SR210 / SR240 / SV280 Tier 4B (final) Alpha Series Skid Steer Loader PIN NGM418237 and above; PIN NHM435463 and above
TR270 / TR310 / TV370 Tier 4B (final) Alpha Series Compact Track Loader PIN NGM418237 and above; PIN NHM435463 and above
SERVICE MANUAL Printed in U.S.A. © 2018 CNH Industrial America LLC. All Rights Reserved.
Part number 48068130
Case is a trademark registered in the United States and many other countries, owned or licensed to CNH Industrial N.V., its subsidiaries or affiliates.
1st edition English January 2018
SERVICE MANUAL SR210 TIER 4B (FINAL) [NGM418237 - ], SR210 TIER 4B (FINAL) [NHM435463 - ], SR240 TIER 4B (FINAL) [NGM418237 - ], SR240 TIER 4B (FINAL) [NHM435463 - ], SV280 TIER 4B (FINAL) [NGM418237 - ], SV280 TIER 4B (FINAL) [NHM435463 - ], TR270 TIER 4B (FINAL) [NGM418237 - ], TR270 TIER 4B (FINAL) [NHM435463 - ], TR310 TIER 4B (FINAL) [NGM418237 - ], TR310 TIER 4B (FINAL) [NHM435463 - ], TV370 TIER 4B (FINAL) [NHM435463 - ]
48068130 29/01/2018 EN
Link Product / Engine Product TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ] SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ]
Market Product North America
Engine F5HFL463A*F001
North America
F5HFL463A*F001
North America
F5HFL463A*F001
North America
F5HFL463A*F001
North America
F5HFL463A*F001
North America
F5HFL463A*F001
North America
F5HFL463A*F001
North America
F5HFL463A*F001
North America
F5HFL463A*F001
North America
F5HFL463A*F001
North America
F5HFL463A*F001
48068130 29/01/2018
Contents INTRODUCTION Engine....................................................................................... 10 [10.001] Engine and crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.1 [10.216] Fuel tanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.2 [10.400] Engine cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3 [10.414] Fan and drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.4 [10.304] Engine lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.5
Power coupling........................................................................... 19 [19.121] Pump-drive assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.1
Front axle system ....................................................................... 25 [25.450] Chain drive system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.1
Rear axle system........................................................................ 27 [27.650] Chain drive system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27.1
Hydrostatic drive......................................................................... 29 [29.200] Mechanical control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29.1 [29.218] Pump and motor components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29.2 [29.202] Hydrostatic transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29.3
Brakes and controls .................................................................... 33 [33.110] Parking brake or parking lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33.1
Hydraulic systems....................................................................... 35 [35.000] Hydraulic systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.1 [35.300] Reservoir, cooler, and filters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.2 [35.104] Fixed displacement pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.3 [35.359] Main control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.4 [35.525] Auxiliary hydraulic valves and lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.5 [35.600] High flow hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.6 48068130 29/01/2018
[35.724] Front loader hydraulic system control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.7 [35.701] Front loader arm hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.8 [35.723] Front loader bucket hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.9 [35.734] Tool quick coupler hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.10
Frames and ballasting ................................................................. 39 [39.140] Ballasts and supports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39.1
Wheels ...................................................................................... 44 [44.511] Front wheels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.1 [44.520] Rear wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.2
Tracks and track suspension ........................................................ 48 [48.130] Track frame and driving wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48.1 [48.100] Tracks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48.2 [48.134] Track tension units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48.3 [48.138] Track rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48.4
Cab climate control ..................................................................... 50 [50.100] Heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50.1 [50.200] Air conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50.2
Electrical systems ....................................................................... 55 [55.000] Electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.1 [55.010] Fuel injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.2 [55.011] Fuel tank system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.3 [55.012] Engine cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.4 [55.019] Hydrostatic drive control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.5 [55.036] Hydraulic system control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.6 [55.050] Heating, Ventilation, and Air-Conditioning (HVAC) control system. . . . . . . . . . . . . . . . . 55.7 [55.051] Cab Heating, Ventilation, and Air-Conditioning (HVAC) controls. . . . . . . . . . . . . . . . . . . 55.8 [55.100] Harnesses and connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.9 [55.201] Engine starting system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.10 48068130 29/01/2018
[55.202] Cold start aid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.11 [55.301] Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.12 [55.302] Battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.13 [55.404] External lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.14 [55.408] Warning indicators, alarms, and instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.15 [55.512] Cab controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.16 [55.518] Wiper and washer system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.17 [55.525] Cab engine controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.18 [55.640] Electronic modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.19 [55.991] Telematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.20 [55.DTC] FAULT CODES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.21
Front loader and bucket............................................................... 82 [82.100] Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82.1 [82.300] Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82.2
Platform, cab, bodywork, and decals ............................................. 90 [90.150] Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.1 [90.160] Cab interior trim and panels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.2 [90.154] Cab doors and hatches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.3 [90.102] Engine shields, hood latches, and trims . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.4 [90.120] Mechanically-adjusted operator seat. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.5 [90.124] Pneumatically-adjusted operator seat. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.6
48068130 29/01/2018
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INTRODUCTION
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Contents INTRODUCTION Foreword - Important notice regarding equipment servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Safety rules - Ecology and the environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Safety rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Safety rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Safety rules - Personal safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Basic instructions - Loader arm lock and cab tilt procedure - radial lift machines (*) . . . . . . . . . . . 8 Basic instructions - Loader arm lock and cab tilt procedure - vertical lift machines (*) . . . . . . . 12 Torque - Standard torque data for hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Basic instructions - Shop and assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Torque - Minimum tightening torques for normal assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Basic instructions - Video links . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 General specification - Biodiesel fuels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Fluids and lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 General specification - Recommended engine oil for operating temperature ranges . . . . . . . . 30 General specification - Hydraulic oil for all models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Product identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Product identification - Machine orientation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
(*) See content for specific models 48068130 29/01/2018
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INTRODUCTION
Foreword - Important notice regarding equipment servicing All repair and maintenance work listed in this manual must be carried out only by qualified dealership personnel, strictly complying with the instructions given, and using, whenever possible, the special tools. Anyone who performs repair and maintenance operations without complying with the procedures provided herein shall be responsible for any subsequent damages. The manufacturer and all the organizations of its distribution chain, including - without limitation - national, regional, or local dealers, reject any responsibility for damages caused by parts and/or components not approved by the manufacturer, 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 - Ecology and the environment 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-conditioning 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
Safety rules Personal safety This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible death or injury.
Throughout this manual you will find the signal words DANGER, WARNING, and CAUTION followed by special instructions. 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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Safety rules
BT09A213
1
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INTRODUCTION
Safety rules - Personal safety Carefully study these precautions, and those included in the external attachment operators manual, and insist that they be followed by those working with and for you. 1.
Thoroughly read and understand this manual and the attachment Operator’s Manual before operating this or any other equipment.
2.
Be sure all people and pets are clear of the machine before starting. Sound the horn, if equipped, three times before starting engine.
3.
Only the operator should be on the machine when in operation. Never allow anyone to climb on to the machine while it is in motion. If the machine is equipped with an Instructors Seat, this must only be used for training purposes. Passengers must not be allowed to use the Instructors Seat.
4.
Keep all shields in place. Never work around the machine or any of the attachments while wearing loose clothing that might catch on moving parts.
5.
Observe the following precautions whenever lubricating the machine or making adjustments.
• Disengage all clutching levers or switches. • Lower the attachment, if equipped, to the ground or raise the attachment completely and engage the cylinder safety locks. Completing these actions will prevent the attachment from lowering unexpectedly. • Engage the parking brake. • Shut off the engine and remove the key. • Wait for all machine movement to stop before leaving the operators platform. 6.
Always keep the machine in gear while travelling downhill.
7.
The machine should always be equipped with sufficient front or rear axle weight for safe operation.
8.
Under some field conditions, more weight may be required at the front or rear axle for adequate stability. This is especially important when operating in hilly conditions or/when using heavy attachments.
9.
Always lower the attachment, shut off the engine, set the parking brake, engage the transmission gears, remove the key and wait for all machine movement to stop before leaving the operators platform.
10. If the attachment or machine should become obstructed or plugged; set the parking brake, shut off the engine and remove the key, engage the transmission gears, wait for all machine or attachment motion to come to a stop, before leaving the operators platform to removing the obstruction or plug. 11. Never disconnect or make any adjustments to the hydraulic system unless the machine and/or the attachment is lowered to the ground or the safety lock(s) is in the engaged position. 12. Use of the flashing lights is highly recommended when operating on a public road. 13. When transporting on a road or highway, use accessory lights and devices for adequate warning to the operators of other vehicles. In this regard, check local government regulations. Various safety lights and devices are available from your CASE CONSTRUCTION dealer. 14. Practice safety 365 days a year. 15. Keep all your equipment in safe operating condition. 16. Keep all guards and safety devices in place. 17. Always set the parking brake, shut off the engine and remove the key, engage the transmission gears, wait for all machine or attachment motion to come to a stop, before leaving the operators platform to service the machine and attachment. 18. Remember: A careful operator is the best insurance against an accident. 19. Extreme care should be taken in keeping hands and clothing away from moving parts.
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INTRODUCTION
Basic instructions - Loader arm lock and cab tilt procedure - radial lift machines SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ]
DANGER Crushing hazard! Do not enter or exit the operator's compartment while the loader arms are raised or unsupported. Rest the loader arms on the ground or verify that loader arm is being supported by the loader arm strut or loader arm lock pin before entering or exiting the operator's compartment. Failure to comply will result in death or serious injury. D0168A
WARNING Crushing hazard! Loader arms are unsupported during support strut removal. Do not enter or exit the operator's compartment with an unsupported loader arm. Two persons are required during storage. One person should remove and store the support strut while the operator remains in the operator's compartment. Failure to comply could result in death or serious injury. W0077B
Raise and lock the loader arm for machine service NOTE: An instructional decal on the inside of the righthand loader arm, just above the support strut is also available. Understand the loader arm lock procedure before continuing. 1. Sit in the operator's seat, fasten the seat belt, pull down the restraint bar down, and start the engine. 2. Press the OPERATE button to enable the hydraulics. 3. Remove the bucket or attachment from the mounting plate. 4. Park the machine on firm and level surface. 5. If an assistant is not available, turn off the engine and exit the machine. 20092924
1
93106848A
2
6. Remove the support strut pin (A) and let the support strut (B) rest on the lift cylinder barrel (C).
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INTRODUCTION
7.
Slowly raise the loader arm until the support strut (B) falls onto the cylinder rod (D).
8.
Stop the engine.
9.
Pull up on the override control knob (red control knob near the right-hand side of the operator’s seat). The support strut (B) will brace against the top of the cylinder barrel (C)..
10. Ask an assistant to insert the pin (A) into the support strut (B). If an assistant is not available visually confirm that the support strut is braced against the top of the cylinder barrel before exiting the machine. 93106854A
3
RAIL14SSL0418AA
4
931001633
5
Tilt and lock the cab forward for machine service 1. Remove the two, rear retaining nuts, located at the rear of the cab.
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INTRODUCTION
2. Pull on the hand holds at the front of the machine until the cab is completely tilted forward.
93107498
6
RAPH12SSL0420BA
7
RAPH12SSL0420BA
8
3. Confirm that the red lock tube has lowered over the cab pivot linkage. If it has the cab tilt position is now secure.
Tilt and secure the cab for machine operation 1. Raise the red lock tube exposing the cab pivot linkage. 2. Push the cab backward into the operation position.
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INTRODUCTION
3. Install the retaining nuts. Torque the nuts to 170 N¡m (125 lb ft).
931001633
9
Unlock and lower the loader arm for machine operation WARNING Crushing hazard! Loader arms are unsupported during support strut removal. Do not enter or exit the operator's compartment with an unsupported loader arm. Two persons are required during storage. One person should remove and store the support strut while the operator remains in the operator's compartment. Failure to comply could result in death or serious injury. W0077B
NOTE: An instructional decal on the inside of the righthand loader arm, just above the support strut is also available. Understand the loader arm unlock procedure before continuing.
RAIL14SSL0418AA
10
93106854A
11
93106848A
12
Placing the support strut in the storage position requires a second person. The operator must remain in the seat during this procedure. 1. Sit in the operator's seat, fasten the seat belt, pull down the restraint bar down, and start the engine. 2. Press the operate button to enable the hydraulics. 3. Raise the loader arm until the support strut (B) is not resting on the end of the cylinder barrel (C). 4. Instruct the second person to remove the support strut pin (A) and place the support strut in the stowed position and reinstall the support strut pin (A). When the second person has cleared the area, the operator may now lower the loader arm. 5. Commence work operations or park the machine and stop the engine.
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INTRODUCTION
Basic instructions - Loader arm lock and cab tilt procedure vertical lift machines SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
WARNING Crushing hazard! Do not enter or exit the operator's compartment while the loader arms are raised or unsupported. Rest the loader arms on the ground or verify that loader arm is being supported by the loader arm strut or loader arm lock pin before entering or exiting the operator's compartment. Failure to comply could result in death or serious injury. W1365A
Raise and lock the loader arm for machine service 1. Sit in the operator's seat, fasten the seat belt, pull down the restraint bar down, and start the engine. 2. Press the operate button to enable the hydraulics. 3. Remove the bucket or attachment from the mounting plate. 4. Park the machine on a level surface.
20092924
1
RAPH14SSL0351BA
2
5. Fully raise the loader arm.
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INTRODUCTION
6. Locate the loader arm lock lever on the left-hand side of the operator’s seat. 7. Rotate the lock lever toward the operator’s seat (clockwise) to engage the lock support pin(s). 8. Stop the engine.
RAIL14SSL0429AA
3
93107457
4
931001633
5
9. Pull up on the override control knob (red control knob near the right-hand side of the operator’s seat). The loader will brace against the lock support pin and keep the loader arm in a raised position. NOTE: Only use the override control knob to lower the loader arm in emergency situations when engine power is not available or to lower it onto the lock support pin for servicing the machine.
Tilt and lock the cab forward for machine service 1. Remove the two, rear retaining nuts, located at the rear of the cab.
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INTRODUCTION
2. Pull on the hand holds at the front of the machine until the cab is completely tilted forward.
RAPH11SSL0016BA
6
RAPH12SSL0420BA
7
RAPH12SSL0420BA
8
3. Confirm that the red lock tube has lowered over the cab pivot linkage. If it has the cab tilt position is now secure.
Tilt and secure the cab for machine operation 1. Raise the red lock tube exposing the cab pivot linkage. 2. Push the cab backward into the operation position.
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3. Install the retaining nuts. Torque the nuts to 170 N¡m (125 lb ft).
931001633
9
Unlock and lower the loader arm for machine operation 1. Sit in the operator's seat, fasten the seat belt, pull down the restraint bar down, and start the engine. 2. Press the operate button to enable the hydraulics. 3. Fully raise the loader arm.
RAPH14SSL0351BA
10
RAIL14SSL0429AA
11
4. Rotate the lock lever away from the seat (counter clockwise) to retract the lock pin(s). 5. Lower the loader arm. 6. Commence work operations or park the machine and stop the engine.
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INTRODUCTION
Torque - Standard torque data for hydraulics INSTALLATION OF ADJUSTABLE FITTINGS IN STRAIGHT THREAD O RING BOSSES 1. Lubricate the O-ring by coating it with a light oil or petroleum. Install the O-ring in the groove adjacent to the metal backup washer which is assembled at the extreme end of the groove (4). 2. Install the fitting into the SAE straight thread boss until the metal backup washer contacts the face of the boss (5). NOTE: Do not over tighten and distort the metal backup washer.
23085659
1
3. Position the fitting by turning out (counterclockwise) up to a maximum of one turn. Holding the pad of the fitting with a wrench, tighten the locknut and washer against the face of the boss (6).
STANDARD TORQUE DATA FOR HYDRAULIC TUBES AND FITTINGS TUBE NUTS FOR 37° FLARED FITTINGS
SIZE
TUBING OD
THREAD SIZE
TORQUE
O-RING BOSS PLUGS ADJUSTABLE FITTING LOCKNUTS, SWIVEL JIC- 37° SEATS TORQUE
4 5 6 8 10 12 14 16 20 24 32
6.4 mm (1/4 in) 7.9 mm (5/16 in) 9.5 mm (3/8 in) 12.7 mm (1/2 in) 15.9 mm (5/8 in) 19.1 mm (3/4 in) 22.2 mm (7/8 in) 25.4 mm (1 in) 31.8 mm (1-1/4 in) 38.1 mm (1-1/2 in) 50.8 mm (2 in)
7/16-20 1/2-20 9/16-18 3/4-16 7/8-14 1-1/16-12 1-3/16-12 1-5/16-12 1-5/8-12 1-7/8-12 2-1/2-12
12 – 16 N·m (9 – 12 lb ft) 16 – 20 N·m (12 – 15 lb ft) 29 – 33 N·m (21 – 24 lb ft) 47 – 54 N·m (35 – 40 lb ft) 72 – 79 N·m (53 – 58 lb ft) 104 – 111 N·m (77 – 82 lb ft) 122 – 136 N·m (90 – 100 lb ft) 149 – 163 N·m (110 – 120 lb ft) 190 – 204 N·m (140 – 150 lb ft) 217 – 237 N·m (160 – 175 lb ft) 305 – 325 N·m (225 – 240 lb ft)
8 – 14 N·m (6 – 10 lb ft) 14 – 20 N·m (10 – 15 lb ft) 20 – 27 N·m (15 – 20 lb ft) 34 – 41 N·m (25 – 30 lb ft) 47 – 54 N·m (35 – 40 lb ft) 81 – 95 N·m (60 – 70 lb ft) 95 – 109 N·m (70 – 80 lb ft) 108 – 122 N·m (80 – 90 lb ft) 129 – 158 N·m (95 – 115 lb ft) 163 – 190 N·m (120 – 140 lb ft) 339 – 407 N·m (250 – 300 lb ft)
These torques are not recommended for tubes of 12.7 mm (1/2 in) OD and larger with wall thickness of 0.889 mm (0.035 in) or less. The torque is specified for 0.889 mm (0.035 in) wall tubes on each application individually. Before installing and torquing 37° flared fittings, clean the face of the flare and threads with a clean solvent or Loctite cleaner and apply hydraulic sealant to the 37° flare and the threads. Install fitting and torque to specified torque, loosen fitting and retorque to specifications.
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INTRODUCTION
PIPE THREAD FITTING TORQUE
PIPE THREAD FITTING
Before installing and tightening pipe fittings, clean the threads with a clean solvent or Loctite cleaner and apply sealant for all fittings including stainless steel or for most metal fittings. For high filtration/zero contamination systems use .
Thread Size 1/8-27 1/4-18 3/8-18 1/2-14 3/4-14
Torque (Maximum) 13 N·m (10 lb ft) 16 N·m (12 lb ft) 22 N·m (16 lb ft) 41 N·m (30 lb ft) 54 N·m (40 lb ft)
INSTALLATION OF ORFS (O-RING FLAT FACED) FITTINGS When installing ORFS fittings thoroughly clean both flat surfaces of the fittings (1) and lubricate the O-ring (2) with light oil. Make sure both surfaces are aligned properly. Torque the fitting to specified torque listed throughout the repair manual. NOTICE: If the fitting surfaces are not properly cleaned, the O-ring will not seal properly. If the fitting surfaces are not properly aligned, the fittings may be damaged and will not seal properly. NOTICE: Always use genuine factory replacement oils and filters to ensure proper lubrication and filtration of engine and hydraulic system oils. The use of proper oils, grease, and keeping the hydraulic system clean will extend machine and component life.
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50011183
2
INTRODUCTION
Basic instructions - Shop and assembly Shimming For each adjustment operation, select adjusting shims and measure the adjusting shims individually using a micrometer, 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. Failure to comply could result in death or serious injury. W0111A
Special tools The special tools that CASE CONSTRUCTION suggests and illustrate in this manual have been specifically researched 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 operation. 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
Torque - Minimum tightening torques for normal assembly METRIC NON-FLANGED HARDWARE NOM. SIZE
M4 M5 M6 M8
CLASS 8.8 BOLT and CLASS 8 NUT PLATED UNPLATED W/ZnCr
CLASS 10.9 BOLT and CLASS 10 NUT PLATED UNPLATED W/ZnCr
2.2 N·m (19 lb in) 4.5 N·m (40 lb in) 7.5 N·m (66 lb in) 18 N·m (163 lb in)
3.2 N·m (28 lb in) 6.4 N·m (57 lb in) 11 N·m (96 lb in) 26 N·m (234 lb in)
M10
37 N·m (27 lb ft)
M12
64 N·m (47 lb ft)
M16 M20 M24
158 N·m (116 lb ft) 319 N·m (235 lb ft) 551 N·m (410 lb ft)
2.9 N·m (26 lb in) 5.9 N·m (52 lb in) 10 N·m (89 lb in) 25 N·m (217 lb in) 49 N·m (36 lb ft) 85 N·m (63 lb ft) 210 N·m (155 lb ft) 425 N·m (313 lb ft) 735 N·m (500 lb ft)
52 N·m (38 lb ft) 91 N·m (67 lb ft) 225 N·m (166 lb ft) 440 N·m (325 lb ft) 762 N·m (560 lb ft)
4.2 N·m (37 lb in) 8.5 N·m (75 lb in) 15 N·m (128 lb in) 35 N·m (311 lb in) 70 N·m (51 lb ft) 121 N·m (90 lb ft) 301 N·m (222 lb ft) 587 N·m (433 lb ft) 1016 N·m (750 lb ft)
LOCKNUT CL.8 W/CL8.8 BOLT
2 N·m (18 lb in) 4 N·m (36 lb in) 6.8 N·m (60 lb in) 17 N·m (151 lb in) 33 N·m (25 lb ft) 58 N·m (43 lb ft) 143 N·m (106 lb ft) 290 N·m (214 lb ft) 501 N·m (370 lb ft)
LOCKNUT CL.10 W/CL10.9 BOLT 2.9 N·m (26 lb in) 5.8 N·m (51 lb in) 10 N·m (89 lb in) 24 N·m (212 lb in) 48 N·m (35 lb ft) 83 N·m (61 lb ft) 205 N·m (151 lb ft) 400 N·m (295 lb ft) 693 N·m (510 lb 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. SIZE
CLASS 8.8 BOLT and CLASS 8 NUT PLATED W/ZnCr
UNPLATED M4 M5 M6 M8
2.4 N·m (21 lb in) 4.9 N·m (43 lb in) 8.3 N·m (73 lb in) 20 N·m (179 lb in)
M10
40 N·m (30 lb ft)
M12
70 N·m (52 lb ft)
M16 M20 M24
174 N·m (128 lb ft) 350 N·m (259 lb ft) 607 N·m (447 lb ft)
3.2 N·m (28 lb in) 6.5 N·m (58 lb in) 11 N·m (96 lb in) 27 N·m (240 lb in) 54 N·m (40 lb ft) 93 N·m (69 lb ft) 231 N·m (171 lb ft) 467 N·m (345 lb ft) 809 N·m (597 lb ft)
CLASS 10.9 BOLT and CLASS 10 NUT
UNPLATED 3.5 N·m (31 lb in) 7.0 N·m (62 lb in) 12 N·m (105 lb in) 29 N·m (257 lb in) 57 N·m (42 lb ft) 100 N·m (74 lb ft) 248 N·m (183 lb ft) 484 N·m (357 lb ft) 838 N·m (618 lb ft)
4.6 N·m (41 lb in) 9.4 N·m (83 lb in) 16 N·m (141 lb in) 39 N·m (343 lb in) 77 N·m (56 lb ft) 134 N·m (98 lb ft) 331 N·m (244 lb ft) 645 N·m (476 lb ft) 1118 N·m (824 lb ft)
Metric Hex head and carriage bolts, classes 5.6 and up
1
1. Manufacturer's Identification 2. Property Class
Metric Hex nuts and locknuts, classes 05 and up
20083681
2
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LOCKNUT CL.10 W/CL10.9 BOLT
2.2 N·m (19 lb in) 4.4 N·m (39 lb in) 7.5 N·m (66 lb in) 18 N·m (163 lb in)
3.1 N·m (27 lb in) 6.4 N·m (57 lb in) 11 N·m (96 lb in) 27 N·m (240 lb in)
PLATED W/ZnCr
IDENTIFICATION
20083680
LOCKNUT CL.8 W/CL8.8 BOLT
37 N·m (27 lb ft) 53 N·m (39 lb ft) 63 N·m (47 lb ft) 91 N·m (67 lb ft) 158 N·m (116 lb ft) 318 N·m (235 lb ft) 552 N·m (407 lb ft)
226 N·m (167 lb ft) 440 N·m (325 lb ft)
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 NOMINAL SIZE
SAE GRADE 5 BOLT and NUT UNPLATED or PLATED SILVER
1/4 5/16 3/8 7/16 1/2 9/16 5/8 3/4 7/8 1
SAE GRADE 8 BOLT and NUT
UNPLATED PLATED W/ZnCr or PLATED GOLD SILVER
LOCKNUT GrB W/ Gr5 BOLT
LOCKNUT GrC W/ Gr8 BOLT
PLATED W/ZnCr GOLD
12 N·m 16 N·m 8 N·m (71 lb 11 N·m (97 lb (106 lb in) (142 lb in) in) in) 17 N·m 23 N·m 24 N·m 32 N·m (150 lb in) (204 lb in) (212 lb in) (283 lb in) 40 N·m 43 N·m (31 lb 57 N·m (42 lb 30 N·m (22 lb (30 lb ft) ft) ft) ft) 65 N·m 48 N·m (36 lb 68 N·m (50 lb 91 N·m (67 lb (48 lb ft) ft) ft) ft) 98 N·m 104 N·m 139 N·m 74 N·m (54 lb (73 lb ft) (77 lb ft) (103 lb ft) ft) 107 N·m 142 N·m 150 N·m 201 N·m (79 lb ft) (105 lb ft) (111 lb ft) (148 lb ft) 147 N·m 196 N·m 208 N·m 277 N·m (108 lb ft) (145 lb ft) (153 lb ft) (204 lb ft) 261 N·m 348 N·m 369 N·m 491 N·m (193 lb ft) (257 lb ft) (272 lb ft) (362 lb ft) 420 N·m 561 N·m 594 N·m 791 N·m (310 lb ft) (413 lb ft) (438 lb ft) (584 lb ft) 630 N·m 841 N·m 890 N·m 1187 N·m (465 lb ft) (620 lb ft) (656 lb ft) (875 lb ft)
12.2 N·m (109 lb in) 17.5 N·m (155 lb 25 N·m (220 lb in) in)
8.5 N·m (75 lb in)
31 N·m (23 lb ft) 44 N·m (33 lb ft) 50 N·m (37 lb ft) 71 N·m (53 lb ft) 108 N·m (80 lb ft) 156 N·m (115 lb 111 N·m (82 lb ft) ft) 153 N·m (113 lb 215 N·m (159 lb ft) ft) 271 N·m (200 lb 383 N·m (282 lb ft) ft) 437 N·m (323 lb 617 N·m (455 lb ft) ft) 654 N·m (483 lb 924 N·m (681 lb ft) ft) 76 N·m (56 lb ft)
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 NOMSAE GRADE 5 BOLT and SAE GRADE 8 BOLT and INAL NUT NUT SIZE PLATED UNPLATED PLATED UNPLATED W/ZnCr or PLATED W/ZnCr or PLATED GOLD SILVER GOLD SILVER 1/4 5/16 3/8 7/16 1/2 9/16 5/8 3/4 7/8 1
9 N·m (80 lb in) 19 N·m (168 lb in) 33 N·m (25 lb ft) 53 N·m (39 lb ft) 81 N·m (60 lb ft) 117 N·m (86 lb ft) 162 N·m (119 lb ft) 287 N·m (212 lb ft) 462 N·m (341 lb ft) 693 N·m (512 lb ft)
LOCKNUT GrG W/ Gr8 BOLT
LOCKNUT GrF W/ Gr5 BOLT
12 N·m (106 lb 13 N·m (115 lb 17 N·m (150 lb 8 N·m (71 lb in) in) in) in) 25 N·m (221 lb 26 N·m (230 lb 35 N·m (310 lb 17 N·m (150 lb in) in) in) in) 44 N·m (33 lb 47 N·m (35 lb 63 N·m (46 lb 30 N·m (22 lb ft) ft) ft) ft) 71 N·m (52 lb 75 N·m (55 lb 100 N·m (74 lb 48 N·m (35 lb ft) ft) ft) ft) 153 N·m 108 N·m (80 lb 115 N·m (85 lb 74 N·m (55 lb ft) (113 lb ft) ft) ft) 156 N·m 165 N·m 221 N·m 106 N·m (78 lb ft) (115 lb ft) (122 lb ft) (163 lb ft) 216 N·m 228 N·m 304 N·m 147 N·m (108 lb (159 lb ft) (168 lb ft) (225 lb ft) ft) 383 N·m 405 N·m 541 N·m 261 N·m (193 lb (282 lb ft) (299 lb ft) (399 lb ft) ft) 617 N·m 653 N·m 871 N·m 421 N·m (311 lb (455 lb ft) (482 lb ft) (642 lb ft) ft) 925 N·m 979 N·m 1305 N·m 631 N·m (465 lb (682 lb ft) (722 lb ft) (963 lb ft) ft)
12 N·m (106 lb in) 24 N·m (212 lb in) 43 N·m (32 lb ft) 68 N·m (50 lb ft) 104 N·m (77 lb ft) 157 N·m (116 lb ft) 207 N·m (153 lb ft) 369 N·m (272 lb ft) 594 N·m (438 lb ft) 890 N·m (656 lb ft)
IDENTIFICATION Inch Bolts and free-spinning nuts
20083682
3
Grade Marking Examples 1 2 3
Grade 2 - No Marks Grade 5 - Three Marks Grade 8 - Five Marks
SAE Grade Identification 4 Grade 2 Nut - No Marks 5 Grade 5 Nut - Marks 120° Apart 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 Grade A Grade B Grade C
Corner Marking Method (1) No Notches One Circumferential Notch Two Circumferential Notches
Flats Marking Method (2) No Mark Letter B Letter C
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Clock Marking Method (3) No Marks Three Marks Six Marks
INTRODUCTION
Basic instructions - Video links This service manual contains video links that are viewable through the eTIM service or through the Dealer Portal. Video links are denoted by the YouTube™ instruction or through the Dealer Portal.
icon within the document, and can be viewed in the eTIM service
The Dealer Portal video location is located under the “Service”, “Training”, “Tech Knowledge Program” tabs.
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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: 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 nonapproved fuels may void CASE CONSTRUCTION Warranty coverage. Biodiesel fuel can be used to run diesel engines as pure biodiesel fuel or when blended with standard diesel fuel: • B5: indicates the blend of 5% biodiesel and 95% diesel fuels. • B7: indicates the blend of 7% biodiesel and 93% diesel fuels. • B20: indicates the blend of 20% biodiesel and 80% diesel fuels. • B100: indicates pure biodiesel, or 100% biodiesel fuel. Do not use. Biodiesel fuel has several positive features in comparison with diesel fuel: • Biodiesel fuel adds lubricity to the fuel, which is beneficial in many circumstances, particularly as sulfur and 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 4a diesel fuel specifications are covered by the following: • ASTM D975-10, Standard Specification for Diesel Fuel Oils. (15 ppm sulfur maximum.) Biodiesel blends are covered by: • United States Diesel Fuel Specification ASTM D6751-09A allows up to 5% biodiesel since 2009. United States fuel suppliers are allowed to use up to 5% biodiesel fuel (B5) to supply the network. • United States Biodiesel Fuel Specification ASTM D7467-09A provides specifications for diesel and biodiesel blends from B5 to B20. Pure biodiesel (B100) specification is covered by the following requirements: • ASTM D6751-09A - Standard specification for biodiesel fuel blend stock (B100) for middle distillate fuels. NOTE: ASTM D6751 specification has been updated to improve the quality of biodiesel in the market place. Before raw oil can be converted into usable biodiesel fuel, it must undergo transesterification to remove glycerides. During the transesterification process, the oil reacts with an alcohol to separate the glycerine from the fat or vegetable oil. This process leaves behind two products: methyl ester (the chemical name for biodiesel) and glycerine (a byproduct usually sold for use in soaps or other products). NOTICE: Biodiesel fuels approved for use in the CASE CONSTRUCTION equipment must be transesterified and comply with the North America Standard ASTM D6751. NOTICE: Cold Pressed Biodiesel, Cold Pressed Oil, Straight Vegetable Oil (SVO), or more generally unrefined vegetable oils used as motor fuel, are fuels that are normally made from Rapeseed oil or similar high oil content crops. 48068130 29/01/2018
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INTRODUCTION
These kinds of fuel are not transesterified, so they do not fulfil the ASTM D6751 requirements. There is no recognized quality standard available for these types of fuel. Therefore the use of Cold Pressed Biodiesel, Cold Pressed Oil, Straight Vegetable Oil (SVO), or more generally unrefined vegetable oils used as motor fuel are NOT APPROVED at any blend in any CASE CONSTRUCTION product. NOTICE: Any engine and fuel injection equipment fitted to a CASE CONSTRUCTION vehicle found to have run with any blend of NON-APPROVED fuel (fuel not fulfilling the specification described in the requirement ASTM D6751) will no longer be covered for Warranty by CASE CONSTRUCTION.
Biodiesel fuel usage conditions You must stringently follow the biodiesel fuel usage conditions. Incorrect application of the biodiesel fuel usage conditions 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 conditions for biodiesel fuel handling and maintenance will not be covered for Warranty by CASE CONSTRUCTION. Purchase biodiesel fuel from a trusted supplier who understands the product and maintains acceptable fuel quality. It is highly recommended that you use biodiesel from BQ 9000 accredited suppliers to maintain the quality and consistency of the fuel. The BQ 9000 Quality Management Program is accredited by the National Biodiesel Board for producers and marketers of biodiesel fuel. See the National Biodiesel Board website at www.biodiesel.org for more information. The use of biodiesel blends above B5 through B20 will not void the CASE CONSTRUCTION warranty as long as the following conditions for biodiesel fuel handling and maintenance are stringently followed: Biodiesel fuel must be pre-blended by the supplier. Mixing biodiesel fuels on-site can result in an incorrect mixture that could damage the engine and/or fuel system. 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.
Maintenance intervals For machines using the all electronic engines with a high pressure common rail fuel system, the engine oil and filter change interval is reduced down to 50% of the standard value when using biodiesel blends greater than B5 up to B20. Please refer to the maintenance intervals specified in the Operator Manual for all engines. Check all hoses, connections and gaskets to ensure integrity and cleanliness every 3 months or 150 hours of operation, whichever comes first. Regular oil sampling is highly recommended to monitor for oil and engine deterioration. NOTE: Oil sampling kits are available from your authorized CASE CONSTRUCTION dealer. When switching back from biodiesel to regular #2 diesel, all fuel filter, oil and oil filter should be changed even if this falls between routine service intervals.
Storage The machine should not be stored for more than three months with biodiesel in the fuel system. For longer storage time, it is strongly suggested that only regular #2 diesel fuel is used. NOTE: If storage for longer than 3 months is necessary, the engine must be run on regular #2 diesel for a minimum of 20 h to flush the biodiesel fuel out of the fuel system prior to storage. 48068130 29/01/2018
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INTRODUCTION
Biodiesel is highly hygroscopic and tends to collect water more than diesel fuel. This increases the risk of algae and bacteria growth which can cause severe damage to the fuel injection system. Keep the machine fuel tanks and on-site storage tanks as full as possible to limit the amount of air and water vapors inside the tank. Drain water from the tanks at least once a week. NOTICE: Do not use biocide additives on Tier 4a engines with an exhaust aftertreatment system.
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INTRODUCTION
Fluids and lubricants Fuel tank Capacity SR130, SR160 SR175, SV185, SR210, TR270, TR310 SR240, SV280, TV370 Specifications
60.5 L (16.0 US gal) 75.5 L (20.0 US gal) 95.5 L (25.5 US gal) #1 or #2 Diesel ultra-low sulfur
Cooling system Capacity SR130 SR160, SR175, SV185 SR210, TR270, TR310 SR240, SV280, TV370 Specifications
15.0 L (4.0 US gal) 15.6 L (4.1 US gal) 17.0 L (4.5 US gal) 19.0 L (5.0 US gal) CASE AKCELA ACTIFULL™ OT EXTENDED LIFE COOLANT
Hydraulic system Reservoir capacity System capacity: SR130, SR160 SR175, SV185, SR210, TR270, TR310 SR240, SV280, TV370 Specifications
15.0 L (3.96 US gal) 29.9 L (7.9 US gal) 38.1 L (10.0 US gal) 45.4 L (12.0 US gal) TUTELA AUTO SUPREME™ ENGINE OIL SAE 10W-30
Chain compartments Capacity - each side SR130, SR160 SR175, SV185 SR210 SR240, SV280 Specifications
6.25 L (6.6 US qt) 7.4 L (7.9 US qt) 26.0 L (27.5 US qt) 22.2 L (23.5 US qt) TUTELA AUTO SUPREME™ ENGINE OIL SAE 10W-30
Grease fittings As required TUTELA MOLY GREASE GR-75 (Molydisulfide)
Quantity Specifications
Engine crank case oil Capacity - with filter change SR130, SR160, SR175, SV185 SR210, SR240, SV280, TR270, TR310, TV370 Specifications
7.0 L (7.5 US qt) 8.5 L (9.0 US qt) CASE AKCELA UNITEK NO. 1™ SBL CJ-4
Final track drive Capacity - each side Specifications
1.0 L (1.06 US qt) +/- 0.1 L (0.1 US qt) TUTELA HYPOIDE EP GEAR LUBE SAE 80W-90
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INTRODUCTION
General specification - Recommended engine oil for operating temperature ranges CASE CONSTRUCTION prefers the use of CASE AKCELA UNITEK NO. 1™ SBL CJ-4 engine oil in your engine. This multi-viscosity oil will lubricate your engine correctly under all operating conditions. CASE AKCELA UNITEK NO. 1™ SBL CJ-4 engine oil has a maximum service change interval of 600 h. You may use other engine oils if the engine oils meet API CJ-4 performance requirements. CASE CONSTRUCTION engine oils exceed API CJ-4 performance requirements. See the following chart for recommended viscosity at varying ambient air temperature ranges. NOTE: Do not put performance additives or other oil additive products in the engine crankcase. CASE CONSTRUCTION develops the oil change intervals given in this manual from tests with CASE CONSTRUCTION lubricants. For machines with Tier 4B (final) engines
(H) (H)
0W-40 CJ-4 UNITEK to CNH MAT3521 0W-40 API CJ-4 (H) (H)
10W-40 CJ-4 UNITEK to CNH MAT3521 10W-40 API CJ-4 (H) (H)
-40 °C -40 °F
-30 °C -22 °F
-20 °C -4 °F
-10 °C 14 °F
15W-40 CJ-4 to CNH MAT3522 15W-40* API CJ-4 0 °C 32 °F
10 °C 50 °F
20 °C 68 °F
30 °C 86 °F
40 °C 104 °F
50 °C 122 °F
(H) CASE CONSTRUCTION recommends the use of an engine oil pan heater or coolant block heater in this range.
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INTRODUCTION
General specification - Hydraulic oil for all models
RAPH12SSL0110FA
1
Block
Viscosity
(1)
CASE AKCELA HYDRAULIC -35 – 38 °C (-31 – 100 °F) EXCAVATOR FLUID TUTELA AUTO SUPREME™ ENGINE OIL -15 – 46 °C (5 – 115 °F) SAE 10W-30 CASE AKCELA UNITEK NO. 1™ -30 – 46 °C (-22 – 115 °F) SSL CJ-4 SAE 0W-40
(2) (3)
Temperature range
NOTE: CNHi recommends SAE 10W30 for applications where continuous operations above 38 °C (100 °F) ambient temperature or frequent roading applications (above 20 – 30 min) are common. NOTE: CNHi recommends CASE AKCELA HYDRAULIC EXCAVATOR FLUID for improved cold weather operation. Standard factory fill oil TUTELA AUTO SUPREME™ ENGINE OIL SAE 10W-30 is acceptable for cold weather operation when sufficient warm up time is provided.
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INTRODUCTION
Product identification Product Identification Number (PIN) • Outside right-hand side of chassis - vertical lift.
RCPH11SSL005AAD
1
931002296A
2
931007505A
3
76075756
4
• Inside left-hand side loader arm tower - radial lift.
Roll Over Protective Structure (ROPS) certification plate. • Front edge (lower) inside cab.
Engine serial number plate location for Models SR130 and SR160 • On the fuel injection pump.
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INTRODUCTION
Engine serial number plate location for Models SR175 and SV185 • On the right-hand side of the engine.
RAPH12SSL0406AA
5
23119866
6
BT04F026-01
7
Engine serial number plate location for Models SR210, SR240, SV280, TR270, TR310, and TV370 • On the side of the Exhaust Gas Recirculation (EGR) cooler. • On top of the valve cover. • The serial number is also stamped on the engine front cover.
Bucket identification plate.
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INTRODUCTION
Product identification - Machine orientation
RAPH12SSL0057BA
1
The terms front (1), right (2), rear (3), and left (4) are used in this manual to indicate the direction as seen from the operator's seat.
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SERVICE MANUAL Engine SR210 TIER 4B (FINAL) [NGM418237 - ], SR210 TIER 4B (FINAL) [NHM435463 - ], SR240 TIER 4B (FINAL) [NGM418237 - ], SR240 TIER 4B (FINAL) [NHM435463 - ], SV280 TIER 4B (FINAL) [NGM418237 - ], SV280 TIER 4B (FINAL) [NHM435463 - ], TR270 TIER 4B (FINAL) [NGM418237 - ], TR270 TIER 4B (FINAL) [NHM435463 - ], TR310 TIER 4B (FINAL) [NGM418237 - ], TR310 TIER 4B (FINAL) [NHM435463 - ], TV370 TIER 4B (FINAL) [NHM435463 - ]
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Contents Engine - 10
[10.001] Engine and crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.1 [10.216] Fuel tanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.2 [10.400] Engine cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3 [10.414] Fan and drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.4 [10.304] Engine lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.5
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Engine - 10 Engine and crankcase - 001
SR210 TIER 4B (FINAL) [NGM418237 - ], SR210 TIER 4B (FINAL) [NHM435463 - ], SR240 TIER 4B (FINAL) [NGM418237 - ], SR240 TIER 4B (FINAL) [NHM435463 - ], SV280 TIER 4B (FINAL) [NGM418237 - ], SV280 TIER 4B (FINAL) [NHM435463 - ], TR270 TIER 4B (FINAL) [NGM418237 - ], TR270 TIER 4B (FINAL) [NHM435463 - ], TR310 TIER 4B (FINAL) [NGM418237 - ], TR310 TIER 4B (FINAL) [NHM435463 - ], TV370 TIER 4B (FINAL) [NHM435463 - ]
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Contents Engine - 10 Engine and crankcase - 001
SERVICE Engine Drain fluid - Remote oil drain (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Drain fluid - Quick-disconnect oil drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
(*) See content for specific models 48068130 29/01/2018
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Engine - Drain fluid - Remote oil drain SR210 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NGM418237 - ]
1. Remove the access cover at the rear, lower left of the machine, exposing the engine oil drain hose and remote oil filter. 2. Remove the drain plug to drain the oil. 3. When the oil has completely drained, reinstall the drain plug and torque to 68 – 82 N·m (50 – 61 lb ft).
63109370
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Engine - Engine and crankcase
Engine - Drain fluid - Quick-disconnect oil drain DANGER Heavy objects! Lift and handle all heavy components using lifting equipment with adequate capacity. Always support units or parts with suitable slings or hooks. Make sure the work area is clear of all bystanders. Failure to comply will result in death or serious injury. D0076A
CAUTION Burn hazard! Do not handle any service fluid (engine coolant, engine oil, hydraulic oil, etc.) at temperatures that exceed 49 °C (120 °F). Allow fluids to cool before proceeding. Failure to comply could result in minor or moderate injury. C0107B
CAUTION Chemical hazard! Avoid getting engine oil on your skin. In case of skin contact, wash with running water. Failure to comply could result in minor or moderate injury. C0202B
NOTE: The images may differ slightly based on the machine configuration. The procedure is the same. 1. Remove the cover (1) underneath the machine by removing the hardware (2).
RAPH17SSL0168QA
1
RAPH17SSL0169QA
2
2. Remove the cap (1) (47786509) from the quick disconnect drain fitting (2) (48103849).
3. Place the drain receptacle under the machine.
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4. Thread the quick-disconnect hose assembly (1) (48109944) onto the quick-disconnect drain fitting (2) (48103849). 5. Allow the oil to drain completely from the crankcase. 6. Remove the receptacle, with the used oil, from under the machine.
RAPH17SSL0170QA
3
RAPH17SSL0170QA
4
RAPH17SSL0169QA
5
7. Remove the quick-disconnect hose assembly (1) (48109944) from the quick-disconnect drain fitting (2) (48103849).
8. Install the cap (1) (47786509) onto the quick-disconnect drain fitting (2) (48103849). NOTE: Make sure the o-ring is installed on the drain fitting (2), if it is damaged, then replace with new. NOTE: The cap (1) is only hand tight on the drain fitting (2).
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9. Install the cover (1) underneath the machine and secure with the hardware (2).
RAPH17SSL0168QA
Next operation: See Engine - Filling (10.001) for the proper procedure to refill the engine oil fluid.
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6
Engine - Engine and crankcase
Engine - Remove WARNING Heavy objects! Lift and handle all heavy components using lifting equipment with adequate capacity. Always support units or parts with suitable slings or hooks. Make sure the work area is clear of all bystanders. Failure to comply could result in death or serious injury. W0398A
The following procedure has been performed on a radial lift machine. Engine removal for vertical lift machines is very similar. Prior operation: Tilt the cab. Please see Cab tilting system - Tilt (90.150). Prior operation: Disconnect the battery. See Battery - Disconnect (55.302). Prior operation: Drain the engine oil. Please see Engine - Drain fluid - Remote oil drain (10.001). Prior operation: Drain the coolant. Please see Radiator - Drain fluid (10.400). Prior operation: Discharge the A/C system (if equipped). See Air conditioning - Discharging (50.200). 1. Remove access plate (1) for the engine oil pan from the chassis.
RAPH12SSL0233AA
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1
Engine - Engine and crankcase
2. Disconnect the hose (1) for the oil drain plug from the engine oil pan.
RAPH12SSL0232AA
2
RAIL14SSL0845BA
3
RAPH12SSL0075AA
4
3. Remove the mounting bolts for the overflow bottle. 4. Remove the overflow bottle from the chassis.
5. If equipped with A/C, disconnect the A/C lines (1) from the condenser. 6. Disconnect the fan motor (2) from the wiring harness.
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7. Support the engine hood with a suitable lifting device. 8. Disconnect the engine hood strut (1) from the engine hood.
RAPH12SSL0074AA
5
RAPH12SSL0073AA
6
931001899
7
9. Remove the mounting hardware (2) from the engine hood. 10. Remove the engine hood (1) from the chassis.
11. Remove the engine cover (1) from the chassis.
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12. Remove the air cooler (1) from the shroud.
RAPH12SSL0067AA
8
RAPH12SSL0065AA
9
13. Disconnect the upper radiator hose (1) from the radiator.
14. Disconnect the lower radiator hose (1) from the radiator. NOTE: The rear access door has been removed for picture clarity.
RAPH12SSL0083AA
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10
Engine - Engine and crankcase
15. Remove the radiator (2) from the shroud. 16.
RAPH12SSL0066AA
11
RAPH12SSL0062AA
12
RAPH12SSL0264AA
13
17. Remove the radiator fan (1) from the engine.
18. Unbolt and remove the shroud (1).
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19. Remove the oil cooler (1).
931001884
14
931001896
15
931001895
16
931002030
17
20. Remove the mounting bolts (1) retaining the mounting flange for the muffler inlet pipe to the turbocharger.
21. Remove the retaining bolts (1) from the muffler support. 22. Remove the muffler.
23. Disconnect the air restriction sensor (1) from the wiring harness.
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24. Loosen the hose clamps on the intake tube at both ends. 25. Remove the tube (1) for the air cleaner and turbocharger.
931001898
18
931001900
19
931001908
20
931001909
21
26. Remove the air cleaner housing (1) from the chassis.
27. Disconnect the alternator (1) from the wiring harness.
28. Disconnect the starter (1) from the wiring harness.
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29. Disconnect the ground connection (1) below the starter (2).
931001910
22
RAPH12SSL0266AA
23
RAPH12SSL0053AA
24
30. Remove the oil filler neck (1) from the engine. 31. If equipped with A/C, disconnect the low pressure line (2) on the A/C compressor.
32. Disconnect the fuel return line (1) on the tank.
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33. Disconnect the fuel feed line (1) on the fuel filter housing.
RAPH12SSL0054AA
25
RAPH12SSL0052AA
26
RAPH12SSL0055AA
27
34. Disconnect the engine harness connectors (1).
35. Disconnect the fuel temperature sensor (1) from the wiring harness. 36. Disconnect the fuel feed line (2) from the engine.
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37. Place a suitable container under the remote engine oil filter lines (1). 38. Label and disconnect oil filter lines (1).
931001923
28
931001929
29
931001928
30
931001936
31
39. Place a suitable support beam (1) across the skid steer frame. 40. Tie a suitable strap (2) around the pump (3) and secure to the support beam.
41. Remove the pump mounting bolts (1).
42. Disengage the pump assembly (1) from the engine housing (2).
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43.
DANGER Heavy parts! Support designated component(s) with adequate lifting equipment. Failure to comply will result in death or serious injury. D0018A
Attach proper lifting equipment (1) to support the engine (2).
931001944
32
931001933
33
931001943
34
931002114
35
44. Remove the front and rear engine mounts bolts (1).
45. Remove heater hose clamp (1).
46. Remove upper heater hose (1).
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47. Remove the lower heater hose (1).
48.
931001940
36
931001946
37
WARNING Heavy object! ALWAYS use adequate lifting equipment (heavy-duty hoist, loader, or forklift) to lift the component. Failure to comply could result in death or serious injury. W0101A
Remove engine (1) from the chassis.
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Engine - Install DANGER Heavy objects! Lift and handle all heavy components using lifting equipment with adequate capacity. Always support units or parts with suitable slings or hooks. Make sure the work area is clear of all bystanders. Failure to comply will result in death or serious injury. D0076A
The following procedure has been performed on a radial lift machine. Engine installation for vertical lift machines is very similar. 1. Attach proper lifting equipment to the front and rear of the engine, and carefully lower the engine into the chassis.
931001946
1
931001936
2
931001928
3
2. Orient the hydraulic pump coupler to the adapter on the engine, ensuring the attachment of the engine plate to the flywheel housing.
3. Apply LOCTITE® 243™ to the threads of the mounting bolts (1) for the hydrostatic drive assembly. 4. Install the mounting bolts and washers (1) into pump housing. Torque the mounting bolts (1) for the hydrostatic drive assembly to 87 – 117 N·m (64 – 86 lb ft).
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5. Apply LOCTITE® 243™ to the threads of the rear mounting bolts (3) for the engine. 6. Install the two rear mounting bolts (3) and bushings for the engine. Torque the rear mounting bolt (3) to a torque of 163 – 176 N·m (120 – 130 lb ft).
931002047
4
931001933
5
931001929
6
931001940
7
7. Apply LOCTITE® 243™ to the threads of the front mounting bolts (2) for the engine. 8. Install the two front mounting bolts (2) and bushings for the engine. Torque the front mounting bolts (2) to 163 – 176 N·m (120 – 130 lb ft).
9. Verify that the mounting bolts for the pump are secure, and carefully remove support brace (4) and straps (5) from pump.
10. Connect the lower heater hose (6) to the engine.
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11. Connect the upper heater hose (7) to the engine.
931002114
8
931001923
9
12. Connect the two remote lines (12), (13) for the oil filter.
13. Connect the fuel temperature sensor (1) to the wiring harness. 14. Connect the fuel feed line (2) to the engine.
RAPH12SSL0055AA
10
RAPH12SSL0052AA
11
15. Connect the engine harness connectors (1) to the engine.
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16. Connect the fuel feed line (1) to the fuel filter housing.
RAPH12SSL0054AA
12
RAPH12SSL0053AA
13
RAPH12SSL0266AA
14
17. Connect the fuel return line (1) to the tank.
18. Install the oil filler neck (1) onto the engine. 19. If equipped with A/C, connect the low pressure line (2) onto the A/C compressor.
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20. Connect the ground connection (1) to the mounting location located below the starter (2).
931001910
15
931001909
16
931001908
17
931001900
18
21. Connect the starter (1) to the wiring harness.
22. Connect the alternator (1) to the wiring harness.
23. Install the air cleaner housing (1) onto the chassis. Torque the bolts to 27 – 31 N·m (20 – 23 lb ft).
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Engine - Engine and crankcase
24. Install the intake tube (1) for the air cleaner and turbocharger. Torque the clamp to 3 – 4 N·m (27 – 35 lb in).
931001898
19
931002030
20
931001895
21
931001896
22
25. Connect the air restriction sensor (1) to the wiring harness.
26. Install the muffler and retaining bolts (1). Torque the mounting bolts to 27 – 31 N·m (20 – 23 lb ft).
27. Install the mounting bolts (1) retaining the mounting flange to the muffler inlet pipe and to the turbocharger. Torque the mounting bolts to 27 – 31 N·m (20 – 23 lb ft).
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Engine - Engine and crankcase
28. Install the oil cooler (1).
931001884
23
RAPH12SSL0264AA
24
RAPH12SSL0062AA
25
29. Install the shroud (1).
30. Apply LOCTITE® 243™ to the threads of the bolts , and install the fan (1).
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Engine - Engine and crankcase
31. Readjust the shroud if there is not 13 mm (1/2 in) of clearance (A) between the fan blades and the shroud.
RAPH14SSL0776BA
26
RAPH12SSL0066AA
27
RAPH12SSL0067AA
28
32. Install the radiator (1) into the shroud. Torque the bolts to 27 – 37 N·m (20 – 27 lb ft). 33. Attach the clamps to the radiator. Torque the hose clamps to 3 – 4 N·m (27 – 35 lb in).
34. Install the air cooler (1) into the shroud. Torque the bolts to 27 – 37 N·m (20 – 27 lb ft).
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Engine - Engine and crankcase
35. Install the engine cover (1) onto the chassis.
931001899
29
RAPH12SSL0073AA
30
RAPH12SSL0074AA
31
36. Install the engine hood (1) onto the chassis.
37. Connect the engine hood strut (1) to the engine hood.
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Engine - Engine and crankcase
38. If equipped with A/C, connect the A/C lines (1) to the condenser. 39. Connect the fan motor (2) to the wiring harness.
RAPH12SSL0075AA
32
RAIL14SSL0845BA
33
RAPH12SSL0232AA
34
40. Install the overflow bottle onto the chassis.
41. Connect the hose (1) for the oil drain plug to the engine oil pan.
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Engine - Engine and crankcase
42. Install access plate (1) for the engine oil pan to the chassis, and torque to 42 – 58 N·m (31 – 43 lb ft).
RAPH12SSL0233AA
Next operation: Add fluids. Please see Capacities () . Next operation: Charge the A/C system (if equipped). Please see Air conditioning - Charging (50.200).
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35
Engine - Engine and crankcase
Engine - Filling 1. Remove the engine oil dipstick (1) to provide crankcase ventilation. NOTICE: Slowly fill to avoid flooding valve cover with oil. 2. Use an oil spout that is smaller than the engine oil fill neck (2), allowing air to pass around the oil fill neck. NOTE: Keep the oil fill spout in the upper half of the oil fill neck. 3. Slowly add the correct type and quantity of oil. Please see Capacities () for specifications. 4. Start the engine and run at low idle.
RAIL13SSL0608AA
5. Check the engine oil filter and drain plug for leaks. After 2 min, stop the engine, wait for 2 – 3 min and check the engine oil level.
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1
Index Engine - 10 Engine and crankcase - 001 Engine - Drain fluid - Quick-disconnect oil drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4
Engine - Drain fluid - Remote oil drain (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3
Engine - Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
30
Engine - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
19
Engine - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7
(*) See content for specific models 48068130 29/01/2018
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Engine - 10 Fuel tanks - 216
SR210 TIER 4B (FINAL) [NGM418237 - ], SR210 TIER 4B (FINAL) [NHM435463 - ], SR240 TIER 4B (FINAL) [NGM418237 - ], SR240 TIER 4B (FINAL) [NHM435463 - ], SV280 TIER 4B (FINAL) [NGM418237 - ], SV280 TIER 4B (FINAL) [NHM435463 - ], TR270 TIER 4B (FINAL) [NGM418237 - ], TR270 TIER 4B (FINAL) [NHM435463 - ], TR310 TIER 4B (FINAL) [NGM418237 - ], TR310 TIER 4B (FINAL) [NHM435463 - ], TV370 TIER 4B (FINAL) [NHM435463 - ]
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Contents Engine - 10 Fuel tanks - 216
SERVICE Fuel tank Drain fluid (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
(*) See content for specific models 48068130 29/01/2018
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Engine - Fuel tanks
Fuel tank - Drain fluid SR240 SV280 TR310 TV370 TIER 4B (FINAL) [NHM435463 - ]
1. Remove the access plate (1) for the engine oil pan.
RAPH12SSL0233AA
1
RAPH12SSL0344AA
2
2. Locate the petcock. NOTE: Engine has been removed for picture clarity. 3. Loosen the petcock, and drain the fluid into a suitable container. 4. When the tank is empty, tighten the petcock.
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Engine - Fuel tanks
5. Center and attach the access plate (1) for the engine oil pan. Torque the bolts (2) to 42 – 58 N·m (31 – 43 lb ft).
RAPH12SSL0233AA
Next operation: Clean the inside area the frame to remove any spilled fuel.
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3
Engine - Fuel tanks
Fuel tank - Remove SR240 SV280 TR310 TV370 TIER 4B (FINAL) [NHM435463 - ]
WARNING Fire hazard! When handling diesel fuel, observe the following precautions: 1. Do not smoke. 2. Never fill the tank when the engine is running. 3. Wipe up spilled fuel immediately. Failure to comply could result in death or serious injury. W0099A
Prior operation: Remove the engine. See Engine - Remove (10.001) Prior operation: Remove the oil cooler. See Oil cooler/Heat exchanger - Remove (35.300) 1. Drain the tank.
RAPH12SSL0344AA
1
RAPH12SSL0042AA
2
2. Disconnect the fuel level sensor (1). 3. Disconnect the fuel outlet line (2).
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Engine - Fuel tanks
4. Remove the right-hand side fuel tank bracket (1).
931002100B
3
RAIL15SSL0013BA
4
931002102B
5
5. Remove the left-hand side fuel tank bracket (1).
6. Carefully remove the fuel tank.
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Engine - Fuel tanks
Fuel tank - Install SR240 SV280 TR310 TV370 TIER 4B (FINAL) [NHM435463 - ]
WARNING Fire hazard! When handling diesel fuel, observe the following precautions: 1. Do not smoke. 2. Never fill the tank when the engine is running. 3. Wipe up spilled fuel immediately. Failure to comply could result in death or serious injury. W0099A
1. Carefully install the fuel tank.
931002102B
1
RAIL15SSL0013BA
2
2. Install the left-hand side fuel tank bracket (1).
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Engine - Fuel tanks
3. Install the right-hand side fuel tank bracket (1).
931002100B
3
RAPH12SSL0042AA
4
4. Connect the fuel level sensor (1). 5. Connect the fuel outlet line (2).
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Index Engine - 10 Fuel tanks - 216 Fuel tank - Drain fluid (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3
Fuel tank - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7
Fuel tank - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5
(*) See content for specific models 48068130 29/01/2018
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Engine - 10 Engine cooling system - 400
SR210 TIER 4B (FINAL) [NGM418237 - ], SR210 TIER 4B (FINAL) [NHM435463 - ], SR240 TIER 4B (FINAL) [NGM418237 - ], SR240 TIER 4B (FINAL) [NHM435463 - ], SV280 TIER 4B (FINAL) [NGM418237 - ], SV280 TIER 4B (FINAL) [NHM435463 - ], TR270 TIER 4B (FINAL) [NGM418237 - ], TR270 TIER 4B (FINAL) [NHM435463 - ], TR310 TIER 4B (FINAL) [NGM418237 - ], TR310 TIER 4B (FINAL) [NHM435463 - ], TV370 TIER 4B (FINAL) [NHM435463 - ]
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Contents Engine - 10 Engine cooling system - 400
SERVICE Radiator Drain fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
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Engine - Engine cooling system
Radiator - Drain fluid 1. Remove the radiator cap (1).
RAIL13SSL0142AA
1
RAPH12SSL0083AA
2
2. Drain the engine coolant system by loosening the drain valve (1), and drain the coolant into a suitable container. When the radiator is empty, tighten the drain valve NOTE: Rear access door removed for picture clarity.
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Engine - Engine cooling system
Radiator - Remove WARNING Burn hazard! Be very careful to avoid contact with hot fluids. If fluid is extremely hot, allow it to cool to a moderately warm temperature before proceeding. Failure to comply could result in death or serious injury. W0362A
Prior operation: Drain the coolant system. See Radiator - Drain fluid (10.400) Prior operation: Remove the air cooler. 1. Disconnect the upper radiator hose (1).
RAPH12SSL0065AA
1
RAPH12SSL0083AA
2
2. Disconnect the lower radiator hose (1). NOTE: Rear access door removed for picture clarity.
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Engine - Engine cooling system
3. Remove the 45° overflow hose elbow (1). NOTE: Engine hood removed for picture clarity. 4. Remove the radiator hold-down bolts (3), and remove the radiator (2).
RAPH12SSL0066AA
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3
Engine - Engine cooling system
Radiator - Install 1. Place the radiator (2) above the hydraulic oil cooler. Install the radiator hold-down bolts (3). Tighten the bolts to a torque of 27 – 37 N·m (20 – 27 lb ft). NOTE: Engine hood and rear access door removed for picture clarity. 2. Apply LOCTITE® 567™ PST PIPE SEALANT to the treads of the 45° overflow hose elbow (1) and install the elbow into the side of the radiator. Tighten the 45° overflow hose elbow (1) two to three turns past finger tight. NOTE: 45° overflow hose elbow (1) is to be positioned with the spout facing downward.
RAPH12SSL0066AA
1
RAPH12SSL0083AA
2
RAPH12SSL0065AA
3
3. Connect the lower radiator hose (1). Tighten the clamp to a torque of 3 – 4 N·m (27 – 35 lb in).
4. Connect the upper radiator hose (1). Tighten the clamp to a torque of 3 – 4 N·m (27 – 35 lb in).
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Engine - Engine cooling system
Radiator - Filling 1. Tighten the drain valve (1). NOTE: Rear access door removed for picture clarity.
RAPH12SSL0083AA
1
RAIL13SSL0142AA
2
RAPH12SSL0414BA
3
2. Remove the radiator cap (1), and add a coolant solution of 50% CASE AKCELA ACTIFULL™ OT EXTENDED LIFE COOLANT and 50% distilled water. 3. Install the radiator cap (1).
4. Start and run the engine until it reaches operating temperature. 5. Stop the engine and check the level of the coolant in the reservoir bottle. The coolant level must be at the cold minimum or hot maximum mark which is stamped on the reservoir bottle. 6. If the coolant level falls below the cold minimum mark, add the proper coolant solution of 50% CASE AKCELA ACTIFULL™ OT EXTENDED LIFE COOLANT and 50% distilled water.
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Index Engine - 10 Engine cooling system - 400 Radiator - Drain fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3
Radiator - Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7
Radiator - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6
Radiator - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4
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Engine - 10 Fan and drive - 414
SR210 TIER 4B (FINAL) [NGM418237 - ], SR210 TIER 4B (FINAL) [NHM435463 - ], SR240 TIER 4B (FINAL) [NGM418237 - ], SR240 TIER 4B (FINAL) [NHM435463 - ], SV280 TIER 4B (FINAL) [NGM418237 - ], SV280 TIER 4B (FINAL) [NHM435463 - ], TR270 TIER 4B (FINAL) [NGM418237 - ], TR270 TIER 4B (FINAL) [NHM435463 - ], TR310 TIER 4B (FINAL) [NGM418237 - ], TR310 TIER 4B (FINAL) [NHM435463 - ], TV370 TIER 4B (FINAL) [NHM435463 - ]
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Contents Engine - 10 Fan and drive - 414
SERVICE Fan Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Belt Tension adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
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Engine - Fan and drive
Fan - Remove 1. Remove the mounting bolts for the overflow bottle. 2. Remove the overflow bottle.
RAIL14SSL0845BA
1
RAIL14SSL0798BA
2
3. Remove the air cooler (1) by removing the bolts.
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Engine - Fan and drive
NOTE: The fan can be removed through the top opening without the radiator removal. The removal of the radiator, steps 4 and 5, is optional. 4. Disconnect the hoses from the radiator (1) by loosening the clamps. 5. Remove the radiator (2) from the shroud by removing the bolts.
RAIL14SSL0797BA
3
RAPH12SSL0062AA
4
6. Remove the fan from the engine by removing the bolts (1). NOTE: Figure 4 is with the radiator removed.
Next operation: Fan - Install (10.414)
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Engine - Fan and drive
Fan - Install Prior operation: Fan - Remove (10.414) 1. Apply LOCTITE® 243™ to the threads of the bolts (2), and install the fan (1).
RAPH12SSL0062AA
1
RAPH14SSL0776BA
2
2. Readjust the shroud if there is not 13 mm (1/2 in) of clearance (A) between the fan blades and the shroud.
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Engine - Fan and drive
NOTE: If the radiator was removed, complete steps 3- 5. If the radiator was not removed, continue to step 6. 3. Place the radiator (3) inside the shroud, but do not install the hardware. 4. Attach the hoses (1) to the radiator. Torque the hose clamps (2) to 3 – 4 N·m (27 – 35 lb in).
RAIL14SSL0797BA
3
RAIL14SSL0797BA
4
RAIL14SSL0798BA
5
5. Install the bolts (1) for the radiator. Torque the bolts (1) to 27 – 37 N·m (20 – 27 lb ft).
6. Install the air cooler (1). Torque the bolts (2) to 27 – 37 N·m (20 – 27 lb ft).
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Engine - Fan and drive
7. Install the overflow container. 8. Attach the overflow hose (1) to the filler neck.
RAIL14SSL0845BA
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6
Engine - Fan and drive
Belt - Tension adjust NOTE: The serpentine belt does not have a tensioning procedure. Adjust the adjusting bolt to the stop on the bracket. 1. Loosen the upper and lower mounting bolts (1) on the alternator. 2. Loosen the adjusting bracket bolt (2). 3. Loosen the jam nut on the adjusting bolt, and turn the adjusting bolt (3) until bracket (4) is adjusted to the stop (as shown). 4. Torque the adjusting bracket bolt (2) to 50 N¡m (37 lb ft). 5. Torque the jam nut for the adjusting bolt to 30 N¡m (22 lb ft). 6. Torque the mounting bolts (1) to 50 N¡m (37 lb ft).
RCPH11SSL038AAP
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1
Index Engine - 10 Fan and drive - 414 Belt - Tension adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8
Fan - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5
Fan - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3
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Engine - 10 Engine lubrication system - 304
SR210 TIER 4B (FINAL) [NGM418237 - ], SR210 TIER 4B (FINAL) [NHM435463 - ], SR240 TIER 4B (FINAL) [NGM418237 - ], SR240 TIER 4B (FINAL) [NHM435463 - ], SV280 TIER 4B (FINAL) [NGM418237 - ], SV280 TIER 4B (FINAL) [NHM435463 - ], TR270 TIER 4B (FINAL) [NGM418237 - ], TR270 TIER 4B (FINAL) [NHM435463 - ], TR310 TIER 4B (FINAL) [NGM418237 - ], TR310 TIER 4B (FINAL) [NHM435463 - ], TV370 TIER 4B (FINAL) [NHM435463 - ]
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Contents Engine - 10 Engine lubrication system - 304
TECHNICAL DATA Engine lubrication system Technical Data - Recommended engine oil for operating temperature ranges . . . . . . . . . . . . . . . . . . . . . . . 3
SERVICE Engine oil filter Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
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Engine - Engine lubrication system
Engine lubrication system - Technical Data - Recommended engine oil for operating temperature ranges CASE CONSTRUCTION prefers the use of CASE AKCELA UNITEK NO. 1™ SBL CJ-4 engine oil in your engine. This multi-viscosity oil will lubricate your engine correctly under all operating conditions. CASE AKCELA UNITEK NO. 1™ SBL CJ-4 engine oil has a maximum service change interval of 500 h. You may use other engine oils if the engine oils meet API CJ-4 performance requirements. The maximum service change interval for these engine oils is 250 h. CASE CONSTRUCTION engine oils exceed API CJ-4 performance requirements. See the following chart for recommended viscosity at varying ambient air temperature ranges. NOTE: Do not put performance additives or other oil additive products in the engine crankcase. CASE CONSTRUCTION develops the oil change intervals given in this manual from tests with CASE CONSTRUCTION lubricants. For machines with Tier 4B (final) engines
(H) (H)
0W-40 CJ-4 UNITEK to CNH MAT3521 0W-40 API CJ-4* (H) (H)
10W-40 CJ-4 UNITEK to CNH MAT3521 10W-40 API CJ-4* (H) (H)
-40 °C -40 °F
-30 °C -22 °F
-20 °C -4 °F
-10 °C 14 °F
15W-40 CJ-4 to CNH MAT3522** 15W-40* API CJ-4* 0 °C 32 °F
10 °C 50 °F
20 °C 68 °F
30 °C 86 °F
40 °C 104 °F
50 °C 122 °F
(H) CASE CONSTRUCTION recommends the use of an engine oil pan heater or coolant block heater in this range. * Maximum engine oil service change interval is 250 h **Maximum engine oil service change interval is 400 h
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Engine - Engine lubrication system
Engine oil filter - Replace 1. Remove the battery cover hardware (1) and the battery cover (2).
931001637
1
RAIL15SSL0051AA
2
2. Turn the engine oil filter (1) counterclockwise to remove. 3. Turn the new oil filter (1) clockwise onto the base until the gasket makes contact with the base. Continue to tighten the filter one full turn or apply a torque of 35 N¡m (26 lb ft) to the engine oil filter. NOTICE: Do not use a filter strap wrench to install the oil filter.
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Index Engine - 10 Engine lubrication system - 304 Engine lubrication system - Technical Data - Recommended engine oil for operating temperature ranges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3
Engine oil filter - Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4
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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. Š 2018 CNH Industrial America LLC. All rights reserved. No part of the text or illustrations of this publication may be reproduced.
CNH Industrial America LLC reserves the right to make improvements in design and changes in specifications at any time without notice and without incurring any obligation to install them on units previously sold. Specifications, descriptions, and illustrative material herein are as accurate as known at the time of publication, but are subject to change without notice. Availability of some models and equipment builds varies according to the country in which the equipment is being used. For exact information about any particular product, please consult your CASE CONSTRUCTION dealer. CASE CONSTRUCTION is a trademark registered in the United States and many other countries, owned or licensed to CNH Industrial N.V., its subsidiaries or affiliates. Any trademarks referred to herein, in association with goods and/or services of companies, other than owned by or licensed to CNH Industrial N.V., its subsidiaries or affiliates, are the property of those respective companies.
48068130 29/01/2018 EN
SERVICE MANUAL Power coupling SR210 TIER 4B (FINAL) [NGM418237 - ], SR210 TIER 4B (FINAL) [NHM435463 - ], SR240 TIER 4B (FINAL) [NGM418237 - ], SR240 TIER 4B (FINAL) [NHM435463 - ], SV280 TIER 4B (FINAL) [NGM418237 - ], SV280 TIER 4B (FINAL) [NHM435463 - ], TR270 TIER 4B (FINAL) [NGM418237 - ], TR270 TIER 4B (FINAL) [NHM435463 - ], TR310 TIER 4B (FINAL) [NGM418237 - ], TR310 TIER 4B (FINAL) [NHM435463 - ], TV370 TIER 4B (FINAL) [NHM435463 - ]
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Contents Power coupling - 19
[19.121] Pump-drive assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.1
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Power coupling - 19 Pump-drive assembly - 121
SR210 TIER 4B (FINAL) [NGM418237 - ], SR210 TIER 4B (FINAL) [NHM435463 - ], SR240 TIER 4B (FINAL) [NGM418237 - ], SR240 TIER 4B (FINAL) [NHM435463 - ], SV280 TIER 4B (FINAL) [NGM418237 - ], SV280 TIER 4B (FINAL) [NHM435463 - ], TR270 TIER 4B (FINAL) [NGM418237 - ], TR270 TIER 4B (FINAL) [NHM435463 - ], TR310 TIER 4B (FINAL) [NGM418237 - ], TR310 TIER 4B (FINAL) [NHM435463 - ], TV370 TIER 4B (FINAL) [NHM435463 - ]
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Contents Power coupling - 19 Pump-drive assembly - 121
TECHNICAL DATA Pump-drive coupling Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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Power coupling - Pump-drive assembly
Pump-drive coupling - Torque Component Flange bolt (1)
Toque 30 – 33 N·m (266 – 292 lb in)
identification
RAPH14SSL0302BA
1
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Consumable LOCTITE® 243™
Index Power coupling - 19 Pump-drive assembly - 121 Pump-drive coupling - Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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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. Š 2018 CNH Industrial America LLC. All rights reserved. No part of the text or illustrations of this publication may be reproduced.
CNH Industrial America LLC reserves the right to make improvements in design and changes in specifications at any time without notice and without incurring any obligation to install them on units previously sold. Specifications, descriptions, and illustrative material herein are as accurate as known at the time of publication, but are subject to change without notice. Availability of some models and equipment builds varies according to the country in which the equipment is being used. For exact information about any particular product, please consult your CASE CONSTRUCTION dealer. CASE CONSTRUCTION is a trademark registered in the United States and many other countries, owned or licensed to CNH Industrial N.V., its subsidiaries or affiliates. Any trademarks referred to herein, in association with goods and/or services of companies, other than owned by or licensed to CNH Industrial N.V., its subsidiaries or affiliates, are the property of those respective companies.
48068130 29/01/2018 EN
SERVICE MANUAL Front axle system SR210 TIER 4B (FINAL) [NGM418237 - ], SR210 TIER 4B (FINAL) [NHM435463 - ], SR240 TIER 4B (FINAL) [NGM418237 - ], SR240 TIER 4B (FINAL) [NHM435463 - ], SV280 TIER 4B (FINAL) [NGM418237 - ], SV280 TIER 4B (FINAL) [NHM435463 - ], TR270 TIER 4B (FINAL) [NGM418237 - ], TR270 TIER 4B (FINAL) [NHM435463 - ], TR310 TIER 4B (FINAL) [NGM418237 - ], TR310 TIER 4B (FINAL) [NHM435463 - ], TV370 TIER 4B (FINAL) [NHM435463 - ]
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Contents Front axle system - 25
[25.450] Chain drive system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.1
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25
Front axle system - 25 Chain drive system - 450
SR210 TIER 4B (FINAL) [NGM418237 - ], SR210 TIER 4B (FINAL) [NHM435463 - ], SR240 TIER 4B (FINAL) [NGM418237 - ], SR240 TIER 4B (FINAL) [NHM435463 - ], SV280 TIER 4B (FINAL) [NGM418237 - ], SV280 TIER 4B (FINAL) [NHM435463 - ], TR270 TIER 4B (FINAL) [NGM418237 - ], TR270 TIER 4B (FINAL) [NHM435463 - ], TR310 TIER 4B (FINAL) [NGM418237 - ], TR310 TIER 4B (FINAL) [NHM435463 - ], TV370 TIER 4B (FINAL) [NHM435463 - ]
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Contents Front axle system - 25 Chain drive system - 450
SERVICE Chain drive system Change fluid (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Axle Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Chain drive Check (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Measure (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
(*) See content for specific models 48068130 29/01/2018
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Front axle system - Chain drive system
Chain drive system - Change fluid SR210 SR240 SV280
1. Park the machine on a level surface. 2. Remove the fill plug (1),
RAIL13SSL0560AA
1
RAIL13SSL0382BA
2
RAIL13SSL0560AA
3
3. Remove the drain plug, and drain the fluid into a suitable container. 4. When the tank is empty, apply LOCTITE® 545™ to the threads of the drain plug, then install the drain plug.
5. Fill the chain tank by pouring oil into the fill plug hole. Please see Capacities () for specifications and capacities. 6. Apply LOCTITE® 545™ to the threads of the fill plug (1), then install the fill plug (1).
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Front axle system - Chain drive system
Axle - Remove SR210 SR240 SV280
WARNING Jack stands can slip or fall over. Dropping, tipping, or slipping of machine or its components is possible. DO NOT work under a vehicle supported by jack stands only. Park machine on a level surface. Block wheels. Support machine with safety stands. Failure to comply could result in death or serious injury. W0069A
NOTE: The following procedure has been performed on the right, front axle. All axles are similar. 1. Drain the chain tank.
RAIL13SSL0382BA
1
RAIL13SSL0383BA
2
2. Lift the of the machine off of the ground, and support the machine with adequate equipment. 3. Remove the tire.
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Front axle system - Chain drive system
4. Support the axle with suitable lifting device. Remove the nuts (1).
RAIL13SSL0562BA
3
RAIL13SSL0384BA
4
5. Disconnect the axle from the sprocket.
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Front axle system - Chain drive system
Axle - Disassemble SR210 SR240 SV280
1. Remove the snap ring.
RAIL13SSL0388BA
1
RAIL13SSL0387BA
2
RAIL13SSL0386BA
3
2. Remove the shim.
3. Remove the spacer.
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Front axle system - Chain drive system
4. Press the axle shaft out of the axle housing.
RAIL13SSL0389BA
4
RAIL13SSL0391BA
5
RAIL13SSL0392BA
6
5. Remove the inner bearing.
6. Remove the outer bearing.
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Front axle system - Chain drive system
7. Remove the seal.
RAIL13SSL0393BA
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7
Front axle system - Chain drive system
Axle - Assemble SR210 SR240 SV280
CAUTION Burn hazard! Always wear heat-resistant protective gloves when handling heated parts. Failure to comply could result in minor or moderate injury. C0047A
Prior operation: Properly grease all bearings with CASE AKCELA 251H EP MULTI-PURPOSE GREASE 1. Before assembling, inspect the disc (1) and bearing cups (2) for damage. Replace if necessary.
RAIL14SSL0738BA
1
RAIL13SSL0396BA
2
2. Heat the outer bearing to 60 °C (140 °F).
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Front axle system - Chain drive system
3.
CAUTION Hot area! Use care when working near hot components. Wear protective gloves. Failure to comply could result in minor or moderate injury. C0034A
Carefully place the outer bearing in the bearing cup.
RAIL13SSL0394BA
3
RAIL13SSL0395BA
4
RAIL13SSL0397BA
5
4. Install the seal.
5. Slowly drop the axle shaft into the axle housing. NOTE: The axle will easily slide through the bearing if the bearing has been heated to 60 °C (140 °F).
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Front axle system - Chain drive system
6. Press the inner bearing onto the shaft and into the housing. NOTE: The maximum pressure allowed on the bearing is 40000 N (9000 lb). 7. Do not release the pressure from the press. 8. Rotate the axle assembly three times. The axle should easily rotate with a maximum pressure of 40000 N (9000 lb) applied to the bearings. If the axle does not rotate easily, please repeat the disassembly and assembly procedure on this axle. 9. Remove the axle assembly from the press.
RAIL13SSL0385BA
6
RAPH14SSL0732BA
7
RAPH14SSL0733BA
8
10. Temporarily install the snap ring.
11. Measure the distance (A) between the inner face of the snap ring and the top of the bearing cone. 12. Using your measurement from step 11, select the correctly sized shim and spacer by using the table below.
Sizing table
Gap (mm) 6.84 - 6.93 6.94 - 7.03 7.04 - 7.13 7.14 - 7.23
Spacer size * #1 #2 5.3 Lg 5.8 Lg 1 1 1 1
#3 6.3 Lg
#4 6.8 Lg
Shim size ** A B 1.6 T 1.7 T 1
C 1.8 T
D 1.9 T
E 2.0 T
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Front axle system - Chain drive system
7.24 - 7.33 7.34 - 7.43 7.44 - 7.53 7.54 - 7.63 7.64 - 7.73 7.74 - 7.83 7.84 - 7.93 7.94 - 8.03 8.04 - 8.13 8.14 - 8.23 8.24 - 8.33 8.34 - 8.43 8.44 - 8.53 8.54 - 8.63
1 1 1 1 1
1 1 1 1 1 1 1 1 1 1
1 1 1 1 1 1 1 1 1
1 1 1 1 * Spacer length has a tolerance of +/- 0.02mm ** Shim length has a tolerance of +0.00mm / -0.04mm
13. Remove the snap ring.
RAPH14SSL0732BA
9
14. Install the new spacer.
RAIL13SSL0386BA
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10
Front axle system - Chain drive system
15. Install the new shim.
RAIL13SSL0387BA
11
RAIL13SSL0388BA
12
RAPH14SSL0734BA
13
16. Install the snap ring.
17. Verity that end play (A) does not exist between the spacer, shim, and snap ring. 18. If you do not find end play, please proceed to step 19. If you find end play between the spacer, shim, and snap ring, please repeat steps 11 – 17.
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Front axle system - Chain drive system
19. Measure the rolling torque of the axle by using the rolling torque tool, part number 380003339. The specification for the rolling torque is 10 – 16 N·m (7 – 12 lb ft) 14 – 26 N·m (10 – 19 lb ft). 20. If the rolling torque of the axle is not within specification, please repeat the disassembly and assembly procedure for this axle.
RAPH14SSL0735BA
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14
Front axle system - Chain drive system
Axle - Install SR210 SR240 SV280
WARNING Jack stands can slip or fall over. Dropping, tipping, or slipping of machine or its components is possible. DO NOT work under a vehicle supported by jack stands only. Park machine on a level surface. Block wheels. Support machine with safety stands. Failure to comply could result in death or serious injury. W0069A
NOTE: The following procedure has been performed on the right, front axle. All axles are similar. 1. Insert the axle shaft into the sprocket, and position the axle assembly on the mounting bolts.
RAIL13SSL0384BA
1
RAIL13SSL0562BA
2
2. Install the nuts (1), but do not tighten.
3. Remove the lifting equipment.
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Front axle system - Chain drive system
4. The drive chain will need adjustment. Either remove the chain tank cover and proceed to step 5 or see Chain drive - Check (25.450) for alternative adjustment procedures.
RAIL13SSL0561BA
3
96091469
4
RAPH13SSL0563BA
5
5. Adjust the axle so the chain has 10 – 15.0 mm (13/32 – 19/32 in) of slack at the center (1) of the chain.
6. Apply a bead of LOCTITE® RTV SILICONE CLEAR to the bolt holes and to the chain tank opening. 7. Install the chain tank cover (1).
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Front axle system - Chain drive system
8. After adjusting the chain play, torque the nuts (1) to 224 – 264 N·m (165 – 195 lb ft).
RAIL13SSL0562BA
6
RAIL13SSL0383BA
7
RAIL13SSL0560AA
8
9. Install the tire. For flange nuts, torque the nuts (1) to 203.5 N·m (150 lb ft) For tapered nuts, torque the nuts (1) to 169.5 N·m (125 lb ft).
10. Fill the chain tank by remove the fill plug (1). 11. Apply LOCTITE® 545™ to the threads of the fill plug (1) before reinstalling the fill plug (1).
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Front axle system - Chain drive system
Chain drive - Check SR210 SR240 SV280
WARNING Jack stands can slip or fall over. Dropping, tipping, or slipping of machine or its components is possible. DO NOT work under a vehicle supported by jack stands only. Park machine on a level surface. Block wheels. Support machine with safety stands. Failure to comply could result in death or serious injury. W0069A
Check the tension of the four drive chains after the first 250 hours of operation on a new machine or if new chains have been installed and every 500 hours of operation. 1. With the machine blocked up, rotate each tire and check for allowable movement. 0.5 – 1.5° or 6 – 12 mm (15/64 – 15/32 in) of movement is the acceptable range.
63107489
1
931002280
2
93109317
3
Drive chain adjustment 2. To adjust the final drive chains, jack up and block the complete skid steer securely off the ground.
3. Each axle drive chain is adjustable by loosening the retaining nuts (1) (left front shown) and sliding the axlehub assembly to remove the excessive slack. To tighten the chains slide the front axle-hubs forward and rear axle-hubs rearward. Torque the axle retaining hardware to 224 – 264 N·m (165 – 195 lb ft).
4. Repeat step 1.
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Front axle system - Chain drive system
Chain drive - Measure SR210 SR240 SV280
1. The individual joints in a roller chain articulate as they enter and leave the sprockets. This articulation results in wear on the pins and bushings. Material that is worn away from these surfaces will cause the chain to gradually elongate. Chains do not stretch. Material is worn from pin and bushing. Critical dimensions of the chain are as follows: 1.
2X pitch
2.
Wear plus 2X pitch
3.
Elongation due to pin and bushing wear
96091478
1
96091469
2
Elongation is normal and may be minimized by proper lubrication and drive maintenance. The rate of wear is dependent upon: the relationship between the load and the amount of bearing area between pin and bushing, the material and surface condition of the bearing surfaces, the adequacy of lubrication, and the frequency and degree of articulation between pins and bushings. The latter is determined by the quantity of sprockets in the drive, their speeds, the number of teeth and the length of the chain in pitches. An accurate wear measurement (1) can be made by using the above illustration. Measure as closely as possible from the center of one pin to the center of another. The more pitches (pins) contained within the measurement increase the accuracy. If the measured value exceeds the nominal by more than the allowable percentage the chain should be replaced. The maximum allowable wear elongation is approximately 3% for most industrial applications, based upon sprocket design. The allowable chain wear in percent can be calculated using the relationship: 200/ (N), where (N) is the number of teeth in the large sprocket. This relationship is often useful since the normal maximum allowable chain wear elongation of 3% is valid only up to 67 teeth in the large sprocket. In drives having fixed center distances, chains running in parallel or where smoother operation is required, wear should be limited to approximately 1.5%. For example, if 12 pitches (12 pins) of a #80 chain were measured and the result was 313.944 mm (12.360 in) or greater (using 3% as the maximum allowable wear), the chain should be replaced. Anything less than 313.944 mm (12.360 in) would still be acceptable by most industrial standards. 48068130 29/01/2018
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Index Front axle system - 25 Chain drive system - 450 Axle - Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9
Axle - Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6
Axle - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15
Axle - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4
Chain drive - Check (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
18
Chain drive - Measure (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
19
Chain drive system - Change fluid (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3
(*) See content for specific models 48068130 29/01/2018
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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. Š 2018 CNH Industrial America LLC. All rights reserved. No part of the text or illustrations of this publication may be reproduced.
CNH Industrial America LLC reserves the right to make improvements in design and changes in specifications at any time without notice and without incurring any obligation to install them on units previously sold. Specifications, descriptions, and illustrative material herein are as accurate as known at the time of publication, but are subject to change without notice. Availability of some models and equipment builds varies according to the country in which the equipment is being used. For exact information about any particular product, please consult your CASE CONSTRUCTION dealer. CASE CONSTRUCTION is a trademark registered in the United States and many other countries, owned or licensed to CNH Industrial N.V., its subsidiaries or affiliates. Any trademarks referred to herein, in association with goods and/or services of companies, other than owned by or licensed to CNH Industrial N.V., its subsidiaries or affiliates, are the property of those respective companies.
48068130 29/01/2018 EN
SERVICE MANUAL Rear axle system SR210 TIER 4B (FINAL) [NGM418237 - ], SR210 TIER 4B (FINAL) [NHM435463 - ], SR240 TIER 4B (FINAL) [NGM418237 - ], SR240 TIER 4B (FINAL) [NHM435463 - ], SV280 TIER 4B (FINAL) [NGM418237 - ], SV280 TIER 4B (FINAL) [NHM435463 - ], TR270 TIER 4B (FINAL) [NGM418237 - ], TR270 TIER 4B (FINAL) [NHM435463 - ], TR310 TIER 4B (FINAL) [NGM418237 - ], TR310 TIER 4B (FINAL) [NHM435463 - ], TV370 TIER 4B (FINAL) [NHM435463 - ]
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Contents Rear axle system - 27
[27.650] Chain drive system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27.1
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27
Rear axle system - 27 Chain drive system - 650
SR210 TIER 4B (FINAL) [NGM418237 - ], SR210 TIER 4B (FINAL) [NHM435463 - ], SR240 TIER 4B (FINAL) [NGM418237 - ], SR240 TIER 4B (FINAL) [NHM435463 - ], SV280 TIER 4B (FINAL) [NGM418237 - ], SV280 TIER 4B (FINAL) [NHM435463 - ], TR270 TIER 4B (FINAL) [NGM418237 - ], TR270 TIER 4B (FINAL) [NHM435463 - ], TR310 TIER 4B (FINAL) [NGM418237 - ], TR310 TIER 4B (FINAL) [NHM435463 - ], TV370 TIER 4B (FINAL) [NHM435463 - ]
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Contents Rear axle system - 27 Chain drive system - 650
SERVICE Chain drive system Change fluid (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Axle Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Chain drive Check (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Measure (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
(*) See content for specific models 48068130 29/01/2018
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Rear axle system - Chain drive system
Chain drive system - Change fluid SR210 SR240 SV280
1. Park the machine on a level surface. 2. Remove the fill plug (1),
RAIL13SSL0560AA
1
RAIL13SSL0382BA
2
RAIL13SSL0560AA
3
3. Remove the drain plug, and drain the fluid into a suitable container. 4. When the tank is empty, apply LOCTITE® 545™ to the threads of the drain plug, then install the drain plug.
5. Fill the chain tank by pouring oil into the fill plug hole. Please see Capacities () for specifications and capacities. 6. Apply LOCTITE® 545™ to the threads of the fill plug (1), then install the fill plug (1).
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Rear axle system - Chain drive system
Axle - Remove SR210 SR240 SV280
WARNING Jack stands can slip or fall over. Dropping, tipping, or slipping of machine or its components is possible. DO NOT work under a vehicle supported by jack stands only. Park machine on a level surface. Block wheels. Support machine with safety stands. Failure to comply could result in death or serious injury. W0069A
NOTE: The following procedure has been performed on the right, front axle. All axles are similar. 1. Drain the chain tank.
RAIL13SSL0382BA
1
RAIL13SSL0383BA
2
2. Lift the of the machine off of the ground, and support the machine with adequate equipment. 3. Remove the tire.
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Rear axle system - Chain drive system
4. Support the axle with suitable lifting device. Remove the nuts (1).
RAIL13SSL0562BA
3
RAIL13SSL0384BA
4
5. Disconnect the axle from the sprocket.
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Rear axle system - Chain drive system
Axle - Disassemble SR210 SR240 SV280
1. Remove the snap ring.
RAIL13SSL0388BA
1
RAIL13SSL0387BA
2
RAIL13SSL0386BA
3
2. Remove the shim.
3. Remove the spacer.
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Rear axle system - Chain drive system
4. Press the axle shaft out of the axle housing.
RAIL13SSL0389BA
4
RAIL13SSL0391BA
5
RAIL13SSL0392BA
6
5. Remove the inner bearing.
6. Remove the outer bearing.
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7. Remove the seal.
RAIL13SSL0393BA
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7
Rear axle system - Chain drive system
Axle - Assemble SR210 SR240 SV280
CAUTION Burn hazard! Always wear heat-resistant protective gloves when handling heated parts. Failure to comply could result in minor or moderate injury. C0047A
Prior operation: Properly grease all bearings with CASE AKCELA 251H EP MULTI-PURPOSE GREASE 1. Before assembling, inspect the disc (1) and bearing cups (2) for damage. Replace if necessary.
RAIL14SSL0738BA
1
RAIL13SSL0396BA
2
2. Heat the outer bearing to 60 °C (140 °F).
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Rear axle system - Chain drive system
3.
CAUTION Hot area! Use care when working near hot components. Wear protective gloves. Failure to comply could result in minor or moderate injury. C0034A
Carefully place the outer bearing in the bearing cup.
RAIL13SSL0394BA
3
RAIL13SSL0395BA
4
RAIL13SSL0397BA
5
4. Install the seal.
5. Slowly drop the axle shaft into the axle housing. NOTE: The axle will easily slide through the bearing if the bearing has been heated to 60 °C (140 °F).
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Rear axle system - Chain drive system
6. Press the inner bearing onto the shaft and into the housing. NOTE: The maximum pressure allowed on the bearing is 40000 N (9000 lb). 7. Do not release the pressure from the press. 8. Rotate the axle assembly three times. The axle should easily rotate with a maximum pressure of 40000 N (9000 lb) applied to the bearings. If the axle does not rotate easily, please repeat the disassembly and assembly procedure on this axle. 9. Remove the axle assembly from the press.
RAIL13SSL0385BA
6
RAPH14SSL0732BA
7
RAPH14SSL0733BA
8
10. Temporarily install the snap ring.
11. Measure the distance (A) between the inner face of the snap ring and the top of the bearing cone. 12. Using your measurement from step 11, select the correctly sized shim and spacer by using the table below.
Sizing table
Gap (mm) 6.84 - 6.93 6.94 - 7.03 7.04 - 7.13 7.14 - 7.23
Spacer size * #1 #2 5.3 Lg 5.8 Lg 1 1 1 1
#3 6.3 Lg
#4 6.8 Lg
Shim size ** A B 1.6 T 1.7 T 1
C 1.8 T
D 1.9 T
E 2.0 T
1 1 1 48068130 29/01/2018
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Rear axle system - Chain drive system
7.24 - 7.33 7.34 - 7.43 7.44 - 7.53 7.54 - 7.63 7.64 - 7.73 7.74 - 7.83 7.84 - 7.93 7.94 - 8.03 8.04 - 8.13 8.14 - 8.23 8.24 - 8.33 8.34 - 8.43 8.44 - 8.53 8.54 - 8.63
1 1 1 1 1
1 1 1 1 1 1 1 1 1 1
1 1 1 1 1 1 1 1 1
1 1 1 1 * Spacer length has a tolerance of +/- 0.02mm ** Shim length has a tolerance of +0.00mm / -0.04mm
13. Remove the snap ring.
RAPH14SSL0732BA
9
14. Install the new spacer.
RAIL13SSL0386BA
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10
Rear axle system - Chain drive system
15. Install the new shim.
RAIL13SSL0387BA
11
RAIL13SSL0388BA
12
RAPH14SSL0734BA
13
16. Install the snap ring.
17. Verity that end play (A) does not exist between the spacer, shim, and snap ring. 18. If you do not find end play, please proceed to step 19. If you find end play between the spacer, shim, and snap ring, please repeat steps 11 – 17.
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Rear axle system - Chain drive system
19. Measure the rolling torque of the axle by using the rolling torque tool, part number 380003339. The specification for the rolling torque is 10 – 16 N·m (7 – 12 lb ft) 14 – 26 N·m (10 – 19 lb ft). 20. If the rolling torque of the axle is not within specification, please repeat the disassembly and assembly procedure for this axle.
RAPH14SSL0735BA
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14
Rear axle system - Chain drive system
Axle - Install SR210 SR240 SV280
WARNING Jack stands can slip or fall over. Dropping, tipping, or slipping of machine or its components is possible. DO NOT work under a vehicle supported by jack stands only. Park machine on a level surface. Block wheels. Support machine with safety stands. Failure to comply could result in death or serious injury. W0069A
NOTE: The following procedure has been performed on the right, front axle. All axles are similar. 1. Insert the axle shaft into the sprocket, and position the axle assembly on the mounting bolts.
RAIL13SSL0384BA
1
RAIL13SSL0562BA
2
2. Install the nuts (1), but do not tighten.
3. Remove the lifting equipment.
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Rear axle system - Chain drive system
4. The drive chain will need adjustment. Either remove the chain tank cover and proceed to step 5 or see Chain drive - Check (25.450) for alternative adjustment procedures.
RAIL13SSL0561BA
3
96091469
4
RAPH13SSL0563BA
5
5. Adjust the axle so the chain has 10 – 15.0 mm (13/32 – 19/32 in) of slack at the center (1) of the chain.
6. Apply a bead of LOCTITE® RTV SILICONE CLEAR to the bolt holes and to the chain tank opening. 7. Install the chain tank cover (1).
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Rear axle system - Chain drive system
8. After adjusting the chain play, torque the nuts (1) to 224 – 264 N·m (165 – 195 lb ft).
RAIL13SSL0562BA
6
RAIL13SSL0383BA
7
RAIL13SSL0560AA
8
9. Install the tire. For flange nuts, torque the nuts (1) to 203.5 N·m (150 lb ft) For tapered nuts, torque the nuts (1) to 169.5 N·m (125 lb ft).
10. Fill the chain tank by remove the fill plug (1). 11. Apply LOCTITE® 545™ to the threads of the fill plug (1) before reinstalling the fill plug (1).
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Rear axle system - Chain drive system
Chain drive - Check SR210 SR240 SV280
WARNING Jack stands can slip or fall over. Dropping, tipping, or slipping of machine or its components is possible. DO NOT work under a vehicle supported by jack stands only. Park machine on a level surface. Block wheels. Support machine with safety stands. Failure to comply could result in death or serious injury. W0069A
Check the tension of the four drive chains after the first 250 hours of operation on a new machine or if new chains have been installed and every 500 hours of operation. 1. With the machine blocked up, rotate each tire and check for allowable movement. 0.5 – 1.5° or 6 – 12 mm (15/64 – 15/32 in) of movement is the acceptable range.
63107489
1
931002280
2
93109317
3
Drive chain adjustment 2. To adjust the final drive chains, jack up and block the complete skid steer securely off the ground.
3. Each axle drive chain is adjustable by loosening the retaining nuts (1) (left front shown) and sliding the axlehub assembly to remove the excessive slack. To tighten the chains slide the front axle-hubs forward and rear axle-hubs rearward. Torque the axle retaining hardware to 224 – 264 N·m (165 – 195 lb ft).
4. Repeat step 1.
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Rear axle system - Chain drive system
Chain drive - Measure SR210 SR240 SV280
1. The individual joints in a roller chain articulate as they enter and leave the sprockets. This articulation results in wear on the pins and bushings. Material that is worn away from these surfaces will cause the chain to gradually elongate. Chains do not stretch. Material is worn from pin and bushing. Critical dimensions of the chain are as follows: 1.
2X pitch
2.
Wear plus 2X pitch
3.
Elongation due to pin and bushing wear
96091478
1
96091469
2
Elongation is normal and may be minimized by proper lubrication and drive maintenance. The rate of wear is dependent upon: the relationship between the load and the amount of bearing area between pin and bushing, the material and surface condition of the bearing surfaces, the adequacy of lubrication, and the frequency and degree of articulation between pins and bushings. The latter is determined by the quantity of sprockets in the drive, their speeds, the number of teeth and the length of the chain in pitches. An accurate wear measurement (1) can be made by using the above illustration. Measure as closely as possible from the center of one pin to the center of another. The more pitches (pins) contained within the measurement increase the accuracy. If the measured value exceeds the nominal by more than the allowable percentage the chain should be replaced. The maximum allowable wear elongation is approximately 3% for most industrial applications, based upon sprocket design. The allowable chain wear in percent can be calculated using the relationship: 200/ (N), where (N) is the number of teeth in the large sprocket. This relationship is often useful since the normal maximum allowable chain wear elongation of 3% is valid only up to 67 teeth in the large sprocket. In drives having fixed center distances, chains running in parallel or where smoother operation is required, wear should be limited to approximately 1.5%. For example, if 12 pitches (12 pins) of a #80 chain were measured and the result was 313.944 mm (12.360 in) or greater (using 3% as the maximum allowable wear), the chain should be replaced. Anything less than 313.944 mm (12.360 in) would still be acceptable by most industrial standards. 48068130 29/01/2018
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Index Rear axle system - 27 Chain drive system - 650 Axle - Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9
Axle - Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6
Axle - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15
Axle - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4
Chain drive - Check (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
18
Chain drive - Measure (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
19
Chain drive system - Change fluid (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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. Š 2018 CNH Industrial America LLC. All rights reserved. No part of the text or illustrations of this publication may be reproduced.
CNH Industrial America LLC reserves the right to make improvements in design and changes in specifications at any time without notice and without incurring any obligation to install them on units previously sold. Specifications, descriptions, and illustrative material herein are as accurate as known at the time of publication, but are subject to change without notice. Availability of some models and equipment builds varies according to the country in which the equipment is being used. For exact information about any particular product, please consult your CASE CONSTRUCTION dealer. CASE CONSTRUCTION is a trademark registered in the United States and many other countries, owned or licensed to CNH Industrial N.V., its subsidiaries or affiliates. Any trademarks referred to herein, in association with goods and/or services of companies, other than owned by or licensed to CNH Industrial N.V., its subsidiaries or affiliates, are the property of those respective companies.
48068130 29/01/2018 EN
SERVICE MANUAL Hydrostatic drive SR210 TIER 4B (FINAL) [NGM418237 - ], SR210 TIER 4B (FINAL) [NHM435463 - ], SR240 TIER 4B (FINAL) [NGM418237 - ], SR240 TIER 4B (FINAL) [NHM435463 - ], SV280 TIER 4B (FINAL) [NGM418237 - ], SV280 TIER 4B (FINAL) [NHM435463 - ], TR270 TIER 4B (FINAL) [NGM418237 - ], TR270 TIER 4B (FINAL) [NHM435463 - ], TR310 TIER 4B (FINAL) [NGM418237 - ], TR310 TIER 4B (FINAL) [NHM435463 - ], TV370 TIER 4B (FINAL) [NHM435463 - ]
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Contents Hydrostatic drive - 29
[29.200] Mechanical control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29.1 [29.218] Pump and motor components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29.2 [29.202] Hydrostatic transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29.3
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Hydrostatic drive - 29 Mechanical control - 200
SR210 TIER 4B (FINAL) [NGM418237 - ], SR210 TIER 4B (FINAL) [NHM435463 - ], SR240 TIER 4B (FINAL) [NGM418237 - ], SR240 TIER 4B (FINAL) [NHM435463 - ], SV280 TIER 4B (FINAL) [NGM418237 - ], SV280 TIER 4B (FINAL) [NHM435463 - ], TR270 TIER 4B (FINAL) [NGM418237 - ], TR270 TIER 4B (FINAL) [NHM435463 - ], TR310 TIER 4B (FINAL) [NGM418237 - ], TR310 TIER 4B (FINAL) [NHM435463 - ], TV370 TIER 4B (FINAL) [NHM435463 - ]
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Contents Hydrostatic drive - 29 Mechanical control - 200
SERVICE Mechanical control Adjust - Machines with only hand controls (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Adjust - Machines with foot controls (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
(*) See content for specific models 48068130 29/01/2018
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Hydrostatic drive - Mechanical control
Mechanical control - Adjust - Machines with only hand controls SR210 SR240 SV280 TR270 TR310 TV370 TIER 4B (FINAL) [NHM435463 - ]
(Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls)
NOTE: Inspect the linkage and linkage components for wear and damage before performing the following steps. Replace all worn and/or damaged parts. 1. Loosen the bolts (1) that attach the self centering dampeners. 2. Loosen the jam nuts (3), (4). 3. Rotate the rod (2) until the handles are in the correct position of 75° (see image 2). 4. Tighten the jam nuts (2), (3). 5. Tighten the bolts (1) that attach the self centering dampeners. 6. Repeat steps 1 – 5 on the other pump.
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23112921
1
23112922
2
Hydrostatic drive - Mechanical control
Adjust the stop bolts NOTE: The following images may or may not represent your exact machine configuration. This procedure is the same for all mechanically operated machines in any configuration. 7. Turn the stop bolt (1) out several turns. 8. Push the handle (2) forward until the pump is fully stroked. Hold the handle in this position and turn stop bolt in until it touches the casting. 9. Repeat steps 7 and 8 on the other side. 10. Start the machine, and test drive. Record the drift. NOTE: The machine should not steer in either direction more than 1.8 m (6 ft) from the centerline after traveling 30.5 m (100 ft) forward or 15.2 m (50 ft) backward. 11. If the machine does steer beyond the specifications in step 10, please repeat steps 7 – 10.
23112915
3
23112916
4
NOTE: The stop bolt should touch the casting when the pump is at full stroke.
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Hydrostatic drive - Mechanical control
Mechanical control - Adjust - Machines with foot controls SR210 SR240 SV280 TR270 TR310 TV370 TIER 4B (FINAL) [NHM435463 - ]
(Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls)
NOTE: Inspect the linkage and linkage components for wear and damage before performing the following steps. Replace all worn and/or damaged parts. 1. Remove the tag along the springs (1) (both sides).
23112920
1
23112919A
2
23112922
3
2. Loosen the jam nuts (2), (3). Rotate the control rods (6) until the handles are in the correct position of 75° (see image 3), then tighten the jam nuts (2), (3).
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Hydrostatic drive - Mechanical control
3. Loosen the roller (4) and position the roller (4) in the center of the cam (5). Tighten the roller (4). 4. Reinstall the tag along springs that was removed in step 1. 5. Repeat steps 2, 3 for the other pump.
23112920
4
RAPH12UTL0663AA
5
RAIL14SSL0856AA
6
6. Loosen the nuts (1) on the rods for the foot controls. 7. Turn the couplings (2) until you have reached a pedal angle of 17° (R). Please see image 6 for details. 8. Tighten the nuts (1).
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Hydrostatic drive - Mechanical control
Adjust the stop bolts NOTE: The following images may or may not represent your exact machine configuration. This procedure is the same for all mechanically operated machines in any configuration. 9. Turn the stop bolt (1) out several turns. 10. Push the handle (2) forward until the pump is fully stroked. Hold the handle in this position and turn stop bolt in until it touches the casting. 11. Repeat steps 9 and 10 on the other side. 12. Start the machine, and test drive. Record the drift. NOTE: The machine should not steer in either direction more than 1.8 m (6 ft) from the centerline after traveling 30.5 m (100 ft) forward or 15.2 m (50 ft) backward. 13. If the machine does steer beyond the specifications in step 12, please repeat steps 9 – 12.
23112915
7
23112916
8
NOTE: The stop bolt should touch the casting when the pump is at full stroke.
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Index Hydrostatic drive - 29 Mechanical control - 200 Mechanical control - Adjust - Machines with foot controls (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5
Mechanical control - Adjust - Machines with only hand controls (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3
(*) See content for specific models 48068130 29/01/2018
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Hydrostatic drive - 29 Pump and motor components - 218
SR210 TIER 4B (FINAL) [NGM418237 - ], SR210 TIER 4B (FINAL) [NHM435463 - ], SR240 TIER 4B (FINAL) [NGM418237 - ], SR240 TIER 4B (FINAL) [NHM435463 - ], SV280 TIER 4B (FINAL) [NGM418237 - ], SV280 TIER 4B (FINAL) [NHM435463 - ], TR270 TIER 4B (FINAL) [NGM418237 - ], TR270 TIER 4B (FINAL) [NHM435463 - ], TR310 TIER 4B (FINAL) [NGM418237 - ], TR310 TIER 4B (FINAL) [NHM435463 - ], TV370 TIER 4B (FINAL) [NHM435463 - ]
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Contents Hydrostatic drive - 29 Pump and motor components - 218
TECHNICAL DATA Pump General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Charge pressure relief valve - Torque (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Torque (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Charge pressure relief valve - Torque (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Pressure limiter valve - Torque (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Motor valves General specification - Mechanical drive - Two speed (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 General specification - Electro-Hydraulic (EH) drive - Two speed (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 General specification - Mechanical drive - Two speed (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 General specification - Electro-Hydraulic (EH) drive - Two speed (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 General specification - Mechanical drive - Single speed (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Motor General specification - Single speed motor (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 General specification - Two-speed motor (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
FUNCTIONAL DATA Pump Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Motor valves Component localization (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Control valve - Component localization (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Motor Dynamic description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Dynamic description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
SERVICE Pump Charge pressure relief valve - Pressure test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
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Pressure limiter valve - Pressure test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Test (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Measure - Piston travel (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Motor valves Remove - Brake, Electro-Hydraulic (EH) option, 2-speed option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 Install - Brake, Electro-Hydraulic (EH) option, 2-speed option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Motor Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 Disassemble - Single speed drive motor (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 Assemble - Single speed drive motor (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87 Disassemble - Two speed drive motor (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96 Assemble - Two speed drive motor (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104 Drain fluid (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112 Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113 Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114 Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128 Filling (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142 Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143 Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
Servo control Adjust (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149 Adjust (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
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Hydrostatic drive - Pump and motor components
Pump - General specification SR210 SR240 SV280 TR270 TR310 TV370 TIER 4B (FINAL) [NHM435463 - ]
(Mechanical (Mechanical (Mechanical (Mechanical (Mechanical
RAPH12SSL0359GA
hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls)
1
Hydrostatic pump Manufacturer Pump displacement Charge pump displacement Charge pump flow at 1800 RPM Charge pressure relief valve (3) Pressure limiter valve
Sauer-Danfoss 46 cm³ (2.8 in³) 22.9 cm³ (1.4 in³) 30 l (8 US gal) 24 – 25 bar (350 – 370 psi) at 1800 RPM Left-hand, forward, drive circuit (1). 360 – 378 bar (5220 – 5481 psi) Rright-hand, reverse, drive circuit (2). 360 – 378 bar (5220 – 5481 psi) Right-hand, forward, drive circuit (4). 360 – 378 bar (5220 – 5481 psi) Left-hand, reverse, drive circuit (5). 360 – 378 bar (5220 – 5481 psi)
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Hydrostatic drive - Pump and motor components
A - Reverse port B - Forward port T - Case drain X1 - Control Pressure, before the orifice X2 - Control Pressure, before the orifice R - Air bleed Ma - Operating pressure A Mb - Operating pressure B G - Pressure for auxiliary circuit G2 - Pressure for auxiliary circuit S - Boost suction Mg - Operating pressure G Yst - Control pressure
Port identification
Pump Charge pressure relief valve - Torque SR210 SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
Component Charge pressure relief valve (1)
(Mechanical hydraulic controls) (Mechanical hydraulic controls) (Mechanical hydraulic controls) (Mechanical hydraulic controls) (Mechanical hydraulic controls)
Torque Consumable 109 N·m (80 lb None ft)
Identification
23111054
1
Pump - Torque SR210 SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Mechanical hydraulic controls) (Mechanical hydraulic controls) (Mechanical hydraulic controls) (Mechanical hydraulic controls) (Mechanical hydraulic controls)
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Hydrostatic drive - Pump and motor components
Torque Consumable 176 N·m (130 lb None ft)
Component Identification Pressure limiter valve (1)
RAPH12SSL0359GA
1
Pump - General specification SR210 SR240 SV280 TR270 TR310 TV370 TIER 4B (FINAL) [NHM435463 - ]
(Electro (Electro (Electro (Electro (Electro
RAPH13SSL0964FA
hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls)
1
Hydrostatic pump Manufacturer Pump displacement Charge pump displacement Charge pump flow Charge pressure relief valve (5)
Bosch Rexroth 35 cm³ (2.1 in³) 14.9 cm³ (0.9 in³) 40 l (10.5 US gal) 24 – 26 bar (347 – 377 psi)
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Pressure limiter valve identification
Right-hand, forward, drive circuit (1). 350 – 370 bar (5075 – 5365 psi) Left-hand, forward, drive circuit (2). 350 – 370 bar (5075 – 5365 psi) Left-hand, reverse, drive circuit (3). 350 – 370 bar (5075 – 5365 psi) Right- hand, reverse, drive circuit (4). 350 – 370 bar (5075 – 5365 psi) A - Reverse port B - Forward port T - Case drain port X1 - Control Pressure, before the orifice X2 - Control Pressure, before the orifice R - Air bleed Ma - Operating pressure for port A Mb - Operating pressure for port B G - Pressure for auxiliary circuit G2 - Pressure for auxiliary circuit S - Boost suction Mg - Operating pressure for port G Yst - Control pressure
Port identification
Pump Charge pressure relief valve - Torque SR210 SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
Component Charge pressure relief valve (1)
(Electro hydraulic controls) (Electro hydraulic controls) (Electro hydraulic controls) (Electro hydraulic controls) (Electro hydraulic controls)
Torque 69 N·m (51 lb ft)
Identification
RAPH13SSL0964FA
1
Pump Pressure limiter valve - Torque SR210 SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TR310 TIER 4B (FINAL) [NGM418237 - ]
(Electro hydraulic controls) (Electro hydraulic controls) (Electro hydraulic controls) (Electro hydraulic controls) (Electro hydraulic controls)
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Consumable None
Hydrostatic drive - Pump and motor components
TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
Torque Consumable 249 N·m (184 lb None ft)
Component Identification Pressure limiter valve (1)
RAPH13SSL0964FA
1
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Hydrostatic drive - Pump and motor components
Motor valves - General specification - Mechanical drive - Two speed SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ]
(Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical
RAPH13SSL0967EA
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls)
1
Brake, two speed valve Hydraulic requirements: Sequence valve setting Filter rating Port identification
Charge pressure = 24 – 25.5 bar (350 – 370 psi) Brake release pressure = 15 bar (218 psi) 12 bar (174 psi) 40 – 50 microns P - Supply inlet T - Tank return 2SPD - Two speed shift B1 - Brake motor 1 B2 - Brake motor 2 PS2 - Brake pressure switch
Motor valves - General specification - Electro-Hydraulic (EH) drive Two speed SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ]
(Electro (Electro (Electro (Electro (Electro (Electro
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
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controls) controls) controls) controls) controls) controls)
Hydrostatic drive - Pump and motor components
RAPH14SSL0006FA
1
Loader pilot interlock, brake, two speed valve Hydraulic requirements Sequence valve setting Filter rating Port identification
Charge pressure = 24 – 25.5 bar (350 – 370 psi) Brake release pressure = 15 bar (218 psi) 12 bar (174 psi) 40 – 50 microns P - Supply inlet T - Tank return 2SPD - Two speed shift B1 - Brake motor 1 B2 - Brake motor 2 LV - Electrohydraulic pilot pressure PS2 - Brake pressure switch
Motor valves - General specification - Mechanical drive - Two speed TR270 TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Mechanical (Mechanical (Mechanical (Mechanical
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hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls)
Hydrostatic drive - Pump and motor components
RAPH14SSL0011FA
1
Brake, two speed valve Hydraulic requirements: Port identification
Charge pressure = 24 – 25.5 bar (350 – 370 psi) Brake release pressure = 15 bar (218 psi) P - Supply inlet T - Tank return 2SPD - Two speed shift B1 - Brake motor 1 B2 - Brake motor 2
Motor valves - General specification - Electro-Hydraulic (EH) drive Two speed TR270 TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Electro (Electro (Electro (Electro
hydraulic hydraulic hydraulic hydraulic
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controls) controls) controls) controls)
Hydrostatic drive - Pump and motor components
RAPH12SSL0381EA
1
Loader pilot interlock, brake, two speed valve Hydraulic requirements Port identification
Charge pressure = 24 – 25.5 bar (350 – 370 psi) Brake release pressure = 15 bar (218 psi) P - Supply inlet T - Tank return 2SPD - Two speed shift B1 - Brake motor 1 B2 - Brake motor 2 LV - Electro-hydraulic pilot pressure PS2 - Brake pressure switch
Motor valves - General specification - Mechanical drive - Single speed SR210 SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ]
(Mechanical (Mechanical (Mechanical (Mechanical (Mechanical
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hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls)
Hydrostatic drive - Pump and motor components
RAPH16SSL0257FA
1
Brake, single speed valve Hydraulic requirements: Port identification
Charge pressure = 24 – 25.5 bar (350 – 370 psi) Brake release pressure = 15 bar (218 psi) P - Supply inlet T - Tank return B1 - Brake motor 1 B2 - Brake motor 2
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Hydrostatic drive - Pump and motor components
Motor - General specification - Single speed motor SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ]
RAPH14SSL0040FA
1
Motor
RAPH17SSL0410BA
2
Motor Ports Bosch-Rexroth
Manufacturer Displacement Brake release pressure Flushing valve setting Port identification
470 cm³ (29 in³) 11 – 15 bar (160 – 218 psi) 19.0 – 21.0 bar (276 – 305 psi) A - Main port B - Main port L - Case drain Z - Brake release
Motor - General specification TR270 TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
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Hydrostatic drive - Pump and motor components
RAPH14SSL0033EA
1
Motor
RAIL17CTL0004FA
2
Motor Ports Manufacturer Displacement Brake release pressure Fluid specification for the planetary gear case Port identification
Bonfiglioli 33.1 – 50.8 cm³ (2.0 – 3.1 in³) 13 bar (189 psi) 1.3 L (1.4 US qt) of TUTELA HYPOIDE EP GEAR LUBE SAE 80W-90 oil 1 – Oil filling and draining plug 2 – Oil level plug P1 – Service P2 – Service Ps – Two-speed control Pp – Mechanical brake pilot Dr – Drain
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Hydrostatic drive - Pump and motor components
Motor - General specification - Two-speed motor SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ]
RAPH14SSL0042FA
1
Motor
RAPH17SSL0411BA
2
Motor Ports Manufacturer Displacement
Bosch-Rexroth
Brake release pressure
11 – 15 bar (160 – 218 psi)
Flushing valve setting Port identification
19.0 – 21.0 bar (276 – 305 psi) A - Main port B - Main port L - Case drain Z - Brake release X - Two-speed port
282 – 470 cm³ (17.2 – 28.7 in³) .
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Hydrostatic drive - Pump and motor components
Pump - Dynamic description The hydrostatic pump is an axial piston pump with the ability to vary the rate and the direction of the oil flow. The change of flow is accomplished by changing the position of the hydrostatic pump's swash plate (2). The angle of the swash plate (2) causes the pistons (1) to stroke in and out of the cylinder block bores as the swash plate (2) rotates. Changing the angle of the swash plate (2) varies the piston stroke and the amount of oil being pumped to the drive motor. Tilting the swash plate (2) in the opposite direction reverses the flow to the drive motor which changes the direction of drive motor’s rotation.
RAIL14SSL0010BA
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1
Hydrostatic drive - Pump and motor components
Motor valves - Component localization SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ]
RAPH13SSL0863FA
1
Valve location Valve identification (1) Ride control valve
(3) Loader pilot interlock, brake, two speed valve (2) Hydraulic coupler valve (4) Second auxiliary valve
(5) High flow valve (6) Override valve for the loader arm
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(7) Self-leveling valve
Hydrostatic drive - Pump and motor components
Control valve - Component localization SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
RAIL13SSL1004FA
1
Valve location Valve identification (1) Ride control valve
(3) Loader pilot interlock, brake, two speed valve (2) Hydraulic coupler valve (4) Second auxiliary valve
(5) Accumulator (6) High flow valve
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(7) Self level valve
Hydrostatic drive - Pump and motor components
Motor - Dynamic description SR210 SR240 SV280
The drive motor is actually a radial piston pump. There are two main parts within a radial piston pump: The rollers (A) and the stationary cam ring (B). As displayed in image 1, high pressure oil from the hydrostatic pump enters port 1 of the drive motor. This oil enters a cavity above the rollers. As the cavities fill with oil, the rollers are forced to move down the cam ring. The rollers are connected to an assembly, and this roller assembly is attached to the output shaft, so spinning the roller assembly spins the output shaft. As the rollers travel up the cam ring, oil is sent back to the hydrostatic pump though port 2. Changing the direction of the oil being sent to the motor, i.e., sending oil to port 2 instead of port 1 changes the rotational direction of the roller assembly, which changes the direction of the output shaft.
RAPH14SSL0034BA
1
RAPH14SSL0035AA
2
The drive motor is available in one-speed or two-speed. Image 2 is an example of the two-speed functionality. In image 1, the high pressure oil from the hydrostatic pump enters every roller, giving that motor a low speed and maximum torque. In image 2, the high pressure oil enters every other roller. Because the hydrostatic pump sends the same amount of oil to half of the rollers during two-speed travel, the roller assembly spins twice as fast, but because half of the rollers are receiving oil, the motor also has half of the torque.
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Hydrostatic drive - Pump and motor components
Motor - Dynamic description TR270 TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
The motor is a fixed displacement pump with axial pistons. Inside the pump are a number of pistons (2) connected to a rotating cylinder block (3). The base of the pistons (2) sit diagonally on the fixed cam plate (1). When high pressure oil enters the pump, the piston (2) is at top dead center. The high pressure oil pushes the piston (2) and fills the cylinder. As oil fills the cylinder, the piston (2) descends the plane of the fixed cam plate (1), which spins the rotating cylinder block (3) and the output shaft. This process is called the reciprocation cycle. As the rotating cylinder block (3) continues to spin, the piston (2) ascends the plane of the fixed cam plate (1) and pushes oil out of the pump. This process is called the discharge cycle. RAPH14SSL0332BA
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1
Hydrostatic drive - Pump and motor components
Pump Charge pressure relief valve - Pressure test WARNING Pressurized hydraulic fluid can penetrate the skin and cause severe injuries. Hydraulic fluid can also infect a minor cut or opening in the skin. Serious infection or reaction can result without immediate medical treatment. If injured by leaking fluid, see your doctor immediately. Failure to comply could result in death or serious injury. W0358A
DANGER Crushing hazard! Always install the safety lock before working under the raised attachment. Failure to comply will result in death or serious injury. D0075A
NOTE: Hydraulic oil temperature should be a minimum of 52 °C (125 °F) before attempting any tests on the hydraulic system. NOTE: You will need two people to perform this test. NOTE: An error code may appear on the instrument cluster during this test. When the unit is shut down and all connections are returned to normal, the fault code will be stored as inactive. This fault can be cleared using the electronic service tool (EST). 1. Raise the machine off of the floor until the tires/tracks are not touching. Support the machine with proper lifting equipment. NOTICE: This is a safety precaution if the parking brakes fail to hold. 2. Disconnect and cap the brake lines and fittings. NOTE: Image 1 may not match your machine. Please see Parking brake control valve or manifold - General specification (33.110) for specifications on the parking brake control valve.
RAPH12SSL0392AA
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1
Hydrostatic drive - Pump and motor components
3. Connect a 41 bar (600 psi) pressure gauge, part number 380500129, to the test port for charge pressure, or connect a T-fitting (1) to an outlet hose for the charge pump and attach a 41 bar (600 psi) pressure gauge , part number 380500129, to the T-fitting. Please see the table below for recommended testing areas or see Pump - General specification (29.218) for specifications about the pumps. Recommended testing areas for charge pressure Models (mechanically controlled): SR130, SR150, SR160, SR175, SV185
RAPH12SSL0420AA
2
RAPH12SSL0421AA
3
RAPH12SSL0424AA
4
Models (mechanically controlled): SR200, SR210, SR220, SR240, SR250, SV250, SR270, SV280, SV300, TR270, TR310, TR320, TR340, TV370, TV380
Models (electro-hydraulic controlled): All models
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Hydrostatic drive - Pump and motor components
4. Start the machine and run at high idle.
931007504
5
RAPH12SSL0422AA
6
5. Read the pressure gauge and record the charge pressure reading. Stop the engine. NOTE: Image 6 is an example of a pressure reading. Image 6 may not match your reading. 6. The pressure reading must be approximately 24 bar (350 psi). Please see Pump - General specification (29.218) for general specifications about the hydrostatic pumps.
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Hydrostatic drive - Pump and motor components
Pump Pressure limiter valve - Pressure test WARNING Pressurized hydraulic fluid can penetrate the skin and cause severe injuries. Hydraulic fluid can also infect a minor cut or opening in the skin. Serious infection or reaction can result without immediate medical treatment. If injured by leaking fluid, see your doctor immediately. Failure to comply could result in death or serious injury. W0358A
DANGER Crushing hazard! Always install the safety lock before working under the raised attachment. Failure to comply will result in death or serious injury. D0075A
NOTE: Hydraulic oil temperature should be a minimum of 52 °C (125 °F) before attempting any tests on the hydraulic system. NOTE: You will need two people to perform this test. NOTE: An error code may appear on the instrument cluster during this test. When the unit is shut down and all connections are returned to normal, the fault code will be stored as inactive. This fault can be cleared by using the Electronic Service Tool (EST). 1. Raise the machine off of the floor until the tires/tracks are not touching. Support the machine with proper lifting equipment. NOTICE: This is a safety precaution if the parking brakes fail to hold. 2. Connect a 690 bar (10000 psi) pressure gauge, part number 380500129, to the test port of the circuit you wish to test. Please see the chart below for port identification, or see Pump - General specification (29.218) for specifications on the hydrostatic pumps. NOTE: Not all pressure test ports on the hydrostatic drive assembly are easily accessible. Remember, you can test all four pressure limiter valves by plugging a pressure gauge into the most available pressure test port and exchanging pressure limiter valves. Test port identification for the pressure limiter valves Mechanical controls Models: SR130, SR150, SR160, SR175, SV185, Pressure port M3 (1) for port C Pressure port M2 (2) for port B NOTE: Port M2 located under the pump assembly. Pressure port M4 (3) for port D Pressure port M1 (4) for port A
RAPH12SSL0357HA
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1
Hydrostatic drive - Pump and motor components
Mechanical controls Models: SR200, SR210, SR220, SR240, SR250, SV250, SR270, SV280, SV300, TR270, TR310, TR320, TR340, TV370, TV380, Pressure port (1) for port C Pressure port (2) for port D Pressure port (3) for port A Pressure port (4) for port B
RAPH12SSL0359GA
2
RAPH15SSL0110BA
3
Electro Hydraulic (EH) controls Models: All models Pressure port MB (1) for port B Pressure port MB (1) for port B Pressure port MA (2) for port A Pressure port MA (2) for port A NOTE: Ports MA are located under the pump assembly.
3. Disconnect and cap the brake lines and fittings. NOTE: Image 4 may not match your machine. Please see Parking brake control valve or manifold - General specification (33.110) for specifications on the parking brake control valve.
RAPH12SSL0392AA
4
931007504
5
4. Start the machine and adjust the throttle to high idle. NOTE: If equipped with two speed drive motors, press the two speed button to activate the two speed option.
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5. Slowly move the correct control lever for the corresponding hydrostatic pump in the correct position. 6. Watch the pressure gauge until the pressure stops increasing. When the pressure gauge stops increasing, record the value on the pressure gauge and move the control lever to neutral. NOTE: To prevent overheating, do not pressurize the system for an extended period of time. 7. Refer to Pump - General specification (29.218) for specifications on the hydrostatic pumps. 8. Retest the circuit after repair.
RAPH12SSL0407AA
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6
Hydrostatic drive - Pump and motor components
Pump - Test SR210 SR240 SV280 TR270 TR310 TV370 TIER 4B (FINAL) [NHM435463 - ]
(Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls)
WARNING Pressurized hydraulic fluid can penetrate the skin and cause severe injuries. Hydraulic fluid can also infect a minor cut or opening in the skin. Serious infection or reaction can result without immediate medical treatment. If injured by leaking fluid, see your doctor immediately. Failure to comply could result in death or serious injury. W0358A
DANGER Crushing hazard! Always install the safety lock before working under the raised attachment. Failure to comply will result in death or serious injury. D0075A
Checking the charge pressure NOTE: Hydraulic oil temperature should be a minimum of 52 °C (125 °F) before attempting any tests on the hydraulic system. NOTE: You will need two people to perform this test. NOTE: An error code may appear on the Instrument Cluster during this test. When the unit is shut down and all connections are returned to normal, the fault code will be stored as inactive. This fault can be cleared using the Electronic Service Tool (EST). 1. Raise the machine off of the floor until the tires are not touching. Support the machine with proper lifting equipment. NOTICE: This is a safety precaution if the parking brakes fail to hold. 2. Disconnect and cap the brake lines and fittings. NOTE: Image 1 may not match your machine. Please see Parking brake control valve or manifold - General specification (33.110) for specifications on the parking brake control valve.
RAPH12SSL0392AA
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1
Hydrostatic drive - Pump and motor components
3. Install a T-fitting (1) at the charge pump outlet. NOTE: Image 2 is an example of a pressure reading. Image 2 may not match your reading. 4. Disconnect and cap the servo inlet line. 5. Connect a hose with a 41 bar (600 psi) pressure gauge (2), part number 380500128, from the T-fitting outlet (1) to the servo inlet (3).
RAPH12SSL0423AA
2
RAPH12SSL0422AA
3
6. Start the machine and run at high idle. NOTE: If equipped with two-speed drive motors, press and hold the two-speed button. 7. Record the charge pressure with the control levers in the neutral position on the data collection sheet located on the following page. NOTE: Image 3 is an example of a pressure reading. Image 3 may not match your reading. 8. Gently move one control lever in the forward position. Watch for the pressure drop on the pressure gauge. Record the pressure drop on the data collection sheet located on the following page. Return the control lever to the neutral position. NOTE: Always maintain the engine RPM for this test. Do not move the control levers to a point where a load is put on the engine. A load on the engine will lower the engine speed and create a difference in pump flow. A difference in pump flow will effect your readings and the accuracy of this test. 9. Gently move the same control lever in the reverse position. Watch for the pressure drop on the pressure gauge. Record the pressure drop on the data collection sheet located on the following page. Return the control lever to the neutral position. 10. Repeat steps 8 and 9 on the other pump and control lever.
Results Review the recorded results on the data collection sheet located on the following page. With the engine speed set and maintained at a high idle, the maximum pressure drop between the system in neutral and the system in forward or reverse must be 2.1 bar (30 psi) or less. Any pressure drop greater than 2.1 bar (30 psi) could indicate an excessive leak in the hydrostatic system, which will require more diagnosis of the hydrostatic system.
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Data collection sheet Front pump bar (psi)
Neutral ___________ Forward __________ Reverse __________
Rear pump bar (psi)
Neutral ___________ Forward __________ Reverse __________
Notes:
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Pump - Disassemble SR210 SR240 SV280 TR270 TR310 TV370 TIER 4B (FINAL) [NHM435463 - ]
(Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls)
Some types of failures will require the disassembly of the tandem pump for cleaning and inspection. If there is failure in the drive motors or tandem pump, disassemble both the rear and front pumps, the drive motors, and all hoses between the pumps and drive motors. 1. Remove the bolts that fasten the pumps together.
83111565
1
83111566
2
83111567
3
2. Remove the nut and bracket from the stud.
3. Separate the pumps (1).
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4. Remove the two O-rings (1) and back-up ring (2).
83111568
4
83111569
5
83111570
6
83111571
7
5. Remove the charge pump cover. Note the position of the charge pump cover pin (1) for use during assembly.
6. Remove the coupling from the inner gear.
7. Remove the inner gear from the outer gear.
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8. Remove the outer gear from the charge pump cover.
83111572
8
83111573
9
9. Remove the bolt stud.
10. Remove the special bolts from the cover.
83111574
10
83111575
11
11. Remove the cover, the gasket, and the shaft assembly.
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12. Remove the swash plate.
83111576
12
83111577
13
83111578
14
83111579
15
13. Remove the retainer and the pistons.
14. Remove the guide.
15. Remove the cylinder block. NOTE: Do not disassemble the cylinder block.
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16. Do not lose the three pins (1) that are inserted into the cylinder block. They must stay in position.
83111580
16
83111581
17
83111582
18
83111583
19
17. Remove the wear plate.
18. Remove the gasket.
19. Remove the snap ring from the seal.
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20. Fasten the cover in a vise with soft jaws. Use a prybar to remove the seal.
83111584
20
83111585
21
83111586
22
83111587
23
21. Remove the snap ring from the groove, just above the ball bearing.
22. Push the shaft out of the cover. Inspect the bearing on the shaft. Replace if necessary.
23. Inspect the bearings (1) on the cover. If the tan surface has worn through to the dark base, use new bearings.
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24. Remove the screws from the cover.
83111588
24
83111589
25
83111590
26
83111591
27
25. Pull out the piston assembly from the housing.
26. Remove and discard the gasket.
27. Fasten the piston assembly in a vise with soft jaws. Hold the special bolt in place. Remove the special nut. Ensure that the special bolt does not turn while removing the special nut.
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28. Measure the distance between the top of the special bolt and the cover. Record that measurement.
83111592
28
83111593
29
83111594
30
83111595
31
29. Thread the cover counterclockwise until it is removed from the special bolt. 30. Fasten the piston in a vise with soft jaws. Hold the adjusting nut in place. Loosen the jam nut.
31. Hold the special bolt in place. Tighten the adjusting nut to push the outer spring guide down, and away from the retaining ring.
32. Remove the retaining ring. NOTE: The retaining ring will be difficult to remove.
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33. Hold onto the end of the special bolt and pull out the spring assembly.
83111596
32
83111597
33
83111598
34
83111599
35
34. Thread the jam nut (1) and the adjusting nut (2) counterclockwise until they are removed from the special bolt. Separate the outer spring guide (3), spring (4), sleeve, and inner spring guide (5) from the special bolt.
35. Remove the piston from the housing. Remove and discard the O-rings, and the piston rings from each end of the piston (1).
36. Remove the screws from the cover.
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37. Remove the cover and discard the gasket.
83111600
36
83111601
37
83111602
38
83111603A
39
38. Go to the spool assembly. Mark the position of where the stop bracket is bolted. Repeat for the other side.
39. Remove the bolts and the spool assembly from the housing.
40. Remove the sleeve from the housing.
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41. Remove the lock nut and washer from the spool.
83111604
40
83111605
41
83111606
42
83111607
43
42. Remove and discard the backup ring (1) and O-ring (2) from the spool.
43. Remove and discard the backup ring (1) and O-ring (2) from the sleeve.
44. Remove the hex plug and shims for the charge pressure relief valve.
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45. Remove the shims from the hex plug. Save the shims for later use.
83111608
44
83111609
45
83111610
46
83111611
47
46. Remove the spring.
47. Remove the valve poppet with a slide hammer.
48. Mark the hex plug that is used for the circuit reliefcheck valve.
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49. Remove the hex plug.
83445485
48
83111612A
49
83111613A
50
83111614B
51
50. Remove the spring.
51. Remove the circuit relief-check valve.
52. Loosen the bypass valve.
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53. Thread the bypass valve counterclockwise until it is removed.
83111615C
52
83115460
53
83115461
54
54. Remove and discard the O-ring (1) and backup ring (2).
55. Remove the plug.
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Pump - Measure - Piston travel SR210 SR240 SV280 TR270 TR310 TV370 TIER 4B (FINAL) [NHM435463 - ]
(Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls)
1. Measure the free travel between the shoes and the pistons. If all of the measurements are not equal to approximately 0.13 mm ( 0.005 in), use a new cylinder assembly.
83115462
1
83115463
2
2. Measure the thickness of each shoe. If the measurements are not equal to approximately 0.02 mm ( 0.0001 in), use a new cylinder assembly.
3. Check the fit of the pistons in the bores. The piston must move freely with minimum clearance. Use a new cylinder assembly as necessary. 4. Measure the gear tip clearance between the inner gear and the outer gear. Clearance must not be more than 0.13 mm ( 0.005 in). 5. Measure the width of the inner gear and the outer gear. The width of each gear must be equal to within 0.05 – 0.06 mm ( 0.002 – 0.003 in).
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Pump - Assemble SR210 SR240 SV280 TR270 TR310 TV370 TIER 4B (FINAL) [NHM435463 - ]
(Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls)
NOTE: Some of the photos in the following procedure may appear slightly different than the model you are repairing. The procedure is the same. 1. Install the plug. Tighten the plug to a torque of 0.9 – 1.3 Nm (8 – 12 lb in).
83115461Z
1
83115460Z
2
83111615L
3
2. Slide a new backup ring (2) and O-ring (1) into the grooves of the bypass valve.
3. Thread the bypass valve into the housing.
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4. Tighten the bypass valve to a torque of 9 – 13 Nm (84 – 120 lb in)
83111614Q
4
83111613H
5
83111612T
6
83445485V
7
5. Thread the circuit relief-check valve into the housing.
6. Insert the spring on top of the circuit relief-check valve.
7. Thread the plug on top of the spring. Tighten the plug to a torque of 115 – 230 Nm ( 85 – 170 lb ft).
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8. Use a slide hammer to insert the valve poppet into the housing for the charge pressure relief valve.
83111610T
8
83111609S
9
9. Insert the spring on top of the valve poppet.
10. Insert the necessary quantity of shims into the hex plug. Thread the hex plug on top of the spring. Tighten but do not overtighten.
83111607-
10
83111606H
11
11. Slide a new O-ring (2) and backup ring (1) into the grooves of the sleeve.
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Hydrostatic drive - Pump and motor components
12. Slide a new O-ring (2) and backup ring (1) into the grooves of the spool.
83111605S
12
83115464G
13
83111604P
14
83111603PNA55
15
13. Insert the spool into and through the stop bracket.
14. Slide the washer and nut onto the protruding threads of the spool. Hold the spool assembly in place. Tighten the nut, but do not overtighten.
15. Lubricate the sleeve. Insert the sleeve into the housing. Ensure that the notch on the end of the sleeve is properly aligned with the notch inside housing.
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16. Lubricate the spool. Insert the spool inside the sleeve.
83115465H0
16
83111602AS
17
83111600HJ
18
83111599FUG
19
17. Ensure the marks are in alignment. Secure the spool assembly with two bolts.
18. Place the new gasket and cover onto the rim of the housing.
19. Secure the cover with screws.
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20. Slide the inner spring guide (5), sleeve, spring (4), outer spring guide (3), the adjusting nut (2), and the jam nut (1) onto the special bolt.
83111597I
20
83115466GH
21
83111598P
22
83111596RQWE
23
21. Hold the bolt assembly in place. Tighten the adjusting nut to begin compression of the spring.
22. Insert one new ring (2) and one O-ring (1) into the grooves on each end of the piston.
23. Fasten the piston in a vise with soft jaws. Hold onto the end of the of the special bolt to insert the spring assembly into the piston.
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24. Hold the special bolt in place. Tighten the adjusting nut until the outer spring guide is below the groove. This will allow space for the retaining ring.
83111594FHJ
24
83115467DB
25
83111594G
26
83115468KIJ
27
25. Install the retaining ring onto the spring assembly.
26. Slightly loosen the special bolt. Ensure that the spring and adjusting nut do not become loose.
27. Hold the adjusting nut and special bolt in place. Tighten the jam nut. Recheck the special bolt and spring. Verify that the spring did not become loose.
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28. Lubricate the piston with clean oil. Slide the piston into the housing.
83115469HY
28
83115470TRY
29
83115471GH
30
83111588SD
31
29. Slide a new gasket and cover onto the special bolt.
30. During disassembly, the measured distance between the top of the special bolt and cover. Thread the cover up or down the special bolt until the distance is equal to that recorded measurement.
31. Secure the cover with four screws. Tighten the screws to the torque of 11 – 15 Nm ( 96 – 132 lb in).
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Hydrostatic drive - Pump and motor components
32. Hold the special bolt in place. Slide the special nut (with the sealing surface side down) onto the special bolt. Tighten the special nut, but do not overtighten.
83115472DFH
32
83115473MIO
33
83115474KO
34
83115475DR
35
33. During disassembly, the bearings on the cover were inspected. If one of the bearings need to be replaced, align and insert the cover roll pin into the hole of the bearing. This will ensure proper placement. NOTE: If a new cover is being used, install new roll pins so the distance between the tops of the roll pins and the face cover are 2.3 – 2.8 mm ( 0.090 – 0.110 in).
34. During disassembly, the ball bearing for the shaft was inspected. If the ball bearing for the shaft has been replaced, install one snap ring on each side of the ball bearing.
35. Fasten the cover in a vice with soft jaws. Firmly press the ball bearing and the shaft into the cover.
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Hydrostatic drive - Pump and motor components
36. Install the snap ring into the groove, just above the ball bearing.
83111585DFDFHFH
36
83115476ASDFG
37
83111583F
38
83111581DFF
39
37. Lubricate the lip of the seal with clean oil. Carefully press the new seal with the lip down, into the cover.
38. Install the snap ring into the seal.
39. Lubricate the wear plate with clean oil. Align the notch on the wear plate with the roll pin that is located inside the cylinder port. Insert the wear plate with the bronze surface side up, into the cylinder port.
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40. Ensure that the three pins are still inserted in the cylinder block.
83111580DFFG
40
83115477WEED
41
83111579CVBNJ
42
83115480SDF
43
41. Hook the retaining collar and slide it up the splines until it reaches the top.
42. Insert the cylinder block into the pump.
43. Align and install the guide on top of the pins.
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44. Slide the retainer on top the guide. Ensure that the holes of the retainer are properly aligned with the holes of the cylinder block
83115479ASD
44
83115480SDF
45
83115481X
46
83115482MKP
47
45. Lubricate the pistons with clean oil. Insert one piston into each aligned hole of the retainer and cylinder block. Ensure that the guide is still properly positioned on top of the three pins.
46. If a new swash plate or pin is being used, go to the underside of the swash plate. Insert the pin into the top, center slot. Press down on the pin until the distance between the top of the pin and the swash plate is 8.4 – 8.9 mm ( 0.33 – 0.35 in).
47. Slide the guide (1) onto the pin located on the side of the swash plate.
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48. Install the swash plate. The pin must engage the slot in the body of the control valve. The retainer must engage the groove in the piston.
83111576CV
48
83115483FN
49
83115484I
50
83111574WER
51
49. Place a new gasket on the outside rim.
50. Carefully place the cover and the shaft assembly onto the gasket. Rotate the shaft to align the support with the cylinder block.
51. Secure the cover with special bolts. Use the bolts to evenly draw the cover to the housing. Tighten the 3/8 in special bolt to a torque of 53 – 64 Nm 39 – 47 lb ft. Tighten the 7/16 in special bolts to a torque of 81 – 100 Nm ( 60 – 74 lb ft).
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52. Insert the bolt stud into the housing.
83111573CFF
52
83111572HJU
53
83111571BL
54
83111570DF
55
53. Slide the outer gear into the charge pump cover.
54. Slide the inner gear into the outer gear.
55. Align the coupling pin with the inner gear slot. Slide the coupling into the inner gear.
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56. Lubricate the charge pump cover with clean oil. Align the cover pin (1) with the hole found at the top of the housing. Slide the cover onto the cylinder block and into the housing.
83111569FTR
56
83111568
57
83111567
58
83111566
59
57. Install new O-rings and back-up ring.
58. Install bracket and nut. Connect the front and rear pump together.
59. Torque the retaining nut to 102 N¡m (75.2 lb ft)
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60. Install the bolts that fasten the front and rear pumps together. Torque the bolts to 91 – 111 Nm ( 67 – 82 lb ft
83111565
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Hydrostatic drive - Pump and motor components
Pump - Remove SR210 SR240 SV280 TR270 TR310 TV370 TIER 4B (FINAL) [NHM435463 - ]
(Electro (Electro (Electro (Electro (Electro (Electro
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls)
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. Failure to comply could result in death or serious injury. W0398A
Prior operation: Tilt the ROPS NOTE: Some of the photos in the following procedure may appear slightly different than the model you are repairing. The procedure is the same. 1. Label and disconnect control wires (1) on bottom of pumps
931001961
1
20111248
2
2. Label and disconnect the two front (1) and two rear (2) pump control connections.
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3. Label and disconnect the hydraulic oil temperature sender (1).
931001963
3
931001964
4
931001965
5
931001966
6
4. Label and disconnect the right hand side hydraulic hose (1).
5. Label and disconnect the oil supply hose (1) by loosening the hose clamp and cap ports.
6. Label and disconnect the top hydraulic tube (1) and cap open ports.
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7. Label and disconnect right hand side drive motor hoses (1) and cap open ports.
931001970
7
931001971
8
931001972
9
8. Label and disconnect left hand side drive motor hoses (1) and cap open ports.
9. Label and disconnect hydraulic hose (1) and cap open ports.
10. Label and disconnect case drain hose (1) and cap open ports.
931001963
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Hydrostatic drive - Pump and motor components
11. Label and disconnect gear pump supply hose (1) and cap open ports.
931001955
11
931001956
12
931001974
13
931001928
14
12. Label and disconnect gear pump hydraulic tubes (1) and cap open ports.
13.
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. Failure to comply could result in death or serious injury. W0398A
Place a lifting strap around the pump and using a hoist support the pump, as shown. 14. Remove the two mounting bolts and washers (1) from the pump.
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15. Using the hoist, carefully remove pumps.
931001976
Next operation: Pump - Install (29.218)
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Hydrostatic drive - Pump and motor components
Pump - Install SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Electro hydraulic controls) (Electro hydraulic controls) (Electro hydraulic controls) (Electro hydraulic controls) (Electro hydraulic controls) (Electro hydraulic controls)
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. Failure to comply could result in death or serious injury. W0398A
Prior operation: Inspect the O-ring on the hydrostatic pump, and replace if necessary. Prior operation: Lubricate the O-ring with clean hydraulic oil. Prior operation: Fill the hydrostatic pump with clean hydraulic oil. Prior operation: Apply TUTELA MOLY GREASE GR-75 to the coupler. NOTE: Some of the photos in the following procedure may appear slightly different than the model you are repairing. The procedure is the same.
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1. Mount the coupler (1) to the pump shaft with the supplier logo facing out toward the engine. 2. Align the coupler on the pump shaft. The distance (A)(pump mounting flange to the coupling face) should be 55.0 – 57.0 mm (2–1/4 – 2–3/8 in). 3. Torque the set screws (2) to 25.7 – 28.3 N·m (19.0 – 20.9 lb ft).
RAPH17SSL0007CA
1
931001928
2
4. Move the pump inward until the mounting flange is flush with the mounting surface of the hydrostatic pump. 5. Apply LOCTITE® 243™ to the pump mounting bolts (1). Install washers on the bolts and install the bolts into the pump mounting flange. Torque the mounting bolts to 86 – 117 N·m (63.4 – 86.3 lb ft).
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6. Connect gear pump hydraulic hoses (1) as shown.
931001956
3
931001955
4
931001963
5
931001972
6
7. Connect the gear pump supply hose (1), and tighten the hose clamp.
8. Connect the case drain hose (1), and secure with the clamp.
9. Connect the hydraulic hose (1), as shown.
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10. Connect the hoses (1) for the left-hand side of the drive motor.
931001971
7
931001970
8
931001966
9
11. Connect the hoses (1) for the right-hand side of the drive motor.
12. Connect the top hydraulic hose (1).
13. Connect the oil supply hose (1), and tighten the hose clamp.
931001965
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10
Hydrostatic drive - Pump and motor components
14. Connect the hose (1) for the right-hand side.
931001964
11
931001963
12
20111248
13
931001961
14
15. Connect the hydraulic oil, temperature sender (1), and secure with the nut.
16. Connect the electrical connectors (2) for the front (1) and rear solenoids.
17. Connect the sensor wires (1) located on the bottom of the pumps.
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Motor valves - Remove - Brake, Electro-Hydraulic (EH) option, 2-speed option Prior operation: Tilt the cab to gain access, see Cab tilting system - Tilt (90.150) for the proper procedure. Prior operation: Tilt the cab to gain access, see Cab tilting system - Tilt (90.150) for the proper procedure. 1. Disconnect the electrical connectors (1) from the solenoids on the valve block (A). NOTE: The valve block shown in Figure 1 has Electro-Hydraulic (EH) drive and the 2–speed option. Your specific machine may not look the same, it is dependant upon the configuration.
RAIL17SSL0163BA
1
RAIL17SSL0163BA
2
RAIL17SSL0164BA
3
2. Remove the tubes and hoses (2) from the fittings on the valve block (A).
3. Remove the bolts (1) that secure the valve block (A) to the left-hand side of the chassis and remove the valve.
Next operation: Motor valves - Install - Brake, Electro-Hydraulic (EH) option, 2-speed option (29.218)
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Motor valves - Install - Brake, Electro-Hydraulic (EH) option, 2-speed option Prior operation: Motor valves - Remove - Brake, Electro-Hydraulic (EH) option, 2-speed option (29.218) 1. Install the valve (A) to the chassis cage nuts on the left-hand side of the chassis. Secure the valve to the chassis with the bolts (A). NOTE: The valve block shown in Figure 1 has Electro-Hydraulic (EH) drive and the 2–speed option. Your specific machine may not look the same, it is dependant upon the configuration.
RAIL17SSL0164BA
1
RAIL17SSL0163BA
2
RAIL17SSL0163BA
3
2. Connect the tubes and hoses (2) to the fittings on the valve block (A). NOTE: See Torque - Standard torque data for hydraulics () for proper torque to the fittings and connections.
3. Connect the electrical connectors (1) to the solenoids on the valve block (A).
Next operation: Lower the cab, see Cab tilting system - Lower (90.150) for the proper procedure. Next operation: Lower the cab, see Cab tilting system - Lower (90.150) for the proper procedure.
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Motor - Remove SR210 SR240 SV280
WARNING Crushing hazard! Unit could fall if not properly supported. Follow jacking instructions provided for the unit. Use suitable jack stands. Be sure to position them properly. Failure to comply could result in death or serious injury. W0919A
DANGER Crushing hazard! Failure to engage the loader arm support pin could cause the loader arm to fall unexpectedly. Verify that the loader arm support pin is engaged. Failure to comply will result in death or serious injury. D0020A
DANGER Heavy objects! Lift and handle all heavy components using lifting equipment with adequate capacity. Always support units or parts with suitable slings or hooks. Make sure the work area is clear of all bystanders. Failure to comply will result in death or serious injury. D0076A
Prior operation: Tilt the ROPS. 1. Place suitable container under chain tank drain plug and remove drain plug (1) and drain chain oil.
RAPH12SSL0087AA
1
931002069
2
2. The loader must be raised and supported with the tires off the ground. Used adequate blocks or jack stands to safely support the loader.
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3. Remove the wheel hardware (1) and pull wheels from hub.
931002070
3
931002080
4
931002082B
5
4. Remove the six bolts (2) securing the drive chain inspection cover and remove cover.
5. Remove front and rear axle housing hardware (4).
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6. Remove front and rear axle housings
931002083B
6
931002084
7
931002085B
8
7. Push the sprocket forward and remove chains from drive sprocket, as shown.
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8. Label and disconnect hydraulic hoses (1) from hydrostatic drive motor and cap the open hoses and ports.
931002086
9
9. Disconnect shift tube (on 2 speed equipped models). 10. Remove and discard hydraulic motor mounting hardware (2). NOTE: DO NOT reuse motor mounting hardware after tightening to spec. Hardware is permanently stretched during tightening and must be discarded if loosened.
11.
931002085B
10
931002087
11
DANGER Heavy objects! Lift and handle all heavy components using lifting equipment with adequate capacity. Always support units or parts with suitable slings or hooks. Make sure the work area is clear of all bystanders. Failure to comply will result in death or serious injury. D0076A
Use acceptable lifting equipment and remove the drive motor/brake assembly.
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Motor - Disassemble - Single speed drive motor SR210 SR240 SV280
1. Make reference marks on the motor case for correct alignment during assembly. Loosen and remove the socket head cap screws alternately, one turn at a time from the cover plate.
83115546
1
83115547
2
83115548
3
2. Remove the cover plate.
3. Remove the gasket.
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4. Remove the disc spring.
83115549
4
83115550
5
83115551
6
83115552
7
5. Use compressed air in the port to force the piston up for removal.
6. Remove the piston
7. Remove the O-ring.
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8. Loosen and remove the socket head cap screws and washers from the brake housing.
83115553
8
83115554
9
9. Use a soft hammer to loosen the brake housing.
10. Remove the brake housing from the motor case.
83115555
10
83115556
11
11. Remove the brake discs and shims as one unit from the shaft.
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12. Remove the O-ring.
83115557
12
83115558
13
83115559
14
83115560
15
13. Loosen the plug for the flushing spool valve.
14. Remove the flushing spool valve plug.
15. Remove the flushing valve spool, 2 springs, and washer from the valve port. Make a record of the parts assembly for use during the assembly procedure.
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16. Loosen the plug for the flushing valve poppet.
83115561
16
83115562
17
83115563
18
83115564
19
17. Remove the plug from the port.
18. Remove the spring and the flushing poppet.
19. Loosen the socket head cap screws.
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20. Remove the socket head cap screws.
83115565
20
83115566
21
83115567
22
83115568
23
21. Remove the rear motor case.
22. Remove the seal from the rear case.
23. Drop the rear case assembly from approximately 80 mm (3.1 in) onto a wooden or plastic surface. This will release the distributor from the rear case.
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24. Remove the distributor from the rear case.
83115569
24
83115570
25
83115571
26
83115572
27
25. Make a record of the number of springs and the stop pin location in the distributor for use during the assembly procedure.
26. Remove the cam from the front case.
27. Remove the seal from the front case.
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28. Remove the cylinder block from the front case.
83115573
28
83115574
29
83115575
30
83115576
31
29. Place the front case assembly in the press. Remove the split ring from the shaft.
30. Press the shaft out of the front case.
31. Press the seal out of the front case.
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32. Press the outer bearing cup from the front case.
83115577
32
83115578
33
33. Press the inner bearing cup from the front case.
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Motor - Assemble - Single speed drive motor SR210 SR240 SV280
1. If removed, install a new inner bearing cup in the front case.
83115577
1
83115578
2
2. If removed, install a new outer bearing cup in the front case.
3. Lubricate a new shaft seal with clean hydraulic oil. Install the new shaft seal onto the shaft. 4. Place the shaft in a press. Warm the outer bearing. Press the outer bearing onto the shaft. 5. Cover the splines on the shaft with tape to protect the seal. Install the shaft into the front case. Remove the tape from the splines. 6. Warm the inner bearing. 7. Press the inner bearing onto the shaft and into the inner bearing cup. Press the bearing into the cup to a preload of 5000 kg (11023.1 lb). Rotate the front case during this procedure. Allow the assembly to cool.
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8. Place special tool 380001894 onto the shaft. Using a press and apply a preload 2000 kg (4409.2 lb) to the inner bearing.
83115575
3
83115574
4
83115574
5
83115574
6
9. Install the split ring onto the shaft.
10. With the preload still applied, measure the gap between the split ring and the bearing.
11. Remove the split ring. Install a shim with a thickness of 0.05 – 0.20 mm (0.002 – 0.008 in) greater than the measured gap between the split ring and the bearing surface.
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12. Install the split ring on the shaft.
83115574
7
83115566
8
83115572
9
13. Release the preload from the bearing and remove the front case assembly from the press. 14. Check the shaft to make sure it rotates in the front case assembly. 15. Install the cylinder block onto the shaft.
16. Lubricate the seal with clean hydraulic oil. Install the seal on the front case.
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17. Install the cam on the cylinder block. Be sure to align the cam with the alignment mark on the front case.
83115571
10
83115570
11
83115569
12
83115567
13
18. Install the springs and the stop pin in the distributor.
19. Lubricate the seals on the distributor with clean hydraulic oil. Install the distributor into the rear case. Be careful not to dislodge the springs while installing the distributor into the rear case. Make sure to the stop pin is aligned with the hole in the rear case. Tap the distributor with a soft hammer until it is seated in the rear case.
20. Lubricate the seal with clean hydraulic oil. Install the seal on the rear case.
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21. Use the marks made during disassembly and install the rear case onto the cam.
83115566
14
83115565
15
83115564
16
83115563
17
22. Apply LOCTITE® 243™ to the threads and install the socket head cap screws into the rear case.
23. Tighten the socket head cap screws alternately from side to side to a torque of 117 – 122 N·m (86.3 – 90.0 lb ft).
24. Lubricate the spring and flushing poppet with clean hydraulic oil. Install the spring and flushing poppet into the port.
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25. Lubricate the O-ring on the plug with clean hydraulic oil. Install and tighten the plug.
83115561
18
83115560
19
83115558
20
83115557
21
26. Lubricate the springs and flushing spool with clean hydraulic oil. Install the 2 springs, washer, and flushing spool into the valve port.
27. Lubricate the O-ring on the plug with clean hydraulic oil. Install and tighten the plug.
28. Lubricate the O-ring with clean hydraulic oil. Install the O-ring on the brake housing.
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29. Lubricate with the brake discs and shims with clean hydraulic oil. Install the brake discs and shims as one unit on the shaft. Make sure all of the tabs on the brakes discs are aligned.
83115556
22
83115555
23
83115553
24
83115552
25
30. Install the brake housing on the rear motor case.
31. Apply LOCTITE® 243™ to the threads and install the socket head cap screws into the brake housing. Tighten the socket head cap screws alternately from side to side to a torque of 70 – 77 N·m (51.6 – 56.8 lb ft).
32. Lubricate the seal with clean hydraulic oil. Install the seal in the brake housing.
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33. Lubricate the seals on the piston with clean hydraulic oil and install the piston into the brake housing.
83115551
26
83115549
27
83115548
28
83115547
29
34. Install the disc spring on top of the piston.
35. Install the gasket on the brake housing.
36. Install the cover plate onto the brake housing.
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37. Install the socket head cap screws into the cover plate. Tighten the socket head cap screws alternately from side to side to a torque of 14 – 16 N·m (10.3 – 11.8 lb ft).
83115546
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30
Hydrostatic drive - Pump and motor components
Motor - Disassemble - Two speed drive motor SR210 SR240 SV280
1. Make reference marks on the motor case for correct alignment during assembly. Loosen and remove the socket head cap screws alternately, one turn at a time from the cover plate.
83115546
1
83115547
2
83115548
3
2. Remove the cover plate.
3. Remove the gasket.
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4. Remove the disc spring.
83115549
4
83115550
5
83115551
6
83115552
7
5. Use compressed air in the port to force the piston up for removal.
6. Remove the piston.
7. Remove the O-ring.
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8. Loosen and remove the socket head cap screws and washers from the brake housing.
83115553
8
83115554
9
9. Use a soft hammer to loosen the brake housing.
10. Remove the brake housing from the motor case.
83115579
10
83115556
11
11. Remove the brake discs and shims as one unit from the shaft.
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12. Remove the O-ring.
83115580
12
83115581
13
83115582
14
83115564
15
13. Remove the two speed spool valve and spring from the valve port.
14. Remove the O-ring.
15. Loosen the socket head cap screws.
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16. Remove the socket head cap screws.
83115565
16
83115708
17
83115567
18
83115568
19
17. Remove the rear motor case.
18. Remove the seal from the rear case.
19. Drop the rear case assembly from approximately 80 mm (3.1 in) onto a wooden or plastic surface. This will release the distributor from the rear case.
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20. Remove the distributor from the rear case. Make a record of the number of springs and the stop pin location in the distributor for use during the assembly procedure.
83115709
20
83115571
21
83115572
22
83115573
23
21. Remove the cam from the front case.
22. Remove the seal from the front case.
23. Remove the cylinder block from the front case.
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24. Place the front case assembly in the press. Remove the split ring from the shaft.
83115574
24
83115575
25
83115576
26
83115577
27
25. Press the shaft out of the front case.
26. Press the seal out of the front case.
27. Press the inner bearing cup from the front case.
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28. Press the outer bearing cup from the front case.
83115578
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28
Hydrostatic drive - Pump and motor components
Motor - Assemble - Two speed drive motor SR210 SR240 SV280
1. If removed, install a new outer bearing cup in the front case.
83115575
1
83115577
2
2. If removed, install a new inner bearing cup in the front case.
3. Lubricate a new shaft seal with clean hydraulic oil. Install the new shaft seal onto the shaft. 4. Place the shaft in a press. Warm the outer bearing. Press the outer bearing onto the shaft. 5. Cover the splines on the shaft with tape to protect the seal. Install the shaft into the front case. Remove the tape from the splines. 6. Warm the inner bearing. 7. Press the inner bearing onto the shaft and into the inner bearing cup. Press the bearing into the cup to a preload of 5000 kg (11023.1 lb). Rotate the front case during this procedure. Allow the assembly to cool.
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8. Place special tool 380001894 onto the shaft. Using a press and apply a preload 2000 kg (4409.2 lb) to the inner bearing.
83115575
3
20115834
4
20115833
5
20115834
6
9. Install the split ring onto the shaft.
10. With the preload still applied, measure the gap between the split ring and the bearing.
11. Remove the split ring. Install a shim with a thickness of 0.05 – 0.20 mm (0.002 – 0.008 in) greater than the measured gap between the split ring and the bearing surface.
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12. Install the split ring on the shaft.
20115834
7
83115573
8
83115571
9
13. Release the preload from the bearing and remove the front case assembly from the press. 14. Check the shaft to make sure it rotates in the front case assembly. 15. Install the cylinder block onto the shaft.
16. Lubricate the seal with clean hydraulic oil. Install the seal on the front case. Install the cam on the cylinder block. Be sure to align the cam with the alignment mark on the front case.
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17. Install the springs and the stop pin in the distributor.
83115709
10
83115569
11
83115567
12
83115583
13
18. Lubricate the seals on the distributor with clean hydraulic oil. Install the distributor into the rear case. Be careful not to dislodge the springs while installing the distributor into the rear case. Make sure to the stop pin is aligned with the hole in the rear case. Tap the distributor with a soft hammer until it is seated in the rear case.
19. Lubricate the seal with clean hydraulic oil. Install the seal on the rear case.
20. Use the marks made during disassembly and install the rear case onto the cam.
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21. Apply LOCTITE® 243™ to the threads and install the socket head cap screws into the rear case.
83115565
14
83115564
15
83115560
16
83115557
17
22. Tighten the socket head cap screws alternately from side to side to a torque of 117 – 122 N·m (86.3 – 90.0 lb ft).
23. Lubricate the two speed valve spring and spool with clean hydraulic oil. Install the two speed valve spring and spool into the valve port.
24. Lubricate the O-ring with clean hydraulic oil. Install the O-ring on the brake housing.
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25. Lubricate with the brake discs and shims with clean hydraulic oil. Install the brake discs and shims as one unit on the shaft. Make sure all of the tabs on the brakes discs are aligned.
83115556
18
83115579
19
83115553
20
83115552
21
26. Install the brake housing on the rear motor case.
27. Apply LOCTITE® 243™ to the threads and install the socket head cap screws into the brake housing. Tighten the socket head cap screws alternately from side to side to a torque of 70 – 77 N·m (51.6 – 56.8 lb ft).
28. Lubricate the seal with clean hydraulic oil. Install the seal in the brake housing.
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29. Lubricate the seals on the piston with clean hydraulic oil and install the piston into the brake housing.
83115551
22
83115549
23
83115548
24
83115547
25
30. Install the disc spring on top of the piston.
31. Install the gasket on the brake housing.
32. Install the cover plate onto the brake housing.
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33. Install the socket head cap screws into the cover plate. Tighten the socket head cap screws alternately from side to side to a torque of 14 – 16 N·m (10.3 – 11.8 lb ft).
83115546
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26
Hydrostatic drive - Pump and motor components
Motor - Drain fluid TR270 TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
1. Position the final drive hub so that one of the drain plugs (2) is in the six o’clock position. 2. Remove the other plug (1). 3. Remove the drain plug (2).
931002652
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1
Hydrostatic drive - Pump and motor components
Motor - Remove TR270 TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
Prior operation: Remove the rubber track. Please see Rubber track - Remove (48.100). 1. Loosen and remove the upper and lower mounting bolts (1) which fasten the rear cover (2) to the frame (3).
BS05C139_1
1
BS05C164_1
2
BS05C164_2
3
2. Loosen and remove all of the hydraulic lines that are connected to the drive motor. Place plugs in all of the lines. 3. Loosen and remove all of the connectors from the ports on the drive motor to allow room to slide the drive motor out of the frame. 4. Install clean plastic plugs into the ports (1) to avoid contamination.
5. Make a reference mark on the drive motor (2) and the frame (3) to be used for alignment of the drive motor during the installation procedure. 6. Loosen and remove the mounting bolts (1) which fasten the drive motor (2) to the frame (3). 7. Slide the drive motor (2) out of the frame (3).
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Motor - Disassemble TR270 TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ]
1. Remove the 2 plugs from the cover plate.
83115710
1
83115711
2
83115712VGFUKV
3
2. Drain motor oil in an acceptable container. 3. Remove the snap ring.
4. Mark the position of the cover plate as a reference for reassembly. 5. Remove the cover plate.
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6. Remove the center gear.
83115713
4
83115714
5
83115715
6
83115716_4
7
7. Remove the gear plate.
8. Remove and discard the O-ring.
9. Mark the position (1) of all the gears as a reference for reassembly. 10. Remove the snap rings.
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11. Remove the gears.
83115717
8
83115718
9
12. Remove the bushing.
NOTE: Disassembly of the flushing spool valve 13. Remove the plugs.
83115725_2
10
83115721
11
14. Remove and discard the O-rings..
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15. Remove the springs from both ends of the plunger.
83115722
12
83115723_3
13
83115724_2
14
83115725_3
15
16. Remove the spring seats from both ends of the plunger.
17. Remove the plunger assembly.
NOTE: Disassembly of the two speed control 18. Remove the plugs.
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19. Remove and discard the O-rings.
83115721
16
83115726_3
17
83115727_3
18
83115728_3
19
20. Remove the two speed spool (1).
NOTE: The two speed spool can only be removed from one opening. 21. Remove the spring (1).
NOTE: Disassembly of the flushing valve 22. Remove plug.
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23. Remove and discard the O-ring.
83115721
20
83115729_3
21
83115730
22
83115731_2
23
24. Remove the spring.
NOTE: Disassembly of the base plate 25. Remove the three plugs from around the bottom of the base plate.
26. Remove the base plate mount bolts.
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27. Carefully lift the base plate off the pins. Remove the base plate.
83115732GSF
24
83115733
25
83115734
26
83115733_3
27
28. Turn the base plate upside down.
29. Remove the valve plate.
30. Remove the pins (1) from their seat..
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31. Remove bearing from the base plate.
83115736
28
83115737
29
83115738
30
83115739
31
NOTE: Disassembly of the motor shaft and cylinder block 32. Remove the bearing inner ring from the motor shaft.
33. Remove the springs from the brake piston.
34. Remove and discard the O-ring.
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35. Mark the position of the brake piston as a reference for reassembly.
83115740
32
83115741
33
83115742
34
83115743
35
36. Remove the brake piston.
37. Separate the brake spacer from the brake piston.
38. Remove and discard the O-rings from the brake piston.
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39. Remove and discard the O-ring from the brake spacer.
83115744
36
83115745
37
83115746
38
83115747
39
NOTE: Remove the brake discs package 40. Remove the brake disc with internal teeth.
41. Then remove an external toothed steel disc.
42. Repeat the above steps until complete brake disc package is removed. NOTE: Brake disc package consists of 3 brake discs and 2 steel discs
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43. Remove the cylinder block.
83115748
40
83115749
41
83115767
42
83115751
43
44. Remove the pistons and retainer plate from the cylinder block.
45. Remove pistons from the retainer plate.
46. Remove the spherical retainer plate holder.
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47. Remove the 3 pins from the cylinder block (1) .
83115752
44
83115753
45
83115754
46
83115755
47
48. Remove the swash plate.
49. Remove the 2 pistons from their seat (1) .
50. Remove the springs from the pistons.
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51. Remove the 2 steel balls from their seats.
83115756
48
83115757
49
83115758
50
83115759
51
52. Remove the motor shaft.
53. Remove the inner bearing ring from the motor shaft.
54. Remove the bearing.
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55. Remove the seal ring.
83115760_2
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52
Hydrostatic drive - Pump and motor components
Motor - Assemble TR270 TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
1. Install the seal ring.
83115760ASSD
1
83115761HJL
2
83115762
3
2. Install the seal ring into the flanged hub.
3. Apply a thin coat of grease over the seal ring (1).
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4. Install bearing.
83115763
4
83115764GHK
5
83115765
6
83115757
7
5. Seat the bearing into the flanged hub.
6. Install the inner bearing ring onto the motor shaft.
7. Place the motor shaft into the bearing.
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8. Place the 2 steel balls into their seats.
83115756
8
83115755
9
9. Install the springs inside the pistons.
10. Install the 2 pistons in their housings (1).
83115754
10
83115753
11
11. Install the swash plate.
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12. Install the three pins into the cylinder block (1).
83115752
12
83115751
13
83115766
14
83115767
15
13. Install the spherical retainer. NOTE: Ensure the two splines are aligned
14. Piston orifice must be free of dust or dirt.
15. Install the pistons into the retainer plate.
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16. Install the pistons and retainer plate into the cylinder lock.
83115749
16
83115748
17
83115745
18
83115746
19
17. Install the cylinder block into the flanged hub on the motor shaft spline.
18. Install the brake disc package according to the following order: first insert one brake disc with internal teeth.
19. Then insert an external toothed steel disc.
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20. Repeat the steps until 3 brake discs and 2 steel discs have been installed.
83115747
20
83115743
21
83115744
22
83115742
23
21. Install the O-rings on the brake piston.
22. Install the O-ring on the brake spacer.
23. Install the brake spacer on the brake piston, paying attention not to damage the O-rings already in place.
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24. Install the brake piston into the flanged hub while aligning the reference marks previously applied.
83115741
24
83115739
25
83115738
26
83115737
27
25. Install O-ring.
26. Install the springs on the brake piston.
27. Install the bearing inner ring onto the motor shaft.
28. Install the bearing into the base plate (1).
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29. Install the pins into the base plate (2).
83115735
28
83115734
29
83115732GSF
30
83115731
31
30. Install the valve plate on the base plate with the bronze surface upwards.
31. Install the 3 O-rings for the oil passages on the flanged hub. 32. Place the base plate on the flanged hub. NOTE: Ensure the base plate is centered on the two pins and the oil passages are matched together
33. Install the base plate mount bolts and tightened to a torque of 145 N¡m (106.95 lb ft).
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34. Install the 3 plugs located around the bottom of the base plate. Torque plus to 2 – 3 N·m (17.7 – 26.6 lb in).
83115730
32
83115727
33
83115726
34
83115721
35
NOTE: Assembly of the two speed control 35. Install the spring (1) into the two-speed spool (2) .
36. Install the two speed spool (1) into the base plate. NOTE: The spool will only fit through 1 of the 2 orifices.
37. Install the O-rings on the plugs.
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38. Install and tighten the plugs to a torque of 49 – 59 N·m (36.1 – 43.5 lb ft).
83115725
36
83115721
37
83115729_1
38
83115728
39
NOTE: Assembly of the flushing valve 39. Install the O-ring on the plug.
40. Install the spring into the base plate.
41. Install and tighten the plug to a torque of 88 – 96 N·m (64.9 – 70.8 lb ft).
NOTE: Assembly of the flushing spool valve
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42. Slide plunger (1) inside the base plate.
83115724
40
83115723_2
41
83115722
42
83115721
43
43. Install the spring seats (1) on each end of the plunger (2) .
44. Install the springs on each end of the plunger.
45. Install the O-rings on the 2 plugs.
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46. Install and tighten the 2 plugs to a torque of 149 – 165 N·m (109.9 – 121.7 lb ft)
83115725_1
44
83115768
45
83115717
46
83115769_1
47
47. Install the bushing into the gearbox (1).
48. Install the gears into the gearbox while aligning the reference marks (1) previously applied to the gears.
49. Seat the gears.
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50. Install the snap rings on the gears.
83115716
48
83115715
49
83115714
50
83115713
51
51. Install the O-ring around the gearbox.
52. Install the gear plate.
53. Install the center gear.
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54. Use reference marks (1) to align and install the cover plate on the gearbox.
83115712
52
83115711
53
83115710
54
55. Install the snap ring.
56. Service gearbox with 550 – 650 ml (18.6 – 22.0 US fl oz) .of CASE AKCELA GEAR 135 H EP 85W-140. 57. Install and tighten the end cover plugs to a torque of 20 – 30 N·m (14.8 – 22.1 lb ft).
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Motor - Filling TR270 TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
1. Position the final drive hub so that one of the fill plugs (1) is in the twelve o’clock position. 2. Remove the other plug (2). 3. Fill the final drive hub with TUTELA HYPOIDE EP GEAR LUBE SAE 80W-90 until oil starts to flow from the plug (2) that is at three o’clock or nine o’clock position.
931002651
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1
Hydrostatic drive - Pump and motor components
Motor - Install SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ]
DANGER Crushing hazard! Failure to engage the loader arm support pin could cause the loader arm to fall unexpectedly. Verify that the loader arm support pin is engaged. Failure to comply will result in death or serious injury. D0020A
WARNING Crushing hazard! Unit could fall if not properly supported. Follow jacking instructions provided for the unit. Use suitable jack stands. Be sure to position them properly. Failure to comply could result in death or serious injury. W0919A
DANGER Heavy objects! Lift and handle all heavy components using lifting equipment with adequate capacity. Always support units or parts with suitable slings or hooks. Make sure the work area is clear of all bystanders. Failure to comply will result in death or serious injury. D0076A
1. Clean the motor mounting face and the chassis mounting face with separate alcohol wipes. Allow the surfaces to dry completely. 2. Apply a bead of LOCTITE® SI 598™ BLACK adhesive, (1), in corner between pilot and flange of motor, around diameter of pilot, similar to o-ring, (approximately 12.5 ml (0.4 US fl oz) per motor).
931001687A
1
931002004
2
3. Apply a 3 mm (0.1 in) bead of LOCTITE® SI 598™ BLACK around the outside of the bolt holes of the motor flange and two dabs per nut between the nut and motors.
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4. Use acceptable lifting equipment and move the drive motor/brake assembly (1) into the chassis mounting location (2). 5. Install the new mounting hardware and snug torque the hardware to 27.0 – 41.0 N·m (19.9 – 30.2 lb ft). Figure 3 shows the torque sequence of the bolts. Final torque the hardware to 122 N·m (90 lb ft) plus 60 degrees following the torque sequence as shown. NOTE: DO NOT reuse motor mounting hardware. Hardware is permanently stretched during tightening and must be discarded if loosened.
RAPH17SSL0011BA
3
931002086
4
931002085B
5
6. Connect the hydraulic hoses (1) to hydrostatic drive motor to the correct ports 7. Connect shift tube (on 2 speed equipped models).
8. Connect chains to drive sprocket
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9. Install front (1) and rear axle housings.
931002083B
6
931002082B
7
RAPH12SSL0087AA
8
10. Install the chains to the drive sprockets. 11. Install front and rear axle housing hardware (1).
12. Install chain oil drain plug (1). oil level is approximately mid-way up the inspection cover. Cover must be installed before filling with oil.
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13. Install chain inspection cover (1) and mounting hardware (2) 14. Fill chain tank to correct level and install check plug.
931002080A
9
15. Install wheels (1) and wheel hardware (2)
931002070
10
931002069
11
16. Remove supports and lower skid steer
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Motor - Install TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
1. On the older style undercarriage, make sure the spacer plate (1) is in place prior to installing the motor into the frame. NOTE: The spacer plate (1) is not used on the newer style undercarriage.
RAPH17CTL0002BA
1
BS05C164_3
2
BS05C164_4
3
2. Slide the drive motor (1) into the frame (2) mounting location. If the same motor is being installed, use the marks made during removal, and align the drive motor in the frame. If a new motor is being installed, transfer the reference mark from the old motor to the same location on the new motor, and align the drive motor in the frame.
3. Apply LOCTITEŽ 243™ to the threads of the mounting bolts (1). 4. Install the mounting bolts (1) into the frame.
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5. Tighten the mounting bolts (1) to an initial torque of 67 – 163 Nm (50 – 120 lb ft), using the tightening sequence shown in the image. 6. After the initial torque is complete, tighten the mounting bolts to a final torque of 125 – 170 Nm (93 – 125 lb ft), using the tightening sequence shown in the image.
BS05C156_1
4
BS05C164_1
5
BS05C139_1
6
7. Install the connectors into the motor ports (1), and tighten the connectors. 8. Connect the lines to the drive motor. Tighten all of the hydraulic lines.
9. Install the rear cover (2) onto the frame (3). 10. Apply LOCTITE® 243™ to the threads of the mounting bolts (1). 11. Install the upper and lower mounting bolts (1) into the rear cover (2). Tighten the mounting bolts (1).
Next operation: Install the rubber track. Please see Rubber track - Install (48.100)
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Servo control - Adjust SR210 SR240 SV280 TR270 TR310 TV370 TIER 4B (FINAL) [NHM435463 - ]
(Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls)
In order to correct a faulty hydrostatic drive, a systematic diagnostic procedure must be followed. Before attempting any of the procedures below, determine if the hydrostatic pump is faulty by raising the machine off of the ground and supporting the machine with a suitable lifting device, disconnecting the control linkage on the pump, releasing the brakes, running the machine, and observing the wheel/track motion. If you disconnect the linkage and the problem disappears, inspect the linkage and correct the problem. Please see Mechanical control - Adjust (29.200) for linkage adjustment procedures. If the machine travels with the linkage disconnected, please see the following steps:
Center the servo piston 1. Raise the machine off of the ground, and support the machine with a suitable lifting device. 2. Disconnect and cap the servo inlet line (1). NOTE: Disconnecting the servo inlet line will allow you to adjust both hydrostatic pumps without receiving hydraulic interference.
RAPH12SSL0449AA
1
RAPH12SSL0439AA
2
3. Start the machine, and run at a high idle. 4. Release the brakes. 5. Locate the faulty pump. 6. Remove the jam nut (1). NOTE: You do not need to remove the hydrostatic pumps for the following procedures; The hydrostatic pumps have been removed for picture clarity.
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7. Turn the servo adjustment screw in one direction until the wheels/track begin to rotate. Record the position of the adjustment screw. NOTE: If the adjustment screw requires more than one, full turn to begin tire/track movement, please see the steps in the “Center the servo piston spring” section of this document. 8. Turn the servo adjustment screw in the opposite direction until the wheels/track begin to rotate. Record the position of the adjustment screw. NOTE: If the adjustment screw requires more than one, full turn to begin tire/track movement, please see the steps in the “Center the servo piston spring” section of this document. RAPH12SSL0441AA
3
RAPH12SSL0438AA
4
9. Repeat steps 7 and 8 to verify your records. 10. Center the servo adjustment screw based on your records. 11. Install the jam nut. 12. Connect the servo inlet line. 13. Follow the steps in the “Center the servo control valve” section of this document.
Center the servo control valve 1. Disconnect the linkage on the faulty hydrostatic pump. 2. Loosen the adjustment bracket bolts (1) on the servo control of hydrostatic pump that is faulty.
3. Adjust the bracket for the servo control until the wheels/ track begin to move. Mark this position. 4. Adjust the bracket for the servo control in the opposite direction. When the wheels/track begin to move in the opposite direction, mark this position. 5. Repeat steps 3 and 4 to verify your markings. Make additional marks if necessary. 6. Center the adjustment bracket between your markings, and tighten the adjustment bracket bolts. 7. Reinstall the linkage. You may need to adjust the linkage. Please see Mechanical control - Adjust (29.200) for linkage adjustment procedures.
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8. Move the faulty hydrostatic pump’s control levers in both directions. The servo control is properly adjusted when an even amount of lever travel is required to begin the rotation of the wheels/tracks in either direction. Readjust the servo control and/or the linkage if necessary. 9. Test drive the machine. If the machine steers in either direction more than 1.8 m (6 ft) from the centerline after traveling 30.5 m (100 ft) forward or 15.2 m (50 ft) backward, or if one or both of the pumps continue to travel after the control levers have returned to neutral, recheck the linkage. Please see Mechanical control Adjust (29.200) for linkage adjustment procedures.
Center the servo piston spring If the adjustment screw requires more than one, full turn to begin tire movement, or a pump has the tendency to continue traveling in the direction that is was last going, please see the following steps:
23111053
5
Exploded view of the piston spring assembly
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1. Remove the jam nut (2). 2. Remove the bolts (1).
RAPH12SSL0439AA
6
RAPH12SSL0442AA
7
RAPH12SSL0440AA
8
3. Unscrew the servo piston cover (1).
4. Check the nuts for looseness. Inspect the spring assembly for damage and excessive movement. Adjust the lock nut and nut if necessary. NOTE: The nut (2) should be finger-tight against the spring cup (1). If the nut (2) is too tight, you will find a gap between the spring cup (1) and the retention ring (3). If the nut (2) is loose, you will find a gap between the nut (2) and the spring cup (1).
5. Install the servo piston cover. 6. Install the bolts. 7. Install the jam nut. 8. Repeat the steps in the “Center the servo piston� section of this document.
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Servo control - Adjust SR210 SR240 SV280 TR270 TR310 TV370 TIER 4B (FINAL) [NHM435463 - ]
(Electro (Electro (Electro (Electro (Electro (Electro
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls)
Travel adjustments for the Electric Hydraulic (EH) pumps are less involved because the EH pumps do not have mechanical control linkage. Before attempting to adjust the pumps, please see Hydrostatic transmission - Troubleshooting (29.202). If there are no problems with the drive motors, hoses, brakes, and axles, and the charge pressure and relief pressures are within specification, please use the Electronic Service Tool (EST) to calibrate the joysticks and the ground drive. If the machine continues to travel irregularly after calibration, please see the following steps:
Center the piston 1. Raise the machine off of the ground, and support the machine with a suitable lifting device. 2. Disconnect and cap the inlet line (1). NOTE: Disconnecting the inlet line will allow you to adjust both hydrostatic pumps without receiving hydraulic interference.
931001814
1
RAPH12SSL0443AA
2
3. Start the machine, and run at a high idle. 4. Release the brakes. 5. Observe the wheel/track movement. If the wheels/ tracks are not moving, please see the steps in the “Adjust the piston stops� section of this document. 6. If the wheels/tracks are moving, please continue with step 7. 7. Loosen the jam nut (1) on the faulty pump. NOTE: You do not need to remove the hydrostatic pumps for the following procedures; The hydrostatic pumps have been removed for picture clarity.
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8. Turn the adjustment screw (1) in one direction until the wheels/track begin to rotate. Record the position of the adjustment screw. 9. Turn the adjustment screw (1) in the opposite direction until the wheels/track begin to rotate. Record the position of the adjustment screw. 10. Repeat steps 8 and 9 to verify your records. 11. Center the adjustment screw based on your records. 12. Tighten the jam nut.
RAPH12SSL0443AA
3
931001814
4
RAPH12SSL0450AA
5
13. Connect the inlet line (1).
14. Calibrate the joysticks and ground drive, using the EST. 15. Test drive the machine. If the machine steers in either direction more than 1.8 m (6 ft) from the centerline after traveling 30.5 m (100 ft) forward or 15.2 m (50 ft) backward, please see the steps in the “Adjust the piston stops� section of this document.
Adjust the piston stops If the machine steers in either direction more than 1.8 m (6 ft) from the centerline after traveling 30.5 m (100 ft) forward or 15.2 m (50 ft) backward, the piston stops (1) for one of the hydrostatic pumps may be out of adjustment, which is causing one pump to travel faster or slower than the other pump.
1. Test drive the machine. Observe which direction the machine travels. 2. Shut off the machine.
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3. To adjust the speed of the drive motor, you will need to do the following: • Determine which drive motor is traveling faster. • Locate the hydrostatic pump associated with the faster drive motor. • Locate the two piston stop screws (2) on the faulty pump. NOTE: The piston stop screws may be covered. Remove the covers by gently tapping on the covers. • Locate the forward and reverse solenoids on the faulty pump. • If the machine incorrectly travels forward, loosen the jam nut (1) and adjust the piston stop screw (2) located near the reverse solenoid. If the machine incorrectly travels backward, loosen the jam nut (1) and adjust the piston stop screw (2) located near the forward solenoid. NOTE: To limit speed, turn the piston stop screw in. To gain speed, turn the piston stop screw out. 4. Tighten the jam nut (1). 5. Test drive the machine. Repeat steps 1 through 4 until machine travels correctly at the desired speed.
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RAPH12SSL0443AA
6
Index Hydrostatic drive - 29 Pump and motor components - 218 Control valve - Component localization (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
19
Motor - Assemble - Single speed drive motor (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
87
Motor - Assemble - Two speed drive motor (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
104
Motor - Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
128
Motor - Disassemble - Single speed drive motor (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
78
Motor - Disassemble - Two speed drive motor (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
96
Motor - Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
114
Motor - Drain fluid (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
112
Motor - Dynamic description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20
Motor - Dynamic description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
21
Motor - Filling (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
142
Motor - General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
14
Motor - General specification - Single speed motor (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
14
Motor - General specification - Two-speed motor (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
16
Motor - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
143
Motor - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
147
Motor - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
74
Motor - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
113
Motor valves - Component localization (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
18
Motor valves - General specification - Electro-Hydraulic (EH) drive - Two speed (*) . . . . . . . . . . . . .
9
Motor valves - General specification - Electro-Hydraulic (EH) drive - Two speed (*) . . . . . . . . . . . . .
11
Motor valves - General specification - Mechanical drive - Single speed (*) . . . . . . . . . . . . . . . . . . . . .
12
Motor valves - General specification - Mechanical drive - Two speed (*) . . . . . . . . . . . . . . . . . . . . . . .
9
Motor valves - General specification - Mechanical drive - Two speed (*) . . . . . . . . . . . . . . . . . . . . . . .
10
Motor valves - Install - Brake, Electro-Hydraulic (EH) option, 2-speed option . . . . . . . . . . . . . . . . . . .
73
Motor valves - Remove - Brake, Electro-Hydraulic (EH) option, 2-speed option . . . . . . . . . . . . . . . . .
72
Pump - Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
46
Pump - Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
31
Pump - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
17
Pump - General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4
Pump - General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6
Pump - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
67
Pump - Measure - Piston travel (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
45
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Pump - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
62
Pump - Test (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
28
Pump - Torque (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5
Pump Charge pressure relief valve - Pressure test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
22
Pump Charge pressure relief valve - Torque (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5
Pump Charge pressure relief valve - Torque (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7
Pump Pressure limiter valve - Pressure test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
25
Pump Pressure limiter valve - Torque (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7
Servo control - Adjust (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
149
Servo control - Adjust (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
153
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Hydrostatic drive - 29 Hydrostatic transmission - 202
SR210 TIER 4B (FINAL) [NGM418237 - ], SR210 TIER 4B (FINAL) [NHM435463 - ], SR240 TIER 4B (FINAL) [NGM418237 - ], SR240 TIER 4B (FINAL) [NHM435463 - ], SV280 TIER 4B (FINAL) [NGM418237 - ], SV280 TIER 4B (FINAL) [NHM435463 - ], TR270 TIER 4B (FINAL) [NGM418237 - ], TR270 TIER 4B (FINAL) [NHM435463 - ], TR310 TIER 4B (FINAL) [NGM418237 - ], TR310 TIER 4B (FINAL) [NHM435463 - ], TV370 TIER 4B (FINAL) [NHM435463 - ]
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Contents Hydrostatic drive - 29 Hydrostatic transmission - 202
FUNCTIONAL DATA Hydrostatic transmission Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SERVICE Hydrostatic transmission Decontaminating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
DIAGNOSTIC Hydrostatic transmission Troubleshooting (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Troubleshooting (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
(*) See content for specific models 48068130 29/01/2018
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Hydrostatic drive - Hydrostatic transmission
Hydrostatic transmission - Dynamic description In a closed loop, hydrostatic transmission, the engine provides power to a pump that sends hydraulic oil to the drive motors. Each hydrostatic pump drives a corresponding drive motor. The drive motor turns a pair of chains by use of a dual sprocket, and the two chains turn the front and rear axles. In a hydrostatic, closed loop system, the hydrostatic pump and the drive motor are directly connected; the hydrostatic pump sends oil to the drive motor and the drive motor returns the oil back to the hydrostatic pump.
RAPH14SSL0013AA
1
Basic, hydrostatic, closed loop system Hydrostatic system components (1) Hydrostatic pump (2) Charge relief valve
(3) Drive motor (4) Pressure limiter valve
(5) Check valve (6) Charge pump
Because of the high pressures required to move the machine, some of the oil in the hydrostatic, closed loop system leaks into the case drain and flushing valve of the components. This lost oil must be resupplied to keep the closed loop system working as designed. A charge pump (6) is used to supply this lost oil. Located on the hydrostatic pump assembly (1), the charge pump (6) supplies cooled, filtered oil from the reservoir to the closed loop system. When the machine is traveling, the drive side of the closed loop has pressures too high to allow flow from the charge pump (6), but the return side of the closed loop has pressures similar to the charge pump’s pressure. The return side of the closed loop is where filtered oil will enter into the closed loop from the charge pump (6). Charge pump oil also enters the closed loop when the machine is in neutral, because pressure inside the closed loop while in neutral is less-than-or-equal-to the charge pump’s pressure. To prevent closed loop oil from escaping back into the charge side of the system, a check valve (5) is placed between the supply of charge pump oil and each side of the closed loop. While the machine is traveling, the load on the drive motor (3) can increase which causes the pressure in the closed loop to become excessive. A pressure limiter valve (4) is installed on each side of the closed loop to limit the maximum pressure. These pressure limiter valves (4) are nonadjustable and operate in only one direction.
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Hydrostatic drive - Hydrostatic transmission
Hydrostatic transmission - Decontaminating Any contamination in the hydrostatic system will stay in the closed loop. If the hydrostatic pump or a motor in the hydrostatic system is removed for repair or replacement, you must clean the hydrostatic system. If any contamination is left in the closed loop, the contamination will damage the remaining components of the hydrostatic system. 1. Remove the hydrostatic pump(s) and motor(s) from the circuit that has failed. If there is a quantity of contamination present, removal of the opposite pump and motor is also required. 2. Clean and inspect the interior and exterior of the hydrostatic pump(s) and motor(s). 3. Clean the hoses and tubes in the hydrostatic system by flushing the hoses and tubes with hot, soapy water. Hang the hoses and tubes and allow them to air dry. Hoses and tubes must be dry before installing. 4. Drain the hydraulic oil from the tank, and inspect for contamination. Replace the hydraulic oil if necessary.
83115762
1
5. Change the hydraulic oil filter. 6. Install the portable filter caddy, part number CAS10162A, and follow the manufacture’s directions. NOTE: The oil cooler has internal passages that can trap and hold contamination, which can be dislodged at a later time causing a repeated failure. Replacement of the oil cooler is necessary if the contamination of the hydraulic oil is significant.
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Hydrostatic drive - Hydrostatic transmission
Hydrostatic transmission - Troubleshooting SR210 SR240 SV280
Problem Possible Cause The machine steers more Throttle speed. than 1.8 m (6 ft) from the centerline after traveling 30.5 m (100 ft) forward or 15.2 m (50 ft) backward Tire(s). Joysticks are not calibrated correctly.
A hose is bent, kinked, or clogged. The parking brake is not releasing.
Correction The machine is designed to operate at high idle.
1. Check the pressures of the tires. 2. Inspect the tires for damage. 1. For electro hydraulic (EH) machines, calibrate the joysticks by using the electronic service tool (EST). 2. For mechanical controlled machines, inspect the linkage between the joysticks and the hydrostatic pumps. Please see Mechanical control - Adjust (29.200) . Inspect the hoses between the hydrostatic pumps, the motors, and the brake valve. 1. Inspect the hoses. 2. Check the charge pressure. Please see Pump Charge pressure relief valve Pressure test (29.218). 3. Check the operation of the solenoid at the brake valve.
4. Inspect the brakes inside the motor(s) for damage. The drive chain is worn. Inspect the drive chain. Please see Chain drive - Check (25.450). The axle bearings are worn. Inspect the axle bearings for looseness and damage. The hydrostatic pump(s) need adjustment. 1. Inspect the pressure limiter valves. Please see Pump Pressure limiter valve - Pressure test (29.218). 2. Adjust the servo(s) inside the pump(s). Please see Servo control - Adjust (29.218) . The hydrostatic drive components are 1. Inspect the motor(s). damaged. 2. Inspect the hydrostatic pump(s).
Hydrostatic transmission - Troubleshooting TR270 TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
Problem Possible Cause The machine steers more Throttle speed. than 1.8 m (6 ft) from the centerline after traveling 30.5 m (100 ft) forward or 15.2 m (50 ft) backward
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Correction The machine is designed to properly operate at high throttle.
Hydrostatic drive - Hydrostatic transmission
Problem
Possible Cause Track(s).
Correction 1. Inspect the tension of the track(s). Please see Rubber track - Tension adjust (48.100). 2. Inspect the track(s) for damage.
Joysticks are not calibrated correctly.
A hose is bent, kinked, or clogged. The parking brake is not releasing.
3. Inspect the track frame(s) and track frame components for damage. 1. For electro hydraulic (EH) machines, calibrate the joysticks by using the electronic service tool (EST). 2. For mechanical controlled machines, inspect the linkage between the joysticks and the hydrostatic pumps. Please see Mechanical control - Adjust - Machines with only hand controls (29.200). Inspect the hoses between the hydrostatic pumps, the motors, and the brake valve. 1. Inspect the hoses. 2. Check the charge pressure. Please see Pump Charge pressure relief valve Pressure test (29.218). 3. Check the operation of the solenoid at the brake valve.
4. Inspect the brakes inside the motor(s) for damage. The hydrostatic pump(s) need adjustment. 1. Inspect the pressure limiter valves. Please see Pump Pressure limiter valve - Pressure test (29.218). 2. Adjust the servo(s) inside the pump(s). Please see Servo control - Adjust (29.218). The hydrostatic drive components are 1. Inspect the motor. damaged. 2. Inspect the hydrostatic pump(s).
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Index Hydrostatic drive - 29 Hydrostatic transmission - 202 Hydrostatic transmission - Decontaminating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4
Hydrostatic transmission - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3
Hydrostatic transmission - Troubleshooting (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5
Hydrostatic transmission - Troubleshooting (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5
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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. Š 2018 CNH Industrial America LLC. All rights reserved. No part of the text or illustrations of this publication may be reproduced.
CNH Industrial America LLC reserves the right to make improvements in design and changes in specifications at any time without notice and without incurring any obligation to install them on units previously sold. Specifications, descriptions, and illustrative material herein are as accurate as known at the time of publication, but are subject to change without notice. Availability of some models and equipment builds varies according to the country in which the equipment is being used. For exact information about any particular product, please consult your CASE CONSTRUCTION dealer. CASE CONSTRUCTION is a trademark registered in the United States and many other countries, owned or licensed to CNH Industrial N.V., its subsidiaries or affiliates. Any trademarks referred to herein, in association with goods and/or services of companies, other than owned by or licensed to CNH Industrial N.V., its subsidiaries or affiliates, are the property of those respective companies.
48068130 29/01/2018 EN
SERVICE MANUAL Brakes and controls SR210 TIER 4B (FINAL) [NGM418237 - ], SR210 TIER 4B (FINAL) [NHM435463 - ], SR240 TIER 4B (FINAL) [NGM418237 - ], SR240 TIER 4B (FINAL) [NHM435463 - ], SV280 TIER 4B (FINAL) [NGM418237 - ], SV280 TIER 4B (FINAL) [NHM435463 - ], TR270 TIER 4B (FINAL) [NGM418237 - ], TR270 TIER 4B (FINAL) [NHM435463 - ], TR310 TIER 4B (FINAL) [NGM418237 - ], TR310 TIER 4B (FINAL) [NHM435463 - ], TV370 TIER 4B (FINAL) [NHM435463 - ]
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Contents Brakes and controls - 33
[33.110] Parking brake or parking lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33.1
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33
Brakes and controls - 33 Parking brake or parking lock - 110
SR210 TIER 4B (FINAL) [NGM418237 - ], SR210 TIER 4B (FINAL) [NHM435463 - ], SR240 TIER 4B (FINAL) [NGM418237 - ], SR240 TIER 4B (FINAL) [NHM435463 - ], SV280 TIER 4B (FINAL) [NGM418237 - ], SV280 TIER 4B (FINAL) [NHM435463 - ], TR270 TIER 4B (FINAL) [NGM418237 - ], TR270 TIER 4B (FINAL) [NHM435463 - ], TR310 TIER 4B (FINAL) [NGM418237 - ], TR310 TIER 4B (FINAL) [NHM435463 - ], TV370 TIER 4B (FINAL) [NHM435463 - ]
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Contents Brakes and controls - 33 Parking brake or parking lock - 110
TECHNICAL DATA Parking brake control valve or manifold General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Control valve - General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Control valve - General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Control valve - General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Control valve - General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
FUNCTIONAL DATA Parking brake control valve or manifold Component localization (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Component localization (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
SERVICE Parking brake control valve or manifold Motor valves - Remove - Brake, Electro-Hydraulic (EH) option, 2-speed option . . . . . . . . . . . . . . . . . . . . 11 Motor valves - Install - Brake, Electro-Hydraulic (EH) option, 2-speed option . . . . . . . . . . . . . . . . . . . . . . 12
(*) See content for specific models 48068130 29/01/2018
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Brakes and controls - Parking brake or parking lock
Parking brake control valve or manifold - General specification SR210 SR240 SV280
(Mechanical hydraulic controls) (Mechanical hydraulic controls) (Mechanical hydraulic controls)
RAPH13SSL0966EA
1
Brake valve Hydraulic requirements: Port identification
Charge pressure = 24 – 25.5 bar (350 – 370 psi) Brake release pressure = 15 bar (218 psi) P - Supply inlet T - Tank return B1 - Brake motor 1 B2 - Brake motor 2
Parking brake control valve or manifold - General specification SR210 SR240 SV280
(Electro hydraulic controls) (Electro hydraulic controls) (Electro hydraulic controls)
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Brakes and controls - Parking brake or parking lock
RAPH13SSL0965EA
1
Electrohydraulic (EH), brake valve Hydraulic requirements Port identification
Charge pressure = 24 – 25.5 bar (350 – 370 psi) Brake release pressure = 15 bar (218 psi) P - Supply inlet T - Tank return B1 - Brake motor 1 B2 - Brake motor 2 LV - EH pilot pressure PS2 - Brake pressure switch
Control valve - General specification SR210 SR240 SV280
(Mechanical hydraulic controls) (Mechanical hydraulic controls) (Mechanical hydraulic controls)
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Brakes and controls - Parking brake or parking lock
RAPH13SSL0967EA
1
Brake, two speed valve Hydraulic requirements: Sequence valve setting Filter rating Port identification
Charge pressure = 24 – 25.5 bar (350 – 370 psi) Brake release pressure = 15 bar (218 psi) 12 bar (174 psi) 40 – 50 microns P - Supply inlet T - Tank return 2SPD - Two speed shift B1 - Brake motor 1 B2 - Brake motor 2 PS2 - Brake pressure switch
Control valve - General specification SR210 SR240 SV280
(Electro hydraulic controls) (Electro hydraulic controls) (Electro hydraulic controls)
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Brakes and controls - Parking brake or parking lock
RAPH14SSL0006FA
1
Loader pilot interlock, brake, two speed valve Hydraulic requirements Sequence valve setting Filter rating Port identification
Charge pressure = 24 – 25.5 bar (350 – 370 psi) Brake release pressure = 15 bar (218 psi) 12 bar (174 psi) 40 – 50 microns P - Supply inlet T - Tank return 2SPD - Two speed shift B1 - Brake motor 1 B2 - Brake motor 2 LV - Electrohydraulic pilot pressure PS2 - Brake pressure switch
Control valve - General specification TR270 TR310 TV370 TIER 4B (FINAL) [NHM435463 - ]
(Mechanical hydraulic controls) (Mechanical hydraulic controls) (Mechanical hydraulic controls)
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Brakes and controls - Parking brake or parking lock
RAPH14SSL0011FA
1
Brake, two speed valve Hydraulic requirements: Port identification
Charge pressure = 24 – 25.5 bar (350 – 370 psi) Brake release pressure = 15 bar (218 psi) P - Supply inlet T - Tank return 2SPD - Two speed shift B1 - Brake motor 1 B2 - Brake motor 2
Control valve - General specification TR270 TR310 TV370 TIER 4B (FINAL) [NHM435463 - ]
(Electro hydraulic controls) (Electro hydraulic controls) (Electro hydraulic controls)
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Brakes and controls - Parking brake or parking lock
RAPH12SSL0381EA
1
Loader pilot interlock, brake, two speed valve Hydraulic requirements Port identification
Charge pressure = 24 – 25.5 bar (350 – 370 psi) Brake release pressure = 15 bar (218 psi) P - Supply inlet T - Tank return 2SPD - Two speed shift B1 - Brake motor 1 B2 - Brake motor 2 LV - Electrohydraulic pilot pressure PS2 - Brake pressure switch
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Brakes and controls - Parking brake or parking lock
Parking brake control valve or manifold - Component localization SR210 SR210 SR240 SR240 TR270
TIER TIER TIER TIER
4B 4B 4B 4B
(FINAL) (FINAL) (FINAL) (FINAL)
[NGM418237 - ] [NHM435463 - ] [NGM418237 - ] [NHM435463 - ]
RAPH13SSL0863FA
1
Valve location Valve identification (1) Ride control valve
(3) Loader pilot interlock, brake, two speed valve (2) Hydraulic coupler valve (4) Second auxiliary valve
(5) High flow valve (6) Override valve for the loader arm
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(7) Self-leveling valve
Brakes and controls - Parking brake or parking lock
Parking brake control valve or manifold - Component localization SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
RAIL13SSL1004FA
1
Valve location Valve identification (1) Ride control valve
(3) Loader pilot interlock, brake, two speed valve (2) Hydraulic coupler valve (4) Second auxiliary valve
(5) Accumulator (6) High flow valve
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(7) Self level valve
Brakes and controls - Parking brake or parking lock
Motor valves - Remove - Brake, Electro-Hydraulic (EH) option, 2-speed option Prior operation: Tilt the cab to gain access, see Cab tilting system - Tilt (90.150) for the proper procedure. Prior operation: Tilt the cab to gain access, see Cab tilting system - Tilt (90.150) for the proper procedure. 1. Disconnect the electrical connectors (1) from the solenoids on the valve block (A). NOTE: The valve block shown in Figure 1 has Electro-Hydraulic (EH) drive and the 2–speed option. Your specific machine may not look the same, it is dependant upon the configuration.
RAIL17SSL0163BA
1
RAIL17SSL0163BA
2
RAIL17SSL0164BA
3
2. Remove the tubes and hoses (2) from the fittings on the valve block (A).
3. Remove the bolts (1) that secure the valve block (A) to the left-hand side of the chassis and remove the valve.
Next operation: Motor valves - Install - Brake, Electro-Hydraulic (EH) option, 2-speed option (29.218)
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Brakes and controls - Parking brake or parking lock
Motor valves - Install - Brake, Electro-Hydraulic (EH) option, 2-speed option Prior operation: Motor valves - Remove - Brake, Electro-Hydraulic (EH) option, 2-speed option (29.218) 1. Install the valve (A) to the chassis cage nuts on the left-hand side of the chassis. Secure the valve to the chassis with the bolts (A). NOTE: The valve block shown in Figure 1 has Electro-Hydraulic (EH) drive and the 2–speed option. Your specific machine may not look the same, it is dependant upon the configuration.
RAIL17SSL0164BA
1
RAIL17SSL0163BA
2
RAIL17SSL0163BA
3
2. Connect the tubes and hoses (2) to the fittings on the valve block (A). NOTE: See Torque - Standard torque data for hydraulics () for proper torque to the fittings and connections.
3. Connect the electrical connectors (1) to the solenoids on the valve block (A).
Next operation: Lower the cab, see Cab tilting system - Lower (90.150) for the proper procedure. Next operation: Lower the cab, see Cab tilting system - Lower (90.150) for the proper procedure.
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Index Brakes and controls - 33 Parking brake or parking lock - 110 Control valve - General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4
Control valve - General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5
Control valve - General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6
Control valve - General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7
Motor valves - Install - Brake, Electro-Hydraulic (EH) option, 2-speed option . . . . . . . . . . . . . . . . . . .
12
Motor valves - Remove - Brake, Electro-Hydraulic (EH) option, 2-speed option . . . . . . . . . . . . . . . . .
11
Parking brake control valve or manifold - Component localization (*) . . . . . . . . . . . . . . . . . . . . . . . . . .
9
Parking brake control valve or manifold - Component localization (*) . . . . . . . . . . . . . . . . . . . . . . . . . .
10
Parking brake control valve or manifold - General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3
Parking brake control valve or manifold - General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3
(*) See content for specific models 48068130 29/01/2018
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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. Š 2018 CNH Industrial America LLC. All rights reserved. No part of the text or illustrations of this publication may be reproduced.
CNH Industrial America LLC reserves the right to make improvements in design and changes in specifications at any time without notice and without incurring any obligation to install them on units previously sold. Specifications, descriptions, and illustrative material herein are as accurate as known at the time of publication, but are subject to change without notice. Availability of some models and equipment builds varies according to the country in which the equipment is being used. For exact information about any particular product, please consult your CASE CONSTRUCTION dealer. CASE CONSTRUCTION is a trademark registered in the United States and many other countries, owned or licensed to CNH Industrial N.V., its subsidiaries or affiliates. Any trademarks referred to herein, in association with goods and/or services of companies, other than owned by or licensed to CNH Industrial N.V., its subsidiaries or affiliates, are the property of those respective companies.
48068130 29/01/2018 EN
SERVICE MANUAL Hydraulic systems SR210 TIER 4B (FINAL) [NGM418237 - ], SR210 TIER 4B (FINAL) [NHM435463 - ], SR240 TIER 4B (FINAL) [NGM418237 - ], SR240 TIER 4B (FINAL) [NHM435463 - ], SV280 TIER 4B (FINAL) [NGM418237 - ], SV280 TIER 4B (FINAL) [NHM435463 - ], TR270 TIER 4B (FINAL) [NGM418237 - ], TR270 TIER 4B (FINAL) [NHM435463 - ], TR310 TIER 4B (FINAL) [NGM418237 - ], TR310 TIER 4B (FINAL) [NHM435463 - ], TV370 TIER 4B (FINAL) [NHM435463 - ]
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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 [35.359] Main control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.4 [35.525] Auxiliary hydraulic valves and lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.5 [35.600] High flow hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.6 [35.724] Front loader hydraulic system control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.7 [35.701] Front loader arm hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.8 [35.723] Front loader bucket hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.9 [35.734] Tool quick coupler hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.10
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Hydraulic systems - 35 Hydraulic systems - 000
SR210 TIER 4B (FINAL) [NGM418237 - ], SR210 TIER 4B (FINAL) [NHM435463 - ], SR240 TIER 4B (FINAL) [NGM418237 - ], SR240 TIER 4B (FINAL) [NHM435463 - ], SV280 TIER 4B (FINAL) [NGM418237 - ], SV280 TIER 4B (FINAL) [NHM435463 - ], TR270 TIER 4B (FINAL) [NGM418237 - ], TR270 TIER 4B (FINAL) [NHM435463 - ], TR310 TIER 4B (FINAL) [NGM418237 - ], TR310 TIER 4B (FINAL) [NHM435463 - ], TV370 TIER 4B (FINAL) [NHM435463 - ]
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Contents Hydraulic systems - 35 Hydraulic systems - 000
FUNCTIONAL DATA Hydraulic systems Component localization (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Component localization (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Hydraulic schematic frame 01 - Single-speed and two-speed mechanical valve assembly (*) . . . . . . . . . 6 Hydraulic schematic frame 02 - Single-speed and Two-speed Electro-Hydraulic (EH) valve assembly (*) 8 Hydraulic schematic frame 03 - Single-speed and Two-speed mechanical drive (pump and motor) assembly (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Hydraulic schematic frame 04 - Single-speed and Two-speed Electro-Hydraulic (EH) drive (pump and motor) assembly (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Hydraulic schematic frame 01 - Mechanical valve assembly (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Hydraulic schematic frame 02 - Electro-Hydraulic (EH) valve assembly (*) . . . . . . . . . . . . . . . . . . . . . . . . 16 Hydraulic schematic frame 03 - Single-speed and Two-speed mechanical drive (pump and motor) assembly (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Hydraulic schematic frame 04 - Two-speed Electro-Hydraulic (EH) track drive (pump and motor) assembly (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Hydraulic schematic frame 03 - Two-speed Electro-Hydraulic (EH) drive and mechanical drive (pump and motor) assembly (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
SERVICE Hydraulic systems Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Depressurising . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Decontaminating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Test - All hydraulic pressure and flow tests (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Check - Hydraulic test data collection form (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 Test - All hydraulic pressure and flow tests (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 Check - Hydraulic test data collection form (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
(*) See content for specific models 48068130 29/01/2018
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Hydraulic systems - Hydraulic systems
Hydraulic systems - Component localization SR210 SR210 SR240 SR240 TR270
TIER TIER TIER TIER
4B 4B 4B 4B
(FINAL) (FINAL) (FINAL) (FINAL)
[NGM418237 - ] [NHM435463 - ] [NGM418237 - ] [NHM435463 - ]
RAPH13SSL0863FA
1
Valve location Valve identification (1) Ride control valve
(3) Loader pilot interlock, brake, two speed valve (2) Hydraulic coupler valve (4) Second auxiliary valve
(5) High flow valve (6) Override valve for the loader arm
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(7) Self-leveling valve
Hydraulic systems - Hydraulic systems
Hydraulic systems - Component localization SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
RAIL13SSL1004FA
1
Valve location Valve identification (1) Ride control valve
(3) Loader pilot interlock, brake, two speed valve (2) Hydraulic coupler valve (4) Second auxiliary valve
(5) Accumulator (6) High flow valve
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(7) Self level valve
Hydraulic systems - Hydraulic systems
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Hydraulic systems - Hydraulic schematic frame 01 - Single-speed and two-speed mechanical valve assembly SR210 TR270 TR310
(Mechanical hydraulic controls) (Mechanical hydraulic controls) (Mechanical hydraulic controls)
Component Call-out reference Check valve (1) Hydraulic coupler valve (if applicable) (2) Ride control valve (if applicable) (3) Self level valve (if applicable) (4) Auxiliary coupler (5) Main control valve (loader valve) (6) Secondary auxiliary valve (if applicable) (7) High flow valve (if applicable) (8) Hydraulic oil filter (9) Hydraulic oil cooler with 5.2 bar (75.0 psi) bypass (10)* NOTE: *Reference (10) does not contain the 5.2 bar (75.0 psi) bypass on the small-frame models (SR130,SR150,SR160).
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RAIL17SSL0369JA
1
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Hydraulic systems - Hydraulic schematic frame 02 - Single-speed and Two-speed Electro-Hydraulic (EH) valve assembly SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] TR270 TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ]
(Electro (Electro (Electro (Electro (Electro
hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls)
Component Call-out reference Check valve (1) Hydraulic coupler valve (if applicable) (2) Ride control valve (if applicable) (3) Self level valve (if applicable) (4) Auxiliary coupler (5) Main control valve (loader valve) (6) Secondary auxiliary valve (if applicable) (7) High flow valve (if applicable) (8) Hydraulic oil filter (9) Hydraulic oil cooler with 5.2 bar (75.0 psi) bypass (10*) NOTE: *Reference (10) does not contain the 5.2 bar (75.0 psi) bypass on the small-frame models (SR130,SR150,SR160).
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RAIL17SSL0370JA
1
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Hydraulic systems - Hydraulic schematic frame 03 - Single-speed and Two-speed mechanical drive (pump and motor) assembly SR210
(Mechanical hydraulic controls)
Component Right-hand drive motor Left-hand drive motor Brake valve Two-speed/brake valve Hydrostatic pump assembly
Call-out reference (1) (2) (3) (4) (5)
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RAIL17SSL0377JA
1
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Hydraulic systems - Hydraulic schematic frame 04 - Single-speed and Two-speed Electro-Hydraulic (EH) drive (pump and motor) assembly SR210
(Electro hydraulic controls)
Component Right-hand drive motor Left-hand drive motor Brake valve Brake/two-speed valve Hydrostatic pump assembly
Call-out reference (1) (2) (3) (4) (5)
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RAIL17SSL0371JA
1
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Hydraulic systems - Hydraulic schematic frame 01 - Mechanical valve assembly SR240 SV280 TV370 TIER 4B (FINAL) [NHM435463 - ]
(Mechanical hydraulic controls) (Mechanical hydraulic controls) (Mechanical hydraulic controls)
Component Check valve Hydraulic coupler valve (if applicable) Ride control valve (if applicable) Self-leveling valve (if applicable) Auxiliary coupler Main control valve (Loader valve) Secondary auxiliary valve (if applicable) High flow valve (if applicable) Hydraulic oil filter Hydraulic oil cooler
Call-out reference (1) (2) (3) (4) (5) (6) (7) (8) (9) (10)
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RAIL17SSL0372JA
1
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Hydraulic systems - Hydraulic schematic frame 02 - Electro-Hydraulic (EH) valve assembly SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Electro (Electro (Electro (Electro (Electro
Component Check valve Hydraulic coupler valve (if applicable) Ride control valve (if applicable) Self-leveling valve (if applicable) Auxiliary coupler Main control valve (Loader valve) Secondary auxiliary valve (if applicable) High flow valve (if applicable) Hydraulic oil filter Hydraulic oil cooler
Call-out reference (1) (2) (3) (4) (5) (6) (7) (8) (9) (10)
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hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls)
Hydraulic systems - Hydraulic systems
RAIL17SSL0375JA
1
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Hydraulic systems - Hydraulic schematic frame 03 - Single-speed and Two-speed mechanical drive (pump and motor) assembly SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ]
(Mechanical (Mechanical (Mechanical (Mechanical
Component Right-hand drive motor Left-hand drive motor Brake valve Two-speed/brake valve Hydrostatic pump assembly
Call-out reference (1) (2) (3) (4) (5)
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hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls)
Hydraulic systems - Hydraulic systems
RAIL17SSL0378JA
1
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Hydraulic systems - Hydraulic systems
Hydraulic systems - Hydraulic schematic frame 04 - Two-speed Electro-Hydraulic (EH) track drive (pump and motor) assembly TR270 TR310 TV370
(Electro hydraulic controls) (Electro hydraulic controls) (Electro hydraulic controls)
Component Left-hand drive motor Right-hand drive motor Electro hydraulic/two-speed/brake valve Hydrostatic pump assembly
Call-out reference (1) (2) (3) (4)
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RAIL17SSL0373JA
1
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Hydraulic systems - Hydraulic schematic frame 03 - Two-speed Electro-Hydraulic (EH) drive and mechanical drive (pump and motor) assembly TR270 TR310 TV370
Component Right-hand drive motor Left-hand drive motor Two-speed/brake valve Electro-hydraulic (EH)/two-speed/brake valve Hydrostatic pump assembly
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Call-out reference (1) (2) (3) (4) (5)
Hydraulic systems - Hydraulic systems
RAIL17SSL0374JA
1
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Hydraulic systems - Cleaning 1. Prepare the portable filter CAS10162A by doing the following steps: (A) Remove all the hydraulic oil from the inlet and outlet hoses for the portable filter. (B) Remove the filter element from the portable filter. (C) Remove all hydraulic oil from the portable filter. (D) Clean the inside of the housing for the filter element. (E) Install a new filter element in the portable filter. 2. Determine whether the contamination is microscopic or visible. 3. If the contamination is microscopic: (A) Check the maintenance schedule for the machine to learn if the hydraulic oil must be changed. If necessary, change the hydraulic oil. Change the hydraulic filter. (B) Do steps 6 through 37. 4. If the contamination is visible, do the following steps: (A) Change the hydraulic oil and hydraulic filter. (B) Do steps 5 through 37. 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 severe contamination and is not the result of normal wear, it is necessary to remove, clean and repair all valves, pumps, lines, cylinders, hydraulic reservoir, etc. in the hydraulic system. 6. Remove the cap from the reservoir and install the adapter CAS1871 on the reservoir. 7. Connect the vacuum pump CAS10192 to the adapter CAS1871. Oil reservoir - Apply vacuum (35.300)
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8. Start the vacuum pump. 9. The hydraulic reservoir is located at the rear of the machine. Loosen and remove the drain plug from the reservoir. 10. Using the fitting kit CAS10508, install the valve in the hole for the drain plug. Make sure that the valve is closed. 11. Stop the vacuum pump. 12. Connect the inlet hose for the portable filter to the valve that is installed in the hole for the drain plug. 13. Disconnect the vacuum pump and remove CAS1871 adapter from reservoir. 14. Install the outlet hose for the portable filter in the hydraulic reservoir filler neck. 15. Open the valve that is installed in the hole for the drain plug. (A) Check fluid level in reservoir. Add if necessary. 16. Move the switch for the portable filter to the ON position. 17. Start and run the engine at half throttle. 18. Run the portable filter for 10 minutes with the engine running at half throttle. 19. Continue to run the portable filter. Increase the engine speed to full throttle. Do the following to heat the oil to operating temperature: (A) Increase the engine speed to full throttle. (B) Hold the bucket control lever in the ROLLBACK position for five seconds. (C) Return the bucket control lever in the NEUTRAL position for five seconds. (D) Repeat steps 19B and 19C until the oil is at operating temperature; 49 – 66 °C (120 – 150 °F). 20. With the engine running at full throttle and the portable filter running, completely extend and retract the lift cylinders and the bucket cylinders. Continue to operate the cylinders, one after the other for 30 minutes. NOTE: If the filter light in the machine illuminates, stop the engine, change the filter, then continue with procedure. 21. Decrease the engine speed to low idle. 22. Continue to run the portable filter for 10 minutes. During this time, move the hose up and down to help mix the oil in the reservoir. 23. Stop the portable filter. 24. Stop the engine. 25. Remove the hose from the hydraulic reservoir. 26. Oil reservoir - Apply vacuum (35.300) 27. Close the valve that is installed in the hole for the drain plug. 28. Disconnect the inlet hose for the portable filter from the valve. 29. Start the vacuum pump. 48068130 29/01/2018
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30. Remove the valve from the hole for the drain plug. 31. Install and tighten the drain plug. 32. Stop the vacuum pump. 33. Disconnect the vacuum pump from the opening in the reservoir. 34. Install new hydraulic filter elements on the machine. 35. Start the engine. Check for oil leakage around the new hydraulic filter. 36. Stop the engine. 37. Check the level of the oil in the reservoir and add oil as required. Oil reservoir - Filling (35.300)
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Hydraulic systems - Depressurising Before removing components from the hydraulic system, depressurize the hydraulic circuits.
Hydraulic cylinders Loader arm cylinders 1.
Support the loader arm with suitable lifting equipment.
2.
Shut OFF the engine.
Hydraulic coupler 1.
Remove the bucket or attachment from the mounting plate.
2.
Leave the hydraulic coupler in the unlocked position.
20092924
1
93109392
2
Pumps and motors Hydrostatic drive pumps, fixed displacement pumps, and motors 1. Shut OFF the engine.
Ride Control™ 1. Ride control system 1.
Raise and secure the loader arm. Please see Cab tilting system - Tilt (90.150) for details about securing the loader arm.
2.
Shut OFF the engine.
3.
Turn the machine ON but do not start the engine.
4.
Press the ride control button (1) while pulling up on the override valve.
Auxiliary and High Flow (HF) 2. For attachments connected to standard auxiliary or standard high flow: • All units are equipped with the “connect under pressure” manifold that bleeds pressure from the circuit during the connect or the disconnect.
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Enhanced High Flow (EHF) 3. For attachments connected to Enhanced High Flow (EHF) aux: • EHF attachments should all be motor driven which will automatically bleed the pressure off when the engine is turned OFF.
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Hydraulic systems - Decontaminating 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. Failure to comply could result in death or serious injury. W0230A
1. Start and run the engine at 1500 RPM (r/min). 2. To depressurize the lift base end of the loader arm, pull the loader boom down valve. 3. To depressurize the tilt rod end, roll the coupler back, then when the handle is moved to dump pressure on the tilt base end, the pressure will be reduced on the rod end. NOTE: This process must be done while the engine is running. Once the engine is off, charge pressure is reduced which closes the port lock valve on the loader valve not allowing the pressure in the cylinders to be relieved. 4. Stop the engine. 5. Depress the auxiliary hydraulic interlock override button, and leave the seat within 30 s. Move each control lever in both directions to release pressure in the hydraulic circuits. 6. Loosen and remove the filler cap from the reservoir. 7. Drain the hydraulic oil from the reservoir. (A) Have available acceptable equipment to drain the hydraulic oil. (B) Remove the drain plug from the bottom of the reservoir. 8. Remove the hydraulic filter element from the machine. 9. Install new hydraulic filter element on the machine. 10. Install the drain plug in the bottom of the reservoir. 11. Fill the hydraulic reservoir. Oil reservoir - Filling (35.300) 12. Disconnect the line from the ROD end and BARREL end of each cylinder. 13. Be sure all control levers are in the NEUTRAL position. 14. Start and run the engine at low idle. NOTICE: Check the oil level in the hydraulic reservoir frequently while doing step 13. Have another person hold a container under the hydraulic lines while you do step 13. 15. Slowly move the control lever for each bucket and lift cylinders in both directions until oil begins to flow from the open line. Hold the control lever in place until clean oil flows from the open line. 16. Stop the engine. 17. Connect the system line to the BARREL end of each cylinder. 48068130 29/01/2018
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18. Connect a suitable drain line to the ROD end of each cylinder and place the other end in an acceptable container for contaminated oil. 19. Start the engine and run the engine at low idle. 20. Slowly and completely extend all cylinders. As the piston rod comes in/out of the cylinder, oil will be pushed out of the ROD end of the cylinders. NOTICE: Any attachment or part of an attachment that is raised must be supported with acceptable equipment to prevent the attachment from falling. 21. Support any attachments that will be in the RAISED position. 22. Stop the engine. 23. Disconnect the drain lines and connect the system lines to the cylinders. 24. Check the oil level in the hydraulic reservoir. Add oil as required. 25. Install the filler cap on the reservoir. 26. Remove the hydraulic filter element from the machine. 27. Install a new hydraulic filter element on the machine. 28. Start and run the engine at 1500 RPM, operate each hydraulic circuit to completely extend and retract the cylinders. 29. Stop the engine and check for leaks. Check the oil level in the hydraulic reservoir. Add oil as required. Oil reservoir - Filling (35.300)
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Hydraulic systems - Test - All hydraulic pressure and flow tests SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TV370 TIER 4B (FINAL) [NHM435463 - ]
See Hydraulic systems - Check - Hydraulic test data collection form (35.000) for data collection form to record test results.
RAPH16SSL0231QA
1
Test 1: Pump efficiency test using the standard auxiliary couplers NOTE: Hydraulic oil temperature should be a minimum of 52 °C (125 °F) before attempting any tests on the hydraulic system. NOTE: Two persons are required to perform the flow meter tests to safely avoid possible injury. One person must be seated in the operators seat when the engine is running. The second person is to control the flow meter and take the readings. 1. Attach the flow meter, part number 380500047, to the auxiliary couplers on the loader arm. NOTE: Verify that the flow inlet and outlet direction is correct on the flow meter.
RAPH12SSL0241AA
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2. Start the machine and run at full throttle. 3. Adjust the machine’s RPM to 2500 RPM. 4. Record the set RPM on the data collection sheet Hydraulic systems - Check - Hydraulic test data collection form (35.000).
931007504
3
RAPH12SSL0242AA
4
RAPH12SSL0243AA
5
Test 1A: Pump flow with no restriction 5. Verify that the flow meter has no restriction on the hydraulic pump. Record the pump flow on the data collection sheet. Please see Fixed displacement pump - General specification (35.104) for specification about the gear pumps. NOTE: A flow reading of 92.3 L/min (24.4 US gpm) is expected. NOTE: Image 4 is an example of a flow reading. Image 4 may not match your reading.
Test 1B: Pump flow with restriction 6. Adjust the flow meter pressure until 152 bar (2200 psi) is achieved. Verify that the machine is running at the set RPM recorded on the data collection sheet. Adjust RPM if necessary. Record the pump flow on the data collection sheet. NOTE: Image 3 is an example of a flow reading. Image 3 may not match your reading.
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Test 1C: Pump efficiency 7. Pump efficiency is determined by dividing the pump flow with restriction value (Test 1B) by the pump flow without restriction value (Test 1A), then multiplying that new value by 100. Record the pump efficiency on the data collection sheet. NOTE: Pump efficiency should be no less than 70%.
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Test 2: Pump efficiency test using the High Flow auxiliary couplers (If equipped) NOTE: Hydraulic oil temperature should be a minimum of 52 °C (125 °F) before attempting any tests on the hydraulic system. NOTE: Two persons are required to perform the flow meter tests to safely avoid possible injury. One person must be seated in the operators seat when the engine is running. The second person is to control the flow meter and take the readings. 1. Attach the flow meter, part number 380500047, to the high flow auxiliary couplers on the loader arm as shown by the arrows. NOTE: Verify that the flow inlet and outlet direction is correct on the flow meter.
RAPH12SSL0241AA
6
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2. Start the machine and run at full throttle. 3. Adjust the machine’s RPM to 2500 RPM. 4. Record the set RPM on the data collection sheet Hydraulic systems - Check - Hydraulic test data collection form (35.000).
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Test 2A: Pump flow with no restriction 5. Verify that the flow meter has no restriction on the hydraulic pump. Record the pump flow on the data collection sheet. Please see Fixed displacement pump - General specification (35.104) for specification about the gear pumps. NOTE: A flow reading of 141.0 L/min (37.3 US gpm) is expected. NOTE: Image 8 is an example of a flow reading. Image 8 may not match your reading.
RAPH12SSL0242AA
8
RAPH12SSL0243AA
9
Test 2B: Pump flow with restriction 6. Adjust the flow meter pressure until 152 bar (2200 psi) is achieved. Verify that the machine is running at the set RPM recorded on the data collection sheet. Adjust the RPM if necessary. Record the pump flow on the data collection sheet. NOTE: Image 9 is an example of a flow reading. Image 9 may not match your reading.
Test 2C: Pump efficiency 7. Pump efficiency is determined by dividing the pump flow with restriction value (Test 2B) by the pump flow without restriction value (Test 2A), then multiplying that new value by 100. Record the pump efficiency on the data collection sheet. NOTE: Pump efficiency should be no less than 70%.
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Test 3: Pump efficiency test using the T fitting method NOTE: Hydraulic oil temperature should be a minimum of 52 °C (125 °F) before attempting any tests on the hydraulic system. NOTE: To avoid possible injury, two people are required to perform the following test . One person must be seated in the operator’s seat while the engine is running and the hydraulic controls are enabled. The second person is to control the flow meter and record the readings on the flow meter. 1. Locate the main control valve. 2. Install the T fitting (1) into the pump outlet, and attach the inlet hose (2) for the flow meter, part number 380500047, to the T fitting. NOTE: Verify that the flow direction is correct on the flow meter.
RAPH12SSL0246AA
10
RAPH12SSL0247AA
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931007504
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3. Place the outlet hose (1) for the flow meter with hose adapter in the hydraulic tank. NOTE: Verify that the flow direction is correct on the flow meter.
4. Start the machine and run the engine at high idle. Adjust the machine’s RPM to 2500 RPM. Record the set RPM on the data collection sheet.
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Test 3A: Pump flow with no restriction 5. Verify that the flow meter has no restriction on the hydraulic pump. Record the pump flow on the data collection sheet. Please see Fixed displacement pump - General specification (35.104) for specification about the gear pumps. NOTE: A flow reading of 92.3 L/min (24.4 US gpm) is expected. NOTE: Image 13 is an example of a flow reading. Image 13 may not match your reading.
RAPH12SSL0242AA
13
RAPH12SSL0243AA
14
Test 3B: Pump flow with restriction 6. Adjust the flow meter pressure until 152 bar (2200 psi) is achieved. Verify that the machine is running at the set RPM recorded on the data collection sheet located on the following page. Adjust the RPM if necessary. Record the pump flow on the data collection sheet. NOTE: Image 14 is an example of a flow reading. Image 14 may not match your reading.
Test 3C: Pump efficiency 7. Pump efficiency is determined by dividing the pump flow with restriction value (Test 3B) by the pump flow without restriction value (Test 3A), then multiplying that new value by 100. Record the pump efficiency on the data collection sheet. NOTE: Pump efficiency should be no less than 70%.
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Test 4: Efficiency test using the T fitting method with High Flow auxiliary hydraulics engaged (If equipped) NOTE: Hydraulic oil temperature should be a minimum of 52 °C (125 °F) before attempting any tests on the hydraulic system. NOTE: Two persons are required to perform the flow meter tests to safely avoid possible injury. One person must be seated in the operators seat when the engine is running. The second person is to control the flow meter and take the readings. 1. Locate the main control valve. 2. Install the T fitting (1) into the pump outlet, and attach the flow meter (2) hose to the T fitting. NOTE: Verify that the flow inlet direction is correct on the flow meter.
RAPH12SSL0246AA
15
RAPH12SSL0247AA
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3. Place the other flow meter hose (1) with hose adapter in the hydraulic tank. NOTE: Verify that the flow outlet direction is correct on the flow meter.
4. Start the machine and run at high idle. Adjust the machine’s RPM to 2500 RPM. Record the set RPM on the data collection sheet.
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5. Select High Flow ( HF) on the rocker switch (1) and activate the auxiliary couplers.
RCPH11SSL003AAD
18
RAPH12SSL0242AA
19
RAPH12SSL0243AA
20
Test 4A: Pump flow with no restriction 6. Verify that the flow meter has no restriction on the pump. Record the pump flow on the data collection sheet. Please see Fixed displacement pump - General specification (35.104) for specification about the gear pumps. NOTE: A flow reading of 141.0 L/min (37.3 US gpm) is expected. NOTE: Image 19 is an example of a flow reading. Image 19 may not match your reading.
Test 4B: Pump flow with restriction 7. Adjust the flow meter pressure until 152 bar (2200 psi) is achieved. Verify that the machine is running at the set RPM recorded on the data collection sheet. Adjust the RPM if necessary. Record the pump flow on the data collection sheet. NOTE: Image 20 is an example of a flow reading. Image 20 may not match your reading.
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Test 4C: Pump efficiency 8. Pump efficiency is determined by dividing the pump flow with restriction value (Test 4B) by the pump flow without restriction value (Test 4A), then multiplying that new value by 100. Record the pump efficiency on the data collection sheet located on the following page. NOTE: Pump efficiency should be no less than 70%.
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Test 5: Main control valve - circuit leakage test NOTE: Hydraulic oil temperature should be a minimum of 52 °C (125 °F) before attempting any tests on the hydraulic system. NOTE: Two persons are required to perform the flow meter tests to safely avoid possible injury. One person must be seated in the operators seat when the engine is running. The second person is to control the flow meter and take the readings. 1. Locate the main control valve. 2. Install the “T” fitting (1) into the hydraulic gear pump outlet, and attach the flow meter, part number 380500047, (2) hose to the “T” fitting. NOTE: Verify that the flow inlet direction is correct on the flow meter.
RAPH12SSL0246AA
21
RAPH12SSL0247AA
22
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3. Place the other flow meter hose (1) with hose adapter in the hydraulic tank. NOTE: Verify that the flow outlet direction is correct on the flow meter.
4. Start the machine and run at 2500 RPM.
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5. Adjust the flow meter pressure until 124 bar (1800 psi) is achieved. While watching the flow meter liter per minute (l/min) gauge or gallon per minute (gpm) gauge, stroke each loader arm and bucket function to the end of cylinder travel on the machine, and activate the primary auxiliary couplers in both directions. Record the pump flow on the data collection sheet Hydraulic systems - Check - Hydraulic test data collection form (35.000). Compare the flow of every stroked function. Differences in the pump flow indicate internal leaks and/or easier paths to tank. NOTE: Pump flow should be within 4 l/min (1 US gpm) of pump specification. A flow reading of 88.3 – 92.3 L/min (23.3 – 24.4 US gpm) is expected. NOTE: Image 24 is an example of a flow reading. Image 24 may not match your reading.
RAPH12SSL0329AA
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24
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Test 6: Main control valve pressure test using the T fitting method NOTE: Hydraulic oil temperature should be a minimum of 52 °C (125 °F) before attempting any tests on the hydraulic system. NOTE: Two persons are required to perform the flow meter tests to safely avoid possible injury. One person must be seated in the operators seat when the engine is running. The second person is to control the flow meter and take the readings. 1. Locate the main control valve. 2. Install the T fitting (1) into the hydraulic gear pump outlet, and attach the flow meter, part number 380500047, (2) hose to the T fitting. NOTE: Verify that the flow inlet direction is correct on the flow meter.
RAPH12SSL0246AA
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RAPH12SSL0247AA
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3. Place the other flow meter hose (1) with hose adapter in the hydraulic tank. NOTE: Verify that the flow outlet direction is correct on the flow meter.
4. Start the machine and run at high idle.
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Test 6A: Main relief pressure 5. Stroke a bucket function to the end of the cylinder travel on the machine, and maintain the bucket in that position; this will put a load on the machine.
BS06H186AA
28
RAPH12SSL0244AA
29
BS06H186AA
30
6. Slowly turn the pressure screw on the flow meter while watching the flow meter pressure gauge and liter per minute (l/min) gauge or gallon per minute (gpm) gauge. Pump flow will remain relatively constant until the main relief pressure is achieved. At the point of pressure relief, pump flow will significantly drop below pump specification on the flow meter. Record the main relief pressure on the data collection sheet. Main relief pressure setting of 207.0 – 217.0 bar (3001.5 – 3146.5 psi) is expected. NOTE: Image 29 is an example of a flow reading. Image 29 may not match your reading.
7. Release the stroked bucket function. 8. Reset the flow meter.
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Test 6B: Cracking pressure 9. Stroke a bucket function to the end of the cylinder travel on the machine, and maintain the bucket in that position; this will put a load on the machine.
BS06H186AA
31
RAPH12SSL0329AA
32
BS06H186AA
33
10. Slowly turn the pressure screw on the flow meter while watching the flow meter pressure gauge and liter per minute (l/min) gauge or gallon per minute (gpm) gauge. Pump flow will remain relatively constant until the cracking pressure is achieved. At the point of cracking pressure, pump flow will drop approximately 11 l/min (3 US gpm). Record the cracking pressure on the data collection sheet. NOTE: Cracking pressure should be within 15% of the main relief pressure.
11. Release the stroked bucket function. 12. Reset the flow meter.
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Test 7: Main control valve pressure test using the auxiliary couplers NOTE: Hydraulic oil temperature should be a minimum of 52 °C (125 °F) before attempting any tests on the hydraulic system. NOTE: Two persons are required to perform the flow meter tests to safely avoid possible injury. One person must be seated in the operators seat when the engine is running. The second person is to control the flow meter and take the readings. 1. Attach the flow meter, part number 380500047, to the auxiliary couplers on the loader arm. NOTE: Verify that the flow inlet and outlet direction is correct on the flow meter.
RAPH12SSL0241AA
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2. Start the machine and run at high idle.
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Test 7A: Main relief pressure 3. Start the machine, activate the hydraulics, and activate the auxiliary function in one direction on the machine. Slowly turn the pressure screw on the flow meter while watching the flow meter pressure gauge and liter per minute (l/min) gauge or gallon per minute (gpm) gauge. Pump flow will remain relatively constant until the main relief pressure is achieved. At the point of pressure relief, pump flow will significantly drop below pump specification on the flow meter. Record the main relief pressure on the data collection sheet. Main relief pressure setting of 207.0 – 217.0 bar (3001.5 – 3146.5 psi) is expected. NOTE: Image 36 is an example of a flow reading. Image 36 may not match your reading.
RAPH12SSL0244AA
36
RAPH12SSL0329AA
37
4. Release the auxiliary switch. Reset the flow meter.
Test 7B: Cracking pressure 5. Activate the auxiliary function in one direction on the machine. Slowly turn the pressure screw on the flow meter while watching the flow meter pressure gauge and liter per minute (l/min) gauge or gallon per minute (gpm) gauge. Pump flow will remain relatively constant until the cracking pressure is achieved. At the point of cracking pressure, pump flow will drop approximately 11 l/min (3 US gpm). Record the cracking pressure on the data collection sheet. NOTE: Cracking pressure should be within 15% of the main relief pressure. 6. Release the auxiliary switch. Reset the flow meter.
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Test 8: Testing for circuit leakage in auxiliary hydraulic valves and lines NOTE: Hydraulic oil temperature should be a minimum of 52 °C (125 °F) before attempting any tests on the hydraulic system. NOTE: To avoid possible injury, two people are required to perform the following test . One person must be seated in the operator’s seat while the engine is running and the hydraulic controls are enabled. The second person is to control the flow meter and record the readings on the flow meter. 1. Locate the fixed displacement pump(s). 2. Install the T fitting into the fixed displacement pump outlet (1), and attach the inlet hose for flow meter, part number 380500047, to the T fitting. NOTE: Verify that the flow direction is correct on the flow meter.
931001956
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3. Place the outlet hose for the flow meter (1) with hose adapter in the hydraulic tank. NOTE: Verify that the flow direction is correct on the flow meter.
4. Start the machine and run the engine at 2500 RPM.
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5. Adjust the flow meter pressure until 124 bar (1800 psi) is achieved. While watching the flow meter liter per minute (l/min) gauge or gallon per minute (gpm) gauge, activate the auxiliary couplers in both directions. Record the pump flow on the data collection sheet located on the following page. Compare the flow of every auxiliary function. Differences in pump flow indicate internal leaks and/or easier paths to tank. NOTE: Pump flow should be within 4 l/min (1 US gpm) of pump specification. A flow reading of 88.3 – 92.3 L/min (23.3 – 24.4 US gpm) is expected. NOTE: Image 41 is an example of a flow reading. Image 41 may not match your reading.
RAPH12SSL0329AA
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Test 9: High Flow pilot valve pressure test NOTE: Hydraulic oil temperature should be a minimum of 52 °C (125 °F) before attempting any tests on the hydraulic system. 1. Connect a 345 bar (5000 psi) pressure gauge, part number 380500129, to the high flow, outlet auxiliary coupler. NOTE: Verify flow direction for accurate reading and machine safety.
93106839B
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BS06H186AA
44
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2. Start the machine, and raise the engine speed to full throttle.
3. Engage the auxiliary hydraulics. 4. Stroke a bucket function to the end of the cylinder travel on the machine, and hold the bucket in that position using the joystick; This will put a load on the machine.
5. Select High Flow (HF) on the rocker switch (1).
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6. Record the pressure shown on the pressure gauge on the data collection sheet Hydraulic systems - Check - Hydraulic test data collection form (35.000). The expected relief valve setting is 224.0 bar (3250.0 psi). Please see Pilot valve - General specification (35.600) for specifications on the high flow pilot valve.
RAPH12SSL0448AA
46
BS06H186AA
47
931001689
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7. Release the stroked bucket function. 8. Disengage the auxiliary hydraulics.
9. If the recorded pressure is not within specification, remove the cap (1) on the relief valve and adjust.
10. Repeat steps 2 through 9 until the relief valve is within specification.
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Hydraulic systems - Check - Hydraulic test data collection form SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TV370 TIER 4B (FINAL) [NHM435463 - ]
See Hydraulic systems - Test - All hydraulic pressure and flow tests (35.000) for the corresponding hydraulic pressure and flow tests. Test 1: Pump efficiency test using the Standard auxiliary couplers Engine RPM - Set RPM (~ 2500 RPM)
__________RPM
Notes: Test 1A: Pump flow - Pump flow without restriction
__________l/min __________gpm
Notes: Test 1B: Pump flow with restriction - Pump flow with 152 bar (2200 psi) restriction
__________l/min __________gpm
Notes: Test 1C: Pump efficiency - Calculated pump efficiency NOTE: Calculated pump efficiency is determined by dividing Test 1B’s value by Test 1A’s value, then multiplying that new value by 100.
__________%
Notes: Test 2: Pump efficiency test using the High Flow auxiliary couplers (If equipped) Engine RPM - Set RPM (~ 2500 RPM)
__________RPM
Notes: Test 2A: Pump flow - Pump flow without restriction
__________l/min __________gpm
Notes: Test 2B: Pump flow with restriction - Pump flow with 152 bar (2200 psi) restriction
__________l/min __________gpm
Notes: Test 2C: Pump efficiency - Calculated pump efficiency
__________% 48068130 29/01/2018
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NOTE: Calculated pump efficiency is determined by dividing Test 2B’s value by Test 2A’s value, then multiplying that new value by 100. Notes:
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Test 3: Pump efficiency test using the T fitting method Engine RPM - Set RPM (~ 2500 RPM)
__________RPM
Notes: Test 3A: Pump flow - Pump flow without restriction
__________l/min __________gpm
Notes: Test 3B: Pump flow with restriction - Pump flow with 152 bar (2200 psi) restriction
__________l/min __________gpm
Notes: Test 3C: Pump efficiency - Calculated pump efficiency NOTE: Calculated pump efficiency is determined by dividing Test 3B’s value by Test 3A’s value, then multiplying that new value by 100.
__________%
Notes: Test 4: Efficiency test using the T fitting method with High Flow auxiliary hydraulics engaged (If equipped) Engine RPM - Set RPM (~ 2500 RPM)
__________RPM
Notes: Test 4A: Pump flow - Pump flow at without restriction
__________l/min __________gpm
Notes: Test 4B: Pump flow with restriction - Pump flow with 152 bar (2200 psi) restriction
__________l/min __________gpm
Notes: Test 4C: Pump efficiency - Calculated pump efficiency NOTE: Calculated pump efficiency is determined by dividing Test 4B’s value by Test 4A’s value, then multiplying that new value by 100.
__________%
Notes:
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Test 5: Main control valve - Circuit leakage with restriction NOTE: For “T� fitting test only - Bucket rollback
__________l/min __________gpm
- Bucket dump
__________l/min __________gpm
- Loader raise
__________l/min __________gpm
- Loader lower
__________l/min __________gpm
- Auxiliary up
__________l/min __________gpm
- Auxiliary down
__________l/min __________gpm
Notes: Test 6: Main relief valve pressure test using the T fitting method - Test 6A: Main pressure relief
__________bar __________psi
- Test 6B: Cracking pressure ( 15% of main relief)
__________bar __________psi
Notes: Test 7: Main relief valve pressure test using the auxiliary couplers - Test 7A: Main pressure relief
__________bar __________psi
- Test 7B: Cracking pressure ( 15% of main relief)
__________bar __________psi
Notes: Test 8: Testing for circuit leakage in auxiliary hydraulic valves and lines NOTE: For T fitting test only - Standard auxiliary up
__________l/min __________gpm
- Standard auxiliary down
__________l/min __________gpm
- Secondary auxiliary up (if applicable)
__________l/min __________gpm
- Secondary auxiliary down (if applicable)
__________l/min __________gpm
Notes: Test 9: High Flow pilot valve pressure test - Initial pressure reading (expected relief valve setting is 224.0 bar (3250.0 psi))
__________bar __________psi
- Adjusted pressure reading
__________bar __________psi
Notes:
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Hydraulic systems - Test - All hydraulic pressure and flow tests SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ]
See Hydraulic systems - Check - Hydraulic test data collection form (35.000) for data collection form to record test results.
RAPH16SSL0231QA
1
Test 1: Pump efficiency test using the standard auxiliary couplers NOTE: Hydraulic oil temperature should be a minimum of 52 °C (125 °F) before attempting any tests on the hydraulic system. NOTE: Two persons are required to perform the flow meter tests to safely avoid possible injury. One person must be seated in the operators seat when the engine is running. The second person is to control the flow meter and take the readings. 1. Attach the flow meter, part number 380500047, to the auxiliary couplers on the loader arm. NOTE: Verify that the flow inlet and outlet direction is correct on the flow meter.
RAPH12SSL0241AA
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2. Start the machine and run at full throttle. 3. Adjust the machine’s RPM to 2475 RPM. 4. Record the set RPM on the data collection sheet Hydraulic systems - Check - Hydraulic test data collection form (35.000).
931007504
3
RAPH12SSL0242AA
4
RAPH12SSL0243AA
5
Test 1A: Pump flow with no restriction 5. Verify that the flow meter has no restriction on the hydraulic pump. Record the pump flow on the data collection sheet. Please see Fixed displacement pump - General specification (35.104) for specification about the gear pumps. NOTE: A flow reading of 92.3 L/min (24.4 US gpm) is expected. NOTE: Image 4 is an example of a flow reading. Image 4 may not match your reading.
Test 1B: Pump flow with restriction 6. Adjust the flow meter pressure until 152 bar (2200 psi) is achieved. Verify that the machine is running at the set RPM recorded on the data collection sheet. Adjust RPM if necessary. Record the pump flow on the data collection sheet. NOTE: Image 3 is an example of a flow reading. Image 3 may not match your reading.
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Test 1C: Pump efficiency 7. Pump efficiency is determined by dividing the pump flow with restriction value (Test 1B) by the pump flow without restriction value (Test 1A), then multiplying that new value by 100. Record the pump efficiency on the data collection sheet. NOTE: Pump efficiency should be no less than 70%.
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Test 2: Pump efficiency test using the High Flow auxiliary couplers (If equipped) NOTE: Hydraulic oil temperature should be a minimum of 52 °C (125 °F) before attempting any tests on the hydraulic system. NOTE: Two persons are required to perform the flow meter tests to safely avoid possible injury. One person must be seated in the operators seat when the engine is running. The second person is to control the flow meter and take the readings. 1. Attach the flow meter, part number 380500047, to the high flow auxiliary couplers on the loader arm as shown by the arrows. NOTE: Verify that the flow inlet and outlet direction is correct on the flow meter.
RAPH12SSL0241AA
6
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2. Start the machine and run at full throttle. 3. Adjust the machine’s RPM to 2475 RPM. 4. Record the set RPM on the data collection sheet Hydraulic systems - Check - Hydraulic test data collection form (35.000).
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Test 2A: Pump flow with no restriction 5. Verify that the flow meter has no restriction on the hydraulic pump. Record the pump flow on the data collection sheet. Please see Fixed displacement pump - General specification (35.104) for specification about the gear pumps. NOTE: A flow reading of 124.5 L/min (32.9 US gpm) is expected. NOTE: Image 8 is an example of a flow reading. Image 8 may not match your reading.
RAPH12SSL0242AA
8
RAPH12SSL0243AA
9
Test 2B: Pump flow with restriction 6. Adjust the flow meter pressure until 152 bar (2200 psi) is achieved. Verify that the machine is running at the set RPM recorded on the data collection sheet. Adjust the RPM if necessary. Record the pump flow on the data collection sheet. NOTE: Image 9 is an example of a flow reading. Image 9 may not match your reading.
Test 2C: Pump efficiency 7. Pump efficiency is determined by dividing the pump flow with restriction value (Test 2B) by the pump flow without restriction value (Test 2A), then multiplying that new value by 100. Record the pump efficiency on the data collection sheet. NOTE: Pump efficiency should be no less than 70%.
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Test 3: Pump efficiency test using the T fitting method NOTE: Hydraulic oil temperature should be a minimum of 52 °C (125 °F) before attempting any tests on the hydraulic system. NOTE: To avoid possible injury, two people are required to perform the following test . One person must be seated in the operator’s seat while the engine is running and the hydraulic controls are enabled. The second person is to control the flow meter and record the readings on the flow meter. 1. Locate the main control valve. 2. Install the T fitting (1) into the pump outlet, and attach the inlet hose (2) for the flow meter, part number 380500047, to the T fitting. NOTE: Verify that the flow direction is correct on the flow meter.
RAPH12SSL0246AA
10
RAPH12SSL0247AA
11
931007504
12
3. Place the outlet hose (1) for the flow meter with hose adapter in the hydraulic tank. NOTE: Verify that the flow direction is correct on the flow meter.
4. Start the machine and run the engine at high idle. Adjust the machine’s RPM to 2475 RPM. Record the set RPM on the data collection sheet.
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Test 3A: Pump flow with no restriction 5. Verify that the flow meter has no restriction on the hydraulic pump. Record the pump flow on the data collection sheet. Please see Fixed displacement pump - General specification (35.104) for specification about the gear pumps. NOTE: A flow reading of 92.3 L/min (24.4 US gpm) is expected. NOTE: Image 13 is an example of a flow reading. Image 13 may not match your reading.
RAPH12SSL0242AA
13
RAPH12SSL0243AA
14
Test 3B: Pump flow with restriction 6. Adjust the flow meter pressure until 152 bar (2200 psi) is achieved. Verify that the machine is running at the set RPM recorded on the data collection sheet located on the following page. Adjust the RPM if necessary. Record the pump flow on the data collection sheet. NOTE: Image 14 is an example of a flow reading. Image 14 may not match your reading.
Test 3C: Pump efficiency 7. Pump efficiency is determined by dividing the pump flow with restriction value (Test 3B) by the pump flow without restriction value (Test 3A), then multiplying that new value by 100. Record the pump efficiency on the data collection sheet. NOTE: Pump efficiency should be no less than 70%.
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Test 4: Efficiency test using the T fitting method with High Flow auxiliary hydraulics engaged (If equipped) NOTE: Hydraulic oil temperature should be a minimum of 52 °C (125 °F) before attempting any tests on the hydraulic system. NOTE: Two persons are required to perform the flow meter tests to safely avoid possible injury. One person must be seated in the operators seat when the engine is running. The second person is to control the flow meter and take the readings. 1. Locate the main control valve. 2. Install the T fitting (1) into the pump outlet, and attach the flow meter (2) hose to the T fitting. NOTE: Verify that the flow inlet direction is correct on the flow meter.
RAPH12SSL0246AA
15
RAPH12SSL0247AA
16
931007504
17
3. Place the other flow meter hose (1) with hose adapter in the hydraulic tank. NOTE: Verify that the flow outlet direction is correct on the flow meter.
4. Start the machine and run at high idle. Adjust the machine’s RPM to 2475 RPM. Record the set RPM on the data collection sheet.
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5. Select High Flow ( HF) on the rocker switch (1) and activate the auxiliary couplers.
RCPH11SSL003AAD
18
RAPH12SSL0242AA
19
RAPH12SSL0243AA
20
Test 4A: Pump flow with no restriction 6. Verify that the flow meter has no restriction on the pump. Record the pump flow on the data collection sheet. Please see Fixed displacement pump - General specification (35.104) for specification about the gear pumps. NOTE: A flow reading of 124.5 L/min (32.9 US gpm) is expected. NOTE: Image 19 is an example of a flow reading. Image 19 may not match your reading.
Test 4B: Pump flow with restriction 7. Adjust the flow meter pressure until 152 bar (2200 psi) is achieved. Verify that the machine is running at the set RPM recorded on the data collection sheet. Adjust the RPM if necessary. Record the pump flow on the data collection sheet. NOTE: Image 20 is an example of a flow reading. Image 20 may not match your reading.
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Test 4C: Pump efficiency 8. Pump efficiency is determined by dividing the pump flow with restriction value (Test 4B) by the pump flow without restriction value (Test 4A), then multiplying that new value by 100. Record the pump efficiency on the data collection sheet located on the following page. NOTE: Pump efficiency should be no less than 70%.
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Test 5: Main control valve - circuit leakage test NOTE: Hydraulic oil temperature should be a minimum of 52 °C (125 °F) before attempting any tests on the hydraulic system. NOTE: Two persons are required to perform the flow meter tests to safely avoid possible injury. One person must be seated in the operators seat when the engine is running. The second person is to control the flow meter and take the readings. 1. Locate the main control valve. 2. Install the “T” fitting (1) into the hydraulic gear pump outlet, and attach the flow meter, part number 380500047, (2) hose to the “T” fitting. NOTE: Verify that the flow inlet direction is correct on the flow meter.
RAPH12SSL0246AA
21
RAPH12SSL0247AA
22
931007504
23
3. Place the other flow meter hose (1) with hose adapter in the hydraulic tank. NOTE: Verify that the flow outlet direction is correct on the flow meter.
4. Start the machine and run at 2475 RPM.
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5. Adjust the flow meter pressure until 124 bar (1800 psi) is achieved. While watching the flow meter liter per minute (l/min) gauge or gallon per minute (gpm) gauge, stroke each loader arm and bucket function to the end of cylinder travel on the machine, and activate the primary auxiliary couplers in both directions. Record the pump flow on the data collection sheet Hydraulic systems - Check - Hydraulic test data collection form (35.000). Compare the flow of every stroked function. Differences in the pump flow indicate internal leaks and/or easier paths to tank. NOTE: Pump flow should be within 4 l/min (1 US gpm) of pump specification. A flow reading of 88.3 – 92.3 L/min (23.3 – 24.4 US gpm) is expected. NOTE: Image 24 is an example of a flow reading. Image 24 may not match your reading.
RAPH12SSL0329AA
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24
Hydraulic systems - Hydraulic systems
Test 6: Main control valve pressure test using the T fitting method NOTE: Hydraulic oil temperature should be a minimum of 52 °C (125 °F) before attempting any tests on the hydraulic system. NOTE: Two persons are required to perform the flow meter tests to safely avoid possible injury. One person must be seated in the operators seat when the engine is running. The second person is to control the flow meter and take the readings. 1. Locate the main control valve. 2. Install the T fitting (1) into the hydraulic gear pump outlet, and attach the flow meter, part number 380500047, (2) hose to the T fitting. NOTE: Verify that the flow inlet direction is correct on the flow meter.
RAPH12SSL0246AA
25
RAPH12SSL0247AA
26
931007504
27
3. Place the other flow meter hose (1) with hose adapter in the hydraulic tank. NOTE: Verify that the flow outlet direction is correct on the flow meter.
4. Start the machine and run at high idle.
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Test 6A: Main relief pressure 5. Stroke a bucket function to the end of the cylinder travel on the machine, and maintain the bucket in that position; this will put a load on the machine.
BS06H186AA
28
RAPH12SSL0244AA
29
BS06H186AA
30
6. Slowly turn the pressure screw on the flow meter while watching the flow meter pressure gauge and liter per minute (l/min) gauge or gallon per minute (gpm) gauge. Pump flow will remain relatively constant until the main relief pressure is achieved. At the point of pressure relief, pump flow will significantly drop below pump specification on the flow meter. Record the main relief pressure on the data collection sheet. Main relief pressure setting of 207.0 – 217.0 bar (3001.5 – 3146.5 psi) is expected. NOTE: Image 29 is an example of a flow reading. Image 29 may not match your reading.
7. Release the stroked bucket function. 8. Reset the flow meter.
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Test 6B: Cracking pressure 9. Stroke a bucket function to the end of the cylinder travel on the machine, and maintain the bucket in that position; this will put a load on the machine.
BS06H186AA
31
RAPH12SSL0329AA
32
BS06H186AA
33
10. Slowly turn the pressure screw on the flow meter while watching the flow meter pressure gauge and liter per minute (l/min) gauge or gallon per minute (gpm) gauge. Pump flow will remain relatively constant until the cracking pressure is achieved. At the point of cracking pressure, pump flow will drop approximately 11 l/min (3 US gpm). Record the cracking pressure on the data collection sheet. NOTE: Cracking pressure should be within 15% of the main relief pressure.
11. Release the stroked bucket function. 12. Reset the flow meter.
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Test 7: Main control valve pressure test using the auxiliary couplers NOTE: Hydraulic oil temperature should be a minimum of 52 °C (125 °F) before attempting any tests on the hydraulic system. NOTE: Two persons are required to perform the flow meter tests to safely avoid possible injury. One person must be seated in the operators seat when the engine is running. The second person is to control the flow meter and take the readings. 1. Attach the flow meter, part number 380500047, to the auxiliary couplers on the loader arm. NOTE: Verify that the flow inlet and outlet direction is correct on the flow meter.
RAPH12SSL0241AA
34
931007504
35
2. Start the machine and run at high idle.
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Test 7A: Main relief pressure 3. Start the machine, activate the hydraulics, and activate the auxiliary function in one direction on the machine. Slowly turn the pressure screw on the flow meter while watching the flow meter pressure gauge and liter per minute (l/min) gauge or gallon per minute (gpm) gauge. Pump flow will remain relatively constant until the main relief pressure is achieved. At the point of pressure relief, pump flow will significantly drop below pump specification on the flow meter. Record the main relief pressure on the data collection sheet. Main relief pressure setting of 207.0 – 217.0 bar (3001.5 – 3146.5 psi) is expected. NOTE: Image 36 is an example of a flow reading. Image 36 may not match your reading.
RAPH12SSL0244AA
36
RAPH12SSL0329AA
37
4. Release the auxiliary switch. Reset the flow meter.
Test 7B: Cracking pressure 5. Activate the auxiliary function in one direction on the machine. Slowly turn the pressure screw on the flow meter while watching the flow meter pressure gauge and liter per minute (l/min) gauge or gallon per minute (gpm) gauge. Pump flow will remain relatively constant until the cracking pressure is achieved. At the point of cracking pressure, pump flow will drop approximately 11 l/min (3 US gpm). Record the cracking pressure on the data collection sheet. NOTE: Cracking pressure should be within 15% of the main relief pressure. 6. Release the auxiliary switch. Reset the flow meter.
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Test 8: Testing for circuit leakage in auxiliary hydraulic valves and lines NOTE: Hydraulic oil temperature should be a minimum of 52 °C (125 °F) before attempting any tests on the hydraulic system. NOTE: To avoid possible injury, two people are required to perform the following test . One person must be seated in the operator’s seat while the engine is running and the hydraulic controls are enabled. The second person is to control the flow meter and record the readings on the flow meter. 1. Locate the fixed displacement pump(s). 2. Install the T fitting into the fixed displacement pump outlet (1), and attach the inlet hose for flow meter, part number 380500047, to the T fitting. NOTE: Verify that the flow direction is correct on the flow meter.
931001956
38
RAPH12SSL0247AA
39
931007504
40
3. Place the outlet hose for the flow meter (1) with hose adapter in the hydraulic tank. NOTE: Verify that the flow direction is correct on the flow meter.
4. Start the machine and run the engine at 2475 RPM.
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5. Adjust the flow meter pressure until 124 bar (1800 psi) is achieved. While watching the flow meter liter per minute (l/min) gauge or gallon per minute (gpm) gauge, activate the auxiliary couplers in both directions. Record the pump flow on the data collection sheet. Compare the flow of every auxiliary function. Differences in pump flow indicate internal leaks and/or easier paths to tank. NOTE: Pump flow should be within 4 l/min (1 US gpm) of pump specification. A flow reading of 88.3 – 92.3 L/min (23.3 – 24.4 US gpm) is expected. NOTE: Image 41 is an example of a flow reading. Image 41 may not match your reading.
RAPH12SSL0329AA
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41
Hydraulic systems - Hydraulic systems
Test 9: High Flow pilot valve pressure test NOTE: Hydraulic oil temperature should be a minimum of 52 °C (125 °F) before attempting any tests on the hydraulic system. 1. Connect a 345 bar (5000 psi) pressure gauge, part number 380500129, to the high flow, outlet auxiliary coupler. NOTE: Verify flow direction for accurate reading and machine safety.
93106839B
42
931007504
43
BS06H186AA
44
RCPH11SSL003AAD
45
2. Start the machine, and raise the engine speed to full throttle.
3. Engage the auxiliary hydraulics. 4. Stroke a bucket function to the end of the cylinder travel on the machine, and hold the bucket in that position using the joystick; This will put a load on the machine.
5. Select High Flow (HF) on the rocker switch (1).
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6. Record the pressure shown on the pressure gauge on the data collection sheet Hydraulic systems - Check - Hydraulic test data collection form (35.000). The expected relief valve setting is 224.0 bar (3250.0 psi). Please see Pilot valve - General specification (35.600) for specifications on the high flow pilot valve.
RAPH12SSL0448AA
46
BS06H186AA
47
931001689
48
7. Release the stroked bucket function. 8. Disengage the auxiliary hydraulics.
9. If the recorded pressure is not within specification, remove the cap (1) on the relief valve and adjust.
10. Repeat steps 2 through 9 until the relief valve is within specification.
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Hydraulic systems - Check - Hydraulic test data collection form SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ]
See Hydraulic systems - Test - All hydraulic pressure and flow tests (35.000) for the corresponding hydraulic pressure and flow tests. Test 1: Pump efficiency test using the Standard auxiliary couplers Engine RPM - Set RPM (~ 2475 RPM)
__________RPM
Notes: Test 1A: Pump flow - Pump flow without restriction
__________l/min __________gpm
Notes: Test 1B: Pump flow with restriction - Pump flow with 152 bar (2200 psi) restriction
__________l/min __________gpm
Notes: Test 1C: Pump efficiency - Calculated pump efficiency NOTE: Calculated pump efficiency is determined by dividing Test 1B’s value by Test 1A’s value, then multiplying that new value by 100.
__________%
Notes: Test 2: Pump efficiency test using the High Flow auxiliary couplers (If equipped) Engine RPM - Set RPM (~ 2475 RPM)
__________RPM
Notes: Test 2A: Pump flow - Pump flow without restriction
__________l/min __________gpm
Notes: Test 2B: Pump flow with restriction - Pump flow with 152 bar (2200 psi) restriction
__________l/min __________gpm
Notes: Test 2C: Pump efficiency - Calculated pump efficiency
__________% 48068130 29/01/2018
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NOTE: Calculated pump efficiency is determined by dividing Test 2B’s value by Test 2A’s value, then multiplying that new value by 100. Notes:
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Test 3: Pump efficiency test using the T fitting method Engine RPM - Set RPM (~ 2475 RPM)
__________RPM
Notes: Test 3A: Pump flow - Pump flow without restriction
__________l/min __________gpm
Notes: Test 3B: Pump flow with restriction - Pump flow with 152 bar (2200 psi) restriction
__________l/min __________gpm
Notes: Test 3C: Pump efficiency - Calculated pump efficiency NOTE: Calculated pump efficiency is determined by dividing Test 3B’s value by Test 3A’s value, then multiplying that new value by 100.
__________%
Notes: Test 4: Efficiency test using the T fitting method with High Flow auxiliary hydraulics engaged (If equipped) Engine RPM - Set RPM (~ 2475 RPM)
__________RPM
Notes: Test 4A: Pump flow - Pump flow at without restriction
__________l/min __________gpm
Notes: Test 4B: Pump flow with restriction - Pump flow with 152 bar (2200 psi) restriction
__________l/min __________gpm
Notes: Test 4C: Pump efficiency - Calculated pump efficiency NOTE: Calculated pump efficiency is determined by dividing Test 4B’s value by Test 4A’s value, then multiplying that new value by 100.
__________%
Notes:
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Test 5: Main control valve - Circuit leakage with restriction NOTE: For “T� fitting test only - Bucket rollback
__________l/min __________gpm
- Bucket dump
__________l/min __________gpm
- Loader raise
__________l/min __________gpm
- Loader lower
__________l/min __________gpm
- Auxiliary up
__________l/min __________gpm
- Auxiliary down
__________l/min __________gpm
Notes: Test 6: Main relief valve pressure test using the T fitting method - Test 6A: Main pressure relief
__________bar __________psi
- Test 6B: Cracking pressure ( 15% of main relief)
__________bar __________psi
Notes: Test 7: Main relief valve pressure test using the auxiliary couplers - Test 7A: Main pressure relief
__________bar __________psi
- Test 7B: Cracking pressure ( 15% of main relief)
__________bar __________psi
Notes: Test 8: Testing for circuit leakage in auxiliary hydraulic valves and lines NOTE: For T fitting test only - Standard auxiliary up
__________l/min __________gpm
- Standard auxiliary down
__________l/min __________gpm
- Secondary auxiliary up (if applicable)
__________l/min __________gpm
- Secondary auxiliary down (if applicable)
__________l/min __________gpm
Notes: Test 9: High Flow pilot valve pressure test - Initial pressure reading (expected relief valve setting is 224.0 bar (3250.0 psi))
__________bar __________psi
- Adjusted pressure reading
__________bar __________psi
Notes:
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Index Hydraulic systems - 35 Hydraulic systems - 000 Hydraulic systems - Hydraulic schematic frame 02 - Single-speed and Two-speed Electro-Hydraulic (EH) valve assembly (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8
Hydraulic systems - Hydraulic schematic frame 03 - Single-speed and Two-speed mechanical drive (pump and motor) assembly (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10
Hydraulic systems - Hydraulic schematic frame 04 - Single-speed and Two-speed Electro-Hydraulic (EH) drive (pump and motor) assembly (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12
Hydraulic systems - Hydraulic schematic frame 01 - Mechanical valve assembly (*) . . . . . . . . . . . . .
14
Hydraulic systems - Hydraulic schematic frame 02 - Electro-Hydraulic (EH) valve assembly (*) . . .
16
Hydraulic systems - Hydraulic schematic frame 03 - Single-speed and Two-speed mechanical drive (pump and motor) assembly (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
18
Hydraulic systems - Hydraulic schematic frame 04 - Two-speed Electro-Hydraulic (EH) track drive (pump and motor) assembly (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20
Hydraulic systems - Hydraulic schematic frame 03 - Two-speed Electro-Hydraulic (EH) drive and mechanical drive (pump and motor) assembly (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
22
Hydraulic systems - Check - Hydraulic test data collection form (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . .
53
Hydraulic systems - Check - Hydraulic test data collection form (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . .
78
Hydraulic systems - Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
25
Hydraulic systems - Component localization (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3
Hydraulic systems - Component localization (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4
Hydraulic systems - Decontaminating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
30
Hydraulic systems - Depressurising . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
28
Hydraulic systems - Hydraulic schematic frame 01 - Single-speed and two-speed mechanical valve assembly (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6
Hydraulic systems - Test - All hydraulic pressure and flow tests (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . .
32
Hydraulic systems - Test - All hydraulic pressure and flow tests (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . .
57
(*) See content for specific models 48068130 29/01/2018
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Hydraulic systems - 35 Reservoir, cooler, and filters - 300
SR210 TIER 4B (FINAL) [NGM418237 - ], SR210 TIER 4B (FINAL) [NHM435463 - ], SR240 TIER 4B (FINAL) [NGM418237 - ], SR240 TIER 4B (FINAL) [NHM435463 - ], SV280 TIER 4B (FINAL) [NGM418237 - ], SV280 TIER 4B (FINAL) [NHM435463 - ], TR270 TIER 4B (FINAL) [NGM418237 - ], TR270 TIER 4B (FINAL) [NHM435463 - ], TR310 TIER 4B (FINAL) [NGM418237 - ], TR310 TIER 4B (FINAL) [NHM435463 - ], TV370 TIER 4B (FINAL) [NHM435463 - ]
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Contents Hydraulic systems - 35 Reservoir, cooler, and filters - 300
SERVICE Oil reservoir Drain fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Apply vacuum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Oil cooler/Heat exchanger Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
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Oil reservoir - Drain fluid WARNING Chemical hazard! When handling fuel, lubricants, and other service chemicals, follow the manufacturer's instructions. Wear Personal Protective Equipment (PPE) as instructed. Do not smoke or use open flame. Collect fluids in proper containers. Obey all local and environmental regulations when disposing of chemicals. Failure to comply could result in death or serious injury. W0371A
Prior operation: Remove the battery. Please see Battery - Remove (55.302) NOTE: The drain plug for the hydraulic tank is located inside of the battery compartment. 1. Remove the filler cap on the hydraulic tank. 2. Place a container under the battery compartment. 3. Slowly remove the drain plug.
RAIL15SSL0099BA
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1
Hydraulic systems - Reservoir, cooler, and filters
Oil reservoir - Apply vacuum 1. Remove the cap from the hydraulic reservoir. 2. Install an adapter cap CAS1871 on the filler neck. 3. Connect the vacuum pump CAS10193 to the adapter. 4. Start the vacuum pump.
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Oil reservoir - Filling 1. Lower the loader lift arms to the ground and shut off the engine. 2. Clean the reservoir filler cap and the area around the filler cap with cleaning solvent. 3. Turn the filler cap 1/2 turn to relieve air pressure from the reservoir. Do not remove the filler cap from the reservoir until the pressure is relieved. 4. Remove the filler cap from the reservoir. 5. Add the correct oil to the reservoir until the proper oil level in the reservoir is established. Fill the reservoir until the oil level is at the midpoint of the sight gauge. Install the reservoir cap.
93107491
1
93106865
2
6. Start and run the engine and operate the hydraulics. Lower the loader lift arms to the ground. Stop the engine and check the oil level in the reservoir. Add oil as required.
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Hydraulic systems - Reservoir, cooler, and filters
Oil cooler/Heat exchanger - Remove Prior operation: Drain the hydraulic tank. Please see Oil reservoir - Drain fluid (35.300). Prior operation: Remove the radiator. Please see Radiator - Remove (10.400). 1. Label and disconnect oil cooler hydraulic lines (1) and cap the opened ports.
931001881
1
931001882
2
931001884
3
2. Remove oil cooler mounting hardware (1).
3. Remove oil cooler (1).
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Hydraulic systems - Reservoir, cooler, and filters
Oil cooler/Heat exchanger - Install 1. Place oil cooler (1) in proper mounting location.
931001884
1
931001882
2
931001881
3
2. Install oil cooler mounting hardware (1).
3. Connect oil cooler hydraulic lines (1) to correct ports.
Next operation: Add hydraulic oil. Please see Oil reservoir - Filling (35.300). Next operation: Install the radiator. Please see Radiator - Install (10.400).
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Index Hydraulic systems - 35 Reservoir, cooler, and filters - 300 Oil cooler/Heat exchanger - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7
Oil cooler/Heat exchanger - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6
Oil reservoir - Apply vacuum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4
Oil reservoir - Drain fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3
Oil reservoir - Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5
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Hydraulic systems - 35 Fixed displacement pump - 104
SR210 TIER 4B (FINAL) [NGM418237 - ], SR210 TIER 4B (FINAL) [NHM435463 - ], SR240 TIER 4B (FINAL) [NGM418237 - ], SR240 TIER 4B (FINAL) [NHM435463 - ], SV280 TIER 4B (FINAL) [NGM418237 - ], SV280 TIER 4B (FINAL) [NHM435463 - ], TR270 TIER 4B (FINAL) [NGM418237 - ], TR270 TIER 4B (FINAL) [NHM435463 - ], TR310 TIER 4B (FINAL) [NGM418237 - ], TR310 TIER 4B (FINAL) [NHM435463 - ], TV370 TIER 4B (FINAL) [NHM435463 - ]
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Contents Hydraulic systems - 35 Fixed displacement pump - 104
TECHNICAL DATA Fixed displacement pump General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SERVICE Fixed displacement pump Flow test - Auxiliary couplers - Video . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Flow test - T fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Preliminary test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
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Hydraulic systems - Fixed displacement pump
Fixed displacement pump - General specification SR240 SV280 TV370 TIER 4B (FINAL) [NHM435463 - ]
RAPH14SSL0002GA
1
Fixed displacement pump Type
Gear pump
Pump displacement
36.6 cm続 (2.23 in続)
Engine RPM
2500 RPM
Pump flow at RPM
92.3 l/min (24.4 US gpm)
High flow pump displacement (if applicable) 20.4 cm続 (1.2 in続) Combined pump flow at RPM (if applicable) 142.3 L/min (37.6 US gpm)
Fixed displacement pump - General specification SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ]
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Hydraulic systems - Fixed displacement pump
RAPH14SSL0002GA
1
Fixed displacement pump Type
Gear pump
Pump displacement
36.6 cm続 (2.23 in続)
Engine RPM
2475 RPM
Pump flow at RPM
92.3 l/min (24.4 US gpm)
High flow pump displacement (if applicable) 13.7 cm続 (0.84 in続) Combined pump flow at RPM (if applicable) 124.5 L/min (32.9 US gpm)
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Hydraulic systems - Fixed displacement pump
Fixed displacement pump - Flow test - Auxiliary couplers - Video CAUTION Burn hazard! Do not handle any service fluid (engine coolant, engine oil, hydraulic oil, etc.) at temperatures that exceed 49 °C (120 °F). Allow fluids to cool before proceeding. Failure to comply could result in minor or moderate injury. C0107B
Pump efficiency test using the auxiliary couplers NOTE: Hydraulic oil temperature should be a minimum of 52 °C (125 °F) before attempting any tests on the hydraulic system. NOTE: Two persons are required to perform the flow meter tests to safely avoid possible injury. One person must be seated in the operators seat when the engine is running. The second person is to control the flow meter and take the readings. 1. The attached YouTube™ video demonstrates how to test pump efficiency through the auxiliary couplers of the machine. NOTE: The readings may be different from your particular machine, refer to your machine’s specifications for analysis.
RAPH16SSL0231QA
1
2. Attach the flow meter, part number 380500047, to the auxiliary couplers on the loader arm. NOTE: Verify that the flow inlet and outlet direction is correct on the flow meter.
RAPH12SSL0241AA
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2
Hydraulic systems - Fixed displacement pump
3. Start the machine and run at full throttle. 4. Adjust the machine’s RPM to 200 RPM less than the full throttle RPM. 5. Record the set RPM on the data collection sheet located on the following page.
931007504
3
RAPH12SSL0242AA
4
RAPH12SSL0243AA
5
Pump flow with no restriction 6. Verify that the flow meter has no restriction on the hydraulic pump. Record the pump flow on the data collection sheet located on the following page. Please see Fixed displacement pump - General specification (35.104) for specification about the gear pumps. NOTE: Image 4 is an example of a flow reading. Image 4 may not match your reading.
Pump flow with restriction 7. Adjust the flow meter pressure until 152 bar (2200 psi) is achieved. Verify that the machine is running at the set RPM recorded on the data collection sheet located on the following page. Adjust RPM if necessary. Record the pump flow on the data collection sheet located on the following page. Please see Fixed displacement pump - General specification (35.104) for specification about the gear pumps. NOTE: Image 3 is an example of a flow reading. Image 3 may not match your reading.
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Hydraulic systems - Fixed displacement pump
Pump efficiency 8. Pump efficiency is determined by dividing the pump flow with restriction value by the pump flow without restriction value, then multiplying that new value by 100. Record the pump efficiency on the data collection sheet located on the following page. NOTE: Pump efficiency should be no less than 70%.
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Hydraulic systems - Fixed displacement pump
Engine RPM - Set RPM
__________RPM
Notes: Test 1: Pump flow - Pump flow at without restriction
__________l/min __________gpm
Notes: Test 2: Pump flow with restriction - Pump flow with 152 bar (2200 psi) restriction
__________l/min __________gpm
Notes: Test 3: Pump efficiency - Calculated pump efficiency __________% NOTE: Calculated pump efficiency is determined by dividing Test 2’s value by Test 1’s value, then multiplying that new value by 100. Notes:
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Hydraulic systems - Fixed displacement pump
Fixed displacement pump - Flow test - T fitting CAUTION Burn hazard! Do not handle any service fluid (engine coolant, engine oil, hydraulic oil, etc.) at temperatures that exceed 49 °C (120 °F). Allow fluids to cool before proceeding. Failure to comply could result in minor or moderate injury. C0107B
Pump efficiency test using the T fitting method NOTE: Hydraulic oil temperature should be a minimum of 52 °C (125 °F) before attempting any tests on the hydraulic system. NOTE: To avoid possible injury, two people are required to perform the following test . One person must be seated in the operator’s seat while the engine is running and the hydraulic controls are enabled. The second person is to control the flow meter and record the readings on the flow meter. 1. Locate the main control valve. 2. Install the T fitting (1) into the pump outlet, and attach the inlet hose (2) for the flow meter, part number 380500047, to the T fitting. NOTE: Verify that the flow direction is correct on the flow meter.
RAPH12SSL0246AA
1
RAPH12SSL0247AA
2
3. Place the outlet hose (1) for the flow meter with hose adapter in the hydraulic tank. NOTE: Verify that the flow direction is correct on the flow meter.
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Hydraulic systems - Fixed displacement pump
4. Start the machine and run the engine at high idle. Adjust the machine’s RPM to 200 RPM less than the full RPM. Record the set RPM on the data collection sheet located on the following page.
931007504
3
RAPH12SSL0242AA
4
RAPH12SSL0243AA
5
Pump flow with no restriction 5. Verify that the flow meter has no restriction on the hydraulic pump. Record the pump flow on the data collection sheet located on the following page. Please see Fixed displacement pump - General specification (35.104) for specification about the pumps. NOTE: Image 4 is an example of a flow reading. Image 4 may not match your reading.
Pump flow with restriction 6. Adjust the flow meter pressure until 152 bar (2200 psi) is achieved. Verify that the machine is running at the set RPM recorded on the data collection sheet located on the following page. Adjust RPM if necessary. Record the pump flow on the data collection sheet located on the following page. Please see Fixed displacement pump - General specification (35.104) for specification about the pumps. NOTE: Image 3 is an example of a flow reading. Image 3 may not match your reading.
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Hydraulic systems - Fixed displacement pump
Pump efficiency 7. Pump efficiency is determined by dividing the pump flow with restriction value by the pump flow without restriction value, then multiplying that new value by 100. Record the pump efficiency on the data collection sheet located on the following page. NOTE: Pump efficiency should be no less than 70%.
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Hydraulic systems - Fixed displacement pump
Engine RPM - Set RPM
__________RPM
Notes: Test 1: Pump flow - Pump flow without restriction
__________l/min __________gpm
Notes: Test 2: Pump flow with restriction - Pump flow with 152 bar (2200 psi) restriction
__________l/min __________gpm
Notes: Test 3: Pump efficiency - Calculated pump efficiency __________% NOTE: Calculated pump efficiency is determined by dividing Test 2’s value by Test 1’s value, then multiplying that new value by 100. Notes:
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Hydraulic systems - Fixed displacement pump
Fixed displacement pump - Remove WARNING Pressurized system! System is still under pressure. Release pressure according to instructions in this manual. Failure to comply could result in death or serious injury. W1044A
1. Label and disconnect the pump supply hose (1). Cap the open ports.
931001955
1
931002073
2
931002073
3
2. Label and disconnect the pump hydraulic tube (1). Cap the open ports.
3. Remove the retaining bolts (1).
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Hydraulic systems - Fixed displacement pump
Fixed displacement pump - Install NOTICE: The hydrostatic pumps have different options for gear pumps. The pictures below may vary from the pump you are working on. The procedure is the same. 1. Install gear pump (1) and retaining bolts (2). Tighten bolts to torque.
931002073
1
931002073
2
931001955
3
2. Connect gear pump hydraulic tube (1). NOTE: Picture shown is of a single gear pump. If the pump you are working on is a double gear pump, connect second hydraulic tube.
3. Connect gear pump supply hose (1).
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Hydraulic systems - Fixed displacement pump
Fixed displacement pump - Preliminary test When hydraulic components are replace, air can get into the hydraulic system. Air bubbles can be catastrophic to a hydraulic system. The following procedure bleeds air from the hydraulic system. Please perform this test if the pump has been removed or if any hydraulic lines for the pump have been removed. 1. Fill the reservoir with the appropriate oil to the proper level. 2. Loosen the supply hose at the pump. 3. Tighten the connection when oil flows from the connection.
931002073
1
RAPH14SSL0351BA
2
RAIL14SSL0418AA
3
4. Lower the cab. Please see Cab tilting system - Lower (90.150) for details.
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Hydraulic systems - Fixed displacement pump
5. Start the engine and run at a low idle for two to three minutes.
931007504
4
RAPH14SSL0351BA
5
RAIL14SSL0418AA
6
6. Lower the loader arm slowly.
7. Turn off the machine. 8. Check the reservoir level, and add oil as necessary.
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Hydraulic systems - Fixed displacement pump
9. Connect a flow meter, part number 380500047, to the auxiliary couplers. Open all of the valves on the flow meter to allow a free flow of oil through the flow meter.
RAPH12SSL0241AA
7
931007504
8
RAPH12SSL0242AA
9
10. Restart the engine and run at a low idle.
11. Engage the standard auxiliary system to purge the auxiliary lines of air. Allow oil to flow through the auxiliary system for two to three minutes. If the pump has been replaced, verify that the pump has the correct flow by observing the flow meter. NOTE: Image 9 is an example of a flow reading. Image 9 may not match your reading. NOTE: Please see Fixed displacement pump - General specification (35.104) for specifications about your pump.
12. Turn off the machine, and check the installation for leaks. 13. Check the reservoir level, and add oil as necessary. 48068130 29/01/2018
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Index Hydraulic systems - 35 Fixed displacement pump - 104 Fixed displacement pump - Flow test - T fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9
Fixed displacement pump - Flow test - Auxiliary couplers - Video . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5
Fixed displacement pump - General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3
Fixed displacement pump - General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3
Fixed displacement pump - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
14
Fixed displacement pump - Preliminary test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15
Fixed displacement pump - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13
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Hydraulic systems - 35 Main control valve - 359
SR210 TIER 4B (FINAL) [NGM418237 - ], SR210 TIER 4B (FINAL) [NHM435463 - ], SR240 TIER 4B (FINAL) [NGM418237 - ], SR240 TIER 4B (FINAL) [NHM435463 - ], SV280 TIER 4B (FINAL) [NGM418237 - ], SV280 TIER 4B (FINAL) [NHM435463 - ], TR270 TIER 4B (FINAL) [NGM418237 - ], TR270 TIER 4B (FINAL) [NHM435463 - ], TR310 TIER 4B (FINAL) [NGM418237 - ], TR310 TIER 4B (FINAL) [NHM435463 - ], TV370 TIER 4B (FINAL) [NHM435463 - ]
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Contents Hydraulic systems - 35 Main control valve - 359
TECHNICAL DATA Main control valve General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SERVICE Main control valve Test - Circuit leakage - Video . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Remove - Proportional auxiliary valve retract solenoid (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Install - Proportional auxiliary valve retract solenoid (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Remove - Proportional auxiliary valve extend solenoid (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Install - Proportional auxiliary valve extend solenoid (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Remove - Spool solenoids (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Install - Spool solenoids (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Remove - Spool position sensors (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Install - Spool position sensors (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Remove - Loader port lock solenoid (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Install - Loader port lock solenoid (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Relief valve Main relief valve - Pressure test - T fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Pressure test - Auxiliary couplers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
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Hydraulic systems - Main control valve
Main control valve - General specification
RAIL15SSL0024FA
1
Main control valve Main relief setting Circuit relief setting
Valve identification
Port identification
207 – 217 bar (3000 – 3145 psi) A1 = 220 – 235 bar (3190 – 3408 psi) A2 = 255 – 270 bar (3698 – 3916 psi) B2 = 225 – 240 bar (3263 – 3481 psi) (1) Main relief (2) Port lock cartridge (3) A1, pressure relief (4) A2, pressure relief (5) Load check (6) B1, hydraulic, anti-cavitation (7) B2, pressure relief (8) Plug P – Supply inlet T – Tank return A1 – Lift cylinder base end B1 – Lift cylinder rod end A2 – Tilt cylinder rod end B2 – Tilt cylinder base end A3 – Auxiliary male coupler B3 – Auxiliary female coupler PLV – Work port lockout pilot supply PLV Drain – Work port lockout tank return P2 – High flow inlet V – EH PRV supply L – EH PRV tank return
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Torque setting (Installation)
42.0 N·m (31.0 lb 24.0 N·m (18.0 lb 24.0 N·m (18.0 lb 24.0 N·m (18.0 lb 42.0 N·m (31.0 lb 24.0 N·m (18.0 lb 24.0 N·m (18.0 lb 42.0 N·m (31.0 lb
ft) ft) ft) ft) ft) ft) ft) ft)
Hydraulic systems - Main control valve
Solenoid identification
(9) Port lock coil
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Hydraulic systems - Main control valve
Main control valve - Test - Circuit leakage - Video CAUTION Burn hazard! Do not handle any service fluid (engine coolant, engine oil, hydraulic oil, etc.) at temperatures that exceed 49 °C (120 °F). Allow fluids to cool before proceeding. Failure to comply could result in minor or moderate injury. C0107B
NOTE: Hydraulic oil temperature should be a minimum of 52 °C (125 °F) before attempting any tests on the hydraulic system. NOTE: Two persons are required to perform the flow meter tests to safely avoid possible injury. One person must be seated in the operators seat when the engine is running. The second person is to control the flow meter and take the readings. 1. The attached YouTube™ video demonstrates how to perform the circuit leakage or “T” test. NOTE: The readings may be different from your particular machine, refer to your machine’s specifications for analysis.
RAPH16SSL0231QA
1
2. Locate the main control valve. 3. Install the “T” fitting (1) into the hydraulic gear pump outlet, and attach the flow meter, part number 380500047, (2) hose to the “T” fitting. NOTE: Verify that the flow inlet direction is correct on the flow meter.
RAPH12SSL0246AA
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2
Hydraulic systems - Main control valve
4. Place the other flow meter hose (1) with hose adapter in the hydraulic tank. NOTE: Verify that the flow outlet direction is correct on the flow meter.
RAPH12SSL0247AA
3
931007504
4
RAPH12SSL0329AA
5
5. Start the machine and run at full throttle.
6. Adjust the flow meter pressure until 124 bar (1800 psi) is achieved. While watching the flow meter liter per minute (l/min) gauge or gallon per minute (gpm) gauge, stroke each loader arm and bucket function to the end of cylinder travel on the machine, and activate the primary auxiliary couplers in both directions. Record the pump flow on the data collection sheet located on the following page. Compare the flow of every stroked function. Differences in pump flow indicate internal leaks and/or easier paths to tank. NOTE: Pump flow should be within 4 l/min (1 US gpm) of pump specification. Please see Fixed displacement pump - General specification (35.104) for specifications on the gear pumps. NOTE: Image 5 is an example of a flow reading. Image 5 may not match your reading.
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Hydraulic systems - Main control valve
Test 6: Circuit leakage with restriction NOTE: For “T” fitting test only - Bucket rollback
__________l/min __________gpm
- Bucket dump
__________l/min __________gpm
- Loader raise
__________l/min __________gpm
- Loader lower
__________l/min __________gpm
- Auxiliary up
__________l/min __________gpm
- Auxiliary down
__________l/min __________gpm
Notes:
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Hydraulic systems - Main control valve
Main control valve - Remove - Proportional auxiliary valve retract solenoid Alpha Series Compact Track Loaders SR210 SR240 SV280
(Mechanical (Mechanical (Mechanical (Mechanical
hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls)
Prior operation: Tilt the ROPS 1. Locate proportional auxiliary valve retract solenoid (1) on the loader valve block (2).
931002092B
1
931002095
2
2. Disconnect connector (1) from the proportional auxiliary valve retract solenoid (2).
3. Remove the two bolts securing the proportional auxiliary valve retract solenoid on the loader valve block.
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Hydraulic systems - Main control valve
Main control valve - Install - Proportional auxiliary valve retract solenoid Alpha Series Compact Track Loaders Alpha Series Skid Steer Loaders SR240 SV280
(Mechanical (Mechanical (Mechanical (Mechanical
hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls)
1. Insert the proportional auxiliary valve retract solenoid (1) into the loader valve block (2).
931002092B
1
931002095
2
931002095
3
2. Connect connector (1) to the proportional auxiliary valve retract solenoid (2).
3. Insert the two retaining screws (1) into proportional auxiliary valve retract solenoid. Tighten to 5 N¡m (3.7 lb ft).
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Hydraulic systems - Main control valve
Main control valve - Remove - Proportional auxiliary valve extend solenoid Alpha Series Compact Track Loaders Alpha Series Skid Steer Loaders SR240 SV280
(Mechanical (Mechanical (Mechanical (Mechanical
hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls)
Prior operation: Tilt the ROPS 1. Locate proportional auxiliary valve extend solenoid (1) on the loader valve block (2).
931002092B
1
931002095
2
2. Disconnect connector (1) from the proportional auxiliary valve extend solenoid (2).
3. Remove the two bolts securing the proportional auxiliary valve extend solenoid on the loader valve block.
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Hydraulic systems - Main control valve
Main control valve - Install - Proportional auxiliary valve extend solenoid Alpha Series Compact Track Loaders Alpha Series Skid Steer Loaders SR240 SV280
(Mechanical (Mechanical (Mechanical (Mechanical
hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls)
1. Insert the proportional auxiliary valve extend solenoid (1) into the loader valve block (2).
931002092B
1
931002095
2
931002095
3
2. Connect connector (1) to the proportional auxiliary valve extend solenoid (2).
3. Insert the two retaining screws (1) into proportional auxiliary valve extend solenoid. Tighten to 5 N¡m (3.7 lb ft).
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Hydraulic systems - Main control valve
Main control valve - Remove - Spool solenoids SR210 SR240 SV280 TR270 TR310 TV370 TIER 4B (FINAL) [NHM435463 - ]
(Electro (Electro (Electro (Electro (Electro (Electro
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls)
Prior operation: Tilt the ROPS 1. Locate the following solenoids: 1.
Loader valve retract
2.
Loader valve extend
3.
Bucket valve extend
4.
Bucket valve retract
5.
Auxiliary valve extend
6.
Auxiliary valve retract
2. Disconnect the electrical connector from the solenoid. 3. Remove the two bolts securing the solenoid on the loader valve block. 4. Remove the solenoid.
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RAPH12SSL0445AA
1
Hydraulic systems - Main control valve
Main control valve - Install - Spool solenoids SR210 SR240 SV280 TR270 TR310 TV370 TIER 4B (FINAL) [NHM435463 - ]
(Electro (Electro (Electro (Electro (Electro (Electro
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls)
1. Locate the following solenoids: 1.
Loader valve retract
2.
Loader valve extend
3.
Bucket valve extend
4.
Bucket valve retract
5.
Auxiliary valve extend
6.
Auxiliary valve retract
2. Install the solenoid. 3. Insert the two retaining screws into the solenoid. Torque the bolts to 5 N¡m (44 lb in). 4. Reconnect the electrical connector.
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RAPH12SSL0445AA
1
Hydraulic systems - Main control valve
Main control valve - Remove - Spool position sensors SR210 SR240 SV280 TR270 TR310 TV370 TIER 4B (FINAL) [NHM435463 - ]
(Electro (Electro (Electro (Electro (Electro (Electro
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls)
1. Locate the following sensors: 1.
Boom position sensor
2.
Bucket position sensor
3.
Auxiliary sensor
2. Disconnect the electrical connector. 3. Remove the nut holding the sensor. 4. Remove the sensor.
RAPH12SSL0446AA
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1
Hydraulic systems - Main control valve
Main control valve - Install - Spool position sensors SR210 SR240 SV280 TR270 TR310 TV370 TIER 4B (FINAL) [NHM435463 - ]
(Electro (Electro (Electro (Electro (Electro (Electro
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls)
1. Locate the following sensors: 1.
Boom position sensor
2.
Bucket position sensor
3.
Auxiliary sensor
2. Insert the sensor into the main control valve. 3. Thread the nut onto sensor. 4. Connect the electrical connector.
RAPH12SSL0446AA
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1
Hydraulic systems - Main control valve
Main control valve - Remove - Loader port lock solenoid Alpha Series Compact Track Loaders Alpha Series Skid Steer Loaders SR240 SV280 TR310
(Electro (Electro (Electro (Electro (Electro
hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls)
1. Locate the loader control valve (1) on the right hand side of the machine. NOTE: Image 1 is an example of the main control valve for Electro-Hydraulic (EH) controlled machines. The loader control valve on mechanically controlled machines is in the same location.
RAPH12SSL0446AA
1
931002090
2
931002090
3
2. Disconnect the electrical connector (1) from the solenoid.
3. Remove the nut from the solenoid (1).
4. Remove the solenoid.
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Hydraulic systems - Main control valve
Main control valve - Install - Loader port lock solenoid Alpha Series Compact Track Loaders Alpha Series Skid Steer Loaders SR240 SV280 TR310
(Electro (Electro (Electro (Electro (Electro
hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls)
1. Place solenoid onto the loader control valve. Thread nut (1) onto valve body.
931002090
1
931002090
2
2. Connect the electrical connector (1) to the solenoid.
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Hydraulic systems - Main control valve
Main control valve - Remove SR210 SR240 SV280 TR270 TR310 TV370 TIER 4B (FINAL) [NHM435463 - ]
(Electro (Electro (Electro (Electro (Electro (Electro
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls)
WARNING Burn hazard! Before performing any service on the hydraulic system, you must allow it to cool. Hydraulic fluid temperature should not exceed 40 °C (104 °F). Failure to comply could result in death or serious injury. W0241A
WARNING Pressurized hydraulic fluid can penetrate the skin and cause severe injuries. Hydraulic fluid can also infect a minor cut or opening in the skin. Serious infection or reaction can result without immediate medical treatment. If injured by leaking fluid, see your doctor immediately. Failure to comply could result in death or serious injury. W0358A
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. Failure to comply could result in death or serious injury. W0905A
WARNING Avoid injury! Always do the following before lubricating, maintaining, or servicing the machine. 1. Disengage all drives. 2. Engage parking brake. 3. Lower all attachments to the ground, or raise and engage all safety locks. 4. Shut off engine. 5. Remove key from key switch. 6. Switch off battery key, if installed. 7. Wait for all machine movement to stop. Failure to comply could result in death or serious injury. W0047A
1. Apply vacuum to the hydraulic reservoir. 2. Label and disconnect the four rear solenoid connections (1).
931001708
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1
Hydraulic systems - Main control valve
3. Label and disconnect the six front solenoid connections (1).
931001709
2
931001713
3
931001715
4
931001710
5
4. Label and disconnect the six hydraulic tubes (1) from the control valve and cap the opened ports.
5. Label and disconnect the drain hoses (1) from the control valve.
6. Label and disconnect the two hoses (1) and one tube (2) from the top of the control valve.
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Hydraulic systems - Main control valve
7. Disconnect the hydraulic tubes (1) located at the bottom of the valve block.
931001714
6
931001711
7
931001718
8
931001719
9
8. Disconnect the hydraulic hoses (1) from the solenoid block.
9. Remove the three valve mounting bolts (1) (one shown).
10. Remove the loader valve.
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Hydraulic systems - Main control valve
Main control valve - Install SR210 SR240 SV280 TR270 TR310 TV370 TIER 4B (FINAL) [NHM435463 - ]
(Electro (Electro (Electro (Electro (Electro (Electro
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls)
1. Position the control valve into the machine mounting location.
931001719
1
931001718
2
931001711
3
2. Install the three valve mounting bolts (1) (one shown).
3. Connect hydraulic hoses (1) to solenoid block.
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Hydraulic systems - Main control valve
4. Connect hydraulic tubes (1) located at the bottom of valve block.
931001714
4
931001710
5
931001715
6
931001713
7
5. Connect two hoses (1) and one tube (2) to the top of control valve.
6. Connect the two drain hoses (1) to control valve.
7. Connect the six hydraulic tubes (1) to there correct ports on the control valve.
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Hydraulic systems - Main control valve
8. Connect the six front solenoid connections (1).
931001709
8
931001708
9
9. Connect rear solenoid connections (1).
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Hydraulic systems - Main control valve
Main relief valve - Pressure test - T fitting CAUTION Burn hazard! Do not handle any service fluid (engine coolant, engine oil, hydraulic oil, etc.) at temperatures that exceed 49 째C (120 째F). Allow fluids to cool before proceeding. Failure to comply could result in minor or moderate injury. C0107B
Pressure test using the T fitting method NOTE: Hydraulic oil temperature should be a minimum of 52 째C (125 째F) before attempting any tests on the hydraulic system. NOTE: Two persons are required to perform the flow meter tests to safely avoid possible injury. One person must be seated in the operators seat when the engine is running. The second person is to control the flow meter and take the readings. 1. Locate the main control valve. 2. Install the T fitting (1) into the hydraulic gear pump outlet, and attach the flow meter, part number 380500047, (2) hose to the T fitting. NOTE: Verify that the flow inlet direction is correct on the flow meter.
RAPH12SSL0246AA
1
RAPH12SSL0247AA
2
3. Place the other flow meter hose (1) with hose adapter in the hydraulic tank. NOTE: Verify that the flow outlet direction is correct on the flow meter.
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Hydraulic systems - Main control valve
4. Start the machine and run at high idle.
931007504
3
BS06H186AA
4
RAPH12SSL0244AA
5
Main relief pressure 5. Stroke a bucket function to the end of the cylinder travel on the machine, and maintain the bucket in that position; this will put a load on the machine.
1. Slowly turn the pressure screw on the flow meter while watching the flow meter pressure gauge and liter per minute (l/min) gauge or gallon per minute (gpm) gauge. Pump flow will remain relatively constant until the main relief pressure is achieved. At the point of pressure relief, pump flow will significantly drop below pump specification on the flow meter. Record the main relief pressure. Please see Main control valve - General specification (35.359) for specification about the main control valve. NOTE: Image 5 is an example of a flow reading. Image 5 may not match your reading.
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Hydraulic systems - Main control valve
2. Release the stroked bucket function. 3. Reset the flow meter.
BS06H186AA
6
BS06H186AA
7
RAPH12SSL0329AA
8
Cracking pressure 4. Stroke a bucket function to the end of the cylinder travel on the machine, and maintain the bucket in that position; this will put a load on the machine.
5. Slowly turn the pressure screw on the flow meter while watching the flow meter pressure gauge and liter per minute (l/min) gauge or gallon per minute (gpm) gauge. Pump flow will remain relatively constant until the cracking pressure is achieved. At the point of cracking pressure, pump flow will drop approximately 11 l/min (3 US gpm). Record the cracking pressure. NOTE: Cracking pressure should be within 15% of the main relief pressure.
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Hydraulic systems - Main control valve
6. Release the stroked bucket function. 7. Reset the flow meter.
BS06H186AA
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9
Hydraulic systems - Main control valve
Relief valve - Pressure test - Auxiliary couplers CAUTION Burn hazard! Do not handle any service fluid (engine coolant, engine oil, hydraulic oil, etc.) at temperatures that exceed 49 째C (120 째F). Allow fluids to cool before proceeding. Failure to comply could result in minor or moderate injury. C0107B
Pressure test using the auxiliary couplers NOTE: Hydraulic oil temperature should be a minimum of 52 째C (125 째F) before attempting any tests on the hydraulic system. NOTE: Two persons are required to perform the flow meter tests to safely avoid possible injury. One person must be seated in the operators seat when the engine is running. The second person is to control the flow meter and take the readings. 1. Attach the flow meter, part number 380500047, to the auxiliary couplers on the loader arm. NOTE: Verify that the flow inlet and outlet direction is correct on the flow meter.
RAPH12SSL0241AA
1
931007504
2
2. Start the machine and run at high idle.
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Hydraulic systems - Main control valve
Main relief pressure 1. Start the machine, activate the hydraulics, and activate the auxiliary function in one direction on the machine. Slowly turn the pressure screw on the flow meter while watching the flow meter pressure gauge and liter per minute (l/min) gauge or gallon per minute (gpm) gauge. Pump flow will remain relatively constant until the main relief pressure is achieved. At the point of pressure relief, pump flow will significantly drop below pump specification on the flow meter. Record the main relief pressure. Please see Main control valve - General specification (35.359) for specification about the main control valve. NOTE: Image 3 is an example of a flow reading. Image 3 may not match your reading.
RAPH12SSL0244AA
3
RAPH12SSL0329AA
4
2. Release the auxiliary switch. Reset the flow meter.
Cracking pressure 3. Activate the auxiliary function in one direction on the machine. Slowly turn the pressure screw on the flow meter while watching the flow meter pressure gauge and liter per minute (l/min) gauge or gallon per minute (gpm) gauge. Pump flow will remain relatively constant until the cracking pressure is achieved. At the point of cracking pressure, pump flow will drop approximately 11 l/min (3 US gpm). Record the cracking pressure. NOTE: Cracking pressure should be within 15% of the main relief pressure.
4. Release the auxiliary switch. Reset the flow meter.
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Index Hydraulic systems - 35 Main control valve - 359 Main control valve - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3
Main control valve - Install - Loader port lock solenoid (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
17
Main control valve - Install - Proportional auxiliary valve extend solenoid (*) . . . . . . . . . . . . . . . . . . . .
11
Main control valve - Install - Proportional auxiliary valve retract solenoid (*) . . . . . . . . . . . . . . . . . . . .
9
Main control valve - Install - Spool position sensors (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15
Main control valve - Install - Spool solenoids (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13
Main control valve - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
21
Main control valve - Remove - Loader port lock solenoid (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
16
Main control valve - Remove - Proportional auxiliary valve extend solenoid (*) . . . . . . . . . . . . . . . . .
10
Main control valve - Remove - Proportional auxiliary valve retract solenoid (*) . . . . . . . . . . . . . . . . . .
8
Main control valve - Remove - Spool position sensors (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
14
Main control valve - Remove - Spool solenoids (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12
Main control valve - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
18
Main control valve - Test - Circuit leakage - Video . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5
Main relief valve - Pressure test - T fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
24
Relief valve - Pressure test - Auxiliary couplers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
28
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Hydraulic systems - 35 Auxiliary hydraulic valves and lines - 525
SR210 TIER 4B (FINAL) [NGM418237 - ], SR210 TIER 4B (FINAL) [NHM435463 - ], SR240 TIER 4B (FINAL) [NGM418237 - ], SR240 TIER 4B (FINAL) [NHM435463 - ], SV280 TIER 4B (FINAL) [NGM418237 - ], SV280 TIER 4B (FINAL) [NHM435463 - ], TR270 TIER 4B (FINAL) [NGM418237 - ], TR270 TIER 4B (FINAL) [NHM435463 - ], TR310 TIER 4B (FINAL) [NGM418237 - ], TR310 TIER 4B (FINAL) [NHM435463 - ], TV370 TIER 4B (FINAL) [NHM435463 - ]
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Contents Hydraulic systems - 35 Auxiliary hydraulic valves and lines - 525
TECHNICAL DATA Optional control valve General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
FUNCTIONAL DATA Optional control valve Component localization (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Component localization (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
SERVICE Auxiliary hydraulic valves and lines Auxiliary hydraulic function control - Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Lines Depressurising . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
(*) See content for specific models 48068130 29/01/2018
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Hydraulic systems - Auxiliary hydraulic valves and lines
Optional control valve - General specification
RAPH14SSL0020FA
1
Secondary auxiliary valve Operating pressure Maximum flow Relief valve setting Port identification
207 – 217 bar (3000 – 3145 psi) at supply inlet: 87 l/min (23.0 US gpm) at ports A and B: 30 – 38 l/min (8 – 10 US gpm) at 138 bar (2000 psi). 221 bar (3200 psi) at 18.9 l/min (5.0 US gpm) P – Pressure inlet L – To main control valve T – Tank return A – Male auxiliary B – Female auxiliary
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Hydraulic systems - Auxiliary hydraulic valves and lines
Optional control valve - Component localization SR210 SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] TR270
RAPH13SSL0863FA
1
Valve location Valve identification (1) Ride control valve
(3) Loader pilot interlock, brake, two speed valve (2) Hydraulic coupler valve (4) Secondary auxiliary valve
(5) High flow valve (6) Override valve for the loader arm
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(7) Self-leveling valve
Hydraulic systems - Auxiliary hydraulic valves and lines
Optional control valve - Component localization SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
RAIL13SSL1004FA
1
Valve location Valve identification (1) Ride control valve
(3) Loader pilot interlock, brake, two speed valve (2) Hydraulic coupler valve (4) Secondary auxiliary valve
(5) Accumulator (6) High flow valve
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(7) Self-leveling valve
Hydraulic systems - Auxiliary hydraulic valves and lines
Auxiliary hydraulic function control - Test CAUTION Burn hazard! Do not handle any service fluid (engine coolant, engine oil, hydraulic oil, etc.) at temperatures that exceed 49 °C (120 °F). Allow fluids to cool before proceeding. Failure to comply could result in minor or moderate injury. C0107B
Testing for circuit leakage NOTE: Hydraulic oil temperature should be a minimum of 52 °C (125 °F) before attempting any tests on the hydraulic system. NOTE: To avoid possible injury, two people are required to perform the following test . One person must be seated in the operator’s seat while the engine is running and the hydraulic controls are enabled. The second person is to control the flow meter and record the readings on the flow meter. 1. Locate the fixed displacement pump(s). 2. Install the T fitting into the fixed displacement pump outlet (1), and attach the inlet hose for flow meter, part number 380500047, to the T fitting. NOTE: Verify that the flow direction is correct on the flow meter.
931001956
1
RAPH12SSL0247AA
2
3. Place the outlet hose for the flow meter (1) with hose adapter in the hydraulic tank. NOTE: Verify that the flow direction is correct on the flow meter.
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Hydraulic systems - Auxiliary hydraulic valves and lines
4. Start the machine and run the engine at high idle.
931007504
3
RAPH12SSL0329AA
4
5. Adjust the flow meter pressure until 124 bar (1800 psi) is achieved. While watching the flow meter liter per minute (l/min) gauge or gallon per minute (gpm) gauge, activate the auxiliary couplers in both directions. Record the pump flow on the data collection sheet located on the following page. Compare the flow of every auxiliary function. Differences in pump flow indicate internal leaks and/or easier paths to tank. NOTE: Pump flow should be within 4 l/min (1 US gpm) of pump specification. Please see Fixed displacement pump - General specification (35.104) for specifications on the pumps. NOTE: Image 4 is an example of a flow reading. Image 4 may not match your reading.
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Hydraulic systems - Auxiliary hydraulic valves and lines
Test 6: Circuit leakage with restriction NOTE: For T fitting test only - Standard auxiliary up
__________l/min __________gpm
- Standard auxiliary down
__________l/min __________gpm
- Secondary auxiliary up (if applicable)
__________l/min __________gpm
- Secondary auxiliary down (if applicable)
__________l/min __________gpm
Notes:
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Hydraulic systems - Auxiliary hydraulic valves and lines
Lines - Depressurising 1. Using the palm of your hand, push the quick disconnect coupling towards the Connect-Under-Pressure (CUP) valve. When done properly, the coupling will move about 10.0 mm (25/64 in), relieving the stored pressure.
631068399
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1
Index Hydraulic systems - 35 Auxiliary hydraulic valves and lines - 525 Auxiliary hydraulic function control - Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6
Lines - Depressurising . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9
Optional control valve - Component localization (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4
Optional control valve - Component localization (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5
Optional control valve - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3
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Hydraulic systems - 35 High flow hydraulics - 600
SR210 TIER 4B (FINAL) [NGM418237 - ], SR210 TIER 4B (FINAL) [NHM435463 - ], SR240 TIER 4B (FINAL) [NGM418237 - ], SR240 TIER 4B (FINAL) [NHM435463 - ], SV280 TIER 4B (FINAL) [NGM418237 - ], SV280 TIER 4B (FINAL) [NHM435463 - ], TR270 TIER 4B (FINAL) [NGM418237 - ], TR270 TIER 4B (FINAL) [NHM435463 - ], TR310 TIER 4B (FINAL) [NGM418237 - ], TR310 TIER 4B (FINAL) [NHM435463 - ], TV370 TIER 4B (FINAL) [NHM435463 - ]
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Contents Hydraulic systems - 35 High flow hydraulics - 600
TECHNICAL DATA High flow hydraulic pump General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Pilot valve General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
FUNCTIONAL DATA High flow hydraulics Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Pilot valve Component localization (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Component localization (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
SERVICE Pilot valve Pressure test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
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Hydraulic systems - High flow hydraulics
High flow hydraulic pump - General specification SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310
RAPH14SSL0003GA
1
High flow pump Type Pump displacement Engine RPM Pump flow at RPM
Gear pump 13.7 cm³ (0.84 in³) 2475 RPM 33.9 L/min (9.0 US gpm)
High flow hydraulic pump - General specification SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
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Hydraulic systems - High flow hydraulics
RAPH14SSL0003GA
1
High flow pump Type Pump displacement Engine RPM Pump flow at RPM
Gear pump 20.4 cm³ (1.2 in³) 2475 RPM 50.5 L/min (13.3 US gpm)
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Hydraulic systems - High flow hydraulics
Pilot valve - General specification
RAPH14SSL0021EA
1
High flow valve Hydraulic requirements
Relief valve setting Port identification
Flow : 45 l/min (12 US gpm) System pressure: 210 bar (3050 psi) Maximum pressure drop across the valve: 45 l/min (12 US gpm) at 10 bar (145 psi) 224 bar (3250 psi) P – Supply inlet T – Tank return AUX – Auxiliary outlet
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Hydraulic systems - High flow hydraulics
High flow hydraulics - Overview If equipped with a high flow system, the operator can command additional flow to the auxiliary circuit by engaging auxiliary high flow function. This will provide increased flow to the auxiliary circuit. Please see High flow hydraulic pump - General specification (35.600) for specifications about the high flow pumps. High flow feature is engaged by pressing the rocker switch (1) mounted on left hand A post. The switch selects HF (high flow) or HP (high pressure) and is illuminated when high flow or enhanced high flow (EHF) is on. This allows the operator to enable/disable the function depending on the attachment requirements. NOTE: HP will activate only if the machine is equipped with EHF. The External Auxiliary Control can be controlled ONLY if ALL of the following conditions are met 1. Operator is seated properly 2. Operator Restraint engaged 3. The ignition is in the ON position 4. HF switch is activated
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RCPH11SSL003AAD
1
Hydraulic systems - High flow hydraulics
Pilot valve - Component localization SR210 SR210 SR240 SR240 TR270
TIER TIER TIER TIER
4B 4B 4B 4B
(FINAL) (FINAL) (FINAL) (FINAL)
[NGM418237 - ] [NHM435463 - ] [NGM418237 - ] [NHM435463 - ]
RAPH13SSL0863FA
1
Valve location Valve identification (1) Ride control valve
(3) Loader pilot interlock, brake, two speed valve (2) Hydraulic coupler valve (4) Second auxiliary valve
(5) High flow valve (6) Override valve for the loader arm
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(7) Self-leveling valve
Hydraulic systems - High flow hydraulics
Pilot valve - Component localization SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
RAIL13SSL1004FA
1
Valve location Valve identification (1) Ride control valve
(3) Loader pilot interlock, brake, two speed valve (2) Hydraulic coupler valve (4) Second auxiliary valve
(5) Accumulator (6) High flow valve
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(7) Self level valve
Hydraulic systems - High flow hydraulics
Pilot valve - Pressure test NOTE: Hydraulic oil temperature should be a minimum of 52 °C (125 °F) before attempting any tests on the hydraulic system. 1. Connect a 345 bar (5000 psi) pressure gauge, part number 380500129, to the high flow, outlet auxiliary coupler. NOTE: Verify flow direction for accurate reading and machine safety.
93106839B
1
931007504
2
BS06H186AA
3
RCPH11SSL003AAD
4
2. Start the machine, and raise the engine speed to full throttle.
3. Engage the auxiliary hydraulics. 4. Stroke a bucket function to the end of the cylinder travel on the machine, and hold the bucket in that position using the joystick; This will put a load on the machine.
5. Select High Flow (HF) on the rocker switch (1).
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Hydraulic systems - High flow hydraulics
6. Record the pressure on the pressure gauge. Please see Pilot valve - General specification (35.600) for specifications on the high flow pilot valve.
RAPH12SSL0448AA
5
BS06H186AA
6
931001689
7
7. Release the stroked bucket function. 8. Disengage the auxiliary hydraulics.
9. If the recorded pressure is not within specification, remove the cap (1) on the relief valve and adjust.
10. Repeat steps 2 through 9 until the relief valve is within specification.
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Hydraulic systems - High flow hydraulics
Pilot valve - Remove 1. Locate valve (1) on floor of the skid loader under hydraulic pump.
931001948
1
931001689
2
931001689
3
931001689
4
2. Disconnect the left hydraulic tube (2). NOTE: Arrow indicates forward direction.
3. Disconnect hydraulic tubes (3) and (4) from the right of the valve. NOTE: Arrow indicates forward direction.
4. Disconnect the valves electrical connection (5).
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Hydraulic systems - High flow hydraulics
5. Remove the two mounting bolts (2).
931001689
5
931001690
6
6. Remove valve.
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Hydraulic systems - High flow hydraulics
Pilot valve - Install 1. Locate the proper location on the floor for installation of valve.
931001948
1
931001689
2
931001689
3
931001689
4
2. Install the two mounting bolts (1) through the valve and secure it to the floor. NOTE: Arrow indicates forward direction.
3. Connect the two hydraulic tubes (2) and (3) to the right side of the valve. NOTE: Arrow indicates forward direction.
4. Connect the top hydraulic tube (4). NOTE: Arrow indicates forward direction.
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Hydraulic systems - High flow hydraulics
5. Connect electrical connection (5). NOTE: Arrow indicates forward direction.
931001689
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5
Index Hydraulic systems - 35 High flow hydraulics - 600 High flow hydraulic pump - General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3
High flow hydraulic pump - General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3
High flow hydraulics - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6
Pilot valve - Component localization (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7
Pilot valve - Component localization (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8
Pilot valve - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5
Pilot valve - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13
Pilot valve - Pressure test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9
Pilot valve - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11
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Hydraulic systems - 35 Front loader hydraulic system control - 724
SR210 TIER 4B (FINAL) [NGM418237 - ], SR210 TIER 4B (FINAL) [NHM435463 - ], SR240 TIER 4B (FINAL) [NGM418237 - ], SR240 TIER 4B (FINAL) [NHM435463 - ], SV280 TIER 4B (FINAL) [NGM418237 - ], SV280 TIER 4B (FINAL) [NHM435463 - ], TR270 TIER 4B (FINAL) [NGM418237 - ], TR270 TIER 4B (FINAL) [NHM435463 - ], TR310 TIER 4B (FINAL) [NGM418237 - ], TR310 TIER 4B (FINAL) [NHM435463 - ], TV370 TIER 4B (FINAL) [NHM435463 - ]
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Contents Hydraulic systems - 35 Front loader hydraulic system control - 724
FUNCTIONAL DATA Loader bucket self-leveling controls Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Exploded view - Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Sectional view - Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Component localization - Valve (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Component localization - Valve (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
SERVICE Loader bucket self-leveling controls Adjust - Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Remove - Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Install - Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
DIAGNOSTIC Loader bucket self-leveling controls Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
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Hydraulic systems - Front loader hydraulic system control
Loader bucket self-leveling controls - Overview As the loader arm cylinder extends, flow from the rod port is directed to port A (1). Flow entering port A (1) is able to pass through the adjustable orifice and fixed orifice in the flow divider spool. The proportion of the flow split is determined by size of the adjustable orifice. Please see the charts below for specifications about your machine’s flow split. The remainder of the flow passes through the fixed orifice, out port B (4) back to the control valve and returns to tank. The flow that passes through the adjustable orifice flows out port D (2) and is teed to the base end of the bucket cylinders. The resistance on the movement of the bucket cylinders creates a pressure high enough to open the unloading spool in the self-leveling valve. As the bucket cylinders extends, the flow from the rod port of the bucket cylinders enters port C (3) past the open unloading spool around the flow divider spool and out port B (4) back to the control valve and returns to tank. RAIL12SSL0327BA
Port identification chart Self leveling valve port identification
A = Lift cylinder rod end B = CV work port B1 C = Tilt cylinder rod end D = Tilt cylinder base end
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1
Hydraulic systems - Front loader hydraulic system control
Loader bucket self-leveling controls - Exploded view - Valve
RAPH12SSL0328FA
1
Self-leveling valve Self-leveling valve identification (1) Plug (4) Valve body (7) Pin (10) Jam nut (13) Plunger
(2) O-ring (5) Load check plunger (8) Adjustment cap (11) Cap (14) Unloading spool
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(3) Flow divider spool (6) Load check spring (9) Set screw (12) Spring
Hydraulic systems - Front loader hydraulic system control
Loader bucket self-leveling controls - Sectional view - Valve The self-leveling control valve consists of a spring loaded, flow divider spool (10) with a fixed orifice (4) in the center. The fixed orifice (4) controls how far the flow divider spool (10) opens when oil is directed to it. An adjustable orifice (3) is used to control the amount of oil sent out of the valve body, and therefore regulates the amount of leveling for the bucket. The self-leveling valve has a check valve assembly (5) that allows oil to flow to the base of the bucket cylinder and prevents oil from backfeeding through the self-leveling valve when the bucket spool is actuated. The unloading spool (9) allows a controlled amount of oil to escape from the rod end of the bucket cylinder as self-leveling is occurring. Because bucket leveling is controlled by a flow divider spool (10), the amount of leveling that occurs depends on the oil flow from the loader lift cylinder, and therefore changes with engine speed. The system is designed to operate with the engine at high idle. At speeds less than high idle, the bucket may not maintain level as the loader is raised. Raising the loader very slowly can affect the bucket leveling, because sufficient oil flow is not available to provide adequate pressure through the fixed orifice (4).
RAIL13SSL0993GA
1
Self-leveling valve
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Hydraulic systems - Front loader hydraulic system control
Self-leveling valve identification (1) Self-leveling solenoid (2) Port A (3) Adjustable orifice (4) Fixed orifice
(5) Check valve (6) Port D (7) Port C (8) Unloading valve spring
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(9) Unloading spool (10) Flow divider spool (11) Port B
Hydraulic systems - Front loader hydraulic system control
Loader bucket self-leveling controls - Component localization Valve SR210 SR210 SR240 SR240 TR270
TIER TIER TIER TIER
4B 4B 4B 4B
(FINAL) (FINAL) (FINAL) (FINAL)
[NGM418237 - ] [NHM435463 - ] [NGM418237 - ] [NHM435463 - ]
RAPH13SSL0863FA
1
Valve location Valve identification (1) Ride control valve
(3) Loader pilot interlock, brake, two speed valve (2) Hydraulic coupler valve (4) Second auxiliary valve
(5) High flow valve (6) Override valve for the loader arm
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(7) Self-leveling valve
Hydraulic systems - Front loader hydraulic system control
Loader bucket self-leveling controls - Component localization Valve SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
RAIL13SSL1004FA
1
Valve location Valve identification (1) Ride control valve
(3) Loader pilot interlock, brake, two speed valve (2) Hydraulic coupler valve (4) Second auxiliary valve
(5) Accumulator (6) High flow valve
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(7) Self-leveling valve
Hydraulic systems - Front loader hydraulic system control
Loader bucket self-leveling controls - Adjust - Valve DANGER Crushing hazard! Failure to engage the loader arm support pin could cause the loader arm to fall unexpectedly. Verify that the loader arm support pin is engaged. Failure to comply will result in death or serious injury. D0020A
DANGER 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. Failure to comply will result in death or serious injury. D0084A
1. Locate the set screw (1) on the top, right of the selfleveling valve. NOTE: The set screw (1) may be covered. Remove the cover by gently tapping on the cover. 2. Loosen the jam nut on the set screw (1). 3. Turn the set screw (1) • counter-clockwise to increase flow to the bucket cylinders • clockwise to decrease flow to the bucket cylinders 4. Tighten the jam nut. 931001981
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1
Hydraulic systems - Front loader hydraulic system control
Loader bucket self-leveling controls - Remove - Valve Prior operation: Tilt the ROPS. 1. Locate the control valve (1).
931001804
1
931001701
2
931001702
3
931001981
4
2. Disconnect the electrical connection (1).
3. Disconnect the hydraulic tube (1) and cap the opened ports.
4. Disconnect the lower tubes (1) and cap the ports.
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Hydraulic systems - Front loader hydraulic system control
5. Disconnect the front tube (1) and cap the port.
931001981
5
931001981
6
931001707
7
6. Remove the mounting hardware (1).
7. Remove the control valve.
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Hydraulic systems - Front loader hydraulic system control
Loader bucket self-leveling controls - Install - Valve 1. Install control valve (1) onto body in correct location.
931001804
1
931001981
2
931001981
3
931001981
4
2. Install mounting hardware (1).
3. Connect front tube (1).
4. Connect lower tubes (1).
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Hydraulic systems - Front loader hydraulic system control
5. Connect hydraulic tube (1).
931001702
5
931001701
6
6. Connect electrical connection (1).
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Hydraulic systems - Front loader hydraulic system control
Loader bucket self-leveling controls - Troubleshooting Problem Possible Cause Correction The loader arm delays at Self-leveling is designed to work at high Run the engine at high idle. the start of self leveling. idle. There is air in system. Lift and lower the loader arm and roll the bucket to rid the system of air. The bucket dumps its The unloading spool in the self leveling Remove and inspect the unloading spool for damage. contents without the valve is leaking. operator’s request. The packing in the cylinder is damaged. Inspect the cylinder’s internal components. Self leveling is Self-leveling is designed to operate at high Run the engine at high idle. insufficient. idle. The adjustable orifice in the self leveling Adjust the orifice in the self leveling valve. valve is out of adjustment. Please see Loader bucket self-leveling controls - Adjust (35.724). The unloading spool spring in the self lev- Inspect the unloading spool components in the self leveling valve. eling valve is damaged. The flow divider spool in the self leveling Inspect the flow divider spool in the self levvalve is stuck. eling valve. With the bucket in the The dampening orifice in the unloading Remove the unloading spool and clean the dumping position, the spool in the self leveling valve is plugged. dampening orifice. loader arm is slow to raise. The bucket does not Self-leveling is designed to work at high Run the engine at high idle. move when using the idle. self-leveling system. The adjustable orifice in the self leveling Adjust the orifice. Please see Loader valve is unadjusted. bucket self-leveling controls - Adjust (35.724). The dampening orifice in the unloading Remove the unloading spool and clean the spool in the self leveling valve is plugged. dampening orifice. Electrical problem. 1. Check for power and ground at the switch and solenoid. The bucket does not maintain level while raising the loader arm with the engine at high idle. The loader arm has an unstable self-level.
The bucket excessively drifts towards the dumping direction.
The bucket excessively drifts towards the scooping direction.
External leakage.
The flow divider spool is stuck.
2. Inspect the solenoid for damage. Inspect the flow divider spool.
Self-leveling is designed to work at high Run the engine at high idle. idle. There is air in system. Lift and lower the loader arm and roll the bucket to rid system of air. The packing in the cylinder is damaged. Inspect the cylinder’s internal components.
There is excessive leakage in the main con- Inspect the main control valve for damage. trol valve. The unloading spool in the self leveling Inspect the unloading spool. valve is stuck. The packing in the cylinder is damaged. Inspect the cylinder’s internal components.
There is excessive leakage in the main con- Inspect the main control valve for damage. trol valve. The lift check in the self leveling valve is Inspect the lift check for leakage. damaged. There may be a damaged o-ring on the self Inspect the o-rings for damage. . leveling valve.
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Index Hydraulic systems - 35 Front loader hydraulic system control - 724 Loader bucket self-leveling controls - Adjust - Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9
Loader bucket self-leveling controls - Component localization - Valve (*) . . . . . . . . . . . . . . . . . . . . . .
7
Loader bucket self-leveling controls - Component localization - Valve (*) . . . . . . . . . . . . . . . . . . . . . .
8
Loader bucket self-leveling controls - Exploded view - Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4
Loader bucket self-leveling controls - Install - Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12
Loader bucket self-leveling controls - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3
Loader bucket self-leveling controls - Remove - Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10
Loader bucket self-leveling controls - Sectional view - Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5
Loader bucket self-leveling controls - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
14
(*) See content for specific models 48068130 29/01/2018
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Hydraulic systems - 35 Front loader arm hydraulic system - 701
SR210 TIER 4B (FINAL) [NGM418237 - ], SR210 TIER 4B (FINAL) [NHM435463 - ], SR240 TIER 4B (FINAL) [NGM418237 - ], SR240 TIER 4B (FINAL) [NHM435463 - ], SV280 TIER 4B (FINAL) [NGM418237 - ], SV280 TIER 4B (FINAL) [NHM435463 - ], TR270 TIER 4B (FINAL) [NGM418237 - ], TR270 TIER 4B (FINAL) [NHM435463 - ], TR310 TIER 4B (FINAL) [NGM418237 - ], TR310 TIER 4B (FINAL) [NHM435463 - ], TV370 TIER 4B (FINAL) [NHM435463 - ]
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Contents Hydraulic systems - 35 Front loader arm hydraulic system - 701
TECHNICAL DATA Front loader arm hydraulic system General specification - Override valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Ride control solenoid valve block General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Relief valve General specification - Lift arm or boom - cylinder override valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Accumulator General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
FUNCTIONAL DATA Front loader arm hydraulic system Overview - Electro-Hydraulic (EH) - Hydraulic system control (loader arm, bucket tilt, auxiliary hydraulics) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Component localization (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Ride control solenoid valve block Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Component localization (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Component localization (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Accumulator Component localization (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
SERVICE Lift arm cylinder Depressurising . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 (*) See content for specific models 48068130 29/01/2018
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Ride control solenoid valve block Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Relief valve Remove - Lift arm or boom - cylinder override valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Install - Lift arm or boom - cylinder override valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Accumulator Visual inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Pressure test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Depressurising . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Discharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
DIAGNOSTIC Front loader arm hydraulic system Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
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Front loader arm hydraulic system - General specification Override valve
RAPH12SSL0340GA
1
Override valve for the loader arm Hydraulic requirements:
Flow = 22.7 l/min (6 US gpm). System pressure = 210 bar (3050 psi).
Port identification
1 - Tank return 2 - Lift cylinder base port
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Front loader arm hydraulic system - General specification SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270
RAPH14SSL0006FA
1
Loader pilot interlock, brake, two speed valve Hydraulic requirements Sequence valve setting Filter rating Port identification
Charge pressure = 24 – 25.5 bar (350 – 370 psi) Brake release pressure = 15 bar (218 psi) 12 bar (174 psi) 40 – 50 microns P - Supply inlet T - Tank return 2SPD - Two speed shift B1 - Brake motor 1 B2 - Brake motor 2 LV - Electrohydraulic pilot pressure PS2 - Brake pressure switch
Front loader arm hydraulic system - General specification TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
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RAPH12SSL0381EA
1
Loader pilot interlock, brake, two speed valve Hydraulic requirements Port identification
Charge pressure = 24 – 25.5 bar (350 – 370 psi) Brake release pressure = 15 bar (218 psi) P - Supply inlet T - Tank return 2SPD - Two speed shift B1 - Brake motor 1 B2 - Brake motor 2 LV - Electrohydraulic pilot pressure PS2 - Brake pressure switch
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Ride control solenoid valve block - General specification
RAPH12SSL0338GA
1
Ride control valve Hydraulic Requirements
Port Identification
Flow = 22.7 l/min (6 US gpm) System Pressure = 210 bar (3045 psi) Maximum pressure drop across valve = 10 bar (145 psi) at 23 l/min (6 US gpm) 1 – Tank Return 2 – Lift Cylinder Rod Port 3 – Accumulator 4 – Lift Cylinder Base Port
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Relief valve - General specification - Lift arm or boom - cylinder override valve NOTE: Depending upon the machine configuration, the override valve may have two or three ports.
RAPH17SSL0416FA
1
Cylinder override valve - 84294239
RAIL17SSL0415AA
2
Port identification - 84294239 Lift arm or boom - cylinder override valve specifications - 84294239 Valve configuration Hydraulic requirements
Operating temperature range Port identification
Two-way, two position, manually operated, normally closed, pull-to-open, directional cartridge valve Flow - 22.7 L/min (6.0 US gpm) System pressure - 210.0 bar (3050.0 psi) Intermittent pressure spikes - 293.0 bar (4250.0 psi) -30.0 – 107.0 °C (-22.0 – 225.0 °F) 1 – Tank return 2 – Lift cylinder base
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RAPH17SSL0417FA
3
Cylinder override valve - 48076574
RAIL17SSL0418FA
4
Port identification - 48076574 Lift arm or boom - cylinder override valve specifications - 48076574 Valve configuration Hydraulic requirements
Operating temperature range Port identification
Three-way, two position, manually operated, normally closed, pull-to-open, directional cartridge valve Flow - 22.7 L/min (6.0 US gpm) System pressure - 238.0 bar (3450.0 psi) Intermittent pressure spikes - 293.0 bar (4250.0 psi) -30.0 – 107.0 °C (-22.0 – 225.0 °F) 1 – Tank return 2 – Lift cylinder rod end 3 – Lift cylinder base end
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Accumulator - General specification
RAPH15SSL0009BA
Manufacturer Fluid Capacity Charge with dry nitrogen Port
1
Parker 750 ml (25.4 US fl oz) 21 bar (300 psi) Internal straight thread 3/4-16 UNF - 2B
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Front loader arm hydraulic system - Overview - Electro-Hydraulic (EH) - Hydraulic system control (loader arm, bucket tilt, auxiliary hydraulics) SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Electro hydraulic controls) (Electro hydraulic controls) (Electro hydraulic controls) (Electro hydraulic controls) (Electro hydraulic controls) (Electro hydraulic controls)
The Alpha series use an open center hydraulic system to operate two loader cylinders, two bucket cylinders, and the auxiliary hydraulic flow. The hydraulic system shares a reservoir, located behind the rear access door, with the hydrostatic system. All other hydrostatic components are a separate system. The only connection between the hydrostatic system and the hydraulic system is the tee near the reservoir. The main hydraulic pump is available as two different pumping gears, either as a standard or as a high-flow option. The main control valve is the heart of the hydraulic system. It directs the flow to operate the loader/boom lift, bucket tilt, and auxiliary functions. The same three spool open center series valves with built-in main relief, circuit relief, and load checks for each spool are used on all size machines. The first spool nearest the main relief is the loader function spool. The loader function spool controls the raise, lower, neutral, and float of the loader arm/boom. The middle spool is the bucket function spool. The bucket function spool controls the bucket rollback, neutral, and dump functions. The third spool is the auxiliary spool. The auxiliary spool controls oil flow to the auxiliary manifold. Each spool has a load check valve. The load check valve prevents the sudden droppage when the spool is slowly engaged to the power position. All models have circuit relief valves for the loader base and rod end and the bucket base and rod end. The load check is removed on the Auxiliary valve if the unit is equipped with the High Flow option.
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Front loader arm hydraulic system - Component localization SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] TR270
(Electro hydraulic controls)
RAPH13SSL0863FA
1
Valve location Valve identification (1) Ride control valve
(3) Loader pilot interlock, brake, two speed valve (2) Hydraulic coupler valve (4) Second auxiliary valve
(5) High flow valve (6) Override valve for the loader arm
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(7) Self-leveling valve
Hydraulic systems - Front loader arm hydraulic system
Ride control solenoid valve block - Overview
RAPH17SSL0177RA
1
Ride Control Reference (1) (2) (3)
Description Lift arm cylinder(s) Accumulator Ride control valve
Ride Control is an option that can be either added at the factory or field installed. The ride control option allows the operator to open the base end of the loader arm lift cylinder to a gas charged accumulator to provide the loader arm/boom with a cushioned ride that eliminates the rocking, forward to backward, motion typical with skid steers and compact track loaders. In order to allow the cylinder to retract and extend freely, the rod side of the cylinder is tied to a tank passage so that the cylinder does not hydraulically lock. The troubleshooting of drift complaints of the loader arm circuit, the ride control valve MUST be capped off to isolate the ride control components.
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Ride control solenoid valve block - Component localization SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ]
RAPH13SSL0863FA
1
Valve location Valve identification (1) Ride control valve
(3) Loader pilot interlock, brake, two speed valve (2) Hydraulic coupler valve (4) Second auxiliary valve
(5) High flow valve (6) Override valve for the loader arm
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(7) Self-leveling valve
Hydraulic systems - Front loader arm hydraulic system
Ride control solenoid valve block - Component localization SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
RAIL13SSL1004FA
1
Valve location Valve identification (1) Ride control valve
(3) Loader pilot interlock, brake, two speed valve (2) Hydraulic coupler valve (4) Second auxiliary valve
(5) Accumulator (6) High flow valve
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(7) Self level valve
Hydraulic systems - Front loader arm hydraulic system
Accumulator - Component localization SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
RAIL13SSL1004FA
1
Valve location Valve identification (1) Ride control valve
(3) Loader pilot interlock, brake, two speed valve (2) Hydraulic coupler valve (4) Second auxiliary valve
(5) Accumulator (6) High flow valve
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(7) Self level valve
Hydraulic systems - Front loader arm hydraulic system
Lift arm cylinder - Depressurising 1. Support the loader arm with suitable lifting equipment. 2. Shut off the engine. 3. Use the override valve (1) to relieve pressure in the cylinders.
RAPH12UTL0644AA
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1
Hydraulic systems - Front loader arm hydraulic system
Lift arm cylinder - Remove SR210 SR240 TR270 TR310
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. Failure to comply could result in death or serious injury. W0398A
WARNING Burn hazard! Before performing any service on the hydraulic system, you must allow it to cool. Hydraulic fluid temperature should not exceed 40 °C (104 °F). Failure to comply could result in death or serious injury. W0241A
WARNING Pressurized hydraulic fluid can penetrate the skin and cause severe injuries. Hydraulic fluid can also infect a minor cut or opening in the skin. Serious infection or reaction can result without immediate medical treatment. If injured by leaking fluid, see your doctor immediately. Failure to comply could result in death or serious injury. W0358A
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. Failure to comply could result in death or serious injury. W0905A
WARNING Avoid injury! Always do the following before lubricating, maintaining, or servicing the machine. 1. Disengage all drives. 2. Engage parking brake. 3. Lower all attachments to the ground, or raise and engage all safety locks. 4. Shut off engine. 5. Remove key from key switch. 6. Switch off battery key, if installed. 7. Wait for all machine movement to stop. Failure to comply could result in death or serious injury. W0047A
Prior operation: Relieve the pressure in the lift arm cylinder. Please see Lift arm cylinder - Depressurising (35.701).
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1. Label and disconnect cylinder hoses (1) and cap open ports
931001628
1
931001621
2
931001616
3
931001625
4
2. Remove lift cylinder rod end snap rings (1) from boom arm.
3. Remove rod end pins and washers (1).
4. Lower cylinders (1) down.
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5. Remove lock nut (1) and pin retaining bolt (2) on both sides of the lift arm.
931001629
5
931001630
6
931001632
7
6. Remove rod end pins and washers from both sides of the lift arm.
7. Remove cylinders
Next operation: Lift arm cylinder - Install (35.736)
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Lift arm cylinder - Remove SV280 TV370 TIER 4B (FINAL) [NHM435463 - ]
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. Failure to comply could result in death or serious injury. W0398A
WARNING Burn hazard! Before performing any service on the hydraulic system, you must allow it to cool. Hydraulic fluid temperature should not exceed 40 °C (104 °F). Failure to comply could result in death or serious injury. W0241A
WARNING Pressurized hydraulic fluid can penetrate the skin and cause severe injuries. Hydraulic fluid can also infect a minor cut or opening in the skin. Serious infection or reaction can result without immediate medical treatment. If injured by leaking fluid, see your doctor immediately. Failure to comply could result in death or serious injury. W0358A
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. Failure to comply could result in death or serious injury. W0905A
WARNING Avoid injury! Always do the following before lubricating, maintaining, or servicing the machine. 1. Disengage all drives. 2. Engage parking brake. 3. Lower all attachments to the ground, or raise and engage all safety locks. 4. Shut off engine. 5. Remove key from key switch. 6. Switch off battery key, if installed. 7. Wait for all machine movement to stop. Failure to comply could result in death or serious injury. W0047A
Prior operation: Relieve the pressure in the lift arm cylinder. Please see Lift arm cylinder - Depressurising (35.701).
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1. Label and disconnect cylinder hoses (1) and cap open ports
93112872
1
93112873
2
931001616
3
93112875
4
2. Remove lift cylinder rod end pin (2) and retaining bolt (1) and nut (3) from boom arm.
3. Remove rod end pins and washers (1).
4. Lower cylinders (1) down.
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5. Remove lock nut (1) and pin retaining bolt (2) on frame.
93112874
5
931001630
6
931001632
7
6. Remove rod end pins and washers from both sides of the frame.
7. Remove cylinders
Next operation: Lift arm cylinder - Install (35.701)
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Lift arm cylinder - Disassemble Prior operation: Lift arm cylinder - Remove (35.701) 1. Clean the outside of the cylinder. If the hoses were removed from the cylinder, remove the hoses. 2. Fasten the tube (1) in a vise, or other holding equipment can be used. Be careful not to damage the tube. 3. Loosen the gland (5) in the tube with a gland wrench. 4. To prevent damage to the tube, pull the piston rod (3) straight out of the tube. 5. Fasten the piston rod end in a vise. To prevent damage to the piston rod, place a padded support below the piston rod near the piston. 6. Loosen and remove the nut that connects the piston on the piston rod. 7. Remove the piston (6) from the piston rod. 8. Remove and discard the seal (11), wear ring (13) and backup ring (12) from the piston. 9. Remove and discard the O-ring (9), backup ring (10), seals (8), and wiper (7) from the gland (5).
20111254
(1) Tube (2) Bushing (3) Piston Rod
(4) Bushing (5) Packing gland (6) Piston
1
(7) Wiper (8) Seal (kit) (9) O-ring
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(10) Backup ring (11) Seal (12) Backup Ring
(13) Wear ring (14) Nut (15) Rod end
Hydraulic systems - Front loader arm hydraulic system
Lift arm cylinder - Assemble Prior operation: Lift arm cylinder - Disassemble (35.701)
20111254
1. 2. 3. 4. 5. 6.
Tube Bushing Piston Rod Bushing Packing gland Piston
1
7. Wiper 8. Seal (kit) 9. O-ring 10. Backup ring 11. Seal 12. Backup Ring
13. Wear ring 14. Nut 15. Rod end
NOTE: If a new gland is being installed, put the part number of the cylinder on the new gland. 1. Before assembly, lubricate the rod (3) and the cylinder bore with hydraulic oil. 2. Lubricate a new seal (8) with clean hydraulic oil. Insert the new seal into the gland so the lips are toward the small end of the gland. 3. Lubricate a new wiper (7) with hydraulic oil. Insert the new wiper into the gland so the lips are toward the large end of the gland. 4. Lubricate a new backup ring (10) with clean hydraulic oil. Insert the new backup ring into the groove on the outside of the gland so the flat side is toward the large end of the gland. 5. Lubricate a new O-ring (9) with clean hydraulic oil. Insert the O-ring into the groove and onto the backup ring on the outside of the gland. 6. Fasten the piston rod end (15) in a vise. 48068130 29/01/2018
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7. Remove any marks or sharp edges on the chamfered end of the piston rod. 8. Lubricate the bore of the gland with clean hydraulic oil. 9. Push the gland onto the piston rod. If the gland will not slide easily onto the piston rod, use a soft hammer to drive the gland onto the piston rod. 10. To prevent damage to the piston rod, place a support below and near the end of the piston rod. Use a shop cloth between the support and the piston rod. 11. Install the piston (6) onto the end of the piston rod. 12. Clean the threads on the end of the piston rod and the threads of the nut using Loctite cleaning solvent. Allow all the parts to dry. Apply 1/2 in of LOCTITE® 243™ onto the threads of the piston rod 1/4 in from the open end of the piston rod. NOTE: Do not apply LOCTITE® 243™ to the first 1/4 in of the piston rod threads. 13. Install the nut (14). 14. Tighten the nut to a torque of 237.0 – 305.0 N·m (175.0 – 225.0 lb ft). A torque multiplier can be used to tighten the nut. 15. Lubricate a new backup ring (12) with clean hydraulic oil. Slide the backup ring into the center groove on the outside of the piston. 16. Lubricate a new seal (11) with clean hydraulic oil. Slide the new seal onto the backup ring on the outside of the piston. 17. Lubricate a new wear ring (13) with clean hydraulic oil. Slide the new wear ring into the end groove on the opposite end of the piston. 18. Lubricate the inside of the tube and the piston with clean hydraulic oil. Use a piston ring compression tool to hold the new wear ring in place. 19. Push the tube straight onto the piston. 20. Start the tube onto the piston rod assembly. Push the tube onto the piston rod until the compression tool is clear of the piston rod. Be careful not to damage the wear ring and the seal. 21. When the piston is in the smooth part of the tube, start the gland into the tube. 22. Lubricate the new O-ring on the gland with clean hydraulic oil. 23. Tighten the gland to the torque of 407.0 – 542.0 N·m (300.0 – 400.0 lb ft). 24. If hoses were removed with the cylinder, install new O-rings, if equipped, on the hose fittings. Lubricate the new O-rings with clean hydraulic oil and install the hoses.
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Lift arm cylinder - Install SR210 SR240 TR270 TR310
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. Failure to comply could result in death or serious injury. W0398A
Prior operation: Lift arm cylinder - Remove (35.701) 1. Lubricate the rod end pins, (1), with LOCTITEÂŽ SILVER GRADE ANTI-SEIZE lubricant. 2. Install the cylinder onto the skid steer.
931001630
1
931001629
2
931001616
3
3. Install pin retaining bolt (1), and locknut, (2). 4. Torque the upper pivot pin hardware to 38 Nm ( 28 lb ft.
5. Install the rod end pins and washers (1) through the lift arms and cylinder end.
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6. Install rod end snap rings (1).
931001618
4
931001628
5
7. Install the hydraulic cylinder hoses (1), and position to prevent contact with other components, fenders, etc. Tighten hose fittings to standard torque. 8. Lower the lift arm. 9. Start the skid steer and cycle the boom several times to remove trapped air from the system and check the cylinder for leaks.
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Lift arm cylinder - Install SV280 TV370 TIER 4B (FINAL) [NHM435463 - ]
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. Failure to comply could result in death or serious injury. W0398A
Prior operation: Lift arm cylinder - Remove (35.701) 1. Lubricate the rod end pins, (1), with LOCTITEÂŽ SILVER GRADE ANTI-SEIZE lubricant. 2. Install the cylinder onto the skid steer.
931001630
1
931001629
2
931001616
3
3. Install pin retaining bolt (1), and locknut, (2). 4. Torque the upper pivot pin hardware to 38 Nm ( 28 lb ft.
5. Install the rod end pins and washers (1) through the lift arms and cylinder end.
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6. Install rod end snap rings (1).
931001618
4
931001628
5
7. Install the hydraulic cylinder hoses (1), and position to prevent contact with other components, fenders, etc. Tighten hose fittings to standard torque. 8. Lower the lift arm 9. Start the skid steer and cycle the boom several times to remove trapped air from the system and check the cylinder for leaks.
