Trax control module measured 12 V on gear command 2 (X-300 pin
47) when it should have measured 0 V. The Trax control module will log the fault code and go into limp home mode
(2nd gear) while the fault is active.
Solution:

3. Measure the voltage at the FNR shift lever while in first gear.
BD08E055-01 1
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RCPH11TLB031GAL 2

Place the FNR switch into first gear.
A. The voltage on pin 2 is between 11 V and 14.8 V and the voltage on pin 3 is less than 0.5 V. Go to step 4.
4. Measure the voltage at the FNR Shift Lever in third gear.
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A. The voltage on pin 2 is less than 0.5 V and the voltage on pin 3 is less than 0.5 V. Go to step 5.
B. The voltage on pin 2 is less than 0.5 V. The voltage on pin 3 is between 11 V and 14.8 V. Temporarily replace
B. The resistance is less than 20,000 Ω. There is a short circuit in the harness. Repair or replace the harness as
6. Measure the voltage on X-300 pin 19.
Disconnect connector X-300.
Remove the breakout harness from the FNR connector.
Measure the voltage between connector X-300 pin 19 and chassis ground. The voltage should be less than 0.5 V.
A. The voltage is less than 0.5 V. Temporarily replace the Trax control module and retest. Return to step 1 to
confirm elimination of the fault.
B. The voltage is greater than 0.5 V. There is a short circuit in the harness. Repair or replace the harness as
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4038 - During transition from third to fourth gear, and Gear CMD_02
Context:
The Trax control module measured 12 V on gear command 2 (X-300 pin 47) when shifting from 3rd gear to 4th gear.
Cause:
During the shift from 3rd gear to 4th gear, the Trax control module measured 12 V on gear command 2 (X-300 pin 47)
when it should have measured 0 V. The Trax control module will log the fault code and go into limp home mode (2nd
gear) while the fault is active.
Solution:

3. Measure the voltage at the FNR shift lever while in third gear.
BD08E055-01 1
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RCPH11TLB031GAL 2

B. The voltage on pin 2 is less than 0.5 V and the voltage on pin 3 is less than 0.5 V. Temporarily replace the FNR
shift lever and retest. Return to step 1 to confirm elimination of fault.
4. Measure the voltage at the FNR shift lever while in fourth gear.
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Place the FNR switch into fourth gear.
A. The voltage on pin 2 is between 11 V and 14.8 V and the voltage on pin 3 is between 11 V and 14.8 V. Go to
step 5.
B. The voltage on pin 2 is between 11 V and 14.8 V and the voltage on pin 3 is less than 0.5 V. Temporarily replace
Fabricate a jumper wire that will connect between the FNR connector pin 2 and pin 3.
RCPH11TLB067FAL 3
1 FNR (Forward-Neutral-Reverse) switch 3 Jumper wire connected between pin 2 and

pin 3.
2 Engine harness
less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition.
A. The resistance is less than 10 Ω. Temporarily replace the Trax controller module and retest. Return to step 1
B. The resistance is greater than 10 Ω. There is an open circuit in the harness. Repair or replace the harness as
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9001 - Hour meter plausibility, internal error

Cause:
Solution:
A. Fault is not recorded again. OK to return the machine to service.

2. Replace instrument cluster.
A. Return to step 1 to confirm elimination of fault.
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9002 - Hour meter RAM checksum failure, internal error

Cause:
Solution:

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9003 - J1939 receive buffer overflow, internal error

Cause:
Solution:

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9004 - EEPROM checksum failure, hour meter location 1, internal

error
Cause:
Solution:

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error
Cause:
Solution:

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error
Cause:
Solution:

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9007 - Abnormal reset watchdog time-out, internal error

Cause:
Solution:

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9008 - A/D fault foot throttle, internal error

Cause:
Solution:

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9009 - A/D fault foot throttle power, internal error

Cause:
Solution:

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9010 - A/D fault hand throttle, internal error

Cause:
Solution:

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9011 - A/D fault foot throttle, internal error

Cause:
Solution:

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9012 - A/D fault, internal error

Cause:
Solution:

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9013 - Cluster Type Checksum Error: Location 1

Cause:
1. Internal failure within the instrument cluster.
Solution:
A. Fault code 9013 – Cluster Type Checksum Error: Location 1 is recorded again. Replace instrument cluster.
B. The fault code is not recorded again. OK to return the machine to service.
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Cause:
Solution:
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Cause:
Solution:
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17195 (DTC 921B) - CAN B Bus off passive failure

Context:
ECU. CAN Node B Bus is the engine devices communications bus. The ECU provides a CAN termination resistor for
the CAN Node B Bus, internal to the ECU. If the ECU senses that CAN Node B Bus is not functioning properly, then
Cause:
ECU has sensed a Bus Off state to be present at the CAN Node B.

2. Faulty CAN circuit wiring, open circuit, or a short to ground.
Solution:
2. Check for other engine Selective Catalytic Reduction (SCR) device CAN faults.
Use the EST to determine if SCR device CAN faults exist.
A. If other SCR device CAN faults do exist, resolve the SCR device CAN faults, then check to see that 17195 –
CAN B Bus off passive failure is also resolved.
B. If other SCR device CAN faults do not exist, continue with step 3.
From To Value
4.
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From To Value
From To Value
From To Value
B. If one or both of the conductors is grounded or the measured resistances are not correct, then locate and repair
the damage to the CAN circuit or to restore the termination resistance or replace the ECU.
has been resolved.
operation.
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17297 (DTC 3167) - EGR valve will not close during after run
service manual, Selective Catalytic Reduction (SCR) exhaust treatment - Configure - Engine restart counter
Context:
this fault to occur. Any one of many Selective Catalytic Reduction (SCR) not displayed faults that remains active for
an Engine Control Module (ECU) predetermined length of time will trigger this fault.
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17301 (DTC 1567) - EGR valve will not open to commanded position
NOTE: Because the Engine Control Unit (ECU) stores historical data relevant to the operation of the Exhaust Gas
Recirculation (EGR) valve, it is necessary to perform the “Replacement of the Exhaust Gas Recirculation Valve (EGR)
– Reset ECU Data” with the Electronic Service Tool (EST), if the EGR valve Z-9000 is replaced. Refer to the engine
service manual Exhaust Gas Recirculation (EGR) valve - Configure - Reset ECU data (EGR valve) (10.501), if
necessary.
Context:
The ECU controls the position of the EGR valve with an H-bridge Pulse Width Modulated (PWM) circuit. The ECU
also monitors the position of the EGR valve by monitoring the potentiometer feedback voltage. If the ECU determines
that the feedback position signal is 12% greater than it should be for the commanded position for a period of time
longer than that established by the ECU, this fault will occur. For information regarding the functional operation of
the Exhaust Gas Recirculation (EGR) valve, refer to the engine service manual Exhaust Gas Recirculation (EGR)
valve - Overview (10.501).
Cause:
The ECU has determined that the positive deviation between the required and measured position of the EGR valve
has been exceeded.
1. Faulty EGR valve, valve sticks, clean or replace, as required.

2. Faulty EGR valve position sensor, internal failure.
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17302 (DTC 2667) - EGR valve will not close to commanded position
– Reset ECU Data” with the Electronic Service Tool (EST), if the EGR valve is replaced. Refer to the engine service
manual Exhaust Gas Recirculation (EGR) valve - Configure - Reset ECU data (EGR valve) (10.501), if necessary.
Context:
The ECU controls the position of the EGR valve with an H-bridge Pulse Width Modulated (PWM) circuit. The ECU
also monitors the position of the EGR valve by monitoring the potentiometer feedback voltage. If the ECU determines
that the feedback position signal is 12% less than it should be for the commanded position for a period of time longer
than that established by the ECU , then this fault will occur. For information regarding the functional operation of the
Exhaust Gas Recirculation (EGR) valve, refer to the engine service manual Exhaust Gas Recirculation (EGR) valve
- Overview (10.501).
Cause:
The ECU has determined that the negative deviation between the required and measured position of the EGR valve
has been exceeded.
1. Faulty EGR valve, valve sticks, clean or replace, as required.

2. Faulty EGR valve position sensor, internal failure.
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17303 (DTC 5767) - EGR valve control circuit open

Context:
The Engine Control Unit (ECU) internally monitors the operation of the H-bridge Pulse Width Modulated (PWM) control
circuit for the Exhaust Gas Recirculation (EGR) valve actuator for electrical defects. If the ECU detects no current flow
when EGR valve actuation is requested, then this fault will occur. For information regarding the functional operation
of the EGR valve, refer to the engine service manual Exhaust Gas Recirculation (EGR) valve - Overview (10.501).
For more information regarding the technical specifications of the EGR valve, refer to the engine service manual
Exhaust Gas Recirculation (EGR) valve actuator - Technical Data (55.989).
Cause:
The ECU is sensing an open circuit condition in the EGR valve control circuit.
1. Faulty EGR valve actuator motor, failed internally.

2. Faulty EGR valve circuit wiring, open conductor.
Solution:
2. Check the condition of the EGR valve actuator motor.
Disconnect the engine harness (EN) from the EGR valve.
Use a multimeter to measure the resistance on the EGR valve actuator motor :
From To Value
EGR valve actuator motor pin 1 EGR valve actuator motor pin 5 There should be between 1.7 – 3.2 Ω
A. If the specified value is measured, then leave connector the EGR valve actuator motor disconnected and con-
tinue with step 3.
B. If the measured resistance is infinite, the EGR valve actuator motor has failed internally. Replace the EGR
valve. Then use the EST, refer to the engine service manual Exhaust Gas Recirculation (EGR) valve - Con-
figure - Reset ECU data (EGR valve) (10.501) if necessary, to perform the Replacement of the Exhaust Gas
Recirculation Valve (EGR) – Reset ECU Data.
3. Check the engine harness (EN) for an open circuit.
Use a multimeter to check for continuity in the engine harness (EN) :
From To Result
EGR valve actuator motor connector X-470 pin 29 There should be continuity.
pin 1
EGR valve actuator motor connector X-470 pin 30 There should be continuity.
pin 5
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A. If there is continuity on both tests, then leave connector X-470 disconnected and continue with step 4.
B. If there is no continuity on either or both of the checks, then there is an open circuit in the engine harness.
4. Check the vehicle harness (VE) for an open circuit.
Use a multimeter to check for continuity in the vehicle harness (VE) :
From To Result
A. If there is no continuity on either or both of the checks, then there is an open circuit in the vehicle harness.
has been resolved.
operation.
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17305 (DTC 8967) - EGR valve control circuit over current

Context:
circuit for the Exhaust Gas Recirculation (EGR) valve actuator for electrical defects. If the ECU detects excessive
current flow when EGR valve actuation is requested, then this fault will occur. For information regarding the functional
operation of the EGR valve, refer to the engine service manual Exhaust Gas Recirculation (EGR) valve - Overview
(10.501). For more information regarding the technical specifications of the EGR valve, refer to the engine service
manual Exhaust Gas Recirculation (EGR) valve actuator - Technical Data (55.989).
Cause:
The ECU is sensing a short circuit condition in the EGR valve control circuit.
1. Faulty EGR valve actuator motor, failed internally.

2. Faulty EGR valve circuit wiring, short circuit.
Solution:
2. Check the condition of the EGR valve actuator motor.
Use a multimeter to measure the resistance, on the EGR valve actuator motor :
From To Value
EGR valve actuator motor pin 1 EGR valve actuator motor pin 5 There should be between 1.7 –
3.2 Ω.
EGR valve actuator motor pin 1 Chassis ground There should be no continuity.
EGR valve actuator motor pin 5 Chassis ground There should be no continuity.
A. If the specified values are measured, then leave the EGR valve actuator disconnected and continue with step
3.
B. If the measured resistance is zero Ω or there is continuity to ground, then the EGR valve actuator motor has
failed internally. Replace the EGR valve. Then use the EST, refer to the engine service manual Exhaust Gas
Recirculation (EGR) valve - Configure - Reset ECU data (EGR valve) (10.501) if necessary, to perform the
“Replacement of the Exhaust Gas Recirculation Valve (EGR) – Reset ECU Data”.
3. Check the EGR valve actuator motor circuit for a short circuit.
From To Result
EGR valve actuator connector pin 1 EGR valve actuator connector pin 5 There should be no continuity.
EGR valve actuator connector pin 1 chassis ground There should be no continuity.
EGR valve actuator connector pin 5 chassis ground There should be no continuity.
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A. If there is continuity on any of the tests, then continue with step 4.
B. If there is no continuity on any of the checks, then check the ECU for the appropriate software and re-flash, if
necessary.
4. Determine the location of the short circuit.
Disconnect the vehicle harness (VE) from the interface connector X-470.
Use a multimeter to check for continuity in the vehicle harness (VE) :
From To Result
X-462 pin 50 chassis ground There should be no continuity.
A. If there is continuity on any of the checks, then there is a short circuit in the vehicle harness. (VE) between
connector X-462 and X-470. Locate and repair the damaged conductors or grounded conductor. Repair or
B. If there is no continuity on any of the checks, then there is a short circuit condition in the engine harness (EN)
between connector X-470 and EGR valve actuator connector. Locate and repair the damaged conductors or
grounded conductor. Repair or replace the harness as required.
has been resolved.
operation.
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17306 (DTC 6A67) - EGR valve control circuit high side shorted
to battery
Context:
circuit for the Exhaust Gas Recirculation (EGR) valve actuator for electrical defects. If the ECU detects a short circuit
of the circuit wiring to an external source, then this fault will occur. For information regarding the functional operation
Cause:
The ECU is sensing a short to a voltage source condition in the EGR valve motor actuator control circuit.
1. Faulty EGR valve circuit wiring, shorted circuit to another voltage source.
Solution:
2. Check the EGR valve motor actuator control circuit for a short circuit to another voltage source condition.
With the key switch in the ON position, use a multimeter to check for voltage on the engine harness (EN) side :
From To Result
EGR valve connector pin 1 Chassis ground There should be no voltage.
A. If there is voltage on either or both tests, then leave the EGR valve connector disconnected. Leave connector
X-462 disconnected and continue with step 3.
B. If there is no voltage on either of the checks, then leave the EGR valve connector disconnected. Leave con-
nector X-462 disconnected and continue with step 4.
3. Locate the short circuit to another voltage source.
Carefully disconnect the vehicle harness (VE) from the engine interface connector X-470.
From To Result
A. If there is no voltage on either of the checks, then the short circuit is in the engine harness (EN) between the
EGR valve connector and X-470. Locate and repair the damaged conductors. Repair or replace the harness
as required.
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B. If there is voltage on either or both tests, then the short circuit is in the vehicle harness (VE) between connector
X-462 and X-470. Locate and repair the damaged conductors. Repair or replace the harness as required.
4. Check the EGR valve motor actuator control circuit for a short circuit.
From To Result
A. If there is continuity on any of the tests, then there is a short circuit in the vehicle harness (VE) between con-
nector X-462 and another circuit in connector X-462. Locate and repair the damaged conductors. Repair or
necessary.
has been resolved.
operation.
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17307 (DTC 6B67) - EGR valve control circuit low side shorted to
battery
Context:
of the circuit wiring to an external source, then this fault will occur. For information regarding the functional operation
Cause:
The ECU is sensing a short to a voltage source condition in the EGR valve motor actuator control circuit.
1. Faulty EGR valve circuit wiring, shorted to voltage source.

Solution:
2. Check the EGR valve motor actuator control circuit for a short circuit to another voltage source.
From To Result
EGR valve motor connector pin 1 chassis ground There should be no voltage.
EGR valve motor connector pin 5 chassis ground There should be no voltage.
A. If there is voltage on either or both tests, then leave the EGR valve connector disconnected. Leave connector
X-462 disconnected and continue with step 3.
B. If there is no voltage on either of the checks, then leave the EGR valve connector disconnected. Leave con-
nector X-462 disconnected and continue with step 4.
3. Locate the short circuit.
From To Result
X-470 pin 29 X-9138 pin 29 Chassis ground There should be no voltage.
X-470 pin 30 X-9138 pin 30 Chassis ground There should be no voltage.
EGR valve connector and connector X-470. Locate and repair the damaged conductors. Repair or replace the
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B. If there is voltage on either or both tests, then the short circuit is in the vehicle harness (VE) between connector
X-470 and X-462. Locate and repair the damaged conductors. Repair or replace the harness as required.
From To Result
A. If there is continuity on any of the tests, there is a short to another circuit condition in the vehicle harness (VE)
between connector X-9121 pin A50 and/or X-9121 pin A35, and another circuit. Use the appropriate service
manual, if necessary, to locate and repair the damaged conductors.
necessary.
has been resolved.
operation.
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17308 (DTC 7C67) - EGR valve control circuit high side shorted
to ground
Context:
of the circuit wiring to chassis ground, then this fault will occur. For information regarding the functional operation of
the EGR valve, refer to the engine service manual Exhaust Gas Recirculation (EGR) valve - Overview (10.501).
Cause:
The ECU is sensing a short to chassis ground condition in the EGR valve motor actuator control circuit.
1. Faulty EGR valve motor, failed internally.

2. Faulty EGR valve circuit wiring, shorted circuit to chassis ground.
Solution:
2. Check the EGR valve motor actuator for a short circuit to ground.
Use a multimeter to check on the component for a grounded condition :
From To Result
EGR valve motor connector pin 1 Chassis ground There should be no continuity.
A. If there is no continuity, then leave the EGR valve motor disconnected and continue with step 3.
B. If there is continuity, the EGR valve motor has failed internally, replace the EGR valve. Then use the EST, refer
to the engine service manual Exhaust Gas Recirculation (EGR) valve - Configure - Reset ECU data (EGR
valve) (10.501) if necessary, to perform the “Replacement of the Exhaust Gas Recirculation Valve (EGR) –
Reset ECU Data”.
3. Check the EGR valve motor actuator control circuit for a short circuit to ground.
From To Result
EGR valve motor connector pin 1 Chassis ground There should be no continuity.
A. If there is continuity, then continue with step 4.
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From To Result
B. If there is no continuity, then the short circuit to ground is in the engine harness (EN) between connector EGR
valve motor connector and X-470. Locate and repair the grounded conductor. Repair or replace the harness
as required.
5. Locate the short to ground.
From To Result
X-462 and X-470. Locate and repair the grounded conductor. Repair or replace the harness as required.
has been resolved.
operation.
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17309 (DTC 7D67) - EGR valve control circuit low side shorted to
ground
Context:
of the circuit wiring to chassis ground, then this fault will occur. For information regarding the functional operation of the
EGR valve, refer to the engine service manual Exhaust Gas Recirculation (EGR) valve - Overview (10.501). For
more information regarding the technical specifications of the EGR valve Z-9000, refer to the engine service manual
Cause:
The ECU is sensing a short to chassis ground condition in the EGR valve motor actuator control circuit.

2. Faulty EGR valve circuit wiring, short circuit to chassis ground.
Solution:
2. Check the EGR valve motor actuator for a short circuit to ground.
Use a multimeter to check on the component for a grounded condition :
From To Result
EGR valve pin 5 Chassis ground There should be no continuity.
A. If there is no continuity, then leave the EGR valve connector disconnected and continue with step 3.
B. If there is continuity, then the EGR valve motor has failed internally. Replace the EGR valve. Then use the
EST, refer to the engine service manual Exhaust Gas Recirculation (EGR) valve - Configure - Reset ECU
data (EGR valve) (10.501) if necessary, to perform the “Replacement of the Exhaust Gas Recirculation Valve
(EGR) – Reset ECU Data”.
From To Result
EGR valve connector pin 5 Chassis ground There should be no continuity.
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From To Result
A. If there is continuity, leave connector X-470 disconnected and continue with step 5.
B. If there is no continuity, then the short circuit to ground is in the engine harness (EN) between the EGR valve
connector and connector X-470. Locate and repair the grounded conductor. Repair or replace the harness as
required.
From To Result
X-9121 pin A35 chassis ground There should be no continuity.
X-462 pin 35 and X-470 pin 30. Locate and repair the grounded conductor. Repair or replace the harness as
required.
has been resolved.
operation.
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17310 (DTC 1E67) - EGR valve control circuit over load

Context:
of the circuit wiring to an external source or to chassis ground, then this fault will occur. For information regarding the
functional operation of the EGR valve, refer to the engine service manual Exhaust Gas Recirculation (EGR) valve
- Overview (10.501). For more information regarding the technical specifications of the EGR valve Z-9000, refer to
the engine service manual Exhaust Gas Recirculation (EGR) valve actuator - Technical Data (55.989).
Cause:
The ECU is sensing a short circuit in the EGR valve motor actuator control circuit.

2. Faulty EGR valve motor actuator circuit wiring, grounded or shorted to voltage source.
Solution:
2. Check the EGR valve motor for a short circuit.
Use a multimeter to perform the following resistance and continuity checks on the EGR valve motor :
From To Result
EGR valve motor pin 1 EGR valve motor pin 1 There should be between 1.7 –
3.2 Ω.
EGR valve motor pin 1 Chassis ground There should be no continuity.
EGR valve motor pin 5 Chassis ground There should be no continuity.
A. If the specified values are measured, then leave the EGR valve motor disconnected and continue with step 3.
B. If the specified values are not measured, then the EGR valve motor has failed internally. Replace the EGR
valve. Then use the EST, refer to the engine service manual Exhaust Gas Recirculation (EGR) valve - Con-
figure - Reset ECU data (EGR valve) (10.501) if necessary, to perform the “Replacement of the Exhaust Gas
Recirculation Valve (EGR) – Reset ECU Data”.
From To Result
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A. If there is continuity on either check, then continue with step 4.
B. If there is no continuity on both checks, then leave the EGR valve disconnected and continue with step 6.
From To Result
X-470 pin 29 X-9138 pin 29 Chassis ground There should be no continuity.
X-470 pin 30 X-9138 pin 30 Chassis ground There should be no continuity.
A. If there is continuity on either check, then leave connector X-470 disconnected and continue with step 5.
B. If there is no continuity on both checks, then the short circuit to ground is in the engine harness (EN) between
the EGR valve connector and X-470. Locate and repair the grounded conductor. Repair or replace the harness
as required.
From To Result
A. If there is continuity on either check, then the short circuit to chassis ground is in the vehicle harness (VE)
between connector X-462 and connector X-470. Locate and repair the grounded conductor. Repair or replace
B. If there is no continuity on both checks, then check the ECU for the appropriate software and re-flash, if nec-
essary.
6. Check the EGR valve motor actuator control circuit for a short circuit to another voltage source.
From To Result
A. If there is voltage on either or both tests, then leave the EGR valve disconnected. Leave connector X-462
disconnected and continue with step 7.
B. If there is no voltage on either of the checks, then leave the EGR valve disconnected. Leave connector X-462
From To Result
EGR valve and connector X-470. Locate and repair the damaged conductors. Repair or replace the harness
as required.
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B. If there is voltage on either or both of the checks, then the short circuit is in the vehicle harness (VE) between
connector X-470 and connector X-462. Locate and repair the damaged conductors. Repair or replace the
From To Result
A. If there is continuity on any of the tests, then there is a short circuit between connector X-462 and another
circuit. Locate and repair the damaged conductors. Repair or replace the harness as required.
necessary.
has been resolved.
operation.
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17322 (DTC 1B97) - EGR valve position sensor voltage is higher

than expected
Context:
The ECU monitors the electrical signal provided by the EGR valve position feedback potentiometer. If the signal
level becomes greater than 4.86 V the ECU provides a replacement value and this fault will occur. For information
regarding the functional operation of the EGR valve, refer to the engine service manual Exhaust Gas Recirculation
(EGR) valve - Overview (10.501). For more information regarding the technical specifications of the EGR valve, refer
to the engine service manual Exhaust Gas Recirculation (EGR) valve actuator - Technical Data (55.989).
Cause:
The ECU is sensing the EGR valve position signal is greater than 4.86 V.
1. Faulty EGR valve, failed internally.

2. Faulty EGR valve position sensor circuit wiring, shorted to a high source.
Solution:
2. Check the EGR valve potentiometer signal circuit for a short circuit to another voltage source.
From To Result
EGR valve pin 2 Chassis ground There should be less than 4.86 V.
A. If there is greater than 4.86 V, then leave the EGR valve disconnected and continue with step 3.
B. If there is less than 4.86 V, then leave the EGR valve disconnected and continue with step 5.
From To Result
X-470 pin 34 Chassis ground There should be less than 4.86 V.
A. If there is less than 4.86 V, then the short circuit in the engine harness (EN) between the EGR valve connector
and X-470. Locate and repair the damaged conductors. Repair or replace the harness as required.
B. If there is greater than 4.86 V, the leave connector X-470 disconnected and continue with step 4.
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From To Result
A. If there is voltage, then there is a short circuit is in the vehicle harness (VE) between connector X-470 and
X-462. Locate and repair the damaged conductors. Repair or replace the harness as required.
B. If there is no voltage, then check the ECU for the appropriate software and re-flash, if necessary. Repair or
5. Replace the EGR valve.
Then use the EST, refer to the engine service manual Exhaust Gas Recirculation (EGR) valve - Configure -
Reset ECU data (EGR valve) (10.501) if necessary, to perform the “Replacement of the Exhaust Gas Recircula-
tion Valve (EGR) – Reset ECU Data”.
A. If the fault is resolved, return the vehicle to operation.
has been resolved.
operation.
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17323 (DTC 2C97) - EGR valve position sensor voltage is lower

than expected
NOTE: Because the Engine Control Unit (ECU) A-9000 stores historical data relevant to the operation of the Exhaust
Gas Recirculation (EGR) valve Z-9000, it is necessary to perform the “Replacement of the Exhaust Gas Recirculation
Valve (EGR) – Reset ECU Data” with the Electronic Service Tool (EST), if the EGR valve Z-9000 is replaced. Refer
to the engine service manual Exhaust Gas Recirculation (EGR) valve - Configure - Reset ECU data (EGR valve)
(10.501), if necessary.
Context:
The Engine Control Unit (ECU) monitors the electrical signal provided by the Exhaust Gas Recirculation (EGR) valve
position feedback potentiometer. If the signal level becomes less than 0.225 V the ECU provides a replacement
value and this fault will occur. For information regarding the functional operation of the EGR valve, refer to the engine
service manual Exhaust Gas Recirculation (EGR) valve - Overview (10.501). For more information regarding the
technical specifications of the EGR valve, refer to the engine service manual Exhaust Gas Recirculation (EGR)
valve actuator - Technical Data (55.989).
Cause:
The ECU is sensing the EGR valve position signal is less than 0.225 V.
1. Faulty EGR valve, failed internally.

2. Faulty EGR valve position sensor circuit wiring, shorted to ground.
Solution:
2. Check the EGR valve potentiometer for a short circuit to ground.
Use a multimeter to check for continuity on the EGR valve potentiometer side :
From To Result
EGR valve pin 2 Chassis ground There should be no continuity.
EGR valve pin 2 EGR valve pin 4 There should be no continuity.
A. If there is continuity, then the EGR valve has failed internally. Replace the EGR valve. Then use the EST, refer
to the engine service manual Exhaust Gas Recirculation (EGR) valve - Configure - Reset ECU data (EGR
valve) (10.501) if necessary, to perform the “Replacement of the Exhaust Gas Recirculation Valve (EGR) –
Reset ECU Data”.
B. If there is no continuity, then leave the EGR valve disconnected and continue with step 3.
3. Check the EGR valve potentiometer signal circuit for a short circuit to ground.
From To Result
A. If there is continuity, then leave the EGR valve disconnected and continue with step 4.
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From To Result
A. If there is no continuity, then the short circuit to ground is in the engine harness (EN) between the EGR valve
connector and connector X-470. Locate and repair the damage to the conductor.
B. If there is continuity, then leave connector X-470 disconnected and continue with step 5.
From To Result
A. If there is continuity, then there is a short circuit to ground in the vehicle harness (VE) between connector X-462
and X-470. Locate and repair the damage to the conductor. Repair or replace the harness as required.
has been resolved.
operation.
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17337 (DTC 9E8C) - Hydrocarbon level 2 exceeded

NOTICE: DO NOT perform the Desulfurization / Thermal Conditioning Test in EST if this fault is active. Permanent
damage to the catalyst could occur.
Context:
This fault indicates a warning for component protection caused from excessive Hydrocarbon (HC) levels that have
accumulated in the exhaust system. This fault indicates a level 2 failure, caused by at least 7500 mg of liquid HC
in the exhaust system. To clear this fault, see Selective Catalytic Reduction (SCR) exhaust treatment - Service
instruction - Hydrocarbon (HC) accumulation (10.500).
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17345 (DTC 4652) - DFC for faulty diagnostic data transmission or

protocol error
Context:
The Engine Control Unit (ECU) requests operation of the glow plug control module via a Pulse Width Modulated
(PWM) control circuit and monitors the status of possible electrical defects via a diagnostic feedback signal from the
glow plug control module. If the ECU determines the diagnostic data transmission is faulty, then this fault will occur.
For information regarding the functional operation of the glow plug control module, refer to the engine service manual
Glow plug system Glow plug control module - Overview - Glow plug control module (55.202).
Cause:
The glow plug control module diagnostic connection with the ECU is damaged or the data protocol is incorrect.
1. Faulty glow plug control module diagnostic circuit wiring, open, shorted or grounded circuit.
2. Faulty glow plug control module, internal failure.
Solution:
2. Check for damaged diagnostic circuit wiring.
From To Result
A. If there is continuity from connector X-461 pin 22 to ground or to any other pin in connector X-461, then there
is a short circuit in the harness. Repair or replace the harness as required.
B. If there is no continuity from connector X-461 pin 22 to ground or to any other pin in connector X-461, then go
to step 3.
3. Check for damaged diagnostic circuit wiring.
Disconnect the vehicle harness (VE) from the glow plug control module at connector X-469.
From To Result
A. If there is continuity from connector X-461 pin 22 and chassis ground, then go to step 4.
B. If there is no continuity between connector X-461 pin 22 and chassis ground,then there is a open circuit be-
tween X-461 pin 22 and X-469 pin 3. Repair or replace the harness as required.
4. Replace the glow plug control module, then use EST to check to see that this fault has been resolved.
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has been resolved.
operation.
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17347 (DTC 5852) - No load error for Low Voltage System

Context:
glow plug control module. If the ECU is notified of an open circuit in one or more of the glow plugs or glow plug circuits,
then this fault will occur. For information regarding the functional operation of the glow plug control module, refer to
the engine service manual Glow plug system Glow plug control module - Overview - Glow plug control module
(55.202).
Cause:
The glow plug control module has communicated to the ECU, via a diagnostic connection, that an open circuit exists
in one or more of the glow plugs or glow plug circuits.
1. Faulty glow plug, internal failure.

2. Faulty glow plug control circuit wiring, open circuit.
Solution:
2. Check each of the glow plugs for an open circuit.
Disconnect the engine harness (EN) from each of the glow plugs.
Use a multimeter to check on the component for an open circuit condition :
From To Result
Glow plug connector pin 1 Chassis ground There should be 0.2 – 5.0 Ω.
A. If there is a nominal amount of resistance measured on each of the glow plugs, then leave all of the glow plugs
B. If there is infinite resistance measured on any of the glow plugs, then that glow plug has failed internally. Re-
place the faulted glow plug and retest.
3. Check the glow plug control circuits for an open circuit.
With the key switch in the OFF position, place a jumper wire from each of the glow plug connectors to chassis
ground.
From To Result
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From To Result
A. If there is continuity on all of the checks, then leave the jumper wires in place. Reconnect connector X-470 and
continue with step 4.
B. If there is no continuity on one or more of the checks, then there is an open circuit in the engine (EN) harness
between the engine interface connector X-470 and the respective glow plug. Locate and repair the broken
4. Locate the open circuit.
From To Result
A. If there is no continuity on one or more of the checks, the open circuit condition is in the vehicle harness (VE)
between the glow plug connector and connector X-470. Locate and repair the broken conductor. Repair or
B. If there is continuity on all of the checks, then continue with step 5.

has been resolved.
operation.
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17348 (DTC 8952) - Over temperature error on ECU powerstage for

Glow plug Low Voltage System
Context:
glow plug control module. If the ECU is notified of a short circuit to ground, over current, in one or more of the glow
plugs or glow plug circuits, then this fault will occur. For information regarding the functional operation of the glow
plug control module Z-9101, refer to the engine service manual Glow plug system Glow plug control module -
Overview - Glow plug control module (55.202).
Cause:
The glow plug control module has communicated to the ECU, via a diagnostic connection, that a short circuit to ground
exists in one or more of the glow plugs or glow plug circuits.

2. Faulty glow plug control circuit wiring, open circuit.
Solution:
2. Check each of the glow plugs for a short circuit.
Use a multimeter to check on the component for a short circuit to ground :
From To Result
B. If there is less than 0.2 Ω resistance measured on any of the glow plugs, then that glow plug has failed internally.
Replace the faulted glow plug and retest.
3. Check the glow plug control circuits in the engine harness (EN) for a short circuit to ground.
From To Result
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A. If there is no continuity on all of the checks, then leave connector X-470 disconnected and continue with step 4.
B. If there is continuity on one or more of the checks, then there is a short circuit to ground in the engine (EN)
harness between the engine interface connector X-470 and the respective glow plug. Locate and repair the
damaged conductor. Repair or replace the harness as required.
4. Check the glow plug control circuits in the vehicle harness (VE) for a short circuit to ground.
From To Result
A. If there is continuity on one or more of the checks, then there is a short circuit to ground in the vehicle harness
(VE) between connector X-469 and chassis ground. Locate and repair the grounded conductor. Repair or
B. If there is no continuity on all of the checks, then continue with step 5.

has been resolved.
operation.
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17349 (DTC 6A52) - Short circuit to battery error for Low Voltage
System
Context:
glow plug control module. If the ECU is notified of a short circuit to another voltage source in one or more of the
glow plug circuits, then this fault will occur. For information regarding the functional operation of the glow plug control
module, refer to the engine service manual Glow plug system Glow plug control module - Overview - Glow plug
control module (55.202).
Cause:
The glow plug control module has communicated to the ECU, via a diagnostic connection, that a short circuit to a
voltage source condition exists in one or more of the glow plug circuits.
1. Faulty glow plug control circuit wiring, short circuit to another voltage source.
Solution:
2. Check each of the glow plug circuits for a short circuit to another voltage source.
From To Result
Glow plug connector pin 1 Chassis ground There should be no voltage.
A. If there is voltage measured on any of the checks, then leave all of the connectors disconnected and continue
with step 3.
B. If there is no voltage measured on any of the checks, then continue with step 4.
From To Result
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A. If there is no voltage on any of the checks, then the short circuit to another voltage source in the engine harness
(EN) between the glow plug connector and connector X-470. Locate and repair the damaged conductors.
B. If there is voltage on one or more of the checks, then the short circuit to another voltage source is in the vehicle
harness (VE) between connector X-469 and connector X-470. Locate and repair the damaged conductors.
has been resolved.
operation.
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17350 (DTC 7B52) - Short circuit to ground error for Low Voltage
System
Context:
glow plug control module. If the ECU is notified of a short circuit to ground in one or more of the glow plug circuits,
then this fault will occur. For information regarding the functional operation of the glow plug control module, refer to
the engine service manual Glow plug system Glow plug control module - Overview - Glow plug control module
(55.202).
Cause:
The glow plug control module has communicated to the ECU, via a diagnostic connection, that a short to ground
circuit condition exists in one or more of the glow plugs or glow plug circuits.

2. Faulty glow plug control circuit wiring, short circuit to ground.
Solution:
2. Check each of the glow plugs for a short circuit condition.
Use a multimeter to check on the component for a short to ground circuit condition :
From To Result
B. If there is less than 0.2 Ω resistance measured on any of the glow plugs, then that glow plug has failed internally.
Replace the faulted glow plug and retest.
3. Check the glow plug control circuits in the engine harness (EN) for a short circuit to ground.
From To Result
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A. If there is no continuity on all of the checks, then leave connector X-470 disconnected and continue with step 4.
B. If there is continuity on one or more of the checks, then there is a short circuit to ground in the engine (EN)
harness between the respective glow plug connector and X-470. Locate and repair the grounded conductor.
4. Check the glow plug control circuits in the vehicle harness (VE) for a short circuit to ground.
From To Result
A. If there is continuity on one or more of the checks, then there is a short circuit to ground in the vehicle harness
(VE) between connector X-469 and X-470. Locate and repair the grounded conductor. Repair or replace the
B. If there is no continuity on all of the checks, then continue with step 5.

has been resolved.
operation.
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17359 (DTC 7562) - Glow plug 1 control circuit shorted to ground

Context:
glow plug control module. If the ECU is notified of a short circuit condition in the glow plug 1 circuit, then this fault will
occur. For information regarding the functional operation of the glow plug control module, refer to the engine service
manual Glow plug system Glow plug control module - Overview - Glow plug control module (55.202).
Cause:
The glow plug control module has communicated to the ECU, via a diagnostic connection, that a short circuit exists
in the glow plug 1 circuit.
1. Faulty glow plug 1, internal failure.

2. Faulty glow plug 1 control circuit wiring, shorted to ground.
Solution:
2. Check the glow plug for a short circuit to ground.
Disconnect the engine harness (EN) from glow plug 1.
Use a multimeter to check on the component for a short circuit to ground :
From To Result
Glow plug 1 pin 1 Chassis ground There should be 0.2 – 5.0 Ω.
A. If there is greater than 0.2 Ω, then leave glow plug 1 disconnected and continue with step 3.
B. If there is less than 0.2 Ω, then glow plug 1 has failed internally. Replace the glow plug and retest.
3. Check the glow plug 1 control circuit for a short circuit to ground.
From To Result
Glow plug 1 connector pin 1 Chassis ground There should be no continuity.

From To Result
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B. If there is no continuity, then the short circuit to ground is in the engine harness (EN) between glow plug 1 and
connector X-470. Locate and repair the grounded conductor. Repair or replace the harness as required.
From To Result
A. If there is continuity, then the short circuit to ground is in the vehicle harness (VE) between connector X-469
and X-470. Locate and repair the grounded conductor. Repair or replace the harness as required.

has been resolved.
operation.
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Context:
glow plug control module. If the ECU is notified of a short circuit condition in the glow plug 3 circuit, then this fault will
occur. For information regarding the functional operation of the glow plug control module, refer to the engine service
manual Glow plug system Glow plug control module - Overview - Glow plug control module (55.202).
Cause:

2. Faulty glow plug 3 control circuit wiring, shorted to ground.
Solution:
Use a multimeter to check on the component for a grounded (shorted) condition :
From To Result
B. If there is less than 0.2 Ω, then glow plug 3 has failed internally. Replace the glow plug and retest.
From To Result

From To Result
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B. If there is no continuity, then the short circuit to ground is in the engine harness (EN) between glow plug 3
required.
From To Result
X-468 and X-470. Locate and repair the grounded conductor. Repair or replace the harness as required.

has been resolved.
operation.
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Context:
glow plug control module. If the ECU is notified of a short circuit in the glow plug 4 circuit, then this fault will occur.
Cause:

2. Faulty glow plug 4 control circuit wiring, short circuit to ground.
Solution:
Use a multimeter to check on the component for a short circuit ground :
From To Result
B. If there is less than 0.2 Ω, then the glow plug 4 has failed internally. Replace the glow plug and retest.
From To Result

From To Result
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B. If there is no continuity, then the short circuit to ground is in the engine harness (EN) between glow plug 4
required.
From To Result
X-469 and connector X-470. Locate and repair the grounded conductor. Repair or replace the harness as
required.

has been resolved.
operation.
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Context:
glow plug control module. If the ECU is notified of a short circuit in the glow plug 2 circuit, then this fault will occur.
Cause:

2. Faulty glow plug 2 control circuit wiring, short circuit to ground.
Solution:
2. Check the glow plug for a short to ground condition.
Use a multimeter to check on the component for a grounded (shorted) condition :
From To Result
A. If there is greater than 0.2 Ω, then leave the glow plug 2 disconnected and continue with step 3.
B. If there is less than 0.2 Ω, then the glow plug 2 has failed internally. Replace the glow plug. Repair or replace
From To Result

From To Result
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B. If there is no continuity, then the short circuit to ground is in the engine harness (EN) between connector X-469
and connector X-470. Locate and repair the grounded conductor. Repair or replace the harness as required.
5. Locate the short to ground condition.
Carefully disconnect the vehicle harness (VE) from the glow plug control module at connector X-469.
From To Result
X-469 and connector X-470. Locate and repair the grounded conductor. Repair or replace the harness as
required.
B. If there is no continuity, continue with step 6.

6. Replace the glow plug control modul, then use EST to check to see that this fault has been resolved.
has been resolved.
operation.
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17377 (DTC 21A6) - MI1 injection quantity is low

Context:
The Engine Control Unit (ECU) checks the condition for splitting the main injection in Injection Rate Shaping (IRS)
mode. If quantities and energizing times for both injection parts are sufficient, there is a split main injection. This fault
is the result of a wrong fuel quantity calculation.
Solution:
1. Check the ECU for the appropriate software and re-flash if necessary.
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17378 (DTC 22A6) - MI1 energizing time is low

Context:
The Engine Control Unit (ECU) checks the condition for splitting the main injection in Injection Rate Shaping (IRS)
mode. If quantities and energizing times for both injection parts are sufficient, there is a split main injection. This fault
is the result of a wrong energizing time calculation.
Solution:
1. Check the ECU for the appropriate software and re-flash if necessary.
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17379 (DTC 43A6) - Measured injection closing time exceeds a limit

Context:
The Engine Control Unit (ECU) monitors for a difference between the measured closing time of the fuel injector to a
reference value from an internal map which is derived from the injector IMA code. If the closing time or energizing
time exceeds the minimum or maximum values in the tolerance curve, this fault will occur.
Cause:
The ECU has determined that the fuel injector number 1 IMA programming is wrong or the injector has drifted.
Solution:
1. Use the Electronic Service Tool (EST) to ensure that the correct IMA code is programmed to the fuel injector
number 1.
A. If the correct code is not programmed. The use the EST to program the correct code.
B. If the correct code is programmed, then continue to step 2.

NOTE: The IMA code may be under the paint on the fuel injector.
NOTE: For more information regarding programming IMA codes, refer to the engine service manual Fuel injectors
- Configure - IMA codes (10.218).
2. Replace the fuel injector number 1.
Then check to see that this fault has been resolved.
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Context:
time exceeds the minimum or maximum values in the tolerance curve, then this fault will occur.
Cause:
Solution:
number 3.
A. If the correct code is not programmed. Use the EST to program the correct code.

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Context:
time exceeds the minimum or maximum values in the tolerance curve, then this fault will occur.
Cause:
Solution:
number 4.

NOTE: For more information regarding programming IMA codes, see Fuel injectors - Configure - IMA codes
(10.218).
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Context:
time exceeds the minimum or maximum values in the tolerance curve, this fault will occur.
Cause:
Solution:
number 3.