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Ride control solenoid valve block - Remove WARNING Burn hazard! Before performing any service on the hydraulic system, you must allow it to cool. Hydraulic fluid temperature should not exceed 40 °C (104 °F). Failure to comply could result in death or serious injury. W0241A
WARNING Pressurized hydraulic fluid can penetrate the skin and cause severe injuries. Hydraulic fluid can also infect a minor cut or opening in the skin. Serious infection or reaction can result without immediate medical treatment. If injured by leaking fluid, see your doctor immediately. Failure to comply could result in death or serious injury. W0358A
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. Failure to comply could result in death or serious injury. W0905A
WARNING Avoid injury! Always do the following before lubricating, maintaining, or servicing the machine. 1. Disengage all drives. 2. Engage parking brake. 3. Lower all attachments to the ground, or raise and engage all safety locks. 4. Shut off engine. 5. Remove key from key switch. 6. Switch off battery key, if installed. 7. Wait for all machine movement to stop. Failure to comply could result in death or serious injury. W0047A
Prior operation: Relieve the pressure in the ride control system. Please see Accumulator - Depressurising (35.701). 1. Locate the ride control valve (1) on the skid steer chassis.
931001804
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1
Hydraulic systems - Front loader arm hydraulic system
2. Disconnect the valve electrical connection (1).
931001696
2
931001693
3
931001693
4
931001698
5
3. Remove hose clamp and disconnect drain hose (1) and cap open ports.
4. Disconnect the lower hydraulic tube (1) and cap open ports.
5. Disconnect the two upper hydraulic tubes (1) and cap open ports.
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6. Remove mounting hardware (1).
931001698
6
931001700
7
7. Remove valve.
Next operation: Ride control solenoid valve block - Install (35.701)
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Ride control solenoid valve block - Install Prior operation: Ride control solenoid valve block - Remove (35.701) 1. Locate valve (1) position on body.
931001804
1
931001698
2
931001698
3
931001693
4
2. Install mounting hardware (1).
3. Connect upper tubes (1).
4. Connect the lower hydraulic tube (1).
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5. Connect drain hose (1) and secure with hose clamp.
931001693
5
931001696
6
6. Connect valve electrical connection (1).
7. Disengage cab lock and tilt cab down.
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Relief valve - Remove - Lift arm or boom - cylinder override valve DANGER Crushing hazard! Failure to engage the loader arm support pin(s) could cause the loader arm to fall unexpectedly. Verify that the loader arm support pin(s) are engaged. Failure to comply will result in death or serious injury. D0133B
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. Failure to comply could result in death or serious injury. W0230A
CAUTION Burn hazard! Do not handle any service fluid (engine coolant, engine oil, hydraulic oil, etc.) at temperatures that exceed 49 °C (120 °F). Allow fluids to cool before proceeding. Failure to comply could result in minor or moderate injury. C0107B
Prior operation: Cab tilting system - Tilt (90.150) NOTE: Depending upon the machine configuration, the override valve may have two or three ports. 1. Remove the red knob (1) from the top of the override valve. NOTE: Figure 1 shows an override valve with three ports. The procedure is the same for a two port valve. 2. Remove the Pressure Relief Valve (PRV) drain tube (2) from the override valve. 3. Remove the override valve hoses, (3) and (4), from the override valve.
RAPH17SSL0419BA
1
RAPH17SSL0420AA
2
4. Remove the bolts (1) that secure the valve to the chassis nut cages. 5. Remove the override valve from the chassis mount bracket. NOTE: The mount bracket is located on the kick panel in the chassis.
Next operation: Relief valve - Install - Lift arm or boom - cylinder override valve (35.701) 48068130 29/01/2018
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Relief valve - Install - Lift arm or boom - cylinder override valve Prior operation: Relief valve - Remove - Lift arm or boom - cylinder override valve (35.701) NOTE: Depending upon the machine configuration, the override valve may have two or three ports. 1. Install the override valve into the chassis mount bracket and secure with the bolts (1) and nuts (not shown). NOTE: Figure 1 shows an override valve with three ports. The procedure is the same for a two port valve.
RAPH17SSL0420AA
1
RAPH17SSL0419BA
2
2. Connect the override valve hoses, (1) and (2), to the override valve. NOTE: Use standard hydraulic fitting torque values for the hoses, (1) and (2), and the drain tube (3). 3. Connect the Pressure Relief Valve (PRV) drain tube (3) to the override valve. 4. Install the red knob (4) onto the top of the override valve. Torque the handle to 11.0 – 16.0 N·m (8.0 – 12.0 lb ft).
5. Top off the hydraulic fluid and test the system. Next operation: Cab tilting system - Lower (90.150)
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Accumulator - Visual inspection
BS96H067
1. 2. 3. 4.
Tube Gland with gas valve Piston Seal
5. 6. 7. 8.
Quad ring O-ring Backup ring (if used) Cap screw
1
9. Guard 10. Gas valve assembly 11. Cap 12. Valve core
Prior operation: Accumulator - Disassemble (35.701) 1. Clean all parts in cleaning solvent. 2. Illuminate the inside of the tube (1). Inspect the inside of the tube for deep grooves or other damage. If the tube is damaged, replace with a new tube or cylinder.
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13. Body 14. Gland without gas valve
Hydraulic systems - Front loader arm hydraulic system
3. In a rotary motion, use an emery cloth with medium grit to remove small scratches on the piston (3), glands (2) and (14), and tube (1). 4. Inspect the glands (2) and (14), for rust or corrosion. Clean and remove the rust or corrosion from the gland. 5. Inspect the piston (3). Check to see if it is worn or damaged. If the piston is worn or damaged, replace with a new accumulator. 6. Inspect the gland ends of the tube (1) for sharp edges. Remove the sharp edges. Sharp edges can damage the seals (4), quad ring (5), and O-rings (6). Next operation: Accumulator - Assemble (35.701)
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Accumulator - Pressure test
BS04D004
1
1. Ensure that the oil side of the accumulator is completely discharged. 2. Put the ride control switch in the "On" position. 3. Lower the loader to the floor. Put the loader control lever in the "Float" position. 4. Stop the engine. Put the key in the "On" position. 5. Move the loader control lever in all directions to release any pressure in the hydraulic circuits. Put the loader control lever in the "Float" position. 6. Find the right and left solenoid valves for the ride control system. Find the pin in the coil end of the solenoid. Depress the pin in the solenoid valves with a soft pin (such as a welding rod) to release any pressure in the loader lift circuit. 7. Leave the ride control switch and key switch in the "On" postion. 8. Leave the loader control lever in the "Float" position. 9. Close the valves (B) and (C) on the nitrogen charging kit. 10. Turn the stem out of valve (F) until the stem stops. 11. Remove the cap screws and guard from the accumulator. 12. Remove the cap from the valve stem on the accumulator. 13. Connect valve (F) to the valve stem.
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14. Make sure that valve (D) is open. 15. Turn the stem into valve (F) and read the pressure on gauge (E). 16. The pressure must be 275 – 325 psi ( 1897 – 2241 kPa, 19 – 23 bar). If the pressure is too low, charge the accumulator with dry nitrogen.
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Accumulator - Depressurising 1. Support the loader arm with suitable lifting equipment. 2. Shut off the engine but do not shut off the machine, i.e. power on, engine off. 3. Press and hold the ride control button (1) to activate ride control .
93109392
1
RAPH12UTL0644AA
2
4. Use the override valve (1) to relieve pressure in the cylinders.
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Accumulator - Discharging NOTICE: Do not attempt to disassemble any accumulator until the nitrogen charge is properly discharged. NOTICE: To help prevent equipment damage, the low pressure gauge (3) must be shut "Off" during high pressure ( 150 psi/ 10 bar and above) applications.
934477A
(A) - Regulator (B)
(C) - Low pressure gauge (D)
1
(E) (F)
1. Use the accumulator charging kit 380001737 to discharge the accumulator. The tool must be disconnected from the nitrogen tank. 2. Close valves (B), (C) and (D). 3. Adjust the regulator (A) to the minimum pressure setting by turning the knob counterclockwise. 4. Turn the T-handle on valve (F) fully out. 5. Remove the guard and cap from the accumulator charging stem. 6. Connect valve (F) to the stem on the accumulator. 7. Turn the T-handle inward on valve (F) to engage the pin in the valve stem. 8. Open valve (D). Check the charge pressure on gauge (E). 9. Partially open valve (B) to discharge the accumulator. The accumulator charge will bleed down through the regulator.
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(G) - To nitrogen tank (H) - To accumulator
Hydraulic systems - Front loader arm hydraulic system
10. Once the accumulator is fully discharged, disconnect valve (F) from the accumulator stem.
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Accumulator - Disassemble 1. Fasten the accumulator tube (1) in a vise with soft jaws. Be careful not to damage the tube. NOTICE: The gland with the gas valve must be removed first. 2. Loosen and remove the glands (2) or (14) from each end of the tube. 3. Use a rod and push the piston (3) out of the gas valve end of the tube. 4. Remove and discard the seals (4) and quad ring (5) from the piston. 5. Remove and discard the O-rings (6) and if used, the backup ring (7) from the glands. 6. Loosen and remove the cap screws (8) and guard (9). 7. Loosen and remove the gas valve assembly (10). 8. Remove the O-ring (6), cap (11), and valve core (12) from the body (13).
BS96H067
1. 2. 3. 4.
Tube Gland with gas valve Piston Seal
5. 6. 7. 8.
Quad ring O-ring Backup ring (if used) Cap screw
1
9. Guard 10. Gas valve assembly 11. Cap 12. Valve core
Next operation: Accumulator - Visual inspection (35.701)
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13. Body 14. Gland without gas valve
Hydraulic systems - Front loader arm hydraulic system
Accumulator - Assemble
BS96H068
1. 2. 3. 4.
Tube Gland with gas valve Piston Seal
5. 6. 7. 8.
Quad ring O-ring Backup ring (if used) Cap screw
1
9. Guard 10. Gas valve assembly 11. Cap 12. Valve core
Prior operation: Accumulator - Disassemble (35.701) 1. Slide one new seal (4), on one end of the piston. 2. Slide one new quad ring (5) into the middle groove of the piston. 3. Slide one new seal (4) on the other end of the piston. 4. Lubricate the bore of the tube (1) and the piston (3) with clean hydraulic oil. NOTE: The piston must be installed slowly to prevent damage to the threads on the quad ring.
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13. Body 14. Gland without gas valve
Hydraulic systems - Front loader arm hydraulic system
5. Start the piston (3) into the gas valve end of the tube (1). A soft hammer and wood block may be used to drive the piston farther into the tube. Carefully drive the piston at least 2 in ( 51 mm) into the tube. Keep pressure against the piston when driving the piston into the tube, to prevent damage to the quad ring (5). Follow the same procedure for the non-gas valve end of the tube. 6. If used, install a new back ring (7) on the gland (2). Make sure the backup ring is installed. Follow the same procedure for the non-gas valve end of the tube. 7. Install the O-ring (6) next to the backup ring (7). If a backup ring is not used, install an O-ring in the groove on the gland. Follow the same procedure for the nongas valve end of the tube.
BS04D006
8. Lubricate the O-ring (6) and the backup ring (7) with clean hydraulic oil. Start the gland (2) into the tube (1). Follow the same procedure for the non-gas valve (14) end of the tube. 9. Fasten the tube (1) in the vise. Tighten the gland (2). Follow the same procedure for the non-gas valve end of the tube 10. Install a new O-ring (6)on the body (13)of the gas valve assembly (10). 11. Install the valve core (12) in the body (13). 12. Lubricate the O-ring (6) with clean hydraulic oil. Install and tighten the gas valve assembly (10)in the gland (2). 13. Install the cap (11). 14. Charge the accumulator with dry nitrogen. Please refer to Accumulator - Charging (35.701) 15. Install the guard (9) and cap screws (8).
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2
Hydraulic systems - Front loader arm hydraulic system
Accumulator - Charging SPECIAL TOOLS
BS06M002
1
380001676 Nitrogen Regulator Valve
BS06M003-01
2
380001390 Accumulator Charging Hose NOTE: Check the pressure in the accumulator according to the instructions in this section. Keep the nitrogen charging kit connected to the accumulator.
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BT09C458
3
Nitrogen Charging Kit NOTE: Do not expose the accumulator to temperatures above 120째F (49째C). A charged accumulator contains nitrogen compressed to 1600 PSI (11 032 kPa). High heat will cause the safety plug to blow out of the accumulator and the escaping nitrogen will propel the accumulator at a dangerous rate of speed. M407
Charging Accumulator with Nitrogen WARNING Explosion hazard! Use only nitrogen when charging the accumulator. Do not use air or oxygen that will cause an explosion. Failure to comply could result in death or serious injury. W0975A
WARNING Explosion hazard! Do not expose the accumulator to temperatures above 120째F (49째C). A charged accumulator contains nitrogen compressed to 110 bar (1600 PSI). High heat will cause the safety plug to blow out of the accumulator and the escaping nitrogen will propel the accumulator at a dangerous rate of speed. Failure to comply could result in death or serious injury. W0977C
NOTICE: The four valves A, D, and E must be in the positions noted in the procedure before connecting the Nitrogen Accumulator Charging Kit to the machine or nitrogen tank refer to image 3. 1. Close the shutoff valve (D) by turning it all the way to the left (counterclockwise). 2. Close the gauge valve (E) by turning it all the way to the right (clockwise). 3. Connect the charging gauges to the nitrogen supply tank, open the supply tank valve.
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4. Slowly turn valve (D) clockwise while watching the pressure gauge (B). Stop turning valve (D) when the needle on gauge (B) reaches 10 bar (145 psi). NOTE: If the needle goes over the needed pressure, quickly open and close valve (E) and check the pressure again. The charging kit is now ready to be installed on the accumulator. 5. Remove the cap from the accumulator. 6. Loosen the sealing plug with an Allen wrench. 7. Back off the needle valve (A) on the accumulator end of the charging hose by turning it counterclockwise to the maximum position. This prevents nitrogen from escaping from the accumulator when the charging hose is attached to the accumulator gas charging valve. 8. Install the charging hose fitting onto the accumulator. 9. Tighten the needle valve by turning it clockwise. Slowly open the gauge valve (E) and observe the reading on the gauge. This reading is the nitrogen pressure level inside the accumulator. 10. Fill the accumulator to a charge pressure of 20.7 – 22.4 bar (300 – 325 psi). 11. Close valve (E) by turning to the right (clockwise). After a few minutes open valve (E) and check the accumulator for leakage. 12. Back off the needle valve (A) on accumulator end of the charging hose by turning it counterclockwise the maximum amount. This will prevent nitrogen from escaping from the accumulator as the hose is removed. 13. Close the valve on the nitrogen supply tank. 14. Adjust the regulator (D) to the minimum pressure setting by turning the knob counterclockwise. 15. Slowly remove the charging hose from the accumulator pressure valve. NOTE: A small amount of nitrogen will escape when disconnecting the hose. 16. Install the cap on the accumulator, torque to 1.13 N¡m (10 lb in). NOTE: A small amount of nitrogen will escape when disconnecting the hose.
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Front loader arm hydraulic system - Troubleshooting Problem The loader arm will not raise when commanded.
Possible Cause The OPERATE button on the instrument cluster has not been pushed. The lap bar is not being used. The seat switch doesn’t not sense an operator. The override valve is releasing pressure in the loader arm cylinders. The cab door (If equipped with cab door) is opened. The cab door switch (If equipped with cab door) is not functioning correctly. The joysticks are not calibrated correctly. The Joystick linkage may need readjustment. The solenoid for the loader pilot interlock (only on electro hydraulic controls) on the brake valve is not functioning as designed. The port lock solenoid on the main control valve is not functioning as designed. Hydraulic pressure is low.
Correction 1. If the OPERATE button is flashing, press the OPERATE button. Use the lap bar. Test the seat switch. Inspect the override valve. Ensure that the cab door is fully closed. 1. Align the cab door switch. 2. Test the cab door switch. Calibrate the joysticks, using the Electronic Service Tool (EST). Adjust the linkage. Inspect the solenoid.
Inspect the port lock solenoid.
Check the charge pressure at the main control valve. Please see Pump Charge pressure relief valve - Pressure test (29.218). Main control valve not operating as de- Inspect the main control valve. signed. Linkage is damaged. Inspect the linkage. Main relief valve faulty Test the main relief valve pressure. Please see Main relief valve - Pressure test - T fitting (35.350). Gear pump faulty Test the main gear pump flow efficiency. Please see Fixed displacement pump Flow test - T fitting (35.104).
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Index Hydraulic systems - 35 Front loader arm hydraulic system - 701 Accumulator - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
46
Accumulator - Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
48
Accumulator - Component localization (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
16
Accumulator - Depressurising . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
42
Accumulator - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
45
Accumulator - Discharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
43
Accumulator - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10
Accumulator - Pressure test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
40
Accumulator - Visual inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
38
Front loader arm hydraulic system - Component localization (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12
Front loader arm hydraulic system - General specification - Override valve . . . . . . . . . . . . . . . . . . . .
4
Front loader arm hydraulic system - General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5
Front loader arm hydraulic system - General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5
Front loader arm hydraulic system - Overview - Electro-Hydraulic (EH) - Hydraulic system control (loader arm, bucket tilt, auxiliary hydraulics) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11
Front loader arm hydraulic system - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
51
Lift arm cylinder - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
25
Lift arm cylinder - Depressurising . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
17
Lift arm cylinder - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
24
Lift arm cylinder - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
27
Lift arm cylinder - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
29
Lift arm cylinder - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
18
Lift arm cylinder - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
21
Relief valve - General specification - Lift arm or boom - cylinder override valve . . . . . . . . . . . . . . . . .
8
Relief valve - Install - Lift arm or boom - cylinder override valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
37
Relief valve - Remove - Lift arm or boom - cylinder override valve . . . . . . . . . . . . . . . . . . . . . . . . . . . .
36
Ride control solenoid valve block - Component localization (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
14
Ride control solenoid valve block - Component localization (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15
Ride control solenoid valve block - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7
Ride control solenoid valve block - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
34
Ride control solenoid valve block - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13
Ride control solenoid valve block - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
31
(*) See content for specific models 48068130 29/01/2018
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Hydraulic systems - 35 Front loader bucket hydraulic system - 723
SR210 TIER 4B (FINAL) [NGM418237 - ], SR210 TIER 4B (FINAL) [NHM435463 - ], SR240 TIER 4B (FINAL) [NGM418237 - ], SR240 TIER 4B (FINAL) [NHM435463 - ], SV280 TIER 4B (FINAL) [NGM418237 - ], SV280 TIER 4B (FINAL) [NHM435463 - ], TR270 TIER 4B (FINAL) [NGM418237 - ], TR270 TIER 4B (FINAL) [NHM435463 - ], TR310 TIER 4B (FINAL) [NGM418237 - ], TR310 TIER 4B (FINAL) [NHM435463 - ], TV370 TIER 4B (FINAL) [NHM435463 - ]
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Contents Hydraulic systems - 35 Front loader bucket hydraulic system - 723
SERVICE Front loader bucket hydraulic system Pressure test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Loader bucket control cylinder Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
DIAGNOSTIC Front loader bucket hydraulic system Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
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Front loader bucket hydraulic system - Pressure test 1. If the hydraulic oil is not at operating temperature run the engine at full throttle and hold the bucket control lever in the ROLLBACK position for 30 seconds. Then return the bucket control lever to NEUTRAL for 15 seconds. Repeat this cycle until the temperature of the oil is at least 52°C (125°F). 2. Disconnect the hydraulic lines from the implement controller where they connect to the main control valve. 3. Connect a 41 bar (600 psi) pressure gauges to pilot line at spool ends. 4. Start the engine and run at high idle. Read the pressure gauge and record the pressure reading at high idle. Pressure should be 0 bar (0.0 psi) with lever in neutral. 5. Move the implement controller lever to tilt the loader bucket. Read the pressure gauge and record the pressure reading. 6. Move the implement controller lever to dump the loader bucket. Read the pressure gauge and record the pressure reading. 7. The pressure readings should vary from 0 bar (0.0 psi) to 25 bar (360 psi) at high idle for a given angle on the implement control handle. 8. If the pressure readings are correct, the test is complete. If the pressure readings are not correct, repair or replace the charge/hydrostatic pump assembly or the main control valve.
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Hydraulic systems - Front loader bucket hydraulic system
Loader bucket control cylinder - Remove WARNING Escaping fluid! Relieve all pressure before disconnecting fluid lines or performing work on the hydraulic system. Make sure all components are in good condition and tighten all connections before pressurizing the system. DO NOT use your hand to check for leaks. Use a piece of cardboard or paper. Failure to comply could result in death or serious injury. W1140A
1. Lower the loader arm down to the stops. 2. Remove the bucket and attachments. 3. Roll the coupler forward to allow for cylinder removal clearance. 4. Support the weight of the coupler to prevent it from rolling forward. 5. Relieve hydraulic pressure to the cylinder. 6. Disconnect the hydraulic hoses (1) from the cylinder (2).
RAPH17SSL0211AA
1
RAPH17SSL0212AA
2
RAPH17SSL0213AA
3
7. Remove the pin securing the cylinder to the coupler. 8. Remove the bolt and washer from the loader arm pin.
9. Remove the cylinder. NOTE: The cylinder weighs approximately 17.3 kg (38.1 lb).
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Next operation: Loader bucket control cylinder - Install (35.723)
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Loader bucket control cylinder - Assemble
RAPH17SSL0239FA
1. 2. 3. 4. 5. 6.
Tube Bushing Piston Rod Bushing Packing gland Piston
1
7. Wiper 8. Seal (kit) 9. O-ring 10. Backup ring 11. Seal 12. Backup Ring
13. 14. 15. 16. 17. 18.
Wear ring Bolt Rod end Washer Weld ring Plug
NOTE: If a new gland is being installed, put the part number of the cylinder on the new gland. 1. Before assembly, lubricate the rod (3) and the cylinder bore with hydraulic oil. 2. Lubricate a new seal (8) with clean hydraulic oil. Insert the new seal into the gland so the lips are toward the small end of the gland. 3. Lubricate a new wiper (7) with hydraulic oil. Insert the new wiper into the gland so the lips are toward the large end of the gland. 4. Lubricate a new backup ring (10) with clean hydraulic oil. Insert the new backup ring into the groove on the outside of the gland so the flat side is toward the large end of the gland. 5. Lubricate a new O-ring (9) with clean hydraulic oil. Insert the O-ring into the groove and onto the backup ring on the outside of the gland. 6. Fasten the piston rod end (15) in a vise. 7. Remove any marks or sharp edges on the chamfered end of the piston rod. 8. Lubricate the bore of the gland with clean hydraulic oil.
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9. Push the gland onto the piston rod. If the gland will not slide easily onto the piston rod, use a soft hammer to drive the gland onto the piston rod. 10. To prevent damage to the piston rod, place a support below and near the end of the piston rod. Use a shop cloth between the support and the piston rod. 11. Install the piston (6) onto the end of the piston rod. 12. Clean the threads on the end of the piston rod and the threads of the nut using Loctite cleaning solvent. Allow all the parts to dry. Apply 1/2 in of LOCTITE® 243™ onto the threads of the piston rod 1/4 in from the open end of the piston rod. NOTE: Do not apply LOCTITE® 243™ to the first 1/4 in of the piston rod threads. 13. Install the bolt (14) with washer (16). 14. Tighten the bolt to a torque of 692.0 – 800.0 N·m (510.0 – 590.0 lb ft). A torque multiplier can be used to tighten the bolt. 15. Lubricate a new backup ring (12) with clean hydraulic oil. Slide the backup ring into the center groove on the outside of the piston. 16. Lubricate a new seal (11) with clean hydraulic oil. Slide the new seal onto the backup ring on the outside of the piston. 17. Lubricate a new wear ring (13) with clean hydraulic oil. Slide the new wear ring into the end groove on the opposite end of the piston. 18. Lubricate the inside of the tube and the piston with clean hydraulic oil. Use a piston ring compression tool to hold the new wear ring in place. 19. Push the tube straight onto the piston. 20. Start the tube onto the piston rod assembly. Push the tube onto the piston rod until the compression tool is clear of the piston rod. Be careful not to damage the wear ring and the seal. 21. When the piston is in the smooth part of the tube, start the gland (5) into the tube. 22. Lubricate the new O-ring (9) on the gland with clean hydraulic oil. 23. Tighten the gland (5) to the torque of 407.0 – 542.0 N·m (300.0 – 400.0 lb ft). 24. If hoses were removed with the cylinder, install new O-rings, if equipped, on the hose fittings. Lubricate the new O-rings with clean hydraulic oil and install the hoses.
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Hydraulic systems - Front loader bucket hydraulic system
Loader bucket control cylinder - Install Prior operation: Loader bucket control cylinder - Remove (35.723) 1. Install the cylinder onto the loader arm and bucket coupler. NOTE: The cylinder weighs approximately 17.3 kg (38.1 lb). NOTE: Apply LOCTITE® 767 to the pins, bosses, and tilt cylinder end bushings.
RAPH17SSL0213AA
1
RAPH17SSL0212AA
2
RAPH17SSL0214BA
3
2. Install the bolt and washer to secure the cylinder to the loader arm pin. 3. Torque the bolt to 181 – 245 N·m (134 – 181 lb ft).
4. Install the pin (1), the bolt (2), the spacer (3), and the nut (4) to secure the cylinder to the bucket coupler. NOTE: The cylinder is hidden for clarity.
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5. Install the hydraulic hoses (1) to the cylinder (2). Use standard hydraulic torques for the hose fittings.
RAPH17SSL0211AA
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4
Hydraulic systems - Front loader bucket hydraulic system
Loader bucket control cylinder - Disassemble 1. Clean the outside of the cylinder. If the hoses were removed from the cylinder, remove the hoses. 2. Fasten the tube (1) in a vise, or other holding equipment can be used. Be careful not to damage the tube. 3. Loosen the gland (5) in the tube with a gland wrench. 4. To prevent damage to the tube, pull the piston rod (3) straight out of the tube. 5. Fasten the piston rod end in a vise. To prevent damage to the piston rod, place a padded support below the piston rod near the piston. 6. Loosen and remove the bolt (14) and the washer (16) that connects the piston on the piston rod. 7. Remove the piston (6) from the piston rod. 8. Remove and discard the seal (11), wear ring (13) and backup ring (12) from the piston. 9. Remove and discard the O-ring (9), backup ring (10), seals (8), and wiper (7) from the gland (5).
RAPH17SSL0239FA
(1) Tube (2) Bushing (3) Piston Rod (4) Bushing
(5) Packing gland (6) Piston (7) Wiper (8) Seal (kit)
1
(9) O-ring (10) Backup ring (11) Seal (12) Backup Ring
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(13) Wear ring (14) Bolt (15) Rod end (16) Washer
(17) Weld ring (18) Plug
Hydraulic systems - Front loader bucket hydraulic system
Front loader bucket hydraulic system - Testing Test N°1 Test Point Check Check to ensure the cab door is fully closed (If equipped with cab door). Expected Result Result Door is closed. Action Go to test 2 Other Result Result Door is opened. (Possible Action Cause) Close door. Test N°2 Test Point Check Check the cab door switch (If equipped with cab door). Expected Result Result Switch is okay. Action Go to test 3 Other Result Result No power or ground. (Possible Door switch is misaligned. Cause) Action Repair. Test N°3 Test Point Check Check the Implement Controller interlock valve power/function. Expected Result Result Valve functioning as designed. Action Go to test 4 Other Result Result No power or ground. (Possible Valve doesn’t function. Cause) Action Repair or replace. Test N°4 Test Point Check Check the charge pressure. Expected Result Result Charge pressure okay. Action Go to test 5 Other Result Result Low charge pressure. (Possible Action Cause) Check the charge pressure.. Test N°5 Test Point Check Check the pilot pressure from the Implement Controller to the Loader Control Valve.
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Hydraulic systems - Front loader bucket hydraulic system
Expected Result Result Pilot pressure is okay. Action Go to test 6 Other Result Result Low pilot pressure. (Possible Action Cause) Please see Front loader arm hydraulic system - Pressure test (35.701) Test N°6 Test Point Check Check the main control valve function. Expected Result Result Main control valve is okay. Other Result Result Main control valve not functioning as designed. (Possible Action Cause) Repair or replace the main control valve.
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Index Hydraulic systems - 35 Front loader bucket hydraulic system - 723 Front loader bucket hydraulic system - Pressure test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3
Front loader bucket hydraulic system - Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11
Loader bucket control cylinder - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6
Loader bucket control cylinder - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10
Loader bucket control cylinder - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8
Loader bucket control cylinder - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4
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Hydraulic systems - 35 Tool quick coupler hydraulic system - 734
SR210 TIER 4B (FINAL) [NGM418237 - ], SR210 TIER 4B (FINAL) [NHM435463 - ], SR240 TIER 4B (FINAL) [NGM418237 - ], SR240 TIER 4B (FINAL) [NHM435463 - ], SV280 TIER 4B (FINAL) [NGM418237 - ], SV280 TIER 4B (FINAL) [NHM435463 - ], TR270 TIER 4B (FINAL) [NGM418237 - ], TR270 TIER 4B (FINAL) [NHM435463 - ], TR310 TIER 4B (FINAL) [NGM418237 - ], TR310 TIER 4B (FINAL) [NHM435463 - ], TV370 TIER 4B (FINAL) [NHM435463 - ]
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Contents Hydraulic systems - 35 Tool quick coupler hydraulic system - 734
TECHNICAL DATA Tool quick coupler hydraulic system General specification - Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
FUNCTIONAL DATA Tool quick coupler hydraulic system Component localization - Valve (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Component localization - Valve (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
SERVICE Tool quick coupler hydraulic system Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Quick coupler cylinder Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
(*) See content for specific models 48068130 29/01/2018
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Tool quick coupler hydraulic system - General specification - Valve
RAPH12SSL0386EA
1
Hydraulic coupler valve Relief pressure Port identification
172 bar (2500 psi) P - Pump supply inlet T - Tank return C1 - Cylinder base end C2 - Cylinder rod end
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Tool quick coupler hydraulic system - Component localization - Valve SR210 SR210 SR240 SR240 TR270
TIER TIER TIER TIER
4B 4B 4B 4B
(FINAL) (FINAL) (FINAL) (FINAL)
[NGM418237 - ] [NHM435463 - ] [NGM418237 - ] [NHM435463 - ]
RAPH13SSL0863FA
1
Valve location Valve identification (1) Ride control valve
(3) Loader pilot interlock, brake, two speed valve (2) Hydraulic coupler valve (4) Second auxiliary valve
(5) High flow valve (6) Override valve for the loader arm
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(7) Self-leveling valve
Hydraulic systems - Tool quick coupler hydraulic system
Tool quick coupler hydraulic system - Component localization - Valve SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
RAIL13SSL1004FA
1
Valve location Valve identification (1) Ride control valve
(3) Loader pilot interlock, brake, two speed valve (2) Hydraulic coupler valve (4) Second auxiliary valve
(5) Accumulator (6) High flow valve
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(7) Self level valve
Hydraulic systems - Tool quick coupler hydraulic system
Tool quick coupler hydraulic system - Remove WARNING Pressurized system! System is still under pressure. Release pressure according to instructions in this manual. Failure to comply could result in death or serious injury. W1044A
1. Remove the bucket or attachment from the mounting plate.
20092924
1
93106838
2
931001722
3
2. Set the quick coupler in the unlocked position.
3. Label and disconnect electrical connection (1).
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4. Label and disconnect the bucket hydraulic tubes (1) and cap the open ports.
931001720
4
931001720
5
931001720
6
931001720
7
5. Label and disconnect the supply tube (1) and cap the open ports.
6. Label and disconnect the drain hose (1).
7. Remove the mounting hardware (2).
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Hydraulic systems - Tool quick coupler hydraulic system
8. Remove the command valve.
931001721
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8
Hydraulic systems - Tool quick coupler hydraulic system
Tool quick coupler hydraulic system - Install 1. Locate where the command valve (1) should be positioned on the body.
931001720
1
931001720
2
931001720
3
931001720
4
2. Install the mounting hardware (1).
3. Connect the valve drain hose (1).
4. Connect the valve supply tube (1).
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5. Connect the bucket hydraulic tubes (2).
931001720
5
931001722
6
6. Connect the electrical connection (1).
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Hydraulic systems - Tool quick coupler hydraulic system
Quick coupler cylinder - Remove WARNING Burn hazard! Before performing any service on the hydraulic system, you must allow it to cool. Hydraulic fluid temperature should not exceed 40 °C (104 °F). Failure to comply could result in death or serious injury. W0241A
WARNING Pressurized hydraulic fluid can penetrate the skin and cause severe injuries. Hydraulic fluid can also infect a minor cut or opening in the skin. Serious infection or reaction can result without immediate medical treatment. If injured by leaking fluid, see your doctor immediately. Failure to comply could result in death or serious injury. W0358A
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. Failure to comply could result in death or serious injury. W0905A
WARNING Avoid injury! Always do the following before lubricating, maintaining, or servicing the machine. 1. Disengage all drives. 2. Engage parking brake. 3. Lower all attachments to the ground, or raise and engage all safety locks. 4. Shut off engine. 5. Remove key from key switch. 6. Switch off battery key, if installed. 7. Wait for all machine movement to stop. Failure to comply could result in death or serious injury. W0047A
1. Remove the bucket or attachment from the mounting plate.
20092924
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1
Hydraulic systems - Tool quick coupler hydraulic system
2. Set the quick coupler in the unlocked position.
93106838
2
931001791
3
931001788
4
931001786
5
3. Remove snap ring (1).
4. Remove retaining pin (1).
5. Disconnect hydraulic hoses (1) and (2), from manifold.
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Hydraulic systems - Tool quick coupler hydraulic system
6. Remove rod end hydraulic hose (1).
931001789
6
931001783
7
931001784
8
7. Disengage the roll pin and bucket locking pin (1).
8. Remove cylinder.
Next operation: Quick coupler cylinder - Install (35.734)
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Hydraulic systems - Tool quick coupler hydraulic system
Quick coupler cylinder - Install Prior operation: Quick coupler cylinder - Remove (35.734) 1. Hold cylinder in mounting location on the skid steer and engage bucket locking pin (1) through the rod end.
931001782
1
931001788
2
931001791
3
931001789
4
2. Through the top of the cylinder install the retaining pin (1).
3. Secure the retaining pin with a snap ring (1).
4. Connect the rod end hydraulic hose (1).
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Hydraulic systems - Tool quick coupler hydraulic system
5.
WARNING Unexpected movement! When cylinders are connected to the machine hydraulic system, cycle the hydraulic circuits several times to remove air from the cylinder and hose. Air in the system can cause erratic operation or can cause equipment to drop unexpectedly. Failure to comply could result in death or serious injury. W1083A
Connect hydraulic hoses (1) and (2), to the manifold. 931001786
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5
Index Hydraulic systems - 35 Tool quick coupler hydraulic system - 734 Quick coupler cylinder - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
14
Quick coupler cylinder - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11
Tool quick coupler hydraulic system - Component localization - Valve (*) . . . . . . . . . . . . . . . . . . . . . .
4
Tool quick coupler hydraulic system - Component localization - Valve (*) . . . . . . . . . . . . . . . . . . . . . .
5
Tool quick coupler hydraulic system - General specification - Valve . . . . . . . . . . . . . . . . . . . . . . . . . . .
3
Tool quick coupler hydraulic system - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9
Tool quick coupler hydraulic system - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6
(*) See content for specific models 48068130 29/01/2018
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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. Š 2018 CNH Industrial America LLC. All rights reserved. No part of the text or illustrations of this publication may be reproduced.
CNH Industrial America LLC reserves the right to make improvements in design and changes in specifications at any time without notice and without incurring any obligation to install them on units previously sold. Specifications, descriptions, and illustrative material herein are as accurate as known at the time of publication, but are subject to change without notice. Availability of some models and equipment builds varies according to the country in which the equipment is being used. For exact information about any particular product, please consult your CASE CONSTRUCTION dealer. CASE CONSTRUCTION is a trademark registered in the United States and many other countries, owned or licensed to CNH Industrial N.V., its subsidiaries or affiliates. Any trademarks referred to herein, in association with goods and/or services of companies, other than owned by or licensed to CNH Industrial N.V., its subsidiaries or affiliates, are the property of those respective companies.
48068130 29/01/2018 EN
SERVICE MANUAL Frames and ballasting SR210 TIER 4B (FINAL) [NGM418237 - ], SR210 TIER 4B (FINAL) [NHM435463 - ], SR240 TIER 4B (FINAL) [NGM418237 - ], SR240 TIER 4B (FINAL) [NHM435463 - ], SV280 TIER 4B (FINAL) [NGM418237 - ], SV280 TIER 4B (FINAL) [NHM435463 - ], TR270 TIER 4B (FINAL) [NGM418237 - ], TR270 TIER 4B (FINAL) [NHM435463 - ], TR310 TIER 4B (FINAL) [NGM418237 - ], TR310 TIER 4B (FINAL) [NHM435463 - ], TV370 TIER 4B (FINAL) [NHM435463 - ]
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Contents Frames and ballasting - 39
[39.140] Ballasts and supports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39.1
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Frames and ballasting - 39 Ballasts and supports - 140
SR210 TIER 4B (FINAL) [NGM418237 - ], SR210 TIER 4B (FINAL) [NHM435463 - ], SR240 TIER 4B (FINAL) [NGM418237 - ], SR240 TIER 4B (FINAL) [NHM435463 - ], SV280 TIER 4B (FINAL) [NGM418237 - ], SV280 TIER 4B (FINAL) [NHM435463 - ], TR270 TIER 4B (FINAL) [NGM418237 - ], TR270 TIER 4B (FINAL) [NHM435463 - ], TR310 TIER 4B (FINAL) [NGM418237 - ], TR310 TIER 4B (FINAL) [NHM435463 - ], TV370 TIER 4B (FINAL) [NHM435463 - ]
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Contents Frames and ballasting - 39 Ballasts and supports - 140
SERVICE Counterweight Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
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Frames and ballasting - Ballasts and supports
Counterweight - Remove DANGER Heavy objects! Lift and handle all heavy components using lifting equipment with adequate capacity. Always support units or parts with suitable slings or hooks. Make sure the work area is clear of all bystanders. Failure to comply will result in death or serious injury. D0076A
Prior operation: Remove the battery. See Battery - Remove (55.302).
Left hand side 1. Support the counterweight with a suitable lifting device. Remove corner mounting hardware (1). 2. Remove the counterweight.
RAPH12SSL0289AA
1
RAPH12SSL0041AA
2
Right hand side 3. Support the counterweight with a suitable lifting device. Remove corner mounting hardware (1). 4. Remove the counterweight.
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Frames and ballasting - Ballasts and supports
Center bumper 5. Support the center bumper with a suitable lifting device. Remove center bumper mounting hardware (1).
RAPH12SSL0040AA
3
931001656
4
6. Remove center bumper (3).
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Frames and ballasting - Ballasts and supports
Counterweight - Install DANGER Heavy objects! Lift and handle all heavy components using lifting equipment with adequate capacity. Always support units or parts with suitable slings or hooks. Make sure the work area is clear of all bystanders. Failure to comply will result in death or serious injury. D0076A
1. Place rear center bumper (1) in position.
931001656
1
RAPH12SSL0040AA
2
RAPH12SSL0289AA
3
2. Install center bumper mounting hardware (2).
3. Install left hand side counterweight and secure in place with mounting hardware (1).
NOTE: Perform the same operation on right hand side.
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Index Frames and ballasting - 39 Ballasts and supports - 140 Counterweight - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5
Counterweight - 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. Š 2018 CNH Industrial America LLC. All rights reserved. No part of the text or illustrations of this publication may be reproduced.
CNH Industrial America LLC reserves the right to make improvements in design and changes in specifications at any time without notice and without incurring any obligation to install them on units previously sold. Specifications, descriptions, and illustrative material herein are as accurate as known at the time of publication, but are subject to change without notice. Availability of some models and equipment builds varies according to the country in which the equipment is being used. For exact information about any particular product, please consult your CASE CONSTRUCTION dealer. CASE CONSTRUCTION is a trademark registered in the United States and many other countries, owned or licensed to CNH Industrial N.V., its subsidiaries or affiliates. Any trademarks referred to herein, in association with goods and/or services of companies, other than owned by or licensed to CNH Industrial N.V., its subsidiaries or affiliates, are the property of those respective companies.
48068130 29/01/2018 EN
SERVICE MANUAL Wheels SR210 TIER 4B (FINAL) [NGM418237 - ], SR210 TIER 4B (FINAL) [NHM435463 - ], SR240 TIER 4B (FINAL) [NGM418237 - ], SR240 TIER 4B (FINAL) [NHM435463 - ], SV280 TIER 4B (FINAL) [NGM418237 - ], SV280 TIER 4B (FINAL) [NHM435463 - ], TR270 TIER 4B (FINAL) [NGM418237 - ], TR270 TIER 4B (FINAL) [NHM435463 - ], TR310 TIER 4B (FINAL) [NGM418237 - ], TR310 TIER 4B (FINAL) [NHM435463 - ], TV370 TIER 4B (FINAL) [NHM435463 - ]
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Contents Wheels - 44
[44.511] Front wheels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.1 [44.520] Rear wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.2
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Wheels - 44 Front wheels - 511
SR210 TIER 4B (FINAL) [NGM418237 - ], SR210 TIER 4B (FINAL) [NHM435463 - ], SR240 TIER 4B (FINAL) [NGM418237 - ], SR240 TIER 4B (FINAL) [NHM435463 - ], SV280 TIER 4B (FINAL) [NGM418237 - ], SV280 TIER 4B (FINAL) [NHM435463 - ], TR270 TIER 4B (FINAL) [NGM418237 - ], TR270 TIER 4B (FINAL) [NHM435463 - ], TR310 TIER 4B (FINAL) [NGM418237 - ], TR310 TIER 4B (FINAL) [NHM435463 - ], TV370 TIER 4B (FINAL) [NHM435463 - ]
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Contents Wheels - 44 Front wheels - 511
TECHNICAL DATA Front wheels Tire pressure (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Torque (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
(*) See content for specific models 48068130 29/01/2018
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Wheels - Front wheels
Front wheels - Tire pressure SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ]
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. Failure to comply could result in death or serious injury. W0109A
TIRE Heavy Duty
Premium
Premium with liner Severe Duty Flotation Mining Non-Pneumatic
SIZE 10 x 16.5 12 x 16.5 27/10.5 x 15 10 x 16.5 12 x 16.5 14 x 17.5 10 x 16.5 12 x 16.5 10 x 16.5 12 x 16.5 33 x 15.5 x 16.5 12 x 16.5 12 x 16.5
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PRESSURE 290 – 345 kPa (42 – 50 psi) 290 – 345 kPa (42 – 50 psi) 359 – 414 kPa (52 – 60 psi) 290 – 345 kPa (42 – 50 psi) 290 – 345 kPa (42 – 50 psi) 290 – 345 kPa (42 – 50 psi) 290 – 345 kPa (42 – 50 psi) not required
Wheels - Front wheels
Front wheels - Torque SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ]
63109344
1
Torque pattern Torque table Taper nut torque Flange nut torque
169.5 N·m (125 lb ft) 203.5 N·m (150 lb ft)
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Index Wheels - 44 Front wheels - 511 Front wheels - Tire pressure (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3
Front wheels - Torque (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4
(*) See content for specific models 48068130 29/01/2018
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Wheels - 44 Rear wheels - 520
SR210 TIER 4B (FINAL) [NGM418237 - ], SR210 TIER 4B (FINAL) [NHM435463 - ], SR240 TIER 4B (FINAL) [NGM418237 - ], SR240 TIER 4B (FINAL) [NHM435463 - ], SV280 TIER 4B (FINAL) [NGM418237 - ], SV280 TIER 4B (FINAL) [NHM435463 - ], TR270 TIER 4B (FINAL) [NGM418237 - ], TR270 TIER 4B (FINAL) [NHM435463 - ], TR310 TIER 4B (FINAL) [NGM418237 - ], TR310 TIER 4B (FINAL) [NHM435463 - ], TV370 TIER 4B (FINAL) [NHM435463 - ]
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Contents Wheels - 44 Rear wheels - 520
TECHNICAL DATA Rear wheels Tire pressure (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Torque (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
(*) See content for specific models 48068130 29/01/2018
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Wheels - Rear wheels
Rear wheels - Tire pressure SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ]
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. Failure to comply could result in death or serious injury. W0109A
TIRE Heavy Duty
Premium
Premium with liner Severe Duty Flotation Mining Non-Pneumatic
SIZE 10 x 16.5 12 x 16.5 27/10.5 x 15 10 x 16.5 12 x 16.5 14 x 17.5 10 x 16.5 12 x 16.5 10 x 16.5 12 x 16.5 33 x 15.5 x 16.5 12 x 16.5 12 x 16.5
Rear wheels - Torque SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ]
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PRESSURE 290 – 345 kPa (42 – 50 psi) 290 – 345 kPa (42 – 50 psi) 359 – 414 kPa (52 – 60 psi) 290 – 345 kPa (42 – 50 psi) 290 – 345 kPa (42 – 50 psi) 290 – 345 kPa (42 – 50 psi) 290 – 345 kPa (42 – 50 psi) not required
Wheels - Rear wheels
63109344
1
Torque pattern Torque table Taper nut torque Flange nut torque
169.5 N·m (125 lb ft) 203.5 N·m (150 lb ft)
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Index Wheels - 44 Rear wheels - 520 Rear wheels - Tire pressure (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3
Rear wheels - Torque (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3
(*) See content for specific models 48068130 29/01/2018
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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. Š 2018 CNH Industrial America LLC. All rights reserved. No part of the text or illustrations of this publication may be reproduced.
CNH Industrial America LLC reserves the right to make improvements in design and changes in specifications at any time without notice and without incurring any obligation to install them on units previously sold. Specifications, descriptions, and illustrative material herein are as accurate as known at the time of publication, but are subject to change without notice. Availability of some models and equipment builds varies according to the country in which the equipment is being used. For exact information about any particular product, please consult your CASE CONSTRUCTION dealer. CASE CONSTRUCTION is a trademark registered in the United States and many other countries, owned or licensed to CNH Industrial N.V., its subsidiaries or affiliates. Any trademarks referred to herein, in association with goods and/or services of companies, other than owned by or licensed to CNH Industrial N.V., its subsidiaries or affiliates, are the property of those respective companies.
48068130 29/01/2018 EN
SERVICE MANUAL Tracks and track suspension SR210 TIER 4B (FINAL) [NGM418237 - ], SR210 TIER 4B (FINAL) [NHM435463 - ], SR240 TIER 4B (FINAL) [NGM418237 - ], SR240 TIER 4B (FINAL) [NHM435463 - ], SV280 TIER 4B (FINAL) [NGM418237 - ], SV280 TIER 4B (FINAL) [NHM435463 - ], TR270 TIER 4B (FINAL) [NGM418237 - ], TR270 TIER 4B (FINAL) [NHM435463 - ], TR310 TIER 4B (FINAL) [NGM418237 - ], TR310 TIER 4B (FINAL) [NHM435463 - ], TV370 TIER 4B (FINAL) [NHM435463 - ]
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Contents Tracks and track suspension - 48
[48.130] Track frame and driving wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48.1 [48.100] Tracks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48.2 [48.134] Track tension units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48.3 [48.138] Track rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48.4
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Tracks and track suspension - 48 Track frame and driving wheels - 130
SR210 TIER 4B (FINAL) [NGM418237 - ], SR210 TIER 4B (FINAL) [NHM435463 - ], SR240 TIER 4B (FINAL) [NGM418237 - ], SR240 TIER 4B (FINAL) [NHM435463 - ], SV280 TIER 4B (FINAL) [NGM418237 - ], SV280 TIER 4B (FINAL) [NHM435463 - ], TR270 TIER 4B (FINAL) [NGM418237 - ], TR270 TIER 4B (FINAL) [NHM435463 - ], TR310 TIER 4B (FINAL) [NGM418237 - ], TR310 TIER 4B (FINAL) [NHM435463 - ], TV370 TIER 4B (FINAL) [NHM435463 - ]
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Contents Tracks and track suspension - 48 Track frame and driving wheels - 130
FUNCTIONAL DATA Track frame and driving wheels Overview (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SERVICE Track frame Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Sprocket Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
(*) See content for specific models 48068130 29/01/2018
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Tracks and track suspension - Track frame and driving wheels
Track frame and driving wheels - Overview TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
RAIL17CTL0001AA
1
Low-Profile Undercarriage The Compact Track Loaders (CTL) now feature a redesigned undercarriage beginning February 2016, starting serial number (NGM414518 – and beyond). The new low-profile design promotes the same quality and long lasting BercoŽ undercarriage components. The primary change from the older style undercarriage is in the frame design of the undercarriage. The newer design changes immediately increase the ease of cleanout by eliminating the large angled carrier design used in the older style undercarriage. The updated carrier design features an improved yoke-to-frame engagement which increases track alignment, maximizes the track life, and produces less operating noise. The new design does not affect or increase performance specifications that were met with the older style undercarriage design. The new design allows for an ease of serviceability to the undercarriage which lowers the cost of operation and in time provides undercarriage longevity.
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Tracks and track suspension - Track frame and driving wheels
Track frame - Remove TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
Prior operation: Refer to Rubber Track - Rubber track - Remove (48.100) and remove the track from the machine. Refer to Sprocket - Remove (48.130) and remove the sprocket from the drive motor. Refer to Motor - Remove (29.218) and remove the drive motor from the frame and cap the hydraulic lines. NOTE: Photos are for reference only. Photo shows four rollers on undercarriage. 1. Support the machine off of the ground, and install supports under the undercarriage. 2. Remove the bolts (1) from the track frame brackets securing the undercarriage to the bottom of the chassis.
RAPH16CTL0009AA
1
RAPH16CTL0008AA
2
RAPH16CTL0010BA
3
3. Remove the nuts (1) securing the undercarriage to the frame. NOTE: There will be a total of eight nuts to be removed.
4. Remove the undercarriage from the chassis. NOTE: Make sure the undercarriage is supported to prevent damage to hydraulic lines.
Next operation: Track frame - Install (48.130)
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Tracks and track suspension - Track frame and driving wheels
Track frame - Install TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
Prior operation: Track frame - Remove (48.130) 1. Install the frame to the chassis.
RAPH16CTL0010BA
1
RAPH16CTL0008AA
2
RAPH16CTL0009AA
3
2. Secure the undercarriage to the frame with the nuts (1). NOTE: Apply LOCTITE® 243™ to the threads of the bolts.
3. Secure the undercarriage to the under-side of the chassis with bolts (1). NOTE: Apply LOCTITE® 243™ to the threads of the bolts.
NOTE: Make sure the undercarriage frame contacts all of the side and bottom mount surfaces prior to torquing the mounting hardware. 4. Torque the mounting hardware, bolts and nuts, to 216.0 – 292.0 N·m (159.0 – 215.0 lb ft). Next operation: Refer to Motor - Install (29.218) and install the drive motor into the frame. Refer to Sprocket - Install (48.130) and install the sprocket onto the drive motor. Refer to Rubber track - Install (48.100) and install the track to the undercarriage.
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Tracks and track suspension - Track frame and driving wheels
Sprocket - Remove TR270 TR310 TV370
Prior operation: Remove the rubber track. Please see Rubber track - Remove (48.100). 1. Make reference marks on the cover (1) and the drive sprocket (2) to be used for alignment and the bolt torque procedure during installation.
231002477A
1
231002477A
2
2. Loosen and remove the bolts (1) from the drive sprocket (2). 3. Using acceptable lifting equipment, lift the track above the drive sprocket to allow the guide teeth to disengage from the drive sprocket. 4. Slide the drive sprocket off of the hub and remove the drive sprocket.
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Tracks and track suspension - Track frame and driving wheels
Sprocket - Install TR270 TR310 TV370
NOTE: The following photos are for reference only. 1. Slide the drive sprocket over the hub. If the same sprocket that was removed is being installed, use the alignment marks that were made during removal procedure to align the drive sprocket on the hub. 2. Lift the track above the drive sprocket to allow the drive sprocket to engage the guide teeth (1) on the track. Make sure the drive sprocket is between the guide teeth (1) on the track.
231002477A
1
231002477A
2
231002477A
3
3. Apply LOCTITE® 243™ to the threads of the bolts (1). 4. Install the bolts (1) into the drive sprocket (2).
5. Use the reference mark on the hub as the starting point, torque the bolts to 67 – 163 Nm (50 – 120 lb ft) in the sequence shown.
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Tracks and track suspension - Track frame and driving wheels
6. Tighten the bolts to a final torque of 285 – 320 Nm (208 – 235 lb ft) in the sequence shown.
231002477A
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4
Index Tracks and track suspension - 48 Track frame and driving wheels - 130 Sprocket - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7
Sprocket - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6
Track frame - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5
Track frame - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4
Track frame and driving wheels - Overview (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3
(*) See content for specific models 48068130 29/01/2018
48.1 [48.130] / 9
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Tracks and track suspension - 48 Tracks - 100
SR210 TIER 4B (FINAL) [NGM418237 - ], SR210 TIER 4B (FINAL) [NHM435463 - ], SR240 TIER 4B (FINAL) [NGM418237 - ], SR240 TIER 4B (FINAL) [NHM435463 - ], SV280 TIER 4B (FINAL) [NGM418237 - ], SV280 TIER 4B (FINAL) [NHM435463 - ], TR270 TIER 4B (FINAL) [NGM418237 - ], TR270 TIER 4B (FINAL) [NHM435463 - ], TR310 TIER 4B (FINAL) [NGM418237 - ], TR310 TIER 4B (FINAL) [NHM435463 - ], TV370 TIER 4B (FINAL) [NHM435463 - ]
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Contents Tracks and track suspension - 48 Tracks - 100
SERVICE Rubber track Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Tension adjust (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
(*) See content for specific models 48068130 29/01/2018
48.2 [48.100] / 2
Tracks and track suspension - Tracks
Rubber track - Remove TR270 TR310 TV370 TIER 4B (FINAL) [NHM435463 - ]
1. Park the machine on a level surface. 2. Lift the machine off of the ground approximately 12.7 cm (5 in), using adequate lifting equipment.
231002469
1
231002468A
2
231002478
3
231002469
4
3. Remove the screws (1) from the adjuster cover (2), and remove the cover.
4. Slowly loosen the grease valve (1) on the adjuster (2) until the grease begins to discharge from the adjuster (2). Allow the grease to completely discharge from the adjuster (2) to release the tension on the track as the idler wheel moves rearward. NOTE: Do not remove the grease valve body from the adjuster. Internal parts (ball, spring, and poppet) may be lost.
5. The idler wheel (1) can be moved farther rearward either by pushing the idler wheel rearward or by lifting on the center (2) of the track.
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Tracks and track suspension - Tracks
6. Lift the track (2) off of the drive sprocket (1).
231002469
5
231002469
6
7. Remove the rubber track from the frame (2)
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Tracks and track suspension - Tracks
Rubber track - Install TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
1. Install the rubber track around the rear idler wheel (1). Verify that the rear idler wheel is between the guide teeth (2) on the track.
231002473
1
231002474
2
2. Continue installing the rubber track towards the front idler wheel (1), engaging the track guide teeth (3) between the rollers (2) and then around the front idler wheel (1). Verify that the front idler wheel (1) is between the guide teeth (3) on the track.
Next operation: Adjust the rubber track. Please see Rubber track - Tension adjust (48.100).
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Tracks and track suspension - Tracks
Rubber track - Tension adjust TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
1. Park the machine on a level surface. 2. Lift the machine off of the ground approximately 12.7 cm (5 in), using adequate lifting equipment.
231002469
1
231002468A
2
231002478
3
3. Remove the screws (1) from the adjuster cover (2), and remove the cover (2).
4. Be sure the grease valve (1) is tight to the spring tensioner assembly. If it is loose, grease will not hold within the adjuster. NOTE: Do not remove the grease valve body from the adjuster. Internal parts (ball, spring, and poppet) may be lost. 5. Install a grease gun on the grease valve (1).
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Tracks and track suspension - Tracks
6. To tighten the track on the frame, apply grease to the adjuster (2).
231002478
4
231002475
5
231002478
6
7. Apply grease to the adjuster until the distance from the bottom of the two center rollers (1) to the top surface (2) of the track is within 12 – 19 mm (7/16 – 3/4 in). 8. To loosen the track, loosen the grease valve on the adjuster until grease discharges from the adjuster. Allow the grease to discharge from the adjuster until the distance from the bottom of the two center rollers to the top surface of the track is within 12 – 19 mm (7/16 – 3/4 in).
9. When the distance is within the specifications, tighten the grease valve (1) to a torque of 90 ± 10 Nm (66 ± 10 lb ft). NOTE: Do not remove the grease valve body from the adjuster. Internal parts (ball, spring, and poppet) may be lost.
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Index Tracks and track suspension - 48 Tracks - 100 Rubber track - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5
Rubber track - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3
Rubber track - Tension adjust (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6
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Tracks and track suspension - 48 Track tension units - 134
SR210 TIER 4B (FINAL) [NGM418237 - ], SR210 TIER 4B (FINAL) [NHM435463 - ], SR240 TIER 4B (FINAL) [NGM418237 - ], SR240 TIER 4B (FINAL) [NHM435463 - ], SV280 TIER 4B (FINAL) [NGM418237 - ], SV280 TIER 4B (FINAL) [NHM435463 - ], TR270 TIER 4B (FINAL) [NGM418237 - ], TR270 TIER 4B (FINAL) [NHM435463 - ], TR310 TIER 4B (FINAL) [NGM418237 - ], TR310 TIER 4B (FINAL) [NHM435463 - ], TV370 TIER 4B (FINAL) [NHM435463 - ]
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Contents Tracks and track suspension - 48 Track tension units - 134
SERVICE Track tensioner Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Idler wheel Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
(*) See content for specific models 48068130 29/01/2018
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Tracks and track suspension - Track tension units
Track tensioner - Remove TR270 TR270 TR310 TR310
TIER TIER TIER TIER
4B 4B 4B 4B
(FINAL) (FINAL) (FINAL) (FINAL)
[NGM418237 - ] [NHM435463 - ] [NGM418237 - ] [NHM435463 - ]
Prior operation: Refer to Rubber track - Remove (48.100) and remove the track from the machine 1. Remove the track from the machine.
231002469
1
RAPH16CTL0006BA
2
RAPH16CTL0007BA
3
2. Slide the track tension assembly (2) out of the main frame (1).
3. Slide the yoke assembly (2) off of the track tension assembly (1).
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Tracks and track suspension - Track tension units
Track tensioner - Install TR270 TR270 TR310 TR310
TIER TIER TIER TIER
4B 4B 4B 4B
(FINAL) (FINAL) (FINAL) (FINAL)
[NGM418237 - ] [NHM435463 - ] [NGM418237 - ] [NHM435463 - ]
1. Slide the yoke assembly (2) onto the track tension assembly (1).
RAPH16CTL0007BA
1
RAPH16CTL0006BA
2
2. Slide the track tension assembly (2) into the main frame (1).
Next operation: Refer to Rubber track - Install (48.100) and install the track. After the track has been installed, follow the procedure Rubber track - Tension adjust (48.100) and adjust the tension of the track.
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Tracks and track suspension - Track tension units
Track tensioner - Remove TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
Prior operation: Refer to Rubber track - Remove (48.100) and remove the track from the machine 1. Remove the track from the machine.
231002469
1
231002470
2
RAPH16CTL0006BA
3
2. Slide the track tension assembly (2) out of the main frame (1). NOTE: Figure 3 shows the newer style undercarriage.
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Tracks and track suspension - Track tension units
3. Slide the yoke assembly (2) off of the track tension assembly (1). NOTE: Figure 5 shows the newer style undercarriage.
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231002470
4
RAPH16CTL0007BA
5
Tracks and track suspension - Track tension units
Track tensioner - Install TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
1. Slide the yoke assembly (2) onto the track tension assembly (1). NOTE: Figure 2 shows the newer style undercarriage.
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231002471
1
RAPH16CTL0007BA
2
Tracks and track suspension - Track tension units
2. Slide the track tension assembly (2) into the main frame (1). NOTE: Figure 4 shows the newer style undercarriage.
231002470
3
RAPH16CTL0006BA
4
Next operation: Refer to Rubber track - Install (48.100) and install the track. After the track has been installed, follow the procedure Rubber track - Tension adjust (48.100) and adjust the tension of the track.
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Tracks and track suspension - Track tension units
Idler wheel - Remove TR270 TR270 TR310 TR310
TIER TIER TIER TIER
4B 4B 4B 4B
(FINAL) (FINAL) (FINAL) (FINAL)
[NGM418237 - ] [NHM435463 - ] [NGM418237 - ] [NHM435463 - ]
Prior operation: Refer to Rubber Track - Rubber track - Remove (48.100) and remove the track from the machine.
Front idler wheel 1. Remove the track from the machine. Slide the track tension assembly (2) out of the main frame (1).
RAPH16CTL0006BA
1
RAPH16CTL0007BA
2
RAIL16CTL0012BA
3
2. Loosen and remove the mounting screw (1) in the yoke (2) which fastens the front idler wheel (3) to the yoke (2). 3. Remove the front idler wheel (3) from the yoke (2).
Rear idler wheel 1. Loosen and remove the bolt (1) and washer from the rear idler wheel (2). 2. Remove the rear idler wheel (2) from the main frame (3).
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Tracks and track suspension - Track tension units
Idler wheel - Install TR270 TR270 TR310 TR310
TIER TIER TIER TIER
4B 4B 4B 4B
(FINAL) (FINAL) (FINAL) (FINAL)
[NGM418237 - ] [NHM435463 - ] [NGM418237 - ] [NHM435463 - ]
Front idler wheel 1. Install the front idler wheel (3) into the yoke (2). 2. Apply LOCTITE® 243™ to the threads of the bolt (1). 3. Install the bolt (1) with the washer into the yoke and into the front idler wheel. NOTE: Torque the bolt (1) to 381.0 – 516.0 N·m (281.0 – 381.0 lb ft).
RAPH16CTL0007BA
1
RAPH16CTL0006BA
2
23112927
3
4. Slide the track tension assembly (2) into the frame (1).
Rear idler wheel 1. Verify that all paint is removed from all contact surfaces on the end cap and the shaft.
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Tracks and track suspension - Track tension units
2. Add one keeper to each end of the rear idler. NOTE: Two keepers are required.
23112930
4
23112931
5
23112932
6
23112933
7
3. Apply LOCTITE® 243™ to the threads of the bolts. 4. Install both bolts, but do not tighten.
5. Insert one shim (1) on each end of the rear idler (2). NOTE: A total of two shims are needed.
Location of the shims.
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Tracks and track suspension - Track tension units
6. Move the idler as far back in holes as possible.
23112934
8
RAIL16CTL0012BA
9
7. Torque the bolt (1) to 381 – 516 N·m (281 – 381 lb ft).
8. Verify that the end cap ears are not pinched by the track frame after the bolts are tightened.
23112935
Next operation: Install the rubber track. Please see Rubber track - Install (48.100).
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10
Tracks and track suspension - Track tension units
Idler wheel - Remove TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
Prior operation: Refer to Rubber Track - Rubber track - Remove (48.100) and remove the track from the machine.
Front idler wheel 1. Remove the track from the machine. Slide the track tension assembly (2) out of the main frame (1). NOTE: Figure 2 shows the newer style undercarriage.
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231002470
1
RAPH16CTL0006BA
2
Tracks and track suspension - Track tension units
2. Loosen and remove the mounting screw (1) in the yoke (2) which fastens the front idler wheel (3) to the yoke (2). NOTE: Figure 4 shows the newer style undercarriage. 3. Remove the front idler wheel (3) from the yoke (2).
231002471
3
RAPH16CTL0007BA
4
231002472
5
Rear idler wheel 1. Loosen and remove the bolt (1) and washer from the rear idler wheel (2). 2. Remove the rear idler wheel (2) from the main frame (3).
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Tracks and track suspension - Track tension units
Idler wheel - Install TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
Front idler wheel 1. Install the front idler wheel (3) into the yoke (2). NOTE: Figure 2 shows the newer style undercarriage. 2. Apply LOCTITE® 243™ to the threads of the bolt (1). 3. Install the bolt (1) with the washer into the yoke and into the front idler wheel. NOTE: Older style (Figure 1) : Torque the M10 x 16 mm bolt (1) to 46.0 – 51.0 N·m (34.0 – 38.0 lb ft). NOTE: Newer style (Figure 2) : Torque the M20 x 40 mm bolt (1) to 381.0 – 516.0 N·m (281.0 – 381.0 lb ft).
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231002471
1
RAPH16CTL0007BA
2
Tracks and track suspension - Track tension units
4. Slide the track tension assembly (2) into the frame (1). NOTE: Figure 4 shows the newer style undercarriage.
231002470
3
RAPH16CTL0006BA
4
23112927
5
23112930
6
Rear idler wheel 1. Verify that all paint is removed from all contact surfaces on the end cap and the shaft.
2. Add one keeper to each end of the rear idler. NOTE: Two keepers are required.
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Tracks and track suspension - Track tension units
3. Apply LOCTITEŽ 243™ to the threads of the bolts. 4. Install both bolts, but do not tighten.
23112931
7
23112932
8
23112933
9
5. Insert one shim (1) on each end of the rear idler (2). NOTE: A total of two shims are needed.
Location of the shims.
6. Move the idler as far back in holes as possible.
23112934
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10
Tracks and track suspension - Track tension units
7. Torque the bolt (1) to 381 – 516 N·m (281 – 381 lb ft). NOTE: The torque range is the same for the older style rear idler bolt and the newer style rear idler bolt.
231002472
11
23112935
12
8. Verify that the end cap ears are not pinched by the track frame after the bolts are tightened.
Next operation: Install the rubber track. Please see Rubber track - Install (48.100).
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Index Tracks and track suspension - 48 Track tension units - 134 Idler wheel - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10
Idler wheel - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15
Idler wheel - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9
Idler wheel - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13
Track tensioner - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4
Track tensioner - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7
Track tensioner - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3
Track tensioner - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5
(*) See content for specific models 48068130 29/01/2018
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Tracks and track suspension - 48 Track rollers - 138
SR210 TIER 4B (FINAL) [NGM418237 - ], SR210 TIER 4B (FINAL) [NHM435463 - ], SR240 TIER 4B (FINAL) [NGM418237 - ], SR240 TIER 4B (FINAL) [NHM435463 - ], SV280 TIER 4B (FINAL) [NGM418237 - ], SV280 TIER 4B (FINAL) [NHM435463 - ], TR270 TIER 4B (FINAL) [NGM418237 - ], TR270 TIER 4B (FINAL) [NHM435463 - ], TR310 TIER 4B (FINAL) [NGM418237 - ], TR310 TIER 4B (FINAL) [NHM435463 - ], TV370 TIER 4B (FINAL) [NHM435463 - ]
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Contents Tracks and track suspension - 48 Track rollers - 138
SERVICE Track rollers Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
(*) See content for specific models 48068130 29/01/2018
48.4 [48.138] / 2
Tracks and track suspension - Track rollers
Track rollers - Remove TR270 TR310 TV370 TIER 4B (FINAL) [NHM435463 - ]
Prior operation: Refer to Rubber track - Remove (48.100) and remove the track from the machine. NOTE: Photos are for reference only. Photo shows track installed on the machine. 1. After the track has been removed from the machine, loosen and remove the cap screws and washers (1) from the roller (2). Remove the roller (2) from the track assembly.
231002476
1
231002476
2
2. Repeat the procedure above and remove the remaining rollers (1) from the track assembly.
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Tracks and track suspension - Track rollers
Track rollers - Install TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TV370 TIER 4B (FINAL) [NHM435463 - ]
1. Verify that all paint is removed from any contact surface on the end cap and shaft.
23112927
1
23112928
2
23112929
3
2. Inspect the inside edge at all roller locations for any excess paint or rough edges. Remove as required.
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Tracks and track suspension - Track rollers
3. Install the roller without the bolts, and push roller against inside track frame wall. 4. Use a shim as a guide to determine the required number of shims needed to fill gap between the roller and the track frame wall. NOTE: A maximum of one shim on each end of the roller may be required. NOTE: If only one shim is required, install the shim between the roller and the outside track frame wall.
23112939
4
23112937
5
23112938
6
23112939
7
5. Install the shim as shown in image 5.
6. Apply LOCTITEŽ 243™ to the threads of the bolts. 7. Install the bolts in the roller, but do not tighten. 8. Repeat steps 1 - 6 for any additional rollers that are being replaced,
9. Spin the roller by hand. NOTE: The rollers should spin easily.
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Tracks and track suspension - Track rollers
10. Torque the mounting bolt (1) to 195 – 265 N·m (144 – 196 lb ft).
231002476
8
23112939
9
11. Spin the roller by hand. NOTE: The rollers should spin easily.
Next operation: Install the rubber track. Please see Rubber track - Install (48.100).
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Index Tracks and track suspension - 48 Track rollers - 138 Track rollers - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4
Track rollers - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3
(*) See content for specific models 48068130 29/01/2018
48.4 [48.138] / 7
CNH Industrial America - Main 700 State Street Racine, Wisconsin United States 53404
SERVICE - Technical Publications & Tools
PRINTED IN U.S.A. Š 2018 CNH Industrial America LLC. All rights reserved. No part of the text or illustrations of this publication may be reproduced.
CNH Industrial America LLC reserves the right to make improvements in design and changes in specifications at any time without notice and without incurring any obligation to install them on units previously sold. Specifications, descriptions, and illustrative material herein are as accurate as known at the time of publication, but are subject to change without notice. Availability of some models and equipment builds varies according to the country in which the equipment is being used. For exact information about any particular product, please consult your CASE CONSTRUCTION dealer. CASE CONSTRUCTION is a trademark registered in the United States and many other countries, owned or licensed to CNH Industrial N.V., its subsidiaries or affiliates. Any trademarks referred to herein, in association with goods and/or services of companies, other than owned by or licensed to CNH Industrial N.V., its subsidiaries or affiliates, are the property of those respective companies.
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SERVICE MANUAL Cab climate control SR210 TIER 4B (FINAL) [NGM418237 - ], SR210 TIER 4B (FINAL) [NHM435463 - ], SR240 TIER 4B (FINAL) [NGM418237 - ], SR240 TIER 4B (FINAL) [NHM435463 - ], SV280 TIER 4B (FINAL) [NGM418237 - ], SV280 TIER 4B (FINAL) [NHM435463 - ], TR270 TIER 4B (FINAL) [NGM418237 - ], TR270 TIER 4B (FINAL) [NHM435463 - ], TR310 TIER 4B (FINAL) [NGM418237 - ], TR310 TIER 4B (FINAL) [NHM435463 - ], TV370 TIER 4B (FINAL) [NHM435463 - ]
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Contents Cab climate control - 50
[50.100] Heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50.1 [50.200] Air conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50.2
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Cab climate control - 50 Heating - 100
SR210 TIER 4B (FINAL) [NGM418237 - ], SR210 TIER 4B (FINAL) [NHM435463 - ], SR240 TIER 4B (FINAL) [NGM418237 - ], SR240 TIER 4B (FINAL) [NHM435463 - ], SV280 TIER 4B (FINAL) [NGM418237 - ], SV280 TIER 4B (FINAL) [NHM435463 - ], TR270 TIER 4B (FINAL) [NGM418237 - ], TR270 TIER 4B (FINAL) [NHM435463 - ], TR310 TIER 4B (FINAL) [NGM418237 - ], TR310 TIER 4B (FINAL) [NHM435463 - ], TV370 TIER 4B (FINAL) [NHM435463 - ]
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SERVICE Heater core Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Cab heater Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
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Cab climate control - Heating
Heater core - Remove Prior operation: Tilt the cab. Please see Cab tilting system - Tilt (90.150) Prior operation: Discharge the A/C (if applicable). Please see Air conditioning - Discharging (50.200). 1. Detach the heater hoses (2) from the heater core. 2. Detach the A/C lines (1) from the evaporator (if applicable). 3. Remove the nuts (3), and detach the seat from the cab.
RAIL15SSL0042BA
1
RAIL14SSL0418AA
2
RAPH14SSL0351BA
3
4. Carefully lower the cab. Please see Cab tilting system - Lower (90.150) for assistance.
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5. Disconnect the seat switch (2) from the wiring harness. 6. Disconnect the seat belt switch (if applicable) (1) from the wiring harness.
RAIL15SSL0041BA
4
93109313
5
93106883
6
7. Remove the seat (1) from the cab.
8. Remove the access cover (1) for the cab filter by turning the knobs (2) counter clockwise and lifting the cover (1) off of the HVAC assembly.
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9. Remove the fasteners from the panel.
RAIL15SSL0073BA
7
RAIL15SSL0040BA
8
RAIL15SSL0028BA
9
10. Remove the panel from the cab.
11. Disconnect the HVAC assembly from the wiring harness.
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12. Disconnect the joystick from the wiring harness.
RAIL15SSL0072BA
10
RAIL15SSL0039BA
11
RAIL15SSL0038BA
12
13. Detach and remove the joystick assembly (1) from the cab. 14. Repeat steps 12 and 13 on the opposite side.
15. Remove the fasteners (2) from the air duct (3). 16. Remove the screws (1) from the HVAC assembly . 17. Remove the air duct (3) from the cab. 18. Repeat steps 15 – 17 on the opposite side.
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19. Remove the screws (1) from the HVAC assembly. 20. Remove the HVAC assembly (2) from the cab.
931001774
13
931001774
14
RAIL15SSL0036BA
15
21. Place the HVAC assembly on a workbench. 22. Remove the screws (1) from the HVAC assembly. 23. Remove the clips (2) from the HVAC assembly.
24. Flip the HVAC assembly. 25. Remove the screws (1) from the HVAC assembly. 26. Remove the clips (2) from the HVAC assembly.
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27. Separate and remove the lower half of the HVAC assembly.
RAIL15SSL0033BA
16
RAIL15SSL0034BA
17
RAIL15SSL0035BA
18
28. Separate the two halves of the HVAC assembly.
29. Remove the heater core from the HVAC assembly.
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Heater core - Install 1. Insert the heater core into the HVAC assembly.
RAIL15SSL0035BA
1
RAIL15SSL0034BA
2
RAIL15SSL0033BA
3
2. Connect the two halves of the HVAC assembly.
3. Connect the lower half to the HVAC assembly.
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4. Verify that the rubber seals are install properly.
RAIL15SSL0032BA
4
RAIL15SSL0036BA
5
931001774
6
5. Install the clips (2) onto the HVAC assembly. 6. Install the screws (1) into the HVAC assembly.
7. Flip the HVAC assembly. 8. Install the clips (2) onto the HVAC assembly. 9. Install the screws (1) into the HVAC assembly.
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10. Install the HVAC assembly (2) into the cab. 11. Install the screws (1) that attach the HVAC assembly to the cab.
931001774
7
RAIL15SSL0038BA
8
RAIL15SSL0072BA
9
12. Install the air duct (3) into the cab. 13. Install the fasteners (2) that attach the air duct (3) to the cab. 14. Install the screws (1) that attach the air duct to the HVAC assembly. 15. Repeat steps 12 – 14 on the opposite side.
16. Connect the joystick to the wiring harness.
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17. Attach the joystick assembly to the cab. 18. Repeat steps 16 and 17 on the opposite side.
RAIL15SSL0039BA
10
RAIL15SSL0028BA
11
RAIL15SSL0040BA
12
19. Connect the HVAC assembly to the wiring harness.
20. Install the panel into the cab.
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21. Install the fasteners that attach the panel to the cab.
RAIL15SSL0073BA
13
93106883
14
93109313
15
22. Install the access cover (1), and tighten onto the HVAC assembly by turning the knobs (2) clockwise.
23. Install the seat (1) from the cab.
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24. Connect the seat switch (2) to the wiring harness. 25. Connect the seat belt switch (if applicable) (1) to the wiring harness.
RAIL15SSL0041BA
16
93107498
17
RAPH11SSL0016BA
18
26. Carefully tilt the cab. Please see Cab tilting system - Tilt (90.150) for assistance.
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27. Attach the seat to the cab by installing the nuts (3). 28. Attach the heater hoses (2) to the heater core. 29. Attach the A/C lines (1) to the evaporator (if applicable).
RAIL15SSL0042BA
Next operation: Add CASE AKCELA ACTIFULLâ„¢ OT EXTENDED LIFE COOLANT. Please see Capacities () for specifications. Next operation: Charge the A/C system (if applicable). Please see Air conditioning - Charging (50.200).
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Cab climate control - Heating
Cab heater - Remove 1. Remove the operators seat. If unit is equipped with EH controls remove the control towers.
93104685
1
93104642
2
93112374
3
2. At the front of the chassis, remove the cleanout hole blockoff plate (1), by removing the four hardware bolts (2).
3. Remove the cab lift strut and floor pan. Do not remove the cab tip safety lock! 4. Drain the existing coolant from the engine and radiator. Save for reuse. 5. Remove heater hoses (1), from the back exterior of the cab and the front corners of the upper chassis. Silicone open ports.
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6. Disconnect the cab supply hose (1), and cab return hose (2) from the heater box (3).
23112382
4
23112385
5
7. Disconnect the heater supply hose (1), from the thermostat housing and install plug fitting.
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8. Disconnect the heater return hose (2), from water pump housing.
23112382
6
23112387D
7
93104640
8
9. Remove the heater hoses (1), and all heater hose hardware from the machine. The hoses are mounted under the engine, between the flywheel side engine mounts. 10. Disconnect the chassis harness electrical connector from the water valve.
11. Remove the headliner and left hand and right hand consoles. 12. Remove three fir tree fasteners, to remove the rear trim panel (1), over the heater box and washer bottle. NOTE: Washer bottle cap (2), must be removed first.
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13. Remove the six directional louvers (1), in the ducts (2).
93104640
9
14. Remove the fir tree fasteners (1), from cab side, and bolts (2) from the heater box. Remove ducts (3), and (4), from the heater box.
93104691
10
93104640
11
93104663
12
15. Disconnect heater box electrical connector from the cab harness. 16. Remove the heater box (1), from the firewall.
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17. Remove air intake duct (1), from firewall.
93104663
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Cab heater - Install 1. Tip cab and remove seat; remove the cover plate from behind the seat, if equipped. If unit has EH controls remove the control towers. 2. Remove HVAC switch blanking decal from left hand console.
93104685
1
93104664
2
93104646
3
93104647
4
3. Take left hand console loose from the a-post. Add heater control decal (1), fan switch (2), and temperature control potentiometer (3) and knob (4). 4. The right hand console and headliner must be removed in order to install the deluxe cab harness and roof foam for added sound reduction. If neither are needed the right hand console and headliner may be left in place. 5. If converting from an open cab without radio, remove and replace the cab harness. Not included in kit. Purchase separately.
6. [Optional] Clean and degrease underside of roof panel and install roof foam (1) using firm even pressure. 7. Remove the blocking plates that cover the fresh air intake hole and plumbing holes in the firewall and cab floor.
8. Install the heater box sealing foam (1) at the back of the cab floor.
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9. Using two of each, bolts (1), nuts (2), and washers (3) install the air intake duct (4) to the firewall.
93104663
5
93104663
6
93104691
7
93104640
8
10. Using four of each, screws (1) and washers (2) install the heater box (3) to the firewall. Be careful to ensure that the plumbing ports are inserted properly through the hole in the cab floor. 11. Connect heater box electrical connector to the cab harness.
12. Install the left hand and right hand ducts (1) and (2) to heater box using four bolts (3) and anchor to side of cab using eight fir tree fasteners (4). Ensure that wiring harness is not pinched between the ducts and the cab side. Then install six directional louvers (5) in the ducts. 13. Reinstall headliner and consoles.
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14. Remove silicone from bottom of J tubes (A) inside the rear of the cab.
93112374
9
15. Install the rear trim panel (1) over the heater box and washer bottle. Cap must be removed from washer bottle to install, then replaced once the panel is secure. Seat belt is routed through the slot in the panel and the upper lip of the panel is under the air filter access cover. Secure the panel with fir tree fasteners. 16. Apply silicone to bottom of J tubes at back exterior of cab and in the front corners of the upper chassis (see figure 9).
93104640
10
93104643
11
23112387C
12
17. Clean and degrease front surface of the chassis crossmember behind the cab. Apply crossmember foam (1) with firm even pressure. 18. Remove floorplate. Cab lift struts have to be removed in order to remove floorplate. Do not remove the cab tip safety lock!
19. Install the water valve (1) to the water valve bracket (2) with bolts (3) and nuts (4) and bolt the bracket under the floorboard using bolts (5) and nuts (6). Ensure that the water valve is facing with the outlet rearward. 20. Connect the chassis harness electrical connector to the water valve. 21. Drain the existing coolant from the engine and radiator. Save for reuse.
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22. Remove the plug from the thermostat housing on the right side of the engine and install the 90° hose nipple adapter (1). Use pipe thread compound on the threads.
23112385A
13
23112382D
14
23112382E
15
23112387D
16
23. Cut the existing coolant return hose (1) under the injector lines and route the two halves over top of the injector lines.
24. Using ctb clamps (1), install the “Y� fitting (2) between the two halves of return hose (3).
25. Route the heater supply (1) and new return hoses (2) from the engine to the front of the machine. Both hoses route under the engine between the flywheel side engine mounts. The cab side end of the return hose has plastic spiral hose guard installed. The hose guard (3) must be installed over both hoses where they pass under the engine and tandem pump. 26. Using two ctb clamps (4), connect the supply hose (1) to the hose nipple (5) on the thermostat housing and to the inlet of the water valve (6).
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27. Using a ctb clamp (1), connect the new return hose (2) to the “Y� fitting (3).
23112382F
17
23112387E
18
23112384
19
23112384A
20
28. Using a ctb clamp (1), connect the other end of the return hose (2) to the right hand hose stub (outlet hose) on the heater box using a nylon hose elbow (3). 29. Using ctb clamps (1), connect the cab supply hose (2) to the water valve (5) outlet and to the heater box inlet using a nylon hose elbow (3).
30. Install the carriage bolt (1) to the square hole in the seat pan and hold in place with a flange nut (2). 31. Place a p-clamp (3) over both hoses and attach to the carriage bolt (1) on the seat pan. Order of installation is washer (4), then p-clamp, then flange nut (2).
32. Install the small spring mount bracket (1) to the top front mounting bolt on the right drive motor. Use a thin nut (2) to secure in place. 33. Install the large spring mount bracket (3) between the brake control valve and the chassis nut cages that the valve mounts to.
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34. Slide one eyelet of the spring (2) on the straight section of the other p-clamp (4), and install the p-clamp over both hoses. There should be 350 mm (14 in) between p-clamps. 35. Connect each end of spring to the spring mounting brackets (1) and (3) on the right side motor and the brake valve. On mechanical units route the springs under the tandem pump control rods so that the springs fall down away from the control rods when the cab is lowered. 36. [OPTIONAL] Install the seat pan mat. 37. Reinstall the seat.
23112384B
21
23111106
22
93104642
23
38. Refill the cooling system and run the engine to check for leaks. 39. Reinstall the floor plate and lift struts. 40. [OPTIONAL] Install the heelplate mat followed by the floormat. a. Place 2 rows of seal strip (1) around the outside edge of plate (2).
41. Install the front cleanout hole blockoff plate (2) using 4 bolts (3).
42. Set the cab down and tip it up again to ensure that the hoses are dropping into the chassis correctly without kinking.
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Index Cab climate control - 50 Heating - 100 Cab heater - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
21
Cab heater - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
16
Heater core - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9
Heater core - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3
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Cab climate control - 50 Air conditioning - 200
SR210 TIER 4B (FINAL) [NGM418237 - ], SR210 TIER 4B (FINAL) [NHM435463 - ], SR240 TIER 4B (FINAL) [NGM418237 - ], SR240 TIER 4B (FINAL) [NHM435463 - ], SV280 TIER 4B (FINAL) [NGM418237 - ], SV280 TIER 4B (FINAL) [NHM435463 - ], TR270 TIER 4B (FINAL) [NGM418237 - ], TR270 TIER 4B (FINAL) [NHM435463 - ], TR310 TIER 4B (FINAL) [NGM418237 - ], TR310 TIER 4B (FINAL) [NHM435463 - ], TV370 TIER 4B (FINAL) [NHM435463 - ]
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Contents Cab climate control - 50 Air conditioning - 200
TECHNICAL DATA Air conditioning General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
FUNCTIONAL DATA Air conditioning Dynamic description - A/C thermal operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Overview - Mechanical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Overview - Electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
SERVICE Air conditioning Leakage test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Discharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Compressor drive belt Tension adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Air-conditioning evaporator Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
DIAGNOSTIC Air conditioning Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Problem solving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Air-conditioning condenser Testing - Condenser Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
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Air conditioning - General specification A/C system capacities • 1.5 kg (3.3 lb) of R134A refrigerant. • 197 ml (6.67 US fl oz) of PAG SP20
Air Temperature (F) Entering A/C Unit (Fresh or Recirculated) 50 60 70 80 90 100 110
Inlet - Outlet Temperature Differential (Low Humidity) 10 15 20 25 30 30 35
Inlet - Outlet Temperature Differential (High Humidity) 10 10 15 20 25 25 30
Ambient Air Temperature (F) Entering Condenser 50 60 70 80 90 100 110
Suction Pressure (PSIG) at Evaporator Outlet 5-15 5-15 10-20 10-20 15-25 15-25 15-30
Discharge Pressure (PSIG) at Compressor Outlet 75-125 100-150 125-175 150-225 175-250 200-275 225-352
NOTE: The pressure temperature chart is based on the following conditions: (1) Engine operating at 1500 rpm. No engine load. (2) Fan speed control in maximum position (full clockwise) and all louvers open. (3) Cab temperature control set to maximum cooling (full counterclockwise). (4) A/C switch ON. Cab door open. (5) All panels and access doors installed and closed. (6) Cab filter clean and installed. Heater valve closed. (7) Measurements taken 15 minutes after start-up. (8) The warmest inlet air temperature (Fresh or Recirculated) should be used for the differential equations.
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Air conditioning - Dynamic description - A/C thermal operation The refrigerant circuit of the air conditioning system contains five major components: • compressor, • condenser, • receiver-drier, • expansion valve, • and evaporator. These components are connected by tubes and hoses and operate as a closed system. The air conditioner system is charged with HFC-134a refrigerant. The compressor receives the refrigerant as a low pressure gas. The compressor then compresses the refrigerant and sends it in the form of a high pressure gas to the condenser. Air flow through the condenser removes the heat from the refrigerant. As the heat is removed the refrigerant is “condensed” to a high pressure liquid. The high pressure refrigerant liquid flows from the condenser to the receiver-drier. The receiver-drier is a container filled with moisture removing material, which removes any moisture that may have entered the air conditioner system in order to prevent corrosion of the internal components. NOTE: Not all refrigerant leaves the condenser as a liquid. Some leaves as a gas without affecting system performance. Liquid refrigerant pools at the bottom of the receiver-drier, while the lighter gas collects at the top. Since the pick-up tube draws refrigerant from the bottom of the receiver-drier, only liquid refrigerant flows to the thermal expansion valve. The refrigerant, still in high pressure liquid form, flows from the receiver-drier to the expansion valve. The expansion valve provides a restriction to refrigerant flow to cause a pressure drop which allows the liquid refrigerant to expand, decreasing its temperature and pressure. NOTE: The thermal expansion valve is internally equalized: the need for refrigerant to handle the heat load is balanced with the ability to fully vaporize the refrigerant within the one valve. This low temperature, low pressure liquid or mist flows through the evaporator. The hot cab air passes through the evaporator fins cooling the air and evaporating the liquid refrigerant. The low pressure gas returns to the compressor and the cycle starts all over again.
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RCPH07CCH490ABC
1
Low pressure gas
1. Compressor
4. Thermal expansion valve
Low pressure liquid
2. Condenser
5. Evaporator
High pressure gas
3. Receiver-drier
High pressure liquid
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Air conditioning - Overview The function of the HVAC system is to improve the operator's comfort by conditioning the air inside the cab. In AC mode, temperature control is achieved by absorbing the heat within the cab into a refrigerant and then allowing the heat absorbed by the refrigerant to be transferred to the outside air. In heat mode, temperature control is achieved by air absorbing heat from a heat exchanger (heater core). The blower switch can provide 4 speed levels (off, low, medium, high) to the electric fan motor (2) (internal to HVAC Box). Low and medium speeds are provided through a resistor (internal to HVAC Box). The fan blows a mix of outside and cab air (1) across an evaporator (3) and across the heater core (4), providing conditioned air entering the cab through vents (5), and is energized anytime the ignition is on.
ACPATHSL57
1
HVAC air flow path In AC mode, with the A/C switch on and an electric fan speed selected, the condenser fan and the A/C compressor are energized, starting the refrigeration cycle and providing cool air to the cab. In heat mode, with AC Switch off and the temperature control potentiometer set to “hot�, the potentiometer provides a control signal to the water valve which directs hot engine coolant to flow to the heater core. The electric fan motor (internal to HVAC Box) blows air across the evaporator (not in use) and hot heater core, providing hot air to cab. If both AC switch is on and temperature control potentiometer is turned to "hot", both the Water Valve and AC components are energized, and the air will cool across the evaporator, then heat across the heater core, then enter the cab. The blower switch, AC switch, and temperature control potentiometer are all located on the Left Console. There are three safety switches in the system that protect the compressor. The single-level pressure switch (internal to HVAC Box) protects from a liquid lock condition in the refrigeration cycle. The high pressure switch protects against an overpressure condition caused by a system blockage or compressor failure. The thermostat (internal to HVAC Box) is a freeze sensor, located on the condenser, that cycles the A/C compressor off preventing an ice over condition, which would prevent heat transfer.
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Air conditioning - Overview - Mechanical system The principal components of an air conditioning system are • Refrigerant • Evaporator • Compressor • Condenser • Expansion Valve To achieve the absorption and the release of heat, which is, in essence, the function of an air conditioning system, requires the use of a suitable refrigerant, a liquid that has a relatively low temperature boiling point, plus certain desirable safety and stability features. The refrigerant used in the air conditioning system is R-134a. The refrigerant starts as a low temperature, low pressure liquid and enters the evaporator. The evaporator (1) consists of a number of turns of continuous coils mounted in a series of thin cooling fins to provide a maximum heat transfer area in a minimum amount of space. Low temperature refrigerant in the evaporator absorbs heat from the hotter air in the cab, cooling the air. The Electric Fan Motor (internal to HVAC Box) blows a mix of outside air and recirculated cab air across the evaporator and blows this cool air into the cab. The refrigerant now changes to a high temperature, low pressure vapor and leaves the evaporator, moving to the suction (low pressure) side of the compressor.
REFCYCLESL57
1
Refrigeration Cycle The compressor (2) acts as a pump which raises the refrigerant temperature and pressure by compression to a higher degree of temperature than the ambient (outside air) temperature and provides the driving force required to circulate the volume of refrigerant through the system. Refrigerant is drawn into the compressor as a high temperature, low pressure vapor which is compressed and then pumped out as a high temperature, high pressure vapor to the condenser. The thermostat (internal to HVAC Box) cycles power to the A/C compressor via removing power to compressor relay control. The condenser (3) consists of a number of turns of continuous coil mounted in a series of thin cooling fins to provide a maximum of heat transfer in a minimum area of space. The condenser receives the high temperature, high pressure refrigerant vapor from the compressor. The hot vapor passes through the condenser coils and outside air is pushed across the condenser by the condenser fan. Heat moves from the hot refrigerant vapor into the cooler outside air flowing across the condenser coils and fins. When the refrigerant vapor reaches the pressure and temperature that will induce a change of state to a liquid, a large quantity of heat is transferred to the outside air and the refrigerant changes to a low temperature, high pressure liquid. The refrigerant from the condenser enters the expansion valve (4) as a low temperature, high pressure liquid. The expansion valve allows the refrigerant to expand rapidly, which causes the pressure and temperature of the refrigerant to be reduced and the refrigerant leaves the expansion valve as a low temperature, low pressure liquid.
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Air conditioning - Overview - Electrical system The HVAC system has several power inputs. One line of source power comes from the accessory relay to the HVAC box. This energizes the auxiliary relay for the electric fan coil (internal to HVAC Box). The accessory relay is powered from the instrument cluster when the ignition is on, which shuts the auxiliary relay for electric fan. NOTE: See HVAC Box overview for more information Heating, Ventilation, and Air-Conditioning (HVAC) control system - Overview (55.050) The auxiliary relay for electric fan main power comes directly from the battery via the HVAC fuse. The auxiliary relay for electric fan is shut anytime the ignition is on, allowing power to the water valve and the temperature control potentiometer, also allowing power to the blower switch. Power is provided to the A/C switch from the blower switch, anytime a fan speed is selected. The blower switch, AC switch, and temperature control potentiometer are all located on the left console. Since the water valve and temperature control potentiometer are energized, cab heat is available anytime the ignition is on. When the AC switch is turned “on” and an electric fan speed is selected, power is provided to HVAC, through the single-level pressure switch (internal to HVAC box), through thermostat (internal to HVAC box), out the HVAC box to the HVAC high pressure switch and back into HVAC Box to the compressor relay coil (internal to HVAC box), shutting the compressor relay (internal to HVAC box). When the compressor relay is shut, this allows battery power the compressor fuse through the HVAC box to the compressor relay, and out of the HVAC box to the A/C compressor. When the A/C switch is turned “on” and an electric fan speed is selected, power is also applied to the condenser relay coil, shutting the condenser relay, providing battery power via a fuse to the condenser fan. The blower switch, since energized, can provide four speed levels (off, low, medium, high) to the electric fan motor (internal to HVAC box). This is done through a resistor (internal to HVAC box).
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Air conditioning - Leakage test WARNING Avoid injury! Avoid breathing air-conditioning refrigerant, lubricant vapor or mist. If accidental system discharge occurs, ventilate the work area before resuming service. Failure to comply could result in death or serious injury. W1000B
NOTICE: A/C systems are to be maintained by a certified professional. Do not attempt the following without A/C certification.
Vacuum test 1. Shut off the engine. 2. Remove the caps from the service ports on the machine. 3. Verify the charging station valves are in the closed position. 4. Connect the hose from the low pressure gauge to the low pressure port on the machine. 5. Connect the hose from the high pressure gauge to the high pressure port on the machine. 6. Turn in both thumbscrews to depress the service valves. 7. Open the high and low valves on the charging station. 8. Make certain the refrigerant tank valves are open. 9. Turn on the charging station, and vacuum the system for approximately 15–30 minutes. 10. Wait approximately 15–30 minutes, then check the gauges on the charging station. If the A/C system has a leak, it will not hold vacuum. 11. Repair all leaks, and charge the system.
LAIL11TS0543B0A
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1
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Electronic leak detection test 1. Verify the appropriate amount of refrigerant in the machine. 2. Start the engine and run the A/C system for approximately ten minutes. 3. Use the electronic leak detector to inspect all connections. ATTENTION: The engine is running. Be aware of moving components. Failure to comply could result in death or serious injury. 4. Shut off the engine. 5. Use the electronic leak detector to inspect all connections. NOTE: When checking the compressor seal for a leak, remove the dust cover and rotate the clutch shaft clockwise.
FNH00855
2
RCPH07CCH416ABC
3
NOTE: To properly check the expansion valve for leaks, remove the insulation tape. 6. Repair all leaks, and charge the system.
UV leak detection test 1. Please see the instructions from the manufacturer of the UV leak detection tool for proper use. 2. Repair all leaks, and charge the system.
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Air conditioning - Discharging WARNING Avoid injury! Avoid breathing air-conditioning refrigerant, lubricant vapor or mist. If accidental system discharge occurs, ventilate the work area before resuming service. Failure to comply could result in death or serious injury. W1000B
Prior operation: Operate the air conditioning system for approximately ten minutes before starting the following procedure. Turn the system off after ten minutes of operation. NOTICE: A/C systems are to be maintained by a certified professional. Do not attempt the following procedure without A/C certification. NOTE: Recovered refrigerant passes through an oil separator and filter-drier before entering the refrigerant tank. The moisture indicator will turn green when dry refrigerant passes over it. 1. Clean the external surfaces of the compressor and hoses. 2. Remove the caps from the service ports on the machine. 3. Verify the valves on the charging station, part number 34788, are in the closed position. 4. Connect the hose from the low pressure gauge to the low pressure port on the machine. 5. Connect the hose from the high pressure gauge to the high pressure port on the machine. 6. Turn in both thumbscrews to depress the service valves. 7. Open the high and low valves on the charging station, part number 34788. 8. Make certain the refrigerant tank valves are open. 9. Turn on the charging station, part number 34788, and recover the refrigerant.
RAPH15SSL0059CA
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Air conditioning - Charging WARNING Avoid injury! Avoid breathing air-conditioning refrigerant, lubricant vapor or mist. If accidental system discharge occurs, ventilate the work area before resuming service. Failure to comply could result in death or serious injury. W1000B
NOTICE: A/C systems are to be maintained by a certified professional. Do not attempt the following procedure without A/C certification. 1. Clean the external surfaces of the compressor and hoses. 2. Remove the caps from the service ports on the machine. 3. Verify the valves on the charging station, part number 34788, are in the closed position. 4. Connect the hose from the low pressure gauge to the low pressure port on the machine. 5. Connect the hose from the high pressure gauge to the high pressure port on the machine. 6. Turn in both thumbscrews to depress the service valves. 7. Open the high and low valves on the charging station, part number 34788. 8. Make certain the refrigerant tank valves are open. 9. Turn on the charging station, part number 34788. 10. Vacuum the system for approximately 15–45 minutes. 11. Verify that the system holds a vacuum for approximately fifteen minutes. If the system does not hold a vacuum, please see Air conditioning - Leakage test (50.200). If the system holds a vacuum, please proceed to step 12 12. Charge the system with 1.5 kg (3.3 lb) of R134A refrigerant. 13. Close any opened valves, and carefully remove the manifold gauge hoses. 14. Install the caps on the service ports. 15. Start the engine and run at 1500 rpm. Operate the air conditioner system at maximum cooling setting and blower speed with the door and windows open. NOTE: The compressor will not operate if the system pressure is too low or too high. If the compressor fails to operate and the condenser blowers also fail to operate when you actuate the A/C switch, check the system pressure to determine if refrigerant is present. Check for continuity at the pressure switch located at the receiver-dryer and the temperature switch located at the evaporator.
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RAPH15SSL0059CA
1
Cab climate control - Air conditioning
Air conditioning - Remove Prior operation: Evacuate the A/C system. See Air conditioning - Evacuate (50.200) NOTICE: A/C systems are to be maintained by a certified professional. Do not attempt the following without A/C certification. 1. Raise cab to disconnect air conditioning system hoses (1) and cap open ports. NOTE: If R134A is still in system, it should be drained and captured prior to disconnecting hoses.
931001817
1
931001817
2
931001759
3
2. Label and disconnect heater hoses (2) and cap open ports. NOTE: Drain coolant into a suitable container prior to disconnecting heater hoses.
3. Remove seat hardware (3).
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4. Disconnect seat safety switch electrical connection (4).
931001793
4
93109313
5
931001752
6
931001751
7
5. Remove operators seat.
6. Remove mounting screws (5) and remove cover (6).
7. Remove rear panel hardware (7).
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8. Remove window wash bottle lid (8).
931001775
8
931001774
9
9. Remove rear panel exposing air conditioning unit.
10. Remove left hand side and right hand side duct work hardware (9).
931001763
10
931001769
11
11. Remove air condition unit mounting hardware (10).
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12. Disconnect air condition electrical connector (11).
931001771
12
931001773
13
13. Remove air condition unit.
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Air conditioning - Install NOTICE: A/C systems are to be maintained by a certified professional. Do not attempt the following without A/C certification. 1. Position the air condition (A/C) unit in the cab.
931001773
1
931001771
2
931001769
3
931001763
4
2. Connect A/C electrical connection (1).
3. Install left and right hand side A/C mounting hardware (2).
4. Install left hand side and right hand side duct work and secure with hardware (3).
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5. Install the rear panel (4).
931001774
5
931001751
6
931001775
7
931001752
8
6. Install rear panel hardware (5).
7. Install window washer bottle lid (6).
8. Install cover and mounting screws (7).
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9. Position operators seat in the cab.
86095343
9
10. Connect seat safety switch electrical connection (A).
931001793
10
931001759
11
931001757
12
11. Install operators seat hardware (2).
12. Connect heater hoses (3).
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13. Connect air condition hoses (4).
931001757
14. After the heater/air conditioning assembly has been installed refer to Radiator - Filling (10.400) and refill the cooling system. 15. Refer to Air conditioning - Discharging (50.200). Connect the Refrigerant Recovery, Recycling and Charging Station to the high and low charge ports in the hose fitting on the compressor. Evacuate the system to remove all moisture from the system. 16. Refer to Air conditioning - Charging (50.200) and charge the system with reclaimed or new refrigerant. Start the engine and test the air conditioning system for proper operation.
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Compressor drive belt - Tension adjust Use the following procedure to adjust the air conditioning compressor belt. 1.
Loosen the adjusting bracket bolt (1).
2.
Loosen the mounting bolt (2).
3.
Loosen the adjusting bolt jam nut (3).
4.
Tighten the adjusting bolt (4) until tight. The belt is tightened correctly when a force of 1 kg (2.2 lb) is applied perpendicular to the belt at the center of the span with a 3 mm (0.1 in) deflection.
5.
Tighten the adjusting bolt jam nut (3).
6.
Tighten the adjusting bracket bolt (1) and mounting bolt (2).
RAPH12SSL0064BA
1
NOTE: Check the compressor belt tension after the first 10 hours of operation on a new machine or if a new belt has been installed. Measure the deflection of the belt at center of span with perpendicular load of applied, and adjust as necessary.
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Air-conditioning evaporator - Remove Prior operation: Tilt the cab. Please see Cab tilting system - Tilt (90.150) Prior operation: Discharge the A/C. Please see Air conditioning - Discharging (50.200). 1. Detach the heater hoses (2) from the heater core. 2. Detach the A/C lines (1) from the evaporator (if applicable). 3. Remove the nuts (3), and detach the seat from the cab.
RAIL15SSL0042BA
1
RAIL14SSL0418AA
2
RAPH14SSL0351BA
3
4. Carefully lower the cab. Please see Cab tilting system - Lower (90.150) for assistance.
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5. Disconnect the seat switch (2) from the wiring harness. 6. Disconnect the seat belt switch (if applicable) (1) from the wiring harness.
RAIL15SSL0041BA
4
93109313
5
93106883
6
7. Remove the seat (1) from the cab.
8. Remove the access cover (1) for the cab filter by turning the knobs (2) counter clockwise and lifting the cover (1) off of the HVAC assembly.
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9. Remove the fasteners from the panel.
RAIL15SSL0073BA
7
RAIL15SSL0040BA
8
RAIL15SSL0028BA
9
10. Remove the panel from the cab.
11. Disconnect the HVAC assembly from the wiring harness.
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12. Disconnect the joystick from the wiring harness.
RAIL15SSL0072BA
10
RAIL15SSL0039BA
11
RAIL15SSL0038BA
12
13. Detach and remove the joystick assembly (1) from the cab. 14. Repeat steps 12 and 13 on the opposite side.
15. Remove the fasteners (2) from the air duct (3). 16. Remove the screws (1) from the HVAC assembly . 17. Remove the air duct (3) from the cab. 18. Repeat steps 15 – 17 on the opposite side.
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19. Remove the screws (1) from the HVAC assembly. 20. Remove the HVAC assembly (2) from the cab.
931001774
13
931001774
14
RAIL15SSL0036BA
15
21. Place the HVAC assembly on a workbench. 22. Remove the screws (1) from the HVAC assembly. 23. Remove the clips (2) from the HVAC assembly.
24. Flip the HVAC assembly. 25. Remove the screws (1) from the HVAC assembly. 26. Remove the clips (2) from the HVAC assembly.
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27. Separate and remove the lower half of the HVAC assembly.
RAIL15SSL0033BA
16
RAIL15SSL0034BA
17
RAIL15SSL0037BA
18
28. Separate the two halves of the HVAC assembly.
29. Remove the evaporator from the HVAC assembly.
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Air-conditioning evaporator - Install 1. Insert the evaporator into the HVAC assembly.
RAIL15SSL0037BA
1
RAIL15SSL0034BA
2
RAIL15SSL0033BA
3
2. Connect the two halves of the HVAC assembly.
3. Connect the lower half to the HVAC assembly.
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4. Verify that the rubber seals are install properly.
RAIL15SSL0032BA
4
RAIL15SSL0036BA
5
931001774
6
5. Install the clips (2) onto the HVAC assembly. 6. Install the screws (1) into the HVAC assembly.
7. Flip the HVAC assembly. 8. Install the clips (2) onto the HVAC assembly. 9. Install the screws (1) into the HVAC assembly.
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10. Install the HVAC assembly (2) into the cab. 11. Install the screws (1) that attach the HVAC assembly to the cab.
931001774
7
RAIL15SSL0038BA
8
RAIL15SSL0072BA
9
12. Install the air duct (3) into the cab. 13. Install the fasteners (2) that attach the air duct (3) to the cab. 14. Install the screws (1) that attach the air duct to the HVAC assembly. 15. Repeat steps 12 – 14 on the opposite side.
16. Connect the joystick to the wiring harness.
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17. Attach the joystick assembly to the cab. 18. Repeat steps 16 and 17 on the opposite side.
RAIL15SSL0039BA
10
RAIL15SSL0028BA
11
RAIL15SSL0040BA
12
19. Connect the HVAC assembly to the wiring harness.
20. Install the panel into the cab.
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21. Install the fasteners that attach the panel to the cab.
RAIL15SSL0073BA
13
93106883
14
93109313
15
22. Install the access cover (1), and tighten onto the HVAC assembly by turning the knobs (2) clockwise.
23. Install the seat (1) from the cab.
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24. Connect the seat switch (2) to the wiring harness. 25. Connect the seat belt switch (if applicable) (1) to the wiring harness.
RAIL15SSL0041BA
16
93107498
17
RAPH11SSL0016BA
18
26. Carefully tilt the cab. Please see Cab tilting system - Tilt (90.150) for assistance.
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27. Attach the seat to the cab by installing the nuts (3). 28. Attach the heater hoses (2) to the heater core. 29. Attach the A/C lines (1) to the evaporator (if applicable).
RAIL15SSL0042BA
Next operation: Add CASE AKCELA ACTIFULL™ OT EXTENDED LIFE COOLANT. Please see Capacities () for specifications. Next operation: Charge the A/C system. Please see Air conditioning - Charging (50.200).
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Air conditioning - Troubleshooting Problem Possible Cause A/C will not blow cold air. The refrigerant is too low. The compressor clutch intermittently engages.
The evaporator fan has failed.
Correction Check for leaks. Please see Air conditioning - Leakage test (50.200). 1. Check the fuse. 2. Check the relay. 3. Check for voltage and ground at the fan.
4. Verify that the fan has movement and is not seized. Low flow rate through the condenser is 1. Check the refrigerant level. causing high pressure which is activating 2. Check the refrigerant quality. the high pressure switch. 3. Check the functionality of the compressor.
A/C will not operate.
Broken low pressure switch. Broken high pressure switch. A refrigerant leak is causing low pressure which is activating the low pressure switch. The electromagnet clutch on the compressor is worn. Damaged or disconnected connector.
Broken fuse. Broken relay. Broken switch. Refrigerant leak.
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4. Check for clogs in the system. Inspect the low pressure switch. Inspect the high pressure switch. Check for leaks. Please see Air conditioning - Leakage test (50.200). Replace the clutch or compressor assembly. Check the electrical connections of the switches, relays, control module, and compressor. Check the fuse. Check the relay. Check the switch. Test for leaks. Please see Air conditioning - Leakage test (50.200).
Cab climate control - Air conditioning
Air conditioning - Problem solving OPERATION To understand the electrical flowpaths and help narrow down the troubleshooting efforts, refer to HVAC System Electrical overview Air conditioning - Overview - Electrical system (50.200). TROUBLESHOOTING Before troubleshooting ensure that 1. HVAC FUSE F-001 is good. 2. COMPRESSOR FUSE F-002 is good. 3. ACCESSORY RELAY K-018 is good. See Electrical system - Component identification Relay Index (55.000). 4. Switches are operated in accordance with Operator's Manual. Problem
Possible Cause Correction Faulty TEMPCONTROL Z-017 potentiometer Heating, Ventilation, and Air-Conditioning (HVAC) control system - Testing HVAC Heat Components (55.050) Faulty WATER VALVE Z-019 Heating, Ventilation, and Air-Conditioning (HVAC) control system - Testing HVAC Heat Components (55.050) Faulty Fan Relay (internal to HVAC Box) Heating, Ventilation, and Air-Conditioning (HVAC) control system - Testing HVAC Box (55.050) Poor Heat Faulty TEMPCONTROL Z-017 potentiometer Heating, Ventilation, and Air-Conditioning (HVAC) control system - Testing HVAC Heat Components (55.050) Faulty WATER VALVE Z-019 Heating, Ventilation, and Air-Conditioning (HVAC) control system - Testing HVAC Heat Components (55.050) Poor cooling No voltage at connector X-74 pin B. Faulty CONDENSER RELAY or associated wiring. See Fuse and controller power relay - Testing Relay Testing (55.640) and Fuse and relay box - Testing Condenser Relay Control (55.100) Air-conditioning condenser - Testing Faulty HVAC CONDENSER FAN Condenser Fan (50.200) Thermostat (internal to HVAC Box) not cy- Heating, Ventilation, and Air-Conditioncling correctly ing (HVAC) control system - Testing HVAC Box (55.050) Poor cooling after engine Faulty WATER VALVE Z-019 Heating, Ventilation, and Air-Conditionis at normal temperature ing (HVAC) control system - Testing HVAC Heat Components (55.050) Faulty TEMPCONTROL Z-017 potentiometer Heating, Ventilation, and Air-Conditioning (HVAC) control system - Testing HVAC Heat Components (55.050) No cooling Faulty Fan Relay (internal to HVAC Box) Heating, Ventilation, and Air-Conditioning (HVAC) control system - Testing HVAC Box (55.050) Faulty BLOWER SWITCH S-020 Heating, Ventilation, and Air-Conditioning (HVAC) control system - Testing Blower Switch (55.050) Faulty AC SWITCH S-017 Heating, Ventilation, and Air-Conditioning (HVAC) control system - Testing A/C Switch (55.050) Faulty Single-Level Pressure Switch (inter- Heating, Ventilation, and Air-Conditionnal to HVAC Box) ing (HVAC) control system - Testing HVAC Box (55.050) No heat
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Cab climate control - Air conditioning
Problem
Possible Cause Correction Faulty Thermostat (internal to HVAC Box) Heating, Ventilation, and Air-Conditioning (HVAC) control system - Testing HVAC Box (55.050) Faulty HVAC HIGH PRESSURE SWITCH Heating, Ventilation, and Air-Conditioning (HVAC) control system - Testing HVAC High Pressure Switch (55.050) Faulty Compressor Relay (internal to HVAC Heating, Ventilation, and Air-ConditionBox) ing (HVAC) control system - Testing HVAC Box (55.050) Air-conditioning compressor - Testing Faulty A/C COMPRESSOR A/C Compressor (50.200) No fan speeds available No voltage at HVAC Box pin 14 Faulty HVAC FUSE F-001 or associated wiring Faulty ACCESSORY RELAY K-018 or assoNo voltage at HVAC Box pin 11 ciated wiring. See Fuse and controller power relay - Testing Relay Testing (55.640) and Fuse and relay box - Testing Accessory Relay Control (55.100) Faulty BLOWER SWITCH S-020 Heating, Ventilation, and Air-Conditioning (HVAC) control system - Testing Blower Switch (55.050) Faulty Fan Relay (internal to HVAC Box) Heating, Ventilation, and Air-Conditioning (HVAC) control system - Testing HVAC Box (55.050) Faulty Electric Fan Motor (internal to HVAC Heating, Ventilation, and Air-Conditionbox) ing (HVAC) control system - Testing HVAC Box (55.050) Faulty HVAC Box ground wiring Use Electrical system - Testing General Wire Testing (55.000) to ensure proper ground from HVAC Box pin 1 Only high speed fan Faulty Resistor (internal to HVAC Box) Heating, Ventilation, and Air-Conditionavailable ing (HVAC) control system - Testing HVAC Box (55.050) Only one fan speed is not Wiring problem common to HVAC BOX Use Electrical system - Testing General available A-003 (Resistor) and BLOWER SWITCH Wire Testing (55.000) to locate faulty wire S-020
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Cab climate control - Air conditioning
Air-conditioning condenser - Testing - Condenser Fan NOTE: Use schematics Wiring harnesses - Electrical schematic sheet 17 (55.100) NOTE: Without the Condenser Fan, the Air Conditioning will work poorly. If Air Conditioning does not work at all, see Air conditioning - Problem solving (50.200) Test N°1 Test Point Condition Disconnect connector X-74 from the HVAC CONDENSER FAN. Use Electrical system - Testing General Wire Testing (55.000) to Check ground wire condition between X-74 pin A and ground. Expected Result Result No wire problems. Action Go to test 2 Other Result Result Wire problems are found. (Possible Action Cause) Locate and repair or replace broken wire 1084 (Black). Test N°2 Test Point Condition With ignition on, Check for voltage from connector X-74 pin B and ground. Expected Result Result 12 V Action The HVAC CONDENSER FAN has failed. Replace the fan. Other Result Result 0 V (Possible Action Cause) Go to test 3 Test N°3 Test Point Condition Disconnect connector X-111 from the CONDENSER RELAY . Use Electrical system - Testing General Wire Testing (55.000) to Check wire condition between X-74 pin B and X-111 pin 87. Expected Result Result No wire problems. Action See the following for further testing • Fuse and relay box - Testing Condenser Relay Control (55.100) Other Result (Possible Cause)
• Air conditioning - Problem solving (50.200) Result Wire problems are found. Action Locate and repair or replace broken wire 237 (White).
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Index Cab climate control - 50 Air conditioning - 200 Air conditioning - Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12
Air conditioning - Discharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11
Air conditioning - Dynamic description - A/C thermal operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4
Air conditioning - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3
Air conditioning - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
17
Air conditioning - Leakage test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9
Air conditioning - Overview - Electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8
Air conditioning - Overview - Mechanical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7
Air conditioning - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6
Air conditioning - Problem solving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
36
Air conditioning - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13
Air conditioning - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
35
Air-conditioning condenser - Testing - Condenser Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
38
Air-conditioning evaporator - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
28
Air-conditioning evaporator - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
22
Compressor drive belt - Tension adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
21
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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. Š 2018 CNH Industrial America LLC. All rights reserved. No part of the text or illustrations of this publication may be reproduced.
CNH Industrial America LLC reserves the right to make improvements in design and changes in specifications at any time without notice and without incurring any obligation to install them on units previously sold. Specifications, descriptions, and illustrative material herein are as accurate as known at the time of publication, but are subject to change without notice. Availability of some models and equipment builds varies according to the country in which the equipment is being used. For exact information about any particular product, please consult your CASE CONSTRUCTION dealer. CASE CONSTRUCTION is a trademark registered in the United States and many other countries, owned or licensed to CNH Industrial N.V., its subsidiaries or affiliates. Any trademarks referred to herein, in association with goods and/or services of companies, other than owned by or licensed to CNH Industrial N.V., its subsidiaries or affiliates, are the property of those respective companies.
48068130 29/01/2018 EN
SERVICE MANUAL Electrical systems SR210 TIER 4B (FINAL) [NGM418237 - ], SR210 TIER 4B (FINAL) [NHM435463 - ], SR240 TIER 4B (FINAL) [NGM418237 - ], SR240 TIER 4B (FINAL) [NHM435463 - ], SV280 TIER 4B (FINAL) [NGM418237 - ], SV280 TIER 4B (FINAL) [NHM435463 - ], TR270 TIER 4B (FINAL) [NGM418237 - ], TR270 TIER 4B (FINAL) [NHM435463 - ], TR310 TIER 4B (FINAL) [NGM418237 - ], TR310 TIER 4B (FINAL) [NHM435463 - ], TV370 TIER 4B (FINAL) [NHM435463 - ]
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Contents Electrical systems - 55
[55.000] Electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.1 [55.010] Fuel injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.2 [55.011] Fuel tank system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.3 [55.012] Engine cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.4 [55.019] Hydrostatic drive control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.5 [55.036] Hydraulic system control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.6 [55.050] Heating, Ventilation, and Air-Conditioning (HVAC) control system. . . . . . . . . . . . . . . . . . . 55.7 [55.051] Cab Heating, Ventilation, and Air-Conditioning (HVAC) controls. . . . . . . . . . . . . . . . . . . . . 55.8 [55.100] Harnesses and connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.9 [55.201] Engine starting system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.10 [55.202] Cold start aid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.11 [55.301] Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.12 [55.302] Battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.13 [55.404] External lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.14 [55.408] Warning indicators, alarms, and instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.15 [55.512] Cab controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.16 [55.518] Wiper and washer system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.17 [55.525] Cab engine controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.18
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[55.640] Electronic modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.19 [55.991] Telematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.20 [55.DTC] FAULT CODES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.21
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Electrical systems - 55 Electrical system - 000
SR210 TIER 4B (FINAL) [NGM418237 - ], SR210 TIER 4B (FINAL) [NHM435463 - ], SR240 TIER 4B (FINAL) [NGM418237 - ], SR240 TIER 4B (FINAL) [NHM435463 - ], SV280 TIER 4B (FINAL) [NGM418237 - ], SV280 TIER 4B (FINAL) [NHM435463 - ], TR270 TIER 4B (FINAL) [NGM418237 - ], TR270 TIER 4B (FINAL) [NHM435463 - ], TR310 TIER 4B (FINAL) [NGM418237 - ], TR310 TIER 4B (FINAL) [NHM435463 - ], TV370 TIER 4B (FINAL) [NHM435463 - ]
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Contents Electrical systems - 55 Electrical system - 000
FUNCTIONAL DATA Electrical system Overview - Electro-Hydraulic (EH) - Electronic Service Tool (EST) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Overview - Electro-Hydraulic (EH) - Electrical System (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
SERVICE Electrical system Electrical test Open Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Electrical test Short to Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Electrical test Short to Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Electrical system Electronic Service Tool (EST) - H1 - Calibration procedures - Requirements - Video . . . . . . . . . . . . . . . . 12 H1 - Calibration procedures - Joystick - Video . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Electronic Service Tool (EST) - H1 - Calibration procedures - Ground Drive - Video . . . . . . . . . . . . . . . . 15 H1 - Calibration procedures - Troubleshooting - Video . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Program - Controller - Video . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Electronic Service Tool (EST) - H1 - Calibration procedures - Loader valve . . . . . . . . . . . . . . . . . . . . . . . 21 Program - Engine controller - Video (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
DIAGNOSTIC Electrical system Testing - Diode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Testing - Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Testing - Wires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
(*) See content for specific models 48068130 29/01/2018
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Electrical systems - Electrical system
Electrical system - Overview - Electro-Hydraulic (EH) - Electronic Service Tool (EST) SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Electro hydraulic controls) (Electro hydraulic controls) (Electro hydraulic controls) (Electro hydraulic controls) (Electro hydraulic controls) (Electro hydraulic controls)
The Electronic Service Tool (EST) has new capabilities. It has the ability to update or program Instrument Cluster parameters. If a newer cluster program is available or a software problem is encountered, it can be fixed by programming instead of replacing. Any time a cluster or UCM is installed into a machine, the machine information is entered through the EST. Parameters such as machine serial number, model number, machine configuration, machine hours, and optional equipment are stored in memory. The EST is also used in troubleshooting system programs and signals. An extensive list of components and sensors that can be monitored or checked out with the EST, is built into the system. With the EST, you can look up, troubleshoot, and clear fault codes. As the machine is operated, the UCM stores fault codes for technician reference. EH calibrations are also done with the EST. The EST can monitor and troubleshoot the Exhaust Gas Recirculation (EGR), Instrument Cluster, and the UCM. The EST connects to the Diagnostic Connector in the front right-hand corner inside the cab. Controllers are captured by the EST at the beginning of the Programming, Calibration, and Machine Configuration procedures. The controllers are released at the end of Programming, Calibration, Machine Configuration, and Clear Controller Faults procedures. The Instrument Cluster and the UCM are power cycled by the operator’s presence switch in the seat cushion, not the key switch or power button. The seat switch is electrically OPEN when no operator present, and electrically CLOSED when the operator is present. Programming the EIC, AIC, or the UCM, be sure to plug the EST power cord into a wall outlet or the machines 12 V power outlet. Do not work off of the EST’s battery supply. Damage can occur to the controller if the EST loses power, and the controller may need to then be replaced. During calibration, the UCM learns the tolerances and limits of each of the components it receives inputs from, and each of the components it sends outputs to. This includes mechanical, hydraulic, and electrical components, as well as slight variations in resistance in components and harnesses between one machine and another. All calibrations are necessary any time a software is downloaded to the UCM, a new UCM is installed, or the UCM is swapped from one machine to another. Individual calibrations are necessary any time there is an operator complaint of a drive operation or loader operation, a fault code in a controlled circuit, or a repair was completed in a controlled circuit (mechanical, electrical, or hydraulic). Beware that each calibration has a time limit, and to continue the enable and sustain conditions prior to timing out. Be sure to be familiar with the calibration steps prior to calibration to ease the process and complete the calibration prior to timing out. Follow the instructions precisely otherwise the calibration will be aborted by the EST.
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Electrical system - Overview - Electro-Hydraulic (EH) - Electrical System SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Electro hydraulic controls) (Electro hydraulic controls) (Electro hydraulic controls) (Electro hydraulic controls) (Electro hydraulic controls) (Electro hydraulic controls)
The Alpha series comes with the standard Electrical Instrument Cluster (EIC) or the optional Advanced Instrument Cluster (AIC). The two instrument clusters are functionally the same. The only difference is the EIC has a key switch and the AIC has a pushbutton start. With the EIC and the AIC, error codes are readable through the dash text display area. In order to clear error codes, the Electronic Service Tool (EST) must be used. On EH driven machines, the dash still controls power and start, however the Universal Control Module (UCM) controls the parking brake and the hydraulic enabler. The controller modules are Controller Area Network (CAN bus) together with the engine controller. The control pad below the bar graph on instrument cluster is where the EIC and the AIC differ from each other. The EIC buttons are only used for “SETUP” navigation. To enter the “SETUP” mode on the instrument cluster, reference the Operator’s Manual for the procedure and individual menu navigation chart. The setup menu can be used to change the drive, lift, or tilt function speed within the EH menu. The machine is also equipped with a button on the machine dash to switch from ISO to H-pattern. Reference the Operator’s Manual for procedure on switching the controls (ISO or H-pattern).
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Electrical system - Electrical test Open Circuit Prior operation: Up to three electrical test may be required to properly troubleshoot electrical concerns. The other two tests are: Short to Ground - refer to Electrical system - Electrical test Short to Ground (55.000). Short to Voltage - refer to Electrical system - Electrical test Short to Voltage (55.000). Each test is described in detail. Ensure that all steps are reviewed and followed when testing. 1. Key switch OFF (sometimes battery disconnected or fuse pulled out if specified in procedure). 2. Connectors at both ends of the circuit disconnected. All other connectors must be reconnected to perform test.
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Electrical systems - Electrical system
3. Set meter to measure resistance or ohms, and measure circuit resistance as illustrated. Use the red meter lead (1) to touch the connector pins, one pin at a time, and avoid contact with the case of metal connectors. Use the black lead (2) to make contact with the connector pin at the other end of the circuit. Avoid contact with other pins in the connector and the connector case, if it is metal. NOTE: Testing continuity from one connector to another is often not possible given the distance between the connectors. The alternate method used in this service manual requires the use of a jumper wire. Attach the jumper wire between the specified pin in one of the connectors and chassis (frame) ground. Use the red lead of the multi-meter to touch the specified pin of the other connector and touch the black lead to chassis (frame) ground. Using chassis (frame) ground as an integral part of the continuity test requires good electrical contact with the metal frame (chassis). Paint and contaminants serve as insulators and reduce the effectiveness of the electrical connection. If possible use frame (chassis) ground points already established for the black lead and one end of the jumper wire.
26093637
4. Determine if measured resistance falls within guidelines specified in the procedure. If the resistance is no more than 3 – 4 ohms, the circuit is continuous. More resistance usually indicates dirty or corroded terminals in connectors, and 100k ohms or greater indicates an open circuit.
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Electrical systems - Electrical system
Electrical system - Electrical test Short to Ground Prior operation: Up to three electrical tests may be required to properly troubleshoot electrical concerns. The other two tests are: Short to Voltage - refer to Electrical system - Electrical test Short to Voltage (55.000). Open Circuit - refer to Electrical system - Electrical test Open Circuit (55.000). Each test is described in detail. Ensure that all steps are reviewed and followed when testing. 1. Key switched power OFF, (sometimes battery disconnected or fuse pulled out if specified in procedure). 2. Connectors at each end or ends of circuit disconnected to prevent false readings.
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3. Set meter to measure resistance or ohms, and measure circuit resistance. Use black lead (2) to make contact with a plated metal part on the chassis such as a jump start post if fitted. Make sure the surface of the part is not corroded. Use the red meter lead (1) to touch the connector pins, one pin at a time, and avoid contact with the case of metal connectors.
26093638
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1
Electrical systems - Electrical system
4. Determine if measured resistance falls within guidelines specified in the procedure. A reading of less than 3 – 4 ohms indicates a direct short to chassis ground and must be located and repaired. Higher resistances usually indicate circuit paths through modules, and that an additional connector needs to be disconnected to perform the test. More than 100k ohms indicates that the circuit is free of shorts to ground. NOTE: All of the output and many of the input devices used in the electrical / electronic system use a reference or chassis ground as a functional part of the control system. Therefore, it is important to remove this intended circuit ground before testing for a "Short to Ground"
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Electrical systems - Electrical system
Electrical system - Electrical test Short to Voltage Prior operation: Up to three electrical test may be required to properly troubleshoot electrical concerns. The other two tests are: Short to Ground - refer to Electrical system - Electrical test Short to Ground (55.000). Open Circuit - refer to Electrical system - Electrical test Open Circuit (55.000). Each test is described in detail. Ensure that all steps are reviewed and followed when testing. 1. Key switch ON (sometimes OFF, if specified in procedure). 2. Connectors at sensor, switch or potentiometer end disconnected. All other connectors must be reconnected to perform test (unless otherwise specified in the procedure).
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3. Set meter to measure DC VOLTS, and measure circuit voltage as illustrated. Use the red meter (1) lead to touch the connector pins, one pin at a time, and avoid contact with the case of metal connectors. Use the black lead (2) to make contact with a plated metal part on the chassis such as a jump start post if fitted. Make sure the surface of the part is not corroded.
26093640
4. Determine if measured voltage falls within guidelines specified in the procedure.
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1
Electrical systems - Electrical system
Electrical system Electronic Service Tool (EST) - H1 - Calibration procedures - Requirements - Video Calibration involves setting correct hardware parameters for joysticks, ground drive pumps, loader valve, and throttle mechanism. Unless noted otherwise, the operator has 30 seconds to complete each calibration step. The calibration procedure will have to be restarted if a step times out. The parameters associated with each calibration procedure will be saved when that particular procedure completes successfully. If there are problems completing one of the five calibration procedures, only that procedure will need to be repeated, not all five. The audible alarm and calibration messages will not be displayed if any error codes are active. If any calibration fails, see Electrical system - H1 - Calibration procedures - Troubleshooting - Video (55.000) for troubleshooting steps.
RAPH16SSL0231QA
1
1. For service training videos on calibration procedures visit the eTim service tool or the dealer portal. 2. If new software is available, download it before calibrating using the following steps. • Connect the EST hardware to the machine diagnostic connector and laptop. • Flash the new Application Software onto the machine controller (UCM) with the Electronic Service Tool (EST) programming menu. • Flash the new instrument cluster (IC) software to the IC with the EST configuration menu. • Set the machine configurations (serial number, model, door, etc.) in the EST configuration menu. 3. Calibration Preparation Steps • Connect the EST hardware to the machine diagnostic connector and laptop. • Open the EST configuration menu. • Clear any fault codes from the IC display by cycling the Aux Override button until the display is clear.
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Electrical system - H1 - Calibration procedures - Joystick - Video The purpose of the Joystick Calibration is to calibrate the main axis of the left-hand and right-hand joystick and the proportional thumbwheel. Perform this calibration if a joystick is replaced, if there is an operator complaint about the feel of the loader or ground drive functions, and a code 1211 – Calibration Functions - Joystick Calibration not Complete JOYNU fault active.
RAPH16SSL0231QA
1
1. For service training videos on calibration procedures visit the dealer portal. 2. Ensure the prerequisite requirements are complete per Electrical system Electronic Service Tool (EST) H1 - Calibration procedures - Requirements - Video (55.000). 3. Ensure the following conditions are met: • Joysticks in Neutral • Proportional Auxiliary Roller Switch in Neutral • Key ON • Engine ON • Hydraulics OFF - Operate button flashing • Operator Present - operator in seat with lap bar (CASE)/ seat belt (New Holland) engaged • No Active Joystick Related Fault Codes 4. In the EST configuration menu, open the 'Calibration Joystick' item. 5. Press the 'SET UP CONTROLLER FOR CALIBRATION' button. • Ensure 'START CALIBRATION' is now active. 6. Press the 'START CALIBRATION' button. • Ensure that the text "C-J1" is displayed on the instrument cluster screen. 7. Press and release the loader float button to start capturing step 1 values. • Verify that an audible beep is heard from the instrument cluster and the text "C-J2" is displayed on the cluster screen upon completion of step 1.
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8. Move the proportional auxiliary roller switch to the upper or left-hand detent (toward the smaller icon). Move both joysticks to the front right-hand corner. Press and release the loader float button to start capturing step 2 values. • Verify that an audible beep is heard from the instrument cluster and the text "C-J3" is displayed on the cluster screen upon completion of step 2. 9. Move the proportional auxiliary roller switch to the lower or right detent (towards the larger icon). Move and hold both joysticks to the back left-hand corner. Press and release the loader float button to start capturing step 3 values. • Verify that an audible beep is heard from the instrument cluster upon completion of step 3. • Verify that the instrument cluster screen returns to normal message display.
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Electrical system Electronic Service Tool (EST) - H1 - Calibration procedures - Ground Drive - Video The purpose of the Ground Drive Calibration is to calibrate the left-hand and right-hand drive pumps. There are 2 parts to the ground drive calibration (Static and Dynamic). This is a semi-automatic procedure, therefore most of the operator interaction is via the instrument cluster display screen only. Perform this calibration whenever one of the pumps is replaced or service, if the operator complains about the feel of the ground drive, if the Universal Control Module (UCM) is replaced, Fault code 1212 – Calibration Functions Ground Drive Calibration not Complete is active, or if a software update requires it.
RAPH16SSL0231QA
1
1. For service training videos on calibration procedures visit the dealer portal. NOTE: It is not unusual to see a small amount of machine movement during calibrations the UCM finds the command current that brings the pump on stroke. Significant machine movement during calibration (more than 0.3 m (1.0 ft)) is not expected and is a symptom of a problem in the system. 2. Ensure the prerequisite requirements are complete per Electrical system Electronic Service Tool (EST) H1 - Calibration procedures - Requirements - Video (55.000). 3. Before performing the electro-hydraulic (EH) ground drive calibration: 1.
Ensure that the Universal Control Module (UCM) software version is v5.4.0.0 or higher.
2.
Place the machine on a level paved surface.
3.
Ensure that all tires (or both track) are the same size and configuration.
4.
Ensure that all tires are inflated to the same air pressure specification, or that the tracks are properly tensioned.
Static Calibration 1. In the EST configuration menu, open the 'Calibration Ground Drive' item. 2. Drive the machine until the hydraulic oil temperature is greater than 50 °C (122 °F). Dead-head the auxiliary hydraulics or use a restrictor (flowmeter) to assist warming up the oil.
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3. After the hydraulic oil has reached a temperature of 50 °C (122 °F) or greater, return the ground drive to neutral. 4. Turn the engine OFF. 5. Securely raise the machine off of the ground. Use blocks or jack stands to secure the machine so the wheels or tracks can turn freely and there is no weight applied. NOTICE: Do not lower the machine back to the ground until instructed. 6. Turn the engine ON. Adjust the engine throttle to 100% and leave the engine throttle at 100% until instructed to reduce the engine throttle. 7. Move the joystick or joysticks forward to the end joystick stop 100% Both wheels will be turning forward) for 30 s and then return the joysticks to neutral. NOTE: After driving forward, DO NOT make any adjustments to the ground drive. NOTICE: Both pumps have to be biased in the same direction for optimal calibration offsets. 8. Complete the EST ground drive static calibration with the engine at full throttle. NOTICE: EST will confirm if the calibration has been successfully completed and exit the calibration dialog box. 9. Fault codes 1215 – Saturation Function not complete - Forward Pumps and 1216 – Saturation Function not complete - Reverse Pumps will be displayed on the instrument cluster indication that the dynamic calibration is required. NOTICE: DO NOT complete the dynamic calibration process at this point. A UCM reset is required before completing the dynamic calibration. See step 1. 10. Turn the machine OFF. key OFF. Get out of the operator seat for 10 s.
Dynamic Calibration - keep the EST connected to the machine. 1. Verify that the hydraulic oil temperature is greater than 50 °C (122 °F). If the temperature is not at least 50 °C (122 °F), then drive the machine until the hydraulic oil temperature is greater than 50 °C (122 °F). Dead-head the auxiliary hydraulics or use a restrictor (flowmeter) to assist warming up the oil. 2. Turn the machine ON. Dynamic calibration requirements 1.
The joystick calibration is complete.
2.
Low speed range is selected (if equipped with twospeed).
3.
The EZ EH speed setting is at MED1 or MED2.
4.
The engine speed must be between 1400 – 1500 RPM.
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3. While fault codes 1215 – Saturation Function not complete - Forward Pumps and 1216 – Saturation Function not complete - Reverse Pumps are active, the engine speed will not be visible to the operator. Use the EST parameter screen to view the engine speed. 1.
Click the “Monitor” icon.
2.
Click the “Change Parameter Selection” button.
3.
Select the “Engine RPM’ in the UCM source section, reference #508.
4.
Click the “ADD” button to insert the engine RPM into the view list.
5.
Click on “Exit” to go to the monitor screen.
6.
The engine speed must be between 1400 – 1500 RPM.
4. Move the ISO joystick straight to the full forward position. 5. Use the EST parameter screen to view: 1.
Left Joystick Axis: greater than 20.8° (maximum forward position)
2.
Left Joystick X Axis: ± 1.5° (neutral position)
3.
Operate until fault code 1215 – Saturation Function not complete - Forward Pumps disappears from the instrument cluster display.
6. Move the ISO joystick straight to the full reverse position. 7. Use the EST parameter screen to view: 1.
Left Joystick Axis: greater than –20.8° (maximum forward position)
2.
Left Joystick X Axis: ± 1.5° (neutral position)
3.
Operate until fault code 1216 – Saturation Function not complete - Reverse Pumps disappears from the instrument cluster display.
Post calibration verification 1. Turn the engine OFF. 2. Lower the machine back to the ground. 3. Verify that the tracking is straight forward at mid-stroke joystick, 100% engine throttle, and in the low range in a machine with two-speed. Employing all of the vehicle settings, mid-stroke joystick in defined as the stroke required to obtain a forward speed of 4.8 – 6.4 km/h (3.0 – 4.0 mph). If the machine is tracking straight then the calibration is complete. If the machine is not tracking straight, then perform the Dynamic Calibration again. Start at step. 2.
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4. If after two attempts and the machine is not tracking straight: 1.
Verify that the machine is OFF.
2.
Verify that the key switch is OFF.
3.
Verify that no one has been sitting in the operators seat for at least 10 s.
5. If the above items in step 4 check out satisfactorily, then continue with the post calibration verification. 6. Good, straight tracking in all control ranges. 1. Ground drive calibration is completed properly. 7. Poor straight tracking in mid-stroke ranges: 1.
Calibration offsets were not captured correctly.
2.
Procedure steps were not followed exactly.
3.
An issue with the machine caused the calibration to not capture the correct offset requirements. 1.
If the dynamic calibration took long periods to complete and had a large deviation during the calibration process then the software did not log good offset values.
2.
If new ground drive components were installed there could be pump / motor sticktion or aeration in the hydraulics, this can cause erratic calibration offsets. 1.
Drive the machine for a period in all directions to ensure these conditions do not affect calibration.
2.
Repeat the EH Ground Drive Calibration Procedure.
8. Poor straight tracking at full speed: 1.
Dynamic calibration may not have completed properly. 1.
Change EZ EH speed setting to "HIGH" to ensure both pumps reach maximum displacement. 1.
If straight tracking improves then the Dynamic Calibration did not complete properly. Repeat the EH Ground Drive Calibration Procedure.
2.
If straight tracking is still poor then the mechanical stops on the pumps will require some adjustments.
NOTICE: Repeat the EH Ground Drive Calibration Procedure after any mechanical adjustments on the pumps.
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Electrical system - H1 - Calibration procedures - Troubleshooting - Video These are the codes that may be encountered during calibration. If seen, check condition description and compare to calibration procedure prerequisite conditions.
RAPH16SSL0231QA
Display Text CD01
Condition Name Calibration Enable Fail
CD02
Calibration Sustain Fail
CD03
Device Fault
CD04
Calibration Timeout
CD05
Operator Interrupt
CD06
Calibration Value High
CD07
Calibration Value Low
CD08
Signal Unstable
1
Condition Description Calibration Enable Condition(s) not met at time of initiation Calibration Sustain Condition(s) not met during cal routine Device Fault Calibration Sustain Condition(s) not met during cal routine Calibration Step was not completed within allotted time Calibration interrupted by Operator via cluster Cal button Calibration value higher than upper-end of acceptance range Calibration value lower than lower-end of acceptance range Signal being calibrated outside of settling noise tolerance
1. Troubleshooting Suggestions 1.
For CD01 - CD05, restart calibration procedure with the 'START CALIBRATION' button. If this does not work, Press 'Exit' on EST calibration procedure and re-enter the calibration state and the individual calibration procedure.
2.
For CD-06 - CD-08, try 'Retry' button on EST. If this does not work, Press 'Exit' on the calibration procedure and re-enter the calibration state and the individual calibration procedure.
3.
Occasionally closing and reopening the EST is required to restart a calibration.
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Software Reaction Exit calibration and use old values Exit calibration and use old values Exit calibration and use old values
Exit calibration and use old values Exit calibration and use old values Beep and flash code - give operator a chance to retry cal step Beep and flash code - give operator a chance to retry cal step Beep and flash code - give operator a chance to retry cal step
Electrical systems - Electrical system
Electrical system - Program - Controller - Video
RAPH16SSL0231QA
1
1. For service training videos on calibration and programming procedures visit the dealer portal.
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Electrical system Electronic Service Tool (EST) - H1 - Calibration procedures - Loader valve The purpose of the Loader Calibration Procedure is to calibrate the command current to a nominal pressure for each spool and calibrate the neutral position of the loader attachment spool sensors. This is a semi-automatic procedure, therefore most of the operator interaction is via the cluster display screen only. NOTE: It is not unusual to see a small amount of loader or bucket movement during calibration as the UCM finds the command current that shifts the valve spools. Significant implement movement during calibration (more than 1 foot) should not be expected and is a symptom of a problem in the system. 1. Ensure the prerequisite requirements are complete per Electrical system Electronic Service Tool (EST) H1 - Calibration procedures - Requirements - Video (55.000). 2. Ensure the following conditions are met • Joysticks in Neutral • Proportional Auxiliary Roller Switch in Neutral • Key ON • Engine ON • Hydraulics ON • Park Brake Engaged (park brake light on) with the park brake switch, not the OPERATE Button on the IC • Hydraulic Oil Temperature between 15 – 80 °C (59.0 – 176.0 °F) • Operator Present • Engine RPM less than 1200 RPM • No Joystick Related Fault Codes • No Loader Related Fault Codes 3. In the EST configuration menu, open the 'Calibration Loader Valve' item. 4. Press the 'SET UP CONTROLLER FOR CALIBRATION' button. • Ensure 'START CALIBRATION' is now active. 5. Press the 'START CALIBRATION' button. • Ensure that the text "C-L1" is displayed on the cluster screen. 6. Move the right joystick to the top right corner (away from the operator) and press and release the loader float button. Keep the right joystick in the top right corner for the entirety of the loader calibration. • Verify that an audible beep is heard from the instrument cluster and the text "C-L2" is displayed on the cluster screen upon completion of the previous step. 7. Keep the right joystick at the top right corner (away from the operator). • Verify that an audible beep is heard from the instrument cluster and the text "C-L3" is displayed on the cluster screen upon completion of the previous step.
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8. Keep the right joystick at the top right corner (away from the operator). • Verify that an audible beep is heard from the instrument cluster and the text "C-L4" is displayed on the cluster screen upon completion of the previous step. 9. Keep the right joystick at the top right corner (away from the operator). • Verify that an audible beep is heard from the instrument cluster and the text "C-L5" is displayed on the cluster screen upon completion of the previous step. 10. Keep the right joystick at the top right corner (away from the operator). • Verify that an audible beep is heard from the instrument cluster and the text "C-L6" is displayed on the cluster screen upon completion of the previous step. 11. Keep the right joystick at the top right corner (away from the operator). • Verify that an audible beep is heard from the instrument cluster and the text "C-L7" is displayed on the cluster screen upon completion of the previous step. 12. Keep the right joystick at the top right corner (away from the operator). • Verify that an audible beep is heard from the instrument cluster upon completion of the previous step. 13. Release the right joystick. • Verify that the EST Calibration Operation Status window says "Calibration Completed Successfully." Verify that the instrument cluster screen returns to normal message display. 14. Exit out of the Calibration - Loader Valve screen.
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Electrical system - Program - Engine controller - Video SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ]
1. The attached YouTubeâ„¢ video demonstrates how to download and program the engine controller of the IHI Shibaura Machinery (ISM) engine.
RAPH16SSL0231QA
1
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Electrical system - Testing - Diode Test N°1 Test Point Condition Disconnect the connector from the diode. Using a multi-meter on the diode setting, measure the diode from pin to pin in both directions. Expected Result Result The reading should be near the range of 0.3 V to 0.7 V one way, and infinite the other. Other Result Result If the reading is the same in both directions, the diode is shorted. (Possible If reading is near 3 V or infinite in both directions, the diode is open. Cause) Action Replace diode.
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Electrical system - Testing - Relay NOTE: See Fuse and relay box Relay - Overview (55.100) for general relay information. NOTE: For 4-pin relays, follow steps 1–2. For 5-pin relays, follow steps 3–5. Test N°1 Test Point Condition Relay removed from fuse and relay panel. Check Use a multi-meter to measure the resistance from pin 86 to pin 85. Expected Result Result There should be approximately 75 – 105 Ω. Action Go to test 2 Other Result Result If there is 0.0 Ω or infinite resistance, the coil is open or shorted internally. (Possible Action Cause) Replace the relay. Test N°2 Test Point Condition For Normally Open (NO) relays Check Use a multi-meter to check for continuity between pin 30 to pin 87. Expected Result Result There should be no continuity. Other Result Result If there is continuity, the relay is shorted. (Possible Action Cause) Replace the relay. Test N°3 Test Point Condition Relay removed from fuse and relay panel. Check Use a multi-meter to measure the resistance from pin 86 to pin 85. Expected Result Result There should be approximately 75 – 105 Ω. Action Go to test 4 Other Result Result If there is 0.0 Ω or infinite resistance, the coil is open or shorted internally. (Possible Action Cause) Replace the relay. Test N°4 Test Point Condition Relay removed from fuse and panel relay. Check Use a multi-meter to check for continuity between pin 30 to pin 87. Expected Result Result There should be no continuity. Action Go to test 5 Other Result Result If there is continuity, the relay is shorted. (Possible Action Cause) Replace the relay.
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Test N°5 Test Point Condition Relay removed from fuse and panel relay. Check Use a multi-meter to check for continuity between pin 30 to pin 87a. Expected Result Result There should be continuity. Other Result Result If there is no continuity, the relay is open. (Possible Action Cause) Replace the relay.
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Electrical system - Testing - Wires Test N°1 Test Point Condition Circuit not functioning. Check Check the wire for an open circuit. Expected Result Result Wire not broken. Action Go to test 2 Other Result Result Wire is broken. (Possible Action Cause) Follow Wiring harnesses - Repair (55.100) Test N°2 Test Point Condition Circuit not functioning. Check Check wire run for a short circuit to ground by following Electrical system - Electrical test Short to Ground (55.000). Expected Result Result Wire not shorted. Action Go to test 3 Other Result Result Wire is shorted. (Possible Action Cause) Follow Wiring harnesses - Repair (55.100) Test N°3 Test Point Condition Circuit not functioning. Check Check wire run for a short circuit to voltage by following Electrical system - Electrical test Short to Voltage (55.000). Expected Result Result Wire not shorted. Action The fault may be intermittent. 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. If no damage is found, continue operation. Other Result Result Wire is shorted. (Possible Action Cause) Follow Wiring harnesses - Repair (55.100)
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Index Electrical systems - 55 Electrical system - 000 Electrical system - Electrical test Open Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5
Electrical system - Electrical test Short to Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7
Electrical system - Electrical test Short to Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10
Electrical system - H1 - Calibration procedures - Joystick - Video . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13
Electrical system - H1 - Calibration procedures - Troubleshooting - Video . . . . . . . . . . . . . . . . . . . . . .
19
Electrical system - Overview - Electro-Hydraulic (EH) - Electrical System (*) . . . . . . . . . . . . . . . . . . .
4
Electrical system - Overview - Electro-Hydraulic (EH) - Electronic Service Tool (EST) (*) . . . . . . . .
3
Electrical system - Program - Controller - Video . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20
Electrical system - Program - Engine controller - Video (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
23
Electrical system - Testing - Diode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
24
Electrical system - Testing - Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
25
Electrical system - Testing - Wires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
27
Electrical system Electronic Service Tool (EST) - H1 - Calibration procedures - Ground Drive - Video ......................................................................................
15
Electrical system Electronic Service Tool (EST) - H1 - Calibration procedures - Loader valve . . . . .
21
Electrical system Electronic Service Tool (EST) - H1 - Calibration procedures - Requirements - Video ......................................................................................
12
(*) See content for specific models 48068130 29/01/2018
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Electrical systems - 55 Fuel injection system - 010
SR210 TIER 4B (FINAL) [NGM418237 - ], SR210 TIER 4B (FINAL) [NHM435463 - ], SR240 TIER 4B (FINAL) [NGM418237 - ], SR240 TIER 4B (FINAL) [NHM435463 - ], SV280 TIER 4B (FINAL) [NGM418237 - ], SV280 TIER 4B (FINAL) [NHM435463 - ], TR270 TIER 4B (FINAL) [NGM418237 - ], TR270 TIER 4B (FINAL) [NHM435463 - ], TR310 TIER 4B (FINAL) [NGM418237 - ], TR310 TIER 4B (FINAL) [NHM435463 - ], TV370 TIER 4B (FINAL) [NHM435463 - ]
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Contents Electrical systems - 55 Fuel injection system - 010
SERVICE Fuel injection system Common rail pressure sensor - Configure - Reset ECU data (Rail pressure sensor) . . . . . . . . . . . . . . . . . 3 Common rail - Configure - Reset ECU data (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
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Common rail pressure sensor - Configure - Reset ECU data (Rail pressure sensor) NOTE: Active dosing faults require additional key cycles in order for the Engine Control Unit (ECU) to determine the fault has been repaired. Afterrun must be completed between each key cycle. 1. Connect the Electronic Service Tool (EST) and turn the key switch ON without starting the engine. 2. Click the “Configuration” icon (1).
NHPH14ENG0006AA
1
NHPH14ENG0017AA
2
3. Select “Replacement of the Rail Pressure Sensor - Reset ECU Data. 4. Click the “CONFIGURE SELECTED ITEM” button. 5. Click the “RESET” button (1).
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Common rail - Configure - Reset ECU data SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ]
The Engine Control Unit (ECU) monitors for sudden decreases in rail pressure. The ECU counts and stores these events to monitor Pressure Relief Valve (PRV) degradation. The counter needs to be manually reset when the PRV is replaced. NOTE: This procedure is only to be used after the PRV has been replaced. 1. Connect the Electronic Service Tool (EST) and turn the key switch ON without starting the engine. 2. Click the “Configuration” icon (1).
NHPH14ENG0006AA
1
NHPH14ENG0020AA
2
NHPH14ENG0021AA
3
3. Select “Replacement of the Rail Pressure Relief Valve (PRV) – Reset ECU Data” (1). 4. Click the “CONFIGURE SELECTED ITEM” button (2).
5. Click the “RESET” button (1).
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Index Electrical systems - 55 Fuel injection system - 010 Common rail - Configure - Reset ECU data (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4
Common rail pressure sensor - Configure - Reset ECU data (Rail pressure sensor) . . . . . . . . . . . . .
3
(*) See content for specific models 48068130 29/01/2018
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Electrical systems - 55 Fuel tank system - 011
SR210 TIER 4B (FINAL) [NGM418237 - ], SR210 TIER 4B (FINAL) [NHM435463 - ], SR240 TIER 4B (FINAL) [NGM418237 - ], SR240 TIER 4B (FINAL) [NHM435463 - ], SV280 TIER 4B (FINAL) [NGM418237 - ], SV280 TIER 4B (FINAL) [NHM435463 - ], TR270 TIER 4B (FINAL) [NGM418237 - ], TR270 TIER 4B (FINAL) [NHM435463 - ], TR310 TIER 4B (FINAL) [NGM418237 - ], TR310 TIER 4B (FINAL) [NHM435463 - ], TV370 TIER 4B (FINAL) [NHM435463 - ]
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Contents Electrical systems - 55 Fuel tank system - 011
TECHNICAL DATA Fuel level sensor General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
FUNCTIONAL DATA Fuel level sensor Overview Potentiometers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
SERVICE Fuel level sensor Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
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Fuel level sensor - General specification
SS13K026
1
Fuel sending unit Conversion table Instrument panel display 8 bars 7 bars 6 bars 5 bars 4 bars 3 bars 2 bars 1 bar
Resistance of the fuel level sensor 0 – 32 Ω 33 – 67 Ω 68 – 87 Ω 88 – 131 Ω 132 – 171 Ω 172 – 200 Ω 201 – 230 Ω 231 – — Ω
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Fuel level sensor - Overview Potentiometers Potentiometers are also a vital part of an electric circuit. Typically potentiometers are configured to provide operator or operational information to an electronic controller. Unlike switches, which are used to provide digital input (on or off type of signal), potentiometers provide an analog input (variable type of signal). Some potentiometers are operator controlled, like the radio volume control knob or the temperature and fan speed control knobs on the HVAC control module, but the majority use of potentiometers is to provide operational information, such as fluid levels or product flow (volume) or device location (position) information.
20095585
1
The Fuel level sensing device contains a potentiometer (1) that is attached to the fuel return (2) and the supply (not used) (3) tubes and controlled by the movement of a float (4) attached to the potentiometer actuator arm (5). Figure 2 is an example of the sender system with a three-wire potentiometer. Only two wires are used in the Skid Steer Loaders (SSL) and Compact Track Loaders (CTL), thus the potentiometer acts a variable resistor or rheostat in the fuel level sensing.
93095586
2
Rotary to linear actuators contain a potentiometer used to provide position information.
1Z0O2004112130
3
Like operator and mechanically controlled switches, checking the operation of potentiometers can be accomplished by disconnecting the potentiometer from the electrical circuit and using a multi-meter to measure resistances. Potentiometers are three-wire devices. Typically a source voltage is connected to one of the pins attached to the stationary (fixed contact) resistive component of the potentiometer and reference ground to the other while the signal is taken 48068130 29/01/2018
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Electrical systems - Fuel tank system
from the pin attached to the wiper (movable contact). First measure the resistance across the full range of the potentiometer, the pins attached to the stationary (fixed contact) resistive component of the potentiometer and then from either end to the pin attached to the wiper (movable contact). In the latter test the resistance value should change, continuously and smoothly, as the wiper is manually moved. As the resistance varies with temperature, the test specifications are usually given at 20 °C (68 °F). NOTE: Like switches a growing number of potentiometers, as well as other variable resistive devices, are incorporating electronics. These devices are referred to as Sensors rather than Potentiometers or Varistors and often cannot be continuity tested with a multi-meter.
Potentiometer Adjustment When installing potentiometers, it is important to ensure that they do not bottom out in either direction, to prevent damage. Most potentiometers have slotted mounting holes to allow some adjustment. Before tightening the mounting hardware, operate the attaching linkage fully in both directions to confirm proper potentiometer positioning.
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Electrical systems - Fuel tank system
Fuel level sensor - Remove 1. Locate and open rear engine hood (1).
93111006AB
1
931002032
2
931002098
3
2. Remove hardware (1) from air filter housing (2).
3. Disconnect connector X-14 (Female) (1) from the fuel level sender B-001 (2).
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Electrical systems - Fuel tank system
4. Label and disconnect the fuel lines (1).
931002098
4
931002098
5
931002098
6
5. Remove hardware (1) and fuel level sender retainer (2).
6. Remove fuel level sender B-001 (1) from fuel tank.
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Electrical systems - Fuel tank system
Fuel level sensor - Install 1. Insert fuel level sender B-001 (1) into the fuel tank.
93111533
1
93111534
2
931002098
3
931002098
4
2. Place the fuel level sender retainer (1), and hardware (2) onto fuel tank. Tighten hardware.
3. Reconnect the fuel lines (1).
4. Reconnect connector X-14 (Female) (1) to the fuel level sender B-001 (2).
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Electrical systems - Fuel tank system
5. Install air filter housing (1) and bolts (2). Tighten the bolts.
931002032
5
93111006AB
6
6. Close rear engine hood (1).
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Index Electrical systems - 55 Fuel tank system - 011 Fuel level sensor - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3
Fuel level sensor - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8
Fuel level sensor - Overview Potentiometers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4
Fuel level sensor - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6
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Electrical systems - 55 Engine cooling system - 012
SR210 TIER 4B (FINAL) [NGM418237 - ], SR210 TIER 4B (FINAL) [NHM435463 - ], SR240 TIER 4B (FINAL) [NGM418237 - ], SR240 TIER 4B (FINAL) [NHM435463 - ], SV280 TIER 4B (FINAL) [NGM418237 - ], SV280 TIER 4B (FINAL) [NHM435463 - ], TR270 TIER 4B (FINAL) [NGM418237 - ], TR270 TIER 4B (FINAL) [NHM435463 - ], TR310 TIER 4B (FINAL) [NGM418237 - ], TR310 TIER 4B (FINAL) [NHM435463 - ], TV370 TIER 4B (FINAL) [NHM435463 - ]
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Contents Electrical systems - 55 Engine cooling system - 012
TECHNICAL DATA Engine coolant temperature sensor and switch General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
FUNCTIONAL DATA Engine coolant temperature sensor and switch Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
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Electrical systems - Engine cooling system
Engine coolant temperature sensor and switch - General specification Conversion chart Sensor resistance >128318 Ω 128318 Ω 88806.4 Ω 63399.2 Ω 44472.7 Ω 32123.4 Ω 23479.7 Ω 17393.7 Ω 13020.7 Ω 9851.1 Ω 7528.2 Ω 5807.9 Ω 4521.3 Ω 3550 Ω 2810 Ω 2241.5 Ω
Coolant temperature <-40 °C (<-40 °F) -40 °C (-40 °F) -35 °C (-31 °F) -30 °C (-22 °F) -25 °C (-13 °F) -20 °C (-4 °F) -15 °C (5 °F) -10 °C (14 °F) -5 °C (23 °F) -0 °C (32 °F) 5 °C (41 °F) 10 °C (50 °F) 15 °C (59 °F) 20 °C (68 °F) 25 °C (77 °F) 30 °C (86 °F)
Sensor resistance 1801.2 Ω 1457.5 Ω 1187.3 Ω 973.3 Ω 802.8 Ω 665.9 Ω 465.8 Ω 392.6 Ω 332.5 Ω 79.2 Ω 70 Ω 62 Ω 55.1 Ω 49.1 Ω > 49.1 Ω
Conversion chart Coolant temperature <21 °C (<70 °F) 21 °C (70 °F) 37 °C (99 °F) 60 °C (140 °F) 82 °C (180 °F) 98 °C (208 °F) 101 °C (214 °F) 104 °C (219 °F) 108 °C (226 °F) >108 °C (>226 °F)
Instrument panel display 1 bar 1 bar 2 bars 3 bars 4 bars 5 bars 6 bars 7 bars 8 bars 8 bars
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Coolant temperature 35 °C (95 °F) 40 °C (104 °F) 45 °C (113 °F) 50 °C (122 °F) 55 °C (131 °F) 60 °C (140 °F) 70 °C (158 °F) 75 °C (167 °F) 80 °C (176 °F) 130 °C (266 °F) 135 °C (275 °F) 140 °C (284 °F) 145 °C (293 °F) 150 °C (302 °F) >150 °C (>302 °F)
Electrical systems - Engine cooling system
Engine coolant temperature sensor and switch - Overview
1Z0O2004112136
1
Temperature sensors generally incorporate a thermistor. A thermistor is a resistor that changes its resistance according to temperature. There are two groups of thermistors: Negative temperature coefficient (NTC) and positive temperature coefficient (PTC). With NTCs, the higher the temperature, then the lower is the resistance. With PTC, the higher the temperature, then the higher the resistance. The NTC type is often used by sensors that indicate temperature change in fluids, like those contained in a hydraulic reservoir or in the engine coolant system. Often the signal provided to the controller is used by the controller to provide information to a display device which could display actual values or operate a warning indicator.
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Index Electrical systems - 55 Engine cooling system - 012 Engine coolant temperature sensor and switch - General specification . . . . . . . . . . . . . . . . . . . . . . . .
3
Engine coolant temperature sensor and switch - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4
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Electrical systems - 55 Hydrostatic drive control system - 019
SR210 TIER 4B (FINAL) [NGM418237 - ], SR210 TIER 4B (FINAL) [NHM435463 - ], SR240 TIER 4B (FINAL) [NGM418237 - ], SR240 TIER 4B (FINAL) [NHM435463 - ], SV280 TIER 4B (FINAL) [NGM418237 - ], SV280 TIER 4B (FINAL) [NHM435463 - ], TR270 TIER 4B (FINAL) [NGM418237 - ], TR270 TIER 4B (FINAL) [NHM435463 - ], TR310 TIER 4B (FINAL) [NGM418237 - ], TR310 TIER 4B (FINAL) [NHM435463 - ], TV370 TIER 4B (FINAL) [NHM435463 - ]
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Contents Electrical systems - 55 Hydrostatic drive control system - 019
FUNCTIONAL DATA Hydrostatic drive control system Overview - Electro-Hydraulic (EH) - Hydrostatic drivetrain control (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Hydrostatic control solenoids Overview (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Hydrostatic drive control sensors Overview (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
SERVICE Hydrostatic control solenoids Remove - Right-hand side (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Install - Right-hand side (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Remove - Left-hand side (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Install - Left-hand side (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Hydrostatic drive control sensors Remove - Right-hand swash plate sensor (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Install - Right-hand swash plate sensor (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Remove - Left-hand swash plate sensor (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Install - Left-hand swash plate sensor (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Test - Swash plate angle sensor test and centering procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
(*) See content for specific models 48068130 29/01/2018
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Electrical systems - Hydrostatic drive control system
Hydrostatic drive control system - Overview - Electro-Hydraulic (EH) - Hydrostatic drivetrain control SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Electro hydraulic controls) (Electro hydraulic controls) (Electro hydraulic controls) (Electro hydraulic controls) (Electro hydraulic controls) (Electro hydraulic controls)
The drive system on the Alpha series uses two axial piston hydrostatic pumps, which are connected in-line with each other. Each hydrostatic pump drives a corresponding hydrostatic drive motor. The motor drives a dual sprocket which then drives the axles through a chain drive system. The EH pump uses electronic solenoids to control the hydraulic servo. This allows operators to switch from ISO to H-pattern without having to change major system components. The Enhanced High-Flow (EHF) option is available on select models. The EHF option adds a third separate pump for an additional set of auxiliary couplers. The EHF only operates the extra set of couplers mounted on the right-hand loader arm/boom. The EH units allow the joysticks to be switch-able between the two patterns (ISO or H-pattern) for both loader and ground drive functions. In the ISO pattern, the left-hand joystick controls the drive functions, and the right-hand joystick controls the loader arm/boom and bucket operations. In the H-pattern, the left-hand joystick controls the left-hand drive functions and the loader arm/boom, and the right-hand joystick controls the right-hand drive and the bucket functions. The parking brake assembly may have up to three different control solenoid valves in it. It also houses the charge pressure switch, two speed sequence valve, screen and orifice assembly when equipped. A pressure of 15 bar is needed to fully release the parking brake. The parking brake can be applied while allowing the loader to still be active. The 2â&#x20AC;&#x201C;Speed sequence valve is a factory set valve assembly. The charge pressure switch sends a signal to the Instrument Cluster when the pressure is too low, indicating there is a problem with the charge pressure circuit. Low charge pressure is indicated by dragging brakes, and slower than normal pilot operation (drive response or loader response).
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Electrical systems - Hydrostatic drive control system
Hydrostatic control solenoids - Overview SR210 SR240 SV280 TR270 TR310 TV370 TIER 4B (FINAL) [NHM435463 - ]
(Electro hydraulic controls) (Electro hydraulic controls) (Electro hydraulic controls) (Electro hydraulic controls)
1Z0O2004112134
1
Whenever it is necessary to provide proportional control to the solenoid valves, it is much better to use a principle of operation called pulse width modulation (PWM). PWM is a variable DC voltage signal that is used to control the solenoid valves. The voltage signal is pulsed on and off many times a second (at a constant frequency of 500 Hz) at a constant supply voltage of 12 volts. The CM modules contain transistors that are supplied with a constant input voltage which is switched on and off to achieve the variable input range. In this way the control module is able to limit the armature movement, so the hydraulic output flow of the solenoid is proportional to the average DC voltage. The lower voltage also allows the solenoid to operate with less residual magnetism and so the entire circuit will operate smoother. The variable DC voltage signal level is determined by varying the duration of the ON pulse relative to the OFF pulse. The ratio between the ON time and the cycle time is called duty cycle and is stated as a percentage of one complete cycle.
1Z0O2004112135
2
Diagrams (1) to (3) show the normal operating range of the PWM valve, and diagram (4), shows the initial 12 volts programming and fill time only. The diagrams in column A show the voltage signal that is sent to the valve, whereas column B shows the relevant spring pressure and column B the reading on a voltmeter connected to the solenoid valve. Diagram (1) shows the OFF position: no signal is directed to the valve, which means no spring pressure in the valve at all and results in a zero voltage reading. Increasing the duty cycle causes some pressure to be made on the circuit (Diagram (2)), which results in a voltmeter reading increase. Diagram (3), shows the maximum signal that is used during the normal activity of the valve: its duty cycle is around 0.5, which results in a spring pressure for the half of its run and in an indication of a 6 volts average DC current. The electrical circuit to the solenoids can be checked by using a digital or analogue DC voltmeter, which will indicate the average voltage readings.
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Electrical systems - Hydrostatic drive control system
Hydrostatic drive control sensors - Overview SR210 SR240 SV280 TR270 TR310 TV370 TIER 4B (FINAL) [NHM435463 - ]
(Electro (Electro (Electro (Electro (Electro
hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls)
Potentiometers are also a vital part of an electric circuit. Typically potentiometers are configured to provide operator or operational information to an electronic controller. Unlike switches, which are used to provide digital input (on or off type of signal), potentiometers provide an analog input (variable type of signal). Some potentiometers are operator controlled, like the radio volume control knob or the temperature and fan speed control knobs on the HVAC control module, but the majority use of potentiometers is to provide operational information, such as fluid levels or product flow (volume) or device location (position) information.
Rotary to linear actuators contain a potentiometer used to provide position information.
1Z0O2004112130
1
Like operator and mechanically controlled switches, checking the operation of potentiometers can be accomplished by disconnecting the potentiometer from the electrical circuit and using a multi-meter to measure resistances. Potentiometers are three-wire devices. Typically a source voltage is connected to one of the pins attached to the stationary (fixed contact) resistive component of the potentiometer and reference ground to the other while the signal is taken from the pin attached to the wiper (movable contact). First measure the resistance across the full range of the potentiometer, the pins attached to the stationary (fixed contact) resistive component of the potentiometer and then from either end to the pin attached to the wiper (movable contact). In the latter test the resistance value should change, continuously and smoothly, as the wiper is manually moved. As the resistance varies with temperature, the test specifications are usually given at 20 °C (68 °F). NOTE: Like switches a growing number of potentiometers, as well as other variable resistive devices, are incorporating electronics. These devices are referred to as Sensors rather than Potentiometers or Varistors and often cannot be continuity tested with a multi-meter.
Potentiometer Adjustment When installing potentiometers, it is important to ensure that they do not bottom out in either direction, to prevent damage. Most potentiometers have slotted mounting holes to allow some adjustment. Before tightening the mounting hardware, operate the attaching linkage fully in both directions to confirm proper potentiometer positioning.
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Electrical systems - Hydrostatic drive control system
Hydrostatic control solenoids - Remove - Right-hand side SR210 SR240 SV280 TR270 TR310 TV370 TIER 4B (FINAL) [NHM435463 - ]
(Electro (Electro (Electro (Electro (Electro
hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls)
NOTE: This procedure covers how to remove the right-hand forward and right-hand reverse drive solenoids located on the electro-hydraulic hydrostatic pump. 1. Locate the electro-hydraulic hydrostatic pump (1).
931001814
1
931001814
2
931001814
3
2. Locate the drive solenoid that needs to be removed. The right-hand reverse (1) and right-hand forward (2) solenoids are located on the input shaft side of the hydrostatic pump.
3. Disconnect the connector (2) from the solenoid. Unscrew the cap (1).
4. Slide the solenoid off.
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Electrical systems - Hydrostatic drive control system
Hydrostatic control solenoids - Install - Right-hand side SR210 SR240 SV280 TR270 TR310 TV370 TIER 4B (FINAL) [NHM435463 - ]
(Electro (Electro (Electro (Electro (Electro
hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls)
NOTE: This procedure covers how to install the right-hand forward and right-hand reverse drive solenoids located on the electro-hydraulic hydrostatic pump. 1. Place the solenoid on to the valve body. See picture for location of solenoids. The right-hand reverse (1) and right-hand forward (2) solenoids are located on the input shaft side of hydrostatic pump.
931001814
1
931001814
2
2. Screw the cap (1) onto valve body. Connect the connector (2) to the solenoid.
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Electrical systems - Hydrostatic drive control system
Hydrostatic control solenoids - Remove - Left-hand side SR210 SR240 SV280 TR270 TR310 TV370 TIER 4B (FINAL) [NHM435463 - ]
(Electro (Electro (Electro (Electro (Electro
hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls)
NOTE: This procedure covers how to remove the left-hand forward and left-hand reverse drive solenoids located on the electro-hydraulic hydrostatic pump. 1. Locate the electro-hydraulic hydrostatic pump (1).
931001814
1
931001814
2
931001814
3
2. Locate the drive solenoid that needs to be removed. The left-hand forward (1) and left-hand reverse (2) solenoids are located near the auxiliary pump.
3. Disconnect the connector (1) from the solenoid. Unscrew the cap (2).
4. Slide the solenoid off.
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Electrical systems - Hydrostatic drive control system
Hydrostatic control solenoids - Install - Left-hand side SR210 SR240 SV280 TR270 TR310 TV370 TIER 4B (FINAL) [NHM435463 - ]
(Electro (Electro (Electro (Electro (Electro
hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls)
NOTE: This procedure covers how to install the left-hand forward and left-hand reverse drive solenoids located on the electro-hydraulic hydrostatic pump. 1. Place the solenoid on to the valve body. See picture for location of solenoids. The left-hand reverse (1) and left-hand forward (2) solenoids are located near the auxiliary pump.
931001814
1
931001814
2
2. Screw the cap (1) onto valve body. Connect the connector (2) to the solenoid.
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Electrical systems - Hydrostatic drive control system
Hydrostatic drive control sensors - Remove - Right-hand swash plate sensor SR210 SR240 SV280 TR270 TR310 TV370 TIER 4B (FINAL) [NHM435463 - ]
(Electro (Electro (Electro (Electro (Electro (Electro
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls)
1. Locate the right-hand swash plate sensor on the bottom of the electro-hydraulic hydrostatic pump (1).
931001814
1
931001961
2
931001961
3
2. Label and disconnect the connector from the swash plate sensor. The right-hand swash plate sensor (1) is located on the input shaft side of the hydrostatic pump.
3. Remove the two screws (1) holding the swash plate shield (2) and sensor.
4. Remove the swash plate sensor.
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Electrical systems - Hydrostatic drive control system
Hydrostatic drive control sensors - Install - Right-hand swash plate sensor SR210 SR240 SV280 TR270 TR310 TV370 TIER 4B (FINAL) [NHM435463 - ]
(Electro (Electro (Electro (Electro (Electro (Electro
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls)
1. Install the right-hand swash plate sensor (1).
931001961
1
931001961
2
2. Place the swash plate shield (2) over the right-hand swash plate sensor. Insert the two screws (1) and tighten to proper torque.
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Electrical systems - Hydrostatic drive control system
Hydrostatic drive control sensors - Remove - Left-hand swash plate sensor SR210 SR240 SV280 TR270 TR310 TV370 TIER 4B (FINAL) [NHM435463 - ]
(Electro (Electro (Electro (Electro (Electro (Electro
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls)
1. Locate the left-hand swash plate sensor on the bottom of the electro-hydraulic hydrostatic pump (1).
931001814
1
931001961
2
931001961
3
2. Label and disconnect the connector from the swash plate sensor. The left-hand swash plate sensor (1) is located near the auxiliary pump.
3. Remove the two screws (1) holding the swash plate shield (2) and sensor.
4. Remove the swash plate sensor.
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Electrical systems - Hydrostatic drive control system
Hydrostatic drive control sensors - Install - Left-hand swash plate sensor SR210 SR240 SV280 TR270 TR310 TV370 TIER 4B (FINAL) [NHM435463 - ]
(Electro (Electro (Electro (Electro (Electro (Electro
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls)
1. Install the left-hand swash plate sensor (1).
931001961
1
931001961
2
2. Place the swash plate shield (2) over the left-hand swash plate sensor. Insert the two screws (1) and tighten to proper torque.
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Electrical systems - Hydrostatic drive control system
Hydrostatic drive control sensors - Test - Swash plate angle sensor test and centering procedure Prior operation: Confirm that the joysticks are returning to the neutral position and there are no electrical issues with the joystick harness before checking the swash plate angle sensors. Prior operation: Place the machine on blocks or ensure that the machine is in an open area with adequate clearance to other objects. NOTE: This procedure is done using the Electronic Service Tool (EST) â&#x20AC;&#x2DC;monitorâ&#x20AC;&#x2122; function.
RAPH16SSL0227GA
1
EST View Parameters List 1. Connect the EST diagnostic connector to the test port of the machine to monitor the four Electro-Hydraulic (EH) parameters shown in the right-hand column of Figure 1.
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Electrical systems - Hydrostatic drive control system
RAPH16SSL0228HA
2
Log Parameter Settings 2. To save the data you select, click on the ‘Log Parameter Selection’, and select the ‘Sampling Rate Selection’ to the 10 ms setting prior to recording. See Figure 2 for detail. 48068130 29/01/2018
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Electrical systems - Hydrostatic drive control system
Swash plate angle sensor voltage chart Neutral from Neutral from Neutral Dead-band Forward Reverse
Forward
LH Sensor 1 Voltage LH Sensor 2 Voltage RH Sensor 1 Voltage RH Sensor 2 Voltage 3. View live or record the data from the four noted parameters and use the chart to record and analyze the results. NOTE: The neutral reading changes depending upon whether the pump is returning to neutral from forward or from reverse driving direction. The difference between these values is called â&#x20AC;&#x2DC;neutral deadbandâ&#x20AC;&#x2122;. Record the values in the chart above. 4. Slowly command the pumps from neutral to the forward direction. Forward specifications for the left-hand pump sensor: 1.
The left-hand swash plate angle Sensor 1 neutral voltage parameter specification is 2.4 V to 2.6 V and increasing voltage when commanded forward.
2.
The left-hand swash plate angle Sensor 2 neutral voltage parameter specification is 2.6 V to 2.4 V and decreasing voltage when commanded forward.
3.
Adding the forward voltages for the Sensor 1 and the Sensor 2 values from the left-hand sensors should equal between 4.9 V and 5.1 V.
Forward specifications for the right-hand pump sensor: 1.
The right-hand swash plate angle Sensor 1 neutral voltage parameter specification is 2.4 V to 2.6 V and increasing voltage when commanded forward.
2.
The right-hand swash plate angle Sensor 2 neutral voltage parameter specification is 2.6 V to 2.4 V and decreasing voltage when commanded forward.
3.
Adding the forward voltages for the Sensor 1 and the Sensor 2 values from the right-hand sensors should equal between 4.9 V and 5.1 V.
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Reverse
Sum of Sensor 1 & 2 - Forward
Sum of Sensor 1 & 2 - Reverse
Electrical systems - Hydrostatic drive control system
5. Slowly command the pumps from neutral to the reverse direction. Reverse specifications for the left-hand pump sensor: 1.
The left-hand swash plate angle Sensor 1 neutral voltage parameter specification is 2.4 V to 2.6 V and decreasing voltage when commanded reverse.
2.
The left-hand swash plate angle Sensor 2 neutral voltage parameter specification is 2.6 V to 2.4 V and increasing voltage when commanded reverse.
3.
Adding the reverse voltages for the Sensor 1 and the Sensor 2 values from the left-hand sensors should equal between 4.9 V and 5.1 V.
Reverse specifications for the right-hand pump sensor: 1.
The right-hand swash plate angle Sensor 1 neutral voltage parameter specification is 2.4 V to 2.6 V and decreasing voltage when commanded reverse.
2.
The right-hand swash plate angle Sensor 2 neutral voltage parameter specification is 2.6 V to 2.4 V and increasing voltage when commanded reverse.
3.
Adding the reverse voltages for the Sensor 1 and the Sensor 2 values from the right-hand sensors should equal between 4.9 V and 5.1 V.
6. If a sensor does not show the correct values in neutral, remove the angle sensor shield, loosen but do not remove the sensor mounting screws, and adjust the sensor to obtain approximately 2.5 V reading at the center of the neutral deadband. NOTE: Neutral readings must be between 2.4 â&#x20AC;&#x201C; 2.6 V at the edges of the deadband. 7. Turn the sensor so that the reading moves toward 2.5 V attempting to center the readings within 0.05 V. 8. Tighten the mounting screws to 4.0 N¡m (3.0 lb ft) and confirm the readings are still within the tolerance range. Repeat steps 4 and 5 to confirm the readings. 9. Once the readings are to specifications, install the angle sensor shield, and re-calibrate the Electro-Hydraulic (EH) ground drive system. See Servo control - Adjust (29.218) for procedure.
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Electrical systems - Hydrostatic drive control system
10. If a value for a noted parameter is not within the specification and adjustment of the sensor does not bring it within the specification, record the data with the EST for the following parameters in Figure 3 for ISO Pattern or Figure 4 for “H” Pattern control while repeating steps 4 and 5.
RAPH16SSL0229FA
3
Parameters to select for ISO Pattern
RAPH16SSL0230FA
4
Parameters to select for “H” Pattern 11. Install a new angle sensor and set the neutral sensor values as in step 6. Re-calibrate the ground drive system. See Servo control - Adjust (29.218) for procedure. Verify that the problem has been resolved.
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Electrical systems - Hydrostatic drive control system
12. Attach the recorded data to an ASIST incident and advise if the new sensor resolves the concern or if the values are all within specification and the concern still exists. Reference the ASIST incident number on the part return tag and in the warranty system.
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Index Electrical systems - 55 Hydrostatic drive control system - 019 Hydrostatic control solenoids - Install - Left-hand side (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9
Hydrostatic control solenoids - Install - Right-hand side (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7
Hydrostatic control solenoids - Overview (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4
Hydrostatic control solenoids - Remove - Left-hand side (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8
Hydrostatic control solenoids - Remove - Right-hand side (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6
Hydrostatic drive control sensors - Install - Left-hand swash plate sensor (*) . . . . . . . . . . . . . . . . . . .
13
Hydrostatic drive control sensors - Install - Right-hand swash plate sensor (*) . . . . . . . . . . . . . . . . . .
11
Hydrostatic drive control sensors - Overview (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5
Hydrostatic drive control sensors - Remove - Left-hand swash plate sensor (*) . . . . . . . . . . . . . . . . .
12
Hydrostatic drive control sensors - Remove - Right-hand swash plate sensor (*) . . . . . . . . . . . . . . . .
10
Hydrostatic drive control sensors - Test - Swash plate angle sensor test and centering procedure .
14
Hydrostatic drive control system - Overview - Electro-Hydraulic (EH) - Hydrostatic drivetrain control (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3
(*) See content for specific models 48068130 29/01/2018
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Electrical systems - 55 Hydraulic system control - 036
SR210 TIER 4B (FINAL) [NGM418237 - ], SR210 TIER 4B (FINAL) [NHM435463 - ], SR240 TIER 4B (FINAL) [NGM418237 - ], SR240 TIER 4B (FINAL) [NHM435463 - ], SV280 TIER 4B (FINAL) [NGM418237 - ], SV280 TIER 4B (FINAL) [NHM435463 - ], TR270 TIER 4B (FINAL) [NGM418237 - ], TR270 TIER 4B (FINAL) [NHM435463 - ], TR310 TIER 4B (FINAL) [NGM418237 - ], TR310 TIER 4B (FINAL) [NHM435463 - ], TV370 TIER 4B (FINAL) [NHM435463 - ]
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Contents Electrical systems - 55 Hydraulic system control - 036
TECHNICAL DATA Hydraulic fluid temperature control sensor General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
FUNCTIONAL DATA Hydraulic fluid temperature control sensor Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
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Electrical systems - Hydraulic system control
Hydraulic fluid temperature control sensor - General specification Conversion chart Sensor resistance >128318 Ω 128318 Ω 88806.4 Ω 63399.2 Ω 44472.7 Ω 32123.4 Ω 23479.7 Ω 17393.7 Ω 13020.7 Ω 9851.1 Ω 7528.2 Ω 5807.9 Ω 4521.3 Ω 3550 Ω 2810 Ω 2241.5 Ω
Oil temperature <-40 °C (<-40 °F) -40 °C (-40 °F) -35 °C (-31 °F) -30 °C (-22 °F) -25 °C (-13 °F) -20 °C (-4 °F) -15 °C (5 °F) -10 °C (14 °F) -5 °C (23 °F) -0 °C (32 °F) 5 °C (41 °F) 10 °C (50 °F) 15 °C (59 °F) 20 °C (68 °F) 25 °C (77 °F) 30 °C (86 °F)
Sensor resistance 1801.2 Ω 1457.5 Ω 1187.3 Ω 973.3 Ω 802.8 Ω 665.9 Ω 465.8 Ω 392.6 Ω 332.5 Ω 79.2 Ω 70 Ω 62 Ω 55.1 Ω 49.1 Ω > 49.1 Ω
Conversion chart Oil temperature <21 °C (<70 °F) 21 °C (70 °F) 37 °C (99 °F) 60 °C (140 °F) 82 °C (180 °F) 90 °C (194 °F) 98 °C (208 °F) 104 °C (219 °F) 110 °C (230 °F) >110 °C (>230 °F)
Instrument panel display 1 bar 1 bar 2 bars 3 bars 4 bars 5 bars 6 bars 7 bars 8 bars 8 bars
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Oil temperature 35 °C (95 °F) 40 °C (104 °F) 45 °C (113 °F) 50 °C (122 °F) 55 °C (131 °F) 60 °C (140 °F) 70 °C (158 °F) 75 °C (167 °F) 80 °C (176 °F) 130 °C (266 °F) 135 °C (275 °F) 140 °C (284 °F) 145 °C (293 °F) 150 °C (302 °F) >150 °C (>302 °F)
Electrical systems - Hydraulic system control
Hydraulic fluid temperature control sensor - Overview
1Z0O2004112136
1
Temperature sensors generally incorporate a thermistor. A thermistor is a resistor that changes its resistance according to temperature. There are two groups of thermistors: Negative temperature coefficient (NTC) and positive temperature coefficient (PTC). With NTCs, the higher the temperature, then the lower is the resistance. With PTC, the higher the temperature, then the higher the resistance. The NTC type is often used by sensors that indicate temperature change in fluids, like those contained in a hydraulic reservoir or in the engine coolant system. Often the signal provided to the controller is used by the controller to provide information to a display device which could display actual values or operate a warning indicator.
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Index Electrical systems - 55 Hydraulic system control - 036 Hydraulic fluid temperature control sensor - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3
Hydraulic fluid temperature control sensor - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4
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Electrical systems - 55 Heating, Ventilation, and Air-Conditioning (HVAC) control system 050
SR210 TIER 4B (FINAL) [NGM418237 - ], SR210 TIER 4B (FINAL) [NHM435463 - ], SR240 TIER 4B (FINAL) [NGM418237 - ], SR240 TIER 4B (FINAL) [NHM435463 - ], SV280 TIER 4B (FINAL) [NGM418237 - ], SV280 TIER 4B (FINAL) [NHM435463 - ], TR270 TIER 4B (FINAL) [NGM418237 - ], TR270 TIER 4B (FINAL) [NHM435463 - ], TR310 TIER 4B (FINAL) [NGM418237 - ], TR310 TIER 4B (FINAL) [NHM435463 - ], TV370 TIER 4B (FINAL) [NHM435463 - ]
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Contents Electrical systems - 55 Heating, Ventilation, and Air-Conditioning (HVAC) control system - 050
DIAGNOSTIC Heating, Ventilation, and Air-Conditioning (HVAC) control system Testing Blower Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Testing A/C Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Testing HVAC Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Testing HVAC Heat Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Testing HVAC High Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
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Electrical systems - Heating, Ventilation, and Air-Conditioning (HVAC) control system
Heating, Ventilation, and Air-Conditioning (HVAC) control system - Testing Blower Switch NOTE: Use schematic Wiring harnesses - Electrical schematic sheet 27 HVAC (55.100) for Electro-Hydraulic (EH) driven machines. Use schematic Wiring harnesses - Electrical schematic sheet 22 HVAC (55.100) for mechanical driven machines. NOTE: Ensure Heating, Ventilation, and Air-Conditioning (HVAC) control system - Testing HVAC Box (55.050) test is satisfactory prior to performing this test Test N°1 Test Point Condition Disconnect connector X-270 from the BLOWER SWITCH S-020. Check for resistance between BLOWER SWITCH pins 1 and 2 while cycling the Blower Switch. Expected Result Result 0 Ω when selecting a fan speed, no continuity when fan is selected off. Action Go to test 2 Other Result Result Any other readings (Possible Action Cause) The BLOWER SWITCH has failed. Replace the switch. Test N°2 Test Point Check for resistance between BLOWER SWITCH pins 2 and 3 (Low) pins 2 and 4 (Medium) pins 2 and 5 (High) while cycling the BLOWER SWITCH. Expected Result Result For each resistance check, 0 Ω in one position, infinite resistance in all others. Action Go to test 3 Other Result Result 0 Ω in more than one position or infinite resistance in all positions. (Possible Action Cause) The BLOWER SWITCH has failed. Replace the switch. Test N°3 Test Point Condition Use Electrical system - Testing - Wires (55.000) to Check wire condition between X-HVC1 pin 10 and connector X-270 pin 2. Expected Result Result No wire problems. Action See the following for further testing • Air conditioning - Problem solving (50.200) Other Result (Possible Cause)
• Heating, Ventilation, and Air-Conditioning (HVAC) control system - Testing HVAC Box (55.050) Result Wire problems are found. Action Locate and repair or replace broken wire 821/846/842 (Orange) or adjacent wiring.
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Electrical systems - Heating, Ventilation, and Air-Conditioning (HVAC) control system
Heating, Ventilation, and Air-Conditioning (HVAC) control system Testing A/C Switch NOTE: Use schematic Wiring harnesses - Electrical schematic sheet 27 HVAC (55.100) for Electro-Hydraulic (EH) driven machines. Use schematic Wiring harnesses - Electrical schematic sheet 22 HVAC (55.100) for mechanical driven machines. NOTE: Ensure Heating, Ventilation, and Air-Conditioning (HVAC) control system - Testing Blower Switch (55.050) test is satisfactory prior to performing this test Test N째1 Test Point Condition Use Air conditioning - Overview (50.200) to set up conditions for the AC system to turn on. Check that AC switch indicator light is on. Expected Result Result Light on Action Go to test 3 Other Result Result Light not on (Possible Action Cause) Go to test 2 Test N째2 Test Point Condition Disconnect connector X-275 from the AC SWITCH S-017. Use Air conditioning - Overview (50.200) to set up conditions for the AC system to turn on. Check for voltage between X-275 pins 1 and ground. Expected Result Result 12 V Action Go to test 3 Other Result Result 0 V (Possible Action Cause) There is an open on wire 825 (Orange). Repair the wire. Test N째3 Test Point Condition Disconnect connector X-275 from the AC SWITCH S-017. Connect a jumper between connector X-275 pins 1 and 2. Check for circuit operation. Expected Result Result No circuit problems. Action The AC SWITCH S-017 has failed. Replace the switch. Other Result Result No change in circuit response. (Possible Action Cause) Go to test 4 Test N째4 Test Point Condition Use Electrical system - Testing - Wires (55.000) to Check wire condition between X-275 pin 2 and connector X-HVC1 pin 6.
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Electrical systems - Heating, Ventilation, and Air-Conditioning (HVAC) control system
Expected Result Result No wire problems. Action See the following for further testing â&#x20AC;˘ Air conditioning - Problem solving (50.200) Other Result (Possible Cause)
â&#x20AC;˘ Heating, Ventilation, and Air-Conditioning (HVAC) control system - Testing HVAC Box (55.050) Result Wire problems are found. Action Locate and repair or replace broken wire 829/837 (White) or adjacent wiring.
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Electrical systems - Heating, Ventilation, and Air-Conditioning (HVAC) control system
Heating, Ventilation, and Air-Conditioning (HVAC) control system Testing HVAC Box NOTE: Ensure HVAC FUSE F-001 COMPRESSOR FUSE F-002 and ACCESSORY RELAY K-018 are working correctly prior to performing this test. NOTE: Use schematic Wiring harnesses - Electrical schematic sheet 27 HVAC (55.100) for Electro-Hydraulic (EH) driven machines. Use schematic Wiring harnesses - Electrical schematic sheet 22 HVAC (55.100) for mechanical driven machines. NOTE: See Heating, Ventilation, and Air-Conditioning (HVAC) control system - Overview (55.050) for additional information Test N°1 Test Point Condition Disconnect connector X-HVC2 from X-HVC1. With the ignition on, Check for voltage from connector X-HVC1 pin 2 and ground, 11 and ground, and 14 and ground. Expected Result Result 12 V for each check Action Go to test 2 Other Result Result 0 V (Possible Action Cause) There is a problem in the DC distribution system upstream of X-HVC1 pin 2, 11, or 14. Test N°2 Test Point Check for resistance between HVAC BOX A-003 pins 1 and 8 and from pins 1 and 11. Expected Result Result 0 Ω Action Go to test 3 Other Result Result Greater than 15 Ω (Possible Action Cause) Either the Compressor Relay or Fan Relay, both internal to the HVAC Box, has failed. Replace the serviceable component. Test N°3 Test Point Check for resistance between HVAC BOX A-003 pins 2 and 12 and from pins 10 and 14. Expected Result Result Open Action Go to test 4 Other Result Result 0 Ω (Possible Action Cause) Either the Compressor Relay or Fan Relay, both internal to the HVAC Box, has failed. Replace the serviceable component. Test N°4 Test Point Check for resistance between HVAC BOX A-003 pins 3 and 4 pins 4 and 5 pins 3 and 5.
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Electrical systems - Heating, Ventilation, and Air-Conditioning (HVAC) control system
Expected Result Result The sum of the resistances from pins 3 and 4 and from pins 4 and 5 should equal the resistance from pins 3 and 5. Action Go to test 5 Other Result Result For any other readings, (Possible Action Cause) The Resistor, internal to the HVAC Box, has failed. Replace the serviceable component. Test N°5 Test Point Check for resistance between HVAC BOX A-003 pins 1 and 5 Expected Result Result 10 Ω Action Go to test 6 Other Result Result Either 0 Ω or greater than 1000 Ω (Possible Action Cause) The Electric Fan Motor, internal to the HVAC Box, has failed. Replace the serviceable component. Test N°6 Test Point Condition Use Electrical system - Testing - Wires (55.000) to Check wire condition between connector X-HVC1 pin 9 and ground. Expected Result Result No wire problems. Action Go to test 7 Other Result Result Wire problems are found. (Possible Action Cause) Locate and repair or replace broken wire 1012 (Black/White) or adjacent wiring. Test N°7 Test Point Condition Use Electrical system - Testing - Wires (55.000) to Check wire condition between connector X-HVC1 pin 1 and ground. Expected Result Result No wire problems. Action See the following for further testing Other Result (Possible Cause)
• Air conditioning - Problem solving (50.200) Result Wire problems are found. Action Locate and repair or replace broken wire 935/1087 or 935/1088 (Black) or adjacent wiring.
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Electrical systems - Heating, Ventilation, and Air-Conditioning (HVAC) control system
Heating, Ventilation, and Air-Conditioning (HVAC) control system Testing HVAC Heat Components NOTE: Use schematic Wiring harnesses - Electrical schematic sheet 27 HVAC (55.100) for Electro-Hydraulic (EH) driven machines. Use schematic Wiring harnesses - Electrical schematic sheet 22 HVAC (55.100) for mechanical driven machines. Test N°1 Test Point Condition Disconnect connector X-252 from the TEMPCONTROL Z-017 potentiometer. With ignition on, Check for voltage from connector X-252 pin 3 and ground. Expected Result Result 12 V Action Go to test 2 Other Result Result 0 V (Possible Action Cause) Go to test 3 Test N°2 Test Point Condition Disconnect connector X-271 from the WATER VALVE Z-019. With ignition on, Check for voltage from connector X-271 pin A and ground. Expected Result Result 12 V Action Go to test 4 Other Result Result 0 V (Possible Action Cause) Go to test 3 Test N°3 Test Point Condition Use Electrical system - Testing - Wires (55.000) to Check wire condition between X-HVC1 pin 10 and connector X-271 pin A and between X-HVC1 pin 10 and connector X-252 pin 3. Expected Result Result No wire problems. Action See the following for further testing • Air conditioning - Problem solving (50.200) Other Result (Possible Cause)
• Heating, Ventilation, and Air-Conditioning (HVAC) control system - Testing HVAC Box (55.050) Result Wire problems are found. Action Locate and repair or replace broken wire 823 (Pink) or 822/846/842 (Orange) or adjacent wiring.
Test N°4 Test Point Check for resistance between TEMPCONTROL Z-017 potentiometer pins 2 and 3 while moving potentiometer.
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Electrical systems - Heating, Ventilation, and Air-Conditioning (HVAC) control system
Expected Result Result Varying resistance with potentiometer movement. Action Go to test 5 Other Result Result 0 Ω, or infinite resistance, or constant value (Possible Action Cause) The TEMPCONTROL potentiometer has failed. Replace the potentiometer. Test N°5 Test Point Check for resistance between WATER VALVE Z-019 pins A and C. Expected Result Result 20 Ω Action Go to test 6 Other Result Result 0 Ω, or greater than 1 K Ω (Possible Action Cause) The WATER VALVE has failed. Replace the valve. Test N°6 Test Point Condition Use Electrical system - Testing - Wires (55.000) to Check signal wire condition between X-252 pin 2 and connector X-271 pin D. Expected Result Result No wire problems. Action Go to test 7 Other Result Result Wire problems are found. (Possible Action Cause) Locate and repair or replace broken wire 824 (Yellow). Test N°7 Test Point Condition Use Electrical system - Testing - Wires (55.000) to Check ground wire condition between X-252 pin 1 and ground and between connector X-271 pin C and ground. Expected Result Result No wire problems. Action The WATER VALVE has failed. Replace the valve. Other Result Result Wire problems are found. (Possible Action Cause) Locate and repair or replace broken wire 912 (Black) or 1013 (Black).
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Electrical systems - Heating, Ventilation, and Air-Conditioning (HVAC) control system
Heating, Ventilation, and Air-Conditioning (HVAC) control system Testing HVAC High Pressure Switch NOTE: Ensure the HVAC system has no mechanical problems before following this procedure. See Air conditioning - Overview (50.200) for more information on the HVAC System. NOTE: Use schematic Wiring harnesses - Electrical schematic sheet 27 HVAC (55.100) for Electro-Hydraulic (EH) driven machines. Use schematic Wiring harnesses - Electrical schematic sheet 22 HVAC (55.100) for mechanical driven machines. Test N°1 Test Point Condition Disconnect connector X-76 from the HVAC HIGH PRESSURE SWITCH. Connect a jumper between connector X-76 pins A and B. Check Use Air conditioning - Overview (50.200) to set up conditions for the A/C system to turn on. Check circuit operation. Expected Result Result No circuit problems. Action The HVAC HIGH PRESSURE SWITCH has failed. Replace the switch. Other Result Result No change in circuit response, remove jumper. (Possible Action Cause) Go to test 2 Test N°2 Test Point Condition Use Electrical system - Testing - Wires (55.000) to Check wire condition between connector X-76 pin B and connector X-HVC1 pin 8. Expected Result Result No wire problems. Action Go to test 3 Other Result Result Wire problems are found. (Possible Action Cause) Repair or replace broken wire 834 (White). Test N°3 Test Point Condition Use Electrical system - Testing - Wires (55.000) to Check wire condition between connector X-76 pin A and connector X-HVC1 pin 7. Expected Result Result No wire problems. Action See the following for further testing • Air conditioning - Problem solving (50.200) Other Result (Possible Cause)
• Heating, Ventilation, and Air-Conditioning (HVAC) control system - Testing HVAC Box (55.050) Result Wire problems are found. Action Repair or replace broken wire 833 (White).
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Index Electrical systems - 55 Heating, Ventilation, and Air-Conditioning (HVAC) control system - 050 Heating, Ventilation, and Air-Conditioning (HVAC) control system - Testing A/C Switch . . . . . . . . . .
4
Heating, Ventilation, and Air-Conditioning (HVAC) control system - Testing Blower Switch . . . . . . .
3
Heating, Ventilation, and Air-Conditioning (HVAC) control system - Testing HVAC Box . . . . . . . . . .
6
Heating, Ventilation, and Air-Conditioning (HVAC) control system - Testing HVAC Heat Components ......................................................................................
8
Heating, Ventilation, and Air-Conditioning (HVAC) control system - Testing HVAC High Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10
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Electrical systems - 55 Cab Heating, Ventilation, and Air-Conditioning (HVAC) controls 051
SR210 TIER 4B (FINAL) [NGM418237 - ], SR210 TIER 4B (FINAL) [NHM435463 - ], SR240 TIER 4B (FINAL) [NGM418237 - ], SR240 TIER 4B (FINAL) [NHM435463 - ], SV280 TIER 4B (FINAL) [NGM418237 - ], SV280 TIER 4B (FINAL) [NHM435463 - ], TR270 TIER 4B (FINAL) [NGM418237 - ], TR270 TIER 4B (FINAL) [NHM435463 - ], TR310 TIER 4B (FINAL) [NGM418237 - ], TR310 TIER 4B (FINAL) [NHM435463 - ], TV370 TIER 4B (FINAL) [NHM435463 - ]
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Contents Electrical systems - 55 Cab Heating, Ventilation, and Air-Conditioning (HVAC) controls - 051
FUNCTIONAL DATA Cab Heating, Ventilation, and Air-Conditioning (HVAC) controls Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Heating, Ventilation, and Air-Conditioning (HVAC) control system - Electrical schema . . . . . . . . . . . . . . . 4
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Electrical systems - Cab Heating, Ventilation, and Air-Conditioning (HVAC) controls
Cab Heating, Ventilation, and Air-Conditioning (HVAC) controls - Overview The HVAC system has several power inputs. One source power comes from the accessory relay to the HVAC box. This energizes the auxiliary relay for the coil for the fan motor (internal to HVAC Box). The accessory relay is powered from the instrument cluster when the ignition is on, which shuts the auxiliary relay for fan motor. The auxiliary relay for the power for the fan motor comes directly from the battery via the HVAC fuse. The auxiliary relay for fan motor is shut anytime the ignition is on, which provides power to the water valve, temperature control potentiometer, and blower switch. Power is provided to the A/C switch from the blower switch, anytime a fan speed is selected. The blower switch, A/C switch, and temperature control potentiometer are all located on the left console. Since the water valve and temperature control potentiometer are energized, cab heat is available anytime the ignition is on. When the A/C switch is turned “on” and an electric fan speed is selected, power is provided to the HVAC through the pressure switch (internal to HVAC box), through the thermostat (internal to HVAC box), out the HVAC box to the HVAC high pressure switch, and back into HVAC box to the compressor relay coil (internal to HVAC box), shutting the compressor relay next to HVAC box). When the compressor relay is shut, this allows battery power from the compressor fuse through the HVAC box to the compressor relay, and out of the HVAC box to the A/C compressor. When the A/C switch is turned “on” and an electric fan speed is selected, power is also applied to the condenser relay coil, shutting the condenser relay, and providing battery power via a fuse to the condenser fan. The blower switch, since energized, can provide four speed levels (off, low, medium, high) to the electric fan motor (internal to HVAC box). This is done through a resistor (internal to HVAC box).
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Electrical systems - Cab Heating, Ventilation, and Air-Conditioning (HVAC) controls
Heating, Ventilation, and Air-Conditioning (HVAC) control system Electrical schema
HVACBOXSCHEMSL5
1
HVAC box schematic Components in the HVAC box Designation (1) (2) (3) (4) (5) (6) (7)
Component Compressor relay Auxiliary relay for fan motor Resistor Fan motor Thermostat Pressure switch HVAC connector
HVAC pin information (numbered from top to bottom on the schematic) Pin number 3 4 5 2 10
14 9 12
Wire description Power to the low speed portion of the resistor from the blower switch Power to the medium speed portion of the resistor from the blower switch High speed power to the fan motor from the blower switch Power to the compressor relay from the fuse Power to the blower switch, temperature control, potentiometer, and water valve from the auxiliary relay for the fan motor Power to the auxiliary relay for the fan motor from the HVAC fuse Ground path from the thermostat Power to the A/C compressor from compressor relay
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Electrical systems - Cab Heating, Ventilation, and Air-Conditioning (HVAC) controls
11 6 1
13 8 7
Power to the auxiliary relay for the fan coil from the accessory relay Power to the pressure switch and thermostat from the A/C switch Ground for the compressor relay Ground for the auxiliary relay for fan coil Ground for the fan motor Not used Power to the compressor relay coil from the high pressure switch Power to the high pressure switch from the thermostat
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Index Electrical systems - 55 Cab Heating, Ventilation, and Air-Conditioning (HVAC) controls - 051 Cab Heating, Ventilation, and Air-Conditioning (HVAC) controls - Overview . . . . . . . . . . . . . . . . . . . .
3
Heating, Ventilation, and Air-Conditioning (HVAC) control system - Electrical schema . . . . . . . . . . .
4
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Electrical systems - 55 Harnesses and connectors - 100
SR210 TIER 4B (FINAL) [NGM418237 - ], SR210 TIER 4B (FINAL) [NHM435463 - ], SR240 TIER 4B (FINAL) [NGM418237 - ], SR240 TIER 4B (FINAL) [NHM435463 - ], SV280 TIER 4B (FINAL) [NGM418237 - ], SV280 TIER 4B (FINAL) [NHM435463 - ], TR270 TIER 4B (FINAL) [NGM418237 - ], TR270 TIER 4B (FINAL) [NHM435463 - ], TR310 TIER 4B (FINAL) [NGM418237 - ], TR310 TIER 4B (FINAL) [NHM435463 - ], TV370 TIER 4B (FINAL) [NHM435463 - ]
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Contents Electrical systems - 55 Harnesses and connectors - 100
FUNCTIONAL DATA Harnesses and connectors Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Wiring harnesses Electrical schematic sheet 02 SH02-MAIN POWER DISTRIBUTION (*) . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Electrical schematic sheet 03 SH03-ACCESSORY POWER DISTRIBUTION (*) . . . . . . . . . . . . . . . . . . . 34 Electrical schematic sheet 04 SH04-IGNITION/CHARGING SYSTEM (*) . . . . . . . . . . . . . . . . . . . . . . . . . 36 Electrical schematic sheet 05 SH05-GROUNDING SYSTEM (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Electrical schematic sheet 06 SH06-ENGINE F5C T4 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Electrical schematic sheet 07 SH07-ENGINE F5C T4 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Electrical schematic sheet 08 SH08-ENGINE F5C T4 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 Electrical schematic sheet 09 SH09-THROTTLE SENSORS (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 Electrical schematic sheet 10 SH10-EH PUMP/HYDRAULICS (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 Electrical schematic sheet 11 SH11-HYDRAULIC INTERLOCKS (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Electrical schematic sheet 12 SH12-LOADER VALVE AND SENSORS (*) . . . . . . . . . . . . . . . . . . . . . . . . 52 Electrical schematic sheet 13 SH13-BULKHEAD CONNECTION (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 Electrical schematic sheet 14 SH14-BULKHEAD CONNECTION (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 Electrical schematic sheet 15 SH15-BULKHEAD CONNECTION (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 Electrical schematic sheet 16 SH16-LEFT HAND CAB CONSOLE (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 Electrical schematic sheet 17 SH17-LEFT NH CONTROL HANDLE (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 Electrical schematic sheet 18 SH18-RIGHT NH CONTROL HANDLE (*) . . . . . . . . . . . . . . . . . . . . . . . . . 64 Electrical schematic sheet 19 SH19-RIGHT NH CONTROL HANDLE (*) . . . . . . . . . . . . . . . . . . . . . . . . . 66 Electrical schematic sheet 20 SH20-UNIVERSAL CONTROL MODULE (*) . . . . . . . . . . . . . . . . . . . . . . . 68 Electrical schematic sheet 21 SH21-UNIVERSAL CONTROL MODULE (*) . . . . . . . . . . . . . . . . . . . . . . . 70 Electrical schematic sheet 22 SH22-LAMPS (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 Electrical schematic sheet 23 SH23-INDICATORS (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 Electrical schematic sheet 24 SH24-EU LIGHT ADAPTER (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 Electrical schematic sheet 25 SH25-BOOM ROAD LIGHTS (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 Electrical schematic sheet 26 SH26-WIPERS / WASHERS (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 Electrical schematic sheet 27 SH27-INSTRUMENT CLUSTER (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82 Electrical schematic sheet 28 SH28-HVAC (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84 Electrical schematic sheet 29 SH29-RADIO (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
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Electrical schematic sheet 30 SH30-UJM CONNECTORS (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88 Electrical schematic sheet 31 SH31-MULTIFUNCTION CONNECTORS (*) . . . . . . . . . . . . . . . . . . . . . . . 90 Electrical schematic sheet 32 SH32-TELEMATICS (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92 Electrical schematic sheet 33 SH33-MULTIFUNCTION JUMPER (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94 Electrical schematic sheet 34 SH34-2ND AUX (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96 Electrical schematic sheet 35 SH35-DIAGNOSTIC CONNECTOR (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98 Electrical schematic sheet 36 SH36-FUEL FILTER JUMPER (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 Electrical schematic sheet 37 SH37-CHASSIS INTERFACE X-900/X-901 LG (*) . . . . . . . . . . . . . . . . . . 102 Electrical schematic sheet 38 SH38-CHASSIS INTERFACE (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104 Electrical schematic sheet 39 SH39-CHASSIS INTERFACE X-900/X-901 MD (*) . . . . . . . . . . . . . . . . . 106 Electrical schematic sheet 02 SH02-MAIN POWER DISTRIBUTION LG (*) . . . . . . . . . . . . . . . . . . . . . . 108 Electrical schematic sheet 03 SH03-MAIN POWER DISTRIBUTION MD (*) . . . . . . . . . . . . . . . . . . . . . . 110 Electrical schematic sheet 04 SH04-MAIN POWER DISTRIBUTION MD (*) . . . . . . . . . . . . . . . . . . . . . . 112 Electrical schematic sheet 05 SH05-ACCESSORY POWER DISTRIBUTION LG (*) . . . . . . . . . . . . . . . 114 Electrical schematic sheet 06 SH06-ACCESSORY POWER DISTRIBUTION MD (*) . . . . . . . . . . . . . . 116 Electrical schematic sheet 07 SH07-GROUNDING SYSTEM (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118 Electrical schematic sheet 08 SH08-IGNITION (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120 Electrical schematic sheet 09 SH09-ENGINE F5C T4 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122 Electrical schematic sheet 10 SH10-ENGINE F5C T4 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124 Electrical schematic sheet 11 SH11-ENGINE F5C T4 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126 Electrical schematic sheet 12 SH12-THROTTLE SENSORS (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128 Electrical schematic sheet 13 SH13-AUXILIARY HYDRAULIC INTERLOCK SWITCH (*) . . . . . . . . . . 130 Electrical schematic sheet 14 SH14-BULKHEAD CONNECTION (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132 Electrical schematic sheet 15 SH15-LEFT HAND CAB CONSOLE (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . 134 Electrical schematic sheet 16 SH16-LH NH CONTROL HANDLE (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136 Electrical schematic sheet 17 SH17-RH NH CONTROL HANDLE (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138 Electrical schematic sheet 18 SH18-SEAT (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140 Electrical schematic sheet 19 SH19-EH AUX PWM (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142 Electrical schematic sheet 20 SH20-LAMPS (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144 Electrical schematic sheet 21 SH21-INDICATORS (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146 Electrical schematic sheet 22 SH22-EU LIGHT ADAPTER (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148 Electrical schematic sheet 23 SH23-BOOM AND ROAD LIGHTS (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150 Electrical schematic sheet 24 SH24-WIPER / WASHER (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152 Electrical schematic sheet 25 SH25-INSTRUMENT CLUSTER (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154 Electrical schematic sheet 26 SH26-HVAC (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156 Electrical schematic sheet 27 SH27-RADIO (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158 Electrical schematic sheet 28 SH28-MULTIFUNCTION CONNECTORS (*) . . . . . . . . . . . . . . . . . . . . . . 160 Electrical schematic sheet 29 SH29-TELEMATICS (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162 Electrical schematic sheet 30 SH30-MULTIFUNCTION JUMPER (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164 Electrical schematic sheet 31 SH31-DIAGNOSTIC CONNECTOR (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . 166 Electrical schematic sheet 32 SH32-FUEL FILTER JUMPER (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
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Electrical schematic sheet 33 SH33-CHASSIS INTERFACE LG (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170 Electrical schematic sheet 34 SH34-CHASSIS INTERFACE (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172 Electrical schematic sheet 35 SH35-CHASSIS INTERFACE MD (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
Wire connectors Component diagram 00 Connectors X-000 to X-009 and Alphanumeric Connectors (*) . . . . . . . . . . . . 177 Connectors Alphanumeric (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195 Component diagram 01 Connectors X-010 to X-019 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211 Component diagram 02 Connectors X-020 to X-029 and Alphanumeric Connectors (*) . . . . . . . . . . . . 218 Component diagram 03 Connectors X-030 to X-039 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224 Component diagram 04 Connectors X-040 to X-049 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227 Component diagram 05 Connectors X-050 to X-059 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228 Component diagram 06 Connectors X-060 to X-069 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229 Component diagram 07 Connectors X-070 to X-079 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230 Component diagram 08 Connectors X-080 to X-089 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233 Component diagram 09 Connectors X-090 to X-099 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236 Component diagram 10 Connectors X-100 to X-109 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239 Component diagram 11 Connectors X-110 to X-119 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242 Component diagram 12 Connectors X-120 to X-129 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244 Component diagram 15 Connectors X-150 to X-159 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245 Component diagram 17 Connectors X-170 to X-179 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247 Component diagram 19 Connectors X-190 to X-199 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248 Component diagram 20 Connectors X-200 to X-209 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250 Component diagram 22 Connectors X-220 to X-229 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 252 Component diagram 23 Connectors X-230 to X-239 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253 Component diagram 25 Connectors X-250 to X-259 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255 Component diagram 27 Connectors X-270 to X-279 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 256 Component diagram 30 Connectors X-300 to X-309 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258 Component diagram 31 Connectors X-310 to X-319 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261 Component diagram 32 Connectors X-320 to X-329 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265 Component diagram 33 Connectors X-330 to X-339 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267 Component diagram 34 Connectors X-340 to X-349 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270 Component diagram 36 Connectors X-360 to X-369 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272 Component diagram 40 Connectors X-400 to X-409 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273 Component diagram 41 Connectors X-410 to X-419 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276 Component diagram 50 Connectors X-500 to X-509 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277 Component diagram 90 Connectors X-900 to X-909 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280 Component diagram 99 Connectors X-9000 to X-9009 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285 Connectors Alphanumeric (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 286 Component diagram 00 Connectors X-000 to X-009 and Alphanumeric Connectors (*) . . . . . . . . . . . . 297 Component diagram 01 Connectors X-010 to X-019 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 311 Component diagram 02 Connectors X-020 to X-029 and Alphanumeric Connectors (*) . . . . . . . . . . . . 320
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Component diagram 03 Connectors X-030 to X-039 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 323 Component diagram 04 Connectors X-040 to X-049 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 326 Component diagram 05 Connectors X-050 to X-059 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 328 Component diagram 06 Connectors X-060 to X-069 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 329 Component diagram 07 Connectors X-070 to X-079 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 330 Component diagram 08 Connectors X-080 to X-089 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 333 Component diagram 09 Connectors X-090 to X-099 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 334 Component diagram 10 Connectors X-100 to X-109 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 335 Component diagram 11 Connectors X-110 to X-119 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 338 Component diagram 15 Connectors X-150 to X-159 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 341 Component diagram 16 Connectors X-160 to X-169 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 343 Component diagram 17 Connectors X-170 to X-179 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 346 Component diagram 19 Connectors X-190 to X-199 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 347 Component diagram 20 Connectors X-200 to X-209 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 349 Component diagram 22 Connectors X-220 to X-229 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 351 Component diagram 23 Connectors X-230 to X-239 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 352 Component diagram 25 Connectors X-250 to X-259 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 354 Component diagram 27 Connectors X-270 to X-279 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 355 Component diagram 30 Connectors X-300 to X-309 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 357 Component diagram 31 Connectors X-010 to X-019 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 360 Component diagram 32 Connectors X-320 to X-329 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 364 Component diagram 33 Connectors X-330 to X-339 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 366 Component diagram 34 Connectors X-340 to X-349 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 369 Component diagram 36 Connectors X-360 to X-369 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 371 Component diagram 40 Connectors X-400 to X-409 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 372 Component diagram 41 Connectors X-410 to X-419 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 374 Component diagram 43 Connectors X-430 to X-439 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 376 Component diagram 50 Connectors X-500 to X-509 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 378 Component diagram 90 Connectors X-900 to X-909 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 381 Component diagram 99 Connectors X-9000 to X-9009 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 386
Fuse and relay box Relay - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 387 Fuse - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 389 Component localization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 390
Electrical components ECU description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 395 Sensor description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 396 Battery description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 399 Diode description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 400 Lamp description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401 Fuse description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
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Voltage source description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 407 Ground description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 408 Speaker description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 410 Power outlet description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 411 Relay description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 412 Motor description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 414 Resistor description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 415 Switch description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 416 Solenoid description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 420 Sub-Assembly description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 422 ECU description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 424 Sensor description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 425 Lamp description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 427 Fuse description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 429 Voltage source description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 434 Ground description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 435 Speaker description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 437 Power outlet description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 438 Relay description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 439 Motor description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 441 Resistor description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 442 Switch description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 443 Solenoid description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 447 Sub-Assembly description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 449
SERVICE Wiring harnesses Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 451 Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 452
DIAGNOSTIC Fuse and relay box Testing Condenser Relay Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 454
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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 protection 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.
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Open circuit • A cut or broken wire.
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Open circuit • There is no contact between the wire(s) and the terminal due to the insulation not being properly removed or positioned when the terminal was fastened to the wire(s) .
Open circuit • Completely disconnected connectors do not make contact with the terminals.
Open circuit • The terminal is not positioned properly or did not stay inside the connector.
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Open circuit • A wire is missing from a connector.
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Open circuit • A wire length that is shortened.
Intermittent circuit • The hardware used to secure the terminal is not completely tightened.
Intermittent circuit • The ring terminal is not secured with hardware.
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Intermittent circuit • The terminal is not crimped on the wire(s).
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Intermittent circuit • 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.
Intermittent circuit • Corrosion on the pin(s) is Indicated by a layer of greenish-white powder appearing on the pins. • Corroded pins may overheat because of increased resistance due to corrosion.
Intermittent circuit • Partially disconnected connectors make contact with only some terminals.
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Intermittent circuit • Cracked, broken or melted connector cause improper connections.
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Intermittent circuit • A ground terminal not fastened or loose on the machine.
Chaffed wire • A section of the wire’s insulation is rubbed away, exposing the bare wire.
Burned wire and/or melted insulation • If the wire(s) are located near a heat source or overheated because of continuous, excessive current, the insulation will be discolored and melt, exposing the wire(s).
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Cross connection â&#x20AC;˘ Terminals that are connected in the wrong cavity will result in system malfunction.
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Incorrect routing â&#x20AC;˘ A wiring harness not routed properly can lead to problems.
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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 connectorâ&#x20AC;&#x2122;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: â&#x20AC;˘ A connector seal which provides an environmental seal between the mating connectors. â&#x20AC;˘ A cable seal which seals the area where each wire enters the connector.
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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.
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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.
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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.
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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).
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.
4. Place the wire (1) on the terminal. Verify that the insulation lies on the insulation barrel (2). 5. Verify that the wire core (3) is exposed to the wire barrel (4).
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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.
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7. Solder all hand-crimped terminals. 8. Check circuit for electrical continuity.
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 â&#x20AC;&#x153;clicksâ&#x20AC;? 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.
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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, depending on the type of connector being used. Some connectors may not have wire or TPA locks. NOTE: Image shows connector without wire lock. RAIL14SSL0617AA
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Sealed connector - wire lock 1. Install the wire lock after all terminals have been seated in the connector. 2. Push the lock over the back of the connector until it locks onto the connector.
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.
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Hinged wire lock 1. On connectors with a hinged wire lock, snap the wire lock over back of the connector .
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Prior to mating the connectors, visually inspect the connectors for damage. Verify that the connector pins are straight.
Bent pins will lead to damage to the connector and may cause a short circuit.
Once the terminals are installed and locked in place, apply dielectric grease to the connector and on the pins to avoid corrosion.
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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 connection. NOTICE: Do not test the connectors by pulling the wires.
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Precautions to be followed while connecting a connector: • Verify that the connections are intact. Loose connections will lead to disconnection and corrosion damage.
• Rubber seals on the connector prevents contamination. Verify that the seal is present on the connectors before mating the connectors.
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• On connectors with a missing seal, the connection will not be intact and may cause intermittent or open circuit.
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• Verify that the connectors without internal locks, the “T” on the pins are flush with the bottom of the mating connector to ensure a proper connection.
• Image 43 shows properly mated connector.
• 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 connector. When the connector is properly locked, you should be able to feel the lever “click” into place.
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• Install the secondary locks or connector position assurance (CPA) locks as required.
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NOTICE: Missing and improperly installed secondary locks will lead to faulty connections.
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.
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Unsealed connector â&#x20AC;&#x201C; 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 deformed.
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Sealed connectors â&#x20AC;&#x201C; 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 deformed.
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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 foremost 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 channel by looking into the connector from the mating end.
RAIL14SSL0638AA
51
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
RAIL14SSL0640AA
53
RAIL14SSL0641AA
54
RAIL14SSL0642AA
55
2. Push the wire cores into the sleeve till they reach the stop at the center of the sleeve.
3. Individually crimp both the ends of the splice sleeve.
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.
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Electrical systems - Harnesses and connectors
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
RAIL14SSL0644AA
57
RAIL14SSL0645AA
58
2. Place the stripped wires in the splice clip.
3. Crimp the splice clip. NOTICE: Do not crimp the insulation.
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Electrical systems - Harnesses and connectors
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 surfaces, such as sharp or abrasive objects, sheet metal holes, sharp metal flanges, etc. • Should be placed at least 75 mm (3 in) away from battery vents
RAIL14SSL0647BA
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60
Electrical systems - Harnesses and connectors
Verify that the bare wires (without conduit) do not contact the hydraulic tubes and hoses.
RAIL14SSL0648AA
61
RAIL14SSL0649AA
62
RAIL14SSL0650BA
63
Verify that the bare wires are not secured with cable ties.
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.
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Electrical systems - Harnesses and connectors
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
RAIL14SSL0652AA
65
RAIL14SSL0653AA
66
Image 65 is an example of a correct bend radius.
Image 66 is an example of an incorrect bend radius.
Harness fastening guidelines The wiring harness must be fastened properly to avoid any possible harness damage such as incorrect routing, pinching, 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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Electrical systems - Harnesses and connectors
Use the double tie to secure the wiring harness to isolated points on the machine.
RAIL14SSL0654AA
67
RAIL14SSL0655AA
68
RAIL14SSL0657AA
69
RAIL14SSL0658AA
70
Use the dual clamp to secure the harnesses without any contact.
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Electrical systems - Harnesses and connectors
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 feature, use lock washers.
RAIL14SSL0701AA
71
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Wiring harnesses - Electrical schematic sheet 02 SH02-MAIN POWER DISTRIBUTION SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
Type Fuse Fuse Fuse Fuse Fuse Fuse Fuse Fuse Fuse Fuse Fuse Fuse Fuse Fuse Fuse Fuse Fuse Fuse Fuse Fuse Fuse Relay Relay Relay Relay Connector Connector Connector Sub-Assembly Sub-Assembly
Component F-001 F-002 F-003 F-004 F-005 F-006 F-007 F-008 F-009 F-010 F-011 F-012 F-013 F-014 F-026 F-030 F-033 F-034 F-035 F-036 F-039 K-001 K-002 K-003 K-004 X-014 X-FUSE1 X-FUSE2 Z-FUSE1 Z-FUSE2
(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
Connector / Link
X-014 X-FUSE1 X-FUSE2 X-FUSE1 X-FUSE2
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Description HVAC COMPRESSOR CRANK REAR WORK LAMPS SIDE LAMPS LH TAIL LAMPS UCM BACKUP ALARM INSTRUMENT CLUSTER IGNITION RH TAIL LAMPS UNSWITCH BATTERY FRONT WORK LAMPS ACCESSORY ACC/BEACON EH UNSWITCHED BATTERY FLASHER/ BRAKE ENGINE SENSORS ECU FUSE 2 ECU FUSE 1 FUSE RELAY GROUND TELEMATICS LIGHTS #1 RELAY LIGHTS #2 RELAY ACCESSORY RELAY MAIN POWER RELAY
POWER DISTRIBUTION EH CHASSIS POWER DISTRIBUTION EH CHASSIS
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Electrical systems - Harnesses and connectors
6
5
SH2: C-6
114 RD 1.0
SH4: D-1
107 RD 8.0
SH3: C-6
157 RD 3.0
SH2: B-6
705 VT 3.0
4
3
2
1
Z-FUSE1 POWER DISTRIBUTION EH CHASSIS F-001 HVAC
SP-042
9
830 OR 3.0 SH13: D-6
1
30.0 A
2
SP-161
3
820 OR 3.0
F-002 SH13: D-6
D
843 OR 5.0
SH14: C-6
844 OR 5.0
SH14: C-6
792 VT 3.0 701 VT 0.8
COMPRESSOR 67
SH4: B-1
183 OR 0.8
SH13: D-6
700 VT 0.8
SH4: D-1
116 RD 2.0
835 OR 3.0
1
25.0 A
2
836 RD 3.0
SH13: D-6
256 RD 2.0
SH8: D-6
156 RD 2.0
SH24: D-6
156 RD 2.0
SH39: D-6
D
F-003 CRANK 11 255 RD 2.0
SH13: D-6
61
1
30.0 A
2
5
710 VT 2.0 F-030
SH20: C-6
189 RD 0.8
SH14: A-6
115 RD 2.0
SH14: A-6
310 RD 0.8
FLASHER/ BRAKE 46
157 RD 3.0
1
15.0 A
2
40
X-FUSE1
X-FUSE1 Z-FUSE1 Z-FUSE1
POWER DISTRIBUTION EH CHASSIS
POWER DISTRIBUTION EH CHASSIS F-004 REAR WORK LAMPS
F-011 47
UNSWITCH BATTERY 70 SH4: D-1
160 RD 0.8
1
2
4.0 A
64
1
15.0 A
2
41 SH38: B-6
706 VT 3.0
310 RD 0.8 F-005
F-014
SIDE LAMPS 59
ACC/BEACON 24
C
SH2: D-6
114 RD 1.0
1
2
20.0 A
18
44 188 RD 0.8
1
2
2.0 A
15.0 A
2
708 VT 3.0
35 38
1
X-FUSE1
4.0 A
2
58
11
1
326 OR 1.0
1
18
57
946 BK 0.8 350 OR 1.0
K-002
10.0 A
2
1
15.0 A
2
23
87
35
85
23
1
4.0 A
SH2: C-1
709 WH 0.8
945 BK 0.8
52
86
528B OR 3.0
87
51
85
39
1
1
704 VT 0.8
SH39: B-6
704 VT 0.8
SH37: B-6
7.5 A
2
110 OR 2.0
SH39: D-6
110 OR 2.0
SH37: D-6
20.0 A
2
1
ENGINE SENSORS 22
528D OR 1.0
87
69
1
7.5 A
2
SH6: B-6
241C OR 0.8
SH37: B-6
241D RD 0.8
SH3: B-6
SP-241
16
241A OR 1.0
85
57
F-013
136 OR 1.0 70
86
144 OR 0.8
ACCESSORY
SP-030
947 BK 0.8
69
135 OR 2.0
1
F-036 68
SH39: D-6
241B OR 0.8
30
118 RD 1.0
1094 BK 0.8
241C OR 0.8 F-033
87A
58
B
SH38: B-6
155A OR 3.0
948 BK 0.8 SP-194
SH3: A-6
SH32: C-5
ECU FUSE 2 7
528C OR 3.0
K-004 MAIN POWER RELAY
SH15: C-6
351 OR 1.0
15
139 OR 0.8
SH4: D-1
SH3: B-6
F-034
125 OR 3.0 SH3: C-6
SH13: D-6
335 WH 0.8
F-035 21
87A
117 RD 3.0
SH4: D-1
SH15: D-6
334 OR 2.0
51
ECU FUSE 1
SP-528
ACCESSORY RELAY 30
SH11: A-5
309 OR 1.0
17
K-003
40
1102 OR 0.8
300 OR 1.0
2
707 VT 2.0 86
SP-037
52
RH TAIL LAMPS
87A
B
SH21: C-6
F-010
30
113 RD 1.0 36
167 OR 0.8
IGNITION
5
85
86
325 WH 0.8
24
2
F-009
LIGHTS #2 RELAY
SH4: D-1
2.0 A
17
116 RD 2.0 SP-031
SH39: A-6
28
710 VT 2.0
30 87
705 VT 3.0
SH37: A-6
703 VT 0.8
INSTRUMENT CLUSTER SP-036
87A
SH2: D-6
SH14: C-6
703 VT 0.8
F-008
K-001 LIGHTS #1 RELAY
790 VT 1.0
795 VT 5.0 29
UCM BACKUP ALARM 34
POWER DISTRIBUTION EH CHASSIS
SH14: A-6
SH2: B-6
189 RD 0.8
Z-FUSE2
6
709 WH 0.8
C
F-006 LH TAIL LAMPS
F-007 X-FUSE1
SP-032
53
115 RD 2.0
F-026 EH UNSWITCHED BATTERY SH4: D-1
1
2.0 A
63
134 OR 2.0
SH15: D-6
798 VT 5.0
SH14: C-6
336 RD 1.0
SH32: B-5
F-012 FRONT WORK LAMPS
FUSE RELAY GROUND 1
20.0 A
2
SP-191
62
2
71
1096 BK 0.8
788 VT 3.0
1
2
65
F-039
X-FUSE2
X-FUSE2
15.0 A
TELEMATICS
A
10 SH4: D-1
119 RD 1.0
SH3: A-6
1067 BK 0.8
SH3: A-1
1098 BK 0.8
1
5.0 A
X-FUSE1
2
4
X-FUSE1
243 OR 2.0
SH3: A-6
SH8: C-1
528A OR 8.0
123 OR 3.0
SH13: D-6
SH8: B-6
528F OR 5.0
127 OR 0.8
SH4: B-6
SH37: D-6
528E OR 2.0
6
5
4
3 SHT_2
1
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1
A
Electrical systems - Harnesses and connectors
Wiring harnesses - Electrical schematic sheet 03 SH03-ACCESSORY POWER DISTRIBUTION SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
Type Fuse Fuse Fuse Fuse Fuse Fuse Fuse Fuse Fuse Fuse Fuse Fuse Fuse Fuse Fuse Fuse Fuse Fuse Relay Relay Relay Connector Connector Connector Sub-Assembly Sub-Assembly
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Component F-015 F-016 F-017 F-018 F-019 F-020 F-021 F-022 F-023 F-024 F-025 F-027 F-028 F-029 F-031 F-032 F-037 F-038 K-005 K-009 K-010 X-CN2A X-FUSE1 X-FUSE2 Z-FUSE1 Z-FUSE2
(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
Connector / Link
X-CN2A X-FUSE1 X-FUSE2 X-FUSE1 X-FUSE2
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Description UCM BRAKE LAMPS EH GRND DRIVE GRD DRIVE REV EH AUX HYD BUCKET CONTROL HYD OPTIONS UCM PUMP FWD LOADER CONTROL AUX FE KEY POWER AUX FE ON/OFF UCM INTERLOCKS TWO SPEED SHIFT FE #1, #2, #3 WIPER/WASHER LEFT BOOM RIGHT BOOM FUSE RELAY GROUND FUSE RELAY GROUND EH CONTROL RELAY AUX FRONT ELECTRIC RELAY OPTION RELAY UCM CN2A
POWER DISTRIBUTION EH CHASSIS POWER DISTRIBUTION EH CHASSIS
Electrical systems - Harnesses and connectors
6
5
SH4: A-1
173 OR 0.8
SH4: B-1
173 OR 0.8
SH4: B-1
184 OR 0.8
3
2
1
Z-FUSE1 POWER DISTRIBUTION EH CHASSIS F-015
SH4: A-1
D
4
187 OR 0.8
SH4: B-1
187 OR 0.8
SH4: A-1
174 OR 0.8
UCM BRAKE LAMPS 1
7.5 A
2
25
166 OR 0.8
SH20: B-6
201 OR 0.8
SH20: B-6
169 OR 0.8
SH21: D-6
168 OR 0.8
SH21: D-6
164 OR 0.8
SH20: D-1
165 OR 0.8
SH20: D-1
102 OR 0.8
SH10: D-6
128 OR 0.8
SH20: C-6
126 OR 0.8
SH20: C-6
142 OR 0.8
SH21: C-6
147 OR 0.8
SH21: C-6
0060 OR 0.8
SH21: D-1
0061 OR 0.8
SH21: D-1
SP-113
172 OR 0.8
D
31 F-016 EH GRND DRIVE
SH4: B-1
174 OR 0.8
SH4: A-1
204 OR 0.8
19
1
4.0 A
2
13
SP-114
185 OR 0.8
F-017
SH4: A-1
203 OR 0.8
SH4: B-1
GRD DRIVE REV 1
203 OR 0.8
5.0 A
2
SP-152
27
122 OR 0.8
33
SH4: A-1
181 OR 0.8
SH4: B-1
181 OR 0.8
F-018 EH AUX HYD 1
4.0 A
2
SP-109
26
177 OR 0.8
32 F-019 BUCKET CONTROL 56
Z-FUSE2
7.5 A
K-009
F-020
AUX FRONT ELECTRIC RELAY SH2: D-6
157 RD 3.0
SH4: D-1
0051 RD 8.0
SP-142
SH2: B-6
87
15
85
3
1
149 OR 3.0
139 OR 0.8
SH15: D-6
743 OR 2.0
30
16
86
K-010
2
744 OR 2.0
3.0 A
2
SH13: B-6 14
C
SH21: C-6
120 OR 0.8
20 F-022
OPTION RELAY
LOADER CONTROL
87A 30
104 RD 2.0
15.0 A
6
F-021
1
2
176 OR 0.8
UCM PUMP FWD
146 WH 0.8
175 WH 0.8
2
HYD OPTIONS 12
87A
4
103 RD 3.0 SP-107
C
1
POWER DISTRIBUTION EH CHASSIS
SP-111
50
87
1
13
4.0 A
2
SP-110
2
178 OR 0.8
154 OR 0.8
SH20: C-1
158 OR 0.8
SH20: B-1
8 14
86
85
1
F-023
972 BK 0.8
148 WH 0.8
AUX FE KEY POWER
SP-065
45
356 OR 3.0
K-005
1
25.0 A
2
39
420 OR 3.0
SH31: B-5
354 OR 0.8
SH14: D-6
EH CONTROL RELAY 87A
20 SH4: D-1
F-028
30
193 RD 3.0
31
87
FE #1, #2, #3 68
32 SH2: B-1
86
19
85
355 OR 0.8
1
7.5 A
2
62
335 WH 0.8 F-027 SP-115
B
SH21: D-6
170 OR 0.8
SH21: C-6
171 OR 0.8
TWO SPEED SHIFT
49
1
179 OR 0.8
2
55 F-025 UCM INTERLOCKS 55
F-024
1
AUX FE ON/OFF
61 SH13: B-6
5.0 A
1
129 OR 1.0
10.0 A
2
5.0 A
2
SP-112
49
182 OR 0.8
159 OR 0.8
SH20: D-1
163 OR 0.8
SH20: C-1
67
145 OR 1.0
F-029
B
WIPER/WASHER 72
SH2: B-1
43
59
241D RD 0.8
970 BK 0.8
1
30.0 A
2
37
233 OR 2.0
SH13: C-6
716 VT 1.0
SH25: B-6
719 VT 1.0
SH39: C-6
719 VT 1.0
SH37: C-6
1098 BK 0.8
SH2: A-6
SP-192 X-FUSE2
X-FUSE2
F-031 LEFT BOOM 48
714 VT 1.0
1
10.0 A
2
42
F-032
SH4: B-1
186 OR 0.8
RIGHT BOOM
SP-057 SH2: A-6
1067 BK 0.8
SH4: B-1
190 OR 3.0
SH4: B-1
180 OR 0.8
36
715 VT 1.0
1
10.0 A
2 30
F-037 FUSE RELAY GROUND 72
1095 BK 0.8 SH2: A-1 SH13: D-6
A
1
2.0 A
2
66
243 OR 2.0 711 VT 2.0 F-038
SH2: A-6
1094 BK 0.8
FUSE RELAY GROUND 60
SH5: B-1
1091 BK 0.8
1092 BK 0.8
1
2.0 A
2
54
1097 BK 0.8
SP-190
X-FUSE1
6
5
4
3 SHT_3
1
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X-FUSE1
2
1
A
Electrical systems - Harnesses and connectors
Wiring harnesses - Electrical schematic sheet 04 SH04-IGNITION/ CHARGING SYSTEM SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
Type Battery Voltage source Voltage source Ground Ground Relay Motor Motor Resistor Resistor Switch Switch Switch Connector Connector Connector Connector Connector Connector Connector
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Component BAT-001 G-001 G-002 GND-007 GND-008 K-006 M-001 M-002 R-003 R-004 S-004 S-008 S-021 X-005A X-006 X-009 X-126 X-508 X-FUSE1 X-POS_TERM
(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Description
Connector / Link BATTERY ALTERNATOR GND-007 GND-008 B_START
STARTER MOTOR M STARTER HOLD-IN STARTER PULL-IN IGNITION SWITCH AIR FILTER RESTRICTION SWITCH
X-005A X-006 X-009 X-126 X-508 X-FUSE1 X-POS_TERM
X-126 AIR FILTER RESTRICTION SWITCH
Electrical systems - Harnesses and connectors
6
5
4
3
2
1
118 RD 1.0
SH2: B-6
116 RD 2.0
SH2: D-6
G-001 BATTERY SP-146 0055 RD 19.0
0051 RD 8.0
SH3: C-6
193 RD 3.0
SH3: C-6
188 RD 0.8
SH2: C-6
119 RD 1.0
SH2: A-6
113 RD 1.0
SH2: B-6
117 RD 3.0
SH2: B-6
107 RD 8.0
SH2: D-6
160 RD 0.8
SH2: C-6
X-POS_TERM 1 1
D
D
X-POS_TERM SP-145 0054 RD 19.0 GND-007 SP-900
3/0 B+ CABLE RD 81.0 S-008 SH4: A-6
IGNITION SWITCH
3/0 B+ CABLE TO STARTER RD 81.0
6
AUX
SH4: B-6
138 OR 0.8
SH27: B-1
132 OR 0.8
SH27: B-6
B+ CABLE TO ALTERNATOR RD 32.0
1
IGN
3 SH27: B-6
140 RD 0.8
C
C
X-009
4
START
624 WH 0.8
SH27: D-6
907 BK 0.8
SH5: C-1
X-009 S-021 AIR FILTER RESTRICTION SWITCH X-508
X-508 SH37: A-1
267 YE 0.8
SH39: A-1
267 YE 0.8
2
1 1
1
2 2 X-508
X-508
SH4: C-6
B+ CABLE TO ALTERNATOR RD 32.0
G-002
X-006
ALTERNATOR
B
X-005A D+(1) SH32: C-5
244 YE 0.8
2 2
244A YE 0.8
1
1
SH20: C-6
124 YE 0.8
4 4
124A YE 0.8
3
2
CHARGE INDICATOR
(3)
SP-119
127 OR 0.8
3 1
2
127A OR 0.8
3
SH3: A-6
173 OR 0.8
SH3: D-6
174 OR 0.8
SH3: D-6
183 OR 0.8
SH2: D-6
184 OR 0.8
SH3: D-6
186 OR 0.8
SH3: A-6
B
1
A B_ALT
W(2) SH2: A-1
190 OR 3.0
SH20: C-6
240 OR 0.8
PHASE X-005A M-001
187 OR 0.8
SH3: D-6
181 OR 0.8
SH3: D-6
180 OR 0.8
SH3: A-6
203 OR 0.8
SH3: D-6
204 OR 0.8
SH3: D-6
240 OR 0.8
SH20: C-6
173 OR 0.8
SH3: D-6
STARTER MOTOR
191 OR 0.8 SP-118 X-126 SH8: D-1
520 WH 2.0
1 3
STARTER HOLD-IN A A
520A WH 2.0
X-126
STARTER PULL-IN
X-006
192 OR 0.8
A
1 SH4: D-6
M
SP-117
3/0 B+ CABLE TO STARTER RD 81.0 B_START
174 OR 0.8
SH3: D-6
181 OR 0.8
SH3: D-6
187 OR 0.8
SH3: D-6
203 OR 0.8
SH3: D-6
GND-008
6
5
4
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Electrical systems - Harnesses and connectors
Wiring harnesses - Electrical schematic sheet 05 SH05-GROUNDING SYSTEM SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
Type Ground Ground Ground Ground Ground Ground Ground Ground Connector Connector Connector Connector
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Component GND-001 GND-002 GND-003 GND-004 GND-005 GND-009 GND-010 GND-011 X-271 X-CAB_GNDA X-CAB_GNDB X-TELE_GND
(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
Connector / Link GND-001 GND-002 GND-003 GND-004 GND-005 GND-009 GND-010 GND-011 X-271 X-CAB_GNDA X-CAB_GNDB X-TELE_GND
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Description
WATER VALVE CAB GROUND GNDB CAB GROUND TELEMATICS GND
Electrical systems - Harnesses and connectors
6
5
4
3
2
1
939 BK 5.0 SH32: B-5
SH26: C-6
910A BK/WH 0.8
SH35: C-5
SH16: D-1
941 BK 0.8
SH16: A-1
952 BK 0.8
SH16: C-1
961 BK/WH 0.8 SP-092
SH27: B-1
SP-173
1
1011 BK/WH 0.8
1094 BK 13.0 SH28: C-1
D
940 BK 3.0
1012 BK/WH 0.8
SH26: B-6
SP-029
942 BK 3.0
X-CAB_GNDB
931 BK 0.8
SH26: C-1
932 BK 0.8
SH26: B-1
1016 BK/WH 0.8
GND-003
SH14: C-6
1090 BK/WH 0.8
SH21: D-1
1034 BK/WH 0.8
939 BK 2.0
1093 BK 13.0
1073 BK/WH 0.8
SH10: C-1
1074 BK/WH 0.8
SH20: C-1
1027 BK/WH 0.8
SH13: A-6
1051 BK/WH 0.8
SH10: D-1
1054 BK/WH 0.8
SH10: D-1
1055 BK/WH 0.8
SH12: A-1
1060 BK/WH 0.8
SH24: A-6
933 BK 1.0
SH19: D-1
937 BK 3.0
SH26: C-6
1088 BK 8.0
SH28: D-1
SP-172
1 SP-125
SH10: D-1
D
X-CAB_GNDA
GND-005
980 BK 1.0
SH25: A-6
975 BK 3.0
SH25: C-6
SP-124
SH24: D-6 SH4: C-1
950 BK 3.0
SH25: C-6
956 BK 0.8
SH37: A-1
1086 BK 2.0
SH8: B-6
SP-177
SP-175
1 984 BK 13.0
C
965 BK 3.0 SP-176
CHS_GND_RR
SP-047 SH14: B-6
981 BK 0.8 907 BK 0.8
965 BK 3.0
1
910 BK/WH 1.0
C
GND-004
971 BK 13.0 NEG_TERM_A
975 BK 3.0
SH25: C-6
950 BK 3.0
SH25: C-6
1084 BK 3.0
SH28: A-1
GND-009
1 SH6: D-6
908A BK 8.0 SH20: C-6
ECU_GND
1025 BK/WH 0.8
908A BK 8.0 SH20: C-6
1026 BK/WH 0.8
SP-908
SP-120 SH20: B-1
1028 BK/WH 0.8
SH20: D-6
1075 BK/WH 0.8
SH20: D-6
1076 BK/WH 0.8
SH21: B-6
1033 BK/WH 0.8
SH21: C-1
1035 BK/WH 0.8
SH8: B-6
908F BK/WH 5.0
1042 BK/WH 0.8
GND-010 SP-184
1063 BL 0.8
SH11: B-2
1064 BK 0.8
SH10: A-1
1069 BK 2.0
B
1044 BK/WH 0.8 SH21: C-1
1036 BK/WH 0.8
SH21: B-1
1037 BK/WH 0.8
SH3: A-6
1091 BK 0.8 SP-123
SP-122
B
1
1068 BK/WH 1.0 UCM_GND
SP-181
1
SP-179
983 BK 13.0
960 BK 0.8
SH10: A-1
1013 BK 0.8
SH28: A-6
955 BK 0.8
SH29: A-6
953 BK 0.8
SH17: B-1
968 BK 2.0
CHS_GND_FRT GND-002
SH20: A-1
1029 BK/WH 0.8
SH21: C-6
1030 BK/WH 0.8
SH21: C-6
1031 BK/WH 0.8
SH21: B-6
1032 BK/WH 0.8
SH20: C-1
1077 BK/WH 0.8
GND-001
SP-121
SH38: A-6
1087 BK 5.0
1043 BK/WH 0.8
SP-182
979 BK 1.0
SH25: B-6
981 BK 0.8
SH24: D-6
982 BK 5.0
SH31: C-5
978 BK 0.8
SH13: B-6
959 BK 0.8
SH34: C-5
958 BK 0.8
SH34: B-5
949 BK 0.8
SH14: C-6
SP-174
986 BK 8.0
1014 BK 8.0
SP-183
1008 BK 1.0 1 SH32: D-5
925 BK/WH 0.8 X-TELE_GND
A
SP-188
GND-011
6
5
951 BK 0.8
SH10: B-1
957 BK 0.8
SH11: C-2
976 BK 0.8
SH13: B-6
998 BK 1.0
4
3 SHT_5
1
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Electrical systems - Harnesses and connectors
Wiring harnesses - Electrical schematic sheet 06 SH06-ENGINE F5C T4 SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
Type ECU ECU Sensor Sensor Sensor Sensor Sensor Sensor Resistor Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector
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(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
Component A-004 A-006 B-005 B-006 B-007 B-008 B-011 B-012 R-005 X-004 X-005 X-006 X-007 X-012 X-013 X-014 X-017 X-018 X-316
Connector / Link X-012 X-013 X-014 X-004 X-005 X-006 X-007 X-018 X-004 X-005 X-006 X-007 X-012 X-013 X-014 X-017 X-018 X-316
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Description ENGINE CONTROL UNIT GCU LAMBDA SENSOR AIR TEMP SENSOR INLET TURBINE TEMP SENSOR DIFF PRESSURE SENSOR EXHAUST GAS TEMP SENSOR #1 EXHAUST GAS TEMP SENSOR #2 FUEL FILTER HEATER AIR TEMPERATURE SENSOR X-005 EXHAUST GAS TEMP SENSOR 2 ECU GCU
FUEL FILTER HEATER IGNITION BACKFEED DIODE
Electrical systems - Harnesses and connectors
6
5
4
3
2
1
A-004 ENGINE CONTROL UNIT SP-155
D
SH38: B-3
248 YE 0.8
SH39: C-1
248 YE 0.8
SH37: C-1
5
155A OR 3.0
155C OR 2.0
EGR ECU K-LINE
BATTERY +C
D
68 3
155B OR 2.0
BATTERY +B 24
SP-908 SH5: C-1
908A BK 8.0
908B BK 2.0
CDB-001
CDB-001
BATTERY MINUS 1
25
908A BK 5.0
4
908C BK 2.0
908E BK 0.8
908D BK 2.0
CDB-023
CDB-023 BATTERY MINUS 2
6 SH38: D-6
SH37: B-1
504C GN 0.8
CAN 1 LO SH8: B-6
SH37: B-1
503C YE 0.8
CAN 1 HI
2
CAN 2 HI
23
503C YE 0.8
SH39: B-1
CAN 2 LO
45
504C GN 0.8
SH39: C-1
BATTERY MINUS 3 30
SH38: D-6
150 YE 0.8
SH38: D-6
133E OR 0.8
WIF SIGNAL SP-133B
SH39: A-1
133B OR 0.8
SH37: A-1
133B OR 0.8
SH39: D-1 SH37: D-1
110 OR 2.0
50 CCV HEATER CONTROL
54
133D OR 0.8
ECU SWITCHED POWER CCV HEATER FEEDBACK
600 WH 0.8
SH8: B-6
601 YE 0.8
SH8: B-6
87
110 OR 2.0 BATTERY VOLTAGE 1
C
SH37: A-1 SH8: C-1
112 BL 0.5
SH39: B-1 SH37: B-1
121 YE 0.8
B-006
112 BL 0.5
AIR TEMP SENSOR ECU MAIN RELAY 28 20
121 YE 0.8 AIR TEMP GND
CRANK ENABLE 1
C
2
254 BK/WH 0.5
T째
27 SH39: A-1 SH37: C-1
161 YE 0.8 19
CRANK ENABLE 2
161 YE 0.8
AIR TEMP SIGNAL
53
1 257 YE 0.5
626 WH 0.8
SH39: B-1 SH37: B-1
START SIGNAL
626 WH 0.8
X-004
8
B-007 INLET TURBINE TEMP SENSOR X-017
A-006 GCU SH38: A-3
82 INLET TURBINE TEMP SIGNAL
212 OR 8.0 4
212 OR 8.0
SH38: B-3
PWR
26
263 YE 0.5
26 T째
52
8 CMD
GCU COMMAND
216 YE 0.5
81 X-017
1110 WH 2.0
60 60
1111 WH 2.0
INLET TURBINE TEMP GND
22
3
2 61 61
FB
25
25 X-017
7
SP-239
5 GND
1
239A BK 3.0
41 B-008
GCU GROUND
239 BK 0.8
DIFF PRESSURE SENSOR
1112 WH 2.0
58 58
X-013
6
1113 WH 2.0
57 57
DIFF PRESSURE GND X-017
B
265 BK/WH 0.5
GCU FEEDBACK
235 YE 0.5
2
36
266 BK/WH 0.5 DP
X-013
SH39: C-6 SH39: D-6 SH39: D-6
249 YE 0.5 DIFF PRESSURE SIGNAL
245 YE 0.5
B
3
58
268 YE 0.5
242 YE 0.8 B-005
DIFF PRESSURE SUPPLY
LAMBDA SENSOR SP-241 SH37: B-1
241A OR 1.0
PWR
269 YE 0.5
7
3
4
241B OR 0.8
1
14
SHEAT
X-005 SENSOR HEATING
242 YE 0.8
X-014 64
1 SH7: D-1
241C OR 0.8
SH2: B-1
241B OR 0.8
SH39: C-6
270 BK/WH 0.5 CPUMP 5
86
CADJ
B-011 CURRENT PUMP
245 YE 0.5 249 YE 0.5
CURRENT ADJUST EXHAUST GAS TEMP GND 1
EXHAUST GAS TEMP SENSOR #1 79
270 BK/WH 0.5
T째
2 2
VGND
85
252 BK 0.5 63
6
VNERNST
VIRTUAL GROUND EXHAUST GAS TEMP SIGNAL 1
80
1
271 YE 0.5
VOLTAGE
253 PK 0.5
X-006 SH39: C-6
271 YE 0.5
X-014 SH39: C-6 SH39: C-6
253 PK 0.5
B-012 EXHAUST GAS TEMP SENSOR #2
252 BK 0.5 R-005 FUEL FILTER HEATER
83 EXHAUST GAS TEMP GND 2 2
1 PWR
T째 84
GND
X-018
EXHAUST GAS TEMP SIGNAL 2
X-018
A
1
273 YE 0.5 X-007
X-012
X-012
SH39: D-1 SH39: D-1 SH39: C-1
RE003
FUEL FILTER HEATER GND
347 BL 0.8
A
2
272 BK/WH 0.5
70
242 YE 0.8 245 YE 0.5
270 BK/WH 0.5
SH39: C-1
271 YE 0.5
SH39: C-1
249 YE 0.5
SH39: C-1
252 BK 0.5
SH39: C-1
253 PK 0.5
6
5
4
3 SHT_6
1
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Electrical systems - Harnesses and connectors
Wiring harnesses - Electrical schematic sheet 07 SH07-ENGINE F5C T4 SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
Type ECU Sensor Sensor Sensor Sensor Sensor Sensor Sensor Sensor Sensor Sensor Connector Connector Connector Solenoid Solenoid Solenoid Solenoid Solenoid Solenoid
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(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
Component A-005+ B-013 B-014 B-016 B-017 B-018 B-019 B-020 B-021 B-022 B-055 X-015 X-016 X-017 Y-046 Y-047 Y-048 Y-049 Y-050 Y-051
Connector / Link X-016
X-015 X-016 X-017
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Description ENGINE CONTROL UNIT RAIL PRESSURE SENSOR INCREMENT SPEED SENSOR SEGMENT SPEED SENSOR COOLANT TEMPERATURE SENSOR FUEL TEMPERATURE SENSOR EXHAUST GAS PRESSURE SENSOR BOOST PRESSURE / AIR TEMPERATURE SENSOR TVA PIERBURG EGR PIERBURG OIL PRESSURE SWITCH X-15 LEFT DRIVE PUMP REVERE INJECTOR ELECTRIC VALVE INJECTOR ELECTRIC VALVE INJECTOR ELECTRIC VALVE INJECTOR ELECTRIC VALVE FUEL METERING UNIT ELECTRIC VALVE (WG)
CYL CYL CYL CYL
1 3 4 2
Electrical systems - Harnesses and connectors
6
5
4
3
2
1 241C OR 0.8
SH6: B-6
Y-046 A-005+
INJECTOR ELECTRIC VALVE CYL 1
SH39: D-1
241C OR 0.8
ENGINE CONTROL UNIT
X-015 CDB-007
16
CDB-007
274 WH 1.0
A A
Y-051
INJECTOR 1 HIGH BANK 1
ELECTRIC VALVE (WG) 32
275 GY 1.0
B B
CDB-018
INJECTOR 1 LOW BANK 1
D
X-017
CDB-018
28
28
27
27
D
4 Y-047
294 GY 1.0
BOOST PRESSURE ACTUATOR 1
INJECTOR ELECTRIC VALVE CYL 3 CDB-008
31
CDB-008
276 GY 1.0
C C
INJECTOR 1 LOW BANK 2
B-019 EXHAUST GAS PRESSURE SENSOR
1
277 WH 1.0
D D
INJECTOR 1 HIGH BANK 2 12 EXHAUST GAS PRESSURE SUPPLY
295 PK 0.5
21
21
296 BK/WH 0.5
22
22
297 YE 0.5
23
23
DP
Y-048
27
INJECTOR ELECTRIC VALVE CYL 4
EXHAUST GAS PRESSURE GROUND CDB-010
17
CDB-010
43 EXHAUST GAS PRESSURE SIGNAL INJECTOR 2 HIGH BANK 1
278 WH 1.0
E E
48
279 GY 1.0
F
F
B-022
INJECTOR 2 LOW BANK 1
EGR ACTUATOR MOTOR PLUS
Y-049
EGR PIERBURG 50
CDB-019
CDB-019
321 WH 0.8
29
29
322 GY 0.8
30
30
318 PK 0.5
33
33
327 YE 0.5
34
34
337 BK/WH 0.5
35
35
INJECTOR ELECTRIC VALVE CYL 2 CDB-011
C
CDB-011
46
280 GY 1.0
G G
INJECTOR 2 LOW BANK 2 2
281 WH 1.0
H H
EGR ACTUATOR MOTOR MINUS
EGR POSITION SENSOR SUPPLY INJECTOR 2 HIGH BANK 2 EGR POSITION SENSOR SIGNAL
35
C
9
39
X-015
B-055
X-017
OIL PRESSURE SWITCH
24 CDB-016
3
CDB-016
3
6
658 YE 0.5
EGR POSITION SENSOR GROUND OIL PRESSURE SWITCH
B-013
B-021
RAIL PRESSURE SENSOR
TVA PIERBURG 26 5
5
RAIL PRESSURE GROUND
282 BL 0.5
DP
49
CDB-020
CDB-020
TVA ACTUATOR MOTOR PLUS
338 WH 0.8
37
37
339 GY 0.8
38
38
340 PK 0.5
41
41
341 YE 0.5
42
42
342 BK/WH 0.5
43
43
41 6
6
283 YE 0.5
7
7
284 PK 0.5
34
RAIL PRESSURE SIGNAL TVA ACTUATOR MOTOR MINUS 11
8
RAIL PRESSURE SUPPLY TVA POSITION SENSOR SUPPLY
53
B-014 TVA POSITION SENSOR SIGNAL
INCREMENT SPEED SENSOR CDB-017
B
CDB-017
9
9
285 YE 0.5
10
10
286 YE 0.5
37
59 TVA POSITION SENSOR GROUND SPEED SIGNAL PLUS
B
44 SPEED SIGNAL MINUS B-020
B-016
BOOST PRESSURE / AIR TEMPERATURE SENSOR
SEGMENT SPEED SENSOR 14 4
4
287 YE 0.5 28
8
8
288 BL 0.5 13
12
12
289 PK 0.5
BOOST PRESSURE SUPPLY SEGMENT SPEED SIGNAL SEGMENT SPEED GROUND
10
343 PK 0.5
17
17
344 YE 0.5
18
18
345 BK/WH 0.5
19
19
346 YE 0.5
20
20
T°
DP
40
BOOST PRESSURE SIGNAL SEGMENT SPEED SUPLY 25 BOOST PRESURE GROUND
B-017 55
COOLANT TEMPERATURE SENSOR
TEMPERATURE SIGNAL 58 13
13
290 BL 0.5
14
14
291 YE 0.5
COOLANT TEMP GROUND
Y-050
57
FUEL METERING UNIT
COOLANT TEMP SIGNAL 60
A
FUEL METERING UNIT
B-018
CDB-021
CDB-021
298 GY 1.0
2
2
299 WH 1.0
1
1
A
FUEL TEMPERATURE SENSOR 15 23 15
15
292 BL 0.5
16
16
293 YE 0.5
FUEL METERING UNIT SUPPLY FUEL TEMP GROUND
38
X-016
X-017
6
X-017 FUEL TEMP SIGNAL
5
X-016
4
3 SHT_7
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Electrical systems - Harnesses and connectors
Wiring harnesses - Electrical schematic sheet 08 SH08-ENGINE F5C T4 SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
Type Relay Relay Motor Motor Switch Connector Connector Connector Connector Connector Connector Connector Connector Connector Sub-Assembly
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Component K-007 K-008 M-003 M-005 S-078 X-025 X-078 X-078A X-078B X-079 X-316 X-ECU_MAIN_RLY X-FUSE1 X-FUSE2 Z-FUSE2
(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Description
Connector / Link
X-025 X-078 X-078A X-078B X-079 X-316 X-ECU_MAIN_RLY X-FUSE1 X-FUSE2 X-FUSE2
ENGINE RELAY A ECU MAIN RELAY FUEL PUMP M PRIMER SWITCH X-25 X-78 X-78A X-78B IGNITION BACKFEED DIODE ECU MAIN RELAY
POWER DISTRIBUTION EH CHASSIS
Electrical systems - Harnesses and connectors
6
5
4
3
2
1
Z-FUSE2
D
D
POWER DISTRIBUTION EH CHASSIS K-007 ENGINE RELAY A
SH2: D-1
87A
42
30
54
86
256 RD 2.0
53
87
SH4: A-6
520 WH 2.0 SH37: B-6
41
85
121 YE 0.8
SH39: B-6
121 YE 0.8 X-FUSE2
161 YE 0.8
SH37: C-6
161 YE 0.8
SH39: A-6
X-FUSE2
K-008
C
C
ECU MAIN RELAY X-ECU_MAIN_RLY SP-527 527A RD 8.0
BATT+
X-ECU_MAIN_RLY
3
30
87
5
1
86
85
2
527B RD 8.0
527C RD 0.5
X-316 1
1
2
2
527D RD 5.0
112 BL 0.5
SH37: A-6
112 BL 0.5
SH6: C-6
527C RD 0.5 SP-528RH
528F OR 5.0
528F OR 5.0 3
528A OR 8.0
3
908F BK/WH 5.0
SH5: B-1
SH2: A-6
SP-527RH
527D RD 5.0 SH2: A-6
528A OR 8.0 527B RD 8.0
X-025
908A BK 5.0
X-316
SH6: D-6
908A BK 5.0
B
B
X-079
528E OR 2.0 SH37: D-1
528E OR 2.0
1
SH6: D-1
600 WH 0.8
2
SH6: C-1
601 YE 0.8
3
SH5: C-1
1086 BK 2.0
4
CCV HEATERS
X-079
S-078 PRIMER SWITCH
M-003 X-079
X-078A A A
X-079
600XXX OR 0.8
X-078
OUT1 IN
A A
BK 0.0
OUT2
C C
WH 0.0
B B
X-079
A
FUEL PUMP
RD 0.0
X-078B
600AXXX OR 0.8
A A
A
X-079
M
X-078 B B
B B
1086XXX BK 0.8 X-078A
6
5
4
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Electrical systems - Harnesses and connectors
Wiring harnesses - Electrical schematic sheet 09 SH09-THROTTLE SENSORS SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
Type Sensor Sensor Connector Connector Connector Connector
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(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
Component B-023 B-024 X-020 X-095 X-20A X-C23
Connector / Link X-20A X-020 X-020 X-095 X-20A X-C23
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Description HAND THROTTLE SENSOR FOOT THROTTLE SENSOR FOOT THROTTLE SENSOR X-95 HAND THROTTLE INSTRUMENT CLUSTER
Electrical systems - Harnesses and connectors
6
5
4
3
2
1
D
D
B-023 HAND THROTTLE SENSOR A
544 YE 0.8
SH27: C-1
1071 BK/WH 0.8
SH27: C-1
260 PK 0.8
SH27: D-1
B
C
X-20A
B-024
C
C
FOOT THROTTLE SENSOR
A SH14: A-6
545 YE 0.8 B
SH15: C-6
1066 BK/WH 0.8 C
SH15: C-6
211 PK 0.8 X-020
X-095
B
1 1
522 YE 0.8
3 3
521 YE 0.8
SH13: C-1
B
SH13: C-1 SP-140 SH27: C-6
5 5
199 OR 0.8
6 6
523 YE 0.8
7 7
197 OR 0.8
8 8
1024 BL 0.8
SH14: B-1
9 9
1023 BL 0.8
SH14: C-1
195 OR 0.8
SH13: C-1
DRIVE PATTERN SELECTOR SW
198 OR 0.8
10 10 X-095
A
A
6
5
4
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Electrical systems - Harnesses and connectors
Wiring harnesses - Electrical schematic sheet 10 SH10-EH PUMP/HYDRAULICS SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
Type Sensor Sensor Motor Motor Motor Motor Switch Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Solenoid Solenoid
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Component B-025 B-026 M-013 M-016 M-017 M-018 S-039 X-013 X-016 X-017 X-018 X-093 X-094 X-BRK X-BRKPRS X-CN3B X-RDCTRL Y-008 Y-010
(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
Connector / Link X-094 X-093 X-013 X-016 X-017 X-018 X-013 X-016 X-017 X-018 X-093 X-094 X-BRK X-BRKPRS X-CN3B X-RDCTRL
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Description LH PUMP SWASH PLATE SENSOR RH PUMP SWASH PLATE SENSOR LEFT DRIVE PUMP FORWARD LEFT DRIVE PUMP REVERSE RIGHT DRIVE PUMP FORWARD RIGHT DRIVE PUMP REVERSE BRAKE PRESSURE SWITCH GCU LEFT DRIVE PUMP REVERE FUEL FILTER HEATER RH PUMP SWASH PLATE SENSOR LH PUMP SWASH PLATE SENSOR X-BRK X-BRKPRS UCM CN3B X-RDCTRL BRAKE VALVE SOLENOID RIDE CONTROL SOLENOID
Electrical systems - Harnesses and connectors
6
5
4
3
2
1
B-025 LH PUMP SWASH PLATE SENSOR
1
GND #1
1054 BK/WH 0.8
SH5: C-6
574 YE 0.8
SH21: D-6
573 YE 0.8
SH21: D-6
1073 BK/WH 0.8
SH5: D-6
5 REF #1
209 PK 0.8
3
ANGLE #2
D
4
ANGLE #1
2
D
REF #2
222 PK 0.8
6
GND #2
X-094
X-094
SH3: D-1
SP-136
102 OR 0.8
B-026 RH PUMP SWASH PLATE SENSOR
1
GND #1
1055 BK/WH 0.8
SH5: C-6
575 YE 0.8
SH20: B-1
576 YE 0.8
SH20: B-1
1074 BK/WH 0.8
SH5: D-6
5 REF #1
221 PK 0.8
3
ANGLE #2
4
ANGLE #1
2 REF #2
223 PK 0.8
6
GND #2
X-093
X-093 M-018
C
C
RIGHT DRIVE PUMP REVERSE 2
1 SH20: D-1
M
518 WH 0.8
1041 BL 0.8 X-018
X-018
SP-099
M-016
1022 BL 0.8
SH20: C-6
1021 BL 0.8
SH20: B-1
LEFT DRIVE PUMP REVERSE 2
1 SH20: C-1
M
517 WH 0.8
1039 BL 0.8 X-016
X-016 M-017
RIGHT DRIVE PUMP FORWARD 2
1 SH21: B-6
M
519 WH 0.8
1040 BL 0.8 X-017
X-017
SP-098
M-013 LEFT DRIVE PUMP FORWARD 2
1 SH21: B-6
M
516 WH 0.8
1038 BL 0.8
B
B
X-013
X-013
Y-010 RIDE CONTROL SOLENOID X-RDCTRL SH13: B-6
IN
1 1
831 WH 0.8
X-RDCTRL
OUT
2 2
SH5: A-1
951 BK 0.8
X-RDCTRL
X-RDCTRL Y-008 BRAKE VALVE SOLENOID X-BRK SH21: D-6
IN
1 1
258 WH 0.8
X-BRK
OUT
2 2
SH5: B-1
960 BK 0.8
X-BRK
X-BRK
S-039 BRAKE PRESSURE SWITCH
A
X-BRKPRS SH20: C-1
1 1
535 YE 0.8
X-BRKPRS 2
1
2 2
X-BRKPRS
6
5
SH5: B-1
1064 BK 0.8 X-BRKPRS
4
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Electrical systems - Harnesses and connectors
Wiring harnesses - Electrical schematic sheet 11 SH11-HYDRAULIC INTERLOCKS SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
Type Switch Connector Connector Connector Connector
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Component S-006 X-904 X-CN2A X-PLTLK X-PORT_LK
(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
Connector / Link X-904 X-CN2A X-PLTLK X-PORT_LK
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Description BOOM LOCK INTERLOCK SWITCH UCM CN2A PILOT INTERLOCK PORT LOCK
Electrical systems - Harnesses and connectors
6
5
4
3
2
1
D
D
U-001 LOADER PORT LOCK SP-187 1
C
308 YE 0.8
SH32: B-5
537 WH 0.8
SH20: D-1
C
304 WH 0.8
2 957 BK 0.8
SH5: A-1
X-PORT_LK
U-002 LOADER PILOT INTERLOCK
A
536 WH 0.8
SH20: D-1
1063 BL 0.8
SH5: B-1
B
X-PLTLK
B
B
S-006 BOOM LOCK INTERLOCK SWITCH
SH2: C-1
X-904
5
X-904
C
NOT USED
A
6
A
B
1102 OR 0.8
SH20: C-1
1103 YE 0.8 X-904
A
X-904
4
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Electrical systems - Harnesses and connectors
Wiring harnesses - Electrical schematic sheet 12 SH12-LOADER VALVE AND SENSORS SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
Type Sensor Sensor Sensor Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Solenoid Solenoid Solenoid Solenoid Solenoid Solenoid
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Component B-027 B-028 B-029 X-010 X-021 X-022 X-023 X-024 X-025 X-026 X-027 X-028 X-029 X-088 X-88 X-CN1A Y-003 Y-006 Y-007 Y-009 Y-011 Y-012
(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
Connector / Link X-023 X-021 X-022 X-010 X-021 X-022 X-023 X-024 X-025 X-026 X-027 X-028 X-029 X-088 X-88 X-CN1A
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Description AUXILIARY SPOOL POSITION SENSOR BUCKET SPOOL POSITION SENSOR BOOM SPOOL POSITION SENSOR X-010 X-21 X-22 X-23 X-24 X-25 X-26 X-27 X-28 X-29 X-88 X-88 UCM CN1A BUCKET VALVE RETRACT BUCKET VALVE EXTEND LOADER VALVE RETRACT LOADER VALVE EXTEND PROPORTIONAL AUX VALVE EXTEND PROPORTIONAL AUX VALVE RETRACT
Electrical systems - Harnesses and connectors
6
5
4
3
2
1
1018A BL 0.8 Y-003 X-088
D
X-025 1
1
2
2
3
3
X-025
BUCKET VALVE RETRACT
D
SP-154
1 1
510A WH 0.8
2 2
X-025
1078 BL 0.8
X-025 Y-006 BUCKET VALVE EXTEND
X-026
X-026
1 1
511A WH 0.8
2 2
X-026 4
1079 BL 0.8
X-026
570A YE 0.8
4
Y-007 LOADER VALVE RETRACT
X-027
X-027
1059 BK/WH 0.8 5
5
512A WH 0.8
6
6
1019A WH 0.8
2 2
1 1
1080 WH 0.8 1 SP-108
X-027
X-027
PWR
7
7
513A WH 0.8
8
8
571A YE 0.8
9
9
B-027
OUT
4
X-028 2 2
1 1
X-023
1081 WH 0.8
X-028
X-028
C
3
AUXILIARY SPOOL POSITION SENSOR X-023
Y-009 LOADER VALVE EXTEND
X-028
GND
208x PK 0.8
1060A BK/WH 0.8
C
1057 BK/WH 0.8 SP-130 X-029
10
10
515A WH 0.8
11
11
1020A BL 0.8
SP-135
Y-012 PROPORTIONAL AUX VALVE RETRACT
1 1
PWR
GND
3
OUT
4
B-028
206x PK 0.8
X-029
BUCKET SPOOL POSITION SENSOR 2 2
X-029
1
X-021
1082 BL 0.8 SP-156
X-029
X-021 Y-011 PROPORTIONAL AUX VALVE EXTEND
X-024 1 12
1 1
514A WH 0.8
12
X-024 13
X-024 2 2
1083 BL 0.8
1058 BK/WH 0.8 1
X-024
572A YE 0.8
13
PWR
GND
3
B-029
207x PK 0.8 BOOM SPOOL POSITION SENSOR
14
236A PK 0.8
14
X-022
OUT
4
X-88 X-022
B
B X-010
CHASSIS/ LOADER INTERFACE
A
1
1
510 WH 0.8
SH21: B-6
2
2
1018 BL 0.8
SH20: D-6 SH21: D-1
3
3
511 WH 0.8
4
4
570 YE 0.8
SH21: B-6
5
5
512 WH 0.8
SH21: C-6
6
6
1019 BL 0.8
SH20: C-1
7
7
513 WH 0.8
SH21: C-6
8
8
571 YE 0.8
SH21: B-6 SH5: C-6
9
9
1060 BK/WH 0.8
10
10
515 WH 0.8
SH20: C-6
11
11
1020 BL 0.8
SH20: C-6
12
12
514 WH 0.8
SH20: B-6
13
13
572 YE 0.8
SH21: B-6
14
14
236 PK 0.8
SH20: D-6
X-010
6
5
4
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Electrical systems - Harnesses and connectors
Wiring harnesses - Electrical schematic sheet 13 SH13-BULKHEAD CONNECTION SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
Type Switch Connector Connector Connector Connector Connector Connector Connector Connector Solenoid Solenoid
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Component S-029 X-101 X-101A X-101B X-311 X-BULKHEAD X-CPLR X-ECC X-HFLO Y-004 Y-013
(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
Connector / Link X-101 X-101B X-101A X-101 X-101A X-101B X-311 X-BULKHEAD X-CPLR X-ECC X-HFLO
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Description STD/ON-ROAD LAMP CONFIGURATOR ON ROAD LIGHT CONFIGURATOR ON ROAD LIGHT CONFIGURATOR STANDARD ON ROAD LIGHT CONFIGURATOR OPTION LAMP SELECTOR SWITCH CAB/CHASSIS INTERCO X-CPLR EH CHASSIS/CAB INTERFACE X-HFLO STD HIGH FLOW SOLENOID HYDRAULIC COUPLER SOLENOID
Electrical systems - Harnesses and connectors
6
5
4
S-029 STD/ON-ROAD LAMP CONFIGURATOR
3
2
1
X-ECC
X-101B SH3: A-6
711 VT 2.0
SH2: D-6
710 VT 2.0
SP-024
702 VT 2.0
791 VT 3.0
5
5
1
1
SH22: A-1
791 VT 3.0
X-101 X-101A
D
SH2: D-6
701 VT 0.8
SH2: D-6
700 VT 0.8
SH38: B-6
237 WH 3.0
SH2: D-1
836 RD 3.0
SH28: C-1
237 WH 3.0 SP-160
2
2
836 RD 3.0
3
3
792 VT 3.0
4
4
SH28: D-1
838 RD 1.0 792 VT 3.0
SH2: D-6 SH2: A-1
123 OR 3.0
SH2: C-1
334 OR 2.0
6
6
SH22: A-1
123 OR 3.0
SH22: A-1
334 OR 2.0
SH19: B-1
334 OR 0.8
SH19: B-1 SH32: B-5
207 TN 2.0 SH32: C-5
207A TN 2.0
SH39: D-6
C
SH20: B-1 SH20: C-6
SH32: A-5
207 TN 0.8
8
769 OR 2.0
SH24: D-6
SH25: B-6
8
770 OR 0.8
SH17: D-6
783 OR 1.0
SH24: C-6
784 OR 1.0
SH16: B-6
785 OR 0.8
SH16: B-6
SP-138
769 OR 2.0
9
769 OR 2.0
9
774 VT 0.8
10
10
774 VT 0.8
SH24: B-6
398 YE 0.8
11
11
398 YE 0.8
SH16: B-1
521 YE 0.8
12
12
521 YE 0.8
SH9: B-2
SH28: C-1
SH39: B-6
D
SH28: B-6
839 RD 3.0
C
841 WH 0.8
SH37: B-6
841 WH 0.8
14
14
841 OR 0.8
SH20: B-1
522 YE 0.8
15
15
522 YE 0.8
SH9: B-2
SH3: B-1
233 OR 2.0
16
16
233 OR 2.0
SH26: C-6
SH20: B-1
523 YE 0.8
17
17
523 YE 0.8
SH9: B-2
SH21: B-6
312 YE 0.8
18
18
312 YE 0.8
SH16: B-1
SH21: C-6
548 GN 0.8
19
19
548 GN 0.8
SH30: B-1
SH20: C-6
560 GN 0.8
20
20
560 GN 0.8
SH30: B-1
21
21
129 OR 1.0
SH33: B-5
22
856 WH 1.0
SH33: B-5
549 WH 0.8
SH30: C-1
SH3: B-6
129 OR 1.0
SH31: C-5
856 WH 1.0
22
SH21: C-1
549 WH 0.8
23
23
24
24
SP-053 SH3: C-1
744 OR 2.0
B
744 OR 2.0
Y-013 HYDRAULIC COUPLER SOLENOID
X-CPLR SH5: A-1
SH16: A-6
751 OR 0.8
SH16: D-6
558 OR 0.8
SH17: C-6
B
X-CPLR 1 1
2 2
978 BK 0.8
753 OR 0.8
752 WH 0.8
25
25 SH16: D-1
752 WH 0.8 X-CPLR
X-CPLR SH21: B-6
755 WH 0.8
26
26
755 WH 0.8
SH16: A-1
SH10: B-6
831 WH 0.8
27
27
831 WH 0.8
SH18: B-1
28
28
Y-004
SH5: A-1
976 BK 0.8
X-HFLO
STD HIGH FLOW SOLENOID
X-HFLO 2 2
1
1
750 WH 0.8
SH16: A-1 SH19: B-1
750 WH 0.8 333 YE 2.0
X-HFLO
X-HFLO
SH19: A-6
333 YE 2.0
7 29
1051 BK/WH 0.8
30
30
SH20: B-1
562 GN 0.8
31
31
562 GN 0.8
SH30: B-6
SH20: B-1
568 GN 0.8
32
32
568 GN 0.8
SH30: B-6
33
561 WH 0.8
SH5: C-6
A
SH19: B-1
333 YE 0.8
7 29
SH21: D-1
SH34: B-5
554 WH 0.8
33
SH34: C-5
552 WH 0.8
34
34
SH39: C-6
SH30: C-1
561 WH 0.8
SH18: B-6
1051 BK/WH 0.8
SH17: C-1
554 WH 0.8
SH17: C-1
552 WH 0.8
780 VT 0.8
SH37: C-6
SH24: C-6
13
13
SH21: C-1
567 WH 0.8
35
35
567 WH 0.8
SH30: C-6
SH21: D-1
569 WH 0.8
36
36
569 WH 0.8
SH30: C-6
780 VT 0.8
780 VT 0.8
X-BULKHEAD
6
5
4
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Electrical systems - Harnesses and connectors
Wiring harnesses - Electrical schematic sheet 14 SH14-BULKHEAD CONNECTION SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
Type Sensor Ground Connector Connector Connector Connector Connector Solenoid
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Component B-003 GND-006 X-318 X-BULKHEAD X-ECC X-HVC1 X-OILTMP Y-318
(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
Connector / Link X-OILTMP GND-006 X-318 X-BULKHEAD X-ECC X-HVC1 X-OILTMP
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Description HYDRAULIC OIL TEMP SENDER SELF LEVEL VALVE CAB/CHASSIS INTERCO EH CHASSIS/CAB INTERFACE CAB/HVAC INTERCONNECT HYDRAULIC OIL TEMPERATURE SENDER SELF LEVEL VALVE
Electrical systems - Harnesses and connectors
6
5
4
3
2
X-ECC
1
359 OR 0.8
SH33: C-5
352 OR 0.8
SH18: D-6
SP-062
D
SH3: B-1
354 OR 0.8
37
37
SH31: C-5
410 WH 0.8
38
SH31: C-5
411 TN 0.8
SH31: C-5
416 VT 0.8
SH31: C-5 SH31: C-5
353 OR 0.8
SH17: C-6
38
410 WH 0.8
SH18: D-1
39
39
411 TN 0.8
SH18: D-1
40
40
416 VT 0.8
SH18: C-1
417 RD 0.8
41
41
417 RD 0.8
SH18: C-1
418 GY 0.8
42
42
418 GY 0.8
SH17: C-1
43
43
NOT USED
354 OR 0.8
NOT USED
SH31: C-5
419 LG 0.8
44
44
419 LG 0.8
SH17: C-1
SH29: A-6
892 WH 0.8
45
45
892 WH 0.8
SH17: B-1
SH21: C-1
546 YE 0.8
46
46
546 YE 0.8
SH18: C-6
SH20: D-6
210 PK 0.8
47
47
210 PK 0.8
SH18: C-6 SH28: C-1
SH2: D-1
844 OR 5.0
48
48
844 OR 5.0
SH2: A-1
798 VT 5.0
49
49
797 VT 5.0
SH24: A-6
SH20: D-6
200 PK 0.8
50
50
214 PK 0.8
SH18: C-6
SH20: B-1
547 YE 0.8
51
51
215 RD 0.8
SH30: C-6
219 RD 0.8
SH30: C-1
200 PK 0.8 SP-132
Y-318 SELF LEVEL VALVE
X-318
C
X-318
SH18: C-6
547 YE 0.8 2 2
949 BK 0.8
SH5: A-1
1 1
52
404 WH 0.8
52
C
SH16: C-1
404 WH 0.8 X-318
X-318
B
D
SH37: C-6 SH39: C-6 SH2: C-1
248 YE 0.8 248 YE 0.8
53
53
248 YE 0.8
SH35: B-5
795 VT 5.0
54
54
795 VT 5.0
SH24: A-6
SH2: D-1
843 OR 5.0
55
55
843 OR 5.0
SH28: C-1
SH28: A-6
824 YE 0.8
56
56
824 YE 0.8
SH28: B-6
SH5: D-6
1090 BK/WH 0.8
57
57
1090 BK/WH 0.8
SH18: C-6
SH20: C-1
1023 BL 0.8
58
58
1023 BL 0.8
SH9: B-2
59
833 WH 0.8
SH28: C-1
SH37: C-6
833 WH 0.8
59
SH39: B-6
833 WH 0.8
60
60
SH20: C-1
1024 BL 0.8
61
61
1024 BL 0.8
SH9: B-2
SH20: B-1
754 YE 0.8
62
62
754 YE 0.8
SH18: A-1
SH21: C-1
541 YE 0.8
63
63
541 YE 0.8
SH23: C-6
SH20: B-1 SH39: B-6
531 YE 0.8
64
64
531 YE 0.8
SH18: B-1
65
65
834 WH 0.8
SH28: C-1
834 WH 0.8 834 WH 0.8
SH37: C-6 CDB-003 SH37: B-6
CDB-003
B
503C YE 0.8
SH37: B-6
504C GN 0.8
SP-503A
CDB-002
CDB-002
CDB-006
CDB-006
CDB-013
CDB-013
SH32: C-5
503B YE 0.8
503A YE 0.8
66
66
503A YE 0.8
SH35: C-5
SH32: C-5
504B GN 0.8
504A GN 0.8
67
67
504A GN 0.8
SH35: C-5
SH21: D-1
524 YE 0.8
68
68
524 YE 0.8
SH5: C-6
910 BK/WH 1.0
69
69
910 BK/WH 0.8
SH32: B-5
70
70
234 YE 0.8
SH27: B-1
832 OR 0.8
SH18: B-6
891 OR 0.8
SH17: B-6
SP-504A
SH39: A-6 SH37: A-6
234 RD 0.8 234 RD 0.8 CBD-023
CBD-023
SH39: C-6 SH39: B-6
SH19: B-1
504C GN 0.8 503C YE 0.8 SP-106
SH32: D-5
357 OR 1.0
71
71
SH2: D-6
115 RD 2.0
72
72
115 RD 2.0
SH16: C-6
73
73
264 YE 0.8
SH27: B-6
357 OR 1.0
B-003 HYDRAULIC OIL TEMP SENDER T
1
264 YE 0.8 X-OILTMP
A
A
GND-006 SH2: D-6
310 RD 0.8
74
74
310 RD 0.8
SH27: C-6
SH9: C-2
545 YE 0.8
75
75
545 YE 0.8
SH27: C-1
76
76
790 VT 1.0
SH22: A-1
790 VT 2.0
SH22: A-1
SH2: B-6
790 VT 1.0
X-BULKHEAD
6
5
4
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Electrical systems - Harnesses and connectors
Wiring harnesses - Electrical schematic sheet 15 SH15-BULKHEAD CONNECTION SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
Type Ground Switch Connector Connector Connector Connector Connector
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Component GND-012 S-044 X-271 X-316 X-BULKHEAD X-ECC X-OILFLT
(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
Connector / Link GND-012 X-OILFLT X-271 X-316 X-BULKHEAD X-ECC X-OILFLT
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Description HYDRAULIC FILTER RESTRICTION SWITCH WATER VALVE IGNITION BACKFEED DIODE CAB/CHASSIS INTERCO EH CHASSIS/CAB INTERFACE HYDRAULIC OIL FILTER SWITCH
Electrical systems - Harnesses and connectors
6
5
4
3
2
1
X-ECC
D
SH3: C-6
175 WH 0.8
SH39: A-6
86
86
175 WH 0.8
SH27: B-1
D
267 YE 0.8
SH37: A-6
267 YE 0.8
82
82
267 YE 0.8
SH27: B-6
SH2: A-1
134 OR 2.0
77
77
134 OR 2.0
SH29: C-6
SH19: B-6
329 YE 0.8
78
78
329 YE 0.8
SH19: C-1
SH2: C-1
309 OR 1.0
79
79
309 OR 1.0
SH27: C-6
SH21: C-6
303 WH 0.8
80
80
303 WH 0.8
SH27: B-1
81
81
261 YE 0.8
SH27: D-6
S-044 HYDRAULIC FILTER RESTRICTION SWITCH 2
1
1
261 YE 0.8 X-OILFLT
GND-012
C
SH9: C-2
1066 BK/WH 0.8
83
83
SH37: B-6
622 WH 0.8
84
84
SH27: C-1
1066 BK/WH 0.8
C
SH27: B-1
622 WH 0.8 V-007 IGNITION BACKFEED DIODE 1
SH2: A-6
144 OR 0.8
85
85
SH9: C-2
211 PK 0.8
87
87
N
144 OR 0.8
P
X-316
2 SH27: B-1
133 OR 0.8 X-316
SH27: D-1
211 PK 0.8 823 PK 0.8
SH28: A-6
821 OR 3.0
SH28: C-1
846 OR 8.0
SH28: C-1
SP-091 SH28: A-6
822 OR 0.8
88
SH19: B-6
332 YE 0.8
89
89
332 YE 0.8
SH19: A-6
330 YE 0.8
90
90
330 YE 0.8
SH19: B-1
91
91
205C YE 0.8
SH27: B-6
92
92
507 WH 0.8
SH35: B-5
93
93
508 BL 0.8
SH35: B-5
94
94
208 BL 0.8
SH32: A-5
NOT USED
95
95
NOT USED
NOT USED
96
96
NOT USED
NOT USED
97
97
NOT USED
NOT USED
98
98
NOT USED
NOT USED
99
99
NOT USED
NOT USED
100
100
NOT USED
NOT USED
101
101
NOT USED
NOT USED
102
102
NOT USED
NOT USED NOT USED NOT USED
B
822 OR 0.8
88
SH32: C-5
208 BL 0.8
SH19: B-1
CDB-022
CDB-022
B
X-BULKHEAD
A
A
6
5
4
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Electrical systems - Harnesses and connectors
Wiring harnesses - Electrical schematic sheet 16 SH16-LEFT HAND CAB CONSOLE SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
Type Diode Switch Switch Switch Switch Switch Switch Switch Connector Connector Connector Connector Connector Connector Connector Connector Connector Sub-Assembly
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Component D-001 S-001 S-005 S-009 S-011 S-013 S-041 S-042 X-178 X-300 X-301 X-302 X-303 X-306 X-317 X-365 X-ACC Z-008
(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
Connector / Link X-301 X-306 X-300 X-365 X-317 X-302 X-303 X-178 X-300 X-301 X-302 X-303 X-306 X-317 X-365 X-ACC X-ACC
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Description ROTATING BEACON SWITCH LOADER LOCKOUT SWITCH HYDRAULIC COUPLER SWITCH NH PARK BRAKE SWITCH SELF LEVEL SWITCH HAZARD LAMP SWITCH HIGH FLOW SWITCH BEACON LAMP SOCKET HYDRAULIC COUPLER SWITCH BEACON LAMP SWITCH HAZARD LAMP SWITCH HI FLOW SWITCH LOADER LOCKOUT SW SELF LEVEL SWITCH NH PARK BRAKE SWITCH ACCESSORY POWER OUTLET ACCESSORY POWER OUTLET
Electrical systems - Harnesses and connectors
6
5
4
3
2
1
S-009 HYDRAULIC COUPLER SWITCH 2 SH13: B-1
3
751 OR 0.8
752 WH 0.8
SH13: B-1
916 BK 0.8
SH29: D-6
927 BK 2.0
SH24: B-6
934 BK 0.8
SH29: C-6
940 BK 3.0
SH5: D-1
761 VT 0.8
SH22: A-1
952 BK 0.8
SH5: D-1
X-300
D
9
918 BK 0.8 X-300
SP-026
D
S-001 ROTATING BEACON SWITCH D
796 VT 0.8 X-301 A
919 BK 0.8 X-301 Z-008 ACCESSORY POWER OUTLET SP-033 SH14: A-1
115 RD 2.0
B
A
801 RD 0.8 X-ACC
X-ACC S-013 SELF LEVEL SWITCH
C
C
E
D SH29: D-1
405 OR 0.8
SH14: C-1
404 WH 0.8 X-317 A
922 BK 0.8 X-317 S-011 NH PARK BRAKE SWITCH
SH27: C-6
2
3
X-365
X-365
194 OR 0.8
306 YE 0.8
SH18: A-1
312 YE 0.8
SH13: C-1
398 YE 0.8
SH13: C-1
776 VT 1.0
SH24: B-6
778 VT 0.8
SH24: C-6
915 BK 0.8
SH23: C-1
917 BK 0.8
SH23: C-1
941 BK 0.8
SH5: D-1
750 WH 0.8
SH13: B-1
755 WH 0.8
SH13: B-1
S-005 LOADER LOCKOUT SWITCH E D SH27: C-6
C
311 OR 0.8
B
X-306
B
A
924 BK 0.8 X-306 S-041 HAZARD LAMP SWITCH B SH13: C-1
784 OR 1.0
SH13: C-1
785 OR 0.8
A
F
E
X-302 C
920 BK 0.8 X-302 SP-025
S-042 HIGH FLOW SWITCH A
921 BK 0.8
A C D SH13: B-1
E
753 OR 0.8 X-303
X-303
6
5
4
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A
Electrical systems - Harnesses and connectors
Wiring harnesses - Electrical schematic sheet 17 SH17-LEFT NH CONTROL HANDLE SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
Type Switch Switch Switch Switch Switch Switch Connector Connector Solenoid Sub-Assembly
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(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
Component S-015 S-023 S-024 S-027 S-032 S-033 X-2SPD X-408 Y-005 Z-005
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Description
Connector / Link HORN 2 SPEED TURN SIGNAL SWITCH
X-2SPD X-408 X-408
2ND AUX HYDRAULIC 2 SPEED VALVE SOLENOID LH HANDLE INTERCONNECT 2 SPEED SOLENOID LEFT CONTROL HANDLE
Electrical systems - Harnesses and connectors
6
5
4
3
2
1
D
D Z-005 LEFT CONTROL HANDLE
S-027 TURN SIGNAL SWITCH 6
LEFT
5 SH13: C-1
770 OR 0.8
768 VT 0.8
SH24: B-6
765 VT 0.8
SH24: C-6
554 WH 0.8
SH13: A-1
552 WH 0.8
SH13: A-1
7 RIGHT
S-033 2ND AUX HYDRAULIC 2
EXT(UP)
1 SH13: B-1
3
558 OR 0.8 RET(DN)
C
C S-015 10 SH14: D-1
11
UP
#2
353 OR 0.8
S-032
SH18: C-1 SH18: C-1
418 GY 0.8
SH14: D-1
419 LG 0.8
SH14: D-1
563 WH 0.8
SH23: C-6
892 WH 0.8
SH14: D-1
13
UP
#3
414 VT 0.8 415 RD 0.8
12
DN
14
DN
S-024 2 SPEED
9
4 SH14: A-1
891 OR 0.8 X-408 S-023 HORN
8
IN X-408
B
Y-005 2 SPEED SOLENOID
X-2SPD SH21: C-6
X-2SPD B B
A A
564 WH 0.8
B
X-2SPD
SH5: B-1
953 BK 0.8
X-2SPD
A
A
6
5
4
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Electrical systems - Harnesses and connectors
Wiring harnesses - Electrical schematic sheet 18 SH18-RIGHT NH CONTROL HANDLE SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
Type Switch Switch Switch Switch Switch Switch Switch Connector Connector Sub-Assembly
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Component S-007 S-014 S-018 S-022 S-031 S-036 S-037 X-403 X-406 Z-012
(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
Connector / Link
X-403 X-406 X-406 X-403
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Description FLOAT SWITCH PARK BRAKE SWITCH RIDE CONTROL/ GLIDE RIDE
RH HANDLE INTERCONNECT F RH HANDLE INTERCONNECT P RIGHT CONTROL HANDLE
Electrical systems - Harnesses and connectors
6
5
4
3
2
1
Z-012 RIGHT CONTROL HANDLE
D
D S-031 5 SH14: D-1
#1
352 OR 0.8
UP
6
DN
7
410 WH 0.8
SH14: D-1
411 TN 0.8
SH14: D-1
415 RD 0.8
SH17: C-1
417 RD 0.8
SH14: D-1
427 RD 0.8
SH33: C-5
425 VT 0.8
SH33: C-5
416 VT 0.8
SH14: D-1
414 VT 0.8
SH17: C-1
S-022 #2
UP
8
DN
9
412 VT 0.8
NOT USED IN 47803842
413 RD 0.8
S-036 10 SH14: C-1
SV SP-064
214 PK 0.8 PROP A 11
SH14: D-1
546 YE 0.8
C
GND
SP-169 SH30: C-1
1047 TN 0.8
12 SP-063
SH30: C-6
C
1053 BK/WH 0.8
1045 TN 0.8
SH14: C-1
1090 BK/WH 0.8
SH30: C-6
218 OR 0.8
SH30: C-1
217 OR 0.8
S-037 SP-137 SH14: D-1
210 PK 0.8
1
213 PK 0.8 2
SH14: C-1
547 YE 0.8
SH13: A-1
1051 BK/WH 0.8 1048 BK 0.8
SH30: B-6
1046 BK 0.8
PROP A
GND
SP-126
SH30: B-1
SV
3
1052 BK/WH 0.8
B
B
S-007 FLOAT SWITCH 14
13 SH18: A-6
406 OR 0.8
531 YE 0.8
SH14: B-1
831 WH 0.8
SH13: B-1
306 YE 0.8
SH16: C-1
754 YE 0.8
SH14: B-1
X-403
X-403
S-018 RIDE CONTROL/ GLIDE RIDE C SH14: A-1
D
832 OR 0.8
S-014 PARK BRAKE SWITCH SH18: B-6
406 OR 0.8
SH27: C-6
320 OR 0.8
SP-105
A
SP-006
B
324 OR 0.8
307 YE 0.8 X-406
X-406
A
A
6
5
4
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Electrical systems - Harnesses and connectors
Wiring harnesses - Electrical schematic sheet 19 SH19-RIGHT NH CONTROL HANDLE SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
Type Resistor Switch Switch Switch Connector Connector Connector Sub-Assembly
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(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
Component R-001 S-002 S-003 S-043 X-104 X-58 X-90 Z-006
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Description
Connector / Link
X-104 X-58 X-90 X-58
SEAT HEAT ELEMENT SEAT SWITCH SEAT HEAT SWITCH LAP BAR SWITCH X-104 CAB/SEAT INTERFACE DIODE PACK SEAT
Electrical systems - Harnesses and connectors
6
5
4
3
2
1
Z-006 SEAT
S-003
D
D
SEAT HEAT SWITCH
1 SH29: D-1
756 OR 1.0 2
933 BK 1.0
SH28: D-1
933 BK 1.0
SH5: D-1
328 YE 0.8
SH27: B-6
329 YE 0.8
SH15: D-1
R-001 SEAT HEAT ELEMENT
S-002 SEAT SWITCH
C
SP-012 SH27: B-6
317 RD 0.8
SP-086
3
4
315 RD 0.8
C
323 YE 0.8
X-58
X-58
S-043 LAP BAR SWITCH
X-104 1 1
316 RD 0.8
X-104 2 2
314 YE 0.8
X-104
X-104
DIODE MODULE P1
DIODE MODULE 228174A1 REPLACE V-005 EH LAP BAR DIODE V-009 EH SEAT SW UCM DIODE V-005 EH UCM WAKEUP DIODE
A
N1
B
P2
C
N2
E
N3
F
X-90
SH15: D-6
SH15: B-1
D
P3
B
SH14: B-1
524 YE 0.8 332 YE 0.8 330 YE 0.8 334 OR 0.8
SH15: B-1 SH13: D-1
334 OR 2.0
SH13: D-1
333 YE 0.8
SH13: A-1
333 YE 2.0
SH13: B-1
B
329 YE 0.8
SH15: B-6
SP-101
332 YE 0.8
SH21: B-6
526 YE 0.8
SH15: B-6
330 YE 0.8
SH20: C-6
525 YE 0.8
SH13: A-6
333 YE 2.0
SP-100
A
A
6
5
4
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Electrical systems - Harnesses and connectors
Wiring harnesses - Electrical schematic sheet 20 SH20-UNIVERSAL CONTROL MODULE SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
Type
Component
ECU
A-002A
Resistor Connector Connector Connector Connector Connector
R-002 X-CN1A X-CN1B X-CN2A X-CN2B X-FUSE1
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(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
Connector / Link X-CN1A X-CN2A X-CN1B X-CN2B X-CN1A X-CN1B X-CN2A X-CN2B X-FUSE1
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Description UNIVERSAL CONTROL MODULE CAN TERMINATOR UCM CN1A UCM CN1B UCM CN2A UCM CN2B
Electrical systems - Harnesses and connectors
6
5
4
3
2
1
A-002A UNIVERSAL CONTROL MODULE
D
D 2 LEFT PUMP REVERSE POWER
1 SH5: B-6
UCM GROUND 1A.01
1075 BK/WH 0.8
SH5: B-6
8 SH14: D-6
210 PK 0.8
LOADER PILOT INTERLOCK SENSOR SUPPLY 1
202 PK 0.8
SW POWER PORT/PILOT LOCK 1
9 SENSOR SUPPLY 3
200 PK 0.8
BUCKET RETURN
1018 BL 0.8
SH19: A-6
525 YE 0.8
SH4: B-6
124 YE 0.8
SW POWER PORT/PILOT LOCK 2
REV DRIVE RETURN
240 OR 0.8
SH4: A-1
240 OR 0.8
SH5: B-6
1026 BK/WH 0.8
PROPORTIONAL AUX RETRACT
9
1025 BK/WH 0.8 13
560 GN 0.8 15
521 YE 0.8
SH3: D-1
128 OR 0.8
SH3: C-1
SH39: B-6
721 VT 0.8
SH10: A-6
562 GN 0.8
SH13: A-6
158 OR 0.8
SH3: C-1
522 YE 0.8
SH13: C-6
523 YE 0.8
SH13: C-6
754 YE 0.8
SH14: B-6
398 YE 0.8
SH13: C-6
532 YE 0.8
SH37: B-6
8
CONTROL PATTERN NEUTRAL
EHF RETURN 9 SW POWER LOADER CONTROL 13 PARK BRAKE PRESSURE SWITCH 14
BRAKE LAMP CIRCUIT OUTPUT #2
LH UA2 X SENSOR OUTPUT 17
BRAKE LAMP CIRCUIT OUTPUT #1 SWITCHED POWER LOADER CONTROL
31 SWITCHED POWER BRAKE LAMP
21
RH UA2 X SENSOR OUTPUT 33
20
CONTROL PATTERN H
32
201 OR 0.8
SH3: C-1
535 YE 0.8
LOADER RETURN
SWITCHED POWER PROP AUX RETRACT
166 OR 0.8
514 WH 0.8
154 OR 0.8
7 RH UA2 Y SENSOR OUTPUT
SWITCHED POWER PROP AUX EXTEND
30
SH12: A-1
SH12: B-1
PATTERN INDICATOR ISO LS OUTPUT
579 VT 0.8
SH3: D-1
SH14: C-6
1019 BL 0.8
2 UCM GROUND 1B.26
27
580 VT 0.8 SP-150
SH3: D-1
1023 BL 0.8
C
X-CN2A
26
29
721 VT 0.8
SH5: C-6
UCM GROUND 1B.34
126 OR 0.8
SH37: A-6
1027 BK/WH 0.8
26
5V REV SUPPLY FUSE X-CN1A 1
SH13: C-6
SH14: B-6
25 PIN24 UCM GROUND 2A.26
SH13: B-6
SH5: A-6
1024 BL 0.8
PIN23
26 SH4: B-1
SH11: A-2
1077 BK/WH 0.8 23
PROPORTIONAL AUX RETURN 24
515 WH 0.8
SH10: C-6
20 UCM GROUND 2A.20
22
1020 BL 0.8
517 WH 0.8 17
BOOM LOCK INTERLOCK SWITCH UCM UNSW BATT
189 RD 0.8
SH5: C-6
SH3: B-1
1103 YE 0.8
PUMP LEFT RESERVE
20
C
163 OR 0.8 14
ENGINE RPM SIGNAL 19
SH12: A-1
SH10: C-6
13
UCM WAKE-UP
1022 BL 0.8
SH12: A-1
SH3: B-1
518 WH 0.8 9
16
SH2: D-6
SH11: C-2
159 OR 0.8
HYDRAULIC CHARGE PRESSURE SWITCH
14
SH10: C-1
SH11: B-2
537 WH 0.8
8 PUMP RIGHT RESERVE
13 SH12: B-1
536 WH 0.8
7
236 PK 0.8
SH14: C-6
SH3: D-1
5 LOADER PORT LOCK
SP-134 SH12: A-1
SH3: D-1
165 OR 0.8 4
UCM GROUND 1A.07
1076 BK/WH 0.8
164 OR 0.8 3
RIGHT PUMP REVERSE POWER
7
CONTROL PATTERN ISO 22
PROPORTIONAL AUX EXTEND
PARK BRAKE SWITCH 23 LOADER LOCKOUT SWITCH NO OUTPUT
X-CN1B
B
24 ENGINE START INPUT
B
25
1021 BL 0.8
SH10: B-1
1028 BK/WH 0.8
SH5: B-6
531 YE 0.8
SH14: B-6
547 YE 0.8
SH14: C-6
568 GN 0.8
SH13: A-6
576 YE 0.8
SH10: C-1
575 YE 0.8
SH10: C-1
DRIVE FORWARD RETURN 26 UCM GROUND 2B.26 27 LOADER FLOAT SWITCH INPUT 28 PROPORTIONAL AUX SWITCH #2 R-002
31 LH UA2 Y SENSOR OUTPUT
CAN TERMINATOR CDB-012
CDB-012
SH32: C-5
503E YE 0.8
SH32: C-5
504E GN 0.8
1
32
CAN HI RH PUMP ANGLE #1
LOAD 10
CAN LO
33
120.0
RH PUMP ANGLE #2 34 UCM GROUND 2B.34
X-CN2B
SH5: B-6
1029 BK/WH 0.8
X-CN2B
A
A
6
5
4
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Electrical systems - Harnesses and connectors
Wiring harnesses - Electrical schematic sheet 21 SH21-UNIVERSAL CONTROL MODULE SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
Type
Component
ECU
A-002A
Connector Connector Connector Connector Connector
X-CN3A X-CN3B X-CN4A X-CN4B X-FUSE1
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(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
Connector / Link X-CN1A X-CN2A X-CN1B X-CN2B X-CN3A X-CN3B X-CN4A X-CN4B X-FUSE1
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Description UNIVERSAL CONTROL MODULE UCM UCM UCM UCM
CN3A CN3B CN4A CN4B
Electrical systems - Harnesses and connectors
6
5
4
3
2
1
A-002A UNIVERSAL CONTROL MODULE
D
D 2 SH3: D-1
168 OR 0.8
SH3: D-1
169 OR 0.8
SWITCHED POWER PARK BRAKE 1 SWITCHED POWER BUCKET CONTROL 1
3
SWITCHED POWER PARK BRAKE 2 PARK BRAKE VALVE SIGNAL
258 WH 0.8
EHF RETRACT SIGNAL SWITCHED POWER TWO SPEED 1
170 OR 0.8
524 YE 0.8
SH14: B-6
561 WH 0.8
SH13: A-6
569 WH 0.8
SH13: A-6
511 WH 0.8
SH12: B-1
1034 BK/WH 0.8
SH5: D-6
549 WH 0.8
SH13: B-6
567 WH 0.8
SH13: A-6
1035 BK/WH 0.8
SH5: B-6
18 LH UA1 Y SENSOR OUT
9 SH10: D-1
LH PUMP ANGLE #1
574 YE 0.8
19 BUCKET EXTEND SIGNAL
10 SH10: D-1
LH PUMP ANGLE #2
573 YE 0.8
20 UCM GROUND 4A.20
11 SH13: B-6
RH UA2 X SENSOR OUT
548 GN 0.8
24 RH UA1 X SENSOR OUT
13 SH3: B-6
SWITCHED POWER TWO SPEED 2
171 OR 0.8 19
25 LH UA1 X SENSOR OUT
EHF EXTEND SIGNAL
26
20 SH5: B-6
UCM GROUND 4A.26 UCM GROUND 3A.20
1030 BK/WH 0.8
X-CN4A
21 SH3: C-1
SH3: C-1
17 RH UA1 Y SENSOR OUT
7
SH3: B-6
SH3: C-1
0061 OR 0.8 10
SEAT BELT OPERATOR INTERLOCK 6
0060 OR 0.8 8
SWITCHED POWER BUCKET CONTROL 2
4 SH10: A-6
1
PUMP FORWARD POWER
120 OR 0.8 22
C
SH12: B-1
512 WH 0.8
SH15: D-6
303 WH 0.8
SH17: B-6
564 WH 0.8
SH5: B-6
1031 BK/WH 0.8
LOADER LOWER SIGNAL 23
C
HYDRAULIC LOADER INTERLOCK SIGNAL 25 2 SPEED VALVE SOLENOID 26 UCM GROUND 3A.26 X-CN3A 3
SH2: C-1
SW POWER BACKUP ALARM
167 OR 0.8
13 EHF INTERLOCK
6 SH12: A-1
LOADER RAISE SIGNAL
513 WH 0.8
SH3: C-1
SW POWER BUCKET CONTROL 1
142 OR 0.8
SW POWER BUCKET CONTROL 2
147 OR 0.8
HIGH FLOW SIGNAL
755 WH 0.8
SH5: B-6
1037 BK/WH 0.8
SH5: B-6
CONTROL VALVE BUCKET POSITION
570 YE 0.8
X-CN4B
13 SH12: A-1
SH14: D-6
1036 BK/WH 0.8 34
UCM GROUND 4B.34
12 SH12: B-1
SH14: B-6
546 YE 0.8 27
UCM GROUND 4B.27
11 SH13: B-6
SH31: B-5
541 YE 0.8 21
PROPORTIONAL AUX SWITCH #1
9 SH3: C-1
423 YE 0.8 15
2 SPEED UCM INPUT
8
CONTROL VALVE LOADER POSITION
571 YE 0.8 14
SH12: A-1
572 YE 0.8
SH12: B-1
510 WH 0.8
SH37: C-6 SH39: C-6 SH13: C-6
895 WH 0.8 895 WH 0.8 312 YE 0.8
CONTROL VALVE AUX POSITION 17 BUCKET RETRACT SIGNAL 18
B
BACKUP ALARM SIGNAL 19
B
LOADER LOCK SWITCH NC OUT
26 SH5: B-6
UCM GROUND 3B.26
1032 BK/WH 0.8 29
2ND AUX EXTEND SWITCH OUT
NOT USED 30 SH19: B-6
SEAT SW OPERATOR INTERLOCK
526 YE 0.8 31 NOT USED
2ND AUX RETRACT SIGNAL POWER
32 SH10: B-6
519 WH 0.8
SH10: B-6
516 WH 0.8
SH5: B-6
1033 BK/WH 0.8
PUMP RIGHT FORWARD 33 PUMP LEFT FORWARD 34 UCM GROUND 3B.34 X-CN3B