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17383 (DTC F976) - IMA type mismatch

Context:
The Engine Control Unit (ECU) uses an IMA code to correct fuel trim for each fuel injector equipped with the engine
at every key ON. If the ECU determines that this trim correction for fuel injector number 1 can not be performed, this
fault will occur. For more information about how to configure injector IMA codes, refer to the engine service manual
Fuel injectors - Configure - IMA codes (10.218).
Cause:
The ECU has determined that the fuel injector number 1 fuel trim correction can not be performed.
Solution:
1. Use the Electronic Service Tool (EST) ensure that the correct IMA code is programmed to fuel injector number 1.

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17384 (DTC FA76) - IMA type mismatch

Context:
fault will occur.
Cause:
Solution:

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17385 (DTC FB76) - IMA type mismatch

Context:
fault will occur. For more information about how to configure injector IMA codes, refer to the engine service manual
Fuel injectors - Configure - IMA codes (10.218).
Cause:
Solution:

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17386 (DTC FC76) - IMA type mismatch

Context:
at every key ON. If the ECU determines that this trim correction for fuel injector number 2 can not be performed, then
Cause:
Solution:

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17387 (DTC E196) - Chip error in the Injector CY33x power stage
component
Context:
The ECU controls and monitors the operation of the fuel injection control circuits. If a power stage failure, internal to
the ECU is detected, then this fault will occur.
Solution:
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17403 (DTC 31B6) - Reporting Error if Relay is stuck at closed

position
Context:
The Engine Control Unit is configured and programmed to control the supply power to the Selective Catalytic Reduc-
tion (SCR) system Diesel Engine Fluid (DEF)/AdBlue® supply module pump motor and purging pump. Operational
testing of this control feature is done once at the beginning of each drive cycle (at key on). If the release conditions for
the monitoring are fulfilled, the ECU control circuit Low Side Driver (LSD) at connector X-462 pin 20 is deactivated for
a calibrated period of time. During this time an open load error of the DEF/AdBlue® supply module back-flow pump
and main pump motor is expected. In the case that these errors do not occur, the ECU assumes that the supply power
was not interrupted and this fault occurs.
Cause:
ECU controlled power interruption to the DEF/AdBlue® supply module did not occur during programmed testing.
1. Faulty SCR relay control circuit, shorted to ground.

2. Faulty SCR relay, shorted power contacts.
Solution:
1. Verify the fault is present and active.
2. Check the, vehicle provided, SCR relay control circuit for a short circuit to ground.
From To Value
B. If there is continuity, then there is a short circuit to ground in the vehicle harness (VE). Locate and repair the
grounded conductor. Repair or replace the harness as required.
3. Check the condition of the SCR relay power contacts.
Disconnect the vehicle harness (VE) from the DEF/AdBlue® supply module.
will energize the SCR relay.
With the key in the ON position, use a multimeter to check for voltage on the vehicle harness (VE) side :
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From To Value
DEF/AdBlue® supply module Chassis ground There should be approximately
connector pin 3 12.0 V.
DEF/AdBlue® supply module Chassis ground There should be approximately
connector pin 5 12.0 V.
To de-energize the SCR relay, remove the jumper wire that is placed between the vehicle harness (VE) side of
connector X-462 pin 20 and chassis ground.
From To Value
DEF/AdBlue® supply module Chassis ground There should be no voltage.
connector pin 3
connector pin 5
A. If the results of the voltage checks are as specified, then check the ECU for the appropriate software and
re-flash, if necessary.
B. If the voltage is present in all of the checks, then there is a short circuit to another voltage source in the vehicle
harness (VE) or the SCR relay power contacts are stuck in the closed position. Locate and repair the damaged
conductors or replace the relay. Repair or replace the harness as required.
has been resolved.
operation.
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17404 (DTC 32B6) - Reporting Error if Relay is stuck at open

position
Context:
The Engine Control Unit is configured and programmed to control the supply power to the Selective Catalytic Reduc-
tion (SCR) system Diesel Engine Fluid (DEF)/AdBlue® supply module pump motor and purging pump. Operational
testing of this control feature is done once at the beginning of each drive cycle (at key on). If the release conditions
for the monitoring are fulfilled, the ECU control circuit Low Side Driver (LSD) at connector X-462 pin 20 is activated for
a calibrated period of time. During this time an open load error of the DEF/AdBlue® supply module back-flow pump
and main pump motor is not expected to occur. In the case that these errors do occur, then the ECU assumes that
the supply power has not been provided and this fault occurs.
Cause:
ECU controlled power to the DEF/AdBlue® supply module did not occur during programmed testing.
1. Faulty SCR relay control circuit, open circuit.

2. Faulty SCR relay, open power contacts.
Solution:
2. Check the condition of the SCR relay power contacts and control circuit.
To energize the main relay, place a jumper wire between the vehicle harness (VE) side of connector X-461 pin 28
and chassis ground.
To energize the SCR relay, place a jumper wire between the vehicle harness (VE) side of connector X-462 pin 20
and chassis ground.
From To Value
DEF/AdBlue® supply module pin 3 chassis ground There should be approximately
12.0 V.
DEF/AdBlue® supply module pin 5 chassis ground There should be approximately
12.0 V.
To de-energize the SCR relay, remove the jumper wire that is placed between the vehicle harness (VE) side of
connector X-462 pin 20 and chassis ground.
From To Value
DEF/AdBlue® supply module pin 3 chassis ground There should be no voltage.
DEF/AdBlue® supply module pin 5 chassis ground There should be no voltage.
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A. If the results of the voltage checks are as specified, then check the ECU for the appropriate software and
re-flash, if necessary.
B. If the voltage is not present in all of the checks, then there is an open circuit in the vehicle harness (VE) or
the SCR relay power contacts are stuck in the open position. Locate and repair the damaged conductors or
replace the relay.
has been resolved.
operation.
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17405 (DTC 1E4A) - DFC used to evaluate filter clog

Context:
Based on the measured Diesel Engine Fluid (DEF)/AdBlue® supply module Z-9102 pump duty cycle and pump speed,
the Engine Control Unit (ECU) A-9000 calculates, for each driving cycle, the actual pump power needed to maintain
the operation pressure at zero dosing. The calculated pump power is always compared to a reference pump power,
which was determined directly after a DEF/AdBlue® supply module Z-9102 filter change. If the current measured
pump power is greater than the reference power multiplied with a filter full threshold of 1.30, this fault will occur.
Cause:
The needed DEF/AdBlue® supply module Z-9102 pump power to maintain the operation pressure at zero dosing is
out of the expected range.
1. Faulty DEF/AdBlue ® tank suction side pre-filter in tank sending unit head, clogged.
2. Faulty DEF/AdBlue ® supply module Z-9102 main or pre-filter, clogged.
3. Faulty DEF/AdBlue ® tank ventilation, blocked.
4. Faulty DEF/AdBlue ® tank suction side tank sending unit, air leakage.
5. Faulty DEF/AdBlue ® system pressure side, leakage.
6. Faulty DEF/AdBlue ® supply module Z-9102, pump membrane failure.
7. Faulty DEF/AdBlue ® supply module Z-9102 pump motor, power loss.
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17409 (DTC 53B6) - Reporting the leakage in the system during

no dosing
Context:
The Engine Control Unit (ECU) monitors operation of the Selective Catalytic Reduction system in part by monitoring
the Diesel Engine Fluid (DEF)/AdBlue® supply module pump motor operation. Leakage detection is performed when
the system is in the state of metering control while there is no dosing. When there is no actuation of the DEF AdBlue®
dosing module (valve), a constant duty cycle ( 34.00%) is needed to hold the pressure at the expected value. If
the DEF AdBlue® supply module pump motor actuation is clearly higher than expected, a leakage in the system is
assumed and this fault will occur.
Cause:
The DEF AdBlue® supply module pump motor duty cycle needed to maintain operation pressure at zero dosing is
out of normal range.
1. Faulty DEF/AdBlue ® pressure line, heavy leakage.

2. Faulty DEF/AdBlue ® fluid level, too low.
5. Faulty DEF/AdBlue ® supply module pre-filter, clogged.
7. Faulty DEF/AdBlue ® supply module, pump membrane failure.
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17410 (DTC 3F9A) - Error in dosing valve plausibility at low voltage

Context:
The Engine Control Unit (ECU) monitors operation of the dosing module valve. If no dosing module valve opening
is detected by the ECU dosing valve driver and the operating conditions are within the evaluation range, then this
fault will occur. For information regarding the functional operation of the Diesel Exhaust Fluid (DEF)/AdBlue® system,
refer to the engine service manual Selective Catalytic Reduction (SCR) exhaust treatment - Dynamic description
(10.500).
Cause:
The ECU is not sensing the opening of the dosing module valve.
1. Faulty dosing module solenoid valve, damaged or restricted.

Solution:
1. Check for physical damage.
Visually inspect the dosing module for thermal or other physical damage.
There should be no damage.
A. If damage is found, then replace the dosing module.
B. If no damage is found, then continue with step 2.

2. Check the electrical integrity of the dosing module solenoid coil.
Disconnect the vehicle (VE) harness from the dosing module.
Use a multimeter to measure the resistance of the dosing module solenoid coil :
From To Value
Dosing module pin 1 Dosing module pin 2 there should be 11.4 – 12.6 Ω.
A. If the measured resistance is within specification, then continue with step 3.
B. If the measured resistance is not within specification, then replace the dosing module.
3. Test the DEF/AdBlue® system.
Use the EST to perform the Urea Dosing System Test (UDST) and follow the on screen instructions.
Use the UDST Troubleshooting Guideline, as required, to identify and resolve the problem.
Then use EST to perform the Engine Restart Counter Reset / Unlock Inducement configuration. Refer to the
engine service manual Selective Catalytic Reduction (SCR) exhaust treatment - Configure - Engine restart
Then perform the SCR Fault Repair Verification Test. Refer to the engine service manual Selective Catalytic
essary.
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Then verify that this fault has been resolved.
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17411 (DTC FEBA) - Defective pressure reduction

Context:
To protect the Selective Catalytic Reduction (SCR) system against damage due to frozen Diesel Exhaust Fluid, the
SCR system must be evacuated at each engine stop (during engine after run). First, the SCR system is depressurized
by actuating the DEF/AdBlue® supply module purging pump which sucks the DEF/AdBlue® fluid from the feeding tube
to the DEF/AdBlue® dosing module valve, while it is fully closed, dropping the DEF/AdBlue® fluid pressure to below
0.0 bar (0.0 psi). After the SCR system is "evacuated," the DEF/AdBlue® supply module purging pump is operated
at 100.00% while the DEF/AdBlue® dosing module valve is energized (opened) until the tubing is completely empty.
Cause:
The Engine Control Unit (ECU) has determined that the DEF/AdBlue® system was not evacuated properly. The
system pressure remained above 0.0 bar (0.0 psi).
1. Faulty DEF/AdBlue® system back flow line (tube), restriction.

2. DEF/AdBlue® supply module purging pump, internally damaged.
Solution:
B. If the fault is no longer present or in an inactive state, then he fault may be intermittent and not currently active.
2. Check for blockage in DEF/AdBlue® system.
Visually inspect the system back flow line (tube) for blockage and/or damage.
There should be no blockage or damage.
A. If blockage or damage is found, then repair or replace the line (tube).
B. If no blockage or damage is found, then continue with step 3.

3. As the components internal to the DEF/AdBlue® system supply module are not serviceable, replace the DEF/
AdBlue® supply module.
Then check to see if this fault is resolved.
has been resolved.
operation.
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17412 (DTC 14B6) - High threshold for pressure sensor plausibility

Context:
Prior to every Diesel Exhaust Fluid (DEF)/AdBlue® system pressure build-up the DEF/AdBlue® supply module pres-
sure sensor signal is checked for plausibility. To accomplish the test the DEF/AdBlue® dosing module valve is en-
ergized (opened) and the DEF/AdBlue® supply module purging pump is actuated for a certain time interval. The
pressure compensation test is done to ensure that the DEF/AdBlue® system achieves environmental pressure and
incorporates a DEF/AdBlue® supply module temperature coefficient. If the DEF/AdBlue® supply module pressure
sensor measurement is above or equal to the upper tolerable limit of 0.35 bar (5.07 psi) higher than the atmospheric
pressure, this fault will occur. In the case of a defective DEF/AdBlue® supply module temperature sensor, fixed tol-
erance limits will be used.
Cause:
The Engine Control Unit (ECU) has determined that the DEF/AdBlue® supply module pressure sensor signal is not
plausible.
1. Faulty DEF/AdBlue® supply module pressure sensor, defective or drifted.
Solution:
1. As the components internal to the DEF/AdBlue® supply module are not serviceable, replace the module.
A. If the fault has been resolved, then return the vehicle to service.
NOTE: If the possibility of ice build-up internal to the DEF/AdBlue® supply module exists, start and run the vehicle
until the catalyst upstream temperature is greater than 180 °C (356 °F) and retest before replacing the module.
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17413 (DTC 25B6) - Low threshold for pressure sensor plausibility

Context:
Prior to every Diesel Exhaust Fluid (DEF)/AdBlue® system pressure build-up the DEF/AdBlue® supply module pres-
sure sensor signal is checked for plausibility. To accomplish the test the DEF/AdBlue® dosing module valve is en-
ergized (opened) and the DEF/AdBlue® supply module purging pump is actuated for a certain time interval. The
pressure compensation test is done to ensure that the DEF/AdBlue® system achieves environmental pressure and
incorporates a DEF/AdBlue® supply module temperature coefficient. If the DEF/AdBlue® supply module pressure
sensor measurement is equal to or below 0.75 bar (10.88 psi), then this fault will occur. In the case of a defective
DEF/AdBlue® supply module temperature sensor, fixed tolerance limits will be used.
Cause:
The Engine Control Unit (ECU) has determined that the DEF/AdBlue® supply module pressure sensor signal is not
plausible.
1. Faulty dosing module solenoid valve, damaged or restricted.

2. Faulty DEF/AdBlue® supply module pressure sensor, defective or drifted.
Solution:
1. Check for physical damage.
Visually and carefully inspect the dosing module for thermal or other physical damage.
There should be no damage.
A. If damage is found, then replace the dosing module.
B. If no damage is found, then continue with step 2.

2. Check the electrical integrity of the dosing module solenoid coil.
Disconnect the vehicle (VE) harness from the dosing module.
Use a multimeter to measure the resistance of the dosing module solenoid coil :
From To Value
Dosing module pin 1 Dosing module pin 2 there should be 11.4 – 12.6 Ω .
A. If the measured resistance is within specification, then continue with step 3.
B. If the measured resistance is not within specification, then replace the dosing module.
3. As the components internal to the DEF/AdBlue® supply module are not serviceable, replace the module.
A. If the fault has been resolved, then return the vehicle to service.
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17414 (DTC 56B6) - DEF/AdBlue Supply module supply voltage

control relay circuit open
Context:
The Engine Control Unit (ECU) controls the Selective Catalytic Reduction (SCR) relay with a low side driver control
circuit. If the ECU detects an open circuit in the low side driver circuit, then this fault will occur.
Cause:
The ECU has detected an open circuit in the SCR low side driver control circuit.
1. Faulty SCR relay, internal failure.

2. Faulty SCR relay wiring, open circuit.
Solution:
2. Check the SCR relay coil for an internal failure.
Remove the SCR relay.
Use a multimeter to measure the relay coil resistance on the SCR relay pins :
From To Value
SCR relay pin 85 SCR relay pin 86 There should be approximately 70 –
130 Ω.
A. If there is approximately 70 – 130 Ω, then leave the SCR relay disconnected and continue to step 3.
B. If there is not approximately 70 – 130 Ω, then the relay has failed. Replace the SCR relay and retest.
3. Check the SCR relay vehicle harness (VE) wiring for an open circuit.
From To Value
SCR relay connector pin 85 Chassis ground There should be continuity.
With the key in the ON position, use a multimeter to check for voltage on the vehicle harness side :
From To Value
SCR relay connector pin 86 Chassis ground There should be 12.0 V.
A. If there is no continuity in the first check or no voltage in the second check, then there is an open circuit in the
SCR relay control circuit wiring in the vehicle harness (VE). Locate and repair the broken conductor or missing
voltage. Repair or replace the harness as required.
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B. If there is continuity in the first check and voltage in the second check, then check the ECU for the appropriate
software and re-flash, if necessary.
has been resolved.
operation.
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control relay short circuit
Context:
circuit. If the ECU detects a short circuit in the low side driver circuit, then this fault will occur.
Cause:
The ECU has detected a short circuit condition in the SCR low side driver control circuit.

2. Faulty SCR relay, wiring, short circuit.
Solution:
From To Value
SCR relay pin 85 SCR relay pin 86 There should be approximately 70 –
130 Ω.
3. Check the SCR relay vehicle harness (VE) wiring for a short circuit.
From To Value
SCR relay connector pin 85 Chassis ground There should be no voltage.
A. If there is voltage, then there is a short circuit to another voltage source in the circuit wiring in the vehicle
harness (VE). Locate and repair the damaged conductors. Repair or replace the harness as required.
has been resolved.
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operation.
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control relay short circuit to battery
Context:
circuit. If the ECU detects a short circuit to battery in the low side driver circuit, then this fault will occur.
Cause:
The ECU has detected a short circuit to battery in the SCR low side driver control circuit.

2. Faulty SCR relay wiring, short circuit.
Solution:
From To Value
SCR relay coil pin 85 SCR relay coil pin 86 There should be approximately 70 –
130 Ω.
3. Check the SCR relay vehicle harness (VE) wiring for a short circuit to battery.
From To Value
SCR relay coil connector pin 85 Chassis ground There should be no voltage.
With the key in the OFF position, use a multimeter to check for continuity on the vehicle harness side :
From To Value
X-462 pin 20 Other pins in connector X-462. There should be no continuity.
A. If there is voltage or continuity to another pin, then there is a short circuit in the circuit wiring in the vehicle
B. If there is no voltage or continuity, then check the ECU for the appropriate software and re-flash, if necessary.
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has been resolved.
operation.
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control relay short circuit to ground
Context:
circuit. If the ECU detects a short circuit to ground in the low side driver circuit, then this fault will occur.
Cause:
The ECU has detected a short circuit to ground in the SCR low side driver control circuit.
1. Faulty SCR relay wiring, short circuit to ground.

Solution:
2. Check the SCR relay vehicle harness (VE) wiring for a short circuit to ground.
Remove the SCR relay from its socket.
side :
From To Value
SCR relay connector 85 Chassis ground There should be no continuity.
A. If there is continuity, then there is a short circuit to ground in the SCR relay control circuit wiring in the vehicle
harness (VE). Locate and repair the damaged conductor. Repair or replace the harness as required.
has been resolved.
operation.
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17420 (DTC 1BB6) - SRC high for Urea Pump Module Pressure
Sensor
Context:
The Engine Control Unit (ECU) monitors operation of the DEF/AdBlue® supply module pressure sensor analog input
signal. If the ECU detects a signal greater than 4.75 V, then this fault will occur.
Cause:
The ECU has detected a signal greater than 4.75 V in the DEF/AdBlue® supply module pressure sensor input circuit.
1. Faulty DEF/AdBlue® supply module pressure sensor input circuit wiring, short circuit to another voltage.
2. Faulty DEF/AdBlue® supply module, internal failure.
Solution:
2. Check the DEF/AdBlue® supply module pressure sensor input circuit wiring in the vehicle harness (VE) wiring for
a short circuit to battery.
From To Value
connector pin 9
A. If there is voltage, then there is a short circuit to another voltage source in the vehicle harness (VE). Locate
and repair the damaged conductors. Repair or replace the harness as required.
B. If there is no voltage, then continue with step 3.

B. If the fault has not been resolved, then replace the DEF/AdBlue® supply module.
has been resolved.
operation.
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17421 (DTC 2CB6) - SRC low for Urea Pump Module Pressure
Sensor
Context:
The Engine Control Unit (ECU) A-9000 monitors the operation of the DEF/AdBlue® supply module Z-9102 pressure
sensor analog input signal. If the ECU A-9000 detects a signal less than 0.25 V, this fault will occur.
Cause:
The ECU A-9000 has detected a signal less than 0.25 V in the DEF/AdBlue® supply module Z-9102 pressure sensor
input circuit.
1. Faulty DEF/AdBlue® supply module Z-9102 pressure sensor input circuit wiring, shorted to ground.
3. Faulty DEF/AdBlue® supply module Z-9102, internal failure.
Solution:
A. If the fault is present and active, continue with Step 2.
Continue with Step 4.
2. Check the DEF/AdBlue® supply module Z-9102 pressure sensor input circuit wiring in the vehicle harness (VE)
wiring for a short circuit to ground condition.
Disconnect the vehicle harness (VE) from the DEF/AdBlue® supply module Z-9102 at connector X-9108.
From To Value
A. If there is continuity, there is a short to ground condition in the vehicle harness (VE). Use the appropriate service
manual, if necessary, to locate and repair the damaged conductors.
B. If there is no continuity, continue with Step 3.

3. Check the ECU A-9000 for the appropriate software and re-flash, if necessary.
B. If the fault has not been resolved, replace the DEF/AdBlue® supply module Z-9102.
has been resolved.
operation.
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17422 (DTC EA2D) - Timer error of ECU off time counter

Context:
The Engine Control Unit (ECU) monitors the shut off time of the power stage supplier internal to the ECU. If there is
an error detected during this monitoring, this fault will occur.
Solution:
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17427 (DTC 1634) - SRC high for air temperature sensor

Context:
temperature sensor signal circuit voltage is greater than 4.93 V, then this fault will occur. Once this fault occurs, the
intake air temperature value is frozen by the ECU A-9000 at the last valid value for a preliminary failure or jumps to a
fixed replacement value of 29.96 °C (85.93 °F) if the failure is validated.
Cause:
The intake air temperature sensor signal circuit voltage is greater than 4.93 V.
1. Faulty intake air temperature sensor wiring, short circuit to another voltage source.
Solution:
2. Check the intake air temperature sensor wiring for a short circuit to battery.
Disconnect the vehicle harness from the intake air temperature sensor.
(VE) side :
From To Value
Intake air temperature sensor Chassis ground There should be no voltage.
connector pin 1
(VE) side :
From To Value
Intake air temperature sensor Chassis ground There should be less than 5.5 V.
connector pin 1
A. If the specified values are measured, then leave the intake air temperature sensor disconnected and continue
to step 3.
B. If the specified values are not measured, then there is a short circuit to battery in the intake temperature sen-
sor signal circuit in the vehicle harness (VE). Locate and repair the shorted conductor. Repair or replace the
3. Check the intake air temperature sensor wiring for an open circuit.
(VE) side :
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From To Value
Intake air temperature sensor X-461 pin 19 There should be continuity.
connector pin 1
Intake air temperature sensor X-461 pin 20 There should be continuity.
connector pin 2
A. If there is continuity, then leave the intake air temperature sensor disconnected. Leave connector X-461 dis-
connected and continue to step 4.
B. If there is no continuity, then there is an open circuit in the intake temperature sensor signal circuit vehicle
harness (VE) wiring.Locate and repair the broken conductor. Repair or replace the harness as required.
4. Check the intake air temperature sensor wiring for a short circuit.
From To Value
A. If there is continuity, then there is a short circuit to ground in the intake temperature sensor signal circuit vehicle
harness (VE).Locate and repair the shorted conductor. Repair or replace the harness as required.
5. Replace the intake temperature sensor.
has been resolved.
operation.
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17428 (DTC 2734) - SRC low for air temperature sensor

Context:
temperature sensor signal circuit voltage is less than 198.00 mV, then this fault will occur. Once this fault occurs, the
intake air temperature value is frozen by the ECU at the last valid value for a preliminary failure or jumps to a fixed
replacement value of 29.96 °C (85.93 °F) if the failure is validated.
Cause:
The intake air temperature sensor signal circuit voltage is less than 198.00 mV.
1. Faulty intake air temperature sensor wiring, short circuit to ground.

Solution:
2. Check the intake air temperature sensor vehicle harness (VE) wiring for a short circuit.
Disconnect the vehicle harness (VE) from the intake air temperature sensor.
(VE) side :
From To Value
Intake air temperature sensor Intake air temperature sensor There should be no continuity.
Intake air temperature sensor Chassis ground There should be no continuity.
connector pin 1
3. Check the intake air temperature sensor vehicle harness (VE) wiring for a short circuit.
(VE) side :
From To Value
4. Replace the intake temperature sensor.
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has been resolved.
operation.
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17429 (DTC F542) - DFC is set if the cold start is detected

Context:
This fault is for information purposes only and does not require any action. The recognition of a cold start condition is
provided by the turbocharger protection speed limitation module. The Engine Control Unit (ECU) will limit the number
of engine revolutions until the engine oil pressure has reached a calibrated threshold.
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17442 (DTC 1EA4) - Permanent governor deviation for valve

NOTE: Once repaired, this fault may take up to 10 min of operation to reset.
Context:
The Engine Control Unit (ECU) monitors the Throttle Valve Actuator (TVA). The TVA provides the ECU with a feedback
using a position sensor. If the ECU determines that there is a positive deviation between the required and measured
position, then this fault will occur. If this fault is active, the ECU will command the TVA to open and close at a fast
rate in order to attempt to “unblock“ the actuator. This fault is not caused by a wiring failure. It is likely caused by
an obstruction to the throttle valve flap or excessive carbon build up on the throttle valve seat. For more information
regarding TVA inspection, refer to the engine service manual Throttle Valve Actuator (TVA) - Inspect (55.014).
Cause:
The ECU has detected a positive deviation between the required and measured position of the TVA Z-9001. The
desired throttle valve position can not be reached.
1. Faulty throttle valve actuator, sticking or blocked.

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17443 (DTC 2FA4) - Permanent governor deviation for valve

NOTE: Once repaired, this fault may take up to up to 10 min of operation to reset.
Context:
The Engine Control Unit (ECU) monitors the Throttle Valve Actuator (TVA). The TVA provides the ECU with a feedback
using a position sensor. If the ECU determines that there is a negative deviation between the required and measured
position, then this fault will occur. If this fault is active, the ECU will command the TVA to open and close at a fast
rate in order to attempt to “unblock“ the actuator. This fault is not caused by a wiring failure. It is likely caused by an
obstruction to the throttle valve flap or excessive carbon build up on the throttle valve seat.
Cause:
The ECU has detected a negative deviation between the required and measured position of the TVA. The desired
throttle valve position can not be reached. For more information regarding TVA inspection, refer to the engine service
manual Throttle Valve Actuator (TVA) - Inspect (55.014).
1. Faulty throttle valve actuator, sticking or blocked.

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17444 (DTC 3DB4) - Open load error for powerstage

Context:
The Engine Control Unit (ECU) monitors the throttle valve actuator output 1 and output 2 h-bridge circuits. If the ECU
detects an open circuit in the throttle valve actuator output h-bridge circuits, then this fault will occur.
Cause:
The ECU has detected an open circuit in the throttle valve actuator output h-bridge circuits.
1. Faulty throttle valve actuator wiring, open circuit.

Solution:
2. Check the throttle valve actuator h-bridge engine harness (EN) wiring for an open circuit.
Disconnect the throttle valve actuator from the engine harness.
With the key in the OFF position, use a multimeter to check for an open circuit on the engine harness (EN) side :
From To Value
Throttle valve actuator connector pin X-470 pin 37 There should be continuity.
6
Throttle valve actuator connector pin X-470 pin 38 There should be continuity.
2
A. If there is no continuity, there is an open circuit in the throttle valve actuator engine harness (EN) h-bridge
circuit. Locate and repair the broken conductor. Repair or replace the harness as required.
B. If there is continuity, then leave the throttle valve actuator disconnected. Leave connector X-470 disconnected
3. Check the throttle valve actuator h-bridge vehicle harness (VE) wiring for an open circuit.
From To Value
A. If there is no continuity, then there is an open circuit in the throttle valve actuator vehicle harness (VE) h-bridge
circuit. Locate and repair the broken conductor. Repair or replace the harness as required.
B. If there is continuity, then leave the throttle valve actuator disconnected and continue to step 4.
4. Replace the throttle valve actuator.
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has been resolved.
operation.
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17446 (DTC 8FB4) - Over temperature error for H-bridge

Context:
detects an over temperature/current condition in the throttle valve actuator h-bridge circuit, then this fault will occur.
Cause:
The ECU has detected an over temperature/current condition in the throttle valve actuator h-bridge circuit.

2. Faulty throttle valve actuator wiring, short circuit to a high source.
Solution:
2. Check the throttle valve actuator h-bridge wiring for a short circuit to battery.
(EN) side :
From To Value
Throttle valve actuator connector pin Chassis ground There should be no voltage.
6
2
A. If there is voltage, then there is a short circuit to battery in the throttle valve actuator h-bridge circuit. Locate
B. If there is no voltage, then leave the throttle valve actuator disconnected. Leave connector X-462 disconnected
3. Check the throttle valve actuator h-bridge wiring for a short circuit to ground.
With the key in the OFF position, use a multimeter to check for a short circuit to ground on the engine harness
(EN) side :
From To Value
Throttle valve actuator connector pin Chassis ground There should be no continuity.
6
2
A. If there is continuity, then there is a short to ground in the throttle valve actuator h-bridge circuit. Locate and
repair the shorted conductor. Repair or replace the harness as required.
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B. If there is no continuity, then leave the throttle valve actuator disconnected. Leave connector X-462 discon-
4. Check the throttle valve actuator engine harness (EN) wiring for a short circuit.
With the key in the OFF position, use a multimeter to check for a short circuit on the engine harness (EN) side :
From To Value
Throttle valve actuator connector pin Throttle valve actuator connector pin There should be no continuity.
6 2
6 1
2 1
A. If there is continuity, there is a short circuit in the throttle valve actuator engine harness (EN) h-bridge circuit.
B. If there is no continuity, then leave the throttle valve actuator disconnected. Leave connector X-462 and con-
nector X-470 disconnected and continue to step 5.
5. Check the throttle valve actuator vehicle harness (VE) h-bridge circuit for a short circuit.
With the key in the OFF position, use a multimeter to check for a short circuit on the vehicle harness (VE) side :
From To Value
A. If there is continuity, there is a short to high source in the throttle valve actuator vehicle harness (VE) h-bridge
B. If there is no continuity,then leave the throttle valve actuator disconnected and continue to step 6.
has been resolved.
operation.
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17447 (DTC 61E4) - Short circuit to battery on Out1 error for

H-bridge
Context:
detects a short circuit to a high source in the throttle valve actuator output 1 h-bridge circuit, then this fault will occur.
Cause:
The ECU has detected a short circuit to a high source in the throttle valve actuator output 1 h-bridge circuit.
Solution:
2. Check the throttle valve actuator output 1 h-bridge wiring for a short circuit to battery.
(EN) side :
From To Value
6
A. If there is voltage, then there is a short circuit to battery in the throttle valve actuator output 1 h-bridge circuit.Lo-
cate and repair the shorted conductor. Repair or replace the harness as required.
(EN) side :
From To Value
6 1
6 2
6
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A. If there is continuity, then there is a short circuit in the throttle valve actuator output 1 h-bridge circuit. Locate
4. Check the throttle valve actuator vehicle harness (VE) wiring for a short circuit.
(VE) side :
From To Value

has been resolved.
operation.
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17448 (DTC 62E4) - Short circuit to battery on Out2 error for

H-bridge
Context:
The Engine Control Unit (ECU) monitors the throttle valve actuator output 1and output 2 h-bridge circuits. If the ECU
detects a short circuit to a high source in the throttle valve actuator output 2 h-bridge circuit, then this fault will occur.
Cause:
The ECU has detected a short circuit to a high source in the throttle valve actuator output 2 h-bridge circuit.
Solution:
2. Check the throttle valve actuator output 2 h-bridge wiring for a short circuit to battery.
Disconnect the vehicle harmess (VE) from the ECU
(EN) side :
From To Value
2
A. If there is voltage, then there is a short circuit to battery in the throttle valve actuator output 2 h-bridge circuit.
(EN) side :
From To Value
2 6
2 1
X-470 pin 38 All pins in connector X470 There should be no continuity.
A. If there is continuity, the there is a short circuit in the throttle valve actuator output 2 h-bridge circuit. Locate
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4. Check the throttle valve actuator vehicle harness (VE) wiring for a short circuit.
(VE) side :
From To Value

has been resolved.
operation.
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17449 (DTC 73E4) - Short circuit to ground on Out1 error for

H-bridge
Context:
detects a short circuit to ground in the throttle valve actuator output 1 h-bridge circuit, then this fault will occur.
Cause:
The ECU has detected a short circuit to ground in the throttle valve actuator output 1 h-bridge circuit.

Solution:
2. Check the throttle valve actuator output 1 h-bridge engine harness (EN) wiring for a short circuit to ground.
Disconnect the throttle valve actuator.
(EN) side :
From To Value
6
6 2
6 3
A. If there is continuity, then there is a short circuit in the throttle valve actuator output 1 h-bridge circuit. locate
3. Check the throttle valve actuator output 1 h-bridge vehicle harness (VE) wiring for a short circuit.
From To Value
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B. If there is no continuity, then leave the throttle valve actuator disconnected and continue to step 4.
has been resolved.
operation.
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17450 (DTC 74E4) - Short circuit to ground on Out2 error for

H-bridge
Context:
detects a short circuit to ground in the throttle valve actuator output 2 h-bridge circuit, then this fault will occur.
Cause:
The ECU has detected a short to ground condition in the throttle valve actuator output 2 h-bridge circuit.

Solution:
2. Check the throttle valve actuator output 2 h-bridge engine harness (EN) wiring for a short circuit.
(EN) side :
From To Value
2
2 3
2 6
3. Check the throttle valve actuator output 2 h-bridge vehicle harness (VE) wiring for a short circuit.
(VE) side :
From To Value
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has been resolved.
operation.
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17451 (DTC 15E4) - Short circuit over load error for H-bridge
Context:
The Engine Control Unit (ECU) monitors the throttle valve actuator output 1 and output 2 h-bridge circuits. The ECU
monitors both circuits for a short circuit. If the ECU determines that the output 1 circuit and output 2 circuits are shorted
together, then this fault will occur.
Cause:
The ECU has detected a short circuit between the throttle valve actuator output 1 and output 2 h-bridge circuits.
1. Faulty throttle valve actuator h-bridge wiring short circuit.

Solution:
2. Check the throttle valve actuator h-bridge circuits engine harness (EN) wiring for a short circuit.
(EN) side :
From To Value
2 6
A. If there is continuity, then there is a short circuit in the throttle valve actuator h-bridge wiring. Locate and repair
B. If there is no continuity, then leave the connectors disconnected and continue to step 3.
3. Check the throttle valve actuator h-bridge circuits vehicle harness (VE) wiring for a short circuit.
(VE) side :
From To Value
A. If there is continuity, then there is a short circuit in the throttle valve actuator h-bridge wiring. Locate and repair
B. If there is no continuity, then leave the connectors disconnected and continue to step 4.
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has been resolved.
operation.
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17453 (DTC 27E4) - Under voltage error for H-bridge

Context:
circuit for the Throttle Valve Actuator (TVA) motor actuator for electrical defects. If the ECU senses too low an output
driver supply voltage, then this fault will occur.
Cause:
The ECU is sensing too high a system voltage fluctuation.
Solution:
2. Check for related faults.
Use the EST to check for faults relative to low battery, control system voltage level or throttle valve actuator.
A. If low voltage level faults are present, then resolve those faults and then return to this fault.
B. If no low voltage level faults are present, then continue with step 3.
or broken wires. Verify that the connectors are fully installed.
has been resolved.
operation.
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17465 (DTC 5DB6) - Open Load error in powerstage of Urea dosing

valve actuator
Context:
The Engine Control Unit (ECU) controls the operation of the Diesel Exhaust Fluid (DEF)/AdBlue® dosing module
solenoid with both a high side and low side driver control circuit. The ECU monitors each of the drivers separately. If
the ECU detects an open circuit in the low side driver circuit, then this fault will occur.
Cause:
The ECU has detected an open circuit in the DEF/AdBlue® dosing module low side driver control circuit.
1. Faulty DEF/AdBlue® dosing module, internal failure.

2. Faulty DEF/AdBlue® dosing module low side driver circuit wiring, open circuit.
Solution:
2. Check the DEF/AdBlue® dosing module solenoid coil for an internal failure.
Disconnect the vehicle harness (VE) from the DEF/AdBlue® dosing module.
Use a multimeter to measure the solenoid coil resistance on the DEF/AdBlue® dosing module Y-9103 pins :
From To Value
DEF/AdBlue® dosing module pin 1 DEF/AdBlue® dosing module pin 2 There should be approximately 10 –
15 Ω.
A. If there is approximately 10 – 15 Ω, then leave the DEF/AdBlue® dosing module disconnected and continue
to step 3.
B. If there is not approximately 10 – 15 Ω, then the DEF/AdBlue® dosing module has failed. Replace the DEF/
AdBlue® dosing module.
3. Check the DEF/AdBlue® dosing module vehicle harness (VE) low side driver circuit wiring for an open circuit.
From To Value
DEF/AdBlue® dosing module Chassis ground There should be continuity.
connector pin 1
A. If there is no continuity, then there is an open circuit condition in the DEF/AdBlue® dosing module low side
driver control circuit wiring in the vehicle harness (VE). Locate and repair the broken conductor. Repair or
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has been resolved.
operation.
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17466 (DTC 6EB6) - Short circuit to battery error in powerstage

of Urea dosing valve actuator
Context:
the ECU detects a short circuit to another voltage source in the low side driver circuit, then this fault will occur.
Cause:
The ECU has detected a short circuit to battery in the DEF/AdBlue® dosing module low side driver control circuit.

2. Faulty DEF/AdBlue® dosing module low side driver control circuit wiring, shorted to a voltage source.
Solution:
2. Check the DEF/AdBlue® dosing module for an internal failure.
Use a multimeter to measure the solenoid coil resistance on the DEF/AdBlue® dosing module pins :
From To Value
15 Ω.
to step 3.
3. Check the DEF/AdBlue® dosing module low side driver control circuit vehicle harness (VE) wiring for a short circuit
to battery.
From To Value
From To Value
X-462 pin 3 All other pins in connector X-462. There should be no continuity.
A. If there is voltage or continuity to another pin, then there is a short circuit in the circuit wiring in the vehicle
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B. If there is no voltage or continuity, then check the ECU for the appropriate software and re-flash, if necessary.
has been resolved.
operation.
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17467 (DTC 6FB6) - Short circuit to battery error in highside

powerstage of Urea dosing valve actuator
Context:
the ECU detects that no current is flowing in the high side driver control circuit and there is no low side driver open
circuit failure, then the ECU assumes a short circuit to another voltage source or an open circuit exists in the high side
driver circuit and this fault will occur.
Cause:
The ECU has detected a short circuit to battery or open circuit in the DEF/AdBlue® dosing module high side driver
control circuit.

2. Faulty DEF/AdBlue® dosing module high side driver control circuit wiring, shorted to another voltage source or
open circuit.
Solution:
Use a multimeter to measure the solenoid coil resistance on the DEF/AdBlue® dosing module pins :
From To Value
15 Ω.
to step 3.
3. Check the DEF/AdBlue® dosing module high side driver control circuit vehicle harness (VE) wiring for a short
circuit.
From To Value
DEF/AdBlue® dosing module Chassis ground There should be no voltage.
connector pin 2
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From To Value
X-462 pin 18 All other pins in connector X-462 There should be no continuity.
With the key in the OFF position, use a multimeter to check for continuity on the vehicle harness (VE) side :
From To Value
DEF/AdBlue® dosing module Chassis ground There should be continuity.
connector pin 2
A. If voltage is measured on the first check or there is continuity to another pin on the second check or there is no
continuity on the last check, then there is a problem in the high side driver control circuit wiring in the vehicle
harness (VE). Locate and repair the damaged conductors or broken conductor. Repair or replace the harness
as required.
B. If no voltage is measured on the first check and there is no continuity to another pin on the second check and
there is continuity on the last check, then check the ECU for the appropriate software and re-flash, if necessary.
has been resolved.
operation.
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17468 (DTC 71C6) - Short circuit to ground error in lowside

Context:
the ECU detects a short circuit to ground in the low side driver circuit, then this fault will occur.
Cause:
The ECU has detected a short circuit to ground in the DEF/AdBlue® dosing module low side driver control circuit.

2. Faulty DEF/AdBlue® dosing module low side driver control circuit wiring, short circuit to ground.
Solution:
Use a multimeter to check for continuity to ground in the solenoid coil in the DEF/AdBlue® dosing module pins :
From To Value
DEF/AdBlue® dosing module pin 1 Chassis ground There should be no continuity.
A. If there is no continuity, then leave the DEF/AdBlue® dosing module disconnected and continue to step 3.
B. If there is continuity, then the DEF/AdBlue® dosing module has failed. Replace the DEF/AdBlue® dosing
module.
3. Check the DEF/AdBlue® dosing module low side driver control circuit vehicle harness (VE) wiring for a short circuit.
From To Value
A. If there is continuity on either or both checks, then there is a short circuit in the vehicle harness (VE). Locate
and repair the grounded conductor or conductors.
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has been resolved.
operation.
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17469 (DTC 72C6) - Short circuit to ground error in highside

Context:
the ECU detects a short circuit to ground in the high side driver circuit, then this fault will occur.
Cause:
The ECU has detected a short circuit to ground in the DEF/AdBlue® dosing module high side driver control circuit.

2. Faulty DEF/AdBlue® dosing module high side driver control circuit wiring, short circuit to ground.
Solution:
Use a multimeter to check for a short circuit to ground in the solenoid coil in the DEF/AdBlue® dosing module pins
:
From To Value
DEF/AdBlue® dosing module pin 2 Chassis ground There should be no continuity.
A. If there is no continuity, then leave the DEF/AdBlue® dosing module disconnected and continue to step 3.
B. If there is continuity, then the DEF/AdBlue® dosing module has failed. Replace the DEF/AdBlue® dosing
module.
3. Check the DEF/AdBlue® dosing module low side driver control circuit vehicle harness (VE) wiring for a short circuit.
From To Value
and repair the grounded conductor or conductors.
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has been resolved.
operation.
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17470 (DTC E3C6) - FET error

Context:
The Engine Control Unit (ECU) monitors the power stage of the DEF/AdBlue® pressure line heater. If the ECU detects
a FET error of the power stage, then this fault will occur.
Cause:
The ECU has detected an error in the DEF/AdBlue® pressure line heater power stage.
1. Faulty Heater Control Unit (HCU), internal failure.