A
A
6
5
4
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Electrical systems - Harnesses and connectors
Wiring harnesses - Electrical schematic sheet 22 SH22-LAMPS SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
Type Lamp Lamp Lamp Lamp Lamp Lamp Lamp Power outlet Switch Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector
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(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
Component E-001 E-002 E-003 E-021 E-023 E-024 E-025 J-001 S-012 X-077 X-085 X-086 X-178 X-311 X-341 X-342 X-343 X-344 X-68 X-82
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Description
Connector / Link X-085 X-086 X-178 X-341
RH DIA SIDE LAMP LH DIA SIDE LAMP ROTATING BEACON LH REAR STROBE
X-343
RH FRONT STROBE
X-077 X-311 X-077 X-085 X-086 X-178 X-311 X-341 X-342 X-343 X-344 X-68 X-82
SIDE LAMP DIA SOCKET LAMP SELECTOR SWITCH SIDE LAMP DIA SOCKET X-85 X-86 BEACON LAMP SOCKET LAMP SELECTOR SWITCH X-341 X-342 X-343 X-344 X-68 X-82
Electrical systems - Harnesses and connectors
6
5
4
3
2
1
E-023 LH FRONT STROBE 2
1
740 VT 0.8
1005 BK 0.8 3
681 PK 0.8
X-344
D
D
X-344 E-021 LH REAR STROBE 2
1
758 VT 0.8
1007 BK 0.8 3
683 PK 0.8
X-341 X-68 X-341 PWR
SP-082
738 VT 0.8
SP-083
E-024 RH FRONT STROBE
SP-084 2
1 GND
1003 BK 0.8
739 VT 0.8
1004 BK 0.8 3
X-68
680 PK 0.8
X-343 X-343 E-025 RH REAR STROBE 2
1
757 VT 0.8
1006 BK 0.8 3
682 PK 0.8
X-342 X-342
C
C
E-001 RH DIA SIDE LAMP 1
P
2
N
0063A VT 0.8 X-085
X-085
1097 BK 0.8
X-82 PWR
0062A BK 1.0
GND
1096A BK 1.0
SP-191A E-002 LH DIA SIDE LAMP SP-192A
X-82
1
P
N
2
0064A VT 0.8 X-086
X-086
1098A BK 0.8
B
B
J-001 SIDE LAMP DIA SOCKET 2
238 VT 0.8
SH24: A-6
1085 BK 0.8
SH26: C-6
1
X-077
E-003 ROTATING BEACON 1
2
N
P
S-012 LAMP SELECTOR SWITCH A 1
A
761 VT 0.8
SH16: D-1
928 BK 0.8
SH26: C-6
X-178
X-178
D
IN
2
B
3
C
SH14: A-1
790 VT 2.0
X-311
790 VT 1.0
SH14: A-1
791 VT 3.0
SH13: D-1
792 VT 3.0
SH13: D-1
A
X-311
123 OR 3.0
6
5
4
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2
SH13: D-1
1
Electrical systems - Harnesses and connectors
Wiring harnesses - Electrical schematic sheet 23 SH23-INDICATORS SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
Type Lamp Connector Connector Connector Connector Connector Sub-Assembly
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Component E-004 X-155B X-156B X-157B X-310 X-408 Z-004
(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
Connector / Link X-155B X-157B X-156B X-155B X-156B X-157B X-310 X-408 X-310
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Description TURN SIGNAL INDICATOR TURN SIGNAL INDICATOR R TURN SIGNAL INDICATOR L TURN SIGNAL INDICATOR G 2 SPD INDICATOR LH HANDLE INTERCONNECT 2 SPEED INDICATOR
Electrical systems - Harnesses and connectors
6
5
4
3
2
1
D
D
Z-004 2 SPEED INDICATOR SH14: B-1
541 YE 0.8 SP-035
7
9
565 VT 0.8 SH17: B-1
917 BK 0.8
563 WH 0.8
SH16: A-1
X-310
X-310
C
C E-004 TURN SIGNAL INDICATOR 1
771 VT 0.8
SH24: C-6
PWR1
X-155B 1
772 YE 0.8
SH24: B-6
GND
1
915 BK 0.8
SH16: A-1
X-157B
PWR2
X-156B
B
B
A
A
6
5
4
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Electrical systems - Harnesses and connectors
Wiring harnesses - Electrical schematic sheet 24 SH24-EU LIGHT ADAPTER SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
Type Switch Connector Connector Connector Connector Connector Connector Sub-Assembly
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Component S-034 X-030 X-031 X-411 X-CTS X-FUSE1 X-HZRDDIODE Z-013
(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
Connector / Link X-CTS X-030 X-031 X-411 X-CTS X-FUSE1 X-HZRDDIODE X-411
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Description TURN SIGNAL SWITCH X-31 FLASHER MODULE TURN SIGNAL SWITCH X-HZRDDIODE FLASHER MODULE
Electrical systems - Harnesses and connectors
6
D
5
4
3
2
1
Z-013 FLASHER MODULE SH5: A-1
981 BK 0.8
SH5: C-1
981 BK 0.8
SH13: C-6
769 OR 2.0
SH39: D-1
769 OR 2.0
SH2: D-1
156 RD 2.0
SH39: D-1
156 RD 2.0
D
X-411 85
Y
87A
30
S-034 TURN SIGNAL SWITCH D
777 VT 1.0
E SH13: C-1
783 OR 1.0
F
775 VT 1.0
C
C
X-CTS X-CTS
V-010 HAZARD SWITCH INDICATOR BACKFEED DIODE X-HZRDDIODE SH16: B-1
778 VT 0.8
SH13: A-1
780 VT 0.8
SH17: D-1
765 VT 0.8
SH23: C-6
771 VT 0.8
X-HZRDDIODE 2
P
N
1
781 VT 0.8
SP-019
SH17: D-1
768 VT 0.8
SH23: C-6
772 YE 0.8
SH13: C-1
774 VT 0.8
SH16: B-1
776 VT 1.0
SP-018
X-031
B
799 VT 2.0
1 1
794 VT 2.0
2 2
3 3
773 VT 0.8
SH16: D-1
B
4 4
927 BK 2.0
X-031
798 VT 2.0 SH14: C-1
X-030
797 VT 5.0
797A VT 2.0
1 1
793 VT 2.0
2 2
779 VT 1.0
3 3
926 BK 2.0
4 4
SP-016 SH14: C-1
795 VT 5.0 SP-015
SH22: B-1
238 VT 0.8
SH26: C-6
A
A
X-030 SH5: D-1
6
939 BK 2.0
5
4
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Electrical systems - Harnesses and connectors
Wiring harnesses - Electrical schematic sheet 25 SH25-BOOM ROAD LIGHTS SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
Type Lamp Lamp Lamp Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Sub-Assembly Sub-Assembly Sub-Assembly Sub-Assembly
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Component E-005 E-006 E-007 X-034 X-035 X-037 X-039 X-044 X-049 X-080 X-081 X-196 X-198 X-201 X-205 X-228 X-229 X-230 X-231 X-232 X-233 X-FUSE1 Z-001 Z-002 Z-009 Z-011
(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
Connector / Link X-035 X-034 X-080 X-081 X-034 X-035 X-037 X-039 X-044 X-049 X-080 X-081 X-196 X-198 X-201 X-205 X-228 X-229 X-230 X-231 X-232 X-233 X-FUSE1 X-228 X-229 X-198 X-037 X-196 X-044
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Description RH REAR WORK LH REAR WORK LICENSE PLATE
LH FRONT ROAD LAMP RH FRONT ROAD LAMP CHASSIS OPTIONS/ LH BOOM LIGHTS INTERCONNECT
LH FRONT ROAD LAMP RH FRONT ROAD LAMP LH REAR ROAD LAMPS RH REAR ROAD LAMPS
Electrical systems - Harnesses and connectors
6
5
4
3
2
1 E-005 RH REAR WORK
X-039 A A
732 VT 0.8
B B
897 VT 0.8
1
N
P
2
729 VT 1.0 LH REAR POSITION LAMP
X-035
X-035 C C
1091 BK 0.8
E-006 LH REAR WORK
X-039 1
D
P
N
2
D
728 VT 1.0
X-049 SP-079 A A RH REAR POSITION LAMP
734 VT 1.0
X-034
X-034
B B
Z-009 LH REAR ROAD LAMPS
C C
1092 BK 0.8 B
X-049
TAIL C GND1
A
STOP X-037
732A VT 0.8 X-037 A
C
GND2
TURN
X-198
X-198 DOOR/CHASSIS INTERFACE X-205 SH38: B-3
E-007
REAR LAMP JUMPER
LICENSE PLATE
X-201
706 VT 3.0
1
1
REAR WORK LAMP POWER
1
1
730 VT 2.0
704 VT 0.8
2
2
RH TAIL LAMP POWER
2
2
733 VT 0.8
703 VT 0.8
3
3
LH TAIL LAMP POWER
3
3
731 VT 0.8
950 BK 3.0
4
4
REAR LAMP GROUND
4
4
1000 BK 0.8
1
N
P
1
898 VT 0.8
950 BK 3.0
SP-190 5
5
LH REAR POSITION LAMP
5
5
717B VT 0.8
718 VT 0.8
6
6
RH REAR POSITION LAMP
6
6
718A VT 0.8
C
Z-011 RH REAR ROAD LAMPS
703 VT 0.8
717 VT 0.8
X-081
B
TAIL
A
STOP
717 VT 0.8
C
BRAKE LAMP SIGNAL POWER
7
7
737 VT 0.8
LH REAR TURN SIGNAL POWER
11 11
735 VT 0.8
7
X-044
734A VT 0.8 SP-081
X-044
766 VT 0.8
A
763 VT 0.8
12 12
RH REAR TURN SIGNAL POWER
12 12
736 VT 0.8
SH5: C-1
975 BK 3.0
13 13
REAR LAMPS GROUND
13 13
975 BK 3.0
SH5: C-1
975 BK 3.0
GND2
C
X-196
X-196
X-201
X-201
TURN
997 BK 2.0
7
11 11
721 VT 0.8
996 BK 2.0
721 VT 0.8 766 VT 0.8
GND1
998 BK 0.8
SH37: A-1 SH39: B-1 SH37: B-1 SH39: B-1 SH25: A-6
X-080
704 VT 0.8
999 BK 0.8
C
SH37: B-1 SH39: B-1 SH37: A-1 SH39: A-1 SH5: C-1 SH5: C-1 SH37: C-1 SH39: B-1 SH25: A-6
1002 BK 0.8 1095 BK 0.8 SP-170
1001 BK 0.8 963 BK 2.0
SH38: C-2
SP-080
B
Z-001
X-232
X-230
B
LH FRONT ROAD LAMP SH5: B-1
D D
979 BK 1.0
SH39: B-6 SH3: B-1
717 VT 0.8 716 VT 1.0
SH37: C-6
717 VT 0.8
SH37: B-6
766A VT 0.8
D D
979A BK 1.0 SP-074
SP-059 A A
712 VT 1.0
A A
712A VT 1.0
2
742 VT 0.8 LOW BEAM 4
SH13: C-6
774 VT 0.8
SH39: B-6
766 VT 0.8
GND
1
741 VT 0.8 B B
767 VT 0.8 SP-051
B B X-230
POSITION
767A VT 0.8
X-228
5
X-232
TURN X-228
X-231
A
SH5: C-1
980 BK 1.0
SH39: C-1 SH37: C-1
719 VT 1.0 719 VT 1.0
SH25: C-6
718 VT 0.8
SH25: C-6
763 VT 0.8
SH37: C-1
780 VT 0.8
SH39: C-1
780 VT 0.8
Z-002 RH FRONT ROAD LAMP
X-233 D D
D D
980A BK 1.0
A A
A A
713A VT 1.0
SP-075
SP-060
713 VT 1.0
2
540 VT 0.8 LOW BEAM 4
GND
1
A
539 VT 0.8 764 VT 0.8 SP-052
B B
B B X-231
POSITION
764A VT 0.8
X-229 5
X-233
TURN X-229
6
5
4
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Electrical systems - Harnesses and connectors
Wiring harnesses - Electrical schematic sheet 26 SH26-WIPERS / WASHERS SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
Type Motor Switch Switch Connector Connector Connector Connector Connector Sub-Assembly Sub-Assembly
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(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
Component M-506 S-016 S-038 X-502 X-502A X-503 X-505 X-506 Z-010 Z-014
Connector / Link X-503 X-502 X-502A X-503 X-505 X-506 X-502 X-502A
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Description FRONT DOOR WASHER PUMP WIPER/WASHER SWITCH DOOR SWITCH DOOR WIPER MOTOR REAR WINDOW WIPER MOTOR WIPER/WASHER SWITCH X-505 X-506 DOOR WIPER MOTOR REAR WIPER MOTOR
Electrical systems - Harnesses and connectors
6
5
4
3
2
1
Z-010 DOOR WIPER MOTOR
D
D
A
227 WH 0.8 D SH27: B-6
S M
220 YE 0.8 C
231 OR 0.8 B
929 BK 0.8 X-502
912 BK 0.8
SH28: B-6
913 BK 0.8
SH28: B-1
939 BK 5.0
SH5: D-1 SH24: A-6
926 BK 2.0 SP-014
SH5: D-1
M-506 FRONT DOOR WASHER PUMP
937 BK 3.0
C
SH22: B-1
1085 BK 0.8
SH22: A-1
928 BK 0.8
X-506
X-506
SP-027
M
A
1 1
970 BK 0.8
B
2 2
X-506
C
X-506
S-016 WIPER/WASHER SWITCH SH5: D-1
931 BK 0.8 1
931 BK 0.8
3
229 OR 0.8
2
SP-022
225 WH 0.8 SH13: C-1
SP-023
233 OR 2.0
6
230 OR 0.8
5
E
224 WH 0.8
CAB EH BS T4
X-503 7
226 VT 0.8 932 BK 0.8
8
X-502A
X-503
B
SH5: D-1
932 BK 0.8
B
A
228 WH 0.8 M C
232 OR 0.8
Z-014 REAR WIPER MOTOR
B
930 BK 0.8
S-038 DOOR SWITCH
X-505 SH5: D-6
2
2 2
1016 BK/WH 0.8
X-505
1
1 1
SH27: B-6
250 YE 0.8
X-505
X-505
A
A
6
5
4
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Electrical systems - Harnesses and connectors
Wiring harnesses - Electrical schematic sheet 27 SH27-INSTRUMENT CLUSTER SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
Type ECU Connector Connector Connector
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(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
Component A-001 X-015 X-365 X-C23
Connector / Link X-C23 X-015 X-365 X-C23
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Description INSTRUMENT CLUSTER X-15 NH PARK BRAKE SWITCH INSTRUMENT CLUSTER
Electrical systems - Harnesses and connectors
6
5
4
3
2
1
D
D
A-001 INSTRUMENT CLUSTER 2 SH15: C-1
HYDRAULIC OIL FILTER
261 YE 0.8
THROTTLE SENSOR SUPPLY
211 PK 0.8
SH15: C-1
260 PK 0.8
SH9: C-2
544 YE 0.8
SH9: D-2
SP-201
17
259 PK 0.8
3 SH4: C-1
KEY START OUTPUT
624 WH 0.8 CDB-015
CDB-015 SH35: C-5
22
5 THROTTLE SIGNAL
CAN LO
505 GN 0.8 6
SH35: C-5
CAN HI
500 YE 0.8
SP-200
25 SH15: D-1
THROTTLE SENSOR GROUND
309 OR 1.0
SH9: B-2
195 OR 0.8
7
1066 BK/WH 0.8
SH15: C-1
1071 BK/WH 0.8
SH9: C-2
CLUSTER SW POWER 1
301 OR 0.8
C
1070 BK/WH 0.8
C
SP-139 SH16: C-6
194 OR 0.8
305 YE 0.8
SP-010 8 CLUSTER SW POWER 2
302 OR 0.8 SH16: B-6
311 OR 0.8
SH18: A-6
320 OR 0.8
SH35: C-5
162 RD 0.8
SH14: A-1
310 RD 0.8
23
SP-004
545 YE 0.8
SH14: A-1
234 YE 0.8
SH14: B-1
138 OR 0.8
SH4: D-1
175 WH 0.8
SH15: D-1
9 CLUSTER UNSW POWER
313 RD 0.8
24 SH19: C-6
317 RD 0.8
SH4: C-6
140 RD 0.8
SH4: C-1
132 OR 0.8
FUEL LEVEL SENDER
10 KEY IGNITION ACCESSORY RELAY SIGNAL
V-004 ACCESSORY BACKFEED DIODE
X-015
29
137 WH 0.8
X-015 P
2
N
1
153 WH 0.8
SP-009
11 SH15: D-1
AIR FILTER/ENGINE MALFUNCTION
267 YE 0.8
B
X-015
X-015
B
12 SH19: C-1
328 YE 0.8
SH15: B-1
205C YE 0.8
SEAT SWITCH CLUSTER INPUT 30 13
HYDRAULIC LOADER INTERLOCK SIGNAL
303 WH 0.8
SH15: D-1
622 WH 0.8
SH15: C-1
REGENERATION INHIBIT SWITCH 32 START RELAY SIGNAL
16 SH14: A-1
264 YE 0.8
SH26: B-1
250 YE 0.8
HYDRAULIC OIL TEMP SENDER 33 MAIN POWER RELAY SIGNAL SP-093
DOOR SWITCH SIGNAL
251 YE 0.8
SH15: C-1
1011 BK/WH 0.8
SH5: D-6
34 CLUSTER GROUND
SH26: D-6
133 OR 0.8
19
220 YE 0.8
X-C23 X-C23
A
A
6
5
4
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Electrical systems - Harnesses and connectors
Wiring harnesses - Electrical schematic sheet 28 SH28-HVAC SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
Type ECU Relay Switch Switch Switch Connector Connector Connector Connector Connector Connector Connector Connector Connector Solenoid Sub-Assembly Sub-Assembly Sub-Assembly
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Component A-003 K-020 S-017 S-020 S-040 X-011 X-074 X-076 X-111 X-252 X-270 X-271 X-275 X-HVC1 Y-002 Z-017 Z-019 Z-074
(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
Connector / Link X-HVC1 X-111 X-275 X-270 X-011 X-074 X-076 X-111 X-252 X-270 X-271 X-275 X-HVC1 AC-COMP X-252 X-271 X-074
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Description HVAC BOX CONDENSER RELAY A/C SWITCH (LEFT CONSOLE) BLOWER SWITCH (LEFT CONSOLE) HVAC HIGH PRESSURE SWITCH X-11 HVAC CONDENSER FAN X-76 CONDENSER RELAY [CAB] TEMP CONTROL SWITCH BLOWER FAN SWITCH WATER VALVE A/C SWITCH CAB/HVAC INTERCONNECT A/C COMP TEMP CONTROL (LH CONSOLE) WATER VALVE HVAC CONDENSER FAN
Electrical systems - Harnesses and connectors
6
5
4
3
2
1
A-003 HVAC BOX
1087 BK 0.8
SH28: B-6
1088 BK 8.0
SH5: D-1
933 BK 1.0
SH19: D-1
SP-168
1 HVAC GROUND
935 BK 5.0
D
D
2 A/C COMP RELAY PIN 30
SH13: D-1
838 RD 1.0 S-020 BLOWER SWITCH (LEFT CONSOLE)
1 3 HVAC FAN LOW
3
2
4
3
5
4
828 WH 3.0 4
HVAC FAN MEDIUM
827 WH 3.0 SP-164
SP-165
5 HVAC FAN HIGH
850 WH 5.0
848 WH 8.0
826 WH 3.0
IN
2
1 6
SH15: C-1
821 OR 3.0
825 OR 0.8
A/C COMP RELAY PIN 86
837 WH 0.8 X-270
X-270
7
THERMOSTAT PRESSURE SW
833 WH 0.8
SH14: C-1
834 WH 0.8
SH14: B-1
8 BINARY PRESSURE SWITCH 9 THERMOSTAT CLEAN GROUND
C
SH5: D-6
1012 BK/WH 0.8 SP-163
10 HVAC RELAY PIN 87
842 OR 5.0
C
SH15: C-1
846 OR 8.0
11 HVAC KEYED POWER
SH29: D-1
143 OR 0.8 12
A/C COMP RELAY PIN 87
SH13: C-1
841 OR 0.8 SP-171
SP-162
14 HVAC RELAY FUSE POWER
845 OR 5.0
854 OR 8.0
X-HVC1
844 OR 5.0
SH14: C-1
843 OR 5.0
SH14: C-1
SH13: D-1
237 WH 3.0
S-017 A/C SWITCH (LEFT CONSOLE)
K-020 CONDENSER RELAY A
87A 30 SH13: D-1
30
839 RD 3.0
87
87
85
86
B SH26: C-1
913 BK 0.8 85
B
SH28: D-1
86
C
840 WH 0.8
1087 BK 0.8
829 WH 0.8
B
SP-157
X-111
X-111
X-275 X-275
3 SH26: D-1
841C WH 0.8 1
GND
3 3
SH37: B-1
841 WH 0.8
SH39: B-1
834 WH 0.8
AC-COMP
912 BK 0.8
SH14: C-1
2
SGL
1
PWR
2
834C WH 0.8
2
833C WH 0.8
1 1
SH37: C-1
834 WH 0.8
824 YE 0.8
SH15: C-1
Y-002 A/C COMP
S-040 HVAC HIGH PRESSURE SWITCH
X-076
823 PK 0.8
2
B B
1
X-076
Z-019 WATER VALVE
SH14: C-6
D
SGL
C
GND
Z-074 HVAC CONDENSER FAN B
M
1013 BK 0.8 A
SH15: C-6
SH38: B-3
1084 BK 3.0
SH5: C-1
A
X-271
5
237 WH 3.0
M
PWR
822 OR 0.8
6
SH37: C-1
833 WH 0.8 X-011
X-076
824 YE 0.8
SH5: B-1
SH39: B-1
833 WH 0.8
X-076
A A
X-252
A
SH39: B-1
841 WH 0.8
X-011 Z-017 TEMP CONTROL (LH CONSOLE)
X-074
4
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A
Electrical systems - Harnesses and connectors
Wiring harnesses - Electrical schematic sheet 29 SH29-RADIO SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
Type Speaker Speaker Speaker Connector Connector Connector Connector Connector Connector Connector Connector Connector
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Component H-009 H-011 H-012 X-097 X-317 X-330 X-331 X-332 X-333 X-335 X-HORN-GND X-HORN-PWR
(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
Connector / Link X-HORN-PWR X-HORN-GND X-330 X-331 X-333 X-332 X-097 X-317 X-330 X-331 X-332 X-333 X-335 X-HORN-GND X-HORN-PWR
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Description HORN RH SPEAKER LH SPEAKER CAB/DOME LAMP JUMPER SELF LEVEL SWITCH RIGHT SPEAKER RIGHT SPEAKER LEFT SPEAKER LEFT SPEAKER X-335 HORN GROUND HORN POWER
Electrical systems - Harnesses and connectors
6
5
4
3
2
1
D
756 OR 1.0
SH19: D-6
405 OR 0.8
SH16: C-6
143 OR 0.8
SH28: C-1
D
SP-058
152 OR 1.0
X-097 SH16: D-1
916 BK 0.8
2 2 CAB/DOME LAMP JUMPER
151 OR 0.8
1 1 X-097
800 OR 0.8
C
C
X-335 SH15: D-1
134 OR 2.0
151 OR 0.8
9 9
130 OR 0.8
SP-011
SP-021
SH16: D-1
7 7
934 BK 0.8
6 6 RADIO CONNECTOR 1 5 5
450 BL 0.8
H-011
X-331
RH SPEAKER
1 4 4
451 WH 0.8 X-330
2 2 X-335
1
453 WH 0.8 H-012
B
X-332
LH SPEAKER
B
1
452 BL 0.8 X-333
H-009 HORN 1 SH14: D-6
892 WH 0.8
SH5: B-1
955 BK 0.8
X-HORN-PWR 1 X-HORN-GND
A
A
6
5
4
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Electrical systems - Harnesses and connectors
Wiring harnesses - Electrical schematic sheet 30 SH30-UJM CONNECTORS SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
Type Connector Connector
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Component X-UJML X-UJMR
(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
Connector / Link X-UJML X-UJMR
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Description UJM LH X-UJMR
Electrical systems - Harnesses and connectors
6
5
4
3
2
1
D
D
X-UJML
C
C
X-UJMR
SH14: C-1
215 RD 0.8
1
1
1
1
219 RD 0.8
SH14: C-1
SH13: A-1
567 WH 0.8
2
2
2
2
549 WH 0.8
SH13: B-1
SH13: A-1
569 WH 0.8
3
3
3
3
561 WH 0.8
SH13: A-1
SH18: C-6
1045 TN 0.8
4
4
4
4
1047 TN 0.8
SH18: C-6
SH18: C-6
218 OR 0.8
7
7
7
7
217 OR 0.8
SH18: C-6
SH13: A-1
562 GN 0.8
8
8
8
8
548 GN 0.8
SH13: B-1
SH13: A-1
568 GN 0.8
9
9
9
9
560 GN 0.8
SH13: B-1
SH18: B-6
1046 BK 0.8
10
10
10
10
1048 BK 0.8
SH18: B-6
X-UJMR
X-UJML
B
B
A
A
6
5
4
3 SHT_30
1
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Electrical systems - Harnesses and connectors
Wiring harnesses - Electrical schematic sheet 31 SH31-MULTIFUNCTION CONNECTORS SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
Type Connector Connector Connector Connector Connector
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Component X-066 X-107 X-323 X-323A X-FUSE1
(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
Connector / Link X-066 X-107 X-323 X-323A X-FUSE1
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Description MULTIFUNCTION WATER PUMP X-107 CHASSIS OPTIONS/MULTIFUNCTION INTERCONNECT CHASSIS OPTIONS/MULTIFUNCTION INTERCONNECT CAP
Electrical systems - Harnesses and connectors
6
5
4
3
2
1
D
D
X-323
X-107
SH14: D-6
419 LG 0.8
1
1
419 LG 0.8
C
C
SH14: D-6
418 GY 0.8
2
2
418 GY 0.8
D
D
SH14: D-6
410 WH 0.8
3
3
E
E
SH14: D-6
411 TN 0.8
4
4
411 TN 0.8
F
F
SH14: D-6
416 VT 0.8
5
5
416 RD 0.8
H
H
SH14: D-6
417 RD 0.8
6
6
417 VT 0.8
G
G
987 BK 0.8
B
B
422 WH 0.8
J
J
420 OR 3.0
K
K
423 YE 0.8
L
L
C
C
MULTIFUNCTION ATTACHMENT CONNECTOR
SP-982 SH5: A-1
7
982 BK 5.0
982 BK 0.8
7
SP-073 SH13: B-6
856 WH 1.0
8
8
SH3: C-1
420 OR 3.0
9
9
SH21: C-1
423 YE 0.8
10
10
856 WH 0.8
X-107
X-323A
B
B X-066
421 WH 0.8
A A
988 BK 0.8
B B
MULTIFUNCTION WATER PUMP
X-066
A
A
6
5
4
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Electrical systems - Harnesses and connectors
Wiring harnesses - Electrical schematic sheet 32 SH32-TELEMATICS SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
Type Connector Connector Connector Connector
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Component X-FUSE1 X-TELE X-TELE_A X-TELE_DIAG
(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
Connector / Link X-FUSE1 X-TELE X-TELE_A X-TELE_DIAG
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Description TELEMATICS TELEMATICS CAP TELEMATICS DIAGNOSTIC
Electrical systems - Harnesses and connectors
6
5
4
3
2
1
D
D TELEMATICS X-TELE
SH5: A-6
925 BK/WH 0.8
SH37: A-6
1
1
TELEMATICS GROUND
2
2
TELEMATICS IGNITION POWER
503D YE 0.8
3
3
TELEMATICS CAN HI
504D GN 0.8
4
4
TELEMATICS CAN LO
5
5
6
6
TELEMATICS RS232 TX
7
7
TELEMATICS RS232 RX
8
8
TELEMATICS ENGINE ON
not used
9
9
not used
10
10
133B OR 0.8 SP-186
SH14: A-6
357 OR 1.0
SH2: B-1
351 OR 1.0
SH39: A-6 SH14: B-6
802 OR 0.8
133B OR 0.8 CDB-002
CDB-002
503B YE 0.8
SH14: B-6
SP-503B
504B GN 0.8
CDB-009
CDB-009
SP-504B CDB-012
CDB-012
C
SH20: B-6
503E YE 0.8
SH20: B-6
504E GN 0.8
SH15: B-6
208 BL 0.8
C not used
SP-207 SH13: C-6
207A TN 2.0
SH4: B-6
207 TN 0.8
244 YE 0.8
SH11: C-2
308 YE 0.8
11
11
VEHICLE WORKING CONDITION
SH2: A-1
336 RD 1.0
12
12
TELEMATICS UNSWITCHED BATTERY
B
B
TELEMATICS DIAGNOSTIC SH14: B-1
910 BK/WH 0.8
X-TELE_DIAG SP-190
SH5: D-6
910A BK/WH 0.8
206 BK/WH 0.8
SH13: D-1
1
1
GROUND
207 TN 2.0
SH13: C-1
207 TN 0.8
2
2
TELEMATICS RS232 RX
SH15: B-1
208 BL 0.8
3
3
TELEMATICS RS232 TX
4
4
NOT USED
A
A
6
5
4
3 SHT_32
1
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2
1
Electrical systems - Harnesses and connectors
Wiring harnesses - Electrical schematic sheet 33 SH33-MULTIFUNCTION JUMPER SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
Type Connector Connector
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(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
Component X-113 X-401
Connector / Link X-113 X-401
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Description FE #2 SWITCH RH HANDLE INTERCONNECT F
Electrical systems - Harnesses and connectors
6
5
4
3
2
1
D
D
X-113 SH18: C-1
C
425 VT 0.8
D D
SH14: D-1
359 OR 0.8
E E
SH18: C-1
427 RD 0.8
F
FE #2 SWITCH
C
F X-113
X-401 SH13: B-1
129 OR 1.0
A A
SH13: B-1
856 WH 1.0
B B
RH HANDLE INTERCONNECT F
X-401
B
B
A
A
6
5
4
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1
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1
Electrical systems - Harnesses and connectors
Wiring harnesses - Electrical schematic sheet 34 SH34-2ND AUX SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
Type Connector Connector
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Component X-AUX_EXT X-AUX_RET
(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
Connector / Link X-AUX_EXT X-AUX_RET
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Description X-AUX_EXT X-AUX_RET
Electrical systems - Harnesses and connectors
6
5
4
3
2
1
D
D
X-AUX_RET
C
SH13: A-6
552 WH 0.8
1 1
SH5: A-1
959 BK 0.8
2 2
C 2ND AUX RETRACT
X-AUX_RET
X-AUX_EXT SH13: A-6
554 WH 0.8
1 1
SH5: A-1
958 BK 0.8
2 2
2ND AUX EXTEND
B
B X-AUX_EXT
A
A
6
5
4
3 SHT_34
1
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1
Electrical systems - Harnesses and connectors
Wiring harnesses - Electrical schematic sheet 35 SH35-DIAGNOSTIC CONNECTOR SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
Type Connector
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Component X-DIAG
(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
Connector / Link X-DIAG
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Description X-DIAG
Electrical systems - Harnesses and connectors
6
5
4
3
2
1
D
D
X-DIAG
C
SH5: D-6
961 BK/WH 0.8
SH27: C-6
A
A
B
B
501 YE 0.8
C
C
506 GN 0.8
D
D
162 RD 0.8 CDB-015
C
CDB-015
SH27: C-6
500 YE 0.8
SH27: C-6
505 GN 0.8
SP-089
CDB-014
CDB-014
SP-090 CDB-013
CDB-013
SH14: B-1
503A YE 0.8
SH14: B-1
504A GN 0.8
SH14: C-1
248 YE 0.8
CAN DIAGNOSTIC CONNECTOR
E
E
F
F
G
G
CDB-022
CDB-022 SH15: B-1
507 WH 0.8
H
H
SH15: B-1
508 BL 0.8
J
J
B
B
X-DIAG
A
A
6
5
4
3 SHT_35
1
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Electrical systems - Harnesses and connectors
Wiring harnesses - Electrical schematic sheet 36 SH36-FUEL FILTER JUMPER SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
Type Connector Connector
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Component X-9000 X-9001
(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
Connector / Link X-9000 X-9001
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Description TO ENGINE FUEL FILTER
Electrical systems - Harnesses and connectors
6
5
4
3
2
1
D
D
C
C
X-9000
X-9001 1 1
1200 YE 0.8
1 1
2 2
1201 BK 0.8
2 2
TO ENGINE
FUEL FILTER
X-9000
X-9001
B
B
A
A
6
5
4
3 SHT_36
1
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1
Electrical systems - Harnesses and connectors
Wiring harnesses - Electrical schematic sheet 37 SH37-CHASSIS INTERFACE X-900/X-901 LG SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
Type Sensor Connector Connector Connector Connector
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Component B-002 X-014 X-900 X-901 X-FUSE1
(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Description
Connector / Link FUEL LEVEL SENDER X-014 X-900 X-901 X-FUSE1
CROSSOVER BULKHEAD CHASSIS INTERFACE
Electrical systems - Harnesses and connectors
6
5
4
3
2
1
CHASSIS INTERFACE X-900
SH2: B-1
110 OR 2.0
D SH2: A-6
528E OR 2.0
SH3: A-1
719 VT 1.0
SH21: B-6
895 WH 0.8
C SH14: C-6
248 YE 0.8
SH8: D-1
161 YE 0.8
1
2
2
3
3
4
4
5
5
6
6
7
7
8
8
9
9
10
10
110 OR 2.0
SH6: C-6
528E OR 2.0
SH8: B-6
719 VT 1.0
SH25: A-6
895 WH 0.8
SH38: C-6
D
11
11
12
12
13
13
14
14
15
15
16
16
17
17
18
18
19
19
248 YE 0.8
SH6: D-1
20
20
161 YE 0.8
SH6: C-6
21
21
C
SH13: A-6
780 VT 0.8
22
22
780 VT 0.8
SH25: A-6
SH14: C-6
833 WH 0.8
23
23
833 WH 0.8
SH28: A-1
SH14: B-6
834 WH 0.8
24
24
834 WH 0.8
SH28: B-1
25
25
26
26
717 VT 0.8
SH25: C-6
27
27
SH25: B-6
B
1
717 VT 0.8
28
28
SH2: B-1
704 VT 0.8
29
29
704 VT 0.8
SH25: C-6
SH25: B-6
766A VT 0.8
30
30
766 VT 0.8
SH25: C-6
31
31
241A OR 1.0
SH6: B-6
SH2: B-1
241C OR 0.8
32
32
SH8: D-6
121 YE 0.8
33
33
CDB-003
CDB-003
CDB-001
CDB-001
SH14: B-6
504C GN 0.8
34
34
504C GN 0.8
SH6: D-1
SH14: B-6
503C YE 0.8
35
35
503C YE 0.8
SH6: D-1
36
36
37
37
SH15: C-6
622 WH 0.8
626 WH 0.8
B
SH6: C-6
121 YE 0.8
SH6: C-6
626 WH 0.8
SP-102
A
SH20: B-1
532 YE 0.8
SH39: B-6
626 WH 0.8
38
38
SH13: C-6
841 WH 0.8
39
39
841 WH 0.8
SH28: B-1
SH20: B-6
721 VT 0.8
40
40
721 VT 0.8
SH25: C-6
SH32: D-5
133B OR 0.8
41
41
133B OR 0.8
SH6: C-6
SH2: C-1
703 VT 0.8
43
43
703 VT 0.8
SH25: C-6
44
44
267 YE 0.8
SH4: C-6
SH15: D-6
267 YE 0.8
45
45
SH8: C-1
112 BL 0.5
46
46
47
47
42
42
SH6: C-6
112 BL 0.5 B-002 FUEL LEVEL SENDER X-014
SH14: B-6
234 RD 0.8
234 RD 0.8 X-901
X-014 B B
A A X-014
5
4
3 SHT_37
1
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SH39: A-1
234 RD 0.8
CHASSIS INTERFACE
6
SH5: C-1
956 BK 0.8
X-014
2
1
A
Electrical systems - Harnesses and connectors
Wiring harnesses - Electrical schematic sheet 38 SH38-CHASSIS INTERFACE SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
Type Speaker Switch Connector Connector Connector Connector Connector Connector Connector Connector
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Component H-002 S-045 X-011 X-195 X-201 X-205 X-313 X-314 X-315 X-FUSE1
(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Description
Connector / Link X-011 X-011 X-195 X-201 X-205 X-313 X-314 X-315 X-FUSE1
WATER IN FUEL SWITCH X-11 GCU FUSE
GCU POWER CHASSIS POWER
Electrical systems - Harnesses and connectors
6
5
4
3
2
1
DOOR/CHASSIS INTERFACE X-201
X-205
D
SH6: D-6
150 YE 0.8
8
8
8
8
1151 YE 0.8
SH6: D-6
908E BK 0.8
9
9
9
9
909 BK 0.8
SH6: C-6
133E OR 0.8
10
10
10
10
1137 OR 0.8
D 3
PWR
X-011
GND
2
OUT
1
S-045
X-011
WATER IN FUEL SWITCH
J28 SH37: C-1
14
895 WH 0.8
14
14
896 WH 0.0
14
1 1
P
1
N
H-002 SH39: C-1
895 WH 0.8 963 BK 2.0
1 J29
X-205
X-201
SH25: B-1
C
C
CHASSIS POWER
B
B
X-314 SH2: B-1 SH13: D-6 SH2: C-1
155A OR 3.0
1 1
155A OR 3.0
SH6: D-6
237 WH 3.0
2 2
237 WH 3.0
SH28: A-1
706 VT 3.0
3 3
212A OR 5.0
4 4
SH25: C-6
706 VT 3.0 212A RD 5.0
SH6: C-6
212 OR 8.0 SP-212
X-314
X-315 SH5: B-1
2
1087 BK 5.0
REMOTE POWER/GROUND
212B OR 5.0
1 X-315 GCU POWER
A
X-313
SP-212
1
212 OR 8.0
GCU FUSE
212A OR 8.0
1 1
SH6: C-6
212 OR 8.0
A
X-195 X-313
6
5
4
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1
Electrical systems - Harnesses and connectors
Wiring harnesses - Electrical schematic sheet 39 SH39-CHASSIS INTERFACE X-900/X-901 MD SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
Type Connector Connector Connector
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Component X-900 X-901 X-FUSE1
(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
Connector / Link X-900 X-901 X-FUSE1
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Description CROSSOVER BULKHEAD CHASSIS INTERFACE
Electrical systems - Harnesses and connectors
6
5
4
3
2
1
CROSSOVER BULKHEAD X-900 D
C
B
A
SH13: C-6
769 OR 2.0
SH2: B-1 SH2: D-1
110 OR 2.0 156 RD 2.0
SH2: B-1 SH6: B-6 SH6: B-6 SH6: B-6 SH6: A-6 SH6: A-6 SH3: A-1 SH6: B-1 SH6: A-1
241C OR 0.8 242 YE 0.8 245 YE 0.5 249 YE 0.5 252 BK 0.5 253 PK 0.5 719 VT 1.0 270 BK/WH 0.5 271 YE 0.5
SH21: B-6 SH14: A-6 SH14: C-6 SH13: A-6 SH14: B-6 SH14: B-6 SH25: B-6 SH2: B-1 SH25: B-6 SH14: A-6 SH8: D-6 SH37: B-6 SH13: C-6 SH20: B-6 SH32: C-5 SH14: B-6 SH2: C-1 SH15: D-6 SH8: D-1
895 WH 0.8 504C GN 0.8 248 YE 0.8 780 VT 0.8 833 WH 0.8 834 WH 0.8 717 VT 0.8 704 VT 0.8 766 VT 0.8 503C YE 0.8 121 YE 0.8 626 WH 0.8 841 WH 0.8 721 VT 0.8 133B OR 0.8 234 RD 0.8 703 VT 0.8 267 YE 0.8 161 YE 0.8
1 2 3 4 5 6 7 8 9
1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 22 23 24 26 29 30 31 33 36 39 40 41 42 43 45 20
10 11 12 13 14 15 16 17 18 19 22 23 24 26 29 30 31 33 36 39 40 41 42 43 45 20
769 OR 2.0
SH24: D-6
110 OR 2.0 156 RD 2.0
SH6: C-6 SH24: D-6
241C OR 0.8 242 YE 0.8 245 YE 0.5 249 YE 0.5 252 BK 0.5 253 PK 0.5 719 VT 1.0 270 BK/WH 0.5 271 YE 0.5
SH7: D-1 SH6: A-6 SH6: A-6 SH6: A-6 SH6: A-6 SH6: A-6 SH25: A-6 SH6: A-1 SH6: A-1
895 WH 0.8 504C GN 0.8 248 YE 0.8 780 VT 0.8 833 WH 0.8 834 WH 0.8 717 VT 0.8 704 VT 0.8 766 VT 0.8 503C YE 0.8 121 YE 0.8 626 WH 0.8 841 WH 0.8 721 VT 0.8
SH38: C-6 SH6: D-1 SH6: D-1 SH25: A-6 SH28: A-1 SH28: B-1 SH25: C-6 SH25: C-6 SH25: C-6 SH6: D-1 SH6: C-6 SH6: C-6 SH28: B-1 SH25: C-6 SH6: C-6 SH37: A-1 SH25: C-6 SH4: B-6 SH6: C-6
133B OR 0.8 234 RD 0.8 703 VT 0.8 267 YE 0.8 161 YE 0.8 X-901
CHASSIS INTERFACE 6
5
4
3 SHT_39
1
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2
1
D
C
B
A
Electrical systems - Harnesses and connectors
Wiring harnesses - Electrical schematic sheet 02 SH02-MAIN POWER DISTRIBUTION LG SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
Type Fuse Fuse Fuse Fuse Fuse Fuse Fuse Fuse Fuse Fuse Fuse Fuse Fuse Fuse Fuse Fuse Fuse Relay Relay Relay Relay Connector Connector Connector Sub-Assembly Sub-Assembly
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Component F-001 F-002 F-003 F-005 F-006 F-007 F-008 F-009 F-011 F-012 F-016 F-019 F-046 F-047 F-049 F-050 F-051 K-001 K-002 K-003 K-004 X-ECU_MAIN_RLY X-FUSE1 X-FUSE2 Z-FUSE1 Z-FUSE2
(Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical
Connector / Link
X-ECU_MAIN_RLY X-FUSE1 X-FUSE2 X-FUSE1 X-FUSE2
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Description REAR WORK LAMPS LH TAIL LAMP SIDE LAMPS UNSWITCHED BATTERY RH TAIL LAMP ACC/BEACON IGNITION INSTRUMENT CLUSTER ECU 2 ECU 1 ENGINE SENSOR ACCESSORY HVAC CRANK WIPER/WASHER FRONT WORK LAMPS COMPRESSOR ACCESSORY RELAY LIGHTS #1 RELAY MAIN POWER RELAY LIGHTS #2 RELAY ECU MAIN RELAY POWER DISTRIBUTION-CHASSIS POWER DISTRIBUTION-CHASSIS POWER DISTRIBUTION CHASSIS POWER DISTRIBUTION CHASSIS
Electrical systems - Harnesses and connectors
6
5
4
3
2
1
Z-FUSE2 POWER DISTRIBUTION-CHASSIS F-007 ACC/BEACON 8 SH7: C-1
114 RD 1.0
1
20.0 A
2
2
115 RD 2.0
SH14: D-1
836 RD 3.0
SH14: D-1
310 RD 0.8
SH14: C-1
820 OR 3.0
SH14: A-4
351 OR 1.0
SH8: C-1
300 OR 1.0
SH14: A-4
110 OR 2.0
SH33: D-6
155A OR 3.0
SH34: B-5
241A OR 1.0
SH33: B-6
134 OR 2.0
SH14: C-1
256 RD 2.0
SH9: C-6
708 VT 3.0
SH14: B-4
703 VT 0.8
SH33: A-6
704 VT 0.8
SH33: B-6
706 VT 3.0
SH34: B-5
798 VT 5.0
SH14: D-4
233 OR 2.0
SH14: D-4
F-051
D
D
COMPRESSOR 7 SH7: A-1
835 RD 3.0
SH7: C-1
160 RD 0.8
SH7: A-1
830 OR 3.0
SH7: C-1
116 RD 2.0
SH20: A-6
710 VT 2.0
1
25.0 A
2
1
F-005 UNSWITCHED BATTERY 32
1
5.0 A
2
26
2
3
F-046 HVAC
SH5: B-1
9
1
30.0 A
947 BK 0.8 Z-FUSE1 X-FUSE2
X-FUSE2
POWER DISTRIBUTION-CHASSIS K-003
Z-FUSE2
MAIN POWER RELAY
POWER DISTRIBUTION-CHASSIS
87A 22 SH7: B-1
F-008
30
118 RD 1.0
87 34
SH14: B-4
86
85
144 OR 0.8
33
IGNITION
SP-036
136 OR 1.0
19
350 OR 1.0
21
1
15.0 A
2
13
F-009 INSTRUMENT CLUSTER 20
C
326 OR 1.0
K-002
1
10.0 A
2
14
C
LIGHTS #1 RELAY 2
87A
7
87
13
F-012 ECU 1
30 21
528B OR 3.0 14 SH14: A-4
86
85
325 WH 0.8
1
7.5 A
2
15
1
946 BK 0.8
F-011 ECU 2
SP-528
33
528C OR 3.0
1
20.0 A
2
27
K-004 F-016
LIGHTS #2 RELAY
ENGINE SENSOR
87A 24 SH7: B-1
56
30
113 RD 1.0 36
SH14: B-4
86
709 WH 0.8
87
35
85
23
528D OR 1.0
1
945 BK 0.8
16
86
117 RD 3.0
2
25
X-FUSE2 Z-FUSE1 POWER DISTRIBUTION-CHASSIS
87A SH7: B-1
20.0 A
X-FUSE2
K-001
B
50
ACCESSORY 1
ACCESSORY RELAY 30
2
F-019 31
4
7.5 A
87
15
85
3
F-047
B
CRANK SH14: B-1
139 OR 0.8
44
948 BK 0.8
1
30.0 A
2
38
SP-194 X-FUSE1
X-FUSE1
F-003 SIDE LAMPS 55
SH14: A-1
1
125 OR 3.0
SH5: B-1
1098 BK 0.8
SH14: A-4
707 VT 2.0
SH33: D-6
528E OR 2.0
SH9: B-1
528A OR 8.0
SH14: A-1
135 OR 2.0
SH7: A-1
255 RD 2.0
15.0 A
2
49
F-002 LH TAIL LAMP 68
1
5.0 A
2
62
F-006 RH TAIL LAMP 56
1
5.0 A
2
50
F-001 REAR WORK LAMPS 43 SH14: D-1
792 VT 3.0
SH14: D-1
701 VT 0.8
SH14: D-1
700 VT 0.8
SH14: A-4
705 VT 3.0
1
15.0 A
2
37
F-050 FRONT WORK LAMPS
A
67
1
15.0 A
2
61
F-049
788 VT 3.0
WIPER/WASHER 31
SH14: A-1
243 OR 2.0
X-FUSE1
6
5
4
3 SHT_2
1
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1
30.0 A
2
25
X-FUSE1
2
1
A
Electrical systems - Harnesses and connectors
Wiring harnesses - Electrical schematic sheet 03 SH03-MAIN POWER DISTRIBUTION MD SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
Type Fuse Fuse Fuse Fuse Fuse Fuse Fuse Fuse Fuse Fuse Relay Relay Relay Relay Connector Connector Sub-Assembly Sub-Assembly
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Component F-021 F-022 F-023 F-024 F-025 F-026 F-027 F-028 F-029 F-031 K-010 K-011 K-012 K-013 X-FUSE1 X-FUSE2 Z-FUSE1 Z-FUSE2
(Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical
Connector / Link
X-FUSE1 X-FUSE2 X-FUSE1 X-FUSE2
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Description COMPRESSOR ACC/BEACON UNSWITCHED BATTERY HVAC INSTRUMENT CLUSTER ACCESSORY CRANK SIDE LAMPS IGNITION WIPER/ WASHER MAIN POWER RELAY LIGHTS #1 RELAY LIGHTS #2 RELAY ACCESSORY RELAY POWER DISTRIBUTION-CHASSIS POWER DISTRIBUTION-CHASSIS POWER DISTRIBUTION CHASSIS POWER DISTRIBUTION CHASSIS
Electrical systems - Harnesses and connectors
6
4
5
SH7: A-1 SH7: C-1 SH20: A-6
2
830 OR 3.0 116 RD 2.0
118 RD 1.0
SH7: B-1
16
144 OR 0.8
23
136 OR 1.0
788 VT 3.0
SH4: C-6
6
2
947 BK 0.8
K-011 LIGHTS #1 RELAY 87A 30
5 7
9
87
325 WH 0.8
14 SH7: A-1
85
22
10 SH14: A-4
86
113 RD 1.0
1 86
85
K-012 LIGHTS #2 RELAY 87A 30
946 BK 0.8
SP-036
326 OR 1.0
21 21 13
B
86
117 RD 3.0
SH7: B-1
4
K-013 ACCESSORY RELAY 87A 30
27
945 BK 0.8
85
709 WH 0.8
SH14: B-4
14
87 22
D
1
2
25.0 A
1
836 RD 3.0
SH14: D-1
115 RD 2.0
SH14: D-1
310 RD 0.8
SH14: C-1
820 OR 3.0
SH14: A-4
300 OR 1.0
SH14: A-4
134 OR 2.0
SH14: C-1
255 RD 2.0
SH7: A-1
F-022 ACC/BEACON
87 24
SH7: C-1 SH7: A-1
F-021 COMPRESSOR 5
15 SH14: B-4
SH7: B-1
Z-FUSE2 POWER DISTRIBUTION CHASSIS
Z-FUSE1 POWER DISTRIBUTION CHASSIS K-010 MAIN POWER RELAY 87A 30
1
160 RD 0.8 114 RD 1.0 835 RD 3.0
710 VT 2.0
D
C
3
37
11
13
326 OR 1.0
87
1
2
20.0 A
F-023 UNSWITCHED BATTERY 1 2 5.0 A F-024 HVAC 1 2 30.0 A F-025 INSTRUMENT CLUSTER 1 2 10.0 A F-026 ACCESSORY 1 2 20.0 A
2
18
C
3
10
17
F-027 CRANK 1 2 30.0 A
31
F-028 SIDE LAMPS 2 1 15.0 A
33
F-029 IGNITION 1 2 15.0 A
9
F-031 WIPER/ WASHER 1 2 30.0 A
26
B
708 VT 3.0
SH14: B-4
351 OR 1.0
SH8: D-1
233 OR 2.0
SH14: D-4
3
139 OR 0.8
SH14: B-1
12
86
85
948 BK 0.8 30
X-FUSE1
SP-194
X-FUSE1
X-FUSE2
X-FUSE2 A
SH14: A-1 SH14: B-4 SH7: C-6 SH6: B-6
125 OR 3.0 707 VT 2.0 1098 BK 2.0 975 BK 0.8
6
5
SH14: A-1 SH14: D-1 SH9: D-6 SH14: A-1
243 OR 2.0 792 VT 3.0 256 RD 2.0 135 OR 2.0
4
3 SHT_3
1
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1
A
Electrical systems - Harnesses and connectors
Wiring harnesses - Electrical schematic sheet 04 SH04-MAIN POWER DISTRIBUTION MD SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
Type Fuse Fuse Fuse Fuse Fuse Fuse Fuse Connector Connector Sub-Assembly
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Component F-032 F-033 F-034 F-035 F-036 F-037 F-038 X-FUSE1 X-FUSE2 Z-FUSE2
(Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical
Connector / Link
X-FUSE1 X-FUSE2 X-FUSE2
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Description ECU 1 ECU 2 REAR WORK LAMPS FRONT WORK LAMPS RH TAIL LAMP LH TAIL LAMP ENGINE SENSOR POWER DISTRIBUTION-CHASSIS POWER DISTRIBUTION-CHASSIS POWER DISTRIBUTION CHASSIS
Electrical systems - Harnesses and connectors
6
5
4
3
2
1
D
D
Z-FUSE2 POWER DISTRIBUTION CHASSIS
15
528B OR 3.0 23
528C OR 3.0 29 C
SH14: A-4
705 VT 3.0 45
SH3: C-6
788 VT 3.0
700 VT 0.8
701 VT 0.8
B
528F OR 5.0
19
F-034 REAR WORK LAMPS 2 1 15.0 A
25
F-035 FRONT WORK LAMPS 2 1 15.0 A
41
528D OR 1.0
110 OR 2.0
SH35: D-5
155A OR 3.0
SH34: B-5
706 VT 3.0
SH34: B-5
798 VT 5.0
SH14: D-4
704 VT 0.8
SH35: B-5
703 VT 0.8
SH35: A-5
C
35
36
F-038 ENGINE SENSOR 2 1 7.5 A
38
SH9: C-6
F-033 ECU 2 2 1 20.0 A
F-037 LH TAIL LAMP 2 1 5.0 A
40 SH14: D-1
11
F-036 RH TAIL LAMP 2 1 5.0 A
39 SH14: D-1
F-032 ECU 1 2 1 7.5 A
B
34 SH10: B-6
241A OR 1.0
SP-528 X-FUSE2
X-FUSE2
A
A
6
5
4
3 SHT_4
1
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Electrical systems - Harnesses and connectors
Wiring harnesses - Electrical schematic sheet 05 SH05-ACCESSORY POWER DISTRIBUTION LG SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
Type Fuse Fuse Fuse Fuse Fuse Fuse Fuse Fuse Fuse Fuse Relay Relay Switch Switch Switch Switch Connector Connector Connector Connector Connector Connector Connector Connector Sub-Assembly Sub-Assembly
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Component F-004 F-010 F-013 F-014 F-015 F-017 F-018 F-020 F-048 F-052 K-005 K-007 S-016 S-020 S-030 S-035 X-161 X-162 X-163 X-164 X-166 X-167 X-FUSE1 X-FUSE2 Z-FUSE1 Z-FUSE2
(Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical
Connector / Link
X-161 X-162 X-163 X-164 X-166 X-167 X-FUSE1 X-FUSE2 X-FUSE1 X-FUSE2
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Description TELEMATICS RH BOOM HIGH FLOW / COUPLER FUSE RELAY GROUND FE #1, #2, #3 FE ON/OFF FE HOT FUSE RELAY GROUND FLASHER/BRAKE 20A LH BOOM OPTION RELAY FRONT ELECTRIC RELAY MECHANICAL BRAKE SWITCH MECHANICAL BRAKE SWITCH MECHANICAL BRAKE PRESSURE SWITCH MECHANICAL BRAKE PRESSURE SWITCH MECH BRK PRESS SW # IN MECH BRK PRESS SW #1 OUT MECH BRK PRESS SW #2 IN MECH BRK PRESS SW #2 OUT MECHANICAL BRAKE SWITCH MECHANICAL BRAKE SWITCH POWER DISTRIBUTION-CHASSIS POWER DISTRIBUTION-CHASSIS POWER DISTRIBUTION CHASSIS POWER DISTRIBUTION CHASSIS
Electrical systems - Harnesses and connectors
6
5
4
3
2
1
355 OR 0.8 Z-FUSE1
Z-FUSE2
POWER DISTRIBUTION-CHASSIS
POWER DISTRIBUTION-CHASSIS F-004
K-007
TELEMATICS
FRONT ELECTRIC RELAY
D
44
87A 58 SH7: B-1
103 RD 3.0
SH14: D-4
146 WH 0.8
30
70
86
149 OR 3.0
38
2
336 RD 1.0
SH29: C-4
156 RD 2.0
SH22: C-6
420 OR 3.0
SH28: C-5
D
F-048
57
85
5.0 A
SP-065
69
87
1
FLASHER/BRAKE 20A
974 BK 0.8
22
1
20.0 A
16
2
X-FUSE2
X-FUSE2 K-005
Z-FUSE2 POWER DISTRIBUTION-CHASSIS
OPTION RELAY 87A 40 SH7: B-1
F-018
30
104 RD 2.0
51
87
FE HOT 68
52 SH14: D-4
86
39
85
148 WH 0.8
1
SP-192
62
2
25.0 A
972 BK 0.8
X-FUSE1
X-FUSE1
F-013 HIGH FLOW / COUPLER 10
1
743 OR 0.8
4
2
15.0 A
744 OR 2.0
F-015
C
C
FE #1, #2, #3 63 SH30: B-5
354 OR 0.8
SH7: C-1
119 RD 1.0
1
7.5 A
2
69
2
64
2
40
2
28
F-017 FE ON/OFF 70
1
145 OR 0.8 SH7: B-1
10.0 A
129 OR 1.0
SH30: C-2
716 VT 1.0
SH23: B-5
719 VT 1.0
SH33: C-6
947 BK 0.8
SH2: D-6
1092 BK 0.8
SH7: D-6
1098 BK 0.8
SH2: B-6
101 RD 2.0 F-052 LH BOOM 46
SH20: A-6
1
714 VT 1.0
10.0 A F-010 RH BOOM
34 SH20: A-6
1
715 VT 1.0
10.0 A
F-014 FUSE RELAY GROUND 55
B
SH7: D-1
1
1094 BK 0.8
2.0 A
49
2
B
F-020 FUSE RELAY GROUND 43
1
1097 BK 0.8
2.0 A
37
2
F-020 FUSE RELAY GROUND 67 SH7: D-1
1
1095 BK 0.8
2.0 A
61
2
X-FUSE2
X-FUSE2
751 OR 0.8
SH14: C-4
720 RD 0.8
753 OR 0.8
SH14: C-4
724 RD 0.8
558 OR 0.8
SH30: D-5
744 OR 2.0
SH6: C-1
SP-053
S-035
S-030
MECHANICAL BRAKE PRESSURE SWITCH
MECHANICAL BRAKE PRESSURE SWITCH X-162
X-161
A
1
1
X-163
X-164 1
760 VT 0.8
S-020 X-166
5
4 1
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X-167
X-166 2
3 SHT_5
725 VT 0.8
SH33: A-6
721 VT 0.8
SH35: A-5
S-016
MECHANICAL BRAKE SWITCH 1
6
1
759 OR 0.8
MECHANICAL BRAKE SWITCH 1
X-167 2
2
2
1
A
Electrical systems - Harnesses and connectors
Wiring harnesses - Electrical schematic sheet 06 SH06-ACCESSORY POWER DISTRIBUTION MD SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
Type Fuse Fuse Fuse Fuse Fuse Fuse Fuse Relay Relay Connector Connector Sub-Assembly Sub-Assembly
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Component F-030 F-039 F-040 F-041 F-042 F-044 F-045 K-014 K-015 X-FUSE1 X-FUSE2 Z-FUSE1 Z-FUSE2
(Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical
Connector / Link
X-FUSE1 X-FUSE2 X-FUSE1 X-FUSE2
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Description RH BOOM FLASHER / BRAKE HIGH FLOW/ COUPLER FE #1, #2, #3 FE HOT FE ON/OFF LH BOOM FRONT ELECTRIC RELAY OPTION RELAY POWER DISTRIBUTION-CHASSIS POWER DISTRIBUTION-CHASSIS POWER DISTRIBUTION CHASSIS POWER DISTRIBUTION CHASSIS
Electrical systems - Harnesses and connectors
6
5
4
3
2
1
D
D
355 OR 0.8 Z-FUSE1 POWER DISTRIBUTION CHASSIS
Z-FUSE2 POWER DISTRIBUTION CHASSIS
SP-065 K-014 FRONT ELECTRIC RELAY
F-040 HIGH FLOW/ COUPLER 8
87A
103 RD 3.0 40
30
SH7: B-1
47
87
F-041
149 OR 3.0 C
SH14: D-4
SH7: B-1
146 WH 0.8 48
104 RD 2.0 28
86
43
39
85
974 BK 0.8 46
K-015 OPTION RELAY 87A 30
356 OR 3.0 48
145 OR 0.8
35
87
743 OR 0.8 SH14: D-4
148 WH 0.8 36
86
SH3: A-6 SH30: B-5 SH20: A-6 SH20: A-6 SH35: D-5
27
85
32
SP-192
972 BK 0.8 X-FUSE1
X-FUSE1
B
1
24
975 BK 0.8 354 OR 0.8 714 VT 1.0 715 VT 1.0
12
1
15.0 A
4
2
744 OR 2.0
SH5: A-1
FE #1, #2, #3 20.0 A
47
2
C
F-042 FE HOT 1 2 25.0 A
42
F-044 FE ON/OFF 1 2 10.0 A
44
F-045 LH BOOM 1 2 10.0 A
28
F-030 RH BOOM 1 2 10.0 A F-039 FLASHER / BRAKE 1 2 20.0 A
420 OR 3.0
SH28: C-5
129 OR 1.0
SH30: C-2
716 VT 1.0
SH23: B-5
719 VT 1.0
SH35: C-5
101 RD 2.0
SH7: A-1
20
B
16
156 RD 2.0 X-FUSE2
X-FUSE2
A
A
6
5
4
3 SHT_6
1
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Electrical systems - Harnesses and connectors
Wiring harnesses - Electrical schematic sheet 07 SH07-GROUNDING SYSTEM SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
Type Voltage source Ground Ground Ground Ground Ground Ground Ground Ground Ground Switch Connector Connector Connector Connector Connector Connector Connector
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Component G-002 GND-001 GND-002 GND-003 GND-004 GND-005 GND-010 GND-011 GND-012 GND-013 S-042 X-411 X-CAB_GNDA X-CAB_GNDB X-NEG_TERM_A X-OPT_POS-PWR X-POS_TERM X-TELE_GND
(Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Description
Connector / Link BATTERY GND-001 GND-002 GND-003 GND-004 GND-005 GND-010 GND-011 GND-012 GND-013 X-411 X-CAB_GNDA X-CAB_GNDB X-NEG_TERM_A X-OPT_POS-PWR X-POS_TERM X-TELE_GND
SWITCH OPTIONAL FLASHER MODULE CAB GROUND CAB GROUND CLEAN GROUND X-POS_TERM BATTERY POWER TELEMATICS GROUND
Electrical systems - Harnesses and connectors
6
5
4
SP-047 SH19: D-1
901 BK/WH 0.8
3
2
1
1
966 BK/WH 2.0 SH7: C-6
1091 BK 2.0
X-NEG_TERM_A SH14: D-1
910 BK/WH 0.8 SH5: B-6
1094 BK 0.8 SH14: B-4 SH5: B-1
D
SH13: D-2
SP-190
206 BK/WH 0.8
1901 BK 0.8
SH13: B-5
1095 BK 0.8
SH5: B-6
1092 BK 0.8 GND-012
1900 BK 0.8
SH13: B-5
958 BK 0.8
SH13: B-5
959 BK 0.8
SP-183
D
SP-182
1008 BK 1.0
1900 BK 0.8
SH34: B-5
1087 BK 5.0
SH22: D-2
981 BK 0.8
SH28: C-5
982 BK 5.0
SH23: B-5
SP-1902
978 BK 0.8
976 BK 0.8
SH14: D-4
951 BK 0.8
SH17: C-1
949 BK 0.8
SH14: B-1
1902 BK 0.8
966 BK/WH 2.0
SH13: C-5
986 BK 8.0
SH14: C-4
SP-174
1 SH9: C-6
908A BK/WH 8.0 ECU_GND
979 BK 1.0
SH3: A-6
1098 BK 2.0
1011 BK/WH 0.8
SH25: A-1
910 BK/WH 0.8
SH14: D-3
SP-092 SH31: C-5
961 BK/WH 0.8 SH7: D-1
1091 BK 2.0
GND-013 CHS_GND_FRT
SH16: B-1 SH16: C-1
C
955 BK 0.8
968 BK 2.0
SH26: A-1
1016 BK/WH 0.8
SH24: A-6
983 BK 13.0
SP-179
953 BK 0.8
1012 BK/WH 0.8
1
SP-181
1 SH29: D-4
908A BK/WH 8.0 SH14: C-1 SH26: A-6 SH19: B-1
960 BK 0.8
X-TELE_GND
1013 BK 0.8
GND-010
1104 BK 0.8 SP-173
SH24: C-6 SH15: C-6
1
939 BK 5.0
1094 BK 13.0
SH24: C-1 SH24: B-1
SH5: C-6
119 RD 1.0
SH29: B-4
160 RD 0.8
SH2: D-6
114 RD 1.0
SH2: D-6
116 RD 2.0
SH3: D-6
116 RD 2.0
SH2: D-6
160 RD 0.8
SH3: D-1
941 BK 0.8 952 BK 0.8
GND-001
105 RD 3.0
SH15: B-1
119 RD 1.0
C
SP-040
942 BK 3.0 SP-029
SH15: A-1
SH3: D-1
GND-011 X-CAB_GNDB
940 BK 3.0
114 RD 1.0
931 BK 0.8 932 BK 0.8
SH22: A-6
939 BK 2.0
SP-043 SH2: B-6
117 RD 3.0 SH18: C-1
933 BK 1.0
SH26: B-6
1088 BK 8.0
SH24: C-6
937 BK 3.0
SH3: B-6
117 RD 3.0 SP-172
1
1093 BK 13.0 X-CAB_GNDA
B
104 RD 2.0
SH5: D-6
103 RD 3.0
SH5: D-6
118 RD 1.0
SH2: C-6
B
GND-004 1 SH10: D-6
108 RD 19.0
908A BK 8.0 ECU_GND
113 RD 1.0
SH2: C-6
101 RD 2.0
SH5: C-6
SP-041
GND-002
SH23: C-6
980 BK 1.0
SH23: B-6
975 BK 3.0
SH23: C-6
950 BK 3.0
106 RD 13.0
984 BK 13.0
CHAS RH TWR MD T4A F5
CHS_GND_RR 967 BK 8.0 G-002
SP-177
965 BK 3.0
S-042 SWITCH OPTIONAL
1084 BK 3.0 SP-176
A
2
950 BK 3.0 956 BK 0.8
SH8: D-1
907 BK 0.8
SH9: A-6
1086 BK 2.0
965 BK 3.0
SH3: C-6 SH6: B-1
101 RD 2.0
X-POS_TERM
SH3: B-1
255 RD 2.0
BATTERY 1
SH3: D-1
835 RD 3.0
1
SH3: D-6
830 OR 3.0 SP-042 107 RD 8.0
109 RD 19.0
GND-003
SH2: A-6
255 RD 2.0
CHAS RH TWR MD T4A F5
SH2: D-6
835 RD 3.0
SH2: D-6
830 OR 3.0
981 BK 0.8 X-OPT_POS-PWR
GND-005 1
6
SH6: C-6
113 RD 1.0
SP-044 SH33: A-1
SH22: C-1
SH3: D-6
104 RD 2.0 SP-175 1
SH23: C-6
SH6: C-6
118 RD 1.0 975 BK 3.0
SH23: A-5
SH26: B-6
103 RD 3.0
5
4
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SH8: B-6
102A RD 85.0
2
1
A
Electrical systems - Harnesses and connectors
Wiring harnesses - Electrical schematic sheet 08 SH08-IGNITION SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
Type Voltage source Ground Relay Motor Switch Switch Connector Connector Connector Connector Connector Connector Connector
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Component G-001 GND-008 K-019 M-003 S-008 S-037 X-005A X-006 X-006A X-009 X-508 X-C23 X-STARTER
(Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Description
Connector / Link ALTERNATOR GND-008 X-STARTER X-009 X-005A X-006 X-006A X-009 X-508 X-C23 X-STARTER
STARTER MOTOR IGNITION SWITCH AIR FILTER RESTRICTION SWITCH ALTERNATOR STARTER/ALTERNATOR STARTER/ALTERNATOR IGNITION SWITCH AIR FILTER RESTRICTION SWITCH INSTRUMENT CLUSTER STARTER
Electrical systems - Harnesses and connectors
6
5
4
3
D
2
1
D
S-037 AIR FILTER RESTRICTION SWITCH X-508 SH33: A-1 SH35: A-1
2
1
267 YE 0.8
X-508
1
2
X-508
267 YE 0.8
SH7: A-6
907 BK 0.8
X-508
G-001 ALTERNATOR X-005A
D+(1)
CHARGE INDICATOR A
SH3: B-1
351 OR 1.0
1 SH35: A-5
133B OR 0.8
B+(3) 3
SH13: D-6
1890 OR 0.8
W(2) 2
PHASE
SH29: D-4
802 OR 0.8
X-006 SP-039 SH14: A-1
127 OR 0.8
3 1
127A OR 0.8
4 4
C
SH29: C-4
244 YE 0.8
124 YE 0.8
2 2
SH17: C-6
832 OR 0.8
SH16: B-6
891 OR 0.8
244A YE 0.8
SH33: C-6
893 WH 0.8
M-003 STARTER MOTOR
C
SH13: C-5
1890 OR 0.8
SH33: A-6
133B OR 0.8
SH2: C-1
351 OR 1.0 STARTER HOLD-IN 1 SH9: C-1
520 WH 2.0
SH9: D-1
520 WH 2.0
1 3
1
520A WH 2.0 X-STARTER
X-006A
STARTER PULL-IN
B_START SH7: A-1
102A RD 85.0
GND M
GND-008
B
B S-008 IGNITION SWITCH
AUX
IGN
3 SH25: C-6
6
138 OR 0.8
SH25: B-1
132 OR 0.8
SH25: C-6
624 WH 0.8
SH25: C-6
1
140 RD 0.8 X-009
START
4
A X-009
6
5
4
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Electrical systems - Harnesses and connectors
Wiring harnesses - Electrical schematic sheet 09 SH09-ENGINE F5C T4 SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
Type Relay Relay Relay Connector Connector Connector Connector Connector Connector Sub-Assembly
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Component K-006 K-009 K-016 X-012 X-025 X-079 X-316 X-ECU_MAIN_RLY X-FUSE1 Z-FUSE1
(Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical
Connector / Link X-ECU_MAIN_RLY X-012 X-025 X-079 X-316 X-ECU_MAIN_RLY X-FUSE1 X-FUSE1
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Description ENGINE RELAY A ECU MAIN RELAY ENGINE RELAY A ECU BATT+ CCV HEATERS IGNITION BACKFEED DIODE ECU MAIN RELAY POWER DISTRIBUTION-CHASSIS POWER DISTRIBUTION CHASSIS
Electrical systems - Harnesses and connectors
6
5
4
3
2
1
CHAS MECH MD T4A
Z-FUSE1 POWER DISTRIBUTION CHASSIS
D
D
K-016 ENGINE RELAY A 87A SH3: A-1
26
30
34
86
256 RD 2.0
SH35: B-5
121 YE 0.8
87
33
85
25
520 WH 2.0 161 YE 0.8
X-FUSE1
SH8: C-6 SH35: C-5
X-FUSE1
SH3:A-6
Z-FUSE1 POWER DISTRIBUTION-CHASSIS K-006 ENGINE RELAY A 87A SH2: B-1
C
42
30
54
86
256 RD 2.0
SH33: B-6
87
53
85
41
121 YE 0.8
X-FUSE1
520 WH 2.0
SH8: C-6
161 YE 0.8
SH33: C-6
C
X-FUSE1
2 SH4: B-6
528F OR 5.0 SP-908
SH7: D-1
3
908A BK/WH 8.0
908F BK/WH 5.0 1
527D RD 5.0
K-009 ECU MAIN RELAY
X-316
SP-527
1 527A RD 8.0
3
30
1
86
527B RD 8.0
87
5
85
2
X-025
527C RD 0.5
SH2: A-6
112 BL 0.5
SH33: A-6
X-ECU_MAIN_RLY
X-ECU_MAIN_RLY SP-527RH
528A OR 8.0
527B RD 8.0 527C RD 0.5
B
B SH10: D-6
112 BL 0.5
4 1
527D RD 5.0 ECU RELAY/GROUND
3 SH10: D-6
908A BK 5.0 2
528F OR 5.0 X-316 SP-528RH
528A OR 8.0
X-079
528E OR 2.0 SH33: D-1
528E OR 2.0
1
SH10: A-1
600 WH 0.8
2
SH10: A-1
601 YE 0.8
3
SH7: A-6
1086 BK 2.0
4
CCV HEATERS
A
6
5
4
A
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Electrical systems - Harnesses and connectors
Wiring harnesses - Electrical schematic sheet 10 SH10-ENGINE F5C T4 SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
Type ECU Sensor Sensor Sensor Sensor Sensor Sensor Connector Connector Connector Connector Connector Connector Connector
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(Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical
Component A-005 B-001 B-006 B-007 B-008 B-011 B-012 X-004 X-006 X-007 X-012 X-013 X-014 X-017
Connector / Link X-016 X-014 X-004 X-013 X-006 X-007 X-004 X-006 X-007 X-012 X-013 X-014 X-017
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Description ENGINE CONTROLLER UNIT LAMBDA SENSOR AIR TEMP SENSOR INLET TURBINE TEMP SENSOR GCU EXHAUST GAS TEMP SENSOR #1 EXHAUST GAS TEMP SENSOR #2 AIR TEMPERATURE SENSOR STARTER/ALTERNATOR EXHAUST GAS TEMP SENSOR 2 ECU GCU ENGINE INTERFACE
Electrical systems - Harnesses and connectors
6
5
4
3
2
1
A-005 ENGINE CONTROLLER UNIT
D
SP-155 SH34: B-2
5
155A OR 3.0
155C OR 2.0
BATTERY +C VIA MAIN RELAY EGR ECU K-LINE
3 SH33: D-1 SH35: D-1
112 BL 0.5 4
SH9: B-6
908A BK 5.0
908C BK 2.0 SP-908
SH7: B-6
2
908A BK 8.0
908B BK 2.0
908E BK 0.8
908D BK 2.0 30
SH34: D-5
150 YE 0.8
SH34: D-5
133E OR 0.8
CAN 2 HIGH
45 CDB-035
CDB-035 SH35: B-1
504C GN 0.8
23
BATTERY MINUS 2
SH35: B-1
503C YE 0.8
BATTERY MINUS 1
CDB-005
CAN LO 25
6
SH34: D-5
CAN 2 LOW MAIN RELAY
112 BL 0.5
GND
CAN HI
WATER IN FUEL LEVEL SENSOR SIGNAL
24 47
CDB-005
504C GN 0.8
SH33: B-1
503C YE 0.8
SH33: B-1 B-006
46 SP-133B SH33: A-1
54
133B OR 0.8
SH35: A-1 SH33: B-1
133D OR 0.8
133B OR 0.8
27
121 YE 0.8
SH35: B-1
121 YE 0.8
SH33: C-1
161 YE 0.8
SH35: C-1
161 YE 0.8
53
C
8
626 WH 0.8
SH35: A-1
CRANK ENABLE FROM ECU 1 AIR TEMP SENSOR SIGNAL
20
2
254 BK/WH 0.5
T째
19
1 257 YE 0.5 X-004
CRANK ENABLE FROM ECU 2
B-007
CRANK SIGNAL INLINE TURBINE TEMP SIGNAL
C
X-017
82
263 YE 0.5
26 26
265 BK/WH 0.5
25 25
T째
626 WH 0.8 B-008
SH34: B-2
212 OR 8.0
INLINE TURBINE TEMP GND
GCU 8
SH34: A-2
52
212 OR 8.0
216 YE 0.5 4
X-017
3
235 YE 0.5 5
41
239A BK 3.0
1111 WH 2.0
60
22
2
1110 WH 2.0
61
7 60
AIR TEMP GND
AIR TEMP SENSOR
INLET TURBINE TEMP SENSOR
SH33: B-1
61
TERMINAL 15 SW BATT+
D
SH35: C-1
248 YE 0.8
BATTERY VOLTAGE VIA MAIN RELAY 28
SH33: C-1
248 YE 0.8
1
110 OR 2.0 110 OR 2.0
SH9: B-6 SH33: A-1
68
BATTERY +B VIA MAIN RELAY
155B OR 2.0
239 BK 0.8
X-013
81 X-017
GLOW PLUG UNIT COMMAND SIGNAL GLOW PLUG FEEDBACK SIGNAL GLOW PLUG UNIT GND DIFF PRESSURE SENSOR GND
36 SH35: C-1
270 BK/WH 0.5
SP-239
1 58
58
1112 WH 2.0
57
57
1113 WH 2.0
DIFF PRESSURE SENSOR SIGNAL
6
X-017
X-013
DIFF PRESSURE SUPPLY
SH35: C-1
271 YE 0.5
58
271 YE 0.5
SH35: C-5
270 BK/WH 0.5
SH35: C-5
14
B-011 EXHAUST GAS TEMP SENSOR #1 79 B-001
EXHAUST GAS TEMP GND
LAMBDA SENSOR
B
7
3
242 YE 0.8 64
1
SH4: B-1
241A OR 1.0
245 YE 0.5 86
5
249 YE 0.5 SH35: D-5
241C OR 0.8
2
85
252 BK 0.5 SP-241 SH33: B-1
241A OR 1.0
4
63
253 PK 0.5
EXHAUST GAS TEMP SIGNAL LAMBDA SENSOR CURRENT PUMP
SH11: D-1
1 X-006 B-012
LAMBDA SENSOR VIRTUELLE GND LAMBDA SENSOR VOLTAGE NERNST 2
83
272 BK/WH 0.5
T째
X-014
241C OR 0.8 EXHAUST GAS TEMP SIGNAL 2
SH35: D-5
1
84
273 YE 0.5
242 YE 0.8 70
SH35: D-5
245 YE 0.5
SH35: D-5
50
252 BK 0.5
SH35: D-5
X-007
FUEL FILTER HEATER GND
249 YE 0.5
SH35: D-5
600 WH 0.8
SH9: A-6
601 YE 0.8
SH9: A-6
87
253 PK 0.5 X-012
X-012 SH35: D-1
A
B
271 YE 0.5
LAMBDA SENSOR CURRENT ADJUST
EXHAUST GAS TEMP GND 2 X-014
T째
80
EXHAUST GAS TEMP SENSOR #2
6
241B OR 0.8
270 BK/WH 0.5 2
LAMBDA SENSOR HEATING
SH11:A-4
242 YE 0.8
SH35: D-1
A
245 YE 0.5
SH35: D-1
249 YE 0.5
SH35: D-1
252 BK 0.5
SH35: D-1
253 PK 0.5 CHAS RH TWR MD T4A F5
6
5
4
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Electrical systems - Harnesses and connectors
Wiring harnesses - Electrical schematic sheet 11 SH11-ENGINE F5C T4 SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
Type ECU Sensor Sensor Sensor Sensor Sensor Sensor Sensor Sensor Sensor Switch Connector Connector Connector Solenoid Solenoid Solenoid Solenoid Solenoid Solenoid
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(Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical
Component A-005 B-005 B-013 B-014 B-016 B-017 B-018 B-019 B-020 B-021 S-039 X-015 X-016 X-017 Y-001 Y-006 Y-009 Y-012 Y-014 Y-015
Connector / Link X-016
X-015 X-016 X-017
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Description ENGINE CONTROLLER UNIT EGR PIERBURG RAIL PRESSURE SENSOR INCREMENT SPEED SENSOR SEGMENT SPEED SENSOR COOLANT TEMPERATURE SENSOR FUEL TEMPERATURE SENSOR EXHAUST GAS PRESSURE SENSOR BOOST PRESSURE / AIR TEMPERATURE SENSOR TVA PIERBURG OIL PRESSURE SWITCH ECU ENGINE INTERFACE ELECTRIC VALVE (WG) FUEL METERING UNIT INJECTOR ELECTRIC VALVE INJECTOR ELECTRIC VALVE INJECTOR ELECTRIC VALVE INJECTOR ELECTRIC VALVE
CYL CYL CYL CYL
2 4 3 1
Electrical systems - Harnesses and connectors
6
5
4
3
2
1
SH35: D-1
241C OR 0.8 Y-015
A-005
INJECTOR ELECTRIC VALVE CYL 1
ENGINE CONTROLLER UNIT X-015 A
CDB-007
A
CDB-007
16
274 WH 1.0
SH10: B-6
241C OR 0.8 Y-001
INJECTOR 1 HIGH BANK 1
ELECTRIC VALVE (WG)
X-017 32 B
D
B
275 GY 1.0
CDB-018
INJECTOR 1 LOW BANK 1
BOOST PRESSURE ACTUATOR 1
CDB-018
CDB-008
CDB-008
CDB-033
INJECTOR ELECTRIC VALVE CYL 3
C
31
INJECTOR 1 LOW BANK 2
1
INJECTOR 1 HIGH BANK 2
28
27
27
276 GY 1.0
CDB-033
294 GY 1.0
Y-014
C
28
D
4
B-019 EXHAUST GAS PRESSURE SENSOR
D
D
277 WH 1.0
Y-012
294 GY 1.0
EXHAUST GAS PRESSURE SENSOR SUPPLY P3
12
EXHAUST GAS PRESSURE SENSOR GROUND P3
27
INJECTOR ELECTRIC VALVE CYL 4 CDB-010 E
F
E
CDB-010
17
INJECTOR 2 HIGH BANK 1
48
INJECTOR 2 LOW BANK 1
278 WH 1.0
F
295 PK 0.5
21
21
296 BK/WH 0.5
22
22
297 YE 0.5
23
23
43
EXHAUST GAS PRESSURE SENSOR SIGNAL P3
279 GY 1.0 B-005 EGR PIERBURG
Y-009 EGR ACTUATOR MOTOR PLUS
INJECTOR ELECTRIC VALVE CYL 2 CDB-011
CDB-011
G
G
280 GY 1.0
H
H
281 WH 1.0
46
EGR ACTUATOR MOTOR MINUS
C
2
CDB-019
50
EGR POSITION SENSOR SUPPLY
EGR POSITION SENSOR SIGNAL 6 3
3
322 GY 0.8
30
30
318 PK 0.5
33
33
327 YE 0.5
34
34
337 BK/WH 0.5
35
35
C
9
39
OIL PRESSURE SWITCH EGR POSITION SENSOR GROUND
658 YE 0.5
29
INJECTOR 2 HIGH BANK 2
X-017
OIL PRESSURE SWITCH
29
35
X-015 S-039
CDB-019
321 WH 0.8 INJECTOR 2 LOW BANK 2
24
B-013 RAIL PRESSURE SENSOR B-021 CDB-016
CDB-016
5
5
282 BL 0.5
6
6
283 YE 0.5
26
TVA PIERBURG
RAIL PRESSURE SENSOR GROUND 49 41
CDB-020
TVA ACTUATOR MOTOR PLUS RAIL PRESSURE SENSOR SIGNAL
CDB-020
338 WH 0.8
37
37
339 GY 0.8
38
38
340 PK 0.5
41
41
341 YE 0.5
42
42
342 BK/WH 0.5
43
43
34 11 7
7
284 PK 0.5
TVA ACTUATOR MOTOR MINUS RAIL PRESSURE SENSOR SUPPLY 8 TVA POSITION SENSOR SUPPLY
B-014 53
INCREMENT SPEED SENSOR
TVA POSITION SENSOR SIGNAL CDB-017
B
CDB-017
9
9
285 YE 0.5
10
10
286 YE 0.5
59 CRANKSHAFT SPEED SENSOR SIGNAL PLUS 44
TVA POSITION SENSOR GROUND CRANKSHAFT SPEED SENSOR SIGNAL MINUS
14
SEGMENT (CAMSHAFT) SPEED SENSOR SIGNAL
28
SEGMENT (CAMSHAFT) SPEED SENSOR GROUND
37
B
B-016 B-020
SEGMENT SPEED SENSOR
BOOST PRESSURE / AIR TEMPERATURE SENSOR 4
4
287 YE 0.5
8
8
288 BL 0.5
10
BOOST PRESSURE SENSOR SUPPLY
343 PK 0.5
17
17
344 YE 0.5
18
18
345 BK/WH 0.5
19
19
346 YE 0.5
20
20
T°
13 12
12
SEGMENT (CAMSHAFT) SPEED SENSOR SUPPLY
289 PK 0.5
40
BOOST PRESSURE SENSOR SIGNAL
25
B-017
BOOST PRESSURE SENSOR GROUND
COOLANT TEMPERATURE SENSOR 58 13
13
290 BL 0.5
14
291 YE 0.5
COOLANT TEMPERATURE SENSOR GROUND
55
BOOST PRESSURE TEMPERATURE SENSOR SIGNAL
57
T°
14
COOLANT TEMPERATURE SENSOR SIGNAL
Y-006 FUEL METERING UNIT
FUEL METERING UNIT
B-018
A
60
FUEL TEMPERATURE SENSOR 23 15
15
292 BL 0.5
16
16
293 YE 0.5
FUEL METERING UNIT SUPPLY
CDB-021
CDB-021
298 GY 1.0
2
2
299 WH 1.0
1
1
A
15
FUEL TEMPERATURE SENSOR GROUND X-016
T°
38
X-017
FUEL TEMPERATURE SENSOR SIGNAL
X-016 SH10:A-3 X-017
6
5
4
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Electrical systems - Harnesses and connectors
Wiring harnesses - Electrical schematic sheet 12 SH12-THROTTLE SENSORS SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
Type Sensor Sensor Connector Connector
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Component B-003 B-004 X-020 X-020A
(Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical
Connector / Link X-020A X-020 X-020 X-020A
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Description HAND THROTTLE SENSOR FOOT THROTTLE SENSOR FOOT THROTTLE SENSOR HAND TROTTLE
Electrical systems - Harnesses and connectors
6
5
4
3
2
1
D
D
C
C
B-003 HAND THROTTLE SENSOR A
544 YE 0.8
SH25: C-1
1071 BK/WH 0.8
SH25: C-1
260 PK 0.8
SH25: C-1
545 YE 0.8
SH14: C-1
1066 BK/WH 0.8
SH14: B-1
211 PK 0.8
SH14: B-1
B
C
X-020A
B-004 FOOT THROTTLE SENSOR A
B
C
B
B
X-020
A
A
6
5
4
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Electrical systems - Harnesses and connectors
Wiring harnesses - Electrical schematic sheet 13 SH13-AUXILIARY HYDRAULIC INTERLOCK SWITCH SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
Type Relay Relay Connector Connector Connector Connector Connector Connector Connector Connector Connector Sub-Assembly Sub-Assembly
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Component K-008 K-017 X-410 X-412 X-AUX_EXT X-AUX_RET X-FUSE1 X-FUSE2 X-PORT_LK X-SPOOL_LK_A X-SPOOL_LK_B Z-FUSE1 Z-FUSE2
(Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Description
Connector / Link SPOOL RELAY SPOOL RELAY X-410 X-412 X-AUX_EXT X-AUX_RET X-FUSE1 X-FUSE2 X-PORT_LK X-SPOOL_LK_A X-SPOOL_LK_B X-FUSE1 X-FUSE2
LOADER LOCK PORT LOCK VALVE CONNECTION 2ND AUX EXTEND POWER DISTRIBUTION-CHASSIS POWER DISTRIBUTION-CHASSIS SPOOL LOCK POWER DISTRIBUTION CHASSIS POWER DISTRIBUTION CHASSIS
Electrical systems - Harnesses and connectors
6
5
4
3
2
1
CHAS MECH MD T4A Z-FUSE1 POWER DISTRIBUTION CHASSIS
D
D
K-017 SPOOL RELAY
SH8: C-1
87A
38
30
46
86
1890 OR 0.8
87
45
85
37 SH7: D-6
1900 BK 0.8
X-FUSE1
1308 WH 0.8
1304 WH 0.8
X-FUSE1
Z-FUSE2
X-SPOOL_LK_A
POWER DISTRIBUTION-CHASSIS
1304A WH 0.8
1 2
C
C
X-SPOOL_LK_A
K-008 SPOOL RELAY 87A
6 SH8: C-1
SP-1304
30
1890 OR 0.8
1304 WH 0.8 18
86
X-SPOOL_LK_B
17
87
1304B WH 0.8
1
5
85
1308 WH 0.8
2 X-SPOOL_LK_B
X-FUSE2
SH7: D-6
X-FUSE2
1900 BK 0.8
1901A BK 0.8 1901B BK 0.8 SH29: C-4
308 YE 0.8
SH14: C-1
303 WH 0.8
X-PORT_LK
304 WH 0.8
1
957 BK 0.8
2
PORT LOCK
SP-187 SH7: D-1
1901 BK 0.8 SP-1901
X-PORT_LK
B
B
X-AUX_EXT SH30: D-5
554 WH 0.8
1
SH7: D-6
958 BK 0.8
2
2ND AUX EXTEND
X-AUX_EXT
X-AUX_RET SH7: D-6
959 BK 0.8
2
SH30: D-5
552 WH 0.8
1
2ND AUX RETRACT
X-AUX_RET X-410 SH14: D-4
311 WH 0.8
1
969 BK 0.8
2
(CHASSIS OPTION) INTERCONNECTOR LOADER LOCK
X-410 X-412 2
A
SH14: D-4
312 WH 0.8
1
(CHASSIS OPTION) PORT LOCK PORT LOCK VALVE CONNECTOR
X-412
6
5
4
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Electrical systems - Harnesses and connectors
Wiring harnesses - Electrical schematic sheet 14 SH14-BULKHEAD CONNECTION SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
Type Sensor Ground Ground Switch Connector Connector Connector Connector Connector Connector Connector Connector Connector Solenoid Solenoid Solenoid Solenoid
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Component B-002 GND-006 GND-007 S-040 X-318 X-430 X-BRK X-BULKHEAD X-CCA X-CPLR X-HFLO X-OILFLT X-OILTMP Y-004 Y-008 Y-011 Y-013
(Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical
Connector / Link
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Description HYDRAULIC OIL TEMPERATURE
GND-006 GND-007 HYDRAULIC FILTER RESTRICTION X-318 X-430 X-BRK X-BULKHEAD X-CCA X-CPLR X-HFLO X-OILFLT X-OILTMP
EH AUX PWM CONTROLLER CAB/CHASSIS INTERCO CHASSIS/CAB INTERFACE HYDRAULIC COUPLER VALVE SOLENOID HYDRAULIC OIL FILTER SWITCH HYDRAULIC OIL TEMPERATURE SENDER STD HIGH FLOW SOLENOID BRAKE VALVE SOLENOID SELF LEVEL VALVE HYDRAULIC COUPLER SOLENOID
Electrical systems - Harnesses and connectors
6
5
4
3
2
1
X-BULKHEAD SH24: C-6
SH4: C-6 SH4: B-6 SH2: A-6
700 VT 0.8 41
233 OR 2.0
SH3: A-1 SH2: A-1
233 OR 2.0 233 OR 2.0
41
701 VT 0.8 X-BULKHEAD
700 VT 0.8 SP-024
148 WH 0.8 146 WH 0.8 SP-056 SH25: B-1 SH15: B-6
D
42
141 WH 0.8
44
311 WH 0.8
42
148 WH 0.8 146 WH 0.8
141 WH 0.8
44
SH6: B-6 SH6: C-6 SH5: C-6 SH5: D-6
SH20: D-1
791 VT 3.0
1
1
SH20: D-1
792 VT 3.0
2
2
791 VT 3.0
701 VT 0.8
SH2: A-6
702 VT 2.0
SH20: A-1 SH2: A-6
792 VT 3.0
SH13: A-5
311 WH 0.8
SH3: A-1
792 VT 3.0 SH15: B-1
45
312 WH 0.8
45
SH13: A-5
312 WH 0.8
SH30: A-5
359 OR 0.8
46
46
359 OR 0.8
SH30: B-5
SH30: A-5
427 RD 0.8
47
47
427 RD 0.8
SH16: A-1
SH22: B-6
797 VT 5.0
SH30: A-5
48
425 VT 0.8
50
48
50
750 WH 0.8
51
51
SH4: C-1
425 VT 0.8
SH16: B-1
IN
1
750 WH 0.8
SH2: A-1
798 VT 5.0
SH15: D-6
751 OR 0.8
52
976 BK 0.8
2
4
237 WH 3.0
SH34: B-5
SH26: B-1
836 RD 3.0
5
5
836 RD 3.0
SH31: C-5
248 YE 0.8
9
9
248 YE 0.8
SH7: C-1
910 BK/WH 0.8
11
11
910 BK/WH 0.8
SH25: B-6
234 YE 0.8
12
12
234 RD 0.8
SH25: C-1
319 OR 0.8
13
13
319 OR 0.8
SH15: B-6
115 RD 2.0
14
14
115 RD 2.0
234 RD 0.8
SH7: D-1 X-OILTMP SH25: B-6
264 YE 0.8
15
1
264 YE 0.8
15
SH25: C-6
310 RD 0.8
16
16
310 RD 0.8
SH25: C-1
545 YE 0.8
17
17
545 YE 0.8
53
53
752 WH 0.8
IN
1 X-CPLR
SH27: C-5
134 OR 2.0
19
19
SH2: D-1 SH3: C-1 SH12: B-2
310 RD 0.8
Y-013
752 WH 0.8
GND-006 X-OILTMP
HYDRAULIC COUPLER SOLENOID SH15: D-1
SH19: D-1 SH3: D-1 SH2: D-1
B-002 HYDRAULIC OIL TEMPERATURE
SH5: A-1
751 OR 0.8
OUT
X-CPLR
978 BK 0.8
2 X-CPLR
SH7: D-6
SH3: C-1
134 OR 2.0
X-CPLR
SH2: B-1
134 OR 2.0
C
C
Y-008 BRAKE VALVE SOLENOID
X-BRK
X-BRK SH15: A-6
753 OR 0.8
56
56
753 OR 0.8
SH5: A-1
SH22: C-6
774 VT 0.8
57
57
774 VT 0.8
SH23: B-5
780 VT 0.8
58
58
780 VT 0.8
SH30: D-5
SH22: C-6
SH25: B-1
258 WH 0.8
20
258 WH 0.8
20
303 WH 0.8
22
784 OR 1.0
782 OR 2.0
59
59
SH22: D-2
782 OR 2.0
261 YE 0.8
23
S-040 HYDRAULIC FILTER RESTRICTION
1
261 YE 0.8
23
785 OR 0.8
X-OILFLT
CDB-031 SH31: B-5
GND-007
CDB-031
507 WH 0.8
61
61
SH25: C-6
not in 47803835
267 YE 0.8
24
267 YE 0.8
139 OR 0.8
SH33: A-6 SH35: A-5 SH12: B-2 SH35: A-5 SH33: B-6 SH3: A-6 SH2: B-6
29
211 PK 0.8
SH12: B-2
30
822 OR 0.8
SH26: A-6
24
267 YE 0.8 SH31: B-5
508 BL 0.8
62
62
not in 47803835
SH25: C-1
1066 BK/WH 0.8
25
25
1066 BK/WH 0.8
SH25: B-6
205C YE 0.8
63
63
not in 47803835
SH25: B-1
622 WH 0.8
26
26
622 WH 0.8
622 WH 0.8 139 OR 0.8
B
SH7: C-6
960 BK 0.8
SH13: B-5
303 WH 0.8
22 X-OILFLT
SH25: D-6 SH15: A-6
2 X-BRK
783 OR 1.0 SP-020
SH15: B-6
IN
OUT
1
X-BRK
SH25: B-1 SH22: A-6
D
SH2: D-1 SH3: D-1 SH33: C-6 SH35: C-5 SH7: D-6 SH35: A-5 SH33: A-6
248 YE 0.8
X-HFLO
X-HFLO
52
4
115 RD 2.0
OUT
X-HFLO
237 WH 3.0
836 RD 3.0
Y-004 STD HIGH FLOW SOLENOID
X-HFLO SH15: A-1
798 VT 5.0
SH26: B-6
SH29: B-4
206 BK/WH 0.8
64
64
206 BK/WH 0.8
SH7: D-6
SH25: B-1
139 OR 0.8
28
28
SH29: B-4
207 TN 0.8
65
65
207 TN 0.8
SH29: C-4
SH25: D-1
211 PK 0.8
29
SH29: B-4
208 BL 0.8
66
66
208 BL 0.8
SH26: D-1
30
SH25: B-1
144 OR 0.8
67
67
SH29: C-4 SH2: C-6 SH3: D-6
144 OR 0.8 144 OR 0.8
821 OR 3.0
822 OR 0.8
B
SP-091 SH26: A-6
823 PK 0.8 Y-011
708 VT 3.0
SH3: B-1
SH26: A-1
709 WH 0.8
SH3: B-6
SH15: C-1
709 WH 0.8
SH2: B-6
708 VT 3.0
SH2: B-1
846 OR 8.0
SELF LEVEL VALVE
X-318
404 WH 0.8
31
404 WH 0.8
31
X-318 2
1
949 BK 0.8
SH7: D-1
SP-032 SH22: B-6
49
795 VT 5.0
795 VT 5.0
49
X-318
X-318
SH21: C-5
565 VT 0.8
32
32
565 VT 0.8
SH26: B-6
824 YE 0.8
33
33
824 YE 0.8
10
10
503A YE 0.8
CDB-032
CDB-032 SH31: C-5
503 YE 0.8
SH16: C-1 SH26: A-6 CDB-006
CDB-006
SH29: D-5
707 VT 2.0
SH3: A-6
SH31: C-5
504 GN 0.8
34
34
504A GN 0.8
705 VT 3.0
SH4: C-6
SH26: A-1
841 WH 0.8
35
35
841 WH 0.8
325 WH 0.8
SH3: C-6
SH26: A-1
833 WH 0.8
37
37
833 WH 0.8
SH29: C-5 SH35: A-5 SH33: B-6 SH35: C-5 SH33: C-6
707 VT 2.0
SH2: B-6
SH25: B-6
307 YE 0.8
39
39
307 YE 0.8
SH17: C-1
705 VT 3.0
SH2: A-6
SH26: A-1
834 WH 0.8
40
40
834 WH 0.8
SH33: C-6
325 WH 0.8
SH2: C-6
841 WH 0.8 SP-031 SH20: D-1
A
18
790 VT 1.0
833 WH 0.8
790 VT 1.0
18
843 OR 5.0
54
54
843 OR 5.0
844 OR 5.0
55
55
844 OR 5.0
820 OR 3.0
SH35: B-5
834 WH 0.8
SH2: D-1
125 OR 3.0
SH2: B-6
127 OR 0.8
SH8: C-6
135 OR 2.0
SH3: A-1
SP-161 SH26: A-1
854 OR 8.0
820 OR 3.0
SH3: C-1
324 OR 0.8
SH17: C-6
300 OR 1.0
SH2: C-1
243 OR 2.0
SH3: A-1
300 OR 1.0
SH3: C-1
125 OR 3.0
SH3: A-6
1102 OR 0.8
SH19: B-6
135 OR 2.0
SH2: A-6
243 OR 2.0
SH2: A-6
SP-030
SP-171
SH20: D-6
123 OR 3.0
3
123 OR 3.0
3
SP-037 SH25: C-6
309 OR 1.0
21
309 OR 1.0
21
X-CCA X-CCA
6
5
4
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Electrical systems - Harnesses and connectors
Wiring harnesses - Electrical schematic sheet 15 SH15-LEFT HAND CAB CONSOLE SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
Type Switch Switch Switch Switch Switch Switch Switch Connector Connector Connector Connector Connector Connector Connector Connector Connector Sub-Assembly
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Component S-001 S-005 S-007 S-009 S-013 S-026 S-028 X-178 X-300 X-301 X-302 X-303 X-306 X-317 X-365 X-ACC Z-008
(Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical
Connector / Link X-301 X-306 X-365 X-300 X-317 X-302 X-303 X-178 X-300 X-301 X-302 X-303 X-306 X-317 X-365 X-ACC X-ACC
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Description ROTATING BEACON /STROBE SWITCH LOADER LOCKOUT SWITCH NH PARK BRAKE SWITCH HYDRAULIC COUPLER SWITCH SELF LEVEL SWITCH HAZARD LAMP SWITCH HIGH FLOW SWITCH BEACON LAMP SOCKET HYD COUPLER SW BEACON SW HAZARD SW HI FLOW SW LOADER LOCKOUT SW SELF LEVEL SW NH PARK BRAKE SW ACCESORY POWER OUTLET ACCESSORY POWER OUTLET
Electrical systems - Harnesses and connectors
6
5
4
3
2
1
S-009 HYDRAULIC COUPLER SWITCH 2 SH14: C-6
3
751 OR 0.8
SH14: C-6
752 WH 0.8 X-300 9
918 BK 0.8
D
D
X-300 S-001 ROTATING BEACON /STROBE SWITCH E
D
761 VT 0.8
SH20: B-1
404 WH 0.8
SH14: B-3
X-301 A SP-026
919 BK 0.8 X-301 SH20: B-1
916 BK 0.8
SH22: B-6
927 BK 2.0
SH27: B-5
934 BK 0.8
SH7: C-6
940 BK 3.0 S-013 SELF LEVEL SWITCH D
SH27: C-5
E
D
E
405 OR 0.8 X-317
C 796 VT 0.8
C
A
A
922 BK 0.8 X-317 S-007 NH PARK BRAKE SWITCH 2
SH25: C-6
3
305 YE 0.8
SH25: B-6
306 YE 0.8 X-365
X-365 Z-008 ACCESSORY POWER OUTLET A
SP-033 SH14: D-3
115 RD 2.0
B
801 RD 0.8
X-ACC
952 BK 0.8
SH7: C-6
312 WH 0.8
SH14: D-6
X-ACC S-005 LOADER LOCKOUT SWITCH E
B
D
SH14: D-6
311 WH 0.8
B
C X-306 A
924 BK 0.8 X-306 S-026 HAZARD LAMP SWITCH
B SH14: C-6
784 OR 1.0
SH14: C-6
785 OR 0.8
A
E
776 VT 1.0
SH22: C-6
778 VT 0.8
SH22: B-6
F
SH7: C-6
941 BK 0.8
X-302 SP-025
C
920 BK 0.8
SH21: C-2
917 BK 0.8
SH21: B-2
915 BK 0.8
X-302 S-028 HIGH FLOW SWITCH
A
A
A
921 BK 0.8 C SH14: D-6
750 WH 0.8
D
SH14: C-6
753 OR 0.8 E X-303 X-303
6
5
4
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Electrical systems - Harnesses and connectors
Wiring harnesses - Electrical schematic sheet 16 SH16-LH NH CONTROL HANDLE SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
Type Speaker Switch Switch Switch Switch Switch Switch Connector Connector Connector Connector Solenoid Sub-Assembly
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Component H-001 S-015 S-023 S-024 S-027 S-032 S-033 X-2SPD X-405 X-HORN-GND X-HORN-PWR Y-005 Z-012
(Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Description Connector / Link X-HORN-PWR X-HORN-GND HORN #2 HORN 2SPD TURN SIGNAL #3 2ND AUX HYDRAULIC X-2SPD X-405 LH HANDLE INTERCONNECT HORN/TWO SPEED X-HORN-GND HORN GROUND X-HORN-PWR HORN POWER 2 SPEED SOLENOID X-405 LEFT HAND CONTROL HANDLE
Electrical systems - Harnesses and connectors
6
5
4
3
2
1
Z-012 LEFT HAND CONTROL HANDLE
S-027 TURN SIGNAL
D
D
1 IN 2
S-033 2ND AUX HYDRAULIC 1 IN 2
S-015 #2 1 IN 2
C
C S-032 #3 1 IN
2
Y-005 2 SPEED SOLENOID
S-024 2SPD
564 WH 0.8
563 WH 0.8
X-2SPD
X-2SPD
SP-035
D
IN
A
OUT
B
953 BK 0.8
SH7: C-6
X-2SPD
X-2SPD H-001
S-023 HORN
HORN B
A SH8: C-1
SH14: B-1
565 VT 0.8
1
891 OR 0.8
892 WH 0.8
P X-HORN-PWR
X-405
1
X-405
N
X-HORN-GND
B
955 BK 0.8
SP-063
424 VT 0.8
SH30: C-5
425 VT 0.8
SH14: D-4
SH30: B-5
412 VT 0.8
416 VT 0.8
SH28: C-5
SH30: B-5
413 RD 0.8
417 RD 0.8
SH28: C-5
427 RD 0.8
SH14: D-4
426 RD 0.8
SH30: C-5
SP-064
B
SH7: C-6
A
A
6
5
4
3 SHT_16
1
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Electrical systems - Harnesses and connectors
Wiring harnesses - Electrical schematic sheet 17 SH17-RH NH CONTROL HANDLE SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
Type Switch Switch Switch Switch Switch Connector
Component S-014 S-018 S-022 S-031 S-036 X-402
Connector X-RDCTRL Y-010 Solenoid Sub-Assembly Z-013
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(Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical
Connector / Link
X-402 X-RDCTRL X-402
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Description PARK BRAKE SWITCH RIDE CONTROL/GLIDE RIDE #2 #1 PROPORTIONAL AUXILIARY HYDRAULIC SWITCH RH HANDLE INTERCONNECT PARK BRAKE/RIDE CONTROL RIDE CONTROL VALVE SOLENOID RIDE CONTROL SOLENOID RIGHT HAND CONTROL HANDLE
Electrical systems - Harnesses and connectors
6
5
4
3
2
1
D
D Z-013 RIGHT HAND CONTROL HANDLE
S-031 #1 1
2
S-022 #2 1
2
Y-010
S-018 RIDE CONTROL/GLIDE RIDE
C
SH8: C-1
RIDE CONTROL SOLENOID
X-RDCTRL
4
5
832 OR 0.8
831 WH 0.8
IN
1
OUT
X-RDCTRL
X-RDCTRL 2
951 BK 0.8
C
SH7: D-1
X-RDCTRL
S-014 PARK BRAKE SWITCH 1 SH14: A-4
2
324 OR 0.8
SH14: A-1
307 YE 0.8 X-402
S-036 PROPORTIONAL AUXILIARY HYDRAULIC SWITCH 10 SH19: C-1
331 OR 0.8
SH19: D-1
699 PK 0.8
SH19: C-1
1010 BK/WH 0.8
GND
PWR
8
OUT
9
X-402
B
B
A
A
6
5
4
3 SHT_17
1
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Electrical systems - Harnesses and connectors
Wiring harnesses - Electrical schematic sheet 18 SH18-SEAT SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
Type Resistor Switch Switch Switch Connector Connector Connector Sub-Assembly
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(Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical
Component R-001 S-002 S-003 S-011 X-058 X-104 X-C23 Z-006
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Description
Connector / Link
X-058 X-104 X-C23 X-058
SEAT HEAT ELEMENT SEAT SWITCH SEAT HEAT SWITCH LAP BAR SWITCH CAB/SEAT INTERFACE INSTRUMENT CLUSTER SEAT
Electrical systems - Harnesses and connectors
6
5
4
3
2
1
D
D
Z-006 SEAT
C
C
S-003 SEAT HEAT SWITCH
1 SH27: C-5
756 OR 1.0
SH7: B-6
933 BK 1.0 2
SH26: B-6
933 BK 1.0 SP-001
R-001 SEAT HEAT ELEMENT P
S-011
N
LAP BAR SWITCH
X-104
316 RD 0.8 SP-012
3
315 RD 0.8
1
X-104 2
X-104
314 YE 0.8
SH25: B-6
X-104 SH25: C-6
317 RD 0.8
4
B
B
SH25: B-6
323 YE 0.8 S-002
X-058
SEAT SWITCH
A
A
6
5
4
3 SHT_18
1
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Electrical systems - Harnesses and connectors
Wiring harnesses - Electrical schematic sheet 19 SH19-EH AUX PWM SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical
Type ECU Switch Connector
A-003 S-041 X-402
X-430
Connector Connector Connector Connector Connector Solenoid Solenoid Solenoid
X-430 X-432 X-433 X-904 X-905 Y-002 Y-003 Y-007
X-430 X-432 X-433 X-904 X-905
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Component
Connector / Link
X-402
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Description EH AUX PWM CONTROLLER BOOM LOCK INTERLOCK SWITCH RH HANDLE INTERCONNECT PARK BRAKE/RIDE CONTROL EH AUX PWM CONTROLLER PROPORTIONAL AUX VALVE EXTEND BOOM LOCK INTERLOCK SWITCH PROPORTIONAL AUX VALVE RETRACT PROPORTIONAL AUX VALVE EXTEND BOOM LOCK VALVE
Electrical systems - Harnesses and connectors
6
D
5
4
3
2
1
D
A-003 EH AUX PWM CONTROLLER
EH AUX POWER CLEAN ENGINE GROUND EH AUX RETRACT SIGNAL 1 EH AUX RETRACT SIGNAL 2 EH AUX VALVE SIGNAL RETURN EH AUX PROPORTIONAL SW SIGNAL OUTPUT EH AUX PROPORTIONAL SW GND EH AUX PROPORTIONAL SW REFERENCE VOLTAGE
1
319 OR 0.8
SH14: D-1
901 BK/WH 0.8
SH7: D-6
2 3
889 WH 0.8 4
890 WH 0.8 5 6
699 PK 0.8
SH17: B-6
1010 BK/WH 0.8
SH17: B-6
331 OR 0.8
SH17: C-6
7 8
1009 BL 0.8
X-430
C
C Y-002 PROPORTIONAL AUX VALVE RETRACT
X-432
X-432 1
2
914 BL 0.8
X-432
X-432
SP-088 Y-003 PROPORTIONAL AUX VALVE EXTEND
X-433
911 BL 0.8
X-433 1
2 X-433
X-433
B
B
S-041
Y-007
BOOM LOCK INTERLOCK SWITCH SH14: A-4
A
B
1102 OR 0.8
BOOM LOCK VALVE
X-904
X-904
X-904
X-905
1103 WH 0.8
X-905 1
X-904
2 X-905
SH7: C-6
1104 BK 0.8
X-905
A
A
6
5
4
3 SHT_19
1
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Electrical systems - Harnesses and connectors
Wiring harnesses - Electrical schematic sheet 20 SH20-LAMPS SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
Type Lamp Lamp Lamp Lamp Lamp Lamp Power outlet Switch Switch Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector
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Component E-003 E-021 E-023 E-024 E-025 E-026 J-001 S-012 S-029 X-068 X-077 X-097 X-101 X-101A X-101B X-178 X-311 X-341 X-342 X-343 X-344 X-FUSE1
(Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical
Connector / Link X-097 X-341 X-344 X-343 X-342 X-178 X-077 X-311 X-101 X-101A X-101B X-068 X-077 X-097 X-101 X-101A X-101B X-178 X-311 X-341 X-342 X-343 X-344 X-FUSE1
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Description DOME LAMP LH REAR STROBE LH FRONT STROBE RH FRONT STROBE RH REAR STROBE ROTATING BEACON SIDE LAMP DIA SOCKET LAMP SELECTOR SWITCH STD/ON-ROAD LAMP CONFIGURATOR SIDE LAMP DIA SOCKET CAB/DOME LAMP JUMPER ON ROAD LIGHT CONFIGURATOR ON ROAD LIGHT CONFIGURATOR STANDARD X-101B ON ROAD LIGHT CONFIGURATOR BEACON LAMP SOCKET LIGHT SELECTOR SW LH REAR STROBE RH REAR STROBE RH FRONT STROBE LH FRONT STROBE POWER DISTRIBUTION-CHASSIS
Electrical systems - Harnesses and connectors
6
5
4
3
2
1
S-012 LAMP SELECTOR SWITCH
D
SH14: A-3
IN
123 OR 3.0
1
A
2
B
3
C
X-311
D
790 VT 1.0
SH14: A-6
791 VT 3.0
SH14: D-3
792 VT 3.0
SH14: D-3
D
X-311 E-023 LH FRONT STROBE 2
1
1005 BK 0.8
740 VT 0.8 3
681 PK 0.8
X-344 X-344 E-021 LH REAR STROBE 2
1
758 VT 0.8
SP-083
1007 BK 0.8 3
SP-084
683 PK 0.8
X-341 X-341 E-024 RH FRONT STROBE X-068 1
738 VT 0.8
PWR PWR
2
739 VT 0.8
1004 BK 0.8
SP-082
3
680 PK 0.8
X-343
1003 BK 0.8
GND GND
C
C
X-343 E-025 RH REAR STROBE
X-068
1
2
757 VT 0.8
1006 BK 0.8 3
682 PK 0.8
X-342 X-342
E-003 DOME LAMP 1 SH27: C-5
2
800 OR 0.8
SH27: C-5
SH15: D-6
916 BK 0.8
151 OR 0.8
X-097
X-097
CAB MECH BASIC T4A
E-026 ROTATING BEACON 1
B
P
2
N
SH15: D-1
761 VT 0.8
B
55 X-178
X-178
SH24: C-6
928 BK 0.8
J-001 SIDE LAMP DIA SOCKET 2 SH22: B-6
238 VT 0.8
SH24: C-6
1085 BK 0.8
1
X-077
SH6: B-6
715 VT 1.0
SH6: B-6
714 VT 1.0
SH5: B-6
715 VT 1.0
SH5: C-6
714 VT 1.0
S-029 STD/ON-ROAD LAMP CONFIGURATOR
A
X-101B SP-057
1
A
ROAD
711 VT 2.0
1
SH2: D-6
710 VT 2.0
SH3: D-6
710 VT 2.0
SH14: D-1
702 VT 2.0
1 STD
X-101
6
5
X-101A
4
3 SHT_20
1
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Electrical systems - Harnesses and connectors
Wiring harnesses - Electrical schematic sheet 21 SH21-INDICATORS SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
Type Lamp Lamp Connector Connector Connector Connector
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Component E-008 E-027 X-155B X-156B X-157B X-310
(Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical
Connector / Link X-155B X-157B X-156B X-310 X-155B X-156B X-157B X-310
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Description TURN SIGNAL INDICATOR 2 SPEED INDICATOR TURN INDI RIGHT TURN INDI LEFT TURN INDI GROUND 2SPD INDICATOR
Electrical systems - Harnesses and connectors
6
5
4
3
2
1
D
D
C
C
E-027 2 SPEED INDICATOR
7 SH14: B-3
9
565 VT 0.8
SH15: A-1
917 BK 0.8 X-310
X-310
E-008 TURN SIGNAL INDICATOR RH TURN
1 SH22: C-6
771 VT 0.8
PWR1
X-155B
GND
1 SH15: A-1
915 BK 0.8 1 SH22: C-6
X-157B
PWR2
772 YE 0.8 X-156B
LH TURN
B
B
A
A
6
5
4
3 SHT_21
1
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Electrical systems - Harnesses and connectors
Wiring harnesses - Electrical schematic sheet 22 SH22-EU LIGHT ADAPTER SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
Type ECU Switch Connector Connector Connector Connector Connector Connector
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Component A-004 S-034 X-030 X-031 X-302 X-411 X-CTS X-HZRDDIODE
(Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical
Connector / Link X-411 X-CTS X-030 X-031 X-302 X-411 X-CTS X-HZRDDIODE
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Description FLASHER MODULE TURN SIGNAL SWITCH
HAZARD SW FLASHER MODULE TURN SIGNAL SWITCH HAZARD SW DIODE
Electrical systems - Harnesses and connectors
6
5
4
3
2
1
SH35: D-5
769 OR 2.0
SH30: D-5
770 OR 0.8
D
SP-050
D
SH14: C-4
782 OR 2.0
SH7: D-6
981 BK 0.8 A-004 FLASHER MODULE
85
87A
769 OR 2.0
30 SH5: D-1
156 RD 2.0 X-411
CHAS RH TWR MD T4A F5
C
C 156 RD 2.0 SH21: B-5
772 YE 0.8
SH21: B-5
771 VT 0.8
SH14: C-6
769 OR 2.0
SH35: D-1 SH35: D-1 SH7: A-6
981 BK 0.8
774 VT 0.8 SP-018
SH15: B-1
776 VT 1.0
SH14: C-6
780 VT 0.8
X-031
V-003 6A DIODE
773 VT 0.8
3
LH WORK LAMP
799 VT 2.0
1
LH SIDE LAMP
794 VT 2.0
2
LH CAB TURN SIGNAL
927 BK 2.0
4
LH CAB LAMPS GND
SP-019 SH15: A-1
2 B
778 VT 0.8
A 1 P
X-HZRDDIODE
X-HZRDDIODE
N X-HZRDDIODE
781 VT 0.8 X-HZRDDIODE
SH15: D-6
X-031
X-030
SP-016
B
SH14: D-6
797 VT 5.0
798 VT 2.0 779 VT 1.0
1
RH WORK LAMP
3
RH SIDE LAMP
2
RH CAB TURN SIGNAL
4
RH CAB LAMPS GND
B
SP-015 SH14: B-6
795 VT 5.0
SH24: C-6
926 BK 2.0
SH20: B-6
238 VT 0.8
793 VT 2.0
X-030
S-034 TURN SIGNAL SWITCH
E SH14: C-6
783 OR 1.0
OUT1
D
OUT2
F
777 VT 1.0
IN
775 VT 1.0
X-CTS X-CTS SH7: B-6
939 BK 2.0
A
A
6
5
4
3 SHT_22
1
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Electrical systems - Harnesses and connectors
Wiring harnesses - Electrical schematic sheet 23 SH23-BOOM AND ROAD LIGHTS SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
Type Lamp Lamp Lamp Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Sub-Assembly Sub-Assembly Sub-Assembly Sub-Assembly Sub-Assembly
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Component E-019 E-028 E-029 X-033A X-037 X-038 X-039 X-044 X-049 X-080 X-081 X-196 X-198 X-201 X-205 X-229 X-230 X-231 X-232 X-233 X-FUSE2 Z-002 Z-005 Z-009 Z-010 Z-228
(Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical
Connector / Link X-080 X-081 X-038 X-033A X-033A X-037 X-038 X-039 X-044 X-049 X-080 X-081 X-196 X-198 X-201 X-205 X-229 X-230 X-231 X-232 X-233 X-FUSE2 X-229 X-196 X-044 X-198 X-037 Z-228 Z-228
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Description LICENSE PLATE RH REAR WORK LH REAR WORK
REAR LAMP JUMPER DOOR/CHASSIS INTERFACE CHASSIS OPTIONS/LH BOOM LIGHTS INTERCONNECT CHASSIS OPTION/ RH BOOMLIGHTS INTERCONNECT
POWER DISTRIBUTION-CHASSIS RH FRONT ROAD LAMP RH REAR ROAD LAMP LH REAR ROAD LAMP LH FRONT ROAD LAMP
Electrical systems - Harnesses and connectors
6
5
4
3
2
1 E-028
RH REAR WORK X-039
A
732 VT 0.8
B
897 VT 0.8
P
A
B
N
729 VT 1.0 LH REAR POSITION LAMP
997 BK 2.0 55 X-038
1091 BK 0.8
C
E-029
X-039
LH REAR WORK SP-079
A
D
728 VT 1.0 X-049
RH REAR POSITION LAMP
X-038
A
734 VT 1.0
B
718A VT 0.8
C
1092 BK 0.8
P
N
B
D
998 BK 0.8
55 X-033A
X-033A Z-009 LH REAR ROAD LAMP
X-049
B
TAIL
A
STOP
731 VT 0.8
C GND1
732A VT 0.8
996 BK 2.0 X-037
X-037 TURN
A
GND2
C
X-198
1001 BK 0.8
X-198 E-019
X-205
C
SH34: B-2 SH35: B-1 SH33: B-1 SH35: A-1 SH33: A-1 SH7: A-6 SH7: A-6 SH33: B-1 SH35: B-1 SH23: A-5
706 VT 3.0 704 VT 0.8 704 VT 0.8 703 VT 0.8 703 VT 0.8 950 BK 3.0 950 BK 3.0 717 VT 0.8 717 VT 0.8 718 VT 0.8
LICENSE PLATE
X-201 1
1
REAR WORK LAMP POWER
1
730 VT 2.0
2
2
RH TAIL LAMP POWER
2
733 VT 0.8
1
3
3
LH TAIL LAMP POWER
3
4
4
REAR LAMP GROUND
4
Z-005
SP-190x 5
1
X-081
C
RH REAR ROAD LAMP
5
LH REAR POSITION LAMP
5
6
RH REAR POSITION LAMP
6
B
717B VT 0.8
TAIL C
6
SH33: A-1 SH35: A-1 SH33: B-1 SH35: B-1 SH23: A-5
721 VT 0.8 721 VT 0.8 766 VT 0.8 766 VT 0.8 763 VT 0.8
7
7
11
11
LH REAR TURN SIGNAL POWER
12
12
RH REAR TURN SIGNAL POWER
SH7: B-6
975 BK 3.0
13
13
REAR LAMP GROUND
975 BK 3.0
N 55
X-080
GND1 A
SH7: A-6
P
898 VT 0.8
BRAKE LAMP SIGNAL POWER
7
737 VT 0.8
11
735 VT 0.8
12
736 VT 0.8
734A VT 0.8
X-044
SP-081 X-044 A
13
X-205
999 BK 0.8
STOP
TURN
GND2
X-196
X-201
C
X-196
1002 BK 0.8
CHAS RH TWR MD T4A F5
975 BK 3.0
1095 BK 0.8 SP-170
1001 BK 0.8 1000 BK 0.8
963 BK 2.0
SH34: C-1
SP-080
B X-230
B
Z-010
X-232
LH FRONT ROAD LAMP SH7: C-6 SH6: B-1
979 BK 1.0
D
D
979A BK 1.0
A
A
712A VT 2.0
716 VT 1.0 SP-074
SP-059 SH5: C-1
716 VT 1.0
SH33: B-6
717 VT 0.8
712 VT 1.0
2
742 VT 0.8 LOW BEAM 4
SH35: B-5
717 VT 0.8
GND
741 VT 0.8
1
SP-051 SH14: C-4
774 VT 0.8
SH30: D-5
768 VT 0.8
SH33: B-6
766A VT 0.8
SH35: B-5
766A VT 0.8
SH7: A-6
980 BK 1.0
767 VT 0.8
B
POSITION
767A VT 0.8
B
Z-228 5
X-232
X-230
TURN Z-228
Z-002
X-231
X-233 RH FRONT ROAD LAMP D
D
980A BK 3.0
A
A
713A VT 1.0
SP-075
SP-060
A
SH33: C-1
719 VT 1.0
SH35: C-1
719 VT 1.0
713 VT 1.0
2
540 VT 0.8
SH23: C-6
718 VT 0.8
SH33: C-1
780 VT 0.8
GND
1
539 VT 0.8 SP-052
SH35: C-1
A
LOW BEAM 4
764 VT 0.8
780 VT 0.8
X-229 5
X-233
X-231
POSITION
764A VT 0.8
B
B
TURN SH23: C-6
6
763 VT 0.8
5
X-229
4
3 SHT_23
1
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Electrical systems - Harnesses and connectors
Wiring harnesses - Electrical schematic sheet 24 SH24-WIPER / WASHER SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
Type Motor Motor Motor Switch Switch Connector Connector Connector Connector Connector Connector
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Component M-001 M-002 M-004 S-017 S-025 X-252 X-502 X-502A X-503 X-505 X-506
(Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical
Connector / Link X-502 X-502A X-503 X-252 X-502 X-502A X-503 X-505 X-506
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Description DOOR WIPER MOTOR REAR WIPER MOTOR FRONT DOOR WASHER PUMP (CAB) WIPER/WASHER SWITCH DOOR SWITCH TEMP CONTROL SW DOOR WIPER MOTOR REAR WINDOW WIPER MOTOR WIPER/WASHER SW
Electrical systems - Harnesses and connectors
6
5
4
3
2
1
D
D
M-004 FRONT DOOR WASHER PUMP (CAB) X-506
X-506
M-001
970 BK 0.8
A
1
M
B
224 WH 0.8
2
X-506
DOOR WIPER MOTOR A
X-506
53 (MOTOR +)
227 WH 0.8 D
SH25: B-6
220 YE 0.8 M
PARK C
53a
231 OR 0.8
B
31 (GND)
X-502
X-502
929 BK 0.8
C
SH7: C-6
939 BK 5.0
SH22: B-6
926 BK 2.0
C
SP-014
SH7: B-6
937 BK 3.0
SH20: A-6
1085 BK 0.8
SH20: B-1
928 BK 0.8
913 BK 0.8
SH26: C-1
912 BK 0.8
SH26: B-6
931 BK 0.8
SH7: C-6
932 BK 0.8
SH7: B-6
SP-027 S-017 WIPER/WASHER SWITCH
1 SP-023 SH14: D-6
233 OR 2.0
931 BK 0.8
3
229 OR 0.8
2
SP-022
225 WH 0.8
6
230 OR 0.8
5 X-503 7
226 VT 0.8 8
B
932 BK 0.8
B
X-503
M-002 REAR WIPER MOTOR A
53 (MOTOR +)
C
53a
228 WH 0.8
PARK
M
232 OR 0.8 31 (GND)
B
X-502A
X-502A
930 BK 0.8
S-025 DOOR SWITCH
X-505
X-505 SH7: C-1
2
1016 BK/WH 0.8
SH25: B-6
250 YE 0.8
1 X-505
X-505
A
A
6
5
4
3 SHT_24
1
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Electrical systems - Harnesses and connectors
Wiring harnesses - Electrical schematic sheet 25 SH25-INSTRUMENT CLUSTER SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
Type ECU Connector Connector Connector Connector
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Component A-002 X-015 X-020A X-316 X-C23
(Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical
Connector / Link X-C23 X-015 X-020A X-316 X-C23
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Description INSTRUMENT CLUSTER HAND TROTTLE IGNITION BACKFEED DIODE INSTRUMENT CLUSTER
Electrical systems - Harnesses and connectors
6
5
4
3
2
1
D
D
A-002 INSTRUMENT CLUSTER
1
1
2 HYDRAULIC OIL FILTER
SH14: C-3
261 YE 0.8
3 SH8: A-1
THROTTLE SENDER SUPPLY
KEY START OUTPUT
211 PK 0.8
SH14: B-3
260 PK 0.8
SH12: C-2
SP-201
17
259 PK 0.8
624 WH 0.8 4 HAND THROTTLE SIGNAL CDB-015
CDB-015 SH31: C-5
5 CAN LOW
SH31: C-5
CAN HIGH
THROTTLE SENDER GND
500 YE 0.8
C
SP-010
305 YE 0.8
SH14: A-6
309 OR 1.0
SH31: C-5
162 RD 0.8
SH14: C-3
310 RD 0.8
SH18: B-1
317 RD 0.8
SH8: A-6
140 RD 0.8
7
INSTRUMENT CLUSTER SW POWER 1
8
INSTRUMENT CLUSTER SW POWER 2
544 YE 0.8
SH12: C-2
545 YE 0.8
SH14: C-3
23
505 GN 0.8 6
SH15: C-6
FOOT THROTTLE SIGNAL
22
SP-200
25
1070 BK/WH 0.8
1066 BK/WH 0.8
SH14: B-3
1071 BK/WH 0.8
SH12: C-2
C
301 OR 0.8 302 OR 0.8 EH AUX POWER
SP-004
9
313 RD 0.8
26
319 OR 0.8
SH14: D-3
258 WH 0.8
SH14: C-3
INSTRUMENT CLUSTER UNSWITCHED POWER
14 10 SH8: A-1
132 OR 0.8
SH14: B-3
267 YE 0.8
SH18: B-1
323 YE 0.8
SH14: B-6
205C YE 0.8
11 12 13
KEY IGNITION
27
AIR FILTER/ENGINE MALFUNCTION SEAT SWITCH CLUSTER INPUT TELEMATICS CRANK DISABLE
28 PARK BRAKE VALVE SIGNAL
15 16 SH14: C-3
264 YE 0.8
HYDRAULIC OIL TEMPERATURE SENDER
139 OR 0.8
SH14: B-3
V-001 18 SH24: A-1
B
29
250 YE 0.8 SP-093
SH24: D-6
19
220 YE 0.8
251 YE 0.8
137 WH 0.8
DOOR SWITCH SIGNAL
P
2
N
X-015 20
SH18: B-1
ACCESSORY RELAY SIGNAL
ACCESSORY BACKFEED DIODE
X-015
314 YE 0.8
LAP BAR/SEAT BELT CLUSTER INPUT
1
SH14: A-3
307 YE 0.8
SH15: C-1
306 YE 0.8
21
754 YE 0.8
153 WH 0.8
141 WH 0.8
SH8: B-1 SH14: D-6
B
SP-009
X-015
30
HYDRAULIC LOADER INTERLOCK SIGNAL SP-006
138 OR 0.8
X-015
303 WH 0.8
SH14: C-3
622 WH 0.8
SH14: B-3
31
PARK BRAKE SW
32 START RELAY SIGNAL 24 SH14: D-3
234 YE 0.8
FUEL LEVEL SENDER
MAIN POWER RELAY SIGNAL
33
133 OR 0.8 V-002
34 CLUSTER GROUND
X-C23
IGNITION BACKFEED DIODE 2
1
144 OR 0.8
X-C23 X-316
SH14: B-6
X-316
1011 BK/WH 0.8
SH7: C-1
A
A
6
5
4
3 SHT_25
1
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Electrical systems - Harnesses and connectors
Wiring harnesses - Electrical schematic sheet 26 SH26-HVAC SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
Type ECU Ground Relay Switch Switch Switch Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Sub-Assembly Sub-Assembly Sub-Assembly Sub-Assembly
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Component A-001 GND-009 K-018 S-010 S-019 S-021 X-011 X-074 X-075 X-076 X-111 X-252 X-270 X-271 X-275 X-HVC1 Z-003 Z-004 Z-007 Z-011
(Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical
Connector / Link X-HVC1 GND-009 X-111 X-270 X-275 X-011 X-074 X-075 X-076 X-111 X-252 X-270 X-271 X-275 X-HVC1 X-271 X-252 AC_COMP1 X-074
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Description HVAC BOX CONDENSER RELAY BLOWER SWITCH (LEFT CONSOLE) AC SWITCH (LEFT CONSOLE) HVAC HIGH PRESSURE SWITCH HVAC CONDENSER FAN
CONDENSER RELAY [CAB] TEMP CONTROL SW BLOWER FAN SW WATER VALVE A/C SW CAB/HVAC INTERCONNECT WATER VALVE TEMP CONTROL (LH CONSOLE) A/C COMPRESSOR HVAC CONDENSER FAN
Electrical systems - Harnesses and connectors
6
5
4
3
2
1
A-001
D
HVAC BOX
D
S-010 BLOWER SWITCH (LEFT CONSOLE)
1 HVAC GROUND
935 BK 5.0 2
COMPRESSOR RELAY PIN 30 POWER HVAC FAN LOW
1
838 RD 1.0 3
3
2
4
3
5
4
828 WH 3.0 4
HVAC FAN MEDIUM
827 WH 3.0
HVAC FAN HIGH
SP-164
SP-165
5
850 WH 5.0
848 WH 8.0
IN
826 WH 3.0
6 A/C COMP RELAY PIN 86
837 WH 0.8 7
1
2
X-270
X-270
THERMOSTART PRESSURE SW BINARY PRESSURE SWITCH HVAC THERMOSTART CLEAN GROUND
821 OR 3.0
SH14: B-3
8 9 10
SP-163
HVAC RELAY PIN 87 OUTPUT POWER
842 OR 5.0 11
HVAC KEYED POWER 12 A/C COMPRESSOR RELAY PIN 87 POWER S-019
14 HVAC RELAY FUSE POWER
C
AC SWITCH (LEFT CONSOLE)
845 OR 5.0
C
SP-162 A
X-HVC1
825 OR 0.8 B
913 BK 0.8 829 WH 0.8
HVAC CONDENSER FAN
X-275
SP-157
B SH34: B-2
SH24: C-1
C
Z-011
X-275
237 WH 3.0
M S-021 A SH7: A-6
HVAC HIGH PRESSURE SWITCH
X-076
1084 BK 3.0
2
B B X-074
1
A A
X-076
833 WH 0.8
X-075
833 WH 0.8
SH33: C-1
834C WH 0.0
2 2
834 WH 0.8 834 WH 0.8
SH35: B-1 SH33: C-1
841C WH 0.0
3 3
841 WH 0.8 841 WH 0.8
SH35: A-1 SH33: B-1
X-076
X-076 K-018
SH35: C-1
1 1
833C WH 0.8
CONDENSER RELAY
87A
SH14: D-3
87
87
85
85
30
86
86
839 RD 3.0
X-011
SP-160
B
237 WH 3.0
SH18: C-1
933 BK 1.0
AC_COMP1
840 WH 0.8
1087 BK 0.8 SP-168
SH7: B-6
1
B
30
X-111
X-111
1088 BK 8.0 Z-007 A/C COMPRESSOR
Z-004 TEMP CONTROL (LH CONSOLE)
SH24: C-1
912 BK 0.8
SH14: B-3
824 YE 0.8
3
GND
2
SGL
1 SH14: B-3
836 RD 3.0
SH14: D-3
833 WH 0.8
SH14: A-3
834 WH 0.8
SH14: A-3
1012 BK/WH 0.8
SH7: C-1
846 OR 8.0
SH14: B-3
143 OR 0.8
SH27: C-5
841 WH 0.8
SH14: A-3
854 OR 8.0
SH14: A-6
PWR
823 PK 0.8 X-252 Z-003 WATER VALVE D
SH14: B-1
A
SGL
824 YE 0.8
C
SH7: C-6
1013 BK 0.8
SH14: B-1
822 OR 0.8
GND
A
M
A
PWR
X-271
6
5
4
3 SHT_26
1
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Electrical systems - Harnesses and connectors
Wiring harnesses - Electrical schematic sheet 27 SH27-RADIO SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
Type Speaker Speaker Connector Connector Connector Connector Connector Connector
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Component H-003 H-004 X-330 X-331 X-332 X-333 X-335 X-HVC1
(Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical
Connector / Link X-331 X-330 X-333 X-332 X-330 X-331 X-332 X-333 X-335 X-HVC1
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Description RH SPEAKER LH SPEAKER RIGHT SPEAKER RIGHT SPEAKER LEFT SPEAKER LEFT SPEAKER RADIO CONNECTOR CAB/HVAC INTERCONNECT
Electrical systems - Harnesses and connectors
6
5
4
3
2
1
D
D
SH18: C-1
756 OR 1.0
SH15: C-6
405 OR 0.8
C
C
SP-058
152 OR 1.0
SP-011 SH14: C-3
134 OR 2.0
SH20: B-6
151 OR 0.8
151 OR 0.8
CAB MECH BASIC T4A
SP-021 SH26: A-1
143 OR 0.8
SH20: B-6
800 OR 0.8 130 OR 0.8
SH15: C-6
9
934 BK 0.8
7
1 H-003
450 BL 0.8
5
451 WH 0.8
4
X-331 RH SPEAKER
1
B
B
X-330
1
453 WH 0.8
H-004
6
X-332
LH SPEAKER
1
452 BL 0.8
2
X-333 X-335
A
A
6
5
4
3 SHT_27
1
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Electrical systems - Harnesses and connectors
Wiring harnesses - Electrical schematic sheet 28 SH28-MULTIFUNCTION CONNECTORS SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical
Type Connector Connector Connector Connector
X-066 X-107 X-323 X-323A
Connector / Link X-066 X-107 X-323 X-323A
Connector
X-FUSE2
X-FUSE2
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Component
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Description
CHASSIS OPTION/MULTIFUNCTION INTERCONNECT X-323A CHASSIS OPTION/MULTIFUNCTION INTERCONNECT CAP POWER DISTRIBUTION-CHASSIS
Electrical systems - Harnesses and connectors
6
5
4
3
2
1
D
D
X-323
C
X-107
SH30: C-5
419 GY 0.8
1
1
419A LG 0.8
C
SH30: C-5
418 GY 0.8
2
2
418A GY 0.8
D
SH30: B-5
410 WH 0.8
3
3
410A WH 0.8
E
SH30: B-5
411 TN 0.8
4
4
411A TN 0.8
F
SH16: B-1
416 VT 0.8
5
5
416A VT 0.8
H
SH16: A-1
417 RD 0.8
6
6
SH30: B-5
856 WH 1.0
8
8
SH5: D-1 SH6: C-1 SH7: D-6
420 OR 3.0
9
9
982 BK 5.0
7
7
10
10
417A RD 0.8
C
G
422 WH 0.8
856A WH 3.0
J
SP-073 K
420A OR 8.0
420 OR 3.0 987 BK 3.0
B
433 YE 0.8
L X-107
X-323A
X-066
982A BK 5.0 SP-072
B
421 WH 0.8
A
988 BK 0.8
B X-066
B
A
A
6
5
4
3 SHT_28
1
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Electrical systems - Harnesses and connectors
Wiring harnesses - Electrical schematic sheet 29 SH29-TELEMATICS SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
Type Fuse Connector Connector Connector Connector
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Component F-053 X-319 X-FUSE2 X-TELE X-TELE_DIAG
(Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical
Connector / Link X-319 X-319 X-FUSE2 X-TELE X-TELE_DIAG
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Description TELEMATIC FUSE POWER DISTRIBUTION-CHASSIS TELEMATICS TELEMATICS DIAGNOS
Electrical systems - Harnesses and connectors
6
5
4
3
2
1
D
D
X-TELE
CDB-006
CDB-006 SH14: B-1
SH7: C-1
925 BK/WH 0.8
SH8: C-1
802 OR 0.8
SP-503A
2
CDB-002
CDB-002
503A YE 0.8
SH14: B-1
1
503B YE 0.8
3
504A GN 0.8 SP-504A CDB-003
SH33: B-6
504B GN 0.8
4
CDB-003
504C GN 0.8 5
NOT USED SH33: B-6
503C YE 0.8 SH14: B-4
208 BL 0.8
6
SH14: B-4
207 TN 0.8
7
SH8: C-6
244 YE 0.8
8
CDB-034 SH35: C-5
C
504C GN 0.8
SH35: B-5
C
503C YE 0.8
NOT USED
9
NOT USED
10
SH13: B-5
308 YE 0.8
11
SH5: D-1
336 RD 1.0
12
X-TELE
X-TELE_DIAG
B
SH14: B-6
206 BK/WH 0.8
1
SH14: B-6
207 TN 0.8
2
SH14: B-6
208 BL 0.8
3
B
TELEMATICS DIAGNOSTIC
4
X-TELE_DIAG
F-053
TELEMATIC FUSE A
336 RD 1.0 B SH7: C-1
119 RD 1.0
2
5.0 A
1
X-319
A
A
6
5
4
3 SHT_29
1
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Electrical systems - Harnesses and connectors
Wiring harnesses - Electrical schematic sheet 30 SH30-MULTIFUNCTION JUMPER SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
Type Connector Connector Connector Connector
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Component X-113 X-114 X-117 X-FUSE2
(Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical
Connector / Link X-113 X-114 X-117 X-FUSE2
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Description
POWER DISTRIBUTION-CHASSIS
Electrical systems - Harnesses and connectors
6
5
4
3
2
1
X-114
D
558 OR 0.8
1
1
SH13: B-5
554 WH 0.8
2
2
SH13: B-5
552 WH 0.8
3
3
SH22: D-2
770 OR 0.8
5
5
SH23: B-5
768 VT 0.8
6
6
7
7
8
8
SH5: A-1
SH14: C-4
765 VT 0.8
780 VT 0.8
D
LH HANDLE INTERCONNECT
SP-780 SH33: C-6 SH35: C-5
780A VT 0.8
857 WH 1.0
9
9
358 OR 0.8
10
10
424 VT 0.8
SH16: B-1
C
246 OR 1.0
780A VT 0.8
11
11
SH16: A-1
426 RD 0.8
12
12
SH28: C-5
418 GY 0.8
13
13
SH28: C-5
419 GY 0.8
14
14
C
X-114
SP-197 SH5: C-1
129 OR 1.0
SH6: C-1
129 OR 1.0
SH5: C-6
354 OR 0.8 SP-062
SH6: B-6 SH14: D-4
354 OR 0.8 359 OR 0.8
X-117
352 OR 0.8
B
1
1
SH28: C-5
410 WH 0.8
2
2
SH28: C-5
411 TN 0.8
3
3
5
5
6
6
SH16: B-6
412 VT 0.8
SH16: A-6
413 RD 0.8 247 OR 1.0
9
9
858 WH 1.0
10
10
B RH HANDLE INTERCONNECT
SP-198 SH28: C-5
856 WH 1.0
X-117
X-113 SH14: D-6
425 VT 0.8
D D
SH14: D-6
359 OR 0.8
E E
SH14: D-6
427 RD 0.8
F
FE #2 SWITCH
F X-113
A
A
6
5
4
3 SHT_30
1
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Electrical systems - Harnesses and connectors
Wiring harnesses - Electrical schematic sheet 31 SH31-DIAGNOSTIC CONNECTOR SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
Type Connector
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Component X-DIAG
(Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical
Connector / Link X-DIAG
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Description CAN DIAGNOSTIC CONNECTO
Electrical systems - Harnesses and connectors
6
5
4
3
2
1
D
D
X-DIAG SH7: C-1 SH25: C-6
C
CDB-015 SH25: C-6
961 BK/WH 0.8
A
162 RD 0.8
B
C
CDB-015
505 GN 0.8 SP-089
SH25: C-6
CDB-014
CDB-014
501 YE 0.8
500 YE 0.8 CDB-032
SH14: B-3
C
SP-090
CDB-032
506 GN 0.8
504 GN 0.8
D CAN DIAGNOSTIC CONNECTOR
SH14: B-3
503 YE 0.8
SH14: D-3
248 YE 0.8
E F G CDB-031
CDB-031 SH14: B-6
507 WH 0.8
SH14: B-6
508 BL 0.8
H J X-DIAG
B
B
A
A
6
5
4
3 SHT_31
1
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Electrical systems - Harnesses and connectors
Wiring harnesses - Electrical schematic sheet 32 SH32-FUEL FILTER JUMPER SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
Type Connector Connector
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Component X-9000 X-9001
(Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical
Connector / Link X-9000 X-9001
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Description
Electrical systems - Harnesses and connectors
6
5
4
3
2
1
D
D
C
C
X-9000
X-9001 1
1
1200 YE 0.8
1 1
2
2
1201 BK 0.8
2 2
TO ENGINE
FUEL FILTER
X-9000
X-9001
B
B
A
A
6
5
4
3 SHT_32
1
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Electrical systems - Harnesses and connectors
Wiring harnesses - Electrical schematic sheet 33 SH33-CHASSIS INTERFACE LG SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
Type Resistor Switch Switch Connector Connector Connector Connector Connector Connector
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Component R-002 S-004 S-006 X-014 X-042 X-043 X-900 X-901 X-FUSE1
(Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical
Connector / Link
X-014 X-042 X-043 X-900 X-901 X-FUSE1
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Description FUEL LEVEL SENDER MECHANICAL BACKUP SWITCH #1 MECHANICAL BACKUP SWITCH #2
MECHANICAL BACKUP SWITCH CHASSIS INTERFACE CHASSIS INTERFACE POWER DISTRIBUTION-CHASSIS
Electrical systems - Harnesses and connectors
6
5
4
3
2
1
X-900
D
SH2: C-1
110 OR 2.0
SH2: B-6
528E OR 2.0
SH5: B-1
719 VT 1.0
S-006 S-004 X-042
X-042
893 WH 0.8
C
2
1 1 X-042
1
2 2
X-042
2
1 1 X-043
2
3
3
4
4
5
5
6
6
7
7
8
8
9
9
10
10
11
11
12
12
13
13
14
14
15
15
16
1
2 2
895 WH 0.8 895 WH 0.8
16
17
17
18
18
SH10: D-6
110 OR 2.0
528E OR 2.0
SH9: A-6
719 VT 1.0
SH23: A-5
895 WH 0.8
SH34: C-5
248 YE 0.8
SH10: D-1
X-043
248 YE 0.8
19
19
SH9: C-1
161 YE 0.8
20
20
21
21
C SH10: C-6
161 YE 0.8
SH30: D-5
780A VT 0.8
22
22
780 VT 0.8
SH23: A-5
SH14: A-1
833 WH 0.8
23
23
833 WH 0.8
SH26: B-1
SH14: A-1
834 WH 0.8
24
24
834 WH 0.8
SH26: B-1
25
25
717 VT 0.8
SH23: C-6
717 VT 0.8
26
26
SH29: C-5
504C GN 0.8
27
27
504C GN 0.8
SH10: D-1
SH29: C-5
503C YE 0.8
28
28
503C YE 0.8
SH10: D-1
CDB-003
CDB-005
CDB-005
SH2: A-1
704 VT 0.8
29
29
704 VT 0.8
SH23: C-6
SH23: A-5
766A VT 0.8
30
30
766 VT 0.8
SH23: C-6
31
31
SH2: C-1
241A OR 1.0
32
32
241A OR 1.0
SH10: B-6
SH9: C-6
121 YE 0.8
33
33
121 YE 0.8
SH10: C-6
34
34
35
35
36
36
626 WH 0.8
SH10: C-6
37
37
38
38
39
39
841 WH 0.8
SH26: B-1
40
40
721 VT 0.8
SH23: C-6
133B OR 0.8
SH10: C-6
703 VT 0.8
SH23: C-6
SH14: B-1
622 WH 0.8
SH14: A-1
841 WH 0.8
SH5: A-1
725 VT 0.8
SH8: C-1
133B OR 0.8
41
41
SH14: D-1
234 RD 0.8
42
42
SH2: B-1
703 VT 0.8
43
43
44
44
SH14: B-1
267 YE 0.8
45
45
267 YE 0.8
SH8: D-6
SH9: B-1
112 BL 0.5
46
46
112 BL 0.5
SH10: D-6
47
47
R-002 FUEL LEVEL SENDER X-014
X-901
234 RD 0.8
X-014 A A
B B X-014
956 BK 0.8
5
4
3 SHT_33
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SH7: A-6
X-014
234 RD 0.8
6
D
SH35: C-5
SH14: D-1
CDB-003
A
X-043
X-043
894 WH 0.8
SH23: B-5
B
1
2
MECHANICAL BACKUP SWITCH #2
MECHANICAL BACKUP SWITCH #1 SH8: C-1
1
2
SH35: A-1
1
B
A
Electrical systems - Harnesses and connectors
Wiring harnesses - Electrical schematic sheet 34 SH34-CHASSIS INTERFACE SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
Type Speaker Switch Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector
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Component H-002 S-043 X-011 X-195 X-201 X-205 X-313 X-314 X-315 X-BKUP-GND X-BKUP-PWR X-FUSE1
(Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical
Connector / Link X-011 X-011 X-195 X-201 X-205 X-313 X-314 X-315 X-BKUP-GND X-BKUP-PWR X-FUSE1
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Description BACKUP ALARM WATER IN FUEL SWITCH GCU FUSE REAR LAMP JUMPER DOOR/CHASSIS INTERFACE GCU POWER CHASSIS POWER
POWER DISTRIBUTION-CHASSIS
Electrical systems - Harnesses and connectors
6
5
4
3
2
1
X-205
D
SH10: D-6
150 YE 0.8
SH10: D-6
908E BK 0.8
8
8
9
9
D
1151 YE 0.8 909 BK 0.8 S-043 WATER IN FUEL SWITCH PWR
3
SH10: C-6
133E OR 0.8
10
GND
2
OUT
1
1137 OR 0.8
10
X-011
X-011
H-002 BACKUP ALARM X-BKUP-PWR SH33: C-1
895 WH 0.8
SH35: C-1
14
896 WH 0.0
14
1 1
P
1 1
N
X-BKUP-GND
895 WH 0.8 X-201
SH23: B-1
963 BK 2.0
C
SH4: C-1
155A OR 3.0
SH4: C-1
706 VT 3.0
C
CHASSIS POWER X-314
SH2: C-1
155A OR 3.0
1 1
155A OR 3.0
SH10: D-6
SH14: D-1
237 WH 3.0
2 2
237 WH 3.0
SH26: C-6
SH2: A-1
706 VT 3.0
3 3
706 VT 3.0
212A OR 8.0
4 4
B
212A RD 5.0
SH23: C-6
212 OR 8.0
B
SH10: C-6
SP-212
X-314
X-315 SH7: D-6
1087 BK 5.0
2 REMOTE POWER/GROUND
212B OR 5.0
1 X-315
X-313
SP-212
1
212 OR 8.0
1 1
212A OR 8.0
X-195
212 OR 8.0
SH10: C-6
X-313
A
A
6
5
4
3 SHT_34
1
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Electrical systems - Harnesses and connectors
Wiring harnesses - Electrical schematic sheet 35 SH35-CHASSIS INTERFACE MD SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
Type Connector Connector
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(Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical
Component X-900 X-901
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Description
Connector / Link X-900 X-901
CHASSIS INTERFACE CHASSIS INTERFACE
Electrical systems - Harnesses and connectors
6
5
4
3
2
1
X-901
D
SH4: D-1 SH6: B-6 SH22: D-2 SH10: B-6 SH10: B-6 SH10: A-6 SH10: A-6 SH10: A-6 SH10: A-6 SH6: B-1 SH10: B-1 SH10: B-1
110 OR 2.0 156 RD 2.0 769 OR 2.0 241C OR 0.8 242 YE 0.8 245 YE 0.5 249 YE 0.5 252 BK 0.5 253 PK 0.5 719 VT 1.0 270 BK/WH 0.5 271 YE 0.5
SH33: C-4 SH29: C-5 SH14: D-1 SH9: D-1
895 WH 0.8 504C GN 0.8 248 YE 0.8 161 YE 0.8
SH30: C-5 SH14: A-1 SH14: A-1
780A VT 0.8 833 WH 0.8 834 WH 0.8
SH23: B-5
717 VT 0.8
4 4 5 5 1 1 7 7 8 8 9 9 10 10 11 11 12 12 13 13 14 14 15 15 16 16 17 17 18 18 19 19 20 20 21 21 22 22 23 23 24 24 25 25
C
26 27 28 29 30 31 32 33 36 39 40 41 42 43 45
B
A
SH4: C-1 SH23: A-5 SH29: C-5
704 VT 0.8 766A VT 0.8 503C YE 0.8
SH9: D-6 SH14: B-1 SH14: B-1 SH5: A-1 SH8: C-1 SH14: D-1 SH4: B-1 SH14: B-1
121 YE 0.8 622 WH 0.8 841 WH 0.8 721 VT 0.8 133B OR 0.8 234 RD 0.8 703 VT 0.8 267 YE 0.8
110 OR 2.0 156 RD 2.0 769 OR 2.0 241C OR 0.8 242 YE 0.8 245 YE 0.5 249 YE 0.5 252 BK 0.5 253 PK 0.5 719 VT 1.0 270 BK/WH 0.5 271 YE 0.5
SH10: D-6 SH22: C-1 SH22: C-1 SH11: D-1 SH10: A-6 SH10: A-6 SH10: A-6 SH10: A-6 SH10: A-6 SH23: A-5 SH10: C-1 SH10: C-1
895 WH 0.8
SH34: C-5
248 YE 0.8 161 YE 0.8
SH10: D-1 SH10: C-6
780 VT 0.8 833 WH 0.8 834 WH 0.8
SH23: A-5 SH26: B-1 SH26: B-1
D
C
26 27 28 29 30 31 32 33 36 39 40 41 42 43 45
CDB-035
717 VT 0.8
CDB-035
504C GN 0.8 503C YE 0.8 704 VT 0.8 766 VT 0.8
SH23: C-6 SH10: D-1 SH10: D-1 SH23: C-6 SH23: C-6
B
SH10: C-6 SH10: C-6 SH26: B-1 SH23: C-6 SH10: C-6 SH33: A-1 SH23: C-6 SH8: D-6
121 YE 0.8 626 WH 0.8 841 WH 0.8 721 VT 0.8 133B OR 0.8 234 RD 0.8 703 VT 0.8 267 YE 0.8
A
X-900
6
5
4
3 SHT_35
1
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Electrical systems - Harnesses and connectors
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Electrical systems - Harnesses and connectors
Wire connectors - Component diagram 00 Connectors X-000 to X-009 and Alphanumeric Connectors SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
X-004 - AIR TEMPERATURE SENSOR [ B-006] (84607243) (Receptacle)
84607243
1
84607243 Pin 2
From X-012 (Receptacle) pin 20 ECU
Wire 254
Description AIR TEMP GND
Frame
Color-Size BK/WH - 0.5
SHEET 06
Color-Size YE - 0.8
SHEET 04
X-005A - ALTERNATOR (84165069) (Receptacle)
84165069
2
84165069 1
Pin
From X-006 (Plug) pin 2
Wire 244A
2 3
X-006 (Plug) pin 1 X-006 (Plug) pin 4
127A 124A
Description ALTERNATOR LAMP TELEMATICS ENGINE ON ALTERNATOR EXCITE ENGINE RPM SIGNAL
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OR - 0.8 YE - 0.8
Frame
Electrical systems - Harnesses and connectors
X-6 - STARTER/ALTERNATOR (87382914) (Plug)
87382914
3
87382914 1
Pin
From Wire X-FUSE2 (Receptacle) pin 53 520
2
X-TELE (Receptacle) pin 8
244
3 4
SPLICE SP-030 X-CN1A (Receptacle) pin 16
127 124
Description STARTER MOTOR POWER ALTERNATOR LAMP TELEMATICS ENGINE ON ALTERNATOR EXCITE ENGINE RPM SIGNAL
Color-Size WH - 0.8
Frame SHEET 04
YE - 0.8
OR - 2.0 YE - 0.8
X-006 - PRE-OXICAT TEMP SENSOR [MEDIUM FRAME ONLY] (87709793) (Receptacle)
87709793
4
87709793 1
Pin
From Wire X-900 MD (Receptacle) pin 15 271
2
X-900 MD (Receptacle) pin 14 270
Description EXHAUST GAS TEMP SIGNAL EXHAUST GAS TEMP GROUND
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Color-Size YE - 0.8 BK/WH - 0.8
Frame SHEET 06
Electrical systems - Harnesses and connectors
X-007 - EXHAUST GAS TEMP SENSOR 2 [ B-012] (87696093) (Receptacle)
87696093
5
87696093 Pin 1 2
From X-012 (Receptacle) pin 84 ECU X-012 (Receptacle) pin 83 ECU
Wire 273 272
Description EXHAUST GAS TEMP SIGNAL 2 EXHAUST GAS TEMP GND 2
Color-Size YE - 0.5
Frame SHEET 06
BK/WH - 0.5
X-009 - IGNITION SWITCH (87693713) (Receptacle)
87693713
6
87693713 Pin 1 3 4 6
From X-C23 (Receptacle) pin 10 INSTRUMENT CLUSTER SPLICE SP-004 X-C23 (Receptacle) pin 3 INSTRUMENT CLUSTER SPLICE SP-009
Wire
Description KEY IGNITION
Color-Size OR - 0.8 RD - 0.8
624
KEY SW UNSWITCHED BATTERY KEY START OUTPUT
WH - 0.8
138
KEY ACCESSORY
OR - 0.8
132 140
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Frame SHEET 04
Electrical systems - Harnesses and connectors
X-2SPD - 2 SPEED VALVE SOLENOID [ Y-005] (87693821) (Plug)
87693821
7
87693821 A
Pin
From X-CN3A (Receptacle) pin 25
564
Wire
B
SPLICE SP-179
953
Description 2 SPEED VALVE SOLENOID SIGNAL 2 SPEED VALVE GROUND
Frame
Color-Size WH - 0.8
SHEET 17
BK - 0.8
SHEET 05
Description 2ND AUX EXTEND SWITCH OUTPUT 2ND AUX EXTEND GROUND
Color-Size WH - 0.8
SHEET 34
Description 2ND AUX RETRACT SIGNAL POWER 2ND AUX RETRACT GROUND
Color-Size WH - 0.8
X-AUX_EXT - 2ND AUX EXTEND (87695582) (Receptacle)
87695582
8
87695582 Pin 1 2
From X-ECC (Plug) pin 33 EH CHASSIS/CAB INTERFACE SPLICE SP-183
Wire 554 958
Frame
BK - 0.8
X-AUX_RET - X-AUX_RET (Receptacle) Pin 1 2
From X-ECC (Plug) pin 34 EH CHASSIS/CAB INTERFACE SPLICE SP-183
Wire 552 959
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BK - 0.8
Frame SHEET 34
Electrical systems - Harnesses and connectors
X-CAB_GNDA - CAB GROUND (84399576) (Plug)
84399576
9
84399576 Pin 1
From SPLICE SP-172
Wire 1093
Description CAB GROUND A
Frame
Color-Size BK - 13.0
SHEET 05
Color-Size BK - 13.0
SHEET 05
X-CAB_GNDB - GNDB CAB GROUND (84399576) (Plug)
84399576
10
84399576 Pin 1
From SPLICE SP-173
Wire 1094
Description CAB GROUND B
X-CN1A - UCM CN1A (82016219) (Receptacle)
82016219
11
82016219
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Frame
Electrical systems - Harnesses and connectors
Pin
13 14 16 19
From SPLICE SP-120 SPLICE SP-120 SPLICE SP-134 X-ECC (Plug) pin 50 EH CHASSIS/CAB INTERFACE X-010 SPLICE SP-100 X-006 (Plug) pin 4 SPLICE SP-099
20
X-FUSE1 PIN 38
189
22
X-010
1020
24
X-010
515
26 26
SPLICE SP-119 SPLICE SP-118
240 240
1 7 8 9
Wire 1075 1076 202 200 1018 525 124 1022
Description UCM GROUND 1A.01 UCM GROUND 1A.07 SENSOR SUPPLY 1 SENSOR SUPPLY 3
Color-Size BK/WH - 0.8 BK/WH - 0.8 PK - 0.8 PK - 0.8
BUCKET RETURN UCM WAKE-UP ENGINE RPM SIGNAL DRIVE REVERSE RETURN UCM UNSWITCHED BATTERY FUSE OUT PROPORTIONAL AUX RETURN PROPORTIONAL AUX RETRACT SIGNAL 5V REF SUPPLY FUSE 5V REF SUPPLY FUSE
BL - 0.8 YE - 0.8 YE - 0.8 BL - 0.8
Frame SHEET 12
SHEET 04 SHEET 12
RD - 0.8 BL - 0.8 WH - 0.8 OR - 0.8 OR - 0.8
SHEET 04
X-CN1B - UCM CN1B [ A-002A] (87410946) (Receptacle)
87410946
12
87410946 Pin 1 9 13
26
From SPLICE SP-120 SPLICE SP-120 X-ECC (Plug) pin 20 EH CHASSIS/CAB INTERFACE X-ECC (Plug) pin 12 EH CHASSIS/CAB INTERFACE SPLICE SP-109
27
SPLICE SP-109
126
29
SPLICE SP-150
580
30
SPLICE SP-150
579
31
SPLICE SP-113
166
32
SPLICE SP-113
201
33
X-010 PIN 12
514
15
Wire 1026 1025 560 521 128
Description UCM GROUND 1B.34 UCM GROUND 1B.26 RH UA2 Y SENSOR OUTPUT CONTROL PATTERN NEUTRAL SWITCHED POWER SUPPLY PROP AUX EXTEND SWITCHED POWER SUPPLY PROP AUX RETRACT BRAKE LAMP CIRCUIT OUTPUT #2 BRAKE LAMP CIRCUIT OUTPUT #1 SWITCHED POWER BRAKE LAMP SWITCHED POWER BRAKE LAMP PROPORTIONAL AUX EXTEND SIGNAL
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Color-Size BK/WH - 0.8 BK/WH - 0.8 GN - 0.8 YE - 0.8 OR - 0.8
OR - 0.8
VT - 0.8 VT - 0.8 OR - 0.8 OR - 0.8 WH - 0.8
Frame SHEET 20
Electrical systems - Harnesses and connectors
X-CN2A - UCM CN2A (82028493) (Receptacle)
82028493
13
82028493 2
Pin
From SPLICE SP-152
164
3
SPLICE SP-152
165
4
X-PLTLK (Receptacle) pin A PILOT INTERLOCK SPLICE SP-187 SPLICE SP-112
536
5 7 8
Wire
537 159
13
X-018 PIN 1 FUEL FILTER HEATER SPLICE SP-112
14 17
X-016 (Receptacle) pin 1 ECU 517 1103 X-904 (Receptacle) pin A
20 23
SPLICE SP-121 X-ECC (Plug) pin 61 EH CHASSIS/CAB INTERFACE SPLICE SP-124
26
518 163
1077 1024 1027
Description LEFT PUMP REVERSE POWER RIGHT PUMP REVERSE POWER LOADER PILOT INTERLOCK LOADER PORT LOCK SWITCHED POWER PORT/PILOT LOCK PUMP RIGHT REVERSE SWITCHED POWER PORT/PILOT LOCK PUMP LEFT REVERSE BOOM LOCK INTERLOCK SW SIGNAL UCM GROUND 2A.20 PATTERN INDICATOR H LS OUTPUT UCM GROUND 2A.26
X-CN2B - UCM CN2B (82028495) (Receptacle)
82028495
14
82028495
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Color-Size OR - 0.8 OR - 0.8 WH - 0.8 WH - 0.8 OR - 0.8 WH - 0.8 OR - 0.8 WH - 0.8 YE - 0.8 BK/WH - 0.8 BL - 0.8 BK/WH - 0.8
Frame SHEET 03
Electrical systems - Harnesses and connectors
Pin
X-ECC (Plug) pin 15 EH CHASSIS/CAB INTERFACE X-ECC (Plug) pin 17 EH CHASSIS/CAB INTERFACE X-ECC (Plug) pin 62 EH CHASSIS/CAB INTERFACE X-ECC (Plug) pin 11 EH CHASSIS/CAB INTERFACE
522
Description CAN HI PATTERN INDICATOR ISO LS OUTPUT LOADER RETURN SWITCHED POWER LOADER CONTROL CAN LO PARK BRAKE PRESSURE SWITCH LH UA2 X SENSOR OUTPUT SWITCHED POWER LOADER CONTROL CONTROL PATTERN H
523
CONTROL PATTERN ISO YE - 0.8
754
PARK BRAKE SWITCH
YE - 0.8
SHEET 14
398
YE - 0.8
SHEET 20
24 25
SPLICE SP-102 SPLICE SP-098
532 1021
26 27
SPLICE SP-120 X-ECC (Plug) pin 64 EH CHASSIS/CAB INTERFACE X-ECC (Plug) pin 51 EH CHASSIS/CAB INTERFACE
1028 531
X-ECC (Plug) pin 32 EH CHASSIS/CAB INTERFACE X-093 (Receptacle) pin 4 RH PUMP SWASH PLATE SENSOR X-093 (Receptacle) pin 3 RH PUMP SWASH PLATE SENSOR SPLICE SP-121
568 576
LOADER LOCKOUT SWITCH N.O. OUTPUT (VALVE OFF) ENGINE START INPUT DRIVE FORWARD RETURN UCM GROUND 2B.26 LOADER FLOAT SWITCH INPUT PROPORTIONAL AUX SWITCH OUTPUT SIGNAL #2 LH UA2 Y SENSOR OUTPUT RH PUMP ANGLE #1
575
RH PUMP ANGLE #2
YE - 0.8
1029
UCM GROUND 2B.34
BK/WH - 0.8
SHEET 20
Color-Size OR - 0.8
SHEET 21
1 2 7 9 10 13 14 17 20 21 22 23
28
31 32
33
34
From SPLICE SP-503 X-ECC (Plug) pin 58 EH CHASSIS/CAB INTERFACE X-010 PIN 6 SPLICE SP-110
Wire 503E 1023
SPLICE SP-504B X-BRKPRS (Plug) pin 1 BRAKE PRESSURE SWITCH X-ECC (Plug) pin 31 EH CHASSIS/CAB INTERFACE SPLICE SP-110
504E 535
1019 154
562 158
547
Color-Size YE - 0.8 BL - 0.8
Frame SHEET 20
BL - 0.8 OR - 0.8 GN - 0.8 YE - 0.8 GN - 0.8 OR - 0.8 YE - 0.8
YE - 0.8 BL - 0.8 BK/WH - 0.8 YE - 0.8 YE - 0.8
GN - 0.8 YE - 0.8
SHEET 10
X-CN3A - UCM CN3A (84130757) (Receptacle)
84130757
15
84130757 2
Pin
From SPLICE SP-114
168
Wire
3
SPLICE SP-114
169
4
X-BRK PIN 1
258
7
SPLICE SP-115
170
Description SWITCHED POWER PARK BRAKE SWITCHED POWER PARK BRAKE PARK BRAKE VALVE SIGNAL SWITCHED POWER TWO SPEED
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OR - 0.8 WH - 0.8 OR - 0.8
Frame
Electrical systems - Harnesses and connectors
Pin
13
From X-094 (Receptacle) pin 3 LH PUMP SWASH PLATE SENSOR X-094 (Receptacle) pin 4 LH PUMP SWASH PLATE SENSOR X-ECC (Plug) pin 19 EH CHASSIS/CAB INTERFACE SPLICE SP-115
20 21
SPLICE SP-121 X-FUSE1 PIN 14
1030 120
22 23
X-010 PIN 5 X-ECC (Plug) pin 80 EH CHASSIS/CAB INTERFACE X-2SPD 2 SPEED VALVE SOLENOID SPLICE SP-121
512 303
9
10
11
25 26
574
Wire
Description LH PUMP ANGLE #1
Color-Size YE - 0.8
573
LH PUMP ANGLE #2
YE - 0.8
548
RH UA2 X SENSOR OUTPUT SWITCHED POWER TWO SPEED UCM GROUND 3A.20 PUMP FORWARD POWER LOADER LOWER SIGNAL HYDRAULIC LOADER INTERLOCK SIGNAL 2 SPEED VALVE SOLENOID SIGNAL UCM GROUND 3A.26
GN - 0.8
171
564 1031
X-CN3B - UCM CN3B (84130760) (Receptacle)
84130760
16
84130760
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OR - 0.8 BK/WH - 0.8 OR - 0.8 WH - 0.8 WH - 0.8 WH - 0.8 BK/WH - 0.8
Frame SHEET 10
SHEET 21
Electrical systems - Harnesses and connectors
3
Pin
From X-FUSE1 PIN 28
167
6 8
X-010 PIN 7 SPLICE SP111
513 142
9
SPLICE SP111
147
11
755
12
X-ECC (Plug) pin 26 EH CHASSIS/CAB INTERFACE X-010 PIN 4
13
X-010 PIN 8
571
14
X-010 PIN 13
572
17
X-010 PIN 1
510
18
X-900 PIN 17 CROSSOVER BULKHEAD X-900 PIN 17 CROSSOVER BULKHEAD X-ECC (Plug) pin 18 EH CHASSIS/CAB INTERFACE
895
Description SWITCHED POWER BACKUP ALARM LOADER RAISE SIGNAL SWITCHED POWER BUCKET CONTROL SWITCHED POWER BUCKET CONTROL HIGH PERFORMANCE HIGH FLOW SIGNAL CONTROL VALVE BUCKET POSITION SENSOR CONTROL VALVE LOADER POSITION SENSOR CONTROL VALVE AUX POSITION SENSOR BUCKET RETRACT SIGNAL BACKUP ALARM SIGNAL
895
BACKUP ALARM SIGNAL WH - 0.8
312
YE - 0.8
18 19
Wire
570
Color-Size OR - 0.8 WH - 0.8 OR - 0.8 OR - 0.8 WH - 0.8 YE - 0.8
YE - 0.8
YE - 0.8 WH - 0.8 WH - 0.8
26 30
SPLICE SP-121 SPLICE SP-101
1032 526
32
X-017 (Receptacle) pin 1 ENGINE INTERFACE X-013 (Receptacle) pin 1 GCU SPLICE SP-122
519
LOADER LOCK SWITCH N.C. OUTPUT (VALVE ON) UCM GROUND 3B.26 SEAT SWITCH OPERATOR INTERLOCK PUMP RIGHT FORWARD
516
PUMP LEFT FORWARD
WH - 0.8
1033
UCM GROUND 3B.34
BK/WH - 0.8
33 34
X-CN4A - UCM CN4A (82028493) (Receptacle)
82028493
17
82028493
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BK/WH - 0.8 YE - 0.8 WH - 0.8
Frame SHEET 10
Electrical systems - Harnesses and connectors
1
Pin
From SPLICE SP-111
0060
8
SPLICE SP-111
0061
10
X-ECC (Plug) pin 68 EH CHASSIS/CAB INTERFACE X-ECC (Plug) pin 29 EH CHASSIS/CAB INTERFACE X-ECC (Plug) pin 36 EH CHASSIS/CAB INTERFACE X-010 PIN 3
524
SPLICE SP-125 X-ECC (Plug) pin 23 EH CHASSIS/CAB INTERFACE X-ECC (Plug) pin 35 EH CHASSIS/CAB INTERFACE SPLICE SP-122
1034 549
17 18 19 20 24 25 26
Wire
561 569 511
567 1035
Description SWITCHED POWER BUCKET CONTROL SWITCHED POWER BUCKET CONTROL SEAT BELT / LAP BAR OPERATOR INTERLOCK RH UA1 Y SENSOR OUTPUT LH UA1 Y SENSOR OUTPUT BUCKET EXTEND SIGNAL UCM GROUND 4A.20 RH UA1 X SENSOR OUTPUT LH UA1 X SENSOR OUTPUT UCM GROUND 4A.26
Color-Size OR - 0.8
Frame SHEET 21
OR - 0.8 YE - 0.8 WH - 0.8 WH - 0.8 WH - 0.8 BK/WH - 0.8 WH - 0.8 WH - 0.8 BK/WH - 0.8
X-CN4B - UCM CN4B (82028495) (Receptacle)
82028495
18
82028495 Pin 13
15 21
27 34
From X-323A (Plug) pin 10 CHASSIS OPTIONS/MULTIFUNCTION IN X-ECC (Plug) pin 63 EH CHASSIS/CAB INTERFACE X-ECC (Plug) pin 46 EH CHASSIS/CAB INTERFACE SPLICE SP-122 SPLICE SP-122
423
Wire
Description EHF INTERLOCK
Color-Size YE - 0.8
541
2 SPEED UCM INPUT
YE - 0.8
546
PROPORTIONAL AUX SWITCH OUTPUT SIGNAL #1 UCM GROUND 4B.27 UCM GROUND 4B.34
YE - 0.8
1036 1037
X-ECU_MAIN_RLY - ECU MAIN RELAY (84297431) (Receptacle)
84297431
19
84297431 48068130 29/01/2018
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BK/WH - 0.8 BK/WH - 0.8
Frame SHEET 21
Electrical systems - Harnesses and connectors
Pin 1 1 2 2 3 3 5 5
From SPLICE SP-527RH SPLICE SP-527 X-012 (Receptacle) pin 28 ECU X-900 PIN 46 CROSSOVER BULKHEAD SPLICE SP-527 SPLICE SP-527RH SPLICE SP-528RH SPLICE SP-528
Wire 527C 527C 112
Description BATT+ BATT+ ECU MAIN RELAY
Color-Size RD - 0.5 RD - 0.5 BL - 0.5
112
ECU MAIN RELAY
BL - 0.5
527B 527B 528A 528A
BATT+ BATT+ BATT+ BATT+
RD - 8.0 RD - 8.0 OR - 8.0 OR - 8.0
Frame SHEET 08 SHEET 06
SHEET 08
X-FUSE1 - FUSE BLOCK 1 (47536466) (Receptacle)
47536466
20
47536466 1
Pin X-314 PIN 1
From
Wire 155A
2
SPLICE SP-110
178
3
SPLICE SP-161
820
4
X-TELE PIN 12
336
5
X-FUSE2 PIN 42
256
6
X-ECC PIN 24
744
7
SPLICE SP-528
528C
8
SPLICE SP-117 SPLICE SP-118
181
9
SPLICE SP-042
830
10
SPLICE SP-145
119
11
SPLICE SP-042
255
12
X-FUSE2 PIN 13
743
13
SPLICE SP-114
185
14
X-CN3A PIN 21
120
15
X-900 PIN 4
110
16
SPLICE SP-241
241A
17
X-900 PIN 29
704
18
X-ECC PIN 72
115
Description OUTPUT FROM FUSE F-034 OUTPUT FROM FUSE F-022 OUTPUT FROM FUSE F-001 OUTPUT FROM FUSE F-039 OUTPUT FROM FUSE F-003 OUTPUT FROM FUSE F-020 BATTERY TO THE ECU FUSE 2 F-034 BATTERY TO THE LOADER CONTROL FUSE F-022 POWER TO HVAC FUSE F-001 BATTERY TO THE TELEMATICS FUSE F-039 POWER TO CRANK FUSE F-003 BATTERY TO THE HYDRAULIC OPTIONS FUSE F-020 OUTPUT FROM FUSE F-016 OUTPUT FROM FUSE F-0.8 OUTPUT FROM FUSE F-035 OUTPUT FROM FUSE F-033 OUTPUT FROM FUSE F-010 OUTPUT FROM THE ACCESSORY/BEACON FUSE F-014
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Frame
Color-Size OR-3.0
SHEET 02
OR-0.8
SHEET 03
OR-3.0
SHEET 02
RD-1.0
SHEET 02
RD-2.0
SHEET 02
OR-2.0
SHEET 03
OR-3.0
SHEET 02
OR-0.8
SHEET 03
OR-3.0
SHEET 02
RD-1.0
SHEET 02
RD-2.0
SHEET 02
OR-2.0
SHEET 03
OR-0.8
SHEET 03
OR-0.8
SHEET 03
OR-2.0
SHEET 02
OR-1.0
SHEET 02
VT-0.8
SHEET 02
RD-2.0
SHEET 02
Electrical systems - Harnesses and connectors
Pin 19
From SPLICE SP-119
20
SPLICE SP-117 SPLICE SP-118
203
21
SPLICE SP-528
528B
22
SPLICE SP-528
528D
23
SPLICE SP-024
700
24
SPLICE SP-042
114
25
SPLICE SP-113
172
26
SPLICE SP-109
177
27
SPLICE SP-152
122
28
X-CN3B PIN 3
167
29
X-900 PIN 43
703
30
Wire 184
719
31
SPLICE SP-117 SPLICE SP-119
173
32
SPLICE SP-117 SPLICE SP-119
174
33
SPLICE SP-117 SPLICE SP-118
187
34
SPLICE SP-119
183
35
SPLICE SP-024
701
36
SPLICE SP-057
715
37
X-ECC PIN 16
233
38
X-CN1A PIN 20
189
39
X-323 PIN 9
420
40
X-411 PIN 30
156
41
X-314 PIN 3
706
42
SPLICE SP-059
716
43
SPLICE SP-030
243
44
SPLICE SP-146
188
45
SPLICE SP-065
356
46
SPLICE SP-142
157
47
SPLICE SP-031
705
Description BATTERY TO THE EH GROUND DRIVE FUSE F-016 BATTERY TO THE UCM PUMP FORWARD FUSE F-021 BATTERY TO THE ECU FUSE 1 F-035 BATTERY TO THE ENGINE SENSOR FUSE F-033 BATTERY TO THE RIGHT-HAND TAIL LAMPS FUSE F-010 BATTERY TO THE ACCESSORY/BEACON FUSE F-014 OUTPUT FROM FUSE F-015 OUTPUT FROM FUSE F-018 OUTPUT FROM FUSE F-017 OUTPUT FROM FUSE F-007 OUTPUT FROM FUSE F-006 OUTPUT FROM FUSE F-032 BATTERY TO THE UCM BRAKE LAMPS FUSE F-015 BATTERY TO THE EH AUXILIARY HYDRAULICS FUSE F-018 BATTERY SUPPLY TO THE GROUND DRIVE REVERSE FUSE F-017 BATTERY TO THE UCM BACKUP ALARM FUSE F-007 BATTERY TO THE LEFT-HAND TAIL LIGHTS FUSE F-006 BATTERY TO THE RIGHT BOOM FUSE F-031 OUTPUT FROM FUSE F-029 OUTPUT FROM THE EH UNSWITCHED BATTERY FUSE F-026 OUTPUT FROM FUSE F-023 OUTPUT FROM FUSE F-030 OUTPUT FROM FUSE F-004 OUTPUT FROM FUSE F-031 BATTERY TO THE WIPER/WASHER FUSE F-029 BATTERY TO THE EH UNSWITCHED BATTERY FUSE F-026 BATTERY TO THE AUX FE KEY POWER FUSE F-023 POWER TO FLASHER/BRAKE FUSE F-030 BATTERY SUPPLY TO THE REAR WORK LAMPS FUSE F-030
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Frame
Color-Size OR-0.8
SHEET 03
OR-0.8
SHEET 03
OR-3.0
SHEET 02
OR–1.0
SHEET 02
VT-0.8
SHEET 02
RD-1.0
SHEET 02
OR-0.8
SHEET 03
OR-0.8
SHEET 03
OR-0.8
SHEET 03
OR-0.8
SHEET 02
VT-0.8
SHEET 02
VT-1.0
SHEET 03
OR-0.8
SHEET 03
OR-0.8
SHEET 03
OR-0.8
SHEET 03
OR–0.8
SHEET 02
VT-0.8
SHEET 02
VT-1.0
SHEET 03
OR-2.0
SHEET 03
RD-0.8
SHEET 02
OR-3.0
SHEET 03
RD-2.0
SHEET 02
VT-3.0
SHEET 02
VT-1.0
SHEET 03
OR-2.0
SHEET 03
RD-0.8
SHEET 02
OR-3.0
SHEET 03
RD-3.0
SHEET 02
VT-3.0
SHEET 02
Electrical systems - Harnesses and connectors
Pin 48
From SPLICE SP-057
714
Wire
49
SPLICE SP-112
182
50
SPLICE SP-111
176
51 52
SPLICE SP-186 SPLICE SP-037
351 300
53
SPLICE SP-032
708
54
SPLICE SP-192
1097
55
SPLICE SP-118
180
56
SPLICE SP-118
204
57
SPLICE SP-036
350
58
SPLICE SP-036
326
59 60
X-ECC PIN 3 SPLICE SP-190
792 1092
61
X-ECC PIN 2
836
62
X-ECC PIN 37
354
63
X-ECC PIN 77
134
64
X-ECC PIN 74
310
65
X-ECC PIN 49
798
66
SPLICE SP-164
1098
67
SPLICE SP-042
835
68
SPLICE SP-065
355
69
SPLICE SP-030
135
70
SPLICE SP-145
160
71
X-FUSE2 PIN 6
788
72
SPLICE SP-190
1095
Description BATTERY TO THE LEFT BOOM FUSE F-031 OUTPUT FROM FUSE F-025 OUTPUT FROM FUSE F-019 OUTPUT FROM F-009 OUTPUT FROM FUSE F-008 OUTPUT FROM FUSE F-005 OUTPUT FROM FUSE F-037 BATTERY TO THE UCM INTERLOCKS FUSE F-025 BATTERY TO THE BUCKET CONTROL FUSE F-019 BATTERY TO THE IGNITION FUSE F-009 BATTERY TO THE INSTRUMENT CLUSTER FUSE F-008 GROUND CONNECTION TO THE FUSE RELAY GROUND FUSE F-038 OUTPUT FROM FUSE F-002 OUTPUT FROM FUSE F-028 OUTPUT FROM FUSE F-013 OUTPUT FROM THE UNSWITHED BATTERY FUSE F-011 OUTPUT FROM FUSE F-012 OUTPUT FROM FUSE F-037 POWER TO HVAC COMPRESSOR FUSE F-002 BATTERY TO THE FE #1, #2, #3 FUSE F-023 BATTERY TO THE ACCESSORY FUSE F-013 BATTERY TO THE UNSWITCHED BATTERY FUSE F-011 BATTERY TO THE FRONT WORK LAMPS FUSE F-012 GROUND CONNECTION TO THE FUSE RELAY GROUND FUSE F-037
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Frame
Color-Size VT-1.0
SHEET 03
OR-0.8
SHEET 03
OR-0.8
SHEET 03
OR-1.0 OR-1.0
SHEET 02 SHEET 02
VT-3.0
SHEET 02
BK-0.8
SHEET 03
OR-0.8
SHEET 03
OR-0.8
SHEET 03
OR-1.0
SHEET 02
OR-036
SHEET 02
VT-3.0 BK-0.8
SHEET 02 SHEET 03
RD-3.0
SHEET 02
OR-0.8
SHEET 03
OR-2.0
SHEET 02
RD-0.8
SHEET 02
VT-5.0
SHEET 02
BK-0.8
SHEET 03
ORâ&#x20AC;&#x201C;3.0
SHEET 02
OR-0.8
SHEET 03
OR-2.0
SHEET 02
RD-0.5
SHEET 02
VT-3.0
SHEET 02
BK-0.8
SHEET 03
Electrical systems - Harnesses and connectors
X-FUSE2 - FUSE BLOCK 2 (47536466) (Receptacle)
47536466
21
47536466 1 2 3
Pin
From SPLICE SP-192 SPLICE SP-142 SPLICE SP-192
972 104 971
Wire
4
SPLICE SP-142
103
5 6 11 13 14 15
SPLICE SP-194 X-FUSE1 PIN 71 X-101A X-FUSE1 PIN 12 SPLICE SP-107 SPLICE SP-065
946 788 710 743 148 149
16
SPLICE SP-107
146
17 18 19 20 23 24 31 32 35 36 39 40 41 42
SPLICE SP-146 SPLICE SP-031 SPLICE SP-191 SPLICE SP-146 SPLICE SP-194 SPLICE SP-146 SPLICE SP-119 SPLICE SP-037 SPLICE SP-031 SPLICE SP-032 SPLICE SP-194 SPLICE SP-145 X-900 PIN 20 X-FUSE1 (Receptacle) pin 5
116 325 1067 193 945 113 190 335 707 709 948 117 161 256
49 51 52 53 54 55 57 58 59 61 62 67 68 69 70 72
SPLICE SP-115 SPLICE SP-030 SPLICE SP-107 X-006 (Plug) pin 1 X-900 PIN 27 SPLICE SP-119 SPLICE SP-191 SPLICE SP-146 SPLICE SP-192 X-ECC PIN 21 SPLICE SP-191 SPLICE SP-065 SPLICE SP-190 SPLICE SP-036 X-ECC PIN 85 SPLICE SP-241
179 125 139 520 121 186 947 118 970 129 1096 970 1094 136 144 241D
Description OPTION RELAY OPTION RELAY AUXILIARY FRONT ELECTRIC RELAY AUXILIARY FRONT ELECTRIC RELAY LIGHTS #1 RELAY LIGHTS #1 RELAY LIGHTS #1 RELAY OPTION RELAY OPTION RELAY AUXILIARY FRONT ELECTRIC RELAY AUXILIARY FRONT ELECTRIC RELAY LIGHTS #1 RELAY LIGHTS #1 RELAY EH CONTROL RELAY EH CONTROL RELAY LIGHTS #2 RELAY LIGHTS #2 RELAY EH CONTROL RELAY EH CONTROL RELAY LIGHTS #2 RELAY LIGHTS #2 RELAY ACCESSORY RELAY ACCESSORY RELAY CRANK ENABLE 2 BATTERY FROM FUSE F-003 TWO SPEED SHIFT FUSE ACCESSORY RELAY ACCESSORY RELAY STARTER CRANK ENABLE 1 TWO SPEED SHIFT FUSE MAIN POWER RELAY MAIN POWER RELAY AUX FE ON/OFF FUSE RELAY GROUND AUX FE ON/OFF FUSE RELAY GROUND MAIN POWER RELAY MAIN RELAY
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Frame
Color-Size BK-0.8 RD-2.0 BK-0.8
SHEET 03 SHEET 03 SHEET 03
RD-3.0
SHEET 03
BK-0.8 VT-3.0 VT-2.0 OR-2.0 WH-0.8 OR-3.0
SHEET SHEET SHEET SHEET SHEET SHEET
WH-0.8
SHEET 03
RD-2.0 WH-0.8 BK-0.8 RD-3.0 BK-0.8 RD-1.0 OR-3.0 WH-0.8 VT-2.0 WH-0.8 BK-0.8 RD-3.0 YE -0.8 RD - 2.0
SHEET SHEET SHEET SHEET SHEET SHEET SHEET SHEET SHEET SHEET SHEET SHEET SHEET SHEET
02 02 03 03 02 02 03 03 02 02 02 02 08 08
OR-0.8 OR-3.0 OR-0.8 WH - 2.0 YE - 0.8 OR-0.8 BK-0.8 RD-1.0 BK-0.8 OR-1.0 BK-0.8 BK-0.8 BK-0.8 OR-1.0 OR-0.8 RD-0.8
SHEET SHEET SHEET SHEET SHEET SHEET SHEET SHEET SHEET SHEET SHEET SHEET SHEET SHEET SHEET SHEET
03 02 02 08 08 03 02 02 03 03 02 03 02 02 02 03
02 02 02 03 03 03
Electrical systems - Harnesses and connectors
X-HVC1 - CAB/HVAC INTERCONNECT [ A-003] (87382926) (Receptacle)
87382926
22
87382926 Pin 1 2 3
From SPLICE SP-168 SPLICE SP-160 X-270 PIN 3 BLOWER FAN SWITCH X-270 PIN 4 BLOWER FAN SWITCH SPLICE SP-165 SPLICE SP-157
4 5 6 7
Wire
Color-Size BK - 5.0 RD - 1.0
828
Description HVAC GROUND A/C COMPRESSOR RELAY PIN 30 PO HVAC FAN LOW
827
HVAC FAN MEDIUM
WH - 3.0
850 837
HVAC FAN HIGH A/C SW COMPRESSOR RELAY PIN 86 THERMOSTAT TO BINARY PRESSURE
WH - 5.0 WH - 0.8
935 838
833
WH - 3.0
WH - 0.8
834
BINARY PRESSURE SW TO COMPRESS
WH - 0.8
9
X-BULKHEAD (Receptacle) pin 59 CAB/CHASSIS INTERCO X-BULKHEAD (Receptacle) pin 65 CAB/CHASSIS INTERCO SPLICE SP-092
1012
BK/WH - 0.8
10
SPLICE SP-163
842
11 12
SPLICE SP-021 X-BULKHEAD (Receptacle) pin 14 CAB/CHASSIS INTERCO SPLICE SP-162
143 841
HVAC THERMOSTAT CLEAN GROUND HVAC RELAY PIN 87 OUTPUT POWER HVAC KEYED POWER A/C COMPRESSOR RELAY PIN 87 PO HVAC RELAY FUSE POWER
OR - 5.0
8
14
845
Frame SHEET 14
OR - 5.0 OR - 0.8 OR - 0.8
X-PORT_LK - PORT LOCK (87695582) (Receptacle)
87695582
23
87695582 1
Pin
From SPLICE SP-187
304
Wire
2
SPLICE SP-188
957
Description HYDRAULIC LOADER INTERLOCK SIGNAL HYDRAULIC LOADER INTERLOCK GROUND 48068130 29/01/2018
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Frame
Color-Size WH - 0.8
SHEET 11
BK - 0.8
SHEET 05
Electrical systems - Harnesses and connectors
X-POS_TERM - BATTERY POWER (SAE N406) (Receptacle) X-TELE_A - TELEMATICS CAP (87700155) (Plug)
87700155
24
87700155 X-TELE_DIAG - TELEMATICS DIAGNOSTIC (87694101) (Receptacle)
87694101
25
87694101 Pin 1 2
2
3
From SPLICE SP-190 X-BULKHEAD (Receptacle) pin 8 CAB/CHASSIS INTERCO X-BULKHEAD (Receptacle) pin 8 CAB/CHASSIS INTERCO X-BULKHEAD (Receptacle) pin 94 CAB/CHASSIS INTERCO
206 207
Wire
Description GROUND RS232 RX
Color-Size BK/WH - 0.8 TN - 0.8
207
RS232 RX
TN - 2.0
208
RS232 TX
BL - 0.8
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Frame SHEET 32 SHEET 13
SHEET 15
Electrical systems - Harnesses and connectors
X-TELE_GND - TELEMATICS GND (84398832) (Plug)
84398832
26
84398832 Pin 1
From X-TELE (Receptacle) pin 1 TELEMATICS
Wire 925
Description TELEMATICS GROUND
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Color-Size BK/WH - 0.8
Frame SHEET 05
Electrical systems - Harnesses and connectors
Wire connectors Connectors Alphanumeric SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
X-ACC - ACCESSORY POWER OUTLET [ Z-008] (87693325) (Receptacle)
87693325
1
87693325 Pin
From
Wire
A
SP-033-P-X
801
B
SP-029-P-X
952
Description ACCESSORY SOCKET POWER ACCESSORY SOCKET GROUND
Color-Size RD - 0.8
Frame SHEET 16
BK - 0.8
X-BRK - BRAKE VALVE SOLENOID (87695584) (Plug)
87695584
2
87695584 1
Pin
From X-CN3A (Receptacle) pin 4
258
Wire
2
SPLICE SP-179
960
Description PARK BRAKE VALVE SIGNAL PARK BRAKE VALVE GROUND
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Frame
Color-Size WH - 0.8
SHEET 10
BK - 0.8
SHEET 05
Electrical systems - Harnesses and connectors
X-BRKPRS - BRAKE PRESSURE SWITCH [ SH10: A-6] (87680689) (Plug)
87680689
3
87680689 Pin 1 2
From X-CN2B (Receptacle) pin 13 UCM CN2B SP-184-P-X
Wire 535 1064
Description Color-Size PARK BRAKE PRESSURE YE - 0.8 SWITCH PARK BRAKE PRESSURE BK - 0.8 SWITCH GROUND
Frame SHEET 10 SHEET 05
X-BULKHEAD - CAB/CHASSIS INTERCO [ SH16: A-1] (87707116) (Receptacle)
87707116
4
87707116
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Electrical systems - Harnesses and connectors
Pin 1 2 3
From X-111 (Receptacle) pin 87 CONDENSER RELAY [CAB] SP-160-P-X
Wire 237 836 792
9
X-311 (Receptacle) pin C LAMP SELECTOR SWITCH X-311 (Receptacle) pin D LAMP SELECTOR SWITCH X-311 (Receptacle) pin B LAMP SELECTOR SWITCH X-90 (Plug) pin E DIODE PACK X-90 (Plug) pin E DIODE PACK X-90 (Plug) pin F DIODE PACK X-TELE_DIAG (Receptacle) pin 2 TELEMATICS DIAGNOSTIC X-TELE_DIAG (Receptacle) pin 2 TELEMATICS DIAGNOSTIC SP-138-P-X
10
SP-018-P-X
774
11
398 X-306 pin C LOADER LOCKOUT SW 521 X-095 (Receptacle) pin 3 DRIVE PATTERN SELECTOR SW 780 SP-019-P-X
4 5 6 6 7 8
8
12
13 14 15
16 17
123 791
Description HVAC CONDENSER FAN POWER COMPRESSOR/ CONDENSER FAN FUSE LAMP SW WORK & SIDE LAMP SIGNA LAMP SW POWER
Color-Size WH - 3.0
Frame SHEET 13
RD - 3.0 VT - 3.0 OR - 3.0 VT - 3.0
207
LAMP SW ROAD LAMP SIGNAL MAIN POWER RELAY UCM WAKEUP DI MAIN POWER RELAY UCM WAKE UP UCM WAKEUP DIODE OUT RS232 RX
TN - 2.0
207
RS232 RX
TN - 0.8
769
FLASHER MODULE OUTPUT POWER LH TURN SIGNAL CHASSIS POWER LOADER LOCKOUT SW N.O. OUTPUT CONTROL PATTERN NEUTRAL
OR - 2.0
YE - 0.8
SHEET 09
RH TURN SIGNAL CHASSIS POWER A/C COMPRESSOR RELAY PIN 87 PO CONTROL PATTERN H
VT - 0.8
SHEET 13
334 334 333
X-HVC1 (Receptacle) pin 12 841 CAB/HVAC INTERCONNECT 522 X-095 (Receptacle) pin 1 DRIVE PATTERN SELECTOR SW 233 SP-023-P-X 523 X-095 (Receptacle) pin 6 DRIVE PATTERN SELECTOR SW
OR - 0.8 OR - 2.0 YE - 0.8
VT - 0.8 YE - 0.8
OR - 0.8 YE - 0.8
SHEET 09
WIPER/WASHER SW OR - 2.0 POWER CONTROL PATTERN ISO YE - 0.8
SHEET 13
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SHEET 09
Electrical systems - Harnesses and connectors
Pin 18 19 20 21 22 23 24 25
26 27 28 29 30 31 32 33 34 35 36
From X-306 pin E LOADER LOCKOUT SW X-UJMR (Receptacle) pin 8 X-UJMR X-UJMR (Receptacle) pin 9 X-UJMR X-401 (Plug) pin A RH HANDLE INTERCONNECT F X-401 (Plug) pin B RH HANDLE INTERCONNECT F X-UJMR (Receptacle) pin 2 X-UJMR SP-053-P-X
Wire 312 548 560 129 856 549 744
752 X-300 (Receptacle) pin 3 HYDRAULIC COUPLER SWITCH X-303 pin E HI FLOW SWITCH 755 831 X-406 (Plug) pin D RH HANDLE INTERCONNECT P X-303 pin C HI FLOW SWITCH 750 X-UJMR (Receptacle) pin 3 X-UJMR SP-126-P-X X-UJML (Receptacle) pin 8 X-UJML X-UJML (Receptacle) pin 9 X-UJML X-408 (Plug) pin 2 LH HANDLE INTERCONNECT X-408 (Plug) pin 3 LH HANDLE INTERCONNECT X-UJML (Receptacle) pin 2 X-UJML X-UJML (Receptacle) pin 3 X-UJML
561 1051 562 568 554 552 567 569
Description LOADER LOCK SW N.C. OUTPUT (VA RH UA2 X SENSOR OUTPUT RH UA2 Y SENSOR OUTPUT AUX ELEC ON/OFF SW IN AUX ELEC ON/OFF SW SIGNAL RH UA1 X SENSOR OUTPUT HIGH FLOW/HYDRAULIC COUPLER SW HYDRAULIC COUPLER SIGNAL
Color-Size YE - 0.8
HIGH PERFORMANCE HIGH FLOW SIG RIDE CONTROL VALVE SOLENOID SI STANDARD HIGH FLOW SIGNAL RH UA1 Y SENSOR OUTPUT UJM SENSOR GROUNDS 2A.26 LH UA2 X SENSOR OUTPUT LH UA2 SENSOR OUTPUT 2ND AUX EXTEND SW OUTPUT 2ND AUX RETRACT SIGNAL POWER LH UA1 X SENSOR OUTPUT LH UA1 Y SENSOR OUTPUT
WH - 0.8
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GN - 0.8 GN - 0.8 OR - 1.0 WH - 1.0 WH - 0.8 OR - 2.0 WH - 0.8
WH - 0.8 WH - 0.8 WH - 0.8 BK/WH - 0.8 GN - 0.8 GN - 0.8 WH - 0.8 WH - 0.8 WH - 0.8 WH - 0.8
Frame SHEET 13
Electrical systems - Harnesses and connectors
Pin 37
From SP-062-P-X
Wire 354
38
X-403 (Receptacle) pin 6 RH 410 HANDLE INTERCONNECT F
39
X-403 (Receptacle) pin 7 RH 411 HANDLE INTERCONNECT F
40
SP-063-P-X
416
41
SP-064-P-X
417
42
X-408 (Plug) pin 13 LH HANDLE INTERCONNECT
418
44
X-408 (Plug) pin 14 LH HANDLE INTERCONNECT
419
45
892
47 48
X-408 (Plug) pin 8 LH HANDLE INTERCONNECT X-403 (Receptacle) pin 11 RH HANDLE INTERCONNECT F SP-137-P-X SP-171-P-X
49
SP-016-P-X
797
50 51
200 547
54
SP-132-P-X X-403 (Receptacle) pin 2 RH HANDLE INTERCONNECT F X-317 pin E SELF LEVEL SWITCH X-DIAG (Plug) pin E CAN DIAGNOSTIC CONNECTOR SP-015-P-X
55
SP-171-P-X
843
56
X-252 (Receptacle) pin 2 TEMP CONTROL SWITCH SP-169-P-X
824
46
52 53
57 58
59 61
546 210 844
404 248 795
1090
1023 X-095 (Receptacle) pin 9 DRIVE PATTERN SELECTOR SW 833 X-HVC1 (Receptacle) pin 7 CAB/HVAC INTERCONNECT 1024 X-095 (Receptacle) pin 8 DRIVE PATTERN SELECTOR SW
Description HANDLE MULTIFUNCTION #1, #2, # RH HANDLE MULTIFUNCTION #1 UP RH HANDLE MULTIFUNCTION #1 DOW HANDLE MULTIFUNCTION #2 UP HANDLE MULTIFUNCTION #2 DOWN LH HANDLE MULTIFUNCTION #3 UP LH HANDLE MULTIFUNCTION #3 DOW HORN POWER SIGNAL
Color-Size OR - 0.8
PROPORTIONAL AUX SW OUTPUT SIG CAB SENSOR SUPPLY 1 HVAC FUSE TO HVAC BOX-VOLTAGE LIGHT RELAY #1 FRONT WORK LAMP SENSOR SUPPLY 3 PROPORTIONAL AUX SW OUTPUT SIG SELF LEVEL SW OUTPUT POWER EGR ECU K-LINE
YE - 0.8
SIDE LAMP POWER SIGNAL HVAC FUSE TO HVAC BOX-VOLTAGE HVAC TEMPERATURE CONTROL SIGNA UJM SENSOR GROUNDS 4A.20 PATTERN INDICATIOR ISO LS OUTP THERMOSTAT TO BINARY PRESSURE PATTERN INDICATOR H LS OUTPUT
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Frame SHEET 14
WH - 0.8
TN - 0.8
VT - 0.8
RD - 0.8
GY - 0.8
LG - 0.8
WH - 0.8
PK - 0.8 OR - 5.0 VT - 5.0 PK - 0.8 YE - 0.8 WH - 0.8 YE - 0.8 VT - 5.0 OR - 5.0 YE - 0.8 BK/WH - 0.8 BL - 0.8
SHEET 09
WH - 0.8
SHEET 14
BL - 0.8
SHEET 09
Electrical systems - Harnesses and connectors
Pin 62 63 64 65 66 67 68 69 70
From SP-006-P-X SP-035-P-X X-403 (Receptacle) pin 14 RH HANDLE INTERCONNECT F X-HVC1 (Receptacle) pin 8 CAB/HVAC INTERCONNECT SP-089-P-X SP-090-P-X X-90 (Plug) pin B DIODE PACK SP-190-P-X
Wire 754 541 531 834 503A 504A 524 910 234
71
X-C23 (Receptacle) pin 24 INSTRUMENT CLUSTER SP-106-P-X
357
72
SP-033-P-X
115
73
X-C23 (Receptacle) pin 16 INSTRUMENT CLUSTER SP-004-P-X
264
74 75
310 545
77
X-C23 (Receptacle) pin 23 INSTRUMENT CLUSTER X-311 (Receptacle) pin A LAMP SELECTOR SWITCH SP-011-P-X
134
78
SP-086-P-X
329
79
SP-010-P-X
309
80
X-C23 (Receptacle) pin 30 INSTRUMENT CLUSTER X-C23 (Receptacle) pin 2 INSTRUMENT CLUSTER X-C23 (Receptacle) pin 11 INSTRUMENT CLUSTER SP-200-P-X
303
76
81 82 83 84
790
261 267 1066
86
622 X-C23 (Receptacle) pin 32 INSTRUMENT CLUSTER X-316 (Receptacle) pin 1 ECU 144 RELAY/GROUND 175 SP-009-P-X
87
SP-201-P-X
211
88
SP-091-P-X
822
89
X-90 (Plug) pin C DIODE PACK X-90 (Plug) pin D DIODE PACK X-C23 (Receptacle) pin 13 INSTRUMENT CLUSTER X-DIAG (Plug) pin H CAN DIAGNOSTIC CONNECTOR X-DIAG (Plug) pin J CAN DIAGNOSTIC CONNECTOR X-TELE_DIAG (Receptacle) pin 3 TELEMATICS DIAGNOSTIC
332
85
90 91 92 93 94
Description PARK BRAKE SW 2 SPEED UCM INPUT LOADER FLOAT SW INPUT BINARY PRESSURE SW TO COMPRESS CAN HI CAN LO SEAT BELT/LAP BAR OPERATOR INT INSTRUMENT CLUSTER GROUND FUEL LEVEL SENDER
Color-Size YE - 0.8 YE - 0.8 YE - 0.8
MAIN POWER RELAY IGNITION FUSE BEACON & ACCESSORY FUSE OUTPUT HYDRAULIC OIL TEMP SENDER UNSWITCHED BATTERY POWER FOOT THROTTLE SIGNAL LAMP SW WORK LAMP SIGNAL WIPER/SEAT ACC/RADIO/DOME LAMP SEAT SWITCH UCM INPUT INSTRUMENT CLUSTER SWITCHED PO HYDRAULIC LOADER INTERLOCK SIG HYDRAULIC OIL FILTER
OR - 1.0
AIR FILTER/ENGINE MALFUNCTION FOOT THROTTLE SENSOR GROUND START RELAY SIGNAL
YE - 0.8
MAIN POWER RELAY SIGNAL EH ACC RELAY CHASSIS INTERFACE FOOT THROTTLE SENSOR SUPPLY HVAC WATER VALVE POWER SEAT SW UCM DIODE IN
OR - 0.8
WH - 0.8 YE - 0.8 GN - 0.8 YE - 0.8 BK/WH - 0.8 YE - 0.8
RD - 2.0 YE - 0.8 RD - 0.8 YE - 0.8 VT - 2.0 OR - 2.0 YE - 0.8 OR - 1.0 WH - 0.8 YE - 0.8
BK/WH - 0.8 WH - 0.8
WH - 0.8 PK - 0.8 OR - 0.8 YE - 0.8
507
EH SEAT SW UCM DIODE YE - 0.8 OUT REGENERATION INHIBIT YE - 0.8 SW WH - 0.8 CAN HI
508
CAN LO
BL - 0.8
208
RS232 TX
BL - 0.8
330 205C
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Frame SHEET 14
SHEET 15
Electrical systems - Harnesses and connectors
X-CPLR - HYDRAULIC COUPLER VALVE SOLENOID (87695582) (Receptacle)
87695582
5
87695582 Pin 1 2
From X-ECC (Plug) pin 25 EH CHASSIS/CAB INTERFACE SP-183-P-X
Wire 752 978
Description HYDRAULIC COUPLER SIGNAL HYDRAULIC COUPLER VALVE GROUND
Frame
Color-Size WH - 0.8
SHEET 13
BK - 0.8
SHEET 05
X-CTS - TURN SIGNAL SWITCH [ S-034] (87697780) (Receptacle)
87697780
6
87697780 Pin
From
Wire
D
SP-019-P-X
777
E
SP-138-P-X
783
F
SP-018-P-X
775
Description CAB TURN SIGNAL SW RH FLASHER POWER OUTPUT CAB TURN SIGNAL SW LH
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Color-Size VT - 1.0 OR - 1.0 VT - 1.0
Frame SHEET 24
Electrical systems - Harnesses and connectors
X-DIAG - CAN DIAGNOSTIC CONNECTOR [ SH35: B-5] (84497873) (Plug)
84497873
7
84497873 Pin
From
Wire
Color-Size BK/WH - 0.8
SHEET 05
RD - 0.8
SHEET 35
501 506 248
Description EST CONNECTOR GROUND UNSWITCHED BATTERY POWER CAN HI CAN LO EGR ECU K-LINE
YE - 0.8 GN - 0.8 YE - 0.8
SHEET 14
507
CAN HI
WH - 0.8
SHEET 15
508
CAN LO
BL - 0.8
A
SP-092-P-X
961
B
SP-004-P-X
162
C D E
SP-089-P-X SP-090-P-X X-BULKHEAD (Receptacle) pin 53 CAB/CHASSIS INTERCO X-BULKHEAD (Receptacle) pin 92 CAB/CHASSIS INTERCO X-BULKHEAD (Receptacle) pin 93 CAB/CHASSIS INTERCO
H
J
Frame
X-ECC - EH CHASSIS/CAB INTERFACE [ SH13: C-6] (47557182) (Plug)
47557182
8
47557182 Pin
2
From X-314 (Plug) pin 2 CHASSIS POWER X-FUSE1 pin 61
836
3
X-FUSE1 pin 59
792
4 5 6
SP-030-P-X SP-024-P-X SP-037-P-X
123 791 334
1
Wire 237
Description HVAC CONDENSER FAN POWER COMPRESSOR / CONDENSER FAN FUSE LAMP SWITCH WORK AND SIDE LAMP SIGNAL LAMP SWITCH POWER ROAD LAMP SIGNAL MAIN POWER RELAY UCM WAKEUP
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Color-Size WH - 3.0
Frame SHEET 13
RD - 3.0 VT - 3.0 OR - 3.0 VT - 3.0 OR - 2.0
SHEET 02
Electrical systems - Harnesses and connectors
Pin
From
Wire
7
SP-100-P-X
333
8 9
SP-207-P-X X-411 (Receptacle) pin 87A FLASHER MODULE X-900 pin 1 CROSSOVER BULKHEAD SP-051-P-X
207A 769
11
X-CN2B (Receptacle) pin 23 UCM CN2B
398
12
X-CN1B (Receptacle) pin 15 UCM CN1B X-900 pin 22 CROSSOVER BULKHEAD X-900 pin 22 CROSSOVER BULKHEAD X-900 pin 39 CROSSOVER BULKHEAD X-900 pin 39 CROSSOVER BULKHEAD X-CN2B (Receptacle) pin 20 UCM CN2B X-FUSE1 pin 37
521
9 10
13 13 14 14 15 16 17 18
19 20 21 22
23 24
25
26 27 28 29 30 31 32 33 34 35 36
769 774
780 780 841 841 522 233
X-CN2B (Receptacle) pin 21 UCM CN2B X-CN3B (Receptacle) pin 19 UCM CN3B
523
X-CN3A (Receptacle) pin 11 UCM CN3A X-CN1B (Receptacle) pin 13 UCM CN1B X-FUSE2 pin 61
548
X-323 (Receptacle) pin 8 CHASSIS OPTIONS/MULTIFUNCTION IN X-CN4A (Receptacle) pin 24 UCM CN4A X-FUSE1 pin 6
X-CPLR (Receptacle) pin 1 HYDRAULIC COUPLER VALVE SOLENOID X-CN3B (Receptacle) pin 11 UCM CN3B X-RDCTRL (Receptacle) pin 1 X-RDCTRL X-HFLO (Receptacle) pin 1 X-HFLO X-CN4A (Receptacle) pin 17 UCM CN4A SP-124-P-X X-CN2B (Receptacle) pin 14 UCM CN2B X-CN2B (Receptacle) pin 31 UCM CN2B X-AUX_EXT (Receptacle) pin 1 2ND AUX EXTEND X-AUX_RET (Receptacle) pin 1 X-AUX_RET X-CN4A (Receptacle) pin 25 UCM CN4A X-CN4A (Receptacle) pin 18 UCM CN4A
312
560 129 856
549 744
752
755 831 750 561 1051 562 568 554 552 567 569
Description UCM WAKEUP DIODE OUT RS232 RX FLASHER MODULE OUTPUT POWER FLASHER MODULE OUTPUT POWER LH TURN SIGNAL CHASSIS POWER LOADER LOCKOUT SWITCH N.O. OUTPUT (VALVE OFF) CONTROL PATTERN NEUTRAL RH TURN SIGNAL CHASSIS POWER RH TURN SIGNAL CHASSIS POWER A/C COMPRESSOR RELAY PIN 87 POWER A/C COMPRESSOR RELAY PIN 87 POWER CONTROL PATTERN H
Color-Size YE - 2.0
Frame SHEET 13
TN - 2.0 OR - 2.0 OR - 2.0 VT - 0.8 YE - 0.8
YE - 0.8 VT - 0.8 VT - 0.8 WH - 0.8 WH - 0.8 YE - 0.8
WIPER / WASHER OR - 2.0 SWITCH POWER CONTROL PATTERN ISO YE - 0.8 LOADER LOCK SWITCH N.C. OUTPUT (VALVE ON) RH UA2 X SENSOR OUTPUT RH UA2 Y SENSOR OUTPUT AUX ELEC ON/OFF SWITCH IN AUX ELEC ON/OFF SWITCH SIGNAL
YE - 0.8
GN - 0.8 GN - 0.8 OR - 1.0 WH - 1.0
RH UA1 X SENSOR OUTPUT HIGH FLOW / HYDRAULIC COUPLER SWITCH POWER HYDRAULIC COUPLER SIGNAL
WH - 0.8
HIGH PERFORMANCE HIGH FLOW SIGNAL RIDE CONTROL VALVE SOLENOID SIGNAL STANDARD HIGH FLOW SIGNAL RH UA1 Y SENSOR OUTPUT UJM SENSOR GROUNDS LH UA2 X SENSOR OUTPUT LH UA2 Y SENSOR OUTPUT 2ND AUX EXTEND SWITCH OUTPUT 2ND AUX RETRACT SIGNAL POWER LH UA1 X SENSOR OUTPUT LH UA1 Y SENSOR OUTPUT
WH - 0.8
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OR - 2.0
WH - 0.8
WH - 0.8
SHEET 10
WH - 0.8
SHEET 13
WH - 0.8 BK/WH - 0.8 GN - 0.8 GN - 0.8 WH - 0.8 WH - 0.8 WH - 0.8 WH - 0.8
Electrical systems - Harnesses and connectors
Pin 37
From X-FUSE1 pin 62
38
X-323 (Receptacle) pin 3 CHASSIS OPTIONS/MULTIFUNCTION IN X-323 (Receptacle) pin 4 CHASSIS OPTIONS/MULTIFUNCTION IN X-323 (Receptacle) pin 5 CHASSIS OPTIONS/MULTIFUNCTION IN X-323 (Receptacle) pin 6 CHASSIS OPTIONS/MULTIFUNCTION IN X-323 (Receptacle) pin 2 CHASSIS OPTIONS/MULTIFUNCTION IN X-323 (Receptacle) pin 1 CHASSIS OPTIONS/MULTIFUNCTION IN X-HORN-PWR (Plug) pin 1 HORN POWER X-CN4B (Receptacle) pin 21 UCM CN4B
39
40
41
42
44
45 46
Wire
Description HANDLE MULTIFUNCTION #1, #2, #3 POWER RH HANDLE MULTIFUNCTION #1 UP
Color-Size OR - 0.8
411
RH HANDLE MULTIFUNCTION #1 DOWN
TN - 0.8
416
HANDLE MULTIFUNCTION #2 UP
VT - 0.8
417
HANDLE MULTIFUNCTION #2 DOWN
RD - 0.8
418
LH HANDLE MULTIFUNCTION #3 UP
GY - 0.8
419
LH HANDLE MULTIFUNCTION #3 DOWN
LG - 0.8
892
HORN POWER SIGNAL
WH - 0.8
546
PROPORTIONAL AUX SWITCH OUTPUT SIGNAL #1 CAB SENSOR SUPPLY 1 HVAC FUSE TO HVAC BOX - VOLTAGE DROP PARALLEL CIRCUIT LIGHT RELAY #1 FRONT WORK LAMP POWER SENSOR SUPPLY 3
YE - 0.8
YE - 0.8
248
PROPORTIONAL AUX SWITCH OUTPUT SIGNAL #2 SELF LEVEL SWITCH OUTPUT POWER EGR ECU K-LINE
354
410
WH - 0.8
47 48
SP-134-P-X SP-161-P-X
210 844
49
X-FUSE1 pin 65
798
50
X-CN1A (Receptacle) pin 9 UCM CN1A X-CN2B (Receptacle) pin 28 UCM CN2B
200
404
248
EGR ECU K-LINE
YE - 0.8
54
X-318 (Receptacle) pin 1 SELF LEVEL VALVE X-900 pin 19 CROSSOVER BULKHEAD X-900 pin 19 CROSSOVER BULKHEAD SP-032-P-X
795
VT - 5.0
55
SP-161-P-X
843
56
X-271 (Receptacle) pin D WATER VALVE SP-125-P-X
824
SIDE LAMP POWER SIGNAL HVAC FUSE TO HVAC BOX - VOLTAGE DROP PARALLEL CIRCUIT HVAC TEMPERATURE CONTROL SIGNAL UJM SENSOR GROUNDS 4A.20
51
52 53 53
57
547
1090
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Frame SHEET 14
PK - 0.8 OR - 5.0
SHEET 02
VT - 5.0
SHEET 14
PK - 0.8
WH - 0.8 YE - 0.8
OR - 5.0
YE - 0.8 BK/WH - 0.8
SHEET 05
Electrical systems - Harnesses and connectors
Pin 58 59
From X-CN2B (Receptacle) pin 2 UCM CN2B X-900 pin 23 CROSSOVER BULKHEAD
Wire
Color-Size BL - 0.8
754
Description PATTERN INDICATOR ISO LS OUTPUT THERMOSTAT TO BINARY PRESSURE SWITCH THERMOSTAT TO BINARY PRESSURE SWITCH PATTERN INDICATOR H LS OUTPUT PARK BRAKE SWITCH
541
2 SPEED UCM INPUT
YE - 0.8
531
YE - 0.8
234
LOADER FLOAT SWITCH INPUT BINARY PRESSURE SWITCH TO COMPRESSOR RELAY PIN 86 BINARY PRESSURE SWITCH TO COMPRESSOR RELAY PIN 86 CAN HI CAN LO SEAT BELT / LAP BAR OPERATOR INTERLOCK INSTRUMENT CLUSTER GROUND FUEL LEVEL SENDER
1023 833
59
X-900 pin 23 CROSSOVER BULKHEAD
833
61
X-CN2A (Receptacle) pin 23 UCM CN2A X-CN2B (Receptacle) pin 22 UCM CN2B X-CN4B (Receptacle) pin 15 UCM CN4B X-CN2B (Receptacle) pin 27 UCM CN2B X-900 pin 24 CROSSOVER BULKHEAD
1024
65
X-900 pin 24 CROSSOVER BULKHEAD
834
66 67 68
SP-503A-P-X SP-504A-P-X X-CN4A (Receptacle) pin 10 UCM CN4A SP-047-P-X
503A 504A 524
62 63 64 65
69 70
834
910
WH - 0.8
WH - 0.8
BL - 0.8 YE - 0.8
WH - 0.8
WH - 0.8
YE - 0.8 GN - 0.8 YE - 0.8 BK/WH - 1.0
SHEET 05
RD - 0.8
SHEET 14
234
FUEL LEVEL SENDER
71
X-900 pin 42 CROSSOVER BULKHEAD X-900 pin 42 CROSSOVER BULKHEAD SP-186-P-X
357
72
X-FUSE1 pin 18
115
73
X-OILTMP (Plug) pin 1 HYDRAULIC OIL TEMPERATURE SENDER X-FUSE1 pin 64
264
MAIN POWER RELAY OR - 1.0 IGNITION FUSE TO CAB RD - 2.0 BEACON AND ACCESSORY FUSE OUTPUT YE - 0.8 HYDRAULIC OIL TEMPERATURE SENDER
70
74 75
310 545
76
X-020 (Receptacle) pin A FOOT THROTTLE SENSOR SP-031-P-X
77
X-FUSE1 pin 63
134
78
SP-101-P-X
329
79
SP-037-P-X
309
80
303
84
X-CN3A (Receptacle) pin 23 UCM CN3A X-OILFLT (Plug) pin 1 HYDRAULIC OIL FILTER SWITCH X-900 pin 45 CROSSOVER BULKHEAD X-900 pin 45 CROSSOVER BULKHEAD X-020 (Receptacle) pin B FOOT THROTTLE SENSOR SP-102-P-X
85
X-FUSE2 pin 70
144
86
SP-107-P-X
175
81
82 82 83
790
261
267 267 1066 622
UNSWITCHED BATTERY POWER FOOT THROTTLE SIGNAL LAMP SWITCH WORK LAMP SIGNAL WIPER/SEAT ACC/RADIO/DOME LAMP/DFRST SW/HVAC RLY/SELF LEVEL SW PWR SEAT SWITCH UCM INPUT INSTRUMENT CLUSTER SWITCHED POWER HYDRAULIC LOADER INTERLOCK SIGNAL HYDRAULIC OIL FILTER
AIR FILTER/ENGINE MALFUNCTION AIR FILTER/ENGINE MALFUNCTION FOOT THROTTLE GROUND KEY SWITCH TO BC RELAY MAIN POWER RELAY SIGNAL EH ACC RELAY CHASSIS INTERFACE SIGNAL
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Frame SHEET 14
RD - 0.8
RD - 0.8 YE - 0.8
SHEET 09
VT - 1.0
SHEET 14
OR - 2.0
SHEET 15
YE - 0.8 OR - 1.0
SHEET 02
WH - 0.8
SHEET 15
YE - 0.8
YE - 0.8 YE - 0.8 BK/WH - 0.8
SHEET 09
WH - 0.8
SHEET 15
OR - 0.8 WH - 0.8
Electrical systems - Harnesses and connectors
Pin 87 88 89 90 94
From X-020 (Receptacle) pin C FOOT THROTTLE SENSOR X-271 (Receptacle) pin A WATER VALVE SP-101-P-X SP-100-P-X X-TELE (Receptacle) pin 6 TELEMATICS
Wire 211 822 332 330 208
Description THROTTLE POSITION SENSOR REFERENCE HVAC WATER VALVE POWER SEAT SW UCM DIODE IN EH SEAT SW UCM DIODE OUT TELEMATICS RS232 TX
Color-Size PK - 0.8
SHEET 09
Frame
OR - 0.8
SHEET 15
Description STANDARD HIGH FLOW SIGNAL
Color-Size WH - 0.8
SHEET 13
Color-Size BK - 0.8
SHEET 29
Color-Size WH - 0.8
SHEET 29
Color-Size VT - 0.8
SHEET 24
YE - 0.8 YE - 0.8 BL - 0.8
X-HFLO - X-HFLO (Receptacle) Pin 1
From X-ECC (Plug) pin 28 EH CHASSIS/CAB INTERFACE
Wire 750
Frame
X-HORN-GND - HORN GROUND [ H-009] (87697629) (Plug)
87697629
9
87697629 Pin 1
From
Wire 955
SP-179-P-X
Description HORN GROUND
Frame
X-HORN-PWR - HORN POWER [ H-009] (87697629) (Plug)
87697629
10
87697629 Pin 1
From X-ECC (Plug) pin 45 EH CHASSIS/CAB INTERFACE
Wire 892
Description HORN POWER SIGNAL
Frame
X-HZRDDIODE - X-HZRDDIODE (Receptacle) Pin
From
Wire
1
SP-019-P-X
781
2
X-302 (Receptacle) pin F HAZARD LAMP SWITCH
778
Description HAZARD SWITCH RH TURN SIGNAL O HAZARD SW RH TURN SIGNAL OUTPU
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VT - 0.8
Frame
Electrical systems - Harnesses and connectors
X-OILFLT - HYDRAULIC OIL FILTER SWITCH [ S-044] (84159852) (Plug)
84159852
11
84159852 Pin 1
From X-ECC (Plug) pin 81 EH CHASSIS/CAB INTERFACE
Wire 261
Description HYDRAULIC OIL FILTER
Color-Size YE - 0.8
Frame SHEET 15
X-OILTMP - HYDRAULIC OIL TEMPERATURE SENDER [ B-003] (84159852) (Plug)
84159852
12
84159852 Pin 1
From X-ECC (Plug) pin 73 EH CHASSIS/CAB INTERFACE
Wire 264
Description Color-Size YE - 0.8 HYDRAULIC OIL TEMPERATURE SENDER
X-PLTLK - PILOT INTERLOCK [ U-002] (87691549) (Receptacle)
87691549
13
87691549
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Frame SHEET 14
Electrical systems - Harnesses and connectors
Pin A B
From X-CN2A (Receptacle) pin 4 UCM CN2A SP-184-P-X
Wire 536 1063
Description LOADER PILOT INTERLOCK LOADER PILOT INTERLOCK GROUND
Color-Size WH - 0.8
Frame SHEET 11
BL - 0.8
X-RDCTRL - X-RDCTRL (87695584) (Plug)
87695584
14
87695584 X-TELE - TELEMATICS [ SH32: D-5] (87700156) (Receptacle)
87700156
15
87700156 Pin 1 2 3 4 6
From X-TELE_GND (Plug) pin 1 TELEMATICS GND SP-186-P-X
Wire 925 802 503D 504D 208
7 8
SP-503B-P-X SP-504B-P-X X-ECC (Plug) pin 94 EH CHASSIS/CAB INTERFACE SP-207-P-X X-006 (Receptacle) pin 2
11
SP-187-P-X
308
12
X-FUSE1 pin 4
336
207 244
Description TELEMATICS GROUND
Color-Size BK/WH - 0.8
SHEET 05
TELEMATICS IGNITION POWER TELEMATICS CAN HI TELEMATICS CAN LO TELEMATICS RS232 TX
OR - 0.8
SHEET 32
TELEMATICS RS232 RX ALTERNATOR LAMP TELEMATICS ENGINE ON VEHICLE WORKING CONDITION TELEMATICS UNSWITCHED BATTERY
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Frame
YE - 0.8 GN - 0.8 BL - 0.8 TN - 0.8 YE - 0.8
SHEET 04
YE - 0.8
SHEET 11
RD - 1.0
SHEET 32
Electrical systems - Harnesses and connectors
X-UJML - X-UJML (87694583) (Plug)
87694583
16
87694583 Pin
From
Wire
1
SP-132
215
2
567
4
X-BULKHEAD (Receptacle) pin 35 X-BULKHEAD (Receptacle) pin 36 SP-169
5 6 7
SP-137
218
8
562
10
X-BULKHEAD (Receptacle) pin 31 X-BULKHEAD (Receptacle) pin 32 SP-126
11 12
-
-
3
9
569 1045
568 1046
Description LH UB1 X-Y SENSOR VOLTAGE LH UA1 X SENSOR OUTPUT LH UA1 Y SENSOR OUTPUT LH OV1 X-Y SENSOR SENSOR GROUND LH UB2 X-Y SENSOR VOLTAGE LH UA2 X SENSOR OUTPUT LH UA2 Y SENSOR OUTPUT LH OV2 X-Y SENSOR GROUND -
Color-Size RD - 0.8
Frame SHEET 14
WH - 0.8 WH - 0.8 TN - 0.8
SHEET 18
OR - 0.8
SHEET 18
GN - 0.8
SHEET 13
GN - 0.8 BK
SHEET 18
-
X-UJMR - X-UJMR (87694583) (Plug)
87694583
17
87694583 Pin
From
Wire
1
SP-132
219
2
549
4
X-BULKHEAD (Receptacle) pin 23 X-BULKHEAD (Receptacle) pin 29 SP-169
5
-
-
3
561 1047
Description RH UB1 X-Y SENSOR VOLTAGE RH UA1 X SENSOR OUTPUT RH UA1 Y SENSOR OUTPUT RH OV1 X-Y SENSOR GROUND -
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Color-Size RD - 0.8
Frame SHEET 14
WH - 0.8 WH - 0.8 TN - 0.8 -
SHEET 18
Electrical systems - Harnesses and connectors
Pin
From
Wire
6 7
SP-137
217
8
548
10
X-BULKHEAD (Receptacle) pin 19 X-BULKHEAD (Receptacle) pin 20 SP-126
11 12
-
-
9
560 1048
Description RH UB2 X-Y SENSOR VOLTAGE RH UA2 X SENSOR OUTPUT RH UA2 Y SENSOR OUTPUT RH OV2 X-Y SENSOR GROUND -
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Frame
Color-Size OR - 0.8
SHEET 18
GN - 0.8
SHEET 13
GN - 0.8 BK -
SHEET 18
Electrical systems - Harnesses and connectors
Wire connectors - Component diagram 01 Connectors X-010 to X-019 SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
X-010 - CHASSIS/LOADER INTERFACE (87382927) (Plug)
87382927
1
87382927 1
Pin
From X-CN3B (Receptacle) pin 17
510
Wire
2 3
X-CN1A (Receptacle) pin 13 X-CN4A (Receptacle) pin 19
1018 511
4
X-CN3B (Receptacle) pin 12
570
5 6 7 8
X-CN3A (Receptacle) pin 22 X-CN2B (Receptacle) pin 7 X-CN3B (Receptacle) pin 6 X-CN3B (Receptacle) pin 13
512 1019 513 571
9
SP-124
1060
10
X-CN1A (Receptacle) pin 24
515
11
X-CN1A (Receptacle) pin 22
1020
12
X-CN1B (Receptacle) pin 33
514
13
X-CN3B (Receptacle) pin 14
572
14
X-CN1A (Receptacle) pin 8
236
Description BUCKET RETRACT SIGNAL BUCKET RETURN BUCKET EXTEND SIGNAL CONTROL VALVE BUCKET POSITION SENSOR LOADER LOWER SIGNAL LOADER RETURN LOADER RAISE SIGNAL CONTROL VALVE LOADER POSITION SENSOR CONTROL VALVE SENSOR GROUNDS PROPORTIONAL AUX RETRACT SIGNAL PROPORTIONAL AUX RETURN PROPORTIONAL AUX EXTEND SIGNAL CONTROL VALVE AUX POSITION SENSOR CONTROL VALVE SENSOR REFERENCE VOLTAGE
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Color-Size WH - 0.8
Frame SHEET 12
BL - 0.8 WH - 0.8 YE - 0.8
WH - 0.8 BL - 0.8 WH - 0.8 YE - 0.8
BK/WH - 0.8
SHEET 05
WH - 0.8
SHEET 12
BL - 0.8 WH - 0.8 YE - 0.8 PK - 0.8
Electrical systems - Harnesses and connectors
X-011 - WATER IN FUEL SWITCH (87709663) (Plug)
87709663
2
87709663 Pin 1 2 3
From X-201 PIN 8 X-201 PIN 9 X-201 PIN 10
Wire 1151 909 1137
Description SENSOR SIGNAL SENSOR GROUND SENSOR POWER
Color-Size YE - 0.8 BK - 0.8 OR - 0.8
Frame SHEET 38
X-011 - A/C COMPRESSOR (87382911) (Plug)
87382911
3
87382911 Pin
From X-076 (Receptacle) pin A X-76
Wire 833C
1
X-901 pin 23 CHASSIS INTERFACE
833
1
X-901 pin 23 CHASSIS INTERFACE
833
2
X-076 (Receptacle) pin B X-76
834C
2
X-901 pin 24 CHASSIS INTERFACE
834
2
X-901 pin 24 CHASSIS INTERFACE
834
3
AC-COMP-P-1
841C
3
X-901 pin 39 CHASSIS INTERFACE X-901 pin 39 CHASSIS INTERFACE
841
1
3
841
Description THERMOSTAT TO BINARY PRESSURE SWITCH THERMOSTAT TO BINARY PRESSURE SWITCH THERMOSTAT TO BINARY PRESSURE SWITCH BINARY PRESSURE SWITCH TO COMPRESSOR RELAY PIN 86 BINARY PRESSURE SWITCH TO COMPRESSOR RELAY PIN 86 BINARY PRESSURE SWITCH TO COMPRESSOR RELAY PIN 86 A/C COMPRESSOR RELAY PIN 87 POWER A/C COMPRESSOR RELAY PIN 87 POWER A/C COMPRESSOR RELAY PIN 87 POWER 48068130 29/01/2018
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Color-Size WH - 0.8
WH - 0.8
WH - 0.8
WH - 0.8
WH - 0.8
WH - 0.8
WH - 0.8 WH - 0.8 WH - 0.8
Frame SHEET 28
Electrical systems - Harnesses and connectors
X-012 - ECU [ A-004] (84474047) (Receptacle)
84474047
4
84474047 Pin
2 3
From X-901 pin 4 CHASSIS INTERFACE X-901 pin 4 CHASSIS INTERFACE SP-908-P-X SP-155-P-X
4 5
SP-908-P-X SP-155-P-X
908C 155C
6 7
908D 242
14
SP-908-P-X X-014 pin 3 LAMBDA SENSOR X-901 pin 8 CHASSIS INTERFACE X-901 pin 36 CHASSIS INTERFACE X-901 pin 36 CHASSIS INTERFACE X-005 (Plug) pin 1 X-005
19
X-004 PIN 1
257
20
X-004 (Receptacle) pin 2 AIR TEMPERATURE SENSOR X-013 (Receptacle) pin 3 GCU X-901 pin 31 CHASSIS INTERFACE X-901 pin 31 CHASSIS INTERFACE X-901 pin 18 CHASSIS INTERFACE X-901 pin 18 CHASSIS INTERFACE X-901 pin 33 CHASSIS INTERFACE X-901 pin 33 CHASSIS INTERFACE X-901 pin 46 CHASSIS INTERFACE X-ECU_MAIN_RLY (Receptacle) pin 2 ECU MAIN RELAY X-011 WIF (Plug) pin 1 X-005 (Plug) pin 2 X-005
254
1 1
7 8 8
22 24 24 25 25 27 27 28 28
30 36 41 50 52 53
SP-239-P-X X-079 (Receptacle) pin 2 CCV HEATERS X-013 (Receptacle) pin 8 GCU X-901 PIN 20
Wire 110 110 908B 155B
242 626 626 269
235
Description BATTERY VOLTAGE VIA MAIN RELAY BATTERY VOLTAGE VIA MAIN RELAY BATTERY MINUS 1 BATTERY +B VIA MAIN RELAY BATTERY MINUS 2 BATTERY +C VIA MAIN RELAY BATTERY MINUS 3 LAMBDA SENSOR HEATING LAMBDA SENSOR HEATING BC RELAY TO ECU SIGNAL BC RELAY TO ECU SIGNAL DIFF PRESSURE SENSOR SUPPLY AIR TEMPERATURE SENSOR SIGNAL AIR TEMP GND
Color-Size OR - 2.0 OR - 2.0 BK - 2.0 OR - 2.0 BK - 2.0 OR - 2.0 BK - 2.0 YE - 0.8 YE - 0.8 WH - 0.8 WH - 0.8 YE - 0.5 YE - 0.5 BK/WH - 0.5
503C
GLOW PLUG FEEDBACK YE - 0.5 SIGNAL YE - 0.8 CAN 1 HI
503C
CAN 1 HI
YE - 0.8
504C
CAN 1 LO
GN - 0.8
504C
CAN 1 LO
GN - 0.8
121
YE - 0.8
112
CRANK ENABLE FROM ECU CRANK ENABLE FROM ECU ECU MAIN RELAY
BL - 0.5
112
ECU MAIN RELAY
BL - 0.5
150 266
WATER IN FUEL SIGNAL DIFF PRESSURE SENSOR GND GLOW PLUG UNIT GND CCV HEATER CONTROL
OR - 0.8 BK/WH - 0.5
121
239 600 216 161
GLOW PLUG UNIT COMMAND SIGNAL CRANK ENABLE 2 48068130 29/01/2018
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YE - 0.8
BK - 0.8 WH - 0.8 YE - 0.5 YE - 0.8
Frame SHEET 06
Electrical systems - Harnesses and connectors
Pin 53 54
From X-900 PIN 20 SP-133B-P-X
Wire 161 133D
58
X-005 (Plug) pin 3 X-005
268
63
X-014 pin 6 LAMBDA SENSOR X-901 pin 12 CHASSIS INTERFACE X-014 pin 1 LAMBDA SENSOR X-901 pin 9 CHASSIS INTERFACE X-901 pin 19 CHASSIS INTERFACE X-901 pin 19 CHASSIS INTERFACE X-018 (Receptacle) pin 2 FUEL FILTER HEATER X-006 pin 2
253
63 64 64 68 68 70 79 79 80 80 81 82 83
84
85 85 86 86 87
248
Description CRANK ENABLE 2 EGR ECU SWITCHED BATTERY POWER DIFF PRESSURE SENSOR SIGNAL LAMBDA SENSOR VOLTAGE NERNST LAMBDA SENSOR VOLTAGE NERNST LAMBDA SENSOR CURRENT PUMP LAMBDA SENSOR CURRENT PUMP EGR ECU K-LINE
YE - 0.8
248
EGR ECU K-LINE
YE - 0.8
347
FUEL FILTER HEATER GROUND EXHAUST GAS TEMP GND EXHAUST GAS TEMP GND EXHAUST GAS TEMP SIGNAL EXHAUST GAS TEMP SIGNAL INLET TURBINE TEMP GND INLET TURBINE TEMP SIGNAL EXHAUST GAS TEMP GND 2
BL - 0.8
273
EXHAUST GAS TEMP SIGNAL 2
YE - 0.5
252
LAMBDA SENSOR VIRTUELLE GND LAMBDA SENSOR VIRTUELLE GND LAMBDA SENSOR CURRENT ADJUST LAMBDA SENSOR CURRENT ADJUST CCV HEATER FEEDBACK
BK - 0.5
253 245 245
270
X-901 pin 14 CHASSIS INTERFACE X-006 pin 1
270
X-901 pin 15 CHASSIS INTERFACE X-017 (Receptacle) pin 25 ENGINE INTERFACE X-017 (Receptacle) pin 26 ENGINE INTERFACE X-007 (Receptacle) pin 2 EXHAUST GAS TEMP SENSOR 2 X-007 (Receptacle) pin 1 EXHAUST GAS TEMP SENSOR 2 X-014 pin 2 LAMBDA SENSOR X-901 pin 11 CHASSIS INTERFACE X-014 pin 5 LAMBDA SENSOR X-901 pin 10 CHASSIS INTERFACE X-079 (Receptacle) pin 3 CCV HEATERS
271
271
265 263 272
252 249 249 601
Frame
Color-Size YE - 0.8 OR - 0.8 YE - 0.5 PK - 0.5 PK - 0.5 YE - 0.5 YE - 0.5
BK/WH - 0.5 BK/WH - 0.5 YE - 0.5 YE - 0.5 BK/WH - 0.5 YE - 0.5 BK/WH - 0.5
BK - 0.5 YE - 0.5 YE - 0.5 YE - 0.8
X-013 - LEFT DRIVE PUMP FORWARD [ M-013] (87695582) (Receptacle)
87695582
5
87695582 Pin 1 2
From X-CN3B (Receptacle) pin 33 SPLICE SP-098
Wire 516 1038
Description PUMP LEFT FORWARD PUMP LEFT FORWARD GROUND
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Color-Size WH - 0.8 BL - 0.8
Frame SHEET 10
Electrical systems - Harnesses and connectors
X-014 - LAMBDA SENSOR [ B-005] (84301132) (Receptacle)
84301132
6
84301132 Pin 1 2 3 4 5 6
From X-012 (Receptacle) pin 64 X-012 (Receptacle) pin 85 X-012 (Receptacle) pin 7 SPLICE SP-241 X-012 (Receptacle) pin 86 X-012 (Receptacle) pin 63
Wire 245 252 242 241B 249 253
Description CURRENT PUMP VIRTUAL GROUND SENSOR HEATING POWER CURRENT ADJUST VOLTAGE
Color-Size YE-0.5 BK-0.5 YE-0.8 OR-0.8 YE-0.5 PK-0.5
Frame SHEET 06
X-015 - INJECTOR HARNESS (Female)
87698252
7
87698252 A B
Pin
From X-016 (Receptacle) pin 16 X-016 (Receptacle) pin 32
274 275
Wire
C
X-016 (Receptacle) pin 31
276
D E F
X-016 (Receptacle) pin 1 X-016 (Receptacle) pin 17 X-016 (Receptacle) pin 48
277 278 279
G
X-016 (Receptacle) pin 46
280
H
X-016 (Receptacle) pin 2
281
Description INJECTOR CYLINDER 1 INJECTOR CYLINDER 1 RETURN INJECTOR CYLINDER 3 RETURN INJECTOR CYLINDER 3 INJECTOR CYLINDER 4 INJECTOR CYLINDER 4 RETURN INJECTOR CYLINDER 2 RETURN INJECTOR CYLINDER 2
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Color-Size WH - 1.0 GY - 1.0 GY - 1.0 WH - 1.0 WH - 1.0 GY - 1.0 GY - 1.0 WH - 1.0
Frame SHEET 07
Electrical systems - Harnesses and connectors
X-015 - ACCESSORY BACKFEED DIODE (84120021) (Plug)
84120021
8
84120021 Pin
From
Wire
1
SP-009-P-X
153
2
X-C23 (Receptacle) pin 29 INSTRUMENT CLUSTER
137
Description ACCESSORY RELAY SIGNAL ACCESSORY RELAY SIGNAL
Color-Size WH - 0.8
Frame SHEET 27
WH - 0.8
X-016 - LEFT DRIVE PUMP REVERSE [ M-016] (87695582) (Receptacle)
87695582
9
87695582 Pin 1 2
From X-CN2A (Receptacle) pin 14 SPLICE SP-099
Wire 517 1039
Description PUMP LEFT REVERSE PUMP LEFT REVERSE GROUND
Color-Size WH - 0.8 BL - 0.8
X-017 - RIGHT DRIVE PUMP FORWARD [ M-017] (87695582) (Receptacle)
87695582
10
87695582
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Frame SHEET 10
Electrical systems - Harnesses and connectors
Pin 1 2
From X-CN3B (Receptacle) pin 32 SPLICE SP-098
Wire 519 1040
Description Color-Size PUMP RIGHT FORWARD WH - 0.8 PUMP RIGHT FORWARD BL - 0.8 GROUND
Frame SHEET 10
X-018 - RIGHT DRIVE PUMP REVERSE [ M-018] (87695582) (Receptacle)
87695582
11
87695582 Pin 1 2
From X-CN2A (Receptacle) pin 8 SPLICE SP-099
Wire 518 1041
Description PUMP RIGHT REVERSE PUMP RIGHT REVERSE GROUND
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Color-Size WH - 0.8 BL - 0.8
Frame SHEET 10
Electrical systems - Harnesses and connectors
Wire connectors - Component diagram 02 Connectors X-020 to X-029 and Alphanumeric Connectors SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
X-020 - FOOT THROTTLE SENSOR [ SH9: C-2] (84398823) (Receptacle)
84398823
1
84398823 Pin A B C
From X-ECC (Plug) pin 75 EH CHASSIS/CAB INTERFACE X-ECC (Plug) pin 83 EH CHASSIS/CAB INTERFACE X-ECC (Plug) pin 87 EH CHASSIS/CAB INTERFACE
Wire 545 1066 211
Description FOOT THROTTLE SIGNAL FOOT THROTTLE GROUND THROTTLE POSITION SENSOR REFERENCE
Color-Size YE - 0.8
Frame SHEET 09
BK/WH - 0.8 PK - 0.8
X-021 - BUCKET SPOOL POSITION SENSOR [ B-028] (87694101) (Receptacle)
87694101
2
87694101
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Electrical systems - Harnesses and connectors
Pin
From
Wire
1
SP-135-P-X
206x
3
SP-130-P-X
1057
4
X-88 (Plug) pin 4 X-88
570A
Description CONTROL VALVE BUCKET POSITION SENSOR REFERENCE CONTROL VALVE BUCKET POSITION SENSOR GROUND CONTROL VALVE BUCKET POSITION SENSOR
Color-Size PK - 0.8
Frame SHEET 12
BK/WH - 0.8
YE - 0.8
X-022 - BOOM SPOOL POSITION SENSOR [ B-029] (87694101) (Receptacle)
87694101
3
87694101 Pin
From
Wire
1
SP-135-P-X
207x
3
SP-130-P-X
1058
4
X-88 (Plug) pin 8 X-88
571A
Description CONTROL VALVE LOADER POSITION SENSOR REFERENCE CONTROL VALVE LOADER POSITION SENSOR GROUND CONTROL VALVE LOADER POSITION SENSOR
Color-Size PK - 0.8
Frame SHEET 12
BK/WH - 0.8
YE - 0.8
X-023 - AUXILIARY SPOOL POSITION SENSOR [ B-027] (87694101) (Receptacle)
87694101
4
87694101 Pin
From
Wire
1
SP-135-P-X
208x
3
SP-130-P-X
1059
4
X-88 (Plug) pin 13 X-88
572A
Description CONTROL VALVE AUX POSITION SENSOR REFERENCE CONTROL VALVE AUX POSITION SENSOR GROUND CONTROL VALVE AUX POSITION SENSOR
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Color-Size PK - 0.8
BK/WH - 0.8
YE - 0.8
Frame SHEET 12
Electrical systems - Harnesses and connectors
X-024 - PROPORTIONAL AUX VALVE EXTEND [ Y-011] (87695582) (Plug)
87695582
5
87695582 1
Pin
From X-88 (Plug) pin 12
514
Wire
2
SPLICE SP-156
1083
Description PROPORTIONAL AUX EXTEND SIGNAL PROPORTIONAL AUX EXTEND RETURN
Color-Size WH - 1.0
Frame SHEET 12
BL - 1.0
X-025 - BUCKET VALVE RETRACT [ Y-003] (87695582) (Plug)
87695582
6
87695582 1
Pin
From X-88 (Plug) pin 1
510
Wire
2
SPLICE SP-154
1078
Description BUCKET RETRACT SIGNAL BUCKET RETRACT RETURN
X-026 - BUCKET VALVE EXTEND [ Y-006] (87695582) (Plug)
87695584
7
87695582 48068130 29/01/2018
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Color-Size WH - 1.0 BL - 1.0
Frame SHEET 12
Electrical systems - Harnesses and connectors
1
Pin
From X-88 (Plug) pin 3
511
Wire
2
SPLICE SP-154
1079
Description BUCKET EXTEND SIGNAL BUCKET EXTEND RETURN
Color-Size WH - 1.0
Frame SHEET 12
BL - 1.0
X-027 - LOADER VALVE RETRACT [ Y-007] (87695582) (Plug)
87695584
8
87695582 Pin 1 2
From X-88 (Plug) pin 5 SPLICE SP-155
Wire 512 1080
Description Color-Size LOADER LOWER SIGNAL WH - 1.0 BL - 1.0 LOADER LOWER RETURN
Frame SHEET 12
X-028 - LOADER VALVE EXTEND [ Y-009] (87695582) (Plug)
87695584
9
87695582 Pin 1 2
From X-88 (Plug) pin 7 SPLICE SP-155
Wire 513 1081
Description Color-Size LOADER RAISE SIGNAL WH - 1.0 LOADER RAISE RETURN BL - 1.0
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Frame SHEET 12
Electrical systems - Harnesses and connectors
X-029 - PROPORTIONAL AUX VALVE RETRACT [ Y-012] (87695582) (Plug)
87695584
10
87695582 1
Pin
From X-88 (Plug) pin 10
515
Wire
2
SPLICE SP-156
1082
Description PROPORTIONAL AUX RETRACT SIGNAL PROPORTIONAL AUX RETRACT RETURN
Color-Size WH - 1.0
Frame SHEET 12
BL - 1.0
X-20A - HAND THROTTLE [ B-023] (84398823) (Receptacle)
84398823
11
84398823 Pin
B
From X-C23 (Receptacle) pin 22 INSTRUMENT CLUSTER SP-200-P-X
1071
C
SP-201-P-X
260
A
Wire 544
Description HAND THROTTLE SIGNAL HAND THROTTLE SENSOR GROUND HAND THROTTLE SENSOR SUPPLY
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Color-Size YE - 0.8 BK/WH - 0.8 PK - 0.8
Frame SHEET 09
Electrical systems - Harnesses and connectors
X-C23 - INSTRUMENT CLUSTER [ SH27: C-1] (82028495) (Receptacle)
82028495
12
82028495 Pin
3 5 6 7
From X-BULKHEAD (Receptacle) pin 81 CAB/CHASSIS INTERCO X-009 (Receptacle) pin 4 SP-090-P-X SP-089-P-X SP-010-P-X
624 505 500 301
8
SP-010-P-X
302
9
SP-004-P-X
313
10 11
X-009 (Receptacle) pin 1 X-BULKHEAD (Receptacle) pin 82 CAB/CHASSIS INTERCO SP-086-P-X
132 267
X-BULKHEAD (Receptacle) pin 91 CAB/CHASSIS INTERCO X-BULKHEAD (Receptacle) pin 73 CAB/CHASSIS INTERCO SP-201-P-X
205C
2
12 13
16
17 19 22 23
24
25 29
30
32
33 34
Wire 261
328
Description HYDRAULIC OIL FILTER
Color-Size YE - 0.8
KEY START OUTPUT CAN LO CAN HI INSTRUMENT CLUSTER SWITCHED PO INSTRUMENT CLUSTER SWITCHED PO INSTRUMENT CLUSTER UNSWITCHED KEY IGNITION AIR FILTER/ENGINE MALFUNCTION
WH - 0.8 GN - 0.8 YE - 0.8 OR - 0.8
RD - 0.8 OR - 0.8 YE - 0.8
YE - 0.8 SEAT SW CLUSTER INPUT REGENERATION INHIBIT YE - 0.8 SW HYDRAULIC OIL TEMP SENDER
YE - 0.8
259
THROTTLE SENSOR SUPPLY DOOR SW SIGNAL HAND THROTTLE SIGNAL FOOT THROTTLE SIGNAL
PK - 0.8
234
FUEL LEVEL SENDER
YE - 0.8
1070
THROTTLE SENSOR GROUND ACCESSORY RELAY SIGNAL
BK/WH - 0.8
303
HYDRAULIC LOADER INTERLOCK SIG
WH - 0.8
622
START RELAY SIGNAL
WH - 0.8
133
MAIN POWER RELAY OR - 0.8 SIGNAL INSTRUMENT CLUSTER BK/WH - 0.8 GROUND
251 544
X-015 (Plug) pin 2 ACCESSORY BACKFEED DIODE X-BULKHEAD (Receptacle) pin 80 CAB/CHASSIS INTERCO X-BULKHEAD (Receptacle) pin 84 CAB/CHASSIS INTERCO X-316 (Receptacle) pin 2 ECU RELAY/GROUND SP-092-P-X
137
545
1011
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SHEET 04 SHEET 09
OR - 0.8
264
SP-093-P-X X-20A (Receptacle) pin A HAND THROTTLE X-BULKHEAD (Receptacle) pin 75 CAB/CHASSIS INTERCO X-BULKHEAD (Receptacle) pin 70 CAB/CHASSIS INTERCO SP-200-P-X
Frame SHEET 09
YE - 0.8 YE - 0.8 YE - 0.8
WH - 0.8
SHEET 04 SHEET 09
Electrical systems - Harnesses and connectors
Wire connectors - Component diagram 03 Connectors X-030 to X-039 SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
X-030 - CAB/RH LAMP JUMPER INTERF [ SH24: A-6] (87694154) (Plug)
87694154
1
87694154 1 1 2 3
Pin SP-016-P-X SP-016-P-X SP-015-P-X SP-019-P-X
From
Wire 798 797A 793 779
4 4
SP-014-P-X SP-173-P-X
926 939
Description RH WORK LAMP POWER RH WORK LAMP POWER RH SIDE LAMP POWER RH CAB TURN SIGNAL POWER RH CAB LAMPS GROUND RH CAB LAMPS/DOOR WIPER MOTOR/
Color-Size VT - 2.0 VT - 2.0 VT - 2.0 VT - 1.0 BK - 2.0 BK - 2.0
Frame SHEET 24
SHEET 05
X-031 - CAB/LH LAMP JUMPER INTERF (87694154) (Plug)
87694154
2
87694154 Pin
From
Wire
1 2 3
SP-016-P-X SP-015-P-X SP-018-P-X
799 794 773
4
SP-026-P-X
927
Description LH WORK LAMP POWER LH SIDE LAMP POWER LH CAB TURN SIGNAL POWER LH CAB LAMPS GROUND
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Color-Size VT - 2.0 VT - 2.0 VT - 0.8 BK - 2.0
Frame SHEET 24
Electrical systems - Harnesses and connectors
X-034 - LEFT-HAND REAR WORK LAMP [ E-006] (87695582) (Plug)
87695582
3
87695582 Pin 1 2
From
Wire 728 996
SP-079-P-X SP-080-P-X
Description 728 996
Color-Size VT - 1.0 BK - 2.0
Frame SHEET 25
X-035 - RIGHT-HAND REAR WORK LAMP [ E-005] (87695582) (Receptacle)
87695582
4
87695582 Pin 1 2
From SP-079-P-X SP-080-P-X
Wire 729 997
Description 729 997
Color-Size VT - 1.0 BK - 2.0
X-037 - LEFT-HAND REAR ROAD LAMPS [ Z-009] (87688716) (Receptacle)
87688716
5
87688716
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Frame SHEET 25
Electrical systems - Harnesses and connectors
Pin A B C
From SP-081-P-X X-201 (Plug) pin 3 REAR LAMP JUMPER SP-080-P-X
Wire 732A 731
732A 731
Description
Color-Size VT - 0.8 VT - 0.8
998
998
BK - 0.8
Frame SHEET 25
X-039 - LEFT-HAND REAR POSITION LAMP (Receptacle)
87688716
6
87688716 A B
Pin
From SPLICE SP-081 SPLICE SP-190
732 897
Wire
C
SPLICE SP-170
1091
Description BRAKE LAMP SIGNAL LEFT-HAND REAR POSITION LAMP GROUND
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Color-Size VT - 0.8 VT - 0.8 BK - 0.8
Frame SHEET 25
Electrical systems - Harnesses and connectors
Wire connectors - Component diagram 04 Connectors X-040 to X-049 SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
X-044 - RIGHT-HAND REAR ROAD LAMPS [ Z-011] (87688716) (Receptacle)
87688716
1
87688716 Pin A B C
From SP-081-P-X X-201 (Plug) pin 2 REAR LAMP JUMPER SP-080-P-X
Wire 734A 733
734A 733
Description
Color-Size VT - 0.8 VT - 0.8
999
999
BK - 0.8
Frame SHEET 25
X-049 - RIGHT-HAND REAR POSITION LAMP (87688716) (Receptacle)
87688716
2
87688716 A B
Pin
From SPLICE SP-081 X-201 (Plug) pin 6
Wire 734 718A
C
SPLICE SP-170
1092
Description BRAKE LAMP SIGNAL RIGHT-HAND REAR POSITION LAMP GROUND
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Color-Size VT - 0.8 VT - 0.8 BK - 0.8
Frame SHEET 25
Electrical systems - Harnesses and connectors
Wire connectors - Component diagram 05 Connectors X-050 to X-059 SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
X-58 - CAB/SEAT INTERFACE [ Z-006] (87694154) (Plug)
87694154
1
87694154 Pin
From
Wire
1
SP-058-P-X
756
2
SP-172-P-X
933
2
SP-168-P-X
933
3
SP-012-P-X
315
4
SP-086-P-X
323
Description SEAT ACCESSORY POWER SEAT ACCESSORY GROUND SEAT ACCESSORY GROUND SEAT SW UNSWITCHED POWER SEAT SW CLUSTER INPUT
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Color-Size OR - 1.0 BK - 1.0 BK - 1.0 RD - 0.8 YE - 0.8
Frame SHEET 19
Electrical systems - Harnesses and connectors
Wire connectors - Component diagram 06 Connectors X-060 to X-069 SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
X-066 - MULTIFUNCTION WATER PUMP (87693821) (Receptacle)
87693821
1
87693821 Pin
From
Wire
A
SP-073-P-X
421
B
SP-982-P-X
988
Description Color-Size MULTIFUNCTION WATER WH - 0.8 PUMP SIGNAL POWER MULTIFUNCTION WATER BK - 0.8 PUMP GROUND
Frame SHEET 31
X-68 - LAMPS (Receptacle)
87696093
2
87696093 Pin PWR B
From SPLICE SP-082 SPLICE SP-083
Wire 738 1003
Description BATTERY GROUND
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Color-Size VY- 0.8 BK - 0.8
Frame SHEET 22
Electrical systems - Harnesses and connectors
Wire connectors - Component diagram 07 Connectors X-070 to X-079 SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
X-074 - HVAC CONDENSER FAN [ Z-074] (87692877) (Plug)
87692877
1
87692877 Pin
From
Wire
A
SP-177-P-X
1084
B
X-314 (Receptacle) pin 2 CHASSIS POWER
237
Description Color-Size HVAC CONDENSER FAN BK - 3.0 GROUND HVAC CONDENSER FAN WH - 3.0 POWER
Frame SHEET 28
X-076 - X-76 HVAC HIGH PRESSURE SWITCH (87692877) (Plug)
87692877
2
87692877 A
Pin
From X-011 AC (Plug) pin 1
Wire 833C
B
X-011 AC (Plug) pin 2
834C
Description HVAC HIGH PRESSURE SWITCH HVAC HIGH PRESSURE SWITCH
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Color-Size WH - 0.8 WH - 0.8
Frame SHEET 28
Electrical systems - Harnesses and connectors
X-077 - SIDE LAMP DIA SOCKET [ J-001] (84398826) (Receptacle)
84398826
3
84398826 Pin 1 2
From SP-027-P-X SP-015-P-X
Wire 1085 238
Description Color-Size DIA SIDE LAMP GROUND BK - 0.8 DIA SIDE LAMP SIGNAL VT - 0.8
Frame SHEET 22
X-078A - FUEL PUMP (87692855) (Receptacle)
87692855
4
87692855 Pin A B
From X-079 (Receptacle) pin A CCV HEATERS X-078B (Plug) pin B X-078B
Wire 600XXX
Description FUEL PUMP
Color-Size OR - 0.8
1086XXX
FUEL PUMP GROUND
BK - 0.8
X-078B - FUEL PUMP (87692877) (Receptacle)
87692877
5
87692877
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Frame SHEET 08
Electrical systems - Harnesses and connectors
Pin A B
From X-079 (Receptacle) pin 2 X-079 PIN B X-078A (Receptacle) pin B
Wire 600AXXX
Description FUEL PUMP
Color-Size OR - 0.8
1086XXX
FUEL PUMP GROUND
BK - 0.8
Frame SHEET 08
X-079 - CCV HEATERS [ SH37: D-1] (87694153) (Receptacle)
87694153
6
87694153 Pin 1 1 2 3 4
From X-901 pin 6 CHASSIS INTERFACE SP-528RH-P-X X-012 (Receptacle) pin 50 ECU X-012 (Receptacle) pin 87 ECU SP-176-P-X
Wire 528E
Description CCV HEATER POWER
528E 600
CCV HEATER POWER OR - 2.0 CCV HEATER CONTROL WH - 0.8
601
CCV HEATER FEEDBACK YE - 0.8
1086
CCV HEATER GROUND
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Color-Size OR - 2.0
BK - 2.0
Frame SHEET 08
Electrical systems - Harnesses and connectors
Wire connectors - Component diagram 08 Connectors X-080 to X-089 SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
X-080 - LICENSE PLATE LAMP POWER [ E-007] (87697629) (Plug)
87697629
1
87697629 Pin 1
From
Wire 898
SP-190-P-X
Description 898
Frame
Color-Size VT - 0.8
SHEET 25
Color-Size BK - 0.8
SHEET 25
X-081 - LICENSE PLATE LAMP GROUND [ E-007] (Plug) Pin 1
From SP-170-P-X
Wire 1095
Description OPTION RELAY COIL GROUND
Frame
X-085 - RIGHT-HAND DIAGNOSTIC SIDE LAMP [ E-001] (87695582) (Receptacle)
87695582
2
87695582 1
Pin
From SP-191A-P-X
Wire 0063A
2
SP-192A-P-X
1097
Description RH DIA SIDE LAMP POWER OPTION RELAY COIL GROUND
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Color-Size VT - 0.8 BK - 0.8
Frame SHEET 22
Electrical systems - Harnesses and connectors
X-086 - LEFT-HAND DIAGNOSTIC SIDE LAMP [ E-002] (87695582) (Receptacle)
87695582
3
87695582 1
Pin
From SP-191A-P-X
Wire 0064A
2
SP-192A-P-X
1098A
Description LH DIA SIDE LAMP POWER LH DIA SIDE LAMP GROUND
Color-Size VT - 0.8
Frame SHEET 22
BK - 0.8
X-088 - LOADER VALVE (87382926) (Receptacle)
87382926
4
87382926 1
Pin
From X-025 (Plug) pin 1
Wire 510A
2
SPLICE SP-154
1018A
3 4
X-026 (Plug) pin 1 X-021 (Receptacle) pin 4
511A 570A
5
X-027 (Plug) pin 1
512A
6
SPLICE SP-108
1019A
7 8 9
X-028 (Plug) pin 1 X-022 (Receptacle) pin 4 SPLICE SP-130
513A 571A 1060A
10
X-029 (Plug) pin 1
515A
11
SPLICE SP-156
1020A
12
X-024 (Plug) pin 1
514A
13
X-023 PIN 4
572A
14
SPLICE SP-135
236A
Description BUCKET VALVE RETRACT BUCKET VALVE GROUND BUCKET VALVE EXTEND BUCKET SPOOL POSITION SENSOR LOADER VALVE RETRACT LOADER VALVE GROUND LOADER VALVE EXTEND BOOM SPOOL SENSOR SPOOL SENSOR GROUND PROPORTIONAL VALVE RETRACT PROPORTIONAL VALVE GROUND PROPORTIONAL VALVE EXTEND AUXILIARY SPOOL POSITION SENSOR SPOOL SENSOR POWER
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Color-Size WH - 0.8
Frame SHEET 12 SHEET 12
WH - 0.8
SHEET 12 SHEET 12
WH - 0.8
SHEET 12
WH - 0.8
SHEET 12
WH - 0.8 BK/WH - 0.8
SHEET 12 SHEET 12 SHEET 12
WH - 0.8
SHEET 12 SHEET 12
WH - 0.8
SHEET 12 SHEET 12 SHEET 12
Electrical systems - Harnesses and connectors
X-82 - DIAGNOSTIC SIDE LAMP (Receptacle) Pin GND PWR
From SP-192A-P-X SP-191A-P-X
Wire 1096A 0062A
Description Color-Size DIA SIDE LAMP GROUND BK - 1.0 DIA SIDE LAMP POWER BK - 1.0
Frame SHEET 22
X-88 - LOADER/CHASSIS INTERFACE (87382927) (Plug)
87382927
5
87382927 Pin
2 3
From Wire 510A X-025 (Receptacle) pin 1 BATT+ 1018A SP-154-P-X X-026 (Receptacle) pin 1 X-26 511A
4
X-021 (Receptacle) pin 4 X-21 570A
5 6 7 8
X-027 (Receptacle) pin 1 X-27 SP-108-P-X X-028 (Receptacle) pin 1 X-28 X-022 (Receptacle) pin 4 X-22
512A 1019A 513A 571A
9
SP-130-P-X
1060A
10
X-029 (Receptacle) pin 1 X-29 515A
11
SP-156-P-X
1020A
12
X-88 (Plug) pin 12 X-88
514A
12
X-88 (Plug) pin 12 X-88
514A
13
X-023 (Receptacle) pin 4 X-23 572A
14
SP-135-P-X
1
236A
Description BUCKET RETRACT SIGNAL BUCKET RETURN BUCKET EXTEND SIGNAL CONTROL VALVE BUCKET POSITION SENSOR LOADER LOWER SIGNAL LOADER RETURN 513A CONTROL VALVE LOADER POSITION SENSOR CONTROL VALVE SENSOR GROUNDS PROPORTIONAL AUX RETRACT SIGNAL PROPORTIONAL AUX RETURN PROPORTIONAL AUX EXTEND SIGNAL PROPORTIONAL AUX EXTEND SIGNAL CONTROL VALVE AUX POSITION SENSOR CONTROL VALVE SENSOR REFERENCE VOLTAGE
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Color-Size WH - 0.8 BL - 0.8 WH - 0.8 YE - 0.8
WH - 0.8 WH - 0.8 WH - 0.8 YE - 0.8
BK/WH - 0.8 WH - 0.8 BL - 0.8 WH - 0.8 WH - 0.8 YE - 0.8 PK - 0.8
Frame SHEET 12
Electrical systems - Harnesses and connectors
Wire connectors - Component diagram 09 Connectors X-090 to X-099 SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
X-093 - RH PUMP SWASH PLATE SENSOR [ B-026] (87694112) (Receptacle)
87694112
1
87694112 Pin
From
Wire
575
Description RH PUMP ANGLE SENSOR GROUND RH PUMP ANGLE SENSOR REFERENCE #1 RH PUMP ANGLE #2
YE - 0.8
576
RH PUMP ANGLE #1
YE - 0.8
221
RH PUMP ANGLE SENSOR REFERENCE #2 RH PUMP ANGLE SENSOR GROUND #2
PK - 0.8
1
SP-124-P-X
1055
2
SP-136-P-X
223
3
5
X-CN2B (Receptacle) pin 33 UCM CN2B X-CN2B (Receptacle) pin 32 UCM CN2B SP-136-P-X
6
SP-125-P-X
1074
4
Color-Size BK/WH - 0.8 PK - 0.8
BK/WH - 0.8
X-094 - LH PUMP SWASH PLATE SENSOR [ B-025] (87694112) (Receptacle)
87694112
2
87694112
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Frame SHEET 10
Electrical systems - Harnesses and connectors
Pin
From
Wire
574
Description LH PUMP ANGLE SENSOR GROUND LH PUMP ANGLE SENSOR REFERENCE #1 LH PUMP ANGLE #1
YE - 0.8
573
LH PUMP ANGLE #2
YE - 0.8
209
LH PUMP ANGLE SENSOR REFERENCE #2 LH PUMP ANGLE SENSOR GROUND #2
PK - 0.8
1
SP-124-P-X
1054
2
SP-136-P-X
222
3
5
X-CN3A (Receptacle) pin 9 UCM CN3A X-CN3A (Receptacle) pin 10 UCM CN3A SP-136-P-X
6
SP-125-P-X
1073
4
Color-Size BK/WH - 0.8
Frame SHEET 10
PK - 0.8
BK/WH - 0.8
X-095 - DRIVE PATTERN SELECTOR SW (84159859) (Receptacle)
84159859
3
84159859 Pin 1
3
5 6
7 8
9
10
From X-BULKHEAD (Receptacle) pin 15 CAB/CHASSIS INTERCO X-BULKHEAD (Receptacle) pin 12 CAB/CHASSIS INTERCO SP-140-P-X X-BULKHEAD (Receptacle) pin 17 CAB/CHASSIS INTERCO SP-140-P-X X-BULKHEAD (Receptacle) pin 61 CAB/CHASSIS INTERCO X-BULKHEAD (Receptacle) pin 58 CAB/CHASSIS INTERCO SP-140-P-X
Wire
Description CONTROL PATTERN H
Color-Size YE - 0.8
521
CONTROL PATTERN NEUTRAL
YE - 0.8
199
CONTROL PATTERN SW OR - 0.8 INPUT POWER CONTROL PATTERN ISO YE - 0.8
522
523
197
PATTERN INDICATOR ISO POWER PATTERN INDICATOR H LS OUTPUT
OR - 0.8
1023
PATTERN INDICATIOR ISO LS OUTP
BL - 0.8
198
PATTERN INDICATOR H POWER
OR - 0.8
1024
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BL - 0.8
Frame SHEET 09
Electrical systems - Harnesses and connectors
X-097 - CAB/DOME LAMP JUMPER (87695584) (Plug)
87695584
4
87695584 Pin 1 2
From SPLICE SP-011 SPLICE SP-026
Wire
Description POWER GROUND
Frame
Color-Size OR - 0.8 BK - 0.8
SHEET 29 SHEET 29
Color-Size YE - 0.8
SHEET 19
YE - 0.8
SHEET 14
332
SEAT SW UCM DIODE IN YE - 0.8
SHEET 15
330
EH SEAT SW UCM DIODE YE - 0.8 OUT
334
MAIN POWER RELAY UCM WAKE UP
OR - 2.0
334
MAIN POWER RELAY UCM WAKEUP DI
OR - 0.8
333
UCM WAKEUP DIODE OUT
YE - 0.8
151 916
X-90 - DIODE PACK [ SH19: B-1] (87039236) (Plug)
87039236
5
87039236 Pin A B
C
D
E
E
F
From X-104 (Receptacle) pin 2 X-104 X-BULKHEAD (Receptacle) pin 68 CAB/CHASSIS INTERCO X-BULKHEAD (Receptacle) pin 89 CAB/CHASSIS INTERCO X-BULKHEAD (Receptacle) pin 90 CAB/CHASSIS INTERCO X-BULKHEAD (Receptacle) pin 6 CAB/CHASSIS INTERCO X-BULKHEAD (Receptacle) pin 6 CAB/CHASSIS INTERCO X-BULKHEAD (Receptacle) pin 7 CAB/CHASSIS INTERCO
Wire 314 524
Description LAP BAR/SEAT BELT CLUSTER INPU SEAT BELT/LAP BAR OPERATOR INT
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Frame
SHEET 13
Electrical systems - Harnesses and connectors
Wire connectors - Component diagram 10 Connectors X-100 to X-109 SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
X-101 - ON ROAD LIGHT CONFIGURATOR [ S-029] (87679525) (Receptacle)
87679525
1
87679525 Pin 1
From SPLICE SP-024
Wire 702
Description LAMP SELECTOR SWITCH
Color-Size VT - 2.0
Frame SHEET 13
X-101A - ON ROAD LIGHT CONFIGURATOR STAND [ S-029] (87687239) (Plug)
87687239
2
87687239 Pin 1
From X-FUSE1 PIN 11
Wire 710
Description LIGHTS #1 RELAY OUTPUT
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Color-Size VT 2.0
Frame SHEET 13
Electrical systems - Harnesses and connectors
X-101B - ON ROAD LIGHT CONFIGURATOR OPTIO [ S-029] (87687239) (Plug)
87687239
3
87687239 Pin 1
From SPLICE SP-057
Wire 711
Description BATTERY
Color-Size VT - 2.0
Frame SHEET 13
X-104 - LAP BAR SWITCH(87382907) (Plug)
87382907
4
87382907 Pin 1
From SPLICE SP-012 X-90 (Plug) pin A
Wire 316 314
Description BATTERY LAP BAR OUTPUT
Color-Size RD - 0.8 YE - 0.8
X-107 - MULTIFUNCTION ATTACHMENT CONNECTOR(87696137) (Plug)
87696137
5
87696137
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Frame SHEET 19
Electrical systems - Harnesses and connectors
Pin
From
Wire
B
SP-982-P-X
987
C
X-323A (Plug) pin 1 CHASSIS OPTIONS/MULTIFUNCTION IN X-323A (Plug) pin 2 CHASSIS OPTIONS/MULTIFUNCTION IN X-323A (Plug) pin 4 CHASSIS OPTIONS/MULTIFUNCTION IN X-323A (Plug) pin 6 CHASSIS OPTIONS/MULTIFUNCTION IN X-323A (Plug) pin 5 CHASSIS OPTIONS/MULTIFUNCTION IN SP-073-P-X X-323A (Plug) pin 9 CHASSIS OPTIONS/MULTIFUNCTION IN X-323A (Plug) pin 10 CHASSIS OPTIONS/MULTIFUNCTION IN
419
D
F
G
H
J K
L
418
411
417
416
422 420
423
Description MULTIFUNCTION ATTACHMENT GROUND LH HANDLE MULTIFUNCTION #3 DOWN LH HANDLE MULTIFUNCTION #3 UP RH HANDLE MULTIFUNCTION #1 DOWN HANDLE MULTIFUNCTION #2 DOWN HANDLE MULTIFUNCTION #2 UP 422 MULTIFUNCTION KEY POWER
Color-Size BK - 0.8
EHF INTERLOCK
YE - 0.8
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LG - 0.8
GY - 0.8
TN - 0.8
VT - 0.8
RD - 0.8
WH - 0.8 OR - 3.0
Frame SHEET 31
Electrical systems - Harnesses and connectors
Wire connectors - Component diagram 11 Connectors X-110 to X-119 SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
X-111 - CONDENSER RELAY [CAB] [ K-020] (87692860) (Receptacle)
87692860
1
87692860 Pin 30
SP-160-P-X
From 839
Wire
85
SP-168-P-X
1087
87
X-BULKHEAD (Receptacle) pin 1 CAB/CHASSIS INTERCO
237
Description Color-Size CONDENSER RELAY PIN RD - 3.0 30 POWER BK - 0.8 CONDENSER RELAY GROUND HVAC CONDENSER FAN WH - 3.0 POWER
X-113 - FE #2 SWITCH (87697780) (Receptacle)
87697780
2
87697780
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Frame SHEET 28
Electrical systems - Harnesses and connectors
Pin
From
Wire
D
SP-063-P-X
425
E
SP-062-P-X
359
F
SP-064-P-X
427
Description LH HANDLE MULTIFUNCTION #2 UP LH HANDLE MULTIFUNCTION #2/#3 LH HANDLE MULTIFUNCTION #2 DOW
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Color-Size VT - 0.8
OR - 0.8 RD - 0.8
Frame SHEET 33
Electrical systems - Harnesses and connectors
Wire connectors - Component diagram 12 Connectors X-120 to X-129 SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
X-126 - STARTER (87697528) (Receptacle)
87697528
1
87697528 Pin A
From X-006 (Plug) pin 3
Wire 520A
Description STARTER MOTOR POWER
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Color-Size WH - 2.0
Frame SHEET 04
Electrical systems - Harnesses and connectors
Wire connectors - Component diagram 15 Connectors X-150 to X-159 SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
X-155B - TURN SIGNAL INDICATOR RIGHT [ E-004] (87697629) (Plug)
87697629
1
87697629 Pin 1
From
Wire 771
SP-019-P-X
Description TURN SIGNAL INDICATOR RH
Color-Size VT - 0.8
Frame SHEET 23
X-156B - TURN SIGNAL INDICATOR LEFT [ E-004] (87697629) (Plug)
87697629
2
87697629 Pin 1
From SP-018-P-X
Wire 772
Description TURN SIGNAL INDICATOR LH
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Color-Size YE - 0.8
Frame SHEET 23
Electrical systems - Harnesses and connectors
X-157B - TURN SIGNAL INDICATOR GROUND [ E-004] (87697629) (Plug)
87697629
3
87697629 Pin 1
From SP-025-P-X
Wire 915
Description TURN SIGNAL INDICATOR GROUND
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Color-Size BK - 0.8
Frame SHEET 23
Electrical systems - Harnesses and connectors
Wire connectors - Component diagram 17 Connectors X-170 to X-179 SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
X-178 - BEACON LAMP SOCKET [ E-003] (84398826) (Receptacle)
84398826
1
84398826 Pin
From
Wire
1
SP-027-P-X
928
2
X-301 (Receptacle) pin D BEACON LAMP SWITCH
761
Description Color-Size BEACON LAMP SOCKET BK - 0.8 GROUND VT - 0.8 BEACON SW OUTPUT
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Frame SHEET 16
Electrical systems - Harnesses and connectors
Wire connectors - Component diagram 19 Connectors X-190 to X-199 SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
X-195 - GCU FUSE (84398828) (Plug)
84398828
1
84398828 Pin 1
From SP-212-P-X
Wire 212
Description BATT+
Color-Size OR - 8.0
Frame SHEET 38
X-196 - RIGHT-HAND REAR ROAD LAMPS[ Z-011] (87688716) (Receptacle)
87688716
2
87688716 Pin A C
From X-201 (Plug) pin 12 REAR LAMP JUMPER SP-170-P-X
Wire
Description
736
736
Color-Size VT - 0.8
1002
1002
BK - 0.8
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Frame SHEET 25
Electrical systems - Harnesses and connectors
X-198 - LEFT-HAND TURN SIGNAL [ Z-009] (87688716) (Receptacle)
87688716
3
87688716 A
Pin
From X-201 (Plug) pin 11
735
Wire
B C
SP-170-P-X
1001
Description Color-Size LEFT-HAND REAR TURN VT - 0.8 SIGNAL POWER 1001 BK - 0.8
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Frame SHEET 25
Electrical systems - Harnesses and connectors
Wire connectors - Component diagram 20 Connectors X-200 to X-209 SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
X-201 - REAR LAMP JUMPER (87382927) (Plug)
87382927
1
87382927 Pin
From
Wire
1
SP-079-P-X
730
2
X-044 (Receptacle) pin B
733
3
X-037 (Receptacle) pin B
731
4 5
SP-080-P-X SP-190-P-X
1000 717B
6
X-049 (Plug) pin B
718A
7
SP-081-P-X
737
8
X-011 WIF (Plug) pin 1
1151
9
X-011 WIF (Plug) pin 2
909
10
X-011 WIF (Plug) pin 3
1137
11
X-198 (Receptacle) pin A
735
12
X-196 (Receptacle) pin A
736
13 14
SP-170-P-X J28 PIN 1
975 896
Description REAR WORK LAMP POWER RIGHT-HAND TAIL LAMP POWER LEFT-HAND TAIL LAMP POWER REAR LAMP GROUND LEFT-HAND REAR POSITION LAMP POWER RIGHT-HAND REAR POSITION LAMP POWER BRAKE LAMP SIGNAL POWER WATER IN FUEL SENSOR SIGNAL WATER IN FUEL SENSOR GROUND WATER IN FUEL SENSOR POWER LEFT-HAND REAR TURN SIGNAL POWER RIGHT-HAND REAR TURN SIGNAL POWER REAR LAMPS GROUND BACKUP ALARM SIGNAL
Frame
Color-Size VT - 2.0
SHEET 25
VT - 0.8
SHEET 25
VT - 0.8
SHEET 25
BK - 0.8 VT - 0.8
SHEET 25 SHEET 25
VT - 0.8
SHEET 25
VT - 0.8
SHEET 25
YE - 0.8
SHEET 38
BK - 0.8
SHEET 38
OR - 0.8
SHEET 38
VT - 0.8
SHEET 25
VT - 0.8
SHEET 25
BK - 3.0 WH - 0.0
SHEET 25 SHEET 38
X-205 - DOOR/CHASSIS INTERFACE [ SH37: A-1] (Receptacle) Pin
From
Wire
1
X-314 PIN 1
706
2
LG MACHINES X-901 LG (Plug) pin 29 MD MACHINES X-901 MD (Plug) pin 29
704
Description Color-Size VT - 2.0 REAR WORK LAMP POWER RIGHT-HAND TAIL LAMP VT - 0.8 POWER
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Frame SHEET 25 SHEET 25
Electrical systems - Harnesses and connectors
Pin
6
From LG MACHINES X-901 LG (Plug) pin 43 MD MACHINES X-901 MD (Plug) pin 43 SPLICE SP-177 LG MACHINES X-901 LG (Plug) pin 26 MD MACHINES X-901 MD (Plug) pin 26 X-901 PIN 26 SPLICE SP-060
7
X-901 PIN 40
721
8
X-012 PIN 30
150
9
SPLICE SP-908
908E
10
SPLICE SP-133B
133E
11
X-901 PIN 30
766
12
SPLICE SP052
763
13 14
SPLICE SP-177 LG MACHINES X-901 LG (Plug) pin 17 MD MACHINES X-901 MD (Plug) pin 17
975 895
3
4 5
Wire 703
Description LEFT-HAND TAIL LAMP POWER
Color-Size VT - 0.8
Frame SHEET 25
950 717
BK - 0.8 REAR LAMP GROUND LEFT-HAND REAR VT - 0.8 POSITION LAMP POWER
SHEET 25 SHEET 25
718
RIGHT-HAND REAR POSITION LAMP POWER BRAKE LAMP SIGNAL POWER WATER IN FUEL SENSOR SIGNAL WATER IN FUEL SENSOR GROUND WATER IN FUEL SENSOR POWER LEFT-HAND REAR TURN SIGNAL POWER RIGHT-HAND REAR TURN SIGNAL POWER REAR LAMPS GROUND BACKUP ALARM SIGNAL
VT - 0.8
SHEET 25
VT - 0.8
SHEET 25
YE - 0.8
SHEET 38
BK - 0.8
SHEET 38
OR - 0.8
SHEET 38
VT - 0.8
SHEET 25
VT - 0.8
SHEET 25
BK - 3.0 WH - 0.0
SHEET 25 SHEET 38
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Electrical systems - Harnesses and connectors
Wire connectors - Component diagram 22 Connectors X-220 to X-229 SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
X-228 - LH FRONT ROAD LAMP [ Z-001] (87694152) (Plug)
87694152
1
87694152 Pin 1 2 4 5
From X-232 (Plug) pin D SP-074-P-X SP-074-P-X X-232 (Plug) pin B
Wire 979A 742 741 767A
Description 979A 742 741 767A
Color-Size BK - 1.0 VT - 0.8 VT - 0.8 VT - 0.8
Frame SHEET 25
X-229 - RH FRONT ROAD LAMP [ Z-002] (87694152) (Plug)
87694152
2
87694152 Pin 1 2 4 5
From X-233 (Plug) pin D SP-075-P-X SP-075-P-X X-233 (Plug) pin B
Wire 980A 540 539 764A
Description 980A 540 539 764A
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Color-Size BK - 1.0 VT - 0.8 VT - 0.8 VT - 0.8
Frame SHEET 25
Electrical systems - Harnesses and connectors
Wire connectors - Component diagram 23 Connectors X-230 to X-239 SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
X-230 - LEFT-HAND FRONT ROAD LAMPS (87697723) (Plug)
87697723
1
87697723 A
Pin
From SPLICE SP-059
712
Wire
B D
SPLICE SP-051 SPLICE SP-174
767 979
Description LOW BEAM AND POSITION LIGHTS TURN SIGNAL GROUND
Color-Size VT - 1.0
Frame SHEET 25
VT - 0.8 BK - 1.0
X-231 - RIGHT-HAND FRONT ROAD LAMPS (87697723) (Plug)
87697723
2
87697723 A
Pin
From SPLICE SP-060
713
Wire
B D
SPLICE SP-052 SPLICE SP-175
764 980
Description LOW BEAM AND POSITION LIGHTS TURN SIGNAL GROUND
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Color-Size VT - 1.0 VT - 0.8 BK - 1.0
Frame SHEET 25
Electrical systems - Harnesses and connectors
X-232 - LEFT-HAND FRONT ROAD LAMPS (87697723) (Plug)
87697723
3
87697723 Pin
From
Wire 712A
A
SP-074-P-X
B
X-228 (Plug) pin 5 LH FRONT 767A ROAD LAMP X-228 (Plug) pin 1 LH FRONT 979A ROAD LAMP
D
Description LOW BEAM AND POSITION LIGHTS TURN SIGNAL
Color-Size VT - 1.0
GROUND
BK - 1.0
Frame SHEET 25
VT - 0.8
X-233 - RIGHT-HAND FRONT ROAD LAMPS (87697723) (Plug)
87697723
4
87697723 Pin
From
Wire 713A
A
SP-075-P-X
B
X-229 (Plug) pin 5 RH FRONT 764A ROAD LAMP X-229 (Plug) pin 1 RH FRONT 980A ROAD LAMP
D
Description LOW BEAM AND POSITION LIGHTS TURN SIGNAL
VT - 0.8
GROUND
BK - 1.0
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Color-Size VT - 1.0
Frame SHEET 25
Electrical systems - Harnesses and connectors
Wire connectors - Component diagram 25 Connectors X-250 to X-259 SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
X-252 - TEMP CONTROL SWITCH [ Z-017] (87714670) (Receptacle)
87714670
1
87714670 Pin
From
Wire
1
SP-091-P-X
823
2
X-BULKHEAD (Receptacle) pin 56 CAB/CHASSIS INTERCO SP-014-P-X
824
3
912
Description HVAC TEMPERATURE SW POWER HVAC TEMPERATURE CONTROL SIGNA
Color-Size PK - 0.8
HVAC TEMPERATURE SWITCH GROUND
BK - 0.8
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YE - 0.8
Frame SHEET 28
Electrical systems - Harnesses and connectors
Wire connectors - Component diagram 27 Connectors X-270 to X-279 SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
X-270 - BLOWER FAN SWITCH [ S-020] (47726797) (Plug)
47726797
1
47726797 Pin 1 2 3 4 5
From X-275 (Receptacle) pin A SPLICE SP091 X-HVC1 (Receptacle) pin 3 X-HVC1 (Receptacle) pin 4 SPLICE SP-164 X-HVC1 (Receptacle) pin 5
Wire 825 821 828 827 826 850
Description GROUND POWER HVAC FAN LOW HVAC FAN MEDIUM HVAC FAN HIGH
Color-Size OR - 0.8 OR - 3.0 WH - 3.0 WH - 3.0 WH - 3.0 WH - 5.0
Frame SHEET 28
X-271 - WATER VALVE [ SH28: A-6] (87694714) (Receptacle)
87694714
2
87694714 Pin A C D
From X-ECC (Plug) pin 88 EH CHASSIS/CAB INTERFACE SP-179-P-X X-ECC (Plug) pin 56 EH CHASSIS/CAB INTERFACE
Wire 822 1013 824
Description Color-Size HVAC WATER VALVE OR - 0.8 POWER WATER VALVE GROUND BK - 0.8 YE - 0.8 HVAC TEMPERATURE CONTROL SIGNAL
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Frame SHEET 05
Electrical systems - Harnesses and connectors
X-275 - A/C SWITCH [ SH26: C-1] (84398822) (Receptacle)
84398822
3
84398822 Pin
B
From X-270 pin 1 BLOWER FAN SWITCH SP-014-P-X
913
C
SP-157-P-X
829
A
Wire 825
Description HVAC CLUTCH
Color-Size OR - 0.8
HVAC COMPRESSOR CLUTCH SW GROU A/C SW OUT
BK - 0.8
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WH - 0.8
Frame SHEET 28
Electrical systems - Harnesses and connectors
Wire connectors - Component diagram 30 Connectors X-300 to X-309 SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
X-300 - HYDRAULIC COUPLER SWITCH [ S-009] (84159859) (Receptacle)
84159859
1
84159859 Pin
From
Wire
2
SP-053-P-X
751
3
X-BULKHEAD (Receptacle) pin 25 CAB/CHASSIS INTERCO SP-026-P-X
752
9
918
Description HYDRAULIC COUPLER SW IN HYDRAULIC COUPLER SIGNAL
Color-Size OR - 0.8
HYDRAULIC COUPLER SW INDICATOR
BK - 0.8
Frame SHEET 16
WH - 0.8
X-301 - BEACON LAMP SWITCH [ S-001] (87697780) (Receptacle)
87697780
2
87697780 A
Pin SP-026-P-X
919
D
X-178 (Receptacle) pin 2 BEACON LAMP SOCKET SP-033-P-X
761
Description Color-Size BEACON SW INDICATOR BK - 0.8 GROUND VT - 0.8 BEACON SW OUTPUT
796
BEACON POWER
E
From
Wire
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VT - 0.8
Frame SHEET 16
Electrical systems - Harnesses and connectors
X-302 - HAZARD LAMP SWITCH [ SH16: B-1] (84159858) (Receptacle)
84159858
3
84159858 Pin
From
Wire
A
SP-018-P-X
776
B
SP-138-P-X
784
C
SP-025-P-X
920
E
SP-138-P-X
785
F
X-HZRDDIODE (Receptacle) pin 2 X-HZRDDIODE
778
Description HAZARD SW LH TURN SIGNAL OUTPU LH HAZARD FLASHER POWER IN HAZARD SW INDICATOR GROUND RH HAZARD FLASHER POWER IN HAZARD SW RH TURN SIGNAL OUTPU
Color-Size VT - 1.0
Frame SHEET 16
OR - 1.0 BK - 0.8 OR - 0.8 VT - 0.8
X-303 - HI FLOW SWITCH [ S-042] (47740181) (Receptacle)
47740181
4
47740181 Pin A C E F
From SPLICE SP-025 X-BULKHEAD (Receptacle) pin 28 SPLICE SP-053 X-BULKHEAD (Receptacle) pin 26
Wire 921 750 753 755
Description HIGH FLOW SW INDICATOR GROUND STANDARD HIGH FLOW SIGNAL HIGH FLOW SW IN HIGH PERFORMANCE HIGH FLOW SIGNAL
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Color-Size BK - 0.8 WH - 0.8 OR - 0.8 WH - 0.8
Frame SHEET 16
Electrical systems - Harnesses and connectors
X-306 - LOADER LOCKOUT SW [ S-005] (47740181) (Receptacle)
47740181
5
47740181 A B C
Pin
From SPLICE SP-025 X-BULKHEAD PIN 11
924 398
Wire
D E
SPLICE SP-139 X-BULKHEAD PIN 18
311 312
Description GROUND LOADER LOCKOUT SWITCH ON BATTERY LOADER LOCKOUT SWITCH OFF
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Color-Size BK - 0.8 YE - 0.8 OR - 0.8 YE - 0.8
Frame SHEET 16
Electrical systems - Harnesses and connectors
Wire connectors - Component diagram 31 Connectors X-310 to X-319 SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
X-310 - 2 SPEED INDICATOR [ Z-004] (84159859) (Receptacle)
84159859
1
84159859 Pin 7 9
From SP-035-P-X SP-025-P-X
Wire 565 917
Description 2 SPEED INDICATOR 2 SPEED INDICATOR GROUND
Color-Size VT - 0.8 BK - 0.8
X-311 - LAMP SELECTOR SWITCH [ S-012] (87697741) (Receptacle)
87697741
2
87697741
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Frame SHEET 23
Electrical systems - Harnesses and connectors
Pin A
B
C
D
From X-BULKHEAD (Receptacle) pin 76 CAB/CHASSIS INTERCO X-BULKHEAD (Receptacle) pin 5 CAB/CHASSIS INTERCO X-BULKHEAD (Receptacle) pin 3 CAB/CHASSIS INTERCO X-BULKHEAD (Receptacle) pin 4 CAB/CHASSIS INTERCO
Wire
Description LAMP SW WORK LAMP SIGNAL
Color-Size VT - 2.0
791
LAMP SW ROAD LAMP SIGNAL
VT - 3.0
792
LAMP SW WORK & SIDE VT - 3.0 LAMP SIGNA
123
LAMP SW POWER
790
Frame SHEET 13
OR - 3.0
X-313 - GCU POWER (87706435) (Plug)
87706435
3
87706435 Pin 1
From SP-212-P-X
Wire 212A
Description BATT+
Frame
Color-Size OR - 8.0
SHEET 06
Color-Size OR - 3.0 WH - 3.0
SHEET 06 SHEET 28
VT - 3.0
SHEET 02
OR - 5.0
SHEET 38
X-314 - CHASSIS POWER [ SH38: B-6] (47525005) (Plug)
47525005
4
47525005 Pin
Wire 155A 237
3
From X-FUSE1 pin 1 X-ECC (Plug) pin 1 EH CHASSIS/CAB INTERFACE X-FUSE1 pin 41
4
SP-212-P-X
212A
1 2
706
Description BATT+ HVAC CONDENSER FAN POWER REAR WORK LAMP FUSE OUT BATT+
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Frame
Electrical systems - Harnesses and connectors
X-315 - REMOTE POWER/GROUND (84190315) (Plug)
84190315
5
84190315 Pin 1 2
From SPLICE SP-212 SPLICE SP-182
Wire 212B 1087
Description SWITCHED BATTERY GROUND
Color-Size OR - 5.0 BK - 5.0
Frame SHEET 38
X-316 - ECU RELAY/GROUND [ SH6: D-6] (47525005) (Plug)
47525005
6
47525005 Pin 1 2 3
From SP-527RH-P-X SP-528RH-P-X SP-908-P-X
Wire 527D 528F 908A
Description BATT+ BATT+ ECU GROUND
Color-Size RD - 5.0 OR - 5.0 BK - 5.0
X-317 - SELF LEVEL SWITCH [ SH16: C-6] (47740181) (Receptacle)
47740181
7
47740181
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Frame SHEET 06 SHEET 02 SHEET 05
Electrical systems - Harnesses and connectors
Pin A D E
From SPLICE SP-026 SPLICE SP-058 X-BULKHEAD (Receptacle) pin 52
Wire 922 405 404
Description GROUND SWITCHED BATTERY SELF-LEVEL SWITCH SIGNAL
Color-Size BK - 0.8 OR - 0.8 WH - 0.8
Frame SHEET 16
X-318 - SELF LEVEL VALVE (87695582) (Receptacle)
87695582
8
87695582 Pin 1
From X-ECC (Plug) pin 52 EH CHASSIS/CAB INTERFACE
Wire 404
Description SELF LEVEL SWITCH OUTPUT POWER
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Color-Size WH - 0.8
Frame SHEET 14
Electrical systems - Harnesses and connectors
Wire connectors - Component diagram 32 Connectors X-320 to X-329 SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
X-323 - CHASSIS OPTIONS/MULTIFUNCTION IN (87382922) (Receptacle)
87382922
1
87382922 Pin 1
From X-ECC (Plug) pin 44 EH CHASSIS/CAB INTERFACE
Wire 419
2
X-ECC (Plug) pin 42 EH CHASSIS/CAB INTERFACE
418
3
X-ECC (Plug) pin 38 EH CHASSIS/CAB INTERFACE
410
4
X-ECC (Plug) pin 39 EH CHASSIS/CAB INTERFACE
411
5
X-ECC (Plug) pin 40 EH CHASSIS/CAB INTERFACE
416
6
X-ECC (Plug) pin 41 EH CHASSIS/CAB INTERFACE
417
7
SP-174-P-X
982
8
X-ECC (Plug) pin 22 EH CHASSIS/CAB INTERFACE X-FUSE1 pin 39
856
X-CN4B (Receptacle) pin 13 UCM CN4B
423
9 10
420
Description LH HANDLE MULTIFUNCTION #3 DOWN LH HANDLE MULTIFUNCTION #3 UP RH HANDLE MULTIFUNCTION #1 UP RH HANDLE MULTIFUNCTION #1 DOWN HANDLE MULTIFUNCTION #2 UP HANDLE MULTIFUNCTION #2 DOWN MULTIFUNCTION GROUND AUX ELEC ON/OFF SWITCH SIGNAL MULTIFUNCTION KEY POWER EHF INTERLOCK
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Frame
Color-Size LG - 0.8
SHEET 14
GY - 0.8
SHEET 31
WH - 0.8
TN - 0.8
VT - 0.8
RD - 0.8
BK - 5.0 WH - 1.0 OR - 3.0 YE - 0.8
SHEET 21
Electrical systems - Harnesses and connectors
X-323A - CHASSIS OPTIONS/MULTIFUNCTION IN (87382923) (Plug)
87382923
2
87382923 1
Pin
From X-107 (Plug) pin C X-107
419
Wire
2
X-107 (Plug) pin D X-107
418
4
X-107 (Plug) pin F X-107
411
5
X-107 (Plug) pin H X-107
416
6
X-107 (Plug) pin G X-107
417
7
SP-982-P-X
982
8
SP-073-P-X
856
9
X-107 (Plug) pin K X-107
420
10
X-107 (Plug) pin L X-107
423
Description LH HANDLE MULTIFUNCTION #3 DOWN LH HANDLE MULTIFUNCTION #3 UP RH HANDLE MULTIFUNCTION #1 DOWN HANDLE MULTIFUNCTION #2 UP HANDLE MULTIFUNCTION #2 DOWN MULTIFUNCTION GROUND AUX ELEC ON/OFF SWITCH SIGNAL MULTIFUNCTION KEY POWER EHF INTERLOCK
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Color-Size LG - 0.8
GY - 0.8
TN - 0.8
RD - 0.8
VT - 0.8
BK - 0.8 WH - 0.8 OR - 3.0 YE - 0.8
Frame SHEET 31
Electrical systems - Harnesses and connectors
Wire connectors - Component diagram 33 Connectors X-330 to X-339 SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
X-330 - RIGHT SPEAKER [ H-011] (87697629) (Plug)
87697629
1
87697629 Pin 1
From X-335 (Plug) pin 4 RADIO CONNECTOR
Wire 451
Description RIGHT SPEAKER (+)
Frame
Color-Size WH - 0.8
SHEET 29
Color-Size BL - 0.8
SHEET 29
X-331 - RIGHT SPEAKER [ H-011] (87697629) (Plug)
87697629
2
87697629 Pin 1
From X-335 (Plug) pin 5 RADIO CONNECTOR
Wire 450
Description RIGHT SPEAKER (-)
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Frame
Electrical systems - Harnesses and connectors
X-332 - LEFT SPEAKER [ H-012] (87697629) (Plug)
87697629
3
87697629 Pin 1
From X-335 (Plug) pin 6 RADIO CONNECTOR
Wire 453
Description LEFT SPEAKER (+)
Frame
Color-Size WH - 0.8
SHEET 29
Color-Size BL - 0.8
SHEET 29
X-333 - LEFT SPEAKER [ H-012] (87697629) (Plug)
87697629
4
87697629 Pin 1
From X-335 (Plug) pin 2 RADIO CONNECTOR
Wire 452
Description LEFT SPEAKER (-)
X-335 - RADIO CONNECTOR (84257494) (Plug)
84257494
5
84257494
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Frame
Electrical systems - Harnesses and connectors
Pin 2 4 5 6 7 9
From X-333 (Plug) pin 1 LEFT SPEAKER X-330 (Plug) pin 1 RIGHT SPEAKER X-331 (Plug) pin 1 RIGHT SPEAKER X-332 (Plug) pin 1 LEFT SPEAKER SP-026-P-X SP-021-P-X
452
Wire
Description LEFT SPEAKER (-)
Color-Size BL - 0.8
451
RIGHT SPEAKER (+)
WH - 0.8
450
RIGHT SPEAKER (-)
BL - 0.8
453
LEFT SPEAKER (+)
WH - 0.8
934 130
RADIO GROUND RADIO POWER
BK - 0.8 OR - 0.8
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Frame SHEET 29
Electrical systems - Harnesses and connectors
Wire connectors - Component diagram 34 Connectors X-340 to X-349 SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
X-341 - LEFT-HAND REAR STROBE [ E-021] (87694153) (Receptacle)
87694153
1
87694153 Pin 1 2 3
From
Wire 758 1007 683
SP-082-P-X SP-083-P-X SP-084-P-X
Description Color-Size LH FRONT STROBE PWR VT - 0.8 LH FRONT STROBE GND BK - 0.8 PK - 0.8 LH FRONT STROBE SYNC
Frame SHEET 22
X-342 - RIGHT-HAND REAR STROBE (87694153) (Receptacle)
87694153
2
87694153 Pin 1 2 3
From SP-082-P-X SP-083-P-X SP-084-P-X
Wire 757 1006 682
Description Color-Size LH FRONT STROBE PWR VT - 0.8 LH FRONT STROBE GND BK - 0.8 PK - 0.8 LH FRONT STROBE SYNC
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Frame SHEET 22
Electrical systems - Harnesses and connectors
X-343 - RIGHT-HAND FRONT STROBE [ E-024] (87694153) (Receptacle)
87694153
3
87694153 Pin 1 2 3
From
Wire 739 1004 680
SP-082-P-X SP-083-P-X SP-084-P-X
Description Color-Size LH FRONT STROBE PWR VT - 0.8 LH FRONT STROBE GND BK - 0.8 PK - 0.8 LH FRONT STROBE SYNC
Frame SHEET 22
X-344 - LEFT-HAND FRONT STROBE (87694153) (Receptacle)
87694153
4
87694153 Pin
From
Wire
1
SP-082-P-X
740
2 3
SP-083-P-X SP-084-P-X
1005 681
Description Color-Size VT - 0.8 LH FRONT STROBE POWER LH FRONT STROBE GND BK - 0.8 PK - 0.8 LH FRONT STROBE SYNC
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Frame SHEET 22
Electrical systems - Harnesses and connectors
Wire connectors - Component diagram 36 Connectors X-360 to X-369 SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
X-365 - NH PARK BRAKE SWITCH [ S-011] (84159859) (Receptacle)
84159859
1
84159859 Pin
From
Wire
2
SP-139-P-X
194
3
SP-006-P-X
306
Description RH CONSOLE PARK BRAKE SW RH CONSOLE PARK BRAKE SW OUT
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Color-Size OR - 0.8 YE - 0.8
Frame SHEET 16
Electrical systems - Harnesses and connectors
Wire connectors - Component diagram 40 Connectors X-400 to X-409 SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
X-401 - RH HANDLE INTERCONNECT F (87693431) (Plug)
87693431
1
87693431 Pin A
B
From X-BULKHEAD (Receptacle) pin 21 CAB/CHASSIS INTERCO X-BULKHEAD (Receptacle) pin 22 CAB/CHASSIS INTERCO
Wire 129
856
Description AUX ELEC ON/OFF SW IN
Color-Size OR - 1.0
AUX ELEC ON/OFF SW SIGNAL
WH - 1.0
X-403 - RH HANDLE INTERCONNECT F [ Z-012] (87382928) (Receptacle)
87382928
2
87382928
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Frame SHEET 33
Electrical systems - Harnesses and connectors
Pin
From
Wire
1
SP-137-P-X
213
2
547
3
X-BULKHEAD (Receptacle) pin 51 CAB/CHASSIS INTERCO SP-126-P-X
1052
5
SP-062-P-X
352
6
X-BULKHEAD (Receptacle) 410 pin 38 CAB/CHASSIS INTERCO X-BULKHEAD (Receptacle) 411 pin 39 CAB/CHASSIS INTERCO X-403 (Receptacle) pin 8 RH 412 HANDLE INTERCONNECT F
7
8
8
X-403 (Receptacle) pin 8 RH 412 HANDLE INTERCONNECT F
9
X-403 (Receptacle) pin 9 RH 413 HANDLE INTERCONNECT F
9
X-403 (Receptacle) pin 9 RH 413 HANDLE INTERCONNECT F
10
SP-132-P-X
214
11
546
12
X-BULKHEAD (Receptacle) pin 46 CAB/CHASSIS INTERCO SP-169-P-X
1053
13
SPLICE SP-105
406
14
X-BULKHEAD (Receptacle) pin 64 CAB/CHASSIS INTERCO
531
Description PROPORTIONAL AUX SW #2 REFEREN PROPORTIONAL AUX SW OUTPUT SIG
Color-Size PK - 0.8
PROPORTIONAL AUX SW #2 GROUND RH HANDLE MULTIFUNCTION #1/#2 RH HANDLE MULTIFUNCTION #1 UP RH HANDLE MULTIFUNCTION #1 DOW RH HANDLE MULTIFUNCTION #2 UP RH HANDLE MULTIFUNCTION #2 UP RH HANDLE MULTIFUNCTION #2 DOWN RH HANDLE MULTIFUNCTION #2 DOWN PROPORTIONAL AUX SW #1 REFEREN PROPORTIONAL AUX SW OUTPUT SIG
BK/WH - 0.8
PROPORTIONAL AUX SW #1 GROUND FLOAT SW INPUT VOLTAGE LOADER FLOAT SW INPUT
BK/WH - 0.8
Frame SHEET 18
YE - 0.8
OR - 0.8 WH - 0.8
TN - 0.8
VT - 0.8
VT - 0.8
RD - 0.8
RD - 0.8
PK - 0.8 YE - 0.8
OR - 0.8 YE - 0.8
X-406 - RH HANDLE INTERCONNECT P [ Z-012] (87697723) (Plug)
87697723
3
87697723 Pin
From
Wire
A
SP-105-P-X
324
B
SP-006-P-X
307
C
SP-106-P-X
832
D
X-BULKHEAD (Receptacle) pin 27 CAB/CHASSIS INTERCO
831
Description RH GRIP PARK BRAKE SW POWER RH GRIP PARK BRAKE SW OUTPUT RIDE CONTROL VALVE SOLENOID SW RIDE CONTROL VALVE SOLENOID SI
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Color-Size OR - 0.8 YE - 0.8 OR - 0.8 WH - 0.8
Frame SHEET 18
Electrical systems - Harnesses and connectors
X-408 - LH HANDLE INTERCONNECT [ SH17: D-1] (87382929) (Plug)
87382929
4
87382929 Pin
4
From SP-053-P-X X-BULKHEAD (Receptacle) pin 33 CAB/CHASSIS INTERCO X-BULKHEAD (Receptacle) pin 34 CAB/CHASSIS INTERCO SP-106-P-X
5
SP-138-P-X
770
6
SP-018-P-X
768
7
SP-019-P-X
765
8
892
9
X-BULKHEAD (Receptacle) pin 45 CAB/CHASSIS INTERCO SP-035-P-X
563
10
SP-062-P-X
353
11
SP-063-P-X
414
12
SP-064-P-X
415
13
X-BULKHEAD (Receptacle) pin 42 CAB/CHASSIS INTERCO X-BULKHEAD (Receptacle) pin 44 CAB/CHASSIS INTERCO
418
1 2
3
14
Wire
Description 2ND AUX SW POWER 2ND AUX EXTEND SW OUTPUT
Color-Size OR - 0.8 WH - 0.8
552
2ND AUX RETRACT SIGNAL POWER
WH - 0.8
891
LH GRIP HORN/2 SPEED SW POWER LH GRIP FLASHER POWER LH GRIP LH TURN SIGNAL OUTPUT LH GRIP RH TURN SIGNAL OUTPUT HORN POWER SIGNAL
OR - 0.8
558 554
419
2 SPEED SW OUTPUT SIGNAL LH HANDLE MULTIFUNCTION #2/#3 LH HANDLE MULTIFUNCTION #2 UP LH HANDLE MULTIFUNCTION #2 DOW LH HANDLE MULTIFUNCTION #3 UP LH HANDLE MULTIFUNCTION #3 DOW
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OR - 0.8 VT - 0.8 VT - 0.8 WH - 0.8
WH - 0.8 OR - 0.8 VT - 0.8
RD - 0.8
GY - 0.8
LG - 0.8
Frame SHEET 17
Electrical systems - Harnesses and connectors
Wire connectors - Component diagram 41 Connectors X-410 to X-419 SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
X-411 - FLASHER MODULE [ Z-013] (87692860) (Receptacle)
87692860
1
87692860 Pin 30
From X-FUSE1 pin 40
30
X-901 pin 5 CHASSIS INTERFACE SP-176-P-X SP-174-P-X X-ECC (Plug) pin 9 EH CHASSIS/CAB INTERFACE X-901 pin 1 CHASSIS INTERFACE
85 85 87A 87A
Wire 156 156 981 981 769 769
Description FLASHER/BRAKE POWER FLASHER/BRAKE POWER FLASHER GROUND FLASHER GROUND FLASHER MODULE OUTPUT POWER FLASHER MODULE OUTPUT POWER
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Color-Size RD - 2.0 RD - 2.0 BK - 0.8 BK - 0.8 OR - 2.0 OR - 2.0
Frame SHEET 24
Electrical systems - Harnesses and connectors
Wire connectors - Component diagram 50 Connectors X-500 to X-509 SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
X-502 - DOOR WIPER MOTOR [ Z-010] (87697724) (Receptacle)
87697724
1
87697724 Pin
From
Wire
A
SP-022-P-X
227
B
SP-014-P-X
929
C
SP-023-P-X
231
D
SP-093-P-X
220
Description DOOR WIPER MOTOR SIGNAL DOOR WIPER MOTOR GROUND DOOR WIPER MOTOR PARK DOOR SW BYPASS
Color-Size WH - 0.8
Frame SHEET 26
BK - 0.8 OR - 0.8 YE - 0.8
X-502A - REAR WINDOW WIPER MOTOR [ Z-014] (87693712) (Receptacle)
87693712
2
87693712 Pin
From
Wire
A
SP-022-P-X
228
B
SP-027-P-X
930
C
SP-023-P-X
232
Description REAR WINDOW WIPER MOTOR SIGNAL REAR WINDOW WIPER MOTOR GROUND REAR WINDOW WIPER MOTOR PARK
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Color-Size WH - 0.8 BK - 0.8 OR - 0.8
Frame SHEET 26
Electrical systems - Harnesses and connectors
X-503 - WIPER/WASHER SWITCH [ S-016] (87716755) (Receptacle)
87716755
3
87716755 Pin
From
Wire
1
SP-014-P-X
931
1
SP-029-P-X
931
2
SP-022-P-X
225
3
SP-023-P-X
229
5
224
6
X-506 (Receptacle) pin 2 X-506 SP-023-P-X
230
7
SP-022-P-X
226
8
SP-014-P-X
932
8
SP-029-P-X
932
Description WIPER/WASHER SW GROUND WIPER/WASHER SW GROUND WIPER MOTOR AND INDICATOR LAMP WIPER/WASHER SWITCH MOTOR POWE WASHER PUMP SIGNAL WIPER/WASHER SW PUMP POWER IN WIPER/WASHER LAMP SIGNAL WIPER/WASHER SW INDICATOR GROU WIPER/WASHER SW INDICATOR GROU
Color-Size BK - 0.8
Frame SHEET 26
BK - 0.8 WH - 0.8 OR - 0.8 WH - 0.8 OR - 0.8 VT - 0.8 BK - 0.8 BK - 0.8
X-505 - DOOR SWITCH (87382907) (Plug)
87382907
4
87382907 1
Pin
From SPLICE SP-093
250
Wire
2
SPLICE SP-092
1016
Description Color-Size DOOR SIGNAL TO THE YE - 0.8 INSTRUMENT CLUSTER DOOR SWITCH GROUND BK/WH - 0.8
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Frame SHEET 26
Electrical systems - Harnesses and connectors
X-506 - FRONT DOOR WASHER PUMP (Receptacle)
87693325
5
87693325 Pin
From
Wire
1
SP-027-P-X
970
2
X-503 (Receptacle) pin 5 WIPER/WASHER SWITCH
224
Description Color-Size BK - 0.8 WASHER PUMP GROUND WASHER PUMP SIGNAL WH - 0.8
Frame SHEET 26
X-508 - AIR FILTER RESTRICTION SWITCH (87691371) (Plug)
87691371
6
87691371 Pin 1
2
From LG MACHINES X-900 LG (Receptacle) pin 45 MD MACHINES X-901 MD (Plug) pin 45 SPLICE SP-176
Wire 267
907
Description AIR FILTER RESTRICTION SWITCH SIGNAL
Color-Size YE - 0.8
GROUND CONNECTION BK - 0.8 TO THE AIR FILTER RESTRICTION
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Frame SHEET 04
Electrical systems - Harnesses and connectors
Wire connectors - Component diagram 90 Connectors X-900 to X-909 SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
X-900 - CROSSOVER BULKHEAD LARGE MACHINES [ SH39: C-6] (47749797) (Receptacle)
47749797
1
47749797 Pin 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
From X-FUSE1 (Receptacle) pin 15 SPLICE SP-528 X-FUSE1 (Receptacle) pin 25 X-CN3B (Receptacle) pin 18 SPLICE SP-504A X-ECC PIN 53 X-FUSE2 PIN 41 X-ECC PIN 13 X-ECC PIN 59
Wire 110 528E 719 895 504C 248 161 780 833
24
X-ECC PIN 65
834
25 26
X-205 PIN 5
717
27 28 29 30
X-FUSE1 PIN 17 SPLICE SP-051
704 766A
31 32
SPLICE SP-503A FUSE F-033
503C 241C
Description ECU FUSE F-035 BATTERY RIGHT BOOM BACKUP ALARM SIGNAL CAN BUS K-LINE CRANK ENABLE 2 HAZARDS HVAC HIGH PRESSURE SWITCH HVAC HIGH PRESSURE SWITCH LEFT-HAND REAR POSITION LAMP FUSE F-010 LEFT-HAND TURN SIGNAL CAN BUS ENGINE SENSORS 48068130 29/01/2018
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Color-Size OR - 2.0 OR - 2.0 VT - 1.0 WH - 0.8 GN - 0.8 YE - 0.8 YE -0.8 VT - 0.8 WH - 0.8
Frame
SHEET 37 SHEET 37
SHEET 37
SHEET SHEET SHEET SHEET
37 37 37 37
SHEET 37 SHEET 37
WH - 0.8
SHEET 37
VT - 0.8
SHEET 37
VT - 0.8 VT - 0.8
SHEET 37 SHEET 37
YE - 0.8 OR - 0.8
SHEET 37 SHEET 37
Electrical systems - Harnesses and connectors
Pin 33 34 35 36 37 38 39
From X-FUSE2 PIN 54 X-ECC PIN 84 X-ECC PIN 14
121 626 841
Wire
40 41 42 43 44 45
SPLICE SP-150 SPLICE SP-186 X-ECC PIN 70 X-FUSE1 PIN 29 X-ECC PIN 82
721 133B 234 703 267
46 47
X-012 PIN 28 -
112 -
Description ENGINE RELAY A START SIGNAL AC COMPRESSOR RELAY BRAKE LAMP SWITCHED BATTERY FUEL LEVEL SENDER LEFT-HAND TAIL LIGHTS AIR FILTER RESTRICTION ECU MAIN RELAY -
Color-Size YE - 0.8 WH - 0.8 WH - 0.8
Frame SHEET 37
SHEET 37
SHEET 37
VT - 0.8 OR - 0.8 RD - 0.8 VT - 0.8 YE - 0.8
SHEET SHEET SHEET SHEET
BL - 0.8 -
SHEET 37
37 37 37 37
SHEET 37
X-900 - CROSSOVER BULKHEAD MEDIUM MACHINES [ SH39: C-6] (47749797) (Receptacle)
47749797
2
47749797 1 2 3 4 5
Pin
From X-ECC PIN 9 X-FUSE1 (Receptacle) pin 15 X-FUSE1 PIN 40
769 110 156
Wire
6 7
SPLICE SP-241
241C
8 9 10 11 12 13 14
X-014 PIN 3 X-014 PIN 1 X-014 PIN 5 X-014 PIN 2 X-014 PIN 6 X-FUSE1 (Receptacle) pin 25 X-012 PIN 79
242 245 249 252 253 719 270
15
X-012 PIN 80
271
16 17 18 19 20 21 22 23
X-CN3B (Receptacle) pin 18 SPLICE SP-504A X-ECC PIN 53 X-FUSE2 PIN 41 X-ECC PIN 13 X-ECC PIN 59
895 504C 248 161 780 833
24
X-ECC PIN 65
834
Description BATTERY ECU FUSE F-035 FUSE F-030 FLASHER/BRAKE FUSE F-033 ENGINE SENSORS LAMBDA SENSOR LAMBDA SENSOR LAMBDA SENSOR LAMBDA SENSOR LAMBDA SENSOR RIGHT BOOM EXHAUST GAS TEMPERATURE GROUND 1 EXHAUST GAS TEMPERATURE SIGNAL 1 BACKUP ALARM SIGNAL CAN BUS K-LINE CRANK ENABLE 2 HAZARDS HVAC HIGH PRESSURE SWITCH HVAC HIGH PRESSURE SWITCH
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Color-Size OR - 2.0 OR - 2.0 RD - 2.0
Frame SHEET 39
SHEET 39 SHEET 39
OR - 0.8
SHEET 39
YE - 0.8 YE - 0.5 YE - 0.5 BK - 0.5 PK - 0.5 VT - 1.0 BK/WH - 0.5
SHEET SHEET SHEET SHEET SHEET SHEET SHEET
YE - 0.5
SHEET 39
WH - 0.8 GN - 0.8 YE - 0.8 YE -0.8 VT - 0.8 WH - 0.8 WH - 0.8
SHEET SHEET SHEET SHEET
39 39 39 39 39 39 39
39 39 39 39
SHEET 39 SHEET 39 SHEET 39
Electrical systems - Harnesses and connectors
Pin 25 26
X-205 PIN 5
From 717
Wire
27 28 29 30
X-FUSE1 PIN 17 SPLICE SP-051
704 766A
31 32 33 34 35 36 37 38 39
SPLICE SP-503A X-FUSE2 PIN 54 X-ECC PIN 84 X-ECC PIN 14
503C 121 626 841
40 41 42 43 44 45
SPLICE SP-150 SPLICE SP-186 X-ECC PIN 70 X-FUSE1 PIN 29 X-ECC PIN 82
721 133B 234 703 267
46 47
X-012 PIN 28 -
112 -
Description LEFT-HAND REAR POSITION LAMP FUSE F-010 LEFT-HAND TURN SIGNAL CAN BUS ENGINE RELAY A START SIGNAL AC COMPRESSOR RELAY BRAKE LAMP SWITCHED BATTERY FUEL LEVEL SENDER LEFT-HAND TAIL LIGHTS AIR FILTER RESTRICTION ECU MAIN RELAY -
Frame
Color-Size VT - 0.8
SHEET 39
VT - 0.8 VT - 0.8
SHEET 39 SHEET 39
YE - 0.8 YE - 0.8 WH - 0.8 WH - 0.8 VT - 0.8 OR - 0.8 RD - 0.8 VT - 0.8 YE - 0.8
SHEET 39 SHEET 39
SHEET 39
SHEET 39 SHEET SHEET SHEET SHEET
39 39 39 39
SHEET 39
BL - 0.8 -
X-901 - CHASSIS INTERFACE LARGE MACHINES [ SH39: C-1] (47712777) (Plug)
47712777
3
47712777 Pin 1 2 3 4 5 6 7 8 9 10 11 12 13
From X-012 PIN 1 X-079 PIN 1 SPLICE SP-060
Wire 110 528E 719
14 15 16 17 18 19 20 21
X-205 X-012 X-012 X-012 -
895 504C 248 161 -
PIN PIN PIN PIN
14 25 68 53
Description ECU BATTERY VOLTAGE BATTERY RIGHT-HAND FRONT ROAD LAMP BACKUP ALARM SIGNAL CAN LOW EGR ECU K-LINE CRANK ENABLE 2 -
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Color-Size OR - 2.0 OR - 2.0 VT - 1.0 WH - 0.8 GN - 0.8 YE - 0.8 YE -0.8 -
Frame
SHEET 37 SHEET 37
SHEET 37
SHEET SHEET SHEET SHEET
37 37 37 37
Electrical systems - Harnesses and connectors
Pin 22
From SPLICE SP-052
780
Wire
23
X-011 PIN 1
833
24
X-011 PIN 2
834
25 26
X-205 PIN 5
717
27 28 29
X-205 PIN 2
704
30
X-205 PIN 11
766A
31 32
X-012 PIN 24 SPLICE SP-241
503C 241C
33 34 35 36 37 38 39
X-012 PIN 27 X-012 PIN 8 X-011 PIN 3
121 626 841
40 41
X-205 PIN 7 SPLICE SP-133B
721 133B
42 43
X-014 PIN B X-205 PIN 3
234 703
44 45
X-508 PIN 1
267
46 47
X-012 PIN 25 -
112 -
Description RIGHT-HAND ROAD LAMP HVAC HIGH PRESSURE SWITCH HVAC HIGH PRESSURE SWITCH LEFT-HAND REAR POSITION LAMP RIGHT-HAND TAIL LAMP POWER LEFT-HAND TURN SIGNAL POWER CAN HIGH LAMBDA SENSOR POWER CRANK ENABLE 1 START SIGNAL AC COMPRESSOR RELAY BRAKE LAMP POWER ECU SWITCHED BATTERY FUEL LEVEL SENDER LEFT-HAND TAIL LIGHTS POWER AIR FILTER RESTRICTION ECU MAIN RELAY -
Frame
Color-Size VT - 0.8
SHEET 37
WH - 0.8
SHEET 37
WH - 0.8
SHEET 37
VT - 0.8
SHEET 37
VT - 0.8
SHEET 37
VT - 0.8
SHEET 37
YE - 0.8 OR - 0.8
SHEET 37 SHEET 37
YE - 0.8 WH - 0.8 WH - 0.8
SHEET 37
SHEET 37
VT - 0.8 OR - 0.8
SHEET 37 SHEET 37
RD - 0.8 VT - 0.8
SHEET 37 SHEET 37
YE - 0.8
SHEET 37
BL - 0.8 -
SHEET 37
SHEET 37
X-901 - CHASSIS INTERFACE MEDIUM MACHINES [ SH39: C-1] (47712777) (Plug)
47712777
4
47712777 1 2 3 4 5 6 7
Pin
From X-411 PIN 87A X-012 PIN 1 X-411 PIN 30 X-017 PIN 28
Wire 769 110 156 241C
8
X-012 PIN 7
242
9
X-012 PIN 64
245
Description FLASHER MODULE ECU BATTERY VOLTAGE FLASHER MODULE BATTERY TO THE ELECTRIC VALVE LAMBDA SENSOR SENSOR HEATING LAMBDA SENSOR CURRENT PUMP
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Color-Size OR - 2.0 OR - 2.0 RD - 2.0 OR - 0.8
Frame SHEET 39
SHEET 39 SHEET 39 SHEET 39
YE - 0.8
SHEET 39
YE - 0.5
SHEET 39
Electrical systems - Harnesses and connectors
Pin 10
From X-012 PIN 86
249
Wire
11
X-012 PIN 85
252
12
X-012 PIN 63
253
13
SPLICE SP-060
719
14
X-012 PIN 79
270
15
X-012 PIN 80
271
16 17 18 19 20 21 22
X-205 PIN 14 X-012 PIN 25 X-012 PIN 68 X-012 PIN 53 SPLICE SP-052
895 504C 248 161 780
23
X-011 PIN 1
833
24
X-011 PIN 2
834
25 26
X-205 PIN 5
717
27 28 29
X-205 PIN 2
704
30
X-205 PIN 11
766A
31 32 33 34 35 36 37 38 39 40
X-012 PIN 24 X-012 PIN 27 X-012 PIN 8 X-011 PIN 3 X-205 PIN 7
503C 121 626 841 721
41 42 43
SPLICE SP-133B X-014 PIN B X-205 PIN 3
133B 234 703
44 45
X-508 PIN 1
267
46 47
-
-
Description LAMBDA SENSOR CURRENT ADJUST LAMBDA SENSOR VIRTUAL GROUND LAMBDA SENSOR VOLTAGE RIGHT-HAND FRONT ROAD LAMP EXHAUST GAS TEMPERATURE GROUND 1 EXHAUST GAS TEMPERATURE SIGNAL 1 BACKUP ALARM SIGNAL CAN LOW EGR ECU K-LINE CRANK ENABLE 2 RIGHT-HAND FRONT ROAD LAMP HVAC HIGH PRESSURE SWITCH HVAC HIGH PRESSURE SWITCH LEFT-HAND REAR POSITION LAMP RIGHT-HAND LAMP POWER LEFT-HAND TURN SIGNAL POWER CAN HIGH CRANK ENABLE 1 START SIGNAL AC COMPRESSOR BRAKE LAMP SIGNAL POWER ECU SWITCHED POWER FUEL LEVEL SENDER LEFT-HAND TAIL LAMP POWER AIR FILTER RESTRICTION -
Frame
Color-Size YE - 0.5
SHEET 39
BK - 0.5
SHEET 39
PK - 0.5
SHEET 39
VT - 1.0
SHEET 39
BK/WH - 0.5
SHEET 39
YE - 0.5
SHEET 39
WH - 0.8 GN - 0.8 YE - 0.8 YE -0.8 VT - 0.8
SHEET SHEET SHEET SHEET
WH - 0.8
SHEET 39
WH - 0.8
SHEET 39
VT - 0.8
SHEET 39
VT - 0.8
SHEET 39
VT - 0.8
SHEET 39
YE - 0.8 YE - 0.8 WH - 0.8 WH - 0.8 VT - 0.8
SHEET 39
SHEET 39 SHEET 39
OR - 0.8 RD - 0.8 VT - 0.8
SHEET 39 SHEET 39 SHEET 39
YE - 0.8
SHEET 39
39 39 39 39
SHEET 39
SHEET 39
SHEET 39
-
X-904 - BOOM LOCK SWITCH [ SH11: A-5] (Receptacle) Pin A B
From X-CN2A (Receptacle) pin 17 UCM CN2A SP-037-P-X
Wire 1103 1102
Description Color-Size BOOM LOCK INTERLOCK YE - 0.8 SW SIGNAL BOOM LOCK VALVE OR - 0.8 POWER
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Frame SHEET 11 SHEET 02
Electrical systems - Harnesses and connectors
Wire connectors - Component diagram 99 Connectors X-9000 to X-9009 SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
X-9000 - FUEL FILTER (84529035) (Receptacle)
84529035
1
84529035 X-9001 - FUEL FILTER (Receptacle) Pin 1 2
From X-9000 (Plug) pin 1 X-9000 X-9000 (Plug) pin 2 X-9000
Wire 1200 1201
Description FUEL FILTER SIGNAL FUEL FILTER GROUND
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Color-Size YE - 0.8 BK - 0.8
Frame SHEET 36
Electrical systems - Harnesses and connectors
Wire connectors Connectors Alphanumeric SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
X-ACC - ACCESORY POWER OUTLET [ Z-008] (87693325) (Receptacle)
87693325
1
87693325 Pin
From
Wire
A
SP-033-P-X
801
B
SP-029-P-X
952
Description ACCESSORY SOCKET POWER ACCESSORY SOCKET GND
Frame
Color-Size RD - 0.8
SHEET 15
BK - 0.8
SHEET 07
Color-Size BK - 2.0
SHEET 34
X-BKUP-GND - (84159851) (Receptacle)
84159851
2
84159851 Pin 1
From SP-080-P-X
Wire 963
Description 963
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Frame
Electrical systems - Harnesses and connectors
X-BKUP-PWR - (84159851) (Receptacle)
84159851
3
84159851 Pin 1
From X-201 (Plug) pin 14 REAR LAMP JUMPER
Wire 896
Description 896
Color-Size WH
Frame SHEET 34
X-BRK - BRAKE VALVE SOLENOID (87695584) (Plug)
87695584
4
87695584 Pin 1 2
From Y-008-P-OUT Y-008-P-IN
Wire WIRE1394 WIRE1393
Description WIRE1394 WIRE1393
Frame
Color-Size SHEET 14 SHEET 07
X-BULKHEAD - CAB/CHASSIS INTERCO [ SH15: C-1] (87707116) (Receptacle)
87707116
5
87707116
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Electrical systems - Harnesses and connectors
Pin 1 2 3 4 5 9 10 11 12 13 14
15 16 17 18 19 20 21 22 23 24 25 26
From X-311 (Receptacle) pin B LIGHT SELECTOR SW X-311 (Receptacle) pin C LIGHT SELECTOR SW X-311 (Receptacle) pin D LIGHT SELECTOR SW X-111 (Receptacle) pin 87 CONDENSER RELAY [CAB] SP-160-P-X
Wire 791 792 123 237 836
234 319
EH AUX POWER
OR - 0.8
115
BEACON AND ACCESSORY FUSE OUTP HYDRAULIC OIL TEMP SENDER UNSWITCHED BATTERY POWER FOOT THROTTLE SIGNAL LAMP SW WORK LAMP SIGNAL WIPER/SEAT ACC/RADIO/DOME LAMP PARK BRAKE VALVE SIGNAL INSTRUMENT CLUSTER SW POWER HYDRAULIC LOADER INTERLOCK SIG HYDRAULIC OIL FILTER
RD - 2.0
X-C23 (Receptacle) pin 16 INSTRUMENT CLUSTER SP-004-P-X X-C23 (Receptacle) pin 23 INSTRUMENT CLUSTER X-311 (Receptacle) pin A LIGHT SELECTOR SW SP-011-P-X X-C23 (Receptacle) pin 28 INSTRUMENT CLUSTER SP-010-P-X X-C23 (Receptacle) pin 30 INSTRUMENT CLUSTER X-C23 (Receptacle) pin 2 INSTRUMENT CLUSTER X-C23 (Receptacle) pin 11 INSTRUMENT CLUSTER SP-200-P-X
264 310 545 790 134 258 309 303 261 267 1066 622
29
SP-201-P-X
211
30
SP-091-P-X
822
31
X-317 pin E SELF LEVEL SW 404
32
X-310 (Receptacle) pin 7 2SPD INDICATOR X-252 (Receptacle) pin 2 TEMP CONTROL SW SP-090-P-X X-HVC1 (Receptacle) pin 12 CAB/HVAC INTERCONNECT X-HVC1 (Receptacle) pin 7 CAB/HVAC INTERCONNECT SP-006-P-X
39
565 824 504 841 833 307
41
834 X-HVC1 (Receptacle) pin 8 CAB/HVAC INTERCONNECT 233 SP-023-P-X
42
SP-009-P-X
141
44
X-306 pin D LOADER LOCKOUT SW
311
40
HVAC CONDENSER FAN WH - 3.0 POWER RD - 3.0 COMPRESSOR/ CONDENSER FAN FUSE YE - 0.8 EGR ECU K-LINE
X-C23 (Receptacle) pin 24 INSTRUMENT CLUSTER X-C23 (Receptacle) pin 26 INSTRUMENT CLUSTER SP-033-P-X
139
37
OR - 3.0
YE - 0.8 CAN HI INSTRUMENT CLUSTER BK/WH - 0.8 GROUND YE - 0.8 FUEL LEVEL SENDER
503 910
Frame SHEET 14
VT - 3.0
248
28
34 35
Color-Size VT - 3.0
X-DIAG (Plug) pin E CAN DIAGNOSTIC CONNECTO SP-089-P-X SP-092-P-X
X-C23 (Receptacle) pin 32 INSTRUMENT CLUSTER SP-009-P-X
33
Description LAMP SW ROAD LAMP SIGNAL LAMP SW WORK AND SIDE LAMP SIG LAMP SW POWER
YE - 0.8 RD - 0.8 YE - 0.8 VT - 1.0 OR - 2.0 WH - 0.8 OR - 1.0 WH - 0.8 YE - 0.8
AIR FILTER/ENGINE MALFUNCTION FOOT THROTTLE SENSOR GND START RELAY SIGNAL
YE - 0.8
ACCESSORY RELAY SIGNAL FOOT THROTTLE SENSOR SUPPLY HVAC WATER VALVE POWER SELF LEVEL SW OUTPUT POWER 2 SPEED INDICATOR
OR - 0.8
HVAC TEMPERATURE CONTROL SIGNA CAN LO A/C COMPRESSOR RELAY PIN 87 PO THERMOSTAT TO BINARY PRESSURE RH GRIP PARK BRAKE SW OUTPUT BINARY PRESSURE SW TO COMPRESS WIPER/WASHER SW POWER OPTIONS RELAYS SIGNAL LOADER LOCKOUT SW IN
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BK/WH - 0.8 WH - 0.8
PK - 0.8 OR - 0.8 WH - 0.8 VT - 0.8 YE - 0.8 GN - 0.8 WH - 0.8 WH - 0.8 YE - 0.8 WH - 0.8 OR - 2.0 WH - 0.8 WH - 0.8
SHEET 07 SHEET 14
Electrical systems - Harnesses and connectors
Pin 45 46
From X-306 pin E LOADER LOCKOUT SW X-113 (Receptacle) pin E FE #2 SWITCH
Wire 312
Color-Size WH - 0.8 OR - 0.8
WH - 0.8
47
X-113 (Receptacle) pin F FE #2 SWITCH
427
48
SP-016-P-X
797
49
SP-015-P-X
795
50
X-113 (Receptacle) pin D FE 425 #2 SWITCH
51
X-303 pin C HI FLOW SW
52
54
X-300 (Receptacle) pin 2 HYD 751 COUPLER SW X-300 (Receptacle) pin 3 HYD 752 COUPLER SW 843 SP-171-P-X
55
SP-171-P-X
844
56 57
X-303 pin D HI FLOW SW SP-018-P-X
753 774
58
SP-019-P-X
780
59
SP-020-P-X
782
61
X-DIAG (Plug) pin H CAN DIAGNOSTIC CONNECTO X-DIAG (Plug) pin J CAN DIAGNOSTIC CONNECTO X-C23 (Receptacle) pin 13 INSTRUMENT CLUSTER X-TELE_DIAG (Receptacle) pin 1 TELEMATICS DIAGNOSTIC X-TELE_DIAG (Receptacle) pin 2 TELEMATICS DIAGNOSTIC X-TELE_DIAG (Receptacle) pin 3 TELEMATICS DIAGNOSTIC X-316 (Receptacle) pin 1 ECU RELAY/GROUND
507
LH HANDLE MULTIFUNCTION #2 / # LH HANDLE MULTIFUNCTION #2 DOW LIGHT RELAY #1 FRONT WORK LAMP SIDE LAMP POWER SIGNAL LH HANDLE MULTIFUNCTION #2 UP STANDARD HIGH FLOW SIGNAL HYDRAULIC COUPLER SW IN HYDRAULIC COUPLER SIGNAL HVAC FUSE TO HVAC BOX - VOLTAG HVAC FUSE TO HVAC BOX - VOLTAG HIGH FLOW SW IN LH TURN SIGNAL CHASSIS POWER RH TURN SIGNAL CHASSIS POWER FLASHER POWER OUTPUT CAN HI
508
CAN LO
BL - 0.8
205C
YE - 0.8
206
TELEMATICS CRANK DISABLE GROUND
BK/WH - 0.8
207
RS232 RX
TN - 0.8
208
RS232 TX
BL - 0.8
144
MAIN POWER RELAY SIGNAL
OR - 0.8
53
62 63 64
65
66
67
359
Description LOADER LOCK SW OUT
750
RD - 0.8
VT - 5.0 VT - 5.0 VT - 0.8
WH - 0.8 OR - 0.8 WH - 0.8 OR - 5.0 OR - 5.0 OR - 0.8 VT - 0.8 VT - 0.8 OR - 2.0
X-CCA - CHASSIS/CAB INTERFACE [ SH16: A-1] (47557182) (Plug)
47557182
6
47557182
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Frame
Electrical systems - Harnesses and connectors
Pin 1 2 2 3 4 5 5 9 9 10 11 12 12 13 14
From SP-024-P-X X-FUSE1 pin 55 POWER DISTRIBUTION-CHASSIS X-FUSE2 pin 37 POWER DISTRIBUTION-CHASSIS SP-030-P-X X-314 (Plug) pin 2 CHASSIS POWER X-FUSE2 pin 1 POWER DISTRIBUTION-CHASSIS X-FUSE2 pin 1 POWER DISTRIBUTION-CHASSIS X-900 pin 19 CROSSOVER BULKHEAD X-900 pin 19 CROSSOVER BULKHEAD SP-503A-P-X SP-047-P-X X-900 pin 42 CROSSOVER BULKHEAD X-900 pin 42 CROSSOVER BULKHEAD X-430 (Receptacle) pin 1 EH AUX PWM CONTROLLER X-FUSE2 pin 2 POWER DISTRIBUTION-CHASSIS
Wire
Color-Size VT - 3.0 VT - 3.0
248
Description ROAD LAMP SIGNAL LAMP SWITCH WORK AND SIDE LAMP SIGNAL LAMP SWITCH WORK AND SIDE LAMP SIGNAL UNSWITCHED BATTERY POWER HVAC CONDENSER FAN POWER COMPRESSOR/ CONDENSER FAN FUSE COMPRESSOR/ CONDENSER FAN FUSE EGR ECU K-LINE
248
EGR ECU K-LINE
YE - 0.8
503A 910
CAN HI INSTRUMENT CLUSTER GROUND UNSWITCHED BATTERY POWER UNSWITCHED BATTERY POWER EH AUX POWER
YE - 0.8 BK/WH - 0.8
SHEET 07
RD - 0.8
SHEET 14
791 792 792 123 237 836 836
234 234 319 115
14
X-FUSE2 pin 2 POWER DISTRIBUTION-CHASSIS
115
15
X-OILTMP (Receptacle) pin 1 HYDRAULIC OIL TEMPERATURE SENDER X-FUSE2 pin 18 POWER DISTRIBUTION-CHASSIS X-FUSE2 pin 26 POWER DISTRIBUTION-CHASSIS X-020 (Receptacle) pin A FOOT THROTTLE SENSOR SP-031-P-X
264
16 16 17 18 19
310
22
SP-187-P-X
303
23 24
X-OILFLT (Receptacle) pin 1 X-900 pin 45 CROSSOVER BULKHEAD X-900 pin 45 CROSSOVER BULKHEAD X-020 (Receptacle) pin B FOOT THROTTLE SENSOR X-900 pin 36 CROSSOVER BULKHEAD X-900 pin 36 CROSSOVER BULKHEAD X-FUSE1 pin 12 POWER DISTRIBUTION-CHASSIS X-FUSE1 pin 16 POWER DISTRIBUTION-CHASSIS X-020 (Receptacle) pin C FOOT THROTTLE SENSOR
261 267
26 28 28 29
OR - 0.8
RD - 2.0 BEACON AND ACCESSORY FUSE OUTPUT RD - 2.0 BEACON AND ACCESSORY FUSE OUTPUT UNSWITCHED BATTERY YE - 0.8 POWER
SHEET 02
RD - 0.8
SHEET 02
OR - 0.8
309
267 1066
139 211
SHEET 14
RD - 0.8
ACCESSORY RELAY SIGNAL ACCESSORY RELAY SIGNAL FOOT THROTTLE SENSOR SUPPLY
SP-037-P-X
26
YE - 0.8
139
21
134
SHEET 02
RD - 3.0
WH - 0.8
258
25
RD - 3.0
CRANK SIGNAL
134
SHEET 14
WH - 3.0
622
790
20
24
OR - 3.0
622
545
X-FUSE2 pin 25 POWER DISTRIBUTION-CHASSIS X-FUSE2 pin 17 POWER DISTRIBUTION-CHASSIS X-BRK (Receptacle) pin 1
19
VT - 3.0
UNSWITCHED BATTERY POWER UNSWITCHED BATTERY POWER FOOT THROTTLE SIGNAL LAMP SWITCH WORK LAMP SIGNAL UNSWITCHED BATTERY POWER UNSWITCHED BATTERY POWER PARK BRAKE VALVE SIGNAL INSTRUMENT CLUSTER SWITCHED POWER HYDRAULIC LOADER INTERLOCK SIGNAL HYDRAULIC OIL FILTER AIR FILTER / ENGINE MALFUNCTION AIR FILTER / ENGINE MALFUNCTION FOOT THROTTLE SENSOR GROUND CRANK SIGNAL
310
Frame SHEET 14 SHEET 03
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SHEET 14
RD - 0.8 YE - 0.8
SHEET 12
VT - 1.0
SHEET 14
OR - 2.0 OR - 2.0 WH - 0.8 OR - 1.0 WH - 0.8 YE - 0.8 YE - 0.8 YE - 0.8 BK/WH - 0.8
SHEET 12
WH - 0.8
SHEET 14
OR - 0.8 PK - 0.8
SHEET 12
Electrical systems - Harnesses and connectors
Pin 30 31 32 33
From X-271 (Receptacle) pin A WATER VALVE X-318 (Receptacle) pin 1
Wire 822 404
SP-035-P-X X-271 (Receptacle) pin D WATER VALVE SP-504A-P-X X-900 pin 39 CROSSOVER BULKHEAD X-900 pin 39 CROSSOVER BULKHEAD X-900 pin 23 CROSSOVER BULKHEAD
565 824
37
X-900 pin 23 CROSSOVER BULKHEAD
833
39
X-402 (Receptacle) pin 2 RH 307 HANDLE INTERCONNECT PARK BRAK 834 X-900 pin 24 CROSSOVER BULKHEAD
34 35 35 37
40
504A 841 841 833
40
X-900 pin 24 CROSSOVER BULKHEAD
834
41
233
45
X-FUSE1 pin 25 POWER DISTRIBUTION-CHASSIS X-FUSE2 pin 26 POWER DISTRIBUTION-CHASSIS SP-056-P-X X-410 (Plug) pin 1 LOADER LOCK/CHASSIS HARNESS INTE X-412 (Receptacle) pin 1
312
46
SP-062-P-X
359
47
SP-064-P-X
427
48
798
49
X-FUSE1 pin 61 POWER DISTRIBUTION-CHASSIS X-FUSE2 pin 41 POWER DISTRIBUTION-CHASSIS SP-032-P-X
795
50
SP-063-P-X
425
51
X-HFLO (Receptacle) pin 1 HIGH FLOW VALVE SOLENOID SP-053-P-X
750
41 42 44
48
52 53
233 141 311
798
751 752
55
X-CPLR (Receptacle) pin 1 HYDRAULIC COUPLER VALVE SOLENOID SP-161-P-X
844
56
SP-053-P-X
753
Description HVAC WATER VALVE POWER SELF LEVEL SWITCH OUTPUT POWER 2 SPEED INDICATOR HVAC TEMPERATURE CONTROL SIGNAL CAN LO A/C COMPRESSOR RELAY PIN 87 POWER A/C COMPRESSOR RELAY PIN 87 POWER THERMOSTAT TO BINARY PRESSURE SWITCH THERMOSTAT TO BINARY PRESSURE SWITCH RH GRIP PARK BRAKE SW OUTPUT BINARY PRESSURE SWITCH TO COMPRESSOR RELAY PIN 86 BINARY PRESSURE SWITCH TO COMPRESSOR RELAY PIN 86 WIPER / WASHER SWITCH POWER WIPER / WASHER SWITCH POWER OPTIONS RELAY SIGNAL LOADER LOCKOUT SWITCH IN
Color-Size OR - 0.8
Frame SHEET 14
WH - 0.8 VT - 0.8 YE - 0.8 GN - 0.8 WH - 0.8 WH - 0.8 WH - 0.8
WH - 0.8
YE - 0.8
WH - 0.8
WH - 0.8
OR - 2.0 OR - 2.0 WH - 0.8 WH - 0.8
LOADER LOCK SWITCH OUT LH MULTIFUNCTION #2, #3 POWER LH HANDLE MULTIFUNCTION #2 DOWN LIGHT RELAY #1 FRONT WORK LAMP POWER LIGHT RELAY #1 FRONT WORK LAMP POWER SIDE LAMP POWER SIGNAL LH MULTIFUNCTION #2 UP STANDARD HIGH FLOW VALVE SIGNAL
WH - 0.8
HYDRAULIC COUPLER SWITCH IN HYDRAULIC COUPLER SIGNAL
OR - 0.8
SHEET 05
WH - 0.8
SHEET 14
HVAC FUSE TO HVAC BOX - VOLTAGE DROP PARALLEL CIRCUIT HIGH FLOW SWITCH IN
OR - 5.0
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OR - 0.8 RD - 0.8
VT - 5.0
SHEET 02
VT - 5.0 VT - 5.0
SHEET 14
VT - 0.8 WH - 0.8
OR - 0.8
SHEET 05
Electrical systems - Harnesses and connectors
Pin 57
SP-051-P-X
774
58
SP-780-P-X
780
59
SP-050-P-X
782
64 65 66 67
SP-047-P-X X-TELE (Receptacle) pin 7 X-TELE (Receptacle) pin 6 X-FUSE1 pin 34 POWER DISTRIBUTION-CHASSIS X-FUSE1 pin 24 POWER DISTRIBUTION-CHASSIS
206 207 208 144
67
From
Wire
144
Description LH TURN SIGNAL CHASSIS POWER RH TURN SIGNAL CHASSIS POWER FLASHER POWER OUTPUT TELEMATICS GROUND TELEMATICS RS232 RX TELEMATICS RX232 TX MAIN POWER RELAY SIGNAL MAIN POWER RELAY SIGNAL
Color-Size VT - 0.8
Frame SHEET 14
VT - 0.8 OR - 2.0 BK/WH - 0.8 TN - 0.8 BL - 0.8 OR - 0.8 OR - 0.8
X-CPLR - HYDRAULIC COUPLER VALVE SOLENOID (87695582) (Receptacle)
87695582
7
87695582 Pin 1 2
From X-CCA (Plug) pin 53 CHASSIS/CAB INTERFACE SP-183-P-X
Wire 752 978
Description HYDRAULIC COUPLER SIGNAL HYDRAULIC COUPLER VALVE GROUND
Frame
Color-Size WH - 0.8
SHEET 14
BK - 0.8
SHEET 07
X-CTS - TURN SIGNAL SWITCH [ SH22: A-6] (87697780) (Receptacle)
87697780
8
87697780 Pin
From
Wire
D
SP-019-P-X
777
E
SP-020-P-X
783
F
SP-018-P-X
775
Description CAB TURN SIGNAL SW RH FLASHER POWER OUTPUT CAB TURN SIGNAL SW LH
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Frame
Color-Size VT - 1.0
SHEET 22
OR - 1.0
SHEET 14
VT - 1.0
SHEET 22
Electrical systems - Harnesses and connectors
X-DIAG - CAN DIAGNOSTIC CONNECTOR [ SH35: B-5] (84497873) (Plug)
84497873
9
84497873 Pin
From
Wire
Color-Size BK/WH - 0.8 RD - 0.8
SHEET 07 SHEET 31
501 506 248
Description EST CONNECTOR GND UNSWITCHED BATTERY POWER CAN HI CAN LO EGR ECU K-LINE
YE - 0.8 GN - 0.8 YE - 0.8
SHEET 14
507
CAN HI
WH - 0.8
SHEET 31
508
CAN LO
BL - 0.8
A B
SP-092-P-X SP-004-P-X
961 162
C D E
SP-089-P-X SP-090-P-X X-BULKHEAD (Receptacle) pin 9 CAB/CHASSIS INTERCO X-BULKHEAD (Receptacle) pin 61 CAB/CHASSIS INTERCO X-BULKHEAD (Receptacle) pin 62 CAB/CHASSIS INTERCO
H
J
Frame
X-HFLO - HIGH FLOW VALVE SOLENOID (87695582) (Receptacle)
87695582
10
87695582 Pin 1
From X-CCA (Plug) pin 51 CHASSIS/CAB INTERFACE
Wire 750
Description STANDARD HIGH FLOW VALVE SIGNAL
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Color-Size WH - 0.8
Frame SHEET 14
Electrical systems - Harnesses and connectors
X-HORN-GND - HORN GROUND [ H-001] (87697629) (Plug)
87697629
11
87697629 Pin 1
From SP-179-P-X
Wire 955
Description HORN GROUND
Frame
Color-Size BK - 0.8
SHEET 07
Color-Size WH - 0.8
SHEET 16
X-HORN-PWR - HORN POWER [ H-001] (87697629) (Plug)
87697629
12
87697629 Pin 1
From X-405 (Plug) pin B LH HANDLE INTERCONNECT HORN/TWO
Wire 892
Description HORN POWER SIGNAL
Frame
X-HZRDDIODE - HAZARD SW DIODE (84120022) (Plug)
84120022
13
84120022 Pin A B
From SPLICE SP-019 X-302 PIN F
Wire 781 778
Description HAZARD LAMP SWITCH OUTPUT 48068130 29/01/2018
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Color-Size VT - 0.8 VT - 0.8
Frame SHEET 22
Electrical systems - Harnesses and connectors
X-OILFLT - OIL FILTER RESTRICTION SWITCH (Receptacle)
84159852
14
84159852 Pin 1
From X-CCA (Plug) pin 23 CHASSIS/CAB INTERFACE
Wire 261
Description HYDRAULIC OIL FILTER
Color-Size YE - 0.8
Frame SHEET 14
X-OILTMP - HYDRAULIC OIL TEMPERATURE SENDER (84159852) (Receptacle)
84159852
15
84159852 Pin 1
From X-CCA (Plug) pin 15 CHASSIS/CAB INTERFACE
Wire 264
Description Color-Size UNSWITCHED BATTERY YE - 0.8 POWER
Frame SHEET 14
X-RDCTRL - RIDE CONTROL SOLENOID (87695584) (Plug)
87695584
16
87695584 Pin 1 2
From Y-010-P-IN Y-010-P-OUT
Wire WIRE1546 WIRE1547
Description WIRE1546 WIRE1547
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Frame
Color-Size SHEET 17 SHEET 07
Electrical systems - Harnesses and connectors
X-STARTER - STARTER [ M-003] (84401279) (Plug)
84401279
17
84401279 Pin 1 1 1
From M-003-P-1 SP249-P-X X-006A (Plug) pin 3 STARTER/ALTERNATOR
Wire WIRE404 WIRE407 520A
Description WIRE404 WIRE407 STARTER
Frame
Color-Size SHEET 08 WH - 2.0
X-TELE - TELEMATICS [ SH29: D-4] (Receptacle) Pin 1 2 3 4 6 7 8
From X-TELE_GND (Plug) pin 1 TELEMATICS GROUND SP-039-P-X SP-503A-P-X SP-504A-P-X X-CCA (Plug) pin 66 CHASSIS/CAB INTERFACE X-CCA (Plug) pin 65 CHASSIS/CAB INTERFACE X-006 (Receptacle) pin 2 PRE-OXICAT TEMP SENSOR
Wire
Description TELEMATICS GROUND
Color-Size BK/WH - 0.8
SHEET 07
OR - 0.8
SHEET 08
503B 504B 208
TELEMATICS IGNITION POWER CAN HI CAN LO TELEMATICS RX232 TX
YE - 0.8 GN - 0.8 BL - 0.8
SHEET 29
207
TELEMATICS RS232 RX
TN - 0.8
244
ALTERNATOR LAMP TELEMATICS ENGINE ON VEHICLE WORKING CONDITION TELEMATICS UNSWITCHED BATTERY TELEMATICS UNSWITCHED BATTERY
YE - 0.8
SHEET 08
YE - 0.8
SHEET 13
RD - 1.0
SHEET 29
925 802
11
SP-187-P-X
308
12
X-FUSE2 pin 38 POWER DISTRIBUTION-CHASSIS X-319 (Receptacle) pin A TELEMATIC FUSE
336
12
336
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RD - 1.0
Frame
Electrical systems - Harnesses and connectors
Wire connectors - Component diagram 00 Connectors X-000 to X-009 and Alphanumeric Connectors SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
X-004 - AIR TEMPERATURE SENSOR [ B-006] (84607243) (Receptacle)
84607243
1
84607243 Pin 2
From X-012 (Receptacle) pin 20 ECU
Wire 254
Description AIR TEMP GND
Frame
Color-Size BK/WH - 0.5
SHEET 10
Color-Size YE - 0.8
SHEET 08
YE - 0.8
X-005A - ALTERNATOR (84165069) (Receptacle)
84165069
2
84165069 Pin 1
2 3
From X-006A (Plug) pin 2 STARTER/ALTERNATOR
Wire 244A
X-006A (Plug) pin 1 STARTER/ALTERNATOR X-006A (Plug) pin 4 STARTER/ALTERNATOR
127A
Description ALTERNATOR LAMP TELEMATICS ENGINE ON ALTERNATOR EXCITE
124
124
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OR - 0.8
Frame
Electrical systems - Harnesses and connectors
X-006 - PRE-OXICAT TEMP SENSOR [ SH9: C-1] (87709793) (Receptacle)
87709793
3
87709793 Pin 1 1 2
From X-FUSE1 pin 33 POWER DISTRIBUTION-CHASSIS X-FUSE1 pin 53 POWER DISTRIBUTION-CHASSIS X-TELE (Receptacle) pin 8
Wire 520 520 244
Description STARTER MOTOR POWER STARTER MOTOR POWER ALTERNATOR LAMP TELEMATICS ENGINE ON
Color-Size WH - 2.0
Frame SHEET 08
WH - 2.0 YE - 0.8
X-006A - STARTER/ALTERNATOR (87382915) (Plug)
87382915
4
87382915 Pin 1 2
3 4
From X-005A (Receptacle) pin 2 ALTERNATOR X-005A (Receptacle) pin 1 ALTERNATOR
Wire 127A
Description ALTERNATOR EXCITE
Color-Size OR - 0.8
244A
YE - 0.8
X-STARTER (Plug) pin 1 STARTER X-005A (Receptacle) pin 3 ALTERNATOR
520A
ALTERNATOR LAMP TELEMATICS ENGINE ON STARTER
WH - 2.0
124
124
YE - 0.8
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Frame SHEET 08
Electrical systems - Harnesses and connectors
X-007 - EXHAUST GAS TEMP SENSOR 2 [ B-012] (87696093) (Receptacle)
87696093
5
87696093 Pin 1 2
From X-012 (Receptacle) pin 84 ECU X-012 (Receptacle) pin 83 ECU
Wire 273 272
Description EXHAUST GAS TEMP SIGNAL 2 EXHAUST GAS TEMP GND 2
Color-Size YE - 0.5
Frame SHEET 10
BK/WH - 0.5
X-009 - IGNITION SWITCH [ S-008] (87693713) (Receptacle)
87693713
6
87693713 Pin 1 3 4 6
From X-C23 (Receptacle) pin 10 INSTRUMENT CLUSTER SP-004-P-X X-C23 (Receptacle) pin 3 INSTRUMENT CLUSTER SP-009-P-X
Wire
Description KEY IGNITION
Color-Size OR - 0.8 RD - 0.8
624
KEY SW UNSWITCHED BATTERY KEY START OUTPUT
138
KEY ACCESSORY
OR - 0.8
132 140
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WH - 0.8
Frame SHEET 08
Electrical systems - Harnesses and connectors
X-2SPD - 2 SPEED VALVE SOLENOID [ SH16: C-1] (87693821) (Receptacle)
87693821
7
87693821 Pin 1 3
From SPLICE SP-035 SPLICE SP-179
Wire 564 953
Description SOLENOID SIGNAL SOLENOID GROUND
Color-Size WH - 0.8 BK - 0.8
Frame SHEET 16
X-AUX_EXT - 2ND AUX EXTEND (87695582) (Receptacle)
87695582
8
87695582 1
Pin
From X-114 (Receptacle) pin 2
554
Wire
2
SP-183-P-X
958
Description 2ND AUX EXTEND SWITCH OUTPUT 2ND AUX EXTEND GROUND
SHEET 13
BK - 0.8
SHEET 07
X-AUX_RET - 2ND AUX RETRACT [ SH13: B-5] (87695582) (Receptacle)
87695582
9
87695582
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Frame
Color-Size WH - 0.8
Electrical systems - Harnesses and connectors
1
Pin
From X-114 (Receptacle) pin 3
552
Wire
2
SP-183-P-X
959
Description 2ND AUX RETRACT SIGNAL POWER 2ND AUX RETRACT GROUND
Frame
Color-Size WH - 0.8
SHEET 13
BK - 0.8
SHEET 07
Color-Size BK - 13.0
SHEET 07
Color-Size BK - 13.0
SHEET 07
X-CAB_GNDA - CAB GROUND (84399576) (Plug)
84399576
10
84399576 Pin 1
From
Wire 1093
SP-172-P-X
Description CAB GND A
Frame
X-CAB_GNDB - CAB GROUND (84399576) (Plug)
84399576
11
84399576 Pin 1
From SP-173-P-X
Wire 1094
Description CAB GND B
X-ECU_MAIN_RLY - ECU MAIN RELAY [ K-009] (84297431) (Receptacle)
84297431
12
84297431 48068130 29/01/2018
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Frame
Electrical systems - Harnesses and connectors
Pin 1 1 2 2 3 3 5 5
From SP-527-P-X SP-527RH-P-X X-900 pin 46 CROSSOVER BULKHEAD X-012 (Receptacle) pin 28 ECU SP-527-P-X SP-527RH-P-X SP-528-P-X SP-528RH-P-X
Wire 527C 527C 112
Description BATT+ BATT+ MAIN RELAY
Color-Size RD - 0.5 RD - 0.5 BL - 0.5
112
ECU MAIN RELAY
BL - 0.5
527B 527B 528A 528A
BATT+ BATT+ BATT+ BATT+
RD - 8.0 RD - 8.0 OR - 8.0 OR - 8.0
Frame SHEET 02
X-FUSE1 - POWER DISTRIBUTION-CHASSIS LARGE MACHINES [ SH2: C-6] (47536466) (Receptacle)
47536466
13
47536466 1
Pin
From SPLICE SP-194
946
Wire
2 3
X-FUSE1 PIN 67 SPLICE SP-194
788 948
4 5 6 7
SPLICE SP-043 X-101A PIN 1
117 710
8 9 10 11 12 13 14
SPLICE SP-040 SPLICE SP-031
116 325
15
SPLICE SP-030
125
16 17 18 19 20 21 22 23
X-CCA PIN 28 X-FUSE2 PIN 49 SPLICE SP-041 SPLICE SP-194
139 947 118 945
24 25 26 27 28 29 30 31 32 33
SPLICE SP-041 X-CCA PIN 41 SPLICE SP-030 SPLICE SP-036
113 233 243 136
Description LIGHTS #1 RELAY GROUND FRONT WORK LAMPS ACCESSORY RELAY GROUND ACCESSORY RELAY STD/ON-ROAD LAMP CONFIGURATION LIGHTS #1 RELAY LAMP SELECTOR SWITCH LAMP SELECTOR SWITCH ACCESSORY RELAY FUSE RELAY GROUND UNSWITCHED BATTERY LIGHTS #2 RELAY GROUND UNSWITCHED BATTERY WIPER/WASHER WIPER/WASHER MAIN POWER RELAY SIGNAL 48068130 29/01/2018
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Frame
Color-Size BK - 0.8
SHEET 02
VT - 3.0 BK - 0.8
SHEET 02 SHEET 02
RD - 3.0 VT - 2.0
SHEET 02
SHEET 02
RD - 2.0 WH - 0.8
SHEET 02 SHEET 02
OR - 3.0
SHEET 02
OR - 0.8 BK - 0.8 RD - 1.0 BK - 0.8
SHEET 02
RD - 1.0 OR - 2.0 OR - 2.0 OR - 1.0
SHEET 02 SHEET 02 SHEET 02 SHEET 02 SHEET 02
SHEET 02 SHEET 02
Electrical systems - Harnesses and connectors
Pin 34
From X-CCA PIN 67
144
Wire
35
SPLICE SP-031
707
36 37 38
SPLICE SP-032 X-314 PIN 3 X-FUSE1 PIN 42
709 706 256
39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57
SPLICE SP-192 SPLICE SP-041 X-900 PIN 20 X-FUSE2 PIN 27 SPLICE SP-031 SPLICE SP-042 SPLICE SP-032 X-900 PIN 29 X-FUSE2 PIN 10 SPLICE SP-056 X-006 PIN 1 X-900 PIN 31 X-CCA PIN 2 SPLICE SP-024 SPLICE SP-192
972 104 161 256 705 255 708 704 743 148 520 121 792 700 974
58 59 60 61 62 63 64 65 66 67 68 69
SPLICE SP-041 X-CCA PIN 48 X-900 PIN 43 X-FUSE1 PIN 2 SPLICE SP-024 SPLICE SP-065
103 798 703 788 701 149
70
SPLICE SP-056
146
71 72
-
-
Description MAIN POWER RELAY SIGNAL LAMP SELECTOR SWITCH LIGHTS #2 RELAY REAR WORK LAMPS CRANK SIGNAL TO ENGINE RELAY A OPTION RELAY GROUND UNSWITCHED BATTERY CRANK ENABLE 2 CRANK FUSE REAR WORK LAMPS CRANK FUSE SIDE LAMPS RIGHT-HAND TAIL LAMP HIGH FLOW/ COUPLER OPTION RELAY STARTER CRANK ENABLE 1 SIDE LAMPS FUSE RIGHT-HAND TAIL LAMP FRONT ELECTRIC RELAY GROUND UNSWITCHED BATTERY FRONT WORK LAMPS LEFT-HAND TAIL LAMP FRONT WORK LAMPS LEFT-HAND TAIL LAMP FRONT ELECTRIC RELAY ACCESSORY RELAY SIGNAL -
Frame
Color-Size OR -0.8
SHEET 02
VT - 2.0
SHEET 02
WH - 0.8 VT - 3.0 RD - 2.0
SHEET 02 SHEET 02 SHEET 02
BK - 0.8 RD -2.0 YE - 0.8 RD - 2.0 VT - 3.0 RD - 2.0 VT - 3.0 VT - 0.8 OR - 0.8 WH - 0.8 WH - 2.0 YE - 0.8 VT - 3.0 VT - 0.8 BK - 0.8
SHEET SHEET SHEET SHEET SHEET SHEET
05 05 09 09 02 02
SHEET SHEET SHEET SHEET SHEET SHEET SHEET SHEET SHEET
02 02 05 05 09 09 02 02 05
RD - 3.0 VT - 5.0 VT - 0.8 VT - 3.0 VT - 0.8 OR - 3.0
SHEET 05
WH - 0.8
SHEET 02 SHEET 02
SHEET 02 SHEET 02 SHEET 05 SHEET 05
-
X-FUSE1 - POWER DISTRIBUTION-CHASSIS MEDIUM MACHINES [ SH2: C-6] (47536466) (Receptacle)
47536466
14
47536466 Pin 1 2 3 4
From SPLICE SP-194 X-FUSE2 PIN 45 SPLICE SP-194 SPLICE SP-043
Wire 946 788 948 117
Description GROUND UNSWITCHED BATTERY GROUND UNSWITCHED BATTERY
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Color-Size BK -0.8 VT - 3.0 BK - 0.8 RD - 3.0
Frame SHEET SHEET SHEET SHEET
03 03 03 03
Electrical systems - Harnesses and connectors
5
Pin
From X-101A PIN 1
710
6 7 8 9 10
SPLICE SP-040 SPLICE SP-031
116 325
11
SPLICE SP-030
125
12
X-CCA PIN 28
139
13 14 15 16 17 18 19 20 21
SPLICE SPLICE SPLICE SPLICE SPLICE
945 113 947 118 707
22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39
SPLICE SP-032 SPLICE SP -036 X-CCA PIN 67 X-900 PIN 2 X-FUSE2 PIN 27 SPLICE SP-192 SPLICE SP-041 X-006 PIN 1 X-900 PIN 31 X-FUSE2 PIN 8
709 136 144 161 256 972 104 520 121 743
SPLICE SP-192
974
40 41 42 43 44 45 46 47
SPLICE SP-041 SPLICE SP-065
103 149
48
SPLICE SP-056
146
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68
-
-
SP-194 SP-041 SP-194 SP-041
SP-031
Wire
Description STD/ ON-ROAD LAMP CONFIGURATOR UNSWITCHED BATTERY LAMP SELECTOR SWITCH LAMP SELECTOR SWITCH ACCESSORY RELAY SIGNAL GROUND UNSWITCHED BATTERY GROUND UNSWITCHED BATTERY LAMP SELECTOR SWITCH TURN SIGNAL MAIN POWER RELAY INSTRUMENT CLUSTER CRANK ENABLE 2 UNSWITCHED BATTERY OPTION RELAY GROUND UNSWITCHED BATTERY STARTER SIGNAL CRANK ENABLE 1 OPTION RELAY FRONT ELECTRIC RELAY GROUND UNSWITCHED BATTERY FRONT ELECTRIC RELAY ACCESSORY RELAY SIGNAL -
48068130 29/01/2018
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Frame
Color-Size VT - 2.0
SHEET 03
RD - 2.0 WH - 0.8
SHEET 03 SHEET 03
OR - 3.0
SHEET 03
OR - 0.8
SHEET 03
BK - 0.8 RD - 1.0 BK - 0.8 RD - 1.0 VT - 2.0
SHEET SHEET SHEET SHEET
WH - 0.8 OR - 1.0 OR - 0.8 YE - 0.8 RD - 2.0 BK - 0.8 RD - 2.0 WH - 2.0 YE - 0.8 OR - 0.8
SHEET SHEET SHEET SHEET SHEET SHEET SHEET
03 03 03 09 09 06 06
SHEET SHEET SHEET SHEET
09 09 06 06
BK - 0.8
03 03 03 03
SHEET 03
SHEET 06
RD - 3.0 OR - 3.0
SHEET 06
WH - 0.8
SHEET 06
-
SHEET 06
Electrical systems - Harnesses and connectors
Pin 69 70 71 72
From -
Wire -
Description -
Frame
Color-Size -
X-FUSE2 - POWER DISTRIBUTION-CHASSIS LARGE MACHINES [ SH30: C-2] (84380518) (Receptacle)
84380518
15
84380518 1 2
Pin
From X-CCA PIN 5 X-CCA PIN 14
836 115
Wire
3 4 5 6 7 8 9 10 11 12 13 14 15
SPLICE SP-161 SPLICE SP-053 SPLICE SP-042 SPLICE SP-040 SPLICE SPâ&#x20AC;&#x201C;042 X-FUSE1 PIN 51 SPLICE SP-039 SPLICE SP-037 X-900 PIN 4
820 744 835 114 830 743 351 300 110
16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43
X-411 PIN 30 -
156 -
Description COMPRESSOR ACCESSORY SWITCH/ BEACON SWITCH HVAC HIGH FLOW/ COUPLER UNSWITCHED BATTERY UNSWITCHED BATTERY UNSWITCHED BATTERY OPTION RELAY IGNITION INSTRUMENT CLUSTER ECU UNSWITCHED BATTERY FLASH MODULE -
Color-Size RD - 3.0 RD 2.0 OR - 3.0 OR - 2.0 RD - 3.0 RD - 1.0 OR - 3.0 OR - 0.8 OR - 1.0 OR - 1.0 OR - 2.0 RD - 2.0 -
SPLICE SP-041 X-CCA PIN 19 X-CCA PIN 16 X-314 PIN 1 X-900 PIN 13 -
101 134 310 155A 719 -
UNSWITCHED BATTERY ACCESSORY INSTRUMENT CLUSTER ECU 2 RIGHT-HAND BOOM -
SPLICE SP-040
160
UNSWITCHED BATTERY RD - 0.8
SPLICE SP-057 SPLICE SP-182 X-TELE PIN 12 SPLICE SP-059 SPLICE SP-192
715 1092 366 716 1097
RIGHT-HAND BOOM FUSE RELAY GROUND TELEMATICS LEFT-HAND BOOM GROUND
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RD - 2.0 OR - 2.0 RD - 0.8 OR - 3.0 VT - 1.0 -
VT - 1.0 BK - 0.8 RD - 1.0 VT - 1.0 BK - 0.8
Frame SHEET 02 SHEET 02 SHEET 02 SHEET 05
SHEET SHEET SHEET SHEET
02 02 02 05
SHEET 02 SHEET 02 SHEET 02 SHEET 05
SHEET SHEET SHEET SHEET
02 02 02 05
SHEET SHEET SHEET SHEET
02 02 02 05
SHEET SHEET SHEET SHEET
02 02 02 05
SHEET 05 SHEET 05 SHEET 05
SHEET 05
Electrical systems - Harnesses and connectors
Pin 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62
From SPLICE SP-040 SPLICE SP-057 X-FUSE1 PIN 21 X-900 PIN 32 SPLICE SP-190
Wire 119 714 947 241A 1094
Description UNSWITCHED BATTERY LEFT-HAND BOOM MAIN POWER RELAY ENGINE SENSORS GROUND
Color-Size RD - 1.0 VT - 1.0 BK - 0.8 OR - 1.0 BK - 0.8
Frame
SPLICE SP-194 X-323 PIN 9
1098 420
BK - 0.8 OR - 3.0
SHEET 05 SHEET 05
63 64
SPLICE SP-062 SPLICE SP-197
354 129
OR - 0.8 OR - 1.0
SHEET 05 SHEET 05
65 66 67 68
SPLICE SP-190 SPLICE SP-065
1095
BK - 0.8 OR
SHEET 05 SHEET 05
69 70
SPLICE SP-065 SPLICE SP-065
355 145
OR - 0.8 OR - 0.8
SHEET 05 SHEET 05
71 72
-
-
FUSE RELAY GROUND MULTIFUNCTION CONNECTORS UNSWITCHED BATTERY MULTIFUNCTION JUMPER GROUND FRONT ELECTRIC RELAY FE #1, #2, AND #3 FRONT ELECTRIC RELAY ON/OFF -
SHEET 05 SHEET 05
SHEET 05 SHEET 02
SHEET 05 SHEET 02
-
X-FUSE2 - POWER DISTRIBUTION-CHASSIS MEDIUM MACHINES [ SH30: C-2] (84380518) (Receptacle)
84380518
16
84380518 Pin 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
From X-CCA PIN 5 X-CCA PIN 14 SPLICE SP-161 SPLICE SP-053 SPLICE SP-042 SPLICE SP-040 SPLICE SP-042 X-FUSE1 PIN 35 SPLICE SP-039 SPLICE SP-037 X-900 PIN 4 X-900 PIN 5 SPLICE SP-036 SPLICE SP-036 SPLICE SP-528 SPLICE SP-041
Wire 836 115 820 744 835 114 830 743 351 300 110 156 350 326 528B 101
Description COMPRESSOR ACCESSORY/ BEACON HVAC HIGH FLOW/ COUPLER UNSWITCHED BATTERY UNSWITCHED BATTERY UNSWITCHED BATTERY OPTIONS RELAY IGNITION INSTRUMENT CLUSTER ECU 1 FLASHER MODULE MAIN POWER RELAY MAIN POWER RELAY UNSWITCHED BATTERY FLASHER/ BRAKE
48068130 29/01/2018
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Color-Size RD - 3.0 RD - 2.0 OR - 3.0 OR - 2.0 RD - 3.0 RD - 1.0 OR - 3.0 OR - 0.8 OR - 1.0 OR - 1.0 OR - 2.0 RD - 2.0 OR - 1.0 OR - 1.0 OR - 3.0 RD - 2.0
Frame SHEET SHEET SHEET SHEET SHEET SHEET SHEET SHEET SHEET SHEET SHEET SHEET SHEET SHEET SHEET SHEET
03 03 03 06 03 03 03 06 03 03 04 06 03 03 04 06
Electrical systems - Harnesses and connectors
Pin 17 18 19 20 21
From X-CCA PIN 19 X-CCA PIN 15 X-314 PIN 1 X-900 PIN 13 SPLICE SP-030
Wire 134 310 155A 719 135
22 23 24
SPLICE SP-040 SPLICE SP-528 SPLICE SP-057
160 528C 715
25 26 27 28 29 30
X-314 PIN 3 X-CCA PIN 41 X-FUSE1 PIN 26 SPLICE SP-059 SPLICE SP-031 SPLICE SP-030
706 233 256 716 705 243
31 32
SPLICE SP-042 SPLICE SP-057
255 714
33 34 35 36 37
SPLICE SP-032 SPLICE SP-241 X-900 PIN 29 X-900 PIN 43 X-CCA PIN 2
708 241A 704 703 792
38 39 40 41 42 43
SPLICE SP-528 SPLICE SP-024 SPLICE SP-024 X-CCA PIN 48 X-323 PIN 9 SPLICE SP-062
528D 700 701 798 420 354
44 45 46
SPLICE SP-197 X-FUSE1 PIN 2 SPLICE SP-065
129 788 356
47 48
SPLICE SP-065 SPLICE SP-065
355 145
Description ACCESSORY UNSWITCHED BATTERY ECU 2 RIGHT-HAND BOOM LAMP SELECTOR SWITCH UNSWITCHED BATTERY UNSWITCHED BATTERY STD/ ON-ROAD LAMP CONFIGURATOR REAR WORK LAMPS WIPER/ WASHER SIDE LAMPS LEFT-HAND BOOM REAR WORK LAMPS LAMP SELECTOR SWITCH CRANK STD/ ON-ROAD LAMP CONFIGURATOR SIDE LAMPS ENGINE SENSORS RIGHT-HAND TAIL LAMP LEFT-HAND TAIL LAMP LAMP SELECTOR SWITCH ENGINE SENSOR RIGHT-HAND TAIL LAMP LEFT-HAND TAIL LAMP FRONT WORK LAMPS FE HOT MULTIFUNCTION JUMPER FE ON/OFF FRONT WORK LAMPS FRONT ELECTRIC RELAY FE #1, #2, AND #3 FRONT ELECTRIC RELAY
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
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Frame
Color-Size OR - 2.0 RD - 0.8 OR - 3.0 VT - 1.0 OR - 2.0
SHEET SHEET SHEET SHEET SHEET
RD - 0.8 OR - 3.0 VT - 1.0
SHEET 03 SHEET 04 SHEET 06
VT - 3.0 OR - 2.0 RD - 2.0 VT - 1.0 VT - 3.0 OR - 2.0
SHEET SHEET SHEET SHEET SHEET SHEET
RD - 2.0 VT - 1.0
SHEET 03 SHEET 06
VT - 3.0 OR - 1.0 VT - 0.8 VT - 0.8 VT - 3.0
SHEET SHEET SHEET SHEET SHEET
03 04 04 04 03
OR - 1.0 VT - 0.8 VT - 0.8 VT - 5.0 OR - 3.0 OR - 0.8
SHEET SHEET SHEET SHEET SHEET SHEET
04 04 04 04 06 06
OR - 1.0 VT - 3.0 OR - 3.0
SHEET 06 SHEET 04 SHEET 06
OR - 0.8 OR - 0.8
SHEET 06 SHEET 06
03 03 04 06 03
04 03 03 06 04 03
Electrical systems - Harnesses and connectors
X-HVC1 - CAB/HVAC INTERCONNECT [ SH26: A-1] (87382926) (Receptacle)
87382926
17
87382926 Pin
From
Wire
Color-Size BK - 5.0 RD - 1.0
828
Description HVAC GND COMPRESSOR RELAY PIN 30 POWER HVAC FAN LOW
827
HVAC FAN MEDIUM
WH - 3.0
850 837
HVAC FAN HIGH A/C SW COMPRESSOR RELAY PIN 86 THERMOSTAT TO BINARY PRESSURE
WH - 5.0 WH - 0.8
1 2
SP-168-P-X SP-160-P-X
935 838
3
X-270 pin 3 BLOWER FAN SW X-270 pin 4 BLOWER FAN SW SP-165-P-X SP-157-P-X
4 5 6 7
833
Frame SHEET 26
WH - 3.0
WH - 0.8
SHEET 14
834
BINARY PRESSURE SW TO COMPRESS
WH - 0.8
9
X-BULKHEAD (Receptacle) pin 37 CAB/CHASSIS INTERCO X-BULKHEAD (Receptacle) pin 40 CAB/CHASSIS INTERCO SP-092-P-X
1012
BK/WH - 0.8
SHEET 07
10
SP-163-P-X
842
OR - 5.0
SHEET 26
11 12
SP-021-P-X X-BULKHEAD (Receptacle) pin 35 CAB/CHASSIS INTERCO SP-162-P-X
143 841
HVAC THERMOSTAT CLEAN GND HVAC RELAY PIN 87 OUTPUT POWER HVAC KEYED POWER A/C COMPRESSOR RELAY PIN 87 PO
OR - 0.8 WH - 0.8
SHEET 14
HVAC RELAY FUSE POWER
OR - 5.0
SHEET 26
Color-Size BK/WH - 2.0
SHEET 07
8
14
845
X-NEG_TERM_A - CLEAN GROUND (84159856) (Plug)
84159856
18
84159856 Pin 1
From SP-047-P-X
Wire 966
Description CLEAN GROUND
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Frame
Electrical systems - Harnesses and connectors
X-OPT_POS-PWR - [ SH7: A-1] (Receptacle) Pin 1
From B_START-P-PIN1
Wire 102A
Description B+ CABLE TO STARTER
Frame
Color-Size RD - 85.0
SHEET 07
Color-Size WH - 0.8
SHEET 13
X-PORT_LK - PORT LOCK [ U-001] (87695582) (Receptacle)
87695582
19
87695582 Pin 1
From
Wire 304
SP-187-P-X
Description HYDRAULIC LOADER INTERLOCK SIGNAL
Frame
X-POS_TERM - X-POS_TERM BATTERY POWER (84417635) (Plug)
84417635
20
84417635 Pin 1
From SP-043-P-X
Wire 108
Description BATTERY POWER
X-SPOOL_LK_A - SPOOL LOCK (Receptacle)
87695582
21
87695582 48068130 29/01/2018
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Color-Size RD - 19.0
Frame SHEET 07
Electrical systems - Harnesses and connectors
Pin 1 2
From SPLICE SP-1304 SPLICE SP-1901
Wire 1304A 1901A
Description SIGNAL GROUND
Frame
Color-Size WH - 0.8 BK - 0.8
SHEET 13
Color-Size WH - 0.8 BK - 0.8
SHEET 13
X-SPOOL_LK_B - SPOOL LOCK (87695582) (Receptacle)
87695582
22
87695582 Pin 1 2
From SPLICE SP-1304 SPLICE SP-1901
Wire 1304B 1901B
Description SIGNAL GROUND
Frame
X-TELE_DIAG - TELEMATICS DIAGNOSTIC [ SH32: A-5] (Receptacle) Pin 1
2
3
From X-BULKHEAD (Receptacle) pin 64 CAB/CHASSIS INTERCO X-BULKHEAD (Receptacle) pin 65 CAB/CHASSIS INTERCO X-BULKHEAD (Receptacle) pin 66 CAB/CHASSIS INTERCO
206
Wire
Description GROUND
Color-Size BK/WH - 0.8
207
RS232 RX
TN - 0.8
208
RS232 TX
BL - 0.8
Frame SHEET 29
X-TELE_GND - TELEMATICS GROUND (84398832) (Plug)
84398832
23
84398832 Pin 1
From X-TELE (Receptacle) pin 1
Wire 925
Description TELEMATICS GROUND
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Color-Size BK/WH - 0.8
Frame SHEET 07
Electrical systems - Harnesses and connectors
Wire connectors - Component diagram 01 Connectors X-010 to X-019 SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
X-011 - A/C COMPRESSOR [ S-043] (87382911) (Plug)
87382911
1
87382911 Pin 1
1 1
From X-901 pin 23 CHASSIS INTERFACE X-201 (Plug) pin 8 REAR LAMP JUMPER X-901 pin 23 CHASSIS INTERFACE
Wire 833
1151 833
2
X-901 pin 24 CHASSIS INTERFACE
834
2
X-201 (Plug) pin 9 REAR LAMP JUMPER X-901 pin 24 CHASSIS INTERFACE
909
2
3 3 3
X-901 pin 39 CHASSIS INTERFACE X-201 (Plug) pin 10 REAR LAMP JUMPER X-901 pin 39 CHASSIS INTERFACE
834
841 1137 841
Description THERMOSTAT TO BINARY PRESSURE SWITCH 1151
Color-Size WH - 0.8
THERMOSTAT TO BINARY PRESSURE SWITCH BINARY PRESSURE SWITCH TO COMPRESSOR RELAY PIN 86 909
WH - 0.8
BINARY PRESSURE SWITCH TO COMPRESSOR RELAY PIN 86 A/C COMPRESSOR RELAY PIN 87 POWER 1137 A/C COMPRESSOR RELAY PIN 87 POWER
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YE - 0.8
WH - 0.8
BK - 0.8 WH - 0.8
WH - 0.8 OR - 0.8 WH - 0.8
Frame SHEET 26
Electrical systems - Harnesses and connectors
X-012 - ECU [ SH9: A-6] (84474047) (Receptacle)
84474047
2
84474047 Pin
2 3
From X-901 pin 4 CHASSIS INTERFACE X-901 pin 4 CHASSIS INTERFACE SP-908-P-X SP-155-P-X
4 5
SP-908-P-X SP-155-P-X
908C 155C
6 7
SP-908-P-X X-014 pin 3
908D 242
7
X-901 pin 8 CHASSIS INTERFACE X-901 pin 36 CHASSIS INTERFACE X-901 pin 36 CHASSIS INTERFACE X-004 (Receptacle) pin 2 AIR TEMPERATURE SENSOR X-013 (Receptacle) pin 3 GCU X-901 pin 31 CHASSIS INTERFACE X-901 pin 31 CHASSIS INTERFACE X-901 pin 18 CHASSIS INTERFACE X-901 pin 18 CHASSIS INTERFACE X-901 pin 33 CHASSIS INTERFACE X-901 pin 33 CHASSIS INTERFACE X-ECU_MAIN_RLY (Receptacle) pin 2 ECU MAIN RELAY X-901 pin 46 CHASSIS INTERFACE X-011 WIF (Plug) pin 1 SP-239-P-X X-079 (Receptacle) pin 2 CCV HEATERS X-013 (Receptacle) pin 8 GCU
242
1 1
8 8 20 22 24 24 25 25 27 27 28
28 30 41 50 52
Wire 110 110 908B 155B
626 626 254 235
Description BATTERY VOLTAGE VIA MAIN RELAY BATTERY VOLTAGE VIA MAIN RELAY BATTERY MINUS 1 BATTERY +B VIA MAIN RELAY BATTERY MINUS 2 BATTERY +C VIA MAIN RELAY BATTERY MINUS 3 LAMBDA SENSOR HEATING LAMBDA SENSOR HEATING BC RELAY TO ECU SIGNAL BC RELAY TO ECU SIGNAL AIR TEMP GND
Color-Size OR - 2.0 OR - 2.0 BK - 2.0 OR - 2.0 BK - 2.0 OR - 2.0 BK - 2.0 YE - 0.8 YE - 0.8 WH - 0.8 WH - 0.8 BK/WH - 0.5
503C
GLOW PLUG FEEDBACK YE - 0.5 SIGNAL YE - 0.8 CAN 1 HI
503C
CAN 1 HI
YE - 0.8
504C
CAN 1 LO
GN - 0.8
504C
CAN 1 LO
GN - 0.8
121
YE - 0.8
112
CRANK ENABLE FROM ECU CRANK ENABLE FROM ECU ECU MAIN RELAY
112
ECU MAIN RELAY
BL - 0.5
150 239 600
WATER IN FUEL SIGNAL OR - 0.8 GLOW PLUG UNIT GND BK - 0.8 CCV HEATER CONTROL WH - 0.8
216
GLOW PLUG UNIT COMMAND SIGNAL CRANK ENABLE EGR ECU SWITCHED BATTERY POWER LAMBDA SENSOR VOLTAGE NERNST LAMBDA SENSOR VOLTAGE NERNST
121
53 54
SP-133B-P-X
161 133D
63
X-014 pin 6
253
63
X-901 pin 12 CHASSIS INTERFACE
253
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YE - 0.8 BL - 0.5
YE - 0.5 YE - 0.8 OR - 0.8 PK - 0.5 PK - 0.5
Frame SHEET 09
Electrical systems - Harnesses and connectors
Pin 64
From
Wire
248
Description LAMBDA SENSOR CURRENT PUMP LAMBDA SENSOR CURRENT PUMP EGR ECU K-LINE
YE - 0.8
248
EGR ECU K-LINE
YE - 0.8
270
EXHAUST GAS TEMP GND EXHAUST GAS TEMP GND EXHAUST GAS TEMP SIGNAL EXHAUST GAS TEMP SIGNAL INLET TURBINE TEMP GND INLET TURBINE TEMP SIGNAL EXHAUST GAS TEMP GND 2
BK/WH - 0.5
273
EXHAUST GAS TEMP SIGNAL 2
YE - 0.5
252
LAMBDA SENSOR VIRTUELLE GND LAMBDA SENSOR VIRTUELLE GND LAMBDA SENSOR CURRENT ADJUST LAMBDA SENSOR CURRENT ADJUST CCV HEATER FEEDBACK
BK - 0.5
X-014 pin 1
245 245
81
X-901 pin 9 CHASSIS INTERFACE X-901 pin 19 CHASSIS INTERFACE X-901 pin 19 CHASSIS INTERFACE X-901 pin 14 CHASSIS INTERFACE X-006 pin 2 PRE-OXICAT TEMP SENSOR X-006 pin 1 PRE-OXICAT TEMP SENSOR X-901 pin 15 CHASSIS INTERFACE X-017 (Receptacle) pin 25
82
X-017 (Receptacle) pin 26
263
83
X-007 (Receptacle) pin 2 EXHAUST GAS TEMP SENSOR 2 X-007 (Receptacle) pin 1 EXHAUST GAS TEMP SENSOR 2 X-014 pin 2
272
X-901 pin 11 CHASSIS INTERFACE X-014 pin 5
252
64 68 68 79 79 80 80
84
85 85 86 86 87
270 271 271 265
249
249 X-901 pin 10 CHASSIS INTERFACE X-079 (Receptacle) pin 3 CCV 601 HEATERS
Frame
Color-Size YE - 0.5 YE - 0.5
BK/WH - 0.5 YE - 0.5 YE - 0.5 BK/WH - 0.5 YE - 0.5 BK/WH - 0.5
BK - 0.5 YE - 0.5 YE - 0.5 YE - 0.8
X-013 - GCU [ SH34: A-2] (84356962) (Receptacle)
84356962
3
84356962 Pin 1 2 3 4 4 5 6 7 8
From X-017 (Receptacle) pin 58 X-017 (Receptacle) pin 61 X-012 (Receptacle) pin 22 ECU X-313 (Receptacle) pin 1 GCU POWER SP-212-P-X SP-239-P-X X-017 (Receptacle) pin 57 X-017 (Receptacle) pin 60 X-012 (Receptacle) pin 52 ECU
Wire 1112 1110 235 212 212 239A 1113 1111 216
Description GLOW PLUG GLOW PLUG GLOW PLUG FEEDBACK SIGNAL BATT+ BATT+ GLOW PLUG UNIT GND GLOW PLUG GLOW PLUG GLOW PLUG UNIT COMMAND SIGNAL
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Color-Size WH - 2.0 WH - 2.0 YE - 0.5 OR - 8.0 OR - 8.0 BK - 3.0 WH - 2.0 WH - 2.0 YE - 0.5
Frame SHEET 10
Electrical systems - Harnesses and connectors
X-014 - LAMBDA SENSOR [ B-005] (84301132) (Receptacle)
84301132
4
84301132 Pin 1 2 3 4 5 6
From X-012 (Receptacle) pin 64 X-012 (Receptacle) pin 85 X-012 (Receptacle) pin 7 SPLICE SP-241 X-012 (Receptacle) pin 86 X-012 (Receptacle) pin 63
Wire 245 252 242 241B 249 253
Description CURRENT PUMP VIRTUAL GROUND SENSOR HEATING POWER CURRENT ADJUST VOLTAGE
Color-Size YE-0.5 BK-0.5 YE-0.8 OR-0.8 YE-0.5 PK-0.5
Frame SHEET 10
X-014 - FUEL LEVEL SENDER (87693431) (Plug)
87693431
5
87693431 Pin A B
From SPLICE SP-176 LG MACHINES X-901 LG (Plug) pin 42 MED MACHINES X-901 MD (Plug) pin 42
Wire 956 234
Description GROUND FUEL LEVEL SIGNAL
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Color-Size BK - 0.8 RD - 0.8
Frame SHEET 33
Electrical systems - Harnesses and connectors
X-015 - INJECTOR HARNESS (Female)
87698252
6
87698252 A B
Pin
From X-016 (Receptacle) pin 16 X-016 (Receptacle) pin 32
274 275
Wire
C
X-016 (Receptacle) pin 31
276
D E F
X-016 (Receptacle) pin 1 X-016 (Receptacle) pin 17 X-016 (Receptacle) pin 48
277 278 279
G
X-016 (Receptacle) pin 46
280
H
X-016 (Receptacle) pin 2
281
Description INJECTOR CYLINDER 1 INJECTOR CYLINDER 1 RETURN INJECTOR CYLINDER 3 RETURN INJECTOR CYLINDER 3 INJECTOR CYLINDER 4 INJECTOR CYLINDER 4 RETURN INJECTOR CYLINDER 2 RETURN INJECTOR CYLINDER 2
Color-Size WH - 1.0 GY - 1.0
Frame SHEET 11
GY - 1.0 WH - 1.0 WH - 1.0 GY - 1.0 GY - 1.0 WH - 1.0
X-015 - ACCESSORY BACK FEED DIODE (84120021) (Plug)
84120021
7
84120021 Pin
From
Wire
1
SP-009-P-X
153
2
X-C23 (Receptacle) pin 29 INSTRUMENT CLUSTER
137
Description ACCESSORY RELAY SIGNAL ACCESSORY RELAY SIGNAL
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Color-Size WH - 0.8 WH - 0.8
Frame SHEET 25
Electrical systems - Harnesses and connectors
X-016 - ECU [ A-005] (84474053) (Receptacle)
84474053
8
84474053 Pin
4
From X-015 (Receptacle) pin D ACCESSORY BACKFEED DIODE X-015 (Receptacle) pin H ACCESSORY BACKFEED DIODE X-017 (Receptacle) pin 27
4
X-017 (Receptacle) pin 27
294
6
X-017 (Receptacle) pin 3
658
8
X-017 (Receptacle) pin 41
340
9
X-017 (Receptacle) pin 33
318
10
X-017 (Receptacle) pin 17
343
11
X-017 (Receptacle) pin 7
284
12
X-017 (Receptacle) pin 21
295
13
X-017 (Receptacle) pin 12
289
14
X-017 (Receptacle) pin 4
287
15
X-017 (Receptacle) pin 1
299
16
274
23
X-015 (Receptacle) pin A ACCESSORY BACKFEED DIODE X-015 (Receptacle) pin E ACCESSORY BACKFEED DIODE X-017 (Receptacle) pin 15
24
X-017 (Receptacle) pin 35
337
25
X-017 (Receptacle) pin 19
345
26
X-017 (Receptacle) pin 5
282
27
X-017 (Receptacle) pin 22
296
28
X-017 (Receptacle) pin 8
288
1
2
17
Wire 277
Description Color-Size INJECTOR 1 HIGH BANK WH - 1.0 2
281
INJECTOR 2 HIGH BANK WH - 1.0 2
294
BOOST PRESSURE ACTUATOR 1 BOOST PRESSURE ACTUATOR 1 OIL PRESSURE SW SIGNAL TVA POSITION SENSOR SUPPLY EGR POSITION SENSOR SUPPLY BOOST PRESSURE SENSOR SUPPLY RAIL PRESSURE SENSOR SUPPLY EXHAUST GAS PRESSURE SENSOR SUPPLY (UPSTREAM TURBINE PRESSURE) P3 SEGMENT(CAMSHAFT) SPEED SENSOR SUPLY SEGMENT(CAMSHAFT) SPEED SENSOR SIGNAL FUEL METERING UNIT SUPPLY INJECTOR 1 HIGH BANK 1
GY - 1.0 GY - 1.0 YE - 0.5 PK - 0.5 PK - 0.5 PK - 0.5 PK - 0.5 PK - 0.5
PK - 0.5 YE - 0.5 WH - 1.0 WH - 1.0
278
INJECTOR 2 HIGH BANK WH - 1.0 1
292
FUEL TEMPERATURE SENSOR GROUND EGR POSITION SENSOR GROUND BOOST PRESURE SENSOR GROUND RAIL PRESSURE SENSOR GROUND EXHAUST GAS PRESSURE SENSOR GROUND P3 (UPSTREAM TURBINE PRESSURE) SEGMENT(CAMSHAFT) SPEED SENSOR GROUND
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BL - 0.5 BK/WH - 0.5 BK/WH - 0.5 BL - 0.5 BK/WH - 0.5
BL - 0.5
Frame SHEET 11
Electrical systems - Harnesses and connectors
Pin 31
34
From X-015 (Receptacle) pin C ACCESSORY BACKFEED DIODE X-015 (Receptacle) pin B ACCESSORY BACKFEED DIODE X-017 (Receptacle) pin 38
35
X-017 (Receptacle) pin 30
322
37
X-017 (Receptacle) pin 43
342
38
X-017 (Receptacle) pin 16
293
39
X-017 (Receptacle) pin 34
327
40
X-017 (Receptacle) pin 18
344
41
X-017 (Receptacle) pin 6
283
43
X-017 (Receptacle) pin 23
297
44
X-017 (Receptacle) pin 10
286
46
280
49
X-015 (Receptacle) pin G ACCESSORY BACKFEED DIODE X-015 (Receptacle) pin F ACCESSORY BACKFEED DIODE X-017 (Receptacle) pin 37
50
X-017 (Receptacle) pin 29
321
53
X-017 (Receptacle) pin 42
341
55
X-017 (Receptacle) pin 20
346
57
X-017 (Receptacle) pin 14
291
58
X-017 (Receptacle) pin 13
290
59
X-017 (Receptacle) pin 9
285
60
X-017 (Receptacle) pin 2
298
32
48
Wire
Description INJECTOR 1 LOW BANK 2
Color-Size GY - 1.0
275
INJECTOR 1 LOW BANK 1
GY - 1.0
339
TVA ACTUATOR MOTOR MINUS EGR ACTUATOR MOTOR MINUS TVA POSITION SENSOR GROUND FUEL TEMPERATURE SENSOR SIGNAL EGR POSITION SENSOR SIGNAL BOOST PRESSURE SENSOR SIGNAL RAIL PRESSURE SENSOR SIGNAL EXHAUST GAS PRESSURE SENSOR SIGNAL P3 (UPSTREAM TURBINE PRESSURE) CRANKSHAFT SPEED SENSOR SIGNAL MINUS INJECTOR 2 LOW BANK 2
GY - 0.8
276
GY - 0.8 BK/WH - 0.5 YE - 0.5 YE - 0.5 YE - 0.5 YE - 0.5 YE - 0.5
YE - 0.5 GY - 1.0
279
INJECTOR 2 LOW BANK 1
GY - 1.0
338
TVA ACTUATOR MOTOR PLUS EGR ACTUATOR MOTOR PLUS TVA POSITION SENSOR SIGNAL BOOST PRESSURE TEMPERATURE SENSOR SIGNAL COOLANT TEMPERATURE SENSOR SIGNAL COOLANT TEMPERATURE SENSOR GROUND CRANKSHAFT SPEED SENSOR SIGNAL PLUS FUEL METERING UNIT
WH - 0.8
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WH - 0.8 YE - 0.5 YE - 0.5
YE - 0.5
BL - 0.5
YE - 0.5 GY - 1.0
Frame
Electrical systems - Harnesses and connectors
X-017 - ENGINE INTERFACE CONNECTOR [ SH11: D-1] (Receptacle) Pin 1 2 3 4
From Wire 299 X-016 (Receptacle) pin 15 ECU 298 X-016 (Receptacle) pin 60 ECU X-016 (Receptacle) pin 6 ECU 658 X-016 ECU X-016 ECU X-016 ECU X-016 ECU X-016 ECU
(Receptacle) pin 14
287
(Receptacle) pin 26
282
(Receptacle) pin 41
283
(Receptacle) pin 11
284
(Receptacle) pin 28
288
X-016 ECU X-016 ECU X-016 ECU X-016 ECU
(Receptacle) pin 59
285
(Receptacle) pin 44
286
(Receptacle) pin 13
289
(Receptacle) pin 58
290
14
X-016 (Receptacle) pin 57 ECU
291
15
X-016 ECU X-016 ECU X-016 ECU X-016 ECU X-016 ECU X-016 ECU
(Receptacle) pin 23
292
(Receptacle) pin 38
293
(Receptacle) pin 10
343
(Receptacle) pin 40
344
(Receptacle) pin 25
345
(Receptacle) pin 55
346
21
X-016 (Receptacle) pin 12 ECU
295
22
X-016 (Receptacle) pin 27 ECU
296
23
X-016 (Receptacle) pin 43 ECU
297
25
27
265 X-012 (Receptacle) pin 81 ECU 263 X-012 (Receptacle) pin 82 ECU X-016 (Receptacle) pin 4 ECU 294
27
X-016 (Receptacle) pin 4 ECU 294
28 28
SP-241-P-X X-901 pin 7 CHASSIS INTERFACE
5 6 7 8
9 10 12 13
16 17 18 19 20
26
241C 241C
Description FUEL METERING UNIT SUPPLY FUEL METERING UNIT
Color-Size WH - 1.0
OIL PRESSURE SW SIGNAL SEGMENT(CAMSHAFT) SPEED SENSOR SIGNAL RAIL PRESSURE SENSOR GROUND RAIL PRESSURE SENSOR SIGNAL RAIL PRESSURE SENSOR SUPPLY SEGMENT(CAMSHAFT) SPEED SENSOR GROUND CRANKSHAFT SPEED SENSOR SIGNAL PLUS CRANKSHAFT SPEED SENSOR SIGNAL MINUS SEGMENT(CAMSHAFT) SPEED SENSOR SUPLY COOLANT TEMPERATURE SENSOR GROUND COOLANT TEMPERATURE SENSOR SIGNAL FUEL TEMPERATURE SENSOR GROUND FUEL TEMPERATURE SENSOR SIGNAL BOOST PRESSURE SENSOR SUPPLY BOOST PRESSURE SENSOR SIGNAL BOOST PRESURE SENSOR GROUND BOOST PRESSURE TEMPERATURE SENSOR SIGNAL EXHAUST GAS PRESSURE SENSOR SUPPLY (UPSTREAM TURBINE PRESSURE) P3 EXHAUST GAS PRESSURE SENSOR GROUND P3 (UPSTREAM TURBINE PRESSURE) EXHAUST GAS PRESSURE SENSOR SIGNAL P3 (UPSTREAM TURBINE PRESSURE) INLET TURBINE TEMP GND INLET TURBINE TEMP SIGNAL BOOST PRESSURE ACTUATOR 1 BOOST PRESSURE ACTUATOR 1 PLUG K PLUG K
YE - 0.5
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Frame SHEET 11
GY - 1.0
YE - 0.5 BL - 0.5 YE - 0.5 PK - 0.5 BL - 0.5
YE - 0.5 YE - 0.5 PK - 0.5 BL - 0.5
YE - 0.5
BL - 0.5 YE - 0.5 PK - 0.5 YE - 0.5 BK/WH - 0.5 YE - 0.5
PK - 0.5
BK/WH - 0.5
YE - 0.5
BK/WH - 0.5
SHEET 10
YE - 0.5 GY - 1.0
SHEET 11
GY - 1.0 OR - 0.8 OR - 0.8
SHEET 10
Electrical systems - Harnesses and connectors
Pin 29 30 33 34 35 37 38 41 42 43 57 58 60 61
From Wire 321 X-016 (Receptacle) pin 50 ECU 322 X-016 (Receptacle) pin 35 ECU X-016 (Receptacle) pin 9 ECU 318
(Receptacle) pin 53
341
(Receptacle) pin 37
342
(Receptacle) pin 6
1113
Description EGR ACTUATOR MOTOR PLUS EGR ACTUATOR MOTOR MINUS EGR POSITION SENSOR SUPPLY EGR POSITION SENSOR SIGNAL EGR POSITION SENSOR GROUND TVA ACTUATOR MOTOR PLUS TVA ACTUATOR MOTOR MINUS TVA POSITION SENSOR SUPPLY TVA POSITION SENSOR SIGNAL TVA POSITION SENSOR GROUND GLOW PLUG
(Receptacle) pin 1
1112
GLOW PLUG
WH - 2.0
(Receptacle) pin 7
1111
GLOW PLUG
WH - 2.0
(Receptacle) pin 2
1110
GLOW PLUG
WH - 2.0
X-016 (Receptacle) pin 39 ECU X-016 (Receptacle) pin 24 ECU X-016 (Receptacle) pin 49 ECU X-016 (Receptacle) pin 34 ECU X-016 (Receptacle) pin 8 ECU X-016 ECU X-016 ECU X-013 GCU X-013 GCU X-013 GCU X-013 GCU
327 337 338 339 340
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Color-Size WH - 0.8
Frame SHEET 11
GY - 0.8 PK - 0.5 YE - 0.5 BK/WH - 0.5 WH - 0.8 GY - 0.8 PK - 0.5 YE - 0.5 BK/WH - 0.5 WH - 2.0
SHEET 10
Electrical systems - Harnesses and connectors
Wire connectors - Component diagram 02 Connectors X-020 to X-029 and Alphanumeric Connectors SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
X-020 - FOOT THROTTLE SENSOR [ B-004] (84398823) (Receptacle)
84398823
1
84398823 Pin A B C
From X-CCA (Plug) pin 17 CHASSIS/CAB INTERFACE X-CCA (Plug) pin 25 CHASSIS/CAB INTERFACE X-CCA (Plug) pin 29 CHASSIS/CAB INTERFACE
Wire 545 1066 211
Description FOOT THROTTLE SIGNAL FOOT THROTTLE SENSOR GROUND FOOT THROTTLE SENSOR SUPPLY
Color-Size YE - 0.8
Frame SHEET 12
BK/WH - 0.8 PK - 0.8
X-020A - HAND TROTTLE [ SH12: C-2] (84398823) (Receptacle)
84398823
2
84398823 Pin
B
From X-C23 (Receptacle) pin 22 INSTRUMENT CLUSTER SP-200-P-X
1071
C
SP-201-P-X
260
A
Wire 544
Description HAND THROTTLE SIGNAL HAND THROTTLE SENSOR GND HAND THROTTLE SENSOR SUPPLY
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Color-Size YE - 0.8 BK/WH - 0.8 PK - 0.8
Frame SHEET 12
Electrical systems - Harnesses and connectors
X-025 - BATT+ (84401281) (Plug)
84401281
3
84401281 X-C23 - INSTRUMENT CLUSTER [ SH18: B-1] (82028495) (Receptacle)
82028495
4
82028495
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Electrical systems - Harnesses and connectors
Pin
261
Description HYDRAULIC OIL FILTER
Color-Size YE - 0.8
624
KEY START OUTPUT
WH - 0.8
5 6 7
From X-BULKHEAD (Receptacle) pin 23 CAB/CHASSIS INTERCO X-009 (Receptacle) pin 4 IGNITION SWITCH SP-090-P-X SP-089-P-X SP-010-P-X
505 500 301
GN - 0.8 YE - 0.8 OR - 0.8
8
SP-010-P-X
302
9
SP-004-P-X
313
10
132 267
AIR FILTER/ENGINE MALFUNCTION
YE - 0.8
323
SEAT SW CLUSTER INPUT TELEMATICS CRANK DISABLE
YE - 0.8
264
HYDRAULIC OIL TEMP SENDER
YE - 0.8
17
X-009 (Receptacle) pin 1 IGNITION SWITCH X-BULKHEAD (Receptacle) pin 24 CAB/CHASSIS INTERCO X-058 (Plug) pin 4 CAB/SEAT INTERFACE X-BULKHEAD (Receptacle) pin 63 CAB/CHASSIS INTERCO X-BULKHEAD (Receptacle) pin 15 CAB/CHASSIS INTERCO SP-201-P-X
CAN LO CAN HI INSTRUMENT CLUSTER SW POWER INSTRUMENT CLUSTER SW POWER INSTRUMENT CLUSTER UNSWITCHED KEY IGNITION
259
PK - 0.8
19 20
SP-093-P-X X-104 (Receptacle) pin 2
251 314
21 22
SP-006-P-X X-020A (Receptacle) pin A HAND TROTTLE X-BULKHEAD (Receptacle) pin 17 CAB/CHASSIS INTERCO X-BULKHEAD (Receptacle) pin 12 CAB/CHASSIS INTERCO SP-200-P-X
754 544
THROTTLE SENSOR SUPPLY DOOR SW SIGNAL LAP BAR/SEAT BELT CLUSTER INPU PARK BRAKE SW HAND THROTTLE SIGNAL FOOT THROTTLE SIGNAL
X-BULKHEAD (Receptacle) pin 13 CAB/CHASSIS INTERCO X-BULKHEAD (Receptacle) pin 20 CAB/CHASSIS INTERCO X-015 (Plug) pin 2 ACCESSORY BACKFEED DIODE X-BULKHEAD (Receptacle) pin 22 CAB/CHASSIS INTERCO X-BULKHEAD (Receptacle) pin 26 CAB/CHASSIS INTERCO X-316 (Receptacle) pin 2 ECU RELAY/GROUND SP-092-P-X
319
2
3
11
12 13
16
23
24
25 26
28
29
30
32
33 34
Wire
205C
545
OR - 0.8 RD - 0.8 OR - 0.8
YE - 0.8
YE - 0.8 YE - 0.8 YE - 0.8 YE - 0.8 YE - 0.8
234
FUEL LEVEL SENDER
YE - 0.8
1070
THROTTLE SENSOR GND EH AUX POWER
BK/WH - 0.8
258
PARK BRAKE VALVE SIGNAL
WH - 0.8
137
ACCESSORY RELAY SIGNAL
WH - 0.8
303
HYDRAULIC LOADER INTERLOCK SIG
WH - 0.8
622
START RELAY SIGNAL
WH - 0.8
133
MAIN POWER RELAY OR - 0.8 SIGNAL INSTRUMENT CLUSTER BK/WH - 0.8 GND
1011
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Frame SHEET 08
OR - 0.8
SHEET 07
Electrical systems - Harnesses and connectors
Wire connectors - Component diagram 03 Connectors X-030 to X-039 SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
X-030 - CAB/RH LAMP JUMPER INTERFACE [ SH24: C-6] (87694154) (Plug)
87694154
1
87694154 Pin
From
Wire
2 3
SP-015-P-X SP-019-P-X
793 779
4 4
SP-014-P-X SP-173-P-X
926 939
Description RH SIDE LAMP POWER RH CAB TURN SIGNAL POWER RH CAB LAMPS GROUND RH CAB LAMPS/DOOR WIPER MOTOR/
Color-Size VT - 2.0 VT - 1.0 BK - 2.0 BK - 2.0
Frame SHEET 22
SHEET 07
X-031 - CAB/LH LAMP JUMPER INTERFACE [ SH15: D-6] (87694154) (Plug)
87694154
2
87694154 Pin 1 2 4
From SP-016-P-X SP-015-P-X SP-026-P-X
Wire 799 794 927
Description Color-Size LH WORK LAMP POWER VT - 2.0 LH SIDE LAMP POWER VT - 2.0 BK - 2.0 LH CAB LAMPS GND
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Frame SHEET 22 SHEET 15
Electrical systems - Harnesses and connectors
X-033A - LEFT-HAND REAR WORK LAMP [ E-029] (82003123) (Receptacle)
82003123
3
82003123 Pin A B
From SP-079-P-X SP-080-P-X
Wire 728 996
Description 728 996
Color-Size VT - 1.0 BK - 2.0
Frame SHEET 23
X-037 - LEFT-HAND REAR ROAD LAMP [ Z-009] (87688716) (Receptacle)
87688716
4
87688716 Pin A B C
From SP-081-P-X X-201 (Plug) pin 3 REAR LAMP JUMPER SP-080-P-X
Wire 732A 731
732A 731
Description
Color-Size VT - 0.8 VT - 0.8
998
998
BK - 0.8
X-038 - RIGHT-HAND REAR WORK LAMP [ E-028] (82003123) (Receptacle)
82003123
5
82003123
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Frame SHEET 23
Electrical systems - Harnesses and connectors
Pin A B
From SP-079-P-X SP-080-P-X
Wire 729 997
Description 729 997
Color-Size VT - 1.0 BK - 2.0
Frame SHEET 23
X-039 - LEFT-HAND REAR POSITION LAMP (87688716) (Receptacle)
87688716
6
87688716 A B
Pin
From SPLICE SP-081 SPLICE SP-190
732 897
Wire
C
SPLICE SP-170
1091
Description BRAKE LAMP SIGNAL LEFT-HAND REAR POSITION LAMP GROUND
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Color-Size VT - 0.8 VT - 0.8 BK - 0.8
Frame SHEET 23
Electrical systems - Harnesses and connectors
Wire connectors - Component diagram 04 Connectors X-040 to X-049 SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
X-042 - MECHANICAL BACKUP SWITCH (87695584) (Plug)
87695584
1
87695584 Pin
From
Wire
1
SP-039-P-X
893
1 2 2
S-004-P-2 S-004-P-1 X-043 (Plug) pin 1 MECHANICAL BACKUP SWITCH
WIRE499 WIRE679 894
Description Color-Size BACKUP ALARM SWITCH WH - 0.8 POWER WIRE499 WIRE679 BACKUP ALARM SWITCH WH - 0.8 TO SWITCH
X-043 - MECHANICAL BACKUP SWITCH (87695584) (Plug)
87695584
2
87695584
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Frame SHEET 08
SHEET 33
Electrical systems - Harnesses and connectors
Pin 1
1 2 2 2
From X-042 (Plug) pin 2 MECHANICAL BACKUP SWITCH S-006-P-2 S-006-P-1 X-900 pin 17 CROSSOVER BULKHEAD X-900 pin 17 CROSSOVER BULKHEAD
894
Wire
Description Color-Size BACKUP ALARM SWITCH WH - 0.8 TO SWITCH
WIRE658 WIRE500 895
WIRE658 WIRE500 BACKUP ALARM SIGNAL WH - 0.8
895
BACKUP ALARM SIGNAL WH - 0.8
Frame SHEET 33
X-044 - RIGHT-HAND REAR ROAD LAMPS [ Z-005] (87688716) (Receptacle)
87688716
3
87688716 Pin A B C
From SP-081-P-X X-201 (Plug) pin 2 REAR LAMP JUMPER SP-080-P-X
Wire 734A 733
734A 733
Description
Color-Size VT - 0.8 VT - 0.8
999
999
BK - 0.8
Frame SHEET 23
X-049 - RIGHT-HAND REAR POSITION LAMP (87688716) (Receptacle)
87688716
4
87688716 A B
Pin
From SPLICE SP-081 X-201 (Plug) pin 6
Wire 734 718A
C
SPLICE SP-170
1092
Description BRAKE LAMP SIGNAL RIGHT-HAND REAR POSITION LAMP GROUND
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Color-Size VT - 0.8 VT - 0.8 BK - 0.8
Frame SHEET 23
Electrical systems - Harnesses and connectors
Wire connectors - Component diagram 05 Connectors X-050 to X-059 SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
X-058 - CAB/SEAT INTERFACE [ SH7: B-6] (87694154) (Plug)
87694154
1
87694154 Pin
From
Wire
1
SP-058-P-X
756
2 2
SP-172-P-X SP-168-P-X
933 933
3
SP-012-P-X
315
4
X-C23 (Receptacle) pin 12 INSTRUMENT CLUSTER
323
Description SEAT ACCESSORY POWER SEAT ACCESSORY GND SEAT ACCESSORY GROUND SEAT SW UNSWITCHED POWER SEAT SW CLUSTER INPUT
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Color-Size OR - 1.0
Frame SHEET 18
BK - 1.0 BK - 1.0
SHEET 07
RD - 0.8
SHEET 18
YE - 0.8
Electrical systems - Harnesses and connectors
Wire connectors - Component diagram 06 Connectors X-060 to X-069 SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
X-066 - MULTIFUNCTION WATER PUMP (87693821) (Receptacle)
87693821
1
87693821 Pin
From
Wire
A
SP-073-P-X
421
B
SP-982-P-X
988
Description Color-Size MULTIFUNCTION WATER WH - 0.8 PUMP SIGNAL POWER MULTIFUNCTION WATER BK - 0.8 PUMP GROUND
Frame SHEET 28
X-68 - LAMPS (Receptacle)
87696093
2
87696093 Pin PWR B
From SPLICE SP-082 SPLICE SP-083
Wire 738 1003
Description BATTERY GROUND
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Color-Size VY- 0.8 BK - 0.8
Frame SHEET 20
Electrical systems - Harnesses and connectors
Wire connectors - Component diagram 07 Connectors X-070 to X-079 SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
X-074 - HVAC CONDENSER FAN [ Z-011] (87692877) (Plug)
87692877
1
87692877 Pin
From
Wire
A
SP-177-P-X
1084
B
X-314 (Receptacle) pin 2 CHASSIS POWER
237
Description Color-Size HVAC CONDENSER FAN BK - 3.0 GROUND HVAC CONDENSER FAN WH - 3.0 POWER
Frame SHEET 07 SHEET 26
X-075 - HVAC HIGH PRESSURE SWITCH AND COMPRESSOR (87382911) (Plug)
87382911
2
87382911 Pin 1 2 3
From X-076 (Receptacle) pin A X-076 (Receptacle) pin B AC_COMP1-P-1
Wire 833C 834C 841C
Description 833C 834C 841C
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Color-Size WH - 0.8 WH WH
Frame SHEET 26
Electrical systems - Harnesses and connectors
X-076 - HVAC HIGH PRESSURE SWITCH (87692877) (Plug)
87692877
3
87692877 Pin A B
From S-021-P-1 S-021-P-2
Wire WIRE1969 WIRE1968
Description WIRE1969 WIRE1968
Frame
Color-Size SHEET 26
X-077 - SIDE LAMP DIA SOCKET [ J-001] (84398826) (Receptacle)
84398826
4
84398826 Pin 1 2
From SP-027-P-X SP-015-P-X
Wire 1085 238
Description DIA SIDE LAMP GND DIA SIDE LAMP SIGNAL
X-079 - CCV HEATERS [ SH10: A-1] (87694153) (Receptacle)
87694153
5
87694153
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Color-Size BK - 0.8 VT - 0.8
Frame SHEET 20
Electrical systems - Harnesses and connectors
Pin 1 1 2 3 4
From X-901 pin 6 CHASSIS INTERFACE SP-528RH-P-X X-012 (Receptacle) pin 50 ECU X-012 (Receptacle) pin 87 ECU SP-176-P-X
Wire 528E
Description CCV HEATER POWER
528E 600
CCV HEATER POWER OR - 2.0 CCV HEATER CONTROL WH - 0.8
601
CCV HEATER FEEDBACK YE - 0.8
1086
CCV HEATER GROUND
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Color-Size OR - 2.0
BK - 2.0
Frame SHEET 09
SHEET 07
Electrical systems - Harnesses and connectors
Wire connectors - Component diagram 08 Connectors X-080 to X-089 SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
X-080 - LICENSE PLATE LAMP [ E-019] (87697629) (Plug)
87697629
1
87697629 Pin 1
From SP-190x-P-X
Wire 898
Description 898
Frame
Color-Size VT - 0.8
SHEET 23
Color-Size BK - 0.8
SHEET 23
X-081 - LICENSE PLATE LAMP GROUND [ E-019] (Plug)
87697629
2
87697629 Pin 1
From SP-170-P-X
Wire 1095
Description 1095
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Frame
Electrical systems - Harnesses and connectors
Wire connectors - Component diagram 09 Connectors X-090 to X-099 SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
X-097 - CAB/DOME LAMP JUMPER [ E-003] (87695582) (Receptacle)
87695582
1
87695582 Pin
From
Wire
1
SP-011-P-X
151
1 2
SP-021-P-X SP-026-P-X
800 916
Description RADIO/DOME LAMP/HVAC RELAY POW DOME LAMP POWER DOME LAMP GROUND
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Frame
Color-Size OR - 0.8
SHEET 20
OR - 0.8 BK - 0.8
SHEET 15
Electrical systems - Harnesses and connectors
Wire connectors - Component diagram 10 Connectors X-100 to X-109 SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
X-101 - ON ROAD LIGHT CONFIGURATOR [ SH20: A-1] (87679525) (Receptacle)
87679525
1
87679525 Pin 1
From SPLICE SP-024
Wire 702
Description LAMP SELECTOR SWITCH
Color-Size VT - 2.0
Frame SHEET 20
X-101A - ON ROAD LIGHT CONFIGURATOR STAND [ S-029] (87687239) (Plug)
87687239
2
87687239 Pin 1
From X-FUSE1 PIN 11
Wire 710
Description LIGHTS #1 RELAY OUTPUT
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Color-Size VT 2.0
Frame SHEET 20
Electrical systems - Harnesses and connectors
X-101B - X-101B ON ROAD LIGHT CONFIGURATOR [ S-029] (87687239) (Plug)
87687239
3
87687239 Pin 1
From SPLICE SP-057
Wire 711
Description BATTERY
Frame
Color-Size VT - 2.0
SHEET 20
Color-Size RD - 0.8
SHEET 18
X-104 - LAP BAR SWITCH (87382907) (Receptacle)
87382907
4
87382907 Pin
From
Wire
1
SP-012-P-X
316
2
X-C23 (Receptacle) pin 20 INSTRUMENT CLUSTER
314
Description LAP BAR SW UNSWITCHED BATT POW LAP BAR/SEAT BELT CLUSTER INPU
X-107 - MULTIFUNCTION CONNECTOR (87696137) (Plug)
87696137
5
87696137
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YE - 0.8
Frame
Electrical systems - Harnesses and connectors
Pin B C
D
E
F
G
H
J K
L
From SP-072-P-X X-323A (Plug) pin 1 X-323A CHASSIS OPTION/MULTIFUNCT X-323A (Plug) pin 2 X-323A CHASSIS OPTION/MULTIFUNCT X-323A (Plug) pin 3 X-323A CHASSIS OPTION/MULTIFUNCT X-323A (Plug) pin 4 X-323A CHASSIS OPTION/MULTIFUNCT X-323A (Plug) pin 6 X-323A CHASSIS OPTION/MULTIFUNCT X-323A (Plug) pin 5 X-323A CHASSIS OPTION/MULTIFUNCT SP-073-P-X X-323A (Plug) pin 9 X-323A CHASSIS OPTION/MULTIFUNCT X-323A (Plug) pin 10 X-323A CHASSIS OPTION/MULTIFUNCT
Wire 987 419A
987 419A
Description
Color-Size BK - 3.0 LG - 0.8
418A
418A
GY - 0.8
410A
410A
WH - 0.8
411A
411A
TN - 0.8
417A
417A
RD - 0.8
416A
416A
VT - 0.8
422 420A
422 420A
WH - 0.8 OR - 8.0
433
433
YE - 0.8
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Frame SHEET 28
Electrical systems - Harnesses and connectors
Wire connectors - Component diagram 11 Connectors X-110 to X-119 SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
X-111 - CONDENSER RELAY [CAB] [ K-018] (87692860) (Receptacle)
87692860
1
87692860 Pin 30
SP-160-P-X
From 839
Wire
85
SP-168-P-X
1087
87
X-BULKHEAD (Receptacle) pin 4 CAB/CHASSIS INTERCO
237
Description Color-Size CONDENSER RELAY PIN RD - 3.0 30 POWER BK - 0.8 CONDENSER RELAY GROUND HVAC CONDENSER FAN WH - 3.0 POWER
X-113 - FE #2 SWITCH [ SH30: A-5] (87697780) (Receptacle)
87697780
2
87697780
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Frame SHEET 26
SHEET 14
Electrical systems - Harnesses and connectors
Pin D
E
F
From X-BULKHEAD (Receptacle) pin 50 CAB/CHASSIS INTERCO X-BULKHEAD (Receptacle) pin 46 CAB/CHASSIS INTERCO X-BULKHEAD (Receptacle) pin 47 CAB/CHASSIS INTERCO
Wire 425
359
427
Description LH HANDLE MULTIFUNCTION #2 UP LH HANDLE MULTIFUNCTION #2 / # LH HANDLE MULTIFUNCTION #2 DOW
Color-Size VT - 0.8
Frame SHEET 14
OR - 0.8
RD - 0.8
X-114 - LEFT HANDLE INTERCONNECT (87382927) (Plug)
87382927
3
87382927 Pin 1 2 3 4 5 6 7 8 9 10 11 12 13 14
From SPLICE SP-053 X-AUX_EXT PIN 1 X-AUX_RET PIN 1 SPLICE SP-770 SPLICE SP-051 SPLICE SP-780 SPLICE SP-197 SPLICE SP-198 SPLICE SP-062 SPLICE SP-063 SPLICE SP-064 X-323 PIN 2 X-323 PIN 1
Wire 558 554 552 770 768 765 246 857 358 424 426 418 419
Description BATTERY 2ND AUX EXTEND 2ND AUX RETRACT FLASHER MODULE TURN SIGNAL
X-117 - RIGHT HANDLE INTERCONNECT (87382925) (Plug)
87382925
4
87382925
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Color-Size OR - 0.8 WH - 0.8 WH - 0.8 OR - 0.8 VT - 0.8 VT - 0.8 OR - 1.0 WH - 1.0 OR - 0.8 VT - 0.8 RD - 0.8 GY - 0.8 GY - 0.8
Frame SHEET 30
Electrical systems - Harnesses and connectors
Pin 1 2 3 4 5 6 7 8 9 10
From SPLICE SP-062 X-323 PIN 3 X-323 PIN 4 SPLICE SP-063 SPLICE SP-064 SPLICE SP-197 SPLICE SP-198
Wire 352 410 411 412 413 247 858
Description
-
-
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Color-Size OR - 0.8 WH - 0.8 TN - 0.8 VT - 0.8 RD - 0.8 OR - 1.0 WH - 1.0
Frame SHEET 30
Electrical systems - Harnesses and connectors
Wire connectors - Component diagram 15 Connectors X-150 to X-159 SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
X-155B - TURN INDICATOR RIGHT [ E-008] (87697629) (Plug)
87697629
1
87697629 Pin 1
From
Wire 771
SP-019-P-X
Description TURN SIGNAL INDICATOR RH
Frame
Color-Size VT - 0.8
SHEET 21
Color-Size YE - 0.8
SHEET 21
X-156B - TURN INDICATOR LEFT [ E-008] (87697629) (Plug)
87697629
2
87697629 Pin 1
From SP-018-P-X
Wire 772
Description TURN SIGNAL INDICATOR LH
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Frame
Electrical systems - Harnesses and connectors
X-157B - TURN INDICATOR GROUND [ E-008] (87697629) (Plug)
87697629
3
87697629 Pin 1
From SP-025-P-X
Wire 915
Description TURN SIGNAL INDICATOR GROUND
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Color-Size BK - 0.8
Frame SHEET 21
Electrical systems - Harnesses and connectors
Wire connectors - Component diagram 16 Connectors X-160 to X-169 SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
X-161 - MECH BRK PRESS SW # IN (87688695) (Receptacle)
87688695
1
87688695 Pin 1
From SP-053-P-X
Wire 724
Description Color-Size BRAKE LAMP SWITCHES RD - 0.8 POWER
Frame SHEET 05
X-162 - MECH BRK PRESS SW #1 OUT (87688695) (Receptacle)
87688695
2
87688695 Pin 1
From Wire 760 X-163 (Receptacle) pin 1 MECH BRK PRESS SW #2 IN
Description Color-Size BRAKE LAMP SWITCHES VT - 0.8
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Frame SHEET 05
Electrical systems - Harnesses and connectors
X-163 - MECH BRK PRESS SW #2 IN (87688695) (Receptacle)
87688695
3
87688695 Pin 1
From X-162 (Receptacle) pin 1 MECH BRK PRESS SW #1 OUT
Wire 760
Description Color-Size BRAKE LAMP SWITCHES VT - 0.8
Frame SHEET 05
X-164 - MECH BRK PRESS SW #2 OUT (87688695) (Receptacle)
87688695
4
87688695 Pin 1
From X-900 pin 40 CROSSOVER BULKHEAD
Wire 725
Description BRAKE LAMP SIGNAL POWER
Color-Size VT - 0.8
X-166 - MECHANICAL BRAKE SWITCH (87695582) (Receptacle)
87695582
5
87695582
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Frame SHEET 05
Electrical systems - Harnesses and connectors
Pin
From
Wire
1
SP-053-P-X
720
2
X-167 (Receptacle) pin 1 MECHANICAL BRAKE SWITCH
759
Description Color-Size BRAKE LAMP SWITCHES RD - 0.8 POWER BRAKE LAMP SWITCHES OR - 0.8 INTERCONNECT
Frame SHEET 05
X-167 - MECHANICAL BRAKE SWITCH (87695582) (Receptacle)
87695582
6
87695582 Pin 1
From X-166 (Receptacle) pin 2 MECHANICAL BRAKE SWITCH
Wire 759
Description Color-Size BRAKE LAMP SWITCHES OR - 0.8 INTERCONNECT
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Frame SHEET 05
Electrical systems - Harnesses and connectors
Wire connectors - Component diagram 17 Connectors X-170 to X-179 SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
X-178 - BEACON LAMP SOCKET [ E-026] (84398826) (Receptacle)
84398826
1
84398826 Pin
From
Wire
1
SP-027-P-X
928
2
X-301 (Receptacle) pin D BEACON SW
761
Description Color-Size BEACON LAMP SOCKET BK - 0.8 GND VT - 0.8 BEACON SW OUTPUT
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Frame SHEET 15
Electrical systems - Harnesses and connectors
Wire connectors - Component diagram 19 Connectors X-190 to X-199 SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
X-195 - GCU FUSE (84398828) (Plug)
84398828
1
84398828 Pin 1
From SP-212-P-X
Wire 212
Description BATT+
Color-Size OR - 8.0
Frame SHEET 34
X-196 - RIGHT-HAND REAR TURN SIGNAL [ Z-005] (87688716) (Receptacle)
87688716
2
87688716 Pin A C
From X-201 (Plug) pin 12 REAR LAMP JUMPER SP-170-P-X
Wire
Description
736
736
Color-Size VT - 0.8
1002
1002
BK - 0.8
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Frame SHEET 23
Electrical systems - Harnesses and connectors
X-198 - LEFT-HAND REAR TURN SIGNAL [ Z-009] (87688716) (Receptacle)
87688716
3
87688716 Pin C
From SP-170-P-X
Wire 1001
Description 1001
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Color-Size BK - 0.8
Frame SHEET 23
Electrical systems - Harnesses and connectors
Wire connectors - Component diagram 20 Connectors X-200 to X-209 SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
X-201 - REAR LAMP JUMPER (87382927) (Plug)
87382927
1
87382927 Pin 1 2 3 4 5 6 7 8 9 10 12 13 14
From SP-079-P-X X-044 (Receptacle) pin B X-037 (Receptacle) pin B SP-080-P-X SP-190x-P-X X-049 (Plug) pin B SP-081-P-X X-011 (Plug) pin 1 A/C COMPRESSOR X-011 (Plug) pin 2 A/C COMPRESSOR X-011 (Plug) pin 3 A/C COMPRESSOR X-196 (Receptacle) pin A SP-170-P-X X-BKUP-PWR (Receptacle) pin 1
Wire 730 733 731 1000 717B 718A 737 1151
730 733 731 1000 717B 718A 737 1151
Description
Color-Size VT - 2.0 VT - 0.8 VT - 0.8 BK - 0.8 VT - 0.8 VT - 0.8 VT - 0.8 YE - 0.8
909
909
BK - 0.8
1137
1137
OR - 0.8
736 975 896
736 975 896
VT - 0.8 BK - 3.0 WH
Frame SHEET 23
SHEET 34
SHEET 23 SHEET 34
X-205 - DOOR/CHASSIS INTERFACE [ SH34: D-5] (Receptacle) Pin 1 2 2 3 3 4 4
From X-314 (Receptacle) pin 3 CHASSIS POWER X-901 pin 29 CHASSIS INTERFACE X-901 pin 29 CHASSIS INTERFACE X-901 pin 43 CHASSIS INTERFACE X-901 pin 43 CHASSIS INTERFACE SP-177-P-X SP-176-P-X
Wire 706 704 704 703 703 950 950
Description REAR WORK LAMP FUSE OUT TAIL LAMP SPLICE RH TAIL LAMP FUSE OUT TAIL LAMP SPLICE RH TAIL LAMP FUSE OUT TAIL LAMP SPLICE LH TAIL LAMP FUSE OUT TAIL LAMP SPLICE LH TAIL LAMP FUSE OUT REAR LAMP GROUND REAR LAMP GROUND
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Color-Size VT - 3.0
Frame SHEET 23
VT - 0.8 VT - 0.8 VT - 0.8 VT - 0.8 BK - 3.0 BK - 3.0
SHEET 07
Electrical systems - Harnesses and connectors
Pin 5 5 6 10 11 11 12 13 13 14 14
From X-901 pin 26 CHASSIS INTERFACE X-901 pin 26 CHASSIS INTERFACE SP-060-P-X
Wire
SP-133B-P-X X-901 pin 30 CHASSIS INTERFACE X-901 pin 30 CHASSIS INTERFACE SP-052-P-X
133E 766
SP-175-P-X SP-177-P-X X-901 pin 17 CHASSIS INTERFACE X-901 pin 17 CHASSIS INTERFACE
975 975 895
Description LH REAR POSITION LAMP LH REAR POSITION LAMP RH REAR POSITION LAMP WIF SENSOR POWER LH REAR TURN SIGNAL POWER LH REAR TURN SIGNAL POWER RH REAR TURN SIGNAL POWER REAR LAMPS GROUND REAR LAMPS GROUND BACKUP ALARM SIGNAL
895
BACKUP ALARM SIGNAL WH - 0.8
717 717 718
766 763
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Color-Size VT - 0.8
Frame SHEET 23
VT - 0.8 VT - 0.8 OR - 0.8 VT - 0.8
SHEET 10 SHEET 23
VT - 0.8 VT - 0.8 BK - 3.0 BK - 3.0 WH - 0.8
SHEET 07 SHEET 34
Electrical systems - Harnesses and connectors
Wire connectors - Component diagram 22 Connectors X-220 to X-229 SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
X-229 - RIGHT-HAND FRONT ROAD LAMP [ Z-002] (87694152) (Plug)
87694152
1
87694152 Pin 1 2 4 5
From X-233 (Plug) pin D SP-075-P-X SP-075-P-X X-233 (Plug) pin B
Wire 980A 540 539 764A
Description 980A 540 539 764A
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Color-Size BK - 3.0 VT - 0.8 VT - 0.8 VT - 0.8
Frame SHEET 23
Electrical systems - Harnesses and connectors
Wire connectors - Component diagram 23 Connectors X-230 to X-239 SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
X-230 - LEFT-HAND FRONT ROAD LAMP (87697723) (Plug)
87697723
1
87697723 A
Pin
From SPLICE SP-059
712
Wire
B D
SPLICE SP-051 SPLICE SP-174
767 979
Description LOW BEAM AND POSITION LIGHTS TURN SIGNAL GROUND
Color-Size VT - 1.0
Frame SHEET 23
VT - 0.8 BK - 1.0
X-231 - RIGHT-HAND FRONT ROAD LAMP (87697723) (Plug)
87697723
2
87697723 A
Pin
From SPLICE SP-060
713
Wire
B D
SPLICE SP-052 SPLICE SP-175
764 980
Description LOW BEAM AND POSITION LIGHTS TURN SIGNAL GROUND
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Color-Size VT - 1.0 VT - 0.8 BK - 1.0
Frame SHEET 23
Electrical systems - Harnesses and connectors
X-232 - LEFT-HAND FRONT ROAD LAMP (87697723) (Plug)
87697723
3
87697723 Pin A B D
From SP-074-P-X Z-228-PLUG-P-5 Z-228-PLUG-P-1
Wire 712A 767A 979A
Description 712A 767A 979A
Color-Size VT - 2.0 VT - 0.8 BK - 1.0
Frame SHEET 23
X-233 - RIGHT-HAND ROAD LAMP (87697723) (Plug)
87697723
4
87697723 Pin A B D
From SP-075-P-X X-229 (Plug) pin 5 X-229 (Plug) pin 1
Wire 713A 764A 980A
Description 713A 764A 980A
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Color-Size VT - 1.0 VT - 0.8 BK - 3.0
Frame SHEET 23
Electrical systems - Harnesses and connectors
Wire connectors - Component diagram 25 Connectors X-250 to X-259 SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
X-252 - TEMP CONTROL SWITCH [ Z-004] (87714670) (Receptacle)
87714670
1
87714670 Pin
From
Wire
1
SP-091-P-X
823
2
X-BULKHEAD (Receptacle) pin 33 CAB/CHASSIS INTERCO SP-014-P-X
824
3
912
Description HVAC TEMPERATURE SW POWER HVAC TEMPERATURE CONTROL SIGNA
Color-Size PK - 0.8
HVAC TEMPERATURE SW GROUND
BK - 0.8
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Frame SHEET 14
YE - 0.8
SHEET 24
Electrical systems - Harnesses and connectors
Wire connectors - Component diagram 27 Connectors X-270 to X-279 SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
X-270 - BLOWER FAN SWITCH [ S-010] (47726797) (Plug)
47726797
1
47726797 Pin 1 2 3 4 5
From X-275 (Receptacle) pin A SPLICE SP091 X-HVC1 (Receptacle) pin 3 X-HVC1 (Receptacle) pin 4 SPLICE SP-164 X-HVC1 (Receptacle) pin 5
Wire 825 821 828 827 826 850
Description GROUND POWER HVAC FAN LOW HVAC FAN MEDIUM HVAC FAN HIGH
Color-Size OR - 0.8 OR - 3.0 WH - 3.0 WH - 3.0 WH - 3.0 WH - 5.0
Frame SHEET 26
X-271 - WATER VALVE [ SH26: A-6] (87694714) (Receptacle)
87694714
2
87694714 Pin A C D
From X-CCA (Plug) pin 30 CHASSIS/CAB INTERFACE SP-179-P-X X-CCA (Plug) pin 33 CHASSIS/CAB INTERFACE
Wire 822 1013 824
Description Color-Size HVAC WATER VALVE OR - 0.8 POWER WATER VALVE GROUND BK - 0.8 YE - 0.8 HVAC TEMPERATURE CONTROL SIGNAL
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Frame SHEET 14 SHEET 07 SHEET 14
Electrical systems - Harnesses and connectors
X-275 - A/C SWITCH [ SH26: C-1] (84398822) (Receptacle)
84398822
3
84398822 Pin
B
From X-270 pin 1 BLOWER FAN SW SP-014-P-X
913
C
SP-157-P-X
829
A
Wire 825
Description HVAC CLUTCH
Color-Size OR - 0.8
SHEET 26
HVAC COMPRESSOR CLUTCH SW GROU A/C SWITCH OUT
BK - 0.8
SHEET 24
WH - 0.8
SHEET 26
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Frame
Electrical systems - Harnesses and connectors
Wire connectors - Component diagram 30 Connectors X-300 to X-309 SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
X-300 - HYDRAULIC COUPLER SWITCH [ S-009] (84159859) (Receptacle)
84159859
1
84159859 Pin 2
3
9
From X-BULKHEAD (Receptacle) pin 52 CAB/CHASSIS INTERCO X-BULKHEAD (Receptacle) pin 53 CAB/CHASSIS INTERCO SP-026-P-X
Wire
Description HYDRAULIC COUPLER SW IN
Color-Size OR - 0.8
752
HYDRAULIC COUPLER SIGNAL
WH - 0.8
918
HYDRAULIC COUPLER SWITCH INDIC
BK - 0.8
751
Frame SHEET 15
X-301 - BEACON SWITCH [ S-001] (87697780) (Receptacle)
87697780
2
87697780 A
Pin SP-026-P-X
919
D
X-178 (Receptacle) pin 2 BEACON LAMP SOCKET SP-033-P-X
761
Description Color-Size BEACON SW INDICATOR BK - 0.8 GROUND VT - 0.8 BEACON SW OUTPUT
796
BEACON POWER
E
From
Wire
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VT - 0.8
Frame SHEET 15
Electrical systems - Harnesses and connectors
X-302 - HAZARD SWITCH [ S-026] (84159858) (Receptacle)
84159858
3
84159858 Pin
From
Wire
A
SP-018-P-X
776
B
SP-020-P-X
784
C
SP-025-P-X
920
E
SP-020-P-X
785
F
X-302 (Receptacle) pin F HAZARD SW X-302 (Receptacle) pin F HAZARD SW
778
F
778
Description HAZARD SW LH TURN SIGNAL OUTPU LH HAZARD FLASHER POWER IN HAZARD SW INDICATOR GROUND RH HAZARD FLASHER POWER IN HAZARD SW RH TURN SIGNAL OUTPU HAZARD SW RH TURN SIGNAL OUTPU
Color-Size VT - 1.0
Frame SHEET 15
OR - 1.0 BK - 0.8 OR - 0.8 VT - 0.8 VT - 0.8
X-303 - HI FLOW SWITCH [ S-028] (47740181) (Receptacle)
47740181
4
47740181 Pin A C E F
From SPLICE SP-025 X-BULKHEAD (Receptacle) pin 28 SPLICE SP-053 X-BULKHEAD (Receptacle) pin 26
Wire 921 750 753 755
Description HIGH FLOW SW INDICATOR GROUND STANDARD HIGH FLOW SIGNAL HIGH FLOW SW IN HIGH PERFORMANCE HIGH FLOW SIGNAL
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Color-Size BK - 0.8 WH - 0.8 OR - 0.8 WH - 0.8
Frame SHEET 15
Electrical systems - Harnesses and connectors
X-306 - LOADER LOCKOUT SWITCH [ S-005] (47740181) (Receptacle)
47740181
5
47740181 A B C
Pin
From SPLICE SP-025 X-BULKHEAD PIN 11
924 398
Wire
D E
SPLICE SP-139 X-BULKHEAD PIN 18
311 312
Description GROUND LOADER LOCKOUT SWITCH ON BATTERY LOADER LOCKOUT SWITCH OFF
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Color-Size BK - 0.8 YE - 0.8 OR - 0.8 YE - 0.8
Frame SHEET 15
Electrical systems - Harnesses and connectors
Wire connectors - Component diagram 31 Connectors X-010 to X-019 SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
X-310 - 2SPD INDICATOR [ SH21: C-5] (84159859) (Receptacle)
84159859
1
84159859 Pin 7
9
From X-BULKHEAD (Receptacle) pin 32 CAB/CHASSIS INTERCO SP-025-P-X
Wire 565
917
Description 2 SPEED INDICATOR
Color-Size VT - 0.8
SHEET 14
2 SPEED INDICATOR GROUND
BK - 0.8
SHEET 21
X-311 - LIGHT SELECTOR SWITCH [ SH20: D-6] (87697741) (Receptacle)
87697741
2
87697741
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Frame
Electrical systems - Harnesses and connectors
Pin A
B
C
D
From X-BULKHEAD (Receptacle) pin 18 CAB/CHASSIS INTERCO X-BULKHEAD (Receptacle) pin 1 CAB/CHASSIS INTERCO X-BULKHEAD (Receptacle) pin 2 CAB/CHASSIS INTERCO X-BULKHEAD (Receptacle) pin 3 CAB/CHASSIS INTERCO
Wire
Description LAMP SW WORK LAMP SIGNAL
Color-Size VT - 1.0
791
LAMP SW ROAD LAMP SIGNAL
VT - 3.0
792
LAMP SW WORK AND SIDE LAMP SIG
VT - 3.0
123
LAMP SW POWER
OR - 3.0
790
Frame SHEET 14
X-313 - GCU POWER (87706435) (Plug)
87706435
3
87706435 Pin 1
From SP-212-P-X
Wire 212A
Description GCU POWER
Frame
Color-Size OR - 8.0
SHEET 34
SHEET 34
X-314 - CHASSIS POWER [ SH38: B-6] (47525005) (Plug)
47525005
4
47525005 Pin 1 1 2 3 3 4
From X-FUSE2 pin 19 POWER DISTRIBUTION-CHASSIS X-FUSE2 pin 27 POWER DISTRIBUTION-CHASSIS X-CCA (Plug) pin 4 CHASSIS/CAB INTERFACE X-FUSE2 pin 25 POWER DISTRIBUTION-CHASSIS X-FUSE1 pin 37 POWER DISTRIBUTION-CHASSIS SP-212-P-X
Wire 155A
BATT+
Color-Size OR - 3.0
155A
BATT+
OR - 3.0
237
HVAC CONDENSER FAN POWER REAR WORK LAMP FUSE OUT REAR WORK LAMP FUSE OUT GCU POWER
WH - 3.0
706 706 212A
Description
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VT - 3.0
Frame
SHEET 23
VT - 3.0 OR - 8.0
SHEET 34
Electrical systems - Harnesses and connectors
X-315 - REMOTE POWER/GROUND [ SH38: A-6] (Receptacle) Pin 1 2
From SP-212-P-X SP-182-P-X
Wire 212B 1087
Description REMOTE POWER REMOTE GROUND
Color-Size OR - 5.0 BK - 5.0
Frame SHEET 34 SHEET 07
X-316 - ECU RELAY/GROUND [ SH6: D-6] (47525005) (Plug)
47525005
5
47525005 Pin 1 2 3
From SP-527RH-P-X SP-528RH-P-X SP-908-P-X
Wire 527D 528F 908A
Description BATT+ BATT+ ECU GROUND
Color-Size RD - 5.0 OR - 5.0 BK - 5.0
Frame SHEET 09
X-317 - SELF LEVEL SWITCH [ S-013] (47740181) (Receptacle)
47740181
6
47740181 Pin A D E
From SPLICE SP-026 SPLICE SP-058 X-BULKHEAD (Receptacle) pin 31
Wire 922 405 404
Description GROUND SWITCHED BATTERY SELF-LEVEL SWITCH SIGNAL
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Color-Size BK - 0.8 OR - 0.8 WH - 0.8
Frame SHEET 15
Electrical systems - Harnesses and connectors
X-318 - SELF LEVEL VALVE (87695584) (Plug)
87695584
7
87695584 Pin 1 2
From Y-011-P-IN Y-011-P-OUT
Wire WIRE1435 WIRE1436
Description WIRE1435 WIRE1436
Frame
Color-Size SHEET 14 SHEET 07
X-319 - TELEMATIC FUSE [ F-053] (87679438) (Receptacle)
87679438
8
87679438 A
Pin
From X-TELE (Receptacle) pin 12
336
Wire
B
SP-040-P-X
119
Description Color-Size RD - 1.0 TELEMATICS UNSWITCHED BATTERY RD - 1.0 TELEMATICS UNSWITCHED BATTERY
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Frame SHEET 29 SHEET 07
Electrical systems - Harnesses and connectors
Wire connectors - Component diagram 32 Connectors X-320 to X-329 SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
X-323 - CHASSIS OPTION/MULTIFUNCTION INTERCONNECT (87382922) (Receptacle)
87382922
1
87382922 1
Pin
From X-114 (Receptacle) pin 14
419
2
X-114 (Receptacle) pin 13
418
3
X-117 (Receptacle) pin 2
410
4
X-117 (Receptacle) pin 3
411
5
SP-063-P-X
416
6
SP-064-P-X
417
7
SP-174-P-X
982
8
SP-198-P-X
856
9
X-FUSE2 pin 42 POWER DISTRIBUTION-CHASSIS X-FUSE2 pin 62 POWER DISTRIBUTION-CHASSIS
420
9
Wire
420
Description LH MULTIFUNCTION #3 DOWN LH MULTIFUNCTION #3 UP RH MULTIFUNCTION #1 UP RH MULTIFUNCTION #1 DOWN HANDLE MULTIFUNCTION #2 UP HANDLE MULTIFUNCTION #2 DOWN MULTIFUNCTION GROUND AUX ELEC ON/OFF SWITCH SIGNAL MULTIFUNCTION KEY POWER MULTIFUNCTION KEY POWER
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Color-Size GY - 0.8
Frame SHEET 28
GY - 0.8 WH - 0.8 TN - 0.8 VT - 0.8
SHEET 16
RD - 0.8
BK - 5.0
SHEET 07
WH - 1.0
SHEET 28
OR - 3.0 OR - 3.0
Electrical systems - Harnesses and connectors
X-323A - CHASSIS OPTION/MULTIFUNCT (87382923) (Plug)
87382923
2
87382923 Pin 1 2 3 4 5 6 7 8 9 10
From X-107 (Plug) pin C X-107 (Plug) pin D X-107 (Plug) pin E X-107 (Plug) pin F X-107 (Plug) pin H X-107 (Plug) pin G SP-072-P-X SP-073-P-X X-107 (Plug) pin K X-107 (Plug) pin L
Wire 419A 418A 410A 411A 416A 417A 982A 856A 420A 433
Description 419A 418A 410A 411A 416A 417A 982A 856A 420A 433
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Color-Size LG - 0.8 GY - 0.8 WH - 0.8 TN - 0.8 VT - 0.8 RD - 0.8 BK - 5.0 WH - 3.0 OR - 8.0 YE - 0.8
Frame SHEET 28
Electrical systems - Harnesses and connectors
Wire connectors - Component diagram 33 Connectors X-330 to X-339 SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
X-330 - RIGHT SPEAKER [ H-003] (87697629) (Plug)
87697629
1
87697629 Pin 1
From X-335 (Plug) pin 4 RADIO CONNECTOR
Wire 451
Description RIGHT SPEAKER (+)
Frame
Color-Size WH - 0.8
SHEET 27
Color-Size BL - 0.8
SHEET 27
X-331 - RIGHT SPEAKER [ H-003] (87697629) (Plug)
87697629
2
87697629 Pin 1
From X-335 (Plug) pin 5 RADIO CONNECTOR
Wire 450
Description RIGHT SPEAKER (-)
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Frame
Electrical systems - Harnesses and connectors
X-332 - LEFT SPEAKER [ H-004] (87697629) (Plug)
87697629
3
87697629 Pin 1
From X-335 (Plug) pin 6 RADIO CONNECTOR
Wire 453
Description LEFT SPEAKER (+)
Frame
Color-Size WH - 0.8
SHEET 27
Color-Size BL - 0.8
SHEET 27
X-333 - LEFT SPEAKER [ H-004] (87697629) (Plug)
87697629
4
87697629 Pin 1
From X-335 (Plug) pin 2 RADIO CONNECTOR
Wire 452
Description LEFT SPEAKER (-)
X-335 - RADIO CONNECTOR [ SH27: B-5] (84257494) (Plug)
84257494
5
84257494
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Frame
Electrical systems - Harnesses and connectors
Pin 2 4 5 6 7 9
From X-333 (Plug) pin 1 LEFT SPEAKER X-330 (Plug) pin 1 RIGHT SPEAKER X-331 (Plug) pin 1 RIGHT SPEAKER X-332 (Plug) pin 1 LEFT SPEAKER SP-026-P-X SP-021-P-X
452
Wire
Description LEFT SPEAKER (-)
Color-Size BL - 0.8
451
RIGHT SPEAKER (+)
WH - 0.8
450
RIGHT SPEAKER (-)
BL - 0.8
453
LEFT SPEAKER (+)
WH - 0.8
934 130
RADIO GROUND RADIO POWER
BK - 0.8 OR - 0.8
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Frame SHEET 27
SHEET 15 SHEET 27
Electrical systems - Harnesses and connectors
Wire connectors - Component diagram 34 Connectors X-340 to X-349 SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
X-341 - LH REAR STROBE [ E-021] (87694153) (Receptacle)
87694153
1
87694153 Pin 1 2 3
From
Wire 758 1007 683
SP-082-P-X SP-083-P-X SP-084-P-X
Description 758 1007 683
Color-Size VT - 0.8 BK - 0.8 PK - 0.8
Frame SHEET 20
X-342 - RH REAR STROBE [ E-025] (87694153) (Receptacle)
87694153
2
87694153 Pin 1 2 3
From SP-082-P-X SP-083-P-X SP-084-P-X
Wire 757 1006 682
Description 757 1006 682
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Color-Size VT - 0.8 BK - 0.8 PK - 0.8
Frame SHEET 20
Electrical systems - Harnesses and connectors
X-343 - RH FRONT STROBE [ E-024] (87694153) (Receptacle)
87694153
3
87694153 Pin 1 2 3
From
Wire 739 1004 680
SP-082-P-X SP-083-P-X SP-084-P-X
Description 739 1004 680
Color-Size VT - 0.8 BK - 0.8 PK - 0.8
Frame SHEET 20
X-344 - LH FRONT STROBE [ E-023] (87694153) (Receptacle)
87694153
4
87694153 Pin 1 2 3
From SP-082-P-X SP-083-P-X SP-084-P-X
Wire 740 1005 681
Description 740 1005 681
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Color-Size VT - 0.8 BK - 0.8 PK - 0.8
Frame SHEET 20
Electrical systems - Harnesses and connectors
Wire connectors - Component diagram 36 Connectors X-360 to X-369 SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
X-365 - NH PARK BRAKE SW [ S-007] (84159859) (Receptacle)
84159859
1
84159859 Pin
From
Wire
2
SP-010-P-X
305
3
SP-006-P-X
306
Description RH CONSOLE PARK BRAKE SW RH CONSOLE PARK BRAKE SW OUT
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Color-Size YE - 0.8 YE - 0.8
Frame SHEET 15
Electrical systems - Harnesses and connectors
Wire connectors - Component diagram 40 Connectors X-400 to X-409 SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
X-402 - RH HANDLE INTERCONNECT PARK BRAK [ Z-013] (87382922) (Receptacle)
87382922
1
87382922 Pin
From
Wire
1
SP-037-P-X
324
2
X-CCA (Plug) pin 39 CHASSIS/CAB INTERFACE SP-039-P-X
307
4
5 8
9 10
832
X-RDCTRL (Receptacle) pin 831 1 X-430 (Receptacle) pin 6 EH 699 AUX PWM CONTROLLER X-430 (Receptacle) pin 7 EH 1010 AUX PWM CONTROLLER X-430 (Receptacle) pin 8 EH 331 AUX PWM CONTROLLER
Description RH GRIP PARK BRAKE SWITCH POWER RH GRIP PARK BRAKE SW OUTPUT RIDE CONTROL VALVE SOLENOID SWITCH POWER RIDE CONTROL VALVE SOLENOID SIGNAL EH AUX PROPORTIONAL SWITCH SIGNAL OUTPUT EH AUX PROPORTIONAL SWITCH GROUND EH AUX PROPORTIONAL SWITCH REFERENCE VOLTAGE
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Color-Size OR - 0.8
Frame SHEET 14
YE - 0.8 OR - 0.8
SHEET 08
WH - 0.8
SHEET 17
PK - 0.8
BK/WH - 0.8 OR - 0.8
Electrical systems - Harnesses and connectors
X-405 - LH HANDLE INTERCONNECT HORN/TWO [ SH16: B-6] (87697723) (Plug)
87697723
2
87697723 Pin
From
Wire
A
SP-039-P-X
891
B
X-HORN-PWR (Plug) pin 1 HORN POWER SP-035-P-X
892
D
563
Description LH GRIP HORN / 2 SSPEED SWITCH POWER HORN POWER SIGNAL
Color-Size OR - 0.8
SHEET 08
WH - 0.8
SHEET 16
2 SPEED SWITCH OUTPUT SIGNAL
WH - 0.8
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Frame
Electrical systems - Harnesses and connectors
Wire connectors - Component diagram 41 Connectors X-410 to X-419 SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
X-410 - LOADER LOCK/CHASSIS HARNESS INTERCONNECT [ SH13: A-5] (87695584) (Plug)
87695584
1
87695584 Pin 1 2
From X-CCA (Plug) pin 44 CHASSIS/CAB INTERFACE X-412 (Receptacle) pin 2
Wire 311 969
Description LOADER LOCKOUT SWITCH IN HYDRAULIC LOADER INTERLOCK GROUND
Color-Size WH - 0.8
Frame SHEET 13
BK - 0.8
X-411 - FLASHER MODULE [ SH22: D-2] (87692860) (Receptacle)
87692860
2
87692860 Pin 30 30 85 85 87A 87A
From X-FUSE2 pin 16 POWER DISTRIBUTION-CHASSIS X-901 pin 5 CHASSIS INTERFACE SP-174-P-X SP-176-P-X SP-050-P-X X-901 pin 1 CHASSIS INTERFACE
Wire 156 156 981 981 769 769
Description FLASHER POWER
Color-Size RD - 2.0
FLASHER/BRAKE POWER FLASHER GROUND FLASHER GROUND FLASHER MODULE OUTPUT POWER FLASHER MODULE OUTPUT POWER
RD - 2.0
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BK - 0.8 BK - 0.8 OR - 2.0 OR - 2.0
Frame SHEET 07
Electrical systems - Harnesses and connectors
X-412 - PORT LOCK VALVE (Receptacle) Pin 1 2
From X-CCA (Plug) pin 45 CHASSIS/CAB INTERFACE X-410 (Plug) pin 2 LOADER LOCK/CHASSIS HARNESS INTE
Wire 312 969
Description LOADER LOCK SWITCH OUT HYDRAULIC LOADER INTERLOCK GROUND
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Color-Size WH - 0.8 BK - 0.8
Frame SHEET 13
Electrical systems - Harnesses and connectors
Wire connectors - Component diagram 43 Connectors X-430 to X-439 SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
X-430 - EH AUX PWM CONTROLLER [ SH19: D-1] (87700325) (Receptacle)
87700325
1
87700325 Pin
2
From X-CCA (Plug) pin 13 CHASSIS/CAB INTERFACE SP-047-P-X
901
3
X-433 (Receptacle) pin 1
889
4
X-432 (Receptacle) pin 1
890
5
SP-088-P-X
1009
6
X-402 (Receptacle) pin 8 RH 699 HANDLE INTERCONNECT PARK BRAK X-402 (Receptacle) pin 9 RH 1010 HANDLE INTERCONNECT PARK BRAK X-402 (Receptacle) pin 10 RH 331 HANDLE INTERCONNECT PARK BRAK
1
7
8
Wire 319
Description EH AUX POWER
Color-Size OR - 0.8
SHEET 14
CLEAN ENGINE GROUND EH AUX RETRACT SIGNAL EH AUX RETRACT SIGNAL EH AUX VALVE SIGNAL RETURN EH AUX PROPORTIONAL SWITCH SIGNAL OUTPUT EH AUX PROPORTIONAL SWITCH GROUND
BK/WH - 0.8
SHEET 07
WH - 0.8
SHEET 14
WH - 0.8 BL - 0.8 PK - 0.8
BK/WH - 0.8
EH AUX PROPORTIONAL OR - 0.8 SWITCH REFERENCE VOLTAGE
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Frame
Electrical systems - Harnesses and connectors
X-432 - PROPORTIONAL AUX VALVE RETRACT (87695584) (Plug)
87695584
2
87695584 Pin 1 2
From Y-002-P-OUT Y-002-P-IN
Wire WIRE1575 WIRE1574
Description WIRE1575 WIRE1574
Frame
Color-Size SHEET 19
X-433 - PROPORTIONAL AUX VALVE EXTEND (87695584) (Plug)
87695584
3
87695584 Pin 1 2
From Y-003-P-OUT Y-003-P-IN
Wire WIRE1577 WIRE1576
Description WIRE1577 WIRE1576
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Frame
Color-Size SHEET 19
Electrical systems - Harnesses and connectors
Wire connectors - Component diagram 50 Connectors X-500 to X-509 SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
X-502 - DOOR WIPER MOTOR [ M-001] (87697724) (Receptacle)
87697724
1
87697724 Pin
From
Wire
A
SP-022-P-X
227
B
SP-014-P-X
929
C
SP-023-P-X
231
D
SP-093-P-X
220
Description DOOR WIPER MOTOR SIGNAL DOOR WIPER MOTOR GROUND DOOR WIPER MOTOR PARK DOOR SW BYPASS
Color-Size WH - 0.8
Frame SHEET 24
BK - 0.8 OR - 0.8 YE - 0.8
X-502A - REAR WINDOW WIPER MOTOR [ M-002] (87693712) (Receptacle)
87693712
2
87693712 Pin
From
Wire
A
SP-022-P-X
228
B
SP-027-P-X
930
C
SP-023-P-X
232
Description REAR WINDOW WIPER MOTOR SIGNAL REAR WINDOW WIPER MOTOR GND REAR WINDOW WIPER MOTOR PARK
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Color-Size WH - 0.8 BK - 0.8 OR - 0.8
Frame SHEET 24
Electrical systems - Harnesses and connectors
X-503 - WIPER/WASHER SW [ SH24: B-1] (87716755) (Receptacle)
87716755
3
87716755 Pin
From
Wire
1
SP-029-P-X
931
1
SP-014-P-X
931
2
SP-022-P-X
225
3
SP-023-P-X
229
5 6
X-506 (Receptacle) pin 2 SP-023-P-X
224 230
7
SP-022-P-X
226
8
SP-029-P-X
932
8
SP-014-P-X
932
Description WIPER/WASHER SW GND WIPER/WASHER SW GROUND WIPER MOTOR AND INDICATOR LAMP WIPER/WASHER SW MOTOR POWER IN WASHER PUMP SIGNAL WIPER/WASHER SW PUMP POWER IN WIPER/WASHER LAMP SIGNAL WIPER/WASHER SW INDICATOR GND WIPER/WASHER SW INDICATOR GROU
Color-Size BK - 0.8
Frame SHEET 07
BK - 0.8 WH - 0.8
SHEET 24
OR - 0.8 WH - 0.8 OR - 0.8 VT - 0.8 BK - 0.8
SHEET 07
BK - 0.8
X-505 - DOOR SWITCH (87382907) (Plug)
87382907
4
87382907 Pin 1 2
From S-025-P-1 S-025-P-2
Wire WIRE1845 WIRE1844
Description WIRE1845 WIRE1844
Frame
Color-Size SHEET 24 SHEET 07
X-506 - FRONT DOOR WASHER PUMP (Receptacle) Pin 1 2
From SP-027-P-X X-503 (Receptacle) pin 5 WIPER/WASHER SW
Wire 970 224
Description Color-Size BK - 0.8 WASHER PUMP GND WASHER PUMP SIGNAL WH - 0.8
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Frame SHEET 24
Electrical systems - Harnesses and connectors
X-508 - AIR FILTER RESTRICTION SWITCH (87691371) (Plug)
87691371
5
87691371 Pin 1 2
From S-037-P-2 S-037-P-1
Wire WIRE838 WIRE839
Description WIRE838 WIRE839
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Frame
Color-Size SHEET 08
Electrical systems - Harnesses and connectors
Wire connectors - Component diagram 90 Connectors X-900 to X-909 SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
X-900 - CROSSOVER BULKHEAD LARGE MACHINES [ SH39: C-6] (47749797) (Receptacle)
47749797
1
47749797 Pin 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
From X-FUSE1 (Receptacle) pin 15 SPLICE SP-528 X-FUSE1 (Receptacle) pin 25 X-CN3B (Receptacle) pin 18 SPLICE SP-504A X-ECC PIN 53 X-FUSE2 PIN 41 X-ECC PIN 13 X-ECC PIN 59
Wire 110 528E 719 895 504C 248 161 780 833
24
X-ECC PIN 65
834
25 26
X-205 PIN 5
717
27 28 29 30
X-FUSE1 PIN 17 SPLICE SP-051
704 766A
31 32
SPLICE SP-503A FUSE F-033
503C 241C
Description ECU FUSE F-035 BATTERY RIGHT BOOM BACKUP ALARM SIGNAL CAN BUS K-LINE CRANK ENABLE 2 HAZARDS HVAC HIGH PRESSURE SWITCH HVAC HIGH PRESSURE SWITCH LEFT-HAND REAR POSITION LAMP FUSE F-010 LEFT-HAND TURN SIGNAL CAN BUS ENGINE SENSORS 48068130 29/01/2018
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Color-Size OR - 2.0 OR - 2.0 VT - 1.0 WH - 0.8 GN - 0.8 YE - 0.8 YE -0.8 VT - 0.8 WH - 0.8
Frame
SHEET 33 SHEET 33
SHEET 33
SHEET SHEET SHEET SHEET
33 33 33 33
SHEET 33 SHEET 37
WH - 0.8
SHEET 33
VT - 0.8
SHEET 33
VT - 0.8 VT - 0.8
SHEET 33 SHEET 33
YE - 0.8 OR - 0.8
SHEET 33 SHEET 33
Electrical systems - Harnesses and connectors
Pin 33 34 35 36 37 38 39
From X-FUSE2 PIN 54 X-ECC PIN 84 X-ECC PIN 14
121 626 841
Wire
40 41 42 43 44 45
SPLICE SP-150 SPLICE SP-186 X-ECC PIN 70 X-FUSE1 PIN 29 X-ECC PIN 82
721 133B 234 703 267
46 47
X-012 PIN 28 -
112 -
Description ENGINE RELAY A START SIGNAL AC COMPRESSOR RELAY BRAKE LAMP SWITCHED BATTERY FUEL LEVEL SENDER LEFT-HAND TAIL LIGHTS AIR FILTER RESTRICTION ECU MAIN RELAY -
Color-Size YE - 0.8 WH - 0.8 WH - 0.8
Frame SHEET 33
SHEET 33
SHEET 33
VT - 0.8 OR - 0.8 RD - 0.8 VT - 0.8 YE - 0.8
SHEET SHEET SHEET SHEET
BL - 0.8 -
SHEET 33
33 37 33 33
SHEET 33
X-900 - CROSSOVER BULKHEAD MEDIUM MACHINES [ SH39: C-6] (47749797) (Receptacle)
47749797
2
47749797 1 2 3 4 5
Pin
From X-ECC PIN 9 X-FUSE1 (Receptacle) pin 15 X-FUSE1 PIN 40
769 110 156
Wire
6 7
SPLICE SP-241
241C
8 9 10 11 12 13 14
X-014 PIN 3 X-014 PIN 1 X-014 PIN 5 X-014 PIN 2 X-014 PIN 6 X-FUSE1 (Receptacle) pin 25 X-012 PIN 79
242 245 249 252 253 719 270
15
X-012 PIN 80
271
16 17 18 19 20 21 22 23
X-CN3B (Receptacle) pin 18 SPLICE SP-504A X-ECC PIN 53 X-FUSE2 PIN 41 X-ECC PIN 13 X-ECC PIN 59
895 504C 248 161 780 833
24
X-ECC PIN 65
834
Description BATTERY ECU FUSE F-035 FUSE F-030 FLASHER/BRAKE FUSE F-033 ENGINE SENSORS LAMBDA SENSOR LAMBDA SENSOR LAMBDA SENSOR LAMBDA SENSOR LAMBDA SENSOR RIGHT BOOM EXHAUST GAS TEMPERATURE GROUND 1 EXHAUST GAS TEMPERATURE SIGNAL 1 BACKUP ALARM SIGNAL CAN BUS K-LINE CRANK ENABLE 2 HAZARDS HVAC HIGH PRESSURE SWITCH HVAC HIGH PRESSURE SWITCH
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Color-Size OR - 2.0 OR - 2.0 RD - 2.0
Frame SHEET 35
SHEET 35 SHEET 35
OR - 0.8
SHEET 35
YE - 0.8 YE - 0.5 YE - 0.5 BK - 0.5 PK - 0.5 VT - 1.0 BK/WH - 0.5
SHEET SHEET SHEET SHEET SHEET SHEET SHEET
YE - 0.5
SHEET 35
WH - 0.8 GN - 0.8 YE - 0.8 YE -0.8 VT - 0.8 WH - 0.8 WH - 0.8
SHEET SHEET SHEET SHEET
35 35 35 35 35 35 35
35 35 35 35
SHEET 35 SHEET 35 SHEET 35
Electrical systems - Harnesses and connectors
Pin 25 26
X-205 PIN 5
From 717
Wire
27 28 29 30
X-FUSE1 PIN 17 SPLICE SP-051
704 766A
31 32 33 34 35 36 37 38 39
SPLICE SP-503A X-FUSE2 PIN 54 X-ECC PIN 84 X-ECC PIN 14
503C 121 626 841
40 41 42 43 44 45
SPLICE SP-150 SPLICE SP-186 X-ECC PIN 70 X-FUSE1 PIN 29 X-ECC PIN 82
721 133B 234 703 267
46 47
X-012 PIN 28 -
112 -
Description LEFT-HAND REAR POSITION LAMP FUSE F-010 LEFT-HAND TURN SIGNAL CAN BUS ENGINE RELAY A START SIGNAL AC COMPRESSOR RELAY BRAKE LAMP SWITCHED BATTERY FUEL LEVEL SENDER LEFT-HAND TAIL LIGHTS AIR FILTER RESTRICTION ECU MAIN RELAY -
Frame
Color-Size VT - 0.8
SHEET 35
VT - 0.8 VT - 0.8
SHEET 35 SHEET 35
YE - 0.8 YE - 0.8 WH - 0.8 WH - 0.8 VT - 0.8 OR - 0.8 RD - 0.8 VT - 0.8 YE - 0.8
SHEET 35 SHEET 35
SHEET 35
SHEET 35 SHEET SHEET SHEET SHEET
35 35 35 35
SHEET 35
BL - 0.8 -
X-901 - CHASSIS INTERFACE LARGE MACHINES [ SH39: C-1] (47712777) (Plug)
47712777
3
47712777 Pin 1 2 3 4 5 6 7 8 9 10 11 12 13
From X-012 PIN 1 X-079 PIN 1 SPLICE SP-060
Wire 110 528E 719
14 15 16 17 18 19 20 21
X-205 X-012 X-012 X-012 -
895 504C 248 161 -
PIN PIN PIN PIN
14 25 68 53
Description ECU BATTERY VOLTAGE BATTERY RIGHT-HAND FRONT ROAD LAMP BACKUP ALARM SIGNAL CAN LOW EGR ECU K-LINE CRANK ENABLE 2 -
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Color-Size OR - 2.0 OR - 2.0 VT - 1.0 WH - 0.8 GN - 0.8 YE - 0.8 YE -0.8 -
Frame
SHEET 33 SHEET 33
SHEET 33
SHEET SHEET SHEET SHEET
33 33 33 33
Electrical systems - Harnesses and connectors
Pin 22
From SPLICE SP-052
780
Wire
23
X-011 PIN 1
833
24
X-011 PIN 2
834
25 26
X-205 PIN 5
717
27 28 29
X-205 PIN 2
704
30
X-205 PIN 11
766A
31 32
X-012 PIN 24 SPLICE SP-241
503C 241C
33 34 35 36 37 38 39
X-012 PIN 27 X-012 PIN 8 X-011 PIN 3
121 626 841
40 41
X-205 PIN 7 SPLICE SP-133B
721 133B
42 43
X-014 PIN B X-205 PIN 3
234 703
44 45
X-508 PIN 1
267
46 47
X-012 PIN 25 -
112 -
Description RIGHT-HAND ROAD LAMP HVAC HIGH PRESSURE SWITCH HVAC HIGH PRESSURE SWITCH LEFT-HAND REAR POSITION LAMP RIGHT-HAND TAIL LAMP POWER LEFT-HAND TURN SIGNAL POWER CAN HIGH LAMBDA SENSOR POWER CRANK ENABLE 1 START SIGNAL AC COMPRESSOR RELAY BRAKE LAMP POWER ECU SWITCHED BATTERY FUEL LEVEL SENDER LEFT-HAND TAIL LIGHTS POWER AIR FILTER RESTRICTION ECU MAIN RELAY -
Frame
Color-Size VT - 0.8
SHEET 33
WH - 0.8
SHEET 33
WH - 0.8
SHEET 33
VT - 0.8
SHEET 33
VT - 0.8
SHEET 33
VT - 0.8
SHEET 33
YE - 0.8 OR - 0.8
SHEET 33 SHEET 33
YE - 0.8 WH - 0.8 WH - 0.8
SHEET 33
VT - 0.8 OR - 0.8
SHEET 33 SHEET 33
RD - 0.8 VT - 0.8
SHEET 33 SHEET 33
YE - 0.8
SHEET 33
BL - 0.8 -
SHEET 33
SHEET 33
SHEET 33
X-901 - CHASSIS INTERFACE MEDIUM MACHINES [ SH39: C-1] (47712777) (Plug)
47712777
4
47712777 1 2 3 4 5 6 7
Pin
From X-411 PIN 87A X-012 PIN 1 X-411 PIN 30 X-017 PIN 28
Wire 769 110 156 241C
8
X-012 PIN 7
242
9
X-012 PIN 64
245
Description FLASHER MODULE ECU BATTERY VOLTAGE FLASHER MODULE BATTERY TO THE ELECTRIC VALVE LAMBDA SENSOR SENSOR HEATING LAMBDA SENSOR CURRENT PUMP
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Color-Size OR - 2.0 OR - 2.0 RD - 2.0 OR - 0.8
Frame SHEET 35
SHEET 35 SHEET 35 SHEET 35
YE - 0.8
SHEET 35
YE - 0.5
SHEET 35
Electrical systems - Harnesses and connectors
Pin 10
From X-012 PIN 86
249
Wire
11
X-012 PIN 85
252
12
X-012 PIN 63
253
13
SPLICE SP-060
719
14
X-012 PIN 79
270
15
X-012 PIN 80
271
16 17 18 19 20 21 22
X-205 PIN 14 X-012 PIN 25 X-012 PIN 68 X-012 PIN 53 SPLICE SP-052
895 504C 248 161 780
23
X-011 PIN 1
833
24
X-011 PIN 2
834
25 26
X-205 PIN 5
717
27 28 29
X-205 PIN 2
704
30
X-205 PIN 11
766A
31 32 33 34 35 36 37 38 39 40
X-012 PIN 24 X-012 PIN 27 X-012 PIN 8 X-011 PIN 3 X-205 PIN 7
503C 121 626 841 721
41 42 43
SPLICE SP-133B X-014 PIN B X-205 PIN 3
133B 234 703
44 45
X-508 PIN 1
267
46 47
-
-
Description LAMBDA SENSOR CURRENT ADJUST LAMBDA SENSOR VIRTUAL GROUND LAMBDA SENSOR VOLTAGE RIGHT-HAND FRONT ROAD LAMP EXHAUST GAS TEMPERATURE GROUND 1 EXHAUST GAS TEMPERATURE SIGNAL 1 BACKUP ALARM SIGNAL CAN LOW EGR ECU K-LINE CRANK ENABLE 2 RIGHT-HAND FRONT ROAD LAMP HVAC HIGH PRESSURE SWITCH HVAC HIGH PRESSURE SWITCH LEFT-HAND REAR POSITION LAMP RIGHT-HAND LAMP POWER LEFT-HAND TURN SIGNAL POWER CAN HIGH CRANK ENABLE 1 START SIGNAL AC COMPRESSOR BRAKE LAMP SIGNAL POWER ECU SWITCHED POWER FUEL LEVEL SENDER LEFT-HAND TAIL LAMP POWER AIR FILTER RESTRICTION -
Frame
Color-Size YE - 0.5
SHEET 35
BK - 0.5
SHEET 35
PK - 0.5
SHEET 35
VT - 1.0
SHEET 35
BK/WH - 0.5
SHEET 35
YE - 0.5
SHEET 35
WH - 0.8 GN - 0.8 YE - 0.8 YE -0.8 VT - 0.8
SHEET SHEET SHEET SHEET
WH - 0.8
SHEET 35
WH - 0.8
SHEET 35
VT - 0.8
SHEET 35
VT - 0.8
SHEET 35
VT - 0.8
SHEET 35
YE - 0.8 YE - 0.8 WH - 0.8 WH - 0.8 VT - 0.8
SHEET 35
SHEET 35 SHEET 35
OR - 0.8 RD - 0.8 VT - 0.8
SHEET 35 SHEET 35 SHEET 35
YE - 0.8
SHEET 35
35 35 35 35
SHEET 35
SHEET 35
SHEET 35
-
X-904 - BOOM INTERLOCK SWITCH [ SH19: B-6] (Receptacle) A
Pin
From X-905 (Receptacle) pin 1
1103
Wire
B
SP-037-P-X
1102
Description BOOM LOCK VALVE DRIVE BOOM LOCK VALVE POWER
Frame
Color-Size WH - 0.8
SHEET 19
OR - 0.8
SHEET 14
Color-Size WH - 0.8
SHEET 19
BK - 0.8
SHEET 07
X-905 - BOOM LOCK VALVE [ SH19: B-1] (Receptacle) 1
Pin
From X-904 (Receptacle) pin A
1103
Wire
2
SP-179-P-X
1104
Description BOOM LOCK VALVE DRIVE BOOM LOCK VALVE GROUND
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Frame
Electrical systems - Harnesses and connectors
Wire connectors - Component diagram 99 Connectors X-9000 to X-9009 SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
X-9000 - FUEL FILTER (84529035) (Receptacle)
84529035
1
84529035 X-9001 - FUEL FILTER (Receptacle) Pin 1 2
From X-9000 (Plug) pin 1 X-9000 X-9000 (Plug) pin 2 X-9000
Wire 1200 1201
Description FUEL FILTER SIGNAL FUEL FILTER GROUND
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Color-Size YE - 0.8 BK - 0.8
Frame SHEET 32
Electrical systems - Harnesses and connectors
Fuse and relay box Relay - Overview
1Z0O2004112131
1
The relay is an electromagnetic switch that uses a small amount of current to switch a larger amount on and off. Relays are electrically operated switches. They are used to switch a circuit on/off in similar way to a manual switch. When the operator closes a switch, current flows through the relay's control circuit. In this circuit there are windings surrounding an iron core which is fixed in place. Current turns the iron core into an electromagnet. The core then attracts an arm which has a contact point on it. When the point on the arm contacts the stationary point, current flows through the power circuit. Two circuits are connected to the relay: • A work circuit, which is switched on/off by the relay, and provides the supply for the equipment to be operated, i.e., bulbs, solenoids, etc.; • A control circuit, switched on/off by switches, used to operate the relay. The part of the relay which is connected to the control circuit consists of the winding of an electro-magnet. When the control circuit is switched off, the contacts are kept apart by a return spring. When the control circuit is switched on, a current flows through the coil and a magnetic force is produced. This force, which is stronger than the spring pressure, pulls the contacts of the relay together, causing the work circuit to operate.
1Z0O2004112132
2
A switch-relay system has two main advantages over a simple switch: • The current that flows through the switch is not the same as all the current requested by the equipment to be operated, but usually by a smaller current: this allows the usage of smaller and less expensive switches; • The distance from the supply, to the equipment, can be made as short as possible to minimize voltage drop.
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Electrical systems - Harnesses and connectors
50004701
3
On the relay cover there are 4 or 5 terminal markings: • 3 or 30: input terminal direct from battery positive, normally live. • 2 or 85: winding output terminal, usually to ground. • 1 or 86: winding input terminal. • 4 or 87: output terminal for normally closed contact. • 5 or 87a: output terminal for normally open contact.
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Electrical systems - Harnesses and connectors
Fuse and relay box Fuse - Overview A fuse contains a thin wire, which either melts or vaporizes when too much current flows through it. The resulting open in the circuit stops current flow. The fuse's current rating is normally stamped on the fuse. The purpose of a fuse is to open a circuit when current flow exceeds a certain amount, which is determined by the rating of the fuse. Opening a circuit under high current conditions can save downstream electronic components from damage and prevents overheating, which could cause a fire. An overload can occur as the result of a short circuit or short to ground circuit condition or by connecting equipment that requires current greater than the circuit is designed to carry. There are several types of fuses, but they all consist of a metal conductor which is capable of carrying a specified amount of current. If the specified amount of current is exceeded, the metal conductor will overheat. The overheating causes the metal conductor to melt and break, creating an open circuit condition. NOTE: The following is for illustration purposes only. See your Operatorâ&#x20AC;&#x2122;s Manual for specific Fuse Block location and layout.
50014700
1
The rating of the fuse relates to the current, in amperes, that the fuse can carry continuously. If a fuse fails, replace the fuse with same type and amp rating. Once replaced, if it fails again, the cause for the over-current condition must be investigated and corrected. There are a number of methods that can be used to verify the condition of a fuse. The fuse can be removed from the fuse and relay panel socket and visually inspected to determine if the link has been melted. A continuity test can be performed across the fuse terminals, while the fuse is removed from the fuse and relay panel, if it is not visually apparent that the fuse link is blown. If one of the fuse terminals is connected to battery or switched battery power, a voltage test to ground can be performed from one of the exposed terminals (1) and then the other (1), the battery or switched battery voltage should be seen on both tests (terminals). If battery or switched battery power is NOT connected to either fuse terminal or the power has been disconnected and the fuse is NOT part of a continuous electrical circuit then the fuse can be continuity tested in place in the fuse and relay panel, by checking continuity across the fuse on the two exposed terminals (1). NOTICE: If not certain of exact circuit conditions, performing continuity tests on fuses should be done with the fuse removed from the fuse and relay panel. Performing the test with the fuse still installed in its socket in the fuse and relay panel could provide false indications of the actual fuse condition.
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Electrical systems - Harnesses and connectors
Fuse and relay box - Component localization NOTE: The following information applies to all machines with an access panel directly beneath the operator seat on the back of the foot plate. Machines that have the fuse panel underneath the cup holder see Fuse and relay box Component localization (55.100).
SR210, SR240, SV280, TR270, TR310 and TV370 with mechanical controls
47842042A
1
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Electrical systems - Harnesses and connectors
SR210, SR240, SV280, TR270, TR310, and TV370 with Electro-Hydraulic (EH) controls
47833186A
2
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Electrical systems - Harnesses and connectors
Fuse and relays in the cab area NOTE: Not applicable to models SR210, SR240, SV280, TR270, TR310, and TV370 with Electro-Hydraulic (EH) controls. 1. Remove all the screws (1) on the fuse panel (2). 2. Remove the fuse panel (2) to expose the cab area fuses and relays (3) 3. The fuse and relay identification decal is on the backside of the fuse panel. 4. Press both locking tabs (4) to release and remove the cover. NOTICE: Only replace fuses or relays with the same type and amperage rating. RAIL15SSL0101BA
3
RAIL15SSL0100BA
4
RAIL15SSL0105AA
5
5. If necessary remove and replace fuses or relays. 6. Install the fuse cover. Align locking tabs and push down until the cover locks in place. 7. Align and secure the fuse panel cover to the machine.
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Electrical systems - Harnesses and connectors
Fuse and relays in the cab area NOTE: Only applicable for models SR210, SR240, SV280, TR270, TR310, and TV370 with Electro-Hydraulic (EH) controls. 1. Remove all the screws (1) on the fuse panel (2). 2. Remove the fuse panel (2) to expose the cab area fuses and relays (3) 3. The fuse and relay identification decal is on the backside of the fuse panel. 4. Press both locking tabs (4) to release and remove the cover. NOTICE: Only replace fuses or relays with the same type and amperage rating.
RAIL14SSL0717AA
6
RAIL14SSL0715AA
7
RAIL14SSL0715AA
8
5. If necessary remove and replace fuses or relays. 6. Install the fuse cover. Align locking tabs and push down until the cover locks in place. 7. Align and secure the fuse panel cover to the machine.
Engine Control Unit (ECU) and relays in the engine area (all models) Tilt the cab forward. See “Loader arm lock and cab tilt procedure - radial lift machines” Basic instructions - Loader arm lock and cab tilt procedure - radial lift machines () or “Loader arm lock and cab tilt procedure - vertical lift machines” Basic instructions - Loader arm lock and cab tilt procedure - vertical lift machines () .
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Electrical systems - Harnesses and connectors
SR210, SR240, TR270, and TR310 Engine Control Unit (ECU) and relay identification • Engine Control Unit (ECU) relay (1) • Flasher relay (2) (if equipped with a turn signals) • Glow-plug Control Unit (GCU) (3) • Engine Control Unit (ECU) (4)
RAIL15SSL0104BA
9
SV280 and TV370 Engine Control Unit (ECU) and relay identification • Engine Control Unit (ECU) (1) • Flasher relay (2) (if equipped with a turn signals) • Engine Control Unit (ECU) relay (3) • Glow-plug Control Unit (GCU) (4)
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RAIL15SSL0103BA
10
RAIL15SSL0096BA
11
Electrical systems - Harnesses and connectors
Electrical components - ECU description SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
A-001 - INSTRUMENT CLUSTER (ECU) Component Type Wiring frames Connectors
ECU SHEET 27 X-C23 (Receptacle)
A-002A - UNIVERSAL CONTROL MODULE (ECU) Component Type Wiring frames Connectors
ECU SHEET 20 SHEET 21 X-CN1A (Receptacle) X-CN2A (Receptacle) X-CN1B (Receptacle) X-CN2B (Receptacle)
A-003 - HVAC BOX (ECU) Component Type Wiring frames Connectors
ECU SHEET 28 X-HVC1 (Receptacle)
A-004 - ENGINE CONTROL UNIT (ECU) Component Type Wiring frames Connectors
ECU SHEET 06 X-012 (Receptacle)
A-005+ - ENGINE CONTROL UNIT (ECU) Component Type Wiring frames Connectors
ECU SHEET 07 X-016 (Receptacle)
A-006 - GCU (ECU) Component Type Wiring frames Connectors
ECU SHEET 06 X-013 (Receptacle)
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controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Electrical systems - Harnesses and connectors
Electrical components - Sensor description SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
B-002 - FUEL LEVEL SENDER (Sensor) Component Type Wiring frames
Sensor SHEET 37
B-003 - HYDRAULIC OIL TEMP SENDER (Sensor) Component Type Wiring frames Connectors
Sensor SHEET 14 X-OILTMP (Plug)
B-005 - LAMBDA SENSOR (Sensor) Component Type Wiring frames Connectors
Sensor SHEET 06 X-014 (Receptacle)
B-006 - AIR TEMP SENSOR (Sensor) Component Type Wiring frames Connectors
Sensor SHEET 06 X-004 (Receptacle)
B-007 - INLET TURBINE TEMP SENSOR (Sensor) Component Type Wiring frames
Sensor SHEET 06
B-008 - DIFF PRESSURE SENSOR (Sensor) Component Type Wiring frames Connectors
Sensor SHEET 06 X-005 (Plug)
B-011 - EXHAUST GAS TEMP SENSOR #1 (Sensor) Component Type Wiring frames Connectors
Sensor SHEET 06 X-006 (Receptacle)
B-012 - EXHAUST GAS TEMP SENSOR #2 (Sensor) Component Type Wiring frames Connectors
Sensor SHEET 06 X-007 (Receptacle)
B-013 - RAIL PRESSURE SENSOR (Sensor) Component Type Wiring frames
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controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Electrical systems - Harnesses and connectors
B-014 - INCREMENT SPEED SENSOR (Sensor) Component Type Wiring frames
Sensor SHEET 07
B-016 - SEGMENT SPEED SENSOR (Sensor) Component Type Wiring frames
Sensor SHEET 07
B-017 - COOLANT TEMPERATURE SENSOR (Sensor) Component Type Wiring frames
Sensor SHEET 07
B-018 - FUEL TEMPERATURE SENSOR (Sensor) Component Type Wiring frames
Sensor SHEET 07
B-019 - EXHAUST GAS PRESSURE SENSOR (Sensor) Component Type Wiring frames
Sensor SHEET 07
B-020 - BOOST PRESSURE / AIR TEMPERATURE SENSOR (Sensor) Component Type Wiring frames
Sensor SHEET 07
B-021 - TVA PIERBURG (Sensor) Component Type Wiring frames
Sensor SHEET 07
B-022 - EGR PIERBURG (Sensor) Component Type Wiring frames
Sensor SHEET 07
B-023 - HAND THROTTLE SENSOR (Sensor) Component Type Wiring frames Connectors
Sensor SHEET 09 X-20A (Receptacle)
B-024 - FOOT THROTTLE SENSOR (Sensor) Component Type Wiring frames Connectors
Sensor SHEET 09 X-020 (Receptacle)
B-025 - LH PUMP SWASH PLATE SENSOR (Sensor) Component Type Wiring frames Connectors
Sensor SHEET 10 X-094 (Receptacle)
B-026 - RH PUMP SWASH PLATE SENSOR (Sensor) Component Type Wiring frames
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Electrical systems - Harnesses and connectors
Connectors
X-093 (Receptacle)
B-027 - AUXILIARY SPOOL POSITION SENSOR (Sensor) Component Type Wiring frames Connectors
Sensor SHEET 12 X-023 (Receptacle)
B-028 - BUCKET SPOOL POSITION SENSOR (Sensor) Component Type Wiring frames Connectors
Sensor SHEET 12 X-021 (Receptacle)
B-029 - BOOM SPOOL POSITION SENSOR (Sensor) Component Type Wiring frames Connectors
Sensor SHEET 12 X-022 (Receptacle)
B-055 - OIL PRESSURE SWITCH (Sensor) Component Type Wiring frames
Sensor SHEET 07
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Electrical systems - Harnesses and connectors
Electrical components - Battery description SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
BAT-001 - (Battery) Component Type Wiring frames
Battery SHEET 04
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controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Electrical systems - Harnesses and connectors
Electrical components - Diode description SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
D-001 - (Diode) Component Type Wiring frames
Diode SHEET 16
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Electrical systems - Harnesses and connectors
Electrical components - Lamp description SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
E-001 - RH DIA SIDE LAMP (Lamp) Component Type Wiring frames Connectors
Lamp SHEET 22 X-085 (Receptacle)
E-002 - LH DIA SIDE LAMP (Lamp) Component Type Wiring frames Connectors
Lamp SHEET 22 X-086 (Receptacle)
E-003 - ROTATING BEACON (Lamp) Component Type Wiring frames Connectors
Lamp SHEET 22 X-178 (Receptacle)
E-004 - TURN SIGNAL INDICATOR (Lamp) Component Type Wiring frames Connectors
Lamp SHEET 23 X-155B (Plug) X-157B (Plug) X-156B (Plug)
E-005 - RH REAR WORK (Lamp) Component Type Wiring frames Connectors
Lamp SHEET 25 X-035 (Receptacle)
E-006 - LH REAR WORK (Lamp) Component Type Wiring frames Connectors
Lamp SHEET 25 X-034 (Plug)
E-007 - LICENSE PLATE (Lamp) Component Type Wiring frames Connectors
Lamp SHEET 25 X-080 (Plug) X-081 (Plug)
E-021 - LH REAR STROBE (Lamp) Component Type Wiring frames
Lamp SHEET 22
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Electrical systems - Harnesses and connectors
Connectors
X-341 (Receptacle)
E-023 - (Lamp) Component Type Wiring frames
Lamp SHEET 22
E-024 - RH FRONT STROBE (Lamp) Component Type Wiring frames Connectors
Lamp SHEET 22 X-343 (Receptacle)
E-025 - (Lamp) Component Type Wiring frames
Lamp SHEET 22
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Electrical systems - Harnesses and connectors
Electrical components - Fuse description SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
F-001 - HVAC (Fuse) Component Type Wiring frames
Fuse SHEET 02
F-002 - COMPRESSOR (Fuse) Component Type Wiring frames
Fuse SHEET 02
F-003 - CRANK (Fuse) Component Type Wiring frames
Fuse SHEET 02
F-004 - REAR WORK LAMPS (Fuse) Component Type Wiring frames
Fuse SHEET 02
F-005 - SIDE LAMPS (Fuse) Component Type Wiring frames
Fuse SHEET 02
F-006 - LH TAIL LAMPS (Fuse) Component Type Wiring frames
Fuse SHEET 02
F-007 - UCM BACKUP ALARM (Fuse) Component Type Wiring frames
Fuse SHEET 02
F-008 - INSTRUMENT CLUSTER (Fuse) Component Type Wiring frames
Fuse SHEET 02
F-009 - IGNITION (Fuse) Component Type Wiring frames
Fuse SHEET 02
F-010 - RH TAIL LAMPS (Fuse) Component Type Wiring frames
Fuse SHEET 02
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Electrical systems - Harnesses and connectors
F-011 - UNSWITCH BATTERY (Fuse) Component Type Wiring frames
Fuse SHEET 02
F-012 - FRONT WORK LAMPS (Fuse) Component Type Wiring frames
Fuse SHEET 02
F-013 - ACCESSORY (Fuse) Component Type Wiring frames
Fuse SHEET 02
F-014 - ACC/BEACON (Fuse) Component Type Wiring frames
Fuse SHEET 02
F-015 - UCM BRAKE LAMPS (Fuse) Component Type Wiring frames
Fuse SHEET 03
F-016 - EH GRND DRIVE (Fuse) Component Type Wiring frames
Fuse SHEET 03
F-017 - GRD DRIVE REV (Fuse) Component Type Wiring frames
Fuse SHEET 03
F-018 - EH AUX HYD (Fuse) Component Type Wiring frames
Fuse SHEET 03
F-019 - BUCKET CONTROL (Fuse) Component Type Wiring frames
Fuse SHEET 03
F-020 - HYD OPTIONS (Fuse) Component Type Wiring frames
Fuse SHEET 03
F-021 - UCM PUMP FWD (Fuse) Component Type Wiring frames
Fuse SHEET 03
F-022 - LOADER CONTROL (Fuse) Component Type Wiring frames
Fuse SHEET 03
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Electrical systems - Harnesses and connectors
F-023 - AUX FE KEY POWER (Fuse) Component Type Wiring frames
Fuse SHEET 03
F-024 - AUX FE ON/OFF (Fuse) Component Type Wiring frames
Fuse SHEET 03
F-025 - UCM INTERLOCKS (Fuse) Component Type Wiring frames
Fuse SHEET 03
F-026 - EH UNSWITCHED BATTERY (Fuse) Component Type Wiring frames
Fuse SHEET 02
F-027 - TWO SPEED SHIFT (Fuse) Component Type Wiring frames
Fuse SHEET 03
F-028 - FE #1, #2, #3 (Fuse) Component Type Wiring frames
Fuse SHEET 03
F-029 - WIPER/WASHER (Fuse) Component Type Wiring frames
Fuse SHEET 03
F-030 - FLASHER/ BRAKE (Fuse) Component Type Wiring frames
Fuse SHEET 02
F-031 - LEFT BOOM (Fuse) Component Type Wiring frames
Fuse SHEET 03
F-032 - RIGHT BOOM (Fuse) Component Type Wiring frames
Fuse SHEET 03
F-033 - ENGINE SENSORS (Fuse) Component Type Wiring frames
Fuse SHEET 02
F-034 - ECU FUSE 2 (Fuse) Component Type Wiring frames
Fuse SHEET 02
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Electrical systems - Harnesses and connectors
F-035 - ECU FUSE 1 (Fuse) Component Type Wiring frames
Fuse SHEET 02
F-036 - FUSE RELAY GROUND (Fuse) Component Type Wiring frames
Fuse SHEET 02
F-037 - FUSE RELAY GROUND (Fuse) Component Type Wiring frames
Fuse SHEET 03
F-038 - FUSE RELAY GROUND (Fuse) Component Type Wiring frames
Fuse SHEET 03
F-039 - TELEMATICS (Fuse) Component Type Wiring frames
Fuse SHEET 02
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Electrical systems - Harnesses and connectors
Electrical components - Voltage source description SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
G-001 - BATTERY (Voltage source) Component Type Wiring frames
Voltage source SHEET 04
G-002 - ALTERNATOR (Voltage source) Component Type Wiring frames
Voltage source SHEET 04
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Electrical systems - Harnesses and connectors
Electrical components - Ground description SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
GND-001 - (Ground) Component Type Wiring frames
Ground SHEET 05
GND-002 - (Ground) Component Type Wiring frames
Ground SHEET 05
GND-003 - (Ground) Component Type Wiring frames
Ground SHEET 05
GND-004 - (Ground) Component Type Wiring frames
Ground SHEET 05
GND-005 - (Ground) Component Type Wiring frames
Ground SHEET 05
GND-006 - (Ground) Component Type Wiring frames
Ground SHEET 14
GND-007 - (Ground) Component Type Wiring frames
Ground SHEET 04
GND-008 - (Ground) Component Type Wiring frames
Ground SHEET 04
GND-009 - (Ground) Component Type Wiring frames
Ground SHEET 05
GND-010 - (Ground) Component Type Wiring frames
Ground SHEET 05
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Electrical systems - Harnesses and connectors
GND-011 - (Ground) Component Type Wiring frames
Ground SHEET 05
GND-012 - (Ground) Component Type Wiring frames
Ground SHEET 15
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Electrical systems - Harnesses and connectors
Electrical components - Speaker description SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
H-002 - (Speaker) Component Type Wiring frames
Speaker SHEET 38
H-009 - HORN (Speaker) Component Type Wiring frames Connectors
Speaker SHEET 29 X-HORN-PWR (Plug) X-HORN-GND (Plug)
H-011 - RH SPEAKER (Speaker) Component Type Wiring frames Connectors
Speaker SHEET 29 X-330 (Plug) X-331 (Plug)
H-012 - LH SPEAKER (Speaker) Component Type Wiring frames Connectors
Speaker SHEET 29 X-333 (Plug) X-332 (Plug)
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Electrical systems - Harnesses and connectors
Electrical components - Power outlet description SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
J-001 - SIDE LAMP DIA SOCKET (Power outlet) Component Type Wiring frames Connectors
Power outlet SHEET 22 X-077 (Receptacle)
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Electrical systems - Harnesses and connectors
Electrical components - Relay description SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
K-001 - LIGHTS #1 RELAY (Relay) Component Type Wiring frames
Relay SHEET 02
K-002 - LIGHTS #2 RELAY (Relay) Component Type Wiring frames
Relay SHEET 02
K-003 - ACCESSORY RELAY (Relay) Component Type Wiring frames
Relay SHEET 02
K-004 - MAIN POWER RELAY (Relay) Component Type Wiring frames
Relay SHEET 02
K-005 - EH CONTROL RELAY (Relay) Component Type Wiring frames
Relay SHEET 03
K-006 - (Relay) Component Type Wiring frames
Relay SHEET 04
K-007 - ENGINE RELAY A (Relay) Component Type Wiring frames
Relay SHEET 08
K-008 - ECU MAIN RELAY (Relay) Component Type Wiring frames
Relay SHEET 08
K-009 - AUX FRONT ELECTRIC RELAY (Relay) Component Type Wiring frames
Relay SHEET 03
K-010 - OPTION RELAY (Relay) Component Type Wiring frames
Relay SHEET 03
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Electrical systems - Harnesses and connectors
K-020 - CONDENSER RELAY (Relay) Component Type Wiring frames Connectors
Relay SHEET 28 X-111 (Receptacle)
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Electrical systems - Harnesses and connectors
Electrical components - Motor description SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
M-001 - STARTER MOTOR (Motor) Component Type Wiring frames
Motor SHEET 04
M-002 - M (Motor) Component Type Wiring frames
Motor SHEET 04
M-003 - FUEL PUMP (Motor) Component Type Wiring frames
Motor SHEET 08
M-005 - M (Motor) Component Type Wiring frames
Motor SHEET 08
M-013 - LEFT DRIVE PUMP FORWARD (Motor) Component Type Wiring frames Connectors
Motor SHEET 10 X-013 (Receptacle)
M-016 - LEFT DRIVE PUMP REVERSE (Motor) Component Type Wiring frames Connectors
Motor SHEET 10 X-016 (Receptacle)
M-017 - RIGHT DRIVE PUMP FORWARD (Motor) Component Type Wiring frames Connectors
Motor SHEET 10 X-017 (Receptacle)
M-018 - RIGHT DRIVE PUMP REVERSE (Motor) Component Type Wiring frames Connectors
Motor SHEET 10 X-018 (Receptacle)
M-506 - FRONT DOOR WASHER PUMP (Motor) Component Type Wiring frames
Motor SHEET 26
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Electrical systems - Harnesses and connectors
Electrical components - Resistor description SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
R-001 - SEAT HEAT ELEMENT (Resistor) Component Type Wiring frames
Resistor SHEET 19
R-002 - CAN TERMINATOR (Resistor) Component Type Wiring frames
Resistor SHEET 20
R-003 - STARTER HOLD-IN (Resistor) Component Type Wiring frames
Resistor SHEET 04
R-004 - STARTER PULL-IN (Resistor) Component Type Wiring frames
Resistor SHEET 04
R-005 - FUEL FILTER HEATER (Resistor) Component Type Wiring frames Connectors
Resistor SHEET 06 X-018 (Receptacle)
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Electrical systems - Harnesses and connectors
Electrical components - Switch description SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
S-001 - ROTATING BEACON SWITCH (Switch) Component Type Wiring frames Connectors
Switch SHEET 16 X-301 (Receptacle)
S-002 - SEAT SWITCH (Switch) Component Type Wiring frames
Switch SHEET 19
S-003 - SEAT HEAT SWITCH (Switch) Component Type Wiring frames
Switch SHEET 19
S-004 - (Switch) Component Type Wiring frames
Switch SHEET 04
S-005 - LOADER LOCKOUT SWITCH (Switch) Component Type Wiring frames Connectors
Switch SHEET 16 X-306 (Receptacle)
S-006 - BOOM LOCK INTERLOCK SWITCH (Switch) Component Type Wiring frames
Switch SHEET 11
S-007 - FLOAT SWITCH (Switch) Component Type Wiring frames
Switch SHEET 18
S-008 - IGNITION SWITCH (Switch) Component Type Wiring frames
Switch SHEET 04
S-009 - HYDRAULIC COUPLER SWITCH (Switch) Component Type Wiring frames Connectors
Switch SHEET 16 X-300 (Receptacle)
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Electrical systems - Harnesses and connectors
S-011 - NH PARK BRAKE SWITCH (Switch) Component Type Wiring frames Connectors
Switch SHEET 16 X-365 (Receptacle)
S-012 - LAMP SELECTOR SWITCH (Switch) Component Type Wiring frames Connectors
Switch SHEET 22 X-311 (Receptacle)
S-013 - SELF LEVEL SWITCH (Switch) Component Type Wiring frames Connectors
Switch SHEET 16 X-317 (Receptacle)
S-014 - PARK BRAKE SWITCH (Switch) Component Type Wiring frames
Switch SHEET 18
S-015 - (Switch) Component Type Wiring frames
Switch SHEET 17
S-016 - WIPER/WASHER SWITCH (Switch) Component Type Wiring frames Connectors
Switch SHEET 26 X-503 (Receptacle)
S-017 - A/C SWITCH (LEFT CONSOLE) (Switch) Component Type Wiring frames Connectors
Switch SHEET 28 X-275 (Receptacle)
S-018 - RIDE CONTROL/ GLIDE RIDE (Switch) Component Type Wiring frames
Switch SHEET 18
S-020 - BLOWER SWITCH (LEFT CONSOLE) (Switch) Component Type Wiring frames Connectors
Switch SHEET 28 X-270 (Plug)
S-021 - AIR FILTER RESTRICTION SWITCH (Switch) Component Type Wiring frames
Switch SHEET 04
S-022 - (Switch) Component Type Wiring frames
Switch SHEET 18
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Electrical systems - Harnesses and connectors
S-023 - HORN (Switch) Component Type Wiring frames
Switch SHEET 17
S-024 - 2 SPEED (Switch) Component Type Wiring frames
Switch SHEET 17
S-027 - TURN SIGNAL SWITCH (Switch) Component Type Wiring frames
Switch SHEET 17
S-029 - STD/ON-ROAD LAMP CONFIGURATOR (Switch) Component Type Wiring frames Connectors
Switch SHEET 13 X-101 (Receptacle) X-101B (Plug) X-101A (Plug)
S-031 - (Switch) Component Type Wiring frames
Switch SHEET 18
S-032 - (Switch) Component Type Wiring frames
Switch SHEET 17
S-033 - 2ND AUX HYDRAULIC (Switch) Component Type Wiring frames
Switch SHEET 17
S-034 - TURN SIGNAL SWITCH (Switch) Component Type Wiring frames Connectors
Switch SHEET 24 X-CTS (Receptacle)
S-036 - (Switch) Component Type Wiring frames
Switch SHEET 18
S-037 - (Switch) Component Type Wiring frames
Switch SHEET 18
S-038 - DOOR SWITCH (Switch) Component Type Wiring frames
Switch SHEET 26
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Electrical systems - Harnesses and connectors
S-039 - BRAKE PRESSURE SWITCH (Switch) Component Type Wiring frames
Switch SHEET 10
S-040 - HVAC HIGH PRESSURE SWITCH (Switch) Component Type Wiring frames
Switch SHEET 28
S-041 - HAZARD LAMP SWITCH (Switch) Component Type Wiring frames Connectors
Switch SHEET 16 X-302 (Receptacle)
S-042 - HIGH FLOW SWITCH (Switch) Component Type Wiring frames Connectors
Switch SHEET 16 X-303 (Receptacle)
S-043 - LAP BAR SWITCH (Switch) Component Type Wiring frames
Switch SHEET 19
S-044 - HYDRAULIC FILTER RESTRICTION SWITCH (Switch) Component Type Wiring frames Connectors
Switch SHEET 15 X-OILFLT (Plug)
S-045 - WATER IN FUEL SWITCH (Switch) Component Type Wiring frames Connectors
Switch SHEET 38 X-011 (Receptacle)
S-078 - PRIMER SWITCH (Switch) Component Type Wiring frames
Switch SHEET 08
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Electrical systems - Harnesses and connectors
Electrical components - Solenoid description SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
Y-002 - A/C COMP (Solenoid) Component Type Wiring frames
Solenoid SHEET 28
Y-003 - BUCKET VALVE RETRACT (Solenoid) Component Type Wiring frames
Solenoid SHEET 12
Y-004 - STD HIGH FLOW SOLENOID (Solenoid) Component Type Wiring frames
Solenoid SHEET 13
Y-005 - 2 SPEED SOLENOID (Solenoid) Component Type Wiring frames
Solenoid SHEET 17
Y-006 - BUCKET VALVE EXTEND (Solenoid) Component Type Wiring frames
Solenoid SHEET 12
Y-007 - LOADER VALVE RETRACT (Solenoid) Component Type Wiring frames
Solenoid SHEET 12
Y-008 - BRAKE VALVE SOLENOID (Solenoid) Component Type Wiring frames
Solenoid SHEET 10
Y-009 - LOADER VALVE EXTEND (Solenoid) Component Type Wiring frames
Solenoid SHEET 12
Y-010 - RIDE CONTROL SOLENOID (Solenoid) Component Type Wiring frames
Solenoid SHEET 10
Y-011 - PROPORTIONAL AUX VALVE EXTEND (Solenoid) Component Type Wiring frames
Solenoid SHEET 12
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controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Electrical systems - Harnesses and connectors
Y-012 - PROPORTIONAL AUX VALVE RETRACT (Solenoid) Component Type Wiring frames
Solenoid SHEET 12
Y-013 - HYDRAULIC COUPLER SOLENOID (Solenoid) Component Type Wiring frames
Solenoid SHEET 13
Y-046 - INJECTOR ELECTRIC VALVE CYL 1 (Solenoid) Component Type Wiring frames
Solenoid SHEET 07
Y-047 - INJECTOR ELECTRIC VALVE CYL 3 (Solenoid) Component Type Wiring frames
Solenoid SHEET 07
Y-048 - INJECTOR ELECTRIC VALVE CYL 4 (Solenoid) Component Type Wiring frames
Solenoid SHEET 07
Y-049 - INJECTOR ELECTRIC VALVE CYL 2 (Solenoid) Component Type Wiring frames
Solenoid SHEET 07
Y-050 - FUEL METERING UNIT (Solenoid) Component Type Wiring frames
Solenoid SHEET 07
Y-051 - ELECTRIC VALVE (WG) (Solenoid) Component Type Wiring frames
Solenoid SHEET 07
Y-318 - SELF LEVEL VALVE (Solenoid) Component Type Wiring frames
Solenoid SHEET 14
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Electrical systems - Harnesses and connectors
Electrical components - Sub-Assembly description SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
Z-001 - LH FRONT ROAD LAMP (Sub-Assembly) Component Type Wiring frames Connectors
Sub-Assembly SHEET 25 X-228 (Plug)
Z-002 - RH FRONT ROAD LAMP (Sub-Assembly) Component Type Wiring frames Connectors
Sub-Assembly SHEET 25 X-229 (Plug)
Z-004 - 2 SPEED INDICATOR (Sub-Assembly) Component Type Wiring frames Connectors
Sub-Assembly SHEET 23 X-310 (Receptacle)
Z-005 - LEFT CONTROL HANDLE (Sub-Assembly) Component Type Wiring frames Connectors
Sub-Assembly SHEET 17 X-408 (Plug)
Z-006 - SEAT (Sub-Assembly) Component Type Wiring frames Connectors
Sub-Assembly SHEET 19 X-58 (Plug)
Z-008 - ACCESSORY POWER OUTLET (Sub-Assembly) Component Type Wiring frames Connectors
Sub-Assembly SHEET 16 X-ACC (Receptacle)
Z-009 - LH REAR ROAD LAMPS (Sub-Assembly) Component Type Wiring frames Connectors
Sub-Assembly SHEET 25 X-198 (Receptacle) X-037 (Receptacle)
Z-010 - DOOR WIPER MOTOR (Sub-Assembly) Component Type Wiring frames Connectors
Sub-Assembly SHEET 26 X-502 (Receptacle)
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controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Electrical systems - Harnesses and connectors
Z-011 - RH REAR ROAD LAMPS (Sub-Assembly) Component Type Wiring frames Connectors
Sub-Assembly SHEET 25 X-196 (Receptacle) X-044 (Receptacle)
Z-012 - RIGHT CONTROL HANDLE (Sub-Assembly) Component Type Wiring frames Connectors
Sub-Assembly SHEET 18 X-406 (Plug) X-403 (Receptacle)
Z-013 - FLASHER MODULE (Sub-Assembly) Component Type Wiring frames Connectors
Sub-Assembly SHEET 24 X-411 (Receptacle)
Z-014 - REAR WIPER MOTOR (Sub-Assembly) Component Type Wiring frames Connectors
Sub-Assembly SHEET 26 X-502A (Receptacle)
Z-017 - TEMP CONTROL (LH CONSOLE) (Sub-Assembly) Component Type Wiring frames Connectors
Sub-Assembly SHEET 28 X-252 (Receptacle)
Z-019 - WATER VALVE (Sub-Assembly) Component Type Wiring frames Connectors
Sub-Assembly SHEET 28 X-271 (Receptacle)
Z-074 - HVAC CONDENSER FAN (Sub-Assembly) Component Type Wiring frames Connectors
Sub-Assembly SHEET 28 X-074 (Plug)
Z-FUSE1 - POWER DISTRIBUTION EH CHASSIS (Sub-Assembly) Component Type Wiring frames Connectors
Sub-Assembly SHEET 02 SHEET 03 X-FUSE1 (Receptacle)
Z-FUSE2 - POWER DISTRIBUTION EH CHASSIS (Sub-Assembly) Component Type Wiring frames
Connectors
Sub-Assembly SHEET 02 SHEET 03 SHEET 08 X-FUSE2 (Receptacle)
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Electrical systems - Harnesses and connectors
Electrical components - ECU description SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical
A-001 - HVAC BOX (ECU) Component Type Wiring frames Connectors
ECU SHEET 26 X-HVC1 (Receptacle)
A-002 - INSTRUMENT CLUSTER (ECU) Component Type Wiring frames Connectors
ECU SHEET 25 X-C23 (Receptacle)
A-003 - EH AUX PWM CONTROLLER (ECU) Component Type Wiring frames Connectors
ECU SHEET 19 X-430 (Receptacle)
A-004 - FLASHER MODULE (ECU) Component Type Wiring frames Connectors
ECU SHEET 22 X-411 (Receptacle)
A-005 - ENGINE CONTROLLER UNIT (ECU) Component Type Wiring frames Connectors
ECU SHEET 10 SHEET 11 X-016 (Receptacle)
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hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Electrical systems - Harnesses and connectors
Electrical components - Sensor description SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical
B-001 - LAMBDA SENSOR (Sensor) Component Type Wiring frames Connectors
Sensor SHEET 10 X-014 (Receptacle)
B-002 - HYDRAULIC OIL TEMPERATURE (Sensor) Component Type Wiring frames
Sensor SHEET 14
B-003 - HAND THROTTLE SENSOR (Sensor) Component Type Wiring frames Connectors
Sensor SHEET 12 X-020A (Receptacle)
B-004 - FOOT THROTTLE SENSOR (Sensor) Component Type Wiring frames Connectors
Sensor SHEET 12 X-020 (Receptacle)
B-005 - EGR PIERBURG (Sensor) Component Type Wiring frames
Sensor SHEET 11
B-006 - AIR TEMP SENSOR (Sensor) Component Type Wiring frames Connectors
Sensor SHEET 10 X-004 (Receptacle)
B-007 - INLET TURBINE TEMP SENSOR (Sensor) Component Type Wiring frames
Sensor SHEET 10
B-008 - GCU (Sensor) Component Type Wiring frames Connectors
Sensor SHEET 10 X-013 (Receptacle)
B-011 - EXHAUST GAS TEMP SENSOR #1 (Sensor) Component Type Wiring frames Connectors
Sensor SHEET 10 X-006 (Receptacle) 48068130 29/01/2018
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hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Electrical systems - Harnesses and connectors
B-012 - EXHAUST GAS TEMP SENSOR #2 (Sensor) Component Type Wiring frames Connectors
Sensor SHEET 10 X-007 (Receptacle)
B-013 - RAIL PRESSURE SENSOR (Sensor) Component Type Wiring frames
Sensor SHEET 11
B-014 - INCREMENT SPEED SENSOR (Sensor) Component Type Wiring frames
Sensor SHEET 11
B-016 - SEGMENT SPEED SENSOR (Sensor) Component Type Wiring frames
Sensor SHEET 11
B-017 - COOLANT TEMPERATURE SENSOR (Sensor) Component Type Wiring frames
Sensor SHEET 11
B-018 - FUEL TEMPERATURE SENSOR (Sensor) Component Type Wiring frames
Sensor SHEET 11
B-019 - EXHAUST GAS PRESSURE SENSOR (Sensor) Component Type Wiring frames
Sensor SHEET 11
B-020 - BOOST PRESSURE / AIR TEMPERATURE SENSOR (Sensor) Component Type Wiring frames
Sensor SHEET 11
B-021 - TVA PIERBURG (Sensor) Component Type Wiring frames
Sensor SHEET 11
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Electrical systems - Harnesses and connectors
Electrical components - Lamp description SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical
E-003 - DOME LAMP (Lamp) Component Type Wiring frames Connectors
Lamp SHEET 20 X-097 (Receptacle)
E-008 - TURN SIGNAL INDICATOR (Lamp) Component Type Wiring frames Connectors
Lamp SHEET 21 X-155B (Plug) X-157B (Plug) X-156B (Plug)
E-019 - LICENSE PLATE (Lamp) Component Type Wiring frames Connectors
Lamp SHEET 23 X-080 (Plug) X-081 (Plug)
E-021 - LH REAR STROBE (Lamp) Component Type Wiring frames Connectors
Lamp SHEET 20 X-341 (Receptacle)
E-023 - LH FRONT STROBE (Lamp) Component Type Wiring frames Connectors
Lamp SHEET 20 X-344 (Receptacle)
E-024 - RH FRONT STROBE (Lamp) Component Type Wiring frames Connectors
Lamp SHEET 20 X-343 (Receptacle)
E-025 - RH REAR STROBE (Lamp) Component Type Wiring frames Connectors
Lamp SHEET 20 X-342 (Receptacle)
E-026 - ROTATING BEACON (Lamp) Component Type Wiring frames
Lamp SHEET 20
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hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Electrical systems - Harnesses and connectors
Connectors
X-178 (Receptacle)
E-027 - 2 SPEED INDICATOR (Lamp) Component Type Wiring frames Connectors
Lamp SHEET 21 X-310 (Receptacle)
E-028 - RH REAR WORK (Lamp) Component Type Wiring frames Connectors
Lamp SHEET 23 X-038 (Receptacle)
E-029 - LH REAR WORK (Lamp) Component Type Wiring frames Connectors
Lamp SHEET 23 X-033A (Receptacle)
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Electrical systems - Harnesses and connectors
Electrical components - Fuse description SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical
F-001 - REAR WORK LAMPS (Fuse) Component Type Wiring frames
Fuse SHEET 02
F-002 - LH TAIL LAMP (Fuse) Component Type Wiring frames
Fuse SHEET 02
F-003 - SIDE LAMPS (Fuse) Component Type Wiring frames
Fuse SHEET 02
F-004 - TELEMATICS (Fuse) Component Type Wiring frames
Fuse SHEET 05
F-005 - UNSWITCHED BATTERY (Fuse) Component Type Wiring frames
Fuse SHEET 02
F-006 - RH TAIL LAMP (Fuse) Component Type Wiring frames
Fuse SHEET 02
F-007 - ACC/BEACON (Fuse) Component Type Wiring frames
Fuse SHEET 02
F-008 - IGNITION (Fuse) Component Type Wiring frames
Fuse SHEET 02
F-009 - INSTRUMENT CLUSTER (Fuse) Component Type Wiring frames
Fuse SHEET 02
F-010 - RH BOOM (Fuse) Component Type Wiring frames
Fuse SHEET 05
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hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Electrical systems - Harnesses and connectors
F-011 - ECU 2 (Fuse) Component Type Wiring frames
Fuse SHEET 02
F-012 - ECU 1 (Fuse) Component Type Wiring frames
Fuse SHEET 02
F-013 - HIGH FLOW / COUPLER (Fuse) Component Type Wiring frames
Fuse SHEET 05
F-014 - FUSE RELAY GROUND (Fuse) Component Type Wiring frames
Fuse SHEET 05
F-015 - FE #1, #2, #3 (Fuse) Component Type Wiring frames
Fuse SHEET 05
F-016 - ENGINE SENSOR (Fuse) Component Type Wiring frames
Fuse SHEET 02
F-017 - FE ON/OFF (Fuse) Component Type Wiring frames
Fuse SHEET 05
F-018 - FE HOT (Fuse) Component Type Wiring frames
Fuse SHEET 05
F-019 - ACCESSORY (Fuse) Component Type Wiring frames
Fuse SHEET 02
F-020 - FUSE RELAY GROUND (Fuse) Component Type Wiring frames
Fuse SHEET 05
F-021 - COMPRESSOR (Fuse) Component Type Wiring frames
Fuse SHEET 03
F-022 - ACC/BEACON (Fuse) Component Type Wiring frames
Fuse SHEET 03
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Electrical systems - Harnesses and connectors
F-023 - UNSWITCHED BATTERY (Fuse) Component Type Wiring frames
Fuse SHEET 03
F-024 - HVAC (Fuse) Component Type Wiring frames
Fuse SHEET 03
F-025 - INSTRUMENT CLUSTER (Fuse) Component Type Wiring frames
Fuse SHEET 03
F-026 - ACCESSORY (Fuse) Component Type Wiring frames
Fuse SHEET 03
F-027 - CRANK (Fuse) Component Type Wiring frames
Fuse SHEET 03
F-028 - SIDE LAMPS (Fuse) Component Type Wiring frames
Fuse SHEET 03
F-029 - IGNITION (Fuse) Component Type Wiring frames
Fuse SHEET 03
F-030 - RH BOOM (Fuse) Component Type Wiring frames
Fuse SHEET 06
F-031 - WIPER/ WASHER (Fuse) Component Type Wiring frames
Fuse SHEET 03
F-032 - ECU 1 (Fuse) Component Type Wiring frames
Fuse SHEET 04
F-033 - ECU 2 (Fuse) Component Type Wiring frames
Fuse SHEET 04
F-034 - REAR WORK LAMPS (Fuse) Component Type Wiring frames
Fuse SHEET 04
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Electrical systems - Harnesses and connectors
F-035 - FRONT WORK LAMPS (Fuse) Component Type Wiring frames
Fuse SHEET 04
F-036 - RH TAIL LAMP (Fuse) Component Type Wiring frames
Fuse SHEET 04
F-037 - LH TAIL LAMP (Fuse) Component Type Wiring frames
Fuse SHEET 04
F-038 - ENGINE SENSOR (Fuse) Component Type Wiring frames
Fuse SHEET 04
F-039 - FLASHER / BRAKE (Fuse) Component Type Wiring frames
Fuse SHEET 06
F-040 - HIGH FLOW/ COUPLER (Fuse) Component Type Wiring frames
Fuse SHEET 06
F-041 - FE #1, #2, #3 (Fuse) Component Type Wiring frames
Fuse SHEET 06
F-042 - FE HOT (Fuse) Component Type Wiring frames
Fuse SHEET 06
F-044 - FE ON/OFF (Fuse) Component Type Wiring frames
Fuse SHEET 06
F-045 - LH BOOM (Fuse) Component Type Wiring frames
Fuse SHEET 06
F-046 - HVAC (Fuse) Component Type Wiring frames
Fuse SHEET 02
F-047 - CRANK (Fuse) Component Type Wiring frames
Fuse SHEET 02
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Electrical systems - Harnesses and connectors
F-048 - FLASHER/BRAKE 20A (Fuse) Component Type Wiring frames
Fuse SHEET 05
F-049 - WIPER/WASHER (Fuse) Component Type Wiring frames
Fuse SHEET 02
F-050 - FRONT WORK LAMPS (Fuse) Component Type Wiring frames
Fuse SHEET 02
F-051 - COMPRESSOR (Fuse) Component Type Wiring frames
Fuse SHEET 02
F-052 - LH BOOM (Fuse) Component Type Wiring frames
Fuse SHEET 05
F-053 - (Fuse) Component Type Wiring frames Connectors
Fuse SHEET 29 X-319 (Receptacle)
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Electrical systems - Harnesses and connectors
Electrical components - Voltage source description SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical
G-001 - ALTERNATOR (Voltage source) Component Type Wiring frames
Voltage source SHEET 08
G-002 - BATTERY (Voltage source) Component Type Wiring frames
Voltage source SHEET 07
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hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Electrical systems - Harnesses and connectors
Electrical components - Ground description SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical
GND-001 - (Ground) Component Type Wiring frames
Ground SHEET 07
GND-002 - (Ground) Component Type Wiring frames
Ground SHEET 07
GND-003 - (Ground) Component Type Wiring frames
Ground SHEET 07
GND-004 - (Ground) Component Type Wiring frames
Ground SHEET 07
GND-005 - (Ground) Component Type Wiring frames
Ground SHEET 07
GND-006 - (Ground) Component Type Wiring frames
Ground SHEET 14
GND-007 - (Ground) Component Type Wiring frames
Ground SHEET 14
GND-008 - (Ground) Component Type Wiring frames
Ground SHEET 08
GND-009 - (Ground) Component Type Wiring frames
Ground SHEET 26
GND-010 - (Ground) Component Type Wiring frames
Ground SHEET 07
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hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Electrical systems - Harnesses and connectors
GND-011 - (Ground) Component Type Wiring frames
Ground SHEET 07
GND-012 - (Ground) Component Type Wiring frames
Ground SHEET 07
GND-013 - (Ground) Component Type Wiring frames
Ground SHEET 07
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Electrical systems - Harnesses and connectors
Electrical components - Speaker description SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical
H-001 - HORN (Speaker) Component Type Wiring frames Connectors
Speaker SHEET 16 X-HORN-PWR (Plug) X-HORN-GND (Plug)
H-002 - BACKUP ALARM (Speaker) Component Type Wiring frames
Speaker SHEET 34
H-003 - RH SPEAKER (Speaker) Component Type Wiring frames Connectors
Speaker SHEET 27 X-331 (Plug) X-330 (Plug)
H-004 - LH SPEAKER (Speaker) Component Type Wiring frames Connectors
Speaker SHEET 27 X-333 (Plug) X-332 (Plug)
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hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Electrical systems - Harnesses and connectors
Electrical components - Power outlet description SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical
J-001 - SIDE LAMP DIA SOCKET (Power outlet) Component Type Wiring frames Connectors
Power outlet SHEET 20 X-077 (Receptacle)
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hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Electrical systems - Harnesses and connectors
Electrical components - Relay description SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical
K-001 - ACCESSORY RELAY (Relay) Component Type Wiring frames
Relay SHEET 02
K-002 - LIGHTS #1 RELAY (Relay) Component Type Wiring frames
Relay SHEET 02
K-003 - MAIN POWER RELAY (Relay) Component Type Wiring frames
Relay SHEET 02
K-004 - LIGHTS #2 RELAY (Relay) Component Type Wiring frames
Relay SHEET 02
K-005 - OPTION RELAY (Relay) Component Type Wiring frames
Relay SHEET 05
K-006 - ENGINE RELAY A (Relay) Component Type Wiring frames
Relay SHEET 09
K-007 - FRONT ELECTRIC RELAY (Relay) Component Type Wiring frames
Relay SHEET 05
K-008 - SPOOL RELAY (Relay) Component Type Wiring frames
Relay SHEET 13
K-009 - ECU MAIN RELAY (Relay) Component Type Wiring frames Connectors
Relay SHEET 09 X-ECU_MAIN_RLY (Receptacle)
K-010 - MAIN POWER RELAY (Relay) Component Type Wiring frames
Relay SHEET 03 48068130 29/01/2018
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hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Electrical systems - Harnesses and connectors
K-011 - LIGHTS #1 RELAY (Relay) Component Type Wiring frames
Relay SHEET 03
K-012 - LIGHTS #2 RELAY (Relay) Component Type Wiring frames
Relay SHEET 03
K-013 - ACCESSORY RELAY (Relay) Component Type Wiring frames
Relay SHEET 03
K-014 - FRONT ELECTRIC RELAY (Relay) Component Type Wiring frames
Relay SHEET 06
K-015 - OPTION RELAY (Relay) Component Type Wiring frames
Relay SHEET 06
K-016 - ENGINE RELAY A (Relay) Component Type Wiring frames
Relay SHEET 09
K-017 - SPOOL RELAY (Relay) Component Type Wiring frames
Relay SHEET 13
K-018 - CONDENSER RELAY (Relay) Component Type Wiring frames Connectors
Relay SHEET 26 X-111 (Receptacle)
K-019 - (Relay) Component Type Wiring frames
Relay SHEET 08
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Electrical components - Motor description SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical
M-001 - DOOR WIPER MOTOR (Motor) Component Type Wiring frames Connectors
Motor SHEET 24 X-502 (Receptacle)
M-002 - REAR WIPER MOTOR (Motor) Component Type Wiring frames Connectors
Motor SHEET 24 X-502A (Receptacle)
M-003 - STARTER MOTOR (Motor) Component Type Wiring frames Connectors
Motor SHEET 08 X-STARTER (Plug)
M-004 - FRONT DOOR WASHER PUMP (CAB) (Motor) Component Type Wiring frames
Motor SHEET 24
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Electrical systems - Harnesses and connectors
Electrical components - Resistor description SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical
R-001 - SEAT HEAT ELEMENT (Resistor) Component Type Wiring frames
Resistor SHEET 18
R-002 - FUEL LEVEL SENDER (Resistor) Component Type Wiring frames
Resistor SHEET 33
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Electrical systems - Harnesses and connectors
Electrical components - Switch description SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical
S-001 - ROTATING BEACON /STROBE SWITCH (Switch) Component Type Wiring frames Connectors
Switch SHEET 15 X-301 (Receptacle)
S-002 - SEAT SWITCH (Switch) Component Type Wiring frames
Switch SHEET 18
S-003 - SEAT HEAT SWITCH (Switch) Component Type Wiring frames
Switch SHEET 18
S-004 - MECHANICAL BACKUP SWITCH #1 (Switch) Component Type Wiring frames
Switch SHEET 33
S-005 - LOADER LOCKOUT SWITCH (Switch) Component Type Wiring frames Connectors
Switch SHEET 15 X-306 (Receptacle)
S-006 - MECHANICAL BACKUP SWITCH #2 (Switch) Component Type Wiring frames
Switch SHEET 33
S-007 - NH PARK BRAKE SWITCH (Switch) Component Type Wiring frames Connectors
Switch SHEET 15 X-365 (Receptacle)
S-008 - IGNITION SWITCH (Switch) Component Type Wiring frames Connectors
Switch SHEET 08 X-009 (Receptacle)
S-009 - HYDRAULIC COUPLER SWITCH (Switch) Component Type Wiring frames Connectors
Switch SHEET 15 X-300 (Receptacle)
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Electrical systems - Harnesses and connectors
S-010 - BLOWER SWITCH (LEFT CONSOLE) (Switch) Component Type Wiring frames Connectors
Switch SHEET 26 X-270 (Plug)
S-011 - LAP BAR SWITCH (Switch) Component Type Wiring frames
Switch SHEET 18
S-012 - LAMP SELECTOR SWITCH (Switch) Component Type Wiring frames Connectors
Switch SHEET 20 X-311 (Receptacle)
S-013 - SELF LEVEL SWITCH (Switch) Component Type Wiring frames Connectors
Switch SHEET 15 X-317 (Receptacle)
S-014 - PARK BRAKE SWITCH (Switch) Component Type Wiring frames
Switch SHEET 17
S-015 - #2 (Switch) Component Type Wiring frames
Switch SHEET 16
S-016 - MECHANICAL BRAKE SWITCH (Switch) Component Type Wiring frames
Switch SHEET 05
S-017 - WIPER/WASHER SWITCH (Switch) Component Type Wiring frames Connectors
Switch SHEET 24 X-503 (Receptacle)
S-018 - RIDE CONTROL/GLIDE RIDE (Switch) Component Type Wiring frames
Switch SHEET 17
S-019 - AC SWITCH (LEFT CONSOLE) (Switch) Component Type Wiring frames Connectors
Switch SHEET 26 X-275 (Receptacle)
S-020 - MECHANICAL BRAKE SWITCH (Switch) Component Type Wiring frames
Switch SHEET 05
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S-021 - HVAC HIGH PRESSURE SWITCH (Switch) Component Type Wiring frames
Switch SHEET 26
S-022 - #2 (Switch) Component Type Wiring frames
Switch SHEET 17
S-023 - HORN (Switch) Component Type Wiring frames
Switch SHEET 16
S-024 - 2SPD (Switch) Component Type Wiring frames
Switch SHEET 16
S-025 - DOOR SWITCH (Switch) Component Type Wiring frames
Switch SHEET 24
S-026 - HAZARD LAMP SWITCH (Switch) Component Type Wiring frames Connectors
Switch SHEET 15 X-302 (Receptacle)
S-027 - TURN SIGNAL (Switch) Component Type Wiring frames
Switch SHEET 16
S-028 - HIGH FLOW SWITCH (Switch) Component Type Wiring frames Connectors
Switch SHEET 15 X-303 (Receptacle)
S-029 - STD/ON-ROAD LAMP CONFIGURATOR (Switch) Component Type Wiring frames Connectors
Switch SHEET 20 X-101 (Receptacle) X-101A (Plug) X-101B (Plug)
S-030 - MECHANICAL BRAKE PRESSURE SWITCH (Switch) Component Type Wiring frames
Switch SHEET 05
S-031 - #1 (Switch) Component Type Wiring frames
Switch SHEET 17
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S-032 - #3 (Switch) Component Type Wiring frames
Switch SHEET 16
S-033 - 2ND AUX HYDRAULIC (Switch) Component Type Wiring frames
Switch SHEET 16
S-034 - TURN SIGNAL SWITCH (Switch) Component Type Wiring frames Connectors
Switch SHEET 22 X-CTS (Receptacle)
S-035 - MECHANICAL BRAKE PRESSURE SWITCH (Switch) Component Type Wiring frames
Switch SHEET 05
S-036 - PROPORTIONAL AUXILIARY HYDRAULIC SWITCH (Switch) Component Type Wiring frames
Switch SHEET 17
S-037 - AIR FILTER RESTRICTION SWITCH (Switch) Component Type Wiring frames
Switch SHEET 08
S-039 - OIL PRESSURE SWITCH (Switch) Component Type Wiring frames
Switch SHEET 11
S-040 - HYDRAULIC FILTER RESTRICTION (Switch) Component Type Wiring frames
Switch SHEET 14
S-041 - BOOM LOCK INTERLOCK SWITCH (Switch) Component Type Wiring frames
Switch SHEET 19
S-042 - SWITCH OPTIONAL (Switch) Component Type Wiring frames
Switch SHEET 07
S-043 - WATER IN FUEL SWITCH (Switch) Component Type Wiring frames Connectors
Switch SHEET 34 X-011 (Plug)
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Electrical components - Solenoid description SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical
Y-001 - ELECTRIC VALVE (WG) (Solenoid) Component Type Wiring frames
Solenoid SHEET 11
Y-002 - PROPORTIONAL AUX VALVE RETRACT (Solenoid) Component Type Wiring frames
Solenoid SHEET 19
Y-003 - PROPORTIONAL AUX VALVE EXTEND (Solenoid) Component Type Wiring frames
Solenoid SHEET 19
Y-004 - STD HIGH FLOW SOLENOID (Solenoid) Component Type Wiring frames
Solenoid SHEET 14
Y-005 - 2 SPEED SOLENOID (Solenoid) Component Type Wiring frames
Solenoid SHEET 16
Y-006 - FUEL METERING UNIT (Solenoid) Component Type Wiring frames
Solenoid SHEET 11
Y-007 - BOOM LOCK VALVE (Solenoid) Component Type Wiring frames
Solenoid SHEET 19
Y-008 - BRAKE VALVE SOLENOID (Solenoid) Component Type Wiring frames
Solenoid SHEET 14
Y-009 - INJECTOR ELECTRIC VALVE CYL 2 (Solenoid) Component Type Wiring frames
Solenoid SHEET 11
Y-010 - RIDE CONTROL SOLENOID (Solenoid) Component Type Wiring frames
Solenoid SHEET 17
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Electrical systems - Harnesses and connectors
Y-011 - SELF LEVEL VALVE (Solenoid) Component Type Wiring frames
Solenoid SHEET 14
Y-012 - INJECTOR ELECTRIC VALVE CYL 4 (Solenoid) Component Type Wiring frames
Solenoid SHEET 11
Y-013 - HYDRAULIC COUPLER SOLENOID (Solenoid) Component Type Wiring frames
Solenoid SHEET 14
Y-014 - INJECTOR ELECTRIC VALVE CYL 3 (Solenoid) Component Type Wiring frames
Solenoid SHEET 11
Y-015 - INJECTOR ELECTRIC VALVE CYL 1 (Solenoid) Component Type Wiring frames
Solenoid SHEET 11
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Electrical components - Sub-Assembly description SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical
Z-002 - RH FRONT ROAD LAMP (Sub-Assembly) Component Type Wiring frames Connectors
Sub-Assembly SHEET 23 X-229 (Plug)
Z-003 - WATER VALVE (Sub-Assembly) Component Type Wiring frames Connectors
Sub-Assembly SHEET 26 X-271 (Receptacle)
Z-004 - TEMP CONTROL (LH CONSOLE) (Sub-Assembly) Component Type Wiring frames Connectors
Sub-Assembly SHEET 26 X-252 (Receptacle)
Z-005 - RH REAR ROAD LAMP (Sub-Assembly) Component Type Wiring frames Connectors
Sub-Assembly SHEET 23 X-196 (Receptacle) X-044 (Receptacle)
Z-006 - SEAT (Sub-Assembly) Component Type Wiring frames Connectors
Sub-Assembly SHEET 18 X-058 (Plug)
Z-007 - A/C COMPRESSOR (Sub-Assembly) Component Type Wiring frames
Sub-Assembly SHEET 26
Z-008 - ACCESSORY POWER OUTLET (Sub-Assembly) Component Type Wiring frames Connectors
Sub-Assembly SHEET 15 X-ACC (Receptacle)
Z-009 - LH REAR ROAD LAMP (Sub-Assembly) Component Type Wiring frames Connectors
Sub-Assembly SHEET 23 X-198 (Receptacle) X-037 (Receptacle)
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Electrical systems - Harnesses and connectors
Z-010 - LH FRONT ROAD LAMP (Sub-Assembly) Component Type Wiring frames
Sub-Assembly SHEET 23
Z-011 - HVAC CONDENSER FAN (Sub-Assembly) Component Type Wiring frames Connectors
Sub-Assembly SHEET 26 X-074 (Plug)
Z-012 - LEFT HAND CONTROL HANDLE (Sub-Assembly) Component Type Wiring frames Connectors
Sub-Assembly SHEET 16 X-405 (Plug)
Z-013 - RIGHT HAND CONTROL HANDLE (Sub-Assembly) Component Type Wiring frames Connectors
Sub-Assembly SHEET 17 X-402 (Receptacle)
Z-228 - (Sub-Assembly) Component Type Wiring frames
Sub-Assembly SHEET 23
Z-FUSE1 - POWER DISTRIBUTION CHASSIS (Sub-Assembly) Component Type Wiring frames
Connectors
Sub-Assembly SHEET 02 SHEET 03 SHEET 05 SHEET 06 SHEET 09 SHEET 13 X-FUSE1 (Receptacle)
Z-FUSE2 - POWER DISTRIBUTION CHASSIS (Sub-Assembly) Component Type Wiring frames
Connectors
Sub-Assembly SHEET 02 SHEET 03 SHEET 04 SHEET 05 SHEET 06 SHEET 13 X-FUSE2 (Receptacle)
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Wiring harnesses - Replace NOTE: For Wiring Harness repair, see Wiring harnesses - Repair (55.100) 1. If a wire within the harness is found to be beyond repair or is open circuit, a jumper wire may be installed as a temporary repair until such time when a new harness assembly can be installed. Use the following procedure to install an additional wire: Locate the faulty wire using the procedures described in the fault code charts. Disconnect the affected connectors. If fitted carefully roll back the seal between the connector and harness outer covering. Remove the pins from the connector blocks of the affected wire using the appropriate removal tool found in the harness repair kit. NOTE: Use the instructions supplied with the kit to ensure correct pin removal.
1Z0O2004112115
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1Z0O2004112116
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2. From the harness repair kit select the correct pin for the connectors. Obtain locally the correct cross-sectional size wire and measure out the length required by following the harness routing. Join the new wire to the new pins as described in the harness repair kit and install one of the pins into its connector. If possible attempt to run the new wire within the existing harness outer covering, if this is not possible run the wire along the harness, securing regularly with suitable ties. With the wire correctly routed instal the second terminal into its connector block. Replace the connector seal if removed. To ensure that the repair has been effective check for continuity of the new wire using a suitable multi-meter. NOTE: This is a temporary repair only. Ensure the damaged cable is replaced as soon as possible to prevent ingress of water or chemicals.
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Wiring harnesses - Repair NOTE: For Wiring Harness replacement, see Wiring harnesses - Replace (55.100) 1. Temporary Wiring Harness Repair The following method to repair wiring is a temporary expedient only. Wiring should be replaced as soon as possible. Do not attempt to repair the wire on any system sensors as these are sealed and should only be replaced with a new component. NOTE: When conducting a cable repair it is important that only RESIN CORED SOLDER is used. Use of other types of solder may result in further cable damage. 2. To carry out a temporary repair, proceed as follows:Locate damaged portion of cable then cut away outer protective cover on both sides of the damaged area.
1Z0O2004112111
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1Z0O2004112112
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1Z0O2004112113
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3. Peel back the cable from both ends of the damaged area and carefully cut away the inner cable cover at the damaged area and strip about 13 mm ( 1/2 in) of insulation from the wires. Do not cut away any wire strands. Using a suitable solvent, clean about 2 in ( 50 mm) from each cover end. Clean the grey cable cover and the individual leads. Twist two bare leads together for each damaged lead, being careful to match wire colours, then solder the leads using resin cored solder. Tape each repaired lead with vinyl insulation tape.
4. Wind a layer of vinyl insulation tape up to the grey cable cover at each end of the repair section. Make a paper trough, then apply silicon rubber compound (non hardening sealant) over the repaired section up to the cover ends. Sufficient sealant must be used to fill the ends of the cut away area.
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5. Allow the compound to cure then cover the area with insulating tape taking the tape well over each end of the repair. An overlap of at least 2 in ( 50 mm) of tape at each end is necessary. Check to ensure the repair is satisfactory and secure the repaired cable so that repeat damage is avoided. NOTE: This is a temporary repair only. Ensure the damaged cable is replaced as soon as possible to prevent ingress of water or chemicals.
1Z0O2004112114
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4
Electrical systems - Harnesses and connectors
Fuse and relay box - Testing Condenser Relay Control NOTE: Use schematics Wiring harnesses - Electrical schematic sheet 17 (55.100) Test N°1 Test Point Condition Disconnect connector X-111 from the CONDENSER RELAY K-020. Use Electrical system - Testing General Wire Testing (55.000) to Check wire condition between connector X-111 pin 85 and ground. Expected Result Result No wire problems. Action Go to test 2 Other Result Result Wire problems are found. (Possible Action Cause) Repair or replace broken wire 1087/1088/1093 (Black). Test N°2 Test Point Condition With the relay removed, and the ignition and HVAC controls on, Check for voltage between connector X-111 pin 86 and ground. Expected Result Result 12 V Action The relay control circuit wiring is good. Go to Fuse and controller power relay - Testing Relay Testing (55.640) to test relay. Other Result Result 0 V (Possible Action Cause) Go to test 3 Test N°3 Test Point Condition Use Electrical system - Testing General Wire Testing (55.000) to Check wire condition between connector X-111 pin 86 and connector X-HVC1 pin 6. Expected Result Result No wire problems. Action • Heating, Ventilation, and Air-Conditioning (HVAC) control system - Testing A/C Switch (55.050) for further testing. Other Result Result Wire problems are found. (Possible Action Cause) Repair or replace broken wire 840/837 (White).
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Index Electrical systems - 55 Harnesses and connectors - 100 Wiring harnesses - Electrical schematic sheet 03 SH03-ACCESSORY POWER DISTRIBUTION (*)
34
Wiring harnesses - Electrical schematic sheet 04 SH04-IGNITION/CHARGING SYSTEM (*) . . . . .
36
Wiring harnesses - Electrical schematic sheet 05 SH05-GROUNDING SYSTEM (*) . . . . . . . . . . . .
38
Wiring harnesses - Electrical schematic sheet 06 SH06-ENGINE F5C T4 (*) . . . . . . . . . . . . . . . . . . .
40
Wiring harnesses - Electrical schematic sheet 07 SH07-ENGINE F5C T4 (*) . . . . . . . . . . . . . . . . . . .
42
Wiring harnesses - Electrical schematic sheet 08 SH08-ENGINE F5C T4 (*) . . . . . . . . . . . . . . . . . . .
44
Wiring harnesses - Electrical schematic sheet 09 SH09-THROTTLE SENSORS (*) . . . . . . . . . . . . .
46
Wiring harnesses - Electrical schematic sheet 10 SH10-EH PUMP/HYDRAULICS (*) . . . . . . . . . . .
48
Wiring harnesses - Electrical schematic sheet 11 SH11-HYDRAULIC INTERLOCKS (*) . . . . . . . . .
50
Wiring harnesses - Electrical schematic sheet 12 SH12-LOADER VALVE AND SENSORS (*) . . . .
52
Wiring harnesses - Electrical schematic sheet 13 SH13-BULKHEAD CONNECTION (*) . . . . . . . . .
54
Wiring harnesses - Electrical schematic sheet 14 SH14-BULKHEAD CONNECTION (*) . . . . . . . . .
56
Wiring harnesses - Electrical schematic sheet 15 SH15-BULKHEAD CONNECTION (*) . . . . . . . . .
58
Wiring harnesses - Electrical schematic sheet 16 SH16-LEFT HAND CAB CONSOLE (*) . . . . . . . .
60
Wiring harnesses - Electrical schematic sheet 17 SH17-LEFT NH CONTROL HANDLE (*) . . . . . .
62
Wiring harnesses - Electrical schematic sheet 18 SH18-RIGHT NH CONTROL HANDLE (*) . . . . .
64
Wiring harnesses - Electrical schematic sheet 19 SH19-RIGHT NH CONTROL HANDLE (*) . . . . .
66
Wiring harnesses - Electrical schematic sheet 20 SH20-UNIVERSAL CONTROL MODULE (*) . . .
68
Wiring harnesses - Electrical schematic sheet 21 SH21-UNIVERSAL CONTROL MODULE (*) . . .
70
Wiring harnesses - Electrical schematic sheet 22 SH22-LAMPS (*) . . . . . . . . . . . . . . . . . . . . . . . . . . .
72
Wiring harnesses - Electrical schematic sheet 23 SH23-INDICATORS (*) . . . . . . . . . . . . . . . . . . . . . .
74
Wiring harnesses - Electrical schematic sheet 24 SH24-EU LIGHT ADAPTER (*) . . . . . . . . . . . . . .
76
Wiring harnesses - Electrical schematic sheet 25 SH25-BOOM ROAD LIGHTS (*) . . . . . . . . . . . . .
78
Wiring harnesses - Electrical schematic sheet 26 SH26-WIPERS / WASHERS (*) . . . . . . . . . . . . . .
80
Wiring harnesses - Electrical schematic sheet 27 SH27-INSTRUMENT CLUSTER (*) . . . . . . . . . . .
82
Wiring harnesses - Electrical schematic sheet 28 SH28-HVAC (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . .
84
Wiring harnesses - Electrical schematic sheet 29 SH29-RADIO (*) . . . . . . . . . . . . . . . . . . . . . . . . . . .
86
Wiring harnesses - Electrical schematic sheet 30 SH30-UJM CONNECTORS (*) . . . . . . . . . . . . . . .
88
Wiring harnesses - Electrical schematic sheet 31 SH31-MULTIFUNCTION CONNECTORS (*) . . .
90
Wiring harnesses - Electrical schematic sheet 32 SH32-TELEMATICS (*) . . . . . . . . . . . . . . . . . . . . .
92
Wiring harnesses - Electrical schematic sheet 33 SH33-MULTIFUNCTION JUMPER (*) . . . . . . . . .
94
Wiring harnesses - Electrical schematic sheet 34 SH34-2ND AUX (*) . . . . . . . . . . . . . . . . . . . . . . . . .
96
Wiring harnesses - Electrical schematic sheet 35 SH35-DIAGNOSTIC CONNECTOR (*) . . . . . . . .
98
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Wiring harnesses - Electrical schematic sheet 36 SH36-FUEL FILTER JUMPER (*) . . . . . . . . . . . .
100
Wiring harnesses - Electrical schematic sheet 37 SH37-CHASSIS INTERFACE X-900/X-901 LG (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102 Wiring harnesses - Electrical schematic sheet 38 SH38-CHASSIS INTERFACE (*) . . . . . . . . . . . . .
104
Wiring harnesses - Electrical schematic sheet 39 SH39-CHASSIS INTERFACE X-900/X-901 MD (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106 Wiring harnesses - Electrical schematic sheet 02 SH02-MAIN POWER DISTRIBUTION LG (*) . . .
108
Wiring harnesses - Electrical schematic sheet 03 SH03-MAIN POWER DISTRIBUTION MD (*) . .
110
Wiring harnesses - Electrical schematic sheet 04 SH04-MAIN POWER DISTRIBUTION MD (*) . .
112
Wiring harnesses - Electrical schematic sheet 05 SH05-ACCESSORY POWER DISTRIBUTION LG (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114 Wiring harnesses - Electrical schematic sheet 06 SH06-ACCESSORY POWER DISTRIBUTION MD (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116 Wiring harnesses - Electrical schematic sheet 07 SH07-GROUNDING SYSTEM (*) . . . . . . . . . . . .
118
Wiring harnesses - Electrical schematic sheet 08 SH08-IGNITION (*) . . . . . . . . . . . . . . . . . . . . . . . . .
120
Wiring harnesses - Electrical schematic sheet 09 SH09-ENGINE F5C T4 (*) . . . . . . . . . . . . . . . . . . .
122
Wiring harnesses - Electrical schematic sheet 10 SH10-ENGINE F5C T4 (*) . . . . . . . . . . . . . . . . . . .
124
Wiring harnesses - Electrical schematic sheet 11 SH11-ENGINE F5C T4 (*) . . . . . . . . . . . . . . . . . . .
126
Wiring harnesses - Electrical schematic sheet 12 SH12-THROTTLE SENSORS (*) . . . . . . . . . . . . .
128
Wiring harnesses - Electrical schematic sheet 13 SH13-AUXILIARY HYDRAULIC INTERLOCK SWITCH (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130 Wiring harnesses - Electrical schematic sheet 14 SH14-BULKHEAD CONNECTION (*) . . . . . . . . .
132
Wiring harnesses - Electrical schematic sheet 15 SH15-LEFT HAND CAB CONSOLE (*) . . . . . . . .
134
Wiring harnesses - Electrical schematic sheet 16 SH16-LH NH CONTROL HANDLE (*) . . . . . . . . .
136
Wiring harnesses - Electrical schematic sheet 17 SH17-RH NH CONTROL HANDLE (*) . . . . . . . .
138
Wiring harnesses - Electrical schematic sheet 18 SH18-SEAT (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
140
Wiring harnesses - Electrical schematic sheet 19 SH19-EH AUX PWM (*) . . . . . . . . . . . . . . . . . . . . .
142
Wiring harnesses - Electrical schematic sheet 20 SH20-LAMPS (*) . . . . . . . . . . . . . . . . . . . . . . . . . . .
144
Wiring harnesses - Electrical schematic sheet 21 SH21-INDICATORS (*) . . . . . . . . . . . . . . . . . . . . . .
146
Wiring harnesses - Electrical schematic sheet 22 SH22-EU LIGHT ADAPTER (*) . . . . . . . . . . . . . .
148
Wiring harnesses - Electrical schematic sheet 23 SH23-BOOM AND ROAD LIGHTS (*) . . . . . . . . .
150
Wiring harnesses - Electrical schematic sheet 24 SH24-WIPER / WASHER (*) . . . . . . . . . . . . . . . . .
152
Wiring harnesses - Electrical schematic sheet 25 SH25-INSTRUMENT CLUSTER (*) . . . . . . . . . . .
154
Wiring harnesses - Electrical schematic sheet 26 SH26-HVAC (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . .
156
Wiring harnesses - Electrical schematic sheet 27 SH27-RADIO (*) . . . . . . . . . . . . . . . . . . . . . . . . . . .
158
Wiring harnesses - Electrical schematic sheet 28 SH28-MULTIFUNCTION CONNECTORS (*) . . .
160
Wiring harnesses - Electrical schematic sheet 29 SH29-TELEMATICS (*) . . . . . . . . . . . . . . . . . . . . .
162
Wiring harnesses - Electrical schematic sheet 30 SH30-MULTIFUNCTION JUMPER (*) . . . . . . . . .
164
Wiring harnesses - Electrical schematic sheet 31 SH31-DIAGNOSTIC CONNECTOR (*) . . . . . . . .
166
Wiring harnesses - Electrical schematic sheet 32 SH32-FUEL FILTER JUMPER (*) . . . . . . . . . . . .
168
Wiring harnesses - Electrical schematic sheet 33 SH33-CHASSIS INTERFACE LG (*) . . . . . . . . . .
170
Wiring harnesses - Electrical schematic sheet 34 SH34-CHASSIS INTERFACE (*) . . . . . . . . . . . . .
172
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Wiring harnesses - Electrical schematic sheet 35 SH35-CHASSIS INTERFACE MD (*) . . . . . . . . .
174
Electrical components - Battery description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
399
Electrical components - Diode description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
400
Electrical components - ECU description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
395
Electrical components - ECU description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
424
Electrical components - Fuse description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
403
Electrical components - Fuse description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
429
Electrical components - Ground description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
408
Electrical components - Ground description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
435
Electrical components - Lamp description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
401
Electrical components - Lamp description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
427
Electrical components - Motor description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
414
Electrical components - Motor description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
441
Electrical components - Power outlet description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
411
Electrical components - Power outlet description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
438
Electrical components - Relay description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
412
Electrical components - Relay description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
439
Electrical components - Resistor description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
415
Electrical components - Resistor description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
442
Electrical components - Sensor description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
396
Electrical components - Sensor description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
425
Electrical components - Solenoid description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
420
Electrical components - Solenoid description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
447
Electrical components - Speaker description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
410
Electrical components - Speaker description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
437
Electrical components - Sub-Assembly description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
422
Electrical components - Sub-Assembly description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
449
Electrical components - Switch description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
416
Electrical components - Switch description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
443
Electrical components - Voltage source description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
407
Electrical components - Voltage source description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
434
Fuse and relay box - Component localization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
390
Fuse and relay box - Testing Condenser Relay Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
454
Fuse and relay box Fuse - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
389
Fuse and relay box Relay - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
387
Harnesses and connectors - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7
Wire connectors - Component diagram 00 Connectors X-000 to X-009 and Alphanumeric Connectors (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177 Wire connectors - Component diagram 00 Connectors X-000 to X-009 and Alphanumeric Connectors (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 297 Wire connectors - Component diagram 01 Connectors X-010 to X-019 (*) . . . . . . . . . . . . . . . . . . . . .
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211
Wire connectors - Component diagram 01 Connectors X-010 to X-019 (*) . . . . . . . . . . . . . . . . . . . . .
311
Wire connectors - Component diagram 02 Connectors X-020 to X-029 and Alphanumeric Connectors (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218 Wire connectors - Component diagram 02 Connectors X-020 to X-029 and Alphanumeric Connectors (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 320 Wire connectors - Component diagram 03 Connectors X-030 to X-039 (*) . . . . . . . . . . . . . . . . . . . . .
224
Wire connectors - Component diagram 03 Connectors X-030 to X-039 (*) . . . . . . . . . . . . . . . . . . . . .
323
Wire connectors - Component diagram 04 Connectors X-040 to X-049 (*) . . . . . . . . . . . . . . . . . . . . .
227
Wire connectors - Component diagram 04 Connectors X-040 to X-049 (*) . . . . . . . . . . . . . . . . . . . . .
326
Wire connectors - Component diagram 05 Connectors X-050 to X-059 (*) . . . . . . . . . . . . . . . . . . . . .
228
Wire connectors - Component diagram 05 Connectors X-050 to X-059 (*) . . . . . . . . . . . . . . . . . . . . .
328
Wire connectors - Component diagram 06 Connectors X-060 to X-069 (*) . . . . . . . . . . . . . . . . . . . . .
229
Wire connectors - Component diagram 06 Connectors X-060 to X-069 (*) . . . . . . . . . . . . . . . . . . . . .
329
Wire connectors - Component diagram 07 Connectors X-070 to X-079 (*) . . . . . . . . . . . . . . . . . . . . .
230
Wire connectors - Component diagram 07 Connectors X-070 to X-079 (*) . . . . . . . . . . . . . . . . . . . . .
330
Wire connectors - Component diagram 08 Connectors X-080 to X-089 (*) . . . . . . . . . . . . . . . . . . . . .
233
Wire connectors - Component diagram 08 Connectors X-080 to X-089 (*) . . . . . . . . . . . . . . . . . . . . .
333
Wire connectors - Component diagram 09 Connectors X-090 to X-099 (*) . . . . . . . . . . . . . . . . . . . . .
236
Wire connectors - Component diagram 09 Connectors X-090 to X-099 (*) . . . . . . . . . . . . . . . . . . . . .
334
Wire connectors - Component diagram 10 Connectors X-100 to X-109 (*) . . . . . . . . . . . . . . . . . . . . .
239
Wire connectors - Component diagram 10 Connectors X-100 to X-109 (*) . . . . . . . . . . . . . . . . . . . . .
335
Wire connectors - Component diagram 11 Connectors X-110 to X-119 (*) . . . . . . . . . . . . . . . . . . . . . .
242
Wire connectors - Component diagram 11 Connectors X-110 to X-119 (*) . . . . . . . . . . . . . . . . . . . . . .
338
Wire connectors - Component diagram 12 Connectors X-120 to X-129 (*) . . . . . . . . . . . . . . . . . . . . .
244
Wire connectors - Component diagram 15 Connectors X-150 to X-159 (*) . . . . . . . . . . . . . . . . . . . . .
245
Wire connectors - Component diagram 15 Connectors X-150 to X-159 (*) . . . . . . . . . . . . . . . . . . . . .
341
Wire connectors - Component diagram 16 Connectors X-160 to X-169 (*) . . . . . . . . . . . . . . . . . . . . .
343
Wire connectors - Component diagram 17 Connectors X-170 to X-179 (*) . . . . . . . . . . . . . . . . . . . . .
247
Wire connectors - Component diagram 17 Connectors X-170 to X-179 (*) . . . . . . . . . . . . . . . . . . . . .
346
Wire connectors - Component diagram 19 Connectors X-190 to X-199 (*) . . . . . . . . . . . . . . . . . . . . .
248
Wire connectors - Component diagram 19 Connectors X-190 to X-199 (*) . . . . . . . . . . . . . . . . . . . . .
347
Wire connectors - Component diagram 20 Connectors X-200 to X-209 (*) . . . . . . . . . . . . . . . . . . . . .
250
Wire connectors - Component diagram 20 Connectors X-200 to X-209 (*) . . . . . . . . . . . . . . . . . . . . .
349
Wire connectors - Component diagram 22 Connectors X-220 to X-229 (*) . . . . . . . . . . . . . . . . . . . . .
252
Wire connectors - Component diagram 22 Connectors X-220 to X-229 (*) . . . . . . . . . . . . . . . . . . . . .
351
Wire connectors - Component diagram 23 Connectors X-230 to X-239 (*) . . . . . . . . . . . . . . . . . . . . .
253
Wire connectors - Component diagram 23 Connectors X-230 to X-239 (*) . . . . . . . . . . . . . . . . . . . . .
352
Wire connectors - Component diagram 25 Connectors X-250 to X-259 (*) . . . . . . . . . . . . . . . . . . . . .
255
Wire connectors - Component diagram 25 Connectors X-250 to X-259 (*) . . . . . . . . . . . . . . . . . . . . .
354
Wire connectors - Component diagram 27 Connectors X-270 to X-279 (*) . . . . . . . . . . . . . . . . . . . . .
256
Wire connectors - Component diagram 27 Connectors X-270 to X-279 (*) . . . . . . . . . . . . . . . . . . . . .
355
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Wire connectors - Component diagram 30 Connectors X-300 to X-309 (*) . . . . . . . . . . . . . . . . . . . . .
258
Wire connectors - Component diagram 30 Connectors X-300 to X-309 (*) . . . . . . . . . . . . . . . . . . . . .
357
Wire connectors - Component diagram 31 Connectors X-010 to X-019 (*) . . . . . . . . . . . . . . . . . . . . .
360
Wire connectors - Component diagram 31 Connectors X-310 to X-319 (*) . . . . . . . . . . . . . . . . . . . . .
261
Wire connectors - Component diagram 32 Connectors X-320 to X-329 (*) . . . . . . . . . . . . . . . . . . . . .
265
Wire connectors - Component diagram 32 Connectors X-320 to X-329 (*) . . . . . . . . . . . . . . . . . . . . .
364
Wire connectors - Component diagram 33 Connectors X-330 to X-339 (*) . . . . . . . . . . . . . . . . . . . . .
267
Wire connectors - Component diagram 33 Connectors X-330 to X-339 (*) . . . . . . . . . . . . . . . . . . . . .
366
Wire connectors - Component diagram 34 Connectors X-340 to X-349 (*) . . . . . . . . . . . . . . . . . . . . .
270
Wire connectors - Component diagram 34 Connectors X-340 to X-349 (*) . . . . . . . . . . . . . . . . . . . . .
369
Wire connectors - Component diagram 36 Connectors X-360 to X-369 (*) . . . . . . . . . . . . . . . . . . . . .
272
Wire connectors - Component diagram 36 Connectors X-360 to X-369 (*) . . . . . . . . . . . . . . . . . . . . .
371
Wire connectors - Component diagram 40 Connectors X-400 to X-409 (*) . . . . . . . . . . . . . . . . . . . . .
273
Wire connectors - Component diagram 40 Connectors X-400 to X-409 (*) . . . . . . . . . . . . . . . . . . . . .
372
Wire connectors - Component diagram 41 Connectors X-410 to X-419 (*) . . . . . . . . . . . . . . . . . . . . .
276
Wire connectors - Component diagram 41 Connectors X-410 to X-419 (*) . . . . . . . . . . . . . . . . . . . . .
374
Wire connectors - Component diagram 43 Connectors X-430 to X-439 (*) . . . . . . . . . . . . . . . . . . . . .
376
Wire connectors - Component diagram 50 Connectors X-500 to X-509 (*) . . . . . . . . . . . . . . . . . . . . .
277
Wire connectors - Component diagram 50 Connectors X-500 to X-509 (*) . . . . . . . . . . . . . . . . . . . . .
378
Wire connectors - Component diagram 90 Connectors X-900 to X-909 (*) . . . . . . . . . . . . . . . . . . . . .
280
Wire connectors - Component diagram 90 Connectors X-900 to X-909 (*) . . . . . . . . . . . . . . . . . . . . .
381
Wire connectors - Component diagram 99 Connectors X-9000 to X-9009 (*) . . . . . . . . . . . . . . . . . . .
285
Wire connectors - Component diagram 99 Connectors X-9000 to X-9009 (*) . . . . . . . . . . . . . . . . . . .
386
Wire connectors Connectors Alphanumeric (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
195
Wire connectors Connectors Alphanumeric (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
286
Wiring harnesses - Electrical schematic sheet 02 SH02-MAIN POWER DISTRIBUTION (*) . . . . . .
32
Wiring harnesses - Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
452
Wiring harnesses - Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
451
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Electrical systems - 55 Engine starting system - 201
SR210 TIER 4B (FINAL) [NGM418237 - ], SR210 TIER 4B (FINAL) [NHM435463 - ], SR240 TIER 4B (FINAL) [NGM418237 - ], SR240 TIER 4B (FINAL) [NHM435463 - ], SV280 TIER 4B (FINAL) [NGM418237 - ], SV280 TIER 4B (FINAL) [NHM435463 - ], TR270 TIER 4B (FINAL) [NGM418237 - ], TR270 TIER 4B (FINAL) [NHM435463 - ], TR310 TIER 4B (FINAL) [NGM418237 - ], TR310 TIER 4B (FINAL) [NHM435463 - ], TV370 TIER 4B (FINAL) [NHM435463 - ]
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Contents Electrical systems - 55 Engine starting system - 201
SERVICE Engine starter Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
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Electrical systems - Engine starting system
Engine starter - Remove SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ]
CAUTION Burn hazard! Exhaust surfaces are hot! Always wear protective gloves when cleaning or working on or near the muffler, catalytic converter, or exhaust stack. Failure to comply could result in minor or moderate injury. C0142A
Prior operations 1. Raise the loader arms and tilt the cab forward. See Cab tilting system - Tilt (90.150) for radial lift units. 2. Remove the battery and/or turn the Master Disconnect Switch to the OFF position. See Battery - Disconnect (55.302) or Battery - Remove (55.302) for further details.
Component removal 3. Disconnect the positive (+) battery cable (1) from the starter motor. 4. Disconnect the starter solenoid wire connector (2) from the starter.
RAIL16SSL0167AA
1
RAIL16SSL0166AA
2
5. Remove the three mounting bolts securing the starter motor (1) to the flywheel housing. NOTE: To remove the three mounting bolts use a wrench (not shown) and a swivel-head socket (A) with a 203.2 â&#x20AC;&#x201C; 304.8 mm (8.0 â&#x20AC;&#x201C; 12.0 in) socket extension (B). 6. Rotate the starter motor (1) to gain clearance within the chassis, and remove the starter from the machine.
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Electrical systems - Engine starting system
Engine starter - Install SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ]
Component installation 1. To gain clearance within the chassis, rotate the starter motor and slide the starter into the flywheel housing. 2. Secure the starter motor (1) to the flywheel housing with the three M10 x 35 mm mounting bolts. Torque the bolts to 40.0 – 47.0 N·m (30.0 – 35.0 lb ft). NOTE: To install the three mounting bolts use a wrench (not shown) and a swivel-head socket (A) with a 203.2 – 304.8 mm (8.0 – 12.0 in) socket extension (B).
RAIL16SSL0166AA
1
RAIL16SSL0167AA
2
3. Connect the starter solenoid wire (1) to the starter. 4. Connect the positive (+) battery cable (2) to the starter motor. Torque the nut to 12.0 – 18.0 N·m (8.9 – 13.3 lb ft).
Post operations 1. Install the battery and/or turn the Master Disconnect Switch to the ON position. See Battery - Connect (55.302) or Battery - Install (55.302) for further details. 2. Lower the loader arms and secure the cab to the chassis. See Cab tilting system - Lower (90.150) for radial units.
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Electrical systems - Engine starting system
Engine starter - Remove SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
CAUTION Burn hazard! Exhaust surfaces are hot! Always wear protective gloves when cleaning or working on or near the muffler, catalytic converter, or exhaust stack. Failure to comply could result in minor or moderate injury. C0142A
Prior operations 1. Raise the loader arms and tilt the cab forward. See Cab tilting system - Tilt (90.150) for vertical lift units. 2. Remove the battery and/or turn the Master Disconnect Switch to the OFF position. See Battery - Disconnect (55.302) or Battery - Remove (55.302) for further details.
Component removal 1. Remove the four nuts securing the Electronic Control Unit (ECU) mounting plate. NOTE: Move the ECU mounting plate just to gain clearance for the starter. NOTE: The procedure may be easier if the left-hand engine side cover is removed, to attempt access to the starter from the top of the engine compartment as opposed to from the rear of the machine. 2. Disconnect the positive (+) battery cable (1) from the starter motor. 3. Disconnect the starter solenoid wire connector (2) from the starter.
RAIL16SSL0167AA
1
RAIL16SSL0166AA
2
4. Remove the three mounting bolts securing the starter motor (1) to the flywheel housing. NOTE: To remove the three mounting bolts use a wrench (not shown) and a swivel-head socket (A) with a 203.2 â&#x20AC;&#x201C; 304.8 mm (8.0 â&#x20AC;&#x201C; 12.0 in) socket extension (B). 5. Rotate the starter motor (1) to gain clearance within the chassis, and remove the starter from the machine.
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Electrical systems - Engine starting system
Engine starter - Install SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
Component installation 1. To gain clearance within the chassis, rotate the starter motor and slide the starter into the flywheel housing. 2. Secure the starter motor (1) to the flywheel housing with the three M10 x 35 mm mounting bolts. Torque the bolts to 40.0 – 47.0 N·m (30.0 – 35.0 lb ft). NOTE: To install the three mounting bolts use a wrench (not shown) and a swivel-head socket (A) with a 203.2 – 304.8 mm (8.0 – 12.0 in) socket extension (B).
RAIL16SSL0166AA
1
RAIL16SSL0167AA
2
3. Connect the starter solenoid wire (1) to the starter. 4. Connect the positive (+) battery cable (2) to the starter motor. Torque the nut to 12.0 – 18.0 N·m (8.9 – 13.3 lb ft).
5. Install the Electronic Control Unit (ECU) mounting plate, and secure with the four nuts.
Post operations 1. Install the battery and/or turn the Master Disconnect Switch to the ON position. See Battery - Connect (55.302) or Battery - Install (55.302) for further details. 2. Lower the loader arms and secure the cab to the chassis. See Cab tilting system - Lower (90.150) for vertical lift units.
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Electrical systems - Engine starting system
Engine starter - Remove SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ]
CAUTION Burn hazard! Exhaust surfaces are hot! Always wear protective gloves when cleaning or working on or near the muffler, catalytic converter, or exhaust stack. Failure to comply could result in minor or moderate injury. C0142A
Prior operations 1. Raise the loader arms and tilt the cab forward. See Cab tilting system - Tilt (90.150) for radial lift units. 2. Remove the battery and/or turn the Master Disconnect Switch to the OFF position. See Battery - Disconnect (55.302) or Battery - Remove (55.302) for further details.
Component removal 1. Remove the four nuts securing the Electronic Control Unit (ECU) mounting plate. NOTE: Move the ECU mounting plate just to gain clearance for the starter. 2. Disconnect the positive (+) battery cable (1) from the starter motor. 3. Disconnect the starter solenoid wire connector (2) from the starter.
RAIL16SSL0167AA
1
RAIL16SSL0166AA
2
4. Remove the three mounting bolts securing the starter motor (1) to the flywheel housing. NOTE: To remove the three mounting bolts use a wrench (not shown) and a swivel-head socket (A) with a 203.2 â&#x20AC;&#x201C; 304.8 mm (8.0 â&#x20AC;&#x201C; 12.0 in) socket extension (B). 5. Rotate the starter motor (1) to gain clearance within the chassis, and remove the starter from the machine.
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Electrical systems - Engine starting system
Engine starter - Install SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ]
Component installation 1. To gain clearance within the chassis, rotate the starter motor and slide the starter into the flywheel housing. 2. Secure the starter motor (1) to the flywheel housing with the three M10 x 35 mm mounting bolts. Torque the bolts to 40.0 – 47.0 N·m (30.0 – 35.0 lb ft). NOTE: To install the three mounting bolts use a wrench (not shown) and a swivel-head socket (A) with a 203.2 – 304.8 mm (8.0 – 12.0 in) socket extension (B).
RAIL16SSL0166AA
1
RAIL16SSL0167AA
2
3. Connect the starter solenoid wire (1) to the starter. 4. Connect the positive (+) battery cable (2) to the starter motor. Torque the nut to 12.0 – 18.0 N·m (8.9 – 13.3 lb ft).
5. Install the Electronic Control Unit (ECU) mounting plate, and secure with the four nuts.
Post operations 1. Install the battery and/or turn the Master Disconnect Switch to the ON position. See Battery - Connect (55.302) or Battery - Install (55.302) for further details. 2. Lower the loader arms and secure the cab to the chassis. See Cab tilting system - Lower (90.150) for radial lift units.
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Index Electrical systems - 55 Engine starting system - 201 Engine starter - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4
Engine starter - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6
Engine starter - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8
Engine starter - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3
Engine starter - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5
Engine starter - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7
(*) See content for specific models 48068130 29/01/2018
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Electrical systems - 55 Cold start aid - 202
SR210 TIER 4B (FINAL) [NGM418237 - ], SR210 TIER 4B (FINAL) [NHM435463 - ], SR240 TIER 4B (FINAL) [NGM418237 - ], SR240 TIER 4B (FINAL) [NHM435463 - ], SV280 TIER 4B (FINAL) [NGM418237 - ], SV280 TIER 4B (FINAL) [NHM435463 - ], TR270 TIER 4B (FINAL) [NGM418237 - ], TR270 TIER 4B (FINAL) [NHM435463 - ], TR310 TIER 4B (FINAL) [NGM418237 - ], TR310 TIER 4B (FINAL) [NHM435463 - ], TV370 TIER 4B (FINAL) [NHM435463 - ]
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Contents Electrical systems - 55 Cold start aid - 202
FUNCTIONAL DATA Cold start aid Glow plug system Glow plug control module - Overview - Glow plug control module . . . . . . . . . . . . . . . . . 3
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Electrical systems - Cold start aid
Glow plug system Glow plug control module - Overview - Glow plug control module
NHIL14ENG0777FA
1
The Fast Glow Plug Control Unit (FGPCU) powers up to four fast glow plugs (low voltage glow plugs that cannot be permanently driven at battery voltage levels) as controlled by the input signal CTRL (active low). The duty cycle of the CTRL signal sets the power level of the plug outputs so the Engine Control Unit (ECU) can control the overall power of the heating elements. The diagnostic functions are implemented for each glow plug putput independently. The diagnostic output signal transmits the current status of the glow plugs to the ECU. Each glow plug may either operate correctly or present a fault condition (open load, short circuit or thermal shutdown).
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Index Electrical systems - 55 Cold start aid - 202 Glow plug system Glow plug control module - Overview - Glow plug control module . . . . . . . . . . . .
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3
Electrical systems - 55 Alternator - 301
SR210 TIER 4B (FINAL) [NGM418237 - ], SR210 TIER 4B (FINAL) [NHM435463 - ], SR240 TIER 4B (FINAL) [NGM418237 - ], SR240 TIER 4B (FINAL) [NHM435463 - ], SV280 TIER 4B (FINAL) [NGM418237 - ], SV280 TIER 4B (FINAL) [NHM435463 - ], TR270 TIER 4B (FINAL) [NGM418237 - ], TR270 TIER 4B (FINAL) [NHM435463 - ], TR310 TIER 4B (FINAL) [NGM418237 - ], TR310 TIER 4B (FINAL) [NHM435463 - ], TV370 TIER 4B (FINAL) [NHM435463 - ]
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Contents Electrical systems - 55 Alternator - 301
SERVICE Alternator Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
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Electrical systems - Alternator
Alternator - Remove Prior operation: Fan - Remove (10.414) 1. Remove the serpentine belt from the alternator pulley.
RCPH11SSL038AAP
1
73092768
2
2. Hold the alternator (1) and detach it from its support loosening the screw (2). Recover the nut and washer.
Next operation: Alternator - Install (55.301)
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Electrical systems - Alternator
Alternator - Install Prior operation: Alternator - Remove (55.301) 1. Install the alternator (1).
73092768
1
RCPH11SSL038AAP
2
2. Tighten the bolts by hand until the belt is in place. 3. Once the belt is on the pulleys and tight, the alternator bolts can be tightened.
Next operation: Belt - Tension adjust (10.414) Next operation: Fan - Install (10.414)
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Index Electrical systems - 55 Alternator - 301 Alternator - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4
Alternator - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3
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Electrical systems - 55 Battery - 302
SR210 TIER 4B (FINAL) [NGM418237 - ], SR210 TIER 4B (FINAL) [NHM435463 - ], SR240 TIER 4B (FINAL) [NGM418237 - ], SR240 TIER 4B (FINAL) [NHM435463 - ], SV280 TIER 4B (FINAL) [NGM418237 - ], SV280 TIER 4B (FINAL) [NHM435463 - ], TR270 TIER 4B (FINAL) [NGM418237 - ], TR270 TIER 4B (FINAL) [NHM435463 - ], TR310 TIER 4B (FINAL) [NGM418237 - ], TR310 TIER 4B (FINAL) [NHM435463 - ], TV370 TIER 4B (FINAL) [NHM435463 - ]
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Contents Electrical systems - 55 Battery - 302
SERVICE Battery Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Connect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
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Electrical systems - Battery
Battery - Disconnect 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. Failure to comply could result in death or serious injury. W0398A
WARNING Hazardous chemicals! Battery electrolyte contains sulfuric acid. Contact with skin and eyes could result in severe irritation and burns. Always wear splash-proof goggles and protective clothing (gloves and aprons). Wash hands after handling. Failure to comply could result in death or serious injury. W0006A
WARNING Chemical hazard! When lifting a plastic-cased battery, excessive pressure on the end walls could cause acid to spill through the vent caps. Lift a plastic-cased battery with a battery carrier or with your hands positioned on opposite corners of the battery. Always wash your hands after handling. Failure to comply could result in death or serious injury. W0385A
Disconnect battery 1. Remove battery access cover (2) by removing the mounting bolts (1).
931001637
1
931001638
2
2. Turn battery disconnector (1) â&#x20AC;&#x201D;if equippedâ&#x20AC;&#x201D; to the off position (2).
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Electrical systems - Battery
3. Disconnect negative battery cable connection (1).
931001641
3
931002054
4
4. Disconnect positive battery connection (1).
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Electrical systems - Battery
Battery - Remove WARNING Heavy objects! Lift and handle all heavy components using lifting equipment with adequate capacity. Always support units or parts with suitable slings or hooks. Make sure the work area is clear of all bystanders. Failure to comply could result in death or serious injury. W0398A
WARNING Hazardous chemicals! Battery electrolyte contains sulfuric acid. Contact with skin and eyes could result in severe irritation and burns. Always wear splash-proof goggles and protective clothing (gloves and aprons). Wash hands after handling. Failure to comply could result in death or serious injury. W0006A
WARNING Chemical hazard! When lifting a plastic-cased battery, excessive pressure on the end walls could cause acid to spill through the vent caps. Lift a plastic-cased battery with a battery carrier or with your hands positioned on opposite corners of the battery. Always wash your hands after handling. Failure to comply could result in death or serious injury. W0385A
Battery removal 1. Remove the battery cover hardware (1) and the battery cover (2).
931001637
1
931001638
2
2. Turn battery disconnector (1) â&#x20AC;&#x201D;if equippedâ&#x20AC;&#x201D; to the off position (2).
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Electrical systems - Battery
3. Disconnect the negative cable connection (1).
931001641
3
931002054
4
931001639
5
931001642
6
4. Disconnect the positive cable connection (1).
5. Loosen the nuts (1), and remove the battery hold-down (2).
6. Remove the battery (1) in direction of the arrow.
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Electrical systems - Battery
Battery - Install WARNING Heavy objects! Lift and handle all heavy components using lifting equipment with adequate capacity. Always support units or parts with suitable slings or hooks. Make sure the work area is clear of all bystanders. Failure to comply could result in death or serious injury. W0398A
WARNING Hazardous chemicals! Battery electrolyte contains sulfuric acid. Contact with skin and eyes could result in severe irritation and burns. Always wear splash-proof goggles and protective clothing (gloves and aprons). Wash hands after handling. Failure to comply could result in death or serious injury. W0006A
WARNING Chemical hazard! When lifting a plastic-cased battery, excessive pressure on the end walls could cause acid to spill through the vent caps. Lift a plastic-cased battery with a battery carrier or with your hands positioned on opposite corners of the battery. Always wash your hands after handling. Failure to comply could result in death or serious injury. W0385A
Battery installation 1. Confirm that the battery quick disconnector (1) is in the off position (2), as shown. NOTE: The battery disconnector is optional.
931001638
1
931001642
2
2. Place the battery (1) in the compartment, in the direction of the arrow.
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Electrical systems - Battery
3. Install the battery hold-down (1), and secure with the nuts (2).
931001640
3
931001639
4
931002054
5
931001641
6
4. Insure that the hold-down (1) is square to the battery (2).
5. Connect the positive cable connection (1).
6. Connect the negative cable connection (1).
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Electrical systems - Battery
7. Turn the battery quick disconnector (1) to the on position (2) as shown. NOTE: The battery disconnector is optional.
931001828
7
931001637
8
8. Install the battery cover (2) and secure with the hardware (1).
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Electrical systems - Battery
Battery - Connect 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. Failure to comply could result in death or serious injury. W0398A
WARNING Hazardous chemicals! Battery electrolyte contains sulfuric acid. Contact with skin and eyes could result in severe irritation and burns. Always wear splash-proof goggles and protective clothing (gloves and aprons). Wash hands after handling. Failure to comply could result in death or serious injury. W0006A
WARNING Chemical hazard! When lifting a plastic-cased battery, excessive pressure on the end walls could cause acid to spill through the vent caps. Lift a plastic-cased battery with a battery carrier or with your hands positioned on opposite corners of the battery. Always wash your hands after handling. Failure to comply could result in death or serious injury. W0385A
Connect battery 1. Turn battery disconnector (1) â&#x20AC;&#x201D;if equippedâ&#x20AC;&#x201D; to the off position (2).
931001638
1
931002054
2
2. Connect the positive battery connection (1).
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Electrical systems - Battery
3. Connect the negative battery connection (1).
931001641
3
931001828
4
4. Turn the battery disconnector (1)â&#x20AC;&#x201D; if equippedâ&#x20AC;&#x201D; to the on position (2).
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Index Electrical systems - 55 Battery - 302 Battery - Connect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10
Battery - Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3
Battery - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7
Battery - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5
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Electrical systems - 55 External lighting - 404
SR210 TIER 4B (FINAL) [NGM418237 - ], SR210 TIER 4B (FINAL) [NHM435463 - ], SR240 TIER 4B (FINAL) [NGM418237 - ], SR240 TIER 4B (FINAL) [NHM435463 - ], SV280 TIER 4B (FINAL) [NGM418237 - ], SV280 TIER 4B (FINAL) [NHM435463 - ], TR270 TIER 4B (FINAL) [NGM418237 - ], TR270 TIER 4B (FINAL) [NHM435463 - ], TR310 TIER 4B (FINAL) [NGM418237 - ], TR310 TIER 4B (FINAL) [NHM435463 - ], TV370 TIER 4B (FINAL) [NHM435463 - ]
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Contents Electrical systems - 55 External lighting - 404
DIAGNOSTIC Work light Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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Electrical systems - External lighting
Work light - Testing Test N°1 Test Point Condition Turn the ignition switch OFF. Check Verify all wiring connections are tight and secure. All connections should be free of corrosion, abrasion and damage. Verify that the chassis ground frame connections are secure and tight and free of oil, paint, dirt, damage and debris. Expected Result Result The connections are secure. The connections are free of corrosion, abrasion and damage. Go to the next step. Other Action Result The connections are not secure or the connections show signs of corrosion, abrasion and damage. Re(Possible pair as required. Cause) Test N°2 Test Point Condition Turn the ignition switch OFF. Check Disconnect the work lamp bulb. Turn the ignition switch ON. Turn the lamp selector switch to the work lamps. Measure the voltage between pin A and chassis ground. The voltage should be between 11.5 V and 14.8 V. Expected Result Result The voltage is between 11.5 V and 14.8 V. Replace the work lamp bulb and retest. Other Action Result The voltage is less than 11.5 V. Go to the next step. (Possible Cause) Test N°3 Test Point Condition Turn the ignition switch OFF. Check Disconnect the work lamp bulb. Measure the resistance between pin B and chassis ground. The resistance should be less than 10 Ω. Expected Result Result The resistance is greater than 10 Ω. There is a problem in the ground circuit to the bulb. Repair as required. Other Action Result The resistance is less than 10 Ω. Go to the next step. (Possible Cause) Test N°4 Test Point Condition Turn the ignition switch OFF. Check Disconnect the lights relay 1. Turn the ignition switch ON. Measure the voltage between Fuse1 B10 and chassis ground. The chassis ground connection must be clean and free of paint, oil, and dirt. The voltage should be between 11.5 V and 14.8 V. Expected Result Result The voltage is between 11.5 V and 14.8 V. Go to the next step. Other Action Result The voltage is less than 11.5 V. There is a problem with the relay battery signal. Repair as required. (Possible Cause)
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Electrical systems - External lighting
Test N°5 Test Point Condition Turn the ignition switch OFF. Check Disconnect the lights relay 1. Measure the resistance between Fuse1 A12 and chassis ground. The chassis ground connection must be clean and free of paint, oil, and dirt. The resistance should be less than 10 Ω. Expected Result Result The resistance is greater than 10 Ω. There is a problem in the ground circuit to the relay. Repair as required. Other Action Result The resistance is less than 10 Ω. Go to the next step. (Possible Cause) Test N°6 Test Point Condition Turn the ignition switch OFF. Check Disconnect the lights relay 1. Turn the ignition switch ON. Measure the voltage between Fuse1 A11 and chassis ground. The chassis ground connection must be clean and free of paint, oil, and dirt. The voltage should be between 11.5 V and 14.8 V. Expected Result Result The voltage is between 11.5 V and 14.8 V. Go to the next step. Other Action Result The voltage is less than 11.5 V. There is a problem with the battery supply from the lamp selector switch. (Possible Repair as required. Cause) Test N°7 Test Point Condition Turn the ignition switch OFF. Check Disconnect the lights relay 1. Turn the ignition switch ON. Measure the voltage between Fuse1 A10 and chassis ground. The chassis ground connection must be clean and free of paint, oil, and dirt. The voltage should be between 11.5 V and 14.8 V. Expected Result Result The voltage is between 11.5 V and 14.8 V. Go to the next step. Other Action Result The voltage is less than 11.5 V. There is a problem with the battery supply to the relay. Repair as required. (Possible Cause) Test N°8 Test Point Condition Turn the ignition switch OFF. Check Reconnect the lights relay 1. Turn the ignition switch ON. Use signal reading probes to measure the voltage between Fuse1 B12 and chassis ground. The chassis ground connection must be clean and free of paint, oil, and dirt. The voltage should be between 11.5 V and 14.8 V. Expected Result Result The voltage is between 11.5 V and 14.8 V. There is a problem with the battery supply to the work lamps. Check fuse F-014. Repair as required. Other Action Result The voltage is less than 11.5 V. Replace the lights relay 1 and retest. (Possible Cause)
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Index Electrical systems - 55 External lighting - 404 Work light - Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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3
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Electrical systems - 55 Warning indicators, alarms, and instruments - 408
SR210 TIER 4B (FINAL) [NGM418237 - ], SR210 TIER 4B (FINAL) [NHM435463 - ], SR240 TIER 4B (FINAL) [NGM418237 - ], SR240 TIER 4B (FINAL) [NHM435463 - ], SV280 TIER 4B (FINAL) [NGM418237 - ], SV280 TIER 4B (FINAL) [NHM435463 - ], TR270 TIER 4B (FINAL) [NGM418237 - ], TR270 TIER 4B (FINAL) [NHM435463 - ], TR310 TIER 4B (FINAL) [NGM418237 - ], TR310 TIER 4B (FINAL) [NHM435463 - ], TV370 TIER 4B (FINAL) [NHM435463 - ]
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Contents Electrical systems - 55 Warning indicators, alarms, and instruments - 408
SERVICE Instrument cluster View - Navigating the Setup Menu - Video . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 View - The “EZEH” menu - Video (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Configure - Lock menu and master code unlock - Video . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
DIAGNOSTIC Instrument cluster Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
(*) See content for specific models 48068130 29/01/2018
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Electrical systems - Warning indicators, alarms, and instruments
Instrument cluster - View - Navigating the Setup Menu - Video 1. The attached YouTubeâ&#x201E;˘ video instructs how to navigate the setup menu of the instrument cluster.
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Electrical systems - Warning indicators, alarms, and instruments
Instrument cluster - View - The “EZEH” menu - Video SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
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1. The attached YouTube™ video instructs how to navigate the “EZEH” setup menu of the instrument cluster.
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Electrical systems - Warning indicators, alarms, and instruments
Instrument cluster - Configure - Lock menu and master code unlock - Video 1. The attached YouTubeâ&#x201E;˘ video instructs how to navigate the lock menu within the setup menu of the instrument cluster.
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Electrical systems - Warning indicators, alarms, and instruments
Instrument cluster - Troubleshooting Problem Possible Cause ATS FAIL is displayed on The Diesel Particulate Filter (DPF) system the instrument cluster. and/or Exhaust Gas Recirculate (EGR) system detected a malfunction. CRKON is displayed on The OPERATE button is being pressed the instrument cluster. while attempting to start the machine. dPF FAIL is displayed on The Engine Control Unit (ECU) concluded the instrument cluster. that the machine is not ready for a regeneration of the Diesel Particulate Filter (DPF).
Correction Scan the control modules for diagnostic trouble codes.
Do not push the OPERATE button while attempting to start the machine. Bring the machine to operating temperatures, place the hand and foot throttle in the idle position, and disable all hydraulics. Wait for IdLE to appear on the instrument cluster. dPF ON is displayed on The Engine Control Unit (ECU) activated a No action needed. The machine is working the instrument cluster. regeneration of the Diesel Particulate Filter as designed. (DPF). dPF OFF is displayed on The Engine Control Unit (ECU) deactivated No action needed. The machine is working the instrument cluster. the regeneration of the Diesel Particulate as designed. Filter (DPF). dPF PARK is displayed on The Engine Control Unit (ECU) is request- Park the machine in a ventilated area, bring the instrument cluster. ing a forced regeneration of the Diesel Par- the machine to operating temperatures, disable all hydraulics, place the hand and ticulate Filter (DPF). foot throttle in idle, and wait for IdLE to appear on the instrument cluster. The Engine Control Unit (ECU) verified all Press the AUX OVERRIDE button on the dPF START PRESS requirements needed to regenerate the instrument cluster. AUXOV is displayed on Diesel Particulate Filter (DPF). the instrument cluster. The instrument cluster is telling the oper- Replace the engine oil, filter, and reset the ENG OIL SERV is ator that the machine needs an engine oil oil life meter on the instrument cluster. displayed on the change. instrument cluster. EOLT is displayed on the The instrument cluster does not have the Program the instrument cluster with the latlatest software. est software, using the Electronic Service instrument cluster. Tool (EST). IdLE is displayed on the The Engine Control Unit (ECU) is verifying No action needed. The machine is working instrument cluster. that the machine is ready for regeneration as designed. of the Diesel Particulate Filter (DPF). JOYNU is displayed on One or both of the control handles are not Return the control handles to the neutral position. the instrument cluster. in the neutral position. One or both of the control handles are not Calibrate both control handles, using the calibrated correctly. Electronic Service Tool (EST). The rubber boots are incorrectly installed or Inspect the rubber boots. worn. The axis signal for one or both of the control Inspect the control handle module that is handles is greater than 1.5° or less than faulty. 1.5° in any direction. The centering spring on one or both of the Inspect the control handle module that is faulty. control handles is worn. The instrument cluster is asking the oper- No action needed. The machine is workLOCK? is displayed on ator if he/she wants to lock the machine to ing as designed. Do not press the AUX the instrument cluster. OVERRIDE button. This will lock the maprevent unwanted machine operation. chine controls. You will not be able to start the machine without an owner’s code if the AUX OVERRIDE button has been pressed. The lap bar does not detect an operator in Use the Electronic Service Tool (EST) to OPRPR is displayed on the machine. monitor the lap bar. Verify that the lap bar the instrument cluster. is working as designed. The seat switch does not detect an opera- Use the Electronic Service Tool (EST) to tor in the machine. monitor the seat switch. Verify that the seat switch is working as designed. The Engine Control Unit (ECU) activated a No action needed. The machine is working REGEN ACTIVE is regeneration of the Diesel Particulate Filter as designed. displayed on the (DPF). instrument cluster. 48068130 29/01/2018
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Electrical systems - Warning indicators, alarms, and instruments
Problem Possible Cause REGEN ENd is displayed The Engine Control Unit (ECU) deactivated on the instrument cluster. the regeneration of the Diesel Particulate Filter (DPF). REGEN FAIL is displayed The Engine Control Unit (ECU) concluded on the instrument cluster. that the machine is not ready for a regeneration of the Diesel Particulate Filter (DPF). REGEN OFF is displayed on the instrument cluster. REGEN PARK is displayed on the instrument cluster.
REGEN START PRESS AUXOV is displayed on the instrument cluster. REGEN IdLE is displayed on the instrument cluster. REGEN WAIT is displayed on the instrument cluster. The instrument cluster displays a 30 second countdown resulting in engine shutdown.
Correction No action needed. The machine is working as designed.
Bring the machine to operating temperatures, place the hand and foot throttle in the idle position, and disable all hydraulics. Wait for REGEN IdLE to appear on the instrument cluster. The Engine Control Unit (ECU) deactivated No action needed. The machine is working the regeneration of the Diesel Particulate as designed. Filter (DPF). The Engine Control Unit (ECU) is request- Park the machine in a ventilated area, bring ing a forced regeneration of the Diesel Par- the machine to operating temperatures, disable all hydraulics, place the hand and ticulate Filter (DPF). foot throttle in idle, and wait for REGEN IdLE to appear on the instrument cluster. The Engine Control Unit (ECU) verified all Press the AUX OVERRIDE button on the requirements needed to regenerate the instrument cluster. Diesel Particulate Filter (DPF). The Engine Control Unit (ECU) is verifying No action needed. The machine is working that the machine is ready for regeneration as designed. of the Diesel Particulate Filter (DPF). The operator did not press AUX OVER- Restart the forced regeneration process. RIDE when prompted and within ten minutes of being prompted. The instrument cluster detected a critical Scan the control modules for diagnostic machine error which resulted in an engine trouble codes. shutdown.
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Index Electrical systems - 55 Warning indicators, alarms, and instruments - 408 Instrument cluster - Configure - Lock menu and master code unlock - Video . . . . . . . . . . . . . . . . . . .
5
Instrument cluster - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6
Instrument cluster - View - Navigating the Setup Menu - Video . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3
Instrument cluster - View - The â&#x20AC;&#x153;EZEHâ&#x20AC;? menu - Video (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4
(*) See content for specific models 48068130 29/01/2018
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Electrical systems - 55 Cab controls - 512
SR210 TIER 4B (FINAL) [NGM418237 - ], SR210 TIER 4B (FINAL) [NHM435463 - ], SR240 TIER 4B (FINAL) [NGM418237 - ], SR240 TIER 4B (FINAL) [NHM435463 - ], SV280 TIER 4B (FINAL) [NGM418237 - ], SV280 TIER 4B (FINAL) [NHM435463 - ], TR270 TIER 4B (FINAL) [NGM418237 - ], TR270 TIER 4B (FINAL) [NHM435463 - ], TR310 TIER 4B (FINAL) [NGM418237 - ], TR310 TIER 4B (FINAL) [NHM435463 - ], TV370 TIER 4B (FINAL) [NHM435463 - ]
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Contents Electrical systems - 55 Cab controls - 512
TECHNICAL DATA Instrument cluster Configure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SERVICE Cab radio set Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Joystick and Electric Hydraulic (EH) control Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
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Electrical systems - Cab controls
Instrument cluster - Configure Menu navigation controls Use the four switch buttons to navigate through the instrument cluster Menu by following the setup menu functions. Many of the setup menu functions are intended for service technicians and owners. Contact your dealer for the service manual or security code information. (1) TEXT DISPLAY Displays the menu text. (2) START Navigates selections on every menu level. Certain menus will prompt the user to enter an access code or allow the user to change a numerical value. NOTE: Pushing the Start button will increment the flashing digit 1,2,3 for number entry. (3) OPERATE Increments the flashing digit 7,8,9,0 for number entry. (4) AUX OVERRIDE Exits the sub-menu and moves top level to the next option. Increments the flashing digit 4,5,6 for number entry. (5) POWER For number entry, moves flashing digit to the next place. Saves entry. Enters the sub-menu. Top level menu options • EXIT — Exit the setup menu. • EH — Customize the speed of the machine’s Electro hydraulic controls (if equipped). • dSPLY — Alternate method to select between the selected display parameters. • UNITS — Allows the operator to select between Fahrenheit (Imperial units) and Celsius (Standard Imperial units). • JTIME — Job timer. Timer that displays engine operating hours since last reset. Ideal for rentals or job tracking. • OIL — Used to reset the oil life monitoring status after an oil change. • LOCK — Used to create/change owner and user codes • TMOUT — Instrument Cluster (IC) Time-out. Used to change the IC Power OFF settings.
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NOTE: The Advanced Instrument Cluster (AIC) images are shown in this section for the four switch buttons (2), (3), (4) and (5) used to navigate through the instrument cluster. The top two switch buttons on the Electronic Instrument Cluster (EIC) are function buttons and function the same as the POWER (5) and START (2) switch buttons on the AIC instrument panel for the setup menu functions.
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Electrical systems - Cab controls
Entering the SETUP mode NOTE: The Advanced Instrument Cluster (AIC) images are shown in this section for the four switch buttons (2), (3), (4) and (5) used to navigate through the instrument cluster. The top two switch buttons on the Electronic Instrument Cluster (EIC) are function buttons and function the same as the POWER (5) and START (2) switch buttons on the AIC instrument panel for the setup menu functions. Entering the set up mode: (â&#x20AC;&#x153;Setupâ&#x20AC;?) 1. Place the machine on firm, level ground with the lift arm and bucket down. 2. Before sitting in the seat, push and hold the OPERATE button (3) and the AUX OVERRRIDE button (4) for five seconds until the display (1) shows the word SETUP. 3. You may now sit down and navigate through the SETUP menu. Familiarize yourself with the use of the switch buttons in order to help prevent erroneous settings.
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Electrical systems - Cab controls
Text display The operator may choose a continuous display of one of the four following parameters or select cycle from the dSPLY top level menu and momentarily display all four of the parameters in a cycle for a few seconds each. • HOUR - Engine hours. • RPM - Engine RPM. • COOLT - Engine coolant temperature. • HOILT - Hydraulic fluid temperature. • CYCLE - Cycle though all four parameters. NOTE: The instrument cluster is programmed to display the last setting selected when you sit in the seat.
Change or select from the dSPLY level menu Access the SETUP menu, press the START button until dSPLY appears on the screen. 1. Push the POWER button (5) to display the current selection. 2. Push the START button (2) to toggle through the selections. 3. Once the desired selection appears on the text display, push the POWER button (5) to save the selection.
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Electrical systems - Cab controls
Setting controllability for Electro Hydraulic (EH) NOTE: The Advanced Instrument Cluster (AIC) images are shown in this section for the four switch buttons (2), (3), (4) and (5) used to navigate through the instrument cluster. The top two switch buttons on the Electronic Instrument Cluster (EIC) are function buttons and function the same as the POWER (5) and START (2) switch buttons on the AIC instrument panel for the setup menu functions. NOTE: These settings can be activated using the Easy Electro-Hydraulic (EZ-EH) menu custom settings SP-C and CR-C. All changes must be made with the engine in the off position and the electronics asleep. 1. Before sitting in the seat, press and hold the AUX OVERRIDE button (4) and the OPERATE button (3) at the same time for five to seven seconds until SETUP (1) appears in the display. After seeing setup in the display, you may sit in the operatorâ&#x20AC;&#x2122;s seat and make changes. 2. Press the START button (2) to scroll between the different menus until EH (1) appears on the display. 3. Press the POWER button (5) to enter the next menu. 4. Press the START button (2) to scroll to the setting selection you want to adjust (Speed: Drive, Lift, or Tilt) or (CTLR: Drive or L-ARM), then press the POWER button (5) to save the entry. For DFLT, press the POWER button (5) to save the settings back to the factory default settings. The default settings are shown in tables for each model on the following pages. NOTE: Use the AUX OVERRIDE button (4) when you want to go up a level. 5. Press the START button (2) to scroll to the desired speed level (High, Med-2, Med-1, or Low) or (DRV1, DRV2, or DRV3) or (LDR1, LDR2, or LDR3), then press the POWER button (5) to save the entry. 6. After you have saved your selection; the monitor will revert back to step 3 so you can make another adjustment. If no other adjustments are needed, use the AUX OVERRRIDE button (4) to exit the machine function menu. You will now be in the main SETUP menu; use the START button (2) to scroll to EXIT and then push the POWER button (5) again to exit the setup menu. 7. Leave the operatorâ&#x20AC;&#x2122;s seat for ten seconds before trying to start the unit. RAIL14SSL0667CA
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Electrical systems - Cab controls
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Electrical systems - Cab controls
Setting controllability with Easy-Electro Hydraulic (EZ-EH) The Easy Electro Hydraulic ( EZ-EH) machines have the EZ-EH information sign (A) located at the top of the instrument cluster on the right-hand column. The following instructions are for the shortcut to the Electro Hydraulic (EH) setup. Use these settings to set the speed of the drive , lift and tilt. Also the drive and loader lift arm settings. All changes must be made with the hydraulics disabled and the operator in the operatorâ&#x20AC;&#x2122;s seat. 1. Press and hold the AUX OVERRIDE button (1) for two seconds to enter the EH shortcut menu. 2. SPEEd will display on the display (2). Press the AUX OVERRIDE button (1) to select a different menu item ( DRIVE, EXIT, HOUR, HOILT, COOLT, RPM, or CYCLE). 3. Press the OPERATE button (3) to enter the SPEEd menu. The current setting will be displayed.
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4. Press the AUX OVERRIDE button (1) to change the SPEEd setting. 5. Press the OPERATE button (3) to save a new setting. If EXIT is selected, you will exit back to the top menu level. NOTE: If a new setting is saved, SAVEd will be displayed and you will exit to the top level shortcut menu. The CTRL menu works the same as the above SPEEd menu.
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Electrical systems - Cab controls
Customize settings • Custom settings SP-C and CR-C allow you to fully customize the EH settings using the setup menu. • SP-C sets to the SETUP menu SPEEd settings: DRIVE, LIFT, and TILT. CR-C sets to setup menu CRTL settings DRIVE and L-ARM. • If you do not use the “Setup” menu to customize settings, SP-C and CR-C will be set by default.
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Electrical systems - Cab controls
Menu structure for Electro Hydraulic ( EH) controls Setup Exit EH DSPLY UNITS
JTIME Oil Lock
Display setup menu. Exit the setup menu. Customize the speed of the machineâ&#x20AC;&#x2122;s EH controls. Alternate method to select between the selected display parameters. Allows the operator to select between Fahrenheit/Imperial units and Celsius/SI units. Job Timer. Displays engine operating hours since last reset. Reset oil life monitor.
Lift Tilt L-ARM
Loader arm up and down function. Attachment tilt function. Loader arm.
High
Quick response to control lever movement.
Med-2
Medium/quick response to control lever movement.
Med-1
Medium/slow response to control lever movement. Aggressive response to control lever movement. Medium response to control lever movement. Smooth response to control lever movement. Aggressive response to control lever movement. Medium response to control lever movement. Smooth response to control lever movement.
DRV1 DRV2
Speed
Used to create/change owner and user codes. Speed of the drive, lift, and tilt functions.
DRV3
CTRL
Controls for drive and loader arm.
LDR1
DFLT
Factory default settings.
LDR2
Drive
Travel forward and reverse function.
LDR3
Default settings for model SR270 and SV340 SPEED Tilt Lift Drive
Low Low Low
Med-1 Med-1 Med-1
Drive L-Arm
DRV3 LDR3
DRV2 LDR2
Med-2 Med-2 Med-2
High High High
CTRL DRV1 LDR1
Default settings for model TR340 and TV380 SPEED Tilt Lift Drive
Low Low Low
Med-1 Med-1 Med-1
Drive L-Arm
DRV3 LDR3
DRV2 LDR2
Med-2 Med-2 Med-2 CTRL
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DRV1 LDR1
High High High
Electrical systems - Cab controls
Temperature display selection NOTE: The Advanced Instrument Cluster (AIC) images are shown in this section for the four switch buttons (2), (3), (4) and (5) used to navigate through the instrument cluster. The top two switch buttons on the Electronic Instrument Cluster (EIC) are function buttons and function the same as the POWER (5) and START (2) switch buttons on the AIC instrument panel for the setup menu functions. The operator may choose to display either Celsius (°C) or Fahrenheit (°F) temperature scales. Access the “Setup” menu and press the START button until UNITS appears on the screen. 1. Push the POWER button (5) to drop down into the sub-menu. Fahrenheit or Celsius will appear in the display. 2. Push the START button (2) to select the temperature scale desired. 3. Once the selected scale appears on the display (1), push the POWER button (5). The display (1) will blink OFF then ON and show the selected temperature scale. 4. To exit, press START button (2) until the display (1) shows the word EXIT. 5. With EXIT in the display (1) press the POWER button (5) to return to normal operation.
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Electrical systems - Cab controls
View or reset Job Timer (JTIME) NOTE: The Advanced Instrument Cluster (AIC) images are shown in this section for the four switch buttons (2), (3), (4) and (5) used to navigate through the instrument cluster. The top two switch buttons on the Electronic Instrument Cluster (EIC) are function buttons and function the same as the POWER (5) and START (2) switch buttons on the AIC instrument panel for the setup menu functions. The operator may choose to set a timer that will run independent from the machine hours. To view or reset the timer: Access the â&#x20AC;&#x153;Setupâ&#x20AC;? menu and press the START button until JTIME appears on the screen. 1. Push the POWER button (5) to view the current timer. 2. Push the START button (2) to reset or view the timer. 3. Use the POWER button (5) to save the selection.
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Electrical systems - Cab controls
Oil life reset NOTE: The Advanced Instrument Cluster (AIC) images are shown in this section for the four switch buttons (2), (3), (4) and (5) used to navigate through the instrument cluster. The top two switch buttons on the Electronic Instrument Cluster (EIC) are function buttons and function the same as the POWER (5) and START (2) switch buttons on the AIC instrument panel for the setup menu functions. To reset the oil life monitoring feature. To reset the oil life monitoring feature. Access the â&#x20AC;&#x153;Setupâ&#x20AC;? menu and press the START button until OIL appears on the screen. 1. Push the POWER button (5) to view RESET on the display. 2. Push the START button (2) to reset the oil life. 3. Push the POWER button (5) to save.
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Electrical systems - Cab controls
Anti-theft operation NOTE: The Advanced Instrument Cluster (AIC) images are shown in this section for the four switch buttons (2), (3), (4) and (5) used to navigate through the instrument cluster. The top two switch buttons on the Electronic Instrument Cluster (EIC) are function buttons and function the same as the POWER (5) and START (2) switch buttons on the AIC instrument panel for the setup menu functions.
Locking the instrument panel If a lock code has been entered; immediately after shutting off the engine the display will show lock? and the AUX OVERRIDE button will flash. Anti-theft is set by pressing the AUX OVERRIDE button. The panel is now locked and LOCKd is displayed. Restarting requires entering the code. If the AUX OVERRIDE button is not pressed, the machine can be started without a code. The panel does not automatically lock. If a lock code has not been entered; when the engine is shut off the display will not show â&#x20AC;&#x153; lock?â&#x20AC;? and the engine can be started without a code until a lock code is entered.
Unlocking the instrument panel 1. Sit in the seat to power the instrument panel. The warning lamps will illuminate and there will be an audible beep. 2. Press the flashing POWER button (5). The display (1) will show unloc. 3. Enter code by using multiple presses of the START button (2), AUX OVERRIDE button (4), and OPERATE button (3) . Press the POWER button (5) to save each digit and move to the next. NOTE: For numbers 1, 2, 3 use the START button. For numbers 4, 5, 6 use the AUX OVERRIDE button. For numbers 7, 8, 9, 0 use the OPERATE button. 4. Press the POWER button (5) after the fifth digit to enter the code. The engine preheat lamp will illuminate and the display (1) will begin the thirty second countdown. NOTE: If the incorrect code is entered, ERROR is displayed, followed by 00000 prompting the operator to enter the correct code.
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Electrical systems - Cab controls
If no owner code has been created If you decide you do not want to create a code, enter all 0s. You will return to OWNCR.
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Creating codes The panel cannot be locked until a code is created. The instrument panel has one owner code and up to ten user codes. The owner code will always unlock the panel. The owner code will be required to create or change user codes and to modify the owner code.
Owner code Access the SETUP menu, press the START button to move to the LOCK menu. Press the POWER button to enter the LOCK menu.
Create an owner code If no owner code exists, the display will show the word OWNCR (Owner Create), followed by 00000 . Write down the planned 5 digit code or use a code you already know. NOTICE: Once the code is created, the panel cannot be unlocked with out the code. If the panel cannot be unlocked, contact your Dealer.
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Electrical systems - Cab controls
1. Enter code by using multiple presses of the START button (2), AUX OVERRIDE button (4), and OPERATE button (3). Press the POWER button (5) to save each digit and move to the next. NOTE: For numbers 1, 2, 3 use the START button. For numbers 4, 5, 6 use the AUX OVERRIDE button. For numbers 7, 8, 9, 0 use the OPERATE button. 2. Press the POWER button (5) after the fifth digit to enter the code. The engine preheat lamp will illuminate and the display will begin the thirty second countdown. 3. Press the START button (2) to move to the exit menu, and press the POWER button (5) to exit the SETUP menu. The panel is not locked at this point.
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Electrical systems - Cab controls
If an owner code has been created and LOCK function is disabled NOTE: You can turn the lock function ON and OFF by pressing the POWER button. If you cannot remember or enter an incorrect code, you will return to OWNCR.
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To modify the owner code Once in the LOCK menu, the display will show OWNER. Press the POWER button to enter the OWNER menu. The display will show open followed by 00000. 1. Enter the current owner code by using multiple presses of the START button (2), AUX OVERRIDE button (4), and OPERATE button (3). Press the POWER button (5) to save each digit and move to the next. NOTE: For numbers 1, 2, 3 use the START button. For numbers 4, 5, 6 use the AUX OVERRIDE button. For numbers 7, 8, 9, 0 use the OPERATE button. 2. Press the POWER button (5) after the fifth digit to save the code. The display (1) will show the word OWNCR followed by the saved owner code. 3. Enter a new owner code to overwrite the existing code. The panel will return to the SETUP menu.
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Electrical systems - Cab controls
User codes Once in the SETUP menu, press the START button to move to the LOCK menu. Press the POWER button to enter the LOCK menu.
To create or modify a user code: NOTE: An owner code must be saved before a user code. Once in the LOCK menu, the display will show the word OWNER. Press the START button to move to the USER menu. 1. Use the START button (2) to move to user0 through user9. Press the POWER button (5) to create or change that user code. The display (1) will show the word USRCR (user create) followed by 00000 . 2. Enter the owner code. 00000 or the existing user code will be displayed. 3. Enter a new user code to enter or overwrite the existing code. The panel will return to the SETUP menu. 4. Press the START button (2) to move to the EXIT menu, and press the POWER button (5) to exit the SETUP menu. The panel is not locked at this point.
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Electrical systems - Cab controls
Instrument cluster time-out feature NOTE: The Advanced Instrument Cluster (AIC) images are shown in this section for the four switch buttons (2), (3), (4) and (5) used to navigate through the instrument cluster. The top two switch buttons on the Electronic Instrument Cluster (EIC) are function buttons and function the same as the POWER (5) and START (2) switch buttons on the AIC instrument panel for the setup menu functions. On both Keyed and Keyless machines, the Instrument Cluster (IC) will automatically go to a Power OFF state, if ALL of the following conditions are true for a continuous period of 10 – 60 min (use the SETUP menu to adjust): • The operator is not in the operator seat • The Instrument Cluster (IC) indicates Power ON ○ Keyed machine, Key in the ON position ○ Keyless machine, Power button is illuminated • Engine is not running NOTE: On a Keyless machine if the Instrument Cluster (IC) enters Power OFF state due to the Time-out feature, the IC will resume normal behavior after entering Power OFF state. On a Keyed machine if the IC enters Power OFF state due to the Time-out feature, the IC will resume normal behavior after turning the Key from the ON position to the OFF position. Once in the “Setup” menu, press the START button until TMOUT appears on the screen. 1. Push the POWER button (5) to enter the TMOUT sub menu. 2. Push the START button (2) until the desired Time-out setting appears on the display (1). Settings are available in 10 min increments up to 60 min. 3. Push the POWER button (5) to save the selection. The display will blink OFF then ON and the new Time-out selection will appear. 4. Press the START button (2) until EXIT appears on the display (1). 5. Press the POWER button (5) to return to normal operation.
RAIL14SSL0667CA
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18
Electrical systems - Cab controls
Cab radio set - Remove Prior operation: Remove the headliner. See Cab headliner - Remove (90.160) for proper procedure. 1. Remove the radio (M) from the headliner and the radio bracket. Retain the spacer for installation NOTE: The spacer provides a gap in between the radio and the headliner so that air can circulate around to keep the radio cool.
RAPH15SSL0218AA
1
RAPH15SSL0214AA
2
RAPH15SSL0236BA
3
RAPH15SSL0212AA
4
2. Remove the speaker brackets (F) on the rear cross member by removing the four self-tapping screws (G).
3. Remove the antenna assembly (A) from the cab, remembering the order of the components. Place a decal or plug in the hole in the cab if a radio is not going to be reinstalled. See figure 4 for location. 4. Antenna assembly components: A. Antenna B. Plastic washer C. Flat metal washer D. Nut E. Antenna cable
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Electrical systems - Cab controls
Cab radio set - Install Installation 1. Locate the radio antenna mount location and remove the decal or the plug covering the hole.
RAPH15SSL0212AA
1
RAPH15SSL0236BA
2
RAPH15SSL0214AA
3
2. Disassemble the antenna assembly (A) carefully, remembering the order of the components. 3. Insert the antenna signal stud through the mounting hole. 4. Slide the plastic washer (B) on to the signal stud. 5. Slide the antenna cable (E) onto the signal stud with the toothed side toward the plastic washer (B). 6. Install the metal flat washer (C) and the nut (D) onto the signal stud. Torque the nut (D) to 2.05 – 2.9 N·m (18.0 – 26.0 lb in).
7. Assemble the speaker brackets (F) to the rear cross member applying the four self-tapping screws (G) in the existing holes. Torque the screws (G) to 11.8 N·m (8.7 lb ft). NOTE: Do not drill out the holes. These screws are selftapping and they will need all of the parent material to cut sufficient threads for holding strength. 8. Install the foam cover (H) over the back of the speakers (J). Cut a small hole near the electrical connector for the harness.
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Electrical systems - Cab controls
9. Attach the speakers (J) and the foam covers (H) to the speaker bracket (F) using the self-tapping screws (K). Torque the screws (K) to 3.5 N·m (2.6 lb ft). NOTE: Do not pre-drill the holes for the screws. The screws are self-tapping and they will need all of the parent material to cut sufficient threads for holding strength.
RAPH15SSL0215BA
4
93109120
5
RAPH15SSL0218AA
6
10. Use the radio bracket plate (L) as a template and line up the two push-in fastener locations with the outer holes in the plate. Mark and trim the four holes at each end of the slots and the one larger hole in the center of the bracket in the headliner.
11. Install the radio (M) to the headliner by adding a spacer in between the radio and headliner on the operator side of mount plate (L) against the headliner. Fasten all of the previously mentioned components together using the four M4 x 22 screws (N) and the four washers (C). Torque the radio screws (N) to 1.7 – 1.8 N·m (15.0 – 15.9 lb in). NOTE: The spacer provides a gap in between the radio and the headliner so that air can circulate around to keep the radio cool.
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Electrical systems - Cab controls
12. Route the harness from the radio through the hole in the headliner and bracket as shown.
63109129
7
RAPH15SSL0217AA
8
RAPH15SSL0216BA
9
13. Drill a 12 mm (1/2 in) hole in the headliner for the headphone jack plug in a desired location next to the radio. See Figure 8 for further detail.
14. Assemble the headphone jack plug (3) into the new hole in the headliner. 15. Connect the radio harness (1) and the cab harness by connecting the matching plugs. 16. Connect the antenna cable to the radio antenna connector (2). 17. Connect the radio harness to the left-hand and righthand speakers.
Next operation: Install the headliner, see Cab headliner - Install (90.160) for proper procedure.
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Electrical systems - Cab controls
Joystick and Electric Hydraulic (EH) control - Remove The following procedure has been performed on the left-hand joystick and an enclosed cab. The procedure for an opened cab is very similar to this procedure. Please use this procedure on the right-hand joystick and opened cabs when necessary.
Joystick replacement 1. Remove the fasteners that attach the panel to the cab. 2. Gently pull the panel towards you.
RAIL15SSL0073BA
1
RAIL15SSL0072BA
2
RAIL12SSL0543AA
3
3. Locate and disconnect the joystick from the wiring harness. 4. Remove every wire tie that attaches the joystick harness to the joystick mount.
5. Pull the bottom of the rubber boot (1) up and expose the jam nut (2). 6. Loosen the jam nut (2).
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Electrical systems - Cab controls
7. Detach the cover (1) from the joystick base. 8. Remove every wire tie that attaches the joystick harness to the joystick base. 9. Turn the joystick counterclockwise to remove the joystick.
RAIL12SSL0544AA
4
RAIL12SSL0558AA
5
RAIL12SSL0559AA
6
Joystick base replacement 10. Remove the screws (1) that attach the joystick base to the joystick mount. 11. Remove every wire tie that attaches the joystick harness to the joystick mount.
12. Remove the joystick base from the joystick mount.
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Electrical systems - Cab controls
Joystick and Electric Hydraulic (EH) control - Install The following procedure has been performed on the left-hand joystick and an enclosed cab. The procedure for an opened cab is very similar to this procedure. Please use this procedure on the right-hand joystick and opened cabs when necessary.
Joystick base replacement 1. Attach the joystick base to the joystick mount, using the screws (1).
RAIL12SSL0558AA
1
RAIL12SSL0545AA
2
RAIL12SSL0544AA
3
Joystick replacement 2. Measure 22.2 mm (8 3/4 in) from the base of the control handle. 3. Mark the harness at 22.2 mm (8 3/4 in). You will reference this mark later.
4. Place the joystick on the shaft. 5. Turn the joystick clockwise to install the joystick.
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Electrical systems - Cab controls
6. Orientate the joystick handle as show in image 4. NOTE: X equals 15° +/- 2°.
RAIL12SSL0567AA
4
RAIL12SSL0544AA
5
RAPH15SSL0045BA
6
7. Tighten the jam nut (1) to 41 N·m (30 lb ft).
8. Wrap the harness around the shaft of the left-hand joystick in a clockwise motion. NOTE: The harness for right-hand joystick wraps around the shaft in a counterclockwise motion. 9. Locate the mark you made in step 3. 10. Attach the marked portion of the harness to the joystick base, using a wire tie.
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Electrical systems - Cab controls
11. Install the cover (1). 12. Install the boot (2).
RAIL12SSL0542AA
7
RAIL15SSL0072BA
8
RAIL15SSL0073BA
9
13. Connect the joystick to the wiring harness. 14. Attach the wiring harness to the joystick mount.
15. Attach the panel to the cab.
Next operation: Calibrate the joystick by using the Electronic Service Tool (EST)..
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Index Electrical systems - 55 Cab controls - 512 Cab radio set - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
22
Cab radio set - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
21
Instrument cluster - Configure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3
Joystick and Electric Hydraulic (EH) control - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
27
Joystick and Electric Hydraulic (EH) control - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
25
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Electrical systems - 55 Wiper and washer system - 518
SR210 TIER 4B (FINAL) [NGM418237 - ], SR210 TIER 4B (FINAL) [NHM435463 - ], SR240 TIER 4B (FINAL) [NGM418237 - ], SR240 TIER 4B (FINAL) [NHM435463 - ], SV280 TIER 4B (FINAL) [NGM418237 - ], SV280 TIER 4B (FINAL) [NHM435463 - ], TR270 TIER 4B (FINAL) [NGM418237 - ], TR270 TIER 4B (FINAL) [NHM435463 - ], TR310 TIER 4B (FINAL) [NGM418237 - ], TR310 TIER 4B (FINAL) [NHM435463 - ], TV370 TIER 4B (FINAL) [NHM435463 - ]
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Contents Electrical systems - 55 Wiper and washer system - 518
TECHNICAL DATA Windshield wiper motor Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SERVICE Windshield wiper motor Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
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Electrical systems - Wiper and washer system
Windshield wiper motor - Torque Component Crown dome nut (1) Wiper nut (2)
Torque Consumable 6 – 7 N·m (53 – None 62 lb in) 9 – 11 N·m (80 None – 97 lb in)
Identification
RAPH15SSL0043BA
Component Bolt (1)
1
Torque Consumable 6 – 7 N·m (53 – LOCTITE® 221 62 lb in)
Identification
RAPH15SSL0044BA
2
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Electrical systems - Wiper and washer system
Windshield wiper motor - Remove 1. Disconnect the washer hose from (1) elbow connector on the outside of the door. 2. Remove the wiper arm by removing the crown nuts (2).
RAPH16SSL0199BA
1
RAPH16SSL0200BA
2
RAPH16SSL0203BA
3
3. Remove the wiper nut (1) securing the wiper motor to the bracket. Remove the bracket (2) retaining the hardware.
4. Disconnect the washer hose (1) and cut the cable tie strap (2) securing the hose to the bracket. 5. Disconnect the electrical connector (3) for the wiper motor.
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Electrical systems - Wiper and washer system
6. Remove the wiper motor assembly with the bracket from the inside of the door.
RAPH16SSL0202BA
7. Remove the bracket (1) and the gasket (2) from the motor (4) by removing the two screws (3).
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4
Electrical systems - Wiper and washer system
Windshield wiper motor - Install 1. Install the bracket (1) and the gasket (2) to the motor (4) by securing with two screws (3). Torque the screws (3) to 6.0 – 7.0 N·m (4.0 – 5.0 lb ft). 2. Install the wiper motor assembly with the bracket into the holes in the door.
RAPH16SSL0202BA
1
RAPH16SSL0203BA
2
RAPH16SSL0200BA
3
3. Connect the electrical connector (3) for the wiper motor to the harness. 4. Connect the washer hose (1) to the elbow, and secure the hose to the bracket with cable tie strap (2).
5. Secure the wiper motor to the bracket (2) on the outside of the door with the wiper nut (1). Torque the nut (1) to 9.0 – 11.0 N·m (6.0 – 8.0 lb ft) NOTE: Be sure to install the spacers and washers prior to installing the bracket on the wiper motor actuator.
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Electrical systems - Wiper and washer system
6. Install the wiper arm onto the bracket and the motor, and secure with the crown nuts (2). Torque the crown nuts (2) to 6.0 – 7.0 N·m (4.0 – 5.0 lb ft). 7. Connect the washer hose (1) to the elbow connector on the outside of the door.
RAPH16SSL0199BA
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4
Index Electrical systems - 55 Wiper and washer system - 518 Windshield wiper motor - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6
Windshield wiper motor - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4
Windshield wiper motor - Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3
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Electrical systems - 55 Cab engine controls - 525
SR210 TIER 4B (FINAL) [NGM418237 - ], SR210 TIER 4B (FINAL) [NHM435463 - ], SR240 TIER 4B (FINAL) [NGM418237 - ], SR240 TIER 4B (FINAL) [NHM435463 - ], SV280 TIER 4B (FINAL) [NGM418237 - ], SV280 TIER 4B (FINAL) [NHM435463 - ], TR270 TIER 4B (FINAL) [NGM418237 - ], TR270 TIER 4B (FINAL) [NHM435463 - ], TR310 TIER 4B (FINAL) [NGM418237 - ], TR310 TIER 4B (FINAL) [NHM435463 - ], TV370 TIER 4B (FINAL) [NHM435463 - ]
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Contents Electrical systems - 55 Cab engine controls - 525
FUNCTIONAL DATA Throttle pedal Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SERVICE Throttle pedal Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
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Electrical systems - Cab engine controls
Throttle pedal - Overview
RAIL17SSL0174AA
1
Foot Throttle Assembly
RCPH10TLB053FAM
2
Signal Voltage from the Foot Throttle Sensor (1) (2)
Throttle Signal Legend Throttle Signal Voltage Throttle movement in degrees of travel. 0° equals low idle. 20° equals WOT (Wide Open Throttle).
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Electrical systems - Cab engine controls
RAPH17SSL0175BA
(A) (B) (C) (D) (E) (F)
3
Throttle Signal Connector Legend Signal Wire Ground Supply Voltage - 4.8 â&#x20AC;&#x201C; 5.2 V Not Used
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Electrical systems - Cab engine controls
Throttle pedal - Remove Prior operation: Battery - Disconnect (55.302) 1. Disconnect the electrical harness from the foot pedal assembly.
RAPH17SSL0176QA
1
RAPH17SSL0176QA
2
2. Remove the two bolts (1) that secure the foot pedal assembly to the floor plate. 3. Remove the foot pedal assembly from the machine.
Next operation: Throttle pedal - Install (55.525)
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Electrical systems - Cab engine controls
Throttle pedal - Install Prior operation: Throttle pedal - Remove (55.525) 1. Place the foot pedal assembly into the right-hand side of the floor plate. 2. Secure the foot pedal assembly to the floor plate with two bolts (1).
RAPH17SSL0176QA
1
RAPH17SSL0176QA
2
3. Connect the electrical harness to the foot pedal assembly.
Next operation: Battery - Connect (55.302)
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Index Electrical systems - 55 Cab engine controls - 525 Throttle pedal - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6
Throttle pedal - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3
Throttle pedal - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5
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Electrical systems - 55 Electronic modules - 640
SR210 TIER 4B (FINAL) [NGM418237 - ], SR210 TIER 4B (FINAL) [NHM435463 - ], SR240 TIER 4B (FINAL) [NGM418237 - ], SR240 TIER 4B (FINAL) [NHM435463 - ], SV280 TIER 4B (FINAL) [NGM418237 - ], SV280 TIER 4B (FINAL) [NHM435463 - ], TR270 TIER 4B (FINAL) [NGM418237 - ], TR270 TIER 4B (FINAL) [NHM435463 - ], TR310 TIER 4B (FINAL) [NGM418237 - ], TR310 TIER 4B (FINAL) [NHM435463 - ], TV370 TIER 4B (FINAL) [NHM435463 - ]
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Contents Electrical systems - 55 Electronic modules - 640
FUNCTIONAL DATA Electronic modules Component localization (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Component localization (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Electronic module Overview - Electro-Hydraulic (EH) drive (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Controller Area Network (CAN) data bus Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Component localization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
(*) See content for specific models 48068130 29/01/2018
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Electrical systems - Electronic modules
Electronic modules - Component localization SR210 SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical (Mechanical
RAIL15SSL0056GA
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
1
Module location Module location table 1. Instrument cluster 2. Engine Control Unit (ECU)
3. Glow plug control unit 4. PWM driver
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Electrical systems - Electronic modules
Electronic modules - Component localization SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
1. Engine Control Unit (ECU) relay 2. Flasher relay (if equipped with a turn signals) 3. Glow-plug Control Unit (GCU) 4. Engine Control Unit (ECU)
RAIL15SSL0104BA
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1
Electrical systems - Electronic modules
1. Engine Control Unit (ECU) 2. Flasher relay (if equipped with a turn signals) 3. Engine Control Unit (ECU) relay 4. Glow-plug Control Unit (GCU)
RAIL15SSL0103BA
2
RAIL15SSL0096BA
3
RAIL15SSL0126BA
4
1. Instrument cluster 2. Unit Control Module (UCM)
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Electrical systems - Electronic modules
Electronic module - Overview - Electro-Hydraulic (EH) drive SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Electro-Hydraulic (EH) controls use electronic solenoids to vary the spool position within the loader control valve. The spool position determines hydraulic flow. In contrast to mechanically controlled machines, in which the spools are physically linked to the controls the operator moves.
Electro-Hydraulic (EH) - Hydraulic system control (loader arm, bucket tilt, auxiliary hydraulics) The Alpha series use an open center hydraulic system to operate two loader cylinders, two bucket cylinders, and the auxiliary hydraulic flow. The hydraulic system shares a reservoir, located behind the rear access door, with the hydrostatic system. All other hydrostatic components are a separate system. The only connection between the hydrostatic system and the hydraulic system is the tee near the reservoir. The main hydraulic pump is available as two different pumping gears, either as a standard or as a high-flow option. The main control valve is the heart of the hydraulic system. It directs the flow to operate the loader/boom lift, bucket tilt, and auxiliary functions. The same three spool open center series valves with built-in main relief, circuit relief, and load checks for each spool are used on all size machines. The first spool nearest the main relief is the loader function spool. The loader function spool controls the raise, lower, neutral, and float of the loader arm/boom. The middle spool is the bucket function spool. The bucket function spool controls the bucket rollback, neutral, and dump functions. The third spool is the auxiliary spool. The auxiliary spool controls oil flow to the auxiliary manifold. Each spool has a load check valve. The load check valve prevents the sudden droppage when the spool is slowly engaged to the power position. All models have circuit relief valves for the loader base and rod end and the bucket base and rod end. The load check is removed on the Auxiliary valve if the unit is equipped with the High Flow option.
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Electrical systems - Electronic modules
Electro-Hydraulic (EH) - Hydrostatic drivetrain control The drive system on the Alpha series uses two axial piston hydrostatic pumps, which are connected in-line with each other. Each hydrostatic pump drives a corresponding hydrostatic drive motor. The motor drives a dual sprocket which then drives the axles through a chain drive system. The EH pump uses electronic solenoids to control the hydraulic servo. This allows operators to switch from ISO to H-pattern without having to change major system components. The Enhanced High-Flow (EHF) option is available on select models. The EHF option adds a third separate pump for an additional set of auxiliary couplers. The EHF only operates the extra set of couplers mounted on the right-hand loader arm/boom. The EH units allow the joysticks to be switch-able between the two patterns (ISO or H-pattern) for both loader and ground drive functions. In the ISO pattern, the left-hand joystick controls the drive functions, and the right-hand joystick controls the loader arm/boom and bucket operations. In the H-pattern, the left-hand joystick controls the left-hand drive functions and the loader arm/boom, and the right-hand joystick controls the right-hand drive and the bucket functions. The parking brake assembly may have up to three different control solenoid valves in it. It also houses the charge pressure switch, two speed sequence valve, screen and orifice assembly when equipped. A pressure of 15 bar is needed to fully release the parking brake. The parking brake can be applied while allowing the loader to still be active. The 2â&#x20AC;&#x201C;Speed sequence valve is a factory set valve assembly. The charge pressure switch sends a signal to the Instrument Cluster when the pressure is too low, indicating there is a problem with the charge pressure circuit. Low charge pressure is indicated by dragging brakes, and slower than normal pilot operation (drive response or loader response).
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Electro-Hydraulic (EH) - Electrical System The Alpha series comes with the standard Electrical Instrument Cluster (EIC) or the optional Advanced Instrument Cluster (AIC). The two instrument clusters are functionally the same. The only difference is the EIC has a key switch and the AIC has a pushbutton start. With the EIC and the AIC, error codes are readable through the dash text display area. In order to clear error codes, the Electronic Service Tool (EST) must be used. On EH driven machines, the dash still controls power and start, however the Universal Control Module (UCM) controls the parking brake and the hydraulic enabler. The controller modules are Controller Area Network (CAN bus) together with the engine controller. The control pad below the bar graph on instrument cluster is where the EIC and the AIC differ from each other. The EIC buttons are only used for “SETUP” navigation. To enter the “SETUP” mode on the instrument cluster, reference the Operator’s Manual for the procedure and individual menu navigation chart. The setup menu can be used to change the drive, lift, or tilt function speed within the EH menu. The machine is also equipped with a button on the machine dash to switch from ISO to H-pattern. Reference the Operator’s Manual for procedure on switching the controls (ISO or H-pattern).
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Electro-Hydraulic (EH) - Electronic Service Tool (EST) The Electronic Service Tool (EST) has new capabilities. It has the ability to update or program Instrument Cluster parameters. If a newer cluster program is available or a software problem is encountered, it can be fixed by programming instead of replacing. Any time a cluster or UCM is installed into a machine, the machine information is entered through the EST. Parameters such as machine serial number, model number, machine configuration, machine hours, and optional equipment are stored in memory. The EST is also used in troubleshooting system programs and signals. An extensive list of components and sensors that can be monitored or checked out with the EST, is built into the system. With the EST, you can look up, troubleshoot, and clear fault codes. As the machine is operated, the UCM stores fault codes for technician reference. EH calibrations are also done with the EST. The EST can monitor and troubleshoot the Exhaust Gas Recirculation (EGR), Instrument Cluster, and the UCM. The EST connects to the Diagnostic Connector in the front right-hand corner inside the cab. Controllers are captured by the EST at the beginning of the Programming, Calibration, and Machine Configuration procedures. The controllers are released at the end of Programming, Calibration, Machine Configuration, and Clear Controller Faults procedures. The Instrument Cluster and the UCM are power cycled by the operatorâ&#x20AC;&#x2122;s presence switch in the seat cushion, not the key switch or power button. The seat switch is electrically OPEN when no operator present, and electrically CLOSED when the operator is present. Programming the EIC, AIC, or the UCM, be sure to plug the EST power cord into a wall outlet or the machines 12 V power outlet. Do not work off of the ESTâ&#x20AC;&#x2122;s battery supply. Damage can occur to the controller if the EST loses power, and the controller may need to then be replaced. During calibration, the UCM learns the tolerances and limits of each of the components it receives inputs from, and each of the components it sends outputs to. This includes mechanical, hydraulic, and electrical components, as well as slight variations in resistance in components and harnesses between one machine and another. All calibrations are necessary any time a software is downloaded to the UCM, a new UCM is installed, or the UCM is swapped from one machine to another. Individual calibrations are necessary any time there is an operator complaint of a drive operation or loader operation, a fault code in a controlled circuit, or a repair was completed in a controlled circuit (mechanical, electrical, or hydraulic). Beware that each calibration has a time limit, and to continue the enable and sustain conditions prior to timing out. Be sure to be familiar with the calibration steps prior to calibration to ease the process and complete the calibration prior to timing out. Follow the instructions precisely otherwise the calibration will be aborted by the EST.
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Controller Area Network (CAN) data bus - Dynamic description 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 1980â&#x20AC;&#x2DC;s. Applications of CAN follow guidelines that are established in SAE J1939.
Glossary of terms Bus CAN CAN HI CAN LO Controller
Terminator
The network, e.g. the wires, connectors, and terminators between the controllers. Controller Area Network. Generally refers to all parts of the system -the controllers, wires, and terminators. A high priority, message carrying wire on the CAN bus. A low priority, message carrying wire on the CAN bus. Components that are connected by the bus and share information. May also be referred to as processors, control modules, units, or modules. 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 sensorâ&#x20AC;&#x2DC;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 announcing its existence. This is done in order to monitor each controllerâ&#x20AC;&#x2122;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 reflections 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 Ί 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: 48068130 29/01/2018
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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 an 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 integrity 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). 48068130 29/01/2018
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NOTE: The CAN circuit that is being tested must be connected to the diagnostic connector.
RAIL13TR03932FA
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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 resistance 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 testing 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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Controller Area Network (CAN) data bus - Component localization 4 NOx Sensor - Upstream
Connector Designator 5 7 6 8 TelemEngine NH3 NOx Control Sensor Sensor atics Module - DownUnit (ECU) stream
X-024 (Female)
X-027 (Female)
X-012 (Female)
X-033 (Female)
X-031 (Female)
9 Universal Control Module (UCM) X-TELE Not used (Female)
X-024 (Female)
X-027 (Female)
X-012 (Female)
X-033 (Female)
X-031 (Female)
X-TELE X-CN2B X-DIAG X-C23 (Fe(Male) (Male) (Female) male)
Model
1 Urea Sender
2 3 Heater 120 Ω Termi- Control Unit nator Resistor
Mechanical, T4, F5H Electro-Hydraulic (EH), T4, F5H
X-019 (Female)
X-105 (Female)
X-019 (Female)
X-105 (Female)
10 11 CAN Di- Instruagnos- ment tic Con- Cluster nector X-DIAG X-C23 (Male) (Female)
NOTE: All of the components listed are shown in the ‘model view” below, however, the existence of any unique component is dependent on model type and model configuration as referenced in the table above.
RAPH17SSL0003FA
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Controller Area Network (CAN) bus components and approximate locations
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Index Electrical systems - 55 Electronic modules - 640 Controller Area Network (CAN) data bus - Component localization . . . . . . . . . . . . . . . . . . . . . . . . . . .
15
Controller Area Network (CAN) data bus - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10
Electronic module - Overview - Electro-Hydraulic (EH) drive (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6
Electronic modules - Component localization (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3
Electronic modules - Component localization (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4
(*) See content for specific models 48068130 29/01/2018
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Electrical systems - 55 Telematics - 991
SR210 TIER 4B (FINAL) [NGM418237 - ], SR210 TIER 4B (FINAL) [NHM435463 - ], SR240 TIER 4B (FINAL) [NGM418237 - ], SR240 TIER 4B (FINAL) [NHM435463 - ], SV280 TIER 4B (FINAL) [NGM418237 - ], SV280 TIER 4B (FINAL) [NHM435463 - ], TR270 TIER 4B (FINAL) [NGM418237 - ], TR270 TIER 4B (FINAL) [NHM435463 - ], TR310 TIER 4B (FINAL) [NGM418237 - ], TR310 TIER 4B (FINAL) [NHM435463 - ], TV370 TIER 4B (FINAL) [NHM435463 - ]
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Contents Electrical systems - 55 Telematics - 991
FUNCTIONAL DATA Telematics Overview (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Overview (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
SERVICE Telematics Startup test and troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Prepare - Telematics unit registration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Module Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Antenna/Receiver Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
(*) See content for specific models 48068130 29/01/2018
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Electrical systems - Telematics
Telematics - Overview SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
RAPH16SSL0294GA
1
Component location Component identification (1) Telematics antenna, with harness (2) Electronic Control Unit (ECU) assembly, Telematics - AM53
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Telematics - Overview SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] TR270 TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ]
RAPH16SSL0295GA
1
Component location Component identification (1) Telematics antenna, with harness (2) Electronic Control Unit (ECU) assembly, Telematics - AM53
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Telematics - Startup test and troubleshooting NOTE: The registration process must be completed before validating the Telematics. Refer to the Telematics - Prepare - Telematics unit registration (55.991) prior to any validation and troubleshooting. 1. Turn the battery disconnect switch to ON. 2. Switch the ignition key to the ON position and wait for the Telematics system to start. 3. Check the four LEDs on the Telematics unit (1) to validate the installation. The color sequence should be: • (1A) Phone or connectivity — RED (steady) • (1B) CAN traffic — RED (blinking) • (1C) GPS — RED (steady) • (1D) Power — GREEN (steady) NOTE: Additional information on the LED display is available on the next page.
RAIL12GEN0174AA
4. After installation validation is complete switch the ignition key to the OFF position. 5. Install all guards and panels that were removed during the installation procedure.
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1
Electrical systems - Telematics
Additional Information on the LED Display The LED display panel is the controller’s minimum interface used to display and control data input and output. (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 connection 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 “stand-by” mode. • 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 “stand-by” mode. • 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).
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Troubleshooting Condition No Power
GPRS is NOT Solid Red
GPS is NOT Solid Red
Solution Check the fuse. If no power light is on, check power (both constant power and switched power must be correct and functioning between 9 â&#x20AC;&#x201C; 32 V). Be Sure that grounding is solid (when in doubt, use a solid chassis ground). 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. Signal power in the network coverage area is too weak. Antenna is defective (replace antenna). GPRS antenna connector failure (test with ohmmeter). 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 - Prepare - Telematics unit registration 1. Access the Case SiteWatch™ or New Holland FleetForce™ using the link provided in the “Dealer Portal” under the “Service Tab”. 2. Once the web portal is reached, go to the “Activation” page in the “Service Management“ section of the “Administration” menu. 3. Select the Serial Number of the Telematics unit that has been installed, assign it to the customer and complete the registration procedure.
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Electrical systems - Telematics
Module - Remove Prior operation: Raise the loader arm and tilt the cab forward. Prior operation: Disconnect the battery power from the machine. Refer to Battery - Disconnect (55.302) procedure for further details. 1. Remove the two bolts (1) securing the Electronic Control Unit (ECU) module assembly (2) on the back of the Universal Control Module (UCM) bracket if equipped with Electro-Hydraulic (EH) controls. Refer to Figure 1 for details. Remove the two bolts (1) securing the Electronic Control Unit (ECU) module assembly (2) to the Telematics bracket if equipped with mechanical drive controls. Refer to Figure 2 for details. 2. Disconnect the chassis harness (3) from the ECU module assembly. 3. Disconnect the Global Positioning System (GPS) antenna (4) from the ECU module assembly. 4. Disconnect the cellular antenna (5) from the ECU module assembly.
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RAPH16SSL0297BA
1
RAPH16SSL0296BA
2
Electrical systems - Telematics
Module - Install 1. Connect the cellular antenna (1) to the Electronics Control Unit (ECU) module assembly (2). Torque the antenna to 0.5 – 0.7 N·m (4.1 – 6.1 lb in). NOTE: Make sure to leave a drip loop in the antenna cabling. 2. Connect the Global Positioning System (GPS) antenna (3) to the ECU module assembly. Torque the antenna to 0.7 – 0.9 N·m (6.0 – 8.0 lb in). 3. Connect the chassis harness (4) to the ECU module assembly. 4. Secure the ECU module assembly (2) to the back of the Universal Control Module (UCM) bracket with two bolts (5) for Electro-Hydraulic (EH) drive machines. Refer to Figure 1 for details. Secure the ECU module assembly (2) to the Telematics bracket with two bolts (5) and two nuts for mechanical drive machines. Refer to Figure 2 for details.
RAPH16SSL0297BA
1
RAPH16SSL0296BA
2
Next operation: Connect the battery power to the machine. Refer to Battery - Connect (55.302) procedure for further details. Next operation: Lower the cab and the loader arm into work position.
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Electrical systems - Telematics
Antenna/Receiver - Remove SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
Prior operation: Raise the loader arm and tilt the cab forward. Prior operation: Disconnect the battery power from the machine. Refer to Battery - Disconnect (55.302) procedure for further details. 1. Disconnect the Global Positioning System (GPS) antenna (1) from the Electronic Control Unit (ECU) module assembly (A). NOTE: Figure 1 is for Electro-Hydraulic (EH) drive machines. NOTE: Figure 2 is for mechanical drive machines. 2. Disconnect the cellular antenna (2) from the ECU module assembly.
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RAPH16SSL0297BA
1
RAPH16SSL0296BA
2
Electrical systems - Telematics
3. Remove the cable ties (1) securing the antenna harness to the chassis. NOTE: Actual harness routing may differ based upon machine configuration.
RAPH16SSL0294GA
3
RAPH16SSL0303BA
4
4. Remove the antenna bracket (1) from the left-hand tower by removing the screws (2). 5. Remove the antenna (3) from the bracket (1) by separating the magnetic pull. 6. Remove the conduit that is protecting the antenna harness.
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Electrical systems - Telematics
Antenna/Receiver - Install SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
1. Install the protective conduit onto the antenna harness. 2. Install the antenna bracket (1) to the left-hand tower using the screws (2). 3. Secure magnetic side of the antenna (3) to the bracket (1).
RAPH16SSL0303BA
1
RAPH16SSL0294GA
2
4. Route the antenna harness through the chassis to the Electronic Control Unit (ECU) module assembly. NOTE: Actual harness routing may differ based upon machine configuration. NOTE: Make sure to leave a 76.2 mm (3.0 in) drip loop near the ECU module assembly connections. 5. Secure the antenna harness to the chassis with cable ties (1).
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Electrical systems - Telematics
6. Connect the Global Positioning System (GPS) antenna (1) to the ECU module assembly (A). Torque the antenna connector to 0.7 – 0.9 N·m (6.0 – 8.0 lb in). NOTE: Figure 1 is for Electro-Hydraulic (EH) drive machines. NOTE: Figure 2 is for mechanical drive machines. 7. Connect the cellular antenna (2) to the ECU module assembly. Torque the antenna connector to 0.5 – 0.7 N·m (4.1 – 6.1 lb in).
RAPH16SSL0297BA
3
RAPH16SSL0296BA
4
Next operation: Connect the battery power to the machine. Refer to Battery - Connect (55.302) procedure for further details. Next operation: Lower the cab and the loader arm into work position.
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Electrical systems - Telematics
Antenna/Receiver - Remove SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] TR270 TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ]
Prior operation: Raise the loader arm and tilt the cab forward. Prior operation: Disconnect the battery power from the machine. Refer to Battery - Disconnect (55.302) procedure for further details. 1. Disconnect the Global Positioning System (GPS) antenna (1) from the Electronic Control Unit (ECU) module assembly (A). NOTE: Figure 1 is for Electro-Hydraulic (EH) drive machines. NOTE: Figure 2 is for mechanical drive machines. 2. Disconnect the cellular antenna (2) from the ECU module assembly.
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RAPH16SSL0297BA
1
RAPH16SSL0296BA
2
Electrical systems - Telematics
3. Remove the cable ties (1) securing the antenna harness to the chassis. NOTE: Actual harness routing may differ based upon machine configuration.
RAPH16SSL0295GA
3
RAPH16SSL0304AA
4
4. Remove the antenna bracket (1) from the left-hand tower. 5. Remove the antenna (2) from the bracket (1) by separating the magnetic pull. 6. Remove the conduit that is protecting the antenna harness.
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Electrical systems - Telematics
Antenna/Receiver - Install SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] TR270 TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ]
1. Install the protective conduit onto the antenna harness. 2. Install the antenna bracket (1) to the left-hand tower. 3. Secure magnetic side of the antenna (2) to the bracket (1).
RAPH16SSL0304AA
1
RAPH16SSL0295GA
2
4. Route the antenna harness through the chassis to the Electronic Control Unit (ECU) module assembly. NOTE: Actual harness routing may differ based upon machine configuration. NOTE: Make sure to leave a 76.2 mm (3.0 in) drip loop near the ECU module assembly connections. 5. Secure the antenna harness to the chassis with cable ties (1).
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Electrical systems - Telematics
6. Connect the Global Positioning System (GPS) antenna (1) to the ECU module assembly (A). Torque the antenna connector to 0.7 – 0.9 N·m (6.0 – 8.0 lb in). NOTE: Figure 1 is for Electro-Hydraulic (EH) drive machines. NOTE: Figure 2 is for mechanical drive machines. 7. Connect the cellular antenna (2) to the ECU module assembly. Torque the antenna connector to 0.5 – 0.7 N·m (4.1 – 6.1 lb in).
RAPH16SSL0297BA
3
RAPH16SSL0296BA
4
Next operation: Connect the battery power to the machine. Refer to Battery - Connect (55.302) procedure for further details. Next operation: Lower the cab and the loader arm into work position.
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Index Electrical systems - 55 Telematics - 991 Antenna/Receiver - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13
Antenna/Receiver - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
17
Antenna/Receiver - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11
Antenna/Receiver - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15
Module - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10
Module - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9
Telematics - Overview (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3
Telematics - Overview (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4
Telematics - Prepare - Telematics unit registration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8
Telematics - Startup test and troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5
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Electrical systems - 55 FAULT CODES - DTC
SR210 TIER 4B (FINAL) [NGM418237 - ], SR210 TIER 4B (FINAL) [NHM435463 - ], SR240 TIER 4B (FINAL) [NGM418237 - ], SR240 TIER 4B (FINAL) [NHM435463 - ], SV280 TIER 4B (FINAL) [NGM418237 - ], SV280 TIER 4B (FINAL) [NHM435463 - ], TR270 TIER 4B (FINAL) [NGM418237 - ], TR270 TIER 4B (FINAL) [NHM435463 - ], TR310 TIER 4B (FINAL) [NGM418237 - ], TR310 TIER 4B (FINAL) [NHM435463 - ], TV370 TIER 4B (FINAL) [NHM435463 - ]
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Contents Electrical systems - 55 FAULT CODES - DTC
DIAGNOSTIC 1002 - Engine Coolant Temperature Is Above Normal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 1004 - Hydraulic Filter Restriction Switch - Hydraulic Filter Restricted . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 1009 - Hydraulic Oil Temperature Is Above Normal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 1014 - Cluster System Voltage Above Normal (>16.5V) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 1015 - Cluster System Voltage Below Normal (<11.5V) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 1022 - Water In Fuel Detected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 1025 - Foot Throttle Sensor Is Above Range - Shorted To Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 1026 - Hand Throttle Sensor Is Above Range - Shorted To Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 1030 - Foot Throttle Sensor Is Below Range - Open Or Shorted To Ground . . . . . . . . . . . . . . . . . . . . . . . 30 1031 - Hand Throttle Sensor Is Below Range - Open Or Shorted To Ground . . . . . . . . . . . . . . . . . . . . . . 33 1040 - RPM Monitoring Over Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 1041 - RPM Monitoring Over Speed Max . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 1044 - Fuel level sensor below 2.0 ohm for 5 seconds, shorted low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 1045 - Fuel Level Sensor Open Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 1051 - No CAN Communication With Engine Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 1053 - Timeout of CAN Message CM1BC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 1054 - Timeout of CAN Message ET1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 1056 - Timeout of CAN Message DPFC1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 1058 - Timeout of CAN Message EDC2BC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 1059 - Timeout of CAN Message DM1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 1064 - Hydraulic Oil Temperature Is Above Normal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 1201 - Hydraulic oil filter switch open circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 1205 - Hydraulic Enable (EH Machines) - Hydraulic Enable Output, Short to Power . . . . . . . . . . . . . . . . 61 1206 - CAN Connection: Configuration Response Timeout (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 1207 - Memory Parameters - Invalid Configuration Between IC and UCM (*) . . . . . . . . . . . . . . . . . . . . . . 65 1208 - Seat Switch Plausibility Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 1211 - Calibration Functions - Joystick Calibration Not Complete (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 1212 - Calibration Functions - Ground Drive Calibration Not Complete (*) . . . . . . . . . . . . . . . . . . . . . . . . . 70 1213 - Calibration Functions - Loader Valve Calibration Not Complete (*) . . . . . . . . . . . . . . . . . . . . . . . . . 71 1215 - Saturation Function not complete - Forward Pumps (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
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1216 - Saturation Function not complete - Reverse Pumps (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 1221 - VCM Temperature / Current Draw Over Limit (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 1222 - VCM Sustained Over Temperature Limit (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 1223 - VCM Sustained Over Current Limit (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 1224 - VCM Internal Memory or Core Monitoring Fault (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 1225 - VCM EEPROM Memory Checksum Fault (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 1350 - Hyd Enable Switch - Implausible State (Hardwire vs CAN) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 1532 - Backup Alarm - Short to Ground (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 1533 - Backup Alarm - Short to Power (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82 1900 - VCM Ground Fault (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84 1901 - VCM - VCM Supply Voltage High (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86 1902 - VCM - VCM Supply Voltage Low (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88 1903 - VCM - VCM Supply Voltage Below Operational Limit (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 1904 - VCM - Rail 12VB - 5V Regulators Supply Input Power Off (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92 1905 - VCM - 5Vref1 Sensor Supply Voltage Out Of Range (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94 1906 - VCM - 5Vref3 Sensor Supply Voltage Out Of Range (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 1907 - VCM - Rail 12VF1 - Aux Retract Input Power Off (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 1908 - VCM - Rail 12VF2 - Bucket Extend Input Power Off (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102 1909 - VCM - Rail 12VF3 - Boom Raise/Lower Input Power Off (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104 1910 - VCM - Rail 12VH - Loader Pilot Interlock And Port Lock Input Power Off (*) . . . . . . . . . . . . . . . . 106 1911 - VCM - Rail 12VH1 - Left And Right Pump Reverse Input Power Off (*) . . . . . . . . . . . . . . . . . . . . 108 1912 - VCM - Rail 12VM - Left And Right Brake Lights And Aux Extend Input Power Off (*) . . . . . . . . 110 1913 - VCM - Rail 12VS1 - Bucket Curl Input Power Off (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112 1914 - VCM - Rail 12VS2 - Backup Alarm Input Power Off (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114 1915 - VCM - Rail 12VT1 - Two Speed Input Power Off (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116 1916 - VCM - Rail 12VU1 - Right And Left Pumps Forward Input Power Off (*) . . . . . . . . . . . . . . . . . . . 118 1917 - UCM - Rail 12VU2: Park Brake Solenoid Input Power Off (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120 3007 (DTC 131-03) - Coolant temperature : SRC High for Engine coolant temperature (down stream) 122 3008 (DTC 131-04) - Coolant temperature : SRC low for Engine coolant temperature (down stream) 124 3010 (DTC 133-03) - Intake air temperature sensor : Diagnostic fault check for SRC high in engine inlet valve air temperature upstream sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126 3011 (DTC 133-04) - Intake air temperature sensor : Diagnostic fault check for SRC low in engine inlet valve air temperature upstream sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129 3015 (DTC 135-03) - Fuel temperature Sensor : Signal Range check high for fuel temperature sensor 131 3016 (DTC 135-04) - Fuel temperature Sensor : Signal Range check low for fuel temperature sensor 134 3019 (DTC 134-03) - Intake air pressure sensor : Diagnostic fault check for SRC high in air pressure upstream of intake valve sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136 3024 (DTC 1EB-03) - Ambient pressure sensor : Signal Range Check High failure . . . . . . . . . . . . . . . . 139 3025 (DTC 1EB-04) - Ambient pressure sensor : Signal Range Check low failure . . . . . . . . . . . . . . . . . 140 3027 (DTC 238-03) - Oil pressure sensor : Defect fault check for plausibility from digital sensor . . . . 141 3037 (DTC 134-04) - Intake air pressure sensor : Diagnostic fault check for SRC low in air pressure upstream of intake valve sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
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55.21 [55.DTC] / 3
3051 (DTC 126-03) - Battery voltage to engine controller - voltage too high . . . . . . . . . . . . . . . . . . . . . . 145 3052 (DTC 126-04) - Battery voltage to engine controller - voltage too low . . . . . . . . . . . . . . . . . . . . . . . 146 3059 (DTC 225-03) - Main Relay : DFC for stuck main relay error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148 3061 (DTC 161-03) - Injector, solenoid : Short circuit Low Side to High Side injector 1 . . . . . . . . . . . . . 150 3063 (DTC 161-02) - Injector, solenoid Power stage : Short circuit in the injector 1 . . . . . . . . . . . . . . . . 152 3069 (DTC 163-03) - Injector, solenoid : short circuit Low Side to High Side Injector 3 . . . . . . . . . . . . . 155 3071 (DTC 163-02) - Injector, solenoid Power stage : Short circuit in the injector 3 . . . . . . . . . . . . . . . . 157 3077 (DTC 162-03) - Injector, solenoid : short circuit Low Side to High Side Injector 2 . . . . . . . . . . . . . 160 3079 (DTC 162-02) - Injector, solenoid Power stage : Short circuit in the injector 2 . . . . . . . . . . . . . . . . 162 3081 (DTC 164-03) - Injector, solenoid : short circuit Low Side to High Side Injector 4 . . . . . . . . . . . . . 165 3083 (DTC 164-02) - Injector, solenoid Power stage : Short circuit in the injector 4 . . . . . . . . . . . . . . . . 167 3088 (DTC 141-02) - Crankshaft Sensor : Crankshaft signal diagnose - no signal . . . . . . . . . . . . . . . . . 170 3089 (DTC 141-04) - Crankshaft Sensor : Crankshaft signal diagnose - disturbed signal . . . . . . . . . . . 173 3090 (DTC 143-02) - Camshaft Sensor : Camshaft signal diagnose - no signal . . . . . . . . . . . . . . . . . . . 176 3091 (DTC 143-04) - Camshaft Sensor : Camshaft signal diagnose - disturbed signal . . . . . . . . . . . . . 179 3093 (DTC 144-03) - Camshaft Sensor : Camshaft offset angle exceeded . . . . . . . . . . . . . . . . . . . . . . . 181 3096 (DTC 1B1-03) - CAN Bus : Bus Off error CAN A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182 3102 (DTC 136-04) - Fuel pressure Sensor : Sensor voltage below lower limit . . . . . . . . . . . . . . . . . . . 184 3104 (DTC 137-03) - Pressure Relief valve : pressure relief valve is open . . . . . . . . . . . . . . . . . . . . . . . 186 3105 (DTC 134-04) - Pressure Relief valve : pressure relief valve is forced to open, perform pressure increase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188 3106 (DTC 137-02) - Pressure Relief valve : pressure relief valve reached maximum allowed opening count . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189 3107 (DTC 259-03) - Fuel Metering Unit : short circuit to battery of metering unit output . . . . . . . . . . . 190 3108 (DTC 359-04) - Fuel Metering Unit : short circuit to ground of metering unit output . . . . . . . . . . . 192 3110 (DTC 236-03) - Fuel pressure Sensor : rail pressure raw value is above maximum offset . . . . . 194 3111 (DTC 236-04) - Fuel pressure Sensor : rail pressure raw value is below minimum offset . . . . . . 195 3112 (DTC 136-03) - Fuel pressure Sensor : Sensor voltage above upper limit . . . . . . . . . . . . . . . . . . . 196 3137 (DTC 159-02) - Fuel Metering Unit : open load of metering unit output . . . . . . . . . . . . . . . . . . . . . . 199 3141 (DTC 158-03) - Fuel Metering Unit : leakage is detected based on fuel quantity balance . . . . . . 201 3146 (DTC 11C-03) - Water sensor in the fuel filter : Water in fuel level sensor defect detection . . . . 202 3157 - ECM Not Detected On CAN Bus - The Engine Dataset Registration Information Was Not Available From The Engine Within The Time Required. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204 3158 - The Engine Dataset Installed Does Not Match The Dataset Registered For This Machine. Register The New Dataset If The Dataset Has Just Been Updated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205 3166 (DTC 149-03) - ECU Power stages : Short circuit to battery error in power stage of fuel filter heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206 3167 (DTC 149-04) - ECU Power stages : Short circuit to ground error in power stage of fuel filter heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208 3168 (DTC 149-02) - ECU Power stages : No load error in power stage of fuel filter heating . . . . . . . . 210 3169 (DTC 149-12) - ECU Power stages : Over Temperature error in power stage of fuel filter heating 212 3176 (DTC 157-03) - Fuel Metering Unit : set point of metering unit in overrun mode not plausible . . 214 3177 (DTC 54C-03) - Engine Protection : Over speed detection in component engine protection . . . 215 3179 (DTC 2B4-02) - CAN Bus Received frames : CAN-Receive-Frame BC2EDC2 . . . . . . . . . . . . . . . 216
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3180 (DTC 1B5-02) - CAN Bus Received frames : CAN-Receive-Frame from the Vehicle Control Module to EDC (VM2EDC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218 3188 (DTC 167-02) - Injector, solenoid : Open load error of an injector 1 (interruption of an electric connection) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220 3192 (DTC 168-02) - Injector, solenoid : Open load error of an injector 2 (interruption of an electric connection) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222 3196 (DTC 169-02) - Injector, solenoid : Open load error of an injector 3 (interruption of an electric connection) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224 3200 (DTC 16A-02) - Injector, solenoid : Open load error of an injector 4 (interruption of an electric connection) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226 3210 (DTC 171-03) - Injector, solenoid : Short circuit in an injection bank 1 (all injectors of the same bank can be affected) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228 3218 (DTC 173-03) - Injector, solenoid : Short circuit in an injection bank 2 (all injectors of the same bank can be affected) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230 3230 (DTC 17C-12) - Injector, solenoid Power stage : Chip error in the Injector CY33x power stage component . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232 3235 (DTC 17E-03) - Injection control : Number of injections is limited by runtime . . . . . . . . . . . . . . . . 233 3236 (DTC 17E-04) - Injection control : Number of injections is limited by system . . . . . . . . . . . . . . . . . 234 3237 (DTC 17E-02) - Injection control : Number of desired injections exceeds threshold . . . . . . . . . . . 235 3238 (DCT 1D1-03) - ECU Power stages : SPI/COM-Errors of the power failure detection of CY320 237 3239 (DTC 1D2-04) - EEPROM : EEP Read Error based on the error for more blocks . . . . . . . . . . . . . 238 3240 (DTC 1D2-02) - EEPROM : EEP Write Error based on the error for one block . . . . . . . . . . . . . . . 239 3241 (DTC 1D2-12) - EEPROM : There was an error during Write/Read EEPROM operation . . . . . . . 240 3242 (DTC 1D3-12) - ECU internal : Visibility of Software Resets in DSM . . . . . . . . . . . . . . . . . . . . . . . . 241 3243 (DTC 2D3-12) - ECU internal : Visibility of Software Resets in DSM . . . . . . . . . . . . . . . . . . . . . . . . 242 3244 (DTC 3D3-12) - ECU internal : Visibility of Software Resets in DSM . . . . . . . . . . . . . . . . . . . . . . . . 243 3245 (DTC 1D4-12) - Analog Digital Converter (ADC) : Diagnostic fault check to report errors in query-/ response-communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244 3252 (DTC 1D8-12) - Analog Digital Converter (ADC) : Diagnostic fault check to report errors in SPIcommunication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245 3253 (DTC 1D9-03) - Analog Digital Converter (ADC) : Diagnostic fault check to report the error in Voltage ratio in ADC monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246 3255 (DTC 1D9-02) - Analog Digital Converter (ADC) : Diagnostic fault check to report the ADC test error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247 3256 (DTC 1D9-12) - Analog Digital Converter (ADC) : Diagnostic fault check to report the NTP error in ADC monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248 3258 (DTC 1E1-03) - ECU Power stages : Starter relay HS power stage output short circuit to battery 249 3258 (DTC 1E1-03) - ECU Power stages : Starter relay HS power stage output short circuit to battery 251 3259 (DTC 1E1-04) - ECU Power stages : Starter relay HS power stage output short circuit to ground 253 3259 (DTC 1E1-04) - ECU Power stages : Starter relay HS power stage output short circuit to ground 255 3260 (DTC 2E1-02) - ECU Power stages : Starter relay HS power stage output open circuit . . . . . . . 257 3260 (DTC 2E1-02) - ECU Power stages : Starter relay HS power stage output open circuit . . . . . . . 259 3261 (DTC 2E1-03) - ECU Power stages : Starter relay power stage: Short circuit to battery error for the Low side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261 3261 (DTC 2E1-03) - ECU Power stages : Starter relay power stage: Short circuit to battery error for the Low side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263 3262 (DTC 2E1-04) - ECU Power stages : Starter relay power stage: Short circuit to ground error for the Low side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265 48068130 29/01/2018
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3262 (DTC 2E1-04) - ECU Power stages : Starter relay power stage: Short circuit to ground error for the Low side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267 3265 (DTC 1E3-03) - Level 2 Monitoring : Diagnostic fault check to report the error due to Over Run 269 3266 (DTC 1E4-03) - Engine speed : Diagnostic fault check to report the engine speed error . . . . . . 270 3283 (DTC 1E7-03) - ECU Sensor Supply Monitor : ECU internal: Error Sensor supplies 2 . . . . . . . . 271 3285 (DTC 1E8-03) - ECU Sensor Supply Monitor : ECU internal: Error Sensor supplies 2 . . . . . . . . 273 3293 (DTC 151-03) - Fuel Metering Unit : maximum positive deviation of rail pressure exceeded . . . 275 3301 (DTC 153-03) - Fuel Metering Unit : maximum negative rail pressure deviation with metering unit on lower limit is exceeded . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276 3305 (DTC 154-03) - Fuel Metering Unit : minimum rail pressure exceeded . . . . . . . . . . . . . . . . . . . . . . 277 3309 (DTC 155-03) - Fuel Metering Unit : maximum rail pressure exceeded . . . . . . . . . . . . . . . . . . . . . 278 3334 (DTC 1C6-03) - CAN Bus Received frames : CAN-Receive-Frame Torque / Speed control from PE to EDC through TSC1_PE Message active . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 279 3335 (DTC 2C6-02) - CAN Bus Received frames : CAN-Receive-Frame Torque / Speed control from PE to EDC through TSC1_PE Message passive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 281 3338 (DTC 3C8-02) - CAN Bus Received frames : CAN-Receive-Frame Torque / Speed control from VE to EDC through TSC1_VE Message passive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 283 3339 (DTC 1C8-03) - CAN Bus Received frames : CAN-Receive-Frame Torque / Speed control from VE to EDC through TSC1_VE Message active . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285 3350 (DTC 11A-03) - Terminal 50 switch : Defective T50 switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 287 3358 (DTC 1B7-02) - CAN Bus Transmitted frames : CAN-Transmit-Frame EEC1, Electronic Engine Control #1 message (Torque, acc.pedal,engine speed, etc.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 289 3361 (DTC 1D2-03) - EEPROM : EEP Erase Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 291 3362 (DTC 1DA-12) - Engine internal calculations : DFC to report if the quantity axis points increase strictly linearly above the torque axis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 292 3368 (DTC 19D-04) - Torque limitation, Engine protection : Torque limitation caused by performance limiter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 293 3369 (DTC 19E-04) - Torque limitation, Engine protection : Torque limitation caused by smoke limitation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 294 3370 (DTC 49E-04) - Torque limitation, Engine protection : Strong torque limitation from engine protection active . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 295 3371 (DTC 69E-04) - Torque limitation, Engine protection : Strong torque limitation from injection system active . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 296 3374 (DTC 17F-12) - Injector Adjustment programming : check of missing injector adjustment value programming: injector 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 297 3390 - Air Filter Restriction Switch Short To Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 298 3402 (DTC 535-03) - Rail pressure sensor : maximum rail pressure exceeded . . . . . . . . . . . . . . . . . . . 300 3403 (DTC 2E1-12) - ECU Power stages : Starter relay HS power stage over temperature . . . . . . . . . 301 3403 (DTC 2E1-12) - ECU Power stages : Starter relay HS power stage over temperature . . . . . . . . . 303 3405 (DTC 393-02) - ECU Power stages : Open load temperature error on the Turbocharger PWM output power stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 305 3406 (DTC 393-12) - ECU Power stages : Over temperature error on the Turbocharger PWM output power stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 307 3409 (DTC 238-04) - Oil pressure sensor : Defect fault check for minimum oil pressure from digital sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 309 3410 (DTC 58C-03) - Throttle valve control governor deviation above threshold . . . . . . . . . . . . . . . . . . 312 3411 (DTC 58C-04) - Throttle valve control governor deviation below threshold . . . . . . . . . . . . . . . . . . . 313 3414 (DTC 72C-00) - Array of DFCs for short circuit in i+1th Glow Plug . . . . . . . . . . . . . . . . . . . . . . . . . . 314 48068130 29/01/2018
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3415 (DTC 72C-01) - Array of DFCs for short circuit in i+1th Glow Plug . . . . . . . . . . . . . . . . . . . . . . . . . . 316 3416 (DTC 72C-02) - Array of DFCs for short circuit in i+1th Glow Plug . . . . . . . . . . . . . . . . . . . . . . . . . . 318 3417 (DTC 72C-03) - Array of DFCs for short circuit in i+1th Glow Plug . . . . . . . . . . . . . . . . . . . . . . . . . . 320 3418 (DTC 393-03) - ECU Power stages : SCB error on the Turbocharger PWM output power stage 322 3419 (DTC 393-04) - ECU Power stages : SCG error on the Turbocharger PWM output power stage 324 3420 (DTC 3CA-03) - CAN Bus Received frames : DFC of Auxiliary Engine Shutdown Switch Message . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 326 3425 (DTC 199-02) - Turbocharger : Over boost deviation at P2 too high in Pressure charger regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 327 3427 (DTC 3F1-04) - Diesel particulate filter (DPF) : Signal range check flow resistance of the particulate filter - low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 328 3428 (DTC 3F3-12) - Diesel Particulate filter Pressure sensor: not plausibility error . . . . . . . . . . . . . . . 329 3429 (DTC 7F3-12) - Diesel Particulate filter Pressure sensor: hoseline plausibility error . . . . . . . . . . . 330 3430 (DTC 15E-03) - EGR Inducement less severe derating level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 331 3431 (DTC 25E-03) - EGR Inducement most severe derating level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 332 3432 (DTC 35E-03) - EGR Inducement warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 333 3433 (DTC 15D-03) - DPF Inducement less severe derating level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 334 3434 (DTC 25D-03) - DPF Inducement most severe derating level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 335 3435 (DTC 35D-03) - DPF Inducement warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 336 3517 (DTC 13C-03) - SRC high for air temperature sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 337 3518 (DTC 13C-04) - SRC low for air temperature sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 339 3616 (DTC 39E-04) - Torque limitation, Engine protection : Torque limitation caused by turbo charger protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 341 3650 (DTC 226-03) - Battery voltage : SRC high for battery voltage sensor . . . . . . . . . . . . . . . . . . . . . . 342 3651 (DTC 226-04) - Battery voltage : SRC low for battery voltage sensor . . . . . . . . . . . . . . . . . . . . . . . 343 3652 (DTC 1B1-04) - CAN Bus : Bus off of CAN node A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 345 3655 (DTC 39D-04) - Torque limitation, Engine protection : General report of the event of torque limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 347 3656 (DTC 49D-04) - Torque limitation, Engine protection : Torque limitation caused by particulate filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 348 3657 (DTC 7BA-02) - CAN Bus Received frames : Timeout Error of CAN-Receive-Frame CM1BC . . 349 3665 (DTC 589-03) - EGR valve control governor deviation above threshold . . . . . . . . . . . . . . . . . . . . . 351 3666 (DTC 589-04) - EGR valve control governor deviation below threshold . . . . . . . . . . . . . . . . . . . . . 352 3667 (DTC 58B-02) - Open load error for EGR valve H-bridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 353 3668 (DTC 58B-12) - Over current error for EGR valve H-bridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 355 3669 (DTC 68B-00) - Over temperature error for EGR valve H-bridge . . . . . . . . . . . . . . . . . . . . . . . . . . . 357 3670 (DTC 68B-03) - Short circuit to battery of EGR valve H-bridge - high pin A50 . . . . . . . . . . . . . . . . 359 3671 (DTC 68B-01) - Short circuit to battery of EGR valve H-bridge - low pin A35 . . . . . . . . . . . . . . . . . 361 3672 (DTC 68B-04) - Short circuit to ground of EGR valve H-bridge - high pin A50 . . . . . . . . . . . . . . . . 363 3673 (DTC 68B-02) - Short circuit to ground of EGR valve H-bridge - low pin A35 . . . . . . . . . . . . . . . . 365 3674 (DTC 68B-07) - Short circuit over load error for EGR valve H-bridge . . . . . . . . . . . . . . . . . . . . . . . 368 3675 (DTC 689-04) - EGR valve too long time drift at closed position . . . . . . . . . . . . . . . . . . . . . . . . . . . 369 3676 (DTC 789-00) - EGR valve position sensor voltage above threshold (Short to battery) . . . . . . . . 370 3677 (DTC 789-01) - EGR valve position sensor voltage below threshold (Short to ground) . . . . . . . . 372
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3680 (DTC 256-03) - Injection cut off : Injection cut off demand (ICO) for shut off coordinator . . . . . . 374 3684 (DTC 3F7-03) - Exhaust temperature : Fault Check for enhanced SRC-Max of Second exhaust gas temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 375 3688 (DTC 11C-02) - Water sensor in the fuel filter : WIF Sensor Check is failed. . . . . . . . . . . . . . . . . . 376 3689 (DTC 52C-01) - DFC for faulty diagnostic data transmission or protocol error . . . . . . . . . . . . . . . . 378 3691 (DTC 32B-02) - No load error for Low Voltage System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 380 3692 (DTC 32B-12) - Over temperature error on ECU power stage for Glow plug Low Voltage System 382 3693 (DTC 32B-03) - Short circuit to battery error for Low Voltage System . . . . . . . . . . . . . . . . . . . . . . . 384 3694 (DTC 32B-04) - Short circuit to ground error for Low Voltage System . . . . . . . . . . . . . . . . . . . . . . . 386 3699 (DTC 5D2-03) - EEPROM : Error in EEPROM block EEPData1. SD correction can not be calculated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 388 3703 (DTC 26F-04) - Injection control : check of minimum rail pressure . . . . . . . . . . . . . . . . . . . . . . . . . 389 3704 (DTC 27F-12) - Injector Adjustment programming : check of missing injector adjustment value programming: injector 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 390 3705 (DTC 37F-12) - Injector Adjustment programming : check of missing injector adjustment value programming: injector 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 391 3706 (DTC 47F-12) - Injector Adjustment programming : check of missing injector adjustment value programming: injector 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 392 3707 (DTC 601-02) - Lambda sensor : Open circuit at the lambda sensor Nernst cell pin . . . . . . . . . . 393 3708 (DTC 602-02) - Lambda sensor : open circuit at the lambda sensor pump current pin - IP (lambda = 1 detection) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 395 3709 (DTC 606-02) - Lambda sensor : Open circuit at the lambda sensor Virtual ground pin . . . . . . . 397 3711 (DTC 18F-03) - Lambda sensor : SCB error of the LSU Heater Power stage . . . . . . . . . . . . . . . . 399 3712 (DTC 18F-04) - Lambda sensor : SCG error of the LSU Heater Power stage . . . . . . . . . . . . . . . . 401 3713 (DTC 18F-02) - Lambda sensor : Open Load error of the LSU Heater Power stage . . . . . . . . . . 403 3714 (DTC 607-03) - Lambda sensor : Fault code to indicate SRC High error for O2 calibration . . . . 405 3715 (DTC 607-04) - Lambda sensor : Fault code to indicate SRC Low error for O2 calibration . . . . . 406 3716 (DTC 605-03) - Lambda sensor : O2 value above the max threshold . . . . . . . . . . . . . . . . . . . . . . . 407 3720 (DTC 60A-04) - Lambda sensor : low battery voltage at the SPI chip . . . . . . . . . . . . . . . . . . . . . . . 409 3721 (DTC 609-02) - Lambda sensor : Fault check to indicate SPI chip error of lambda sensor . . . . . 410 3722 (DTC 60C-03) - Lambda sensor : LSU sensor temperature Ri exceeds the maximum limit . . . . 411 3723 (DTC 60C-04) - Lambda sensor : LSU sensor temperature Ri is below the minimum limit . . . . . 413 3724 (DTC 60B-03) - Lambda sensor : short to battery at IA,IP, UN, VG . . . . . . . . . . . . . . . . . . . . . . . . . 415 3725 (DTC 60B-04) - Lambda sensor : short to ground at IA,IP, UN, VG . . . . . . . . . . . . . . . . . . . . . . . . . 417 3727 (DTC 1FF-04) - Info : Low oil viscosity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 419 3728 (DTC 1FF-02) - Info : Too low oil viscosity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 420 3735 (DTC 559-12) - Fuel Metering Unit : over temperature of device driver of metering unit . . . . . . . 421 3738 (DTC 2D4-04) - Analog Digital Converter (ADC) : Diagnostic fault check to report multiple error while checking the complete ROM-memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 423 3739 (DTC 3D4-12) - Power stages, Injector : Loss of synchronization sending bytes to the MM from CPU. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 424 3740 (DTC 3D4-02) - Power stages, Injector : DFC to set a torque limitation once an error is detected before MoCSOP's error reaction is set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 425 3741 (DTC 3D4-03) - Power stages, Injector : Wrong set response time . . . . . . . . . . . . . . . . . . . . . . . . . 426 3742 (DTC 3D4-04) - Power stages, Injector : Too many SPI errors during MoCSOP execution. . . . . 427
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3743 (DTC 4D4-04) - Power stages, Injector : Diagnostic fault check to report the error in under voltage monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 428 3744 (DTC 4D4-03) - Power stages, Injector : Diagnostic fault check to report the error in overvoltage monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 429 3745 (DTC 5D4-02) - Power stages, Injector : Diagnostic fault check to report that WDA is not working correct . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 430 3746 (DTC 5D4-03) - Power stages, Injector : OS timeout in the shut off path test. Failure setting the alarm task period. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 431 3747 (DTC 5D4-04) - Power stages, Injector : Diagnostic fault check to report that the positive test failed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 432 3748 (DTC 5D4-12) - Power stages, Injector : Diagnostic fault check to report the timeout in the shut off path test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 433 3750 (DTC 3E3-00) - Injection control : Error in the plausibility of the injection energizing time . . . . . . 434 3751 (DTC 3E3-01) - Injection control : Error in the plausibility of the start of energizing angles . . . . . 435 3752 (DTC 3E3-02) - Level 2 Monitoring: Error in the plausibility of the energizing times of the zero fuel quantity calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 436 3753 (DTC 3E3-03) - Level 2 Monitoring : Diagnostic fault check to report the error due to Over heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 437 3754 (DTC 3E3-04) - Level 2 Monitoring : Diagnostic fault check to report the plausibility error in rail pressure monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 438 3755 (DTC 3E3-12) - Level 2 Monitoring : Diagnostic fault check to report the error due to torque comparison . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 439 3756 (DTC 4E3-03) - Level 2 Monitoring : Diagnosis fault check to report the demand for normal mode due to an error in the PoI2 quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 440 3757 (DTC 4E3-04) - Level 2 Monitoring : Diagnosis fault check to report the error to demand for an ICO due to an error in the PoI2 shut-off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 441 3758 (DTC 4E3-12) - Level 2 Monitoring : Diagnosis fault check to report the error to demand for an ICO due to an error in the PoI3 efficiency factor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 442 3759 (DTC 5E3-03) - Level 2 Monitoring : Diagnosis of curr path limitation forced by ECU monitoring level 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 443 3760 (DTC 5E3-04) - Level 2 Monitoring : Diagnosis air path limitation due to a functional control unit monitoring forced by ECU monitoring level 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 444 3761 (DTC 5E3-12) - Level 2 Monitoring : Diagnosis quantity path limitation due to a functional control unit monitoring (level 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 445 3762 (DTC 426-03) - Level 2 Monitoring : Reported Overvoltage of Supply . . . . . . . . . . . . . . . . . . . . . . 446 3763 (DTC 426-04) - Level 2 Monitoring : Reported Under Voltage of Supply . . . . . . . . . . . . . . . . . . . . 447 3764 (DTC 225-04) - Main Relay : Early opening defect of main relay . . . . . . . . . . . . . . . . . . . . . . . . . . . 448 3766 (DTC 1F3-12) - Diesel Particulate filter Pressure sensor : Fault check for the pressure sensor plausibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 451 3767 (DTC 6D4-02) - ECU internal : Diagnostic fault check to report 'WDA active' due to errors in query-/ response communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 452 3768 (DTC 6D4-04) - ECU internal : Diagnostic fault check to report 'ABE active' due to under voltage detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 453 3769 (DTC 6D4-03) - ECU internal : Diagnostic fault check to report 'ABE active' due to overvoltage detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 454 3770 (DTC 6D4-12) - ECU internal : Diagnostic fault check to report 'WDA/ABE active' due to unknown reason . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 455 3773 (DTC 299-04) - Turbocharger : Under boost detected in Pressure charger regulator . . . . . . . . . . 456 3786 (DTC 3F9-03) - Diesel particulate filter (DPF) : Signal range check flow resistance of the particulate filter - high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 457 48068130 29/01/2018
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3787 (DTC 4F9-03) - Diesel particulate filter (DPF) : Signal range check flow resistance of the particulate filter - very high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 458 3789 (DTC 6F4-12) - To check if regeneration duration exceeds maximum allowed duration . . . . . . . 459 3794 (DTC 134-00) - Intake air pressure sensor : Plausibility Check for air pressure at the upstream of intake valve sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 460 3795 (DTC 134-01) - Intake air pressure sensor : Plausibility Check for air pressure at the upstream of intake valve sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 461 3796 (DTC 5F5-12) - Diesel Particulate filter Pressure sensor : DFC to indicate hose line error . . . . . 462 3797 (DTC 1F1-03) - Diesel Particulate filter Pressure sensor : SRC High for PFlt differential pressure sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 463 3798 (DTC 1F1-04) - Diesel Particulate filter Pressure sensor : SRC low for PFlt differential pressure sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 465 3799 (DTC 237-04) - Pressure Relief valve : pressure relief valve is forced to open, perform pressure shock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 467 3800 (DTC 237-12) - Pressure Relief valve : Quantity balance check if a successful PRV opening is ensured . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 468 3801 (DTC 49B-03) - Turbine upstream pressure sensor : SRC High for Turbine upstream pressure sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 469 3802 (DTC 49B-04) - Turbine upstream pressure sensor : SRC low for Turbine upstream pressure sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 471 3803 (DTC 2D1-03) - ECU internal : Error on R2S2 module (Low-Level Chip driver for the Power stageChips) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 473 3808 (DTC 455-03) - Fuel Metering Unit : set point of metering unit in idle mode not plausible . . . . . . 474 3810 (DTC 435-12) - Fuel pressure Sensor : Rail pressure raw value is intermittent . . . . . . . . . . . . . . . 475 3811 (DTC 1E6-12) - ECU Sensor Supply Monitor : ECU internal: Error Sensor supplies 1 . . . . . . . . 477 3812 (DTC 2CC-00) - Physical Range Check high for ECU temperature sensor . . . . . . . . . . . . . . . . . . 483 3813 (DTC 2CC-01) - Physical Range Check low for ECU temperature sensor . . . . . . . . . . . . . . . . . . . 484 3814 (DTC 2CC-12) - ECU temperature sensor : SPI Error ECU temperature sensor (LM71) . . . . . . . 485 3818 (DTC 48D-02) - Open load error for throttle valve H-bridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 486 3819 (DTC 48D-03) - Over current error for throttle valve H-bridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 488 3820 (DTC 48D-12) - Over temperature error for throttle valve H-bridge . . . . . . . . . . . . . . . . . . . . . . . . . 490 3821 (DTC 58D-03) - Short circuit to battery of throttle valve H-bridge - high pin A49 . . . . . . . . . . . . . . 492 3822 (DTC 68D-03) - Short circuit to battery of throttle valve H-bridge - low pin A34 . . . . . . . . . . . . . . . 494 3823 (DTC 58D-04) - Short circuit to ground of throttle valve H-bridge - high pin A49 . . . . . . . . . . . . . . 496 3824 (DTC 68D-04) - Short circuit to ground of throttle valve H-bridge - low pin A34 . . . . . . . . . . . . . . . 498 3825 (DTC 78D-03) - Short circuit over load error for throttle valve H-bridge . . . . . . . . . . . . . . . . . . . . . 500 3827 (DTC 78D-04) - Under voltage error for throttle valve H-bridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . 502 3834 (DTC 78B-03) - Throttle valve position sensor voltage above threshold (Short to battery) . . . . . 503 3835 (DTC 78B-04) - Throttle valve position sensor voltage below threshold (Short to ground) . . . . . 505 3838 (DTC 3F6-03) - OxiCat upstream temperature sensor : Diagnostic fault check for SRC high in Oxidation Catalyst upstream temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 507 3839 (DTC 3F6-04) - OxiCat upstream temperature sensor : Diagnostic fault check for SRC low in Oxidation Catalyst upstream temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 509 3840 (DTC 1F7-03) - Diesel Particulate filter upstream temperature sensor : Diagnostic fault check for SRC high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 511 3841 (DTC 1F7-04) - Diesel Particulate filter upstream temperature sensor : Diagnostic fault check for SRC low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 513
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3842 (DTC 29B-03) - Turbine upstream temperature sensor : SRC High for turbine upstream temperature sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 515 3843 (DTC 29B-04) - Turbine upstream temperature sensor : SRC low for turbine upstream temperature sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 518 3844 (DTC 25A-03) - Zero Fuel Calibration by Lambda (ZFL) : DFC reporting error state on comparing energizing time to Max value injector 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 520 3845 (DTC 35A-03) - Zero Fuel Calibration by Lambda (ZFL) : DFC reporting error state on comparing energizing time to Max value injector 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 521 3846 (DTC 45A-03) - Zero Fuel Calibration by Lambda (ZFL) : DFC reporting error state on comparing energizing time to Max value injector 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 522 3847 (DTC 55A-03) - Zero Fuel Calibration by Lambda (ZFL) : DFC reporting error state on comparing energizing time to Max value injector 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 523 3848 (DTC 25A-04) - Zero Fuel Calibration by Lambda (ZFL) : DFC reporting error state on comparing energizing time to Min value injector 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 524 3849 (DTC 35A-04) - Zero Fuel Calibration by Lambda (ZFL) : DFC reporting error state on comparing energizing time to Min value injector 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 525 3850 (DTC 45A-04) - Zero Fuel Calibration by Lambda (ZFL) : DFC reporting error state on comparing energizing time to Min value injector 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 526 3851 (DTC 55A-04) - Zero Fuel Calibration by Lambda (ZFL) : DFC reporting error state on comparing energizing time to Min value injector 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 527 3870 (DTC 1B4-02) - CAN Bus Received frames : CAN-Receive-Frame BC2EDC1 . . . . . . . . . . . . . . . 528 3899 (DTC 432-03) - Engine Protection : Engine temperature reaches prewarning level . . . . . . . . . . . 530 3900 (DTC 532-03) - Engine Protection : Engine temperature reaches warning level . . . . . . . . . . . . . . 531 3906 (DTC 17E-12) - Injection control : Number of injections is limited by quantity balance of high pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 532 3910 (DTC 459-03) - Fuel Metering Unit : Intermittent contact between ECU and MeUn . . . . . . . . . . . 533 3915 (DTC 137-12) - Pressure Relief valve : Averaged rail pressure is outside the expected tolerance range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 535 3916 (DTC 237-03) - Pressure Relief valve : pressure relief valve reached maximum allowed open time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 536 3978 (DTC 3FB-03) - Level 2 of PFlt Overloaded . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 537 3979 (DTC 4FB-03) - Level 3 of PFlt Overloaded . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 538 3992 (DTC 182-12) - EGR Control : Not plausible state 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 539 3993 (DTC 489-03) - DFC for valve drift at closed position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 540 4043 - Hydraulic Oil Temperature Sensor Shorted To Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 541 4044 - Hydraulic Oil Temperature Sensor Open Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 543 4055 - Park Brake Valve (On/Off) - Solenoid Supply Open Circuit (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 545 4056 - Park Brake Valve (On/Off) - Solenoid Supply Short to Ground (*) . . . . . . . . . . . . . . . . . . . . . . . . . 547 4057 - Park Brake Valve (On/Off) - Solenoid Supply Short to Power (*) . . . . . . . . . . . . . . . . . . . . . . . . . . 549 4061 - Forward Pump Control Valves (Directional) - Solenoid Right (A) Supply Open Circuit (*) . . . . . 551 4062 - Forward Pump Control Valves (Directional) - Solenoid Right (A) Supply Short to Ground (*) . . 553 4071 - Forward Pump Control Valves (Directional) - Solenoid Left (B) Supply Open Circuit (*) . . . . . . 555 4072 - Forward Pump Control Valves (Directional) - Solenoid Left (B) Supply Short to Ground (*) . . . 557 4081 - Forward Pump Control Valves (Directional) - Common Solenoid Return Short to Power (*) . . . 559 4082 - Forward Pump Control Valves (Directional) - Pumps Forward Solenoids Short to Ground (*) . 561
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4083 - Forward Pump Control Valves (Directional) - Common Solenoid Return Open Circuit (*) . . . . . 563 4309 - Park Brake Button - Park Brake Button Timeout (30 sec) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 565 4361 - Reverse Pump Control Valves (Directional) - Solenoid Right (A) Supply Open Circuit (*) . . . . . 567 4362 - Reverse Pump Control Valves (Directional) - Solenoid Right (A) Supply Short to Ground (*) . . 569 4371 - Reverse Pump Control Valves (Directional) - Solenoid Left (B) Supply Open Circuit (*) . . . . . . 571 4372 - Reverse Pump Control Valves (Directional) - Solenoid Left (B) Supply Short to Ground (*) . . . 573 4381 - Reverse Pump Control Valves (Directional) - Common Solenoid Return Short to Power (*) . . . 575 4382 - Reverse Pump Control Valves (Directional) - Pumps Reverse Solenoids Short to Ground (*) . 577 4383 - Reverse Pump Control Valves (Directional) - Common Solenoid Return Open Circuit (*) . . . . . 579 4401 - Park Brake (Mechanical Machines) Solenoid Open Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 581 4402 - Park Brake (Mechanical Machines) Shorted To Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 583 4431 - Park Brake Pressure Switch - Pressure Switch (Plausibility Check With Solenoid Valve) (*) . . 584 4731 - Right Swash Plate Angle Sensor - Pin A Short to Ground/ Open Circuit (*) . . . . . . . . . . . . . . . . . 587 4732 - Right Swash Plate Angle Sensor - Pin A Short to Power (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 590 4734 - Right Swash Plate Angle Sensor - Pin B Short to Ground/ Open Circuit (*) . . . . . . . . . . . . . . . . . 592 4735 - Right Swash Plate Angle Sensor - Pin B Short to Power (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 595 4737 - Right Swash Plate Angle Sensor - In Range Fault (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 597 4741 - Left Swash Plate Angle Sensor - Pin A Short to Ground/ Open Circuit (*) . . . . . . . . . . . . . . . . . . 600 4742 - Left Swash Plate Angle Sensor - Pin A Short to Power (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 603 4744 - Left Swash Plate Angle Sensor - Pin B Short to Ground/ Open Circuit (*) . . . . . . . . . . . . . . . . . . 605 4745 - Left Swash Plate Angle Sensor - Pin B Short to Power (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 608 4747 - Left Swash Plate Angle Sensor - In Range Fault (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 610 4752 - Left Swash Plate Angle Sensor - Implausible Command, Command Does Not Match With Swash Plate Angle (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 613 4754 - Right Swash Plate Angle Sensor - Implausible Command, Command Does Not Match With Swash Plate Angle (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 615 4781 - Solenoid Valve - Solenoid Supply Open Circuit (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 617 4782 - Solenoid Valve - Solenoid Supply Short to Ground (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 619 4783 - Solenoid Valve - Solenoid Supply Short to Power (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 621 4951 - Hydraulic Interlock Solenoid Shorted To Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 623 4952 - Hydraulic Interlock Solenoid Open Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 624 5051 - Loader Pilot Interlock Valve (On/Off) - Solenoid Supply Open Circuit (*) . . . . . . . . . . . . . . . . . . . 626 5052 - Loader Pilot Interlock Valve (On/Off) - Solenoid Supply Short to Ground (*) . . . . . . . . . . . . . . . . 628 5053 - Loader Pilot Interlock Valve (On/Off) - Solenoid Supply Short to Power (*) . . . . . . . . . . . . . . . . . 630 5061 - Port Lock Valve (On/Off) - Solenoid Supply Open Circuit (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 632 5062 - Port Lock Valve (On/Off) - Solenoid Supply Short to Ground (*) . . . . . . . . . . . . . . . . . . . . . . . . . . 634 5063 - Port Lock Valve (On/Off) - Solenoid Supply Short to Power (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . 636 5121 - Right Joystick F-B Axis - Pin A Short to Power/ Short to Ground/ Open Circuit (*) . . . . . . . . . . . 638 5122 - Right Joystick F-B Axis - Pin B Short to Power/ Short to Ground/ Open Circuit (*) . . . . . . . . . . . 642 5124 - Right Joystick F-B Axis - In Range Fault (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 646 5131 - Right Joystick R-L Axis (ISO/H Pattern) - Pin A Short to Ground/ Open Circuit (*) . . . . . . . . . . . 651 5132 - Right Joystick R-L Axis (ISO/H Pattern) - Pin A Short to Power (*) . . . . . . . . . . . . . . . . . . . . . . . . 655 (*) See content for specific models 48068130 29/01/2018
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5134 - Right Joystick R-L Axis (ISO/H Pattern) - Pin B Short to Ground/ Open Circuit (*) . . . . . . . . . . . 659 5135 - Right Joystick R-L Axis (ISO/H Pattern) - Pin B Short to Power (*) . . . . . . . . . . . . . . . . . . . . . . . . 663 5137 - Right Joystick R-L Axis (ISO/H Pattern) - In Range Fault (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 667 5141 - Aux Thumbwheel Axis - Pin A Short to Ground/ Open Circuit (*) . . . . . . . . . . . . . . . . . . . . . . . . . . 672 5142 - Aux Thumbwheel Axis - Pin A Short to Power (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 675 5144 - Aux Thumbwheel Axis - Pin B Short to Ground/ Open Circuit (*) . . . . . . . . . . . . . . . . . . . . . . . . . . 677 5145 - Aux Thumbwheel Axis - Pin B Short to Power (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 680 5147 - Aux Thumbwheel Axis - In Range Fault (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 682 5201 - Left Joystick L-R Axis - Pin A Short to Power/ Short to Ground/ Open Circuit (*) . . . . . . . . . . . . 685 5202 - Left Joystick L-R Axis - Pin B Short to Power/ Short to Ground/ Open Circuit (*) . . . . . . . . . . . . 689 5204 - Left Joystick L-R Axis - In Range Fault (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 693 5211 - Left Joystick F-B Axis - Pin A Short to Ground/ Open Circuit (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . 698 5212 - Left Joystick F-B Axis - Pin A Short to Power (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 702 5214 - Left Joystick F-B Axis - Pin B Short to Ground/ Open Circuit (*) . . . . . . . . . . . . . . . . . . . . . . . . . . 706 5215 - Left Joystick F-B Axis - Pin B Short to Power (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 710 5217 - Left Joystick F-B Axis - In Range Fault (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 714 5221 - Loader Arm Valve (Directional) Solenoid Raise (A) Supply Open Circuit (*) . . . . . . . . . . . . . . . . 719 5222 - Loader Arm Valve (Directional) Solenoid Raise (A) Supply Shorted To Ground (*) . . . . . . . . . . . 721 5231 - Loader Arm Valve (Directional) Solenoid Lower (B) Supply Open Circuit (*) . . . . . . . . . . . . . . . . 723 5232 - Loader Arm Valve (Directional) Solenoid Lower (B) Supply Shorted To Ground (*) . . . . . . . . . . 725 5241 - Loader Arm Valve (Directional) Loader Arm Solenoid(s) Shorted To Power (*) . . . . . . . . . . . . . . 727 5242 - Loader Arm Valve (Directional) Loader Arm Solenoid(s) Shorted To Ground (*) . . . . . . . . . . . . . 729 5243 - Loader Arm Valve (Directional) Solenoids Return Open Circuit (*) . . . . . . . . . . . . . . . . . . . . . . . . 731 5251 - Loader Bucket Valve (Directional) Solenoid Rollback (A) Supply Open Circuit (*) . . . . . . . . . . . 733 5252 - Loader Bucket Valve (Directional) Solenoid Rollback (A) Supply Shorted To Ground (*) . . . . . . 735 5261 - Loader Bucket Valve (Directional) Solenoid Dump (B) Supply Open Circuit (*) . . . . . . . . . . . . . . 737 5262 - Loader Bucket Valve (Directional) Solenoid Dump (B) Supply Shorted To Ground (*) . . . . . . . . 739 5271 - Loader Bucket Valve (Directional) Loader Bucket Solenoid(s) Shorted To Power (*) . . . . . . . . . 741 5272 - Loader Bucket Valve (Directional) Loader Bucket Solenoid(s) Shorted To Ground (*) . . . . . . . . 743 5273 - Loader Bucket Valve (Directional) Solenoids Return Open Circuit (*) . . . . . . . . . . . . . . . . . . . . . . 745 5281 - Loader Auxiliary Valve (Directional) Solenoid Forward (A) Supply Open Circuit (*) . . . . . . . . . . 747 5282 - Loader Auxiliary Valve (Directional) Solenoid Forward (A) Supply Shorted To Ground (*) . . . . 749 5291 - Loader Auxiliary Valve (Directional) Solenoid Reverse (B) Supply Open Circuit (*) . . . . . . . . . . 751 5292 - Loader Auxiliary Valve (Directional) Solenoid Reverse (B) Supply Shorted To Ground (*) . . . . 753 5309 - Float Button - Float Button Timeout (30 sec) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 755 5313 - EHF Enable Switch STP (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 757 5323 - EHF Fwd/Rev Switch STP (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 759 5371 - EHF Forward Solenoid (A) Supply STG (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 762 5372 - EHF Forward Solenoid (A) Supply OC (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 764 5381 - EHF Reverse Solenoid (B) Supply STG (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 766 5382 - EHF Reverse Solenoid (B) Supply OC (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 768
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5391 - EHF Solenoids Return OC (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 770 5392 - EHF Pump Solenoid(s) STG (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 772 5393 - EHF Pump Solenoid(s) STP (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 774 5409 - Aux Override Disabled Due To Aux Override Button Timeout (30 Seconds) (*) . . . . . . . . . . . . . 776 5501 - Loader Arm Spool Sensor Open or Shorted To Ground (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 777 5502 - Loader Arm Spool Sensor Shorted To Power (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 779 5503 - Electro-Hydraulic Aux Output Shorted To Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 781 5504 - Bucket Valve Spool Sensor Open Or Shorted To Ground (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 782 5505 - Bucket Valve Spool Sensor Shorted To Power (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 784 5507 - Auxiliary Valve Spool Sensor Open Or Shorted To Ground (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 786 5508 - Auxiliary Valve Spool Sensor Shorted To Power (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 788 5511 - Implausible Loader Arm Sensor State Vs Loader Arm Command - Stuck Spool Or PRV (*) . . 790 5512 - Implausible Bucket Sensor State Vs Loader Bucket Command - Stuck Spool Or PRV (*) . . . . 793 5513 - Implausible Auxiliary Sensor State Vs Auxiliary Command - Stuck Spool Or PRV (*) . . . . . . . . 796 5601 - Loader Auxiliary Valve (Directional) Loader Auxiliary Solenoid(s) Shorted To Power (*) . . . . . . 799 5602 - Loader Auxiliary Valve (Directional) Loader Auxiliary Solenoid(s) Shorted To Ground (*) . . . . . 801 5603 - Loader Auxiliary Valve (Directional) Solenoids Return Open Circuit (*) . . . . . . . . . . . . . . . . . . . . 803 5701 - Pattern Switch Open Or Shorted To Ground (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 805 5703 - Pattern Switch Shorted To Power (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 808 5811 - Loader Port Lock Switch Is In An Implausible State (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 811 9004 - Memory Error - Triple Redundant - Hour Meter Location 1 Corrupt . . . . . . . . . . . . . . . . . . . . . . . . 814 9005 - Memory Error - Triple Redundant - Hour Meter Location 2 Corrupt . . . . . . . . . . . . . . . . . . . . . . . . 815 9006 - Memory Error - Triple Redundant - Hour Meter Location 3 Corrupt . . . . . . . . . . . . . . . . . . . . . . . . 816 9151 - Bus-Warn at CAN-Bus No.1 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 817 9152 - Bus-Warn at CAN-Bus No.1 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 819 9153 - Timeout of CAN Message EEC1 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 821 9154 - Timeout of CAN Message TSC1 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 823 9156 - Hydraulic Enable Button Error From AIC (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 825 9158 - H Pattern Indicator Shorted To Ground (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 826 9159 - ISO Pattern Indicator Shorted To Ground (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 828 9160 - H Pattern Indicator Shorted To Power (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 830 9161 - ISO Pattern Indicator Shorted To Power (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 833 9401 - Memory Error - Double Redundant Memory - Corruption Detected And Repaired . . . . . . . . . . . 836 9403 - Memory Error - Double Redundant Memory - Unrecoverable Memory Corruption Operable . . 837 9404 - Memory Error - Triple Redundant - Hour Meter Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 838 9405 - Loss Of DM1 Message From VCM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 839 9406 - No CAN Communication From VCM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 840 9407 - Memory Error - Unrecoverable Hardware ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 841 9408 - Memory Error - Unrecoverable Panel ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 842 9410 - Loss Of EGR Inducement Status Message From EDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 843 17100 (DTC 382-12) - EGR Control : Not plausible state 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 844
(*) See content for specific models 48068130 29/01/2018
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17101 (DTC 482-12) - EGR Control : Not plausible state 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 845 17102 (DTC 582-12) - EGR Control : Not plausible state 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 846 17103 (DTC 682-12) - EGR Control : Not plausible state 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 847 17104 (DTC 782-12) - EGR Control : Not plausible state 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 848 17105 (DTC 399-03) - Turbo protection cold start detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 849 17513 (DTC 1F7-00) - Physical Range Check high for ECU temperature sensor . . . . . . . . . . . . . . . . . . 850 17514 (DTC 7CC-12) - TSC1 blocked or with wrong checksum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 851 19191 (DTC 6BA-02) - CAN Bus Received frames : CAN-Receive-Frame CCSSBC timeout . . . . . . . 852 19192 (DTC 1BD-02) - CAN Bus Received frames : CAN-Receive-Frame CCVSV timeout Christian 853
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Electrical systems - FAULT CODES
1002 - Engine Coolant Temperature Is Above Normal Context: The instrument cluster has received a message from the ECU that the coolant temperature is above 111 °C (232 °F) for a period greater than 5 s. Cause: The coolant temperature is above normal. The instrument cluster has received a message from the ECU that the coolant temperature above 111 °C (232 °F) for a period greater than 5 s. Possible failure modes: 1. The engine has a low coolant level. 2. Faulty wiring or connections. 3. A faulty coolant temperature sensor. 4. A faulty ECU. 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 is not recorded again. OK to return the machine to service. B. Fault code 1002 – Engine Coolant Temperature Is Above Normal is recorded again. Refer to procedure 3007 - Engine coolant temperature sensor voltage is higher than expected (55.640).
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Electrical systems - FAULT CODES
1004 - Hydraulic Filter Restriction Switch - Hydraulic Filter Restricted Context: The instrument cluster measures an open circuit in the hydraulic oil filter restriction input. A connection to ground indicates that the hydraulic filter is not clogged. An open circuit indicates that the hydraulic filter is restricted. Cause: The instrument cluster measures an open circuit in the hydraulic oil filter restriction input, X-C23 pin 15. Possible failure modes: 1. The hydraulic temperature sender is shorted out on the hydrostatic pressure lines. Refer to KA00589730 for more information. 2. Clogged hydraulic filter. 3. There is an open circuit in the signal wire. 4. A faulty reading from the switch. 5. A 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 6. B. Fault code 1004 â&#x20AC;&#x201C; Hydraulic Filter Restriction Switch - Hydraulic Filter Restricted is recorded again. Go to step 2. 2. Inspect the hydraulic oil filter. Inspect the hydraulic filter. Replace the filter if needed. A. The filter is in good condition and does not need to be replaced. Go to step 3. B. The filter is in poor condition or is clogged. Replace the filter. Return to step 3 to confirm the elimination of the fault. 3. Verify the harness and connectors are not damaged. Inspect the instrument cluster and hydraulic filter restriction switch connections. All connections should be secure, tight, free of corrosion, abrasion and damage. Inspect the harness from the instrument cluster to the hydraulic filter restriction switch. Verify that the harness is free of damage, corrosion, abrasion or incorrect attachment. A. The wiring is free of corrosion, damage, abrasion, and incorrect attachment. Go to step 3. B. The wiring is not free of corrosion, damage, abrasion, or incorrect attachment. Repair or replace the harness as required. Return to step 1 to confirm the elimination of the fault. 4. Measure the resistance through the filter restriction switch. Turn the ignition switch OFF. Disconnect the oil filter switch from the harness. Disconnect the instrument cluster connector X-C23.
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Electrical systems - FAULT CODES
Fabricate a jumper wire that will connect between the hydraulic filter restriction switch X-OILFILT pin 1 and chassis ground. The chassis ground connection must be clean and free of paint, oil, and dirt. Connect the jumper wire between the hydraulic filter restriction switch X-OILFILT pin 1 and chassis ground. Measure the resistance between X-C23 pin 2 and chassis ground. The resistance should be less than 5 Ω. Wiggle the harness during measurement to reveal an intermittent condition. A. The resistance is less than 5 Ω. Go to step 5. B. The resistance is greater than 5 Ω. There is an open circuit in the wiring. Repair or replace the harness as required. Return to step 1 to confirm the elimination of the fault. 5. Test the instrument cluster. Turn the ignition switch OFF. Leave the jumper wire installed between the hydraulic filter restriction switch X-OILFILT pin 1 and chassis ground. Reconnect the instrument cluster connector X-C23. Turn the ignition switch ON. Start the engine. Verify that the hydraulic oil temperature is greater than 43 °C (109 °F). Use EST to access the fault code screen. Fault code 1004 – Hydraulic Filter Restriction Switch - Hydraulic Filter Restricted should not be active. A. Fault code 1004 – Hydraulic Filter Restriction Switch - Hydraulic Filter Restricted is not active. Replace the hydraulic filter restriction switch and retest. Return to step 1 to confirm the elimination of the fault. B. Fault code 1004 – Hydraulic Filter Restriction Switch - Hydraulic Filter Restricted is still active. Replace the instrument cluster and retest. Return to step 1 to confirm the elimination of the fault. 6. 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 discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and return the machine to service.
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Electrical systems - FAULT CODES
1009 - Hydraulic Oil Temperature Is Above Normal Context: The instrument cluster monitored a hydraulic oil temperature that is greater than 110 °C (230 °F) for a period greater than 3 s. Cause: The hydraulic oil temperature is above 110 °C (230 °F) for a period greater than 3 s. Possible failure modes: 1. Low hydraulic oil level. 2. Faulty fan operation. 3. Clogged cooling core. 4. Faulty reading from sensor. 5. 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. OK to return the machine to service. B. Fault code 1009 is recorded again. Go to step 2. 2. Verify hydraulic oil level. Check the hydraulic oil level, add oil as required. Refer to the Operator's Manual for more details. A. The oil level is correct and the fault is not recorded again. Return the machine to service. B. The oil level is correct, but the fault is recorded again. Go to step 3. 3. Check fan operations. Operate the engine at 1500 RPM. Check the fan operation. Check the cooling core for clogs. A. The cooling system is operating properly. Go to step 4. B. The cooling system is not operating properly or the cooling core is clogged. Repair the fan or clear the clogs from the cooling core. Repair as required. Return to step 1 to confirm elimination of fault. 4. Check the temperature sender. Disconnect the terminal connector from the hydraulic oil temperature sender. Measure the resistance between the hydraulic oil temperature sender ground connection and chassis ground. The resistance should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition. Measure the resistance across the temperature sender terminals. Hydraulic Oil Temperature Sensor Open Circuit Resistance Measurements Temperature Resistance in ohms (± 10%) 110 °C (230 °F) 130 Ω 105 °C (221 °F) 151 Ω 48068130 29/01/2018
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Electrical systems - FAULT CODES
Hydraulic Oil Temperature Sensor Open Circuit Resistance Measurements 100 °C (212 °F) 175 Ω 95 °C (203 °F) 202 Ω 92 °C (198 °F) 223 Ω 88 °C (190 °F) 258 Ω 85 °C (185 °F) 280 Ω 81 °C (178 °F) 323 Ω 78 °C (172 °F) 358 Ω 74 °C (165 °F) 412 Ω 68 °C (154 °F) 511 Ω 16 °C (61 °F) 4250 Ω A. The resistance measurements compare to the values in the table. Go to step 5. B. The resistance measurements are not acceptable. The measured resistance is less than 100 Ω and greater than 5,000 Ω. Replace the hydraulic oil temperature sender. Return to step 1 to confirm elimination of fault. 5. Check the wiring to the instrument cluster. Disconnect the instrument cluster connector X-C23. Disconnect the hydraulic oil temperature sensor. Measure the resistance between the hydraulic oil temperature sender connector pin 1 (signal wire) 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. Return to step 1 to confirm elimination of the fault. B. The resistance is less than 20,000 Ω. There is a short circuit to chassis ground in the wire. Repair or replace the wire as required. Return to step 1 to confirm elimination of fault.
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Electrical systems - FAULT CODES
1014 - Cluster System Voltage Above Normal (>16.5V) Context: The instrument cluster measured an alternator voltage greater than 16 V for a period greater than 5 s. The fault will reset once the alternator voltage drops below 16 V for a period greater than 5 s. Cause: The voltage on the instrument cluster input, X-C23 pin 9 is greater than 16 V. Possible failure modes: 1. A faulty alternator. The alternator output is greater than 16 V. 2. A faulty instrument cluster. Solution: 1. Verify that the fault code is active. Connect the Electronic Service Tool to the service tool connector. To check for fault codes: Start and operate the machine. A. Fault code 1014 is not recorded again. OK to return the machine to service. B. Fault code 1014 is recorded again. Go to step 2. 2. Measure the alternator output. Start the engine. Set the engine speed to low idle and measure the voltage at the alternator. The voltage should be approximately 14.5 V. A. The voltage is approximately 14.5 V. Go to step 3. B. The voltage is greater than 16 V. Replace the alternator. Return to step 1 to confirm elimination of fault. 3. Measure the voltage at instrument cluster. Disconnect the instrument cluster connector X-C23. Turn the ignition switch ON. Start the engine. Measure the voltage between pin X-C23 pin 9 and chassis ground. The chassis ground connection should be clean and free of paint, oil, and dirt. The voltage should be approximately 14.5 V. Wiggle the harness during measurement to reveal an intermittent condition. A. The voltage is approximately 14.5 V. Temporarily replace the instrument cluster and retest. Return to step 1 to confirm elimination of the fault code. B. The voltage is greater than 16 V. Replace the alternator. Return to step 1 to confirm elimination of fault.
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Electrical systems - FAULT CODES
1015 - Cluster System Voltage Below Normal (<11.5V) Context: The instrument cluster has measured an alternator voltage less than 11.5 V for a period greater than 5 s. The fault will reset once the alternator voltage is greater than 12 V for a period greater than 5 s. Cause: The voltage on the instrument cluster input, X-C23 pin 9 is less than 11.5 V. Possible failure modes: 1. A problem in the wiring. 2. A faulty alternator. The alternator output is less than 11.5 V. 3. A faulty instrument cluster. Solution: 1. Verify that the fault code is active. Connect the Electronic Service Tool to the service tool connector. To check for fault codes: Start and operate the machine. A. Fault code 1015 is not recorded again. OK to return the machine to service. B. Fault code 1015 is recorded again. Go to step 2. 2. Measure the alternator output. Start the engine. Set the engine speed to low idle. Measure the voltage at the alternator. The voltage should be approximately 14.5 V. A. The voltage is approximately 14.5 V. Go to step 3. B. The voltage is less than 11.5 V. Replace the alternator. Return to test step 1 to confirm elimination of fault. 3. Measure the voltage at the instrument cluster. Disconnect the instrument cluster X-C23. Turn the ignition switch ON. Start the engine. Measure the voltage between pin X-C23 pin 9 and chassis ground. The chassis ground connection should be clean and free of paint, oil, and dirt. The voltage should be approximately 14.5 V. Wiggle the harness during measurement to reveal an intermittent condition. A. The voltage is approximately 14.5 V. Temporarily replace the instrument cluster and retest. Return to step 1 to confirm elimination of the fault code. B. The voltage is less than 11.5 V. There is a problem in the wiring between the alternator and the instrument cluster. Repair as required. Return to step 1 to confirm elimination of the fault.
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Electrical systems - FAULT CODES
1022 - Water In Fuel Detected Context: The ECU has detected water in the fuel. The instrument cluster will illuminate the amber warning lamp and WIF will be displayed in the instrument cluster LCD. Fault code 1022 â&#x20AC;&#x201C; Water In Fuel Detected will be active with fault code 3146 â&#x20AC;&#x201C; Water detected in fuel. Follow the procedure for 3146 - Water in fuel detected or water in fuel circuit failure (55.640) The fault will reset once the ECU no longer detects water in the fuel. Cause: The ECU has detected water in the fuel.
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Electrical systems - FAULT CODES
1025 - Foot Throttle Sensor Is Above Range - Shorted To Power Context: The instrument cluster has detected an problem with the foot throttle signal to the instrument cluster. Diagnostic Trouble Code 1025 has an error priority of White. Engine speed is based on the signal from the hand throttle while Diagnostic Trouble Code 1025 is active. Cause: The instrument cluster has sensed a higher than normal voltage on throttle signal pin, X-C23 pin 23. The fault is active while the ignition switch is on and throttle voltage is greater than 5.6 V. Possible failure modes: 1. A short circuit in the foot throttle wiring to another voltage source. 2. A failure of the throttle position sensor. 3. The instrument cluster has an internal failure. 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. OK to return the machine to service. B. Fault code 1025 is recorded again. Go to step 2. 2. Verify the harness is not damaged Turn the ignition switch OFF. Verify the connections from the instrument cluster to the foot throttle position sensor are tight and secure. Verify the harness is free of damage, abrasion, corrosion, and incorrect attachment from the instrument cluster to the foot throttle position sensor. A. The foot throttle position sensor harness is not damaged and all of the connections are secure. Go to step 3. B. The throttle position sensor harness is damaged or the connectors are loose or damaged. Repair or replace the harness or the connectors as required. Return to step 1 to confirm elimination of fault. 3. Measure the supply voltage to the throttle sensor. Turn the ignition switch OFF. Disconnect the foot throttle sensor connector X-20. Turn the ignition switch ON. Measure the voltage between pin C and pin B. The voltage should be between 4.8 V and 5.2 V. Wiggle the harness during measurement to reveal an intermittent condition. A. The voltage is between 4.8 V and 5.2 V. Go to step 4. B. The voltage is greater than 5.2 V or less than 4.8 V. Go to step 7. 4. Measure the voltage on the sensor signal line. Turn the ignition switch OFF. Disconnect the foot throttle position sensor from the harness.
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Electrical systems - FAULT CODES
Disconnect the instrument cluster connector X-C23. Turn the ignition switch ON. Measure the voltage between X-20 pin A and chassis ground. The voltage should be less than 0.5 V. Wiggle the harness during measurement to reveal an intermittent condition. A. The voltage is less than 0.5 V. Go to step 5. B. The voltage is greater than 0.5 V. There is a short circuit to another voltage source. Repair or replace the wire as required. Return to step 1 to confirm elimination of the fault. 5. Check the signal voltage from the sensor.
RCPH10TLB053FAM
(1) (2)
1
Throttle Signal Legend Throttle Signal Voltage Throttle movement in degrees of travel. 0° equals low idle. 20° equals WOT (Wide Open Throttle).
This step is used to monitor the throttle signal. The sensor must be connected and active in order to continue. The dealer must build a breakout harness as shown below. Connect the breakout harness between the foot throttle sensor and the instrument cluster. Measure the voltage between pin A and pin B (or slide back probes into pin A and pin B). Turn the ignition switch ON, engine OFF. Measure the voltage between pin A and pin B. 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. Go to step 6. B. The voltage did not change from 0.55 V to 4.2 V as the throttle moved from low idle to WOT or the voltage was less than 0.55 V. Temporarily replace the sensor and retest. Return to step 1 to confirm elimination of fault. 6. Measure the throttle signal from the sensor to the instrument cluster. Turn the ignition switch OFF. 48068130 29/01/2018
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Electrical systems - FAULT CODES
Remove the breakout harness. Reconnect the sensor to the instrument cluster harness. Remove pin 23 from connector X-C23. Turn the ignition switch ON, engine OFF. Measure the voltage between the removed wire, pin 23 and chassis ground. 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. Return to step 1 to confirm elimination of the fault. B. The voltage did not change from 0.55 V to 4.2 V as the throttle moved from low idle to WOT or the voltage was less than 0.55 V at low idle. 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. 7. Measure the voltage at the instrument cluster Turn the ignition switch OFF. Remove the wires from instrument cluster connector X-C23 pin 17 and X-C23 25. Fabricate two jumper wires that will connect into X-C23 pin 25 and X-C23 pin 17. Connect the jumper wires into X-C23 pin 25 and X-C23 pin 17. Turn the ignition switch ON. Use the jumper wires to measure the voltage between X-C23 pin 25 and X-C23 pin 17. A. The voltage is correct. There is a problem in the wiring harness from the instrument cluster to the throttle position sensor. Repair or replace the harness as required. Return to step 1. B. The voltage is greater than 5.2 V or less than 4.8 V. Temporarily replace the instrument cluster and retest. Return to step 1 to confirm elimination of the fault.
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Electrical systems - FAULT CODES
1026 - Hand Throttle Sensor Is Above Range - Shorted To Power Context: The instrument cluster has detected an problem with the hand throttle signal to the instrument cluster. Diagnostic Trouble Code 1026 has an error priority of White. The engine speed is based on the signal from the hand throttle while Diagnostic Trouble Code 1026 is active. Cause: The instrument cluster has sensed a higher than normal voltage on throttle signal pin, X-C23 pin 22. The fault is active while the ignition switch is on and throttle voltage is greater than 5.6 V. Possible failure modes: 1. A short circuit in the throttle wiring to another voltage source. 2. A failure of the hand throttle position sensor. 3. The instrument cluster has an internal failure. 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. OK to return the machine to service. B. Fault code 1026 is recorded again. Go to step 2. 2. Verify the harness is not damaged Turn the ignition switch OFF. Verify the connections from the instrument cluster to the hand throttle position sensor are tight and secure. Verify the harness is free of damage, abrasion, corrosion, and incorrect attachment from the instrument cluster to the hand throttle position sensor. A. The hand throttle position sensor harness is not damaged and all of the connections are secure. Go to step 3. B. The throttle position sensor harness is damaged or the connectors are loose or damaged. Repair or replace the harness or the connectors as required. Return to step 1 to confirm elimination of fault. 3. Measure the supply voltage to the throttle sensor. Turn the ignition switch OFF. Disconnect the hand throttle sensor connector X-20A. Turn the ignition switch ON. Measure the voltage between pin C and pin B. The voltage should be between 4.8 V and 5.2 V. Wiggle the harness during measurement to reveal an intermittent condition. A. The voltage is between 4.8 V and 5.2 V. Go to step 4. B. The voltage is greater than 5.2 V or less than 4.8 V. Go to step 7. 4. Measure the voltage on the sensor signal line. Turn the ignition switch OFF. Disconnect the hand throttle position sensor from the harness.
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Electrical systems - FAULT CODES
Disconnect the instrument cluster connector X-C23. Turn the ignition switch ON. Measure the voltage between X-20A pin A and chassis ground. The voltage should be less than 0.5 V. Wiggle the harness during measurement to reveal an intermittent condition. A. The voltage is less than 0.5 V. Go to step 5. B. The voltage is greater than 0.5 V. There is a short circuit to another voltage source. Repair or replace the wire as required. Return to step 1 to confirm elimination of the fault. 5. Check the signal voltage from the sensor.
RCPH10TLB053FAM
(1) (2)
1
Throttle Signal Legend Throttle Signal Voltage Throttle movement in degrees of travel. 0° equals low idle. 20° equals WOT (Wide Open Throttle).
This step is used to monitor the throttle signal. The sensor must be connected and active in order to continue. The dealer must build a breakout harness as shown below. Connect the breakout harness between the hand throttle sensor and the instrument cluster. Measure the voltage between pin A and pin B (or slide back probes into pin A and pin B). Turn the ignition switch ON, engine OFF. Measure the voltage between pin A and pin B. 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. Go to step 6. B. The voltage did not change from 0.55 V to 4.2 V as the throttle moved from low idle to WOT or the voltage was less than 0.55 V. Temporarily replace the sensor and retest. Return to step 1 to confirm elimination of fault. 6. Measure the throttle signal from the sensor to the instrument cluster. Turn the ignition switch OFF. 48068130 29/01/2018
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Remove the breakout harness. Reconnect the sensor to the instrument cluster harness. Remove pin 22 from connector X-C23. Turn the ignition switch ON, engine OFF. Measure the voltage between the removed wire, pin 22 and chassis ground. 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. Return to step 1 to confirm elimination of the fault. B. The voltage did not change from 0.55 V to 4.2 V as the throttle moved from low idle to WOT or the voltage was less than 0.55 V at low idle. 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. 7. Measure the voltage at the instrument cluster Turn the ignition switch OFF. Remove the wires from instrument cluster connector X-C23 pin 17 and X-C23 25. Fabricate two jumper wires that will connect into X-C23 pin 25 and X-C23 pin 17. Connect the jumper wires into X-C23 pin 25 and X-C23 pin 17. Turn the ignition switch ON. Use the jumper wires to measure the voltage between X-C23 pin 25 and X-C23 pin 17. A. The voltage is correct. There is a problem in the wiring harness from the instrument cluster to the throttle position sensor. Repair or replace the harness as required. Return to step 1. B. The voltage is greater than 5.2 V or less than 4.8 V. Temporarily replace the instrument cluster and retest. Return to step 1 to confirm elimination of the fault.
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1030 - Foot Throttle Sensor Is Below Range - Open Or Shorted To Ground Context: The instrument cluster has detected an problem with the foot throttle signal to the instrument cluster. Diagnostic Trouble Code 1030 has an error priority of White. The engine speed is based on the hand throttle sensor while Diagnostic Trouble Code 1030 is active. Cause: The instrument cluster has sensed that the foot throttle signal has failed. The fault is active while the engine is on and the foot throttle input voltage, X-C23 pin 22 falls below 0.2 V. Possible failure modes: 1. A short circuit in the wiring. 2. An open circuit in the wiring. 3. A failure of the foot throttle position sensor. 4. A failure of the 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. OK to return the machine to service. B. Fault code 1030 is recorded again. Go to step 2. 2. Verify the harness is not damaged. Turn the ignition switch OFF. Verify the connections from the instrument cluster to the foot throttle position sensor are tight and secure. Verify the harness is free of damage, abrasion, corrosion, and incorrect attachment from the instrument cluster to the foot throttle position sensor. A. The foot throttle position sensor harness is not damaged and all connections are secure. Go to step 3. B. The foot throttle position sensor harness is damaged or the connectors are loose or damaged. Repair or replace the harness or the connectors as required. Return to step 1 to confirm elimination of fault. 3. Measure the supply voltage to the foot throttle sensor. Turn the ignition switch OFF. Disconnect the foot throttle connector. Turn the ignition switch to the ON position. Measure the voltage between pin C and pin B. The voltage should be approximately between 5 V. Wiggle the harness during measurement to reveal an intermittent condition. A. The voltage is between 4.8 V and 5.2 V. Go to step 4. B. The voltage is greater than 5.2 V or less than 4.8 V. Go to step 6.
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4. Measure the foot throttle signal from the sensor.
RCPH10TLB053FAM
(1) (2)
1
Foot Throttle Signal Legend Foot Throttle Signal Voltage Foot throttle movement in degrees of travel. 0° equals low idle. 20° equals WOT (Wide Open foot throttle).
This step is used to monitor the foot throttle signal. The sensor must be connected and active in order to continue. The dealer must build a breakout harness as shown below. Connect the breakout harness between the foot throttle connector X-20 and the instrument cluster harness. Measure the voltage between pin A and pin B (or slide back probes into pin A and pin B). Turn the ignition switch ON, engine OFF. Measure the voltage between pin A and pin B. Move the foot throttle from low idle to WOT (wide open foot 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. Go to step 5. B. The voltage did not change between 0.55 V and 4.2 V as the foot throttle moved from low idle to WOT or the voltage was less than 0.5 V at low idle. Temporarily replace the sensor and retest. Return to step 1 to confirm elimination of fault. 5. Measure the foot throttle signal from the sensor to the instrument cluster. Turn the ignition switch OFF. Remove the breakout harness. Reconnect the sensor to the instrument cluster harness. Remove pin 22 from connector X-C23. Turn the ignition switch ON, engine OFF.
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Measure the voltage between removed wire, pin 22 and chassis ground. Move the foot throttle from low idle to WOT (wide open foot throttle). The voltage should change from approximately 0.55 V volts 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. Return to step 1 to confirm elimination of the fault. B. The voltage did not change between 0.55 V and 4.2 V as the foot throttle moved from low idle to WOT or the voltage was less than 0.55 V at low idle. There is a problem in the foot 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. 6. Measure the voltage at the instrument cluster Turn the ignition switch OFF. Remove the pin 17 and pin 25 from connector X-C23. Fabricate two jumper wires and insert them into X-C23 pin 25 and X-C23 pin 17. Turn the ignition switch ON. Use the jumper wires to measure the voltage between X-C23 pin 25 and X-C23 pin 17. A. The voltage is correct. There is a problem in the wiring harness from the instrument cluster to the foot throttle position sensor. Repair or replace the harness as required. Return to step 1. B. The voltage is greater than 5.2 V or less than 4.8 V. Temporarily replace the instrument cluster and retest. Return to step 1 to confirm elimination of the fault.
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1031 - Hand Throttle Sensor Is Below Range - Open Or Shorted To Ground Context: The instrument cluster has detected an problem with the hand throttle signal to the instrument cluster. Diagnostic Trouble Code 1031 has an error priority of White. The engine speed is based on the foot throttle sensor while Diagnostic Trouble Code 1031 is active. Cause: The instrument cluster has sensed that the hand throttle signal has failed. The fault is active while the engine is on and the hand throttle input voltage, X-C23 pin 22 falls below 0.2 V. Possible failure modes: 1. A short circuit in the wiring. 2. An open circuit in the wiring. 3. A failure of the hand throttle position sensor. 4. A failure of the 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. OK to return the machine to service. B. Fault code 1031 is recorded again. Go to step 2. 2. Verify the harness is not damaged. Turn the ignition switch OFF. Verify the connections from the instrument cluster to the hand throttle position sensor are tight and secure. Verify the harness is free of damage, abrasion, corrosion, and incorrect attachment from the instrument cluster to the hand throttle position sensor. A. The hand throttle position sensor harness is not damaged and all connections are secure. Go to step 3. B. The hand throttle position sensor harness is damaged or the connectors are loose or damaged. Repair or replace the harness or the connectors as required. Return to step 1 to confirm elimination of fault. 3. Measure the supply voltage to the hand throttle sensor. Turn the ignition switch OFF. Disconnect the hand throttle connector. Turn the ignition switch to the ON position. Measure the voltage between pin C and pin B. The voltage should be approximately between 5 V. Wiggle the harness during measurement to reveal an intermittent condition. A. The voltage is between 4.8 V and 5.2 V. Go to step 4. B. The voltage is greater than 5.2 V or less than 4.8 V. Go to step 6.
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4. Measure the hand throttle signal from the sensor.
RCPH10TLB053FAM
(1) (2)
1
Hand Throttle Signal Legend Hand Throttle Signal Voltage Hand throttle movement in degrees of travel. 0° equals low idle. 20° equals WOT (Wide Open hand throttle).
This step is used to monitor the hand throttle signal. The sensor must be connected and active in order to continue. The dealer must build a breakout harness as shown below. Connect the breakout harness between the hand throttle connector X-20A and the instrument cluster harness. Measure the voltage between pin A and pin B (or slide back probes into pin A and pin B). Turn the ignition switch ON, engine OFF. Measure the voltage between pin A and pin B. Move the hand throttle from low idle to WOT (wide open hand 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. Go to step 5. B. The voltage did not change between 0.55 V and 4.2 V as the hand throttle moved from low idle to WOT or the voltage was less than 0.5 V at low idle. Temporarily replace the sensor and retest. Return to step 1 to confirm elimination of fault. 5. Measure the hand throttle signal from the sensor to the instrument cluster. Turn the ignition switch OFF. Remove the breakout harness. Reconnect the sensor to the instrument cluster harness. Remove pin X-C23 pin 22 from the connector X-C23. Turn the ignition switch ON, engine OFF.
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Measure the voltage between removed wire, X-C23 pin 22 and chassis ground. Move the hand throttle from low idle to WOT (wide open hand throttle). The voltage should change from approximately 0.55 V volts 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. Return to step 1 to confirm elimination of the fault. B. The voltage did not change between 0.55 V and 4.2 V as the hand throttle moved from low idle to WOT or the voltage was less than 0.55 V at low idle. There is a problem in the hand 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. 6. Measure the voltage at the instrument cluster Turn the ignition switch OFF. Remove the pin X-C23 pin 17 and pin X-C23 pin 25 from the connector X-C23. Fabricate two jumper wires and insert them into X-C23 pin 25 and X-C23 pin 17. Turn the ignition switch ON. Use the jumper wires to measure the voltage between X-C23 pin 25 and X-C23 pin 17. A. The voltage is correct. There is a problem in the wiring harness from the instrument cluster to the hand throttle position sensor. Repair or replace the harness as required. Return to step 1. B. The voltage is greater than 5.2 V or less than 4.8 V. Temporarily replace the instrument cluster and retest. Return to step 1 to confirm elimination of the fault.
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1040 - RPM Monitoring Over Speed Cause: The instrument cluster has detected an engine speed greater than 2750 RPM for a period greater than 5 s. The warning lamp will illuminate Amber. The fault will stay active until engine speed drops below 2700 RPM. Solution: 1. Fault code 1040 â&#x20AC;&#x201C; RPM Monitoring Over Speed is a CAN data link message from the ECU to the instrument cluster. The fault code is displayed on the instrument cluster to warn the operator that the engine speed has exceeded 2750 RPM for a period greater than 5 s.
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1041 - RPM Monitoring Over Speed Max Cause: The instrument cluster has received a message from the ECU that the engine speed is greater than 3000 RPM for a period greater than 5 s. Solution: 1. Stop the engine. Fault code 1041 â&#x20AC;&#x201C; RPM Monitoring Over Speed Max is a CAN data link message from the ECU to the instrument cluster. This fault code is displayed on the instrument cluster to alert the operator that the engine speed has exceeded 3000 RPM.
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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 sender resistance is below 2 Ω for a period greater than 30 s. Cause: The instrument cluster has detected the fuel sender resistance is below 2 Ω for a period greater than 30 s. Possible failure modes: 1. Wiring or circuits shorted to minus battery or chassis ground. 2. A faulty fuel level sensor. 3. A 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 is not recorded again. OK to return the machine to service. B. Fault code 1044 is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the instrument cluster and the fuel level sender connections. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the instrument cluster to the fuel level sender. Verify that the harness is free of damage, corrosion, abrasion, and incorrect attachment. A. The connectors are secure and the harness is free of damage. Go to step 3. 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 resistance at the fuel level sensor. Tilt the cab. Remove the fuel level sender from the tank. Disconnect the sender from the harness. Move the fuel level float from the low position to the high position while measuring the resistance of the sender. The resistance should change linearly from approximately 4.5 Ω at the full tank position to approximately 340 Ω at the empty tank position. The resistance should change linearly without any fluctuations to a higher or lower resistance. A. The resistance measurements from the sensor are within specifications. Go to step 4. 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. 4. Check the fuel level sensor wiring. Measure the resistance between X-14 pin A and chassis ground. The resistance should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition. Fabricate a jumper wire that will connect between connector X-C23 pin 24 and chassis ground.
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Connect the jumper wire between connector X-C23 pin 24 and chassis ground. Measure the resistance between X-14 pin B and chassis ground. The resistance should be less than 10 Ί. Wiggle the harness during measurement to reveal an intermittent condition. A. Both resistance measurements are less than 10 Ί. Temporarily replace the instrument cluster and retest. Return to step 1 to confirm elimination of the fault. B. One or both resistance measurements are greater than 10 Ί. There is a problem in the wiring harness. Repair or replace the harness as required. Return to step 1 to confirm elimination of fault.
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1045 - Fuel Level Sensor Open Circuit Context: The instrument cluster has detected an open circuit in the fuel sender signal. Cause: The instrument cluster has determined that the fuel level sensor resistance has failed high. The resistance of the fuel level sensor is greater than 5,000 立. Possible failure modes: 1. An open circuit in the wiring. 2. A faulty fuel level sensor. 3. The instrument cluster has internal failure. 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. OK to return the machine to service. B. Fault code 1045 is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the instrument cluster and the fuel level sender connections. All connections should be secure, tight, free of corrosion, abrasion and damage. Inspect the harness from the instrument cluster to the fuel level sender. Verify that the harness is free of damage, corrosion, abrasion or incorrect attachment. 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 the connectors as required. Return to step 1 to confirm elimination of fault. 3. Measure the resistance at the fuel level sensor. Tilt the cab. Remove the fuel level sender from the tank. Disconnect the sender from the harness. Move the fuel level float from the low position to the high position while measuring the resistance across the sender. The resistance should change linearly from approximately 4.5 立 at the full tank position to approximately 340 立 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 4. B. The resistance readings from the sensor were not steady or the values were not accurate. Temporarily replace the sensor and retest. Return to step 1 to confirm elimination of fault. 4. Check fuel level wiring. Measure the resistance between X-14 pin A and chassis ground. The resistance should be less than 10 立. Wiggle the harness during measurement to reveal an intermittent condition.
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Measure the resistance from X-14 pin B to instrument cluster connector X-C23, pin 24. The resistance should be less than 10 Ί. Wiggle the harness during measurement to reveal an intermittent condition. Measure the resistance between X-14 pin B and chassis ground. The resistance should be greater than 20,000 Ί. Wiggle the harness during measurement to reveal an intermittent condition. A. The resistance measurements are within specifications. Temporarily replace the instrument cluster and retest. Go to step 1 to confirm elimination of the fault. B. The resistance readings are not with the limits defined in the step. Repair or replace the harness as required. Return to step 1 to confirm elimination of fault.