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17476 (DTC 49C6) - Diagnostic Fault Check for Supply Module

temperature Duty cycle in failure range
NOTE: If this fault is sporadic and the DEF/AdBlue® supply module pump motor is delivering, then probably no action
is needed.
Context:
The Engine Control Unit (ECU) requests a data package containing the two pieces of temperature information, the
current pump motor speed and the internal pump motor Pulse Width Modulation (PWM) signal from the Diesel Exhaust
Fluid (DEF)/AdBlue® supply module. For this purpose, the ECU sends the data request signal with a specific duty
cycle. If there's a transmission error, then this fault occurs. After sending the data request signal the ECU waits
a specific fixed time period (set speed freeze) after which the ECU automatically restarts the transmission of the
set (commanded) speed. This procedure of the automatic set speed restart by the ECU ensures the uninterrupted
pressure control even in the case that the pump motor has missed the data request signal due to disturbances on
the signal line and thereby remaining at the speed according to the last valid set speed occurring before the data
request signal. The data acquisition circuit is a parallel configuration with the ECU PWM low side driver control circuit
(command signal) for the DEF/AdBlue® supply module pump motor.
Cause:
The ECU requested data package from the DEF/AdBlue® supply module was not received or was interrupted.
1. Faulty DEF/AdBlue® supply module data acquisition circuit wiring, open circuit or a short circuit.
Solution:
2. Check the vehicle harness (VE) data acquisition circuit wiring.
From To Value
connector pin 2
From To Value
DEF/AdBlue® supply module Chassis ground There should be no continuity.
connector pin 2
A. If there is voltage in the first check or continuity in the second check, then leave the DEF/AdBlue® supply
module disconnected and continue with step 3.
B. If there is no voltage in the first check and no continuity in the second check, then leave the DEF/AdBlue®
supply module disconnected and continue with step 4.
3. Locate the short circuit.
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From To Value
connector pin 2
From To Value
connector pin 2
A. If there is voltage in the first check or continuity in the second check, then there is a short circuit in the vehicle
harness (VE) circuit wiring. Locate and repair the damaged conductors or grounded conductor. Repair or
B. If there is no voltage in the first check and no continuity in the second check, then the ECU has failed internally.
Replace the ECU.
4. Check the vehicle harness (VE) data acquisition circuit wiring for an open circuit or a short circuit.
Place a jumper wire between the vehicle harness (VE) side of connector X-461 pin 76 and chassis ground.
From To Value
DEF/AdBlue® supply module Chassis ground There should be continuity.
connector pin 2
Remove the jumper wire from the vehicle harness (VE) side of connector X-461 pin 76 and chassis ground.
From To Value
X-461 pin 76 All other pins on connector X-461 There should be no continuity.
A. If there is no continuity in the first check or there is continuity in the second check, then there is a problem
in the vehicle harness (VE) data acquisition circuit wiring. Locate and repair the broken conductor or shorted
conductors. Repair or replace the harness as required.
B. If there is continuity in the first check and no continuity in the second check, then continue with step 5.
5. As there is no method of field testing or re-flashing the DEF/AdBlue® supply module, replace the DEF/AdBlue®
supply module.
has been resolved.
operation.
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17477 (DTC 1AC6) - Diagnostic Fault Check for Supply Module

Context:
The Engine Control Unit (ECU) evaluates the data value of a received Pulse Width Modulated (PWM) duty cycle,
transmitted by the Diesel Exhaust Fluid (DEF)/AdBlue® supply module, by measuring the current time between the
falling edges of each PWM period and also measuring the current off-time, which represents the transmitted duty
cycle, of that corresponding PWM period. Based on these two measured time data of a PWM period the ECU, the
receiver of the PWM signal, is able to calculate the current duty cycle of the PWM period independent of the timing
accuracy of the DEF/AdBlue® supply module, the sender of the PWM signal. The right value is in the range of 5 –
85% corresponding to a physical value of 0 – 100%. If the DEF/AdBlue® supply module transmitted internal pump
duty cycle to the ECU is higher than expected, this fault will occur.
Cause:
The DEF/AdBlue® supply module raw duty cycle value being sent to the ECU is greater than 86%.
1. Faulty DEF/AdBlue® supply module data acquisition circuit wiring, an open circuit or a short circuit.
Solution:
Disconnect the vehicle harness (VE) from the DEF/AdBlue® supply module at connector X-605.
From To Value
From To Value
A. If there is voltage in the first check or continuity in the second check, then leave connector X-605 disconnected
and continue with step 3.
B. If there is no voltage in the first check and no continuity in the second check, then leave connector X-605
3. Locate the short circuit to another voltage source or the short circuit to ground.
From To Value
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From To Value
A. If there is voltage in the first check or continuity in the second check, then there is a short circuit to another
voltage source or a short circuit to ground in the vehicle harness (VE) circuit wiring. Locate and repair the
damaged conductors or grounded conductor. Repair or replace the harness as required.
Replace the ECU.
From To Value
From To Value
A. If there is no continuity in the first check or there is continuity in the second check, then there is an open circuit or
short circuit in the vehicle harness (VE) data acquisition circuit wiring. Locate and repair the broken conductor
or shorted conductors. Repair or replace the harness as required.
supply module.
has been resolved.
operation.
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17478 (DTC 2BC6) - Diagnostic Fault Check for Supply Module

Context:
85% corresponding to a physical value of 0 – 100%. If the DEF/AdBlue® supply module transmitted internal pump
duty cycle to the ECU is lower than expected, this fault will occur.
Cause:
The DEF/AdBlue® supply module raw duty cycle value being sent to the ECU is less than 4%.
Solution:
From To Value
From To Value
3. Locate the short circuit to another voltage source or the short circuit ground.
From To Value
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From To Value
A. If there is voltage in the first check or continuity in the second check, then there is a short circuit in the vehicle
harness (VE) circuit wiring. Locate and repair the damaged conductors or grounded conductor. Repair or
Replace the ECU.
4. Check the vehicle harness (VE) data acquisition circuit wiring for an open circuit or short circuit.
From To Value
From To Value
A. If there is no continuity in the first check or there is continuity in the second check, there is an open circuit or a
short circuit in the vehicle harness (VE) data acquisition circuit wiring. Locate and repair the broken conductor
or shorted conductors. Repair or replace the harness as required.
supply module.
has been resolved.
operation.
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17479 (DTC 1CC6) - Diagnostic Fault Check for Supply Module

Context:
85% corresponding to a physical value of -40 – 90 °C (-40 – 194 °F). If the DEF/AdBlue® supply module transmitted
internal pump duty cycle to the ECU is higher than expected, then this fault will occur.
Cause:
Solution:
From To Value
From To Value
B. If there is no voltage in the first check and no continuity in the second check, leave connector X-9108 discon-
nected and continue with step 4.
From To Value
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From To Value
B. If there is no voltage in the first check and no continuity in the second check, the ECU has failed internally.
Replace the ECU.
4. Check the vehicle harness (VE) data acquisition circuit wiring for an open circuit or short circuit condition.
From To Value
From To Value
A. If there is no continuity in the first check or there is continuity in the second check, then there is an open circuit
or short circuit to another circuit in the vehicle harness (VE) data acquisition circuit wiring. Locate and repair
the broken conductor or shorted conductors. Repair or replace the harness as required.
supply module.
has been resolved.
operation.
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17480 (DTC 2DC6) - Diagnostic Fault Check for Supply Module

Context:
internal pump duty cycle to the ECU is lower than expected, then this fault will occur.
Cause:
1. Faulty DEF/AdBlue® supply module data acquisition circuit wiring, an open circuit, a short circuit to ground, or
short circuit to another voltage source.
Solution:
Disconnect the vehicle harness (VE) from the DEF/AdBlue® supply module at connector X-605
From To Value
From To Value
From To Value
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From To Value
Replace the ECU.
From To Value
From To Value
A. If there is no continuity in the first check or there is continuity in the second check, then there is an open
circuit or a short circuit in the vehicle harness (VE) data acquisition circuit wiring. Locate and repair the broken
conductor or shorted conductors. Repair or replace the harness as required.
supply module.
has been resolved.
operation.
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17481 (DTC 1EC6) - Diagnostic Fault Check for Supply Module

Context:
accuracy of the DEF/AdBlue® supply module, the sender of the PWM signal. The right value is in the range of 5
– 85% corresponding to a physical value of 0 – 3500 RPM. If the DEF/AdBlue® supply module transmitted internal
pump duty cycle to the ECU is higher than expected, then this fault will occur.
Cause:
Solution:
From To Value
From To Value
From To Value
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From To Value
Replace the ECU.
From To Value
From To Value
X-461 pin 76 All other pins on connector X-461. There should be no continuity.
A. If there is no continuity in the first check or there is continuity in the second check, there is an open circuit or
short to another circuit condition in the vehicle harness (VE) data acquisition circuit wiring. Use the appropriate
service manual, if necessary, to locate and repair the broken conductor or shorted conductors.
B. If there is continuity in the first check and no continuity in the second check, continue with step 5.
supply module.
has been resolved.
operation.
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17482 (DTC 2FC6) - Diagnostic Fault Check for Supply Module

Context:
accuracy of the DEF/AdBlue® supply module, the sender of the PWM signal. The right value is in the range of 5
– 85% corresponding to a physical value of 0 – 3500 RPM. If the DEF/AdBlue® supply module transmitted internal
pump duty cycle to the ECU is lower than expected, this fault will occur.
Cause:
Solution:
From To Value
From To Value
From To Value
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From To Value
Replace the ECU.
From To Value
From To Value
X-461 pin 76 All other pins on connector There should be no continuity.
or a short circuit to another circuit in the vehicle harness (VE) data acquisition circuit wiring. Locate and repair
supply module.
has been resolved.
operation.
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17483 (DTC 11D6) - Diagnostic Fault Check for Supply Module

Context:
internal pump duty cycle to the ECU is higher than expected, this fault will occur.
Cause:
1. Faulty DEF/AdBlue® supply module data acquisition circuit wiring, an open circuit, a short circuit to ground, or a
Solution:
From To Value
From To Value
From To Value
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From To Value
Replace the ECU.
From To Value
From To Value
or a short circuit to another circuit in the vehicle harness (VE) data acquisition circuit wiring. Locate and repair
supply module.
has been resolved.
operation.
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17484 (DTC 22D6) - Diagnostic Fault Check for Supply Module

Context:
internal pump duty cycle to the ECU is lower than expected, this fault will occur.
Cause:
Solution:
From To Value
From To Value
From To Value
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From To Value
Replace the ECU.
From To Value
From To Value
A. If there is no continuity in the first check or there is continuity in the second check, then there is an open
circuit or a short circuit in the vehicle harness (VE) data acquisition circuit wiring. Locate and repair the broken
conductor or shorted conductors. Repair or replace the harness as required.
supply module.
has been resolved.
operation.
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17485 (DTC 53D6) - No load error on low powerstage for Urea back
flow pump
Context:
The Engine Control Unit (ECU) monitors the DEF/AdBlue® back-flow pump circuit. If the ECU detects an open circuit
in the DEF/AdBlue® back-flow pump circuit, then this fault will occur.
Cause:
The ECU has detected an open circuit in the DEF/AdBlue® back-flow pump circuit.
1. Faulty DEF/AdBlue® back-flow pump circuit, open circuit.

2. Faulty DEF/AdBlue® back-flow pump, internal failure.
Solution:
2. Check the DEF/AdBlue® back-flow pump circuit for an open circuit.
(VE) side :
From To Value
DEF/AdBlue® supply module X-462 pin 45. There should be no continuity.
connector pin 6
A. If there is no continuity, then there is an open circuit in the DEF/AdBlue® back-flow pump circuit. Locate and
repair the broken conductor. Repair or replace the harness as required.
has been resolved.
operation.
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17486 (DTC 84D6) - Over temperature error on low powerstage for

Urea back flow pump
Context:
The Engine Control Unit (ECU) monitors the DEF/AdBlue® back-flow pump circuit. If the ECU detects a short circuit
to another voltage source in the DEF/AdBlue® back-flow pump circuit, then this fault will occur.
Cause:
The ECU has detected a short circuit to another voltage source in the DEF/AdBlue® back-flow pump circuit.
1. Faulty DEF/AdBlue® back-flow pump circuit, short circuit to another voltage source.
Solution:
2. Check the DEF/AdBlue® back-flow pump circuit for a short circuit to another voltage source.
(VE) side :
From To Value
connector pin 6
A. If there is voltage, then there is a short circuit to battery power in the DEF/AdBlue® back-flow pump circuit.
B. If there is no continuity, then leave the DEF/AdBlue® supply module disconnected and continue to step 3.
(VE) side :
From To Value
connector pin 6
A. If there is voltage, then there is a short circuit in the DEF/AdBlue® back-flow pump circuit. Locate and repair
4. Check the DEF/AdBlue® back-flow pump circuit for a short circuit.
(VE) side :
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From To Value
DEF/AdBlue® supply module All pins in the DEF/AdBlue® supply There should be no continuity.
connector pin 6 module connector
A. If there is continuity, then there is a short circuit in the DEF/AdBlue® back-flow pump circuit. Locate and repair
has been resolved.
operation.
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17487 (DTC 65D6) - Short circuit to battery error on low powerstage

for Urea back flow pump
Context:
to another voltage source in the DEF/AdBlue® back-flow pump circuit, then this fault will occur.
Cause:
The ECU has detected a short circuit to another voltage source in the DEF/AdBlue® back-flow pump circuit.
1. Faulty DEF/AdBlue® back-flow pump circuit, short circuit to another voltage source.
Solution:
(VE) side :
From To Value
connector pin 6
A. If there is voltage, then there is a short circuit to battery power in the DEF/AdBlue® back-flow pump circuit.
(VE) side :
From To Value
connector pin 6
A. If there is voltage, then there is a short circuit in the DEF/AdBlue® back-flow pump circuit. Locate and repair
4. Check the DEF/AdBlue® back-flow pump circuit for a short circuit.
(VE) side :
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From To Value
has been resolved.
operation.
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17488 (DTC 76D6) - Short circuit to ground error on low powerstage

for Urea back flow pump
Context:
to ground in the DEF/AdBlue® back-flow pump circuit, then this fault will occur.
Cause:
The ECU has detected a short circuit to ground in the DEF/AdBlue® back-flow pump circuit.
1. Faulty DEF/AdBlue® back-flow pump circuit, short circuit to ground.

Solution:
2. Check the DEF/AdBlue® back-flow pump circuit for a short to ground condition.
(VE) side :
From To Value
connector pin 6
has been resolved.
operation.
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17494 (DTC 624E) - Short circuit to Battery (reported via CAN frame
ComRx_CRI1)
Context:
For information regarding the functional operation of the DEF/AdBlue® urea quality sensor, refer to the engine service
manual Diesel Exhaust Fluid (DEF)/AdBlue®/ARLA quality sensor - Overview (55.988). The DEF/AdBlue® urea
quality sensor has internal monitoring for operating conditions and reports status along with sensed data to the Engine
Control Unit (ECU). If the sensor determines that an internal failure such as a short circuit to source voltage exists,
Cause:
The DEF/AdBlue® urea quality sensor has reported to the ECU that a short circuit to source voltage exists internally
in the quality sensing circuitry.
1. Faulty DEF/AdBlue® urea quality sensor hardware or firmware.

Solution:
1. As there is no method for field testing, replace the DEF/AdBlue® urea quality sensor.
A. If the fault is resolved, then use EST, refer to the engine service manual Selective Catalytic Reduction (SCR)
exhaust treatment - Configure - Engine restart counter reset (10.500), if necessary, to perform the Engine
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17495 (DTC 734E) - Short circuit to Ground (reported via CAN

Frame ComRx_CRI1)
Context:
Control Unit (ECU). If the sensor determines that an internal failure such as a short circuit to ground exists, then this
fault will occur.
Cause:
The DEF/AdBlue® urea quality sensor has reported to the ECU that a short circuit to ground exists internally in the
quality sensing circuitry.

Solution:
A. If the fault is resolved, use EST, refer to the engine service manual Selective Catalytic Reduction (SCR)
exhaust treatment - Configure - Engine restart counter reset (10.500), if necessary, to perform the Engine
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17498 (DTC 464E) - Sensor internal fault (via CAN Frame

ComRx_CRI1)
Context:
Control Unit (ECU). If an internal sensor system error is detected, then this fault will occur.
Cause:
The DEF/AdBlue® urea quality sensor has reported to the ECU that it has an internal sensor system error.

Solution:
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17500 (DTC 684E) - Short to Battery of the temperature sensor

located in the Urea Quality sensor (reported via CAN Frame
ComRx_CRI1)
Context:
Control Unit (ECU). If an internal sensor failure, temperature sensing circuitry short circuit to battery is detected, then
Cause:
The DEF/AdBlue® urea quality sensor has reported to the ECU that it has an internal sensor failure.

Solution:
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17501 (DTC 794E) - Short to Ground of the temperature sensor

located in the Urea Quality sensor (reported via CAN Frame
ComRx_CRI1)
Context:
Control Unit (ECU). If an internal sensor failure, temperature sensing circuitry short to ground, is detected, this fault
will occur.
Cause:
The DEF/AdBlue® urea quality sensor has reported to the ECU that it has an internal sensor failure.

Solution:
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17504 (DTC 4C4E) - Signal fault of the temperature sensor located

in the Urea Quality sensor (reported via CAN Frame ComRx_CRI1)
Context:
Control Unit (ECU). If an internal sensor system error is detected, this fault will occur.
Cause:
The DEF/AdBlue® urea quality sensor has reported to the ECU that it has an internal sensor system error.

Solution:
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17524 (DTC 31E9) - Hydrocarbon level 1 exceeded

Context:
This fault indicates a warning for component protection caused from excessive Hydrocarbon (HC) levels that have
accumulated in the exhaust system. This fault indicates a level 1 failure, caused by at least 6500 mg of liquid HC
in the exhaust system. To clear this fault, see Selective Catalytic Reduction (SCR) exhaust treatment - Service
instruction - Hydrocarbon (HC) accumulation (10.500).
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17525 (DTC 3E27) - EGR OBD Monitoring error

Context:
The Engine Control Unit (ECU) performs a system check of the Exhaust Gas Recirculation (EGR) valve by performing
a fast sweep of the valve while slightly closing the Throttle Valve Actuator (TVA). The ECU then evaluates the impact
on intake pressure. If a minimum intake pressure of 0.01 bar (0.14 psi) is not detected, then this fault will occur.
1. Faulty EGR Valve, stuck.

2. Faulty EGR Valve cooler/path, clogged.
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19001 (DTC 1361) - Battery voltage is higher than expected

Context:
The Electronic Control Unit (ECU) monitors battery voltage. If the ECU determines that battery voltage has exceeded
35.7 V, then this fault will occur.
Cause:
Battery voltage is greater than 35.7 V.

Solution:
The engine must be running.
From To Value
Battery (+) terminal Battery (–) terminal There should be approximately 12 V
A. If there is not approximately 12 V, then continue to step 3.
B. If there is approximately 12 V, then check the ECU for the appropriate software and re-flash, if necessary.
B. If the charging system is functioning properly, then check the ECU for the appropriate software and re-flash, if
necessary.
has been resolved.
operation.
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19002 (DTC 2461) - Battery voltage is lower than expected

Context:
The Electronic Control Unit (ECU) monitors battery voltage. If the ECU determines that battery is less than 5.4 V,
Cause:
Battery voltage is less than 5.4 V.
1. Faulty Battery.
2. Faulty ECU supply wiring.
Solution:
Use a multimeter to perform the following voltage check:
From To Value
A. If there is not approximately 12 V, then charge the battery and then perform load test on the battery. If the
battery passes the load test, then continue to step 3. If the battery fails the load test, then continue to step 4.
B. If there is approximately 12 V, continue to step 3.

B. If the charging system is functioning properly, then continue to step 5.

4. Replace the battery.
A. If the fault has been resolved, then 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.
has been resolved.
operation.
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19008 (DTC E7DE) - NH3 sensor open or short in ground circuit

Context:
The NH3 Control Unit is required to report information at regular intervals to the Engine Control Unit (ECU) via Con-
troller Area Network (CAN). If the NH3 Control Unit senses no current on the NH3 sensor signal ground line, then this
fault will occur. For information regarding the functional operation of the NH3 sensor and the NH3 Control Unit, refer
to the engine service manual Ammonia (NH3) sensor - Dynamic description (55.988).
Cause:
The NH3 Control Unit has reported a short circuit to ground or an open circuit error via CAN to the ECU.
1. Faulty NH3 sensor or wiring, an open circuit or a short circuit or ground.

2. Faulty NH3 Control Unit, hardware or firmware.
Solution:
2. As there is no method for field testing the temperature sensing portion of the sensor and it is not recommended to
perform repairs to the sensor wiring between the NH3 sensor and the NH3 Control Unit, replace the NH3 sensor.
B. If the fault is not resolved, then continue with step 3.

3. As there is no method of field testing or re-flashing the NH3 Control Unit, replace the controller.
has been resolved.
operation.
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19009 (DTC 18DE) - NH3 sensor short in heater circuit causing

overheating
Context:
troller Area Network (CAN). If a sensor over heating condition exists, then this fault will occur. This fault is considered
a second failure fault because it requires two different failures to activate. The heater + (positive) and the heater -
(negative) control circuits are shorted to a voltage source and ground, respectively. For information regarding the
functional operation of the NH3 sensor and/or NH3 Control Unit, refer to the engine service manual Ammonia (NH3)
sensor - Dynamic description (55.988).
Cause:
The NH3 Control Unit has reported a short circuit to another voltage source in the Heater + (positive) and a short to
ground in the Heater - (negative) control circuits to the ECU.
1. Faulty NH3 sensor and/or NH3 sensor to NH3 Control Unit wiring, heater positive signal short circuit to another
voltage source and the negative signal has a short circuit to ground.
Solution:
Disconnect the NH3 Control Unit to NH3 sensor harness (cable) from the NH3 Control Unit.
Use a multimeter to measure the resistance and check for continuity on the harness (cable) side :
From To Value
NH3 Control Unit connector pin 1 NH3 Control Unit connector pin 5 There should be between 2.8 –
4.0 Ω.
NH3 Control Unit connector pin 1 All other pins in the NH3 Control Unit There should be no continuity
connector
NH3 Control Unit connector pin 5 All other pins in the NH3 Control Unit There should be no continuity
connector
A. If the measured resistance is within the specified range and the harness (cable) wiring is not shorted, then
continue with step .3.
B. If the measured resistance is not within the specified range or the harness (cable) wiring is shorted, then replace
the NH3 sensor.
3. As there is no method for field testing or re-flashing the sensor controller and the only battery level voltage available
in the NH3 Control Unit to NH3 sensor harness (cable) is the NH3 sensor heater + (positive) circuit wiring, replace
the NH3 Control Unit and check to see that the fault is resolved.
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has been resolved.
operation.
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19010 (DTC 161A) - Downstream SCR catalyst temperature sensor

Context:
The Engine Control Unit (ECU) monitors the Selective Catalytic Reduction (SCR) downstream temperature sensor.
If the ECU detects a voltage greater than 3.59 V in the SCR downstream temperature sensor signal circuit, then this
fault will occur. For more information regarding the technical specifications of the SCR downstream temperature sen-
sor, refer to the engine service manual Exhaust Gas Recirculation (EGR) temperature sensors Diesel Oxidation
Catalyst (DOC) inlet temperature sensor - Technical Data (55.989).
Cause:
The ECU has detected a voltage greater than 3.59 V in the SCR downstream temperature sensor signal circuit.
1. Faulty SCR downstream temperature sensor wiring, short circuit to another voltage source.
2. Faulty SCR downstream temperature sensor wiring, open circuit.
3. Faulty SCR downstream temperature sensor, internal failure.
Solution:
2. Check the SCR downstream temperature sensor for an internal failure.
Disconnect the vehicle harness (VE) from the SCR downstream temperature sensor.
Use a multimeter to measure the resistance on the SCR downstream temperature sensor :
From To Value
SCR downstream temperature SCR downstream temperature There should be between 170.2 –
sensor pin 1 sensor pin 2 849.7 Ω.
A. If there is between 170.2 – 849.7 Ω, then leave the SCR downstream temperature sensor disconnected and
continue to step 3.
B. If there is not between 170.2 – 849.7 Ω, then the SCR downstream temperature sensor has failed. Replace
the SCR downstream temperature sensor.
3. Check the SCR downstream temperature sensor vehicle harness (VE) wiring for a short circuit.
side :
From To Value
SCR downstream temperature Chassis ground There should be no voltage.
A. If there is voltage, then there is a short circuit to battery in the SCR downstream temperature sensor wiring.
B. If there is no voltage, then leave the SCR downstream temperature sensor disconnected and continue to step
4.
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4. Check the SCR downstream temperature sensor vehicle harness (VE) wiring for an open circuit.
(VE) side :
From To Value
SCR downstream temperature X-461 pin 80 There should be continuity.
SCR downstream temperature X-461 pin 79 There should be continuity.
A. If there is no continuity, then there is an open circuit in the SCR downstream temperature sensor vehicle har-
ness (VE) wiring.Locate and repair the broken conductor. Repair or replace the harness as required.
B. If there is continuity, then leave connector X-461 disconnected and continue to step 5.
(VE) side :
From To Value
A. If there is continuity, then there is a short circuit in the SCR downstream temperature sensor vehicle harness
(VE) wiring.Locate and repair the shorted conductor. Repair or replace the harness as required.
has been resolved.
operation.
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19011 (DTC 271A) - Downstream SCR catalyst temperature sensor

Context:
The Engine Control Unit (ECU) monitors the Selective Catalytic Reduction (SCR) downstream temperature sensor. If
the ECU detects a voltage less than 200.00 mV in the SCR downstream temperature sensor signal circuit, then this
fault will occur. For more information regarding the technical specifications of the SCR downstream temperature sen-
sor, refer to the engine service manual Exhaust Gas Recirculation (EGR) temperature sensors Diesel Oxidation
Catalyst (DOC) inlet temperature sensor - Technical Data (55.989).
Cause:
The ECU has detected a voltage less than 200.00 mV in the SCR downstream temperature sensor signal circuit.
1. Faulty SCR downstream temperature sensor wiring, short circuit to ground.

2. Faulty SCR downstream temperature sensor, internal failure.
Solution:
2. Check the SCR downstream temperature sensor for an internal failure.
Disconnect the vehicle harness (VE) from the SCR downstream temperature sensor.
Use a multimeter to measure the resistance on the SCR downstream temperature sensor pins :
From To Value
SCR downstream temperature SCR downstream temperature There should be between 170.2 –
A. If there is between 170.2 – 849.7 Ω, then leave the SCR downstream temperature sensor disconnected and
continue to step 3.
B. If there is not between 170.2 – 849.7 Ω, then the SCR downstream temperature sensor has failed. Replace
the SCR downstream temperature sensor.
(VE) side :
From To Value
SCR downstream temperature SCR downstream temperature There should be no continuity.
SCR downstream temperature Chassis ground There should be no continuity.
A. If there is continuity, then there is a short circuit to ground in the SCR downstream temperature sensor wiring.
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has been resolved.
operation.
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19012 (DTC E9DE) - NH3 sensor open in heater circuit causing

underheating
Context:
troller Area Network (CAN). If a sensor under heating condition exists, then this fault will occur. For information
regarding the functional operation of the NH3 sensor and the NH3 Control Unit, refer to the engine service manual
Ammonia (NH3) sensor - Dynamic description (55.988).
Cause:
The NH3 Control Unit has reported, via CAN, to the ECU that an open circuit in either control circuit or a short circuit to
ground or a short circuit to another voltage source exists in the heater - (negative) or in the heater + (positive) control
circuit, respectively.
1. Faulty NH3 sensor, an open circuit or a short circuit.

2. Faulty NH3 sensor control circuit, damaged wiring.
Solution:
2. Verify condition of the NH3 sensor heater circuit.
Use a multimeter to measure the resistance on the NH3 Control Unit to NH3 sensor harness (cable) side:
From To Value
NH3 Control Unit connector pin 1 NH3 Control Unit connector pin 5 There should be 2.8 – 4.0 Ω.
NH3 Control Unit connector pin 1 All other pins and chassis ground There should be no continuity.
NOTE: Connector NH3 Control Unit connector pin 3 and NH3 Control Unit connector pin 7 are ground circuits.
NOTE: The only source voltage in the NH3 Control Unit to NH3 sensor harness (cable) is that provided to the
Heater + control circuit, therefore the first check indirectly checks for a Heater - short circuit to another voltage
source.
A. If the measured resistance is within the specified range and there is no continuity to any of the other pins or
ground, then leave the NH3 Control Unit disconnected and continue with step 3.
B. If there is zero or infinite resistance or continuity to any another pin or ground, then there is either a short circuit
, an open circuit or a short circuit to ground in the heater circuit wiring or the NH3 sensor has failed internally.
Replace the sensor and its controller connecting cable.
3. As there is no method for field testing or re-flashing the NH3 Control Unit, replace the NH3 Control Unit.
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- Configure - Engine restart counter reset (10.500) if necessary, to perform the Engine Restart Counter Reset
has been resolved.
operation.
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19013 (DTC EADE) - NH3 sensor open or short in temperature cell

circuit
Context:
The NH3 control unit is required to report information at regular intervals to the Engine Control Unit (ECU) via Con-
troller Area Network (CAN). If no signal is sensed on the heater temperature sensing signal line, then this fault will
occur. For information regarding the functional operation of the NH3 sensor and the NH3 control unit, refer to the
engine service manual Ammonia (NH3) sensor - Dynamic description (55.988).
Cause:
The NH3 control unit has reported a short circuit to ground or an open circuit error via CAN to the ECU.
1. Faulty NH3 sensor, open or shorted or grounded internally.

2. Faulty NH3 control unit, hardware or firmware.
Solution:
2. As there is no method for field testing the temperature sensing portion of the sensor, replace the NH3 sensor.

3. As there is no method of field testing or re-flashing the NH3 control unit, replace the NH3 control unit.
has been resolved.
operation.
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19014 (DTC EBDE) - NH3 sensor open or short in trim resistor circuit
Context:
troller Area Network (CAN). If the reference trim resistor circuit is affected in any way, then this fault will occur. For
information regarding the functional operation of the NH3 sensor and the NH3 control unit, refer to the engine service
manual Ammonia (NH3) sensor - Dynamic description (55.988).
Cause:
The NH3 control unit has reported, via CAN, to the ECU that an open circuit or a short circuit exists in the reference
trim resistor control circuit.
1. Faulty NH3 sensor to the NH3 control unit cable wiring, and open circuit or a short circuit in the trim resistor.
Solution:
2. Verify the condition of the trim resistor in the NH3 sensor to the NH3 control unit cable.
Disconnect the NH3 control unit to the NH3 sensor harness (cable) from the NH3 control unit.
Use a multimeter to measure the resistance and check for continuity on the NH3 control unit to NH3 sensor harness
side:
From To Value
NH3 control unit connector pin 2 NH3 control unit connector pin 3
There should be between 500 –
2000 Ω.
NH3 control unit connector pin 2 All other pins and chassis ground There should be no continuity.
NH3 control unit connector pin 3 All other pins and chassis ground There should be no continuity.
NOTE: Connector NH3 control unit connector pin 3 and NH3 control unit connector pin 7 are ground circuits.
A. If the measured resistance is within the specified range and there is no continuity to any other pin, then leave
the NH3 control unit disconnected and continue with step 3.
B. If the measured resistance is not within the specified range or there is continuity to any of the other pins, then
the NH3 sensor trim resistor has failed or the cabling is damaged. Replace the NH3 sensor and attached
cabling.
3. As there is no method for field testing or re-flashing the NH3 control unit, replace the NH3 control unit.
- Configure - Engine restart counter reset (10.500) if necessary. to perform the Engine Restart Counter Reset
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has been resolved.
operation.
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19015 (DTC 4CDE) - NH3 sensor heater control failure

Context:
troller Area Network (CAN). This fault is the result of a heater control failure. For information regarding the functional
operation of the NH3 sensor and the NH3 control unit, refer to the engine service manual Ammonia (NH3) sensor -
Dynamic description (55.988).
Cause:
The NH3 control unit has reported, via CAN, to the ECU that a heater control failure has occurred.
1. Faulty NH3 sensor, open circuit or a short circuit.

Solution:

has been resolved.
operation.
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19016 (DTC 37EE) - NH3 sensor heater performance failure

Context:
troller Area Network (CAN). The NH3 sensor is expected to reach its heated up state within 120 s after the dew point
has been reached. If the heated up state is not reached in the allotted time, an under heating condition exists, and
this fault will occur. For information regarding the functional operation of the NH3 sensor and/or NH3 Control Unit,
refer to the engine service manual Ammonia (NH3) sensor - Dynamic description (55.988).
Cause:
The NH3 Control Unit has reported, to the ECU, that the NH3 sensor did not reach its heated up state within the
allotted time.
1. Faulty NH3 sensor and/or NH3 sensor to NH3 Control Unit wiring, heater not functioning.
Solution:
Use a multimeter to measure the resistance and check for continuity on the harness (cable) side:
From To Value
NH3 Control Unit connector pin 1 NH3 Control Unit connector pin 5 There should be between 2.8 –
4.0 Ω.
NH3 Control Unit connector pin 1 All other pins and chassis ground There should be no continuity
NH3 Control Unit connector pin 5 All other pins There should be no continuity
A. If the measured resistance is within the specified range and the harness (cable) wiring is not shorted, then
continue with step .3.
B. If the measured resistance is not within the specified range or the harness (cable) wiring is shorted, then replace
the NH3 sensor.
3. As there is no method for field testing or re-flashing the sensor controller, replace the NH3 Control Unit A-9101
and check to see that the fault is resolved.
has been resolved.
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operation.
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19017 (DTC 38EE) - NH3 sensor signal out of range failure

Context:
troller Area Network (CAN). Two sensing plates internal to the NH3 sensor sense the levels of ammonia and NO2.
One plate (EMF1) senses both ammonia and NO2 while the second plate (EMF2) senses only NO2. The filtered signal
difference between the two plates (EMF1 and EMF2) should be 0.025 – 1.000 V. If the filtered signal difference is not
with in the range, then this fault will occur. For information regarding the functional operation of the NH3 sensor and/or
NH3 control unit, refer to the engine service manual Ammonia (NH3) sensor - Dynamic description (55.988).
Cause:
The NH3 control unit has reported, via CAN, to the ECU that the filtered sensing plate data is not with in specification.
1. Faulty NH3 sensor, drifted.

Solution:
2. As there is no method for field testing the sensing plate portion of the sensor, replace the NH3 sensor.
Check to see that this fault is resolved.
B. If the fault is not resolved, continue with step 3.

3. As there is no method for field testing or re-flashing the sensor controller, replace the NH3 Control Unit.
Check to see that this fault is resolved.
has been resolved.
operation.
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19018 (DTC 4DDE) - NH3 sensor power supply failure

Context:
troller Area Network (CAN). This fault will occur if the NH3 Control Unit reports an error related to the expected voltage
required for heater or sensor operation. For information regarding the functional operation of the NH3 sensor and/or
the NH3 Control Unit, refer to the engine service manual Ammonia (NH3) sensor - Dynamic description (55.988).
Cause:
The NH3 Control Unit has reported, via CAN, to the ECU that there is an error related to the expected power supply
voltage.
1. Faulty supply voltage, sourcing circuit failure.

Solution:
2. Check the level of the NH3 Control Unit supply voltage.
Disconnect the vehicle harness (VE) from the NH3 Control Unit.
Use a multimeter to measure the voltage on the vehicle harness (VE) side :
From To Value
NH3 Control Unit connector pin 1 NH3 Control Unit connector pin 1 There should be approximately 12 V.
NOTE: If voltage measurement is appreciably less than 12 V, it may be necessary to start the vehicle and recheck
the voltage measurement.
A. If less than adequate voltage is measured, refer to the appropriate vehicle electrical schematics to locate and
resolve the issue.
B. If adequate voltage is measured, continue with step 3.

3. As there is no method for field testing or re-flashing the NH3 Control Unit, replace the controller.
has been resolved.
operation.
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19019 (DTC 1A1A) - Upstream SCR catalyst temperature sensor

Context:
The Engine Control Unit (ECU) monitors the Selective Catalytic Reduction (SCR) upstream temperature sensor. If
the ECU detects a voltage greater than 3.59 V in the SCR upstream temperature sensor signal circuit, then this fault
will occur. For more information regarding the technical specifications of the SCR upstream temperature sensor, refer
to the engine service manual Exhaust Gas Recirculation (EGR) temperature sensors Diesel Oxidation Catalyst
(DOC) inlet temperature sensor - Technical Data (55.989).
Cause:
The ECU has detected a voltage greater than 3.59 V in the SCR upstream temperature sensor signal circuit.
1. Faulty SCR upstream temperature sensor wiring, short circuit to another voltage source.
2. Faulty SCR upstream temperature sensor wiring, open circuit.
3. Faulty SCR upstream temperature sensor, internal failure.
Solution:
2. Check the SCR upstream temperature sensor for an internal failure.
Disconnect the vehicle harness (VE) from the SCR upstream temperature sensor.
Use a multimeter to measure the resistance on the DOC inlet temperature sensor :
From To Value
SCR upstream temperature sensor SCR upstream temperature sensor There should be between 170.2 –
pin 1 pin 2 849.7 Ω.
A. If there is between 170.2 – 849.7 Ω, leave the SCR upstream temperature sensor disconnected and continue
to step 3.
B. If there is not between 170.2 – 849.7 Ω, then the SCR upstream temperature sensor has failed. Replace the
SCR upstream temperature sensor.
3. Check the SCR upstream temperature sensor vehicle harness (VE) wiring for a short circuit.
side :
From To Value
SCR upstream temperature sensor Chassis ground There should be no voltage.
connector pin 1
A. If there is voltage, then there is a short circuit to battery in the SCR upstream temperature sensor wiring. Locate
B. If there is no voltage, then leave the SCR upstream temperature sensor disconnected and continue to step 4.
4. Check the SCR upstream temperature sensor vehicle harness (VE) wiring for an open circuit.
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(VE) side :
From To Value
SCR upstream temperature sensor X-461 pin 82 There should be continuity.
connector pin 1
SCR upstream temperature sensor X-461 pin 81 There should be continuity.
connector pin 2
A. If there is no continuity, then there is an open circuit in the SCR upstream temperature sensor vehicle harness
(VE) wiring. Locate and repair the broken conductor. Repair or replace the harness as required.
5. Check the SCR upstream temperature sensor vehicle harness (VE) wiring for a short circuit.
(VE) side :
From To Value
A. If there is continuity, then there is a short circuit in the SCR upstream temperature sensor vehicle harness (VE)
has been resolved.
operation.
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19020 (DTC 2B1A) - Upstream SCR catalyst temperature sensor

Inducement configuration with the Electronic Service Tool (EST) before you return the machine to service. Refer
to Selective Catalytic Reduction (SCR) exhaust treatment - Configure - Engine restart counter reset (10.500)
within engine technical information, if necessary.
Context:
The Engine Control Unit (ECU) monitors the catalyst temperature (upstream) sensor circuit voltage. The ECU will
freeze the catalyst upstream temperature value at the last valid value upon a preliminary failure and ramp the value
to a fixed replacement value of 0.06 °C (32.11 °F), if failure is validated. If the ECU detects a voltage less than 0.5 V
in the catalyst temperature (upstream) sensor signal circuit, then this fault will occur.
Cause:
The ECU has detected a voltage less than 0.5 V in the catalyst temperature (upstream) sensor signal circuit.
1. Faulty catalyst temperature (upstream) sensor signal circuit wiring, grounded.

2. Faulty catalyst temperature (upstream) sensor, internal failure.
Solution:
2. Check the catalyst temperature (upstream) sensor signal circuit for a short circuit to ground.
Disconnect the vehicle harness (VE) from the catalyst temperature (upstream) sensor at connector X-617.
From To Value
B. If there is no continuity on either check, then continue to step 3.

3. Replace the catalyst temperature (upstream) sensor.
Then use the EST to verify that this fault has been resolved.
A. If the fault has been resolved, then use EST, see Selective Catalytic Reduction (SCR) exhaust treatment -
Configure - Engine restart counter reset (10.500) within engine technical information, if necessary, to per-
form the Engine Restart Counter Reset / Unlock Inducement configuration then return the machine to service.
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has been resolved.
operation.
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19023 (DTC 4EDE) - NH3 sensor controller failure

Context:
troller Area Network (CAN). The NH3 Control Unit contains more than one memory type device. If a failure condition
or failure mode is detected or communicated, internally, this fault will occur. For information regarding the functional
operation of the NH3 sensor and the NH3 Control Unit refer to the engine service manual Ammonia (NH3) sensor
Cause:
The NH3 Control Unit has reported, via CAN, to the ECU that it has experienced an internal memory failure.

Solution:
1. As there is no method for field testing or re-flashing the sensor controller, replace the NH3 Control Unit.
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19024 (DTC 92EE) - CAN timeout error from NH3 sensor - NH3Sens
message
Context:
troller Area Network (CAN). If this information is not communicated within the allotted time frame, then this ECU
timeout fault will occur. For information regarding the functional operation of the NH3 sensor and the NH3 control unit,
refer to the engine service manual Ammonia (NH3) sensor - Dynamic description (55.988).
Cause:
The ECU has reported, via the engine sensor CAN bus, that a NH3 control unit timeout of the NH3 sensor message
has occurred.

2. Faulty CAN wiring, open circuit or short circuit.
Solution:
2. Check the NH3 control unit supply voltage.
Disconnect the vehicle (VE) harness from the NH3 control unit.
From To Value
NH3 control unit connector pin 1 NH3 control unit connector pin 4 There should be 12.0 V .
A. If the voltage is present, then leave the NH3 control unit disconnected and continue with step 3.
B. If the voltage is not present, then continue with step 4.

3. Determine the condition of the NH3 control unit A-9101 CAN circuit.
Use a multimeter to measure the resistance of the CAN connection on the vehicle (VE) harness side:
From To Value
NH3 control unit connector pin 2 NH3 control unit connector pin 3 There should be 60 Ω.

4. Check for other engine Selective Catalytic Reduction (SCR) CAN faults.
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A. If other faults exist, then there is a failure in the SCR devices power, ground or CAN wiring. Locate and repair
the faulted condition. Repair or replace the harness as required.
B. If no other faults exist, then the SCR vehicle (VE) harness wiring is damaged between the harness splice and
the NH3 control unit connector. Locate and repair the damage to the SCR supply power and ground or CAN
circuit wiring.
5. As there is no method for field testing or re-flashing the sensor controller, replace the NH3 control unit.
A. If the fault is resolved, use the EST, refer to the engine service manual Selective Catalytic Reduction (SCR)
exhaust treatment - Configure - Engine restart counter reset (10.500) if necessary. to perform the Engine
has been resolved.
operation.
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19036 (DTC 3F1C) - SCR downstream temperature sensor signal

drift at cold start
Context:
The Electronic Control Unit (ECU) monitors the downstream SCR catalyst sensor. If the ECU determines that the
temperature value is greater than 890.0 °C (1633.9 °F), then this fault will occur.
Cause:
The downstream SCR temperature is too high.
1. A problem in the downstream SCR catalyst temperature sensor wiring.