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1051 - No CAN Communication With Engine Controller Context: CAN bus communications between the instrument cluster and the ECU may have been interrupted. The instrument cluster did not receive the EEC1 message from the ECU. This fault code may be displayed with other CAN bus fault messages. The instrument cluster will illuminate the stop lamp and will continually sound the audible alarm while this fault is active. Cause: The instrument cluster did not receive a CAN message from the ECU. CAN bus communications between the instrument cluster and the ECU may have been interrupted. This fault code may also occur when a new, blank ECU has been installed on the machine. Program the ECU before troubleshooting. Possible failure modes: 1. A new, blank ECU has been installed on the machine. 2. A failed main relay. 3. Blown ECU fuse 1 or fuse 2. 4. An open circuit in the CAN bus wiring. 5. A short circuit in the CAN bus wiring. 6. A faulty instrument cluster. 7. A faulty ECU. Solution: 1. Verify that the fault code is active. Connect the Electronic Service Tool to the service tool connector. To check for fault codes: Start and operate the machine. A. Fault code 1051 – No CAN Communication With Engine Controller is not recorded again. Go to step 2. B. Fault code 1051 – No CAN Communication With Engine Controller is recorded again. There may be one or two other CAN bus fault codes associated with 1051 – No CAN Communication With Engine Controller. Go to step 2. C. Fault code 1051 – No CAN Communication With Engine Controller is recorded along with other CAN data link faults such as 1053 – Timeout of CAN Message CM1BC - 1059 – Timeout of CAN Message DM1, and/or 3096 – CAN A Bus off failure, 3179 – CAN communication failure between vehicle controller and ECU - BC2ECU2 message and 3180 – CAN communication error between vehicle controller to ECU. Go to step 5. 2. Check the ECU fuses in the fuse panel. Check the ECU fuse 1 and fuse 2. Verify that they are not blown and have 12 V when the ignition switch is ON. A. The fuses are OK. There is 12 V when the ignition switch is ON. Go to step 3. B. The fuses are blown. Replace the fuses and retest. Locate the cause of the blown fuse. Check the main relay for water intrusion. Return to step 1 to confirm elimination of the fault. C. There is no power to the fuses. Check the 2 A ground fuses located along the left side of the engine. The ground fuses are in the Black/Blue fuse holders hanging from the engine harness along the front edge of the hydraulic tank. Repair as required. Return to step 1 to confirm elimination of the fault. 3. Check the main relay. Remove the main relay from the panel. The ECU relay is located in the engine relay panel by the battery box, left-side engine compartment. 48068130 29/01/2018
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Check the main relay for water intrusion. A. There are no signs of water intrusion in the main relay. Go to step 4. B. The main relay shows signs of water intrusion such as corrosion or water inside the relay. Replace the relay and retest. Return to step 1 to confirm elimination of the fault. 4. Verify that the CAN bus circuit is functioning properly. Connect the Electronic Service Tool to the service tool connector. Turn the ignition switch ON. Verify the connections to the ECU, instrument cluster, diagnostic connector, and the optional Telematics unit are tight and secure. Check for CAN bus fault codes while wiggling the harness. Turn the ignition switch OFF. Disconnect the instrument cluster connector X-C23. Measure the resistance between X-C23 pin 6 and X-C23 pin 5 on the instrument cluster. The resistance should be between 108 Ω and 132 Ω. Disconnect ECU connector X-012. Measure the resistance between X-012 pin 24 and X-012 pin 25 on the ECU. The resistance should be between 108 Ω and 132 Ω. A. All connections are secure. Both resistance measurements are within range. OK to return the machine to service. B. The harness is damaged or the connectors are loose or damaged. Repair or replace the harness as required. Return to step 1 to confirm elimination of fault. 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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5. Verify the harness is not damaged. Turn the ignition switch OFF. Verify the connections to the ECU, instrument cluster, diagnostic connector, the UCM, and the optional 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 bus harness is not damaged and all connections are secure. Go to step 6. B. The harness is damaged or the connectors are loose or damaged. Repair or replace the harness or the connectors as required. Return to step 1 to confirm elimination of fault. 6. Measure the resistance through the CAN data link harness. Turn the ignition switch OFF. Measure the resistance between the diagnostic port connector, pins X-DIAG pin C and X-DIAG pin D. The resistance should be approximately 60 Ω. Wiggle the harness during measurement to reveal an intermittent condition. A. The resistance is less than 54 Ω. Go to step 8. B. The resistance is between 54 Ω and 66 Ω. Go to step 7. C. The resistance is greater than 66 Ω. Go to step 9. 7. Measure the harness resistance between chassis ground and positive battery. Turn the ignition switch OFF. Disconnect the instrument cluster connector, X-C23. Disconnect all other devices connected to the CAN bus. Measure the resistance between X-C23 pin 6 and chassis ground. The resistance should be greater than 20,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition. Measure the resistance between X-C23 pin 6 and positive battery (X-C23 pin 9). The resistance should be greater than 20,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition. Measure the resistance between X-C23 pin 5 and chassis ground. The resistance should be greater than 20,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition. Measure the resistance between X-C23 pin 5 and positive battery (X-C23 pin 9). The resistance should be greater than 20,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition. Circuit description Positive battery Minus battery CAN high CAN low
Instrument cluster connection X-C23 pin 9 X-C23 pin 34 X-C23 pin 6 X-C23 pin 5
Alternate diagnostic port connection X-DIAG pin B X-DIAG pin A X-DIAG pin C X-DIAG pin D
A. All resistance measurements are greater than 20,000 Ω. Verify the ECU is powered and operational. Verify that all minus battery and chassis ground connections to the CAN bus modules are clean and secure. Repair as required. 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 CAN bus. Temporarily replace the CAN bus wires and retest. Repair or replace the harness as required. Return to step 1 to confirm elimination of the fault code. 8. Measure the resistance between the CAN high and CAN low wires. Turn the ignition switch OFF.
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Disconnect all modules on the CAN bus. Measure the resistance between CAN high (diagnostic connector pin C) and CAN low (diagnostic connector pin D). A. The resistance is greater than 20,000 Ω. Connect each component to the CAN bus one at a time. The resistance should be greater than 54 Ω. Replace the module that drops the CAN bus resistance below 54 Ω. Return to step 1 to confirm elimination of the fault. B. The resistance is less than 54 Ω there is a short circuit between the CAN high and CAN low wires. Repair or replace the harness as required. Return to test step 1 to confirm elimination of the fault. 9. Measure the resistance through the CAN bus circuit. Turn the ignition switch OFF. Disconnect all components connected to the CAN bus. Fabricate a jumper 20 cm (8 in) that will connect between ECU connector X-012 pin 24 and X-012 pin 25. Connect the jumper between X-012 pin 24 and X-012 pin 25. Measure the resistance between the diagnostic port connector X-DIAG pin C and X-DIAG pin D. The resistance should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition.
RAIL12FRK1168FA
(1)
Digital volt meter set to measure resistance.
(4)
(2)
Diagnostic port X-DIAG
(5)
(3)
The jumper wire is installed between the (6) CAN high pin and the CAN low pin
1
CAN Bus to Instrument Cluster CAN high X-C23 pin 6 CAN low X-C23 pin 5 CAN Bus to ECU CAN high X-012 pin 24 CAN low X-012 pin 25 CAN Bus to UCM CAN high X-CN2B pin 1 CAN low X-CN2B pin 10 CAN Bus to Telematics (optional) CAN high X-TELE pin 3 CAN low X-TELE pin 4
Measure the resistance between Telematics connector pin 3 and pin 4. The resistance should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition.
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Measure the resistance between the UCM connector pin 1 and pin 10. The resistance should be less than 10 立. Wiggle the harness during measurement to reveal an intermittent condition. Measure the resistance between instrument cluster connector pin 6 and pin 5. The resistance should be less than 10 立. Wiggle the harness during measurement to reveal an intermittent condition.
RAIL12FRK1167FA
(1)
Digital volt meter set to measure resistance.
(4)
(2)
Diagnostic port X-001
(5)
(3)
Jumper wire installed between the CAN high and CAN low pins
(6)
2
CAN Bus to Instrument Cluster CAN high X-C23 pin 6 CAN low X-C23 pin 5 CAN Bus to ECU CAN high X-012 pin 24 CAN low X-012 pin 25 CAN Bus to UCM CAN high X-CN2B pin 1 CAN low X-CN2B pin 10 CAN Bus to Telematics (optional) CAN high X-TELE pin 3 CAN low X-TELE pin 4
A. All resistance measurements are less than 10 立. Temporarily replace the instrument cluster and retest. Return to step 1 to confirm elimination of the fault. B. One or more resistance measurements are greater than 20,000 立. There is an open circuit in the CAN bus wires. Repair or replace the harness as required. Go to step 1 to confirm elimination of the fault.
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1053 - Timeout of CAN Message CM1BC Context: CAN bus communications between the instrument cluster and the ECU may have been interrupted. The instrument cluster did not receive the CM1BC message from the ECU. This fault code may be displayed with other CAN bus fault messages. Cause: The instrument cluster did not receive a CAN message from the ECU. CAN bus communications between the instrument cluster and the ECU may have been interrupted. Possible failure modes: 1. An open circuit in the CAN data link wiring. 2. A short circuit in the CAN data link wiring. 3. A faulty device on the CAN data link. 4. A faulty instrument cluster. 5. A faulty ECU. Solution: 1. Use the EST to verify the controller status. Connect the EST to the service tool connector. Turn the ignition switch ON. Verify that the all of the controllers are ONLINE. A. The ECU status is OFFLINE and fault codes 9153 and 1051 are active. Check the 2 A relay ground fuses. Replace the fuses as required. Verify that the fault codes are no longer active. If the fault code is still active, refer to 1051 - No CAN Communication With Engine Controller (55.408) B. The ECU status is ONLINE. Go to step 2. 2. Verify that the fault code is active. Connect the Electronic Service Tool to the service tool connector. To check for fault codes: Start and operate the machine. A. Fault code 1053 – Timeout of CAN Message CM1BC is not recorded again. Go to step 3. B. Fault code 1053 – Timeout of CAN Message CM1BC is recorded again. There are one or two other CAN bus fault codes associated with 1053 – Timeout of CAN Message CM1BC. Go to step 3. C. Fault code 1053 – Timeout of CAN Message CM1BC is recorded along with multiple CAN data link faults such as 1051-1063, and/or 3096, 3179 and 3180. Go to 1051 - No CAN Communication With Engine Controller (55.408) step 3. 3. Verify that the CAN bus circuit is functioning properly. Connect the Electronic Service Tool to the service tool connector. Turn the ignition switch ON. Verify the connections to the ECU, the instrument cluster, the diagnostic connector, the UCM (if installed), and the optional Telematics unit are tight and secure. Check for CAN bus fault codes while wiggling the harness. Turn the ignition switch OFF.
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Disconnect the instrument cluster connector X-C23. Measure the resistance between X-C23 pin 5 and X-C23 pin 6 on the instrument cluster. The resistance should be between 108 Ω and 132 Ω. Disconnect the ECU connector X-012. Measure the resistance between X-012 pin 24 and X-012 pin 25 on the ECU. The resistance should be between 108 Ω and 132 Ω. A. All connections are secure. Both resistance measurements are within the specified range. OK to return the machine to service. B. The harness is damaged or the connectors are loose or damaged. Repair or replace the harness or the connectors as required. Return to step 2 to confirm elimination of the fault. C. One or both resistance measurements are less than 108 Ω or greater than 132 Ω. Replace the control module that has the bad resistance value. Return to step 2 to confirm elimination of fault.
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1054 - Timeout of CAN Message ET1 Context: CAN bus communications between the instrument cluster and the ECU may have been interrupted. The instrument cluster did not receive the ET1 message from the ECU. This fault code may be displayed with other CAN bus fault messages. Cause: The instrument cluster did not receive a CAN message from the ECU. CAN bus communications between the instrument cluster and the ECU may have been interrupted. Possible failure modes: 1. An open circuit in the CAN data link wiring. 2. A short circuit in the CAN data link wiring. 3. A faulty device on the CAN data link. 4. A faulty instrument cluster. 5. A faulty ECU. Solution: 1. Use the EST to verify the controller status. Connect the EST to the service tool connector. Turn the ignition switch ON. Verify that the all of the controllers are ONLINE. A. The ECU status is OFFLINE and fault codes 9153 and 1051 are active. Check the 2 A relay ground fuses. Replace the fuses as required. Verify that the fault codes are no longer active. If the fault code is still active, refer to 1051 - No CAN Communication With Engine Controller (55.408) B. The ECU status is ONLINE. Go to step 2. 2. Verify that the fault code is active. Connect the Electronic Service Tool to the service tool connector. To check for fault codes: Start and operate the machine. A. Fault code 1054 – Timeout of CAN Message ET1 is not recorded again. Go to step 3. B. Fault code 1054 – Timeout of CAN Message ET1 is recorded again. There are one or two other CAN bus fault codes associated with 1054 – Timeout of CAN Message ET1. Go to step 3. C. Fault code 1054 – Timeout of CAN Message ET1 is recorded along with multiple CAN data link faults such as 1051-1063, and/or 3096, 3179 and 3180. Go to 1051 - No CAN Communication With Engine Controller (55.408) step 3. 3. Verify that the CAN bus circuit is functioning properly. Connect the Electronic Service Tool to the service tool connector. Turn the ignition switch ON. Verify the connections to the ECU, the instrument cluster, the diagnostic connector, the UCM (if installed), and the optional Telematics unit are tight and secure. Check for CAN bus fault codes while wiggling the harness. Turn the ignition switch OFF.
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Disconnect the instrument cluster connector X-C23. Measure the resistance between X-C23 pin 5 and X-C23 pin 6 on the instrument cluster. The resistance should be between 108 Ω and 132 Ω. Disconnect the ECU connector X-012. Measure the resistance between X-012 pin 24 and X-012 pin 25 on the ECU. The resistance should be between 108 Ω and 132 Ω. A. All connections are secure. Both resistance measurements are within the specified range. OK to return the machine to service. B. The harness is damaged or the connectors are loose or damaged. Repair or replace the harness or the connectors as required. Return to step 2 to confirm elimination of the fault. C. One or both resistance measurements are less than 108 Ω or greater than 132 Ω. Replace the control module that has the bad resistance value. Return to step 2 to confirm elimination of fault.
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1056 - Timeout of CAN Message DPFC1 Context: CAN bus communications between the instrument cluster and the ECU may have been interrupted. The instrument cluster did not receive the DPFC1 message from the ECU. This fault code may be displayed with other CAN bus fault messages. Cause: The instrument cluster did not receive a CAN message from the ECU. CAN bus communications between the instrument cluster and the ECU may have been interrupted. Possible failure modes: 1. An open circuit in the CAN data link wiring. 2. A short circuit in the CAN data link wiring. 3. A faulty device on the CAN data link. 4. A faulty instrument cluster. 5. A faulty ECU. Solution: 1. Use the EST to verify the controller status. Connect the EST to the service tool connector. Turn the ignition switch ON. Verify that the all of the controllers are ONLINE. A. The ECU status is OFFLINE and fault codes 9153 and 1051 are active. Check the 2 A relay ground fuses. Replace the fuses as required. Verify that the fault codes are no longer active. If the fault code is still active, refer to 1051 - No CAN Communication With Engine Controller (55.408) B. The ECU status is ONLINE. Go to step 2. 2. Verify that the fault code is active. Connect the Electronic Service Tool to the service tool connector. To check for fault codes: Start and operate the machine. A. Fault code 1056 – Timeout of CAN Message DPFC1 is not recorded again. Go to step 3. B. Fault code 1056 – Timeout of CAN Message DPFC1 is recorded again. There are one or two other CAN bus fault codes associated with 1056 – Timeout of CAN Message DPFC1. Go to step 3. C. Fault code 1056 – Timeout of CAN Message DPFC1 is recorded along with multiple CAN data link faults such as 1051-1063, and/or 3096, 3179 and 3180. Go to 1051 - No CAN Communication With Engine Controller (55.408) step 3. 3. Verify that the CAN bus circuit is functioning properly. Connect the Electronic Service Tool to the service tool connector. Turn the ignition switch ON. Verify the connections to the ECU, the instrument cluster, the diagnostic connector, the UCM (if installed), and the optional Telematics unit are tight and secure. Check for CAN bus fault codes while wiggling the harness. Turn the ignition switch OFF.
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Disconnect the instrument cluster connector X-C23. Measure the resistance between X-C23 pin 5 and X-C23 pin 6 on the instrument cluster. The resistance should be between 108 Ω and 132 Ω. Disconnect the ECU connector X-012. Measure the resistance between X-012 pin 24 and X-012 pin 25 on the ECU. The resistance should be between 108 Ω and 132 Ω. A. All connections are secure. Both resistance measurements are within the specified range. OK to return the machine to service. B. The harness is damaged or the connectors are loose or damaged. Repair or replace the harness or the connectors as required. Return to step 2 to confirm elimination of the fault. C. One or both resistance measurements are less than 108 Ω or greater than 132 Ω. Replace the control module that has the bad resistance value. Return to step 2 to confirm elimination of fault.
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1058 - Timeout of CAN Message EDC2BC Context: CAN bus communications between the instrument cluster and the ECU may have been interrupted. The instrument cluster did not receive the EDC2BC message from the ECU. This fault code may be displayed with other CAN bus fault messages. Cause: The instrument cluster did not receive a CAN message from the ECU. CAN bus communications between the instrument cluster and the ECU may have been interrupted. Possible failure modes: 1. An open circuit in the CAN data link wiring. 2. A short circuit in the CAN data link wiring. 3. A faulty device on the CAN data link. 4. A faulty instrument cluster. 5. A faulty ECU. Solution: 1. Use the EST to verify the controller status. Connect the EST to the service tool connector. Turn the ignition switch ON. Verify that the all of the controllers are ONLINE. A. The ECU status is OFFLINE and fault codes 9153 and 1051 are active. Check the 2 A relay ground fuses. Replace the fuses as required. Verify that the fault codes are no longer active. If the fault code is still active, refer to 1051 - No CAN Communication With Engine Controller (55.408) B. The ECU status is ONLINE. Go to step 2. 2. Verify that the fault code is active. Connect the Electronic Service Tool to the service tool connector. To check for fault codes: Start and operate the machine. A. Fault code 1058 – Timeout of CAN Message EDC2BC is not recorded again. Go to step 3. B. Fault code 1058 – Timeout of CAN Message EDC2BC is recorded again. There are one or two other CAN bus fault codes associated with 1058 – Timeout of CAN Message EDC2BC. Go to step 3. C. Fault code 1058 – Timeout of CAN Message EDC2BC is recorded along with multiple CAN data link faults such as 1051-1063, and/or 3096, 3179 and 3180. Go to 1051 - No CAN Communication With Engine Controller (55.408) step 3. 3. Verify that the CAN bus circuit is functioning properly. Connect the Electronic Service Tool to the service tool connector. Turn the ignition switch ON. Verify the connections to the ECU, the instrument cluster, the diagnostic connector, the UCM (if installed), and the optional Telematics unit are tight and secure. Check for CAN bus fault codes while wiggling the harness. Turn the ignition switch OFF.
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Disconnect the instrument cluster connector X-C23. Measure the resistance between X-C23 pin 5 and X-C23 pin 6 on the instrument cluster. The resistance should be between 108 Ω and 132 Ω. Disconnect the ECU connector X-012. Measure the resistance between X-012 pin 24 and X-012 pin 25 on the ECU. The resistance should be between 108 Ω and 132 Ω. A. All connections are secure. Both resistance measurements are within the specified range. OK to return the machine to service. B. The harness is damaged or the connectors are loose or damaged. Repair or replace the harness or the connectors as required. Return to step 2 to confirm elimination of the fault. C. One or both resistance measurements are less than 108 Ω or greater than 132 Ω. Replace the control module that has the bad resistance value. Return to step 2 to confirm elimination of fault.
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1059 - Timeout of CAN Message DM1 Context: CAN bus communications between the instrument cluster and the ECU may have been interrupted. The instrument cluster did not receive the DM1 message from the ECU. This fault code may be displayed with other CAN bus fault messages. Cause: The instrument cluster did not receive a CAN message from the ECU. CAN bus communications between the instrument cluster and the ECU may have been interrupted. Possible failure modes: 1. An open circuit in the CAN data link wiring. 2. A short circuit in the CAN data link wiring. 3. A faulty device on the CAN data link. 4. A faulty instrument cluster. 5. A faulty ECU. Solution: 1. Use the EST to verify the controller status. Connect the EST to the service tool connector. Turn the ignition switch ON. Verify that the all of the controllers are ONLINE. A. The ECU status is OFFLINE and fault codes 9153 and 1051 are active. Check the 2 A relay ground fuses. Replace the fuses as required. Verify that the fault codes are no longer active. If the fault code is still active, refer to 1051 - No CAN Communication With Engine Controller (55.408) B. The ECU status is ONLINE. Go to step 2. 2. Verify that the fault code is active. Connect the Electronic Service Tool to the service tool connector. To check for fault codes: Start and operate the machine. A. Fault code 1059 – Timeout of CAN Message DM1 is not recorded again. Go to step 3. B. Fault code 1059 – Timeout of CAN Message DM1 is recorded again. There are one or two other CAN bus fault codes associated with 1059 – Timeout of CAN Message DM1. Go to step 3. C. Fault code 1059 – Timeout of CAN Message DM1 is recorded along with multiple CAN data link faults such as 1051-1063, and/or 3096, 3179 and 3180. Go to 1051 - No CAN Communication With Engine Controller (55.408) step 3. 3. Verify that the CAN bus circuit is functioning properly. Connect the Electronic Service Tool to the service tool connector. Turn the ignition switch ON. Verify the connections to the ECU, the instrument cluster, the diagnostic connector, the UCM (if installed), and the optional Telematics unit are tight and secure. Check for CAN bus fault codes while wiggling the harness. Turn the ignition switch OFF.
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Disconnect the instrument cluster connector X-C23. Measure the resistance between X-C23 pin 5 and X-C23 pin 6 on the instrument cluster. The resistance should be between 108 Ω and 132 Ω. Disconnect the ECU connector X-012. Measure the resistance between X-012 pin 24 and X-012 pin 25 on the ECU. The resistance should be between 108 Ω and 132 Ω. A. All connections are secure. Both resistance measurements are within the specified range. OK to return the machine to service. B. The harness is damaged or the connectors are loose or damaged. Repair or replace the harness or the connectors as required. Return to step 2 to confirm elimination of the fault. C. One or both resistance measurements are less than 108 Ω or greater than 132 Ω. Replace the control module that has the bad resistance value. Return to step 2 to confirm elimination of fault.
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1064 - Hydraulic Oil Temperature Is Above Normal Context: The instrument cluster monitored a hydraulic oil temperature that is greater than 102 °C (216 °F) but less than or equal to 110 °C (230 °F) for a period greater than 3 s. Cause: The hydraulic oil temperature is above 102 °C (216 °F) but less than or equal to 110 °C (230 °F) for a period greater than 3 s. Possible failure modes: 1. Low hydraulic oil level. 2. Faulty fan operation. 3. Clogged cooling core. 4. Faulty reading from sensor. 5. 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. OK to return the machine to service. B. Fault code 1064 is recorded again. Go to step 2. 2. Verify hydraulic oil level. Check the hydraulic oil level, add oil as required. Refer to the Operator's Manual for more details. A. The oil level is correct and the fault is not recorded again. Return the machine to service. B. The oil level is correct, but the fault is recorded again. Go to step 3. 3. Check fan operations. Operate the engine at 1500 RPM. Check the fan operation. Check the cooling core for clogs. A. The cooling system is operating properly. Go to step 4. B. The cooling system is not operating properly or the cooling core is clogged. Repair the fan or clear the clogs from the cooling core. Repair as required. Return to step 1 to confirm elimination of fault. 4. Check the temperature sender. Disconnect the terminal connector from the hydraulic oil temperature sender. Measure the resistance between the hydraulic oil temperature sender ground connection and chassis ground. The resistance should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition. Measure the resistance across the temperature sender terminals. Temperature 110 °C (230 °F)
Hydraulic Oil Temperature Sensor Open Circuit Resistance Measurements Resistance in ohms (± 10%) 130 Ω 48068130 29/01/2018
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Hydraulic Oil Temperature Sensor Open Circuit Resistance Measurements 105 °C (221 °F) 151 Ω 100 °C (212 °F) 175 Ω 95 °C (203 °F) 202 Ω 92 °C (198 °F) 223 Ω 88 °C (190 °F) 258 Ω 85 °C (185 °F) 280 Ω 81 °C (178 °F) 323 Ω 78 °C (172 °F) 358 Ω 74 °C (165 °F) 412 Ω 68 °C (154 °F) 511 Ω 16 °C (61 °F) 4250 Ω A. The resistance measurements compare to the values in the table. Go to step 5. B. The resistance measurements are not acceptable. The measured resistance is less than 100 Ω and greater than 5,000 Ω. Replace the hydraulic oil temperature sender. Return to step 1 to confirm elimination of fault. 5. Check the wiring to the instrument cluster. Disconnect the instrument cluster connector X-C23. Disconnect the hydraulic oil temperature sensor. Measure the resistance between the hydraulic oil temperature sender connector pin 1 (signal wire) 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. Return to step 1 to confirm elimination of the fault. B. The resistance is less than 20,000 Ω. There is a short circuit to chassis ground in the wire. Repair or replace the wire as required. Return to step 1 to confirm elimination of fault.
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1201 - Hydraulic oil filter switch open circuit Context: The instrument cluster has sensed that there is an open circuit in the hydraulic filter restriction circuit. Diagnostic trouble code 1201 has an error priority of white. There are no restrictions while Diagnostic Trouble Code 1201 is active. Cause: The instrument cluster has sensed that there is an open circuit in the hydraulic filter restriction circuit. The fault is active when the ignition switch is ON and the start input is low and there is an open circuit in the hydraulic filter circuit. Possible failure modes: 1. An open circuit in the wiring. 2. A failure of the hydraulic filter restriction switch. 3. A failure in the 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 machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 1201 is recorded again. Go to step 2. 2. Check the hydraulic oil filter. Verify that the hydraulic oil filter is clean. Replace the oil filter as required. A. The oil filter is dirty. Replace the oil filter and retest. Return the step 1 to confirm elimination of fault. B. The filter is not dirty and does not need to be replaced. Go to step 3. 3. Verify that the wiring and connectors are free of damage. Inspect the instrument cluster and the hydraulic oil filter switch connections. All connections should be secure, tight, free of corrosion, abrasion and damage. Inspect the harness from the instrument cluster to the hydraulic oil filter 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 4. 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. Test the UCM. Turn the ignition switch OFF. Disconnect the hydraulic oil filter switch connector. Fabricate a jumper wire that will connect between connector X-OILFTL pin 1 and chassis ground. Connect the jumper wire between connector X-OILFTL pin 1 and chassis ground. Turn the ignition switch on and access the fault code screen. Fault code 1201 should no longer be active. A. Fault code 1201 is not active. Replace the hydraulic filter restriction switch and retest. Return to step 1 to confirm elimination of fault. 48068130 29/01/2018
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B. Fault code 1201 is still active. Go to step 5. 5. Measure the resistance through the signal wire. Turn the ignition switch OFF. Leave the hydraulic oil filter switch disconnected. Leave the jumper wire connected to connector X-OILFLT. Disconnect instrument cluster connector X-C23. Measure the resistance between instrument cluster connector X-C23 pin 2 and chassis ground. The resistance should be less than 10 Ω. A. The resistance is less than 10 Ω. Temporarily replace the instrument cluster and retest. Return to step 1 to confirm elimination of the fault. B. The resistance is greater than 10 Ω. There is an open circuit in the wiring. Replace the wiring harness as required. Return to step 1 to confirm elimination of fault.
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1205 - Hydraulic Enable (EH Machines) - Hydraulic Enable Output, Short to Power Context: Fault code 1205 has an error priority of Amber. There are no restrictions with Fault code 1205. Cause: The Instrument Cluster has determined that the Hydraulic Enable output from the Instrument Cluster does not match the request from the Instrument Cluster. (The fault is only activated when Ignition is on and Hydraulic Enable Commanded State is Low and Hydraulic Enable Solenoid is energized.) Possible failure modes: 1. Shorted or open wire in circuit. 2. Failure of UCM. 3. Instrument Cluster has internal failure. Solution: 1. Use the machine to recreate conditions for error. Use the EST to verify 1205 â&#x20AC;&#x201C; Hydraulic Enable (EH Machines) - Hydraulic Enable Output, Short to Power is active. A. If the fault is active, continue with step 2. B. If the fault is not active, the fault may be intermittent and not currently active, continue with step 9. 2. Check for short to high. Disconnect connector X-CN3A from the UCM. Disconnect connector X-C23 from the INSTRUMENT CLUSTER. Using a multi-meter, check for voltage between connector X-CN3A pin 23, or connector X-C23 pin 30 and ground. A. If there is no voltage, continue with step 4. B. If there is voltage, there is a short to high source on wire 303 (White) between connector X-CN3A pin 23 and connector X-C23 pin 30. Continue with step 3. 3. Locate the short to high. Disconnect connector X-ECC2A from connector X-ECC2B. Using a multi-meter, check for voltage between connector X-CN3A pin 23, or connector X-ECC2B pin 5 and ground. A. If there is no voltage, there is a short to high source on wire 303 (White) between connector X-ECC2A pin 5 and connector X-C23 pin 30. Repair or replace the wire. B. If there is voltage, there is a short to high source on wire 303 (White) between connector X-CN3A pin 23 and connector X-ECC2B pin 5. Repair or replace the wire. 4. Check for open circuit. Disconnect connector X-CN3A from the UCM. Disconnect connector X-C23 from the UCM. Using a multi-meter, check continuity between connector X-CN3A pin 23 and connector X-C23 pin 30. A. If there is continuity, continue with step 7. B. If there is no continuity, there is an open wire condition on wire 303 (White) between connector X-CN3A pin 23 and connector X-C23 pin 30. Continue with step 5. 5. Locate the open circuit. Disconnect connector X-ECC2A from connector X-ECC2B. Using a multi-meter, check continuity between connector X-ECC2A pin 5 and connector X-C23 pin 30. A. If there is no continuity, there is an open wire condition on wire 303 (White) between connector X-ECC2A pin 5 and connector X-C23 pin 30. Repair or replace the wire. B. If there is continuity, continue with step 6 6. Locate the open circuit. Using a multi-meter, check continuity between connector X-ECC2B pin 5 and connector X-CN3A pin 23.
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A. If there is no continuity, there is an open wire condition on wire 303 (White) between connector X-ECC2B pin 5 and connector X-CN3A pin 23. Repair or replace the wire. B. If there is continuity, connectors X-ECC2A and X-ECC2B are not making a good connection at pin 5. Repair the connector. 7. Check for a short to ground. Disconnect connector X-CN3A from the UCM. Disconnect connector X-C23 from the INSTRUMENT CLUSTER. Using a multi-meter, check for continuity between connector X-CN3A pin 23, or connector X-C23 pin 30 and ground. A. If there is no continuity, continue with step 9. B. If there is continuity, there is a short to ground condition on wire 303 (White) between connector X-CN3A pin 23 and connector X-C23 pin 30. Continue with step 8. 8. Locate the short to ground. Disconnect connector X-ECC2A from connector X-ECC2B. Using a multi-meter, check for continuity between connector X-ECC2A pin 5, or connector X-C23 pin 30 and ground. A. If there is no continuity, there is a short to ground on wire 303 (White) between connector X-CN3A pin 23 and X-ECC2B pin 5. Repair or replace the shorted wire. B. If there is continuity, there is a short to ground condition on wire 303 (White) between connector X-ECC2A pin 5 and connector X-C23 pin 30. Repair or replace the shorted wire. 9. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while monitoring the EST and Display. Investigate nearby wiring. A. If damage is found or other than normal display readings are indicated, repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If no damage or other than normal display readings are indicated, erase the Diagnostic Trouble Code and continue operation.
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1206 - CAN Connection: Configuration Response Timeout SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Context: CAN bus communications between the instrument cluster and the ECU may have been interrupted. The instrument cluster did not receive the EEC3 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 instrument cluster and the ECU may have been interrupted. Possible failure modes: 1. An open circuit in the CAN bus wiring. 2. A short circuit in the CAN bus wiring. 3. A faulty instrument cluster. 4. A faulty ECU. Solution: 1. Verify that the fault code is active. Connect the Electronic Service Tool to the service tool connector. To check for fault codes: Start and operate the machine. A. Fault code 1206 – CAN Connection: Configuration Response Timeout is not recorded again. Go to step 2. B. Fault code 1206 – CAN Connection: Configuration Response Timeout is recorded again. There are one or two other CAN bus fault codes associated with 1206 – CAN Connection: Configuration Response Timeout. Go to step 2. C. Fault code 1206 – CAN Connection: Configuration Response Timeout is recorded along with other CAN data link faults such as 1051-1059, and/or 3096, 3179 and 3180. Go to 1051 - No CAN Communication With Engine Controller (55.640) step 3. 2. Verify that the CAN bus circuit is functioning properly. Connect the Electronic Service Tool to the service tool connector. Turn the ignition switch ON. Verify the connections to the ECU, the instrument cluster, the UCM, the diagnostic connector, and the optional Telematics unit are tight and secure. Check for CAN bus fault codes while wiggling the harness. Turn the ignition switch OFF. Disconnect the instrument cluster connector X-C23 (Receptacle) . Measure the resistance between X-C23 (Receptacle) pin 6 and X-C23 (Receptacle) pin 5 on the instrument cluster. The resistance should be between 108 Ω and 132 Ω.
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Disconnect the ECU connector X-012 (Receptacle) . Measure the resistance between X-012 (Receptacle) pin 24 and X-012 (Receptacle) pin 25 on the ECU. The resistance should be between 108 立 and 132 立. A. All connections are secure. Both resistance measurements are within the specified range. OK to return the machine to service. B. The harness is damaged or the connectors are loose or damaged. Repair or replace the harness or the connectors as required. Return to step 1 to confirm elimination of the fault. C. One or both resistance measurements are less than 108 立 or greater than 132 立. Replace the control module that has the bad resistance value. Return to step 1 to confirm elimination of fault.
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1207 - Memory Parameters - Invalid Configuration Between IC and UCM SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Context: On EH controled machines, error code 9403 – Memory Error - Double Redundant Memory - Unrecoverable Memory Corruption Operable and/or 1207 – Memory Parameters - Invalid Configuration Between IC and UCM displays after updating the earlier instrument cluster software to version 1.3.0.0 Diagnostic Trouble Code 1207 – Memory Parameters - Invalid Configuration Between IC and UCM has an error priority of Amber. There are no restrictions with Diagnostic Trouble Code 1207 – Memory Parameters - Invalid Configuration Between IC and UCM. Cause: The Instrument Cluster expects the Enhanced High Flow (EHF) option is on the machine and displays the error codes when the machine model configuration does not match the expectation of the Instrument Cluster. Solution: 1. Use EST to reset the machine model configurations and clear the fault code(s). (1) Connect the EST to the machine diagnostics connector per the Cable and Adapter Help icon. (2) Sit in the seat to power the controllers. (3) Click on the Controller Status icon. Verify that the Instrument Cluster (IC) and the Vehicle Control Module (VCM) are both online. (4) Click on the configuration icon. (5) Double click on the Machine Configurations selection. (6) Click on Set up Controller for Configuring. . (7) Change the drop down box selections to match the machine. a) In Panel identifier, Select Electro-hydraulic. b) Select Door Status. c) Select Model d) Select Region e) If the machine is EHF, Select available and if the machine is not EHF, select not available. (8) Click on Send Modified Values to Controller. (9) Wait 5 seconds and then Power Cycle the machine by exiting the seat. (10) Verify error code 9403 – Memory Error - Double Redundant Memory - Unrecoverable Memory Corruption Operable and/or 1207 – Memory Parameters - Invalid Configuration Between IC and UCM is no longer displayed. A. Error code 9403 – Memory Error - Double Redundant Memory - Unrecoverable Memory Corruption Operable and/or 1207 – Memory Parameters - Invalid Configuration Between IC and UCM is no longer displayed. OK to return the machine to service.
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B. Error code 9403 – Memory Error - Double Redundant Memory - Unrecoverable Memory Corruption Operable and/or 1207 – Memory Parameters - Invalid Configuration Between IC and UCM are active, For non-EHF machines continue with step 2 C. Error code 9403 – Memory Error - Double Redundant Memory - Unrecoverable Memory Corruption Operable and/or 1207 – Memory Parameters - Invalid Configuration Between IC and UCM are active, For EHF machines continue with step 3 2. Configure the machine to a model that offers EHF as an option and reconfigure to the original model. Example: The SR150 or L215 are models that do not offer the EHF option and is displaying fault code 9403 – Memory Error - Double Redundant Memory - Unrecoverable Memory Corruption Operable after configuring correctly and performing the power cycle. (1) Change the drop down box selections to match the machine. a) In Panel identifier, Select Electro-hydraulic. b) Select Door Status. c) Select a known EHF model such as SV300 or L230. d) Select Region e) Select available. (2) Click on Send Modified Values to Controller. (3) Wait 5 seconds and then Power Cycle the machine by exiting the seat. (4) Verify error code 9403 – Memory Error - Double Redundant Memory - Unrecoverable Memory Corruption Operable and/or 1207 – Memory Parameters - Invalid Configuration Between IC and UCM is no longer displayed. (5) Configure the machine to the correct settings of SR150 or L215 and EHF Not Available. 3. Ensure Enhanced High Flow is available and select a different model that offers EHF option. Example: SV300 and L230 are models that offer EHF option and display 9403 – Memory Error - Double Redundant Memory - Unrecoverable Memory Corruption Operable after configuring correctly. (1) Change the drop down box selections to match the machine. a) In Panel identifier, Select Electro-hydraulic. b) Select Door Status. c) Select a different known model that is not the same model as the actual machine. d) Select Region e) If the machine is EHF, Select available and if the machine is not EHF, select not available. (2) Click on Send Modified Values to Controller. (3) Wait 5 seconds and then Power Cycle the machine by exiting the seat. (4) Verify error code 9403 – Memory Error - Double Redundant Memory - Unrecoverable Memory Corruption Operable and/or 1207 – Memory Parameters - Invalid Configuration Between IC and UCM is no longer displayed. (5) When fault code 9403 – Memory Error - Double Redundant Memory - Unrecoverable Memory Corruption Operable and/or 1207 – Memory Parameters - Invalid Configuration Between IC and UCM are no longer displayed, follow steps 1 - 4 again to reconfigure the machine back to the correct model.
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Electrical systems - FAULT CODES
1208 - Seat Switch Plausibility Fault Context: The instrument cluster and the UCM do not agree on the presence of an operator. Diagnostic Trouble Code 1208 – Seat Switch Plausibility Fault has an error priority of Amber. There are no restrictions while Diagnostic Trouble Code 1208 – Seat Switch Plausibility Fault is active. Cause: The instrument cluster X-C23 pin 12 and UCM connector X-CN3B pin 30 do not agree on the presence of an operator. Possible failure modes: 1. Faulty wiring. 2. Failure of the instrument cluster. 3. Failure of the UCM. 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 machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 1208 – Seat Switch Plausibility Fault is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the UCM, the instrument cluster, and the seat switch connections. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the UCM and the instrument cluster to the seat 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 the connectors as required. Return to step 1 to confirm elimination of fault. 3. Use EST to test the circuit. Turn the ignition switch ON. Sit in the operator’s seat. Use the EST to access the status of the seat switch. The switch status should be ON. EST seat switch parameters Reference
Data Description Seat switch status
Source UCM
A. The UCM seat switch status is OFF. Go to step 4. B. The UCM seat switch status is ON. Go to step 5. 4. Test the UCM input. Turn the ignition switch OFF. Fabricate a jumper wire that will connect between the positive battery terminal and UCM connector X-CN3B pin 30.
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Connect the jumper wire between the positive battery terminal and UCM connector X-CN3B pin 30. Turn the ignition switch ON. Sit in the operator’s seat. Use the EST to access the status of the seat switch. The switch status should be ON. A. The UCM seat switch status is OFF. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. B. The UCM seat switch status is ON. There is a problem in the wiring between the seat switch and UCM connector X-CN3B. Check splice SP-101. Repair or replace the harness as required. Return to step 1 to confirm elimination of the fault. 5. Test the instrument cluster input. Turn the ignition switch OFF. Fabricate a jumper wire that can connect between the positive battery terminal and instrument cluster connector X-C23 pin 12. Connect the jumper wire between the positive battery terminal and instrument cluster connector X-C23 pin 12. Turn the ignition switch ON. Sit in the operator’s seat. Use the EST to access the active fault codes. Fault code 1208 – Seat Switch Plausibility Fault should no longer be active. A. Fault code 1208 – Seat Switch Plausibility Fault is no longer active. There is a problem in the wiring between the seat switch and instrument cluster connector X-C23. Check splice SP-086. Return to step 1 to confirm elimination of the fault. B. Fault code 1208 – Seat Switch Plausibility Fault is still active. Temporarily replace the instrument cluster and retest. Return to step 1 to confirm elimination of the fault.
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Electrical systems - FAULT CODES
1211 - Calibration Functions - Joystick Calibration Not Complete SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Context: Diagnostic Trouble Code 1211 – Calibration Functions - Joystick Calibration Not Complete has an error priority of Amber. There are no restrictions with Diagnostic Trouble Code 1211 – Calibration Functions - Joystick Calibration Not Complete. Cause: UCM has sensed that the Joystick Calibration is not complete. Possible failure modes: 1. The joystick calibration is not complete. 2. A faulty UCM. Solution: 1. Use the machine to recreate conditions for error. Use the EST to verify fault code 1211 – Calibration Functions - Joystick Calibration Not Complete is active. A. If the fault is active, continue with step 2. B. If the fault is not active, the fault may be intermittent and not currently active, continue with step 3. 2. Use the EST to perform calibration on the Joystick. Electrical system - H1 - Calibration procedures - Joystick - Video (55.000) A. If the fault code clears, continue normal operation. B. If the fault code does not clear, replace the joystick and perform the joystick calibration. If the code persists, replace the UCM. 3. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while monitoring the EST and the display. Investigate nearby wiring. This Diagnostic Trouble Code resolution procedure does not completely rule out the UCM as a failure point. Therefore, all other possibilities should be investigated before the UCM is considered for replacement. A. If damage is found or other than normal display readings are indicated, repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If no damage or other than normal display readings are indicated, erase the Diagnostic Trouble Code and continue operation.
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Electrical systems - FAULT CODES
1212 - Calibration Functions - Ground Drive Calibration Not Complete SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Context: Diagnostic Trouble Code 1212 – Calibration Functions - Ground Drive Calibration Not Complete has an error priority of Amber. There are no restrictions with Diagnostic Trouble Code 1212 – Calibration Functions - Ground Drive Calibration Not Complete. Cause: UCM has sensed that the Ground Drive Calibration is not complete. Possible failure modes: 1. The ground drive calibration not complete. 2. A faulty UCM. Solution: 1. Use the machine to recreate conditions for error. Use the EST to verify fault code 1212 – Calibration Functions - Ground Drive Calibration Not Complete is active. A. If the fault is active, continue with step 2. B. If the fault is not active, the fault may be intermittent and not currently active, continue with step 3. 2. Use the EST to perform calibration on the Ground Drive. Electrical system Electronic Service Tool (EST) - H1 - Calibration procedures - Ground Drive - Video (55.000) A. If the fault code clears, continue normal operation. B. If the fault code does not clear, and calibration will not complete, submit an Asist concern for the machine model and a brief explanation of the error message that was received and record the step the calibration failed on. 3. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while monitoring the EST and the display. Investigate nearby wiring. This Diagnostic Trouble Code resolution procedure does not completely rule out the UCM as a failure point. Therefore, all other possibilities should be investigated before the UCM is considered for replacement. A. If damage is found or other than normal display readings are indicated, repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If no damage or other than normal display readings are indicated, erase the Diagnostic Trouble Code and continue operation.
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Electrical systems - FAULT CODES
1213 - Calibration Functions - Loader Valve Calibration Not Complete SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Context: Diagnostic Trouble Code 1213 – Calibration Functions - Loader Valve Calibration Not Complete has an error priority of Amber. There are no restrictions with Diagnostic Trouble Code 1213 – Calibration Functions - Loader Valve Calibration Not Complete. Cause: UCM has sensed that the Loader Valve Calibration is not complete. Possible failure modes: 1. The loader valve calibration is not complete. 2. A faulty UCM. Solution: 1. Use the machine to recreate conditions for error. Use the EST to verify fault code 1213 – Calibration Functions - Loader Valve Calibration Not Complete is active. A. If the fault is active, continue with step 2. B. If the fault is not active, the fault may be intermittent and not currently active, continue with step 3. 2. Use the EST to perform calibration on the loader valve. A. If the fault code clears, continue normal operation. B. If the fault code does not clear, replace the loader valve and perform the loader valve calibration. If the code persists, submit an Asist concern for the machine model and a brief explanation of the error message that was received and record the step the calibration failed on. 3. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while monitoring the EST and the display. Investigate nearby wiring. This Diagnostic Trouble Code resolution procedure does not completely rule out the UCM as a failure point. Therefore, all other possibilities should be investigated before the UCM is considered for replacement. A. If damage is found or other than normal display readings are indicated, repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If no damage or other than normal display readings are indicated, erase the Diagnostic Trouble Code and continue operation.
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Electrical systems - FAULT CODES
1215 - Saturation Function not complete - Forward Pumps SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Context: 1215 â&#x20AC;&#x201C; Saturation Function not complete - Forward Pumps is triggered each time a ground drive calibration is performed with the service tool. This fault code is a reminder to complete the full-stroke calibration procedure. Solution: 1. Use the EST to perform calibration on the Ground Drive. Electrical system Electronic Service Tool (EST) - H1 - Calibration procedures - Ground Drive - Video (55.000) A. If the fault code clears, continue normal operation. B. If the fault code does not clear, and calibration will not complete, submit an Asist concern for the machine model and a brief explanation of the error message that was received and record the step the calibration failed on.
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Electrical systems - FAULT CODES
1216 - Saturation Function not complete - Reverse Pumps SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Context: 1216 â&#x20AC;&#x201C; Saturation Function not complete - Reverse Pumps is triggered each time a ground drive calibration is performed with the service tool. This fault code is a reminder to complete the full-stroke calibration procedure. Solution: 1. Use the EST to perform calibration on the Ground Drive. Electrical system Electronic Service Tool (EST) - H1 - Calibration procedures - Ground Drive - Video (55.000) A. If the fault code clears, continue normal operation. B. If the fault code does not clear, and calibration will not complete, submit an Asist concern for the machine model and a brief explanation of the error message that was received and record the step the calibration failed on.
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Electrical systems - FAULT CODES
1221 - VCM Temperature / Current Draw Over Limit SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Context: Diagnostic Trouble Code 1221 – VCM Temperature / Current Draw Over Limit has an error priority of Amber. Limp Home Hydraulics are enabled while Diagnostic Trouble Code 1221 – VCM Temperature / Current Draw Over Limit is active. Cause: The UCM has sensed a high current or a high temperature within the UCM. Possible failure modes: 1. A failure of the UCM. Solution: 1. Turn off the machine. Restart the machine and recreate conditions for error. Use the EST to verify fault code 1221 – VCM Temperature / Current Draw Over Limit is active. A. If the fault is active, the UMC has failed. Replace the UCM. B. If the fault is not active, the fault may be intermittent and not currently active, continue with step 2. 2. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while monitoring the EST and the display. Investigate the nearby wiring. This Diagnostic Trouble Code resolution procedure does not completely rule out the UCM as a failure point. Therefore, all other possibilities should be investigated before the UCM is considered for replacement. A. If damage is found or other than normal display readings are indicated, repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If no damage or other than normal display readings are indicated, erase the Diagnostic Trouble Code and continue operation.
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Electrical systems - FAULT CODES
1222 - VCM Sustained Over Temperature Limit SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Context: Diagnostic Trouble Code 1222 â&#x20AC;&#x201C; Health Monitor Functions - UCM - UCM Sustained Over Temperature Limit has an error priority of Red. The hydraulics are disabled while this fault code is active. Cause: The UCM has sensed a high temperature within the UCM. Possible failure modes: 1. A failure of the UCM. Solution: 1. Turn off the machine. Restart the machine and recreate conditions for error. Use the EST to verify that fault code 1222 â&#x20AC;&#x201C; VCM Sustained Over Temperature Limit is active. A. If the fault is active, the UCM has failed. Replace the UCM. B. If the fault is not active, the fault may be intermittent and not currently active, continue with step 2. 2. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while monitoring the EST and the display. Investigate the nearby wiring. This Diagnostic Trouble Code resolution procedure does not completely rule out the UCM as a failure point. Therefore, all other possibilities should be investigated before the UCM is considered for replacement. A. If damage is found or other than normal display readings are indicated, repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If no damage or other than normal display readings are indicated, erase the Diagnostic Trouble Code and continue operation.
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Electrical systems - FAULT CODES
1223 - VCM Sustained Over Current Limit SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Context: Diagnostic Trouble Code 1223 â&#x20AC;&#x201C; Health Monitor Functions - UCM - UCM Sustained Over Current Limit has an error priority of Red. The hydraulics are disabled while the fault is active. Cause: The UCM has sensed a high current within the UCM. Possible failure modes: 1. A failure of the UCM. Solution: 1. Turn off the machine. Restart the machine and recreate conditions for error. Use the EST to verify fault code 1223 â&#x20AC;&#x201C; VCM Sustained Over Current Limit is active. A. If the fault is active, the UCM has failed. Replace the UCM. B. If the fault is not active, the fault may be intermittent and not currently active, continue with step 2. 2. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while monitoring the EST and the display. Investigate the nearby wiring. This Diagnostic Trouble Code resolution procedure does not completely rule out the UCM as a failure point. Therefore, all other possibilities should be investigated before the UCM is considered for replacement. A. If damage is found or other than normal display readings are indicated, repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If no damage or other than normal display readings are indicated, erase the Diagnostic Trouble Code and continue operation.
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Electrical systems - FAULT CODES
1224 - VCM Internal Memory or Core Monitoring Fault SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Context: Diagnostic Trouble Code 1224 â&#x20AC;&#x201C; Health Monitor Functions - UCM - Internal Memory or Core Monitoring Fault has an error priority of Red. The hydraulics are disabled while the fault is active. Cause: The UCM has sensed an internal fault within the UCM. Possible failure modes: 1. A failure of the UCM. Solution: 1. Turn off the machine. Restart the machine and recreate conditions for error. Use the EST to verify fault code 1224 â&#x20AC;&#x201C; VCM Internal Memory or Core Monitoring Fault is active. A. If the fault is active, the UCM has failed. Replace the UCM. B. If the fault is not active, the fault may be intermittent and not currently active, continue with step 2. 2. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while monitoring the EST and the display. Investigate the nearby wiring. This Diagnostic Trouble Code resolution procedure does not completely rule out the UCM as a failure point. Therefore, all other possibilities should be investigated before the UCM is considered for replacement. A. If damage is found or other than normal display readings are indicated, repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If no damage or other than normal display readings are indicated, erase the Diagnostic Trouble Code and continue operation.
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Electrical systems - FAULT CODES
1225 - VCM EEPROM Memory Checksum Fault SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Context: Diagnostic Trouble Code 1225 â&#x20AC;&#x201C; Health Monitor Functions - UCM - EEPROM Memory Checksum Fault has an error priority of Red. The hydraulics are disabled while the fault is active. Cause: The UCM has sensed a checksum failure within the UCM memory. Possible failure modes: 1. A failure of the UCM. Solution: 1. Turn off the machine. Restart the machine and recreate conditions for error. Use the EST to verify fault code 1225 â&#x20AC;&#x201C; VCM EEPROM Memory Checksum Fault is active. A. If the fault persists for three machine restarts, the UCM has failed. Replace the UCM. B. If the fault is not active, the fault may be intermittent and not currently active, continue with step 2. 2. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while monitoring the EST and the display. Investigate the nearby wiring. This Diagnostic Trouble Code resolution procedure does not completely rule out the UCM as a failure point. Therefore, all other possibilities should be investigated before the UCM is considered for replacement. A. If damage is found or other than normal display readings are indicated, repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If no damage or other than normal display readings are indicated, erase the Diagnostic Trouble Code and continue operation.
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Electrical systems - FAULT CODES
1350 - Hyd Enable Switch - Implausible State (Hardwire vs CAN) SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Context: Diagnostic Trouble Code 1350 – Hyd Enable Switch - Implausible State (Hardwire vs CAN) has an error priority of amber. The loader functions and the ground drive functions will operate in limp home mode while this fault is active. Cause: The UCM is receiving conflicting information about the hydraulic enable switch. The fault is active when the ignition is on and the hydraulic enable pin voltage is opposite of value transmitted from instrument cluster.
Possible failure modes: 1. A 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 code: Start and operate machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 1350 – Hyd Enable Switch - Implausible State (Hardwire vs CAN) is recorded again. Fault code 9156 – Hyd Enable Switch - Hyd Enable Button Error from AIC may also be active. Temporarily replace the instrument cluster and retest. Return to step 1 to confirm elimination of the fault.
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1532 - Backup Alarm - Short to Ground SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Context: The UCM has sensed an improper current from the backup alarm. Diagnostic Trouble Code 1532 – Backup Alarm Short to Ground has an error priority of White. The backup alarm is disabled while Diagnostic Trouble Code 1532 – Backup Alarm - Short to Ground is active. Cause: The UCM has sensed an improper current from the backup alarm. The fault is active only when both pumps are in reverse and the backup alarm solenoid output current is high. Possible failure modes: 1. A short circuit in the wiring. 2. A faulty backup alarm. 3. The UCM has an internal failure. Solution: 1. Use the machine to recreate conditions for error. Use the EST to verify fault code 1532 – Backup Alarm - Short to Ground is active. A. If the fault is active, continue with step 2. B. If the fault is not active, the fault may be intermittent and not currently active, continue with step 4. 2. Check for a short circuit to ground. Disconnect connector X-BKUP-PWR from the backup alarm. Disconnect UCM connector X-CN3B (Receptacle) . Measure the resistance between X-CN3B (Receptacle) pin 18 and chassis ground. The resistance should be greater than 20,000 Ω. 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 in the wiring. Repair as required. Return to step 1 to confirm elimination of the fault. 3. Measure the resistance through the backup alarm. Disconnect connector X-BKUP-GND from the backup alarm. Use a multi-meter to measure the resistance between the pins on the backup alarm. A. If resistance is normal, replace the UCM. B. If resistance is infinite, the backup alarm has developed an open. Replace the backup alarm . C. If resistance is 0 Ω, the backup alarm has shorted internally. Replace the backup alarm. 4. 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 48068130 29/01/2018
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breaks or shorts in the wiring concerned. Operate the machine while monitoring the EST and the display. Investigate the nearby wiring. A. If damage is found or other than normal display readings are indicated, repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If no damage or other than normal display readings are indicated, erase the Diagnostic Trouble Code and continue operation. Wiring harnesses - Electrical schematic sheet 21 SH21-UNIVERSAL CONTROL MODULE (55.100.DP-C.20.E.21) Wiring harnesses - Electrical schematic sheet 05 SH05-GROUNDING SYSTEM (55.100.DP-C.20.E.05)
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1533 - Backup Alarm - Short to Power SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Context: The UCM has sensed that the backup alarm output does not agree with the desired backup alarm status. Diagnostic Trouble Code 1533 – Backup Alarm - Short to Power has an error priority of White. The backup alarm is disabled while Diagnostic Trouble Code 1533 – Backup Alarm - Short to Power is active. Cause: The UCM has sensed that the backup alarm output does not agree with the desired backup alarm status. The fault is activate while the pumps are not in reverse and the backup alarm solenoid output voltage is greater than 8 V. Possible failure modes: 1. A short circuit in the wiring. 2. A faulty backup alarm. 3. The UCM has an internal failure. Solution: 1. Use the machine to recreate conditions for error. Use the EST to verify fault code 1533 – Backup Alarm - Short to Power is active. A. If the fault is active, continue with step 2. B. If the fault is not active, the fault may be intermittent and not currently active, continue with step 4. 2. Check for short circuit to another voltage. Disconnect connector X-BKUP-PWR from the backup alarm. Disconnect UCM connector X-CN3B (Receptacle) . Use a multi-meter to measure the voltage between UCM connector X-CN3B (Receptacle) pin 18 and chassis ground. A. If there is no voltage, continue with step 3. B. If there is voltage, there is a short to another voltage source on the between the UCM connector and the backup alarm. Repair or replace the wire as required. 3. Check for proper operation of the UCM. Reconnect the UCM connector X-CN3B (Receptacle) . Use a multi-meter to measure the voltage between connector X-BKUP-PWR pin 1 and chassis ground. A. If voltage is greater than 8 V, the UCM has failed. Replace the UCM. B. If voltage is less than 8 V, continue with step 4. 4. 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
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breaks or shorts in the wiring concerned. Operate the machine while monitoring the EST and the display. Investigate the nearby wiring. A. If damage is found or other than normal display readings are indicated, repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If no damage or other than normal display readings are indicated, erase the Diagnostic Trouble Code and continue operation. Wiring harnesses - Electrical schematic sheet 21 SH21-UNIVERSAL CONTROL MODULE (55.100.DP-C.20.E.21) Wiring harnesses - Electrical schematic sheet 05 SH05-GROUNDING SYSTEM (55.100.DP-C.20.E.05)
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1900 - VCM Ground Fault SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Context: The UCM has sensed low current in the UCM ground line. Diagnostic Trouble Code 1900 – VCM Ground Fault has an error priority of Red. All hydraulics are disabled while Diagnostic Trouble Code 1900 – VCM Ground Fault is active. Cause: The UCM has sensed low current in the UCM ground line. The fault is active while the ignition is on and there is a high resistance in the UCM ground line. Possible failure modes: 1. Faulty chassis ground connections. 2. An open circuit in the UCM ground circuit. Solution: 1. Verify that the fault code is active. Connect the Electronic Service Tool to the service tool connector. To check for fault code: Start and operate machine. A. The fault code is not recorded again. Verify that the chassis ground connection is clean and secure to the frame. Verify that the frame connection is free of paint, grease, oil, dirt, and debris. OK to return the machine to service. B. Fault code 1900 – VCM Ground Fault is recorded again. Go to step 2. C. If fault code 1900 – VCM Ground Fault is recorded along with other UCM fault codes, verify that the chassis ground connection is clean and secure to the frame. Verify that the frame connection is free of paint, grease, oil, dirt, and debris. Return to step 1 to confirm elimination of the fault. 2. Verify the harness is not damaged. Turn the ignition switch OFF. Verify the connections from the UCM to the chassis ground are tight and secure. Verify the harness is free of damage, abrasion, corrosion, and incorrect attachment from the UCM to the chassis ground connection. Verify that the chassis ground connections are clean and secure to the frame. Verify that the connection is free of paint, grease, oil, dirt, and debris. A. The 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. Return to step 1 to confirm elimination of fault. 3. Measure the resistance of the UCM ground connection.
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Turn the ignition switch OFF. Disconnect the UCM connector X-CN1A (Receptacle) . Measure the resistance between X-CN1A (Receptacle) pin 7 and chassis ground. The chassis ground connection must be clean and free of paint, oil, and dirt. The resistance should be less than 10 立. Wiggle the harness during measurement to reveal an intermittent condition. Measure the resistance between X-CN1A (Receptacle) pin 1 and chassis ground. The chassis ground connection must be clean and free of paint, oil, and dirt. The resistance should be less than 10 立. Wiggle the harness during measurement to reveal an intermittent condition. A. Both resistance measurements are less than 10 立. The UCM ground connection is free of grease, oil, paint, dirt and debris. Temporarily replace the UCM and retest. Return to 1 to confirm elimination of the fault. B. One or both resistance measurements are greater than 10 立. There is a high resistance or an open circuit in the UCM chassis ground connection. Verify that the UCM ground connection is free of paint, oil, grease, dirt, and debris. Repair or replace the UCM ground wire as required. Return to 1 to confirm elimination of the fault. Wiring harnesses - Electrical schematic sheet 20 SH20-UNIVERSAL CONTROL MODULE (55.100.DP-C.20.E.20) Wiring harnesses - Electrical schematic sheet 05 SH05-GROUNDING SYSTEM (55.100.DP-C.20.E.05) Wiring harnesses - Electrical schematic sheet 21 SH21-UNIVERSAL CONTROL MODULE (55.100.DP-C.20.E.21)
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1901 - VCM - VCM Supply Voltage High SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Context: The Universal Control Module (UCM) has sensed that the voltage on CN1A pin 20 is greater than 16 V. There are no restrictions while Diagnostic Trouble Code 1901 – VCM - VCM Supply Voltage High is active. Cause: The UCM has sensed that the voltage on X-CN1A (Receptacle) pin 20 is greater than 16 V. The fault is active while the ignition is ON and the input voltage is greater than 16 V. Possible failure modes: 1. A faulty ground connection on the rear right-hand ground lug. 2. A problem with the battery or the battery charging system. 3. A corruption of the UCM software. 4. A faulty UCM. Solution: 1. Verify that the fault code is active. Connect the Electronic Service Tool to the service tool connector. Update the UCM software to the latest version prior to further troubleshooting. To check for fault codes: Start and operate machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 1901 – VCM - VCM Supply Voltage High is recorded again. Go to step 2. C. If fault code 1901 – VCM - VCM Supply Voltage High is recorded along with other diagnostic codes such 1014 – Cluster Battery Monitor: Over Voltage > 16.5 volts and 3051 – Battery voltage is higher than expected, there is a problem in the electrical charging system on the machine. Troubleshoot the alternator charging system. 2. Verify the harness is not damaged Turn the ignition switch OFF. Verify the connections to the UCM and to the alternator are tight and secure. Verify the chassis ground connections to the UCM are tight and secure. The chassis ground connections must be free of paint, rust, oil, dirt, and debris. Verify the harness is free of damage, abrasion, corrosion, and incorrect attachment. A. The wiring 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 or the connectors as required. Return to step 1 to confirm elimination of fault. 3. Check the ground connection on the rear right-hand ground lugs. 48068130 29/01/2018
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Verify that the grounding boss is free of paint, oil, dirt, and debris. Verify that the ground connection is tight and secure. A. The grounding boss is clean and free of paint. The grounding connection is secure. Go to step 4. B. The grounding boss is dirty or cover with paint. Remove the dirt. Remove the paint. Repair as required. Return to step 1 to confirm elimination of fault. 4. Measure the alternator output voltage. Start the engine. Set engine speed to low idle. Measure the voltage at the alternator. The voltage should be approximately 14.8 V. A. The voltage is approximately 14.8 V. Go to step 5. B. The voltage is greater than 16 V. There is a problem with the alternator. Replace the alternator and retest. Return to step 1 to confirm elimination of fault. 5. Measure the voltage at the UCM. Turn the ignition switch ON. Disconnect UCM connector X-CN1A (Receptacle) . Start the engine. Measure the voltage between UCM connector X-CN1A (Receptacle) pin 20 and chassis ground. The voltage should be between 11 V and 14.8 V. A. The voltage is approximately 14.8 V. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. B. The voltage is greater than 16 V. Replace the alternator. Return to step 1 to confirm elimination of fault. Wiring harnesses - Electrical schematic sheet 20 SH20-UNIVERSAL CONTROL MODULE (55.100.DP-C.20.E.20) Wiring harnesses - Electrical schematic sheet 02 SH02-MAIN POWER DISTRIBUTION (55.100.DP-C.20.E.02) Wiring harnesses - Electrical schematic sheet 03 SH03-ACCESSORY POWER DISTRIBUTION (55.100.DP-C.20.E.03)
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1902 - VCM - VCM Supply Voltage Low SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Context: The UCM has sensed that the voltage on X-CN1A (Receptacle) pin 20 is less than 11.5 V. There are no restrictions while Diagnostic Trouble Code 1902 – VCM - VCM Supply Voltage Low is active. Cause: The UCM has sensed that the voltage on X-CN1A (Receptacle) pin 20 is less than 11.5 V, but greater than 9 V. The fault has been active for a period greater than 30 s. Possible failure modes: 1. A problem with the battery or the battery charging system. 2. A short circuit in the wiring. 3. A faulty UCM. 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 machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 1902 – VCM - VCM Supply Voltage Low is recorded again. Go to step 2. C. If fault code 1902 – VCM - VCM Supply Voltage Low is recorded along with other diagnostic codes such 1015 – Cluster Battery Monitor: Under Voltage < 11.5 volts and 3052 – Battery voltage is lower than expected, then there is a problem in the electrical charging system on the machine. Troubleshoot the alternator charging system. 2. Verify the harness is not damaged Turn the ignition switch OFF. Verify the connections to the UCM and the alternator are tight and secure. Verify the chassis ground connections to the UCM are tight and secure. The chassis ground connections should be free of paint, rust, oil, dirt, and debris. Verify the harness is free of damage, abrasion, corrosion, and incorrect attachment. A. The wiring 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 or the connectors as required. Return to step 1 to confirm elimination of fault. 3. Measure the alternator output. Start the engine.
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Set engine speed to low idle. Measure the voltage at the alternator. The voltage should be approximately 14.8 V. A. The voltage is approximately 14.8 V. Go to step 4. B. The voltage is less than 11.5 V. There is a problem with the alternator. Replace the alternator. Return to step 1 to confirm elimination of fault. 4. Measure the voltage at the UCM. Turn the ignition switch ON. Disconnect UCM connector X-CN1A (Receptacle) . Start the engine. Measure the voltage between UCM connector X-CN1A (Receptacle) pin 20 and chassis ground. The voltage should be between 11 V and 14.8 V. A. The voltage is approximately 14.8 V. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. B. The voltage is less than 11.5 V. There is a problem with the alternator. Replace the alternator. Return to step 1 to confirm elimination of fault. Wiring harnesses - Electrical schematic sheet 20 SH20-UNIVERSAL CONTROL MODULE (55.100.DP-C.20.E.20) Wiring harnesses - Electrical schematic sheet 03 SH03-ACCESSORY POWER DISTRIBUTION (55.100.DP-C.20.E.03) Wiring harnesses - Electrical schematic sheet 02 SH02-MAIN POWER DISTRIBUTION (55.100.DP-C.20.E.02)
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1903 - VCM - VCM Supply Voltage Below Operational Limit SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Context: The UCM has sensed that the voltage on X-CN1A (Receptacle) pin 20 is less than 9 V. Diagnostic Trouble Code 1903 – VCM - VCM Supply Voltage Below Operational Limit has an error priority of Red. All hydraulics are disabled while Diagnostic Trouble Code 1903 – VCM - VCM Supply Voltage Below Operational Limit is active. Cause: The UCM has sensed that the voltage on X-CN1A (Receptacle) pin 20 is less than 9 V. The fault is active for a period greater than 30 s. Possible failure modes: 1. A problem with the battery or the battery charging system. 2. A short circuit in the wiring. 3. A faulty UCM. 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 machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 1903 – VCM - VCM Supply Voltage Below Operational Limit is recorded again. Go to step 2. C. If fault code 1903 – VCM - VCM Supply Voltage Below Operational Limit is recorded along with other diagnostic codes such 1015 – Cluster Battery Monitor: Under Voltage < 11.5 volts and 3052 – Battery voltage is lower than expected, there is a problem in the electrical charging system on the machine. Troubleshoot the alternator charging system. 2. Verify the harness is not damaged. Turn the ignition switch OFF. Verify the connections to the UCM and the alternator are tight and secure. Verify the chassis ground connections to the UCM are tight and secure. The chassis ground connections should be free of paint, rust, oil, dirt, and debris. Verify the harness is free of damage, abrasion, corrosion, and incorrect attachment. A. The wiring 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. Return to step 1 to confirm elimination of fault. 3. Measure the alternator output.
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Start the engine. Set engine speed to low idle. Measure the voltage at the alternator. The voltage should be approximately 14.8 V. A. The voltage is approximately 14.8 V. Go to step 4. B. The voltage is less than 9 V. Replace the alternator. Return to step 1 to confirm elimination of fault. 4. Measure the voltage at the UCM. Turn the ignition switch ON. Disconnect UCM connector X-CN1A (Receptacle) . Start the engine. Measure the voltage between UCM connector X-CN1A (Receptacle) pin 20 and chassis ground. The voltage should be between 11 V and 14.8 V. A. The voltage is approximately 14.5 V. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. B. The voltage is less than 9 V. Replace the alternator and retest. Return to step 1 to confirm elimination of fault. Wiring harnesses - Electrical schematic sheet 20 SH20-UNIVERSAL CONTROL MODULE (55.100.DP-C.20.E.20) Wiring harnesses - Electrical schematic sheet 03 SH03-ACCESSORY POWER DISTRIBUTION (55.100.DP-C.20.E.03) Wiring harnesses - Electrical schematic sheet 02 SH02-MAIN POWER DISTRIBUTION (55.100.DP-C.20.E.02)
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1904 - VCM - Rail 12VB - 5V Regulators Supply Input Power Off SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Context: The UCM has sensed that the voltage on X-CN1A (Receptacle) pin 26 is less than 9 V. Diagnostic Trouble Code 1904 – VCM - Rail 12VB - 5V Regulators Supply Input Power Off has an error priority of Red. All hydraulics are disabled while Diagnostic Trouble Code 1904 – VCM - Rail 12VB - 5V Regulators Supply Input Power Off is active. Cause: The UCM has sensed that voltage on X-CN1A (Receptacle) pin 26 is less than 9 V. The fault is active while the ignition is ON, the engine is not cranking, and Diagnostic Code 1904 – VCM - Rail 12VB - 5V Regulators Supply Input Power Off is not active. Possible failure modes: 1. A problem with the battery or the battery charging system. 2. An open circuit in the wiring. 3. A short circuit in the wiring. 4. A faulty UCM. Solution: 1. Verify that the fault code is active. Connect the Electronic Service Tool to the service tool connector. To check for fault code: Start and operate machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 1904 – VCM - Rail 12VB - 5V Regulators Supply Input Power Off is recorded again. Go to step 2. C. Fault code 1904 – VCM - Rail 12VB - 5V Regulators Supply Input Power Off is recorded along with other diagnostic codes such as 1907 – VCM - Rail 12VF1 - Aux Retract Input Power Off and/or 1917 – VCM - Rail 12VU1 - Right And Left Pumps Forward Input Power Off. Test the fuses and relays. Repair as required. Return to step 1 to confirm elimination of the fault. 2. Verify the harness is not damaged. Turn the ignition switch OFF. Verify the connections to the UCM connector are tight and secure. Verify the harness is free of damage, abrasion, corrosion, and incorrect attachment. A. The wiring 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 or the connectors as required. Return to step 1 to confirm elimination of fault. 3. Test the UCM connection 48068130 29/01/2018
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Turn the ignition switch OFF. Fabricate a jumper wire that will connect from the positive battery post to UCM connector X-CN1A (Receptacle) pin 26. Connect the jumper from the positive battery post to UCM connector X-CN1A (Receptacle) pin 26. Turn the ignition switch ON. Go to the fault code screen and refresh the display. The fault code should no longer be active. A. The fault code is not longer active. There is a problem in the wiring from between splice SP-119 and the UCM connector. Repair as required. Return to step 1 to confirm elimination of the fault. B. The fault code is still active. There is a problem with UCM. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. Wiring harnesses - Electrical schematic sheet 20 SH20-UNIVERSAL CONTROL MODULE (55.100.DP-C.20.E.20) Wiring harnesses - Electrical schematic sheet 04 SH04-IGNITION/CHARGING SYSTEM (55.100.DP-C.20.E.04) Wiring harnesses - Electrical schematic sheet 03 SH03-ACCESSORY POWER DISTRIBUTION (55.100.DP-C.20.E.03)
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1905 - VCM - 5Vref1 Sensor Supply Voltage Out Of Range SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Context: The UCM has sensed that the sensor supply voltage X-CN1A (Receptacle) pin 8 is out of range. Diagnostic Trouble Code 1905 – VCM - 5Vref1 Sensor Supply Voltage Out Of Range has an error priority of Red. All hydraulics are disabled while Diagnostic Trouble Code 1905 – VCM - 5Vref1 Sensor Supply Voltage Out Of Range is active. Cause: The UCM has sensed that the sensor supply voltage X-CN1A (Receptacle) pin 8 is out of range. The fault is active while the ignition switch is ON and the voltage on X-CN1A (Receptacle) pin 8 is less than 4.4 V or greater than 5.6 V. Possible failure modes: 1. An open circuit in the wiring. 2. A short circuit in the wiring. 3. A faulty sensor. 4. A faulty UCM. 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 machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 1905 – VCM - 5Vref1 Sensor Supply Voltage Out Of Range is active and recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the UCM, the right hand control handle, the chassis loader interface, and the universal joystick module. All connections should be secure, tight, free of corrosion, abrasion and damage. Inspect the UCM, the right hand control handle, the chassis loader interface, and the universal joystick module. 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. 3. Measure the voltage at the UCM Turn the ignition switch ON. Measure the voltage between UCM connector X-CN1A (Receptacle) pin 8 and chassis ground. The voltage should be approximately 5 V. Wiggle the harness during measurement to reveal an intermittent condition.
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A. The voltage is less than 4.4 V. Go to step 4. B. The voltage is greater than 5.6 V. Go to step 6. C. The voltage is greater than 4.4 V but less than 5.6 V. There does not seem to be a problem at this time. Reprogram the UCM with the latest software. If the fault code persists, temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. 4. Check for a short circuit to chassis ground. Turn the ignition switch OFF. Disconnect the UCM connector X-CN1A (Receptacle) . Disconnect the right hand control handle, the chassis loader interface, and the universal joystick module. Use a digital voltmeter to measure the resistance between X-CN1A (Receptacle) pin 8 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. Go to step 5. 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 1 to confirm elimination of the fault. 5. Reconnect the components to the harness while monitoring the resistance. Use a digital voltmeter to measure the resistance between X-CN1A (Receptacle) pin 8 and chassis ground. Reconnect the components one at a time (the right hand control handle, the chassis loader interface, and the universal joystick module), while monitoring the resistance reading. The resistance should be greater than 20,000 Ω while the components are reconnected into the circuit. A. The resistance is greater than 20,000 Ω but dropped below 20,000 Ω when a component was reconnected into the circuit. Temporarily replace the component that dropped the resistance and retest. Return to step 1 to confirm elimination of the fault. B. The resistance is greater than 20,000 Ω while each component was reconnected into the circuit. Temporarily replace the UCM and retest. Return to step 1 to confirm the elimination of the fault. 6. Check for an open circuit in the wiring. Turn the ignition switch OFF. Disconnect the UCM connector X-CN1A (Receptacle) . Fabricate a jumper wire that will connect X-CN1A (Receptacle) pin 8 and chassis ground. Connect the jumper wire between X-CN1A (Receptacle) pin 8 and chassis ground. The chassis ground connection must be clean and free of paint, dirt, and oil. Disconnect the right hand control handle, the chassis loader interface, and the universal joystick module. Measure the resistance between the chassis/loader interface connector X-010 CHAS/LOAD (Plug) pin 14 and chassis ground. The resistance should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition. Measure the resistance between the right control module connector X-403 (Receptacle) pin 1 and chassis ground. The resistance should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition. Measure the resistance between the universal joystick module connector X-UJML pin 7 and chassis ground. The resistance should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition. Measure the resistance between the universal joystick module connector X-UJMR pin 7 and chassis ground. The resistance should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition. 48068130 29/01/2018
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A. All resistance measurements are less than 10 Ί. Go to step 7. B. One of more resistance readings are greater than 10 Ί. There is an open circuit in the wiring. Repair or replace the harness as required. Return to step 1 to confirm the elimination of the fault. 7. Check for a short circuit to battery. Turn the ignition switch OFF. Disconnect the UCM connector X-CN1A (Receptacle) . Disconnect the right hand control handle, the chassis loader interface, and the universal joystick module. Turn the ignition switch ON. Measure the voltage between X-CN1A (Receptacle) pin 8 and chassis ground. The voltage should be less than 0.5 V. Wiggle the harness during measurement to reveal and intermittent condition. A. The voltage is less than 0.5 V. Go to step 8. B. The voltage is greater than 0.5 V. There is a short circuit to another voltage source. Repair or replace the harness as required. Return to step 1 to confirm the elimination of the fault. 8. Reconnect the components to the harness while monitoring the voltage. Use a digital voltmeter to measure the voltage between X-CN1A (Receptacle) pin 8 and chassis ground. Reconnect the components one at a time (the right hand control handle, the chassis loader interface, and the universal joystick module), while monitoring the voltage reading. The voltage should be less than 0.5 V while the components are reconnected into the circuit. A. The voltage is less than 0.5 V but changed to a voltage greater than 1 V when a component was reconnected into the circuit. Temporarily replace the component that changed the voltage. Return to step 1 to confirm elimination of the fault. B. The voltage is less than 0.5 V while each component was reconnected into the circuit. Temporarily replace the UCM and retest. Return to step 1 to confirm the elimination of the fault. Wiring harnesses - Electrical schematic sheet 20 SH20-UNIVERSAL CONTROL MODULE (55.100.DP-C.20.E.20) Wiring harnesses - Electrical schematic sheet 18 SH18-RIGHT NH CONTROL HANDLE (55.100.DP-C.20.E.18) Wiring harnesses - Electrical schematic sheet 30 SH30-UJM CONNECTORS (55.100.DP-C.20.E.30)
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1906 - VCM - 5Vref3 Sensor Supply Voltage Out Of Range SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Context: The UCM has sensed that the sensor supply voltage X-CN1A (Receptacle) pin 9 is out of range. Diagnostic Trouble Code 1906 – VCM - 5Vref3 Sensor Supply Voltage Out Of Range has an error priority of Red. All hydraulics are disabled while Diagnostic Trouble Code 1906 – VCM - 5Vref3 Sensor Supply Voltage Out Of Range is active. Cause: The UCM has sensed that the sensor supply voltage X-CN1A (Receptacle) pin 9 is out of range. The fault is active while the ignition switch is ON and the voltage at X-CN1A (Receptacle) pin 9 is less than 4.4 V or greater than 5.6 V. Possible failure modes: 1. An open circuit in the wiring. 2. A short circuit in the wiring. 3. A faulty sensor. 4. A faulty UCM. 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 machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 1906 – VCM - 5Vref3 Sensor Supply Voltage Out Of Range is active and recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the UCM, the right hand control handle, and the universal joystick module. All connections should be secure, tight, free of corrosion, abrasion and damage. Inspect the UCM, the right hand control handle, and the universal joystick module. 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 the connectors as required. Return to step 1 to confirm elimination of fault. 3. Measure the voltage at the UCM Turn the ignition switch ON. Measure the voltage between UCM connector X-CN1A (Receptacle) pin 9 and chassis ground. The voltage should be approximately 5 V. Wiggle the harness during measurement to reveal an intermittent condition.
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A. The voltage is less than 4.4 V. Go to step 4. B. The voltage is greater than 5.6 V. Go to step 6. C. The voltage is greater than 4.4 V but less than 5.6 V. There does not seem to be a problem at this time. Reprogram the UCM with the latest software. If the fault code persists, temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. 4. Check for a short circuit to chassis ground. Turn the ignition switch OFF. Disconnect the UCM connector X-CN1A (Receptacle) . Disconnect the right hand control handle, and the universal joystick module. Use a digital voltmeter to measure the resistance between X-CN1A (Receptacle) pin 9 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. Go to step 5. 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 1 to confirm elimination of the fault. 5. Reconnect the components to the harness while monitoring the resistance. Use a digital voltmeter to measure the resistance between X-CN1A (Receptacle) pin 9 and chassis ground. Reconnect the components one at a time (the right hand control handle, and the universal joystick module), while monitoring the resistance reading. The resistance should be greater than 20,000 Ω while the components are reconnected into the circuit. A. The resistance is greater than 20,000 Ω but dropped below 20,000 Ω when a component was reconnected into the circuit. Temporarily replace the component that dropped the resistance and retest. Return to step 1 to confirm elimination of the fault. B. The resistance is greater than 20,000 Ω while each component was reconnected into the circuit. Temporarily replace the UCM and retest. Return to step 1 to confirm the elimination of the fault. 6. Check for an open circuit in the wiring. Turn the ignition switch OFF. Disconnect the UCM connector X-CN1A (Receptacle) . Fabricate a jumper wire that will connect X-CN1A (Receptacle) pin 9 and chassis ground. Connect the jumper wire between X-CN1A (Receptacle) pin 9 and chassis ground. The chassis ground connection must be clean and free of paint, dirt, and oil. Disconnect the right hand control handle, and the universal joystick module. Measure the resistance between the right control module connector X-403 (Receptacle) pin 10 and chassis ground. The resistance should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition. Measure the resistance between the universal joystick module connector X-UJML (Plug) pin 1 and chassis ground. The resistance should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition. Measure the resistance between the universal joystick module connector X-UJMR (Plug) pin 1 and chassis ground. The resistance should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition. A. All resistance measurements are less than 10 Ω. Go to step 7. 48068130 29/01/2018
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B. One of more resistance readings are greater than 10 Ί. There is an open circuit in the wiring. Repair or replace the harness as required. Return to step 1 to confirm the elimination of the fault. 7. Check for a short circuit to battery. Turn the ignition switch OFF. Disconnect the UCM connector X-CN1A (Receptacle) . Disconnect the right hand control handle, and the universal joystick module. Turn the ignition switch ON. Measure the voltage between X-CN1A (Receptacle) pin 9 and chassis ground. The voltage should be less than 0.5 V. Wiggle the harness during measurement to reveal and intermittent condition. A. The voltage is less than 0.5 V. Go to step 8. B. The voltage is greater than 0.5 V. There is a short circuit to another voltage source. Repair or replace the harness as required. Return to step 1 to confirm the elimination of the fault. 8. Reconnect the components to the harness while monitoring the voltage. Use a digital voltmeter to measure the voltage between X-CN1A (Receptacle) pin 9 and chassis ground. Reconnect the components one at a time (the right hand control handle, and the universal joystick module), while monitoring the voltage reading. The voltage should be less than 0.5 V while the components are reconnected into the circuit. A. The voltage is less than 0.5 V, but changed to a voltage greater than 1 V when a component was reconnected into the circuit. Temporarily replace the component that changed the voltage. Return to step 1 to confirm elimination of the fault. B. The voltage is less than 0.5 V while each component was reconnected into the circuit. Temporarily replace the UCM and retest. Return to step 1 to confirm the elimination of the fault. Wiring harnesses - Electrical schematic sheet 20 SH20-UNIVERSAL CONTROL MODULE (55.100.DP-C.20.E.20) Wiring harnesses - Electrical schematic sheet 18 SH18-RIGHT NH CONTROL HANDLE (55.100.DP-C.20.E.18) Wiring harnesses - Electrical schematic sheet 30 SH30-UJM CONNECTORS (55.100.DP-C.20.E.30)
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1907 - VCM - Rail 12VF1 - Aux Retract Input Power Off SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Context: The UCM has sensed that the voltage on X-CN1B (Receptacle) pin 26 and X-CN1B (Receptacle) pin 27 is less than 9 V. Diagnostic Trouble Code 1907 – VCM - Rail 12VF1 - Aux Retract Input Power Off has an error priority of Amber. The auxiliary functions are disabled while Diagnostic Trouble Code 1907 – VCM - Rail 12VF1 - Aux Retract Input Power Off is active. Cause: The UCM has sensed that the voltage on X-CN1B (Receptacle) pin 26 and X-CN1B (Receptacle) pin 27 is less than 9 V. The fault is active while the ignition is ON, the engine is not cranking, and Diagnostic Code 1903 – VCM VCM Supply Voltage Below Operational Limit is not active. Possible failure modes: 1. Fuse F-018 is blown or missing. 2. An open circuit in the wiring. 3. A failure of the UCM. 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. OK to return the machine to service. B. Fault code 1907 – VCM - Rail 12VF1 - Aux Retract Input Power Off is recorded again. Go to step 2. 2. Verify the harness is not damaged. Turn the ignition switch OFF. Inspect the UCM connections and the accessory power distribution fuse block #1 X-FUSE1 (Receptacle) connections. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the UCM connector X-CN1B (Receptacle) to the accessory power distribution fuse block #1 X-FUSE1 (Receptacle) . Verify that the harness is free of damage, corrosion, abrasion, and incorrect attachment. A. The wiring 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. Return to step 1 to confirm elimination of fault. 3. Measure the voltage at the fuse. Turn the ignition switch ON.
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Measure voltage between the accessory power distribution fuse block X-FUSE1 (Receptacle) pin 26 and chassis ground. The voltage should be approximately 12 V. A. The voltage is between 9 V and 14.8 V. Go to step 4. B. The voltage is less than 9 V. Go to step 5. 4. Test the UCM connection. Turn the ignition switch OFF. Fabricate a jumper wire that will connect from the positive battery post to UCM connector CN1B pin 26 and CN1B pin 27. Turn the ignition switch ON. Go to the fault code screen and refresh the display. The fault code should no longer be active. A. The fault code is not longer active. There is a problem in the wiring from between fuse F-018 and the UCM connector. Repair as required. Return to step 1 to confirm elimination of the fault. B. The fault code is still active. There is a problem with UCM. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. 5. Measure the voltage at the fuse. Turn the ignition switch ON. Measure voltage between the accessory power distribution fuse block X-FUSE1 (Receptacle) pin 32 and chassis ground. The voltage should be approximately 12 V. A. The voltage is between 9 V and 14.8 V. Replace the fuse. Return to step 1 to confirm elimination of the fault. B. The voltage is less than 9 V. There is a problem in the wiring between the EH control relay and the fuse. Check splice SP-109 and splice SP-119 and the associated wiring. Repair as required. Return to step 1 to confirm elimination of the fault. Wiring harnesses - Electrical schematic sheet 20 SH20-UNIVERSAL CONTROL MODULE (55.100.DP-C.20.E.20) Wiring harnesses - Electrical schematic sheet 03 SH03-ACCESSORY POWER DISTRIBUTION (55.100.DP-C.20.E.03)
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1908 - VCM - Rail 12VF2 - Bucket Extend Input Power Off SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Context: The UCM has sensed that the voltage on X-CN4A (Receptacle) pin 1 and X-CN4A (Receptacle) pin 8 is less than 9 V. Diagnostic Trouble Code 1908 – VCM - Rail 12VF2 - Bucket Extend Input Power Off has an error priority of Red. Bucket functions are disabled while Diagnostic Trouble Code 1908 – VCM - Rail 12VF2 - Bucket Extend Input Power Off is active. Cause: The UCM has sensed that the voltage on X-CN4A (Receptacle) pin 1 and X-CN4A (Receptacle) pin 8 is less than 9 V. The fault is active while the ignition is ON, the engine is not cranking, and Diagnostic Code 1903 – VCM - VCM Supply Voltage Below Operational Limit is not active. Possible failure modes: 1. An open circuit in the wiring. 2. A failure of the UCM. 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 machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 1908 – VCM - Rail 12VF2 - Bucket Extend Input Power Off is recorded again. Go to step 2. C. Fault code 1908 – VCM - Rail 12VF2 - Bucket Extend Input Power Off is recorded along with fault code 1913 – VCM - Rail 12VS1 - Bucket Curl Input Power Off. Check fuse F-019. Check splice SP-111. Repair as required. Return to step 1 to confirm elimination of the fault. 2. Verify the harness is not damaged. Turn the ignition switch OFF. Inspect the UCM connections and the accessory power distribution fuse block #1 X-FUSE1 (Receptacle) connections. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the UCM connector X-CN4A (Receptacle) to the accessory power distribution fuse block #1 X-FUSE1 (Receptacle) . Verify that the harness is free of damage, corrosion, abrasion, and incorrect attachment. A. The wiring 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. Return to step 1 to confirm elimination of fault. 3. Test the UCM connection.
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Turn the ignition switch OFF. Fabricate a jumper wire that will connect from the positive battery post to UCM connector X-CN4A (Receptacle) pin 1 and X-CN4A (Receptacle) pin 8. Connect the jumper from the positive battery post to UCM connector X-CN4A (Receptacle) pin 1 and X-CN4A (Receptacle) pin 8 . Turn the ignition switch ON. Go to the fault code screen and refresh the display. The fault code should no longer be active. A. The fault code is not longer active. There is a problem in the wiring from between splice SP-111 and the UCM connector. Repair as required. Return to step 1 to confirm elimination of the fault. B. The fault code is still active. There is a problem with UCM. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. Wiring harnesses - Electrical schematic sheet 21 SH21-UNIVERSAL CONTROL MODULE (55.100.DP-C.20.E.21) Wiring harnesses - Electrical schematic sheet 03 SH03-ACCESSORY POWER DISTRIBUTION (55.100.DP-C.20.E.03)
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1909 - VCM - Rail 12VF3 - Boom Raise/Lower Input Power Off SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Context: The UCM has sensed that the voltage on X-CN2B (Receptacle) pin 9 and X-CN2B (Receptacle) pin 17 is less than 9 V. Diagnostic Trouble Code 1909 – VCM - Rail 12VF3 - Boom Raise/Lower Input Power Off has an error priority of Red. Boom functions are disabled while Diagnostic Trouble Code 1909 – VCM - Rail 12VF3 - Boom Raise/Lower Input Power Off is active. Cause: The UCM has sensed that the voltage on X-CN2B (Receptacle) pin 9 and X-CN2B (Receptacle) pin 17 is less than 9 V. The fault is active while the ignition is ON, the engine is not cranking, and Diagnostic Code 1903 – VCM - VCM Supply Voltage Below Operational Limit is not active. Possible failure modes: 1. Fuse F-022 is blown or missing. 2. An open circuit in the wiring. 3. A failure of the UCM. 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 machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 1909 – VCM - Rail 12VF3 - Boom Raise/Lower Input Power Off is recorded again. Go to step 2. 2. Verify the harness is not damaged. Turn the ignition switch OFF. Inspect the UCM connections and the accessory power distribution fuse block #1 connections. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the UCM connector X-CN2B (Receptacle) to the accessory power distribution fuse block #1. Verify that the harness is free of damage, corrosion, abrasion, and incorrect attachment. A. The wiring 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. Return to step 1 to confirm elimination of fault. 3. Measure the voltage at the fuse. Turn the ignition switch ON. Measure voltage between the accessory power distribution fuse block X-FUSE1 (Receptacle) pin 50 and chassis ground. The voltage should be approximately 12 V. 48068130 29/01/2018
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A. The voltage is between 9 V and 14.8 V. Go to step 4. B. The voltage is less than 9 V. Go to step 5. 4. Test the UCM connection. Turn the ignition switch OFF. Fabricate a jumper wire that will connect from the positive battery post to UCM connector X-CN2B (Receptacle) pin 9 and X-CN2B (Receptacle) pin 17. Connect the jumper wire from the positive battery post to UCM connector X-CN2B (Receptacle) pin 9 and X-CN2B (Receptacle) pin 17. Turn the ignition switch ON. Go to the fault code screen and refresh the display. The fault code should no longer be active. A. The fault code is not longer active. There is a problem in the wiring between fuse F-022 and the UCM connector. Check splice SP-110 and the associated wiring. Repair as required. Return to step 1 to confirm elimination of the fault. B. The fault code is still active. There is a problem with UCM. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. 5. Measure the voltage at the fuse. Turn the ignition switch ON. Measure voltage between the accessory power distribution fuse block X-FUSE1 (Receptacle) pin 56 and chassis ground. The voltage should be approximately 12 V. A. The voltage is between 9 V and 14.8 V. Replace the fuse. Return to step 1 to confirm elimination of the fault. B. The voltage is less than 9 V. There is a problem in the wiring between the EH control relay and the fuse. Check splice SP-119 and Splice SP-118 and the associated wiring. Repair as required. Return to step 1 to confirm elimination of the fault. Wiring harnesses - Electrical schematic sheet 21 SH21-UNIVERSAL CONTROL MODULE (55.100.DP-C.20.E.21) Wiring harnesses - Electrical schematic sheet 03 SH03-ACCESSORY POWER DISTRIBUTION (55.100.DP-C.20.E.03)
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1910 - VCM - Rail 12VH - Loader Pilot Interlock And Port Lock Input Power Off SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Context: The UCM has sensed that the voltage on X-CN2A (Receptacle) pin 7 and X-CN2A (Receptacle) pin 13 is less than 9 V. Diagnostic Trouble Code 1910 – VCM - Rail 12VH - Loader Pilot Interlock And Port Lock Input Power Off has an error priority of Red. Loader hydraulic functions are disabled while Diagnostic Trouble Code 1910 – VCM - Rail 12VH - Loader Pilot Interlock And Port Lock Input Power Off is active. Cause: The UCM has sensed that the voltage on X-CN2A (Receptacle) pin 7 and X-CN2A (Receptacle) pin 13 is less than 9 V. The fault is active while the ignition is ON, the engine is not cranking, and Diagnostic Code 1903 – VCM - VCM Supply Voltage Below Operational Limit is not active. Possible failure modes: 1. Fuse F-025 is blown or missing. 2. An open circuit in the wiring. 3. A failure of the UCM. 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 machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 1910 – VCM - Rail 12VH - Loader Pilot Interlock And Port Lock Input Power Off is recorded again. Go to step 2. 2. Verify the harness is not damaged. Turn the ignition switch OFF. Inspect the UCM connections and the accessory power distribution fuse block #1 X-FUSE1 (Receptacle) connections. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the UCM connector X-CN2A (Receptacle) to the accessory power distribution fuse block #1 X-FUSE1 (Receptacle) . Verify that the harness is free of damage, corrosion, abrasion, and incorrect attachment. A. The wiring 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. Return to step 1 to confirm elimination of fault. 3. Measure the voltage at the fuse.
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Turn the ignition switch ON. Measure voltage between the accessory power distribution fuse block X-FUSE1 (Receptacle) pin 49 and chassis ground. The voltage should be approximately 12 V. A. The voltage is between 9 V and 14.8 V. Go to step 4. B. The voltage is less than 9 V. Go to step 5. 4. Test the UCM connection. Turn the ignition switch OFF. Fabricate a jumper wire that will connect from the positive battery post to UCM connector X-CN2A (Receptacle) pin 7 and X-CN2A (Receptacle) pin 13. Connect the jumper from the positive battery post to UCM connector X-CN2A (Receptacle) pin 7 and X-CN2A (Receptacle) pin 13. Turn the ignition switch ON. Go to the fault code screen and refresh the display. The fault code should no longer be active. A. The fault code is not longer active. There is a problem in the wiring between fuse F-025 and the UCM connector. Check splice SP-112 and the associated wiring. Repair as required. Return to step 1 to confirm elimination of the fault. B. The fault code is still active. There is a problem with UCM. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. 5. Measure the voltage at the fuse. Turn the ignition switch ON. Measure voltage between the accessory power distribution fuse block X-FUSE1 (Receptacle) pin 55 and chassis ground. The voltage should be approximately 12 V. A. The voltage is between 9 V and 14.8 V. Replace the fuse. Return to step 1 to confirm elimination of the fault. B. The voltage is less than 9 V. There is a problem in the wiring between the EH control relay and the fuse. Check splice SP-119 and splice SP-118 and the associated wiring. Repair as required. Return to step 1 to confirm elimination of the fault. Wiring harnesses - Electrical schematic sheet 20 SH20-UNIVERSAL CONTROL MODULE (55.100.DP-C.20.E.20) Wiring harnesses - Electrical schematic sheet 03 SH03-ACCESSORY POWER DISTRIBUTION (55.100.DP-C.20.E.03)
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1911 - VCM - Rail 12VH1 - Left And Right Pump Reverse Input Power Off SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Context: The UCM has sensed that the voltage on X-CN2A (Receptacle) pin 2 and X-CN2A (Receptacle) pin 3 is less than 9 V. Diagnostic Trouble Code 1911 – VCM - Rail 12VH1 - Left And Right Pump Reverse Input Power Off has an error priority of Red. The reverse ground drive functions are disabled while Diagnostic Trouble Code 1911 – VCM - Rail 12VH1 - Left And Right Pump Reverse Input Power Off is active. Cause: The UCM has sensed that the voltage on X-CN2A (Receptacle) pin 2 and X-CN2A (Receptacle) pin 3 is less than 9 V. The fault is active while the ignition is ON, the engine is not cranking, and Diagnostic Code 1903 – VCM - VCM Supply Voltage Below Operational Limit is not active. Possible failure modes: 1. An open circuit in the wiring. 2. A failure of the UCM. 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 machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 1911 – VCM - Rail 12VH1 - Left And Right Pump Reverse Input Power Off is recorded again. Go to step 2. C. Fault code 1911 – VCM - Rail 12VH1 - Left And Right Pump Reverse Input Power Off is recorded along with swash plate sensor faults such as 4734 – Right Swash Plate Angle Sensor Pin B Open Or Shorted To Ground and 4744 – Left Swash Plate Angle Sensor Pin B Open Or Shorted To Ground. Check the wiring to fuse F-017. Check fuse F-017 and the associated wiring. Check splice SP-152. Repair as required. Return to step 1 to confirm elimination of the fault. 2. Verify the harness is not damaged. Turn the ignition switch OFF. Verify the connections to the UCM connector are tight and secure. Verify the harness is free of damage, abrasion, corrosion, and incorrect attachment. A. The wiring 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 or the connectors as required. Return to step 1 to confirm elimination of fault. 3. Test the UCM connection. 48068130 29/01/2018
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Turn the ignition switch OFF. Fabricate a jumper wire that will connect from the positive battery post to UCM connector X-CN2A (Receptacle) pin 2 and X-CN2A (Receptacle) pin 3. Connect the jumper from the positive battery post to UCM connector X-CN2A (Receptacle) pin 2 and X-CN2A (Receptacle) pin 3. Turn the ignition switch ON. Go to the fault code screen and refresh the display. The fault code should no longer be active. A. The fault code is not longer active. There is a problem in the wiring from between splice SP-152 and the UCM connector. Repair as required. Return to step 1 to confirm elimination of the fault. B. The fault code is still active. There is a problem with UCM. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. Wiring harnesses - Electrical schematic sheet 20 SH20-UNIVERSAL CONTROL MODULE (55.100.DP-C.20.E.20) Wiring harnesses - Electrical schematic sheet 03 SH03-ACCESSORY POWER DISTRIBUTION (55.100.DP-C.20.E.03)
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1912 - VCM - Rail 12VM - Left And Right Brake Lights And Aux Extend Input Power Off SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Context: The UCM has sensed that the voltage on X-CN1B (Receptacle) pin 31 and X-CN1B (Receptacle) pin 32 is less than 9 V. Diagnostic Trouble Code 1912 – VCM - Rail 12VM - Left And Right Brake Lights And Aux Extend Input Power Off has an error priority of Amber. Auxiliary functions are disabled while Diagnostic Trouble Code 1912 – VCM - Rail 12VM - Left And Right Brake Lights And Aux Extend Input Power Off is active. Cause: The UCM has sensed that the voltage on X-CN1B (Receptacle) pin 31 and X-CN1B (Receptacle) pin 32 is less than 9 V. The fault is active while the ignition is ON, the engine is not cranking, and Diagnostic Code 1903 – VCM VCM Supply Voltage Below Operational Limit is not active. Possible failure modes: 1. Fuse F-015 is blown or missing. 2. An open circuit in the wiring. 3. A failure of the UCM. 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 machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 1912 – VCM - Rail 12VM - Left And Right Brake Lights And Aux Extend Input Power Off is recorded again. Go to step 2. 2. Verify the harness is not damaged. Turn the ignition switch OFF. Inspect the UCM connections and the accessory power distribution fuse block #1 connections. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the UCM connector X-CN1B (Receptacle) to the accessory power distribution fuse block #1. Verify that the harness is free of damage, corrosion, abrasion, and incorrect attachment. A. The wiring 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. Return to step 1 to confirm elimination of fault. 3. Measure the voltage at the fuse. Turn the ignition switch ON. 48068130 29/01/2018
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Measure voltage between the accessory power distribution fuse block #1 X-FUSE1 (Receptacle) pin 25 and chassis ground. The voltage should be approximately 12 V. A. The voltage is between 9 V and 14.8 V. Go to step 4. B. The voltage is less than 9 V. Go to step 5. 4. Test the UCM connection. Turn the ignition switch OFF. Fabricate a jumper wire that will connect from the positive battery post to UCM connector X-CN1B (Receptacle) pin 31 and X-CN1B (Receptacle) pin 32. Connect the jumper from the positive battery post to UCM connector X-CN1B (Receptacle) pin 31 and X-CN1B (Receptacle) pin 32. Turn the ignition switch ON. Go to the fault code screen and refresh the display. The fault code should no longer be active. A. The fault code is not longer active. There is a problem in the wiring between fuse F-015 and the UCM connector. Check splice SP-113 and the associated wiring. Repair as required. Return to step 1 to confirm elimination of the fault. B. The fault code is still active. There is a problem with UCM. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. 5. Measure the voltage at the fuse. Turn the ignition switch ON. Measure voltage between the accessory power distribution fuse block #1 X-FUSE1 (Receptacle) pin 31 and chassis ground. The voltage should be approximately 12 V. A. The voltage is between 9 V and 14.8 V. Replace the fuse. Return to step 1 to confirm elimination of the fault. B. The voltage is less than 9 V. There is a problem in the wiring between the EH control relay and the fuse. Check splice SP-119 and the associated wiring. Repair as required. Return to step 1 to confirm elimination of the fault. Wiring harnesses - Electrical schematic sheet 20 SH20-UNIVERSAL CONTROL MODULE (55.100.DP-C.20.E.20) Wiring harnesses - Electrical schematic sheet 03 SH03-ACCESSORY POWER DISTRIBUTION (55.100.DP-C.20.E.03)
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1913 - VCM - Rail 12VS1 - Bucket Curl Input Power Off SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Context: The UCM has sensed that the voltage on X-CN3B (Receptacle) pin 8 and X-CN3B (Receptacle) pin 9 is less than 9 V. Diagnostic Trouble Code 1913 – VCM - Rail 12VS1 - Bucket Curl Input Power Off has an error priority of Red. Bucket functions are disabled while Diagnostic Trouble Code 1913 – VCM - Rail 12VS1 - Bucket Curl Input Power Off is active. Cause: The UCM has sensed that the voltage on X-CN3B (Receptacle) pin 8 and X-CN3B (Receptacle) pin 9 is less than 9 V. The fault is active while the ignition is ON, the engine is not cranking, and Diagnostic Code 1903 – VCM - VCM Supply Voltage Below Operational Limit is not active. Possible failure modes: 1. An open circuit in the wiring. 2. A failure of the UCM. 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 machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 1913 – VCM - Rail 12VS1 - Bucket Curl Input Power Off is recorded again. Go to step 2. C. Fault code 1913 – VCM - Rail 12VS1 - Bucket Curl Input Power Off is recorded along with fault code 1908 – VCM - Rail 12VF2 - Bucket Extend Input Power Off. Check Fuse F-019. Check splice SP-111. Repair as required. Return to step 1 to confirm elimination of the fault. 2. Verify the harness is not damaged. Turn the ignition switch OFF. Inspect the UCM connections and the accessory power distribution fuse block #1 connections. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the UCM connector X-CN3B (Receptacle) to the accessory power distribution fuse block #1. Verify that the harness is free of damage, corrosion, abrasion, and incorrect attachment. A. The wiring 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. Return to step 1 to confirm elimination of fault. 3. Test the UCM connection. Turn the ignition switch OFF.
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Fabricate a jumper wire that will connect from the positive battery post to UCM connector X-CN3B (Receptacle) pin 8 and X-CN3B (Receptacle) pin 9. Connect the jumper from the positive battery post to UCM connector X-CN3B (Receptacle) pin 8 and X-CN3B (Receptacle) pin 9. Turn the ignition switch ON. Go to the fault code screen and refresh the display. The fault code should no longer be active. A. The fault code is not longer active. There is a problem in the wiring from between splice SP-111 and the UCM connector. Repair as required. Return to step 1 to confirm elimination of the fault. B. The fault code is still active. There is a problem with UCM. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. Wiring harnesses - Electrical schematic sheet 21 SH21-UNIVERSAL CONTROL MODULE (55.100.DP-C.20.E.21) Wiring harnesses - Electrical schematic sheet 03 SH03-ACCESSORY POWER DISTRIBUTION (55.100.DP-C.20.E.03)
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1914 - VCM - Rail 12VS2 - Backup Alarm Input Power Off SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Context: The UCM has sensed that the voltage on X-CN3B (Receptacle) pin 3 is less than 9 V. Diagnostic Trouble Code 1914 – VCM - Rail 12VS2 - Backup Alarm Input Power Off has an error priority of Amber. This an informational fault code and no functions are disabled while Diagnostic Trouble Code 1914 – VCM - Rail 12VS2 - Backup Alarm Input Power Off is active. Cause: The UCM has sensed that the voltage on X-CN3B (Receptacle) pin 3 is less than 9 V. The fault is active while the ignition is ON, the engine is not cranking, and Diagnostic Code 1903 – VCM - VCM Supply Voltage Below Operational Limit is not active. Possible failure modes: 1. Fuse F-007 is blown or missing. 2. An open circuit in the wiring. 3. A failure of the UCM. 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 machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 1914 – VCM - Rail 12VS2 - Backup Alarm Input Power Off is recorded again. Go to step 2. 2. Verify the harness is not damaged. Turn the ignition switch OFF. Inspect the UCM connections and the main power distribution fuse block #1 connections. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the UCM connector X-CN3B (Receptacle) to the main power distribution fuse block #1. Verify that the harness is free of damage, corrosion, abrasion, and incorrect attachment. A. The wiring 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. Return to step 1 to confirm elimination of fault. 3. Measure the voltage at the fuse. Turn the ignition switch ON. Measure voltage between the main power distribution fuse block X-FUSE1 (Receptacle) pin 28 and chassis ground. The voltage should be approximately 12 V.
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A. The voltage is between 9 V and 14.8 V. Go to step 4. B. The voltage is less than 9 V. Go to step 5. 4. Test the UCM connection. Turn the ignition switch OFF. Fabricate a jumper wire that will connect from the positive battery post to UCM connector X-CN3B (Receptacle) pin 3. Connect the jumper from the positive battery post to UCM connector X-CN3B (Receptacle) pin 3. Turn the ignition switch ON. Go to the fault code screen and refresh the display. The fault code should no longer be active. A. The fault code is not longer active. There is a problem in the wiring between fuse F-007 and the UCM connector. Repair as required. Return to step 1 to confirm elimination of the fault. B. The fault code is still active. There is a problem with UCM. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. 5. Measure the voltage at the fuse. Turn the ignition switch ON. Measure voltage between the main power distribution fuse block X-FUSE1 (Receptacle) pin 34 and chassis ground. The voltage should be approximately 12 V. A. The voltage is between 9 V and 14.8 V. Replace the fuse. Return to step 1 to confirm elimination of the fault. B. The voltage is less than 9 V. There is a problem in the wiring between the EH control relay and the fuse. Check splice SP-119 and the associated wiring. Repair as required. Return to step 1 to confirm elimination of the fault. Wiring harnesses - Electrical schematic sheet 21 SH21-UNIVERSAL CONTROL MODULE (55.100.DP-C.20.E.21) Wiring harnesses - Electrical schematic sheet 02 SH02-MAIN POWER DISTRIBUTION (55.100.DP-C.20.E.02)
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1915 - VCM - Rail 12VT1 - Two Speed Input Power Off SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Context: The UCM has sensed that the voltage on X-CN3A (Receptacle) pin 7 and X-CN3A (Receptacle) pin 13 is less than 9 V. Diagnostic Trouble Code 1915 – VCM - Rail 12VT1 - Two Speed Input Power Off has an error priority of Amber. There are no restrictions while Diagnostic Trouble Code 1915 – VCM - Rail 12VT1 - Two Speed Input Power Off is active. Cause: The UCM has sensed that the voltage on X-CN3A (Receptacle) pin 7 and X-CN3A (Receptacle) pin 13 is less than 9 V. The fault is active while the ignition is ON, the engine is not cranking, and Diagnostic Code 1903 – VCM - VCM Supply Voltage Below Operational Limit is not active. Possible failure modes: 1. Fuse F-027 is blown or missing. 2. An open circuit in the wiring. 3. A failure of the UCM. Solution: 1. Verify that the fault code is active. Connect the Electronic Service Tool to the service tool connector. To check for fault codes: Start and operate the machine. A. Fault code is not recorded again. OK to return the machine to service. B. Fault code 1915 – VCM - Rail 12VT1 - Two Speed Input Power Off is recorded again. Go to step 2. 2. Verify the harness is not damaged. Turn the ignition switch OFF. Inspect the UCM connections and the accessory power distribution fuse block #2 connections. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the UCM connector X-CN3A (Receptacle) to the accessory power distribution fuse block #2. Verify that the harness is free of damage, corrosion, abrasion, and incorrect attachment. A. The wiring 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. Return to step 1 to confirm elimination of fault. 3. Measure the voltage at the fuse. Turn the ignition switch ON. Measure voltage between the accessory power distribution fuse block X-FUSE2 (Receptacle) pin 49 and chassis ground. The voltage should be approximately 12 V.
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A. The voltage is between 9 V and 14.8 V. Go to step 4. B. The voltage is less than 9 V. Go to step 5. 4. Test the UCM connection. Turn the ignition switch OFF. Fabricate a jumper wire that will connect from the positive battery post to UCM connector X-CN3A (Receptacle) pin 7 and X-CN3A (Receptacle) pin 13. Connect the jumper from the positive battery post to UCM connector X-CN3A (Receptacle) pin 7 and X-CN3A (Receptacle) pin 13. Turn the ignition switch ON. Go to the fault code screen and refresh the display. The fault code should no longer be active. A. The fault code is not longer active. There is a problem in the wiring between fuse F-027 and the UCM connector. Check splice SP-115 and the associated wiring. Repair as required. Return to step 1 to confirm elimination of the fault. B. The fault code is still active. There is a problem with UCM. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. 5. Measure the voltage at the fuse. Turn the ignition switch ON. Measure voltage between the accessory power distribution fuse block X-FUSE2 (Receptacle) pin 55 and chassis ground. The voltage should be approximately 12 V. A. The voltage is between 9 V and 14.8 V. Replace the fuse. Return to step 1 to confirm elimination of the fault. B. The voltage is less than 9 V. There is a problem in the wiring between the EH control relay and the fuse. Check splice SP-119 and the associated wiring. Repair as required. Return to step 1 to confirm elimination of the fault. Wiring harnesses - Electrical schematic sheet 21 SH21-UNIVERSAL CONTROL MODULE (55.100.DP-C.20.E.21) Wiring harnesses - Electrical schematic sheet 03 SH03-ACCESSORY POWER DISTRIBUTION (55.100.DP-C.20.E.03)
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1916 - VCM - Rail 12VU1 - Right And Left Pumps Forward Input Power Off SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Context: The UCM has sensed that the voltage on X-CN3A (Receptacle) pin 21 is less than 9 V. Diagnostic Trouble Code 1916 – VCM - Rail 12VU1 - Right And Left Pumps Forward Input Power Off has an error priority of Red. The forward ground drive functions are disabled while Diagnostic Trouble Code 1916 – VCM - Rail 12VU1 - Right And Left Pumps Forward Input Power Off is active. Cause: The UCM has sensed that the voltage on X-CN3A (Receptacle) pin 21 is less than 9 V. The fault is active while the ignition is ON, the engine is not cranking, and Diagnostic Code 1903 – VCM - VCM Supply Voltage Below Operational Limit is not active. Possible failure modes: 1. Fuse F-021 is blown or missing. 2. An open circuit in the wiring. 3. A failure of the UCM. 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. OK to return the machine to service. B. Fault code 1916 – VCM - Rail 12VU1 - Right And Left Pumps Forward Input Power Off is recorded again. Go to step 2. 2. Verify the harness is not damaged. Turn the ignition switch OFF. Verify the connections to the UCM are tight and secure. Verify the harness is free of damage, abrasion, corrosion, and incorrect attachment. A. The wiring 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. Return to step 1 to confirm elimination of fault. 3. Measure the voltage at the fuse. Turn the ignition switch ON. Measure voltage between the accessory power distribution fuse block X-FUSE1 (Receptacle) pin 14 and chassis ground. The voltage should be approximately 12 V. 48068130 29/01/2018
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A. The voltage is between 9 V and 14.8 V. Go to step 4. B. The voltage is less than 9 V. Go to step 5. 4. Test the UCM connection. Turn the ignition switch OFF. Fabricate a jumper wire that will connect from the positive battery post to UCM connector X-CN3A (Receptacle) pin 21. Connect the jumper from the positive battery post to UCM connector X-CN3A (Receptacle) pin 21. Turn the ignition switch ON. Go to the fault code screen and refresh the display. The fault code should no longer be active. A. The fault code is not longer active. There is a problem in the wiring between fuse F-021 and the UCM connector. Repair as required. Return to step 1 to confirm elimination of the fault. B. The fault code is still active. There is a problem with UCM. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. 5. Measure the voltage at the fuse. Turn the ignition switch ON. Measure voltage between the accessory power distribution fuse block X-FUSE1 (Receptacle) pin 20 and chassis ground. The voltage should be approximately 12 V. A. The voltage is between 9 V and 14.8 V. Replace the fuse. Return to step 1 to confirm elimination of the fault. B. The voltage is less than 9 V. There is a problem in the wiring between the EH control relay and the fuse. Check splice SP-119 and the associated wiring. Repair as required. Return to step 1 to confirm elimination of the fault. Wiring harnesses - Electrical schematic sheet 21 SH21-UNIVERSAL CONTROL MODULE (55.100.DP-C.20.E.21) Wiring harnesses - Electrical schematic sheet 03 SH03-ACCESSORY POWER DISTRIBUTION (55.100.DP-C.20.E.03)
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1917 - UCM - Rail 12VU2: Park Brake Solenoid Input Power Off SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Context: The UCM has sensed that the voltage on X-CN3A (Receptacle) pin 2 and X-CN3A (Receptacle) pin 3 is less than 9 V. Diagnostic Trouble Code 1917 – UCM - Rail 12VU2: Park Brake Solenoid Input Power Off has an error priority of Red. Ground drive is disabled while Diagnostic Trouble Code 1917 – UCM - Rail 12VU2: Park Brake Solenoid Input Power Off is active. Cause: The UCM has sensed that the voltage on X-CN3A (Receptacle) pin 2 and X-CN3A (Receptacle) pin 3 is less than 9 V. The fault is active while the ignition is ON, the engine is not cranking, and Diagnostic Code 1903 – VCM - VCM Supply Voltage Below Operational Limit is not active. Possible failure modes: 1. Fuse F-016 is blown or missing. 2. An open circuit in the wiring. 3. A failure of the UCM. Solution: 1. Verify that the fault code is active. Connect the Electronic Service Tool to the service tool connector. To check for fault codes: Start and operate the machine. A. Fault code is not recorded again. OK to return the machine to service. B. Fault code 1917 – UCM - Rail 12VU2: Park Brake Solenoid Input Power Off is recorded again. Go to step 2. 2. Verify the harness is not damaged. Turn the ignition switch OFF. Inspect the UCM connections and the accessory power distribution fuse block #1 X-FUSE1 (Receptacle) connections. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the UCM connector to the accessory power distribution fuse block #1 X-FUSE1 (Receptacle) . Verify that the harness is free of damage, corrosion, abrasion, and incorrect attachment. A. The wiring 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. Return to step 1 to confirm elimination of fault. 3. Measure the voltage at the fuse. Turn the ignition switch ON. Measure voltage between the accessory power distribution fuse block X-FUSE1 (Receptacle) pin 13 and chassis ground. The voltage should be approximately 12 V. 48068130 29/01/2018
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A. The voltage is between 9 V and 14.8 V. Go to step 4. B. The voltage is less than 9 V. Go to step 5. 4. Test the UCM connection. Turn the ignition switch OFF. Fabricate a jumper wire that will connect from the positive battery post to UCM connector X-CN3A (Receptacle) pin 2 and X-CN3A (Receptacle) pin 3. Connect the jumper from the positive battery post to UCM connector X-CN3A (Receptacle) pin 2 and X-CN3A (Receptacle) pin 3. Turn the ignition switch ON. Go to the fault code screen and refresh the display. The fault code should no longer be active. A. The fault code is not longer active. There is a problem in the wiring between fuse F-016 and the UCM connector. Check splice SP-114 and the associated wiring. Repair as required. Return to step 1 to confirm elimination of the fault. B. The fault code is still active. There is a problem with UCM. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. 5. Measure the voltage at the fuse. Turn the ignition switch ON. Measure voltage between the accessory power distribution fuse block X-FUSE1 (Receptacle) pin 19 and chassis ground. The voltage should be approximately 12 V. A. The voltage is between 9 V and 14.8 V. Replace the fuse. Return to step 1 to confirm elimination of the fault. B. The voltage is less than 9 V. There is a problem in the wiring between the EH control relay and the fuse. Check splice SP-119 and the associated wiring. Repair as required. Return to step 1 to confirm elimination of the fault. Wiring harnesses - Electrical schematic sheet 21 SH21-UNIVERSAL CONTROL MODULE (55.100.DP-C.20.E.21) Wiring harnesses - Electrical schematic sheet 03 SH03-ACCESSORY POWER DISTRIBUTION (55.100.DP-C.20.E.03)
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3007 (DTC 131-03) - Coolant temperature : SRC High for Engine coolant temperature (down stream) Context: The Engine Control Unit (ECU) monitors the engine coolant temperature sensor signal circuit. If the ECU 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. Possible failure modes: 1. Faulty engine coolant temperature sensor wiring, short to a voltage source. 2. Faulty engine coolant temperature sensor, internal failure. 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 6. 2. Check the coolant temperature sensor wiring for a short to a voltage source. Disconnect the engine harness (EN) from the coolant temperature sensor. With the key in the OFF position, use a multimeter to perform the following voltage check on the engine harness side : From Coolant temperature sensor connector pin 1
To Chassis ground
Value There should be no voltage.
With the key in the ON position, use a multimeter to perform the following voltage check on the engine harness side : From Coolant temperature sensor connector pin 1
To Chassis ground
Value There should be less than 5.5 V.
A. If the specified values are not measured, then there is a short circuit to another voltage source in the coolant temperature sensor wiring. Locate and repair the shorted conductor. Repair or replace the harness as required. B. If the specified values are not measured, then leave the coolant temperature sensor disconnected and continue to step 3. 3. Check the coolant temperature sensor engine harness (EN) wiring for a short circuit. Disconnect the vehicle harness (VE) from the engine interface at connector X-017. With the key in the OFF position, use a multimeter to perform the following continuity check on the engine harness (EN) side :
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From Coolant temperature sensor connector pin 1 Coolant temperature sensor connector pin 2 X-017 (Receptacle) pin 14 X-017 (Receptacle) pin 13
To X-017 (Receptacle) pin 14
Value There should be continuity.
X-017 (Receptacle) pin 13
There should be continuity.
All pins in connector X-017 All pins in connector X-017
There should be no continuity. There should be no continuity.
A. If the specified values are measured, leave the coolant temperature sensor disconnected. Leave the engine interface connector X-017 disconnected. Continue to step 4. B. If the specified values are not measured, there is an open or short circuit condition in the wiring. Locate and repair the broken or shorted conductor. 4. Check the coolant temperature sensor vehicle harness (VE) wiring for a short circuit. Disconnect the vehicle harness (VE) from the ECU at connector X-016. With the key in the OFF position, use a multimeter to perform the following continuity check on the vehicle harness (VE) side : From X-017 (Receptacle) pin 14 X-017 (Receptacle) pin 13 X-017 (Receptacle) pin 14 X-017 (Receptacle) pin 13
To X-016 (Receptacle) pin 57 X-016 (Receptacle) pin 58 All pins in connector X-017 All pins in connector X-017
Value There should be continuity. There should be continuity. There should be no continuity. There should be no continuity.
A. If the specified values are measured, then continue to step 5. B. If the specified values are not measured, then there is a problem in the coolant temperature sensor wiring in the vehicle harness (VE). Locate and repair the shorted or broken conductor. Repair or replace the harness as required. 5. Replace the engine coolant temperature sensor. Use the EST to verify the status of the this fault. A. If the fault is no longer active, return the machine to service. B. If the fault is still active, check the ECU for the appropriate software and re-flash, if necessary. 6. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals, or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 07 SH07-ENGINE F5C T4 (55.100.DP-C.20.E.07) Wiring harnesses - Electrical schematic sheet 11 SH11-ENGINE F5C T4 (55.100.DP-C.20.E.11)
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3008 (DTC 131-04) - Coolant temperature : SRC low for Engine coolant temperature (down stream) 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, then this fault will occur. If this fault is active, then 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 198.00 mV. Possible failure modes: 1. Faulty engine coolant temperature sensor wiring, short circuit to ground. 2. Faulty engine coolant temperature sensor, internal failure. 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, then the fault may be intermittent and not currently active. Continue with step 5. 2. Check the coolant temperature sensor engine harness (EN) wiring for a short circuit to ground. Disconnect the engine harness (EN) from the coolant temperature sensor. Disconnect the vehicle harness (VE) from the engine interface at connector X-017. With the key in the OFF position, use a multimeter to perform the following continuity check on the engine harness side : To Coolant temperature sensor connector pin 1 Coolant temperature sensor connector pin 1 X-017 (Receptacle) pin 14
From Coolant temperature sensor connector pin 2 Chassis ground
Value There should be no continuity. There should be no continuity.
All pins in connector X-017
There should be no continuity.
A. If there is no continuity, then the coolant temperature sensor disconnected. Leave connector X-017 connector disconnected. 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 shorted conductor. Repair or replace the harness as required. 3. Check the coolant temperature sensor vehicle harness (VE) wiring for a short circuit to ground. Disconnect the vehicle harness (VE) from the ECU at connector X-016. With the key in the OFF position, use a multimeter to perform the following continuity check on the vehicle harness (VE) side : From X-017 (Receptacle) pin 14 X-016 (Receptacle) pin 57
To All pins in connector X-017 All pins in connector X-016
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Value There should be no continuity. There should be no continuity.
Electrical systems - FAULT CODES
A. If there is no continuity, then leave the coolant temperature sensor disconnected. Continue to step 4. B. If there is continuity, then there is a short circuit in the coolant temperature sensor vehicle harness (VE) wiring. Locate and repair the shorted or broken conductor. Repair or replace the harness as required. 4. Replace the engine coolant temperature sensor. Use the EST to verify the status of the this fault. A. If the fault is no longer active, return the machine to service. B. If the fault is still active, check the ECU for the appropriate software and re-flash, if necessary. 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. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 07 SH07-ENGINE F5C T4 (55.100.DP-C.20.E.07) Wiring harnesses - Electrical schematic sheet 11 SH11-ENGINE F5C T4 (55.100.DP-C.20.E.11)
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3010 (DTC 133-03) - Intake air temperature sensor : Diagnostic fault check for SRC high in engine inlet valve air temperature upstream sensor 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. Possible failure modes: 1. Faulty intake manifold temperature sensor wiring, short circuit to another voltage source. 2. Faulty intake manifold temperature sensor wiring, open circuit. 3. Faulty intake manifold temperature sensor, internal failure. 4. 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, then the fault may be intermittent and not currently active. Continue with step 7. 2. Check the intake manifold temperature sensor wiring for a short circuit to battery. 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 voltage check on the engine harness (EN) side : From To Intake manifold temperature sensor Chassis ground connector pin 1
Value There should be no voltage.
With the key in the ON position, use a multimeter to perform the following voltage check on the engine harness (EN) side : From To Intake manifold temperature sensor Chassis ground connector pin 1
Value There should be less than 5.5 V.
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 harness as required. B. If the specified values are measured, then leave the intake manifold temperature sensor disconnected. Continue to step 3. 3. Check the intake manifold temperature sensor wiring for an open circuit. Disconnect the vehicle harness (VE) from the engine interface at connector X-017. Disconnect the vehicle harness (VE) from the ECU at connector X-016.
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With the key in the OFF position, use a multimeter to perform the following continuity check for an open circuit on the engine harness (EN) side : From To Intake manifold temperature sensor X-017 (Receptacle) pin 20 connector pin 1 Intake manifold temperature sensor X-017 (Receptacle) pin 19 connector pin 2 NOTE: Wiggle the harness during the reveal an intermittent condition.
Value There should be continuity. There should be continuity.
With the key in the OFF position, use a multimeter to perform the following continuity check for an open circuit on the vehicle harness (VE) side : From To Value There should be continuity. X-017 (Receptacle) pin 20 X-016 (Receptacle) pin 55 There should be continuity. X-017 (Receptacle) pin 19 X-016 (Receptacle) pin 25 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 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-017 and X-016 disconnected and continue to step 4. 4. Check the intake manifold temperature sensor engine harness (EN) wiring for a short circuit. With the key in the OFF position, use a multimeter to perform the following continuity check on the engine harness (EN) side : From X-017 (Receptacle) pin 20
To All pins in connector X-017
Value There should be no continuity.
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. With the key in the OFF position, use a multimeter to perform the following continuity check on the vehicle harness (VE) side : From X-017 (Receptacle) pin 20 X-016 (Receptacle) pin 55
To All pins in connector X-017 All pins in connector X-016
Value There should be no continuity. There should be no continuity.
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. 6. Replace the intake manifold temperature sensor. Use the Electronic Service Tool (EST) to check the status of this fault. A. If the fault is no longer active, return the machine to service. B. If the fault is still active, check the ECU for the appropriate software and re-flash, if necessary. 7. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals, or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. 48068130 29/01/2018
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B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 07 SH07-ENGINE F5C T4 (55.100.DP-C.20.E.07) Wiring harnesses - Electrical schematic sheet 11 SH11-ENGINE F5C T4 (55.100.DP-C.20.E.11)
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3011 (DTC 133-04) - Intake air temperature sensor : Diagnostic fault check for SRC low in engine inlet valve air temperature upstream sensor 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. Possible failure modes: 1. Faulty intake manifold temperature sensor wiring, short circuit to ground. 2. Faulty intake manifold temperature sensor, internal failure. 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, then continue with step 2. 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. Check the intake manifold temperature sensor engine harness (EN) wiring. Disconnect the engine harness (EN) from the intake manifold temperature sensor. Disconnect the vehicle harness (VE) from the engine interface at connector X-017. With the key in the OFF position, use a multimeter to perform the following continuity check on the engine harness (EN) side : From Intake manifold temperature sensor connector pin 1 Intake manifold temperature sensor connector pin 1 X-017 (Receptacle) pin 20
To Value Intake manifold temperature sensor There should be no continuity. connector pin 2 There should be no continuity. Chassis ground All pins in connector X-017
There should be no continuity.
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 leave the Iintake manifold temperature sensor disconnected. Leave connector X-017 disconnected. Continue to step 3. 3. Check the intake manifold temperature sensor vehicle harness (VE) wiring. Disconnect the vehicle harness (VE) from the ECU at connector X-016. With the key in the OFF position, use a multimeter to perform the following continuity check on the vehicle harness (VE) side : From X-017 (Receptacle) pin 20 X-017 (Receptacle) pin 20 X-016 (Receptacle) pin 55
To Chassis ground All pins in connector X-017 All pins in connector X-9121 48068130 29/01/2018
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Value There should be no continuity. There should be no continuity. There should be no continuity.
Electrical systems - FAULT CODES
A. If there is continuity, 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 leave the intake manifold temperature sensor disconnected and continue to step 4. 4. Replace the intake manifold temperature sensor. Use the Electronic Service Tool (EST) to check the status of this fault. 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. 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. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 07 SH07-ENGINE F5C T4 (55.100.DP-C.20.E.07) Wiring harnesses - Electrical schematic sheet 11 SH11-ENGINE F5C T4 (55.100.DP-C.20.E.11)
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3015 (DTC 135-03) - Fuel temperature Sensor : Signal Range check high for fuel temperature sensor 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, 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). Cause: The fuel temperature sensor signal circuit voltage is greater than 4.93 V. Possible failure modes: 1. Faulty fuel temperature sensor wiring, short circuit to another voltage source. 2. Faulty fuel temperature sensor wiring, open circuit. 3. Faulty fuel temperature sensor, internal failure. 4. 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, then continue with step 2. 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 8. 2. Check the fuel temperature sensor for an internal failure. Disconnect the engine harness (EN) from the fuel temperature sensor at connector X-9005. Use a multimeter to measure the resistance of the fuel temperature sensor B-9002 on the sensor pins : From
Value At approximately 20.0 °C (68.0 °F), there should be between 2351 – 2648 Ω. NOTE: The fuel temperature sensor B-9002 is a Negative Temperature Coefficient (NTC) thermistor. The thermistor’s conductivity increases with increasing temperature and resistance decreases with increasing temperature. X-9005 pin 1
To
X-9005 pin 2
A. If there is a nominal resistance value, e.g. greater than 100 Ω, leave connector X-9005 disconnected and continue to step 3. B. If there is not a nominal resistance value, e.g. 0 Ω, the fuel temperature sensor B-9002 has failed. Replace the fuel temperature sensor B-9002. 3. Check the fuel temperature sensor B-9002 wiring for a short to battery. With the key in the OFF position, use the a multimeter to perform the following voltage check on the engine harness (EN) side : From X-9005 pin 1
To Chassis ground
Value There should be no voltage.
With the key in the ON position, use the a multimeter to perform the following voltage check on the engine harness (EN) side : From X-9005 pin 1
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Value There should be less than 5.5 V.
Electrical systems - FAULT CODES
A. If the specified values are measured, leave connector X-9005 disconnected and continue to step 4. B. If the specified values are not measured, there is a short to battery or switched battery in the fuel temperature sensor B-9002 wiring. Use the appropriate service manual, if necessary, to locate and repair the failed conductor. 4. Check the fuel temperature sensor engine harness (EN) wiring for an open circuit condition. Disconnect the vehicle harness (VE) from the engine interface at connector X-017. With the key in the OFF position, use the a multimeter to perform the following continuity check on the engine harness (EN) side : From To Fuel temperature sensor connector X-017 (Receptacle) pin 16 pin 1 Fuel temperature sensor connector X-017 (Receptacle) pin 15 pin 2
Value There should be continuity. There should be continuity.
A. If there is continuity, then leave the fuel temperature sensor disconnected. Leave connector X-017 disconnected. Continue to step 5. B. If there is no continuity, then there is an open circuit in the fuel temperature sensor wiring in the engine harness (EN). Locate and repair the broken conductor. Repair or replace the harness as required. 5. Check the fuel temperature sensor engine harness (EN) wiring for a short circuit. With the key in the OFF position, use the a multimeter to perform the following continuity check on the engine harness (EN) side : From X-017 (Receptacle) pin 16 X-017 (Receptacle) pin 15
To All pins in connector X-017 All pins in connector X-017
Value There should be no continuity. There should be no continuity.
A. 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 shorted conductor. Repair or replace the harness as required. B. If there is no continuity, then leave the fuel temperature sensor disconnected. Leave connector X-017 disconnected. Continue to step 6. 6. Check the fuel temperature sensor vehicle harness (VE) wiring for an open circuit. Disconnect the vehicle harness (VE) from the ECU at connector X-016. With the key in the OFF position, use the a multimeter to perform the following continuity check on the vehicle harness (VE) side : From X-017 (Receptacle) pin 16 X-017 (Receptacle) pin 15
To X-016 (Receptacle) pin 38 X-016 (Receptacle) pin 23
Value There should be continuity. There should be continuity.
A. If there is continuity, then leave connectors X-016 and X-017 disconnected and continue to step 7. B. If there is no continuity, then there is an open circuit in the fuel temperature sensor wiring in the vehicle harness (EN). Locate and repair the broken conductor. Repair or replace the harness as required. 7. Check the fuel temperature sensor vehicle harness (VE) wiring for a short circuit. With the key in the OFF position, use the a multimeter to perform the following continuity check on the vehicle harness (EN) side : From X-017 (Receptacle) pin 16 X-017 (Receptacle) pin 15 X-016 (Receptacle) pin 38 X-016 (Receptacle) pin 23
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Value There should be no continuity. There should be no continuity. There should be no continuity. There should be no continuity.
Electrical systems - FAULT CODES
A. If there is continuity, there is a short circuit in the fuel 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 check the ECU for the appropriate software and re-flash, if necessary. 8. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals, or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 07 SH07-ENGINE F5C T4 (55.100.DP-C.20.E.07) Wiring harnesses - Electrical schematic sheet 11 SH11-ENGINE F5C T4 (55.100.DP-C.20.E.11)
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3016 (DTC 135-04) - Fuel temperature Sensor : Signal Range check low for fuel temperature sensor Context: The Engine Control Unit (ECU) monitors the fuel temperature sensor signal circuit voltage. If the ECU detects a voltage less than 198.00 mV 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). Cause: The fuel temperature sensor signal circuit voltage is less than 198.00 mV. Possible failure modes: 1. Faulty fuel temperature sensor wiring, short circuit to ground. 2. Faulty fuel temperature sensor, internal failure. 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 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 Fuel temperature sensor pin 1
To Fuel temperature sensor pin 2
Value 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 conductivity increases with increasing temperature and resistance decreases with increasing temperature. A. If the resistance is greater than 100 Ω, then leave the fuel temperature sensor disconnected and continue to step 3. B. If the resistance is 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. Disconnect the vehicle harness (VE) from the engine interface at connector X-017. With the key in the OFF position, use the a multimeter to perform the following continuity checks for a short circuit to ground on the engine harness (EN) side : From Fuel temperature sensor connector pin 1 Fuel temperature sensor connector pin 1 X-017 (Receptacle) pin 16
To Value Fuel temperature sensor connector There should be no continuity. pin 2 There should be no continuity. Chassis ground All pins in connector X-017
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There should be no continuity.
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A. If there is no continuity, then leave the fuel temperature sensor disconnected. Leave connector X-017 disconnected. Continue to step 4. 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. Repair or replace the harness as required. 4. Check the fuel temperature sensor vehicle harness (VE) wiring for a short circuit to ground. Disconnect the vehicle harness (VE) from the ECU at connector X-016. With the key in the OFF position use the a multimeter to check for a short circuit to ground on the vehicle harness (VE) side : From X-017 (Receptacle) pin 16 X-017 (Receptacle) pin 16 X-016 (Receptacle) pin 38
To X-017 (Receptacle) pin 15 Chassis ground All pins in connector X-016
Value There should be no continuity. There should be no continuity. There should be no continuity.
A. If the specified values are not measured, 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. 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. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 07 SH07-ENGINE F5C T4 (55.100.DP-C.20.E.07) Wiring harnesses - Electrical schematic sheet 11 SH11-ENGINE F5C T4 (55.100.DP-C.20.E.11)
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3019 (DTC 134-03) - Intake air pressure sensor : Diagnostic fault check for SRC high in air pressure upstream of intake valve sensor Context: The Engine Control Unit (ECU) monitors the intake manifold pressure sensor . If the ECU determines that the intake manifold pressure sensor signal circuit voltage is greater than 4.92 V, then this fault will occur. If this fault is active, then the intake manifold pressure value will be frozen at the last valid value for a preliminary failure or jump to a fixed replacement value of 0.98 bar (14.21 psi) if the failure is validated. Cause: The ECU has determined that the intake manifold pressure sensor signal circuit voltage is greater than 4.92 V. Possible failure modes: 1. Faulty intake manifold pressure sensor wiring, short circuit to another voltage source. 2. Faulty intake manifold pressure sensor wiring, open circuit. 3. Faulty intake manifold pressure sensor, internal failure. 4. 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, then the fault may be intermittent and not currently active. Continue with step 7. 2. Check the intake manifold pressure sensor wiring for a short circuit to another voltage source. Disconnect the engine harness (EN) from the intake manifold pressure sensor. With the key in the OFF position, use a multimeter to perform the following voltage check on the engine harness side : From Intake manifold pressure sensor connector pin 4
To Chassis ground
Value There should be no voltage.
With the key in the ON position, use a multimeter to perform the following voltage check on the engine harness side : From Intake manifold pressure sensor connector pin 4
To Chassis ground
Value There should be less than 5.5 V.
A. If there is voltage, then there is a short circuit to battery or a short circuit switched battery in the intake manifold pressure sensor wiring. Locate and repair the shorted conductor. Repair or replace the harness as required. B. If there is no voltage, then leave the intake manifold pressure sensor disconnected. Continue to step 3. 3. Check the intake manifold pressure sensor wiring in the engine harness (EN) for an open circuit. Disconnect the vehicle harness (VE) from the engine interface connector X-017. With the key in the OFF position, use a multimeter to perform the following continuity check on the engine harness (EN) side :
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From To Value There should be continuity. Intake manifold pressure sensor X-017 (Receptacle) pin 18 connector pin 4 There should be continuity. Intake manifold pressure sensor X-017 (Receptacle) pin 17 connector pin 3 NOTE: Wiggle the harness during measurement to reveal an intermittent condition. Disconnect the vehicle harness (VE) from the ECU at connector X-016. 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 There should be continuity. X-017 (Receptacle) pin 18 X-016 (Receptacle) pin 40 There should be continuity. X-017 (Receptacle) pin 17 X-016 (Receptacle) pin 10 NOTE: Wiggle the harness during measurement to reveal an intermittent condition. A. If there is no continuity, then there is an open circuit in the intake manifold pressure 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 pressure sensor disconnected. Leave connectors X-017 and X-016 disconnected. Continue to step 4. 4. Check the intake manifold pressure sensor wiring in the engine harness (EN) for a short circuit to another voltage source. With the key in the OFF position, use a multimeter to perform the following continuity check on the engine harness (EN) side : From Intake manifold pressure sensor connector pin 4 X-017 (Receptacle) pin 18 X-017 (Receptacle) pin 17
To Intake manifold pressure sensor connector pin 3 All pins in connector X-017 All pins in connector X-017
Value There should be no continuity. There should be no continuity. There should be no continuity.
A. If there is continuity, then there is a short circuit in the intake manifold pressure 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 pressure sensor disconnected. Leave connectors X-017 and X-016 disconnected. Continue to step 5. 5. Check the intake manifold pressure sensor wiring in the vehicle harness (VE) for a short circuit. With the key in the OFF position, use a multimeter to perform the following continuity check on the vehicle harness (VE) side : From X-017 (Receptacle) pin 18 X-017 (Receptacle) pin 17 X-016 (Receptacle) pin 40 X-016 (Receptacle) pin 10
To All pins in connector X-017 All pins in connector X-017 All pins in connector X-016 All pins in connector X-016
Value There should be no continuity. There should be no continuity. There should be no continuity. There should be no continuity.
A. If there is continuity, then there is a short circuit in the intake manifold pressure 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 pressure sensor disconnected and continue to step 6. 6. Replace the intake manifold pressure sensor. Use the Electronic Service Tool (EST) to check the status of this fault, 3019 (DTC 134-03) â&#x20AC;&#x201C; Intake air pressure sensor : Diagnostic fault check for SRC high in air pressure upstream of intake valve sensor. A. If the fault is no longer active, return the machine to service.
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B. If the fault is still active, check the ECU for the appropriate software and re-flash, if necessary. 7. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals, or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 07 SH07-ENGINE F5C T4 (55.100.DP-C.20.E.07) Wiring harnesses - Electrical schematic sheet 11 SH11-ENGINE F5C T4 (55.100.DP-C.20.E.11)
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3024 (DTC 1EB-03) - Ambient pressure sensor : Signal Range Check High failure Context: The Engine Control Unit (ECU) monitors atmospheric pressure. The ECU performs a signal range check of the atmospheric pressure sensor value. If the ECU determines that the value is too high, this fault will occur. The atmospheric pressure sensor is internal to the ECU. 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 1EB-04) - Ambient pressure sensor : Signal Range Check low failure Context: The Engine Control Unit (ECU) monitors atmospheric pressure. The ECU performs a signal range check of the atmospheric pressure sensor value. If the ECU determines that the value is too low, this fault will occur. The atmospheric pressure sensor is internal to the ECU. 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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3027 (DTC 238-03) - Oil pressure sensor : 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 the off state to the on state when the oil pressure is between 0.6 â&#x20AC;&#x201C; 0.9 bar (8.7 â&#x20AC;&#x201C; 13.0 psi). If the oil pressure switch does not return to the 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 the off state. Possible failure modes: 1. Faulty oil pressure switch, failed internally. 2. Faulty oil pressure switch circuit wiring, open circuit. 3. Faulty ECU, software. Solution: 1. Verify that the fault is present and active. Use the Electronic Service Tool (EST) to check the status of this fault. A. If the fault is present and active, then continue with step 2. 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. 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 Oil pressure switch pin 1
To Chassis ground
Result There should be continuity.
A. If there is continuity, then leave the oil pressure switch disconnected. 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. Disconnect the vehicle harness (VE) from the ECU at connector X-016. Place a jumper wire between connector X-016 (Receptacle) pin 6 and chassis ground. Use a multimeter to check for continuity on the engine harness (EN) side : From To Oil pressure switch connector pin 1 Chassis ground
Result 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-016 disconnected. 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 condition. Disconnect the vehicle harness (VE) from the engine interface connector X-017. Use a multimeter to check for continuity on the vehicle harness (VE) side :
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From X-017 (Receptacle) pin 3
To Chassis ground
Result There should be continuity.
A. If there is continuity, then the open circuit is the engine harness (EN) between connector X-017 and the oil pressure switch connector. Locate and repair the broken conductor. Repair or replace the harness as required. B. If there is no continuity, then open circuit is in the vehicle harness (VE) between connector X-017 and connector X-016. Locate and repair the broken conductor. Repair or replace the harness as required. 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. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 07 SH07-ENGINE F5C T4 (55.100.DP-C.20.E.07) Wiring harnesses - Electrical schematic sheet 11 SH11-ENGINE F5C T4 (55.100.DP-C.20.E.11)
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3037 (DTC 134-04) - Intake air pressure sensor : Diagnostic fault check for SRC low in air pressure upstream of intake valve sensor Context: The Engine Control Unit (ECU) monitors the intake manifold pressure sensor. If the ECU determines that the intake manifold pressure sensor signal circuit voltage is less than 202.80 mV, then this fault will occur. If this fault is active, then the intake manifold pressure value will be frozen at the last valid value for a preliminary failure or jump to a fixed replacement value of 0.98 bar (14.21 psi) if the failure is validated. Cause: The ECU has determined that the intake manifold pressure sensor signal circuit voltage is less than 202.80 mV. Possible failure modes: 1. Faulty intake manifold pressure sensor wiring, short circuit to ground. 2. Faulty intake manifold pressure sensor, internal failure. 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, then continue with step 2. 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. Check the intake manifold pressure sensor wiring in the engine harness (EN) for a short circuit to ground. Disconnect the engine harness (EN) from the intake manifold pressure sensor. Disconnect the vehicle harness (VE) from the engine interface at connector X-017. With the key in the OFF position, use a multimeter to perform the following continuity check on the engine harness (EN) side : From Intake manifold pressure sensor connector pin 4 Intake manifold pressure sensor connector pin 4 X-017 (Receptacle) pin 18
To Chassis ground Intake manifold pressure sensor connector pin 1 All pins in connector X-017
Value There should be no continuity. There should be no continuity. There should be no continuity.
A. If there is continuity, then there is a short circuit in the intake manifold pressure 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 pressure sensor disconnected. Leave connector X-017 disconnected. Continue to step 3. 3. Check the intake manifold pressure sensor wiring in the vehicle harness (VE) for a short circuit to ground. Disconnect the vehicle harness from the ECU at connector X-016. With the key in the OFF position, use a multimeter to perform the following continuity check on the vehicle harness (VE) side : From X-017 (Receptacle) pin 18 X-017 (Receptacle) pin 18 X-016 (Receptacle) pin 40
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Value There should be no continuity. There should be no continuity. There should be no continuity.
Electrical systems - FAULT CODES
A. If there is continuity, then there is a short circuit in the intake manifold pressure 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 pressure sensor disconnected. Continue to step 4. 4. Replace the intake manifold pressure sensor. Use the Electronic Service Tool (EST) to check the status of this fault. 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. 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. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 07 SH07-ENGINE F5C T4 (55.100.DP-C.20.E.07) Wiring harnesses - Electrical schematic sheet 11 SH11-ENGINE F5C T4 (55.100.DP-C.20.E.11)
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3051 (DTC 126-03) - Battery voltage to engine controller - voltage too high Context: The Electronic Control Unit (ECU) monitors battery voltage. If the determines that battery voltage has exceeded 16.1 V, then this fault will occur. Cause: Battery voltage is greater than 16.1 V. Possible failure modes: 1. Faulty charging system. 2. 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, then continue with step 2. 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 4. 2. Check the battery voltage. The engine must be running. Use a multimeter to perform the following voltage check : From Battery (+) terminal
To Battery (â&#x20AC;&#x201C;) terminal
Value 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. 4. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals, or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation.
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3052 (DTC 126-04) - Battery voltage to engine controller - voltage too low Context: The Electronic Control Unit (ECU) monitors battery voltage. If the determines that battery is less than 10.2 V, then his fault will occur. Cause: Battery voltage is less than 10.2 V. Possible failure modes: 1. Faulty Battery. 2. Engine cranked for extended period of time. 3. Faulty ECU supply wiring. 4. Faulty charging system. 5. 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, then continue with step 2. 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. Check the battery voltage. Use a multimeter to perform the following voltage check : From Battery (+) terminal
To Battery (â&#x20AC;&#x201C;) terminal
Value There should be approximately 12 V
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, then continue to step 3. 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 continue to step 4. 4. Replace the battery. 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. 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.
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A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation.
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3059 (DTC 225-03) - Main Relay : DFC for stuck main relay error Context: The Engine Control Unit controls the ECU main relay. The ECU main relay is powered on by the ECU to achieve after-run. The ECU main relay is powered off once after-run is completed. If the ECU determines that the ECU main relay is stuck or that the ECU main relay will not shut off as commanded, then this fault will occur. Cause: The ECU has determined that the ECU main relay will not shut off as commanded. Possible failure modes: 1. Faulty ECU main relay, wiring. 2. Faulty ECU main relay, internal failure. 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, then the fault may be intermittent and not currently active. Continue with step 7. 2. Check the ECU main relay coil for an internal failure. Remove the ECU main relay. Use a multimeter to measure the resistance on the ECU main relay pins : From ECU main relay pin 85
To ECU main relay pin 86
Value There should be approximately 70 – 130 Ω.
A. If there is approximately 70 – 130 Ω, then leave the ECU main relay disconnected and continue to step 3. B. If there is not approximately 70 – 130 Ω, then the ECU main relay has failed. Replace the ECU main relay and retest. 3. Check the ECU 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 following continuity check for a short circuit to ground on the vehicle harness (VE) side : From ECU main relay connector pin 85
To Chassis ground
Value There should be no continuity.
A. If there is continuity, then there is a short circuit in the ECU 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 ECU main relay disconnected and continue to step 4. 4. Check the ECU main relay low side driver wiring for a short circuit. Disconnect the vehicle harness (VE) from the ECU at connector X-012. With the key in the OFF position, use a multimeter to perform the following continuity checks for a short circuit on the vehicle harness (VE) side : From X-012 (Receptacle) pin 28
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Value There should be no continuity.
Electrical systems - FAULT CODES
A. If there is continuity, then there is a short circuit in the ECU 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 ECU main relay disconnected. Leave connector X-012 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 the following voltage checks for a short circuit to another voltage source on the vehicle harness (VE) side : From X-012 (Receptacle) pin 1 X-012 (Receptacle) pin 3 X-012 (Receptacle) pin 5
To Chassis ground Chassis ground Chassis ground
Value There should be no voltage. There should be no voltage. There should be no voltage.
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 ECU main relay disconnected. Leave connector X-012 disconnected. Continue to step 6. 6. Check the ECU voltage supply wiring for a short circuit to another voltage source. Re-connect the ECU main relay. With the key in the OFF position, use a multimeter to perform the following voltage checks for a short circuit to another voltage source on the vehicle harness (VE) side : From X-012 (Receptacle) pin 1 X-012 (Receptacle) pin 3 X-012 (Receptacle) pin 5
To Chassis ground Chassis ground Chassis ground
Value There should be no voltage. There should be no voltage. There should be no voltage.
A. If there is voltage, then the ECU main relay has failed. Replace the ECU main relay and retest. B. If there is no voltage, then check the ECU for the appropriate software and re-flash, if necessary. 7. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals, or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 06 SH06-ENGINE F5C T4 (55.100.DP-C.20.E.06) Wiring harnesses - Electrical schematic sheet 08 SH08-ENGINE F5C T4 (55.100.DP-C.20.E.08) Wiring harnesses - Electrical schematic sheet 09 SH09-ENGINE F5C T4 (55.100.DP-C.20.E.09) Wiring harnesses - Electrical schematic sheet 10 SH10-ENGINE F5C T4 (55.100.DP-C.20.E.10)
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3061 (DTC 161-03) - Injector, solenoid : Short circuit Low Side to High Side injector 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 between the high side driver and the low side driver of the fuel injector number 1. Possible failure modes: 1. Faulty fuel injector number 1, wiring. 2. Faulty fuel injector number 1, internal failure. 3. Faulty ECU, software. 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 the fault is in an inactive state, then the fault may be intermittent and not currently active. Continue with step 7. 2. Check the fuel injector number 1 internal resistance. Disconnect the injector harness (INJ) from the fuel injector number 1. Use a multimeter to measure the resistance of fuel injector number 1 on the injector pins : From Fuel injector 1 pin 1
To Fuel injector 1 pin 2
Value There should be between .03 – .05 Ω
A. If there is between .03 – .05 Ω, then leave fuel injector 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. Disconnect the vehicle harness (VE) from the engine interface at connector X-015. With the key in the OFF position, use a multimeter to perform the following continuity check on the injector harness (INJ) side : From Fuel injector 1 connector pin 1
To Fuel injector 1 connector pin 2
Value There should be no continuity.
A. If there is no continuity, then leave fuel injector 1 disconnected. Leave connector X-015 disconnected. Continue to step 4. B. If there is continuity, then there is a short circuit in the fuel injector number 1 wiring in the injector harness. Locate and repair the shorted conductor. Repair or replace the harness as required. 4. Check the fuel injector number 1 vehicle harness (VE) wiring for a short circuit. Disconnect the vehicle harness (VE) from the ECU at connector X-016.
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With the key in the OFF position, use a multimeter to perform the following continuity check on vehicle harness (VE) side : From X-015 (Female) pin A
To X-015 (Female) pin B
Value 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. locate and repair the shorted conductor. Repair or replace or replace the harness as required. B. If there is no continuity, then continue with step 5. 5. Check the ECU voltage supply wiring. Disconnect the vehicle harness (VE) from the ECU at connector X-012. Place a jumper wire between X-012 (Receptacle) pin 28 and chassis ground. This will energize the ECU 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 X-012 (Receptacle) pin 1
Chassis ground
To
X-012 (Receptacle) pin 3
Chassis ground
X-012 (Receptacle) pin 5
Chassis ground
Value There should be approximately 12.0 V. There should be approximately 12.0 V. There should be approximately 12.0 V.
A. If there is approximately 12.0 V, then leave connector X-012 disconnected and continue to step 6. 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. 6. Check the ECU ground connections. With the key in the OFF position, use a multimeter to perform the following continuity check on the vehicle harness (VE) side : : From X-012 (Receptacle) pin 2 X-012 (Receptacle) pin 4 X-012 (Receptacle) pin 6
To Chassis ground Chassis ground Chassis ground
Value There should be continuity. There should be continuity. There should be continuity.
A. If there is no continuity, then there is a problem with the ground connection to the ECU. Locate and repair the failed conductor. Repair or replace the harness as required. B. If there is continuity, then check the ECU for the appropriate software and re-flash, if necessary. 7. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals, or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 06 SH06-ENGINE F5C T4 (55.100.DP-C.20.E.06) Wiring harnesses - Electrical schematic sheet 07 SH07-ENGINE F5C T4 (55.100.DP-C.20.E.07) Wiring harnesses - Electrical schematic sheet 10 SH10-ENGINE F5C T4 (55.100.DP-C.20.E.10) Wiring harnesses - Electrical schematic sheet 11 SH11-ENGINE F5C T4 (55.100.DP-C.20.E.11)
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3063 (DTC 161-02) - Injector, solenoid Power stage : Short circuit in the injector 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. Possible failure modes: 1. Faulty fuel injector number 1, wiring. 2. Faulty fuel injector number 1, internal failure. 3. Faulty ECU, software. 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 the fuel injector number 1. Use a multimeter to measure the resistance of fuel injector number 1 on the injector pins : From Fuel injector number 1 pin 1
To Fuel injector number 1 pin 2
Value 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 Fuel injector number 1 connector pin Chassis ground 1 Fuel injector number 1 connector pin Chassis ground 2
Value There should be no voltage. There should be no voltage.
With the key in the ON position, use a multimeter to perform the following voltage check on the injector harness (INJ) side : From To Fuel injector number 1 connector pin Chassis ground 1 Fuel injector number 1 connector pin Chassis ground 2 48068130 29/01/2018
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Value There should be no voltage. There should be no voltage.
Electrical systems - FAULT CODES
A. If there is no voltage, then leave fuel injector number 1 disconnected and continue to step 4. 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 harness as required. 4. Check the fuel injector number 1 injector harness (INJ) wiring for a short circuit to ground. Disconnect the vehicle harness (VE) from the engine interface at connector X-015. With the key in the OFF position, use a multimeter to perform the following continuity checks on the injector harness (INJ) side : From Fuel injector number 1 connector pin 1 Fuel injector number 1 connector pin 1 Fuel injector number 1 connector pin 2 X-015 (Female) pin A X-015 (Female) pin B
To Value Fuel injector number 1 connector pin There should be no continuity. 2 There should be no continuity. Chassis ground Chassis ground
There should be no continuity.
All pins in connector X-015 All pins in connector X-015
There should be no continuity. There should be no continuity.
A. If there is no continuity, then leave fuel injector number 1 disconnected. Leave connector X-015 disconnected and continue to step 5. 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. Disconnect the vehicle harness (VE) from the ECU at connector X-016. With the key in the OFF position, use a multimeter to perform the following continuity checks on vehicle harness (VE) side : X-015 X-015 X-015 X-015 X-015
From (Female) pin A (Female) pin A (Female) pin B (Female) pin A (Female) pin B
To X-015 (Female) pin B Chassis ground Chassis ground All pins in connector X-015 All pins in connector X-015
Value There should be no continuity. There should be no continuity. There should be no continuity. There should be no continuity. 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. Disconnect the vehicle harness (VE) from the ECU at connector X-012. Place a jumper wire between X-012 (Receptacle) pin 28 and chassis ground. This will energize the ECU 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 X-012 (Receptacle) pin 1
Chassis ground
To
X-012 (Receptacle) pin 3
Chassis ground
X-012 (Receptacle) pin 5
Chassis ground 48068130 29/01/2018
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Value There should be approximately 12.0 V. There should be approximately 12.0 V. There should be approximately 12.0 V.
Electrical systems - FAULT CODES
A. If there is approximately 12.0 V, then leave connector X-012 disconnected and continue to step 7. B. If there is not approximately 12.0 V, 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. With the key in the OFF position, use a multimeter to perform the following continuity check on the vehicle harness (VE) side : : From X-012 (Receptacle) pin 2 X-012 (Receptacle) pin 4 X-012 (Receptacle) pin 6
To Chassis ground Chassis ground Chassis ground
Value There should be continuity. There should be continuity. There should be continuity.
A. If there is no continuity, then there is a problem with the ground connection to the ECU. faulty ECU ground connection. Locate and repair the failed conductor. Repair or replace the harness as required. B. If there is continuity, then check the ECU for the appropriate software and re-flash, if necessary. 8. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals, or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 06 SH06-ENGINE F5C T4 (55.100.DP-C.20.E.06) Wiring harnesses - Electrical schematic sheet 07 SH07-ENGINE F5C T4 (55.100.DP-C.20.E.07) Wiring harnesses - Electrical schematic sheet 10 SH10-ENGINE F5C T4 (55.100.DP-C.20.E.10) Wiring harnesses - Electrical schematic sheet 11 SH11-ENGINE F5C T4 (55.100.DP-C.20.E.11)
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3069 (DTC 163-03) - Injector, solenoid : short circuit Low Side to High Side Injector 3 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 3 circuit, then this fault will occur. Cause: The ECU has detected a short circuit between the high side driver and low side driver of the fuel injector number 3. Possible failure modes: 1. Faulty fuel injector number 3, wiring. 2. Faulty fuel injector number 3, internal failure. 3. Faulty ECU, software. 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 7. 2. Check the fuel injector number 3 internal resistance. Disconnect the injector harness (INJ) from the fuel injector number 3. Use a multimeter to measure the resistance of fuel injector number 3 on the injector pins : From Fuel injector number 3 pin 1
To Fuel injector number 3 pin 2
Value There should be between .03 – .05 Ω
A. If there is between .03 – .05 Ω, then leave fuel injector number 3 disconnected and continue to step 3. B. If the resistance is not between .03 – .05 Ω, then fuel injector number 3 solenoid coil has failed. Replace fuel injector number 3 and retest. 3. Check the fuel injector number 3 injector harness (INJ) wiring. Disconnect the vehicle harness (VE) from the engine interface at connector X-015. With the key in the OFF position, use a multimeter to perform the following continuity check on the injector harness (INJ) side : From To Value Fuel injector number 3 connector pin Fuel injector number 3 connector pin There should be no continuity. 1 2 A. If there is no continuity, then leave fuel injector number 3 disconnected. Leave connector X-015 disconnected. Continue to step 4. B. If there is continuity, then there is a short circuit in the fuel injector number 3 wiring in the injector harness. Locate and repair the shorted conductor. Repair or replace the harness as required. 4. Check the fuel injector number 3 vehicle harness (VE) wiring for a short circuit. Disconnect the vehicle harness (VE) from the ECU at connector X-016.
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With the key in the OFF position, use a multimeter to perform the following continuity check on vehicle harness (VE) side : From X-015 (Female) pin D
To X-015 (Female) pin C
Value 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. Locate and repair the shorted conductor. Repair or replace the harness as required. B. If there is no continuity, then continue with step 5. 5. Check the ECU voltage supply wiring. Disconnect the vehicle harness (VE) from the ECU at connector X-012. Place a jumper wire between X-012 (Receptacle) pin 28 and chassis ground. This will energize the ECU 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 X-012 (Receptacle) pin 1
Chassis ground
To
X-012 (Receptacle) pin 3
Chassis ground
X-012 (Receptacle) pin 5
Chassis ground
Value There should be approximately 12.0 V. There should be approximately 12.0 V. There should be approximately 12.0 V.
A. If there is approximately 12.0 V, then leave connector X-012 disconnected and continue to step 6. 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. 6. Check the ECU ground connections. With the key in the OFF position, use a multimeter to perform the following continuity check on the vehicle harness (VE) side : From X-012 (Receptacle) pin 2 X-012 (Receptacle) pin 4 X-012 (Receptacle) pin 6
To Chassis ground Chassis ground Chassis ground
Value There should be continuity. There should be continuity. There should be continuity.
A. If there is no continuity, then there is a problem with the ground connection to the ECU. Locate and repair the failed conductor. Repair or replace the harness as required. B. If there is continuity, then check the ECU for the appropriate software and re-flash, if necessary. 7. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals, or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 06 SH06-ENGINE F5C T4 (55.100.DP-C.20.E.06) Wiring harnesses - Electrical schematic sheet 07 SH07-ENGINE F5C T4 (55.100.DP-C.20.E.07) Wiring harnesses - Electrical schematic sheet 10 SH10-ENGINE F5C T4 (55.100.DP-C.20.E.10) Wiring harnesses - Electrical schematic sheet 11 SH11-ENGINE F5C T4 (55.100.DP-C.20.E.11)
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3071 (DTC 163-02) - Injector, solenoid Power stage : Short circuit in the injector 3 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 3 circuit, then this fault will occur. Cause: The ECU has detected a short circuit in the fuel injector number 3 circuit. Possible failure modes: 1. Faulty fuel injector number 3, wiring. 2. Faulty fuel injector number 3, internal failure. 3. Faulty ECU, software. 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 3 internal resistance. Disconnect the injector harness (INJ) from the fuel injector number 3. Use a multimeter to measure the resistance of fuel injector number 3 on the injector pins : From Fuel injector number 3 pin 1
To Fuel injector number 3 pin 2
Value There should be between .03 – .05 Ω.
A. If there is between .03 – .05 Ω, then leave fuel injector number 3 disconnected and continue to step 3. B. If the resistance is not between .03 – .05 Ω, fuel injector number 3 solenoid coil has failed. Replace fuel injector number 3. 3. Check the fuel injector number 3 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 Fuel injector number 3 connector pin Chassis ground 1 Fuel injector number 3 connector pin Chassis ground 2
Value There should be no voltage. There should be no voltage.
With the key in the ON position, use a multimeter to perform the following voltage check on the injector harness (INJ) side : From To Fuel injector number 3 connector pin Chassis ground 1 Fuel injector number 3 connector pin Chassis ground 2 48068130 29/01/2018
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Value There should be no voltage. There should be no voltage.
Electrical systems - FAULT CODES
A. If there is no voltage, then leave fuel injector number 3 disconnected and continue to step 4. B. If there is voltage, then there is a short circuit to battery or a short circuit to switched battery in the fuel injector number 3 wiring in the injector harness (INJ). Locate and repair the shorted conductor. Repair or replace the harness as required. 4. Check the fuel injector number 3 injector harness (INJ) wiring for a short circuit to ground. Disconnect the vehicle harness (VE) from the engine interface at connector X-015. With the key in the OFF position, use a multimeter to perform the following continuity checks on the injector harness (INJ) side : From Fuel injector number 3 connector pin 1 Fuel injector number 3 connector pin 1 Fuel injector number 3 connector pin 2 X-015 (Female) pin D X-015 (Female) pin C
To Value Fuel injector number 3 connector pin There should be no continuity. 2 There should be no continuity. Chassis ground Chassis ground
There should be no continuity.
All pins in connector X-015 All pins in connector X-015
There should be no continuity. There should be no continuity.
A. If there is no continuity, then leave Fuel injector number 3 disconnected. Leave connector X-015 disconnected. Continue to step 5. B. If there is continuity, then there is a short circuit in the fuel injector number 3 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 3 vehicle harness (VE) wiring for a short circuit. Disconnect the vehicle harness (VE) from the ECU at connector X-016. With the key in the OFF position, use a multimeter to perform the following continuity checks on vehicle harness (VE) side : X-015 X-015 X-015 X-015 X-015
From (Female) pin D (Female) pin D (Female) pin C (Female) pin D (Female) pin C
To X-015 (Female) pin C Chassis ground Chassis ground All pins in connector X-015 All pins in connector X-015
Value There should be no continuity. There should be no continuity. There should be no continuity. There should be no continuity. 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). 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. Disconnect the vehicle harness (VE) from the ECU at connector X-012. Place a jumper wire between X-012 (Receptacle) pin 28 and chassis ground. This will energize the ECU 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 X-012 (Receptacle) pin 1
Chassis ground
To
X-012 (Receptacle) pin 3
Chassis ground
X-012 (Receptacle) pin 5
Chassis ground 48068130 29/01/2018
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Value There should be approximately 12.0 V. There should be approximately 12.0 V. There should be approximately 12.0 V.
Electrical systems - FAULT CODES
A. If there is approximately 12.0 V, then leave connector X-012 disconnected and continue to step 7. B. If there is not approximately 12.0 V, 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. With the key in the OFF position, use a multimeter to perform the following continuity check on the vehicle harness (VE) side : From X-012 (Receptacle) pin 2 X-012 (Receptacle) pin 4 X-012 (Receptacle) pin 4
To Chassis ground Chassis ground Chassis ground
Value There should be continuity. There should be continuity. There should be continuity.
A. If there is no continuity, then there is a problem with the ground connection to the ECU.Locate and repair the failed conductor. Repair or replace the harness as required. B. If there is continuity, then check the ECU for the appropriate software and re-flash, if necessary. 8. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals, or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 06 SH06-ENGINE F5C T4 (55.100.DP-C.20.E.06) Wiring harnesses - Electrical schematic sheet 07 SH07-ENGINE F5C T4 (55.100.DP-C.20.E.07) Wiring harnesses - Electrical schematic sheet 10 SH10-ENGINE F5C T4 (55.100.DP-C.20.E.10) Wiring harnesses - Electrical schematic sheet 11 SH11-ENGINE F5C T4 (55.100.DP-C.20.E.11)
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3077 (DTC 162-03) - Injector, solenoid : short circuit Low Side to High Side Injector 2 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 2 circuit, then this fault will occur. Cause: The ECU has detected a short circuit between the high side driver and low side driver of the fuel injector number 2. Possible failure modes: 1. Faulty fuel injector number 2, wiring. 2. Faulty fuel injector number 2, internal failure. 3. Faulty ECU, software. 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 7. 2. Check the fuel injector number 2 internal resistance. Disconnect the injector harness (INJ) from the fuel injector number 2. Use a multimeter to measure the resistance of fuel injector number 2 on the injector pins : From Fuel injector number 2 pin 1
To Fuel injector number 2 pin 2
Value There should be between .03 – .05 Ω.
A. If there is between .03 – .05 Ω, then leave fuel injector number 2 disconnected and continue to step 3. B. If the resistance is not between .03 – .05 Ω, then fuel injector number 2 solenoid coil has failed. Replace fuel injector number 2 and retest. 3. Check the fuel injector number 2 injector harness (INJ) wiring. Disconnect the vehicle harness (VE) from the engine interface at connector X-015. With the key in the OFF position, use a multimeter to perform the following continuity check on the injector harness (INJ) side : From To Fuel injector number 2 connector pin Fuel injector number 2 pin 2 1
Value There should be no continuity.
A. If there is no continuity, then leave fuel injector number 2 disconnected. Leave connector X-015 disconnected. Continue to step 4. B. If there is continuity, then there is a short circuit in the fuel injector number 2 wiring in the injector harness. Locate and repair the shorted conductor. Repair or replace the harness as required. 4. Check the fuel injector number 2 vehicle harness (VE) wiring for a short circuit. Disconnect the vehicle harness (VE) from the ECU at connector X-016. 48068130 29/01/2018
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With the key in the OFF position, use a multimeter to perform the following continuity check on vehicle harness (VE) side : From X-015 (Female) pin H
To X-015 (Female) pin G
Value There should be no continuity.
A. If there is continuity, then there is a short circuit in the fuel injector number 2 wiring in the vehicle harness. Locate and repair the shorted conductor. Repair or replace the harness as required. B. If there is no continuity, then continue with step 5. 5. Check the ECU voltage supply wiring. Disconnect the vehicle harness (VE) from the ECU at connector X-012. Place a jumper wire between X-012 (Receptacle) pin 28 and chassis ground. This will energize the ECU 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 X-012 (Receptacle) pin 1
Chassis ground
To
X-012 (Receptacle) pin 3
Chassis ground
X-012 (Receptacle) pin 5
Chassis ground
Value There should be approximately 12.0 V. There should be approximately 12.0 V. There should be approximately 12.0 V.
A. If there is approximately 12.0 V, then leave connector X-012 disconnected and continue to step 6. 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. 6. Check the ECU ground supply. With the key in the OFF position, use a multimeter to perform the following continuity check on the vehicle harness (VE) side : From X-012 (Receptacle) pin 2 X-012 (Receptacle) pin 4 X-012 (Receptacle) pin 6
To Chassis ground Chassis ground Chassis ground
Value There should be continuity. There should be continuity. There should be continuity.
A. If there is no continuity, there is a problem with the minus battery connection to the ECU. Locate and repair the failed conductor. Repair or replace the harness as required. B. If there is continuity, then check the ECU for the appropriate software and re-flash, if necessary. 7. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals, or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 06 SH06-ENGINE F5C T4 (55.100.DP-C.20.E.06) Wiring harnesses - Electrical schematic sheet 07 SH07-ENGINE F5C T4 (55.100.DP-C.20.E.07) Wiring harnesses - Electrical schematic sheet 10 SH10-ENGINE F5C T4 (55.100.DP-C.20.E.10) Wiring harnesses - Electrical schematic sheet 11 SH11-ENGINE F5C T4 (55.100.DP-C.20.E.11)
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3079 (DTC 162-02) - Injector, solenoid Power stage : Short circuit in the injector 2 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 2 circuit, then this fault will occur. Cause: The ECU has detected a short circuit in the fuel injector number 2 circuit. Possible failure modes: 1. Faulty fuel injector number 2, wiring. 2. Faulty fuel injector number 2, internal failure. 3. Faulty ECU, software. 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, the fault may be intermittent and not currently active. Continue with step 8. 2. Check the fuel injector number 2 internal resistance. Disconnect the injector harness (INJ) from the fuel injector number 2. Use a multimeter to measure the resistance of fuel injector number 2 on the injector pins : From Fuel injector number 2 pin 1
To Fuel injector number 2 pin 2
Value There should be between .03 – .05 Ω.
A. If there is between .03 – .05 Ω, then leave fuel injector number 2 disconnected and continue to step 3. B. If the resistance is not between .03 – .05 Ω, then fuel injector number 2 solenoid coil has failed. Replace fuel injector number 2 and retest. 3. Check the fuel injector number 2 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 Fuel injector number 2 connector pin Chassis ground 1 Fuel injector number 2 connector pin Chassis ground 2
Value There should be no voltage. There should be no voltage.
With the key in the ON position, use a multimeter to perform the following voltage check on the injector harness (INJ) side : From To Fuel injector number 2 connector pin Chassis ground 1 Fuel injector number 2 connector pin Chassis ground 2 48068130 29/01/2018
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Value There should be no voltage. There should be no voltage.
Electrical systems - FAULT CODES
A. If there is no voltage, then leave fuel injector number 2 disconnected and continue to step 4. B. If there is voltage, then there is a short circuit to battery or a short circuit to switched battery in the fuel injector number 2 wiring in the injector harness (INJ). Locate and repair the shorted conductor. Repair or replace the harness as required. 4. Check the fuel injector number 2 injector harness (INJ) wiring for a short circuit to ground. Disconnect the vehicle harness (VE) from the engine interface at connector X-015. With the key in the OFF position, use a multimeter to perform the following continuity checks on the injector harness (INJ) side : From Fuel injector number 2 connector pin 1 Fuel injector number 2 connector pin 1 Fuel injector number 2 connector pin 2 X-015 (Female) pin H X-015 (Female) pin G
To Value Fuel injector number 2 connector pin There should be no continuity. 2 There should be no continuity. Chassis ground Chassis ground
There should be no continuity.
All pins in connector X-015 All pins in connector X-015
There should be no continuity. There should be no continuity.
A. If there is no continuity, then leave fuel injector number 2 disconnected. Leave connector X-015 disconnected. Continue to step 5. B. If there is continuity, then there is a short circuit in the fuel injector number 2 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 2 vehicle harness (VE) wiring for a short circuit. Disconnect the vehicle harness (VE) from the ECU at connector X-016. With the key in the OFF position, use a multimeter to perform the following continuity checks on vehicle harness (VE) side : X-015 X-015 X-015 X-015 X-015
From (Female) pin H (Female) pin H (Female) pin G (Female) pin H (Female) pin G
To X-015 (Female) pin G Chassis ground Chassis ground All pins in connector X-015 All pins in connector X-015
Value There should be no continuity. There should be no continuity. There should be no continuity. There should be no continuity. There should be no continuity.
A. If there is continuity, then there is a short circuit in the fuel injector number 2 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. Disconnect the vehicle harness (VE) from the ECU at connector X-012. Place a jumper wire between X-012 (Receptacle) pin 28 and chassis ground. This will energize the ECU 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 X-012 (Receptacle) pin 1
Chassis ground
To
X-012 (Receptacle) pin 3
Chassis ground
X-012 (Receptacle) pin 5
Chassis ground 48068130 29/01/2018
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Value There should be approximately 12.0 V. There should be approximately 12.0 V. There should be approximately 12.0 V.
Electrical systems - FAULT CODES
A. If there is approximately 12.0 V, then leave connector X-012 disconnected and continue to step 7. B. If there is not approximately 12.0 V, 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. With the key in the OFF position, use a multimeter to perform the following continuity check on the vehicle harness (VE) side : : From X-012 (Receptacle) pin 2 X-012 (Receptacle) pin 4 X-012 (Receptacle) pin 6
To Chassis ground Chassis ground Chassis ground
Value There should be continuity. There should be continuity. There should be continuity.
A. If there is no continuity, then there is a problem with the minus battery connection to the ECU. Locate and repair the failed conductor. Repair or replace the harness as required. B. If there is continuity, check the ECU for the appropriate software and re-flash, if necessary. 8. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals, or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 06 SH06-ENGINE F5C T4 (55.100.DP-C.20.E.06) Wiring harnesses - Electrical schematic sheet 07 SH07-ENGINE F5C T4 (55.100.DP-C.20.E.07) Wiring harnesses - Electrical schematic sheet 10 SH10-ENGINE F5C T4 (55.100.DP-C.20.E.10) Wiring harnesses - Electrical schematic sheet 11 SH11-ENGINE F5C T4 (55.100.DP-C.20.E.11)
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3081 (DTC 164-03) - Injector, solenoid : short circuit Low Side to High Side Injector 4 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 4 circuit, then this fault will occur. Cause: The ECU has detected a short circuit between the high side driver and low side driver of the fuel injector number 4. Possible failure modes: 1. Faulty fuel injector number 4, wiring. 2. Faulty fuel injector number 4, internal failure. 3. Faulty ECU, software. 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 7. 2. Check the fuel injector number 4 internal resistance. Disconnect the injector harness (INJ) from the fuel injector number 4. Use a multimeter to measure the resistance of fuel injector number 4 on the injector pins : From Fuel injector number 4 pin 1
To Fuel injector number 4 pin 2
Value There should be between .03 – .05 Ω.
A. If there is between .03 – .05 Ω, then leave fuel injector number 4 disconnected and continue to step 3. B. If the resistance is not between .03 – .05 Ω, then fuel injector number 4 solenoid coil has failed. Replace fuel injector number 4 and retest. 3. Check the fuel injector number 4 injector harness (INJ) wiring. Disconnect the vehicle harness (VE) from the engine interface at connector X-015. With the key in the OFF position, use a multimeter to perform the following continuity check on the injector harness (INJ) side : From To Value Fuel injector number 4 connector pin Fuel injector number 4 connector pin There should be no continuity. 1 2 A. If there is no continuity, then leave fuel injector number 4 disconnected. Leave connector X-015 disconnected. Continue to step 4. B. If there is continuity, then there is a short circuit in the fuel injector number 4 wiring in the injector harness. Locate and repair the shorted conductor. Repair or replace the harness as required. 4. Check the fuel injector number 4 vehicle harness (VE) wiring for a short circuit. Disconnect the vehicle harness (VE) from the ECU at connector X-016. 48068130 29/01/2018
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With the key in the OFF position, use a multimeter to perform the following continuity check on vehicle harness (VE) side : From X-015 (Female) pin E
To X-015 (Female) pin F
Value There should be no continuity.
A. If there is continuity, then there is a short circuit in the fuel injector number 4 wiring in the vehicle harness. Locate and repair the shorted conductor. Repair or replace the harness as required. B. If there is no continuity, then continue with step 5. 5. Check the ECU voltage supply wiring. Disconnect the vehicle harness (VE) from the ECU at connector X-012. Place a jumper wire between X-012 (Receptacle) pin 28 and chassis ground. This will energize the ECU 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 X-012 (Receptacle) pin 1
Chassis ground
To
X-012 (Receptacle) pin 3
Chassis ground
X-012 (Receptacle) pin 5
Chassis ground
Value There should be approximately 12.0 V. There should be approximately 12.0 V. There should be approximately 12.0 V.
A. If there is approximately 12.0 V, then leave connector X-012 disconnected and continue to step 6. B. If there is not approximately 12.0 V, there is a problem with the battery supply to the ECU. Locate and repair the failed conductor. Repair or replace the harness as required. 6. Check the ECU ground supply. With the key in the OFF position, use a multimeter to perform the following continuity check on the vehicle harness (VE) side : From X-012 (Receptacle) pin 2 X-012 (Receptacle) pin 4 X-012 (Receptacle) pin 6
To Chassis ground Chassis ground Chassis ground
Value There should be continuity. There should be continuity. There should be continuity.
A. If there is no continuity, then there is a problem in the minus battery connection to the ECU. Locate and repair the failed conductor. Repair or replace the harness as required. B. If there is continuity, then check the ECU for the appropriate software and re-flash, if necessary. 7. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals, or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 06 SH06-ENGINE F5C T4 (55.100.DP-C.20.E.06) Wiring harnesses - Electrical schematic sheet 07 SH07-ENGINE F5C T4 (55.100.DP-C.20.E.07) Wiring harnesses - Electrical schematic sheet 10 SH10-ENGINE F5C T4 (55.100.DP-C.20.E.10) Wiring harnesses - Electrical schematic sheet 11 SH11-ENGINE F5C T4 (55.100.DP-C.20.E.11)
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Electrical systems - FAULT CODES
3083 (DTC 164-02) - Injector, solenoid Power stage : Short circuit in the injector 4 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 4 circuit, then this fault will occur. Cause: The ECU has detected a short circuit in the fuel injector number 4 circuit. Possible failure modes: 1. Faulty fuel injector number 4, wiring. 2. Faulty fuel injector number 4, internal failure. 3. Faulty ECU, software. 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 4 internal resistance. Disconnect the injector harness (INJ) from the fuel injector number 4. Use a multimeter to measure the resistance of fuel injector number 4 on the injector pins : From Fuel injector number 4 pin 1
To Fuel injector number 4 pin 2
Value There should be between .03 – .05 Ω.
A. If there is between .03 – .05 Ω, then leave fuel injector number 4 disconnected and continue to step 3. B. If the resistance is not between .03 – .05 Ω, then fuel injector number 4 solenoid coil has failed. Replace fuel injector number 4 and retest. 3. Check the fuel injector number 4 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 Fuel injector number 4 connector pin Chassis ground 1 Fuel injector number 4 connector pin Chassis ground 2
Value There should be no voltage. There should be no voltage.
With the key in the ON position, use a multimeter to perform the following voltage check on the injector harness (INJ) side : From To Fuel injector number 4 connector pin Chassis ground 1 Fuel injector number 4 connector pin Chassis ground 2 48068130 29/01/2018
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Value There should be no voltage. There should be no voltage.
Electrical systems - FAULT CODES
A. If there is no voltage, then leave fuel injector number 4 disconnected and continue to step 4. B. If there is voltage, then there is a short circuit to battery or a short circuit switched battery in the fuel injector number 4 wiring in the injector harness (INJ). Locate and repair the shorted conductor. Repair or replace the harness as required. 4. Check the fuel injector number 4 injector harness (INJ) wiring for a short circuit to ground. Disconnect the vehicle harness (VE) from the engine interface at connector X-015. With the key in the OFF position, use a multimeter to perform the following continuity checks on the injector harness (INJ) side : From Fuel injector number 4 connector pin 1 Fuel injector number 4 connector pin 1 Fuel injector number 4 connector pin 2 X-015 (Female) pin E X-015 (Female) pin F
To Value Fuel injector number 4 connector pin There should be no continuity. 2 There should be no continuity. Chassis ground Chassis ground
There should be no continuity.
All pins in connector X-015 All pins in connector X-015
There should be no continuity. There should be no continuity.
A. If there is no continuity, then leave fuel injector number 4 disconnected. Leave connector X-015 disconnected. Continue to step 5. B. If there is continuity, then there is a short circuit in the fuel injector number 4 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 4 vehicle harness (VE) wiring for a short circuit. Disconnect the vehicle harness (VE) from the ECU at connector X-016. With the key in the OFF position, use a multimeter to perform the following continuity checks on vehicle harness (VE) side : X-015 X-015 X-015 X-015 X-015
From (Female) pin E (Female) pin E (Female) pin F (Female) pin E (Female) pin F
To X-015 (Female) pin F Chassis ground Chassis ground All pins in connector X-015 All pins in connector X-015
Value There should be no continuity. There should be no continuity. There should be no continuity. There should be no continuity. There should be no continuity.
A. If there is continuity, then there is a short circuit in the fuel injector number 4 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. Disconnect the vehicle harness (VE) from the ECU at connector X-012. Place a jumper wire between X-012 (Receptacle) pin 28 and chassis ground. This will energize the ECU 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 X-012 (Receptacle) pin 1
Chassis ground
To
X-012 (Receptacle) pin 3
Chassis ground
X-012 (Receptacle) pin 5
Chassis ground 48068130 29/01/2018
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Value There should be approximately 12.0 V. There should be approximately 12.0 V. There should be approximately 12.0 V.
Electrical systems - FAULT CODES
A. If there is approximately 12.0 V, leave connector X-012 disconnected and continue to step 7. B. If there is not approximately 12.0 V, 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. With the key in the OFF position, use a multimeter to perform the following continuity check on the vehicle harness (VE) side : : From X-012 (Receptacle) pin 2 X-012 (Receptacle) pin 4 X-012 (Receptacle) pin 6
To Chassis ground Chassis ground Chassis ground
Value There should be continuity. There should be continuity. There should be continuity.
A. If there is no continuity, then there is a problem with the minus battery connection to the ECU. Locate and repair the failed conductor. Repair or replace the harness as required. B. If there is continuity, then check the ECU for the appropriate software and re-flash, if necessary. 8. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals, or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 06 SH06-ENGINE F5C T4 (55.100.DP-C.20.E.06) Wiring harnesses - Electrical schematic sheet 07 SH07-ENGINE F5C T4 (55.100.DP-C.20.E.07) Wiring harnesses - Electrical schematic sheet 10 SH10-ENGINE F5C T4 (55.100.DP-C.20.E.10) Wiring harnesses - Electrical schematic sheet 11 SH11-ENGINE F5C T4 (55.100.DP-C.20.E.11)
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Electrical systems - FAULT CODES
3088 (DTC 141-02) - Crankshaft Sensor : Crankshaft signal diagnose - no signal 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, this fault will occur. Cause: The ECU has determined that there is no crankshaft position signals detected for at least 4 engine revolutions. Possible failure modes: 1. The crankshaft position sensor is not fully seated or is loose. 2. The crankshaft tone wheel is damaged or misaligned. 3. A short circuit in the crankshaft position sensor wiring. 4. An internal failure in the crankshaft position sensor. 5. A faulty ECU. Solution: 1. Verify that the fault is present and active. Use the Electronic Service Tool (EST) to check the status of this fault. A. If the fault is present and active, then continue with step 2. 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 8. 2. Check the physical integrity of the crankshaft position sensor . The sensor should be fully seated and mounted tightly. Remove the crankshaft position sensor and inspect the crankshaft tool wheel. The tone wheel should not be damaged or loose. A. If the sensor or tone wheel is damaged or is not mounted/secured properly, then repair as required. . B. If the sensor and tone wheel are not damaged and are mounted/secured properly, then continue to step 3. 3. Check the crankshaft position sensor internal resistance. Disconnect the crankshaft position sensor. Use a multimeter to measure the resistance of the crankshaft position sensor on the sensor pins : From Crankshaft position sensor pin 1
To Crankshaft position sensor pin 2
Value 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 wiring for a short circuit to battery. With the key in the OFF position, use a multimeter to perform the following voltage check :
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Electrical systems - FAULT CODES
From To Crankshaft position sensor connector Chassis ground pin 1
Value There should be no voltage.
With the key in the ON position, use a multimeter to perform the following voltage check : From To Crankshaft position sensor connector Chassis ground pin 1
Value There should be no voltage.
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 switched battery in the crankshaft position sensor wiring. Locate and repair the shorted conductor. Repair or replace the harness as required. 5. Check the crankshaft position sensor engine harness wiring. Disconnect the engine interface connector X-017. With the key in the OFF position, use a multimeter to perform the following continuity checks : From To Value Crankshaft position sensor connector Crankshaft position sensor connector There should be no continuity. pin 1 pin 2 There should be no continuity. Crankshaft position sensor connector Chassis ground pin 1 There should be no continuity. Crankshaft position sensor connector Chassis ground pin 2 With the key in the OFF position, use a multimeter to perform the following continuity checks : From To Crankshaft position sensor connector X-017 (Receptacle) pin 9 pin 1 Crankshaft position sensor connector X-017 (Receptacle) pin 10 pin 2
Value There should be continuity. There should be continuity.
With the key in the OFF position, use a multimeter to perform the following continuity checks : From X-017 (Receptacle) pin 9 X-017 (Receptacle) pin 10
To All pins in connector X-017 All pins in connector X-017
Value There should be no continuity. There should be no continuity.
A. If the specified values are measured, then leave the crankshaft position sensor disconnected. Leave connector X-017 disconnected. Continue to step 6. B. If the specified values are not measured, then there is a problem in the crankshaft position sensor wiring. Locate and repair the failed conductor. Repair or replace the harness as required. 6. Check the crankshaft position sensor wiring. Disconnect the ECU connector X-016. With the key in the OFF position, use a multimeter to perform the following continuity check : From X-017 (Receptacle) pin 9
To X-017 (Receptacle) pin 10
Value There should be no continuity.
With the key in the OFF position, use a multimeter to perform the following continuity checks : From X-017 (Receptacle) pin 9 X-017 (Receptacle) pin 10
To X-016 (Receptacle) pin 59 X-016 (Receptacle) pin 44
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Value There should be continuity. There should be continuity.
Electrical systems - FAULT CODES
With the key in the OFF position, use a multimeter to perform the following continuity checks : From X-017 (Receptacle) pin 9 X-017 (Receptacle) pin 10
To All pins in connector X-017 All pins in connector X-017
Value There should be no continuity. There should be no continuity.
A. If the specified values are measured, then leave the crankshaft position sensor disconnected. Leave connectors X-017 and X-016 disconnected. Continue to step 7. B. If the specified values are not measured, then there is a problem in the crankshaft position sensor wiring. Locate and repair the failed conductor. 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, 3088 (DTC 141-02) â&#x20AC;&#x201C; Crankshaft Sensor : Crankshaft signal diagnose - no signal. A. If the fault has been resolved, 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. 8. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals, or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 07 SH07-ENGINE F5C T4 (55.100.DP-C.20.E.07) Wiring harnesses - Electrical schematic sheet 11 SH11-ENGINE F5C T4 (55.100.DP-C.20.E.11)
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Electrical systems - FAULT CODES
3089 (DTC 141-04) - Crankshaft Sensor : Crankshaft signal diagnose - disturbed signal 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, this fault will occur. Cause: The ECU has detected more than 80 crankshaft position signal plausibility errors. Possible failure modes: 1. The crankshaft position sensor is not fully seated or is loose. 2. The crankshaft tone wheel is damaged or misaligned. 3. There is a short circuit in the crankshaft position sensor wiring. 4. An internal failure in the crankshaft position sensor. 5. A faulty ECU. Solution: 1. Verify that the fault is present and active. Use the Electronic Service Tool (EST) to check the status of this fault. A. If the fault is present and active, then continue with step 2. 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 8. 2. Check the physical integrity of the crankshaft position sensor . The sensor should be fully seated and mounted tightly. Remove the crankshaft position sensor and inspect the crankshaft tone wheel. The tone wheel should not be damaged or loose. A. If the sensor or tone wheel is damaged or is not mounted/secured properly, then repair as required. B. If the sensor and tone wheel are not damaged and are mounted/secured properly, then continue to step 3. 3. Check the crankshaft position sensor internal resistance. Disconnect the crankshaft position sensor. Use a multimeter to measure the resistance of the crankshaft position sensor on the sensor pins : From Crankshaft position sensor pin 1
To Crankshaft position sensor pin 2
Value 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 wiring for a short circuit to battery. With the key in the OFF position, use a multimeter to perform the following voltage check : From X-017 (Receptacle) pin 9
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Value There should be no voltage.
Electrical systems - FAULT CODES
With the key in the ON position, use a multimeter to perform the following voltage check on the engine harness (EN) side : From X-017 (Receptacle) pin 9
To Chassis ground
Value There should be no voltage.
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 switched switch battery in the crankshaft position sensor wiring. Locate and repair the shorted conductor. Repair or replace the wiring as required. 5. Check the crankshaft position sensor engine wiring. Disconnect the engine interface connector X-017. With the key in the OFF position, use a multimeter to perform the following continuity checks : From Crankshaft position sensor pin 1 Crankshaft position sensor pin 1 Crankshaft position sensor pin 2
To Crankshaft position sensor pin 2 Chassis ground Chassis ground
Value There should be no continuity. There should be no continuity. There should be no continuity.
With the key in the OFF position, use a multimeter to perform the following continuity checks : From Crankshaft position sensor pin 1 Crankshaft position sensor pin 2
To X-017 (Receptacle) pin 9 X-017 (Receptacle) pin 10
Value There should be continuity. There should be continuity.
With the key in the OFF position, use a multimeter to perform the following continuity checks : From X-017 (Receptacle) pin 9 X-017 (Receptacle) pin 10
To All pins in connector X-017 All pins in connector X-017
Value There should be no continuity. There should be no continuity.
A. If the specified values are measured, then leave the crankshaft position sensor disconnected. Leave connector X-017 disconnected. Continue to step 6. B. If the specified values are not measured, then there is a problem in the crankshaft position sensor wiring. Locate and repair the failed conductor. Repair or replace the harness as required. 6. Check the crankshaft position sensor wiring. Disconnect the ECU connector X-016. With the key in the OFF position, use a multimeter to perform the following continuity check : From X-017 (Receptacle) pin 9
To X-017 (Receptacle) pin 10
Value There should be no continuity.
With the key in the OFF position, use a multimeter to perform the following continuity checks : From X-017 (Receptacle) pin 9 X-017 (Receptacle) pin 10
To X-016 (Receptacle) pin 59 X-016 (Receptacle) pin 44
Value There should be continuity. There should be continuity.
With the key in the OFF position, use a multimeter to perform the following continuity checks : From X-017 (Receptacle) pin 9 X-017 (Receptacle) pin 10
To All pins in connector X-017 All pins in connector X-017
Value There should be no continuity. There should be no continuity.
A. If the specified values are measured, then leave the crankshaft position sensor disconnected. Leave connectors X-017 and X-016 disconnected. Continue to step 7. 48068130 29/01/2018
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B. If the specified values are not measured, then there is a problem in the crankshaft position sensor wiring. Locate and repair the failed conductor. 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, 3089 (DTC 141-04) â&#x20AC;&#x201C; Crankshaft Sensor : Crankshaft signal diagnose - disturbed signal. A. If the fault has been resolved, return the machine to service. B. If the fault has not been resolved, check the ECU for the appropriate software and re-flash, if necessary. 8. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals, or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 07 SH07-ENGINE F5C T4 (55.100.DP-C.20.E.07) Wiring harnesses - Electrical schematic sheet 11 SH11-ENGINE F5C T4 (55.100.DP-C.20.E.11)
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3090 (DTC 143-02) - Camshaft Sensor : Camshaft signal diagnose - no signal 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, this fault will occur. Cause: The ECU has detected no camshaft edge for at least four crankshaft revolutions. Possible failure modes: 1. An improperly seated or mounted camshaft position sensor. 2. A problem in the camshaft position sensor wiring. 3. A faulty camshaft position sensor. 4. A faulty ECU. Solution: 1. Verify that the fault is present and active. Use the Electronic Service Tool (EST) to check the status of this fault. A. If the fault is present and active, then continue with step 2. 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 6. 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 necessary. B. If the sensor is not damaged and is mounted/secured properly, then continue to step 3. 3. Check the camshaft position sensor wiring. Disconnect the camshaft position sensor. Disconnect the engine interface connector X-017. With the key in the OFF position, use a multimeter to perform the following continuity check. : From To Camshaft position sensor connector X-017 (Receptacle) pin 4 pin 2 Camshaft position sensor connector X-017 (Receptacle) pin 8 pin 1 Camshaft position sensor connector X-017 (Receptacle) pin 12 pin 3
Value There should be continuity. There should be continuity. There should be continuity.
With the key in the OFF position, use a multimeter to perform the following continuity check : From To Camshaft position sensor connector Chassis ground pin 2
Value There should be no continuity.
With the key in the OFF position, use a multimeter to perform the following continuity check :
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From X-017 (Receptacle) pin 4
To All pins in connector X-017
Value There should be no continuity.
With the key in the ON position, use a multimeter to perform the following voltage check : From To Camshaft position sensor connector Chassis ground pin 2
Value There should be no voltage.
A. If the specified values are measured, then leave the camshaft position sensor disconnected. Leave connector X-017 disconnected. Continue to step 4. B. If the specified values are not measured, then there is a problem in the wiring. Locate and repair the failed conductor or conductors. Repair or replace the harness as required. 4. Check the camshaft position sensor wiring in the harness. Disconnect the ECU connector X-016. With the key in the OFF position, use a multimeter to perform the following continuity check : From X-017 (Receptacle) pin 4 X-017 (Receptacle) pin 8 X-017 (Receptacle) pin 12
To X-016 (Receptacle) pin 14 X-016 (Receptacle) pin 28 X-016 (Receptacle) pin 13
Value There should be continuity. There should be continuity. There should be continuity.
With the key in the OFF position, use a multimeter to perform the following continuity check : From X-016 (Receptacle) pin 14
To Chassis ground
Value There should be no continuity.
With the key in the OFF position, use a multimeter to perform the following continuity check : From X-017 (Receptacle) pin 4
To All pins in connector X-017
Value There should be no continuity.
With the key in the ON position, use a multimeter to perform the following voltage check : From X-016 (Receptacle) pin 14
To Chassis ground
Value There should be no voltage.
A. If the specified values are measured, then leave the camshaft position sensor disconnected. 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. Use the Electronic Service Tool (EST) to verify the status of this fault, 3090 (DTC 143-02) â&#x20AC;&#x201C; Camshaft Sensor : Camshaft signal diagnose - no signal. A. If the fault has been resolved, return the machine to service. B. If the fault has not been resolved, check the ECU for the appropriate software and re-flash, if necessary. 6. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals, or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved.
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B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 07 SH07-ENGINE F5C T4 (55.100.DP-C.20.E.07) Wiring harnesses - Electrical schematic sheet 11 SH11-ENGINE F5C T4 (55.100.DP-C.20.E.11)
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3091 (DTC 143-04) - Camshaft Sensor : Camshaft signal diagnose - disturbed signal 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, this fault will occur. Cause: The ECU has detected a camshaft pattern signal error. Possible failure modes: 1. A problem in the camshaft position sensor wiring. 2. An improperly seated or mounted camshaft position sensor. 3. A faulty camshaft position sensor. 4. A faulty ECU. Solution: 1. Verify that the fault is present and active. Use the Electronic Service Tool (EST) to check the status of this fault. A. If the fault is present and active, then continue with step 2. 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 6. 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 wiring. Disconnect the camshaft position sensor. Disconnect the engine interface connector X-017. With the key in the OFF position, use a multimeter to perform the following continuity check : From X-017 (Receptacle) pin 4
To Value Camshaft position sensor connector There should be continuity. pin 2 There should be no continuity. Camshaft position sensor connector Chassis ground pin 2 All pins in connector X-017 There should be no continuity. X-017 (Receptacle) pin 4 With the key in the ON position, use a multimeter to perform the following voltage check : From To Camshaft position sensor connector Chassis ground pin 2
Value There should be no voltage.
A. If the specified values are measured, leave the camshaft position sensor disconnected. Leave connector X-017 disconnected. Continue to step 4.
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B. If the specified values are not measured, then there is failure in the camshaft position sensor wiring. Locate and repair the failed conductor. Repair or replace the harness as required. 4. Check the camshaft position sensor wiring. Disconnect the ECU connector X-016. With the key in the OFF position, use a multimeter to perform the following continuity check : From X-017 (Receptacle) pin 4 X-017 (Receptacle) pin 4 X-017 (Receptacle) pin 4
To X-016 (Receptacle) pin 14 Chassis ground All pins in connector X-017
Value There should be continuity. There should be no continuity. There should be no continuity.
With the key in the ON position, use a multimeter to perform the following voltage check : From X-016 (Receptacle) pin 14
To Chassis ground
Value There should be no voltage.
A. If the specified values are measured, then leave 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. Repair or replace the harness as required. 5. Replace the camshaft position sensor. Use the Electronic Service Tool (EST) to verify the status of this fault, 3091 (DTC 143-04) â&#x20AC;&#x201C; Camshaft Sensor : Camshaft signal diagnose - disturbed signal. A. If the fault has been resolved, 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. 6. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals, or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 07 SH07-ENGINE F5C T4 (55.100.DP-C.20.E.07) Wiring harnesses - Electrical schematic sheet 11 SH11-ENGINE F5C T4 (55.100.DP-C.20.E.11)
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3093 (DTC 144-03) - Camshaft Sensor : Camshaft offset angle exceeded Context: The Engine Control Unit (ECU) monitors the camshaft position sensor and the crankshaft position sensor characteristics for angle, speed determination, signal plausibility, and quality. If the ECU determines that the offset between the crankshaft signal and the expected camshaft first edge is less or greater than 10.00° for longer than four consecutive cycles, this fault will occur. Possible failure modes: 1. The camshaft position sensor is improperly mounted or not seated properly. 2. The crankshaft position sensor is improperly mounted or not seated properly. 3. A loose or damaged camshaft tone wheel. 4. A loose or damaged crankshaft tone wheel. 5. The engine is not timed properly. 6. A faulty ECU. Wiring harnesses - Electrical schematic sheet 07 SH07-ENGINE F5C T4 (55.100.DP-C.20.E.07) Wiring harnesses - Electrical schematic sheet 11 SH11-ENGINE F5C T4 (55.100.DP-C.20.E.11)
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3096 (DTC 1B1-03) - CAN Bus : Bus Off error CAN A Context: The Engine Control Unit (ECU) 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 function of the ECU. CAN Node A Bus is the main vehicle interface bus. The ECU provides an internal CAN termination resistor for the CAN Node A Bus. If the ECU senses that CAN Node A Bus is not functioning properly, then this fault will occur. Cause: ECU has sensed a Bus Off state to be present at the CAN Node A. Possible failure modes: 1. Faulty supply voltage or ground, missing. 2. Faulty CAN circuit wiring, an open circuit or a short circuit. 3. Faulty ECU, termination resistor or software. Solution: 1. Verify fault is present and in active state. Use the Electronic Service Tool (EST) to check the status of this fault. A. If the fault is 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 6. 2. Check for other vehicle CAN faults. Use the EST to determine if vehicle CAN faults exist. A. If other vehicle CAN faults exist, then resolve the vehicle CAN faults, then check to see that 3096 (DTC 1B1-03) â&#x20AC;&#x201C; CAN Bus : Bus Off error CAN A 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-012. To energize the ECU main relay, place a jumper wire between the vehicle harness (VE) side of connector X-012 (Receptacle) pin 28 and chassis ground. Use a multimeter to check for voltage on the vehicle (VE) harness side : From X-012 (Receptacle) pin 1 X-012 (Receptacle) pin 3 X-012 (Receptacle) pin 5
To Chassis ground Chassis ground Chassis ground
Value There should be 12.0 V. There should be 12.0 V. There should be 12.0 V.
A. If the voltage is present on all of the checks, then leave connector X-012 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 replace 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 X-012 (Receptacle) pin 2 X-012 (Receptacle) pin 4 X-012 (Receptacle) pin 6
To Chassis ground Chassis ground Chassis ground
Value There should be continuity. There should be continuity. There should be continuity.
A. If there is continuity on all of the checks, then leave connector X-012 disconnected. Continue with step 5. B. If there is no continuity for one or more of the checks, then there is a problem with the minus battery 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 X-012 (Receptacle) pin 24 X-012 (Receptacle) pin 24 X-012 (Receptacle) pin 25
To X-012 (Receptacle) pin 25 Chassis ground Chassis ground
Value There should be 120 Ί. There should not be continuity. There should not be continuity.
Use a multimeter to measure the resistance of the CAN termination resistor, internal to the ECU : From X-012 (Receptacle) pin 24
To X-012 (Receptacle) pin 25
Value There should be 120 Ί.
A. If the measured resistances are correct and neither conductor is grounded, then check the ECU 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, Locate and restore the termination resistance to the CAN circuit. 6. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals, or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 06 SH06-ENGINE F5C T4 (55.100.DP-C.20.E.06) Wiring harnesses - Electrical schematic sheet 10 SH10-ENGINE F5C T4 (55.100.DP-C.20.E.10)
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3102 (DTC 136-04) - Fuel pressure Sensor : Sensor voltage below lower limit 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. Possible failure modes: 1. Faulty rail pressure sensor wiring, short circuit to ground. 2. Faulty rail pressure sensor, internal failure. 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, then continue with step 2. 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. Check the rail pressure sensor engine harness (EN) wiring for a short circuit. Disconnect the engine harness (EN) from the rail pressure sensor. Disconnect the vehicle harness (VE) from the engine interface at connector X-017. 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 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. All pins in connector X-017 There should be no continuity. X-017 (Receptacle) pin 6 A. If there is continuity, then there is a short circuit in the rail pressure sensor engine 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 rail pressure sensor disconnected. Leave connector X-017 disconnected. Continue to step 3. 3. Check the rail pressure sensor vehicle harness (VE) wiring for a short circuit. Disconnect the vehicle harness from the ECU at connector X-016. With the key in the OFF position, use a multimeter to perform the following continuity check on the vehicle harness (VE) side : From X-017 (Receptacle) pin 6 X-016 (Receptacle) pin 41
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Value There should be no continuity. There should be no continuity.
Electrical systems - FAULT CODES
A. If there is continuity, then there is a short 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 no continuity, then continue to step 4. 4. Replace the rail pressure sensor. Use the Electronic Service Tool (EST) to check the status of this fault. 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. 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. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 07 SH07-ENGINE F5C T4 (55.100.DP-C.20.E.07) Wiring harnesses - Electrical schematic sheet 11 SH11-ENGINE F5C T4 (55.100.DP-C.20.E.11)
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3104 (DTC 137-03) - Pressure Relief valve : pressure relief valve is open 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. Possible failure modes: 1. Faulty fuel metering unit wiring, short circuit to another voltage source. 2. Faulty fuel metering unit, internal failure. 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, then continue with step 2. 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 6. 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 Fuel metering unit pin 1
To Fuel metering unit pin 2
Value There should be between 2.6 – 3.2 Ω at approximately 20.0 °C (68.0 °F).
A. If there is between 2.6 – 3.2 Ω, leave the fuel metering unit disconnected. 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. With the key in the OFF position, use a multimeter to perform the following voltage check on the engine harness (EN) side : From Fuel metering unit connector pin 2
To Chassis ground
Value There should be no voltage.
With the key in the ON position, use a multimeter to perform the following voltage check on the engine harness (EN) side : From Fuel metering unit connector pin 2
To Chassis ground
Value 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. 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. Disconnect the vehicle harness (VE) from the engine interface at connector X-017. With the key in the OFF position, use a multimeter to perform the following voltage check on the engine harness (EN) side : From X-017 (Receptacle) pin 2
To All pins in connector X-017.
Value There should be no continuity.
A. If there is no continuity, then leave connector X-017 disconnected. 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. Disconnect the vehicle harness (VE) from the ECU at connector X-016. With the key in the OFF position, use a multimeter to perform the following continuity check from the vehicle harness (VE) side : From X-017 (Receptacle) pin 2 X-016 (Receptacle) pin 60
To All pins in connector X-017. All pins in connector X-016.
Value There should be no continuity. There should be no continuity.
A. If there is continuity, then there is a short circuit in the fuel metering unit low side driver vehicle harness (VE) wiring. Locate and repair the shorted 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. 6. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals, or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 07 SH07-ENGINE F5C T4 (55.100.DP-C.20.E.07) Wiring harnesses - Electrical schematic sheet 11 SH11-ENGINE F5C T4 (55.100.DP-C.20.E.11)
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3105 (DTC 134-04) - Pressure Relief valve : pressure relief valve is forced to open, perform pressure increase 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 - Configure - Reset ECU data (10.218), if necessary. 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), 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, then 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 137-02) - Pressure Relief valve : pressure relief valve reached maximum allowed opening count 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 - Configure - Reset ECU data (10.218), if necessary. NOTE: If the rail pressure sensor is replaced, then 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 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. Possible failure modes: 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. 5. Faulty ECU, software.
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3107 (DTC 259-03) - Fuel Metering Unit : short circuit to battery of metering unit output 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. Possible failure modes: 1. Faulty fuel metering unit wiring, short circuit to another voltage source. 2. Faulty fuel metering unit, internal failure. 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, then continue with step 2. 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 6. 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 Fuel metering unit pin 1
To Fuel metering unit pin 2
Value 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 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. With the key in the OFF position, use a multimeter to perform the following voltage check on the engine harness (EN) side : From Fuel metering unit connector pin 2
To Chassis ground
Value There should be no voltage.
With the key in the ON position, use a multimeter to perform the following voltage check on the engine harness (EN) side : From Fuel metering unit connector pin 2
To Chassis ground
Value 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.
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4. Check the fuel metering unit low side driver engine harness (EN) wiring for a short circuit. Disconnect the vehicle harness (VE) from the engine interface at connector X-017. With the key in the OFF position, use a multimeter to perform the following voltage check on the engine harness (EN) side : From X-017 (Receptacle) pin 2
To All pins in connector X-017.
Value There should be no continuity.
A. If there is no continuity, then leave connector X-017 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. Disconnect the vehicle harness (VE) from the ECU at connector X-016. With the key in the OFF position, use a multimeter to perform the following continuity check from the vehicle harness (VE) side : From X-017 (Receptacle) pin 2 X-016 (Receptacle) pin 60
To All pins in connector X-017. All pins in connector X-016.
Value There should be no continuity. There should be no continuity.
A. If there is continuity, then there is a short circuit in the fuel metering unit low side driver vehicle harness (VE) wiring. Locate and repair the shorted 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. 6. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals, or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 07 SH07-ENGINE F5C T4 (55.100.DP-C.20.E.07) Wiring harnesses - Electrical schematic sheet 11 SH11-ENGINE F5C T4 (55.100.DP-C.20.E.11)
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3108 (DTC 359-04) - Fuel Metering Unit : short circuit to ground of metering unit output 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. Possible failure modes: 1. Faulty fuel metering unit wiring, short circuit to ground. 2. Faulty fuel metering unit, internal failure. 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, then continue with step 2. 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 for a short circuit to ground. Disconnect the engine harness (EN) from the fuel metering unit. Use a multimeter to perform the following continuity and resistance check on the fuel metering unit pins : From Fuel metering unit pin 2 Fuel metering unit pin 1
To Chassis ground Fuel metering unit pin 2
Value There should be no continuity. There should be between 2.6 – 3.2 Ω 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 disconnected and continue to step 3. B. If the specified values are not measured, then the fuel metering unit has a short circuit to ground 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. Disconnect the vehicle harness (VE) from the engine interface at connector X-017. With the key switch in the OFF position, use a multimeter to perform the following continuity check on the engine harness (EN) side : From X-017 (Receptacle) pin 2 X-017 (Receptacle) pin 2
To Chassis ground All pins in connector X-017
Value There should be no continuity. There should be no continuity.
A. If there is continuity, then there is a short circuit in the fuel metering unit engine harness (EN) wiring. Locate and repair the shorted conductor. Repair or replace the harness as required. B. If there is no continuity, then leave connector X-017 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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Disconnect the vehicle harness (VE) from the ECU at connector X-016. With the key switch in the OFF position, use a multimeter to perform the following continuity check on the vehicle harness (VE) side : From X-017 (Receptacle) pin 2 X-017 (Receptacle) pin 2 X-016 (Receptacle) pin 60
To Chassis ground All pins in connector X-017 All pins in connector X-016.
Value There should be no continuity. There should be no continuity. There should be no continuity.
A. If there is continuity, then there is a short circuit in the fuel metering unit vehicle harness (VE) wiring. Locate and repair the shorted conductor. Repair or replace the harness as required. B. If there is no continuity, then check the ECU for the appropriate service manual and re-flash, if necessary. 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. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 07 SH07-ENGINE F5C T4 (55.100.DP-C.20.E.07) Wiring harnesses - Electrical schematic sheet 11 SH11-ENGINE F5C T4 (55.100.DP-C.20.E.11)
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3110 (DTC 236-03) - Fuel pressure Sensor : rail pressure raw value is above maximum offset 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.
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3111 (DTC 236-04) - Fuel pressure Sensor : rail pressure raw value is below minimum offset 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.
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3112 (DTC 136-03) - Fuel pressure Sensor : Sensor voltage above upper limit 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 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 signal circuit. Possible failure modes: 1. Faulty rail pressure sensor wiring, short circuit to another voltage source. 2. Faulty rail pressure sensor wiring, open circuit. 3. Faulty rail pressure sensor, internal failure. 4. 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, then the fault may be intermittent and not currently active. Continue with step 7. 2. Check the rail pressure sensor wiring for a short circuit. Disconnect the engine harness (EN) from the rail pressure sensor. With the key in the OFF position, use a multimeter to perform the following voltage check on the engine harness (EN) side : From To Rail pressure sensor connector pin 2 Chassis ground
Value There should be no voltage.
With the key in the ON position, use a multimeter to perform the following voltage check on the engine harness (EN) side : From To Rail pressure sensor connector pin 2 Chassis ground
Value 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 to 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. Disconnect the vehicle harness (VE) from the engine interface at connector X-017. With the key in the OFF position, use a multimeter to perform the following continuity check on the engine harness (EN) side :
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From To Rail pressure sensor connector pin 2 X-017 (Receptacle) pin 6 Rail pressure sensor connector pin 3 X-017 (Receptacle) pin 7
Value There should be continuity. There should be continuity.
Disconnect the vehicle harness from the ECU at connector X-016. With the key in the OFF position, use a multimeter to perform the following continuity check on the vehicle harness (VE) side : From X-017 (Receptacle) pin 6 X-017 (Receptacle) pin 7
To X-016 (Receptacle) pin 41 X-016 (Receptacle) pin 11
Value There should be continuity. There should be continuity.
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-017 and X-016 disconnected. Continue to step 4. 4. Check the rail pressure sensor engine harness (EN) wiring for a short circuit to another voltage source. 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 Rail pressure sensor connector pin 2 Rail pressure sensor connector pin 3 There should be no continuity. All pins in connector X-017 There should be no continuity. X-017 (Receptacle) pin 6 A. If there is continuity, then there is a short circuit in the rail pressure sensor engine 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 rail pressure sensor disconnected. Leave connectors X-017 and X-016 disconnected. Continue to step 5. 5. Check the rail pressure sensor 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 continuity check on the vehicle harness (VE) side : From X-017 (Receptacle) pin 6 X-016 (Receptacle) pin 41
To All pins in connector X-017 All pins in connector X-016
Value There should be no continuity. There should be no continuity.
A. If there is continuity, then there is a short 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 no continuity, then leave the rail pressure sensor disconnected. Continue to step 6. 6. Replace the rail pressure sensor. Use the Electronic Service Tool (EST) to check the status of this fault. 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. 7. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals, or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved.
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B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 07 SH07-ENGINE F5C T4 (55.100.DP-C.20.E.07) Wiring harnesses - Electrical schematic sheet 11 SH11-ENGINE F5C T4 (55.100.DP-C.20.E.11)
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3137 (DTC 159-02) - Fuel Metering Unit : open load of metering unit output Context: The Engine Control Unit (ECU) monitors the fuel metering unit signal circuit. If the ECU detects an open circuit in the fuel metering unit signal circuit, then this fault will occur. Cause: There is open circuit in the fuel metering unit signal circuit. Possible failure modes: 1. Faulty fuel metering unit wiring, open circuit. 2. Faulty fuel metering unit, internal failure. 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, then continue with step 2. 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. Measure 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 Fuel metering unit pin 1
To Fuel metering unit pin 2
Value 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 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 engine harness (EN) wiring for an open circuit. Disconnect the vehicle harness (VE) from the engine interface at connector X-017. With the key in the OFF position, use a multimeter to perform the following continuity check on the engine harness (EN) side : From To Value X-9007 pin 1 X-9138 pin 1 There should be continuity. X-9007 pin 2 X-9138 pin 2 There should be continuity. NOTE: Wiggle the harness during measurement to reveal an intermittent condition. A. If there is continuity, then leave connector X-017 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 and repair the broken conductor. Repair or replace the harness as required. 4. Check the fuel metering unit vehicle harness (VE) wiring for an open circuit. Disconnect the vehicle harness (VE) from the ECU at connector X-016. 48068130 29/01/2018
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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 There should be continuity. X-017 (Receptacle) pin 1 X-016 (Receptacle) pin 15 There should be continuity. X-017 (Receptacle) pin 2 X-016 (Receptacle) pin 60 NOTE: Wiggle the harness during measurement to reveal an intermittent condition. A. If there is no continuity, then there is an open circuit in the fuel metering unit vehicle harness (VE) wiring. 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 software and re-flash, if necessary. 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. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 07 SH07-ENGINE F5C T4 (55.100.DP-C.20.E.07) Wiring harnesses - Electrical schematic sheet 11 SH11-ENGINE F5C T4 (55.100.DP-C.20.E.11)
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3141 (DTC 158-03) - Fuel Metering Unit : leakage is detected based on fuel quantity balance 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 - Configure - Reset ECU data (10.218), if necessary. 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 fuel rail pressure. If the ECU determines that the requested fuel pressure can not be reached, then 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. Possible failure modes: 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. 11. Faulty ECU, software.
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3146 (DTC 11C-03) - Water sensor in the fuel filter : Water in fuel level sensor defect detection 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, then 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 Engine Control Unit (ECU) has detected excess water in the fuel system or a fault in the water in fuel switch circuit. Possible failure modes: 1. Excess water in the fuel supply. 2. Faulty water in fuel switch, wiring or internal (mechanical and/or electrical) failure. 3. Faulty ECU, software. 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. 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 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 open circuit or a short circuit in the water in fuel switch circuit. Disconnect the water in fuel switch. Disconnect the vehicle (VE) harness from the ECU at connector X-9122. With the key switch in the OFF position, use a multimeter to perform the following tests, on the vehicle (VE) harness from : From X-011 WIF (Plug) pin 1 X-011 WIF (Plug) pin 2 X-011 WIF (Plug) pin 3
To X-012 (Receptacle) pin 30 Chassis ground X-012 (Receptacle) pin 54
Value There should be continuity. There should be continuity. There should be continuity.
Then use the multimeter to perform the following tests, on the vehicle (VE) harness from : 48068130 29/01/2018
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From X-011 WIF (Plug) pin 1 X-011 WIF (Plug) pin 1 X-011 WIF (Plug) pin 2
To X-011 WIF (Plug) pin 2 X-011 WIF (Plug) pin 3 X-011 WIF (Plug) pin 3
Value There should be no continuity. There should be no continuity. There should be no continuity.
Then use the multimeter to perform the following tests, on the vehicle (VE) harness from : From X-011 WIF (Plug) pin 1 X-011 WIF (Plug) pin 3
To Chassis ground Chassis ground
Value There should be no continuity. 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 vehicle harness (VE) wiring. 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 ok. Leave connectors X-012 and X-011 WIF 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 X-011 WIF (Plug) pin 3 X-011 WIF (Plug) pin 1
To Chassis ground Chassis ground
Value There should be key switch voltage. 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 tcontinue with step 6. B. If key switch voltage is not present in the first check or present in the second check, hen there is a problem in the wiring. Repair or replace the harness as required. 6. Replace the water in fuel switch, 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. 7. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals, or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the display indicates other than normal readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 06 SH06-ENGINE F5C T4 (55.100.DP-C.20.E.06) Wiring harnesses - Electrical schematic sheet 38 SH38-CHASSIS INTERFACE (55.100.DP-C.20.E.38) Wiring harnesses - Electrical schematic sheet 10 SH10-ENGINE F5C T4 (55.100.DP-C.20.E.10) Wiring harnesses - Electrical schematic sheet 34 SH34-CHASSIS INTERFACE (55.100.DP-C.20.E.34)
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3157 - ECM Not Detected On CAN Bus - The Engine Dataset Registration Information Was Not Available From The Engine Within The Time Required. Cause: Engine configuration does not match the instrument cluster configuration stored. Possible failure modes: 1. Configuration error 2. Problem in the CAN bus wiring. Solution: 1. Verify the harness is not damaged. Turn the ignition switch OFF. Verify the connections to the ECU, the instrument cluster, the diagnostic connector, the UCM (if installed) and the optional 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. Verify the ground circuits to the control modules are tight and secure. Inspect the rear engine relay box. A. The CAN bus harness is not damaged and all connections are secure. Go to step 1. B. The harness is damaged or the connectors are loose or damaged. Repair or replace the harness as required. Go to step 2 to confirm elimination of fault. 2. Verify that the fault code is active. Connect the Electronic Service Tool to the service tool connector. To check for fault codes: Start and operate the machine. A. Fault code 3157 and/or 3158 are active. No other fault codes are active. The engine configuration does not match the instrument cluster configuration stored. Correct the configuration error. Verify all modules on the CAN bus have the latest software versions. B. Fault code 3157 and other CAN Data Link fault codes such as 9151 - 9154, 9405, 9406, 9410, or 1051 through 1059 are present and ACTIVE. This is an indication of a problem in the CAN Data Link circuit. Refer to 1051 - No CAN Communication With Engine Controller (55.408), step 3.
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3158 - The Engine Dataset Installed Does Not Match The Dataset Registered For This Machine. Register The New Dataset If The Dataset Has Just Been Updated Cause: The engine configuration does not match the instrument cluster configuration stored. Possible failure modes: 1. Configuration error Solution: 1. The engine configuration does not match the instrument cluster configuration stored. Correct the configuration error.
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3166 (DTC 149-03) - ECU Power stages : Short circuit to battery error in power stage of fuel filter heating Context: The Engine Control Unit (ECU) controls the fuel filter heater relay using a low side driver. 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 fuel filter heater relay low side driver circuit. Possible failure modes: 1. Faulty fuel filter heater relay, wiring or internal failure. 2. 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, then the fault may be intermittent and not currently active. Continue with step 6. 2. Check the fuel filter heater relay coil. Remove the fuel filter heater relay. Using a multimeter, perform the following resistance check on the fuel filter heater relay pins from : From Fuel filter heater relay pin 85
To Fuel filter heater relay pin 86
Value There should be approximately 70 – 130 Ω.
A. If there is approximately 70 – 130 Ω, then leave the Fuel filter heater relay disconnected and continue to step 3. B. If there is not approximately 70 – 130 Ω, then the relay has failed. Replace the relay and retest. 3. Check the fuel filter heater relay low side driver vehicle harness (VE) wiring for a short circuit. With the key in the ON position, use a multimeter to perform the following voltage check from the vehicle harness (VE) side of the connector from : From To Fuel filter heater relay connector pin Chassis ground 85
Value There should be no voltage.
With the key in the OFF position, use a multimeter to perform the following continuity check from the vehicle harness (VE) side of the connector from : From Fuel filter heater relay connector pin 85 Fuel filter heater relay connector pin 85 Fuel filter heater relay connector pin 85
To Chassis ground
Value There should be no voltage.
Fuel filter heater relay connector pin There should be no continuity. 86 Fuel filter heater relay connector pin There should be no continuity. 30
A. If the specified values are not measured, then there is a short circuit in the fuel filter heater relay vehicle harness (VE) wiring. Locate and repair the shorted conductor. Repair or replace the harness as required. 48068130 29/01/2018
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B. If the specified values are measured, then leave the connector disconnected and continue to step 4. 4. Check the fuel filter heater relay low side driver vehicle harness (VE) wiring for a short circuit. Disconnect the ECU connector X-012. With the key in the OFF position, use a multimeter to perform the following continuity check from the vehicle harness (VE) side of the connector from : From X-012 (Receptacle) pin 70
To All pins in connector X-012
Value There should be no continuity.
A. If there is continuity, then there is a short circuit in the fuel filter heater 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 continue to step 5. 5. Replace the fuel filter heater relay. Use the Electronic Service Tool (EST) to verify the status of this fault. 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. 6. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals, or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 06 SH06-ENGINE F5C T4 (55.100.DP-C.20.E.06) Wiring harnesses - Electrical schematic sheet 10 SH10-ENGINE F5C T4 (55.100.DP-C.20.E.10)
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3167 (DTC 149-04) - ECU Power stages : Short circuit to ground error in power stage of fuel filter heating Context: The Engine Control Unit (ECU) controls the fuel filter heater relay using a low side driver. 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 fuel filter heater relay low side driver circuit. Possible failure modes: 1. Faulty fuel filter heater relay, wiring or internal failure. 2. 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, then continue with step 2. 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. Check the fuel filter heater relay coil. Remove the fuel filter heater relay. Using a multimeter, perform the following resistance check on the fuel filter heater relay pins from : From Fuel filter heater relay pin 85
To Fuel filter heater relay pin 86
Value There should be approximately 70 – 130 Ω.
A. If there is approximately 70 – 130 Ω, then leave the fuel filter heater relay disconnected and continue to step 3. B. If there is not approximately 70 – 130 Ω, then the relay has failed. Replace the relay and retest. 3. Check the fuel filter heater relay low side driver vehicle harness (VE) wiring for a short circuit. Disconnect the ECU connector X-012. With the key in the OFF position, use a multimeter to perform the following continuity check from the vehicle harness (VE) side of the connector from : From X-012 (Receptacle) pin 70 X-012 (Receptacle) pin 70
To Chassis ground All pins in connector X-9122
Value There should be no continuity. There should be no continuity.
A. If there is continuity, then there is a short circuit to ground in the fuel filter heater 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 continue to step 4. 4. Replace the fuel filter heater relay. Use the Electronic Service Tool (EST) to verify the status of this fault. 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. 48068130 29/01/2018
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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. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 06 SH06-ENGINE F5C T4 (55.100.DP-C.20.E.06) Wiring harnesses - Electrical schematic sheet 10 SH10-ENGINE F5C T4 (55.100.DP-C.20.E.10)
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3168 (DTC 149-02) - ECU Power stages : No load error in power stage of fuel filter heating Context: The Engine Control Unit (ECU) controls the fuel filter heater relay using a low side driver. 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 fuel filter heater relay low side driver circuit. Possible failure modes: 1. Faulty fuel filter heater relay, wiring or internal failure. 2. 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, then the fault may be intermittent and not currently active. Continue with step 5. 2. Check the fuel filter heater relay coil. Remove the fuel filter heater relay. Using a multimeter, perform the following resistance check on the fuel filter heater relay pins from : From Fuel filter heater relay pin 85
To Fuel filter heater relay pin 86
Value There should be approximately 70 – 130 Ω.
A. If there is approximately 70 – 130 Ω, then leave the fuel filter heater relay disconnected and continue to step 3. B. If there is not approximately 70 – 130 Ω, then the relay has failed. Replace the relay and retest. 3. Check the fuel filter heater relay low side driver vehicle harness (VE) wiring for an open circuit. Disconnect the ECU connector X-012. With the key in the OFF position, use a multimeter to perform the following voltage check from the vehicle harness (VE) side of the connector from : From To Value There should be continuity. Fuel filter heater relay connector pin X-012 (Receptacle) pin 70 85 NOTE: Wiggle the harness during measurement to reveal an intermittent condition. A. If there is no continuity, then there is an open circuit in the fuel filter heater relay 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 connector disconnected and continue to step 4. 4. Replace the fuel filter heater relay. Use the Electronic Service Tool (EST) to verify the status of this fault. A. If the fault is no longer active, then return the machine to service.
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B. If the fault is still active, then check the ECU for the appropriate software and re-flash, if necessary. 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. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 06 SH06-ENGINE F5C T4 (55.100.DP-C.20.E.06) Wiring harnesses - Electrical schematic sheet 10 SH10-ENGINE F5C T4 (55.100.DP-C.20.E.10)
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3169 (DTC 149-12) - ECU Power stages : Over Temperature error in power stage of fuel filter heating Context: The Engine Control Unit (ECU) controls the fuel filter heater relay using a low side driver. If the ECU detects an over temperature/current condition in the low side driver circuit, then this fault will occur. Cause: The ECU has detected an over temperature/current condition in the fuel filter heater relay low side driver circuit. Possible failure modes: 1. Faulty fuel filter heater relay wiring, short circuit. 2. Faulty fuel filter heater relay, internal failure. 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, then continue with step 2. 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 6. 2. Check the fuel filter heater relay coil. Remove the fuel filter heater relay. Use a multimeter to measure the resistance on the fuel filter heater relay pins : From Fuel filter heater relay pin 85
To Fuel filter heater relay pin 86
Value There should be approximately 70 – 130 Ω.
A. If there is approximately 70 – 130 Ω, then leave the fuel filter heater relay disconnected and continue to step 3. B. If there is not approximately 70 – 130 Ω, then the fuel filter heater relay has failed. Replace the fuel filter heater relay and retest. 3. Check the fuel filter heater relay low side driver vehicle harness (VE) wiring for a short circuit. With the key in the OFF position, use a multimeter to perform the following voltage check on the vehicle harness (VE) side : From To Fuel filter heater relay connector pin Chassis ground 85
Value There should be no voltage.
With the key in the ON position, use a multimeter to perform the following voltage check on the vehicle harness (VE) side : From To Fuel filter heater relay connector pin Chassis ground 85
Value There should be no voltage.
A. If there is voltage, then there is a short circuit in the fuel filter heater relay low side driver circuit in the vehicle harness (VE). Locate and repair the shorted conductor. B. If there is no voltage, then leave the fuel filter heater relay disconnected and continue to step 4. 48068130 29/01/2018
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4. Check the fuel filter heater relay 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 on the vehicle harness (VE) side : From To Value Fuel filter heater relay connector pin Fuel filter heater relay connector pin There should be no continuity. 85 86 A. If there is continuity, then there is a short circuit in the fuel filter heater relay low 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 continue to step 5. 5. Check the fuel filter heater relay low side driver vehicle harness (VE) wiring for a short circuit. Disconnect the vehicle harness (VE) from the ECU at connector X-012. With the key in the OFF position, use a multimeter to perform the following continuity check on the vehicle harness (VE) side : From X-012 (Receptacle) pin 70
To All pins in connector X-012
Value There should be no continuity.
A. If there is continuity, then there is a short circuit in the fuel filter heater 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 check the ECU for the appropriate software and re-flash, if necessary. 6. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals, or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 06 SH06-ENGINE F5C T4 (55.100.DP-C.20.E.06) Wiring harnesses - Electrical schematic sheet 10 SH10-ENGINE F5C T4 (55.100.DP-C.20.E.10)
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3176 (DTC 157-03) - Fuel Metering Unit : set point of metering unit in overrun mode not plausible Context: The Engine Control Unit (ECU) monitors the high pressure fuel system for leakage during overrun. If the ECU detects that the high pressure pump quantity in overrun exceeds the expected threshold, then this fault will occur. Cause: The ECU has determined that the high pressure fuel pump quantity is higher than the expected fuel quantity threshold. Possible failure modes: 1. Faulty fuel metering unit, internal failure. 2. Faulty high pressure fuel pump, internal failure. 3. Faulty ECU, software.
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3177 (DTC 54C-03) - Engine Protection : Over speed detection in component engine protection Context: This fault is intended for information purposes only and does not require any further action. Other active faults may have caused this fault to occur. Diagnose any other active faults first and then return to this fault, 3177 (DTC 54C03) â&#x20AC;&#x201C; Engine Protection : Over speed detection in component engine protection. 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 2B4-02) - CAN Bus Received frames : CAN-ReceiveFrame BC2EDC2 Context: The Engine Control Unit (ECU) 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 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. If the ECU senses that CAN Node A Bus is not functioning properly, then this fault will occur. Cause: ECU has sensed a time out of required vehicle controller data provided on CAN Node A. Possible failure modes: 1. Faulty supply voltage or ground, missing. 2. Faulty CAN circuit wiring, open circuit, short circuit to ground, or short circuit. 3. Faulty ECU, termination resistor or software. Solution: 1. Verify fault is present and in active state. Use the Electronic Service Tool (EST) to check the status of this fault. A. If the fault is 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 6. 2. Check for other vehicle CAN faults. Use the EST to determine if vehicle CAN faults exist. A. If other vehicle CAN faults exist, then resolve the vehicle CAN faults, then check to see that 3179 (DTC 2B4-02) â&#x20AC;&#x201C; CAN Bus Received frames : CAN-Receive-Frame BC2EDC2 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-012. To energize the ECU main relay, place a jumper wire between X-012 (Receptacle) pin 28 and chassis ground. With the key switch in the ON position, use a multimeter to check for voltage on the vehicle (VE) harness side : From X-012 (Receptacle) pin 1 X-012 (Receptacle) pin 3 X-012 (Receptacle) pin 5
To Chassis ground Chassis ground Chassis ground
Value There should be 12.0 V. There should be 12.0 V. There should be 12.0 V.
A. If the voltage is present on all of the checks, then leave connector X-012 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 replace the harness as required. 4. Check the ECU grounding. 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 X-012 (Receptacle) pin 2 X-012 (Receptacle) pin 4 X-012 (Receptacle) pin 6
To Chassis ground Chassis ground Chassis ground
Value There should be continuity. There should be continuity. There should be continuity.
A. If there is continuity on all of the checks, then leave connector X-012 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 minus battery 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 X-012 (Receptacle) pin 24 X-012 (Receptacle) pin 24 X-012 (Receptacle) pin 25
To X-012 (Receptacle) pin 25 Chassis ground Chassis ground
Value There should be 120 Ί. There should not be continuity. There should not be continuity.
Use a multimeter to measure the resistance of the CAN termination resistor, internal to the ECU : From X-012 (Receptacle) pin 24
To X-012 (Receptacle) pin 25
Value There should be 120 Ί.
A. If the measured resistances are correct and neither conductor is grounded, then check the ECU 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, then locate and restore the termination resistance to the CAN circuit. 6. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals, or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 06 SH06-ENGINE F5C T4 (55.100.DP-C.20.E.06) Wiring harnesses - Electrical schematic sheet 10 SH10-ENGINE F5C T4 (55.100.DP-C.20.E.10)
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3180 (DTC 1B5-02) - CAN Bus Received frames : CAN-ReceiveFrame from the Vehicle Control Module to EDC (VM2EDC) 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 time out of the required vehicle controller data provided on CAN Node A. Possible failure modes: 1. Faulty vehicle system, related CAN fault. 2. Faulty supply voltage or ground, missing. 3. Faulty CAN circuit wiring, open circuit, short to ground, or short circuit. 4. Faulty ECU, termination resistor or software. Solution: 1. Verify fault is present and in active state. Use the Electronic Service Tool (EST) to check the status of this fault. A. If the fault is 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 6. 2. Check for other vehicle CAN faults. Use the EST to determine if vehicle CAN faults exist. A. If other vehicle CAN faults exist, then resolve the vehicle CAN faults, then check to see that this fault 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-012. To energize the ECU main relay which provides power to the ECU, place a jumper wire between the vehicle harness (VE) side of connector X-012 (Receptacle) pin 28 and chassis ground. Use a multimeter to check for voltage on the vehicle (VE) harness side : From X-012 (Receptacle) pin 1 X-012 (Receptacle) pin 3 X-012 (Receptacle) pin 5
To Chassis ground Chassis ground Chassis ground
Value There should be 12.0 V. There should be 12.0 V. There should be 12.0 V.
A. If the voltage is present on all of the checks, then leave connector X-012 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 replace the harness as required. 4. Check the ECU grounding. 48068130 29/01/2018
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Use a multimeter to check for continuity on the vehicle (VE) harness side : From X-012 (Receptacle) pin 2 X-012 (Receptacle) pin 4 X-012 (Receptacle) pin 6
To Chassis ground Chassis ground Chassis ground
Value There should be continuity. There should be continuity. There should be continuity.
A. If there is continuity on all of the checks, then leave connector X-012 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 minus battery 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 X-012 (Receptacle) pin 24 X-012 (Receptacle) pin 24 X-012 (Receptacle) pin 25
To X-012 (Receptacle) pin 25 Chassis ground Chassis ground
Value There should be 120 Ω. There should not be continuity. There should not be continuity.
Use a multimeter to measure the resistance of the CAN termination resistor, internal to the ECU : From X-012 (Receptacle) pin 24
To X-012 (Receptacle) pin 25
Value There should be 120 Ω.
A. If the measured resistances are correct and neither conductor is grounded, then check the ECU 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, then locate and restore the termination resistance to the CAN circuit or replace the ECU. 6. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals, or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 06 SH06-ENGINE F5C T4 (55.100.DP-C.20.E.06) Wiring harnesses - Electrical schematic sheet 10 SH10-ENGINE F5C T4 (55.100.DP-C.20.E.10)
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3188 (DTC 167-02) - Injector, solenoid : Open load error of an injector 1 (interruption of an electric connection) Context: The Engine Control Unit (ECU) monitors the fuel injector number 1 circuit. If the ECU determines that there is an open circuit 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. Possible failure modes: 1. Faulty fuel injector number 1, internal failure. 2. Faulty fuel injector number 1 wiring, open circuit. 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, then continue with step 2. 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. Check fuel injector number 1 for an internal failure. Disconnect the engine harness from the fuel injector number 1. Use a multimeter to perform the following resistance check on the fuel injector pins : From Fuel injector number 1 pin 1
To Fuel injector number 1 pin 2
Value There should be approximately 0.3 â&#x20AC;&#x201C; 0.5 Ί.
A. If the specified range is not measured, then the fuel injector has failed. Replace the fuel injector number 1 and retest. 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-015 from the engine interface connector. With they key in the OFF position, use a multimeter to perform the following continuity check on the engine harness (EN) side: From X-015 (Female) pin A X-015 (Female) pin B
To Value Fuel injector number 1 connector pin There should be continuity. 1 Fuel injector number 1 connector pin There should be continuity. 2
A. If there is no continuity, then there is an open circuit in the fuel injector number 1 engine harness (EN) wiring. Locate and repair the broken conductor. Repair or replace the harness as required. B. If there is continuity, then leave fuel injector number 1 disconnected. Leave connector X-015 disconnected. Continue to step 4. 4. Check the fuel injector number 1 vehicle harness (VE) wiring for an open circuit.
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Disconnect the vehicle harness (VE) from the ECU at connector X-016. With they key in the OFF position, use a multimeter to perform the following continuity check on the vehicle harness (VE) side: From X-015 (Female) pin A X-015 (Female) pin B
To X-016 (Receptacle) pin 16 X-016 (Receptacle) pin 32
Value There should be continuity. There should be continuity.
A. If there is no continuity, then there is an open circuit in the fuel injector number 1 vehicle harness (VE) wiring. 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. 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. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 07 SH07-ENGINE F5C T4 (55.100.DP-C.20.E.07) Wiring harnesses - Electrical schematic sheet 11 SH11-ENGINE F5C T4 (55.100.DP-C.20.E.11)
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3192 (DTC 168-02) - Injector, solenoid : Open load error of an injector 2 (interruption of an electric connection) Context: The Engine Control Unit (ECU) monitors the fuel injector number 2 circuit. If the ECU determines that there is an open circuit in the fuel injector number 2 circuit, then this fault will occur. Cause: The ECU has detected an open circuit in the fuel injector number 2 circuit. Possible failure modes: 1. Faulty fuel injector number 2, internal failure. 2. Faulty fuel injector number 2 wiring, open circuit. 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, then continue with step 2. 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. Check fuel injector number 2 for an internal failure. Disconnect the engine harness from fuel injector number 2. Use a multimeter to perform the following resistance check on the fuel injector pins : From Fuel injector number 2 pin 1
To Fuel injector number 2 pin 2
Value There should be approximately 0.3 â&#x20AC;&#x201C; 0.5 Ί.
A. If the specified range is not measured, then the fuel injector has failed. Replace the fuel injector number 2 and retest. B. If the specified range is measured, then leave fuel injector number 2 disconnected and continue to step 3. 3. Check the fuel injector number 2 engine harness (EN) wiring for an open circuit. Disconnect connector X-015 from the engine interface connector. With they key in the OFF position, use a multimeter to perform the following continuity check on the engine harness (EN) side : From X-015 (Female) pin H X-015 (Female) pin G
To Value Fuel injector number 2 connector pin There should be continuity. 1 Fuel injector number 2 connector pin There should be continuity. 2
A. If there is no continuity, then there is an open circuit in the fuel injector number 2 Y-9002 engine harness (EN) wiring. Locate and repair the broken conductor. Repair or replace the harness as required. B. If there is continuity, then leave fuel injector number 2 disconnected. Leave connector X-015 disconnected. Continue to step 4. 4. Check the fuel injector number 2 vehicle harness (VE) wiring for an open circuit.
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Disconnect the vehicle harness (VE) from the ECU at connector X-016. With they key in the OFF position, use a multimeter to perform the following continuity check on the vehicle harness (VE) side : From X-015 (Female) pin H X-015 (Female) pin G
To X-016 (Receptacle) pin 2 X-016 (Receptacle) pin 46
Value There should be continuity. There should be continuity.
A. If there is no continuity, then there is an open circuit in the fuel injector number 2 vehicle harness (VE) wiring. 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. 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. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 07 SH07-ENGINE F5C T4 (55.100.DP-C.20.E.07) Wiring harnesses - Electrical schematic sheet 11 SH11-ENGINE F5C T4 (55.100.DP-C.20.E.11)
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3196 (DTC 169-02) - Injector, solenoid : Open load error of an injector 3 (interruption of an electric connection) Context: The Engine Control Unit (ECU) monitors the fuel injector number 3 circuit. If the ECU determines that there is an open circuit in the fuel injector number 3 circuit, then this fault will occur. Cause: The ECU has detected an open circuit in the fuel injector number 3 circuit. Possible failure modes: 1. Faulty fuel injector number 3, internal failure. 2. Faulty fuel injector number 3 wiring, open circuit. 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, then continue with step 2. 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. Check fuel injector number 3 for an internal failure. Disconnect the engine harness from fuel injector number 3. Use a multimeter to perform the following resistance check on the fuel injector pins : From Fuel injector number 3 pin 1
To Fuel injector number 3 pin 2
Value There should be approximately 0.3 â&#x20AC;&#x201C; 0.5 Ί.
A. If the specified range is not measured, then the fuel injector has failed. Replace the fuel injector number 3 and retest. B. If the specified range is measured, then leave fuel injector number 3 disconnected and continue to step 3. 3. Check the fuel injector number 3 engine harness (EN) wiring for an open circuit. Disconnect connector X-015 from the engine interface connector. With they key in the OFF position, use a multimeter to perform the following continuity check on the engine harness (EN) side : From X-015 (Female) pin D X-015 (Female) pin C
To Fuel injector number 3 pin 1 Fuel injector number 3 pin 2
Value There should be continuity. There should be continuity.
A. If there is no continuity, then there is an open circuit in the fuel injector number 3 engine harness (EN) wiring. Locate and repair the broken conductor. Repair or replace the harness as required. B. If there is continuity, then leave fuel injector number 3 disconnected. Leave connector X-015 disconnected. Continue to step 4. 4. Check the fuel injector number 3 vehicle harness (VE) wiring for an open circuit. Disconnect the vehicle harness (VE) from the ECU at connector X-016.
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With they key in the OFF position, use a multimeter to perform the following continuity check on the vehicle harness (VE) side : From X-015 (Female) pin D X-015 (Female) pin C
To X-016 (Receptacle) pin 1 X-016 (Receptacle) pin 31
Value There should be continuity. There should be continuity.
A. If there is no continuity, then there is an open circuit in the fuel injector number 3 vehicle harness (VE) wiring. 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. 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. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 07 SH07-ENGINE F5C T4 (55.100.DP-C.20.E.07) Wiring harnesses - Electrical schematic sheet 11 SH11-ENGINE F5C T4 (55.100.DP-C.20.E.11)
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3200 (DTC 16A-02) - Injector, solenoid : Open load error of an injector 4 (interruption of an electric connection) Context: The Engine Control Unit (ECU) monitors the fuel injector number 4 circuit. If the ECU determines that there is an open circuit in the fuel injector number 4 circuit, then this fault will occur. Cause: The ECU has detected an open circuit in the fuel injector number 4 circuit. Possible failure modes: 1. Faulty fuel injector number 4, internal failure. 2. Faulty fuel injector number 4 wiring, open circuit. 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, then continue with step 2. 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. Check fuel injector number 4 for an internal failure. Disconnect the engine harness from fuel injector number 4. Use a multimeter to perform the following resistance check on the fuel injector pins : From Fuel injector number 4 pin 1
To Fuel injector number 4 pin 2
Value There should be approximately 0.3 â&#x20AC;&#x201C; 0.5 Ί.
A. If the specified range is not measured, then the fuel injector has failed. Replace the fuel injector number 4 and retest. B. If the specified range is measured, then leave fuel injector number 4 disconnected and continue to step 3. 3. Check the fuel injector number 4 engine harness (EN) wiring for an open circuit. Disconnect connector X-015 from the engine interface connector. With they key in the OFF position, use a multimeter to perform the following continuity check on the engine harness (EN) side: From X-015 (Female) pin E X-015 (Female) pin F
To Value Fuel injector number 4 connector pin There should be continuity. 1 Fuel injector number 4 connector pin There should be continuity. 2
A. If there is no continuity, then there is an open circuit in the fuel injector number 4 engine harness (EN) wiring. Locate and repair the broken conductor. Repair or replace the harness as required. B. If there is continuity, then leave fuel injector number 4 disconnected. Leave connector X-015 disconnected. Continue to step 4. 4. Check the fuel injector number 4 vehicle harness (VE) wiring for an open circuit.
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Disconnect the vehicle harness (VE) from the ECU at connector X-016. With they key in the OFF position, use a multimeter to perform the following continuity check on the vehicle harness (VE) side : From X-015 (Female) pin E X-015 (Female) pin F
To X-016 (Receptacle) pin 17 X-016 (Receptacle) pin 48
Value There should be continuity. 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. 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. 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. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 07 SH07-ENGINE F5C T4 (55.100.DP-C.20.E.07) Wiring harnesses - Electrical schematic sheet 11 SH11-ENGINE F5C T4 (55.100.DP-C.20.E.11)
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3210 (DTC 171-03) - Injector, solenoid : Short circuit in an injection bank 1 (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 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 a short circuit between both bank 1 fuel injectors. Possible failure modes: 1. Faulty fuel injector wiring, short circuit. 2. Fault 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, then the fault may be intermittent and not currently active. Continue with step 5. 2. Use the Electronic Service Tool (EST) to check if the following related faults are active: 3063 (DTC 161-02) – Injector, solenoid Power stage : Short circuit in the injector 1 3083 (DTC 164-02) – Injector, solenoid Power stage : Short circuit in the injector 4 A. If any of the related faults are active, diagnose them first and then return to this fault, 3210 (DTC 171-03) – Injector, solenoid : Short circuit in an injection bank 1 (all injectors of the same bank can be affected). B. If none of the related faults are active, continue to step 3. 3. Check the fuel injector harness (INJ) for a short circuit. Disconnect the vehicle harness (VE) from the engine interface connector X-015. With the key in the OFF position, use a multimeter to perform the following continuity check on the fuel injector harness (INJ) side : X-015 X-015 X-015 X-015
From (Female) pin A (Female) pin A (Female) pin B (Female) pin B
X-015 X-015 X-015 X-015
(Female) (Female) (Female) (Female)
To pin pin pin pin
E F E F
Value There should be no continuity. There should be no continuity. There should be no continuity. There should be no continuity.
A. If there is continuity, then there is a short circuit in the fuel injector number 4 fuel injector harness (INJ) wiring. Locate and repair the shorted conductor. Repair or replace the harness as required. B. If there is no continuity, then leave the engine interface connector X-015 disconnected and continue to step 4. 4. Check the fuel injector number 4 vehicle harness (VE) 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 :
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X-015 X-015 X-015 X-015
From (Female) pin A (Female) pin A (Female) pin B (Female) pin B
X-015 X-015 X-015 X-015
(Female) (Female) (Female) (Female)
To pin pin pin pin
E F E F
Value There should be no continuity. There should be no continuity. There should be no continuity. There should be no continuity.
A. If there is continuity, then there is a short circuit in the fuel injector number 4 vehicle harness (VE) wiring. Locate and repair the shorted 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. 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. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 07 SH07-ENGINE F5C T4 (55.100.DP-C.20.E.07) Wiring harnesses - Electrical schematic sheet 11 SH11-ENGINE F5C T4 (55.100.DP-C.20.E.11)
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3218 (DTC 173-03) - Injector, solenoid : Short circuit in an injection bank 2 (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 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 a short circuit between both bank 2 fuel injectors. Possible failure modes: 1. Faulty bank fuel injector wiring, short circuit. 2. Fault 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, then continue with step 2. 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. Use the Electronic Service Tool (EST) to check if the following related faults are active: 3071 (DTC 163-02) – Injector, solenoid Power stage : Short circuit in the injector 3 3079 (DTC 162-02) – Injector, solenoid Power stage : Short circuit in the injector 2 A. If any of the related faults are active, then diagnose them first and then return to this fault, 3218 (DTC 173-03) – Injector, solenoid : Short circuit in an injection bank 2 (all injectors of the same bank can be affected). 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. Disconnect the vehicle harness (VE) from the engine interface at connector X-015. With the key in the OFF position, use a multimeter to perform the following continuity check on the injector harness (INJ) side : X-015 X-015 X-015 X-015
From (Female) pin D (Female) pin D (Female) pin C (Female) pin C
X-015 X-015 X-015 X-015
(Female) (Female) (Female) (Female)
To pin pin pin pin
H G H G
Value There should be no continuity. There should be no continuity. There should be no continuity. 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 conductor. Repair or replace the harness as required. B. If there is no continuity, then leave the engine interface connector X-015 disconnected and continue to step 4. 4. Check the fuel injector vehicle harness (VE) 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 :
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X-015 X-015 X-015 X-015
From (Female) pin D (Female) pin D (Female) pin C (Female) pin C
X-015 X-015 X-015 X-015
(Female) (Female) (Female) (Female)
To pin pin pin pin
H G H G
Value There should be no continuity. There should be no continuity. There should be no continuity. 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 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. 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. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 07 SH07-ENGINE F5C T4 (55.100.DP-C.20.E.07) Wiring harnesses - Electrical schematic sheet 11 SH11-ENGINE F5C T4 (55.100.DP-C.20.E.11)
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3230 (DTC 17C-12) - Injector, solenoid Power stage : Chip error in the Injector CY33x power stage component Context: The Engine Control Unit (ECU) monitors diagnostic checks on the fuel injection power stages. This diagnostic procedure uses pattern detection to identify specific errors and can trigger the appropriate reaction. If the ECU detects a specific combination of errors in the injection power stages, this fault will occur. Solution: 1. Check the ECU for the appropriate software and re-flash, if necessary. A. If the fault has been resolved, return the machine to service. B. If the fault has not been resolved, escalate an ASIST concern.
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3235 (DTC 17E-03) - Injection control : Number of injections is limited by runtime Context: The ECU monitors the requested number of fuel injections and the current capability of the injection system fulfilling that request. If the ECU determines that the requested number of injections is greater than the current capability of the fuel injection system for the current engine speed, then this fault will occur. Cause: The ECU has determined that the requested number of fuel injections is greater than the capability of the fuel injection system based on engine speed. Solution: 1. Check the ECU for the appropriate software and re-flash, if necessary. A. If the fault has been resolved, return the machine to service. B. If the fault has not been resolved, escalate an ASIST concern.
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3236 (DTC 17E-04) - Injection control : Number of injections is limited by system 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, then 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. Possible failure modes: 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.
6.
Faulty fuel filters, clogged.
7.
Faulty charge gear pump, low efficiency.
8.
Faulty Pressure Relief Valve (PRV), leakage.
9.
Faulty rail pressure sensor, drifted signal or leakage.
10. Faulty fuel injection system, leaking or blocked lines. 11. Faulty ECU, software.
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3237 (DTC 17E-02) - Injection control : 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. Possible failure modes: 1. Faulty battery, low voltage. 2. Faulty ECU, power supply. 3. Faulty ECU, software. 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 ECU connector X-012. With the key in the ON position, use a multimeter to perform the following voltage check : From X-012 (Receptacle) pin 1
Chassis ground
To
X-012 (Receptacle) pin 3
Chassis ground
X-012 (Receptacle) pin 5
Chassis ground
Value There should be approximately 12.0 V. There should be approximately 12.0 V. There should be approximately 12.0 V.
A. If there is approximately 12.0 V, then leave the connector disconnected and continue to step 3. 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. 3. Check the ECU ground supply wiring. With the key in the OFF position, use a multimeter to perform the following continuity check : From X-012 (Receptacle) pin 2 X-012 (Receptacle) pin 4 X-012 (Receptacle) pin 6
To Chassis ground Chassis ground Chassis ground
Value There should be continuity. There should be continuity. There should be continuity.
A. If there is no continuity, then there is a problem with the minus battery connection to the ECU. Repair or replace the harness as required. B. If there is continuity, then continue to step 4. 4. Check the ECU for the appropriate software and re-flash, if necessary. 48068130 29/01/2018
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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. Wiring harnesses - Electrical schematic sheet 06 SH06-ENGINE F5C T4 (55.100.DP-C.20.E.06) Wiring harnesses - Electrical schematic sheet 10 SH10-ENGINE F5C T4 (55.100.DP-C.20.E.10)
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3238 (DCT 1D1-03) - ECU Power stages : SPI/COM-Errors of the power failure detection of CY320 Context: The Engine Control Unit (ECU) performs a diagnostic check of the sensor supplies by monitoring the sensor supplies communication. If the ECU detects a communication error during this diagnostic check, then this fault will occur. Cause: The ECU has detected a communication error during a diagnostic check. 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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3239 (DTC 1D2-04) - EEPROM : EEP Read Error based on the error for more blocks Context: The Engine Control Unit (ECU) has detected an error during the last EEPROM write operation. The hardware encapsulation of the ECU checks each data block of the EEPROM and sets a status flag depending on if an error is found or not found. These flags are processed every 20 milliseconds by the Diagnostic System Management (DSM) and if the value is out of range, then this fault will occur. 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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3240 (DTC 1D2-02) - EEPROM : EEP Write Error based on the error for one block Context: The Engine Control Unit (ECU) has detected an error during the last EEPROM write operation. The hardware encapsulation of the ECU checks each data block of the EEPROM and sets a status flag depending on if an error is found or not found. These flags are processed every 20 milliseconds by the Diagnostic System Management (DSM) and if the value is out of range, this fault will occur. Solution: 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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3241 (DTC 1D2-12) - EEPROM : There was an error during Write/Read EEPROM operation Context: The Engine Control Unit (ECU) has detected an error during the last EEPROM write operation. The hardware encapsulation of the ECU checks each data block of the EEPROM and sets a status flag depending on if an error is found or not found. These flags are processed every 20 milliseconds by the Diagnostic System Management (DSM) and if the value is out of range, then this fault will occur. 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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3242 (DTC 1D3-12) - ECU internal : Visibility of Software Resets in DSM Context: If this fault is active, the Engine Control Unit (ECU) has detected an error that has led to a software reset. 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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3243 (DTC 2D3-12) - ECU internal : Visibility of 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: 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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3244 (DTC 3D3-12) - ECU internal : Visibility of 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: 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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3245 (DTC 1D4-12) - Analog Digital Converter (ADC) : Diagnostic fault check to report errors in query-/response-communication Context: The Engine Control Unit (ECU) monitors the communication between the ECU processor and the power stage controller over the SPI bus. If there is an error in the communication, then this fault will occur. 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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3252 (DTC 1D8-12) - Analog Digital Converter (ADC) : Diagnostic fault check to report errors in SPI-communication Context: The Engine Control Unit (ECU) monitors the communication between the ECU processor and the power stage controller over the SPI bus. If there is an error in the communication, then this fault will occur. 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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3253 (DTC 1D9-03) - Analog Digital Converter (ADC) : Diagnostic fault check to report the error in Voltage ratio in ADC monitoring Context: The Engine Control Unit (ECU) monitors the Analog Digital Converter (ADC) for plausibility by providing a test voltage to be converted. If the converted voltage is out of range, then this fault will occur. 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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3255 (DTC 1D9-02) - Analog Digital Converter (ADC) : Diagnostic fault check to report the ADC test error Context: The Engine Control Unit (ECU) monitors the Analog Digital Converter (ADC) plausibility by performing a fixed input voltage test. If the voltage during the test is out of range, this fault will occur. Solution: 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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3256 (DTC 1D9-12) - Analog Digital Converter (ADC) : Diagnostic fault check to report the NTP error in ADC monitoring Context: The Engine Control Unit (ECU) monitors the Analog Digital Converter (ADC) plausibility by running a No-load Test Pulse operation (NTP). If the ECU detects an error during this operation, then this fault will occur. 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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3258 (DTC 1E1-03) - ECU Power stages : Starter relay HS power stage output short circuit to battery Context: The Engine Control Unit (ECU) controls the engine relay A 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 engine relay A high side driver circuit. Possible failure modes: 1. Faulty engine relay A wiring, short circuit to another voltage source. 2. Faulty engine relay A, internal failure. 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, then the fault may be intermittent and not currently active. Continue with step 5. 2. Check the engine relay A coil for an internal failure. Remove the engine relay A. Use a multimeter to measure the relay coil resistance on the engine relay A pins : From Engine relay A pin 85
To Engine relay A pin 86
Value There should be approximately 70 – 130 Ω.
A. If there is approximately 70 – 130 Ω, then leave the engine relay A disconnected and continue to step 3. B. If there is not approximately 70 – 130 Ω, then the relay has failed. Replace the engine relay A and retest. 3. Check the engine relay A 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 perform the following voltage check for short circuit to another voltage source on the vehicle harness (VE) side : From X-FUSE2 (Receptacle) pin 41
To Chassis ground
Value There should be no voltage.
With the key in the ON position, use a multimeter to perform the following voltage check for short circuit to another voltage source on the vehicle harness (VE) side : From X-FUSE2 (Receptacle) pin 41
To Chassis ground
Value There should be no voltage.
A. If there is voltage, then there is a short circuit to another voltage source in the engine relay A 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. 4. Check the engine relay A high side driver vehicle harness (VE) wiring for a short circuit. Disconnect the vehicle harness (VE) from the ECU at connector X-012. 48068130 29/01/2018
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With the key in the OFF position, use a multimeter to perform the following continuity check for short circuit on the vehicle harness (VE) side : From X-012 (Receptacle) pin 53
To All pins in connector X-012
Value There should be no continuity.
A. If there is continuity, then there is a short circuit in the engine relay A 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 check the ECU for the appropriate service manual and re-flash, if necessary. 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. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 06 SH06-ENGINE F5C T4 (55.100.DP-C.20.E.06) Wiring harnesses - Electrical schematic sheet 08 SH08-ENGINE F5C T4 (55.100.DP-C.20.E.08) Wiring harnesses - Electrical schematic sheet 37 SH37-CHASSIS INTERFACE X-900/X-901 LG (55.100.DP-C.20.E.37) Wiring harnesses - Electrical schematic sheet 39 SH39-CHASSIS INTERFACE X-900/X-901 MD (55.100.DP-C.20.E.39)
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3258 (DTC 1E1-03) - ECU Power stages : Starter relay HS power stage output short circuit to battery Context: The Engine Control Unit (ECU) controls the engine relay A 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 engine relay A high side driver circuit. Possible failure modes: 1. Faulty engine relay A wiring, short circuit to another voltage source. 2. Faulty engine relay A, internal failure. 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, then the fault may be intermittent and not currently active. Continue with step 5. 2. Check the engine relay A coil for an internal failure. Remove the engine relay A. Use a multimeter to measure the relay coil resistance on the engine relay A pins : From Engine relay A pin 85
To Engine relay A pin 86
Value There should be approximately 70 – 130 Ω.
A. If there is approximately 70 – 130 Ω, then leave the engine relay A disconnected and continue to step 3. B. If there is not approximately 70 – 130 Ω, then the relay has failed. Replace the engine relay A and retest. 3. Check the engine relay A 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 perform the following voltage check for short circuit to another voltage source on the vehicle harness (VE) side : From Medium machines X-FUSE1 MD (Receptacle) pin 25 Large machines X-FUSE1 LG (Receptacle) pin 41
To Chassis ground
Value There should be no voltage.
With the key in the ON position, use a multimeter to perform the following voltage check for short circuit to another voltage source on the vehicle harness (VE) side : From Medium machines X-FUSE1 MD (Receptacle) pin 25 Large machines X-FUSE1 LG (Receptacle) pin 41
To Chassis ground
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Value There should be no voltage.
Electrical systems - FAULT CODES
A. If there is voltage, then there is a short circuit to another voltage source in the engine relay A 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. 4. Check the engine relay A high side driver vehicle harness (VE) wiring for a short circuit. Disconnect the vehicle harness (VE) from the ECU at connector X-012. With the key in the OFF position, use a multimeter to perform the following continuity check for short circuit on the vehicle harness (VE) side : From X-012 (Receptacle) pin 53
To All pins in connector X-012
Value There should be no continuity.
A. If there is continuity, then there is a short circuit in the engine relay A 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 check the ECU for the appropriate service manual and re-flash, if necessary. 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. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 10 SH10-EH PUMP/HYDRAULICS (55.100.DP-C.20.E.10) Wiring harnesses - Electrical schematic sheet 09 SH09-ENGINE F5C T4 (55.100.DP-C.20.E.09) Wiring harnesses - Electrical schematic sheet 33 SH33-CHASSIS INTERFACE LG (55.100.DP-C.20.E.33) Wiring harnesses - Electrical schematic sheet 35 SH35-CHASSIS INTERFACE MD (55.100.DP-C.20.E.35)
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3259 (DTC 1E1-04) - ECU Power stages : Starter relay HS power stage output short circuit to ground Context: The Engine Control Unit (ECU) controls the engine relay A using a low side and high side driver. If 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 engine relay A high side driver circuit. Possible failure modes: 1. Faulty engine relay A wiring, short circuit to ground. 2. Faulty engine relay A, internal failure. 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, then continue with step 2. 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. Check the engine relay A coil for an internal failure. Remove the engine relay A. Use a multimeter to measure the relay coil resistance on the engine relay A pins : From Engine relay A pin 85
To Engine relay A pin 86
Value There should be approximately 70 – 130 Ω.
A. If there is approximately 70 – 130 Ω, then leave the engine relay A disconnected and continue to step 3. B. If there is not approximately 70 – 130 Ω, then the relay has failed. Replace the engine relay A and retest. 3. Check the engine relay A 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 a short circuit to ground on the vehicle harness (VE) side : From X-FUSE2 (Receptacle) pin 41 X-FUSE2 (Receptacle) pin 41
To Chassis ground X-FUSE2 (Receptacle) pin 54
Value There should be no continuity. There should be no continuity.
A. If there is continuity, then there is a short circuit to ground in the engine relay A 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 to step 4. 4. Check the engine relay A high side driver vehicle harness (VE) wiring for a short circuit. Disconnect the vehicle harness (VE) from the ECU at connector X-012. With the key in the OFF position, use a multimeter to perform the following continuity check for a short circuit to ground on the vehicle harness (VE) side :
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From X-012 (Receptacle) pin 53
To All pins in connector X-012
Value There should be no continuity.
A. If there is continuity, then there is a short circuit to ground in the engine relay A 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 check the ECU for the appropriate service manual and re-flash, if necessary. 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. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 06 SH06-ENGINE F5C T4 (55.100.DP-C.20.E.06) Wiring harnesses - Electrical schematic sheet 08 SH08-ENGINE F5C T4 (55.100.DP-C.20.E.08) Wiring harnesses - Electrical schematic sheet 37 SH37-CHASSIS INTERFACE X-900/X-901 LG (55.100.DP-C.20.E.37) Wiring harnesses - Electrical schematic sheet 39 SH39-CHASSIS INTERFACE X-900/X-901 MD (55.100.DP-C.20.E.39)
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3259 (DTC 1E1-04) - ECU Power stages : Starter relay HS power stage output short circuit to ground Context: The Engine Control Unit (ECU) controls the engine relay A using a low side and high side driver. If 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 engine relay A high side driver circuit. Possible failure modes: 1. Faulty engine relay A wiring, short circuit to ground. 2. Faulty engine relay A, internal failure. 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, then continue with step 2. 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. Check the engine relay A coil for an internal failure. Remove the engine relay A. Use a multimeter to measure the relay coil resistance on the engine relay A pins : From Engine relay A pin 85
To Engine relay A pin 86
Value There should be approximately 70 – 130 Ω.
A. If there is approximately 70 – 130 Ω, then leave the engine relay A disconnected and continue to step 3. B. If there is not approximately 70 – 130 Ω, then the relay has failed. Replace the engine relay A and retest. 3. Check the engine relay A 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 a short circuit to ground on the vehicle harness (VE) side : From Medium machines X-FUSE1 MD (Receptacle) pin 25 Large machines X-FUSE1 LG (Receptacle) pin 41 Medium machines X-FUSE1 MD (Receptacle) pin 25 Large machines X-FUSE1 LG (Receptacle) pin 41
To Chassis ground
Medium machines X-FUSE1 MD (Receptacle) pin 34 Large machines X-FUSE1 LG (Receptacle) pin 54
Value There should be no continuity.
There should be no continuity.
A. If there is continuity, then there is a short circuit to ground in the engine relay A 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 to step 4. 4. Check the engine relay A high side driver vehicle harness (VE) wiring for a short circuit. 48068130 29/01/2018
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Disconnect the vehicle harness (VE) from the ECU at connector X-012. With the key in the OFF position, use a multimeter to perform the following continuity check for a short circuit to ground on the vehicle harness (VE) side : From X-012 (Receptacle) pin 53
To All pins in connector X-012
Value There should be no continuity.
A. If there is continuity, then there is a short circuit to ground in the engine relay A 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 check the ECU for the appropriate service manual and re-flash, if necessary. 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. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 10 SH10-EH PUMP/HYDRAULICS (55.100.DP-C.20.E.10) Wiring harnesses - Electrical schematic sheet 09 SH09-ENGINE F5C T4 (55.100.DP-C.20.E.09) Wiring harnesses - Electrical schematic sheet 33 SH33-CHASSIS INTERFACE LG (55.100.DP-C.20.E.33) Wiring harnesses - Electrical schematic sheet 35 SH35-CHASSIS INTERFACE MD (55.100.DP-C.20.E.35)
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3260 (DTC 2E1-02) - ECU Power stages : Starter relay HS power stage output open circuit Context: The Engine Control Unit (ECU) controls the engine relay A using a low side and 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 engine relay A high side driver circuit. Possible failure modes: 1. Faulty engine relay A wiring, open circuit. 2. Faulty engine relay A, internal failure. 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, then continue with step 2. 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 4. 2. Check the engine relay A coil for an internal failure. Remove the engine relay A. Use a multimeter to measure the relay coil resistance on the engine relay A pins : From Engine relay A pin 85
To Engine relay A pin 86
Value There should be approximately 70 – 130 Ω.
A. If there is approximately 70 – 130 Ω, then leave the engine relay A disconnected and continue to step 3. B. If there is not approximately 70 – 130 Ω, then the relay has failed. Replace the engine relay A and retest. 3. Check the engine relay A vehicle harness (VE) wiring for an open circuit. Disconnect the vehicle harness (VE) from the ECU at connector X-012. With the key in the OFF position, use a multimeter to perform the following continuity check for an open circuit on the vehicle harness (VE) side : From To Value There should be continuity. X-FUSE2 (Receptacle) pin 41 X-012 (Receptacle) pin 53 There should be continuity. X-FUSE2 (Receptacle) pin 54 X-012 (Receptacle) pin 27 NOTE: Wiggle the harness during measurement to reveal an intermittent connection. A. If there is no continuity, there is an open circuit in the engine relay A 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. 4. 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.
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A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 06 SH06-ENGINE F5C T4 (55.100.DP-C.20.E.06) Wiring harnesses - Electrical schematic sheet 08 SH08-ENGINE F5C T4 (55.100.DP-C.20.E.08) Wiring harnesses - Electrical schematic sheet 37 SH37-CHASSIS INTERFACE X-900/X-901 LG (55.100.DP-C.20.E.37) Wiring harnesses - Electrical schematic sheet 39 SH39-CHASSIS INTERFACE X-900/X-901 MD (55.100.DP-C.20.E.39)
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3260 (DTC 2E1-02) - ECU Power stages : Starter relay HS power stage output open circuit Context: The Engine Control Unit (ECU) controls the engine relay A using a low side and 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 engine relay A high side driver circuit. Possible failure modes: 1. Faulty engine relay A wiring, open circuit. 2. Faulty engine relay A, internal failure. 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, then continue with step 2. 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 4. 2. Check the engine relay A coil for an internal failure. Remove the engine relay A. Use a multimeter to measure the relay coil resistance on the engine relay A pins : From Engine relay A pin 85
To Engine relay A pin 86
Value There should be approximately 70 – 130 Ω.
A. If there is approximately 70 – 130 Ω, then leave the engine relay A disconnected and continue to step 3. B. If there is not approximately 70 – 130 Ω, then the relay has failed. Replace the engine relay A and retest. 3. Check the engine relay A vehicle harness (VE) wiring for an open circuit. Disconnect the vehicle harness (VE) from the ECU at connector X-012. With the key in the OFF position, use a multimeter to perform the following continuity check for an open circuit on the vehicle harness (VE) side : From To Value There should be continuity. X-012 (Receptacle) pin 53 Medium machines X-FUSE1 MD (Receptacle) pin 25 Large machines X-FUSE1 LG (Receptacle) pin 41 There should be continuity. X-012 (Receptacle) pin 27 Medium machines X-FUSE1 MD (Receptacle) pin 34 Large machines X-FUSE1 LG (Receptacle) pin 54 NOTE: Wiggle the harness during measurement to reveal an intermittent connection. A. If there is no continuity, there is an open circuit in the engine relay A wiring in the vehicle harness (VE). Locate and repair the broken conductor. Repair or replace the harness as required.
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B. If there is continuity, then check the ECU for the appropriate service manual and re-flash, if necessary. 4. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals, or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 10 SH10-EH PUMP/HYDRAULICS (55.100.DP-C.20.E.10) Wiring harnesses - Electrical schematic sheet 09 SH09-ENGINE F5C T4 (55.100.DP-C.20.E.09) Wiring harnesses - Electrical schematic sheet 33 SH33-CHASSIS INTERFACE LG (55.100.DP-C.20.E.33) Wiring harnesses - Electrical schematic sheet 35 SH35-CHASSIS INTERFACE MD (55.100.DP-C.20.E.35)
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3261 (DTC 2E1-03) - ECU Power stages : Starter relay power stage: Short circuit to battery error for the Low side Context: The Engine Control Unit (ECU) controls the engine relay A using a low side and high side driver. 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 engine relay A low side driver circuit. Possible failure modes: 1. Faulty engine relay A wiring, short circuit to another voltage source. 2. Faulty engine relay A, internal failure. 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, then continue with step 2. 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. Check the engine relay A coil for an internal failure. Remove the engine relay A. Use a multimeter to measure the relay coil resistance on the engine relay A pins : From Engine relay A pin 85
To Engine relay A pin 86
Value There should be approximately 70 – 130 Ω.
A. If there is approximately 70 – 130 Ω, then leave the engine relay A disconnected and continue to step 3. B. If there is not approximately 70 – 130 Ω, then the relay has failed. Replace the engine relay A and retest. 3. Check the engine relay A 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 on the vehicle harness (VE) side : From X-FUSE2 (Receptacle) pin 54
To Chassis ground
Value There should be no voltage.
With the key in the ON position, use a multimeter to perform the following voltage check for a short circuit to another voltage source on the vehicle harness (VE) side : From X-FUSE2 (Receptacle) pin 54
To Chassis ground
Value There should be no voltage.
A. If there is voltage, then there is a short circuit to another voltage source in the engine relay A 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 engine relay A disconnected and continue to step 4. 4. Check the engine relay A low side driver vehicle harness (VE) wiring for a short circuit. 48068130 29/01/2018
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Disconnect the vehicle harness (VE) from the ECU at connector X-012. With the key in the OFF position, use a multimeter to perform the following continuity check on the vehicle harness (VE) side : From X-FUSE2 (Receptacle) pin 54 X-012 (Receptacle) pin 27
To X-FUSE2 (Receptacle) pin 41 All pins in connector X-012
Value There should be no continuity. There should be no continuity.
A. If there is continuity, then there is a short circuit in the engine relay A 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 check the ECU for the appropriate service manual and re-flash, if necessary. 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. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 06 SH06-ENGINE F5C T4 (55.100.DP-C.20.E.06) Wiring harnesses - Electrical schematic sheet 08 SH08-ENGINE F5C T4 (55.100.DP-C.20.E.08) Wiring harnesses - Electrical schematic sheet 37 SH37-CHASSIS INTERFACE X-900/X-901 LG (55.100.DP-C.20.E.37) Wiring harnesses - Electrical schematic sheet 39 SH39-CHASSIS INTERFACE X-900/X-901 MD (55.100.DP-C.20.E.39)
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3261 (DTC 2E1-03) - ECU Power stages : Starter relay power stage: Short circuit to battery error for the Low side Context: The Engine Control Unit (ECU) controls the engine relay A using a low side and high side driver. 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 engine relay A low side driver circuit. Possible failure modes: 1. Faulty engine relay A wiring, short circuit to another voltage source. 2. Faulty engine relay A, internal failure. 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, then continue with step 2. 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. Check the engine relay A coil for an internal failure. Remove the engine relay A. Use a multimeter to measure the relay coil resistance on the engine relay A pins : From Engine relay A pin 85
To Engine relay A pin 86
Value There should be approximately 70 – 130 Ω.
A. If there is approximately 70 – 130 Ω, then leave the engine relay A disconnected and continue to step 3. B. If there is not approximately 70 – 130 Ω, then the relay has failed. Replace the engine relay A and retest. 3. Check the engine relay A 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 on the vehicle harness (VE) side : From Medium machines X-FUSE1 MD (Receptacle) pin 34 Large machines X-FUSE1 LG (Receptacle) pin 54
To Chassis ground
Value There should be no voltage.
With the key in the ON position, use a multimeter to perform the following voltage check for a short circuit to another voltage source on the vehicle harness (VE) side : From Medium machines X-FUSE1 MD (Receptacle) pin 34 Large machines X-FUSE1 LG (Receptacle) pin 54
To Chassis ground
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Value There should be no voltage.
Electrical systems - FAULT CODES
A. If there is voltage, then there is a short circuit to another voltage source in the engine relay A 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 engine relay A disconnected and continue to step 4. 4. Check the engine relay A low side driver vehicle harness (VE) wiring for a short circuit. Disconnect the vehicle harness (VE) from the ECU at connector X-012. With the key in the OFF position, use a multimeter to perform the following continuity check on the vehicle harness (VE) side : From Medium machines X-FUSE1 MD (Receptacle) pin 34 Large machines X-FUSE1 LG (Receptacle) pin 54 X-012 (Receptacle) pin 27
To Medium machines X-FUSE1 MD (Receptacle) pin 25 Large machines X-FUSE1 LG (Receptacle) pin 41 All pins in connector X-012
Value There should be no continuity.
There should be no continuity.
A. If there is continuity, then there is a short circuit in the engine relay A 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 check the ECU for the appropriate service manual and re-flash, if necessary. 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. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 10 SH10-EH PUMP/HYDRAULICS (55.100.DP-C.20.E.10) Wiring harnesses - Electrical schematic sheet 09 SH09-ENGINE F5C T4 (55.100.DP-C.20.E.09) Wiring harnesses - Electrical schematic sheet 33 SH33-CHASSIS INTERFACE LG (55.100.DP-C.20.E.33) Wiring harnesses - Electrical schematic sheet 35 SH35-CHASSIS INTERFACE MD (55.100.DP-C.20.E.35)
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3262 (DTC 2E1-04) - ECU Power stages : Starter relay power stage: Short circuit to ground error for the Low side Context: The Engine Control Unit (ECU) controls the engine relay A using a low side and high side driver. If the ECU detects a short circuit to ground in the low side driver circuit, this fault will occur. Cause: The ECU has detected a short circuit to ground in the engine relay A low side driver circuit. Possible failure modes: 1. Faulty engine relay A wiring, short circuit to ground. 2. Faulty engine relay A, internal failure. 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 4. 2. Check the engine relay A coil internal resistance. Remove the engine relay A. Using a multimeter, to measure the resistance on the engine relay A pins : From Engine relay A pin 85
To Engine relay A pin 86
Value There should be approximately 70 – 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 engine relay A has failed. Replace the engine relay A and retest. 3. Check the engine relay A 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 on the vehicle harness (VE) side : From X-FUSE2 (Receptacle) pin 54
To Chassis ground
Value There should be no continuity.
Disconnect the ECU connector X-012. With the key in the OFF position, use a multimeter to perform the following continuity check on the vehicle harness (VE) side : From X-012 (Receptacle) pin 27
To All pins in connector X-012
Value There should be no continuity.
A. If there is continuity, then there is a short circuit in the engine relay A vehicle harness (VE) wiring. Locate and repair the shorted conductor. B. If there is no continuity, then check the ECU for the appropriate software and re-flash, if necessary. 48068130 29/01/2018
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4. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals, or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 06 SH06-ENGINE F5C T4 (55.100.DP-C.20.E.06) Wiring harnesses - Electrical schematic sheet 08 SH08-ENGINE F5C T4 (55.100.DP-C.20.E.08) Wiring harnesses - Electrical schematic sheet 37 SH37-CHASSIS INTERFACE X-900/X-901 LG (55.100.DP-C.20.E.37) Wiring harnesses - Electrical schematic sheet 39 SH39-CHASSIS INTERFACE X-900/X-901 MD (55.100.DP-C.20.E.39)
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3262 (DTC 2E1-04) - ECU Power stages : Starter relay power stage: Short circuit to ground error for the Low side Context: The Engine Control Unit (ECU) controls the engine relay A using a low side and high side driver. If the ECU detects a short circuit to ground in the low side driver circuit, this fault will occur. Cause: The ECU has detected a short circuit to ground in the engine relay A low side driver circuit. Possible failure modes: 1. Faulty engine relay A wiring, short circuit to ground. 2. Faulty engine relay A, internal failure. 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 4. 2. Check the engine relay A coil internal resistance. Remove the engine relay A. Using a multimeter, to measure the resistance on the engine relay A pins : From Engine relay A pin 85
To Engine relay A pin 86
Value There should be approximately 70 – 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 engine relay A has failed. Replace the engine relay A and retest. 3. Check the engine relay A 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 on the vehicle harness (VE) side : From Medium machines X-FUSE1 MD (Receptacle) pin 34 Large machines X-FUSE1 LG (Receptacle) pin 54
To Chassis ground
Value There should be no continuity.
Disconnect the ECU connector X-012. With the key in the OFF position, use a multimeter to perform the following continuity check on the vehicle harness (VE) side : From X-012 (Receptacle) pin 27
To All pins in connector X-012
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Value There should be no continuity.
Electrical systems - FAULT CODES
A. If there is continuity, then there is a short circuit in the engine relay A vehicle harness (VE) wiring. Locate and repair the shorted conductor. B. If there is no continuity, then check the ECU for the appropriate software and re-flash, if necessary. 4. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals, or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 10 SH10-EH PUMP/HYDRAULICS (55.100.DP-C.20.E.10) Wiring harnesses - Electrical schematic sheet 09 SH09-ENGINE F5C T4 (55.100.DP-C.20.E.09) Wiring harnesses - Electrical schematic sheet 33 SH33-CHASSIS INTERFACE LG (55.100.DP-C.20.E.33) Wiring harnesses - Electrical schematic sheet 35 SH35-CHASSIS INTERFACE MD (55.100.DP-C.20.E.35)
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3265 (DTC 1E3-03) - Level 2 Monitoring : Diagnostic fault check to report the error due to Over Run 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: 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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3266 (DTC 1E4-03) - Engine speed : Diagnostic fault check to report the engine speed error 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: 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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3283 (DTC 1E7-03) - ECU Sensor Supply Monitor : ECU internal: Error Sensor supplies 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-012 pin 12, X-012 pin 13, X-012 pin 14, X-012 pin 15, and X-012 pin 16. Cause: The ECU has determined that the sensor supply 2 voltage is out of range. Possible failure modes: 1. Faulty battery voltage. 2. Faulty ECU supply voltage. 3. Faulty ECU sensor supply 2 pins. 4. Faulty ECU connector X-012, corrosion or damage. 5. 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 6. 2. Check the battery voltage. Charge the battery, then, perform a load test on the battery. A. If the battery passes the load test, continue to step 3. B. If the battery fails the load test, the battery has failed. Replace the battery and retest. 3. Check the ECU supply voltage. Disconnect the ECU connector X-012. Place a jumper wire between X-012 (Receptacle) pin 28 and chassis ground. This will energize the ECU main relay. With the key in the ON position, use a multimeter to perform the following voltage check on the vehicle harness (VE) side : From X-012 (Receptacle) pin 1 X-012 (Receptacle) pin 3 X-012 (Receptacle) pin 5
To X-012 (Receptacle) pin 2 X-012 (Receptacle) pin 4 X-012 (Receptacle) pin 6
Value There should be approximately 12 V. There should be approximately 12 V. There should be approximately 12 V.
A. If there is approximately 12 V, then leave connector X-012 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 or the minus battery connection to the ECU. Repair or replace the harness as required. 4. Check the following pins listed below on the ECU and in connector X-012. 48068130 29/01/2018
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Pin X-012 pin 12 X-012 pin 13 X-012 pin 14 X-012 pin 15 X-012 pin 16
Physical condition The pin and connector should be free of corrosion damage. The pin and connector should be free of corrosion damage. The pin and connector should be free of corrosion damage. The pin and connector should be free of corrosion damage. The pin and connector should be free of corrosion damage.
or or or or or
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. 5. 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. 6. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals, or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 06 SH06-ENGINE F5C T4 (55.100.DP-C.20.E.06) Wiring harnesses - Electrical schematic sheet 07 SH07-ENGINE F5C T4 (55.100.DP-C.20.E.07) Wiring harnesses - Electrical schematic sheet 10 SH10-ENGINE F5C T4 (55.100.DP-C.20.E.10) Wiring harnesses - Electrical schematic sheet 11 SH11-ENGINE F5C T4 (55.100.DP-C.20.E.11)
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3285 (DTC 1E8-03) - ECU Sensor Supply Monitor : ECU internal: Error Sensor supplies 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 3 is out of range, then this fault will occur. The ECU pin numbers associated with sensor supply 3 are X-012 pin 17, X-012 pin 18 and X-016 pin 29.
Cause: The ECU has determined that the sensor supply 3 voltage is out of range. Possible failure modes: 1. Faulty battery voltage. 2. Faulty ECU, supply voltage. 3. Faulty ECU sensor supply 3 pins. 4. Faulty ECU connector X-012 or X-016, corrosion or damage. 5. 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, then continue with step 2. 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 6. 2. Check the battery voltage. Charge the battery, then perform a load test on the battery. A. If the battery passes the load test, then continue to step 3. B. If the battery fails the load test, the battery has failed. Replace the battery and retest. 3. Check the ECU supply voltage. Disconnect the ECU connector X-012. Place a jumper wire between X-012 (Receptacle) pin 28 and chassis ground. This will energize the ECU main relay. With the key in the ON position, use a multimeter to perform the following voltage check on the vehicle harness (VE) side : From X-012 (Receptacle) pin 1 X-012 (Receptacle) pin 3 X-012 (Receptacle) pin 5
To X-012 (Receptacle) pin 2 X-012 (Receptacle) pin 4 X-012 (Receptacle) pin 6
Value There should be approximately 12 V. There should be approximately 12 V. There should be approximately 12 V.
A. If there is approximately 12 V, then leave connector X-012 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 or the minus battery connection to the ECU. Repair or replace the harness as required. 4. Disconnect the vehicle harness (VE) from the ECU at connector X-016. 48068130 29/01/2018
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Check the following pins listed below on the ECU and in connectors X-012 and X-016. Pin X-012 pin 17 X-012 pin 18 X-016 pin 29
Physical condition The pin and connector should be free of corrosion or damage. The pin and connector should be free of corrosion or damage. The pin and connector should be free of corrosion or damage.
A. If a pin or connector shows signs of corrosion or damage, then repair as necessary. B. If a pin or connector shows no signs of corrosion or damage, then continue to step 5. 5. 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. 6. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals, or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the display indicates other than normal display readings, Then, repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, Then, erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 06 SH06-ENGINE F5C T4 (55.100.DP-C.20.E.06) Wiring harnesses - Electrical schematic sheet 07 SH07-ENGINE F5C T4 (55.100.DP-C.20.E.07) Wiring harnesses - Electrical schematic sheet 10 SH10-ENGINE F5C T4 (55.100.DP-C.20.E.10) Wiring harnesses - Electrical schematic sheet 11 SH11-ENGINE F5C T4 (55.100.DP-C.20.E.11)
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3293 (DTC 151-03) - Fuel Metering Unit : maximum positive deviation of rail pressure exceeded 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 - Configure - Reset ECU data (10.218), if necessary. 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 fuel rail pressure. If the measured rail pressure is lower than the desired pressure by 100 bar (1450 psi) depending on engine speed, then 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 100 bar (1450 psi) lower than desired fuel pressure based on engine speed. Possible failure modes: 1.
Faulty fuel metering unit, internal failure.
2.
Faulty charge gear pump, low efficiency.
3.
Faulty fuel filters, clogged.
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, drifted or leaking.
10. Faulty ECU, software.
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3301 (DTC 153-03) - Fuel Metering Unit : maximum negative rail pressure deviation with metering unit on lower limit is exceeded 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 - Configure - Reset ECU data (10.218), if necessary. 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 fuel rail pressure. If the ECU determines that fuel pressure is higher than the desired fuel pressure, depending on engine speed, then 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. Possible failure modes: 1. Faulty fuel metering unit, stuck open. 2. Faulty fuel back-flow, clogged or damaged. 3. Faulty Pressure Relief Valve (PRV), stuck or blocked. 4. Faulty rail pressure sensor, drifted. 5. Faulty high pressure pump. 6. Faulty ECU, software.
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3305 (DTC 154-03) - Fuel Metering Unit : minimum rail pressure exceeded 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 - Configure - Reset ECU data (10.218), if necessary. 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 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, 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 measured rail pressure is less than a dependent engine speed value. Possible failure modes: 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, 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. 11. Faulty ECU, software.
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3309 (DTC 155-03) - Fuel Metering Unit : maximum rail pressure exceeded 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 - Configure - Reset ECU data (10.218), if necessary. 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 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. Possible failure modes: 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. 5. Faulty rail pressure sensor, drifted signal. 6. Faulty ECU, software.
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3334 (DTC 1C6-03) - CAN Bus Received frames : CAN-ReceiveFrame Torque / Speed control from PE to EDC through TSC1_PE Message active Context: The Engine Control Unit (ECU) 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 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. If the ECU senses that CAN Node A Bus is not functioning properly, then this fault will occur. Cause: The ECU has sensed a time out of vehicle data provided on CAN Node A. Possible failure modes: 1. Faulty supply voltage or ground, missing. 2. Faulty CAN circuit wiring, open circuit, short circuit to ground, or short circuit. 3. Faulty ECU, termination resistor or software. Solution: 1. Verify fault is present and in active state. Use the Electronic Service Tool (EST) to check the status of this fault. A. If the fault is 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 6. 2. Check for other vehicle CAN faults. Use the EST to determine if vehicle CAN faults exist. A. If other vehicle CAN faults exist, then resolve the vehicle CAN faults, then check to see that 3334 (DTC 1C6-03) â&#x20AC;&#x201C; CAN Bus Received frames : CAN-Receive-Frame Torque / Speed control from PE to EDC through TSC1_PE Message active 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-012. With the key switch in the ON position, use a multimeter to check for voltage on the vehicle (VE) harness side : From X-012 (Receptacle) pin 1 X-012 (Receptacle) pin 3 X-012 (Receptacle) pin 5
To Chassis ground Chassis ground Chassis ground
Value There should be 12.0 V. There should be 12.0 V. There should be 12.0 V.
A. If the voltage is present on all of the checks, then leave connector X-012 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 replace the harness as required. 4. Check the ECU grounding. 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 X-012 (Receptacle) pin 2 X-012 (Receptacle) pin 4 X-012 (Receptacle) pin 6
To Chassis ground Chassis ground Chassis ground
Value There should be continuity. There should be continuity. There should be continuity.
A. If there is continuity on all of the checks, then leave connector X-012 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 minus battery 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 X-012 (Receptacle) pin 24 X-012 (Receptacle) pin 24 X-012 (Receptacle) pin 25
To X-012 (Receptacle) pin 25 Chassis ground Chassis ground
Value There should be 120 Ί. There should not be continuity. There should not be continuity.
Use a multimeter to measure the resistance of the CAN termination resistor, internal to the ECU : From X-012 (Receptacle) pin 24
To X-012 (Receptacle) pin 25
Value There should be 120 Ί.
A. If the measured resistances are correct and neither conductor is grounded, then check the ECU 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, then locate and restore the termination resistance to the CAN circuit. 6. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals, or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 06 SH06-ENGINE F5C T4 (55.100.DP-C.20.E.06) Wiring harnesses - Electrical schematic sheet 10 SH10-ENGINE F5C T4 (55.100.DP-C.20.E.10)
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3335 (DTC 2C6-02) - CAN Bus Received frames : CAN-ReceiveFrame Torque / Speed control from PE to EDC through TSC1_PE Message passive Context: The Engine Control Unit (ECU) 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 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. If the ECU senses that CAN Node A Bus is not functioning properly, then this fault will occur. Cause: The ECU has sensed a time out of vehicle data provided on CAN Node A. Possible failure modes: 1. Faulty supply voltage or ground, missing. 2. Faulty CAN circuit wiring, open circuit, short circuit to ground, or short circuit. 3. Faulty ECU, termination resistor or software. Solution: 1. Verify fault is present and in active state. Use the Electronic Service Tool (EST) to check the status of this fault. A. If the fault is 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 6. 2. Check for other vehicle CAN faults. Use the EST to determine if vehicle CAN faults exist. A. If other vehicle CAN faults exist, then resolve the vehicle CAN faults, then check to see that 3335 (DTC 2C6-02) â&#x20AC;&#x201C; CAN Bus Received frames : CAN-Receive-Frame Torque / Speed control from PE to EDC through TSC1_PE Message passive 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-012. With the key switch in the ON position, use a multimeter to check for voltage on the vehicle (VE) harness side : From X-012 (Receptacle) pin 1 X-012 (Receptacle) pin 3 X-012 (Receptacle) pin 5
To Chassis ground Chassis ground Chassis ground
Value There should be 12.0 V . There should be 12.0 V. There should be 12.0 V.
A. If the voltage is present on all of the checks, then leave connector X-012 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 in the battery supply to the ECU. Repair as required. 4. Check the ECU grounding. 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 X-012 (Receptacle) pin 2 X-012 (Receptacle) pin 4 X-012 (Receptacle) pin 6
To Chassis ground Chassis ground Chassis ground
Value There should be continuity. There should be continuity. There should be continuity.
A. If there is continuity on all of the checks, then leave connector X-012 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 minus battery 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 X-012 (Receptacle) pin 24 X-012 (Receptacle) pin 24 X-012 (Receptacle) pin 25
To X-012 (Receptacle) pin 25 Chassis ground Chassis ground
Value There should be 120 Ί. There should not be continuity. There should not be continuity.
Use a multimeter to measure the resistance of the CAN termination resistor, internal to the ECU : From X-012 (Receptacle) pin 24
To X-012 (Receptacle) pin 25
Value There should be 120 Ί.
A. If the measured resistances are correct and neither conductor is grounded, then check the ECU 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, then locate and restore the termination resistance to the CAN circuit. 6. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals, or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 06 SH06-ENGINE F5C T4 (55.100.DP-C.20.E.06) Wiring harnesses - Electrical schematic sheet 10 SH10-ENGINE F5C T4 (55.100.DP-C.20.E.10)
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3338 (DTC 3C8-02) - CAN Bus Received frames : CAN-ReceiveFrame Torque / Speed control from VE to EDC through TSC1_VE Message passive Context: The Engine Control Unit (ECU) 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 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. If the ECU senses that CAN Node A Bus is not functioning properly, then this fault will occur. Cause: then ECU has sensed a time out of required vehicle controller data provided on CAN Node A. Possible failure modes: 1. Faulty supply voltage or ground, missing. 2. Faulty CAN circuit wiring, open circuit, short circuit to ground, or short circuit. 3. Faulty ECU, termination resistor or software. Solution: 1. Verify fault is present and in active state. Use the Electronic Service Tool (EST) to check the status of this fault. A. If the fault is 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 6. 2. Check for other vehicle CAN faults. Use the EST to determine if vehicle CAN faults exist. A. If other vehicle CAN faults exist, then resolve the vehicle CAN faults, then check to see that 3338 (DTC 3C8-02) â&#x20AC;&#x201C; CAN Bus Received frames : CAN-Receive-Frame Torque / Speed control from VE to EDC through TSC1_VE Message passive 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-012. With the key switch in the ON position, use a multimeter to check for voltage on the vehicle (VE) harness side : From X-012 (Receptacle) pin 1 X-012 (Receptacle) pin 3 X-012 (Receptacle) pin 5
To Chassis ground Chassis ground Chassis ground
Value There should be 12.0 V . There should be 12.0 V. There should be 12.0 V.
A. If the voltage is present on all of the checks, then leave connector X-012 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 in the battery supply to the ECU. Repair as required. 4. Check the ECU grounding. 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 X-012 (Receptacle) pin 2 X-012 (Receptacle) pin 4 X-012 (Receptacle) pin 6
To Chassis ground Chassis ground Chassis ground
Value There should be continuity. There should be continuity. There should be continuity.
A. If there is continuity on all of the checks, then leave connector X-012 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 minus battery 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 X-012 (Receptacle) pin 24 X-012 (Receptacle) pin 24 X-012 (Receptacle) pin 25
To X-012 (Receptacle) pin 25 Chassis ground Chassis ground
Value There should be 120 Ί. There should not be continuity. There should not be continuity.
Use a multimeter to measure the resistance of the CAN termination resistor, internal to the ECU : From X-012 (Receptacle) pin 24
To X-012 (Receptacle) pin 25
Value There should be 120 Ί.
A. If the measured resistances are correct and neither conductor is grounded, then check the ECU 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, then locate and restore the termination resistance to the CAN circuit. 6. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals, or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 06 SH06-ENGINE F5C T4 (55.100.DP-C.20.E.06) Wiring harnesses - Electrical schematic sheet 10 SH10-ENGINE F5C T4 (55.100.DP-C.20.E.10)
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3339 (DTC 1C8-03) - CAN Bus Received frames : CAN-ReceiveFrame Torque / Speed control from VE to EDC through TSC1_VE Message active Context: The Engine Control Unit (ECU) 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 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. If the ECU senses that CAN Node A Bus is not functioning properly, then this fault will occur. Cause: The ECU has sensed a time out of required vehicle controller data provided on CAN Node A. Possible failure modes: 1. Faulty supply voltage or ground, missing. 2. Faulty CAN circuit wiring, open circuit, short circuit to ground, or short circuit. 3. Faulty ECU, termination resistor or software. Solution: 1. Verify fault is present and in active state. Use the Electronic Service Tool (EST) to check the status of this fault. A. If the fault is 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 6. 2. Check for other vehicle CAN faults. Use the EST to determine if vehicle CAN faults exist. A. If other vehicle CAN faults exist, then resolve the vehicle CAN faults, then check to see that 3339 (DTC 1C8-03) â&#x20AC;&#x201C; CAN Bus Received frames : CAN-Receive-Frame Torque / Speed control from VE to EDC through TSC1_VE Message active 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-012. With the key switch in the ON position, use a multimeter to check for voltage on the vehicle (VE) harness side : From X-012 (Receptacle) pin 1 X-012 (Receptacle) pin 3 X-012 (Receptacle) pin 5
To Chassis ground Chassis ground Chassis ground
Value There should be 12.0 V . There should be 12.0 V. There should be 12.0 V.
A. If the voltage is present on all of the checks, then leave connector X-012 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 in the battery supply to the ECU. Repair as required. 4. Check the ECU grounding. 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 X-012 (Receptacle) pin 2 X-012 (Receptacle) pin 4 X-012 (Receptacle) pin 6
To Chassis ground Chassis ground Chassis ground
Value There should be continuity. There should be continuity. There should be continuity.
A. If there is continuity on all of the checks, then leave connector X-012 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 minus battery 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 X-012 (Receptacle) pin 24 X-012 (Receptacle) pin 24 X-012 (Receptacle) pin 25
To X-012 (Receptacle) pin 25 Chassis ground Chassis ground
Value There should be 120 Ί. There should not be continuity. There should not be continuity.
Use a multimeter to measure the resistance of the CAN termination resistor, internal to the ECU : From X-012 (Receptacle) pin 24
To X-012 (Receptacle) pin 25
Value There should be 120 Ί.
A. If the measured resistances are correct and neither conductor is grounded, then check the ECU 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, then locate and restore the termination resistance to the CAN circuit. 6. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals, or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 06 SH06-ENGINE F5C T4 (55.100.DP-C.20.E.06) Wiring harnesses - Electrical schematic sheet 10 SH10-ENGINE F5C T4 (55.100.DP-C.20.E.10)
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3350 (DTC 11A-03) - Terminal 50 switch : Defective T50 switch Context: The Engine Control Unit (ECU) is notified of a request for engine cranking at connector X-012 (Receptacle) pin 28. 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 the start relay or the ECU detects a short circuit to another voltage source exists in the input circuit and then this fault occurs. Cause: The engine cranking signal has exceeded the signal ON time established be the ECU. Possible failure modes: 1. Faulty vehicle cranking circuit component, key switch or crank / start relay. 2. Faulty cranking circuit wiring, short circuit to another voltage source. 3. Faulty ECU, software. Solution: 1. Verify that the fault present and active. Use the Electronic Service Tool (EST) to check the status of this fault. A. If the fault is present and active, then continue with step 2. 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 4. 2. Check the cranking circuit wiring for a short circuit to another voltage source. Disconnect the vehicle harness (VE) from the ECU at connector X-012. With the key switch in the ON position, use a multimeter to check for voltage on the vehicle harness (VE) side : From X-012 (Receptacle) pin 8
To Chassis ground
Result There should be no voltage.
A. If there is voltage, then locate the voltage source. Repair or replace the harness as required. B. If there is no voltage, then leave connector X-012 disconnected and continue with step 3. 3. Check the cranking circuit wiring for a short circuit to another voltage source. With the key switch in the OFF position, use a multimeter to check for continuity on the vehicle harness (VE) side : From X-012 (Receptacle) pin 8
To to all other pins in connector X-012
Result 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. B. If there is no continuity, then check the ECU for the appropriate software and re-flash, if necessary. 4. 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.
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A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 06 SH06-ENGINE F5C T4 (55.100.DP-C.20.E.06) Wiring harnesses - Electrical schematic sheet 10 SH10-ENGINE F5C T4 (55.100.DP-C.20.E.10)
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3358 (DTC 1B7-02) - CAN Bus Transmitted frames : CAN-Transmit-Frame EEC1, Electronic Engine Control #1 message (Torque, acc.pedal,engine speed, etc.) Context: The Engine Control Unit (ECU) 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 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. If the ECU senses that CAN Node A Bus is not functioning properly, this fault will occur. Cause: The ECU has sensed a time out of required vehicle controller data provided on CAN Node A. Possible failure modes: 1. Faulty supply voltage or ground, missing. 2. Faulty CAN circuit wiring, open circuit, short circuit to ground, or short circuit. 3. Faulty ECU, termination resistor or software. Solution: 1. Verify fault is present and in active state. Use the Electronic Service Tool (EST) to check the status of this fault. A. If the fault is 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 6. 2. Check for other vehicle CAN faults. Use the EST to determine if vehicle CAN faults exist. A. If other vehicle CAN faults exist, then resolve the vehicle CAN faults, then check to see that 3358 (DTC 1B7-02) â&#x20AC;&#x201C; CAN Bus Transmitted frames : CAN-Transmit-Frame EEC1, Electronic Engine Control #1 message (Torque, acc.pedal,engine speed, etc.) 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-012. With the key switch in the ON position, use a multimeter to check for voltage on the vehicle (VE) harness side : From X-012 (Receptacle) pin 1 X-012 (Receptacle) pin 3 X-012 (Receptacle) pin 5
To Chassis ground Chassis ground Chassis ground
Value There should be 12.0 V . There should be 12.0 V. There should be 12.0 V.
A. If the voltage is present on all of the checks, then leave connector X-012 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 in the battery supply to the ECU. Repair as required. 4. Check the ECU grounding. 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 X-012 (Receptacle) pin 2 X-012 (Receptacle) pin 4 X-012 (Receptacle) pin 6
To Chassis ground Chassis ground Chassis ground
Value There should be continuity. There should be continuity. There should be continuity.
A. If there is continuity on all of the checks, then leave connector X-012 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 minus battery 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 X-012 (Receptacle) pin 24 X-012 (Receptacle) pin 24 X-012 (Receptacle) pin 25
To X-012 (Receptacle) pin 25 Chassis ground Chassis ground
Value There should be 120 Ί. There should not be continuity. There should not be continuity.
Use a multimeter to measure the resistance of the CAN termination resistor, internal to the ECU : From X-012 (Receptacle) pin 24
To X-012 (Receptacle) pin 25
Value There should be 120 Ί.
A. If the measured resistances are correct and neither conductor is grounded, then check the ECU 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, then locate and restore the termination resistance to the CAN circuit. 6. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals, or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 06 SH06-ENGINE F5C T4 (55.100.DP-C.20.E.06) Wiring harnesses - Electrical schematic sheet 10 SH10-ENGINE F5C T4 (55.100.DP-C.20.E.10)
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3361 (DTC 1D2-03) - EEPROM : EEP Erase Error Context: The Engine Control Unit (ECU) has the capability of reading and writing values to flash or EEPROM. The ECU monitors the reading and writing capability of this function. If the ECU determines that calibrated parameters for bad rate cannot be read from EEPROM during this monitoring, then this fault will occur. 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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3362 (DTC 1DA-12) - Engine internal calculations : DFC to report if the quantity axis points increase strictly linearly above the torque axis Context: The Engine Control Unit (ECU) checks the map for the conversion from fuel quantity to torque for consistency. If there is an error during this conversion check, this fault will occur. Solution: 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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3368 (DTC 19D-04) - Torque limitation, Engine protection : Torque limitation caused by performance limiter Context: This fault is for informational purposes only and may have been caused by another fault. The Engine Control Unit (ECU) has detected higher level of NOx emissions than expected. If this fault occurs, a toque limitation of equal to or greater than 25% will occur. Other active faults may have caused this fault to occur.
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3369 (DTC 19E-04) - Torque limitation, Engine protection : Torque limitation caused by smoke limitation Context: This fault is for informational purposes only and is active because there has been a torque limitation set by the Engine Control Unit (ECU). The (ECU) monitors the air/fuel ratio. If the ECU determines that the ratio is too lean, a torque limitation of 25% will be active to prevent engine damage. Though no action is necessary due to this error, if the power reduction occurred due to an actual defect, the error triggering the torque limitation should also be in fault memory. Use the Electronic Service Tool (EST) to check for related faults. Diagnose the related faults first and then return to this fault, 3369 â&#x20AC;&#x201C; Torque limitation caused by smoke limitation. Also, see the list below of possible mechanical failures that may have caused this fault. Refer to the engine service manual Fuel injection system - Poor quality (10.218) for more information on troubleshooting a lean air/fuel ratio condition. Cause: The ECU has set a torque limitation due to a lean air/fuel ratio. Possible failure modes: 1.
Operating in extreme high altitudes, greater than an altitude of 1800 m (5906 ft).
2.
Operating in low ambient pressure conditions, less than an ambient pressure of 0.78 bar (11.31 psi).
3.
Faulty lambda sensor, drifted.
4.
Faulty Exhaust Gas Recirculation (EGR) actuator, stuck or inoperative.
5.
Faulty turbocharger wastegate, sticking or stuck open.
6.
Faulty turbocharger, low efficiency.
7.
Faulty air induction, leakage or blockage.
8.
Faulty intake manifold pressure sensor. At key ON there should be approximately the value of ambient pressure.
9.
Faulty ECU, software.
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3370 (DTC 49E-04) - Torque limitation, Engine protection : Strong torque limitation from engine protection active Context: This fault is for information purposes only and may have been caused by another fault. The Engine Control Unit (ECU) has detected an active power reduction due to too high exhaust gas temperature, engine coolant temperature, engine oil temperature or fuel temperature. If this fault is active, an engine power or engine speed reduction of equal to or greater than 25% of the desired torque will be active to protect the engine from damage. Though no action is necessary due to this error, if the power reduction occurred due to an actual defect, the error triggering the torque limitation should also be in fault memory. Use the Electronic Service Tool (EST) to check for related fault codes and diagnose them first, then check the status of this fault, 3370 (DTC 49E-04) â&#x20AC;&#x201C; Torque limitation, Engine protection : Strong torque limitation from engine protection active. Cause: This fault is an information only fault. It has been triggered by another fault. Solution: 1. Use the Electronic Service Tool (EST) to check for other faults that may have caused this fault to occur. A. If any related faults are active, diagnose them first, then return to this fault, 3370 (DTC 49E-04) â&#x20AC;&#x201C; Torque limitation, Engine protection : Strong torque limitation from engine protection active. B. If there are no related faults active, continue to step 2. 2. 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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3371 (DTC 69E-04) - Torque limitation, Engine protection : Strong torque limitation from injection system active Context: This fault is for information purposes only and may have been caused by another fault. The Engine Control Unit (ECU) has detected an active power reduction due to higher than expected fuel temperature. If this fault is active, a power reduction of equal to or greater than 25% of the desired torque will be active to protect the high pressure fuel pump from damage. Though no action is necessary due to this error, if the power reduction occurred due to an actual defect, the error triggering the torque limitation should also be in fault memory. Use the Electronic Service Tool (EST) to check for related fuel system faults and diagnose them first, then check the status of this fault, 3371 (DTC 69E-04) â&#x20AC;&#x201C; Torque limitation, Engine protection : Strong torque limitation from injection system active. For information regarding fuel system troubleshooting, refer to the engine service manual Fuel injection system - Troubleshooting (10.218).
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3374 (DTC 17F-12) - Injector Adjustment programming : check of missing injector adjustment value programming: injector 1 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, then 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. A. If the correct code is not programmed. 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. 2. 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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3390 - Air Filter Restriction Switch Short To Ground Context: The instrument cluster detects a signal to ground on X-C23 pin 11 indicating that the air filter restriction switch has been tripped. 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. A faulty air filter restriction switch. 4. A 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 machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 3390 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 to 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 the connectors as required. Return to step 1 to confirm elimination of fault. 4. Test 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 3390 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. Temporarily replace the air filter restriction switch and retest. Return to step 1 to confirm elimination of fault. 6. Measure the resistance of the signal wire to chassis ground. Turn the ignition switch OFF. Disconnect instrument cluster connector X-C23. Measure the resistance between X-C23 pin 11 and chassis ground. The resistance should be greater than 20,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition. A. The resistance is greater than 20,000 Ω. Temporarily replace the instrument cluster and retest. Return to step 1 to confirm elimination of the fault. B. The resistance is less than 20,000 Ω. There is a short to chassis ground in the signal wire. Repair or replace the wire as required. Return to step 1 to confirm elimination of fault.
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3402 (DTC 535-03) - Rail pressure sensor : maximum rail pressure exceeded NOTE: If the rail pressure sensor is replaced, then 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 fuel rail pressure using the rail pressure sensor. If the ECU determines that rail pressure has exceeded 1790 bar (25955 psi), then this fault will occur. A Pressure Relief Valve (PRV), integral to the fuel rail, is designed to open in the event of an over-pressure in the fuel rail at approximately 1790 bar (25955 psi). If the ECU determines that rail pressure has exceeded this threshold, a PRV failure is assumed. Other related faults may have caused this fault to occur. Diagnose any related fault that is active and may have caused this fault to occur first, then return to this fault, 3402 (DTC 535-03) â&#x20AC;&#x201C; Rail pressure sensor : maximum rail pressure exceeded. For more information regarding fuel system troubleshooting, refer to the engine service manual Fuel injection system Troubleshooting (10.218). Cause: The ECU has determined that rail pressure has exceeded 1790 bar (25955 psi). Possible failure modes: 1. Faulty fuel back-flow, clogged. 2. Faulty PRV, unable to open to clogged return. 3. Faulty fuel metering unit, stuck open or internal failure. 4. Faulty rail pressure sensor, drifted. 5. Faulty ECU, software.
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3403 (DTC 2E1-12) - ECU Power stages : Starter relay HS power stage over temperature Context: The Engine Control Unit (ECU) controls the engine relay A using a low side and high side driver. If the ECU detects an over temperature/current condition in the high side driver circuit, then this fault will occur. Cause: The ECU has detected an over temperature/current condition in the engine relay A high side driver circuit. Possible failure modes: 1. Faulty engine relay A wiring, short circuit. 2. Faulty engine relay A, internal failure. 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, then continue with step 2. 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 6. 2. Check the engine relay A coil for an internal failure. Remove the engine relay A. Use a multimeter to measure the relay coil resistance on the engine relay A pins : From Engine relay A pin 85
To Engine relay A pin 86
Value There should be approximately 70 – 130 Ω.
A. If there is approximately 70 – 130 Ω, then leave the engine relay A disconnected and continue to step 3. B. If there is not approximately 70 – 130 Ω, then the relay has failed. Replace the engine relay A and retest. 3. Check the engine relay A 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 X-FUSE2 (Receptacle) pin 41 X-FUSE2 (Receptacle) pin 41
To X-FUSE2 (Receptacle) pin 54 Chassis ground
Value There should be no continuity. There should be no continuity.
A. If there is continuity, then there is a short circuit to ground in the engine relay A 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 engine relay A disconnected and continue to step 4. 4. Check the engine relay A 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 perform the following voltage check for a short circuit to another voltage source on the vehicle harness (VE) side : From X-FUSE2 (Receptacle) pin 41
To Chassis ground
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Value There should be no voltage.
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With the key in the ON position, use a multimeter to perform the following voltage check for a short circuit to another voltage source on the vehicle harness (VE) side : From X-FUSE2 (Receptacle) pin 41
To Chassis ground
Value There should be no voltage.
A. If there is voltage, then there is a short circuit to another voltage source in the engine relay A 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 voltage, then continue to step 5. 5. Check the engine relay A high side driver vehicle harness (VE) wiring for a short circuit to another voltage source. Disconnect the vehicle harness (VE) from the ECU at connector X-012. With the key in the OFF position, use a multimeter to perform the following continuity check for a short circuit to another voltage source on the vehicle harness (VE) side : From X-012 (Receptacle) pin 53
To All pins in connector X-012
Value There should be no continuity.
A. If there is continuity, then there is a short circuit in the engine relay A 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 voltage, then check the ECU for the appropriate software and re-flash, if necessary. 6. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals, or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 06 SH06-ENGINE F5C T4 (55.100.DP-C.20.E.06) Wiring harnesses - Electrical schematic sheet 08 SH08-ENGINE F5C T4 (55.100.DP-C.20.E.08) Wiring harnesses - Electrical schematic sheet 37 SH37-CHASSIS INTERFACE X-900/X-901 LG (55.100.DP-C.20.E.37) Wiring harnesses - Electrical schematic sheet 39 SH39-CHASSIS INTERFACE X-900/X-901 MD (55.100.DP-C.20.E.39)
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3403 (DTC 2E1-12) - ECU Power stages : Starter relay HS power stage over temperature Context: The Engine Control Unit (ECU) controls the engine relay A using a low side and high side driver. If the ECU detects an over temperature/current condition in the high side driver circuit, then this fault will occur. Cause: The ECU has detected an over temperature/current condition in the engine relay A high side driver circuit. Possible failure modes: 1. Faulty engine relay A wiring, short circuit. 2. Faulty engine relay A, internal failure. 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, then continue with step 2. 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 6. 2. Check the engine relay A coil for an internal failure. Remove the engine relay A. Use a multimeter to measure the relay coil resistance on the engine relay A pins : From Engine relay A pin 85
To Engine relay A pin 86
Value There should be approximately 70 – 130 Ω.
A. If there is approximately 70 – 130 Ω, then leave the engine relay A disconnected and continue to step 3. B. If there is not approximately 70 – 130 Ω, then the relay has failed. Replace the engine relay A and retest. 3. Check the engine relay A 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 Medium machines X-FUSE1 MD (Receptacle) pin 25 Large machines X-FUSE1 LG (Receptacle) pin 41 Medium machines X-FUSE1 MD (Receptacle) pin 25 Large machines X-FUSE1 LG (Receptacle) pin 41
To Medium machines X-FUSE1 MD (Receptacle) pin 34 Large machines X-FUSE1 LG (Receptacle) pin 54 Chassis ground
Value There should be no continuity.
There should be no continuity.
A. If there is continuity, then there is a short circuit to ground in the engine relay A 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 engine relay A disconnected and continue to step 4. 4. Check the engine relay A high side driver vehicle harness (VE) wiring for a short circuit to another voltage source. 48068130 29/01/2018
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With the key in the OFF position, use a multimeter to perform the following voltage check for a short circuit to another voltage source on the vehicle harness (VE) side : From Medium machines X-FUSE1 MD (Receptacle) pin 25 Large machines X-FUSE1 LG (Receptacle) pin 41
To Chassis ground
Value There should be no voltage.
With the key in the ON position, use a multimeter to perform the following voltage check for a short circuit to another voltage source on the vehicle harness (VE) side : From Medium machines X-FUSE1 MD (Receptacle) pin 25 Large machines X-FUSE1 LG (Receptacle) pin 41
To Chassis ground
Value There should be no voltage.
A. If there is voltage, then there is a short circuit to another voltage source in the engine relay A 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 voltage, then continue to step 5. 5. Check the engine relay A high side driver vehicle harness (VE) wiring for a short circuit to another voltage source. Disconnect the vehicle harness (VE) from the ECU at connector X-012. With the key in the OFF position, use a multimeter to perform the following continuity check for a short circuit to another voltage source on the vehicle harness (VE) side : From X-012 (Receptacle) pin 53
To All pins in connector X-012
Value There should be no continuity.
A. If there is continuity, then there is a short circuit in the engine relay A 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 voltage, then check the ECU for the appropriate software and re-flash, if necessary. 6. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals, or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 10 SH10-EH PUMP/HYDRAULICS (55.100.DP-C.20.E.10) Wiring harnesses - Electrical schematic sheet 09 SH09-ENGINE F5C T4 (55.100.DP-C.20.E.09) Wiring harnesses - Electrical schematic sheet 33 SH33-CHASSIS INTERFACE LG (55.100.DP-C.20.E.33) Wiring harnesses - Electrical schematic sheet 35 SH35-CHASSIS INTERFACE MD (55.100.DP-C.20.E.35)
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3405 (DTC 393-02) - ECU Power stages : Open load temperature error on the Turbocharger PWM output power stage 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. Possible failure modes: 1. Faulty wastegate pressure modulator valve wiring, open circuit. 2. Faulty wastegate pressure modulator valve, internal failure. 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, then continue with step 2. 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 6. 2. Check the wastegate pressure modulator valve internal resistance. Disconnect the engine harness from 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 continue to step 3. B. If there is not between 21.8 – 24.2 Ω, then the wastegate pressure modulator valve has failed internally. Replace the wastegate pressure modulator valve and retest. 3. Check the wastegate pressure modulator valve engine harness (EN) wiring for an open circuit. Disconnect the vehicle harness (VE) from the engine interface at connector X-017. 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 Wastegate pressure modulator valve X-017 (Receptacle) pin 28 There should be continuity. pin 1 Wastegate pressure modulator valve X-017 (Receptacle) pin 27 There should be continuity. pin 2 NOTE: Wiggle the harness during measurement to reveal an intermittent condition. 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. Repair or replace the harness as required.
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B. If there is continuity, then leave the wastegate pressure modulator valve disconnected. Leave connector X-017 disconnected. Continue to step 4. 4. Check the wastegate pressure modulator valve vehicle harness (VE) wiring for an open circuit. With the key in the ON position, use a multimeter to perform the following voltage check on the vehicle harness side : From X-017 (Receptacle) pin 28
To
Value There should be approximately 12.0 V. NOTE: Wiggle the harness during measurement to reveal an intermittent condition. Chassis ground
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-017 disconnected and continue to step 5. 5. Check the wastegate pressure modulator valve vehicle harness (VE) wiring for an open circuit. Disconnect the vehicle harness (VE) from the ECU at connector X-016. 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 There should be continuity. X-017 (Receptacle) pin 27 X-016 (Receptacle) pin 4 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 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 continuity, then check the ECU for the appropriate software and re-flash, if necessary. 6. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals, or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 07 SH07-ENGINE F5C T4 (55.100.DP-C.20.E.07) Wiring harnesses - Electrical schematic sheet 11 SH11-ENGINE F5C T4 (55.100.DP-C.20.E.11)
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3406 (DTC 393-12) - ECU Power stages : Over temperature error on the Turbocharger PWM output power stage Context: The Engine Control Unit (ECU) monitors the wastegate pressure modulator valve circuit. If the ECU determines that 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. Possible failure modes: 1. Faulty wastegate pressure modulator valve wiring, short circuit to another voltage source. 2. Faulty wastegate pressure modulator valve, internal failure. 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, then continue with step 2. 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 7. 2. Check the wastegate pressure modulator valve internal resistance. Disconnect the engine harness from 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 continue to step 3. B. If there is not between 21.8 – 24.2 Ω, then the wastegate pressure modulator valve has failed internally. Replace the wastegate pressure modulator valve and retest. 3. Check the wastegate pressure modulator valve wiring for a short circuit. 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 Wastegate pressure modulator valve Wastegate pressure modulator valve There should be no continuity. connector pin 1 connector pin 2 A. If there is continuity, then there is a short circuit in the wastegate pressure modulator valve wiring. Locate and repair the shorted conductor. Repair or replace the harness as required. B. If there is no continuity, then continue to step 4. 4. Check the wastegate pressure modulator valve wiring for a short circuit to battery.
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With the key in the OFF position, use a multimeter to perform the following voltage check on the engine harness (EN) side : From To Wastegate pressure modulator valve Chassis ground connector pin 2
Value There should be no voltage.
A. If there is voltage, then there is a short circuit to battery in the wastegate pressure modulator valve wiring. Locate and repair the shorted conductor. Repair or replace the harness as required. B. If there is no voltage, then continue to step 5. 5. Check the wastegate pressure modulator valve wiring for a short circuit to another voltage source. Disconnect the vehicle harness (VE) from the engine interface at connector X-017. With the key in the ON position, use a multimeter to perform the following voltage check on the engine harness (EN) side : From X-017 (Receptacle) pin 2
To Chassis ground
Value There should be no voltage.
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. B. If there is no voltage, then continue to step 6. 6. Check the wastegate pressure modulator valve wiring for a short circuit to another voltage source. Disconnect the vehicle harness (VE) from the ECU at connector X-016. With the key in the ON position, use a multimeter to perform the following voltage check on the vehicle harness (VE) side : From X-017 (Receptacle) pin 27
To Chassis ground
Value There should be no voltage.
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. B. If there is no voltage, then check the ECU for the appropriate software and re-flash, if necessary. 7. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals, or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 07 SH07-ENGINE F5C T4 (55.100.DP-C.20.E.07) Wiring harnesses - Electrical schematic sheet 11 SH11-ENGINE F5C T4 (55.100.DP-C.20.E.11)
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3409 (DTC 238-04) - Oil pressure sensor : 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 the off state to the on state when the oil pressure is between 0.6 – 0.9 bar (8.7 – 13.0 psi). If the oil pressure switch does not actuate once the engine has been running for 6.0 s at and engine speed greater than 500.0 RPM, then this fault will occur. Cause: The ECU has determined that the oil pressure switch did not actuate. Possible failure modes: 1. Faulty oil level, too low. 2. Faulty oil pressure switch, failed internally. 3. Faulty oil pressure switch circuit wiring, short circuit to chassis ground. 4. Faulty oil pressure, too low or blockage. 5. Faulty ECU, hardware or software. Solution: 1. Verify that the fault is present and active. Use the Electronic Service Tool (EST) to check the status of this fault. A. If the fault is present and active, then continue with step 2. 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 8. 2. Check the oil level. Refer to the operator’s manual or the 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 less than the minimum acceptable level of oil, then refer to the operator’s manual or the service manual to determine the type and quantity of oil required to refill 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 Oil pressure switch pin 1
To Chassis ground
Result There should be continuity.
Start the engine and allow the engine to run at and engine speed greater than 500 RPM for at least 6.0 s. While the engine is running at an engine speed greater than 500 RPM, use a multimeter to check for continuity on the component side : From Oil pressure switch pin 1
To Chassis ground
Result There should be no continuity.
A. If the specified values are measured, then 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 Oil pressure switch connector pin 1 Chassis ground
Result There should be no continuity.
A. If there is continuity, then leave the oil pressure switch disconnected and continue with step 5. B. If there is no continuity, then check the ECU for the appropriate software and re-flash, if necessary. 5. Locate the short circuit to ground. Disconnect the vehicle harness (VE) from the engine interface connector X-017. With the key switch in the OFF position, use a multimeter to check for continuity on the vehicle harness (VE) side : From X-017 (Receptacle) pin 3
To Chassis ground
Result There should be no continuity.
A. If there is continuity, then leave connector X-017 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 connector the oil pressure switch and connector X-017. Locate and repair the grounded conductor. Repair or replace the harness as required. 6. Locate the short circuit to ground. Disconnect the vehicle harness (VE) from the ECU at connector X-016. Use a multimeter to check for continuity on the vehicle harness (VE) side : From X-016 (Receptacle) pin 6
To Chassis ground
Result There should be no continuity.
A. If there is continuity, then the short circuit to chassis ground is in the vehicle harness (VE) between connector X-016 and connector X-017. 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. An oil pressure between 0.6 â&#x20AC;&#x201C; 0.9 bar (8.7 â&#x20AC;&#x201C; 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 oil pressure 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. Repair as required. 8. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals, or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. 48068130 29/01/2018
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B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 07 SH07-ENGINE F5C T4 (55.100.DP-C.20.E.07) Wiring harnesses - Electrical schematic sheet 11 SH11-ENGINE F5C T4 (55.100.DP-C.20.E.11)
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3410 (DTC 58C-03) - Throttle valve control governor deviation above threshold 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 signal using a position sensor. If the ECU determines that there is a positive deviation between the required position 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. The desired throttle valve position can not be reached. Possible failure modes: 1. Faulty throttle valve actuator, sticking or blocked. 2. Faulty throttle valve actuator, internal failure. 3. Faulty ECU, software.
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3411 (DTC 58C-04) - Throttle valve control governor deviation below threshold 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 signal 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). Possible failure modes: 1. Faulty throttle valve actuator, sticking or blocked. 2. Faulty throttle valve actuator, internal failure. 3. Faulty ECU, software.
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3414 (DTC 72C-00) - Array of DFCs for short circuit in i+1th Glow Plug Context: 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). 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 is notified of a short circuit in the glow plug 1 circuit, this fault will occur. 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. Possible failure modes: 1. Faulty glow plug 1, internal failure. 2. Faulty glow plug 1 control circuit wiring, short circuit to ground. 3. Faulty ECU, software. Solution: 1. Verify that the fault is present and active. Use the Electronic Service Tool (EST) to check the status of this fault. A. If the fault is present and active, then continue with step 2. 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 7. 2. Check the glow plug for a short circuit to ground. Disconnect the engine harness (EN) from glow plug 1. Use a multimeter to measure the resistance of the glow plug : From Glow plug 1 pin 1
To Chassis ground
Result There should be 0.2 – 5.0 Ω.
A. If there is greater than 0.2 Ω, then leave the glow plug disconnected. Continue with step 3. B. If there is less than 0.2 Ω, then the 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. With the key switch in the OFF position, use a multimeter to check for continuity on the engine harness (EN) side : From Glow plug 1 connector pin 1
To Chassis ground
Result There should be no continuity.
A. If there is continuity, then continue with step 4. B. If there is no continuity, then continue with step 6. 4. Locate the short circuit to ground. Disconnect the vehicle harness (VE) from the engine interface connector X-017. With the key switch in the OFF position, use a multimeter to check for continuity on the vehicle harness (VE) side : From X-017 (Receptacle) pin 61
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Result There should be no continuity.
Electrical systems - FAULT CODES
A. If there is continuity, then leave connector X-017 disconnected and continue with step 5. B. If there is no continuity, the short circuit to ground is in the engine harness (EN) between the glow plug 1 and connector X-017. Locate and repair the grounded conductor. Repair or replace the harness as required. 5. Locate the short circuit to ground. Disconnect the vehicle harness (VE) from the glow plug control module at connector X-013. With the key switch in the OFF position, use a multimeter to check for continuity on the vehicle harness (VE) side : From X-013 (Receptacle) pin 2
To Chassis ground
Result There should be no continuity.
A. If there is continuity, then the short circuit to chassis ground is in the vehicle harness (VE) between connector X-013 and connector X-017. Locate and repair the grounded conductor. Repair or replace the harness as required. B. If there is no continuity, then continue with step 6. 6. Replace the glow plug control module, then use EST to check to see that this fault has been resolved. A. If the fault has been resolved, 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. 7. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals, or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 06 SH06-ENGINE F5C T4 (55.100.DP-C.20.E.06) Wiring harnesses - Electrical schematic sheet 10 SH10-ENGINE F5C T4 (55.100.DP-C.20.E.10)
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3415 (DTC 72C-01) - Array of DFCs for short circuit in i+1th Glow Plug Context: 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). 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 is notified of a short circuit in the glow plug 2 circuit, then this fault will occur. Cause: The glow plug control module has communicated to the ECU, via a diagnostic connection, that a short circuit exists in the glow plug 2 circuit. Possible failure modes: 1. Faulty glow plug 2, internal failure. 2. Faulty glow plug 2 control circuit wiring, short circuit to ground. 3. Faulty ECU, software. Solution: 1. Verify that the fault is present and active. Use the Electronic Service Tool (EST) to check the status of this fault. A. If the fault is present and active, then continue with step 2. 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 7. 2. Check the glow plug for a short circuit to ground. Disconnect the engine harness (EN) from glow plug 2. Use a multimeter to measure the resistance of the glow plug : From Glow plug 2 pin 1
To Chassis ground
Result There should be 0.2 – 5.0 Ω.
A. If there is greater than 0.2 Ω, then leave the glow plug 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 and retest. 3. Check the glow plug 2 control 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 Glow plug 2 connector pin 1
To Chassis ground
Result There should be no continuity.
A. If there is continuity, then continue with step 4. B. If there is no continuity, then continue with step 6. 4. Locate the short circuit to ground. Disconnect the vehicle harness (VE) from the engine interface connector X-017. With the key switch in the OFF position, use a multimeter to check for continuity on the vehicle harness (VE) side : From X-017 (Receptacle) pin 60
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Result There should be no continuity.
Electrical systems - FAULT CODES
A. If there is continuity, then leave connector X-017 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 glow plug 2 and connector X-017. Locate and repair the grounded conductor. Repair or replace the harness as required. 5. Locate the short circuit to ground. Disconnect the vehicle harness (VE) from the glow plug control module at connector X-013. With the key switch in the OFF position, use a multimeter to check for continuity on the vehicle harness (VE) side : From X-013 (Receptacle) pin 7
To Chassis ground
Result There should be no continuity.
A. If there is continuity, then the short circuit to chassis ground is in the vehicle harness (VE) between connector X-013 and connector X-017. Locate and repair the grounded conductor. Repair or replace the harness as required. B. If there is no continuity, then continue with step 6. 6. Replace the glow plug control module, then use EST to check to see that this fault has been resolved. A. If the fault has been resolved, 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. 7. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals, or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 06 SH06-ENGINE F5C T4 (55.100.DP-C.20.E.06) Wiring harnesses - Electrical schematic sheet 08 SH08-ENGINE F5C T4 (55.100.DP-C.20.E.08) Wiring harnesses - Electrical schematic sheet 09 SH09-ENGINE F5C T4 (55.100.DP-C.20.E.09) Wiring harnesses - Electrical schematic sheet 10 SH10-ENGINE F5C T4 (55.100.DP-C.20.E.10)
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3416 (DTC 72C-02) - Array of DFCs for short circuit in i+1th Glow Plug Context: 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). 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 is notified of a short circuit in the glow plug 3 circuit, then this fault will occur. Cause: The glow plug control module has communicated to the ECU, via a diagnostic connection, that a short circuit exists in the glow plug 3 circuit. Possible failure modes: 1. Faulty glow plug 3, internal failure. 2. Faulty glow plug 3 control circuit wiring, short circuit to ground. 3. Faulty ECU, software. Solution: 1. Verify that the fault is present and active. Use the Electronic Service Tool (EST) to check the status of this fault. A. If the fault is present and active, continue with step 2. B. If the fault is no longer present or in an inactive state, the fault may be intermittent and not currently active. Continue with step 7. 2. Check the glow plug for a short circuit to ground. Disconnect the engine harness (EN) from glow plug 3. Use a multimeter to measure the resistance of the glow plug : From Glow plug 3 pin 1
To Chassis ground
Result There should be 0.2 – 5.0 Ω.
A. If there is greater than 0.2 Ω, then leave glow plug 3 disconnected and continue with step 3. B. If there is less than 0.2 Ω, then the glow plug 3 has failed internally. Replace the glow plug and retest. 3. Check the glow plug 3 control 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 Glow plug 3 connector pin 1
To Chassis ground
Result There should be no continuity.
A. If there is continuity, then continue with step 4. B. If there is no continuity, then continue with step 6. 4. Locate the short circuit to ground. Disconnect the vehicle harness (VE) from the engine interface connector X-017. With the key switch in the OFF position, use a multimeter to check for continuity on the vehicle harness (VE) side : From X-017 (Receptacle) pin 58
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Result There should be no continuity.
Electrical systems - FAULT CODES
A. If there is continuity, then leave connector X-017 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 glow plug 3 and connector X-017. Locate and repair the grounded conductor. Repair or replace the harness as required. 5. Locate the short circuit to ground. Disconnect the vehicle harness (VE) from the glow plug control module at connector X-013. With the key switch in the OFF position, use a multimeter to check for continuity on the vehicle harness (VE) side : From X-013 (Receptacle) pin 1
To Chassis ground
Result There should be no continuity.
A. If there is continuity, then the short circuit to chassis ground is in the vehicle harness (VE) between connector X-013 and connector X-017. Locate and repair the grounded conductor. Repair or replace the harness as required. B. If there is no continuity, then continue with step 6. 6. Replace the glow plug control module, then use EST to check to see that this fault has been resolved. A. If the fault has been resolved, 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. 7. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals, or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 06 SH06-ENGINE F5C T4 (55.100.DP-C.20.E.06) Wiring harnesses - Electrical schematic sheet 10 SH10-ENGINE F5C T4 (55.100.DP-C.20.E.10)
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3417 (DTC 72C-03) - Array of DFCs for short circuit in i+1th Glow Plug Context: 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). 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 is notified of a short circuit in the glow plug 4 circuit, then this fault will occur. Cause: The glow plug control module has communicated to the ECU, via a diagnostic connection, that a short circuit exists in the glow plug 4 circuit. Possible failure modes: 1. Faulty glow plug 4, internal failure. 2. Faulty glow plug 4 control circuit wiring, short circuit to ground. 3. Faulty ECU, software. Solution: 1. Verify that the fault is present and active. Use the Electronic Service Tool (EST) to check the status of this fault. A. If the fault is present and active, continue with step 2. B. If the fault is no longer present or in an inactive state, then the fault may be intermittent and not currently active. Continue with step 7. 2. Check the glow plug for a short circuit to ground. Disconnect the engine harness (EN) from glow plug 4. Use a multimeter to measure the resistance of the glow plug : From Glow plug 4 pin 1
To Chassis ground
Result There should be 0.2 – 5.0 Ω.
A. If there is greater than 0.2 Ω, then leave the glow plug disconnected. Continue with step 3. B. If there is less than 0.2 Ω, then the glow plug 4 has failed internally. Replace the glow plug and retest. 3. Check the glow plug 4 control 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 Glow plug 4 connector pin 1
To Chassis ground
Result There should be no continuity.
A. If there is continuity, then continue with step 4. B. If there is no continuity, then continue with step 6. 4. Locate the short circuit to ground. Disconnect the vehicle harness (VE) from the engine interface connector X-017. With the key switch in the OFF position, use a multimeter to check for continuity on the vehicle harness (VE) side : From X-017 (Receptacle) pin 57
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Result There should be no continuity.
Electrical systems - FAULT CODES
A. If there is continuity, then leave connector X-017 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 glow plug 4 and connector X-017. Locate and repair the grounded conductor. Repair or replace the harness as required. 5. Locate the short circuit to ground. Disconnect the vehicle harness (VE) from the glow plug control module at connector X-013. With the key switch in the OFF position, use a multimeter to check for continuity on the vehicle harness (VE) side : From X-013 (Receptacle) pin 6
To Chassis ground
Result There should be no continuity.
A. If there is continuity, then the short circuit to chassis ground is in the vehicle harness (VE) between connector X-013 and connector X-017. Locate and repair the grounded conductor. Repair or replace the harness as required. B. If there is no continuity, then continue with step 6. 6. Replace the glow plug control module, then use EST to check to see that this fault has been resolved. A. If the fault has been resolved, 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. 7. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals, or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 06 SH06-ENGINE F5C T4 (55.100.DP-C.20.E.06) Wiring harnesses - Electrical schematic sheet 10 SH10-ENGINE F5C T4 (55.100.DP-C.20.E.10)
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3418 (DTC 393-03) - ECU Power stages : SCB error on the Turbocharger PWM output power stage Context: The Engine Control Unit (ECU) monitors the wastegate pressure modulator valve circuit. If the ECU determines that 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. Possible failure modes: 1. Faulty wastegate pressure modulator valve wiring, short circuit to another voltage source. 2. Faulty wastegate pressure modulator valve, internal failure. 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, then the fault may be intermittent and not currently active. Continue with step 7. 2. Check the wastegate pressure modulator valve internal resistance. Disconnect the engine harness from 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 continue to step 3. B. If there is not between 21.8 – 24.2 Ω, then the wastegate pressure modulator valve has failed internally. Replace the wastegate pressure modulator valve and retest. 3. Check the wastegate pressure modulator valve wiring for a short circuit. 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 Wastegate pressure modulator valve Wastegate pressure modulator valve There should be no continuity. connector pin 1 connector pin 2 A. If there is continuity, then there is a short circuit in the wastegate pressure modulator valve wiring. Locate and repair the shorted conductor. Repair or replace the harness as required. B. If there is no continuity, then continue to step 4. 4. Check the wastegate pressure modulator valve wiring for a short circuit to battery.
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With the key in the OFF position, use a multimeter to perform the following voltage check on the engine harness (EN) side : From To Wastegate pressure modulator valve Chassis ground connector pin 2
Value There should be no voltage.
A. If there is voltage, then there is a short circuit to battery in the wastegate pressure modulator valve wiring. Locate and repair the shorted conductor. Repair or replace the harness as required. B. If there is no voltage, then continue to step 5. 5. Check the wastegate pressure modulator valve wiring for a short circuit to another voltage source. Disconnect the vehicle harness (VE) from the engine interface at connector X-017. With the key in the ON position, use a multimeter to perform the following voltage check on the engine harness (EN) side : From To Wastegate pressure modulator valve Chassis ground connector pin 2
Value There should be no voltage.
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. B. If there is no voltage, then continue to step 6. 6. Check the wastegate pressure modulator valve wiring for a short circuit to another voltage source. Disconnect the vehicle harness (VE) from the ECU at connector X-016. With the key in the ON position, use a multimeter to perform the following voltage check on the vehicle harness (VE) side : From X-017 (Receptacle) pin 27
To Chassis ground
Value There should be no voltage.
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. B. If there is no voltage, then check the ECU for the appropriate software and re-flash, if necessary. 7. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals, or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 07 SH07-ENGINE F5C T4 (55.100.DP-C.20.E.07) Wiring harnesses - Electrical schematic sheet 11 SH11-ENGINE F5C T4 (55.100.DP-C.20.E.11)
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3419 (DTC 393-04) - ECU Power stages : SCG error on the Turbocharger PWM output power stage Context: The Engine Control Unit (ECU) monitors the wastegate pressure modulator valve circuit. If the ECU determines that 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. Possible failure modes: 1. Faulty wastegate pressure modulator valve wiring, short circuit to ground. 2. Faulty wastegate pressure modulator valve, internal failure. 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, then continue with step 2. 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. Check the wastegate pressure modulator valve internal resistance. Disconnect the engine harness from 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 continue to step 3. B. If there is not between 21.8 – 24.2 Ω, then the wastegate pressure modulator valve has failed internally. Replace the wastegate pressure modulator valve and retest. 3. Check the wastegate pressure modulator valve engine harness (EN) wiring. Disconnect the vehicle harness (VE) from the engine interface at connector X-017. With the key in the OFF position, use a multimeter to perform the following continuity check on the engine harness (EN) side : From To Wastegate pressure modulator valve Chassis ground connector pin 2 All pins in connector X-017 X-017 (Receptacle) pin 27
Value There should be no continuity. There should be no continuity.
A. If there is continuity, then there is a short circuit in the wastegate pressure modulator valve engine harness (EN) wiring. Locate and repair the shorted conductor. Repair or replace the harness as required. B. If there is no continuity, then leave connector X-017 disconnected and continue to step 4. 4. Check the wastegate pressure modulator valve vehicle harness (VE) wiring. 48068130 29/01/2018
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Disconnect the vehicle harness (VE) from the ECU at connector X-016. With the key in the OFF position, use a multimeter to perform the following continuity check on the vehicle harness (VE) side of the connectors from : From X-017 (Receptacle) pin 27 X-017 (Receptacle) pin 27
To Chassis ground All pins in connector X-017
Value There should be no continuity. There should be no continuity.
A. If there is continuity, then there is a short circuit in the wastegate pressure modulator valve vehicle harness (VE) wiring. Locate and repair the shorted 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. 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. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 07 SH07-ENGINE F5C T4 (55.100.DP-C.20.E.07) Wiring harnesses - Electrical schematic sheet 11 SH11-ENGINE F5C T4 (55.100.DP-C.20.E.11)
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3420 (DTC 3CA-03) - CAN Bus Received frames : DFC of Auxiliary Engine Shutdown Switch Message Context: The ECU received a shutdown message via the CAN Bus. This fault code does not indicate a failure, but rather an external shut down request was sent to the ECU.
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Electrical systems - FAULT CODES
3425 (DTC 199-02) - Turbocharger : Over boost deviation at P2 too high in Pressure charger regulator Context: The Engine Control Unit (ECU) monitors boost pressure using the intake manifold pressure sensor. If the ECU determines that boost pressure is higher than expected, then this fault will occur. For more information regarding the troubleshooting of an over-boost condition, refer to the engine service manual Turbocharger - Troubleshooting (10.250). Cause: The ECU has determined that boost pressure is higher than expected. Possible failure modes: 1. Faulty wastegate pressure modulator valve, if applicable. 2. Faulty wastegate, sticking or broken linkage. 3. Faulty intake manifold pressure sensor, signal drifted. 4. Faulty ECU, software.
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Electrical systems - FAULT CODES
3427 (DTC 3F1-04) - Diesel particulate filter (DPF) : Signal range check flow resistance of the particulate filter - low Context: The engine control unit (ECU) has detected the DPF filter flow resistance is low. Check that the DPF filter is installed properly. If the DPF filter is not installed properly, refit the DPF filter correctly. If damaged is determined, replace the DPF filter. This fault will clear at the end of the next regeneration cycle. If the error still persists, check for other DPF related error codes and continue to those tests.
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3428 (DTC 3F3-12) - Diesel Particulate filter Pressure sensor: not plausibility error Context: The Engine Control Unit (ECU) has detected a pressure variance that is outside the acceptable pressure range. This is an indication of a cracked, clogged or improperly installed differential pressure sensor. Verify that the sensor is not damaged. Verify the air lines leading to the sensor are installed properly and are free of cracks, kinks and holes. Repair or replace the air lines or sensor as required. Repair or replace the particulate filter as required.
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3429 (DTC 7F3-12) - Diesel Particulate filter Pressure sensor: hoseline plausibility error Context: The Engine Control Unit (ECU) has detected a pressure variance that is outside the acceptable pressure range. This is an indication of a cracked, clogged or improperly installed differential pressure sensor. Verify that the sensor is not damaged. Verify the air lines leading to the sensor are installed properly and are free of cracks, kinks and holes. Repair or replace the air lines or sensor as required. Repair or replace the particulate filter as required.
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3430 (DTC 15E-03) - EGR Inducement less severe derating level Context: The Engine Control Unit (ECU) monitors the efficiency of the Exhaust Gas Recirculation (EGR) valve. If the ECU detects an efficiency failure, inducement will be triggered and this fault will occur. This fault indicates a least severe inducement level. Other active faults may have caused this fault to occur.
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Electrical systems - FAULT CODES
3431 (DTC 25E-03) - EGR Inducement most severe derating level Context: The Engine Control Unit (ECU) monitors the efficiency of the Exhaust Gas Recirculation (EGR) valve. If the ECU detects an efficiency failure, inducement will be triggered and this fault will occur. This fault indicates a most severe inducement level. Other active faults may have caused this fault to occur.
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Electrical systems - FAULT CODES
3432 (DTC 35E-03) - EGR Inducement warning Context: The Engine Control Unit (ECU) monitors the efficiency of the Exhaust Gas Recirculation (EGR) valve. If the ECU detects an efficiency failure, an inducement warning will be triggered and this fault will occur. Other active faults may have caused this fault to occur.
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Electrical systems - FAULT CODES
3433 (DTC 15D-03) - DPF Inducement less severe derating level Context: The Engine Control Unit (ECU) monitors the Particulate Matter (PM) catalytic converter efficiency. If the ECU detects an failure of efficiency, inducement will be triggered and this fault will occur. Other active faults may have caused this fault to occur. This fault indicates the least severe level of inducement.
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Electrical systems - FAULT CODES
3434 (DTC 25D-03) - DPF Inducement most severe derating level Context: The Engine Control Unit (ECU) monitors the Particulate Matter (PM) catalytic converter efficiency. If the ECU detects an failure of efficiency, inducement will be triggered and this fault will occur. Other active faults may have caused this fault to occur. This fault indicates the most severe level of inducement.
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Electrical systems - FAULT CODES
3435 (DTC 35D-03) - DPF Inducement warning Context: The Engine Control Unit (ECU) monitors the Particulate Matter (PM) catalytic converter efficiency. If the ECU detects an failure of efficiency, an inducement warning will be triggered and this fault will occur. Other active faults may have caused this fault to occur.
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3517 (DTC 13C-03) - SRC high for air temperature sensor 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, 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 greater than 4.93 V. Possible failure modes: 1. Faulty intake air temperature sensor wiring, short circuit to another voltage source. 2. Faulty intake air temperature sensor, internal failure. 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, then continue with step 2. 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 6. 2. Check the intake air temperature sensor wiring for a short circuit to battery. Disconnect the vehicle harness from the intake air temperature sensor at connector X-004. With the key in the OFF position, use a multimeter to perform the following voltage check on the vehicle harness (VE) side : From Intake air temperature sensor connector pin 1
To Chassis ground
Value There should be no voltage.
With the key in the ON position, use a multimeter to perform the following voltage check on the vehicle harness (VE) side : From Intake air temperature sensor connector pin 1
To Chassis ground
Value There should be less than 5.5 V
A. If the specified values are measured, then leave connector X-004 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 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. Disconnect the vehicle harness from the ECU at connector X-012. With the key in the OFF position, use a multimeter to perform the following continuity check on the vehicle harness (VE) side :
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From Intake air temperature sensor connector pin 1 Intake air temperature sensor connector pin 2
To X-012 (Receptacle) pin 19
Value There should be continuity.
X-012 (Receptacle) pin 20
There should be continuity.
A. If there is continuity, then leave the intake air temperature sensor disconnected. Leave connector X-012 disconnected 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 X-012 (Receptacle) pin 19 X-012 (Receptacle) pin 20
To All pins in connector X-012 All pins in connector X-012
Value There should be no continuity. There should be no continuity.
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. 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. Use the Electronic Service Tool (EST) to check the status of this fault. A. If the fault has been resolved, 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. 6. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals, or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 06 SH06-ENGINE F5C T4 (55.100.DP-C.20.E.06) Wiring harnesses - Electrical schematic sheet 10 SH10-ENGINE F5C T4 (55.100.DP-C.20.E.10)
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3518 (DTC 13C-04) - SRC low for air temperature sensor 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 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. Possible failure modes: 1. Faulty intake air temperature sensor wiring, short circuit to ground. 2. Faulty intake air temperature sensor, internal failure. 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, then continue with step 2. 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. 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-004. With the key in the OFF position, use a multimeter to perform the following continuity check on the vehicle harness (VE) side : From Intake air temperature sensor connector pin 1 Intake air temperature sensor connector pin 1
To Intake air temperature sensor connector pin 1 Chassis ground
Value There should be no continuity. There should be no continuity.
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 shorted conductor. B. If there is no continuity, then leave connector X-004 disconnected and continue to step 3. 3. Check the intake air temperature sensor vehicle harness (VE) wiring for a short circuit to ground. Disconnect the vehicle harness (VE) from the ECU at connector X-012. With the key in the OFF position, use a multimeter to perform the following continuity check on the vehicle harness (VE) side : From X-012 (Receptacle) pin 19 X-012 (Receptacle) pin 19
To Chassis ground All pins in connector X-012
Value There should be no continuity. There should be no continuity.
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 shorted conductor. B. If there is no continuity, then leave connector X-004 disconnected and continue to step 4. 4. Replace the intake temperature sensor. 48068130 29/01/2018
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Use the Electronic Service Tool (EST) to check the status of this fault, 3518 (DTC 13C-04) â&#x20AC;&#x201C; SRC low for air temperature sensor. A. If the fault has been resolved, 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. 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. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 06 SH06-ENGINE F5C T4 (55.100.DP-C.20.E.06) Wiring harnesses - Electrical schematic sheet 10 SH10-ENGINE F5C T4 (55.100.DP-C.20.E.10)
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3616 (DTC 39E-04) - Torque limitation, Engine protection : Torque limitation caused by turbo charger protection Context: This fault is for information purposes only and may have been caused by another fault. The Engine Control Unit (ECU) has detected an active power reduction due to turbocharger protection. This fault may have been caused by a detection of high altitude or extreme working conditions for a period greater than 120.00 s. If this fault occurs, a power reduction or engine speed reduction of equal to or greater than 25% of the desired torque will be active in order to protect the turbocharger from a potential overspeed condition. If the power reduction occurred due to actual defect, the failure triggering the torque limitation should also be in the failure memory. Use the Electronic Service Tool (EST) to check for related fault codes and diagnose them first, then check the status of this fault, 3616 (DTC 39E-04) â&#x20AC;&#x201C; Torque limitation, Engine protection : Torque limitation caused by turbo charger protection.
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3650 (DTC 226-03) - Battery voltage : SRC high for battery voltage sensor Context: The Engine Control Unit (ECU) monitors the battery voltage. If the ECU detects a battery voltage greater than 28.8 V, then this fault will occur. Cause: The ECU has detected a battery voltage of greater than 28.8 V. Possible failure modes: 1. Faulty alternator, failed regulator. 2. 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 3. 2. Check the battery voltage. Start the engine. Set the engine speed to 1500 RPM. Let the engine run at this speed for at least 1.00 min. Reduce the engine speed to low idle. With the engine running, use a multimeter to perform the following voltage check on the battery posts : From Battery +
To Battery -
Value 14.8 â&#x20AC;&#x201C; 16.2 V
A. If the voltage is greater than 16.2 V, then the alternator has failed. Replace the alternator and retest. B. If the voltage is between 14.8 â&#x20AC;&#x201C; 16.2 V, then check the ECU for the appropriate software and re-flash, if necessary. 3. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals, or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 06 SH06-ENGINE F5C T4 (55.100.DP-C.20.E.06) Wiring harnesses - Electrical schematic sheet 10 SH10-ENGINE F5C T4 (55.100.DP-C.20.E.10)
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3651 (DTC 226-04) - Battery voltage : SRC low for battery voltage sensor Context: The Engine Control Unit (ECU) monitors the battery voltage. If the ECU detects the battery voltage is lower than 8.3 V, then this fault will occur. Cause: The ECU has detected that the battery voltage is less than 8.3 V. Possible failure modes: 1. Faulty battery. 2. Faulty alternator, failed regulator. 3. Engine started in extreme cold conditions. 4. 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, then continue with step 2. 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 6. 2. Charge the battery and perform a battery load test. A. If the pass battery does not pass the load test, then replace the battery. B. If the battery passes the load test, then continue to step 3. 3. Start the engine and raise the Revolutions Per Minute (RPM) to about 1500 RPM for 1.00 min. Lower the RPM to idle speed and check the battery voltage with the engine running. With the engine running, use a multimeter to perform the following voltage check on the battery posts : From Battery +
To Battery -
Value 14.8 â&#x20AC;&#x201C; 16.2 V
Check the battery voltage. Start the engine. Set the engine speed to 1500 RPM. Let the engine run at this speed for at least 1.00 min. Reduce the engine speed to low idle. With the engine running, use a multimeter to perform the following voltage check on the battery posts : From Battery +
To Battery -
Value 14.8 â&#x20AC;&#x201C; 16.2 V
A. If the voltage is less than 14.8 V, then the alternator has failed. Replace the alternator and retest. B. If the voltage is between 14.8 â&#x20AC;&#x201C; 16.2 V, then continue to step 4. 4. Check the ECU voltage supply wiring. Disconnect the vehicle harness (VE) from the ECU at connector X-012. 48068130 29/01/2018
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Place a jumper wire between X-012 (Receptacle) pin 28 and chassis ground. This will energize the ECU main relay. With the key in the ON position, use a multimeter to perform the following voltage check on the vehicle harness (VE) side : From X-012 (Receptacle) pin 1 X-012 (Receptacle) pin 3 X-012 (Receptacle) pin 5
To Chassis ground Chassis ground Chassis ground
Value There should be approximately 12 V. There should be approximately 12 V. There should be approximately 12 V.
A. If the voltage is less than 12 V, then continue to step 5. B. If there is approximately 12 V, then check the ECU for the appropriate software and re-flash, if necessary. 5. Check the ECU voltage supply wiring for a short circuit to ground. With the key in the ON position, use a multimeter to perform the following voltage check on the vehicle harness (VE) side : From X-012 (Receptacle) pin 1 X-012 (Receptacle) pin 3 X-012 (Receptacle) pin 5
To Chassis ground Chassis ground Chassis ground
Value There should be no continuity. There should be no continuity. There should be no continuity.
A. If there is continuity, there is a short circuit to ground in the ECU voltage supply wiring. Locate and repair the shorted 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. 6. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals, or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 06 SH06-ENGINE F5C T4 (55.100.DP-C.20.E.06) Wiring harnesses - Electrical schematic sheet 10 SH10-ENGINE F5C T4 (55.100.DP-C.20.E.10)
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3652 (DTC 1B1-04) - CAN Bus : Bus off of CAN node A Context: The Engine Control Unit (ECU) 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 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. If the ECU senses that CAN Node A Bus is not functioning properly, then this fault will occur. Cause: ECU has sensed a Bus Off state to be present at the CAN Node A. Possible failure modes: 1. Faulty supply voltage or ground, missing. 2. Faulty CAN circuit wiring, open circuit, short circuit to ground, or short circuit. 3. Faulty ECU, termination resistor or software. Solution: 1. Verify fault is present and in active state. Use the Electronic Service Tool (EST) to check the status of this fault. A. If the fault is 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 6. 2. Check for other vehicle CAN faults. Use the EST to determine if vehicle CAN faults exist. A. If other vehicle CAN faults exist, then resolve the vehicle CAN faults, then check to see that 3652 (DTC 1B1-04) â&#x20AC;&#x201C; CAN Bus : Bus off of CAN node A 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-012. With the key switch in the ON position, use a multimeter to check for voltage on the vehicle (VE) harness side : From X-012 (Receptacle) pin 1 X-012 (Receptacle) pin 3 X-012 (Receptacle) pin 5
To Chassis ground Chassis ground Chassis ground
Value There should be 12.0 V. There should be 12.0 V. There should be 12.0 V.
A. If the voltage is present on all of the checks, then leave connector X-012 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 replace the harness as required. 4. Check the ECU grounding. With the key switch in the OFF position, use a multimeter to check for continuity on the vehicle (VE) harness side: From X-012 (Receptacle) pin 2 X-012 (Receptacle) pin 4 X-012 (Receptacle) pin 6
To Chassis ground Chassis ground Chassis ground 48068130 29/01/2018
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Value There should be continuity. There should be continuity. There should be continuity.
Electrical systems - FAULT CODES
A. If there is continuity on all of the checks, then leave connector X-012 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 minus battery 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 X-012 (Receptacle) pin 24 X-012 (Receptacle) pin 24 X-012 (Receptacle) pin 25
To X-012 (Receptacle) pin 25 Chassis ground Chassis ground
Value There should be 120 Ί. There should not be continuity. There should not be continuity.
Use a multimeter to measure the resistance of the CAN termination resistor, internal to the ECU : From X-012 (Receptacle) pin 24
To X-012 (Receptacle) pin 25
Value There should be 120 Ί.
A. If the measured resistances are correct and neither conductor is grounded, then check the ECU 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, then locate and restore the termination resistance to the CAN circuit. 6. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals, or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 06 SH06-ENGINE F5C T4 (55.100.DP-C.20.E.06) Wiring harnesses - Electrical schematic sheet 10 SH10-ENGINE F5C T4 (55.100.DP-C.20.E.10)
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3655 (DTC 39D-04) - Torque limitation, Engine protection : General report of the event of torque limitations Context: This fault is for informational purposes only and may have been caused by another fault. The Engine Control Unit (ECU) has detected one or more torque reductions. Though there are no actions necessary for this fault alone, if the power reduction occurred due to actual defect, the failure triggering the torque limitation should also be in the failure memory. Use the Electronic Service Tool (EST) to check for related faults and diagnose them first, then check the status of this fault, 3655 (DTC 39D-04) â&#x20AC;&#x201C; Torque limitation, Engine protection : General report of the event of torque limitations.
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3656 (DTC 49D-04) - Torque limitation, Engine protection : Torque limitation caused by particulate filter Context: This fault has set due to a performance limitation to protect the particulate filter from high pressure. If there was a power reduction greater than 25% or an engine speed limitation greater than 25% due to particulate filter protection for more than 120.00 s a fault code was stored. This fault code is for information only and does not require any further action. That there was an active performance limitation due to the particulate filter protection against too high pressure, which was not caused by a failure, but an extreme working condition. If other fault codes are present that could influence the particulate filter high pressure, those faults could pinpoint an actual failure. Follow the troubleshooting procedure for the other fault.
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3657 (DTC 7BA-02) - CAN Bus Received frames : Timeout Error of CAN-Receive-Frame CM1BC Context: The Engine Control Unit (ECU) 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 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. If the ECU senses that CAN Node A Bus is not functioning properly, this fault will occur. Cause: The ECU has sensed a time out of required vehicle controller data provided on CAN Node A. Possible failure modes: 1. Faulty supply voltage or ground, missing. 2. Faulty CAN circuit wiring, open circuit, short circuit to ground, or short circuit. 3. Faulty ECU, termination resistor or software. Solution: 1. Verify fault is present and in active state. Use the Electronic Service Tool (EST) to check the status of this fault. A. If the fault is 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 6. 2. Check for other vehicle CAN faults. Use the EST to determine if vehicle CAN faults exist. A. If other vehicle CAN faults exist, then resolve the vehicle CAN faults, then check to see that 3657 (DTC 7BA-02) â&#x20AC;&#x201C; CAN Bus Received frames : Timeout Error of CAN-Receive-Frame CM1BC 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-012. With the key switch in the ON position, use a multimeter to check for voltage on the vehicle (VE) harness side : From X-012 (Receptacle) pin 1 X-012 (Receptacle) pin 3 X-012 (Receptacle) pin 5
To Chassis ground Chassis ground Chassis ground
Value There should be 12.0 V. There should be 12.0 V. There should be 12.0 V.
A. If the voltage is present on all of the checks, then leave connector X-012 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 replace the harness as required. 4. Check the ECU grounding. With the key switch in the OFF position, use a multimeter to check for continuity on the vehicle (VE) harness side: From X-012 (Receptacle) pin 2 X-012 (Receptacle) pin 4
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Value There should be continuity. There should be continuity.
Electrical systems - FAULT CODES
From X-012 (Receptacle) pin 6
To Chassis ground
Value There should be continuity.
A. If there is continuity on all of the checks, then leave connector X-012 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 minus battery 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 X-012 (Receptacle) pin 24 X-012 (Receptacle) pin 24 X-012 (Receptacle) pin 25
To X-012 (Receptacle) pin 25 Chassis ground Chassis ground
Value There should be 120 Ί. There should not be continuity. There should not be continuity.
Use a multimeter to measure the resistance of the CAN termination resistor, internal to the ECU : From X-012 (Receptacle) pin 24
To X-012 (Receptacle) pin 25
Value There should be 120 Ί.
A. If the measured resistances are correct and neither conductor is grounded, then check the ECU 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, then locate and restore the termination resistance to the CAN circuit. 6. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals, or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 06 SH06-ENGINE F5C T4 (55.100.DP-C.20.E.06) Wiring harnesses - Electrical schematic sheet 10 SH10-ENGINE F5C T4 (55.100.DP-C.20.E.10)
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3665 (DTC 589-03) - EGR valve control governor deviation above threshold NOTE: Because the Engine Control Unit (ECU) stores historical data relevant to the operation of the EGR valve, it is necessary to perform the Replacement of the Exhaust GAs Recirculation Valve (EGR) â&#x20AC;&#x201C; 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 Engine Control Unit (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, 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 positive deviation between the required and measured position of the EGR valve has been exceeded. Possible failure modes: 1. Faulty EGR valve, valve sticks, clean or replace, as required. 2. Faulty EGR valve position sensor, internal failure.
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3666 (DTC 589-04) - EGR valve control governor deviation below threshold 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 is replaced. Refer to the engine service manual for 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, 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. Possible failure modes: 1. Faulty EGR valve, valve sticks, clean or replace, as required. 2. Faulty EGR valve position sensor, internal failure.
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3667 (DTC 58B-02) - Open load error for EGR valve H-bridge NOTE: If the Exhaust Gas Recirculation (EGR) valve is replaced, it is necessary to perform the “Replacement of the Exhaust Gas Recirculation Valve (EGR) – Reset ECU Data” with the Electronic Service Tool (EST) before you return the machine to service. Refer to the engine service manual Exhaust Gas Recirculation (EGR) valve - Configure Reset ECU data (EGR valve) (10.501), if necessary. Context: The Engine Control Unit (ECU) 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, 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 in the EGR valve control circuit. Possible failure modes: 1. Faulty EGR valve actuator motor, failed internally. 2. Faulty EGR valve circuit wiring, open circuit. 3. Faulty ECU, software. Solution: 1. Verify that the fault is present and active. Use the Electronic Service Tool (EST) to check the status of this fault. A. If the fault is present and active, then continue with step 2. 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. 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 pins : From EGR valve actuator motor pin 1
To EGR valve actuator motor pin 5
Value There should be between 1.7 – 3.2 Ω.
A. If the specified value is measured, then leave the EGR valve actuator motor disconnected and continue with step 3. B. If the measured resistance is infinite, then the EGR valve actuator motor has failed internally. Replace the EGR valve and retest. Then use the EST, see Exhaust Gas Recirculation (EGR) valve - Configure - Reset ECU data (EGR valve) (10.501) if necessary, to perform the Replacement of the Exhaust Gas Recirculation Valve (EGR) – Reset ECU Data. 3. Check the engine harness (EN) for an open circuit. Disconnect the vehicle harness (VE) from the engine interface at connector X-017. Use a multimeter to check for continuity in the engine harness (EN) : From To EGR valve actuator motor connector X-017 (Receptacle) pin 29 pin 1 EGR valve actuator motor pin 5 X-017 (Receptacle) pin 30 48068130 29/01/2018
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Result There should be continuity. There should be continuity.
Electrical systems - FAULT CODES
A. If there is continuity on both tests, then leave connector X-017 disconnected and continue with step 4. B. If there is no continuity on one or both of the checks, then there is an open circuit in the engine harness (EN) between the EGR valve actuator motor and connector X-017. Locate and repair the broken conductor. Repair or replace the harness as required. 4. Check the vehicle harness (VE) for an open circuit. Disconnect the vehicle harness (VE) from the ECU at connector X-016. Use a multimeter to check for continuity in the vehicle harness (VE) : From X-016 (Receptacle) pin 50 X-016 (Receptacle) pin 35
To X-017 (Receptacle) pin 29 X-017 (Receptacle) pin 30
Result There should be continuity. There should be continuity.
A. If there is no continuity on one or both of the checks, then there is an open circuit in the vehicle harness (VE) between connector X-016 and X-017. 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 software and re-flash, if necessary. 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. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 07 SH07-ENGINE F5C T4 (55.100.DP-C.20.E.07) Wiring harnesses - Electrical schematic sheet 11 SH11-ENGINE F5C T4 (55.100.DP-C.20.E.11)
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3668 (DTC 58B-12) - Over current error for EGR valve H-bridge NOTE: If the Exhaust Gas Recirculation (EGR) valve is replaced, then it is necessary to perform the Replacement of the Exhaust Gas Recirculation Valve (EGR) – Reset ECU Data with the Electronic Service Tool (EST) before you return the machine to service. Refer to the engine service manual, Exhaust Gas Recirculation (EGR) valve - Configure - Reset ECU data (EGR valve) (10.501), if necessary. Context: The Engine Control Unit (ECU) 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 an 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 in the EGR valve control circuit. Possible failure modes: 1. Faulty EGR valve actuator motor, failed internally. 2. Faulty EGR valve circuit wiring, short circuit. 3. Faulty ECU, software. Solution: 1. Verify that the fault is present and active. Use the Electronic Service Tool (EST) to check the status of this fault. A. If the fault is present and active, then continue with step 2. 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. 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 pins : From EGR valve actuator motor pin 1
To EGR valve actuator motor pin 5
EGR valve actuator motor pin 1 EGR valve actuator motor pin 5
Chassis ground Chassis ground
Value There should be between 1.7 – 3.2 Ω. There should be no continuity. There should be no continuity.
A. If the specified values are measured, then leave the EGR valve actuator motor 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 and retest. 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. Use a multimeter to check for continuity on the engine harness (EN) side :
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From EGR valve actuator motor connector pin 1 EGR valve actuator motor connector pin 1 EGR valve actuator motor connector pin 5
To Result EGR valve actuator motor connector There should be no continuity. pin 5 There should be no continuity. Chassis ground There should be no continuity.
Chassis ground
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-017. Disconnect the vehicle harness (VE) from the ECU at connector X-9121. Use a multimeter to check for continuity in the vehicle harness (VE) : From X-9121 pin A50 X-9121 pin A50 X-9121 pin A35
To X-9121 pin A35 chassis ground chassis ground
Result There should be no continuity. There should be no continuity. There should be no continuity.
A. If there is continuity on any of the checks, there is a short circuit in the vehicle harness (VE) between connector X-9121 pin A50 and X-9121 pin A35 or a short to ground condition between connector X-9121 pin A50 and X-9138 pin 29 or X-9121 pin A35 and X-9138 pin 30. Use the appropriate service manual, if necessary, to locate and repair the damaged conductors or grounded conductor. B. If there is no continuity on any of the checks, there is a short circuit in the engine harness (EN) between connector X-9010 pin 1 and X-9010 pin 5 or a short to ground condition between connector X-9010 pin 1 and X-9138 pin 29 or X-9010 pin 5 and X-9138 pin 30. Locate and repair the damaged conductors or grounded conductor. 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. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 07 SH07-ENGINE F5C T4 (55.100.DP-C.20.E.07) Wiring harnesses - Electrical schematic sheet 11 SH11-ENGINE F5C T4 (55.100.DP-C.20.E.11)
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3669 (DTC 68B-00) - Over temperature error for EGR valve H-bridge 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 a short circuit to another voltage source, 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 to another voltage source in the EGR valve motor actuator control circuit. Possible failure modes: 1. Faulty EGR valve circuit wiring, short circuit to another voltage source. 2. Faulty ECU, software. Solution: 1. Verify that the fault is present and active. Use the Electronic Service Tool (EST) to check the status of this fault. A. If the fault is present and active, then continue with step 2. 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. Check the EGR valve motor actuator control circuit for a short circuit to another voltage source. Disconnect the vehicle harness (VE) from the ECU at connector X-016. Disconnect the engine harness (EN) from the EGR valve. With the key switch in the ON position, use a multimeter to check for voltage on the engine harness (EN) side : From EGR valve pin 1 EGR valve pin 5
To Chassis ground Chassis ground
Result There should be no voltage. There should be no voltage.
A. If there is voltage on one or both tests, then leave the EGR valve disconnected. Leave connector X-016 disconnected. Continue with step 3. B. If there is no voltage on either of the checks, then leave the EGR valve disconnected. Leave connector X-016 disconnected. Continue with step 4. 3. Locate the short circuit to another voltage source. Disconnect the vehicle harness (VE) from the engine interface connector X-017. With the key switch in the ON position, use a multimeter to check for voltage on the vehicle harness (VE) side : From X-017 (Receptacle) pin 29 X-017 (Receptacle) pin 30
To Chassis ground Chassis ground
Result There should be no voltage. There should be no voltage.
A. If there is no voltage on either of the checks, then the short circuit to another voltage source is in the engine harness (EN) between the EGR valve and connector X-017. 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 to another voltage source is in the vehicle harness (VE) between connector X-016 and X-017. 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. Use a multimeter to check for continuity on the vehicle harness (VE) side : From X-016 (Receptacle) pin 50 X-016 (Receptacle) pin 35
To All other pins in connector X-016 All other pins in connector X-016
Result There should be no continuity. There should be no continuity.
A. If there is continuity on any of the tests, then there is a short circuit in the vehicle harness (VE). Locate and repair the damaged conductors. Repair or replace the harness as required. B. If there is no continuity on any of the checks, then check the ECU for the appropriate software and re-flash, if necessary. 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. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 07 SH07-ENGINE F5C T4 (55.100.DP-C.20.E.07) Wiring harnesses - Electrical schematic sheet 11 SH11-ENGINE F5C T4 (55.100.DP-C.20.E.11)
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3670 (DTC 68B-03) - Short circuit to battery of EGR valve H-bridge - high pin A50 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 a short circuit to another voltage source, 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 to a voltage source in the EGR valve motor actuator control circuit. Possible failure modes: 1. Faulty EGR valve circuit wiring, short circuit to another voltage source. 2. Faulty ECU, software. Solution: 1. Verify that the fault is present and active. Use the Electronic Service Tool (EST) to check the status of this fault. A. If the fault is present and active, then continue with step 2. 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. Check the EGR valve motor actuator control circuit for a short circuit to another voltage source. Disconnect the vehicle harness (VE) from the ECU at connector X-016. Disconnect the engine harness (EN) from the EGR valve. With the key switch in the ON position, use a multimeter to check for voltage on the engine harness (EN) side : From EGR valve connector pin 1 EGR valve connector pin 5
To Chassis ground Chassis ground
Result There should be no voltage. There should be no voltage.
A. If there is voltage on one or both tests, then leave the EGR valve disconnected. Leave connector X-016 disconnected. Continue with step 3. B. If there is no voltage on either of the checks, then leave the EGR valve disconnected. Leave connector X-016 disconnected. Continue with step 4. 3. Locate the short circuit to another voltage source. Disconnect the vehicle harness (VE) from the engine interface connector X-017. With the key switch in the ON position, use a multimeter to check for voltage on the vehicle harness (VE) side : From X-017 (Receptacle) pin 29 X-017 (Receptacle) pin 30
To Chassis ground Cchassis ground
Result There should be no voltage. There should be no voltage.
A. If there is no voltage on either of the checks, then the short circuit to another voltage source is in the engine harness (EN) between the EGR valve and connector X-017. Locate and repair the damaged conductors. Repair or replace the harness as required.
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B. If there is voltage on one or both tests, then the short circuit to another voltage source is in the vehicle harness (VE) between connector X-016 and X-017. 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. Use a multimeter to check for continuity on the vehicle harness (VE) side : From X-016 (Receptacle) pin 50 X-016 (Receptacle) pin 35
To All other pins in connector X-016 All other pins in connector X-016
Result There should be no continuity. There should be no continuity.
A. If there is continuity on any of the tests, then there is a short circuit in the vehicle harness (VE). Locate and repair the damaged conductors. Repair or replace the harness as required. B. If there is no continuity on any of the checks, then check the ECU for the appropriate software and re-flash, if necessary. 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. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 07 SH07-ENGINE F5C T4 (55.100.DP-C.20.E.07) Wiring harnesses - Electrical schematic sheet 11 SH11-ENGINE F5C T4 (55.100.DP-C.20.E.11)
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3671 (DTC 68B-01) - Short circuit to battery of EGR valve H-bridge - low pin A35 NOTE: If the Exhaust Gas Recirculation (EGR) valve is replaced, it is necessary to perform the Replacement of the Exhaust Gas Recirculation Valve (EGR) â&#x20AC;&#x201C; Reset ECU Data with the Electronic Service Tool (EST) before you return the machine to service. Refer to the engine service manual Exhaust Gas Recirculation (EGR) valve - Configure Reset ECU data (EGR valve) (10.501), if necessary. Context: The Engine Control Unit (ECU) 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 a short circuit 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, service manual Exhaust Gas Recirculation (EGR) valve actuator - Technical Data (55.989). Cause: The ECU is sensing a short circuit to chassis ground in the EGR valve motor actuator control circuit. Possible failure modes: 1. Faulty EGR valve motor, failed internally. 2. Faulty EGR valve circuit wiring, short circuit to ground. 3. Faulty ECU, software. Solution: 1. Verify that the fault is present and active. Use the Electronic Service Tool (EST) to check the status of this fault. A. If the fault is present and active, then continue with step 2. 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 6. 2. Check the EGR valve motor actuator for a short circuit to ground. Disconnect the engine harness (EN) from the EGR valve. Use a multimeter to check on the component for a short circuit to ground : From EGR valve pin 1
To Chassis ground
Result There should be no continuity.
A. If there is no continuity, then leave the EGR valve disconnected and continue with step 3. B. If there is continuity, then the EGR valve motor has failed internally. Replace the EGR valve and retest. 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) â&#x20AC;&#x201C; Reset ECU Data. 3. Check the EGR valve motor actuator control 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 EGR valve connector pin 1
To Chassis ground
A. If there is continuity, then continue with step 4. B. If there is no continuity, then continue with step 5. 48068130 29/01/2018
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Result There should be no continuity.
Electrical systems - FAULT CODES
4. Locate the short circuit to ground. Disconnect the vehicle harness (VE) from the engine interface connector X-017. With the key switch in the OFF position, use a multimeter to check for continuity on the vehicle harness (VE) side : From X-017 (Receptacle) pin 29
To Chassis ground
Result There should be no continuity.
A. If there is continuity, then leave connector X-017 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 and connector X-017. Locate and repair the grounded conductor. Repair or replace the harness as required. 5. Locate the short circuit to ground. Disconnect the vehicle harness (VE) from the ECU at connector X-016. With the key switch in the OFF position, use a multimeter to check for continuity on the vehicle harness (VE) side : From X-016 (Receptacle) pin 50
To Chassis ground
Result There should be no continuity.
A. If there is continuity, then the short circuit to chassis ground is in the vehicle harness (VE) between connector X-016 and connector X-017. Locate and repair the grounded 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. 6. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals, or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 07 SH07-ENGINE F5C T4 (55.100.DP-C.20.E.07) Wiring harnesses - Electrical schematic sheet 11 SH11-ENGINE F5C T4 (55.100.DP-C.20.E.11)
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3672 (DTC 68B-04) - Short circuit to ground of EGR valve H-bridge - high pin A50 NOTE: If the Exhaust Gas Recirculation (EGR) valve is replaced, it is necessary to perform the Replacement of the Exhaust Gas Recirculation Valve (EGR) â&#x20AC;&#x201C; Reset ECU Data with the Electronic Service Tool (EST) before you return the machine to service. Refer to the engine service manual Exhaust Gas Recirculation (EGR) valve - Configure Reset ECU data (EGR valve) (10.501), if necessary. Context: The Engine Control Unit (ECU) 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 a short circuit of the circuit wiring to chassis ground, 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 to chassis ground in the EGR valve motor actuator control circuit. Possible failure modes: 1. Faulty EGR valve motor, failed internally. 2. Faulty EGR valve circuit wiring, short circuit to chassis ground. 3. Faulty ECU, software. Solution: 1. Verify that the fault is present and active. Use the Electronic Service Tool (EST) to check the status of this fault. A. If the fault is present and active, then continue with step 2. 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 6. 2. Check the EGR valve motor actuator for a short circuit to ground. Disconnect the engine harness (EN) from the EGR valve. Use a multimeter to check the component for an internal short circuit : From EGR valve pin 5
To Chassis ground
Result There should be no continuity.
A. If there is no continuity, then leave the EGR valve disconnected. Continue with step 3. B. If there is continuity, the EGR valve motor has failed internally. Replace the EGR valve and retest. 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) â&#x20AC;&#x201C; Reset ECU Data. 3. Check the EGR valve motor actuator control 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 EGR valve connector pin 5
To Chassis ground
A. If there is continuity, then continue with step 4. B. If there is no continuity, then continue with step 5. 48068130 29/01/2018
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Result There should be no continuity.
Electrical systems - FAULT CODES
4. Locate the short circuit to ground. Disconnect the vehicle harness (VE) from the engine interface connector X-017. With the key switch in the OFF position, use a multimeter to check for continuity on the vehicle harness (VE) side : From X-017 (Receptacle) pin 30
To Chassis ground
Result There should be no continuity.
A. If there is continuity, then leave connector X-017 disconnected. 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 and connector X-017. Locate and repair the grounded conductor. Repair or replace the harness as required. 5. Locate the short circuit to ground. Disconnect the vehicle harness (VE) from the ECU at connector X-016. With the key switch in the OFF position, use a multimeter to check for continuity on the vehicle harness (VE) side : From X-016 (Receptacle) pin 35
To Chassis ground
Result There should be no continuity.
A. If there is continuity, then the short circuit to chassis ground is in the vehicle harness (VE) between connector X-016 and connector X-017. Locate and repair the grounded 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. 6. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals, or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 07 SH07-ENGINE F5C T4 (55.100.DP-C.20.E.07) Wiring harnesses - Electrical schematic sheet 11 SH11-ENGINE F5C T4 (55.100.DP-C.20.E.11)
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3673 (DTC 68B-02) - Short circuit to ground of EGR valve H-bridge - low pin A35 NOTE: If the Exhaust Gas Recirculation (EGR) valve is replaced, it is necessary to perform the Replacement of the Exhaust Gas Recirculation Valve (EGR) – Reset ECU Data with the Electronic Service Tool (EST) before you return the machine to service. Refer to the engine service manual Exhaust Gas Recirculation (EGR) valve - Configure Reset ECU data (EGR valve) (10.501), if necessary. Context: The Engine Control Unit (ECU) 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 a short circuit in the wiring, 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 to another voltage source or a short circuit to chassis ground in the EGR valve motor actuator control circuit. Possible failure modes: 1. Faulty EGR valve motor, failed internally. 2. Faulty EGR valve motor actuator circuit wiring, short circuit. 3. Faulty ECU, software. Solution: 1. Verify that the fault is present and active. Use the Electronic Service Tool (EST) to check the status of this fault. A. If the fault is present and active, then continue with step 2. 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 9. 2. Check the EGR valve motor for a short circuit. Disconnect the engine harness (EN) from the EGR valve. Use a multimeter to perform the following checks on the component side of the EGR valve : From EGR valve pin 1
EGR valve pin 5
To
EGR valve pin 1 EGR valve pin 5
Chassis ground Chassis ground
Result There should be between 1.7 – 3.2 Ω. There should be no continuity. There should be no continuity.
A. If the specified values are measured, then leave the EGR valve disconnected. Continue with step 3. B. If the specified values are not measured, then the EGR valve motor has failed internally. Replace the EGR valve and retest. 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. With the key switch in the OFF position, use a multimeter to check for continuity on the engine harness (EN) side :
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From EGR valve connector pin 1 EGR valve connector pin 5
To Chassis ground Chassis ground
Result There should be no continuity. There should be no continuity.
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. Continue with step 6. 4. Locate the short circuit to ground. Disconnect the vehicle harness (VE) from the engine interface connector X-017. With the key switch in the OFF position, use a multimeter to check for continuity on the vehicle harness (VE) side : From X-017 (Receptacle) pin 29 X-017 (Receptacle) pin 30
To Chassis ground Chassis ground
Result There should be no continuity. There should be no continuity.
A. If there is continuity on either check, then leave connector X-017 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 and connector X-017. Locate and repair the grounded conductor. Repair or replace the harness as required. 5. Locate the short circuit to ground. Disconnect the vehicle harness (VE) from the ECU at connector X-016. With the key switch in the OFF position, use a multimeter to check for continuity on the vehicle harness (VE) side : From X-016 (Receptacle) pin 50 X-016 (Receptacle) pin 35
To Chassis ground Chassis ground
Result There should be no continuity. There should be no continuity.
A. If there is continuity on either check, then the short circuit to chassis ground is in the vehicle harness (VE) between connector X-016 and X-017. Locate and repair the grounded conductor. Repair or replace the harness as required. B. If there is no continuity on both checks, then check the ECU for the appropriate software and re-flash, if necessary. 6. Check the EGR valve motor actuator control circuit for a short circuit to another voltage source. Disconnect the vehicle harness (VE) from the ECU at connector X-016. With the key switch in the ON position, use a multimeter to check for voltage on the engine harness (EN) side : From EGR valve connector pin 1 EGR valve connector pin 5
To Chassis ground Chassis ground
Result There should be no voltage. There should be no voltage.
A. If there is voltage on either or both tests, then leave the EGR valve disconnected. Leave connector X-016 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-016 disconnected and continue with step 8. 7. Locate the short circuit to another voltage source. Disconnect the vehicle harness (VE) from the engine interface connector X-017. With the key switch in the ON position, use a multimeter to check for voltage on the vehicle harness (VE) side : From X-017 (Receptacle) pin 29 X-017 (Receptacle) pin 30
To Chassis ground Chassis ground 48068130 29/01/2018
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Result There should be no voltage. There should be no voltage.
Electrical systems - FAULT CODES
A. If there is no voltage on either of the checks, then the short circuit to another voltage source is in the engine harness (EN) between the EGR valve and connector X-017. Locate and repair the damaged conductors. Repair or replace the harness as required. B. If there is voltage on either or both of the checks, then the short circuit to another voltage source is in the vehicle harness (VE) between connector X-017 and X-016 Locate and repair the damaged conductors. Repair or replace the harness as required. 8. Check the EGR valve motor actuator control circuit for a short circuit. Use a multimeter to check for continuity on the vehicle harness (VE) side : From X-016 (Receptacle) pin 50 X-016 (Receptacle) pin 35
To to all other pins in connector X-016 to all other pins in connector X-016
Result There should be no continuity. There should be no continuity.
A. If there is continuity on any of the tests, then there is a short circuit in the vehicle harness (VE) between connector X-017 and/or X-016. Locate and repair the damaged conductors. Repair or replace the harness as required. B. If there is no continuity on any of the checks, then check the ECU for the appropriate software and re-flash, if necessary. 9. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals, or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 07 SH07-ENGINE F5C T4 (55.100.DP-C.20.E.07) Wiring harnesses - Electrical schematic sheet 11 SH11-ENGINE F5C T4 (55.100.DP-C.20.E.11)
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3674 (DTC 68B-07) - Short circuit over load error for EGR valve H-bridge 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 motor actuator for electrical defects. If the ECU detects that the output driver supply voltage is too low, 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 detects that the output driver supply voltage is too low. Solution: 1. Verify that the fault is present and active. Use the Electronic Service Tool (EST) to check the status of this fault. A. If the fault is present and active, then continue with step 2. 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 4. 2. Check for related faults. Use the EST to check for faults relative to low battery or control system voltage level. A. If low voltage level faults are present, then resolve those faults. Then determine if this fault has also been resolved. B. If no low voltage level faults are present, then continue with step 3. 3. 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. 4. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals, or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation.
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3675 (DTC 689-04) - EGR valve too long time drift at closed position Context: 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).
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3676 (DTC 789-00) - EGR valve position sensor voltage above threshold (Short to battery) NOTE: If the Exhaust Gas Recirculation (EGR) valve is replaced, it is necessary to perform the Replacement of the Exhaust Gas Recirculation Valve (EGR) â&#x20AC;&#x201C; Reset ECU Data with the Electronic Service Tool (EST) before you return the machine to service. Refer to the engine service manual Exhaust Gas Recirculation (EGR) valve - Configure Reset ECU data (EGR valve) (10.501), if necessary. Context: The Engine Control Unit (ECU) monitors the electrical signal provided by the Exhaust Gas Recirculation (EGR) valve position feedback potentiometer. If the signal level becomes greater than 4.86 V, then 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. Possible failure modes: 1. Faulty EGR valve, failed internally. 2. Faulty EGR valve position sensor circuit wiring, short circuit to another voltage source. 3. Faulty ECU, software. Solution: 1. Verify that the fault is present and active. Use the Electronic Service Tool (EST) to check the status of this fault. A. If the fault is present and active, then continue with step 2. 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 6. 2. Check the EGR valve potentiometer signal circuit for a short circuit to another voltage source. Disconnect the engine harness (EN) from the EGR valve. With the key switch in the ON position, use a multimeter to check for voltage on the engine harness (EN) side : From EGR valve pin 2
To Chassis ground
Result 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. 3. Locate the short circuit to another voltage source. Disconnect the vehicle harness (VE) from the engine interface connector X-017. With the key switch in the ON position, use a multimeter to check for voltage on the vehicle harness (VE) side : From X-017 (Receptacle) pin 34
To Chassis ground
Result There should be less than 4.86 V.
A. If there is less than 4.86 V, then the short circuit to another voltage source is in the engine harness (EN) between the EGR valve and connector X-017. Locate and repair the damaged conductors. Repair or replace the harness as required.
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B. If there is greater than 4.86 V, then leave connector X-017 disconnected and continue with step 4. 4. Locate the short circuit to another voltage source. Disconnect the vehicle harness (VE) from the ECU at connector X-017. With the key switch in the ON position, use a multimeter to check for voltage on the vehicle harness (VE) side : From X-016 (Receptacle) pin 39
To Chassis ground
Result There should be no voltage.
A. If there is voltage, then there is a short circuit to another voltage source in the vehicle harness (VE) between connector X-017 and connector X-016. 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. 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 Recirculation Valve (EGR) â&#x20AC;&#x201C; Reset ECU Data. Then check to see that the fault is resolved. A. If the fault is resolved, then return the vehicle to operation. B. If the fault is not resolved, then check the ECU for the appropriate software and re-flash, if necessary. 6. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals, or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 07 SH07-ENGINE F5C T4 (55.100.DP-C.20.E.07) Wiring harnesses - Electrical schematic sheet 11 SH11-ENGINE F5C T4 (55.100.DP-C.20.E.11)
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3677 (DTC 789-01) - EGR valve position sensor voltage below threshold (Short to ground) NOTE: If the Exhaust Gas Recirculation (EGR) valve is replaced, it is necessary to perform the Replacement of the Exhaust Gas Recirculation Valve (EGR) â&#x20AC;&#x201C; Reset ECU Data with the Electronic Service Tool (EST) before you return the machine to service. Refer to the engine service manual Exhaust Gas Recirculation (EGR) valve - Configure Reset ECU data (EGR valve) (10.501), if necessary. Context: The Engine Control Unit (ECU) 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, then 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. Possible failure modes: 1. Faulty EGR valve, failed internally. 2. Faulty EGR valve position sensor circuit wiring, short circuit to ground. 3. Faulty ECU, software. Solution: 1. Verify that the fault is present and active. Use the Electronic Service Tool (EST) to check the status of this fault. A. If the fault is present and active, then continue with step 2. 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 6. 2. Check the EGR valve potentiometer for a short circuit to ground. Disconnect the engine harness (EN) from the EGR valve. Use a multimeter to check for continuity on the EGR valve potentiometer side : From EGR valve pin 2 EGR valve pin 2
To Chassis ground EGR valve pin 4
Result There should be no continuity. 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) â&#x20AC;&#x201C; 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. With the key switch in the OFF position, use a multimeter to check for continuity on the engine harness (EN) side : From EGR valve connector pin 2
To Chassis ground
Result There should be no continuity.
A. If there is continuity, then leave the EGR valve disconnected and continue with step 4.
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B. If there is no continuity, then check the ECU for the appropriate software and re-flash, if necessary. 4. Locate the short circuit to ground. Disconnect the vehicle harness (VE) from the engine interface connector X-017. With the key switch in the OFF position, use a multimeter to check for continuity on the vehicle harness (VE) side : From X-017 (Receptacle) pin 34
To Chassis ground
Result There should be no continuity.
A. If there is no continuity, then the short circuit to ground is in the engine harness (EN) between the EGR valve and connector X-017. Locate and repair the damage to the conductor. Repair or replace the harness as required. B. If there is continuity, then leave connector X-017 disconnected and continue with step 5. 5. Locate the short circuit to ground. Disconnect the vehicle harness (VE) from the ECU at connector X-016. With the key switch in the OFF position, use a multimeter to check for continuity on the vehicle harness (VE) side : From X-016 (Receptacle) pin 39
To Chassis ground
Result There should be no continuity.
A. If there is continuity, then there is a short circuit to ground in the vehicle harness (VE) between connector X-016 and connector X-017. Locate and repair the damage to the 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. 6. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals, or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 07 SH07-ENGINE F5C T4 (55.100.DP-C.20.E.07) Wiring harnesses - Electrical schematic sheet 11 SH11-ENGINE F5C T4 (55.100.DP-C.20.E.11)
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3680 (DTC 256-03) - Injection cut off : Injection cut off demand (ICO) for shut off coordinator 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, then this fault will occur. Other active faults may have caused this fault to occur. 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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3684 (DTC 3F7-03) - Exhaust temperature : Fault Check for enhanced SRC-Max of Second exhaust gas temperature Context: The Engine Control Unit (ECU) monitors the exhaust manifold temperature sensor. If the ECU detects an exhaust manifold temperature greater than 950 째C (1742 째F), then this fault will occur. For more information regarding the exhaust manifold temperature sensor B-9018, refer to the engine service manual Exhaust manifold temperature sensor - Overview (55.014). For more information regarding the technical specifications of the exhaust manifold temperature sensor, refer to the engine service manual Exhaust manifold temperature sensor - Technical Data (55.014). Cause: The ECU has detected a temperature greater than 950 째C (1742 째F) from the exhaust manifold temperature sensor. Possible failure modes: 1. Faulty exhaust manifold temperature sensor, drifted signal. 2. Faulty ECU, software.
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3688 (DTC 11C-02) - Water sensor in the fuel filter : WIF Sensor Check is failed. NOTE: This fault code is for the Water in Fuel switch with black connector housing. Context: The water in fuel switch provides a diagnostic self-test signal (less than 3.9 V for 2.5 s +/- 20%) at key-ON. If the Engine Control Unit (ECU) does not sense the diagnostic self-test signal, then this fault will occur and there will be no monitoring of water content in the fuel supply. Cause: The ECU has not received an acceptable water in fuel switch self-test signal. Possible failure modes: 1. Faulty water in fuel switch circuit wiring, damaged. 2. Faulty water in fuel switch, internal failure. 3. Faulty ECU, software. 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. 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. Use the EST to check the status of the related fault 3146 (DTC 11C-03) – Water sensor in the fuel filter : Water in fuel level sensor defect detection. A. If fault 3146 (DTC 11C-03) – Water sensor in the fuel filter : Water in fuel level sensor defect detection is active, then resolve fault 3146 (DTC 11C-03) – Water sensor in the fuel filter : Water in fuel level sensor defect detection, then return to this fault, 3688 (DTC 11C-02) – Water sensor in the fuel filter : WIF Sensor Check is failed.. B. If fault 3146 (DTC 11C-03) – Water sensor in the fuel filter : Water in fuel level sensor defect detection is not active, then continue with step 3. 3. Check the water in fuel switch for the initial self-test voltage pulse. Carefully back probe the water in fuel switch at connector X-011 WIF (Plug) . With the help of an assistant, use a multimeter to perform the following test at Key-ON: From X-011 WIF (Plug) pin 1
To
Value There should be less than 3.9 V for 2.5 s +/- 20%. NOTE: The signal line should switch to battery voltage after the self-test period. Chassis ground
A. If the self-test is successful, then continue with step 4. B. If the self-test is not successful, then the water in fuel switch has failed internally. Replace the switch and retest. 4. Check for open, short and grounded circuit conditions in the water in fuel switch circuit. Disconnect the water in fuel switch at connector X-011. Disconnect the ECU connector X-012. With the key switch in the OFF position, use a multimeter to perform the following test : 48068130 29/01/2018
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From X-011 WIF (Plug) pin 1 X-011 WIF (Plug) pin 2 X-011 WIF (Plug) pin 3
To X-012 (Receptacle) pin 30 Chassis ground X-012 (Receptacle) pin 54
Value There should be continuity. There should be continuity. There should be continuity.
Then use the multimeter to perform the following test : From X-011 WIF (Plug) pin 1 X-011 WIF (Plug) pin 1 X-011 WIF (Plug) pin 2
To X-011 WIF (Plug) pin 2 X-011 WIF (Plug) pin 3 X-011 WIF (Plug) pin 3
Value There should be no continuity. There should be no continuity. There should be no continuity.
Then use the multimeter to perform the following test : From X-011 WIF (Plug) pin 1 X-011 WIF (Plug) pin 3
To Chassis ground Chassis ground
Value There should be no continuity. 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. 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 connectors X-012 and X-011 WIF disconnected and continue with step 5. 5. Check for key switch voltage supply to the water in fuel switch. With the key switch in an ON position, use a multimeter to perform the following test : From X-011 WIF (Plug) pin 3 X-011 WIF (Plug) pin 1
To Chassis ground Chassis ground
Value There should be key switch voltage. 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 harness. Repair or replace the harness as required. 6. Replace the water in fuel switch, then check to see if this fault has been resolved. A. If the fault is resolved, return the machine to service. B. If the fault is not resolved, check the ECU for the appropriate software and re-flash, if necessary. 7. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals, or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the display indicates other than normal readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 06 SH06-ENGINE F5C T4 (55.100.DP-C.20.E.06) Wiring harnesses - Electrical schematic sheet 10 SH10-ENGINE F5C T4 (55.100.DP-C.20.E.10)
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3689 (DTC 52C-01) - DFC for faulty diagnostic data transmission or protocol error Context: 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). 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. Cause: The glow plug control module diagnostic connection with the ECU is damaged or the data protocol is incorrect. Possible failure modes: 1. Faulty glow plug control module diagnostic circuit wiring, a problem in the wiring. 2. Faulty glow plug control module, internal failure. 3. Faulty ECU, software. Solution: 1. Verify that the fault is present and active. Use the Electronic Service Tool (EST) to check the status of this fault. A. If the fault is present and active, then continue with step 2. 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 4. 2. Check for damaged diagnostic circuit wiring. Disconnect the vehicle harness (VE) from the ECU at connector X-012. With the key switch in the OFF position, use a multimeter to check for continuity on the vehicle harness (VE) side : From X-012 (Receptacle) pin 22 X-012 (Receptacle) pin 22
To Chassis ground All pins in connector X-012
Result There should be no continuity. There should be no continuity.
Disconnect the vehicle harness (VE) from the glow plug control module at connector X-013. Place a jumper wire between connector X-013 (Receptacle) pin 3 and chassis ground. With the key switch in the OFF position, use a multimeter to check for continuity on the vehicle harness (VE) side : From X-012 (Receptacle) pin 22
To Chassis ground
Result There should be continuity.
A. If there is continuity from connector X-012 (Receptacle) pin 22 to ground or any other pin in connector X-012 or there is no continuity from X-012 (Receptacle) pin 22 to connector X-013 (Receptacle) pin 3, there is a short circuit to ground or another circuit or an open circuit is in the vehicle harness (VE) between connector X-013 (Receptacle) pin 3 and connector X-012 (Receptacle) pin 22. Locate and repair the damage in the circuit. Repair or replace the harness as required. B. If there is no continuity from connector X-012 (Receptacle) pin 22 to ground or any other pin in connector X-012 and there is continuity from X-012 (Receptacle) pin 22 to connector X-013 (Receptacle) pin 3, continue with step 3. 3. Replace the glow plug control module, then use EST to check to see that this fault has been resolved. A. If the fault has been resolved, then return the machine to service. 48068130 29/01/2018
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B. If the fault has not been resolved, then check the ECU for the appropriate software and re-flash, if necessary. 4. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals, or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 06 SH06-ENGINE F5C T4 (55.100.DP-C.20.E.06) Wiring harnesses - Electrical schematic sheet 10 SH10-ENGINE F5C T4 (55.100.DP-C.20.E.10)
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3691 (DTC 32B-02) - No load error for Low Voltage System Context: 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). 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 is notified of an open circuit in one or more of the glow plugs or glow plug circuits, then this fault will occur. 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. Possible failure modes: 1. Faulty glow plug, internal failure. 2. Faulty glow plug control circuit wiring, open circuit. 3. Faulty ECU, software. Solution: 1. Verify that the fault is present and active. Use the Electronic Service Tool (EST) to check the status of this fault. A. If the fault is present and active, then continue with step 2. 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 6. 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 : Glow Glow Glow Glow
plug plug plug plug
From 1 pin 1 2pin 1 3 pin 1 4 pin 1
To Chassis Chassis Chassis Chassis
ground ground ground ground
Result There should be 0.2 – 5.0 Ω. There should be 0.2 – 5.0 Ω. There should be 0.2 – 5.0 Ω. 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 disconnected and continue with step 3. B. If there is infinite 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 for an open circuit. Disconnect the vehicle harness (VE) from the engine interface connector X-017. With the key switch in the OFF position, place a jumper wire from each of the glow plug connectors to chassis ground. Use a multimeter to check for continuity on the engine harness (EN) side : From X-017 (Receptacle) pin 61 X-017 (Receptacle) pin 60 X-017 (Receptacle) pin 58
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Result There should be continuity. There should be continuity. There should be continuity.
Electrical systems - FAULT CODES
From X-017 (Receptacle) pin 57
To Chassis ground
Result There should be continuity.
A. If there is continuity on all of the checks, then leave the jumper wires in place. Reconnect connector X-017. 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-017 and the respective glow plug. Locate and repair the broken conductor. Repair or replace the harness as required. 4. Locate the open circuit. Disconnect the vehicle harness (VE) from the glow plug control module at connector X-013. With the key switch in the OFF position, use a multimeter to check for continuity on the vehicle harness (VE) side : From X-013 (Receptacle) pin 2 X-013 (Receptacle) pin 7 X-013 (Receptacle) pin 1 X-013 (Receptacle) pin 6
To Chassis Chassis Chassis Chassis
ground ground ground ground
Result There should be continuity. There should be continuity. There should be continuity. There should be continuity.
A. If there is no continuity on one or more of the checks, then the open circuit is in the vehicle harness (VE) between connector X-013 and connector X-017. Locate and repair the broken conductor. Repair or replace the harness as required. B. If there is continuity on all of the checks, then continue with step 5. 5. Replace the glow plug control module, then use EST to check to see that this fault has been resolved. A. If the fault has been resolved, 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. 6. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals, or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 06 SH06-ENGINE F5C T4 (55.100.DP-C.20.E.06) Wiring harnesses - Electrical schematic sheet 10 SH10-ENGINE F5C T4 (55.100.DP-C.20.E.10)
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3692 (DTC 32B-12) - Over temperature error on ECU power stage for Glow plug Low Voltage System Context: 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). 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 is notified of a short circuit to ground in one or more of the glow plugs or glow plug circuits, then this fault will occur. 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. Possible failure modes: 1. Faulty glow plug, internal failure. 2. Faulty glow plug control circuit wiring, short circuit. 3. Faulty ECU, software. Solution: 1. Verify that the fault is present and active. Use the Electronic Service Tool (EST) to check the status of this fault. A. If the fault is present and active, then continue with step 2. 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 6. 2. Check each of the glow plugs for a short circuit. Disconnect the engine harness (EN) from each of the glow plugs. Use a multimeter to check on the component for a short circuit to ground : Glow Glow Glow Glow
plug plug plug plug
1 2 3 4
From pin 1 pin 1 pin 1 pin 1
To Chassis Chassis Chassis Chassis
ground ground ground ground
Result There should be 0.2 – 5.0 Ω. There should be 0.2 – 5.0 Ω. There should be 0.2 – 5.0 Ω. 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 disconnected and continue with step 3. 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 failed glow plug and retest. 3. Check the glow plug control circuits in the engine harness (EN) for a short circuit to ground. Disconnect the vehicle harness (VE) from the engine interface connector X-017. With the key switch in the OFF position, use a multimeter to check for continuity on the engine harness (EN) side : From X-017 (Receptacle) pin 61 X-017 (Receptacle) pin 60 X-017 (Receptacle) pin 58 X-017 (Receptacle) pin 57
To Chassis Chassis Chassis Chassis
ground ground ground ground
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Result There should be no continuity. There should be no continuity. There should be no continuity. There should be no continuity.
Electrical systems - FAULT CODES
A. If there is no continuity on all of the checks, then leave connector X-017 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-017 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. Disconnect the vehicle harness (VE) from the glow plug control module at connector X-013. With the key switch in the OFF position, use a multimeter to check for continuity on the vehicle harness (VE) side : From X-013 (Receptacle) pin 2 X-013 (Receptacle) pin 7 X-013 (Receptacle) pin 1 X-013 (Receptacle) pin 6
To Chassis Chassis Chassis Chassis
ground ground ground ground
Result There should be no continuity. There should be no continuity. There should be no continuity. There should be no continuity.
A. If there is continuity on one or more of the checks, there is a short circuit to ground in the vehicle harness (VE) between connector X-013 and connector X-017. Locate and repair the grounded conductor. Repair or replace the harness as required. B. If there is no continuity on all of the checks, then continue with step 5. 5. Replace the glow plug control module, then use EST to check to see that this fault has been resolved. A. If the fault has been resolved, 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. 6. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals, or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 06 SH06-ENGINE F5C T4 (55.100.DP-C.20.E.06) Wiring harnesses - Electrical schematic sheet 10 SH10-ENGINE F5C T4 (55.100.DP-C.20.E.10)
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3693 (DTC 32B-03) - Short circuit to battery error for Low Voltage System Context: 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). 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 is notified of a short circuit to another voltage source in one or more of the glow plug circuits, this fault will occur. Cause: The glow plug control module has communicated to the ECU, that a short circuit to another voltage source exists in one or more of the glow plug circuits. Possible failure modes: 1. Faulty glow plug control circuit wiring, short circuit to another voltage source. 2. Faulty ECU, software. Solution: 1. Verify that the fault is present and active. Use the Electronic Service Tool (EST) to check the status of this fault. A. If the fault is present and active, then continue with step 2. 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. Check each of the glow plug circuits for a short circuit to another voltage source. Disconnect the vehicle harness (VE) from the glow plug control module at connector X-013. Disconnect the engine harness (EN) from each of the glow plugs. With the key switch in the ON position, use a multimeter to check for voltage on the engine harness (EN) side : From Glow plug 1 connector pin 1 Glow plug 2 connector pin 1 Glow plug 3 connector pin 1 Glow plug 4 connector pin 1
To Chassis Chassis Chassis Chassis
ground ground ground ground
Result There should be no voltage. There should be no voltage. There should be no voltage. 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. 3. Locate the short circuit to another voltage source. Disconnect the vehicle harness (VE) from the engine interface connector X-017. With the key switch in the ON position, use a multimeter to check for voltage on the vehicle harness (VE) side : From X-017 (Receptacle) pin 61 X-017 (Receptacle) pin 60 X-017 (Receptacle) pin 58 X-017 (Receptacle) pin 57
To Chassis Chassis Chassis Chassis
ground ground ground ground
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Result There should be no voltage. There should be no voltage. There should be no voltage. There should be no voltage.
Electrical systems - FAULT CODES
A. If there is no voltage on any of the checks, then the short circuit to another voltage source is in the engine harness (EN) between glow plug connector and connector X-017. Locate and repair the damaged wires. Repair or replace the harness as required. 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-013 and connector X-017. Locate and repair the damaged conductors. 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. A. If the fault has been resolved, 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. 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. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 06 SH06-ENGINE F5C T4 (55.100.DP-C.20.E.06) Wiring harnesses - Electrical schematic sheet 10 SH10-ENGINE F5C T4 (55.100.DP-C.20.E.10)
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3694 (DTC 32B-04) - Short circuit to ground error for Low Voltage System 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 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 that a short circuit to ground exists in one or more of the glow plugs or glow plug circuits. Possible failure modes: 1. Faulty glow plug, internal failure. 2. Faulty glow plug control circuit wiring, short circuit to ground. 3. Faulty ECU, software. Solution: 1. Verify that the fault is present and active. Use the Electronic Service Tool (EST) to check the status of this fault. A. If the fault is present and active, continue with step 2. B. If the fault is no longer present or in an inactive state, then the fault may be intermittent and not currently active. Continue with step 6. 2. Check each of the glow plugs for a short circuit. Disconnect the engine harness (EN) from each of the glow plugs. Use a multimeter to check on the component for a short circuit to ground : Glow Glow Glow Glow
plug plug plug plug
1 2 3 4
From pin 1 pin 1 pin 1 pin 1
To Chassis Chassis Chassis Chassis
ground ground ground ground
Result There should be 0.2 – 5.0 Ω. There should be 0.2 – 5.0 Ω. There should be 0.2 – 5.0 Ω. 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 disconnected and continue with step 3. 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. 3. Check the glow plug control circuits in the engine harness (EN) for a short circuit to ground. Disconnect the vehicle harness (VE) from the engine interface connector X-017. With the key switch in the OFF position, use a multimeter to check for continuity on the engine harness (EN) side : From X-017 (Receptacle) pin 61 X-017 (Receptacle) pin 60 X-017 (Receptacle) pin 58 X-017 (Receptacle) pin 57
To Chassis Chassis Chassis Chassis
ground ground ground ground
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Result There should be no continuity. There should be no continuity. There should be no continuity. There should be no continuity.
Electrical systems - FAULT CODES
A. If there is no continuity on all of the checks, then leave connector X-017 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 connector X-017. Locate and repair the grounded 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. Disconnect the vehicle harness (VE) from the glow plug control module at connector X-013. With the key switch in the OFF position, use a multimeter to check for continuity on the vehicle harness (VE) side : From X-013 (Receptacle) pin 2 X-013 (Receptacle) pin 7 X-013 (Receptacle) pin 1 X-013 (Receptacle) pin 6
To Chassis Chassis Chassis Chassis
ground ground ground ground
Result There should be no continuity. There should be no continuity. There should be no continuity. There should be no continuity.
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-013 and connector X-017. Locate and repair the grounded conductor. Repair or replace the harness as required. B. If there is no continuity on all of the checks, then continue with step 5. 5. Replace the glow plug control module, then use EST to check to see that this fault has been resolved. A. If the fault has been resolved, 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. 6. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals, or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 06 SH06-ENGINE F5C T4 (55.100.DP-C.20.E.06) Wiring harnesses - Electrical schematic sheet 10 SH10-ENGINE F5C T4 (55.100.DP-C.20.E.10)
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3699 (DTC 5D2-03) - EEPROM : Error in EEPROM block EEPData1. SD correction can not be calculated Context: The Engine Control Unit (ECU) calculates the correction values from the EEPROM. If the ECU detects an error in the EEPROM block, then this fault will occur. 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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3703 (DTC 26F-04) - Injection control : check of minimum rail pressure 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 - Configure - Reset ECU data (10.218), if necessary. 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 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, 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 fuel rail pressure is too low to continue engine operation. Possible failure modes: 1.
Faulty fuel metering unit, stuck closed or internal failure.
2.
Faulty high pressure pump, low efficiency.
3.
Faulty charge gear pump, low efficiency.
4.
Faulty fuel filters, clogged.
5.
Faulty fuel lines, leakage or blockage.
6.
Faulty electric fuel pump (if equipped).
7.
Faulty fuel injectors, internal leakage or stuck open.
8.
Faulty Pressure Relief Valve (PRV), leakage.
9.
Faulty rail pressure sensor drifted signal or leaking.
10. Faulty ECU, software.
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3704 (DTC 27F-12) - Injector Adjustment programming : check of missing injector adjustment value programming: injector 2 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 2 cannot be performed, then this fault will occur. Cause: The ECU has determined that the fuel injector number 2 fuel trim correction cannot be performed. Solution: 1. Use the Electronic Service Tool (EST) ensure that the correct IMA code is programmed to fuel injector number 2. A. If the correct code is not programmed. Use the EST to program the correct code. B. If the correct code is programmed, continue to step 2. NOTE: The IMA code may be under the paint on the fuel injector. NOTE: For more information regarding programming IMA codes, refer to the engine service manual Fuel injectors - Configure - IMA codes (10.218). 2. 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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3705 (DTC 37F-12) - Injector Adjustment programming : check of missing injector adjustment value programming: injector 3 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 3 cannot be performed, then this fault will occur. Cause: The ECU has determined that the fuel injector number 3 fuel trim correction cannot be performed. Solution: 1. Use the Electronic Service Tool (EST) ensure that the correct IMA code is programmed to fuel injector number 3. A. If the correct code is not programmed. 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 service manual Fuel injectors Configure - IMA codes (10.218). 2. 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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3706 (DTC 47F-12) - Injector Adjustment programming : check of missing injector adjustment value programming: injector 4 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 4 cannot be performed, then 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 4 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 4. A. If the correct code is not programmed. 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. 2. 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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Electrical systems - FAULT CODES
3707 (DTC 601-02) - Lambda sensor : Open circuit at the lambda sensor Nernst cell pin NOTE: If the Lambda sensor is replaced, it is necessary to perform the Replacement of the Lambda Sensor - Reset ECU Data with the Electronic Service Tool (EST) before you return the machine to service. Refer to the engine service manual Lambda sensor - Configure - Reset ECU data (Lambda sensor) (55.989), if necessary. Context: For information regarding the functional operation of the Lambda sensor, refer to the engine service manual Lambda sensor - Overview (55.989). The Engine Control Unit (ECU) has determined that the Lambda sensor nernst signal is not present. The Lambda sensor is the primary measurement device for ECU fuel control, to determine if the engine is too rich or too lean. Cause: The ECU is sensing an open circuit in the Lambda sensor nernst signal circuit. Possible failure modes: 1. Faulty Lambda sensor circuit wiring, open circuit. 2. Faulty Lambda sensor, failed internally. 3. Faulty ECU, software. Solution: 1. Verify that the fault present and active. Use the Electronic Service Tool (EST) to check the status of this fault. A. If the fault is present and active, then continue with step 2. 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 4. 2. Check the Lambda sensor nernst signal circuit wiring for an open circuit. Disconnect the vehicle harness (VE) from the Lambda sensor at connector X-014 LAMBDA SENSOR. Disconnect the vehicle harness (VE) from the ECU at connector X-012 and place a jumper wire between X-012 (Receptacle) pin 63 and chassis ground. Use a multimeter to check for continuity on the vehicle harness (VE) side : From X-014 LAMBDA SENSOR (Receptacle) pin 6
To Chassis ground
Result There should be continuity.
A. If there is no continuity, then there is an open circuit in the vehicle harness (VE) between connector X-014 LAMBDA SENSOR (Receptacle) pin 6 and X-012 (Receptacle) pin 63. Locate and repair the broken conductor. Repair or replace the harness as required. B. If there is continuity, then continue with step 3. 3. Replace the Lambda sensor. Use EST to check to see that this fault has been resolved. A. If the fault has been resolved, then return the machine to service. B. If this fault has not been resolved, then check the ECU for the appropriate software and re-flash, if necessary. 4. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals, or broken wires.
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Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 06 SH06-ENGINE F5C T4 (55.100.DP-C.20.E.06) Wiring harnesses - Electrical schematic sheet 39 SH39-CHASSIS INTERFACE X-900/X-901 MD (55.100.DP-C.20.E.39) Wiring harnesses - Electrical schematic sheet 10 SH10-ENGINE F5C T4 (55.100.DP-C.20.E.10) Wiring harnesses - Electrical schematic sheet 35 SH35-CHASSIS INTERFACE MD (55.100.DP-C.20.E.35)
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3708 (DTC 602-02) - Lambda sensor : open circuit at the lambda sensor pump current pin - IP (lambda = 1 detection) NOTE: If the Lambda sensor is replaced, it is necessary to perform the Replacement of the Lambda Sensor - Reset ECU Data with the Electronic Service Tool (EST) before you return the machine to service. Refer to the engine service manual Lambda sensor - Configure - Reset ECU data (Lambda sensor) (55.989), if necessary. Context: The Engine Control Unit (ECU) has determined that the Lambda sensor pump current is not present. The Lambda sensor is the primary measurement device for ECU fuel control, to determine if the engine is too rich or too lean. For information regarding the functional operation of the Lambda sensor, refer to the engine service manual Lambda sensor - Overview (55.989). For more information regarding the technical specifications of the lambda sensor, refer to the engine service manual Lambda sensor - Technical Data (55.989). Cause: The ECU is sensing an open circuit in the Lambda sensor pump current control circuit. Possible failure modes: 1. Faulty Lambda sensor pump current control circuit wiring, open circuit. 2. Faulty Lambda sensor, failed internally. 3. Faulty ECU, software. Solution: 1. Verify that the fault 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 4. 2. Check the Lambda sensor pump current control circuit wiring for an open circuit. Disconnect the vehicle harness (VE) from the Lambda sensor at connector X-014 LAMBDA SENSOR. Disconnect the vehicle harness (VE) from the ECU at connector X-012 and place a jumper wire between X-012 (Receptacle) pin 64 and chassis ground. Use a multimeter to check for continuity on the vehicle harness (VE) side : From X-014 LAMBDA SENSOR (Receptacle) pin 1
To Chassis ground
Result There should be continuity.
A. If there is no continuity, then here is an open circuit in the vehicle harness (VE) between connector X-014 LAMBDA SENSOR (Receptacle) pin 1 and X-012 (Receptacle) pin 64. Locate and repair the broken conductor. Repair or replace the harness as required. B. If there is continuity, then continue with step 3. 3. Replace the Lambda sensor. Use the EST, refer to the engine service manual Lambda sensor - Configure - Reset ECU data (Lambda sensor) (55.989) if necessary, to perform the Replacement of the Lambda Sensor - Reset ECU Data. Use EST to check to see that this fault has been resolved. A. If the fault has been resolved, then return the machine to service.
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B. If this fault has not been resolved, then check the ECU for the appropriate software and re-flash, if necessary. 4. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals, or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 06 SH06-ENGINE F5C T4 (55.100.DP-C.20.E.06) Wiring harnesses - Electrical schematic sheet 39 SH39-CHASSIS INTERFACE X-900/X-901 MD (55.100.DP-C.20.E.39) Wiring harnesses - Electrical schematic sheet 10 SH10-ENGINE F5C T4 (55.100.DP-C.20.E.10) Wiring harnesses - Electrical schematic sheet 35 SH35-CHASSIS INTERFACE MD (55.100.DP-C.20.E.35)
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3709 (DTC 606-02) - Lambda sensor : Open circuit at the lambda sensor Virtual ground pin NOTE: If the Lambda sensor is replaced, it is necessary to perform the Replacement of the Lambda Sensor - Reset ECU Data with the Electronic Service Tool (EST) before you return the machine to service. Refer to the engine service manual Lambda sensor - Configure - Reset ECU data (Lambda sensor) (55.989), if necessary. Context: For information regarding the functional operation of the Lambda sensor refer to the engine service manual Lambda sensor - Overview (55.989). The Engine Control Unit (ECU) has determined that the Lambda sensor virtual ground circuit is open. The Lambda sensor is the primary measurement device for ECU fuel control, to determine if the engine is too rich or too lean. Cause: The ECU is sensing an open circuit in the Lambda sensor virtual ground circuit. Possible failure modes: 1. Faulty Lambda sensor virtual ground circuit wiring, open circuit. 2. Faulty Lambda sensor, failed internally. 3. Faulty ECU, software. Solution: 1. Verify that the fault present and active. Use the Electronic Service Tool (EST) to check the status of this fault. A. If the fault is present and active, then continue with step 2. 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 4. 2. Check the Lambda sensor virtual ground circuit wiring for an open circuit. Disconnect the vehicle harness (VE) from the Lambda sensor at connector X-014 LAMBDA SENSOR. Disconnect the vehicle harness (VE) from the ECU at connector X-012 and place a jumper wire between X-012 (Receptacle) pin 85 and chassis ground. Use a multimeter to check for continuity on the vehicle harness (VE) side : From X-014 LAMBDA SENSOR (Receptacle) pin 2
To Chassis ground
Result There should be continuity.
A. If there is no continuity, then there is an open circuit in the vehicle harness (VE) between connector X-014 LAMBDA SENSOR (Receptacle) pin 2 and X-012 (Receptacle) pin 85. Locate and repair the broken conductor. Repair or replace the harness as required. B. If there is continuity, then continue with step 3. 3. Replace the Lambda sensor. Use EST to check to see that this fault has been resolved. A. If the fault has been resolved, then use the EST, refer to the engine service manual Lambda sensor - Configure - Reset ECU data (Lambda sensor) (55.989) if necessary, to perform the Replacement of the Lambda Sensor - Reset ECU Data. Then return the machine to service. B. If this fault has not been resolved, then check the ECU for the appropriate software and re-flash, if necessary.
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4. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals, or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 06 SH06-ENGINE F5C T4 (55.100.DP-C.20.E.06) Wiring harnesses - Electrical schematic sheet 39 SH39-CHASSIS INTERFACE X-900/X-901 MD (55.100.DP-C.20.E.39) Wiring harnesses - Electrical schematic sheet 10 SH10-ENGINE F5C T4 (55.100.DP-C.20.E.10) Wiring harnesses - Electrical schematic sheet 35 SH35-CHASSIS INTERFACE MD (55.100.DP-C.20.E.35)
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3711 (DTC 18F-03) - Lambda sensor : SCB error of the LSU Heater Power stage NOTE: If the Lambda sensor is replaced, then it is necessary to perform the Replacement of the Lambda Sensor Reset ECU Data with the Electronic Service Tool (EST) before you return the machine to service. Refer to the engine service manual Lambda sensor - Configure - Reset ECU data (Lambda sensor) (55.989), if necessary. Context: The Lambda sensor has a heating element encased in ceramic that heats the sensor tip. Whenever the heater is operating, the heater low side driver power stage contained in the Engine Control Unit (ECU) is monitored for a short circuit to battery condition. If a short circuit to another voltage source exists in the heater control circuit, this fault will occur. For information regarding the functional operation of the Lambda sensor B-9123, refer to the engine service manual Lambda sensor - Overview (55.989). For more information regarding the technical specifications of the lambda sensor, refer to the engine service manual Lambda sensor - Technical Data (55.989). Cause: The Lambda sensor low side driver heater control circuit is short circuit to another voltage source. Possible failure modes: 1. Faulty Lambda sensor heater control circuit wiring, short circuit to another voltage source. 2. Faulty Lambda sensor B-9123, failed internally. 3. Faulty ECU A-9000, software. Solution: 1. Verify that the fault 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 Lambda sensor heater control circuit wiring for a short circuit to another voltage source. Disconnect the vehicle harness (VE) from the Lambda sensor at connector X-014 LAMBDA SENSOR. With the key switch in the ON position, use a multimeter to check for voltage on the vehicle harness (VE) side : From X-014 LAMBDA SENSOR (Receptacle) pin 3
To Chassis ground
Result There should be no voltage.
A. If there is voltage, then leave connector X-014 LAMBDA SENSOR disconnected and continue with step 3. B. If there is no voltage, then continue with step 4. 3. Locate the Lambda sensor heater control circuit wiring short circuit to another voltage source. Disconnect the vehicle harness (VE) from the ECU at connector X-012. Use a multimeter to check for continuity on the vehicle harness (VE) side : From X-012 (Receptacle) pin 7
To All other pins in connector X-012
Result 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.
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B. If there is no continuity, then the ECU connector X-012 is damaged or the ECU has failed. Locate and repair the damage or replace the ECU. 4. Replace the Lambda sensor. Use the EST, refer to the engine service manual Lambda sensor - Configure - Reset ECU data (Lambda sensor) (55.989) if necessary, to perform the Replacement of the Lambda Sensor - Reset ECU Data. Use EST to check to see that this fault has been resolved. A. If the fault has been resolved, then return the machine to service. B. If this fault has not been resolved, then check the ECU for the appropriate software and re-flash, if necessary. 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. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 06 SH06-ENGINE F5C T4 (55.100.DP-C.20.E.06) Wiring harnesses - Electrical schematic sheet 39 SH39-CHASSIS INTERFACE X-900/X-901 MD (55.100.DP-C.20.E.39) Wiring harnesses - Electrical schematic sheet 10 SH10-ENGINE F5C T4 (55.100.DP-C.20.E.10) Wiring harnesses - Electrical schematic sheet 35 SH35-CHASSIS INTERFACE MD (55.100.DP-C.20.E.35)
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3712 (DTC 18F-04) - Lambda sensor : SCG error of the LSU Heater Power stage NOTE: If the Lambda sensor is replaced, it is necessary to perform the Replacement of the Lambda Sensor - Reset ECU Data with the Electronic Service Tool (EST) before you return the machine to service. Refer to the engine service manual Lambda sensor - Configure - Reset ECU data (Lambda sensor) (55.989), if necessary. Context: The Lambda sensor has a heating element encased in ceramic that heats the sensor tip. Whenever the heater is operating, the heater low side driver power stage contained in the Engine Control Unit (ECU) is monitored for a short circuit to ground condition. If a short circuit to ground exists in the heater control circuit, then this fault will occur. For information regarding the functional operation of the Lambda sensor, refer to the engine service manual Lambda sensor - Overview (55.989). For more information regarding the technical specifications of the lambda sensor, refer to the engine service manual Lambda sensor - Technical Data (55.989). Cause: There is a short circuit to ground in the Lambda sensor low side driver heater control circuit. Possible failure modes: 1. Faulty Lambda sensor heater control circuit wiring, short circuit to ground. 2. Faulty Lambda sensor, failed internally. 3. Faulty ECU, software. Solution: 1. Verify that the fault present and active. Use the Electronic Service Tool (EST) to check the status of this fault. A. If the fault is present and active, then continue with step 2. 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. Check the Lambda sensor heater control circuit wiring for a short circuit to ground. Disconnect the vehicle harness (VE) from the Lambda sensor at connector X-014 LAMBDA SENSOR. Use a multimeter to check for continuity on the vehicle harness (VE) side : From X-014 LAMBDA SENSOR (Receptacle) pin 3
To Chassis ground
Result There should be no continuity.
A. If there is continuity, then continue with step 3. B. If there is no continuity, then continue with step 4. 3. Locate the Lambda sensor heater control circuit wiring for a short circuit to ground. Disconnect the vehicle harness (VE) from the ECU at connector X-012. Use a multimeter to check for continuity on the vehicle harness (VE) side : From X-012 (Receptacle) pin 7
To Chassis ground
Result There should be no continuity.
A. If there is continuity, then there is a short circuit to ground in the vehicle harness (VE) between connector X-014 LAMBDA SENSOR (Receptacle) pin 3 and X-012 (Receptacle) pin 7. Locate and repair the grounded conductor. Repair or replace the harness as required.
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B. If there is no continuity, the ECU connector X-012 is damaged or the ECU has failed. Locate and repair the damage or replace the ECU. 4. Replace the Lambda sensor. Use the EST, refer to the engine service manual Lambda sensor - Configure - Reset ECU data (Lambda sensor) (55.989) if necessary, to perform the Replacement of the Lambda Sensor - Reset ECU Data. Use EST to check to see that this fault has been resolved. A. If the fault has been resolved, then return the machine to service. B. If this fault has not been resolved, then check the ECU for the appropriate software and re-flash, if necessary. 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. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 06 SH06-ENGINE F5C T4 (55.100.DP-C.20.E.06) Wiring harnesses - Electrical schematic sheet 39 SH39-CHASSIS INTERFACE X-900/X-901 MD (55.100.DP-C.20.E.39) Wiring harnesses - Electrical schematic sheet 10 SH10-ENGINE F5C T4 (55.100.DP-C.20.E.10) Wiring harnesses - Electrical schematic sheet 35 SH35-CHASSIS INTERFACE MD (55.100.DP-C.20.E.35)
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3713 (DTC 18F-02) - Lambda sensor : Open Load error of the LSU Heater Power stage NOTE: If the Lambda sensor is replaced, it is necessary to perform the Replacement of the Lambda Sensor - Reset ECU Data with the Electronic Service Tool (EST) before you return the machine to service. Refer to the engine service manual Lambda sensor - Configure - Reset ECU data (Lambda sensor) (55.989), if necessary. Context: The Lambda sensor has a heating element encased in ceramic that heats the sensor tip. When the heater is operating, the heater low side driver power stage contained in the Engine Control Unit (ECU) is monitored for an open circuit. If an open circuit exists in the heater control circuit, then this fault will occur. For information regarding the functional operation of the Lambda sensor, refer to the engine service manual Lambda sensor - Overview (55.989). For more information regarding the technical specifications of the lambda sensor, refer to the engine service manual Lambda sensor - Technical Data (55.989). Cause: The Lambda sensor low side driver heater control circuit is open. Possible failure modes: 1. Faulty Lambda sensor heater control circuit wiring, open circuit. 2. Faulty Lambda sensor, failed internally. 3. Faulty ECU, software. Solution: 1. Verify that the fault present and active. Use the Electronic Service Tool (EST) to check the status of this fault. A. If the fault is present and active, then continue with step 2. 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 4. 2. Check the Lambda sensor heater circuit wiring for an open circuit. Disconnect the vehicle harness (VE) from the Lambda sensor at connector X-014 LAMBDA SENSOR. With the key switch in the ON position, use a multimeter to check for voltage on the vehicle harness (VE) side : From X-014 LAMBDA SENSOR (Receptacle) pin 4
To Chassis ground
Result There should be approximately 12.0 V.
Disconnect the vehicle harness (VE) from the ECU at connector X-012 and place a jumper wire between X-012 (Receptacle) pin 7 and chassis ground. Use a multimeter to check for continuity on the vehicle harness (VE) side : From X-014 LAMBDA SENSOR (Receptacle) pin 3
To Chassis ground
Result There should be continuity.
A. If there is no voltage or no continuity, then there is a problem in the wiring. Locate and repair the broken conductor. Repair or replace the harness as required. B. If there is voltage and continuity, then leave connector X-014 LAMBDA SENSOR disconnected and continue with step 3. 3. Replace the Lambda sensor.
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Use the EST, refer to the engine service manual Lambda sensor - Configure - Reset ECU data (Lambda sensor) (55.989) if necessary, to perform the Replacement of the Lambda Sensor - Reset ECU Data. Use EST to check to see that this fault has been resolved. A. If the fault has been resolved, then return the machine to service. B. If this fault has not been resolved, then check the ECU for the appropriate software and re-flash, if necessary. 4. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals, or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 06 SH06-ENGINE F5C T4 (55.100.DP-C.20.E.06) Wiring harnesses - Electrical schematic sheet 39 SH39-CHASSIS INTERFACE X-900/X-901 MD (55.100.DP-C.20.E.39) Wiring harnesses - Electrical schematic sheet 10 SH10-ENGINE F5C T4 (55.100.DP-C.20.E.10) Wiring harnesses - Electrical schematic sheet 35 SH35-CHASSIS INTERFACE MD (55.100.DP-C.20.E.35)
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3714 (DTC 607-03) - Lambda sensor : Fault code to indicate SRC High error for O2 calibration NOTE: If the Lambda sensor is replaced, it is necessary to perform the Replacement of the Lambda Sensor - Reset ECU Data with the Electronic Service Tool (EST) before you return the machine to service. Refer to the engine service manual Lambda sensor - Configure - Reset ECU data (Lambda sensor) (55.989), if necessary. Context: The Engine Control Unit (ECU) performs an electrical zero-offset calibration every 10 min of engine operation on the Lambda sensor as long as the engine has been running for longer than 10 s after start, after-treatment regeneration is not active, the engine is in operating range one (speed between 300 – 1200 RPM and load between 2.00 – 11.00 mg per stroke), and the calibration is not inhibited due to a failure. The measured oxygen signal during calibration should be between - 0.200 – 0.200 V. If the oxygen signal, during this calibration is higher than 0.200 V, then this fault will occur. For more information regarding rich air/fuel ratio troubleshooting, refer to the engine service manual Fuel injection system - Poor quality (10.218). For more information regarding fuel system troubleshooting, refer to the engine service manual Fuel injection system - Troubleshooting (10.218). For information regarding the functional operation of the Lambda sensor, refer to the engine service manual Lambda sensor - Overview (55.989). For more information regarding the technical specifications of the lambda sensor, refer to the engine service manual Lambda sensor - Technical Data (55.989). Cause: The Lambda sensor oxygen level signal, during calibration, to the ECU is greater than 0.200 V. Possible failure modes: 1. Faulty injector, leaking. 2. Faulty Exhaust Gas Recirculation (EGR) valve, stuck closed. 3. Faulty Lambda sensor, contaminated. 4. Faulty ECU, software.
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3715 (DTC 607-04) - Lambda sensor : Fault code to indicate SRC Low error for O2 calibration NOTE: If the Lambda sensor is replaced, it is necessary to perform the Replacement of the Lambda Sensor - Reset ECU Data with the Electronic Service Tool (EST) before you return the machine to service. Refer to the engine service manual Lambda sensor - Configure - Reset ECU data (Lambda sensor) (55.989), if necessary. Context: The Engine Control Unit (ECU) performs an electrical zero-offset calibration every 10 min of engine operation on the Lambda sensor B-9123 as long as the engine has been running for longer than 10 s after start, after-treatment regeneration is not active, the engine is in operating range one (speed between 300 – 1200 RPM and load between 2.00 – 11.00 mg per stroke), and the calibration is not inhibited due to a failure. The measured oxygen signal during calibration should be between - 0.200 – 0.200 V. If the oxygen signal during this calibration is less than - 0.200 V, then this fault will occur. For more information regarding lean air/fuel ratio troubleshooting, refer to the engine service manual Fuel injection system - Poor quality (10.218). For more information regarding fuel system troubleshooting, refer to the engine service manual Fuel injection system - Troubleshooting (10.218). For information regarding the functional operation of the Lambda sensor refer to the engine service manual Lambda sensor - Overview (55.989). For more information regarding the technical specifications of the lambda sensor, refer to the engine service manual Lambda sensor - Technical Data (55.989). Cause: The Lambda sensor oxygen level signal during calibration to the ECU is less than – 0.200 V. Possible failure modes: 1. Faulty fuel back-flow, excessive. 2. Faulty Exhaust Gas Recirculation (EGR) valve, stuck open. 3. Faulty Lambda sensor, contaminated. 4. Faulty ECU, software.
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3716 (DTC 605-03) - Lambda sensor : O2 value above the max threshold NOTE: If the Lambda sensor is replaced, it is necessary to perform the Replacement of the Lambda Sensor - Reset ECU Data with the Electronic Service Tool (EST) before you return the machine to service. Refer to the engine service manual Lambda sensor - Configure - Reset ECU data (Lambda sensor) (55.989), if necessary. Context: The Engine Control Unit (ECU) has detected a fault associated with the oxygen sensor. This fault is a result of an open circuit in the factory installed trim resistor circuit. For information regarding the functional operation of the Lambda sensor, refer to the engine service manual Lambda sensor - Overview (55.989). For more information regarding the technical specifications of the lambda sensor, see Lambda sensor - Technical Data (55.989). Cause: The ECU is sensing an open circuit in the Lambda sensor trim resistor circuit. Possible failure modes: 1. Faulty Lambda sensor circuit wiring, open circuit. 2. Faulty Lambda sensor, failed internally. 3. Faulty ECU, software. Solution: 1. Verify that the fault present and active. Use the Electronic Service Tool (EST) to check the status of this fault. A. If the fault is present and active, then continue with step 2. 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 4. 2. Check the Lambda sensor trim resistor circuit wiring for an open circuit. Disconnect the vehicle harness (VE) from the Lambda sensor at connector X-014 LAMBDA SENSOR. Disconnect the vehicle harness (VE) from the ECU at connector X-012 and place a jumper wire between X-012 (Receptacle) pin 86 and chassis ground. Use a multimeter to check for continuity on the vehicle harness (VE) side : From X-014 LAMBDA SENSOR (Receptacle) pin 5
To Chassis ground
Result There should be continuity.
A. If there is no continuity, then there is an open circuit in the vehicle harness (VE) between connector X-014 LAMBDA SENSOR (Receptacle) pin 5 and X-012 (Receptacle) pin 86. Locate and repair the broken conductor. Repair or replace the harness as required. B. If there is continuity, then continue with step 3. 3. Replace the Lambda sensor. Use EST to check to see that this fault has been resolved. A. If the fault has been resolved, then return the machine to service. B. If this fault has not been resolved, then check the ECU for the appropriate software and re-flash, if necessary. 4. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals, or broken wires.
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Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 06 SH06-ENGINE F5C T4 (55.100.DP-C.20.E.06) Wiring harnesses - Electrical schematic sheet 39 SH39-CHASSIS INTERFACE X-900/X-901 MD (55.100.DP-C.20.E.39) Wiring harnesses - Electrical schematic sheet 10 SH10-ENGINE F5C T4 (55.100.DP-C.20.E.10) Wiring harnesses - Electrical schematic sheet 35 SH35-CHASSIS INTERFACE MD (55.100.DP-C.20.E.35)
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3720 (DTC 60A-04) - Lambda sensor : low battery voltage at the SPI chip Context: The SPI chip, which is internal to the ECU, controls the Lambda sensor device for the measuring or the calibrating of the inner resistance for temperature evaluation, switches on and off the pump current to measure O2 content and monitors the hardware related to the open load and short circuit monitoring devices. If the SPI chip senses a voltage less than 9.0 V, then this fault will occur. 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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3721 (DTC 609-02) - Lambda sensor : Fault check to indicate SPI chip error of lambda sensor Context: The SPI chip, which is internal to the ECU , controls the Lambda sensor device for the measuring or the calibrating of the inner resistance for temperature evaluation, switches on and off the pump current to measure O2 content and monitors the hardware related to the open load and short circuit monitoring devices. The requests for these listed actions are made by software and result in a configuration of the initialization register, which is hardware controlled. The same configuration is calculated by software. If both configurations are not identical, the SPI is not plausible and this fault will occur. For information regarding the functional operation of the Lambda sensor, refer to the engine service manual Lambda sensor - Overview (55.989). For more information regarding the technical specifications of the lambda sensor, refer to the engine service manual Lambda sensor - Technical Data (55.989). 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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3722 (DTC 60C-03) - Lambda sensor : LSU sensor temperature Ri exceeds the maximum limit NOTE: If the Lambda sensor is replaced, it is necessary to perform the Replacement of the Lambda Sensor - Reset ECU Data with the Electronic Service Tool (EST) before you return the machine to service. Refer to the engine service manual, Lambda sensor - Configure - Reset ECU data (Lambda sensor) (55.989), if necessary. Context: The Engine Control Unit (ECU) monitors the internal resistance of the nernst cell to estimate the internal temperature of the Lambda sensor. If the ECU calculates the internal temperature to be greater than 929.96 째C (1705.9 째F), then this fault will occur. For information regarding the functional operation of the Lambda sensor, refer to the engine service manual Lambda sensor - Overview (55.989). For more information regarding the technical specifications of the lambda sensor B-9123, refer to the engine service manual Lambda sensor - Technical Data (55.989). Cause: The ECU calculated temperature, based on inner resistance of the Lambda sensor is greater than 929.96 째C (1705.9 째F). Possible failure modes: 1. Faulty Lambda sensor nernst cell circuit wiring, short circuit to ground. 2. Faulty Lambda sensor connection, loose. 3. Faulty Lambda sensor, failed internally. 4. Faulty ECU, software. Solution: 1. Verify that the fault present and active. Use the Electronic Service Tool (EST) to check the status of this fault. A. If the fault is present and active, then continue with step 2. 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. Visually inspect the Lambda sensor for proper connection. A. If the Lambda sensor is not properly connected or is loose, then repair as necessary. B. If the Lambda sensor is properly connected, then continue to step 3. 3. Check the Lambda sensor nernst cell circuit wiring for a short circuit to ground. Disconnect the vehicle harness (VE) from the Lambda sensor at connector X-014 LAMBDA SENSOR. With the key in the OFF position, use a multimeter to check for continuity on the vehicle harness (VE) side : From X-014 LAMBDA SENSOR (Receptacle) pin 6
To Chassis ground
Value There should be no continuity.
A. If there is continuity, then there is a short circuit to ground in the vehicle harness (VE) between connector X-014 LAMBDA SENSOR (Receptacle) pin 6 and connector X-012 (Receptacle) pin 63. Locate and repair the grounded conductor. Repair or replace the harness as required. B. If there is no continuity, then continue with step 4. 4. Replace the Lambda sensor. Use EST to check to see that this fault has been resolved.
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A. If the fault has been resolved, then return the machine to service. B. If this fault has not been resolved, then check the ECU for the appropriate software and re-flash, if necessary. 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. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 06 SH06-ENGINE F5C T4 (55.100.DP-C.20.E.06) Wiring harnesses - Electrical schematic sheet 39 SH39-CHASSIS INTERFACE X-900/X-901 MD (55.100.DP-C.20.E.39) Wiring harnesses - Electrical schematic sheet 10 SH10-ENGINE F5C T4 (55.100.DP-C.20.E.10) Wiring harnesses - Electrical schematic sheet 35 SH35-CHASSIS INTERFACE MD (55.100.DP-C.20.E.35)
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3723 (DTC 60C-04) - Lambda sensor : LSU sensor temperature Ri is below the minimum limit NOTE: If the Lambda sensor is replaced, it is necessary to perform the Replacement of the Lambda Sensor - Reset ECU Data with the Electronic Service Tool (EST) before you return the machine to service. Refer to the engine service manual, Lambda sensor - Configure - Reset ECU data (Lambda sensor) (55.989), if necessary. Context: The Engine Control Unit (ECU) monitors the internal resistance of the nernst cell to estimate the internal temperature of the Lambda sensor. If the ECU calculates the internal temperature to be equal to or less than 719.96 째C (1327.9 째F), then this fault will occur. For information regarding the functional operation of the Lambda sensor refer to the engine service manual Lambda sensor - Overview (55.989). For more information regarding the technical specifications of the lambda sensor, refer to the engine service manual Lambda sensor - Technical Data (55.989). Cause: The ECU calculated temperature, based on inner resistance of the Lambda sensor, is below or equal to 719.96 째C (1327.9 째F). Possible failure modes: 1. Faulty Lambda sensor nernst cell or virtual ground circuit wiring, open circuit. 2. Faulty Lambda sensor, failed internally. 3. Faulty ECU, software. Solution: 1. Verify that the fault present and active. Use the Electronic Service Tool (EST) to check the status of this fault. A. If the fault is present and active, then continue with step 2. 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 4. 2. Check the Lambda sensor nernst cell and virtual ground circuit wiring for an open circuit. Disconnect the vehicle harness (VE) from the Lambda sensor at connector X-014 LAMBDA SENSOR. Disconnect the vehicle harness (VE) from the ECU at connector X-012 and place a jumper wire between X-012 (Receptacle) pin 85 and chassis ground. Use a multimeter to check for continuity on the vehicle harness (VE) side : From X-014 LAMBDA SENSOR (Receptacle) pin 2
To Chassis ground
Result There should be continuity.
Move the connector X-012 end of the jumper wire from connector X-012 (Receptacle) pin 85 to connector X-012 (Receptacle) pin 63. Use a multimeter to check for continuity on the vehicle harness (VE) side : From X-014 LAMBDA SENSOR (Receptacle) pin 6
To Chassis ground
Result There should be continuity.
A. If there is no continuity on either of the checks, then there is an open circuit in the vehicle harness (VE). Locate and repair the broken conductor. Repair or replace the harness as required. B. If there is continuity on both checks, then continue with step 3.
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3. Replace the Lambda sensor. Use EST to check to see that this fault has been resolved. A. If the fault has been resolved, then return the machine to service. B. If this fault has not been resolved, then check the ECU for the appropriate software and re-flash, if necessary. 4. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals, or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 06 SH06-ENGINE F5C T4 (55.100.DP-C.20.E.06) Wiring harnesses - Electrical schematic sheet 39 SH39-CHASSIS INTERFACE X-900/X-901 MD (55.100.DP-C.20.E.39) Wiring harnesses - Electrical schematic sheet 10 SH10-ENGINE F5C T4 (55.100.DP-C.20.E.10) Wiring harnesses - Electrical schematic sheet 35 SH35-CHASSIS INTERFACE MD (55.100.DP-C.20.E.35)
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Electrical systems - FAULT CODES
3724 (DTC 60B-03) - Lambda sensor : short to battery at IA,IP, UN, VG NOTE: If the Lambda sensor is replaced, it is necessary to perform the Replacement of the Lambda Sensor - Reset ECU Data with the Electronic Service Tool (EST) before you return the machine to service. Refer to the engine service manual Lambda sensor - Configure - Reset ECU data (Lambda sensor) (55.989), if necessary. Context: The Engine Control Unit (ECU) monitors the condition of the nernst cell, pump cell and virtual ground circuits. If the ECU detects a short circuit to another voltage source in any of the circuits or an open circuit in the virtual ground circuit, then this fault will occur. For information regarding the functional operation of the Lambda sensor, refer to the engine service manual Lambda sensor - Overview (55.989). For more information regarding the technical specifications of the lambda sensor, refer to the engine service manual Lambda sensor - Technical Data (55.989). Cause: The ECU is sensing an open circuit in the Lambda sensor virtual ground circuit or a short circuit to another voltage source in the nernst cell, pump cell or virtual ground circuit. Possible failure modes: 1. Faulty Lambda sensor nernst cell, pump cell, or virtual ground circuit wiring, short circuit to another voltage source. 2. Faulty Lambda sensor virtual ground circuit wiring, open circuit. 3. Faulty Lambda sensor, failed internally. 4. Faulty ECU, software. Solution: 1. Verify that the fault present and active. Use the Electronic Service Tool (EST) to check the status of this fault. A. If the fault is present and active, then continue with step 2. 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. Check the Lambda sensor nernst cell, pump cell, and virtual ground circuit wiring for a short circuit to another voltage source. Disconnect the vehicle harness (VE) from the Lambda sensor at connector X-014 LAMBDA SENSOR. Disconnect the vehicle harness (VE) from the ECU at connector X-012. With the key switch in the OFF position, use a multimeter to check for continuity on the vehicle harness (VE) side : From X-012 (Receptacle) pin 63 X-012 (Receptacle) pin 64 X-012 (Receptacle) pin 85 X-012 (Receptacle) pin 86
To All other pins in connector X-012 All other pins in connector X-012 All other pins in connector X-012 All other pins in connector X-012
Result There should be no continuity. There should be no continuity. There should be no continuity. There should be no continuity.
With the key switch in the ON position, use a multimeter to check for voltage on the vehicle harness (VE) side : From X-012 (Receptacle) pin 63 X-012 (Receptacle) pin 64 X-012 (Receptacle) pin 85 X-012 (Receptacle) pin 86
To Chassis Chassis Chassis Chassis
ground ground ground ground
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Result There should be no voltage. There should be no voltage. There should be no voltage. There should be no voltage.
Electrical systems - FAULT CODES
A. If there is no continuity or voltage, then leave connector X-014 LAMBDA SENSOR disconnected. Leave connector X-012 disconnected. Continue with step 3. B. If there is continuity or voltage, then there is a short circuit in the vehicle harness (VE). Locate and repair the damaged conductors. Repair or replace the harness as required. 3. Check the Lambda sensor virtual ground circuit wiring for an open circuit. Place a jumper wire between X-012 (Receptacle) pin 85 and chassis ground. Use a multimeter to check for continuity on the vehicle harness (VE) side : From X-014 LAMBDA SENSOR (Receptacle) pin 2
To Chassis ground
Result There should be continuity.
A. If there is no continuity, then there is an open circuit in the vehicle harness (VE) between connector X-014 LAMBDA SENSOR (Receptacle) pin 2 and X-012 (Receptacle) pin 85. Locate and repair the broken conductor. Repair or replace the harness as required. B. If there is continuity, then continue with step 4. 4. Replace the Lambda sensor. Use the EST, refer to the engine service manual Lambda sensor - Configure - Reset ECU data (Lambda sensor) (55.989) if necessary, to perform the Replacement of the Lambda Sensor - Reset ECU Data. Use EST to check to see that this fault has been resolved. A. If the fault has been resolved, then return the machine to service. B. If this fault has not been resolved, then check the ECU for the appropriate software and re-flash, if necessary. 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. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 06 SH06-ENGINE F5C T4 (55.100.DP-C.20.E.06) Wiring harnesses - Electrical schematic sheet 39 SH39-CHASSIS INTERFACE X-900/X-901 MD (55.100.DP-C.20.E.39) Wiring harnesses - Electrical schematic sheet 10 SH10-ENGINE F5C T4 (55.100.DP-C.20.E.10) Wiring harnesses - Electrical schematic sheet 35 SH35-CHASSIS INTERFACE MD (55.100.DP-C.20.E.35)
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3725 (DTC 60B-04) - Lambda sensor : short to ground at IA,IP, UN, VG NOTE: If the Lambda sensor is replaced, it is necessary to perform the Replacement of the Lambda Sensor - Reset ECU Data with the Electronic Service Tool (EST) before you return the machine to service. Refer to the engine service manual Lambda sensor - Configure - Reset ECU data (Lambda sensor) (55.989), if necessary. Context: The Engine Control Unit (ECU) monitors the condition of the Lambda sensor nernst cell, pump cell and virtual ground circuits. If the ECU detects a short circuit to ground in any of the circuits, then this fault will occur. For information regarding the functional operation of the Lambda sensor, refer to the engine service manual Lambda sensor Overview (55.989). For more information regarding the technical specifications of the lambda sensor, refer to the engine service manual Lambda sensor - Technical Data (55.989). Cause: The ECU is sensing a short circuit to ground in the Lambda sensor nernst cell, pump cell or virtual ground circuit. Possible failure modes: 1. Faulty Lambda sensor circuit wiring, short circuit to ground. 2. Faulty Lambda sensor, failed internally. 3. Faulty ECU, software. Solution: 1. Verify that the fault 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, then the fault may be intermittent and not currently active. Continue with step 4. 2. Check the Lambda sensor circuit wiring for a short circuit to ground. Disconnect the vehicle harness (VE) from the Lambda sensor at connector X-014 LAMBDA SENSOR. Disconnect the vehicle harness (VE) from the ECU at connector X-012. Use a multimeter to check for continuity on the vehicle harness (VE) side : From X-014 LAMBDA SENSOR (Receptacle) pin 1 X-014 LAMBDA SENSOR (Receptacle) pin 2 X-014 LAMBDA SENSOR (Receptacle) pin 3
Chassis ground
To
Result There should be no continuity.
Chassis ground
There should be no continuity.
Chassis ground
There should be no continuity.
A. If there is continuity on any of the checks, then there is a short circuit to ground in the vehicle harness (VE) between connector X-014 LAMBDA SENSOR and connector X-012. Locate and repair the damaged conductor. Repair or replace the harness as required. B. If there is no continuity on any of the checks, continue with step 3. 3. Replace the Lambda sensor. Use the EST, refer to the engine service manual Lambda sensor - Configure - Reset ECU data (Lambda sensor) (55.989) if necessary, to perform the Replacement of the Lambda Sensor - Reset ECU Data. Use EST to check to see that this fault has been resolved. 48068130 29/01/2018
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A. If the fault has been resolved, then return the machine to service. B. If this fault has not been resolved, then check the ECU for the appropriate software and re-flash, if necessary. 4. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals, or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 06 SH06-ENGINE F5C T4 (55.100.DP-C.20.E.06) Wiring harnesses - Electrical schematic sheet 39 SH39-CHASSIS INTERFACE X-900/X-901 MD (55.100.DP-C.20.E.39) Wiring harnesses - Electrical schematic sheet 10 SH10-ENGINE F5C T4 (55.100.DP-C.20.E.10) Wiring harnesses - Electrical schematic sheet 35 SH35-CHASSIS INTERFACE MD (55.100.DP-C.20.E.35)
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Electrical systems - FAULT CODES
3727 (DTC 1FF-04) - Info : Low oil viscosity NOTE: If the engine oil/filter is replaced, it is necessary to perform the Replacement of the Engine Oil/Filter - Reset Change Reminder with the Electronic Service Tool (EST) before you return the machine to service. Refer to the engine service manual Engine oil system - Configure - Replacement of the Engine Oil/Filter - Reset Change Reminder (55.013), if necessary. Context: The ECU monitors engine oil viscosity. If the ECU determines that the engine oil viscosity is low, an oil change is necessary and this fault will occur. For more information on lubrication system troubleshooting, refer to the engine service manual Engine lubrication system - Troubleshooting (10.304).
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Electrical systems - FAULT CODES
3728 (DTC 1FF-02) - Info : Too low oil viscosity NOTE: If the engine oil/filter is replaced, it is necessary to perform the Replacement of the Engine Oil/Filter - Reset Change Reminder with the Electronic Service Tool (EST) before you return the machine to service. Refer to the engine service manual Engine oil system - Configure - Replacement of the Engine Oil/Filter - Reset Change Reminder (55.013), if necessary. Context: The ECU monitors engine oil viscosity. If the ECU determines that the engine oil viscosity is too low, an oil change is necessary and this fault will occur. For more information on lubrication system troubleshooting, refer to the engine service manual Engine lubrication system - Troubleshooting (10.304).
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Electrical systems - FAULT CODES
3735 (DTC 559-12) - Fuel Metering Unit : over temperature of device driver of metering unit 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, then this fault will occur. Cause: The ECU has detected an over temperature/current condition in the fuel metering unit signal circuit. Possible failure modes: 1. Faulty fuel metering unit wiring, short circuit to another voltage source. 2. Faulty fuel metering unit, internal failure. 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, then the fault may be intermittent and not currently active. Continue with step 6. 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 Fuel metering unit pin 1
To Fuel metering unit pin 2
Value 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 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. With the key in the OFF position, use a multimeter to perform the following voltage check on the engine harness (EN) side : From Fuel metering unit connector pin 2
To Chassis ground
Value There should be no voltage.
With the key in the ON position, use a multimeter to perform the following voltage check on the engine harness (EN) side : From Fuel metering unit connector pin 2
To Chassis ground
Value 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. 48068130 29/01/2018
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4. Check the fuel metering unit low side driver engine harness (EN) wiring for a short circuit. Disconnect the vehicle harness (VE) from the engine interface at connector X-017. With the key in the OFF position, use a multimeter to perform the following voltage check on the engine harness (EN) side : From X-017 (Receptacle) pin 2
To All pins in connector X-017
Value There should be no continuity.
A. If there is no continuity, then leave connector X-017 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. Disconnect the vehicle harness (VE) from the ECU at connector X-016. With the key in the OFF position, use a multimeter to perform the following continuity check from the vehicle harness (VE) side : From X-017 (Receptacle) pin 2 X-016 (Receptacle) pin 60
To All pins in connector X-017. All pins in connector X-016.
Value There should be no continuity. There should be no continuity.
A. If there is continuity, then there is a short circuit in the fuel metering unit low side driver vehicle harness (VE) wiring. Locate and repair the shorted conductor. B. If there is no continuity, then check the ECU for the appropriate software and re-flash, if necessary. 6. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals, or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 07 SH07-ENGINE F5C T4 (55.100.DP-C.20.E.07) Wiring harnesses - Electrical schematic sheet 11 SH11-ENGINE F5C T4 (55.100.DP-C.20.E.11)
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Electrical systems - FAULT CODES
3738 (DTC 2D4-04) - Analog Digital Converter (ADC) : Diagnostic fault check to report multiple error while checking the complete ROM-memory Context: The Engine Control Unit (ECU) runs a diagnostic fault check of the ROM memory. If any checksum errors in ROMmemory blocks are detected, then this fault will occur. 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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Electrical systems - FAULT CODES
3739 (DTC 3D4-12) - Power stages, Injector : Loss of synchronization sending bytes to the MM from CPU. Context: The Engine Control Unit (ECU) performs a shut-off path test of the fuel injection power stages. Every time the key is turned ON, this test is performed to verify the correct functioning of the shut-off procedure. If an error is detected during the shut-off test, the fault will occur. Solution: 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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Electrical systems - FAULT CODES
3740 (DTC 3D4-02) - Power stages, Injector : DFC to set a torque limitation once an error is detected before MoCSOP's error reaction is set Context: The Engine Control Unit (ECU) performs a series of â&#x20AC;&#x153;shut-off pathâ&#x20AC;? tests which deactivates all power stages relevant to fuel injection if certain ECU errors are detected. If an incorrect response to the power stage supply (CY320) is detected during this test, this fault will occur. 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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Electrical systems - FAULT CODES
3741 (DTC 3D4-03) - Power stages, Injector : Wrong set response time Context: The Engine Control Unit (ECU) performs a series of â&#x20AC;&#x153;shut-off pathâ&#x20AC;? tests which deactivates all power stages relevant to fuel injection if certain ECU errors are detected. If there is a time-out error during this test, this fault will occur. 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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Electrical systems - FAULT CODES
3742 (DTC 3D4-04) - Power stages, Injector : Too many SPI errors during MoCSOP execution. Context: The Engine Control Unit (ECU) performs a series of â&#x20AC;&#x153;shut-off pathâ&#x20AC;? tests which deactivates all power stages relevant to fuel injection if certain ECU errors are detected. If there is a faulty communication detected during this test, this fault will occur. 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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Electrical systems - FAULT CODES
3743 (DTC 4D4-04) - Power stages, Injector : Diagnostic fault check to report the error in under voltage monitoring Context: The Engine Control Unit (ECU) performs â&#x20AC;&#x153;shut-off pathsâ&#x20AC;? which deactivate all power stages relevant to fuel injection if certain ECU errors are detected. If an under-voltage condition is detected during this test, this fault will occur. 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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Electrical systems - FAULT CODES
3744 (DTC 4D4-03) - Power stages, Injector : Diagnostic fault check to report the error in overvoltage monitoring Context: The Engine Control Unit (ECU) performs â&#x20AC;&#x153;shut-off pathsâ&#x20AC;? which deactivate all power stages relevant to fuel injection if certain ECU errors are detected. If an over-voltage condition is detected during this test, then this fault will occur. 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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Electrical systems - FAULT CODES
3745 (DTC 5D4-02) - Power stages, Injector : Diagnostic fault check to report that WDA is not working correct Context: The Engine Control Unit (ECU) performs â&#x20AC;&#x153;shut-off pathsâ&#x20AC;? which deactivate all power stages relevant to fuel injection if certain ECU errors are detected. If an implausible response in the power-stage feedback is detected during this test, then this fault will occur. 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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Electrical systems - FAULT CODES
3746 (DTC 5D4-03) - Power stages, Injector : OS timeout in the shut off path test. Failure setting the alarm task period. Context: The Engine Control Unit (ECU) performs â&#x20AC;&#x153;shut-off pathsâ&#x20AC;? which deactivate all power stages relevant to fuel injection if certain ECU errors are detected. If an alarm task can not be set or reset after having detected a time-out error during this test, then this fault will occur. 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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Electrical systems - FAULT CODES
3747 (DTC 5D4-04) - Power stages, Injector : Diagnostic fault check to report that the positive test failed Context: The Engine Control Unit (ECU) performs â&#x20AC;&#x153;shut-off pathsâ&#x20AC;? which deactivate all power stages relevant to fuel injection if certain ECU errors are detected. If the ECU determines that the test has failed, then this fault will occur. 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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Electrical systems - FAULT CODES
3748 (DTC 5D4-12) - Power stages, Injector : Diagnostic fault check to report the timeout in the shut off path test Context: The Engine Control Unit (ECU) performs â&#x20AC;&#x153;shut-off pathsâ&#x20AC;? which deactivate all power stages relevant to fuel injection if certain ECU errors are detected. If a time-out in the power-stage feedback is detected during this test, then this fault will occur. 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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Electrical systems - FAULT CODES
3750 (DTC 3E3-00) - Injection control : Error in the plausibility of the injection energizing time Context: The Engine Control Unit (ECU) monitors fuel injector energizing time for plausibility. If the ECU determines that this value is implausible for either pilot, main or post injection, then this fault will occur. 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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Electrical systems - FAULT CODES
3751 (DTC 3E3-01) - Injection control : Error in the plausibility of the start of energizing angles Context: The Engine Control Unit (ECU) monitors fuel injector energizing start time for plausibility. If the ECU determines that this value is implausible for either pilot, main or post injection, this fault will occur. 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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Electrical systems - FAULT CODES
3752 (DTC 3E3-02) - Level 2 Monitoring: Error in the plausibility of the energizing times of the zero fuel quantity calibration 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, this fault will occur. 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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Electrical systems - FAULT CODES
3753 (DTC 3E3-03) - Level 2 Monitoring : Diagnostic fault check to report the error due to Over heating 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, this fault will occur. 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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Electrical systems - FAULT CODES
3754 (DTC 3E3-04) - Level 2 Monitoring : Diagnostic fault check to report the plausibility error in rail pressure monitoring Context: The Engine Control Unit (ECU) monitors fuel pressure in the common rail. This monitoring is performed using two software levels of monitoring because fuel pressure monitoring is a critical functionality. If the ECU sees an error in the level two monitoring but not in level one monitoring, this fault will occur. 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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Electrical systems - FAULT CODES
3755 (DTC 3E3-12) - Level 2 Monitoring : Diagnostic fault check to report the error due to torque comparison Context: The Engine Control Unit (ECU) performs a diagnostic comparison of requested engine torque to allowed engine torque. If the ECU determines that requested engine torque is greater than maximum allowed torque, then this fault will occur. 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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Electrical systems - FAULT CODES
3756 (DTC 4E3-03) - Level 2 Monitoring : Diagnosis fault check to report the demand for normal mode due to an error in the PoI2 quantity Context: The Engine Control Unit (ECU) performs a diagnostic fault check for post injection 2 by monitoring start angle and efficiency. If the ECU determines that there is an error during this check, then this fault will occur. 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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Electrical systems - FAULT CODES
3757 (DTC 4E3-04) - Level 2 Monitoring : Diagnosis fault check to report the error to demand for an ICO due to an error in the PoI2 shut-off Context: The Engine Control Unit (ECU) performs a diagnostic fault check for post injection 2. If the ECU determines that the post injection 2 quantity has exceeded the expected value, then this fault will occur. 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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Electrical systems - FAULT CODES
3758 (DTC 4E3-12) - Level 2 Monitoring : Diagnosis fault check to report the error to demand for an ICO due to an error in the PoI3 efficiency factor Context: The Engine Control Unit (ECU) performs a diagnostic fault check for post injection 3. If the ECU determines that there is a post injection 3 plausibility error, then this fault will occur. 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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Electrical systems - FAULT CODES
3759 (DTC 5E3-03) - Level 2 Monitoring : Diagnosis of curr path limitation forced by ECU monitoring level 2 Context: The Engine Control Unit (ECU) monitors “lead torque”, which is the input torque request that is calculated for determining fuel pressure. If the ECU determines that “lead torque” is less than the limited maximal torque, then this fault will occur. 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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Electrical systems - FAULT CODES
3760 (DTC 5E3-04) - Level 2 Monitoring : Diagnosis air path limitation due to a functional control unit monitoring forced by ECU monitoring level 2 Context: The Engine Control Unit (ECU) monitors “lead torque”, which is the input torque request that is calculated for determining fuel pressure. If the ECU determines that “lead torque” is less than the limited maximal torque, then this fault will occur. 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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Electrical systems - FAULT CODES
3761 (DTC 5E3-12) - Level 2 Monitoring : Diagnosis quantity path limitation due to a functional control unit monitoring (level 2) Context: The Engine Control Unit (ECU) calculates and monitors “inner torque”, torque produced by the engine. The ECU compares “inner torque” to allowed “inner torque”. If the ECU determines that “Inner torque” is greater than allowed “inner torque”, then this fault will occur. 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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3762 (DTC 426-03) - Level 2 Monitoring : Reported Overvoltage of Supply Context: The Engine Control Unit (ECU) monitors the ECU internal 5 V supply. If the 5 V supply exceeds the maximum limit, then this fault will occur. Cause: The ECU has determined that the 5 V internal voltage supply is too high. Possible failure modes: 1. Faulty voltage supply. 2. 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, then continue with step 2. 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 3. 2. Check the ECU supply voltage. Disconnect the ECU connector X-012. Place a jumper wire between X-012 (Receptacle) pin 28 and chassis ground. This will energize the ECU main relay. With the key in the ON position, use a multimeter to perform the following voltage check on the vehicle harness (VE) side : From X-012 (Receptacle) pin 1 X-012 (Receptacle) pin 3 X-012 (Receptacle) pin 5
To X-012 (Receptacle) pin 2 X-012 (Receptacle) pin 4 X-012 (Receptacle) pin 6
Value There should be approximately 12 V. There should be approximately 12 V. There should be approximately 12 V.
A. If there is not approximately 12 V, then there is a problem with the battery supply to the ECU. Repair or replace the harness as required. B. If there is approximately 12 V, then check the ECU for the appropriate software and re-flash, if necessary. 3. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals, or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 06 SH06-ENGINE F5C T4 (55.100.DP-C.20.E.06) Wiring harnesses - Electrical schematic sheet 10 SH10-ENGINE F5C T4 (55.100.DP-C.20.E.10)
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3763 (DTC 426-04) - Level 2 Monitoring : Reported Under Voltage of Supply Context: The Engine Control Unit (ECU) monitors the ECU internal 5 V supply. If the 5 V supply is below the minimal limit, then this fault will occur. Cause: The ECU has determined that the 5 V internal voltage supply is too low. Possible failure modes: 1. Faulty voltage supply. 2. 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, then the fault may be intermittent and not currently active. Continue with step 3. 2. Check the ECU supply voltage. Disconnect the ECU connector X-012. Place a jumper wire between X-012 (Receptacle) pin 28 and chassis ground. This will energize the ECU main relay. With the key in the ON position, use a multimeter to perform the following voltage check on the vehicle harness (VE) side : From X-012 (Receptacle) pin 1 X-012 (Receptacle) pin 3 X-012 (Receptacle) pin 5
To X-012 (Receptacle) pin 2 X-012 (Receptacle) pin 4 X-012 (Receptacle) pin 6
Value There should be approximately 12 V. There should be approximately 12 V. There should be approximately 12 V.
A. If there is not approximately 12 V, then there is a problem with the battery supply to the ECU. Repair or replace the harness as required. B. If there is approximately 12 V, then check the ECU for the appropriate software and re-flash, if necessary. 3. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals, or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 06 SH06-ENGINE F5C T4 (55.100.DP-C.20.E.06) Wiring harnesses - Electrical schematic sheet 10 SH10-ENGINE F5C T4 (55.100.DP-C.20.E.10)
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3764 (DTC 225-04) - Main Relay : Early opening defect of main relay Context: The Engine Control Unit controls the ECU main relay. The ECU main relay is powered on by the ECU to achieve after-run. The ECU main relay is powered off once after-run is completed. If the ECU determines that the ECU main relay has shut off before commanded, then this fault will occur. Cause: The ECU has determined that the ECU main relay has shut off before commanded to shut off. Possible failure modes: 1. Faulty ECU main relay, wiring. 2. Faulty ECU main relay, internal failure. 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, then continue with step 2. 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 9. 2. Check the ECU main relay coil for an internal failure. Remove the ECU main relay. Use a multimeter to measure the resistance on the ECU main relay pins : From ECU main relay pin 85
To ECU main relay pin 85
Value There should be approximately 70 – 130 Ω.
A. If there is approximately 70 – 130 Ω, then leave the ECU main relay disconnected and continue to step 3. B. If there is not approximately 70 – 130 Ω, then the ECU main relay has failed. Replace the ECU main relay and retest. 3. Check the ECU main relay 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 on the vehicle harness (VE) side : From To Value There should be no voltage. X-ECU_MAIN_RLY (Receptacle) Chassis ground pin 2 NOTE: Wiggle the harness during measurement to reveal an intermittent connection. With the key in the ON position, use a multimeter to perform the following voltage check for a short circuit to another voltage source on the vehicle harness (VE) side : From To Value There should be no voltage. X-ECU_MAIN_RLY (Receptacle) Chassis ground pin 2 NOTE: Wiggle the harness during measurement to reveal an intermittent connection. A. If there is voltage, then there is a short circuit to another voltage source in the ECU main relay wiring in the vehicle harness (VE). Locate and repair the shorted conductor. Repair or replace the harness as required. 48068130 29/01/2018
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B. If there is no voltage, then leave the ECU main relay disconnected and continue to step 4. 4. Check the ECU main relay 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 a short circuit to ground on the vehicle harness (VE) side : From To Value There should be no continuity. X-ECU_MAIN_RLY (Receptacle) Chassis ground pin 2 NOTE: Wiggle the harness during measurement to reveal an intermittent connection. A. If there is continuity, then there is a short circuit to ground in the ECU 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 ECU main relay disconnected and continue to step 5. 5. Check the ECU main relay vehicle harness (VE) wiring for an open circuit. Disconnect the vehicle harness (VE) from the ECU at connector X-012. With the key in the OFF position, use a multimeter to perform the following continuity check for an open circuit on the vehicle harness (VE) side : From To Value There should be continuity. X-ECU_MAIN_RLY (Receptacle) X-012 (Receptacle) pin 28 pin 2 NOTE: Wiggle the harness during measurement to reveal an intermittent connection. A. If there is no continuity, then there is an open circuit in the ECU 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 ECU main relay disconnected. Leave connector X-012 disconnected. Continue to step 6. 6. Check the ECU main relay wiring for a short circuit. With the key in the OFF position, use a multimeter to perform the following continuity checks for a short circuit on the vehicle harness (VE) side : From To Value There should be no continuity. X-ECU_MAIN_RLY (Receptacle) X-ECU_MAIN_RLY (Receptacle) pin 2 pin 1 All pins in connector X-012 There should be no continuity. X-012 (Receptacle) pin 28 NOTE: Wiggle the harness during measurement to reveal an intermittent connection. A. If there is continuity, then there is a short circuit in the ECU 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 ECU main relay disconnected. Leave connector X-012 disconnected. Continue to step 7. 7. Check the ECU 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 There should be approximately X-ECU_MAIN_RLY (Receptacle) Chassis ground 12.0 V. pin 1 There should be approximately X-ECU_MAIN_RLY (Receptacle) Chassis ground 12.0 V. pin 3 NOTE: Wiggle the harness during measurement to reveal an intermittent connection.
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A. If there is not approximately 12.0 V, then there is a failure in the ECU main relay load-side wiring. Locate and repair the shorted conductor. Repair or replace the harness as required. B. If there is approximately 12.0 V, then leave the ECU main relay disconnected. Leave connector X-012 disconnected. Continue to step 8. 8. Check the ECU 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 : From To Value There should be continuity. X-ECU_MAIN_RLY (Receptacle) X-012 (Receptacle) pin 1 pin 5 There should be continuity. X-ECU_MAIN_RLY (Receptacle) X-012 (Receptacle) pin 3 pin 5 There should be continuity. X-ECU_MAIN_RLY (Receptacle) X-012 (Receptacle) pin 5 pin 5 NOTE: Wiggle the harness during measurement to reveal an intermittent connection. A. If there is no continuity, then there is an open circuit in the ECU main relay load-side wiring or fuse. Locate and repair the shorted conductor or open fuse. Repair or replace the harness as required. B. If there is continuity, then check the ECU for the appropriate software and re-flash, if necessary. 9. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals, or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 06 SH06-ENGINE F5C T4 (55.100.DP-C.20.E.06) Wiring harnesses - Electrical schematic sheet 10 SH10-ENGINE F5C T4 (55.100.DP-C.20.E.10)
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3766 (DTC 1F3-12) - Diesel Particulate filter Pressure sensor : Fault check for the pressure sensor plausibility Context: The exhaust differential pressure is measured between the intake and exhaust of the diesel particulate filter in the exhaust. This fault is a result of the differential pressure being inaccurate. The pressure value is above 2.5 kPa (0.4 psi). Check the differential pressure sensor hoses, and connections. If all the connections are good, and no damage is found. Replace the differential pressure sensor.
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3767 (DTC 6D4-02) - ECU internal : Diagnostic fault check to report 'WDA active' due to errors in query-/response communication Context: The Engine Control Unit (ECU) monitors the communication between CJ945 (power stage chips) and CY320 (power stage voltage supplier). If the ABE wire between the CJ-945 and CY320 becomes active due to an unknown reason, then this fault will occur. 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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3768 (DTC 6D4-04) - ECU internal : Diagnostic fault check to report 'ABE active' due to under voltage detection Context: The Engine Control Unit (ECU) monitors the communication between CJ945 (power stage chips) and CY320 (power stage voltage supplier). If the ABE wire between the CJ-945 and CY320 becomes active due to an under-voltage detection, then this fault will occur. 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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3769 (DTC 6D4-03) - ECU internal : Diagnostic fault check to report 'ABE active' due to overvoltage detection Context: The Engine Control Unit (ECU) monitors the communication between CJ945 (power stage chips) and CY320 (power stage voltage supplier). If the ABE wire between the CJ-945 and CY320 becomes active due to an over-voltage detection, then this fault will occur. 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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Electrical systems - FAULT CODES
3770 (DTC 6D4-12) - ECU internal : Diagnostic fault check to report 'WDA/ABE active' due to unknown reason Context: The Engine Control Unit (ECU) monitors the communication between CJ945 (power stage chips) and CY320 (power stage voltage supplier). If there is an unexpected communication during this process, then this fault will occur. 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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Electrical systems - FAULT CODES
3773 (DTC 299-04) - Turbocharger : Under boost detected in Pressure charger regulator Context: The Engine Control Unit (ECU) monitors boost pressure using the intake manifold pressure sensor. If the ECU determines that boost pressure is lower than expected, this fault will occur. For more information regarding the troubleshooting of an under-boost condition, refer to the engine service manual Turbocharger - Troubleshooting (10.250). Cause: The ECU has determined that boost pressure is lower than expected. Possible failure modes: 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. 8. Faulty ECU, software.
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3786 (DTC 3F9-03) - Diesel particulate filter (DPF) : Signal range check flow resistance of the particulate filter - high Context: The engine control unit (ECU) has detected the soot level in the DPF filter is exceeding the threshold limit, or the flow resistance is high. If this fault occurs, black smoke should be visible at the exhaust pipe. Check that the DPF filter is mounted properly and is not cracked. If the DPF filter is not mounted properly, refit the DPF filter correctly. If damaged is determined, replace the DPF filter. This fault will clear at the end of the next regeneration cycle.
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3787 (DTC 4F9-03) - Diesel particulate filter (DPF) : Signal range check flow resistance of the particulate filter - very high Context: The engine control unit (ECU) has detected the regeneration cycle did not complete in time. This could be a cause of exhaust restrictions, differential pressure sensor measuring wrong. Check the exhaust for any kind of restrictions. Check rear differential pressure sensor hose is not clogged. Perform the manual regeneration procedure.
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3789 (DTC 6F4-12) - To check if regeneration duration exceeds maximum allowed duration Context: The engine control unit (ECU) has detected the regeneration cycle did not complete in time. This could be a cause of exhaust restrictions, differential pressure sensor measuring wrong. Check the exhaust for any kind of restrictions. Check rear differential pressure sensor hose is not clogged. Perform the manual regeneration procedure.
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3794 (DTC 134-00) - Intake air pressure sensor : Plausibility Check for air pressure at the upstream of intake valve sensor Context: The Engine Control Unit (ECU) monitors boost pressure. The boost pressure is compared to environmental pressure by the ECU. If the ECU determines that the difference between the measured boost pressure and the environmental pressure is greater than 0.1 bar (1.5 psi), then this fault will occur. Cause: The ECU has determined that the boost pressure is greater than the environmental pressure by 0.1 bar (1.5 psi). Possible failure modes: 1. Faulty intake manifold pressure sensor, internal failure. 2. 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, then continue with step 2. 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 4. 2. Use the Electronic Service Tool (EST) to check the status of following related faults: 3019 (DTC 134-03) – Intake air pressure sensor : Diagnostic fault check for SRC high in air pressure upstream of intake valve sensor 3037 (DTC 134-04) – Intake air pressure sensor : Diagnostic fault check for SRC low in air pressure upstream of intake valve sensor A. If any of the listed faults are active, then diagnose these fault codes first, then check to see if 3794 (DTC 134-00) – Intake air pressure sensor : Plausibility Check for air pressure at the upstream of intake valve sensor has been resolved. B. If none of the listed faults are active, then continue to step 3. 3. Replace the intake manifold pressure sensor. Use the EST to verify the status of this fault, 3794 (DTC 134-00) – Intake air pressure sensor : Plausibility Check for air pressure at the upstream of intake valve sensor. 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. 4. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals, or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation.
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Electrical systems - FAULT CODES
3795 (DTC 134-01) - Intake air pressure sensor : Plausibility Check for air pressure at the upstream of intake valve sensor Context: The Engine Control Unit (ECU) monitors boost pressure. The boost pressure is compared to the environmental pressure by the ECU. If the ECU determines that the boost pressure is less than the environmental pressure by 0.1 bar (1.5 psi), then this fault will occur. Cause: The ECU has determined that the boost pressure is less than environmental pressure by 0.1 bar (1.5 psi). Possible failure modes: 1. Faulty intake manifold pressure sensor, internal failure. 2. 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, then continue with step 2. 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 4. 2. Use the Electronic Service Tool (EST) to check the status of following related faults: 3019 (DTC 134-03) – Intake air pressure sensor : Diagnostic fault check for SRC high in air pressure upstream of intake valve sensor 3037 (DTC 134-04) – Intake air pressure sensor : Diagnostic fault check for SRC low in air pressure upstream of intake valve sensor A. If any of the listed faults are active, then diagnose these fault codes first, then check to see if 3795 (DTC 134-01) – Intake air pressure sensor : Plausibility Check for air pressure at the upstream of intake valve sensor has been resolved. B. If none of the listed faults are active, then continue to step 3. 3. Replace the intake manifold pressure sensor. Use the EST to verify the status of this fault, 3795 (DTC 134-01) – Intake air pressure sensor : Plausibility Check for air pressure at the upstream of intake valve sensor. 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. 4. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals, or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation.
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Electrical systems - FAULT CODES
3796 (DTC 5F5-12) - Diesel Particulate filter Pressure sensor : DFC to indicate hose line error Context: The engine control unit (ECU) has detected the filtered differential pressure signal is below 1.0 kPa (0.1 psi). This fault is a cause of a hose connection upstream from the diesel particulate filter not being attached, or is clogged. Check mounting of the hose lines, and check the hose line is free of clogs.
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Electrical systems - FAULT CODES
3797 (DTC 1F1-03) - Diesel Particulate filter Pressure sensor : SRC High for PFlt differential pressure sensor Context: The Engine Control Unit (ECU) monitors the differential pressure signal for electrical defects. Cause: The ECU has sensed the differential pressure sensor signal is greater than 6.5 V. Possible failure modes: 1. The differential pressure sensor has failed. 2. There is a short circuit to another voltage source in the differential pressure sensor wiring. 3. The ECU has failed internally. Solution: 1. Verify that the fault is present and active. A. If the fault is active, then continue with step 2. B. If the fault is not active, then the fault may be intermittent. Continue with step 6. 2. Verify that the wiring harness and connectors are free of damage. Inspect the wiring harness from the ECU to the differential pressure sensor connector. Verify that the wiring harness is free of damage, corrosion, abrasion and incorrect attachment. A. The connectors are secure and the wiring harness is free of damage. Continue with step 3. B. The connectors or the wiring harness has damage. Repair or replace the wiring harness or connectors as required. 3. Check the signal circuit. Disconnect the wiring harness from the differential pressure sensor. Place a jumper wire between the wiring harness sensor connector pin 2 and pin 3. Place the key switch ON. Monitor the diagnostic screen for the fault code to change from “Shorted to high source” to “Shorted to low source”. A. If the fault code changed, remove the jumper wire. Continue with step 4. B. If the fault code did not change, remove the jumper wire. Continue with step 5. 4. Check the 5.0 V supply and ground reference circuit. Place the key switch ON. Use a multimeter to check for voltage from the wiring harness sensor connector pin 1 to pin 2. There should be approximately 4.5 – 5.5 V. A. If the voltage reading is not in range, continue with step 5. B. If the voltage is in range, the sensor has failed. Replace the sensor. 5. Check the wiring harness for a short to high source. Place the key switch OFF.
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Carefully disconnect the wiring harness from the ECU. Place the key switch ON. Use a multimeter to check to perform the following checks. From To Sensor wiring harness connector pin Chassis ground 1 Sensor wiring harness connector pin Chassis ground 2 Sensor wiring harness connector pin Chassis ground 3
Result There should be no voltage. There should be no voltage. There should be no voltage.
A. If the wiring harness test is good, verify the ECU for proper operation. B. If the wiring harness test fails, locate and repair the broken conductor. 6. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals, or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation.
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Electrical systems - FAULT CODES
3798 (DTC 1F1-04) - Diesel Particulate filter Pressure sensor : SRC low for PFlt differential pressure sensor Context: The Engine Control Unit (ECU) monitors the differential pressure signal for electrical defects. Cause: The ECU has sensed the differential pressure sensor signal is less than 0.5 V. Possible failure modes: 1. The differential pressure sensor has failed. 2. The differential pressure sensor circuit is shorted to a low source. 3. The ECU has failed internally. Solution: 1. Verify that the fault is present and active. A. If the fault is active, then continue with step 2. B. If the fault is not active, then the fault may be intermittent. Continue with step 6. 2. Verify that the wiring harness and connectors are free of damage. Inspect the wiring harness from the ECU to the differential pressure sensor connector. Verify that the wiring harness is free of damage, corrosion, abrasion and incorrect attachment. A. The connectors are secure and the wiring harness is free of damage. Continue with step 3. B. The connectors or the wiring harness has damage. Repair or replace the wiring harness or connectors as required. 3. Check the signal circuit. Disconnect the wiring harness from the differential pressure sensor. Place a jumper wire between the wiring harness sensor connector pin 1and pin 3. Place the key switch ON. Monitor the diagnostic screen for the fault code to change from “Shorted to low source” to “Shorted to high source”. A. If the fault code changed, remove the jumper wire. Continue with step 4. B. If the fault code did not change, remove the jumper wire. Continue with step 5. 4. Check the 5.0 V supply and ground reference circuit. Place the key switch ON. Use a multimeter to check for voltage from the wiring harness sensor connector pin 1 to pin 2. There should be approximately 4.5 – 5.5 V. A. If the voltage reading is not in range, continue with step 5. B. If the voltage is in range, the sensor has failed. Replace the sensor. 5. Check the wiring harness for a short to low source. Place the key switch OFF.
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Carefully disconnect the wiring harness from the ECU. Use a multimeter to check to perform the following checks. From To Sensor wiring harness connector pin Chassis ground 1 Sensor wiring harness connector pin Chassis ground 2 Sensor wiring harness connector pin Chassis ground 3
Result There should be no continuity. There should be no continuity. There should be no continuity.
A. If the wiring harness test is good, verify the ECU for proper operation. B. If the wiring harness test fails, locate and repair the broken conductor. 6. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals, or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation.
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Electrical systems - FAULT CODES
3799 (DTC 237-04) - Pressure Relief valve : pressure relief valve is forced to open, perform pressure shock Context: This fault is intended for information purposes only. Other active faults may have caused this fault to occur. The Engine Control Unit (ECU), 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, then the ECU has performed a fuel pressure shock to achieve limp home mode. Cause: The ECU has performed a fuel pressure shock to achieve limp home mode.
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Electrical systems - FAULT CODES
3800 (DTC 237-12) - Pressure Relief valve : Quantity balance check if a successful PRV opening is ensured Context: This fault is intended for information purposes only. Other active faults may have caused this fault to occur. The Engine Control Unit (ECU), monitors the fuel Pressure Relief Valve (PRV). To determine mechanical wear-out of the PRV, the ECU will perform a fuel pressure increase and pressure shock, thus opening the PRV. Both steps are recorded in the ECU failure memory.
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3801 (DTC 49B-03) - Turbine upstream pressure sensor : SRC High for Turbine upstream pressure sensor 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. Possible failure modes: 1. Faulty exhaust gas absolute pressure sensor, wiring to internal failure. 2. 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, then continue with step 2. 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 6. 2. Check the exhaust gas absolute pressure sensor engine harness (EN) wiring. Disconnect the engine harness from 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 Exhaust gas absolute pressure sensor connector pin 3
To Chassis ground
Value There should be no voltage.
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 exhaust gas absolute pressure sensor disconnect and continue to step 3. 3. Check the exhaust gas absolute pressure sensor engine harness (EN) wiring. Disconnect the engine interface connector X-017. With the key in the OFF position, use a multimeter to perform the following continuity check at the engine harness (EN) side of the connector from : From X-017 (Receptacle) pin 23
To All pins in connector X-017
Value There should be no continuity.
A. If there is continuity, 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 continuity, then leave the connector disconnect and continue to step 4. 4. Check the exhaust gas absolute pressure sensor vehicle harness (VE) wiring. Disconnect the ECU connector X-012.
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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 X-017 (Receptacle) pin 23
To All pins in connector X-017
Value There should be no continuity.
A. If there is continuity, then there is a short circuit in the exhaust gas absolute pressure sensor signal circuit 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 connector disconnect and continue to step 5. 5. Replace the exhaust gas absolute pressure sensor. Use the Electronic Service Tool (EST) to verify the status of this fault. 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. 6. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals, or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 07 SH07-ENGINE F5C T4 (55.100.DP-C.20.E.07) Wiring harnesses - Electrical schematic sheet 11 SH11-ENGINE F5C T4 (55.100.DP-C.20.E.11)
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3802 (DTC 49B-04) - Turbine upstream pressure sensor : SRC low for Turbine upstream pressure sensor 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, 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. Possible failure modes: 1. Faulty exhaust gas absolute pressure sensor, wiring to internal failure. 2. 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, then continue with step 2. 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 6. 2. Check the exhaust gas absolute pressure sensor engine harness (EN) wiring. Disconnect the engine harness from the exhaust gas absolute pressure sensor. With the key in the OFF position, use a multimeter to perform the following continuity check at the engine harness (EN) side of the connector from : From Exhaust gas absolute pressure sensor connector pin 3
To Exhaust gas absolute pressure sensor connector pin 2
Value There should be no continuity.
A. If there is continuity, 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 continuity, then leave the exhaust gas absolute pressure sensor disconnect and continue to step 3. 3. Check the exhaust gas absolute pressure sensor engine harness (EN) wiring. Disconnect the engine interface connector X-017. With the key in the OFF position, use a multimeter to perform the following continuity check at the engine harness (EN) side of the connector from : From X-017 (Receptacle) pin 23 X-017 (Receptacle) pin 23
To Chassis ground All pins in connector X-017
Value There should be no continuity. There should be no continuity.
A. If there is continuity, 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 continuity, then leave the connector disconnect and continue to step 4. 4. Check the exhaust gas absolute pressure sensor vehicle harness (VE) wiring.
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Disconnect the ECU connector X-016. 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 X-017 (Receptacle) pin 23 X-017 (Receptacle) pin 23 X-016 (Receptacle) pin 57
To Chassis ground All pins in connector X-017 All pins in connector X-016
Value There should be no continuity. There should be no continuity. There should be no continuity.
A. If there is continuity, then there is a short circuit in the exhaust gas absolute pressure sensor signal circuit 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 connector disconnect and continue to step 5. 5. Replace the exhaust gas absolute pressure sensor. Use the Electronic Service Tool (EST) to verify the status of this fault. 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. 6. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals, or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 07 SH07-ENGINE F5C T4 (55.100.DP-C.20.E.07) Wiring harnesses - Electrical schematic sheet 11 SH11-ENGINE F5C T4 (55.100.DP-C.20.E.11)
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3803 (DTC 2D1-03) - ECU internal : Error on R2S2 module (Low-Level Chip driver for the Power stage-Chips) Context: The Engine Control Unit (ECU) has detected an error on the R2S2 module (low-level chip driver for the power-stage chips). 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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3808 (DTC 455-03) - Fuel Metering Unit : set point of metering unit in idle mode not plausible Context: The Engine Control Unit (ECU) monitors fuel rail pressure. If the ECU determines that the requested fuel pressure is greater than the actual fuel pressure at idle, leakage is assumed and this fault will occur. Other active faults may have caused this fault to occur. Use the Electronic Service Tool (EST) to check for other active faults. Diagnose any active faults related to the fuel system first and then return to this fault. For more information regarding fuel system troubleshooting, refer to the engine service manual Fuel injection system - Troubleshooting (10.218). Cause: The ECU has determined that the requested fuel pressure is greater than the actual fuel pressure at idle. Possible failure modes: 1.
Faulty low pressure fuel system, clogged filter or leakage/blockage.
2.
Faulty charge gear pump, low efficiency or line clogged/damaged.
3.
Faulty electric fuel pump (if equipped).
4.
Faulty fuel metering unit, unable to fully open.
5.
Faulty high pressure pump, low efficiency.
6.
Faulty fuel injectors, stuck open or internal leakage.
7.
Faulty Pressure Relief Valve (PRV), leakage.
8.
Faulty rail pressure sensor drifted signal or leaking.
9.
Faulty ECU, software.
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3810 (DTC 435-12) - Fuel pressure Sensor : Rail pressure raw value is intermittent 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 more than 5 pressure jumps of greater than 500 bar (7250 psi) and the time between the pressure jumps is less than 3.00 s, then an intermittent connection is assumed and this fault will occur. Cause: The ECU has detected an intermittent connection in the rail pressure sensor signal circuit. Possible failure modes: 1. Faulty rail pressure sensor wiring, intermittent electrical connection. 2. Faulty rail pressure sensor, internal failure. 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, then continue with step 2. 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. Check the rail pressure sensor engine harness (EN) harness wiring for an open circuit. Disconnect the engine harness (EN) from the rail pressure sensor. Disconnect the vehicle harness (VE) from the engine interface at connector X-017. 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 Rail pressure sensor connector pin 2 X-017 (Receptacle) pin 6 There should be continuity. NOTE: Wiggle the harness during measurement to reveal an intermittent connection. A. If there is no continuity, then there is an open circuit in the rail pressure 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 rail pressure sensor disconnected. Leave connector X-017 disconnected. Continue to step 3. 3. Check the rail pressure sensor vehicle harness (VE) wiring for an open circuit. Disconnect the vehicle harness (VE) from the ECU at connector X-016. 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 There should be continuity. X-017 (Receptacle) pin 6 X-016 (Receptacle) pin 41 NOTE: Wiggle the harness during measurement to reveal an intermittent connection. 48068130 29/01/2018
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A. If there is no continuity, then there is an open circuit in the rail pressure sensor 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 leave the rail pressure sensor disconnected. Continue to step 4. 4. Replace the rail pressure sensor. Use the Electronic Service Tool (EST) to check the status of this fault. 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. 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. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 07 SH07-ENGINE F5C T4 (55.100.DP-C.20.E.07) Wiring harnesses - Electrical schematic sheet 11 SH11-ENGINE F5C T4 (55.100.DP-C.20.E.11)
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3811 (DTC 1E6-12) - ECU Sensor Supply Monitor : ECU internal: Error Sensor supplies 1 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 1 is out of range, then this fault will occur. The ECU pin numbers associated with sensor supply 1 are X-016 (Receptacle) pin 8, X-016 (Receptacle) pin 9, X-016 (Receptacle) pin 10, X-016 (Receptacle) pin 11, X-016 (Receptacle) pin 12, and X-016 (Receptacle) pin 13. Cause: The ECU has determined that the sensor supply 1 voltage is out of range. Possible failure modes: 1.
Faulty battery voltage.
2.
Faulty ECU supply voltage.
3.
Faulty ECU sensor supply 1 pins.
4.
Faulty ECU connector X-016, corrosion or damage.
5.
Faulty Throttle Valve Actuator (TVA), position sensor wiring or internal failure.
6.
Faulty Exhaust Gas Recirculation (EGR) valve, position sensor wiring or internal failure.
7.
Faulty intake manifold pressure and temperature sensor, wiring or internal failure.
8.
Faulty rail pressure sensor, wiring or internal failure.
9.
Faulty exhaust manifold pressure sensor, wiring to internal failure.
10. Faulty camshaft speed sensor, wiring or internal failure. 11. 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, then continue with step 2. 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 13.
2.
Check the battery voltage. Charge the battery. After the battery is fully charged, perform a load test on the battery. A. If the battery passes the load test, then continue to step 3. B. If the battery fails the load test, then the battery has failed. Replace the battery and retest.
3.
Disconnect the ECU connector X-016. Check the following pins listed below on the ECU and in connector X-016 . Pin X-016 (Receptacle) pin 8 X-016 (Receptacle) pin 9 X-016 (Receptacle) pin 10
Physical condition The pin and connector should be free of corrosion or damage. The pin and connector should be free of corrosion or damage. The pin and connector should be free of corrosion or damage. 48068130 29/01/2018
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Pin X-016 (Receptacle) pin 11
Physical condition The pin and connector should be free of corrosion or damage. The pin and connector should be free of corrosion or damage. The pin and connector should be free of corrosion or damage.
X-016 (Receptacle) pin 12 X-016 (Receptacle) pin 13
A. If a pin or connector shows signs of corrosion or damage, then repair as necessary. B. If a pin or connector shows no signs of corrosion or damage, then reconnect the ECU connector X-016 and continue to step 4. 4.
Check the ECU supply voltage. Disconnect the ECU connector X-012. Place a jumper wire between X-012 (Receptacle) pin 28 and chassis ground. This will energize the ECU main relay. With the key in the ON position, use a multimeter to perform the following voltage check on the vehicle harness (VE) side : From X-012 (Receptacle) pin 1 X-012 (Receptacle) pin 3 X-012 (Receptacle) pin 5
To X-012 (Receptacle) pin 2 X-012 (Receptacle) pin 4 X-012 (Receptacle) pin 6
Value There should be approximately 12 V. There should be approximately 12 V. There should be approximately 12 V.
A. If there is approximately 12 V, then remove the jumper wire and reconnect the ECU at connector X-012. Continue to step 5. B. If there is not approximately 12 V, then there is a problem with the battery voltage to the ECU. Repair or replace the harness as required. 5.
Disconnect each of the following connectors one at a time. Monitor the status of this fault, 3811 (DTC 1E6-12) â&#x20AC;&#x201C; ECU Sensor Supply Monitor : ECU internal: Error Sensor supplies 1 during the check. Disconnect the TVA connector from the engine harness. Disconnect the EGR valve connector from the engine harness. Disconnect the intake manifold pressure and temperature sensor connector from the engine harness. Disconnect the rail pressure sensor connector from the engine harness. Disconnect the exhaust manifold connector from the engine harness. Disconnect the camshaft speed sensor connector from the engine harness. A. If the fault is no longer active after a component disconnection, then the relevant component has failed. Replace the component and retest. B. If the fault is still active after the component disconnections, then leave all of the connectors disconnected and continue to step 6.
6.
Check the TVA voltage supply wiring. Disconnect the vehicle harness (VE) from the ECU at connectors X-012 and X-016. With the key in the ON position, use a multimeter to perform the following voltage check on the engine harness (EN) side : From TVA connector pin 1
To Chassis ground
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Value There should be no voltage.
Electrical systems - FAULT CODES
Disconnect the vehicle harness (VE) from the engine interface at connector X-017. With the key in the OFF position, use a multimeter to perform the following continuity checks on the engine harness (EN) side : From TVA connector pin 1 TVA connector pin 1 TVA connector pin 1 TVA connector pin 1 X-017 (Receptacle) pin 41
To Chassis ground TVA connector pin 3 TVA connector pin 2 TVA connector pin 6 All pins in connector X-017
Value There should be no continuity. There should be no continuity. There should be no continuity. There should be no continuity. There should be no continuity.
With the key in the OFF position, use a multimeter to perform the following continuity checks on the vehicle harness (VE) side : From X-017 (Receptacle) pin 41 X-016 (Receptacle) pin 8
To All pins in connector X-017 All pins in connector X-016
Value There should be no continuity. There should be no continuity.
A. If the specified values are measured, then reconnect the engine interface connector X-017. Leave the ECU connectors X-016 and X-012 disconnected. Continue to step 7. B. If the specified values are not measured, then there is a problem in the TVA voltage supply wiring. Locate and repair the failed conductor. Repair or replace the harness as required. 7.
Check the EGR valve Z-9000 voltage supply wiring. With the key in the ON position, use a multimeter to perform the following voltage check on the engine harness (EN) side : From EGR valve connector pin 6
To Chassis ground
Value There should be no voltage.
Disconnect the vehicle harness (VE) from the engine interface at connector X-017. With the key in the OFF position, use a multimeter to perform the following continuity checks on the engine harness (EN) side : From EGR valve connector pin 6 EGR valve connector pin 6 EGR valve connector pin 6 EGR valve connector pin 6 X-017 (Receptacle) pin 33
To Chassis ground EGR valve connector pin 4 EGR valve connector pin 5 EGR valve connector pin 1 All pins in connector X-017
Value There should be no continuity. There should be no continuity. There should be no continuity. There should be no continuity. There should be no continuity.
With the key in the OFF position, use a multimeter to perform the following continuity checks on the vehicle harness (VE) side : From X-017 (Receptacle) pin 33 X-016 (Receptacle) pin 9
To All pins in connector X-017 All pins in connector X-016
Value There should be no continuity. There should be no continuity.
A. If the specified values are measured, then reconnect the engine interface connector X-017. Leave the ECU connectors X-016 and X-012 disconnected. Continue to step 8. B. If the specified values are not measured, then there is a failure in the EGR valve voltage supply wiring. Locate and repair the failed conductor. Repair or replace the harness as required. 8.
Check the intake manifold pressure and temperature sensor voltage supply wiring. With the key in the ON position, use a multimeter to perform the following voltage check on the engine harness (EN) side :
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From To Intake manifold pressure and Chassis ground temperature sensor connector pin 3
Value There should be no voltage.
Disconnect the vehicle harness (VE) from the engine interface at connector X-017. With the key in the OFF position, use a multimeter to perform the following continuity checks on the engine harness (EN) side : From Intake manifold pressure and temperature sensor connector pin 3 Intake manifold pressure and temperature sensor connector pin 3 X-017 (Receptacle) pin 17
To Chassis ground
Value There should be no continuity.
There should be no continuity. Intake manifold pressure and temperature sensor connector pin 1 All pins in connector X-017 There should be no continuity.
With the key in the OFF position, use a multimeter to perform the following continuity checks on the vehicle harness (VE) side : From X-017 (Receptacle) pin 17 X-016 (Receptacle) pin 10
To All pins in connector X-017 All pins in connector X-016
Value There should be no continuity. There should be no continuity.
A. If the specified values are measured, then reconnect the engine interface connector X-017. Leave the ECU connectors X-016 and X-012 disconnected. Continue to step 9. B. If the specified values are not measured, then there is a failure in the intake manifold pressure and temperature sensor voltage supply wiring. Locate and repair the failed conductor. Repair or replace the harness as required. 9.
Check the rail pressure sensor voltage supply wiring. With the key in the ON position, use a multimeter to perform the following voltage check on the engine harness (EN) side : From To Rail pressure sensor connector pin 3 Chassis ground
Value There should be no voltage.
Disconnect the vehicle harness (VE) from the engine interface at connector X-017. With the key in the OFF position, use a multimeter to perform the following continuity checks on the engine harness (EN) side : From To Value Rail pressure sensor connector pin 3 Chassis ground There should be no continuity. Rail pressure sensor connector pin 3 Rail pressure sensor connector pin 1 There should be no continuity. All pins in connector X-017 There should be no continuity. X-017 (Receptacle) pin 7 With the key in the OFF position, use a multimeter to perform the following continuity checks on the vehicle harness (VE) side : From X-017 (Receptacle) pin 7 X-016 (Receptacle) pin 11
To All pins in connector X-017 All pins in connector X-016
Value There should be no continuity. There should be no continuity.
A. If the specified values are measured, then reconnect the engine interface connector X-017. Leave the ECU connectors X-016 and X-012 disconnected. Continue to step 10. B. If the specified values are not measured, then there is a failure in the rail pressure sensor voltage supply wiring. Locate and repair the failed conductor. Repair or replace the harness as required. 10. Check the exhaust manifold pressure sensor voltage supply wiring.
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With the key in the ON position, use a multimeter to perform the following voltage check on the engine harness (EN) side : From Exhaust manifold pressure sensor connector pin 1
To Chassis ground
Value There should be no voltage.
Disconnect the vehicle harness (VE) from the engine interface at connector X-017. With the key in the OFF position, use a multimeter to perform the following continuity checks on the engine harness (EN) side : From Exhaust manifold pressure sensor connector pin 1 Exhaust manifold pressure sensor connector pin 1 X-017 (Receptacle) pin 21
To Chassis ground Exhaust manifold pressure sensor connector pin 2 All pins in connector X-017
Value There should be no continuity. There should be no continuity. There should be no continuity.
With the key in the OFF position, use a multimeter to perform the following continuity checks on the vehicle harness (VE) side : From X-017 (Receptacle) pin 21 X-016 (Receptacle) pin 12
To All pins in connector X-017 All pins in connector X-016
Value There should be no continuity. There should be no continuity.
A. If the specified values are measured, then reconnect the engine interface connector X-017. Leave the ECU connectors X-016 and X-012 disconnected. Continue to step 11. B. If the specified values are not measured, then there is a failure in the rail pressure sensor voltage supply wiring. Locate and repair the failed conductor. Repair or replace the harness as required. 11. Check the camshaft speed sensor voltage supply wiring. With the key in the ON position, use a multimeter to perform the following voltage check on the engine harness (EN) side : From Camshaft speed sensor connector pin 3
To Chassis ground
Value There should be no voltage.
Disconnect the vehicle harness (VE) from the engine interface at connector X-017. With the key in the OFF position, use a multimeter to perform the following continuity checks on the engine harness (EN) side : From Camshaft speed sensor connector pin 1 Camshaft speed sensor connector pin 1 X-017 (Receptacle) pin 8
To Chassis ground Camshaft speed sensor connector pin 3 All pins in connector X-017
Value There should be no continuity. There should be no continuity. There should be no continuity.
With the key in the OFF position, use a multimeter to perform the following continuity checks on the vehicle harness (VE) side : From X-017 (Receptacle) pin 8 X-016 (Receptacle) pin 28
To All pins in connector X-017 All pins in connector X-016
Value There should be no continuity. There should be no continuity.
A. If the specified values are measured, then reconnect all of the connectors and continue to step 12.
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B. If the specified values are not measured, then there is a failure in the camshaft speed sensor voltage supply wiring. Locate and repair the failed conductor. 12. 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. 13. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals, or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the display indicates other than normal display readings, Then, repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, Then, erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 07 SH07-ENGINE F5C T4 (55.100.DP-C.20.E.07) Wiring harnesses - Electrical schematic sheet 11 SH11-ENGINE F5C T4 (55.100.DP-C.20.E.11)
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3812 (DTC 2CC-00) - Physical Range Check high for ECU temperature sensor Context: The Engine Control Unit (ECU) has an internal temperature sensor. If the ECU determines that the temperature sensor value is too high, then this fault will occur. Cause: The ECU has determined that the internal ECU temperature sensor value is too high. Possible failure modes: 1. Machine is operating in extreme environmental conditions. 2. Faulty ECU, software. 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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3813 (DTC 2CC-01) - Physical Range Check low for ECU temperature sensor Context: The Engine Control Unit (ECU) has an internal temperature sensor. If the ECU determines that the temperature sensor value is too low, then this fault will occur. Cause: The ECU has determined that the internal ECU temperature sensor value is too low. Possible failure modes: 1. Machine is operating in extreme environmental conditions. 2. Faulty ECU, software. 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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3814 (DTC 2CC-12) - ECU temperature sensor : SPI Error ECU temperature sensor (LM71) Context: The Engine Control Unit (ECU) has an internal temperature sensor. If the ECU determines that there is an internal SPI communication error, then this fault will occur. Cause: The ECU has detected an error in the internal ECU temperature sensor communication. Possible failure modes: 1. Faulty ECU, software. 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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3818 (DTC 48D-02) - Open load error for throttle valve H-bridge 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. Possible failure modes: 1. Faulty throttle valve actuator wiring, open circuit. 2. Faulty throttle valve actuator, internal failure. 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, then continue with step 2. 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. Check the throttle valve actuator h-bridge engine harness (EN) wiring for an open circuit. Disconnect the engine harness from the throttle valve actuator. Disconnect the vehicle harness (VE) from the engine interface connector X-017. With the key in the OFF position, use a multimeter to perform the following continuity check for an open circuit on the engine harness (EN) side : From TVA connector pin 6 TVA connector pin 2
To X-017 (Receptacle) pin 37 X-017 (Receptacle) pin 38
Value There should be continuity. There should be continuity.
A. If there is no continuity, then 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 TVA disconnected. Leave connector X-017 disconnected. Continue to step 3. 3. Check the throttle valve actuator h-bridge vehicle harness (VE) wiring for an open circuit. Disconnect the ECU connector X-016. With the key in the OFF position, use a multimeter to perform the following continuity check for an open circuit on the vehicle harness (VE) side : From X-017 (Receptacle) pin 37 X-017 (Receptacle) pin 38
To X-016 (Receptacle) pin 49 X-016 (Receptacle) pin 34
Value There should be continuity. There should be continuity.
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. B. If there is continuity, then leave the TVA disconnected. Continue to step 4. 4. Replace the throttle valve actuator.
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Use the Electronic Service Tool (EST) to check the status of this fault. 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 A-9000 for the appropriate software and re-flash, if necessary. 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. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 07 SH07-ENGINE F5C T4 (55.100.DP-C.20.E.07) Wiring harnesses - Electrical schematic sheet 11 SH11-ENGINE F5C T4 (55.100.DP-C.20.E.11)
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3819 (DTC 48D-03) - Over current error for throttle valve H-bridge Context: The Engine Control Unit (ECU) monitors the throttle valve actuator output 1 and output 2 h-bridge circuits. If the ECU 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. Possible failure modes: 1. Faulty throttle valve actuator wiring, short circuit to ground. 2. Faulty throttle valve actuator wiring, short circuit to another voltage source. 3. Faulty throttle valve actuator, internal failure. 4. 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, then continue with step 2. 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 7. 2. Check the throttle valve actuator h-bridge wiring for a short circuit to battery. Disconnect the engine harness (EN) from the throttle valve actuator. Disconnect the vehicle harness (VE) from the ECU at connector X-016 (Receptacle) . With the key in the ON position, use a multimeter to perform the following voltage check on the engine harness (EN) side : From To Throttle valve actuator connector pin Chassis ground 6 Throttle valve actuator connector pin Chassis ground 2
Value There should be no voltage. There should be no voltage.
A. If there is voltage, then there is a short circuit in the throttle valve actuator h-bridge 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 disconnected. Leave connector X-016 disconnected. Continue to step 3. 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 perform the following continuity check for a short circuit to ground on the engine harness (EN) side : From To Throttle valve actuator connector pin Chassis ground 6 Throttle valve actuator connector pin Chassis ground 2
Value There should be no continuity. There should be no continuity.
A. If there is continuity, then there is a short circuit 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-016 disconnected. Continue to step 4. 4. Check the throttle valve actuator engine harness (EN) wiring for a short circuit. Disconnect the vehicle harness (VE) from the engine interface connector X-017. With the key in the OFF position, use a multimeter to perform the following continuity check for a short circuit on the engine harness (EN) side : From To Throttle valve actuator connector pin Throttle valve actuator connector pin 6 2 Throttle valve actuator connector pin Throttle valve actuator connector pin 6 1 Throttle valve actuator connector pin Throttle valve actuator connector pin 2 1 All pins in connector X-017 X-017 (Receptacle) pin 37 All pins in connector X-017 X-017 (Receptacle) pin 38
Value There should be no continuity. There should be no continuity. There should be no continuity. There should be no continuity. There should be no continuity.
A. If there is continuity, then there is a short circuit in the throttle valve actuator engine harness (EN) h-bridge circuit. 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 disconnected. Leave connectors X-017 and X-016disconnected. Continue to step 5. 5. Check the throttle valve actuator vehicle harness (VE) h-bridge circuit for a short circuit to another voltage source. With the key in the OFF position, use a multimeter to perform the following continuity check for a short circuit on the vehicle harness (VE) side : From X-017 (Receptacle) pin 37 X-017 (Receptacle) pin 38 X-016 (Receptacle) pin 49 X-016 (Receptacle) pin 34
To All pins in connector X-017 All pins in connector X-017 All pins in connector X-016 All pins in connector X-016
Value There should be no continuity. There should be no continuity. There should be no continuity. There should be no continuity.
A. If there is continuity, then there is a short circuit in the throttle valve actuator vehicle harness (VE) h-bridge circuit. 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 disconnected and continue to step 6. 6. Replace the throttle valve actuator. Use the Electronic Service Tool (EST) to check the status of this fault. 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. 7. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals, or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 07 SH07-ENGINE F5C T4 (55.100.DP-C.20.E.07) Wiring harnesses - Electrical schematic sheet 11 SH11-ENGINE F5C T4 (55.100.DP-C.20.E.11)
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3820 (DTC 48D-12) - Over temperature error for throttle valve H-bridge Context: The Engine Control Unit (ECU) monitors the throttle valve actuator output 1 and output 2 h-bridge circuits. If the ECU 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. Possible failure modes: 1. Faulty throttle valve actuator wiring, short circuit to ground. 2. Faulty throttle valve actuator wiring, short circuit to another voltage source. 3. Faulty throttle valve actuator, internal failure. 4. 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, then continue with step 2. 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 7. 2. Check the throttle valve actuator h-bridge wiring for a short circuit to battery. Disconnect the engine harness (EN) from the throttle valve actuator. Disconnect the vehicle harness (VE) from the ECU at connector X-016. With the key in the ON position, use a multimeter to perform the following voltage check on the engine harness (EN) side : From Throttle valve actuator pin 6 Throttle valve actuator pin 2
To Chassis ground Chassis ground
Value There should be no voltage. There should be no voltage.
A. If there is voltage, then there is a short circuit to battery in the throttle valve actuator h-bridge 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 disconnected. Leave connector X-016 disconnected. Continue to step 3. 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 perform the following continuity check for a short circuit to ground on the engine harness (EN) side : From Throttle valve actuator pin 6 Throttle valve actuator pin 2
To Chassis ground Chassis ground
Value There should be no continuity. There should be no continuity.
A. If there is continuity, then there is a short circuit to ground in the throttle valve actuator h-bridge circuit. 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 disconnected. Leave connector X-016 disconnected. Continue to step 4. 48068130 29/01/2018
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4. Check the throttle valve actuator engine harness (EN) wiring for a short circuit. Disconnect the vehicle harness (VE) from the engine interface connector X-017. With the key in the OFF position, use a multimeter to perform the following continuity check for a short circuit on the engine harness (EN) side : From Throttle valve actuator pin 6 Throttle valve actuator pin 6 Throttle valve actuator pin 2 X-017 (Receptacle) pin 37 X-017 (Receptacle) pin 38
To Throttle valve actuator pin 2 Throttle valve actuator pin 1 Throttle valve actuator pin 1 All pins in connector X-017 All pins in connector X-017
Value There should be no continuity. There should be no continuity. There should be no continuity. There should be no continuity. There should be no continuity.
A. If there is continuity, there is a short circuit in the throttle valve actuator engine harness (EN) h-bridge circuit. 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 disconnected. Leave connectors X-017 and X-016 disconnected. Continue to step 5. 5. Check the throttle valve actuator vehicle harness (VE) h-bridge circuit for a short circuit to another voltage source. With the key in the OFF position, use a multimeter to perform the following continuity check for a short circuit on the vehicle harness (VE) side : From X-017 (Receptacle) pin 37 X-017 (Receptacle) pin 38 X-016 (Receptacle) pin 49 X-016 (Receptacle) pin 34
To All pins in connector X-017 All pins in connector X-017 All pins in connector X-016 All pins in connector X-016
Value There should be no continuity. There should be no continuity. There should be no continuity. There should be no continuity.
A. If there is continuity, then there is a short circuit in the throttle valve actuator vehicle harness (VE) h-bridge circuit. 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 disconnected and continue to step 6. 6. Replace the throttle valve actuator. Use the Electronic Service Tool (EST) to check the status of this fault. 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. 7. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals, or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 07 SH07-ENGINE F5C T4 (55.100.DP-C.20.E.07) Wiring harnesses - Electrical schematic sheet 11 SH11-ENGINE F5C T4 (55.100.DP-C.20.E.11)
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3821 (DTC 58D-03) - Short circuit to battery of throttle valve H-bridge - high pin A49 Context: The Engine Control Unit (ECU) monitors the throttle valve actuator output 1 and output 2 h-bridge circuits. If the ECU detects a short circuit to 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 high source in the throttle valve actuator output 1 h-bridge circuit. Possible failure modes: 1. Faulty throttle valve actuator wiring, short circuit to a voltage source. 2. Faulty throttle valve actuator, internal failure. 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, then continue with step 2. 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 6. 2. Check the throttle valve actuator output 1 h-bridge wiring for a short circuit to battery. Disconnect the engine harness (EN) from the throttle valve actuator. Disconnect the vehicle harness (VE) from the ECU at connector X-016. With the key in the ON position, use a multimeter to perform the following voltage check on the engine harness (EN) side : From To Throttle valve actuator connector pin Chassis ground 6
Value There should be no voltage.
A. If there is voltage, then there is a short circuit to battery in the throttle valve actuator output 1 h-bridge 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 disconnected. Leave connector X-016 disconnected. Continue to step 3. 3. Check the throttle valve actuator engine harness (EN) wiring for a short circuit. Disconnect the vehicle harness (VE) from the engine interface connector X-017. With the key in the OFF position, use a multimeter to perform the following continuity check on the engine harness (EN) side : From To Throttle valve actuator connector pin Throttle valve actuator connector pin 6 1 Throttle valve actuator connector pin Throttle valve actuator connector pin 6 2 Throttle valve actuator connector pin Chassis ground 6 All pins in connector X-017 X-017 (Receptacle) pin 37
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Value There should be no continuity. There should be no continuity. There should be no continuity. There should be no continuity.
Electrical systems - FAULT CODES
A. If there is continuity, then there is a short circuit in the throttle valve actuator output 1 h-bridge circuit. Locate and repair the shorted conductor. Repair or replace the harness as required. B. If there is no continuity, then leave connector X-017 disconnected and continue to step 4. 4. Check the throttle valve actuator vehicle harness (VE) wiring for a short circuit. With the key in the OFF position, use a multimeter to perform the following continuity check on the vehicle harness (VE) side : From X-017 (Receptacle) pin 37 X-016 (Receptacle) pin 49
To All pins in connector X-017 All pins in connector X-016
Value There should be no continuity. There should be no continuity.
A. If there is continuity, then there is a short circuit in the throttle valve actuator output 1 h-bridge circuit. Locate and repair the shorted conductor. Repair or replace the harness as required. B. If there is no continuity, then continue to step 5. 5. Replace the throttle valve actuator. Use the Electronic Service Tool (EST) to check the status of this fault. 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. 6. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals, or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 07 SH07-ENGINE F5C T4 (55.100.DP-C.20.E.07) Wiring harnesses - Electrical schematic sheet 11 SH11-ENGINE F5C T4 (55.100.DP-C.20.E.11)
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3822 (DTC 68D-03) - Short circuit to battery of throttle valve H-bridge - low pin A34 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 another voltage 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 another voltage source in the throttle valve actuator output 2 h-bridge circuit. Possible failure modes: 1. Faulty throttle valve actuator wiring, short circuit to another voltage source. 2. Faulty throttle valve actuator, internal failure. 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, then the fault may be intermittent and not currently active. Continue with step 6. 2. Check the throttle valve actuator output 2 h-bridge wiring for a short circuit to battery. Disconnect the engine harness (EN) from the throttle valve actuator. Disconnect the vehicle harness (VE) from the ECU at connector X-016. With the key in the ON position, use a multimeter to perform the following voltage check on the engine harness (EN) side : From To Throttle valve actuator connector pin Chassis ground 2
Value There should be no voltage.
A. If there is voltage, then there is a short circuit to battery in the throttle valve actuator output 2 h-bridge 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 disconnected. Leave connector X-016 disconnected. Continue to step 3. 3. Check the throttle valve actuator engine harness (EN) wiring for a short circuit to another voltage source. Disconnect the vehicle harness (VE) from the engine interface at connector X-017. 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 Throttle valve actuator connector pin Throttle valve actuator connector pin There should be no continuity. 2 6 Throttle valve actuator connector pin Throttle valve actuator connector pin There should be no continuity. 2 1 All pins in connector X-017 There should be no continuity. X-017 (Receptacle) pin 38
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A. If there is continuity, then there is a short circuit in the throttle valve actuator output 2 h-bridge circuit. Locate and repair the shorted conductor. Repair or replace the harness as required. B. If there is no continuity, then leave connector X-017 disconnected and continue to step 4. 4. Check the throttle valve actuator 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 continuity check on the vehicle harness (VE) side : From X-017 (Receptacle) pin 38 X-016 (Receptacle) pin 34
To All pins in connector X-017 All pins in connector X-016
Value There should be no continuity. There should be no continuity.
A. If there is continuity, then there is a short circuit in the throttle valve actuator output 2 h-bridge circuit. Locate and repair the shorted conductor. Repair or replace the harness as required. B. If there is no continuity, then continue to step 5. 5. Replace the throttle valve actuator. Use the Electronic Service Tool (EST) to check the status of this fault. 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. 6. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals, or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 07 SH07-ENGINE F5C T4 (55.100.DP-C.20.E.07) Wiring harnesses - Electrical schematic sheet 11 SH11-ENGINE F5C T4 (55.100.DP-C.20.E.11)
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3823 (DTC 58D-04) - Short circuit to ground of throttle valve H-bridge - high pin A49 Context: The Engine Control Unit (ECU) monitors the throttle valve actuator output 1 and output 2 h-bridge circuits. If the ECU 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. Possible failure modes: 1. Faulty throttle valve actuator wiring, short circuit to ground. 2. Faulty throttle valve actuator, internal failure. 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, then continue with step 2. 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. Check the throttle valve actuator output 1 h-bridge engine harness (EN) wiring for a short circuit to ground. Disconnect the engine harness from the throttle valve actuator. Disconnect the vehicle harness (VE) from the engine interface connector X-017. With the key in the OFF position, use a multimeter to perform the following continuity check on the engine harness (EN) side : From Throttle valve actuator connector pin 6 Throttle valve actuator connector pin 6 Throttle valve actuator connector pin 6 X-017 (Receptacle) pin 37
To Chassis ground
Value There should be no continuity.
Throttle valve actuator connector pin There should be no continuity. 2 Throttle valve actuator connector pin There should be no continuity. 3 All pins in connector X-017 There should be no continuity.
A. If there is continuity, then there is a short circuit in the throttle valve actuator output 1 h-bridge circuit. 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 disconnected. Leave connector X-017 disconnected. Continue to step 3. 3. Check the throttle valve actuator output 1 h-bridge vehicle harness (VE) wiring for a short circuit to ground. Disconnect the ECU connector X-016. 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 X-017 (Receptacle) pin 37 X-016 (Receptacle) pin 49
To All pins in connector X-017 All pins in connector X-016
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Value There should be no continuity. There should be no continuity.
Electrical systems - FAULT CODES
A. If there is continuity, then there is a short circuit in the throttle valve actuator output 1 h-bridge circuit. 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 disconnected and continue to step 4. 4. Replace the throttle valve actuator. Use the Electronic Service Tool (EST) to check the status of this fault. 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. 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. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 07 SH07-ENGINE F5C T4 (55.100.DP-C.20.E.07) Wiring harnesses - Electrical schematic sheet 11 SH11-ENGINE F5C T4 (55.100.DP-C.20.E.11)
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3824 (DTC 68D-04) - Short circuit to ground of throttle valve H-bridge - low pin A34 Context: The Engine Control Unit (ECU) monitors the throttle valve actuator output 1 and output 2 h-bridge circuits. If the ECU 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 circuit to ground in the throttle valve actuator output 2 h-bridge circuit. Possible failure modes: 1. Faulty throttle valve actuator wiring, short circuit to ground. 2. Faulty throttle valve actuator, internal failure. 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, then continue with step 2. 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. Check the throttle valve actuator output 2 h-bridge engine harness (EN) wiring for a short circuit to ground. Disconnect the engine harness (EN) from the throttle valve actuator. Disconnect the vehicle harness (VE) from the engine interface at connector X-017. With the key in the OFF position, use a multimeter to perform the following continuity check on the engine harness (EN) side : From Throttle valve actuator connector pin 2 Throttle valve actuator connector pin 2 Throttle valve actuator connector pin 2 X-017 (Receptacle) pin 38
To Chassis ground
Value There should be no continuity.
Throttle valve actuator connector pin There should be no continuity. 3 Throttle valve actuator connector pin There should be no continuity. 6 All pins in connector X-017 There should be no continuity.
A. If there is continuity, then there is a short circuit in the throttle valve actuator output 2 h-bridge circuit. 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 disconnected. Leave connector X-017 disconnected. Continue to step 3. 3. Check the throttle valve actuator output 2 h-bridge vehicle harness (VE) wiring for a short circuit to ground. Disconnect the vehicle harness (VE) from the ECU at connector X-016. With the key in the OFF position, use a multimeter to perform the following continuity check on the vehicle harness (VE) side : From X-017 (Receptacle) pin 38 X-016 (Receptacle) pin 34
To All pins in connector X-017 All pins in connector X-016
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Value There should be no continuity. There should be no continuity.
Electrical systems - FAULT CODES
A. If there is continuity, then there is a short circuit in the throttle valve actuator output 2 h-bridge circuit. Locate and repair the shorted conductor. Repair or replace the harness as required. B. If there is no continuity, then continue to step 4. 4. Replace the throttle valve actuator. Use the Electronic Service Tool (EST) to check the status of this fault. 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. 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. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 07 SH07-ENGINE F5C T4 (55.100.DP-C.20.E.07) Wiring harnesses - Electrical schematic sheet 11 SH11-ENGINE F5C T4 (55.100.DP-C.20.E.11)
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3825 (DTC 78D-03) - Short circuit over load error for throttle valve 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. Possible failure modes: 1. Faulty throttle valve actuator h-bridge wiring, short circuit. 2. Faulty throttle valve actuator, internal failure. 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, then continue with step 2. 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. Check the throttle valve actuator h-bridge circuits engine harness (EN) wiring for a short circuit. Disconnect the engine harness (EN) from the throttle valve actuator. Disconnect the vehicle harness (VE) from the engine interface at connector X-017. 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 Throttle valve actuator connector pin Throttle valve actuator connector pin There should be no continuity. 2 6 A. If there is continuity, then there is a short circuit in the throttle valve actuator h-bridge wiring. Locate and repair the shorted conductor. Repair or replace the harness as required. 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. Disconnect the vehicle harness (VE) from the ECU at connector X-016. With the key in the OFF position, use a multimeter to perform the following continuity check on the vehicle harness (VE) side : From X-017 (Receptacle) pin 37
To X-017 (Receptacle) pin 38
Value There should be no continuity.
A. If there is continuity, then there is a short circuit in the throttle valve actuator h-bridge wiring. Locate and repair the shorted conductor. Repair or replace the harness as required. B. If there is no continuity, then leave the connectors disconnected and continue to step 4. 4. Replace the throttle valve actuator.
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Use the Electronic Service Tool (EST) to check the status of this fault. 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. 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. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 07 SH07-ENGINE F5C T4 (55.100.DP-C.20.E.07) Wiring harnesses - Electrical schematic sheet 11 SH11-ENGINE F5C T4 (55.100.DP-C.20.E.11)
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3827 (DTC 78D-04) - Under voltage error for throttle valve H-bridge Context: The Engine Control Unit (ECU) internally monitors the operation of the H-bridge Pulse Width Modulated (PWM) control circuit for the Throttle Valve Actuator (TVA) motor actuator for electrical defects. If the ECU senses that an output driver supply voltage is too low, then this fault will occur. Cause: The ECU is sensing too high a system voltage fluctuation. Solution: 1. Verify that the fault is present and active. Use the Electronic Service Tool (EST) to check the status of this fault. A. If the fault is present and active, continues with step 2. 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 4. 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. 3. 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. 4. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals, or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 07 SH07-ENGINE F5C T4 (55.100.DP-C.20.E.07) Wiring harnesses - Electrical schematic sheet 11 SH11-ENGINE F5C T4 (55.100.DP-C.20.E.11)
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3834 (DTC 78B-03) - Throttle valve position sensor voltage above threshold (Short to battery) 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, then this fault will occur. Cause: The ECU has detected a voltage greater than 4.75 V in the throttle valve actuator position sensor signal circuit. Possible failure modes: 1. Faulty throttle valve actuator wiring, short circuit to another voltage source. 2. Faulty throttle valve actuator, internal failure. 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, then continue with step 2. 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 7. 2. Check the throttle valve actuator position sensor wiring for a short circuit to battery. Disconnect the engine harness (EN) from the throttle valve actuator. Disconnect the vehicle harness (VE) from the engine interface at connector X-017. Disconnect the vehicle harness (VE) from the ECU at connector X-016. With the key in the ON position, use a multimeter to perform the following voltage check on the engine harness (EN) side : From To Throttle valve actuator connector pin Chassis ground 5
Value There should be no voltage.
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. B. If there is no voltage, then leave the throttle valve actuator disconnected. Leave connector X-017 and X-016 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 connector pin X-017 (Receptacle) pin 42 There should be continuity. 5 There should be continuity. X-017 (Receptacle) pin 42 X-016 (Receptacle) pin 53 NOTE: Wiggle the harness during measurement to reveal an intermittent connection. A. If there is no continuity, then there is an open circuit in the throttle valve actuator position sensor signal circuit. Locate and repair the broken conductor. Repair or replace the harness as required. B. If there is continuity, then continue to step 4. 48068130 29/01/2018
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4. Check the throttle valve actuator position sensor engine harness (EN) wiring for a short circuit. . With the key in the OFF position, use a multimeter to perform the following continuity check on the engine harness (EN) side : From To Throttle valve actuator connector pin Throttle valve actuator connector pin 5 6 Throttle valve actuator connector pin Throttle valve actuator connector pin 5 2 Throttle valve actuator connector pin Throttle valve actuator connector pin 5 1 All pins in connector X-017 X-017 (Receptacle) pin 42
Value There should be no continuity. There should be no continuity. There should be no continuity. There should be no continuity.
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. B. If there is no continuity, then continue to step 5. 5. Check the throttle valve actuator position sensor vehicle harness (VE) wiring for a short circuit. . With the key in the OFF position, use a multimeter to perform the following continuity check on the vehicle harness (VE) side : From X-017 (Receptacle) pin 42 X-016 (Receptacle) pin 53
To All pins in connector X-017 All pins in connector X-016
Value There should be no continuity. There should be no continuity.
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. B. If there is no continuity, then continue to step 5. 6. Replace the throttle valve actuator. Use the Electronic Service Tool (EST) to check the status of this fault. 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. 7. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals, or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 07 SH07-ENGINE F5C T4 (55.100.DP-C.20.E.07) Wiring harnesses - Electrical schematic sheet 11 SH11-ENGINE F5C T4 (55.100.DP-C.20.E.11)
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3835 (DTC 78B-04) - Throttle valve position sensor voltage below threshold (Short to ground) 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. Possible failure modes: 1. Faulty throttle valve actuator wiring, short circuit to ground. 2. Faulty throttle valve actuator, internal failure. 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, then the fault may be intermittent and not currently active. Continue with step 5. 2. Check the throttle valve actuator position sensor engine harness (EN) wiring for a short circuit to ground. Disconnect the engine harness (EN) from the throttle valve actuator. Disconnect the vehicle harness (VE) from the engine interface at connector X-017. With the key in the OFF position, use a multimeter to perform the following continuity check on the engine harness (EN) side : From To Throttle valve actuator connector pin Chassis ground 5 Throttle valve actuator connector pin Throttle valve actuator connector pin 5 3 Throttle valve actuator connector pin Throttle valve actuator connector pin 5 2 All pins in connector X-017 X-017 (Receptacle) pin 42
Value There should be no continuity. There should be no continuity. There should be no continuity. 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 disconnected. Leave connector X-017 disconnected. Continue to step 3. 3. Check the throttle valve actuator position sensor vehicle harness (VE) wiring for a short circuit to ground. Disconnect the vehicle harness from the ECU at connector X-016. With the key in the OFF position, use a multimeter to perform the following continuity check on the vehicle harness (VE) side : From X-017 (Receptacle) pin 42 X-016 (Receptacle) pin 53
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Value There should be no continuity. There should be no continuity.
Electrical systems - FAULT CODES
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 disconnected and continue to step 4. 4. Replace the throttle valve actuator. Use the Electronic Service Tool (EST) to check the status of this fault. 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. 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. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 07 SH07-ENGINE F5C T4 (55.100.DP-C.20.E.07) Wiring harnesses - Electrical schematic sheet 11 SH11-ENGINE F5C T4 (55.100.DP-C.20.E.11)
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3838 (DTC 3F6-03) - OxiCat upstream temperature sensor : Diagnostic fault check for SRC high in Oxidation Catalyst upstream temperature Context: The Engine Control Unit (ECU) monitors the Diesel Oxidation Catalyst (DOC) inlet temperature sensor. If the ECU detects a voltage greater than 3.59 V in the diesel oxidation catalyst inlet temperature sensor signal circuit, then this fault will occur. Cause: The ECU has detected a voltage greater than 3.59 V in the diesel oxidation catalyst inlet temperature sensor signal circuit. For more information regarding the technical specifications of the DOC inlet 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). Possible failure modes: 1. Faulty diesel oxidation catalyst inlet temperature sensor wiring, short circuit to another voltage source. 2. Faulty diesel oxidation catalyst inlet temperature sensor wiring, open circuit. 3. Faulty diesel oxidation catalyst inlet temperature sensor, internal failure. 4. 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, then continue with step 2. 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 6. 2. Check the diesel oxidation catalyst inlet temperature sensor for an internal failure. Disconnect the engine harness (EN) from the diesel oxidation catalyst inlet temperature sensor. Use a multimeter to measure the resistance on the diesel oxidation catalyst inlet temperature sensor B-9127 : From Diesel oxidation catalyst inlet temperature sensor pin 1
To Diesel oxidation catalyst inlet temperature sensor pin 2
Value There should be between 170.2 – 849.7 Ω.
A. If there is between 170.2 – 849.7 Ω, then leave the diesel oxidation catalyst inlet temperature sensor disconnected and continue to step 3. B. If there is not between 170.2 – 849.7 Ω, then the diesel oxidation catalyst inlet temperature sensor has failed. Replace the diesel oxidation catalyst inlet temperature sensor and retest. 3. Check the diesel oxidation catalyst inlet temperature sensor vehicle harness (VE) wiring for a short circuit. With the key in the OFF position, use a multimeter to perform the following voltage check on the vehicle harness side : From To Diesel oxidation catalyst inlet Chassis ground temperature sensor connector pin 1
Value There should be no voltage.
A. If there is voltage, then there is a short circuit to battery in the diesel oxidation catalyst inlet temperature sensor wiring. Locate and repair the shorted conductor. Repair or replace the harness as required.
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B. If there is no voltage, then leave the diesel oxidation catalyst inlet temperature sensor disconnected and continue to step 4. 4. Check the diesel oxidation catalyst inlet temperature sensor vehicle harness (VE) wiring for an open circuit. Disconnect the vehicle harness (VE) from the ECU at connector X-012. With the key in the OFF position, use a multimeter to perform the following continuity check on the vehicle harness (VE) side : From To Diesel oxidation catalyst inlet X-012 (Receptacle) pin 84 temperature sensor connector pin 1 Diesel oxidation catalyst inlet X-012 (Receptacle) pin 83 temperature sensor connector pin 2
Value There should be continuity. There should be continuity.
A. If there is no continuity, then there is an open circuit in the diesel oxidation catalyst inlet temperature sensor vehicle harness (VE) wiring. Locate and repair the broken conductor. Repair or replace the harness as required. B. If there is continuity, leave connector X-012 disconnected and continue to step 5. 5. Check the diesel oxidation catalyst inlet temperature sensor vehicle harness (VE) 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 connectors from : From X-012 (Receptacle) pin 84
To All pins in connector X-012
Value There should be no continuity.
A. If there is continuity, then there is a short circuit in the diesel oxidation catalyst inlet temperature sensor vehicle harness (VE) wiring. Locate and repair the shorted 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. 6. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals, or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 07 SH07-ENGINE F5C T4 (55.100.DP-C.20.E.07) Wiring harnesses - Electrical schematic sheet 11 SH11-ENGINE F5C T4 (55.100.DP-C.20.E.11)
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3839 (DTC 3F6-04) - OxiCat upstream temperature sensor : Diagnostic fault check for SRC low in Oxidation Catalyst upstream temperature Context: The Engine Control Unit (ECU) monitors the Diesel Oxidation Catalyst (DOC) inlet temperature sensor. If the ECU detects a voltage less than 459.40 mV in the diesel oxidation catalyst inlet temperature sensor signal circuit, then this fault will occur. Cause: The ECU has detected a voltage less than 459.40 mV in the diesel oxidation catalyst inlet temperature sensor signal circuit. For more information regarding the technical specifications of the DOC inlet 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). Possible failure modes: 1. Faulty diesel oxidation catalyst inlet temperature sensor wiring, short circuit to ground. 2. Faulty diesel oxidation catalyst inlet temperature sensor, internal failure. 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, then continue with step 2. 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. Check the diesel oxidation catalyst inlet temperature sensor for an internal failure. Disconnect the engine harness (EN) from the diesel oxidation catalyst inlet temperature sensor. Use a multimeter to measure the resistance on the diesel oxidation catalyst inlet temperature sensor : From Diesel oxidation catalyst inlet temperature sensor pin 1
To Diesel oxidation catalyst inlet temperature sensor pin 2
Value There should be between 170.2 – 849.7 Ω.
A. If there is between 170.2 – 849.7 Ω, then leave the diesel oxidation catalyst inlet temperature sensor disconnected and continue to step 3. B. If there is not between 170.2 – 849.7 Ω, then the diesel oxidation catalyst inlet temperature sensor has failed. Replace the diesel oxidation catalyst inlet temperature sensor and retest. 3. Check the diesel oxidation catalyst inlet temperature sensor vehicle harness (VE) wiring for a short circuit. Disconnect the engine harness from the diesel oxidation catalyst inlet temperature sensor. 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 Diesel oxidation catalyst inlet Diesel oxidation catalyst inlet There should be no continuity. temperature sensor connector pin 1 temperature sensor connector pin 2 Diesel oxidation catalyst inlet There should be no continuity. Chassis ground temperature sensor connector pin 1
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A. If there is continuity, then there is a short circuit in the diesel oxidation catalyst inlet temperature sensor 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 diesel oxidation catalyst inlet temperature sensor disconnected and continue to step 4. 4. Check the diesel oxidation catalyst inlet temperature sensor vehicle harness (VE) wiring for a short circuit. Disconnect the vehicle harness (VE) from the ECU at connector X-012. With the key in the OFF position, use a multimeter to perform the following continuity check on the vehicle harness (VE) side : From X-012 (Receptacle) pin 84
To All pins in connector X-012
Value There should be no continuity.
A. If there is continuity, then there is a short circuit in the diesel oxidation catalyst inlet temperature sensor vehicle harness (VE) wiring. Locate and repair the shorted 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. 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. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 07 SH07-ENGINE F5C T4 (55.100.DP-C.20.E.07) Wiring harnesses - Electrical schematic sheet 11 SH11-ENGINE F5C T4 (55.100.DP-C.20.E.11)
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3840 (DTC 1F7-03) - Diesel Particulate filter upstream temperature sensor : Diagnostic fault check for SRC high Context: The Engine Control Unit (ECU) monitors the Particulate Matter (PM) catalytic converter inlet temperature sensor. If the ECU detects a voltage greater than 3.59 V in the PM catalytic converter inlet temperature sensor signal circuit, then this fault will occur. If this fault is active, the last valid temperature value will be frozen for a preliminary failure or set to a fixed replacement value of 99.96 °C (211.93 °F) if the failure is validated. Cause: The ECU has detected a voltage greater than 3.59 V in the PM catalytic converter inlet temperature sensor signal circuit. Possible failure modes: 1. Faulty PM catalytic converter inlet temperature sensor wiring, short circuit to another voltage source. 2. Faulty PM catalytic converter inlet temperature sensor, internal failure. 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, then continue with step 2. 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 6. 2. Check the PM catalytic converter inlet temperature sensor for an internal failure. Disconnect the vehicle harness from the PM catalytic converter inlet temperature sensor. Use a multimeter to measure the resistance on the PM catalytic converter inlet temperature sensor : From PM catalytic converter inlet temperature sensor pin 1
To PM catalytic converter inlet temperature sensor pin 2
Value There should be between 170.2 – 849.7 Ω.
A. If there is between 170.2 – 849.7 Ω, then leave the PM catalytic converter inlet temperature sensor disconnected and continue to step 3. B. If there is not between 170.2 – 849.7 Ω, then the PM catalytic converter inlet temperature sensor has failed. Replace the PM catalytic converter inlet temperature sensor and retest. 3. Check the PM catalytic converter inlet temperature sensor vehicle harness (VE) 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 vehicle harness side : From To PM catalytic converter inlet Chassis ground temperature sensor connector pin 2
Value There should be no voltage.
With the key in the ON position, use a multimeter to perform the following voltage check on the vehicle harness side : From To PM catalytic converter inlet Chassis ground temperature sensor connector pin 2
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Value There should be less than 5.5 V.
Electrical systems - FAULT CODES
A. If the specified values are not measured, then there is a short circuit to battery in the PM catalytic converter inlet temperature 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 PM catalytic converter inlet temperature sensor disconnected and continue to step 4. 4. Check the PM catalytic converter inlet temperature sensor vehicle harness (VE) wiring for an open circuit. Disconnect the vehicle harness from the ECU at connector X-012. With the key in the OFF position, use a multimeter to perform the following continuity check on the vehicle harness (VE) side : From To PM catalytic converter inlet X-012 (Receptacle) pin 80 temperature sensor connector pin 2 PM catalytic converter inlet X-012 (Receptacle) pin 79 temperature sensor connector pin 1
Value There should be continuity. There should be continuity.
A. If there is no continuity, then there is an open circuit in the PM catalytic converter inlet temperature 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 PM catalytic converter inlet temperature sensor disconnected. Leave connector X-012 and disconnected. Continue to step 5. 5. Check the PM catalytic converter inlet temperature sensor vehicle harness (VE) wiring for a short circuit. With the key in the OFF position, use a multimeter to perform the following continuity check on the vehicle harness (VE) side : From X-012 (Receptacle) pin 80 X-012 (Receptacle) pin 79
To All pins in connector X-012 All pins in connector X-012
Value There should be no continuity. There should be no continuity.
A. If there is continuity, then there is a short circuit in the PM catalytic converter inlet temperature sensor vehicle harness (VE) wiring. Locate and repair the shorted conductor. B. If there is no continuity, then check the ECU for the appropriate software and re-flash, if necessary. 6. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals, or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 07 SH07-ENGINE F5C T4 (55.100.DP-C.20.E.07) Wiring harnesses - Electrical schematic sheet 11 SH11-ENGINE F5C T4 (55.100.DP-C.20.E.11)
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3841 (DTC 1F7-04) - Diesel Particulate filter upstream temperature sensor : Diagnostic fault check for SRC low Context: The Engine Control Unit (ECU) monitors the Particulate Matter (PM) catalytic converter inlet temperature sensor. If the ECU detects a voltage less than 459.40 mV in the PM catalytic converter inlet temperature sensor signal circuit, then this fault will occur. If this fault is active, the last valid temperature value will be frozen for a preliminary failure or set to a fixed replacement value of 99.96 °C (211.93 °F) if the failure is validated. Cause: The ECU has detected a voltage less than 459.40 mV in the PM catalytic converter inlet temperature sensor signal circuit. Possible failure modes: 1. Faulty PM catalytic converter inlet temperature sensor wiring, short circuit to ground. 2. Faulty PM catalytic converter inlet temperature sensor, internal failure. 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, then continue with step 2. 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. Check the PM catalytic converter inlet temperature sensor for an internal failure. Disconnect the vehicle harness from the PM catalytic converter inlet temperature sensor. Use a multimeter to measure the resistance on the PM catalytic converter inlet temperature sensor pins : From PM catalytic converter inlet temperature sensor pin 1
To PM catalytic converter inlet temperature sensor pin 2
Value There should be between 170.2 – 849.7 Ω.
A. If there is between 170.2 – 849.7 Ω, then leave the PM catalytic converter inlet temperature sensor disconnected and continue to step 3. B. If there is not between 170.2 – 849.7 Ω, then the PM catalytic converter inlet temperature sensor has failed. Replace the PM catalytic converter inlet temperature sensor and retest. 3. Check the PM catalytic converter inlet temperature sensor vehicle harness (VE) wiring for a short circuit. With the key in the OFF position, use a multimeter to perform the following continuity check on vehicle harness (VE) side : From To PM catalytic converter inlet PM catalytic converter inlet temperature sensor connector pin 2 temperature sensor pin 1 PM catalytic converter inlet Chassis ground temperature sensor connector pin 2
Value There should be no continuity. There should be no continuity.
A. If there is continuity, there is a short circuit in the PM catalytic converter inlet temperature sensor vehicle harness (VE) wiring. Locate and repair the shorted conductor. Repair or replace the harness as required. B. If there is no continuity, leave the connectors disconnected and continue to step 4.
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4. Check the PM catalytic converter inlet temperature sensor vehicle harness (VE) wiring for a short circuit. Disconnect the vehicle harness from the ECU at connector X-012. With the key in the OFF position, use a multimeter to perform the following continuity check at the vehicle harness (VE) side of the connectors from : From X-012 (Receptacle) pin 80
To All pins in connector X-012
Value There should be no continuity.
A. If there is continuity, then there is a short circuit in the PM catalytic converter inlet temperature sensor vehicle harness (VE) wiring. Locate and repair the shorted 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. 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. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 07 SH07-ENGINE F5C T4 (55.100.DP-C.20.E.07) Wiring harnesses - Electrical schematic sheet 11 SH11-ENGINE F5C T4 (55.100.DP-C.20.E.11)
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3842 (DTC 29B-03) - Turbine upstream temperature sensor : 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. Possible failure modes: 1. Faulty exhaust manifold temperature sensor circuit wiring, short circuit to another voltage source. 2. Faulty exhaust manifold temperature sensor circuit wiring, open circuit. 3. Faulty exhaust manifold temperature sensor, internal failure. 4. 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, then continue with step 2. 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 7. 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 Exhaust manifold temperature sensor pin 1
To Exhaust manifold temperature sensor pin 2
Value There should be between 170.2 – 849.7 Ω.
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 and retest. 3. Check the exhaust manifold temperature sensor engine harness (EN) wiring. With the key in the OFF position, use a multimeter to perform the following voltage check on the engine harness (EN) side : From Exhaust manifold temperature sensor connector pin 1
To Chassis ground
Value There should be no voltage.
With the key in the ON position, use a multimeter to perform the following voltage check on the engine harness (EN) side :
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From Exhaust manifold temperature sensor connector pin 1
To Chassis ground
Value 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 temperature 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-017. Disconnect the vehicle harness (VE) from the ECU at connector X-016. With the key in the OFF position, use a multimeter to perform the following continuity check on the engine harness (EN) side : From Exhaust manifold temperature sensor connector pin 1 Exhaust manifold temperature sensor connector pin 2
To X-017 (Receptacle) pin 26
Value There should be continuity.
X-017 (Receptacle) pin 25
There should be continuity.
With the key in the OFF position, use a multimeter to perform the following continuity check on the vehicle harness (VE) side : From X-017 (Receptacle) pin 26 X-017 (Receptacle) pin 25
To X-012 (Receptacle) pin 82 X-012 (Receptacle) pin 81
Value There should be continuity. There should be continuity.
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 shorted conductor. Repair or replace the harness as required. B. If there is continuity on both checks, then leave connector X-017 and connector X-016 disconnected and continue to step 5. 5. Check the exhaust manifold temperature sensor engine harness (EN) wiring. With the key in the OFF position, use a multimeter to perform the following continuity check at the engine harness (EN) side : From X-017 (Receptacle) pin 26 X-017 (Receptacle) pin 25
To All pins in connector X-017 All pins in connector X-017
Value There should be no continuity. There should be no continuity.
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. B. If there is no continuity, then continue to step 6. 6. Check the exhaust manifold temperature sensor vehicle harness (VE) wiring. With the key in the OFF position, use a multimeter to perform the following continuity check on the vehicle harness (VE) side : From X-017 (Receptacle) pin 26 X-017 (Receptacle) pin 25 X-012 (Receptacle) pin 82 X-012 (Receptacle) pin 81
To All pins in connector X-017 All pins in connector X-017 All pins in connector X-012 All pins in connector X-012 48068130 29/01/2018
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Value There should be no continuity. There should be no continuity. There should be no continuity. There should be no continuity.
Electrical systems - FAULT CODES
A. If there is continuity, then there is a short circuit in the exhaust manifold temperature sensor signal circuit in 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. 7. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals, or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 07 SH07-ENGINE F5C T4 (55.100.DP-C.20.E.07) Wiring harnesses - Electrical schematic sheet 11 SH11-ENGINE F5C T4 (55.100.DP-C.20.E.11)
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3843 (DTC 29B-04) - Turbine upstream temperature sensor : 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). Possible failure modes: 1. Faulty exhaust manifold temperature sensor wiring, short circuit to ground. 2. Faulty exhaust manifold temperature sensor, internal failure. 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, then continue with step 2. 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. 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 Exhaust manifold temperature sensor pin 1
To Exhaust manifold temperature sensor pin 2
Value There should be between 170.2 – 849.7 Ω.
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 and retest. 3. Check the exhaust manifold temperature sensor engine harness (EN) wiring. Disconnect the vehicle harness (VE) from the engine interface connector X-017. With the key in the OFF position, use a multimeter to perform the following continuity check on the engine harness (EN) side : From X-017 (Receptacle) pin 26 X-017 (Receptacle) pin 26
To X-017 (Receptacle) pin 25 All pins in connector X-017
Value There should be no continuity. There should be no continuity.
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.
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B. If there is no continuity, then leave connector X-017 disconnected and continue to step 4. 4. Check the exhaust manifold temperature sensor vehicle harness (VE) wiring. Disconnect the vehicle harness (VE) from the ECU at connector X-016. With the key in the OFF position, use a multimeter to perform the following continuity check on the vehicle harness (VE) side : From X-017 (Receptacle) pin 26 X-017 (Receptacle) pin 26 X-012 (Receptacle) pin 82
To X-017 (Receptacle) pin 25 All pins in connector X-017 All pins in connector X-012
Value There should be no continuity. There should be no continuity. There should be no continuity.
A. If there is continuity, there is a short circuit in the exhaust manifold temperature sensor signal circuit in the vehicle harness (VE) wiring. Locate and repair the shorted conductor. Repair or replace the harness as required. B. If there is no continuity, then check the ECU for the appropriate service manual and re-flash, if necessary. 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. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 07 SH07-ENGINE F5C T4 (55.100.DP-C.20.E.07) Wiring harnesses - Electrical schematic sheet 11 SH11-ENGINE F5C T4 (55.100.DP-C.20.E.11)
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3844 (DTC 25A-03) - Zero Fuel Calibration by Lambda (ZFL) : DFC reporting error state on comparing energizing time to Max value injector 1 Context: The Zero Fuel Calibration (ZFL) evaluates energizing time for injectors at low idle. The ZFL uses learned calibration values to change the energizing time of the pilot fuel injection. If the Engine Control Unit (ECU) determines that there is an error during this process, then this fault will occur. Cause: The ECU has determined that there is an error in the ZFL process for fuel injector number 1. Solution: 1. Verify that the correct IMA injector code has been programmed to injector number 1. A. If the correct IMA code is present, then continue to step 2. B. If the correct IMA code has not been uploaded, then program the correct IMA code. 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. Use the Electronic Service Tool (EST) to verify the status of this fault. A. If the fault has been resolved, then return the machine to service. B. If the fault has not been resolved, then continue to step 3. 3. 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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3845 (DTC 35A-03) - Zero Fuel Calibration by Lambda (ZFL) : DFC reporting error state on comparing energizing time to Max value injector 2 Context: The Zero Fuel Calibration (ZFL) evaluates energizing time for injectors at low idle. The ZFL uses learned calibration values to change the energizing time of the pilot fuel injection. If the Engine Control Unit (ECU) determines that there is an error during this process, then this fault will occur. Cause: The ECU has determined that there is an error in the ZFL process for fuel injector number 2. Solution: 1. Verify that the correct IMA injector code has been programmed to injector number 2. A. If the correct IMA code is present, then continue to step 2. B. If the correct IMA code has not been uploaded, then program the correct IMA code. 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 2. Use the Electronic Service Tool (EST) to verify the status of this fault. A. If the fault has been resolved, then return the machine to service. B. If the fault has not been resolved, then continue to step 3. 3. 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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3846 (DTC 45A-03) - Zero Fuel Calibration by Lambda (ZFL) : DFC reporting error state on comparing energizing time to Max value injector 3 Context: The Zero Fuel Calibration (ZFL) evaluates energizing time for injectors at low idle. The ZFL uses learned calibration values to change the energizing time of the pilot fuel injection. If the Engine Control Unit (ECU) determines that there is an error during this process, then this fault will occur. Cause: The ECU has determined that there is an error in the ZFL process for fuel injector number 3. Solution: 1. Verify that the correct IMA injector code has been programmed to injector number 3. A. If the correct IMA code is present, then continue to step 2. B. If the correct IMA code has not been uploaded, then program the correct IMA code. 2. Replace the fuel injector number 3. Use the Electronic Service Tool (EST) to verify the status of this fault, 3846 (DTC 45A-03) â&#x20AC;&#x201C; Zero Fuel Calibration by Lambda (ZFL) : DFC reporting error state on comparing energizing time to Max value injector 3. A. If the fault has been resolved, then return the machine to service. B. If the fault has not been resolved, then continue to step 3. 3. 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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3847 (DTC 55A-03) - Zero Fuel Calibration by Lambda (ZFL) : DFC reporting error state on comparing energizing time to Max value injector 4 Context: The Zero Fuel Calibration (ZFL) evaluates energizing time for injectors at low idle. The ZFL uses learned calibration values to change the energizing time of the pilot fuel injection. If the Engine Control Unit (ECU) determines that there is an error during this process, then this fault will occur. Cause: The ECU has determined that there is an error in the ZFL process for fuel injector number 4. Solution: 1. Verify that the correct IMA injector code has been programmed to injector number 4. A. If the correct IMA code is present, then continue to step 2. B. If the correct IMA code has not been uploaded, then program the correct IMA code. 2. Replace the fuel injector number 4. Use the Electronic Service Tool (EST) to verify the status of this fault, 3847 (DTC 55A-03) â&#x20AC;&#x201C; Zero Fuel Calibration by Lambda (ZFL) : DFC reporting error state on comparing energizing time to Max value injector 4. A. If the fault has been resolved, then return the machine to service. B. If the fault has not been resolved, continue to step 3. 3. 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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3848 (DTC 25A-04) - Zero Fuel Calibration by Lambda (ZFL) : DFC reporting error state on comparing energizing time to Min value injector 1 Context: The Zero Fuel Calibration (ZFL) evaluates energizing time for injectors at low idle. The ZFL uses learned calibration values to change the energizing time of the pilot fuel injection. If the Engine Control Unit (ECU) determines that there is an error during this process, then this fault will occur. Cause: The ECU has determined that there is an error in the ZFL process for fuel injector number 1. Solution: 1. Verify that the correct IMA injector code has been programmed to injector number 1. A. If the correct IMA code is present, then continue to step 2. B. If the correct IMA code has not been uploaded, the program the correct IMA code. 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. Use the Electronic Service Tool (EST) to verify the status of this fault. A. If the fault has been resolved, then return the machine to service. B. If the fault has not been resolved, then continue to step 3. 3. 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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3849 (DTC 35A-04) - Zero Fuel Calibration by Lambda (ZFL) : DFC reporting error state on comparing energizing time to Min value injector 2 Context: The Zero Fuel Calibration (ZFL) evaluates energizing time for injectors at low idle. The ZFL uses learned calibration values to change the energizing time of the pilot fuel injection. If the Engine Control Unit (ECU) determines that there is an error during this process, this fault will occur. Cause: The ECU has determined that there is an error in the ZFL process for fuel injector number 2. Solution: 1. Verify that the correct IMA injector code has been programmed to injector number 2. A. If the correct IMA code is present, then continue to step 2. B. If the correct IMA code has not been uploaded, then program the correct IMA code. 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 2. Use the Electronic Service Tool (EST) to verify the status of this fault. A. If the fault has been resolved, then return the machine to service. B. If the fault has not been resolved, then continue to step 3. 3. 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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3850 (DTC 45A-04) - Zero Fuel Calibration by Lambda (ZFL) : DFC reporting error state on comparing energizing time to Min value injector 3 Context: The Zero Fuel Calibration (ZFL) evaluates energizing time for injectors at low idle. The ZFL uses learned calibration values to change the energizing time of the pilot fuel injection. If the Engine Control Unit (ECU) determines that there is an error during this process, then this fault will occur. Cause: The ECU has determined that there is an error in the ZFL process for fuel injector number 3. Solution: 1. Verify that the correct IMA injector code has been programmed to injector number 3. A. If the correct IMA code is present, then continue to step 2. B. If the correct IMA code has not been uploaded, then program the correct IMA code. 2. Replace the fuel injector number 3. Use the Electronic Service Tool (EST) to verify the status of this fault, 3850 (DTC 45A-04) â&#x20AC;&#x201C; Zero Fuel Calibration by Lambda (ZFL) : DFC reporting error state on comparing energizing time to Min value injector 3. A. If the fault has been resolved, then return the machine to service. B. If the fault has not been resolved, then continue to step 3. 3. 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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3851 (DTC 55A-04) - Zero Fuel Calibration by Lambda (ZFL) : DFC reporting error state on comparing energizing time to Min value injector 4 Context: The Zero Fuel Calibration (ZFL) evaluates energizing time for injectors at low idle. The ZFL uses learned calibration values to change the energizing time of the pilot fuel injection. If the Engine Control Unit (ECU) determines that there is an error during this process, this fault will occur. Cause: The ECU has determined that there is an error in the ZFL process for fuel injector number 4. Solution: 1. Verify that the correct IMA injector code has been programmed to injector number 4. A. If the correct IMA code is present, then continue to step 2. B. If the correct IMA code has not been uploaded, then program the correct IMA code. 2. Replace the fuel injector number 4. Use the Electronic Service Tool (EST) to verify the status of this fault, 3851 (DTC 55A-04) â&#x20AC;&#x201C; Zero Fuel Calibration by Lambda (ZFL) : DFC reporting error state on comparing energizing time to Min value injector 4. A. If the fault has been resolved, then return the machine to service. B. If the fault has not been resolved, then continue to step 3. 3. 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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3870 (DTC 1B4-02) - CAN Bus Received frames : CAN-ReceiveFrame BC2EDC1 NOTE: It is normal to log Controller Area Network (CAN) fault codes while the control module is being programmed. In this case, clear the fault codes from the modules and retest the system. NOTE: Check for multiple CAN fault codes. If there are CAN Bus fault codes, check the entire CAN bus circuit. Context: The Engine Control Unit (ECU) 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 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. If the ECU senses that CAN Node A Bus is not functioning properly, this fault will occur. Cause: The ECU has sensed a time out of required vehicle controller data provided on CAN Node A. Possible failure modes: 1. Faulty supply voltage or ground, missing. 2. Faulty CAN circuit wiring, open circuit, short circuit to ground, or short circuit. 3. Faulty ECU, termination resistor or software. Solution: 1. Verify fault is present and in active state. Use the Electronic Service Tool (EST) to check the status of this fault. A. If the fault is 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 6. 2. Check for other vehicle CAN faults. Use the EST to determine if vehicle CAN faults exist. A. If other vehicle CAN faults exist, then resolve the vehicle CAN faults, then check to see that 3870 (DTC 1B4-02) â&#x20AC;&#x201C; CAN Bus Received frames : CAN-Receive-Frame BC2EDC1 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-012. With the key switch in the ON position, use a multimeter to check for voltage on the vehicle (VE) harness side : From X-012 (Receptacle) pin 1 X-012 (Receptacle) pin 3 X-012 (Receptacle) pin 5
To Chassis ground Chassis ground Chassis ground
Value There should be 12.0 V. There should be 12.0 V. There should be 12.0 V.
A. If the voltage is present on all of the checks, then leave connector X-012 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 replace the harness as required. 4. Check the ECU grounding.
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With the key switch in the OFF position, use a multimeter to check for continuity on the vehicle (VE) harness side: From X-012 (Receptacle) pin 2 X-012 (Receptacle) pin 4 X-012 (Receptacle) pin 6
To Chassis ground Chassis ground Chassis ground
Value There should be continuity. There should be continuity. There should be continuity.
A. If there is continuity on all of the checks, then leave connector X-012 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 minus battery 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 X-012 (Receptacle) pin 24 X-012 (Receptacle) pin 24 X-012 (Receptacle) pin 25
To X-012 (Receptacle) pin 25 Chassis ground Chassis ground
Value There should be 120 Ί. There should not be continuity. There should not be continuity.
Use a multimeter to measure the resistance of the CAN termination resistor, internal to the ECU : From X-012 (Receptacle) pin 24
To X-012 (Receptacle) pin 25
Value There should be 120 Ί.
A. If the measured resistances are correct and neither conductor is grounded, then check the ECU 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, then locate and restore the termination resistance to the CAN circuit. 6. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals, or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while you monitor the display. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 06 SH06-ENGINE F5C T4 (55.100.DP-C.20.E.06) Wiring harnesses - Electrical schematic sheet 10 SH10-ENGINE F5C T4 (55.100.DP-C.20.E.10)
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3899 (DTC 432-03) - Engine Protection : Engine temperature reaches prewarning level Context: The Engine Control Unit (ECU) monitors the engine coolant temperature. Two engine temperature thresholds are monitored by the ECU, a pre-warning threshold and a warning threshold. If the ECU monitors a temperature greater than 107.96 °C (226.33 °F), then a pre-warning is set and this fault will occur. For more information regarding cooling system troubleshooting, refer to the engine service manual Engine cooling system - Troubleshooting (10.400). Cause: A coolant temperature level pre-warning has been set by the ECU. Possible failure modes: 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. 5. Faulty ECU, software.
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3900 (DTC 532-03) - Engine Protection : Engine temperature reaches warning level Context: The Engine Control Unit (ECU) monitors the engine coolant temperature. Two engine temperature thresholds are monitored by the ECU, a pre-warning threshold and a warning threshold. If the ECU monitors a temperature greater than 111.96 °C (233.53 °F), then a warning is set and this fault will occur. For more information regarding cooling system troubleshooting, see Engine cooling system - Troubleshooting (10.400) in the engine service manual. Cause: A coolant temperature level warning has been set by the ECU. Possible failure modes: 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. 5. Faulty ECU, software.
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3906 (DTC 17E-12) - Injection control : Number of injections is limited by quantity balance of high pressure pump Context: The Engine Control Unit (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 requested number of fuel injections can not be reached, then this fault will occur. Cause: The ECU has determined that the requested number of fuel injections is greater than the current capability of the fuel injection system. 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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3910 (DTC 459-03) - Fuel Metering Unit : Intermittent contact between ECU and MeUn Context: The Engine Control Unit (ECU) monitors the fuel metering unit signal circuit. If the ECU detects an intermittent connection in the fuel metering unit signal circuit, then this fault will occur. Cause: The ECU has detected a intermittent connection in the fuel metering unit signal circuit. Possible failure modes: 1. Faulty fuel metering unit wiring, open circuit. 2. Faulty fuel metering unit, internal failure. 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, then the fault may be intermittent and not currently active. Continue with step 5. 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 Fuel metering unit pin 1
To Fuel metering unit pin 2
Value 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 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 engine harness (EN) wiring for an open circuit. Disconnect the vehicle harness (VE) from the engine interface at connector X-017. 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 Fuel metering unit connector pin 1 X-017 (Receptacle) pin 1 There should be continuity. Fuel metering unit connector pin 2 X-017 (Receptacle) pin 2 There should be continuity. NOTE: Wiggle the harness during measurement to reveal an intermittent electrical connection. A. If there is continuity, then leave connector X-017 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 and repair the broken conductor. Repair or replace the harness as required. 4. Check the fuel metering unit vehicle harness (VE) wiring for an open circuit. Disconnect the vehicle harness (VE) from the ECU at connector X-016. 48068130 29/01/2018
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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 There should be continuity. X-017 (Receptacle) pin 1 X-016 (Receptacle) pin 15 There should be continuity. X-017 (Receptacle) pin 2 X-016 (Receptacle) pin 60 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 fuel metering unit vehicle harness (VE) wiring. 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 software and re-flash, if necessary. 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. A. If you find damage or the display indicates other than normal display readings, then repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If you do not find damage and the display indicates only normal readings, then erase the fault code and continue operation. Wiring harnesses - Electrical schematic sheet 07 SH07-ENGINE F5C T4 (55.100.DP-C.20.E.07) Wiring harnesses - Electrical schematic sheet 11 SH11-ENGINE F5C T4 (55.100.DP-C.20.E.11)
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3915 (DTC 137-12) - Pressure Relief valve : Averaged rail pressure is outside the expected tolerance range 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 - Configure - Reset ECU data (10.218), if necessary. 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 fuel rail pressure using the rail pressure sensor. After a fuel pressure evaluation, if the ECU suspects that the Pressure Relief Valve (PRV) should be open but has not opened, then this fault occur. If this fault is active, then 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. Possible failure modes: 1. Faulty PRV, unable to open or partially open. 2. Faulty PRV fuel back-flow, clogged or damaged. 3. Faulty rail pressure sensor, drifted signal. 4. Faulty ECU, software.
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3916 (DTC 237-03) - Pressure Relief valve : pressure relief valve reached maximum allowed open time 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 - Configure - Reset ECU data (10.218), if necessary. 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. Diagnose any faults that may have caused this one to occur first, and then return to this fault, 3916 â&#x20AC;&#x201C; Fuel pressure relief valve has reached maximum allowed open time. 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. Possible failure modes: 1. Faulty PRV, stuck open or worn. 2. Faulty fuel back-flow, clogged or damaged. 3. Faulty fuel metering unit, internal failure. 4. Faulty rail pressure sensor, internal failure. 5. Faulty ECU, software.
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3978 (DTC 3FB-03) - Level 2 of PFlt Overloaded Context: The Engine Control Unit (ECU) monitors the Particulate Matter Catalytic Converter (PMcat) soot load level. If the ECU determines that the soot load level is high, then this fault will occur. If this fault is active, then it may be necessary to use the Electronic Service Tool (EST) to perform a service regeneration.
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3979 (DTC 4FB-03) - Level 3 of PFlt Overloaded Context: The Engine Control Unit (ECU) monitors the Particulate Matter Catalytic Converter (PMcat) soot load level. If the ECU determines that the soot load level is very high, then this fault will occur. If this fault is active, then it may be necessary to use the Electronic Service Tool (EST) to perform a service regeneration.
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3992 (DTC 182-12) - EGR Control : Not plausible state 1 Context: The Engine Control Unit evaluates the main physical parameters of intake temperature and pressure, lambda, Exhaust Gas Recirculation (EGR) position, temperature and pressure in the exhaust path in order to discover a leakage in the intake charge air path. If a hole (leakage) in the intake path is detected, 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 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 has determined that there is leakage in the intake charge air system. Possible failure modes: 1. Faulty charge air system, leakage due to improper connection or hole in piping.
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3993 (DTC 489-03) - DFC for valve drift at closed position Context: The Engine Control Unit (ECU) monitors the position of the Exhaust Gas Recirculation (EGR) valve by monitoring the potentiometer feedback voltage. During after run, the EGR valve will open and close in attempt to remove any build-up from the valve seat. If during after run, the ECU determines that the feedback voltage is not within the desired range 0.5 s after full closure, 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). 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 has detected an EGR valve actuator feedback voltage outside of the 0.75 â&#x20AC;&#x201C; 1.30 V range for the closed position. Possible failure modes: 1. Faulty EGR valve, dirt or debris on valve seat, requires cleaning. 2. Faulty EGR valve, blocked or mechanically damaged, does not fully close. 3. Faulty EGR valve position sensor, internal failure. 4. Faulty ECU, software.
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4043 - Hydraulic Oil Temperature Sensor Shorted To Ground Context: The hydraulic oil temperature signal is shorted to ground. Cause: The hydraulic oil temperature signal, X-C23 pin 16 has a short circuit to ground. The oil temperature sensor resistance is less than 25 Ω. Possible failure modes: 1. Faulty wiring or connections from the hydraulic oil temperature sensor to the instrument cluster. 2. A faulty temperature sensor. 3. A 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 machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 4043 is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the instrument cluster connector X-C23 and the hydraulic oil temperature sensor connections. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the instrument cluster to the hydraulic oil temperature sensor. 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 the connectors as required. Return to step 1 to confirm elimination of fault. 3. Measure the resistance of the signal wire to chassis ground. Turn the ignition switch OFF. Disconnect the instrument cluster connector X-C23. Disconnect the hydraulic oil temperature sensor connector. Measure the resistance between X-C23 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. Go to step 4. 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 1 to confirm elimination of the fault. 4. Measure the resistance of the temperature sensor. Measure the resistance of the temperature sensor to chassis ground. Temperature 110 °C (230 °F)
Hydraulic Oil Temperature Sensor Open Circuit Resistance Measurements Resistance in ohms (± 10%) 130 Ω
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Hydraulic Oil Temperature Sensor Open Circuit Resistance Measurements 105 °C (221 °F) 151 Ω 100 °C (212 °F) 175 Ω 95 °C (203 °F) 202 Ω 92 °C (198 °F) 223 Ω 88 °C (190 °F) 258 Ω 85 °C (185 °F) 280 Ω 81 °C (178 °F) 323 Ω 78 °C (172 °F) 358 Ω 74 °C (165 °F) 412 Ω 68 °C (154 °F) 511 Ω 16 °C (61 °F) 4250 Ω A. The resistance measurements are within the values from the table. The measured resistance is greater than 30 Ω. Temporarily replace the instrument cluster and retest. Return to step 1. B. The resistance measurements are not within range. The measured resistance is less than 30 Ω. Temporarily replace the temperature sensor and retest. Return to step 1 to confirm elimination of fault.
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4044 - Hydraulic Oil Temperature Sensor Open Circuit Context: The instrument cluster detects an open circuit in the hydraulic oil temperature signal. Cause: The hydraulic oil temperature signal, X-C23 pin 16 has an open circuit. The oil temperature sensor resistance is greater than 30,000 Ω. Possible failure modes: 1. Faulty wiring or connections from the hydraulic oil temperature sensor to the instrument cluster. 2. A faulty hydraulic oil temperature sensor. 3. A 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 machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 4044 is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the instrument cluster connector X-C23 and the hydraulic oil temperature sensor connections. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the instrument cluster to the hydraulic oil temperature sensor. 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. 3. Measure the resistance of the temperature signal wire. Turn the ignition switch OFF. Disconnect the instrument cluster connector X-C23. Disconnect the hydraulic oil temperature sensor connector. Measure the resistance from the hydraulic oil temperature sensor pin 1 to X-C23 pin 16. The resistance should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition. Measure the resistance from the hydraulic oil temperature sensor pin 2 to chassis ground. 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. B. The resistance is greater than 10 Ω. There is an open circuit in the wire. Repair or replace the harness as required. Return to step 1 to confirm elimination of fault. 4. Measure the voltage on the temperature signal wire. Turn the ignition switch ON.
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Measure the voltage from X-C23 pin 16 to chassis ground. The voltage should be less than 0.5 V. Wiggle the harness during measurement to reveal an intermittent condition. A. The voltage is less than 0.5 V. Go to step 5. B. The voltage is greater than 0.5 V. There is a short circuit to another voltage source. Repair or replace the harness as required. Return to step 1 to confirm elimination of fault. 5. Measure the resistance of the temperature sensor. Measure the resistance of the temperature sensor. Hydraulic Oil Temperature Sensor Open Circuit Resistance Measurements Temperature Resistance in ohms (± 10%) 110 °C (230 °F) 130 Ω 105 °C (221 °F) 151 Ω 100 °C (212 °F) 175 Ω 95 °C (203 °F) 202 Ω 92 °C (198 °F) 223 Ω 88 °C (190 °F) 258 Ω 85 °C (185 °F) 280 Ω 81 °C (178 °F) 323 Ω 78 °C (172 °F) 358 Ω 74 °C (165 °F) 412 Ω 68 °C (154 °F) 511 Ω 16 °C (61 °F) 4250 Ω A. The resistance measurements are within the values from the table. The measured resistance is less than 10,000 Ω. Temporarily replace the instrument cluster and retest. Return to step 1 to confirm elimination of fault. B. The resistance measurements were not within range. The measured resistance is greater than 10,000 Ω. Temporarily replace the temperature sensor and retest. Return to step 1 to confirm elimination of fault.
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4055 - Park Brake Valve (On/Off) - Solenoid Supply Open Circuit SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Context: The UCM has sensed that the voltage on X-CN3A (Receptacle) pin 4 is less than 1 V or greater than 8 V. Diagnostic Trouble Code 4055 – Park Brake Valve (On/Off) - Solenoid Supply Open Circuit has an error priority of Red. Ground drive is disabled while Diagnostic Trouble Code 4055 – Park Brake Valve (On/Off) - Solenoid Supply Open Circuit is active. Cause: The UCM has sensed that the voltage on X-CN3A (Receptacle) pin 4 is less than 1 V or greater than 8 V. Possible failure modes: 1. An open circuit in the wiring. 2. The park brake valve solenoid has failed. 3. The UCM has an internal failure. 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. OK to return the machine to service. B. Fault code 4055 – Park Brake Valve (On/Off) - Solenoid Supply Open Circuit is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the UCM and the park brake solenoid connections. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the UCM to the park brake solenoid. 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 the connectors as required. Return to step 1 to confirm elimination of fault. 3. Measure the resistance through the signal wire. Turn the ignition switch OFF. Disconnect UCM connector X-CN3A (Receptacle) . Disconnect the brake valve solenoid connector X-BRK (Plug) . Fabricate a jumper wire that will connect between X-BRK (Plug) pin 1 and X-BRK (Plug) pin 2.
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Connect the jumper wire between X-BRK (Plug) pin 1 and X-BRK (Plug) pin 2. Measure the resistance between X-CN3A (Receptacle) pin 4 and chassis ground. 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. 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 the fault. 4. Measure the resistance through the solenoid. Disconnect the brake valve solenoid connector X-BRK (Plug) . Measure the resistance across the solenoid terminals. The resistance should be less than 100 Ω. A. The resistance is less than 100 Ω. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. B. The resistance is greater than 100 Ω. There is an open circuit in the solenoid. Replace the solenoid and retest. Return to step 1 to confirm elimination of the fault. Wiring harnesses - Electrical schematic sheet 21 SH21-UNIVERSAL CONTROL MODULE (55.100.DP-C.20.E.21) Wiring harnesses - Electrical schematic sheet 10 SH10-EH PUMP/HYDRAULICS (55.100.DP-C.20.E.10)
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4056 - Park Brake Valve (On/Off) - Solenoid Supply Short to Ground SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Context: The UCM has sensed that the current on X-CN3A (Receptacle) pin 4 is greater than 3 A. Diagnostic Trouble Code 4056 – Park Brake Valve (On/Off) - Solenoid Supply Short to Ground has an error priority of Red. Ground drive is disabled while Diagnostic Trouble Code 4056 – Park Brake Valve (On/Off) - Solenoid Supply Short to Ground is active. Cause: The UCM has sensed short circuit to ground on X-CN3A (Receptacle) pin 4. The current on the park brake valve signal line is greater than 3 A. Possible failure modes: 1. The signal wire has a short circuit to chassis ground. 2. The park brake valve has failed. 3. The UCM has an internal failure. 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. OK to return the machine to service. B. Fault code 4056 – Park Brake Valve (On/Off) - Solenoid Supply Short to Ground is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the UCM and the park brake solenoid connections. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the UCM to the park brake solenoid. 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 the connectors as required. Return to step 1 to confirm elimination of fault. 3. Measure the resistance through the solenoid wire. Turn the ignition switch OFF. Disconnect UCM connector X-CN3A (Receptacle) . Disconnect the park brake solenoid connector X-BRK (Plug) .
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Measure the resistance between X-CN3A (Receptacle) pin 4 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. Go to step 4. 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 1 to confirm elimination of the fault. 4. Measure the resistance through the solenoid. Disconnect the brake valve solenoid connector X-BRK (Plug) . Measure the resistance across the solenoid terminals. The resistance should be between 7 Ω and 10 Ω. A. The resistance is between 7 Ω and 10 Ω. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. B. The resistance is less than 5 Ω. There is a short circuit in the solenoid. Replace the solenoid and retest. Return to step 1 to confirm elimination of the fault. Wiring harnesses - Electrical schematic sheet 21 SH21-UNIVERSAL CONTROL MODULE (55.100.DP-C.20.E.21) Wiring harnesses - Electrical schematic sheet 10 SH10-EH PUMP/HYDRAULICS (55.100.DP-C.20.E.10)
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4057 - Park Brake Valve (On/Off) - Solenoid Supply Short to Power SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Context: The UCM has tried to turn off the park brake valve solenoid, but the voltage on X-CN3A (Receptacle) pin 4 is still greater than 8 V. Diagnostic Trouble Code 4057 – Park Brake Valve (On/Off) - Solenoid Supply Short to Power has an error priority of Red. Ground drive is disabled while Diagnostic Trouble Code 4057 – Park Brake Valve (On/Off) - Solenoid Supply Short to Power is active. Cause: The UCM has tried to turn off the park brake valve solenoid, but the voltage on X-CN3A (Receptacle) pin 4 is still greater than 8 V. The fault is active while the hydraulics are disabled or the park brake is enabled and the voltage on the park brake solenoid pin, X-CN3A (Receptacle) pin 4 is greater than 8 V. Possible failure modes: 1. The solenoid signal wire has a short circuit to another voltage source. 2. The UCM has an internal failure. 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 is not recorded again. OK to return the machine to service. B. Fault code 4057 – Park Brake Valve (On/Off) - Solenoid Supply Short to Power is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the UCM and the park brake solenoid connections. All connections should be secure, tight, free of corrosion, abrasion and damage. Inspect the harness from the UCM to the park brake solenoid. 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 the connectors as required. Return to step 1 to confirm elimination of fault. 3. Measure the voltage on the solenoid wire. Turn the ignition switch OFF. Disconnect UCM connector X-CN3A (Receptacle) . Disconnect the park brake solenoid connector X-BRK (Plug) .
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Turn the ignition switch ON. Measure the voltage between X-CN3A (Receptacle) pin 4 and chassis ground. The voltage should be less than 0.5 V. Wiggle the harness during measurement to reveal an intermittent condition. A. The voltage is less than 0.5 V. Temporarily replace the UCM 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 to another voltage source. Repair or replace the harness as required. Return to step 1 to confirm elimination of the fault. Wiring harnesses - Electrical schematic sheet 21 SH21-UNIVERSAL CONTROL MODULE (55.100.DP-C.20.E.21) Wiring harnesses - Electrical schematic sheet 10 SH10-EH PUMP/HYDRAULICS (55.100.DP-C.20.E.10)
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4061 - Forward Pump Control Valves (Directional) - Solenoid Right (A) Supply Open Circuit SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Context: The UCM has sensed an open circuit in the right drive pump forward solenoid signal line. Diagnostic Trouble Code 4061 – Forward Pump Control Valves (Directional) - Solenoid Right (A) Supply Open Circuit has an error priority of Red. Forward ground drive is disabled while Diagnostic Trouble Code 4061 – Forward Pump Control Valves (Directional) - Solenoid Right (A) Supply Open Circuit is active. Cause: The UCM has sensed an open circuit in X-CN3B (Receptacle) pin 32. The fault is active while the hydraulics are enabled and the solenoid resistance is greater than normal. Possible failure modes: 1. An open circuit in the wiring. 2. There is an open circuit in the right drive pump forward solenoid. 3. The UCM has an internal failure. 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. OK to return the machine to service. B. Fault code 4061 – Forward Pump Control Valves (Directional) - Solenoid Right (A) Supply Open Circuit is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the UCM and the right drive pump forward solenoid connections. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the UCM to the right drive pump forward solenoid. 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 the connectors as required. Return to step 1 to confirm elimination of fault. 3. Measure the resistance through the harness. Turn the ignition switch OFF. Disconnect UCM connectors CN3B and CN2B.
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Electrical systems - FAULT CODES
Disconnect the right drive pump forward solenoid connector X-017 (Receptacle) . Fabricate a jumper wire that will connect between the right drive pump forward solenoid connector X-017 (Receptacle) pin 1 and X-017 (Receptacle) pin 2. Connect the jumper wire between X-017 (Receptacle) pin 1 and X-017 (Receptacle) pin 2. Measure the resistance between X-CN3B (Receptacle) pin 32 and X-CN2B (Receptacle) pin 25. 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. B. The resistance is greater than 10 Ω. There is an open circuit in the solenoid signal wire or the solenoid ground line. Check splice SP-098. Repair or replace the harness as required. Return to step 1 to confirm elimination of the fault. 4. Test the UCM. Leave the jumper wire installed between X-017 (Receptacle) pin 1 and X-017 (Receptacle) pin 2. Reconnect UCM connectors X-CN3B (Receptacle) and X-CN2B (Receptacle) . Turn the ignition switch ON. Activate the hydraulics while monitoring the fault code screen. Fault code 4061 – Forward Pump Control Valves (Directional) - Solenoid Right (A) Supply Open Circuit should no longer be active. Fault code 4062 – Forward Pump Control Valves (Directional) - Solenoid Right (A) Supply Short to Ground should become active. A. Fault code 4062 – Forward Pump Control Valves (Directional) - Solenoid Right (A) Supply Short to Ground is active and fault code 4061 – Forward Pump Control Valves (Directional) - Solenoid Right (A) Supply Open Circuit is no longer active. Temporarily replace the solenoid and retest. Return to step 1 to confirm elimination of the fault. B. Fault code 4061 – Forward Pump Control Valves (Directional) - Solenoid Right (A) Supply Open Circuit is still active. Fault code 4062 – Forward Pump Control Valves (Directional) - Solenoid Right (A) Supply Short to Ground did not become active. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. Wiring harnesses - Electrical schematic sheet 20 SH20-UNIVERSAL CONTROL MODULE (55.100.DP-C.20.E.20) Wiring harnesses - Electrical schematic sheet 10 SH10-EH PUMP/HYDRAULICS (55.100.DP-C.20.E.10) Wiring harnesses - Electrical schematic sheet 21 SH21-UNIVERSAL CONTROL MODULE (55.100.DP-C.20.E.21)
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Electrical systems - FAULT CODES
4062 - Forward Pump Control Valves (Directional) - Solenoid Right (A) Supply Short to Ground SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Context: The UCM has sent a signal to the right forward ground drive solenoid to energize, but no voltage was detected. Diagnostic Trouble Code 4062 – Forward Pump Control Valves (Directional) - Solenoid Right (A) Supply Short to Ground has an error priority of Red. Forward ground drive is disabled while Diagnostic Trouble Code 4062 – Forward Pump Control Valves (Directional) - Solenoid Right (A) Supply Short to Ground is active. Cause: The UCM has sent a signal to the right forward ground drive solenoid to energize, but no voltage was detected. The current on CN3B pin 32 is greater than 3 A. The fault is active while the hydraulics are enabled and the current on X-CN3B (Receptacle) pin 32 is greater than 3 A. Possible failure modes: 1. A short circuit in the wiring. 2. The right drive pump forward solenoid has an internal short circuit. 3. The UCM has an internal failure. 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. OK to return the machine to service. B. Fault code 4062 – Forward Pump Control Valves (Directional) - Solenoid Right (A) Supply Short to Ground is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the UCM and the right drive pump forward solenoid connections. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the UCM to the right drive pump forward solenoid. 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 the connectors as required. Return to step 1 to confirm elimination of fault. 3. Measure the resistance of the signal wire to chassis ground. Turn the ignition switch OFF.
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Electrical systems - FAULT CODES
Disconnect UCM connector X-CN3B (Receptacle) , X-CN2B (Receptacle) , and the right drive pump forward solenoid connector X-017 (Receptacle) . Measure the resistance between X-CN3B (Receptacle) pin 32 and chassis ground. The resistance should be greater than 20,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition. Measure the resistance between X-CN2B (Receptacle) pin 25 and chassis ground. The resistance should be greater than 20,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition. A. Both resistance measurements are greater than 20,000 Ω. Go to step 4. B. One or both resistance measurements are less than 20,000 Ω. There is a short circuit to chassis ground in the wiring. Repair or replace the harness as required. Return to step 1 to confirm elimination of the fault. 4. Test the UCM. Reconnect UCM connectors X-CN3B (Receptacle) and X-CN2B (Receptacle) . Leave the right drive pump forward solenoid connector, X-017 (Receptacle) , disconnected. Turn the ignition switch ON. Activate the hydraulics while monitoring the fault code screen. Fault code 4062 – Forward Pump Control Valves (Directional) - Solenoid Right (A) Supply Short to Ground should no longer be active. Fault code 4061 – Forward Pump Control Valves (Directional) - Solenoid Right (A) Supply Open Circuit should become active. A. Fault code 4061 – Forward Pump Control Valves (Directional) - Solenoid Right (A) Supply Open Circuit is active and fault code 4062 – Forward Pump Control Valves (Directional) - Solenoid Right (A) Supply Short to Ground is no longer active. Temporarily replace the solenoid and retest. Return to step 1 to confirm elimination of the fault. B. Fault code 4062 – Forward Pump Control Valves (Directional) - Solenoid Right (A) Supply Short to Ground is still active. Fault code 4061 – Forward Pump Control Valves (Directional) - Solenoid Right (A) Supply Open Circuit did not become active. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. Wiring harnesses - Electrical schematic sheet 20 SH20-UNIVERSAL CONTROL MODULE (55.100.DP-C.20.E.20) Wiring harnesses - Electrical schematic sheet 10 SH10-EH PUMP/HYDRAULICS (55.100.DP-C.20.E.10) Wiring harnesses - Electrical schematic sheet 21 SH21-UNIVERSAL CONTROL MODULE (55.100.DP-C.20.E.21)
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Electrical systems - FAULT CODES
4071 - Forward Pump Control Valves (Directional) - Solenoid Left (B) Supply Open Circuit SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Context: The UCM has sensed an open circuit in the left drive pump forward solenoid signal line. Diagnostic Trouble Code 4071 has an error priority of Red. Forward ground drive is disabled while Diagnostic Trouble Code 4071 â&#x20AC;&#x201C; Forward Pump Control Valves (Directional) - Solenoid Left (B) Supply Open Circuit is active. Cause: The UCM has sensed an open circuit in X-CN3B (Receptacle) pin 33. The fault is active while the hydraulics are enabled and the solenoid resistance is greater than normal. Possible failure modes: 1. An open circuit in the wiring. 2. There is an open circuit in the left drive pump forward solenoid. 3. The UCM has an internal failure. 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. OK to return the machine to service. B. Fault code 4071 â&#x20AC;&#x201C; Forward Pump Control Valves (Directional) - Solenoid Left (B) Supply Open Circuit is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the UCM and the left drive pump forward solenoid connections. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the UCM to the left drive pump forward solenoid. 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 the connectors as required. Return to step 1 to confirm elimination of fault. 3. Measure the resistance through the harness. Turn the ignition switch OFF. Disconnect UCM connectors X-CN3B (Receptacle) and X-CN2B (Receptacle) . Disconnect the left drive pump forward solenoid connector X-013 (Receptacle) . 48068130 29/01/2018
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Electrical systems - FAULT CODES
Fabricate a jumper wire that will connect between the left drive pump forward solenoid connector X-013 (Receptacle) pin 1 and X-013 (Receptacle) pin 2. Connect the jumper wire between X-013 (Receptacle) pin 1 and X-013 (Receptacle) pin 2. Measure the resistance between X-CN3B (Receptacle) pin 33 and X-CN2B (Receptacle) pin 25. 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. B. The resistance is greater than 10 Ω. There is an open circuit in the solenoid signal wire or the solenoid ground line. Check splice SP-098. Repair or replace the harness as required. Return to step 1 to confirm elimination of the fault. 4. Test the UCM. Leave the jumper wire installed between X-013 (Receptacle) pin 1 and X-013 (Receptacle) pin 2. Reconnect UCM connectors X-CN3B (Receptacle) and X-CN2B (Receptacle) . Turn the ignition switch ON. Activate the hydraulics while monitoring the fault code screen. Fault code 4071 – Forward Pump Control Valves (Directional) - Solenoid Left (B) Supply Open Circuit should no longer be active. Fault code 4072 – Forward Pump Control Valves (Directional) - Solenoid Left (B) Supply Short to Ground should become active. A. Fault code 4072 – Forward Pump Control Valves (Directional) - Solenoid Left (B) Supply Short to Ground is active and fault code 4071 – Forward Pump Control Valves (Directional) - Solenoid Left (B) Supply Open Circuit is no longer active. Temporarily replace the solenoid and retest. Return to step 1 to confirm elimination of the fault. B. Fault code 4071 – Forward Pump Control Valves (Directional) - Solenoid Left (B) Supply Open Circuit is still active. Fault code 4072 – Forward Pump Control Valves (Directional) - Solenoid Left (B) Supply Short to Ground did not become active. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. Wiring harnesses - Electrical schematic sheet 20 SH20-UNIVERSAL CONTROL MODULE (55.100.DP-C.20.E.20) Wiring harnesses - Electrical schematic sheet 10 SH10-EH PUMP/HYDRAULICS (55.100.DP-C.20.E.10) Wiring harnesses - Electrical schematic sheet 21 SH21-UNIVERSAL CONTROL MODULE (55.100.DP-C.20.E.21)
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Electrical systems - FAULT CODES
4072 - Forward Pump Control Valves (Directional) - Solenoid Left (B) Supply Short to Ground SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Context: The UCM has sent a signal to the left forward ground drive solenoid to energize, but no voltage was detected. Diagnostic Trouble Code 4072 – Forward Pump Control Valves (Directional) - Solenoid Left (B) Supply Short to Ground has an error priority of Red. Forward ground drive is disabled while Diagnostic Trouble Code 4072 – Forward Pump Control Valves (Directional) - Solenoid Left (B) Supply Short to Ground is active. Cause: The UCM has sent a signal to the left forward ground drive solenoid to energize, but no voltage was detected. The current on X-CN3B (Receptacle) pin 33 is greater than 3 A. The fault is active while the hydraulics are enabled and the current on X-CN3B (Receptacle) pin 33 is greater than 3 A. Possible failure modes: 1. A short circuit in the wiring. 2. The left drive pump forward solenoid has an internal short circuit. 3. The UCM has an internal failure. 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. OK to return the machine to service. B. Fault code 4072 – Forward Pump Control Valves (Directional) - Solenoid Left (B) Supply Short to Ground is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the UCM and the left drive pump forward solenoid connections. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the UCM to the left drive pump forward solenoid. 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 the connectors as required. Return to step 1 to confirm elimination of fault. 3. Measure the resistance of the signal wire to chassis ground. Turn the ignition switch OFF.
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Electrical systems - FAULT CODES
Disconnect UCM connector X-CN3B (Receptacle) , X-CN2B (Receptacle) , and the left drive pump forward solenoid connector X-013 (Receptacle) . Measure the resistance between X-CN3B (Receptacle) pin 33 and chassis ground. The resistance should be greater than 20,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition. Measure the resistance between X-CN2B (Receptacle) pin 25 and chassis ground. The resistance should be greater than 20,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition. A. Both resistance measurements are greater than 20,000 Ω. Go to step 4. B. One or both resistance measurements are less than 20,000 Ω. There is a short circuit to chassis ground in the wiring. Repair or replace the harness as required. Return to step 1 to confirm elimination of the fault. 4. Test the UCM. Reconnect UCM connectors X-CN3B (Receptacle) and X-CN2B (Receptacle) . Leave the left drive pump forward solenoid connector X-013 (Receptacle) disconnected. Turn the ignition switch ON. Activate the hydraulics while monitoring the fault code screen. Fault code 4072 – Forward Pump Control Valves (Directional) - Solenoid Left (B) Supply Short to Ground should no longer be active. Fault code 4071 – Forward Pump Control Valves (Directional) - Solenoid Left (B) Supply Open Circuit should become active. A. Fault code 4071 – Forward Pump Control Valves (Directional) - Solenoid Left (B) Supply Open Circuit is active and fault code 4072 – Forward Pump Control Valves (Directional) - Solenoid Left (B) Supply Short to Ground is no longer active. Temporarily replace the solenoid and retest. Return to step 1 to confirm elimination of the fault. B. Fault code 4072 – Forward Pump Control Valves (Directional) - Solenoid Left (B) Supply Short to Ground is still active. Fault code 4071 – Forward Pump Control Valves (Directional) - Solenoid Left (B) Supply Open Circuit did not become active. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. Wiring harnesses - Electrical schematic sheet 20 SH20-UNIVERSAL CONTROL MODULE (55.100.DP-C.20.E.20) Wiring harnesses - Electrical schematic sheet 10 SH10-EH PUMP/HYDRAULICS (55.100.DP-C.20.E.10) Wiring harnesses - Electrical schematic sheet 21 SH21-UNIVERSAL CONTROL MODULE (55.100.DP-C.20.E.21)
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Electrical systems - FAULT CODES
4081 - Forward Pump Control Valves (Directional) - Common Solenoid Return Short to Power SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Context: The UCM has sensed that the voltage on X-CN3B (Receptacle) pin 32, X-CN3B (Receptacle) pin 33, and X-CN2B (Receptacle) pin 25 is greater than 5 V. Diagnostic Trouble Code 4081 – Forward Pump Control Valves (Directional) - Common Solenoid Return Short to Power has an error priority of Red. Forward ground drive is disabled while Diagnostic Trouble Code 4081 – Forward Pump Control Valves (Directional) - Common Solenoid Return Short to Power is active. Cause: The UCM has sensed a higher than normal voltage on the forward ground drive valve solenoids lines. The fault is active while the hydraulics are disabled and the solenoid voltage feedback is greater than 5 V. Possible failure modes: 1. A short circuit to another voltage source in the wiring. 2. The UCM has internal failure. 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. OK to return the machine to service. B. Fault code 4081 – Forward Pump Control Valves (Directional) - Common Solenoid Return Short to Power is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the UCM, the right drive pump forward solenoid and the left drive pump forward solenoid connections. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the UCM to the right drive pump forward solenoid and the left drive pump forward solenoid. 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 the connectors as required. Return to step 1 to confirm elimination of fault. 3. Measure the voltage of the solenoid wires to chassis ground. Turn the ignition switch OFF. Disconnect solenoid connectors X-013 (Receptacle) and X-017 (Receptacle) . Disconnect UCM connectors X-CN2B (Receptacle) and X-CN3B (Receptacle) .
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Electrical systems - FAULT CODES
Turn the ignition switch ON. Measure the voltage between X-017 (Receptacle) pin 1 and chassis ground. The voltage should be less than 0.5 V. Wiggle the harness during measurement to reveal an intermittent condition. Measure the voltage between X-017 (Receptacle) pin 2 and chassis ground. The voltage should be less than 0.5 V. Wiggle the harness during measurement to reveal an intermittent condition. Measure the voltage between X-013 (Receptacle) pin 1 and chassis ground. The voltage should be less than 0.5 V. Wiggle the harness during measurement to reveal an intermittent condition. Measure the voltage between X-013 (Receptacle) pin 2 and chassis ground. The voltage should be less than 0.5 V. Wiggle the harness during measurement to reveal an intermittent condition. A. All voltage measurement are less than 0.5 V. Go to step 4. B. One or more voltage measurements are greater than 0.5 V. There is an short circuit to another voltage source in the harness. Repair or replace the harness as required. Return to step 1 to confirm elimination of fault. 4. Test the UCM. Turn the ignition switch OFF. Reconnect UCM connectors X-CN2B (Receptacle) and X-CN3B (Receptacle) . Leave connectors X-013 (Receptacle) and X-017 (Receptacle) disconnected. Turn the ignition switch ON. Activate the hydraulics while monitoring the fault code screen. Fault code 4083 – Forward Pump Control Valves (Directional) - Common Solenoid Return Open Circuit should no longer be active. Fault code 4081 – Forward Pump Control Valves (Directional) - Common Solenoid Return Short to Power should become active. A. Fault code 4083 – Forward Pump Control Valves (Directional) - Common Solenoid Return Open Circuit is active and fault code 4081 – Forward Pump Control Valves (Directional) - Common Solenoid Return Short to Power is no longer active. Temporarily replace both solenoids and retest. Return to step 1 to confirm elimination of the fault. B. Fault code 4081 – Forward Pump Control Valves (Directional) - Common Solenoid Return Short to Power is still active. Fault code 4083 – Forward Pump Control Valves (Directional) - Common Solenoid Return Open Circuit did not become active. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. Wiring harnesses - Electrical schematic sheet 20 SH20-UNIVERSAL CONTROL MODULE (55.100.DP-C.20.E.20) Wiring harnesses - Electrical schematic sheet 10 SH10-EH PUMP/HYDRAULICS (55.100.DP-C.20.E.10) Wiring harnesses - Electrical schematic sheet 21 SH21-UNIVERSAL CONTROL MODULE (55.100.DP-C.20.E.21)
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Electrical systems - FAULT CODES
4082 - Forward Pump Control Valves (Directional) - Pumps Forward Solenoids Short to Ground SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Context: The UCM has sensed that the voltage on X-CN3B (Receptacle) pin 32, X-CN3B (Receptacle) pin 33, and X-CN2B (Receptacle) pin 25 is less than 5 V. Diagnostic Trouble Code 4082 – Forward Pump Control Valves (Directional) - Pumps Forward Solenoids Short to Ground has an error priority of Red. Forward ground drive is disabled while Diagnostic Trouble Code 4082 – Forward Pump Control Valves (Directional) - Pumps Forward Solenoids Short to Ground is active. Cause: The UCM has sensed that the voltage on X-CN3B (Receptacle) pin 32, X-CN3B (Receptacle) pin 33, and X-CN2B (Receptacle) pin 25 is less than 5 V. The fault is active while the hydraulics are disabled and solenoid return voltage feedback is low. Possible failure modes: 1. A short circuit in the wiring. 2. The UCM has internal failure. 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. OK to return the machine to service. B. Fault code 4082 – Forward Pump Control Valves (Directional) - Pumps Forward Solenoids Short to Ground is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the UCM, the right drive pump forward and the left drive pump forward connections. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the UCM to the right drive pump forward solenoid and the left drive pump forward solenoid. 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 the connectors as required. Return to step 1 to confirm elimination of fault. 3. Measure the resistance of the solenoid wires to chassis ground. Turn the ignition switch OFF. Disconnect solenoid connectors X-013 (Receptacle) and X-017 (Receptacle) . Disconnect UCM connectors X-CN2B (Receptacle) and X-CN3B (Receptacle) . 48068130 29/01/2018
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Electrical systems - FAULT CODES
Measure the resistance between X-017 (Receptacle) pin 1 and chassis ground. The resistance should be greater than 20,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition. Measure the resistance between X-017 (Receptacle) pin 2 and chassis ground. The resistance should be greater than 20,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition. Measure the resistance between X-013 (Receptacle) pin 1 and chassis ground. The resistance should be greater than 20,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition. Measure the resistance between X-013 (Receptacle) pin 2 and chassis ground. The resistance should be greater than 20,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition. A. All resistance measurements are greater than 20,000 Ω. Go to step 4. B. One or more resistance measurements are less than 20,000 Ω. There is an short circuit to chassis ground. Repair or replace the harness as required. Return to step 1 to confirm elimination of fault. 4. Test the UCM. Turn the ignition switch OFF. Reconnect UCM connectors X-CN2B (Receptacle) and X-CN3B (Receptacle) . Leave connectors X-013 (Receptacle) and X-017 (Receptacle) disconnected. Turn the ignition switch ON. Activate the hydraulics while monitoring the fault code screen. Fault code 4082 – Forward Pump Control Valves (Directional) - Pumps Forward Solenoids Short to Ground should no longer be active. Fault code 4083 – Forward Pump Control Valves (Directional) - Common Solenoid Return Open Circuit should become active. A. Fault code 4083 – Forward Pump Control Valves (Directional) - Common Solenoid Return Open Circuit is active and fault code 4082 – Forward Pump Control Valves (Directional) - Pumps Forward Solenoids Short to Ground is no longer active. Temporarily replace both solenoids and retest. Return to step 1 to confirm elimination of the fault. B. Fault code 4082 – Forward Pump Control Valves (Directional) - Pumps Forward Solenoids Short to Ground is still active. Fault code 4083 – Forward Pump Control Valves (Directional) - Common Solenoid Return Open Circuit did not become active. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. Wiring harnesses - Electrical schematic sheet 20 SH20-UNIVERSAL CONTROL MODULE (55.100.DP-C.20.E.20) Wiring harnesses - Electrical schematic sheet 10 SH10-EH PUMP/HYDRAULICS (55.100.DP-C.20.E.10) Wiring harnesses - Electrical schematic sheet 21 SH21-UNIVERSAL CONTROL MODULE (55.100.DP-C.20.E.21)
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4083 - Forward Pump Control Valves (Directional) - Common Solenoid Return Open Circuit SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Context: The UCM has sensed an open circuit on X-CN2B (Receptacle) pin 25. Diagnostic Trouble Code 4083 – Forward Pump Control Valves (Directional) - Common Solenoid Return Open Circuit has an error priority of Red. Forward ground drive operating mode is disabled while Diagnostic Trouble Code 4083 – Forward Pump Control Valves (Directional) - Common Solenoid Return Open Circuit is active. Cause: The UCM has sensed improper forward pump control valve solenoid current, X-CN2B (Receptacle) pin 25. The fault is active when the hydraulics are enabled and the solenoid return current is incorrect. Possible failure modes: 1. An open circuit in solenoid ground circuit. 2. Faulty forward drive pump solenoids. 3. The UCM has internal failure. 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. OK to return the machine to service. B. Fault code 4083 – Forward Pump Control Valves (Directional) - Common Solenoid Return Open Circuit is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the UCM, the right drive pump forward solenoid and the left drive pump forward solenoid connections. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the UCM to the right drive pump forward solenoid and the left drive pump forward solenoid. 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 the connectors as required. Return to step 1 to confirm elimination of fault. 3. Measure the resistance through the signal wires. Turn the ignition switch OFF. Disconnect solenoid connectors X-013 (Receptacle) and X-017 (Receptacle) . Disconnect UCM connectors X-CN2B (Receptacle) and X-CN3B (Receptacle) . 48068130 29/01/2018
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Fabricate a jumper wire that will connect between X-017 (Receptacle) pin 1 and X-017 (Receptacle) pin 2. Connect the jumper wire between X-017 (Receptacle) pin 1 and X-017 (Receptacle) pin 2. Measure the resistance between X-CN3B (Receptacle) pin 32 and X-CN2B (Receptacle) pin 25. The resistance should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition. Remove the jumper wire from connector X-017 (Receptacle) . Connect the jumper wire between X-013 (Receptacle) pin 1 and X-013 (Receptacle) pin 2. Measure the resistance between X-CN3B (Receptacle) pin 33 and X-CN2B (Receptacle) pin 25. The resistance should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition. A. Both resistance measurement are less than 10 Ω. Go to step 4. B. One or both resistance measurement are greater than 10 Ω. There is an open circuit in the harness. Repair or replace the harness as required. Return to step 1 to confirm elimination of fault. 4. Test the UCM. Turn the ignition switch OFF. Reconnect UCM connectors X-CN2B (Receptacle) and X-CN3B (Receptacle) . Leave connectors X-013 (Receptacle) and X-017 (Receptacle) disconnected. Fabricate a jumper wire that will connect between X-017 (Receptacle) pin 1 and X-017 (Receptacle) pin 2. Connect the jumper wire between X-017 (Receptacle) pin 1 and X-017 (Receptacle) pin 2. Fabricate a jumper wire that will connect between X-013 (Receptacle) pin 1 and X-013 (Receptacle) pin 2. Connect the jumper wire between X-013 (Receptacle) pin 1 and X-013 (Receptacle) pin 2. Turn the ignition switch ON. Activate the hydraulics while monitoring the fault code screen. Fault code 4083 – Forward Pump Control Valves (Directional) - Common Solenoid Return Open Circuit should no longer be active. Fault code 4082 – Forward Pump Control Valves (Directional) - Pumps Forward Solenoids Short to Ground should become active. A. Fault code 4082 – Forward Pump Control Valves (Directional) - Pumps Forward Solenoids Short to Ground is active and fault code 4083 – Forward Pump Control Valves (Directional) - Common Solenoid Return Open Circuit is no longer active. Temporarily replace both solenoids and retest. Return to step 1 to confirm elimination of the fault. B. Fault code 4083 – Forward Pump Control Valves (Directional) - Common Solenoid Return Open Circuit is still active. Fault code 4082 – Forward Pump Control Valves (Directional) - Pumps Forward Solenoids Short to Ground did not become active. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. Wiring harnesses - Electrical schematic sheet 20 SH20-UNIVERSAL CONTROL MODULE (55.100.DP-C.20.E.20) Wiring harnesses - Electrical schematic sheet 10 SH10-EH PUMP/HYDRAULICS (55.100.DP-C.20.E.10) Wiring harnesses - Electrical schematic sheet 21 SH21-UNIVERSAL CONTROL MODULE (55.100.DP-C.20.E.21)
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4309 - Park Brake Button - Park Brake Button Timeout (30 sec) SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Context: The UCM has detected that the voltage on X-CN2B (Receptacle) pin 22 is greater than 10 V. Diagnostic Trouble Code 4309 – Park Brake Button - Park Brake Button Timeout (30 sec) has an error priority of White. There are no restrictions while Diagnostic Trouble Code 4309 – Park Brake Button - Park Brake Button Timeout (30 sec) is active. Cause: The UCM has sensed that the voltage on X-CN2B (Receptacle) pin 22 is greater than 10 V. The fault is active while the voltage on the park brake input, X-CN2B (Receptacle) pin 22 is greater than 10 V for more than 30 s. Possible failure modes: 1. The signal wire has a short circuit to another voltage source. 2. Failure of the park brake switch. 3. Failure of the UCM. 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. OK to return the machine to service. B. Fault code 4309 – Park Brake Button - Park Brake Button Timeout (30 sec) is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the UCM and the park brake switch connections. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the UCM to the park brake 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 the connectors as required. Return to step 1 to confirm elimination of fault. 3. Measure the voltage on the signal wire. Turn the ignition switch OFF. Disconnect UCM connector X-CN2B (Receptacle) . Disconnect the park brake switch connector X-406 (Plug) . Turn the ignition switch ON.
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Measure the voltage between connector X-406 (Plug) pin B and chassis ground. The voltage should be less than 0.5 V. Wiggle the harness during measurement to reveal an intermittent condition. A. The voltage is less than 0.5 V. Go to step 4. B. The voltage is greater than 0.5 V. There is a short circuit to another voltage source. Verify wire is not shorted to another voltage source. Repair or replace the harness or connectors as required. Return to step 1 to confirm elimination of fault. 4. Test the switch. Turn the ignition switch OFF. Leave connector X-406 (Plug) disconnected. Verify that the parking brake switch is in the OFF position. Measure the resistance between the parking brake switch connector, X-406 (Plug) pin A and X-406 (Plug) pin B. The resistance should be greater than 20,000 Ω. A. The resistance is greater than 20,000 Ω. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. B. The resistance is less than 20,000 Ω. The switch has an internal short circuit. Replace the switch and retest. Return to step 1 to confirm elimination of fault. Wiring harnesses - Electrical schematic sheet 20 SH20-UNIVERSAL CONTROL MODULE (55.100.DP-C.20.E.20) Wiring harnesses - Electrical schematic sheet 14 SH14-BULKHEAD CONNECTION (55.100.DP-C.20.E.14) Wiring harnesses - Electrical schematic sheet 18 SH18-RIGHT NH CONTROL HANDLE (55.100.DP-C.20.E.18) Wiring harnesses - Electrical schematic sheet 16 SH16-LEFT HAND CAB CONSOLE (55.100.DP-C.20.E.16)
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4361 - Reverse Pump Control Valves (Directional) - Solenoid Right (A) Supply Open Circuit SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Context: The UCM has sensed an open circuit in the right drive pump reverse solenoid signal line. Diagnostic Trouble Code 4361 – Reverse Pump Control Valves (Directional) - Solenoid Right (A) Supply Open Circuit has an error priority of Red. Reverse ground drive is disabled while Diagnostic Trouble Code 4361 – Reverse Pump Control Valves (Directional) - Solenoid Right (A) Supply Open Circuit is active. Cause: The UCM has sensed an open circuit in X-CN2A (Receptacle) pin 8. The fault is active while the hydraulics are enabled and the solenoid resistance is greater than normal. Possible failure modes: 1. An open circuit in the wiring. 2. There is an open circuit in the right drive pump reverse solenoid. 3. The UCM has an internal failure. 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. OK to return the machine to service. B. Fault code 4361 – Reverse Pump Control Valves (Directional) - Solenoid Right (A) Supply Open Circuit is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the UCM and the right drive pump reverse solenoid connections. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the UCM to the right drive pump reverse solenoid. 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 the connectors as required. Return to step 1 to confirm elimination of fault. 3. Measure the resistance through the harness. Turn the ignition switch OFF. Disconnect UCM connectors X-CN2A (Receptacle) and X-CN1A (Receptacle) .
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Disconnect the right drive pump reverse solenoid connector X-018 (Receptacle) . Fabricate a jumper wire that will connect between the right drive pump reverse solenoid connector X-018 (Receptacle) pin 1 and X-018 (Receptacle) pin 2. Connect the jumper wire between X-018 (Receptacle) pin 1 and X-018 (Receptacle) pin 2. Measure the resistance between X-CN2A (Receptacle) pin 8 and X-CN1A (Receptacle) pin 19. 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. B. The resistance is greater than 10 Ω. There is an open circuit in the solenoid signal wire or the solenoid ground line. Check splice SP-099. Repair or replace the harness as required. Return to step 1 to confirm elimination of the fault. 4. Test the UCM. Leave the jumper wire installed between X-018 (Receptacle) pin 1 and X-018 (Receptacle) pin 2. Reconnect UCM connectors X-CN2A (Receptacle) and X-CN1A (Receptacle) . Turn the ignition switch ON. Activate the hydraulics while monitoring the fault code screen. Fault code 4361 – Reverse Pump Control Valves (Directional) - Solenoid Right (A) Supply Open Circuit should no longer be active. Fault code 4362 – Reverse Pump Control Valves (Directional) - Solenoid Right (A) Supply Short to Ground should become active. A. Fault code 4362 – Reverse Pump Control Valves (Directional) - Solenoid Right (A) Supply Short to Ground is active and fault code 4361 – Reverse Pump Control Valves (Directional) - Solenoid Right (A) Supply Open Circuit is no longer active. Temporarily replace the solenoid and retest. Return to step 1 to confirm elimination of the fault. B. Fault code 4361 – Reverse Pump Control Valves (Directional) - Solenoid Right (A) Supply Open Circuit is still active. Fault code 4362 – Reverse Pump Control Valves (Directional) - Solenoid Right (A) Supply Short to Ground did not become active. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. Wiring harnesses - Electrical schematic sheet 20 SH20-UNIVERSAL CONTROL MODULE (55.100.DP-C.20.E.20) Wiring harnesses - Electrical schematic sheet 10 SH10-EH PUMP/HYDRAULICS (55.100.DP-C.20.E.10)
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4362 - Reverse Pump Control Valves (Directional) - Solenoid Right (A) Supply Short to Ground SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Context: The UCM has sent a signal to the right reverse ground drive solenoid to energize, but no voltage was detected. Diagnostic Trouble Code 4362 – Reverse Pump Control Valves (Directional) - Solenoid Right (A) Supply Short to Ground has an error priority of Red. Reverse ground drive is disabled while Diagnostic Trouble Code 4362 – Reverse Pump Control Valves (Directional) - Solenoid Right (A) Supply Short to Ground is active. Cause: The UCM has sent a signal to the right reverse ground drive solenoid to energize, but no voltage was detected. The current on X-CN3B (Receptacle) pin 32 is greater than 3 A. The fault is active while the hydraulics are enabled and the current on X-CN2A (Receptacle) pin 8 is greater than 3 A. Possible failure modes: 1. A short circuit in the wiring. 2. The right drive pump forward solenoid has an internal short circuit. 3. The UCM has an internal failure. 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. OK to return the machine to service. B. Fault code 4362 – Reverse Pump Control Valves (Directional) - Solenoid Right (A) Supply Short to Ground is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the UCM and the right drive pump reverse solenoid connections. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the UCM to the right drive pump reverse solenoid. 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 the connectors as required. Return to step 1 to confirm elimination of fault. 3. Measure the resistance of the signal wire to chassis ground. Turn the ignition switch OFF.
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Disconnect UCM connectors X-CN2A (Receptacle) , X-CN1A (Receptacle) , and the right drive pump reverse solenoid connector X-018 (Receptacle) . Measure the resistance between X-CN2A (Receptacle) pin 8 and chassis ground. The resistance should be greater than 20,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition. Measure the resistance between X-CN1A (Receptacle) pin 19 and chassis ground. The resistance should be greater than 20,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition. A. Both resistance measurements are greater than 20,000 Ω. Go to step 4. B. One or both resistance measurements are less than 20,000 Ω. There is a short circuit to chassis ground in the wiring. Repair or replace the harness as required. Return to step 1 to confirm elimination of the fault. 4. Test the UCM. Reconnect UCM connectors X-CN2A (Receptacle) and X-CN1A (Receptacle) . Leave the right drive pump reverse solenoid connector, X-018 (Receptacle) disconnected. Turn the ignition switch ON. Activate the hydraulics while monitoring the fault code screen. Fault code 4362 – Reverse Pump Control Valves (Directional) - Solenoid Right (A) Supply Short to Ground should no longer be active. Fault code 4361 – Reverse Pump Control Valves (Directional) - Solenoid Right (A) Supply Open Circuit should become active. A. Fault code 4361 – Reverse Pump Control Valves (Directional) - Solenoid Right (A) Supply Open Circuit is active and fault code 4362 – Reverse Pump Control Valves (Directional) - Solenoid Right (A) Supply Short to Ground is no longer active. Temporarily replace the solenoid and retest. Return to step 1 to confirm elimination of the fault. B. Fault code 4362 – Reverse Pump Control Valves (Directional) - Solenoid Right (A) Supply Short to Ground is still active. Fault code 4361 – Reverse Pump Control Valves (Directional) - Solenoid Right (A) Supply Open Circuit did not become active. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. Wiring harnesses - Electrical schematic sheet 20 SH20-UNIVERSAL CONTROL MODULE (55.100.DP-C.20.E.20) Wiring harnesses - Electrical schematic sheet 10 SH10-EH PUMP/HYDRAULICS (55.100.DP-C.20.E.10)
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4371 - Reverse Pump Control Valves (Directional) - Solenoid Left (B) Supply Open Circuit SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Context: The UCM has sensed an open circuit in the left drive pump reverse solenoid signal line. Diagnostic Trouble Code 4371 – Reverse Pump Control Valves (Directional) - Solenoid Left (B) Supply Open Circuit has an error priority of Red. Reverse ground drive is disabled while Diagnostic Trouble Code 4371 – Reverse Pump Control Valves (Directional) - Solenoid Left (B) Supply Open Circuit is active. Cause: The UCM has sensed an open circuit in X-CN2A (Receptacle) pin 14. The fault is active while the hydraulics are enabled and the solenoid resistance is greater than normal. Possible failure modes: 1. An open circuit in the wiring. 2. There is an open circuit in the left drive pump reverse solenoid. 3. The UCM has an internal failure. 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. OK to return the machine to service. B. Fault code 4371 – Reverse Pump Control Valves (Directional) - Solenoid Left (B) Supply Open Circuit is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the UCM and the left drive pump reverse solenoid connections. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the UCM to the left drive pump reverse solenoid. 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 the connectors as required. Return to step 1 to confirm elimination of fault. 3. Measure the resistance through the harness. Turn the ignition switch OFF. Disconnect UCM connectors X-CN2A (Receptacle) and X-CN1A (Receptacle) .
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Disconnect the left drive pump reverse solenoid connector X-016 (Receptacle) . Fabricate a jumper wire that will connect between the left drive pump reverse solenoid connector X-016 (Receptacle) pin 1 and X-016 (Receptacle) pin 2. Connect the jumper wire between X-016 (Receptacle) pin 1 and X-016 (Receptacle) pin 2. Measure the resistance between X-CN2A (Receptacle) pin 14 and X-CN1A (Receptacle) pin 19. 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. B. The resistance is greater than 10 Ω. There is an open circuit in the solenoid signal wire or the solenoid ground line. Check splice SP-099. Repair or replace the harness as required. Return to step 1 to confirm elimination of the fault. 4. Test the UCM. Leave the jumper wire installed between X-016 (Receptacle) pin 1 and X-016 (Receptacle) pin 2. Reconnect UCM connectors X-CN2A (Receptacle) and X-CN1A (Receptacle) . Turn the ignition switch ON. Activate the hydraulics while monitoring the fault code screen. Fault code 4371 – Reverse Pump Control Valves (Directional) - Solenoid Left (B) Supply Open Circuit should no longer be active. Fault code 4372 – Reverse Pump Control Valves (Directional) - Solenoid Left (B) Supply Short to Ground should become active. A. Fault code 4372 – Reverse Pump Control Valves (Directional) - Solenoid Left (B) Supply Short to Ground is active and fault code 4371 – Reverse Pump Control Valves (Directional) - Solenoid Left (B) Supply Open Circuit is no longer active. Temporarily replace the solenoid and retest. Return to step 1 to confirm elimination of the fault. B. Fault code 4371 – Reverse Pump Control Valves (Directional) - Solenoid Left (B) Supply Open Circuit is still active. Fault code 4372 – Reverse Pump Control Valves (Directional) - Solenoid Left (B) Supply Short to Ground did not become active. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. Wiring harnesses - Electrical schematic sheet 20 SH20-UNIVERSAL CONTROL MODULE (55.100.DP-C.20.E.20) Wiring harnesses - Electrical schematic sheet 10 SH10-EH PUMP/HYDRAULICS (55.100.DP-C.20.E.10)
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Electrical systems - FAULT CODES
4372 - Reverse Pump Control Valves (Directional) - Solenoid Left (B) Supply Short to Ground SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Context: The UCM has sent a signal to the left reverse ground drive solenoid to energize, but no voltage was detected. Diagnostic Trouble Code 4372 – Reverse Pump Control Valves (Directional) - Solenoid Left (B) Supply Short to Ground has an error priority of Red. Reverse ground drive is disabled while Diagnostic Trouble Code 4372 – Reverse Pump Control Valves (Directional) - Solenoid Left (B) Supply Short to Ground is active. Cause: The UCM has sent a signal to the left reverse ground drive solenoid to energize, but no voltage was detected. The current on X-CN2A (Receptacle) pin 14 is greater than 3 A. The fault is active while the hydraulics are enabled and the current on X-CN2A (Receptacle) pin 14 is greater than 3 A. Possible failure modes: 1. A short circuit in the wiring. 2. The left drive pump reverse solenoid has an internal short circuit. 3. The UCM has an internal failure. 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. OK to return the machine to service. B. Fault code 4372 – Reverse Pump Control Valves (Directional) - Solenoid Left (B) Supply Short to Ground is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the UCM and the left drive pump reverse solenoid connections. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the UCM to the left drive pump reverse solenoid. 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 the connectors as required. Return to step 1 to confirm elimination of fault. 3. Measure the resistance of the signal wire to chassis ground. Turn the ignition switch OFF.
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Disconnect UCM connector X-CN2A (Receptacle) , X-CN1A (Receptacle) , and the left drive pump reverse solenoid connector X-016 (Receptacle) . Measure the resistance between X-CN2A (Receptacle) pin 14 and chassis ground. The resistance should be greater than 20,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition. Measure the resistance between X-CN1A (Receptacle) pin 19 and chassis ground. The resistance should be greater than 20,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition. A. Both resistance measurements are greater than 20,000 Ω. Go to step 4. B. One or both resistance measurements are less than 20,000 Ω. There is a short circuit to chassis ground in the wiring. Repair or replace the harness as required. Return to step 1 to confirm elimination of the fault. 4. Test the UCM. Reconnect UCM connectors X-CN2A (Receptacle) and X-CN1A (Receptacle) . Leave the left drive pump reverse solenoid connector X-016 (Receptacle) disconnected. Turn the ignition switch ON. Activate the hydraulics while monitoring the fault code screen. Fault code 4372 – Reverse Pump Control Valves (Directional) - Solenoid Left (B) Supply Short to Ground should no longer be active. Fault code 4371 – Reverse Pump Control Valves (Directional) - Solenoid Left (B) Supply Open Circuit should become active. A. Fault code 4371 – Reverse Pump Control Valves (Directional) - Solenoid Left (B) Supply Open Circuit is active and fault code 4372 – Reverse Pump Control Valves (Directional) - Solenoid Left (B) Supply Short to Ground is no longer active. Temporarily replace the solenoid and retest. Return to step 1 to confirm elimination of the fault. B. Fault code 4372 – Reverse Pump Control Valves (Directional) - Solenoid Left (B) Supply Short to Ground is still active. Fault code 4371 – Reverse Pump Control Valves (Directional) - Solenoid Left (B) Supply Open Circuit did not become active. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. Wiring harnesses - Electrical schematic sheet 20 SH20-UNIVERSAL CONTROL MODULE (55.100.DP-C.20.E.20) Wiring harnesses - Electrical schematic sheet 10 SH10-EH PUMP/HYDRAULICS (55.100.DP-C.20.E.10)
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4381 - Reverse Pump Control Valves (Directional) - Common Solenoid Return Short to Power SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Context: The UCM has sensed that the voltage on X-CN2A (Receptacle) pin 8, X-CN2A (Receptacle) pin 14, and X-CN1A (Receptacle) pin 19 is greater than 5 V. Diagnostic Trouble Code 4381 – Reverse Pump Control Valves (Directional) - Common Solenoid Return Short to Power has an error priority of Red. Reverse ground drive is disabled while Diagnostic Trouble Code 4381 – Reverse Pump Control Valves (Directional) - Common Solenoid Return Short to Power is active. Cause: UCM has sensed higher than normal voltage on the reverse ground drive valve solenoids ground line. The fault is active while the hydraulics are disabled and the solenoid voltage feedback is greater than 5 V. Possible failure modes: 1. Shorted wire in circuit. 2. UCM has internal failure. 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. OK to return the machine to service. B. Fault code 4381 – Reverse Pump Control Valves (Directional) - Common Solenoid Return Short to Power is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the UCM, the right drive pump reverse solenoid and the left drive pump reverse solenoid connections. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the UCM to the right drive pump reverse solenoid and the left drive pump reverse solenoid. 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. 3. Measure the voltage of the solenoid wires to chassis ground. Turn the ignition switch OFF. Disconnect solenoid connector X-016 (Receptacle) and X-018 (Receptacle) . Disconnect UCM connector X-CN2A (Receptacle) and X-CN1A (Receptacle) .
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Turn the ignition switch ON. Measure the voltage between X-018 (Receptacle) pin 1 and chassis ground. The voltage should be less than 0.5 V. Wiggle the harness during measurement to reveal an intermittent condition. Measure the voltage between X-018 (Receptacle) pin 2 and chassis ground. The voltage should be less than 0.5 V. Wiggle the harness during measurement to reveal an intermittent condition. Measure the voltage between X-016 (Receptacle) pin 1 and chassis ground. The voltage should be less than 0.5 V. Wiggle the harness during measurement to reveal an intermittent condition. Measure the voltage between X-016 (Receptacle) pin 2 and chassis ground. The voltage should be less than 0.5 V. Wiggle the harness during measurement to reveal an intermittent condition. A. All voltage measurement are less than 0.5 V. Go to step 4. B. One or more voltage measurements are greater than 0.5 V. There is an short circuit to another voltage source in the harness. Repair or replace the harness as required. Return to step 1 to confirm elimination of fault. 4. Test the UCM. Turn the ignition switch OFF. Reconnect UCM connectors X-CN2A (Receptacle) and X-CN1A (Receptacle) . Leave connectors X-016 (Receptacle) and X-018 (Receptacle) disconnected. Turn the ignition switch ON. Activate the hydraulics while monitoring the fault code screen. Fault code 4381 – Reverse Pump Control Valves (Directional) - Common Solenoid Return Short to Power should no longer be active. Fault code 4383 – Reverse Pump Control Valves (Directional) - Common Solenoid Return Open Circuit should become active. A. Fault code 4383 – Reverse Pump Control Valves (Directional) - Common Solenoid Return Open Circuit is active and fault code 4381 – Reverse Pump Control Valves (Directional) - Common Solenoid Return Short to Power is no longer active. Temporarily replace both solenoids and retest. Return to step 1 to confirm elimination of the fault. B. Fault code 4381 – Reverse Pump Control Valves (Directional) - Common Solenoid Return Short to Power is still active. Fault code 4383 – Reverse Pump Control Valves (Directional) - Common Solenoid Return Open Circuit did not become active. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. Wiring harnesses - Electrical schematic sheet 20 SH20-UNIVERSAL CONTROL MODULE (55.100.DP-C.20.E.20) Wiring harnesses - Electrical schematic sheet 10 SH10-EH PUMP/HYDRAULICS (55.100.DP-C.20.E.10)
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4382 - Reverse Pump Control Valves (Directional) - Pumps Reverse Solenoids Short to Ground SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Context: The UCM has sensed that the voltage on CN2A pin 8, CN2A pin 14, and CN1A pin 19 is less than 5 V. Diagnostic Trouble Code 4382 – Reverse Pump Control Valves (Directional) - Pumps Reverse Solenoids Short to Ground has an error priority of Red. Reverse ground drive is disabled while Diagnostic Trouble Code 4382 – Reverse Pump Control Valves (Directional) - Pumps Reverse Solenoids Short to Ground is active. Cause: The UCM has sensed that the voltage on CN2A pin 8, CN2A pin 14, and CN1A pin 19 is less than 5 V. The fault is active while the hydraulics are disabled and solenoid return voltage feedback is low. Possible failure modes: 1. A short circuit in the wiring. 2. The UCM has internal failure. Solution: 1. Verify that the fault code is active. Connect the Electronic Service Tool to the service tool connector. To check for fault code: Start and operate the machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 4382 – Reverse Pump Control Valves (Directional) - Pumps Reverse Solenoids Short to Ground is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the UCM, the right drive pump reverse solenoid and the left drive pump reverse solenoid connections. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the UCM to the right drive pump reverse solenoid and the left drive pump reverse solenoid. 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 the connectors as required. Return to step 1 to confirm elimination of fault. 3. Measure the resistance of the solenoid wires to chassis ground. Turn the ignition switch OFF. Disconnect solenoid connectors X-18 and X-16. Disconnect UCM connectors CN2A and CN1A.
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Measure the resistance between X-18 pin 1 and chassis ground. The resistance should be greater than 20,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition. Measure the resistance between X-18 pin 2 and chassis ground. The resistance should be greater than 20,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition. Measure the resistance between X-16 pin 1 and chassis ground. The resistance should be greater than 20,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition. Measure the resistance between X-16 pin 2 and chassis ground. The resistance should be greater than 20,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition. A. All resistance measurements are greater than 20,000 Ω. Go to step 4. B. One or more resistance measurements are less than 20,000 Ω. There is an short circuit to chassis ground. Repair or replace the harness as required. Return to step 1 to confirm elimination of fault. 4. Test the UCM. Turn the ignition switch OFF. Reconnect UCM connectors CN2A and CN1A. Leave connectors X-18 and X-16 disconnected. Turn the ignition switch ON. Activate the hydraulics while monitoring the fault code screen. Fault code 4382 – Reverse Pump Control Valves (Directional) - Pumps Reverse Solenoids Short to Ground should no longer be active. Fault code 4383 – Reverse Pump Control Valves (Directional) - Common Solenoid Return Open Circuit should become active. A. Fault code 4383 – Reverse Pump Control Valves (Directional) - Common Solenoid Return Open Circuit is active and fault code 4382 – Reverse Pump Control Valves (Directional) - Pumps Reverse Solenoids Short to Ground is no longer active. Temporarily replace both solenoids and retest. Return to step 1 to confirm elimination of the fault. B. Fault code 4382 – Reverse Pump Control Valves (Directional) - Pumps Reverse Solenoids Short to Ground is still active. Fault code 4383 – Reverse Pump Control Valves (Directional) - Common Solenoid Return Open Circuit did not become active. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. Wiring harnesses - Electrical schematic sheet 19 Unit Control Module (55.100.DP-C.20.E.19) Wiring harnesses - Electrical schematic sheet 09 EH Pump/ Hydraulics (55.100.DP-C.20.E.09)
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4383 - Reverse Pump Control Valves (Directional) - Common Solenoid Return Open Circuit SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Context: The UCM has sensed an open circuit on X-CN1A (Receptacle) pin 19. Diagnostic Trouble Code 4383 – Reverse Pump Control Valves (Directional) - Common Solenoid Return Open Circuit has an error priority of Red. Reverse ground drive operating mode is disabled while Diagnostic Trouble Code 4383 – Reverse Pump Control Valves (Directional) - Common Solenoid Return Open Circuit is active. Cause: The UCM has sensed improper reverse pump control valve solenoid current, X-CN1A (Receptacle) pin 19. The fault is active when the hydraulics are enabled and the solenoid return current is incorrect. Possible failure modes: 1. An open circuit in solenoid ground circuit. 2. Faulty reverse drive pump solenoids. 3. The UCM has internal failure. 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. OK to return the machine to service. B. Fault code 4383 – Reverse Pump Control Valves (Directional) - Common Solenoid Return Open Circuit is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the UCM, the right drive pump reverse solenoid and the left drive pump reverse solenoid connections. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the UCM to the right drive pump reverse solenoid and the left drive pump reverse solenoid. 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 the connectors as required. Return to step 1 to confirm elimination of fault. 3. Measure the resistance through the signal wires. Turn the ignition switch OFF. Disconnect solenoid connectors X-016 (Receptacle) and X-018 (Receptacle) . Disconnect UCM connectors X-CN2A (Receptacle) and X-CN1A (Receptacle) . 48068130 29/01/2018
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Fabricate a jumper wire that will connect between X-018 (Receptacle) pin 1 and X-018 (Receptacle) pin 2. Connect the jumper wire between X-018 (Receptacle) pin 1 and X-018 (Receptacle) pin 2. Measure the resistance between X-CN2A (Receptacle) pin 8 and X-CN1A (Receptacle) pin 19. The resistance should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition. Remove the jumper wire from connector X-018 (Receptacle) . Connect the jumper wire between X-016 (Receptacle) pin 1 and X-016 (Receptacle) pin 2. Measure the resistance between X-CN2A (Receptacle) pin 14 and X-CN1A (Receptacle) pin 19. The resistance should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition. A. Both resistance measurement are less than 10 Ω. Go to step 4. B. One or both resistance measurement are greater than 10 Ω. There is an open circuit in the harness. Repair or replace the harness as required. Return to step 1 to confirm elimination of fault. 4. Test the UCM. Turn the ignition switch OFF. Reconnect UCM connectors X-CN2A (Receptacle) and X-CN1A (Receptacle) . Leave connectors X-016 (Receptacle) and X-018 (Receptacle) disconnected. Fabricate a jumper wire that will connect between X-018 (Receptacle) pin 1 and X-018 (Receptacle) pin 2. Connect the jumper wire between X-018 (Receptacle) pin 1 and X-018 (Receptacle) pin 2. Fabricate a jumper wire that will connect between X-016 (Receptacle) pin 1 and X-016 (Receptacle) pin 2. Connect the jumper wire between X-016 (Receptacle) pin 1 and X-016 (Receptacle) pin 2. Turn the ignition switch ON. Activate the hydraulics while monitoring the fault code screen. Fault code 4383 – Reverse Pump Control Valves (Directional) - Common Solenoid Return Open Circuit should no longer be active. Fault code 4382 – Reverse Pump Control Valves (Directional) - Pumps Reverse Solenoids Short to Ground should become active. A. Fault code 4382 – Reverse Pump Control Valves (Directional) - Pumps Reverse Solenoids Short to Ground is active and fault code 4383 – Reverse Pump Control Valves (Directional) - Common Solenoid Return Open Circuit is no longer active. Temporarily replace both solenoids and retest. Return to step 1 to confirm elimination of the fault. B. Fault code 4383 – Reverse Pump Control Valves (Directional) - Common Solenoid Return Open Circuit is still active. Fault code 4382 – Reverse Pump Control Valves (Directional) - Pumps Reverse Solenoids Short to Ground did not become active. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. Wiring harnesses - Electrical schematic sheet 20 SH20-UNIVERSAL CONTROL MODULE (55.100.DP-C.20.E.20) Wiring harnesses - Electrical schematic sheet 10 SH10-EH PUMP/HYDRAULICS (55.100.DP-C.20.E.10)
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4401 - Park Brake (Mechanical Machines) Solenoid Open Circuit Context: The instrument cluster has sent a signal to the brake valve solenoid to energize, but the solenoid is off. Diagnostic Trouble Code 4401 has an error priority of Red. Cause: The instrument cluster has sent a signal to the brake valve solenoid to energize, but the solenoid is off. The fault is activate while the instrument cluster solenoid output, X-C23 pin 28 is off and brake commanded state, X-C23 pin 21 is high. Possible failure modes: 1. An open circuit in the wiring. 2. The brake valve solenoid has failed. 3. The instrument cluster has an internal failure. 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 machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 4401 is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the instrument cluster and the park brake solenoid connections. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the instrument cluster to the park brake solenoid. 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 the connectors as required. Return to step 1 to confirm elimination of fault. 3. Measure the resistance through the solenoid wire. Turn the ignition switch OFF. Disconnect instrument cluster connector X-C23. Measure the resistance between X-C23 pin 28 and chassis ground. The resistance should be less than 100 Ω. Wiggle the harness during measurement to reveal an intermittent condition. A. The resistance is less than 100 Ω. Temporarily replace the instrument cluster and retest. Return to step 1 to confirm elimination of the fault. B. The resistance is greater than 100 Ω. There is an open circuit in the harness. Go to step 4. 4. Measure the resistance through the solenoid. Disconnect the brake valve solenoid connector X-BRK. Measure the resistance across the solenoid terminals. The resistance should be less than 100 Ω. A. The resistance is less than 100 Ω. Go to step 5.
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B. The resistance is greater than 100 立. There is an open circuit in the solenoid. Replace the solenoid and retest. Return to step 1 to confirm elimination of the fault. 5. Measure the resistance through the solenoid ground wire. Leave connector X-BRK disconnected. Measure the resistance between X-BRK pin 2 and chassis ground. The chassis ground connection must be clean and free of paint, oil, and dirt. The resistance should be less than 10 立. Wiggle the harness during measurement to reveal an intermittent condition. A. The resistance is less than 10 立. There is an open circuit in the solenoid ground connection. Repair or replace the harness as required. Return to step 1 to confirm elimination of the fault. B. The resistance is greater than 10 立. There is an open circuit in the solenoid ground wire. Repair or replace the harness as required. Return to step 1 to confirm elimination of the fault.
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Electrical systems - FAULT CODES
4402 - Park Brake (Mechanical Machines) Shorted To Power Context: The instrument cluster has sent a signal to the brake valve solenoid to de-energize, but the solenoid remains on. Diagnostic Trouble Code 4402 has an error priority of Red. The vehicle is disabled while Diagnostic Trouble Code 4402 is active. Cause: The instrument cluster has sent a signal to the brake valve solenoid to de-energize, but the solenoid remains on. The fault is activate while the instrument cluster solenoid output, X-C23 pin 28 is on and the brake commanded state, X-C23 pin 21 is low. Possible failure modes: 1. The signal wire has a short circuit to another voltage source. 2. The instrument cluster has an internal failure. 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 machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 4402 is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the instrument cluster and the park brake solenoid connections. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the instrument cluster to the park brake solenoid. 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 the connectors as required. Return to step 1 to confirm elimination of fault. 3. Measure the voltage through the solenoid wire. Turn the ignition switch OFF. Disconnect the instrument cluster connector X-C23. Disconnect the park brake solenoid connector X-BRK. Turn the ignition switch ON. Measure the voltage between X-C23 pin 28 and chassis ground. The voltage should be less than 0.5 V. Wiggle the harness during measurement to reveal an intermittent condition. A. The voltage is less than 0.5 V. Temporarily replace the instrument cluster 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 to another voltage source. Repair or replace the harness as required. Return to step 1 to confirm elimination of the fault.
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4431 - Park Brake Pressure Switch - Pressure Switch (Plausibility Check With Solenoid Valve) SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Context: The UCM has sensed a disagreement between the park brake pressure switch and the park brake solenoid. Diagnostic Trouble Code 4431 – Park Brake Pressure Switch - Pressure Switch (Plausibility Check With Solenoid Valve) has an error priority of amber. There are no restrictions while Diagnostic Trouble Code 4431 – Park Brake Pressure Switch - Pressure Switch (Plausibility Check With Solenoid Valve) is active. Cause: The UCM has sensed a disagreement between the park brake pressure switch and the park brake solenoid. The fault is active while the engine is running and the park brake pressure switch input X-CN2B (Receptacle) pin 13 is ON and the solenoid current output X-CN3A (Receptacle) pin 4 is less than 1 A or the park brake pressure switch input X-CN2B (Receptacle) pin 13 is OFF and the solenoid current output X-CN3A (Receptacle) pin 4 is greater than 1 A. Possible failure modes: 1. Low charge pressure. 2. An open circuit or a short circuit in the wiring. 3. A faulty park brake solenoid. 4. A faulty park brake pressure switch. 5. A faulty UCM. 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. OK to return the machine to service. B. Fault code 4431 – Park Brake Pressure Switch - Pressure Switch (Plausibility Check With Solenoid Valve) is recorded again. Go to step 2. 2. Verify the charge pressure. Verify the charge pressure is approximately 2482 kPa (360 psi) at low idle. Verify the charge pressure is approximately 2758 kPa (400 psi) at full throttle. A. Charge pressure is in the correct range and fault code 4431 – Park Brake Pressure Switch - Pressure Switch (Plausibility Check With Solenoid Valve) is still active. Go to step 3. B. Charge pressure is not correct. Repair the cause of the low charge pressure and retest. Return to step 1 to confirm elimination of the fault. 3. Verify that the wiring and connectors are free of damage. 48068130 29/01/2018
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Inspect the UCM, the park brake solenoid, and the park brake switch connections. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the UCM to the park brake solenoid and the park brake 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 4. 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. 4. Use EST to test the system. Turn the ignition switch ON. Turn the park brake switch OFF. Use the EST to access the status of the park brake pressure switch. The switch status should be OFF. Reference 534 670 539 518 502
EST park brake parameters Data Description Park Brake Button Park Brake Indicator Lamp Park Brake Pressure Switch Park Brake Solenoid Output (EH machines only) Park Brake Status
Source UCM Instrument Cluster UCM UCM UCM
Enable the hydraulic system. Use the EST to access the status of the park brake valve. The valve status should OFF. A. The park brake switch status is ON. The solenoid status is OFF. Fault code 4309 – Park Brake Button - Park Brake Button Timeout (30 sec) will be come active after 30 minutes. Go to troubleshooting procedure 4309 – Park Brake Button - Park Brake Button Timeout (30 sec). B. The park brake switch status is OFF. The solenoid status is ON. Fault code 4056 – Park Brake Valve (On/Off) - Solenoid Supply Short to Ground is active. Go to troubleshooting procedure 4056 – Park Brake Valve (On/Off) - Solenoid Supply Short to Ground. C. The park brake switch status is OFF and the solenoid status is OFF. Fault code 4431 – Park Brake Pressure Switch - Pressure Switch (Plausibility Check With Solenoid Valve) is active. Go to step 5. 5. Use EST to test the system. Turn the ignition switch ON and start the engine. Turn the park brake switch ON. Use the EST to access the status of the park brake pressure switch. The switch status should be ON. Use the EST to access the status of the park brake valve. The valve status should ON. A. The park brake switch status is OFF. The solenoid status is ON. Fault code 4431 – Park Brake Pressure Switch - Pressure Switch (Plausibility Check With Solenoid Valve) is active. Go to step 6. B. The park brake switch status is ON and the solenoid status is ON. Fault code 4431 – Park Brake Pressure Switch - Pressure Switch (Plausibility Check With Solenoid Valve) is not active. There does not appear to be a problem at this time. OK to return the machine to service. 6. Measure the resistance through the solenoid wire. Turn the key switch OFF. Disconnect park brake switch connector X-BRKPRS (Plug) . Fabricate a jumper wire that will connect between X-BRKPRS (Plug) pin 1 and X-BRKPRS (Plug) pin 2. 48068130 29/01/2018
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Install the jumper wire between X-BRKPRS (Plug) pin 1 and X-BRKPRS (Plug) pin 2. Turn the ignition switch ON. Start the engine. Turn the park brake switch ON. Use the EST to access the status of the park brake pressure switch. The switch status should be ON. A. The park brake status is ON. Fault code 4431 – Park Brake Pressure Switch - Pressure Switch (Plausibility Check With Solenoid Valve) is no longer active. Replace the pressure switch. Return to step 1 to confirm elimination of the fault. B. The park brake status is OFF. Fault code 4431 – Park Brake Pressure Switch - Pressure Switch (Plausibility Check With Solenoid Valve) is still active. Go to step 7. 7. Measure the resistance through the wire. Turn the ignition switch OFF. Leave the jumper wire installed between X-BRKPRS (Plug) pin 1 and X-BRKPRS (Plug) pin 2. Disconnect UCM connector X-CN2B (Receptacle) . Measure the resistance between X-CN2B (Receptacle) pin 13 and chassis ground. 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. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. B. The resistance is greater than 10 Ω. There is an open circuit in the wire. Go to step 8. 8. Measure the resistance of the solenoid ground wire. Turn the ignition switch OFF. Remove the jumper wire between X-BRKPRS (Plug) pin 1 and X-BRKPRS (Plug) pin 2. Measure the resistance between X-BRKPRS (Plug) pin 2 and chassis ground. 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. There is an open circuit in the wiring between the UCM and the park brake pressure switch. Repair or replace the harness as required. Return to step 1 to confirm elimination of the fault. B. The resistance is greater than 10 Ω. There is an open circuit in the ground circuit. Verify the chassis ground connections are tight and secure. Repair or replace the harness as required. Return to step 1 to confirm elimination of the fault. Wiring harnesses - Electrical schematic sheet 20 SH20-UNIVERSAL CONTROL MODULE (55.100.DP-C.20.E.20) Wiring harnesses - Electrical schematic sheet 10 SH10-EH PUMP/HYDRAULICS (55.100.DP-C.20.E.10)
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4731 - Right Swash Plate Angle Sensor - Pin A Short to Ground/ Open Circuit SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Context: The UCM has sensed that the swash plate angle sensor signal has failed. Diagnostic Trouble Code 4731 – Right Swash Plate Angle Sensor - Pin A Short to Ground/ Open Circuit has an error priority of Amber. Ground drive will operate in limp home mode while Diagnostic Trouble Code 4731 – Right Swash Plate Angle Sensor - Pin A Short to Ground/ Open Circuit is active. Cause: The UCM has sensed that the swash plate angle sensor signal has failed low. The fault is active while the engine is ON and the right swash plate angle sensor voltage, CN2B pin 32 is less than 0.2 V. Possible failure modes: 1. The sensor signal wire is shorted to chassis ground. 2. An open circuit in the sensor signal wire. 3. A failure of the swash plate angle sensor. 4. The UCM has an internal failure. 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. OK to return the machine to service. B. Fault code 4731 – Right Swash Plate Angle Sensor - Pin A Short to Ground/ Open Circuit is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the UCM, the left-hand swash plate sensor connection and the right-hand swash plate sensor connection. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the UCM to the swash plate sensors. 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 the connectors as required. Return to step 1 to confirm elimination of fault. 3. Measure the voltage at the sensor. Turn the ignition switch OFF. Disconnect the right-hand swash plate sensor connector X-093 (Receptacle) .
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Turn the ignition switch ON. Measure the voltage between X-093 (Receptacle) pin 5 and X-093 (Receptacle) pin 1. The voltage should be approximately 12 V. Wiggle the harness during measurement to reveal an intermittent condition. Measure the voltage between X-093 (Receptacle) pin 2 and X-093 (Receptacle) pin 6. The voltage should be approximately 12 V. Wiggle the harness during measurement to reveal an intermittent condition. A. The voltage measurement is approximately 12 V. Go to step 4. B. The voltage measurement is less than 10 V. There is a problem in the voltage supply or sensor ground wire to the sensor. Repair or replace the harness or connectors as required. Return to step 1 to confirm elimination of fault. 4. Measure the resistance of the signal wire to chassis ground. Turn the ignition switch OFF. Disconnect UCM connector X-CN2B (Receptacle) . Disconnect the right-hand swash plate sensor connector X-093 (Receptacle) . Measure the resistance between X-CN2B (Receptacle) pin 32 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. Go to step 5. B. The resistance measurement is less than 20,000 Ω. There is a short circuit to chassis ground in the signal wire. Repair or replace the harness or connectors as required. Return to step 1 to confirm elimination of fault. 5. Measure the resistance through the signal wire. Turn the ignition switch OFF. Disconnect UCM connector X-CN2B (Receptacle) . Disconnect connector X-093 (Receptacle) . Fabricate a jumper wire that will connect between the UCM connector X-CN2B (Receptacle) pin 32 and chassis ground. Connect the jumper wire between X-CN2B (Receptacle) pin 32 and chassis ground. Measure the resistance between X-093 (Receptacle) pin 4 and chassis ground. The resistance should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition. A. The resistance measurement is less than 10 Ω. Go to step 6. B. The resistance measurement is greater than 10 Ω. There is an open circuit in the signal wire. Repair or replace the harness or connectors as required. Return to step 1 to confirm elimination of fault. 6. Test the UCM. Turn the ignition switch OFF. Remove the jumper wire. Reconnect the UCM connector X-CN2B (Receptacle) . Disconnect the swash plate sensor connectors X-093 (Receptacle) and X-094 (Receptacle) . Connect the left hand swash plate sensor into the right hand swash plate sensor connector X-093 (Receptacle) . Connect the right hand swash plate sensor into the left hand swash plate sensor connector X-094 (Receptacle) . Turn the ignition switch ON.
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Monitor the active diagnostic screen. Fault code 4731 – Right Swash Plate Angle Sensor - Pin A Short to Ground/ Open Circuit should no longer be active. Fault code 4744 – Left Swash Plate Angle Sensor Pin B Open Or Shorted To Ground is active. A. Fault code 4731 – Right Swash Plate Angle Sensor - Pin A Short to Ground/ Open Circuit is no longer active. Fault code 4744 – Left Swash Plate Angle Sensor Pin B Open Or Shorted To Ground is active. Replace the Swash Plate Angle sensor and retest. Return to step 1 to confirm elimination of the fault. B. Fault code 4731 – Right Swash Plate Angle Sensor - Pin A Short to Ground/ Open Circuit is still active. Fault code 4744 – Left Swash Plate Angle Sensor Pin B Open Or Shorted To Ground did not become active. Replace the UCM and retest. Return to step 1 to confirm elimination of fault. Wiring harnesses - Electrical schematic sheet 20 SH20-UNIVERSAL CONTROL MODULE (55.100.DP-C.20.E.20) Wiring harnesses - Electrical schematic sheet 10 SH10-EH PUMP/HYDRAULICS (55.100.DP-C.20.E.10)
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4732 - Right Swash Plate Angle Sensor - Pin A Short to Power SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Context: The UCM has sensed a higher than normal voltage from the right-hand swash plate sensor. Diagnostic Trouble Code 4732 – Right Swash Plate Angle Sensor - Pin A Short to Power has an error priority of Amber. Ground drive will operate in limp home mode while Diagnostic Trouble Code 4732 – Right Swash Plate Angle Sensor - Pin A Short to Power is active. Cause: The UCM has sensed a higher than normal voltage from the right-hand swash plate sensor. The fault is active while the engine is ON and the swash plate angle sensor voltage, X-CN2B (Receptacle) pin 32 is greater than 4.8 V. Possible failure modes: 1. The signal wire has a short circuit to another voltage source. 2. A failure of the swash plate sensor. 3. The UCM has an internal failure. 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. OK to return the machine to service. B. Fault code 4732 – Right Swash Plate Angle Sensor - Pin A Short to Power is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the UCM, the left-hand swash plate sensor connection and the right-hand swash plate sensor connection. All connections should be secure, tight, free of corrosion, abrasion and damage. Inspect the harness from the UCM to the swash plate sensors. 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 the connectors as required. Return to step 1 to confirm elimination of fault. 3. Measure the voltage on the sensor signal wire. Turn the ignition switch OFF. Disconnect UCM connector X-CN2B (Receptacle) . Disconnect the right-hand swash plate sensor connector X-093 (Receptacle) . Turn the ignition switch ON.
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Measure the voltage between X-093 (Receptacle) pin 4 and chassis ground. The voltage should be less than 0.5 V. Wiggle the harness during measurement to reveal an intermittent condition. A. The voltage measurement is less than 0.5 V. Go to step 4. B. The voltage measurement is greater than 0.5 V. There is a short circuit to another voltage source. Repair or replace the harness or the connectors as required. Return to step 1 to confirm elimination of fault. 4. Test the UCM. Turn the ignition switch OFF. Reconnect UCM connector X-CN2B (Receptacle) . Disconnect swash plate sensor connectors X-093 (Receptacle) and X-094 (Receptacle) . Connect the left-hand swash plate sensor into the right-hand swash plate sensor connector X-093 (Receptacle) . Connect the right-hand swash plate sensor into the left-hand swash plate sensor connector X-094 (Receptacle) . Turn the ignition switch ON. Monitor the active diagnostic screen. Fault code 4732 – Right Swash Plate Angle Sensor - Pin A Short to Power should no longer be active. Fault code 4745 – Left Swash Plate Angle Sensor - Pin B Short to Power is active. A. Fault code 4732 – Right Swash Plate Angle Sensor - Pin A Short to Power is no longer active. Fault code 4745 – Left Swash Plate Angle Sensor - Pin B Short to Power is active. Replace the right hand swash plate angle sensor and retest. Return to step 1 to confirm elimination of the fault. B. Fault code 4732 – Right Swash Plate Angle Sensor - Pin A Short to Power is still active. Fault code 4745 – Left Swash Plate Angle Sensor - Pin B Short to Power did not become active. Replace the UCM and retest. Return to step 1 to confirm elimination of fault. Wiring harnesses - Electrical schematic sheet 20 SH20-UNIVERSAL CONTROL MODULE (55.100.DP-C.20.E.20) Wiring harnesses - Electrical schematic sheet 10 SH10-EH PUMP/HYDRAULICS (55.100.DP-C.20.E.10)
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Electrical systems - FAULT CODES
4734 - Right Swash Plate Angle Sensor - Pin B Short to Ground/ Open Circuit SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Context: The UCM has sensed that the swash plate angle sensor signal has failed. Diagnostic Trouble Code 4734 – Right Swash Plate Angle Sensor - Pin B Short to Ground/ Open Circuit has an error priority of Amber. Ground drive will operate in limp home mode while Diagnostic Trouble Code 4734 – Right Swash Plate Angle Sensor - Pin B Short to Ground/ Open Circuit is active. Cause: The UCM has sensed that the swash plate angle sensor signal has failed low. The fault is active while the engine is ON and the right swash plate angle sensor voltage, X-CN2B (Receptacle) pin 33 is less than 0.2 V. Possible failure modes: 1. The sensor signal wire is shorted to chassis ground. 2. An open circuit in the sensor signal wire. 3. A failure of the swash plate angle sensor. 4. The UCM has an internal failure. 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. OK to return the machine to service. B. Fault code 4734 – Right Swash Plate Angle Sensor - Pin B Short to Ground/ Open Circuit is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the UCM, the left-hand swash plate sensor connection and the right-hand swash plate sensor connection. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the UCM to the swash plate sensors. 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 the connectors as required. Return to step 1 to confirm elimination of fault. 3. Measure the voltage at the sensor. Turn the ignition switch OFF. Disconnect the right-hand swash plate sensor connector X-093 (Receptacle) .
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Turn the ignition switch ON. Measure the voltage between X-093 (Receptacle) pin 5 and X-093 (Receptacle) pin 1. The voltage should be approximately 12 V. Wiggle the harness during measurement to reveal an intermittent condition. Measure the voltage between X-093 (Receptacle) pin 2 and X-093 (Receptacle) pin 6. The voltage should be approximately 12 V. Wiggle the harness during measurement to reveal an intermittent condition. A. The voltage measurement is approximately 12 V. Go to step 4. B. The voltage measurement is less than 10 V. There is a problem in the voltage supply or sensor ground wire to the sensor. Repair or replace the harness or connectors as required. Return to step 1 to confirm elimination of fault. 4. Measure the resistance of the signal wire to chassis ground. Turn the ignition switch OFF. Disconnect UCM connector X-CN2B (Receptacle) . Disconnect the right-hand swash plate sensor connector X-093 (Receptacle) . Measure the resistance between X-CN2B (Receptacle) pin 33 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. Go to step 5. B. The resistance measurement is less than 20,000 Ω. There is a short circuit to chassis ground in the signal wire. Repair or replace the harness or connectors as required. Return to step 1 to confirm elimination of fault. 5. Measure the resistance through the signal wire. Turn the ignition switch OFF. Disconnect UCM connector X-CN2B (Receptacle) . Disconnect connector X-093 (Receptacle) . Fabricate a jumper wire that will connect between the UCM connector X-CN2B (Receptacle) pin 33 and chassis ground. Connect the jumper wire between X-CN2B (Receptacle) pin 33 and chassis ground. Measure the resistance between X-093 (Receptacle) pin 3 and chassis ground. The resistance should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition. A. The resistance measurement is less than 10 Ω. Go to step 6. B. The resistance measurement is greater than 10 Ω. There is an open circuit in the signal wire. Repair or replace the harness or connectors as required. Return to step 1 to confirm elimination of fault. 6. Test the UCM. Turn the ignition switch OFF. Remove the jumper wire. Reconnect UCM connector X-CN2B (Receptacle) . Disconnect swash plate sensor connectors X-093 (Receptacle) and X-094 (Receptacle) . Connect the left-hand swash plate sensor into the right-hand swash plate sensor connector X-093 (Receptacle) . Connect the right-hand swash plate sensor into the left-hand swash plate sensor connector X-094 (Receptacle) . Turn the ignition switch ON.
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Monitor the active diagnostic screen. Fault code 4734 – Right Swash Plate Angle Sensor - Pin B Short to Ground/ Open Circuit should no longer be active. Fault code 4741 – Left Swash Plate Angle Sensor - Pin A Short to Ground/ Open Circuit is active. A. Fault code 4734 – Right Swash Plate Angle Sensor - Pin B Short to Ground/ Open Circuit is no longer active. Fault code 4741 – Left Swash Plate Angle Sensor - Pin A Short to Ground/ Open Circuit is active. Replace the Swash Plate Angle sensor and retest. Return to step 1 to confirm elimination of the fault. B. Fault code 4734 – Right Swash Plate Angle Sensor - Pin B Short to Ground/ Open Circuit is still active. Fault code 4741 – Left Swash Plate Angle Sensor - Pin A Short to Ground/ Open Circuit did not become active. Replace the UCM and retest. Return to step 1 to confirm elimination of fault. Wiring harnesses - Electrical schematic sheet 20 SH20-UNIVERSAL CONTROL MODULE (55.100.DP-C.20.E.20) Wiring harnesses - Electrical schematic sheet 10 SH10-EH PUMP/HYDRAULICS (55.100.DP-C.20.E.10)
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4735 - Right Swash Plate Angle Sensor - Pin B Short to Power SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Context: The UCM has sensed a higher than normal voltage from the right-hand swash plate sensor. Diagnostic Trouble Code 4735 – Right Swash Plate Angle Sensor - Pin B Short to Power has an error priority of Amber. Ground drive will operate in limp home mode while Diagnostic Trouble Code 4735 – Right Swash Plate Angle Sensor - Pin B Short to Power is active. Cause: The UCM has sensed a higher than normal voltage from the right-hand swash plate sensor. The fault is active while the engine is ON and the swash plate angle sensor voltage, X-CN2B (Receptacle) pin 33 is greater than 4.8 V. Possible failure modes: 1. The signal wire has a short circuit to another voltage source. 2. A failure of the swash plate sensor. 3. The UCM has an internal failure. 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. OK to return the machine to service. B. Fault code 4735 – Right Swash Plate Angle Sensor - Pin B Short to Power is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the UCM, the left-hand swash plate sensor connection and the right-hand swash plate sensor connection. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the UCM to the swash plate sensors. 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 the connectors as required. Return to step 1 to confirm elimination of fault. 3. Measure the voltage on the sensor signal wire. Turn the ignition switch OFF. Disconnect UCM connector X-CN2B (Receptacle) . Disconnect the right-hand swash plate sensor connector X-093 (Receptacle) . Turn the ignition switch ON.
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Measure the voltage between X-093 (Receptacle) pin 3 and chassis ground. The voltage should be less than 0.5 V. Wiggle the harness during measurement to reveal an intermittent condition. A. The voltage measurement is less than 0.5 V. Go to step 4. B. The voltage measurement is greater than 0.5 V. There is a short circuit to another voltage source. Repair or replace the harness or the connectors as required. Return to step 1 to confirm elimination of fault. 4. Test the UCM. Turn the ignition switch OFF. Reconnect UCM connector X-CN2B (Receptacle) . Disconnect swash plate sensor connectors X-093 (Receptacle) and X-094 (Receptacle) . Connect the left-hand swash plate sensor into the right-hand swash plate sensor connector X-093 (Receptacle) . Connect the right-hand swash plate sensor into the left-hand swash plate sensor connector X-094 (Receptacle) . Turn the ignition switch ON. Monitor the active diagnostic screen. Fault code 4735 – Right Swash Plate Angle Sensor - Pin B Short to Power should no longer be active. Fault code 4742 – Left Swash Plate Angle Sensor - Pin A Short to Power is active. A. Fault code 4735 – Right Swash Plate Angle Sensor - Pin B Short to Power is no longer active. Fault code 4742 – Left Swash Plate Angle Sensor - Pin A Short to Power is active. Replace the right hand swash plate angle sensor and retest. Return to step 1 to confirm elimination of the fault. B. Fault code 4735 – Right Swash Plate Angle Sensor - Pin B Short to Power is still active. Fault code 4742 – Left Swash Plate Angle Sensor - Pin A Short to Power did not become active. Replace the UCM and retest. Return to step 1 to confirm elimination of fault. Wiring harnesses - Electrical schematic sheet 20 SH20-UNIVERSAL CONTROL MODULE (55.100.DP-C.20.E.20) Wiring harnesses - Electrical schematic sheet 10 SH10-EH PUMP/HYDRAULICS (55.100.DP-C.20.E.10)
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Electrical systems - FAULT CODES
4737 - Right Swash Plate Angle Sensor - In Range Fault SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Context: The UCM has sensed that the right swash plate angle sensor has failed. Diagnostic Trouble Code 4737 – Right Swash Plate Angle Sensor - In Range Fault has an error priority of Amber. Ground drive will operate in limp home mode while Diagnostic Trouble Code 4737 – Right Swash Plate Angle Sensor - In Range Fault is active. Cause: The UCM has sensed that the right swash plate angle sensor has failed. The fault is active while of the swash plate angle sensor inputs, X-CN2B (Receptacle) pin 32 and X-CN2B (Receptacle) pin 33 are less than 4.4 V or greater than 5.6 V. Possible failure modes: 1. An open circuit in the supply voltage to the sensor. 2. A failure of the swash plate angle sensor. 3. The UCM has an internal failure. 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. OK to return the machine to service. B. Fault code 4737 – Right Swash Plate Angle Sensor - In Range Fault is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the UCM, the left-hand swash plate sensor connection and the right-hand swash plate sensor connection. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the UCM to the swash plate sensors. 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 the connectors as required. Return to step 1 to confirm elimination of fault. 3. Measure the voltage at the sensor. Turn the ignition switch OFF. Disconnect the right-hand swash plate sensor connector X-093 (Receptacle) . Turn the ignition switch ON.
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Measure the voltage between X-093 (Receptacle) pin 5 and X-093 (Receptacle) pin 1. The voltage should be approximately 12 V. Wiggle the harness during measurement to reveal an intermittent condition. Measure the voltage between X-093 (Receptacle) pin 2 and X-093 (Receptacle) pin 6. The voltage should be approximately 12 V. Wiggle the harness during measurement to reveal an intermittent condition. A. The voltage measurement is approximately 12 V. Go to step 4. B. The voltage measurement is less than 10 V. There is a problem with the voltage supply to the sensor or a problem with the sensor ground connections. Check splice SP-136. Repair or replace the harness or the connectors as required. Return to step 1 to confirm elimination of fault. 4. Measure the resistance of the signal wire to chassis ground. Turn the ignition switch OFF. Disconnect UCM connector X-CN2B (Receptacle) . Disconnect the right-hand swash plate sensor connector X-093 (Receptacle) . Measure the resistance between connector X-CN2B (Receptacle) pin 32 and chassis ground. The resistance should be greater than 20,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition. Measure the resistance between connector CN2B pin 33 and chassis ground. The resistance should be greater than 20,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition. A. Both resistance measurement 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 to chassis ground in the signal wire. Repair or replace the harness or the connectors as required. Return to step 1 to confirm elimination of fault. 5. Measure the resistance through the signal wire. Turn the ignition switch OFF. Disconnect UCM connector X-CN2B (Receptacle) . Disconnect connector X-093 (Receptacle) . Fabricate a jumper wire that will connect between the UCM connector X-CN2B (Receptacle) pin 32 and chassis ground. Connect the jumper wire between X-CN2B (Receptacle) pin 32 and chassis ground. Measure the resistance between X-093 (Receptacle) pin 4 and chassis ground. The resistance should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition. Remove the jumper wire from X-CN2B (Receptacle) pin 32. Use the jumper wire to connect X-CN2B (Receptacle) pin 33 to chassis ground. Measure the resistance between X-093 (Receptacle) pin 3 and chassis ground. The resistance should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition. A. Both resistance measurements are less than 10 Ω. Go to step 6. B. One or both resistance measurements are greater than 10 Ω. There is an open circuit in the signal wire. Repair or replace the harness or connectors as required. Return to step 1 to confirm elimination of fault. 6. Test the UCM. Turn the ignition switch OFF. Remove the jumper wire. Reconnect UCM connector X-CN2B (Receptacle) . 48068130 29/01/2018
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Disconnect the swash plate sensor connectors X-093 (Receptacle) and X-094 (Receptacle) . Connect the left-hand swash plate sensor into the right-hand swash plate sensor connector X-093 (Receptacle) . Connect the right-hand swash plate sensor into the left-hand swash plate sensor connector X-094 (Receptacle) . Turn the ignition switch ON. Monitor the active diagnostic screen. Fault code 4737 – Right Swash Plate Angle Sensor - In Range Fault should no longer be active. Fault code 4747 – Left Swash Plate Angle Sensor - In Range Fault is active. A. Fault code 4737 – Right Swash Plate Angle Sensor - In Range Fault is no longer active. Fault code 4747 – Left Swash Plate Angle Sensor - In Range Fault is active. Replace the Swash Plate Angle sensor and retest. Return to step 1 to confirm elimination of the fault. B. Fault code 4737 – Right Swash Plate Angle Sensor - In Range Fault is still active. Fault code 4747 – Left Swash Plate Angle Sensor - In Range Fault did not become active. Replace the UCM and retest. Return to step 1 to confirm elimination of fault. Wiring harnesses - Electrical schematic sheet 20 SH20-UNIVERSAL CONTROL MODULE (55.100.DP-C.20.E.20) Wiring harnesses - Electrical schematic sheet 10 SH10-EH PUMP/HYDRAULICS (55.100.DP-C.20.E.10)
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Electrical systems - FAULT CODES
4741 - Left Swash Plate Angle Sensor - Pin A Short to Ground/ Open Circuit SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Context: The UCM has sensed that the swash plate angle sensor signal has failed. Diagnostic Trouble Code 4741 – Left Swash Plate Angle Sensor - Pin A Short to Ground/ Open Circuit has an error priority of Amber. Ground drive will operate in limp home mode while Diagnostic Trouble Code 4741 – Left Swash Plate Angle Sensor - Pin A Short to Ground/ Open Circuit is active. Cause: The UCM has sensed that the swash plate angle sensor signal has failed low. The fault is active while the engine is ON and the left swash plate angle sensor voltage, X-CN3A (Receptacle) pin 9 is less than 0.2 V. Possible failure modes: 1. The sensor signal wire is shorted to chassis ground. 2. An open circuit in the sensor signal wire. 3. A failure of the swash plate angle sensor. 4. The UCM has an internal failure. 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. OK to return the machine to service. B. Fault code 4741 – Left Swash Plate Angle Sensor - Pin A Short to Ground/ Open Circuit is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the UCM, the left-hand swash plate sensor connection and the right-hand swash plate sensor connection. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the UCM to the swash plate sensors. 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 the connectors as required. Return to step 1 to confirm elimination of fault. 3. Measure the voltage at the sensor. Turn the ignition switch OFF. Disconnect the left-hand swash plate sensor connector X-094 (Receptacle) .
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Turn the ignition switch ON. Measure the voltage between X-094 (Receptacle) pin 5 and X-094 (Receptacle) pin 1. The voltage should be approximately 12 V. Wiggle the harness during measurement to reveal an intermittent condition. Measure the voltage between X-094 (Receptacle) pin 2 and X-094 (Receptacle) pin 6. The voltage should be approximately 12 V. Wiggle the harness during measurement to reveal an intermittent condition. A. The voltage measurement is approximately 12 V. Go to step 4. B. The voltage measurement is less than 10 V. There is a problem in the voltage supply or sensor ground wire to the sensor. Repair or replace the harness or connectors as required. Return to step 1 to confirm elimination of fault. 4. Measure the resistance of the signal wire to chassis ground. Turn the ignition switch OFF. Disconnect UCM connector X-CN3A (Receptacle) . Disconnect the left-hand swash plate sensor connector X-094 (Receptacle) . Measure the resistance between X-CN3A (Receptacle) pin 9 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. Go to step 5. B. The resistance measurement is less than 20,000 Ω. There is a short circuit to chassis ground in the signal wire. Repair or replace the harness or connectors as required. Return to step 1 to confirm elimination of fault. 5. Measure the resistance through the signal wire. Turn the ignition switch OFF. Disconnect UCM connector X-CN3A (Receptacle) . Disconnect connector X-094 (Receptacle) . Fabricate a jumper wire that will connect between the UCM connector X-CN3A (Receptacle) pin 9 and chassis ground. Connect the jumper wire between X-CN3A (Receptacle) pin 9 and chassis ground. Measure the resistance between X-094 (Receptacle) pin 3 and chassis ground. The resistance should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition. A. The resistance measurement is less than 10 Ω. Go to step 6. B. The resistance measurement is greater than 10 Ω. There is an open circuit in the signal wire. Repair or replace the harness or connectors as required. Return to step 1 to confirm elimination of fault. 6. Test the UCM. Turn the ignition switch OFF. Remove the jumper wire. Reconnect UCM connector X-CN3A (Receptacle) . Disconnect swash plate sensor connectors X-093 (Receptacle) and X-094 (Receptacle) . Connect the left hand swash plate sensor into the right hand swash plate sensor connector X-093 (Receptacle) . Connect the right hand swash plate sensor into the left hand swash plate sensor connector X-094 (Receptacle) . Turn the ignition switch ON.
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Monitor the active diagnostic screen. Fault code 4741 – Left Swash Plate Angle Sensor - Pin A Short to Ground/ Open Circuit should no longer be active. Fault code 4734 – Right Swash Plate Angle Sensor Pin B Open Or Shorted To Ground is active. A. Fault code 4741 – Left Swash Plate Angle Sensor - Pin A Short to Ground/ Open Circuit is no longer active. Fault code 4734 – Right Swash Plate Angle Sensor Pin B Open Or Shorted To Ground is active. Replace the Swash Plate Angle sensor and retest. Return to step 1 to confirm elimination of the fault. B. Fault code 4741 – Left Swash Plate Angle Sensor - Pin A Short to Ground/ Open Circuit is still active. Fault code 4734 – Right Swash Plate Angle Sensor Pin B Open Or Shorted To Ground did not become active. Replace the UCM and retest. Return to step 1 to confirm elimination of fault. Wiring harnesses - Electrical schematic sheet 21 SH21-UNIVERSAL CONTROL MODULE (55.100.DP-C.20.E.21) Wiring harnesses - Electrical schematic sheet 10 SH10-EH PUMP/HYDRAULICS (55.100.DP-C.20.E.10)
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4742 - Left Swash Plate Angle Sensor - Pin A Short to Power SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Context: The UCM has sensed a higher than normal voltage from the left-hand swash plate sensor. Diagnostic Trouble Code 4742 – Left Swash Plate Angle Sensor - Pin A Short to Power has an error priority of Amber. Ground drive will operate in limp home mode while Diagnostic Trouble Code 4742 – Left Swash Plate Angle Sensor - Pin A Short to Power is active. Cause: The UCM has sensed a higher than normal voltage from the left hand swash plate sensor. The fault is active while the engine is ON and the swash plate angle sensor voltage, X-CN3A (Receptacle) pin 9 is greater than 4.8 V. Possible failure modes: 1. A faulty ground connection on the rear right-hand ground lug. 2. The signal wire has a short circuit to another voltage source. 3. A failure of the swash plate sensor. 4. The UCM has an internal failure. 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. OK to return the machine to service. B. Fault code 4742 – Left Swash Plate Angle Sensor - Pin A Short to Power is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the UCM, the left-hand swash plate sensor connection and the right-hand swash plate sensor connection. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the UCM to the swash plate sensors. 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. 3. Check the ground connection on the rear right-hand ground lugs. Verify that the grounding boss is free of paint, oil, dirt, and debris. Verify that the ground connection is tight and secure. A. The grounding boss is clean and free of paint. The grounding connection is secure. Go to step 4.
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B. The grounding boss is dirty or cover with paint. Remove the dirt. Remove the paint. Repair as required. Return to step 1 to confirm elimination of fault. 4. Measure the voltage on the sensor signal wire. Turn the ignition switch OFF. Disconnect UCM connector X-CN3A (Receptacle) . Disconnect the left-hand swash plate sensor connector X-094 (Receptacle) . Turn the ignition switch ON. Measure the voltage between X-094 (Receptacle) pin 3 and chassis ground. The voltage should be less than 0.5 V. Wiggle the harness during measurement to reveal an intermittent condition. A. The voltage measurement is less than 0.5 V. Go to step 5. B. The voltage measurement is greater than 0.5 V. There is a short circuit to another voltage source. Repair or replace the harness or the connectors as required. Return to step 1 to confirm elimination of fault. 5. Test the UCM. Turn the ignition switch OFF. Reconnect UCM connector X-CN3A (Receptacle) . Disconnect swash plate sensor connectors X-093 (Receptacle) and X-094 (Receptacle) . Connect the left-hand swash plate sensor into the right-hand swash plate sensor connector X-093 (Receptacle) . Connect the right-hand swash plate sensor into the left-hand swash plate sensor connector X-094 (Receptacle) . Turn the ignition switch ON. Monitor the active diagnostic screen. Fault code 4742 – Left Swash Plate Angle Sensor - Pin A Short to Power should no longer be active. Fault code 4735 – Right Swash Plate Angle Sensor - Pin B Short to Power is active. A. Fault code 4742 – Left Swash Plate Angle Sensor - Pin A Short to Power is no longer active. Fault code 4735 – Right Swash Plate Angle Sensor - Pin B Short to Power is active. Replace the right hand swash plate angle sensor and retest. Return to step 1 to confirm elimination of the fault. B. Fault code 4742 – Left Swash Plate Angle Sensor - Pin A Short to Power is still active. Fault code 4735 – Right Swash Plate Angle Sensor - Pin B Short to Power did not become active. Replace the UCM and retest. Return to step 1 to confirm elimination of fault. Wiring harnesses - Electrical schematic sheet 21 SH21-UNIVERSAL CONTROL MODULE (55.100.DP-C.20.E.21) Wiring harnesses - Electrical schematic sheet 10 SH10-EH PUMP/HYDRAULICS (55.100.DP-C.20.E.10)
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Electrical systems - FAULT CODES
4744 - Left Swash Plate Angle Sensor - Pin B Short to Ground/ Open Circuit SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Context: The UCM has sensed that the swash plate angle sensor signal has failed low. Diagnostic Trouble Code 4744 – Left Swash Plate Angle Sensor - Pin B Short to Ground/ Open Circuit has an error priority of Amber. Ground drive will operate in limp home mode while Diagnostic Trouble Code 4744 – Left Swash Plate Angle Sensor - Pin B Short to Ground/ Open Circuit is active. Cause: The UCM has sensed that the swash plate angle sensor signal has failed low. The fault is active while the engine is ON and the left swash plate angle sensor voltage, X-CN3A (Receptacle) pin 10 is less than 0.2 V. Possible failure modes: 1. The sensor signal wire is shorted to chassis ground. 2. An open circuit in the sensor signal wire. 3. A failure of the swash plate angle sensor. 4. The UCM has an internal failure. 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. OK to return the machine to service. B. Fault code 4744 – Left Swash Plate Angle Sensor - Pin B Short to Ground/ Open Circuit is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the UCM, the left-hand swash plate sensor connection and the right-hand swash plate sensor connection. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the UCM to the swash plate sensors. 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 the connectors as required. Return to step 1 to confirm elimination of fault. 3. Measure the supply voltage to the sensor. Turn the ignition switch OFF. Disconnect the left-hand swash plate sensor connector X-094 (Receptacle)
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Turn the ignition switch ON. Measure the voltage between X-094 (Receptacle) pin 5 and X-094 (Receptacle) pin 1. The voltage should be approximately 12 V. Wiggle the harness during measurement to reveal an intermittent condition. Measure the voltage between X-094 (Receptacle) pin 2 and X-094 (Receptacle) pin 6. The voltage should be approximately 12 V. Wiggle the harness during measurement to reveal an intermittent condition. A. The voltage measurement is approximately 12 V. Go to step 4. B. The voltage measurement is less than 10 V. There is a problem in the voltage supply or sensor ground wire to the sensor. Repair or replace the harness or connectors as required. Return to step 1 to confirm elimination of fault. 4. Measure the resistance of the signal wire to chassis ground. Turn the ignition switch OFF. Disconnect UCM connector X-CN3A (Receptacle) . Disconnect the left-hand swash plate sensor connector X-094 (Receptacle) . Measure the resistance between X-CN3A (Receptacle) pin 10 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. Go to step 5. B. The resistance measurement is less than 20,000 Ω. There is a short circuit to chassis ground in the signal wire. Repair or replace the harness or connectors as required. Return to step 1 to confirm elimination of fault. 5. Measure the resistance through the signal wire. Turn the ignition switch OFF. Disconnect UCM connector X-CN3A (Receptacle) . Disconnect connector X-094 (Receptacle) . Fabricate a jumper wire that will connect between the UCM connector X-CN3A (Receptacle) pin 10 and chassis ground. Connect the jumper wire between X-CN3A (Receptacle) pin 10 to chassis ground. Measure the resistance between X-094 (Receptacle) pin 4 and chassis ground. The resistance should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition. A. The resistance measurement is less than 10 Ω. Go to step 6. B. The resistance measurement is greater than 10 Ω. There is an open circuit in the signal wire. Repair or replace the harness or connectors as required. Return to step 1 to confirm elimination of fault. 6. Test the UCM. Turn the ignition switch OFF. Remove the jumper wire. Reconnect UCM connector X-CN3A (Receptacle) . Disconnect swash plate sensor connectors X-093 (Receptacle) and X-094 (Receptacle) . Connect the left-hand swash plate sensor into the right-hand swash plate sensor connector X-093 (Receptacle) . Connect the right-hand swash plate sensor into the left-hand swash plate sensor connector X-094 (Receptacle) . Turn the ignition switch ON.
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Monitor the active diagnostic screen. Fault code 4744 – Left Swash Plate Angle Sensor - Pin B Short to Ground/ Open Circuit should no longer be active. Fault code 4731 – Right Swash Plate Angle Sensor Pin A Open Or Shorted To Ground is active. A. Fault code 4744 – Left Swash Plate Angle Sensor - Pin B Short to Ground/ Open Circuit is no longer active. Fault code 4731 – Right Swash Plate Angle Sensor Pin A Open Or Shorted To Ground is active. Replace the Swash Plate Angle sensor and retest. Return to step 1 to confirm elimination of the fault. B. Fault code 4744 – Left Swash Plate Angle Sensor - Pin B Short to Ground/ Open Circuit is still active. Fault code 4731 – Right Swash Plate Angle Sensor Pin A Open Or Shorted To Ground did not become active. Replace the UCM and retest. Return to step 1 to confirm elimination of fault. Wiring harnesses - Electrical schematic sheet 21 SH21-UNIVERSAL CONTROL MODULE (55.100.DP-C.20.E.21) Wiring harnesses - Electrical schematic sheet 10 SH10-EH PUMP/HYDRAULICS (55.100.DP-C.20.E.10)
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Electrical systems - FAULT CODES
4745 - Left Swash Plate Angle Sensor - Pin B Short to Power SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Context: The UCM has sensed a higher than normal voltage from the left-hand swash plate sensor. Diagnostic Trouble Code 4745 – Left Swash Plate Angle Sensor - Pin B Short to Power has an error priority of Amber. Ground drive will operate in limp home mode while Diagnostic Trouble Code 4745 – Left Swash Plate Angle Sensor - Pin B Short to Power is active. Cause: The UCM has sensed a higher than normal voltage from the left-hand swash plate sensor. The fault is active while the engine is on and the swash plate angle sensor voltage, X-CN3A (Receptacle) pin 10 is greater than 4.8 V. Possible failure modes: 1. The signal wire has a short circuit to another voltage source. 2. A failure of the swash plate sensor. 3. The UCM has an internal failure. 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. OK to return the machine to service. B. Fault code 4745 – Left Swash Plate Angle Sensor - Pin B Short to Power is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the UCM, the left-hand swash plate sensor connection and the right-hand swash plate sensor connection. All connections should be secure, tight, free of corrosion, abrasion and damage. Inspect the harness from the UCM to the swash plate sensors. 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 the connectors as required. Return to step 1 to confirm elimination of fault. 3. Measure the voltage on the sensor signal wire. Turn the ignition switch OFF. Disconnect UCM connector X-CN3A (Receptacle) . Disconnect the left-hand swash plate sensor connector X-094 (Receptacle) . Turn the ignition switch ON.
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Measure the voltage between X-094 (Receptacle) pin 4 and chassis ground. The voltage should be less than 0.5 V. Wiggle the harness during measurement to reveal an intermittent condition. A. The voltage measurement is less than 0.5 V. Go to step 4. B. The voltage measurement is greater than 0.5 V. There is a short circuit to another voltage source. Repair or replace the harness or the connectors as required. Return to step 1 to confirm elimination of fault. 4. Test the UCM. Turn the ignition switch OFF. Reconnect UCM connector X-CN3A (Receptacle) . Disconnect swash plate sensor connectors X-093 (Receptacle) and X-094 (Receptacle) . Connect the left-hand swash plate sensor into the right-hand swash plate sensor connector X-093 (Receptacle) . Connect the right-hand swash plate sensor into the left-hand swash plate sensor connector X-094 (Receptacle) . Turn the ignition switch ON. Monitor the active diagnostic screen. Fault code 4745 – Left Swash Plate Angle Sensor - Pin B Short to Power should no longer be active. Fault code 4732 – Right Swash Plate Angle Sensor - Pin A Short to Power is active. A. Fault code 4745 – Left Swash Plate Angle Sensor - Pin B Short to Power is no longer active. Fault code 4732 – Right Swash Plate Angle Sensor - Pin A Short to Power is active. Replace the right hand swash plate angle sensor and retest. Return to step 1 to confirm elimination of the fault. B. Fault code 4745 – Left Swash Plate Angle Sensor - Pin B Short to Power is still active. Fault code 4732 – Right Swash Plate Angle Sensor - Pin A Short to Power did not become active. Replace the UCM and retest. Return to step 1 to confirm elimination of fault. Wiring harnesses - Electrical schematic sheet 21 SH21-UNIVERSAL CONTROL MODULE (55.100.DP-C.20.E.21) Wiring harnesses - Electrical schematic sheet 10 SH10-EH PUMP/HYDRAULICS (55.100.DP-C.20.E.10)
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4747 - Left Swash Plate Angle Sensor - In Range Fault SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Context: The UCM has sensed that the left swash plate angle sensor has failed. Diagnostic Trouble Code 4747 – Left Swash Plate Angle Sensor - In Range Fault has an error priority of Amber. Ground drive will operate in limp home mode while Diagnostic Trouble Code 4747 – Left Swash Plate Angle Sensor - In Range Fault is active. Cause: The UCM has sensed that the left swash plate angle sensor has failed. The fault is active while of the swash plate angle sensor inputs, X-CN3A (Receptacle) pin 9 and X-CN3A (Receptacle) pin 10 are less than 4.4 V or greater than 5.6 V. Possible failure modes: 1. An open circuit in the supply voltage to the sensor. 2. Failure of the swash plate angle sensor. 3. The UCM has an internal failure. 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. OK to return the machine to service. B. Fault code 4747 – Left Swash Plate Angle Sensor - In Range Fault is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the UCM, the left-hand swash plate sensor connection and the right-hand swash plate sensor connection. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the UCM to the swash plate sensors. 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 the connectors as required. Return to step 1 to confirm elimination of fault. 3. Measure the voltage at the sensor. Turn the ignition switch OFF. Disconnect the left-hand swash plate sensor connector X-094 (Receptacle) . Turn the ignition switch ON.
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Measure the voltage between X-094 (Receptacle) pin 5 and X-094 (Receptacle) pin 1. The voltage should be approximately 12 V. Wiggle the harness during measurement to reveal an intermittent condition. Measure the voltage between X-094 (Receptacle) pin 2 and X-094 (Receptacle) pin 6. The voltage should be approximately 12 V. Wiggle the harness during measurement to reveal an intermittent condition. A. The voltage measurement is approximately 12 V. Go to step 4. B. The voltage measurement is less than 10 V. There is a problem with the voltage supply to the sensor or a problem with the sensor ground connections. Check splice SP-136. Repair or replace the harness or the connectors as required. Return to step 1 to confirm elimination of fault. 4. Measure the resistance of the signal wire to chassis ground. Turn the ignition switch OFF. Disconnect UCM connector X-CN3A (Receptacle) . Disconnect left-hand swash plate sensor connector X-094 (Receptacle) . Measure the resistance between connector X-CN3A (Receptacle) pin 9 and chassis ground. The resistance should be greater than 20,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition. Measure the resistance between connector X-CN3A (Receptacle) pin 10 and chassis ground. The resistance should be greater than 20,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition. A. Both resistance measurement 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 to chassis ground in the signal wire. Repair or replace the harness or the connectors as required. Return to step 1 to confirm elimination of fault. 5. Measure the resistance through the signal wire. Turn the ignition switch OFF. Disconnect UCM connector X-CN3A (Receptacle) . Disconnect connector X-094 (Receptacle) . Fabricate a jumper wire that will connect between the UCM connector X-CN3A (Receptacle) pin 9 and chassis ground. Connect the jumper wire between X-CN3A (Receptacle) pin 9 and chassis ground. Measure the resistance between X-094 (Receptacle) pin 3 and chassis ground. The resistance should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition. Remove the jumper wire from X-CN3A (Receptacle) pin 9. Connect the jumper wire between X-CN3A (Receptacle) pin 10 and chassis ground. Measure the resistance between X-094 (Receptacle) pin 4 and chassis ground. The resistance should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition. A. Both resistance measurements are less than 10 Ω. Go to step 6. B. One or both resistance measurements are greater than 10 Ω. There is an open circuit in the signal wire. Repair or replace the harness or connectors as required. Return to step 1 to confirm elimination of fault. 6. Test the UCM. Turn the ignition switch OFF. Remove the jumper wire. Reconnect UCM connector X-CN3A (Receptacle) . 48068130 29/01/2018
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Disconnect swash plate sensor connectors X-093 (Receptacle) and X-094 (Receptacle) . Connect the left-hand swash plate sensor into the right-hand swash plate sensor connector X-093 (Receptacle) . Connect the right-hand swash plate sensor into the left-hand swash plate sensor connector X-094 (Receptacle) . Turn the ignition switch ON. Monitor the active diagnostic screen. Fault code 4747 – Left Swash Plate Angle Sensor - In Range Fault should no longer be active. Fault code 4737 – Right Swash Plate Angle Sensor - In Range Fault is active. A. Fault code 4747 – Left Swash Plate Angle Sensor - In Range Fault is no longer active. Fault code 4737 – Right Swash Plate Angle Sensor - In Range Fault is active. Replace the Swash Plate Angle sensor and retest. Return to step 1 to confirm elimination of the fault. B. Fault code 4747 – Left Swash Plate Angle Sensor - In Range Fault is still active. Fault code 4737 – Right Swash Plate Angle Sensor - In Range Fault did not become active. Replace the UCM and retest. Return to step 1 to confirm elimination of fault. Wiring harnesses - Electrical schematic sheet 21 SH21-UNIVERSAL CONTROL MODULE (55.100.DP-C.20.E.21) Wiring harnesses - Electrical schematic sheet 10 SH10-EH PUMP/HYDRAULICS (55.100.DP-C.20.E.10)
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4752 - Left Swash Plate Angle Sensor - Implausible Command, Command Does Not Match With Swash Plate Angle SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Context: The UCM has sensed that the swash plate sensor signal does not agree with the direction of vehicle travel. Diagnostic Trouble Code 4752 – Left Swash Plate Angle Sensor - Implausible Command, Command Does Not Match With Swash Plate Angle has an error priority of Red. Forward ground drive and reverse ground drive functions are disabled while Diagnostic Trouble Code 4752 – Left Swash Plate Angle Sensor - Implausible Command, Command Does Not Match With Swash Plate Angle is active. Cause: The UCM has sensed that the swash plate sensor signal does not agree with the direction of vehicle travel. The fault active is when the swash plate sensor senses vehicle movement while the solenoids are not energized or while vehicle movement is opposite of the energized solenoid. Possible failure modes: 1. A faulty ground connection on the rear right-hand ground lug. 2. Improper wiring in the circuit. 3. Mechanical pump adjustment. 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. OK to return the machine to service. B. Fault code 4752 – Left Swash Plate Angle Sensor - Implausible Command, Command Does Not Match With Swash Plate Angle is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the UCM, the left-hand swash plate sensor connection and the right-hand swash plate sensor connection. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the UCM to the swash plate sensors. 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. 3. Check the ground connection on the rear right-hand ground lugs. Verify that the grounding boss is free of paint, oil, dirt, and debris.
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Verify that the ground connection is tight and secure. A. The grounding boss is clean and free of paint. The grounding connection is secure. Go to step 4. B. The grounding boss is dirty or cover with paint. Remove the dirt. Remove the paint. Repair as required. Return to step 1 to confirm elimination of fault. 4. Verify that the pump harness is installed correctly. Verify that connector X-018 (Receptacle) is connected to the right-drive pump reverse solenoid. Verify that connector X-017 (Receptacle) is connected to the right-drive pump forward solenoid. Verify that connector X-016 (Receptacle) is connected to the left-drive pump reverse solenoid. Verify that connector X-013 (Receptacle) is connected to the left-drive pump forward solenoid. A. The connectors are secure and installed in the proper location. Go to step 5. B. The connectors are not secure or are not installed in the proper locations. Repair the harness or connectors as required. Return to step 1 to confirm elimination of fault. 5. Verify that the swash plate sensors are connected properly. Verify that connector X-093 (Receptacle) is connected to the right-hand pump swash plate sensor. Verify that connector X-094 (Receptacle) is connected to the left-hand pump swash plate sensor. A. The connectors are secure and installed in the proper location. Check the adjustment for mechanical neutral in the left-hand pump drive circuit. Return to step 1. The Electronic Service Tool (EST) parameters (544/545/ 546/547) with key on should read 2.5 V. B. The connectors are not secure or are not installed in the proper locations. Repair the harness or connectors as required. Return to step 1 to confirm elimination of fault. Wiring harnesses - Electrical schematic sheet 21 SH21-UNIVERSAL CONTROL MODULE (55.100.DP-C.20.E.21) Wiring harnesses - Electrical schematic sheet 10 SH10-EH PUMP/HYDRAULICS (55.100.DP-C.20.E.10)
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4754 - Right Swash Plate Angle Sensor - Implausible Command, Command Does Not Match With Swash Plate Angle SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Context: The UCM has sensed that the swash plate sensor signal does not agree with the direction of vehicle travel. Diagnostic Trouble Code 4754 – Right Swash Plate Angle Sensor - Implausible Command, Command Does Not Match With Swash Plate Angle has an error priority of Red. Forward and reverse ground drive functions are disabled while Diagnostic Trouble Code 4754 – Right Swash Plate Angle Sensor - Implausible Command, Command Does Not Match With Swash Plate Angle is active. Cause: The UCM has sensed that the swash plate sensor signal does not agree with the direction of vehicle travel. The fault active is when the swash plate sensor senses vehicle movement while the solenoids are not energized or while vehicle movement is opposite of the energized solenoid. Possible failure modes: 1. Improper wiring in the circuit. 2. Mechanical pump adjustment. 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. OK to return the machine to service. B. Fault code 4754 – Right Swash Plate Angle Sensor - Implausible Command, Command Does Not Match With Swash Plate Angle is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the UCM, the left-hand swash plate sensor connection and the right-hand swash plate sensor connection. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the UCM to the swash plate sensors. 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. 3. Verify that the pump harness is installed correctly. Verify that connector X-018 (Receptacle) is connected to the right-drive pump reverse solenoid. Verify that connector X-017 (Receptacle) is connected to the right-drive pump forward solenoid. Verify that connector X-016 (Receptacle) is connected to the left-drive pump reverse solenoid. 48068130 29/01/2018
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Verify that connector X-013 (Receptacle) is connected to the left-drive pump forward solenoid. A. The connectors are secure and installed in the proper location. Go to step 4. B. The connectors are not secure or are not installed in the proper locations. Repair the harness or connectors as required. Return to step 1 to confirm elimination of fault. 4. Verify that the swash plate sensors are connected properly. Verify that connector X-093 (Receptacle) is connected to the right hand pump swash plate sensor. Verify that connector X-094 (Receptacle) is connected to the left hand pump swash plate sensor. A. The connectors are secure and installed in the proper location. Check the adjustment for mechanical neutral in the right-hand pump drive circuit. Return to step 1. The Electronic Service Tool (EST) parameters (544/545/ 546/547) with key on should read 2.5 V. B. The connectors are not secure or are not installed in the proper locations. Repair the harness or connectors as required. Return to step 1 to confirm elimination of fault. Wiring harnesses - Electrical schematic sheet 20 SH20-UNIVERSAL CONTROL MODULE (55.100.DP-C.20.E.20) Wiring harnesses - Electrical schematic sheet 10 SH10-EH PUMP/HYDRAULICS (55.100.DP-C.20.E.10)
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4781 - Solenoid Valve - Solenoid Supply Open Circuit SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Context: The UCM has sent a signal to the two speed solenoid to energize, but the UCM does not sense proper voltage. Diagnostic Trouble Code 4781 – Solenoid Valve - Solenoid Supply Open Circuit has an error priority of White. The two speed operating mode is disabled while Diagnostic Trouble Code 4781 – Solenoid Valve - Solenoid Supply Open Circuit is active. Cause: The UCM has sent a signal to the two speed solenoid to energize, but the UCM does not sense proper voltage. The fault is active while the engine is ON and the solenoid output X-CN3A (Receptacle) pin 25 is greater than 8 V or less than 1 V. Possible failure modes: 1. An open circuit in the wiring. 2. A short circuit in the wiring. 3. The two speed solenoid has failed. 4. The UCM has an internal failure. 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. OK to return the machine to service. B. Fault code 4781 – Solenoid Valve - Solenoid Supply Open Circuit is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the UCM and two speed solenoid connections. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the UCM to the two speed solenoid. 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 the connectors as required. Return to step 1 to confirm elimination of fault. 3. Measure the resistance through the harness. Turn the ignition switch OFF. Disconnect the two speed connector, X-2SPD (Plug) .
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Fabricate a jumper wire that will connect between the two speed solenoid connector X-2SPD (Plug) pin A and X-2SPD (Plug) pin B. Use the jumper wire to short X-2SPD (Plug) pin A to X-2SPD (Plug) pin B. Disconnect UCM connector X-CN3A (Receptacle) . Measure the resistance between X-CN3A (Receptacle) pin 25 and chassis ground. 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. B. The resistance is greater than 10 Ω. There is an open circuit in the solenoid signal or the solenoid ground line. Repair or replace the harness as required. Return to step 1 to confirm elimination of the fault. 4. Test the UCM. Leave the jumper wire installed between X-2SPD (Plug) pin A and X-2SPD (Plug) pin B. Reconnect UCM connectors X-CN3A (Receptacle) . Turn the ignition switch ON. Activate the two speed feature while monitoring the fault code screen. Fault code 4781 – Solenoid Valve - Solenoid Supply Open Circuit should no longer be active. Fault code 4782 – Solenoid Valve - Solenoid Supply Short to Ground should become active. A. Fault code 4782 – Solenoid Valve - Solenoid Supply Short to Ground is active and fault code 4781 – Solenoid Valve - Solenoid Supply Open Circuit is no longer active. Temporarily replace the solenoid and retest. Return to step 1 to confirm elimination of the fault. B. Fault code 4781 – Solenoid Valve - Solenoid Supply Open Circuit is still active. Fault code 4782 – Solenoid Valve - Solenoid Supply Short to Ground did not become active. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. Wiring harnesses - Electrical schematic sheet 21 SH21-UNIVERSAL CONTROL MODULE (55.100.DP-C.20.E.21) Wiring harnesses - Electrical schematic sheet 17 SH17-LEFT NH CONTROL HANDLE (55.100.DP-C.20.E.17) Wiring harnesses - Electrical schematic sheet 05 SH05-GROUNDING SYSTEM (55.100.DP-C.20.E.05)
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4782 - Solenoid Valve - Solenoid Supply Short to Ground SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Context: The UCM has sent a signal to the two speed solenoid to energize, but no voltage was detected. Diagnostic Trouble Code 4782 – Solenoid Valve - Solenoid Supply Short to Ground has an error priority of White. The two speed operating mode is disabled while Diagnostic Trouble Code 4782 – Solenoid Valve - Solenoid Supply Short to Ground is active. Cause: The UCM has sent a signal to the two speed solenoid to energize, but no voltage was detected. The fault is active while the two speed operating mode is on and the solenoid output, X-CN3A (Receptacle) pin 25 current is high. Possible failure modes: 1. A short circuit in the wiring. 2. The two speed solenoid has failed. 3. The UCM has an internal failure. 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. OK to return the machine to service. B. Fault code 4782 – Solenoid Valve - Solenoid Supply Short to Ground is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the UCM and the two speed solenoid connections. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the UCM to the two speed solenoid. 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 the connectors as required. Return to step 1 to confirm elimination of fault. 3. Measure the resistance of the solenoid wire to chassis ground. Turn the ignition switch OFF. Disconnect UCM connector X-CN3A (Receptacle) . Disconnect solenoid connector X-2SPD (Plug) . Measure the resistance between X-2SPD (Plug) pin A and chassis ground. The resistance should be greater than 20,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition. 48068130 29/01/2018
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A. The resistance measurement is greater than 20,000 Ω. Go to step 4. B. The resistance measurement is less than 20,000 Ω. There is an short circuit to chassis ground in the harness. Repair or replace the harness as required. Return to step 1 to confirm elimination of fault. 4. Test the UCM. Turn the ignition switch OFF. Reconnect UCM connector X-CN3A (Receptacle) . Leave connector X-2SPD (Plug) disconnected. Turn the ignition switch ON. Activate the two speed function while monitoring the fault code screen. Fault code 4782 – Solenoid Valve Solenoid Supply Short to Ground should no longer be active. Fault code 4781 – Solenoid Valve - Solenoid Supply Open Circuit should become active. A. Fault code 4781 – Solenoid Valve - Solenoid Supply Open Circuit is active and fault code 4782 – Solenoid Valve - Solenoid Supply Short to Ground is no longer active. Temporarily replace the solenoid and retest. Return to step 1 to confirm elimination of the fault. B. Fault code 4782 – Solenoid Valve - Solenoid Supply Short to Ground is still active. Fault code 4781 – Solenoid Valve - Solenoid Supply Open Circuit did not become active. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. Wiring harnesses - Electrical schematic sheet 21 SH21-UNIVERSAL CONTROL MODULE (55.100.DP-C.20.E.21) Wiring harnesses - Electrical schematic sheet 17 SH17-LEFT NH CONTROL HANDLE (55.100.DP-C.20.E.17) Wiring harnesses - Electrical schematic sheet 05 SH05-GROUNDING SYSTEM (55.100.DP-C.20.E.05)
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4783 - Solenoid Valve - Solenoid Supply Short to Power SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Context: The UCM has sensed higher than normal voltage on the two speed solenoid. Diagnostic Trouble Code 4783 – Solenoid Valve - Solenoid Supply Short to Power has an error priority of Amber. Ground Drive Limp Home operating mode is enabled while Diagnostic Trouble Code 4783 – Solenoid Valve - Solenoid Supply Short to Power is active. Cause: The UCM has sensed higher than normal voltage on the two speed solenoid. The fault is active when the Two Speed function is off and the two speed solenoid output voltage, X-CN3A (Receptacle) pin 25 is greater than 8 V. Possible failure modes: 1. A short circuit in the wiring. 2. The two speed solenoid has failed. 3. The UCM has an internal failure. 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. OK to return the machine to service. B. Fault code 4783 – Solenoid Valve - Solenoid Supply Short to Power is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the UCM and the two speed solenoid connections. All connections should be secure, tight, free of corrosion, abrasion and damage. Inspect the harness from the UCM to the two speed solenoid. 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. 3. Measure the voltage of the solenoid wire to chassis ground. Turn the ignition switch OFF. Disconnect UCM connector X-CN3A (Receptacle) . Disconnect solenoid connector X-2SPD (Plug) . Turn the ignition switch ON.