2. An internal failure in the downstream SCR catalyst temperature sensor.
3. The catalyst efficiency is low.
4. An excessive exhaust back pressure.
5. An over fueling condition.
6. The Electronic Variable Geometric Turbocharger (EVGT) actuator is stuck (If equipped).
7. The intake air temperature is too high.
8. The engine valve lash is too tight.
9. Faulty injection timing.
10. Faulty camshaft timing.
11. A faulty ECU.
Solution:
1. Use the EST to check for the following related faults that may have caused this fault to occur.
19010 – Downstream SCR catalyst temperature sensor voltage is higher than expected
19042 – Downstream SCR temperature sensor comparison to a calculated temperature value failure
19036 – SCR downstream temperature sensor signal drift at cold start
3985 – Exhaust gas pressure sensor voltage is higher than expected
3986 – Exhaust gas pressure sensor voltage is lower than expected
3450 – eVGT actuator blocked
3861 – eVGT power supply electrical failure
3457 – Intake manifold temperature sensor voltage is higher than expected
3517 – Ambient temperature sensor voltage is higher than expected
3093 – Compared camshaft and crankshaft speed sensor values are not plausible
3091 – Camshaft speed sensor pattern is not plausible
3090 – Camshaft speed sensor values are not plausible
3089 – Crankshaft speed sensor pattern is not plausible
3088 – Crankshaft speed sensor values are not plausible
A. If any of the listed faults are active, then diagnose them first. Then return to this fault, 19067 – Downstream
SCR catalyst temperature is too high.
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2. Use an infrared type temperature gun to check the physical temperature of the downstream SCR catalyst sensor
at the sensor base.
Run the engine until operating temperature is reached.
A. If the temperature exceeds 537.8 °C (1000.0 °F), then refer to the possible failure modes listed above and
B. If the temperature does not exceed 537.8 °C (1000.0 °F), then continue to step 3.
3. Check the downstream SCR catalyst sensor wiring.
The key must be in the OFF position for continuity and ON position for voltage.
Use a multimeter to perform the following wiring checks :
From To Value
A. If the specified values are measured, then continue to step 4.
B. If the specified values have not been measured, there is a problem in the downstream SCR catalyst sensor
4. Replace the downstream SCR catalyst sensor.
Use the EST to verify the status of this fault, 19036 – SCR downstream temperature sensor signal drift at cold
start.
B. If the fault has been not resolved, then check the ECU for the appropriate software and re-flash, if necessary.
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19040 (DTC 352C) - Upstream SCR temperature sensor comparison

to a calculated temperature value failure
Selective Catalytic Reduction (SCR) exhaust treatment - Configure - Engine restart counter reset (10.500) if
necessary.
Context:
The Engine Control Unit (ECU) monitors the upstream SCR temperature sensor temperature value. If the ECU de-
termines that there is a calculated temperature value failure, then this fault will occur.
Cause:
The ECU has detected a calculated temperature value failure.
1. A higher than normal exhaust temperature due to engine misfire, etc.

2. The upstream SCR temperature sensor is not installed properly.
3. A problem in the upstream SCR temperature sensor wiring.
4. A faulty ECU.
Solution:
2. Check for other faults.
A. If any other the faults are active, then diagnose them first. Then return to this fault.
B. If no other the faults are active, then continue to step 3.

3. Check the upstream SCR temperature sensor for proper installation.
A. If the sensor is incorrectly mounted, loose, or damaged, then repair as necessary.
B. If no faults are found, then continue to step 4.

4. Replace the upstream SCR temperature sensor.
Then use the EST, refer to Selective Catalytic Reduction (SCR) exhaust treatment - Configure - Engine restart
counter reset (10.500) if necessary, to perform the Engine Restart Counter Reset / Unlock Inducement configu-
ration.
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has been resolved.
operation.
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19041 (DTC 362C) - Downstream SCR temperature sensor

comparison to a calculated temperature value failure
NOTE: Because this fault causes inducement, it is necessary to perform the Engine Restart Counter Reset / Un-
lock Inducement configuration with the Electronic Service Tool (EST) before you return the machine to service. See
necessary.
Context:
The Engine Control Unit (ECU) monitors the downstream SCR temperature sensor temperature value. If the ECU
determines that there is a calculated temperature value failure, then this fault will occur.
Cause:

2. The downstream SCR temperature sensor is not installed properly.
3. A problem in the downstream SCR temperature sensor wiring.
4. A faulty ECU.
Solution:
2. Check for other faults.
A. If other faults are active, then diagnose them first. Then return to this fault.
B. If no other faults are active, then continue to step 3.

3. Check the downstream SCR temperature sensor for proper installation.
A. If the sensor is incorrectly mounted, loose or damaged, then repair as necessary.

4. Replace the downstream SCR temperature sensor.
Then use the EST, see Selective Catalytic Reduction (SCR) exhaust treatment - Configure - Engine restart
counter reset (10.500) if necessary, to perform the Engine Restart Counter Reset / Unlock Inducement configu-
ration.
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has been resolved.
operation.
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19042 (DTC 372C) - Downstream SCR temperature sensor

comparison to a calculated temperature value failure
the engine service manual for more information.
Context:
The Electronic Control Unit (ECU) monitors the downstream SCR temperature sensor temperature value. If the ECU
determines that there is a calculated temperature value failure, then this fault will occur.
Cause:

2. The downstream SCR temperature sensor is not installed properly.
3. A problem in the downstream SCR temperature sensor wiring.
4. A faulty ECU.
Solution:
2. Check for the following related faults:
19010 – Downstream SCR catalyst temperature sensor voltage is higher than expected
19011 – Downstream SCR catalyst temperature sensor voltage is lower than expected
19036 – SCR downstream temperature sensor signal drift at cold start
19067 – Downstream SCR catalyst temperature is too high
19068 – Downstream SCR catalyst temperature is too low
A. If any of these faults are active, then repair these faults first and then return to this fault, 19042 – Downstream
SCR temperature sensor comparison to a calculated temperature value failure.
B. If none of the faults are active, then continue to step 3.

3. Check the downstream SCR temperature sensor for proper installation.
A. If the sensor is incorrectly mounted, loose or damaged, then repair as necessary.

4. Replace the downstream SCR temperature sensor.
Use the EST to verify the status of this fault, 19042 – Downstream SCR temperature sensor comparison to a
calculated temperature value failure.
A. If the fault has been resolved, then use EST to perform the Engine Restart Counter Reset / Unlock Inducement
configuration then return the machine to service.
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has been resolved.
operation.
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19045 (DTC 94BE) - Timeout Error of Message from ECU to NOx

downstream Sensor
Context:
The NOx sensor downstream is required to report information at regular intervals to the Engine Control Unit (ECU)
via CAN. If this information is not communicated within the allotted time frame, then this ECU timeout fault will occur.
Cause:
The ECU has reported, via the engine sensor CAN bus, that a NOx sensor downstream timeout of the NOx sensor
downstream message has occurred.

2. Faulty CAN wiring, an open circuit or a short circuit.
3. Faulty NOx sensor downstream, hardware or firmware.
Solution:
2. Check NOx sensor downstream controller supply voltage.
Disconnect the vehicle (VE) harness from the NOx sensor downstream controller.
Use a multimeter to check for voltage on the VE harness side:
From To Value
NOx sensor downstream connector NOx sensor downstream connector There should be 12.0 V.
pin 1 pin 2
A. If the voltage is present, then leave the NOx sensor downstream connector disconnected and continue with
step 3.

3. Determine the condition of the NOx sensor downstream controller CAN circuit.
Use a multimeter to measure the resistance of the CAN connection on the VE harness side:
From To Value
NOx sensor downstream connector NOx sensor downstream connector There should be 60 Ω.
pin 3 pin 4

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A. If other faults exist, then troubleshoot these faults first.
B. If no other faults exist, then the vehicle (VE) harness wiring is damaged between the SCR devices harness
splice and the NOx sensor downstream controller connector. Locate and repair the damage to the SCR supply
power and ground or CAN circuit wiring.
5. As there is no method for field testing or re-flashing the sensor controller, replace the NOx sensor downstream
unit.
A. If the fault is resolved, then use the EST, refer to the engine service manual Selective Catalytic Reduction
(SCR) exhaust treatment - Configure - Engine restart counter reset (10.500), if necessary to perform the
Engine Restart Counter Reset / Unlock Inducement configuration. Then return the machine to service.
has been resolved.
operation.
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19050 (DTC 478E) - Downstream NOx sensor supply voltage is out

of range
Context:
The SCR downstream NOx sensor A-9102 has internal monitoring for operating conditions and reports status along
with sensed data. The normal operating range of the battery power supply voltage to the SCR downstream NOx
sensor A-9102 should be 10.0 – 16.0 V. If the expected voltage is deemed to be too low or out of range, by the SCR
downstream NOx sensor A-9102, this fault will occur. For information regarding the functional operation of the smart
Selective Catalytic Reduction (SCR) downstream NOx sensor A-9102, refer to the engine service manual Nitrogen
Oxide (NOx) sensor - Dynamic description (55.988).
Cause:
The SCR downstream NOx sensor A-9102 has reported, via CAN, to the Engine Control Unit (ECU) A-9000 that the
expected voltage is deemed to be too low or out of range.
1. Faulty supply voltage, out of range.

2. Faulty SCR downstream NOx sensor A-9102, hardware or firmware.
Solution:
A. If the fault is present and active, continue with Step 2.
Continue with Step 5.
2. Check supply voltage.
Disconnect the vehicle (VE) harness from the SCR downstream NOx sensor A-9102 at connector X-9134.
Use a multimeter to measure the voltage on the vehicle (VE) harness side:
From To Value
X-9134 pin 1 X-9134 pin 2 There should be between 10.0 –
16.0 V.
A. If the supply voltage is not within the specified range, continue with Step 3.
B. If the supply voltage is within the specified range, continue with Step 4.
3. Check for related supply voltage faults.
Use EST to determine the presence of 19063 – Upstream NOx sensor supply voltage is out of range.
A. If fault 19063 – Upstream NOx sensor supply voltage is out of range is present, use the appropriate vehicle
service manual to locate faulted condition and restore the supply voltage.
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B. If fault 19063 – Upstream NOx sensor supply voltage is out of range is not present, the faulted condition is
between X-9134 pin 1 or X-9134 pin 2 and the vehicle (VE) harness splice. Locate and repair the conductor
failure.
4. As there is no method for field testing the SCR downstream NOx sensor A-9102, replace the SCR downstream
NOx sensor A-9102.
data (Downstream sensor) (55.988) if necessary, to perform the “Replacement of Nox Downstream Sensor -
Reset ECU Data” configuration.
- Configure - Engine restart counter reset (10.500), if necessary, to perform the “Engine Restart Counter Reset
/ Unlock Inducement” configuration.
A. If this fault is resolved, return the machine to service.
B. If this fault is not resolved, check the ECU A-9000 for the appropriate software and re-flash, if necessary.
has been resolved.
operation.
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19051 (DTC E46E) - Upstream NOx sensor internal failure (heater

open circuit error)
Context:
For information regarding the functional operation of the smart Diesel Oxidation Catalyst (DOC) upstream NOx sen-
sor, refer to the engine service manual Nitrogen Oxide (NOx) sensor - Dynamic description (55.988). The DOC
upstream NOx sensor has internal monitoring for an open circuit or a short circuit and sends an error status in case
of a detected failure. This failure is the result of an open circuit error in the sensor heater circuit.
Cause:
The DOC upstream NOx sensor has reported, via CAN, to the ECU that an open circuit exists in the heater control
circuit.
1. Faulty DOC upstream NOx sensor, hardware or firmware.

Solution:
2. As there is no method for field testing or re-flashing the sensor controller, replace the DOC upstream NOx sensor.
data (Upstream sensor) (55.988) if necessary, to perform the Replacement of the Nox Upstream Sensor - Reset
ECU Data configuration.
B. If this fault is not resolved, check the ECU for the appropriate software and re-flash, if necessary.
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has been resolved.
operation.
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19052 (DTC 256E) - Upstream NOx sensor internal failure (heater

short circuit error)
Context:
The DOC upstream NOx sensor has internal monitoring for an open circuit or a short circuit and sends an error status
in case of a detected failure. This failure is the result of a short circuit in the sensor heater circuit. For information
regarding the functional operation of the smart Diesel Oxidation Catalyst (DOC) upstream NOx sensor, refer to the
engine service manual Nitrogen Oxide (NOx) sensor - Dynamic description (55.988).
Cause:
The DOC upstream NOx sensor has reported, via CAN, to the ECU that a short circuit exists in the heater control
circuit.

Solution:
data (Upstream sensor) (55.988) if necessary, to perform the Replacement of Nox Upstream Sensor - Reset
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has been resolved.
operation.
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19053 (DTC A66E) - Upstream NOx sensor internal failure (Heater

Performance Plausibility Error)
Context:
The DOC upstream NOx sensor has internal monitoring and delivers information about its error status and the results
of self diagnosis procedure, via CAN, to the Engine Control Unit (ECU). One of the monitored conditions is whether
or not the DOC upstream NOx sensor reached the appropriate operating temperature within the allotted time. Once
the dew point has been reached, the sensor has 3.0 min to reach heat up. If the sensor heat up is not completed
in time, then this fault will occur. For information regarding the functional operation of the smart Diesel Oxidation
Catalyst (DOC) upstream NOx sensor, refer to the engine service manual Nitrogen Oxide (NOx) sensor - Dynamic
description (55.988).
Cause:
The DOC upstream NOx sensor has reported, via CAN, to the ECU that the sensor failed to reach heater working
temperature in the allotted time.

Solution:
2. Check for other relevant faults.
Use the EST to check for the presence of fault 19063 – Upstream NOx sensor supply voltage is out of range.
A. If fault 19063 – Upstream NOx sensor supply voltage is out of range is present, resolve fault 19063 –
Upstream NOx sensor supply voltage is out of range. Then check to see that fault 19053 – Upstream NOx
sensor internal failure (Heater Performance Plausibility) is also resolved.
B. If fault 19063 – Upstream NOx sensor supply voltage is out of range is not present, then continue with step
3.
Then use EST, refer to the engine service manual Nitrogen Oxide (NOx) sensor - Configure - Reset ECU data
(Upstream sensor) (55.988) if necessary, to perform the Replacement of the Nox Upstream Sensor - Reset ECU
Data configuration.
Run the machine and use the EST capability to view parameters to verify that the sensor has reached dew point.
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has been resolved.
operation.
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19054 (DTC E48E) - Upstream NOx sensor internal failure (open

circuit error)
Context:
upstream NOx sensor has internal monitoring for an open circuit or a short circuit and sends an error status in case
of a detected failure. This failure is the result of an open circuit error in the sensor NOx and/or Oxygen level circuit.
Cause:
The DOC upstream NOx sensor has reported, via CAN, to the ECU that an open circuit exists in the NOx and/or

Solution:
data (Upstream sensor) (55.988) if necessary, to perform the Replacement of the Nox Upstream Sensor - Reset
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has been resolved.
operation.
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19059 (DTC 258E) - Upstream NOx sensor internal failure (Short

Circuit Error)
Context:
The DOC upstream NOx sensor has internal monitoring for an open circuit or a short circuit and sends an error status
in case of a detected failure. This failure is the result of a short circuit error in the sensor NOx and/or Oxygen level
circuit. For information regarding the functional operation of the smart Diesel Oxidation Catalyst (DOC) upstream NOx
sensor, refer to the engine service manual Nitrogen Oxide (NOx) sensor - Dynamic description (55.988).
Cause:
The DOC upstream NOx sensor has reported, via CAN, to the ECU that a short circuit exists in the NOx and/or Oxygen
level circuit.

Solution:
data (Upstream sensor) (55.988) if necessary, to perform the Replacement of Nox Upstream Sensor - Reset
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has been resolved.
operation.
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19060 (DTC 9E6E) - CAN timeout error from upstream NOx sensor
Inducement configuration with the Electronic Service Tool (EST) before you return the machine to service, refer to
necessary.
Context:
The NOx sensor upstream is required to report information at regular intervals to the Engine Control Unit (ECU) via
Controller Area Network (CAN). If this information is not communicated within the allotted time frame, this ECU timeout
fault will occur. For information regarding the functional operation of the NOx sensor upstream, refer to Nitrogen
Oxide (NOx) sensor - Dynamic description (55.988).
Cause:
The ECU has reported, via the CAN data link, that a NOx sensor upstream message timeout has occurred.

2. Faulty CAN wiring, open or short circuit.
3. Faulty NOx sensor upstream, hardware or firmware.
Solution:
2. Check for the presence of supply voltage fault.
Use EST to determine the presence of fault DTC 4A8E – Upstream NOx sensor supply voltage is out of range.
A. If fault 19063 – Upstream NOx sensor supply voltage is out of range is present, resolve the 19063 – Up-
stream NOx sensor supply voltage is out of range fault. Then determine if this fault is also resolved.
B. If fault 19063 – Upstream NOx sensor supply voltage is out of range is not present, continue with step 3.
3. Determine the condition of the NOx sensor upstream CAN circuit.
Disconnect the NOx sensor upstream at connector X-607.
Use a multimeter to measure the resistance of the CAN circuit on the vehicle (VE) harness side :
From To Value
Determine the condition of the NOx sensor upstream address switch circuit.
Use a multimeter to check for continuity to ground in the address switch circuit on the vehicle (VE) harness side :
From To Value
A. If the measured resistance is correct and the address switch circuit is grounded, continue with step 4.
B. If the measured resistance is not correct or the address switch circuit is not grounded, continue with step 5.
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NOTE: Grounding X-607 pin 5 on the NOx sensor upstream distinguishes it from the NOx sensor downstream.
4. As there is no method for field testing or re-flashing the sensor controller, replace the NOx sensor upstream.
Run the engine until the NOx sensor reaches dewpoint.
A. If this fault is resolved, use the EST, refer to Selective Catalytic Reduction (SCR) exhaust treatment - Con-
figure - Engine restart counter reset (10.500) if necessary, to perform the Engine Restart Counter Reset /
Unlock Inducement configuration. Then return the machine to service.
5. Check for other engine SCR CAN faults.
A. If other faults do exist, use the appropriate vehicle service manual and electrical schematics to locate and repair
the faulted condition.
B. If no other faults exist, the SCR vehicle (VE) harness wiring is damaged between the network harness splice
and the NOx sensor upstream connector X-607 pin 3 and/or X-607 pin 4 or the address switch grounding circuit
has failed between X-607 pin 5 and chassis ground. Locate and repair the damage to the SCR CAN circuit or
grounding circuit wiring.
has been resolved.
operation.
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19061 (DTC 32BE) - Upstream NOx sensor lambda signal deviation

- NOx sensor possible removal detected
Context:
upstream NOx sensor has internal monitoring for operating conditions and reports status along with sensed data. If
the sensor lambda data value is outside the values established by the minimum/maximum curves specified in the
Engine Control Unit (ECU), dependent on the lambda value itself, then this fault will occur.
Cause:
The ECU has determined that the DOC upstream NOx sensor is not measuring correct lambda values.

Solution:
1. Determine proper installation of the DOC upstream NOx sensor.
Remove and re-install, if necessary, the DOC upstream NOx sensor to assure that it is properly aligned and se-
curely installed.
Use the EST, refer to the engine service manual Selective Catalytic Reduction (SCR) exhaust treatment -
Configure - Engine restart counter reset (10.500), if necessary, to perform the Engine Restart Counter Reset /
Unlock Inducement configuration.
B. If the fault is not resolved, continue with step 2.

data (Upstream sensor) (55.988), if necessary, to perform the Replacement of Nox Upstream Sensor - Reset
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19062 (DTC E98E) - Upstream NOx sensor values are not plausible
Context:
For information regarding the functional operation of the smart Diesel Oxidation Catalyst (DOC) upstream NOx sensor,
refer to the engine service manual Nitrogen Oxide (NOx) sensor - Dynamic description (55.988). The smart DOC
upstream NOx sensor delivers information about its error status and the results of self diagnosis procedure, via CAN,
to the Engine Control Unit (ECU). If the DOC upstream NOx sensor sends the message Lambda or NOx signal not
plausible, then this fault will occur.
Cause:
The DOC upstream NOx sensor has reported, via CAN, to the ECU that the Lambda or NOx signal is not plausible.
Solution:
Use the Electronic Service Tool (EST) to check for fault 19071 – SCR catalyst efficiency lower than first NOx
production threshold level.
DOC upstream NOx sensor is poisoned. Replace the DOC upstream NOx sensor. Then use EST, refer to the
engine service manual Nitrogen Oxide (NOx) sensor - Configure - Reset ECU data (Upstream sensor)
(55.988) if necessary, to perform the Replacement of Nox Upstream Sensor - Reset ECU Data configuration.
ignore fault 19062 – Upstream NOx sensor values are not plausible.
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19063 (DTC 4A8E) - Upstream NOx sensor supply voltage is out

of range
Context:
The Diesel Oxidation Catalyst (DOC) upstream NOx sensor has internal monitoring for operating conditions and re-
ports status along with sensed data. The expected normal operating range of the battery power supply voltage to the
DOC upstream NOx sensor is 10.0 – 16.0 V. If the expected voltage is deemed to be too low or out of range, by the
DOC upstream NOx sensor then this fault will occur. For information regarding the functional operation of the smart
DOC upstream NOx sensor, refer to the engine service manual Nitrogen Oxide (NOx) sensor - Dynamic descrip-
tion (55.988).
Cause:
The DOC upstream NOx sensor has reported, via CAN, to the Engine Control Unit (ECU) that the expected voltage
is deemed to be too low or out of range.
1. Faulty supply voltage, out of range.

Solution:
2. Check supply voltage.
Disconnect the vehicle (VE) harness from the DOC upstream NOx sensor.
Use a multimeter to measure the voltage on the vehicle (VE) harness side :
From To Value
DOC upstream NOx sensor DOC upstream NOx sensor There should be between 10.0 –
connector pin 1 connector pin 2 16.0 V .
A. If the supply voltage is not within the specified range, then continue with step 3.
B. If the supply voltage is within the specified range, then continue with step 4.
3. Check for related supply voltage faults.
Use EST to determine the presence of DTC 478E – Downstream NOx sensor supply voltage is out of range.
A. If fault 19050 – Downstream NOx sensor supply voltage is out of range is present, then troubleshoot this
fault first.
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B. If fault 19050 – Downstream NOx sensor supply voltage is out of range is not present, then the faulted
condition is between the DOC upstream NOx sensor connector and the vehicle harness (VE) splice. Locate
and repair the conductor failure.
4. As there is no method for field testing the DOC upstream NOx sensor, replace the DOC upstream NOx sensor.
(Upstream sensor) (55.988), if necessary, to perform the Replacement of the Nox Upstream Sensor - Reset ECU
Data configuration.
has been resolved.
operation.
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19064 (DTC 563A) - Open Load error of DEF/AdBlue Supply Module

Heater Actuator powerstage
Context:
The Heater Control Unit (HCU) controls and monitors the operation of the Diesel Exhaust Fluid (DEF)/AdBlue® supply
module suction line heater, the DEF/AdBlue® supply module back-flow line heater, the DEF/AdBlue® supply module
pressure line heater and the Diesel Exhaust Fluid (DEF)/AdBlue® supply module internal heater. The DEF/AdBlue®
supply module suction line heater and the DEF/AdBlue® supply module back-flow line heater are wired in series
and share a high side driver controlled circuit. The DEF/AdBlue® supply module pressure line heater and the DEF/
AdBlue® supply module internal heater have their own high side driver controlled circuit. The HCU communicates
electrical failures, via Controller Area Network (CAN), to the Engine Control Unit (ECU). If the HCU senses an open
circuit in the DEF/AdBlue® supply module internal heater control circuit, this fault will occur.
Cause:
The HCU has communicated, via CAN, to the ECU that an open circuit has been detected in the DEF/AdBlue® supply
module internal heater circuit.
1. Faulty DEF/AdBlue® supply module internal heater, internal failure.

2. Faulty DEF/AdBlue® supply module internal heater circuit wiring, open circuit.
3. Faulty HCU, internal failure.
Solution:
2. Verify the condition of the DEF/AdBlue® supply module internal heater.
Use a multimeter to measure the resistance of the internal heater :
From To Value
X-605 pin 11 X-605 pin 12 There should be a nominal amount
of resistance, typically around 3 Ω.
A. If there is a nominal amount of resistance, then reconnect connector X-605 and continue with step 3.
B. If there is an infinite amount of resistance, then the DEF/AdBlue® supply module internal heater has an open
circuit. Replace the module.
3. Check the vehicle harness (VE) circuit wiring for an open circuit.
Disconnect the vehicle harness (VE) from the HCU at connector X-612.
Use a multimeter to measure the resistance on the vehicle harness (VE) side :
From To Value
X-612 pin 1 Chassis ground There should be a nominal amount
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A. If there is an infinite amount of resistance, then there is an open circuit in the vehicle harness (VE) circuit wiring.
B. If there is a nominal amount of resistance, then continue with step 4.

4. As there is no method of field testing or re-flashing the HCU, replace the HCU.
has been resolved.
operation.
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19066 (DTC 1899) - Upstream oxidation catalyst temperature sensor

Context:
The Engine Control Unit (ECU) monitors the Diesel Oxidation Catalyst (DOC) upstream temperature sensor. If the
ECU detects a voltage greater than 3.59 V in the DOC upstream temperature sensor signal circuit, then this fault will
occur.
Cause:
The ECU has detected a voltage greater than 3.59 V in the DOC upstream temperature sensor signal circuit. For
more information regarding the technical specifications of the DOC upstream temperature sensor, refer to the engine
service manual Exhaust Gas Recirculation (EGR) temperature sensors Diesel Oxidation Catalyst (DOC) inlet
temperature sensor - Technical Data (55.989).
1. Faulty DOC upstream temperature sensor wiring, short circuit to another voltage source.
2. Faulty DOC upstream temperature sensor wiring, open circuit.
3. Faulty DOC upstream temperature sensor, internal failure.
Solution:
2. Check the DOC upstream temperature sensor for an internal failure.
Disconnect the vehicle harness (VE) from the DOC upstream temperature sensor.
Use a multimeter to measure the resistance on the DOC upstream temperature sensor pins :
From To Value
DOC upstream temperature sensor DOC upstream temperature sensor There should be between 170.2 –
pin 1 pin 2 849.7 Ω.
A. If there is between 170.2 – 849.7 Ω, then leave the DOC upstream temperature sensor disconnected and
continue to step 3.
B. If there is not between 170.2 – 849.7 Ω, then the DOC upstream temperature sensor has failed. Replace the
DOC upstream temperature sensor.
side :
From To Value
DOC upstream temperature sensor Chassis ground There should be no voltage.
connector pin 1
A. If there is voltage, then there is a short circuit to battery in the DOC upstream temperature sensor wiring. Locate
B. If there is no voltage, then leave the DOC upstream temperature sensor disconnected and continue to step 4.
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4. Check the DOC upstream temperature sensor vehicle harness (VE) wiring for an open circuit.
(VE) side :
From To Value
DOC upstream temperature sensor X-461 pin 56 There should be continuity.
pin 1
DOC upstream temperature sensor X-461 pin 65 There should be continuity.
pin 2
A. If there is no continuity, then there is an open circuit in the DOC upstream temperature sensor vehicle harness
(VE) wiring.Locate and repair the broken conductor. Repair or replace the harness as required.
(VE) side :
From To Value
A. If there is continuity, then there is a short circuit in the DOC upstream temperature sensor vehicle harness (VE)
has been resolved.
operation.
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19071 (DTC 2DDA) - SCR catalyst efficiency lower than first NOx
production threshold level
NOTE: Before troubleshooting, download the ‘Data Stored’ information from the Engine Control Unit (ECU). See Elec-
tronic module - Download (55.640).
the fault has been resolved. See Selective Catalytic Reduction (SCR) exhaust treatment - Service instruction -
SCR fault repair verification test (10.500) if necessary.
NOTE: Because this fault causes inducement, it is necessary to perform the Engine Restart Counter Reset / Un-
lock Inducement configuration with the Electronic Service Tool (EST) before you return the machine to service. See
necessary.
Context:
For information regarding the functional operation of the Selective Catalytic Reduction (SCR) system refer to Se-
lective Catalytic Reduction (SCR) exhaust treatment - Dynamic description (10.500). The instantaneous SCR
catalyst efficiency is obtained from the Diesel Oxidation Catalyst (DOC) upstream NOx sensor and the SCR down-
stream NOx sensor. When the Engine Control Unit (ECU) determines that the SCR catalyst efficiency is lower than
expected, this fault occurs.
Cause:
The ECU calculated that the SCR catalyst efficiency is lower than expected.
1. Faulty SCR downstream NOx sensor, measures too high values.

2. Faulty DOC upstream NOx sensor, measures too high values.
3. Faulty NH3 sensor, measures too high values.
4. Faulty DEF/AdBlue® quality sensor, measures too high values with too low DEF/AdBlue® concentration at the
same time.
5. Faulty DEF/AdBlue® mixture concentration, too low.
6. Faulty DEF/AdBlue® injection quantity, too low.
7. Faulty DOC and Mixing chamber assembly, catalyst contamination or damage or mixing chamber damage.
8. Faulty SCR assembly, catalyst contamination or damage.
Solution:
active.
Use the Electronic Service Tool (EST) to check for the presence of SCR Downstream NOx sensor fault DTC
319E – Downstream NOx sensor values are not plausible or DOC upstream NOx sensor fault DTC E98E –
Upstream NOx sensor values are not plausible.
A. If either DTC 319E – Downstream NOx sensor values are not plausible or DTC E98E – Upstream NOx
sensor values are not plausible is present, then resolve theses faults first. Then determine if fault DTC
2DDA – SCR catalyst efficiency lower than first NOx production threshold level is also resolved.
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B. If neither DTC 319E – Downstream NOx sensor values are not plausible nor DTC E98E – Upstream NOx
sensor values are not plausible is present, then continue with step 3.
Use the EST to check for the presence of SCR downstream NOx sensor fault DTC 43CE – Downstream NOx
sensor signal is stuck at a constant value or NH3 sensor fault DTC 38CB – NH3 sensor signal is not chang-
ing.
A. If either DTC 43CE – Downstream NOx sensor signal is stuck at a constant value or DTC 38CB – NH3
sensor signal is not changing is present, then resolve these faults first. Then determine if fault DTC 2DDA
– SCR catalyst efficiency lower than first NOx production threshold level is also resolved.
B. If neither DTC 43CE – Downstream NOx sensor signal is stuck at a constant value nor DTC 38CB – NH3
sensor signal is not changing is present, then continue with step 4.
Use the EST to check for the presence of DEF/AdBlue® quality sensor fault DTC 4BCA – DEF/AdBlue concen-
tration is out of range or DTC 144E – DEF/AdBlue quality sensor internal failure (Concentration value is
higher than expected) or DTC 254E – DEF/AdBlue quality sensor internal failure (Concentration value is
lower than expected).
A. If either DTC 4BCA – DEF/AdBlue concentration is out of range or DTC 144E – DEF/AdBlue quality sen-
sor internal failure (Concentration value is higher than expected) or DTC 254E – DEF/AdBlue quality
sensor internal failure (Concentration value is lower than expected) is present, the resolve these faults
first. Then determine if fault DTC 2DDA – SCR catalyst efficiency lower than first NOx production thresh-
old level is also resolved.
B. If neither DTC 4BCA – DEF/AdBlue concentration is out of range nor DTC 144E – DEF/AdBlue qual-
ity sensor internal failure (Concentration value is higher than expected) nor DTC 254E – DEF/AdBlue
quality sensor internal failure (Concentration value is lower than expected) is present, then continue
with step 5.
5. Check the DEF/AdBlue® level and the DEF/AdBlue® mixture concentration.
Visually determine that the DEF/AdBlue® quality sensor is sufficiently immersed.
Use a refractometer to determine the concentration level of the DEF/AdBlue® mixture.
There should be 28.75 – 36.25% mixture concentration.
A. If there is an insufficient level of DEF/AdBlue® to adequately cover the DEF/AdBlue® quality sensor or if the
DEF/AdBlue® mixture concentration is not between 28.75 – 36.25%, drain the DEF/AdBlue® tank. Then
remove, inspect and clean the DEF/AdBlue® quality sensor to assure the DEF/AdBlue® quality sensor cover
holes are free of debris. Then fill the DEF/AdBlue® tank with properly concentrated DEF/AdBlue® mixture.
B. If there is a sufficient level of DEF/AdBlue® to adequately cover the DEF/AdBlue® quality sensor and the
DEF/AdBlue® mixture concentration is between 28.75 – 36.25%, then continue with step 6.
6. Check the SCR exhaust system.
Check the exhaust pipes, and connections for external soot or DEF/AdBlue® leakage.
There should be no leakage.
A. If leakage does exist, then repair or replace the component.
B. If there is no visible signs of external leakage, then continue with step

7.
7. Check dosing module and flange interface for deposits.
Remove the dosing module and check for large deposits that would inhibit injection.
There should be no blockage or leakages.
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A. If significant blockage exists, then repair or replace the dosing module as required.
B. If significant blockage is not visible, then do not install the dosing module. Continue with step 8.
8. Check DEF/AdBlue® system for pressure, leaks and quantity.
Orient the dosing module and a piece of cardboard to a location that would allow capture of a produced spray
pattern.
Use the EST and follow the on-screen instructions to perform a Urea Dosing System Test (UDST).
During the UDST record DEF/AdBlue® system pressure and capture the injection pattern on the cardboard.
Also, visually check for any DEF/AdBlue® system leakage.
There should be 5.00 – 7.00 bar (72.50 – 101.50 psi) before injection, a uniform spray pattern, and no leakage.
A. If the pressure is out of specification or the pattern is not uniform or leakage is seen, then clean, repair or
replace system components, as required.
B. If the pressure is within specification, the spray pattern is uniform, and leakage is not seen, then do not install
the dosing module. Continue with step 9.
9. Check the condition of the DEF/AdBlue® mixing chamber.
Visually inspect the DEF/AdBlue® and exhaust gas mixing chamber, through the dosing module mounting hole,
for large deposits (at least 25.0% of the surface is blocked) or damage.
A. If large deposits are discovered, then clean the DOC assembly. Clean the mixing chamber manually, if pos-
sible. Use EST to run the ‘Desulfurization / Thermal Conditioning Procedure’, see Selective Catalytic Re-
duction (SCR) exhaust treatment - Test (10.500). If damage is discovered, then repair or replace the DOC
assembly as required. See Selective Catalytic Reduction (SCR) muffler and catalyst - Configure - Reset
ECU data (10.500), if necessary, to perform the Replacement of Catalyst - Reset ECU Data configuration.
B. If large deposits or damage is not discovered, then install the dosing module. Continue with step 10.
10. Check the condition of the DOC catalyst.
Remove the DOC upstream exhaust gas temperature sensor.
Visually inspect the catalyst, through the DOC upstream exhaust gas temperature sensor mounting hole, for
substrate contamination or damage.
There should be no contamination or damage.
A. If substrate contamination or damage exists, then replace the DOC assembly. Then use EST, see Selective
Catalytic Reduction (SCR) muffler and catalyst - Configure - Reset ECU data (10.500), if necessary, to
perform the Replacement of Catalyst - Reset ECU Data configuration.
B. If substrate contamination or damage does not exist, then continue with step 11.
11. Check the condition of the SCR catalyst.
Remove the SCR upstream exhaust gas temperature sensor.
Visually inspect the catalyst through the SCR upstream exhaust gas temperature sensor mounting hole, for sub-
strate contamination and damage.
There should be no contamination or damage.
A. If substrate contamination or damage exists, then replace the SCR assembly. Then use EST, see Selective
Catalytic Reduction (SCR) muffler and catalyst - Configure - Reset ECU data (10.500), if necessary, to
perform the Replacement of Catalyst - Reset ECU Data configuration.
B. If substrate contamination or damage does not exist, then continue with step 12.
12. Check the ECU software.
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Use the EST to check for the appropriate ECU software.
A. If the ECU is not running appropriate software, then use the EST to re-flash the ECU.
B. If the ECU is currently running appropriate software, then use the EST to retrieve stored engine data, then
use ASIST to escalate a concern.
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19077 (DTC 334A) - DEF/AdBlue pressure stabilization failure

Context:
The Engine Control Unit (ECU) monitors the DEF/AdBlue® system pressure with a pressure stabilization check using
a pressure sensor inside of the DEF/AdBlue® supply module. If the ECU determines that the DEF/AdBlue® system
pressure can be stabilized, this fault will occur.
1. Faulty DEF/AdBlue® system back-flow lines, blocked.

2. Faulty DEF/AdBlue® system back-flow pump, blocked closed.
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19079 (DTC 1A4A) - DEF/AdBlue over pressure failure

Context:
The Engine Control Unit (ECU) monitors DEF/AdBlue® pressure using a pressure sensor inside the DEF/AdBlue®
supply module. If the ECU determines that DEF/AdBlue® pressure is greater than 6.10 bar (88.45 psi), the system
will go into a stand-by state and this fault will occur. This is a first-level failure. There will be a second-level failure
active if DEF/AdBlue® pressure becomes greater than 7.50 bar (108.75 psi).
1. Faulty DEF/AdBlue® supply module back-flow line, blocked.

2. Faulty DEF/AdBlue® supply module back-flow filter, clogged.
3. Faulty DEF/AdBlue® supply module back-flow throttle, clogged.
4. Faulty DEF/AdBlue® supply module back-flow non-return valve, does not open.
5. Faulty DEF/AdBlue® supply module pump, internal failure.
6. Faulty DEF/AdBlue® supply module pressure sensor, internal failure.
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19080 (DTC 294A) - DEF/AdBlue under pressure failure

Context:
The Engine Control Unit (ECU) monitors DEF/AdBlue® pressure using a pressure sensor inside of the DEF/AdBlue®
supply module. If the ECU determines that DEF/AdBlue® pressure is below 3.90 bar (56.55 psi), then this fault will
occur.
1. Faulty DEF/AdBlue® tank level, too low.

2. Faulty DEF/AdBlue® system, leakage on the pressure side.
3. Faulty DEF/AdBlue® system, blockage in tank ventilation.
4. Faulty DEF/AdBlue® system suction side, pre-filter in DEF/AdBlue® tank sending unit.
5. Faulty DEF/AdBlue® system suction side, air entrance from leaking DEF/AdBlue tank sending unit.
6. Faulty DEF/AdBlue® supply module, failed DEF/AdBlue® pump.
7. Faulty DEF/AdBlue® supply module, failed DEF/AdBlue® pressure sensor.
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19085 (DTC 857A) - DEF/AdBlue dosing valve ECU driver over

temperature failure
Context:
For information regarding the functional operation of the Selective Catalytic Reduction (SCR) system, refer to the
engine service manual Selective Catalytic Reduction (SCR) exhaust treatment - Dynamic description (10.500).
The Engine Control Unit (ECU) monitors the electrical current used to energize the dosing module (valve). In the
event of an excessive current requirement, the ECU interrupts current flow to prevent damage and this fault occurs.
Cause:
The ECU detects an over current (temperature) condition in the DEF/AdBlue® dosing module solenoid high side
control circuit.
1. Faulty DEF/AdBlue® dosing module solenoid coil, short circuit.

2. Faulty DEF/AdBlue® dosing module high side control circuit wiring, short circuit to ground.
3. Faulty DEF/AdBlue® dosing module low side control circuit wiring, short circuit to another voltage source.
Solution:
2. Verify the condition of the DEF/AdBlue® dosing module.
Disconnect the vehicle (VE) harness from the DEF/AdBlue® dosing module.
Use a multimeter to measure the resistance of the DEF/AdBlue® dosing module solenoid coil :
From To Value
DEF/AdBlue® dosing module pin 1 DEF/AdBlue® dosing module pin 2 There should be between 11.4 –
12.6 Ω.
A. If the measured resistance is within the specified range, then leave the DEF/AdBlue® dosing module discon-
nected and continue with step 3.
B. If there is no resistance ( 0.0 Ω), then there is a short circuit in the DEF/AdBlue® dosing module. Replace the
DEF/AdBlue® dosing module.
3. Check the DEF/AdBlue® dosing module high side driver control wiring for a short circuit to ground.
With the key switch in the OFF position, use a multimeter to check for continuity on the vehicle (VE) harness side
from :
From To Value
DEF/AdBlue® dosing module Chassis ground There should be no continuity.
connector pin 2
DEF/AdBlue® dosing module DEF/AdBlue® dosing module There should be no continuity.
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A. If there is continuity, then there is a short circuit to ground in the DEF/AdBlue® dosing module vehicle (VE)
harness. Locate and repair the damaged conductor. Repair or replace the harness as required.

4. Check the DEF/AdBlue® dosing module low side driver control wiring for short circuit to another voltage source.
With the key switch in the ON position, use a multimeter to check for continuity on the vehicle (VE) harness side
from:
From To Value
DEF/AdBlue® dosing module Chassis ground There should be no voltage.
connector pin 1
A. If there is voltage, then there is a short circuit to another voltage source in the DEF/AdBlue® dosing module
vehicle (VE) harness. Locate and repair the damaged conductor. Repair or replace the harness as required.
has been resolved.
operation.
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19086 (DTC 3DBA) - DEF/AdBlue pressure line heater failure and

DEF/AdBlue tank temperature is too low
Context:
The Engine Control Unit (ECU) monitors the temperature of the DEF/AdBlue® fluid. If after defrosting, pressure build-
up, and injection the DEF/AdBlue® fluid temperature falls below -10 °C (14 °F) and the engine coolant temperature
is high enough [greater than 50 °C (122 °F)] to provide sufficient heating, then this fault will occur. Additionally, the
DEF/AdBlue® fluid injection system will be shut down in order to protect the DEF/AdBlue® supply module.
Cause:
The ECU has determined that a mechanical failure or problem exists in the DEF/AdBlue® fluid heating system and
the DEF/AdBlue® fluid temperature is too low to continue system operation.
1. Faulty DEF/AdBlue® fluid heating system, heating valve not opening.

2. Faulty DEF/AdBlue® fluid heating system, heating lines (tubes) restricted and/or damaged.
3. Faulty DEF/AdBlue® fluid heating system, heating lines (tubes) not properly installed (connected) or additional /
external heating unit, if used not properly installed (connected).
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19087 (DTC 8DAA) - DEF/AdBlue tank temperature is not within

acceptable limits
Context:
The Engine Control Unit (ECU) monitors the DEF/AdBlue® tank temperature using the DEF/AdBlue® quality, level,
and temperature sensor via Controller Area Network (CAN). If the ECU determines that the DEF/AdBlue® tank tem-
perature is too high, this fault will occur.
1. Faulty coolant control valve, stuck open.

2. Faulty DEF/AdBlue® quality, level, and temperature sensor, internal failure.
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19090 (DTC 3C3A) - Error DEF/AdBlue supply module heater

temperature sensor cold start plausibility
NOTE: The DEF/AdBlue® Supply Module Pulse Width Modulation (PWM) signals are monitored by the Engine Con-
trol Unit (ECU).
Context:
The ECU monitors the signal of the DEF/AdBlue® Supply Module heater temperature after a vehicle cold start. If the
ECU determines that the heater temperature signal is not plausible, this fault will occur.
Cause:
The DEF/AdBlue® Supply Module heater temperature value is not plausible after vehicle cold start.
1. Faulty DEF/AdBlue® Supply Module internal heater has failed.

2. Faulty DEF/AdBlue® Supply Module temperature feedback circuit wiring is faulty.
3. Faulty DEF/AdBlue® Supply Module temperature sensor has failed.
4. Faulty ECU.
Solution:
2. Check the DEF/AdBlue® Supply Module temperature feedback wire.
Disconnect connector X-605 from the DEF/AdBlue® Supply Module.
With the key in the ON position, use a multimeter to perform the following voltage check:
From To Value
With the key in the OFF position, use a multimeter to perform the following continuity check:
From To Value
A. If the specified values are measured, leave connector X-605 and X-461 disconnected and continue to step 3.
B. If the specified values are not measured, there is a failure in the circuit wiring. Locate and repair the faulty
3. Check the DEF/AdBlue® Supply Module internal heater.
With the key in the OFF position, use a multimeter to perform the following resistance measurement on the DEF/
AdBlue® Supply Module pins:
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From To Value
DEF/AdBlue® Supply Module pin 11 DEF/AdBlue® Supply Module pin 12 There should be between 2.25
– 3.25 Ω at approximately 20 °C
(68 °F).
A. If there is between 2.25 – 2.75 Ω at approximately 20 °C (68 °F), continue with step 4.
B. If there is not between 2.25 – 2.75 Ω at approximately 20 °C (68 °F), the DEF/AdBlue® Supply Module internal
heater has failed. Replace the DEF/AdBlue® Supply Module.
4. Check the DEF/AdBlue® Supply Module internal temperature value.
Use the Electronic Service Tool (EST) to monitor the DEF/AdBlue® Supply Module temperature. Compare the
DEF/AdBlue® Supply Module temperature with the ambient temperature. The temperature value should be simi-
lar.
Start the engine and monitor the DEF/AdBlue® Supply Module temperature. After approximately 5 min, the tem-
perature should have increased at least 5 °C (41 °F).
A. If the values are not stated as above, the DEF/AdBlue® Supply Module is unable to warm up as needed. Check
the DEF/AdBlue® system for heating failures. Use the EST to check for related DEF/AdBlue® system fault
codes, if necessary.
B. If the values are measured as stated above, check the ECU for the appropriate software and re-flash, if nec-
essary.
NOTE: This test is based on approximate values. The theory of the test is to determine if the DEF/AdBlue® Supply
Module is effectively warming up.
has been resolved.
operation.
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19095 (DTC 2F3A) - DEF/AdBlue tank temperature sensor

plausibility failure
Context:
The Engine Control Unit (ECU) checks for temperature increase in the DEF/AdBlue® fluid during defrost. If the DEF/
AdBlue® fluid temperature fails to increase by :
1.46 °C (2.63 °F) at -35.04 °C (-31.07 °F) within 60 min or
1.46 °C (2.63 °F) at -25.04 °C (-13.07 °F) within 60 min or
1.46 °C (2.63 °F) at -14.04 °C (6.73 °F) within 120 min or
0.96 °C (1.73 °F) at -5.04 °C (22.93 °F) within 30 min, this fault will occur.
Cause:
The ECU has determined that the DEF/AdBlue® fluid temperature did not increase the required minimum amount
within the allotted time and the DEF/AdBlue® tank heater valve is actuated.
1. Extreme ambient conditions, time required is outside the established parameters.

2. Insufficient engine load, not great enough to generate required engine heat.
3. Faulty DEF/AdBlue® tank heater valve, stuck in deactivated position.
4. Faulty coolant line between DEF/AdBlue® tank and DEF/AdBlue® tank heater valve, damaged or restricted.
5. Faulty DEF/AdBlue® system, coolant lines improperly connected to the DEF/AdBlue® tank heater valve.
6. Faulty DEF/AdBlue® tank temperature sensor, internal failure.
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19103 (DTC 643A) - Short Circuit to Battery of DEF/AdBlue Supply

Module Heater Actuator powerstage
Context:
The Heater Control Unit (HCU) controls and monitors the operation of the Diesel Exhaust Fluid (DEF)/AdBlue® supply
electrical failures, via Controller Area Network (CAN), to the Engine Control Unit (ECU). If the HCU senses a short
circuit to another voltage source in the DEF/AdBlue® supply module internal heater control circuit, this fault will occur.
Cause:
The HCU has communicated, via CAN, to the ECU that a short circuit to another voltage source has been detected
in the DEF/AdBlue® supply module internal heater control circuit.
1. Faulty DEF/AdBlue® supply module internal heater circuit wiring, short circuit to another voltage source.
Solution:
2. Check the vehicle harness (VE) circuit wiring for a short circuit to another voltage source.
From To Value
A. If there is voltage, then leave connector X-612 disconnected and continue with step 3.

3. Verify the condition of the DEF/AdBlue® supply module internal heater circuit.
From To Value
A. If there is voltage, then there is a short circuit to another voltage source in the vehicle harness (VE). Locate
B. If there is no voltage, then the DEF/AdBlue® supply module internal heater has an internal short circuit. Re-
place the module.
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has been resolved.
operation.
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19104 (DTC 753A) - Short Circuit to Ground of DEF/AdBlue Supply

Module Heater Actuator powerstage
Context:
The Heater Control Unit (HCU) controls and monitors operation of the Diesel Exhaust Fluid (DEF)/AdBlue® supply
electrical failures, via Controller Area Network (CAN), to the Engine Control Unit (ECU). If the HCU senses a short
circuit to ground in the DEF/AdBlue® supply module internal heater control circuit, then this fault will occur.
Cause:
The HCU has communicated, via CAN, to the ECU that a short circuit to ground circuit has been detected in the
DEF/AdBlue® supply module internal heater circuit.
1. Faulty DEF/AdBlue® supply module internal heater circuit wiring, grounded circuit.
Solution:
2. Check the vehicle harness (VE) circuit wiring for a short circuit to ground.
From To Value

From To Value
A. If there is continuity, then there is a short circuit to ground in the vehicle harness (VE) circuit wiring. Locate and
repair the grounded conductor. Repair or replace the harness as required.
B. If there is no continuity, then there is a short circuit to ground in the DEF/AdBlue® supply module. Replace the
module.
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4. As there is no method of field testing or reflashing the HCU, replace the HCU.
has been resolved.
operation.
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19105 (DTC 879A) - DEF/AdBlue tank heater ECU driver over

temperature failure
Context:
The Engine Control Unit (ECU) monitors the DEF/Adblue® tank heating valve circuit. If the ECU detects a short circuit
power condition in the DEF/Adblue® tank heating valve control circuit, this fault will occur.
Cause:
The ECU has detected a short circuit power condition in the DEF/Adblue® tank heating valve circuit.
1. An internal failure in the DEF/Adblue® tank heating valve.

2. The DEF/Adblue® tank heating valve low side driver control wiring is shorted to another voltage source.
3. A faulty ECU.
Solution:
2. Check the DEF/Adblue® tank heating valve for an internal failure.
Disconnect the DEF/Adblue® tank heating valve.
Use a multimeter to perform the following resistance check on the DEF/Adblue® tank heating valve pins :
From To Value
DEF/Adblue® tank heating valve pin DEF/Adblue® tank heating valve pin There should be between 11 – 16 Ω.
1 3
A. If the value is within the specified range, leave connector X-611 disconnected and continue to step 3.
B. If the value is not within the specified range, the DEF/Adblue® tank heating valve has failed internally. Replace
the DEF/Adblue® tank heating valve and retest.
3. Check the DEF/Adblue® tank heating valve for a short circuit to switched battery power.
With the key in the ON position, use a multimeter to perform the following voltage check :
From To Value
A. If there is voltage, there is a short circuit to switched battery power in the DEF/Adblue® tank heating valve
wiring. Locate and repair the shorted conductors. Repair or replace the harness as required.
B. If there is no voltage, continue to step 4.

4. Check the DEF/Adblue® tank heating valve for a short circuit to another voltage source.
Disconnect connector the ECU connector X-462.
With the key in the OFF position, use a multimeter to perform the following continuity check :
From To Value
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A. If there is continuity, there is a short circuit in the DEF/Adblue® tank heating valve wiring. Locate and repair
the shorted conductors. Repair or replace the harness as required.
B. If there is no continuity, check the ECU for the appropriate software and re-flash if necessary.
has been resolved.
operation.
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19106 (DTC 759A) - DEF/AdBlue tank heater actuator short circuit

to ground failure
Context:
The Engine Control Unit (ECU) monitors the DEF/Adblue® tank heating valve circuit. If the ECU detects a short to
ground condition in the DEF/Adblue® tank heating valve circuit, this fault will occur.
Cause:
The ECU has detected a short to ground condition in the DEF/Adblue® tank heating valve circuit.
1. A short circuit to ground in the DEF/Adblue® tank heating valve wiring.

2. An internal failure in the DEF/Adblue® tank heating valve.
3. A faulty ECU.
Solution:
Disconnect the DEF/Adblue® tank heating valve.
From To Value
1 3
A. If the value is within the specified range, leave connector X-611 disconnected and continue to step 3.
B. If the value is not within the specified range, the DEF/Adblue® tank heating valve has failed internally. Replace
the DEF/Adblue® tank heating valve and retest.
3. Check the DEF/Adblue® tank heating valve for a short circuit to ground.
From To Value
A. If there is continuity, there is a short circuit in the DEF/Adblue® tank heating valve wiring. Locate and repair
B. If there is no continuity, check the ECU for the appropriate software and re-flash, if necessary.
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has been resolved.
operation.
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19107 (DTC 515A) - DEF/AdBlue supply module pump motor open

load failure
Context:
The Electronic Control Unit (ECU) monitors the DEF/Adblue® supply pump circuit for an open circuit condition. If the
ECU detects an open circuit condition, this fault will occur.
Cause:
The ECU has detected an open circuit condition in the DEF/Adblue® supply pump circuit.
1. An open circuit in the DEF/Adblue® supply pump wiring.

2. An internal failure in the DEF/Adblue® supply pump.
3. A faulty ECU.
Solution:
2. Check the DEF/Adblue® supply pump wiring for an open circuit.
Disconnect the DEF/Adblue® supply module at connector X-605.
From To Value
A. If there is no continuity, there is an open circuit condition in the DEF/Adblue® supply pump wiring. Locate and
repair the broken conductor. Check splice SP-121. Repair or replace the harness as required.
B. If there is continuity, leave connector X-605 disconnected and continue to step 3.

3. Replace the DEF/Adblue® supply module.
B. If the fault has not been resolved, check the ECU for the appropriate software and re-flash, if necessary.
has been resolved.
operation.
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19108 (DTC 613A) - DEF/AdBlue supply module pump motor short

circuit to battery failure
Context:
The Electronic Control Unit (ECU) monitors the DEF/Adblue® supply pump circuit for a short circuit to battery power
condition. If the ECU detects a short circuit to battery power, this fault will occur.
Cause:
The ECU has detected a short circuit to battery power in the DEF/Adblue® supply pump circuit.
1. A problem in the DEF/Adblue® supply pump wiring.

3. A faulty ECU.
Solution:
2. Check the DEF/Adblue® supply pump wiring for short circuit to battery.
With the key in the ON position, use a multimeter to perform the following voltage check :
From To Value
A. If there is voltage, there is a short to a voltage source in the DEF/Adblue® supply pump wiring. Locate and
B. If there is no voltage, leave connectors X-461 and X-605 disconnected and continue to step 3.
3. Check the DEF/Adblue® supply pump wiring for short circuit to another voltage source.
From To Value
X-461 pin 72 All other pins in connector X-461 There should be no continuity to any
other pin except X-461 pin 76
NOTE: There should be continuity to
X-461 pin 76
X-461 pin 72
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A. If there is continuity, there is a short circuit in the DEF/Adblue® supply pump wiring. Locate and repair the
shorted conductor. Repair or replace the harness as required.
B. If there is no continuity, leave connector X-605 disconnected and continue to step 4.

4. Replace the supply module.
has been resolved.
operation.
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19111 (DTC 723A) - DEF/AdBlue supply module pump motor short

circuit to ground failure
Context:
The Electronic Control Unit (ECU) monitors the DEF/Adblue® supply pump circuit for a short circuit to ground condi-
tion. If the ECU detects a short circuit to ground condition, this fault will occur.
Cause:
The ECU has detected a short circuit to ground condition in the DEF/Adblue® supply pump circuit.
1. A problem in the DEF/Adblue® supply pump wiring.

3. A faulty ECU.
Solution:
2. Check the DEF/Adblue® supply pump wiring for a short circuit to ground.
From To Value
X-461 pin 76
X-461 pin 72
A. If there is continuity, there is a short circuit condition in the DEF/Adblue® supply pump wiring. Locate and
B. If there is no continuity, leave connector X-605 disconnected and continue to step 3.

3. Replace the DEF/Adblue® supply module.
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has been resolved.
operation.
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19126 (DTC FF9F) - SCR Inducement: Warning, triggered by

tampering fault
Context:
this fault to occur. Any one of many Selective Catalytic Reduction (SCR) DEF/AdBlue® technical failure detection
faults will cause this fault to occur. The active fault causing this fault needs to be identified and resolved within the
next 36 h of operation to avoid engine de-rate.
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19140 (DTC 4BCA) - DEF/AdBlue concentration is out of range

Context:
The Engine Control Unit (ECU) monitors the DEF/AdBlue® quality, level, and temperature sensor via Controller Area
Network (CAN). If the ECU detects that the DEF/AdBlue® concentration is out of range, then this fault will occur.
1. Faulty DEF/AdBlue®, contaminated with diesel fuel or other fluids.

2. Faulty DEF/AdBlue®, ageing due to excessive storage time.
3. Faulty DEF/AdBlue®, exposure to very high temperatures.
4. Faulty DEF/AdBlue® quality, level, and temperature sensor, drifted or contamination of sensor.
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19141 (DTC 4CCA) - DEF/AdBlue quality sensor detects diesel fuel

in DEF/AdBlue tank
Context:
Control Unit (ECU). If a contaminant, such as diesel fuel is sensed in the DEF/AdBlue® fluid, then this fault will occur.
Cause:
The DEF/AdBlue® urea quality sensor has reported to the ECU that diesel fuel has been sensed in the DEF/AdBlue®
fluid.
1. Faulty DEF/AdBlue® fluid, contaminated with diesel fuel.

Solution:
1. Check for DEF/AdBlue® fluid contamination.
Secure a sample of the DEF/AdBlue® fluid from the tank to determine if diesel fuel exists in the tank.
There should be no diesel fuel.
A. If there is diesel fuel contamination, then flush the DEF/AdBlue® tank. After the tank is clean, replace the
DEF/AdBlue® fluid. Refer to the engine service manual Diesel Exhaust Fluid (DEF)/AdBlue®/ARLA tank -
Cleaning (10.500), if necessary.
B. If there is no contamination, then continue with step 2.

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19144 (DTC 9AEA) - CAN timeout error from DEF/AdBlue quality

sensor
Context:
The DEF/AdBlue® quality level temperature sensor is required to report information at regular intervals to the Engine
Control Unit (ECU) via CAN. If this information is not communicated within the allotted time frame, then this ECU
timeout fault will occur.
Cause:
The ECU has reported, via the engine sensor CAN bus, that a DEF/AdBlue® quality level temperature sensor timeout
of the DEF/AdBlue® quality sensor level temperature message has occurred.

3. Faulty DEF/AdBlue® quality level temperature sensor, hardware or firmware.
Solution:
2. Check DEF/AdBlue® quality level temperature sensor controller supply voltage.
Disconnect the vehicle (VE) harness from the DEF/AdBlue® quality sensor controller at connector X-608.
Use a multimeter to check for voltage on the VE harness side:
From To Value
X-608 pin 1 X-608 pin 3 There should be 12.0 V.
A. If the voltage is present, then leave connector X-608 disconnected and continue with step 3.

3. Determine the condition of the DEF/AdBlue® quality level temperature sensor controller CAN circuit.
Use a multimeter to measure the resistance of the CAN connection on the VE harness side:
From To Value

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A. If other faults exist, then locate and repair the faulted power, ground or CAN wiring condition.
splice and the DEF/AdBlue® quality level temperature sensor controller connector X-608. Locate and repair
the damage to the SCR supply power and ground or CAN circuit wiring.
5. As there is no method for field testing or re-flashing the sensor controller, replace the DEF/AdBlue® quality level
temperature sensor unit.
A. If the fault is resolved, use the EST, refer to the engine service manual Selective Catalytic Reduction (SCR)
exhaust treatment - Configure - Engine restart counter reset (10.500), if necessary. to perform the Engine
has been resolved.
operation.
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19155 (DTC 345A) - DEF/AdBlue Supply Module Pump Motor Speed

Deviation
Context:
The Engine Control Unit (ECU) monitors the DEF/AdBlue® supply module pump motor speed through an intelligent
pump motor driver chip inside the DEF/AdBlue® supply module. If the ECU detects a pump speed deviation, this fault
will occur.

2. Faulty DEF/AdBlue® supply module pump driver chip, failed.
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19156 (DTC 335A) - DEF/AdBlue supply module pump motor severe

speed deviation
Context:
For information regarding the functional operation of the Diesel Exhaust Fluid (DEF/AdBlue®) system, refer to the
The DEF/Adblue® supply pump control board monitors pump speed according to Pulse Width Modulated (PWM)
request. If an excessive current situation occurs and the DEF/Adblue® supply pump is restarted more than five times
in the same driving cycle (key cycle), then this fault will occur.
Cause:
The Engine Control Unit (ECU) has restarted the DEF/AdBlue® system supply module pump motor more than five
times due to an over-current condition.
1. Faulty DEF/AdBlue® system supply module, internal failure.
Solution:
1. Check DEF/AdBlue® supply module operation.
Use the Electronic Service Tool (EST) and follow the on-screen instructions to perform the Urea Dosing System
Test (UDST).
Follow the UDST Troubleshooting Guideline to determine the problem.
A. If the UDST identifies a problem, follow the UDST Troubleshooting Guideline to repair the failure.
B. If the UDST does not identify a problem, check the ECU for the appropriate software and re-flash, if necessary.
NOTE: Cold ambient (frozen DEF/AdBlue®) or extended period of non-use (crystalization) condition may be pre-
venting pump motor operation.
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19210 (DTC 57BA) - Open Load error of DEF/AdBlue Backflow Line

Context:
The Heater Control Unit (HCU) controls and monitors the operation of the Diesel Exhaust Fluid (DEF)/AdBlue® sup-
ply module suction line heater, the DEF/AdBlue® supply module back-flow line heater, and the DEF/AdBlue® supply
module pressure line heater. The DEF/AdBlue® supply module suction line heater and the DEF/AdBlue® supply
module back-flow line heater are wired in series and share a high side driver controlled circuit. The HCU communi-
cates electrical failures, via Controller Area Network (CAN) to the Engine Control Unit (ECU). If the HCU senses an
open circuit in the DEF/AdBlue® supply module suction line heater and the DEF/AdBlue® supply module back-flow
line heater shared circuit, then this fault will occur.
Cause:
module suction line heater and the DEF/AdBlue® supply module back-flow line heater circuit.
1. Faulty DEF/AdBlue® supply module suction line heater and the DEF/AdBlue® supply module back-flow line heater
circuit wiring, open circuit.
Solution:
From To Value
of resistance, typically 5 – 20 Ω.
A. If there is an infinite amount of resistance, then there is an open circuit in the DEF/AdBlue® supply module
suction line heater and the DEF/AdBlue® supply module back-flow line heater circuit wiring. Continue with
step 3.
B. If there is a nominal amount of resistance, then leave connector X-612 disconnected and continue to step 4.
3. Verify the condition of the series connected heater strips.
Disconnect the vehicle harness (VE) from the DEF/AdBlue® supply module suction line heater at connector X-634.
Use a multimeter to measure the resistance of the heater strip :
From To Value
of resistance, typically 3 – 10 Ω.
A. The resistance is between 3 – 10 Ω, then there is an open circuit in the wiring between X-612 and X-634.
Repair or replace the harness as required. Return to step 1 to confirm the elimination of the fault.
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B. If there is greater than 10 Ω, then there is an open circuit in the heater strips.Repair or replace the appropriate
heater strip.
4. As there is no method of field testing or re-flashing the HCU , replace the HCU.
has been resolved.
operation.
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19253 (DTC 69BA) - Short Circuit to Battery of DEF/AdBlue Pressure

Line heater Actuator powerstage
Context:
module suction line heater, the DEF/AdBlue® supply module back-flow line heater, and the DEF/AdBlue® supply
module pressure line heater. The DEF/AdBlue® supply module suction line heate and the DEF/AdBlue® supply mod-
ule back-flow line heater are wired in series and share a high side driver controlled circuit. The DEF/AdBlue® supply
module pressure line heater has its own high side driver controlled circuit. The HCU communicates electrical failures,
via Controller Area Network (CAN), to the Engine Control Unit (ECU). If the HCU senses a short circuit to another
voltage source in the DEF/AdBlue® supply module pressure line heater control circuit, then this fault will occur.
Cause:
in the DEF/AdBlue® supply module pressure line heater circuit.
1. Faulty DEF/AdBlue® supply module pressure line heater circuit wiring, short circuit to another voltage source.
Solution:
From To Value
A. If there is voltage, then there is a short circuit to another voltage source in the vehicle harness (VE) circuit
wiring. Locate and repair the damaged conductors. Repair or replace the harness as required.

has been resolved.
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operation.
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19255 (DTC 5BBA) - Open Load error of DEF/AdBlue Pressure Line

Context:
module back-flow line heater are wired in series and share a high side driver controlled circuit. The DEF/AdBlue®
supply module pressure line heater has its own high side driver controlled circuit. The HCU communicates electrical
failures, via Controller Area Network (CAN), to the Engine Control Unit (ECU). If the HCU senses an open circuit in
the DEF/AdBlue® supply module pressure line heater control circuit, then this fault will occur.
Cause:
module pressure line heater circuit.
1. Faulty DEF/AdBlue® supply module pressure line heater circuit wiring, open circuit.
Solution:
2. Verify the condition of the heater strip.
Disconnect the vehicle harness (VE) from the DEF/AdBlue® supply module pressure line heater at connector
X-633.
Use a multimeter to measure the resistance of the heater strip :
From To Value
A. If there is a nominal amount of resistance, the reconnect connector X-633 and continue with step 3.
B. If there is an infinite amount of resistance, the DEF/AdBlue® supply module pressure line heater heater strip
is open. Repair or replace the heater strip.
From To Value
A. If there is an infinite amount of resistance, then there is an open circuit between connector X-612 and connector
X-633. Locate and repair the broken conductor. Repair or replace the harness as required.
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B. If there is a nominal amount of resistance, continue with step 4.

A. If the fault is resolved, the return the machine to service.
has been resolved.
operation.
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19262 (DTC 649A) - DEF/AdBlue tank heater actuator short circuit

to battery failure
Context:
The Engine Control Unit (ECU) monitors the DEF/Adblue® tank heating valve circuit. If the ECU detects a short circuit
to battery power in the DEF/Adblue® tank heating valve circuit, then this fault will occur.
Cause:
The ECU has detected a short circuit to battery in the DEF/Adblue® tank heating valve circuit.
1. Faulty DEF/Adblue® tank heating valve, internal failure.

2. Faulty DEF/Adblue® tank heating valve wiring.
Solution:
Disconnect the vehicle harness (VE) from the DEF/Adblue® tank heating valve at connector X-611.
From To Value
1 3
A. If the value is within the specified range, then leave connector X-611 disconnected and continue to step 3.
B. If the value is not within the specified range, then the DEF/Adblue® tank heating valve has failed internally.
Replace the DEF/Adblue® tank heating valve.
3. Check the DEF/Adblue® tank heating valve for a short circuit to key battery power.
(VE) side :
From To Value
A. If there is voltage, then there is a short circuit to key battery power in the DEF/Adblue® tank heating valve

4. Check the DEF/Adblue® tank heating valve for a short circuit to another voltage source.
Disconnect connector the vehicle harness (VE) from the ECU at connector X-461.
harness (VE) side :
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From To Value
A. If there is continuity, then there is a short circuit in the DEF/Adblue® tank heating valve circuit. Locate and
B. If there is no continuity, then check the ECU A-9000 for the appropriate software and re-flash, if necessary.
has been resolved.
operation.
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19264 (DTC 569A) - DEF/AdBlue tank heater actuator open load

failure
Context:
The Engine Control Unit (ECU) monitors the DEF/Adblue® tank heating valve circuit. If the ECU detects an open
circuit in the DEF/Adblue® tank heating valve circuit, then this fault will occur.
Cause:
The ECU has detected an open circuit in the DEF/Adblue® tank heating valve circuit.
1. Faulty DEF/Adblue® tank heating valve wiring, open circuit.

2. Faulty DEF/Adblue® tank heating valve, internal failure.
Solution:
Disconnect the vehicle harness (VE) from the DEF/Adblue® tank heating valve at connector X-611.
From To Value
1 3
A. If the value is within the specified range, then leave connector X-611 disconnected and continue to step 3.
B. If the value is not within the specified range, then the DEF/Adblue® tank heating valve has failed internally.
Replace the DEF/Adblue® tank heating valve.
3. Check the DEF/Adblue® tank heating valve circuit for an open circuit.
Disconnect connector the vehicle harness (VE) from the ECU at connector X-461.
harness (VE) side :
From To Value
A. If there is no continuity, then there is an open circuit in the DEF/Adblue® tank heating valve circuit. Locate and
repair the broken conductor. Repair or replace the harness as required.
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has been resolved.
operation.
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19267 (DTC F2AF) - Engine idle shutdown commanded from SCR

inducement
Context:
This failure path is only for information. No actions are necessary due to this failure alone. If an application calibrated
period of time at low idle is exceeded, the engine is shutdown, and this fault occurs.
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19323 (DTC 94FB) - External engine shutdown request received

Context:
This fault is for informational purposes and requires no action. This fault is the result of a request for engine shutdown
via Controller Area Network (CAN) to the Engine Control Unit (ECU).
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19335 (DTC 224A - Pressure build-up error

Context:
As the DEF/AdBlue ® system is evacuated at each system stop (during after-run) to prevent dosing valve damages
due to frozen DEF/AdBlue ® fluid, the system must be refilled and pressurized after each engine start. In general the
pressure build up can be separated into two phases. The first phase is pressure build up to 1.0 bar (14.5 psi). For this
the pump motor internal to the DEF/AdBlue ® supply module is set to 68.01% for high feeding until the DEF/AdBlue ®
fluid pressure exceeds 1.0 bar (14.5 psi), which means that the system is refilled and the detection mode back-flow
check can be executed. If the DEF/AdBlue ® fluid pressure does not reach 1.0 bar (14.5 psi) within 50.0 s a new
pressure build up cycle is started. After 10 unsuccessful "pressure build up cycles" the system goes into a "stand-by
state" and a failure is reported. In the case of a successful detection mode back-flow check, the system enters the
second phase of the pressure build up cycle. The second phase is pressure build up to 3.5 bar (50.8 psi), which
means that the system can enter the “metering control state” (normal operation). For this the pump motor internal to
the DEF/AdBlue ® supply module is set to 68.01% for high feeding until the DEF/AdBlue ® fluid pressure exceeds
3.5 bar (50.8 psi), which means the pressure build up is passed and the metering control state is entered (normal
operation). If the DEF/AdBlue ® fluid pressure does not reach 3.5 bar (50.8 psi) within 50.0 s a new pressure build
up cycle is started. After 10 unsuccessful "pressure build up cycles" the system goes into a "stand-by state" and a
failure is reported.
Cause:
The Engine Control Unit has recorded 10 unsuccessful "pressure build up cycles" and placed the DEF/AdBlue ®
system into a "stand-by state".
1. Faulty DEF/AdBlue ® fluid level, too low.

2. Faulty DEF/AdBlue ® suction and back-flow lines, crossed at DEF/AdBlue ® supply module or DEF/AdBlue ®
tank.
3. Faulty DEF/AdBlue ® back-flow line, blocked.
4. Faulty DEF/AdBlue ® pressure line, heavy leakage.
7. Faulty DEF/AdBlue ® supply module pre-filter, clogged.
9. Faulty DEF/AdBlue ® supply module, pump membrane or pressure sensor failure.
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19336 (DTC 354A) - DEF/AdBlue general pressure check failure

Context:
The Engine Control Unit (ECU) monitors the DEF/AdBlue® system pressure with a general pressure check using a
pressure sensor inside of the DEF/AdBlue® supply module. If the DEF/AdBlue® system pressure is greater than
4.60 bar (66.70 psi) while the DEF/AdBlue® dosing module is open, and the pressure line heating is active, this fault
will occur.
1. Faulty DEF/AdBlue® system pressure lines, frozen or blocked.

2. Faulty DEF/AdBlue® heating system, ineffective.
3. Faulty DEF/AdBlue® dosing module solenoid valve, blocked or damaged.
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19337 (DTC 344A) - DEF/AdBlue dosing system backflow line

pressure too high plausibility failure
Context:
For information regarding the functional operation of the Diesel Exhaust Fluid (DEF/AdBlue®) system, refer to the
The Engine Control Unit (ECU) checks the back-flowline and back-flow connector for blockages. If a frozen or other-
wise blocked back-flow line or back-flow connector is detected, this fault will occur.
Cause:
The ECU has determined that a high pressure condition exists in the back-flow line (tube) portion of the DEF/AdBlue®
system.
1. Faulty DEF/AdBlue® back-flowline (tube), restricted.

2. Faulty DEF/AdBlue® connector (throttle), restricted.
3. Faulty DEF/AdBlue® system heater, ineffective.
Solution:
1. Check DEF/AdBlue® system back-flowline (tube).
Visually and tactually inspect the supply module to tank back-flowline for blockage or damage.
A. If any blockage or damage is found, replace or repair as required.
B. If no blockage or damage is found, continue with step 2.

2. Check DEF/AdBlue® supply module back-flow connector (throttle).
Visually inspect the supply module back-flow connector (throttle) for blockage or damage.
A. If any blockage or damage is found, then replace or repair as required.
B. If no blockage or damage is found, then continue with step 3.

3. Check DEF/AdBlue® supply module back-flowline (tube) and connector (throttle) for freezing.
Visually and tactually inspect the supply module back-flowline (tube) and connector (throttle) for blockage due to
freezing.
There should be no blockage.
A. If any blockage due to freezing is found, then the DEF/AdBlue® heating system is deficient. Locate and repair
or replace, as required, the heating system deficiency.
B. If no blockage due to freezing is found, then continue with step 4.

4. Replace the DEF/AdBlue® supply module.
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Check to see that this fault has been resolved.
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19345 (DTC 9ECA) - Timeout error of CAN receive frame HCU Data
Context:
The Heater Control Unit is required to report information at regular intervals to the Engine Control Unit (ECU) via CAN.
If this information is not communicated within the allotted time frame, then this ECU timeout fault will occur.
Cause:
The ECU has reported, via the engine sensor CAN bus, that a HCU timeout of the HCU message has occurred.
1. Faulty HCU supply voltage, out of required range.

2. Faulty HCU CAN wiring, an open circuit or a short circuit.
3. Faulty HCU, hardware or firmware.
Solution:
2. Check HCU controller supply voltage.
Disconnect the vehicle (VE) harness from the HCU controller at connector X-612.
With the key switch in the ON position, use a multimeter to check for voltage on the VE harness side :
From To Value
B. If the voltage is not present, then locate and repair the faulted power or ground wiring condition.
3. Determine the condition of the HCU controller CAN circuit.
VE harness side
From To Value
A. If the measured resistance is correct, then nue with step 5.

A. If other faults exist, then repair these faults first.
splice and the HCU controller connector X-612. Locate and repair the damage to the CAN circuit wiring.
5. As there is no method for field testing or re-flashing the controller, replace the HCU module.
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has been resolved.
operation.
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19346 (DTC BFBA) - Timeout error of CAN receive frame HCU Data
Context:
The Heater Control Unit is required to report information at regular intervals to the Engine Control Unit (ECU) via CAN.
If this information is not communicated within the allotted time frame, this ECU timeout fault will occur.
Cause:
The ECU has reported, via the engine sensor CAN bus, that a HCU timeout of the HCU message has occurred.
1. Faulty HCU supply voltage, out of required range.

2. Faulty HCU CAN wiring, an open circuit or a short circuit.
Solution:
2. Check HCU controller supply voltage.
Disconnect the vehicle (VE) harness from the HCU controller at connector X-612.
With the key switch in the ON position, use a multimeter to check for voltage on the VE harness side:
From To Value
X-612 6 X-612 pin 7 There should be 12.0 V.
B. If the voltage is not present, then locate and repair the faulted power or ground wiring condition.
3. Determine the condition of the HCU A-9105 controller CAN circuit.
VE harness side:
From To Value

A. If other faults do exist, use the appropriate vehicle service manual to locate and repair the faulted CAN wiring
condition.
B. If no other faults exist, the vehicle (VE) harness wiring is damaged between the SCR devices harness splice
and the HCU controller connector X-612. Locate and repair the damage to the CAN circuit wiring.
5. As there is no method for field testing or re-flashing the controller, replace the HCU module.
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has been resolved.
operation.
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19356 (DTC 3FDE) - Downstream NOx sensor signal and NH3

sensor signal plausibility check failure
Context:
For information regarding the functional operation of the NH3 sensor and the NH3 control unit, refer to the engine
service manual Ammonia (NH3) sensor - Dynamic description (55.988). The NH3 control unit is required to report
information at regular intervals to the Engine Control Unit (ECU) via Controller Area Network (CAN). The NH3 sensor
senses both NH3 and NOx. If the NOx signal is smaller than the NH3 signal, then this fault will occur.
Cause:
The NH3 control unit has reported via CAN to the ECU that the NOx and/or NH3 signal is not plausible.
1. Faulty NH3 sensor, drifted or defective.

Solution:

has been resolved.
operation.
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19402 (DTC 9AAA) - CAN timeout error - Urea tank level

Context:
The DEF/AdBlue® quality level temperature sensor is required to report information at regular intervals to the Engine
Control Unit (ECU) via Controller Area Network (CAN). If this information is not communicated within an allotted time
frame, then this ECU timeout fault will occur.
Cause:
The ECU has reported, via the engine sensor CAN bus, that a DEF/AdBlue® quality level temperature sensor timeout
of the DEF/AdBlue® quality level temperature sensor level message has occurred.

3. Faulty DEF/AdBlue® quality level temperature sensor, hardware or firmware.
Solution:
2. Check DEF/AdBlue® quality level temperature sensor controller supply voltage.
Disconnect the vehicle (VE) harness from the DEF/AdBlue® quality level temperature sensor controller at con-
nector X-608.
With the key switch in the ON position, use a multimeter to check for voltage on the VE harness side:
From To Value

3. Determine the condition of the DEF/AdBlue® quality level temperature sensor controller CAN circuit.
VE harness side :
From To Value
A. If the measured resistance is correct, continue with step 5.
B. If the measured resistance is not correct, continue with step 4.

A. If other faults do exist, then locate and repair the faulted power, ground or CAN wiring condition.
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splice and the DEF/AdBlue® quality level temperature sensor controller connector X-608. Locate and repair
the damage to the SCR supply power and ground or CAN circuit wiring.
5. As there is no method for field testing or re-flashing the sensor controller, replace the DEF/AdBlue® quality level
temperature sensor unit.
A. If the fault is resolved, then use the EST, refer to the engine service manual Selective Catalytic Reduction
(SCR) exhaust treatment - Configure - Engine restart counter reset (10.500), if necessary. to perform the
Engine Restart Counter Reset / Unlock Inducement configuration. Then return the machine to service.
has been resolved.
operation.
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19415 (DTC FABF) - Remaining DEF/AdBlue is below the empty

threshold
Context:
For information regarding the functional operation of the Selective Catalytic Reduction (SCR) system refer to the
The Engine Control Unit (ECU) monitors the level and temperature of the DEF/AdBlue® fluid. If the level of the fluid
becomes 0.0% of full (empty), this fault will occur.
Cause:
The DEF/AdBlue® quality, level and temperature sensor level signal to the ECU is 0.0% of full.
1. DEF/AdBlue® tank fluid level, too low.

2. Faulty DEF/AdBlue® quality, level and temperature sensor, failed internally.
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19421 (DTC 33BE) - Downstream NOx sensor failed negative drift

test monitoring
Context:
The SCR downstream NOx sensor is required to report information at regular intervals to the Engine Control Unit
(ECU) via Controller Area Network (CAN). The ECU checks the possible negative drift on the SCR downstream NOx
sensor measuring its value during a time period in which zero is expected. If the SCR downstream NOx sensor minimal
value, measured at idle following a catalyst saturation phase (monitor stage), is below -40.00 ppm, this fault will occur.
sensor, refer to the engine service manual Nitrogen Oxide (NOx) sensor - Dynamic description (55.988).
Cause:
The ECU has determined that the SCR downstream NOx sensor is drifted.

Solution:
sensor.
data (Downstream sensor) (55.988) if necessary, to perform the Replacement of NOx Downstream Sensor -
essary.
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19422 (DTC 43CE) - Downstream NOx sensor signal is stuck at a

constant value
Context:
The SCR downstream NOx sensor is required to report information at regular intervals to the Engine Control Unit
(ECU) via Controller Area Network (CAN). If the SCR downstream NOx sensor signal, during engine operation, does
not vary sufficiently, this fault will occur. For information regarding the functional operation of the smart Selective Cat-
alytic Reduction (SCR) downstream NOx sensor, refer to the engine service manual Nitrogen Oxide (NOx) sensor
Cause:
The SCR downstream NOx sensor has reported, via CAN, to the ECU that the expected signal dynamic is not being
sensed.
1. Faulty SCR downstream NOx sensor, incorrectly / improperly installed (signal is not changing).
Solution:
2. Determine proper installation of the SCR downstream NOx sensor.
Remove and re-install, if necessary, the SCR downstream NOx sensor to assure that it is properly aligned and
securely installed.
Then check to see if the fault is resolved.

3. As there is no method for flashing or field testing the SCR downstream NOx sensor, replace the sensor.
(Downstream sensor) (55.988), if necessary, to perform the Replacement of the Nox Downstream Sensor - Reset
has been resolved.
operation.
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19423 (DTC 3CDA) - Upstream NOx sensor comparison to a

calculated NOx value failure
Context:
The upstream NOx sensor plausibility monitoring, done by the Engine Control Unit (ECU), is established by monitoring
the filtered difference between the NOx estimation output, as determined by the ECU, and the corrected NOx sensor
signal. The upstream NOx sensor deviation is checked comparing the measured signal with the estimated one. If
deviation, in certain enabling conditions, is higher than estimated one, according to a calibrated threshold, this fault
will occur. For information regarding the functional operation of the smart Diesel Oxidation Catalyst (DOC) upstream
NOx sensor, refer to the engine service manual Nitrogen Oxide (NOx) sensor - Dynamic description (55.988).
Cause:
The ECU has determined the upstream NOx sensor signal is not plausible.
1. Faulty upstream NOx sensor, hardware or firmware.
Solution:
Use the Electronic Service Tool (EST) to check for fault 19071 – SCR catalyst efficiency lower than first NOx
production threshold level.
upstream NOx sensor A-9103 is poisoned. Replace the upstream NOx sensor. Then use EST, refer to the
engine service manual Nitrogen Oxide (NOx) sensor - Configure - Reset ECU data (Upstream sensor)
(55.988) if necessary, to perform the Replacement of Nox Upstream Sensor - Reset ECU Data configuration.
ignore this fault.
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19434 (DTC E26D) - ECU internal failure - EEPROM erase error

Context:
the ECU determines that flash memory can not be performed, then this fault will occur.
Solution:
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19435 (DTC E36D) - ECU internal failure - EEPROM read error

Context:
the ECU determines that at least three memory blocks can not be read during this monitoring, this fault will occur.
Solution:
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19436 (DTC E46D) - ECU internal failure - EEPROM write error

Context:
the ECU determines that if one memory block can not be written at least three times during this monitoring, this fault
will occur.
Solution:
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19496 (DTC 184A) - Monitoring of over pressure

Context:
The Engine Control Unit (ECU) monitors DEF/AdBlue® pressure using a pressure sensor inside the DEF/AdBlue®
supply module. If the ECU determines that DEF/AdBlue® pressure is greater than 7.50 bar (108.75 psi), the system
will go into a stand-by state and this fault will occur.
1. Faulty DEF/AdBlue® supply module back-flow line, blocked.

2. Faulty DEF/AdBlue® supply module back-flow filter, clogged.
3. Faulty DEF/AdBlue® supply module back-flow throttle, clogged.
4. Faulty DEF/AdBlue® supply module back-flow non-return valve, does not open.
6. Faulty DEF/AdBlue® supply module pressure sensor, internal failure.
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19523 (DTC 49AA) - DEF/AdBlue tank temperature failure

Context:
The Engine Control Unit (ECU) monitors the DEF/AdBlue® quality level temperature sensor via Controller Area Net-
work (CAN). The physical value of the DEF tank temperature is updated with sensed value available through CAN. If
the ECU detects an error in the DEF/AdBlue® quality level temperature sensor, this fault will occur.
1. Faulty DEF/AdBlue® quality level temperature sensor, internal failure.

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19559 (DTC F18F) - DEF/AdBlue level too low warning is active -

Stage 1
Context:
The Engine Control Unit (ECU) monitors the level, temperature, and quality of the DEF/AdBlue® fluid. If the level of
the fluid falls below 10% of full, this fault will occur.
Cause:
The DEF/AdBlue® tank level sensor level signal to the ECU is less than 10% of full.

2. Faulty DEF/AdBlue® tank level and temperature sensor, failed internally.
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19568 (DTC F28F) - DEF/AdBlue level too low warning is active -

Stage 2
Context:
The Engine Control Unit (ECU) monitors the level, temperature, and quality of the DEF/AdBlue® fluid. If the level of
the fluid falls below 4.80% of full, then this fault will occur.
Cause:
The DEF/AdBlue® tank level sensor level signal to the ECU is less than 4.80% of full.