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Measure the voltage between X-2SPD (Plug) pin A and chassis ground. The voltage should be less than 0.5 V. Wiggle the harness during measurement to reveal an intermittent condition. A. The voltage measurement is less than 0.5 V. Go to step 4. B. The voltage measurement is greater than 0.5 V. There is a short circuit to another voltage source. Repair or replace the harness as required. Return to step 1 to confirm elimination of fault. 4. Test the UCM. Turn the ignition switch OFF. Reconnect UCM connector X-CN3A (Receptacle) . Leave connector X-2SPD (Plug) disconnected. Turn the ignition switch ON. Activate the two speed function while monitoring the fault code screen. Fault code 4783 – Solenoid Valve Solenoid Supply Short to Power should no longer be active. Fault code 4781 – Solenoid Valve - Solenoid Supply Open Circuit should become active. A. Fault code 4781 – Solenoid Valve - Solenoid Supply Open Circuit is active. Fault code 4783 – Solenoid Valve - Solenoid Supply Short to Power is no longer active. Temporarily replace the solenoid and retest. Return to step 1 to confirm elimination of the fault. B. Fault code 4783 – Solenoid Valve - Solenoid Supply Short to Power is still active. Fault code 4781 – Solenoid Valve - Solenoid Supply Open Circuit did not become active. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. Wiring harnesses - Electrical schematic sheet 21 SH21-UNIVERSAL CONTROL MODULE (55.100.DP-C.20.E.21) Wiring harnesses - Electrical schematic sheet 17 SH17-LEFT NH CONTROL HANDLE (55.100.DP-C.20.E.17) Wiring harnesses - Electrical schematic sheet 05 SH05-GROUNDING SYSTEM (55.100.DP-C.20.E.05)
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4951 - Hydraulic Interlock Solenoid Shorted To Power Context: The instrument cluster has sensed a short circuit to another voltage source in the hydraulic interlock circuit. Diagnostic Trouble Code 4951 has an error priority of Red. The vehicle is disabled while Diagnostic Trouble Code 4951 is active. Cause: The instrument cluster has sensed a short circuit to another voltage source in the hydraulic interlock circuit. The fault is active while the ignition switch is ON and the hydraulic enable commanded state is low and hydraulic enable solenoid is energized. Possible failure modes: 1. Faulty wiring or connectors. 2. A 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 machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 4951 is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the instrument cluster connector X-C23 and the hydraulic interlock solenoid connections. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the instrument cluster to the hydraulic interlock solenoid. 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 harness has damage. Repair or replace the harness or connectors as required. Return to step 1 to confirm elimination of fault. 3. Measure the voltage on the signal wire. Turn the ignition switch OFF. Disconnect the instrument cluster connector X-C23. Disconnect the Telematics connector X-TELE. Disconnect connector X-PORT_LK. Turn the ignition switch ON. Measure the voltage between the instrument cluster connector X-C23 pin 30 and chassis ground. The voltage should be less than 0.5 V. Wiggle the harness during measurement to reveal an intermittent condition. A. The voltage is less than 0.5 V. Temporarily replace the instrument cluster and retest. Return to step 1 to confirm the elimination of the fault. B. The voltage is greater than 0.5 V. The solenoid wire is shorted to another voltage source. Repair or replace the harness as required. Return to step 1 to confirm elimination of the fault.
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4952 - Hydraulic Interlock Solenoid Open Circuit NOTE: A machine with Loader Lock on will trigger trouble code 4952. This is normal. Context: The instrument cluster has sensed an open circuit condition in the hydraulic interlock circuit. Diagnostic Trouble Code 4952 has an error priority of Amber. There are no restrictions with Diagnostic Trouble Code 4952. Cause: The instrument cluster has sensed an open circuit condition in the hydraulic interlock circuit. The fault is active while the ignition switch is ON and the hydraulic enable commanded state is high but the hydraulic enable solenoid is not energized. Possible failure modes: 1. Faulty wiring or connectors. 2. An open circuit in the hydraulic interlock solenoid wiring. 3. An open circuit in the hydraulic interlock solenoid. 4. A 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 machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 4952 is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the instrument cluster connector X-C23 and the hydraulic interlock solenoid connections. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the instrument cluster to the hydraulic interlock solenoid. 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 harness has damage. Repair or replace the harness or connectors as required. Return to step 1 to confirm elimination of fault. 3. Measure the resistance through the signal wire. Turn the ignition switch OFF. Disconnect the instrument cluster connector X-C23. Measure the resistance between X-C23 pin 30 and chassis ground. The resistance should be less than 10 Ί. Wiggle the harness during measurement to reveal an intermittent condition. A. The resistance is less than 10 Ί. Temporarily replace the instrument cluster and retest. Return to step 1 to confirm the elimination of the fault. B. The resistance is greater than 10 Ί. There is a problem in the solenoid circuit. Go to step 4. 4. Measure the resistance of the hydraulic interlock solenoid. Turn the ignition switch OFF. 48068130 29/01/2018
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Disconnect connector X-PORT_LK from the hydraulic interlock solenoid. Measure the resistance across the solenoid terminals of the solenoid. The resistance should be approximately 7.25 Ω. A. The resistance is between 6.5 Ω and 8 Ω. Go to step 5. B. The resistance is greater than 8 Ω. The hydraulic interlock solenoid has an internal open circuit. Replace the hydraulic interlock solenoid and retest. Return to step 1 to confirm elimination of fault. 5. Measure the resistance through the signal wire. Disconnect the instrument cluster connector X-C23 and the hydraulic interlock solenoid connector, X-PORT_LK. Fabricate a jumper wire that will connect between connector X-PORT_LK pin 1 and X-PORT_LK pin 2. Connect the jumper wire between connector X-PORT_LK pin 1 and X-PORT_LK pin 2. Measure the resistance between X-C23 pin 30 and X-C23 pin 34 (chassis ground). 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. Temporarily replace the instrument cluster and retest. Return to step 1 to confirm elimination of the fault. B. The resistance is greater than 10 Ω. There is an open circuit in the harness. Inspect connectors from the instrument cluster to the hydraulic interlock solenoid. Verify all connections are tight and secure and free of damage. Repair or replace the wires as required. Return to step 1 to confirm elimination of fault.
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5051 - Loader Pilot Interlock Valve (On/Off) - Solenoid Supply Open Circuit SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Context: The UCM has sensed an open circuit in the solenoid signal line, X-CN2A (Receptacle) pin 4. Diagnostic Trouble Code 5051 – Loader Pilot Interlock Valve (On/Off) - Solenoid Supply Open Circuit has an error priority of Red. Loader hydraulics are disabled while Diagnostic Trouble Code 5051 – Loader Pilot Interlock Valve (On/Off) - Solenoid Supply Open Circuit is active. Cause: The UCM has sensed an open circuit in the solenoid signal line, X-CN2A (Receptacle) pin 4. The fault is active while the engine is ON and the voltage on X-CN2A (Receptacle) pin 4 is less 1 V or greater than 8 V. Possible failure modes: 1. An open circuit in the solenoid wiring. 2. The loader pilot interlock valve has failed. 3. The UCM has an internal failure. 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. OK to return the machine to service. B. Fault code 5051 – Loader Pilot Interlock Valve (On/Off) - Solenoid Supply Open Circuit is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the UCM and the loader pilot interlock connections. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the UCM to the loader pilot interlock. 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 the connectors as required. Return to step 1 to confirm elimination of fault. 3. Measure the resistance through the solenoid circuit. Turn the ignition switch OFF. Disconnect UCM connector X-CN2A (Receptacle) . Fabricate a jumper wire that will connect between X-CN2A (Receptacle) pin 4 and chassis ground. 48068130 29/01/2018
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Connect the jumper wire between X-CN2A (Receptacle) pin 4 and chassis ground. Disconnect connector X-PLTLK (Receptacle) . Measure the resistance between X-PLTLK (Receptacle) pin A and chassis ground. The resistance should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition. Measure the resistance between X-PLTLK (Receptacle) pin B and chassis ground. The resistance should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition. A. Both resistance measurements are less than 10 Ω. Go to step 4 to confirm elimination of the fault. B. One or both resistance measurements are 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 the fault. 4. Measure the resistance through the solenoid. Measure the resistance across the loader interlock solenoid terminals, X-PLTLK (Receptacle) pin A and X-PLTLK (Receptacle) pin B. The resistance should be less than 1,000 Ω. A. The resistance is less than 1,000 Ω. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. B. The resistance is greater than 1,000 Ω. There is an open circuit in the solenoid. Replace the solenoid and retest. Return to step 1 to confirm elimination of the fault. Wiring harnesses - Electrical schematic sheet 20 SH20-UNIVERSAL CONTROL MODULE (55.100.DP-C.20.E.20) Wiring harnesses - Electrical schematic sheet 11 SH11-HYDRAULIC INTERLOCKS (55.100.DP-C.20.E.11) Wiring harnesses - Electrical schematic sheet 05 SH05-GROUNDING SYSTEM (55.100.DP-C.20.E.05)
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5052 - Loader Pilot Interlock Valve (On/Off) - Solenoid Supply Short to Ground SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Context: The UCM has sent a signal to the Loader Pilot Interlock solenoid to energize, but no voltage was detected. Diagnostic Trouble Code 5052 – Loader Pilot Interlock Valve (On/Off) - Solenoid Supply Short to Ground has an error priority of Red. Loader hydraulics are disabled while Diagnostic Trouble Code 5052 – Loader Pilot Interlock Valve (On/Off) - Solenoid Supply Short to Ground is active. Cause: The UCM has sent a signal to the loader pilot interlock solenoid to energize, but no voltage was detected. The fault is active while the hydraulics are enabled and the loader pilot interlock solenoid output, X-CN2A (Receptacle) pin 4 is greater than 3 A. Possible failure modes: 1. A short circuit in the solenoid wiring. 2. The loader pilot interlock valve has failed. 3. The UCM has an internal failure. 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. OK to return the machine to service. B. Fault code 5052 – Loader Pilot Interlock Valve (On/Off) - Solenoid Supply Short to Ground is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the UCM and the loader pilot interlock connections. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the UCM to the loader pilot interlock. 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 the connectors as required. Return to step 1 to confirm elimination of fault. 3. Measure the resistance through the solenoid circuit. Turn the ignition switch OFF. Disconnect UCM connector X-CN2A (Receptacle) . 48068130 29/01/2018
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Disconnect solenoid connector X-PLTLK (Receptacle) . Measure the resistance between X-CN2A (Receptacle) pin 4 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. Go to step 4. B. The resistance measurement is less than 20,000 Ω. There is a short circuit to chassis ground in the wiring. Repair or replace the harness as required. Return to step 1 to confirm elimination of the fault. 4. Measure the solenoid resistance. Measure the resistance across the loader interlock solenoid terminals, pin A and pin B. The resistance should be greater than 1 Ω. A. The resistance is greater than 1 Ω. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. B. The resistance is less than 1 Ω. There is a short circuit in the solenoid. Replace the solenoid and retest. Return to step 1 to confirm elimination of the fault. Wiring harnesses - Electrical schematic sheet 20 SH20-UNIVERSAL CONTROL MODULE (55.100.DP-C.20.E.20) Wiring harnesses - Electrical schematic sheet 11 SH11-HYDRAULIC INTERLOCKS (55.100.DP-C.20.E.11) Wiring harnesses - Electrical schematic sheet 05 SH05-GROUNDING SYSTEM (55.100.DP-C.20.E.05)
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5053 - Loader Pilot Interlock Valve (On/Off) - Solenoid Supply Short to Power SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Context: The UCM has sensed that the voltage on X-CN2A (Receptacle) pin 4 is greater than 8 V. Diagnostic Trouble Code 5053 – Loader Pilot Interlock Valve (On/Off) - Solenoid Supply Short to Power has an error priority of Red. Loader hydraulics are disabled while Diagnostic Trouble Code 5053 – Loader Pilot Interlock Valve (On/Off) - Solenoid Supply Short to Power is active. Cause: The UCM has sent a signal to the loader pilot interlock solenoid to de-energize, but the UCM detects a voltage on the output. The fault is active when the hydraulics are disabled and the loader port lock solenoid output, X-CN2A (Receptacle) pin 4 is greater than 8 V. Possible failure modes: 1. A short circuit in the solenoid wiring. 2. The loader pilot interlock valve has failed. 3. The UCM has an internal failure. 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. OK to return the machine to service. B. Fault code 5053 – Loader Pilot Interlock Valve (On/Off) - Solenoid Supply Short to Power is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the UCM and the loader pilot interlock connections. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the UCM to the loader pilot interlock. 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 the connectors as required. Return to step 1 to confirm elimination of fault. 3. Measure the resistance through the solenoid circuit. Turn the ignition switch OFF. Disconnect UCM connector X-CN2A (Receptacle) .
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Disconnect solenoid connector X-PLTLK (Receptacle) . Turn the ignition switch ON. Measure the voltage between X-CN2A (Receptacle) pin 4 and chassis ground. The voltage should be less than 0.5 V. Wiggle the harness during measurement to reveal an intermittent condition. Measure the voltage between X-PLTLK (Receptacle) pin B and chassis ground. The voltage should be less than 0.5 V. Wiggle the harness during measurement to reveal an intermittent condition. A. Both voltage measurements are less than 0.5 V. Go to step 4. 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 the fault. 4. Test the UCM. Turn the ignition switch OFF. Connect UCM connector X-CN2A (Receptacle) . Leave connector X-PLTLK (Receptacle) disconnected. Turn the ignition switch ON. Access the EST fault code screen and refresh the screen. Fault code 5053 – Loader Pilot Interlock Valve (On/ Off) - Solenoid Supply Short to Power should not be active. Fault code 5053 – Loader Pilot Interlock Valve (On/Off) - Solenoid Supply Short to Power should be active. A. Fault code 5053 – Loader Pilot Interlock Valve (On/Off) - Solenoid Supply Short to Power is not active. Fault code 5053 – Loader Pilot Interlock Valve (On/Off) - Solenoid Supply Short to Power is active. Temporarily replace the loader pilot interlock and retest. Return to step 1 to confirm elimination of the fault. B. Fault code 5053 – Loader Pilot Interlock Valve (On/Off) - Solenoid Supply Short to Power is still active. Fault code 5053 – Loader Pilot Interlock Valve (On/Off) - Solenoid Supply Short to Power is not active. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. Wiring harnesses - Electrical schematic sheet 20 SH20-UNIVERSAL CONTROL MODULE (55.100.DP-C.20.E.20) Wiring harnesses - Electrical schematic sheet 11 SH11-HYDRAULIC INTERLOCKS (55.100.DP-C.20.E.11) Wiring harnesses - Electrical schematic sheet 05 SH05-GROUNDING SYSTEM (55.100.DP-C.20.E.05)
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5061 - Port Lock Valve (On/Off) - Solenoid Supply Open Circuit SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Context: The UCM has sensed an open circuit in the solenoid signal line, X-CN2A (Receptacle) pin 5. Diagnostic Trouble Code 5061 – Port Lock Valve (On/Off) - Solenoid Supply Open Circuit has an error priority of Red. Loader hydraulics are disabled while Diagnostic Trouble Code 5061 – Port Lock Valve (On/Off) - Solenoid Supply Open Circuit is active. Cause: The UCM has sensed an open circuit in the solenoid supply. The fault is active when the engine is ON and the UCM pin voltage, CN2A pin 5 is less 1 V or greater than 8 V. Possible failure modes: 1. A faulty ground connection on the rear right-hand ground lug. 2. An open circuit in the solenoid wiring. 3. The loader lock interlock valve has failed. 4. The UCM has an internal failure. 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. OK to return the machine to service. B. Fault code 5061 – Port Lock Valve (On/Off) - Solenoid Supply Open Circuit is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the UCM and the loader port lock connections. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the UCM to the loader port lock. 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 the connectors as required. Return to step 1 to confirm elimination of fault. 3. Check the ground connection on the rear right-hand ground lugs. Verify that the grounding boss is free of paint, oil, dirt, and debris. Verify that the ground connection is tight and secure. A. The grounding boss is clean and free of paint. The grounding connection is secure. Go to step 4.
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B. The grounding boss is dirty or cover with paint. Remove the dirt. Remove the paint. Repair as required. Return to step 1 to confirm elimination of fault. 4. Measure the resistance through the solenoid circuit. Turn the ignition switch OFF. Disconnect UCM connector X-CN2A (Receptacle) . Fabricate a jumper wire that will connect between X-CN2A (Receptacle) pin 5 and chassis ground. Connect the jumper wire between X-CN2A (Receptacle) pin 5 and chassis ground. Disconnect connector X-PORT_LK (Receptacle) . Measure the resistance between X-PORT_LK (Receptacle) pin 1 and chassis ground. The resistance should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition. Measure the resistance between X-PORT_LK (Receptacle) pin 2 and chassis ground. The resistance should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition. A. Both resistance measurements are less than 10 Ω. Go to step 5 to confirm elimination of the fault. B. One or both resistance measurements are greater than 10 Ω. There is an open circuit in the wiring. Repair or replace the harness as required. Check splice SP-187. Return to step 1 to confirm elimination of the fault. 5. Measure the resistance through the solenoid. Measure the resistance across the loader interlock solenoid terminals, X-PORT_LK (Receptacle) pin 1 and X-PORT_LK (Receptacle) pin 2. The resistance should be less than 1,000 Ω. A. The resistance is less than 1,000 Ω. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. B. The resistance is greater than 1,000 Ω. There is an open circuit in the solenoid. Replace the solenoid and retest. Return to step 1 to confirm elimination of the fault. Wiring harnesses - Electrical schematic sheet 20 SH20-UNIVERSAL CONTROL MODULE (55.100.DP-C.20.E.20) Wiring harnesses - Electrical schematic sheet 11 SH11-HYDRAULIC INTERLOCKS (55.100.DP-C.20.E.11) Wiring harnesses - Electrical schematic sheet 32 SH32-TELEMATICS (55.100.DP-C.20.E.32) Wiring harnesses - Electrical schematic sheet 05 SH05-GROUNDING SYSTEM (55.100.DP-C.20.E.05)
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5062 - Port Lock Valve (On/Off) - Solenoid Supply Short to Ground SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Context: The UCM has sent a signal to the loader port lock solenoid to energize, but no voltage was detected. Diagnostic Trouble Code 5062 – Port Lock Valve (On/Off) - Solenoid Supply Short to Ground has an error priority of Red. Loader hydraulics are disabled while Diagnostic Trouble Code 5062 – Port Lock Valve (On/Off) - Solenoid Supply Short to Ground is active. Cause: The UCM has sent a signal to the loader port lock solenoid to energize, but no voltage was detected. The fault is active while hydraulics are enabled and the loader port lock solenoid output, X-CN2A (Receptacle) pin 5 is greater than 3 A. Possible failure modes: 1. A short circuit in the solenoid wiring. 2. The loader port lock solenoid has failed. 3. The UCM has an internal failure. 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. OK to return the machine to service. B. Fault code 5062 – Port Lock Valve (On/Off) - Solenoid Supply Short to Ground is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the UCM and the loader port lock connections. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the UCM to the loader port lock solenoid. 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 the connectors as required. Return to step 1 to confirm elimination of fault. 3. Measure the resistance through the solenoid circuit. Turn the ignition switch OFF. Disconnect UCM connector X-CN2A (Receptacle) . Disconnect solenoid connector X-PORT_LK (Receptacle) .
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Measure the resistance between X-CN2A (Receptacle) pin 5 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. Go to step 4. B. The resistance measurement is less than 20,000 Ω. There is a short circuit to chassis ground in the wiring. Repair or replace the harness as required. Return to step 1 to confirm elimination of the fault. 4. Measure the solenoid resistance. Measure the resistance across the loader port lock solenoid terminals, X-PORT_LK (Receptacle) pin 1 and X-PORT_LK (Receptacle) pin 2. The resistance should be greater than 1 Ω. A. The resistance is greater than 1 Ω. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. B. The resistance is less than 1 Ω. There is a short circuit in the solenoid. Replace the solenoid and retest. Return to step 1 to confirm elimination of the fault. Wiring harnesses - Electrical schematic sheet 20 SH20-UNIVERSAL CONTROL MODULE (55.100.DP-C.20.E.20) Wiring harnesses - Electrical schematic sheet 11 SH11-HYDRAULIC INTERLOCKS (55.100.DP-C.20.E.11) Wiring harnesses - Electrical schematic sheet 32 SH32-TELEMATICS (55.100.DP-C.20.E.32) Wiring harnesses - Electrical schematic sheet 05 SH05-GROUNDING SYSTEM (55.100.DP-C.20.E.05)
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Electrical systems - FAULT CODES
5063 - Port Lock Valve (On/Off) - Solenoid Supply Short to Power SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Context: The UCM has sensed that the voltage on X-CN2A (Receptacle) pin 5 is greater than 8 V. Diagnostic Trouble Code 5063 – Port Lock Valve (On/Off) - Solenoid Supply Short to Power has an error priority of Red. Loader hydraulics are disabled while Diagnostic Trouble Code 5063 – Port Lock Valve (On/Off) - Solenoid Supply Short to Power is active. Cause: The UCM has sent a signal to the loader port lock solenoid to de-energize, but the UCM detects a voltage on the output. The fault is active when the hydraulics are disabled and the loader port lock solenoid output, X-CN2A (Receptacle) pin 5 is greater than 8 V. Possible failure modes: 1. A faulty ground connection on the rear right-hand ground lug. 2. A short circuit in the solenoid wiring. 3. The loader port lock valve has failed. 4. The UCM has an internal failure. 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. OK to return the machine to service. B. Fault code 5063 – Port Lock Valve (On/Off) - Solenoid Supply Short to Power is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the UCM and the loader port lock connections. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the UCM to the loader port lock solenoid. 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. 3. Check the ground connection on the rear right-hand ground lugs. Verify that the grounding boss is free of paint, oil, dirt, and debris. Verify that the ground connection is tight and secure.
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A. The grounding boss is clean and free of paint. The grounding connection is secure. Go to step 4. B. The grounding boss is dirty or cover with paint. Remove the dirt. Remove the paint. Repair as required. Return to step 1 to confirm elimination of fault. 4. Measure the resistance through the solenoid circuit. Turn the ignition switch OFF. Disconnect UCM connector X-CN2A (Receptacle) . Disconnect solenoid connector X-PORT_LK (Receptacle) . Turn the ignition switch ON. Measure the voltage between X-CN2A (Receptacle) pin 5 and chassis ground. The voltage should be less than 0.5 V. Wiggle the harness during measurement to reveal an intermittent condition. Measure the voltage between X-PORT_LK (Receptacle) pin 2 and chassis ground. The voltage should be less than 0.5 V. Wiggle the harness during measurement to reveal an intermittent condition. 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 the fault. 5. Test the UCM. Turn the ignition switch OFF. Connect UCM connector X-CN2A (Receptacle) . Leave connector X-PORT_LK (Receptacle) disconnected. Turn the ignition switch ON. Access the EST fault code screen and refresh the screen. Fault code 5063 – Port Lock Valve (On/Off) - Solenoid Supply Short to Power should not be active. Fault code 5061 – Port Lock Valve (On/Off) - Solenoid Supply Open Circuit should be active. A. Fault code 5063 – Port Lock Valve (On/Off) - Solenoid Supply Short to Power is not active. Fault code 5061 – Port Lock Valve (On/Off) - Solenoid Supply Open Circuit is active. Temporarily replace the loader port lock valve and retest. Return to step 1 to confirm elimination of the fault. B. Fault code 5063 – Port Lock Valve (On/Off) - Solenoid Supply Short to Power is still active. Fault code 5061 – Port Lock Valve (On/Off) - Solenoid Supply Open Circuit is not active. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. Wiring harnesses - Electrical schematic sheet 20 SH20-UNIVERSAL CONTROL MODULE (55.100.DP-C.20.E.20) Wiring harnesses - Electrical schematic sheet 11 SH11-HYDRAULIC INTERLOCKS (55.100.DP-C.20.E.11) Wiring harnesses - Electrical schematic sheet 32 SH32-TELEMATICS (55.100.DP-C.20.E.32) Wiring harnesses - Electrical schematic sheet 05 SH05-GROUNDING SYSTEM (55.100.DP-C.20.E.05)
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5121 - Right Joystick F-B Axis - Pin A Short to Power/ Short to Ground/ Open Circuit SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Context: The UCM has sensed that the right joystick F-B signal has failed. Diagnostic Trouble Code 5121 – Right Joystick F-B Axis - Pin A Short to Power/ Short to Ground/ Open Circuit has an error priority of Amber. Ground drive will operate in limp home mode while Diagnostic Trouble Code 5121 – Right Joystick F-B Axis - Pin A Short to Power/ Short to Ground/ Open Circuit is active. Cause: The UCM has sensed that the right joystick F-B signal has failed. The fault is active while the voltage on X-CN4A (Receptacle) pin 17 is less than 0.2 V or the voltage is greater than 4.8 V. The normal operating voltage of the sensor output is 0.5 V to 4.5 V. The output of the sensor with the joystick in the neutral position is approximately 2.5 V. Possible failure modes: 1. A short circuit in the signal wire. 2. An open circuit in the signal wire. 3. A failure of the right control handle. 4. The UCM has an internal failure. 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. OK to return the machine to service. B. Fault code 5121 – Right Joystick F-B Axis - Pin A Short to Power/ Short to Ground/ Open Circuit is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the UCM and the right joystick connections. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the UCM to the right joystick. 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 the connectors as required. Return to step 1 to confirm elimination of fault. 3. Measure the voltage of the signal wire to chassis ground. Turn the ignition switch OFF.
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Disconnect the UCM connector X-CN4A (Receptacle) . Disconnect the right joystick connector X-UJMR (Plug) . Turn the ignition switch ON. Measure the voltage between X-UJMR (Plug) pin 3 and chassis ground. The voltage should be less than 0.5 V. Wiggle the harness during measurement to reveal an intermittent condition. A. The voltage is less than 0.5 V. Go to step 4. B. The voltage is greater than 0.5 V. There is a short circuit to another voltage source. Repair or replace the harness as required. Return to step 1 to confirm elimination of fault. 4. Measure the resistance of the signal wire to chassis ground. Turn the ignition switch OFF. Disconnect the UCM connector X-CN4A (Receptacle) . Disconnect the right joystick connector X-UJMR (Plug) . Measure the resistance between X-UJMR (Plug) pin 3 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. Go to step 5. 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 1 to confirm elimination of fault. 5. Measure the resistance through the signal wire. Fabricate a jumper wire that will connect between connector X-CN4A (Receptacle) pin 17 and chassis ground. Connect the jumper wire between X-CN4A (Receptacle) pin 17 and chassis ground. The chassis ground connection must be clean and free of rust, dirt oil and paint. Measure the resistance between connector X-UJMR (Plug) pin 3 and chassis ground. 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 6. B. The resistance is greater than 10 Ω. There is an open circuit in the signal wire. Repair or replace the harness as required. Return to step 1 to confirm elimination of fault. 6. Measure the voltage to the sensor. Turn the ignition switch OFF. Disconnect the right joystick connector X-UJMR (Plug) . Reconnect the UCM connector(s). Turn the ignition switch ON. Measure the voltage between X-UJMR (Plug) pin 1 and X-UJMR (Plug) pin 4. The voltage should be approximately 5 V. Wiggle the harness during measurement to reveal an intermittent condition.
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RAPH12SSL0351FA
(1) (2)
Connector X-UJMR (Plug) Joystick X-Y Position Sensor
1
Schematic legend (3) (4)
DVM set to measure voltage. Right joystick F-B X-CN4A (Receptacle) pin 17
A. The voltage is approximately 5 V. Go to step 7. B. The voltage is not within range. There is a problem with the voltage supply to the sensor. Verify the voltage from the UCM. If the voltage from the UCM is correct, there is a problem in the voltage supply to the sensor. Repair as required. Return to step 1 to confirm elimination of fault. 7. Measure the voltage output of the sensor. Turn the ignition switch OFF. Disconnect the right joystick connector X-UJMR (Plug) . Fabricate a breakout harness to measure the voltage output of the sensor.
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RAPH12SSL0352GA
(1)
2
Schematic legend Dealer supplied breakout harness (2)
DVM set to measure voltage.
Connect the breakout harness between the two mating connectors on X-UJMR (Plug) . Turn the ignition switch ON. Measure the voltage between X-UJMR (Plug) pin 3 and X-UJMR (Plug) pin 4 on the break out harness. The voltage should be approximately 2.5 V while the joystick in the neutral position. Continue measuring the voltage while slowly moving the throttle in the F-B position. The voltage should change between 0.5 V and 4.5 V. The voltage change should be smooth and steady as the joystick is moved between the stop points. A. The voltage is approximately 2.5 V in the neutral position and the voltage changes between 0.5 V and 4.5 V. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. B. The voltage is not 2.5 V in the neutral position or the voltage change is erratic. Temporarily replace the joystick and retest. Return to step 1 to confirm elimination of fault. Wiring harnesses - Electrical schematic sheet 21 SH21-UNIVERSAL CONTROL MODULE (55.100.DP-C.20.E.21) Wiring harnesses - Electrical schematic sheet 15 SH15-BULKHEAD CONNECTION (55.100.DP-C.20.E.15) Wiring harnesses - Electrical schematic sheet 18 SH18-RIGHT NH CONTROL HANDLE (55.100.DP-C.20.E.18)
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Electrical systems - FAULT CODES
5122 - Right Joystick F-B Axis - Pin B Short to Power/ Short to Ground/ Open Circuit SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Context: The UCM has sensed that the right joystick F-B signal has failed. Diagnostic Trouble Code 5122 – Right Joystick F-B Axis - Pin B Short to Power/ Short to Ground/ Open Circuit has an error priority of Amber. Ground drive will operate in limp home mode while Diagnostic Trouble Code 5122 – Right Joystick F-B Axis - Pin B Short to Power/ Short to Ground/ Open Circuit is active. Cause: The UCM has sensed that the right joystick F-B signal has failed. The fault is active while the voltage on X-CN1B (Receptacle) pin 13 is less than 0.2 V or the voltage is greater than 4.8 V. The normal operating voltage of the sensor output is 0.5 V to 4.5 V. The output of the sensor with the joystick in the neutral position is approximately 2.5 V. Possible failure modes: 1. A short circuit in the signal wire. 2. An open circuit in the signal wire. 3. A failure of the right control handle. 4. The UCM has an internal failure. 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. OK to return the machine to service. B. Fault code 5122 – Right Joystick F-B Axis - Pin B Short to Power/ Short to Ground/ Open Circuit is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the UCM and the right joystick connections. All connections should be secure, tight, free of corrosion, abrasion and damage. Inspect the harness from the UCM to the right joystick. 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 the connectors as required. Return to step 1 to confirm elimination of fault. 3. Measure the voltage of the signal wire to chassis ground. Turn the ignition switch OFF.
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Disconnect the UCM connector X-CN1B (Receptacle) . Disconnect the right joystick connector X-UJMR (Plug) . Turn the ignition switch ON. Measure the voltage between X-UJMR (Plug) pin 9 and chassis ground. The voltage should be less than 0.5 V. Wiggle the harness during measurement to reveal an intermittent condition. A. The voltage is less than 0.5 V. Go to step 4. B. The voltage is greater than 0.5 V. There is a short circuit to another voltage source. Repair or replace the harness as required. Return to step 1 to confirm elimination of fault. 4. Measure the resistance of the signal wire to chassis ground. Turn the ignition switch OFF. Disconnect the UCM connector X-CN1B (Receptacle) . Disconnect the right joystick connector X-UJMR (Plug) . Measure the resistance between X-UJMR (Plug) pin 9 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. Go to step 5. 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 1 to confirm elimination of fault. 5. Measure the resistance through the signal wire. Fabricate a jumper wire that will connect between connector X-CN1B (Receptacle) pin 13 and chassis ground. Connect the jumper wire between X-CN1B (Receptacle) pin 13 and chassis ground. The chassis ground connection must be clean and free of rust, dirt oil and paint. Measure the resistance between connector X-UJMR (Plug) pin 9 and chassis ground. 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 6. B. The resistance is greater than 10 Ω. There is an open circuit in the signal wire. Repair or replace the harness as required. Return to step 1 to confirm elimination of fault. 6. Measure the voltage to the sensor. Turn the ignition switch OFF. Disconnect the right joystick connector X-UJMR (Plug) . Reconnect the UCM connector(s). Turn the ignition switch ON. Measure the voltage between X-UJMR (Plug) pin 7 and X-UJMR (Plug) pin 10. The voltage should be approximately 5 V. Wiggle the harness during measurement to reveal an intermittent condition.
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RAPH12SSL0353FA
(1) (2)
Connector X-UJMR (Plug) Joystick X-Y Position Sensor
1
Schematic legend (3) (4)
DVM set to measure voltage. Right joystick F-B X-CN1B (Receptacle) pin 13
A. The voltage is approximately 5 V. Go to step 7. B. The voltage is not within range. There is a problem with the voltage supply to the sensor. Verify the voltage from the UCM. If the voltage from the UCM is correct, there is a problem in the voltage supply to the sensor. Repair as required. Return to step 1 to confirm elimination of fault. 7. Measure the voltage output of the sensor. Turn the ignition switch OFF. Disconnect the right joystick connector X-UJMR (Plug) . Fabricate a breakout harness to measure the voltage output of the sensor.
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RAPH12SSL0354GA
(1)
2
Schematic legend Dealer supplied breakout harness (2)
DVM set to measure voltage.
Connect the breakout harness between the two mating connectors on X-UJMR (Plug) . Turn the ignition switch ON. Measure the voltage between X-UJMR (Plug) pin 3 and X-UJMR (Plug) pin 4 on the break out harness. The voltage should be approximately 2.5 V while the joystick in the neutral position. Continue measuring the voltage while slowly moving the throttle in the F-B position. The voltage should change between 0.5 V and 4.5 V. The voltage change should be smooth and steady as the joystick is moved between the stop points. A. The voltage is approximately 2.5 V in the neutral position and the voltage changes between 0.5 V and 4.5 V. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. B. The voltage is not 2.5 V in the neutral position or the voltage change is erratic. Temporarily replace the joystick and retest. Return to step 1 to confirm elimination of fault. Wiring harnesses - Electrical schematic sheet 20 SH20-UNIVERSAL CONTROL MODULE (55.100.DP-C.20.E.20) Wiring harnesses - Electrical schematic sheet 14 SH14-BULKHEAD CONNECTION (55.100.DP-C.20.E.14) Wiring harnesses - Electrical schematic sheet 18 SH18-RIGHT NH CONTROL HANDLE (55.100.DP-C.20.E.18)
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Electrical systems - FAULT CODES
5124 - Right Joystick F-B Axis - In Range Fault SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Context: The UCM has sensed that the right joystick F-B signal has failed. Diagnostic Trouble Code 5124 – Right Joystick F-B Axis - In Range Fault has an error priority of Amber. Ground drive will operate in limp home mode while Diagnostic Trouble Code 5124 – Right Joystick F-B Axis - In Range Fault is active. Cause: The UCM has sensed that the right joystick F-B signal has failed. The fault is active while the voltage on X-CN4A (Receptacle) pin 17 and X-CN1B (Receptacle) pin 13 is less than 0.2 V or the voltage is greater than 4.8 V. The normal operating voltage of the sensor output is 0.5 V to 4.5 V. The output of the sensor in the neutral position is approximately 2.5 V. Possible failure modes: 1. An open circuit in the signal wire. 2. A short circuit in the signal wire. 3. Failure of the right control handle. 4. The UCM has an internal failure. 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. OK to return the machine to service. B. Fault code 5124 – Right Joystick F-B Axis - In Range Fault is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the UCM and the right joystick connections. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the UCM to the right joystick. 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 the connectors as required. Return to step 1 to confirm elimination of fault. 3. Measure the voltage of the signal wire to chassis ground. Turn the ignition switch OFF. Disconnect UCM connectors X-CN4A (Receptacle) and X-CN1B (Receptacle) .
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Disconnect the right joystick connector X-UJMR (Plug) . Turn the ignition switch ON. Measure the voltage between X-UJMR (Plug) pin 3 and chassis ground. The voltage should be less than 0.5 V. Wiggle the harness during measurement to reveal an intermittent condition. Measure the voltage between X-UJMR (Plug) pin 9 and chassis ground. The voltage should be less than 0.5 V. Wiggle the harness during measurement to reveal an intermittent condition. A. The voltage is less than 0.5 V. Go to step 4. B. The voltage is greater than 0.5 V. There is a short circuit to another voltage source. Repair or replace the harness as required. Return to step 1 to confirm elimination of fault. 4. Measure the resistance of the signal wire to chassis ground. Turn the ignition switch OFF. Disconnect the UCM connector X-CN4A (Receptacle) and X-CN1B (Receptacle) . Disconnect the right joystick connector X-UJMR (Plug) . Measure the resistance between X-UJMR (Plug) pin 3 and chassis ground. The resistance should be greater than 20,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition. Measure the resistance between X-UJMR (Plug) pin 9 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. Go to step 5. 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 1 to confirm elimination of fault. 5. Measure the resistance through the signal wire. Turn the ignition switch OFF. Fabricate a jumper wire that will connect between connector X-CN4A (Receptacle) pin 17 and chassis ground. Connect the jumper wire between X-CN4A (Receptacle) pin 17 and chassis ground. The chassis ground connection must be clean and free of rust, dirt oil and paint. Measure the resistance between connector X-UJMR (Plug) pin 3 and chassis ground. The resistance should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition. Remove the jumper wire. Connect the jumper wire between X-CN1B (Receptacle) pin 13 and chassis ground. The chassis ground connection must be clean and free of rust, dirt oil and paint. Measure the resistance between connector X-UJMR (Plug) pin 9 and chassis ground. The resistance should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition. A. Both resistance measurements are less than 10 Ω. Go to step 6. B. One of both resistance measurements are greater than 10 Ω. There is an open circuit in the signal wire. Repair or replace the harness as required. Return to step 1 to confirm elimination of fault. 6. Measure the voltage to the sensor. Turn the ignition switch OFF. Disconnect the right joystick connector X-UJMR (Plug) . Reconnect the UCM connector(s). Turn the ignition switch ON.
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Measure the voltage between X-UJMR (Plug) pin 1 and X-UJMR (Plug) pin 4. The voltage should be approximately 5 V. Wiggle the harness during measurement to reveal an intermittent condition. Measure the voltage between X-UJMR (Plug) pin 7 and X-UJMR (Plug) pin 10. The voltage should be approximately 5 V. Wiggle the harness during measurement to reveal an intermittent condition.
RAPH12SSL0355FA
1
Schematic legend (4)
(1)
Connector X-UJMR (Plug)
(2)
Joystick X-Y position sensor
(3)
DVM set to measure voltage.
(5)
Right joystick F-B X-CN4A (Receptacle) pin 17 Right joystick F-B X-CN1B (Receptacle) pin 13
A. The voltage is approximately 5 V. Go to step 7. B. The voltage is not within range. There is a problem with the voltage supply to the sensor. Verify the voltage from the UCM. If the voltage from the UCM is correct, there is a problem in the voltage supply to the sensor. Repair as required. Return to step 1 to confirm elimination of fault. 7. Measure the voltage output of the sensor. Turn the ignition switch OFF. Disconnect the right joystick connector X-UJMR (Plug) . Fabricate a breakout harness to measure the voltage output of the sensor.
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RAPH12SSL0356GA
(1)
2
Schematic legend Dealer supplied breakout harness. (2)
DVM set to measure voltage.
Turn the ignition switch OFF. Connect the breakout harness between the two mating connectors on X-UJMR (Plug) . Turn the ignition switch ON. Measure the voltage between X-UJMR (Plug) pin 3 and X-UJMR (Plug) pin 4 on the break out harness. The voltage should be approximately 2.5 V while the joystick in the neutral position. Continue measuring the voltage while slowly moving the throttle in the F-B position. The voltage should change between 0.5 V and 4.5 V. The voltage change should be smooth and steady as the joystick is moved between the stop points. Measure the voltage between X-UJMR (Plug) pin 9 and X-UJMR (Plug) pin 10 on the break out harness. The voltage should be approximately 2.5 V while the joystick in the neutral position. Continue measuring the voltage while slowly moving the throttle in the F-B position. The voltage should change between 0.5 V and 4.5 V. The voltage change should be smooth and steady as the joystick is moved between the stop points. A. For both measurements, the voltage is approximately 2.5 V in the neutral position and the voltage changes at a smooth rate between 0.5 V and 4.5 V. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. 48068130 29/01/2018
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B. For one or both measurements, the voltage is not 2.5 V in the neutral position or the voltage change is erratic. Temporarily replace the joystick and retest. Return to step 1 to confirm elimination of fault. Wiring harnesses - Electrical schematic sheet 21 SH21-UNIVERSAL CONTROL MODULE (55.100.DP-C.20.E.21) Wiring harnesses - Electrical schematic sheet 15 SH15-BULKHEAD CONNECTION (55.100.DP-C.20.E.15) Wiring harnesses - Electrical schematic sheet 20 SH20-UNIVERSAL CONTROL MODULE (55.100.DP-C.20.E.20) Wiring harnesses - Electrical schematic sheet 14 SH14-BULKHEAD CONNECTION (55.100.DP-C.20.E.14) Wiring harnesses - Electrical schematic sheet 18 SH18-RIGHT NH CONTROL HANDLE (55.100.DP-C.20.E.18)
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Electrical systems - FAULT CODES
5131 - Right Joystick R-L Axis (ISO/H Pattern) - Pin A Short to Ground/ Open Circuit SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Context: The UCM has sensed that the right joystick R-L signal has failed low. Diagnostic Trouble Code 5131 – Right Joystick R-L Axis (ISO/H Pattern) - Pin A Short to Ground/ Open Circuit has an error priority of Amber. Implement functions will operate in limp home mode while Diagnostic Trouble Code 5131 – Right Joystick R-L Axis (ISO/H Pattern) - Pin A Short to Ground/ Open Circuit is active. Cause: The UCM has sensed that the right joystick R-L signal has failed low. The fault is active while the engine is ON and the voltage on X-CN4A (Receptacle) pin 24 is less than 0.2 V. The normal operating voltage of the sensor output is 0.5 V to 4.5 V. The output of the sensor with the joystick in the neutral position is approximately 2.5 V. Possible failure modes: 1. A short circuit in the signal wire. 2. An open circuit in the signal wire. 3. A failure of the right control handle. 4. The UCM has an internal failure. 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. OK to return the machine to service. B. Fault code 5131 – Right Joystick R-L Axis (ISO/H Pattern) - Pin A Short to Ground/ Open Circuit is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the UCM and the right joystick connections. All connections should be secure, tight, free of corrosion, abrasion and damage. Inspect the harness from the UCM to the right joystick. 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 the connectors as required. Return to step 1 to confirm elimination of fault. 3. Measure the resistance of the signal wire to chassis ground. Turn the ignition switch OFF.
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Disconnect the UCM connector X-CN4A (Receptacle) . Disconnect the right joystick connector X-UJMR (Plug) . Measure the resistance between X-UJMR (Plug) pin 2 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. Go to step 4. 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 1 to confirm elimination of fault. 4. Measure the resistance through the signal wire. Fabricate a jumper wire that will connect between connector X-CN4A (Receptacle) pin 24 and chassis ground. Connect the jumper wire between X-CN4A (Receptacle) pin 24 and chassis ground. The chassis ground connection must be clean and free of rust, dirt oil and paint. Measure the resistance between connector X-UJMR (Plug) pin 2 and chassis ground. 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 5. B. The resistance is greater than 10 Ω. There is an open circuit in the signal wire. Repair or replace the harness as required. Return to step 1 to confirm elimination of fault. 5. Measure the voltage to the sensor. Turn the ignition switch OFF. Reconnect the UCM connector(s). Disconnect the right joystick connector X-UJMR (Plug) . Turn the ignition switch ON. Measure the voltage between X-UJMR (Plug) pin 1 and X-UJMR (Plug) pin 4. The voltage should be approximately 5 V. Wiggle the harness during measurement to reveal an intermittent condition.
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(1) (2)
Connector X-UJMR (Plug) Joystick X-Y position sensor
Schematic legend (3) (4)
DVM set to measure voltage. Right joystick R-L X-CN4A (Receptacle) pin 24
A. The voltage is approximately 5 V. Go to step 6. B. The voltage is not within range. There is a problem with the voltage supply to the sensor. Verify the voltage from the UCM. If the voltage from the UCM is correct, there is a problem in the voltage supply to the sensor. Repair as required. Return to step 1 to confirm elimination of fault. 6. Measure the voltage output of the sensor. Turn the ignition switch OFF. Disconnect the right joystick connector X-UJMR (Plug) . Fabricate a breakout harness to measure the voltage output of the sensor.
RAPH12SSL0373GA
(1)
2
Schematic legend Dealer supplied breakout harness. (2)
DVM set to measure voltage.
Turn the ignition switch OFF. Connect the breakout harness between the two mating connectors on X-UJMR (Plug) .
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Turn the ignition switch ON. Measure the voltage between pin 2 and pin 4 on the break out harness. The voltage should be approximately 2.5 V while the joystick in the neutral position. Continue measuring the voltage while slowly moving the throttle in the R-L position. The voltage should change between 0.5 V and 4.5 V. The voltage change should be smooth and steady as the joystick is moved between the stop points. A. The voltage is approximately 2.5 V in the neutral position and the voltage changes between 0.5 V and 4.5 V. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. B. The voltage is not 2.5 V in the neutral position or the voltage change is erratic. Temporarily replace the joystick and retest. Return to step 1 to confirm elimination of fault. Wiring harnesses - Electrical schematic sheet 21 SH21-UNIVERSAL CONTROL MODULE (55.100.DP-C.20.E.21) Wiring harnesses - Electrical schematic sheet 15 SH15-BULKHEAD CONNECTION (55.100.DP-C.20.E.15) Wiring harnesses - Electrical schematic sheet 17 SH17-LEFT NH CONTROL HANDLE (55.100.DP-C.20.E.17)
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5132 - Right Joystick R-L Axis (ISO/H Pattern) - Pin A Short to Power SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Context: The UCM has sensed that the right joystick R-L signal has failed. Diagnostic Trouble Code 5132 – Right Joystick R-L Axis (ISO/H Pattern) - Pin A Short to Power has an error priority of Amber. Implement functions will operate in limp home mode while Diagnostic Trouble Code 5132 – Right Joystick R-L Axis (ISO/H Pattern) - Pin A Short to Power is active. Cause: The UCM has sensed that the right joystick R-L signal has failed. The fault is active when the voltage on X-CN4A (Receptacle) pin 24 is greater than 4.8 V. Normal operating voltage of the sensor output is 0.5 V to 4.5 V. The output of the sensor with the joystick in the neutral position is approximately 2.5 V. Possible failure modes: 1. A short circuit in the signal wire to another voltage source. 2. A failure of the right control handle. 3. The UCM has an internal failure. 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. OK to return the machine to service. B. Fault code 5132 – Right Joystick R-L Axis (ISO/H Pattern) - Pin A Short to Power is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the UCM and the right joystick connections. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the UCM to the right joystick. 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 the connectors as required. Return to step 1 to confirm elimination of fault. 3. Measure the voltage on the signal wire to chassis ground. Turn the ignition switch OFF. Disconnect the UCM connector X-CN4A (Receptacle) . Disconnect the right joystick connector X-UJMR (Plug) . 48068130 29/01/2018
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Turn the ignition switch ON. Measure the voltage between X-UJMR (Plug) pin 2 and chassis ground. The voltage should be less than 0.5 V. Wiggle the harness during measurement to reveal an intermittent condition. A. The voltage is less than 0.5 V. Go to step 4. B. The voltage is greater than 0.5 V. There is a short circuit to another voltage source. Repair or replace the harness as required. Return to step 1 to confirm elimination of fault. 4. Measure the resistance through the signal wire. Turn the ignition switch OFF. Fabricate a jumper wire that will connect between connector X-CN4A (Receptacle) pin 24 and chassis ground. Connect the jumper wire between X-CN4A (Receptacle) pin 24 and chassis ground. The chassis ground connection must be clean and free of rust, dirt, oil, and paint. Measure the resistance between connector X-UJMR (Plug) pin 2 and chassis ground. 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 5. B. The resistance is greater than 10 Ω. There is an open circuit in the signal wire. Repair or replace the harness as required. Return to step 1 to confirm elimination of fault. 5. Measure the voltage to the sensor. Turn the ignition switch OFF. Disconnect the right joystick connector X-UJMR (Plug) . Reconnect the UCM connector(s). Turn the ignition switch ON. Measure the voltage between X-UJMR (Plug) pin 1 and X-UJMR (Plug) pin 4. The voltage should be approximately 5 V. Wiggle the harness during measurement to reveal an intermittent condition.
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(1) (2)
Connector X-UJMR (Plug) Joystick X-Y Position Sensor
Schematic legend (3) (4)
DVM set to measure voltage. Right joystick R-L X-CN4A (Receptacle) pin 24
A. The voltage is approximately 5 V. Go to step 6. B. The voltage is not within range. There is a problem with the voltage supply to the sensor. Verify the voltage from the UCM. If the voltage from the UCM is correct, there is a problem in the voltage supply to the sensor. Repair as required. Return to step 1 to confirm elimination of fault. 6. Measure the voltage output of the sensor. Turn the ignition switch OFF. Disconnect the right joystick connector X-UJMR (Plug) . Fabricate a breakout harness to measure the voltage output of the sensor.
RAPH12SSL0373GA
(1)
2
Schematic legend Dealer supplied breakout harness. (2)
DVM set to measure voltage.
Turn the ignition switch OFF. Connect the breakout harness between the two mating connectors on X-UJMR (Plug) .
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Turn the ignition switch ON. Measure the voltage between X-UJMR (Plug) pin 2 and X-UJMR (Plug) pin 4 on the break out harness. The voltage should be approximately 2.5 V while the joystick is in the neutral position. Continue measuring the voltage while slowly moving the throttle in the R-L position. The voltage should change between 0.5 V and 4.5 V. The voltage change should be smooth and steady as the joystick is moved between the stop points. A. The voltage is approximately 2.5 V in the neutral position and the voltage changes between 0.5 V and 4.5 V. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. B. The voltage is not 2.5 V in the neutral position or the voltage change is erratic. Temporarily replace the joystick and retest. Return to step 1 to confirm elimination of fault. Wiring harnesses - Electrical schematic sheet 21 SH21-UNIVERSAL CONTROL MODULE (55.100.DP-C.20.E.21) Wiring harnesses - Electrical schematic sheet 15 SH15-BULKHEAD CONNECTION (55.100.DP-C.20.E.15) Wiring harnesses - Electrical schematic sheet 17 SH17-LEFT NH CONTROL HANDLE (55.100.DP-C.20.E.17)
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5134 - Right Joystick R-L Axis (ISO/H Pattern) - Pin B Short to Ground/ Open Circuit SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Context: The UCM has sensed that the right joystick R-L signal has failed low. Diagnostic Trouble Code 5134 – Right Joystick R-L Axis (ISO/H Pattern) - Pin B Short to Ground/ Open Circuit has an error priority of Amber. Implement functions will operate in limp home mode while Diagnostic Trouble Code 5134 – Right Joystick R-L Axis (ISO/H Pattern) - Pin B Short to Ground/ Open Circuit is active. Cause: The UCM has sensed that the right joystick R-L signal has failed low. The fault is active while the voltage on X-CN3A (Receptacle) pin 11 is less than 0.2 V. The normal operating voltage of the sensor output is 0.5 V to 4.5 V. The output of the sensor with the joystick in the neutral position is approximately 2.5 V. Possible failure modes: 1. A short circuit in the signal wire. 2. An open circuit in the signal wire. 3. A failure of the right control handle. 4. The UCM has an internal failure. 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. OK to return the machine to service. B. Fault code 5134 – Right Joystick R-L Axis (ISO/H Pattern) - Pin B Short to Ground/ Open Circuit is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the UCM and the right joystick connections. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the UCM to the right joystick. 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 the connectors as required. Return to step 1 to confirm elimination of fault. 3. Measure the resistance of the signal wire to chassis ground. Turn the ignition switch OFF.
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Disconnect the UCM connector X-CN3A (Receptacle) . Disconnect the right joystick connector X-UJMR (Plug) . Measure the resistance between X-UJMR (Plug) pin 8 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. Go to step 4. 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 1 to confirm elimination of fault. 4. Measure the resistance through the signal wire. Fabricate a jumper wire that will connect between connector X-CN3A (Receptacle) pin 11 to chassis ground. The chassis ground connection must be clean and free of rust, dirt, oil, and paint. Connect the jumper wire between connector X-CN3A (Receptacle) pin 11 to chassis ground. The chassis ground connection must be clean and free of rust, dirt, oil and paint. Measure the resistance between connector X-UJMR (Plug) pin 8 and chassis ground. 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 5. B. The resistance is greater than 10 Ω. There is an open circuit in the signal wire. Repair or replace the harness as required. Return to step 1 to confirm elimination of fault. 5. Measure the voltage to the sensor. Turn the ignition switch OFF. Reconnect the UCM connector(s). Disconnect the right joystick connector X-UJMR (Plug) . Turn the ignition switch ON. Measure the voltage between X-UJMR (Plug) pin 7 and X-UJMR (Plug) pin 10. The voltage should be approximately 5 V. Wiggle the harness during measurement to reveal an intermittent condition.
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(1) (2)
Connector X-UJMR (Plug) Joystick X-Y position sensor
Schematic legend (3) (4)
DVM set to measure voltage. Right joystick R-L X-CN3A (Receptacle) pin 11
A. The voltage is approximately 5 V. Go to step 6. B. The voltage is not within range. There is a problem with the voltage supply to the sensor. Verify the voltage from the UCM. If the voltage from the UCM is correct, there is a problem in the voltage supply to the sensor. Repair as required. Return to step 1 to confirm elimination of fault. 6. Measure the voltage output of the sensor. Turn the ignition switch OFF. Disconnect the right joystick connector X-UJMR (Plug) . Fabricate a breakout harness to measure the voltage output of the sensor.
RAPH12SSL0374GA
(1)
2
Schematic legend Dealer supplied breakout harness. (2)
DVM set to measure voltage.
Turn the ignition switch OFF. Connect the breakout harness between the two mating connectors on X-UJMR (Plug) .
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Turn the ignition switch ON. Measure the voltage between pin 8 and pin 10 on the breakout harness. The voltage should be approximately 2.5 V while the joystick in the neutral position. Continue measuring the voltage while slowly moving the throttle in the R-L position. The voltage should change between 0.5 V and 4.5 V. The voltage change should be smooth and steady as the joystick is moved between the stop points. A. The voltage is approximately 2.5 V in the neutral position and the voltage changes between 0.5 V and 4.5 V. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. B. The voltage is not 2.5 V in the neutral position or the voltage change is erratic. Temporarily replace the joystick and retest. Return to step 1 to confirm elimination of fault. Wiring harnesses - Electrical schematic sheet 21 SH21-UNIVERSAL CONTROL MODULE (55.100.DP-C.20.E.21) Wiring harnesses - Electrical schematic sheet 14 SH14-BULKHEAD CONNECTION (55.100.DP-C.20.E.14) Wiring harnesses - Electrical schematic sheet 18 SH18-RIGHT NH CONTROL HANDLE (55.100.DP-C.20.E.18)
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5135 - Right Joystick R-L Axis (ISO/H Pattern) - Pin B Short to Power SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Context: The UCM has sensed that the right joystick R-L signal has failed. Diagnostic Trouble Code 5135 – Right Joystick R-L Axis (ISO/H Pattern) - Pin B Short to Power has an error priority of Amber. Implement functions will operate in limp home mode while Diagnostic Trouble Code 5135 – Right Joystick R-L Axis (ISO/H Pattern) - Pin B Short to Power is active. Cause: The UCM has sensed that the right joystick R-L signal has failed. The fault is active when the voltage on X-CN3A (Receptacle) pin 11 is greater than 4.8 V. The normal operating voltage of the sensor output is 0.5 V to 4.5 V. The output of the sensor with the joystick in the neutral position is approximately 2.5 V. Possible failure modes: 1. A short circuit in the signal wire to another voltage source. 2. A failure of the right control handle. 3. The UCM has an internal failure. 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. OK to return the machine to service. B. Fault code 5135 – Right Joystick R-L Axis (ISO/H Pattern) - Pin B Short to Power is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the UCM and the right joystick connections. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the UCM to the right joystick. 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 the connectors as required. Return to step 1 to confirm elimination of fault. 3. Measure the voltage on the signal wire to chassis ground. Turn the ignition switch OFF. Disconnect the UCM connector X-CN3A (Receptacle) . Disconnect the right joystick connector X-UJMR (Plug) . 48068130 29/01/2018
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Turn the ignition switch ON. Measure the voltage between X-UJMR (Plug) pin 8 and chassis ground. The voltage should be less than 0.5 V. Wiggle the harness during measurement to reveal an intermittent condition. A. The voltage is less than 0.5 V. Go to step 4. B. The voltage is greater than 0.5 V. There is a short circuit to another voltage source. Repair or replace the harness as required. Return to step 1 to confirm elimination of fault. 4. Measure the resistance through the signal wire. Turn the ignition switch OFF. Fabricate a jumper wire that will connect between connector X-CN3A (Receptacle) pin 11 and chassis ground. Connect the jumper wire between connector X-CN3A (Receptacle) pin 11 and chassis ground. The chassis ground connection must be clean and free of rust, dirt oil and paint. Measure the resistance between connector X-UJMR (Plug) pin 8 and chassis ground. 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 5. B. The resistance is greater than 10 Ω. There is an open circuit in the signal wire. Repair or replace the harness as required. Return to step 1 to confirm elimination of fault. 5. Measure the voltage to the sensor. Turn the ignition switch OFF. Reconnect the UCM connector(s). Disconnect the right joystick connector X-UJMR (Plug) . Turn the ignition switch ON. Measure the voltage between X-UJMR (Plug) pin 7 and X-UJMR (Plug) pin 10. The voltage should be approximately 5 V. Wiggle the harness during measurement to reveal an intermittent condition.
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(1) (2)
Connector X-UJMR (Plug) Joystick X-Y position sensor
Schematic legend (3) (4)
DVM set to measure voltage. Right Joystick R-L X-CN3A (Receptacle) pin 11
A. The voltage is approximately 5 V. Go to step 6. B. The voltage is not within range. There is a problem with the voltage supply to the sensor. Verify the voltage from the UCM. If the voltage from the UCM is correct, there is a problem in the voltage supply to the sensor. Repair as required. Return to step 1 to confirm elimination of fault. 6. Measure the voltage output of the sensor. Turn the ignition switch OFF. Disconnect the right joystick connector X-UJMR (Plug) . Fabricate a breakout harness to measure the voltage output of the sensor.
RAPH12SSL0374GA
(1)
2
Schematic legend Dealer supplied breakout harness. (2)
DVM set to measure voltage.
Turn the ignition switch OFF. Connect the breakout harness between the two mating connectors on X-UJMR (Plug) .
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Turn the ignition switch ON. Measure the voltage between pin 8 and pin 10 on the breakout harness. The voltage should be approximately 2.5 V while the joystick is in the neutral position. Continue measuring the voltage while slowly moving the throttle in the R-L position. The voltage should change between 0.5 V and 4.5 V. The voltage change should be smooth and steady as the joystick is moved between the stop points. A. The voltage is approximately 2.5 V in the neutral position and the voltage changes between 0.5 V and 4.5 V. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. B. The voltage is not 2.5 V in the neutral position or the voltage change is erratic. Temporarily replace the joystick and retest. Return to step 1 to confirm elimination of fault. Wiring harnesses - Electrical schematic sheet 21 SH21-UNIVERSAL CONTROL MODULE (55.100.DP-C.20.E.21) Wiring harnesses - Electrical schematic sheet 14 SH14-BULKHEAD CONNECTION (55.100.DP-C.20.E.14) Wiring harnesses - Electrical schematic sheet 18 SH18-RIGHT NH CONTROL HANDLE (55.100.DP-C.20.E.18)
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Electrical systems - FAULT CODES
5137 - Right Joystick R-L Axis (ISO/H Pattern) - In Range Fault SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Context: The UCM has sensed that the right joystick R-L signal has failed. Diagnostic Trouble Code 5137 – Right Joystick R-L Axis (ISO/H Pattern) - In Range Fault has an error priority of Red. The bucket functions are disabled while Diagnostic Trouble Code 5137 – Right Joystick R-L Axis (ISO/H Pattern) - In Range Fault is active. Cause: The UCM has sensed that the right joystick R-L signal has failed. The fault is active while the engine is ON and the voltage on X-CN4A (Receptacle) pin 24 and X-CN3A (Receptacle) pin 11 is less than 0.2 V or greater than 4.8 V. The normal operating voltage of the sensor output is 0.5 V to 4.5 V. The output of the sensor in the neutral position is approximately 2.5 V. Possible failure modes: 1. A short circuit in the signal wire. 2. An open circuit in the signal wire. 3. A failure of the right control handle. 4. The UCM has an internal failure. 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. OK to return the machine to service. B. Fault code 5137 – Right Joystick R-L Axis (ISO/H Pattern) - In Range Fault is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the UCM and the right joystick connections. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the UCM to the right joystick. 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 the connectors as required. Return to step 1 to confirm elimination of fault. 3. Measure the voltage of the signal wire to chassis ground. Turn the ignition switch OFF. Disconnect UCM connectors X-CN4A (Receptacle) and X-CN3A (Receptacle) .
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Electrical systems - FAULT CODES
Disconnect the right joystick connector X-UJMR (Plug) . Turn the ignition switch ON. Measure the voltage between X-UJMR (Plug) pin 2 and chassis ground. The voltage should be less than 0.5 V. Wiggle the harness during measurement to reveal an intermittent condition. Measure the voltage between X-UJMR (Plug) pin 8 and chassis ground. The voltage should be less than 0.5 V. Wiggle the harness during measurement to reveal an intermittent condition. A. The voltage is less than 0.5 V. Go to step 4. B. The voltage is greater than 0.5 V. There is a short circuit to another voltage source. Repair or replace the harness as required. Return to step 1 to confirm elimination of fault. 4. Measure the resistance of the signal wire to chassis ground. Turn the ignition switch OFF. Disconnect UCM connectors X-CN4A (Receptacle) and X-CN3A (Receptacle) . Disconnect the right joystick connector X-UJMR (Plug) . Measure the resistance between X-UJMR (Plug) pin 2 and chassis ground. The resistance should be greater than 20,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition. Measure the resistance between X-UJMR (Plug) pin 8 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. Go to step 5. 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 1 to confirm elimination of fault. 5. Measure the resistance through the signal wire. Fabricate a jumper wire that will connect between connector X-CN4A (Receptacle) pin 24 and chassis ground. Connect the jumper wire between connector X-CN4A (Receptacle) pin 24 and chassis ground. The chassis ground connection must be clean and free of rust, dirt, oil, and paint. Measure the resistance between connector X-UJMR (Plug) pin 2 to chassis ground. The resistance should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition. Connect the jumper wire between connector X-CN3A (Receptacle) pin 11 and chassis ground. The chassis ground connection must be clean and free of rust, dirt, oil, and paint. Measure the resistance between connector X-UJMR (Plug) pin 8 and chassis ground. 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 6. B. The resistance is greater than 10 Ω. There is an open circuit in the signal wire. Repair or replace the harness as required. Return to step 1 to confirm elimination of fault. 6. Measure the voltage to the sensor. Turn the ignition switch OFF. Reconnect the UCM connectors. Disconnect the right joystick connector X-UJMR (Plug) . Turn the ignition switch ON. Measure the voltage between X-UJMR (Plug) pin 1 and X-UJMR (Plug) pin 4. The voltage should be approximately 5 V. Wiggle the harness during measurement to reveal an intermittent condition. 48068130 29/01/2018
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Measure the voltage between X-UJMR (Plug) pin 7 and X-UJMR (Plug) pin 10. The voltage should be approximately 5 V. Wiggle the harness during measurement to reveal an intermittent condition.
RAPH12SSL0355FA
1
Schematic legend (4)
(1)
Connector X-UJMR (Plug)
(2)
Joystick X-Y position sensor
(3)
DVM set to measure voltage.
(5)
Right joystick R-L X-CN4A (Receptacle) pin 24 Right joystick R-L X-CN3A (Receptacle) pin 11
A. The voltage is approximately 5 V. Go to step 7. B. The voltage is not within range. There is a problem with the voltage supply to the sensor. Verify the voltage from the UCM. If the voltage from the UCM is correct, there is a problem in the voltage supply to the sensor. Repair as required. Return to step 1 to confirm elimination of fault. 7. Measure the voltage output of the sensor. Turn the ignition switch OFF. Disconnect the right joystick connector X-UJMR (Plug) . Fabricate a breakout harness to measure the voltage output of the sensor.
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RAPH12SSL0375GA
(1)
2
Schematic legend Dealer supplied breakout harness. (2)
DVM set to measure voltage.
Turn the ignition switch OFF. Connect the breakout harness between the two mating connectors on X-UJMR (Plug) . Turn the ignition switch ON. Measure the voltage between X-UJMR (Plug) pin 2 and X-UJMR (Plug) pin 4 on the break out harness. The voltage should be approximately 2.5 V while the joystick in the neutral position. Continue measuring the voltage while slowly moving the throttle in the R-L position. The voltage should change between 0.5 V and 4.5 V. The voltage change should be smooth and steady as the joystick is moved between the stop points. Measure the voltage between X-UJMR (Plug) pin 8 and X-UJMR (Plug) pin 10 on the break out harness. The voltage should be approximately 2.5 V while the joystick in the neutral position. Continue measuring the voltage while slowly moving the throttle in the R-L position. The voltage should change between 0.5 V and 4.5 V. The voltage change should be smooth and steady as the joystick is moved between the stop points. A. For both measurements, the voltage is approximately 2.5 V in the neutral position and the voltage changes at a smooth rate between 0.5 V and 4.5 V. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. 48068130 29/01/2018
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B. For one or both measurements, the voltage is not 2.5 V in the neutral position or the voltage change is erratic. Temporarily replace the joystick and retest. Return to step 1 to confirm elimination of fault. Wiring harnesses - Electrical schematic sheet 21 SH21-UNIVERSAL CONTROL MODULE (55.100.DP-C.20.E.21) Wiring harnesses - Electrical schematic sheet 15 SH15-BULKHEAD CONNECTION (55.100.DP-C.20.E.15) Wiring harnesses - Electrical schematic sheet 17 SH17-LEFT NH CONTROL HANDLE (55.100.DP-C.20.E.17) Wiring harnesses - Electrical schematic sheet 14 SH14-BULKHEAD CONNECTION (55.100.DP-C.20.E.14) Wiring harnesses - Electrical schematic sheet 18 SH18-RIGHT NH CONTROL HANDLE (55.100.DP-C.20.E.18)
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Electrical systems - FAULT CODES
5141 - Aux Thumbwheel Axis - Pin A Short to Ground/ Open Circuit SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Context: The UCM has sensed that the auxiliary thumbwheel signal has failed. Diagnostic Trouble Code 5141 – Aux Thumbwheel Axis - Pin A Short to Ground/ Open Circuit has an error priority of White. The auxiliary hydraulics are disabled while Diagnostic Trouble Code 5141 – Aux Thumbwheel Axis - Pin A Short to Ground/ Open Circuit is active. Cause: The UCM has sensed that the auxiliary thumbwheel signal has failed. The fault is active when the ignition is ON and the aux thumbwheel axis input voltage, X-CN2B (Receptacle) pin 28 is less than 0.2 V. Possible failure modes: 1. A short circuit in the signal wire. 2. An open circuit in the signal wire. 3. A failure of the right control handle. 4. The UCM has an internal failure. 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. OK to return the machine to service. B. Fault code 5141 – Aux Thumbwheel Axis - Pin A Short to Ground/ Open Circuit is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the UCM and the right joystick connections. All connections should be secure, tight, free of corrosion, abrasion and damage. Inspect the harness from the UCM to the right joystick. 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 the connectors as required. Return to step 1 to confirm elimination of fault. 3. Measure the thumbwheel supply voltage. Turn the ignition switch OFF. Disconnect connector X-403 (Receptacle) from the right joystick. Turn the ignition switch ON. 48068130 29/01/2018
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Measure the voltage between X-403 (Receptacle) pin 1 and X-403 (Receptacle) pin 3. The voltage should be approximately 5 V. Wiggle the harness during measurement to reveal an intermittent condition. A. The voltage is approximately 5 V. Go to step 4. B. The voltage is less than 4 V. There is a problem in the voltage supply or a problem with ground connection to the sensor. Repair or replace the harness as required. Return to step 1 to confirm elimination of the fault. 4. Measure the resistance of the signal wire to chassis ground. Turn the ignition switch OFF. Disconnect UCM connector X-CN2B (Receptacle) . Disconnect connector X-403 (Receptacle) . Measure the resistance between X-CN2B (Receptacle) pin 28 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. Go to step 5. 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 1 to confirm elimination of the fault. 5. Check for an open circuit in the signal wire. Fabricate a jumper that will connect between X-403 (Receptacle) pin 2 and chassis ground. Connect the jumper wire between X-403 (Receptacle) pin 2 and chassis ground. The chassis ground connection must be clean and free of paint, dirt, oil, and grease. Measure the resistance between X-CN2B (Receptacle) pin 28 and chassis ground. 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 6. B. The resistance is greater than 10 Ω. There is an open circuit in the signal wire. Repair or replace the harness as required. Return to step 1 to confirm elimination of the fault. 6. Test the UCM. Disconnect the jumper wire. Reconnect UCM connector X-CN2B (Receptacle) . Remove the wire from X-403 (Receptacle) pin 1. Remove the wire from X-403 (Receptacle) pin 2. Use a jumper wire with alligator clips to connect X-403 (Receptacle) pin 1 to X-403 (Receptacle) pin 2. Reconnect X-403 (Receptacle) on to the joystick. Turn the ignition switch ON. Use EST to access the fault code screen. Fault code 5141 – Aux Thumbwheel Axis - Pin A Short to Ground/ Open Circuit should no longer be active. Fault code 5142 – Aux Thumbwheel Axis - Pin A Short to Power is now active. A. Fault code 5141 – Aux Thumbwheel Axis - Pin A Short to Ground/ Open Circuit is no longer active. Fault code 5142 – Aux Thumbwheel Axis - Pin A Short to Power is now active. Replace the aux thumbwheel and retest. Return to step 1 to confirm elimination of the fault. B. Fault code 5141 – Aux Thumbwheel Axis - Pin A Short to Ground/ Open Circuit is active. Fault code 5142 – Aux Thumbwheel Axis - Pin A Short to Power did not become active. Replace the UCM and retest. Return to step 1 to confirm elimination of the fault.
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Electrical systems - FAULT CODES
Wiring harnesses - Electrical schematic sheet 20 SH20-UNIVERSAL CONTROL MODULE (55.100.DP-C.20.E.20) Wiring harnesses - Electrical schematic sheet 15 SH15-BULKHEAD CONNECTION (55.100.DP-C.20.E.15) Wiring harnesses - Electrical schematic sheet 18 SH18-RIGHT NH CONTROL HANDLE (55.100.DP-C.20.E.18)
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Electrical systems - FAULT CODES
5142 - Aux Thumbwheel Axis - Pin A Short to Power SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Context: The UCM has sensed that the auxiliary thumbwheel signal has failed. Diagnostic Trouble Code 5142 – Aux Thumbwheel Axis - Pin A Short to Power has an error priority of White. The auxiliary hydraulics are disabled while Diagnostic Trouble Code 5142 – Aux Thumbwheel Axis - Pin A Short to Power is active. Cause: The UCM has sensed that the auxiliary thumbwheel signal has failed. The fault is active when the ignition is ON and the aux thumbwheel axis input voltage, X-CN2B (Receptacle) pin 28 is greater than 4.8 V. Possible failure modes: 1. The signal wire had a short circuit to another voltage source. 2. A failure of the right control handle. 3. The UCM has an internal failure. 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. OK to return the machine to service. B. Fault code 5142 – Aux Thumbwheel Axis - Pin A Short to Power is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the UCM and the right joystick connections. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the UCM to the right joystick. 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 the connectors as required. Return to step 1 to confirm elimination of fault. 3. Measure the voltage of the signal wire to chassis ground. Turn the ignition switch OFF. Disconnect UCM connector X-CN2B (Receptacle) . Disconnect connector X-403 (Receptacle) . Turn the ignition switch ON.
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Measure the voltage between X-CN2B (Receptacle) pin 28 and chassis ground. The voltage should be less than 0.5 V. Wiggle the harness during measurement to reveal an intermittent condition. A. The voltage is less than 0.5 V. Go to step 4. B. The voltage is greater than 0.5 V. There is a short circuit to another voltage source. Repair or replace the harness as required. Return to step 1 to confirm elimination of the fault. 4. Test the UCM. Reconnect UCM connector X-CN2B (Receptacle) . Remove the wire from X-403 (Receptacle) pin 2. Remove the wire from X-403 (Receptacle) pin 3. Use a jumper wire with alligator clips to connect X-403 (Receptacle) pin 2 to X-403 (Receptacle) pin 3. Reconnect joystick connector X-403 (Receptacle) . Turn the ignition switch ON. Use EST to access the fault code screen. Fault code 5142 – Aux Thumbwheel Axis - Pin A Short to Power should no longer be active. Fault code 5141 – Aux Thumbwheel Axis - Pin A Short to Ground/ Open Circuit is now active. A. Fault code 5142 – Aux Thumbwheel Axis - Pin A Short to Power is no longer active. Fault code 5141 – Aux Thumbwheel Axis - Pin A Short to Ground/ Open Circuit is now active. Replace the aux thumbwheel and retest. Return to step 1 to confirm elimination of the fault. B. Fault code 5142 – Aux Thumbwheel Axis - Pin A Short to Power is active. Fault code 5141 – Aux Thumbwheel Axis - Pin A Short to Ground/ Open Circuit did not become active. Replace the UCM and retest. Return to step 1 to confirm elimination of the fault. Wiring harnesses - Electrical schematic sheet 20 SH20-UNIVERSAL CONTROL MODULE (55.100.DP-C.20.E.20) Wiring harnesses - Electrical schematic sheet 15 SH15-BULKHEAD CONNECTION (55.100.DP-C.20.E.15) Wiring harnesses - Electrical schematic sheet 18 SH18-RIGHT NH CONTROL HANDLE (55.100.DP-C.20.E.18)
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Electrical systems - FAULT CODES
5144 - Aux Thumbwheel Axis - Pin B Short to Ground/ Open Circuit SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Context: The UCM has sensed that the auxiliary thumbwheel signal has failed. Diagnostic Trouble Code 5144 – Aux Thumbwheel Axis - Pin B Short to Ground/ Open Circuit has an error priority of White. The auxiliary hydraulics are disabled while Diagnostic Trouble Code 5144 – Aux Thumbwheel Axis - Pin B Short to Ground/ Open Circuit is active. Cause: The UCM has sensed that the auxiliary thumbwheel signal has failed. The fault is active when the ignition is ON and the aux thumbwheel axis input voltage, X-CN4B (Receptacle) pin 21 is less than 0.2 V. Possible failure modes: 1. A short circuit in the signal wire. 2. An open circuit in the signal wire. 3. A failure of the right control handle. 4. The UCM has an internal failure. 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. OK to return the machine to service. B. Fault code 5144 – Aux Thumbwheel Axis - Pin B Short to Ground/ Open Circuit is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the UCM and the right joystick connections. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the UCM to the right joystick. 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. 3. Measure the thumbwheel supply voltage. Turn the ignition switch OFF. Disconnect connector X-403 (Receptacle) from the right joystick. Turn the ignition switch ON. 48068130 29/01/2018
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Measure the voltage between X-403 (Receptacle) pin 10 and X-403 (Receptacle) pin 12. The voltage should be approximately 5 V. Wiggle the harness during measurement to reveal an intermittent condition. A. The voltage is approximately 5 V. Go to step 4. B. The voltage is less than 4 V. There is a problem in the voltage supply or ground to the sensor. Repair or replace the harness as required. Return to step 1 to confirm elimination of the fault. 4. Measure the resistance of the signal wire to chassis ground. Turn the ignition switch OFF. Disconnect UCM connector X-CN4B (Receptacle) . Disconnect connector X-403 (Receptacle) . Measure the resistance between X-CN4B (Receptacle) pin 21 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. Go to step 5. 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 1 to confirm elimination of the fault. 5. Check for an open circuit in the signal wire. Fabricate a jumper that will connect between X-403 (Receptacle) pin 11 and chassis ground. Connect the jumper wire between X-403 (Receptacle) pin 11 and chassis ground. The chassis ground connection must be clean and free of paint, dirt, oil, and grease. Measure the resistance between X-CN4B (Receptacle) pin 21 and chassis ground. 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 6. B. The resistance is greater than 10 Ω. There is an open circuit in the signal wire. Repair or replace the harness as required. Return to step 1 to confirm elimination of the fault. 6. Test the UCM. Disconnect the jumper wire. Reconnect UCM connector X-CN4B (Receptacle) . Remove the wire from X-403 (Receptacle) pin 10. Remove the wire from X-403 (Receptacle) pin 11. Use a jumper wire with alligator clips to connect X-403 (Receptacle) pin 10 to X-403 (Receptacle) pin 11. Reconnect X-403 (Receptacle) to the joystick. Turn the ignition switch ON. Use EST to access the fault code screen. Fault code 5144 – Aux Thumbwheel Axis - Pin B Short to Ground/ Open Circuit should no longer be active. Fault code 5145 – Aux Thumbwheel Axis - Pin B Short to Power is now active. A. Fault code 5144 – Aux Thumbwheel Axis - Pin B Short to Ground/ Open Circuit is no longer active. Fault code 5145 – Aux Thumbwheel Axis - Pin B Short to Power is now active. Replace the aux thumbwheel and retest. Return to step 1 to confirm elimination of the fault. B. Fault code 5144 – Aux Thumbwheel Axis - Pin B Short to Ground/ Open Circuit is active. Fault code 5145 – Aux Thumbwheel Axis - Pin B Short to Power did not become active. Replace the UCM and retest. Return to step 1 to confirm elimination of the fault.
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Electrical systems - FAULT CODES
Wiring harnesses - Electrical schematic sheet 21 SH21-UNIVERSAL CONTROL MODULE (55.100.DP-C.20.E.21) Wiring harnesses - Electrical schematic sheet 15 SH15-BULKHEAD CONNECTION (55.100.DP-C.20.E.15) Wiring harnesses - Electrical schematic sheet 18 SH18-RIGHT NH CONTROL HANDLE (55.100.DP-C.20.E.18)
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Electrical systems - FAULT CODES
5145 - Aux Thumbwheel Axis - Pin B Short to Power SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Context: The UCM has sensed that the auxiliary thumbwheel signal has failed. Diagnostic Trouble Code 5145 – Aux Thumbwheel Axis - Pin B Short to Power has an error priority of White. The auxiliary hydraulics are disabled while Diagnostic Trouble Code 5145 – Aux Thumbwheel Axis - Pin B Short to Power is active. Cause: The UCM has sensed that the auxiliary thumbwheel signal has failed. The fault is active when the ignition is ON and the aux thumbwheel axis input voltage, X-CN4B (Receptacle) pin 21 is greater than 4.8 V. Possible failure modes: 1. The signal wire had a short circuit to another voltage source. 2. A failure of the right control handle. 3. The UCM has an internal failure. 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. OK to return the machine to service. B. Fault code 5145 – Aux Thumbwheel Axis - Pin B Short to Power is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the UCM and the right joystick connections. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the UCM to the right joystick. 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 the connectors as required. Return to step 1 to confirm elimination of fault. 3. Measure the voltage of the signal wire to chassis ground. Turn the ignition switch OFF. Disconnect UCM connector X-CN4B (Receptacle) . Disconnect connector X-403 (Receptacle) . Turn the ignition switch ON.
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Measure the voltage between X-CN4B (Receptacle) pin 21 and chassis ground. The voltage should be less than 0.5 V. Wiggle the harness during measurement to reveal an intermittent condition. A. The voltage is less than 0.5 V. Go to step 4. B. The voltage is greater than 0.5 V. There is a short circuit to another voltage source. Repair or replace the harness as required. Return to step 1 to confirm elimination of the fault. 4. Test the UCM. Reconnect UCM connector X-CN4B (Receptacle) . Remove the wire from X-403 (Receptacle) pin 11. Remove the wire from X-403 (Receptacle) pin 12. Use a jumper wire with alligator clips to connect X-403 (Receptacle) pin 11 to X-403 (Receptacle) pin 12. Reconnect joystick connector X-403 (Receptacle) . Turn the ignition switch ON. Use EST to access the fault code screen. Fault code 5145 – Aux Thumbwheel Axis - Pin B Short to Power should no longer be active. Fault code 5144 – Aux Thumbwheel Axis - Pin B Short to Ground/ Open Circuit is now active. A. Fault code 5145 – Aux Thumbwheel Axis - Pin B Short to Power is no longer active. Fault code 5144 – Aux Thumbwheel Axis - Pin B Short to Ground/ Open Circuit is now active. Replace the aux thumbwheel and retest. Return to step 1 to confirm elimination of the fault. B. Fault code 5145 – Aux Thumbwheel Axis - Pin B Short to Power is active. Fault code 5144 – Aux Thumbwheel Axis - Pin B Short to Ground/ Open Circuit did not become active. Replace the UCM and retest. Return to step 1 to confirm elimination of the fault. Wiring harnesses - Electrical schematic sheet 21 SH21-UNIVERSAL CONTROL MODULE (55.100.DP-C.20.E.21) Wiring harnesses - Electrical schematic sheet 15 SH15-BULKHEAD CONNECTION (55.100.DP-C.20.E.15) Wiring harnesses - Electrical schematic sheet 18 SH18-RIGHT NH CONTROL HANDLE (55.100.DP-C.20.E.18)
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Electrical systems - FAULT CODES
5147 - Aux Thumbwheel Axis - In Range Fault SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Context: The UCM has sensed that the aux thumbwheel has failed. Diagnostic Trouble Code 5147 – Aux Thumbwheel Axis - In Range Fault has an error priority of White. The auxiliary hydraulics are disabled while Diagnostic Trouble Code 5147 – Aux Thumbwheel Axis - In Range Fault is active. Cause: The UCM has sensed that the aux thumbwheel has failed. The fault is active while the engine is ON and the sum of aux thumbwheel output voltages, X-CN2B (Receptacle) pin 28 and X-CN4B (Receptacle) pin 21 is greater than 5.2 V or less than 4.8 V. Possible failure modes: 1. A short circuit in the signal wire. 2. An open circuit in the signal wire. 3. A failure of the right control handle. 4. The UCM has an internal failure. 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. OK to return the machine to service. B. Fault code 5147 – Aux Thumbwheel Axis - In Range Fault is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the UCM and the right joystick connections. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the UCM to the right joystick. Verify that the harness is free of damage, corrosion, abrasion, and incorrect attachment. Inspect the cab to chassis interface harness. Inspect the chassis ground and minus battery connections. Verify that the connections are 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 the connectors as required. Return to step 1 to confirm elimination of fault. 3. Measure the thumbwheel supply voltage. Turn the ignition switch OFF.
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Electrical systems - FAULT CODES
Disconnect connector X-403 (Receptacle) from the right joystick. Turn the ignition switch ON. Measure the voltage between X-403 (Receptacle) pin 1 and X-403 (Receptacle) pin 3. The voltage should be approximately 5 V. Wiggle the harness during measurement to reveal an intermittent condition. Measure the voltage between X-403 (Receptacle) pin 10 and X-403 (Receptacle) pin 12. The voltage should be approximately 5 V. Wiggle the harness during measurement to reveal an intermittent condition. A. The voltage is approximately 5 V. Go to step 4. B. The voltage is less than 4 V. There is a problem in the voltage supply or ground to the sensor. Repair or replace the harness as required. Return to step 1 to confirm elimination of the fault. 4. Measure the voltage on the signal wire. Turn the ignition switch OFF. Disconnect UCM connector X-CN2B (Receptacle) . Disconnect UCM connector X-CN4B (Receptacle) . Disconnect connector X-403 (Receptacle) . Turn the ignition switch ON. Measure the voltage between X-CN2B (Receptacle) pin 28 and chassis ground. The voltage should be less than 0.5 V. Wiggle the harness during measurement to reveal an intermittent condition. Measure the voltage between X-CN4B (Receptacle) pin 21 and chassis ground. The voltage should be less than 0.5 V. Wiggle the harness during measurement to reveal an intermittent condition. A. Both voltage measurements are less than 0.5 V. Go to step 5. B. One or both measurements are greater than 0.5 V. There is a short circuit to another voltage source. Repair or replace the harness as required. Return to step 1 to confirm elimination of the fault. 5. Check for an open circuit in the signal wire. Turn the ignition switch OFF. Leave UCM connectors X-CN2B (Receptacle) and X-CN4B (Receptacle) disconnected. Fabricate a jumper that will connect between X-403 (Receptacle) pin 2 and X-403 (Receptacle) pin 11. Connect the jumper wire between X-403 (Receptacle) pin 2 and X-403 (Receptacle) pin 11. Measure the resistance between X-CN2B (Receptacle) pin 28 and X-CN4B (Receptacle) pin 21. 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 6. B. The resistance is greater than 10 Ω. There is an open circuit in the signal wires. Repair or replace the harness as required. Return to step 1 to confirm elimination of the fault. 6. Measure the resistance of the signal wire to chassis ground. Turn the ignition switch OFF. Disconnect UCM connector X-CN2B (Receptacle) . Disconnect UCM connector X-CN4B (Receptacle) . Disconnect connector X-403 (Receptacle) .
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Electrical systems - FAULT CODES
Measure the resistance between X-CN2B (Receptacle) pin 28 and chassis ground. The resistance should be less than 10 立. Wiggle the harness during measurement to reveal an intermittent condition. Measure the resistance between X-CN4B (Receptacle) pin 21 and chassis ground. The resistance should be less than 10 立. Wiggle the harness during measurement to reveal an intermittent condition. A. Both resistance measurements are less than 10 立. Temporarily replace the thumb wheel switch and retest. Return to step 1 to confirm elimination of the fault. B. One or both measurements are greater than 10 立. There is a short circuit to chassis ground. Repair or replace the harness as required. Return to step 1 to confirm elimination of the fault. Wiring harnesses - Electrical schematic sheet 20 SH20-UNIVERSAL CONTROL MODULE (55.100.DP-C.20.E.20) Wiring harnesses - Electrical schematic sheet 15 SH15-BULKHEAD CONNECTION (55.100.DP-C.20.E.15) Wiring harnesses - Electrical schematic sheet 18 SH18-RIGHT NH CONTROL HANDLE (55.100.DP-C.20.E.18) Wiring harnesses - Electrical schematic sheet 21 SH21-UNIVERSAL CONTROL MODULE (55.100.DP-C.20.E.21)
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Electrical systems - FAULT CODES
5201 - Left Joystick L-R Axis - Pin A Short to Power/ Short to Ground/ Open Circuit SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Context: The UCM has sensed that the left joystick L-R signal has failed. Diagnostic Trouble Code 5201 – Left Joystick L-R Axis - Pin A Short to Power/ Short to Ground/ Open Circuit has an error priority of Amber. Implement functions will operate in limp home mode while Diagnostic Trouble Code 5201 – Left Joystick L-R Axis Pin A Short to Power/ Short to Ground/ Open Circuit is active. Cause: The UCM has sensed that the left joystick L-R signal has failed. The fault is active while the voltage on X-CN4A (Receptacle) pin 25 is less than 0.2 V or the voltage is greater than 4.8 V. The normal operating voltage of the sensor output is 0.5 V to 4.5 V. The output of the sensor in the neutral position is approximately 2.5 V. Possible failure modes: 1. A short circuit in the signal wire. 2. An open circuit in the signal wire. 3. A failure of the left control handle. 4. The UCM has an internal failure. Solution: 1. Verify that the fault code is active. Connect the Electronic Service Tool to the service tool connector. To check for fault code: Start and operate the machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 5201 – Left Joystick L-R Axis - Pin A Short to Power/ Short to Ground/ Open Circuit is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the UCM and the left joystick connections. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the UCM to the left joystick. 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 the connectors as required. Return to step 1 to confirm elimination of fault. 3. Measure the voltage of the signal wire to chassis ground. Turn the ignition switch OFF.
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Electrical systems - FAULT CODES
Disconnect the UCM connector X-CN4A (Receptacle) . Disconnect the left joystick connector X-UJML (Plug) . Turn the ignition switch ON. Measure the voltage between X-UJML (Plug) pin 2 and chassis ground. The voltage should be less than 0.5 V. Wiggle the harness during measurement to reveal an intermittent condition. A. The voltage is less than 0.5 V. Go to step 4. B. The voltage is greater than 0.5 V. There is a short circuit to another voltage source. Repair or replace the harness as required. Return to step 1 to confirm elimination of fault. 4. Measure the resistance of the signal wire to chassis ground. Turn the ignition switch OFF. Disconnect the UCM connector X-CN4A (Receptacle) . Disconnect the left joystick connector X-UJML (Plug) . Measure the resistance between X-UJML (Plug) pin 2 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. Go to step 5. 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 1 to confirm elimination of fault. 5. Measure the resistance through the signal wire. Fabricate a jumper wire that will connect between connector X-CN4A (Receptacle) pin 25 and chassis ground. Connect the jumper wire between connector X-CN4A (Receptacle) pin 25 and chassis ground. The chassis ground connection must be clean and free of rust, dirt, oil, and paint. Measure the resistance between connector X-UJML (Plug) pin 2 and chassis ground. 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 6. B. The resistance is greater than 10 Ω. There is an open circuit in the signal wire. Repair or replace the harness as required. Return to step 1 to confirm elimination of fault. 6. Measure the voltage to the sensor. Turn the ignition switch OFF. Reconnect the UCM connector. Disconnect the left joystick connector X-UJML (Plug) . Turn the ignition switch ON. Measure the voltage between X-UJML (Plug) pin 1 and X-UJML (Plug) pin 4. The voltage should be approximately 5 V. Wiggle the harness during measurement to reveal an intermittent condition.
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Electrical systems - FAULT CODES
RAPH12SSL0339FA
(1) (2)
Connector X-UJML (Plug) Joystick X-Y position sensor
1
Schematic legend (3) (4)
DVM set to measure voltage. Left Joystick L-R X-CN4A (Receptacle) pin 25
A. The voltage is approximately 5 V. Go to step 7. B. The voltage is not within range. There is a problem with the voltage supply to the sensor. Verify the voltage from the UCM. If the voltage from the UCM is correct, there is a problem in the voltage supply to the sensor. Repair as required. Return to step 1 to confirm elimination of fault. 7. Measure the voltage output of the sensor. Turn the ignition switch OFF. Disconnect the left joystick connector X-UJML (Plug) . Fabricate a breakout harness to measure the voltage output of the sensor.
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Electrical systems - FAULT CODES
RAPH12SSL0363GA
(1)
2
Schematic legend Dealer supplied breakout harness. (2)
DVM set to measure voltage.
Turn the ignition switch OFF. Connect the breakout harness between the two mating connectors on X-UJML (Plug) . Turn the ignition switch ON. Measure the voltage between X-UJML (Plug) pin 2 and X-UJML (Plug) pin 4 on the breakout harness. The voltage should be approximately 2.5 V while the joystick in the neutral position. Continue measuring the voltage while slowly moving the throttle in the L-R position. The voltage should change between 0.5 V and 4.5 V. The voltage change should be smooth and steady as the joystick is moved between the stop points. A. The voltage is approximately 2.5 V in the neutral position and the voltage changes at a smooth rate between 0.5 V and 4.5 V. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. B. The voltage is not 2.5 V in the neutral position or the voltage change is erratic. Temporarily replace the joystick and retest. Return to step 1 to confirm elimination of fault. Wiring harnesses - Electrical schematic sheet 21 SH21-UNIVERSAL CONTROL MODULE (55.100.DP-C.20.E.21) Wiring harnesses - Electrical schematic sheet 15 SH15-BULKHEAD CONNECTION (55.100.DP-C.20.E.15) Wiring harnesses - Electrical schematic sheet 17 SH17-LEFT NH CONTROL HANDLE (55.100.DP-C.20.E.17)
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Electrical systems - FAULT CODES
5202 - Left Joystick L-R Axis - Pin B Short to Power/ Short to Ground/ Open Circuit SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Context: The UCM has sensed that the left joystick L-R signal has failed. Diagnostic Trouble Code 5202 – Left Joystick L-R Axis - Pin B Short to Power/ Short to Ground/ Open Circuit has an error priority of Amber. Implement functions will operate in limp home mode while Diagnostic Trouble Code 5202 – Left Joystick L-R Axis Pin B Short to Power/ Short to Ground/ Open Circuit is active. Cause: The UCM has sensed that the left joystick L-R signal has failed. The fault is active while the voltage on X-CN2B (Receptacle) pin 14 is less than 0.2 V or the voltage is greater than 4.8 V. The normal operating voltage of the sensor output is 0.5 V to 4.5 V. The output of the sensor in the neutral position is approximately 2.5 V. Possible failure modes: 1. A short circuit in the signal wire. 2. An open circuit in the signal wire. 3. A failure of the left control handle. 4. The UCM has an internal failure. 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. OK to return the machine to service. B. Fault code 5202 – Left Joystick L-R Axis - Pin B Short to Power/ Short to Ground/ Open Circuit is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the UCM and the left joystick connections. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the UCM to the left joystick. 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 the connectors as required. Return to step 1 to confirm elimination of fault. 3. Measure the voltage of the signal wire to chassis ground. Turn the ignition switch OFF.
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Electrical systems - FAULT CODES
Disconnect the UCM connector X-CN2B (Receptacle) . Disconnect the left joystick connector X-UJML (Plug) . Turn the ignition switch ON. Measure the voltage between X-UJML (Plug) pin 8 and chassis ground. The voltage should be less than 0.5 V. Wiggle the harness during measurement to reveal an intermittent condition. A. The voltage is less than 0.5 V. Go to step 4. B. The voltage is greater than 0.5 V. There is a short circuit to another voltage source. Repair or replace the harness as required. Return to step 1 to confirm elimination of fault. 4. Measure the resistance of the signal wire to chassis ground. Turn the ignition switch OFF. Disconnect the UCM connector X-CN2B (Receptacle) . Disconnect the left joystick connector X-UJML (Plug) . Measure the resistance between X-UJML (Plug) pin 8 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. Go to step 5. 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 1 to confirm elimination of fault. 5. Measure the resistance through the signal wire. Fabricate a jumper wire that will connect between connector X-CN2B (Receptacle) pin 14 and chassis ground. Connect the jumper wire between connector X-CN2B (Receptacle) pin 14 and chassis ground. The chassis ground connection must be clean and free of rust, dirt, oil, and paint. Measure the resistance between connector X-UJML (Plug) pin 8 and chassis ground. 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 6. B. The resistance is greater than 10 Ω. There is an open circuit in the signal wire. Repair or replace the harness as required. Return to step 1 to confirm elimination of fault. 6. Measure the voltage to the sensor. Turn the ignition switch OFF. Reconnect the UCM connector. Disconnect the left joystick connector X-UJML (Plug) . Turn the ignition switch ON. Measure the voltage between X-UJML (Plug) pin 7 and X-UJML (Plug) pin 10. The voltage should be approximately 5 V. Wiggle the harness during measurement to reveal an intermittent condition.
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Electrical systems - FAULT CODES
RAPH12SSL0346FA
(1) (2)
Connector X-UJML (Plug) Joystick X-Y position sensor
1
Schematic legend (3) (4)
DVM set to measure voltage. Left Joystick L-R X-CN2B (Receptacle) pin 14
A. The voltage is approximately 5 V. Go to step 7. B. The voltage is not within range. There is a problem with the voltage supply to the sensor. Verify the voltage from the UCM. If the voltage from the UCM is correct, there is an open circuit in the voltage supply to the sensor. Repair as required. Return to step 1 to confirm elimination of fault. 7. Measure the voltage output of the sensor. Turn the ignition switch OFF. Disconnect the left joystick connector X-UJML (Plug) . Fabricate a breakout harness to measure the voltage output of the sensor.
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Electrical systems - FAULT CODES
RAPH12SSL0370GA
(1)
2
Schematic legend Dealer supplied breakout harness. (2)
DVM set to measure voltage.
Turn the ignition switch OFF. Connect the breakout harness between the two mating connectors on X-UJML (Plug) . Turn the ignition switch ON. Measure the voltage between X-UJML (Plug) pin 8 and X-UJML (Plug) pin 10 on the breakout harness. The voltage should be approximately 2.5 V while the joystick in the neutral position. Continue measuring the voltage while slowly moving the throttle in the L-R position. The voltage should change between 0.5 V and 4.5 V. The voltage change should be smooth and steady as the joystick is moved between the stop points. A. The voltage is approximately 2.5 V in the neutral position and the voltage changes between 0.5 V and 4.5 V. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. B. The voltage is not 2.5 V in the neutral position or the voltage change is erratic. Temporarily replace the joystick and retest. Return to step 1 to confirm elimination of fault. Wiring harnesses - Electrical schematic sheet 20 SH20-UNIVERSAL CONTROL MODULE (55.100.DP-C.20.E.20) Wiring harnesses - Electrical schematic sheet 15 SH15-BULKHEAD CONNECTION (55.100.DP-C.20.E.15) Wiring harnesses - Electrical schematic sheet 17 SH17-LEFT NH CONTROL HANDLE (55.100.DP-C.20.E.17)
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Electrical systems - FAULT CODES
5204 - Left Joystick L-R Axis - In Range Fault SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Context: The UCM has sensed that the left joystick L-R signal has failed. Diagnostic Trouble Code 5204 – Left Joystick L-R Axis - In Range Fault has an error priority of Red. Boom functions are disabled while Diagnostic Trouble Code 5204 – Left Joystick L-R Axis - In Range Fault is active. Cause: The UCM has sensed that the left joystick L-R signal has failed. The fault is active while the voltage on X-CN4A (Receptacle) pin 25 and X-CN2B (Receptacle) pin 14 is less than 0.2 V or greater than 4.8 V. The normal operating voltage of the sensor output is 0.5 V to 4.5 V. The output of the sensor in the neutral position is approximately 2.5 V. Possible failure modes: 1. An open circuit in the signal wire. 2. A short circuit in the signal wire. 3. Failure of the left control handle. 4. The UCM has an internal failure. 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. OK to return the machine to service. B. Fault code 5204 – Left Joystick L-R Axis - In Range Fault is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the UCM and the left joystick connections. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the UCM to the left joystick. 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 the connectors as required. Return to step 1 to confirm elimination of fault. 3. Measure the voltage of the signal wire to chassis ground. Turn the ignition switch OFF. Disconnect the UCM connectors X-CN4A (Receptacle) and X-CN2B (Receptacle) . Disconnect the left joystick connector X-UJML (Plug) . 48068130 29/01/2018
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Electrical systems - FAULT CODES
Turn the ignition switch ON. Measure the voltage between X-UJML (Plug) pin 2 and chassis ground. The voltage should be less than 0.5 V. Wiggle the harness during measurement to reveal an intermittent condition. Measure the voltage between X-UJML (Plug) pin 8 and chassis ground. The voltage should be less than 0.5 V. Wiggle the harness during measurement to reveal an intermittent condition. A. The voltage is less than 0.5 V. Go to step 4. B. The voltage is greater than 0.5 V. There is a short circuit to another voltage source. Repair or replace the harness as required. Return to step 1 to confirm elimination of fault. 4. Measure the resistance of the signal wire to chassis ground. Turn the ignition switch OFF. Disconnect the UCM connector X-CN4A (Receptacle) and X-CN2B (Receptacle) . Disconnect the left joystick connector X-UJML (Plug) . Measure the resistance of X-UJML (Plug) pin 2 to chassis ground. The resistance should be greater than 20,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition. Measure the resistance of X-UJML (Plug) pin 8 to 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. Go to step 5. 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 1 to confirm elimination of fault. 5. Measure the resistance of the signal wire. Fabricate a jumper wire that will connect between connector X-CN4A (Receptacle) pin 25 and chassis ground. Connect the jumper wire between connector X-CN4A (Receptacle) pin 25 and chassis ground. The chassis ground connection must be clean and free of rust, dirt, oil and paint. Measure the resistance between connector X-UJML (Plug) pin 2 to chassis ground. The resistance should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition. Connect the jumper wire between connector X-CN2B (Receptacle) pin 14 and chassis ground. The chassis ground connection must be clean and free of rust, dirt, oil and paint. Measure the resistance between connector X-UJML (Plug) pin 8 to chassis ground. 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 6. B. The resistance is greater than 10 Ω. There is an open circuit in the signal wire. Repair or replace the harness as required. Return to step 1 to confirm elimination of fault. 6. Measure the voltage to the sensor. Turn the ignition switch OFF. Reconnect the UCM connectors. Disconnect the left joystick connector X-UJML (Plug) . Turn the ignition switch ON. Measure the voltage between X-UJML (Plug) pin 1 and X-UJML (Plug) pin 4. The voltage should be approximately 5 V. Wiggle the harness during measurement to reveal an intermittent condition.
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Electrical systems - FAULT CODES
Measure the voltage between X-UJML (Plug) pin 7 and X-UJML (Plug) pin 10. The voltage should be approximately 5 V. Wiggle the harness during measurement to reveal an intermittent condition.
RAPH12SSL0348FA
1
Schematic legend (4)
(1)
Connector X-UJML (Plug)
(2)
Joystick X-Y position sensor
(3)
DVM set to measure voltage.
(5)
Left Joystick L-R X-CN4A (Receptacle) pin 25 Left Joystick L-R X-CN2B (Receptacle) pin 14
A. The voltage is approximately 5 V. Go to step 7. B. The voltage is not within range. There is a problem with the voltage supply to the sensor. Verify the voltage from the UCM. If the voltage from the UCM is correct, there is a problem in the voltage supply to the sensor. Repair as required. Return to step 1 to confirm elimination of fault. 7. Measure the voltage output of the sensor. Turn the ignition switch OFF. Disconnect the left joystick connector X-UJML (Plug) . Fabricate a breakout harness to measure the voltage output of the sensor.
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Electrical systems - FAULT CODES
RAPH12SSL0371GA
(1)
2
Schematic legend Dealer supplied breakout harness. (2)
DVM set to measure voltage.
Turn the ignition switch OFF. Connect the breakout harness between the two mating connectors on X-UJML (Plug) . Turn the ignition switch ON. Measure the voltage between X-UJML (Plug) pin 2 and X-UJML (Plug) pin 4 on the break out harness. The voltage should be approximately 2.5 V while the joystick in the neutral position. Continue measuring the voltage while slowly moving the throttle in the L-R position. The voltage should change between 0.5 V and 4.5 V. The voltage change should be smooth and steady as the joystick is moved between the stop points. Measure the voltage between X-UJML (Plug) pin 8 and X-UJML (Plug) pin 10 on the breakout harness. The voltage should be approximately 2.5 V while the joystick in the neutral position. Continue measuring the voltage while slowly moving the throttle in the L-R position. The voltage should change between 0.5 V and 4.5 V. The voltage change should be smooth and steady as the joystick is moved between the stop points. A. For both measurements, the voltage is approximately 2.5 V in the neutral position and the voltage changes at a smooth rate between 0.5 V and 4.5 V. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. 48068130 29/01/2018
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Electrical systems - FAULT CODES
B. On one or both measurements, the voltage is not 2.5 V in the neutral position or the voltage change is erratic. Temporarily replace the joystick and retest. Return to step 1 to confirm elimination of fault. Wiring harnesses - Electrical schematic sheet 21 SH21-UNIVERSAL CONTROL MODULE (55.100.DP-C.20.E.21) Wiring harnesses - Electrical schematic sheet 15 SH15-BULKHEAD CONNECTION (55.100.DP-C.20.E.15) Wiring harnesses - Electrical schematic sheet 17 SH17-LEFT NH CONTROL HANDLE (55.100.DP-C.20.E.17) Wiring harnesses - Electrical schematic sheet 20 SH20-UNIVERSAL CONTROL MODULE (55.100.DP-C.20.E.20)
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Electrical systems - FAULT CODES
5211 - Left Joystick F-B Axis - Pin A Short to Ground/ Open Circuit SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Context: The UCM has sensed that the left joystick F-B 5 V signal has failed. Diagnostic Trouble Code 5211 – Left Joystick F-B Axis - Pin A Short to Ground/ Open Circuit has an error priority of Amber. Ground drive will operate in limp home mode while Diagnostic Trouble Code 5211 – Left Joystick F-B Axis - Pin A Short to Ground/ Open Circuit is active. Cause: The UCM has sensed that the left joystick F-B 5 V signal has failed low. The fault is active while the engine is ON and the voltage on X-CN4A (Receptacle) pin 18 is less than 0.2 V. The normal operating voltage of the sensor output is 0.5 V to 4.5 V. The output of the sensor with the joystick in the neutral position is approximately 2.5 V. Possible failure modes: 1. A short circuit in the signal wire. 2. An open circuit in the signal wire. 3. A failure of the left control handle. 4. The UCM has an internal failure. 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. OK to return the machine to service. B. Fault code 5211 – Left Joystick F-B Axis - Pin A Short to Ground/ Open Circuit is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the UCM and the left joystick connections. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the UCM to the left joystick. 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 the connectors as required. Return to step 1 to confirm elimination of fault. 3. Measure the resistance of the signal wire to chassis ground. Turn the ignition switch OFF. Disconnect the UCM connector X-CN4A (Receptacle) . 48068130 29/01/2018
55.21 [55.DTC] / 698
Electrical systems - FAULT CODES
Disconnect the left joystick connector X-UJML (Plug) . Measure the resistance between X-UJML (Plug) pin 3 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. Go to step 4. 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 1 to confirm elimination of fault. 4. Measure the resistance through the signal wire. Fabricate a jumper wire that will connect between connector X-CN4A (Receptacle) pin 18 and chassis ground. Connect the jumper wire between connector X-CN4A (Receptacle) pin 18 and chassis ground. The chassis ground connection must be clean and free of rust, dirt oil and paint. Measure the resistance between connector X-UJML (Plug) pin 3 and chassis ground. 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 5. B. The resistance is greater than 10 Ω. There is an open circuit in the signal wire. Repair or replace the harness as required. Return to step 1 to confirm elimination of fault. 5. Measure the voltage to the sensor. Turn the ignition switch OFF. Reconnect the UCM connectors. Disconnect the left joystick connector X-UJML (Plug) . Turn the ignition switch ON. Measure the voltage between X-UJML (Plug) pin 1 and X-UJML (Plug) pin 4. The voltage should be approximately 5 V. Wiggle the harness during measurement to reveal an intermittent condition.
RAPH12SSL0339FA
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Electrical systems - FAULT CODES
(1) (2)
Connector X-UJML (Plug) Joystick X-Y position sensor
Schematic legend (3) (4)
DVM set to measure voltage. Left joystick F-B X-CN4A (Receptacle) pin 18
A. The voltage is approximately 5 V. Go to step 6. B. The voltage is not within range. There is a problem with the voltage supply to the sensor. Verify the voltage from the UCM. If the voltage from the UCM is correct, there is a problem in the voltage supply to the sensor. Repair as required. Return to step 1 to confirm elimination of fault. 6. Measure the voltage output of the sensor. Turn the ignition switch OFF. Disconnect the left joystick connector X-UJML (Plug) . Fabricate a breakout harness to measure the voltage output of the sensor.
RAPH12SSL0342GA
(1)
2
Schematic legend Dealer supplied breakout harness. (2)
DVM set to measure voltage.
Turn the ignition switch OFF. Connect the breakout harness between the two mating connectors on X-UJML (Plug) .
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Electrical systems - FAULT CODES
Turn the ignition switch ON. Measure the voltage between X-UJML (Plug) pin 3 and X-UJML (Plug) pin 4 on the breakout harness. The voltage should be approximately 2.5 V while the joystick in the neutral position. Continue measuring the voltage while slowly moving the throttle in the F-B position. The voltage should change between 0.5 V and 4.5 V. The voltage change should be smooth and steady as the joystick is moved between the stop points. A. The voltage is approximately 2.5 V in the neutral position and the voltage changes between 0.5 V and 4.5 V. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. B. The voltage is not 2.5 V in the neutral position or the voltage change is erratic. Temporarily replace the joystick and retest. Return to step 1 to confirm elimination of fault. Wiring harnesses - Electrical schematic sheet 21 SH21-UNIVERSAL CONTROL MODULE (55.100.DP-C.20.E.21) Wiring harnesses - Electrical schematic sheet 15 SH15-BULKHEAD CONNECTION (55.100.DP-C.20.E.15) Wiring harnesses - Electrical schematic sheet 17 SH17-LEFT NH CONTROL HANDLE (55.100.DP-C.20.E.17)
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Electrical systems - FAULT CODES
5212 - Left Joystick F-B Axis - Pin A Short to Power SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Context: The UCM has sensed that the left joystick F-B signal has failed. Diagnostic Trouble Code 5212 – Left Joystick F-B Axis - Pin A Short to Power has an error priority of Amber. Ground drive will operate in limp home mode while Diagnostic Trouble Code 5212 – Left Joystick F-B Axis - Pin A Short to Power is active. Cause: The UCM has sensed that the left joystick F-B signal has failed. The fault is active when the voltage on X-CN4A (Receptacle) pin 18 is greater than 4.8 V. Normal operating voltage of the sensor output is 0.5 V to 4.5 V. Output of the sensor with the joystick in the neutral position is approximately 2.5 V. Possible failure modes: 1. A short circuit in the signal wire to another voltage source. 2. A failure of the left control handle. 3. The UCM has an internal failure. 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. OK to return the machine to service. B. Fault code 5212 – Left Joystick F-B Axis - Pin A Short to Power is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the UCM and the left joystick connections. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the UCM to the left joystick. 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. 3. Measure the voltage on the signal wire to chassis ground. Turn the ignition switch OFF. Disconnect the UCM connector X-CN4A (Receptacle) . Disconnect the left joystick connector X-UJML (Plug) .
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Electrical systems - FAULT CODES
Turn the ignition switch ON. Measure the voltage between X-UJML (Plug) pin 3 and chassis ground. The voltage should be less than 0.5 V. Wiggle the harness during measurement to reveal an intermittent condition. A. The voltage is less than 0.5 V. Go to step 4. B. The voltage is greater than 0.5 V. There is a short circuit to another voltage source. Repair or replace the harness as required. Return to step 1 to confirm elimination of fault. 4. Measure the resistance through the signal wire. Turn the ignition switch OFF. Fabricate a jumper wire that will connect between connector X-CN4A (Receptacle) pin 18 and chassis ground. Connect the jumper wire between connector X-CN4A (Receptacle) pin 18 and chassis ground. The chassis ground connection must be clean and free of rust, dirt, oil, and paint. Measure the resistance between connector X-UJML (Plug) pin 3 and chassis ground. 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 5. B. The resistance is greater than 10 Ω. There is an open circuit in the signal wire. Repair or replace the harness as required. Return to step 1 to confirm elimination of fault. 5. Measure the voltage to the sensor. Turn the ignition switch OFF. Reconnect the UCM connectors. Disconnect the left joystick connector X-UJML (Plug) . Turn the ignition switch ON. Measure the voltage between X-UJML (Plug) pin 1 and X-UJML (Plug) pin 4. The voltage should be approximately 5 V. Wiggle the harness during measurement to reveal an intermittent condition.
RAPH12SSL0339FA
1
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Electrical systems - FAULT CODES
(1) (2)
Connector X-UJML (Plug) Joystick X-Y position sensor
Schematic legend (3) (4)
DVM set to measure voltage. Left joystick F-B X-CN4A (Receptacle) pin 18
A. The voltage is approximately 5 V. Go to step 6. B. The voltage is not within range. There is a problem with the voltage supply to the sensor. Verify the voltage from the UCM. If the voltage from the UCM is correct, there is an open circuit in the voltage supply to the sensor. Repair as required. Return to step 1 to confirm elimination of fault. 6. Measure the voltage output of the sensor. Turn the ignition switch OFF. Disconnect the left joystick connector X-UJML (Plug) . Fabricate a breakout harness to measure the voltage output of the sensor.
RAPH12SSL0342GA
(1)
2
Schematic legend Dealer supplied breakout harness. (2)
DVM set to measure voltage.
Turn the ignition switch OFF. Connect the breakout harness between the two mating connectors on X-UJML (Plug) .
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Electrical systems - FAULT CODES
Turn the ignition switch ON. Measure the voltage between X-UJML (Plug) pin 3 and X-UJML (Plug) pin 4 on the breakout harness. The voltage should be approximately 2.5 V while the joystick in the neutral position. Continue measuring the voltage while slowly moving the throttle in the F-B position. The voltage should change between 0.5 V and 4.5 V. The voltage change should be smooth and steady as the joystick is moved between the stop points. A. The voltage is approximately 2.5 V in the neutral position and the voltage changes between 0.5 V and 4.5 V. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. B. The voltage is not 2.5 V in the neutral position or the voltage change is erratic. Temporarily replace the joystick and retest. Return to step 1 to confirm elimination of fault. Wiring harnesses - Electrical schematic sheet 21 SH21-UNIVERSAL CONTROL MODULE (55.100.DP-C.20.E.21) Wiring harnesses - Electrical schematic sheet 15 SH15-BULKHEAD CONNECTION (55.100.DP-C.20.E.15) Wiring harnesses - Electrical schematic sheet 17 SH17-LEFT NH CONTROL HANDLE (55.100.DP-C.20.E.17)
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55.21 [55.DTC] / 705
Electrical systems - FAULT CODES
5214 - Left Joystick F-B Axis - Pin B Short to Ground/ Open Circuit SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Context: The UCM has sensed that the left joystick F-B signal has failed. Diagnostic Trouble Code 5214 – Left Joystick F-B Axis - Pin B Short to Ground/ Open Circuit has an error priority of Amber. Ground drive will operate in limp home mode while Diagnostic Trouble Code 5214 – Left Joystick F-B Axis - Pin B Short to Ground/ Open Circuit is active. Cause: The UCM has sensed that the left joystick F-B signal has failed. The fault is active while the voltage on X-CN2B (Receptacle) pin 31 is less than 0.2 V. The normal operating voltage of the sensor output is 0.5 V to 4.5 V. The output of the sensor with the joystick in the neutral position is approximately 2.5 V. Possible failure modes: 1. A short circuit in the signal wire. 2. An open circuit in the signal wire. 3. A failure of the right control handle. 4. The UCM has an internal failure. 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. OK to return the machine to service. B. Fault code 5214 – Left Joystick F-B Axis - Pin B Short to Ground/ Open Circuit is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the UCM and the left joystick connections. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the UCM to the left joystick. 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 the connectors as required. Return to step 1 to confirm elimination of fault. 3. Measure the resistance of the signal wire to chassis ground. Turn the ignition switch OFF. Disconnect the UCM connector X-CN2B (Receptacle) . 48068130 29/01/2018
55.21 [55.DTC] / 706
Electrical systems - FAULT CODES
Disconnect the left joystick connector X-UJML (Plug) . Measure the resistance between X-UJML (Plug) pin 9 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. Go to step 4. 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 1 to confirm elimination of fault. 4. Measure the resistance through the signal wire. Fabricate a jumper wire that will connect between connector X-CN2B (Receptacle) pin 31 and chassis ground. Connect the jumper wire between connector X-CN2B (Receptacle) pin 31 and chassis ground. The chassis ground connection must be clean and free of rust, dirt, oil, and paint. Measure the resistance between connector X-UJML (Plug) pin 9 and chassis ground. 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 5. B. The resistance is greater than 10 Ω. There is an open circuit in the signal wire. Repair or replace the harness as required. Return to step 1 to confirm elimination of fault. 5. Measure the voltage to the sensor. Turn the ignition switch OFF. Reconnect the UCM connector. Disconnect the left joystick connector X-UJML (Plug) . Turn the ignition switch ON. Measure the voltage between X-UJML (Plug) pin 7 and X-UJML (Plug) pin 10. The voltage should be approximately 5 V. Wiggle the harness during measurement to reveal an intermittent condition.
RAPH12SSL0346FA
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Electrical systems - FAULT CODES
(1) (2)
Connector X-UJML (Plug) Joystick X-Y Position Sensor
Schematic legend (3) (4)
DVM set to measure voltage. Left Joystick F-B X-CN2B (Receptacle) pin 31
A. The voltage is approximately 5 V. Go to step 6. B. The voltage is not within range. There is a problem with the voltage supply to the sensor. Verify the voltage from the UCM. If the voltage from the UCM is correct, there is an open circuit in the voltage supply to the sensor. Repair as required. Return to step 1 to confirm elimination of fault. 6. Measure the voltage output of the sensor. Turn the ignition switch OFF. Disconnect the left joystick connector X-UJML (Plug) . Fabricate a breakout harness to measure the voltage output of the sensor.
RAPH12SSL0347GA
(1)
2
Schematic legend Dealer supplied breakout harness. (2)
DVM set to measure voltage.
Turn the ignition switch OFF. Connect the breakout harness between the two mating connectors on X-UJML (Plug) .
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Electrical systems - FAULT CODES
Turn the ignition switch ON. Measure the voltage between X-UJML (Plug) pin 9 and X-UJML (Plug) pin 10 on the break out harness. The voltage should be approximately 2.5 V while the joystick in the neutral position. Continue measuring the voltage while slowly moving the throttle in the F-B position. The voltage should change between 0.5 V and 4.5 V. The voltage change should be smooth and steady as the joystick is moved between the stop points. A. The voltage is approximately 2.5 V in the neutral position and the voltage changes between 0.5 V and 4.5 V. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. B. The voltage is not 2.5 V in the neutral position or the voltage change is erratic. Temporarily replace the joystick and retest. Return to step 1 to confirm elimination of fault. Wiring harnesses - Electrical schematic sheet 20 SH20-UNIVERSAL CONTROL MODULE (55.100.DP-C.20.E.20) Wiring harnesses - Electrical schematic sheet 15 SH15-BULKHEAD CONNECTION (55.100.DP-C.20.E.15) Wiring harnesses - Electrical schematic sheet 17 SH17-LEFT NH CONTROL HANDLE (55.100.DP-C.20.E.17)
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Electrical systems - FAULT CODES
5215 - Left Joystick F-B Axis - Pin B Short to Power SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Context: The UCM has sensed that the left joystick F-B signal has failed. Diagnostic Trouble Code 5215 – Left Joystick F-B Axis - Pin B Short to Power has an error priority of Amber. Ground drive will operate in limp home mode while Diagnostic Trouble Code 5215 – Left Joystick F-B Axis - Pin B Short to Power is active. Cause: The UCM has sensed that the right joystick R-L signal has failed. The fault is active when the voltage on X-CN2B (Receptacle) pin 31 is greater than 4.8 V. The normal operating voltage of the sensor output is 0.5 V to 4.5 V. The output of the sensor with the joystick in the neutral position is approximately 2.5 V. Possible failure modes: 1. A short circuit in the signal wire to another voltage source. 2. A failure of the right control handle. 3. The UCM has an internal failure. 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. OK to return the machine to service. B. Fault code 5215 – Left Joystick F-B Axis - Pin B Short to Power is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the UCM and the left joystick connections. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the UCM to the left joystick. 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 the connectors as required. Return to step 1 to confirm elimination of fault. 3. Measure the voltage on the signal wire to chassis ground. Turn the ignition switch OFF. Disconnect the UCM connector X-CN2B (Receptacle) . Disconnect the left joystick connector X-UJML (Plug) .
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Electrical systems - FAULT CODES
Turn the ignition switch ON. Measure the voltage between X-UJML (Plug) pin 9 and chassis ground. The voltage should be less than 0.5 V. Wiggle the harness during measurement to reveal an intermittent condition. A. The voltage is less than 0.5 V. Go to step 4. B. The voltage is greater than 0.5 V. There is a short circuit to another voltage source. Repair or replace the harness as required. Return to step 1 to confirm elimination of fault. 4. Measure the resistance through the signal wire. Fabricate a jumper wire that will connect between connector X-CN2B (Receptacle) pin 31 and chassis ground. Connect the jumper wire between connector X-CN2B (Receptacle) pin 31 and chassis ground. The chassis ground connection must be clean and free of rust, dirt oil and paint. Measure the resistance between connector X-UJML (Plug) pin 9 and chassis ground. 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 5. B. The resistance is greater than 10 Ω. There is an open circuit in the signal wire. Repair or replace the harness as required. Return to step 1 to confirm elimination of fault. 5. Measure the voltage to the sensor. Turn the ignition switch OFF. Reconnect the UCM connector. Disconnect the left joystick connector X-UJML (Plug) . Turn the ignition switch ON. Measure the voltage between X-UJML (Plug) pin 7 and X-UJML (Plug) pin 10. The voltage should be approximately 5 V. Wiggle the harness during measurement to reveal an intermittent condition.
RAPH12SSL0346FA
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55.21 [55.DTC] / 711
Electrical systems - FAULT CODES
(1) (2)
Connector X-UJML (Plug) Joystick X-Y Position Sensor
Schematic legend (3) (4)
DVM set to measure voltage. Left Joystick F-B X-CN2B (Receptacle) pin 31
A. The voltage is approximately 5 V. Go to step 6. B. The voltage is not within range. There is a problem with the voltage supply to the sensor. Verify the voltage from the UCM. If the voltage from the UCM is correct, there is an open circuit in the voltage supply to the sensor. Repair as required. Return to step 1 to confirm elimination of fault. 6. Measure the voltage output of the sensor. Turn the ignition switch OFF. Disconnect the left joystick connector X-UJML (Plug) . Fabricate a breakout harness to measure the voltage output of the sensor.
RAPH12SSL0347GA
(1)
2
Schematic legend Dealer supplied breakout harness. (2)
DVM set to measure voltage.
Turn the ignition switch OFF. Connect the breakout harness between the two mating connectors on X-UJML (Plug) .
48068130 29/01/2018
55.21 [55.DTC] / 712
Electrical systems - FAULT CODES
Turn the ignition switch ON. Measure the voltage between X-UJML (Plug) pin 9 and X-UJML (Plug) pin 10 on the break out harness. The voltage should be approximately 2.5 V while the joystick in the neutral position. Continue measuring the voltage while slowly moving the throttle in the F-B position. The voltage should change between 0.5 V and 4.5 V. The voltage change should be smooth and steady as the joystick is moved between the stop points. A. The voltage is approximately 2.5 V in the neutral position and the voltage changes between 0.5 V and 4.5 V. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. B. The voltage is not 2.5 V in the neutral position or the voltage change is erratic. Temporarily replace the joystick and retest. Return to step 1 to confirm elimination of fault. Wiring harnesses - Electrical schematic sheet 20 SH20-UNIVERSAL CONTROL MODULE (55.100.DP-C.20.E.20) Wiring harnesses - Electrical schematic sheet 15 SH15-BULKHEAD CONNECTION (55.100.DP-C.20.E.15) Wiring harnesses - Electrical schematic sheet 17 SH17-LEFT NH CONTROL HANDLE (55.100.DP-C.20.E.17)
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Electrical systems - FAULT CODES
5217 - Left Joystick F-B Axis - In Range Fault SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Context: The UCM has sensed that the left joystick F-B signal has failed. Diagnostic Trouble Code 5217 – Left Joystick F-B Axis - In Range Fault has an error priority of Red. Ground drive is disabled while Diagnostic Trouble Code 5217 – Left Joystick F-B Axis - In Range Fault is active. Cause: The UCM has sensed that the left joystick F-B signal has failed. The fault is active while voltage on X-CN4A (Receptacle) pin 18 and X-CN2B (Receptacle) pin 31 is less than 0.2 V or greater than 4.8 V. The normal operating voltage of the sensor output is 0.5 V to 4.5 V. The output of the sensor in the neutral position is approximately 2.5 V. Possible failure modes: 1. An open circuit in the signal wire. 2. A short circuit in the signal wire. 3. Failure of the left control handle. 4. The UCM has an internal failure. Solution: 1. Verify that the fault code is active. Connect the Electronic Service Tool to the service tool connector. To check for fault code: Start and operate the machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 5217 – Left Joystick F-B Axis - In Range Fault is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the UCM and the left joystick connections. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the UCM to the left joystick. 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 the connectors as required. Return to step 1 to confirm elimination of fault. 3. Measure the voltage of the signal wire to chassis ground. Turn the ignition switch OFF. Disconnect the UCM connectors X-CN4A (Receptacle) and X-CN2B (Receptacle) . Disconnect the left joystick connector X-UJML (Plug) . 48068130 29/01/2018
55.21 [55.DTC] / 714
Electrical systems - FAULT CODES
Turn the ignition switch ON. Measure the voltage between X-UJML (Plug) pin 3 and chassis ground. The voltage should be less than 0.5 V. Wiggle the harness during measurement to reveal an intermittent condition. Measure the voltage between X-UJML (Plug) pin 9 and chassis ground. The voltage should be less than 0.5 V. Wiggle the harness during measurement to reveal an intermittent condition. A. The voltage is less than 0.5 V. Go to step 4. B. The voltage is greater than 0.5 V. There is a short circuit to another voltage source. Repair or replace the harness as required. Return to step 1 to confirm elimination of fault. 4. Measure the resistance of the signal wire to chassis ground. Turn the ignition switch OFF. Disconnect the UCM connector X-CN4A (Receptacle) and X-CN2B (Receptacle) . Disconnect the left joystick connector X-UJML (Plug) . Measure the resistance of X-UJML (Plug) pin 3 to chassis ground. The resistance should be greater than 20,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition. Measure the resistance of X-UJML (Plug) pin 9 to 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. Go to step 5. 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 1 to confirm elimination of fault. 5. Measure the resistance of the signal wire. Fabricate a jumper wire that will connect between connector X-CN4A (Receptacle) pin 18 to chassis ground. Connect the jumper wire between connector X-CN4A (Receptacle) pin 18 and chassis ground. The chassis ground connection must be clean and free of rust, dirt oil and paint. Measure the resistance between connector X-UJML (Plug) pin 3 and chassis ground. The resistance should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition. Connect the jumper wire between connector X-CN2B (Receptacle) pin 31 and chassis ground. The chassis ground connection must be clean and free of rust, dirt, oil, and paint. Measure the resistance between connector X-UJML (Plug) pin 9 and chassis ground. 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 6. B. The resistance is greater than 10 Ω. There is an open circuit in the signal wire. Repair or replace the harness as required. Return to step 1 to confirm elimination of fault. 6. Measure the voltage to the sensor. Turn the ignition switch OFF. Reconnect the UCM connectors. Disconnect the left joystick connector X-UJML (Plug) . Turn the ignition switch ON. Measure the voltage between X-UJML (Plug) pin 1 and X-UJML (Plug) pin 4. The voltage should be approximately 5 V. Wiggle the harness during measurement to reveal an intermittent condition.
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Electrical systems - FAULT CODES
Measure the voltage between X-UJML (Plug) pin 7 and X-UJML (Plug) pin 10. The voltage should be approximately 5 V. Wiggle the harness during measurement to reveal an intermittent condition.
RAPH12SSL0348FA
1
Schematic legend (4)
(1)
Connector X-UJML (Plug)
(2)
Joystick X-Y position sensor
(3)
DVM set to measure voltage.
(5)
Left Joystick F-B X-CN4A (Receptacle) pin 18 Left Joystick F-B X-CN2B (Receptacle) pin 31
A. The voltage is approximately 5 V. Go to step 7. B. The voltage is not within range. There is a problem with the voltage supply to the sensor. Verify the voltage from the UCM. If the voltage from the UCM is correct, there is a problem in the voltage supply to the sensor. Repair as required. Return to step 1 to confirm elimination of fault. 7. Measure the voltage output of the sensor. Turn the ignition switch OFF. Disconnect the left joystick connector X-UJML (Plug) . Fabricate a breakout harness to measure the voltage output of the sensor.
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Electrical systems - FAULT CODES
RAPH12SSL0349GA
(1)
2
Schematic legend Dealer supplied breakout harness. (2)
DVM set to measure voltage.
Turn the ignition switch OFF. Connect the breakout harness between the two mating connectors on X-UJML (Plug) . Turn the ignition switch ON. Measure the voltage between X-UJML (Plug) pin 3 and X-UJML (Plug) pin 4 on the breakout harness. The voltage should be approximately 2.5 V while the joystick in the neutral position. Continue measuring the voltage while slowly moving the throttle in the F-B position. The voltage should change between 0.5 V and 4.5 V. The voltage change should be smooth and steady as the joystick is moved between the stop points. Measure the voltage between X-UJML (Plug) pin 9 and X-UJML (Plug) pin 10 on the break out harness. The voltage should be approximately 2.5 V while the joystick in the neutral position. Continue measuring the voltage while slowly moving the throttle in the F-B position. The voltage should change between 0.5 V and 4.5 V. The voltage change should be smooth and steady as the joystick is moved between the stop points. A. For both measurements, the voltage is approximately 2.5 V in the neutral position and the voltage changes at a smooth rate between 0.5 V and 4.5 V. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. 48068130 29/01/2018
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Electrical systems - FAULT CODES
B. On one or both measurements, the voltage is not 2.5 V in the neutral position or the voltage change is erratic. Temporarily replace the Joystick and retest. Return to step 1 to confirm elimination of fault. Wiring harnesses - Electrical schematic sheet 21 SH21-UNIVERSAL CONTROL MODULE (55.100.DP-C.20.E.21) Wiring harnesses - Electrical schematic sheet 15 SH15-BULKHEAD CONNECTION (55.100.DP-C.20.E.15) Wiring harnesses - Electrical schematic sheet 17 SH17-LEFT NH CONTROL HANDLE (55.100.DP-C.20.E.17) Wiring harnesses - Electrical schematic sheet 20 SH20-UNIVERSAL CONTROL MODULE (55.100.DP-C.20.E.20)
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Electrical systems - FAULT CODES
5221 - Loader Arm Valve (Directional) Solenoid Raise (A) Supply Open Circuit SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Context: The UCM has sensed an open circuit in the loader solenoid circuit. Diagnostic Trouble Code 5221 – Loader Arm Valve (Directional) Solenoid Raise (A) Supply Open Circuit has an error priority of Red. The boom functions are disabled while Diagnostic Trouble Code 5221 – Loader Arm Valve (Directional) Solenoid Raise (A) Supply Open Circuit is active. Cause: The UCM has sensed an open circuit in the loader solenoid circuit, X-CN3B (Receptacle) pin 6. The fault is active while the hydraulics are enabled and the calculated solenoid resistance has increased over 70%. Possible failure modes: 1. An open circuit in the solenoid circuit. 2. The loader valve extend solenoid has failed. 3. The UCM has an internal failure. 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. OK to return the machine to service. B. Fault code 5221 – Loader Arm Valve (Directional) Solenoid Raise (A) Supply Open Circuit is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the UCM and the loader solenoid connections. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the UCM to the loader solenoids. 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 the connectors as required. Return to step 1 to confirm elimination of fault. 3. Measure the resistance through the solenoid circuit. Turn the ignition switch OFF. Disconnect UCM connectors X-CN3B (Receptacle) and X-CN2B (Receptacle) . Disconnect connector X-028 (Plug) . 48068130 29/01/2018
55.21 [55.DTC] / 719
Electrical systems - FAULT CODES
Fabricate a jumper wire that will connect between X-CN3B (Receptacle) pin 6 and chassis ground. Connect the jumper wire between X-CN3B (Receptacle) pin 6 and chassis ground. The chassis ground connection must be clean and free of paint, oil, and dirt. Measure the resistance between X-028 (Plug) pin 1 and chassis ground. The resistance should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition. Connect the jumper wire between X-CN2B (Receptacle) pin 7 and chassis ground. The chassis ground connection must be clean and free of paint, oil, and dirt. Measure the resistance between X-028 (Plug) pin 2 and chassis ground. The resistance should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition. A. Both resistance measurements are less than 10 Ω. Go to step 4. B. One or both resistance measurements are 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 the fault. 4. Measure the resistance through the solenoid. Measure the resistance across the loader extend solenoid terminals, X-028 (Plug) pin 1 and X-028 (Plug) pin 2. The resistance should be less than 1,000 Ω. A. The resistance is less than 1,000 Ω. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. B. The resistance is greater than 1,000 Ω. There is an open circuit in the solenoid. Temporarily replace the solenoid and retest. Return to step 1 to confirm elimination of the fault. Wiring harnesses - Electrical schematic sheet 21 SH21-UNIVERSAL CONTROL MODULE (55.100.DP-C.20.E.21) Wiring harnesses - Electrical schematic sheet 12 SH12-LOADER VALVE AND SENSORS (55.100.DP-C.20.E.12)
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Electrical systems - FAULT CODES
5222 - Loader Arm Valve (Directional) Solenoid Raise (A) Supply Shorted To Ground SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Context: The UCM has sensed that the loader extend solenoid current is too high. Diagnostic Trouble Code 5222 – Loader Arm Valve (Directional) Solenoid Raise (A) Supply Shorted To Ground has an error priority of Red. The boom functions are disabled while Diagnostic Trouble Code 5222 – Loader Arm Valve (Directional) Solenoid Raise (A) Supply Shorted To Ground is active. Cause: The UCM has sensed that the loader extend solenoid current is too high. The fault is active when the hydraulics are enabled and the solenoid output current, X-CN3B (Receptacle) pin 6 is greater than 3 A. Possible failure modes: 1. A short circuit in the solenoid wiring. 2. The loader valve solenoid has failed. 3. The UCM has an internal failure. 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. OK to return the machine to service. B. Fault code 5222 – Loader Arm Valve (Directional) Solenoid Raise (A) Supply Shorted To Ground is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the UCM and the loader solenoid connections. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the UCM to the loader solenoids. 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 the connectors as required. Return to step 1 to confirm elimination of fault. 3. Test the UCM. Turn the ignition switch OFF. Disconnect solenoid connector X-028 (Plug) . Turn the ignition switch ON. 48068130 29/01/2018
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Electrical systems - FAULT CODES
Use the electronic service tool and access the fault code screen. Fault code 5222 – Loader Arm Valve (Directional) Solenoid Raise (A) Supply Shorted To Ground should no longer be active. Fault code 5221 – Loader Arm Valve (Directional) Solenoid Raise (A) Supply Open Circuit is now active. A. Fault code 5222 – Loader Arm Valve (Directional) Solenoid Raise (A) Supply Shorted To Ground is no longer active. Fault code 5221 – Loader Arm Valve (Directional) Solenoid Raise (A) Supply Open Circuit is now active. Replace the solenoid and retest. Return to step 1 to confirm elimination of the fault. B. Fault code 5222 – Loader Arm Valve (Directional) Solenoid Raise (A) Supply Shorted To Ground is active. Fault code 5221 – Loader Arm Valve (Directional) Solenoid Raise (A) Supply Open Circuit did not become active. Go to step 4. 4. Measure the resistance of the solenoid wire to chassis ground. Turn the ignition switch OFF. Disconnect UCM connectors X-CN3B (Receptacle) and X-CN2B (Receptacle) . Disconnect solenoid connector X-028 (Plug) . Measure the resistance between X-CN3B (Receptacle) pin 6 and chassis ground. The resistance should be greater than 20,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition. Measure the resistance between X-CN2B (Receptacle) pin 7 and chassis ground. The resistance should be greater than 20,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition. Measure the resistance between X-CN3B (Receptacle) pin 6 and X-CN2B (Receptacle) pin 7. 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 UCM and retest. Return to step 1 to confirm elimination of the fault. B. One or more resistance measurements are less than 20,000 Ω. There is a short circuit in the wiring. Repair or replace the harness as required. Return to step 1 to confirm elimination of the fault. Wiring harnesses - Electrical schematic sheet 21 SH21-UNIVERSAL CONTROL MODULE (55.100.DP-C.20.E.21) Wiring harnesses - Electrical schematic sheet 12 SH12-LOADER VALVE AND SENSORS (55.100.DP-C.20.E.12)
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Electrical systems - FAULT CODES
5231 - Loader Arm Valve (Directional) Solenoid Lower (B) Supply Open Circuit SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Context: The UCM has sensed an open circuit in the loader solenoid circuit. Diagnostic Trouble Code 5231 – Loader Arm Valve (Directional) Solenoid Lower (B) Supply Open Circuit has an error priority of Red. The boom functions are disabled while Diagnostic Trouble Code 5231 – Loader Arm Valve (Directional) Solenoid Lower (B) Supply Open Circuit is active. Cause: The UCM has sensed an open circuit in the loader solenoid circuit, X-CN3A (Receptacle) pin 22. The fault is active when the hydraulics are enabled and the calculated solenoid resistance has increased over 70%. Possible failure modes: 1. An open circuit in the solenoid circuit. 2. The loader valve retract solenoid has failed. 3. The UCM has an internal failure. 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. OK to return the machine to service. B. Fault code 5231 – Loader Arm Valve (Directional) Solenoid Lower (B) Supply Open Circuit is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the UCM and the loader solenoid connections. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the UCM to the loader solenoids. 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 the connectors as required. Return to step 1 to confirm elimination of fault. 3. Measure the resistance through the solenoid circuit. Turn the ignition switch OFF. Disconnect UCM connectors X-CN3A (Receptacle) and X-CN2B (Receptacle) . Disconnect connector X-027 (Plug) . 48068130 29/01/2018
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Electrical systems - FAULT CODES
Fabricate a jumper wire that will connect between X-CN3A (Receptacle) pin 22 and chassis ground. Connect the jumper wire between X-CN3A (Receptacle) pin 22 and chassis ground. The chassis ground connection must be clean and free of paint, oil, and dirt. Measure the resistance between X-027 (Plug) pin 1 and chassis ground. The resistance should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition. Connect the jumper wire between X-CN2B (Receptacle) pin 7 and chassis ground. The chassis ground connection must be clean and free of paint, oil, and dirt. Measure the resistance between X-027 (Plug) pin 2 and chassis ground. The resistance should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition. A. Both resistance measurements are less than 10 Ω. Go to step 4. B. One or both resistance measurements are 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 the fault. 4. Measure the resistance through the solenoid. Measure the resistance across the loader extend solenoid terminals, X-027 (Plug) pin 1 and X-027 (Plug) pin 2. The resistance should be less than 1,000 Ω. A. The resistance is less than 1,000 Ω. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. B. The resistance is greater than 1,000 Ω. There is an open circuit in the solenoid. Temporarily replace the solenoid and retest. Return to step 1 to confirm elimination of the fault. Wiring harnesses - Electrical schematic sheet 21 SH21-UNIVERSAL CONTROL MODULE (55.100.DP-C.20.E.21) Wiring harnesses - Electrical schematic sheet 12 SH12-LOADER VALVE AND SENSORS (55.100.DP-C.20.E.12)
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Electrical systems - FAULT CODES
5232 - Loader Arm Valve (Directional) Solenoid Lower (B) Supply Shorted To Ground SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Context: The UCM has sensed that the loader retract solenoid current is too high. Diagnostic Trouble Code 5232 – Loader Arm Valve (Directional) Solenoid Lower (B) Supply Shorted To Ground has an error priority of Red. The boom functions are disabled while Diagnostic Trouble Code 5232 – Loader Arm Valve (Directional) Solenoid Lower (B) Supply Shorted To Ground is active. Cause: The UCM has sensed that the loader retract solenoid current is too high. The fault is active when hydraulics are enabled and solenoid output current, X-CN3A (Receptacle) pin 22 is greater than 3 A. Possible failure modes: 1. A short circuit in the solenoid wiring. 2. The loader valve solenoid has failed. 3. The UCM has an internal failure. 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. OK to return the machine to service. B. Fault code 5232 – Loader Arm Valve (Directional) Solenoid Lower (B) Supply Shorted To Ground is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the UCM and the loader solenoid connections. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the UCM to the loader solenoids. 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 the connectors as required. Return to step 1 to confirm elimination of fault. 3. Test the UCM. Turn the ignition switch OFF. Disconnect solenoid connector X-027 (Plug) . Turn the ignition switch ON. 48068130 29/01/2018
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Electrical systems - FAULT CODES
Use the electronic service tool and access the fault code screen. Fault code 5232 – Loader Arm Valve (Directional) Solenoid Lower (B) Supply Shorted To Ground should no longer be active. Fault code 5231 – Loader Arm Valve (Directional) Solenoid Lower (B) Supply Open Circuit is now active. A. Fault code 5232 – Loader Arm Valve (Directional) Solenoid Lower (B) Supply Shorted To Ground is no longer active. Fault code 5231 – Loader Arm Valve (Directional) Solenoid Lower (B) Supply Open Circuit is now active. Replace the solenoid and retest. Return to step 1 to confirm elimination of the fault. B. Fault code 5232 – Loader Arm Valve (Directional) Solenoid Lower (B) Supply Shorted To Ground is active. Fault code 5231 – Loader Arm Valve (Directional) Solenoid Lower (B) Supply Open Circuit did not become active. Go to step 4. 4. Measure the resistance of the solenoid wire to chassis ground. Turn the ignition switch OFF. Disconnect UCM connectors X-CN3A (Receptacle) and X-CN2B (Receptacle) . Disconnect solenoid connector X-027 (Plug) . Measure the resistance between X-CN3A (Receptacle) pin 22 and chassis ground. The resistance should be greater than 20,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition. Measure the resistance between X-CN2B (Receptacle) pin 7 and chassis ground. The resistance should be greater than 20,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition. Measure the resistance between X-CN3A (Receptacle) pin 22 and X-CN2B (Receptacle) pin 7. 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 UCM and retest. Return to step 1 to confirm elimination of the fault. B. One or more resistance measurements are less than 20,000 Ω. There is a short circuit in the wiring. Repair or replace the harness as required. Return to step 1 to confirm elimination of the fault. Wiring harnesses - Electrical schematic sheet 21 SH21-UNIVERSAL CONTROL MODULE (55.100.DP-C.20.E.21) Wiring harnesses - Electrical schematic sheet 12 SH12-LOADER VALVE AND SENSORS (55.100.DP-C.20.E.12)
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55.21 [55.DTC] / 726
Electrical systems - FAULT CODES
5241 - Loader Arm Valve (Directional) Loader Arm Solenoid(s) Shorted To Power SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Context: The UCM has sensed a higher than normal voltage on the loader solenoid lines. Fault code 5241 – Loader Arm Valve (Directional) Loader Arm Solenoid(s) Shorted To Power has an error priority of Red. Boom functions are disabled while Diagnostic Trouble Code 5241 – Loader Arm Valve (Directional) Loader Arm Solenoid(s) Shorted To Power is active. Cause: The UCM has sensed the voltage on the loader solenoid lines, X-CN3B (Receptacle) pin 6 , X-CN3A (Receptacle) pin 22, and X-CN2B (Receptacle) pin 7 is too high. The fault is active when hydraulics are disabled and the solenoid feedback voltage is greater than 5 V. Possible failure modes: 1. A short circuit in the signal wire to another voltage source. 2. The UCM has an internal failure. 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. OK to return the machine to service. B. Fault code 5241 – Loader Arm Valve (Directional) Loader Arm Solenoid(s) Shorted To Power is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the UCM and the loader solenoid connections. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the UCM to the loader solenoids. 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. 3. Measure the voltage on the signal wires. Turn the ignition switch OFF. Disconnect UCM connectors X-CN3A (Receptacle) , X-CN2B (Receptacle) , and X-CN3B (Receptacle) . Turn the ignition switch ON.
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55.21 [55.DTC] / 727
Electrical systems - FAULT CODES
Measure the voltage between X-CN3B (Receptacle) pin 6 and chassis ground. The voltage should be less than 0.5 V. Wiggle the harness to reveal an intermittent condition. Measure the voltage between X-CN3A (Receptacle) pin 22 and chassis ground. The voltage should be less than 0.5 V. Wiggle the harness to reveal an intermittent condition. Measure the voltage between X-CN2B (Receptacle) pin 7 and chassis ground. The voltage should be less than 0.5 V. Wiggle the harness to reveal an intermittent condition. A. All voltage measurements are less than 0.5 V. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. B. One or more of the voltage measurements are greater than 0.5 V. There is a short circuit to another voltage source. Repair or replace the harness as required. Return to step 1 to confirm elimination of fault. Wiring harnesses - Electrical schematic sheet 20 SH20-UNIVERSAL CONTROL MODULE (55.100.DP-C.20.E.20) Wiring harnesses - Electrical schematic sheet 21 SH21-UNIVERSAL CONTROL MODULE (55.100.DP-C.20.E.21) Wiring harnesses - Electrical schematic sheet 12 SH12-LOADER VALVE AND SENSORS (55.100.DP-C.20.E.12)
48068130 29/01/2018
55.21 [55.DTC] / 728
Electrical systems - FAULT CODES
5242 - Loader Arm Valve (Directional) Loader Arm Solenoid(s) Shorted To Ground SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Context: The UCM has sensed a lower than normal voltage on the loader solenoid lines. Fault code 5242 – Loader Arm Valve (Directional) Loader Arm Solenoid(s) Shorted To Ground has an error priority of Red. Boom functions are disabled while Diagnostic Trouble Code 5242 – Loader Arm Valve (Directional) Loader Arm Solenoid(s) Shorted To Ground is active. Cause: The UCM has sensed that the voltage on the loader solenoid lines, X-CN3B (Receptacle) pin 6, X-CN3A (Receptacle) pin 22, and X-CN2B (Receptacle) pin 7 is too low. The fault is active when hydraulics are disabled and the solenoid feedback voltage is less than 2 V. Possible failure modes: 1. A short circuit in the signal wire to chassis ground. 2. The UCM has an internal failure. 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. OK to return the machine to service. B. Fault code 5242 – Loader Arm Valve (Directional) Loader Arm Solenoid(s) Shorted To Ground is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the UCM and the loader solenoid connections. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the UCM to the loader solenoids. 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. 3. Measure the resistance of the solenoid wire to chassis ground. Turn the ignition switch OFF. Disconnect UCM connectors X-CN3A (Receptacle) , X-CN2B (Receptacle) , and X-CN3B (Receptacle) . Disconnect solenoid connectors, X-027 (Plug) and X-028 (Plug) .
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Electrical systems - FAULT CODES
Measure the resistance between X-CN3B (Receptacle) pin 6 and chassis ground. The resistance should be greater than 20,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition. Measure the resistance between X-CN3A (Receptacle) pin 22 and chassis ground. The resistance should be greater than 20,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition. Measure the resistance between X-CN2B (Receptacle) pin 7 and chassis ground. The resistance should be greater than 20,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition. Measure the resistance between X-CN3B (Receptacle) pin 6 and X-CN2B (Receptacle) pin 7. The resistance should be greater than 20,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition. Measure the resistance between X-CN3A (Receptacle) pin 22 and X-CN2B (Receptacle) pin 7. The resistance should be greater than 20,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition. A. All resistance measurements are greater than 20,000 Ω. Go to step 4. B. One or more resistance measurements are less than 20,000 Ω. There is a short circuit in the wiring. Repair or replace the harness as required. Return to step 1 to confirm elimination of the fault. 4. Measure the resistance through the solenoid. Disconnect connector X-027 (Plug) and X-028 (Plug) . Measure the resistance across the loader extend solenoid terminals. The resistance should be greater than 1 Ω. Measure the resistance across the loader retract solenoid terminals. The resistance should be greater than 1 Ω. A. Both resistance measurements are greater than 1 Ω. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. B. One or both resistance measurements are less than 1 Ω. There is a short circuit in the solenoid. Replace the solenoid as required. Return to step 1 to confirm elimination of the fault. Wiring harnesses - Electrical schematic sheet 20 SH20-UNIVERSAL CONTROL MODULE (55.100.DP-C.20.E.20) Wiring harnesses - Electrical schematic sheet 21 SH21-UNIVERSAL CONTROL MODULE (55.100.DP-C.20.E.21) Wiring harnesses - Electrical schematic sheet 12 SH12-LOADER VALVE AND SENSORS (55.100.DP-C.20.E.12)
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55.21 [55.DTC] / 730
Electrical systems - FAULT CODES
5243 - Loader Arm Valve (Directional) Solenoids Return Open Circuit SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Context: The UCM has sensed an open circuit in the loader solenoid return circuit. Diagnostic Trouble Code 5243 – Loader Arm Valve (Directional) Solenoids Return Open Circuit has an error priority of Red. Boom functions are disabled while Diagnostic Trouble Code 5243 – Loader Arm Valve (Directional) Solenoids Return Open Circuit is active. Cause: The UCM has sensed an open circuit in the loader solenoid return circuit, X-CN2B (Receptacle) pin 7. The fault is active when the ignition is ON and the calculated solenoid resistances have increased over 70%. Possible failure modes: 1. An open circuit in the solenoid return wiring. 2. The loader solenoids have failed. 3. The UCM has an internal failure. 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. OK to return the machine to service. B. Fault code 5243 – Loader Arm Valve (Directional) Solenoids Return Open Circuit is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the UCM and the loader solenoid connections. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the UCM to the loader solenoids. 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 the connectors as required. Return to step 1 to confirm elimination of fault. 3. Measure the resistance through the solenoid circuit. Turn the ignition switch OFF. Disconnect UCM connectors X-CN3A (Receptacle) , X-CN2B (Receptacle) , and X-CN3B (Receptacle) .
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55.21 [55.DTC] / 731
Electrical systems - FAULT CODES
Measure the resistance between X-CN3A (Receptacle) pin 22 and X-CN2B (Receptacle) pin 7. The resistance should be less than 100 Ω. Wiggle the harness during measurement to reveal an intermittent condition. Measure the resistance between X-CN3B (Receptacle) pin 6 and X-CN2B (Receptacle) pin 7. The resistance should be less than 100 Ω. Wiggle the harness during measurement to reveal an intermittent condition. A. Both resistance measurements are less than 100 Ω. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. B. One or both resistance are greater than 100 Ω. There is an open circuit in the wiring. Go to step 4. 4. Measure the solenoid resistance. Measure the resistance across the extend solenoid terminals, pin 1 and pin 2. The resistance should be less than 20 Ω. Measure the resistance across the retract solenoid terminals, pin 1 and pin 2. The resistance should be less than 20 Ω. A. The resistance is less than 20 Ω. Go to step 5. B. The resistance is greater than 20 Ω. There is an open circuit in the solenoid. Replace the solenoid and retest. Return to step 1 to confirm elimination of the fault. 5. Measure the resistance through the circuit. Leave UCM connectors X-CN3A (Receptacle) , X-CN2B (Receptacle) , and X-CN3B (Receptacle) disconnected. Fabricate a jumper wire that will connect between X-027 (Plug) pin 1 and X-027 (Plug) pin 2. Connect the jumper wire between X-027 (Plug) pin 1 and X-027 (Plug) pin 2. Measure the resistance between X-CN3A (Receptacle) pin 22 and X-CN2B (Receptacle) pin 7. The resistance should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition. Remove the jumper from X-027 (Plug) . Connect the jumper wire between X-028 (Plug) pin 1 and X-028 (Plug) pin 2. Measure the resistance between X-CN3B (Receptacle) pin 6 and X-CN2B (Receptacle) pin 7. 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. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. 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 the fault. Wiring harnesses - Electrical schematic sheet 20 SH20-UNIVERSAL CONTROL MODULE (55.100.DP-C.20.E.20) Wiring harnesses - Electrical schematic sheet 21 SH21-UNIVERSAL CONTROL MODULE (55.100.DP-C.20.E.21) Wiring harnesses - Electrical schematic sheet 12 SH12-LOADER VALVE AND SENSORS (55.100.DP-C.20.E.12)
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Electrical systems - FAULT CODES
5251 - Loader Bucket Valve (Directional) Solenoid Rollback (A) Supply Open Circuit SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Context: The UCM has sensed an open circuit in the bucket solenoid circuit. Diagnostic Trouble Code 5251 – Loader Bucket Valve (Directional) Solenoid Rollback (A) Supply Open Circuit has an error priority of Red. The bucket functions are disabled while Diagnostic Trouble Code 5251 – Loader Bucket Valve (Directional) Solenoid Rollback (A) Supply Open Circuit is active. Cause: The UCM has sensed an open circuit in the bucket solenoid circuit, X-CN3B (Receptacle) pin 17. The fault is active when the hydraulics are enabled and the calculated solenoid resistance has increased over 70%. Possible failure modes: 1. An open circuit in the solenoid circuit. 2. The bucket valve retract solenoid has failed. 3. The UCM has an internal failure. 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. OK to return the machine to service. B. Fault code 5251 – Loader Bucket Valve (Directional) Solenoid Rollback (A) Supply Open Circuit is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the UCM and the bucket solenoid connections. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the UCM to the bucket solenoids. 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 the connectors as required. Return to step 1 to confirm elimination of fault. 3. Measure the resistance through the solenoid circuit. Turn the ignition switch OFF. Disconnect UCM connectors X-CN3B (Receptacle) and X-CN1A (Receptacle) . Disconnect connector X-025 (Plug) . 48068130 29/01/2018
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Electrical systems - FAULT CODES
Fabricate a jumper wire that will connect between X-CN3B (Receptacle) pin 17 and chassis ground. Connect the jumper wire between X-CN3B (Receptacle) pin 17 and chassis ground. The chassis ground connection must be clean and free of paint, oil, and dirt. Measure the resistance between X-025 (Plug) pin 1 and chassis ground. The resistance should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition. Connect the jumper wire between X-CN1A (Receptacle) pin 13 and chassis ground. The chassis ground connection must be clean and free of paint, oil, and dirt. Measure the resistance between X-025 (Plug) pin 2 and chassis ground. The resistance should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition. A. Both resistance measurements are less than 10 Ω. Go to step 4. B. One or both resistance measurements are 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 the fault. 4. Measure the solenoid resistance. Measure the resistance across the retract solenoid terminals, pin 1 and pin 2. The resistance should be less than 20 Ω. A. The resistance is less than 20 Ω. Go to step 5. B. The resistance is greater than 20 Ω. There is an open circuit in the solenoid. Replace the solenoid and retest. Return to step 1 to confirm elimination of the fault. 5. Measure the resistance through the circuit. Leave UCM connectors X-CN3B (Receptacle) and X-CN1A (Receptacle) disconnected. Fabricate a jumper wire that will connect between X-025 (Plug) pin 1 and X-025 (Plug) pin 2. Connect the jumper wire between X-025 (Plug) pin 1 and X-025 (Plug) pin 2. Measure the resistance between X-CN3B (Receptacle) pin 17 and X-CN1A (Receptacle) pin 13. 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. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. 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 the fault. Wiring harnesses - Electrical schematic sheet 21 SH21-UNIVERSAL CONTROL MODULE (55.100.DP-C.20.E.21) Wiring harnesses - Electrical schematic sheet 12 SH12-LOADER VALVE AND SENSORS (55.100.DP-C.20.E.12)
48068130 29/01/2018
55.21 [55.DTC] / 734
Electrical systems - FAULT CODES
5252 - Loader Bucket Valve (Directional) Solenoid Rollback (A) Supply Shorted To Ground SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Context: The UCM has sensed that the bucket retract solenoid current is too high. Diagnostic Trouble Code 5252 – Loader Bucket Valve (Directional) Solenoid Rollback (A) Supply Shorted To Ground has an error priority of Red. Bucket functions are disabled while Diagnostic Trouble Code 5252 – Loader Bucket Valve (Directional) Solenoid Rollback (A) Supply Shorted To Ground is active. Cause: The UCM has sensed that the bucket retract solenoid current is too high. The fault is active when the hydraulics are enabled and the solenoid output current, X-CN3B (Receptacle) pin 17 is greater than 3 A. Possible failure modes: 1. A short circuit in the solenoid wiring. 2. The bucket valve retract solenoid has failed. 3. The UCM has an internal failure. 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. OK to return the machine to service. B. Fault code 5252 – Loader Bucket Valve (Directional) Solenoid Rollback (A) Supply Shorted To Ground is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the UCM and the bucket solenoid connections. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the UCM to the bucket solenoids. 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. 3. Test the UCM. Turn the ignition switch OFF. Disconnect solenoid connector X-025 (Plug) . Turn the ignition switch ON, activate the hydraulics. 48068130 29/01/2018
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Electrical systems - FAULT CODES
Use the electronic service tool and access the fault code screen. Fault code 5252 – Loader Bucket Valve (Directional) Solenoid Rollback (A) Supply Shorted To Ground should no longer be active. Fault code 5251 – Loader Bucket Valve (Directional) Solenoid Rollback (A) Supply Open Circuit is now active. A. Fault code 5252 – Loader Bucket Valve (Directional) Solenoid Rollback (A) Supply Shorted To Ground is no longer active. Fault code 5251 – Loader Bucket Valve (Directional) Solenoid Rollback (A) Supply Open Circuit is now active. Replace the solenoid and retest. Return to step 1 to confirm elimination of the fault. B. Fault code 5252 – Loader Bucket Valve (Directional) Solenoid Rollback (A) Supply Shorted To Ground is active. Fault code 5251 – Loader Bucket Valve (Directional) Solenoid Rollback (A) Supply Open Circuit did not become active. Go to step 4. 4. Measure the resistance of the solenoid wire to chassis ground. Turn the ignition switch OFF. Leave solenoid connector X-025 (Plug) disconnected. Disconnect UCM connectors X-CN3B (Receptacle) and X-CN1A (Receptacle) . Measure the resistance between X-CN3B (Receptacle) pin 17 and chassis ground. The resistance should be greater than 20,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition. Measure the resistance between X-CN1A (Receptacle) pin 13 and chassis ground. The resistance should be greater than 20,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition. Measure the resistance between X-CN3B (Receptacle) pin 17 and X-CN1A (Receptacle) pin 13. 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 UCM 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 wiring. Repair or replace the harness as required. Return to step 1 to confirm elimination of the fault. Wiring harnesses - Electrical schematic sheet 21 SH21-UNIVERSAL CONTROL MODULE (55.100.DP-C.20.E.21) Wiring harnesses - Electrical schematic sheet 12 SH12-LOADER VALVE AND SENSORS (55.100.DP-C.20.E.12)
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Electrical systems - FAULT CODES
5261 - Loader Bucket Valve (Directional) Solenoid Dump (B) Supply Open Circuit SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Context: The UCM has sensed an open circuit in the bucket solenoid circuit. Diagnostic Trouble Code 5261 – Loader Bucket Valve (Directional) Solenoid Dump (B) Supply Open Circuit has an error priority of Red. The bucket functions are disabled while Diagnostic Trouble Code 5261 – Loader Bucket Valve (Directional) Solenoid Dump (B) Supply Open Circuit is active. Cause: The UCM has sensed an open circuit in the bucket solenoid circuit, X-CN4A (Receptacle) pin 19. The fault is active when the hydraulics are enabled and the calculated solenoid resistance has increased over 70%. Possible failure modes: 1. An open circuit in the solenoid circuit. 2. The bucket valve extend solenoid has failed. 3. The UCM has an internal failure. 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. OK to return the machine to service. B. Fault code 5261 – Loader Bucket Valve (Directional) Solenoid Dump (B) Supply Open Circuit is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the UCM and the bucket solenoid connections. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the UCM to the bucket solenoids. 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 the connectors as required. Return to step 1 to confirm elimination of fault. 3. Measure the resistance through the solenoid circuit. Turn the ignition switch OFF. Disconnect UCM connectors X-CN4A (Receptacle) and X-CN1A (Receptacle) . Disconnect connector X-26. 48068130 29/01/2018
55.21 [55.DTC] / 737
Electrical systems - FAULT CODES
Fabricate a jumper wire that will connect between X-CN4A (Receptacle) pin 19 and chassis ground. Connect the jumper wire between X-CN4A (Receptacle) pin 19 and chassis ground. The chassis ground connection must be clean and free of paint, oil, and dirt. Measure the resistance between X-026 (Plug) pin 1 and chassis ground. The resistance should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition. Connect the jumper wire between X-CN1A (Receptacle) pin 13 and chassis ground. The chassis ground connection must be clean and free of paint, oil, and dirt. Measure the resistance between X-026 (Plug) pin 2 and chassis ground. The resistance should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition. A. Both resistance measurements are less than 10 Ω. Go to step 4. B. One or both resistance measurements are 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 the fault. 4. Measure the solenoid resistance. Measure the resistance across the extend solenoid terminals, pin 1 and pin 2. The resistance should be less than 20 Ω. A. The resistance is less than 20 Ω. Go to step 5. B. The resistance is greater than 20 Ω. There is an open circuit in the solenoid. Replace the solenoid and retest. Return to step 1 to confirm elimination of the fault. 5. Measure the resistance through the circuit. Leave UCM connectors X-CN4A (Receptacle) and X-CN1A (Receptacle) disconnected. Fabricate a jumper wire that will connect between X-026 (Plug) pin 1 and X-026 (Plug) pin 2. Connect the jumper wire between X-026 (Plug) pin 1 and X-026 (Plug) pin 2. Measure the resistance between X-CN4A (Receptacle) pin 19 and X-CN1A (Receptacle) pin 13. 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. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. 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 the fault. Wiring harnesses - Electrical schematic sheet 21 SH21-UNIVERSAL CONTROL MODULE (55.100.DP-C.20.E.21) Wiring harnesses - Electrical schematic sheet 12 SH12-LOADER VALVE AND SENSORS (55.100.DP-C.20.E.12)
48068130 29/01/2018
55.21 [55.DTC] / 738
Electrical systems - FAULT CODES
5262 - Loader Bucket Valve (Directional) Solenoid Dump (B) Supply Shorted To Ground SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Context: The UCM has sensed that the bucket extend solenoid current is too high. Diagnostic Trouble Code 5262 – Loader Bucket Valve (Directional) Solenoid Dump (B) Supply Shorted To Ground has an error priority of Red. Bucket functions are disabled while Diagnostic Trouble Code 5262 – Loader Bucket Valve (Directional) Solenoid Dump (B) Supply Shorted To Ground is active. Cause: The UCM has sensed that the bucket extend solenoid current is too high. The fault is active when hydraulics are enabled and solenoid output current, X-CN4A (Receptacle) pin 19 is greater than 3 A. Possible failure modes: 1. A short circuit in the solenoid wiring. 2. The bucket valve solenoid has failed. 3. The UCM has an internal failure. 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. OK to return the machine to service. B. Fault code 5262 – Loader Bucket Valve (Directional) Solenoid Dump (B) Supply Shorted To Ground is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the UCM and the bucket solenoid connections. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the UCM to the bucket solenoids. 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 the connectors as required. Return to step 1 to confirm elimination of fault. 3. Test the UCM. Turn the ignition switch OFF. Disconnect solenoid connector X-026 (Plug) . Turn the ignition switch ON, activate the hydraulics. 48068130 29/01/2018
55.21 [55.DTC] / 739
Electrical systems - FAULT CODES
Use the electronic service tool and access the fault code screen. Fault code 5262 – Loader Bucket Valve (Directional) Solenoid Dump (B) Supply Shorted To Ground should no longer be active. Fault code 5261 – Loader Bucket Valve (Directional) Solenoid Dump (B) Supply Open Circuit is now active. A. Fault code 5262 – Loader Bucket Valve (Directional) Solenoid Dump (B) Supply Shorted To Ground is no longer active. Fault code 5261 – Loader Bucket Valve (Directional) Solenoid Dump (B) Supply Open Circuit is now active. Replace the solenoid and retest. Return to step 1 to confirm elimination of the fault. B. Fault code 5262 – Loader Bucket Valve (Directional) Solenoid Dump (B) Supply Shorted To Ground is active. Fault code 5261 – Loader Bucket Valve (Directional) Solenoid Dump (B) Supply Open Circuit did not become active. Go to step 4. 4. Measure the resistance of the solenoid wire to chassis ground. Turn the ignition switch OFF. Leave solenoid connector X-026 (Plug) disconnected. Disconnect UCM connectors X-CN4A (Receptacle) and X-CN1A (Receptacle) . Measure the resistance between X-CN4A (Receptacle) pin 19 and chassis ground. The resistance should be greater than 20,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition. Measure the resistance between X-CN1A (Receptacle) pin 13 and chassis ground. The resistance should be greater than 20,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition. Measure the resistance between X-CN4A (Receptacle) pin 19 and X-CN1A (Receptacle) pin 13. 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 UCM 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 wiring. Repair or replace the harness as required. Return to step 1 to confirm elimination of the fault. Wiring harnesses - Electrical schematic sheet 21 SH21-UNIVERSAL CONTROL MODULE (55.100.DP-C.20.E.21) Wiring harnesses - Electrical schematic sheet 12 SH12-LOADER VALVE AND SENSORS (55.100.DP-C.20.E.12)
48068130 29/01/2018
55.21 [55.DTC] / 740
Electrical systems - FAULT CODES
5271 - Loader Bucket Valve (Directional) Loader Bucket Solenoid(s) Shorted To Power SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Context: The UCM has sensed higher than normal voltage on the bucket solenoid lines. Fault code 5271 – Loader Bucket Valve (Directional) Loader Bucket Solenoid(s) Shorted To Power has an error priority of Red. Bucket functions are disabled while Diagnostic Trouble Code 5271 – Loader Bucket Valve (Directional) Loader Bucket Solenoid(s) Shorted To Power is active. Cause: The UCM has sensed higher than normal voltage on the bucket solenoid lines, X-CN3B (Receptacle) pin 17, X-CN4A (Receptacle) pin 19, and X-CN1A (Receptacle) pin 13. The fault is active when hydraulics are disabled and the solenoid voltage feedback is greater than 5 V. Possible failure modes: 1. A short circuit in the signal wire to another voltage source. 2. The UCM has an internal failure. 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. OK to return the machine to service. B. Fault code 5271 – Loader Bucket Valve (Directional) Loader Bucket Solenoid(s) Shorted To Power is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the UCM and the bucket solenoid connections. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the UCM to the bucket solenoids. 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. 3. Measure the voltage on the signal wires. Turn the ignition switch OFF. Disconnect UCM connectors X-CN3B (Receptacle) , X-CN1A (Receptacle) , and X-CN4A (Receptacle) . Turn the ignition switch ON.
48068130 29/01/2018
55.21 [55.DTC] / 741
Electrical systems - FAULT CODES
Measure the voltage between X-CN3B (Receptacle) pin 17 and chassis ground. The voltage should be less than 0.5 V. Wiggle the harness to reveal an intermittent condition. Measure the voltage between X-CN1A (Receptacle) pin 13 and chassis ground. The voltage should be less than 0.5 V. Wiggle the harness to reveal an intermittent condition. Measure the voltage between X-CN4A (Receptacle) pin 19 and chassis ground. The voltage should be less than 0.5 V. Wiggle the harness to reveal an intermittent condition. A. All measured voltages are less than 0.5 V. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. B. One or more of the voltage measurements are greater than 0.5 V. There is a short circuit to another voltage source. Repair or replace the harness or connectors as required. Return to step 1 to confirm elimination of fault. Wiring harnesses - Electrical schematic sheet 20 SH20-UNIVERSAL CONTROL MODULE (55.100.DP-C.20.E.20) Wiring harnesses - Electrical schematic sheet 21 SH21-UNIVERSAL CONTROL MODULE (55.100.DP-C.20.E.21) Wiring harnesses - Electrical schematic sheet 12 SH12-LOADER VALVE AND SENSORS (55.100.DP-C.20.E.12)
48068130 29/01/2018
55.21 [55.DTC] / 742
Electrical systems - FAULT CODES
5272 - Loader Bucket Valve (Directional) Loader Bucket Solenoid(s) Shorted To Ground SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Context: The UCM has sensed a lower than normal voltage on the bucket solenoid lines. Fault code 5272 – Loader Bucket Valve (Directional) Loader Bucket Solenoid(s) Shorted To Ground has an error priority of Red. Bucket functions are disabled while Diagnostic Trouble Code 5272 – Loader Bucket Valve (Directional) Loader Bucket Solenoid(s) Shorted To Ground is active. Cause: The UCM has sensed that the voltage on the loader solenoid lines, X-CN3B (Receptacle) pin 17, X-CN4A (Receptacle) pin 19, and X-CN1A (Receptacle) pin 13 is too low. The fault is active when hydraulics are disabled and the solenoid feedback voltage is less than 2 V. Possible failure modes: 1. A short circuit in the signal wire to chassis ground. 2. The UCM has an internal failure. 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. OK to return the machine to service. B. Fault code 5272 – Loader Bucket Valve (Directional) Loader Bucket Solenoid(s) Shorted To Ground is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the UCM and the bucket solenoid connections. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the UCM to the bucket solenoids. 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 the connectors as required. Return to step 1 to confirm elimination of fault. 3. Measure the resistance of the solenoid wire to chassis ground. Turn the ignition switch OFF. Disconnect UCM connectors X-CN3B (Receptacle) , X-CN4A (Receptacle) , and X-CN1A (Receptacle) . Disconnect solenoid connectors, X-025 (Plug) and X-026 (Plug) .
48068130 29/01/2018
55.21 [55.DTC] / 743
Electrical systems - FAULT CODES
Measure the resistance between X-CN3B (Receptacle) pin 17 and chassis ground. The resistance should be greater than 20,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition. Measure the resistance between X-CN4A (Receptacle) pin 19 and chassis ground. The resistance should be greater than 20,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition. Measure the resistance between X-CN1A (Receptacle) pin 13 and chassis ground. The resistance should be greater than 20,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition. Measure the resistance between X-CN3B (Receptacle) pin 17 and X-CN1A (Receptacle) pin 13. The resistance should be greater than 20,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition. Measure the resistance between X-CN4A (Receptacle) pin 19 and X-CN1A (Receptacle) pin 13. The resistance should be greater than 20,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition. A. All resistance measurements are greater than 20,000 Ω. Go to step 4. B. One or more resistance measurements are less than 20,000 Ω. There is a short circuit in the wiring. Repair or replace the harness as required. Return to step 1 to confirm elimination of the fault. 4. Measure the resistance through the solenoid. Disconnect connector X-025 (Plug) and X-026 (Plug) . Measure the resistance across the bucket extend solenoid terminals. The resistance should be greater than 1 Ω. Measure the resistance across the bucket retract solenoid terminals. The resistance should be greater than 1 Ω. A. Both resistance measurements are greater than 1 Ω. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. B. One or both resistance measurements are less than 1 Ω. There is a short circuit in the solenoid. Replace the solenoid as required. Return to step 1 to confirm elimination of the fault. Wiring harnesses - Electrical schematic sheet 20 SH20-UNIVERSAL CONTROL MODULE (55.100.DP-C.20.E.20) Wiring harnesses - Electrical schematic sheet 21 SH21-UNIVERSAL CONTROL MODULE (55.100.DP-C.20.E.21) Wiring harnesses - Electrical schematic sheet 12 SH12-LOADER VALVE AND SENSORS (55.100.DP-C.20.E.12)
48068130 29/01/2018
55.21 [55.DTC] / 744
Electrical systems - FAULT CODES
5273 - Loader Bucket Valve (Directional) Solenoids Return Open Circuit SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Context: The UCM has sensed an open circuit in the bucket solenoid return circuit. Diagnostic Trouble Code 5273 – Loader Bucket Valve (Directional) Solenoids Return Open Circuit has an error priority of Red. The bucket functions are disabled while Diagnostic Trouble Code 5273 – Loader Bucket Valve (Directional) Solenoids Return Open Circuit is active. Cause: The UCM has sensed an open circuit in the loader solenoid return circuit, X-CN1A (Receptacle) pin 13. The fault is active when the ignition is ON and the calculated solenoid resistances have increased over 70%. Possible failure modes: 1. An open circuit in the solenoid return wiring. 2. The bucket solenoids have failed. 3. The UCM has an internal failure. 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. OK to return the machine to service. B. Fault code 5273 – Loader Bucket Valve (Directional) Solenoids Return Open Circuit is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the UCM and the bucket solenoid connections. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the UCM to the bucket solenoids. 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 the connectors as required. Return to step 1 to confirm elimination of fault. 3. Measure the resistance through the solenoid circuit. Turn the ignition switch OFF. Disconnect UCM connectors X-CN3B (Receptacle) , X-CN1A (Receptacle) , and X-CN4A (Receptacle) .
48068130 29/01/2018
55.21 [55.DTC] / 745
Electrical systems - FAULT CODES
Measure the resistance between X-CN3B (Receptacle) pin 17 and X-CN1A (Receptacle) pin 13. The resistance should be less than 100 Ω. Wiggle the harness during measurement to reveal an intermittent condition. Measure the resistance between X-CN4A (Receptacle) pin 19 and X-CN1A (Receptacle) pin 13. The resistance should be less than 100 Ω. Wiggle the harness during measurement to reveal an intermittent condition. A. Both resistance measurements are less than 100 Ω. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. B. One or both resistance are greater than 100 Ω. There is an open circuit in the wiring. Go to step 4. 4. Measure the solenoid resistance. Measure the resistance across the extend solenoid terminals, pin 1 and pin 2. The resistance should be less than 20 Ω. Measure the resistance across the retract solenoid terminals, pin 1 and pin 2. The resistance should be less than 20 Ω. A. The resistance is less than 20 Ω. Go to step 5. B. The resistance is greater than 20 Ω. There is an open circuit in the solenoid. Replace the solenoid and retest. Return to step 1 to confirm elimination of the fault. 5. Measure the resistance through the circuit. Leave UCM connectors X-CN3B (Receptacle) , X-CN1A (Receptacle) , and X-CN4A (Receptacle) disconnected. Fabricate a jumper wire that will connect between X-025 (Plug) pin 1 and X-025 (Plug) pin 2. Connect the jumper wire between X-025 (Plug) pin 1 and X-025 (Plug) pin 2. Measure the resistance between X-CN3B (Receptacle) pin 17 and X-CN1A (Receptacle) pin 13. The resistance should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition. Remove the jumper from X-025 (Plug) . Connect the jumper wire between X-026 (Plug) pin 1 and X-026 (Plug) pin 2. Measure the resistance between X-CN4A (Receptacle) pin 19 and X-CN1A (Receptacle) pin 13. 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. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. 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 the fault. Wiring harnesses - Electrical schematic sheet 20 SH20-UNIVERSAL CONTROL MODULE (55.100.DP-C.20.E.20) Wiring harnesses - Electrical schematic sheet 21 SH21-UNIVERSAL CONTROL MODULE (55.100.DP-C.20.E.21) Wiring harnesses - Electrical schematic sheet 12 SH12-LOADER VALVE AND SENSORS (55.100.DP-C.20.E.12)
48068130 29/01/2018
55.21 [55.DTC] / 746
Electrical systems - FAULT CODES
5281 - Loader Auxiliary Valve (Directional) Solenoid Forward (A) Supply Open Circuit SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Context: The UCM has sensed an open circuit in the proportional aux extend solenoid circuit. Diagnostic Trouble Code 5281 – Loader Auxiliary Valve (Directional) Solenoid Forward (A) Supply Open Circuit has an error priority of White. Auxiliary hydraulic functions are disabled while Diagnostic Trouble Code 5281 – Loader Auxiliary Valve (Directional) Solenoid Forward (A) Supply Open Circuit is active. Cause: The UCM has sensed an open circuit in the proportional aux extend solenoid circuit, X-CN1B (Receptacle) pin 33 and X-CN1A (Receptacle) pin 22. The fault is active when the ignition is ON and the calculated solenoid resistance has increased over 70%. Possible failure modes: 1. An open circuit in the wiring. 2. The proportional aux extend solenoid has failed. 3. The UCM has an internal failure. 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. OK to return the machine to service. B. Fault code 5281 – Loader Auxiliary Valve (Directional) Solenoid Forward (A) Supply Open Circuit is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the UCM and the proportional aux solenoid connections. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the UCM to the proportional aux solenoids. 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 the connectors as required. Return to step 1 to confirm elimination of fault. 3. Measure the resistance through the solenoid circuit. Turn the ignition switch OFF. Disconnect UCM connector X-CN1A (Receptacle) .
48068130 29/01/2018
55.21 [55.DTC] / 747
Electrical systems - FAULT CODES
Disconnect UCM connector X-CN1B (Receptacle) . Measure the resistance between X-CN1B (Receptacle) pin 33 and X-CN1A (Receptacle) pin 22. The resistance should be less than 100 Ω. Wiggle the harness during measurement to reveal an intermittent condition. A. The resistance is less than 100 Ω. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. B. The resistance is greater than 100 Ω. There is an open circuit. Go to step 4. 4. Measure the solenoid resistance. Measure the resistance across the solenoid terminals pin 1 and pin 2. The resistance should be less than 100 Ω. A. The resistance is less than 100 Ω. Go to step 5. B. The resistance is greater than 100 Ω. There is an open circuit in the solenoid. Replace the solenoid and retest. Return to step 1 to confirm elimination of the fault. 5. Measure the resistance through the circuit. Leave UCM connectors X-CN1A (Receptacle) and X-CN1B (Receptacle) disconnected. Fabricate a jumper wire that will connect between X-024 (Plug) pin 1 and X-024 (Plug) pin 2. Connect the jumper wire between X-024 (Plug) pin 1 and X-024 (Plug) pin 2. Measure the resistance between X-CN1B (Receptacle) pin 33 and X-CN1A (Receptacle) pin 22. 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. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. 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 the fault. Wiring harnesses - Electrical schematic sheet 20 SH20-UNIVERSAL CONTROL MODULE (55.100.DP-C.20.E.20) Wiring harnesses - Electrical schematic sheet 12 SH12-LOADER VALVE AND SENSORS (55.100.DP-C.20.E.12)
48068130 29/01/2018
55.21 [55.DTC] / 748
Electrical systems - FAULT CODES
5282 - Loader Auxiliary Valve (Directional) Solenoid Forward (A) Supply Shorted To Ground SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Context: The UCM has sensed that the proportional aux extend solenoid current is too high. Diagnostic Trouble Code 5282 – Loader Auxiliary Valve (Directional) Solenoid Forward (A) Supply Shorted To Ground has an error priority of White. Auxiliary hydraulic functions are disabled while Diagnostic Trouble Code 5282 – Loader Auxiliary Valve (Directional) Solenoid Forward (A) Supply Shorted To Ground is active. Cause: The UCM has sensed that the proportional aux extend solenoid current is too high. The fault is active when the hydraulics are enabled and the solenoid output current, X-CN1B (Receptacle) pin 33 is greater than 3 A. Possible failure modes: 1. A short circuit in the solenoid wiring. 2. A failure of the proportional aux extend solenoid. 3. The UCM has an internal failure. 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. OK to return the machine to service. B. Fault code 5282 – Loader Auxiliary Valve (Directional) Solenoid Forward (A) Supply Shorted To Ground is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the UCM and the proportional aux solenoid connections. All connections should be secure, tight, free of corrosion, abrasion and damage. Inspect the harness from the UCM to the proportional aux solenoids. 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 the connectors as required. Return to step 1 to confirm elimination of fault. 3. Test the UCM. Turn the ignition switch OFF. Disconnect solenoid connector X-024 (Plug) .
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Electrical systems - FAULT CODES
Turn the ignition switch ON. Use the electronic service tool and access the fault code screen. Fault code 5282 – Loader Auxiliary Valve (Directional) Solenoid Forward (A) Supply Shorted To Ground should no longer be active. Fault code 5281 – Loader Auxiliary Valve (Directional) Solenoid Forward (A) Supply Open Circuit is now active. A. Fault code 5282 – Loader Auxiliary Valve (Directional) Solenoid Forward (A) Supply Shorted To Ground is no longer active. Fault code 5281 – Loader Auxiliary Valve (Directional) Solenoid Forward (A) Supply Open Circuit is now active. Replace the solenoid and retest. Return to step 1 to confirm elimination of the fault. B. Fault code 5282 – Loader Auxiliary Valve (Directional) Solenoid Forward (A) Supply Shorted To Ground is active. Fault code 5281 – Loader Auxiliary Valve (Directional) Solenoid Forward (A) Supply Open Circuit did not become active. Go to step 4. 4. Measure the resistance of the solenoid wire to chassis ground. Turn the ignition switch OFF. Disconnect UCM connector X-CN1A (Receptacle) . Disconnect UCM connector X-CN1B (Receptacle) . Measure the resistance between X-CN1B (Receptacle) pin 33 and chassis ground. The resistance should be greater than 20,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition. Measure the resistance between X-CN1A (Receptacle) pin 22 and chassis ground. The resistance should be greater than 20,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition. Measure the resistance between X-CN1B (Receptacle) pin 33 and X-CN1A (Receptacle) pin 22. 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 UCM 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 wiring. Repair or replace the harness as required. Return to step 1 to confirm elimination of the fault. Wiring harnesses - Electrical schematic sheet 20 SH20-UNIVERSAL CONTROL MODULE (55.100.DP-C.20.E.20) Wiring harnesses - Electrical schematic sheet 12 SH12-LOADER VALVE AND SENSORS (55.100.DP-C.20.E.12)
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55.21 [55.DTC] / 750
Electrical systems - FAULT CODES
5291 - Loader Auxiliary Valve (Directional) Solenoid Reverse (B) Supply Open Circuit SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Context: The UCM has sensed an open circuit in the proportional aux retract solenoid circuit. Diagnostic Trouble Code 5291 – Loader Auxiliary Valve (Directional) Solenoid Reverse (B) Supply Open Circuit has an error priority of White. Auxiliary hydraulic functions are disabled while Diagnostic Trouble Code 5291 – Loader Auxiliary Valve (Directional) Solenoid Reverse (B) Supply Open Circuit is active. Cause: The UCM has sensed an open circuit in the proportional aux retract solenoid circuit, X-CN1A (Receptacle) pin 24 and X-CN1A (Receptacle) pin 22. The fault is active when the ignition is ON and the calculated solenoid resistance has increased over 70%. Possible failure modes: 1. An open circuit in the wiring. 2. The proportional aux retract solenoid has failed. 3. The UCM has an internal failure. 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. OK to return the machine to service. B. Fault code 5291 – Loader Auxiliary Valve (Directional) Solenoid Reverse (B) Supply Open Circuit is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the UCM and the proportional aux solenoid connections. All connections should be secure, tight, free of corrosion, abrasion and damage. Inspect the harness from the UCM to the proportional aux solenoids. 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 the connectors as required. Return to step 1 to confirm elimination of fault. 3. Measure the resistance through the solenoid circuit. Turn the ignition switch OFF. Disconnect UCM connector X-CN1A (Receptacle) .
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Measure the resistance between X-CN1A (Receptacle) pin 24 and X-CN1A (Receptacle) pin 22. The resistance should be less than 100 Ω. Wiggle the harness during measurement to reveal an intermittent condition. A. The resistance is less than 100 Ω. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. B. The resistance is greater than 100 Ω. There is an open circuit. Go to step 4. 4. Measure the solenoid resistance. Measure the resistance across the solenoid terminals pin 1 and pin 2. The resistance should be less than 100 Ω. A. The resistance is less than 100 Ω. Go to step 5. B. The resistance is greater than 100 Ω. There is an open circuit in the solenoid. Replace the solenoid and retest. Return to step 1 to confirm elimination of the fault. 5. Measure the resistance through the circuit. Leave UCM connector X-CN1A (Receptacle) disconnected. Fabricate a jumper wire that will connect between X-029 (Plug) pin 1 and X-029 (Plug) pin 2. Connect the jumper wire between X-029 (Plug) pin 1 and X-029 (Plug) pin 2. Measure the resistance between X-CN1A (Receptacle) pin 24 and X-CN1A (Receptacle) pin 22. 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. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. 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 the fault. Wiring harnesses - Electrical schematic sheet 20 SH20-UNIVERSAL CONTROL MODULE (55.100.DP-C.20.E.20) Wiring harnesses - Electrical schematic sheet 12 SH12-LOADER VALVE AND SENSORS (55.100.DP-C.20.E.12)
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Electrical systems - FAULT CODES
5292 - Loader Auxiliary Valve (Directional) Solenoid Reverse (B) Supply Shorted To Ground SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Context: The UCM has sensed that the proportional aux valve retract solenoid current is too high. Diagnostic Trouble Code 5292 – Loader Auxiliary Valve (Directional) Solenoid Reverse (B) Supply Shorted To Ground has an error priority of White. Auxiliary hydraulic functions are disabled while Diagnostic Trouble Code 5292 – Loader Auxiliary Valve (Directional) Solenoid Reverse (B) Supply Shorted To Ground is active. Cause: The UCM has sensed that the proportional aux valve retract solenoid current is too high. The fault is active when hydraulics are enabled and solenoid output current, X-CN1A (Receptacle) pin 24 is greater than 3 A. Possible failure modes: 1. A short circuit in the solenoid wiring. 2. A failure of the proportional aux retract solenoid. 3. The UCM has an internal failure. 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. OK to return the machine to service. B. Fault code 5292 – Loader Auxiliary Valve (Directional) Solenoid Reverse (B) Supply Shorted To Ground is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the UCM and the proportional aux solenoid connections. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the UCM to the proportional aux solenoids. 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 the connectors as required. Return to step 1 to confirm elimination of fault. 3. Test the UCM. Turn the ignition switch OFF. Disconnect solenoid connector X-029 (Plug) .
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Electrical systems - FAULT CODES
Turn the ignition switch ON. Use the electronic service tool to access the fault code screen. Fault code 5292 – Loader Auxiliary Valve (Directional) Solenoid Reverse (B) Supply Shorted To Ground should no longer be active. Fault code 5291 – Loader Auxiliary Valve (Directional) Solenoid Reverse (B) Supply Open Circuit is now active. A. Fault code 5292 – Loader Auxiliary Valve (Directional) Solenoid Reverse (B) Supply Shorted To Ground is no longer active. Fault code 5291 – Loader Auxiliary Valve (Directional) Solenoid Reverse (B) Supply Open Circuit is now active. Replace the solenoid and retest. Return to step 1 to confirm elimination of the fault. B. Fault code 5292 – Loader Auxiliary Valve (Directional) Solenoid Reverse (B) Supply Shorted To Ground is active. Fault code 5291 – Loader Auxiliary Valve (Directional) Solenoid Reverse (B) Supply Open Circuit did not become active. Go to step 4. 4. Measure the resistance of the solenoid wire to chassis ground. Turn the ignition switch OFF. Disconnect UCM connector X-CN1A (Receptacle) . Disconnect solenoid connector X-029 (Plug) . Measure the resistance between X-CN1A (Receptacle) pin 24 and chassis ground. The resistance should be greater than 20,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition. Measure the resistance between X-CN1A (Receptacle) pin 22 and chassis ground. The resistance should be greater than 20,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition. Measure the resistance between X-CN1A (Receptacle) pin 24 and X-CN1A (Receptacle) pin 22. 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 UCM 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 wiring. Repair or replace the harness as required. Return to step 1 to confirm elimination of the fault. Wiring harnesses - Electrical schematic sheet 20 SH20-UNIVERSAL CONTROL MODULE (55.100.DP-C.20.E.20) Wiring harnesses - Electrical schematic sheet 12 SH12-LOADER VALVE AND SENSORS (55.100.DP-C.20.E.12)
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Electrical systems - FAULT CODES
5309 - Float Button - Float Button Timeout (30 sec) SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Context: UCM has sensed that the float switch signal has been ON for more than 30 s. Diagnostic Trouble Code 5309 – Float Button - Float Button Timeout (30 sec) has an error priority of White. Loader float feature is disabled while Diagnostic Trouble Code 5309 – Float Button - Float Button Timeout (30 sec) is active. Cause: The UCM has sensed that the float switch input signal, X-CN2B (Receptacle) pin 27 has been high for more than 30 s. Possible failure modes: 1. A short circuit to another voltage source. 2. A failure of the float switch. 3. A failure of the UCM. 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. OK to return the machine to service. B. Fault code 5309 – Float Button - Float Button Timeout (30 sec) is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the UCM and the float switch connections on the right joystick. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the UCM to the float switch on the right joystick. 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 the connectors as required. Return to step 1 to confirm elimination of fault. 3. Measure the resistance through the float switch. Turn the ignition switch OFF. Disconnect connector X-403 (Receptacle) from the right joystick. Measure the resistance between X-403 (Receptacle) pin 13 and X-403 (Receptacle) pin 14. The resistance should be greater than 20,000 Ω.
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Electrical systems - FAULT CODES
Actuate the float switch while measuring the resistance between X-403 (Receptacle) pin 13 and X-403 (Receptacle) pin 14. The resistance should be less than 10 Ω while the float switch is activated. A. The resistance is greater than 20,000 Ω when the switch is in the open (not actuated) position and the resistance is less than 10 Ω while the float switch is actuated. Go to step 4. B. The resistance is less than 10 Ω when the switch is in the open (not actuated) position and the resistance is less than 10 Ω while the float switch is actuated. There is a short circuit in the float switch, temporarily replace the right joystick and retest. Return to step 1 to confirm elimination of the fault. 4. Measure the voltage on the signal wire. Turn the ignition switch OFF. Disconnect UCM connector X-CN2B (Receptacle) . Reconnect the right joystick connector X-403 (Receptacle) . Turn the ignition switch ON. Measure the voltage between X-CN2B (Receptacle) pin 27 and chassis ground. The voltage should be less than 0.5 V. Wiggle the harness during measurement to reveal an intermittent condition. A. The voltage is less than 0.5 V. Temporarily replace the UCM 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 to another voltage source. Repair or replace the harness as required. Return to step 1 to confirm elimination of the fault. Wiring harnesses - Electrical schematic sheet 20 SH20-UNIVERSAL CONTROL MODULE (55.100.DP-C.20.E.20) Wiring harnesses - Electrical schematic sheet 14 SH14-BULKHEAD CONNECTION (55.100.DP-C.20.E.14) Wiring harnesses - Electrical schematic sheet 18 SH18-RIGHT NH CONTROL HANDLE (55.100.DP-C.20.E.18)
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Electrical systems - FAULT CODES
5313 - EHF Enable Switch STP SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Context: The UCM has sensed the voltage on the EHF enable input, X-CN3B (Receptacle) pin 11, is greater than 3.5 V. Diagnostic Trouble Code 5313 – EHF Enable Switch STP has an error priority of White. The EHF functions are disabled while Diagnostic Trouble Code 5313 – EHF Enable Switch STP is active. Cause: The UCM has sensed the voltage on the EHF enable input, X-CN3B (Receptacle) pin 11 is greater than 3.5 V. Possible failure modes: 1. A short circuit in the wiring. 2. A faulty EHF switch. 3. The UCM has internal failure. 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. OK to return the machine to service. B. Fault code 5313 – EHF Enable Switch STP is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the UCM and the EHF switch connections. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the UCM to the EHF 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 the connectors as required. Return to step 1 to confirm elimination of fault. 3. Measure the voltage at the switch inputs to the UCM. Turn the ignition switch OFF. Remove the EHF switch from the left-hand post. Disconnect connector X-303 from the EHF switch. Disconnect UCM connector X-CN3B. Turn the ignition switch ON.
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Electrical systems - FAULT CODES
Measure the voltage between X-303 pin A and chassis ground. The voltage should be less than 0.5 V. Wiggle the harness during measurement to reveal an intermittent condition. A. The voltage is less than 0.5 V. Go to step 4. B. The voltage is greater than 0.5 V. There is a short circuit to another voltage source. Repair as required. Return to step 1 to confirm elimination of fault. 4. Measure the resistance through the signal wire. Fabricate a jumper wire that will connect between connector X-CN3B (Receptacle) pin 11 and chassis ground. Connect the jumper wire between connector X-CN3B (Receptacle) pin 11 and chassis ground. The chassis ground connection must be clean and free of rust, dirt oil and paint. Measure the resistance between connector X-303 pin A and chassis ground. 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 5. B. The resistance is greater than 10 Ω. There is an open circuit in the signal wire. Repair or replace the harness as required. Return to step 1 to confirm elimination of fault. 5. Test the UCM. Turn the ignition switch OFF. Remove the jumper wire that is connected between connector X-CN3B (Receptacle) pin 11 and chassis ground. Reconnect UCM connector X-CN3B. Fabricate a jumper wire that will connect between connector X-303 pin A and positive battery. Connect the jumper wire between connector X-303 pin A and positive battery. Turn the ignition switch ON. Use the Electronic Service Tool to monitor the switch status. The switch status should read that the EHF switch is ON. The switch status should read ON while the jumper wire is connected and OFF when it is disconnected. A. The switch status reads ON while the jumper wire is connected and OFF when it is disconnected. Replace the EHF switch and retest. Return to step 1 to confirm elimination of fault. B. The EHF switch status reads OFF when the jumper wire is connected. The EHF switch status reads OFF when the jumper wire is not connected. Replace the UCM and retest. Return to step 1 to confirm elimination of fault. Wiring harnesses - Electrical schematic sheet 20 SH20-UNIVERSAL CONTROL MODULE (55.100.DP-C.20.E.20) Wiring harnesses - Electrical schematic sheet 12 SH12-LOADER VALVE AND SENSORS (55.100.DP-C.20.E.12)
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Electrical systems - FAULT CODES
5323 - EHF Fwd/Rev Switch STP SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Context: The UCM has sensed the voltage on the switch input of the 2nd aux hydraulic,CN3B pin 29 and CN3B pin 31 is greater than 3.5 V. Diagnostic Trouble Code 5323 – EHF Fwd/Rev Switch STP has an error priority of White. The EHF functions are disabled while Diagnostic Trouble Code 5323 – EHF Fwd/Rev Switch STP is active. Cause: The UCM has sensed the voltage on the switch input of the 2nd aux hydraulic, CN3B pin 29 and CN3B pin 31 is greater than 3.5 V. Possible failure modes: 1. A short circuit in the wiring. 2. A faulty 2nd aux hydraulic switch. 3. The UCM has internal failure. 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. OK to return the machine to service. B. Fault code 5323 – EHF Fwd/Rev Switch STP is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the UCM and the 2nd aux hydraulic switch connections. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the UCM to the 2nd aux hydraulic 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 the connectors as required. Return to step 1 to confirm elimination of fault. 3. Measure the voltage at the switch inputs to the UCM. Turn the ignition switch OFF. Disconnect connector X-408 from the left control handle. Disconnect UCM connector X-CN3B. Disconnect the 2nd aux connector X-AUX_EXT and X-AUX_RET. Turn the ignition switch ON. 48068130 29/01/2018
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Measure the voltage between X-408 (Plug) pin 2 and chassis ground. The voltage should be less than 0.5 V. Wiggle the harness during measurement to reveal an intermittent condition. Measure the voltage between X-408 (Plug) pin 3 and chassis ground. The voltage should be less than 0.5 V. Wiggle the harness during measurement to reveal an intermittent condition. Measure the voltage between X-AUX_RET (Receptacle) pin 1 and chassis ground. The voltage should be less than 0.5 V. Wiggle the harness during measurement to reveal an intermittent condition. Measure the voltage between X-AUX_EXT (Receptacle) pin 1 and chassis ground. The voltage should be less than 0.5 V. Wiggle the harness during measurement to reveal an intermittent condition. A. The voltage is less than 0.5 V. Go to step 4. B. The voltage is greater than 0.5 V. There is a short circuit to another voltage source. Repair as required. Return to step 1 to confirm elimination of fault. 4. Measure the resistance through the signal wire. Fabricate a jumper wire that will connect between connector CN3B pin 29 and CN3B pin 31. Connect the jumper wire between connector CN3B pin 29 and CN3B pin 31. Measure the resistance between connector X-408 (Plug) pin 2 and X-408 (Plug) pin 3. The resistance should be less than 10 立. Wiggle the harness during measurement to reveal an intermittent condition. Measure the resistance between connector X-AUX_RET (Receptacle) pin 1 and X-AUX_EXT (Receptacle) pin 1. The resistance should be less than 10 立. Wiggle the harness during measurement to reveal an intermittent condition. A. The resistance is less than 10 立. Go to step 5. B. The resistance is greater than 10 立. There is an open circuit in the signal wire. Repair or replace the harness as required. Return to step 1 to confirm elimination of fault. 5. Test the UCM. Turn the ignition switch OFF. Remove the jumper wire that is connected between connector CN3B pin 29 and CN3B pin 31. Reconnect UCM connector X-CN3B. Fabricate a jumper wire that will connect between connector X-408 (Plug) pin 2 and positive battery. Connect the jumper wire between connector X-408 (Plug) pin 2 and positive battery. Turn the ignition switch ON. Use the Electronic Service Tool to monitor the switch status. The switch status for the extend solenoid of the 2nd aux hydraulics should read ON. The switch status for the extend solenoid of the 2nd aux hydraulics should read ON while the jumper wire is connected and OFF when it is disconnected. Turn the ignition switch OFF. Connect the jumper wire between connector X-408 (Plug) pin 3 and positive battery. Turn the ignition switch ON. Use the Electronic Service Tool to monitor the switch status. The switch status for the retract solenoid of the 2nd aux hydraulics should read ON. The switch status for the retract solenoid of the 2nd aux hydraulics should read ON while the jumper wire is connected and OFF when it is disconnected. 48068130 29/01/2018
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A. The switch status reads ON while the jumper wire is connected and OFF when it is disconnected. Replace the left joystick module and retest. Return to step 1 to confirm elimination of fault. B. The 2nd aux switch status reads OFF when the jumper wire is connected. The 2nd aux switch status reads OFF when the jumper wire is not connected. Replace the UCM and retest. Return to step 1 to confirm elimination of fault. Wiring harnesses - Electrical schematic sheet 20 SH20-UNIVERSAL CONTROL MODULE (55.100.DP-C.20.E.20) Wiring harnesses - Electrical schematic sheet 12 SH12-LOADER VALVE AND SENSORS (55.100.DP-C.20.E.12)
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Electrical systems - FAULT CODES
5371 - EHF Forward Solenoid (A) Supply STG SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Context: The UCM has sensed a short circuit in the EHF forward solenoid circuit. Diagnostic Trouble Code 5371 – EHF Forward Solenoid (A) Supply STG has an error priority of White. The EHF function is disabled while Diagnostic Trouble Code 5371 – EHF Forward Solenoid (A) Supply STG is active. Cause: The UCM has sensed a short circuit condition in the EHF forward solenoid, CN3A pin 19. The fault is active when the EHF function is active, the hydraulics are enabled, and the solenoid current is below normal. Possible failure modes: 1. A short circuit in the wiring. 2. A failure of the EHF forward solenoid. 3. A faulty UCM. 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. OK to return the machine to service. B. Fault code 5371 – EHF Forward Solenoid (A) Supply STG is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the UCM and the EHF forward solenoid connections. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the UCM to the EHF forward solenoid. 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 the connectors as required. Return to step 1 to confirm elimination of fault. 3. Measure the resistance through the harness. Turn the ignition switch OFF. Disconnect UCM connectors X-CN3A and X-CN2B. Disconnect connector X-19. Measure the resistance between CN3A pin 19 and chassis ground. The resistance should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition. 48068130 29/01/2018
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Electrical systems - FAULT CODES
Measure the resistance between CN2B pin 8 and chassis ground. The resistance should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition. Measure the resistance between CN3A pin 19 and CN2B pin 8. The resistance should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition. A. All resistance measurements are less than 10 Ω. Go to step 4. B. One or more resistance measurements are greater than 10 Ω. There is a short circuit in the harness. Repair or replace the harness as required. Return to step 1 to confirm elimination of the fault. 4. Test the UCM. Reconnect UCM connectors X-CN3A and X-CN2B. Disconnect connector X-19. Turn the ignition switch ON. Activate the hydraulics while monitoring the fault code screen. Fault code 5371 – EHF Forward Solenoid (A) Supply STG should no longer be active. Fault code 5372 – EHF Pump Control PRV's (Directional) - Forward Solenoid (A) Supply Short to Ground should become active. A. Fault code 5372 – EHF Pump Control PRV's (Directional) - Forward Solenoid (A) Supply Short to Ground is active and fault code 5371 – EHF Forward Solenoid (A) Supply STG is no longer active. Temporarily replace the solenoid and retest. Return to step 1 to confirm elimination of the fault. B. Fault code 5371 – EHF Forward Solenoid (A) Supply STG is still active. Fault code 5372 – EHF Pump Control PRV's (Directional) - Forward Solenoid (A) Supply Short to Ground did not become active. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. Wiring harnesses - Electrical schematic sheet 20 SH20-UNIVERSAL CONTROL MODULE (55.100.DP-C.20.E.20) Wiring harnesses - Electrical schematic sheet 12 SH12-LOADER VALVE AND SENSORS (55.100.DP-C.20.E.12)
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Electrical systems - FAULT CODES
5372 - EHF Forward Solenoid (A) Supply OC SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Context: The UCM has sensed an open circuit condition for the EHF forward solenoid. Diagnostic Trouble Code 5372 – EHF Forward Solenoid (A) Supply OC has an error priority of White. The EHF functions are disabled while Diagnostic Trouble Code 5372 – EHF Forward Solenoid (A) Supply OC is active. Cause: The UCM has sensed an open circuit condition for the EHF forward solenoid, CN3A pin 19. The fault is active when the EHF setting is active, the hydraulics are enabled, and the solenoid current is greater than 3 A. Possible failure modes: 1. An open circuit in the wiring. 2. A failure of the EHF forward solenoid. 3. A faulty UCM. 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. OK to return the machine to service. B. Fault code 5372 – EHF Forward Solenoid (A) Supply OC is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the UCM and the EHF forward solenoid connections. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the UCM to the EHF forward solenoid. 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 the connectors as required. Return to step 1 to confirm elimination of fault. 3. Measure the resistance of the solenoid wires to chassis ground Turn the ignition switch OFF. Disconnect UCM connectors X-CN3A and X-CN2B. Disconnect solenoid connector X-19. Fabricate a jumper wire that will connect between X-19 pin 1 and X-19 pin 2.
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Electrical systems - FAULT CODES
Connect the jumper wire between X-19 pin 1 and X-19 pin 2. Measure the resistance between CN3A pin 19 and CN2B pin 8. The resistance should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition. A. The resistance measurement is less than 10 Ω. Go to step 4. B. The resistance measurement 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. Test the UCM Turn the ignition switch OFF. Reconnect UCM connectors X-CN3A and X-CN2B. Leave the jumper wire connected between X-19 pin 1 and X-19 pin 2. Turn the ignition switch ON. Activate the EHF hydraulics while monitoring the fault code screen. Fault code 5372 – EHF Forward Solenoid (A) Supply OC should no longer be active. Fault code 5371 – EHF Pump Control PRV's (Directional) - Forward Solenoid (A) Supply Open Circuit should become active. A. Fault code 5371 – EHF Pump Control PRV's (Directional) - Forward Solenoid (A) Supply Open Circuit is active and fault code 5372 – EHF Forward Solenoid (A) Supply OC is no longer active. Temporarily replace the solenoid and retest. Return to step 1 to confirm elimination of the fault. B. Fault code 5372 – EHF Forward Solenoid (A) Supply OC is still active. Fault code 5371 – EHF Pump Control PRV's (Directional) - Forward Solenoid (A) Supply Open Circuit did not become active. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. Wiring harnesses - Electrical schematic sheet 20 SH20-UNIVERSAL CONTROL MODULE (55.100.DP-C.20.E.20) Wiring harnesses - Electrical schematic sheet 12 SH12-LOADER VALVE AND SENSORS (55.100.DP-C.20.E.12)
48068130 29/01/2018
55.21 [55.DTC] / 765
Electrical systems - FAULT CODES
5381 - EHF Reverse Solenoid (B) Supply STG SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Context: The UCM has sensed a short circuit in the EHF reverse solenoid circuit. Diagnostic Trouble Code 5381 – EHF Reverse Solenoid (B) Supply STG has an error priority of White. The EHF function is disabled while Diagnostic Trouble Code 5381 – EHF Reverse Solenoid (B) Supply STG is active. Cause: The UCM has sensed a short circuit condition in the EHF reverse solenoid, CN3A pin 6. The fault is active when the EHF function is active, the hydraulics are enabled, and the solenoid current is below normal. Possible failure modes: 1. A short circuit in the wiring. 2. A failure of the EHF reverse solenoid. 3. A faulty UCM. 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. OK to return the machine to service. B. Fault code 5381 – EHF Reverse Solenoid (B) Supply STG is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the UCM and the EHF reverse solenoid connections. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the UCM to the EHF reverse solenoid. 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 the connectors as required. Return to step 1 to confirm elimination of fault. 3. Measure the resistance through the harness. Turn the ignition switch OFF. Disconnect UCM connectors X-CN3A and X-CN2B. Disconnect connector X-40. Measure the resistance between CN3A pin 6 and chassis ground. The resistance should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition. 48068130 29/01/2018
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Electrical systems - FAULT CODES
Measure the resistance between CN2B pin 8 and chassis ground. The resistance should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition. Measure the resistance between CN3A pin 6 and CN2B pin 8. The resistance should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition. A. All resistance measurements are less than 10 Ω. Go to step 4. B. One or more resistance measurements are greater than 10 Ω. There is a short circuit in the harness. Repair or replace the harness as required. Return to step 1 to confirm elimination of the fault. 4. Test the UCM. Reconnect UCM connectors X-CN3A and X-CN2B. Disconnect connector X-40. Turn the ignition switch ON. Activate the hydraulics while monitoring the fault code screen. Fault code 5381 – EHF Reverse Solenoid (B) Supply STG should no longer be active. Fault code 5382 – EHF Pump Control PRV's (Directional) - Reverse Solenoid (B) Supply Short to Ground should become active. A. Fault code 5382 – EHF Pump Control PRV's (Directional) - Reverse Solenoid (B) Supply Short to Ground is active and fault code 5381 – EHF Reverse Solenoid (B) Supply STG is no longer active. Temporarily replace the solenoid and retest. Return to step 1 to confirm elimination of the fault. B. Fault code 5381 – EHF Reverse Solenoid (B) Supply STG is still active. Fault code 5382 – EHF Pump Control PRV's (Directional) - Reverse Solenoid (B) Supply Short to Ground did not become active. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. Wiring harnesses - Electrical schematic sheet 20 SH20-UNIVERSAL CONTROL MODULE (55.100.DP-C.20.E.20) Wiring harnesses - Electrical schematic sheet 12 SH12-LOADER VALVE AND SENSORS (55.100.DP-C.20.E.12)
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Electrical systems - FAULT CODES
5382 - EHF Reverse Solenoid (B) Supply OC SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Context: The UCM has sensed an open circuit condition for the EHF reverse solenoid. Diagnostic Trouble Code 5382 – EHF Reverse Solenoid (B) Supply OC has an error priority of White. The EHF functions are disabled while Diagnostic Trouble Code 5382 – EHF Reverse Solenoid (B) Supply OC is active. Cause: The UCM has sensed an open circuit condition for the EHF reverse solenoid, CN3A pin 6. The fault is active when the EHF setting is active, the hydraulics are enabled, and the solenoid current is greater than 3 A. Possible failure modes: 1. An open circuit in the wiring. 2. A failure of the EHF reverse solenoid. 3. A faulty UCM. 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. OK to return the machine to service. B. Fault code 5382 – EHF Reverse Solenoid (B) Supply OC is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the UCM and the EHF reverse solenoid connections. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the UCM to the EHF reverse solenoid. 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 the connectors as required. Return to step 1 to confirm elimination of fault. 3. Measure the resistance of the solenoid wires to chassis ground Turn the ignition switch OFF. Disconnect UCM connectors CN3A and CN2B. Disconnect solenoid connector X-40. Fabricate a jumper wire that will connect between X-40 pin 1 and X-40 pin 2.
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Electrical systems - FAULT CODES
Connect the jumper wire between X-40 pin 1 and X-40 pin 2. Measure the resistance between CN3A pin 6 and CN2B pin 8. The resistance should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition. A. The resistance measurement is less than 10 Ω. Go to step 4. B. The resistance measurement 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. Test the UCM Turn the ignition switch OFF. Reconnect UCM connectors X-CN3A and X-CN2B. Leave the jumper wire connected between X-40 pin 1 and X-40 pin 2. Turn the ignition switch ON. Activate the EHF hydraulics while monitoring the fault code screen. Fault code 5382 – EHF Reverse Solenoid (B) Supply OC should no longer be active. Fault code 5381 – EHF Pump Control PRV's (Directional) - Reverse Solenoid (B) Supply Open Circuit should become active. A. Fault code 5381 – EHF Pump Control PRV's (Directional) - Reverse Solenoid (B) Supply Open Circuit is active and fault code 5382 – EHF Reverse Solenoid (B) Supply OC is no longer active. Temporarily replace the solenoid and retest. Return to step 1 to confirm elimination of the fault. B. Fault code 5382 – EHF Reverse Solenoid (B) Supply OC is still active. Fault code 5381 – EHF Pump Control PRV's (Directional) - Reverse Solenoid (B) Supply Open Circuit did not become active. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. Wiring harnesses - Electrical schematic sheet 20 SH20-UNIVERSAL CONTROL MODULE (55.100.DP-C.20.E.20) Wiring harnesses - Electrical schematic sheet 12 SH12-LOADER VALVE AND SENSORS (55.100.DP-C.20.E.12)
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Electrical systems - FAULT CODES
5391 - EHF Solenoids Return OC SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Context: The UCM has sensed an open circuit condition in the EHF solenoid return line. Diagnostic Trouble Code 5391 – EHF Solenoids Return OC has an error priority of White. The EHF functions are disabled while Diagnostic Trouble Code 5391 – EHF Solenoids Return OC is active. Cause: The UCM has sensed an open circuit condition in the EHF solenoid return line, CN2B pin 8. The fault is active while the EHF setting is active, the hydraulics are enabled, and the extend solenoid and the retract solenoid current is incorrect. Possible failure modes: 1. An open circuit in the solenoid return line. 2. A failure of the EHF extend solenoid and the EHF retract solenoid. 3. A faulty UCM. 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. OK to return the machine to service. B. Fault code 5391 – EHF Solenoids Return OC is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the UCM, the EHF forward solenoid, and the EHF reverse solenoid connections. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the UCM to both EHF solenoids. 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 the connectors as required. Return to step 1 to confirm elimination of fault. 3. Measure the resistance through the harness. Fabricate a jumper wire that will connect between the EHF extend solenoid connector X-19 pin 1 and X-19 pin 2. Turn the ignition switch OFF. Disconnect UCM connectors X-CN3A and X-CN2B. Disconnect solenoid connectors X-19 and X-40.
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Electrical systems - FAULT CODES
Connect jumper wire between X-19 pin 1 to X-19 pin 2. Measure the resistance between CN3A pin 19 and CN2B pin 8. The resistance should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition. Remove the jumper wire from connector X-19. Connect the jumper wire between X-40 pin 1 to X-40 pin 2. Measure the resistance between CN3A pin 6 and CN2B pin 8. The resistance should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition. A. Both resistance measurements are less than 10 Ω. Go to step 4. B. One or both resistance measurement is greater than 10 Ω. There is an open circuit in the wiring. Check splice SP-193. Repair or replace the harness as required. Return to step 1 to confirm elimination of the fault. 4. Measure the resistance of the solenoids. Disconnect connectors X-19 and X-40. Measure the resistance between X-19 pin 1 and X-19 pin 2. The resistance should be less than 1,000 Ω. Measure the resistance between X-40 pin 1 and X-40 pin 2. The resistance should be less than 1,000 Ω. A. Both resistance measurements are less than 1,000 Ω. Replace the solenoids. Return to step 1 to confirm elimination of the fault. B. One or both resistance measurement is greater than 1,000 Ω. There is an open circuit in the solenoid. Check splice SP-193. Replace the solenoid and retest. Return to step 1 to confirm elimination of the fault. Wiring harnesses - Electrical schematic sheet 20 SH20-UNIVERSAL CONTROL MODULE (55.100.DP-C.20.E.20) Wiring harnesses - Electrical schematic sheet 12 SH12-LOADER VALVE AND SENSORS (55.100.DP-C.20.E.12)
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Electrical systems - FAULT CODES
5392 - EHF Pump Solenoid(s) STG SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Context: The UCM has sensed a short to ground condition for the EHF pump solenoids. Diagnostic Trouble Code 5392 – EHF Pump Solenoid(s) STG has an error priority of White. The EHF functions are disabled while Diagnostic Trouble Code 5392 – EHF Pump Solenoid(s) STG is active. Cause: The UCM has sensed a short to ground condition for the EHF pump solenoids. The fault is active when the EHF setting is active, the hydraulics are disabled, and the solenoid return voltage is low. Possible failure modes: 1. A short circuit in the wiring. 2. A failure of EHF Pump solenoid. 3. A faulty UCM 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. OK to return the machine to service. B. Fault code 5392 – EHF Pump Solenoid(s) STG is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the UCM, the EHF forward solenoid, and the EHF reverse solenoid connections. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the UCM to both EHF solenoids. 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 the connectors as required. Return to step 1 to confirm elimination of fault. 3. Measure the resistance of the solenoid wires to chassis ground Turn the ignition switch OFF. Disconnect UCM connectors X-CN3A and X-CN2B. Disconnect solenoid connectors X-19 and X-40. Measure the resistance between X-19 pin 1 and chassis ground. The resistance should be greater than 20,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition.
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Electrical systems - FAULT CODES
Measure the resistance between X-19 pin 2 and chassis ground. The resistance should be greater than 20,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition. Measure the resistance between X-40 pin 1 and chassis ground. The resistance should be greater than 20,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition. Measure the resistance between X-40 pin 2 and chassis ground. The resistance should be greater than 20,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition. Measure the resistance between CN3A pin 19 and CN2B pin 8. The resistance should be greater than 20,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition. Measure the resistance between CN3A pin 6 and CN2B pin 8. The resistance should be greater than 20,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition. A. All resistance measurements are greater than 20,000 Ω. Go to step 4. B. One or more resistance measurements is less than 20,000 Ω. There is a short circuit to chassis ground in the harness. Repair or replace the harness as required. Return to step 1 to confirm elimination of fault. 4. Test the UCM. Turn the ignition switch OFF. Reconnect UCM connectors X-CN3A and X-CN2B. Leave connectors X-19 and X-40 disconnected. Turn the ignition switch ON. Activate the hydraulics while monitoring the fault code screen. Fault code 5392 – EHF Pump Solenoid(s) STG should no longer be active. Fault code 5391 – EHF Pump Control PRV's (Directional) - Solenoids Return Open Circuit should become active. A. Fault code 5391 – EHF Pump Control PRV's (Directional) - Solenoids Return Open Circuit is active and fault code 5392 – EHF Pump Solenoid(s) STG is no longer active. Temporarily replace both solenoids and retest. Return to step 1 to confirm elimination of the fault. B. Fault code 5392 – EHF Pump Solenoid(s) STG is still active. Fault code 5391 – EHF Pump Control PRV's (Directional) - Solenoids Return Open Circuit did not become active. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. Wiring harnesses - Electrical schematic sheet 20 SH20-UNIVERSAL CONTROL MODULE (55.100.DP-C.20.E.20) Wiring harnesses - Electrical schematic sheet 12 SH12-LOADER VALVE AND SENSORS (55.100.DP-C.20.E.12)
48068130 29/01/2018
55.21 [55.DTC] / 773
Electrical systems - FAULT CODES
5393 - EHF Pump Solenoid(s) STP SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Context: The UCM has sensed a short circuit to another voltage source in the EHF Pump solenoid circuit. Diagnostic Trouble Code 5393 – EHF Pump Solenoid(s) STP has an error priority of White. The EHF function is disabled while Diagnostic Trouble Code 5393 – EHF Pump Solenoid(s) STP is active. Cause: The UCM has sensed a short circuit to another voltage source in the EHF Pump solenoid circuit. The fault is active when the EHF setting is active, the hydraulics are disabled, and the solenoid voltage feedback is greater than 5 V. Possible failure modes: 1. A short circuit to another voltage source in the wiring. 2. A faulty UCM 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. OK to return the machine to service. B. Fault code 5393 – EHF Pump Solenoid(s) STP is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the UCM, the EHF forward solenoid, and the EHF reverse solenoid connections. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the UCM to both EHF solenoids. 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 the connectors as required. Return to step 1 to confirm elimination of fault. 3. Measure the voltage on the solenoid wires. Turn the ignition switch OFF. Disconnect UCM connectors X-CN3A and X-CN2B. Disconnect solenoid connector X-19 and X-40. Turn the ignition switch ON. Measure the voltage between X-19 pin 1 and chassis ground. The voltage should be less than 0.5 V. Wiggle the harness during measurement to reveal an intermittent condition.
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Electrical systems - FAULT CODES
Measure the voltage between X-19 pin 2 and chassis ground. The voltage should be less than 0.5 V. Wiggle the harness during measurement to reveal an intermittent condition. Measure the voltage between X-40 pin 1 and chassis ground. The voltage should be less than 0.5 V. Wiggle the harness during measurement to reveal an intermittent condition. Measure the voltage between X-40 pin 2 and chassis ground. The voltage should be less than 0.5 V. Wiggle the harness during measurement to reveal an intermittent condition. A. All voltage measurements are less than 0.5 V. Go to step 4. B. One or more voltage measurements are greater than 0.5 V. There is a short circuit to another voltage source. Repair or replace the harness as required. Return to step 1 to confirm elimination of fault. 4. Test the UCM Turn the ignition switch OFF. Reconnect UCM connectors X-CN3A and X-CN2B. Leave connectors X-19 and X-40 disconnected. Turn the ignition switch ON. Activate the hydraulics while monitoring the fault code screen. Fault code 5393 – EHF Pump Solenoid(s) STP should no longer be active. Fault code 5391 – EHF Pump Control PRV's (Directional) - Solenoids Return Open Circuit should become active. A. Fault code 5391 – EHF Pump Control PRV's (Directional) - Solenoids Return Open Circuit is active and fault code 5393 – EHF Pump Solenoid(s) STP is no longer active. Temporarily replace both solenoids and retest. Return to step 1 to confirm elimination of the fault. B. Fault code 5393 – EHF Pump Solenoid(s) STP is still active. Fault code 5391 – EHF Pump Control PRV's (Directional) - Solenoids Return Open Circuit did not become active. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. Wiring harnesses - Electrical schematic sheet 20 SH20-UNIVERSAL CONTROL MODULE (55.100.DP-C.20.E.20) Wiring harnesses - Electrical schematic sheet 12 SH12-LOADER VALVE AND SENSORS (55.100.DP-C.20.E.12)
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Electrical systems - FAULT CODES
5409 - Aux Override Disabled Due To Aux Override Button Timeout (30 Seconds) SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Context: The UCM has sensed an error with the aux override button status. Diagnostic Trouble Code 5409 – Aux Override Disabled Due To Aux Override Button Timeout (30 Seconds) has an error priority of White. The aux override is disabled while Diagnostic Trouble Code 5409 – Aux Override Disabled Due To Aux Override Button Timeout (30 Seconds) is active. Cause: The UCM has sensed an error with the aux override Button status. The fault is active when ignition is on and CAN message from the instrument cluster is high for more than 30 s. Possible failure modes: 1. A failure of the instrument cluster. Solution: 1. Use the EST to verify fault code 5409 – Aux Override Disabled Due To Aux Override Button Timeout (30 Seconds) is active. A. If the fault is active, erase the fault with the EST. 2. If the fault persists, this is an indication of an instrument cluster failure. Replace the instrument cluster and retest.
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Electrical systems - FAULT CODES
5501 - Loader Arm Spool Sensor Open or Shorted To Ground SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Context: The UCM has sensed that the loader position sensor signal has failed. Diagnostic Trouble Code 5501 – Loader Arm Spool Sensor Open or Shorted To Ground has an error priority of White. The loader function will operate in limp home mode while Diagnostic Trouble Code 5501 – Loader Arm Spool Sensor Open or Shorted To Ground is active. Cause: The UCM has sensed that the loader position sensor signal, X-CN3B (Receptacle) pin 13 has failed. The fault is active when the engine is ON and the loader position sensor signal is less than 0.2 V. Possible failure modes: 1. A short circuit in the wiring. 2. An open circuit in the wiring. 3. The boom spool position sensor has failed. 4. The UCM has an internal failure. 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. OK to return the machine to service. B. Fault code 5501 – Loader Arm Spool Sensor Open or Shorted To Ground is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the UCM, the loader solenoid, and loader position sensor connection. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the UCM to the loader solenoids and loader position sensor. 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. 3. Measure the voltage at the sensor. Disconnect the boom spool position sensor. Turn the ignition switch ON. Measure the voltage between X-022 (Receptacle) pin 1 and X-022 (Receptacle) pin 3. The voltage should be approximately 5 V. Wiggle the harness during measurement to reveal an intermittent condition. 48068130 29/01/2018
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A. The voltage is approximately 5 V. Go to step 4. B. The voltage is less the 4.5 V. There is a problem in the supply voltage to the sensor. Check UCM connector X-CN1A (Receptacle) pin 8. Verify the chassis ground connection from X-010 is secure. Repair or replace the harness as required. Return to step 1 to confirm elimination of the fault. 4. Measure the resistance of the signal wire to chassis ground. Turn the ignition switch OFF. Disconnect UCM connector X-CN3B. Disconnect the boom spool position sensor from the harness. Measure the resistance between X-CN3B (Receptacle) pin 13 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. Go to step 5. 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 1 to confirm elimination of fault. 5. Measure the resistance through the signal wire. Turn the ignition switch OFF. Fabricate a jumper wire that will connect between connector X-CN3B (Receptacle) pin 13 and chassis ground. Connect the jumper wire between connector X-CN3B (Receptacle) pin 13 and chassis ground. The chassis ground connection must be clean and free of rust, dirt, oil, and paint. Measure the resistance between connector X-022 (Receptacle) pin 4 and chassis ground. 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 6. B. The resistance is greater than 10 Ω. There is an open circuit in the signal wire. Repair or replace the harness as required. Return to step 1 to confirm elimination of fault. 6. Test the UCM. Reconnect UCM connector X-CN3B. Fabricate a jumper wire that will connect between X-022 (Receptacle) pin 1 and X-022 (Receptacle) pin 4. Connect the jumper wire between X-022 (Receptacle) pin 1 and X-022 (Receptacle) pin 4. Turn the ignition switch ON and monitor the active fault screen. Fault code 5502 – Loader Arm Spool Sensor Shorted To Power should become active. Fault code 5501 – Loader Arm Spool Sensor Open or Shorted To Ground should no longer be active. A. Fault code 5502 – Loader Arm Spool Sensor Shorted To Power is active and fault code 5501 – Loader Arm Spool Sensor Open or Shorted To Ground is no longer active. Temporarily replace the boom spool position sensor and retest. Return to step 1 to confirm elimination of the fault. B. Fault code 5501 – Loader Arm Spool Sensor Open or Shorted To Ground is still active. Fault code 5502 – Loader Arm Spool Sensor Shorted To Power is not active. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. Wiring harnesses - Electrical schematic sheet 20 SH20-UNIVERSAL CONTROL MODULE (55.100.DP-C.20.E.20) Wiring harnesses - Electrical schematic sheet 12 SH12-LOADER VALVE AND SENSORS (55.100.DP-C.20.E.12)
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5502 - Loader Arm Spool Sensor Shorted To Power SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Context: The UCM has sensed a higher than normal voltage on the boom spool position sensor input. Diagnostic Trouble Code 5502 – Loader Arm Spool Sensor Shorted To Power has an error priority of Amber. The loader function will operate in limp home mode while Diagnostic Trouble Code 5502 – Loader Arm Spool Sensor Shorted To Power is active. Cause: The UCM has sensed a higher than normal voltage on the loader valve spool input, X-CN3B (Receptacle) pin 13. The fault is active while the ignition is ON and the loader position sensor voltage is greater than 4.8 V. Possible failure modes: 1. The signal wire is shorted to another voltage source. 2. A faulty boom spool position sensor. 3. The UCM has an internal failure. 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. OK to return the machine to service. B. Fault code 5502 – Loader Arm Spool Sensor Shorted To Power is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the UCM and the boom spool position sensor connections. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the UCM to the boom spool position sensor. 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 the connectors as required. Return to step 1 to confirm elimination of fault. 3. Measure the voltage at the sensor. Disconnect the boom spool position sensor. Turn the ignition switch ON. Measure the voltage between X-022 (Receptacle) pin 1 and X-022 (Receptacle) pin 3. The voltage should be approximately 5 V. Wiggle the harness during measurement to reveal an intermittent condition. A. The voltage is approximately 5 V. Go to step 4. 48068130 29/01/2018
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B. The voltage is less the 4.5 V. There is a problem in the supply voltage to the sensor. Check UCM connector X-CN1A (Receptacle) pin 8. Verify the chassis ground connection from connector X-010 is secure. Repair or replace the harness as required. Return to step 1 to confirm elimination of the fault. 4. Measure the voltage of the signal wire. Disconnect UCM connector X-CN3B. Disconnect the boom spool position sensor from the harness. Turn the ignition switch ON. Measure the voltage between X-CN3B (Receptacle) pin 13 and chassis ground. The voltage should be less than 0.5 V. Wiggle the harness during measurement to reveal an intermittent condition. A. The voltage is less than 0.5 V. Go to step 5. B. The voltage is greater than 0.5 V. There is a short circuit to another voltage source. Repair or replace the harness as required. Return to step 1 to confirm elimination of the fault. 5. Measure the resistance through the signal wire. Turn the ignition switch OFF. Fabricate a jumper wire that will connect between X-CN3B (Receptacle) pin 13 and chassis ground. Connect the jumper wire between X-CN3B (Receptacle) pin 13 and chassis ground. The chassis ground connection must be clean and free of rust, dirt, oil, and paint. Measure the resistance between connector X-022 (Receptacle) pin 4 and chassis ground. 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 6. B. The resistance is greater than 10 Ω. There is an open circuit in the signal wire. Repair or replace the harness as required. Return to step 1 to confirm elimination of the fault. 6. Test the UCM. Turn the ignition switch OFF. Reconnect UCM connector X-CN3B. Turn the ignition switch ON and monitor the active fault screen. Fault code 5501 – Loader Arm Spool Sensor Open or Shorted To Ground should become active. Fault code 5502 – Loader Arm Spool Sensor Shorted To Power should no longer be active. A. Fault code 5501 – Loader Arm Spool Sensor Open or Shorted To Ground is active. Fault code 5502 – Loader Arm Spool Sensor Shorted To Power is no longer active. Temporarily replace the boom spool position sensor and retest. Return to step 1 to confirm elimination of the fault. B. Fault code 5502 – Loader Arm Spool Sensor Shorted To Power is still active. Fault code 5501 – Loader Arm Spool Sensor Open or Shorted To Ground is not active. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. Wiring harnesses - Electrical schematic sheet 20 SH20-UNIVERSAL CONTROL MODULE (55.100.DP-C.20.E.20) Wiring harnesses - Electrical schematic sheet 12 SH12-LOADER VALVE AND SENSORS (55.100.DP-C.20.E.12)
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Electrical systems - FAULT CODES
5503 - Electro-Hydraulic Aux Output Shorted To Power Context: The instrument cluster has sensed a short circuit to another voltage source in the EH aux power output circuit, X-C23 pin 26. Diagnostic Trouble Code 5503 has an error priority of Red. The vehicle is disabled while Diagnostic Trouble Code 5503 is active. Cause: The instrument cluster has sensed a short circuit to another voltage source in the EH aux power output circuit. The fault is active while the ignition is ON, the Aux output is low, and the EH aux output is still energized. Possible failure modes: 1. Faulty wiring or connectors. 2. A 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. OK to return the machine to service. B. Fault code 5503 is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the instrument cluster connector X-C23 and the EH Aux PWM controller connections. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the instrument cluster to the EH Aux PWM controller. 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 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 voltage on the power wire. Turn the ignition switch OFF. Disconnect the instrument cluster connector X-C23. Disconnect EH Aux PWM connector X-430. Turn the ignition switch ON. Measure the voltage between the instrument cluster connector X-C23 pin 26 and chassis ground. The voltage should be less than 0.5 V. Wiggle the harness during measurement to reveal an intermittent condition. A. The voltage is less than 0.5 V. Temporarily replace the instrument cluster and retest. Return to step 1 to confirm the elimination of the fault. B. The voltage is greater than 0.5 V. The EH Aux power wire is shorted to another voltage source. Repair or replace the harness as required. Return to step 1 to confirm elimination of the fault.
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Electrical systems - FAULT CODES
5504 - Bucket Valve Spool Sensor Open Or Shorted To Ground SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Context: The UCM has sensed that the bucket spool position sensor signal has failed. Diagnostic Trouble Code 5504 – Bucket Valve Spool Sensor Open Or Shorted To Ground has an error priority of Amber. Bucket functions will operate in limp home mode while Diagnostic Trouble Code 5504 – Bucket Valve Spool Sensor Open Or Shorted To Ground is active. Cause: The UCM has sensed that the bucket spool position sensor signal, X-CN3B (Receptacle) pin 12 has failed. The fault is active when the engine is ON and the loader position sensor signal is less than 0.2 V. Possible failure modes: 1. The spool is sticking inside the valve body. 2. Improper wiring in the circuit. Connector X-25 is swapped with connector X-26. 3. A failure of the bucket spool position sensor. 4. A faulty UCM. Solution: 1. Verify that the spool is not stuck in the valve. Turn the ignition switch OFF. Remove the bucket spool position sensor from the valve body. Turn the ignition switch ON. Access EST and monitor the spool position. Move the pintle arm while monitoring the valve position sensor signal. The value should change linearly and not become erratic. A. The sensor values change in a linear fashion. The problem is in the valve body. Repair or replace the valve or spool as required. B. The fault sensor values did not change in a linear fashion. The problem is in the sensor circuit. Go to step 2. 2. 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. OK to return the machine to service. B. Fault code 5504 – Bucket Valve Spool Sensor Open Or Shorted To Ground is recorded again. Go to step 3. 3. Verify that the wiring and connectors are free of damage. Inspect the UCM and the bucket spool position sensor connections. All connections should be secure, tight, free of corrosion, abrasion, and damage. 48068130 29/01/2018
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Inspect the harness from the UCM to the bucket spool position sensor. 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 4. B. The connectors or the harness has damage. Repair or replace the harness or the connectors as required. Return to step 2 to confirm elimination of fault. 4. Measure the voltage at the sensor. Disconnect the bucket spool position sensor. Turn the ignition switch ON. Measure the voltage between X-022 (Receptacle) pin 1 and X-022 (Receptacle) pin 3. The voltage should be approximately 5 V. Wiggle the harness during measurement to reveal an intermittent condition. A. The voltage is approximately 5 V. Go to step 5. B. The voltage is less the 4.5 V. There is a problem in the supply voltage to the sensor. Check UCM connector X-CN1A (Receptacle) pin 8. Verify the chassis ground connection from connector X-010 is tight and secure. Repair or replace the harness as required. Return to step 2 to confirm elimination of fault. 5. Test the UCM. Turn the ignition switch OFF. Disconnect the bucket spool position sensor from the harness. Fabricate a jumper wire that will connect between X-022 (Receptacle) pin 1 and X-022 (Receptacle) pin 4. Connect the jumper between X-022 (Receptacle) pin 1 and X-022 (Receptacle) pin 4. Turn the ignition switch ON. Monitor the EST fault code screen. Fault code 5505 – Bucket Valve Spool Sensor Shorted To Power should be active. A. Fault code 5504 – Bucket Valve Spool Sensor Open Or Shorted To Ground is active while the sensor is disconnected. Fault code 5505 – Bucket Valve Spool Sensor Shorted To Power is active while the jumper wire is installed. Temporarily replace the bucket spool position sensor and retest. Return to step 2 to confirm elimination of the fault. B. Fault code 5505 – Bucket Valve Spool Sensor Shorted To Power is not active while the jumper wire is installed. Fault code 5504 – Bucket Valve Spool Sensor Open Or Shorted To Ground is still active. Temporarily replace the UCM and retest. Return to step 2 to confirm elimination of the fault. Wiring harnesses - Electrical schematic sheet 20 SH20-UNIVERSAL CONTROL MODULE (55.100.DP-C.20.E.20) Wiring harnesses - Electrical schematic sheet 12 SH12-LOADER VALVE AND SENSORS (55.100.DP-C.20.E.12)
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Electrical systems - FAULT CODES
5505 - Bucket Valve Spool Sensor Shorted To Power SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Context: The UCM has sensed a higher than normal voltage on the bucket spool position sensor. Diagnostic Trouble Code 5505 – Bucket Valve Spool Sensor Shorted To Power has an error priority of Amber. Implement functions will operate in limp home mode while Diagnostic Trouble Code 5505 – Bucket Valve Spool Sensor Shorted To Power is active. Cause: The UCM has sensed a higher than normal voltage on the bucket spool position sensor. The fault is active when the ignition is ON and the bucket spool position sensor voltage is high. Possible failure modes: 1. A short circuit in the wiring. 2. A failure of the bucket spool position sensor. 3. The UCM has internal failure. Solution: 1. Verify that the fault code is active. Connect the Electronic Service Tool to the service tool connector. To check for fault code: Start and operate the machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 5505 – Bucket Valve Spool Sensor Shorted To Power is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the UCM and bucket spool position sensor connections. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the UCM to the bucket spool position sensor. 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 the connectors as required. Return to step 1 to confirm elimination of fault. 3. Measure the voltage at the sensor. Disconnect the bucket spool position sensor. Turn the ignition switch ON. Measure the voltage between X-021 (Receptacle) pin 1 and X-021 (Receptacle) pin 3. The voltage should be approximately 5 V. Wiggle the harness during measurement to reveal an intermittent condition. A. The voltage is approximately 5 V. Go to step 4. 48068130 29/01/2018
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B. The voltage is less the 4.5 V. There is a problem in the supply voltage to the sensor. Check UCM connector X-CN1A (Receptacle) pin 8. Repair or replace the harness as required. Return to step 1 to confirm elimination of fault. 4. Measure the voltage of the signal wire. Disconnect UCM connector X-CN3B. Disconnect the bucket spool position sensor from the harness. Turn the ignition switch ON. Measure the voltage between X-CN3B (Receptacle) pin 12 and chassis ground. The voltage should be less than 0.5 V. Wiggle the harness during measurement to reveal an intermittent condition. A. The voltage is less than 0.5 V. Go to step 5. B. The voltage is greater than 0.5 V. There is a short circuit to another voltage source. Repair or replace the harness as required. Return to step 1 to confirm elimination of fault. 5. Measure the resistance of the signal wire. Turn the ignition switch OFF. Fabricate a jumper wire that will connect between connector X-CN3B (Receptacle) pin 12 and chassis ground. Connect the jumper wire between connector X-CN3B (Receptacle) pin 12 and chassis ground. The chassis ground connection must be clean and free of rust, dirt, oil, and paint. Measure the resistance between connector X-021 (Receptacle) pin 4 and chassis ground. 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 6. B. The resistance is greater than 10 Ω. There is an open circuit in the signal wire. Repair or replace the harness as required. Return to step 1 to confirm elimination of fault. 6. Test the UCM. Reconnect UCM connector X-CN3B. Fabricate a jumper wire that will connect between X-021 (Receptacle) pin 3 and X-021 (Receptacle) pin 4. Connect the jumper wire between connector X-021 (Receptacle) pin 3 and X-021 (Receptacle) pin 4. Turn the ignition switch ON and monitor the active fault screen. Fault code 5504 – Bucket Valve Spool Sensor Open Or Shorted To Ground should become active. Fault code 5505 – Bucket Valve Spool Sensor Shorted To Power should no longer be active. A. Fault code 5504 – Bucket Valve Spool Sensor Open Or Shorted To Ground is active and fault code 5505 – Bucket Valve Spool Sensor Shorted To Power is no longer active. Temporarily replace the bucket spool position sensor and retest. Return to step 1 to confirm elimination of the fault. B. Fault code 5505 – Bucket Valve Spool Sensor Shorted To Power is still active. Fault code 5504 – Bucket Valve Spool Sensor Open Or Shorted To Ground is not active. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. Wiring harnesses - Electrical schematic sheet 20 SH20-UNIVERSAL CONTROL MODULE (55.100.DP-C.20.E.20) Wiring harnesses - Electrical schematic sheet 12 SH12-LOADER VALVE AND SENSORS (55.100.DP-C.20.E.12)
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5507 - Auxiliary Valve Spool Sensor Open Or Shorted To Ground SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Context: The UCM has sensed that the auxiliary spool position sensor signal has failed low. Diagnostic Trouble Code 5507 – Auxiliary Valve Spool Sensor Open Or Shorted To Ground has an error priority of White. The auxiliary hydraulic functions are disabled while Diagnostic Trouble Code 5507 – Auxiliary Valve Spool Sensor Open Or Shorted To Ground is active. Cause: The UCM has sensed that the auxiliary spool position sensor signal, X-CN3B (Receptacle) pin 14 has failed low. The fault is active while the engine is ON and the auxiliary spool position sensor signal is less than 0.2 V. Possible failure modes: 1. A short circuit in the wiring. 2. An open circuit in the wiring. 3. The auxiliary spool position sensor has failed. 4. The UCM has an internal failure. 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. OK to return the machine to service. B. Fault code 5507 – Auxiliary Valve Spool Sensor Open Or Shorted To Ground is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the UCM and the auxiliary spool position sensor connections. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the UCM to the auxiliary spool position sensor. 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 the connectors as required. Return to step 1 to confirm elimination of the fault. 3. Measure the voltage at the sensor. Disconnect the auxiliary spool position sensor. Turn the ignition switch ON.
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Measure the voltage between X-023 (Receptacle) pin 1 and X-023 (Receptacle) pin 3. The voltage should be approximately 5 V. Wiggle the harness during measurement to reveal an intermittent condition. A. The voltage is approximately 5 V. Go to step 4. B. The voltage is less the 4.5 V. There is a problem in the supply voltage to the sensor. Check UCM connector X-CN1A (Receptacle) pin 8. Verify the chassis ground connection from X-010 is secure. Repair or replace the harness as required. Return to step 1 to confirm elimination of the fault. 4. Measure the resistance of the signal wire to chassis ground. Turn the ignition switch OFF. Disconnect UCM connector X-CN3B. Disconnect the auxiliary spool position sensor from the harness. Measure the resistance between X-CN3B (Receptacle) 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 is greater than 20,000 Ω. Go to step 5. B. The resistance is less than 20,000 Ω. There is a short circuit in the wiring. Repair or replace the harness as required. Return to step 1 to confirm elimination of fault. 5. Measure the resistance through the signal wire. Turn the ignition switch OFF. Fabricate a jumper wire that will connect between X-CN3B (Receptacle) pin 14 and chassis ground. Connect the jumper wire between X-CN3B (Receptacle) pin 14 and chassis ground. The chassis ground connection must be clean and free of rust, dirt, oil, and paint. Measure the resistance between connector X-023 (Receptacle) pin 4 and chassis ground. 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 6. B. The resistance is greater than 10 Ω. There is an open circuit in the signal wire. Repair or replace the harness as required. Return to step 1 to confirm elimination of fault. 6. Test the UCM. Reconnect UCM connector X-CN3B. Fabricate a jumper wire that will connect between X-023 (Receptacle) pin 1 and X-023 (Receptacle) pin 4. Connect the jumper wire between X-023 (Receptacle) pin 1 and X-023 (Receptacle) pin 4. Turn the ignition switch ON and monitor the active fault screen. Fault code 5508 – Auxiliary Valve Spool Sensor Shorted To Power should become active. Fault code 5507 – Auxiliary Valve Spool Sensor Open Or Shorted To Ground should no longer be active. A. Fault code 5508 – Auxiliary Valve Spool Sensor Shorted To Power is active. Fault code 5507 – Auxiliary Valve Spool Sensor Open Or Shorted To Ground is no longer active. Temporarily replace the auxiliary spool position sensor and retest. Return to step 1 to confirm elimination of the fault. B. Fault code 5507 – Auxiliary Valve Spool Sensor Open Or Shorted To Ground is still active. Fault code 5508 – Auxiliary Valve Spool Sensor Shorted To Power is not active. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. Wiring harnesses - Electrical schematic sheet 20 SH20-UNIVERSAL CONTROL MODULE (55.100.DP-C.20.E.20) Wiring harnesses - Electrical schematic sheet 12 SH12-LOADER VALVE AND SENSORS (55.100.DP-C.20.E.12)
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5508 - Auxiliary Valve Spool Sensor Shorted To Power SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Context: The UCM has sensed a higher than normal voltage on the auxiliary spool position sensor input. Diagnostic Trouble Code 5508 – Auxiliary Valve Spool Sensor Shorted To Power has an error priority of White. The auxiliary hydraulic functions are disabled while Diagnostic Trouble Code 5508 – Auxiliary Valve Spool Sensor Shorted To Power is active. Cause: The UCM has sensed a higher than normal voltage on the auxiliary valve spool input, X-CN3B (Receptacle) pin 14. The fault is active while the ignition is ON and the auxiliary position sensor signal is greater than 4.8 V. Possible failure modes: 1. The signal wire is shorted to another voltage source. 2. A failure of the auxiliary spool position sensor. 3. The UCM has internal failure. 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. OK to return the machine to service. B. Fault code 5508 – Auxiliary Valve Spool Sensor Shorted To Power is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the UCM and the auxiliary spool position sensor connections. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the UCM to the auxiliary spool position sensor. 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 the connectors as required. Return to step 1 to confirm elimination of the fault. 3. Measure the voltage at the sensor. Disconnect the auxiliary spool position sensor. Turn the ignition switch ON. Measure the voltage between X-023 (Receptacle) pin 1 and X-023 (Receptacle) pin 3. The voltage should be approximately 5 V. Wiggle the harness during measurement to reveal an intermittent condition. A. The voltage is approximately 5 V. Go to step 4. 48068130 29/01/2018
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B. The voltage is less the 4.5 V. There is a problem in the supply voltage to the sensor. Check UCM connector X-CN1A (Receptacle) pin 8. Verify the chassis ground connection from connector X-010 is secure. Repair or replace the harness as required. Return to step 1 to confirm elimination of the fault. 4. Measure the voltage on the signal wire. Disconnect UCM connector X-CN3B. Disconnect the auxiliary spool position sensor from the harness. Turn the ignition switch ON. Measure the voltage between X-CN3B (Receptacle) pin 14 and chassis ground. The voltage should be less than 0.5 V. Wiggle the harness during measurement to reveal an intermittent condition. A. The voltage is less than 0.5 V. Go to step 5. B. The voltage is greater than 0.5 V. There is a short circuit to another voltage source. Repair or replace the harness as required. Return to step 1 to confirm elimination of the fault. 5. Measure the resistance through the signal wire. Turn the ignition switch OFF. Fabricate a jumper wire that will connect between connector X-CN3B (Receptacle) pin 14 and chassis ground. Connect the jumper wire between connector X-CN3B (Receptacle) pin 14 and chassis ground. The chassis ground connection must be clean and free of rust, dirt, oil, and paint. Measure the resistance between connector X-023 (Receptacle) pin 4 and chassis ground. 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 6. B. The resistance is greater than 10 Ω. There is an open circuit in the signal wire. Repair or replace the harness as required. Return to step 1 to confirm elimination of the fault. 6. Test the UCM. Reconnect UCM connector X-CN3B. Fabricate a jumper wire that will connect between X-023 (Receptacle) pin 3 and X-023 (Receptacle) pin 4. Connect the jumper wire between X-023 (Receptacle) pin 3 and X-023 (Receptacle) pin 4. Turn the ignition switch ON and monitor the active fault screen. Fault code 5507 – Auxiliary Valve Spool Sensor Open Or Shorted To Ground should become active. Fault code 5508 – Auxiliary Valve Spool Sensor Shorted To Power should no longer be active. A. Fault code 5507 – Auxiliary Valve Spool Sensor Open Or Shorted To Ground is active. Fault code 5508 – Auxiliary Valve Spool Sensor Shorted To Power is no longer active. Temporarily replace the auxiliary spool position sensor and retest. Return to step 1 to confirm elimination of the fault. B. Fault code 5508 – Auxiliary Valve Spool Sensor Shorted To Power is still active. Fault code 5507 – Auxiliary Valve Spool Sensor Open Or Shorted To Ground is not active. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. Wiring harnesses - Electrical schematic sheet 20 SH20-UNIVERSAL CONTROL MODULE (55.100.DP-C.20.E.20) Wiring harnesses - Electrical schematic sheet 12 SH12-LOADER VALVE AND SENSORS (55.100.DP-C.20.E.12)
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Electrical systems - FAULT CODES
5511 - Implausible Loader Arm Sensor State Vs Loader Arm Command - Stuck Spool Or PRV SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Context: The UCM has sensed that the loader arm position sensor does not agree with the direction of travel for the loader arm the command. Diagnostic Trouble Code 5511 â&#x20AC;&#x201C; Implausible Loader Arm Sensor State Vs Loader Arm Command - Stuck Spool Or PRV has an error priority of Red. The loader hydraulics are disabled while Diagnostic Trouble Code 5511 â&#x20AC;&#x201C; Implausible Loader Arm Sensor State Vs Loader Arm Command - Stuck Spool Or PRV is active. Cause: The UCM has sensed that the loader arm position sensor does not agree with the direction of travel for the loader arm the command. The fault is active while the engine is ON and the loader arm position sensor senses the loader arm movement but the solenoids are not energized or the loader arm movement is opposite of the energized solenoid. Possible failure modes: 1. Improper wiring in the circuit. Connector X-28 is swapped with connector X-27. 2. The spool is sticking inside the valve body. 3. A failure of the boom spool position sensor. 4. A faulty UCM. Solution: 1. Verify that the spool is not stuck in the valve. Turn the ignition switch OFF. Remove the boom spool position sensor from the valve body. Turn the ignition switch ON. Access EST and monitor the spool position. Move the pintle arm while monitoring the valve position sensor signal. The value should change linearly and not become erratic. A. The sensor value changes in a linear fashion. The problem is in the valve body. Repair or replace the valve or the spool as required. Return to step 2 to confirm elimination of the fault. B. The sensor values did not change in a linear fashion. The problem is in the sensor circuit. Go to step 2. 2. 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. OK to return the machine to service.
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B. Fault code 5511 – Implausible Loader Arm Sensor State Vs Loader Arm Command - Stuck Spool Or PRV is recorded again. Go to step 3. 3. Verify that the wiring and connectors are free of damage. Inspect the UCM, the loader valve solenoids, and the boom spool position sensor connections. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the UCM to the loader valve solenoids, and the boom spool position sensor connections. Verify that the harness is free of damage, corrosion, abrasion, and incorrect attachment.
20111502
Legend (1) (2)
Boom / Loader Extend Boom / Loader Retract
1
(3)
Boom / Loader Position Sensor
A. The connectors are secure and the harness is free of damage. Go to step 4. B. The connectors or the harness has damage. Repair or replace the harness or the connectors as required. Return to step 2 to confirm elimination of fault. 4. Measure the voltage at the sensor. Disconnect the boom spool position sensor. Turn the ignition switch ON. Measure the voltage between X-022 (Receptacle) pin 1 and X-022 (Receptacle) pin 3. The voltage should be approximately 5 V. Wiggle the harness during measurement to reveal an intermittent condition. A. The voltage is approximately 5 V. Go to step 5. B. The voltage is less the 4.5 V. There is a problem in the supply voltage to the sensor. Check UCM connector X-CN1A (Receptacle) pin 8. Verify the chassis ground connection from connector X-010 is tight and secure. Repair or replace the harness as required. Return to step 2 to confirm elimination of fault. 5. Test the UCM. Turn the ignition switch OFF. Disconnect the boom spool position sensor from the harness. Turn the ignition switch ON. Monitor the EST fault code screen. Fault code 5511 – Implausible Loader Arm Sensor State Vs Loader Arm Command - Stuck Spool Or PRV should be active. Use a jumper wire to short X-022 (Receptacle) pin 1 to X-022 (Receptacle) pin 4. Fault code 5502 – Loader Arm Spool Sensor Shorted To Power should be active. Fault code 5511 – Implausible Loader Arm Sensor State Vs Loader Arm Command - Stuck Spool Or PRV should no longer be active. A. Fault code 5511 – Implausible Loader Arm Sensor State Vs Loader Arm Command - Stuck Spool Or PRV is active while the sensor is disconnected and fault code 5502 – Loader Arm Spool Sensor Shorted
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To Power is active while the X-022 (Receptacle) pin 1 is shorted to X-022 (Receptacle) pin 4. Temporarily replace the boom spool position sensor and retest. Return to step 2 to confirm elimination of the fault. B. Fault code 5502 â&#x20AC;&#x201C; Loader Arm Spool Sensor Shorted To Power is not active while X-022 (Receptacle) pin 1 is shorted to X-022 (Receptacle) pin 4. Temporarily replace the UCM and retest. Return to step 2 to confirm elimination of the fault. Wiring harnesses - Electrical schematic sheet 20 SH20-UNIVERSAL CONTROL MODULE (55.100.DP-C.20.E.20) Wiring harnesses - Electrical schematic sheet 12 SH12-LOADER VALVE AND SENSORS (55.100.DP-C.20.E.12)
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Electrical systems - FAULT CODES
5512 - Implausible Bucket Sensor State Vs Loader Bucket Command - Stuck Spool Or PRV SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Context: The UCM has sensed that the bucket spool position sensor does not agree with the direction of bucket travel. Diagnostic Trouble Code 5512 â&#x20AC;&#x201C; Implausible Bucket Sensor State Vs Loader Bucket Command - Stuck Spool Or PRV has an error priority of Red. The loader hydraulics are disabled while Diagnostic Trouble Code 5512 â&#x20AC;&#x201C; Implausible Bucket Sensor State Vs Loader Bucket Command - Stuck Spool Or PRV. Cause: The UCM has sensed that the bucket spool position sensor does not agree with the direction of bucket travel. The fault is active while the engine is ON and the bucket spool position sensor senses the bucket movement but the solenoids are not energized or bucket movement is opposite of the energized solenoid. Possible failure modes: 1. Improper wiring in circuit. Connector X-25 swapped with connector X-26. 2. The spool is sticking inside the valve body. 3. A failure of bucket spool position sensor. 4. A faulty UCM. Solution: 1. Verify that the spool is not stuck in the valve. Turn the ignition switch OFF. Remove the bucket spool position sensor from the valve body. Turn the ignition switch ON. Access EST and monitor the spool position. Move the pintle arm while monitoring the valve position sensor signal. The value should change linearly and not become erratic. A. The sensor value changes in a linear fashion. The problem is in the valve body. Repair or replace the valve or spool as required. Return to step 2 to confirm elimination of the fault. B. The sensor values did not change in a linear fashion. The problem is in the sensor circuit. Go to step 2. 2. 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. OK to return the machine to service.
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B. Fault code 5512 – Implausible Bucket Sensor State Vs Loader Bucket Command - Stuck Spool Or PRV is recorded again. Go to step 3. 3. Verify that the wiring and connectors are free of damage. Inspect the UCM, the bucket valve solenoids, and the bucket spool position sensor connections. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the UCM to the bucket valve solenoids, and the bucket spool position sensor connections. Verify that the harness is free of damage, corrosion, abrasion, and incorrect attachment.
20111502
Legend (1) (2)
Bucket Position Sensor Bucket Valve Retract
1
(3) (4)
Boom Position Sensor Aux Position Sensor
A. The connectors are secure and the harness is free of damage. The bucket Valve Spools are connected properly. Go to step 4. B. The connectors or the harness has damage. Repair or replace the harness or the connectors as required. Return to step 2 to confirm elimination of fault. 4. Measure the voltage at the sensor. Disconnect the bucket spool position sensor. Turn the ignition switch ON. Measure the voltage between X-21 pin 1 and X-21 pin 3. The voltage should be approximately 5 V. Wiggle the harness during measurement to reveal an intermittent condition. A. The voltage is approximately 5 V. Go to step 5. B. The voltage is less the 4.5 V. There is a problem in the supply voltage to the sensor. Check UCM connector CN1A pin 8. Repair or replace the harness as required. Return to step 2 to confirm elimination of fault. 5. Test the UCM. Turn the ignition switch OFF. Disconnect the bucket spool position sensor from the harness. Turn the ignition switch ON. Monitor the EST fault code screen. Fault code 5512 – Implausible Bucket Sensor State Vs Loader Bucket Command - Stuck Spool Or PRV should be active. Use a jumper wire to connect X-21 pin 1 to X-21 pin 4. Fault code 5505 – Bucket Valve Spool Sensor Shorted To Power should be active. A. Fault code 5512 – Implausible Bucket Sensor State Vs Loader Bucket Command - Stuck Spool Or PRV is active while the sensor is disconnected and fault code 5505 – Bucket Valve Spool Sensor Shorted To Power is active while the X-21 pin 1 is shorted to X-21 pin 4. Temporarily replace the bucket spool position sensor and retest. Return to step 2 to confirm elimination of the fault. 48068130 29/01/2018
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B. Fault code 5512 â&#x20AC;&#x201C; Implausible Bucket Sensor State Vs Loader Bucket Command - Stuck Spool Or PRV is not active while the X-21 pin 1 is shorted to X-21 pin 4. Temporarily replace the UCM and retest. Return to step 2 to confirm elimination of the fault. Wiring harnesses - Electrical schematic sheet 20 SH20-UNIVERSAL CONTROL MODULE (55.100.DP-C.20.E.20) Wiring harnesses - Electrical schematic sheet 12 SH12-LOADER VALVE AND SENSORS (55.100.DP-C.20.E.12)
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Electrical systems - FAULT CODES
5513 - Implausible Auxiliary Sensor State Vs Auxiliary Command Stuck Spool Or PRV SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Context: The UCM has sensed that the auxiliary position sensor does not agree with the direction of travel for the auxiliary valve command. Diagnostic Trouble Code 5513 â&#x20AC;&#x201C; Implausible Auxiliary Sensor State Vs Auxiliary Command Stuck Spool Or PRV has an error priority of Red. The loader hydraulics are disabled while Diagnostic Trouble Code 5513 â&#x20AC;&#x201C; Implausible Auxiliary Sensor State Vs Auxiliary Command - Stuck Spool Or PRV is active. Cause: The UCM has sensed that the auxiliary spool position sensor does not agree with the direction of travel for the auxiliary valve command. The fault is active when the engine is ON and the auxiliary spool position sensor senses movement but the solenoids are not energized or the auxiliary spool movement is opposite of the energized solenoid. Possible failure modes: 1. Improper wiring in the circuit. Connector X-29 is swapped with connector X-24. 2. The spool is sticking inside the valve body. 3. A failure of the auxiliary spool position sensor. 4. A faulty UCM. Solution: 1. Verify that the spool is not stuck in the valve. Turn the ignition switch OFF. Remove the auxiliary spool position sensor from the valve body. Turn the ignition switch ON. Access EST and monitor the spool position. Move the pintle arm while monitoring the valve position sensor signal. The value should change linearly and not become erratic. A. The sensor values change in a linear fashion. The problem is in the valve body. Repair or replace the valve or the spool as required. Return to step 2 to confirm elimination of the fault. B. The sensor values did not change in a linear fashion. The problem is in the sensor circuit. Go to step 2. 2. 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. OK to return the machine to service.
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Electrical systems - FAULT CODES
B. Fault code 5513 – Implausible Auxiliary Sensor State Vs Auxiliary Command - Stuck Spool Or PRV is recorded again. Go to step 3. 3. Verify that the wiring and connectors are free of damage. Inspect the UCM, the proportional aux solenoid connections, and the auxiliary spool position sensor connections. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the UCM to the proportional aux solenoids, and the auxiliary spool position sensor. Verify that the harness is free of damage, corrosion, abrasion, and incorrect attachment.
20111502
Legend (1) (2)
Aux Valve Retract Aux Position Sensor
1
(3) (4)
Bucket Position Sensor Boom Position Sensor
A. The connectors are secure and the harness is free of damage. Go to step 4. B. The connectors or the harness has damage. Repair or replace the harness or the connectors as required. Return to step 2 to confirm elimination of fault. 4. Measure the voltage at the sensor. Disconnect the auxiliary spool position sensor. Turn the ignition switch ON. Measure the voltage between X-23 pin 1 and X-23 pin 3. The voltage should be approximately 5 V. Wiggle the harness during measurement to reveal an intermittent condition. A. The voltage is approximately 5 V. Go to step 5. B. The voltage is less the 4.5 V. There is a problem in the supply voltage to the sensor. Check UCM connector X-CN1A pin 8. Verify the chassis ground connection from connector X-10 is tight and secure. Repair or replace the harness as required. Return to step 2 to confirm elimination of fault. 5. Test the UCM. Turn the ignition switch OFF. Disconnect the auxiliary spool position sensor from the harness. Turn the ignition switch ON. Monitor the EST fault code screen. Fault code 5513 – Implausible Auxiliary Sensor State Vs Auxiliary Command - Stuck Spool Or PRV should be active. Use a jumper wire to short X-23 pin 1 to X-23 pin 4. Fault code 5508 – Auxiliary Valve Spool Sensor Shorted To Power should be active. A. Fault code 5513 – Implausible Auxiliary Sensor State Vs Auxiliary Command - Stuck Spool Or PRV is active while the sensor is disconnected and fault code 5508 – Auxiliary Valve Spool Sensor Shorted To Power is active while the X-23 pin 1 is shorted to X-23 pin 4. Temporarily replace the auxiliary spool position sensor and retest. Return to step 2 to confirm elimination of the fault. 48068130 29/01/2018
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B. Fault code 5508 â&#x20AC;&#x201C; Auxiliary Valve Spool Sensor Shorted To Power is not active while the X-23 pin 1 is shorted to X-23 pin 4. Temporarily replace the UCM and retest. Return to step 2 to confirm elimination of the fault. Wiring harnesses - Electrical schematic sheet 20 SH20-UNIVERSAL CONTROL MODULE (55.100.DP-C.20.E.20) Wiring harnesses - Electrical schematic sheet 12 SH12-LOADER VALVE AND SENSORS (55.100.DP-C.20.E.12)
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Electrical systems - FAULT CODES
5601 - Loader Auxiliary Valve (Directional) Loader Auxiliary Solenoid(s) Shorted To Power SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Context: The UCM has sensed a higher than normal voltage on the proportional aux solenoid lines. Fault code 5601 – Loader Auxiliary Valve (Directional) Loader Auxiliary Solenoid(s) Shorted To Power has an error priority of White. The auxiliary hydraulic functions are disabled while Diagnostic Trouble Code 5601 – Loader Auxiliary Valve (Directional) Loader Auxiliary Solenoid(s) Shorted To Power is active. Cause: The UCM has sensed a higher than normal voltage on the proportional aux solenoid lines, X-CN1A (Receptacle) pin 24 or X-CN1B (Receptacle) pin 33. The fault is active while the ignition is on, the hydraulics are disabled, and the solenoid voltage feedback is greater than 5 V. Possible failure modes: 1. A shorted wire in the circuit. 2. The UCM has an internal failure. 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. OK to return the machine to service. B. Fault code 5601 – Loader Auxiliary Valve (Directional) Loader Auxiliary Solenoid(s) Shorted To Power is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the UCM and the proportional aux solenoid connections. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the UCM to the proportional aux solenoids. 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 the connectors as required. Return to step 1 to confirm elimination of fault. 3. Measure the voltage on the signal wires. Turn the ignition switch OFF. Disconnect UCM connectors X-CN1A and X-CN1B. Turn the ignition switch ON.
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55.21 [55.DTC] / 799
Electrical systems - FAULT CODES
Measure the voltage between X-CN1A (Receptacle) pin 24 and chassis ground. The voltage should be less than 0.5 V. Wiggle the harness to reveal an intermittent condition. Measure the voltage between X-CN1A (Receptacle) pin 22 and chassis ground. The voltage should be less than 0.5 V. Wiggle the harness to reveal an intermittent condition. Measure the voltage between X-CN1B (Receptacle) pin 33 and chassis ground. The voltage should be less than 0.5 V. Wiggle the harness to reveal an intermittent condition. A. All measured voltages are less than 0.5 V. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. B. One or more of the voltage measurements are greater than 0.5 V. There is a short circuit to another voltage source. Repair or replace the harness or the connectors as required. Return to step 1 to confirm elimination of fault. Wiring harnesses - Electrical schematic sheet 20 SH20-UNIVERSAL CONTROL MODULE (55.100.DP-C.20.E.20) Wiring harnesses - Electrical schematic sheet 12 SH12-LOADER VALVE AND SENSORS (55.100.DP-C.20.E.12)
48068130 29/01/2018
55.21 [55.DTC] / 800
Electrical systems - FAULT CODES
5602 - Loader Auxiliary Valve (Directional) Loader Auxiliary Solenoid(s) Shorted To Ground SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Context: The UCM has sensed that the solenoid voltages are too low. Fault code 5602 – Loader Auxiliary Valve (Directional) Loader Auxiliary Solenoid(s) Shorted To Ground has an error priority of White. Auxiliary hydraulic functions are disabled while Diagnostic Trouble Code 5602 – Loader Auxiliary Valve (Directional) Loader Auxiliary Solenoid(s) Shorted To Ground is active. Cause: The UCM has sensed that the solenoid voltages are too low. The fault is active while the hydraulics are disabled and the solenoid voltages on pin X-CN1A (Receptacle) pin 22 and X-CN1A (Receptacle) pin 24 are less than 2 V. Possible failure modes: 1. A short circuit in the wiring. 2. Faulty proportional auxiliary valves. 3. A failure of the UCM. 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. OK to return the machine to service. B. Fault code 5602 – Loader Auxiliary Valve (Directional) Loader Auxiliary Solenoid(s) Shorted To Ground is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the UCM and the proportional aux solenoid connections. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the UCM to the proportional aux solenoids. 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 the connectors as required. Return to step 1 to confirm elimination of fault. 3. Test the UCM. Turn the ignition switch OFF. Disconnect solenoid connectors X-29 and X-24. Turn the ignition switch ON. 48068130 29/01/2018
55.21 [55.DTC] / 801
Electrical systems - FAULT CODES
Use the electronic service tool to access the fault code screen. Fault code 5602 – Loader Auxiliary Valve (Directional) Loader Auxiliary Solenoid(s) Shorted To Ground should no longer be active. Fault code 5603 – Loader Auxiliary Valve (Directional) Solenoids Return Open Circuit is now active. A. Fault code 5602 – Loader Auxiliary Valve (Directional) Loader Auxiliary Solenoid(s) Shorted To Ground is no longer active. Fault code 5603 – Loader Auxiliary Valve (Directional) Solenoids Return Open Circuit is now active. Replace both solenoids and retest. Return to step 1 to confirm elimination of the fault. B. Fault code 5602 – Loader Auxiliary Valve (Directional) Loader Auxiliary Solenoid(s) Shorted To Ground is active. Fault code 5603 – Loader Auxiliary Valve (Directional) Solenoids Return Open Circuit did not become active. Go to step 4. 4. Measure the resistance of the solenoid wire to chassis ground. Turn the ignition switch OFF. Disconnect UCM connector X-CN1A and both solenoid connectors, X-29 and X-24. Measure the resistance between X-CN1A (Receptacle) pin 24 and chassis ground. The resistance should be greater than 20,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition. Measure the resistance between X-CN1A (Receptacle) pin 22 and chassis ground. The resistance should be greater than 20,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition. Measure the resistance between X-CN1A (Receptacle) pin 24 and X-CN1A (Receptacle) pin 22. The resistance should be greater than 20,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition. Leave UCM connector X-CN1A disconnected. Disconnect UCM connector X-CN1B. Measure the resistance between X-CN1B (Receptacle) pin 33 and chassis ground. The resistance should be greater than 20,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition. Measure the resistance between X-CN1B (Receptacle) pin 33 and X-CN1A (Receptacle) pin 22. The resistance should be greater than 20,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition. Measure the resistance between X-CN1B (Receptacle) pin 33 and X-CN1A (Receptacle) pin 24. The resistance should be greater than 20,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition. A. All resistance measurements are greater than 20,000 Ω. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. B. One or more resistance measurements are less than 20,000 Ω. There is a short circuit in the wiring. Repair or replace the harness as required. Return to step 1 to confirm elimination of the fault. Wiring harnesses - Electrical schematic sheet 20 SH20-UNIVERSAL CONTROL MODULE (55.100.DP-C.20.E.20) Wiring harnesses - Electrical schematic sheet 12 SH12-LOADER VALVE AND SENSORS (55.100.DP-C.20.E.12)
48068130 29/01/2018
55.21 [55.DTC] / 802
Electrical systems - FAULT CODES
5603 - Loader Auxiliary Valve (Directional) Solenoids Return Open Circuit SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Context: The UCM has sensed an open circuit in the proportional aux solenoid return circuit. Diagnostic Trouble Code 5603 – Loader Auxiliary Valve (Directional) Solenoids Return Open Circuit has an error priority of White. The auxiliary hydraulic functions are disabled while Diagnostic Trouble Code 5603 – Loader Auxiliary Valve (Directional) Solenoids Return Open Circuit is active. Cause: The UCM has sensed an open circuit in the proportional aux solenoid return circuit, X-CN1A (Receptacle) pin 22. The fault is active while the ignition is ON and the calculated solenoid resistances have increased over 70%. Possible failure modes: 1. An open circuit in the solenoid wiring. 2. The proportional aux solenoids have failed. 3. The UCM has an internal failure. 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. OK to return the machine to service. B. Fault code 5603 – Loader Auxiliary Valve (Directional) Solenoids Return Open Circuit is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the UCM and the proportional aux solenoid connections. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the UCM to the proportional aux solenoids. 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 the connectors as required. Return to step 1 to confirm elimination of fault. 3. Measure the resistance through the solenoid circuit. Turn the ignition switch OFF. Disconnect UCM connectors X-CN1A and X-CN1B.
48068130 29/01/2018
55.21 [55.DTC] / 803
Electrical systems - FAULT CODES
Measure the resistance between X-CN1A (Receptacle) pin 24 and X-CN1A (Receptacle) pin 22. The resistance should be less than 1,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition. Measure the resistance between X-CN1B (Receptacle) pin 33 and X-CN1A (Receptacle) pin 22. The resistance should be less than 1,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition. A. Both resistance measurements are less than 1,000 Ω. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. B. One or both resistance are greater than 1,000 Ω. There is an open circuit in the wiring. Go to step 4. 4. Measure the solenoid resistance. Measure the resistance across the extend solenoid terminals, pin 1 and pin 2. The resistance should be less than 1,000 Ω. Measure the resistance across the retract solenoid terminals, pin 1 and pin 2. The resistance should be less than 1,000 Ω. A. The resistance is less than 1,000 Ω. Go to step 5. B. The resistance is greater than 1,000 Ω. There is an open circuit in the solenoid. Replace the solenoid and retest. Return to step 1 to confirm elimination of the fault. 5. Measure the resistance through the circuit. Leave UCM connectors CN1A and CN1B disconnected. Fabricate a jumper wire that will connect between X-29 pin 1 and pin 2. Connect the jumper wire between X-29 pin 1 and X-29 pin 2. Measure the resistance between X-CN1A (Receptacle) pin 24 and X-CN1A (Receptacle) pin 22. The resistance should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition. Remove the jumper from X-29. Connect the jumper wire between X-24 pin 1 and X-24 pin 2. Measure the resistance between X-CN1B (Receptacle) pin 33 and X-CN1A (Receptacle) pin 22. 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. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. 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 the fault. Wiring harnesses - Electrical schematic sheet 20 SH20-UNIVERSAL CONTROL MODULE (55.100.DP-C.20.E.20) Wiring harnesses - Electrical schematic sheet 12 SH12-LOADER VALVE AND SENSORS (55.100.DP-C.20.E.12)
48068130 29/01/2018
55.21 [55.DTC] / 804
Electrical systems - FAULT CODES
5701 - Pattern Switch Open Or Shorted To Ground SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Context: The UCM has sensed the voltage at X-CN1B (Receptacle) pin 15, X-CN2B (Receptacle) pin 20, and X-CN2B (Receptacle) pin 21 is less than 1.5 V. Diagnostic Trouble Code 5701 – Pattern Switch Open Or Shorted To Ground has an error priority of White. The selected joystick pattern is locked and cannot be changed while Diagnostic Trouble Code 5701 – Pattern Switch Open Or Shorted To Ground is active. Cause: The UCM has sensed the voltage at X-CN1B (Receptacle) pin 15, X-CN2B (Receptacle) pin 20, and X-CN2B (Receptacle) pin 21 is less than 1.5 V. Possible failure modes: 1. A short circuit in the wiring 2. An open circuit in the wiring. 3. A faulty drive pattern select switch. 4. The UCM has internal failure. 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. OK to return the machine to service. B. Fault code 5701 – Pattern Switch Open Or Shorted To Ground is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the UCM and the drive pattern selector switch connections. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the UCM to the drive pattern selector 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 the connectors as required. Return to step 1 to confirm elimination of fault. 3. Measure the voltage at the switch. Turn the ignition switch OFF. Remove the drive pattern switch (ISO/ H pattern) from the right hand post. Turn the ignition switch ON. 48068130 29/01/2018
55.21 [55.DTC] / 805
Electrical systems - FAULT CODES
Measure the voltage between X-095 (Receptacle) pin 5 and chassis ground. The voltage should be approximately 12 V. Wiggle the harness during measurement to reveal an intermittent condition. A. The voltage is approximately 12 V. Go to step 4. B. The voltage is less than 10 V. There is a problem in the battery supply to the switch. Repair as required. Return to step 1 to confirm elimination of fault. 4. Measure the resistance of the signal wire to chassis ground. Turn the ignition switch OFF. Disconnect UCM connectors X-CN1B and X-CN2B. Disconnect the drive pattern (ISO/ H Pattern) selector switch. Measure the resistance between X-095 (Receptacle) pin 1 and chassis ground. The resistance should be greater than 20,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition. Measure the resistance between X-095 (Receptacle) pin 3 and chassis ground. The resistance should be greater than 20,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition. Measure the resistance between X-095 (Receptacle) pin 6 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. Go to step 5. 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 1 to confirm elimination of fault. 5. Measure the resistance of the signal wire. Fabricate a jumper wire the will connect between connector X-CN2B (Receptacle) pin 20 and chassis ground. Connect the jumper wire between connector X-CN2B (Receptacle) pin 20 and chassis ground. The chassis ground connection must be clean and free of rust, dirt, oil, and paint. Measure the resistance between connector X-095 (Receptacle) pin 1 and chassis ground. The resistance should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition. Connect the jumper wire between connector X-CN2B (Receptacle) pin 21 and chassis ground. The chassis ground connection must be clean and free of rust, dirt, oil, and paint. Measure the resistance between connector X-095 (Receptacle) pin 6 and chassis ground. The resistance should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition. Connect the jumper wire between connector X-CN1B (Receptacle) pin 15 and the chassis ground. The chassis ground connection must be clean and free of rust, dirt, oil, and paint. Measure the resistance between connector X-095 (Receptacle) pin 3 and chassis ground. 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 6. B. The resistance is greater than 10 Ω. There is an open circuit in the signal wire. Repair or replace the harness as required. Return to step 1 to confirm elimination of fault. 6. Test the drive pattern (ISO/ H pattern) switch. Turn the ignition switch OFF. Remove the drive pattern (ISO/ H pattern) switch from the right hand post. Measure the resistance between pin 5 and pin 3 on the drive pattern (ISO/ H pattern) switch. The resistance should be less than 10 Ω. Actuate the switch to another function. The resistance should be greater than 20,000 Ω. 48068130 29/01/2018
55.21 [55.DTC] / 806
Electrical systems - FAULT CODES
A. The resistance is less than 10 Ω in the neutral state and the resistance changed to a value greater than 20,000 Ω when the switch was actuated. Go to step 7. B. The resistance is not less than 10 Ω in the neutral state or the resistance did not change to a value greater than 20,000 Ω when the switch was actuated. Temporarily replace the drive pattern (ISO/ H pattern) switch and retest. Return to step 1 to confirm elimination of fault. 7. Test the drive pattern (ISO/ H pattern) switch. Measure the resistance between pin 5 and pin 1 on the drive pattern (ISO/ H pattern) switch. The resistance should be greater than 20,000 Ω. Actuate the switch to the H pattern. The resistance should be less than 10 Ω. Measure the resistance between pin 5 and pin 6 on the drive pattern (ISO/ H pattern) switch. The resistance should be greater than 20,000 Ω. Actuate the switch to the ISO Pattern. The resistance should be less than 10 Ω. A. The resistance is greater than 20,000 Ω when the switch is in the neutral state and the resistance changed to a value less than 10 Ω when the switch was actuated. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. B. The resistance is less than 20,000 Ω while the switch is in the neutral state or the resistance did not change to a value less than 10 Ω when the switch was actuated. Temporarily replace the drive pattern (ISO/ H pattern) switch and retest. Return to step 1 to confirm elimination of fault. Wiring harnesses - Electrical schematic sheet 20 SH20-UNIVERSAL CONTROL MODULE (55.100.DP-C.20.E.20) Wiring harnesses - Electrical schematic sheet 09 SH09-THROTTLE SENSORS (55.100.DP-C.20.E.09) Wiring harnesses - Electrical schematic sheet 14 SH14-BULKHEAD CONNECTION (55.100.DP-C.20.E.14)
48068130 29/01/2018
55.21 [55.DTC] / 807
Electrical systems - FAULT CODES
5703 - Pattern Switch Shorted To Power SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Context: The UCM has sensed the voltage at two or more drive pattern selector (ISO/ H pattern) switch pins, X-CN1B (Receptacle) pin 15, X-CN2B (Receptacle) pin 20, or X-CN2B (Receptacle) pin 21 is greater than 3.5 V. Diagnostic Trouble Code 5703 – Pattern Switch Shorted To Power has an error priority of White. The selected joystick pattern is locked and cannot be changed while Diagnostic Trouble Code 5703 – Pattern Switch Shorted To Power is active. Cause: The UCM has sensed the voltage at two or more drive pattern selector (ISO/ H pattern) switch pins, X-CN1B (Receptacle) pin 15, X-CN2B (Receptacle) pin 20, or X-CN2B (Receptacle) pin 21 is greater than 3.5 V. Possible failure modes: 1. A short circuit in the wiring. 2. A faulty drive pattern selector (ISO/ H pattern) switch. 3. The UCM has internal failure. 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. OK to return the machine to service. B. Fault code 5703 – Pattern Switch Shorted To Power is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the UCM and the drive pattern selector switch connections. All connections should be secure, tight, free of corrosion, abrasion and damage. Inspect the harness from the UCM to the drive pattern selector 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. 3. Measure the voltage at the switch inputs to the UCM. Turn the ignition switch OFF. Remove the drive pattern switch (ISO/ H pattern) from the right-hand post. Disconnect connector X-095 from the drive pattern selector switch. Disconnect UCM connectors X-CN1B and X-CN2B from the UCM. 48068130 29/01/2018
55.21 [55.DTC] / 808
Electrical systems - FAULT CODES
Turn the ignition switch ON. Measure the voltage between X-095 (Receptacle) pin 1 and chassis ground. The voltage should be less than 0.5 V. Wiggle the harness during measurement to reveal an intermittent condition. Measure the voltage between X-095 (Receptacle) pin 3 and chassis ground. The voltage should be less than 0.5 V. Wiggle the harness during measurement to reveal an intermittent condition. Measure the voltage between X-095 (Receptacle) pin 6 and chassis ground. The voltage should be less than 0.5 V. Wiggle the harness during measurement to reveal an intermittent condition. A. The voltage is less than 0.5 V. Go to step 4. B. The voltage is greater than 0.5 V, there is a short circuit to another voltage source. Check for a short circuit to battery supply on X-095 (Receptacle) pin 5. Repair as required. Return to step 1 to confirm elimination of fault. 4. Measure the resistance of the signal wire. Fabricate a jumper wire that will connect between connector X-CN2B (Receptacle) pin 20 and chassis ground. The chassis ground connection must be clean and free of rust, dirt oil and paint. Measure the resistance between connector X-095 (Receptacle) pin 1 and chassis ground. The resistance should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition. Connect one end of the jumper wire to connector X-CN2B (Receptacle) pin 21 and the other end to chassis ground. The chassis ground connection must be clean and free of rust, dirt oil and paint. Measure the resistance between connector X-095 (Receptacle) pin 6 and chassis ground. The resistance should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition. Connect one end the jumper wire between connector X-CN1B (Receptacle) pin 15 and chassis ground. The chassis ground connection must be clean and free of rust, dirt oil and paint. Measure the resistance between connector X-095 (Receptacle) pin 3 and chassis ground. 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 5. B. The resistance is greater than 10 Ω. There is an open circuit in the signal wire. Repair or replace the harness as required. Return to step 1 to confirm elimination of fault. 5. Test the drive pattern (ISO/ H pattern) switch. Turn the ignition switch OFF. Remove the drive pattern (ISO/ H pattern) switch from the right-hand post. Use a pair of jumper wires with alligator clips to connect the DVM to the switch. Measure the resistance between pin 5 and pin 3 on the drive pattern (ISO/ H pattern) switch. The resistance should be less than 10 Ω. Actuate the switch to the other function. The resistance should change to a value greater than 20,000 Ω. A. The resistance is less than 10 Ω in the neutral state and the resistance changed to a value greater than 20,000 Ω when the switch was actuated. Go to step 6. B. The resistance is not less than 10 Ω in the neutral state or the resistance did not change to a value greater than 20,000 Ω when the switch was actuated. Temporarily replace the drive pattern (ISO/ H pattern) switch and retest. Return to step 1 to confirm elimination of fault. 6. Test the drive pattern (ISO/ H pattern) switch. Use a pair of jumper wires with alligator clips to connect the DVM to the switch.
48068130 29/01/2018
55.21 [55.DTC] / 809
Electrical systems - FAULT CODES
Measure the resistance between pin 5 and pin 1 on the drive pattern (ISO/ H pattern) switch. The resistance should be greater than 20,000 Ω. Actuate the switch to the H Pattern. The resistance should change to a value less than 10 Ω. Measure the resistance between pin 5 and pin 6 on the drive pattern (ISO/ H pattern) switch. The resistance should be greater than 20,000 Ω. Actuate the switch to the ISO Pattern. The resistance should change to a value less than 10 Ω. A. The resistance is greater than 20,000 Ω when the switch is in the neutral state and the resistance changed to a value less than 10 Ω when the switch was actuated. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. B. The resistance is less than 20,000 Ω while the switch is in the neutral state or the resistance did not change to a value less than 10 Ω when the switch was actuated. Temporarily replace the drive pattern (ISO/ H pattern) switch and retest. Return to step 1 to confirm elimination of fault. Wiring harnesses - Electrical schematic sheet 20 SH20-UNIVERSAL CONTROL MODULE (55.100.DP-C.20.E.20) Wiring harnesses - Electrical schematic sheet 09 SH09-THROTTLE SENSORS (55.100.DP-C.20.E.09) Wiring harnesses - Electrical schematic sheet 14 SH14-BULKHEAD CONNECTION (55.100.DP-C.20.E.14)
48068130 29/01/2018
55.21 [55.DTC] / 810
Electrical systems - FAULT CODES
5811 - Loader Port Lock Switch Is In An Implausible State SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Context: The UCM has sensed an implausible state of the loader lockout switch. Diagnostic Trouble Code 5811 – Loader Port Lock Switch Is In An Implausible State has an error priority of Amber. There are no restrictions while Diagnostic Trouble Code 5811 – Loader Port Lock Switch Is In An Implausible State is active. Cause: The UCM has sensed an implausible state on the loader lockout switch. The fault is active when the engine is running and both UCM inputs CN2B pin 23 and CN3B pin 19, are less than 1.5 V or greater than 3.5 V. Possible failure modes: 1. Faulty wiring or connectors. 2. A faulty loader lockout switch. 3. A faulty UCM. 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. OK to return the machine to service. B. Fault code 5811 – Loader Port Lock Switch Is In An Implausible State is recorded again. Go to step 2. 2. Verify the harness and connectors are not damaged. Inspect the UCM and loader lockout switch connections. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the UCM to the loader lockout switch. 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, or incorrect attachment. Repair or replace the harness as required. Go to step 1 to confirm elimination of the fault. 3. Measure the voltage at the switch. Turn the ignition switch OFF. Disconnect the loader lockout switch connector X-306. Turn the ignition switch ON. Measure the voltage between X-306 (Receptacle) pin C and chassis ground. The voltage should be approximately 12 V. Wiggle the harness to reveal an intermittent condition. 48068130 29/01/2018
55.21 [55.DTC] / 811
Electrical systems - FAULT CODES
A. The voltage is approximately 12 V. Go to step 3. B. The voltage is less than 10 V. There is a problem with the battery supply to the switch. Check the fuses. Repair or replace the harness as required. Return to step 1 to confirm elimination of the fault. 4. Test the UCM. Turn the ignition switch OFF. Disconnect the loader lockout switch. Fabricate a jumper with that will connect between X-306 (Receptacle) pin C and X-306 (Receptacle) pin D. Connect the jumper between X-306 (Receptacle) pin C and X-306 (Receptacle) pin D. Turn the ignition switch ON. Monitor the fault code screen. Fault code 5811 – Loader Port Lock Switch Is In An Implausible State should no longer be active. Use the EST to monitor the loader lockout switch status. The switch status should change from OFF to ON. Turn the ignition switch OFF. Connect the jumper between X-306 (Receptacle) pin C and X-306 (Receptacle) pin D. Turn the ignition switch ON. Monitor the fault code screen. Fault code 5811 – Loader Port Lock Switch Is In An Implausible State should no longer be active. Use the EST to monitor the loader lockout switch status. The switch status should change from ON to OFF. A. The switch status displayed ON when the jumper was connected between X-306 (Receptacle) pin C and X-306 (Receptacle) pin D. The switch status displayed OFF when the jumper was not connected between X-306 (Receptacle) pin C and X-306 (Receptacle) pin D. Replace the loader lockout switch and retest. Return to step 1 to confirm elimination of the fault. B. The switch status did not change or fault code 5811 – Loader Port Lock Switch Is In An Implausible State remained active. Go to step 5. 5. Measure the resistance through the signal wires. Turn the ignition switch OFF. Use the jumper wire to connect X-306 (Receptacle) pin C to X-306 (Receptacle) pin E. Disconnect UCM connectors X-CN2A and X-CN3B. Measure the resistance between X-CN2B (Receptacle) pin 23 and X-CN3B (Receptacle) pin 19. The resistance should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition. A. The measured resistance is less than 10 Ω. Go to step 6. B. The measured resistance is greater than 10 Ω. There is an open circuit in the wiring. Repair or replace the harness or connectors as required. Return to step 1 to confirm elimination of the fault. 6. Measure the voltage on the signal wires. Remove the jumper wire connected between X-306 (Receptacle) pin C and X-306 (Receptacle) pin E. Turn the ignition switch ON. Measure the voltage between X-CN2B (Receptacle) pin 23 and chassis ground. The voltage should be less than 0.5 V. Wiggle the harness to reveal an intermittent condition.
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55.21 [55.DTC] / 812
Electrical systems - FAULT CODES
Measure the voltage between X-CN3B (Receptacle) pin 19 and chassis ground. The voltage should be less than 0.5 V. Wiggle the harness to reveal an intermittent condition. A. Both measured voltages are less than 0.5 V. Temporarily replace the UCM and retest. Return to step 6. B. One or both voltage measurements are greater than 0.5 V. There is a short circuit to another voltage source. Repair or replace the harness as required. Return to step 1 to confirm elimination of the fault. Wiring harnesses - Electrical schematic sheet 16 SH16-LEFT HAND CAB CONSOLE (55.100.DP-C.20.E.16) Wiring harnesses - Electrical schematic sheet 13 SH13-BULKHEAD CONNECTION (55.100.DP-C.20.E.13) Wiring harnesses - Electrical schematic sheet 27 SH27-INSTRUMENT CLUSTER (55.100.DP-C.20.E.27) Wiring harnesses - Electrical schematic sheet 21 SH21-UNIVERSAL CONTROL MODULE (55.100.DP-C.20.E.21)
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Electrical systems - FAULT CODES
9004 - Memory Error - Triple Redundant - Hour Meter Location 1 Corrupt Cause: 1. An internal failure within the instrument cluster. Solution: 1. Verify that the fault code is active. Connect the Electronic Service Tool to the service tool connector. To check for fault codes: Start and operate the machine. A. Fault code 9004 â&#x20AC;&#x201C; Memory Error - Triple Redundant - Hour Meter Location 1 Corrupt is recorded again. Replace the instrument cluster. Return to step 1 to confirm elimination of the fault. B. The fault code is not recorded again. OK to return the machine to service.
48068130 29/01/2018
55.21 [55.DTC] / 814
Electrical systems - FAULT CODES
9005 - Memory Error - Triple Redundant - Hour Meter Location 2 Corrupt Context: Diagnostic Trouble Code 9005 has an error priority of White. There are no restrictions with Diagnostic Trouble Code 9005. Cause: 1. Internal failure within the instrument cluster. Solution: 1. Verify that the fault code is active. Connect the Electronic Service Tool to the service tool connector. To check for fault codes: Start and operate the machine. A. Fault code 9005 â&#x20AC;&#x201C; Memory Error - Triple Redundant - Hour Meter Location 2 Corrupt is recorded again. Replace the instrument cluster. Return to step 1 to confirm elimination of the fault. B. The fault code is not recorded again. OK to return the machine to service.
48068130 29/01/2018
55.21 [55.DTC] / 815
Electrical systems - FAULT CODES
9006 - Memory Error - Triple Redundant - Hour Meter Location 3 Corrupt Context: Diagnostic Trouble Code 9006 has an error priority of White. There are no restrictions with Diagnostic Trouble Code 9006. Cause: 1. Internal failure within the instrument cluster. Solution: 1. Verify that the fault code is active. Connect the Electronic Service Tool to the service tool connector. To check for fault codes: Start and operate the machine. A. Fault code 9006 â&#x20AC;&#x201C; Memory Error - Triple Redundant: Hour Meter - Location 3 Corrupt is recorded again. Replace the instrument cluster. Return to step 1 to confirm elimination of the fault. B. The fault code is not recorded again. OK to return the machine to service.
48068130 29/01/2018
55.21 [55.DTC] / 816
Electrical systems - FAULT CODES
9151 - Bus-Warn at CAN-Bus No.1 SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Context: CAN bus communications between the modules on the data link have been lost. This fault code may be displayed with other CAN bus fault code messages. Cause: CAN bus communications between the modules on the data link have been lost. Possible failure modes: 1. An open circuit in the CAN data link wiring. 2. A short circuit in the CAN data link wiring. 3. A faulty device on the CAN data link. 4. A faulty instrument cluster. 5. A faulty ECU. Solution: 1. Verify that the fault code is active. Connect the Electronic Service Tool to the service tool connector. To check for fault codes: Start and operate the machine. A. Fault code 9151 – Bus-Warn at CAN-Bus No.1 is not recorded again. Go to step 2. B. Fault code 9151 – Bus-Warn at CAN-Bus No.1 is recorded again. There are one or two other CAN bus fault codes associated with 9151 – Bus-Warn at CAN-Bus No.1. Go to step 2. C. Fault code 9151 – Bus-Warn at CAN-Bus No.1 is recorded along with multiple CAN data link faults such as 1051 – Timeout of CAN message EEC1 - 1063 – Timeout of CAN message EEC2, and/or 3096 – CAN A Bus off failure, 3179 – CAN communication failure between vehicle controller and ECU - BC2ECU2 message and 3180 – CAN communication error between vehicle controller to ECU. Go to 1051 - No CAN Communication With Engine Controller (55.640) step 3. 2. Verify that the CAN bus circuit is functioning properly. Connect the Electronic Service Tool to the service tool connector. Turn the ignition switch ON. Verify the connections to the ECU, the instrument cluster, the diagnostic connector, the UCM (if installed), and the optional Telematics unit are tight and secure. Check for CAN bus fault codes while wiggling the harness. Turn the ignition switch OFF. Disconnect the instrument cluster connector X-C23. Measure the resistance between X-C23 (Receptacle) pin 5 and X-C23 (Receptacle) pin 6 on the instrument cluster. The resistance should be between 108 Ω and 132 Ω.
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55.21 [55.DTC] / 817
Electrical systems - FAULT CODES
Disconnect the ECU connector X-012. Measure the resistance between X-012 (Receptacle) pin 24 and X-012 (Receptacle) pin 25 on the ECU. The resistance should be between 108 立 and 132 立. A. All connections are secure. Both resistance measurements are within the specified range. OK to return the machine to service. B. The harness is damaged or the connectors are loose or damaged. Repair or replace the harness or the connectors as required. Return to step 1 to confirm elimination of the fault. C. One or both resistance measurements are less than 108 立 or greater than 132 立. Replace the control module that has the bad resistance value. Return to step 1 to confirm elimination of fault.
48068130 29/01/2018
55.21 [55.DTC] / 818
Electrical systems - FAULT CODES
9152 - Bus-Warn at CAN-Bus No.1 SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Context: CAN bus communications between the modules on the data link have been lost. This fault code may be displayed with other CAN bus fault code messages. Cause: CAN bus communications between the modules on the data link have been lost. Possible failure modes: 1. An open circuit in the CAN data link wiring. 2. A short circuit in the CAN data link wiring. 3. A faulty device on the CAN data link. 4. A faulty instrument cluster. 5. A faulty ECU. Solution: 1. Verify that the fault code is active. Connect the Electronic Service Tool to the service tool connector. To check for fault codes: Start and operate the machine. A. Fault code 9152 – Bus-Warn at CAN-Bus No.1 is not recorded again. Go to step 2. B. Fault code 9152 – Bus-Warn at CAN-Bus No.1 is recorded again. There are one or two other CAN bus fault codes associated with 9151 – Bus-Warn at CAN-Bus No.1. Go to step 2. C. Fault code 9152 – Bus-Warn at CAN-Bus No.1 is recorded along with multiple CAN data link faults such as 1051 – Timeout of CAN message EEC1 - 1063 – Timeout of CAN message EEC2, and/or 3096 – CAN A Bus off failure, 3179 – CAN communication failure between vehicle controller and ECU - BC2ECU2 message and 3180 – CAN communication error between vehicle controller to ECU. Go to 1051 - No CAN Communication With Engine Controller (55.640) step 3. 2. Verify that the CAN bus circuit is functioning properly. Connect the Electronic Service Tool to the service tool connector. Turn the ignition switch ON. Verify the connections to the ECU, the instrument cluster, the diagnostic connector, the UCM (if installed), and the optional Telematics unit are tight and secure. Check for CAN bus fault codes while wiggling the harness. Turn the ignition switch OFF. Disconnect the instrument cluster connector X-C23. Measure the resistance between X-C23 (Receptacle) pin 5 and X-C23 (Receptacle) pin 6 on the instrument cluster. The resistance should be between 108 Ω and 132 Ω.
48068130 29/01/2018
55.21 [55.DTC] / 819
Electrical systems - FAULT CODES
Disconnect the ECU connector X-012. Measure the resistance between X-012 (Receptacle) pin 24 and X-012 (Receptacle) pin 25 on the ECU. The resistance should be between 108 立 and 132 立. A. All connections are secure. Both resistance measurements are within the specified range. OK to return the machine to service. B. The harness is damaged or the connectors are loose or damaged. Repair or replace the harness or the connectors as required. Return to step 1 to confirm elimination of the fault. C. One or both resistance measurements are less than 108 立 or greater than 132 立. Replace the control module that has the bad resistance value. Return to step 1 to confirm elimination of fault.
48068130 29/01/2018
55.21 [55.DTC] / 820
Electrical systems - FAULT CODES
9153 - Timeout of CAN Message EEC1 SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Context: CAN bus communications between the modules on the data link have been lost. This fault code may be displayed with other CAN bus fault code messages. Cause: CAN bus communications between the modules on the data link have been lost. This fault code may also occur when a new, blank ECU has been installed on the machine. Program the ECU before troubleshooting. Possible failure modes: 1. A new, blank ECU has been installed on the machine. 2. A failed main relay. 3. An open circuit in the CAN data link wiring. 4. A short circuit in the CAN data link wiring. 5. A faulty device on the CAN data link. 6. A faulty instrument cluster. 7. A faulty ECU. Solution: 1. Check the main relay. Remove the main relay from the panel. Check the main relay for water intrusion. A. There are no signs of water intrusion in the main relay. Go to step 2. B. The main relay shows signs of water intrusion such as corrosion or water inside the relay. Replace the relay and retest. Return to step 3 to confirm elimination of the fault. 2. Use the EST to verify the controller status. Connect the EST to the service tool connector. Turn the ignition switch ON. Verify that the all of the controllers are ONLINE. A. The ECU status is OFFLINE and fault codes 9153 â&#x20AC;&#x201C; Timeout of CAN Message EEC1 and 1051 â&#x20AC;&#x201C; Timeout of CAN message EEC1 are active. Check the 2 A relay ground fuses. Replace the fuses as required. Verify that the fault codes are no longer active. If the fault code is still active, refer to 1051 - No CAN Communication With Engine Controller (55.640). B. The ECU status is ONLINE. Go to step 3. 3. Verify that the fault code is active.
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55.21 [55.DTC] / 821
Electrical systems - FAULT CODES
Connect the Electronic Service Tool to the service tool connector. To check for fault codes: Start and operate the machine. A. Fault code 9153 – Timeout of CAN Message EEC1 is not recorded again. Go to step 4. B. Fault code 9153 – Timeout of CAN Message EEC1 is recorded again. There are one or two other CAN bus fault codes associated with 9151 – Bus-Warn at CAN-Bus No.1. Go to step 4. C. Fault code 9153 – Timeout of CAN Message EEC1 is recorded along with multiple CAN data link faults such as 1051 – Timeout of CAN message EEC1 - 1063 – Timeout of CAN message EEC2, and/or 3096 – CAN A Bus off failure, 3179 – CAN communication failure between vehicle controller and ECU - BC2ECU2 message and 3180 – CAN communication error between vehicle controller to ECU. Go to 1051 - No CAN Communication With Engine Controller (55.640) step 3. 4. Verify that the CAN bus circuit is functioning properly. Connect the Electronic Service Tool to the service tool connector. Turn the ignition switch ON. Verify the connections to the ECU, the instrument cluster, the diagnostic connector, the UCM (if installed), and the optional Telematics unit are tight and secure. Check for CAN bus fault codes while wiggling the harness. Turn the ignition switch OFF. Disconnect the instrument cluster connector X-C23. Measure the resistance between X-C23 (Receptacle) pin 5 and X-C23 (Receptacle) pin 6 on the instrument cluster. The resistance should be between 108 Ω and 132 Ω. Disconnect the ECU connector X-012. Measure the resistance between X-012 (Receptacle) pin 24 and X-012 (Receptacle) pin 25 on the ECU. The resistance should be between 108 Ω and 132 Ω. A. All connections are secure. Both resistance measurements are within the specified range. OK to return the machine to service. B. The harness is damaged or the connectors are loose or damaged. Repair or replace the harness or the connectors as required. Return to step 3 to confirm elimination of the fault. C. One or both resistance measurements are less than 108 Ω or greater than 132 Ω. Replace the control module that has the bad resistance value. Return to step 3 to confirm elimination of fault.
48068130 29/01/2018
55.21 [55.DTC] / 822
Electrical systems - FAULT CODES
9154 - Timeout of CAN Message TSC1 SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Context: CAN bus communications between the modules on the data link have been lost. This fault code may be displayed with other CAN bus fault code messages. Cause: CAN bus communications between the modules on the data link have been lost. Possible failure modes: 1. An open circuit in the CAN data link wiring. 2. A short circuit in the CAN data link wiring. 3. A faulty device on the CAN data link. 4. A faulty instrument cluster. 5. A faulty ECU. Solution: 1. Use the EST to verify the controller status. Connect the EST to the service tool connector. Turn the ignition switch ON. Verify that the all of the controllers are ONLINE. A. The ECU status is OFFLINE and fault codes 9153 – Timeout of CAN Message EEC1 and 1051 – Timeout of CAN message EEC1 are active. Check the 2 A relay ground fuses. Replace the fuses as required. Verify that the fault codes are no longer active. If the fault code is still active, refer to 1051 - No CAN Communication With Engine Controller (55.640) B. The ECU status is ONLINE. Go to step 2. 2. Verify that the fault code is active. Connect the Electronic Service Tool to the service tool connector. To check for fault codes: Start and operate the machine. A. Fault code 9154 – Timeout of CAN Message TSC1 is not recorded again. Go to step 3. B. Fault code 9154 – Timeout of CAN Message TSC1 is recorded again. There are one or two other CAN bus fault codes associated with 9154 – Timeout of CAN Message TSC1. Go to step 3. C. Fault code 9154 – Timeout of CAN Message TSC1 is recorded along with multiple CAN data link faults such as 1051 – Timeout of CAN message EEC1 - 1063 – Timeout of CAN message EEC2, and/or 3096 – CAN A Bus off failure, 3179 – Timeout of CAN Message BC2EDC2 and 3180 – Timeout of CAN Message VCM2EDC. Go to 1051 - No CAN Communication With Engine Controller (55.640) step 3. 3. Verify that the CAN bus circuit is functioning properly.
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55.21 [55.DTC] / 823
Electrical systems - FAULT CODES
Connect the Electronic Service Tool to the service tool connector. Turn the ignition switch ON. Verify the connections to the ECU, the instrument cluster, the diagnostic connector, the UCM (if installed), and the optional Telematics unit are tight and secure. Check for CAN bus fault codes while wiggling the harness. Turn the ignition switch OFF. Disconnect the instrument cluster connector X-C23. Measure the resistance between X-C23 (Receptacle) pin 5 and X-C23 (Receptacle) pin 6 on the instrument cluster. The resistance should be between 108 Ω and 132 Ω. Disconnect the ECU connector X-012. Measure the resistance between X-012 (Receptacle) pin 24 and X-012 (Receptacle) pin 25 on the ECU. The resistance should be between 108 Ω and 132 Ω. A. All connections are secure. Both resistance measurements are within the specified range. OK to return the machine to service. B. The harness is damaged or the connectors are loose or damaged. Repair or replace the harness or the connectors as required. Return to step 2 to confirm elimination of the fault. C. One or both resistance measurements are less than 108 Ω or greater than 132 Ω. Replace the control module that has the bad resistance value. Return to step 2 to confirm elimination of fault.
48068130 29/01/2018
55.21 [55.DTC] / 824
Electrical systems - FAULT CODES
9156 - Hydraulic Enable Button Error From AIC SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Context: Diagnostic Trouble Code 9156 – Hydraulic Enable Button Error From AIC has an error priority of amber. Loader limp home and ground drive limp home operating modes are enabled while Diagnostic Trouble Code 9156 – Hydraulic Enable Button Error From AIC is active. Cause: The UCM is receiving conflicting information about the hydraulic enable button. The fault is active when the ignition is on and hydraulic enable pin voltage is opposite of value transmitted from instrument cluster. Possible failure modes: 1. A short circuit in the wiring. 2. An open circuit in the wiring. 3. A failure of the instrument cluster. 4. A failure of the UCM. Solution: 1. Verify that the fault code is active. Connect the Electronic Service Tool to the service tool connector. To check for fault code: Start and operate machine. A. The fault code is not recorded again. OK to return the machine to service. B. Fault code 9156 – Hydraulic Enable Button Error From AIC is recorded again. Go to 1350 - Hyd Enable Switch - Implausible State (Hardwire vs CAN) (55.640).
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55.21 [55.DTC] / 825
Electrical systems - FAULT CODES
9158 - H Pattern Indicator Shorted To Ground SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Context: The UCM has sensed that the H pattern indicator voltage signal has failed low. Diagnostic Trouble Code 9158 – H Pattern Indicator Shorted To Ground has an error priority of White. The ISO pattern will remain active while Diagnostic Trouble Code 9158 – H Pattern Indicator Shorted To Ground is active. Cause: The UCM has sensed that the H pattern indicator voltage signal has failed low. The fault is active while the H pattern indicator voltage, X-CN2A (Receptacle) pin 23 is less than 5 V. Possible failure modes: 1. A short circuit to ground in the signal wire. 2. A faulty pattern select switch. 3. The UCM has an internal failure. 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. OK to return the machine to service. B. Fault code 9158 – H Pattern Indicator Shorted To Ground is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the UCM and the drive pattern switch connections. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the UCM to the drive pattern 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 the connectors as required. Return to step 1 to confirm elimination of fault. 3. Measure the voltage at the switch. Turn the ignition switch OFF. Remove the pattern select switch from the right side column. Disconnect connector X-095. Turn the ignition switch ON. Measure the voltage between X-095 (Receptacle) pin 5 and chassis ground. The voltage should be approximately 12 V. Wiggle the harness to reveal an intermittent condition. 48068130 29/01/2018
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Electrical systems - FAULT CODES
Measure the voltage between X-095 (Receptacle) pin 7 and chassis ground. The voltage should be approximately 12 V. Wiggle the harness to reveal an intermittent condition. Measure the voltage between X-095 (Receptacle) pin 10 and chassis ground. The voltage should be approximately 12 V. Wiggle the harness to reveal an intermittent condition. A. All voltage measurements are approximately 12 V. Go to step 4. B. One or more voltage measurements are less than 10 V. There is a problem with the voltage supply to the switch. Check fuses and splices. Repair or replace the harness or connectors as required. Return to step 1 to confirm elimination of fault. 4. Measure the resistance of the indicator wire to other circuits. Turn the ignition switch OFF. Disconnect connector X-095. Disconnect UCM connectors X-CN2A and X-CN2B. Measure the resistance between connector X-095 (Receptacle) pin 8 and chassis ground. The resistance should be greater than 20,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition. Measure the resistance between connector X-095 (Receptacle) pin 8 and X-095 (Receptacle) pin 9. The resistance should be greater than 20,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition. A. All resistance measurements are greater than 20,000 Ω. Go to step 5. B. One or more resistance measurements are less than 20,000 Ω. There is a short circuit in the signal wire. Repair or replace the harness as required. Return to step 1 to confirm elimination of fault. 5. Test the switch. Leave the switch in the neutral position. Measure the resistance between pin 8 and pin 9. The resistance should be greater than 20,000 Ω. A. The resistance is greater than 20,000 Ω. Temporarily replace the UCM and retest. Return to step 1. B. The resistance is less than 20,000 Ω. There is a short circuit in the switch. Temporarily replace the switch and retest. Return to step 1 to confirm elimination of fault. Wiring harnesses - Electrical schematic sheet 20 SH20-UNIVERSAL CONTROL MODULE (55.100.DP-C.20.E.20) Wiring harnesses - Electrical schematic sheet 09 SH09-THROTTLE SENSORS (55.100.DP-C.20.E.09) Wiring harnesses - Electrical schematic sheet 14 SH14-BULKHEAD CONNECTION (55.100.DP-C.20.E.14)
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55.21 [55.DTC] / 827
Electrical systems - FAULT CODES
9159 - ISO Pattern Indicator Shorted To Ground SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Context: The UCM has sensed that the ISO pattern indicator voltage signal has failed. Diagnostic Trouble Code 9159 – ISO Pattern Indicator Shorted To Ground has an error priority of White. The H pattern will remain active while Diagnostic Trouble Code 9159 – ISO Pattern Indicator Shorted To Ground is active. Cause: The UCM has sensed that the ISO pattern indicator voltage signal has failed. The fault is active while the ISO pattern indicator voltage, X-CN2B (Receptacle) pin 2 is less than 5 V. Possible failure modes: 1. The signal wire is shorted to chassis ground. 2. A faulty pattern select switch. 3. The UCM has an internal failure. 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. OK to return the machine to service. B. Fault code 9159 – ISO Pattern Indicator Shorted To Ground is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the UCM and the drive pattern switch connections. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the UCM to the drive pattern 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. 3. Measure the voltage at the switch. Turn the ignition switch OFF. Remove the pattern select switch from the right side column. Disconnect connector X-095. Turn the ignition switch ON. Measure the voltage between X-095 (Receptacle) pin 5 and chassis ground. The voltage should be approximately 12 V. Wiggle the harness to reveal an intermittent condition. 48068130 29/01/2018
55.21 [55.DTC] / 828
Electrical systems - FAULT CODES
Measure the voltage between X-095 (Receptacle) pin 7 and chassis ground. The voltage should be approximately 12 V. Wiggle the harness to reveal an intermittent condition. Measure the voltage between X-095 (Receptacle) pin 10 and chassis ground. The voltage should be approximately 12 V. Wiggle the harness to reveal an intermittent condition. A. All voltage measurements are approximately 12 V. Go to step 4. B. One or more voltage measurements are less than 10 V. There is a problem with the voltage supply to the switch. Check the fuses and the splices. Repair or replace the harness or connectors as required. Return to step 1 to confirm elimination of fault. 4. Measure the resistance of the indicator wire to other circuits. Turn the ignition switch OFF. Disconnect connector X-095. Disconnect UCM connectors X-CN2A and X-CN2B. Measure the resistance between connector X-095 (Receptacle) pin 9 and chassis ground. The resistance should be greater than 20,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition. Measure the resistance between connector X-095 (Receptacle) pin 8 and X-095 (Receptacle) pin 9. The resistance should be greater than 20,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition. A. All resistance measurements are greater than 20,000 Ω. Go to step 5. B. One or more resistance measurements are less than 20,000 Ω. The signal wire has a short circuit to chassis ground. Repair or replace the harness as required. Return to step 1 to confirm elimination of fault. 5. Test the switch. Leave the switch in the neutral position. Measure the resistance between pin 8 and pin 9. The resistance should be greater than 20,000 Ω. A. The resistance is greater than 20,000 Ω. Temporarily replace the UCM and retest. Return to step 1. B. The resistance is less than 20,000 Ω. There is a short circuit in the switch. Temporarily replace the switch and retest. Return to step 1 to confirm elimination of fault. Wiring harnesses - Electrical schematic sheet 20 SH20-UNIVERSAL CONTROL MODULE (55.100.DP-C.20.E.20) Wiring harnesses - Electrical schematic sheet 09 SH09-THROTTLE SENSORS (55.100.DP-C.20.E.09) Wiring harnesses - Electrical schematic sheet 14 SH14-BULKHEAD CONNECTION (55.100.DP-C.20.E.14)
48068130 29/01/2018
55.21 [55.DTC] / 829
Electrical systems - FAULT CODES
9160 - H Pattern Indicator Shorted To Power SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Context: The UCM has sensed that the H pattern indicator voltage signal has failed. Diagnostic Trouble Code 9160 – H Pattern Indicator Shorted To Power has an error priority of White. The ISO pattern will remain active while Diagnostic Trouble Code 9160 – H Pattern Indicator Shorted To Power is active. Cause: The UCM has sensed that the H pattern indicator voltage signal has failed. The fault is active while the H pattern indicator voltage, X-CN2A (Receptacle) pin 23 is greater than 8 V. Possible failure modes: 1. The signal wire is shorted to another voltage source. 2. A faulty pattern select switch. 3. The UCM has an internal failure. 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. OK to return the machine to service. B. Fault code 9160 – H Pattern Indicator Shorted To Power is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the UCM and the drive pattern switch connections. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the UCM to the drive pattern 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. 3. Measure the voltage at the switch. Turn the ignition switch OFF. Remove the pattern select switch from the right side column. Disconnect connector X-095. Disconnect UCM connector X-CN2A. Turn the ignition switch ON.
48068130 29/01/2018
55.21 [55.DTC] / 830
Electrical systems - FAULT CODES
Measure the voltage between X-095 (Receptacle) pin 8 and chassis ground. The voltage should be less than 0.5 V. Wiggle the harness to reveal an intermittent condition. A. The voltage is less than 0.5 V. Go to step 4. B. The voltage is greater than 0.5 V. There is a short circuit to another voltage source. Repair or replace the harness as required. Return to step 1 to confirm elimination of fault. 4. Measure the resistance of the signal wire to other circuits. Turn the ignition switch OFF. Disconnect UCM connector X-CN2A and X-CN2B. Measure the resistance between connector X-095 (Receptacle) pin 8 and X-095 (Receptacle) pin 10. The resistance should be greater than 20,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition. Measure the resistance between connector X-095 (Receptacle) pin 8 and X-095 (Receptacle) pin 9. The resistance should be greater than 20,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition. Measure the resistance between connector X-095 (Receptacle) pin 8 and X-095 (Receptacle) pin 7. The resistance should be greater than 20,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition. Measure the resistance between connector X-095 (Receptacle) pin 8 and X-095 (Receptacle) pin 6. The resistance should be greater than 20,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition. Measure the resistance between connector X-095 (Receptacle) pin 8 and X-095 (Receptacle) pin 5. The resistance should be greater than 20,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition. Measure the resistance between connector X-095 (Receptacle) pin 8 and X-095 (Receptacle) pin 3. The resistance should be greater than 20,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition. Measure the resistance between connector X-095 (Receptacle) pin 8 and X-095 (Receptacle) pin 1. The resistance should be greater than 20,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition. A. All resistance measurements are greater than 20,000 Ω. Go to step 5. B. One or more resistance measurements are less than 20,000 Ω. The signal wire has a short circuit to another circuit. Repair or replace the harness as required. Return to step 1 to confirm elimination of fault. 5. Test the switch. Leave the switch in the neutral position. Measure the resistance between pin 5 and pin 3. The resistance should be less than 10 Ω. Measure the resistance between pin 8 and pin 10. The resistance should be greater than 20,000 Ω. Measure the resistance between pin 8 and pin 9. The resistance should be greater than 20,000 Ω. Measure the resistance between pin 8 and pin 6. The resistance should be greater than 20,000 Ω. Measure the resistance between pin 8 and pin 5. The resistance should be greater than 20,000 Ω. Measure the resistance between pin 8 and pin 3. The resistance should be greater than 20,000 Ω. Measure the resistance between pin 8 and pin 1. The resistance should be greater than 20,000 Ω. A. All resistance measurements are correct. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. 48068130 29/01/2018
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Electrical systems - FAULT CODES
B. One or more resistance measurements are incorrect. Temporarily replace the switch and retest. Return to step 1 to confirm elimination of fault. Wiring harnesses - Electrical schematic sheet 20 SH20-UNIVERSAL CONTROL MODULE (55.100.DP-C.20.E.20) Wiring harnesses - Electrical schematic sheet 09 SH09-THROTTLE SENSORS (55.100.DP-C.20.E.09) Wiring harnesses - Electrical schematic sheet 14 SH14-BULKHEAD CONNECTION (55.100.DP-C.20.E.14)
48068130 29/01/2018
55.21 [55.DTC] / 832
Electrical systems - FAULT CODES
9161 - ISO Pattern Indicator Shorted To Power SR210 TIER 4B (FINAL) [NGM418237 - ] SR210 TIER 4B (FINAL) [NHM435463 - ] SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] SV280 TIER 4B (FINAL) [NGM418237 - ] SV280 TIER 4B (FINAL) [NHM435463 - ] TR270 TIER 4B (FINAL) [NGM418237 - ] TR270 TIER 4B (FINAL) [NHM435463 - ] TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ] TV370 TIER 4B (FINAL) [NHM435463 - ]
(Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro (Electro
hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic hydraulic
controls) controls) controls) controls) controls) controls) controls) controls) controls) controls) controls)
Context: The UCM has sensed that the ISO pattern indicator voltage signal has failed. Diagnostic Trouble Code 9161 – ISO Pattern Indicator Shorted To Power has an error priority of White. The H pattern will remain active while Diagnostic Trouble Code 9161 – ISO Pattern Indicator Shorted To Power is active. Cause: The UCM has sensed that the ISO pattern indicator voltage signal has failed. The fault is active while the ISO pattern indicator voltage, X-CN2B (Receptacle) pin 2 is greater than 8 V. Possible failure modes: 1. The signal wire is shorted to another voltage source. 2. A faulty pattern select switch. 3. The UCM has an internal failure. 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. OK to return the machine to service. B. Fault code 9161 – ISO Pattern Indicator Shorted To Power is recorded again. Go to step 2. 2. Verify that the wiring and connectors are free of damage. Inspect the UCM and the drive pattern switch connections. All connections should be secure, tight, free of corrosion, abrasion, and damage. Inspect the harness from the UCM to the drive pattern 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. 3. Measure the voltage at the switch. Turn the ignition switch OFF. Remove the pattern select switch from the right side column. Disconnect connector X-095. Disconnect UCM connector X-CN2B. Turn the ignition switch ON.
48068130 29/01/2018
55.21 [55.DTC] / 833
Electrical systems - FAULT CODES
Measure the voltage between X-095 (Receptacle) pin 9 and chassis ground. The voltage should be less than 0.5 V. Wiggle the harness to reveal an intermittent condition. A. The voltage is less than 0.5 V. Go to step 4. B. The voltage is greater than 0.5 V. There is a short circuit to another voltage source. Repair or replace the harness as required. Return to step 1 to confirm elimination of fault. 4. Measure the resistance of the signal wire to other circuits. Turn the ignition switch OFF. Disconnect UCM connector X-CN2A and X-CN2B. Measure the resistance between connector X-095 (Receptacle) pin 9 and X-095 (Receptacle) pin 10. The resistance should be greater than 20,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition. Measure the resistance between connector X-095 (Receptacle) pin 9 and X-095 (Receptacle) pin 8. The resistance should be greater than 20,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition. Measure the resistance between connector X-095 (Receptacle) pin 9 and X-095 (Receptacle) pin 7. The resistance should be greater than 20,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition. Measure the resistance between connector X-095 (Receptacle) pin 9 and X-095 (Receptacle) pin 6. The resistance should be greater than 20,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition. Measure the resistance between connector X-095 (Receptacle) pin 9 and X-095 (Receptacle) pin 5. The resistance should be greater than 20,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition. Measure the resistance between connector X-095 (Receptacle) pin 9 and X-095 (Receptacle) pin 3. The resistance should be greater than 20,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition. Measure the resistance between connector X-095 (Receptacle) pin 9 and X-095 (Receptacle) pin 1. The resistance should be greater than 20,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition. A. All resistance measurements are greater than 20,000 Ω. Go to step 5. B. One or more resistance measurements are less than 20,000 Ω. The signal wire has a short circuit to another circuit. Repair or replace the harness as required. Return to step 1 to confirm elimination of fault. 5. Test the switch. Leave the switch in the neutral position. Measure the resistance between pin 5 and pin 3. The resistance should be less than 10 Ω. Measure the resistance between pin 9 and pin 8. The resistance should be greater than 20,000 Ω. Measure the resistance between pin 9 and pin 7. The resistance should be greater than 20,000 Ω. Measure the resistance between pin 9 and pin 6. The resistance should be greater than 20,000 Ω. Measure the resistance between pin 9 and pin 5. The resistance should be greater than 20,000 Ω. Measure the resistance between pin 9 and pin 3. The resistance should be greater than 20,000 Ω. Measure the resistance between pin 9 and pin 1. The resistance should be greater than 20,000 Ω. A. All resistance measurements are correct. Temporarily replace the UCM and retest. Return to step 1 to confirm elimination of the fault. 48068130 29/01/2018
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Electrical systems - FAULT CODES
B. One or more resistance measurements are incorrect. Temporarily replace the switch and retest. Return to step 1 to confirm elimination of fault. Wiring harnesses - Electrical schematic sheet 20 SH20-UNIVERSAL CONTROL MODULE (55.100.DP-C.20.E.20) Wiring harnesses - Electrical schematic sheet 09 SH09-THROTTLE SENSORS (55.100.DP-C.20.E.09) Wiring harnesses - Electrical schematic sheet 14 SH14-BULKHEAD CONNECTION (55.100.DP-C.20.E.14)
48068130 29/01/2018
55.21 [55.DTC] / 835
Electrical systems - FAULT CODES
9401 - Memory Error - Double Redundant Memory - Corruption Detected And Repaired Context: Diagnostic Trouble Code 9401 has an error priority of White. There are no restrictions while Diagnostic Trouble Code 9401 is active. Cause: 1. An internal failure within the instrument cluster. Solution: 1. Verify that the fault code is active. Connect the Electronic Service Tool to the service tool connector. To check for fault codes: Start and operate the machine. A. Fault code 9401 â&#x20AC;&#x201C; Memory Error - Double Redundant Memory - Corruption Detected And Repaired is recorded again. Replace the instrument cluster. Return to step 1 to confirm elimination of the fault. B. The fault code is not recorded again. OK to return the machine to service.
48068130 29/01/2018
55.21 [55.DTC] / 836
Electrical systems - FAULT CODES
9403 - Memory Error - Double Redundant Memory - Unrecoverable Memory Corruption Operable Context: Diagnostic Trouble Code 9403 has an error priority of White. There are no restrictions while Diagnostic Trouble Code 9403 is active. Cause: 1. An internal failure within the instrument cluster. Solution: 1. Verify that the fault code is active. Connect the Electronic Service Tool to the service tool connector. To check for fault codes: Start and operate the machine. A. Fault code 9403 â&#x20AC;&#x201C; Memory Error - Double Redundant Memory - Unrecoverable Memory Corruption Operable is recorded again. Replace the instrument cluster. Return to step 1 to confirm elimination of the fault. B. The fault code is not recorded again. OK to return the machine to service.
48068130 29/01/2018
55.21 [55.DTC] / 837
Electrical systems - FAULT CODES
9404 - Memory Error - Triple Redundant - Hour Meter Failure Context: Diagnostic Trouble Code 9404 has an error priority of White. There are no restrictions while Diagnostic Trouble Code 9404 is active. Cause: 1. An internal failure within the instrument cluster. Solution: 1. Verify that the fault code is active. Connect the Electronic Service Tool to the service tool connector. To check for fault codes: Start and operate the machine. A. Fault code 9404 â&#x20AC;&#x201C; Memory Error - Triple Redundant - Hour Meter Failure is recorded again. Replace the instrument cluster. Return to step 1 to confirm elimination of the fault. B. The fault code is not recorded again. OK to return the machine to service.
48068130 29/01/2018
55.21 [55.DTC] / 838
Electrical systems - FAULT CODES
9405 - Loss Of DM1 Message From VCM Context: CAN bus communications between modules on the data link have been lost. This fault code may be displayed with other CAN bus fault code messages. Cause: CAN bus communications between modules on the data link have been lost. Possible failure modes: 1. CAN data link wiring or circuits open. 2. CAN data link wiring or circuits shorted. 3. Faulty CAN Data Link device. 4. Faulty instrument cluster. 5. Faulty ECU. Solution: 1. Verify that the fault code is active. Use the Electronic Service Tool to verify that the CAN data link faults are ACTIVE. To check for fault codes: Start and operate the machine. Wiggle the harness to reveal an intermittent condition. 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 the wiring and connectors to verify they are secure and free of damage, corrosion, abrasion or incorrect attachment. A. CAN bus fault codes are not recorded again and are no longer ACTIVE. OK to return the machine to service. B. CAN bus fault codes are present and ACTIVE. Refer to 1051 - No CAN Communication With Engine Controller (55.408).
48068130 29/01/2018
55.21 [55.DTC] / 839
Electrical systems - FAULT CODES
9406 - No CAN Communication From VCM Context: CAN bus communications between modules on the data link have been lost. This fault code may be displayed with other CAN bus fault code messages. Cause: CAN bus communications between modules on the data link have been lost. Possible failure modes: 1. CAN data link wiring or circuits open. 2. CAN data link wiring or circuits shorted. 3. Faulty CAN Data Link device. 4. Faulty instrument cluster. 5. Faulty ECU. Solution: 1. Verify that the fault code is active. Use the Electronic Service Tool to verify that the CAN data link faults are ACTIVE. To check for fault codes: Start and operate the machine. Wiggle the harness to reveal an intermittent condition. 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 the wiring and connectors to verify they are secure and free of damage, corrosion, abrasion or incorrect attachment. A. CAN bus fault codes are not recorded again and are no longer ACTIVE. OK to return the machine to service. B. CAN bus fault codes are present and ACTIVE. Refer to 1051 - No CAN Communication With Engine Controller (55.408).
48068130 29/01/2018
55.21 [55.DTC] / 840
Electrical systems - FAULT CODES
9407 - Memory Error - Unrecoverable Hardware ID Context: Diagnostic Trouble Code 9407 has an error priority of Red. The vehicle is immediately disabled with Diagnostic Trouble Code 9407. Cause: The instrument cluster has sensed an internal failure. Possible failure modes: 1. A failure of the instrument cluster. Solution: 1. Use the machine to recreate conditions for error. Use the EST to verify fault code 9407 â&#x20AC;&#x201C; Memory Error - Unrecoverable Hardware ID is active. A. If the fault is active, the instrument cluster has failed. Replace the instrument cluster. B. If the fault is not active, the fault may be intermittent and not currently active, continue with step 2. 2. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while monitoring the EST and Display. Investigate nearby wiring. A. If damage is found or other than normal display readings are indicated, repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If no damage or other than normal display readings are indicated, erase the Diagnostic Trouble Code and continue operation.
48068130 29/01/2018
55.21 [55.DTC] / 841
Electrical systems - FAULT CODES
9408 - Memory Error - Unrecoverable Panel ID Context: Diagnostic Trouble Code 9408 has an error priority of Red. The vehicle is immediately disabled with Diagnostic Trouble Code 9408. Cause: The instrument cluster has sensed an internal failure. Possible failure modes: 1. A failure of the instrument cluster. Solution: 1. Use the machine to recreate conditions for error. Use the EST to verify fault code 9408 â&#x20AC;&#x201C; Memory Error - Unrecoverable Panel ID is active. A. If the fault is active, the instrument cluster has failed. Replace the instrument cluster. B. If the fault is not active, the fault may be intermittent and not currently active, continue with step 2. 2. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while monitoring the EST and Display. Investigate nearby wiring. A. If damage is found or other than normal display readings are indicated, repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If no damage or other than normal display readings are indicated, erase the Diagnostic Trouble Code and continue operation.
48068130 29/01/2018
55.21 [55.DTC] / 842
Electrical systems - FAULT CODES
9410 - Loss Of EGR Inducement Status Message From EDC Context: CAN bus communications between modules on the data link have been lost. This fault code may be displayed with other CAN bus fault code messages. Cause: CAN bus communications between modules on the data link have been lost. Possible failure modes: 1. CAN data link wiring or circuits open. 2. CAN data link wiring or circuits shorted. 3. Faulty CAN Data Link device. 4. Faulty instrument cluster. 5. Faulty ECU. Solution: 1. Verify that the fault code is active. Use the Electronic Service Tool to verify that the CAN data link faults are ACTIVE. To check for fault codes: Start and operate the machine. Wiggle the harness to reveal an intermittent condition. 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 the wiring and connectors to verify they are secure and free of damage, corrosion, abrasion or incorrect attachment. A. CAN bus fault codes are not recorded again and are no longer ACTIVE. OK to return the machine to service. B. CAN bus fault codes are present and ACTIVE. Refer to 1051 - No CAN Communication With Engine Controller (55.408)
48068130 29/01/2018
55.21 [55.DTC] / 843
Electrical systems - FAULT CODES
17100 (DTC 382-12) - EGR Control : Not plausible state 2 Context: The Engine Control Unit evaluates the main physical parameters of intake temperature and pressure, lambda, Exhaust Gas Recirculation (EGR) position, temperature and pressure in the exhaust path in order to discover a leakage in the intake charge air path. If a hole (leakage) in the intake path is detected, then this fault will occur. For information regarding the functional operation of the EGR valve, see Exhaust Gas Recirculation (EGR) valve - Overview (10.501). For more information regarding technical specifications of the EGR valve, see Exhaust Gas Recirculation (EGR) valve actuator - Technical Data (55.989). Cause: The ECU has determined that there is leakage in the intake charge air system. Possible failure modes: 1. Faulty charge air system, leakage due to improper connection or hole in piping.
48068130 29/01/2018
55.21 [55.DTC] / 844
Electrical systems - FAULT CODES
17101 (DTC 482-12) - EGR Control : Not plausible state 3 Context: The Engine Control Unit evaluates the main physical parameters of intake temperature and pressure, lambda, Exhaust Gas Recirculation (EGR) position, temperature and pressure in the exhaust path in order to discover a leakage in the intake charge air path. If a hole (leakage) in the intake path is detected, this fault will occur. For information regarding the functional operation of the EGR valve, see Exhaust Gas Recirculation (EGR) valve - Overview (10.501). For more information regarding technical specifications of the EGR valve, see Exhaust Gas Recirculation (EGR) valve actuator - Technical Data (55.989). Cause: The ECU has determined that there is leakage in the intake charge air system. Possible failure modes: 1. Faulty charge air system, leakage due to improper connection or hole in piping.
48068130 29/01/2018
55.21 [55.DTC] / 845
Electrical systems - FAULT CODES
17102 (DTC 582-12) - EGR Control : Not plausible state 4 Context: The Engine Control Unit evaluates the main physical parameters of intake temperature and pressure, lambda, Exhaust Gas Recirculation (EGR) position, temperature and pressure in the exhaust path in order to discover a leakage in the intake charge air path. If a hole (leakage) in the intake path is detected, this fault will occur. For information regarding the functional operation of the EGR valve, see Exhaust Gas Recirculation (EGR) valve - Overview (10.501). For more information regarding technical specifications of the EGR valve, see Exhaust Gas Recirculation (EGR) valve actuator - Technical Data (55.989). Cause: The ECU has determined that there is leakage in the intake charge air system. Possible failure modes: 1. Faulty charge air system, leakage due to improper connection or hole in piping.
48068130 29/01/2018
55.21 [55.DTC] / 846
Electrical systems - FAULT CODES
17103 (DTC 682-12) - EGR Control : Not plausible state 5 Context: The Engine Control Unit evaluates the main physical parameters of intake temperature and pressure, lambda, Exhaust Gas Recirculation (EGR) position, temperature and pressure in the exhaust path in order to discover a leakage in the intake charge air path. If a hole (leakage) in the intake path is detected, this fault will occur. For information regarding the functional operation of the EGR valve, see Exhaust Gas Recirculation (EGR) valve - Overview (10.501). For more information regarding technical specifications of the EGR valve, see Exhaust Gas Recirculation (EGR) valve actuator - Technical Data (55.989). Cause: The ECU has determined that there is leakage in the intake charge air system. Possible failure modes: 1. Faulty charge air system, leakage due to improper connection or hole in piping.
48068130 29/01/2018
55.21 [55.DTC] / 847
Electrical systems - FAULT CODES
17104 (DTC 782-12) - EGR Control : Not plausible state 6 Context: The Engine Control Unit evaluates the main physical parameters of intake temperature and pressure, lambda, Exhaust Gas Recirculation (EGR) position, temperature and pressure in the exhaust path in order to discover a leakage in the intake charge air path. If a hole (leakage) in the intake path is detected, this fault will occur. For information regarding the functional operation of the EGR valve, see Exhaust Gas Recirculation (EGR) valve - Overview (10.501). For more information regarding technical specifications of the EGR valve, see Exhaust Gas Recirculation (EGR) valve actuator - Technical Data (55.989). Cause: The ECU has determined that there is leakage in the intake charge air system. Possible failure modes: 1. Faulty charge air system, leakage due to improper connection or hole in piping.
48068130 29/01/2018
55.21 [55.DTC] / 848
Electrical systems - FAULT CODES
17105 (DTC 399-03) - Turbo protection cold start detection Context: This fault is for information purposes only and does not require any action. The recognition of a cold start condition is provided by the turbocharger protection speed limitation module. The Engine Control Unit (ECU) will limit the number of engine revolutions until the engine oil pressure has reached a calibrated threshold.
48068130 29/01/2018
55.21 [55.DTC] / 849
Electrical systems - FAULT CODES
17513 (DTC 1F7-00) - Physical Range Check high for ECU temperature sensor Context: The Engine Control Unit (ECU) monitors the Particulate Matter (PM) catalytic converter inlet temperature sensor. If the ECU detects a temperature greater than 1000 °C (1832 °F) from the PM catalytic converter inlet temperature sensor, this fault will occur. Other active faults may have caused this fault to occur. Cause: The ECU has detected a temperature too high from the PM catalytic converter inlet temperature sensor. Possible failure modes: 1. PM catalytic converter temperature too high. 2. Faulty PM catalytic converter inlet temperature sensor. 3. Faulty ECU, software.
48068130 29/01/2018
55.21 [55.DTC] / 850
Electrical systems - FAULT CODES
17514 (DTC 7CC-12) - TSC1 blocked or with wrong checksum Context: The Engine Control Unit (ECU) monitors Controller Area Network (CAN) communication by performing a CAN bus data check. If the ECU detects a failure during this check, then this fault will occur. 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.
48068130 29/01/2018
55.21 [55.DTC] / 851
Electrical systems - FAULT CODES
19191 (DTC 6BA-02) - CAN Bus Received frames : CAN-Receive-Frame CCSSBC timeout Context: The CAN messages received by ECM are monitored for timeouts. BC2EDC2 is the proprietary CAN message from Body Computer (BC) containing information about following status: Clutch, parking brake, main brake, cabin tilt, gearbox neutral switch, fuel filter heating, ignition switch, oil life monitoring. It also contains following request information: fan activation, speed limiter, air conditioning, PTO request. Possible failure modes: 1. Defective CAN controller of Body Computer. 2. Under voltage of BC. 3. Missing BC. 4. CAN cable connecting the BC is disconnected or broken. 5. Short circuit in wiring. Solution: 1. Check presence and correct connection of the BC to the network. 2. Check correct functioning of the BC CAN controller and its voltage supply. 3. Check wiring.
48068130 29/01/2018
55.21 [55.DTC] / 852
Electrical systems - FAULT CODES
19192 (DTC 1BD-02) - CAN Bus Received frames : CAN-Receive-Frame CCVSV timeout Christian Context: The CAN messages received by ECM are monitored for timeouts. BC2EDC2 is the proprietary CAN message from Body Computer (BC) containing information about following status: Clutch, parking brake, main brake, cabin tilt, gearbox neutral switch, fuel filter heating, ignition switch, oil life monitoring. It also contains following request information: fan activation, speed limiter, air conditioning, PTO request. Possible failure modes: 1. Defective CAN controller of Body Computer. 2. Under voltage of BC. 3. Missing BC. 4. CAN cable connecting the BC is disconnected or broken. 5. Short circuit in wiring. Solution: 1. Check presence and correct connection of the BC to the network. 2. Check correct functioning of the BC CAN controller and its voltage supply. 3. Check wiring.
48068130 29/01/2018
55.21 [55.DTC] / 853
Index Electrical systems - 55 FAULT CODES - DTC 1002 - Engine Coolant Temperature Is Above Normal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
16
1004 - Hydraulic Filter Restriction Switch - Hydraulic Filter Restricted . . . . . . . . . . . . . . . . . . . . . . . . .
17
1009 - Hydraulic Oil Temperature Is Above Normal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
19
1014 - Cluster System Voltage Above Normal (>16.5V) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
21
1015 - Cluster System Voltage Below Normal (<11.5V) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
22
1022 - Water In Fuel Detected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
23
1025 - Foot Throttle Sensor Is Above Range - Shorted To Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
24
1026 - Hand Throttle Sensor Is Above Range - Shorted To Power . . . . . . . . . . . . . . . . . . . . . . . . . . . .
27
1030 - Foot Throttle Sensor Is Below Range - Open Or Shorted To Ground . . . . . . . . . . . . . . . . . . . .
30
1031 - Hand Throttle Sensor Is Below Range - Open Or Shorted To Ground . . . . . . . . . . . . . . . . . . .
33
1040 - RPM Monitoring Over Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
36
1041 - RPM Monitoring Over Speed Max . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
37
1044 - Fuel level sensor below 2.0 ohm for 5 seconds, shorted low . . . . . . . . . . . . . . . . . . . . . . . . . . .
38
1045 - Fuel Level Sensor Open Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
40
1051 - No CAN Communication With Engine Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
42
1053 - Timeout of CAN Message CM1BC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
47
1054 - Timeout of CAN Message ET1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
49
1056 - Timeout of CAN Message DPFC1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
51
1058 - Timeout of CAN Message EDC2BC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
53
1059 - Timeout of CAN Message DM1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
55
1064 - Hydraulic Oil Temperature Is Above Normal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
57
1201 - Hydraulic oil filter switch open circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
59
1205 - Hydraulic Enable (EH Machines) - Hydraulic Enable Output, Short to Power . . . . . . . . . . . . .
61
1206 - CAN Connection: Configuration Response Timeout (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
63
1207 - Memory Parameters - Invalid Configuration Between IC and UCM (*) . . . . . . . . . . . . . . . . . . .
65
1208 - Seat Switch Plausibility Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
67
1211 - Calibration Functions - Joystick Calibration Not Complete (*) . . . . . . . . . . . . . . . . . . . . . . . . . .
69
1212 - Calibration Functions - Ground Drive Calibration Not Complete (*) . . . . . . . . . . . . . . . . . . . . .
70
1213 - Calibration Functions - Loader Valve Calibration Not Complete (*) . . . . . . . . . . . . . . . . . . . . . .
71
1215 - Saturation Function not complete - Forward Pumps (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
72
1216 - Saturation Function not complete - Reverse Pumps (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
73
1221 - VCM Temperature / Current Draw Over Limit (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
74
1222 - VCM Sustained Over Temperature Limit (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
75
(*) See content for specific models 48068130 29/01/2018
55.21 [55.DTC] / 854
1223 - VCM Sustained Over Current Limit (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
76
1224 - VCM Internal Memory or Core Monitoring Fault (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
77
1225 - VCM EEPROM Memory Checksum Fault (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
78
1350 - Hyd Enable Switch - Implausible State (Hardwire vs CAN) (*) . . . . . . . . . . . . . . . . . . . . . . . . . .
79
1532 - Backup Alarm - Short to Ground (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
80
1533 - Backup Alarm - Short to Power (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
82
17100 (DTC 382-12) - EGR Control : Not plausible state 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
844
17101 (DTC 482-12) - EGR Control : Not plausible state 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
845
17102 (DTC 582-12) - EGR Control : Not plausible state 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
846
17103 (DTC 682-12) - EGR Control : Not plausible state 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
847
17104 (DTC 782-12) - EGR Control : Not plausible state 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
848
17105 (DTC 399-03) - Turbo protection cold start detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
849
17513 (DTC 1F7-00) - Physical Range Check high for ECU temperature sensor . . . . . . . . . . . . . . .
850
17514 (DTC 7CC-12) - TSC1 blocked or with wrong checksum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
851
1900 - VCM Ground Fault (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
84
1901 - VCM - VCM Supply Voltage High (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
86
1902 - VCM - VCM Supply Voltage Low (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
88
1903 - VCM - VCM Supply Voltage Below Operational Limit (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
90
1904 - VCM - Rail 12VB - 5V Regulators Supply Input Power Off (*) . . . . . . . . . . . . . . . . . . . . . . . . . .
92
1905 - VCM - 5Vref1 Sensor Supply Voltage Out Of Range (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
94
1906 - VCM - 5Vref3 Sensor Supply Voltage Out Of Range (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
97
1907 - VCM - Rail 12VF1 - Aux Retract Input Power Off (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
100
1908 - VCM - Rail 12VF2 - Bucket Extend Input Power Off (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
102
1909 - VCM - Rail 12VF3 - Boom Raise/Lower Input Power Off (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . .
104
1910 - VCM - Rail 12VH - Loader Pilot Interlock And Port Lock Input Power Off (*) . . . . . . . . . . . . .
106
1911 - VCM - Rail 12VH1 - Left And Right Pump Reverse Input Power Off (*) . . . . . . . . . . . . . . . . . .
108
1912 - VCM - Rail 12VM - Left And Right Brake Lights And Aux Extend Input Power Off (*) . . . . . .
110
1913 - VCM - Rail 12VS1 - Bucket Curl Input Power Off (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
112
1914 - VCM - Rail 12VS2 - Backup Alarm Input Power Off (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
114
1915 - VCM - Rail 12VT1 - Two Speed Input Power Off (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
116
1916 - VCM - Rail 12VU1 - Right And Left Pumps Forward Input Power Off (*) . . . . . . . . . . . . . . . . .
118
1917 - UCM - Rail 12VU2: Park Brake Solenoid Input Power Off (*) . . . . . . . . . . . . . . . . . . . . . . . . . .
120
19191 (DTC 6BA-02) - CAN Bus Received frames : CAN-Receive-Frame CCSSBC timeout . . . . .
852
19192 (DTC 1BD-02) - CAN Bus Received frames : CAN-Receive-Frame CCVSV timeout Christian . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 853 3007 (DTC 131-03) - Coolant temperature : SRC High for Engine coolant temperature (down stream) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122 3008 (DTC 131-04) - Coolant temperature : SRC low for Engine coolant temperature (down stream) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124 3010 (DTC 133-03) - Intake air temperature sensor : Diagnostic fault check for SRC high in engine inlet valve air temperature upstream sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
(*) See content for specific models 48068130 29/01/2018
55.21 [55.DTC] / 855
3011 (DTC 133-04) - Intake air temperature sensor : Diagnostic fault check for SRC low in engine inlet valve air temperature upstream sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129 3015 (DTC 135-03) - Fuel temperature Sensor : Signal Range check high for fuel temperature sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131 3016 (DTC 135-04) - Fuel temperature Sensor : Signal Range check low for fuel temperature sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134 3019 (DTC 134-03) - Intake air pressure sensor : Diagnostic fault check for SRC high in air pressure upstream of intake valve sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136 3024 (DTC 1EB-03) - Ambient pressure sensor : Signal Range Check High failure . . . . . . . . . . . . .
139
3025 (DTC 1EB-04) - Ambient pressure sensor : Signal Range Check low failure . . . . . . . . . . . . . .
140
3027 (DTC 238-03) - Oil pressure sensor : Defect fault check for plausibility from digital sensor . .
141
3037 (DTC 134-04) - Intake air pressure sensor : Diagnostic fault check for SRC low in air pressure upstream of intake valve sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143 3051 (DTC 126-03) - Battery voltage to engine controller - voltage too high . . . . . . . . . . . . . . . . . . . .
145
3052 (DTC 126-04) - Battery voltage to engine controller - voltage too low . . . . . . . . . . . . . . . . . . . . .
146
3059 (DTC 225-03) - Main Relay : DFC for stuck main relay error . . . . . . . . . . . . . . . . . . . . . . . . . . . .
148
3061 (DTC 161-03) - Injector, solenoid : Short circuit Low Side to High Side injector 1 . . . . . . . . . .
150
3063 (DTC 161-02) - Injector, solenoid Power stage : Short circuit in the injector 1 . . . . . . . . . . . . .
152
3069 (DTC 163-03) - Injector, solenoid : short circuit Low Side to High Side Injector 3 . . . . . . . . . . .
155
3071 (DTC 163-02) - Injector, solenoid Power stage : Short circuit in the injector 3 . . . . . . . . . . . . .
157
3077 (DTC 162-03) - Injector, solenoid : short circuit Low Side to High Side Injector 2 . . . . . . . . . . .
160
3079 (DTC 162-02) - Injector, solenoid Power stage : Short circuit in the injector 2 . . . . . . . . . . . . .
162
3081 (DTC 164-03) - Injector, solenoid : short circuit Low Side to High Side Injector 4 . . . . . . . . . . .
165
3083 (DTC 164-02) - Injector, solenoid Power stage : Short circuit in the injector 4 . . . . . . . . . . . . .
167
3088 (DTC 141-02) - Crankshaft Sensor : Crankshaft signal diagnose - no signal . . . . . . . . . . . . . .
170
3089 (DTC 141-04) - Crankshaft Sensor : Crankshaft signal diagnose - disturbed signal . . . . . . . .
173
3090 (DTC 143-02) - Camshaft Sensor : Camshaft signal diagnose - no signal . . . . . . . . . . . . . . . . .
176
3091 (DTC 143-04) - Camshaft Sensor : Camshaft signal diagnose - disturbed signal . . . . . . . . . . .
179
3093 (DTC 144-03) - Camshaft Sensor : Camshaft offset angle exceeded . . . . . . . . . . . . . . . . . . . . .
181
3096 (DTC 1B1-03) - CAN Bus : Bus Off error CAN A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
182
3102 (DTC 136-04) - Fuel pressure Sensor : Sensor voltage below lower limit . . . . . . . . . . . . . . . . .
184
3104 (DTC 137-03) - Pressure Relief valve : pressure relief valve is open . . . . . . . . . . . . . . . . . . . . .
186
3105 (DTC 134-04) - Pressure Relief valve : pressure relief valve is forced to open, perform pressure increase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188 3106 (DTC 137-02) - Pressure Relief valve : pressure relief valve reached maximum allowed opening count . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189 3107 (DTC 259-03) - Fuel Metering Unit : short circuit to battery of metering unit output . . . . . . . . .
190
3108 (DTC 359-04) - Fuel Metering Unit : short circuit to ground of metering unit output . . . . . . . . .
192
3110 (DTC 236-03) - Fuel pressure Sensor : rail pressure raw value is above maximum offset . . .
194
3111 (DTC 236-04) - Fuel pressure Sensor : rail pressure raw value is below minimum offset . . . .
195
3112 (DTC 136-03) - Fuel pressure Sensor : Sensor voltage above upper limit . . . . . . . . . . . . . . . . .
196
3137 (DTC 159-02) - Fuel Metering Unit : open load of metering unit output . . . . . . . . . . . . . . . . . . .
199
3141 (DTC 158-03) - Fuel Metering Unit : leakage is detected based on fuel quantity balance . . . .
201
3146 (DTC 11C-03) - Water sensor in the fuel filter : Water in fuel level sensor defect detection . .