2. Faulty DEF/AdBlue® tank level and temperature sensor, failed internally.
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19748 (DTC 833A) - DEF/AdBlue supply module pump motor ECU

driver over temperature failure
Context:
The Electronic Control Unit (ECU) monitors the DEF/Adblue® supply pump circuit for an over temperature/current
condition. If the ECU detects over temperature/current condition, this fault will occur.
Cause:
The ECU has detected over temperature/current condition in the DEF/Adblue® supply pump circuit.
1. Faulty DEF/Adblue® supply pump, wiring.

2. Faulty DEF/Adblue® supply pump, internal failure.
Solution:
2. Check the DEF/Adblue® supply pump wiring for short to battery power condition.
(VE) side :
From To Value
A. If there is voltage, then there is a short circuit to another voltage source in the DEF/Adblue® supply pump
wiring. Locate and repair the shorted conductor.
B. If there is no voltage, then leave connector X-462 and connector X-605 disconnected. Continue to step 3.
3. Check the DEF/Adblue® supply pump wiring for short circuit.
(VE) side :
From To Value
other pin except X-461 pin 76.
X-461 pin 76.
other pin except X-461 pin 72.
X-461 pin 72.
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A. If there is continuity, then there is a short circuit in the DEF/Adblue® supply pump wiring. Locate and repair
the shorted conductor.
4. Replace the supply module.
has been resolved.
operation.
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19787 (DTC F49F) - SCR Inducement: Level 1 (Torque reduction),

triggered by DEF/AdBlue dosing interruption fault
Context:
this fault to occur. Any one of many Selective Catalytic Reduction (SCR) DEF/AdBlue® fluid injection interruption
faults that remains active for more than 10 h will cause this fault to occur.
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19788 (DTC F59F) - SCR Inducement: Level 3 (creep mode),

triggered by DEF/AdBlue dosing interruption fault
Context:
faults that remains active for more than 20 h will cause this fault to occur.
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19789 (DTC F69F) - SCR Inducement: Warning, triggered by

DEF/AdBlue dosing interruption fault
Context:
faults will cause this fault to occur. The active fault causing this fault needs to be identified and resolved within the
next 10 h of operation to avoid engine derate.
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19797 (DTC FA9F) - SCR Inducement: Level 1 (torque reduction),

triggered by DEF/AdBlue quality fault
Context:
This fault is only for informational purposes and requires no action other than the resolution of other active faults that
may have caused this fault to occur. Other actives faults, after being active for more than 10 h, will cause this fault to
occur.
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19798 (DTC FB9F) - SCR Inducement: Level 3 (creep mode),

triggered by DEF/AdBlue Quality fault
Context:
may have caused this fault to occur. Other active faults which after being active for more than 20 h will cause this
fault to occur.
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19799 (DTC FC9F) - SCR Inducement: Warning, triggered by

DEF/AdBlue Quality fault
Context:
may have caused this fault to occur. The active fault causing this fault needs to be identified and resolved within the
next 10 h of operation to avoid engine derate.
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19800 (DTC FD9F) - SCR Inducement: Level 1 (Torque reduction),

triggered by Tampering fault
Context:
this fault to occur. Any one of many Selective Catalytic Reduction (SCR) DEF/AdBlue® technical failure tampering
detection faults that remains active for more than 36 h will cause this fault to occur.
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19801 (DTC FE9F) - SCR Inducement: Level 3 (creep mode),

triggered by Tampering fault
Context:
this fault to occur. Any one of many Selective Catalytic Reduction (SCR) DEF/AdBlue® technical failure tampering
detection faults that remains active for more than 100 h will cause this fault to occur.
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19817 (DTC 377A) - DEF/AdBlue dosing valve is blocked

Context:
The Engine Control Unit (ECU) monitors the functionality of the DEF/AdBlue® dosing module by detection of the
needle movement, called BIP (Beginning of Injection Period). The needle is opened by a magnetic field, which is
produced by a coil during electrical valve actuation. The inductivity of the coil is changing as soon as the needle
reaches the rear stop, which causes a variation of the current (negative peak). If the needle does not move, this
negative current peak does not occur and this fault will occur.
1. Faulty DEF/AdBlue® dosing module, stuck open or stuck closed mechanically or frozen.
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19835 (DTC 5468) - Open load temperature error on the

Turbocharger PWM output powerstage
Context:
The Engine Control Unit (ECU) monitors the wastegate pressure modulator valve circuit. If the ECU determines that
there is an open circuit in the wastegate pressure modulator valve circuit, then this fault will occur.
Cause:
The ECU has detected an open circuit in the wastegate pressure modulator valve circuit.
1. Faulty wastegate pressure modulator valve wiring, open circuit.

2. Faulty wastegate pressure modulator valve, internal failure.
Solution:
2. Check the wastegate pressure modulator valve internal resistance.
Disconnect the wastegate pressure modulator valve.
Use a multimeter to perform the following resistance check on the wastegate pressure modulator valve pins :
From To Value
Wastegate pressure modulator valve Wastegate pressure modulator valve There should be between 21.8 –
pin 1 pin 2 24.2 Ω.
NOTE: The provided value should be measured at a temperature of approximately 20 °C (68 °F).
A. If there is between 21.8 – 24.2 Ω, then leave the wastegate pressure modulator valve disconnected and con-
tinue to step 3.
B. If there is not between 21.8 – 24.2 Ω, then the wastegate pressure modulator valve has failed internally. Re-
place the wastegate pressure modulator valve.
3. Check the wastegate pressure modulator valve engine harness (EN) wiring for an open circuit.
(EN) side :
From To Value
Wastegate pressure modulator valve X-470 pin 28 There should be continuity.
pin 1
Wastegate pressure modulator valve X-470 pin 27 There should be continuity.
pin 2
A. If there is no continuity, then there is an open circuit in the wastegate pressure modulator valve wiring in the
engine harness (EN). Locate and repair the broken conductor.
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4. Check the wastegate pressure modulator valve vehicle harness (VE) wiring for an open circuit.
side :
From To Value
12.0 V.
A. If there is no voltage, then there is an open circuit in the wastegate pressure modulator valve wiring in the
vehicle harness (VE). Locate and repair the broken conductor. Repair or replace the harness as required.
B. If there is approximately 12.0 V, then leave connector X-470 disconnected and continue to step 5.
5. Check the wastegate pressure modulator valve vehicle harness (VE) wiring for an open circuit.
(VE) side :
From To Value
A. If there is no continuity, then there is an open circuit in the wastegate pressure modulator valve wiring in the
vehicle harness (VE). Locate and repair the broken conductor. Repair or replace the harness as required.
has been resolved.
operation.
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19836 (DTC 8368) - Over temperature error on the Turbocharger

PWM output powerstage
Context:
there is an over temperature/current condition in the wastegate pressure modulator valve circuit, then this fault will
occur.
Cause:
The ECU has detected an over temperature/current condition in the wastegate pressure modulator valve circuit.
1. Faulty wastegate pressure modulator valve wiring, short circuit to another voltage source.
Solution:
Disconnect the harness from the wastegate pressure modulator valve.
From To Value
pin 1 pin 2 24.2 Ω.
tinue to step 3.
3. Check the wastegate pressure modulator valve wiring for a short circuit.
(EN) side :
From To Value
Wastegate pressure modulator valve Wastegate pressure modulator valve There should be no continuity.
A. If there is continuity, then there is a short circuit in the wastegate pressure modulator valve wiring. Locate and

4. Check the wastegate pressure modulator valve wiring for a short circuit to battery condition.
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(EN) side :
From To Value
Wastegate pressure modulator valve Chassis ground There should be no voltage.
connector pin 2
A. If there is voltage, then there is a short circuit to battery in the wastegate pressure modulator valve wiring.

5. Check the wastegate pressure modulator valve wiring for a short circuit to another voltage source.
(EN) side :
From To Value
Wastegate pressure modulator valve Chassis ground There should be no voltage.
connector pin 2
A. If there is voltage, then there is a short circuit to another voltage source in the wastegate pressure modulator
valve wiring in the engine harness (EN). Locate and repair the shorted conductor. Repair or replace the harness
as required.

6. Check the wastegate pressure modulator valve wiring for a short circuit to another voltage source.
(VE) side :
From To Value
A. If there is voltage, then there is a short circuit to another voltage source in the wastegate pressure modulator
valve wiring in the vehicle harness (VE). Locate and repair the shorted conductor. Repair or replace the harness
as required.
has been resolved.
operation.
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19837 (DTC 6168) - SCB error on the Turbocharger PWM output

powerstage
Context:
there is a short circuit to another voltage source in the wastegate pressure modulator valve circuit, then this fault will
occur.
Cause:
The ECU has detected a short circuit to another voltage source in the wastegate pressure modulator valve circuit.
1. Faulty wastegate pressure modulator valve wiring, short circuit to another voltage source.
Solution:
From To Value
pin 1 pin 2 24.2 Ω.
tinue to step 3.
3. Check the wastegate pressure modulator valve wiring for a short circuit.
(EN) side :
From To Value
Wastegate pressure modulator valve Wastegate pressure modulator valve There should be no continuity.
A. If there is continuity, then there is a short circuit in the wastegate pressure modulator valve wiring. Locate and
B. If there is no continuity, continue to step 4.

4. Check the wastegate pressure modulator valve Y-9008 wiring for a short to battery condition.
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(EN) side :
From To Value
A. If there is voltage, there is a short to battery in the wastegate pressure modulator valve wiring. Use the appro-
priate service manual, if necessary to locate and repair the shorted conductor.

5. Check the wastegate pressure modulator valve Y-9008 wiring for a short to a voltage source.
(EN) side :
From To Value
A. If there is voltage, there is a short to a voltage source in the wastegate pressure modulator valve wiring in the
engine harness (EN). Locate and repair the shorted conductor.

6. Check the wastegate pressure modulator valve Y-9008 wiring for a short to a voltage source.
Disconnect the vehicle harness (VE) from the ECU A-9000 at connector X-9121.
(VE) side :
From To Value
A. If there is voltage, there is a short to a voltage source in the wastegate pressure modulator valve wiring in the
vehicle harness (VE). Locate and repair the shorted conductor.
B. If there is no voltage, check the ECU A-9000 for the appropriate software and re-flash, if necessary.
has been resolved.
operation.
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19838 (DTC 7268) - SCG error on the Turbocharger PWM output

powerstage
Context:
there is a short circuit to ground in the wastegate pressure modulator valve circuit, then this fault will occur.
Cause:
The ECU has detected a short circuit to ground in the wastegate pressure modulator valve circuit.
1. Faulty wastegate pressure modulator valve wiring, short circuit to ground.

Solution:
From To Value
pin 1 pin 2 24.2 Ω.
tinue to step 3.
3. Check the wastegate pressure modulator valve engine harness (EN) wiring.
(EN) side :
From To Value
Wastegate pressure modulator valve Chassis ground There should be no continuity.
connector pin 2
A. If there is continuity, then there is a short circuit in the wastegate pressure modulator valve engine harness
4. Check the wastegate pressure modulator valve vehicle harness (VE) wiring.
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(VE) side of the connectors from :
From To Value
A. If there is continuity, then there is an short circuit in the wastegate pressure modulator valve vehicle harness
has been resolved.
operation.
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19858 (DTC 1748) - SRC High for turbine upstream temperature

sensor
Context:
The Engine Control Unit (ECU) monitors the exhaust manifold temperature sensor. If the ECU detects a voltage
greater than 3.59 V in the exhaust manifold temperature sensor signal circuit, then this fault will occur. The sensor
value will be frozen at the last valid value for a preliminary failure or jump to a fixed replacement value of 350 °C
(662 °F) if the failure is validated. For more information regarding the technical specifications of the exhaust manifold
temperature sensor, refer to the engine service manual Exhaust manifold temperature sensor - Technical Data
(55.014).
Cause:
The ECU has detected a voltage greater than 3.59 V in the exhaust manifold temperature sensor signal circuit.
1. Faulty exhaust manifold temperature sensor circuit wiring, a short circuit to another voltage source.
2. Faulty exhaust manifold temperature sensor circuit wiring, open circuit.
3. Faulty exhaust manifold temperature sensor, internal failure.
Solution:
2. Check the exhaust manifold temperature sensor for an internal failure.
Disconnect the engine harness (EN) from the exhaust manifold temperature sensor.
Use a multimeter to measure the resistance on the exhaust manifold temperature sensor pins :
From To Value
Exhaust manifold temperature Exhaust manifold temperature There should be between 170.2 –
A. If there is between 170.2 – 849.7 Ω, then leave the exhaust manifold temperature sensor disconnected and
continue to step 3.
B. If there is not between 170.2 – 849.7 Ω, then the exhaust manifold temperature sensor has failed. Replace the
exhaust manifold temperature sensor.
3. Check the exhaust manifold temperature sensor engine harness (EN) wiring.
(EN) side :
From To Value
Exhaust manifold temperature Chassis ground There should be no voltage.
(EN) side :
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From To Value
Exhaust manifold temperature Chassis ground There should be less than 5.5 V.
A. If the specified values are not measured, then there is a short circuit to battery in the exhaust manifold temper-
ature sensor signal circuit wiring. Locate and repair the damaged conductors. Repair or replace the harness
as required.
B. If the specified values are measured, then leave the exhaust manifold temperature sensor disconnected and
continue to step 4.
4. Check the exhaust manifold temperature sensor circuit wiring for an open circuit.
Disconnect the vehicle harness (VE) from the engine interface connector at connector X-470.
(EN) side :
From To Value
Exhaust manifold temperature X-470 pin 26 There should be continuity.
Exhaust manifold temperature X-470 pin 25 There should be continuity.
(VE) side :
From To Value
A. If there is no continuity, then there is an open circuit in the exhaust manifold temperature sensor signal circuit
wiring.Locate and repair the open circuit. Repair or replace the harness as required.
B. If there is continuity on both checks, then leave connector X-470 and connector X-462 disconnected and con-
tinue to step 5.
(EN) side :
From To Value
A. If there is continuity, then there is a short circuit in the exhaust manifold temperature sensor signal circuit in
the engine harness (EN) wiring.Locate and repair the shorted conductor. Repair or replace the harness as
required.

6. Check the exhaust manifold temperature sensor vehicle harness (VE) wiring.
(VE) side :
From To Value
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the vehicle harness (VE) wiring.Locate and repair the damaged conductors. Repair or replace the harness as
required.
B. If there is no continuity, then check the ECU software and re-flash, if necessary.
has been resolved.
operation.
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19859 (DTC 2848) - SRC low for turbine upstream temperature

sensor
Context:
The Engine Control Unit (ECU) monitors the exhaust manifold temperature sensor. If the ECU detects a voltage less
than 0.45 V in the exhaust manifold temperature sensor signal circuit, then this fault will occur. The sensor value will
be frozen at the last valid value for a preliminary failure or jump to a fixed replacement value of 350 °C (662 °F) if the
failure is validated.
Cause:
The ECU has detected a voltage less than 0.45 V in the exhaust manifold temperature sensor signal circuit. For more
information regarding the technical specifications of the exhaust manifold temperature sensor, refer to the engine
service manual Exhaust manifold temperature sensor - Technical Data (55.014).
1. Faulty exhaust manifold temperature sensor wiring, short circuit to ground.

2. Faulty exhaust manifold temperature sensor, internal failure.
Solution:
2. Check the exhaust manifold temperature sensor for an internal failure.
Disconnect the engine harness (EN) from the exhaust manifold temperature sensor.
Use a multimeter to measure the resistance on the exhaust manifold temperature sensor pins :
From To Value
Exhaust manifold temperature Exhaust manifold temperature There should be between 170.2 –
A. If there is between 170.2 – 849.7 Ω, then leave the exhaust manifold temperature sensor disconnected and
continue to step 3.
B. If there is not between 170.2 – 849.7 Ω, then the exhaust manifold temperature sensor has failed. Replace the
exhaust manifold temperature sensor.
(EN) side :
From To Value
the engine harness (EN) wiring. Locate and repair the shorted conductor. Repair or replace the harness as
required.
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4. Check the exhaust manifold temperature sensor vehicle harness (VE) wiring.
(VE) side :
From To Value
the vehicle harness (VE) wiring. Locate and repair the shorted conductor. Repair or replace the harness as
required.
has been resolved.
operation.
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19862 (DTC E86A) - Power stage error in HCU for DEF/AdBlue Back
flow line Heater
Context:
The power stage, internal to the Heater Control Unit (HCU), for the back-flow and suction line heaters is monitored
by the HCU for electrical failures. This failure information is transmitted via the Controller Area Network (CAN) from
the HCU to the Engine Control Unit (ECU). If an internal HCU power stage failure is detected, this fault will occur.
Cause:
The HCU has communicated, via CAN, to the ECU that it has experienced an internal power stage failure.

Solution:
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19865 (DTC 65BA) - Short Circuit to Battery of DEF/AdBlue

Backflow Line Heater Actuator powerstage
Context:
module suction line heater, the DEF/AdBlue® supply module back-flow line heater, and the DEF/AdBlue® supply mod-
ule pressure line heater. The DEF/AdBlue® supply module suction line heater and the DEF/AdBlue® supply module
back-flow line heater are wired in series and share a high side driver controlled circuit. The HCU communicates elec-
trical failures, via Controller Area Network (CAN) to the Engine Control Unit (ECU). If the HCU senses a short to high
source circuit condition exists in the DEF/AdBlue® supply module suction line heater and the DEF/AdBlue® supply
module back-flow line heater shared circuit, this fault will occur.
Cause:
in the DEF/AdBlue® supply module suction line heater and the DEF/AdBlue® supply module back-flow line heater
circuit.
circuit wiring, short circuit to another voltage source.
Solution:
From To Value
A. If there is no voltage, then continue with step 3.
B. If there is voltage, then there is a short circuit to another voltage source in the vehicle harness (VE). Locate
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has been resolved.
operation.
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19866 (DTC 66BA) - Short Circuit to Ground of DEF/AdBlue

Backflow Line Heater Actuator powerstage
Context:
module back-flow line heater are wired in series and share a high side driver controlled circuit. The HCU communi-
cates electrical failures, via Controller Area Network (CAN) to the Engine Control Unit (ECU). If the HCU senses that
a short circuit to ground exists in the DEF/AdBlue® supply module suction line heater and the DEF/AdBlue® supply
module back-flow line heater shared circuit, then this fault will occur.
Cause:
The HCU has communicated, via CAN, to the ECU that a short to ground circuit condition has been detected in the
DEF/AdBlue® supply module suction line heater and the DEF/AdBlue® supply module back-flow line heater circuit.
circuit wiring, short circuit to ground.
Solution:
From To Value
A. If there is no continuity, then continue with step 3.
B. If there is continuity, then there is a short circuit to ground in the vehicle harness (VE), use the appropriate
service manual, if necessary, to locate and repair the grounded conductor.
has been resolved.
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operation.
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19870 (DTC 7ABA) - Short Circuit to Ground of DEF/AdBlue

Pressure Line Heater Actuator powerstage
Context:
module back-flow line heater are wired in series and share a high side driver controlled circuit. The DEF/AdBlue®
supply module pressure line heater has its own high side driver controlled circuit. The HCU communicates electrical
failures, via Controller Area Network (CAN), to the Engine Control Unit (ECU). If the HCU senses a short circuit to
ground in the DEF/AdBlue® supply module pressure line heater control circuit, then this fault will occur.
Cause:
The HCU has communicated, via CAN, to the ECU that a short circuit to ground has been detected in the DEF/
AdBlue® supply module pressure line heater circuit.
1. Faulty DEF/AdBlue® supply module pressure line heater circuit wiring, short circuit to ground.
Solution:
From To Value
A. If there is continuity, there is a short circuit to ground in the vehicle harness (VE) circuit wiring. Locate and
repair the grounded conductor. Repair or replace the harness as required.

has been resolved.
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operation.
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19872 (DTC E96A) - Power stage error in HCU for DEF/AdBlue

Supply Module Heater
Context:
The power stage, internal to the Heater Control Unit (HCU), for the Diesel Exhaust Fluid (DEF)/AdBlue® supply mod-
ule heater is monitored by the HCU for electrical failures. This failure information is transmitted, via the Controller Area
Network (CAN), from the HCU to the Engine Control Unit (ECU). If an internal HCU power stage failure is detected,
Cause:
The HCU has communicated, via CAN, to the ECU that it has experienced an internal power stage failure.

Solution:
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Index
FAULT CODES - DTC

1001 - Engine Air Filter Blocked . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1002 - Engine coolant temperature too high, critical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1003 - Air conditioning pressure too high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
1009 - Transmission oil temperature too high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
1010 - Foot throttle signal out of range, IVS not changing state in 300 ms . . . . . . . . . . . . . . . . . . . . . 22
1011 - Foot throttle signal out of range, throttle above 95% of input for 5 seconds . . . . . . . . . . . . . . 25
1012 - Foot throttle signal out of range, throttle below 5% of input for 5 seconds . . . . . . . . . . . . . . . . 28
1013 - Foot throttle signal out of range, signal unusable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
1014 - Battery charge voltage too high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
1015 - Battery charge voltage too low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
1018 - Boost air temperature too high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
1019 - Engine coolant temperature too high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
1020 - Transmission oil temperature above normal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
1021 - Fuel temperature above normal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
1022 - Water in fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
1023 - Foot throttle supply voltage too high, over 5.2 volts for 5 seconds . . . . . . . . . . . . . . . . . . . . . . 43
1024 - Foot throttle supply voltage too low, under 4.8 volts for 5 seconds . . . . . . . . . . . . . . . . . . . . . . 45
1025 - Foot throttle sensor voltage over 5.3 volts for 5 seconds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
1026 - Foot throttle sensor voltage under 200 mV for 5 seconds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
1032 - Hand throttle supply voltage too low, under 4.8 volts for 5 seconds . . . . . . . . . . . . . . . . . . . . . 53
1033 - Hand throttle sensor voltage over 5.3 volts for 5 seconds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
1034 - Hand throttle sensor voltage under 200 mV for 5 seconds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
1035 - Hand throttle sensor signal above 95% of input for 5 seconds . . . . . . . . . . . . . . . . . . . . . . . . . 60
1036 - Hand throttle sensor signal below 5% of input for 5 seconds . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
1037 - Hand throttle sensor out of range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
1039 - Hand throttle sensor voltage under 200 mV for 5 seconds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
1040 - Engine overspeed warning, Engine speed greater than 2750 RPM for 5 seconds . . . . . . . . . 72
1041 - Engine overspeed fault, Engine speed greater than 3000 RPM for 5 seconds . . . . . . . . . . . . 73
1044 - Fuel level sensor below 2.0 ohm for 5 seconds, shorted low . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
1045 - Fuel level sensor open circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
1047 - Transmission Temperature Sensor is Shorted Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
1050 - Alternator L+ terminal under 1.5 volts for 5 seconds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
1051 - Timeout of CAN message EEC1, 5 seconds without message . . . . . . . . . . . . . . . . . . . . . . . . . 82
1052 - Timeout of CAN message EEC3, 5 seconds without message . . . . . . . . . . . . . . . . . . . . . . . . . 86
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1053 - Timeout of CAN message CNFBAM, 25 seconds without message . . . . . . . . . . . . . . . . . . . . . 87
1054 - Timeout of CAN message engine temperature, 5 seconds without message . . . . . . . . . . . . . 88
1055 - Timeout of CAN message inlet/exhaust, 5 seconds without message . . . . . . . . . . . . . . . . . . . 89
1056 - Timeout of CAN message DPFC1, 5 seconds without message . . . . . . . . . . . . . . . . . . . . . . . . 90
1057 - Timeout of CAN message vehicle electrical, 5 seconds without message . . . . . . . . . . . . . . . . 91
1058 - Timeout of CAN message EDC2BC, 5 seconds without message . . . . . . . . . . . . . . . . . . . . . . 92
1059 - Timeout of CAN message DM1, 5 seconds without message . . . . . . . . . . . . . . . . . . . . . . . . . . 93
1060 - Timeout Of CAN Message EGRIND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
1090 - Vehicle Model ID in VCM is UNCONFIGURED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
17195 (DTC 921B) - CAN B Bus off passive failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 378
17297 (DTC 3167) - EGR valve will not close during after run . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 380
17301 (DTC 1567) - EGR valve will not open to commanded position . . . . . . . . . . . . . . . . . . . . . . . . . 381
17302 (DTC 2667) - EGR valve will not close to commanded position . . . . . . . . . . . . . . . . . . . . . . . . . 382
17303 (DTC 5767) - EGR valve control circuit open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 383
17305 (DTC 8967) - EGR valve control circuit over current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 385
17306 (DTC 6A67) - EGR valve control circuit high side shorted to battery . . . . . . . . . . . . . . . . . . . . . 387
17307 (DTC 6B67) - EGR valve control circuit low side shorted to battery . . . . . . . . . . . . . . . . . . . . . 389
17308 (DTC 7C67) - EGR valve control circuit high side shorted to ground . . . . . . . . . . . . . . . . . . . . 391
17309 (DTC 7D67) - EGR valve control circuit low side shorted to ground . . . . . . . . . . . . . . . . . . . . . 393
17310 (DTC 1E67) - EGR valve control circuit over load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 395
17322 (DTC 1B97) - EGR valve position sensor voltage is higher than expected . . . . . . . . . . . . . . . 398
17323 (DTC 2C97) - EGR valve position sensor voltage is lower than expected . . . . . . . . . . . . . . . . 400
17337 (DTC 9E8C) - Hydrocarbon level 2 exceeded . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 402
17345 (DTC 4652) - DFC for faulty diagnostic data transmission or protocol error . . . . . . . . . . . . . . 403
17347 (DTC 5852) - No load error for Low Voltage System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405
17348 (DTC 8952) - Over temperature error on ECU powerstage for Glow plug Low Voltage System
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 407
17349 (DTC 6A52) - Short circuit to battery error for Low Voltage System . . . . . . . . . . . . . . . . . . . . . 409
17350 (DTC 7B52) - Short circuit to ground error for Low Voltage System . . . . . . . . . . . . . . . . . . . . . 411
17359 (DTC 7562) - Glow plug 1 control circuit shorted to ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . 413
17377 (DTC 21A6) - MI1 injection quantity is low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 421
17378 (DTC 22A6) - MI1 energizing time is low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 422
17379 (DTC 43A6) - Measured injection closing time exceeds a limit . . . . . . . . . . . . . . . . . . . . . . . . . 423
17383 (DTC F976) - IMA type mismatch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 427
17384 (DTC FA76) - IMA type mismatch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 428
17385 (DTC FB76) - IMA type mismatch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 429
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17386 (DTC FC76) - IMA type mismatch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 430
17387 (DTC E196) - Chip error in the Injector CY33x power stage component . . . . . . . . . . . . . . . . . 431
17403 (DTC 31B6) - Reporting Error if Relay is stuck at closed position . . . . . . . . . . . . . . . . . . . . . . . 432
17404 (DTC 32B6) - Reporting Error if Relay is stuck at open position . . . . . . . . . . . . . . . . . . . . . . . . 434
17405 (DTC 1E4A) - DFC used to evaluate filter clog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 436
17409 (DTC 53B6) - Reporting the leakage in the system during no dosing . . . . . . . . . . . . . . . . . . . . 437
17410 (DTC 3F9A) - Error in dosing valve plausibility at low voltage . . . . . . . . . . . . . . . . . . . . . . . . . . 438
17411 (DTC FEBA) - Defective pressure reduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 440
17412 (DTC 14B6) - High threshold for pressure sensor plausibility . . . . . . . . . . . . . . . . . . . . . . . . . . . 441
17413 (DTC 25B6) - Low threshold for pressure sensor plausibility . . . . . . . . . . . . . . . . . . . . . . . . . . . 442
17414 (DTC 56B6) - DEF/AdBlue Supply module supply voltage control relay circuit open . . . . . . . 443
17415 (DTC 87B6) - DEF/AdBlue Supply module supply voltage control relay short circuit . . . . . . . 445
17416 (DTC 68B6) - DEF/AdBlue Supply module supply voltage control relay short circuit to battery
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 447
17417 (DTC 79B6) - DEF/AdBlue Supply module supply voltage control relay short circuit to ground
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 449
17420 (DTC 1BB6) - SRC high for Urea Pump Module Pressure Sensor . . . . . . . . . . . . . . . . . . . . . . 450
17421 (DTC 2CB6) - SRC low for Urea Pump Module Pressure Sensor . . . . . . . . . . . . . . . . . . . . . . . 452
17422 (DTC EA2D) - Timer error of ECU off time counter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 453
17427 (DTC 1634) - SRC high for air temperature sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 454
17428 (DTC 2734) - SRC low for air temperature sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 456
17429 (DTC F542) - DFC is set if the cold start is detected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 458
17442 (DTC 1EA4) - Permanent governor deviation for valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 459
17443 (DTC 2FA4) - Permanent governor deviation for valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 460
17444 (DTC 3DB4) - Open load error for powerstage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 461
17446 (DTC 8FB4) - Over temperature error for H-bridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 463
17447 (DTC 61E4) - Short circuit to battery on Out1 error for H-bridge . . . . . . . . . . . . . . . . . . . . . . . . 465
17448 (DTC 62E4) - Short circuit to battery on Out2 error for H-bridge . . . . . . . . . . . . . . . . . . . . . . . . 467
17449 (DTC 73E4) - Short circuit to ground on Out1 error for H-bridge . . . . . . . . . . . . . . . . . . . . . . . . 469
17450 (DTC 74E4) - Short circuit to ground on Out2 error for H-bridge . . . . . . . . . . . . . . . . . . . . . . . . 471
17451 (DTC 15E4) - Short circuit over load error for H-bridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 473
17453 (DTC 27E4) - Under voltage error for H-bridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 475
17465 (DTC 5DB6) - Open Load error in powerstage of Urea dosing valve actuator . . . . . . . . . . . . . 476
17466 (DTC 6EB6) - Short circuit to battery error in powerstage of Urea dosing valve actuator . . . 478
17467 (DTC 6FB6) - Short circuit to battery error in highside powerstage of Urea dosing valve actu-
ator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 480
17468 (DTC 71C6) - Short circuit to ground error in lowside powerstage of Urea dosing valve actu-
ator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 482
17469 (DTC 72C6) - Short circuit to ground error in highside powerstage of Urea dosing valve ac-
tuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 484
17470 (DTC E3C6) - FET error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 486
17476 (DTC 49C6) - Diagnostic Fault Check for Supply Module temperature Duty cycle in failure
range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 487
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17477 (DTC 1AC6) - Diagnostic Fault Check for Supply Module temperature Duty cycle in failure
range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 490
17478 (DTC 2BC6) - Diagnostic Fault Check for Supply Module temperature Duty cycle in failure
range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 492
17479 (DTC 1CC6) - Diagnostic Fault Check for Supply Module temperature Duty cycle in failure
range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 494
17480 (DTC 2DC6) - Diagnostic Fault Check for Supply Module temperature Duty cycle in failure
range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 496
17481 (DTC 1EC6) - Diagnostic Fault Check for Supply Module temperature Duty cycle in failure
range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 498
17482 (DTC 2FC6) - Diagnostic Fault Check for Supply Module temperature Duty cycle in failure
range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 500
17483 (DTC 11D6) - Diagnostic Fault Check for Supply Module temperature Duty cycle in failure
range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 502
17484 (DTC 22D6) - Diagnostic Fault Check for Supply Module temperature Duty cycle in failure
range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 504
17485 (DTC 53D6) - No load error on low powerstage for Urea back flow pump . . . . . . . . . . . . . . . . 506
17486 (DTC 84D6) - Over temperature error on low powerstage for Urea back flow pump . . . . . . . 507
17487 (DTC 65D6) - Short circuit to battery error on low powerstage for Urea back flow pump . . . 509
17488 (DTC 76D6) - Short circuit to ground error on low powerstage for Urea back flow pump . . . 511
17494 (DTC 624E) - Short circuit to Battery (reported via CAN frame ComRx_CRI1) . . . . . . . . . . . . 512
17495 (DTC 734E) - Short circuit to Ground (reported via CAN Frame ComRx_CRI1) . . . . . . . . . . . 513
17498 (DTC 464E) - Sensor internal fault (via CAN Frame ComRx_CRI1) . . . . . . . . . . . . . . . . . . . . . 514
17500 (DTC 684E) - Short to Battery of the temperature sensor located in the Urea Quality sensor
(reported via CAN Frame ComRx_CRI1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 515
17501 (DTC 794E) - Short to Ground of the temperature sensor located in the Urea Quality sensor
(reported via CAN Frame ComRx_CRI1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 516
17504 (DTC 4C4E) - Signal fault of the temperature sensor located in the Urea Quality sensor (re-
ported via CAN Frame ComRx_CRI1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 517
17524 (DTC 31E9) - Hydrocarbon level 1 exceeded . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 518
17525 (DTC 3E27) - EGR OBD Monitoring error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 519
19001 (DTC 1361) - Battery voltage is higher than expected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 520
19002 (DTC 2461) - Battery voltage is lower than expected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 521
19008 (DTC E7DE) - NH3 sensor open or short in ground circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 523
19009 (DTC 18DE) - NH3 sensor short in heater circuit causing overheating . . . . . . . . . . . . . . . . . . . 524
19010 (DTC 161A) - Downstream SCR catalyst temperature sensor voltage is higher than expected
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 526
19011 (DTC 271A) - Downstream SCR catalyst temperature sensor voltage is lower than expected 528
19012 (DTC E9DE) - NH3 sensor open in heater circuit causing underheating . . . . . . . . . . . . . . . . . 530
19013 (DTC EADE) - NH3 sensor open or short in temperature cell circuit . . . . . . . . . . . . . . . . . . . . . 532
19014 (DTC EBDE) - NH3 sensor open or short in trim resistor circuit . . . . . . . . . . . . . . . . . . . . . . . . . 533
19015 (DTC 4CDE) - NH3 sensor heater control failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 535
19016 (DTC 37EE) - NH3 sensor heater performance failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 536
19017 (DTC 38EE) - NH3 sensor signal out of range failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 538
19018 (DTC 4DDE) - NH3 sensor power supply failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 539
19019 (DTC 1A1A) - Upstream SCR catalyst temperature sensor voltage is higher than expected 541
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19020 (DTC 2B1A) - Upstream SCR catalyst temperature sensor voltage is lower than expected . 543
19023 (DTC 4EDE) - NH3 sensor controller failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 545
19024 (DTC 92EE) - CAN timeout error from NH3 sensor - NH3Sens message . . . . . . . . . . . . . . . . 546
19036 (DTC 3F1C) - SCR downstream temperature sensor signal drift at cold start . . . . . . . . . . . . . 548
19040 (DTC 352C) - Upstream SCR temperature sensor comparison to a calculated temperature
value failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 550
19041 (DTC 362C) - Downstream SCR temperature sensor comparison to a calculated temperature
value failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 552
19042 (DTC 372C) - Downstream SCR temperature sensor comparison to a calculated temperature
value failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 554
19045 (DTC 94BE) - Timeout Error of Message from ECU to NOx downstream Sensor . . . . . . . . . 556
19050 (DTC 478E) - Downstream NOx sensor supply voltage is out of range . . . . . . . . . . . . . . . . . . 558
19051 (DTC E46E) - Upstream NOx sensor internal failure (heater open circuit error) . . . . . . . . . . . 560
19052 (DTC 256E) - Upstream NOx sensor internal failure (heater short circuit error) . . . . . . . . . . . 562
19053 (DTC A66E) - Upstream NOx sensor internal failure (Heater Performance Plausibility Error) 564
19054 (DTC E48E) - Upstream NOx sensor internal failure (open circuit error) . . . . . . . . . . . . . . . . . 566
19059 (DTC 258E) - Upstream NOx sensor internal failure (Short Circuit Error) . . . . . . . . . . . . . . . . 568
19060 (DTC 9E6E) - CAN timeout error from upstream NOx sensor . . . . . . . . . . . . . . . . . . . . . . . . . . 570
19061 (DTC 32BE) - Upstream NOx sensor lambda signal deviation - NOx sensor possible removal
detected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 572
19062 (DTC E98E) - Upstream NOx sensor values are not plausible . . . . . . . . . . . . . . . . . . . . . . . . . . 573
19063 (DTC 4A8E) - Upstream NOx sensor supply voltage is out of range . . . . . . . . . . . . . . . . . . . . . 574
19064 (DTC 563A) - Open Load error of DEF/AdBlue Supply Module Heater Actuator powerstage 576
19066 (DTC 1899) - Upstream oxidation catalyst temperature sensor voltage is higher than expected
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 578
19071 (DTC 2DDA) - SCR catalyst efficiency lower than first NOx production threshold level . . . . . 580
19077 (DTC 334A) - DEF/AdBlue pressure stabilization failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 584
19079 (DTC 1A4A) - DEF/AdBlue over pressure failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 585
19080 (DTC 294A) - DEF/AdBlue under pressure failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 586
19085 (DTC 857A) - DEF/AdBlue dosing valve ECU driver over temperature failure . . . . . . . . . . . . 587
19086 (DTC 3DBA) - DEF/AdBlue pressure line heater failure and DEF/AdBlue tank temperature is
too low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 589
19087 (DTC 8DAA) - DEF/AdBlue tank temperature is not within acceptable limits . . . . . . . . . . . . . . 590
19090 (DTC 3C3A) - Error DEF/AdBlue supply module heater temperature sensor cold start plausi-
bility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 591
19095 (DTC 2F3A) - DEF/AdBlue tank temperature sensor plausibility failure . . . . . . . . . . . . . . . . . . 593
19103 (DTC 643A) - Short Circuit to Battery of DEF/AdBlue Supply Module Heater Actuator power-
stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 594
19104 (DTC 753A) - Short Circuit to Ground of DEF/AdBlue Supply Module Heater Actuator power-
stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 596
19105 (DTC 879A) - DEF/AdBlue tank heater ECU driver over temperature failure . . . . . . . . . . . . . 598
19106 (DTC 759A) - DEF/AdBlue tank heater actuator short circuit to ground failure . . . . . . . . . . . . 600
19107 (DTC 515A) - DEF/AdBlue supply module pump motor open load failure . . . . . . . . . . . . . . . . 602
19108 (DTC 613A) - DEF/AdBlue supply module pump motor short circuit to battery failure . . . . . . 603
19111 (DTC 723A) - DEF/AdBlue supply module pump motor short circuit to ground failure . . . . . . 605
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19126 (DTC FF9F) - SCR Inducement: Warning, triggered by tampering fault . . . . . . . . . . . . . . . . . . 607
19140 (DTC 4BCA) - DEF/AdBlue concentration is out of range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 608
19141 (DTC 4CCA) - DEF/AdBlue quality sensor detects diesel fuel in DEF/AdBlue tank . . . . . . . . 609
19144 (DTC 9AEA) - CAN timeout error from DEF/AdBlue quality sensor . . . . . . . . . . . . . . . . . . . . . . 610
19155 (DTC 345A) - DEF/AdBlue Supply Module Pump Motor Speed Deviation . . . . . . . . . . . . . . . . 612
19156 (DTC 335A) - DEF/AdBlue supply module pump motor severe speed deviation . . . . . . . . . . 613
19210 (DTC 57BA) - Open Load error of DEF/AdBlue Backflow Line Heater Actuator powerstage 614
19253 (DTC 69BA) - Short Circuit to Battery of DEF/AdBlue Pressure Line heater Actuator power-
stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 616
19255 (DTC 5BBA) - Open Load error of DEF/AdBlue Pressure Line Heater Actuator powerstage 618
19262 (DTC 649A) - DEF/AdBlue tank heater actuator short circuit to battery failure . . . . . . . . . . . . 620
19264 (DTC 569A) - DEF/AdBlue tank heater actuator open load failure . . . . . . . . . . . . . . . . . . . . . . 622
19267 (DTC F2AF) - Engine idle shutdown commanded from SCR inducement . . . . . . . . . . . . . . . . 624
19323 (DTC 94FB) - External engine shutdown request received . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 625
19335 (DTC 224A - Pressure build-up error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 626
19336 (DTC 354A) - DEF/AdBlue general pressure check failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 627
19337 (DTC 344A) - DEF/AdBlue dosing system backflow line pressure too high plausibility failure 628
19345 (DTC 9ECA) - Timeout error of CAN receive frame HCU Data . . . . . . . . . . . . . . . . . . . . . . . . . 630
19346 (DTC BFBA) - Timeout error of CAN receive frame HCU Data . . . . . . . . . . . . . . . . . . . . . . . . . 632
19356 (DTC 3FDE) - Downstream NOx sensor signal and NH3 sensor signal plausibility check fail-
ure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 634
19402 (DTC 9AAA) - CAN timeout error - Urea tank level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 635
19415 (DTC FABF) - Remaining DEF/AdBlue is below the empty threshold . . . . . . . . . . . . . . . . . . . . 637
19421 (DTC 33BE) - Downstream NOx sensor failed negative drift test monitoring . . . . . . . . . . . . . . 638
19422 (DTC 43CE) - Downstream NOx sensor signal is stuck at a constant value . . . . . . . . . . . . . . 639
19423 (DTC 3CDA) - Upstream NOx sensor comparison to a calculated NOx value failure . . . . . . 640
19434 (DTC E26D) - ECU internal failure - EEPROM erase error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 641
19435 (DTC E36D) - ECU internal failure - EEPROM read error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 642
19436 (DTC E46D) - ECU internal failure - EEPROM write error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 643
19496 (DTC 184A) - Monitoring of over pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 644
19523 (DTC 49AA) - DEF/AdBlue tank temperature failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 645
19559 (DTC F18F) - DEF/AdBlue level too low warning is active - Stage 1 . . . . . . . . . . . . . . . . . . . . . 646
19568 (DTC F28F) - DEF/AdBlue level too low warning is active - Stage 2 . . . . . . . . . . . . . . . . . . . . . 647
19748 (DTC 833A) - DEF/AdBlue supply module pump motor ECU driver over temperature failure 648
19787 (DTC F49F) - SCR Inducement: Level 1 (Torque reduction), triggered by DEF/AdBlue dosing
interruption fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 650
19788 (DTC F59F) - SCR Inducement: Level 3 (creep mode), triggered by DEF/AdBlue dosing
interruption fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 651
19789 (DTC F69F) - SCR Inducement: Warning, triggered by DEF/AdBlue dosing interruption fault 652
19797 (DTC FA9F) - SCR Inducement: Level 1 (torque reduction), triggered by DEF/AdBlue quality
fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 653
19798 (DTC FB9F) - SCR Inducement: Level 3 (creep mode), triggered by DEF/AdBlue Quality fault
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 654
19799 (DTC FC9F) - SCR Inducement: Warning, triggered by DEF/AdBlue Quality fault . . . . . . . . . 655
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19800 (DTC FD9F) - SCR Inducement: Level 1 (Torque reduction), triggered by Tampering fault . 656
19801 (DTC FE9F) - SCR Inducement: Level 3 (creep mode), triggered by Tampering fault . . . . . . 657
19817 (DTC 377A) - DEF/AdBlue dosing valve is blocked . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 658
19835 (DTC 5468) - Open load temperature error on the Turbocharger PWM output powerstage . 659
19836 (DTC 8368) - Over temperature error on the Turbocharger PWM output powerstage . . . . . . 661
19837 (DTC 6168) - SCB error on the Turbocharger PWM output powerstage . . . . . . . . . . . . . . . . . 663
19838 (DTC 7268) - SCG error on the Turbocharger PWM output powerstage . . . . . . . . . . . . . . . . . 665
19858 (DTC 1748) - SRC High for turbine upstream temperature sensor . . . . . . . . . . . . . . . . . . . . . . 667
19859 (DTC 2848) - SRC low for turbine upstream temperature sensor . . . . . . . . . . . . . . . . . . . . . . . 670
19862 (DTC E86A) - Power stage error in HCU for DEF/AdBlue Back flow line Heater . . . . . . . . . . 672
19865 (DTC 65BA) - Short Circuit to Battery of DEF/AdBlue Backflow Line Heater Actuator power-
stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 673
19866 (DTC 66BA) - Short Circuit to Ground of DEF/AdBlue Backflow Line Heater Actuator power-
stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 675
19870 (DTC 7ABA) - Short Circuit to Ground of DEF/AdBlue Pressure Line Heater Actuator power-
stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 677
19872 (DTC E96A) - Power stage error in HCU for DEF/AdBlue Supply Module Heater . . . . . . . . . 679
3007 (DTC 1113) - Engine coolant temperature sensor voltage is higher than expected . . . . . . . . . 97
3008 (DTC 2213) - Engine coolant temperature sensor voltage is lower than expected . . . . . . . . . . 100
3010 (DTC 2474) - Intake manifold temperature sensor voltage is lower than expected . . . . . . . . . . 102
3015 (DTC 1C15) - Fuel temperature sensor voltage is higher than expected . . . . . . . . . . . . . . . . . . 104
3016 (DTC 2D15) - Fuel temperature sensor voltage is lower than expected . . . . . . . . . . . . . . . . . . . 107
3019 (DTC 1D64) - Intake manifold pressure sensor voltage is higher than expected . . . . . . . . . . . 109
3024 (DTC 13C4) - ECU internal failure - Ambient pressure sensor voltage is higher than expected 112
3025 (DTC 24C4) - ECU internal failure - Ambient pressure sensor voltage is lower than expected 113
3027 (DTC 34D3) - Defect fault check for plausibility from digital sensor . . . . . . . . . . . . . . . . . . . . . . . 114
3028 (DTC 26D3) - Oil pressure is too low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
3037 (DTC 2E64) - Intake manifold pressure sensor voltage is lower than expected . . . . . . . . . . . . 118
3051 (DTC 1161) - Battery voltage is higher than expected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
3052 (DTC 2261) - Battery voltage is lower than expected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
3059 (DTC 4661) - Main relay stuck error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
3063 (DTC 6226) - Short circuit error of injector in cylinder 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
3088 (DTC 4512) - Crankshaft speed sensor values are not plausible . . . . . . . . . . . . . . . . . . . . . . . . . 137
3089 (DTC 4412) - Crankshaft speed sensor pattern is not plausible . . . . . . . . . . . . . . . . . . . . . . . . . . 140
3090 (DTC 4212) - Camshaft speed sensor values are not plausible . . . . . . . . . . . . . . . . . . . . . . . . . . 143
3091 (DTC 4112) - Camshaft speed sensor pattern is not plausible . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
3093 (DTC 3312) - Compared camshaft and crankshaft speed sensor values are not plausible . . . 149
3096 (DTC 951B) - CAN A Bus off failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
3097 (DTC 961B) - CAN B Bus off failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
3102 (DTC 2525) - Fuel rail pressure sensor voltage is lower than expected . . . . . . . . . . . . . . . . . . . 154
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3104 (DTC F445) - Fuel pressure relief valve is open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
3105 (DTC F245) - Fuel pressure relief valve is forced to open, perform pressure increase . . . . . . 157
3106 (DTC 1145) - Fuel pressure relief valve reached maximum allowed opening count . . . . . . . . . 158
3107 (DTC 6655) - Fuel metering unit is shorted to battery voltage at the low side . . . . . . . . . . . . . . 159
3108 (DTC 7755) - Fuel metering unit is shorted to ground at the low side . . . . . . . . . . . . . . . . . . . . . 161
3112 (DTC 1425) - Fuel rail pressure sensor voltage is higher than expected . . . . . . . . . . . . . . . . . . 163
3137 (DTC 5255) - Fuel metering unit has an open load error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
3141 (DTC 4465) - Fuel pump pressure has exceeded desired pressure limits . . . . . . . . . . . . . . . . . 168
3146 (DTC 4415) - Water in fuel detected or water in fuel circuit failure . . . . . . . . . . . . . . . . . . . . . . . . 169
3170 (DTC 38CB) - NH3 sensor signal is not changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
3173 (DTC F623) - Engine coolant temperature has exceeded the warning threshold . . . . . . . . . . . 172
3176 (DTC 3B65) - High pressure pump fuel delivery quantity in over run exceeds a maximum
threshold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
3177 (DTC F1A2) - Engine over speed condition detected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
3179 (DTC 956B) - CAN communication failure between vehicle controller and ECU - BC2ECU2
message . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
3180 (DTC 9B7B) - CAN communication error between vehicle controller to ECU . . . . . . . . . . . . . . 177
3188 (DTC 5316) - Open load error of injector in cylinder 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
3210 (DTC 7116) - Injection bank 1 short circuit failure (all injectors of the same bank can be affected)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
3218 (DTC 7216) - Injection bank 2 short circuit failure (all injectors of the same bank can be af-
fected) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
3235 (DTC F936) - Exceeded the number of injections for a given engine speed . . . . . . . . . . . . . . . 191
3236 (DTC F836) - Number of injections is limited by system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
3237 (DTC 1636) - Number of desired injections exceeds threshold . . . . . . . . . . . . . . . . . . . . . . . . . . 193
3245 (DTC E51D) - ECU internal failure - Query/response communication errors . . . . . . . . . . . . . . . 195
3252 (DTC E61D) - ECU internal failure - SPI communication error . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
3253 (DTC E41D) - ECU internal failure - Voltage ratio in ADC monitoring . . . . . . . . . . . . . . . . . . . . . 197
3255 (DTC E31D) - ECU internal failure - ADC test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
3256 (DTC E21D) - ECU internal failure - NTP error in ADC monitoring . . . . . . . . . . . . . . . . . . . . . . . 199
3258 (DTC 6722) - Starter relay high side driver circuit short to battery failure . . . . . . . . . . . . . . . . . . 200
3259 (DTC 7822) - Starter relay high side driver circuit short to ground failure . . . . . . . . . . . . . . . . . . 202
3260 (DTC 5922) - Starter relay low side driver circuit open failure . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
3261 (DTC 6B22) - Starter relay low side driver circuit short to battery failure . . . . . . . . . . . . . . . . . . 206
3262 (DTC 7C22) - Starter relay low side driver circuit short to ground failure . . . . . . . . . . . . . . . . . . 208
3265 (DTC E4DD) - Fuel injection requested during overrun . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
3283 (DTC E32D) - ECU internal failure - Sensor 5 volt supply 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
3285 (DTC E42D) - ECU internal failure - Sensor 5 volt supply 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
3293 (DTC 2265) - Fuel rail pressure has exceeded maximum positive deviation limits . . . . . . . . . . 215
3301 (DTC 1565) - Fuel rail pressure has exceeded maximum negative deviation limits . . . . . . . . . 216
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3305 (DTC 2765) - Fuel rail pressure has exceeded minimum limit . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
3309 (DTC 1865) - Fuel rail pressure has exceeded maximum limit . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
3334 (DTC 98BB) - CAN communication failure between vehicle controller and ECU controller -
TSC1_PE message . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
3338 (DTC 91CB) - CAN communication failure between vehicle controller and ECU controller -
TSC1_VE message . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221
3339 - Timeout of CAN Message TSC1 Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223
3358 (DTC 962B) - CAN transmit error - EEC1 message (Electronic Engine Control 1 message -
Torque, accelerator pedal, engine speed, and other signals) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227
3361 (DTC E16D) - ECU internal failure - EEPROM write/read error . . . . . . . . . . . . . . . . . . . . . . . . . . 229
3368 (DTC F6EF) - Torque limitation caused by performance limiter . . . . . . . . . . . . . . . . . . . . . . . . . . 230
3369 (DTC F8EF) - Torque limitation caused by smoke limitation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231
3370 (DTC F2EF) - Strong torque limitation from engine protection active . . . . . . . . . . . . . . . . . . . . . 232
3371 (DTC F3EF) - Strong torque limitation from injection system active . . . . . . . . . . . . . . . . . . . . . . 233
3403 (DTC 8A22) - Starter relay low side ECU driver circuit over temperature failure . . . . . . . . . . . . 234
3409 (DTC 23D3) - Defect fault check for minimum oil pressure from digital sensor . . . . . . . . . . . . . 236
3425 (DTC 1438) - Turbocharger boost pressure is higher than expected . . . . . . . . . . . . . . . . . . . . . . 239
3436 (DTC FBBF) - Inducement system is locked due to 3 detections in 40 hours. The system must
be reset using the dealer service tool screen "Engine Restart Counter Reset" . . . . . . . . . . . . . . . . . . 240
3449 (DTC E812) - ECU internal failure - Calculated engine speed . . . . . . . . . . . . . . . . . . . . . . . . . . . 241
3457 (DTC 1374) - Intake manifold temperature sensor voltage is higher than expected . . . . . . . . . 242
3461 (DTC E69D) - ECU internal failure - Timeout in the shut off path test error . . . . . . . . . . . . . . . . 245
3462 (DTC E79D) - ECU internal failure - Overvoltage monitoring error . . . . . . . . . . . . . . . . . . . . . . . 246
3501 (DTC ED1D) - ECU internal failure - Software resets in DSM 0 . . . . . . . . . . . . . . . . . . . . . . . . . . 247
3502 (DTC EE1D) - ECU internal failure - Software resets in DSM 1 . . . . . . . . . . . . . . . . . . . . . . . . . . 248
3503 (DTC EF1D) - ECU internal failure - Software resets in DSM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249
3507 (DTC 4761) - Engine cranked for too long or keyswitch failure . . . . . . . . . . . . . . . . . . . . . . . . . . 250
3508 (DTC FAEF) - Torque limitation active . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 252
3517 (DTC 19C4) - Ambient temperature sensor voltage is higher than expected . . . . . . . . . . . . . . . 253
3518 (DTC 2AC4) - Ambient temperature sensor voltage is lower than expected . . . . . . . . . . . . . . . 255
3525 (DTC E18E) - Downstream NOx sensor internal failure (open circuit error) . . . . . . . . . . . . . . . . 257
3526 (DTC E28E) - Downstream NOx sensor internal failure (short circuit error) . . . . . . . . . . . . . . . . 259
3528 (DTC 319E) - Downstream NOx sensor values are not plausible . . . . . . . . . . . . . . . . . . . . . . . . 261
3529 (DTC E16E) - Downstream NOx sensor internal failure (heater open circuit error) . . . . . . . . . 262
3530 (DTC E26E) - Downstream NOx sensor internal failure (heater short circuit error) . . . . . . . . . 264
3531 (DTC A36E) - Downstream NOx sensor internal failure (heater performance plausibility error) 266
3533 (DTC 9D6E) - CAN timeout error from downstream NOx sensor . . . . . . . . . . . . . . . . . . . . . . . . . 268
3581 (DTC FD8F) - Torque limitation is active . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270
3616 (DTC F1EF) - Torque limitation caused by turbo charger protection . . . . . . . . . . . . . . . . . . . . . . 271
3623 (DTC 3CAE) - Downstream NOx sensor lambda signal deviation - NOx sensor possible re-
moval detected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272
3652 (DTC 911B) - CAN A Bus off passive failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274
3680 (DTC E536) - Engine speed limitation via fuel injection cut off is active . . . . . . . . . . . . . . . . . . . 276
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55.9 [55.DTC] / 688
3703 (DTC 2B36) - The minimum rail pressure value necessary to allow fuel injection has not been
reached . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277
3735 (DTC 8355) - Fuel metering unit has an over temperature error . . . . . . . . . . . . . . . . . . . . . . . . . 278
3738 (DTC E71D) - ECU internal failure - ROM error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280
3739 (DTC E13D) - ECU internal failure - Loss of synchronization to MM from CPU . . . . . . . . . . . . 281
3740 (DTC E23D) - ECU internal failure - ECU shutdown test failure . . . . . . . . . . . . . . . . . . . . . . . . . . 282
3741 (DTC E33D) - ECU internal failure - Wrong set response time . . . . . . . . . . . . . . . . . . . . . . . . . . . 283
3742 (DTC E43D) - ECU internal failure - SPI errors during MoCSOP execution . . . . . . . . . . . . . . . . 284
3743 (DTC E53D) - ECU internal failure - Undervoltage monitoring error . . . . . . . . . . . . . . . . . . . . . . 285
3745 (DTC E63D) - ECU internal failure - WDA is not working correctly . . . . . . . . . . . . . . . . . . . . . . . 286
3746 (DTC E73D) - ECU internal failure - Alarm task period error . . . . . . . . . . . . . . . . . . . . . . . . . . . . 287
3747 (DTC E83D) - ECU internal failure - Positive test failed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 288
3749 (DTC E5B1) - ECU internal failure - Accelerator pedal position sensor . . . . . . . . . . . . . . . . . . . 289
3750 (DTC EC36) - ECU internal failure - Fuel injection energizing time not plausible . . . . . . . . . . . 290
3751 (DTC ED36) - ECU internal failure - Fuel injection energizing phase is not plausible . . . . . . . 291
3752 (DTC EE36) - Fuel injection correction has exceeded a minimum limit . . . . . . . . . . . . . . . . . . . 292
3753 (DTC E5DD) - ECU internal failure - Injection quality correction . . . . . . . . . . . . . . . . . . . . . . . . . 293
3754 (DTC E6DD) - ECU internal failure - Rail pressure plausibility . . . . . . . . . . . . . . . . . . . . . . . . . . . 294
3755 (DTC E7DD) - ECU internal failure - Torque request comparison . . . . . . . . . . . . . . . . . . . . . . . . 295
3756 (DTC E1DD) - ECU internal failure - Post injection quality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 296
3757 (DTC E2DD) - ECU internal failure - Post injection shut off failure . . . . . . . . . . . . . . . . . . . . . . . 297
3759 (DTC E8DD) - ECU internal failure - Torque request due to fuel pressure exceeds maximum
torque limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 298
3760 (DTC E9DD) - ECU internal failure - Torque request due to air control exceeds maximum torque
limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 299
3761 (DTC EADD) - ECU internal failure - Torque request exceeds maximum torque limit . . . . . . . 300
3764 (DTC F561) - ECU after run power interruption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301
3767 (DTC E81D) - ECU internal failure - 'WDA active' reported due to errors in query/response
communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 304
3768 (DTC E91D) - ECU internal failure - 'ABE active' reported due to undervoltage detection . . . 305
3769 (DTC EA1D) - ECU internal failure - 'ABE active' report due to overvoltage detection . . . . . . . 306
3770 (DTC EB1D) - ECU internal failure - 'WDA/ABE active' reported . . . . . . . . . . . . . . . . . . . . . . . . . 307
3773 (DTC 2838) - Turbocharger boost pressure is lower than expected . . . . . . . . . . . . . . . . . . . . . . 308
3794 (DTC 3B64) - Plausibility check for air pressure at the upstream of intake valve sensor . . . . . 309
3795 (DTC 3C64) - Plausibility check for air pressure at the upstream of intake valve sensor . . . . . 310
3799 (DTC F345) - Fuel pressure relief valve is forced to open, perform pressure shock . . . . . . . . . 311
3838 (DTC 2999) - Upstream oxidation catalyst temperature sensor voltage is lower than expected 312
3906 (DTC 4736) - Number of injections is limited by quantity balance of high pressure pump . . . . 314
3910 (DTC 4155) - Fuel metering unit intermittent electrical connection failure . . . . . . . . . . . . . . . . . 315
3915 (DTC 3645) - Averaged rail pressure is outside the expected tolerance range . . . . . . . . . . . . . 317
3916 (DTC 1745) - Fuel pressure relief valve has reached maximum allowed open time . . . . . . . . . 318
3959 (DTC 17A4) - Intake throttle valve position is higher than expected . . . . . . . . . . . . . . . . . . . . . . 319
3960 (DTC 28A4) - Intake throttle valve position is lower than expected . . . . . . . . . . . . . . . . . . . . . . . 321
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3961 (DTC ED2D) - CAN communication failure - External torque/speed checksum and counter . 323
3985 (DTC 1758) - Exhaust gas pressure sensor voltage is higher than expected . . . . . . . . . . . . . . 325
3986 (DTC 2858) - Exhaust gas pressure sensor voltage is lower than expected . . . . . . . . . . . . . . . 327
3998 - Unknown error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 329
3999 - Unknown error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 331
4029 - Shifter Lever improperly connected, no power to pin 16, pin 18, or pin 46 for more than 3
seconds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 333
4030 - Shifter Lever malfunction: transmission in neutral receives forward and neutral together . . 336
4031 - Shifter Lever malfunction: transmission in neutral receives reverse and neutral together . . 339
4032 - Shifter Lever malfunction: transmission in forward receives forward and reverse together . 342
4033 - Shifter Lever malfunction: transmission in reverse receives forward and reverse together . 345
4034 - Shifter Lever malfunction: transmission in forward receives neutral and forward together . . 348
4035 - Shifter Lever malfunction: transmission in reverse receives neutral and reverse together . . 351
4036 - During transition from second to third gear, and Gear CMD_01 signal erratic or incorrect . . 354
4037 - During transition from first to second gear, and Gear CMD_02 signal erratic or incorrect . . . 357
4038 - During transition from third to fourth gear, and Gear CMD_02 signal erratic or incorrect . . . 360
9001 - Hour meter plausibility, internal error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 363
9002 - Hour meter RAM checksum failure, internal error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 364
9003 - J1939 receive buffer overflow, internal error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 365
9004 - EEPROM checksum failure, hour meter location 1, internal error . . . . . . . . . . . . . . . . . . . . . . . 366
9007 - Abnormal reset watchdog time-out, internal error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 369
9008 - A/D fault foot throttle, internal error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 370
9009 - A/D fault foot throttle power, internal error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 371
9010 - A/D fault hand throttle, internal error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 372
9011 - A/D fault foot throttle, internal error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 373
9012 - A/D fault, internal error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 374
9013 - Cluster Type Checksum Error: Location 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 375
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PRINTED IN U.S.A.
48090752 24/02/2017
EN
SERVICE MANUAL
Front loader and bucket

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82
Contents
Front loader and bucket - 82
[82.100] Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82.1
[82.300] Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82.2
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Arm - 100

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Contents
Arm - 100
FUNCTIONAL DATA
Front loader arm

SERVICE
Front loader arm

Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Front loader arm locking device
Service instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
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Front loader and bucket - Arm
Front loader arm - Dynamic description

Loader attachment operation
Neutral and hold

With the lever in the neutral/hold position (0), the attach-
ment movement can be stopped.
As soon as the lever is released, it automatically returns

to the neutral position (0) and the attachment remains in
the position where it was when movement stopped.
LELI12TLB2097AB 1
Raising the loader attachment

With the lever in position (1), the attachment rises.
LELI12TLB2099AB 2
Lowering the loader attachment

With the lever in position (2), the attachment lowers.
LELI12TLB2100AB 3
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Loader bucket float control

With the lever in position (3), the bucket follows the con-
tours of the ground without it being necessary to operate
the lever.
NOTE: In this position the lever does not automatically
return to neutral when it is released. It is necessary to
move it manually.
LELI12TLB2501AB 4
Filling the loader bucket

With the lever in position (4), the bucket rolls back (fills).
LELI12TLB2505AB 5
Dumping the loader bucket

With the lever in position (5), the bucket rolls forward
(dumps).
LELI12TLB2506AB 6
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Automatic return to loader bucket filling

With the lever in position (6), the attachment lowers and,
simultaneously, the bucket places itself to the digging po-
sition.
NOTE: It is possible to adjust the tilt angle for bucket filling.
LELI12TLB2507AB 7
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Front loader arm - Remove

1. Remove the loader bucket (Refer to Bucket - Remove
(82.300)).
2. Fully retract bucket cylinders and raise arm until lift
cylinder pivots can be seen above engine guard.
3. Support the loader arm with a suitable stand under the
end of the arm.
4. Turn off the engine and relieve hydraulic pressure.
LELI12TLB2543AA 1
5. Remove the safety pins (2) and drive out the pins (1).
Detach the cylinder rod end from the loader arm.
LELI12TLB2544AB 2
6. Remove the snap rings (3) and drive out the pins (4).
Detach the cylinder rod end from the loader arm.
LELI12TLB2545AB 3
7. Disconnect and cap the lift cylinder hoses (5) at the

top of the loader arm on each side of the machine.
Disconnect the return to dig sensor cable (7) on the
right hand side.
8. If the 4x1 bucket is fitted, disconnect and cap hose (6)
on each side of the loader.
LELI12TLB2546AB 4
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9. Support loader using a suitable lifting device.
LELI12TLB2548A 5
10. Remove the safety ring and pins. Pull out the pin (8).
LELI12TLB2549AB 6
11. Remove the loader from the machine.
LELI12TLB2550AA 7
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Front loader arm - Install

For installation, follow the removal procedure in reverse
order.
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Front loader arm - Remove

Remove loader bucket. Refer to Bucket - Remove
(82.300).
Remove loader cylinder. Refer to Bucket cylinder -
Remove (35.738).
Remove loader lift cylinder. Refer to Lift arm cylinder
- Remove (35.701).
1. Lower the loader assembly to the ground and attach a
suitable lifting device.
PTIL14TLB0136AA 1
2. Disconnect the linkages (1) by removing the retainer

bracket bolts (2) and washers from the right hand side
of the loader frame.
PTIL13TLB0470AB 2
3. Remove the retainer bracket (1), shims (2), washers (3)

and bolt (4).
PTIL13TLB0471AB 3
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4. Remove the pivot bolt (1), shim (2) and washer (3) from
the left hand side of the loader frame.
PTIL13TLB0472AB 4
5. Remove the locking bolt (1) located at the loader frame

center to release the pivot pin.
PTIL13TLB0473AB 5
6. Tap and remove the pivot pin (1) using a mandrel and
wooden hammer to slide the loader from the machine.
PTIL13TLB0474AB 6
7. Lift the suspending loader frame assembly (1) using the

attached lifting device and place it aside.
PTIL13TLB0476AB 7
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Front loader arm - Install

1. Lift the suspending loader frame assembly (1) using
the attached lifting device and position on the machine
frame.
PTIL13TLB0476AB 1
2. Tap and install the pivot pin (1) using a wooden hammer
to attach the loader to the machine.
PTIL13TLB0474AB 2
3. Install the locking bolt (1) located at the loader frame

center to fix the pivot pin.
PTIL13TLB0473AB 3
4. Install the pivot bolt (1), shim (2) and washer (3) from
the left hand side of the loader frame.
PTIL13TLB0472AB 4
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5. Install the retainer bracket (1), shims (2) and washers

(3) on the right hand side of the machine.
moval.
PTIL13TLB0471AB 5
6. Connect the linkages (1) by installing the retainer

bracket bolt (2) and washer on the loader frame using
LOCTITE® 242®. Torque: 186 N·m (137 lb ft).
PTIL13TLB0470AB 6
7. Install the loader bucker. Refer to Bucket - Install

(82.300).
8. Install loader lift cylinder. Refer Bucket cylinder - In-
stall (35.738).
9. Install loader cylinder.
10. Release the lifting device and lower the loader assem-
bly to the ground.
PTIL14TLB0136AA 7
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Front loader arm locking device - Service instruction

Loader attachment control lock (Specific to certain countries)
This pin (1), located next to the control lever, is used to
lock the attachment controls.
To lock the controls, remove the pin from its housing and
install it in the specially provided hole in the console.
NOTICE: Before leaving the operator’s compartment, un-
dertaking any road travel or working with the backhoe at-
tachment, place the pin in locking position.
LELI12TLB2516AB 1
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Index
Arm - 100
Front loader arm - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Front loader arm - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Front loader arm - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Front loader arm - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Front loader arm - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Front loader arm locking device - Service instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
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Bucket - 300

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Contents
Bucket - 300
TECHNICAL DATA
Bucket
FUNCTIONAL DATA
Bucket
Static description - Loader controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
OPERATING
Bucket
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
SERVICE
Bucket
Service instruction - Loader bucket self-levelling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Bucket
Replace the bucket teeth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Loading bucket forks
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
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Front loader and bucket - Bucket
Bucket - General specification

Loader buckets
0.88 m³ (31.08 ft³) 1 m³ (35.3 ft³)
Type 4x1 6x1 (with forks)
Standard Standard
Heaped capacity 0.88 m³ (31.08 ft³) 1.0 m³ (35.3 ft³) 1.0 m³ (35.3 ft³) 1.0 m³ (35.3 ft³)
2WS Width 2250 mm (88.58 in) 2250 mm (88.58 in) 2250 mm (88.58 in) 2250 mm (88.58 in)
Weight 310 kg (683 lb) 400 kg (882 lb) 750 kg (1653 lb) 950 kg (2094 lb)
Heaped capacity – 1.15 m³ (40.6 ft³) 1.15 m³ (40.6 ft³) 1.15 m³ (40.6 ft³)
4WS Width – 2350 mm (92.52 in) 2350 mm (92.52 in) 2350 mm (92.52 in)
Weight – 415 kg (915 lb) 770 kg (1698 lb) 970 kg (2138 lb)
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Bucket - Static description - Loader controls

WARNING
Misuse hazard!
Before starting the engine, make sure you are fully aware of the location and the function of each
control.
W0226A
NOTICE: Before using the controls make sure that the operator’s seat is correctly adjusted in the loader attachment
position.
With standard loader bucket

Located on the right of the steering wheel, this nine position lever operates all the loader attachment controls.
The speed of movement of each control depends on the angle to which the lever is tilted. In the intermediate position,
two movements can be obtained simultaneously.
With 4 x 1 loader bucket

The function of the lever is identical to that of the machine fitted with the standard loader bucket, with the addition of
the clam control.
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Bucket - Dynamic description

4x1 Loader bucket control (optional)
This control operates the opening and closing of the 4x1
bucket clam.
This control is proportional:
When releasing the roller (7) , it automatically returns to

the initial position (neutral) and the bucket remains in the
When shifting the roller (7) forward: the loader bucket

clam closes (A).
When shifting the roller (7) backward: the loader bucket

clam opens (B).
LELI12TLB2511AC 1
4x1 Loader bucket control roller detent procedure

The operator may install a detent position for the 4x1
bucket operation.
This position alters operation in order to allow the operator

to lock the switch in the open circuit position, so that this
position is held until the operator unlocks the switch
The standard position of the switch is with the open U

shape pointing upwards. In this configuration, the switch
will automatically spring back to the neutral position when
released, from any position.
To set the detent position to the bucket open position, it is

necessary to remove the top of the switch, rotating it by LELI12TLB2512AB 2
180°.
Remove the screw (2) of the roller (1) using a small phillips
screwdriver.
Lift and remove the top portion (3) of the roller switch,
rotate it by 180° and tighten the screw in the top portion
of the roller.
NOTE: The open U shape must point downwards.
Carefully restore the screw (2) into place and do not over-
tighten.
Test the switch by lifting it up into detent position before

restoring the cap into place. The switch should lock into
position.
In this condition, the 4x1 loader bucket control roller is

locked. To unlock it, it is necessary to rotate the top por- LELI12TLB2515AC 3
tion again and take it back to its initial position.
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Bucket - Remove
2. Lower the bucket to the ground in dump position (tilted
completely forward).
4. If the machine is fitted with a 4x1 bucket, release the
pressure from the bucket circuit: turn the key to ON
(with engine stopped) and operate the accelerator
knob.
CAUTION
Flying objects!
Wear eye protection. Do not strike steel parts
with a steel hammer. Parts may break.
Failure to comply could result in minor or
moderate injury.
C0024A
5. Remove the retaining rings and pins, then drive out the
pins (1).
6. (4x1 bucket) Disconnect and plug the hydraulic supply
lines.
7. Start the engine. LEEN11T0165AA 1
8. Operate the attachment controls so as to release the

bucket.
9. Reverse the machine from the bucket.
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Bucket - Install
1. Make sure all bushings are completely clean. Re-
move any dirt or foreign matter, if necessary.
3. Use the attachment controls to engage the attach-
ment between the bucket lugs.
4. Reinstall the arm/bucket pins (1) and then install the
relevant retaining pins and rings.
5. Use the bucket controls to align the connecting rod
holes (3) with the bucket lugs.
7. (4x1 bucket) Release the pressure from the bucket LEEN11T0166AA 1
circuit.
8. Install the rod/bucket pins (2) and then install the rel-
evant retaining pins and rings.
9. (4x1 bucket) Remove the plugs and reconnect the
hydraulic lines.
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Bucket - Service instruction - Loader bucket self-levelling

1. The self-levelling linkage mounted on the right hand
loader arm and frame automatically controls the angle
of the loader bucket during the raising cycle of the lift
arms to maintain a constant bucket level. There is no
self-levelling during the lowering cycle.
2. Self-levelling begins when the tube (2) on the loader
arm contacts the bell crank (1) and lifts the vertical link-
age rod (3).
3. The tie rod then moves the bucket spool to the dump
position to level the bucket.
LELI12TLB2520AB 1
Automatic self-levelling control adjustment

2. Disconnect the vertical tie rod (3) at the lower bell
crank.
3. Raise the loader attachment so that the lower bucket
pin is 800 mm (31.5 in) above the ground, and fully turn
over the bucket to the rear.
LELI12TLB2521AA 2
4. Rotate the bell crank (1) until it touches the tube (2) on
the loader arm. Make sure the lower bell crank arm is
directed upwards.
5. Adjust the length of the vertical rod (3) so that, when
re-connected, the end of the loader arm tube remains
in contact with the bell crank.
6. Securely tighten the lock nuts on a vertical tie rod.
LELI12TLB2522AB 3
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“Return to dig” device - 2WS

1. The “return to dig” device is an electrically activated fea-
ture which enables the operator to automatically return
the bucket to a level digging position for a further work
cycle, with one simple movement of the control lever
(3).
2. Whenever the bucket is rolled forward to dump the re-
turn to dig electric circuit is completed and the solenoid
on the bucket spool is energized.
3. When the loader bucket control lever (3) is moved di-
agonally left to the return to dig position (2) the electro-
magnet will hold the bucket spool in the roll back po-
sition until the bucket is in the level digging position
at which time the indicator on the rod of the bucket
self-levelling linkage will pass in front of the sensor
which de-energizes the electromagnet on the bucket
spool enabling the spool to return to the neutral posi-
tion.
LELI12TLB2526BB 4
Return to dig sensor - Adjustment

1. The “return to dig” device consists of an electromagnet
mounted on the bucket spool, a sensor (1) mounted on
top of the loader arm and a pointer attached to the tube
of the bucket self-levelling linkage.
2. Place the bucket on the ground in the preferred digging
position.
3. Adjust the position of the sensor such that when the
bucket is in digging position and loader arms are low-
ered, half (50%) of the sensor face is obscured by the
self-levelling linkage pointer.
4. Ensure the face of the sensor (1) is 3 – 6 mm (0.12 –
0.24 in) from the pointer (2) on the self-levelling link- LELI12TLB2527AB 5
age.
5. As a visual aid for the operator, while seated in the cab,
the pointer mounted on the loader arm can be seen to
align with the pointer on the self-levelling linkage, when
the loader arms are lowered and the bucket is in the
level digging position.
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“Return to dig” system - 4WS

1. The “return to dig” device is an electrically activated fea-
ture which enables the operator to automatically return
the bucket to a level digging position for a further work
cycle, with one simple movement of the control lever
(3).
2. Whenever the bucket is rolled forward to dump the re-
turn to dig electric circuit is completed and the solenoid
on the bucket spool is energized.
3. When the loader bucket control lever (3) is moved di-
agonally left to the return to dig position (2) the electro-
magnet will hold the bucket spool in the roll back po-
sition until the bucket is in the level digging position at
which time the indicator on the rod of the bucket linkage
will pass in front of the sensor which de-energizes the
electromagnet on the bucket spool enabling the spool
to return to the neutral position.
LELI12TLB2530BB 6
Return to dig sensor - Adjustment

1. The “return to dig” device consists of an electromagnet
mounted on the loader bucket control valve spool, a
sensor (1) mounted on top of the loader arm and a
pointer attached to the tube of the bucket self-levelling
linkage.
2. Place the bucket on the ground in the preferred digging
position.
3. Check the dimensions of 88.5 mm (3.5 in) and 7.5 mm
(0.3 in) are maintained as shown.
4. Make sure that the sensor (1) is 6 mm (0.24 in) from
the tie rod (2).
LELI12TLB2519AB 7
5. As a visual aid for the operator, while seated in the cab,
the pointer mounted on the loader arm can be seen to
align with the pointer on the return to dig linkage, when
the loader arms are lowered and the bucket is in the
level digging position.
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Bucket - Replace the bucket teeth

2. Position the loader bucket so that the bucket teeth can
be replaced.
neutral position.
6. Remove the bolts (2) and nuts (3).
7. Remove the tooth (1).
1
8. Clean the area around the tooth. LELI12TLB2540AB
9. Install the new tooth (1) with the bolts (2) and nuts (3).
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Loading bucket forks - Install

NOTICE: The forks are heavy, so use great care when swinging them into their working and stowage position.
Install forks in working position

1. Move the bucket to a level and firm ground.
3. Raise the parking brake lever.
4. Remove the retained pin and pin (1).
5. Lower the fork (2) manually and carefully until it is laying
in position against the bucket cutting edge.
NOTICE: The forks must be laying against the cutting edge
of the bucket, and never against bucket teeth.
LELI12TLB2535AB 1
6. Install the pin (1) and safety pin.

7. Repeat the same operations for the other fork.
8. Slide the forks until they are suitably spaced for the
intended job.
NOTICE: The two forks must be positioned at the same
distance from the centre of the bucket.
NOTICE: Never use the forks to lift the machine.
NOTICE: When using the forks with a 4x1 bucket, never
attempt to use the bucket jaw opening function.
LELI12TLB2536AB 2
Install the forks in rest position

9. Rest the loader bucket on a level and firm ground. Stop
the engine and remove the starter key. Apply the park-
ing brake.
10. Remove the retainer pin and pin (1).
11. Tilt the fork (2) manually and carefully until it is rear-
wards into transport position.
LELI12TLB2536AB 3
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12. Reinstall the pin (1) and the safety pin into their hous-
ing.
NOTE: If necessary, slide the fork to the side to bring it into
its housing.
13. Repeat the same operations for the other fork.
NOTICE: The forks must be securely retained in their
proper storage position using the pins and split pins pro-
vided for this purpose. If forks are not correctly secured,
they can cause serious injury.
LELI12TLB2535AB 4
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Index
Bucket - 300
Bucket - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Bucket - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Bucket - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Bucket - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Bucket - Replace the bucket teeth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Bucket - Service instruction - Loader bucket self-levelling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Bucket - Static description - Loader controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Loading bucket forks - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
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PRINTED IN U.S.A.
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EN
SERVICE MANUAL
Booms, dippers, and buckets

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84
Contents
Booms, dippers, and buckets - 84
[84.114] Boom pivoting support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84.1
[84.910] Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84.2
[84.912] Dipper arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84.3
[84.100] Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84.4
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Boom pivoting support - 114

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Contents
TECHNICAL DATA
Sliding support
Dimension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
FUNCTIONAL DATA
Sliding support
Component localization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
SERVICE
Swing tower
Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
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Booms, dippers, and buckets - Boom pivoting support
Sliding support - Dimension

Handling cylinder
LELI12TLB2398FA 1
1. Stroke
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Sliding support - Component localization
LELI12TLB2726GB 1
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1. M14 X 210 hex screw 14. Spacer

[Tightening torque = 85 – 115 N·m (62.69 –
84.82 lb ft)]
2. Washer 15. Snap ring
3. Plate 16. Pin
4. Pin 17. Cylinder support
5. Snap ring 18. Handling cylinder
6. Nut M14 19. M8 X 14 hex screw
7. Support 20. Shim
8. Shoe 21. Washer
9. Shim 22. Shoe
10. Handling cylinder assy 23. Shim
M14 X 50 hex screw 24. Fitting
11. [Tightening torque = 135 – 183 N·m (99.57 –
134.97 lb ft)]
12. Washer 25. M12 X 20 socket head screw
13. Spacer 26. Shoe
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Swing tower - Remove

DRIVE (2WD)
DRIVE (4WD)
1. Use a suitable lifting device or safety support stands to

support the weight and movement of the swing tower.
2. Disconnect the boom (transport) lock device.
3. Remove the snap ring (3) and washers (2) from the
swing cylinder lock pin (4).
4. Remove the swing cylinder lock pin (4) from the swing
tower.
5. Knock out or press out the swing cylinder pivot pin (1).
You may remove the pin through the top or bottom of
the swing tower.
6. Repeat on the other swing cylinder pivot pin.
RAIL17TLB0043BA 1
7. Retract the swing cylinder rods.

8. Remove the upper swing tower pivot bolt (2) and
washer (3) .
9. Remove the upper swing tower pivot pin (1).
RAIL17TLB0011AA 2
10. Remove the snap ring (1) and washers (2) from the
lower swing tower pivot lock pin (3).
11. Take note of the orientation of the lower swing tower
wear spacers (5). The wear spacers are between the
swing tower and the side-shift frame or center-pivot
frame (shown).
12. Remove the lower swing tower pivot pin (4). You may
choose to remove the pin from the bottom or the top
of the swing tower. If you decide to press the pivot pin
upward out of the swing tower; remove the snap ring
from the bottom of the pivot pin.
RAIL17TLB0009AA 3
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Swing tower - Install

DRIVE (2WD)
DRIVE (4WD)
1. Position the swing tower on the side-shift frame of the

center-pivot frame.
2. Position the lower swing tower wear spacers (1) be-
tween the swing tower (2) and the frame (3). Make sure
that the tab (A) on the spacer (1) engages the notch (B)
on the swing tower (2).
RAIL17TLB0010AA 1
RAIL17TLB0012AA 2
3. Install the lower swing tower pivot pin (4).

4. Install the lower swing tower pivot lock pin (1). Secure
the position with the snap ring (3) and washers (2) on
both sides.
RAIL17TLB0044BA 3
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5. Extend the swing cylinder rods until the rod eye (1)
aligns with pivot pin opening (3).
6. Install the swing cylinder pivot pin (2).
7. Install the swing cylinder lock pin (6). Secure the po-
sition with the snap ring (5) and washers (4) on both
sides.
8. Repeat on the other swing cylinder pivot pin.
RAIL17TLB0043BA 4
9. Install the upper swing tower pivot pin (1).

10. Apply LOCTITE® 270 to the threads of the upper swing
tower pivot bolt (2).
11. Install and tighten the upper swing tower pivot bolt
(2) and washer (3). Torque to 295 – 345 N·m (218
– 254 lb ft).
RAIL17TLB0045BA 5
12. Connect the boom (transport) lock device.

NOTE: If you removed the boom lock cylinder bolt (1)
(shown) or the mechanical boom lock bracket bolt (1).
Torque bolt to 49 – 66 N·m (36 – 49 lb ft).
RAIL17TLB0009AA 6
13. Remove the lifting device or safety support stands.

14. Grease all fittings with TUTELA MULTI -PURPOSE EP
GREASE 251H, GR-9.
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Index

Sliding support - Component localization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Sliding support - Dimension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Swing tower - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Swing tower - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
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Boom - 910

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Contents
Boom - 910
SERVICE
Boom
Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
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Booms, dippers, and buckets - Boom
Boom - Remove
DRIVE (2WD)
DRIVE (4WD)
NOTE: The procedure is the same for machines with center pivot or side-shift.
1. Park the machine on a flat surface and position the
backhoe on the ground.
LELI12TLB2380AA 1
2. Lower stabilizers sufficiently and however ensure that

the rear tires are in contact with the ground to remove
the weight from the rear wheels.
NOTICE: The rear wheels must remain in contact with the
ground.
LELI12TLB2381AA 2
LELI12TLB2382AA 3
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3. On machines fitted with telescopic dipper install locking

pin in transport hole (1).
4. Fully retract telescopic dipper.
LELI12TLB2383AB 4
5. Fully retract dipper cylinder and lower boom until

bucket is firmly resting on the ground.
6. Support the backhoe using suitable stand with a capac-
ity of carrying 1500 kg (3307 lb).
7. Turn OFF the engine. Move the backhoe control levers
through all operating positions to relieve pressure in the
system.
LELI12TLB2384AA 5
8. Prepare a suitable container to collect the flow of hy-

draulic oil from the hoses and valves.
9. Label and disconnect all hoses and electrical har-
nesses that travel through the swing tower to the
backhoe.
10. Disconnect the boom locking device (1) from the boom
lock (transport) bracket (2).
RAIL17TLB0008AA 6
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11. Remove the grease fitting (2), snap ring (3), and
washer (1) from the cylinder bushing pin (4).
RAIL17TLB0041BA 7
12. Support the cylinder rod (3) and remove the bushing
pin (2).
13. Remove the boom lock (transport) bracket (1).
RAIL17TLB0042BA 8
14. Remove the grease fitting (3), the lower bolt (4), the
washer (5), and the bracket (1) from the cylinder bush-
ing pin (2).
15. Remove the lower pin (2) of from the swing tower and
boom.
16. Repeat steps 14 - 15 on the other side of the boom.
RAIL17TLB0040BA 9
17. Remove the backhoe assembly from the machine.
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Boom - Install
DRIVE (2WD)
DRIVE (4WD)
1. Using a lifting device move the boom assembly and

position it on the machine carefully.
PTIL13TLB0465AA 1
2. Install the lower pin (2).

3. Apply LOCTITE® 242® to bolt (5).
4. Install the grease fitting (3), the lower bolt (4), the
washer (5), and the bracket (1) to secure the cylinder
bushing pin (2) position.
RAIL17TLB0040BA 2
5. Repeat steps 2 - 4 on the other side of the boom.