202
48068130 29/01/2018
55.21 [55.DTC] / 856
3157 - ECM Not Detected On CAN Bus - The Engine Dataset Registration Information Was Not Available From The Engine Within The Time Required. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204 3158 - The Engine Dataset Installed Does Not Match The Dataset Registered For This Machine. Register The New Dataset If The Dataset Has Just Been Updated . . . . . . . . . . . . . . . . . . . . . . . . . . . 205 3166 (DTC 149-03) - ECU Power stages : Short circuit to battery error in power stage of fuel filter heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206 3167 (DTC 149-04) - ECU Power stages : Short circuit to ground error in power stage of fuel filter heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208 3168 (DTC 149-02) - ECU Power stages : No load error in power stage of fuel filter heating . . . . .
210
3169 (DTC 149-12) - ECU Power stages : Over Temperature error in power stage of fuel filter heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212 3176 (DTC 157-03) - Fuel Metering Unit : set point of metering unit in overrun mode not plausible
214
3177 (DTC 54C-03) - Engine Protection : Over speed detection in component engine protection .
215
3179 (DTC 2B4-02) - CAN Bus Received frames : CAN-Receive-Frame BC2EDC2 . . . . . . . . . . . . .
216
3180 (DTC 1B5-02) - CAN Bus Received frames : CAN-Receive-Frame from the Vehicle Control Module to EDC (VM2EDC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218 3188 (DTC 167-02) - Injector, solenoid : Open load error of an injector 1 (interruption of an electric connection) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220 3192 (DTC 168-02) - Injector, solenoid : Open load error of an injector 2 (interruption of an electric connection) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222 3196 (DTC 169-02) - Injector, solenoid : Open load error of an injector 3 (interruption of an electric connection) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224 3200 (DTC 16A-02) - Injector, solenoid : Open load error of an injector 4 (interruption of an electric connection) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226 3210 (DTC 171-03) - Injector, solenoid : Short circuit in an injection bank 1 (all injectors of the same bank can be affected) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228 3218 (DTC 173-03) - Injector, solenoid : Short circuit in an injection bank 2 (all injectors of the same bank can be affected) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230 3230 (DTC 17C-12) - Injector, solenoid Power stage : Chip error in the Injector CY33x power stage component . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232 3235 (DTC 17E-03) - Injection control : Number of injections is limited by runtime . . . . . . . . . . . . . .
233
3236 (DTC 17E-04) - Injection control : Number of injections is limited by system . . . . . . . . . . . . . .
234
3237 (DTC 17E-02) - Injection control : Number of desired injections exceeds threshold . . . . . . . .
235
3238 (DCT 1D1-03) - ECU Power stages : SPI/COM-Errors of the power failure detection of CY320
237
3239 (DTC 1D2-04) - EEPROM : EEP Read Error based on the error for more blocks . . . . . . . . . . .
238
3240 (DTC 1D2-02) - EEPROM : EEP Write Error based on the error for one block . . . . . . . . . . . . .
239
3241 (DTC 1D2-12) - EEPROM : There was an error during Write/Read EEPROM operation . . . .
240
3242 (DTC 1D3-12) - ECU internal : Visibility of Software Resets in DSM . . . . . . . . . . . . . . . . . . . . .
241
3243 (DTC 2D3-12) - ECU internal : Visibility of Software Resets in DSM . . . . . . . . . . . . . . . . . . . . .
242
3244 (DTC 3D3-12) - ECU internal : Visibility of Software Resets in DSM . . . . . . . . . . . . . . . . . . . . .
243
3245 (DTC 1D4-12) - Analog Digital Converter (ADC) : Diagnostic fault check to report errors in query-/response-communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244 3252 (DTC 1D8-12) - Analog Digital Converter (ADC) : Diagnostic fault check to report errors in SPI-communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245 3253 (DTC 1D9-03) - Analog Digital Converter (ADC) : Diagnostic fault check to report the error in Voltage ratio in ADC monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246
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3255 (DTC 1D9-02) - Analog Digital Converter (ADC) : Diagnostic fault check to report the ADC test error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247 3256 (DTC 1D9-12) - Analog Digital Converter (ADC) : Diagnostic fault check to report the NTP error in ADC monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248 3258 (DTC 1E1-03) - ECU Power stages : Starter relay HS power stage output short circuit to battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249 3258 (DTC 1E1-03) - ECU Power stages : Starter relay HS power stage output short circuit to battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251 3259 (DTC 1E1-04) - ECU Power stages : Starter relay HS power stage output short circuit to ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253 3259 (DTC 1E1-04) - ECU Power stages : Starter relay HS power stage output short circuit to ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255 3260 (DTC 2E1-02) - ECU Power stages : Starter relay HS power stage output open circuit . . . . .
257
3260 (DTC 2E1-02) - ECU Power stages : Starter relay HS power stage output open circuit . . . . .
259
3261 (DTC 2E1-03) - ECU Power stages : Starter relay power stage: Short circuit to battery error for the Low side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261 3261 (DTC 2E1-03) - ECU Power stages : Starter relay power stage: Short circuit to battery error for the Low side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263 3262 (DTC 2E1-04) - ECU Power stages : Starter relay power stage: Short circuit to ground error for the Low side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265 3262 (DTC 2E1-04) - ECU Power stages : Starter relay power stage: Short circuit to ground error for the Low side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267 3265 (DTC 1E3-03) - Level 2 Monitoring : Diagnostic fault check to report the error due to Over Run
269
3266 (DTC 1E4-03) - Engine speed : Diagnostic fault check to report the engine speed error . . . .
270
3283 (DTC 1E7-03) - ECU Sensor Supply Monitor : ECU internal: Error Sensor supplies 2 . . . . . .
271
3285 (DTC 1E8-03) - ECU Sensor Supply Monitor : ECU internal: Error Sensor supplies 2 . . . . . .
273
3293 (DTC 151-03) - Fuel Metering Unit : maximum positive deviation of rail pressure exceeded .
275
3301 (DTC 153-03) - Fuel Metering Unit : maximum negative rail pressure deviation with metering unit on lower limit is exceeded . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276 3305 (DTC 154-03) - Fuel Metering Unit : minimum rail pressure exceeded . . . . . . . . . . . . . . . . . . . .
277
3309 (DTC 155-03) - Fuel Metering Unit : maximum rail pressure exceeded . . . . . . . . . . . . . . . . . . .
278
3334 (DTC 1C6-03) - CAN Bus Received frames : CAN-Receive-Frame Torque / Speed control from PE to EDC through TSC1_PE Message active . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 279 3335 (DTC 2C6-02) - CAN Bus Received frames : CAN-Receive-Frame Torque / Speed control from PE to EDC through TSC1_PE Message passive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 281 3338 (DTC 3C8-02) - CAN Bus Received frames : CAN-Receive-Frame Torque / Speed control from VE to EDC through TSC1_VE Message passive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 283 3339 (DTC 1C8-03) - CAN Bus Received frames : CAN-Receive-Frame Torque / Speed control from VE to EDC through TSC1_VE Message active . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285 3350 (DTC 11A-03) - Terminal 50 switch : Defective T50 switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
287
3358 (DTC 1B7-02) - CAN Bus Transmitted frames : CAN-Transmit-Frame EEC1, Electronic Engine Control #1 message (Torque, acc.pedal,engine speed, etc.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 289 3361 (DTC 1D2-03) - EEPROM : EEP Erase Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
291
3362 (DTC 1DA-12) - Engine internal calculations : DFC to report if the quantity axis points increase strictly linearly above the torque axis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 292 3368 (DTC 19D-04) - Torque limitation, Engine protection : Torque limitation caused by performance limiter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 293
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3369 (DTC 19E-04) - Torque limitation, Engine protection : Torque limitation caused by smoke limitation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 294 3370 (DTC 49E-04) - Torque limitation, Engine protection : Strong torque limitation from engine protection active . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 295 3371 (DTC 69E-04) - Torque limitation, Engine protection : Strong torque limitation from injection system active . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 296 3374 (DTC 17F-12) - Injector Adjustment programming : check of missing injector adjustment value programming: injector 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 297 3390 - Air Filter Restriction Switch Short To Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
298
3402 (DTC 535-03) - Rail pressure sensor : maximum rail pressure exceeded . . . . . . . . . . . . . . . . .
300
3403 (DTC 2E1-12) - ECU Power stages : Starter relay HS power stage over temperature . . . . . .
301
3403 (DTC 2E1-12) - ECU Power stages : Starter relay HS power stage over temperature . . . . . .
303
3405 (DTC 393-02) - ECU Power stages : Open load temperature error on the Turbocharger PWM output power stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 305 3406 (DTC 393-12) - ECU Power stages : Over temperature error on the Turbocharger PWM output power stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 307 3409 (DTC 238-04) - Oil pressure sensor : Defect fault check for minimum oil pressure from digital sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 309 3410 (DTC 58C-03) - Throttle valve control governor deviation above threshold . . . . . . . . . . . . . . . .
312
3411 (DTC 58C-04) - Throttle valve control governor deviation below threshold . . . . . . . . . . . . . . . .
313
3414 (DTC 72C-00) - Array of DFCs for short circuit in i+1th Glow Plug . . . . . . . . . . . . . . . . . . . . . . .
314
3415 (DTC 72C-01) - Array of DFCs for short circuit in i+1th Glow Plug . . . . . . . . . . . . . . . . . . . . . . .
316
3416 (DTC 72C-02) - Array of DFCs for short circuit in i+1th Glow Plug . . . . . . . . . . . . . . . . . . . . . . .
318
3417 (DTC 72C-03) - Array of DFCs for short circuit in i+1th Glow Plug . . . . . . . . . . . . . . . . . . . . . . .
320
3418 (DTC 393-03) - ECU Power stages : SCB error on the Turbocharger PWM output power stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 322 3419 (DTC 393-04) - ECU Power stages : SCG error on the Turbocharger PWM output power stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 324 3420 (DTC 3CA-03) - CAN Bus Received frames : DFC of Auxiliary Engine Shutdown Switch Message . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 326 3425 (DTC 199-02) - Turbocharger : Over boost deviation at P2 too high in Pressure charger regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 327 3427 (DTC 3F1-04) - Diesel particulate filter (DPF) : Signal range check flow resistance of the particulate filter - low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 328 3428 (DTC 3F3-12) - Diesel Particulate filter Pressure sensor: not plausibility error . . . . . . . . . . . . .
329
3429 (DTC 7F3-12) - Diesel Particulate filter Pressure sensor: hoseline plausibility error . . . . . . . .
330
3430 (DTC 15E-03) - EGR Inducement less severe derating level . . . . . . . . . . . . . . . . . . . . . . . . . . . .
331
3431 (DTC 25E-03) - EGR Inducement most severe derating level . . . . . . . . . . . . . . . . . . . . . . . . . . .
332
3432 (DTC 35E-03) - EGR Inducement warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
333
3433 (DTC 15D-03) - DPF Inducement less severe derating level . . . . . . . . . . . . . . . . . . . . . . . . . . . .
334
3434 (DTC 25D-03) - DPF Inducement most severe derating level . . . . . . . . . . . . . . . . . . . . . . . . . . .
335
3435 (DTC 35D-03) - DPF Inducement warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
336
3517 (DTC 13C-03) - SRC high for air temperature sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
337
3518 (DTC 13C-04) - SRC low for air temperature sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
339
3616 (DTC 39E-04) - Torque limitation, Engine protection : Torque limitation caused by turbo charger protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 341
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3650 (DTC 226-03) - Battery voltage : SRC high for battery voltage sensor . . . . . . . . . . . . . . . . . . . .
342
3651 (DTC 226-04) - Battery voltage : SRC low for battery voltage sensor . . . . . . . . . . . . . . . . . . . . .
343
3652 (DTC 1B1-04) - CAN Bus : Bus off of CAN node A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
345
3655 (DTC 39D-04) - Torque limitation, Engine protection : General report of the event of torque limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 347 3656 (DTC 49D-04) - Torque limitation, Engine protection : Torque limitation caused by particulate filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 348 3657 (DTC 7BA-02) - CAN Bus Received frames : Timeout Error of CAN-Receive-Frame CM1BC
349
3665 (DTC 589-03) - EGR valve control governor deviation above threshold . . . . . . . . . . . . . . . . . . .
351
3666 (DTC 589-04) - EGR valve control governor deviation below threshold . . . . . . . . . . . . . . . . . . .
352
3667 (DTC 58B-02) - Open load error for EGR valve H-bridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
353
3668 (DTC 58B-12) - Over current error for EGR valve H-bridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
355
3669 (DTC 68B-00) - Over temperature error for EGR valve H-bridge . . . . . . . . . . . . . . . . . . . . . . . . .
357
3670 (DTC 68B-03) - Short circuit to battery of EGR valve H-bridge - high pin A50 . . . . . . . . . . . . . .
359
3671 (DTC 68B-01) - Short circuit to battery of EGR valve H-bridge - low pin A35 . . . . . . . . . . . . . .
361
3672 (DTC 68B-04) - Short circuit to ground of EGR valve H-bridge - high pin A50 . . . . . . . . . . . . .
363
3673 (DTC 68B-02) - Short circuit to ground of EGR valve H-bridge - low pin A35 . . . . . . . . . . . . . .
365
3674 (DTC 68B-07) - Short circuit over load error for EGR valve H-bridge . . . . . . . . . . . . . . . . . . . . .
368
3675 (DTC 689-04) - EGR valve too long time drift at closed position . . . . . . . . . . . . . . . . . . . . . . . . .
369
3676 (DTC 789-00) - EGR valve position sensor voltage above threshold (Short to battery) . . . . . .
370
3677 (DTC 789-01) - EGR valve position sensor voltage below threshold (Short to ground) . . . . . .
372
3680 (DTC 256-03) - Injection cut off : Injection cut off demand (ICO) for shut off coordinator . . . .
374
3684 (DTC 3F7-03) - Exhaust temperature : Fault Check for enhanced SRC-Max of Second exhaust gas temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 375 3688 (DTC 11C-02) - Water sensor in the fuel filter : WIF Sensor Check is failed. . . . . . . . . . . . . . .
376
3689 (DTC 52C-01) - DFC for faulty diagnostic data transmission or protocol error . . . . . . . . . . . . .
378
3691 (DTC 32B-02) - No load error for Low Voltage System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
380
3692 (DTC 32B-12) - Over temperature error on ECU power stage for Glow plug Low Voltage System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 382 3693 (DTC 32B-03) - Short circuit to battery error for Low Voltage System . . . . . . . . . . . . . . . . . . . . .
384
3694 (DTC 32B-04) - Short circuit to ground error for Low Voltage System . . . . . . . . . . . . . . . . . . . . .
386
3699 (DTC 5D2-03) - EEPROM : Error in EEPROM block EEPData1. SD correction can not be calculated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 388 3703 (DTC 26F-04) - Injection control : check of minimum rail pressure . . . . . . . . . . . . . . . . . . . . . . .
389
3704 (DTC 27F-12) - Injector Adjustment programming : check of missing injector adjustment value programming: injector 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 390 3705 (DTC 37F-12) - Injector Adjustment programming : check of missing injector adjustment value programming: injector 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 391 3706 (DTC 47F-12) - Injector Adjustment programming : check of missing injector adjustment value programming: injector 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 392 3707 (DTC 601-02) - Lambda sensor : Open circuit at the lambda sensor Nernst cell pin . . . . . . . .
393
3708 (DTC 602-02) - Lambda sensor : open circuit at the lambda sensor pump current pin - IP (lambda = 1 detection) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 395 3709 (DTC 606-02) - Lambda sensor : Open circuit at the lambda sensor Virtual ground pin . . . . .
397
3711 (DTC 18F-03) - Lambda sensor : SCB error of the LSU Heater Power stage . . . . . . . . . . . . . .
399
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3712 (DTC 18F-04) - Lambda sensor : SCG error of the LSU Heater Power stage . . . . . . . . . . . . . .
401
3713 (DTC 18F-02) - Lambda sensor : Open Load error of the LSU Heater Power stage . . . . . . . .
403
3714 (DTC 607-03) - Lambda sensor : Fault code to indicate SRC High error for O2 calibration . .
405
3715 (DTC 607-04) - Lambda sensor : Fault code to indicate SRC Low error for O2 calibration . .
406
3716 (DTC 605-03) - Lambda sensor : O2 value above the max threshold . . . . . . . . . . . . . . . . . . . . .
407
3720 (DTC 60A-04) - Lambda sensor : low battery voltage at the SPI chip . . . . . . . . . . . . . . . . . . . . .
409
3721 (DTC 609-02) - Lambda sensor : Fault check to indicate SPI chip error of lambda sensor . .
410
3722 (DTC 60C-03) - Lambda sensor : LSU sensor temperature Ri exceeds the maximum limit . .
411
3723 (DTC 60C-04) - Lambda sensor : LSU sensor temperature Ri is below the minimum limit . . .
413
3724 (DTC 60B-03) - Lambda sensor : short to battery at IA,IP, UN, VG . . . . . . . . . . . . . . . . . . . . . . .
415
3725 (DTC 60B-04) - Lambda sensor : short to ground at IA,IP, UN, VG . . . . . . . . . . . . . . . . . . . . . . .
417
3727 (DTC 1FF-04) - Info : Low oil viscosity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
419
3728 (DTC 1FF-02) - Info : Too low oil viscosity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
420
3735 (DTC 559-12) - Fuel Metering Unit : over temperature of device driver of metering unit . . . . .
421
3738 (DTC 2D4-04) - Analog Digital Converter (ADC) : Diagnostic fault check to report multiple error while checking the complete ROM-memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 423 3739 (DTC 3D4-12) - Power stages, Injector : Loss of synchronization sending bytes to the MM from CPU. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 424 3740 (DTC 3D4-02) - Power stages, Injector : DFC to set a torque limitation once an error is detected before MoCSOP's error reaction is set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 425 3741 (DTC 3D4-03) - Power stages, Injector : Wrong set response time . . . . . . . . . . . . . . . . . . . . . . .
426
3742 (DTC 3D4-04) - Power stages, Injector : Too many SPI errors during MoCSOP execution. . .
427
3743 (DTC 4D4-04) - Power stages, Injector : Diagnostic fault check to report the error in under voltage monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 428 3744 (DTC 4D4-03) - Power stages, Injector : Diagnostic fault check to report the error in overvoltage monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 429 3745 (DTC 5D4-02) - Power stages, Injector : Diagnostic fault check to report that WDA is not working correct . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 430 3746 (DTC 5D4-03) - Power stages, Injector : OS timeout in the shut off path test. Failure setting the alarm task period. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 431 3747 (DTC 5D4-04) - Power stages, Injector : Diagnostic fault check to report that the positive test failed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 432 3748 (DTC 5D4-12) - Power stages, Injector : Diagnostic fault check to report the timeout in the shut off path test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 433 3750 (DTC 3E3-00) - Injection control : Error in the plausibility of the injection energizing time . . .
434
3751 (DTC 3E3-01) - Injection control : Error in the plausibility of the start of energizing angles . .
435
3752 (DTC 3E3-02) - Level 2 Monitoring: Error in the plausibility of the energizing times of the zero fuel quantity calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 436 3753 (DTC 3E3-03) - Level 2 Monitoring : Diagnostic fault check to report the error due to Over heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 437 3754 (DTC 3E3-04) - Level 2 Monitoring : Diagnostic fault check to report the plausibility error in rail pressure monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 438 3755 (DTC 3E3-12) - Level 2 Monitoring : Diagnostic fault check to report the error due to torque comparison . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 439 3756 (DTC 4E3-03) - Level 2 Monitoring : Diagnosis fault check to report the demand for normal mode due to an error in the PoI2 quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 440
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3757 (DTC 4E3-04) - Level 2 Monitoring : Diagnosis fault check to report the error to demand for an ICO due to an error in the PoI2 shut-off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 441 3758 (DTC 4E3-12) - Level 2 Monitoring : Diagnosis fault check to report the error to demand for an ICO due to an error in the PoI3 efficiency factor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 442 3759 (DTC 5E3-03) - Level 2 Monitoring : Diagnosis of curr path limitation forced by ECU monitoring level 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 443 3760 (DTC 5E3-04) - Level 2 Monitoring : Diagnosis air path limitation due to a functional control unit monitoring forced by ECU monitoring level 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 444 3761 (DTC 5E3-12) - Level 2 Monitoring : Diagnosis quantity path limitation due to a functional control unit monitoring (level 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 445 3762 (DTC 426-03) - Level 2 Monitoring : Reported Overvoltage of Supply . . . . . . . . . . . . . . . . . . . .
446
3763 (DTC 426-04) - Level 2 Monitoring : Reported Under Voltage of Supply . . . . . . . . . . . . . . . . . .
447
3764 (DTC 225-04) - Main Relay : Early opening defect of main relay . . . . . . . . . . . . . . . . . . . . . . . . .
448
3766 (DTC 1F3-12) - Diesel Particulate filter Pressure sensor : Fault check for the pressure sensor plausibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 451 3767 (DTC 6D4-02) - ECU internal : Diagnostic fault check to report 'WDA active' due to errors in query-/response communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 452 3768 (DTC 6D4-04) - ECU internal : Diagnostic fault check to report 'ABE active' due to under voltage detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 453 3769 (DTC 6D4-03) - ECU internal : Diagnostic fault check to report 'ABE active' due to overvoltage detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 454 3770 (DTC 6D4-12) - ECU internal : Diagnostic fault check to report 'WDA/ABE active' due to unknown reason . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 455 3773 (DTC 299-04) - Turbocharger : Under boost detected in Pressure charger regulator . . . . . . .
456
3786 (DTC 3F9-03) - Diesel particulate filter (DPF) : Signal range check flow resistance of the particulate filter - high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 457 3787 (DTC 4F9-03) - Diesel particulate filter (DPF) : Signal range check flow resistance of the particulate filter - very high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 458 3789 (DTC 6F4-12) - To check if regeneration duration exceeds maximum allowed duration . . . . .
459
3794 (DTC 134-00) - Intake air pressure sensor : Plausibility Check for air pressure at the upstream of intake valve sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 460 3795 (DTC 134-01) - Intake air pressure sensor : Plausibility Check for air pressure at the upstream of intake valve sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 461 3796 (DTC 5F5-12) - Diesel Particulate filter Pressure sensor : DFC to indicate hose line error . . .
462
3797 (DTC 1F1-03) - Diesel Particulate filter Pressure sensor : SRC High for PFlt differential pressure sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 463 3798 (DTC 1F1-04) - Diesel Particulate filter Pressure sensor : SRC low for PFlt differential pressure sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 465 3799 (DTC 237-04) - Pressure Relief valve : pressure relief valve is forced to open, perform pressure shock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 467 3800 (DTC 237-12) - Pressure Relief valve : Quantity balance check if a successful PRV opening is ensured . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 468 3801 (DTC 49B-03) - Turbine upstream pressure sensor : SRC High for Turbine upstream pressure sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 469 3802 (DTC 49B-04) - Turbine upstream pressure sensor : SRC low for Turbine upstream pressure sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 471 3803 (DTC 2D1-03) - ECU internal : Error on R2S2 module (Low-Level Chip driver for the Power stage-Chips) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 473 3808 (DTC 455-03) - Fuel Metering Unit : set point of metering unit in idle mode not plausible . . .
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474
3810 (DTC 435-12) - Fuel pressure Sensor : Rail pressure raw value is intermittent . . . . . . . . . . . .
475
3811 (DTC 1E6-12) - ECU Sensor Supply Monitor : ECU internal: Error Sensor supplies 1 . . . . . .
477
3812 (DTC 2CC-00) - Physical Range Check high for ECU temperature sensor . . . . . . . . . . . . . . . .
483
3813 (DTC 2CC-01) - Physical Range Check low for ECU temperature sensor . . . . . . . . . . . . . . . . .
484
3814 (DTC 2CC-12) - ECU temperature sensor : SPI Error ECU temperature sensor (LM71) . . . .
485
3818 (DTC 48D-02) - Open load error for throttle valve H-bridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
486
3819 (DTC 48D-03) - Over current error for throttle valve H-bridge . . . . . . . . . . . . . . . . . . . . . . . . . . .
488
3820 (DTC 48D-12) - Over temperature error for throttle valve H-bridge . . . . . . . . . . . . . . . . . . . . . . .
490
3821 (DTC 58D-03) - Short circuit to battery of throttle valve H-bridge - high pin A49 . . . . . . . . . . . .
492
3822 (DTC 68D-03) - Short circuit to battery of throttle valve H-bridge - low pin A34 . . . . . . . . . . . .
494
3823 (DTC 58D-04) - Short circuit to ground of throttle valve H-bridge - high pin A49 . . . . . . . . . . . .
496
3824 (DTC 68D-04) - Short circuit to ground of throttle valve H-bridge - low pin A34 . . . . . . . . . . . .
498
3825 (DTC 78D-03) - Short circuit over load error for throttle valve H-bridge . . . . . . . . . . . . . . . . . . .
500
3827 (DTC 78D-04) - Under voltage error for throttle valve H-bridge . . . . . . . . . . . . . . . . . . . . . . . . . .
502
3834 (DTC 78B-03) - Throttle valve position sensor voltage above threshold (Short to battery) . . .
503
3835 (DTC 78B-04) - Throttle valve position sensor voltage below threshold (Short to ground) . . .
505
3838 (DTC 3F6-03) - OxiCat upstream temperature sensor : Diagnostic fault check for SRC high in Oxidation Catalyst upstream temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 507 3839 (DTC 3F6-04) - OxiCat upstream temperature sensor : Diagnostic fault check for SRC low in Oxidation Catalyst upstream temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 509 3840 (DTC 1F7-03) - Diesel Particulate filter upstream temperature sensor : Diagnostic fault check for SRC high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 511 3841 (DTC 1F7-04) - Diesel Particulate filter upstream temperature sensor : Diagnostic fault check for SRC low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 513 3842 (DTC 29B-03) - Turbine upstream temperature sensor : SRC High for turbine upstream temperature sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 515 3843 (DTC 29B-04) - Turbine upstream temperature sensor : SRC low for turbine upstream temperature sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 518 3844 (DTC 25A-03) - Zero Fuel Calibration by Lambda (ZFL) : DFC reporting error state on comparing energizing time to Max value injector 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 520 3845 (DTC 35A-03) - Zero Fuel Calibration by Lambda (ZFL) : DFC reporting error state on comparing energizing time to Max value injector 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 521 3846 (DTC 45A-03) - Zero Fuel Calibration by Lambda (ZFL) : DFC reporting error state on comparing energizing time to Max value injector 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 522 3847 (DTC 55A-03) - Zero Fuel Calibration by Lambda (ZFL) : DFC reporting error state on comparing energizing time to Max value injector 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 523 3848 (DTC 25A-04) - Zero Fuel Calibration by Lambda (ZFL) : DFC reporting error state on comparing energizing time to Min value injector 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 524 3849 (DTC 35A-04) - Zero Fuel Calibration by Lambda (ZFL) : DFC reporting error state on comparing energizing time to Min value injector 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 525 3850 (DTC 45A-04) - Zero Fuel Calibration by Lambda (ZFL) : DFC reporting error state on comparing energizing time to Min value injector 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 526 3851 (DTC 55A-04) - Zero Fuel Calibration by Lambda (ZFL) : DFC reporting error state on comparing energizing time to Min value injector 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 527 3870 (DTC 1B4-02) - CAN Bus Received frames : CAN-Receive-Frame BC2EDC1 . . . . . . . . . . . . .
528
3899 (DTC 432-03) - Engine Protection : Engine temperature reaches prewarning level . . . . . . . . .
530
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3900 (DTC 532-03) - Engine Protection : Engine temperature reaches warning level . . . . . . . . . . . .
531
3906 (DTC 17E-12) - Injection control : Number of injections is limited by quantity balance of high pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 532 3910 (DTC 459-03) - Fuel Metering Unit : Intermittent contact between ECU and MeUn . . . . . . . . .
533
3915 (DTC 137-12) - Pressure Relief valve : Averaged rail pressure is outside the expected tolerance range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 535 3916 (DTC 237-03) - Pressure Relief valve : pressure relief valve reached maximum allowed open time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 536 3978 (DTC 3FB-03) - Level 2 of PFlt Overloaded . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
537
3979 (DTC 4FB-03) - Level 3 of PFlt Overloaded . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
538
3992 (DTC 182-12) - EGR Control : Not plausible state 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
539
3993 (DTC 489-03) - DFC for valve drift at closed position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
540
4043 - Hydraulic Oil Temperature Sensor Shorted To Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
541
4044 - Hydraulic Oil Temperature Sensor Open Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
543
4055 - Park Brake Valve (On/Off) - Solenoid Supply Open Circuit (*) . . . . . . . . . . . . . . . . . . . . . . . . . .
545
4056 - Park Brake Valve (On/Off) - Solenoid Supply Short to Ground (*) . . . . . . . . . . . . . . . . . . . . . . .
547
4057 - Park Brake Valve (On/Off) - Solenoid Supply Short to Power (*) . . . . . . . . . . . . . . . . . . . . . . . .
549
4061 - Forward Pump Control Valves (Directional) - Solenoid Right (A) Supply Open Circuit (*) . . .
551
4062 - Forward Pump Control Valves (Directional) - Solenoid Right (A) Supply Short to Ground (*)
553
4071 - Forward Pump Control Valves (Directional) - Solenoid Left (B) Supply Open Circuit (*) . . . .
555
4072 - Forward Pump Control Valves (Directional) - Solenoid Left (B) Supply Short to Ground (*) .
557
4081 - Forward Pump Control Valves (Directional) - Common Solenoid Return Short to Power (*)
559
4082 - Forward Pump Control Valves (Directional) - Pumps Forward Solenoids Short to Ground (*)
561
4083 - Forward Pump Control Valves (Directional) - Common Solenoid Return Open Circuit (*) . .
563
4309 - Park Brake Button - Park Brake Button Timeout (30 sec) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . .
565
4361 - Reverse Pump Control Valves (Directional) - Solenoid Right (A) Supply Open Circuit (*) . .
567
4362 - Reverse Pump Control Valves (Directional) - Solenoid Right (A) Supply Short to Ground (*)
569
4371 - Reverse Pump Control Valves (Directional) - Solenoid Left (B) Supply Open Circuit (*) . . . .
571
4372 - Reverse Pump Control Valves (Directional) - Solenoid Left (B) Supply Short to Ground (*) .
573
4381 - Reverse Pump Control Valves (Directional) - Common Solenoid Return Short to Power (*)
575
4382 - Reverse Pump Control Valves (Directional) - Pumps Reverse Solenoids Short to Ground (*)
577
4383 - Reverse Pump Control Valves (Directional) - Common Solenoid Return Open Circuit (*) . .
579
4401 - Park Brake (Mechanical Machines) Solenoid Open Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . .
581
4402 - Park Brake (Mechanical Machines) Shorted To Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
583
4431 - Park Brake Pressure Switch - Pressure Switch (Plausibility Check With Solenoid Valve) (*)
584
4731 - Right Swash Plate Angle Sensor - Pin A Short to Ground/ Open Circuit (*) . . . . . . . . . . . . . .
587
4732 - Right Swash Plate Angle Sensor - Pin A Short to Power (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . .
590
4734 - Right Swash Plate Angle Sensor - Pin B Short to Ground/ Open Circuit (*) . . . . . . . . . . . . . .
592
4735 - Right Swash Plate Angle Sensor - Pin B Short to Power (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . .
595
4737 - Right Swash Plate Angle Sensor - In Range Fault (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
597
4741 - Left Swash Plate Angle Sensor - Pin A Short to Ground/ Open Circuit (*) . . . . . . . . . . . . . . . .
600
(*) See content for specific models 48068130 29/01/2018
55.21 [55.DTC] / 864
4742 - Left Swash Plate Angle Sensor - Pin A Short to Power (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
603
4744 - Left Swash Plate Angle Sensor - Pin B Short to Ground/ Open Circuit (*) . . . . . . . . . . . . . . . .
605
4745 - Left Swash Plate Angle Sensor - Pin B Short to Power (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
608
4747 - Left Swash Plate Angle Sensor - In Range Fault (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
610
4752 - Left Swash Plate Angle Sensor - Implausible Command, Command Does Not Match With Swash Plate Angle (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 613 4754 - Right Swash Plate Angle Sensor - Implausible Command, Command Does Not Match With Swash Plate Angle (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 615 4781 - Solenoid Valve - Solenoid Supply Open Circuit (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
617
4782 - Solenoid Valve - Solenoid Supply Short to Ground (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
619
4783 - Solenoid Valve - Solenoid Supply Short to Power (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
621
4951 - Hydraulic Interlock Solenoid Shorted To Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
623
4952 - Hydraulic Interlock Solenoid Open Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
624
5051 - Loader Pilot Interlock Valve (On/Off) - Solenoid Supply Open Circuit (*) . . . . . . . . . . . . . . . . .
626
5052 - Loader Pilot Interlock Valve (On/Off) - Solenoid Supply Short to Ground (*) . . . . . . . . . . . . . .
628
5053 - Loader Pilot Interlock Valve (On/Off) - Solenoid Supply Short to Power (*) . . . . . . . . . . . . . . .
630
5061 - Port Lock Valve (On/Off) - Solenoid Supply Open Circuit (*) . . . . . . . . . . . . . . . . . . . . . . . . . . .
632
5062 - Port Lock Valve (On/Off) - Solenoid Supply Short to Ground (*) . . . . . . . . . . . . . . . . . . . . . . . .
634
5063 - Port Lock Valve (On/Off) - Solenoid Supply Short to Power (*) . . . . . . . . . . . . . . . . . . . . . . . . .
636
5121 - Right Joystick F-B Axis - Pin A Short to Power/ Short to Ground/ Open Circuit (*) . . . . . . . .
638
5122 - Right Joystick F-B Axis - Pin B Short to Power/ Short to Ground/ Open Circuit (*) . . . . . . . .
642
5124 - Right Joystick F-B Axis - In Range Fault (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
646
5131 - Right Joystick R-L Axis (ISO/H Pattern) - Pin A Short to Ground/ Open Circuit (*) . . . . . . . .
651
5132 - Right Joystick R-L Axis (ISO/H Pattern) - Pin A Short to Power (*) . . . . . . . . . . . . . . . . . . . . . .
655
5134 - Right Joystick R-L Axis (ISO/H Pattern) - Pin B Short to Ground/ Open Circuit (*) . . . . . . . .
659
5135 - Right Joystick R-L Axis (ISO/H Pattern) - Pin B Short to Power (*) . . . . . . . . . . . . . . . . . . . . . .
663
5137 - Right Joystick R-L Axis (ISO/H Pattern) - In Range Fault (*) . . . . . . . . . . . . . . . . . . . . . . . . . . .
667
5141 - Aux Thumbwheel Axis - Pin A Short to Ground/ Open Circuit (*) . . . . . . . . . . . . . . . . . . . . . . .
672
5142 - Aux Thumbwheel Axis - Pin A Short to Power (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
675
5144 - Aux Thumbwheel Axis - Pin B Short to Ground/ Open Circuit (*) . . . . . . . . . . . . . . . . . . . . . . .
677
5145 - Aux Thumbwheel Axis - Pin B Short to Power (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
680
5147 - Aux Thumbwheel Axis - In Range Fault (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
682
5201 - Left Joystick L-R Axis - Pin A Short to Power/ Short to Ground/ Open Circuit (*) . . . . . . . . . .
685
5202 - Left Joystick L-R Axis - Pin B Short to Power/ Short to Ground/ Open Circuit (*) . . . . . . . . . .
689
5204 - Left Joystick L-R Axis - In Range Fault (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
693
5211 - Left Joystick F-B Axis - Pin A Short to Ground/ Open Circuit (*) . . . . . . . . . . . . . . . . . . . . . . . .
698
5212 - Left Joystick F-B Axis - Pin A Short to Power (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
702
5214 - Left Joystick F-B Axis - Pin B Short to Ground/ Open Circuit (*) . . . . . . . . . . . . . . . . . . . . . . . .
706
5215 - Left Joystick F-B Axis - Pin B Short to Power (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
710
5217 - Left Joystick F-B Axis - In Range Fault (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
714
5221 - Loader Arm Valve (Directional) Solenoid Raise (A) Supply Open Circuit (*) . . . . . . . . . . . . . .
719
(*) See content for specific models 48068130 29/01/2018
55.21 [55.DTC] / 865
5222 - Loader Arm Valve (Directional) Solenoid Raise (A) Supply Shorted To Ground (*) . . . . . . . .
721
5231 - Loader Arm Valve (Directional) Solenoid Lower (B) Supply Open Circuit (*) . . . . . . . . . . . . . .
723
5232 - Loader Arm Valve (Directional) Solenoid Lower (B) Supply Shorted To Ground (*) . . . . . . . .
725
5241 - Loader Arm Valve (Directional) Loader Arm Solenoid(s) Shorted To Power (*) . . . . . . . . . . .
727
5242 - Loader Arm Valve (Directional) Loader Arm Solenoid(s) Shorted To Ground (*) . . . . . . . . . .
729
5243 - Loader Arm Valve (Directional) Solenoids Return Open Circuit (*) . . . . . . . . . . . . . . . . . . . . . .
731
5251 - Loader Bucket Valve (Directional) Solenoid Rollback (A) Supply Open Circuit (*) . . . . . . . . .
733
5252 - Loader Bucket Valve (Directional) Solenoid Rollback (A) Supply Shorted To Ground (*) . . .
735
5261 - Loader Bucket Valve (Directional) Solenoid Dump (B) Supply Open Circuit (*) . . . . . . . . . . .
737
5262 - Loader Bucket Valve (Directional) Solenoid Dump (B) Supply Shorted To Ground (*) . . . . . .
739
5271 - Loader Bucket Valve (Directional) Loader Bucket Solenoid(s) Shorted To Power (*) . . . . . . .
741
5272 - Loader Bucket Valve (Directional) Loader Bucket Solenoid(s) Shorted To Ground (*) . . . . . .
743
5273 - Loader Bucket Valve (Directional) Solenoids Return Open Circuit (*) . . . . . . . . . . . . . . . . . . . .
745
5281 - Loader Auxiliary Valve (Directional) Solenoid Forward (A) Supply Open Circuit (*) . . . . . . . .
747
5282 - Loader Auxiliary Valve (Directional) Solenoid Forward (A) Supply Shorted To Ground (*) . .
749
5291 - Loader Auxiliary Valve (Directional) Solenoid Reverse (B) Supply Open Circuit (*) . . . . . . . .
751
5292 - Loader Auxiliary Valve (Directional) Solenoid Reverse (B) Supply Shorted To Ground (*) . .
753
5309 - Float Button - Float Button Timeout (30 sec) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
755
5313 - EHF Enable Switch STP (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
757
5323 - EHF Fwd/Rev Switch STP (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
759
5371 - EHF Forward Solenoid (A) Supply STG (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
762
5372 - EHF Forward Solenoid (A) Supply OC (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
764
5381 - EHF Reverse Solenoid (B) Supply STG (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
766
5382 - EHF Reverse Solenoid (B) Supply OC (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
768
5391 - EHF Solenoids Return OC (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
770
5392 - EHF Pump Solenoid(s) STG (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
772
5393 - EHF Pump Solenoid(s) STP (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
774
5409 - Aux Override Disabled Due To Aux Override Button Timeout (30 Seconds) (*) . . . . . . . . . . .
776
5501 - Loader Arm Spool Sensor Open or Shorted To Ground (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
777
5502 - Loader Arm Spool Sensor Shorted To Power (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
779
5503 - Electro-Hydraulic Aux Output Shorted To Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
781
5504 - Bucket Valve Spool Sensor Open Or Shorted To Ground (*) . . . . . . . . . . . . . . . . . . . . . . . . . . .
782
5505 - Bucket Valve Spool Sensor Shorted To Power (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
784
5507 - Auxiliary Valve Spool Sensor Open Or Shorted To Ground (*) . . . . . . . . . . . . . . . . . . . . . . . . . .
786
5508 - Auxiliary Valve Spool Sensor Shorted To Power (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
788
5511 - Implausible Loader Arm Sensor State Vs Loader Arm Command - Stuck Spool Or PRV (*)
790
5512 - Implausible Bucket Sensor State Vs Loader Bucket Command - Stuck Spool Or PRV (*) . .
793
5513 - Implausible Auxiliary Sensor State Vs Auxiliary Command - Stuck Spool Or PRV (*) . . . . . .
796
5601 - Loader Auxiliary Valve (Directional) Loader Auxiliary Solenoid(s) Shorted To Power (*) . . . .
799
5602 - Loader Auxiliary Valve (Directional) Loader Auxiliary Solenoid(s) Shorted To Ground (*) . . .
801
(*) See content for specific models 48068130 29/01/2018
55.21 [55.DTC] / 866
5603 - Loader Auxiliary Valve (Directional) Solenoids Return Open Circuit (*) . . . . . . . . . . . . . . . . . .
803
5701 - Pattern Switch Open Or Shorted To Ground (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
805
5703 - Pattern Switch Shorted To Power (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
808
5811 - Loader Port Lock Switch Is In An Implausible State (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
811
9004 - Memory Error - Triple Redundant - Hour Meter Location 1 Corrupt . . . . . . . . . . . . . . . . . . . . .
814
9005 - Memory Error - Triple Redundant - Hour Meter Location 2 Corrupt . . . . . . . . . . . . . . . . . . . . .
815
9006 - Memory Error - Triple Redundant - Hour Meter Location 3 Corrupt . . . . . . . . . . . . . . . . . . . . .
816
9151 - Bus-Warn at CAN-Bus No.1 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
817
9152 - Bus-Warn at CAN-Bus No.1 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
819
9153 - Timeout of CAN Message EEC1 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
821
9154 - Timeout of CAN Message TSC1 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
823
9156 - Hydraulic Enable Button Error From AIC (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
825
9158 - H Pattern Indicator Shorted To Ground (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
826
9159 - ISO Pattern Indicator Shorted To Ground (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
828
9160 - H Pattern Indicator Shorted To Power (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
830
9161 - ISO Pattern Indicator Shorted To Power (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
833
9401 - Memory Error - Double Redundant Memory - Corruption Detected And Repaired . . . . . . . . .
836
9403 - Memory Error - Double Redundant Memory - Unrecoverable Memory Corruption Operable
837
9404 - Memory Error - Triple Redundant - Hour Meter Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
838
9405 - Loss Of DM1 Message From VCM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
839
9406 - No CAN Communication From VCM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
840
9407 - Memory Error - Unrecoverable Hardware ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
841
9408 - Memory Error - Unrecoverable Panel ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
842
9410 - Loss Of EGR Inducement Status Message From EDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
843
(*) See content for specific models 48068130 29/01/2018
55.21 [55.DTC] / 867
CNH Industrial America - Main 700 State Street Racine, Wisconsin United States 53404
SERVICE - Technical Publications & Tools
PRINTED IN U.S.A. Š 2018 CNH Industrial America LLC. All rights reserved. No part of the text or illustrations of this publication may be reproduced.
CNH Industrial America LLC reserves the right to make improvements in design and changes in specifications at any time without notice and without incurring any obligation to install them on units previously sold. Specifications, descriptions, and illustrative material herein are as accurate as known at the time of publication, but are subject to change without notice. Availability of some models and equipment builds varies according to the country in which the equipment is being used. For exact information about any particular product, please consult your CASE CONSTRUCTION dealer. CASE CONSTRUCTION is a trademark registered in the United States and many other countries, owned or licensed to CNH Industrial N.V., its subsidiaries or affiliates. Any trademarks referred to herein, in association with goods and/or services of companies, other than owned by or licensed to CNH Industrial N.V., its subsidiaries or affiliates, are the property of those respective companies.
48068130 29/01/2018 EN
SERVICE MANUAL Front loader and bucket SR210 TIER 4B (FINAL) [NGM418237 - ], SR210 TIER 4B (FINAL) [NHM435463 - ], SR240 TIER 4B (FINAL) [NGM418237 - ], SR240 TIER 4B (FINAL) [NHM435463 - ], SV280 TIER 4B (FINAL) [NGM418237 - ], SV280 TIER 4B (FINAL) [NHM435463 - ], TR270 TIER 4B (FINAL) [NGM418237 - ], TR270 TIER 4B (FINAL) [NHM435463 - ], TR310 TIER 4B (FINAL) [NGM418237 - ], TR310 TIER 4B (FINAL) [NHM435463 - ], TV370 TIER 4B (FINAL) [NHM435463 - ]
48068130 29/01/2018
82
Contents Front loader and bucket - 82
[82.100] Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82.1 [82.300] Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82.2
48068130 29/01/2018
82
Front loader and bucket - 82 Arm - 100
SR210 TIER 4B (FINAL) [NGM418237 - ], SR210 TIER 4B (FINAL) [NHM435463 - ], SR240 TIER 4B (FINAL) [NGM418237 - ], SR240 TIER 4B (FINAL) [NHM435463 - ], SV280 TIER 4B (FINAL) [NGM418237 - ], SV280 TIER 4B (FINAL) [NHM435463 - ], TR270 TIER 4B (FINAL) [NGM418237 - ], TR270 TIER 4B (FINAL) [NHM435463 - ], TR310 TIER 4B (FINAL) [NGM418237 - ], TR310 TIER 4B (FINAL) [NHM435463 - ], TV370 TIER 4B (FINAL) [NHM435463 - ]
48068130 29/01/2018
82.1 [82.100] / 1
Contents Front loader and bucket - 82 Arm - 100
SERVICE Arm Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Raise - No-start machine - Video . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
(*) See content for specific models 48068130 29/01/2018
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Front loader and bucket - Arm
Arm - Repair When the pivot pins fail or the retaining hardware for the bucket release device or the bucket cylinders is loose for an extended period of time, the tapered hole in the bosses become damaged and requires replacement. In this procedure, you will find directions for replacing the upper and lower bosses on the loader arm. Bosses are to be replaced only one at a time. Do not attempt to replace more than one boss at the same time. You will not be able to use the boss alignment tool, part number 380100288, which is required for this procedure if you attempt to replace more than one boss at a time. All welding procedures are to be performed by a certified welder. Protect your work area from moisture, low temperatures, and excessive wind when repairing the bosses on the loader arm. Prior operation: Bucket release device - Remove (82.300) Prior operation: Remove the bucket cylinders.
Upper boss repair 1. Attach a magnetic hole drill to the loader arm.
RAIL14SSL0303BA
1
RAIL14SSL0304BA
2
2. Cut the welds that attach the boss to the loader arm.
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3. Remove the worn boss.
4. Install the boss 380100288.
alignment
tool,
part
RAIL14SSL0305BA
3
RAIL12SSL0494AA
4
RAIL12SSL0493AA
5
number
NOTE: The rods center the tool with the existing bosses and the tube helps to position the new boss to the loader frame. NOTE: Identify which way the rectangular tube assembly mounts on the rods. The lower rectangular section has the longer portion to the front, and the rod goes through the hole that is almost in the center line of the long rectangular tube.
5. Install the boss 380100288.
alignment
tool,
part
number
NOTE: The rods center the tool with the existing bosses and the tube helps to position the new boss to the loader frame. NOTE: The tool is installed with the short rectangular tube welded on the lower portion and is positioned toward the rear of the unit. The lower rod goes through the hole that is furthest from the center line of the long tube.
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6. To position the new boss horizontally, you must measure the distance from the new boss to the other pivot pin boss that is welded to the loader arm. To achieve the correct measurement of 787 mm (31 in) Âą 2 mm (5/64 in), slide the new boss, short tapered pin, and alignment tool on the upper rod, and adjust the equipment as necessary.
RAPH14SSL0327BA
6
RAIL14SSL0306BA
7
RAPH14SSL0328BA
8
7. Disconnect the battery negative cable and positive cable. 8. Tack weld (1) the boss to the inner side and outer side of the loader arm. NOTE: A certified welder must complete the welding procedure when replacing one boss or both upper bosses.
9. Remove the boss alignment tool. 10. Weld the boss to the loader arm. *No stop/start welds NOTE: For a description of the 2x weld, please see image 9.
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Weld specifications and locations 1.
Loader arm
2.
10 mm (25/64 in)
3.
15 mm (19/32 in)
4.
Upper boss
NOTE: Triple pass weld requirement.
RAPH14SSL0330BA
9
11. Inspect the new weld, and paint the loader arm.
RAIL14SSL0307BA
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10
Front loader and bucket - Arm
Lower boss repair 1. Remove the front portion of the lower boss as shown in image 11. NOTE: Remove all material up to the plates of the loader frame.
RAIL12SSL0501AA
11
RAIL12SSL0500AA
12
RAIL12SSL0502AA
13
RAIL12SSL0503AA
14
2. Cut through the circular weld (1) next to the boss.
3. Use a disc grinder and a chisel to cut the upper and lower welds between the boss and the loader arm. 4. Remove the original boss.
5. Use a grinder to remove the weld material on the sides and upper plate and lower plate of the loader arm. Do not remove the base material of the loader arm. You will use the base material for positioning and rewelding when installing the new boss.
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6. Use a drum grinder to clean the surfaces on the loader arm.
7. Install the boss 380100288.
alignment
tool,
part
RAIL12SSL0504AA
15
RAIL12SSL0494AA
16
RAIL12SSL0493AA
17
RAIL12SSL0507AA
18
number
NOTE: The rods center the tool with the existing bosses and the tube helps to position the new boss to the loader frame. NOTE: Identify which way the rectangular tube assembly mounts on the rods. The lower rectangular section has the longer portion to the front, and the rod goes through the hole that is almost in the center line of the long rectangular tube.
8. Install the boss 380100288.
alignment
tool,
part
number
NOTE: The rods center the tool with the existing bosses and the tube helps to position the new boss to the loader frame. NOTE: The tool is installed with the short rectangular tube welded on the lower portion and is positioned toward the rear of the unit. The lower rod goes through the hole that is furthest from the center line of the long tube.
9. Install the short tapered pin (2) (included with the boss alignment tool, part number 380100288) in the new pivot boss (3), and slide this assembly onto the lower rod and against the alignment tool (1) on the loader arm (4).
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10. To position the new boss horizontally, you must measure the distance from the new boss to the other pivot pin boss that is welded to the loader arm. To achieve the correct measurement of 822 mm (32 23/64 in) Âą 2 mm (5/64 in) (1), slide the new boss, short tapered pin, and alignment tool on the lower rod, and adjust the equipment as necessary.
RAIL12SSL0570AA
19
RAIL12SSL0508AA
20
11. Disconnect the battery negative cable and positive cable. 12. Tack weld (1) the new pin boss into position. NOTE: A certified welder must complete the welding procedure when replacing one boss or both lower bosses.
13. Remove the boss alignment tool. 14. Install a new tapered pin with the new hardware into the new boss. Torque the flanged nut to 203 N¡m (150 lb ft) NOTE: The pin will keep the tapered bore round during welding and keep weld spatter out of the bore.
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15. Weld the new boss in place. Refer to the weld information in image 21.
RAIL12SSL0492FA
21
Weld information Weld information (1) = 2x multi-pass weld from (C) to (D). Final total weld is 12 mm (15/32 in) high, extending out 36 mm (1 7/16 in) from the boss. (2) = 34 mm (1 11/32 in) weld (4) = 6 mm (15/64 in) (3) = 12 mm (15/32 in) (5) = 12 mm (15/32 in) 16. After the parts have cooled, prepare and paint as required.
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Arm - Remove SR210 SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] TR270 TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ]
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. Failure to comply could result in death or serious injury. W0398A
WARNING Burn hazard! Before performing any service on the hydraulic system, you must allow it to cool. Hydraulic fluid temperature should not exceed 40 °C (104 °F). Failure to comply could result in death or serious injury. W0241A
WARNING Pressurized hydraulic fluid can penetrate the skin and cause severe injuries. Hydraulic fluid can also infect a minor cut or opening in the skin. Serious infection or reaction can result without immediate medical treatment. If injured by leaking fluid, see your doctor immediately. Failure to comply could result in death or serious injury. W0358A
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. Failure to comply could result in death or serious injury. W0905A
WARNING Avoid injury! Always do the following before lubricating, maintaining, or servicing the machine. 1. Disengage all drives. 2. Engage parking brake. 3. Lower all attachments to the ground, or raise and engage all safety locks. 4. Shut off engine. 5. Remove key from key switch. 6. Switch off battery key, if installed. 7. Wait for all machine movement to stop. Failure to comply could result in death or serious injury. W0047A
Prior operation: Relieve the pressure in the lift arm cylinder. Please see Lift arm cylinder - Depressurising (35.701) 1. If applicable, disconnect the case drain hose (1) on the loader arm.
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2. Label and disconnect the auxiliary coupler hoses (1), and cap the open ports.
931002065
1
931002066
2
931001736
3
RAPH12SSL0049AA
4
3. Label and disconnect the bucket cylinder hoses, and the cap open ports.
4. Label and disconnect the quick disconnect hoses (if applicable), and cap the open ports.
5. Unplug the electrical connection (1).
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6. Support the loader arm (1) using an adequate lifting device.
931002023
5
931001618
6
931001616
7
931001625
8
7. Remove the snap rings (1) for the rod ends.
8. Remove the pins and washers (1) for the rod end. NOTE: Right hand side has the lock out.
9. Lower the cylinders (1) away from the loader arm.
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10. Lower the loader arm.
931002067A
9
11. Remove the left-hand side and right-hand side retaining bolts (1) for the loader arm.
931001622
10
931002068
11
931001624A
12
12. Remove left-hand side and right-hand side pins (1) for the loader arm.
13. Remove the loader arm.
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Arm - Install SR210 SR240 TIER 4B (FINAL) [NGM418237 - ] SR240 TIER 4B (FINAL) [NHM435463 - ] TR270 TR310 TIER 4B (FINAL) [NGM418237 - ] TR310 TIER 4B (FINAL) [NHM435463 - ]
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. Failure to comply could result in death or serious injury. W0398A
1. Using an adequate lifting device, raise the loader arm (1) into position on the machine.
931002023
1
931002068
2
931001622
3
2. Install the left-hand side and right-hand side pins (1) for the loader arm.
3. Install the left-hand side and right-hand side retaining bolts (1).
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4. Raise the cylinders (1), and position them in the loader arm.
931001625
4
931001616
5
931001618
6
RAPH12SSL0049AA
7
5. Insert the cylinders into the arm and secure the piston rod -end with the pins and washers (1). NOTE: Right-hand side has the lock out.
6. Install the snap rings (1) for the piston rod end.
7. Connect the electrical connections (1).
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Front loader and bucket - Arm
8. Connect the quick coupler hoses (if applicable).
931001736
8
931002066
9
9. Connect the bucket cylinder hoses.
10. Connect the auxiliary coupler hoses (1).
931002065
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10
Front loader and bucket - Arm
Arm - Remove SV280 TV370 TIER 4B (FINAL) [NHM435463 - ]
NOTE: The following steps show left side, loader arm components. Please repeat all steps to right side, loader arm components. 1. Raise the loader arm, and engage the loader arm lock pins (1). Lower the loader arm down on the pins (1).
RAPH14SSL0351BA
1
RAPH12SSL0326AA
2
RAPH12SSL0325AA
3
2. Remove the hold-down clamp (1) for the auxiliary hoses, located on the loader arm link.
3. Remove the hold-down clamp (1) for the bucket cylinder hoses, located on the loader arm link.
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Front loader and bucket - Arm
4. Raise the loader arm, and release loader arm lock pins. Carefully lower the loader arms.
RAPH14SSL0351BA
4
RAPH12SSL0314AA
5
RAPH12SSL0323AA
6
5. Place a suitable lifting device on the bucket end of the loader arm.
6. Disconnect, label, and cap the auxiliary hoses (2). 7. Remove the horn (1). 8. Disconnect and cap the hydraulic coupler hoses (3) (if applicable).
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Front loader and bucket - Arm
9. Pull the hydraulic coupler hoses through the loader arm (if applicable).
RAPH15SSL0014BA
7
RAPH12SSL0313AA
8
RAPH12SSL0320AA
9
10. Disconnect, label, and cap the bucket cylinder hoses (1).
11. Remove the cylinder hardware (1) for the loader arm, and disconnect the loader arm cylinders from the loader arm.
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Front loader and bucket - Arm
12. Support the loader arm link with a suitable lifting device.
RAPH15SSL0018BA
10
RAPH15SSL0017BA
11
RAPH12SSL0322AA
12
13. Support the loader arm with a suitable lifting device, and remove the loader arm link hardware (1).
14. Remove the hardware (1) for the loader arm link.
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Front loader and bucket - Arm
15. Carefully remove the loader arm link.
RAPH15SSL0015BA
13
RAPH15SSL0016BA
14
RAPH12SSL0318AA
15
16. Support the loader arm with a suitable lifting device.
17. Remove the loader arm hardware (1), and lower the loader arm links (2).
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18. Carefully remove the loader arm.
RAPH12SSL0317AA
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16
Front loader and bucket - Arm
Arm - Install SV280 TV370 TIER 4B (FINAL) [NHM435463 - ]
NOTE: The following steps show left side, loader arm components. Please repeat all steps to right side, loader arm components. 1. Carefully move the loader arm into the installation position.
RAPH12SSL0317AA
1
RAPH12SSL0318AA
2
RAPH15SSL0015BA
3
2. Apply LOCTITEÂŽ SILVER GRADE ANTI-SEIZE to the tapered area of the pins and bosses. 3. Carefully place the loader arm link into installation position. 4. Install the loader arm link hardware (1).
5. Carefully place the loader arm link into installation position.
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Front loader and bucket - Arm
6. Apply LOCTITE® SILVER GRADE ANTI-SEIZE to the tapered area of the pins and bosses. 7. Install the loader arm hardware (1). Torque the link bolt (1) to 645 – 873 N·m (476 – 644 lb ft).
RAPH15SSL0017BA
4
RAPH12SSL0322AA
5
RAPH12SSL0320AA
6
8. Install the hardware (1) for the loader arm link.
9. Connect the loader arm cylinders to the loader arm. 10. Install the hardware (1) for the loader arm cylinder.
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Front loader and bucket - Arm
11. Push the hydraulic coupler hoses through the loader arm (if applicable).
RAPH15SSL0014BA
7
RAPH12SSL0323AA
8
RAPH12SSL0313AA
9
12. Connect the auxiliary hoses (2). 13. Install the horn (1). 14. Connect the hydraulic coupler hoses (3) (if applicable).
15. Connect the bucket cylinder hoses (1).
16. Remove the lifting device.
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17. Raise the loader arm, and engage the loader arm lock pins (1).
RAPH14SSL0351BA
10
RAPH12SSL0325AA
11
RAPH12SSL0326AA
12
18. Install the bucket cylinder hoses hold-down clamp (1) located on the loader arm link.
19. Install the hold-down clamp (1) for the auxiliary hoses, located on the loader arm link.
Next operation: Grease all lubrication points on the loader arm. Please see the operatorâ&#x20AC;&#x2122;s manual for locations.
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Arm - Raise - No-start machine - Video DANGER 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. Failure to comply will result in death or serious injury. D0084A
DANGER Crushing hazard! Failure to engage the boom lock pin could cause the boom to fall unexpectedly. Verify that the boom lock pin is engaged. Failure to comply will result in death or serious injury. D0019A
1. The attached YouTubeâ&#x201E;˘ video demonstrates how to raise the boom/loader arm in a no-start machine situation.
RAPH16SSL0231QA
1
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Index Front loader and bucket - 82 Arm - 100 Arm - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15
Arm - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
24
Arm - Raise - No-start machine - Video . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
28
Arm - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11
Arm - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
18
Arm - Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3
(*) See content for specific models 48068130 29/01/2018
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Front loader and bucket - 82 Bucket - 300
SR210 TIER 4B (FINAL) [NGM418237 - ], SR210 TIER 4B (FINAL) [NHM435463 - ], SR240 TIER 4B (FINAL) [NGM418237 - ], SR240 TIER 4B (FINAL) [NHM435463 - ], SV280 TIER 4B (FINAL) [NGM418237 - ], SV280 TIER 4B (FINAL) [NHM435463 - ], TR270 TIER 4B (FINAL) [NGM418237 - ], TR270 TIER 4B (FINAL) [NHM435463 - ], TR310 TIER 4B (FINAL) [NGM418237 - ], TR310 TIER 4B (FINAL) [NHM435463 - ], TV370 TIER 4B (FINAL) [NHM435463 - ]
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Contents Front loader and bucket - 82 Bucket - 300
TECHNICAL DATA Bucket General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
FUNCTIONAL DATA Bucket release device Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
SERVICE Bucket Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Bucket release device Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Quick coupler Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
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Front loader and bucket - Bucket
Bucket - General specification
BT97G325
1. 10 mm ( 3/8 in) fillet (weld twice 1 root pass 1 cover pass) 2. 6 mm ( 1/4 in) fillet (weld 4 times)
1
3. 6 mm ( 1/4 in) groove 6 mm ( 1/4 in) fillet (weld twice-wrap ends)
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Front loader and bucket - Bucket
Bucket release device - Exploded view
BS04E150
1
Mechanical coupling mounting plate assembly (1) (2) (3) (4) (5)
Mounting Plate Left Hand Handle Dust Cap Grease Zerk Plate
(7) Latch Pin (8) Plug (9) Clip (10) Pin (11) Compression Spring 48068130 29/01/2018
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(13) (14) (15) (16) (17)
Pin Bolt Right Hand Handle Pin Bushing
Front loader and bucket - Bucket
(6) Spring Pin
(12) Guide
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Front loader and bucket - Bucket
Bucket - Replace 1. Cut or grind the old cutting edge from the bucket floor and sides. Remove all old weld and foreign material from the welding area.
SH88030
2. Straighten the bucket floor and sides if required. 3. Thoroughly clean the area where the new cutting edge will be welded. 4. Use dry AWS-E7018 low hydrogen electrodes or either of the following equivalent low hydrogen wire feed electrodes: Gas metal arc welding (C0² or argon C0²) AWS-E70S6 or flux cored arc welding AWS-E70T1. 5. Preheat the parts to be welded (both tack and final welds) to a minimum of 204 °C (400 °F). The preheat temperature must be throughout the entire thickness of the parts joined, and at least 51 mm ( 2 in) back from the joint. Maintain preheat throughout the entire welding operation. NOTE: This is a hardened steel edge. If not preheated, the cutting edge may later crack during use. 6. Tack weld the preheated parts starting at the center of the bucket and working toward the outside ends. 7. Finish welding the preheated parts starting at the center of the front edge of the bucket floor and working toward the outside ends. Repeat this operation at the back side of the cutting edge to bucket floor. 8. Do not remove the bucket from the welding environment until the weld and metal temperature drops to the ambient temperature. Do not force the cooling rate of the welds and material. 9. Follow the same welding procedure for welding the side cutting edges and bottom wear plates to the bucket.
Bolt On Cutting Edge Replacement 10. Loosen and remove the bolts from the cutting edge. 11. Remove the cutting edge from the bucket. 12. Install new cutting edge on the bucket. Install new bolts and tighten the bolts.
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1
Front loader and bucket - Bucket
Dirt Tooth Kit Installation/Bucket Dirt Tooth Kit 13. The dirt tooth kit consists of six teeth that are welded to the bucket cutting edge as indicated in image 4. The teeth are used to break up the material when rough digging conditions are experienced. This will make it easier to fill the bucket. The teeth are intended to be used only on dirt and foundry or low-profile buckets.
SH88032
2
SH88033
3
SH88034
4
Tooth Point Replacement 14. The points of the teeth are a replaceable "pin-on" design and can be obtained from Parts. 15. To replace the "pin-on" points, use a punch that just fits into the pin hole, (1), and drive the old retaining pin from the shank. 16. Place the new point over the shank and insert the retaining pin into the hole, (1). With a punch that contacts both sides of the metal part of the retaining pin, drive the pin until it is centered in the shank. NOTE: If the punch or driver is too small and just contacts the rubber center of the retaining pin, the pin will be damaged and will not retain the point.
Tooth Location and Installation 17. The bucket should be flat on the floor when placing and welding the teeth to maintain good weld points, (1). NOTICE: Remove the bucket from the loader while welding teeth to prevent damage to the loader electrical system. 18. Slide the replaceable points in place but do not attach with the steel/rubber pins as the rubber may be damaged during the welding process.
19. Locate the teeth on the bucket edge as indicated (see image 5). Please see table below for spacing values.
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Front loader and bucket - Bucket
BS04E165
5
Bucket Tooth Spacing NOTE: Position the teeth at these spacings, then re-center if necessary for equal spacing. Bucket width (1) 152.4 cm (60 in) 167.6 cm (66 in) 182.8 cm (72 in) 198.1 cm (78 in) 213.3 cm (84 in)
From end (2)
2nd tooth (3)
3rd tooth (4)
4th tooth (5)
5th tooth (6)
4.6 cm (1 13/16 in) 4.6 cm (1 13/16 in) 4.6 cm (1 13/16 in) 4.6 cm (1 13/16 in) 4.6 cm (1 13/16 in)
27.7 cm (10 15/16 in) 35.1 cm (13 27/32 in) 33 cm (13 in)
54.1 cm (21 5/16 in) 66.4 cm (25 27/32 in) 66 cm (26 in)
36 cm (14 3/16 in) 39 cm (15 3/8 in)
73.2 cm (28 5/6 in) 78.1 cm (30 3/4 in)
81.3 cm (32 in) 108.2 cm 5/8 in) 98.2 cm (37 127.5 cm 29/32 in) 7/32 in) 98.9 cm (38 131.7 cm 15/16 in) 7/8 in) 107.9 cm (42 143.9 cm 1/2 in) 11/16 in) 117.1 cm (46 156.2 cm 1/8 in) 1/2 in)
(42 (50 (51 (56 (61
6th tooth (7) 135.4 cm (53 5/16 in) 158.1 cm (62 1/4 in) 164.7 cm (64 7/8 in) 180 cm (70 7/8 in) 195.1 cm (76 13/16 in)
20. Welds are high carbon steel (tooth) to high carbon steel (bucket). Use welding rods marked 7018 or some comparable rod. Weld on both sides of the tooth from the back of the tooth towards the replaceable point at (1). Stop welding 13 mm ( 1/2 in) from the cutting edge as noted at (2). Weld along the back of the tooth at (3). A minimum 5 mm ( 3/16 in) fillet weld is required for this application.
SH88036
21. Weld in the direction shown at (1). 48068130 29/01/2018
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Front loader and bucket - Bucket
22. Weld a 5 mm ( 3/16 in) fillet weld along both sides and rear of the tooth at (2), high carbon steel to high carbon steel.
BS04E166
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7
Front loader and bucket - Bucket
Bucket release device - Remove 1.
WARNING Avoid injury! Always do the following before lubricating, maintaining, or servicing the machine. 1. Disengage all drives. 2. Engage parking brake. 3. Lower all attachments to the ground, or raise and engage all safety locks. 4. Shut off engine. 5. Remove key from key switch. 6. Switch off battery key, if installed. 7. Wait for all machine movement to stop. Failure to comply could result in death or serious injury. W0047A
Before removing the coupler, remove any attachment from the machine. 2. Tilt the coupler forward until the face of the plate is resting on the ground. 3. On the left-hand side of the coupler, remove the hardware (1) securing the pin (2) attached to the tilt cylinder. 4. Remove the pin (2) from the coupler. This will remove the tilt cylinder from the coupler. 5. Repeat steps 3 and 4 on the right-hand side.
931002056
1
20115831
2
6. Remove the hardware (1) from the pivot pin (2) securing the coupler to the machine. 7. Repeat step 7 for the left-hand side.
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Bucket release device - Disassemble Prior operation: Remove the bucket release device. See Bucket release device - Remove (82.300) NOTE: Remove all attachments from working arm prior to removal of the mechanical coupler 1. Release locking pins by placing coupler handles (1) in up position.
931002056
1
86092923
2
931001791
3
2. Using a hammer and punch remove the spring pin (1), dropping the latch pin out of the bottom of the coupler (2).
3. Remove clip (1) from handle pivot pin.
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4. While supporting coupler handle, remove handle pivot pin (1).
931001788
4
20115824
5
20115823
6
5. Remove handle and locking pin assembly from coupler.
6. To disassemble the locking pin assembly carefully unthread pin (1), from bolt (2) and check parts for wear.
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Bucket release device - Assemble 1. Assemble the handle and locking pin assembly by inserting pin (1) through hole (2) in the handle. Install bolt (3) through pin (2). Install bushing spacer (4), compression spring (5), and thread pin (6) onto bolt (3) holding assembly together.
20115823
1
20115824
2
86092923
3
931001788
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2. Install the assembled unit (1) through the inside of the coupler (2).
3. While supporting the coupler handle in place, install pivot pin (1).
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4. Install clip (1) on backside of pivot pin.
931001790
5
86092922
6
5. Insert the latch pin (1) through the bottom of the coupler, and secure to the locking pin assembly with a spring pin (2).
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Bucket release device - Install 1. Move the machine into position, and align the holes to insert the pivot pins (2). 2. On the right-hand side of machine, insert the pivot pin and install the hardware (1) to secure the pin in place. Torque the hardware (1) to 181.0 â&#x20AC;&#x201C; 245 N¡m (134 â&#x20AC;&#x201C; 181 lb ft). 3. Repeat step 2 for the left-hand side of the machine.
931002057
1
931002056
2
4. Extend the tilt cylinders (3) until they align with the top holes of the coupler. 5. On the left-hand side of machine, insert the pin (2) into the coupler as shown, through the cylinder-end and out the other side of the coupler. 6. Install the hardware (1) to the pin locking plate, and securing the pin to the coupler. 7. Repeat steps 5 and 6 for the right-hand side of the machine.
8. Start the machine and cycle through the positions of the coupler to bleed the system of air.
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Quick coupler - Remove WARNING Pressurized hydraulic fluid can penetrate the skin and cause severe injuries. Hydraulic fluid is under extreme pressure. Rest the bucket or attachment on the ground. Shut the engine off, turn the key on, and move the hydraulic control lever through all movements several times to relieve residual pressure in the system. Failure to comply could result in death or serious injury. W0161A
WARNING Escaping fluid! Hydraulic fluid or diesel fuel leaking under pressure can penetrate the skin and cause infection or other injury. To prevent personal injury: Relieve all pressure before disconnecting fluid lines or performing work on the hydraulic system. Before applying pressure, make sure all connections are tight and all components are in good condition. Never use your hand to check for suspected leaks under pressure. Use a piece of cardboard or wood for this purpose. If injured by leaking fluid, see your doctor immediately. Failure to comply could result in death or serious injury. W0178A
WARNING Burn hazard! Before performing any service on the hydraulic system, you must allow it to cool. Hydraulic fluid temperature should not exceed 40 °C (104 °F). Failure to comply could result in death or serious injury. W0241A
WARNING Avoid injury! Always do the following before lubricating, maintaining, or servicing the machine. 1. Disengage all drives. 2. Engage parking brake. 3. Lower all attachments to the ground, or raise and engage all safety locks. 4. Shut off engine. 5. Remove key from key switch. 6. Switch off battery key, if installed. 7. Wait for all machine movement to stop. Failure to comply could result in death or serious injury. W0047A
1. Remove the bucket or attachment from the mounting plate.
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2. Set the quick coupler in the unlocked position.
93106838
2
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3
20111349
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3. Tilt the coupler forward until the face of the plate is resting on the ground. 4. On the right-hand side of the coupler, remove the hardware (1) securing the pin (2) attached to the tilt cylinder. 5. Remove the pin (2) from the couple. This will remove the tilt cylinder from the coupler.
6. Repeat steps 4 and 5 on the left-hand side. 7. Mark the hoses and ports on the valve. This will help when reinstalling the hoses to the proper ports. 8. Remove the two hoses (1) from the hydraulic valve (2). 9. Plug or cap the valve ports and the hose ends. This will keep the hydraulic system from getting contaminated.
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NOTE: For units built November 2013 and prior follow steps 10 through 14. 10. Remove the dust cap (1) by prying it from the inner side of the coupler hub. NOTE: Loader arm removed from Figure 5 for clarity.
RAPH16SSL0068BA
5
RAPH16SSL0069BA
6
931002057
7
11. Remove the M16 x 180 mm flange bolt (1).
12. Remove the hardware (1) from the pivot pin (2) securing the coupler to the loader arm. 13. Remove the pivot pin from the machine. 14. Repeat steps 10 through 13 on the left-hand side.
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NOTE: For units built November 2013 and later follow steps 15 through 19. 15. Remove the snap ring (1) from the inner side of the coupler hub.
RAPH16SSL0070BA
8
RAPH16SSL0071BA
9
16. Remove the o-ring (1), then the cap (2) from the coupler hub.
17. Remove the M16 nut (1).
RAPH16SSL0073BA
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10
Front loader and bucket - Bucket
18. Remove the M16 x 180 mm flange bolt (1) from the loader arm, the washer (2), the rod wiper (3), and the pivot pin to disconnect from the loader arm.
RAPH16SSL0072BA
19. Repeat steps 15 through 18 on the left-hand side.
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Front loader and bucket - Bucket
Quick coupler - Install NOTE: The images in these instructions may not be the actual model being worked on. All models have the same concept. NOTE: For units built November 2013 and prior, follow steps 1 through 5. 1. Move the machine into position and align the holes to insert the pivot pins (2). NOTE: Apply LOCTITE® ANTI-SEIZE to the tapered ends of the pivot pins (2) prior to the installation. 2. On the right-hand side of machine, insert the pivot pin (2) and place the wiper seal then the washer onto the pin, in between the coupler and the loader arm. 3. Install the M16 x 180 mm bolt (3) from the inside of the coupler frame outwards through the loader arm and secure with the M16 nut (1). Torque the nut (1) to 181 – 215 N·m (134 – 159 lb ft). 931002057
1
RAPH16SSL0069BA
2
RAPH16SSL0068BA
3
4. Install the dust cap (1) onto the inner side of the coupler hub by tapping it into place. 5. Repeat steps 2 through 4 for the left-hand side of the machine.
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NOTE: For units built November 2013 and later, follow steps 6 through 11. 6. Move the machine into position and align the holes to insert the pivot pins (1). NOTE: Apply LOCTITE® ANTI-SEIZE to the tapered ends of the pivot pins (1) prior to the installation. 7. Install the rod wiper (2), and the washer (3) onto the pivot pin (1). 8. Insert the M16 x 180 mm bolt (4) through the loader arm and into the pivot pin (1) securing with the M16 nut (5). Torque the nut (5) to 181 – 215 N·m (134 – 159 lb ft).
RAPH16SSL0072BA
4
RAPH16SSL0073BA
5
RAPH16SSL0071BA
6
9. Install the cap (2) and the o-ring (1) over the nut.
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10. Secure the cap and the o-ring with the snap ring (1). 11. Repeat steps 6 through 10 for the left-hand side of the machine.
RAPH16SSL0070BA
7
20111348
8
20111349
9
12. Extend the tilt cylinders until they align with the top holes of the coupler. 13. On the right hand side of machine, insert the pin (2) into the coupler as shown, through the cylinder end and out the other side of the coupler. 14. Install the hardware (1) to the pin locking plate, securing the pin to the coupler. 15. Repeat steps five and six for the left hand side of the machine.
16. Remove the caps or plugs from the hydraulic valve (2) and the hoses (1) and install the two hoses into their correct ports. Tighten hoses to standard torque.
17. Start the machine and cycle through the positions of the coupler to bleed the system of air.
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Index Front loader and bucket - 82 Bucket - 300 Bucket - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3
Bucket - Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6
Bucket release device - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13
Bucket release device - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11
Bucket release device - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4
Bucket release device - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15
Bucket release device - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10
Quick coupler - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
21
Quick coupler - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
16
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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. Š 2018 CNH Industrial America LLC. All rights reserved. No part of the text or illustrations of this publication may be reproduced.
CNH Industrial America LLC reserves the right to make improvements in design and changes in specifications at any time without notice and without incurring any obligation to install them on units previously sold. Specifications, descriptions, and illustrative material herein are as accurate as known at the time of publication, but are subject to change without notice. Availability of some models and equipment builds varies according to the country in which the equipment is being used. For exact information about any particular product, please consult your CASE CONSTRUCTION dealer. CASE CONSTRUCTION is a trademark registered in the United States and many other countries, owned or licensed to CNH Industrial N.V., its subsidiaries or affiliates. Any trademarks referred to herein, in association with goods and/or services of companies, other than owned by or licensed to CNH Industrial N.V., its subsidiaries or affiliates, are the property of those respective companies.
48068130 29/01/2018 EN
SERVICE MANUAL Platform, cab, bodywork, and decals SR210 TIER 4B (FINAL) [NGM418237 - ], SR210 TIER 4B (FINAL) [NHM435463 - ], SR240 TIER 4B (FINAL) [NGM418237 - ], SR240 TIER 4B (FINAL) [NHM435463 - ], SV280 TIER 4B (FINAL) [NGM418237 - ], SV280 TIER 4B (FINAL) [NHM435463 - ], TR270 TIER 4B (FINAL) [NGM418237 - ], TR270 TIER 4B (FINAL) [NHM435463 - ], TR310 TIER 4B (FINAL) [NGM418237 - ], TR310 TIER 4B (FINAL) [NHM435463 - ], TV370 TIER 4B (FINAL) [NHM435463 - ]
48068130 29/01/2018
90
Contents Platform, cab, bodywork, and decals - 90
[90.150] Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.1 [90.160] Cab interior trim and panels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.2 [90.154] Cab doors and hatches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.3 [90.102] Engine shields, hood latches, and trims . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.4 [90.120] Mechanically-adjusted operator seat. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.5 [90.124] Pneumatically-adjusted operator seat. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.6
48068130 29/01/2018
90
Platform, cab, bodywork, and decals - 90 Cab - 150
SR210 TIER 4B (FINAL) [NGM418237 - ], SR210 TIER 4B (FINAL) [NHM435463 - ], SR240 TIER 4B (FINAL) [NGM418237 - ], SR240 TIER 4B (FINAL) [NHM435463 - ], SV280 TIER 4B (FINAL) [NGM418237 - ], SV280 TIER 4B (FINAL) [NHM435463 - ], TR270 TIER 4B (FINAL) [NGM418237 - ], TR270 TIER 4B (FINAL) [NHM435463 - ], TR310 TIER 4B (FINAL) [NGM418237 - ], TR310 TIER 4B (FINAL) [NHM435463 - ], TV370 TIER 4B (FINAL) [NHM435463 - ]
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Contents Platform, cab, bodywork, and decals - 90 Cab - 150
SERVICE Cab and platform Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Cab tilting system Tilt (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Lower (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Tilt (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Lower (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
(*) See content for specific models 48068130 29/01/2018
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Cab and platform - Remove DANGER Heavy objects! Lift and handle all heavy components using lifting equipment with adequate capacity. Always support units or parts with suitable slings or hooks. Make sure the work area is clear of all bystanders. Failure to comply will result in death or serious injury. D0076A
The following procedure has been performed on a vertical lift machine with an inclosed, HVAC cab. Removing an opened cab is very similar. Removing the cab on a radial lift machine is very similar. Please use this procedure for all cab removals on all types of machines. Prior operation: If equipped with a cab heater, drain the coolant. Please see Radiator - Drain fluid (10.400) Prior operation: If equipped with a cab air conditioner, discharge the refrigerant. Please see Air conditioning - Discharging (50.200) Prior operation: Tilt the cab. Please see Cab tilting system - Tilt (90.150) 1. Disconnect the A/C lines (1), if applicable. 2. Disconnect the heater hoses (2), if applicable.
931001757
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93106923
2
3. Remove the cup holder (1).
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4. Detach the grounds (1) from the body.
5.
RAIL14SSL0464BA
3
RAPH14SSL0494BA
4
RAIL14SSL0466BA
5
WARNING Crushing hazard! Use extreme caution during the following procedure. Perform this procedure exactly as instructed in this manual. Failure to comply could result in death or serious injury. W0368A
Verify that the red lock tube (2) is over the pivot linkage. 6. Disconnect the support strut (1) from the cab. NOTICE: Do not remove the pivot linkage. 7. Remove the support strut mount (3). 8. Remove the red knob from the override valve for the loader arm. 9. Detach the rubber mat from the heel plate.
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10. Detach the linkage (1) from the locking device for the loader arm, if applicable.
RAIL14SSL0465BA
6
23112407
7
RAPH12UTL0646AA
8
11. Detach the linkage (1).
12. Unbolt the heel plate (1).
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13. Unbolt the heel plate.
RAIL14SSL0471BA
9
14. Disconnect the harnesses (1).
RAIL14SSL0465BA
10
RAIL14SSL0468BA
11
15. Move the heel plate (1) away from the harness. 16. Carefully pull the harness through the access hole.
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17.
WARNING Heavy parts! Support designated component(s) with adequate lifting equipment. Failure to comply could result in death or serious injury. W1024A
Using adequate lifting equipment, carefully lower the cab.
RAPH14SSL0351BA
12
RAIL14SSL0469BA
13
RAIL14SSL0470BA
14
18. Remove the bolts on the pivot points.
19. Remove the CAN diagnostic connector (1). 20. Disconnect the pivot linkage (2) from the cab and from the body.
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21. Remove the windows from the cab, if applicable. 22. Using adequate lifting equipment, carefully lift and remove the cab.
RAIL14SSL0473BA
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Platform, cab, bodywork, and decals - Cab
Cab and platform - Install DANGER Heavy objects! Lift and handle all heavy components using lifting equipment with adequate capacity. Always support units or parts with suitable slings or hooks. Make sure the work area is clear of all bystanders. Failure to comply will result in death or serious injury. D0076A
The following procedure has been performed on a vertical lift machine with an inclosed, HVAC cab. Installing an opened cab is very similar. Installing a cab on a radial lift machine is very similar. Please use this procedure for all cab installations on all types of machines. Prior operation: If applicable, remove the windows from the cab. 1. Using adequate lifting equipment, carefully lower the cab onto the frame.
RAIL14SSL0473BA
1
RAIL14SSL0469BA
2
2. Install the bolts on the pivot mounts. Torque the bolts to 42 N¡m (31 lb ft). NOTE: The bolts must have the nuts on the inside of the mounts.
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3.
WARNING Heavy parts! Support designated component(s) with adequate lifting equipment. Failure to comply could result in death or serious injury. W1024A
Tilt the cab forward and onto a jack stand. 4. Secure the cab to the jack stand by attaching a strap to the top of the cab and bottom of the chassis, and tighten the strap.
RAIL14SSL0014BA
3
RAPH14SSL0494BA
4
RAPH15SSL0076BA
5
5. Attach the pivot linkage (1) to the cab. 6. Verify that the red lock tube (2) is over the pivot linkage (1). 7. Apply LOCTITE® 567™ PST PIPE SEALANT to the threads of the mounting bolt (3) for the support strut (4). 8. Install the mounting bolt (3) into the body. Torque the mounting bolt (3) to 27 N·m (20 lb ft). 9. Install the support strut (4).
10. Install the CAN diagnostic connector (1).
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11. Attach the grounds (1) to the body.
RAIL14SSL0464BA
6
RAIL14SSL0468BA
7
23111115
8
12. Carefully insert the harness through the access hole.
13. Apply a bead of LOCTITEÂŽ RTV SILICONE CLEAR (2), from arrow to arrow, between frame and the heel plate (1). NOTE: The cab, axles, motors, and pumps have been removed for picture clarity. You do not need to remove these items to apply silicone to the required areas.
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14. Install the heel plate. NOTE: Install the bolts closest to the foot plate first for easier assembly.
RAIL14SSL0471BA
9
15. Install the heel plate (1). NOTE: Install the bolts closest to the foot plate first for easier assembly.
RAPH12UTL0646AA
10
RAIL14SSL0465BA
11
16. Connect the harnesses (1). 17. Attach the linkage (2) to the locking device for the loader arm, if applicable.
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18. Attach the linkage (1). 19. Connect the linkage (1) to the hydrostatic drive pumps and main control valve, if applicable.
23112407
12
RAIL14SSL0466BA
13
93106923
14
931001817
15
20. Install the rubber mat onto the heel plate. 21. Install the red knob onto the override valve for the loader arm. Torque the red knob to 11 – 16 N·m (97 – 142 lb in).
22. Install the cup holder (1).
23. Connect the A/C lines (1), if applicable. 24. Connect the heater hoses (2), if applicable.
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25. Carefully lower the cab. Verify that the cab tilts and lowers without damaging any components.
RAPH14SSL0351BA
Next operation: Remove the lifting equipment from the cab. Next operation: Install the windows, If applicable.
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Platform, cab, bodywork, and decals - Cab
Cab tilting system - Tilt SR210 SR240 TR270 TR310
DANGER Crushing hazard! The loader arm is unsupported during support strut removal. Do not enter or exit the operator's compartment with an unsupported loader arm. Two persons are required during storage. One person should remove and store the support strut while the operator remains in the operator's compartment. Failure to comply will result in death or serious injury. D0021B
Raise and lock the loader arm for machine service NOTE: An instructional decal on the inside of the right-hand loader arm, just above the support strut is also available. Understand the loader arm lock procedure before continuing. 1. Sit in the operator's seat, fasten the seat belt, pull down the restraint bar down, and start the engine. 2. Press the OPERATE button to enable the hydraulics. 3. Remove the bucket or attachment from the mounting plate.
20092924
1
93106848A
2
4. Park the machine on a level surface. 5. If an assistant is not available, turn off the engine and exit the machine. 6. Remove the support strut pin (A) and let the support strut (B) rest on the lift cylinder barrel (C).
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Platform, cab, bodywork, and decals - Cab
7. Slowly raise the loader arm until the support strut (B) falls onto the cylinder rod (D). 8. Stop the engine.
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93107465A
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93106854A
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9. Pull up on the override control knob (E) (red control knob near the right-hand side of the operatorâ&#x20AC;&#x2122;s seat). The support strut (B) will brace against the top of the cylinder barrel (C) supporting the weight of the loader arm. NOTICE: Only use the override control knob for emergency situations where engine power is not available or to lock the loader arm on to the support strut for servicing the machine.
10. Ask an assistant to insert the pin (A) into the support strut (B). If an assistant is not available visually confirm that the support strut is braced against the top of the cylinder barrel before exiting the machine.
Tilt and lock the cab forward for machine service 11. Remove the two, rear retaining nuts, located at the rear of the cab.
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Platform, cab, bodywork, and decals - Cab
12. Pull on the hand holds at the front of the machine until the cab is completely tilted forward.
93107498
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RAPH12SSL0420BA
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13. Confirm that the red lock tube has lowered over the cab pivot linkage. If it has, the cab tilt position is now secure.
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Platform, cab, bodywork, and decals - Cab
Cab tilting system - Lower SR210 SR240 TR270 TR310
Tilt and secure the cab for machine operation 1. Raise the red lock tube over the cab pivot linkage. 2. Push the cab backward into the operation position.
RAPH12SSL0420BA
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931001633
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3. Install the retaining nuts. Torque the nuts to 170 N¡m (125 lb ft).
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Platform, cab, bodywork, and decals - Cab
Unlock and lower the loader arm for machine operation DANGER Crushing hazard! The loader arm is unsupported during support strut removal. Do not enter or exit the operator's compartment with an unsupported loader arm. Two persons are required during storage. One person should remove and store the support strut while the operator remains in the operator's compartment. Failure to comply will result in death or serious injury. D0021B
NOTE: An instructional decal on the inside of the right-hand loader arm, just above the support strut is also available. Understand the loader arm unlock procedure before continuing. Placing the support strut in storage requires a second person. The operator must remain in the seat during this procedure. 4. Sit in the operator's seat, fasten the seat belt, pull down the restraint bar, and start the engine. 5. Press the OPERATE button to enable the hydraulics. 6. Raise the loader arm until the support strut (B) is not resting on the end of the cylinder barrel (C).
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93106854A
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93106848A
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7. Instruct the second person to remove the support strut pin (A) and place the support strut in the stowed position and reinstall the support strut pin (A). When the second person has cleared the area, the operator may now lower the loader arm. 8. Commence work operations or park the machine and stop the engine.
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Platform, cab, bodywork, and decals - Cab
Cab tilting system - Tilt SV280 TV370 TIER 4B (FINAL) [NHM435463 - ]
DANGER Crushing hazard! Failure to engage the loader arm support pin(s) could cause the loader arm to fall unexpectedly. Verify that the loader arm support pin(s) are engaged. Failure to comply will result in death or serious injury. D0133B
Raise and lock the loader arm for machine service 1. Sit in the operator's seat, fasten the seat belt, pull down the restraint bar down, and start the engine. 2. Press the OPERATE button to enable the hydraulics. 3. Remove the bucket or attachment from the mounting plate.
20092924
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4. Fully raise the loader arm.
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Platform, cab, bodywork, and decals - Cab
5. Locate the loader arm lock lever on the right-hand side of the operator’s seat. 6. Stop the engine. 7. Rotate the lock lever toward the operator’s seat (clockwise) to engage the lock pin(s). NOTE: The lock lever for the lift arm is located on the lefthand side of the operator’s seat. See the instructional sign located by the lock lever.
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93107465A
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8. Pull up on the override control knob (red control knob (1) near the right-hand side of the operator’s seat). The loader arm (3) will brace against the lock support pin (2) and keep the loader arm in a raised position. NOTE: Only use the override control knob to lower the loader arm in emergency situations when engine power is not available or to lower the loader arm onto the lock support pin for servicing the machine.
Tilt and lock the cab forward for machine service 9. Remove the two, rear retaining nuts, located at the rear of the cab.
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Platform, cab, bodywork, and decals - Cab
10. Pull on the hand holds at the front of the machine until the cab is completely tilted forward.
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11. Confirm that the red lock tube has lowered over the cab pivot linkage. If it has, the cab tilt position is now secure.
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Platform, cab, bodywork, and decals - Cab
Cab tilting system - Lower SV280 TV370 TIER 4B (FINAL) [NHM435463 - ]
Tilt and secure the cab for machine operation 1. Raise the red lock tube exposing the cab pivot linkage. 2. Push the cab backward into the operation position.
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1
931001633
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3. Install the retaining nuts. Torque the nuts to 170 N¡m (125 lb ft).
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Platform, cab, bodywork, and decals - Cab
Unlock and lower the loader arm for machine operation 4. Sit in the operator's seat, fasten the seat belt, pull down the restraint bar, and start the engine. 5. Press the OPERATE button to enable the hydraulics. 6. Fully raise the loader arm.
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RAIL15SSL0353AA
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7. Rotate the lock lever away from the seat (counterclockwise) to retract the lock pin(s). 8. Lower the loader arm. 9. Commence work operations or park the machine and stop the engine.
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Index Platform, cab, bodywork, and decals - 90 Cab - 150 Cab and platform - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9
Cab and platform - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3
Cab tilting system - Lower (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
18
Cab tilting system - Lower (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
23
Cab tilting system - Tilt (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15
Cab tilting system - Tilt (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20
(*) See content for specific models 48068130 29/01/2018
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Platform, cab, bodywork, and decals - 90 Cab interior trim and panels - 160
SR210 TIER 4B (FINAL) [NGM418237 - ], SR210 TIER 4B (FINAL) [NHM435463 - ], SR240 TIER 4B (FINAL) [NGM418237 - ], SR240 TIER 4B (FINAL) [NHM435463 - ], SV280 TIER 4B (FINAL) [NGM418237 - ], SV280 TIER 4B (FINAL) [NHM435463 - ], TR270 TIER 4B (FINAL) [NGM418237 - ], TR270 TIER 4B (FINAL) [NHM435463 - ], TR310 TIER 4B (FINAL) [NGM418237 - ], TR310 TIER 4B (FINAL) [NHM435463 - ], TV370 TIER 4B (FINAL) [NHM435463 - ]
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Contents Platform, cab, bodywork, and decals - 90 Cab interior trim and panels - 160
SERVICE Cab headliner Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
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Platform, cab, bodywork, and decals - Cab interior trim and panels
Cab headliner - Remove 1. Remove the console screws (A), six per side, on the right-hand and the left-hand sides of the cab. Retain the screws (A) for reassembly. See Figure 1 for detail. NOTE: Allow the consoles to hang down so that the headliner may be removed.
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RAPH15SSL0211BA
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Cab radio not installed 1. Remove the eight push-in fasteners (B) from the headliner of the cab. 2. Lower the headliner and remove from the cab.
Cab radio installed 1. Remove the six push-in fasteners (B), and the two bolts (C) securing the radio to the cab. 2. Lower the headliner and disconnect any further electrical connections. Remove the headliner from the cab.
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Platform, cab, bodywork, and decals - Cab interior trim and panels
Cab headliner - Install Cab radio not installed 1. Raise the headliner into the cab. Connect the dome light electrical. Secure the headliner with eight push-in fasteners (B) to the cab roof.
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RAPH15SSL0209BA
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Cab radio installed 1. Connect the radio electrical connections and dome light connection. Raise the headliner with radio into the cab and secure with six push-in fasteners (B) and the two bolts (C) with washers.
Console installation 2. Install the console screws (A), six per side, on the righthand and the left-hand sides of the cab. See Figure 3 for detail.
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Index Platform, cab, bodywork, and decals - 90 Cab interior trim and panels - 160 Cab headliner - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4
Cab headliner - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3
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Platform, cab, bodywork, and decals - 90 Cab doors and hatches - 154
SR210 TIER 4B (FINAL) [NGM418237 - ], SR210 TIER 4B (FINAL) [NHM435463 - ], SR240 TIER 4B (FINAL) [NGM418237 - ], SR240 TIER 4B (FINAL) [NHM435463 - ], SV280 TIER 4B (FINAL) [NGM418237 - ], SV280 TIER 4B (FINAL) [NHM435463 - ], TR270 TIER 4B (FINAL) [NGM418237 - ], TR270 TIER 4B (FINAL) [NHM435463 - ], TR310 TIER 4B (FINAL) [NGM418237 - ], TR310 TIER 4B (FINAL) [NHM435463 - ], TV370 TIER 4B (FINAL) [NHM435463 - ]
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Contents Platform, cab, bodywork, and decals - 90 Cab doors and hatches - 154
FUNCTIONAL DATA Cab doors and hatches Overview - Door switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SERVICE Cab doors and hatches Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
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Platform, cab, bodywork, and decals - Cab doors and hatches
Cab doors and hatches - Overview - Door switch If a unit has a door, the door switch will prevent the operator from operating the loader arm and bucket while the door is open. This safety switch prevents damage to the machine and to the operator. If the operator opens the door, the joystick control of loader and bucket will be shut off and the port locks will engage. Once the door is closed, the operator will regain control of the attachment. The door switch is a magnetic reed switch. The switch operates on low current, and closes in the presence of metal. The switch mush be adjusted properly to function correctly. The door switch function is active when Ignition is ON. ATTENTION: Usage of the override connector (1) will bypass all safety features associated with the door switch. Use the override connector with extreme caution. Failure to comply will result in serious injury or death. Failure to comply can result in machine damage. The operator can bypass the door switch by using the override connector (1). To use, unplug the washer nozzle tube (2) and remove the override connector (1), disconnect the door switch harness (3), and plug the override connector (1) into the door switch harness (3).
RAPH12SSL0300BA
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1
Platform, cab, bodywork, and decals - Cab doors and hatches
Cab doors and hatches - Remove Prior operation: Windshield wiper motor - Remove (55.518) 1. Remove the gas spring (1) from the ball on the door assembly (2) and from the ball on the door jamb (3). 2. Disconnect the door switch (4) from the plug in the cab deluxe harness. NOTE: The cab deluxe harness plug is located behind the left-hand side console panel.
RAPH12SSL0300BA
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1
Platform, cab, bodywork, and decals - Cab doors and hatches
3. Remove the front door assembly (1) from the attached hinges. NOTE: The glass front door assembly is shown in Figure 2, and the demo front door assembly is shown in Figure 3. Both of the doors are removed the same way.
Next operation: Cab doors and hatches - Install (90.154)
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RAPH12SSL0295BA
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Platform, cab, bodywork, and decals - Cab doors and hatches
Cab doors and hatches - Install Prior operation: Cab doors and hatches - Remove (90.154) NOTE: The glass front door assembly is shown in image 1, and the demo front door assembly is shown in image 2. Both of the doors are installed the same way. 1. Hang the front door assembly (1) onto the attached hinges and align the door striker. Once the desired alignment is achieved tighten the attached hinge screws to a torque 11.8 N¡m (8.7 lb ft). 2. If removed: Insert the two Grease Zerk fittings onto the top of the upper and the lower hinges and tighten the fittings to a torque of 10.0 N¡m (7.5 lb ft).
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RAPH12SSL0295BA
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Platform, cab, bodywork, and decals - Cab doors and hatches
3. If removed: Install the non-contact door switch (2) and the spacer (1) to the bracket using the screws (3) as shown. Tighten, but do not crack the plastic. NOTE: Apply the LOCTITE® 425 to the screws (3). The LOCTITE® must be compatible with the plastic. NOTE: When the door is closed, the switch (2) must be between 7.0 – 12.0 mm (5/16 – 1/2 in) from the door latch. 11. Plug the door switch (7) into the plug in the cab deluxe harness. NOTE: The cab deluxe harness plug is located behind the left-hand side console panel. 12. Install the gas spring (4) to the ball on the door assembly (5) and the ball on the door jamb (6).
Next operation: Windshield wiper motor - Install (55.518)
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Index Platform, cab, bodywork, and decals - 90 Cab doors and hatches - 154 Cab doors and hatches - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6
Cab doors and hatches - Overview - Door switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3
Cab doors and hatches - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4
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Platform, cab, bodywork, and decals - 90 Engine shields, hood latches, and trims - 102
SR210 TIER 4B (FINAL) [NGM418237 - ], SR210 TIER 4B (FINAL) [NHM435463 - ], SR240 TIER 4B (FINAL) [NGM418237 - ], SR240 TIER 4B (FINAL) [NHM435463 - ], SV280 TIER 4B (FINAL) [NGM418237 - ], SV280 TIER 4B (FINAL) [NHM435463 - ], TR270 TIER 4B (FINAL) [NGM418237 - ], TR270 TIER 4B (FINAL) [NHM435463 - ], TR310 TIER 4B (FINAL) [NGM418237 - ], TR310 TIER 4B (FINAL) [NHM435463 - ], TV370 TIER 4B (FINAL) [NHM435463 - ]
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90.4 [90.102] / 1
Contents Platform, cab, bodywork, and decals - 90 Engine shields, hood latches, and trims - 102
SERVICE Engine inspection door Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
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Platform, cab, bodywork, and decals - Engine shields, hood latches, and trims
Engine inspection door - Remove DANGER Heavy objects! Lift and handle all heavy components using lifting equipment with adequate capacity. Always support units or parts with suitable slings or hooks. Make sure the work area is clear of all bystanders. Failure to comply will result in death or serious injury. D0076A
1. Disconnect and remove the rear jumper harness that is connected to the lights on the light bar (A) above the rear inspection door.
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RAPH17SSL0172QA
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2. Use a sling to support the weight of the rear inspection door (1). ATTENTION: The door assembly weights approximately 69.0 kg (153.0 lb), use caution when removing. 3. Remove the hardware (2) from the top bracket of the rear inspection door.
4. Lift the rear inspection door up and off of the door pin (1) and away from the chassis.
Next operation: Engine inspection door - Install (90.102)
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Platform, cab, bodywork, and decals - Engine shields, hood latches, and trims
Engine inspection door - Install DANGER Heavy objects! Lift and handle all heavy components using lifting equipment with adequate capacity. Always support units or parts with suitable slings or hooks. Make sure the work area is clear of all bystanders. Failure to comply will result in death or serious injury. D0076A
Prior operation: Engine inspection door - Remove (90.102) 1. Lift the rear inspection door, with a sling, up and onto the door pin (1) into the chassis. NOTE: Make sure there is a washer between the door pin and the rear inspection door bracket. ATTENTION: The door assembly weights approximately 69.0 kg (153.0 lb), use caution when installing.
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RAPH17SSL0172QA
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RAPH17SSL0124AA
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2. Secure the rear inspection door (1) with the hardware (2). Torque the hardware (2) to 271.0 – 298.0 N·m (200.0 – 220.0 lb ft).
3. Install the rear jumper harness onto the rear light bar (A) and route through the fir tree ties as shown. NOTE: Leave the tie straps loose until all electrical connections have been made. 4. Connect the rear jumper harness to the lights and secure the harness with the fir tree straps.
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Index Platform, cab, bodywork, and decals - 90 Engine shields, hood latches, and trims - 102 Engine inspection door - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4
Engine inspection door - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3
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Platform, cab, bodywork, and decals - 90 Mechanically-adjusted operator seat - 120
SR210 TIER 4B (FINAL) [NGM418237 - ], SR210 TIER 4B (FINAL) [NHM435463 - ], SR240 TIER 4B (FINAL) [NGM418237 - ], SR240 TIER 4B (FINAL) [NHM435463 - ], SV280 TIER 4B (FINAL) [NGM418237 - ], SV280 TIER 4B (FINAL) [NHM435463 - ], TR270 TIER 4B (FINAL) [NGM418237 - ], TR270 TIER 4B (FINAL) [NHM435463 - ], TR310 TIER 4B (FINAL) [NGM418237 - ], TR310 TIER 4B (FINAL) [NHM435463 - ], TV370 TIER 4B (FINAL) [NHM435463 - ]
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90.5 [90.120] / 1
Contents Platform, cab, bodywork, and decals - 90 Mechanically-adjusted operator seat - 120
SERVICE Operator seat Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
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Platform, cab, bodywork, and decals - Mechanically-adjusted operator seat
Operator seat - Remove Prior operations 1. Remove the bucket and/or attachments from the coupler. 2. Raise the loader arms, and tilt the cab forward. See 3. Disconnect the battery from the machine. See Battery - Disconnect (55.302) for the procedure.
Removal 1. Remove the four nuts (1) and the four washers (2) that retain the seat assembly from the underside of the cab. NOTE: The right-hand nuts (1) are shown in Figure 1. The Heating, Ventilation, and Air-Conditioning (HVAC) lines are covering the left-hand nuts.
RAIL15SSL0042BA
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RAPH16SSL0198BA
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2. Disconnect the connector (1) from the rear of the seat to the cab harness. 3. Lift the seat out of the cab.
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Platform, cab, bodywork, and decals - Mechanically-adjusted operator seat
Operator seat - Install 1. Place the seat into the cab, aligning the seat adjustment studs into the cab holes. 2. Connect the connector (1) from the rear of the seat to the cab harness.
RAPH16SSL0198BA
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RAIL15SSL0042BA
2
3. Install the four washers (1) and the four nuts (2) to the protruding seat studs from the underside of the cab. Torque the nuts (2) to 15.0 – 24.0 N·m (11.0 – 18.0 lb ft).
Post operations 1. Connect the battery to the machine. See Battery Connect (55.302) for the procedure. 2. Tilt the cab back and secure to the chassis. Lower the loader arms. See
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Platform, cab, bodywork, and decals - Mechanically-adjusted operator seat
Operator seat - Disassemble Prior operation: Remove the seat assembly from the cab. Refer to Operator seat - Remove (90.120) for the proper procedure. 1. Remove the knob for the adjustment rod on the front of the seat assembly. 2. Remove the back seat cover by removing the five screws (1) securing the cover to the upper frame.
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RAPH16SSL0336BA
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RAPH16SSL0337BA
3
3. Remove the upper seat cushion by removing the six push-in fasteners (1) securing the cloth to the upper frame.
4. Remove the upper frame from the seat by removing the one bolt (1) on the left-hand side, and the two bolts (2) on the right-hand side of the seat.
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Platform, cab, bodywork, and decals - Mechanically-adjusted operator seat
5. Remove the seat belt tether strap (1) by removing the bolt (2) on the right-hand side of the seat. 6. Remove the seat adjustment slider assemblies (3) by removing the four bolts securing them to the seat frame.
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RAPH16SSL0339BA
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RAPH16SSL0340BA
6
7. Remove the lower seat cushion (1) by removing the screws (2) securing the cushion to the frame. 8. Disconnect the operators presence switch from the electrical harness (3) under the seat cushion and remove the seat cushion (1) from the frame. Remove the push-in fasteners and the screws from the seat cushion that are securing the front bracket in place. 9. Remove the water drain (not shown) and the operators presence switch (not shown) from the seat cushion.
10. Remove the lower protective boot (1) from the mechanical suspension assembly (2) of the seat by removing the push-in fasteners.
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Platform, cab, bodywork, and decals - Mechanically-adjusted operator seat
11. Remove the upper frame of the suspension by removing the bolts (1) and screws (3), securing the load shaft (2), and by sliding the load shaft out. 12. Pull the upper frame toward the back spring assembly to free the posts from the slides in the upper frame.
RAPH16SSL0341BA
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7
Platform, cab, bodywork, and decals - Mechanically-adjusted operator seat
Operator seat - Assemble 1. Install the upper frame to lower suspension by sliding frame forward and connecting the lower suspension post into the slots of the upper frame. 2. Secure the upper frame by sliding the load shaft (2) in from the side and securing it using bolts (1) and screws (3).
RAPH16SSL0341BA
1
RAPH16SSL0340BA
2
RAPH16SSL0339BA
3
3. Install the lower protective boot (1) to the mechanical suspension assembly (2) of the seat using the push-in fasteners to secure in place.
4. Install the water drain (not shown) and the operators presence switch (not shown) into the seat cushion. 5. Connect the operators presence switch to the electrical harness (3) under the seat cushion and install the seat cushion (1) to the frame. Install the front bracket using the push-in fasteners and the screws to secure into position. 6. Secure the lower seat cushion to the frame using the screws (2).
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Platform, cab, bodywork, and decals - Mechanically-adjusted operator seat
7. Install the seat adjustment slide assemblies (3) to the frame using the four bolts to secure. 8. Install the seat belt tether strap (1) using the bolt (2) onto the right-hand side of the seat frame. NOTE: Torque the bolt and nut to 58.0 N·m (43.0 lb ft).
RAPH16SSL0338BA
4
RAPH16SSL0337BA
5
RAPH16SSL0336BA
6
9. Install the upper frame to the seat using one bolt (1) on the left-hand side, and the two bolts (2)(shoulder bolt on top, hex bolt on the bottom) on the right-hand side of the seat frame. NOTE: The lower hex bolt on the right-hand side is to be torqued to 6.8 – 13.6 N·m (5.0 – 10.0 lb ft). NOTE: The upper shoulder bolt on the right-hand side and the shoulder bolt on the left-hand side are to be torqued to 13.5 – 20.3 N·m (10.0 – 15.0 lb ft).
10. Install the upper seat cushion by securing the cloth in place with six push-in fasteners (1) to the upper frame.
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Platform, cab, bodywork, and decals - Mechanically-adjusted operator seat
11. Install the back seat cover to the upper frame using the five screws (1). NOTE: Torque the screws (1) to 4.1 – 8.1 N·m (3.0 – 6.0 lb ft). 12. Install the knob for the adjustment on the front of the seat assembly.
RAPH16SSL0335BA
Next operation: Install the seat assembly into the cab. Refer to Operator seat - Install (90.120) for the proper procedure.
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7
Index Platform, cab, bodywork, and decals - 90 Mechanically-adjusted operator seat - 120 Operator seat - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8
Operator seat - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5
Operator seat - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4
Operator seat - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3
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Platform, cab, bodywork, and decals - 90 Pneumatically-adjusted operator seat - 124
SR210 TIER 4B (FINAL) [NGM418237 - ], SR210 TIER 4B (FINAL) [NHM435463 - ], SR240 TIER 4B (FINAL) [NGM418237 - ], SR240 TIER 4B (FINAL) [NHM435463 - ], SV280 TIER 4B (FINAL) [NGM418237 - ], SV280 TIER 4B (FINAL) [NHM435463 - ], TR270 TIER 4B (FINAL) [NGM418237 - ], TR270 TIER 4B (FINAL) [NHM435463 - ], TR310 TIER 4B (FINAL) [NGM418237 - ], TR310 TIER 4B (FINAL) [NHM435463 - ], TV370 TIER 4B (FINAL) [NHM435463 - ]
48068130 29/01/2018
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Contents Platform, cab, bodywork, and decals - 90 Pneumatically-adjusted operator seat - 124
SERVICE Pneumatically-adjusted operator seat Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
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Platform, cab, bodywork, and decals - Pneumatically-adjusted operator seat
Pneumatically-adjusted operator seat - Remove Prior operations 1. Remove the bucket and/or attachments from the coupler. 2. Raise the loader arms, and tilt the cab forward. See 3. Disconnect the battery from the machine. See Battery - Disconnect (55.302) for the procedure.
Removal 1. Remove the four nuts (1) and the four washers (2) that retain the seat assembly from the underside of the cab. NOTE: The right-hand nuts (1) are shown in Figure 1. The Heating, Ventilation, and Air-Conditioning (HVAC) lines are covering the left-hand nuts.
RAIL15SSL0042BA
1
RAPH16SSL0198BA
2
2. Disconnect the connector (1) from the rear of the seat to the cab harness. 3. Lift the seat out of the cab.
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Platform, cab, bodywork, and decals - Pneumatically-adjusted operator seat
Pneumatically-adjusted operator seat - Install 1. Place the seat into the cab, aligning the seat adjustment studs into the cab holes. 2. Connect the connector (1) from the rear of the seat to the cab harness.
RAPH16SSL0198BA
1
RAIL15SSL0042BA
2
3. Install the four washers (1) and the four nuts (2) to the protruding seat studs from the underside of the cab. Torque the nuts (2) to 15.0 – 24.0 N·m (11.0 – 18.0 lb ft).
Post operations 1. Connect the battery to the machine. See Battery Connect (55.302) for the procedure. 2. Tilt the cab back and secure to the chassis. Lower the loader arms. See
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Platform, cab, bodywork, and decals - Pneumatically-adjusted operator seat
Pneumatically-adjusted operator seat - Assemble NOTICE: Instructions include individual torque values. If an individual torque value is not present, then hand tighten only. 1. Install the electric lift pump (3), the heater switch (4), and the air valve (5) into the frame and the front bracket. NOTE: DO NOT exceed the max torque on the air valve nut which is 21.7 N¡m (16.0 lb ft). 2. Install the air bladder (1), and the shock (2) into the frame.
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RAPH16SSL0222BA
1
RAPH16SSL0221BA
2
Platform, cab, bodywork, and decals - Pneumatically-adjusted operator seat
3. Install the pneumatic lines (2) into the frame and connect them to the components. NOTE: Finger tighten the sleeve nuts on the air fitting bodies, and insert the tubing until it bottoms out in the fitting. Tighten the sleeve nut one full turn ( 360°) with a wrench to complete the seal. NOTE: The electrical harness is highlighted in RED, the pneumatic hose is highlighted in BLUE. 4. Secure the electrical harness (1) into the base frame and connect it to the components.
RAPH16SSL0220BA
3
RAPH16SSL0219BA
4
RAPH16SSL0217BA
5
5. Install the front bracket (6) to the upper frame structure (1) using the bolts. Install the upper frame structure (1) to the lower frame structure (2), by sliding the weight adjustment bar (4) into the front side cages (5), then installing the pins (3).
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Platform, cab, bodywork, and decals - Pneumatically-adjusted operator seat
6. Connect the operators presence switch (1) to the electrical harness under the seat cushion and install the seat cushion (2) to the frame. Install the push-in fasteners and the screws to the seat cushion to secure the front bracket in place.
RAPH16SSL0215BA
6
RAPH16SSL0216BA
7
RAPH16SSL0218AA
8
RAPH16SSL0214AA
9
7. Install the lower boot (1) to the frame assembly with the push-in fasteners (2). 8. Install the seat adjustment slider assemblies (3) by securing with the four bolts to the seat frame. 9. Install the seat belt tether strap (4) by installing the bolt (5) on the right-hand side of the seat. NOTE: Torque the bolt and nut to 58.0 N¡m (43.0 lb ft).
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Platform, cab, bodywork, and decals - Pneumatically-adjusted operator seat
10. Install the upper frame to the seat assembly by installing the one shoulder bolt (1) on the left-hand side, and the two bolts (2)(shoulder bolt on top, hex bolt on the bottom) on the right-hand side of the seat. NOTE: The lower hex bolt on the right-hand side is to be torqued to 6.8 – 13.6 N·m (5.0 – 10.0 lb ft). NOTE: The upper shoulder bolt on the right-hand side and the shoulder bolt on the left-hand side are to be torqued to 13.5 – 20.3 N·m (10.0 – 15.0 lb ft).
RAPH16SSL0213BA
10
RAPH16SSL0212BA
11
RAPH16SSL0211BA
12
11. Install the upper seat cushion by pressing the cushion into the frame and securing the cloth with the six push-in fasteners (1).
12. Install the back seat cover by installing the four screws (1) to the upper frame. NOTE: Torque the screws (1) to 4.1 – 8.1 N·m (3.0 – 6.0 lb ft).
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Platform, cab, bodywork, and decals - Pneumatically-adjusted operator seat
13. Install the seat literature tray by installing the screw (1) at the top of the seat cover. NOTE: Torque the screw (1) to 4.1 – 8.1 N·m (3.0 – 6.0 lb ft).
RAPH16SSL0210BA
Post operation 1. Install the seat assembly into the cab. See Pneumatically-adjusted operator seat - Install (90.124) for the proper procedure.
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13
Platform, cab, bodywork, and decals - Pneumatically-adjusted operator seat
Pneumatically-adjusted operator seat - Disassemble Prior operations 1. Remove the seat assembly from the cab. See Pneumatically-adjusted operator seat - Remove (90.124) for the proper procedure. 2. Relieve the air pressure from the pneumatic bladder by pulling the air valve on the front side of the seat and allowing the pressure to escape.
Disassembly 1. Remove the seat literature tray by removing the screw (1) at the top of the seat cover.
RAPH16SSL0210BA
1
RAPH16SSL0211BA
2
2. Remove the back seat cover by removing the four screws (1) securing the cover to the upper frame.
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Platform, cab, bodywork, and decals - Pneumatically-adjusted operator seat
3. Remove the upper seat cushion by removing the six push-in fasteners (1) securing the cloth to the upper frame.
RAPH16SSL0212BA
3
RAPH16SSL0213BA
4
RAPH16SSL0214AA
5
4. Remove the upper frame from the seat by removing the one bolt (1) on the left-hand side, and the two bolts (2) on the right-hand side of the seat.
5. Remove the seat belt tether strap (1) by removing the bolt (2) on the right-hand side of the seat. 6. Remove the seat adjustment slider assemblies (3) by removing the four bolts securing them to the seat frame.
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Platform, cab, bodywork, and decals - Pneumatically-adjusted operator seat
7. Remove the lower boot (1) from the seat by removing the push-in fasteners (3) securing it to the frame. 8. Disconnect the operators presence switch (4) from the electrical harness under the seat cushion and remove the seat cushion (2) from the frame. Remove the push-in fasteners and the screws from the seat cushion that are securing the front bracket in place.
RAPH16SSL0218AA
6
RAPH16SSL0216BA
7
RAPH16SSL0215BA
8
RAPH16SSL0217BA
9
9. Remove the front bracket (6) from the upper frame structure (1) by removing the bolts. Remove the upper frame structure (1) from the lower frame structure (2), by removing the pins (3) and sliding the weight adjustment bar (4) out of the front-side frame cages (5).
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Platform, cab, bodywork, and decals - Pneumatically-adjusted operator seat
10. Disconnect the electrical harness (1) from the components, and remove the harness from the base frame. NOTE: The electrical harness is highlighted in RED, the pneumatic hose is highlighted in BLUE. 11. Disconnect the pneumatic lines (2) and remove from the frame.
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RAPH16SSL0219BA
10
RAPH16SSL0220BA
11
Platform, cab, bodywork, and decals - Pneumatically-adjusted operator seat
12. Remove the air bladder (1), and the shock (2) from the frame. 13. Remove the electric lift pump (3), the heater switch (4), and the air valve (5) from the frame and the front bracket.
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RAPH16SSL0221BA
12
RAPH16SSL0222BA
13
Index Platform, cab, bodywork, and decals - 90 Pneumatically-adjusted operator seat - 124 Pneumatically-adjusted operator seat - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5
Pneumatically-adjusted operator seat - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10
Pneumatically-adjusted operator seat - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4
Pneumatically-adjusted operator seat - 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. Š 2018 CNH Industrial America LLC. All rights reserved. No part of the text or illustrations of this publication may be reproduced.
CNH Industrial America LLC reserves the right to make improvements in design and changes in specifications at any time without notice and without incurring any obligation to install them on units previously sold. Specifications, descriptions, and illustrative material herein are as accurate as known at the time of publication, but are subject to change without notice. Availability of some models and equipment builds varies according to the country in which the equipment is being used. For exact information about any particular product, please consult your CASE CONSTRUCTION dealer. CASE CONSTRUCTION is a trademark registered in the United States and many other countries, owned or licensed to CNH Industrial N.V., its subsidiaries or affiliates. Any trademarks referred to herein, in association with goods and/or services of companies, other than owned by or licensed to CNH Industrial N.V., its subsidiaries or affiliates, are the property of those respective companies.
48068130 29/01/2018 EN
SPECIAL TOOL INDEX Genuine 380003339 [Small Universal rolling torque tool] 380003339 [Small Universal rolling torque tool] 380500129 [7 Gauge Hydraulic Pressure Test Kit] 380500129 [7 Gauge Hydraulic Pressure Test Kit] 380500129 [7 Gauge Hydraulic Pressure Test Kit] 380500128 [4 Gauge Hydraulic Pressure Test Kit] CAS1871 [Seal Press] CAS1871 [Seal Press] CAS1871 [Seal Press] 380500047 [Mechanical Hydraulic flow and Pressure Test Meter - 75 GPM NA] 380500047 [Mechanical Hydraulic flow and Pressure Test Meter - 75 GPM NA] 380500047 [Mechanical Hydraulic flow and Pressure Test Meter - 75 GPM NA] 380500047 [Mechanical Hydraulic flow and Pressure Test Meter - 75 GPM NA] 380500047 [Mechanical Hydraulic flow and Pressure Test Meter - 75 GPM NA] 380500047 [Mechanical Hydraulic flow and Pressure Test Meter - 75 GPM NA] 380500047 [Mechanical Hydraulic flow and Pressure Test Meter - 75 GPM NA] 380500129 [7 Gauge Hydraulic Pressure Test Kit] 380500047 [Mechanical Hydraulic flow and Pressure Test Meter - 75 GPM NA] 380500047 [Mechanical Hydraulic flow and Pressure Test Meter - 75 GPM NA] 380500047 [Mechanical Hydraulic flow and Pressure Test Meter - 75 GPM NA] 380500047 [Mechanical Hydraulic flow and Pressure Test Meter - 75 GPM NA] 380500047 [Mechanical Hydraulic flow and Pressure Test Meter - 75 GPM NA]
Reference
PAGE
Axle - Assemble
25.1 / 14
Axle - Assemble
27.1 / 14
Pump Charge pressure relief valve - Pressure test
29.2 / 23
Pump Charge pressure relief valve - Pressure test
29.2 / 23
Pump Pressure limiter valve - Pressure test
29.2 / 25
Pump - Test
29.2 / 29
Hydraulic systems - Cleaning Hydraulic systems - Cleaning Hydraulic systems - Cleaning Hydraulic systems - Test - All hydraulic pressure and flow tests
35.1 35.1 35.1 35.1
Hydraulic systems - Test - All hydraulic pressure and flow tests
35.1 / 35
Hydraulic systems - Test - All hydraulic pressure and flow tests
35.1 / 37
Hydraulic systems - Test - All hydraulic pressure and flow tests
35.1 / 42
Hydraulic systems - Test - All hydraulic pressure and flow tests
35.1 / 44
Hydraulic systems - Test - All hydraulic pressure and flow tests
35.1 / 47
Hydraulic systems - Test - All hydraulic pressure and flow tests
35.1 / 49
Hydraulic systems - Test - All hydraulic pressure and flow tests
35.1 / 51
Hydraulic systems - Test - All hydraulic pressure and flow tests
35.1 / 57
Hydraulic systems - Test - All hydraulic pressure and flow tests
35.1 / 60
Hydraulic systems - Test - All hydraulic pressure and flow tests
35.1 / 62
Hydraulic systems - Test - All hydraulic pressure and flow tests
35.1 / 67
Hydraulic systems - Test - All hydraulic pressure and flow tests
35.1 / 69
48068130 29/01/2018
/ / / /
25 25 26 32
Genuine 380500047 [Mechanical Hydraulic flow and Pressure Test Meter - 75 GPM NA] 380500047 [Mechanical Hydraulic flow and Pressure Test Meter - 75 GPM NA] 380500129 [7 Gauge Hydraulic Pressure Test Kit] CAS1871 [Seal Press] 380500047 [Mechanical Hydraulic flow and Pressure Test Meter - 75 GPM NA] 380500047 [Mechanical Hydraulic flow and Pressure Test Meter - 75 GPM NA] 380500047 [Mechanical Hydraulic flow and Pressure Test Meter - 75 GPM NA] 380500047 [Mechanical Hydraulic flow and Pressure Test Meter - 75 GPM NA] 380500047 [Mechanical Hydraulic flow and Pressure Test Meter - 75 GPM NA] 380500047 [Mechanical Hydraulic flow and Pressure Test Meter - 75 GPM NA] 380500047 [Mechanical Hydraulic flow and Pressure Test Meter - 75 GPM NA] 380500129 [7 Gauge Hydraulic Pressure Test Kit] 34788 [Refrigerant Recover Station for R134a] 34788 [Refrigerant Recover Station for R134a] 34788 [Refrigerant Recover Station for R134a] 34788 [Refrigerant Recover Station for R134a] 34788 [Refrigerant Recover Station for R134a] 34788 [Refrigerant Recover Station for R134a] 380040185 [Harness Diagnostic /Repair Kit (NEF)] 380040185 [Harness Diagnostic /Repair Kit (NEF)] 380100288 [Loader Arm Pivot Boss Alignment Tool] 380100288 [Loader Arm Pivot Boss Alignment Tool] 380100288 [Loader Arm Pivot Boss Alignment Tool] 380100288 [Loader Arm Pivot Boss Alignment Tool]
Reference
PAGE
Hydraulic systems - Test - All hydraulic pressure and flow tests
35.1 / 72
Hydraulic systems - Test - All hydraulic pressure and flow tests
35.1 / 74
Hydraulic systems - Test - All hydraulic pressure and flow tests
35.1 / 76
Oil reservoir - Apply vacuum Fixed displacement pump - Flow test - Auxiliary couplers - Video
35.2 / 4 35.3 / 5
Fixed displacement pump - Flow test - T fitting
35.3 / 9
Fixed displacement pump - Preliminary test
35.3 / 17
Main control valve - Test - Circuit leakage - Video
35.4 / 5
Main relief valve - Pressure test - T fitting
35.4 / 24
Relief valve - Pressure test - Auxiliary couplers
35.4 / 28
Auxiliary hydraulic function control - Test
35.5 / 6
Pilot valve - Pressure test
35.6 / 9
Air conditioning - Discharging
50.2 / 11
Air conditioning - Discharging
50.2 / 11
Air conditioning - Discharging
50.2 / 11
Air conditioning - Charging
50.2 / 12
Air conditioning - Charging
50.2 / 12
Air conditioning - Charging
50.2 / 12
Harnesses and connectors - Overview
55.9 / 13
Harnesses and connectors - Overview
55.9 / 23
Arm - Repair
82.1 / 3
Arm - Repair
82.1 / 4
Arm - Repair
82.1 / 4
Arm - Repair
82.1 / 8
48068130 29/01/2018
Genuine
Reference
380100288 [Loader Arm Pivot Arm - Repair Boss Alignment Tool] 380100288 [Loader Arm Pivot Arm - Repair Boss Alignment Tool]
Kit CAS10162A [Portable Filter Caddy] CAS10162A [Portable Filter Caddy] CAS10192 [Vacuum Pump] CAS10508 [Fitting Kit For Unions] CAS10193 [ Kit For Vacuum Pump] 380001737 [Nitrogen Charging Kit With High Pressure Regulator And Hoses Complete]
PAGE 82.1 / 8 82.1 / 8
Reference
PAGE
Hydrostatic transmission - Decontaminating
29.3 / 4
Hydraulic systems - Cleaning
35.1 / 25
Hydraulic systems - Cleaning Hydraulic systems - Cleaning
35.1 / 25 35.1 / 26
Oil reservoir - Apply vacuum
35.2 / 4
Accumulator - Discharging
35.8 / 43
48068130 29/01/2018
CNH Industrial America - Main 700 State Street Racine, Wisconsin United States 53404
SERVICE - Technical Publications & Tools
PRINTED IN U.S.A. Š 2018 CNH Industrial America LLC. All rights reserved. No part of the text or illustrations of this publication may be reproduced.
CNH Industrial America LLC reserves the right to make improvements in design and changes in specifications at any time without notice and without incurring any obligation to install them on units previously sold. Specifications, descriptions, and illustrative material herein are as accurate as known at the time of publication, but are subject to change without notice. Availability of some models and equipment builds varies according to the country in which the equipment is being used. For exact information about any particular product, please consult your CASE CONSTRUCTION dealer. CASE CONSTRUCTION is a trademark registered in the United States and many other countries, owned or licensed to CNH Industrial N.V., its subsidiaries or affiliates. Any trademarks referred to herein, in association with goods and/or services of companies, other than owned by or licensed to CNH Industrial N.V., its subsidiaries or affiliates, are the property of those respective companies.
48068130 29/01/2018 EN
Diagram
SYMBOLS
Diagram
SH01 - TITLE PAGE
SH21 - UNIT CONTROL MODULE
SH02 - MAIN POWER DISTRIBUTION
SH22 - LAMPS
SH03 - ACCESSORY POWER DISTRIBUTION
PRESSURE SWITCH
SH23 - INDICATORS
SH04 - IGNITION / CHARGING SYSTEM
SH24 - EU LIGHT ADAPTER
SH05 - GROUNDING SYSTEM
SH25 - BOOM ROAD LIGHTS
SH06 - ENGINE F5C T4
SH26 - WIPERS / WASHERS
SH07 - ENGINE F5C T4
LAMP
SPEAKER
TEMPERATURE
PRESSURE
DIODE
MOTOR
SH2: C-6
114 RD 1.0
SH4: D-1
107 RD 8.0
SH3: C-6
157 RD 3.0
SH2: B-6
705 VT 3.0
SH13: D-6
792 VT 3.0
SH13: D-6
701 VT 0.8
SH4: B-1
183 OR 0.8
SH13: D-6
700 VT 0.8
SH4: D-1
116 RD 2.0
SH13: D-6
710 VT 2.0
SH20: C-6
189 RD 0.8
SH14: A-6
LIGHT EMITTING DIODE (LED)
SH14: A-6
SH4: D-1
115 RD 2.0
SH15 - BULKHEAD CONNECTION
SH35 - DIAGNOSTIC CONNECTOR
SH16 - LEFT-HAND CAB CONSOLE
SH36 - FUEL FILTER JUMPER
SH4: D-1
S.P. D.T.
FUSE
D.P. S.T.
70
160 RD 0.8
1
24
114 RD 1.0
1
44
188 RD 0.8
1
RELAY
SH14: A-6
790 VT 1.0
SH2: D-6
705 VT 3.0
4.0 A
SH39 - CHASSIS INTERFACE X-900 / X-901 MD
SH20 - UNIT CONTROL MODULE
SH40 - CHASSIS INTERFACE X-900 / X-901 MD
COLOR ABBREVIATION BLACK BK BLUE BL LIGHT BLUE LB BLACK/WHITE BK/WH GREEN GN LIGHT GREEN LG ORANGE OR PINK PK VIOLET VT RED RD GREY GY TAN TN WHITE WH YELLOW YE
20.0 A
2.0 A
86
SP-031
CIRCUIT DIAGRAM LEGEND WIRE ID
SHEET 799 VT 0.8 SPLICE SP-123
WIRE SIZE CHART Sq. mm AWG 0.5 20 0.8 18 1.0 16 2.0 14 3.0 12 5.0 10 8.0 8
18
2
24
113 RD 1.0
38
2
40
SH3: C-6
139 OR 0.8
52
86
86
86
1
11
87
17
116 RD 2.0
85
5
946 BK 0.8
34
SP-900 S-008
SH2: B-6
116 RD 2.0
SH2: D-6
6
IGN
57
350 OR 1.0
35
707 VT 2.0
85
23
945 BK 0.8
87
51
125 OR 3.0
85
39
948 BK 0.8
85
57
4
267 YE 0.8
1096 BK 0.8
2
2
244A YE 0.8
1
1
SH20: C-6
124 YE 0.8
4
SH2: A-1
127 OR 0.8
3
4
124A YE 0.8
3
2
1
127A OR 0.8
2
3
A
1 B_ALT
PHASE
M-001 STARTER MOTOR
1
520A WH 2.0
3
A A
SH2: A-6 SH2: B-6
117 RD 3.0
SH2: B-6
107 RD 8.0
SH2: D-6
160 RD 0.8
SH2: C-6
SH3: A-6
174 OR 0.8
SH3: D-6
183 OR 0.8
SH2: D-6
184 OR 0.8
SH3: D-6
186 OR 0.8
SH3: A-6
240 OR 0.8
SH20: C-6
191 OR 0.8
X-126 STARTER PULL-IN
X-006
SH4: D-6
192 OR 0.8
M
1
3/0 B+ CABLE TO STARTER RD 81.0
SP-117
B_START
1
1
2
20.0 A
22
1
16
2
7.5 A
241A OR 1.0
SP-030
69
135 OR 2.0
1
63
2
20.0 A
SP-191
71
788 VT 3.0
1
274 WH 1.0
A-005+ ENGINE CONTROL UNIT
CDB-007
16 32
275 GY 1.0
B B
Y-047 INJECTOR ELECTRIC VALVE CYL 3 CDB-008
276 GY 1.0
D D
277 WH 1.0
CDB-008
31 1
CDB-010 E E F
278 WH 1.0
CDB-010
279 GY 1.0
F
B-055 OIL PRESSURE SWITCH
G G
280 GY 1.0
H H
281 WH 1.0
CDB-011
3
658 YE 0.5
3
CDB-016
28
27
27
SH26: B-6
15.0 A
12
295 PK 0.5
21
21
27
296 BK/WH 0.5
22
22
17
43
297 YE 0.5
23
23
48
INJECTOR 2 LOW BANK 1
1
4
2
5.0 A
SH14: C-6
1090 BK/WH 0.8
SH21: D-1
1034 BK/WH 0.8
SH10: D-1
1073 BK/WH 0.8
SH10: C-1
1074 BK/WH 0.8
SH20: C-1
1027 BK/WH 0.8
SH13: A-6
1051 BK/WH 0.8
SH10: D-1
1054 BK/WH 0.8
SH10: D-1
1055 BK/WH 0.8
SH12: A-1
1060 BK/WH 0.8
SH14: B-6
910 BK/WH 1.0
50
46
EGR ACTUATOR MOTOR MINUS INJECTOR 2 LOW BANK 2
35
2
EGR POSITION SENSOR SUPPLY INJECTOR 2 HIGH BANK 2
9
6
OIL PRESSURE EGR POSITION SWITCH SENSOR GROUND
CDB-019
321 WH 0.8
29
29
322 GY 0.8
30
30
318 PK 0.5
33
33
327 YE 0.5
34
34
24
337 BK/WH 0.5
35
35
SH20: C-6
1026 BK/WH 0.8
SH20: B-1
1028 BK/WH 0.8
SH20: D-6
1075 BK/WH 0.8
SH20: D-6
1076 BK/WH 0.8
SH21: B-6
1033 BK/WH 0.8
SH21: C-1
1035 BK/WH 0.8
SH21: C-1
1036 BK/WH 0.8
SH21: B-1
1037 BK/WH 0.8
SH3: A-6
SH21: C-6
1030 BK/WH 0.8
203 OR 0.8
SH3: D-6
SH21: C-6
1031 BK/WH 0.8
204 OR 0.8
SH3: D-6
SH21: B-6
1032 BK/WH 0.8
240 OR 0.8
SH20: C-6
SH20: C-1
1077 BK/WH 0.8
SH3: D-6 SH3: D-6
SP-173 942 BK 3.0
SP-029
DP
26
RAIL PRESSURE GROUND TVA ACTUATOR MOTOR PLUS
49
6
6
283 YE 0.5
41
RAIL PRESSURE SIGNAL TVA ACTUATOR MOTOR MINUS
34
RAIL PRESSURE SUPPLY TVA POSITION SENSOR SUPPLY
7
11
284 PK 0.5
7
B-014 INCREMENT SPEED SENSOR CDB-017 9
9
285 YE 0.5
10
10
286 YE 0.5
CDB-017
59 44
CDB-020
203 OR 0.8
SH3: D-6
338 WH 0.8
37
37
339 GY 0.8
38
38
8
340 PK 0.5
41
41
TVA POSITION SENSOR SIGNAL
53
341 YE 0.5
42
42
TVA POSITION SENSOR GROUND SPEED SIGNAL PLUS
37
342 BK/WH 0.5
43
43
1
SP-125
4
287 YE 0.5
8
8
288 BL 0.5
28
12
12
289 PK 0.5
13
B-017 COOLANT TEMPERATURE SENSOR 13
14
13
14
290 BL 0.5
291 YE 0.5
58
57
SEGMENT SPEED GROUND BOOST PRESSURE SIGNAL SEGMENT SPEED SUPLY
40
344 YE 0.5
18
18
BOOST PRESURE GROUND
25
345 BK/WH 0.5
19
19
TEMPERATURE SIGNAL
55
346 YE 0.5
20
20
X-017
343 PK 0.5
17
SP-172
1093 BK 13.0
SP-124
SP-047
1
971 BK 13.0
FUEL METERING UNIT SUPPLY FUEL TEMP GROUND
16
16
293 YE 0.5
38
FUEL TEMP SIGNAL
X-016
ENGINE F5C T4
155A OR 3.0 241C OR 0.8
SH38: B-6 SH39: D-6
241B OR 0.8
SH6: B-6
241C OR 0.8
SH37: B-6
241D RD 0.8
SH3: B-6
298 GY 1.0
984 BK 13.0
299 WH 1.0
2
1
1
16
86
56
1
104 RD 2.0
2
148 WH 0.8
14
12
743 OR 2.0 15
87
1
149 OR 3.0 20
SH21: D-6
170 OR 0.8
SH21: C-6
171 OR 0.8
335 WH 0.8
32
1 87
13
85
1
8
743 OR 2.0
179 OR 0.8
49
4.0 A
2
26
177 OR 0.8
7.5 A
2
50
972 BK 0.8
SP-065
356 OR 3.0
45
19
85
190 OR 3.0
355 OR 0.8
68
1067 BK 0.8
15.0 A
2
6
744 OR 2.0
3.0 A
2
4.0 A
2
1
25.0 A
2
SH16: A-1 SH16: C-1
931 BK 0.8
SH26: C-1
932 BK 0.8
SH26: B-1
1
5.0 A
55
2
FE #1, #2, #3 1
186 OR 0.8
129 OR 1.0
61
241D RD 0.8
72
1
10.0 A
55 67
2
59
SH2: A-6
1067 BK 0.8
SH4: B-1
190 OR 3.0
SH4: B-1
1
145 OR 1.0 970 BK 0.8
43
SH13: D-6
1
7.5 A
2
5.0 A
2
30.0 A
2
LEFT BOOM
48
1
14
120 OR 0.8
2
178 OR 0.8
1094 BK 0.8
SH5: B-1
1091 BK 0.8
SP-175
967 BK 8.0
SP-177
965 BK 3.0
SH38: B-3
SP-057
39
SH5: C-1 SH8: B-6
908A BK 5.0
SH38: D-6
908E BK 0.8
SH39: A-1
133B OR 0.8
1088 BK 8.0
SH28: D-1
SH37: A-1
133B OR 0.8
SH39: D-1 SH37: D-1
110 OR 2.0
950 BK 3.0
SH25: C-6
956 BK 0.8
SH38: A-1
1086 BK 2.0
SH8: B-6
SH37: A-1 SH8: C-1
112 BL 0.5
SH39: B-1 SH37: B-1
121 YE 0.8
SH39: A-1 SH37: C-1
161 YE 0.8
SH39: B-1 SH37: B-1
626 WH 0.8
SP-120
SP-908 1042 BK/WH 0.8
950 BK 3.0
SH25: C-6
SH38: B-3
1084 BK 3.0
SH28: A-1
X-017
SH38: A-3
1
72
1095 BK 0.8
1
60
SP-122
1044 BK/WH 0.8
1 CHS_GND_FRT
983 BK 13.0
SP-181
968 BK 2.0
SP-179
GND-002 SP-121
SP-182 1014 BK 8.0
986 BK 8.0
10.0 A
10.0 A
2.0 A
1
2.0 A
SP-183
1
925 BK/WH 0.8
X-TELE_GND
998 BK 1.0
SP-188
BATTERY +B
908B BK 2.0
2
BATTERY MINUS 1
SH14: D-6
49
182 OR 0.8
233 OR 2.0
SH13: C-6
2
42
716 VT 1.0
SH25: B-6
719 VT 1.0
SH40: C-6
719 VT 1.0
SH38: C-6
2
30
2
66
2
54
1097 BK 0.8
3
54
CAN 1 HI CAN 1 LO
CDB-001 24
4
PWR 2
245 YE 0.5
249 YE 0.5 242 YE 0.8
SH8: B-6
B-006
AIR TEMP SENSOR AIR TEMP GND
20
AIR TEMP SIGNAL
19
SH37: B-1
241A OR 1.0
241B OR 0.8
SH11: C-2 SH13: B-6
SH39: C-6 SH39: C-6
T°
1
257 YE 0.5
X-004
GCU COMMAND
235 YE 0.5
22
INLET TURBINE TEMP GND GCU FEEDBACK
SP-239
239 BK 0.8
41
253 PK 0.5
82
263 YE 0.5
26
81
265 BK/WH 0.5
25
4
26
PWR
3
SHEAT
1 5
T°
25 X-017
B-008
GCU GROUND
DIFF PRESSURE SENSOR DIFF PRESSURE GND
36
266 BK/WH 0.5
2
DIFF PRESSURE SIGNAL
58
268 YE 0.5
3
DIFF PRESSURE SUPPLY
14
269 YE 0.5
7
245 YE 0.5
64
CURRENT PUMP
249 YE 0.5
86
CURRENT ADJUST EXHAUST GAS TEMP GND 1
79
VIRTUAL GROUND EXHAUST GAS TEMP SIGNAL 1 VOLTAGE
80
VGND
2
252 BK 0.5
85
VNERNST
6
253 PK 0.5
63
DP
1 X-005
242 YE 0.8
SENSOR HEATING
270 BK/WH 0.5 B-011
SH39: C-6
EXHAUST GAS TEMP SENSOR #1 270 BK/WH 0.5
T°
2 1
271 YE 0.5
X-006
SH39: C-6
271 YE 0.5
X-014
B-012
252 BK 0.5
EXHAUST GAS TEMP SENSOR #2
R-005
FUEL FILTER HEATER 1
2
X-018
5
GROUNDING SYSTEM
239A BK 3.0
X-014
CADJ
976 BK 0.8
2
254 BK/WH 0.5
START SIGNAL
B-005
241B OR 0.8
957 BK 0.8
503C YE 0.8
BATTERY VOLTAGE
LAMBDA SENSOR SP-241
SH2: B-1
SH10: B-1
SH37: B-1
SH8: B-6
X-013
SH17: B-1
951 BK 0.8
SH39: B-1
601 YE 0.8
CDB-023
X-013
SH29: A-6
SH14: C-6
5
GND
953 BK 0.8
949 BK 0.8
CDB-023
600 WH 0.8
52
216 YE 0.5
3
FB
955 BK 0.8
SH35: B-5
8
CMD
CPUMP
SH35: C-5
SH37: B-1
X-017
241C OR 0.8
958 BK 0.8
CDB-001
504C GN 0.8
87
INLET TURBINE TEMP SIGNAL
SH7: D-1
959 BK 0.8
503C YE 0.8
50
WIF SIGNAL
GCU
SH28: A-6
SH13: B-6
SH37: C-1
INLET TURBINE TEMP SENSOR
1013 BK 0.8
978 BK 0.8
SH39: C-1
248 YE 0.8
ECU MAIN RELAY
8
1110 WH 2.0
SH39: C-6 SH39: D-6 SH39: D-6
SH10: A-1
SH31: C-5
248 YE 0.8
CCV HEATER CONTROL ECU SWITCHED POWER CCV HEATER FEEDBACK
BATTERY MINUS 3
133D OR 0.8
68
SH39: C-1
6
626 WH 0.8
1113 WH 2.0
982 BK 5.0
SH2: A-6
1098 BK 0.8
504C GN 0.8
908D BK 2.0
CRANK ENABLE 2
6
SH24: D-6
SH20: C-1
37
45
BATTERY MINUS 2
53
1
SH25: B-6
SH20: D-1
163 OR 0.8
CAN 2 LO
4
CRANK ENABLE 1
1112 WH 2.0
981 BK 0.8
159 OR 0.8
CAN 2 HI
908C BK 2.0
27
1111 WH 2.0
979 BK 1.0
SP-112
25 23
161 YE 0.8
5858
SH10: A-1
SH20: B-1
X-FUSE1
EGR ECU K-LINE
121 YE 0.8
SH39: A-6
SP-174
3
28
6060
1064 BK 0.8
1087 BK 5.0
155B OR 2.0
1
GND-001 1043 BK/WH 0.8
BATTERY +C
112 BL 0.5
SH6: D-6
SH11: B-2
960 BK 0.8
UCM_GND
5
110 OR 2.0
212 OR 8.0
SH3: A-6
1
1068 BK/WH 1.0
155C OR 2.0
30
SP-133B
X-017
1091 BK 0.8 SP-123
SP-908
SH8: B-6
1063 BL 0.8
SH20: C-1
154 OR 0.8
354 OR 0.8
ENGINE CONTROL UNIT
SP-155
212 OR 8.0
5757
SP-184
SP-110
62
F-038 FUSE RELAY GROUND
1092 BK 0.8
SP-190
7
GND-010 1069 BK 2.0
SH21: C-6
B-007
SH25: C-6
908F BK/WH 5.0
SH21: D-1
SH31: B-5
A-006
975 BK 3.0
908A BK 8.0 908A BK 8.0
SH21: D-1
F-037 FUSE RELAY GROUND
908A BK 8.0
SH26: C-6
907 BK 0.8
SH21: C-6
0060 OR 0.8
420 OR 3.0
RIGHT BOOM
36
715 VT 1.0
155A OR 3.0
937 BK 3.0
SP-176
SH21: C-6
147 OR 0.8
ACCESSORY POWER DISTRIBUTION
150 YE 0.8
SH4: C-1
SH20: C-6
142 OR 0.8
158 OR 0.8
F-032
711 VT 2.0
SH2: A-6
133E OR 0.8
SH24: D-6
SH20: C-6
126 OR 0.8
SP-192
243 OR 2.0
SH38: D-6
981 BK 0.8
128 OR 0.8
SH13: B-6
F-029 WIPER/WASHER
180 OR 0.8
SH38: D-6
975 BK 3.0
SH10: D-6
X-FUSE2
186 OR 0.8
SH19: D-1
SH25: C-6
SH20: D-1
102 OR 0.8
0061 OR 0.8
F-025 UCM INTERLOCKS
F-024 AUX FE ON/OFF
SH4: B-1
933 BK 1.0
SH25: A-6
SH20: D-1
165 OR 0.8
F-027 TWO SPEED SHIFT
SP-115
714 VT 1.0
SH32: B-5
952 BK 0.8
SP-111
176 OR 0.8
SH21: D-6
164 OR 0.8
F-031
SH14: C-6
941 BK 0.8
SP-109
SH21: D-6
168 OR 0.8
F-028
31
87
X-FUSE2
SH15: D-6
SH16: D-1
SP-152
122 OR 0.8
F-023 AUX FE KEY POWER
30
86
27
F-022 LOADER CONTROL
30
20
193 RD 3.0
2
F-021 UCM PUMP FWD
3
85
86
5.0 A
F-020 HYD OPTIONS
1
GND-004
ECU_GND
EXHAUST GAS TEMP GND 2 70
347 BL 0.8
EXHAUST GAS TEMP SIGNAL 2
X-018
SH39: D-1 SH39: D-1 SH39: C-1
242 YE 0.8
SH39: C-1
252 BK 0.5
SH39: C-1
253 PK 0.5
249 YE 0.5
83
2
272 BK/WH 0.5
FUEL FILTER HEATER GND
X-012
84
T°
1
273 YE 0.5
X-012
X-007
270 BK/WH 0.5
245 YE 0.5
RE003
SH39: C-1 SH39: C-1
271 YE 0.5
6
ENGINE F5C T4
ELECTRICAL SCHEMATIC
87A
SH2: D-1 SH37: B-6 SH39: B-6
256 RD 2.0
42
30
121 YE 0.8
54
86
121 YE 0.8
87
53
520 WH 2.0
SH4: A-6
85
41
161 YE 0.8
SH37: C-6
X-FUSE2
161 YE 0.8
X-FUSE2
SH39: A-6
TIER 4B (FINAL) ELECTRO-HYDRAULIC (EH) CONTROLS
DP
K-008
ECU MAIN RELAY X-ECU_MAIN_RLY BATT+
X-025
527A RD 8.0
SP-527
527B RD 8.0
527D RD 5.0 SH2: A-6
528F OR 5.0
SH5: B-1
908F BK/WH 5.0
SH6: D-6
908A BK 5.0
X-ECU_MAIN_RLY
3
30
87
5
528A OR 8.0
SH2: A-6
1
86
85
2
112 BL 0.5
SH37: A-6
112 BL 0.5
SH6: C-6
527B RD 8.0
527C RD 0.5
1
1
527D RD 5.0
2
2
528F OR 5.0
3
3
908A BK 5.0
SP-527RH 527C RD 0.5
SP-528RH
Skid Steer Loaders: SR210 - NGM418237 and above SR210 - NHM435463 and above SR240 - NGM418237 and above SR240 - NHM435463 and above SV280 - NGM418237 and above SV280 - NHM435463 and above
528A OR 8.0
X-079
528E OR 2.0
T°
SH37: D-1
528E OR 2.0
1
SH6: D-1
600 WH 0.8
2
SH6: C-1
601 YE 0.8
3
SH5: C-1
1086 BK 2.0
4
X-079
X-078A A A
600XXX OR 0.8
X-078
BK
A A
0.0
X-079
OUT1
RD
0.0
C C
OUT2
WH
0.0
B B
IN
X-079
X-078B
STARTING SEQUENCE
600AXXX OR 0.8
M-003 FUEL PUMP
SWITCHED POWER
A A
X-079
M X-078
X-017
1086XXX BK 0.8
B B
POWER RELAY OUTPUT
B B
X-078A
X-016
7
ENGINE F5C T4
Compact Track Loaders: TR270 - NGM418237 and above TR270 - NHM435463 and above TR310 - NGM418237 and above TR310 - NHM435463 and above TV370 - NHM435453 and above
BATTERY POWER
CCV HEATERS
X-079
CDB-021 2
30
SP-114
185 OR 0.8
F-019 BUCKET CONTROL
K-010 OPTION RELAY
SH2: B-1
K-007 ENGINE RELAY A
DP
CDB-021
146 WH 0.8
SH13: B-6
S-078
15
23
SH37: D-6
980 BK 1.0
NEG_TERM_A
PRIMER SWITCH
60
292 BL 0.5
110 OR 2.0
940 BK 3.0
965 BK 3.0
Y-050 FUEL METERING UNIT
FUEL METERING UNIT
15
SH39: D-6
139 OR 0.8 175 WH 0.8
4
13
SH20: B-6
169 OR 0.8
Z-FUSE2 POWER DISTRIBUTION EH CHASSIS
17
COOLANT TEMP SIGNAL
15
110 OR 2.0
GND-005
COOLANT TEMP GROUND
B-018 FUEL TEMPERATURE SENSOR
SH37: B-6
SH2: B-6 SH15: D-6
SP-107
2
SH20: B-6
201 OR 0.8
SH6: B-6
B-020 BOOST PRESSURE / AIR TEMPERATURE SENSOR 4
704 VT 0.8
SH24: A-6
X-CAB_GNDA
SPEED SIGNAL MINUS
10
SH39: B-6
0051 RD 8.0
SH2: B-1
X-316
BOOST PRESSURE SUPPLY SEGMENT SPEED SIGNAL
1
87A
SP-142 103 RD 3.0
4.0 A
166 OR 0.8
SH40: D-1
CDB-020
B-016 SEGMENT SPEED SENSOR 14
704 VT 0.8
939 BK 2.0
1008 BK 1.0 SH32: D-5
B-021 TVA PIERBURG 282 BL 0.5
SH32: C-5
157 RD 3.0
SP-113
172 OR 0.8
F-018 EH AUX HYD
87A
SH26: C-6
X-CAB_GNDB
X-316
B-013 RAIL PRESSURE SENSOR 5
351 OR 1.0
336 RD 1.0
1094 BK 13.0
1
180 OR 0.8
187 OR 0.8
1
33
2
1
1025 BK/WH 0.8
CDB-019
39
5
SH3: B-6
1
K-009 AUX FRONT ELECTRIC RELAY
SH4: D-1
6161
1029 BK/WH 0.8
181 OR 0.8
181 OR 0.8
25
F-017 GRD DRIVE REV
K-005 EH CONTROL RELAY
X-FUSE1
SP-092
B-022 EGR PIERBURG
EGR ACTUATOR MOTOR PLUS
335 WH 0.8
798 VT 5.0
1016 BK/WH 0.8
SH20: A-1
SH3: D-6
SH4: B-1
SH2: A-1
GND-003
B-019 EXHAUST GAS PRESSURE SENSOR
INJECTOR 1 HIGH BANK 2
EGR POSITION SENSOR SIGNAL CDB-016
294 GY 1.0
28
EXHAUST GAS PRESSURE SIGNAL INJECTOR 2 HIGH BANK 1
X-015 X-017
CDB-018
EXHAUST GAS PRESSURE GROUND
Y-049 INJECTOR ELECTRIC VALVE CYL 2 CDB-011
X-017
INJECTOR 1 LOW BANK 2
EXHAUST GAS PRESSURE SUPPLY
Y-048 INJECTOR ELECTRIC VALVE CYL 4
CDB-018
4
SH13: D-6
939 BK 5.0
Y-051 ELECTRIC VALVE (WG)
INJECTOR 1 HIGH BANK 1
BOOST PRESSURE ACTUATOR 1
C C
241C OR 0.8
INJECTOR 1 LOW BANK 1
SH15: D-6
334 OR 2.0
134 OR 2.0
65
2
910A BK/WH 0.8
SH3: D-6
174 OR 0.8
181 OR 0.8
2
X-FUSE1
SH3: D-6
SH3: D-6
SH4: A-1
19
87A
F-039 TELEMATICS
4 241C OR 0.8
CDB-007
309 OR 1.0
SH4: B-6
181 OR 0.8
IGNITION / CHARGING SYSTEM
A A
SH11: A-5
127 OR 0.8
187 OR 0.8
173 OR 0.8
203 OR 0.8
SH2: D-6
F-012 FRONT WORK LAMPS
GND-008
X-015
SP-241
F-013 ACCESSORY
GND-011
Y-046 INJECTOR ELECTRIC VALVE CYL 1
1102 OR 0.8
528F OR 5.0
1012 BK/WH 0.8
SH3: D-6
STARTER HOLD-IN
X-126
167 OR 0.8
SH21: C-6
528E OR 2.0
SH28: C-1
173 OR 0.8
SP-118 520 WH 2.0
SH39: A-6
SH8: B-6
961 BK/WH 0.8
190 OR 3.0
X-005A
SH8: D-1
15
F-033 ENGINE SENSORS
SH5: C-1
SP-119
CHARGE INDICATOR
(3)
2
7.5 A
SH37: A-6
703 VT 0.8
SH37: D-6
1011 BK/WH 0.8
907 BK 0.8
2
D+(1)
W(2)
17
703 VT 0.8
SH13: D-6
SH27: B-1
SH27: D-6
G-002
244 YE 0.8
2
4.0 A
SH14: C-6
SH3: A-6
SH36: C-5
SH27: B-6
ALTERNATOR
X-005A
51
2
15.0 A
795 VT 5.0
123 OR 3.0
SH2: C-6
SH27: B-1
B+ CABLE TO ALTERNATOR RD 32.0
X-006
SP-037
300 OR 1.0
SH2: B-6
243 OR 2.0
SH20: C-6
SH4: C-6
SH32: C-5
X-508
52
2
10.0 A
GND-009 X-508
X-508
7
528C OR 3.0
X-FUSE2
AIR FILTER RESTRICTION SWITCH
SH39: A-1
28
2
2.0 A
709 WH 0.8
1098 BK 0.8
SH3: C-6
113 RD 1.0
SH4: B-1
7.5 A
F-016 EH GRND DRIVE
32
SH38: B-6
528A OR 8.0
188 RD 0.8
624 WH 0.8
2
1
SP-194
947 BK 0.8
62
2
203 OR 0.8
1
31
SH39: D-6
SH3: A-1
193 RD 3.0
132 OR 0.8
1
29
2
4.0 A
708 VT 3.0
F-034 ECU FUSE 2
136 OR 1.0
S-021
2
1
21
528B OR 3.0
528D OR 1.0 69
204 OR 0.8
SH4: A-1
SH4: D-1
SP-032
53
2
15.0 A
F-035 ECU FUSE 1
SP-528
X-009
1
1
23
700 VT 0.8
1
1
706 VT 3.0
F-010 RH TAIL LAMPS
87
SH24: D-6
SH4: A-1
F-015 UCM BRAKE LAMPS
Z-FUSE2 POWER DISTRIBUTION EH CHASSIS
F-009 IGNITION
CHS_GND_RR
X-508
SH8: D-6
SH8: C-1
SH3: C-6
X-009
267 YE 0.8
1
10
0051 RD 8.0
138 OR 0.8
1
START
156 RD 2.0
41
2
15.0 A
X-FUSE1
SH32: B-5
B+ CABLE TO ALTERNATOR RD 32.0
3
SH13: D-6
Z-FUSE1 POWER DISTRIBUTION EH CHASSIS
A-004
IGNITION SWITCH AUX
SH37: A-1
1
58
326 OR 1.0
710 VT 2.0
87
2.0 A
156 RD 2.0
INSTRUMENT CLUSTER
SP-036
87A
F-036 FUSE RELAY GROUND
68
1094 BK 0.8
119 RD 1.0
15.0 A
F-008
X-FUSE2
118 RD 1.0
119 RD 1.0
GND-007
140 RD 0.8
1
30
70
144 OR 0.8
1067 BK 0.8
256 RD 2.0
40
2
F-006 LH TAIL LAMPS
30
58
118 RD 1.0
SH3: A-6
SH14: C-6
MAIN POWER DISTRIBUTION
SP-145
0054 RD 19.0
SH27: B-6
1
35
183 OR 0.8
87A
SH4: D-1
30.0 A
F-007 UCM BACKUP ALARM
K-004 MAIN POWER RELAY
DIAGRAM SHOWN WITH VEHICLE PARKED & POWER OFF
1
X-POS_TERM
SH4: B-6
1
59
701 VT 0.8
189 RD 0.8
30
36
709 WH 0.8
117 RD 3.0
SH3: A-6
5
2
F-005 SIDE LAMPS
K-002 LIGHTS #2 RELAY
SH4: D-1
SH15: C-6
836 RD 3.0
X-FUSE1
87A
NOTE:
SP-146
0055 RD 19.0
3/0 B+ CABLE TO STARTER RD 81.0
1
47
792 VT 3.0
115 RD 2.0
TABLE OF CONTENTS / STANDARD SYMBOLS
SH4: A-6
1
46
705 VT 3.0
310 RD 0.8
K-003 ACCESSORY RELAY
SH4: D-1
61
2
25.0A
SH14: C-6
F-004 REAR WORK LAMPS
64
2
30
18
325 WH 0.8
BATTERY
GROUND
843 OR 5.0
Z-FUSE1 POWER DISTRIBUTION EH CHASSIS
K-001 LIGHTS #1 RELAY
SH2: C-1
SH19 - RIGHT NH CONTROL HANDLE
3/0 B+ CABLE RD 81.0
11
X-FUSE1
D.P. D.T.
SH4: D-1
SH38 - CHASSIS INTERFACE
1
1
87A
SH18 - RIGHT NH CONTROL HANDLE
X-POS_TERM
174 OR 0.8
SP-161
820 OR 3.0
844 OR 5.0
X-FUSE1
6
G-001 BATTERY
SH4: B-1
67
310 RD 0.8
X-FUSE1
SH37 - CHASSIS INTERFACE X-900 / X-901
COLOR WIRE SIZE
174 OR 0.8
157 RD 3.0
F-026 EH UNSWITCHED BATTERY
S.P. S.T.
SH34 - 2ND AUX
SH5: B-1
SH4: A-1
3
2
30.0 A
F-030 FLASHER/ BRAKE
Z-FUSE2 POWER DISTRIBUTION EH CHASSIS
SH14 - BULKHEAD CONNECTION
GRID LOCATION
187 OR 0.8
255 RD 2.0
F-014 ACC/BEACON SH2: D-6
SH33 - MULTIFUNCTION JUMPER
SH17 - LEFT NH CONTROL HANDLE
187 OR 0.8
SH4: B-1
1
F-003 CRANK
SH32 - TELEMATICS
SH13 - BULKHEAD CONNECTION
SH4: A-1
9
835 OR 3.0
COIL
RESISTOR
VARIABLE RESISTOR
SH31 - MULTIFUNCTION CONNECTOR
SH12 - LOADER VALVE AND SENSORS
184 OR 0.8
F-011
SH30 - UJM CONNECTORS
SH11 - HYDRAULIC INTERLOCKS
SH4: B-1
F-002 COMPRESSOR
UNSWITCH BATTERY
SH29 - RADIO
SH10 - ET PUMP / HYDRAULICS
173 OR 0.8
F-001 HVAC
830 OR 3.0
Z-FUSE1 POWER DISTRIBUTION EH CHASSIS
SH28 - HVAC
SH09 - THROTTLE SENSORS
173 OR 0.8
SH4: B-1
SP-042
SH27 - INSTRUMENT CLUSTER
SH08 - ENGINE F5C T4
SH4: A-1 Z-FUSE1 POWER DISTRIBUTION EH CHASSIS
8
RAC 48144044 RAC 48144044 S1S1
B-025 LH PUMP SWASH PLATE SENSOR
B-023 HAND THROTTLE SENSOR A B
544 YE 0.8
SH27: C-1
1071 BK/WH 0.8
SH27: C-1
260 PK 0.8
SH27: D-1
C
209 PK 0.8
5
222 PK 0.8
2
REF #1
REF #2
GND #1
1
1054 BK/WH 0.8
SH5: C-6
ANGLE #2
3
574 YE 0.8
SH21: D-6
ANGLE #1
4
573 YE 0.8
SH21: D-6
GND #2
6
1073 BK/WH 0.8
SH5: D-6
X-094
U-001 LOADER PORT LOCK SP-187
308 YE 0.8
SH32: B-5
537 WH 0.8
SH20: D-1
957 BK 0.8
SH5: A-1
A
536 WH 0.8
SH20: D-1
B
1063 BL 0.8
SH5: B-1
1
304 WH 0.8
X-094
SH3: D-1
SP-136
102 OR 0.8
B-026 RH PUMP SWASH PLATE SENSOR
X-20A
5
221 PK 0.8
B-024 FOOT THROTTLE SENSOR
REF #1
2
223 PK 0.8
REF #2
2
GND #1
1
1055 BK/WH 0.8
SH5: C-6
ANGLE #2
3
575 YE 0.8
SH20: B-1
ANGLE #1
4
576 YE 0.8
SH20: B-1
GND #2
6
1074 BK/WH 0.8
SH5: D-6
X-093
X-PORT_LK
U-002 LOADER PILOT INTERLOCK
X-093
A
SH14: A-6
545 YE 0.8
B
M-018 RIGHT DRIVE PUMP REVERSE
SH15: C-6
1066 BK/WH 0.8
SH20: D-1
1
518 WH 0.8
2
M
X-018
C
SH15: C-6
211 PK 0.8
1041 BL 0.8
X-018
SP-099
M-016 LEFT DRIVE PUMP REVERSE
X-020 SH20: C-1
1
517 WH 0.8
2
M
X-016
1022 BL 0.8
SH20: C-6
1021 BL 0.8
SH20: B-1
951 BK 0.8
SH5: A-1
960 BK 0.8
SH5: B-1
X-PLTLK
1039 BL 0.8
X-016
M-017 RIGHT DRIVE PUMP FORWARD SH21: B-6
X-095 1 3 5
5
199 OR 0.8
6
6
523 YE 0.8
7
7
197 OR 0.8
8
8
1024 BL 0.8
SP-140
SH21: B-6
1
516 WH 0.8
SH13: C-1
1038 BL 0.8
X-013
Y-010 RIDE CONTROL SOLENOID SH13: B-6
X-RDCTRL
831 WH 0.8
1
1
IN
OUT
X-RDCTRL
SH14: B-1
X-RDCTRL
2
2
2
2
X-RDCTRL
S-006
BOOM LOCK INTERLOCK SWITCH
Y-008 BRAKE VALVE SOLENOID SH21: D-6
SH14: C-1
1023 BL 0.8
9
2
M
X-013
DRIVE PATTERN SELECTOR SW
9
SP-098
X-1 3-1
SH27: C-6
195 OR 0.8
1040 BL 0.8
X-017
M-013 LEFT DRIVE PUMP FORWARD
SH13: C-1
521 YE 0.8
3
2
M
X-017
SH13: C-1
522 YE 0.8
1
1
519 WH 0.8
X-BRK
258 WH 0.8
1
1
IN
SH2: C-1
OUT
X-BRK
X-BRK
X-BRK
1102 OR 0.8
B
NOT USED
X-904
S-039 BRAKE PRESSURE SWITCH
198 OR 0.8
1010
X-904
X-904
X-904
SH20: C-1
1103 YE 0.8
A
C
X-095
SH20: C-1
535 YE 0.8
X-BRKPRS
9
THROTTLE SENSORS
1
1
X-BRKPRS
2
1
X-BRKPRS
2
2
SH5: B-1
1064 BK 0.8
X-BRKPRS
10
ET PUMP / HYDRAULICS
11
HYDRAULIC INTERLOCKS X-ECC
1018A BL 0.8
S-029
STD/ON-ROAD LAMP CONFIGURATOR
Y-003 BUCKET VALVE RETRACT X-088
1
2 3 4
510A WH 0.8
1
X-025
1
1
X-025
X-025
2
2
X-025
SP-154
1078 BL 0.8
Y-006 BUCKET VALVE EXTEND
2
511A WH 0.8
3
X-026
1
1
X-026
X-026
2
2
X-026
1079 BL 0.8
570A YE 0.8
4
Y-007 LOADER VALVE RETRACT 5
5
512A WH 0.8
6
6
1019A WH 0.8
X-027
1
1
X-027
7
513A WH 0.8
8
8
571A YE 0.8
9
X-028
1
1
X-028
X-027
2
2
X-027
1080 WH 0.8 SP-108
1
208x PK 0.8
X-028
2
2
X-028
10
515A WH 0.8
11
11
1020A BL 0.8
GND OUT
3
B-027
AUXILIARY SPOOL POSITION SENSOR
4 X-023
1081 WH 0.8
1057 BK/WH 0.8 SP-130
Y-012 PROPORTIONAL AUX VALVE RETRACT 10
PWR
X-023
1060A BK/WH 0.8
9
X-029
1
1
X-029
X-029
2
2
X-029
SP-135
1
206x PK 0.8
1082 BL 0.8
PWR
X-021
GND
3
OUT
4
SP-156
B-028
BUCKET SPOOL POSITION SENSOR
X-024
514A WH 0.8
12
13
13
572A YE 0.8
14
14
236A PK 0.8
1
1
X-024
SH2: D-6
710 VT 2.0
SH2: D-6
701 VT 0.8
X-024
2
2
X-024
1083 BL 0.8
1058 BK/WH 0.8 1
207x PK 0.8
PWR
X-022
GND
3
OUT
4
B-029
BOOM SPOOL POSITION SENSOR
X-022 X-010 1
1
510 WH 0.8
SH21: B-6
2
2
1018 BL 0.8
SH20: D-6
X-101B
702 VT 2.0
X-101
X-101A
SP-024
791 VT 3.0
5
SH2: D-6
700 VT 0.8 237 WH 3.0
1
1
SH2: D-1
836 RD 3.0
2
2
SH2: D-6
792 VT 3.0
3
123 OR 3.0
4
SH28: B-6
SH31: C-5
410 WH 0.8
38
SH31: C-5
411 TN 0.8
SH31: C-5
416 VT 0.8
SH31: C-5 SH31: C-5
SH31: C-5
419 LG 0.8
SH29: A-6
SH2: D-1
844 OR 5.0
48
48
844 OR 5.0
SH28: C-1
SH32: A-5
SH2: A-1
798 VT 5.0
49
49
797 VT 5.0
SH24: A-6
770 OR 0.8
SH17: D-6
SH20: D-6
200 PK 0.8
50
50
214 PK 0.8
SH18: C-6
783 OR 1.0
SH24: C-6
SH20: B-1
547 YE 0.8
51
51
215 RD 0.8
SH30: C-6
784 OR 1.0
SH16: B-6
219 RD 0.8
SH30: C-1
785 OR 0.8
SH16: B-6
547 YE 0.8
SH18: C-6
404 WH 0.8
SH16: C-1
769 OR 2.0
9
841 WH 0.8
14
14
841 OR 0.8
SH28: C-1
SH20: B-1
522 YE 0.8
15
15
522 YE 0.8
SH9: B-2
SH3: B-1
233 OR 2.0
16
16
233 OR 2.0
SH26: C-6
SH20: B-1
523 YE 0.8
17
17
523 YE 0.8
SH9: B-2
SH21: B-6
312 YE 0.8
18
18
312 YE 0.8
SH16: B-1
SH21: C-6
548 GN 0.8
19
19
548 GN 0.8
SH30: B-1
SH20: C-6
560 GN 0.8
20
20
560 GN 0.8
SH30: B-1
SH35: B-5
SH2: D-1
843 OR 5.0
55
55
843 OR 5.0
SH28: C-1
SH28: A-6
824 YE 0.8
56
56
824 YE 0.8
SH28: B-6
1090 BK/WH 0.8
57
57
1090 BK/WH 0.8
1023 BL 0.8
58
58
1023 BL 0.8
SH9: B-2
833 WH 0.8
SH28: C-1
SH37: C-6
833 WH 0.8
59
59
SH39: B-6
833 WH 0.8
60
60
SH20: C-1
1024 BL 0.8
61
61
1024 BL 0.8
SH9: B-2
SH20: B-1
754 YE 0.8
62
62
754 YE 0.8
SH18: A-1
SH21: C-1
541 YE 0.8
63
63
541 YE 0.8
SH23: C-6
531 YE 0.8
64
64
531 YE 0.8
SH18: B-1
65
65
834 WH 0.8
SH28: C-1
66
66
503A YE 0.8
67
67
504A GN 0.8
68
68
524 YE 0.8
69
69
910 BK/WH 0.8
SH32: B-5
70
70
234 YE 0.8
SH27: B-1
832 OR 0.8
SH18: B-6
549 WH 0.8
23
23
549 WH 0.8
SH30: C-1
SH3: C-1
744 OR 2.0
24
24
753 OR 0.8
SH16: A-6
SH20: B-1 SH39: B-6 SH37: C-6
SH16: D-6
SH37: B-6
SH21: C-6
6
6
1019 BL 0.8
SH20: C-1
SH5: A-1
976 BK 0.8
7
7
513 WH 0.8
SH21: C-6
SH19: A-6
333 YE 2.0
8
8
571 YE 0.8
SH21: B-6
SH21: D-1
9
9
1060 BK/WH 0.8
SH5: C-6
10
10
515 WH 0.8
SH20: C-6
11
11
1020 BL 0.8
SH20: C-6
12
12
514 WH 0.8
13
13
14
14
STD HIGH FLOW SOLENOIDX-HFLO
X-HFLO
2
2 X-HFLO
1
750 WH 0.8
1
28
SH17: C-6
SH37: B-6 SH32: C-5
26
755 WH 0.8
SH16: A-1
SH32: C-5
504B GN 0.8
27
831 WH 0.8
SH18: B-1
SH21: D-1
524 YE 0.8
SH5: C-6
910 BK/WH 1.0
28
750 WH 0.8
SH16: A-1
333 YE 2.0
SH19: B-1
SH39: A-6 SH37: A-6 SH39: C-6 SH39: B-6
7
333 YE 0.8
SH19: B-1
561 WH 0.8
29
29
561 WH 0.8
SH30: C-1
SH5: C-6
1051 BK/WH 0.8
30
30
1051 BK/WH 0.8
SH18: B-6
SH20: B-1
562 GN 0.8
31
31
562 GN 0.8
SH30: B-6
SH20: B-1
568 GN 0.8
32
32
568 GN 0.8
SH30: B-6
SH35: B-5
554 WH 0.8
33
33
554 WH 0.8
SH17: C-1
SH20: B-6
SH35: C-5
552 WH 0.8
34
34
552 WH 0.8
SH17: C-1
572 YE 0.8
SH21: B-6
SH40: C-6
780 VT 0.8
SH2: D-6
236 PK 0.8
SH20: D-6
SH38: C-6
780 VT 0.8
13
13
780 VT 0.8
SH24: C-6
SH9: C-2
SH21: C-1
567 WH 0.8
35
35
567 WH 0.8
SH30: C-6
SH2: B-6
SH21: D-1
569 WH 0.8
36
36
569 WH 0.8
SH30: C-6
CDB-003
503C YE 0.8
SH16: D-1
CDB-002
834 WH 0.8
834 WH 0.8
558 OR 0.8
7
X-010
CDB-003
752 WH 0.8
X-HFLO
504C GN 0.8
CDB-006
CDB-006
503A YE 0.8 504A GN 0.8
SP-504A
234 RD 0.8 234 RD 0.8 CBD-023
SP-503A
CDB-002
503B YE 0.8
CBD-023
504C GN 0.8 503C YE 0.8
CDB-013
SH32: D-5
357 OR 1.0
71
71
SH2: D-6
115 RD 2.0
72
12
SH17: B-6
72
115 RD 2.0
SH16: C-6
73
73
264 YE 0.8
SH27: B-6
310 RD 0.8
74
74
310 RD 0.8
SH27: C-6
545 YE 0.8
75
75
545 YE 0.8
SH27: C-1
790 VT 1.0
76
76
790 VT 1.0
SH22: A-1
790 VT 2.0
SH22: A-1
B-003
2
751 OR 0.8
86
3
9
SH27: B-1
175 WH 0.8
86
918 BK 0.8
X-300
267 YE 0.8
SH38: A-6
267 YE 0.8
82
82
267 YE 0.8
SH27: B-6
SH2: A-1
134 OR 2.0
77
77
134 OR 2.0
SH29: C-6
T
1 X-OILTMP
264 YE 0.8
GND-006
SP-026
S-001 ROTATING BEACON SWITCH D
796 VT 0.8
SH19: B-6
329 YE 0.8
78
78
329 YE 0.8
SH19: C-1
A
SH2: C-1
309 OR 1.0
79
79
309 OR 1.0
SH27: C-6
X-301
SH21: C-6
303 WH 0.8
80
80
303 WH 0.8
SH27: B-1
752 WH 0.8
SH13: B-1
916 BK 0.8
SH29: D-6
927 BK 2.0
SH24: B-6
934 BK 0.8
SH29: C-6
940 BK 3.0
SH5: D-1
761 VT 0.8
SH22: A-1
Z-005
LEFT CONTROL HANDLE S-027 TURN SIGNAL SWITCH
81
81
261 YE 0.8
SH27: D-6
S-044
1 X-OILFLT
SH14: A-1
261 YE 0.8
LEFT
SH13: C-1
770 OR 0.8
5
115 RD 2.0
SP-033
801 RD 0.8
A
B
X-ACC
X-ACC
RIGHT
952 BK 0.8
2ND AUX HYDRAULIC EXT(UP)
SH13: B-1
558 OR 0.8
1 RET(DN)
SH29: D-1
SH9: C-2
1066 BK/WH 0.8
83
83
SH38: B-6
622 WH 0.8
84
84
405 OR 0.8
SH27: C-1
1066 BK/WH 0.8 622 WH 0.8
SH27: B-1
V-007
144 OR 0.8
85
85
SH9: C-2
211 PK 0.8
87
87
SH28: A-6
822 OR 0.8
88
88
144 OR 0.8
1
N
P
X-316
2
X-316
SH19: B-6
332 YE 0.8
SH19: A-6
330 YE 0.8 NOT USED
SH27: B-1
133 OR 0.8
823 PK 0.8
SH28: A-6
821 OR 3.0
SH28: C-1
846 OR 8.0
SH28: C-1
90
90
330 YE 0.8
SH19: B-1
91
91
205C YE 0.8
SH27: B-6 CDB-022
92
92
NOT USED
93
93
508 BL 0.8
SH36: B-5
94
94
208 BL 0.8
SH32: A-5
NOT USED
95
95
NOT USED
NOT USED
96
96
NOT USED
NOT USED
97
97
NOT USED
NOT USED
98
98
NOT USED
NOT USED
99
99
NOT USED
NOT USED
100
100
NOT USED
NOT USED
101
101
NOT USED
NOT USED
102
102
NOT USED
SH27: C-6
SH24: C-6
2
554 WH 0.8
SH13: A-1
3
552 WH 0.8
SH13: A-1
S-015 SH14: D-1
3 X-365
311 OR 0.8
D
306 YE 0.8
UP
11
414 VT 0.8
SH18: C-1
DN
12
415 RD 0.8
SH18: C-1
UP
13
418 GY 0.8
SH14: D-1
DN
14
419 LG 0.8
SH14: D-1
9
563 WH 0.8
SH23: C-6
8
892 WH 0.8
SH14: D-1
953 BK 0.8
SH5: B-1
#2
SH18: A-1
#3
S-024 2 SPEED
E
312 YE 0.8
SH13: C-1
C
398 YE 0.8
SH13: C-1
A
353 OR 0.8
10
S-032
X-306
SH14: A-1
891 OR 0.8
4 X-408
S-023 HORN
924 BK 0.8 IN
X-306
X-408
S-041 HAZARD LAMP SWITCH SH13: C-1
784 OR 1.0
SH13: C-1
785 OR 0.8
B
A
776 VT 1.0
SH24: B-6
E
F
778 VT 0.8
SH24: C-6
Y-005
X-302 C
920 BK 0.8
915 BK 0.8
SH21: C-6
SH23: C-1
S-042 HIGH FLOW SWITCH
SP-025 A
SH13: B-1
753 OR 0.8
D X-303
15
564 WH 0.8
2 SPEED SOLENOID
X-2SPD A A
917 BK 0.8
SH23: C-1
941 BK 0.8
SH5: D-1
C
750 WH 0.8
SH13: B-1
E
755 WH 0.8
SH13: B-1
921 BK 0.8
X-2SPD B B
X-2SPD
X-302
X-BULKHEAD
BULKHEAD CONNECTION
2 X-365
SH36: B-5
NOT USED
208 BL 0.8
922 BK 0.8
S-005 LOADER LOCKOUT SWITCH
SH19: B-1
332 YE 0.8
89
507 WH 0.8
194 OR 0.8
SH27: D-1
89
CDB-022
A
SH24: B-6
765 VT 0.8
SH14: C-1
S-011 NH PARK BRAKE SWITCH SH27: C-6
SP-091
404 WH 0.8
X-317
211 PK 0.8
822 OR 0.8
E
768 VT 0.8
7
X-317
IGNITION BACKFEED DIODE SH2: A-6
D
6
S-033
SH5: D-1
S-013 SELF LEVEL SWITCH
GND-012
SH32: C-5
919 BK 0.8
Z-008 ACCESSORY POWER OUTLET
HYDRAULIC FILTER RESTRICTION SWITCH 1
14
BULKHEAD CONNECTION
X-301
2
357 OR 1.0
HYDRAULIC OIL TEMP SENDER
13
X-300
175 WH 0.8
SH19: B-1
S-009 HYDRAULIC COUPLER SWITCH SH13: B-1
SH3: C-6
SH35: C-5 SH35: C-5
X-BULKHEAD
BULKHEAD CONNECTION
X-ECC
SH40: A-6
SP-106
CDB-013
891 OR 0.8
X-BULKHEAD
LOADER VALVE AND SENSORS
SH18: C-6
SH5: D-6 SH20: C-1
SH21: C-1
512 WH 0.8
X-318
SH24: A-6
SH34: B-5
5
52
795 VT 5.0
SH34: B-5
5
52
54
129 OR 1.0
27
404 WH 0.8
54
856 WH 1.0
26
X-318
248 YE 0.8
22
25
1
53
21
25
1
53
22
X-CPLR
2
248 YE 0.8 248 YE 0.8 795 VT 5.0
21
HYDRAULIC COUPLER SOLENOID
2
SH37: C-6 SH39: C-6 SH2: C-1
129 OR 1.0
751 OR 0.8
X-318
X-318
856 WH 1.0
SP-053
949 BK 0.8
SH5: A-1
SH3: B-6
744 OR 2.0
SP-132
SELF LEVEL VALVE
SH31: C-5
Y-013
200 PK 0.8
Y-318
841 WH 0.8
Y-004
SH17: B-1
SH32: B-5
SH9: B-2
831 WH 0.8
892 WH 0.8
207 TN 0.8
521 YE 0.8
SH10: B-6
45
207 TN 2.0
12
SH21: B-6
SH17: C-1
45
SH18: C-6
12
570 YE 0.8
419 LG 0.8
892 WH 0.8
NOT USED
SH18: C-6
521 YE 0.8
4
44
210 PK 0.8
SH20: C-6
4
43
44
47
SH16: B-1
755 WH 0.8
43
NOT USED
47
398 YE 0.8
SH21: B-6
SH17: C-1
210 PK 0.8
11
SH21: D-1
SH18: C-1
418 GY 0.8
SH20: D-6
11
511 WH 0.8
417 RD 0.8
42
SH19: B-1
398 YE 0.8
3
41
42
334 OR 0.8
SH20: B-1
3
41
546 YE 0.8
SH24: B-6
752 WH 0.8
417 RD 0.8 418 GY 0.8
46
774 VT 0.8
X-CPLR
SH18: C-1
46
10
1
SH18: D-1
416 VT 0.8
546 YE 0.8
10
1
411 TN 0.8
40
SH21: C-1
774 VT 0.8
X-CPLR
39
40
SH22: A-1
SH25: B-6
2
39
SH19: B-1
SP-138
2
SH18: D-1
334 OR 2.0
8
X-CPLR
410 WH 0.8
4
8
978 BK 0.8
SH17: C-6
38
123 OR 3.0
207A TN 2.0
SH5: A-1
SH18: D-6
353 OR 0.8
354 OR 0.8
SH28: D-1
SH32: C-5
9
839 RD 3.0
37
SH22: A-1
6
769 OR 2.0
SH28: C-1
37
SH33: C-5
352 OR 0.8
792 VT 3.0
6
769 OR 2.0
SP-160
237 WH 3.0
354 OR 0.8
359 OR 0.8
3
334 OR 2.0
SH24: D-6
836 RD 3.0
SH22: A-1
SH3: B-1
SP-062
838 RD 1.0
SH2: C-1
SH40: D-6
791 VT 3.0
5
SH39: B-6
SH40: B-6
X-021
X-88
CHASSIS/ LOADER INTERFACE
711 VT 2.0
SH38: B-6
Y-011 PROPORTIONAL AUX VALVE EXTEND 12
SH3: A-6
SH2: A-1
1059 BK/WH 0.8
Y-009 LOADER VALVE EXTEND 7
X-ECC
X-2SPD
X-303
LEFT-HAND CAB CONSOLE
16
LEFT-HAND NH CONTROL HANDLE
17
RAC 48144044 S1S2
Diagram
SYMBOLS
Diagram
SH01 - TITLE PAGE
SH21 - UNIT CONTROL MODULE
SH02 - MAIN POWER DISTRIBUTION
SH22 - LAMPS SH23 - INDICATORS
SH04 - IGNITION / CHARGING SYSTEM
SH24 - EU LIGHT ADAPTER
SH05 - GROUNDING SYSTEM
SH25 - BOOM ROAD LIGHTS
SH06 - ENGINE F5C T4
SH26 - WIPERS / WASHERS
SH07 - ENGINE F5C T4
SH27 - INSTRUMENT CLUSTER
SH08 - ENGINE F5C T4
SH28 - HVAC
LAMP
MOTOR
DIODE
SH14: D-1
PRESSURE
SPEAKER
TEMPERATURE
LIGHT EMITTING DIODE (LED)
VARIABLE RESISTOR
SH14: C-1
COIL
RESISTOR
214 PK 0.8
SV
11
PROP A
12
GND
546 YE 0.8
SH11 - HYDRAULIC INTERLOCKS
SH31 - MULTIFUNCTION CONNECTOR
SH30: C-1
1047 TN 0.8
SH30: C-6
1045 TN 0.8
SH32 - TELEMATICS S.P. S.T.
SH13 - BULKHEAD CONNECTION
SH33 - MULTIFUNCTION JUMPER
SH14 - BULKHEAD CONNECTION
SH34 - 2ND AUX
SH15 - BULKHEAD CONNECTION
SH35 - DIAGNOSTIC CONNECTOR
S.P. D.T.
D.P. S.T.
D.P. D.T.
SH14: C-1
1090 BK/WH 0.8
SH30: C-6
218 OR 0.8
SH30: C-1
217 OR 0.8
SH14: D-1 FUSE
SH36 - FUEL FILTER JUMPER
SH17 - LEFT NH CONTROL HANDLE
SH37 - CHASSIS INTERFACE X-900 / X-901
SH18 - RIGHT NH CONTROL HANDLE
SH38 - CHASSIS INTERFACE
SH19 - RIGHT NH CONTROL HANDLE
SH39 - CHASSIS INTERFACE X-900 / X-901 MD
SH20 - UNIT CONTROL MODULE
SH40 - CHASSIS INTERFACE X-900 / X-901 MD
RELAY
GROUND
COLOR ABBREVIATION BLACK BK BLUE BL LIGHT BLUE LB BLACK/WHITE BK/WH GREEN GN LIGHT GREEN LG ORANGE OR PINK PK VIOLET VT RED RD GREY GY TAN TN WHITE WH YELLOW YE
CIRCUIT DIAGRAM LEGEND WIRE ID
SHEET 799 VT 0.8 COLOR WIRE SIZE
SPLICE SP-123
WIRE SIZE CHART Sq. mm AWG 0.5 20 0.8 18 1.0 16 2.0 14 3.0 12 5.0 10 8.0 8
SP-169
1053 BK/WH 0.8
SP-137
213 PK 0.8
SH5: B-6
1075 BK/WH 0.8
1
UCM GROUND 1A.01
SH5: B-6
1076 BK/WH 0.8
7
UCM GROUND 1A.07
8
SENSOR SUPPLY 1
236 PK 0.8
SH14: C-6 SH12: B-1
202 PK 0.8
200 PK 0.8
9
1018 BL 0.8
13
547 YE 0.8
SH13: A-1
1051 BK/WH 0.8
SH30: B-1
1048 BK 0.8
SH30: B-6
1046 BK 0.8
SH18: A-6
SP-126
1052 BK/WH 0.8
BUCKET RETURN
525 YE 0.8
14
UCM WAKE-UP
SH4: B-6
124 YE 0.8
16
ENGINE RPM SIGNAL
SH10: C-1
1022 BL 0.8
19
REV DRIVE RETURN
SH2: A-1
189 RD 0.8
20
UCM UNSW BATT
SH12: A-1
1020 BL 0.8
22 24
515 WH 0.8
SH4: B-1
240 OR 0.8
SH4: A-1
240 OR 0.8
SH5: B-6
1026 BK/WH 0.8
SH5: B-6
26
X-CN1B
165 OR 0.8
SH3: D-1
LOADER PILOT INTERLOCK
4
536 WH 0.8
SH11: B-2
LOADER PORT LOCK
5
537 WH 0.8
SH11: C-2
SW POWER PORT/PILOT LOCK 1
7
159 OR 0.8
SH3: B-1
PUMP RIGHT RESERVE
8
518 WH 0.8
SH10: C-6
HYDRAULIC CHARGE PRESSURE SWITCH
9
SW POWER PORT/PILOT LOCK 2
13
PUMP LEFT RESERVE
163 OR 0.8
SH3: B-1
14
517 WH 0.8
SH10: C-6
BOOM LOCK INTERLOCK SWITCH
17
1103 YE 0.8
SH11: A-2
UCM GROUND 2A.20
20
1077 BK/WH 0.8
SH5: A-6
PIN23
23
1024 BL 0.8
SH14: B-6
PIN24
25
UCM GROUND 2A.26
26
5V REV SUPPLY FUSE
SH14: A-1
UCM GROUND 1B.26
560 GN 0.8 521 YE 0.8
15
CONTROL PATTERN NEUTRAL
SH3: D-1
128 OR 0.8
26
SH3: C-1
126 OR 0.8
27
2
PROP A
3
GND
14
C
SP-105
406 OR 0.8
A
B
X-406
X-406
324 OR 0.8
320 OR 0.8
431 WH 0.8 1030 BK/WH 0.8
20
SH3: C-1
120 OR 0.8
21
PUMP FORWARD POWER
512 WH 0.8
22
LOADER LOWER SIGNAL
SH15: D-6
303 WH 0.8
23
HYDRAULIC LOADER INTERLOCK SIGNAL
SH17: B-6
564 WH 0.8
25
2 SPEED VALVE SOLENOID
1031 BK/WH 0.8
26
UCM GROUND 3A.26
4
SH33: B-5
430 WH 0.8
6
170 OR 0.8
7
SH10: D-1
574 YE 0.8
9
SH10: D-1
573 YE 0.8
10
SH13: B-6
548 GN 0.8
11
SH3: B-6
171 OR 0.8
13
SH33: C-5
315 RD 0.8
SP-086
4
X-058
X-058
X-104
1
1
X-104
X-104
SH14: B-1
SH15: D-6
329 YE 0.8
SH15: C-6
332 YE 0.8
SH21: B-6
526 YE 0.8
SH15: C-6
330 YE 0.8
SH20: C-6
525 YE 0.8
SH13: D-6
333 YE 2.0
P1
A
N1 P2
B C
SH5: C-1
328 YE 0.8
SH27: B-6
329 YE 0.8
SH15: D-1
323 YE 0.8
2
2
X-104
314 YE 0.8
524 YE 0.8 332 YE 0.8
N2 P3
D E
N3
F
X-090
SP-101
SH14: B-1 SH15: C-1
330 YE 0.8
SH15: C-1
334 OR 0.8
SH13: D-1
334 OR 2.0
SH13: D-1
333 YE 0.8
SH13: D-1
333 YE 2.0
SH13: D-1
SH13: B-1
SP-006
306 YE 0.8
SH16: C-1
754 YE 0.8
SH14: B-1
SP-100
19
RIGHT-HAND NH CONTROL HANDLE
SH12: B-1
SH5: A-6
SH2: C-1
29
BRAKE LAMP CIRCUIT OUTPUT #2
14
562 GN 0.8
SH13: A-6
SH3: C-1
17
158 OR 0.8
SH3: C-1
SH3: C-1
147 OR 0.8
9
CONTROL PATTERN H
20
522 YE 0.8
SH13: C-6
SH13: B-6
755 WH 0.8
11
CONTROL PATTERN ISO
21
523 YE 0.8
SH13: C-6
SH12: B-1
570 YE 0.8
12
CONTROL VALVE BUCKET POSITION
PARK BRAKE SWITCH
22
754 YE 0.8
SH14: B-6
SH12: A-1
571 YE 0.8
13
CONTROL VALVE LOADER POSITION
LOADER LOCKOUT SWITCH NO OUTPUT
23
398 YE 0.8
SH13: C-6
SH12: A-1
572 YE 0.8
14
CONTROL VALVE AUX POSITION
ENGINE START INPUT
24
532 YE 0.8
SH38: B-6
SH12: B-1
510 WH 0.8
17
BUCKET RETRACT SIGNAL
DRIVE FORWARD RETURN
25
1021 BL 0.8
SH10: B-1
SH38: C-6 SH40: C-6 SH13: C-6
895 WH 0.8 895 WH 0.8 312 YE 0.8
18
BACKUP ALARM SIGNAL
19
LOADER LOCK SWITCH NC OUT
1032 BK/WH 0.8
26
UCM GROUND 3B.26
29
2ND AUX EXTEND SWITCH OUT
30
SEAT SW OPERATOR INTERLOCK
LH UA2 X SENSOR OUTPUT
SWITCHED POWER BRAKE LAMP
SH3: D-1
201 OR 0.8
32
RH UA2 X SENSOR OUTPUT
SH12: A-1
514 WH 0.8
33
PROPORTIONAL AUX EXTEND
SH14: C-6
1019 BL 0.8
SH12: B-1
UCM GROUND 2B.26
26
1028 BK/WH 0.8
SH5: B-6
27
531 YE 0.8
SH14: B-6
PROPORTIONAL AUX SWITCH #2
28
547 YE 0.8
SH14: C-6
LH UA2 Y SENSOR OUTPUT
31
568 GN 0.8
SH13: A-6
LOAD
RH PUMP ANGLE #1
32
576 YE 0.8
SH10: C-1
120.0
RH PUMP ANGLE #2
33
575 YE 0.8
SH10: C-1
UCM GROUND 2B.34
34
1029 BK/WH 0.8
1
0060 OR 0.8
SH3: C-1
8
0061 OR 0.8
SH3: C-1
10
524 YE 0.8
SH14: B-6
17
561 WH 0.8
SH13: A-6
18
569 WH 0.8
SH13: A-6
19
511 WH 0.8
SH12: B-1
20
1034 BK/WH 0.8
SH5: D-6
24
549 WH 0.8
SH13: B-6
25
567 WH 0.8
SH13: A-6
26
1035 BK/WH 0.8
SH5: B-6
SH5: A-6
167 OR 0.8
SW POWER BACKUP ALARM
6
LOADER RAISE SIGNAL
142 OR 0.8
8
SW POWER BUCKET CONTROL 1
not used SH19: B-6
526 YE 0.8
1
758 VT 0.8
X-341 X-068 PWR
GND
PWR
738 VT 0.8
GND
1003 BK 0.8
EHF INTERLOCK
1007 BK 0.8
3
683 PK 0.8
E-024 RH FRONT STROBE
SP-082
1
739 VT 0.8
X-343
SP-083 SP-084
2
1004 BK 0.8
3
680 PK 0.8
X-343
E-025 RH REAR STROBE
X-082 PWR
13
423 YE 0.8
SH31: B-5
2 SPEED UCM INPUT
15
541 YE 0.8
SH14: B-6
PROPORTIONAL AUX SWITCH #1
21
546 YE 0.8
SH14: D-6
UCM GROUND 4B.27
27
1036 BK/WH 0.8
SH5: B-6
UCM GROUND 4B.34
34
1037 BK/WH 0.8
SH5: B-6
HIGH FLOW SIGNAL
2ND AUX RETRACT SIGNAL POWER
519 WH 0.8
32
PUMP RIGHT FORWARD
SH10: B-6
516 WH 0.8
33
PUMP LEFT FORWARD
SH5: B-6
1033 BK/WH 0.8
34
UCM GROUND 3B.34
not used
2
X-341
X-068
X-CN4B
31
SH10: B-6
SH5: B-6
SW POWER BUCKET CONTROL 2
681 PK 0.8
E-021 LH REAR STROBE
1
1
P
2
1006 BK 0.8
3
682 PK 0.8
GND
2
N
X-085
513 WH 0.8
1005 BK 0.8
3 X-344
0063A VT 0.8
3
2
X-342
X-CN3B
LOADER FLOAT SWITCH INPUT
X-344
U-003 RH DIA SIDE LAMP
SH12: A-1
1023 BL 0.8
1
X-CN4A
X-342
SH3: C-1
CAN LO
317 RD 0.8
3
757 VT 0.8
SH10: A-6
10
SH27: B-6
S-002 SEAT SWITCH
SP-012
740 VT 0.8
SH5: A-6
169 OR 0.8 258 WH 0.8
535 YE 0.8
503E YE 0.8
SH17: C-1
18
19
SH3: D-1 SH10: A-6
154 OR 0.8
504E GN 0.8
307 YE 0.8
SWITCHED POWER PARK BRAKE 1 SWITCHED POWER BUCKET CONTROL 1 SWITCHED POWER PARK BRAKE 2 SWITCHED POWER BUCKET CONTROL 2 PARK BRAKE VALVE SIGNAL SEAT BELT OPERATOR INTERLOCK EHF RETRACT SIGNAL RH UA1 Y SENSOR OUT SWITCHED POWER TWO SPEED 1 LH UA1 Y SENSOR OUT LH PUMP ANGLE #1 BUCKET EXTEND SIGNAL LH PUMP ANGLE #2 UCM GROUND 4A.20 RH UA2 X SENSOR OUT RH UA1 X SENSOR OUT SWITCHED POWER TWO SPEED 2 LH UA1 X SENSOR OUT EHF EXTEND SIGNAL UCM GROUND 4A.26 UCM GROUND 3A.20
3
SH3: B-6
SH5: C-6
2
13
31
SH32: C-5
1027 BK/WH 0.8
168 OR 0.8
9
1
SH14: D-1
414 VT 0.8
RIGHT-HAND NH CONTROL HANDLE
SWITCHED POWER PROP AUX EXTEND SW POWER LOADER CONTROL SWITCHED POWER PROP AUX RETRACT PARK BRAKE PRESSURE SWITCH
30
SH32: C-5
SH34: C-5
416 VT 0.8
831 WH 0.8
S-014 PARK BRAKE SWITCH
8
R-002
425 VT 0.8
531 YE 0.8
D
EHF RETURN
CAN TERMINATOR
SH34: C-5
X-403
7
CAN HI
SH14: D-1
427 RD 0.8
DIODE MODULE 228174A1 REPLACE V-005 EH LAP BAR DIODE V-009 EH SEAT SW UCM DIODE V-005 EH UCM WAKEUP DIODE
2
X-CN2B
SH17: C-1
417 RD 0.8
316 RD 0.8
LOADER RETURN
166 OR 0.8
579 VT 0.8
415 RD 0.8
933 BK 1.0
S-043 LAP BAR SWITCH
SV
PATTERN INDICATOR ISO LS OUTPUT
BRAKE LAMP CIRCUIT OUTPUT #1 SWITCHED POWER LOADER CONTROL
721 VT 0.8
NOT USED IN 47803842
SH28: D-1
DIODE PACK
832 OR 0.8
SH3: D-1
X-CN2B
SH13: C-6
SH3: D-1
413 RD 0.8
X-CN3A
3
RH UA2 Y SENSOR OUTPUT
SH40: B-6
9
13
34
RIGHT PUMP REVERSE POWER
9
580 VT 0.8
DN
933 BK 1.0
DIAGRAM SHOWN WITH VEHICLE PARKED & POWER OFF
SH3: D-1
13
SP-150
412 VT 0.8
S-018 RIDE CONTROL/ GLIDE RIDE
SH27: C-6
164 OR 0.8
1025 BK/WH 0.8
721 VT 0.8
8
UNIT CONTROL MODULE
PROPORTIONAL AUX RETRACT
UCM GROUND 1B.34
1
756 OR 1.0
E-023 LH FRONT STROBE
PROPORTIONAL AUX RETURN
1
SH29: D-1
2 UP
X-403
NOTE:
2
SH13: B-6
SH38: A-6
SH14: D-1
DIODE MODULE
406 OR 0.8
SH18: B-6
LEFT PUMP REVERSE POWER
SENSOR SUPPLY 3
SH19: A-6
SH12: A-1
411 TN 0.8
S-003 SEAT HEAT SWITCH
S-007 FLOAT SWITCH
X-CN2A
X-CN1A
SH12: A-1
7
SP-064
1
UNIT CONTROL MODULE
SP-134
DN
SP-063
A-002A
210 PK 0.8
SH14: D-1
S-037
210 PK 0.8
SH14: C-1
BATTERY
TABLE OF CONTENTS / STANDARD SYMBOLS
SH14: D-6
410 WH 0.8
S-036 10
SH14: D-1
SH5: B-1
6
R-001 SEAT HEAT ELEMENT
SH30 - UJM CONNECTORS
GRID LOCATION
UP #1
#2
SH10 - ET PUMP / HYDRAULICS
SH16 - LEFT-HAND CAB CONSOLE
5
352 OR 0.8
S-022
SH29 - RADIO
SH12 - LOADER VALVE AND SENSORS
SEAT
S-031
PRESSURE SWITCH
SH03 - ACCESSORY POWER DISTRIBUTION
SH09 - THROTTLE SENSORS
Z-006
Z-012
RIGHT CONTROL HANDLE
X-085
1097 BK 0.8 PWR GND X-082
SP-191A
0062A BK 1.0 1096A BK 1.0
SP-192A
U-004 LH DIA SIDE LAMP 1
0064A VT 0.8
P
2
N
X-086
X-086
1098A BK 0.8 J-001 SIDE LAMP DIA SOCKET 2
238 VT 0.8
SH24: A-6
1
1085 BK 0.8
SH26: C-6
761 VT 0.8
SH16: D-1
928 BK 0.8
SH26: C-6
X-077
U-007 ROTATING BEACON 1
P
2
N
X-178
X-178
S-012 LAMP SELECTOR SWITCH D X-311
IN
1
A
790 VT 1.0
SH14: A-1 SH14: A-1
2
B
791 VT 3.0
SH13: D-1
3
C
792 VT 3.0
SH13: D-1
790 VT 2.0
X-311
SH13: D-1
123 OR 3.0
20
UNIVERSAL CONTROL MODULE
21
UNIVERSAL CONTROL MODULE
SH5: B-1
981 BK 0.8
SH5: C-1
981 BK 0.8
SH13: C-6
769 OR 2.0
SH40: D-1
769 OR 2.0
SH2: D-1
156 RD 2.0
SH40: D-1
156 RD 2.0
Z-013 FLASHER MODULE X-411 85
Y
ELECTRICAL SCHEMATIC
87A
30
TIER 4B (FINAL) ELECTRO-HYDRAULIC (EH) CONTROLS
S-034 TURN SIGNAL SWITCH Z-004
2 SPEED INDICATOR SH14: B-1
SH17: B-1
541 YE 0.8
SP-035
SH13: C-1
563 WH 0.8
7
9
X-310
X-310
SH16: A-1
917 BK 0.8
SH24: B-6
771 VT 0.8
772 YE 0.8
D
777 VT 1.0
F
775 VT 1.0
1
PWR1
X-155B 1
GND PWR2
1 X-157B
915 BK 0.8
Skid Steer Loaders: SR210 - NGM418237 and above SR210 - NHM435463 and above SR240 - NGM418237 and above SR240 - NHM435463 and above SV280 - NGM418237 and above SV280 - NHM435463 and above
V-010 HAZARD SWITCH INDICATOR BACKFEED DIODE
Z-023 TURN SIGNAL INDICATOR SH24: C-6
X-CTS E
783 OR 1.0
X-CTS
565 VT 0.8
SH16: B-1
778 VT 0.8
SH13: C-1
780 VT 0.8
SH17: D-1
765 VT 0.8
SH23: C-6
771 VT 0.8
X-HZRDDIODE 2
P
N
X-HZRDDIODE 1
781 VT 0.8 SP-019
SH16: A-1
X-156B
SH17: D-1
768 VT 0.8
SH23: C-6
772 YE 0.8
SH13: C-1
774 VT 0.8
SH16: B-1
776 VT 1.0
22
LAMPS
SP-018
X-031
SH16: D-1
799 VT 2.0
1
1
794 VT 2.0
2
2
773 VT 0.8
3
3
927 BK 2.0
4
4
Compact Track Loaders: TR270 - NGM418237 and above TR270 - NHM435463 and above TR310 - NGM418237 and above TR310 - NHM435463 and above TV370 - NHM435453 and above
BATTERY POWER
X-031
SP-016 798 VT 2.0 SH14: C-1
797 VT 5.0
SH14: C-1
795 VT 5.0
SH22: B-1
238 VT 0.8
SP-015
SH26: C-6 SH5: D-1
INDICATORS
23
X-030
797A VT 2.0
1
1
793 VT 2.0
2
2
779 VT 1.0
3
3
926 BK 2.0
4
4
STARTING SEQUENCE SWITCHED POWER X-030
939 BK 2.0
POWER RELAY OUTPUT EU LIGHT ADAPTER
24
RAC 48144044 RAC 48144044 S2S1
U-005xx
RH REAR WORK
X-039
LH REAR POSITION LAMP
A
732 VT 0.8
B
897 VT 0.8
X-035
1091 BK 0.8
C
RH REAR POSITION LAMP
2
U-006xx
N
X-034
2
1092 BK 0.8
B
TAIL
A
STOP
732A VT 0.8
X-205
704 VT 0.8
SH38: A-1 SH40: A-1
703 VT 0.8
SH5: C-1 SH5: C-1
REAR LAMP JUMPER X-201
LH TAIL LAMP POWER
3
C X-198
E-019xx
730 VT 2.0
2
733 VT 0.8
3
731 VT 0.8
4
1000 BK 0.8
4
REAR LAMP GROUND
717 VT 0.8
5
LH REAR POSITION LAMP
SH25: A-6
718 VT 0.8
6
RH REAR POSITION LAMP
5
717B VT 0.8
SH38: A-1 SH40: B-1
721 VT 0.8
7
BRAKE LAMP SIGNAL POWER
718A VT 0.8
721 VT 0.8
6 7
SH38: B-1 SH40: B-1
737 VT 0.8
766 VT 0.8
11
735 VT 0.8
12
736 VT 0.8
13
975 BK 3.0
950 BK 3.0
GND2
LICENSE PLATE
1
950 BK 3.0
SH38: C-1 SH40: B-1
TURN
A X-198
703 VT 0.8
717 VT 0.8
766 VT 0.8
11
LH REAR TURN SIGNAL POWER
SH25: A-6
763 VT 0.8
12
RH REAR TURN SIGNAL POWER
SH5: C-1
975 BK 3.0
13
REAR LAMPS GROUND
SH5: C-1
975 BK 3.0
P
1
898 VT 0.8
N
X-081
Z-011xx
RH REAR ROAD LAMPS B
TAIL
A
734A VT 0.8
SP-081
939 BK 5.0
SH24: A-6
926 BK 2.0
SH5: C-1
937 BK 3.0
SH22: B-1
1085 BK 0.8
SH22: A-1
928 BK 0.8
SP-014
STOP
X-044
A
TURN
GND2
C X-196
X-196
X-506
SP-027
970 BK 0.8
SH38: C-6
717 VT 0.8
SH38: B-6
766A VT 0.8
SH13: C-6
774 VT 0.8
SH40: B-6
766 VT 0.8
712 VT 1.0
A
M
A
1
B
712A VT 1.0
A
SH13: C-1 963 BK 2.0
SP-051
POSITION
767A VT 0.8
B X-232
980 BK 1.0
SH39: C-2
6
230 OR 0.8
SH40: C-1 SH38: C-1
719 VT 1.0 719 VT 1.0
SH25: C-6
718 VT 0.8
SH25: C-6
763 VT 0.8
SH38: C-1
780 VT 0.8
SH40: C-1
5
E
X-503
713 VT 1.0
A
SP-052
780 VT 0.8
B
SP-075
713A VT 1.0
540 VT 0.8
2
539 VT 0.8
4
X-233
X-231
S
1
SH5: D-6
X-229
1016 BK/WH 0.8
2
2
2
1
X-505
X-505 1
25
SP-168
1087 BK 0.8
SH28: B-6
1088 BK 8.0
SH5: C-1
5
CAN LO
6
CAN HI
THROTTLE SENSOR SUPPLY
17
THROTTLE SIGNAL
22
THROTTLE SENSOR GROUND
25
259 PK 0.8
SP-200
1070 BK/WH 0.8
211 PK 0.8
SH15: C-1
260 PK 0.8
SH9: C-2
544 YE 0.8
SH9: D-2
1066 BK/WH 0.8
SH15: D-1
195 OR 0.8
311 OR 0.8
SH18: A-6
320 OR 0.8
SH36: C-5
162 RD 0.8
SH14: A-1
310 RD 0.8
SH19: C-6
317 RD 0.8
SH4: C-6
140 RD 0.8
SP-139
305 YE 0.8
301 OR 0.8
7
CLUSTER SW POWER 1
1071 BK/WH 0.8
SH9: C-2
302 OR 0.8
8
CLUSTER SW POWER 2
SP-010 23
545 YE 0.8
SH14: A-1
SP-004
313 RD 0.8
9
24
234 YE 0.8
SH14: B-1
138 OR 0.8
SH4: D-1
CLUSTER UNSW POWER FUEL LEVEL SENDER
V-004 ACCESSORY BACKFEED DIODE 10
132 OR 0.8 267 YE 0.8
KEY IGNITION
11
AIR FILTER/ENGINE MALFUNCTION SEAT SWITCH CLUSTER INPUT
P
2
X-15
N
X-15
1
SP-009
153 WH 0.8
X-15
30
303 WH 0.8
SH15: D-1
START RELAY SIGNAL
32
622 WH 0.8
SH15: D-1
MAIN POWER RELAY SIGNAL
33
133 OR 0.8
SH15: C-1
CLUSTER GROUND
34
1011 BK/WH 0.8
SH5: D-6
12
SH15: C-1
205C YE 0.8
13
SH14: A-1
264 YE 0.8
16
HYDRAULIC OIL TEMP SENDER
SH26: B-1
250 YE 0.8
19
DOOR SWITCH SIGNAL
220 YE 0.8
X-15
SH15: C-1
328 YE 0.8
251 YE 0.8
137 WH 0.8
175 WH 0.8
SH19: C-1
SP-093
29
ACCESSORY RELAY SIGNAL
HYDRAULIC LOADER INTERLOCK SIGNAL REGENERATION INHIBIT SWITCH
X-C23
X-C23
X-505
26
WIPERS / WASHERS
SH13: D-1
838 RD 1.0
756 OR 1.0
SH19: D-6
405 OR 0.8
SH16: C-6
143 OR 0.8
SH28: C-1
27
INSTRUMENT CLUSTER
SP-058
152 OR 1.0
SH19: D-1
933 BK 1.0 2
KEY START OUTPUT
SP-201
SH27: B-6
250 YE 0.8
1
A-003
A/C COMP RELAY PIN 30
3
309 OR 1.0
SH16: B-6
SH26: D-6
HVAC BOX 935 BK 5.0
HYDRAULIC OIL FILTER
TURN
BOOM ROAD LIGHTS
1
500 YE 0.8
B
S-038 DOOR SWITCH
X-505
M
C
930 BK 0.8
5 X-229
HVAC GROUND
CDB-015
505 GN 0.8
194 OR 0.8
SH15: D-1
X-502A A
232 OR 0.8
GND
SH5: D-1
Z-014 REAR WIPER MOTOR 228 WH 0.8
POSITION
764A VT 0.8
B
932 BK 0.8
932 BK 0.8
TURN
LOW BEAM
764 VT 0.8
226 VT 0.8
X-228
980A BK 1.0
A
CDB-015
SH16: C-6
SH4: C-1
X-503
1
RH FRONT ROAD LAMP D
224 WH 0.8
5
X-233 D
SP-060
624 WH 0.8
SP-022
SP-023
233 OR 2.0
Z-002 X-231
225 WH 0.8
8 GND
4
741 VT 0.8 B
931 BK 0.8
2
2
742 VT 0.8
SH5: D-1
931 BK 0.8 1
3
229 OR 0.8
LOW BEAM
767 VT 0.8
SH15: D-1
2
7
SP-074
X-228
SH5: C-1
2
979A BK 1.0
D
SH28: B-1
SH36: C-5
X-506 1
LH FRONT ROAD LAMP
X-232 D
SP-059
913 BK 0.8
SH36: C-5
SH9: B-2
S-016 WIPER/WASHER SWITCH
1001 BK 0.8 SP-080
717 VT 0.8 716 VT 1.0
SH28: B-6
M-506 FRONT DOOR WAHERS PUMP
Z-001 979 BK 1.0
2
261 YE 0.8
X-044
1002 BK 0.8
X-230
912 BK 0.8
C
GND1
SP-170
SH5: B-1
SH15: D-1
1
X-080
SP-190
SH5: D-1
1095 BK 0.8
SH40: B-6 SH3: B-1
B
X-037
996 BK 2.0
RH TAIL LAMP POWER
929 BK 0.8
M
SH4: C-1
997 BK 2.0
REAR WORK LAMP POWER
2
C
X-502
998 BK 0.8
1
704 VT 0.8
231 OR 0.8
INSTRUMENT CLUSTER
X-037
999 BK 0.8
706 VT 3.0
220 YE 0.8
C
GND1 DOOR/CHASSIS INTERFACE
S
D
LH REAR ROAD LAMPS
X-049
SH38: B-1 SH40: B-1
SH27: B-6
A-001
A
227 WH 0.8
X-034
Z-009xx
B C
SH39: B-3
Z-010 DOOR WIPER MOTOR
X-035
P
1
728 VT 1.0
SP-079
734 VT 1.0
A
N
LH REAR WORK
X-039
X-049
P
1
729 VT 1.0
S-020 BLOWER SWITCH (LEFT CONSOLE) 1 HVAC FAN LOW
3
HVAC FAN MEDIUM
4
HVAC FAN HIGH
5
A/C COMP RELAY PIN 86
828 WH 3.0
3
2
827 WH 3.0
4
3
826 WH 3.0
5
4
825 OR 0.8
1
2
X-270
X-270
850 WH 5.0
6
SP-165
SP-164
848 WH 8.0
837 WH 0.8
X-097
SH16: D-1
IN
151 OR 0.8 821 OR 3.0
7
833 WH 0.8
SH14: C-1
BINARY PRESSURE SWITCH
8
834 WH 0.8
SH14: B-1
THERMOSTAT CLEAN GROUND
9
1012 BK/WH 0.8
HVAC RELAY PIN 87
10
842 OR 5.0
HVAC KEYED POWER
11
143 OR 0.8
SH29: D-1
A/C COMP RELAY PIN 87
12
841 OR 0.8
SH13: C-1
14
845 OR 5.0
SP-171
X-HVC1
844 OR 5.0
SH14: C-1
843 OR 5.0
SH14: C-1
K-020 CONDENSER RELAY
30
SH28: D-1
1087 BK 0.8
85 X-111
134 OR 2.0
87
87
85
86
SP-011
840 WH 0.8
C
829 WH 0.8 SP-157
3
SH14: C-1
824 YE 0.8
2
SGL
SH15: C-1
823 PK 0.8
1
PWR
SGL
SH14: C-6
824 YE 0.8
SH5: B-1
1013 BK 0.8
C
GND
SH15: C-6
822 OR 0.8
A
PWR
2 X-76
7
7
6
6
5
5
4
4
2
2 X-335
841C WH 0.8
3
3
834C WH 0.8
2
2
X-76
1
A A
833C WH 0.8
1
1
X-76
H-012 LH SPEAKER
1
1
1
1
219 RD 0.8
SH14: C-1
SH13: A-1
567 WH 0.8
2
2
2
2
549 WH 0.8
SH13: B-1
SH13: A-1
569 WH 0.8
3
3
3
3
561 WH 0.8
SH13: A-1
SH18: C-6
1045 TN 0.8
4
4
4
4
1047 TN 0.8
SH18: C-6
SH18: C-6
218 OR 0.8
7
7
7
7
217 OR 0.8
SH18: C-6
SH13: A-1
562 GN 0.8
8
8
8
8
548 GN 0.8
SH13: B-1
SH13: A-1
568 GN 0.8
9
9
9
9
560 GN 0.8
SH13: B-1
SH18: B-6
1046 BK 0.8
10 10
1048 BK 0.8
SH18: B-6
834 WH 0.8
SH40: B-1
834 WH 0.8
SH38: C-1
833 WH 0.8
SH40: B-1
833 WH 0.8
SH38: C-1
10 10 X-UJMR
453 WH 0.8
X-333 1
452 BL 0.8
SH38: B-1
841 WH 0.8
X-UJMR
215 RD 0.8
X-UJML
SH40: B-1
841 WH 0.8
X-011
H-009 HORN
Z-074 HVAC CONDENSER FAN
SH14: D-6
B
M
451 WH 0.8
X-332 1
S-040 HVAC HIGH PRESSURE SWITCH B B
X-252
D
9
SH26: C-1
913 BK 0.8
AC-COMP
X-76
450 BL 0.8
X-330 1
X-275
Y-002 A/C COMP
Z-019 WATER VALVE
9
SP-021 934 BK 0.8
H-011 RH SPEAKER
X-075
1
GND
912 BK 0.8
X-UJML
SH14: C-1
X-275
Z-017 TEMP CONTROL (LH CONSOLE) SH26: D-1
130 OR 0.8
X-331 1
B
X-111
151 OR 0.8
SH16: D-1
A
30
86
SH15: D-1
S-017 A/C SWITCH (LEFT CONSOLE)
87A
839 RD 3.0
1
SH13: D-1
237 WH 3.0
SH13: D-1
1
X-335
SH15: C-1
846 OR 8.0
854 OR 8.0
2
800 OR 0.8
SH5: D-6
SP-163
SP-162
2
X-097
SH15: C-1
THERMOSTAT PRESSURE SW
HVAC RELAY FUSE POWER
916 BK 0.8
237 WH 3.0
SH39: B-3
1084 BK 3.0
SH5: C-1
X-HORN-PWR
892 WH 0.8
SH5: B-1
1 X-HORN-GND
955 BK 0.8
1
M A
X-271
X-74
28
HVAC
29
RADIO
30
UJM CONNECTORS
TELEMATICS X-TELE
SH5: A-6 X-323
SH14: D-6
419 LG 0.8
925 BK/WH 0.8
419 LG 0.8
1
SH14: D-6
418 GY 0.8
2
SH14: D-6
410 WH 0.8
3
SH38: A-6
133B OR 0.8
SH14: A-6
357 OR 1.0
D D
SH2: B-1
351 OR 1.0
E E
SH14: B-6
C C
418 GY 0.8
SH40: A-6 CDB-002
SH14: B-6
SH14: D-6
411 TN 0.8
411 TN 0.8
4
F
SH20: B-6
416 VT 0.8
5
416 RD 0.8
H H
SH14: D-6
417 RD 0.8
6
417 VT 0.8
G G
SH5: B-1
982 BK 5.0
7
987 BK 0.8
B B
SH13: B-6
856 WH 1.0
8
SH3: C-1
420 OR 3.0
9
423 YE 0.8
982 BK 0.8 856 WH 0.8
SP-982 SP-073
1
TELEMATICS GROUND
2
2
TELEMATICS IGNITION POWER
3
3
TELEMATICS CAN HI
4
4
TELEMATICS CAN LO
5
5
6
6
TELEMATICS RS232 TX
7
7
TELEMATICS RS232 RX
8
8
TELEMATICS ENGINE ON
422 WH 0.8
J
420 OR 3.0
K K L
CDB-002
SP-503B
504B GN 0.8 CDB-012
802 OR 0.8
133B OR 0.8 503B YE 0.8
503E YE 0.8
SH20: B-6
504E GN 0.8
SH15: C-6
208 BL 0.8
SH13: C-6
207A TN 2.0
SH4: B-6
423 YE 0.8
10
SP-186
F
SH14: D-6
SH21: C-1
1
X-107
CDB-012
CDB-009
SP-504B
503D YE 0.8
X-019
CDB-009
504D GN 0.8 not used
SP-207
207 TN 0.8
244 YE 0.8
SH21: C-6
431 WH 0.8
1100 BL 0.8
1
1
2
2 X-019
1099 BL 0.8
SP-193
J
L
X-323A
not used
9
9
not used
10
10
X-040
SH11: C-2
308 YE 0.8
11
11
VEHICLE WORKING CONDITION
SH2: A-1
336 RD 1.0
12
12
TELEMATICS UNSWITCHED BATTERY
1101 BL 0.8
2
2
1
1
X-107
SH21: D-6
430 WH 0.8
X-040
421 WH 0.8
TELEMATICS DIAGNOSTIC
X-066 A A
SH14: B-1 SH5: D-6
988 BK 0.8
B B
910 BK/WH 0.8 910A BK/WH 0.8
SH13: D-1 X-066
X-TELE_DIAG
SP-190
206 BK/WH 0.8
31
GROUND
207 TN 2.0
SH13: C-1
207 TN 0.8
2
TELEMATICS RS232 RX
SH15: C-1
208 BL 0.8
3
TELEMATICS RS232 TX
NOT USED
MULTIFUNCTION CONNECTORS
1
TELEMATICS
4
32
MULTIFUNCTION JUMPER
33
RAC 48144044 S2S2
Diagram
SYMBOLS
Diagram
SH01 - TITLE PAGE
SH21 - UNIT CONTROL MODULE
SH02 - MAIN POWER DISTRIBUTION
SH22 - LAMPS
SH03 - ACCESSORY POWER DISTRIBUTION
SH23 - INDICATORS
SH04 - IGNITION / CHARGING SYSTEM
SH24 - EU LIGHT ADAPTER
SH05 - GROUNDING SYSTEM
SH25 - BOOM ROAD LIGHTS
SH06 - ENGINE F5C T4
SH26 - WIPERS / WASHERS
SH07 - ENGINE F5C T4
SH27 - INSTRUMENT CLUSTER
SH08 - ENGINE F5C T4
PRESSURE SWITCH
LAMP
SPEAKER
TEMPERATURE
PRESSURE
DIODE
MOTOR
LIGHT EMITTING DIODE (LED) X-113
SH18: C-1
SH28 - HVAC
SH09 - THROTTLE SENSORS
SH29 - RADIO
SH10 - ET PUMP / HYDRAULICS
SH30 - UJM CONNECTORS
SH11 - HYDRAULIC INTERLOCKS
359 OR 0.8
SH18: C-1
427 RD 0.8
F
F
SH33 - MULTIFUNCTION JUMPER
SH14 - BULKHEAD CONNECTION
SH34 - 2ND AUX
SH15 - BULKHEAD CONNECTION
SH35 - DIAGNOSTIC CONNECTOR
SH16 - LEFT-HAND CAB CONSOLE
SH36 - FUEL FILTER JUMPER
S.P. D.T.
D.P. S.T.
FUSE
RELAY
BATTERY
GROUND
SH13: B-1
SH18 - RIGHT NH CONTROL HANDLE
SH38 - CHASSIS INTERFACE
SH19 - RIGHT NH CONTROL HANDLE
SH39 - CHASSIS INTERFACE X-900 / X-901 MD
SH20 - UNIT CONTROL MODULE
SH40 - CHASSIS INTERFACE X-900 / X-901 MD
CIRCUIT DIAGRAM LEGEND WIRE ID
SHEET 799 VT 0.8 SPLICE SP-123
COLOR ABBREVIATION BLACK BK BLUE BL LIGHT BLUE LB BLACK/WHITE BK/WH GREEN GN LIGHT GREEN LG ORANGE OR PINK PK VIOLET VT RED RD GREY GY TAN TN WHITE WH YELLOW YE
129 OR 1.0
SP-089
505 GN 0.8
SH13: B-1
CDB-013
SH14: B-1
504A GN 0.8
SH14: C-1
248 YE 0.8
856 WH 1.0
SH15: B-1
B B
CDB-022
110 OR 2.0
528E OR 2.0
719 VT 1.0
SH21: B-6
895 WH 0.8
1
1
FUEL FILTER
TO ENGINE 1201 BK 0.8
D
E
E
F
F
G
G
H
H
J
J
2
X-9000
1
2
2
3
3
4
4
5
5
6
6
7
7
8
8
9
9
10
10
11
11
12
12
13
13
14
14
15
15
16
16
17
17
18
18
110 OR 2.0
SH6: C-6
528E OR 2.0
SH8: B-6
719 VT 1.0
SH25: A-6
895 WH 0.8
SH38: C-6
SH6: D-1
SH8: D-1
161 YE 0.8
20
20
161 YE 0.8
SH6: C-6
SH13: A-6
780 VT 0.8
22
22
780 VT 0.8
833 WH 0.8
23
23
833 WH 0.8
SH14: B-6
834 WH 0.8
24
24
834 WH 0.8
SH28: B-1
25
25
SH25: B-6
717 VT 0.8
26
26
717 VT 0.8
SH25: C-6
27
27 28
29
29
704 VT 0.8
SH25: C-6
SH25: B-6
766A VT 0.8
30
30
766 VT 0.8
SH25: C-6
31
31
32
32
241A OR 1.0
SH6: B-6
33
33
34
34
504C GN 0.8
35
35
503C YE 0.8
36
36
37
37
38
38
SH14: B-6
CDB-003
SH14: B-6 SH15: C-6
504C GN 0.8 503C YE 0.8
622 WH 0.8
SH20: B-1
532 YE 0.8
SH39: B-6
626 WH 0.8
SP-102
626 WH 0.8
909 BK 0.8
SH6: C-6
133E OR 0.8
10
10
10
10
1137 OR 0.8
PWR
3
GND
2
OUT
1 X-011
SH37: C-1
895 WH 0.8
SH39: C-1
14
14
14
896 WH 0.0
14
895 WH 0.8
963 BK 2.0
J29
1
1
1
1
P
H-002
N
X-205
SH25: B-1
CHASSIS POWER
28
CDB-003
1151 YE 0.8
9
SH28: A-1
704 VT 0.8
121 YE 0.8
8
9
SH25: A-6
SH2: B-1
SH8: D-6
8
9
X-201
SH14: C-6
241C OR 0.8
8
9
J28
248 YE 0.8
SH2: B-1
8
S-045
19
21
150 YE 0.8 908E BK 0.8
WATER IN FUEL SWITCH
19
21
SH6: D-6 SH6: D-6
X-011
248 YE 0.8
2
X-201
X-205 1
35
DIAGNOSTIC CONNECTOR DOOR/CHASSIS INTERFACE
SH14: C-6
X-9000
X-9001
CDB-022
508 BL 0.8
34
2ND AUX
SH3: A-1
2
D
DIAGRAM SHOWN WITH VEHICLE PARKED & POWER OFF
SH2: A-6
2
C
X-DIAG
34
1200 YE 0.8
506 GN 0.8
507 WH 0.8
SH15: B-1
X-401
SH2: B-1
1
C
CAN DIAGNOSTIC CONNECTOR
CHASSIS INTERFACE X-900
1
B
NOTE:
TABLE OF CONTENTS / STANDARD SYMBOLS
X-9001
B
CDB-014
501 YE 0.8
SP-090
CDB-013
503A YE 0.8
CDB-014
A A
RH HANDLE INTERCONNECT F
WIRE SIZE CHART Sq. mm AWG 0.5 20 0.8 18 1.0 16 2.0 14 3.0 12 5.0 10 8.0 8
A
CDB-015
500 YE 0.8
SH27: C-6
X-401
SH37 - CHASSIS INTERFACE X-900 / X-901
162 RD 0.8 CDB-015
D.P. D.T.
SH14: B-1
SH17 - LEFT NH CONTROL HANDLE
COLOR WIRE SIZE
SH27: C-6
X-113 S.P. S.T.
A
E E
SH32 - TELEMATICS
GRID LOCATION
X-DIAG
961 BK/WH 0.8
SH27: C-6
SH13 - BULKHEAD CONNECTION
SH5: B-1
SH14: D-1
SH31 - MULTIFUNCTION CONNECTOR
SH12 - LOADER VALVE AND SENSORS
D D
SH5: D-6
COIL
RESISTOR
VARIABLE RESISTOR
425 VT 0.8
121 YE 0.8
CDB-001
CDB-001
X-314
SH2: B-1 SH13: D-6
SH6: C-6
SH2: C-1
SH6: D-1 SH6: D-1
155A OR 3.0
1
1
155A OR 3.0
SH6: D-6
237 WH 3.0
2
2
237 WH 3.0
SH28: A-1
706 VT 3.0
3
3
706 VT 3.0
SH25: C-6
212A OR 5.0
4
4
212A RD 5.0
SH6: C-6
626 WH 0.8
SH6: C-6
212 OR 8.0 SP-212
X-314
SH13: C-6
841 WH 0.8
39
39
841 WH 0.8
SH28: B-1
SH20: B-6
721 VT 0.8
40
40
721 VT 0.8
SH25: C-6
SH32: D-5
133B OR 0.8
41
41
133B OR 0.8
SH6: C-6
SH2: C-1
703 VT 0.8
43
43
703 VT 0.8
SH25: C-6
44
44
SH15: D-6
267 YE 0.8
45
45
267 YE 0.8
SH4: C-6
SH8: C-1
112 BL 0.5
46
46
47
47
42
42
X-315
SH5: B-1
1087 BK 5.0
2
212B OR 5.0
1
REMOTE POWER/GROUND
SH14: B-6
234 RD 0.8
234 RD 0.8
CHASSIS INTERFACE
36
GCU POWER
B-002
CHASSIS INTERFACE X-900 / X-901 LG
X-014
B B X-014
A A
X-313
X-195
FUEL LEVEL SENDER
X-901
FUEL FILTER JUMPER
X-315
SH6: C-6
112 BL 0.5
X-014
956 BK 0.8
GCU FUSE
SH5: C-1
X-014
234 RD 0.8
1
212 OR 8.0
SP-212
212A OR 8.0
1
X-313
SH39: A-1
37
SH6: C-6
212 OR 8.0
1
38
CHASSIS INTERFACE
CROSSOVER BULKHEAD X-900 SH13: C-6
769 OR 2.0
1
1
2
2
3
3
769 OR 2.0
SH24: D-6
SH2: B-1
110 OR 2.0
4
4
110 OR 2.0
SH6: C-6
SH2: D-1
156 RD 2.0
5
5
156 RD 2.0
SH24: D-6
6
6
SH2: B-1
241C OR 0.8
7
7
241C OR 0.8
SH7: D-1
SH6: B-6
242 YE 0.8
8
8
242 YE 0.8
SH6: A-6
SH6: B-6
245 YE 0.5
9
9
245 YE 0.5
SH6: A-6
SH6: B-6
249 YE 0.5
10
10
249 YE 0.5
SH6: A-6
SH6: A-6
252 BK 0.5
11
11
252 BK 0.5
SH6: A-6
SH6: A-6
253 PK 0.5
12
12
253 PK 0.5
SH6: A-6
SH3: A-1
719 VT 1.0
13
13
719 VT 1.0
SH25: A-6
SH6: B-1
270 BK/WH 0.5
14
14
270 BK/WH 0.5
SH6: A-1
SH6: A-1
271 YE 0.5
15
15
271 YE 0.5
SH6: A-1
16
16
17
17
SH21: B-6
895 WH 0.8
SH38: C-6
18
504C GN 0.8
SH6: D-1
19
248 YE 0.8
SH6: D-1
22
22
780 VT 0.8
SH25: A-6
833 WH 0.8
23
23
833 WH 0.8
SH28: A-1
SH14: B-6
834 WH 0.8
24
24
834 WH 0.8
SH28: B-1
SH25: B-6
717 VT 0.8
26
26
717 VT 0.8
SH25: C-6
SH2: B-1
704 VT 0.8
29
29
704 VT 0.8
SH25: C-6
SH25: B-6
766 VT 0.8
30
30
766 VT 0.8
SH25: C-6
SH14: A-6
503C YE 0.8
31
31
503C YE 0.8
SH6: D-1
SH8: D-6
121 YE 0.8
33
33
121 YE 0.8
SH6: C-6
SH37: B-6
626 WH 0.8
36
36
626 WH 0.8
SH6: C-6
SH13: C-6
841 WH 0.8
39
39
841 WH 0.8
SH28: B-1
SH20: B-6
721 VT 0.8
40
40
721 VT 0.8
SH25: C-6
SH32: C-5
133B OR 0.8
41
41
133B OR 0.8
SH6: C-6
SH14: B-6
234 RD 0.8
42
42
234 RD 0.8
SH37: A-1
SH2: C-1
703 VT 0.8
43
43
703 VT 0.8
SH25: C-6
SH15: D-6
267 YE 0.8
45
45
267 YE 0.8
SH4: B-6
20
20
161 YE 0.8
SH6: C-6
895 WH 0.8
SH14: A-6
504C GN 0.8
18
SH14: C-6
248 YE 0.8
19
SH13: A-6
780 VT 0.8
SH14: B-6
SH8: D-1
161 YE 0.8
X-901 CHASSIS INTERFACE
CHASSIS INTERFACE X-900 / X-901 MD
ELECTRICAL SCHEMATIC TIER 4B (FINAL) ELECTRO-HYDRAULIC (EH) CONTROLS Skid Steer Loaders: SR210 - NGM418237 and above SR210 - NHM435463 and above SR240 - NGM418237 and above SR240 - NHM435463 and above SV280 - NGM418237 and above SV280 - NHM435463 and above
Compact Track Loaders: TR270 - NGM418237 and above TR270 - NHM435463 and above TR310 - NGM418237 and above TR310 - NHM435463 and above TV370 - NHM435453 and above
BATTERY POWER STARTING SEQUENCE SWITCHED POWER POWER RELAY OUTPUT 39
EU LIGHT ADAPTER
24
RAC 48144044 RAC 48144044 S3S1
RIGHT HAND TOWER CHASSIS HARNESS - MECHANICAL AND ELECTRO-HYDRAULIC DRIVE
CHASSIS HARNESS - ELECTRO-HYDRAULIC DRIVE (WITH ENHANCED HIGH FLOW AUXILIARY HYDRAULICS -EHF)
CAB HARNESS - CLOSED (DELUXE) CAB - ELECTRO HYDRAULIC DRIVE
CHASSIS HARNESS - MECHANICAL DRIVE
CAB HARNESS - CLOSED (DELUXE) CAB - MECHANICAL DRIVE
CHASSIS HARNESS - ELECTRO-HYDRAULIC DRIVE (NO ENHANCED HIGH FLOW AUXILIARY HYDRAULICS -EHF)
CAB HARNESS - OPEN CAB - MECHANICAL DRIVE
CAB HARNESS - OPEN CAB - ELECTRO HYDRAULIC DRIVE
RAC 48144044 S3S2
Diagram
Diagram
SH01 - TITLE PAGE
SH19 - EH AUX PWM
SH02 - MAIN POWER DISTRIBUTION LG
SH20 - LAMPS
SH03 - MAIN POWER DISTRIBUTION MD
SH21 - INDICATORS
SH04 - MAIN POWER DISTRIBUTION MD
Z-FUSE2 POWER DISTRIBUTION-CHASSIS F-007
SYMBOLS
ACC/BEACON
PRESSURE SWITCH
SH05 - ACCESSORY POWER DISTRIBUTION LG
SH23 - BOOM AND ROAD LIGHTS
SH06 - ACCESSORY POWER DISTRIBUTION MD
SH24 - WIPER / WASHER
LAMP
SH7: C-1
160 RD 0.8
SH7: A-1 2
115 RD 2.0
SH14: D-1
1
836 RD 3.0
SH14: D-1
2
26
310 RD 0.8
SH14: C-1
2
3
2
20.0 A
830 OR 3.0
SH7: C-1
116 RD 2.0
SH20: A-6
710 VT 2.0
SH5: B-1
LIGHT EMITTING DIODE (LED)
SPEAKER
SH7: A-1
1
SH26 - HVAC
1
9
1
SH09 - ENGINE F5C T4
SH27 - RADIO
SH10 - ENGINE F5C T4
SH28 - MULITFUNCTION CONNECTORS
SH11 - ENGINE F5C T4
SH29 - TELEMATICS
SH12 - THROTTLE SENSORS
SH30 - MULTIFUNCTION JUMPER
SH13 - AUXILIARY HYD INTERLOCK SWITCH
SH31 - DIAGNOSTIC CONNECTOR
SH14: B-4
X-FUSE2
30
144 OR 0.8
34
86
SH32 - FUEL FILTER JUMPER
SH15 - LEFT-HAND CAB CONSOLE
SH33 - CHASSIS INTERFACE
SH16 - LEFT-HAND NH CAB CONSOLE
SH34 - CHASSIS INTERFACE
S.P. D.T.
D.P. S.T.
33
85
21
136 OR 1.0
SP-036
IGNITION
19
350 OR 1.0
1
14
325 WH 0.8
86
20
326 OR 1.0
87A
7
87
13
85
1
30
D.P. D.T.
1
SH7: B-1
113 RD 1.0
24
30
SH14: B-4
709 WH 0.8
36
86
1
33
1
COLOR ABBREVIATION BLACK BK BLUE BL LIGHT BLUE LB BLACK/WHITE BK/WH GREEN GN LIGHT GREEN LG ORANGE OR PINK PK VIOLET VT RED RD GREY GY TAN TN WHITE WH YELLOW YE
CIRCUIT DIAGRAM LEGEND WIRE ID
SHEET 799 VT 0.8 SPLICE SP-123
WIRE SIZE CHART Sq. mm AWG 0.5 20 0.8 18 1.0 16 2.0 14 3.0 12 5.0 10 8.0 8
SH14: B-1
139 OR 0.8
16
87
35
85
23
56
528D OR 1.0
1
87
15
85
3
15
2
27
20.0 A
SH5: B-1
1098 BK 0.8 707 VT 2.0
SH33: D-6
528E OR 2.0
SH9: B-1
528A OR 8.0
SH14: A-1
135 OR 2.0
SH7: A-1
255 RD 2.0
SH14: D-1
792 VT 3.0
SH14: D-1
701 VT 0.8
SH14: D-1
700 VT 0.8
SH14: A-4
705 VT 3.0
SH14: A-1
243 OR 2.0
788 VT 3.0
SH14: A-4
325 WH 0.8
1
948 BK 0.8
22
20.0 A
2
50
241A OR 1.0
SH33: B-6
25
134 OR 2.0
SH14: C-1
113 RD 1.0
87
9
85
1
7
CRANK 1
SP-194
30.0 A
1
SP-036
SH14: B-4
709 WH 0.8
1
1
1
85
50
2
5.0 A
1
13
27
945 BK 0.8
37
2
15.0 A
703 VT 0.8
SH33: A-6
704 VT 0.8
SH33: B-6
SH7: B-1
117 RD 3.0
SH14: B-1
139 OR 0.8
37
2
15.0 A
WIPER/WASHER
31
1
2
30.0 A
1
30
4
3
820 OR 3.0
SH14: A-4
10.0 A
2
10
300 OR 1.0
SH14: A-4
20.0 A
2
17
134 OR 2.0
SH14: C-1
30.0 A
2
31
255 RD 2.0
SH7: A-1
86
12
15.0 A
2
33
708 VT 3.0
SH14: B-4
2
9
351 OR 1.0
SH8: D-1
2
26
233 OR 2.0
SH14: D-4
IGNITION
87
11
85
3
13
350 OR 1.0
1
15.0 A
948 BK 0.8
F-031
30
61
798 VT 5.0
SH14: D-4
25
233 OR 2.0
SH14: D-4
X-FUSE1
X-FUSE1
SH14: A-1
125 OR 3.0
SH14: B-4
707 VT 2.0
30.0 A
SH7: C-6
1098 BK 2.0
SH6: B-6
975 BK 0.8
X-FUSE2
X-FUSE2
SH14: A-1
243 OR 2.0
SH14: D-1
792 VT 3.0
SH9: D-6
256 RD 2.0
SH14: A-1
135 OR 2.0
2
MAIN POWER DISTRIBUTION LG
1
X-FUSE1
SP-194
F-049
788 VT 3.0
2
F-029
X-FUSE1
FRONT WORK LAMPS 1
SH14: C-1
SIDE LAMPS
SH34: B-5
706 VT 3.0
F-050
67
310 RD 0.8
WIPER/ WASHER
REAR WORK LAMPS 1
1
87A
F-001
43
18
F-027
F-006
1
2
F-028
SH14: B-4
708 VT 3.0
62
RH TAIL LAMP
56
30.0 A
21
ACCESSORY RELAY
49
2
5.0 A
5.0 A
F-026
SH9: C-6
256 RD 2.0
LH TAIL LAMP 68
SH14: D-1
ACCESSORY 21
86
22
F-002
TABLE OF CONTENTS / STANDARD SYMBOLS
14
326 OR 1.0
K-013
2
15.0 A
115 RD 2.0
F-025
87
F-003
SIDE LAMPS
2
CRANK
38
2
2
INSTRUMENT CLUSTER
946 BK 0.8
30
14
SH14: D-1
F-024
87A SH7: A-1
2
836 RD 3.0
HVAC
X-FUSE2
44
DIAGRAM SHOWN WITH VEHICLE PARKED & POWER OFF
1
5
K-012
7.5 A
1
UNSWITCHED BATTERY
86
10
2
F-023
30
2
20.0 A
947 BK 0.8
SH34: B-5
155A OR 3.0
1
LIGHTS #2 RELAY
ACCESSORY
55
SH14: A-4
SH33: D-6
F-047
X-FUSE1
125 OR 3.0
110 OR 2.0
SH4: C-6
Z-FUSE1 POWER DISTRIBUTION-CHASSIS
X-FUSE1
NOTE:
2
X-FUSE2
SH14: A-1
SH14: A-4
F-019
945 BK 0.8
30
86
300 OR 1.0
ENGINE SENSOR
87A
4
7.5 A
15
K-011
F-016
K-001
117 RD 3.0
14
2
10.0 A
ECU 2
ACCESSORY RELAY
SH18 - SEAT
85
LIGHTS #1 RELAY
F-011
SP-528 528C OR 3.0
31
SH7: B-1
144 OR 0.8
86
24
25.0 A ACC/BEACON
87A
ECU 1
21
946 BK 0.8
K-004
SH35 - CHASSIS INTERFACE
87
SH8: C-1
351 OR 1.0
F-012
528B OR 3.0
BATTERY
GROUND
SH14: B-4
1
F-022
6
13
2
15.0 A
INSTRUMENT CLUSTER
87A
RELAY
118 RD 1.0
5
136 OR 1.0
X-FUSE2
LIGHTS #2 RELAY
FUSE
SH7: B-1
23
30
F-009
2
SH14 - BULKHEAD CONNECTION
87
K-002
S.P. S.T.
SH14: A-4
820 OR 3.0
F-021
COMPRESSOR
87A
F-008
LIGHTS #1 RELAY
SH14: A-4
K-010
Z-FUSE2 POWER DISTRIBUTION-CHASSIS
COIL
RESISTOR
VARIABLE RESISTOR
22
30.0 A
Z-FUSE2 POWER DISTRIBUTION CHASSIS
MAIN POWER RELAY
16
SH7: A-1
835 RD 3.0
Z-FUSE1 POWER DISTRIBUTION CHASSIS
F-046
HVAC
87A
118 RD 1.0
5.0 A
SH7: C-1
114 RD 1.0
710 VT 2.0
F-005
32
SH7: B-1
160 RD 0.8
116 RD 2.0
UNSWITCHED BATTERY
947 BK 0.8 Z-FUSE1 POWER DISTRIBUTION-CHASSIS
SH7: B-1
2
25.0 A
830 OR 3.0
SH7: C-1 SH20: A-6
COMPRESSOR
K-003
SH08 - IGNITION
COLOR WIRE SIZE
835 RD 3.0
7
1
MAIN POWER RELAY
SH25 - INSTRUMENT CLUSTER
SH5: B-1
SH7: A-1
DIODE
MOTOR
TEMPERATURE
PRESSURE
SH07 - GROUNDING SYSTEM
GRID LOCATION
8
F-051
SH22 - EU LIGHT ADAPTER
SH17 - RIGHT-HAND NH CONTROL HANDLE
114 RD 1.0
SH7: C-1
3
MAIN POWER DISTRIBUTION MD
355 OR 0.8 Z-FUSE1 POWER DISTRIBUTION-CHASSIS
Z-FUSE2 POWER DISTRIBUTION-CHASSIS F-004
K-007
FRONT ELECTRIC RELAY SH7: B-1
Z-FUSE2 POWER DISTRIBUTION CHASSIS
SH14: D-4
103 RD 3.0
58
30
146 WH 0.8
70
86
F-032
ECU 1
1
15
528B OR 3.0
1
57
2
7.5 A
11
SH35: D-5
110 OR 2.0
SH7: B-1
104 RD 2.0
40
30
SH14: D-4
148 WH 0.8
52
86
FLASHER/BRAKE 20A
22
1
SH14: A-4
705 VT 3.0
51
85
39
SP-192
68
1
45
25
SH34: B-5
706 VT 3.0
10
SH30: B-5
354 OR 0.8
SH7: C-1
119 RD 1.0
63
700 VT 0.8
SH14: D-1
SH7: B-1
2
41
SH14: D-4
798 VT 5.0
101 RD 2.0
SH20: A-6
714 VT 1.0
SH20: A-6
5.0 A
35
SH14: D-1
701 VT 0.8
34
715 VT 1.0
528F OR 5.0
1
38
528D OR 1.0
SH7: D-1
2
5.0 A
7.5 A
62
2
420 OR 3.0
36
55
1094 BK 0.8
HIGH FLOW / COUPLER 1
15.0 A
2
4
SH14: D-4
FE #1, #2, #3 1
7.5 A
SH35: A-5
703 VT 0.8
34
SH7: D-1
SH10: B-6
241A OR 1.0
FE ON/OFF 1
10.0 A
2
LH BOOM 1
10.0 A
2
64
129 OR 1.0
SH30: C-2
40
716 VT 1.0
SH23: B-5
1
10.0 A
28
2
SH14: D-4
FUSE RELAY GROUND 1
43
2.0 A
2
FUSE RELAY GROUND 1
67
1095 BK 0.8
2.0 A
2
FUSE RELAY GROUND 1
49
947 BK 0.8
SH2: D-6
37
1092 BK 0.8
SH7: D-6
X-161
2.0 A
2
61
1
1
X-162
4
SH14: B-4
206 BK/WH 0.8
SH5: B-1
1092 BK 0.8
958 BK 0.8
SH13: B-5
959 BK 0.8
SH14: C-4
978 BK 0.8
SH13: C-5
1900 BK 0.8
981 BK 0.8
SH28: C-5
982 BK 5.0
1091 BK 2.0
960 BK 0.8
SH26: A-6
1013 BK 0.8
968 BK 2.0
1
SP-173
1094 BK 13.0
1
GND-011
X-CAB_GNDB
910 BK/WH 0.8
SH26: B-6
1088 BK 8.0
SH24: C-6
937 BK 3.0
GND-001
SP-043
1093 BK 13.0
SH24: A-6
ECU_GND
SP-041
956 BK 0.8
SH8: D-1
907 BK 0.8
SH9: A-6
1086 BK 2.0
SH22: C-1
981 BK 0.8
114 RD 1.0
SH3: D-1
119 RD 1.0
SH5: C-6
119 RD 1.0
SH29: B-4
160 RD 0.8
SH2: D-6
114 RD 1.0
SH2: D-6
116 RD 2.0
SH3: D-6
116 RD 2.0
SH2: D-6
160 RD 0.8
SH3: D-1
744 OR 2.0
SH6: C-1
X-163
1
1
X-164
725 VT 0.8
SH33: A-6
967 BK 8.0
1 CHS_GND_RR
SP-177 965 BK 3.0
S-042
SWITCH OPTIONAL
SP-176
2
965 BK 3.0
G-002
BATTERY
X-POS_TERM
SH5: D-6
103 RD 3.0
SH5: D-6
118 RD 1.0
SH2: C-6
113 RD 1.0
SH2: C-6
101 RD 2.0
SH5: C-6
103 RD 3.0
SH6: C-6
118 RD 1.0
SH3: D-6
113 RD 1.0 101 RD 2.0 255 RD 2.0
1
835 RD 3.0
1
109 RD 19.0
GND-003
SP-044
107 RD 8.0
SP-042
830 OR 3.0 255 RD 2.0 835 RD 3.0 830 OR 3.0
GND-005
GROUNDING SYSTEM
1
X-OPT_POS-PWR
102A RD 85.0
25.0 A
2
42
420 OR 3.0
SH28: C-5
104 RD 2.0
28
2
44
129 OR 1.0
SH30: C-2
2
28
716 VT 1.0
SH23: B-5
2
20
719 VT 1.0
SH35: C-5
16
101 RD 2.0
SH7: A-1
F-044
FE ON/OFF
30
145 OR 0.8
87
35
48
1
743 OR 0.8
10.0 A F-045
148 WH 0.8
36
86
85
SP-192 27
32
972 BK 0.8
1
10.0 A F-030
X-FUSE1
RH BOOM
1
975 BK 0.8
10.0 A F-039
FLASHER / BRAKE
354 OR 0.8 12
714 VT 1.0
1
20.0 A
2
715 VT 1.0 156 RD 2.0 X-FUSE2
721 VT 0.8
SH35: A-5
S-016
MECHANICAL BRAKE SWITCH
759 OR 0.8
X-167
1
2
2
X-167
5
6
ACCESSORY POWER DISTRIBUTION MD
SH7: A-6
907 BK 0.8
ELECTRICAL SCHEMATIC
B+(3) W(2)
1
X-005A
3
127 OR 0.8
SH29: C-4
244 YE 0.8
3
1
4
4
2
2
2
SP-039
127A OR 0.8 124 YE 0.8 244A YE 0.8
SH9: D-1
520 WH 2.0
1
520A WH 2.0
3 X-006A
1
802 OR 0.8 832 OR 0.8
893 WH 0.8 1890 OR 0.8
STARTER HOLD-IN 520 WH 2.0
SH35: A-5
891 OR 0.8
M-003 STARTER MOTOR
SH9: C-1
SH3: B-1
133B OR 0.8 1890 OR 0.8
X-006
SH14: A-1
351 OR 1.0
TIER 4B (FINAL) MECHANICAL HYDRAULIC CONTROLS
SH13: D-6 SH29: D-4 SH17: C-6 SH16: B-6 SH33: C-6
Skid Steer Loaders: SR210 - NGM418237 and above SR210 - NHM435463 and above SR240 - NGM418237 and above SR240 - NHM435463 and above SV280 - NGM418237 and above SV280 - NHM435463 and above
SH13: C-5
133B OR 0.8
SH33: A-6
351 OR 1.0
SH2: C-1
1
X-STARTER
STARTER PULL-IN
B_START
SH7: A-1
102A RD 85.0
GND
M
SH2: B-6
104 RD 2.0
1
X-FUSE2
SH3: B-6
104 RD 2.0
106 RD 13.0
984 BK 13.0
SH33: A-1
SH30: D-5
GND-008
SP-175
980 BK 1.0
950 BK 3.0
D+(1)
SH29: D-4
117 RD 3.0
975 BK 3.0
1084 BK 3.0
X-508
1
GND-002
SH26: B-6
2
X-CAB_GNDA
1
908A BK 8.0
950 BK 3.0
X-508
CHARGE INDICATOR
SH31: C-5 SH26: A-1
117 RD 3.0
SP-172
108 RD 19.0
SH10: D-6
SH23: C-6
558 OR 0.8
SH20: A-6 SH35: D-5
G-001
SH14: D-3
1016 BK/WH 0.8
GND-004
975 BK 3.0
SH14: C-4
ALTERNATOR
SH25: A-1
1012 BK/WH 0.8
SP-040
942 BK 3.0 SP-029
939 BK 2.0 933 BK 1.0
1
X-508
SH9: C-6
961 BK/WH 0.8
GND-010
932 BK 0.8
SH18: C-1
SH23: C-6
SH14: B-1
925 BK/WH 0.8
X-TELE_GND
931 BK 0.8
SH22: A-6
SH23: B-6
949 BK 0.8
105 RD 3.0
952 BK 0.8
2
1
PHASE
1
SP-181
939 BK 5.0
941 BK 0.8
SH23: A-5
SH17: C-1
908A BK/WH 8.0
GND-013
CHS_GND_FRT
983 BK 13.0
SP-179
940 BK 3.0
SH15: B-1
SH23: C-6
SH14: D-4
1104 BK 0.8
SH15: A-1
SH24: B-1
1
SP-092
955 BK 0.8
SH24: C-6
X-508
267 YE 0.8 267 YE 0.8
A
1098 BK 2.0
953 BK 0.8
SH24: C-1
SH35: A-1
1011 BK/WH 0.8
SH14: C-1
SH15: C-6
SH33: A-1
SH5: B-6
ECU_GND
SH16: C-1
SH19: B-1
SH13: B-5
951 BK 0.8
46
AIR FILTER RESTRICTION SWITCH
1095 BK 0.8
976 BK 0.8
20.0 A
S-037
SH7: C-6 SH5: B-6
1901 BK 0.8
SP-1902 1902 BK 0.8
979 BK 1.0
SH7: D-1
SH14: C-4
753 OR 0.8
SP-182
SP-174
SH3: A-6
SH16: B-1
X-166
751 OR 0.8
1008 BK 1.0
1087 BK 5.0
SH22: D-2
SH23: B-5
SP-183
1014 BK 8.0
SH13: B-5
SH34: B-5
GND-012
1900 BK 0.8
986 BK 8.0
SH13: D-2
SP-190
2
SH30: B-5 SH20: A-6
ACCESSORY POWER DISTRIBUTION LG
1
1094 BK 0.8
47
SH5: A-1
MECHANICAL BRAKE PRESSURE SWITCH 760 VT 0.8
S-020
1
SH2: B-6
1098 BK 0.8
S-030
MECHANICAL BRAKE SWITCH
X-166
1091 BK 2.0
2
744 OR 2.0
F-042
24
SH3: A-6
SP-053
MECHANICAL BRAKE PRESSURE SWITCH
X-NEG_TERM_A
974 BK 0.8
356 OR 3.0
X-FUSE1
X-FUSE2
S-035
SP-047 966 BK/WH 2.0
4
OPTION RELAY
SH33: C-6
719 VT 1.0
724 RD 0.8
901 BK/WH 0.8
39
1
87A
X-FUSE2
910 BK/WH 0.8
85
K-015
SH7: B-1
RH BOOM
2
FE HOT
720 RD 0.8
SH14: D-1
146 WH 0.8
86
15.0 A FE #1, #2, #3
149 OR 3.0
69
2
X-FUSE2
MAIN POWER DISTRIBUTION MD
47
43 48
1
F-041
87
744 OR 2.0
F-020
2
103 RD 3.0
40
8
30
F-020
1097 BK 0.8
X-FUSE2
SH19: D-1
87A
SH28: C-5
F-014
ENGINE SENSOR
SP-528
25.0 A
HIGH FLOW/ COUPLER
LH BOOM
F-038
SH9: C-6
1
F-040
FRONT ELECTRIC RELAY
FE HOT
SH35: B-5
704 VT 0.8
LH TAIL LAMP
1
SP-065
F-010
2
Z-FUSE2 POWER DISTRIBUTION CHASSIS
K-014
F-052
46
F-037
40
Z-FUSE1 POWER DISTRIBUTION CHASSIS
F-017
70
145 OR 0.8
RH TAIL LAMP
1
SH22: C-6
X-FUSE1
F-036
39
156 RD 2.0
F-015
2
15.0 A
16
F-013
FRONT WORK LAMPS 788 VT 3.0
2
SH7: B-1
F-035
SH3: C-6
SH29: C-4
X-FUSE2
972 BK 0.8
743 OR 0.8
15.0 A
336 RD 1.0
F-018
87
SH34: B-5
155A OR 3.0
38
Z-FUSE2 POWER DISTRIBUTION-CHASSIS
REAR WORK LAMPS
1
20.0 A
X-FUSE2
X-FUSE1
19
2
F-048
974 BK 0.8
F-034
29
5.0 A
87A
2
20.0 A
1
SP-065
149 OR 3.0
K-005
ECU 2 23
69
85
OPTION RELAY
F-033
528C OR 3.0
87
355 OR 0.8
TELEMATICS
44
87A
S-008 IGNITION SWITCH AUX
6
138 OR 0.8
SH25: B-1
1
132 OR 0.8
SH25: C-6
4
624 WH 0.8
SH25: C-6
Compact Track Loaders: TR270 - NGM418237 and above TR270 - NHM435463 and above TR310 - NGM418237 and above TR310 - NHM435463 and above TV370 - NHM435453 and above
BATTERY POWER
SH6: C-6 SH3: C-6 SH6: B-1
SH25: C-6
140 RD 0.8
3
IGN
STARTING SEQUENCE
X-009
SH3: B-1 SH3: D-1
SWITCHED POWER
SH3: D-6 SH2: A-6
START
SH2: D-6 SH2: D-6
X-009
POWER RELAY OUTPUT
SH8: B-6
7
IGNITION
8
RAC 48144045 RAC 48144045 S1S1
SH9: B-6 SH33: A-1
112 BL 0.5
SH8: C-6
SH9: B-6
908A BK 5.0
SH35: C-5
SH7: B-6
908A BK 8.0
SH34: D-5
908E BK 0.8
87A
SH3: A-1 SH35: B-5
256 RD 2.0
30
121 YE 0.8
34
86
87
33
85
25
X-FUSE1
520 WH 2.0 161 YE 0.8
X-FUSE1
110 OR 2.0
110 OR 2.0
SH2: B-1
42
256 RD 2.0
SH33: B-6
54
121 YE 0.8
53
86
41
85
X-FUSE1
SH8: C-6
520 WH 2.0
SH4: B-6 908A BK/WH 8.0
SP-908
3
908F BK/WH 5.0
1
527D RD 5.0
K-009 ECU MAIN RELAY
X-316
1
SP-527
527A RD 8.0
X-025
527B RD 8.0
3
527C RD 0.5
1
86
87
5
528A OR 8.0
SH2: A-6
85
2
112 BL 0.5
SH33: A-6
CDB-035
6
GND
CDB-035
504C GN 0.8
504C GN 0.8
25 CAN HI
54
TERMINAL 15 SW BATT+
27
CRANK ENABLE FROM ECU 1
19
AIR TEMP SENSOR SIGNAL
53
2
254 BK/WH 0.5
8
61
X-017
1110 WH 2.0
2
60
60
1111 WH 2.0
7
58
58
1112 WH 2.0
1
57
57
1113 WH 2.0
6
SH11: D-1
82
8 3 5
216 YE 0.5
52
GLOW PLUG UNIT COMMAND SIGNAL
235 YE 0.5
22
GLOW PLUG FEEDBACK SIGNAL
41
GLOW PLUG UNIT GND
239A BK 3.0
239 BK 0.8
SP-239
X-013
X-017
263 YE 0.5
81
265 BK/WH 0.5
36
DIFF PRESSURE SENSOR GND
26 26
25 25
527D RD 5.0
4
241B OR 0.8
X-014
241C OR 0.8
SH35: D-5
X-316
SH35: D-5
528A OR 8.0
14
X-079
528E OR 2.0
1
SH10: A-1
600 WH 0.8
2
242 YE 0.8
7
1
245 YE 0.5
64
LAMBDA SENSOR CURRENT PUMP
SH10: A-1
601 YE 0.8
3
E
E
F
F
G
G
H
H
3
3
5
5
SH35: C-5
6
DP
7
5
249 YE 0.5
86
LAMBDA SENSOR CURRENT ADJUST
2
252 BK 0.5
85
LAMBDA SENSOR VIRTUELLE GND
6
253 PK 0.5
63
LAMBDA SENSOR VOLTAGE NERNST
271 YE 0.5
83
84
1 X-006
272 BK/WH 0.5
2
CDB-010
278 WH 1.0
273 YE 0.5
1 X-007
87 X-012
SH9: A-6
601 YE 0.8
X-012
T°
SH11:A-4
242 YE 0.8 245 YE 0.5 249 YE 0.5 252 BK 0.5
CDB-011
9
38
1890 OR 0.8
9
9
10
10
CDB-016
86
CDB-017
4
287 YE 0.5
8
288 BL 0.5
28
12
12
289 PK 0.5
13
13
13
290 BL 0.5
58
14
14
291 YE 0.5
57
41
141 WH 0.8
42
292 BL 0.5
15
141 WH 0.8
42
1890 OR 0.8
311 WH 0.8
44
44
311 WH 0.8
6 18
86
312 WH 0.8
SH13: A-5
359 OR 0.8
SH30: B-5
85
37
SH30: A-5
427 RD 0.8
47
47
427 RD 0.8
SH16: A-1
SH22: B-6
797 VT 5.0
48
48
798 VT 5.0
SH2: A-1
SH7: D-6
1900 BK 0.8
425 VT 0.8
SH15: A-1
50
30
EGR POSITION SENSOR SUPPLY
9
318 PK 0.5
33
33
EGR POSITION SENSOR SIGNAL
39
327 YE 0.5
34
34
EGR POSITION SENSOR GROUND
24
337 BK/WH 0.5
35
35
TVA ACTUATOR MOTOR PLUS
49
TVA ACTUATOR MOTOR MINUS
34
TVA POSITION SENSOR SUPPLY
8
TVA POSITION SENSOR SIGNAL
TVA POSITION SENSOR GROUND
B-021 TVA PIERBURG CDB-020
CDB-020
338 WH 0.8
37
37
339 GY 0.8
38
38
340 PK 0.5
41
41
53
341 YE 0.5
42
42
37
342 BK/WH 0.5
43
43
RAIL PRESSURE SENSOR SIGNAL
RAIL PRESSURE SENSOR SUPPLY
CRANKSHAFT SPEED SENSOR SIGNAL PLUS
10
343 PK 0.5
17
17
BOOST PRESSURE SENSOR SIGNAL
40
344 YE 0.5
18
18
BOOST PRESSURE SENSOR GROUND
25
345 BK/WH 0.5
19
19
55
346 YE 0.5
20
20
SEGMENT (CAMSHAFT) SPEED SENSOR GROUND BOOST PRESSURE SENSOR SUPPLY
DP
SEGMENT (CAMSHAFT) SPEED SENSOR SUPPLY
COOLANT TEMPERATURE SENSOR GROUND
COOLANT TEMPERATURE SENSOR SIGNAL
FUEL TEMPERATURE SENSOR GROUND
T°
Y-006 FUEL METERING UNIT FUEL METERING UNIT
60
FUEL METERING UNIT SUPPLY
15
CDB-021
CDB-021
298 GY 1.0 299 WH 1.0
2
2
1
1
X-017
FUEL TEMPERATURE SENSOR SIGNAL
SH10:A-3
545 YE 0.8
SH29: C-4
SH14: B-1
1066 BK/WH 0.8
SH14: C-1 SH7: D-1
1901 BK 0.8
SH14: B-1
211 PK 0.8
51
751 OR 0.8
51
750 WH 0.8
52
Y-004
IN
OUT
X-SPOOL_LK_A
SH15: D-1
752 WH 0.8
53
53
752 WH 0.8
IN
1
X-CPLR
2
17 5
1304 WH 0.8
X-SPOOL_LK_B
1304B WH 0.8
304 WH 0.8
SP-187
957 BK 0.8
SH26: B-6
237 WH 3.0
4
4
237 WH 3.0
836 RD 3.0
5
5
836 RD 3.0
SH31: C-5
248 YE 0.8
9
9
248 YE 0.8
SH7: C-1
910 BK/WH 0.8
11
11
910 BK/WH 0.8
SH25: B-6
234 YE 0.8
12
12
234 RD 0.8
SH25: C-1
319 OR 0.8
13
13
319 OR 0.8
SH15: B-6
115 RD 2.0
14
14
115 RD 2.0
SH25: B-6
264 YE 0.8
15
15
SP-1901
753 OR 0.8
56
56
753 OR 0.8
SH5: A-1
SH22: C-6
774 VT 0.8
57
57
774 VT 0.8
SH23: B-5
780 VT 0.8
58
58
780 VT 0.8
SH30: D-5
59
59
782 OR 2.0
SH22: D-2
SH22: A-6
783 OR 1.0
SH15: B-6
784 OR 1.0
SH15: A-6
1 PORT LOCK
SP-020 782 OR 2.0
554 WH 0.8
SH7: D-6
958 BK 0.8
1
CDB-031
CDB-031
2
SH30: D-5
552 WH 0.8
1
311 WH 0.8
1 X-410
312 WH 0.8
234 RD 0.8
115 RD 2.0 B-002 HYDRAULIC OIL TEMPERATURE
SH19: D-1 SH3: D-1 SH2: D-1
SH25: C-6
GND-006
1
310 RD 0.8
16
16
310 RD 0.8
SH25: C-1
545 YE 0.8
17
17
545 YE 0.8
SH27: C-5
134 OR 2.0
19
19
134 OR 2.0
SH2: D-1 SH3: C-1 SH12: B-2
310 RD 0.8
SH3: C-1 SH2: B-1
SH25: B-1
SH25: B-1
1
OUT
1
303 WH 0.8
22
X-BRK
IN
960 BK 0.8
2
SH7: C-6
X-BRK
303 WH 0.8
22
SH13: B-5
S-040
SH25: D-6
261 YE 0.8
23
23
X-OILFLT
261 YE 0.8
1
X-OILFLT
GND-007
not in 47803835
SH25: C-6
267 YE 0.8
24
24
62
not in 47803835
SH25: C-1
1066 BK/WH 0.8
25
25
SH25: B-6
205C YE 0.8
63
63
not in 47803835
SH25: B-1
622 WH 0.8
26
26
SH29: B-4
206 BK/WH 0.8
64
64
206 BK/WH 0.8
SH7: D-6
SH25: B-1
139 OR 0.8
28
28
SH29: B-4
207 TN 0.8
65
65
207 TN 0.8
SH29: C-4
SH25: D-1
211 PK 0.8
29
29
211 PK 0.8
SH12: B-2
SH29: B-4
208 BL 0.8
66
66
208 BL 0.8
SH26: D-1
30
30
822 OR 0.8
SH26: A-6
SH25: B-1
144 OR 0.8
67
67
SH29: C-4 SH2: C-6 SH3: D-6
144 OR 0.8
795 VT 5.0
49
795 VT 5.0
49
144 OR 0.8
SH26: A-6
790 VT 1.0
18
18
SP-031 790 VT 1.0
SH26: A-1
SH25: C-6
854 OR 8.0
SP-171
309 OR 1.0
843 OR 5.0
54
54
843 OR 5.0
844 OR 5.0
55
55
844 OR 5.0
21
SP-161
309 OR 1.0
21
SP-037
821 OR 3.0
822 OR 0.8
267 YE 0.8 267 YE 0.8 1066 BK/WH 0.8 622 WH 0.8 622 WH 0.8 139 OR 0.8 139 OR 0.8
SP-091
823 PK 0.8
SH33: A-6 SH35: A-5 SH12: B-2 SH35: A-5 SH33: B-6 SH3: A-6 SH2: B-6
Y-011
SELF LEVEL VALVE
708 VT 3.0
SH3: B-1
SH26: A-1
709 WH 0.8
SH3: B-6
SH15: C-1
404 WH 0.8
31
31
709 WH 0.8
SH2: B-6
708 VT 3.0
SH2: B-1
SH21: C-5
565 VT 0.8
32
32
565 VT 0.8
SH16: C-1
SH26: B-6
824 YE 0.8
33
33
824 YE 0.8
SH26: A-6
846 OR 8.0
CDB-032
X-318
404 WH 0.8
1
CDB-006
X-318
X-318 2
X-318
503 YE 0.8
CDB-032 10
10
707 VT 2.0
SH3: A-6
SH31: C-5
504 GN 0.8
34
34
504A GN 0.8
705 VT 3.0
SH4: C-6
SH26: A-1
841 WH 0.8
35
35
841 WH 0.8
325 WH 0.8
SH3: C-6
SH26: A-1
833 WH 0.8
37
37
833 WH 0.8
707 VT 2.0
SH2: B-6
SH25: B-6
307 YE 0.8
39
39
307 YE 0.8
705 VT 3.0
SH2: A-6
SH26: A-1
834 WH 0.8
40
40
834 WH 0.8
325 WH 0.8
SH2: C-6
949 BK 0.8
CDB-006
503A YE 0.8 841 WH 0.8 833 WH 0.8
SH7: D-1
SH29: D-5 SH29: C-5 SH35: A-5 SH33: B-6 SH35: C-5 SH33: C-6 SH17: C-1 SH33: C-6 SH35: B-5
834 WH 0.8
SH2: D-1
125 OR 3.0
SH2: B-6
127 OR 0.8
SH8: C-6
135 OR 2.0
SH3: A-1
SH2: C-1
243 OR 2.0
SH3: A-1
300 OR 1.0
SH3: C-1
125 OR 3.0
SH3: A-6
1102 OR 0.8
SH19: B-6
135 OR 2.0
SH2: A-6
243 OR 2.0
SH2: A-6
820 OR 3.0 820 OR 3.0
SH3: C-1
324 OR 0.8
SH17: C-6
300 OR 1.0
SH20: D-6
123 OR 3.0
3
SP-030 123 OR 3.0
3
X-CCA
X-CCA
13
AUXILIARY HYDRAULIC INTERLOCK SWITCH
258 WH 0.8
HYDRAULIC FILTER RESTRICTION
SH31: C-5
(CHASSIS OPTION) PORT LOCK PORT LOCK VALVE CONNECTOR
2
20
61
2ND AUX RETRACT
2
20
62
SP-032
(CHASSIS OPTION) INTERCONNECTOR LOADER LOCK
258 WH 0.8
X-BRK
2ND AUX EXTEND
X-410
BRAKE VALVE SOLENOID
61
SH20: D-1
959 BK 0.8
248 YE 0.8
508 BL 0.8
507 WH 0.8
2
SH7: D-6
SH34: B-5 SH2: D-1 SH3: D-1 SH33: C-6 SH35: C-5 SH7: D-6 SH35: A-5 SH33: A-6
836 RD 3.0
134 OR 2.0
785 OR 0.8
X-PORT_LK
X-AUX_EXT
SH3: A-1
X-OILTMP
264 YE 0.8
SH7: D-6
X-CPLR
SH15: A-6
SH22: C-6
1
2
SH20: A-1
Y-008
2
X-PORT_LK
SH2: A-6
702 VT 2.0
SH2: A-6
SH26: B-1
X-BRK
SP-1304
85
701 VT 0.8
792 VT 3.0
2
X-SPOOL_LK_A
87
SP-024
791 VT 3.0
1
2
SH30: D-5
14
BULKHEAD CONNECTION
Z-012 LEFT HAND CONTROL HANDLE
SH14: C-6
752 WH 0.8
978 BK 0.8
2 X-CPLR
792 VT 3.0
1
X-OILTMP
SH5: A-1
OUT
X-CPLR
X-BULKHEAD
SH7: D-1
X-HFLO
751 OR 0.8
52
1
SH22: B-6
3
976 BK 0.8
2 X-HFLO
SH4: C-6 SH4: B-6 SH2: A-6
701 VT 0.8 700 VT 0.8
792 VT 3.0
STD HIGH FLOW SOLENOID 1
791 VT 3.0
SH20: D-1
Y-013
1901B BK 0.8
12
SH20: D-1
HYDRAULIC COUPLER SOLENOID
SH31: B-5
308 YE 0.8 303 WH 0.8
750 WH 0.8
SH15: D-6
1304A WH 0.8
11 700 VT 0.8
SH16: B-1
425 VT 0.8
50
X-HFLO
1901A BK 0.8
S-027
TURN SIGNAL
918 BK 0.8
1 IN
S-001 ROTATING BEACON /STROBE SWITCH
2
D
SH20: B-1
761 VT 0.8
X-301
919 BK 0.8
Z-013 RIGHT HAND CONTROL HANDLE
S-033
SP-026
2ND AUX HYDRAULIC
X-301
S-031
#1
1
1
IN 2
2
S-013 SELF LEVEL SWITCH D
405 OR 0.8
S-015
#2
E
E
SH14: B-3
404 WH 0.8
796 VT 0.8
S-022
#2
1
1
IN
X-317 A
A
922 BK 0.8
2
X-317
2
S-007 NH PARK BRAKE SWITCH 2
305 YE 0.8
S-032
3
#3
SH25: B-6
306 YE 0.8
X-365
SH8: C-1 2
801 RD 0.8
A
B
X-ACC
X-ACC
D
564 WH 0.8
X-2SPD
IN
A
OUT
H-001
HORN
S-023
HORN
SH14: D-6
312 WH 0.8
SH8: C-1
C
X-306 A
563 WH 0.8
SP-035
X-2SPD
E
D
2 SPEED SOLENOID
2SPD
S-005 LOADER LOCKOUT SWITCH
891 OR 0.8
924 BK 0.8
A
B
X-405
X-405
1
892 WH 0.8
X-HORN-PWR 1
SH14: A-4
X-2SPD B
953 BK 0.8
A
E
F
D
X-RDCTRL
1
IN
OUT
2
X-RDCTRL
951 BK 0.8
SH7: D-1
X-RDCTRL
2
S-036
307 YE 0.8
SH14: A-1
X-402
PROPORTIONAL AUXILIARY HYDRAULIC SWITCH SH19: C-1
331 OR 0.8
10
N
SH19: D-1
699 PK 0.8
8
SH19: C-1
1010 BK/WH 0.8
PWR
GND
OUT
9
920 BK 0.8
941 BK 0.8 917 BK 0.8 915 BK 0.8
SH7: C-6 SH21: C-2
424 VT 0.8
SH21: B-2
425 VT 0.8
SP-063
921 BK 0.8
C
750 WH 0.8
SH7: C-6
SH22: B-6
778 VT 0.8 SP-025
S-028 HIGH FLOW SWITCH
X-303
831 WH 0.8
X-RDCTRL
1
SH7: C-6
P
955 BK 0.8
SH22: C-6
776 VT 1.0
X-302
A
5
X-402
X-302 C
324 OR 0.8
X-2SPD
X-HORN-GND
X-306
4
S-014
S-026 HAZARD LAMP SWITCH B
RIDE CONTROL SOLENOID
PARK BRAKE SWITCH
Y-005
S-024
SH7: C-6
952 BK 0.8
832 OR 0.8
SH14: B-1
565 VT 0.8
Z-008 ACCESSORY POWER OUTLET SP-033
Y-010
S-018
RIDE CONTROL/GLIDE RIDE
1
IN X-365
753 OR 0.8
30
RAIL PRESSURE SENSOR GROUND
SH4: C-1
798 VT 5.0
1900 BK 0.8
X-300
SH14: C-6
29
322 GY 0.8
321 WH 0.8
OIL PRESSURE SWITCH
SH13: A-5
46
X-FUSE2
SH14: C-1
146 WH 0.8
45
SH31: B-5
SH7: D-6
X-300
785 OR 0.8
29
35
INJECTOR 2 HIGH BANK 2
SH6: B-6 SH6: C-6 SH5: C-6 SH5: D-6
46
1304 WH 0.8
1308 WH 0.8 SH8: C-1
30
146 WH 0.8
148 WH 0.8
45
87A
SH25: C-1
260 PK 0.8
S-009 HYDRAULIC COUPLER SWITCH
SH14: C-6
CDB-019
50
SH3: A-1 SH2: A-1
233 OR 2.0 233 OR 2.0
41
359 OR 0.8
K-008
THROTTLE SENSORS
784 OR 1.0
38
293 YE 0.5
16
SH15: B-6
X-412
SH14: C-6
23
312 WH 0.8
SPOOL RELAY
SH14: D-4
311 WH 0.8
CDB-019
EGR ACTUATOR MOTOR PLUS
EGR ACTUATOR MOTOR MINUS
BOOST PRESSURE TEMPERATURE SENSOR SIGNAL
SH15: B-1
X-412
SH14: D-6
DP
INJECTOR 2 LOW BANK 2
SEGMENT (CAMSHAFT) SPEED SENSOR SIGNAL
SH30: A-5
969 BK 0.8
115 RD 2.0
23
CRANKSHAFT SPEED SENSOR SIGNAL MINUS
45
Z-FUSE2 POWER DISTRIBUTION-CHASSIS
SH14: D-4
SH14: D-3
23
44
8
X-AUX_RET
SH25: C-6
22
297 YE 0.5
286 YE 0.5
87
X-AUX_RET
SH27: C-5
59
4
X-AUX_EXT
940 BK 3.0
CDB-017
285 YE 0.5
148 WH 0.8
X-020
SH7: C-6
11
284 PK 0.5
X-FUSE1
SH25: C-1
1071 BK/WH 0.8
B-004 FOOT THROTTLE SENSOR
934 BK 0.8
26 41
283 YE 0.5
SP-056
X-SPOOL_LK_B
SH27: B-5
CDB-016
282 BL 0.5
14
16
233 OR 2.0
SH25: B-1
X-FUSE2
927 BK 2.0
22
43
ENGINE F5C T4 SH24: C-6
30
SH25: C-1
544 YE 0.8
1308 WH 0.8
SH22: B-6
6
658 YE 0.5
10
ENGINE F5C T4
X-020A
916 BK 0.8
296 BK/WH 0.5
EXHAUST GAS PRESSURE SENSOR SIGNAL P3
X-017
B-003 HAND THROTTLE SENSOR
SH20: B-1
2
281 WH 1.0
X-HFLO
A
CDB-011 46
X-016
SH30: A-5
E
21
X-016
X-FUSE1
9
21
B-005 EGR PIERBURG
280 GY 1.0
7
15
46
2
295 PK 0.5
27
253 PK 0.5
SH8: C-1
751 OR 0.8
B-019 EXHAUST GAS PRESSURE SENSOR
EXHAUST GAS PRESSURE SENSOR GROUND P3
B-018 FUEL TEMPERATURE SENSOR
87A
SH14: C-6
27
294 GY 1.0
B-017 COOLANT TEMPERATURE SENSOR
SH9: A-6
600 WH 0.8
SPOOL RELAY
C
INJECTOR 2 LOW BANK 1
27
12
FUEL FILTER HEATER GND
K-017
B
48
28
B-020 BOOST PRESSURE / AIR TEMPERATURE SENSOR
T°
Z-FUSE1 POWER DISTRIBUTION CHASSIS
A
INJECTOR 2 HIGH BANK 1
279 GY 1.0
X-BULKHEAD
C
CDB-010 17
294 GY 1.0
28
B-016 SEGMENT SPEED SENSOR
T°
ENGINE F5C T4
B
4
EXHAUST GAS PRESSURE SENSOR SUPPLY P3
B-014 INCREMENT SPEED SENSOR
T°
B-012 EXHAUST GAS TEMP SENSOR #2 EXHAUST GAS TEMP GND 2
253 PK 0.5
2
4
A
INJECTOR 1 HIGH BANK 2
277 WH 1.0
6
80 EXHAUST GAS TEMP SIGNAL
252 BK 0.5
SH35: D-1
INJECTOR 1 LOW BANK 2
1
X-017
SH35: C-5
LAMBDA SENSOR HEATING
X-014
SH35: D-1
CCV HEATERS
CDB-008 31
SH10: B-6 Y-001 ELECTRIC VALVE (WG)
X-017
CDB-018
B-013 RAIL PRESSURE SENSOR
SH35: C-1
270 BK/WH 0.5
50
SH35: D-1
SH33: D-1
1086 BK 2.0
3
70
SH35: D-1
CDB-018
Y-009 INJECTOR ELECTRIC VALVE CYL 2
SH35: C-1
270 BK/WH 0.5
EXHAUST GAS TEMP GND
249 YE 0.5
SH35: D-1
INJECTOR 1 LOW BANK 1
79
245 YE 0.5
SH35: D-5
276 GY 1.0
X-015
271 YE 0.5
242 YE 0.8
SH35: D-5
ECU RELAY/GROUND
2
528F OR 5.0
241C OR 0.8
SH35: D-5
3
T°
X-017
271 YE 0.5 DIFF PRESSURE SUPPLY
32
Y-012 INJECTOR ELECTRIC VALVE CYL 4
T°
270 BK/WH 0.5
58
DIFF PRESSURE SENSOR SIGNAL
241A OR 1.0
SP-241
CDB-008
D
S-039 OIL PRESSURE SWITCH
X-013
241A OR 1.0
C
D
B-007 INLET TURBINE TEMP SENSOR
EXHAUST GAS TEMP SIGNAL 2
1
908A BK 5.0
C
X-004
INLINE TURBINE TEMP SIGNAL
INJECTOR 1 HIGH BANK 1
1
257 YE 0.5
CRANK ENABLE FROM ECU 2
CRANK SIGNAL
CDB-007 16
275 GY 1.0
SH33: B-1 B-006 AIR TEMP SENSOR
20
AIR TEMP GND
B
274 WH 1.0
241C OR 0.8
BOOST PRESSURE ACTUATOR 1
SH33: B-1
503C YE 0.8
24 47
WATER IN FUEL LEVEL SENSOR SIGNAL
CDB-005
B
X-015 CDB-007
Y-014 INJECTOR ELECTRIC VALVE CYL 3
SH35: B-1
503C YE 0.8 CDB-005
CAN LO
INLINE TURBINE TEMP GND
4
212 OR 8.0
SH35: B-1
A
626 WH 0.8
B-008 GCU
212 OR 8.0
SH4: B-1
X-ECU_MAIN_RLY
4
SH7: A-6
121 YE 0.8
626 WH 0.8
SH33: B-1
528E OR 2.0
23
161 YE 0.8
SH35: D-5
SP-528RH
BATTERY MINUS 1
B-001 LAMBDA SENSOR
112 BL 0.5
SH10: D-6
CAN 2 HIGH
30
527C RD 0.5 SH10: D-6
45
B-011 EXHAUST GAS TEMP SENSOR #1
X-ECU_MAIN_RLY
527B RD 8.0
SP-527RH
X-017
133D OR 0.8
161 YE 0.8
SH34: A-2
2
528F OR 5.0
CAN 2 LOW
121 YE 0.8
SH34: B-2
61
SH7: D-1
133B OR 0.8
SH35: A-1
X-FUSE1
BATTERY MINUS 2
2
SH35: C-1
248 YE 0.8
A
SH35: D-1
241C OR 0.8
A-005 ENGINE CONTROLLER UNIT
SH33: C-1
248 YE 0.8
46
SH33: B-1
SH33: C-6
161 YE 0.8
4
30
SP-133B
SH35: C-1
87
908B BK 2.0 908D BK 2.0
SH35: B-1
30
BATTERY VOLTAGE VIA MAIN RELAY
68
EGR ECU K-LINE
908C BK 2.0
SP-908
SH33: C-1
87A
1
Y-015 INJECTOR ELECTRIC VALVE CYL 1
MAIN RELAY
133B OR 0.8
SH35: A-1 SH33: B-1
K-006
BATTERY +B VIA MAIN RELAY
28
133E OR 0.8
SH33: A-1
ENGINE RELAY A
3
150 YE 0.8
SH34: D-5
Z-FUSE1 POWER DISTRIBUTION-CHASSIS
155B OR 2.0
112 BL 0.5
SH34: D-5 SH3:A-6
155C OR 2.0
BATTERY +C VIA MAIN RELAY
CDB-033
SH33: D-1 SH35: D-1
K-016
ENGINE RELAY A 26
155A OR 3.0
5
CDB-033
SH34: B-2
Z-FUSE1 POWER DISTRIBUTION CHASSIS
A-005 ENGINE CONTROLLER UNIT
SP-155
SH30: B-5
412 VT 0.8
SH30: B-5
413 RD 0.8
416 VT 0.8 417 RD 0.8 SP-064
SH14: D-6
E
SH30: C-5 SH14: D-4 SH28: C-5 SH28: C-5
427 RD 0.8
SH14: D-4
426 RD 0.8
SH30: C-5
X-303
LEFT-HAND CAB CONSOLE
15
LEFT-HAND NH CONTROL HANDLE
16
RIGHT-HAND NH CONTROL HANDLE
17
RAC 48144045 S1S2
SYMBOLS
Diagram
SH01 - TITLE PAGE
SH19 - EH AUX PWM
SH02 - MAIN POWER DISTRIBUTION LG
SH20 - LAMPS
SH03 - MAIN POWER DISTRIBUTION MD
SH21 - INDICATORS
SH04 - MAIN POWER DISTRIBUTION MD
SH22 - EU LIGHT ADAPTER
SH05 - ACCESSORY POWER DISTRIBUTION LG
PRESSURE SWITCH
SH07 - GROUNDING SYSTEM
SH25 - INSTRUMENT CLUSTER
SH08 - IGNITION
SH26 - HVAC
SH09 - ENGINE F5C T4
SH27 - RADIO
SH10 - ENGINE F5C T4
SH28 - MULITFUNCTION CONNECTORS
SH11 - ENGINE F5C T4
SH29 - TELEMATICS
SH12 - THROTTLE SENSORS
SH30 - MULTIFUNCTION JUMPER
LIGHT EMITTING DIODE (LED)
S-003 SEAT HEAT SWITCH
COIL
RESISTOR
1
SH14 - BULKHEAD CONNECTION
SH32 - FUEL FILTER JUMPER
S.P. S.T.
S.P. D.T.
D.P. S.T.
SH14: D-1
901 BK/WH 0.8
SH7: D-6
EH AUX RETRACT SIGNAL 1
3
889 WH 0.8 890 WH 0.8
EH AUX RETRACT SIGNAL 2
4
EH AUX VALVE SIGNAL RETURN
5
EH AUX PROPORTIONAL SW SIGNAL OUTPUT
6
699 PK 0.8
EH AUX PROPORTIONAL SW GND
7
1010 BK/WH 0.8
SH17: B-6
EH AUX PROPORTIONAL SW REFERENCE VOLTAGE
8
331 OR 0.8
SH17: C-6
SH17: B-6
Y-002
2
R-001
P
FUSE
RELAY
S-011
914 BL 0.8
LAP BAR SWITCH 316 RD 0.8 3
X-104
1
SP-012
315 RD 0.8
2 X-104
X-104
COLOR ABBREVIATION BLACK BK BLUE BL LIGHT BLUE LB BLACK/WHITE BK/WH GREEN GN LIGHT GREEN LG ORANGE OR PINK PK VIOLET VT RED RD GREY GY TAN TN WHITE WH YELLOW YE
SH18 - SEAT
CIRCUIT DIAGRAM LEGEND WIRE ID
SHEET 799 VT 0.8 SPLICE SP-123
WIRE SIZE CHART Sq. mm AWG 0.5 20 0.8 18 1.0 16 2.0 14 3.0 12 5.0 10 8.0 8
2
1
Y-003
PROPORTIONAL AUX VALVE EXTEND
SH25: C-6
317 RD 0.8
X-433
2
1 X-433
SH25: B-6
323 YE 0.8
X-432
X-432
SP-088
SH25: B-6
314 YE 0.8
X-104
911 BL 0.8 4
X-432
X-432
N
BATTERY
GROUND
PROPORTIONAL AUX VALVE RETRACT
SH26: B-6
933 BK 1.0
SP-001
SH35 - CHASSIS INTERFACE
COLOR WIRE SIZE
319 OR 0.8
2
SH7: B-6
933 BK 1.0
D.P. D.T.
SH34 - CHASSIS INTERFACE
GRID LOCATION
1
SH27: C-5
756 OR 1.0
SEAT HEAT ELEMENT
SH33 - CHASSIS INTERFACE
SH17 - RIGHT-HAND NH CONTROL HANDLE
EH AUX POWER CLEAN ENGINE GROUND
X-430
SH31 - DIAGNOSTIC CONNECTOR
SH16 - LEFT-HAND NH CAB CONSOLE
A-003 EH AUX PWM CONTROLLER
Z-006 SEAT
VARIABLE RESISTOR
SH13 - AUXILIARY HYD INTERLOCK SWITCH
SH15 - LEFT-HAND CAB CONSOLE
SPEAKER
TEMPERATURE
PRESSURE
SH24 - WIPER / WASHER
DIODE
MOTOR
SH23 - BOOM AND ROAD LIGHTS
SH06 - ACCESSORY POWER DISTRIBUTION MD
SH5: B-1
LAMP
1009 BL 0.8
Diagram
X-433
X-433
X-058
S-002
SEAT SWITCH
S-041
Y-007
BOOM LOCK INTERLOCK SWITCH SH14: A-4
X-904
1102 OR 0.8
B
A
BOOM LOCK VALVE
X-904
X-905
1103 WH 0.8
2 X-905
X-904
X-904
1
X-905
NOTE: DIAGRAM SHOWN WITH VEHICLE PARKED & POWER OFF
TABLE OF CONTENTS / STANDARD SYMBOLS
18
SEAT
19
EH AUX PWM
S-012
IN
D
123 OR 3.0
X-311
SH35: D-5
769 OR 2.0
LAMP SELECTOR SWITCH SH14: A-3
SH7: C-6
1104 BK 0.8
X-905
1
A
790 VT 1.0
SH14: A-6
2
B
791 VT 3.0
SH14: D-3
3
C
792 VT 3.0
SH14: D-3
SH30: D-5
770 OR 0.8
SP-050
SH14: C-4
782 OR 2.0
SH7: D-6
981 BK 0.8
X-311
A-004
E-023 LH FRONT STROBE 740 VT 0.8
FLASHER MODULE
1
2
1005 BK 0.8
X-344
3
681 PK 0.8
85
X-344
769 OR 2.0
E-021 LH REAR STROBE 758 VT 0.8
1
2
1007 BK 0.8
X-341
3
683 PK 0.8
SP-083 SP-084
X-341
E-024 RH FRONT STROBE
X-068
738 VT 0.8
PWR PWR
GND GND
739 VT 0.8
SP-082
1003 BK 0.8
X-068
1
2
X-343
3
SH5: D-1
E-027 2 SPEED INDICATOR SH14: B-3
1004 BK 0.8 680 PK 0.8
30
156 RD 2.0
X-411
7
9
X-310
X-310
565 VT 0.8
87A
SH15: A-1
917 BK 0.8
X-343
E-025 RH REAR STROBE 757 VT 0.8
1
2
X-342
3
156 RD 2.0 1006 BK 0.8 682 PK 0.8
X-342
800 OR 0.8
SH27: C-5
151 OR 0.8
1
2
X-097
X-097
SH22: C-6
SH15: D-6
916 BK 0.8
X-155B
GND
X-156B
1
55
X-178
2
SH15: A-1
LH TURN
SH24: C-6
V-003
780 VT 0.8
778 VT 0.8
X-HZRDDIODE
2
B
P
A 1
N
X-HZRDDIODE X-HZRDDIODE
781 VT 0.8
SP-019
X-HZRDDIODE
X-031
773 VT 0.8
3
799 VT 2.0
1
LH SIDE LAMP
794 VT 2.0
2
LH CAB TURN SIGNAL
927 BK 2.0
4
LH CAB LAMPS GND
X-031
LH WORK LAMP
X-178
SH24: C-6
SH14: D-6
2
1
1085 BK 0.8
SH35: D-1
SP-018
776 VT 1.0
SH15: D-6
J-001 SIDE LAMP DIA SOCKET 238 VT 0.8
SH35: D-1
SH7: A-6
981 BK 0.8
6A DIODE
SH15: D-1
761 VT 0.8
928 BK 0.8
SH22: B-6
769 OR 2.0
774 VT 0.8
SH14: C-6
SH15: A-1
915 BK 0.8
X-157B
PWR2
1
772 YE 0.8
E-026
N
771 VT 0.8
SH15: B-1
ROTATING BEACON P
SH21: B-5
SH14: C-6
RH TURN
PWR1
1
771 VT 0.8
SH22: C-6
1
772 YE 0.8
E-008
TURN SIGNAL INDICATOR
E-003 DOME LAMP SH27: C-5
SH21: B-5
SP-016
797 VT 5.0
SH14: B-6
795 VT 5.0
SH24: C-6
926 BK 2.0
SH20: B-6
238 VT 0.8
798 VT 2.0
1
779 VT 1.0
SP-015
793 VT 2.0 X-030
X-030
RH WORK LAMP
3
RH SIDE LAMP
2
RH CAB TURN SIGNAL
4
RH CAB LAMPS GND
X-077
S-034
SH6: B-6
TURN SIGNAL SWITCH
715 VT 1.0
SH6: B-6
S-029
714 VT 1.0
SH5: B-6
STD/ON-ROAD LAMP CONFIGURATOR
715 VT 1.0
SH5: C-6
X-101B
SP-057
714 VT 1.0
SH2: D-6
710 VT 2.0
SH14: D-1
702 VT 2.0
SH7: B-6
X-101
STD
783 OR 1.0
E X-CTS
1
1
710 VT 2.0
SH3: D-6
ROAD
1
711 VT 2.0
SH14: C-6
IN
OUT1
D
OUT2
F
777 VT 1.0 775 VT 1.0
X-CTS
939 BK 2.0
X-101A
20
LAMPS
21
INDICATORS
22
EU LIGHT ADAPTER
E-028
X-039
LH REAR POSITION LAMP
RH REAR WORK A
732 VT 0.8
B
897 VT 0.8
C
1091 BK 0.8
X-039
RH REAR POSITION LAMP
B
997 BK 2.0
X-038
E-029
M-004
LH REAR WORK 728 VT 1.0
FRONT DOOR WASHER PUMP (CAB)
B
996 BK 2.0
970 BK 0.8
X-033A
X-506
Z-009
LH REAR ROAD LAMP
1092 BK 0.8
X-049
N 55
X-033A
718A VT 0.8
B
P
A
734 VT 1.0
A
C
N 55
X-038
SP-079 X-049
P
A
729 VT 1.0
C
GND1 STOP
A
732A VT 0.8
A
M
B
X-506
X-506
SH25: B-6
TAIL
B
731 VT 0.8
1
2
X-506
227 WH 0.8
D
31 (GND)
X-037
TURN
X-502
GND2
X-198
C
1001 BK 0.8
706 VT 3.0 704 VT 0.8 704 VT 0.8 703 VT 0.8 703 VT 0.8 950 BK 3.0
SH7: A-6 SH33: B-1 SH35: B-1 SH23: A-5
950 BK 3.0 717 VT 0.8 717 VT 0.8 718 VT 0.8
SH33: A-1 SH35: A-1 SH33: B-1 SH35: B-1 SH23: A-5 SH7: B-6 SH7: A-6
721 721 766 766 763
VT VT VT VT VT
0.8 0.8 0.8 0.8 0.8
975 BK 3.0 975 BK 3.0
X-205
LICENSE PLATE
X-201 1
1
REAR WORK LAMP POWER
1
730 VT 2.0
2
2
RH TAIL LAMP POWER
2
733 VT 0.8
3
3
LH TAIL LAMP POWER
3
4
4
REAR LAMP GROUND
4
5
5
LH REAR POSITION LAMP
5
6
6
RH REAR POSITION LAMP
6
7
7
11
11
LH REAR TURN SIGNAL POWER
11
735 VT 0.8
12
12
RH REAR TURN SIGNAL POWER
12
736 VT 0.8
13
13
REAR LAMP GROUND
13
X-205
X-080
N
1 X-081
55
SH7: C-6
939 BK 5.0
SH22: B-6
926 BK 2.0
SH7: B-6
Z-005
RH REAR ROAD LAMP B
717B VT 0.8
7
BRAKE LAMP SIGNAL POWER
898 VT 0.8
SP-190x
737 VT 0.8
P
1
TAIL C
GND1
SP-081
A
734A VT 0.8
STOP
999 BK 0.8
X-044
A
TURN
GND2
SH20: A-6
1085 BK 0.8
SH20: B-1
928 BK 0.8
X-201
SH14: D-6
C
SP-023
233 OR 2.0
229 OR 0.8
3
230 OR 0.8
6
1
1001 BK 0.8
2
SH7: C-6 SH6: B-1
716 VT 1.0
SH5: C-1
716 VT 1.0
SH33: B-6
717 VT 0.8
SH35: B-5
717 VT 0.8
SH14: C-4
774 VT 0.8
SH30: D-5
768 VT 0.8
SH33: B-6
766A VT 0.8
SH35: B-5
766A VT 0.8
979 BK 1.0 SP-059
712 VT 1.0
D
979A BK 1.0
A
A
712A VT 2.0
767 VT 0.8
B
963 BK 2.0
719 VT 1.0
SH35: C-1
719 VT 1.0
SH23: C-6
718 VT 0.8
SH33: C-1
780 VT 0.8
SH35: C-1
780 VT 0.8
SH23: C-6
763 VT 0.8
932 BK 0.8
SH7: B-6
SH34: C-1
7
226 VT 0.8
8
932 BK 0.8
X-503
2
741 VT 0.8
4
228 WH 0.8 GND
POSITION
X-232
53 (MOTOR +)
C
53a
PARK
Z-228
232 OR 0.8 TURN
713 VT 1.0
A
713A VT 1.0
764 VT 0.8
B
SP-075
S-025
540 VT 0.8
2
539 VT 0.8
4
DOOR SWITCH
X-233
SH7: C-1
1
1016 BK/WH 0.8
X-505
2
1 X-505
X-505
250 YE 0.8
SH25: B-6
SWITCHED POWER
X-505
X-229
POWER RELAY OUTPUT
5 X-229
BOOM AND ROAD LIGHTS
GND POSITION
764A VT 0.8
B X-231
STARTING SEQUENCE
X-502A
930 BK 0.8
LOW BEAM
SP-052
B
RH FRONT ROAD LAMP
980A BK 3.0
A
BATTERY POWER
M
31 (GND)
Z-002
D
REAR WIPER MOTOR
A
1
5
X-233
D
SP-060
Compact Track Loaders: TR270 - NGM418237 and above TR270 - NHM435463 and above TR310 - NGM418237 and above TR310 - NHM435463 and above TV370 - NHM435453 and above
M-002
742 VT 0.8
X-502A
980 BK 1.0
SH33: C-1
SP-074
Z-228
X-231
SH7: A-6
SH7: C-6
Skid Steer Loaders: SR210 - NGM418237 and above SR210 - NHM435463 and above SR240 - NGM418237 and above SR240 - NHM435463 and above SV280 - NGM418237 and above SV280 - NHM435463 and above
LH FRONT ROAD LAMP
767A VT 0.8
B X-230
931 BK 0.8 SP-022
225 WH 0.8
LOW BEAM
SP-051
SH26: B-6
5
Z-010
D
SH26: C-1
912 BK 0.8
X-503
SP-080
X-232
931 BK 0.8
X-196
1000 BK 0.8
X-230
913 BK 0.8
S-017 WIPER/WASHER SWITCH
1095 BK 0.8 SP-170
X-502
SP-027
1002 BK 0.8 975 BK 3.0
SP-014
937 BK 3.0
X-044
X-196
B
929 BK 0.8
X-198
E-019
SH34: B-2 SH35: B-1 SH33: B-1 SH35: A-1 SH33: A-1 SH7: A-6
TIER 4B (FINAL) MECHANICAL HYDRAULIC CONTROLS
M
PARK 53a
C
231 OR 0.8
X-037 A
DOOR WIPER MOTOR
53 (MOTOR +)
A
220 YE 0.8
998 BK 0.8
ELECTRICAL SCHEMATIC
M-001
224 WH 0.8
TURN
23
WIPER / WASHER
24
RAC 48144045 RAC 48144045 S2S1
A-001 HVAC BOX
A-002 INSTRUMENT CLUSTER
THROTTLE SENDER SUPPLY
KEY START OUTPUT
4
SH31: C-5
CDB-015
CDB-015
505 GN 0.8
SH31: C-5
500 YE 0.8
SH15: C-6
305 YE 0.8
SH14: A-6
309 OR 1.0
SH31: C-5
162 RD 0.8
SH14: C-3
310 RD 0.8
SH18: B-1
317 RD 0.8
SH8: A-6
140 RD 0.8
SP-010
SP-004
5
CAN LOW
6
CAN HIGH
301 OR 0.8
7
302 OR 0.8
8
313 RD 0.8
9
267 YE 0.8
AIR FILTER/ENGINE MALFUNCTION
SH18: B-1
323 YE 0.8
12
SEAT SWITCH CLUSTER INPUT
SH14: B-6
205C YE 0.8
13
TELEMATICS CRANK DISABLE
15
FOOT THROTTLE SIGNAL
23
THROTTLE SENDER GND
25
259 PK 0.8
EH AUX POWER
26
SH24: D-6
250 YE 0.8 220 YE 0.8
SP-093
SH18: B-1 SH14: A-3 SH15: C-1
307 YE 0.8
SP-006
16
HVAC FAN HIGH
5
850 WH 5.0 837 WH 0.8
A/C COMP RELAY PIN 86
6
THERMOSTART PRESSURE SW
7
260 PK 0.8
SH12: C-2
BINARY PRESSURE SWITCH
8
SH12: C-2
HVAC THERMOSTART CLEAN GROUND
9
545 YE 0.8
SH14: C-3 1066 BK/WH 0.8
SH14: B-3
1071 BK/WH 0.8
SH12: C-2
PARK BRAKE VALVE SIGNAL
28
HVAC KEYED POWER
11
A/C COMPRESSOR RELAY PIN 87 POWER
12
HVAC RELAY FUSE POWER
14
SP-165 848 WH 8.0
845 OR 5.0
SP-164
826 WH 3.0
139 OR 0.8
ACCESSORY RELAY SIGNAL
29
251 YE 0.8 314 YE 0.8
20
LAP BAR/SEAT BELT CLUSTER INPUT HYDRAULIC LOADER INTERLOCK SIGNAL
30
PARK BRAKE SW
31 START RELAY SIGNAL
32
FUEL LEVEL SENDER
MAIN POWER RELAY SIGNAL
33
CLUSTER GROUND
34
X-C23
138 OR 0.8
ACCESSORY BACKFEED DIODE
137 WH 0.8
X-015
2
P
N
X-015
X-015
1
X-015
153 WH 0.8
SP-009
141 WH 0.8
SH18: C-1
303 WH 0.8
SH14: C-3
622 WH 0.8
SH14: B-3
SH7: B-6
933 BK 1.0
SP-168
1088 BK 8.0
C
829 WH 0.8
2
X-C23
X-316
1
144 OR 0.8
X-076
87
87
85
85
3
912 BK 0.8
SH24: C-1
913 BK 0.8
X-275
X-076
A A
30
30
839 RD 3.0
86
86
840 WH 0.8
833 WH 0.8
X-075
833C WH 0.8 834C WH 0.0 841C WH 0.0
1 2 3
SH35: C-1
1
833 WH 0.8
SH33: C-1
2
834 WH 0.8 834 WH 0.8
SH35: B-1 SH33: C-1
756 OR 1.0
SH15: C-6
405 OR 0.8
SP-058 152 OR 1.0
3
841 WH 0.8 841 WH 0.8
SH35: A-1 SH33: B-1
X-011
SH14: C-3
134 OR 2.0
SP-011 151 OR 0.8
SH20: B-6
151 OR 0.8
SH26: A-1
143 OR 0.8
SH20: B-6
800 OR 0.8
SP-021
130 OR 0.8 SH15: C-6
H-003
AC_COMP1
2
SGL
SH14: B-3
823 PK 0.8
1
PWR
X-252
Z-003 WATER VALVE SGL
SH14: B-1
824 YE 0.8
D
SH7: C-6
1013 BK 0.8
C
GND
SH14: B-1
822 OR 0.8
A
PWR
7
1
450 BL 0.8
5
1
451 WH 0.8
4
1
453 WH 0.8
6
1
452 BL 0.8
Z-007 A/C COMPRESSOR
GND
824 YE 0.8
9
934 BK 0.8
X-331
RH SPEAKER
X-111
SH14: B-3
SH7: C-1
1011 BK/WH 0.8
X-076
1
SH18: C-1
X-330
SH14: B-6
X-316
2
B B
X-111
V-002
IGNITION BACKFEED DIODE
SH14: B-3
821 OR 3.0
S-021
HVAC HIGH PRESSURE SWITCH
X-076
Z-004 TEMP CONTROL (LH CONSOLE) SH24: C-1
133 OR 0.8
1087 BK 0.8
2 X-270
B
A
87A
SH14: D-6
1 X-270
A
825 OR 0.8
B
237 WH 3.0
IN
X-275
SH14: B-3 SH14: D-3
4
AC SWITCH (LEFT CONSOLE)
K-018 CONDENSER RELAY
SH8: B-1
3
5
S-019
Z-011 HVAC CONDENSER FAN
1084 BK 3.0
2
4
SP-162
X-HVC1
237 WH 3.0
3
SP-163
842 OR 5.0
SH14: C-3
258 WH 0.8
V-001
24
10
827 WH 3.0
SH14: D-3
319 OR 0.8
HYDRAULIC OIL TEMPERATURE SENDER
21
HVAC RELAY PIN 87 OUTPUT POWER
1
X-074
DOOR SWITCH SIGNAL
234 YE 0.8
4
SH7: A-6
306 YE 0.8
SH14: D-3
HVAC FAN MEDIUM
SH34: B-2
19
754 YE 0.8
SH14: B-3
544 YE 0.8
SP-200
1070 BK/WH 0.8
18
SH24: A-1
828 WH 3.0
M
KEY IGNITION
264 YE 0.8
22
SP-201
211 PK 0.8
INSTRUMENT CLUSTER UNSWITCHED POWER
11
SH14: C-3
HAND THROTTLE SIGNAL
INSTRUMENT CLUSTER SW POWER 2
10
SH14: B-3
17
INSTRUMENT CLUSTER SW POWER 1
132 OR 0.8
SH8: A-1
838 RD 1.0
3
HYDRAULIC OIL FILTER
3
624 WH 0.8
2
HVAC FAN LOW
1
SH8: A-1
COMPRESSOR RELAY PIN 30 POWER
S-010 BLOWER SWITCH (LEFT CONSOLE)
935 BK 5.0
SP-157
2
261 YE 0.8
1
SP-160
SH14: C-3
HVAC GROUND
M
836 RD 3.0
SH14: D-3
833 WH 0.8
SH14: A-3
834 WH 0.8
SH14: A-3
1012 BK/WH 0.8
SH7: C-1
846 OR 8.0
SH14: B-3
143 OR 0.8
SH27: C-5
841 WH 0.8
SH14: A-3
854 OR 8.0
SH14: A-6
H-004
X-332
LH SPEAKER
X-333
2 X-335
X-271
25
INSTRUMENT CLUSTER
26
HVAC
27
RADIO X-114
SH5: A-1
558 OR 0.8
1
1
SH13: B-5
554 WH 0.8
2
2
SH13: B-5
552 WH 0.8
3
3
SH22: D-2
770 OR 0.8
5
5
6
6
7
7
X-TELE
SH14: B-1
SH30: C-5
419 GY 0.8
SH30: C-5
X-323
1
419A LG 0.8
C
418 GY 0.8
2
2
418A GY 0.8
D
SH33: B-6
SH30: B-5
410 WH 0.8
3
3
410A WH 0.8
E
SH33: B-6
SH30: B-5
411 TN 0.8
4
4
411A TN 0.8
F
SH16: B-1
416 VT 0.8
5
5
416A VT 0.8
H
SH35: C-5
SH16: A-1
417 RD 0.8
6
6
417A RD 0.8
G
SH35: B-5
SH30: B-5
856 WH 1.0
8
8
420 OR 3.0
9
9
982 BK 5.0
7
7
10
10
SH5: D-1 SH6: C-1 SH7: D-6
420 OR 3.0
SP-073 420A OR 8.0
CDB-006
925 BK/WH 0.8
1
SH8: C-1
802 OR 0.8
2
SP-503A
CDB-002
503B YE 0.8
CDB-003
504C GN 0.8
3
504B GN 0.8
SH23: B-5
CDB-034
504C GN 0.8 503C YE 0.8
4
SH14: B-4 SH8: C-6
208 BL 0.8
6
207 TN 0.8
7
244 YE 0.8
K
780 VT 0.8
SH33: C-6
NOT USED 5
SH14: B-4
768 VT 0.8
SH14: C-4
CDB-003
503C YE 0.8
J
987 BK 3.0
CDB-002
504A GN 0.8 SP-504A
1
422 WH 0.8
503A YE 0.8
SH14: B-1
X-107
856A WH 3.0
CDB-006
SH7: C-1
8
SP-780
780A VT 0.8
SH35: C-5
780A VT 0.8
SH16: B-1
424 VT 0.8
988 BK 0.8
B
SP-072
9
358 OR 0.8
10
10
11
11
SH16: A-1
426 RD 0.8
12
12
418 GY 0.8
13
13
SH28: C-5
419 GY 0.8
14
14 X-114
SP-197
SH13: B-5
308 YE 0.8
11
SH5: D-1
336 RD 1.0
12
SH5: C-6
354 OR 0.8
SH6: B-6
SP-062
354 OR 0.8
SH14: D-4
X-TELE_DIAG
SH14: B-6
206 BK/WH 0.8
1
SH14: B-6
207 TN 0.8
2
SH14: B-6
208 BL 0.8
3
SH6: C-1
359 OR 0.8
X-117
352 OR 0.8
X-TELE
X-066
SH5: C-1
129 OR 1.0 129 OR 1.0
X-066 A
8
9
NOT USED 10 X-107
421 WH 0.8
8
LH HANDLE INTERCONNECT
NOT USED 9
L
X-323A
246 OR 1.0 857 WH 1.0
SH28: C-5
B
433 YE 0.8
982A BK 5.0
765 VT 0.8
TELEMATICS DIAGNOSTIC
1
1
SH28: C-5
410 WH 0.8
2
2
SH28: C-5
411 TN 0.8
3
3
5
5
SH16: B-6
412 VT 0.8
SH16: A-6
413 RD 0.8
SH28: C-5
SP-198
856 WH 1.0
6
6
247 OR 1.0
9
9
858 WH 1.0
10
10
RH HANDLE INTERCONNECT
X-117
4 X-TELE_DIAG
F-053
TELEMATIC FUSE
SH7: C-1
336 RD 1.0
A
119 RD 1.0
B
2
A 5.0
1
X-319
X-113
SH14: D-6
425 VT 0.8
D D
SH14: D-6
359 OR 0.8
E E
SH14: D-6
427 RD 0.8
F
FE #2 SWITCH
F X-113
28
MULTIFUNCTION CONNECTORS
29
TELEMATICS
X-900
SH2: C-1
110 OR 2.0
SH2: B-6
SH7: C-1
961 BK/WH 0.8
A
SH25: C-6
162 RD 0.8
B
SH25: C-6
CDB-015
SH25: C-6 SH14: B-3
505 GN 0.8
CDB-015
SP-089
500 YE 0.8 CDB-032
SH14: B-3
504 GN 0.8
CDB-032
SP-090
501 YE 0.8
CDB-014
SH14: D-3
1
C D
X-9000 1
1200 YE 0.8
1
SH8: C-1
248 YE 0.8
2
1201 BK 0.8
X-9001
E
2
2
893 WH 0.8
X-042
1
1
2 X-042
1
SH14: D-1
TO ENGINE 2
CAN DIAGNOSTIC CONNECTOR
503 YE 0.8
S-006
S-004
FUEL FILTER
506 GN 0.8
719 VT 1.0
MECHANICAL BACKUP SWITCH #1
X-9001 CDB-014
528E OR 2.0
SH5: B-1
X-DIAG
1
2
2
X-042
MECHANICAL BACKUP SWITCH #2
894 WH 0.8
X-042
X-043
1
1
2 X-043
X-043
1
2 2
X-043
161 YE 0.8
SH14: B-6
CDB-031
507 WH 0.8
CDB-031
508 BL 0.8
3
4
4
5
5
6
6
7
7
8
8
110 OR 2.0
SH10: D-6
528E OR 2.0
SH9: A-6
719 VT 1.0
SH23: A-5
895 WH 0.8
SH34: C-5
9
9
10
10
11
11
12
12
13
13
14
14
15
15
16
16
17
17
18
18
19
19
248 YE 0.8
SH10: D-1
20
20
161 YE 0.8
SH10: C-6
21
21
22
22
780 VT 0.8
SH23: A-5
833 WH 0.8
23
23
833 WH 0.8
SH26: B-1
SH14: A-1
834 WH 0.8
24
24
834 WH 0.8
SH26: B-1
25
25
26
26
27
27
SH29: C-5
J
2
3
780A VT 0.8
SH29: C-5
H
1
2
SH14: A-1
SH23: B-5
SH14: B-6
1
SH30: D-5
F G
SH35: C-5
895 WH 0.8 895 WH 0.8
248 YE 0.8
SH9: C-1
X-9000
30
MULTIFUNCTION CONNECTORS
717 VT 0.8 CDB-003
504C GN 0.8
CDB-003
SH23: C-6
717 VT 0.8 CDB-005
CDB-005
504C GN 0.8
SH10: D-1
28
28
SH2: A-1
704 VT 0.8
29
29
704 VT 0.8
SH23: C-6
SH23: A-5
766A VT 0.8
30
30
766 VT 0.8
SH23: C-6
31
31
X-DIAG
503C YE 0.8
503C YE 0.8
SH2: C-1
241A OR 1.0
32
32
241A OR 1.0
SH10: B-6
SH9: C-6
121 YE 0.8
33
33
121 YE 0.8
SH10: C-6
34
34
35
35
36
36
626 WH 0.8
SH10: C-6
37
37
38
38
39
SH14: B-1
SH14: A-1
622 WH 0.8
841 WH 0.8
39
841 WH 0.8
SH26: B-1
SH5: A-1
725 VT 0.8
40
40
721 VT 0.8
SH23: C-6
133B OR 0.8
SH10: C-6
703 VT 0.8
SH23: C-6
SH8: C-1
133B OR 0.8
41
41
SH14: D-1
234 RD 0.8
42
42
SH2: B-1
703 VT 0.8
43
43
44
44
SH14: B-1
267 YE 0.8
45
45
267 YE 0.8
SH8: D-6
SH9: B-1
112 BL 0.5
46
46
112 BL 0.5
SH10: D-6
47
47
R-002 FUEL LEVEL SENDER
X-901
234 RD 0.8
X-014
B B
A
X-014
A
X-014
31
FUEL FILTER JUMPER
32
CHASSIS INTERFACE LG
956 BK 0.8
SH7: A-6
X-014
234 RD 0.8
DIAGNOSTIC CONNECTOR
SH10: D-1
SH35: A-1
33
RAC 48144045 S2S2
X-901
X-205
SH10: D-6
150 YE 0.8
8
8
SH10: D-6
908E BK 0.8
9
9
1151 YE 0.8 909 BK 0.8
S-043
WATER IN FUEL SWITCH SH10: C-6
133E OR 0.8
10
3
1137 OR 0.8
10
PWR
X-011
GND
2
OUT
1 X-011
H-002
BACKUP ALARM SH33: C-1 SH35: C-1
895 WH 0.8
14
X-BKUP-PWR
896 WH 0.0
14
895 WH 0.8
X-BKUP-GND X-201
1
1
1
1
P N
963 BK 2.0
SH4: C-1
155A OR 3.0
SH4: C-1
SH23: B-1
CHASSIS POWER
706 VT 3.0
X-314
SH4: D-1
110 OR 2.0
4
4
110 OR 2.0
SH6: B-6
156 RD 2.0
5
5
156 RD 2.0
SH22: C-1
SH22: D-2
769 OR 2.0
1
1
769 OR 2.0
SH22: C-1
SH10: B-6
241C OR 0.8
7
7
241C OR 0.8
SH11: D-1
SH10: B-6
242 YE 0.8
8
8
242 YE 0.8
SH10: A-6
SH10: A-6
245 YE 0.5
9
9
245 YE 0.5
SH10: A-6
SH10: A-6
249 YE 0.5
10
10
249 YE 0.5
SH10: A-6
SH10: A-6
252 BK 0.5
11
11
252 BK 0.5
SH10: A-6
SH10: A-6
253 PK 0.5
12
12
253 PK 0.5
SH10: A-6
SH6: B-1
719 VT 1.0
13
13
719 VT 1.0
SH23: A-5
SH10: B-1
270 BK/WH 0.5
14
14
270 BK/WH 0.5
SH10: C-1
SH10: B-1
271 YE 0.5
15
15
271 YE 0.5
SH10: C-1
16
16
SH33: C-4
895 WH 0.8
17
17
895 WH 0.8
SH34: C-5
SH29: C-5
504C GN 0.8
18
18
SH14: D-1
248 YE 0.8
19
19
248 YE 0.8
SH10: D-1
SH9: D-1
161 YE 0.8
20
20
161 YE 0.8
SH10: C-6
21
21
SH30: C-5
780A VT 0.8
22
22
780 VT 0.8
SH23: A-5
SH14: A-1
833 WH 0.8
23
23
833 WH 0.8
SH26: B-1
SH14: A-1
834 WH 0.8
24
24
834 WH 0.8
SH26: B-1
25
25
SH23: B-5
717 VT 0.8
26
26
SH2: C-1
155A OR 3.0
1
1
155A OR 3.0
SH10: D-6
SH14: D-1
237 WH 3.0
2
2
237 WH 3.0
SH26: C-6
SH2: A-1
706 VT 3.0
3
3
706 VT 3.0
SH23: C-6
27
27
212A OR 8.0
4
4
SH10: C-6
28
28
SH7: D-6
X-314
X-315
1087 BK 5.0
212A RD 5.0
SP-212
212 OR 8.0
2 REMOTE POWER/GROUND
212B OR 5.0
1 X-315
1 X-195
212 OR 8.0
SP-212
212A OR 8.0
X-313
1
1
X-313
212 OR 8.0
SH10: C-6
SH10: D-6
504C GN 0.8 503C YE 0.8
TIER 4B (FINAL) MECHANICAL HYDRAULIC CONTROLS Skid Steer Loaders: SR210 - NGM418237 and above SR210 - NHM435463 and above SR240 - NGM418237 and above SR240 - NHM435463 and above SV280 - NGM418237 and above SV280 - NHM435463 and above
SH23: C-6
717 VT 0.8 CDB-035
ELECTRICAL SCHEMATIC
CDB-035
SH10: D-1 SH10: D-1
SH4: C-1
704 VT 0.8
29
29
704 VT 0.8
SH23: C-6
SH23: A-5
766A VT 0.8
30
30
766 VT 0.8
SH23: C-6
SH29: C-5
503C YE 0.8
31
31
32
32
SH9: D-6
121 YE 0.8
33
33
121 YE 0.8
SH10: C-6
SH14: B-1
622 WH 0.8
36
36
626 WH 0.8
SH10: C-6
SH14: B-1
841 WH 0.8
39
39
841 WH 0.8
SH26: B-1
SH5: A-1
721 VT 0.8
40
40
721 VT 0.8
SH23: C-6
SH8: C-1
133B OR 0.8
41
41
133B OR 0.8
SH10: C-6
SH14: D-1
234 RD 0.8
42
42
234 RD 0.8
SH33: A-1
SH4: B-1
703 VT 0.8
43
43
703 VT 0.8
SH23: C-6
SH14: B-1
267 YE 0.8
45
45
267 YE 0.8
SH8: D-6
BATTERY POWER STARTING SEQUENCE SWITCHED POWER POWER RELAY OUTPUT
X-900
CHASSIS INTERFACE
34
CHASSIS INTERFACE MD
Compact Track Loaders: TR270 - NGM418237 and above TR270 - NHM435463 and above TR310 - NGM418237 and above TR310 - NHM435463 and above TV370 - NHM435453 and above
35
RAC 48144045
SEE SHEET 3 SIDE 2 FOR ADDITIONAL WIRING INFORMATION
RAC 48144045 S3S1
RIGHT HAND TOWER CHASSIS HARNESS - MECHANICAL AND ELECTRO-HYDRAULIC DRIVE
CHASSIS HARNESS - ELECTRO-HYDRAULIC DRIVE (WITH ENHANCED HIGH FLOW AUXILIARY HYDRAULICS -EHF)
CAB HARNESS - CLOSED (DELUXE) CAB - ELECTRO HYDRAULIC DRIVE
CHASSIS HARNESS - MECHANICAL DRIVE
CAB HARNESS - CLOSED (DELUXE) CAB - MECHANICAL DRIVE
CHASSIS HARNESS - ELECTRO-HYDRAULIC DRIVE (NO ENHANCED HIGH FLOW AUXILIARY HYDRAULICS -EHF)
CAB HARNESS - OPEN CAB - MECHANICAL DRIVE
CAB HARNESS - OPEN CAB - ELECTRO HYDRAULIC DRIVE
RAC 48144045 S3S2
MECHANICAL VALVE ASSEMBLY
SINGLE-SPEED AND TWO-SPEED MECHANICAL VALVE ASSEMBLY RAC 51423450 SR130 / SR150 / SR160 SR175 / SV185 / SR200 SR210 / TR270 / TR310
2 3 4
FLUSHING VALVE -10 BAR SPRINGS -2 mm FLUSHING ORIFICE -290 PSI (20BAR) CUTOFF RELIEF LOAD CHECK REMOVED IF HIGH FLOW INSTALLED. Charge Pressure forPort Lock
IN-LINE ORIFICE AT MANIFOLD BLOCK FOR VERTICAL MACHINES ONLY.
RELIEF PRESSURE TABLE
B2
V1
V2
C2
C1
B
CONNECT UNDER PRESSURE VALVE
A
CPLRV
2
4
C
3 Orifice Vertical Only
P
Case Drain From Pumps and Motors
B
1
B1
Ride Control Option
A1
Pilot Control Pressure from Charge Pump
PR1
A2
B2
PR2
PR3
B3
A3
TANK
Secondary Auxiliary Quick Disconnects
CASE
Secondary Auxiliary Option B
_ 72.5 (210 BAR) MAIN 3046 PSI + PR1- 3263 PSI +145/-73 (225 BAR) PR2- 3236 PSI +145/-73 (225 BAR) PR3- 3771 PSI +145/-73 (260 BAR) PR3- OPTIONAL 80 BAR OR 100 BAR (SERVICE) HFV- 3250 PSI (224 BAR) CPLRV- 2500 PSI (172 BAR)
Case
A
SL
POUT
SL
MR A
PYB
PIN - Main
B .6mm P
2
AUXIN
PIN
Gear Pump interface to Tandem Pump
L
HFV
T
Loader Valve PIN
High Flow Option
HYDROSTATIC PUMP CHARGE PUMP PILOT CONTROL PRESSURE RETURN TO TANK/SUMP
Crossover Pump Suction Line Charge Pump Suction Line
QUICK DISCONNECTS Hyd Oil Filter w/ 50psi Bypass
A C
D
3
Auxiliary Pump Non-Reg Tier 4 34.1cc 36.6cc -F5C 24.9cc 27.8cc -ISM Med Frm 20.4cc 23.7cc -ISM Sml Frm High Flow Pump (as applicable) Non-Reg Tier 4 18.3cc 20.4cc -F5C 61-67kW 12.5cc 13.7cc -F5C 55kW 12.5cc 13.7cc -ISM Med Frm Not Avail on Sml Frm
Auxiliary Quick Disconnects
Boom Down Valve
T
LIFT CYLINDERS ARE CUSHIONED FOR VERTICAL FRAME MACHINES ONLY.
B1
Tip Cylinders
Self Level Option
Hydraulic Coupler Option
NOTES: 1
A2
A1
4
Lift Cylinders
Hydraulic Coupler
Oil Cooler w/ 75psi Bypass
Right-hand MCR03
MECHANICAL SINGLE-SPEED DRIVE ASSEMBLY
MECHANICAL TWO-SPEED DRIVE ASSEMBLY
SR130, SR150, SR160, SR175, SV185, SR200, SR210
SR175, SV185, SR200, SR210 FWD
FWD
Motor
Right-hand MCR03
Left-hand MCR03
Motor
Motor
1
FLUSHING VALVE -10 BAR SPRINGS -2 mm FLUSHING ORIFICE -290 PSI (20BAR) CUTOFF RELIEF
Left-hand MCR03
FWD
FWD
X
X
L
L
Y
Y
Motor
1
1
1
To Case Drain Tube
1
Z
B1&B2
To Case Drain Tube Brake
To Case Drain Tube Charge Pressure to Port Lock
T P
2SPD 174 PSI
B1&B2
0.60 MM
Brake/Shift Manifold
Brake
Shift
To Case Drain Tube Charge Pressure to Port Lock
T P
Brake/Shift Manifold
HYDROSTATIC PUMP A
B
B
CHARGE PUMP
A
PILOT CONTROL PRESSURE RETURN TO TANK/SUMP
A
B
B
A
QUICK DISCONNECTS
Charge Pump
Gear Pump interface to Tandem Pump
Charge Pump
Gear Pump interface to Tandem Pump
To Case Drain Tube
Sauer M35 - Manual Displacement Pump Main Relief(all ports) - 345bar (5000psi) Charge Relief - 25bar (360psi)
51423450
Crossover Pump Suction Line Charge Pump Suction Line
To Case Drain Tube Sauer M35 - Manual Displacement Pump Main Relief(all ports) - 345bar (5000psi) Charge Relief - 25bar (360psi)
Crossover Pump Suction Line Charge Pump Suction Line
EH VALVE ASSEMBLY
SINGLE-SPEED AND TWO-SPEED ELECTRO-HYDRAULIC (EH) VALVE ASSEMBLY RAC 51423450 SR130 / SR150 / SR160 SR175 / SV185 / SR200 SR210 / TR270 / TR310
A1
FLUSHING VALVE -10 BAR SPRINGS -2 mm FLUSHING ORIFICE -290 PSI (20BAR) CUTOFF RELIEF
2
LOAD CHECK REMOVED IF HIGH FLOW INSTALLED.
3
IN-LINE ORIFICE AT MANIFOLD BLOCK FOR VERTICAL MACHINES ONLY.
4
Charge Pressure forPort Lock
A2
B1
V1
V2
C2
C1
Boom Down Valve
B
D
2 CPLRV
CONNECT UNDER PRESSURE VALVE
4
C
3 P
LIFT CYLINDERS ARE CUSHIONED FOR VERTICAL FRAME MACHINES ONLY.
3
Case Drain From Pumps and Motors
Orifice Vertical Only
1
B
B1
Ride Control Option
A1
A2
B2
B3
High Flow Pump (as applicable) Non-Reg Tier 4 18.3cc 20.4cc -F5C 61-67kW 12.5cc 13.7cc -F5C 55kW 12.5cc 13.7cc -ISM Med Frm Not Avail on Sml Frm RELIEF PRESSURE TABLE
Auxiliary Quick Disconnects
B2
A
T
Auxiliary Pump Non-Reg Tier 4 34.1cc 36.6cc -F5C 24.9cc 27.8cc -ISM Med Frm 20.4cc 23.7cc -ISM Sml Frm
Tip Cylinders
4
Self Level Option
Hydraulic Coupler Option
NOTES: 1
Lift Cylinders
Hydraulic Coupler
Pilot Control Pressure from Brk/Shft/EH Valve
PR1
PR2
A3
PR3
TANK
Secondary Auxiliary Option
Secondary Auxiliary Quick Disc
_ 72.5 (210 BAR) MAIN 3046 PSI + PR1- 3263 PSI +145/-73 (225 BAR) PR2- 3236 PSI +145/-73 (225 BAR) PR3- 3771 PSI +145/-73 (260 BAR) PR3- OPTIONAL 80 BAR OR 100 BAR (SERVICE) HFV- 3250 PSI (224 BAR) CPLRV- 2500 PSI (172 BAR)
B
CASE
Case
POUT
A
MR A
PIN - Main
B
PYB
.6mm P
2 AUXIN
PIN
L
Gear Pump interface to Tandem Pump
HYDROSTATIC PUMP CHARGE PUMP PILOT CONTROL PRESSURE RETURN TO TANK/SUMP
HFV
T
PIN
Loader Valve
High Flow Option
Crossover Pump Suction Line
Charge Pump Suction Line
QUICK DISCONNECTS Hyd Oil Filter w/ 50psi Bypass
Oil Cooler w/ 75psi Bypass
C
A
EH TWO-SPEED DRIVE ASSEMBLY
EH SINGLE-SPEED DRIVE ASSEMBLY
SR175, SV185, SR200, SR210
SR130, SR150, SR160
Right-Hand MCR03 Motor
Left-Hand MCR03
FWD
FWD
Left-Hand MCR03
Right-Hand MCR03
Motor
Motor
Motor FWD
FWD
X
X
L
L
1
FLUSHING VALVE -10 BAR SPRINGS -2 mm FLUSHING ORIFICE -290 PSI (20BAR) CUTOFF RELIEF
HYDROSTATIC PUMP CHARGE PUMP
Y
Y
PILOT CONTROL PRESSURE RETURN TO TANK/SUMP QUICK DISCONNECTS 1
1
1
1
Z
To Case Drain Tube To Case Drain Tube LV
2SPD
174 PSI
0.60 MM
Shift
15b (225psi)
B1&B2
Brake
15.5b (225psi)
Pilot Control Pressure from Brk/Shft/EH Valve
Brake
EH Intrlk
B1&B2
LV
Brake
EH Intrlk
Brake
To Case Drain Tube
T
Charge Pressure to Port Lock
P
To Case Drain Tube T
Brake/Shift Manifold
Charge Pressure to Port Lock
P
Brake/Shift Manifold
G1 YST
A
B
B
G1
A
YST
Charge Pump
A
B
B
A
Charge Pump
Gear Pump interface to Tandem Pump Charge Pump Suction Line
To Case Drain Tube
Rexroth - A20VG - ET (EH) pump Main Relief(all ports) - 362bar(5250psi) Charge Relief - 25bar(360psi)
51423450
Crossover Pump Suction Line
Gear Pump interface to Tandum Pump
Charge Pump Suction Line To Case Drain Tube
Rexroth - A20VG - ET (EH) pump Main Relief(all ports) - 362bar(5250psi) Charge Relief - 25bar(360psi)
Crossover Pump Suction Line
EHF OPTION PUMP ASSEMBLY
ENHANCED HIGH FLOW (EHF) OPTION PUMP ASSEMBLY
EHF QD's on Right Hand Loader Arm
RAC 51423450 SR250 / SR270 / SV300 / SV340 TR320 / TR340 / TV380
A
B
C
NOTES: 1
FLUSHING VALVE -10 BAR SPRINGS -2 mm FLUSHING ORIFICE -290 PSI (20BAR) CUTOFF RELIEF
2
LOAD CHECK REMOVED IF HIGH FLOW INSTALLED.
3
STANDARD PUMP STACK NOT USED ON EHF OPTION SEE NOTE ON DRAWING.
4
IN-LINE ORIFICE AT MANIFOLD BLOCK FOR VERTICAL MACHINES ONLY.
5
LIFT CYLINDERS ARE CUSHIONED FOR VERTICAL FRAME MACHINES ONLY.
6
BOOM ROD LOCK VALVE FOR LARGE FRAME VERTICAL MACHINES ONLY.
A
C
E
0.083
LOOP FLUSHING VALVE B
F
D
To Case Drain Tube
STANDARD RELIEF PRESSURE TABLE
TO RESPECTIVE MOTOR PORTS
CONTROL PRESSURE FROM BRAKE/SHIFT VALVE
_ 72.5 (210 BAR) MAIN 3046 PSI + PR1- 3263 PSI +145/-73 (225 BAR) PR2- 3263 PSI +145/-73 (225 BAR) PR3- 3771 PSI +145/-73 (260 BAR) PR3- OPTIONAL 80 BAR OR 100 BAR (SERVICE) HFV- 3250 PSI (224 BAR) CPLRV- 2500 PSI (172 BAR)
TO BRAKE/SHIFT VALVE
G1 YST
A
B
B
A
HIGH PRESSURE RELIEF PRESSURE TABLE
Flow to EH Loader Valve - PIN Main
_ 72.5 (238 BAR) MAIN 3450 PSI + PR1- 3625 PSI +290/-73 (250 BAR) PR2- 3625 PSI +290/-73 (250 BAR) PR3- 3916 PSI +290/-73 (270 BAR) HFV- 3655 PSI +218/-0 (252 BAR) CPLRV- 2500 PSI (172 BAR)
Charge Pump Suction Line Reservoir Suction Line To Case Drain Tube
HYDROSTATIC PUMP CHARGE PUMP
A10VG - EP
PILOT CONTROL PRESSURE
A port - 275bar(4kpsi)
RETURN TO TANK/SUMP
B port - 210bar(3kpsi)
QUICK DISCONNECTS
Large Frame Rexroth - A20VG - ET (EH) Main Relief(all ports) - 362bar(5250psi) Charge Relief - 25bar(360psi)
Auxiliary Pump 34.1cc- Non Reg 36.6cc- Tier 4
Charge Pump 23.7cc- Non Reg 23.7cc- Tier 4
ELECTRO-HYDRAULIC (EH) VALVE ASSEMBLY
EH VALVE ASSEMBLY
RAC 51423450 SR220 / SR240 / SR250 / SV250 SR270 / SV280 / SV300 / SV340 TR320 / TR340 / TV370 / TV380
A1
Hydraulic Coupler Option
2 3 4 5 6
FLUSHING VALVE -10 BAR SPRINGS -2 mm FLUSHING ORIFICE -290 PSI (20BAR) CUTOFF RELIEF LOAD CHECK REMOVED IF HIGH FLOW INSTALLED. STANDARD PUMP STACK NOT USED ON EHF OPTION SEE NOTE ON DRAWING. IN-LINE ORIFICE AT MANIFOLD BLOCK FOR VERTICAL MACHINES ONLY. LIFT CYLINDERS ARE CUSHIONED FOR VERTICAL FRAME MACHINES ONLY. BOOM ROD LOCK VALVE FOR LARGE FRAME VERTICAL MACHINES ONLY.
STANDARD RELIEF PRESSURE TABLE
Charge Pressure forPort Lock
A2
B1
B2
V1
V2
C2
C1
Self Level Option
Boom Down Valve
A 2
4
CPLRV C
4 T
Orifice Vertical Only
P 3
Case Drain From Pumps and Motors
_ 72.5 (210 BAR) MAIN 3046 PSI + PR1- 3263 PSI +145/-73 (225 BAR) Secondary Auxiliary Quick PR2- 3263 PSI +145/-73 (225 BAR) Disc PR3- 3771 PSI +145/-73 (260 BAR) Secondary Auxiliary PR3- OPTIONAL 80 BAR OR 100 BAR (SERVICE) Option HFV- 3250 PSI (224 BAR) CPLRV- 2500 PSI (172 BAR)
CONNECT UNDER PRESSURE VALVE
D
1
Ride Control Option
B
B1
A1
PR1
Pilot Control Pressure from Brk/Shft/EH Valve
B
Tip Cylinders
5
Auxiliary Quick Disconnects
NOTES: 1
Lift Cylinders
Hydraulic Coupler
A2
B2
PR3
PR2
B3
A3
TANK CASE
Case
POUT
A
MR A
HIGH PRESSURE RELIEF PRESSURE TABLE _ 72.5 (238 BAR) MAIN 3450 PSI + PR1- 3625 PSI +290/-73 (250 BAR) PR2- 3625 PSI +290/-73 (250 BAR) PR3- 3916 PSI +290/-73 (270 BAR) HFV- 3655 PSI +218/-0 (252 BAR) CPLRV- 2500 PSI (172 BAR)
B
PIN - Main .6mm P
2 AUXIN
PIN
L HFV
Gear Pump interface to Tandem Pump
HYDROSTATIC PUMP CHARGE PUMP PILOT CONTROL PRESSURE RETURN TO TANK/SUMP QUICK DISCONNECTS
PYB
T
PIN
Loader Valve
High Flow Option
Crossover Pump Suction Line 3
Auxiliary Pump -F5C Non-Reg Tier 4 238BAR 34.1cc 36.6cc 36.5cc High Flow Pump -F5C 61-67kW (as applicable) Non-Reg Tier 4 238BAR 18.3cc 20.4cc 23.3cc
Charge Pump Suction Line Hyd Oil Filter w/ 50psi Bypass
Oil Cooler w/ 75psi Bypass
A
B C
EH TWO-SPEED TRACK DRIVE ASSEMBLY
Right-Hand Motor
PB PS
DR
FWD FWD
DR
NOTES:
FWD FWD
PB
RAC 51423450 TR270 / TR310 / TR320 TR340 / TV370 / TV380
Left-Hand Motor
Rexroth - A20VG - ET (EH) pump Main Relief(all ports) - 362bar(5250psi) Charge Relief - 25bar(360psi)
PS
ELECTRO-HYDRAULIC (EH) TWO-SPEED TRACK DRIVE
STANDARD PUMP STACK NOT USED ON EHF OPTION SEE NOTE ON DRAWING.
4
IN-LINE ORIFICE AT MANIFOLD BLOCK FOR VERTICAL MACHINES ONLY.
5
LIFT CYLINDERS ARE CUSHIONED FOR VERTICAL FRAME MACHINES ONLY.
6
BOOM ROD LOCK VALVE FOR LARGE FRAME VERTICAL MACHINES ONLY.
1
P2
3
1
P1
LOAD CHECK REMOVED IF HIGH FLOW INSTALLED.
P1
2
P2
1
FLUSHING VALVE -10 BAR SPRINGS -2 mm FLUSHING ORIFICE -290 PSI (20BAR) CUTOFF RELIEF
To Case Drain Tube
STANDARD RELIEF PRESSURE TABLE _ 72.5 (210 BAR) MAIN 3046 PSI + PR1- 3263 PSI +145/-73 (225 BAR) PR2- 3263 PSI +145/-73 (225 BAR) PR3- 3771 PSI +145/-73 (260 BAR) PR3- OPTIONAL 80 BAR OR 100 BAR (SERVICE) HFV- 3250 PSI (224 BAR) CPLRV- 2500 PSI (172 BAR)
LV
2SPD
Pilot Control Pressure from Brk/Shft/EH Valve
B1&B2 15.5b (225psi)
Brake
EH Intrlk
Brake
Shift
To Case Drain Tube T
Charge Pressure to Port Lock
P
HIGH PRESSURE RELIEF PRESSURE TABLE
Brake/Shift Manifold
_ 72.5 (238 BAR) MAIN 3450 PSI + PR1- 3625 PSI +290/-73 (250 BAR) PR2- 3625 PSI +290/-73 (250 BAR) PR3- 3916 PSI +290/-73 (270 BAR) HFV- 3655 PSI +218/-0 (252 BAR) CPLRV- 2500 PSI (172 BAR)
G1 YST
A
B
B
A Charge Pump
Gear Pump interface to Tandem Pump
HYDROSTATIC PUMP CHARGE PUMP
Charge Pump Suction Line
PILOT CONTROL PRESSURE RETURN TO TANK/SUMP QUICK DISCONNECTS
Crossover Pump Suction Line To Case Drain Tube
MECHANICAL TWO-SPEED DRIVE ASSEMBLY
MECHANICAL SINGLE-SPEED DRIVE ASSEMBLY
SR220, SR240, SR250, SV250, SR270, SV280, SV300, SV340
SR220, SR240, SR250, SV250, SR270, SV280, SV300, SV340
1 Right-Hand MCR05
Left-Hand MCR05 FWD FWD
Motor
FWD FWD
X
Motor
FLUSHING VALVE -10 BAR SPRINGS -2 mm FLUSHING ORIFICE -290 PSI (20BAR) CUTOFF RELIEF
Right-Hand MCR05 Motor
FWD
FWD FWD
Left-Hand MCR05 Motor
HYDROSTATIC PUMP
X
CHARGE PUMP L
PILOT CONTROL PRESSURE
L
RETURN TO TANK/SUMP Y
Y
QUICK DISCONNECTS 1
1
1
1
Z
To Case Drain Tube B1&B2
To Case Drain Tube 2SPD 174 PSI
B1&B2 Brake
0.60 MM
To Case Drain Tube Charge Pressure to Port Lock
T P
Shift
Brake
To Case Drain Tube
T
Brake/Shift Manifold
Charge Pressure to Port Lock
P
Brake/Shift Manifold
A
B
B
A
A
B
B
A
Crossover Pump Suction Line
Crossover Pump Suction Line
Charge Pump Suction Line
Charge Pump Suction Line
Charge Pump
Charge Pump
Gear Pump interface to Tandem Pump
To Case Drain Tube Sauer M46 - Servo Displacement pump Main Relief(all ports) - 362bar(5250psi) Charge Relief - 25bar(360psi)
51423450
To Case Drain Tube
Sauer M46 - Servo Displacement pump Main Relief(all ports) - 362bar(5250psi) Charge Relief - 25bar(360psi)
Gear Pump interface to Tandem Pump
MECHANICAL VALVE ASSEMBLY
MECHANICAL VALVE ASSEMBLY
Hydraulic Coupler
RAC 51423450 SR220 / SR240 / SR250 / SV250 SR270 / SV280 / SV300 / SV340 TR320 / TR340 / TV370 / TV380
A1 A2
Hydraulic Coupler Option
2 3 4 5 6
Tip Cylinders
4
Auxiliary Quick Disconnects
B2
Self Level Option
NOTES: 1
B1
Lift Cylinders
FLUSHING VALVE -10 BAR SPRINGS -2 mm FLUSHING ORIFICE -290 PSI (20BAR) CUTOFF RELIEF LOAD CHECK REMOVED IF HIGH FLOW INSTALLED.
Charge Pressure forPort Lock
STANDARD PUMP STACK NOT USED ON EHF OPTION SEE NOTE ON DRAWING.
Boom Down Valve V1
V2
CONNECT UNDER PRESSURE VALVE
A
CPLRV
2
4
C
4 T
Orifice Vertical Only
P
3
B
1 C
6
Case Drain From Pumps and Motors
Ride Control
B1
V
A1
A2
B2
Option
BOOM ROD LOCK VALVE FOR LARGE FRAME VERTICAL MACHINES ONLY. Pilot Control Pressure from Charge Pump
STANDARD RELIEF PRESSURE TABLE _ 72.5 (210 BAR) MAIN 3046 PSI + PR1- 3263 PSI +145/-73 (225 BAR) PR2- 3263 PSI +145/-73 (225 BAR) PR3- 3771 PSI +145/-73 (260 BAR) PR3- OPTIONAL 80 BAR OR 100 BAR (SERVICE) HFV- 3250 PSI (224 BAR) CPLRV- 2500 PSI (172 BAR)
Secondary Auxiliary Quick Disc
PR1
PR3
B3
A3
TANK CASE
Secondary Auxiliary Option Case
B
PR2
POUT
A
MR A
HIGH PRESSURE RELIEF PRESSURE TABLE _ 72.5 (238 BAR) MAIN 3450 PSI + PR1- 3625 PSI +290/-73 (250 BAR) PR2- 3625 PSI +290/-73 (250 BAR) PR3- 3916 PSI +290/-73 (270 BAR) HFV- 3655 PSI +218/-0 (252 BAR) CPLRV- 2500 PSI (172 BAR)
.6mm
P
2
Gear Pump interface to Tandem Pump
RETURN TO TANK/SUMP QUICK DISCONNECTS
Loader Valve PIN
High Flow Option
Crossover Pump Suction Line
HYDROSTATIC PUMP PILOT CONTROL PRESSURE
AUXIN
PIN
L HFV T
CHARGE PUMP
PYB
PIN - Main
B
3
Auxiliary Pump -F5C Non-Reg Tier 4 238BAR 34.1cc 36.6cc 36.5cc High Flow Pump -F5C 61-67kW (as applicable) Non-Reg Tier 4 238BAR 18.3cc 20.4cc 23.3cc
Charge Pump Suction Line
Hyd Oil Filter w/ 50psi Bypass
A C
C1
C2
IN-LINE ORIFICE AT MANIFOLD BLOCK FOR VERTICAL MACHINES ONLY. LIFT CYLINDERS ARE CUSHIONED FOR VERTICAL FRAME MACHINES ONLY.
B
D
Oil Cooler w/ 75psi Bypass
MECHANICAL TWO-SPEED TRACK DRIVE ASSEMBLY
EH TWO-SPEED DRIVE ASSEMBLY SR220, SR240, SR250, SV250, SR270, SV280, SV300, SV340
TR270, TR310, TR320, TR340, TV370, TV380 Right-Hand Motor
Left-Hand Motor
FWD FWD
FWD FWD
1
FLUSHING VALVE -10 BAR SPRINGS -2 mm FLUSHING ORIFICE -290 PSI (20BAR) CUTOFF RELIEF
FWD FWD
Right-Hand MCR05 Motor
HYDROSTATIC PUMP PB
PILOT CONTROL PRESSURE
DR
DR
PB
X
X
L
L
Y
Y
Left-Hand MCR05
RETURN TO TANK/SUMP
PS
PS
1
1
P2
P1
P2
P1
1
To Case Drain Tube
To Case Drain Tube
LV
2SPD
174 PSI
Shift
Pilot Control pressure from Brk/Shft/EH valve
B1&B2
2SPD
Brake
Motor
CHARGE PUMP
QUICK DISCONNECTS 1
FWD FWD
B1&B2
0.60 MM
To Case Drain Tube
T
Brake
EH Intrlk
Charge Pressure to Port Lock
P
15.5b (225psi)
Shift
Brake
To Case Drain Tube
T
Charge Pressure to Port Lock
P
Brake/Shift Manifold Brake/Shift Manifold
A
B
B
A
Crossover Pump Suction Line Charge Pump Suction Line
G1 YST
A
B
B
A Charge Pump
Charge Pump
Gear Pump interface to Tandem Pump
Gear Pump interface to Tandem Pump
Charge Pump Suction Line Crossover Pump Suction Line To Case Drain Tube
51423450
Sauer M46 - Servo Displacement pump Main Relief(all ports) - 362bar(5250psi) Charge Relief - 25bar(360psi)
To Case Drain Tube Rexroth - A20VG - ET (EH) pump Main Relief(all ports) - 362bar(5250psi) Charge Relief - 25bar(360psi)