6. Torque both bolts (5) to 425 – 575 N·m (313 – 424 lb
ft).
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7. Position the cylinder rod end (2) and boom lock (trans-
port) bracket (1) on the swing tower.
RAIL17TLB0041BA 3
8. Insert the cylinder bushing pin (4) through the boom

lock bracket and cylinder rod eye.
9. Secure the busing pin position with washers (1) and
snap rings (2).
RAIL17TLB0041BA 4
10. Attach the boom locking device (1) to the boom lock
(transport) bracket.
11. Identify and connect all the hydraulic hoses.
RAIL17TLB0008AA 5
12. Grease the bushing pin grease fittings with TUTELA

MULTI -PURPOSE EP GREASE 251H, GR-9.
13. Release the lifting device from the boom.
14. Check hydraulic oil reservoir level. If necessary add
hydraulic oil.
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Index
Boom - 910
Boom - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Boom - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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Dipper arm - 912

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Contents
Dipper arm - 912
FUNCTIONAL DATA
Dipper arm
Exploded view - Extendable dipper Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Sectional view - Extendable dipper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
SERVICE
Dipper arm
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Telescopic dipper
Service instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
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Booms, dippers, and buckets - Dipper arm
Dipper arm - Exploded view - Extendable dipper Installation
RAIL17TLB0069GA 1
(1) Grease zerk (boom-to-dipper bushing) (15) Dipper coupler link

(2) Backhoe pivot pin seal (16) Dipper link pivot pin
(3) Pin (17) Backhoe pivot pin seal
(4) Extendable outer dipper (18) Pin lock assembly
(5) Snap ring (19) Pin
(6) Hose clamp assembly (20) Ring
(7) Cylinder ring gear hose clamp with spacer (21) Grease zerk
(8) Backhoe pivot pin seal (22) Snap ring
(9) Extendable dipper cylinder (23) Extendable dipper cylinder pin
(10) Bolt and washer for upper slide rail (24) Bucket cylinder pin assembly
Torque 41 – 49 N·m (30 – 36 lb ft)
(11) Extendable dipper lock pin (25) Extendable inner dipper
(12) Bucket cylinder (26) Bolt and washer for lower slide rail
Torque 350 – 400 N·m (258 – 295 lb ft)
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(13) Snap ring (27) Bolt and washer for inner clamp
(14) Washer
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Dipper arm - Sectional view - Extendable dipper
RAIL17TLB0070GA 1
(1) Upper slide rail for inner dipper (5) Washer

(2) Bolt (6) Lower slide rail for inner dipper
Torque 41 – 49 N·m (30 – 36 lb ft)
(3) Washer (7) Inner dipper
(4) Bolt
Torque 350 – 400 N·m (258 – 295 lb ft)
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Dipper arm - Remove

1. Park the machine on a level, firm surface and position
the backhoe on the ground.
LELI12TLB2709AA 1
2. Lower stabilizers sufficiently to remove the weight from

the rear wheels.
ground.
LELI12TLB2710AA 2
LELI12TLB2711AA 3
3. Install the locking pin in transport hole (1) [on machines

fitted with telescopic dipper].
LELI12TLB2712AB 4
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4. Lower the backhoe to the ground and support using a

suitable stand.
5. Turn off engine, then move backhoe control levers
through all operating positions to relieve pressure in
the system.
LELI12TLB2713AA 5
6. Disconnect the hoses to the dipper cylinders.

Arm hoses:
• Telescopic dipper;
LELI12TLB2714AA 6
• Standard dipper.
LELI12TLB2715AA 7
7. Support the dipper cylinder, remove the bolt (2), slide

out the pin (3).
8. Lower cylinder onto boom. Use suitable cylinder sup-
ports to make sure that the weight of cylinder does not
damage hydraulic tubes attached to the dipper.
LELI12TLB2716AB 8
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9. Support the dipper using suitable hoist.

10. Remove the screw (4), slide out the pin (5). Carefully
lower dipper to the ground.
LELI12TLB2717AB 9
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Dipper arm - Install

1. Lift the complete arm assembly using the lifting device
and position it on the machine after aligning with the
boom.
PTIL13TLB0475AA 1
2. Tap and install the retainer bracket (1) and pivot pin to
the arm assembly.
moval.
PTIL13TLB0460AB 2
3. Install the retainer bracket bolt (1) and washer in the

boom and arm joining location using LOCTITE® 242®.
Torque: 186 N·m (137 lb ft).
NOTE: Ensure to install the shims, collected during re-
moval.
4. Connect the arm cylinder to the arm. Refer to Dipper
arm - Install (84.912).
5. Install the dipper cylinder. Refer to Dipper cylinder -
Install (35.737).
PTIL13TLB0459AB 3
6. Adjust and extend the bucket cylinder rod manually to

bring the connecting rod to their housing.
7. Reinstall the arm/bucket link pin (1) and install the lock
rings and pins.
8. Slightly raise the attachment and operate the bucket
and dipper control to align the dipper hole with the
bucket lugs.
9. Reinstall the rod/bucket link pin (2) and install the lock
rings and pins.
PTIL12TLB0165AB 4
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10. Release the lifting device from the arm assembly.

11. Clamp the hydraulic lines to the dipper arm and bucket
cylinder.
12. Connect the lines and hoses to the cylinder.
PTIL13TLB0458AA 5
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Telescopic dipper - Service instruction

Inspection of guide pads
1. Park the machine on level ground and retract the tele-
scopic dipper.
2. Position the dipper on a suitable stand with the bucket
raised from the ground.
3. Clean the area around the pads.
LELI12TLB2718AA 1
4. Inspect each upper guide pad. If the chamfered edge

(1) on the corner of the pads is no longer visible the
pads have worn beyond their limit and must be re-
placed.
5. If pads do not require replacement visually check if the
gap between the inner part of the dipper and upper
guide pad is greater than 1.5 mm (0.06 in).
6. If the gap is greater than 1.5 mm (0.06 in) the guide
pads must be adjusted.
LELI12TLB2719BB 2
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Adjustment of guide pads

1. Position the dipper in the vertical position.
2. Count the number of shims behind the adjusting screws
on the left and right hand sides of the dipper to deter-
mine which side has the most shims.
3. Remove one shim from behind an adjusting screw on
the side of the dipper which contains the most shims.
4. Reassemble the screw and tighten it to a tightening
torque of 350 – 400 N·m (258 – 295 lb ft).
NOTICE: DO NOT exceed the torque limits.
5. Repeat the procedure for the remaining three screws
on the same side of the dipper.
6. Recheck the gap.
7. If the gap remains greater than 1.5 mm (0.06 in) re-
move a shim from behind each of the adjusting screws
on the opposite side of the dipper.
8. After performing an adjustment apply a coat of Dry
Moly-coat grease to the slide rails of the dipper.
NOTE: When all shims have been removed the guide pads
must be replaced.
LELI12TLB2720BA 3
Replacement of guide pads

To replace the guide pads it is necessary to separate
the inner and outer parts of the telescopic dipper using
either of the following procedures which are dependent
on workshop facilities.
Guide pads can be replaced by following one of the
procedures listed below:
Procedure 1
1. Park the machine on level ground and lower the loader
attachment bucket.
2. Lower stabilizers sufficiently to remove the weight from
the rear wheels.
ground.
3. Position the dipper on a suitable stand.
4. Attach hoist to inner part of the dipper.
5. Disconnect the hose connections to the bucket and the
telescopic dipper cylinders.
LELI12TLB2721AB 4
6. Remove the telescopic dipper cylinder pin (1) and sep-
arate the inner and the outer parts of the telescopic dip-
per.
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8. Remove the guide pads (3).
9. Install new pads and apply thread sealant part to the
bolts. Torque to 41 – 49 N·m (30 – 36 lb ft).
10. Do not over tighten or damage to the threaded inserts
may occur.
11. Re-assemble the inner and the outer parts of the tele-
scopic dipper.
12. Place 5 shims beneath the heads of each adjusting
screw.
LELI12TLB2722AB 5
13. Adjust guide pads as described previously.
Procedure 2
NOTICE: This procedure requires the use of a loading dock or service pit.
1. Park the machine with backhoe positioned over loading
dock or service pit.
2. Place the loader bucket on the ground and lower sta-
bilizers sufficiently to remove the weight from the rear
wheels.
3. Attach suitable hoist to top of inner section of dipper
and position boom so that dipper is hanging vertically.
4. Disconnect the hose connections to the bucket and the
telescopic dipper cylinders.
5. Remove the telescopic dipper cylinder retaining pin.
6. Slowly lower hoist allowing inner and outer parts of tele- LELI12TLB2723AA 6
scopic dipper to separate.
8. Remove the guide pads (3).
9. Install new guide pads and apply thread sealant to the
retaining bolts. Torque to 41 – 49 N·m (30 – 36 lb ft).
10. Do not over tighten or damage to the threaded inserts
may occur.
11. Position new lower guide pads in the outer part of the
telescopic dipper.
12. Re-assemble the inner and the outer parts of the tele-
scopic dipper.
LELI12TLB2722AB 7
13. Place 5 shims beneath the heads of each adjusting
screw.
14. Adjust guide pads as described previously.
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Telescopic dipper - Disassemble

1. Stretch the backhoe attachment on the ground.
2. Lower the stabilizer, engage the Extendahoe® (1) and
place the bucket on the ground.
4. Remove the lock rings, pins (2) and the rod/bucket link
pin (3).
ATTENTION: Wear eye protection. Do not strike steel
parts with a steel hammer. Parts may break. Failure to
comply could result in minor or moderate injury.
PTIL13TLB1768AB 1
6. Retract the Extendahoe® (1) to release the bucket.
7. Operate the attachment controls so that the dipper /
bucket pin is not supporting the load of the dipper.
8. Remove the lock rings and pins (1) from Extendahoe®.
9. Stop the engine and remove the starter switch key after
extending the Extendahoe®.
10. Remove the bucket cylinder. Refer to Bucket cylin-
der - Remove (35.738).
PTIL13TLB1770AB 2
11. Remove the lock ring and pin (1) from the Extenda-
hoe® end, connected to the Extendahoe® dipper.
12. De-clamp the hydraulic lines to the dipper arm.
13. Cap the lines and hoses immediately after unplugging.
14. Attach a lifting device to the arm assembly.
15. Disconnect the dipper cylinder at dipper arm end.
16. Tie the Extendahoe® to a rope and hold it using a
hoist.
ATTENTION: Do not stand beneath the components. It
may fall and cause serious injuries. PTIL13TLB1771AB 3
17. Slide the Extendahoe® from the dipper (2) and place
it safely on the ground with the help of hoist.
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Telescopic dipper - Assemble

WARNING
Heavy objects!
W0398A
RAIL17TLB0069GA 1
1. Connect the hydraulic tube (6) to the rod end of the

extendable dipper cylinder (12).
2. Secure the hydraulic tube (6) with cylinder clamp (4).
3. Slide the extendable dipper cylinder (12) into the ex-
tendable dipper (8).
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4. Secure the extendable dipper rod (12) end inside the

extendable dipper (8) with the pin (10) and snap rings
(8).
5. Slide the extendable dipper with cylinder into the dipper
arm (7) between the slide rails.
6. Connect the dipper cylinder at the dipper arm end with
pin (3) and snap rings (2) .
7. Secure all hydraulic connections.
8. Secure all tubes and hoses with the appropriate
clamps.
9. Install the bucket cylinder.
10. Adjust the extendable dipper position. Refer to Tele-
scopic dipper - Service instruction (84.912).
11. Check hydraulic oil. If necessary add hydraulic oil.
12. Start the machine operate all hydraulic functions nu-
merous times.
13. Stop the machine, allow the hydraulic oil to cool, and
check the hydraulic oil level. If necessary add hy-
draulic oil.
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Index
Dipper arm - 912

Dipper arm - Exploded view - Extendable dipper Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Dipper arm - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Dipper arm - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Dipper arm - Sectional view - Extendable dipper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Telescopic dipper - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Telescopic dipper - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Telescopic dipper - Service instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
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Bucket - 100

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Contents
Bucket - 100
TECHNICAL DATA
Bucket
OPERATING
Bucket
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Adjust - universal backhoe coupler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Lock/Unlock - hydraulic quick coupler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Adjust - digging angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
SERVICE
Bucket teeth
Replace - nut and bolt style . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Replace - wedge style . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
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Booms, dippers, and buckets - Bucket
Bucket - General specification

Backhoe buckets
NOTE: Chart applies to models with an overlapping cylinder boom.
Type Width Weight

300 mm (12 in) 86 kg (190 lb)
400 mm (16 in) 104 kg (229 lb)
450 mm (18 in) 112 kg (247 lb)
Standard
600 mm (24 in) 130 kg (287 lb)
750 mm (30 in) 151 kg (333 lb)
900 mm (35 in) 171 kg (377 lb)
406 mm (16 in) 139 kg (306 lb)
457 mm (18 in) 149 kg (328 lb)
Heavy duty
610 mm (24 in) 176 kg (388 lb)
914 mm (36 in) 228 kg (503 lb)
Ditch cleaning 1500 mm (59 in) 160 kg (353 lb)
NOTE: Chart applies to models with an in-line cylinder boom.
Type Width Weight

305 mm (12 in) 119 kg (262 lb)
457 mm (18 in) 138 kg (304 lb)
Standard 610 mm (24 in) 166 kg (366 lb)
762 mm (30 in) 217 kg (478 lb)
914 mm (36 in) 248 kg (547 lb)
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Bucket - Remove
Mechanical coupler
NOTE: Only applicable to models with an overlapping
cylinder boom.
1. Move the machine to level and firm ground.

2. Lower the stabilizers until they are resting on the
ground.
3. Place the bucket on the ground as shown.
CAUTION
Flying objects!
Wear eye protection. Do not strike steel parts
with a steel hammer. Parts may break.
Failure to comply could result in minor or
moderate injury.
C0024A
5. Remove the snap ring (3) and the washer (4).

6. Slide out the pin (5).
8. Operate the backhoe attachment controls so that the
LEEN11T0192AA 1
mechanical coupler hook (2) releases from the bucket
pin (1).
RCPH10TLB397AAF 2
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Straight links coupler

NOTE: Only applicable to models with an in-line cylinder
boom.

2. Lower the stabilizers and place the bucket on the
ground.
4. CAUTION
Flying objects!
Wear eye protection. Do not strike steel parts with
RAIL15TLB0533AA 3
a steel hammer. Parts may break.
Failure to comply could result in minor or moder-
ate injury.
C0024A
Remove the snap rings, washers, and the dipper link-

to-bucket pin (1).
6. Retract the bucket cylinder rod.
7. Operate the attachment controls so that the dipper-
to-bucket pin is not supporting the load of the dipper
(just touching the ground).
9. Remove the snap rings, washers, and the dipper-to-
bucket pivot pin (2).
11. Operate the attachment controls to confirm the
bucket does not disconnect from the dipper.
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Bucket - Install
Mechanical coupler
NOTE: Only applicable to models with an overlapping
cylinder boom.

2. Move the machine so that you can easily view and
access the bucket with the backhoe.
3. Lower the stabilizers.
4. Slowly move the end of the dipper arm between the
bucket lugs paying attention that the mechanical cou-
pler hook (2) engages the bucket pin (1).
RCPH10TLB397AAF 1
NOTE: Make sure that the bucket does not rotate off
the mechanical coupler when maneuvering the back-
hoe cylinders.
5. Raise the boom and adjust the bucket cylinder until
the hole on the dipper arm (3) aligns with the hole in
bucket opening (4).
7. CAUTION
Flying objects!
ate injury.
C0024A
Insert pin (3).

8. Secure the position of the pin (3) with washers (2) and
the snap rings (1).
LEEN11T0192AA 2
9. Carefully operate the backhoe controls to confirm the
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Straight links coupler

NOTE: Only applicable to model 580ST with an in-line
cylinder boom.
1. Move the machine so that you can easily view and

access the bucket with the backhoe.
2. Lower the stabilizers.
3. Insert the end of the dipper into the bucket pivot point
(2). Make sure that you align the hole at the end of the
dipper with the bucket opening.
4. Stop the engine.
RAIL15TLB0533AA 3
5. CAUTION
Flying objects!
ate injury.
C0024A
Install the dipper arm to bucket pin (2).

6. Secure the position of the pin with washers and snap
rings.
8. Slightly raise the attachment and operate the bucket
and dipper control to align the dipper arm linkage hole
(1) with the bucket.
9. Stop the engine.
10. CAUTION
Flying objects!
ate injury.
C0024A
Install the dipper arm linkage to the bucket pin (1).

11. Secure the position of the pin with washers and snap
rings.
13. Carefully operate the backhoe controls to confirm the
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Bucket - Adjust - universal backhoe coupler

WARNING
Avoid injury and/or machine damage!
Before operating the machine, make sure the attachment is securely connected to the machine. Apply
downward pressure with the bucket to the ground to make sure the coupler connection is secure.
W0932A
The universal backhoe coupler allows bucket compatibility with CASE CONSTRUCTION and J.C. Bamford Ltd.
(JCB™) backhoe buckets. Use the embossed letters as a guide; CASE ( CASE CONSTRUCTION), JCB (JCB™).
CASE CONSTRUCTION compatible buckets:
CASE CONSTRUCTION compatible buckets:
• K and SK-series
• L and SL-series
• M and SM-series
• N and SN-series
• P and SP-series
• R and SR-series
• T and ST-series
RAIL16TLB0750AA 1
JCB™ compatible buckets:

• 980/89980 - 980/89986 (Deep profile)
• 980/89988 - 980/89995 (General purpose)
• 900/90005 - 980/90012 (Heavy duty)
RAIL16TLB0750AA 2
1. Use the hook on the universal coupler (3) to engage

the pre-installed front bucket pin (2) on the bucket.
2. Rotate the coupler to align the lower holes in the uni-
versal coupler (4) with the upper holes in the lower lug
of the bucket (1).
3. Insert the bucket pin (7) through the upper holes in the
lower lug of the bucket (1) and the lower holes in the
universal coupler (4).
4. Secure the bucket pin (7) in place with the washer (6)
and the lock pin (5).
RAIL16TLB0738AA 3
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Bucket - Lock/Unlock - hydraulic quick coupler

The machine can be equipped with hydraulic quick cou-
pler for a quicker procedure of assembly/disassembly of
the backhoe bucket.
Move the machine to a level and firm ground.
Lower the loader attachment to the ground.
Place the direction-of-travel lever and gearshift lever in

neutral position.
Immobilize the machine with the parking brake.
Turn the backhoe bucket outwards and place it to the

LEEN11T0281AA 1
ground.
With the two switches (1), by pressing them on

side, engage/disengage the locking pins.
NOTE: Both switches must always be pressed at the
same time.
LEEN11T0282AA 2
Keep both switches of the quick coupler pressed,

extend the bucket cylinder, turn the quick coupler and re-
move it from the bucket.
NOTICE: Do not use the boom to move the machine if the
bucket is not installed. The quick coupler can get dam-
aged.
LEEN11T0283AA 3
Now it is possible to position the new bucket for fastening.
Retract the bucket cylinder, then insert the quick coupler

in the bucket.
Check alignment between locking pins and bucket holes

(2).
Press both switches (1), on side to lock the quick

coupler by inserting/extending the locking pins.
NOTE: Make sure that the pins of the quick coupler are
completely inserted in the bucket holes, before the activa- LEEN11T0284AA 4
tion of the backhoe attachment.
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Bucket - Adjust - digging angle

It is possible to change the backhoe bucket opening an-
gle, depending on the work which is to be carried out.
Position (1): Enables the bucket to open by 30° more and,

therefore, to dig vertical side trenches closer to the ma-
chine.
Position (2): Bucket maximum power.
RAIL15TLB0533AA 1
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Bucket teeth - Replace - nut and bolt style

2. Position the backhoe bucket so that the bucket teeth
can be replaced.
neutral position.
6. Remove the bolts (2) and nuts (3).
7. Remove the tooth (1).
8. Clean the area around the tooth. LELI12TLB2389AB 1
9. Install the new tooth (1) with the bolts (2) and nuts (3).
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Bucket teeth - Replace - wedge style

WARNING
Flying object!
Always wear eye or full face protection when performing this procedure.
W0313A

2. Position the backhoe bucket so that the bucket teeth
can be replaced.
neutral position.
6. Remove the tooth holder (2) using a hammer and a
chisel.
7. Remove the tooth (1) from the tooth holder (3).
8. Clean the inside of the tooth holder, removing any dirt
or rust.
9. Insert a new tooth (1) into the tooth holder (3).
10. Lock the new tooth by installing the tooth holder (2).
LELI12TLB2393AB 1
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Index
Bucket - 100
Bucket - Adjust - digging angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Bucket - Adjust - universal backhoe coupler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Bucket - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Bucket - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Bucket - Lock/Unlock - hydraulic quick coupler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Bucket - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Bucket teeth - Replace - nut and bolt style . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Bucket teeth - Replace - wedge style . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
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PRINTED IN U.S.A.
48090752 24/02/2017
EN
SERVICE MANUAL
Platform, cab, bodywork, and decals

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90
Contents
Platform, cab, bodywork, and decals - 90
[90.105] Machine shields and guards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.1
48090752 24/02/2017
90
Machine shields and guards - 105

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90.1 [90.105] / 1
Contents
SERVICE
Engine hood
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
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Platform, cab, bodywork, and decals - Machine shields and guards
Engine hood - Remove

1. Remove the front grille.
2. Fully open the hood.
3. Detach the engine hood gas lift struts. One on each
side.
4. Attach a suitable lifting device to the engine hood.
5. Tilt the engine hood slightly towards the closed position.
Tilt just enough to release the tension on the engine
hood restraint strap on the front left-hand side.
6. Remove the engine hood restraint strap.
7. Tilt the engine hood to an almost closed position.
8. Remove the engine hood pivot bolts.
LELI12TLB0012AB 1
9. Remove the hood.
RAIL15TLB0181AA 2
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Engine hood - Install

1. Move the hood into position.
RAIL15TLB0181AA 1
2. Align and install both engine hood pivot bolts.
LELI12TLB0012AB 2
3. Keep the hood lifting device attached.

4. Open the hood enough to secure the engine hood re-
straint strap on the left-hand side.
5. Attach the engine hood gas lift struts. One on each
side.
6. Remove the engine hood lifting device.
7. Open and close the engine hood.
8. Install the front grille.
Next operation:
See “Engine hood – Adjust” Engine hood - Adjust (90.105) if necessary.
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Engine hood - Adjust

Hood adjustment test
1. Close the hood and engage the hood lock. If the hood
latch will not engage. See “Hood latch bracket adjust-
ment”.
2. Attempt to open the hood with the hood lock engaged.
A. The hood barely moves. A properly engaged hood
will only move slightly.
B. The hood opens. See “Hood latch bracket adjust-
ment”.
C. The hood moves more than several millimeters or
has a loose fit. A loose fitting hood may vibrate
during operation or may not lock as intended. See
“Hood latch bolt adjustment”.
Hood latch bracket adjustment

1. Open the hood.
2. Loosen the bolts (3) underneath the hood latch bracket
(2) on the left-hand side of fixed hood (1).
RAIL15TLB0289BA 1
3. Slide the hood latch bracket (1) forward or backward.

4. Tighten the bolts just enough to close the hood and
check the latch engagement.
RAIL15TLB0269AA 2
48090752 24/02/2017
90.1 [90.105] / 5
5. Close the hood.

6. Push down on the latch to engage the lock. Repeat the
procedure as necessary.
7. Tighten the bolts to secure the hood latch bracket po-
sition.
8. If necessary continue to the “Hood latch bolt adjust-
ment”.
RAIL15TLB0086AA 3
Hood latch bolt adjustment

1. Open the hood and safely support the hood so that you
have enough room to adjust the hood latch bolt (1) and
stop nut (2) on the underside of the engine hood.
2. Adjust the bolt as necessary.
3. Secure the position of the bolt (1) with the stop nut (2).
RAIL15TLB0270AA 4
48090752 24/02/2017
90.1 [90.105] / 6
Index

Engine hood - Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Engine hood - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Engine hood - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
48090752 24/02/2017
90.1 [90.105] / 7
PRINTED IN U.S.A.
48090752 24/02/2017
EN
SPECIAL TOOL INDEX
Genuine Reference PAGE

380000988 [Starter opening Engine - Remove 10.1 / 8
plate and Flywheel Rotation
Blocker]
380000988 [Starter opening Engine - Install 10.1 / 11
plate and Flywheel Rotation
Blocker]
CAS1804 [Pressure Test Power shuttle transmission - Special tools 21.1 / 5
Fitting Kit]
380001740 [Flowmeter Fitting Power shuttle transmission - Special tools 21.1 / 5
Kit]
380040161 [Case M Series Power shuttle transmission - Special tools 21.1 / 6
Transmission Tool Kit]
CAS2379 [Clutch Power shuttle transmission - Special tools 21.1 / 6
Holder/Spring Compressor]
CAS2381 [Tool] Power shuttle transmission - Special tools 21.1 / 6
CAS2327 [Expanding Seal Power shuttle transmission - Special tools 21.1 / 6
pusher]
380000732 [Engine Turning Power shuttle transmission - Remove 21.1 / 28
Tool]
380000732 [Engine Turning Power shuttle transmission - Install 21.1 / 31
Tool]
380000732 [Engine Turning Powershift transmission - Remove H-type 21.4 / 36
Tool]
380000732 [Engine Turning Powershift transmission - Install H-type 21.4 / 141
Tool]
380200190 [Buffer Assembly Transmission housing - Disassemble 21.4 / 161
And Disassembly Of Several
Bearings]
380200226 [Buffer Assembly Transmission housing - Assemble 21.4 / 168
Of SAHR Seal Ring For
Parking Brake]
380200257 [Protection Transmission housing - Assemble 21.4 / 170
Assembly Of Seal Ring On
PTO Shaft]
380200225 [Plunger Transmission housing - Assemble 21.4 / 170
Assembly Of Seal Ring
On PTO Shaft And 4WD
Shaft]
380200214 [Calibrator Transmission housing - Assemble 21.4 / 170
Shaft]
380200226 [Buffer Assembly Transmission housing - Assemble 21.4 / 171
Parking Brake]
380200218 [Buffer Assembly Transmission lubrication pump - Install 21.6 / 27
Of Oil Pump Seal Ring]
380200215 [Attachment Shaft assemblies - Disassemble 21.7 / 18
Disassembly And Assembly
Of Clutch]
Of Clutch]
380200256 [Bush] Shaft assemblies - Disassemble 21.7 / 27
380200239 [Axle B C E Raise Shaft assemblies - Disassemble 21.7 / 27
Tool]
48090752 24/02/2017
Of Clutch]
Of Clutch]
Tool]
Of Clutch]
Of Clutch]
Of Clutch]
Of Clutch]
Of Clutch]
Of Clutch]
Tool]
380200258 [Tool Disassembly Shaft assemblies - Disassemble 21.7 / 60
And Assembly Of Snap Ring
On 4WD Shaft]
Tool]
On 4WD Shaft]
Tool]
On 4WD Shaft]
380001926 [Protection Clutch Shaft assemblies - Assemble 21.7 / 78
Piston Assembly]
380200215 [Attachment Shaft assemblies - Assemble 21.7 / 79
Of Clutch]
Of Clutch]
380200190 [Buffer Assembly Shaft assemblies - Assemble 21.7 / 83
Bearings]
380200224 [Cover And Shims Shaft assemblies - Assemble 21.7 / 84
Shaft]
Shaft]
48090752 24/02/2017
Shaft]
380200225 [Plunger Shaft assemblies - Assemble 21.7 / 85
Shaft]
Shaft]
Shaft]
Shaft]
380200214 [Calibrator Shaft assemblies - Assemble 21.7 / 85
Shaft]
Of Bearings Of Shaft]
Shaft]
Shaft]
Shaft]
On Shaft]
Shaft]
On Shaft]
Shaft]
On Shaft]
Shaft]
Shaft]
Shaft]
48090752 24/02/2017
Bearings]
Shaft]
Piston Assembly]
Of Clutch]
Of Clutch]
Of Bearings Of Shaft ]
380200240 [Protection And Shaft assemblies - Assemble 21.7 / 102
Shims]
380200242 [Pusher] Shaft assemblies - Assemble 21.7 / 102
380200241 [Gauger] Shaft assemblies - Assemble 21.7 / 102
380200248 [Protection] Shaft assemblies - Assemble 21.7 / 103
Of Clutch]
Of Clutch]
Piston Assembly]
Of Clutch]
Of Clutch]
Bearings]
380200251 [380200251] Shaft assemblies - Assemble 21.7 / 113
380200252 [Pusher] Shaft assemblies - Assemble 21.7 / 113
Bearings]
Bearings]
Bearings]
380200256 [Bush] Shaft assemblies - Assemble 21.7 / 114
Piston Assembly]
Of Clutch]
Of Clutch]
48090752 24/02/2017
Bearings]
Shaft]
380200239 [Axle B C E Raise Shaft assemblies - Assemble 21.7 / 123
Tool]
Bearings]
Shaft]
380200223 [Check Tool] Shaft assemblies - Assemble 21.7 / 132
Tool]
Bearings]
Shaft]
380200223 [Check Tool] Shaft assemblies - Assemble 21.7 / 143
Tool]
380200229 [Driver] Shaft assemblies - Assemble 21.7 / 151
380200220 [Driver] Shaft assemblies - Assemble 21.7 / 152
380200264 [Proction] Shaft assemblies - Assemble 21.7 / 153
On Shaft]
On Shaft]
380200265 [4WD Tool] Shaft assemblies - Assemble 21.7 / 153
Tool]
CAS1840C-1 [Wrench Pins] Four-Wheel Drive 25.1 / 6
CAS2151A [Pinion Nut Four-Wheel Drive 25.1 / 6
Socket]
CAS1842 [Tool Kit] Four-Wheel Drive 25.1 / 7
CAS2369 [Tool] Four-Wheel Drive 25.1 / 7
DMT100005 [Buffer Assembly Axle housing - Assemble 25.1 / 35
Of Bushing Into The Axle
Body]
DMT100006 [Buffer Assembly Axle housing - Assemble 25.1 / 35
Of Seal Ring In Axle Body]
DMT100005 [Buffer Assembly Differential - Install 25.2 / 22
Of Bushing Into The Axle
Body]
DMT100006 [Buffer Assembly Differential - Install 25.2 / 22
Of Seal Ring In Axle Body]
380000268 [Bevel Pinion Ring Bevel pinion - Disassemble 27.2 / 7
Nut Wrench]
48090752 24/02/2017
380000269 [Wheel Hub Bevel pinion - Disassemble 27.2 / 7
Bearing Ring Socket]
380200268 [Wrench To Screw Bevel pinion - Assemble 27.2 / 14
/ Unscrew The Pinion Ring
Nut]
380200269 [Wrench To Bevel pinion - Assemble 27.2 / 14
Measure The Pinion Rolling
Torque]
380200269 [Wrench To Bevel pinion - Assemble 27.2 / 14
Torque]
380200218 [Buffer Assembly Differential - Assemble 27.2 / 24
380200269 [Wrench To Differential housing - Disassemble 27.2 / 26
Torque]
380200243 [Wrench, Screw Differential housing - Disassemble 27.2 / 27
And Unscrew The Pinion Ring
Nuts]
380200218 [Buffer Assembly Differential housing - Assemble 27.2 / 28
380200243 [Wrench, Screw Differential housing - Assemble 27.2 / 28
Nuts]
380200243 [Wrench, Screw Differential housing - Assemble 27.2 / 29
Nuts]
380200259 [Plunger, Differential lock - Disassemble 27.2 / 33
Assembly And Disassembly
Of Differential Locking Yoke]
380200259 [Plunger, Differential lock - Disassemble 27.2 / 34
380200259 [Plunger, Differential lock - Assemble 27.2 / 37
380200260 [Guide, Assembly Differential lock - Assemble 27.2 / 38
And Disassembly Of
Differential Locking Yoke]
380200259 [Plunger, Differential lock - Assemble 27.2 / 38
380200260 [Guide, Assembly Differential lock - Assemble 27.2 / 38
And Disassembly Of
Differential Locking Yoke]
380200227 [Buffer Assembly Planetary and final drives - Replace the bronze bushing of the 27.3 / 15
Of Bushing In The Half-Beam] double joint
380200244 [Wrench, Screw Wheel hub - Disassemble 27.3 / 17
And Unscrew The Wheel Hub
Ring Nuts]
380200211 [Buffer Wheel Wheel hub - Assemble 27.3 / 20
Hub Seal Ring And Bearing
Assembly]
380002222 [Driver For The Wheel hub - Assemble 27.3 / 20
Assembly Of Bearing Cups In
The Wheel Hub]
Assembly]
Assembly]
48090752 24/02/2017
380200244 [Wrench, Screw Wheel hub - Assemble 27.3 / 21
And Unscrew The Wheel Hub
Ring Nuts]
380200255 [Buffer Assembly Wheel hub - Assemble 27.3 / 22
Of Bearings Into Gears]
380200196 [Buffer Ball Rear-powered steerable axle - Assemble the beam assembly 27.4 / 16
Bearing Assembly Of The
Upper King Pin]
380200196 [Buffer Ball Rear-powered steerable axle - Assemble the beam assembly 27.4 / 16
Upper King Pin]
380200227 [Buffer Assembly Rear-powered steerable axle - Assemble the beam assembly 27.4 / 16
Of Bushing In The Half-Beam]
380002226 [Driver For The Rear-powered steerable axle - Assemble the beam assembly 27.4 / 16
Assembly Of Bushing In The
Half Beam]
380200267 [Buffer Pinion Seal Rear-powered steerable axle - Assemble the front flange 27.4 / 26
Ring Assembly]
380200209 [Wrench, Tighten Differential carrier assembly - Remove 27.4 / 31
And Loosen The Brake
Cylinder Ring Nut]
380000020 [Wrench, Measure Differential carrier assembly - Disassemble - Bevel pinion 27.4 / 33
Of Pinion Rolling Torque]
380200188 [Buffer Assembly Differential carrier assembly - Assemble - Non-self locking 27.4 / 36
Of Bearing Cups Into The differential
Differential Box]
380200205 [Buffer Assembly Differential carrier assembly - Assemble - Limited slip differential 27.4 / 39
Of Bushings Into The
Differential Box]
380200188 [Buffer Assembly Differential carrier assembly - Assemble - Limited slip differential 27.4 / 39
Of Bearing Cups Into The
Differential Box]
380200216 [Kit Assembly Of Differential carrier assembly - Assemble - Bevel pinion 27.4 / 41
Pinion Bearing Cups]
380200202 [False Pinion, Differential carrier assembly - Assemble - Bevel pinion 27.4 / 41
Differential And Pinion
Assembly]
380200217 [False Differential Differential carrier assembly - Assemble - Bevel pinion 27.4 / 42
Box Differential And Pinion
Assembly]
380200202 [False Pinion, Differential carrier assembly - Assemble - Bevel pinion 27.4 / 43
Differential And Pinion
Assembly]
380200217 [False Differential Differential carrier assembly - Assemble - Bevel pinion 27.4 / 43
Box Differential And Pinion
Assembly]
380200190 [Buffer Assembly Differential carrier assembly - Assemble - Bevel pinion 27.4 / 44
Bearings]
380200190 [Buffer Assembly Differential carrier assembly - Assemble - Bevel pinion 27.4 / 44
Bearings]
380000021 [Bevel Pinion Ring Differential carrier assembly - Assemble - Bevel pinion 27.4 / 44
Nut Wrench]
380000020 [Wrench, Measure Differential carrier assembly - Assemble - Bevel pinion 27.4 / 44
380200237 [Tool For Measure Differential carrier assembly - Assemble - Bevel pinion 27.4 / 45
Of Pinion Preload]
380200237 [Tool For Measure Differential carrier assembly - Assemble - Bevel pinion 27.4 / 45
Of Pinion Preload]
380000020 [Wrench, Measure Differential carrier assembly - Assemble - Bevel pinion 27.4 / 46
48090752 24/02/2017
380200218 [Buffer Assembly Differential carrier assembly - Install 27.4 / 47
380200209 [Wrench, Tighten Differential carrier assembly - Install 27.4 / 49
Cylinder Ring Nut]
380200222 [Tool Backlash Differential carrier assembly - Install 27.4 / 49
Measure Between Pinion And
Ring Gear]
380200222 [Tool Backlash Differential carrier assembly - Install 27.4 / 49
Measure Between Pinion And
Ring Gear]
380200209 [Wrench, Tighten Differential carrier assembly - Install 27.4 / 50
Cylinder Ring Nut]
380200237 [Tool For Measure Differential carrier assembly - Install 27.4 / 51
Of Pinion Preload]
Of Pinion Preload]
Of Pinion Preload]
380000020 [Wrench, Measure Differential carrier assembly - Install 27.4 / 51
380200192 [Ring Gear Carrier Wheel hub - Disassemble 27.4 / 54
Hub installer and remover]
380000024 [Wheel Pivot Wheel hub - Assemble 27.4 / 57
Swivel Housing Half Shaft
Bushing And Seal Installer]
380200266 [Buffer Seal Ring Wheel hub - Assemble 27.4 / 57
Assembly Into The Swivel
Housing]
380200195 [Tool for Ball Wheel hub - Assemble 27.4 / 57
Lower King Pin]
Assembly]
380200210 [Wheel Hub Seal Wheel hub - Assemble 27.4 / 58
Ring Installer]
380200192 [Ring Gear Carrier Wheel hub - Assemble 27.4 / 59
380200192 [Ring Gear Carrier Wheel hub - Assemble 27.4 / 60
380200245 [Buffer Assembly Brakes - Disassemble 33.1 / 18
And Disassembly Of
Self-Adjust Kit]
380200245 [Buffer Assembly Brakes - Assemble 33.1 / 23
And Disassembly Of
Self-Adjust Kit]
And Disassembly Of
Self-Adjust Kit]
380200245 [Buffer Assembly Brakes - Disassemble 33.1 / 30
And Disassembly Of
Self-Adjust Kit]
And Disassembly Of
Self-Adjust Kit]
And Disassembly Of
Self-Adjust Kit]
48090752 24/02/2017
380200194 [Install and Brakes - Disassemble 33.1 / 40
remove Self-Adjust Kit]
380200194 [Install and Brakes - Assemble 33.1 / 41
remove Self-Adjust Kit]
380200238 [Buffer Brake Brakes - Assemble 33.1 / 42
Piston Assembly]
380200238 [Buffer Brake Brakes - Assemble 33.1 / 43
Piston Assembly]
380200238 [Buffer Brake Brakes - Replace 33.1 / 46
Piston Assembly]
380200226 [Buffer Assembly Parking brake or parking lock - Assemble 33.2 / 10
Parking Brake]
380200226 [Buffer Assembly Parking brake or parking lock - Assemble 33.2 / 16
Parking Brake]
380002714 [UCA Universal Accumulator - Check 35.2 / 9
Charging & Gauging Kit Tool]
380002714 [UCA Universal Accumulator - Check 35.2 / 9
Charging & Gauging Kit Tool]
380000725 [Wrench For Lift arm cylinder - Disassemble 35.12 / 8
Backhoe Bucket, Swing
Cylinder and Loader Cylinder
Heads]
380000722 [Wrench For Loader bucket control cylinder - Disassemble 35.13 / 8
Loader Bucket Cylinder Head]
380000724 [Wrench For Boom cylinder - Disassemble 35.15 / 9
Backhoe Boom And Dipper
Cylinder Head]
380000725 [Wrench For Bucket cylinder - Disassemble 35.17 / 9
Heads]
380000725 [Wrench For Swing cylinder - Disassemble 35.18 / 6
Heads]
380000726 [Wrench For Stabilizer cylinder - Disassemble 35.19 / 8
Stabilizer Cylinder Head
(Center Pivot)]
380000721 [Wrench For Stabilizer cylinder - Disassemble 35.19 / 11
Stabilizer Cylinder Head
(Sideshift) And Telescopic
Dipper Cylinder Head]
380040185 [Harness Harnesses and connectors - Overview 55.1 / 13
Diagnostic /Repair Kit (NEF)]
380040185 [Harness Harnesses and connectors - Overview 55.1 / 23
Diagnostic /Repair Kit (NEF)]
Kit Reference PAGE
CAS40033 [Tool Kit] Power shuttle transmission - Special tools 21.1 / 5
CAS2771 [Seal install kit] Power shuttle transmission - Special tools 21.1 / 6
48090752 24/02/2017
PRINTED IN U.S.A.
48090752 24/02/2017
EN

SM 695ST T4b 48090752

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SERVICE MANUAL

Part number 48090752

© 2017 CNH Industrial America LLC. All Rights Reserved.

580ST STAGE IV, SIDE-SHIFT (SS), FOUR-WHEEL DRIVE (4WD), MARBLE

Product Market Product Engine

[10.216] Fuel tanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.2

[10.206] Fuel filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3

[10.218] Fuel injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.4

[10.500] Selective Catalytic Reduction (SCR) exhaust treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.5

[10.400] Engine cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.6

[10.414] Fan and drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.7

[21.134] Power shuttle transmission external controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.2

[21.154] Power shuttle transmission internal components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.3

[21.113] Powershift transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.4

[21.135] Powershift transmission external controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.5

[21.105] Powershift transmission hydraulic components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.6

[21.155] Powershift transmission internal components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.7

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

[25.400] Non-powered front axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.4

Rear axle system........................................................................ 27

[27.120] Planetary and final drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27.3

[27.450] Rear-powered steerable axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27.4

Brakes and controls .................................................................... 33

[33.110] Parking brake or parking lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33.2

[35.300] Reservoir, cooler, and filters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.2

[35.104] Fixed displacement pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.3

[35.106] Variable displacement pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.4

[35.102] Pump control valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.5

[35.350] Safety and main relief valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.6

[35.357] Pilot system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.7

[35.128] Auxiliary hydraulic function control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.8

[35.355] Hydraulic hand control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.9

[35.352] Hydraulic swing system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.10

[35.724] Front loader hydraulic system control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.11

[35.701] Front loader arm hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.12

[35.723] Front loader bucket hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.13

[35.726] Excavator and backhoe hydraulic controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.14

[35.736] Boom hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.15

[35.737] Dipper hydraulic system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.16

[35.738] Excavator and backhoe bucket hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.17

[35.739] Swing arm hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.18

[35.703] Stabilizer hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.19

[35.740] Telescopic arm hydraulic system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.20

Frames and ballasting ................................................................. 39

[39.140] Ballasts and supports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39.2

[41.106] Tie rods. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.2

[41.200] Hydraulic control components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.3

[41.216] Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.4

[44.520] Rear wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.2

Cab climate control ..................................................................... 50

[50.104] Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50.2

[50.200] Air conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50.3

Electrical systems ....................................................................... 55

[55.301] Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.2

[55.302] Battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.3

[55.011] Fuel tank system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.4

[55.012] Engine cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.5

[55.640] Electronic modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.6

[55.512] Cab controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.7

[55.991] Telematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.8

[55.DTC] FAULT CODES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.9

Front loader and bucket............................................................... 82